MODEL 7710 INTELLIBOOST INSTRUCTION AND INSTALLATION MANUAL

Transcription

1 MODEL 7710 INTELLIBOOST INSTRUCTION AND INSTALLATION MANUAL NOTE! To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible party who maintains the system. Part # A Pentair Ltd. 12/03/12

2 SECTION 6 ITEM 7710 DATED SEPTEMBER 2009 This instruction and installation manual is applicable to the model 7710 Intelliboost. WARNING Read and address all safety warnings concerning this system. Warnings may be found in this procedure, in the PVM Pump instruction manual, and in the Variable Speed Drive manual. WARNING The voltage used in this system is very dangerous and if connected incorrectly may cause injury or even death. Please make sure that all instructions are followed, that all precautions are taken, and that all practices are consistent with the National Electric Code and with the Occupational Safety and Health Authority. 1. This system must be properly grounded. 2. Power should be disconnected at a service disconnect prior to opening the panel and servicing. CALIFORNIA PROPOSITION 65 WARNING: This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. System Receipt and Inspection: Inspect this system for any signs of damage and report this damage to the trucking firm. Check the system for any missing parts and report this to the Aurora Pump representative. Check the system for any loose parts and make corrections. System Installation: Mount, level, align and anchor the system. Attach building piping to the system without adding stress to any part of the system. We recommend that the guidelines of the Hydraulic Institute and the National Building Code be followed regarding anchoring and grouting of the base of the system. Grout the system base in place with non-shrink grout. Pipe thermal relief valves to a common drain. Bring power wiring to the system drives per requirements of the National Electric Code and all local codes. Also bring 110 volts single phase to the master control panel of the system. NOTE: If optional single point power connection has been purchased then bring required power wiring to the system disconnect per the National Electric Code. If the system is equipped with an enhanced controller with Ethernet connection, provide an Ethernet connection to the RJ45 connection on the back of the Magelis touch screen display inside the PLC controller. System Checks to be Made Prior to Start-up Check the drive nameplate for horsepower and voltage ratings. Record the VFD Serial Number on the test form. Check the motors for horsepower and voltage ratings. Record the motor model numbers and brand on the test form. Check inside the primary PLC control panel and VFDs for any loose screws and tighten as needed. Look for any evidence of a possible problem. Check available suction water supplies for water availability to the system.

3 Model 7710 CONSTRUCTION & OPERATING PRINCIPLE: BASIC CONTROLLER PLC The Intelliboost System with a basic controller consists of two to four pumps and motors with a variable frequency drive for each, all interconnected to a primary PLC control panel. The primary PLC control panel has a programmable controller with a proportional integral derivative to aid in precise control. It uses an input from a pressure transducer to stage, alternate, and vary the speed of all pumps to maintain a constant pressure at manifold discharge. All pumps have check valves and suction and discharge isolation valves. Communication from PLC controller to and from drives is through an RS485 port using Modbus Protocol. 1. System Start-up Preliminary Steps Make sure that all variable speed drives and primary PLC control panel are shut off. Bring water to the system through the suction header. Open all system isolation valves. Open petcocks on manifolds and open pumps to insure that all air is purged from the system and pumps. Open a vent plug on the PVM pump at the top of the impeller stack to insure air removal. Close all ports used for air release from the system and pumps. Bring power to the variable speed drives and to the primary PLC control panel. NOTE: Be sure to review the Pentair Variable Speed Drive instruction manual and follow all procedures and warnings. 2. Set Variable Speed Drive Parameters Danfoss VFDs (may be labeled Pentex) Turn the drives disconnect to the on position and note the power up of the drive. Both the primary PLC control panel and the variable speed drives have received a standard program prior to being shipped to make start-up more convenient. However, some information needs to be added reflecting local needs. All information for the PLC controller is displayed and is entered through a touch screen. Information is input to the drive through the keypad and LCD display as follows: PARAMETER DESIGNATION 0-01 US English 0-02 Hertz 0-03 North America 1-03 Variable Torque-VT 1-23 Motor Frequency 60 per motor nameplate 1-24 Full load amps per motor nameplate 1-25 Motor Nominal Speed from nameplate = approx rpm 3-03 Max Ref 60 Hz 3-41 Ramp Time Up 5 sec Ramp Time Down 5 sec Motor High Speed Limit 60 Hertz 4-19 Maximum Output Frequency 60.1 Hz 4-12 Motor Speed Low Limit 6 Hz No Operation 8-01 Control Site Control Word Only 8-03 Control Time Out Limit 20 sec Control Time Out Function = Stop 8-10 Control Word Profile = FC Profile 8-30 Protocol = Mod Bus RTU 8-31 Address 3,4,5,6. Drive1 = 3, Drive 2 = 4, Drive 3 = 5, Drive 4 = FC Port Baud Rate Parity = No Parity 2 Stop Bits 8-50 Thru 56 = Bus 0-50 LCP Copy (1) All To LCP Program all drives in a similar manner. With all program information input to drive # 1 and transferred as in parameter 8-50 above to the LCP, it can then be downloaded to all other drives by placing the LCP from drive #1 in each of the other drives and then using parameter 0-50 (2) to download the LCP to the drive. Refer to parameter 8-30 above to change the address of each drive.

