Xylem IM043 AQUAVAR Variable Speed Pump Control User Manual

Installation Programming & Operationfor Pump Mounted, V120 Software Controllers.Models covered:04168321 - 2 HP - single phase, 230V04168331 - 3 H

Diagram 3 3a 3c9Step 1- Identify Materials The following materials are provided with the AQUAVAR controller. Please familiarize yourself with each

10Step 2 - Mounting the AQUAVAR controller: 1. The AQUAVAR controller drive head is supplied with all mounting hardware. 2. Remove the

Electrical/Mechanical Specifications11AQUAVAR Controller Technical Data: AQUAVAR Controller Motor Supply Voltage Recommended Part Nos. Rated Out

12Electrical ConnectionsInstallation ProceduresFAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER AND WAIT FIVE MINUTES FOR CAPACITOR DISCHARGE BEFORE

Electrical Connections continuedStep 3 - Wiring the AQUAVAR controller to motor (Parts in the electrical fittings package will be required for this pr

14AQUAVARDiagram 5AQUAVAR®AQUAVAR®RS485 InterfaceControl TerminalsRS485 InterfaceControl Terminals Power Supply Motor Connection 1x230 VAC 3 Phase

15Electrical Connections continued 4. Thermal Sensor Wire Connections Locate the terminal block labeled X1 inside the AQUAVAR controller.   •

16Electrical Connections continued 5. Connections in Conduit Box Now that the wires have been routed through the port in the AQUAVAR controller.

17Electrical Connections continued 10. Now select one of the ports in the AQUAVAR controller to route the trans- ducer cable. Cut to length an

18Installation ProceduresElectrical Connections (Line Reactors)Input Line RequirementsLine Voltage See the Power and Current Ratings table for the a

19Electrical Connections continued 13. Route cable through strain relief and connect to the appropriate terminal block. Tighten strain relie

20 17. Pump running signal and fault signal Pump running and fault signals such as lights may be wired to the AQUAVAR and set up in rem

Instructions 1. Check all wiring. (Rotation of motor.) All motors used with the AQUAVAR controller are three phase. You will need to check

Installation Procedures22 6. Press the up arrow to turn on the AQUAVAR controller. 7. Open the discharge valve slowly until the pump starts. O

23Instructions 1. Check Power Light 2. Press the down arrow to advance the display to: 3. Press Select to advance the display

24 6. Press to advance the display to: This display shows the last recorded error or fault encountered by the AQUAVAR controller.

Programming25AQUAVAR Controller Program Flow ChartSingle Pump Constant PressureII. Single Pump - Pump ProtectionThe AQUAVAR controller has the ability

2. Press the key until you reach the number 66. You will now be able to access all of the alternate menus for all AQUAVAR controller

27To set timed protection: 7. Delay Time Enter the amount of time that the pump is allowed to run at maximum frequency after pressure begins to

28Programming - Single Pump ProtectionDiagram 13REQUIREDVALUE50 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE??+PAS

2AQUAVAR Controller Model ________________ Transducer Model ______________________AQUAVAR Serial Number _________________ Transducer Rating ____

29III. Single Pump - System Curve CompensationThe AQUAVAR controller can automatically compensate for system friction losses due to increased flow. Ta

30Entering compensation values: (system curve)For steps 1 through 4, refer to the flow chart.Instructions 1. From the main menu, hold down the

31Programming - System Curve CompensationDiagram 15REQUIREDVALUE50 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE??–

32Circulator applicationsOn circulator pumps, the system curve can be automatically tracked through the use of a differential pressure transducer. Thi

33Single Pump Constant Flow continued 5. Use the to change the units to GPM if you are using a flow sensor or % if you are using the o

V. Single Pump - Level Control ApplicationsFor drainage applications using a surface pump, the transducer is typically needed to measure pres-sure on

35VI. Single Pump - Submersible Applications and Minimum FrequencyIt is possible to use the wall mounted version of the AQUAVAR controller with a s

Programming36At the status window, hold the key until you reach the password screen. Enter the password.Use the key to advance to:Us

VII. Setting A Second Fixed Required ValueThe AQUAVAR controller can also be used in applications where the required value changes. As an example, a

ProgrammingEnter the submenu by holding the key.Enter the password and press the key. Press the key until you see the screen:

3 System Design ... 5 Important Safety Instructions ... 6 Inst

Programming39 VIII. Variable Second Required ValueIn this section, we will cover the set up and programming of the AQUAVAR for a second sensor input.

Programming40Enter the submenu by holding the key.Enter the password and press the key.Press the key until you see the screen:

Offsets41It is also possible to use second sensor input as an offset for the primary required value. An example would be locating the second sensor in

Programming42At Level 1 and Level 2, you enter the required value in percent from the Second Additional input (20%) and (80%).Intensity one and two de

Programming43Press key to advance to:Use the and arrow keys to enter the % of the required value you want to increase or decrease when

Electrical ConnectionDry contacts are available to connect a relay at X2/4-X2/5 (normally closed) or X2/6-X2/5 (normally open). The relay is located b

Hold the key to return to the synchronous control submenu.Hold the key again to return to the sequence control submenu.Press the

X. Multiple Pump Constant Pressure and System Curve CompensationWhen two, three, or four AQUAVAR controller controlled pumps are connected in a sys

