544607 3 Aquavar CPC Manual

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INSTRUCTION MANUAL
IM167R08

AQUAVAR CPC
®

(Centrifugal Pump Control)
INSTALLATION AND OPERATION MANUAL

NOTE: This guide does not provide detailed
installation, safety or operational instructions. See the Installation Operation Manual
for complete information.

This guide provides a quick reference for
installing Aquavar CPC drives having a standard enclosure (NEMA 1).

Application

START-UP Wizards

APPLY power

REINSTALL the cover

CHECK installation

INSTALL wiring

MOUNT the drive

REMOVE the front cover

PREPARE mounting location

UNPACK the drive

PREPARE for installation

Task

The installation of the AQUAVAR CPC adjustable speed drive follows the outline below.

Overview

Centrifugal Pump Controller
Quick Start Guide

AQUAVAR® CPC

2 – 230 Volt
370 Amps
1 – NEMA 1
2 – NEMA 12

*See Technical Section

NOTE: Lift the Aquavar by its chassis and not by
its cover.
1. Unpack the drive.
2. Check for any damage and notify the
shipper immediately if damaged components are found.

Unpack the Drive

Collect Motor Data
Collect the following data from the motor nameplate
plate for later use in the Aquavar startup:
• Voltage_______________________________
• Nominal Motor Current________________
• Nominal Frequency____________________
• Nominal Speed_______________________
• Nominal Power________________________

* Consult factory for other options, if available.
Not all combinations may be available.

Options

CPC 4 370 1

4 – 460 Volt

NEMA Enclosure Rating

Amps

Voltage

AQUAVAR® (Series)

Tools Required
Screwdrivers, wire stripper, tape measure, mounting screws or bolts, and drill.
Use the following chart to interpret the type code
found on the drive label.

Check
• Motor Compatibility – Motor type, nominal current,
frequency and voltage range must match drive
specifications (3 phase motor only).
• Suitable Environment – Drive requires heated,
indoor controlled environment that is suitable for
the selected enclosure below 104º F.
• Wiring – Follow local codes for wiring and fusing
requirements. Refer to NEC, Local, State or Municipal codes.
Refer to the Installation Operation Manual and
confirm that all preparations are complete.

WARNING! The Aquavar should ONLY
be installed by a qualified electrician.

Prepare for Installation

1
X0002

Wiring Power
1. Connect conduit runs to box.
2. Route input power and motor
wiring through conduits.

1. Install thin-wall conduit clamps (not
supplied) in the conduit/gland box.
2. Install conduit/gland box.

Install the Wiring (copper only)

2. Attach a warning
sticker in the
appropriate language on the inside
plastic shell.

1. Position the
AQUAVAR and use
screws or bolts to
securely tighten all
four corners.

Mount the Drive

3. Pull near the
top to remove
the cover.

2. Loosen the
captive screw
at
the top.

1. Remove the control panel
(display), if attached.

Remove the Front Cover

1. Mark the mounting
points.
2. Drill the mounting holes.

The drive requires a smooth,
vertical, solid surface, free from
heat and moisture, with free
space for air flow – 200 mm (8
in.) above and below, and 25
mm (1 in.) around the sides of
the drive.

Prepare the Mounting Location

3. Check the contents against the order
and the shipping label to verify that all
parts have been received.

WARNING!
For floating networks remove
screws at
F1 and F2
on Frame
Sizes R5 or R6.

Frame Size R6

Frame Size R5

WARNING! For floating networks
remove screws at EM1 and EM3 on
Frame Sizes R1…R4.

* Single phase input power must use U1, W1
and PE for wiring.

Frame Sizes R1…R4

3. Strip wires.
4. Connect power, motor and
ground wires to the drive terminals.
See “Power Connections”
in the instruction manual.

Relay Outputs

Relay output 1, programmable. Default2
= run power to drive
Maximum: 250 VAC/
30 VDC, 2 A
Minimum: 500 mW
(12 V, 10 mA)
Relay output 2, programmable. Default2
= ready, pump is
running
Maximum: 250 VAC/
30 VDC, 2 A
Minimum: 500 mW
(12 V, 10 mA)
Relay output 3, programmable. Default2
= not used
Maximum: 250 VAC/
30 VDC, 2 A
Minimum: 500 mW
(12 V, 10 mA)

AI1: 0…10 V
AI2: 0(4)…20 mA (default)

6. Install the conduit/gland box cover (1
screw).

19 RO1C

20 RO1A

21 RO1B

22 RO2C

23 RO2A

24 RO2B

25 RO3C

26 RO3A

27 RO3B

Note 1. Jumper Setting: (Analog Input)

1. Route the
transducer
3
cable
through
5
the conduit.
2. Strip the
transducer
cable
sheathing
and twist
1
the screen
wire.
3. Connect the screen
wire of the
transducer to
terminal X1-1.
4. Connect the power supply wire of the
transducer (red or brown) to terminal
X1-10.
5. Connect analog output wire from the
transducer (white or black) to X1-5.
See chart in next column.

Control Wiring

and
12

Terminal for transducer
shield. (Connected internally to chassis ground.)
Analog input channel 1,
2nd transducer. Default2
= frequency reference.
Resolution 0.1%,

2 AI1 accuracy ±1%.
J1:AI1 OFF: 0…10 V (Ri =
312 kΩ)
J1:AI1 ON: 0…20 mA (Ri
= 100 Ω)
Analog input circuit com mon. (Connected interJumper
Wire 3
AGND nally to chassis gnd.
through 1 MW. Jumper
wire to X1-11.)
(–)
10 V/10 mA reference

Trans-
voltage output for analog
4 +10V input potentiometer,
ducer
(4 -20
accuracy ±2%. (Not used.)
mA)
Analog input channel 2.
Conn-
Resolution 0.1%,
ection
5 AI2 accuracy ±1%.
(White
Transducer input
or
4–20 mA
Black)

Analog input circuit com

mon. (Connected inter6 AGND nally to chassis gnd.

through 1 MΩ)

Analog output, program

mable. Default2 = Not
7 AO1 used. Current 0…20 mA

(–)
(load < 500 Ω)
Trans
Analog output, programducer

mable. Default2 = Not
Power
8 AO2 used. 0…20 mA
Supply
(load < 500 Ω)
(Brown

Analog output circuit
or Red)

common (Connected
9 AGND internally to chassis gnd.

through 1 MΩ)
Auxiliary voltage output
10–15
24 VDC / 250 mA
E-stop
(reference to GND).
or
10 +24V Short circuit protected.
Jump-

Transducer/digital input
er
power supply.
Jump-
Auxiliary voltage output
er
11 GND common. (Connected
Wire
internally as floating.)
11

Trans-

1 SCR
ducer

Screen/

Shield

Analog I/O

Digital Inputs1

Control Wiring

may be provided by the
AQUAVAR (X1-10) or by
an external 12…24V
source of either polarity.

Digital input 1, selectable.
13 DI1 Default2 = run enable

Digital input 2, selectable.
14 DI2 Default2 = low water
10–15
E-stop
Digital input 3,
or
15 DI3 selectable. Default2
Jump-
= E-stop or jumper
er
Digital input 4,
16 DI4 selectable. Default2
E-stop

= set point selection
/start
Jump
Digital input 5, selectable.
17 DI5 Default2 = not used
to
+24V
Digital input 6, selectable.
for en-
18 DI6 Default2 = not used
able

JumpDigital input common.
er
To activate a digital input,
Wire
11
there must be ≥+10V
and (or ≤-10V) between that
12 12
DCOM input and DCOM. The 24V

Check
Environment conforms to specifications.
The drive is mounted securely.
Proper cooling space around the drive.
Motor and driven equipment are ready for start.
Floating networks: Internal RFI filter disconnected.
Drive is properly grounded, with pump/motor.
Input power (mains) voltage matches the drive
nominal input voltage.
The input power (mains) terminals, U1, V1, W1,
are connected and tightened as specified.
The input power (mains) fuses / mains switch installed.
The motor terminals, U2, V2, W2, are connected
and tightened as specified.
Motor cable is routed away from other cables.
NO power factor compensation capacitors are
connected to the motor cable.
Control terminals are wired and tightened as specified.
NO tools or foreign objects (such as drill shavings) are
inside the drive.
NO alternate power source for the motor is connected
– no input voltage is applied to the output of the drive.

√

Before applying power, perform the following checks.

Check Installation

specified are for the default macro, single/multipump.
NOTE: Jumper Wires between 3 and 11, 10 and 15,
11 and 12.

(15
1
Digital input impedance 1.5 kΩ. Maximum voltage
to 10
Jump- 2 for digital inputs is 30 V.
Default values depend on the macro used. Values
er)

Digital Inputs1

Wiring the Transducer

LOC
REM

DIR

REM

40.2 PSI sp
0.0 PSI ac
0.0 HZ

11.1%

NOTE! For common parameters and
menu items, use the Help Key
to
display descriptions. If you encounter
Alarms or Faults, use the Help Key or
refer to the Diagnostic section of the
instruction manual.

1. Use the MENU key to access the
Menu list.
2. Select Wizards.
3. Select Start-Up Wizards.
4. Follow the screen instructions to
configure the system.
DEFAULT PASSWORD IS “66”.

Wizards
The Start-Up
Wizard steps through
typical start-up selections and runs
automatically upon the initial power
up. At other times, use the steps
below to run the Start-Up Wizard.

In Start-Up, enter motor
data (collected earlier)
and, if needed, edit parameters that define how
the drive operates and
communicates.

Start-Up

NOTE! Before increasing motor
speed, check that the motor is running in the desired direction.

1. Apply input power.
When power is applied to the AQUAVAR, the green LED comes on.

WARNING! The AQUAVAR
will start up automatically at
power up, if the external run
command is on.

