Xylem CentriPro AQUAVAR CPC4 FD Series Owner's manual

AQUAVAR®CPC - FD
Variable Speed Drive with Fused Disconnect
SUPPLEMENT TO THE INSTALLATION AND OPERATION MANUAL (IM167)
SUPPLEMENT MANUAL
IM250R02

2
SAFETY
Use of Warnings and Notes...................................................................................................................................................3
INSTALLATION
Application ..............................................................................................................................................................................4
Input Disconnect Features and Functions ...........................................................................................................................4
Installation Flow Chart............................................................................................................................................................6
Preparing for Installation (Supplement to Aquavar CPC-01/U1 User’s Manual).............................................................7
Installing the Drive (Supplement to Aquavar CPC-01/U1 User’s Manual).......................................................................9
Installing the Wiring (Supplement to Aquavar CPC-01/U1 User’s Manual) ................................................................. 10
MAINTENANCE
Maintenance Intervals ......................................................................................................................................................... 14
Drive Module Fan Replacement ........................................................................................................................................ 14
Enclosure Fan Replacement – NEMA 12 Enclosures....................................................................................................... 15
Enclosure Air Filter Replacement – NEMA 12 Enclosures............................................................................................... 16
TECHNICAL DATA
Ratings (Supplement to Aquavar CPC-01/U1 User’s Manual)........................................................................................ 19
Input Power Connections (Supplement to Aquavar CPC-01/U1 User’s Manual) ........................................................ 20
Motor Connections.............................................................................................................................................................. 26
Cooling – R7/R8.................................................................................................................................................................... 26
Dimensions and Weights (Supplement to Aquavar CPC-01/U1 User’s Manual)......................................................... 27
Applicable Standards.......................................................................................................................................................... 34
INDEX
TABLE OF CONTENTS

3
WARNING! The AQUAVAR CPC adjustable speed AC drive with Input Disconnect should ONLY be
installed by a qualified electrician.
WARNING! Even when the motor is stopped, dangerous voltage is present at the Power Circuit terminals
U1, V1, W1 and U2, V2, W2 and, depending on the frame size, UDC+ and UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present when input power is connected. After disconnecting the
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 CPC, there may be
dangerous voltage (from external sources) on the terminals of the relay outputs.
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! The AQUAVAR CPC will start up automatically after an input voltage interruption if the
external run command is on.
WARNING! When the AQUAVAR CPC with Input Disconnect is connected to the line power, the Motor
Terminals T1, T2 and T3 are live even if the motor is not running. Do not make any connections when the
AQUAVAR CPC with Input Disconnect is connected to the line. Disconnect and lock out power to the
drive before servicing the drive. Failure to disconnect power may cause serious injury or death.
NOTE! For more technical information, contact the factory or your local AQUAVAR representative.
USE OF WARNINGS AND NOTES
There are two types of safety instructions throughout this manual:
• Notes draw attention to a particular condition or fact, or give information on a subject.
• Warnings caution you about conditions which can result in serious injury or death and/or damage to 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
damage 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

4
Study these installation instructions carefully before proceeding. Failure to observe the warn-
ings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read “Safety” on page 3.
WARNING! When the Aquavar CPC with Input Disconnect is connected to the line
power, the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do
not make any connections when the Aquavar CPC with Input Disconnect is connected
to the line. Disconnect and lock out power to the drive before servicing the drive. Fail-
ure to disconnect power may cause serious injury or death.
Application
This manual contains supplemental information that is unique to Aquavar CPC input dis-
connect configurations (“FD” suffix). Refer to the base manual, Aquavar CPC User’s Manual
(IM167), for all other information.
Input Disconnect Features and Functions
The Aquavar CPC with Input Disconnect is an Aquavar CPC AC adjustable frequency drive
packaged with an input disconnect switch, and with a door mounted, external operating
handle. The operating handle can be padlocked in the OFF position (padlock not supplied).
Enclosure options are NEMA 1, NEMA 12 and NEMA 3R (UL Type 1, UL Type 12 and UL Type
3R).
The following is a typical power diagram:
Aquavar
CPC
Drive
3Ø
Motor
3
Drive with Input Disconnect
Disconnect Switch
or Circuit Breaker
3
3 Phase
Input Power
or
1 Phase
Input Power
INSTALLATION

