IM213
Commercial Water
ITT
Goulds Pumps
S-Drive™ Constant Pressure
Aquavar SPD™
Variable Speed Pump Control
Installation, Operation &
Maintenance
Models Covered:
S-Drive™
Aquavar SPD™
(5 – 30 HP)
U
®
L
C
US
Goulds Pumps is a brand of ITT Corporation.
Engineered for life
Download from Www.Somanuals.com. All Manuals Search And Download.
! 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.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
DANGER
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Used without a safety alert symbol indicates a potentially hazardous situation which, if
not avoided, could result in property damage.
CAUTION
NOTE
Indicates special instructions which are very important and must be followed.
Note
All operating instructions must be read, understood, and followed by the operating personnel.
Goulds Pumps accepts no liability for damages or operating disorders which are the result of
non-compliance with the operating instructions.
1. This manual is intended to assist in the installation, operation and repair of the system and must be kept with
the system.
2. Installation and maintenance MUST be performed by properly trained and qualified personnel.
3. Review all instructions and warnings prior to performing any work on the system.
4. Any safety decals MUST be left on the controller and/or pump system.
5.
The system MUST be disconnected from the main power supply before attempting any operation
or maintenance on the electrical or mechanical part of the system. Failure to disconnect electrical
power before attempting any operation or maintenance can result in electrical shock, burns or
death.
DANGER
Hazardous
voltage
6.
When in operation, the motor and pump could start unexpectedly and cause serious injury.
CAUTION
Hazardous
Pressure
3
Download from Www.Somanuals.com. All Manuals Search And Download.
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 connec-
WARNING
Hazardous
voltage
tions, especially the pressure sensor connection, are completed. The pump should
not be run dry. All electrical work must be performed by a qualified technician. Al-
CAUTION
Hazardous
Pressure
ways follow the National Electrical Code (NEC), or the Canadian Electrical Code (CEC)
as well as all local, state and provincial codes. Code questions should be directed to
your local electrical inspector or code enforcement agency. Failure to follow electrical
codes and OSHA safety standards may result in personal injury or equipment damage. Failure to
follow manufacturer's installation instructions may result in electrical shock, fire hazard,
personal injury, death, damage to equipment, unsatisfactory performance and may void
manufacturer's warranty.
Controller Product Code Information
SPD Y XXXX
F
F = WITH OUTPUT FILTER
BLANK = NO OUTPUT FILTER
4 DIGITS FOR HP
5 HP = 0050
7.5 HP = 0075
10 HP = 0100
15 HP = 0150
20 HP = 0200
25 HP = 0250
30 HP = 0300
1 DIGIT FOR INPUT VOLTAGE
230 VOLT = 2
460 VOLT = 4
575 VOLT = 5
SERIES
4
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
1
2
6
L1
L2
T1
T2
L3
T3
GND
GND
4
5
7
8
3
FLOW
1 S-DRIVE CONTROLLER
2 FUSIBLE DISCONNECT
3 PRESSURE GAUGE
11
4 AIR DIAPHRAGM TANK
5 PRESSURE TRANSDUCER
9
6 3 PHASE OUTPUT (ALWAYS)
7 DISCHARGE CHECK VALVE
8 GATE VALVE (HIGHLY RECOMMENDED)
9 SUBMERSIBLE PUMP END
10 SUBMERSIBLE MOTOR (3 PHASE)
11 PRESSURE RELIEF VALVE
10
NOTE: FOR SINGLE PHASE INPUT, CONNECT L1 AND L3, THEN SET MOTOR
OVERLOAD SWITCHES TO 50% OF CONTROLLER RATING OR LOWER.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
System Design
Section 3 (continued)
Diagram #2 shows a set-up for municipal water connection.
1
2
SUPPLY POWER
L1
L2
L3
GND
5
AIR
6
T1
T2
7
T3
GND
3 PHASE OUTPUT
TO MOTOR
9
10
9
SUCTION
FLOW
4
8
8
3
1
2
3
4
5
SPD CONTROLLER
FUSIBLE DISCONNECT
CENTRIFUGAL PUMP
CHECK VALVE
6
7
8
9
AIR DIAPHRAGM TANK
3 PHASE MOTOR
GATE VALVE (BALL VALVE)
PRESSURE GAUGE
PRESSURE TRANSDUCER (CABLE ASSEMBLY)
10 PRESSURE RELIEF VALVE
NOTES: For single phase input power, use L1 and L3 terminals and adjust motor overload switches to
50% of controller rating or lower.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Some pump and motor combinations supplied with this system can create dangerous pressure.