4 Model 7710 Alternate Parameter Settings for ABB Brand VFDs CHANGE TO DEFAULT Group 98- Options 9802 Comm Prot Sel STD Modbus Not Sel Group 99 Start Up Data 9901 Language English AM English 9902 APPLIC Macro AVAC Default 9904 Motor Control Mode Scalar: Freq 9905 Motor Nominal Volt per motor data V 9906 Motor Nominal Curr per motor data 1.0*In A 9907 Motor Nominal Freq per motor data 60.0 Hz 9908 Motor Nominal Speed per motor data 3550 rpm 9909 Motor nominal power per motor data 1.0*Pn hp 9909 ID Run Off Group 10 Start/Stop/Dir 1001 Ext1 Commands Comm D11 Group 11 Reference Select 1103 Ref1 Select Comm Al1 Group 16 System Controls 1604 Fault Reset Sel Comm Keypad 1608 Start Enable 1 Not Enable D14 Group 22 Accel.Decel 2202 Acceler Time sec 30.0 s 2203 Deceller Time sec 30.0 s Group 53 RFB Protocol 5302 EFB Station ID as reqrd (3 thru 6) EFB Party 8N2 8 None 1 NOTE: Power drive off and restart after changes. Upload Drive Parameters to the Keypad Go to the Main Menu Scroll up or down to PAR BACK UP and press enter Scroll up to Upload To Panel and press SEL using the soft keys on the screen The text Copying Parameters is displayed followed by Parameter Upload Successful, Exit and return to the Main Menu Remove Keypad Download Drive Parameters to other drives from Keypad Select Menu Scroll to Par Back Up and press enter Scroll to Download To Drive and press SEL The text Restoring Parameters is displayed followed by Download Successful Refer back to Parameter 5302 above to set the address of each drive Exit and return to main menu Keypad can now be removed to program other drives. 3. Check Pump Rotation Turn the first Variable Speed Drive to the hand on position. Push hand button and observe the motor rotation. Check each motor and drive in this same way to determine the motor rotation. Return the drive to off. The correct rotation for all pumps is CCW when looking down. There is an arrow on each pump to support this. If rotation is wrong, motor leads should be changed to correct rotation. Lock out all power prior to making any wiring changes. Change direction of rotation by switching two motor leads at the drive. Check each pump rotation in the same way and make changes as needed. Return the drive to the manual position and observe manual speed change to verify operation. If any faults in the drive operation are noted refer to the Variable Speed manual for instructions and diagnostics. Check the trouble shooting section of this manual to see if the problem is addressed. Return all drives to the off position. The drives should all be operational but shut off at this point.

