Ingersoll-Rand ARO EP20 Series User manual

RELEASED: XX-XX-21
(REV: A)
INGERSOLL RAND COMPANY INC
209 NORTH MAIN STREET – BRYAN, OHIO 43506
[phone] FAX [phone] © 2021
arozone.com
OPERATOR’S MANUAL EP20-XXXXX-XXX-XXX
INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE
2” ELECTRIC OPERATED POSITIVE DISPLACEMENT PUMP
1:1 RATIO (METALLIC)

Page 2 of 40 EP20-XXXXX-XXX-XXX (en)
TABLE OF CONTENTS
1. TECHNICAL SPECIFICATIONS ........................................................................... 3
1.1. Pump Data....................................................................................... 3
1.2. Variable Frequency Drive (VFD) Data .............................................................. 3
1.3. Electric Motor Data ............................................................................... 4
1.4. Nameplate Details................................................................................ 5
2. MODEL DESCRIPTION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. OPERATING AND SAFETY PRECAUTIONS ................................................................ 7
4. GENERAL DESCRIPTION ................................................................................ 8
4.1. Introduction ..................................................................................... 8
4.2. Storage .......................................................................................... 8
4.3. Unpacking ....................................................................................... 8
5. MECHANICAL INSTALLATION ........................................................................... 9
5.1. Pump & Motor Installation ........................................................................ 9
5.2. VFD Mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. ELECTRICAL INSTALLATION............................................................................10
6.1. VFD-Wiring Diagram.............................................................................10
6.2. General Wiring practice..........................................................................10
6.3. VFD AC Mains – Input Power Requirements ......................................................11
6.4. Power Wiring: ...................................................................................11
6.4.1 VFD - Input Power Wiring ...................................................................11
6.4.2. VFD - Output Motor Wiring .................................................................11
6.4.3. Motor - Input Power Wiring.................................................................11
6.5. Control Wiring (Required)........................................................................12
6.5.1. Leak detector wiring diagram ..............................................................12
6.5.2. Leak Detector Safe Loop Calculations.......................................................13
6.5.3. Thermal protection – Ordinary motor.......................................................14
6.5.4. Thermal Protection – Hazardous motor .....................................................14
6.5.5. Encoder Wiring – Ordinary Motor...........................................................15
6.5.6. Encoder Wiring – Hazardous Motor .........................................................15
6.6. Control Wiring (Recommended) .................................................................15
6.6.1. Safe Stop wiring diagram...................................................................15
6.6.2. Digital start/ stop control...................................................................16
6.7. Control Wiring (Optional) ........................................................................16
6.7.1. Analog Input – Speed control ..............................................................16
6.7.2. Analog Inputs – Torque (Pressure) Control ..................................................17
6.7.3. Additional available Input/output (Optional)................................................17
6.8. Congured I/O’s (summary)......................................................................18
6.9. VFD serial communication .......................................................................18
6.10. User dened readout...........................................................................19
7. GROUNDING .........................................................................................19
7.1. Pump Grounding................................................................................19
7.2. VFD Grounding..................................................................................19
7.3. Electric Motor Grounding........................................................................19
8. LUBRICATION REQUIREMENT ..........................................................................20
8.1. Oil Filling instruction ............................................................................20
9. OPERATION...........................................................................................21
9.1. Pre Operation Checklist..........................................................................21
9.2. Personal Menu Settings .........................................................................21
10. MAINTENANCE ......................................................................................23
10.1. Service Kits ....................................................................................23
11. SUBSYSTEM OVERVIEW ..............................................................................24
11.1. Fluid section ...................................................................................24
11.2. PRV section ....................................................................................27
11.3. Actuator section ...............................................................................29
11.4. Oil Piston pump section ........................................................................32
12. TROUBLESHOOTING .................................................................................34
13. DIMENSIONAL DATA .................................................................................35
13.1 Pump With Motor...............................................................................35
13.2. Variable Frequency Drive (VFD) .................................................................36
14. PERFORMANCE CURVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
15. CERTIFICATION ......................................................................................38