Select pipe and fittings accordingly per your pipe suppliers’ recommendation. Consult local codes
for piping requirements in your area.
CAUTION
Hazardous
Pressure
All joints must be airtight. Use Teflon tape or another type of pipe sealant to seal threaded connections. Please
be careful when using thread sealant as any excess that gets inside the pipe may plug the pressure sensor.
Galvanized fittings or pipe should never be connected directly to the stainless steel discharge head or casing as
galvanic corrosion may occur. Barb type connectors should always be double clamped.
Pressure Tank, Pressure Relief Valve and Discharge Piping
Use only “pre-charged” tanks on this system. Do not use galvanized tanks. Select an area that is always above
34º F (1.1º C) in which to install the tank, pressure sensor and pressure relief valve. If this is an area where a
water leak or pressure relief valve blow-off may damage property, connect a drain line to the pressure relief
valve. Run the drain line from the pressure relief valve to a suitable drain or to an area where water
will not damage property.
Pressure Tank, System Pressure
Sizing – A bladder tank (not included) is used to cushion the pressure system during start-up and shut-down. It
should be sized to at least 20% of the total capacity of your pump. Example: If your pump is sized for 100 GPM
then size your tank for at least 20 gal. total volume, not draw down. Pre-charge your bladder tank to 10-15 PSI
below your system pressure. The controller is pre-set for 50 PSI at the factory. Therefore a 35-40 PSI pre-charge
in your tank would be required. Use the higher tank pre-charge setting if the system drifts over 5 PSI at a
constant flow rate. NOTE: Pre-charge your tank before filling with water!
Caution
CAUTION
Maximum working pressure of HydroPro bladder tank is 125 psi.
Hazardous
Pressure
Installing the Pressure Sensor
The pressure sensor requires a ¼" FNPT fitting for installation. Install the pressure sensor with the electrical
connector pointing up to avoid clogging the pressure port with debris. Install the pressure sensor in a straight
run of pipe away from elbows or turbulence. For optimum pressure control install the pressure sensor in the
same straight run of pipe as the pressure tank. Ensure the pressure sensor is within 10ft of the pressure tank.
Installing the pressure sensor far away from the pressure tank may result in pressure oscillations. Do not
install the pressure sensor in a location where freezing can occur. A frozen pipe can cause damage to the
pressure sensor.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Maintain a distance
of at least 8” between the pressure sensor cable and input or output wiring.
Ensure the pressure sensor cable is connected as follows: Brown to terminal 7 (24VDC SUPPLY), White to
terminal 6 (TRANSDUCER INPUT), Drain to chassis. Connecting the Drain wire to the chassis electrically
connects the sensor case to the chassis of the controller. In some cases this drain wire must be disconnected
from the controller chassis. In cases where the there is grounded metal piping which is continuous between
the transducer and the motor or the transducer is installed in grounded metal piping, a ground loop can result
so the drain wire must be disconnected from the chassis. In cases where there are sections of nonmetallic
piping between the transducer and motor or the transducer is installed in ungrounded piping this drain wire
should be connected to the controller chassis.
Mounting the Controller
Section 5
General
Mount the controller in a well ventilated, shaded area using 4 screws. The controller must be mounted
vertically. Be sure to leave 8 inches of free air space on every side of the unit. The controller must be in an
area with an ambient between -22º F and 122º F. If installation is above 3300 feet above sea level, ambient
temperatures are derated 1% per 330 feet above 3300 feet. The altitude limit for this controller is 6500 ft.
Do not install above 6500 ft.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
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
The controller access cover should always be securely fastened to the control box due
Hazardous
voltage
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.
Always follow the National Electrical Code (NEC) or Canadian Electric Code (CEC), as well as all
state, local and provincial codes when wiring the system.
The type of transformer and the connection configuration feeding a drive plays an important role in its performance
and safety. The following is a brief description of some of the more common configurations and a discussion of their
virtues and shortcomings. Always ask what type of power system the site has before sizing the drive.
Delta/Wye with grounded Wye neutral
This configuration is one of if not the most common. It provides rebalancing of unbalanced voltage with a 30
degree phase shift. 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.
9
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Leaving the secondary floating can permit dangerously high voltages between the chassis of the
drive and the internal power structure components. In many cases this voltage could exceed the rating of the
EMC filter and input MOV protection devices of the drive causing a catastrophic failure. In all cases, the input
power to the drive should be referenced to ground. If the transformer can not be grounded, then an isolation
transformer must be installed with the secondary of the transformer grounded.