5
The following figures show the front view of the Aquavar CPC Input Disconnect standard
configurations and identify the major components.
R1 … R4 R5, R6 R7, R8
NEMA 1 & 12 NEMA 1 & 12 NEMA 1 & 12
Enclosures Enclosures Enclosures
Aquavar CPC Drive
Control Panel
Operating Handle
for Disconnect Switch
BP0096
BP0094
BP0093
INSTALLATION

6
Installation Flow Chart
The installation of Input Disconnect configurations for Aquavar CPC drives follows the outline
below. The steps must be carried out in the order shown. At the right of each step are refer-
ences to the detailed information needed for the correct installation of the unit.
NOTE! References in the middle column below are to the Aquavar CPC User’s Manual
(IM167). References in the third column below are to this manual.
Refer to the Additional Reference
Task Aquavar CPC User’s Manual in this Manual
“Installation” Section
PREPARE for “Preparing for Installation” • R7/R8: “Lifting the Drive”
installation on page 7.
• “Drive Identication” on page 8.
• “Suitable Mounting Location”
on page 9.
PREPARE the “Prepare the Mounting Location” • R7/R8: “Prepare the Mounting
Mounting Location – R7 and R8” on
Location page 9.
• “Dimensions and Weights
(Supplement to Aquavar CPC
User’s Manual)” on page 27.
REMOVE the “Remove Front Cover” R7/R8: “Remove Side Panel- R7 and
front cover R8 NEMA 1 and 12 Enclosures” on
page 9.
MOUNT the drive “Mount the Drive” R7/R8: “Mount the Drive” on
page 10.
INSTALL wiring “Wiring Overview” and “Installing the Wiring (Supplement
“Install the Wiring” to Aquavar CPC User’s Manual)”
starting on page 10.
CHECK installation “Check Installation” —
REINSTALL the “Reinstall Cover” —
cover
APPLY power “Apply Power” —
START-UP “Start-Up” —
INSTALLATION

7
Preparing for Installation (Supplement to Aquavar CPC User’s Manual)
Lifting the Drive
R7…R8 Frames
WARNING! Handle and ship floor mounted enclosures only in
the upright position. These units are not designed to be laid on their backs.
1. Use a pallet truck to move the package/enclosure to the installation site.
2. Remove the cabinet side panels from NEMA 1 and 12 enclosures for
access to the cabinet/pallet mounting bolts. (Six (6) torx screws hold
each cabinet side panel in place. Leave the side panels off until later.)
3. Remove the 4 bolts that secure the cabinet to the shipping pallet.
WARNING! Use the lifting lugs/bars at the top of the unit
to lift R7/R8 drives.
4. Use a hoist to lift the drive. (Do not place drive in final position until
mounting site is prepared.
PC00005
R70010
2
PC00003
30º
INSTALLATION

8
Preparing for Installation (Supplement to Aquavar CPC User’s Manual)
Drive Identification
To identify the type of device you are installing, refer to the type code number on the device
identification label.
• Wall mounting base drives – label attached on the side surface of the heat sink.
• Packaged drive with screw cover – label attached to outside surface on the left ide of the
enclosure.
• Enclosure with hinged cover/door – label on inside surface of the cover/door.
Type Code Number
Use the following to interpret the type code found on the identification label.
CPC 4 370 1 FD
AQUAVAR®(Series)
Voltage
2 – 208-240 Volt
4 – 480 Volt
5 – 575 Volt
Amps
370 Amps
*See Technical Section
NEMA Enclosure Rating
1 – NEMA 1
2 – NEMA 12
Fused Disconnect
NOTE: Standard equipment on 200 HP and above models, R7-R8 Frames.
Options
* Consult factory for other options, if available. Not all combinations may be available.
Ratings and Frame Size
Charts in the “Ratings” sections of the Aquavar CPC User’s Manual and this manual list
technical specifications, and identify the drive’s frame size.
NOTE! Some instructions in this document vary, depending on the drive’s frame size. To
read the Ratings table, you need the “Output current rating” entry from the type code (see
above).
INSTALLATION

