YASKAWA iQpump 7 User manual

Fig. 3 Digital Operator
Next, push 2 times on the digital operator until
In this step, the iQpump is setup for a simplex pump
application using the Pump Quick Setup menu. Apply
power to the iQpump after all the electrical connections
have been made and the terminal cover has been
re-attached. At this point DO NOT RUN THE MOTOR the
digital operator should be reading as shown below in
Fig. 3.
FWD LED
ON
RUN LED OFF
01 Flashing
the digital operator shows the Pump Quick Setup Main Menu.
Next press to start
the Pump Quick Setup procedure.
The Pump Quick Start Menu consists of the most important
parameters to setup your iQpump for use with your pump system.
Press to access a parameter, and use
to select the digit and use to change the
parameter value.
Press to save the value.
Press to go to the next parameter to continue the Pump
Quick Setup programming. When Quick Setup is completed, press
to exit the Pump Quick Setup menu and go to operation.
Note: Refer to Step 5 for a Pump Quick
Setup Parameter Overview.
Feedback
Value
IMPORTANT: Enter service factor amps (SFA) when using an
iQpump with a submersible pump motor.
STOP LED ON
Step
1
iQpump Model Identification
and Mounting
To make sure you received the correct model, it is essential to
verify the iQpump nameplate with your order and make sure
the iQpump has the correct rating so it can be used with your
motor. Please check the nameplate information as shown in
the example below.
· Check that the available power will meet the
input power
requirements.
· Ensure that the
output power
from the iQpump is
compatible with the pump motor requirements.
Mounting the iQpump
· In the case of systems with more than one iQpump, follow
the above procedure for each iQpump and pump motor.
Open Chassis
NEMA 1
The mounting of the iQpump is extremely important
regarding environment and accessibility. Depending on your
system, there are various models available and the mounting
dimensions (footprint) may be different. Because the
mounting procedure is fairly extensive, it is beyond the scope
of this document; the user is referred to the iQpump User
Manual (Document No. TM.iQp.06) received with the
iQpump,
Section 1 Physical Installation
. Match the model
that you received and follow the procedure described in the
manual to ensure a safe and functional installation. In cases
where the system has more than one iQpump, refer to the
proper clearances required for adequate ventilation.
Please
pay particular attention to:
· The clearances to be maintained around the enclosure
for adequate ventilation.
· The environmental specifications such as avoiding
excessive dampness, extreme temperatures, chemical
exposure, corrosive areas, etc. to avoid damage to the
equipment and to maintain safety.
Removing and Attaching the Terminal Cover
Improper removal of the iQpump terminal cover as well as
front cover can cause extensive damage to the iQpump. To
avoid damage to these items, please pay particular attention
to the iQpump User Manual, Document No. TM.iQp.06,
Section 1.8, R
Removing and Attaching the Terminal Cover.
Drive Model
Number
Input Power
Rating
Output Power
Rating
Serial
Number
UL File
Number
Drive Spec
Number
Weight
0034
WARNING DO NOT CONNECT ANY OF THE
FOLLOWING TERMINALS TO EARTH GROUND
B1 B2
-
++1+2
R/L1 S/L2 T/L3 -+1+2B1B2 U/T1 V/T2 W/T3
NOT USED
3Ø Induction
motor
Use L1, L2, L3 for
3Ø Input Power
Connect
frame to
ground
Input
Protection
(Fuse or Circuit
Breaker)
To change direction of
pump motor rotation
swap any two of the
three motor leads
(See Step 2)
L1 L2 L3
Fig. 1 Input Power and Output Motor Electrical Connections for
Models: 20P4 to 2018 and 40P4 to 4018
NOT USED
3Ø Induction
motor
Connect
frame to
ground
Input
Protection
(Fuse or Circuit
Breaker)
To change direction of pump
motor rotation swap any two
of the three motor leads
(See Step 2)
Fig. 2 Input Power and Output Motor Electrical Connections for
Models: 2022 & Larger and 4030 & Larger
R/L1
R1/L11
S/L2
S1/L21
T/L3
T1/L31
U/T1 V/T2 W/T3
-+
1
+
2
(R/L1) (S/L2) (T/L3) (U/T1)
(V/T2)
(W/T3)
Connect to
chassis
ground
(R/L1) (S/L2) (T/L3) (U/T1) (V/T2) (W/T3)
Connect to
chassis
ground
Use L1, L2 for
1Ø Input Power
Use L1, L2, L3 for
3Ø Input Power
L1 L2 L3
Use L1, L2 for
1Ø Input Power
Connect to
chassis ground
Fig.1 & 2 below show the electrical connections for the
input power and motor terminals for various iQpump
models. Select the proper diagram for the model you are
installing (see Step 1). WITH POWER OFF make the
appropriate connections.