EP20-XXXXX-XXX-XXX (en) Page 3 of 40
1. TECHNICAL SPECIFICATIONS
Models...... See Model Description Chart for “-XXXXX”.
Pump Type.. Electric Operated Positive
Displacement Pump (EOPD)
Material .... See Model Description Chart.
Weight (without motor)
EP20-CXX-XXXX-XXXX............539 lbs (245 kg)
EP20-AXX-XXXX-XXXX............448 lbs (203 kg)
EP20-SXX-XXXX-XXXX ............584 lbs (265 kg)
Maximum Material
Inlet Pressure ..................... 10 psig (0.69 bar)
Maximum Outlet Pressure ........ 120 psig (8.3 bar)
Maximum Flow Rate (ooded inlet) .... 125 gpm (473 lpm)
Displacement / Cycle @ 100 psig .. 0.68 gal. (2.6 lit.)
Maximum Particle Size ........... 1/4” dia. (6.4 mm)
Wet Suction Lift................... 32 ft
Dry Suction Lift ...................16 ft
Maximum Deadhead Pressure....180 psi (12.4 bar)
Maximum Temperature Limits
(Diaphragm / Ball / Seat material)
E.P.R. / EPDM..........-60to 280F (-51to 138C)
Hytrel...............
-20to 180F (-29ºto 82C)
Nitrile ................10to 180F (-12ºto 82C)
Polypropylene ........32to 175F (0to 79C)
Santoprene.........-40to 225F (-40to 107C)
PTFE..................40to 225F (4to 107C)
Viton................
-40to 350F (-40to 177C)
Dimensional Data......see page 35
MountingDimension. . . 3 Equally placed
∅0.63” (∅ 16 mm) hole on
∅29.8” (∅ 758 mm) B.C.
1.2. Variable Frequency Drive (VFD) Data
Ordinary Hazardous
Part Number 136Z7170 136Z7171
Power 7.5 kw 7.5 kw
Input Voltage 380-500 VAC +/-10%, 3 Phase, 50/60 Hz 380-500 VAC +/-10%, 3 Phase, 50/60 Hz
Frame Size A5 A5
Ingress Protection NEMA 4X / IP66 NEMA 4X / IP66
Option B Slot MCB 102 ENCODER CARD MCB 102 ENCODER CARD
Dual Option B With A-Slot Adapter MCF 107 N/A MCB 112 PTC THERMISTER CARD
Eciency 97% 97%
Approximate Weight 14.3 kg 14.3 kg
Operating Temperature (Full Scale) 0 to 45C 0 to 45C
Operating Temperature (Derate) -10 to 50C -10 to 50C
Max Altitude (Without Derating) 1000 M 1000 M
Max Altitude (With Derating) 3000 M 3000 M
Continuous Output Current (380-440 V) 16 A 16 A
Intermittent Output Current (380-440 V) 25.6 A 25.6 A
Continuous Output Current (441-500 V) 14.5 A 14.5 A
Intermittent Output Current (441-500 V) 23.2 A 23.2 A
Continuous Input Current (380-440 V) 14.4 A 14.4 A
Intermittent Input Current (380-440 V) 23.0 A 23.0 A
Continuous Input Current (441-500 V) 13.0 A 13.0 A
Intermittent Input Current (441-500 V) 20.8 A 20.8 A
1.1. Pump Data

Page 4 of 40 EP20-XXXXX-XXX-XXX (en)
1.3. Electric Motor Data
ORDINARY Hazardous NEC
Part Number 67559 67560-1 67560-2
Rated Power 5.5 kw 5.5 w 5.5 kw
Rated Torque 36 Nm 36 Nm 36 Nm
Eciency IE3 IE3 IE3
Number Of Phases 3 3 3
Polarity 4P 4P 4P
Voltage 400V 400V 400V
Frequency 50 Hz 50 Hz 50 Hz
Index Of Protection IP66 IP66 IP66
Insulation Class F F F
Encoder Type Incremental Incremental Incremental
Encoder Characteristics 5V 1024 PTS TTL - IP65 5V RS422 (TTL), 1024 PTS - IP66 5V RS422 (TTL), 1024 PTS - IP66 / 67
Encoder Connection 12 Pin connector 2m cable - ying leads 10m cable - ying leads
Drain Plug Position Drive end with plug N/A - Flameproof motor N/A - Flameproof motor
Thermal Protection 2 Pto sensors in series 3 Ptc sensors in series (150-1000 ohms) 3 Ptc sensors in series (150-1000 ohms)
Approx. Weight 100 Kg 138 Kg 138 Kg
Exact Ratio 12.7 12.7 12.7
Output Shaft Spline Spline Spline
Lubricant Type PAO ISO VG 150 PAO ISO VG 150 PAO ISO VG 150
Lubricant Qty 4.5 Liters (pre-lled) 4.5 Liters (pre-lled) 4.5 Liters (pre-lled)
Main Cable Gland Type 2 x m25 + 1 x m16 with plugs 2 x m25 + 1 x m16 with plugs 2 x m25 + 1 x m16 with plugs
Lifting Point 4 x Lifting eye - Casted 4 x Threaded holes - 3 x Lifting eye tted 4 x Threaded holes - 3 x Lifting eye tted
ORDINARY MOTORHAZARDOUS MOTOR
Figure 1

EP20-XXXXX-XXX-XXX (en) Page 5 of 40
1.4. Nameplate Details
Items supplied vary according to product conguration.
Make sure that the items supplied and the information on the nameplate correspond to the order conrmation.
PUMP MODELPUMP MODEL
SERIAL NO
AVG W.P.
ASSEMBLED IN
MAX W.P.
II 2 G Ex db IIB T4 GB
II 2 D Ex tb IIIC T125 C Db
CERTIFICATE NUMBERS ......................................................................................
CLASS I DIV 2 GROUPS A-D T4
CLASS II DIV 2 GROUPS E-G T125 C
98179
EP20-AFAAA-CSV-ABA
ARO ___ SERIES PUMPS
SPG2231001 USA
120 8.3
psig bar 180 12.4psig bar
arozone.com
US: Bryan, OH 43506
EU: Lakeview Dr, IE Swords