Always reinstall the front cover before
turning power on.

Apply Power

1. Align the cover
and slide
it on.
2. Tighten
the
captive screw.
3. Reinstall the
control panel.

Reinstall the Cover

FEATURES

Quick Reference Guide
Analog Output, 102
Auto Restart, 102
Energy Savings Information, 103
Fieldbus Control, 103
Keypad (Control Panel), 104
Language, 104
Locking,104
Low Water Protection, 108
Manual Override, 104
Minimum Speed Options, 105
Priming Delay, 106
Pump Protect Control, 107
Ramp Hysteresis, 113
Ramp Settings, 113
Regulation Mode, 107
Relay Outputs, 107
Restart Value, 106
Secondary Protection, 108
Setpoints, Dual, 109
System Curve Compensation, 110
Test Run, 111
Tuning, 111
Window (Regulation), 112

TABLE OF CONTENTS
Section 1 SAFETY

Use of Warnings and Notes.........................................................................................................................................7

Section 2 POWER DISTRIBUTION SYSTEMS

Delta / Wye with grounded Wye neutral....................................................................................................................9
Delta / Delta with grounded leg..................................................................................................................................9
Ungrounded secondary...............................................................................................................................................9
Resistance grounding and ground fault protection................................................................................................10
Open Delta...................................................................................................................................................................10
Single Phase Connection............................................................................................................................................10

Section 3 INTRODUCTION

Input Power and Line Transformer Requirements...................................................................................................11
Issues for Drive Input Isolation Transformers...........................................................................................................11
Installation Flow Chart................................................................................................................................................13
Aquavar CPC Product Numbering............................................................................................................................14
Preparing for Installation; Drive Identification.........................................................................................................15
Section 4 INSTALLATION (Frames R1-R6)

Supply Connection......................................................................................................................................................19

Thermal Overload and Short-Circuit Protection......................................................................................................19

Ground Fault Protection.............................................................................................................................................19

Emergency Off Devices..............................................................................................................................................19

Selecting the Power Cables........................................................................................................................................20

Motor Cable Shield.....................................................................................................................................................20

Additional US Requirements......................................................................................................................................20

Installing the Drive.......................................................................................................................................................21

Wiring Connection Diagrams....................................................................................................................................24

Single Phase Wiring / Connection Diagram............................................................................................................26

Wiring IP 21 / UL Type 1 Enclosure with Conduit....................................................................................................27

Wiring IP 54 / UL Type 12 Enclosure with Conduit..................................................................................................28

Power Connections.....................................................................................................................................................29

Control Wiring.............................................................................................................................................................30

Communications..........................................................................................................................................................31

Installation Check Sheet.............................................................................................................................................32

Reinstall Cover.............................................................................................................................................................33
Section 4 INSTALLATION (Frames R7-R8)

Aquavar Drive Manuals Descriptions........................................................................................................................34

Introduction, Planning , Moving the Unit and Mounting........................................................................................35

Connecting Power and Control Cables....................................................................................................................36

R7 Frame Size...............................................................................................................................................................37

R8 Frame Size...............................................................................................................................................................38

Maintenance.................................................................................................................................................................39

Technical Data - Extension Module R7......................................................................................................................41

Detail R7.......................................................................................................................................................................42

Technical Data - Extension Module R8......................................................................................................................43

Detail R8.......................................................................................................................................................................44

Section 5 START-UP

Wizards and Assistant Control Panel (Display).........................................................................................................45
Controls / Display Overview.......................................................................................................................................45
Start-Up Wizard............................................................................................................................................................48

Section 6 PARAMETER LISTINGS

Aquavar CPC Parameter List......................................................................................................................................50

Section 7 PROGRAMMING

Single Pump Programming (Pressure Transducer)..................................................................................................73
Single Pump – Submersible Pump Constant Pressure............................................................................................78
MultiPump – Constant Pressure Control...................................................................................................................87
MultiPump – Slave Pump Control..............................................................................................................................94

Section 8 FEATURES

Analog Outputs........................................................................................................................................................ 102
Auto Restart, Energy Saving Information (Group 26)........................................................................................... 102
5

TABLE OF CONTENTS

Fieldbus Control....................................................................................................................................................... 103
Language, Locking................................................................................................................................................... 104
Minimum Speed Options........................................................................................................................................ 105
Priming Delay, Pump Protect Ctrl, Regulation Mode................................................................................... 106-107
Relay Outputs; Restart Options; Low Water (Suction) Protection............................................................... 107-108
Keypad Failure.......................................................................................................................................................... 109
Set Points, Dual with example................................................................................................................................. 109
System Curve Compensation.................................................................................................................................. 110
Test Run; Tuning, System Pressure.......................................................................................................................... 111
Window Setting (Reg Window)............................................................................................................................... 112
Ramp Hysteresis....................................................................................................................................................... 113
Adjusting Ramp Rates.............................................................................................................................................. 113

Section 9 FAULTS/ALARMS

Diagnostic Displays.................................................................................................................................................. 115
Correcting Faults...................................................................................................................................................... 116
Fault Resetting.......................................................................................................................................................... 119
Correcting Alarms.................................................................................................................................................... 120

Section 10 MAINTENANCE (Frame Sizes R1-R6)

Maintenance Intervals.............................................................................................................................................. 122
Heatsink..................................................................................................................................................................... 122
Main Fan Replacement............................................................................................................................................ 122
Internal Enclosure Fan Replacement...................................................................................................................... 123
Capacitors................................................................................................................................................................. 124
Control Panel............................................................................................................................................................. 124

Section 10 MAINTENANCE (Frame Sizes R7-R8)

Layout......................................................................................................................................................................... 125
Heatsink, Fan............................................................................................................................................................. 126
Replacing the Fan..................................................................................................................................................... 126
Capacitors................................................................................................................................................................. 128
LEDs........................................................................................................................................................................... 129
Control Panel............................................................................................................................................................. 129

Section 11 TECHNICAL DATA

Sizing; Derating........................................................................................................................................................ 130
Cable Sizing / Ratings 208-240 Volt Drives........................................................................................................... 131
Cable Sizing / Ratings 380-480 Volt Drives........................................................................................................... 132
Fuse Sizing / Ratings 208-240 Volt Drives............................................................................................................. 133
Fuse Sizing / Ratings 380-480 Volt Drives............................................................................................................. 134
Cable Terminals (frames R1-R6 and frames R7-R8).............................................................................................. 135
Input Power (Mains) Connection............................................................................................................................ 136
Motor Connection.................................................................................................................................................... 136
Control Connection.................................................................................................................................................. 137
Efficiency (frames R1-R8); Cooling (frames R1-R6)............................................................................................... 137
Cooling (frames R7-R8); Mounting Orientations a & b........................................................................................ 138
Air Flow 380-480 Volt Drives................................................................................................................................... 139
Air Flow 208-240 Volt Drives................................................................................................................................... 140
Dimensions and Weights (Frames R1-R6)............................................................................................................. 141
Units with IP 54 / UL Type 12 Enclosures............................................................................................................... 143
Weights and Dimensions (Frames R7-R8) 460 Volt.............................................................................................. 144
Degrees of Protection.............................................................................................................................................. 144
Ambient Conditions................................................................................................................................................. 145
Materials; Applicable Standards............................................................................................................................. 146
UL Markings; Liability Limits.................................................................................................................................... 147

Section 12 APPENDIX

Pressure Transducer................................................................................................................................................. 148

Transducer Data / Specifications Drawing #A00462C........................................................................................ 149

Transducer Data / Specifications Drawing #A00436C........................................................................................ 150

Spare Parts List.......................................................................................................................................................... 151

Warranty..................................................................................................................................................................... 152

SAFETY
WARNING! The AQUAVAR adjustable speed AC drive should ONLY be installed by a qualified electrician.
WARNING! Even when the motor is stopped, dangerous voltage is present at the Power Circuit terminals U1, V1, W1 and U2, V2, W2 and, depending on the frame size, UDC+ and UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present when input power is connected. After disconnecting the
supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the
cover.
WARNING! Even when power is removed from the input terminals of the AQUAVAR, there may be dangerous voltage (from external sources) on the terminals of the relay outputs R01…R03.
WARNING! When the control terminals of two or more drive units are connected in parallel, the auxiliary
voltage for these control connections must be taken from a single source which can either be one of the
units or an external supply.
WARNING! The AQUAVAR CPC wall mount version is not a field repairable unit. Never attempt to repair
a malfunctioning unit; contact the factory or your local Authorized Service Center for replacement.
WARNING! The AQUAVAR will start up automatically after an input voltage interruption if the external
run command is on.
WARNING! The heat sink may reach a high temperature, in excess of 200º F. Severe burns are possible.
WARNING! If the drive will be used in a floating network, remove screws at EM1 and EM3 (Frame size
R1…R4), or F1 and F2 (Frame size R5 or R6). See diagrams on pages 24 and 25 respectively.
NOTE! For more technical information, contact the factory or your local AQUAVAR representative.
WARNING! Always consult your local, state, municipal or NEC codes for proper wiring, electrical installation of inverter drives and AC motors.
USE OF WARNINGS AND NOTES
There are two types of safety instructions throughout this manual:
• Notes draw attention to a particular condition or fact, or give information on a subject.
• Warnings caution you about conditions which can result in serious injury or death and/or damage to
the equipment. They also tell you how to avoid the danger. The warning symbols are used as follows:
DANGEROUS VOLTAGE WARNING warns of high voltage which can cause physical injury and/or damage to the equipment.
GENERAL WARNING warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the equipment.