Make sure to follow good wiring practices and all
applicable codes. Ensure that the equipment is
grounded properly as shown.
DANGER; LETHAL VOLTAGES ARE PRESENT- Before
applying power to the iQpump, ensure that the
terminal cover is fastened and all wiring connections
are secure. After the power has been turned OFF, wait
at least five minutes until the charge indicator
extinguishes completely before touching any wiring,
circuit boards or components.
!
*
* Make sure the
iQpump has been properly sized for single phase input power.
*
Connect Pump Motor and
Line Power
Step
2
Step
3
Control Wiring
Step
4
Pump Quick Setup
The following
procedure is a
supplement to
other
documentation
supplied with this
equipment and
will guide the user
in properly wiring
the iQpump and
motor. It will also
show the user
how to configure
the iQpump for a
simplex pump
application.
Danger:
Improper wiring
can and will
cause bodily
harm as well as
damage to the
equipment.
When installing
the system, be
sure to follow
good wiring
practices and all
applicable codes.
Ensure that the
mounting of the
various
components are
secure and that
the environment,
such as extreme
dampness, poor
ventilation, etc.
will not cause
system
degradation.
Please read this
cheat sheet and
other
documentation
provided with
the iQpump
thoroughly
before
attempting any
installation.
Page 1 of 4
iQpump 7 AC Drive (Software 0034)
Simplex Quick Start Procedure
The iQpump is D
DEFAULT SETUP TO START/STOP FROM THE
KEYPAD
(digital operator). If this is the preferred start/stop
method, then continue to the feedback signal connection section.
Please refer to the wiring diagram below to start/stop the iQpump
using an external switch or contact.
This step shows how to connect control wiring and feedback signal
to the iQpump. Before making any control connections, M
MAKE
SURE POWER TO THE iQpump IS TURNED OFF!
Next remove
the terminal cover to gain access to the control terminals. (Step 1.)
SELECT START / STOP CONTROL METHOD
S3 S5 S6 S7 FM AC AM IGS2 S4S1
2-Wire Control
Use for permanent contacts
iQpump User Control Terminals
S+ S-
SP A2 +V AC ACSC A1SN R+ R-
Connect switch or contact to
terminal S1 and terminal SN
S3 S5 S6 S7 FM AC AM IGS2 S4S1
3-Wire Control
Use for momentary contacts
S+ S-
SP A2 +V AC ACSC A1SN R+ R-
Connect momentary contacts
to terminal S1, S2 and SN
Normally Open
Normally Closed
To use 3-Wire Control first
initialize the iQpump using
parameter A1-03 = 3330
(Refer to TM.iQp.06)
FEEDBACK SIGNAL WIRING (TRANSDUCER)
S3 S5 S6 S7 FM AC AM IGS2 S4S1
For use with 3-Wire, 0 – 10V Transducer
iQpump User Control Terminals
S+ S-
SP A2 +V AC ACSC A1SN R+ R-
Brown or Red: +Power (1)
O
F
F
1
2
S1-2 in ON
Position
S3 S5 S6 S7 FM AC AM IGS2 S4S1 S+ S-
SP A2 +V AC ACSC A1SN R+ R-
Brown or Red: +Power (1)
Black or White Output
0 – 10V (3)
O
F
F
1
2
S1-2 in OFF
Position
Blue or Black
Common Signal (2)
Black: Output
4 – 20mA (2)
Cable
Type
DIN
Type
For use with 2-Wire, 4 – 20mA Transducer
Important Note: Signal colors and numbering may vary
depending on feedback device used.
Please consult feedback device manual.
!