Page 6 of 40 EP20-XXXXX-XXX-XXX (en)
2. MODEL DESCRIPTION CHART
Model Code Explanation
EP - 20 XX
Wetted Parts
A -
Port
F - ANSI/DIN Hybrid Flange
Ball
Diaphragms
Bellows
V - FKM
NOTICE: All possible options are shown in the chart, however, certain combinations may not be recommended.
Consult a representative or the factory if you have questions concerning availability.
Special Testing
Pumps requiring special tests will have a separate line item on the Purchase Order
S - Stainless Steel
0 - No Motor or Drive
A - Ordinary Motor / Drive
B - ATEX Motor / Drive
C - NEC Motor / Drive
Motor / Drive
A - Santoprene
C - Hytrel
S - 316 SST
T - PTFE
V - FKM
A - Santoprene
C - Hytrel
T - PTFE
XXX- XXXXXX
X
0 - None
A -3meter encoder cable
B -6meter encoder cable
C -9meter encoder cable
D - 15 meter encoder cable
E - 50 meter encoder cable
F - 100 meter encoder cable
Accessories
A - Revision
Revision
-
C -Cast Iron
Aluminum
Seat
A - Santoprene
C - Hytrel
F - Aluminum
H - 440 SST
S - 316 SST
Pump Crank case
C - Cast Iron
S - Integrated Spline Shaft
Pump Input Shaft

EP20-XXXXX-XXX-XXX (en) Page 7 of 40
3. OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
EXCESSIVE FLUID PRESSURE
STATIC SPARK
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE
WARNING
STATIC SPARK. Can cause explosion re-
sulting in severe injury or death. Ground pump and
pumping system.
ySparks can ignite ammable material and vapors.
yThe pumping system and object being sprayed must
be grounded when it is pumping, ushing, recirculat-
ing or spraying flammable materials such as paints,
solvents, lacquers, etc. or used in a location where
surrounding atmosphere is conducive to spontaneous
combustion. Ground the dispensing valve or device,
containers, hoses and any object to which material is
being pumped.
ySecure pump, connections and all contact points to
avoid vibration and generation of contact or static
spark.
yConsult local building codes and electrical codes for
specic grounding requirements.
yAfter grounding, periodically verify continuity of
electrical path to ground. Test with an ohmmeter from
each component (e.g., hoses, pump, clamps, contain-
er, spray gun, etc.) to ground to ensure continuity.
Ohmmeter should show 0.1 ohms or less.
ySubmerse the outlet hose end, dispensing valve or de-
vice in the material being dispensed if possible. (Avoid
free streaming of material being dispensed.)
yUse hoses incorporating a static wire.
yUse proper ventilation.
yKeep inammables away from heat, open ames and
sparks.
yKeep containers closed when not in use.
WARNING
Excessive fluid pressure developed by
pump can cause personal injury, pump damage or
property damage.
yFluid pressure developed by the pump do not exceed
the maximum as stated on the pump model plate.
yBe sure material hoses and other components are
able to withstand fluid pressures developed by this
pump. Check all hoses for damage or wear. Be certain
dispensing device is clean and in proper working con-
dition.
WARNING
INSTALLATION OF ELECTRICAL COMPO-
NENTS FOR HAZARDOUS DUTY APPLICATIONS.
yPumps that will operate in environments defined as
“hazardous locations” must only be installed, con-
nected and set-up by qualied personnel with knowl-
edge and understanding of protection classes, regula-
tions and provisions for apparatus in hazardous areas,
for the region where the pump will operate, because
these regulations and provisions, along with the de-
nition of what constitutes hazardous areas vary by
location.
WARNING
ELECTRIC SHOCK HAZARD. This equip-
ment must be grounded. Improper grounding, setup,
or usage of the system can cause electric shock.
yTurn o and remove power before disconnecting any
cables and before servicing or installing equipment.
yConnect only to grounded power source.
yAll electrical wiring must be done by a qualied elec-
trician and comply with all local codes and regula-
tions.
yWait Five minutes for capacitor discharge before
opening equipment.
WARNING
HAZARDOUS PRESSURE. Can result in
serious injury or property damage. Do not service or
clean pump, hoses or dispensing valve while the sys-
tem is pressurized.
yDisconnect power supply to electric motor and VFD.
Relieve pressure from the system by opening dispens-
ing valve or device and / or carefully and slowly loos-
ening and removing outlet hose or piping from pump.
WARNING
HAZARDOUS MATERIALS. Can cause se-
rious injury or property damage. Do not attempt to
return a pump to the factory or service center that
contains hazardous material. Safe handling practices
must comply with local and national laws and safety
code requirements.
yObtain Material Safety Data Sheets on all materials
from the supplier for proper handling instructions.
WARNING
EXPLOSION HAZARD. Models contain-
ing aluminum wetted parts cannot be used with I I I.
-Trichloroethane,Methylene Chloride or other Halo-
genated Hydrocarbon solvents which may react and
explode.
yCheck pump actuator section, PRV section, Oil module
section, uid caps, manifolds and all wetted parts to
assure compatibility before using with solvents of this
type.
WARNING
MISAPPLICATION HAZARD. Do not use
models containing aluminum wetted parts with food
products for human consumption. Plated parts can
contain trace amounts of lead.
CAUTION
Verify the chemical compatibility of the
pump wetted parts and the substance being pumped,
flushed or recirculated. Chemical compatibility may
change with temperature and concentration of the
chemical(s) within the substances being pumped,
flushed or circulated. For specific fluid compatibility,
consult the chemical manufacturer.
CAUTION
Maximum temperatures are based on
mechanical stress only. Certain chemicals will signi-
cantly reduce maximum safe operating temperature.
Consult the chemical manufacturer for chemical com-
patibility and temperature limits. Refer to PUMP DATA
on page 3 of this manual.
CAUTION
Be certain all operators of this equipment
have been trained for safe working practices, under-
stand it’s limitations, and wear safety goggles / equip-
ment when required.
CAUTION
Do not use the pump for the structural
support of the piping system. Be certain the system
components are properly supported to prevent stress
on the pump parts.
ySuction and discharge connections should be flexi-
ble connections (such as hose), not rigid piped, and
should be compatible with the substance being
pumped.

