IM213 IT T Goulds Pumps S-Drive™ Constant Pressure Aquavar SPD™ Variable Speed Pump Control Installation, Operation & Maintenance Models Covered: S-Drive™ Aquavar SPD™ (5 – 30 HP) C UL ® US Goulds Pumps is a brand of ITT Corporation. www.goulds.
INDEX Index Important Safety Instructions ......................................................................................................... 3 System Components . ...................................................................................................................... 4 System Design ................................................................................................................................. 5 Piping ....................................................................
! Safety Instructions Section 1 Important: Read all safety information prior to installation of the Controller. Note This is a SAFETY ALERT SYMBOL. When you see this symbol on the controller, pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury or property damage. Obey all messages that follow this symbol to avoid injury or death.
System Components Section 2 Please review the S-Drive components and insure that you have all the parts and are familiar with their names. Be sure to inspect all components Goulds Pumps supplies for shipping damage. S-Drive Variable Speed Controller: 1. S-Drive Controller 2. Pressure Transducer with Cable 3. Conduit Plate Caps Warning DO NOT power the unit or run the pump until all electrical and plumbing connections, especially the pressure sensor connection, are completed. The pump should not be run dry.
System Design Section 3 Note Systems MUST be designed by qualified technicians only and meet all applicable state and local code requirements. The following diagrams show a typical system using the S-Drive Constant Pressure Controller. Diagram #1 shows a typical set up for a submersible system.
System Design Section 3 (continued) Diagram #2 shows a set-up for municipal water connection.
Piping Section 4 General Note All plumbing work must be performed by a qualified technician. Always follow all local, state and provincial codes. A proper installation requires a pressure relief valve, a ¼" female N.P.T. threaded fitting for the pressure sensor, and properly sized pipe. Piping should be no smaller than the pump discharge and/or suction connections. Piping should be kept as short as possible. Avoid the use of unnecessary fittings to minimize friction losses.
Piping Section 4 (continued) The pressure sensor cable is prewired to the controller. The cable can be shortened for a cleaner installation. Longer cable lengths are available, consult factory. Maximum recommended pressure sensor cable length is 300ft. Avoid leaving a coil of pressure sensor cable as this can induce unwanted transient voltages and noise into the system. Do not run the pressure sensor cable alongside the input or output wiring.
Mounting the Controller Section 5 (continued) Note Do not block the heat sink (fins) and fans and do not set anything on the units. Warning WARNING Hazardous voltage The controller access cover should always be securely fastened to the control box due to the dangerous voltage/shock hazard inside the unit. A lock can be used to prevent unwanted entry. Power Supply and Wiring Section 6 Power Supply Note Installation and maintenance MUST be performed by properly trained and qualified personnel.
Power Supply and Wiring Section 6 (continued) Delta/Delta with grounded leg Another common configuration providing voltage rebalancing with no phase shift between input and output. Again, depending on the output connections from the drive to motor, the grounded neutral may be a path for common mode current caused by the drive output. Ungrounded secondary Grounding of the transformer secondary is essential to the safety of personnel as well as the safe operation of the drive.
Power Supply and Wiring Section 6 (continued) To remove the line to ground MOV protection, locate the jumper shown below. The jumper is located between the input and output terminal blocks on the main board. Move to the position shown. For Frame Size 1 Controllers: For Frame Sizes 2 and 3 Controllers: Resistance grounding and ground fault protection Connecting the Wye secondary neutral to ground through a resistor is an acceptable method of grounding.
Power Supply and Wiring Section 6 (continued) Single Phase Connection For small drives with diode rectifier front end it is possible to run a three phase output with a single phase input. Only part of the three phase input bridge is used. Ripple current becomes 120 Hz rather than 360. This places a greater demand on the DC filter components (capacitor bank and DC choke). The result is that the drive must be derated to 50% current.
Power Supply and Wiring Section 6 (continued) Conduit, Wire and Fuse Sizing The use of metal conduit with metal conduit connectors is recommended for all electrical connections. Use the NEC or CEC to determine the required conduit size for the application. Refer to the chart below for the minimum allowable wire size for each controller. Note that these wire sizes are not adjusted for voltage drop due to long cable lengths.
Power Supply and Wiring Section 6 (continued) Input Power and Line Transformer Requirements The line input voltage and transformer power must meet certain phase and balance requirements. If you or your installing electrical contractor is in doubt of the requirements, the following provide guidelines for installation. When in doubt contact the local power utility or the factory. Before connecting power to the controller measure the line to line and line to ground voltage from the power source.