Multiple Pump Constant Pressure... continued Generally, a slight pressure drop is allowed on the first pump before the next is started. This al

Multiple Pump Constant Pressure... continued 8. Enter the value required.   •Press toadvancetothenextscreen: •EnterthePSI drop bef

Operator Custom Features and Displays (continued)  • ActualValueIncrease ... 58  • ActualValueDecre

Multiple Pump Constant Pressure... continuedSource Required ValueThe next screen refers to the use of a second input signal for changing the required

Multiple Pump Constant Pressure... continued 12. Pump Address In this section you will give the pump an address number. General- ly, the firs

51Programming- Multiple Pump Constant PressureREQUIREDVALUE50 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE??– + vP

XI. Multiple Pump - Pump ProtectionThe AQUAVAR controller can protect the pump by shutting it off in low/no suction or run out conditions. To set low/

53Multiple Pump Pump Protection... continuedInstructions 3. Error Reset Turning this control on will enable the AQUAVAR controller to retr

Refer to the overall Program Flow Chart for the location of the following operator custom features. To access a particular feature: • Enterthepass

Ramp 1 This ramp is the fast run up time used when the pump first comes on and is trying to reach the set point. The normal set point for this

Minimum Frequency Settings between 0 and 50 Hz are possible. When a minimum frequency is set, the AQUAVAR will not run the pump below this spee

Controller - Used for a single AQUAVAR controlled pump Multicontroller - Used where several AQUAVAR pumps are connected via RS485 Synchronous Control

Regulation Mode The “Normal” setting increases the output speed with falling signal (constant pressure in dis- charge). The “Inverse” setting dec

5Typical Constant Pressure SystemsThe following diagrams show typical single pump and multi-pump systems using the AQUAVAR con-troller. Connection can

Synchronous Limit To deactivate synchronous control, set this value below 0 HZ. This will be the lowest speed that multiple pumps will operate p

60 ADC Reference This setting tells the unit where to look for the actual value signal. Set to “LOCAL” if the actual  valueisobtainedfroma4-2

Test Run The AQUAVAR controller can carry out a test run of the pump either automatically or manually. For automatic settings, enter the number

Operating Hours This counter displays the total amount of time that the AQUAVAR controller drive head has operated, (whether the pump was runni

Repair of Faults and Errors Lack of Water This error message will be displayed when a switch has indicated that the incoming water pressure or w

64 Overloaded The most common problem is incorrect program settings causing the pump to exceed its duty range. When this happens, the AQUAVAR co

65AQUAVAR Controller Flow ChartDiagram 19REQUIREDVALUE50 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE??– + vPASSWO

Help WindowsYou can access a help display at any time by pressing and holding the “ “ and arrow keys at the same time. This will change the s

67Help Windows Window text Help Text Window Pressure window 4% Ramp Hysteresis Hysteresis 50% Ramp 1 Ramp 1: fast acceleration time 4.0 Sec

68Help Windows Window text Help Text Regulation Mode Pumping regulation mode, normal or increased Start Value Start value Allows system pressur

Important: Read all safety information prior to installation of the AQUAVAR controller. 1. This manual is intended to assist in the installation,

69Help Windows Window text Help Text Submenu Submenu: synchronous regulation; to enter Synch. control push select at least one second. Syn

70Help Windows Window text Help Text Test Run Man. Start test run with Increase + Decrease (Inc + Dec) Test Frequency Test frequency 30.0 hz

Series 1200 Gems Type71Appendix A3.451.073⁄4” HEX1⁄4” NPTDiagram 20Pressure Transducer DataSpecificationsMeasuring Range (FS): .52 bar 10 bar 25 ba

72Differential Pressure TransmitterSeries PD-39S The sensors of this differential transmitter are two piezoresistive silicon pressure sensors, mounte

73Model Delta 692 Differential Pressure Transducer and Orifice Plate Appendix A34521P1P2Diagram 22Specifications Standard 80096 NDRange (FS)” 2, 5

AQUAVAR Controller Drive Head Technical Data and TerminalsInstructions: Use this supplement for installation and wiring of AQUAVAR models 04168321, 04

AQUAVAR Controller Drive Head Technical Data and Terminals continued Air Pollution: Minor amounts of dust and dirt are permitted. Excessive dust, ac

76AQUAVAR Controller Drive Head Technical Data and Terminals continued 9 Thermoswitch return connection. 10 Ground connection for analog outp

Interference Suppression Measures Introduction Electrical/electronic devices are capable of influencing or disturbing each other through connecting

 •Takecarenottodamagetheshieldcrosssectionwhenconnectingittothecontinuinglines. This raises the RF resistance of the shield and

7 3. Installation and maintenance MUST be performed by properly trained and qualified personnel. 4. Review all instructions and warnings prior

Appendix DThe final difference is the addition of a DIP switch SW4 which can be used to select a lower switch-ing frequency. This could be used to imp

80Operating InstructionTechnical Data - Frequency Inverter Output voltage: Three phase unit: 3 x 400-460 V AC Max. frequency: See: max. Frequency

Notes81

Notes82

Goulds Pumps1 Goulds DriveAuburn, NY 13021ITTGoulds Pumps, Aquavar and the ITT Engineered Blocks Symbol are registered trademarks and tradenames of IT

8 8. The AQUAVAR controller has electronic safety devices which will stop the motor in the event of electrical or thermal faults. This does not