5.2 Basic electrical connection....................41 5.3 Power connections......................43 5.4 Power and control wiring for unshielded cables............50 5.5 Grounding.......................... 50 5.6 Extra protection (RCD)...................... 51 5.7 Torque..........................51 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 4
7.4 Warnings and alarms...................... 138 8 Troubleshooting........................147 8.1 Start up and operation troubleshooting...............147 9 Technical Specification......................150 9.1 Power-dependent specifications...................150 9.2 General technical data....................153 9.3 Fuse tables........................159 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
Use safety equipment according to the company regulations. Use this safety equipment within the work area: • Hard hat • Safety goggles, preferably with side shields • Protective shoes • Protective gloves • Gas mask • Hearing protection Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
1. Hold your eyelids apart forcibly with your fingers. eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes. 3. Seek medical attention. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Observe the local regulations and codes regarding: • Reporting of emissions to the appropriate authorities • Sorting, recycling and disposal of solid or liquid waste • Clean-up of spills Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 10
1 Introduction and Safety Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon. Recycling guidelines Always follow local laws and regulations regarding recycling.
Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
The product must be stored in a covered and dry location free from heat, dirt, and vibrations. NOTICE: Protect the product against humidity, heat sources, and mechanical damage. NOTICE: Do not place heavy weights on the packed product. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
J = N·m ft-lb, Btu °F Fahrenheit Adjustable Frequency Drive Frequency Kilohertz LCP Local Control Panel Milliampere millisecond Minute Motion Control Tool M-TYPE Motor Type Dependent Newton meters in-lbs Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
The curve shows that at lower speed the ETR cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from overheating even at low Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 15
• Using a digital input and the 24 V as a power supply. – Parameter set-up: – Set [1-90] Motor Thermal Protection to Thermistor Trip [2] – Set [1-93] Thermistor Source to Digital Input 19 [4] Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 16
Figure 4: ON/OFF with a digital input and the 10 V as a power supply • Using an analog input and 10 V as a power supply – Parameter set-up: Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 17
If the motor is overloaded without reaching the Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 23
400 kW) at 690 V 160 kW) at 400 V (525–690 V) (380–480 V) Enclosure protection 21/54 21/54 NEMA Type 1/Type 12 Chassis Type 1/Type 12 Chassis Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Line power input terminals 91 (L1), 92 (L2), 93 (L3) TB5 (IP21/54 only). Terminal block for anti-condensation heater. For location of TB6 (terminal block for contactor), see Terminal Locations: D5h-D8h. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• User interface and external commands are monitored and performed. • Status output and control can be provided. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
To perform the mechanical installation, the following tools are needed: • Drill with 0.39 or 0.47 in (10 or 12 mm) drill. • Tape measure • Wrench with relevant metric sockets (0.28–0.67 in (7–17 mm)) Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• Motor connection and cables • Fuses and circuit breakers • Control terminals cables Quick Setup • Local control panel, LCP • Automatic Motor Adaptation, AMA • Programming Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the adjustable frequency drive. Figure 23: Recommended lifting method, frame sizes D and E Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 32
Terminal locations — E1 492 (19.4) 323 (12.7) 0 (0.0) 195 (7.7) Figure 30: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 33
4 Mechanical Installation 19 Nm [14 FTa 453 (17.8) 0 (0.0) Figure 31: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Position (Detail B) Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 34
IP54/IP21 UL and NEMA 1/ NEMA12 450–600 HP (575 V) (15.6) (10.5) (13.1) (15.6) (20.8) 500–600 HP (400 V) 246 (9.7) (16.1) (12.8) (16.0) (16.5) (18.1) Terminal locations — E2 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 35
W/T3 98 17 (0.7) 0 (0.0) Figure 33: IP00 Enclosure Power Connection Positions R 81 019Nm (14 F) 147 (5.8) 0(0.0) Figure 34: IP00 Enclosure Power Connection Positions Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
4.1.8 Gland/Conduit entry IP21 (NEMA 1) and IP54 (NEMA12) Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