Warning
WARNING
If a power system with an ungrounded secondary is used, the line to ground EMC filter
Hazardous
voltage
components and line to ground MOV protection must be disconnected or damage to
the controller can result.
To remove the line to ground EMC filter components, locate the jumper shown below. The jumper is on the left
hand side of the controller on the main board. Move to the disconnected position shown below.
10
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Under a short circuit secondary condition, any of the output phases to ground will not exceed the normal
line to line voltage. This is within the rating of the MOV input protection devices on the drive. The resistor is
often used to detect ground current by monitoring the associated voltage drop. Since high frequency ground
current can flow through this resistor, care should be taken to properly connect the drive motor leads using
the recommended cables and methods. In some cases, multiple drives on one transformer can produce a
cumulative ground current that can trigger the ground fault interrupt circuit.
Open Delta (consult factory)
This type of configuration is common on 230 volt systems. From time to time it may be encountered where
only single phase power is available and three-phase power is required. The technique uses two single phase
transformers to derive a third phase. When used to power a drive this configuration must be derated to about
70% of the single phase rating of one transformer. This system provides poor regulation and it is possible that
only the two line connected phases will provide power. In this case the drive must be derated to 50 % of its
rating. (Ex. A 20 HP 230 volt drive now becomes a 10 HP 230 volt drive.)
11
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
The chart below shows the full load output current ratings of the controller when single phase or 3 phase
power is used. If single phase input power is used the Motor Overload switches must be set to 50% or lower.
Nominal
HP Rating
Controller Full Load
Output Current Rating
Supply
Voltage
Frame
Size
Model
Number
3 Phase
Input
1 Phase
Input
3 Phase
Input
1 Phase
Input
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
1
5.0
2.0
3.0
17.8
26.4
37.0
47.4
60.6
76.0
94.0
8.9
8.1
7.5
10.9
17.8
26.4
33.0
40.2
47.4
2
10.0
15.0
20.0
25.0
30.0
5.0
5.0
208/230
7.5
3
4
1
10.0
12.0
15.0
7.5
13.2
18.5
23.7
30.3
37.5
47.0
10.0
15.0
20.0
25.0
30.0
460
2
3
12
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Refer to the wire sizing chart in the appendix to
determine the maximum length for the input cable. Refer to the motor manual for maximum output cable
length. The maximum recommended voltage drop on both input and output cable combined is 5%. Standard
wire sizing charts give maximum cable lengths for only input or output cables. Because of this the lengths
given in the table must be adjusted so the total voltage drop does not exceed 5%. For example, if the input
wire sizing chart in the appendix gives the maximum length of 400' and only 100' is used then only 25% of the
total voltage drop (1.25% drop) is used. The maximum output cable length read from the motor‘s wire sizing
chart must then be adjusted to 75% of its value so that the maximum voltage drop of 5% is not exceeded.
Use only fast acting class T fuses. The wire used for the input power connections on models SPD20300 and
SPD20300F must have a temperature rating of 90ºC minimum. All other wire must be rated 75 ºC minimum.
The chart below shows the recommended sizes for wire and fuses for each controller. Note that the wire sizes
were not adjusted for voltage drop due to long cable lengths.
Maximum Ambient Temperature ➞
20ºC
30ºC
Output
Cable
40ºC
Output
Cable
50ºC
Generator
Size
(VA)
Input
Cable
Output
Input
Cable
Input
Cable
Input
Cable
Output
Voltage Frame Model
Full Load
Nominal Fuse
HP
Cable
Cable
Size
Number Output Current
Size
Min. AWG Min. AWG Min. AWG Min. AWG Min. AWG Min. AWG Min. AWG Min. AWG
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
1
17.8
5.0
30.0
7700
11400
16000
20500
26200
10
8
14
12
10
8
10
8
14
10
8
10
8
12
10
8
8
6
12
8
26.4
7.5
40.0
50.0
70.0
80.0
2
3
4
1
37.0
10.0
15.0
20.0
8
8
6
4
8
47.4
4
4
8
4
6
3
6
230
60.6
4
6
4
6
4
4
2
4
76.0
25.0 110.0 32800
2
4
2
4
1
3
1/0
1/0*
14
10
8
2
94.0
30.0 135.0 40600
2*
14
12
10
8
3
1*
14
12
10
8
3
1*
14
12
10
8
2
1
8.9
5.0
7.5
15.0
20.0
30.0
40.0
50.0
60.0
70.0
7700
11400
16000
20500
26200
32400
40600
14
14
14
12
10
8
14
14
14
12
10
8
14
14
12
10
10
8
14
14
12
10
8
13.2
18.5
10.0
15.0
20.0
25.0
30.0
460
2
3
23.7
6
30.3
8
8
6
4
37.5
6
6
4
4
8
47.0
4
8
4
8
4
6
3
6
* 90ºC Wire Required on input to controller.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
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. The line to line voltage must be in the range of 195Vac to 265Vac (230V +/– 15%) for 230V models
and 391Vac to 529Vac (460V +/– 15%) for 460V models. The maximum phase to phase imbalance is +/– 3%.