TYPICAL DRIVE LABEL

ACS550-U1-046A-2 ACS550-U1-046A-2

SW:

V.2.06B

2053901277

2053901277
S/N2053901277

S/N2053901277

Input
Voltage (U1)
Current (11n)

3 PH 48…63
208…240 Vac
46.2 A

1 PH 48…63 Hz
208…240 Vac
46.2 A

Short Circuit

100 kAIC

Output
Voltage (U2)
Current (12n)
Current (12hd)

3 PH 0…500 Hz
0…U1 Vac
46.2 A
30.8 A

3 PH 0…500 Hz
0…U1 Vac
22 A

Power (Pn)
Power (Phd)

15 HP

7.5 HP

ACS550-U1-046A-2

Made in USA of foreign parts
LISTED 45Y1
®

159339
206578

UL
®

IND. CONT. EQ.

Mfg. Date: 31-October-2005

Orig. Firmware: V.2.06B

S/N2053901277

POWER DISTRIBUTION SYSTEMS
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.

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 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.

POWER DISTRIBUTION SYSTEMS
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.)

Single Phase Connection:
For small drive with a 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. Single phase
will not work with an SCR front end drive.

INTRODUCTION
Input Power and Line Transformer Requirements
The Aquavar CPC™ requires that the input line voltage and transformer power that meet
certain phase and balance requirements. If you or your installing electrical contractor is in
doubt of the requirements, the following provide guidelines for the Aquavar CPC. When
in doubt contact the local power utility or the factory.
Drive input isolation transformers are not generally required for the Aquavar CPC. The
Aquavar CPC utilizes as standard 3% line impedance, therefore unless additional filtering is
needed, an input line reactor is not required.
NOTE: 60 THROUGH 550 HP UNITS PROVIDE AN ACTUAL 3% IMPEDANCE LINE REACTOR
BUILT INTO THE DRIVE CABINET.
The internal power circuit of the drive is floating with respect to earth ground except for
transient protection (MOV’s and EMI capacitors) therefore earth ground potential reference is
established only by the user’s power line grounding configuration. The drive can operate with
many different power grounding schemes. The drive requires only that the steady state RMS
voltage from any input line to ground be always less than 110% of the nominal power line to
line voltage. The use of optional RFI/EMC filters may require that the voltage from any input
line to ground be less than 110% of the nominal power line to neutral voltage.
Drive input isolation or dry type transformers may be required for the following:
1. Step up or down: An input transformer may be required to step the local input power
line voltage up or down to the level of the drive input rating.
2. Ground Isolation: An input isolation transformer with a direct or a high impedance wye
neutral secondary ground connection may be required to establish a local power source
with a ground relationship different from the utility power source.
A. If ground isolation is required to prevent a ground fault in one section from shutting
down equipment in another section.
B. To bring local line voltages within the line to ground limits (110% balance) stated in
the opening paragraph.
C. Some ground fault protection schemes and peripheral components require a
grounded neutral power source.
D. A symmetrical wye neutral grounded power source along with proper ground wiring
techniques according to NEC (good ac grounding from motor to drive and from
drive to earth ground) provides the best means to control the ground currents that
the drive switching frequency and dv/dt rate insert into the motor frame and shaft.
3. Phase shifting delta-wye or “zig-zag” isolation transformers are used to feed 12 or 18
pulse drive inputs to provide harmonic mitigation.
If an isolation transformer is used for 6 pulse input, 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 impedance is greater than 2%. A K Factor of 5 is sufficient
11

INTRODUCTION
if transformer impedance 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! Never use phase converters with drives as nuisance tripping and possible
damage may occur. Size the drive for single phase input using 50% derate factor.
WARNING! Use of “Open Delta” 230 volt power systems should be sized using the
50% derate factor. Consult factory.
Sometimes drive input isolation transformers are specified to deal with one or more of
the following issues:
1. Short Circuit Protection: Input transformers are sometimes used to provide impedance
to reduce the available short circuit current to levels that the input clearing devices,
such as fuses or circuit breakers, are rated to handle. Line reactors can perform this
impedance function much more cost effectively.
2. Transient Protection: Input transformers are sometimes used to provide transient
surge impedance. All the Aquavar CPC drives have capacitors and MOV’s (Metal Oxide
Varistor transient protectors) providing 120 to 360 joules, line to line and line to ground
transient protection. Isolation transformers are not required for this protection within
those energy levels. Additional distribution transformer primary transient surge arrestors
may be required if the potential transient energy reflected to the drive exceed those
levels. MOV’s are rated to handle high levels of one shot transient energy. MOV’s are not
meant to handle continuously recurring transients. A problem of continuously recurring
transients should be corrected before connecting a drive.
3. Harmonic Mitigation: Input transformers are sometimes used to provide impedance to
reduce the harmonic currents generated in the drive. Line reactors can perform this
function much more cost effectively.
4. Power Factor Capacitor Isolation: Input transformers are sometimes used to provide
impedance to isolate drives from line connected power factor correction capacitors.
PWM drive inputs do not require power factor correction capacitors as drive power
factors are generally greater than 92% and cannot be significantly improved with
power factor correction capacitors which only correct for fundamental. However drives
should be isolated from power factor correction capacitors by about 3 to 6% additional
impedance with respect to the drives. Line reactors can perform this function much more
cost effectively than isolation transformers. ABB drives have either an internal 3% line
reactor or an equivalent 3 to 5% bus reactor.
5. RFI/EMI Mitigation: Neither input isolation transformers nor line or bus reactors provide
good high frequency filtering although an isolation transformer with a static shield will
provide some RFI mitigation. If RFI/EMI mitigation is required, an RFI/EMI filter mounted
inside the drive should be used together with all the proper wiring and grounding
techniques. Some RFI/EMI filters may operate only on a power source with a grounded
neutral. Establishing a local neutral ground may require the use of an input isolation
transformer.

INTRODUCTION
Study these installation instructions carefully before proceeding. Failure to observe the
warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read “Safety” on page 7.

Installation Flow Chart
The installation of the AQUAVAR adjustable speed pump controller follows the outline below.
The steps must be carried out in the order shown. At the right of each step are references to
the detailed information needed for the correct installation of the unit.

Task

PREPARE for installation

UNPACK the drive

PREPARE the Mounting Location

REMOVE the front cover

MOUNT the drive

INSTALL wiring

CHECK installation

REINSTALL the cover

APPLY power

START-UP

See
“Preparing for Installation” on page 15.
“Unpack the Drive” on page 21.
“Prepare the Mounting Location”
on page 21.
“Remove Front Cover” on page 21.
“Mount the Unit” on page 22.
“Install the Wiring” on page 23.
“Check Installation” on page 32.
“Reinstall Cover” on page 33.
“Apply Power” on page 33.
“Start-Up” on page 33.

INTRODUCTION
AQUAVAR CPC Product Numbering
Voltage

Phase

NEMA 1 Base Model

Full Load Amps
Normal Duty

Frame Size

Normal Duty
Horsepower

CPC20071
3.7
R1
1
CPC20171
8.5
R1
2
CPC20241
12
R2
3
CPC20311
15.5
R2
5
CPC20461
23
R3
7.5
CPC20591
29.5
R3
10
230
1
CPC20881
44.0
R4
15
CPC21141
57.0
R4
20
CPC21431
71.5
R6
25
CPC21781
89.0
R6
30
CPC22481
124.0
R6
40
CPC22481
124.0
R6
50
CPC20041
4.6
R1
1
CPC20071
7.5
R1
2
CPC20121
11.8
R1
3
CPC20171
16.7
R1
5
CPC20241
24.2
R2
7.5
CPC20311
30.8
R2
10
CPC20461
46.2
R3
15
230
3
CPC20591
59.4
R3
20
CPC20751
74.8
R4
25
CPC20881
88.0
R4
30
CPC21141
114.0
R4
40
CPC21431
143.0
R6
50
CPC21781
178.0
R6
60
CPC22211
221.0
R6
75
CPC22481
248.0
R6
100
CPC40061
6.9
R1
3
CPC40081
8.8
R1
5
CPC40121
11.9
R1
7.5
CPC40151
15.4
R2
10
CPC40231
23
R2
15
CPC40311
31
R3
20
CPC40381
38
R3
25
CPC40451
45
R3
30
CPC40591
59
R4
40
CPC40721
72
R4
50
CPC40781
78
R4
60
460
3
CPC40971
97
R4
75
CPC41251
125
R5
100
CPC41571
157
R6
125
CPC41801
180
R6
150
CPC42451
245
R7
200
CPC43161
316
R7
250
CPC43681
368
R8
300
CPC44141
414
R8
350
CPC44861
486
R8
400
CPC45261
526
R8
450
CPC46021
602
R8
500
CPC46451
645
R8
550
CPC50031
2.7
R2
2
CPC50041
3.9
R2
3
CPC50061
6.1
R2
5
CPC50091
9
R2
7.5
CPC50111
11
R2
10
CPC50171
17
R2
15
CPC50221
22
R2
20
CPC50271
27
R3
25
575
3
CPC50321
32
R4
30
CPC50411
41
R4
40
CPC50521
52
R4
50
CPC50621
62
R4
60
CPC50771
77
R6
75
CPC50991
99
R6
100
CPC51251
125
R6
125
CPC51441
144
R6
150
*** - HP classifications are for reference purposes only, always size the Aquavar according to the output amps and the service factor amps of the motor.