Cable
Shield
Cable
Shield
E(G)
E(G)
(Factory Default)
E(G)
Cable
Shield
Cable
Shield
E(G)

Parameter Value Description Reference Comments
E2-01 Drive Size
Dependent Motor Rated Current Set to the motor nameplate full load amps. For submersible motors use service factor amps (SFA).
E2-04 2 Number of Motor Poles Number of motor poles is used to show the correct motor RPM on the display
Enter ’4’ for an 1800 RPM motor and ‘2’ for a 3600 RPM motor.
Confirm number of poles
2 Pole Motor = 3600 RPM
4 Pole Motor = 1800 RPM
6 Pole Motor = 1200 RPM
8 Pole Motor = 900 RPM
P1-03 145 Feedback Device
Scaling
System Scaling: Enter feedback device maximum:
Example: Enter 200 for pressure transducer with a maximum of 200 PSI at 20mA.
Confirm feedback device scaling.
(See Illustration 1)
d1-01 0 Set-Point 1 Set System Set-Point Set to system pressure
P1-04 0.0 PSI Start Level
When the iQpump is turned On and the feedback signal level (transducer) falls below this
level, the pump system will start after the time specified in P1-05 (default 1 sec).
Programming the Start Level as an Absolute Value
Start Level has to programmed to a positive value in order for the Start Level to be an
absolute value. Example: Start Level P1-04 set to 50 PSI and delay time P1-05 set to
5 sec. Pump system will start when the pressure drops below 50 PSI for 5 sec.
Programming the Start Level as a Delta Level from the System Set-Point
Start Level has to programmed to a negative value in order for the Start Level to be a
delta value from the set-point.
Example: Start Level P1-04 set to –10 PSI with a system set-point of 50 PSI and a delay
time P1-05 set to 5 sec. Pump system will start when the pressure drops below 40 PSI
(50 - 10) for 5 sec.
It is mandatory to program the Start Level
in order to use the sleep function.
(See Illustration 2 and 3)
P1-06 40.0 Hz Minimum Pump
Frequency
Minimum speed (Hz) the pump motor has to operate at.
Example: Base pump motor speed is 3600 RPM, minimum speed is 2400 RPM. Set
minimum pump frequency to 40.0 Hz. (2400 ÷ 3600 x 60 Hz = 40 Hz)
Minimum pump frequency should be set to
a value where the pump enters a no-flow
condition.
P4-10 0
Disabled
Auto Mode Operator
Run Power Down
Storage
Stores the run status in the Auto mode when operating from digital operator (b1-02=0).
0: Disabled
1: Enabled
Recommended for use when Start/Stop
command is from keypad.
(See Illustration 6)
P5-04 1
Enabled
Hand Key
Enable / Disable
Enables or disables the Hand Key on the digital operator.
0: Disabled
1: Enabled
Hand Key on keypad.
(See Illustration 4)
START LEVEL
Examples:
0 – 1000, no decimals, P1-03 = 1000
0 – 300.0, one decimal, P1-03 = 10300
0 – 50.00, two decimals, P1-03 = 25000
P1-03 = 0 0 0 0 0 Feedback Scaling
Feedback
Maximum
Decimal Point
Position
TRANSDUCER / FEEDBACK DEVICE SCALING
Start Pump System
Start
Delay
200 PSI
Start Level P1-04 (Absolute)
(Example 100 PSI)
System Set-Point
(Example 150 PSI)
Feedback Signal from
pressure transducer
(4 – 20 mA)
0
Time
Pressure
Start Level Delay (P1-05)
(Example 5.0 sec.)
Feedback Scaling (P1-03)
(Example 200 PSI)
SLEEP MODE (Example)
Minimum Speed P1-06
(Example 40.0 Hz)
Output
Frequency
(pump motor
speed)
0
Sleep Delay Time (P2-03)
(Example 5.0 sec.)
