CentriPro AQUAVAR CPC User manual
AQUAVAR®CPC
(Centrifugal Pump Control)
INSTALLATION AND OPERATION MANUAL
INSTRUCTION MANUAL
IM167R08
2
AQUAVAR®CPC
Centrifugal Pump Controller
Quick Start Guide
Overview
The installation of the AQUAVAR CPC adjust-
able speed drive follows the outline below.
Task
PREPARE for installation
UNPACK the drive
PREPARE mounting location
REMOVE the front cover
MOUNT the drive
INSTALL wiring
CHECK installation
REINSTALL the cover
APPLY power
START-UP Wizards
Application
This guide provides a quick reference for
installing Aquavar CPC drives having a stan-
dard enclosure (NEMA 1).
NOTE: This guide does not provide detailed
installation, safety or operational instruc-
tions. See the Installation Operation Manual
for complete information.
Prepare for Installation
WARNING! The Aquavar should ONLY
Check
frequency and voltage range must match drive
specifications (3 phase motor only).
indoor controlled environment that is suitable for
the selected enclosure below 104º F.
requirements. Refer to NEC, Local, State or Munici-
pal codes.
Refer to the Installation Operation Manual and
confirm that all preparations are complete.
Tools Required
Screwdrivers, wire stripper, tape measure, mount-
ing screws or bolts, and drill.
Use the following chart to interpret the type code
found on the drive label.
Collect Motor Data
Collect the following data from the motor nameplate
plate for later use in the Aquavar startup:
______________________________
_______________
___________________
______________________
_______________________
Unpack the Drive
NOTE: Lift the Aquavar by its chassis and not by
its cover.
1. Unpack the drive.
2. Check for any damage and notify the
shipper immediately if damaged com-
ponents are found.
3. Check the contents against the order
and the shipping label to verify that all
parts have been received.
Prepare the Mounting Location
The drive requires a smooth,
vertical, solid surface, free from
heat and moisture, with free
in.) above and below, and 25
mm (1 in.) around the sides of
the drive.
1. Mark the mounting
points.
Remove the Front Cover
1. Remove the control panel
(display), if attached.
2. Loosen the
captive screw
at
the top.
3. Pull near the
top to remove
the cover.
Mount the Drive
1. Position the
AQUAVAR and use
screws or bolts to
securely tighten all
four corners.
2. Attach a warning
sticker in the
appropriate lan-
guage on the inside
plastic shell.
Install the Wiring (copper only)
1. Install thin-wall conduit clamps (not
supplied) in the conduit/gland box.
2. Install conduit/gland box.
Wiring Power
1. Connect conduit runs to box.
2. Route input power and motor
wiring through conduits.
1
X0002
CPC 4 370 1
AQUAVAR®(Series)
Voltage
Amps
370 Amps *See Technical Section
NEMA Enclosure Rating
Options
* Consult factory for other options, if available.
Not all combinations may be available.
3. Strip wires.
4. Connect power, motor and
ground wires to the drive terminals.
See “Power Connections”
in the instruction manual.
Frame Sizes R1…R4
* Single phase input power must use U1, W1
and PE for wiring.
WARNING!
remove screws at EM1 and EM3 on
Frame Sizes R1…R4.
Frame Size R5
Frame Size R6
WARNING!
-
works remove
screws at
F1 and F2
on Frame
Sizes R5 or R6.
3
Wiring the Transducer
1. Route the
transducer
cable
through
the conduit.
2. Strip the
transducer
cable
sheathing
and twist
the screen
wire.
3. Connect the screen
wire of the
transducer to
terminal X1-1.
4. Connect the power supply wire of the
transducer (red or brown) to terminal
X1-10.
5. Connect analog output wire from the
transducer (white or black) to X1-5.
See chart in next column.
Note 1. Jumper Setting: (Analog Input)
J1 AI1: 0…10 V
AI2: 0(4)…20 mA (default)
Relay output 1, pro-
2
= run power to drive
20 RO1A Maximum: 250 VAC/
21 RO1B Minimum: 500 mW
(12 V, 10 mA)
Relay output 2, pro-
22 RO2C
2
= ready, pump is
running
23 RO2A Maximum: 250 VAC/
24 RO2B Minimum: 500 mW
(12 V, 10 mA)
Relay output 3, pro-
2
= not used
26 RO3A Maximum: 250 VAC/
27 RO3B Minimum: 500 mW
(12 V, 10 mA)
6. Install the conduit/gland box cover (1
screw).