Page 8 of 40 EP20-XXXXX-XXX-XXX (en)
CAUTION
Prevent unnecessary damage to the
pump. Do not allow pump to operate when out of ma-
terial for long periods of time.
yDisconnect power supply from motor when system
sits idle for long period of time.
CAUTION
Use only genuine ARO replacement parts
to assure compatible pressure rating and longest ser-
vice life.
NOTICE
TORQUE ALL FASTENERS BEFORE OPER-
ATION. Creep of housing and gasket materials may
cause fasteners to loosen. Torque all fasteners to en-
sure against uid or air leakage.
WARNING
=Hazards or unsafe practices which could
result in severe personal injury, death or
substantial property damage.
CAUTION
=Hazards or unsafe practices which could
result in minor personal injury, product
or property damage.
NOTICE
=Important installation, operation or
maintenance information.
4. GENERAL DESCRIPTION
4.1. Introduction
The ARO® Electric operated positive displacement pump
works on the principle of changing rotary motion to recipro-
cating motion. An electric gear motor coupled with eccentric
crankshaft to provide rotary motion. The rotary motion of the
shaft is transferred to the reciprocating movement of the dia-
phragm shaft through connecting rod.
Pump cycling will begin as Electric motor powered up. Crank
shaft start to rotate and it will continue to pump and keep up
with the demand. It will build and maintain line pressure and
will stop cycling once maximum line pressure is reached (dis-
pensing device closed) and will resume pumping as needed.
Pumping frequency can be controlled in VFD drive.
4.2. Storage:
Place the equipment in a clean dry area, protected from
impacts, vibrations, temperature extremes and in an environ-
ment with relative humidity less than 90%.
When storing for longer than six months, consult the manu-
facturer.
4.3. Unpacking
Items supplied vary according to product conguration.
Make sure that the items supplied and the information on the
nameplate correspond to the order conrmation.
Check the individual packaging and the product visually for
damage caused by inappropriate handling during shipment.
NOTE: In-case of damage, report the damage to the transport
company and thereafter contact IR distributor.
NOTICE
To protect consumer rights please keep the Label intact on the
Motor, Pump and Drive.

EP20-XXXXX-XXX-XXX (en) Page 9 of 40
5. MECHANICAL INSTALLATION
5.1. Pump & Motor Installation
WARNING
Pump and motors are industrial products. They
must therefore be installed by qualied, experienced and autho-
rized personnel. The safety of people, animals and property must
be ensured when tting the motors into pump.
CAUTION
Prior to commissioning for all motors, rotate
the motor at no load (no mechanical load) for 2 to 5 minutes,
checking that there is no abnormal noise. If there is any abnormal
noise, see section 5 on motor manual (Page 18).
WARNING
Before starting the motor, it is advisable to
check the insulation between the phases and earth, and between
phases.
Once Pump has been fully unpackaged and inspected, use
lifting points on crankcase to move into nal operating posi-
tion.
yEnsure straps and lifting device are properly rated. Refer
section 1.1 for pump weight
yAll three lifting points to be used for stability
yLifting point on crankcase intended to only move pump.
yDo not use pump manifolds to lift the equipment.
yEnsure installation location has enough overhead room
to install motor vertically from top
yEnsure adequate clearance around pump for sufficient
access and ventilation.
yEnsure the pump is installed on at level surface.
Secure pump legs to oor with M14 anchors.
yRefer to section 13.1 for bolt circle spacing.
yPump must be positioned such that fluid inlet and fluid
outlet port are easily accessible.
Install motor onto the pump crank case
yEnsure gearbox motor does not damage pump manifolds.
yRefer to electric motor manual for lifting points and rec-
ommendations.
yEnsure motor is vertical with shaft pointing downward
when mounting over to pump.
yEnsure pump crankshaft is greased from factory.
yMotor should be carefully lowered to ensure spline teeth
are properly engaged. There should not be excessive
pressure on crankshaft. Motor may require some degree
of rotation for spline engagement.
Secure gearbox ange to crankcase ange with 4X M12 bolts.
Figure 2
5.2. VFD Mechanical installation
yRefer to section 3 of VFD manual for detailed mechanical
installation.
yDo not remove the nameplate from the drive.
yEnsure that the lifting device is suitable for the task.
yMount drive to a flat surface or ensure back plate is in-
stalled to allow adequate air ow across cooling ns.
yRefer to section 13.2 for VFD mounting dimension.
4” (100 mm
)
FOR AIR FLOW
4” (100 mm
)
FOR AIR FLOW
AIR FLOW
AIR FLOW
Figure 3

