INSTRUCTION MANUAL IM244R04 Models Covered: SPD Plus 230V 1Ø Input 20-30 HP 230V 3Ø Input 40-60 HP 460V 40-100 HP 575V 40-100 HP C SPD Plus VARIABLE SPEED PUMP CONTROL INSTALLATION AND OPERATION MANUAL UL ® US
NOTE: This guide does not provide detailed installation, safety or operational instructions. See the Installation Operation Manual for complete information. This guide provides a quick reference for installing SPD PLUS drives having a standard enclosure (NEMA 1).
Digital input impedance 1.5 kΩ. Maximum voltage for digital inputs is 30 V. Check Environment conforms to specifications. The drive is mounted securely. Proper cooling space around the drive. Motor and driven equipment are ready for start. Floating networks: Internal RFI filter disconnected. Drive is properly grounded, with pump/motor. Input power (mains) voltage matches the drive nominal input voltage.
INDEX Important Safety Instructions................................................................................................................................................5 System Components..............................................................................................................................................................6 System Design.............................................................................................................................................
SECTION 1: SAFETY INSTRUCTIONS 5. TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL AND ON EQUIPMENT. THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE UNIT. This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump, the controller or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.
SECTION 2: SYSTEM COMPONENTS Please review the SPD Plus Variable Speed Pump Controller components and ensure that you have all the parts and are familiar with their names. Be sure to inspect all components supplies for shipping damage.
PART NUMBERS Nominal HP Rating Supply Voltage 208/230 460 575 Full Load Output Current (50C) Full Load Output Current (40C) 3 Phase Input 1 Phase Input 3 Phase Input 1 Phase Input 3 Phase Input 1 Phase Input Frame Size SPD20400 40 20 103 51 114 57 N6 SPD20400F 40 20 129 64 143 72 N6 SPD20400N1 40 20 103 51 114 57 R4 SPD20500 50 25 129 64 143 72 N6 SPD20500F 50 25 160 80 178 89 N6 SPD20500N1 50 25 129 64 143 72 R6 SPD20600 60 30 160 80 178 8
SECTION 3: SYSTEM DESIGN SPD PLUS CENTRIFUGAL PUMP CONTROL SYSTEM The SPD Plus pump controller is a simple, easy to use and commission Variable Speed Drive (VSD) designed specifically for use in submersible or above ground pump systems. The SPD Plus features an integrated Start-Up Assistant which simplifies system commissioning and setup. NOTE The SPD Plus is not recommended for the residential well applications. Consult CentriPro for suitable Variable Speed Controllers designed for residential well pumps.
SECTION 3: SYSTEM DESIGN DIAGRAM #2 shows a set-up for an Above Ground booster pump and control system. 1 2 SUPPLY POWER U1 V1 W1 GND 5 AIR 6 U2 7 V2 W2 3 PHASE OUTPUT GND TO MOTOR 9 10 9 SUCTION FLOW 4 8 8 3 1 2 3 4 5 SPD CONTROLLER FUSIBLE DISCONNECT CENTRIFUGAL PUMP CHECK VALVE PRESSURE TRANSDUCER (CABLE ASSEMBLY) SECTION 4: PIPING GENERAL NOTE All plumbing work must be performed by a qualified technician. Always follow all local, state and provincial codes.
SECTION 4: PIPING (CONTINUED) PRESSURE TANK, SYSTEM PRESSURE Sizing – A bladder tank (not included) is used to cushion the pressure system during start-up and shutdown. 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 15-20 PSI below your system pressure.
SECTION 6: POWER SUPPLY AND WIRING POWER CONNECTION DIAGRAMS The following diagrams show the power connection layout for each frame size. • For sizes R4 and N4 FIGURE 1 WARNING WARNING Hazardous voltage If the secondary of the transformer is a delta with a grounded leg (corner grounded delta) or floating network, the line to ground EMC filter components and line to ground MOV protection must be disconnected or damage to the controller can result.
SECTION 6: POWER SUPPLY AND WIRING (CONTINUED) POWER CONNECTION DIAGRAMS The following diagrams show the power connection layout for each frame size. • For sizes R5 and N5 • For sizes R6 and N6 FIGURE 2 FIGURE 3 WARNING WARNING Hazardous voltage If the secondary of the transformer is a delta with a grounded leg (corner grounded delta) or floating network, the line to ground EMC filter components and line to ground MOV protection must be disconnected or damage to the controller can result.