X1 Control Wiring
To activate a digital input,
there must be ≥+10V
(or ≤-10V) between that
12
may be provided by the
AQUAVAR (X1-10) or by
an external 12…24V
source of either polarity.
2= run enable
2= low water
2
= E-stop or jumper
2
= set point selection
2= not used
2= not used
1Ω. Maximum voltage
for digital inputs is 30 V.
2
pump.
NOTE: Jumper Wires between 3 and 11, 10 and 15,
11 and 12.
Check Installation
Before applying power, perform the follow-
ing checks.
√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.
Input power (mains) voltage matches the drive
nominal input voltage.
The input power (mains) terminals, U1, V1, W1,
are connected and tightened as specified.
The input power (mains) fuses / mains switch installed.
The motor terminals, U2, V2, W2, are connected
and tightened as specified.
Motor cable is routed away from other cables.
NO power factor compensation capacitors are
connected to the motor cable.
Control terminals are wired and tightened as specified.
NO tools or foreign objects (such as drill shavings) are
inside the drive.
NO alternate power source for the motor is connected
Reinstall the Cover
1. Align the cover
and slide
it on.
2. Tighten
the
captive screw.
3. Reinstall the
control panel.
Apply Power
Always reinstall the front cover before
turning power on.
WARNING! The AQUAVAR
will start up automatically at
power up, if the external run
command is on.
1. Apply input power.
When power is applied to the AQ-
NOTE! Before increasing motor
speed, check that the motor is run-
ning in the desired direction.
Start-Up
In Start-Up, enter motor
data (collected earlier)
and, if needed, edit pa-
the drive operates and
communicates.
Wizards
The Start-Up
Wizard steps through
typical start-up selections and runs
automatically upon the initial power
up. At other times, use the steps
below to run the Start-Up Wizard.
1. Use the MENU key to access the
Menu list.
2. Select Wizards.
3. Select Start-Up Wizards.
4. Follow the screen instructions to
configure the system.
DEFAULT PASSWORD IS “66”.
NOTE! For common parameters and
menu items, use the Help Key to
display descriptions. If you encounter
Alarms or Faults, use the Help Key or
instruction manual.
5
3
1
ON
ON
DIR MENU
REM 11.1%
LOC
REM
40.2 PSI sp
0.0 PSI ac
0.0 HZ
Relay Outputs
E-stop
or
Jump-
er
Jumper
Wire
ON
ON
X1 Control Wiring
Terminal for transducer
1 SCR shield. (Connected inter-
nally to chassis ground.)
Analog input channel 1,
2
= frequency reference.
Resolution 0.1%,
2 AI1 accuracy ±1%.
J1:AI1 OFF: 0…10 V (Ri =
312 kΩ)
J1:AI1 ON: 0…20 mA (Ri
= 100 Ω)
Analog input circuit com-
mon. (Connected inter-
3
nally to chassis gnd.
through 1 MW. Jumper
wire to X1-11.)
10 V/10 mA reference
4
+10V
voltage output for analog
input potentiometer,
accuracy ±2%. (Not used.)
Analog input channel 2.
Resolution 0.1%,
5 AI2 accuracy ±1%.
Transducer input
Analog input circuit com-
6
mon. (Connected inter-
nally to chassis gnd.
through 1 MΩ)
Analog output, program-
7AO1 2= Not
used. Current 0…20 mA
(load < 500 Ω)
Analog output, program-
8AO2 2= Not
used. 0…20 mA
(load < 500 Ω)
Analog output circuit
9
common (Connected
internally to chassis gnd.
through 1 MΩ)
Auxiliary voltage output
10
+24V
Short circuit protected.
Transducer/digital input
power supply.