INTRODUCTION
Preparing for Installation
Drive Identification
Drive Labels

To determine the type of drive you are installing, refer to either:

• Serial number label attached on upper part of the chokeplate between the mounting
holes.
ACS550-01-08A8-4
U1
I2N / I2hd
PN / Phd

3~380…480 V
8.8 A / 6.9 A
4 / 3 kW

Ser. no. *2030700001*

• Type code label attached on the heat sink – on the right side of the unit cover.
Input U1
I1N
f1

3~380…480 V
8.8 A
48…63 Hz

Input U2 3~0…U1 V
I2N / I2hd 8.8 A / 6.9 A
0…500 Hz
f2
Input PN / Phd

4 / 3 kW

UL
®

LISTED

Ser. no. *2030700001*

ACS550-01-08A8-4

Type Code

CPC 4 370 1 FD

AQUAVAR® (Series)

Voltage
2 – 208-240 Volt
4 – 480 Volt
5 – 575 Volt

Amps
370 Amps

*See Technical Section

NEMA Enclosure Rating
1 – NEMA 1
2 – NEMA 12

** Fused Disconnect
Options
* Consult factory for other options, if available. Not all combinations may be available.
** Standard equipment on 200 HP and above 460 volt models.

INTRODUCTION
Ratings and Frame Size
The chart in “Ratings” on page 131 lists technical specifications, and identifies the drive’s
frame size – significant, since some instructions in this document, vary, depending on the
drive’s frame size. To read the Ratings table, you need the “Output current rating” entry from
the type code. Also, when using the Ratings table, note that the table is broken into sections
based on the drive’s “Voltage rating”.
Motor Compatibility
The motor, drive and supply power must be compatible:

Motor
Specification
Motor type

Verify Reference
3-phase induction motor

NEMA MG1

Nominal current
Motor value is within this

range: 0.2…2.0 * I2hd

(I2hd = drive heavy duty)

• Type code label on drive,
entry for Output Current or
• Type code on drive and
rating current table in
“Technical Data” on
page 131.

50 – 70 Hz

—

Motor is compatible
with the AQUAVAR
voltage range.

208…240 V (for CPC2XXXX) or
380…480 V (for CPC4XXXX)

Nominal frequency

Voltage range

Tools Required
To install the AQUAVAR you need the following:
• True RMS multimeter
• Screwdrivers (as appropriate for the mounting hardware used)
• Wire stripper
• Tape measure
• Drill
• Mounting hardware: screws or nuts and bolts, four each. The type of hardware depends on
the mounting surface and the frame size:

Frame Size

Mounting Hardware

R1…R4
M5
#10

R5
M6
¼ in.
5
R6 M8 ⁄16 in.
Suitable Environment and Enclosure
Confirm that the site meets the environmental requirements. To prevent damage prior to
installation, store and transport the drive according to the environmental requirements
specified for storage and transportation. See “Ambient Conditions” on page 145.
Confirm that the enclosure is appropriate, based on the site contamination level:
• IP 21 / UL type 1 enclosure, indoor use only. The site must be free of airborne dust,
corrosive gases or liquids, and conductive contaminants such as condensation, carbon
dust and metallic particles.
16

INTRODUCTION
• IP 54 / UL type 12 enclosure, indoor use only. This enclosure provides protection from
airborne dust and light sprays or splashing water from all directions.
• UL Type 3R- Enclosures are intended for outdoor use to provide a degree of protection
from falling rain. Undamaged by the formation of ice on the enclosure. May be cooled by
forced air and louvers for vents.
• IP 56 / UL type 4 enclosure. Constructed for outdoor use or hose down applications.
Provides a degree of protection against falling dirt, rain, sleet, snow, windblown dust and
splashing water. Not suitable for direct sun. A sun shield or canopy may be required.
Suitable Mounting Location
Confirm that the mounting location meets the following constraints:
• The drive must be mounted vertically on a smooth, solid surface, and in a suitable
environment as defined above.
• The minimum space requirements for the drive are the outside dimensions (see “Outside
Dimensions” on page 141 and 143), plus air flow space around the unit (see “Cooling” on
page 137).
• The distance between the motor and the drive is limited by the maximum motor cable
length. See “Motor Connection” on page 136.
• The mounting site must support the drive’s modest weight and noise output. See
“Dimensions and Weights” on page 141.
Wiring and EMC Considerations
Determine electromagnetic compliance (EMC) requirements per local codes. In general,
always follow the NEC in the absence of a local code.
• Follow local codes for cable size, conduit, grounding and motors.
• Keep these four classes of wiring separated: input power wiring, motor wiring, control/
communications wiring. Always use separate conduit for motor/control wires.
• Refer to the specifications/recommendations in:
“Cable Sizing/Rating” on page 131, “Cable Terminals” on page 135, “Input Power (Mains)
Connection” on page 136 and “Motor Connection” on page 136.
• Multiple motor wire should always be run in separate conduit. Shielded and grounded!
Control Cables
General Recommendations
Use shielded cables, temperature rated at 60º C (140º F) or above:
• Control cables must be multi-core cables with a braided copper wire screen.

Double Shielded
Example: JAMAK by Draka NK Cables

Single Shielded
Example: NOMAK by Draka NK Cables

• The screen must be twisted together into a bundle not longer than five times its width and
connected to terminal X1-1 (for digital and analog I/O cables) or to either X1-28 or X1-32
(for RS485 cables).
17

INTRODUCTION
Route control cables to minimize radiation to the cable:
• Route as far away as possible from the input power and motor cables (at least 20 cm (8 in)).
• Where control cables must cross power cables make sure they are at an angle as near 90º
as possible.
• Stay at least 20 cm (8 in) from the sides of the drive.
Use care in mixing signal types on the same cable:
• Do not mix analog and digital input signals on the same cable.
• Run relay-controlled signals as twisted pairs (especially if voltage > 48 V). Relay-controlled
signals using less than 48 V can be run in the same cables as digital input signals.
NOTE! Never mix 24 VDC and AC power signals in the same cable.
Analog Cables
Recommendations for analog signal runs:
• Use double shielded, twisted pair cable
• Use one individually shielded pair for each signal.
• Do not use a common return for different analog signals.
Digital Cables
Recommendations for digital signal runs:
• A double shielded cable is the best alternative, but single shielded twisted multi-pair cable
is also usable.
Control Panel Cable
If the control panel is connected to the drive with a cable, use only Category 5 Patch ethernet
cable.

INSTALLATION (Frames R1-R6)
Supply Connection
Disconnecting Device (Mains)
Install a hand-operated input disconnecting device between the AC power source (MCC) and
the drive. The disconnecting device must be of a type that can be locked to the open position
for installation and maintenance work. Follow all local NEC codes.
Fuses
See Technical Data: Fuse Sizing/Rating on pages 133 and 134.

Thermal Overload and Short-circuit Protection
The drive protects itself and the input and motor cables against thermal overload when the
cables are dimensioned according to the nominal current of the drive. No additional thermal
protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
The drive protects the motor cable and the motor in a short-circuit situation when the motor
cable is dimensioned according to the nominal current of the drive.
Mains Cable (AC line cable) Short-circuit Protection
Always protect the input cable with fuses. Standard gG (US: T or L) very fast acting, fuses
will protect the input cable in short-circuit situations and prevent damage to adjoining
equipment in case of a short-circuit inside the drive.
Size the fuses according to local safety regulations, appropriate input voltage and the rated
current of the drive. For fuse ratings, see Technical Data, pages 133 and 134.
WARNING! Circuit breakers are not capable of providing sufficient protection
because they are inherently slower than fuses. Always use fuses with circuit breakers, if
you are not sure of the circuit braking capacity and mains short circuit power.

Ground Fault Protection
The drive is equipped with an internal ground fault protective function to protect the unit
against ground faults in the motor and the motor cable. This is not a personal safety or a fire
protection feature. The ground fault protective function can be disabled with a parameter
contact factory for more information.
The EMC filter of the drive includes capacitors connected between the main circuit and the
frame. These capacitors and long motor cables increase the ground leakage current and may
cause fault current circuit breakers to function.

Emergency Off Devices
For safety reasons, install the emergency off devices at each operator control station and at other
operating stations where emergency off may be needed. Pressing the stop key
on the control
panel of the drive does not generate an emergency off of the motor or separate the drive from
dangerous potential.
19

INSTALLATION (Frames R1-R6)
Selecting the Power Cables (copper only)
General Rules
Dimension the mains (input power) and motor cables according to local regulations:
• Do not use aluminum wires.
• The cable must be able to carry the drive load current. See Technical Data for the rated
currents.
• The cable must be rated for at least 70º C (158º F) maximum permissible temperature of
conductor in continuous use. For US, follow local codes for cable size, or refer to NEC table
310.16.
• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated
according to permissible touch voltage appearing under fault conditions (so that the fault
point voltage will not rise excessively when an ground fault occurs).
• 600 VAC cable is accepted for up to 500 VAC concerning the entire AQUAVAR CPC range.
For frame sizes R7 and R8, symmetrical shielded motor cable must be used (figure below). A
four-conductor system used up to 30 kW motors cannot be used.
Compared to a four conductor system, the use of symmetrical shielded cable reduces
electromagnetic emission of the whole drive system as well as motor bearing currents and wear
of bearings.
The motor cable and its PE pigtail (twisted screen) should be kept as short as possible in order
to reduce electromagnetic emission as well as capacitive current.
Insulation Jacket

Copper Wire Screen

Helix of Copper Tape

Inner Insulation

Cable Core

Motor Cable Shield
To effectively suppress radiated and conducted radio-frequency emissions, the shield
conductivity must be at least 1/10 of the phase conductivity. The requirements are easily met
with a copper or aluminum shield. The minimum requirement of the motor cable shield of the
drive is shown below. It consists of a concentric layer of copper wires with an open helix of
copper tape. The better and tighter the shield, the lower the emission level and the bearing
currents.

Additional US Requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded
power cable must be used for the motor cables if metallic conduit is not used. For the North
American market, 600 VAC cable is accepted for up to 500 VAC. For drives rated over 100
amperes, the power cables must be rated for 70ºC (158ºF).