The NEMA 3R kit contains the following parts: • Top plate (1) • Gland plate with attached gasket (1) • NEMA 3R cover (1) • Adhesive label (1) • 3–sectioned plastic bag containing: Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
4. Secure the new gland plate to the frequency converter using the provided screws with captive washers (6) for D1h or (8) for the D2h. Torque to 2.3 Nm (20 in/lbs). Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 39
4 Mechanical Installation Figure 40: Removing Gland Plate Figure 41: Installing NEMA 3R Gland Plate 1. Gasket 2. Screw with captive washer 3. Gland plate Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Using the NEMA 3R cover kit requires derating due to higher ambient temperatures within the enclosure. Using SFAVM (stator flux asynchronous vector modulation) gives greater switching control, but generates more heat than using 60°AVM (asynchronous Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 41
45˚C 50˚C 45˚C 52˚C 50˚C 52˚C Figure 45: SFAVM, High Overload HO, 150% Figure 46: SFAVM, Normal Overload HO, 110% % of drive output, nominal HO current Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• It is recommended the all power connections be made with a minimum 75°C rated copper wire. • See Power-dependent specifications section for recommended wire sizes. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• Wiring the AC mains to the frequency converter input terminals • Connecting control and serial communication wiring • After power has been applied, checking input and motor power; programming control terminals for their intended functions Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 44
(terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
If an unshielded/unarmored cable is used, see section Power and Control Wiring for Unshielded Cables. For more information, see EMC Test Results in the Design Guide. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 46
(such as an adjustable frequency drive), fit a sine-wave filter on the output of the adjustable frequency drive. Figure 50: Motor connections Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 47
Figure 52: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) with disconnect, fuse and RFI filter, frame size D2 1. AUX Relay 2. Temperature switch Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 48
6. SMPS Fuse (see fuse tables for part number) 7. AUX Fan 8. Fan fuse (see fuse tables for part number) 9. Line power ground 10.Motor Figure 53: Compact IP 00 (chassis), frame size D3 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 49
7. AUX Fan 8. Fan fuse (see fuse tables for part number) 9. Line power ground 10.Motor Figure 55: Position of ground terminals IP00, frame sizes D Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 50
Figure 56: Position of ground terminals IP21 (NEMA type 1) and IP54 (NEMA type 12) D2 and D4 shown as examples. D1 and D3 are equivalent. Figure 57: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) frame size E1 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 51
7. AUX Fan 8. Fan fuse (see fuse tables for part number) 9. Line power ground 10.Motor Figure 59: Position of ground terminals IP00, frame sizes E Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• Safety, grounding: Please note that the adjustable frequency drive has a high leakage current and must be grounded appropriately for safety reasons. Always follow local safety regulations. • High-frequency grounding: Keep the ground wire connections as short as possible. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
It is important that shielded and armored cables are connected properly to ensure high EMC immunity and low emissions. Connection can be made by either cable connectors or clamps: Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
[4–10] Motor Speed Direction. Motor Rotation Check can be performed by using [1–28] Motor Rotation Check and following the steps that are shown in the display. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
IEC 61800–3. • Size wiring is based upon the input current of the frequency converter. • Comply with local and national electrical codes for cable sizes. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines, etc., must be short-circuited and overcurrent protected according to national/international regulations. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
– Make sure the impedance from adjustable frequency drive to building ground is lower than the grounding impedance of the machine. This can be difficult for pumps. Make a direct ground connection between the motor and load motor. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
If found to be necessary and after consultation with Xylem: 1. Lower the IGBT switching frequency 2. Modify the inverter waveform, 60° AVM vs. SFAVM 3.
Using shielded control cables Xylem recommends braided shielded/armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the incoming and outgoing radiation of electric noise depends on the transfer impedance (Z ).
