Xylem Aquavar IPC User manual

Aquavar® IPC
WARNINGS AND ALARMS DOCUMENT
INSTRUCTION MANUAL
IM299

PAGE 2
Aquavar Intelligent Pump Controller
CentriPro
Warnings and Alarms
Warning/Alarm Description Cause Remedy
1 — 10 V low The control card voltage is below 10 V
from terminal 50.
A short in a connected
potentiometer or improper wiring
of the potentiometer.
Remove the wiring from terminal 50.
If the warning clears, the problem is
with the customer wiring.
2 — Sensor Fault This warning or alarm will only appear
if programmed by the user in 6–01
Sensor Fault Timeout Function.The
signal on one of the analog inputs is
less than 50% of the minimum value
that is programmed for that input.
Broken wiring or faulty device
sending the signal.
Check the connections on all the
analog input terminals. Control card
terminals 53 and 54 for signals,
terminal 55 common. General
Purpose I/O Option Card terminals
11 and 12 for signals, terminal 10
common. Analog I/O Option Card
terminals 1, 3, 5 for signals, terminals
2, 4, 6 common.
Check that the frequency converter
programming and switch settings
match the analog signal type.
Perform Input Terminal Signal Test
4 — Input phase loss A phase is missing on the supply side,
or the mains voltage imbalance is
too high. This message also appears
for a fault in the input rectier on
the frequency converter. Options are
programmed at [14–12] Function at
Input Imbalance (not applicable for
single-phase drives).
Check the supply voltage and supply
currents to the frequency converter.
5 — DC link voltage high The intermediate circuit voltage (DC) is
higher than the high voltage warning
limit.
The limit is dependent on the
frequency converter voltage
rating.The frequency converter is
still active.
6 — DC link voltage low The intermediate circuit voltage (DC)
is lower than the low voltage warning
limit.
The limit is dependent on the
frequency converter voltage
rating.The frequency converter is
still active.
7 — DC overvoltage If the intermediate circuit voltage
exceeds the limit, the frequency
converter trips after a time.
Connect a brake resistor
Extend a ramp time
Change the ramp type
Activate functions in [2–10] Brake
Function
Increase [14–26] Trip Delay at Inverter
Fault
8 — DC under voltage If the intermediate circuit voltage (DC)
drops below the under voltage limit,
the frequency converter checks if a 24
VDC backup supply is connected.
If no 24 VDC backup supply
is connected, the frequency
converter trips after a xed time
delay.The time delay varies with
unit size.
Check that the supply voltage
matches the frequency converter
voltage.
Perform input voltage test
Perform soft charge and rectier
circuit test.

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Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
9 — Inverter overloaded The frequency converter is about
to cut-out because of an overload
(too high current for too long).The
counter for electronic, thermal inverter
protection gives a warning at 98% and
trips at 100% while giving an alarm.
The frequency converter cannot be
reset until the counter is below 90%.
The fault is that the frequency
converter is overloaded by more
than 100% for too long.
Compare the output current shown
on the LCP with the frequency
converter rated current.
Compare the output current shown
on the LCP with the measured motor
current.
Display the Thermal Drive Load on
the LCP and
10 — Motor overload
temperature
According to the electronic thermal
protection (ETR), the motor is too hot.
Select whether the frequency converter
gives a warning or an alarm when the
counter reaches 100% in 1–90 Motor
Thermal Protection.
The fault occurs when the motor
is overloaded by more than 100%
for too long.
Check for motor overheating.
Check if the motor is mechanically
overloaded.
Check that the motor current set in
[1–24] Motor Current is correct.
11 — Motor thermistor over
temp
The thermistor might be disconnected.
Select whether the frequency converter
gives a warning or an alarm in 1–90
Motor Thermal Protection.
Check for motor overheating.
Check if the motor is mechanically
overloaded.
When using terminal 54, check that
the thermistor is connected correctly
between terminal 54 (analog voltage
input) and terminal 50 (+10 V
supply) and that the terminal switch
for 54 is set for voltage. Check [1–93]
Thermistor Source selects terminal
54.
When using digital inputs 18 or
19, check that the thermistor is
connected correctly between either
terminal 18 or 19 (digital input PNP
only) and terminal 50. Check [1–93]
Thermistor Source selects terminal
18 or 19.
12 — Torque limit The torque has exceeded the value in
4–16 Torque Limit Motor Mode or the
value in 4–17 Torque Limit Generator
Mode. 14–25 Trip Delay at Torque Limit
can change this from a warning only
condition to a warning followed by an
alarm.
If the motor torque limit is exceeded
during ramp up, extend the ramp up
time.
If the generator torque limit is
exceeded during ramp down, extend
the ramp down time.
If torque limit occurs while running,
possibly increase the torque limit. Be
sure the system can operate safely at
a higher torque.
Check the application for excessive
current draw on the motor.