9
Suitable Mounting Location
For selecting a suitable mounting location for FD configurations, refer to:
• Preparing for installation in the Aquavar CPC User’s Manual, and
• The Technical Data section of this manual for information on dimensions and weights.
Installing the Drive (Supplement to Aquavar CPC User’s Manual - IM167)
WARNING! Metal shavings or debris in the enclosure can damage electrical
equipment and create a hazardous condition. Where parts, such as conduit plates
require cutting or drilling, first remove the part. If that is not practical, cover nearby
electrical components to protect them from all shavings or debris.
Prepare the Mounting Location – R7 and R8
The Aquavar CPC should only be mounted where all of
the requirements defined in “Preparing for Installation”
are met.
Frame sizes R7 and R8 have mounting holes inside
the enclosure base. See “NEMA 1 and 12, R7…R8
Mounting Dimensions” on page 28.
Where it is not possible to use either mounting hole
at the back of the base, use an L-bracket at the top of
the enclosure to secure the cabinet to a wall or to the
back of another enclosure. Bolt the L-bracket to the
enclosure using the lifting lug bolt hole on the top of
the enclosure.
Remove Side Panels – R7 and R8 NEMA 1 and 12 Enclosures
Cabinet Door
1. To open the cabinet door, loosen the quarter-turn screws
that hold the cabinet door closed.
2. Installation access is easier if these panels are kept off
throughout the installation.
PC00023
Fastening points when installed
back against a wall (top view)
Fastening points when installed
back against back
Fastening the cabinet at the top
using L-brackets (side view)
L-bracket
M12 bolt (1/2 to 9/16 in)
Cabinet top
INSTALLATION
R70020
2

10
Mount the Drive
R7…R8
1. Use a hoist to move the cabinet into position.
NOTE! If the cabinet location does not provide access to the cabinet
sides, be sure to re-mount side panels before positioning cabinet.
2. Install and tighten mounting bolts.
Installing the Wiring (Supplement to Aquavar CPC User’s Manual)
WARNING!
• Metal shavings or debris in the enclosure can damage electrical equipment and create a
hazardous condition. Where parts, such as conduit plates require cutting or drilling, first
remove the part. If that is not practical, cover nearby electrical components to protect
them from all shavings or debris.
• Do not connect or disconnect input or output power wiring, or control wires, when power
is applied.
• Never connect line voltage to drive output Terminals T1, T2 and T3.
• Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of the unit.
Disconnect motor wires before taking any measurements in the motor or motor wires.
• Make sure that power factor correction capacitors are not connected between the drive
and the motor.
Wiring Requirements
Refer to the “Wiring Requirements” Section in the Aquavar CPC User’s Manual. The
requirements apply to all Aquavar CPC drives. In particular:
• Use separate, metal conduit runs for the following different classes of wiring:
– Input power wiring
– Motor wiring
– Control/communications wiring
• Properly and individually ground the drive, the motor and cable shields.
• Ground the pressure transducer or piping back to the Aquavar chassis or common
grounding point.
PC00003
30º
INSTALLATION

11
Wiring Overview
Power Connection – Standard Input Disconnect (R1…R6, Wall Mounted)
The following figures show the Standard Input Disconnect (wall mounted) wiring connection
points. Refer to the Aquavar CPC User’s Manual for control connections to the drive.
INSTALLATION
R1…R4
NEMA 1 & 12
Enclosures
Aquavar
CPC
R5, R6
NEMA 1 & 12
Enclosures I/O Conduit
(Top)
Motor
Terminals
Ground
Lug(s)
Motor
Terminals
Gnd
Input Power
Terminals
Input Power
Terminals
I/O Conduit
(Bottom)
BP0058
Disconnect Switch
or Circuit Breaker
BP0057