SECTION 6: POWER SUPPLY AND WIRING (CONTINUED) CONTROL TERMINAL CONNECTION DIAGRAM The diagram below describes the control terminal connections. NOTE Pressure sensor cable must be wired during installation. All other connections are wired at the factory.
SECTION 6: POWER SUPPLY AND WIRING UNGROUNDED SECONDARY (CONTINUED) INPUT POWER AND LINE TRANSFORMER REQUIREMENTS 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.
OPEN DELTA (CONSULT FACTORY) LINE TRANSFORMER 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 the SPD Plus installation. When in doubt contact the local power utility or the factory. This type of configuration is common on 230 volt systems.
SECTION 6: POWER SUPPLY AND WIRING 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 must then be adjusted to 75% of its value so that the maximum voltage drop of 5% is not exceeded.
WARNING Measure and verify site voltage phase to phase and phase to ground prior to connected power to the controller. NOTE Verify that there is at least 8” between input and output connections or input connections and control wiring. DANGER The controller has a high leakage current to ground. The input terminals marked “GND” must be directly connected to the service entrance ground. Failure to properly ground the controller or motor will create an electrical shock hazard.
SECTION 7: CONTROL INPUT AND OUTPUT FUNCTIONS The control terminals allow for a variety of control functions. Some of the terminals are prewired by the factory. Removing prewired connections can disable some controller functions. Refer to the information below before removing prewired connections. WARNING Turn off all power to the controller before wiring devices to the control terminals. WARNING All the DI inputs are switch inputs.
SECTION 8: STARTING THE SYSTEM APPLY POWER When power is applied to the SPD Plus Controller, the status LED turns green. SPD Plus Drive keypad functionality and Main Screen display is described below: Status LED Control Mode Motor State REM Motor Speed Reference Value 40.2 PSI sp 0.0 PSI ac 0.0 HZ DIR 11.
SECTION 8: STARTING THE SYSTEM (CONTINUED) START-UP ASSISTANT Do you want to use the start-up assistant? YES NO EXIT If this is the first time that the drive has been powered or the StartUp Assistant has not been run, the display will prompt the user if they would like to run the Start-Up Assistant. Select Yes using the up and down arrows then press OK to run the Start-Up Assistant.
RAMP SPEED SETTING: Select the ramp speed based on the system requirements. The ramp speed sets the acceleration and deceleration time for the motor. The acceleration time is the time for the motor to transition from 0Hz (stopped) to 60Hz (full speed). The deceleration time is the time for the motor to transition from 60Hz (full speed) to 0Hz (full stopped). The FAST ramp selection sets the acceleration ramp to 5 seconds and the deceleration ramp to 8 seconds.
SETTING PRESSURE SETPOINT When in REM mode, set the desired pressure setpoint by pressing the Up or Down arrow keys on keypad. Push and hold the Up or Down arrow keys until the desired pressure setting is obtained. The pressure setpoint is displayed on the first row of the Main Screen display with units of ‘PSI SP’. The actual system pressure reported by the pressure transducer is displayed on the second row of the Main Screen display with units of ‘PSI AC’.
SECTION 9: TROUBLESHOOTING (CONTINUED) The fault code on the control panel display is temporary. Pressing any of the following buttons removes the fault message: MENU, ENTER, UP button, or DOWN button. The message reappears after a few seconds if the control panel is not touched and the fault is still active. FLASHING GREEN – ALARMS: For less severe errors, called alarms, the diagnostic display is advisory. For these situations, the drive is simply reporting that it had detected something “unusual.
SECTION 9: TROUBLESHOOTING (CONTINUED) FAULT LISTING Fault Code 8 Fault Name In Panel TRANSDUCER LOSS Description and Recommended Corrective Action Signal from the pressure transducer is out of range. Check for and correct: • Source and connection for analog input. • Vacuum in the system. Remove sensor from piping to release vacuum. • Failed pressure transducer. To diagnose this failure a meter capable of reading milliamperes (mA) and DC voltage (VDC) is required.
SECTION 9: TROUBLESHOOTING (CONTINUED) FAULT LISTING Fault Code Fault Name In Panel Description and Recommended Corrective Action 16 EARTH FAULT Possible ground fault detected in the motor or motor cables. The drive monitors for ground faults while the drive is running the motor and while the motor is stopped. Detection is motor sensitive when the drive is not running and can produce false positives. Possible corrections: • Check for/correct faults in the input and output wiring.
