Xylem IM131R01 AQUAVAR AV II User Manual

Variable SpeedPump ControlInstallation Programming & OperationModels covered:All AV2 Model AQUAVAR IIControllerssoftware revision 120AQUAVAR®AV II

Step 1- Identify MaterialsThe following materials are provided with the AQUAVAR II controller. Please familiarize yourself with each prior toinstallat

10Installation ProceduresStep 2 - Mounting the AQUAVARIIcontroller:AQUAVAR ControllerThe AQUAVAR controller may be installed as a wall or panel mounte

Installation ProceduresStep 2 - Mounting the AQUAVAR controller:(continued)Power Rating WeightHP Pounds Kilograms1 24.0 10.92 24.0 10.93 24.0 10.95 24

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

Electrical Connections continuedStep 3 - Preliminary InspectionBefore storing or installing the AQUAVAR controller, thoroughly inspect the device for

14Electrical Connections continuedStep 5 - Considerations for Mounting AQUAVAR Controllers in Host EnclosuresThe AQUAVAR controller is available from

Installation Procedures15AQUAVARSwitching FrequencyMax. SwitchingModelWatts Dissipated Watts Dissipated Watts DissipatedFrequency forAV2V-at 4 kHz at

Installation Procedures16AQUAVAR ModelWatts DissipatedAV2V2S010D 19AV2V2S020D 20AV2V2S030D 27AV2V20010D 19AV2V20020D 20AV2V20030D 27AV2V20050D 29AV2V2

Installation Procedures17Electrical Connections continuedStep 6 - MaintenanceMinimum Torque Values to Secure Cover If you remove the cover of an IP55

Electrical Connections continued• Use circuit breakers on the incoming power lines.• Grounding must be in accordance with NEC and CEC. If multiple AQU

Model NumberWire SizeAWG mm2AV2V50010D 14 2.5AV2V50020D 14 2.5AV2V50030D 14 2.5AV2V50050D 14 2.5AV2V50075D 14 2.5AV2V50100D 12 4.0AV2V50150D 10 6.0AV2

Installation ProceduresElectrical Connections continuedStep 8 - Input Line RequirementsLine Voltage See the Power and Current Ratings table for the al

Electrical Connections continuedPhase Imbalance Phase voltage imbalance of the input AC source can cause unbalanced currents and excessive heat in the

Electrical Connections continuedTypical Power Connections Diagram 5 shows the terminal connections for line power and motor output. See Step 8 for inp

Installation Procedures23Electrical Connections continuedTable 10: Recommended Fuses (460 Vac Models)Fuse Size 380 Vac Fuse Size 460 VacModel NumberJJ

Electrical Connections continued1. The wires routed from the terminal block U, V, W, and ground screw, should now be connected to the motor leads usin

Installation Procedures25Electrical Connections continued3. Place the square gasket over the end of the transducer, plug the cable connector on, and t

26Installation ProceduresElectrical Connections continuedTable 12: Description of AV II Drive Control Terminals (Internal Drive)Terminal DescriptionTB

6. For multi-pump systems:Use a three core shielded cable to connect terminals 1, 2, and 3 on X5 between the AQUAVAR controller units. These are the R

Pump PrimingRefer to your pump operation manual for instructions on pump priming. You will need to unscrewthe pressure transducer and adapter if you u

2AQUAVARII Controller Model_________________ Transducer Model_______________________AQUAVARII Serial Number_________________ Transducer Rating________

4. Check Display. * If these conditions exist, proceed. If NOT, check all wiring.5. Drive Component Keypad (Internal Drive) The AQUAVARIIunits have an

G. Use the up or down arrow keys to change the parameter’s value to the desired value.H. Press ENTER to save the new value. (If you do not wish to sav

Installation Procedures continued19. If the direction of rotation was correct, proceed to the Programming section beginning on the following page. 20.

