INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 10-001-262 REV 5 AQUAFORCE Pump Controller VARIABLE SPEED PUMPING SYSTEMS
AQUAFORCE Installation, Operation, and Maintenance
Table of Contents Table of Contents 1. Introduction and safety.....................................................................................................................................................1 1.1 Introduction.....................................................................................................................................................................1 1.2 Safety.........................................................................................................
Table of Contents 4.10.22 Test Set Up.................................................................................................................................................. 28 4.10.23 Digital Input Test....................................................................................................................................... 28 4.10.24 Digital Output Test....................................................................................................................................
Table of Contents 6.13.12 Events.......................................................................................................................................................... 47 6.14.13 System On/Off ......................................................................................................................................... 47 6.14.14 Alternation............................................................................................................................................
AQUAFORCE Installation, Operation, and Maintenance
Introduction and Safety 1. Introduction and Safety 1.1 Introduction 1.1.0 Purpose of the manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. NOTICE: Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety 1.3.1 Hazard levels Hazard level Indication DANGER: A hazardous situation which, if not avoided, will result in death or serious injury. WARNING: A hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE: • A potential situation which, if not avoided, could result in undesirable conditions.
Introduction and Safety 1.6 User safety 1.6.0 General safety rules These safety rules apply: • Always keep the work area clean. • Pay attention to the risks presented by gas and vapors in the work area. • Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards. • Always bear in mind the risk of drowning, electrical accidents, and burn injuries. 1.6.1 Safety equipment Use safety equipment according to the company regulations.
Introduction and Safety 1.6.4 Wash the skin and eyes Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin: If you need to wash your . . . Then . . . Eyes 1. Hold your eyelids apart forcibly with your fingers. 2. Rinse the eyes with eyewash or running water for at least 15 minutes. 3. Seek medical attention. Skin 1. Remove contaminated clothing. 2. Wash the skin with soap and water for at least one minute. 3.
Transportation and Storage 2. Transportation and Storage 2.1 Inspect the delivery 2.1.0 Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. 2.1.1 Inspect the unit 1. Remove packing materials from the product.
Product Description 3. Product Description 3.1 General description 3.1.0 Description The controller is a specific purpose programmable pump controller. This provides: • Optimum pump control without the cost of general purpose control hardware. • Software dedicated and established for the unit. • Unique analog input protection of other members of the control family. In the event of a short circuit condition, the current limit circuitry prevents failure of the analog input components.
Product Description Nameplate Data Explanation Model Number The manufacturer’s number to indicate the particular type of product which has been acquired. Serial Number A set of characters that uniquely identifies a single unit and can be used for traceability and warranty purposes. Station Voltage The rated voltage at which the station has been designed for. Should match the application site supply voltage.
Product Description 3.4.4 Analog signals Shielded cable (#22 AWG, Belden type 8762, Alpha #2411, or equal) should be installed for all D.C. control wiring. The shield must be terminated in the Controller panel. Do not connect the shield at the other end of the cable! Insulate the shield so that no electrical connection is made at the other end of the cable. A twisted pair of #22 AWG conductors (Belden 8442, or equal) can be used in place of shielded cable.
Installation 4. Installation 4.1 Field connections 4.1.0 Diagrams Review the wiring diagrams and dimensional drawings before you install and operate the unit. 4.1.1 Electrical precautions WARNING: • Prevent electrical shocks. Disconnect the power supply before beginning installation. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH AND/OR PROPERTY DAMAGE. • Each motor must have a properly sized drive. Ground fault protection should be sized properly.
Installation To control variable frequency drives it is necessary to wire RS485 with each VFD. With certain bypass and control methods it is necessary to disable the adjustable frequency drive from running. This is accomplished by wiring from the terminals to each VFD’s interlock terminals. Should this wiring be required, any jumpers which may be found on the VFD’s interlock terminals should be removed. The control family may be provided with the capability to accept many analog inputs.
Installation 4.5 System piping and unit installation – final checklist 1. Check that the unit base is properly leveled, grouted and secured. 2. Check that all lubrication points are properly lubricated per motor manufacturer’s instructions. 3. Check that the shut-off valves to the transmitters open. 4. Check that the shut-off valves to the pump suction open. 5. Check that the shut-off valves to the discharge line open. 6. Check that the piping is properly supported to prevent strains on the unit. 7.