5 Model 7710 LOCAL PROGRAMMING TO PRIMARY PLC CONTROLLER 1. Primary PLC Controller Defined The primary PLC controller consists of a programmable logic controller to handle staging of pumps, timers, logic and alarms. All personal access to the PLC is through an HMI module. The HMI (Human Machine Interface) module consists of a touch screen with access to all information about the system and performance settings. There are three control systems for the primary PLC controller: 1. The Basic Control System uses an HMI that is the Magelis XBT GT 3.8 inch backlit monochrome LCD display, with touch sensitive resistive film, and real time clock. Communication with the variable frequency drives is through a RS 485 port using Modbus. This magelis offers 8 Mb EPROM flash memory. 2. The Advanced Control System has an HMI, which is a Magelis XBT GT inch backlit LCD display with 4096 colors. 3. The Enhanced Control System with Ethernet interface. Additional features: Data logging with a graph of flow, suction pressure, discharge pressure are plotted against time with continuous updates in real time, and a 6 month record of performance. Event logging with a record of faults, alarms, performance, and status, dated, recorded and retrieval for 6 months. Ethernet access using web browser. Advanced System Graphics Display 2. Start-up Turn on the primary PLC controller by a switch on the front of the panel. The panel has an audible alarm system, which will indicate the alarm that the drives are not active. Use the touch screen silence button to silence the audible alarm. The Basic PLC Controller has a 3.8 monochrome screen with tables but with no pictorial graphics as is seen with the advanced color screen. The menu should indicate a Start Up Screen which has a series of pressure settings etc., which need to be input based on local conditions. NOTE: Some of the screen indicators must be touched and held for several seconds continuously to activate On a system, which is not yet programmed, the first screen will say Critical System Settings. Press this button. This screen will not appear after settings are made. Enter the number of pumps in the system and press next to proceed. Enter the System Discharge Pressure Wake Up Pressure (after sleep mode) is usually 5 PSI less than system pressure. Sleep Speed is the single pump churn or no flow speed and will be different Critcal Systems Settings for each system. As a preliminary value use 80 % of full speed. Variations in suction pressure will affect this setting and several actual run tests should be done to fine tune the setting. A. Lag Pump Staging: -To stage the lag pump by pressure, set the value at start is 95-98% of full speed. -If lag pump staging is to be by flow instead of pressure as entered in the Advanced Menu and select staging by flow. Set the staging points as follows: 1. First Lag Pump Set at 98% of the GPM rating of pump # one. 2. Second Lag pump set at 98% of the GPM rating of pumps one and two. 3. Set other pumps in a similar way. B. Lag Pump Stop: -To Stage the lag pump off by pressure set the speed at the same speed as the sleep speed, or as a preliminary use 80%. -If the lag pump is to be staged by flow instead of pressure, set stage off points as follows: 1. Stage off the first lag pump at flow = pump flow x Stage off the second lag pump at flow = pump flow x 2 pumps x Stage off the third lag pump at flow = pump flow x 3 pump x.75. NOTE: If the last lag pump is just a spare pump, set its start point abnormally high to prevent staging.

6 SYSTEM HEAD FEET Model 7710 A= Single pump head at 98% full speed lag start speed B= Head of two pumps at reduced speed or lag pump stop speed A Full speed with one pump with losses Full speed head with two pumps with losses B System Head Duty point one pump 98% Pump speed pump two start Duty point two pump Both pumps reduced speed lag pump stop Suction Pressure FLOW GPM Illustration of Lag Pump Start and Stop Points C. Access To High System Pressure Fault: -High System Pressure Fault (or shut down) should be an abnormal high pressure compared to system pressure. Use system pressure plus 25 PSI. -High System Pressure Reset should be about 12 PSI above system pressure. -High System Pressure Fault can be disabled by entering 999 for the pressure. D. Access To Low Suction Pressure Fault (shut down): NOTE: Some areas have mandatory shut down pressures. This option requires the addition of a suction pressure transducer rated neg 14.7 to 150 PSI. -Low Suction Pressure Fault. This is an abnormal suction pressure shut down and will depend on the location. Some locations have a mandatory shut down pressure. -Low Suction Pressure Fault Reset. This should be about half the pressure difference between normal suction pressure and fault pressure. -Low Suction Pressure Fault can be disabled by entering 999 for the pressure. E. Access to Low System Pressure Alarm: -Low System Pressure Alarm is a warning that the system pressure is abnormally low and should be set at about 10 PSI below system pressure. -Low System Pressure Alarm reset should be set at about 5 PSI below system pressure. -Low System Pressure Alarm can be disabled by entering 999 for the pressure. F. Access to High System Pressure Alarm: -High System Pressure Alarm is a warning that system pressure is higher than it should be. Set at 12 PSI above normal system pressure. -High System Pressure Alarm Reset. This value should be set as half the difference between alarm setting and normal pressure. -High System Pressure Alarm can be disabled by entering 999 for the pressure. G. Access to Low Suction Pressure Alarm: -Low Suction Pressure Alarm. This is a warning that you are close to a low suction pressure shut down. Set this value the same as the suction fault reset pressure. -Low Suction Pressure Alarm Reset This value should be set as half the difference between alarm setting and normal pressure. -Low Suction Pressure Alarm can be disabled by entering 999 for the pressure.