PAGE 4
Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
13 — Over current The inverter peak current limit (approx.
200% of the rated current) is exceeded.
The warning lasts about 1.5 seconds,
then the frequency converter trips
and issues an alarm.This fault may
be caused by shock loading or fast
acceleration with high inertia loads. If
extended mechanical brake control is
selected, trip can be reset externally.
Remove power and check if the motor
can be turned.
Check that the motor size matches
the frequency converter.
Check parameters 1–20 through
1–25 for correct motor data.
14 — Ground/Earth fault There is current from the output
phases to ground, either in the cable
between the frequency converter and
the motor or in the motor itself.
Remove power to the frequency
converter and repair the earth fault.
Check for ground faults in the motor
by measuring the resistance to
ground of the motor leads and the
motor megohmmeter.
15 — Hardware mismatch A tted option is not operational with
the present control board hardware or
software.
Record the value of the following
parameters and contact your Xylem
supplier:
• [15–40] FC Type
• [15–41] Power Section
• [15–42] Voltage
• [15–43] Software Version
• [15–45] Actual Typecode String
• [15–49] SW ID Control Card
• [15–50] SW ID Power Cord
• [15–60] Option Mounted
• [15–61] Option SW Version
16 — Short circuit There is a short circuit in the motor or
motor wiring.
Remove power to the frequency
converter and repair the short circuit.
17 — Control word timeout There is no communication to the
frequency converter.
The warning will only be active when
[8–04] Control Timeout Function is NOT
set to [0] OFF.
If [8–04] Control Timeout
Function is set to Stop and Trip,
a warning appears and the
frequency converter ramps down
until it stops then displays an
alarm.
Check connections on the series
communication cable.
Increase [8–03] Control Timeout
Time Check operation of the
communication equipment
Verify proper installation based on
EMC requirements.
18 — Start failed The speed has not been able to exceed
[1–77] Compressor Start Max Speed
[RPM] during start within the allowed
time. (set in [1– 79] Compressor Start
Max Time to Trip).
This may be caused by a blocked
motor.
23 — Internal fan fault The fan warning function checks if the
fan is running. The fan warning can be
disabled on [14– 53] Fan Monitor.
Check for proper fan operation.
Cycle power to the frequency
converter and check that the fan
operates briey at startup.
Check the sensors on the heatsink
and control card.