Ramp or Coast to Stop, b1-02
Output Frequency
60 Hz
Pump Running Go to Sleep
Time
WAIT FOR PRESSURE TO FALL BELOW
START LEVEL (P1-04)
WAIT
SYSTEM STARTS WHEN
PRESSURE SIGNAL
FALLS BELOW 100 PSI
SYSTEM GOES TO SLEEP
WHEN PUMP MOTOR SPEED
DROPS BELOW 2400 RPM
2
1
3
Start Pump System
Start
Delay
200 PSI
System Set-Point
(Example 150 PSI)
Feedback Signal from
pressure transducer
(4 – 20 mA)
0
Time
Pressure
Start Level Delay (P1-05)
(Example 5.0 sec.)
Feedback Scaling (P1-03)
(Example 200 PSI)
WAIT
SYSTEM STARTS WHEN
PRESSURE SIGNAL
FALLS BELOW 100 PSI
Start Level P1-04 (Delta)
(Example -50 PSI,
Start Level = 150 – 50 = 100 PSI)
Example: Absolute Level (Positive Start Level)
Example: Delta Level (Negative Start Level)
Note: When System Set-point is changed, the start level is automatically adjusted.
-50 PSI
100 PSI
100 PSI
150
150
Step
5
iQpump Quick Setup Parameter Overview (Simplex)
Use to change the sign.
Page 2 of 4
iQpump 7 AC Drive (Software 0034)
Simplex Quick Start Procedure

Parameter Value Description Reference Comments
b5-03 3.0 sec. PI Integral Time Decrease integral time to make iQpump more responsive. Caution: can cause instability if
value is too low.
b5-12 2
(Fault)
PI Feedback Reference Missing
Detection Selection
Select what to do when the feedback device (transducer) fails or gets disconnected.
0: Disabled, continue running no message is displayed
1: Alarm, show warning on the keypad when the feedback device fails or is disconnected
2: Fault, stop pump system when the feedback fails or is disconnected
NOTE: Disable parameter b5-12
if no transducer is installed.
b5-14 2.0 sec. PI Feedback Loss Detection Time
Delay time before iQpump shows alarm or fault when feedback device has failed or is
disconnected. Example: 2.0 sec., iQpump displays alarm or fault 2 sec. after the device has
failed or is disconnected.
C1-01 20.0 sec. Acceleration Time 1 Time it takes to accelerate the pump motor from zero to maximum speed.
Adjusted depending on system
performance
C1-02 10.0 sec. Deceleration Time 1 Time it takes to decelerate the pump motor from maximum speed to zero.
L5-01 5 Number of Restart Attempts
Determines the number of times iQpump will perform an automatic restart on the faults listed
in the comments column.
iQpump System Protection Faults that can be setup to restart are Low Level Feedback,
High Level Feedback, Transducer Loss, Not Maintaining Set-point, Loss of Prime,
Pump Over Cycle. Refer to parameters P4-07 and P4-08. The number of restart attempts is
set by L5-01.
 Overcurrent
 Ground Fault
 Output Phase Loss
 Input Phase Loss
 iQpump Overload
 Motor Overload
 Overtorque
 DC Bus Fuse Blown
 DC Bus Undervoltage
 DC Bus Overvoltage
 Overheat
L5-03 20 sec. Maximum Restart Time After Fault If the restart fails (or is not attempted due to a continuing fault condition) iQpump waits the
Maximum Restart Time After Fault, before attempting another restart.
P1-06 40.0 Hz Minimum Pump Frequency
Minimum speed (Hz) the pump motor has to operate at.
Example: Base pump motor speed is 3600 RPM, minimum speed is 2400 RPM. Set minimum
pump frequency to 40.0 Hz. (2400 ÷ 3600 x 60 Hz = 40 Hz)
P1-06 should be set to the level
where the pump can produce the
minimum pressure even at zero
flow.
P2-03 5 sec. Sleep Delay Time Time it takes before the pump system goes to sleep when the selected signal level (P2-01)
falls below the specified sleep level (P2-02)
Adjust according to system
requirements.
P4-05 30.0 Hz Thrust Bearing Frequency Sets the frequency reference used when the thrust bearing function is active. A value of 0
disables this function.
Primarily used for submersible
pumps. Program P4-05 = 0.0 Hz
to disable function when iQpump
is used with a centrifugal pump.
P4-11 0.2 Min Utility Start Delay When utility power is restored and P4-10 is enabled (1), iQpump waits the time specified in
P4-11 before auto operation becomes active.