Page 60
With very long control cables, ground loops may occur. To eliminate ground loops, connect one end of the screen-to-ground with a 100 nF capacitor (keeping leads short). Figure 68: 50/60 Hz ground loops Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Alternatively, the connection to terminal 61 can be omitted: Figure 70: Twisted-pair cables without terminal 61 Min. 6 AWG or 16 mm Equalizing cable 5.16 Control terminal types Figure 71: Control terminal locations Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 62
Usable for AC or DC 04, 05, 06 [5–40] Relay 2 [5] Running voltages and either resistive or inductive loads. Refer to Relay for relay wiring contact current and voltage ratings. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 63
[5–15] [23] SP1/SP2 Select Digital input. Configured for use as a Setpoint 1/Setpoint 2 select (SP1/SP2). – Common Common for digital inputs and reference for 24V supply Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Strip the control wire back 9–10mm (0.35–0.40 in) b. Insert a screwdriver (2.5–3.5 mm) in the rectangular hole in between two circular holes and push it down. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 65
Transducer voltage or current type of switch A54 can be verified at parameter [16-63] Terminal 54 Switch Setting. NOTE: [16-61] Terminal 53 Switch Setting always displays current type. ® Aquavar Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
The frequency converter has been configured to require a start command on terminal 18. To apply a start signal connect the device used to control starting of the drive or a jumper Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
80 V DC, 2A Maximum terminal load (DC-13)1) on 1–2 )NO) (Inductive load) 24 V DC, 0.1A Maximum terminal load (AC-1))1) on 1–3 (NC) (resistive load) 240 V AC, 2A Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 68
The factory default settings are configured to require a start signal wired to DI18 as shown below. Figure 75: Required terminal connections for use with factory default settings Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 69
This is the time between when an alarm/warning is issued and when the controller attempts the next restart. Default setting is 30 seconds. * To configure DI 27, set [5–12] to Pump Protect. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 70
Terminal 54 High Ref./Feedb.Value Maximum transducer feedback value. For example, for a 300psi transducer, set to 300. [6-27]* Terminal 54 Sensor Fault (North Enabled America) / Live Zero (International) Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 71
The diagrams below show the connections for an external speed command. • Speed control mode can be configured using the Start-Up Genie. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 72
Figure 79: Connections for speed control with external potentiometer Figure 80: Connections for speed control over current signal from PLC or BMS Figure 81: Connections for speed control with PLC or BMS Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 73
When the setpoint or reference is supplied to the controller from the external device both a transducer and the external Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 74
To configure the controller for this type of system, a specific wiring configuration is required. The diagram below shows the wiring required to implement the duplex control system. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 75
RTU and BACnet. The parameter list in the second table below shows parameters that determine the control source for certain drive functions. Use these parameters to determine whether digital inputs or the BMS/PLC has control of the function. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 76
Set to Logic AND to use the serial bus AND a digital input. Set to Logic OR to use the serial bus OR a digital input. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• View and display the status of the controller, pump and system • Provides access to all parameters and start up functions • Manually reset the controller after a fault • Perform parameter backup Figure 86: Default configuration Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 78
• Coast inverse was selected as a function for a digital input (parameter group [5–1]* Digital Inputs). The corresponding terminal is not connected. • Coast activated by serial communication. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 79
• The Jog Function is activated via the serial communication. • The Jog function was selected as a reaction for a monitoring function (e.g. No signal). The monitoring function is active. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 80
Start delay In [1–71] Start Delay, a delay starting time was set. A start command is activated and the motor will start after the start delay time expires. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 81
Menu] for 5 seconds provides access to the Parameter Shortcut. The Parameter shortcut allows the user to enter a parameter number to give direct access to that parameter. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 82
WARN light comes on and text appears in the display area identifying the problem. ALARM A fault condition causes the red alarm light to flash and an alarm text is displayed/ Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 83
NOTE: Parameter data can be uploaded to the LCP through the use of the Start-Up Genie. Simply select Copy to LCP from the setup selection menu at the beginning of the Genie. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 84
1. Remove power from the unit and wait for the LCP to turn off. 2. Press and hold [Status], [Main Menu], and [OK] at the same time. While holding down the buttons, apply power to the unit. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
5. Press the [OK] key. The display shows “Press [Hand on] to start”. 6. Press the [Hand on] key. A progress bar indicates if the AMA is in progress. Stop the AMA during operation Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 86
AMA before the adjustable frequency drive entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact Xylem for service, make sure to mention the number and alarm description. NOTE: Unsuccessful AMA is often caused by incorrectly registered motor nameplate data or a too big difference between the motor power size and the adjustable frequency drive power size.