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Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
24 — External fan fault The fan warning function checks if the
fan is running. The fan warning can be
disabled on [14– 53] Fan Monitor.
Check for proper fan operation.
Cycle power to the frequency
converter and check that the fan
operates briey at startup.
Check the sensors on the heatsink
and control card.
25 — Brake resistor short
circuit
The brake resistor is monitored during
operation. If a short circuit occurs,
the brake function is disabled and
the warning appears.The frequency
converter is still operational but
without the brake function.
Remove power to the frequency
converter and replace the brake
resistor (see [2–15] Brake Check).
26 — Brake resistor power
limit
The power transmitted to the brake
resistor is calculated as a mean value
over the last 120 seconds of run
time. The calculation is based on the
intermediate circuit voltage and the
brake resistance value set in [2–16]
brake Max. Current.
The warning is active when the
dissipated braking is higher
than 90% of the brake resistance
power.
If Trip [2] is selected in [2–13]
Brake Power Monitoring, the
frequency converter will trip
when the dissipated braking
power reaches 100%.
27 — Brake chopper fault The brake transistor is monitored
during operation and if a short circuit
occurs, the brake function is disabled
and a warning is issued.
The frequency converter is still
operational but, since the brake
transistor has short-circuited,
substantial power is transmitted
to the brake resistor, even if it is
inactive.
Remove power to the frequency
converter and remove the brake
resistor.
28 — Brake check failed The brake resistor is not connected or
not working.
Check [2–15] Brake Check.
29 — Heatsink temp The maximum temperature of the
heatsink has been exceeded.The
temperature fault will not reset until
the temperature falls below the
reset heatsink temperature.The trip
and reset points are based on the
frequency converter power size.
Check for the following conditions:
• Ambient temperature too high.
• Motor cable too long.
• Incorrect airow clearance above
and below the frequency converter.
• Blocked airow around the
frequency converter.
• Damaged heatsink fan.
• Dirty heatsink.
30 — Motor phase U
missing
Motor phase U between the frequency
converter and the motor is missing.
Remove power from the frequency
converter and check motor phase U.
31 — Motor phase V
missing
Motor phase V between the frequency
converter and the motor is missing.
Remove power from the frequency
converter and check motor phase V.
32 — Motor phase W
missing
Motor phase W between the frequency
converter and the motor is missing.
Remove power from the frequency
converter and check motor phase W.
33 — Inrush fault Too many power-ups have occurred
within a short time period.
Let the unit cool to operating
temperature.
34 — Fieldbus
communication fault
Communication between the eldbus
and the communication option card is
not operating.

PAGE 6
Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
36 — Mains failure This warning/alarm is only active if
the supply voltage to the frequency
converter is lost and 14– 10 Mains
Failure is NOT set to [0] No Function.
Check the fuses to the frequency
converter and mains power supply to
the unit.
38 — Internal fault When an internal fault occurs, a code
number dened in the table below is
displayed.
Cycle power to the frequency
converter.
Check that the option is properly
installed.
Check for loose or missing wiring.
It may be necessary to contact
your Xylem supplier or service
department. Note the code number
for further troubleshooting directions.
39 — Heatsink sensor No feedback from the heatsink
temperature sensor.
The signal from the IGBTThermal
sensor is not available on the
power card.The problem could
be on the power card, on the gate
drive card, or the ribbon cable
between the power card and gate
drive card.
40 — Overload of digital
output terminal 27
Check the load connected to terminal
27 or remove short-circuit connection.
Check [5–00] Digital I/O Mode and
5–01 Terminal 27 Mode.
41 — Overload of digital
output terminal 29
Check the load connected to terminal
29 or remove short-circuit connection.
Check [5–00] Digital I/O Mode and
[5–02] Terminal 29 Mode.
42 — Overload of digital
output on X30/6 or
overload of digital output
on X30/7
For X30/6, check the load connected
to X30/6 or remove short-circuit
connection. Check 5– 32 Term X30/6
Digi Out (General Purpose I/O Option
Card).
For X30/7, check the load connected
to X30/7 or remove short-circuit
connection. Check 5– 33 Term X30/7
Digi Out (General Purpose I/O Option
Card).
45 — Ground fault 2 Ground (earth) fault on startup. Check for proper grounding
(earthing) and loose connections.
Check for proper wire size.
Check motor cables for shortcircuits
or leakage currents.