INSTALLATION (Frames R1-R6)
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor bonded
to the conduit on each side of the joint. Bond the conduits also to the drive enclosure. Use
separate conduits for input power, motor, brake resistors, and control wiring. Do not run
motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V power wiring. Control and
signal cables must not be run in the same tray as power cables. Six conductor (3 phases and 3
ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is
available from the following suppliers (tradenames in parenthesis):

• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)

• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (OLEFLEX) and Pirelli.

Installing the Drive
WARNING! Before installing the AQUAVAR, ensure the input power supply to the
drive is off.
Unpack the Drive
1. Unpack the drive.
2. Check for any damage and notify the shipper immediately if
damaged components are found.
3. Check the contents against the order and the shipping label to verify
that all parts have been received.
Prepare the Mounting Location
The AQUAVAR should only be mounted where all of the requirements
defined “Preparing for Installation” on page 15 are met.
1. Mark the position of the mounting holes. Refer to page 138 for
mounting hole location.
2. Drill the holes.

1
X0002

NOTE! Frame sizes R3 and R4 have four holes along the top.
Use only two. If possible, use the two outside holes (to allow
room to remove the fan for maintenance).
Remove Front Cover
IP 21 / UL Type 1
1. Remove the control panel, if attached.
2. Loosen the captive screw at the top.
3. Pull near the top to remove the cover.

INSTALLATION (Frames R1-R6)
IP 54 / UL Type 12
1. If hood is present: Remove screws (2) holding hood in
place.
2. If hood is present: Slide hood up and off of the cover.
3. Loosen the captive screws around the edge of the cover.
4. Remove the cover.

Mount the Drive
IP 21 / UL Type 1
1. Position the AQUAVAR onto the mounting screws or bolts and
securely tighten in all four corners.
NOTE! Lift the AQUAVAR by its metal chassis.
2. Non-English speaking locations: Add a warning sticker in the
appropriate language over the existing warning on the top of
the module.

IP 54 / UL Type 12
For the IP54 / UL Type 12 enclosures, rubber plugs are required in
the holes provided for access to the drive mounting slots.
1. As required for access, remove the rubber plugs. Push plugs
out from the back of the drive.
2. Position the AQUAVAR onto the mounting screws or bolts and
securely tighten in all four corners.
NOTE! Lift the AQUAVAR by its metal chassis.
3. Reinstall the rubber plugs.
4. Non-English speaking locations: Add a warning sticker in the
appropriate language over the existing warning on the top of the module.

INSTALLATION (Frames R1-R6)
Install the Wiring
Conduit/Gland Kit
Wiring drives with the IP 21 / UL type 1 Enclosure requires a conduit/gland kit with the
following items:
• Conduit/gland box
• Screws
• Cover
The kit is included with IP 21 / UL type 1 Enclosures.
Overview
As you install the wiring, observe the following:
• There are four sets of wiring instructions – one set for each combination of drive enclosure
type (IP 21 / UL type 1 and IP 54 / UL type 12), and wiring type (conduit or cable). Be sure
to select the appropriate procedure.
• “Connection Diagrams” on page 24 shows the connection points on the drive.
• “Power Connections” on page 29 describes specific instructions for wiring the power. Use
in combination with the appropriate general procedure.
• “Control Connections” on page 29 describes specific instructions for wiring the control.
Use in combination with the appropriate general procedure.
• “Cable Terminals” on page 135 list the recommended tightening torques.
• Where applicable, observe EMC recommendations. For example, properly ground the wire
screen cable shields.

INSTALLATION (Frames R1-R6)
Three Phase Wiring/Connection Diagrams
The layout of connection terminals is similar for all frame sizes (R1…R6). The only significant
layout difference is in the power and ground terminals for frame sizes R5 and R6. The
following diagrams show:
• Terminal layout for frame size R3, which, in general, applies to all frame sizes except as
noted above.
• Power and ground terminal layout for frame sizes R5 and R6.

WARNING! For floating networks remove screws at EM1 and EM3.

INSTALLATION (Frames R1-R6)
Three Phase Wiring/Connection Diagrams continued

Not used

WARNING! For floating networks remove screws at F1 and F2.

INSTALLATION (Frames R1-R6)
Single Phase Wiring/Connection Diagram

Not used

WARNING! For floating networks remove screws at EM1 and EM2.
WARNING! For single phase wiring, derate the 3 phase nominal HP and
amps 50%.

INSTALLATION (Frames R1-R6)
Wiring IP 21 / UL Type 1 Enclosure with Conduit
1. Open the appropriate knockouts in the conduit/
gland box.
2. Install thin-wall conduit clamps (not supplied).
3. Install conduit/gland box.
4. Connect conduit runs to box. Always follow
appropriate NEC or local electrical codes for inverter
drives, motor wiring.
5. Route input power and motor wiring through
conduits. Preferably metal, grounded type.
6. Strip wires.
7. Connect power, motor, and ground wires to the drive
terminals. See “Power Connections” on page 29.
8. Route the control cable, transducer cable through the
conduit.
9. Strip the control cable sheathing and twist the copper
screen into a pigtail.
10. Connect the transducer screen pigtail for digital and
analog I/O cables at X1-1.
11. Strip and connect the individual control wires to the
drive terminals. See “Control Connections” on page
29. Including transducer.
12. Install the conduit/gland box cover (1 screw).
13. Wire transducer leads to analog 2, terminal(s) +24V,
AI2 and GND.
14. Wire positive lead of transducer to terminal 10
(+24VDC). Color is red or brown.
15. Wire analog lead (negative) to terminal 10 of X1 for
4-20mA signal. Color is white or black.
16. Take the transducer cable screen to X1, #1 Terminal.

INSTALLATION (Frames R1-R6)
Wiring IP 54 / UL Type 12 Enclosure with Conduit
1. Remove and discard the clamping plate.
2. Remove and discard the cable seals where
conduit will be installed. (The cable seals are
cone-shaped, rubber seals on the bottom of the
drive.)

3. For each conduit run, install water tight conduit
connectors (not supplied).

4. Route the power wiring through the conduit.
5. Route the motor wiring through the conduit.
6. Strip the wires.
7. Connect the power, motor and ground wires to
the drive terminals. See “Power Connections” on
page 29.
8. Route the control wiring through the conduit.
9. Strip the control cable sheathing and twist the
copper screen into a pigtail.
10. Connect the ground screen pigtail for digital and
analog I/O cables X1-1.
11. Strip and connect the individual control wires to
the drive terminals. See “Control Connections” on
pages 29 and 30.
12. Install the conduit/gland box cover (1 screw).
13. Install and wire transducer as stated in previous
steps on pages 27 and 28.
28

INSTALLATION (Frames R1-R6)
Power Connections
WARNING! Ensure the motor is compatible for use with the AQUAVAR. The AQUAVAR
must be installed by a competent person in accordance with the considerations
defined in “Preparing for Installation” on page 15. If in doubt, contact your local AQUAVAR
sales or service office. Always consult the NEC for information.
• Refer to the following table to complete the power connections. If appropriate, also
perform the instructions for the braking and floating networks.
Terminal

Description

Note

U1, V1, W1*
3-phase power supply input

“Input Power (Mains) Connection”
on page 136.

Follow local rules for cable size.

Protective Ground

U2, V2, W2
Power output to motor

“Motor Connection” on
page 136.

* NOTE: The AQUAVAR (208…240V series) can be used with a single phase supply, if output current is derated by 50%.
For single phase supply voltage, connect power at U1 and W1. Refer to page 26.

Floating Networks
For floating networks (also known as IT, ungrounded or high impedance networks):
• Disconnect the internal RFI filter by removing both the EM1 and EM3 screws (frame sizes
R1…R4, see page 24), or F1 and F2 screws (frame sizes R5…R6, see page 25).
• Where EMC requirements exist, check for excessive emission propagated to neighboring
low voltage networks. In some cases, the natural suppression in transformers and cables is
sufficient. If in doubt, use a supply transformer with static screening between the primary
and secondary windings.
• Do NOT install an external filter. Using an RFI filter grounds the input power through the
filter capacitors, which could be dangerous and could damage the unit.
Control Connections
To complete the control connections, use:
• Following tables
• “Single/Multipump”
• “Complete Parameter Descriptions”
• Cable recommendations in “Control Cables”

INSTALLATION (All Frames)

Transducer

1
SCR
Screen/

Shield

Control Wiring

Terminal for transducer shield. (Connected internally to chassis ground.)
Analog input channel 1, 2nd transducer. Default2 = frequency reference.

2
AI1
Resolution 0.1%, accuracy ±1%.

J1:AI1 OFF: 0…10 V (Ri = 312 kΩ)

J1:AI1 ON: 0…20 mA (Ri = 100 Ω)
Switch positions listed on page 25.

3
AGND
Analog input circuit common. (Connected internally to chassis gnd.

through 1 MW. Jumper wire to X1-11.)
Jumper
Wire

4
+10 V
10 V/10 mA reference voltage output for analog input potentiometer,

accuracy ±2%. (Not used.)
(–)

Analog input channel 2.
Transducer

5
AI2
Resolution 0.1%, accuracy ±1%.
(4-20mA)

Transducer input
Connection

4–20 mA
(White
or
Black)
6
AGND
Analog input circuit common. (Connected internally to chassis gnd.

through 1 MΩ)

7
AO1
Analog output, programmable. Default2 = Not used. Current 0…20 mA

(load < 500 Ω)

8
AO2
Analog output, programmable. Default2 = Not used. 0…20 mA
(+)

(load < 500 Ω)
Transducer

9
AGND
Analog output circuit common (Connected internally to chassis gnd.
Power

through 1 MΩ)
Supply
(Brown

10 +24V
Auxiliary voltage output 24 VDC / 250 mA (reference to GND). Short
or
Red)

circuit protected. Transducer/digital input power supply.