Instructions1. Check Power Light 2.Press the down arrow to advance the display to:3. Press Select to advance the display to:4. Enter the pressure

6. Press to advance the display to:This display shows the last recorded error or fault encountered by the AQUAVAR controller. 7. Press

AQUAVARIIController Program Flow ChartSingle Pump Constant PressureII. Single Pump - Pump ProtectionTheAQUAVARIIcontroller has the ability to protect

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 optional con

Press the to enter the number of seconds. The pump will run after pressure begins to drop at pump run out or a suction switch activates.8.Err

37Programming - Single Pump ProtectionDiagram 14REQUIREDVALUE126.9 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE ??+

III. Single Pump - System Curve CompensationThe AQUAVAR controller can automatically com-pensate for system friction losses due toincreased flow. Tabl

3IndexSystem Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Important Safety Instructions

Entering compensation values:For steps 1 through 4, refer to the flow chart.Instructions1. From the main menu, hold down the key for 2-3 seconds unt

40Programming - System Curve CompensationDiagram 16REQUIREDVALUE126.9 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE

Circulator applicationsOn circulator pumps, the system curve can be automatically tracked through the use of a differentialpressure transducer. This p

Single Pump Constant Flow continued5. Use the to change the units to GPM if you are using a flow sensor or % if you are using the orifice plate.6

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

44VI. Single Pump - Submersible Applications and Minimum FrequencyIt is possible to use the wall mounted version of the AQUAVARIIcontroller with a sub

Programming45At the status window, hold the key until youreach the password screen. Enter the password.Use the key to advance to:Use

VII. Setting A Second Fixed Required ValueThe AQUAVARIIcontroller can also be used in applications where the required value changes. As anexample, a s

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

Programming48VIII. Variable Second Required ValueIn this section, we will cover the set up and programming of the AQUAVARIIfor a second sensor input.T

Index (continued)Operator Custom Features and Displays (continued)• Actual Value Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming49Enter the submenu by holding the key.Enter the password and press the key.Press the key until you see the screen:

Offsets50It is also possible to use second sensor input as an offset for the primary required value. An examplewould be locating the second sensor in

Programming51At Level 1and Level 2, you enter the required value in percent from the Second Additionalinput(20%) and (80%).Intensity one and two depen

Programming52Press key to advance to:Use the and arrow keys to enter the % of therequired value you want to increase or decreasewhen th

IX. Multiple Pump Constant Pressure and System Curve CompensationWhen two, three, or four AQUAVARIIcontroller controlled pumps are connected in a syst

Multiple Pump Constant Pressure... continuedGenerally, a slight pressure drop is allowed on the first pump before the next is started. This allows for

Multiple Pump Constant Pressure... continued8. Enter the value required.• Press to advance to the next screen:• Enter the PSI drop before the next pu

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... continued12. Pump AddressIn this section you will give the pump an address number. General-ly, the first pump progr

58Programming- Multiple Pump Constant PressureREQUIREDVALUE126.9 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE ??– +

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

X. 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/no

Multiple Pump Pump Protection... continuedInstructions3. Error ResetTurning this control on will enable the AQUAVARII controller to retry its operatio

Operator Custom Features and DisplaysRefer to the overall Program Flow Chart for the location of the following operator custom features.To access a pa

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 ramp is

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

Synchronous Controller- Used for multipump systems where all pumps will run at the same frequency. (Used for more efficient pump operation.)Actuator-

Submenu Sequence Control - for further information see Section IX, page 53Use this menu to allow starting and stopping of up to 4 pumps with the RS-48

Pump SequenceThis screen is located in the Sequence Control Submenu and displays the address and status of the pump as follows:AdrX * Pump address 1-4

Analog OutIt is possible for the AQUAVARIIcontroller to supply an output signal from 0-10 Volts at a maximum of 2 mA. Connection of the outside record

reset by removing all power to the unit for at least one minute. This will reset the fault counter to zero. NOTE: Error reset will not apply to “Low W

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

Lack of Water This error message will be displayed when a switch has indicated that the incoming water pressure or water level in a suction tank falls

External Device Error This indicates that there is an electrical problem with the input line, drive or pump motor. To determine the exact problem, ope

Table 13: AQUAVAR Electrical Fault Codes (continued)Fault Code Fault Name Possible Cause(s) How to Recover04 TSP 24V Supply Overloaded +24 Vdc supply.