• Check for proper fusing or circuit breakers. • Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are in the open position. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
To avoid electrical hazards, disconnect: • AC mains • Any permanent magnet type motors • Any remote DC-link power supplies, including battery backups, ups and DC-link connections to other frequency converters. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• Use the up and down arrows to scroll to 5-** Digital In/Out. Press [OK] to enter the parameter group. • Use the up and down arrows to scroll to 5-4* Relays. Press [OK] to enter the parameter sub-group. The screen is shown below. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 90
Use My Personal Menu to change parameters while the system is running, such as changing Setpoint. The parameters found in My Personal Menu are shown below. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 91
No Water/Loss of Prime Function will be implemented after the time specified in No Water/Loss of Prime Protection Delay [22-27]. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 92
3-42 Ramp 1 Ramp Down Time Ramp down time (full speed to 0). Increasing this time will produce a slower ramp down. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 93
Analog In/Out Comm. and Options Profibus* CAN Fieldbus* LonWorks* Smart Logic Special Functions Drive Information Data Readouts Info & Readouts Drive Closed Loop Ext. Closed Loop Appl. Functions Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Quick Menus screen by pressing [Quick Menu] then using the up and down arrows to highlight Q4 Start-Up Genie. Press [OK] to enter the Genie. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 95
The first menu requires the user to set the language. To select a language, press [OK] to enable parameter editing. Use the up and down arrows to highlight the language then press [OK] to save the selection. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 96
Motor Current (FLA). For example, if the Motor Current (FLA) indicated on the motor nameplate is 10A and the Motor Service Factor Current (SFA) is 11.5A, enter 115% for Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 97
Pumps can then be destaged as the system demand decreases. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 98
• The PID Normal/Inverse Control [20-81] parameter is set to Inverse for the ‘Empty’ application and to Normal for the ‘Fill’ application. The ramp times are selected next. Select from either a Fast, Medium or Slow ramp. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 99
The fixed speed pumps can be staged and destaged to create a lead/lag system. The Application Type can be set to either Constant Pressure or Level Control. Set control variable units and ramps as described in Single Pump Operating Mode. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 100
If the pressure transitions back inside the SBW before the delay time expires, the timer will reset. Parameter [25-24] SBW Destaging Delay sets the delay time associated with pumps being destaged. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 101
Start Delay [1-71]. Set the Start Delay [1-71] longer than the Ramp Down Time [3-42] of the other pump or 3 seconds, whichever is longer, to avoid this condition. Refer Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 102
Pump Exercise Time is set to 10 seconds, the new lead pump will run for 10 seconds when the lead and lag pumps alternate. Set Pump Exercise Time to 0s to disable the function. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 103
If Duty Standby is enabled, set the Start Delay longer than the Ramp Down Time [3-42] of the other pump to ensure both pumps do not run at the same time. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 104
The speed range will be limited to the Minimum Speed Reference as the low speed limit and Maximum Speed Reference as the high speed Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 105
If multiple feedback sources are selected then the Feedback Function [20-20] can be configured. The Feedback Function determines how the multiple feedbacks will be used to control the system. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 106
Set-up Select Bit 0 and DI 33 is closed (connected to 24V), the controller will use SP2 (Setpoint 1 [20-21] Setup 2) as the target pressure, flow or level for the system. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 107
Setpoint and [22-86] Speed at Design Point [Hz]correlates with point B. With this information the controller can then calculate the control curve. Refer to the diagram below. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 108
[22-88] Pressure at Rated Speed. Knowing points A, C and D allow the controller to calculate point E along with the control curve which includes point B (speed, pressure and flow at design speed). Refer to the diagram below. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 109
The Dual Pump Value Increase setting applies an increase to the setpoint which will offset the additional losses associated with both pumps running. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Minimum Run Time [22-40]. The Minimum Sleep Time [22-41] forces the pump to stay in sleep mode (turned off) for the time entered in Minimum Sleep Time [22-41]. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 111
Flow Check Window. The Flow Check High Time defines how long the controller will run at setpoint plus the value set in Flow Check Window. These times are Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 112
The No Flow Power Calibration Setup provides the method to program the no flow power curve in to the controller. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 113
[OK] and then the down arrow. If any issues were encountered during the calibration process discard the data by pressing [Cancel] and repeat the calibration process. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 114
No Water/Loss of Prime Limit [22-39] corresponds the pump power consumption at 85% of full speed. The controller internally scales the No Water/Loss of Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 115
Under Pressure Delay Time [22-51]. This ensures a No Water/Loss of Prime condition will be detected properly before the Under Pressure function is triggered. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 116