Page 10 of 40 EP20-XXXXX-XXX-XXX (en)
6. ELECTRICAL INSTALLATION
6.1. VFD-Wiring Diagram
––
Motor
Analog Output
ON=Terminated
OFF=Open
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
53 (A IN)
54 (A IN)
37 (D IN)
1)
18 (D IN)
10 V DC
15 mA 130/200 mA
+- +-
(U) 96
(V) 97
(W) 98
(PE) 99
(P RS485) 68
(N RS485) 69
0 V
5V
S801
0/4–20 mA
RS-485
03
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
24 V
0 V
0 V (PNP)
24 V (NPN)
(D IN/OUT)
1)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
12
ON
S201
ON
21
S202
ON=0/4–20 mA
95
P 5-00
21
ON
S801
(R+) 82
(R-) 81
: Chassis
240 V AC, 2 A
400 V AC, 2 A
: PE
3-phase
power
input
+10 V DC
DC bus
0/-10 V DC to
+10 V DC
0/4–20 mA
0/-10 V DC to
+10 V DC
0/4–20 mA
50 (+10 V OUT)
55 (COM A IN)
12 (+24 V OUT)
13 (+24 V OUT)
20 (COM D IN)
27 (D IN/OUT)
Switch mode
power supply
Brake
resistor
Relay 1
Relay 2
1)
(COM A OUT) 39
(A OUT) 42
: Ground
: Ground 1
: Ground 2
(COM RS485) 61
2)
RS485
interface
OFF=0/-10 V DC
to +10 V DC
A Analog
DDigital
1 Terminal 37 (optional) is used for Safe Torque O
(STO).
2 Do not connect cable shield.
6.2. General Wiring practice
yDue to limited number of knockouts in VFD, it is recommended to combine signal wires (Safe Stop cable, Leak detector ca-
ble, Thermistor cable) into a single cable.
yRoute control wiring in separate conduit and as far away from power wires as possible
yA dedicated ground wire is needed, It is not recommended grounding through the conduit
yKeep wire runs as short as possible to help avoid problems.
Encoder
Cable
Safe Stop
cable
Leak detector
cable Thermistor
cable
Power Input
cable to VF
D
Power Cable
VFD to Motor
Figure 4

EP20-XXXXX-XXX-XXX (en) Page 11 of 40
6.3. VFD AC Mains – Input Power Requirements:
WARNING
To ensure the power line, the drive and motor rated for the same voltage
Supply terminals (6-pulse) L1, L2, L3
Supply voltage
(1)(2)
380 – 500 V +/- 10%
Supply frequency 47.5 – 63 Hz
Maximum imbalance temporary between mains phases 3.0% of rated supply voltage
True power factor (λ) ≥ 0.9 nominal at rated load
Displacement power factor (cos Φ) Near unity (> 0.98)
Switching on the input supply L1, L2, L3 (power - ups) ≤ 7.5 kW (10 hp) Maximum twice per minute
Environment according to EN60664-1 Overvoltage category III / pollution degree 2
1. Mains voltage low/mains dropout: During low mains voltage or a mains dropout, the drive continues until the DC-link voltage drops below the mini-
mum stop level, which typically corresponds to 15% below the drive’s lowest rated supply voltage. Power-up and full torque cannot be exptected at
mains voltage lower than 10% below the drive’s lowest rated supply voltage.
2. The unit is suitable for use on a circuit capable of delivering not more than 100000 RMS symmetrical Amperes, 240/500/600 V maximum.
6.4. Power Wiring:
6.4.1 VFD - Input Power Wiring
yConnect the 3-phase AC input power wiring to terminals L1, L2, and L3.
yGround the cable in accordance with the grounding instructions, see 4.3 Grounding and 4.5.1 Grounding the Cable Shield.
yWhen supplied from an isolated mains source (IT mains or oating delta) or TT/TN-S mains with a grounded leg (ground-
ed delta), ensure that parameter 14-50 RFI Filter is set to [0] O. This setting prevents damage to the DC link and reduces
ground capacity currents in accordance with IEC 61800-3.
6.4.2. VFD - Output Motor Wiring
yRun output separately or use shielded cables.
yComply with local and national electrical codes for cable sizes.
yStrip a section of the outer cable insulation.
yPosition the stripped wire under the cable clamp to establish mechanical xation and electrical contact between the cable
shield and ground.
yConnect the ground wire to the nearest grounding terminal in accordance with the grounding instructions, Refer to sec-
tion 7.2 for Grounding.
yConnect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W).
yDo not wire a starting or pole-changing device (for example a Dahlander motor or slip ring asynchronous motor) between
the drive and the motor.
99(PE)
91(L1)92(L2)93(L3)95(PE)
3-PHAS
E
POWER
INPUT
U2V2W2
U1
V1W1
96(U)97(V)98(W)
MOTOR VFD
6.4.3. Motor - Input Power Wiring
yThe cables must be tted with connectors suitable for the cable cross-section and the terminal diameter.
yThey must be crimped in accordance with the connector supplier’s instructions.
yIf using cables without connectors, attach some calipers.
yIf any nuts on the brass terminal block are lost, they must be replaced by brass nuts, not steel ones.
yWhen closing the box, ensure that the seal is correctly.
Type of cable gland Ø min. - Ø max. (mm) cable
Steel Polyamide cable gland Brass cable gland
ISO M16 5-10 5.5-9.5
ISO M20 9.5-15 8.5-13
ISO M25 13-19 12-17