PAGE 7
Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
46 — Power card supply The supply on the power card is out of
range.
There are three power supplies
generated by the switch mode
power supply (SMPS) on the
power card: 24 V, 5 V, +/- 18 V.
When powered with 24 VDC with
the 24VDC Backup Option Card
option, only the 24 V and 5 V
supplies are monitored. When
powered with three-phase mains
voltage, all three supplied are
monitored.
Check for a defective power cord.
Check for a defective control card.
Check for a defective option card.
If a 24 VDC power supply is used,
verify proper supply power.
47 — 24 V supply low The 24 V DC is measured on the
control card.
The external 24 V DC backup
power supply may be overloaded.
Contact your Xylem supplier.
48 — 1.8 V supply low The power supply is measured on the
control card.
The 1.8 V DC supply used on
the control card is outside of
allowable limits.
Check for a defective control card.
If an option card is present, check for
an overvoltage condition.
49 — Speed limit When the speed is not within the
specied range in [4–11] Motor Speed
Low Limit [RPM] and [4–13] Motor
Speed High Limit [RPM], the frequency
converter will show a warning.
When the speed is below the
specied limit in [1–86] Trip
Speed Low [RPM] (except
when starting or stopping) the
frequency converter will trip.
50 — AMA calibration failed Contact your Xylem supplier or Xylem
Service Department.
51 — AMA check Unom and
Inom
The settings for motor voltage, motor
current, and motor power are wrong.
Check the settings in parameters
1–20 to 1–25.
52 — AMA low Inom The motor current is too low. Check the setting in [4–18] Current
Limit.
53 — AMA motor too big The motor is too big for the AMA to
operate.
54 — AMA motor too small The motor is too small for the AMA to
operate.
55 — AMA Parameter out
of range
The parameter values of the motor are
outside of the acceptable range. AMA
will not run.
56 — AMA interrupted by
the user
The AMA has been interrupted by the
user.
57 — AMA timeout Try to restart AMA again. Repeated
restarts may overheat the motor.
58 — AMA internal fault Contact your Xylem supplier.
59 — Current limit The current is higher than the value in
[4–18] Current Limit.
Ensure that motor data in parameters
1–20 through 1–25 are set correctly.
Possibly increase the current limit.
Be sure that the system can operate
safely at a higher limit.
60 — Pump Protect A digital input signal is indicating
a pump protection external to the
controller is active.

PAGE 8
Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
62 — Output frequency at
maximum limit
The output frequency has reached
the value set in [4–19] Max Output
Frequency.
Check the application to determine
the cause. Possibly increase the
output frequency. Be sure the system
can operate safely at a higher output
frequency.The warning will clear
wieh the output drops below the
maximum limit.
65 — Control card over
temperature
The cut-out temperature of the control
card is 80°C.
Check that the ambient operating
temperature is within limits.
Check for clogged lters.
Check fan operation.
Check the control card.
66 — Heatsink temperature
low
The frequency converter is too cold
to operate.This warning is based on
the temperature sensor in the IGBT
module.
Increase the ambient temperature of
the unit.
A trickle amount of current can be
supplied to the frequency controller
whenever the motor is stopped by
setting [2–00] DC Hold/Preheat
Current at 5% and [1–80] Function
at Stop.
67 — Option module
conguration has changed
One or more options have either been
added or removed since the last power
down.
Check that the conguration change
is intentional and reset the frequency
controller.
68 — Safe stop activated Loss of the 24 VDC signal on terminal
37 has caused the frequency controller
to trip.
To resume normal operation, apply
24 VDC to terminal 37 and reset the
frequency controller.
69 — Power card
temperature
The temperature sensor on the power
card is either too hot or too cold.
Check that the ambient operating
temperature is within limits.
Check for clogged lters.
Check fan operation.
Check the power card.
70 — Illegal FC
conguration
The control card and power card are
incompatible.
Contact your supplier with the
typecode of the unit from the
80 — Drive initialized to
default value
Parameter settings are initialized to
default settings after a manual reset.
Reset the unit to clear the alarm.
92 — No ow A no-ow condition has been detected
in the system.
[22–23] No-Flow Function is set
for alarm.
Troubleshoot the system and reset
the frequency converter after the fault
has been cleared.
93 — No Water/Loss of
Prime
A low power condition in the system
with the frequency converter operating
at high speed may indicate a the pump
is out of water or has lost prime.
[22–26] No Water/Loss of Prime
Function is set for alarm.The [22–
39] No Water/Loss of Prime Limit
is set too high.
Troubleshoot the system and reset
the frequency converter after the fault
has been cleared.
94 — Under Pressure The system pressure is below the
Under Pressure limit (Under Pressure
Limit = Setpoint [22–25] Under
Pressure Difference).
This may indicate leakage in the
system. [22–50] Under Pressure
Function is set for alarm.
Troubleshoot the system, and reset
the frequency converter after the fault
has been cleared.
95 — Broken belt Torque is below the torque level set for
no load, indicating a broken belt.
[22–60] Broken Belt Function is
set for alarm.
Troubleshoot the system and reset
the frequency converter after the fault
has been cleared.