Note: Only active when P4-10 is
enabled (1) and operation
(start/stop) is from the
digital operator.
Step
5
iQpump Factory Defaults Overview (only adjust settings based on your application)
THRUST BEARING - SUBMERSIBLE MOTORS (e.g. Franklin)
When using a submersible motor in combination with iQpump, it is recommended to use the Thrust Bearing
function to prevent excess motor wear. To enable this function, enter the minimum motor frequency in parameter
P4-05. Example: Minimum motor speed 1800 RPM, 1800 RPM ÷ 3600 RPM x 60.0 Hz = 30.0 Hz
Output Frequency
Output Frequency
Thrust Bearing Frequency P4-05
(Example 30.0 Hz)
Time
Thrust Bearing Auto/Hand Operation
Turn Off Thrust Bearing Function
(Output Frequency Reached)
P4-04Accel.Time
Thrust Acceleration Time P4-04
(Example 1.0 sec.)
C1-01 Acceleration Time
5
AUTO OPERATION – POWER DOWN STORAGE
6
Allows iQpump to automatically start after power failure when operated from keypad / digital operator. This function
is recommended for use when operating the iQpump in remote / unmanned areas.
When the iQpump is powered down while running, an internal run
command will automatically be initiated upon power-up.
HAND MODE OPERATION
4
Hand Mode speed can be adjusted by pressing , use
to move the cursor and to adjust the hand speed reference.
Press to save new active hand speed reference.
Hand Speed from the Keypad/Digital Operator (Default)
Set parameter P5-01 ‘Hand Mode Ref.’ to ‘0’ to adjust the hand mode
reference from an external 0 – 10V signal connected to terminal A1 and AC.
Hand Speed from Analog Input (0 – 10V)
S3 S5 S6 S7 FM AC AM IGS2 S4S1 S+ S-
SP A2 +V AC ACSC A1SN R+ R-
+-
0 – 10V
Press the HAND KEY on the digital operator to run the system in Hand Mode.
‘0’ Blinking
HAND KEY
Note: Hand Key can be disabled with parameter P5-04
Note: Thrust Bearing Function is Enabled by Default
Page 3 of 4
iQpump 7 AC Drive (Software 0034)
Simplex Quick Start Procedure

Step
7
Auto Mode Operation
Step
6
Pump Rotation and Feedback Signal Check
Displays when the iQpump is about to
start. The feedback level has fallen below
the Start Level (P1-04) and the start delay
timer is active. Once the Start Level Delay
Time (P1-05) expires the iQpump will start.
Displays when the iQpump is in “sleep”
mode or when the iQpump is waiting for
the feedback level to drop below the Start
Level (P1-04).
Displays when “Thrust Bearing” mode is
active. To enable, enter value in parameter
P4-05
The feedback level has risen above P1-09
level for the time specified in P1-10. High
feedback fault is active in Hand Mode,
Auto Mode, Pre-Charge and Thrust Mode
when the iQpump is running.
TYPICAL DISPLAY MESSAGES
Yaskawa Electric America, Inc.
2121 Norman Drive South
Waukegan, IL 60085
(800) YASKAWA (927-5292) / Fax [phone]
[e-mail]
www.yaskawa.com
YEA Document Number: TM.iQp.04 5/08/2013
© 2009 Yaskawa Electric America, Inc.
Sleep and Anti-No-Flow (ANF) Detection
NOTE:
Before adjusting Anti-No-Flow operation ensure your system is regulating
satisfactory while operating under normal running conditions.
If stable continue to Step 1 to verify no-flow/sleep operation. If unstable turn off the
Anti-No-Flow function (P2-23 = 0.00%) and adjust the PI control parameters b5-02
and b5-03 to stabilize pump system. Refer to iQpump User Manual
(Document No. TM.iQp.06) for additional information. Once the system is stable,
re-enable the Anti-No-Flow function by setting P2-23 to 0.40% and continue to Step 1
to verify no-flow/sleep operation.
Step 1:
Verify system holds pressure by creating a no-flow situation (e.g. close off
discharge valve).
Step 2:
Press OFF button on the digital operator, wait 1 min. until system stabilizes
and verify system pressure feedback U1-91. If the pressure drops more than 3 PSI
(U1-91) adjust P2-25 to the actual delta pressure drop plus 1 PSI.