Starting the System Section 7 (continued) Consult motor manual to determine the wire size for the application. Ensure the ground connection to the motor is continuous. Connect wires to the output terminal block labeled T1/U, T2/V, T3/W, and GND/ . Connect the ground wire to the terminal labeled GND/ . Connect the other phase leads to T1/U, T2/V and T3/W. For CentriPro Motors, connecting T1/U to Red, T2/V to Black and T3/W to Yellow will give the correct rotation.
Starting the System Section 7 (continued) Setting the Motor Overload Switches The Motor Overload Setting Switches adjust the level of motor overload current protection necessary to protect the motor in case of an over current condition. Bank 1 switches 1, 2 and 3 allow adjustment of the motor overload setting. These switches adjust the motor overload protection as a percentage of the full load output current rating of the controller.
Starting the System Section 7 (continued) Caution Failure to properly set the Motor Overload Setting switches can result in loss of motor overload protection and will void the motor warranty. Nuisance tripping or motor damage can occur if these switches are not set properly. Setting the Acceleration/Deceleration Switches Switch 4 from bank 1 and switches 1 and 2 from bank 2 control the acceleration/deceleration ramp times.
Starting the System Section 7 (continued) Setting the Pressure When power is applied the pump will start and the system pressure will increase to the factory preset pressure (50 PSI if SP1 is enabled and a 300 PSI sensor is used or 75PSI if SP2 is enabled and a 300 PSI sensor is used). After the pressure has stabilized, use the increase (INC) or decrease (DEC) pressure adjust pushbuttons to adjust the pressure setting.
Input and Output Functions Section 8 The control terminal strips allow for a variety of input and output functions. Warning: Turn off all power to the controller before wiring devices to the control terminals. Warning: Inputs RUN/STOP, HAND/AUTO, SP2/SP1 and PRESSURE DROP are switch inputs. Do not connect power to these inputs or damage to the controller will result. Only connect non-powered switch contacts to these inputs.
Troubleshooting Section 9 General The S-Drive and Aquavar SPD drive are self-diagnosing controllers. If a problem occurs, observe the Status Code Indicator Light on the front of the unit. No Status Code Indicator Light means either no or low input voltage (less than 140Vac). Danger DANGER Hazardous voltage Status Code Indicator Light is not a voltage indicator! Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing. High voltage may still remain on controller.
Troubleshooting Orange Light Codes Flashes Constant Controller Status Low Input Voltage Description Constant orange light indicates the system input voltage is low. For 230V units, the orange light will be indicated when the input voltage is between 140Vac and 170Vac. For 460V units, the orange light will be displayed when the input voltage is between 140Vac and 310Vac. Red Light Codes Constant Red Controller Error Internal controller fault. The controller may be internally damaged.
Troubleshooting Red Light Codes (continued) Flashes Controller Status 3 Blinks (contd.) Description - Disconnect the White wire in the sensor cable from terminal 6. - Set the meter to read DC current (mA) - Connect the black lead from the meter to terminal 6 (TRANSDUCER INPUT) - Connect the red lead from the meter to the White wire in the sensor cable. - The meter will display the output of the sensor.
Troubleshooting Red Light Codes (continued) Flashes 4 Blinks Controller Status Pump or Motor Bound 5 Blinks Short Circuit 6 Blinks Input Phase Loss 7 Blinks Temperature Description This fault can be caused by: • Mechanical binding from debris in pump. • Electrical failure of the motor. • Incorrect setting of Motor Overload Setting switches. • Incorrect rotation. • Motor phase loss. This fault will be displayed if the output current exceeds 125% of the controller rating.
Troubleshooting Red Light Codes (continued) Flashes 8 Blinks Controller Status Over Voltage 9 Blinks Motor Overload Description This fault can be caused by: • High input voltage. This fault will be displayed if the phase to phase input voltage is greater than 275V for 230V units and 560V for 460V units. This fault can be caused by: • Mechanical binding from debris in pump. • Electrical failure of the motor. • Incorrect setting of Motor Overload Setting switches. • Incorrect rotation.
Controller Dimensions 25
Lengths in BOLD require 90˚C wire 230V, 3 Phase Input 460V, 3 Phase Input Motor SFA 2.9 3.8 4.7 6.1 7.6 10.1 17.0 26.0 33.0 47.4 2.9 3.8 4.7 6.1 7.6 10.1 17.0 26.0 33.0 46.0 60.0 76.0 94.0 8.5 13.0 16.5 23.0 30.0 37.0 47.
Notes 27
IT T Commercial Water GOULDS PUMPS LIMITED WARRANTY This warranty applies to all water systems pumps manufactured by Goulds Pumps. Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist for a period of twenty-four (24) months from date of installation or thirty (30) months from date of manufacture, whichever period is shorter.