PAGE 9
Aquavar Intelligent Pump Controller
CentriPro
Warning/Alarm Description Cause Remedy
96 — Start delayed Motor start has been delayed due to
short-cycle protection.
[22–76] Interval between Starts is
enabled.
Troubleshoot the system and reset
the frequency converter after the fault
has been cleared.
97 — Stop delayed Stopping the motor has been delayed
due to short cycle protection.
[22–76] Interval between Starts is
enabled.
Troubleshoot the system and reset
the frequency converter after the fault
has been cleared.
98 — Clock fault Time is not set or the RTC clock has
failed.
Reset the clock in [0–70] Date and
Time.
200 — Fire mode This indicates the frequency
controller is operating in re
mode.
Cycle power to the unit to remove the
warning. See the re mode data in
the alarm log on the controller.
201 — Fire mode was active This indicates the frequency controller
had entered re mode.
Cycle power to the unit to remove the
warning. See the re mode data in
the alarm log on the controller.
202 — Fire mode limits
exceeded
While operating in re mode one
or more alarm conditions has been
ignored which would normally trip the
unit.
Operating in this condition voids
unit warranty.
Cycle power to the unit to remove the
warning. See the re mode data in
the alarm log on the controller.
203 — Missing motor With a frequency converter operating
multi-motors, an underload condition
was detected.
This could indicate a missing
motor.
Inspect the system for proper
operation.
204 — Locked rotor With a frequency converter operating
multi-motors, an overload condition
was detected.
This could indicate a locked rotor. Inspect the motor for proper
operation.
250 — New spare part A component in the frequency
converter has been replaced.
Reset the frequency converter for
normal operation.
251 — New typecode A component in the frequency
converter has been replaced and the
typecode changed.
Reset the frequency converter for
normal operation.

PAGE 10
Aquavar Intelligent Pump Controller
CentriPro
9 Troubleshooting
9.1 Start up and operation troubleshooting
Table 30: Troubleshooting
Symptom Possible cause Test Solution
Display dark/No function
Missing or open fuses or circuit
breaker tripped
See Pre-startup inspections table
in this manual.
Check the input power source
No power to the LCP Check the LCP cable for proper
connection or damage
Replace the faulty LCP or
connection cable
Shortcut on control voltage
(terminal 12 or 50) or at control
terminals
Check the 24 V control voltage
supply for terminals 12/13 to 20-
39 or 10 V supply for terminals 50
to 55
Wire the terminals properly
Wrong LCP Use only LCP #9K651.
Wrong contrast setting Press [status] + [▲]/[▼] to adjust
the contrast
Display (LCP) is defective Test using a different LCP Replace the faulty LCP or
connection cable
Internal voltage supply fault or
SMPS is defective
Contact supplier
Intermittent display Overloaded power supply (SMPS)
due to improper control wiring or
fault within the frequency
converter
To rule out a problem in the
control wiring, disconnect all
control wiring by removing the
terminal blocks.
If the display stays lit, then the
problem is in the control wiring.
Check the wiring for shorts or
incorrect connections. If the
display continues to cut out, follow
the procedure for display dark.
Motor not running
Service switch open or missing
motor connection
Check if the motor is connected
and the connection is not
interrupted (by a service switch or
other device)
Connect the motor and check the
service switch
No mains power with 24 V DC
option card
If the display is functioning but no
output, check that mains power is
applied to the frequency converter
Apply mains power to run the unit
LCP Stop Check if [Off] has been pressed Press [Auto On] or [Hand On]
(depending on operation mode) to
run the motor
Missing start signal (Standby) Check 5–10 Terminal 18 Digital
Input for correct setting for
terminal 18 (use default setting)
Apply a valid start signal to start
the motor
Motor coast signal active
(Coasting)
Check 5–12 Coast inv. for correct
setting for terminal 27 (use
default setting)
Apply 24 V on terminal 27 or
program this terminal to No
operation
Wrong reference signal source Check reference signals: Local,
remote or bus reference? Preset
reference active? Terminal
connection correct? Scaling of
terminals correct? Reference
signal available?
Program correct settings. Check 3–
13 Reference Site. Set preset
reference active in parameter
group 3–1* References. Check for
correct wiring. Check scaling or
terminals. Check reference signal.
9 Troubleshooting
118 Aquavar®Intelligent Pump Controller INSTRUCTION MANUAL
Troubleshooting
Start up and operation troubleshooting