Hayward 421501P User manual

Hayward Industries
400 Connell Drive, Suite 6100
Berkeley Heights, NJ 07922
Phone: [phone]
www.hayward.com
AC Variable Frequency Drive
Hayward Commercial Aquatics
Owner's Manual
421501P 620401P
520201P 620501P
520251P 620601P
620301P
Contents
Before you Begin...................3
Installation............................4
Operation.............................8
Troubleshooting...................12
1004021 RevA
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IMPORTANT SAFETY INSTRUCTIONS
When using this electrical equipment, basic safety precautions should always be followed, including the fol-
lowing:
READ AND FOLLOW ALL INSTRUCTIONS
WARNING: Follow all applicable electrical codes.
WARNING: Turn off power at main source before making any electrical connections or servicing the unit.
WARNING: To reduce the risk of electric shock, injury or death disconnect unit from power supply.
WARNING: Follow the instructions or risk of serious injury or death could occur!
WARNING - Read and follow all instructions in this owner’s manual and on the equipment. Failure
to follow instructions can cause severe injury and/or death.
WARNING – Suction Entrapment Hazard Suction in suction outlets and/or suction outlet covers
which are, damaged, broken, cracked, missing, or unsecured can cause severe injury and/or death
due to the following entrapment hazards:
Hair Entrapment- Hair can become entangled in suction outlet cover.
Limb Entrapment- A limb inserted into an opening of a suction outlet sump or suction outlet
cover that is damaged, broken, cracked, missing, or not securely attached can result in a mechani-
cal bind or swelling of the limb.
Body Suction Entrapment- A negative pressure applied to a large portion of the body or limbs can
result in an entrapment.
Evisceration/ Disembowelment - A negative pressure applied directly to the intestines through
an unprotected suction outlet sump or suction outlet cover which is, damaged, broken, cracked,
missing, or unsecured can result in evisceration/ disembowelment.
Mechanical Entrapment- There is potential for jewelry, swimsuit, hair decorations, finger, toe or
knuckle to be caught in an opening of a suction outlet cover resulting in mechanical entrapment.
WARNING - To Reduce the risk of Entrapment Hazards:
• When outlets are small enough to be blocked by a person, a minimum of two functioning
suction outlets per pump must be installed. Suction outlets in the same plane (i.e. floor or
wall), must be installed a minimum of three feet (3’) [1 meter] apart, as measured from near
point to near point.
• Dual suction fittings shall be placed in such locations and distances to avoid “dual blockage”
by a user.
• Dual suction fittings shall not be located on seating areas or on the backrest for such seating
areas.
• Never use Pool or Spa if any suction outlet component is damaged, broken, cracked, missing,
or not securely attached.
• Replace damaged, broken, cracked, missing, or not securely attached suction outlet compo-
nents immediately.
• Two or more suction outlets per pump installed in accordance with latest ASME, APSP Stan-
dards and CPSC guidelines, follow all National, State, and Local codes applicable.
• Installation of a vacuum release or vent system, which relieves entrapping suction, is recom-
mended.
WARNING – Failure to remove pressure test plugs and/or plugs used in winterization of the pool/
spa from the suction outlets can result in an increase potential for suction entrapment as described
above.
WARNING – Failure to keep suction outlet components clear of debris, such as leaves, dirt, hair,
paper and other material can result in an increase potential for suction entrapment as described
above.
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WARNING – Suction outlet components have a finite life, the cover/grate should be inspected
frequently and replaced at least every ten years or if found to be damaged, broken, cracked, miss-
ing, or not securely attached.
CAUTION – Components such as the filtration system, pumps and heater must be positioned so
as to prevent their being used as means of access to the pool by young children. To reduce risk
of injury, do not permit children to use or climb on this product. Closely supervise children at all
times. Components such as the filtration system, pumps, and heaters must be positioned to pre-
vent children from using them as a means of access to the pool.