Auxiliary voltage output
Trans-
ducer
Screen/
Shield
Trans-
ducer
(4 -20
mA)
Conn-
ection
(White
or
Black)
Analog I/O
Trans-
ducer
Power
Supply
(Brown
or Red)
Jump-
er
Wire
11
and
12
Digital Inputs1
E-stop
or
Jump-
er
Jump-
er
Wire
11
and
12
E-stop
/start
Jump
to
+24V
for en-
able
(15
to 10
Jump-
er)
Digital Inputs1
4
FEATURES
Quick Reference Guide
Analog Output, 102
Auto Restart, 102
Energy Savings Information, 103
Fieldbus Control, 103
Keypad (Control Panel), 104
Language, 104
Locking,104
Low Water Protection, 108
Manual Override, 104
Minimum Speed Options, 105
Pump Protect Control, 107
Ramp Hysteresis, 113
Ramp Settings, 113
Regulation Mode, 107
Relay Outputs, 107
Restart Value, 106
Secondary Protection, 108
System Curve Compensation, 110
Test Run, 111
Tuning, 111
Window (Regulation), 112
5
Section 1 SAFETY
Use of Warnings and Notes.........................................................................................................................................7
Section 2 POWER DISTRIBUTION SYSTEMS
...................................................................................................................9
.................................................................................................................................9
Ungrounded secondary...............................................................................................................................................9
Resistance grounding and ground fault protection...............................................................................................10
..................................................................................................................................................................10
Single Phase Connection...........................................................................................................................................10
Section 3 INTRODUCTION
Input Power and Line Transformer Requirements ..................................................................................................11
..........................................................................................................11
Installation Flow Chart ...............................................................................................................................................13
Aquavar CPC Product Numbering ...........................................................................................................................14
........................................................................................................15
Section 4 INSTALLATION (Frames R1-R6)
Supply Connection.....................................................................................................................................................19
Thermal Overload and Short-Circuit Protection.....................................................................................................19
Ground Fault Protection.............................................................................................................................................19
.............................................................................................................................................19
Selecting the Power Cables.......................................................................................................................................20
Motor Cable Shield ....................................................................................................................................................20
Additional US Requirements.....................................................................................................................................20
......................................................................................................................................................21
...................................................................................................................................24
...........................................................................................................26
Wiring IP 21 / UL Type 1 Enclosure with Conduit...................................................................................................27
Wiring IP 54 / UL Type 12 Enclosure with Conduit.................................................................................................28
Power Connections ....................................................................................................................................................29
Control Wiring.............................................................................................................................................................30
Communications.........................................................................................................................................................31
Installation Check Sheet ............................................................................................................................................32
Reinstall Cover ............................................................................................................................................................33
Section 4 INSTALLATION (Frames R7-R8)
.......................................................................................................................34
Introduction, Planning , Moving the Unit and Mounting.......................................................................................35
Connecting Power and Control Cables ...................................................................................................................36
R7 Frame Size..............................................................................................................................................................37
R8 Frame Size..............................................................................................................................................................38
Maintenance................................................................................................................................................................39
.....................................................................................................................41
......................................................................................................................................................................42
.....................................................................................................................43
......................................................................................................................................................................44
Section 5 START-UP
........................................................................................................45
......................................................................................................................................45
Start-Up Wizard...........................................................................................................................................................48
Section 6 PARAMETER LISTINGS
Aquavar CPC Parameter List .....................................................................................................................................50
Section 7 PROGRAMMING
Single Pump Programming (Pressure Transducer) .................................................................................................73
...........................................................................................78
..................................................................................................................87
.............................................................................................................................94
Section 8 FEATURES
Analog Outputs ....................................................................................................................................................... 102
Auto Restart, Energy Saving Information (Group 26).......................................................................................... 102
TABLE OF CONTENTS
6
Fieldbus Control ...................................................................................................................................................... 103
Language, Locking .................................................................................................................................................. 104
Minimum Speed Options ....................................................................................................................................... 105
.................................................................................. 106-107
Relay Outputs; Restart Options; Low Water (Suction) Protection.............................................................. 107-108