7 Model 7710 Example of alarm settings Suggested settings example(s): Low Suction Pressure. Assume suction pressure varies from 30 PSI to 40 PSI -Low Suction Pressure alarm. Set the alarm condition at 24 PSI and reset at 27 PSI -Low Suction Pressure fault. Set the fault or shut down condition at 18 PSI. Set condition reset at 24 PSI High System Pressure. Assume discharge pressure is 150 PSI -High System Pressure alarm could be set at 162 PSI with a reset at 156 PSI. -High System Pressure fault could be set at 175 PSI with a reset at 156 PSI. Low System Pressure Alarm. -With a discharge pressure of 150 PSI, a Typical Low System Pressure Alarm setting is 140 PSI with a reset of 145 PSI. NOTE: All settings are only approximations and must take into account the system pressure desired, the suction pressure available statically and then suction pressure during times of full flow. TOTAL PRESSURE single pump full speed including losses single pump curve speed High Syst. Pres. Alarm System Pressure Waking Pressure system loss Low System Pressure pump curve at reduced speed for sleep mode Suction Pressure L. S. Pres. Reset L.S. Pres. Alarm L.S. Pres. Fault 0 TDH 0 FLOW Example of System Settings 3. Check the system summary screen to recap settings One of Several Summary Screens

8 Model Programming in the advanced menu Advanced Settings Access Access to System Timer Settings -All timers in this section will have a factory timer setting. Typically timers are set at 5 seconds and do not need to be changed unless there are operating problems. Access to PID Loop -The PID loop has been programmed at the factory and should not be changed unless there are operating issues. Access to Systems Miscellaneous Settings -Flow meter full scale GPM: This applies only to advanced and enhanced system with optional flow meter. -Power Failure Restart Delay: Three seconds is a good rule of thumb. -Alternation Method Standard: system alternate on each complete cycle; however, in the advanced or enhanced system a 24-hour alternator can be chosen. -Lag Pump Staging: In the advanced and enhanced systems with optional flow meter, optional staging by flow can be chosen. If staging by flow is selected then return to the Start Up Assistant to provide staging GPM in the program. Access to Display Settings -Values for the display are set at the factory and should not need adjusting unless there are performance problems with the display. To check ethernet address with this option 1. press Offline 2. Network to display the address 3. Make changes if needed and then OK to Run 4. Shut down & Restart Optional Flow Sensing - Only the advanced and the enhanced IntelliBoost PLC control panels are designed to be able to accept the 4-20 ma signal from a flow transducer to indicate flow in GPM on the display and to sequence pumps using the flow transducer instead of the pressure transducer. Wire the flow transducer per the wiring diagram. Accuracy in flow meter display is dependent on straight-line pipe before and after the flow meter. If mounted in the system piping, we will mount on the suction manifold and slightly compromise the straight-line pipe after the flow meter. For the greatest accuracy allow 10-pipe diameters straight-line pipe before the flow meter. Data input for flow sensing is in the Advanced Menu, under Misc. Settings. Input the flow meter full-scale capacity. To sequence by flow, enter the Type of Lag Pump Control. -All suction pressure related settings in the PLC require a suction pressure transducer with 4-20 ma. Connected to the PLC controller. The PLC controller will accept a pressure switch for low suction pressure shut down in place of the suction pressure transducer. The same input channel can be used for low level shut down if a 4-20 ma level transducer is provided.