Page 12 of 40 EP20-XXXXX-XXX-XXX (en)
6.5. Control Wiring (Required)
6.5.1. Leak detector wiring diagram
General Description:
An ARO diaphragm pump equipped with the ARO Leak Detection Sensor warns of a diaphragm failure by sensing the pressure
of liquid in the air cap of the pump. This system uses a liquid sensor in each of the three air caps ehich will send an output sig-
nal when uid is dected.
Installation and Warnings:
NOTE: All WIRING MUST COMPLYWITH ALL LOCAL AND / OR NATIONAL ELECTRICAL CODES.
yElectrical codes that apply must be strictly adhered to; failure to do so may lead to shock hazard or serious injury.
ySome local electrical codes may require the installation of rigid conduit.
yThe Leak Detection Sensor components must be installed by a qualied electrician in compliance with all national, state
and local codes and regulations to reduce the risk of electrical shock or other serious injury during installation and opera-
tion.
yARO is not responsible for accidents resulting from improper installation of components or hardware.
yHAZARDOUS VOLTAGE. Do not attempt any service without disconnecting all electrical supply source.
HAZARDOUS AREA SAFE AREA
Pin 18 on VFD
(Digital input)
Pin 19 on VFD
(Digital input)
Pin 32 on VFD
(Digital input)
Pin 13 on VFD
(24V DC)
Pin 20 on VFD
(Common)
White
Red
Black
White
Red
Black
White
Red
Black
Leak Detect Diaphragm 1
Leak Detect Diaphragm 2
Leak Detect Diaphragm 3
+DC
BR- B
M A I N S
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
U V W
MOTOR
99
Mains input, motor, and grounding for basic drives. Actual congurations vary with unit types and optional equipment
Figure 5
NOTE: Motor should be wired for wye or star conguration with V and W leads switched as shown in wiring diagram to get the
desired direction of rotation.

EP20-XXXXX-XXX-XXX (en) Page 13 of 40
ZENER Barrier, Leak Detection Sensor PN Voltage Device Rating (mA) Temperature Rating
97414 (ATEX / IECEx / NEC / CEC) 24 VDC 100 -4°F - 140°F (-20°C - 60°C)
Leak Detection Sensor PN Voltage Device Rating (mA) Temperature Rating
96270-1 24 VDC 40 -0°F - 176°F (-18°C - 80°C)
96270-2 (ATEX / IECEx) 24 VDC 40 -0°F - 176°F (-18°C - 80°C)
yRecommended cable (3 Conductor with Single Outer Jacket)
Manufacturer Alpha Wire
Part Number 1173C
Conductor 22 AWG
Voltage Rating 300 V RMS
C 33 PF/FT @ 1KHz
L 0.18 mH/Ft
yLeak detector wires are connected to VFD directly for ordinary pump. Two Zener Barriers (ARO Part No – 97414) are needed
per leak detector for hazardous duty pump. Zener Barrier is connected between leak detector and VFD drive.
6.5.2. Leak Detector Safe Loop Calculations
Leak Detector Cable Zener Barrier
IR Part Number 96270-2 Alpha Wire 1173C IR Part Number 97414
Ui = 32 VDC Uo = 25.2 VDC
Ii = 87 mA Io = 74 mA
Pi = 0.616 W Po = 0.464 W
Ci = 0.052 uF Cc 0.055uF Co = 0.107 uF
Li = 3.7 uH Lc 6.488mH Lo = 6.492 mH
Um = 250 VAC/DC Um = 250 VAC/DC
Ta = -18oC To +80oC Ta = -40° C To +60°C
Ui ≥ Uo (32 V > 25.2 V)
Ii ≥ Io (87 mA > 74 mA)
Pi ≥ Po (0.616 W > 0.464 W)
Maximum Cable Capacitance Cc = Co-Ci ≥ 0.107 uF - 0.052 uF = 0.055 uF
Maximum Cable Inductance Lc = Lo-Li ≥ 6.492 mH - 0.0037 mH = 6.488 mH
As per cable manufacturer Alpha Wire, Cable Capacitance = 33PF/FT, Cable Inductance = 0.00018 mH/FT
Maximum cable run length = 359 feet
Calculated Cable Capacitance = 11.8 nF < 0.055 uF
Calculated Cable Inductance = 6.48 mH < 6.462 mH

Page 14 of 40 EP20-XXXXX-XXX-XXX (en)
6.5.3. Thermal protection – Ordinary motor
yMotor is installed with 2 normally closed contact sensors (PTO) in series for ordinary motors and will need to be wired from
the motor terminal box to the VFD as per below wiring diagram.
PTO Thremal switches
(Installed on motor)
Normally closed
(NC)
Normally closed
(NC)
Pin 20 on VFD
(Common)
Pin 33 on VFD
(Digital Input)
6.5.4. Thermal Protection – Hazardous motor
WARNING
Do not Connect from logic out 10 to pin 33 because VFD digital input is set to NPN. MCB112 output signal is PNP type.
yThe motor is installed with 3 PTC thermal sensors in series for hazardous duty application. It need to be wired to the
MCB112 Card in the option A slot on the VFD.
PTC
M 3~
TP TP
12 13 18 19 27 29 32 33 20 37
MS 220 DA
Code No. 130B1137
Motor protection
SEE MANUAL FOR
MCB 112 PTC Thermistor Option B
ADDITIONAL INSTRUCTIONS.
PTB 14 ATEX 3012U
CAUTION:
II (2) G [Ex e] [Ex d] [Ex n]
ε
10 10 mA
60 mA
12
20-28 VDC
20-28 VDC
II (2) D [Ex tb][Ex tc]
0102 12030-1201-03
.com
X44 1
T1 T2 NC NC NC NC NC NC NC NC
LOGIC SAFE STOP
OUT T37
2345678910 11 12
NOTE: Remove jumper wire from terminal 37 of the control card to T12 of MCB
in case of using Estop button and terminate Estop wiring between them
as shown in wiring diagram.