WARNING – Hazardous Pressure Pool and spa water circulation systems operate under hazard-
ous pressure during start up, normal operation, and after pump shut off. Stand clear of circulation
system equipment during pump start up. Failure to follow safety and operation instructions could
result in violent separation of the pump housing and cover, and/or filter housing and clamp due to
pressure in the system, which could cause property damage, severe personal injury, or death. Be-
fore servicing pool and spa water circulation system, all system and pump controls must be in off
position and filter manual air relief valve must be in open position. Before starting system pump,
all system valves must be set in a position to allow system water to return back to the pool. Do not
change filter control valve position while system pump is running. Before starting system pump,
fully open filter manual air relief valve. Do not close filter manual air relief valve until a steady
stream of water (not air or air and water) is discharged.
WARNING – Separation Hazard Failure to follow safety and operation instructions could result
in violent separation of pump and/or filter components. Strainer cover must be properly secured
to pump housing with strainer cover lock ring. Before servicing pool and spa circulation system,
filters manual air relief valve must be in open position. Do not operate pool and spa circulation
system if a system component is not assembled properly, damaged, or missing. Do not operate
pool and spa circulation system unless filter manual air relief valve body is in locked position in
filter upper body. Never operate or test the circulation system at more than 50 PSI. Do not purge
the system with compressed air. Purging the system with compressed air can cause components
to explode, with risk of severe injury or death to anyone nearby. Use only a low pressure (below 5
PSI), high volume blower when air purging the pump, filter, or piping.
WARNING – Risk of Electric Shock All electrical wiring MUST be in conformance with applicable
local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can shock, burn,
and cause death or serious property damage. To reduce the risk of electric shock, do NOT use an
extension cord to connect unit to electric supply. Provide a properly located electrical receptacle.
Before working on any electrical equipment, turn off power supply to the equipment. To reduce
the risk of electric shock replace damaged wiring immediately. Locate conduit to prevent abuse
from lawn mowers, hedge trimmers and other equipment. Do NOT ground to a gas supply line.
WARNING – Risk of Electric Shock Failure to ground all electrical equipment can cause serious
or fatal electrical shock hazard. Electrical ground all electrical equipment before connecting to
electrical power supply.
WARNING – Risk of Electric Shock Failure to bond all electrical equipment to pool structure will
increase risk for electrocution and could result in injury or death. To reduce the risk of electric
shock, see installation instructions and consult a professional electrician on how to bond all elec-
trical equipment. Also, contact a licensed electrician for information on local electrical codes for
bonding requirements.
Notes to electrician: Use a solid copper conductor, size 8 or larger. Run a continuous wire from
external bonding lug to reinforcing rod or mesh. Connect a No. 8 AWG (8.4 mm2) [No. 6 AWG
(13.3 mm2) for Canada] solid copper bonding wire to the pressure wire connector provided on the
electrical equipment and to all metal parts of swimming pool, spa, or hot tub, and metal piping (ex-
cept gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool, spa, or hot tub.
IMPORTANT - Reference NEC codes for all wiring standards including, but not limited to, ground-
ing, bonding and other general wiring procedures.
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WARNING – Risk of Electric Shock The electrical equipment must be connected only to a supply circuit that is
protected by a ground-fault circuit-interrupter (GFCI). Such a GFCI should be provided by the installer and should
be tested on a routine basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push reset
button. Power should be restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI
interrupts power to the electrical equipment without the test button being pushed, a ground current is flowing,
indicating the possibility of an electrical shock. Do not use this electrical equipment. Disconnect the electrical
equipment and have the problem corrected by a qualified service representative before using.
CAUTION – HAYWARD®pumps are intended for use with permanently-installed pools and may be used with hot
tubs and spas if so marked. Do not use with storable pools. A permanently-installed pool is constructed in or on
the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed
so that it is capable of being readily disassembled for storage and reassembled to its original integrity.
SAVE THESE INSTRUCTIONS
Before you Begin
Before installing the new Variable Frequency Drive (VFD), check that you've received the correct drive and that
the motor type and specs are suitable for your installation.
Identifying the Drive by Model Number
Each drive can be identified by its model number, as shown below.