If the phase to phase imbalance is greater than +/– 3% then an isolation transformer may be necessary. The
line to ground voltage must be less than 110% of the nominal (230V or 460V) line to line voltage. If the line to
ground voltage is not in this range the EMC filter and MOV components may need to be removed (see section on
“Ungrounded secondary” transformers) or an isolation transformer with a grounded secondary may be necessary.
If an isolation transformer is used, the best choice is ONE three phase, six winding transformer. A delta primary
is best for third harmonic cancellation. A wye secondary avoids circulating current problems and provides the
very desirable option of grounding the secondary neutral for minimum voltage stress and ripple to ground. The
transformer should have a KVA rating at least 1.1 times the maximum connected HP. A K factor of 6 is sufficient
if transformer impedence is greater than 2%. A K Factor of 5 is sufficient if transformer impedence is greater
than 3%. The transformer manufacturer may provide derating for non K Factor rated transformers to operate at
the drive produced K Factor levels.
Other transformer configurations are acceptable. Three single phase transformers can be used if they are
identical for phase to phase symmetry and balance. A wye connected primary neutral should never be
grounded. Great care should be taken with delta primary delta secondary configurations. Any lack of phase to
phase symmetry could result in circulating currents and unacceptable transformer heating.
Warning
WARNING
Never use phase converters with drives as nuisance tripping and possible damage may
occur. Instead, use single phase input power and 50% derate factor.
Hazardous
voltage
Warning
WARNING
“Open Delta” power systems should be sized using the 50% derate factor.
Consult factory.
Hazardous
voltage
Starting the System
Section 7
Output Power Connections
Run the motor lead wire from the motor or conduit box through metal conduit to the bottom of the
controller. Use metal conduit and metal conduit connectors. Size the conduits according to the NEC,
CEC or local codes. Connect conduit and insert the wires through the second or third opening from the
DANGER
Hazardous
voltage
left. Choose the opening that fits or is larger than the conduit used. If the opening is larger than the conduit,
use conduit bushings to attach the conduit to the controller.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Danger
DANGER The controller has high leakage current to ground. The output terminals marked
Hazardous
voltage
“GND” or “ ” must be directly connected to the motor ground. Failure to properly
ground the controller or motor will create an electrical shock hazard.
Input Power Connections
Make sure disconnect switches or circuit breakers are securely in the OFF position before making this
connection. Run the input power wires from the fused disconnect through metal conduit to the bottom
of the controller. Use metal conduit and metal conduit connectors. Size the conduits according to the
DANGER
Hazardous
voltage
NEC, CEC or local codes. Use the wire sizing chart in the appendix to determine the size of the input power wires.
Connect the conduit and insert the wires into the far left opening on the controller. Connect wires to the “INPUT”
terminal block. Connect the ground wire to the terminal labeled GND. For three phase input, connect the input
phase wires to L1, L2 and L3. For single phase input, connect the input wires to L1 and L3. If single phase input is
used the motor overload switches must be set to 50% or lower.
Caution
The wire used for input power connections on models SPD20300 and SPD20300F must have a
temperature rating of 90ºC minimum.
Danger
DANGER
The controller has a high leakage current to ground. The input terminals marked “GND”
must be directly connected to the service entrance ground. Failure to properly ground the
controller or motor will create an electrical shock hazard.
Hazardous
voltage
Note
If single phase input power is used the Motor Overload switches must be set to 50% or lower or
nuisance input phase loss errors can result.
Note
Do not use GFCI protection with this controller. Nuisance tripping will result.
Danger
DANGER
Status Code Indicator Light is not a voltage indicator! Always turn off disconnect
switch and circuit breaker and wait 5 minutes before servicing.
Hazardous
voltage
Danger
DANGER
The controller will remain electrically charged for 5 minutes after power is turned off.
Hazardous
voltage
Wait 5 minutes after disconnecting power before opening controller access cover as
there is a severe shock hazard.