12
Power Connection – Standard Input Disconnect (R7…R8, Floor Mounted)
The R7 and R8 Aquavar CPC Standard Input Disconnect units are configured for wiring access
from the top and include a removable conduit mounting plate. The following figure shows the
Standard Input Disconnect (floor mounted) wiring connection points. Refer to the Aquavar
CPC User’s Manual for control connections to the drive.
R7
NEMA 1 & 12
Motor
Terminals
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
CPC
BP0054 BP0055
Disconnect Switch
or Circuit Breaker
Input Power
Terminals
Motor
Terminals
CPC
R8
NEMA 1 & 12
Ground Lug
Bar Ground Lug Bar
INSTALLATION

13
Install the Line Input Wiring
Line Input Connections – Standard Input Disconnect Configurations
Connect input power to the terminals of the disconnect switch or circuit breaker. Connect the
equipment grounding conductor to the ground lug. The figure below shows the connection
points for Standard Input Disconnect configurations.
WARNING! Check the motor and motor wiring insulation before connecting the
Aquavar CPC to line power. Follow the procedure in the Aquavar CPC User’s Manual.
Before proceeding with the insulation resistance measurements, check that the Aquavar
CPC is disconnected from incoming line power. Failure to disconnect line power could
result in death or serious injury.
NOTE! For the remainder of the installation and start-up (motor and control wiring) refer to
the Aquavar CPC User’s Manual.
INSTALLATION
R1…R4
NEMA 1 & 12
Enclosures
R5, R6
NEMA 1 & 12
Enclosures
Input
Power
BP0058
R7, R8
NEMA 1 & 12
Enclosures
Input
Power
BP0057
BP0054
Dashed line is ground run. R7 shown.
R8 similar to R7.

14
Maintenance Intervals
If installed in an appropriate environment, the drive requires very little maintenance. This table
lists the routine maintenance intervals recommended by CentriPro.
Maintenance Configuration Interval Instruction
Check/replace R5/R6 R5/R6 NEMA 12 Check every 3 “Frame Sizes R5/R6 – Enclosure
enclosure inlet air filter enclosures months. Replace Inlet Air Filter” on page 16.
as needed.
Check/replace R7/R8 R7/R8 NEMA 12 Check every 3 “Frame Sizes R7/R8 – NEMA 12
enclosure inlet air filter enclosures months. Replace Enclosure Inlet Air Filter” on
as needed. page 16.
Check/replace R7/R8 R7/R8 NEMA 12 Check every 6 “Frame Sizes R7/R8 – NEMA 12
enclosure exhaust air enclosures months. Replace Enclosure Exhaust Filters” on
filter as needed. page 18.
Check and clean All Depends on the See “Maintenance” in Aquavar
heatsink dustiness of the CPC User’s Manual.
environment
(every 6…12
months)
Replace drive All Every 6 years See “Maintenance” in Aquavar
module fan CPC User’s Manual.
Replace enclosure NEMA 12 Every 3 years See “Frame Sizes R7/R8 – NEMA
fan(s) 12 Enclosures” on page 15. For
other frame sizes, see
“Maintenance” in Aquavar CPC
User’s Manual.
Change capacitor Frame sizes R5 and Every 10 years See “Maintenance” in Aquavar
R6 CPC User’s Manual.
Replace battery in the All Every 10 years See “Maintenance” in Aquavar
Assistant control panel CPC User’s Manual.
Drive Module Fan Replacement
The drive module fan cools the heatsink. Fan failure can be predicted by the increasing
noise from fan bearings and the gradual rise in the heatsink temperature in spite of
heatsink cleaning. If the drive is operated in a critical part of a process, fan replacement is
recommended once these symptoms start appearing. Replacement fans are available from
the factory. Do not use other than CentriPro specified spare parts.
To monitor the running time of the cooling fan, see “Group 29: Maintenance Trig” in the
Aquavar CPC Users’s Manual.
Frame Sizes R7 and R8
Refer to the installation instructions supplied with the fan kit.
MAINTENANCE