HCP VFD -4 2 150 -1 P
Market
Product Type
Drive Size 4, 5, 6
Input
Voltage 2 = 200 – 240
No. Of Input Phases, 1P or 3P
Size 4 = for 1 phase HP x 20, for 3-phase HP x 10
Size 5 & 6 = for 1 phase HP x 2, for 3-phase HP x 1
Model Motor HP
HCPVFD421501P 15
HCPVFD520201P 20
HCPVFD520251P 25
HCPVFD520251P 30
HCPVFD620401P 40
HCPVFD620501P 50
HCPVFD620601P 60
Model Motor HP
HCPVFD421501P 7.5
HCPVFD520201P 10
HCPVFD520251P 12.5
HCPVFD620301P 15
HCPVFD620401P 20
HCPVFD620501P 25
HCPVFD620601P 30
Single Phase Supply 3- Phase Supply
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Installation
Mounting Location
When preparing the mounting location, consider the following:
• The drive must be mounted in a vertical position only.
• Installation should be on a suitable flat, flame resistant surface, away from flammable material.
• Refer to Technical Data and ensure the chosen mounting location is within the drive specification.
• The mounting location should be free from vibration.
• Do not mount the drive in any area with excessive humidity, corrosive airborne chemicals or potentially
dangerous dust particles.
• Avoid mounting close to high heat sources.
• The drive must not be mounted in direct sunlight. If necessary, install a suitable shade cover.
• The mounting location must be free from frost.
• Do not restrict the flow of air through the drive heatsink. The drive generates heat which must be naturally
allowed to dissipate. Correct air clearance around the drive must be observed.
• If the location is subject to wide ambient temperature and air pressure variation, install a suitable pressure
compensation valve in the drive gland plate.
NOTE: If the drive has been in storage for a period longer than 2 years, the DC link capacitors must be reformed.
Refer to online documentation for further information.
Specifications
Refer to the diagram below and the table on page 5 for dimensions of the VFD. Refer to your model number for
the Drive Size (page 3).
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Drive
Size
A B C D E Weight
mm in mm in mm in mm in mm in kg lb
4450 17.72 171 6.73 252 9.92 428 16.85 110 4.33 11.5 25.4
5540 21.26 235 9.25 270 10.63 520 20.47 175 6.89 23 50.7
6865 34.06 330 12.99 332 13.07 840 33.07 200 7.87 55 121.2
Wiring
Gland Plate and Lock Off
The use of a suitable gland system is required to maintain the appropriate IP / NEMA rating. Remove the gland plate
at the bottom of the drive and drill holes for the appropriate sized cable gland fitting. Please take care when drilling
to avoid leaving any particles within the product.
UL rated ingress protection (“Type” ) is only met when cables are installed using a UL recognized bushing or fitting
for a flexible-conduit system which meets the required level of protection (“Type”).
For conduit installations the conduit entry holes require standard opening to the required sizes specified per the
NEC. Not intended for installation using rigid conduit system.
The power input cables should be dimensioned according to any local codes or regulations. Maximum dimensions
are given in the Rating Tables section of this manual.
• For 1 phase supply, the mains power cables should be connected to L1/L, L2/N.
• For 3 phase supply, the mains power cables should be connected to L1, L2, and L3. Phase sequence is not
important.
NOTE: The motor cable length should not exceed 300 feet (100 meters). If longer cable lengths are necessary,
please contact Hayward for additional installation requirements.
Mounting Bolts
Frame Size Metric UNF
4 M8 5/16
5 M8 5/16
6 M10 3/8
Tightening Torques
Frame Size Required Torque
Control Terminals All 0.5 Nm 4.5 lb-in
Power Terminals
4 2 Nm 18 lb-in
5 4 Nm 35.5 lb-in
6 15 Nm 11 lb-ft
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Motor Terminal Box Connections
Most general purpose motors are wound for operation on dual voltage supplies. This is indicated on the
nameplate of the motor. This operational voltage is normally selected when installing the motor by selecting either
STAR or DELTA connection. STAR always gives the higher of the two voltage ratings.
Incoming
Supply Voltage
Motor Nameplate
Voltages Connection
208 / 230 230 / 460 Delta
Δ
Not normally
used for these
drives
Star
λ
Information for UL Compliance
The drive is designed to meet the UL requirements. For an up-to-date list of UL compliant products, please refer
to UL listing NMMS.E226333. Reference numbers are on the drive label. In order to ensure full compliance, the
following must be fully observed.