15
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Choose a motor overload setting that
meets or is less than the motor’s SFA rating. For example, if the full load output
current rating of the controller is 37A and the motor SFA rating is 33A, the motor
overload setting should be set to 85% (33A/37A = 89%, next lowest setting is
85%).
In applications where the pump and motor are not used to the full capacity the
system may not draw current close to the motor’s SFA rating. In this case choose
a motor overload setting that is close to the actual full load running current.
Note
If single phase input power is used the motor overload switches must be set to 50% or lower or
nuisance input phase loss errors can result.
The chart below shows the motor overload setting for each model.
Motor Overload Setting
Supply
Voltage
Frame
Size
Model
Number
100%
95%
90%
85%
80%
70%
50%
40%
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
1
17.8
16.9
16.0
15.1
14.2
12.5
8.9
7.1
26.4
37.0
47.4
60.6
76.0
94.0
8.9
25.1
35.2
45.0
57.6
72.2
89.3
8.5
23.8
33.3
42.7
54.5
68.4
84.6
8.0
22.4
31.5
40.3
51.5
64.6
79.9
7.6
21.1
29.6
37.9
48.5
60.8
75.2
7.1
18.5
25.9
33.2
42.4
53.2
65.8
6.2
13.2
18.5
23.7
30.3
38.0
47.0
4.5
10.6
14.8
19.0
24.2
30.4
37.6
3.6
2
208/230
3
4
1
13.2
18.5
23.7
30.3
37.5
47.0
12.5
17.6
22.5
28.8
35.6
44.7
11.9
16.7
21.3
27.3
33.8
42.3
11.2
15.7
20.1
25.8
31.9
40.0
10.6
14.8
19.0
24.2
30.0
37.6
9.2
6.6
5.3
460
13.0
16.6
21.2
26.3
32.9
9.3
7.4
2
3
11.9
15.2
18.8
23.5
9.5
12.1
15.0
18.8
16
Download from Www.Somanuals.com. All Manuals Search And Download.
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. The
acceleration/deceleration switches (ACCEL/DECEL RAMP SETTINGS) control how fast the controller will change
the speed of the motor. The ramp setting is the time it takes the motor to change from minimum speed to
maximum speed. For example, if the ramp setting is set to 1 second and the minimum speed is set to 30Hz, the
motor will ramp up from 30Hz to 60Hz in 1 second. A faster ramp setting should be used in systems where the
flow rate can change quickly. This means that the motor can react faster to maintain the set pressure. A slower
ramp setting should be used in systems where the flow rate changes slowly or where fast changes in speed
can cause water hammer or pressure surges.
Setting the No Water Restart Time Switches
Switches 3 and 4 from bank 2 control the no water restart time. The no water (dry well) restart time switches
control the time between a no water (dry well) error and the restart of the system. For example, if the no water
restart time switches are set to 30 minutes, the system will restart 30 minutes after a no water (dry well) error
has been detected. For the 10 minute restart time, the controller will not restart if 5 faults are detected within 60
minutes. All other settings will continue to restart after the chosen restart time.
Note
Failure to properly set the motor overload switches can result in nuisance no water (dry well)
faults.
Setting the Minimum Frequency Switch
Switch 1 from bank 3 controls the minimum frequency. The minimum frequency switch controls the slowest
speed that the motor will run. For submersible pump/motor applications these switches must always be set to
30Hz minimum speed. For above ground applications with high suction pressure, the 15Hz setting can be used to
prevent pressure oscillation at low speeds. In some cases the suction pressure may be high enough that the pump
exceeds the pressure setting at 30Hz. In this case the 15Hz setting can be used.
Caution
Failure to properly set the minimum frequency switch can result in motor damage and will void the
motor warranty. The minimum frequency must be set to 30Hz for submersible applications.
Setting the Carrier Frequency Switch
Switch 2 from bank 3 controls the carrier frequency. For model numbers without the F suffix, the switch can be
used to change the output carrier frequency to avoid audible noise issues in above ground applications. For
model numbers with the F suffix, this switch is disabled and the carrier frequency is always set to 2 kHz.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Push and Hold the increase or decrease pushbutton until the desired pressure setting is
reached. The new pressure setting will save when the system goes into standby mode (solid green light/pump
off). Pressure set point 1 will be adjusted and stored when the SP2/SP1 switch input is open. Pressure set point 1
is preset to 50 PSI when used with a 300 PSI transducer. Pressure set point 2 will be adjusted and stored when
the SP2/SP1 switch input is closed. Pressure set point 2 is preset to 75 PSI when used with a 300 PSI transducer.