9 Model 7710 Troubleshooting 1. One common problem is incomplete or inconsistent information given to the PLC controller and to the drives. Go back and check all input fields to see that they are complete and consistent with system operating parameters. Go through the PLC set-up; then go through the drive set-up with uplink to keypad and then downlink to each drive. 2. One of the biggest problems to a packaged system is variable suction pressure. The only sure way to eliminate variable suction pressure is to use a suction break tank (open reservoir). In the absence of a break tank the times in the PID loop may need to be changed to respond more rapidly. Retain the factory settings so that they could be reproduced if needed. Initial settings of the PID loop could be as follows: -Gain: This is the largest component to set point correction and should be set as large as the system will allow. Start with a settings of 1. -Integral Time: This setting is important to moderating the effects of gain. Give the system an artificial surge or drop in pressure and observe the time for a complete cycle of drop in pressure and return to normal. Set the integral time to 1.5 times this cycle time. Try 2 seconds. -Derivative Time: The derivative has little value due to the short cycle times. Set to 0 seconds. -PID Control Scan: The PID scan time is the time for each monitoring cycle and associated changes to control. A long set time may make the system sluggish and a short time will not give enough time for corrections to be made in each cycle. Start with a 0.1 second scan time. 3. Another source of poor control is the VFD ramp times. However, any changes in the VFD ramp time should be as a last resort. Consult Aurora Pump for advice. This is the time from full stop to full speed. Since we control between 2600 and 3500 RPM typically and most variations in speed would be about 50 RPM, we are controlling this 50-RPM in.2 seconds. Ramp time for a smooth system could be 10 seconds, and for an erratic system try 30 seconds. 4. In low flow situations, the IntelliBoost is designed to shut down all drives and restart on a pressure drop. If this does not happen it is likely that the settings of sleep RPM, Start Pressure, and shut down timer are not set properly. This shut down depends heavily on changes in suction pressure and should be reset accordingly. 5. Low System Pressure may indicate that set points are not set correctly. Examine system pressure setting in the PLC panel, and RPM limits that may be set in the drives. The PLC will display system pressure. See if this pressure agrees with your system gage on the manifold. The system transducer maintains 1% accuracy but can easily be changed. Check the transducer input to the PLC. Look for a cable or connector problem. 6. The drive may give a high current alarm. Check the acceleration ramp time, which may be too short. 7. The drive may give a high or low voltage alarm. Check the building supply power for adequacy. 8. The drive may trip out with a DC Buss failure alarm. This may be caused by a deceleration time or ramp down time being to short. In this case, the drive powers down quickly leaving the motor to coast, and generate power into the drive. The drive responds with a DC Bus failure alarm. 9. For other drive related problems, consult the VFD manual. 10. Contact Aurora Pump Systems Group for advice in system set up (boostersystems@pentair.com). If your system is equipped with Ethernet, and has an IP Address assigned, give this to the Aurora Pump representative so that they can observe your settings over the Internet.