Installation 4.7 Operator interface panel 4.7.0 Diagrams The OIP consists of a 4 x 20 character LCD screen and a 26 button keypad with LEDs which display system status. The OIP communicates through a CAN bus to the CPU 4.7.1 Key functionality The names of the keys on the Operator Interface Panel (OIP) are shown as CAPITAL LETTERS in this manual. Table 1 shows the functionality of the keys on the OIP.
Installation 4.7.2 Table 1 Key Functionality Key Name START/STOP Functionality Starts or stops the system. AUTO/ MANUAL Toggles the operation mode. The system must be stopped to change the operation mode. PUMP 1-4 ENABLE Enables or disables the corresponding pump. Pumps cannot be disabled while they are failed. RESET/ SILENCE This key is used to reset alarms and events. When the A/V Alarm relay output is set. Pressing of this key resets the alarms and events.
Installation 4.8 LEDs Table 2 gives the meaning of the LED states. LED Description START/STOP On = Start Off = Stop AUTO/ MANUAL On = Auto Off = Manual PUMP 1-4 On = Pump On Off = Pump Disabled Blink = Pump Ready, Blink Fast = Pump Failed RESET/ SILENCE Off = OK Blink = Reset Required HELP Off = OK Blink = Event/Alarm(press HELP from the status screens to view) 4.9 I/O 4.9.
Installation 4.10 Set up & features Note: Many sections of the Set up & Features show a path for navigation. An example is shown below to understand the given path. Example for system setup path. Path: Status Screen / Setup(3) / System(4) To follow the above path press the SETUP/3 key from the system status screen. Then press the ALT/4 key for number 4 which is a selection number for system and press ENTER key. It will lead to the system setup screen.
Installation REDIS MENU ITEMS Menu Item Variable Default Range Field Value REDIS Active Sensor : ## 1 1-2 5 0-100 Enter the active discharge pressure sensor number Drift Threshold: ##% Pressure difference limit between the active and redundant pressure sensor in % Drift Pr Tm : ##s Proof timer prior to give warning when exceed the drift threshold limit, in seconds 0 0-999 To set up each field, press the NO/0 key and then press the ENTER key.
Installation To set up each field, press the NO/0 key and ENTER key. Modify the values as desired using the appropriate keys. Modify the values as desired for pump 1. Note: For example, to enter a value of 3.5 Amps, go to the amps field, press numerical key 3 and enter. Then press key 5 and enter. press ▲ To change the values for other pumps, press the NEXT/( ) key. This is only applicable if the total numbers of pumps selected in TOTAL PUMPS: # field are more than 1.
Installation < SELECTION: # > 8 = PASSWORD 0 = EXIT 9 = I/O SETUP 10 =COMMUNICATIONS < ) key to go to the next screen. The display now shows: ▲ Press the NEXT/( SELECTION: # > 11 = FRIC. LOSS COMP. 12 = SAVE/LOAD 13 = DISPLAY 0 = EXIT ▲ Pressing the NEXT/( ) key again will take the screen back to the first screen. Use the appropriate numeric key to select the desired menu, then press the ENTER key. A detailed description of each menu follows.
Installation STAGE/DESTAGE SETUP MENU ITEMS (continued) Menu Item Variable Default Range Field Value PV Destage Destage: ###% 85 0-100 Enter the percentage of the stabilized speed at which the lag pump will stop, %. Destg Pr Timer: ### s Proof timer prior to stopping lag pump, seconds. HD Spd: ### % The lowest speed at which parallel pumps will operate prior to destaging the lag pump, %. It must be greater or equal to minimum frequency.
Installation Use the appropriate numeric key to select the desired menu, then press the ENTER key. See the following table for all VFD menu items.
Installation Note: 1. Use the (▲) and (▼) keys to select the appropriate resolution values ▲ ) key and Prev/( ▲ 2. Use the Next/( variables ) key to select the desired sign(+ or -) for VALUE and OFFSET 4.10.5 Exercise menu Paths: Status Screens / Set up(3) / System(4) / Exercise(3) See the following table for all EXERCISE menu items.