11 GND
Auxiliary voltage output common. (Connected internally as floating.)
Jumper
Wire

Digital input common. To activate a digital input, there must be ≥+10 V
11
and 12
12 DCOM (or ≤-10 V) between that input and DCOM. The 24 V may be provided by

the AQUAVAR (X1-10) or by an external 12…24 V source of either polarity.
10 – 15

13 DI1
Digital input 1, programmable. Default2 = run enable (Group 24)
E-stop
or Jumper
14 DI2
Digital input 2, programmable. Default2 = low water (Group 24)

15 DI3
Digital input 3, programmable. Default2 = E-stop or jumper
E-stop/
Jump
16 DI4
Digital input 4, programmable. Default2 = set point selection
start
17 DI5
Digital input 5, programmable. Default2 = HOA (Group 12)
to +24V for
enable

18 DI6
Digital input 6, programmable. Default2 = not used
(15 to 10

19 RO1C
Relay output 1, programmable. Default2 = drive ready
Jumper)

20 RO1A
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

21 RO1B

22 RO2C
Relay output 2, programmable. Default2 = pump run

23 RO2A
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

24 RO2B

Relay Outputs

Digital Inputs1

Analog I/O

25 RO3C
26 RO3A
27 RO3B

Relay output 3, programmable. Default2 = fault
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

Digital input impedance 1.5 kΩ. Maximum voltage for digital inputs is 30 V.
Default values depend on the macro used. Values specified are for the default macro, single/multipump.
NOTE: Jumper Wires between 3 and 11, 10 and 15, 11 and 12.

1
2

NOTE! Terminals 3, 6 and 9 are at the same potential.
NOTE! For safety reasons the fault relay signals a “fault” when the AQUAVAR is
powered down.
30

INSTALLATION (Frames R1-R6)
You can wire the digital input terminals in either a PNP or NPN configuration.

PNP Connection (Source)
X1

NPN Connection (Sink)
X1

10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6

Communications
Terminals 28…32 are for RS485 or modbus communications. Use shielded cables. For lengths
of cable beyond 100 feet, use screen connections.
Do not directly ground the RS485 network at any point. Ground all devices on the network
using their corresponding earthing terminals.
As always, the grounding wires should not form any closed loops, and all the devices should
be earthed to a common ground.
Terminate the RS485 network using 120 Ω resistors at both ends of the network. Use the DIP
switch to connect or disconnect the termination resistors. See following diagram and table.
Terminated
Station

Station

X1 Identification
28 Screen
29 B

RS485
Multipump
Connections

30 A
31 AGND
32 Screen

Terminated
Station

Station

Hardware Description1
RS485 Multidrop Application
Other Modbus Devices

SCR
B
A
GND
B
A
GND
SCR

28
29
30
31
32

SCR
B
A
AGND
SCR

RS485 Interface
J2 J5
J2 J5
ON ON
ON ON

off position on position
Bus Termination

For functional descriptions, see “Standard Serial Communication” addendum.

INSTALLATION (Frames R1-R6)
Check Installation
Before applying power, perform the following checks.

√ Check

Installation environment conforms to the drive’s specifications for ambient
conditions.

The drive is mounted securely.

Space around the drive meets the drive’s specifications for cooling.

The motor and driven equipment are ready for start (3 phase motor).

For floating networks: The internal RFI filter is disconnected.

The drive is properly grounded, along with the pump, motor and control panel.

The input power (mains) voltage matches the drive nominal input voltage (watch
for “open delta” power).

The input power (mains) connections at U1, V1 and W1 are connected and
tightened as specified. Loose connections may cause arcing!

The input power (mains) fuses are installed, according to NEC.

The motor connections at U2, V2 and W2 are connected and tightened as
specified.

The motor cable is routed away from other cables and in separate conduit.

NO power factor compensation capacitors are in the motor cable.

The control connections are connected and tightened as specified.

NO tools or foreign objects (such as drill shavings) are inside the drive.

NO alternate power source for the motor (such as a bypass connection) is
connected – no voltage is applied to the output of the drive.

Single phase power is connected to U1 and W1 with GND.

INSTALLATION (Frames R1-R6)
Reinstall Cover
IP 21 / UL Type 1
1. Align the cover and slide it on.
2. Tighten the captive screw.
3. Reinstall the control panel.

IP 54 / UL Type 12
1. Align the cover and slide it on.
2. Tighten the captive screws around the edge of the cover.
3. Slide the hood down over the top of the cover.
4. Install the two screws that attach the hood.
5. Reinstall the control panel.
NOTE! The control panel window must be closed to
comply with IP 54/UL type 12.
6. Optional: Add a lock (not supplied) to secure the control
panel window.
Apply Power
Always reinstall the front cover before turning power on.
WARNING! The AQUAVAR will start up automatically at power up, if the
external run command is on.
1. Apply input power.
When power is applied to the AQUAVAR, the green LED comes on.
NOTE! Before increasing motor speed, check that the motor is running in
the desired direction.
Start-Up
The AQUAVAR has default parameter settings that are sufficient for many situations. However,
review the following situations. Perform the associated procedures as appropriate. Proceed to
Start-Up section of this manual.

INSTALLATION (Frames R7-R8)
AQUAVAR Drive Manuals
GENERAL MANUALS
AQUAVAR User’s Manual (IOM) (1…150 HP)

• Safety
• Diagnostics

• Installation
• Maintenance

• Start-Up
• Technical Data
AQUAVAR User’s Manual (IOM) (200…550 HP)

• Safety
• Diagnostics

• Installation
• Maintenance

• Start-Up
• Technical Data
OPTION MANUALS
(Fieldbus Adapters, I/O Extension Modules etc.,
manuals delivered with optional equipment.)

Relay Output Extension Module (typical title)

• Installation
• Diagnostics

• Start-Up
• Technical Data

INSTALLATION (Frames R7-R8)
Introduction
AQUAVAR CPC drives include an extension module that
is not covered in the AQUAVAR User’s Manual. The extension module is attached to the drive module at the factory,
which includes fusible disconnect.
This supplement provides the additional extension module information required for AQUAVAR drives:
• Additional installation steps and considerations.
• Steps for separating the drive from the extension module for drive service access.
Extension
• Dimensions for the extension module.

Module

Drive
Module

WARNING! Only qualified electricians are allowed to carry out the work described
in this chapter. Follow requirements in “Safety” on the first pages of this manual.
Ignoring the safety instructions can cause injury or death.

Planning
When planning for cable/conduit routing, refer to the AQUAVAR User’s Manual, but note that,
for the AQUAVAR, all connections are routed through the top of the extension module.

Moving the Unit
1. Move the transport package by pallet truck to the installation site.
2. Unpack the transport package.
3. To position the unit, use a lift, connected as shown.

Mounting
Fastening the Unit
See the “Dimensional Drawings” on page 41 for the exact locations
of the mounting points.
1. Use at least four screws – two at the front, two at the back – to attach the unit base plate to
the floor.
2. Use at least two screws to attach the back of the enclosure to a wall.
There are two holes available at the top of each: the extension module and the drive module.

INSTALLATION (Frames R7-R8)
Connecting Power and Control Cables
Additional considerations that apply with the enclosure extension:
• The power cable connection diagram that applies for the AQUAVAR is:
AQUAVAR
Drive Module

Extension Module

OMIO
3
Switch-fuse
Disconnect

Control
Panel

U1 V1 W1

Control
Wiring

L3 PE

Supply

W1
PE

3~
Motor

• Temporarily remove the upper high voltage shield (clear plastic) to gain access to the
power connections in the extension module.
• To avoid metal shavings inside the cabinet, temporarily remove the gland/conduit plate
at the top of the extension module. Then drill holes and mount conduit or cable fittings as
needed.
• Route all power and control wiring through the top of the extension module.

INSTALLATION (Frames R7-R8)
• The following diagram shows the power and control connection points in the enclosure
module supplied with the R7 drive module.

INSTALLATION (Frames R7-R8)
• The following diagram shows the power and control connection points in the enclosure
module supplied with the R8 drive module.

• Re-mount the high voltage shield.
WARNING! Always replace all high voltage shields before applying power.
• See the AQUAVAR User’s Manual for detailed instructions on control connections,
installation check list and drive start-up process.

INSTALLATION (Frames R7-R8)
Maintenance
This section describes the procedure for separating the drive and extension modules, which is
required to provide service access to the drive module.
Safety
WARNING! Read “Safety” on the first pages of this manual before performing any
maintenance on the equipment. Ignoring the safety instructions can cause injury or
death. Note: There are parts carrying dangerous voltages near the OMIO board when the
drive is powered.
Separating the Drive and Extension Modules
The drive module is mounted on a trolley that straddles a pedestal. The following procedure
removes mechanical connections so that the drive module and trolley can roll forward for
service access.
1. Disconnect all power sources from the drive/extension modules
and wait at least 5 minutes for internal capacitors to fully
discharge.

2. Remove all front covers from the drive module.
3. Disconnect the control panel cable.
4. Remove the upper side plate from the drive module if convenient.
5. Remove screws (if any) that fasten the drive module to the wall.
6. Inside the pedestal, toward the rear are screws that attach the
drive bus bars to the pedestal bus bars. The connections are
staggered for easy access using a wrench with an extension.
Remove these screws (6).
Torque when re-assembling:
• R7: M8 (5/16 in) screws, 15…22 Nm (11…16 lb ft)
• R8: M10 (3/8 in) screws, 30…44 Nm (22…32 lb ft)

WARNING! Be careful not to drop screws inside the pedestal.
Loose metal pieces inside the unit may cause damage.
R7
7. The following cables between the drive and the extension
module are split by a connector located at the front of the drive.
Disconnect both cables at this location.
• The power supply cable to the OMIO board.
• The power supply cable to the extensionmodule cooling fan.