Keypad Failure ......................................................................................................................................................... 109
................................................................................................................................ 109
System Curve Compensation................................................................................................................................. 110
Test Run; Tuning, System Pressure......................................................................................................................... 111
Window Setting (Reg Window).............................................................................................................................. 112
Ramp Hysteresis....................................................................................................................................................... 113
Adjusting Ramp Rates............................................................................................................................................. 113
Section 9 FAULTS/ALARMS
................................................................................................................................................. 115
Correcting Faults ..................................................................................................................................................... 116
Fault Resetting.......................................................................................................................................................... 119
Correcting Alarms ................................................................................................................................................... 120
Section 10 MAINTENANCE (Frame Sizes R1-R6)
Maintenance Intervals............................................................................................................................................. 122
Heatsink .................................................................................................................................................................... 122
Main Fan Replacement ........................................................................................................................................... 122
Internal Enclosure Fan Replacement..................................................................................................................... 123
Capacitors................................................................................................................................................................. 124
Control Panel............................................................................................................................................................ 124
Section 10 MAINTENANCE (Frame Sizes R7-R8)
Layout........................................................................................................................................................................ 125
Heatsink, Fan ............................................................................................................................................................ 126
Replacing the Fan.................................................................................................................................................... 126
Capacitors................................................................................................................................................................. 128
.......................................................................................................................................................................... 129
Control Panel............................................................................................................................................................ 129
Section 11 TECHNICAL DATA
....................................................................................................................................................... 130
.......................................................................................................... 131
.......................................................................................................... 132
............................................................................................................ 133
............................................................................................................ 134
Cable Terminals (frames R1-R6 and frames R7-R8) ............................................................................................. 135
Input Power (Mains) Connection ........................................................................................................................... 136
Motor Connection ................................................................................................................................................... 136
Control Connection................................................................................................................................................. 137
.............................................................................................. 137
Cooling (frames R7-R8); Mounting Orientations a & b....................................................................................... 138
.................................................................................................................................. 139
.................................................................................................................................. 140
............................................................................................................ 141
Units with IP 54 / UL Type 12 Enclosures .............................................................................................................. 143
............................................................................................. 144
............................................................................................................................................. 144
Ambient Conditions................................................................................................................................................ 145
Materials; Applicable Standards............................................................................................................................ 146
UL Markings; Liability Limits................................................................................................................................... 147
Section 12 APPENDIX
Pressure Transducer ................................................................................................................................................ 148
....................................................................................... 149
....................................................................................... 150
Spare Parts List......................................................................................................................................................... 151
Warranty.................................................................................................................................................................... 152
TABLE OF CONTENTS
7
WARNING!-
cian.
WARNING! Even when the motor is stopped, dangerous voltage is present at the Power Circuit termi-
WARNING!
supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the
cover.
WARNING! Even when power is removed from the input terminals of the AQUAVAR, there may be dan-
gerous voltage (from external sources) on the terminals of the relay outputs R01…R03.
WARNING! When the control terminals of two or more drive units are connected in parallel, the auxiliary
voltage for these control connections must be taken from a single source which can either be one of the
units or an external supply.
WARNING!
a malfunctioning unit; contact the factory or your local Authorized Service Center for replacement.
WARNING! The AQUAVAR will start up automatically after an input voltage interruption if the external
run command is on.
WARNING! The heat sink may reach a high temperature, in excess of 200º F. Severe burns are possible.
WARNING!
R1…R4), or F1 and F2 (Frame size R5 or R6). See diagrams on pages 24 and 25 respectively.
NOTE! For more technical information, contact the factory or your local AQUAVAR representative.
WARNING! Always consult your local, state, municipal or NEC codes for proper wiring, electrical installa-
tion of inverter drives and AC motors.
USE OF WARNINGS AND NOTES
There are two types of safety instructions throughout this manual:
the equipment. They also tell you how to avoid the danger. The warning symbols are used as follows:
DANGEROUS VOLTAGE WARNING warns of high voltage which can cause physical injury and/or dam-
age to the equipment.
GENERAL WARNING warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the equipment.