15
PC00021
PC00018
Enclosure Fan Replacement – NEMA 12 Enclosures
NEMA 12 enclosures include an additional fan (or fans) to move air through the enclosure.
Frame Sizes R7/R8 – NEMA 12 Enclosures
The enclosure fan is located in the exhaust box on top of the NEMA 12
enclosure.
1. Remove the left and right filter frames of the exhaust fan box by lifting
them upwards.
2. Disconnect the fan’s electrical connector from the cabinet roof (top
right Inside the cabinet).
3. Undo the four fastening screws at the corners of the fan frame. The
screws are through bolts with nuts on the inside of the cabinet.
(Do not drop the hardware into the drive).
4. Remove the fan and fan frame as one unit.
5. Disconnect the fan wiring and capacitor from the fan frame.
Then remove the four screws attaching the fan to the fan frame.
Remove the old fan.
6. Install the new fan and capacitor with the
replacement part for CentriPro in the reverse
order of the above. Ensure the fan is centered
on the velocity stack and rotates freely.
PC00018
PC00014
PC00017
PC00014
MAINTENANCE
PC00020
Capacitor
PC00014
Velocity
Stack

16
Enclosure Air Filter Replacement – NEMA 12 Enclosures
Frame Sizes R5/R6 – Enclosure Inlet Air Filter
This procedure applies to disconnect configurations in R5 and R6 frame sizes with NEMA 12
enclosures. This filter is located at the bottom of the enclosure. Use the following procedure to
check and replace filters.
1. On the enclosure, remove the screw holding the filter bracket in place.
2. Slide the filter bracket forward until the hooks on the bracket clear the slots on the
enclosure base. This step allows the filter and bracket to drop free from the enclosure.
3. Lift the filter out of the filter bracket and replace as appropriate.
4. With the filter in the filter bracket, align the hooks on the bracket with the slots in the
enclosure base, and press the hooks up into the slots.
5. Slide the filter bracket back, making sure that the hooks catch on the enclosure.
6. Replace the mounting screw. Tighten until the gasket on the bracket is about 50%
compressed.
Frame Sizes R7/R8 – Nema 12 Enclosure Inlet Air Filter
The inlet air filter for the R7/R8 NEMA 12 enclosure is
located in the enclosure front door.
1. While holding the top of the filter frame, pull up on
the bottom of the frame. The filter frame will slide up
approximately ¾ inch and can then safely removed
by tilting away from the cabinet and lifting up.
Back of Enclosure
Slot
Hook
Mounting
Screw Filter Bracket
Enclosure
MAINTENANCE
PC00010PC00015

17
2. Lay the filter frame on a flat work surface. Remove
the 3 retaining brackets by squeezing the tabbed
corners in towards the middle of each bracket
until the bracket clears the filter frame. Save these
brackets for replacement. Remove and inspect the
filter.
3. Install the replacement filter. Be sure to tuck the filter
into the grove around the entire filter frame. This is very
important for proper installation.
4. Reinstall the 3 filter restraining brackets. These will
prevent the filter from being pulled out of the filter
frame.
• Install the center bracket rst.
• Install the 2nd bracket overlapping the center
bracket by ½ to the left.
• Install the 3rd bracket overlapping the center bracket by ½ to the right.
1st filter retaining bracket
1st and 2nd filter retaining brackets
All 3 filter retaining brackets
5. Install the filter frame back to the cabinet door. Carefully
align the mounting hooks to the slots in the cabinet
door. The hooks should be pointing down. Press in at the
center of the filter frame with your knee and gently press
down with your hands at the top of the frame. The filter
frame will slide down approximately ¾ inch and should
be sealed securely to the door around the entire filter
frame.
PC00009 PC00007
PC00007 PC00009
PC00013
MAINTENANCE
PC00008PC00006