Installation 4.10.8 Alternation basis See the following table for ALTERNATION BASIS menu items. Alternation Basis Menu Items Menu Item Variable Default Range Field Value Alternation Basis 1=Pump Sequence 1 1-2 (The next pump in sequence will become the lead pump after alternation) 2=Pump Run Time (The pump with the lowest run time will become the lead pump after alternation) 4.10.
Installation 4.10.11 Date, time menu Paths: Status Screens / Set up(3) / System(4) / Date, Time(7) See the following table for all DATE, TIME menu items Date, time Menu Items Menu Item Variable Default Range Field Value Date/Time MM Enter the current month using both digits, example Jan. should be entered as 01. DD Enter the current date using both digits, example the 6th should be entered as 06. YYYY Enter the current year using all 4 digits.
Installation Password Menu Items (continued) Menu Item Variable Default Range Field Value Verify VERIFY THE PASSWORD PASSWD >_ _ _ _ _ _< After entering data in password definition screen this screen requires the user to confirm the requested password. If the confirmed number does not agree with the first number the Enter New Password screen is repeated to allow the user to get both input screens to agree. 4.10.
Installation See following table for all MODBUS menu items. Modbus Menu Items Menu Item Variable Default Range Field Value Modbus Baud: ##### 9600 9600, The baud rate is user adjustable parameter 19200, 38400 Node: ### 10 0-255 The node number should be supplied by the BMS communications port. AI Ovrd: $ N Y/N Select “Y” to override analog inputs through the communications port. 4.10.
Installation Note: “Setpoint” In figure 1 is the maximum control setpoint, will correspond to the controlling setpoint from the SP1 value. Refer to section 5 for SP1 value selection. Friction Loss Compensation Menu Items Menu Item Variable Default Range Field Value Frict. Loss: ### 0 0-999 Total friction loss of the system in PSI. Contact to piping engineer to calculate system friction loss.
Installation 4.10.18 Save to flash The Save To Flash screen is displayed below: SAVE TO FLASH Previously Saved Data Will be overwritten! PROCEED: $(Y/N) Press YES and ENTER to save all of the user setup to the flash memory. Saving to flash will overwrite any data that was previously saved. Saving to flash memory will save all setup information to the Flash PROM chip within the controller A load from flash will have to be performed to recover this saved data. See the following section. 4.10.
Installation See following table for all DISPLAY menu items.
Installation 4.10.25 Analog input test Paths: Status Screens / Set up(3) / Test(5) / AI(3) The Analog Input Test screen is displayed below: Analog Inputs 1=###% 2=###% The signal received on the corresponding analog input channel will be indicated in percent next to each input. 4mA = 0%, and 20mA = 100%. Analog inputs 1-2 are 4-20mA inputs. Press CLEAR key to exit the test. 4.10.
Installation 4.10.30 Communication test Paths: Status Screens / Set up(3) / Test(5) / Comm(8) The COMMUNICATION test screen is shown below: Communication Test Read: #### Write: #### Press Clear to Exit If the controller is communicating properly with the building automation system, both numbers will continue increasing in value. For Modbus protocol, the read and write numbers should be equal and increasing with every poll.
Installation 4.10.33 Low discharge pressure Paths: Status Screens / Set up(3) / AlrmEvt(6) / Low Discharge(2) The Low Discharge Pressure menu is displayed below: Low Dis Press: ##PSI Low Dis Pr Tm: ##s Alarm: $ Stop Pumps: $ OK? $ (Y/N) See following table for all LOW DISCHARGE PRESSURE menu items.
Installation See following table for all LOW SUCTION PRESSURE menu items. Low Suction Pressure Menu Items Menu Item Variable Default Range Field Value Low Suction Pressure Low Suct Press: ### 5 0-999 The pressure below which an alarm or event will be set. Pr Tm: ###s 20 0-999 The proof timer prior to setting an alarm or event. A value of 0 will disable this alarm.
Installation 4.10.37 Low water Paths: Status Screens / Set up(3) / AlrmEvt(6) / LowWater(7) The Low Water menu is displayed below: Low Water Proof Time: ###s Alarm: $(Y/N) OK: $ (Y/N) See following table for all LOW WATER menu items. Note: To use the Low Water function connect the low water switch as a optional D1. See the wiring diagram in Appendix to connect the switch.