Hayward Part Number UL Listing
HCPVFD421501P
HCPVFD520201P
HCPVFD520251P
HCPVFD620301P
HCPVFD620401P
HCPVFD620501P
HCPVFD620601P
ODP-2-42150-3HF4N
ODP-2-52020-3HF4N
ODP-2-52025-3HF4N
ODP-2-62030-3HF4N
ODP-2-62040-3HF4N
ODP-2-62050-3HF4N
ODP-2-62060-3HF4N
Input Power Supply Requirements
Supply
Voltage
200 – 240 RMS Volts for 230 Volt rated units, + /- 10% variation allowed. 240 Volt RMS
Maximum.
Frequency 50 – 60Hz + / - 5% Variation
Short Circuit
Capacity
All drives are suitable for use on a circuit capable of delivering not more than 100kA maximum
short-circuit Amperes symmetrical with the specified maximum supply voltage when protected
by Class J fuses.
Mechanical Installation Requirements
All drive units are intended for installation within controlled environments which meet the condition limits
shown in the Environment section of this manual.
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Control Terminal Connections
Drive Control Terminals
Enable
Full
Speed
Safety
Relay
Inhibit
When
Open
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
+24Vdc
DI 1
DI 2
DI 3
+10V
AI1/DI4
0V
AO1
0V
AI2/DI5
AO2
STO+
STO-
RL1-C
RL1-NO
RL1-NC
RL2-A
RL2-B
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
+24V
DI 1
DI 2
DI 3
+10V
AI1/DI4
0V
AO1
0V
AI2/DI5
AO2
STO+
STO-
RL1-C
RL1-NO
RL1-NC
RL2-A
RL2-B
24 Volt DC Input / Output
Closed: Keypad Enable
Unused
Closed: Full Speed
+10 Volt DC Output
Analog Input 1 / Digital Input 4
0 Volt Common
Analog Output 1
0 Volt Common
Analog Input 2 / Digital Input 5
Analog Output 2
STO + 24VDC Connection
STO 0 Volt Connection
Relay Output 1 Common
Relay Output 1 Normally Open
Relay Output 2 Normally Closed
Relay Output 2
Relay Output 2
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Drive Functions
1. Connect terminals 1 to 2. This enables the drive when powered up.
2. Press the "Start" button on the keypad to run at the drive preset minimum speed (default, 36 Hz). This speed
can be adjusted using the "Minimum Speed" setting at parameter P1-02. Take care to keep the pump speed
above the minimum required to prime the pump so that it cannot run dry. The run speed can be raised and
lowered using the UP and DOWN keys on the keypad. This speed setting will be memorized if the drive is
stopped or the power turned off. If the drive is powered off, you will need to press "Start" button to restart.
3. Press "Stop" or disconnect the connection between terminals 1 and 2 to coast to stop.
4. When in the "Run" mode, connect terminal 1 to terminal 4 to run at the maximum set speed. This can be
adjusted by changing the "Maximum Speed" setting at parameter P1-01.
NOTES:
1. The maximum speed should never be set greater than the rated speed shown on the motor nameplate.
2. Always refer to the pump and motor manuals before setting up and starting the drive.
Drive Set Up
Before setting up the drive, check and note the supply voltage and the motor nameplate data:
Supply Volts: ____________ Supply Phases: ____________
Motor Nameplate Data:
Model #: ____________ Motor Type: Standard Induction / PMAC / Sync Reluctance
Horsepower: ____________ (KW:____________) Base Speed: ____________ RPM
Base Volts: ____________ volts, 3-phase Base Frequency: ____________ Hz
Operation
Before starting the VFD, ensure that all connections have been made properly and are secure.
Keypad and Display
The drive is configured and its operation monitored via the keypad and display. Refer to the table below for basic
operation.
START When in keypad mode, used to start a stopped drive or to reverse the direction of rotation if bi-
directional keypad mode is enabled.
UP Used to increase speed in real-time mode or to increase parameter values in parameter edit
mode.