SAFETY
8
TYPICAL DRIVE LABEL
SW: ACS550-U1-046A-2 ACS550-U1-046A-2 SW:
V.2.06B V.2.06B
2053901277 2053901277
S/N2053901277 S/N2053901277
Input 3 PH 48…63 1 PH 48…63 Hz
Voltage (U1) 208…240 Vac 208…240 Vac
Current (11n) 46.2 A 46.2 A
Short Circuit 100 kAIC 100 kAIC
Output 3 PH 0…500 Hz 3 PH 0…500 Hz
Voltage (U2) 0…U1 Vac 0…U1 Vac
Current (12n) 46.2 A 22 A
Current (12hd) 30.8 A
Power (Pn) 15 HP 7.5 HP
Power (Phd)
ACS550-U1-046A-2
Made in USA of foreign parts
Mfg. Date: 31-October-2005 Orig. Firmware: V.2.06B
S/N2053901277
CUS
UL
®
IND. CONT. EQ.
LISTED 45Y1
CUS
®
159339
206578
9
POWER DISTRIBUTION SYSTEMS
role in its performance and safety. The following is a brief description of some of the more
type of power system the site has before sizing the drive.
Delta / Wye with grounded Wye neutral:
motor, the grounded neutral may be a path for common mode current caused by the drive
output.
Delta / Delta with grounded leg:
input and output. Again, depending on the output connections from the drive to motor, the
grounded neutral may be a path for common mode current caused by the drive output.
Ungrounded secondary:
Grounding of the transformer secondary is essential to the safety of personnel as well as
voltages between the chassis of the drive and the internal power structure components.
In many cases this voltage could exceed the rating of the input MOV protection devices of
the drive causing a catastrophic failure. In all cases, the input power to the drive should be
referenced to ground. If the transformer can not be grounded, then an isolation transformer
must be installed with the secondary of the transformer grounded.
10
POWER DISTRIBUTION SYSTEMS
Resistance grounding and ground fault protection:
Connecting the Wye secondary neutral to ground through a resistor is an acceptable
method of grounding. Under a short circuit secondary condition, any of the output phases
to ground will not exceed the normal line to line voltage. This is within the rating of the MOV
input protection devices on the drive. The resistor is often used to detect ground current
through this resistor, care should be taken to properly connect the drive motor leads using
the recommended cables and methods. In some cases, multiple drives on one transformer
can produce a cumulative ground current that can trigger the ground fault interrupt circuit.
Open Delta (consult factory):
encountered where only single phase power is available and three-phase power is required.
The technique uses two single phase transformers to derive a third phase. When used to
one transformer. This system provides poor regulation and it is possible that only the two line
connected phases will provide power. In this case the drive must be derated to 50% of its
rating. (Ex. A 20 HP 230 volt drive now becomes a 10 HP 230 volt drive.)
Single Phase Connection:
single phase input. Only part of the three phase input bridge is used. Ripple current becomes
will not work with an SCR front end drive.
11
INTRODUCTION
Input Power and Line Transformer Requirements
The Aquavar CPC™ requires that the input line voltage and transformer power that 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 Aquavar CPC. When
in doubt contact the local power utility or the factory.
needed, an input line reactor is not required.
NOTE:
transient protection (MOV’s and EMI capacitors) therefore earth ground potential reference is
many different power grounding schemes. The drive requires only that the steady state RMS
voltage from any input line to ground be always less than 110% of the nominal power line to
line to ground be less than 110% of the nominal power line to neutral voltage.
Drive input isolation or dry type transformers may be required for the following:
1. Step up or down: An input transformer may be required to step the local input power
line voltage up or down to the level of the drive input rating.
2. Ground Isolation: An input isolation transformer with a direct or a high impedance wye
neutral secondary ground connection may be required to establish a local power source
with a ground relationship different from the utility power source.
A. If ground isolation is required to prevent a ground fault in one section from shutting
down equipment in another section.
B. To bring local line voltages within the line to ground limits (110% balance) stated in
the opening paragraph.
C. Some ground fault protection schemes and peripheral components require a
grounded neutral power source.
techniques according to NEC (good ac grounding from motor to drive and from
drive to earth ground) provides the best means to control the ground currents that
the drive switching frequency and dv/dt rate insert into the motor frame and shaft.
3. Phase shifting delta-wye or “zig-zag” isolation transformers are used to feed 12 or 18
pulse drive inputs to provide harmonic mitigation.