4.11 Q-Start Paths: Status Screens / Set up(3) Press the PV/1 key at the Main Set Up menu display. Then press the ENTER key. ▲ Q-Start will prompt the user for the parameters required to start up the system quickly. Some of these values will already be correct due to the factory setup that is done for each AquaForce Pump Controller. Use PREV/( ) and NEXT/( ) to navigate through these screens.
Operation 5. Operation 5.1 Normal Scrolling Operation Other screens may be viewed by scrolling from the AquaForce Pump Controller screen shown below: CONTROLLER MM/DD/YY HH:MM:SS A/P STAT1 STAT2 STAT3 The STAT1 portion of the display indicates the current start/stop status of the system. The STAT2 portion of the display indicates the current auto/manual mode of operation.
Operation 5.2 Auto Operation System can run up to 4 pumps/VFDs in Auto Operation. All pumps may stage and run variable speed. Confirm the setup of the following items: Section Item Value 4.10.1 Total # of pumps Up to 4 4.10.3 PV stage speed % 95% 5.2.0 Local automatic operation With the JUMPER connected on Terminal 200 and +24V check that the LED indicators on the Operator Interface Panel (OIP) for two pumps are as follows: LED Condition Meaning Start/Stop Off System is stopped.
Operation 5.4 Hand Manual Operation 1. If system is running press the START/STOP key to stop the system. The solid green LED for start/stop will turn off and any running pumps will stop. 2. Press the AUTO/MANUAL key and the screen will display the following: < > Manual Speed: #% STAT1 STAT3 STAT2 3. If the PUMP LED is not flashing green, enable a pump to run in manual by pressing the PUMP 1 or PUMP 2 key. 4. Press the START/STOP key to run the enabled pump(s) in manual.
Operation 5.6 Process Variable Monitoring To view the actual process variable signals that are being sent to the controller press the PV/1 key. The following will be displayed: ACT = ### SP1 = ### HZ = ## The # symbol will be replaced by the actual value of process variables and set points. 5.7 Alarms/Events When the controller detects an alarm/event condition, the display will flash *ALARM/EVENT* in the lower right corner of the main screen.
Operation 5.8 Quick Access Using quick access function user can directly jump to the setup screen need to be setup. To use this function press QUICK ACCESS/6 key from status screen. The display now shows. Enter Quick Access Number. See Section 7.6 for Quick Access numbers. Exit $ (Y/N) Press NO/0 to edit the page number. Enter the screen number need to be access and press the ENTER key. It will lead to the setup screen entered. Refer the appendix for the quick access screen numbers.
Maintenance 6. Maintenance 6.1 Preface The following is a description of the hardware, diagnostics, and corrective action to maintain a process being controlled by the Pump Controller. NOTE: THE FOLLOWING SHOULD NOT BE INTERPRETED AS THE MAXIMUM CONFIGURATION OF THIS CONTROLLER, RATHER THIS DESCRIBES ITS APPLICATION AS AN AQUAFORCE PUMP CONTROLLER ONLY. 6.
Maintenance 6.8 Power Supply The power supply provides 24 VDC for all digital and analog signals as well as the CPU. It is specifically rated only for the controller and other loads should not be applied without factory approval. The power supply is protected with both primary and secondary fusing as indicated in the wiring diagram. The size of these fuses is indicated on a sticker inside each enclosure. DANGER: • Troubleshooting live control panels exposes personnel to hazardous voltages.
Maintenance 6.11 Field Repair 6.11.0 General Typical field repair should include: replacing fuses, replacing input/output modules and assuring connections are correct and secure. DANGER: • Troubleshooting live control panels exposes personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE. 6.
Maintenance 6.13 Troubleshooting VFD FAILURE a. Remedy: i. Cycle Power to VFD and Station. ii. Check power wiring and fuses for affected VFD. iii. Check all wiring between VFD and PLC. iv. Check to be sure VFD is not in LOC mode. HIGH SYSTEM (Discharge): a. Remedy: i. Check application for high discharge pressure conditions. Does the mechanical gauge on the discharge header match the actual pressure displayed on the PLC? ii. Check suction pressure conditions.