SECTION 9: TROUBLESHOOTING (CONTINUED) FAULT RESETTING WARNING If an external source for start command is selected and it is active, the SPD Plus may start immediately after fault reset. FLASHING RED LED To reset the drive for faults indicated by a flashing red LED: • Turn the power off and wait 5 minutes. Turn the power back on CONSTANT RED LED To reset the drive for faults indicated by a constant (not flashing) LED, correct the problem and do one of the following: • Press RESET from the control panel.
SECTION 9: TROUBLESHOOTING (CONTINUED) TROUBLESHOOTING FAULTS, ALARMS AND PERFORMANCE PROBLEMS In Troubleshooting, always consider the following possibilities: • Faults — Press Reset key first, enter Start Up Assistant and verify the settings are appropriate. • Electrical supply/ motor/ wiring/grounding — check your supply voltage, motor wiring, transducer wiring, and grounding. • Mechanical/Pump/ Rotation — check pump rotation, rubbing or other mechanical problems; pump “run out”.
APPENDIX A: INPUT POWER SPECIFICATIONS (CONTINUED) capacitors (do this also if the grounding configuration of the system is unknown), see SECTION 6: POWER SUPPLY AND WIRING for details. 4) Power Factor Capacitor Isolation: Input transformers are sometimes used to provide impedance to isolate drives from line connected power factor correction capacitors.
APPENDIX B: FUSE AND WIRE SIZING FUSES Branch circuit protection must be provided by the end user and sized per national and local electric codes. The following tables provide fuse recommendations for short circuit protection on the drive's input power. The rated fuse currents given in the tables are the maximums for the mentioned fuse types. If smaller fuse ratings are used, check that the fuse Arms current rating is larger than the input current.
APPENDIX B: FUSE AND WIRE SIZING (CONTINUED) WIRE SIZING The tables below show the maximum recommended cable lengths for each model. Note that the tables show the cable length which will produce a 5% voltage drop on the cable. The recommended total voltage drop across all system cables is 5%. Because of this the lengths given in the table must be adjusted so the total voltage drop does not exceed 5%.
APPENDIX B: FUSE AND WIRE SIZING (CONTINUED) SPD PLUS OUTPUT WIRE SIZING CHARTS Maximum Allowable Conductor Length (50˚C Ambient, 5% drop) Controller Ratings Controller Output 230V 460V 575V Conductor Size for 75˚C Rated Wire (Lengths in Bold Require 90˚C Rated Wire) Motor HP Motor FLA 20 54 25 68 30 82 40 96 50 116 60 130 40 53 50 70 60 80 75 96 100 127 40 43 50 54 60 64 75 76 100 101 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 408 522 667 846 1075 1364 17
APPENDIX C: WEIGHTS AND DIMENSIONS (CONTINUED) NEMA 1 Mounting Dimensions R4 Ref. R5 R6 mm in mm in mm in W1* 160 6.3 238 9.4 263 10.4 W2* 98 3.9 — — — — H1* 578 22.8 588 23.2 675 26.6 a 6.5 0.25 6.5 0.25 9 0.35 b 13 0.5 14 0.55 14 0.55 c 8 0.3 8.5 0.3 8.5 0.3 d 6.5 0.25 6.5 0.25 9 0.35 *Center to center dimension. NEMA 1 Weights R4 32 R5 R6 kg lb. kg lb. kg lb. 22.8 50.
APPENDIX C: WEIGHTS AND DIMENSIONS (CONTINUED) NEMA 3R Enclosures Frame Size N4 Frame Size N5 Frame Size N6 NEMA 3R Enclosure Dimensions N4 Ref. N5 N6 mm in mm in mm in W 530.9 20.9 762.0 30.0 914.4 36 H 967.7 38.1 990.6 39.0 1590.0 62.6 D 388.6 15.3 33.7 15.5 546.1 21.5 NEMA 3R Wall Mounting Dimensions N4 Ref. N5 N6 mm in mm in W1 398.8 15.7 723.9 28.5 H1 916.9 36.1 876.3 34.
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LIMITED WARRANTY This warranty applies to this Xylem Inc. product. 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 Xylem Inc.