DOWN Used to decrease speed in real-time mode or to decrease parameter values in parameter edit
mode.
NAVIGATE Used to display real-time information, to access and exit parameter edit mode and to store
parameter changes.
RESET /STOP Used to reset a tripped drive.
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Keypad and Display Layout
Control Keypad provides access to the drive parameters, and also allows control of the drive when Keypad Mode
is selected in P1-12.
Operating Displays
P2 01
STOP
37kW 400V 3Ph
F1 F2
IP20, IP55 & IP66 models keypad with TFT display
Main Displayed Parameter
Shows the drive status or the value of whichever
of the selectable parameters is currently being
shown on the main display.
Operating Information
Provides a real time display of key operating
information, e.g. output current and power.
Quick Help Button
Provides access to short description of the
displayed messages.
F1 Button
Not used.
Start Button
When in Hand mode, used to start the drive.
Stop / Reset Button
Used to reset a tripped drive. When in Keypad
mode, used to Stop the drive.
Drive Address
Not used.
Navigate Button
Used to display real-time information, to access
and exit parameter edit mode, and to store
parameter changes.
F2 Button
Not used.
Up Button
Used to increase speed in Real-Time mode or
to increase parameter values in Parameter Edit
mode.
Down Button
Used to decrease speed in Real-Time mode or
to decrease parameter values in Parameter Edit
mode.
P2 01
INHIBIT
15kW 400V 3Ph
Inhibit /
STO Active
Drive Inhibited. The STO
connections are not
made.
Refer to section 4.14.8.
Recommended “STO”
Wiring on page 31.
P2 01
STOP
15kW 400V 3Ph
Drive Stopped
Drive Stopped / Disabled.
Output Frequency 01
23.7Hz
15.3A 6.9kW
Drive Running
Output Frequency
Display
Drive is enabled /
running. Display shows
the output frequency (Hz).
Press the Navigate key to
select alternate displays.
Motor Current 01
15.3A
6.9kW 23.7Hz
Drive Running
Output Current
Display
Press the Navigate key
for < 1 second.
The display will show the
motor current (Amps).
Motor Power 01
6.9kW
23.7Hz 15.3A
Drive Running
Motor Power
Display
Press the Navigate key
for < 1 second.
The display will show the
motor power (kW).
Motor Speed 01
718rpm
23.7Hz 15.3A
Drive Running
Motor Speed
Display
If P1-10 > 0, pressing
the Navigate key for < 1
second will display the
motor speed (RPM).
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Changing Parameters
Available Parameters
The parameters available are shown in the table below.
Par. Description Min Max Default Units
P-01
Maximum Frequency/Speed Limit P-02 500.0 50.0
(60.0) Hz/RPM
P-02 Minimum Frequency/Speed Limit 0.0 P-01 36.0 Hz/RPM
P-03 Acceleration Ramp Time 0.00 600.0 5.0 s
P-04 Deceleration Ramp Time 0.00 600.0 5.0 s
P-07 Motor Rated Voltage/Back EMF at
rated speed (PM/BLDC)
0250/
500 230/460 V
P-08 Motor Rated Current Drive Rating Dependent A
P-09 Motor Rated Frequency 10 500 60 Hz
P-10 Motor Rated Speed 0 30000 0 RPM
P-11 Low Frequency Torque Boost 0.0 Drive Dependent %
Technical Data
Operational ambient temperature range
IP55, NEMA 12 drives: -20 ... 40°C (frost and condensation free)
Storage Temperature: -40 … 60°C
Maximum Altitude: 2000m. Derate above 1000m: 1% / 100m
Maximum Humidity: 95%, non-condensing
Stop
15kW
Press and hold the
Navigate key > 2
seconds.
3Ph
400V
P1-01
50.0Hz
Use the up and down
keys to select the
required parameter.
Drives with TFT display
will show the present
parameter value on the
lower line of the display.
P2 01
P1-08
30.0A
Press the Navigate key
for < 1 second.
P2 01
30.0A
P1-08
Adjust the value using the
Up and Down keys.
Drives with TFT display
will show the maximum
and minimum possible
settings on the lower line
of the display.