If an isolation transformer is used for 6 pulse input, the best choice is ONE three phase,
six winding transformer. A delta primary is best for third harmonic cancellation. A
wye secondary avoids circulating current problems and provides the very desirable option
of grounding the secondary neutral for minimum voltage stress and ripple to ground. The
transformer should have a KVA rating at least 1.1 times the maximum connected HP. A K
12
if transformer impedance is greater than 3%. The transformer manufacturer may provide
derating for non K Factor rated transformers to operate at the drive produced K Factor levels.
Three single phase transformers can be
used if they are identical for phase to phase symmetry and balance. A wye connected
primary neutral should never be grounded. Great care should be taken with delta primary
circulating currents and unacceptable transformer heating.
WARNING! Never use phase converters with drives as nuisance tripping and possible
damage may occur. Size the drive for single phase input using 50% derate factor.
WARNING!
50% derate factor. Consult factory.
Sometimes drive input isolation transformers are specied to deal with one or more of
the following issues:
1. Short Circuit Protection: Input transformers are sometimes used to provide impedance
to reduce the available short circuit current to levels that the input clearing devices,
such as fuses or circuit breakers, are rated to handle. Line reactors can perform this
impedance function much more cost effectively.
2. Transient Protection: Input transformers are sometimes used to provide transient
surge impedance. All the Aquavar CPC drives have capacitors and MOV’s (Metal Oxide
Varistor transient protectors) providing 120 to 360 joules, line to line and line to ground
transient protection. Isolation transformers are not required for this protection within
those energy levels. Additional distribution transformer primary transient surge arrestors
levels. MOV’s are rated to handle high levels of one shot transient energy. MOV’s are not
meant to handle continuously recurring transients. A problem of continuously recurring
transients should be corrected before connecting a drive.
3. Harmonic Mitigation: Input transformers are sometimes used to provide impedance to
reduce the harmonic currents generated in the drive. Line reactors can perform this
function much more cost effectively.
4. Power Factor Capacitor Isolation: Input transformers are sometimes used to provide
impedance to isolate drives from line connected power factor correction capacitors.
PWM drive inputs do not require power factor correction capacitors as drive power
power factor correction capacitors which only correct for fundamental. However drives
should be isolated from power factor correction capacitors by about 3 to 6% additional
impedance with respect to the drives. Line reactors can perform this function much more
cost effectively than isolation transformers. ABB drives have either an internal 3% line
reactor or an equivalent 3 to 5% bus reactor.
5. RFI/EMI Mitigation: Neither input isolation transformers nor line or bus reactors provide
inside the drive should be used together with all the proper wiring and grounding
neutral. Establishing a local neutral ground may require the use of an input isolation
transformer.
INTRODUCTION
13
INTRODUCTION
Study these installation instructions carefully before proceeding. Failure to observe the
warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read “Safety” on page 7.
Installation Flow Chart
The installation of the AQUAVAR adjustable speed pump controller follows the outline below.
The steps must be carried out in the order shown. At the right of each step are references to
the detailed information needed for the correct installation of the unit.
Task See
PREPARE for installation “Preparing for Installation” on page 15.
UNPACK
PREPARE the Mounting Location “Prepare the Mounting Location”
on page 21.
REMOVE the front cover “Remove Front Cover” on page 21.
MOUNT the drive “Mount the Unit” on page 22.
INSTALL wiring “Install the Wiring” on page 23.
CHECK installation “Check Installation” on page 32.
REINSTALL the cover “Reinstall Cover” on page 33.
APPLY power “Apply Power” on page 33.
START-UP “Start-Up” on page 33.