EP20-XXXXX-XXX-XXX (en) Page 15 of 40
6.5.5. Encoder Wiring – Ordinary Motor
yMotor is installed with a 1024 pts TTL encoder with a 12-pin connector on the outside of the motor terminal box.
yExtension cable is available for dierent length and need to order according to requirement.
yying leads need to be wired to the MCB102 encoder card installed in the option B slot of the VFD as per encoder card wir-
ing.
TO MOTOR
12 PIN CONNECTOR TO MCB 102
ON VFD
6.5.6. Encoder Wiring – Hazardous Motor
yHazardous duty Motor is installed with a 1024 pts TTL with 2-3M of cable length and ying leads (no connector).
yFlying leads need to be wired to the MCB102 encoder card installed in the option B slot of the VFD as per encoder card wir-
ing.
6.6. Control Wiring (Recommended)
6.6.1. Safe Stop wiring diagram
yIt is recommended to install external Estop.
yThe VFD will come with pin 37 wired to 24VDC. This will need to be removed when e-stop is installed.
yThe e-stop (safe stop) should be normally closed and will stop the pump with an open circuit.
Pin 12 on VFD
(+24 V OUT)
Pin 37 on VFD
Digital Input)
Wire Color Encoder card Terminal Description
Brown (3) 5V
White (4) GND
Yellow (5) A INPUT
Green (6) A INV INPUT
Pink (7) B INPUT
Grey (8) B INV INPUT
Blue (9) Z INPUT
Red (10) Z INV INPUT
Grey (11) NC

Page 16 of 40 EP20-XXXXX-XXX-XXX (en)
6.7. Control Wiring (Optional)
6.7.1. Analog Input – Speed control
yDrive is set to 0-10 volt signal from factory. Manually have to ip switch inside the drive (A53) to change to 4-20 mA signal.
+10V
A IN
A IN
COM
A OUT
COM
50
53
54
55
42
39
A53
U - I
0–10 V
+
-
Drive
+10 V
A IN
A IN
COM
A OUT
COM
50
53
54
55
42
39
+
-
A53
U - I
4-20mA
Drive
+10 V
A IN
A IN
COM
A OUT
COM
50
53
54
55
42
39
A53
U - I
≈5kΩ
Drive
VFD Parameter Description Default Parameter
610 Terminal 53 Low Voltage 0.07 V
611 Terminal 53 High Voltage 10.00 V
612 Terminal 53 Low Current 4 mA
613 Terminal 53 High Current 20 mA
NOTE: Analog speed control can be used only with auto on mode.
6.6.2. Digital start/ stop control
1. Digital input 27 will be used in place of 18 shown in the VFD manual.
yThe VFD will come with pin 37 wired to 24VDC. This will need to be removed when e-stop is installed.
2. Digital inputs are set to NPN and needs to be wired to common (Terminal 20) instead of +24V.
+24 V
+24 V
D IN
D IN
D IN
COM
D IN
D IN
D IN
D IN
12
13
18
19
20
27
29
32
33
37
Drive
VFD Parameter Function Setting
512 Terminal 27 digital input [8] Start
513 Terminal 29 digital input [1] Reset

EP20-XXXXX-XXX-XXX (en) Page 17 of 40
6.7.2. Analog Inputs – Torque (Pressure) Control
yTo active torque control, VFD parameter 420 needs to be changed from “[0] No Function” to “[6] Analog in 54”.
yTorque and speed control when put together in the system, torque control will override speed control and maintain load
on the motor.
yManually have to ip switch inside the drive (A54) to change to 4-20 mA signal.
+10 V
A IN
A IN
COM
A OUT
COM
50
53
54
55
42
39
A54
U - I
≈5kΩ
Drive
VFD Parameter Description Default Parameter
620 Terminal 54 Low Voltage 0.07 V
621 Terminal 54 High Voltage 10.00 V
622 Terminal 54 Low Current 0.14 A
623 Terminal 54 High Current 20.00 A
6.7.3. Additional available Input/output (Optional)
1. T27 & T29 are congurable for digital input or output.
yDigital output can be either digital or pulse output. The options for parameters 530 and 531 are all digital, however,
to enable pulse output the parameters in the table below should be set as shown. The pulse output variable can then be
selected using parameters 552 and 563.
VFD Parameter Function Setting
501 Terminal 27 mode [1] Output
502 Terminal 29 mode [1] Output
530 Terminal 27 Digital Output [55] Pulse Output
531 Terminal 29 Digital Output [55] Pulse Output
560 Terminal 27 Pulse Output Variable Select output variable to display from the list
552 Pulse Output Max Freq #27 5000 (default)
563 Terminal 29 Pulse Output Variable Select output variable to display from the list
555 Pulse Output Max Freq #29 5000 (default)
2. T33 digital input is available for hazardous location models only
yOrdinary motor will connect Thermistor cable to this terminal
3. T42 analog output
yRefer to Personal menu table (650, 651 & 652) to set parameter in VFD for this terminal
4. Relays
yTwo relays are available for use (Parameter 540)
yRefer to section 8.6.11 (page – 69) in VFD manual for detailed relay information