Example:
Set-point is 80 PSI, pressure feedback U1-91 shows 76 PSI, P2-25 should
be 4 + 1 or 5 PSI. N
Note:
This value should always be more than your start level
(P1-04). If not, the system pressure is not holding and this needs to be corrected, or
the pump system will continue to cycle on and off.
Step 3:
Run system in normal automatic operation with flow. Next check monitor
U1-99 “ANF Timer” and verify that the value is incrementing and resetting back to zero
continuously. If the value holds at 10 sec. (P2-24) increase P2-24 “Anti-No-Flow
Detection Time” by increments of 5 sec. Repeat Step 3 each time P2-24 is adjusted.
Step 4:
Create a no-flow situation (e.g. close discharge valve) and monitor that U1-99
“ANF Timer” increments and holds at P2-24 time (value set in Step 3). Once the
Anti-No-Flow timer expires the speed will reduce gradually until it reaches minimum
pump speed (P1-06) where it will hold for 5 sec. (P2-03) before going to sleep.
Step 5:
Run system in normal automatic operation and verify sleep and wake-up
operation until system performs satisfactory.
(P2-23, P2-24, P2-25)
Fig. 5 Digital Operator
Next, push
RUN LED should be ON.
OFF
Using Safety precaution, and referring to Fig.1 or 2, swap any two of the three output
leads to the pump motor (U/T1, V/T2 and W/T3). After the wiring change repeat
Step 6 and recheck motor direction.
The motor should now be operating at low speed in the correct direction of pump.
Push
If the direction is not correct, then power down the iQpump.
on the digital operator; the display should read
on the digital operator; the display should read as in Fig. 3.
In this step the pump motor is checked for proper direction and operation. This test is to
be performed solely from the digital operator. Apply power to the iQpump after all the
electrical connections have been made and the terminal cover has been reattached. At
this point, DO NOT RUN THE MOTOR, the digital operator should display as shown
below in Fig. 5.
DANGER, LETHAL VOLTAGES ARE PRESENT- Before applying power to the
iQpump, ensure that the terminal cover is fastened and all wiring connections
are secure. After the power has been turned OFF, wait at least five minutes until
the charge indicator extinguishes completely before touching any wiring, circuit
boards or components.
!
Hand reference speed can be adjusted by pressing , use to move cursor
and to adjust the value. Press to save changes.
Verify feedback on display (show keypad) matches mechanical pressure gauge.
FEEDBACK SIGNAL CHECK
FEEDBACK SIGNAL LEVEL
Refer to parameter P1-02 and P1-03, if the feedback
device scaling or system units are incorrect.
When Pump Quick Setup is completed, press to exit the Pump Quick Setup
menu and go to operation.
FWD LED
ON
01 Flashing
RUN LED OFF STOP LED ON
HAND
FWD LED
ON
Fig. 6 Digital Operator
01 Flashing
Next, press to access or modify the system set-point that was entered using
iQpump can be operated in automatic mode when the following actions have been
performed:
 All parameters are programmed
 Pump motor direction has been checked
 Feedback signal has been checked
SET SYSTEM SET-POINT
iQpump automatically starts in Auto Mode when the feedback signal level falls below
the programmed level in parameter P1-04 for the specified time in P1-05.
At this point, DO NOT RUN THE MOTOR, the digital operator should display as shown
below in Fig. 6.
Use to select the digit and to change the system set-point.
Next press
Next, press the AUTO
button to start the
iQpump.
Start Pump System
Start
Delay
145 PSI
Start Level P1-04
System Set-Point
(Example 80 PSI)
Feedback signal from
pressure transducer
(4 – 20 mA)
0
Pressure
Start Level Delay (P1-05)
(Example 5.0 sec.)
WAIT
to store set-point and press
operation menu.
to return to the main
Refer to Illustration 2 on Page 2 of 4 for additional information on the Start Level Function.
parameter d1-01 System Set-point in the Pump Quick Setup Menu
Example: 80 PSI
RUN LED OFF
STOP LED ON
Page 4 of 4
iQpump 7 AC Drive (Software 0034)
Simplex Quick Start Procedure