14
INTRODUCTION
AQUAVAR CPC Product Numbering
Voltage Phase NEMA 1 Base Model Full Load Amps
Normal Duty Frame Size Normal Duty
Horsepower
230 1
CPC20071 3.7 R1 1
CPC20171 8.5 R1 2
CPC20241 12 R2 3
CPC20311 15.5 R2 5
CPC20461 23 R3 7.5
CPC20591 29.5 R3 10
CPC20881 44.0 R4 15
CPC21141 57.0 R4 20
CPC21431 71.5 R6 25
CPC21781 89.0 R6 30
CPC22481 124.0 R6 40
CPC22481 124.0 R6 50
230 3
CPC20041 4.6 R1 1
CPC20071 7.5 R1 2
CPC20121 11.8 R1 3
CPC20171 16.7 R1 5
CPC20241 24.2 R2 7.5
CPC20311 30.8 R2 10
CPC20461 46.2 R3 15
CPC20591 59.4 R3 20
CPC20751 74.8 R4 25
CPC20881 88.0 R4 30
CPC21141 114.0 R4 40
CPC21431 143.0 R6 50
CPC21781 178.0 R6 60
CPC22211 221.0 R6 75
CPC22481 248.0 R6 100
460 3
CPC40061 6.9 R1 3
CPC40081 8.8 R1 5
CPC40121 11.9 R1 7.5
CPC40151 15.4 R2 10
CPC40231 23 R2 15
CPC40311 31 R3 20
CPC40381 38 R3 25
CPC40451 45 R3 30
CPC40591 59 R4 40
CPC40721 72 R4 50
CPC40781 78 R4 60
CPC40971 97 R4 75
CPC41251 125 R5 100
CPC41571 157 R6 125
CPC41801 180 R6 150
CPC42451 245 R7 200
CPC43161 316 R7 250
CPC43681 368 R8 300
CPC44141 414 R8 350
CPC44861 486 R8 400
CPC45261 526 R8 450
CPC46021 602 R8 500
CPC46451 645 R8 550
575 3
CPC50031 2.7 R2 2
CPC50041 3.9 R2 3
CPC50061 6.1 R2 5
CPC50091 9 R2 7.5
CPC50111 11 R2 10
CPC50171 17 R2 15
CPC50221 22 R2 20
CPC50271 27 R3 25
CPC50321 32 R4 30
CPC50411 41 R4 40
CPC50521 52 R4 50
CPC50621 62 R4 60
CPC50771 77 R6 75
CPC50991 99 R6 100
CPC51251 125 R6 125
CPC51441 144 R6 150
*** - HP classications are for reference purposes only, always size the Aquavar according to the output amps and the service factor amps of the motor.
15
Preparing for Installation
Drive Identication
Drive Labels
To determine the type of drive you are installing, refer to either:
holes.
Type Code
ACS550-01-08A8-4
U13~380…480 V
I2N / I2hd 8.8 A / 6.9 A
PN/ Phd 4 / 3 kW Ser. no. *2030700001*
CPC 4 370 1 FD
AQUAVAR®(Series)
Voltage
Amps
370 Amps
*See Technical Section
NEMA Enclosure Rating
** Fused Disconnect
Options
* Consult factory for other options, if available. Not all combinations may be available.
** Standard equipment on 200 HP and above 460 volt models.
Input U13~380…480 V
I1N 8.8 A
f148…63 Hz
Input U23~0…U1V
I2N / I2hd 8.8 A / 6.9 A
f20…500 Hz
Input PN/ Phd 4 / 3 kW
ACS550-01-08A8-4
Ser. no. *2030700001*
CUS
UL
®
LISTED
INTRODUCTION
16
Ratings and Frame Size
drive’s frame size. To read the Ratings table, you need the “Output current rating” entry from
the type code. Also, when using the Ratings table, note that the table is broken into sections
based on the drive’s “Voltage rating”.
Motor Compatibility
The motor, drive and supply power must be compatible:
Motor Verify Reference
Specication
Motor type 3-phase induction motor NEMA MG1
range: 0.2…2.0 * I2hd entry for Output Current or
(I2hd
rating current table in
page 131.
Voltage range Motor is compatible 208…240 V (for CPC2XXXX) or
with the AQUAVAR 380…480 V (for CPC4XXXX)
voltage range.
Tools Required
To install the AQUAVAR you need the following:
the mounting surface and the frame size:
Frame Size Mounting Hardware
R5 M6 ¼ in.
R6 M8
516 in.
Suitable Environment and Enclosure
installation, store and transport the drive according to the environmental requirements
corrosive gases or liquids, and conductive contaminants such as condensation, carbon
dust and metallic particles.
INTRODUCTION
17
airborne dust and light sprays or splashing water from all directions.
UL Type 3R- Enclosures are intended for outdoor use to provide a degree of protection
from falling rain. Undamaged by the formation of ice on the enclosure. May be cooled by
forced air and louvers for vents.