Repair of Faults and Errors72Table 13: AQUAVAR Electrical Fault Codes (continued)Fault Code Fault Name Possible Cause(s) How to Recover16 Motor Over T

Table 13: AQUAVAR Electrical Fault Codes (continued)Fault Code Fault Name Possible Cause(s) How to Recover23 Motor Underload The load on the motor is

Repair of Faults and ErrorsTable 13: AQUAVAR Electrical Fault Codes (continued)Fault Code Fault Name Possible Cause(s) How to Recover40 Loss of Keypad

75AQUAVAR Controller Flow ChartDiagram 21REQUIREDVALUE126.9 PSIAuto-STARTONERROR 1 ERROR 2 ERROR 3 ERROR 4 ERROR 5TOTAL RUNTIME0000: 41SAVE ??– + vPAS

You can access a help display at any time by pressing the “ “ and keys at the same time. Thiswill change the second line of the window to a “ru

77Help WindowsWindow text Help TextWindow Pressure window, percentage above and5% below set pressure. See pages 61 and 62.Ramp Hysteresis Hysteresis,

78Help WindowsWindow text Help TextRegulation Mode (Normal Default) Pumping regulation mode, normal or inverse.See page 64. Start Value Start value, a

7Safety Instructions3. Installation and maintenance MUST be performed by properly trained and qualified personnel.4. Review all instructions and warni

79Help WindowsWindow text Help TextSubmenu Submenu: synchronous regulation; to enter Synch. Control push select at least one second. See page 56.Sync

80Help WindowsWindow text Help TextTest Run Man. Start test run with up and down arrows(Inc + Dec) simultaneously.Test Frequency Test frequency. Frequ

Series 120081Appendix A3.451.073⁄4” HEX1⁄4” NPTDiagram 22Pressure Transducer DataSpecificationsMeasuring Range (FS): .52 bar 10 bar 25 bar(other range

Differential Pressure TransmitterSeries PD-39S The sensors of this differential transmitter are twopiezoresistive silicon pressure sensors, mountedon

83Model Delta 692 Differential PressureTransducer and Orifice PlateAppendix A34521P1P2Diagram 24SpecificationsStandard 80096 NDRange (FS)” 2, 5 bar -

Interpreting Model Numbers The model number of the AQUAVAR appears on the shipping carton label and on the technical datalabel affixed to the model. T

Technical Characteristics85Power and Current Ratings (continued)Motor Power InputMaximum LoadMaximumOutputOutput Current (A)ModelHP kWVoltageCurrent (

Power and Current Ratings (continued)SpecificationsEnvironmental MAXIMUM HEATSINK TEMP. = 100º C (212º F)Operating temperature 0ºC to +40ºC (32ºF to

AQUAVAR Controller Drive Head Technical Data and TerminalsTerminals: There is a terminal strip inside the AQUAVAR controller which will allow the conn

4 ** Pump operation signal relay connection. This relay turns on the run light on the control panel when the pump is operating. This relay may also be

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

89Appendix CInterference Suppression MeasuresIntroduction Electrical/electronic devices are capable of influencing or disturbing each other through co

• Use a shielded motor cable which is grounded over a large surface area at both ends. The shield on this cable should be uninterrupted. If a shielded

© 2002 ITT Industries, Inc. Goulds PumpsOctober, 2002 1 Goulds DrivePrinted in U.S.A. Auburn, NY 13021GOULDS PUMPS LIMITED WARRANTYThis warranty appli