18
Frame Sizes R7/R8 – NEMA 12 Enclosure Exhaust Filters
The exhaust filters in the R7/R8 NEMA 12 enclosure are located in the exhaust box at the top
of the enclosure.
There are 2 filter frames attached to the exhaust box.
1. Remove each filter frame:
• Lift up on the lter frame until it slides approximately ¾ inch.
• Pull away from the exhaust box to remove.
2. For each filter frame, remove the wire retainers
that hold the filters in place:
• Lay the lter frames on a at work surface.
• The wire retainers have a square “U” shape.
Remove by squeezing the open end of the“U”
towards the middle of the “square” until the
retainer top (open end of “U”) clears the filter
frame.
• Save the retainers for reinstallation.
3. Remove and inspect the filter.
4. Install clean filters.
NOTE! When installing DUSTLOK®filter media, the white side must face
to outside of the cabinet, and the orange side faces in. Be sure to tuck
the filter edges into the groove around the entire filter frame. This detail
is very important for proper operation.
5. Reinstall the filter restrainers.
• Insert the base of a retainer (bottom of “U”
shape) into a filter frame channel.
• Squeeze the open end of the “U” until it
clears the filter frame.
• Seat the open end of the “U” in the lter
frame channel.
• Release the retainer to its relaxed, square
shape.
6. Install each filter frame to the bonnet on top of the
cabinet.
• Carefully align the frame’s mounting hooks with the
slots in the bonnet. (The hooks should be pointing
down.)
• Press down at the top of the lter frame. (The lter
frame slides down approximately ¾ inch).
• Check all around the lter frame for a secure seal to
the exhaust box.
PC00021
PC00001 PC00019
MAINTENANCE
PC00022
PC00001PC00019
PC00011PC00012

19
Ratings (Supplement to Aquavar CPC User’s Manual - IM167)
NOTE! The ratings listed below are exceptions to the ratings listed in the Aquavar CPC
User’s Manual.
Ratings, 380…480 Volt Drives
Type Code Valid up to 40°C (104 °F)
Normal Use Heavy-Duty Use Frame Size
AQUAVAR CPC-FD- I2N PNI2hd Phd
see below A HP A HP
CPC4245xFD 245 200 192 150 R7
CPC4316xFD 316 250 240 200 R8
CPC4368xFD 368 300 302 250 R8
CPC414xFD 414 350 368 300 R8
CPC486xFD 486 400 414 350 R8
CPC526xFD 526 450 477 400 R8
CPC602xFD 602 500 515 450 R8
CPC645xFD 645 550 590 500 R8
NOTE: I2N = Motor current draw normal
PN= Normal rated power
I2hd = Heavy-duty current rating
Phd = Heavy-duty NEMA power rating
TECHNICAL DATA

20
Input Power Connections (Supplement to Aquavar CPC User’s Manual)
Fuses
NOTE! Although fuses listed are similar in functional characteristics to fuses listed in
the Aquavar CPC User’s Manual, physical characteristics may differ. Fuses from other
manufacturers can be used if they meet the functional characteristics of those in these
tables.
Drive input fuses are provided to disconnect the drive from power in the event that a
component fails in the drive’s power circuitry.
208…240 Volt Fuses
208 … 240 Volt Base Drive Input Fuse Ratings
Drive Amps Bussmann
HP Identification Frame
(600V) Type
Size
1 CPC2004xFD R1 15 KTK-R-15
2 CPC2007xFD R1 15 KTK-R-15
3 CPC2012xFD R1 15 KTK-R-15
5 CPC2017xFD R1 30 KTK-R-30
7.5 CPC2024xFD R2 30 KTK-R-30
10 CPC2031xFD R2 50 JJS-50
15 CPC2046xFD R3 80 JJS-80
20 CPC2059xFD R3 80 JJS-80
25 CPC2075xFD R4 100 JJS-100
30 CPC2088xFD R4 125 170M1368
40 CPC2114xFD R4 160 170M1369
50 CPC2143xFD R6 200 170M1370
60 CPC2178xFD R6 250 170M1371
75 CPC2221xFD R6 315 170M1372
100 CPC2248xFD R6 315 170M1372
NOTE: “x” represents both NEMA 1 and NEMA 12 enclosures.
TECHNICAL DATA