P2 01
30.0 3.0
P1-08
30.0A
Press for < 1 second to
return to the parameter
menu.
P2 01
Stop
15kW
Press for > 2 seconds to
return to the operating
display.
3Ph
400V
P2 01
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Ratings Table
For applications with Single phase, 208 - 230 volts supply & 3-phase, 230 volts motors
Frame
Size kW HP
Input
Current
(Amps)
Fuse/MCB
(Type B)
Maximum Cable
Size
Output
Current
Model
Non
UL UL mm
AWG A
4 5.5 7.5 50.1 63 70 16 5 23 HCPVFD421501P
5 7.5 10 63.9 80 80 35 2 30 HCPVFD520201P
5 9 12.5 74 100 90 35 2 36 HCPVFD520251P
6 11 15 99.1 125 125 150 300MCM 45 HCPVFD620301P
6 15 20 121 160 150 150 300MCM 55 HCPVFD620401P
6 18 25 159.7 200 200 150 300MCM 75 HCPVFD620501P
6 22 30 163.4 200 200 150 300MCM 90 HCPVFD620601P
For applications with 3-phase, 208 - 230 volts supply & 3-phase, 230 volts motors
Frame
Size kW HP
Input
Current
(Amps)
Fuse/MCB
(Type B)
Maximum Cable
Size
Output
Current
Model
Non
UL UL mm
AWG A
4 11 15 50.1 63 70 16 5 46 HCPVFD421501P
5 15 20 63.9 80 80 35 2 61 HCPVFD520201P
5 18.5 25 74.0 100 90 35 2 72 HCPVFD520251P
6 22 30 99.1 125 125 150 300MCM 90 HCPVFD620301P
6 30 40 121.0 160 150 150 300MCM 110 HCPVFD620401P
6 37 50 159.7 200 200 150 300MCM 150 HCPVFD620501P
6 45 60 163.4 200 200 150 300MCM 180 HCPVFD620601P
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Troubleshooting
Fault Code Messages
Fault Code No. Description
0I-b 01 Brake channel over current
OL-br 02 Brake resistor overload
0-I 03 Output Over Current
I_t-trP 04 Motor Thermal Overload (I2t)
0-volt 06 Over voltage on DC bus
U-volt 07 Under voltage on DC bus
0-t 08 Heatsink over temperature
U-t 09 Under temperature
U-deF 10 Reset drive to defaults
E-trip 11 External trip
FLt-dc 13 DC bus ripple too high
P-LOSS 14 Input phase loss trip
h0-I 15 Output Over Current
th-Flt 16 Faulty thermistor on heatsink
dAtA-F 17 Internal memory fault (IO)
4-20 F 18 4-20mA Signal Lost
dAtA-E 19 Internal memory fault (DSP)
F-Ptc 21 Motor PTC thermistor trip
FAn-F 22 Cooling Fan Fault (IP66 only)
O-heat 23 Drive internal temperature too high
OUt-F 26 Output Fault
NOTE: Following an over current or overload trip (3, 4, 5, 15), the drive may not be reset until the reset time delay
has elapsed to prevent damage to the drive.
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Resetting the Drive Following a Trip
The drive has many protection features, designed to protect both the drive and motor from accidental damage.
When any of these protection features are activated, the drive will trip, and display a fault message. The fault
messages are listed on the previous page. When a trip occurs, after the cause of the trip has been investigated
and rectified, the user can reset the trip in one of the following ways:
1. Press the keypad Stop key.
2. Power off the drive completely, then power on again
Stop
P1-08
Press and hold the Up,
Down, and Stop keys for
> 2 seconds.
3.0
30.0
P2 01
U-Def
30.0a
The display shows U-Def.
Briefly press the Stop key.
P2 01
Stop
15kW
The display returns to
Stop. All parameters are
reset to Factory defaults.
P2 01
400V 3Ph
User Parameter Reset
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For further information or consumer
technical support, visit our website at
www.hayward.com
Hayward is a registered trademark
of Hayward Industries, Inc. © 2022 Hayward Industries, Inc.
All other trademarks not owned by Hayward are the property of their respective owners.
Hayward is not in any way affiliated with or endorsed by those third parties.
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