Maintenance 6.14 Program type and version number To check the program type and version number, press the INFO/8 key while at the Pump Controller status screen. The screen will now display: Sys Info CPU V ### AS V ### OS #### Prog Type: ##### Scheme No: # SW# ## Press the CLEAR key to exit this screen. The # symbol will be replaced by the actual version numbers and program type. If the factory is called for information or service on this unit this information may be requested. 6.14.
Maintenance 6.14.3 Pump log Paths: Status Screens / Log(5) / Pump Log (2) / Pump Log(1) The display now shows: MMDD HHMM PUMP ON/OFF MESSAGE MMDD HHMM PUMP ON/OFF MESSAGE MMDD HHMM PUMP ON/OFF MESSAGE MMDD HHMM PUMP ON/OFF MESSAGE ▲ ▲ Every pump ON/OFF occurrence will be logged along with the date and time. The forty most recent occurrences will be stored. The date is displayed in MMDD format and the time is displayed in HHMM format. The most recent occurrence is shown first.
Maintenance 6.14.8 Totalized value Paths: Status Screens / Log(5) / Data Log(3) / Totalized Value(2) The display now shows: Total KWHr ### The total accumulated kilowatt hours and Flow is displayed as the Totalized Value 6.14.9 Operation Paths: Status Screens / Log(5) / Operation(4) The display now shows: 1=Op Mode Changes 2=Power Cycles 3=Events ) key to go to the next screen.
Maintenance 6.14.12 Events Paths: Status Screens / Log(5) / Operation(4) / Events(3) The display now shows: Selection: # 0=Exit 1=System On/Off 2=Alternation 3= Sys Rset 4=Events Use the appropriate numeric key to select the desired sub-menu, then press the ENTER key. A detailed description of each sub-menu appears. 6.14.
Maintenance 6.14.16 Events Paths: Status Screens / Log(5) / Operation(4) / Events(3) / Events(4) The display now shows: MMDD HHMM Event Message MMDD HHMM Event Message MMDD HHMM Event Message MMDD HHMM Event Message ▲ ▲ Every time an event occurs, it gets logged. The forty most recent logs will be stored. The date is displayed in MMDD format and the time in 24 hour HHMM format. The most recent event will be shown first. Press NEXT/( ) and PREV/( ) to view more log events. Press CLEAR to exit.
Maintenance 6.14.20 Service log Paths: Status Screens / Log(5) / Service Log(5) The display now shows: 1 = Error Log 2 = Operation Hours 3 = Destage Speed 4 = Run Time Setpoint Press the Next (►) key to see the next display. The display now shows: Use the appropriate numeric key to select the desired sub-menu, then press the ENTER key. A detailed description of each sub-menu appears. 6.14.
6.15 Maintenance (Physical) 6.15.0 Electrical No maintenance is required for the electrical panel except to keep the modules free of dirt and dust that might hold moisture. Cabinet door should be kept closed, and the components kept dry. 6.15.1 Mechanical • If a Goulds pump was supplied it was lubricated at the factory. Future lubrication should be according to the instructions that came with the pump. • If there is a danger of freezing, drain the pump. Inspect pump and system piping regularly.
7. Appendix 7.
Appendix 7.2 AquaForce MODBUS Communication Points Function Points # Point Code Description 52 Range/ Value Modbus Address Units 02 1 Pump #1 VFD Failure 1 = Failure 0 = O.K. 10001 02 2 Pump #1 Off Alarm 1 = Alarm 0 = O.K. 10002 02 3 Pump #2 VFD Failure 1 = Failure 0 = O.K. 10003 02 4 Pump #2 Off Alarm 1 = Alarm 0 = O.K. 10004 02 5 Pump #3 VFD Failure 1 = Failure 0 = O.K. 10005 02 6 Pump #3 Off Alarm 1 = Alarm 0 = O.K.
Appendix 7.
Appendix 7.
Appendix 8. Symbols # - Numeric input field, such as 0, 1, 2,...
Notes 56 AQUAFORCE Installation, Operation, and Maintenance
Notes AQUAFORCE Installation, Operation, and Maintenance 57
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