Motor Rotation Direction
If the pressure/flow seems low or the system is indicating Motor Overload error check the motor rotation
direction. Turn the breaker/disconnect switch to the off position and wait 5 minutes. Switch any two leads on the
controller output (T1/U, T2/V or T3/W). Turn the breaker/disconnect switch to the on position. Observe pressure
and flow. If the pressure or flow still seems low check plumbing.
For CentriPro Motors, connecting T1/U to Red, T2/V to Black and T3/W to Yellow will give the correct rotation.
Note
It is possible for the pump to maintain constant pressure with a low flow or a high suction head
even if the pump is rotating backwards. While the pump is running use an amp probe on one of the
output power leads connected to the motor and compare the current draw between the two rotation
directions. The lowest current reading indicates the pump is running in the correct direction.
System Status
The status indicator light displays the status of the controller. A constant green status code indicates that the
pump is in standby mode (pump not running). A blinking green status code indicates that the pump is running.
A constant orange light indicates the input voltage is low. A blinking or constant red light indicates a problem
with the controller or system. Refer to the access cover side panel for a list of status codes. See Section 9 for more
details.
Danger
The status code indicator light is not a voltage indicator! Always turn off disconnect
switch and circuit breaker and wait 5 minutes before servicing.
DANGER
Hazardous
voltage
18
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
RUN/STOP: This input allows the pump/motor to be turned on and off by an
external switch. Connect the contacts of a non-powered external switch to
terminals 1 (COM) and 2 (RUN/STOP). When the switch is closed the controller
is in RUN mode (output to motor is enabled). When the switch is open the
controller is in STOP mode (output to motor is disabled).
HAND/AUTO: This input allows the controller to run the motor at full speed
without the use of a pressure transducer. This input can be controlled by an
external non-powered switch. Connect the contacts of a non-powered external
switch to terminals 3 (COM) and 4 (HAND/AUTO). When the switch is closed the
controller is in HAND mode. While in HAND mode the RUN/STOP input is used to start and stop the motor and the
pressure transducer input is ignored. When the switch is open the controller is in AUTO mode. While in AUTO mode
the controller uses the pressure transducer feedback to control the speed of the motor.
INPUT and +24V: These terminals are the transducer feedback and transducer power supply. Connect the white
lead from the transducer cable to terminal 6 (INPUT). Connect the brown lead from the transducer cable to terminal 7
(+24V). Connecting the drain (bare) wire to the chassis allows grounding of the case of the pressure transducer. The
controller is configured with a 300 PSI 4-20mA output pressure transducer.
ANALOG OUTPUT: This output is a 4-20mA signal based on motor speed (4mA = 0Hz, 20mA = 60Hz) and can be
connected to external monitoring or external control devices. Connect terminal 10 (ANALOG OUTPUT) to the 4-20mA
input of the external device. Connect terminal 9 (COM) to the negative side of the current loop on the external device.
The external device must have an input resistance (impedance) in the range of 45Ω to 250Ω. The maximum output
voltage is 24V.
SP2/SP1: This input allows the system to operate at one of 2 pressure settings. This input can be controlled by an
external non-powered switch. Connect the contacts of a non-powered external switch to terminals 5 (COM) and 11
(SP2/SP1). When the switch is closed pressure set point 2 is enabled (preset to 75 PSI when used with a 300 PSI
transducer). When the switch is open pressure set point 1 is enabled (preset to 50 PSI when used with a 300 PSI
transducer).
PRESSURE DROP: This input allows the user to select the amount of pressure drop in the system before the pump
starts. This input can be controlled by an external non-powered switch. Connect the contacts of a non-powered
external switch to terminals 5 or 9 (COM) and 12 (PRESSURE DROP). When the switch is closed the system pressure
will drop 20 PSI (when used with a 300 PSI transducer) before restarting the pump. When the switch is open the
system pressure will drop 5 PSI (when used with a 300 PSI transducer) before restarting the pump.
RUN RELAY: This output indicates when the pump/motor is running. This output can be used to control power to a
light, an alarm or other external device. When the pump/motor is off terminal 13 (RELAY1 – NO) will be open and
terminal 14 (RELAY 1 – NC) will be connected to terminal 15 (RELAY1 – COM). When the pump/motor is on terminal
13 (RELAY1 – NO) will be connected to terminal 15 (RELAY1 – COM) and terminal 14 (RELAY 1 – NC) will be open.
The relay rating is 250Vac, 5 amps maximum.