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12 WARRANTY Seller warrants equipment (and its component parts) of its own manufacture against defects in materials and workmanship under normal use and service for one (1) year from the date of installation or start-up, or for eighteen (18) months after the date of shipment, whichever occurs first. Seller does not warrant accessories or components that are not manufactured by Seller; however, to the extent possible, Seller agrees to assign to Buyer its rights under the original manufacturer's warranty, without recourse to Seller. Buyer must give Seller notice in writing of any alleged defect covered by this warranty (together with all identifying details, including the serial number, the type of equipment, and the date of purchase) within thirty (30) days of the discovery of such defect during the warranty period. No claim made more than 30 days after the expiration of the warranty period shall be valid. Guarantees of performance and warranties are based on the use of original equipment manufactured (OEM) replacement parts. Seller assumes no responsibility or liability if alterations, non-authorized design modifications and/or non-oem replacement parts are incorporated If requested by Seller, any equipment (or its component parts) must be promptly returned to Seller prior to any attempted repair, or sent to an authorized service station designated by Seller, and Buyer shall prepay all shipping expenses. Seller shall not be liable for any loss or damage to goods in transit, nor will any warranty claim be valid unless the returned goods are received intact and undamaged as a result of shipment. Repaired or replaced material returned to customer will be shipped F.O.B., Seller's factory. Seller will not give Buyer credit for parts or equipment returned to Seller, and will not accept delivery of any such parts or equipment, unless Buyer has obtained Seller's approval in writing. The warranty extends to repaired or replaced parts of Seller's manufacture for ninety (90) days or for the remainder of the original warranty period applicable to the equipment or parts being repaired or replaced, whichever is greater. This warranty applies to the repaired or replaced part and is not extended to the product or any other component of the product being repaired. Repair parts of its own manufacture sold after the original warranty period are warranted for a period of one (1) year from shipment against defects in materials and workmanship under normal use and service. This warranty applies to the replacement part only and is not extended to the product or any other component of the product being repaired. Seller may substitute new equipment or improve part(s) of any equipment judged defective without further liability. All repairs or services performed by Seller, which are not covered by this warranty, will be charged in accordance with Seller's standard prices then in effect. THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND SELLER HEREBY EXPRESSLY DISCLAIMS AND BUYER WAIVES ALL OTHER WARRANTIES EXPRESSED, IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller's sole obligation under this warranty shall be, at its option, to repair or replace any equipment (or its component parts) which has a defect covered by this warranty, or to refund the purchase price of such equipment or part. Under the terms of this warranty, Seller shall not be liable for (a) consequential, collateral, special or liquidated losses or damages; (b) equipment conditions caused by normal wear and tear, abnormal conditions of use, accident, neglect, or misuse of said equipment; (c) the expense of, and loss or damage caused by, repairs or alterations made by anyone other than the Seller; (d) damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage, mishandling, or other similar conditions; (e) any loss, damage, or expense relating to or resulting from installation, removal or reinstallation of equipment; (f) any labor costs or charges incurred in repairing or replacing defective equipment or parts, including the cost of reinstalling parts that are repaired or replaced by Seller; (g) any expense of shipment of equipment or repaired or replacement parts; or (h) any other loss, damage or expense of any nature. The above warranty shall not apply to any equipment which may be separately covered by any alternate or special warranties. PERFORMANCE: In the absence of Certified Pump Performance Tests, equipment performance is not warranted or guaranteed. Performance curves and other information submitted to Buyer are approximate and no warranty or guarantee shall be deemed to arise as a result of such submittal. All testing shall be done in accordance with Seller's standard policy under Hydraulic Institute procedures. LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability under the Order or otherwise for liquidated damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of construction, regardless of the cause of such damages or losses. In any event, Seller's aggregate total liability under the Order or otherwise shall not exceed the contract price. ACTS OF GOD: Seller shall in no event be liable for delays in delivery of the equipment or other failures to perform caused by fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Seller's control. COMPLIANCE WITH LAW: Seller agrees to comply with all United States laws and regulations applicable to the manufacturing of the subject equipment. Such compliance shall include: The Fair Labor Standards Acts of 1938, as amended; Equal Employment Opportunity clauses of Executive Order 11246, as amended; Occupational Safety and Health Act of 1970 and the standards promulgated thereunder, if applicable. Since compliance with the various Federal, State, and Local laws and regulations concerning occupational health and safety, pollution or local codes are affected by the use, installation and operation of the equipment and other matters over which Seller has no control, Seller assumes no responsibility for compliance with those laws and regulations, whether by way of indemnity, warranty, or otherwise. It is incumbent upon the Buyer to specify equipment which complies with local codes and ordinances. 800 Airport Road North Aurora, Illinois