(terminal 19 for digital input 19 or terminal 27 for digital input 27). Refer to the Common terminal wiring configurations section in this manual for details on control terminal wiring. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Control mode due to the specific functionality assigned to the digital inputs. NOTICE: Changing the function of any assigned digital input or output when set to Duplex Control Mode will cause the controller to malfunction. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 118
No Water/ Loss of Prime Restart signal in the Single Pump and Constant Slave mode. Refer to the Pump Protection section for details. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 119
This input can be configured for use as a Pump Protect Warning or Alarm input. See Pump Protect section to enable the Warning or Alarm associated with this input. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
= SP2. — Common Common supply 6.5.5 Relay and Analog Output Setup The Relay and Analog Output Setup allows configuration of the onboard relays and analog output signal. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 121
Below speed, low [17] Above speed, high [18] Out of feedb. range [19] Below feedback, low [20] Above feedback, high [21] Thermal warning [25] Reverse [26] Bus OK Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 122
Hand / Off [169] Auto mode [180] Clock Fault [181] Prev. Maintenance [189] External Fan Control [190] No Flow [191] No Water/Loss of Prime [192] Under Pressure Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 123
Power 4–20 mA 0–Motor rated power [137] Speed 4–20 mA 0–Speed High Limit ([4–13] and [4– 14]) [139] Bus ctrl. 0–100%, (0–20 mA) [140] Bus ctrl. 4–20 mA 0–100% Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
LCP to the controller. Select [Application only] from the Copy Setup from LCP menu to download all size independent parameters from the LCP to the controller. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
NOTE: If the power to the unit is lost, the date and time will reset to factory defaults. Battery backup for real time clock is available on the Analog I/O Option Card (Input/ Output Option "A" or Repair part number 9K653). Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
International/North American Default Parameter Settings for a complete list.) 6. Press [Quick Menu] on the LCP. 7. Use the navigation keys to scroll to parameter group Q2 Quick Setup and press [OK]. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
9. A jumper wire should be in place between control terminals 12 and 27. If this is the case, leave 5–12 Terminal 27 Digital Input at factory default. Otherwise select No Operation. For frequency converters with an optional Xylem bypass, no jumper wire is required.
Page 128
Start the motor at nominal speed. In case the application does not run well, check the plus PM settings. Recommendations in different applications can be seen in the following table: Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
When operating in local mode, [▲] and [▼] increase and decrease the speed output of the frequency converter. [◄] and [►] move the display cursor in the numeric display. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
• Speed Bypass, parameter group 4–6* • Over-modulation, 14–03 Overmodulation set to off • Switching pattern and switching frequency parameter group 14–0* • Resonance Dampening, 1–64 Resonance Dampening Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
This action puts the frequency converter into a trip condition as described above and may be reset in any of those 4 ways. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Warnings/Alarm messages A warning or an alarm is signaled by the relevant LED on the front of the frequency converter and indicated by a code on the display. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 133
DC overvoltage DC undervoltage Inverter overloaded Motor ETR over- [1–90] Motor temperature Temperature Motor thermistor over [1–90] Motor temperature Temperature Torque limit Over current Ground/earth fault Hardware mismatch Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 134
Overload of Digital [5–00] Digital I/O Output Terminal 29 mode, [5–02] Terminal 29 Mode Ovrld X30/6–7 Ext. Supply (option) Earth Fault 2 Pwr. card supply 24 V supply low Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 135
Safe Stop Auto Restart (X) [5–19] Terminal 37 Safe Stop PTC Thermistor Illegal Profile Sel. Power Unit Setup Reduced power mode X [14–59] Actual Number of Inverter Units Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 136
Home vel zero Position error Index not found Unknown cmd. SW end limit Unknown param FC not enabled Too many loops Par. save failed Param. memory Progr. memory Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 137
A trip lock is an action when an alarm occurs, which could damage the frequency converter or connected parts. A trip lock situation can only be reset by a power cycling. Table 33: LED indication Warning Yellow Alarm Flashing red Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 138
Over (A10) Over (W10) Current Low current < 4– 00000200 Inverter Discharge Onverter Discharge Output Freq Quick Stop Overld. (A9) High Overld (W9) High High speed > 4–53 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 139
< 4– 00200000 2097152 W phase Loss reserved Speed Limit RESERVED Local Sleep (A32) (W49) Reference reference site = REMOTE > auto on pressed & active Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Option Card terminals 1, 3, 5 for signals, terminals 2, 4, 6 common. Check that the frequency converter programming and switch settings match the analog signal type. Perform Input Terminal Signal Test Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 141
Check that the motor current set in warning or an alarm when the [1–24] Motor Current is correct. counter reaches 100% in [1–90] Motor Thermal Protection. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 142
Check for ground faults in the motor itself. motor by measuring the resistance to ground of the motor leads and the motor megohmmeter. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 143
A fitted option is not operational Record the value of the following with the present control board parameters and contact your hardware or software. Xylem supplier: • [15–40] FC Type • [15–41] Power Section • [15–42] Voltage • [15–43] Software Version •...