FAULT RELAY: This output indicates when the system is faulted. This output can be used to control power to a light,
an alarm or other external device. When the system is not faulted terminal 16 (RELAY2 – NO) will be open and
terminal 17 (RELAY 2 – NC) will be connected to terminal 18 (RELAY2 – COM). When the system is faulted terminal
16 (RELAY2 – NO) will be connected to terminal 18 (RELAY2 – COM) and terminal 17 (RELAY 2 – NC) will be open.
The relay rating is 250Vac, 5 amps maximum.
19
Download from Www.Somanuals.com. All Manuals Search And Download.
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
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.
DANGER
Hazardous
voltage
Refer to the status code label on the side of the controller access cover to diagnose system errors.
See the following diagram.
Red Flashes
Fault Code
Restart Action
Constant
Replace Controller
Controller will not restart. Power must
be reset to clear the fault.
2 Blinks
3 Blinks
4 Blinks
No Water/Loss of Prime
Sensor Fault
Controller will restart automatically
according to the No Water Restart Time
switches (switches 3&4 of bank 2).
Controller will restart automatically when
the sensor signal is within the valid
operating range.
Pump or Motor Bound
Controller will restart automatically 5
times. After 5 faults the power must be
reset to clear the fault.
5 Blinks
6 Blinks
Short Circuit/Ground Fault
Input Phase Loss
Controller will not restart. Power must be
reset to clear the fault.
Controller will restart automatically 5 times.
After 5 faults the power must be reset to
clear the fault.
7 Blinks
8 BLINKS
9 Blinks
Temperature
Controller will restart automatically when
temperature is within the operating range
of the controller.
Over Voltage
Motor Overload
Controller will restart automatically when
the input voltage is within the operating
range of the controller.
Controller will restart automatically.
Use the following table to help troubleshoot problems.
No Light
Controller Status
Description
Low/No Input Voltage
Check the input voltage to the controller. Measure the input voltage
between phases using an AC Voltmeter. This voltage should be
greater than 140Vac for the status indicator light to turn on.
Green Light Codes
Flashes
Controller Status
Description
Constant
Standby
Constant Green Light indicates the pump is off. The system is in
Standby mode when there is no flow in the system and the pressure
setting has been reached or the RUN/STOP input is set to STOP (open
switch).
Blinking
Pump Running
Flashing Green Light indicates the pump is running.
20
Download from Www.Somanuals.com. All Manuals Search And Download.
Troubleshooting
Orange Light Codes
Flashes
Controller Status
Description
Constant
Low Input Voltage
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.
Verify the error by turning power off, waiting 5 minutes then apply
power. If the error persists, replace controller.
2 Blinks
No Water/Loss Of Prime
This fault can be caused by:
• Water supply level in well falls below suction inlet of pump.
• Plugged suction screen.
• Restriction in pipe between pump and pressure sensor.
• Air bound pump.
• Deadheaded pump, pump running against a closed valve.
• Filling long irrigation lines on start-up
• Incorrect setting of Motor Overload Setting switches.
In systems where the motor operates at less than Service Factor
Amps the controller may show a false No Water/Loss of Prime
fault. Reducing the motor overload setting will eliminate the
false readings.
If problem persists, please verify supply capacity.
The controller will automatically restart according to the No Water
Restart Time switches.
3 Blinks
Sensor Fault
This fault can be caused by:
• Disconnected sensor. Disconnect sensor from sensor cable
connector and reconnect to ensure a good connection.
• Disconnected sensor cable lead inside the controller. Check for
loose wires where the sensor cable connects to the circuit board by
tugging on each wire.
• Broken wire in the sensor cable.
• Miswired sensor cable. Check that the wires are connected to the
correct terminals on the control terminal block. Connect terminal
7(24VDCSUPPLY)totheBrownwire.Connectterminal6(TRANSDUCER
INPUT) to the White wire. Connect the drain wire to chassis.
• Failed sensor. To diagnose this failure a meter capable of reading
milliamperes (mA) and DC voltage (VDC) is required.
- Set the meter to read DC voltage (VDC)
- Place the black lead on terminal 5 (COM) and the red lead on
terminal 7 (24VDC SUPPLY)
- If functioning properly, the DC voltage will be 24VDC +/- 15%. If
this voltage is not present, disconnect all control terminals and
repeat the measurement. If voltage does not recover, replace
controller.
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Troubleshooting
Red Light Codes (continued)
Flashes
Controller Status
Description
3 Blinks (contd.)
- 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. If functioning
properly, the output of the sensor will be between 4mA and
20mA depending on the pressure in the system. Refer to the
chart below to determine the sensor feedback at various pressures.