Provides a degree of protection against falling dirt, rain, sleet, snow, windblown dust and
splashing water. Not suitable for direct sun. A sun shield or canopy may be required.
Suitable Mounting Location
page 137).
length. See “Motor Connection” on page 136.
Wiring and EMC Considerations
always follow the NEC in the absence of a local code.
communications wiring. Always use separate conduit for motor/control wires.
“Cable Sizing/Rating” on page 131, “Cable Terminals” on page 135, “Input Power (Mains)
Connection” on page 136 and “Motor Connection” on page 136.
Control Cables
General Recommendations
Use shielded cables, temperature rated at 60º C (140º F) or above:
connected to terminal X1-1 (for digital and analog I/O cables) or to either X1-28 or X1-32
(for RS485 cables).
INTRODUCTION
18
Route control cables to minimize radiation to the cable:
as possible.
Use care in mixing signal types on the same cable:
signals using less than 48 V can be run in the same cables as digital input signals.
NOTE!
Analog Cables
Recommendations for analog signal runs:
Digital Cables
Recommendations for digital signal runs:
is also usable.
Control Panel Cable
If the control panel is connected to the drive with a cable, use only Category 5 Patch ethernet
cable.
INTRODUCTION
19
Supply Connection
Disconnecting Device (Mains)
Install a hand-operated input disconnecting device between the AC power source (MCC) and
the drive. The disconnecting device must be of a type that can be locked to the open position
for installation and maintenance work. Follow all local NEC codes.
Fuses
Thermal Overload and Short-circuit Protection
The drive protects itself and the input and motor cables against thermal overload when the
cables are dimensioned according to the nominal current of the drive. No additional thermal
protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
The drive protects the motor cable and the motor in a short-circuit situation when the motor
cable is dimensioned according to the nominal current of the drive.
Mains Cable (AC line cable) Short-circuit Protection
Always protect the input cable with fuses. Standard gG (US: T or L) very fast acting, fuses
will protect the input cable in short-circuit situations and prevent damage to adjoining
equipment in case of a short-circuit inside the drive.
Size the fuses according to local safety regulations, appropriate input voltage and the rated
WARNING!
because they are inherently slower than fuses. Always use fuses with circuit breakers, if
you are not sure of the circuit braking capacity and mains short circuit power.
Ground Fault Protection
The drive is equipped with an internal ground fault protective function to protect the unit
protection feature. The ground fault protective function can be disabled with a parameter
contact factory for more information.
frame. These capacitors and long motor cables increase the ground leakage current and may
cause fault current circuit breakers to function.
Emergency Off Devices
For safety reasons, install the emergency off devices at each operator control station and at other
operating stations where emergency off may be needed. Pressing the stop key on the control
panel of the drive does not generate an emergency off of the motor or separate the drive from
dangerous potential.
INSTALLATION (Frames R1-R6)
20
Selecting the Power Cables (copper only)
General Rules
currents.
conductor in continuous use. For US, follow local codes for cable size, or refer to NEC table
310.16.
according to permissible touch voltage appearing under fault conditions (so that the fault
point voltage will not rise excessively when an ground fault occurs).
four-conductor system used up to 30 kW motors cannot be used.
Compared to a four conductor system, the use of symmetrical shielded cable reduces
electromagnetic emission of the whole drive system as well as motor bearing currents and wear
of bearings.
The motor cable and its PE pigtail (twisted screen) should be kept as short as possible in order
to reduce electromagnetic emission as well as capacitive current.
Motor Cable Shield
To effectively suppress radiated and conducted radio-frequency emissions, the shield
conductivity must be at least 1/10 of the phase conductivity. The requirements are easily met
with a copper or aluminum shield. The minimum requirement of the motor cable shield of the
drive is shown below. It consists of a concentric layer of copper wires with an open helix of
copper tape. The better and tighter the shield, the lower the emission level and the bearing
currents.
Additional US Requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded
power cable must be used for the motor cables if metallic conduit is not used. For the North
American market, 600 VAC cable is accepted for up to 500 VAC. For drives rated over 100
amperes, the power cables must be rated for 70ºC (158ºF).
Insulation Jacket Copper Wire Screen Helix of Copper Tape Inner Insulation
Cable Core
INSTALLATION (Frames R1-R6)
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