Page 144
[14–10] Mains Failure is NOT set to [0] No Function. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 145
Check that the option is properly installed. Check for loose or missing wiring. It may be necessary to contact your Xylem supplier or service department. Note the code number for further troubleshooting directions. 39 — Heatsink sensor...
Page 146
50 — AMA calibration failed Contact your Xylem supplier or Xylem Service Department. 51 — AMA check Unom and Inom The settings for motor voltage, Check the settings in [1–20] to [1–...
Page 147
Cycle power to the unit to remove controller is operating in fire the warning. See the fire mode mode. data in the alarm log on the controller. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 148
251 — New typecode A component in the frequency Reset the frequency converter for converter has been replaced and normal operation. the typecode changed. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Scaling of group 3–1* References. Check for terminals correct? Reference correct wiring. Check scaling or signal available? terminals. Check reference signal. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 150
If imbalance leg stays on same converters position: U to V, V to W, W to U. output terminal, it is a problem with the unit. Contact the supplier. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 151
Change switching pattern and acceptable limit certain frequencies) frequency in parameter group 14– 0* Inverter Switching Increase Resonance Dampening in 1–64 Resonance Dampening Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
5000 5500 6000 Typical shaft output at 400 V [kW] Typical shaft output at 460 V [hp] Enclosure IP21 Enclosure IP54 Enclosure IP20/IP00 Enclosure 3R Output current Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 153
Continuous KVA (at 550 V) [KVA] Continuous KVA (at 690 V) [KVA] Maximum input current Continuous (at 550 V) [A] Continuous (at 575 V) [A] Continuous (at 690 V) [A] Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 154
, 600 V 5493 5852 6132 Estimated power loss at rated maximum load [W] , 690 V 5821 6149 6440 Weight, enclosure IP21, IP54 [kg] Weight, enclosure IP00 [kg] Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Power card ambient trip 154.4°F (68°C) 9.2 General technical data Line powersupply Supply terminals L1, L2, L3 Supply voltage 380–480 V ±10% Supply voltage 525–690 V ±10% Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 156
Terminal number 18, 19, 27 , 29 , 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic ‘0’ PNP <5 V DC Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 157
3. 37 4. Functional isolation 5. RS485 6. Control 7. PELV isolation 8. High voltage 9. Mains 10.Motor 11.DC-Bus Figure 99: PELV isolation Pulse inputs Programmable pulse inputs Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 158
200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 159
Overvoltage category II UL applications 300 V AC 2A Control card, 10 V DC output Terminal number Output voltage 10.5 V ±0.5 V Maximum load 15 mA Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 160
The USB ground connection is not galvanically isolated from protection earth. Use only an isolated laptop as PC connection to the USB connector on the frequency converter. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 162
Table 48: Fan fuses 4500–6000, 380–480 V KLK-15 15A, 600 V Size/Type Bussmann* LittelFuse Rating 1500–4000, 380–480 V KTK-4 4A, 600 V 1500–6000, 525–690 V KTK-4 4A, 600 V Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 163
NEC fuse size (3x550/575/690 V AC) (3x550/575/690 V AC) 1500 158/151/155 2000 198/189/197 2500 245/234/240 3000 299/286/296 3500 355/339/352 4000 408/390/400 600/500/600 4500 453/434/434 5000 504/482/482 6000 574/549/549 800/700/700 Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 165
Cable lengths for each model listed is a single cable length with the numbers of wires in a phase considered, up to its corresponding Max AWG: 2x3/0, 2x350 or 4x500. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE, LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF REPUTATION. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 169
This warranty gives you specific legal rights, and you may also have other rights which may vary from state to state. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 170
To make a warranty claim, check first with the dealer from whom you purchased the product or visit www.xyleminc.com for the name and location of the nearest dealer providing warranty service. Aquavar ® Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL...
Page 172
For more information on how Xylem can help you, go to www.xylem.com Xylem Inc. Visit our Web site for the latest version of this document and more information 2881 East Bayard St.
Need help?
Do you have a question about the Aquavar and is the answer not in the manual?
Questions and answers