The following formula gives the transducer output based on applied
pressure:
Output Current Range
Output Current =
x System Pressure + 4mA
[(
) ]
Pressure Range
Where:
• Output Current is the transducer output
• Output Current Range is the maximum output signal of the
transducer minus the minimum output signal of the transducer. In
this case:
Output Current Range = 20mA – 4mA, or 16mA
• Pressure Range is the pressure that corresponds to the maximum
output signal. For a 300 PSI transducer the Pressure Range =
300 PSI – 0 PSI = 300 PSI
• System Pressure is the system pressure as read on the pressure
gauge.
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Troubleshooting
Red Light Codes (continued)
Flashes
Controller Status
Description
4 Blinks
Pump or Motor Bound
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. The controller will attempt to restart 5 times. If the
condition persists the controller will lock out and will need to be reset.
Verify the error by turning power to controller off for 5 minutes and
then on. Pump/Motor/Wiring must be checked if fault persists.
5 Blinks
Short Circuit
This fault can be caused by:
• Electrical failure of the motor
• Electrical failure of wiring between controller and motor.
This fault will be displayed if the output current exceeds 150% of the
controller rating. Verify the error by turning power to controller off for
1 minute and then on. If error persists, motor and wiring between
controller and motor must be checked. Turn power off for 5 minutes.
Remove the three motor wires from the terminal block. Check output
wiring and motor for shorting phase to phase and phase to ground.
Refer to motor's manual for information on resistance readings and
megger readings.
6 Blinks
Input Phase Loss
This fault can be caused by:
• Disconnected input power phase.
• Incorrect Motor Overload Setting switches. When using single
phase input power the Motor Overload Setting switches must be set
to 50% or lower.
For three phase input operation; this fault will be displayed if the
phase to phase input voltage is more than 25% lower than the
nominal. The controller will attempt to restart 5 times. If the
condition persists the controller will lock out and will need to be reset.
7 Blinks
Temperature
This fault can be caused by:
• High ambient temperature. The maximum ambient temperature
rating is 122 ºF (50ºC).
• Low ambient temperature. The minimum ambient temperature
rating is -22ºF (-30ºC).
This fault will be displayed if the ambient temperature is greater than
122ºF (50ºC) or less than -22ºF (-30ºC). Do not install the controller
where it will be exposed to direct sunlight. Check for a fan failure. The
fans on the back of the controller will turn on only when needed. The
fans will turn on when the motor is running and the heatsink
temperature reaches 104 ºF (40ºC).
23
Download from Www.Somanuals.com. All Manuals Search And Download.
Troubleshooting
Red Light Codes (continued)
Flashes
Controller Status
Description
8 Blinks
Over Voltage
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.
9 Blinks
Motor Overload
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.
The controller will protect the motor from over current by limiting the
current applied to the motor. The current limit is set according to the
Motor Overload Setting switches. This fault is displayed if the output
frequency is reduced to limit the current to the motor by more than
10Hz for 5 minutes.
24
Download from Www.Somanuals.com. All Manuals Search And Download.
Controller Dimensions
25
Download from Www.Somanuals.com. All Manuals Search And Download.
Appendix: Input Wire Sizing Charts
26
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
27
Download from Www.Somanuals.com. All Manuals Search And Download.
Commercial Water
ITT
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.
A dealer who believes that a warranty claim exists must contact the authorized Goulds Pumps distributor from whom the pump was purchased
and furnish complete details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Goulds Pumps Cus-
tomer Service Department.
The warranty excludes:
(a) Labor, transportation and related costs incurred by the dealer;
(b) Reinstallation costs of repaired equipment;
(c) Reinstallation costs of replacement equipment;
(d) Consequential damages of any kind; and,
(e) Reimbursement for loss caused by interruption of service.
For purposes of this warranty, the following terms have these definitions:
(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Goulds Pumps
and the dealer in purchases, consignments or contracts for sale of the subject pumps.
(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling
or leasing pumps to customers.
(3) “Customer” means any entity who buys or leases the subject pumps from a dealer. The “customer” may mean an individual, partnership,
corporation, limited liability company, association or other legal entity which may engage in any type of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
Goulds Pumps, AquaBoost II and the ITT Engineered Blocks Symbol are
registered trademarks and tradenames of ITT Corporation.
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
IM213 Revision Number 0
November, 2008
Copyright (c) 2008 ITT Corporation
Engineered for life
Download from Www.Somanuals.com. All Manuals Search And Download.
|