Page 18 of 40 EP20-XXXXX-XXX-XXX (en)
6.8. Congured I/O’s (summary)
Intended function Warning text Digital I/O Terminal Ground Terminal 24VDC Terminal
Diaphragm 1 Leak Detect Diaphragm 1 Leak 18 20 13
Diaphragm 2 Leak Detect Diaphragm 2 Leak 19 20 13
Diaphragm 3 Leak Detect Diaphragm 3 Leak 32 20 13
PTO (normally closed) -
Ordinary pump only
Alarm 11 33 20 N / A
Safe Stop (E Stop) Alarm 68 37 N / A 12
User Congurable I/O 27
User Congurable I/O 29
Anlog In Terminal Ground Terminal 10VDC Terminal
Speed 53 39 /5 5 50
Torque 54 39 / 55 50
Anlog In Terminal
User Congurable 42
6.9. VFD serial communication
1. Drive will have RS485 serial communication port.
yConnect RS485 serial communication wiring to terminals (+) 68 and (-) 69
2. Connect RS485 serial communication wiring to terminals (+) 68 and (-) 69
3. Drive will support Modbus RTU eld communication.
4. Set the below parameter for serial communication set-up
VFD Parameter Function
8-30 Select Option [2] for Modbus RTU. Changing parameter is not
eective until after powering o frequency converter
8-31 Enter the valid address for the frequency converter
(standard) port. e.g. [1-247]
8-32 Select option for the Baud rate match with FC (standard) port.
531 Terminal 29 Digital Output
560 Terminal 27 Pulse Output Variable
552 Pulse Output Max Freq # 27
563 Terminal 29 Pulse Output Variable
555 Pulse Output Max Freq # 29
RS485
61
68
69
+
_

EP20-XXXXX-XXX-XXX (en) Page 19 of 40
6.10. User dened readout
yParameters 030, 031, & 032 are available to modify the “User Dened Readout” that will display in the top left corner of the
main menu screen. By default, these values are set to scale motor frequency to actual pump rpm. To update the “User De-
ned Readout”, refer to the following parameter descriptions.
1. Select the unit to be displayed on LCP from option given in parameter 030.
2. Minimum value is set to zero in parameter 031.
3. Maximum value is set for parameter 032 based on maximum motor frequency (92 Hz) set in parameter 414 & calculat-
ed as below.
Pump unit (Maximum) = Motor sync. RPM (1500) X Maximum motor frequency (92 Hz) x unit conversion factor (X)
“Motor Freuency (50 Hz) X GB ratio (12.7)”
Pump Unit (parameter 030) * Unit conversion factor (X)
RPM 1
GPM 0.65
NOTE: Adjust unit conversion factor for the selected unit given in parameter 030 to calculate maximum value for parameter
032 per the above formula.
* Unit conversion factor values are approximate and depend on back pressure.
7. GROUNDING
Before operating the pump, ground the system as explained below.
7.1. Pump Grounding
yAll pump have a ground screw installed in crankcase
housing. Connect one end of the grounding wire to
ground screw and other end of the grounding wire to
suitable earth ground.
Ground Lug
Figure 6
7.2. VFD Grounding
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the drive
properly can result in death or serious injury.
Ensure that the minimum size of the ground conductor complies
with the local safety regulations for high touch current equip-
ment.
yGround the variable frequency drive through a proper
connection to a power source.
yGround the drive in accordance with applicable standards
and directives.
yUse a dedicated ground wire for input power, motor pow-
er, and control wiring.
yDo not ground 1 drive to another in a daisy-chain fashion.
yKeep the ground wire connections as short as possible.
yFollow motor manufacturer wiring requirements.
yMinimum cable cross-section for the ground wires: 10
mm2 (7 AWG).
ySeparately terminate individual ground wires, both com-
plying with the dimension requirements.
7.3. Electric Motor Grounding
WARNING
It is compulsory to earth the motor. Earthing must be performed
in accordance with current regulations (protection of workers).
Motors have a ground screw inside the terminal box. Use it to
ground the motor to the controller.

Page 20 of 40 EP20-XXXXX-XXX-XXX (en)
8. LUBRICATION REQUIREMENT
WARNING
You must use lubricating oil of the recommended type.
Pump is lubricated at the factory. Pump is shipped with syn-
thetic oil PAO ISO VG 460. it should lled in crankcase hous-
ing to keep center rod bearing and lower bearing lubricated
during operation and function smoothly. Pump is designed
to circulate oil through piston pump and pass through oil
filter. This improved life of the bearing and maintained oil
cleanliness in the system. Upper bearing is grease lled and
it is separated from oil chamber to avoid any contamination.
There is no need to add an inline lubricator under normal op-
erating conditions.
F
ill Port
Figure 7
8.1. Oil Filling instruction
yPump is shipped with 2.5 gallon Oil container. Crankcase
unit will hold approx. 1.7 gallons (6.4 L). Store leftover oil
for future.
yRemove 3/8” NPT plug from ll port in actuator cap above
highest cylinder.
yPut 3/8” NPT threaded elbow facing on top and funnel for
ease in lling.
yEnsure 3/8” NPT drain plug is inserted in the crankcase
housing.
yRemove breather in actuator cap above lowest cylinder
for vent.
yFill oil to half way up sight glass located in crankcase
housing above the lowest cylinder.
yOnce full, reinsert 3/8” NPT plug to the fill port and
breather in top cap.
Sight Glass
Breather
Drain Plug
Figure 8