8. At the OTIF board, disconnect the two fiber optic cables. Make
note of the terminal colors for use when reconnecting.

8
9

9. Carefully remove the cables disconnected in the above steps: Pull
the cables down inside the pedestal and bundle them so that they
will not get damaged or caught in the trolley when the drive module is wheeled out.
39

INSTALLATION (Frames R7-R8)
10. Remove screws fastening the drive module trolley to the
pedestal.

WARNING! These screws are an important step during reassembly – the screws are required for grounding the drive.
11. R8: The front of the trolley includes support braces that fold
out. Lift each brace slightly and fold it out.
12. Remove screws that fasten the drive module to the extension
module.
CAUTION! The drive module is now separated and could
tip over. Use care when moving the drive module.
13. Pull on the handle to wheel the drive module out.
Drive Maintenance
See the AQUAVAR User’s Manual for drive maintenance
procedures, page 34.
Re-Assembly
Re-attach the modules in reverse order to the above.

13
10
10

Pedestal
Trolley

INSTALLATION (Frames R7-R8)
Technical Data
Dimensional Drawings
See the AQUAVAR User’s Manual for drive module dimensions.
Extension Module R7

200
[7.87]

0
[.00]

161.4
[6.35]

361.4
[14.23]

Dimensions are listed in millimeters and [inches].

598.9
[23.58]
523
[20.59]

294
[11.57]

323
[12.72]

29
[1.14]
0
[.00]
BOTTOM PLATE HOLE Ø14 (6 pcs)

[.55]

81
[3.19]

Ø12

81
[3.19]

520
[20]
381
[15.00]

29.55
[1.16]

33
[1.30]

286
[11.26]

A
LIFTING LUG (4 pcs)

(2 pcs.)

1501
[59.1]
1459
[57.44]

[.47]

352
[13.86]
190
[7.48]

DET. B

SEE SHEET 2

DET. A

SEE SHEET 2
465.5
[18]

MAIN
SWITCH

2.5
[.10]

12
[.47]

26.5
[1.04]

298.5
[11.75]

17
[.67]
45
[1.77]

734
[28.90]

193.7
[7.63]

27
[1.06]

A-A

C-C

425.1
[16.74]
598.4
[23.56]

3AFE 64626264 30.04.02

INSTALLATION (Frames R7-R8)
Detail R7
Dimensions are listed in millimeters and [inches].

520
[20.47]
0
[0.00]

133.9
[5.27]

0
[0.00]

U2, V2
V2
R–, R+

52.1
[2.05]

223.3
[9.15]
278.3
[10.96]

201.5
[7.93]

0
[0.00]

132.5
[3.22]
125.3
[4.93]
102.5
[4.04]

155.5
[6.12]

78.8
[3.10]
24.8
[4.91]

<425.9 >
[16.77]

0
[0.00]

133.9
[5.27]

109.8
[4.32]

159.8
[6.29]

239.8
[10.23]

309.8
[12.19]

PE HOLE Ø2 (4 pcs.)
[.47]

R–

488
[19.21]

493.4
[19.43]

R+

540.5
[21.28]

578
[22.76]

DET.B
2.5

250.5
[9.86]
256.8
[10.11]
285.5
[11.24]
300.5
[11.83]

186
[7.32]

151
[5.94]

2.5

87.5
[3.44]

DET.A

52.3
[2.07]

321.7
[12.67]

0
[0.00]

Ø12 .5 (12 pcs.)
[.49]

11.1 (2 pcs.)
[0.43]

INSTALLATION (Frames R7-R8)
Extension Module R8
Dimensions are listed in millimeters and [inches].

260
[10.24]

152.3
[6.00]

35.5
[1.40]

700
[27.56]

BOTTOM PLATE HOLE Ø14
[.55]

446
[17.56]
260
[10.24]

491.4
[19.35]

21.2
[0.83]

26
[1.02]

393.9
[15.51]

1882.5
[74.11]

2018
[79.45]

93
[3.66]

617
[24.3]

611.8
[24.09]

272.2
[10.72]

946.7
[37.27]

563.1
[22.2]

17
[0.67]

392.5
[15.45]

46
[7.81]

2.5
[0.10]

12
[0.47]

B
554.5
[21.83]
787
[30.98]

3AFE 64626388 30.04.02

44
372
[14.65]

327
[12.87]

222.5
[8.76]

177.5
[6.99]

117
[4.61]

72
[2.83]

Ø14 (6 pcs.)
[.55]

0
[0.00]

382.5
[15.06]

280.5
[11.04]

208.5
[8.21]

136.5
[5.37]

82
[3.23]

128
[5.04]

174
[6.85]

873.8
[34.40]

0
[0.00]

110.8
[4.36]

160.8
[6.33]

210.8
[8.30]

310.8
[12.24]

360.8
[14.20]

410.8
[16.17]

PE HOLE Ø11 (6 pcs.)
[.43]

0
[0.00]

47.5
[1.87]

115.5
[4.55]

379.3
[14.93]

INSTALLATION (Frames R7-R8)

Detail R8
Dimensions are listed in millimeters and [inches].

617
[24.3]

0
[0.00]

222.3
[8.75]

59.2
[2.33]

730.9
[28.77]

Ø14 (6 pcs.)
[.55]

Ø12.5 (2 pcs.)
[.49]

START-UP
Wizards
The “Wizard” configures the drive. This process sets parameters that define how the drive operates and communicates. Depending on the control and communication requirements, the
start-up process may require any or all of the following:
• The Start-up Wizard steps you through the default configuration. The Start-up Wizard can
be activated at the first power up, or can be accessed at any time using the main menu.
• Application macros can be selected to define common, alternate system configurations, using the default settings. See “Single or Multipump Setup/Programming” on page 73.
• Additional refinements can be made using the control panel to manually select and set
individual parameters. See “Complete Parameter Descriptions” on page 50.

Assistant Control Panel (Display)
Features
The AQUAVAR CPC Control Panel features:
• Alphanumeric control panel with a LCD display
• Language selection for the display
• Drive connection that can be made or detached at any time
• Start-Up Wizard to ease drive commissioning
• Copy function – Parameters can be copied to the Control Panel memory for later transfer to
other drives or for backup of a particular system.
• Context sensitive help
Control Panel (Keypad)
The following table summarizes the button functions and displays on the Control Panel.
LCD Display – Divided into three main areas:
• Top line – variable, depending on the mode of operation.
For example, see “Status Information”
• Middle area – variable, in general, shows parameter values, menus or
lists.
• Bottom line – shows current function of the two soft keys and the clock
display, if enabled.

Soft key 1 – Function varies and is
defined by the text in the lower-left
corner of the LCD display.
Up Arrow
• Scrolls up through a menu or list
displayed in the middle of the LCD
Display.

Soft key 2 – Function varies and is
defined by the text in the lower-right
corner of the LCD display.
REM

40.2 PSI sp
0.0 PSI ac
0.0 HZ

DIR

12:45

50%

Down Arrow

• Decrements a value if a parameter
is selected.

• Increments a value if a parameter
is selected.
• Increments the reference if the
upper-right corner is highlighted
(in reverse video).

• Scrolls down through a menu or list
displayed in the middle of the LCD
Display.

• Decrements the reference if the
upper-right corner is highlighted
(in reverse video).

LOC
REM

Help – Displays context sensitive
information when the button is pressed.
The information displayed describes the
item currently highlighted in the middle
area of the display.

LOC/REM – Changes between local
and remote control of the AQUAVAR.
STOP – Stops the drive.
START – Starts the drive.

START-UP
Output mode
Use the output mode to read information on the drive’s status and to operate the drive. To
reach the Output Mode, press EXIT until the LCD display shows status information as described below.
Status Information
Top – The top line of the LCD display shows the basic status information of the drive.
• LOC – indicates that the drive control is local, that is, from the control panel.
• REM – indicates that the drive control is remote, which is required to operate the pump
and automatically control pressure. This mode is also used for fieldbus control. (e.g. Transducer or PLC control)
• – indicates the drive status as follows:

Control Panel Display
Rotating arrow blinking

Significance
Drive is running

Stationary arrow

Drive is stopped

• Upper right (50%) – shows the percentage of full scale the transducer is operating.
Middle – The middle of the LCD display will display:
• For Single Pump
– Reference or set point. “Pressure SP”
– Actual set point. “Pressure AC”
– Frequency in HZ.

REM

DIR

40.2 PSI sp
0.0 PSI ac
0.0 HZ
12:45

50%

NOTE! The AQUAVAR display will show (set pressure), (actual pressure) and Frequency
(Hz), in single pump mode.
Bottom – The bottom of the LCD display shows:
• Lower corners – show the functions currently assigned to the two soft keys.
• Lower middle (12:45) – displays the current time (if configured to show the time).
Operating the Drive
LOC/REM – The very first time the drive is powered up, it is in the remote control (REM) mode,
and is controlled from the Transducer and Control Panel.
To switch to local control (LOC) and control the drive using the Control Panel, press and hold
the
button. The drive must be stopped!
• The Remote (REM) Mode uses the transducer and set point to control the speed output to
the pump.
• The Local (LOC) Mode uses the control panel for manual control of the drive output. Speed
up or down.
LOC
REM

To switch back to remote control (REM) press and hold the
button until REMOTE CONTROL is displayed.
Start/Stop – To start and stop the drive press the START or STOP buttons.
LOC
REM

START-UP
Other Modes
Besides the Output Mode, the Control Panel has:
• Other operating modes that are available through the main menu.
• A fault mode that is triggered by faults. The fault mode includes a diagnostic assistant
mode.
REM
MAIN MENU
1
Access to Main Menu Modes
PARAMETERS
To reach the main menu:
1. Press EXIT, as necessary, to step back through the menus or WIZARDS
CHANGED PAR
lists associated with a particular mode. Continue until you
EXIT
ENTER
are back to the Output Mode.
2. Press MENU from the Output Mode. At this point, the middle of the display is a listing of
the other modes, and the top-right text says “Main Menu”.
3. Press UP/DOWN to scroll to the desired mode.
4. Press ENTER to enter the mode that is highlighted. The following sections describe each
of the other modes.

Parameters Mode
Use the Parameters Mode to view and edit parameter values:
1. Select PARAMETERS in the main menu.

REM

MAIN MENU

PARAMETERS
WIZARDS
CHANGED PAR
EXIT

2. Press UP/DOWN to highlight the appropriate parameter
group, then press SEL.

REM

ENTER

PAR GROUPS

99 START-UP DATA
01 OPERATING DATA
04 FAULT HISTORY
10 START/STOP/DIR
11 REFERENCE SELECT
EXIT

3. Press UP/DOWN to highlight the appropriate parameter
in a group.

REM

SEL

PARAMETERS

1101 LANGUAGE
1102 APPLIC MACRO
SINGLE PUMP
NOTE! The current parameter value appears below the high- 1104 MOTOR NOM VOLT
1105 MOTOR NOM CURR
lighted parameter.
EXIT

EDIT

4. Press EDIT.
5. Press UP/DOWN to step to the desired parameter value.
NOTE! To view the parameter default value: In the set mode, press UP/DOWN
simultaneously.
• Press SAVE to store the modified value or press CANCEL
to leave the set mode. Any modifications not saved are
cancelled.
• Press EXIT to return to the listing of parameter groups
and again to return to the main menu.

LOC

PAR EDIT

1102 EXT1/EXT2 SEL

EXT1

CANCEL

SAVE
47

START-UP
Wizard Mode
When the drive is first powered up, the Start-Up Wizard guides you through the setup of a few
basic parameters. For example, at the first start, the drive automatically suggests entering the
first task, password.
The Start-Up Wizard is divided into tasks. You may activate the tasks one after the other, as the
Start-Up Wizard suggests, or independently. (You are not required to use the assistant, you
may use instead, the parameter mode to set the drive parameters.)
The order of the tasks presented by the Start-Up Wizard depends on your entries. The task list
in the following table (next page) is typical.

Start-Up Wizard
The start-up wizard is a tool that can be used to quickly program an Aquavar with the most
commonly used single / mult-pump parameters. The wizard will prompt the programmer to
enter the required parameters by automatically bringing them to the screen. To enable the
wizard following the steps below:
1. In the main screen select MENU. Then press enter.
2. Press the up / down arrow to select WIZARDS, then press SELECT.
3. Enter the values for the parameters as seen in the table below, and follow each entry by
pressing the SAVE key.
4. When complete, press the EXIT key until the main screen is displayed again.
5. Set the required system pressure using the up and down arrows, then start the pump
using the green START key.

Task Name

Description

10.02 Pass Code
Pass word setting to open the parameter lock.
10.01 Parameter Lock
Enables or disables the parameters from being changed.
11.01 Language
Selects the display language.
11.04 Motor Nom Voltage
Defines the motor nameplate voltage.
11.05 Motor Nom Current
Defines the motor nameplate current.
11.06 Motor Frequency
Defines the motor nameplate frequency.
11.08 Nominal Motor Power Defines the motor nominal power.
15.06 Sensor Min
Adjusts the transducer to a zero reference point.

Changed Parameters Mode
Use the Changed Parameters Mode to view (and edit) a listing of all parameters that have
been changed from default values.
Procedure:
1. Select CHANGED PAR in the Main Menu. The display lists all changed parameters.
2. Press ENTER.
3. Press UP/DOWN to select a changed parameter. As each parameter is highlighted, the
parameter value appears.
4. Press EDIT to edit the parameter value.

START-UP
5. Press UP/DOWN to select a new value / edit the parameter value. (Pressing both keys at
the same time sets a parameter to its default value.)
6. Press SAVE to save the new parameter value. (If the new value is the default value, the parameter will no longer appear on the Changed Parameters listing.)
Par Backup Mode
The Control Panel can store a full set of drive parameters. If two sets of parameters are defined, both are copied and transferred when using this feature.
The Par Backup Mode has three functions:
• Upload to Panel – Copies all parameters from the drive to the Control Panel. The Control
Panel memory is nonvolatile and does not depend on the panel’s battery.
• Restore All (Download To Drive All) – Restores the full parameter set(s) from the Control
Panel to the drive. Use this option to restore a drive or to configure identical drives. Drive
must be in local mode.
NOTE! The Restore All function writes all parameters to the drive, including motor parameters. Only use this function to restore a drive or to transfer parameters to systems that are
identical to the original system.
• Download Application – Copies partial parameter set(s) from the Control Panel to a drive.
The partial set does not include internal motor parameters. Use this option to transfer parameters to systems that use similar configurations - the drive and motor sizes do not need
to be the same.
1. Select COPY in the Main Menu.
2. Press UP/DOWN to step to the desired option.
3. Press SAVE. The parameter set is transferred as directed. During the transfer, the
display shows the transfer status as a percent of completion.
4. Press EXIT to step back to the Output Mode.
Clock Set Mode
Use the Clock Set Mode to:
• Enable/disable the clock function.
• Set date and time.
• Select display format.
1. Select CLOCK SET in the Main Menu.
2. Press UP/DOWN to step to the desired option.
3. Press EDIT.
4. Press UP/DOWN to select the desired setting.
5. Press SAVE to save setting.

PARAMETER LISTINGS
Aquavar CPC Parameter List
The Aquavar CPC parameter list contains all of the necessary pump, drive, fault and control
parameters needed for programming this unit. Each group indicates a certain function and
control for the Aquavar, in order to set up single or multipump control.
To view the available parameter list, on your keypad, press the MENU button to access the
parameter list. The parameters are write protected with a password. Please contact your
Aquavar representative for more information on this password (located in GROUP 10 LOCKS/
PASSWORDS).
Group 01, VFD SIGNALS – (READ ONLY DATA) This set of parameters sets up the drive and
motor. These parameters can only be adjusted and changed when the motor has stopped.
Monitoring of motor output, and various analog and digital outputs.
Group 02, PUMP SIGNALS – (Data output only) Provides output set points, energy savings
and wire to water power.
Group 03, STATUS WORDS – Provides status of drive and alarm condition.
Group 10, LOCKS/PASSWORDS – Provides password and parameter save information.
Keypad and set point locks.
Group 11, START UP DATA – Provides parameters used for initial start up information (e.g
language, application, voltage, motor current, motor RPM, horsepower). Used for initial motor
setup.
Group 12, START/ STOP – Determines method(s) of starting and stopping the Aquavar. i.e.
Keypad, external switch, Modbus, manual, test run and motor jog.
Group 13, RAMPS & WINDOWS – Parameters used for the acceleration and deceleration
of the pump. Window and Hysterisis contains modulation of algorithm (pressure control
regulation).
Group 14, SPD LIM/START LVL – Parameters that contain speed control, max and min
frequency, restart value, priming delay.
Group 15, TRANSDUCER VAR – Parameters used for the setup and tuning of the pressure
transducer, flow meter and adjustment of transducer range.
Group 16, REFERENCE SELECT – Parameters that control how the set point is maintained. i.e.
Modbus, keypad, analog input (transducer).
Group 18, RELAY OUTPUTS – Parameters that define how the Aquavar output relays are
controlled and what delay time is actuated for each relay. Three total relays can be used (RO1,
RO2, RO3).
50

PARAMETER LISTINGS
Aquavar CPC Parameter List (continued)
Group 19, ANALOG OUTPUTS – Defines the analog outputs available on the drive. Two
possible analog outputs that can be used to monitor various parameters (AO1, AO2).
Group 21, REGULATE – Defines type of control regulation with analog input from transducer.
Normal, Inverse modes. Friction loss compensation.
Group 22, MULTIPUMP CONTROL – Defines parameters for multi-pump control algorithm.
Addresses each drive. Required group for alternating each pump.
Group 24, FAULT FUNCTIONS – Defines parameters for faults, pump protection and run
enable mode (e.g. keypad failure, pump protect, low water, error reset).
Group 25, AUTOMATIC RESET – This group defines conditions for automatic reset. An
automatic reset occurs after a particular fault is detected. The Aquavar holds for a delay time,
then automatically restarts. You can limit the number of restarts in a specific period of time for
a variety of faults (e.g. overcurrent, over/ under voltage).
Group 26, ENERGY SAVINGS – Defines parameters used for energy savings, and kW/hr
usage.
Group 27, CRITICAL SPEEDS – This group defines up to three critical speeds or resonant
frequencies. This mechanical resonance may occur on certain loads at certain frequencies.
Group 30, OPTION MODULES – Defines parameters used for fieldbus communication
networks and optional fieldbus adapter.
Group 31, FIELD BUS SETUP – Parameters used for actual set up for the field bus
communication via the RS485 terminals.
Group 32, MODBUS SETUP – Defines parameters used for the Modbus setup and protocol,
baud rate, parity, status functions.
Group 50, MOTOR CONTROL – Provides adjustment of the switching frequency for the drive.
Group 51, MAINTENANCE TRIGGERS – Defines the parameters for trigger points on the
cooling fan, motor revolutions, run time, used power in Megawatts. Provides actual time run
on each component.
Group 99, INFORMATION – Provides firmware version, drive rating for the Aquavar.

PARAMETER LISTINGS
Defaults
Group VFD Signals
Range
Description
01➀
0101 Motor
0.0...500.0 Hz

Frequency

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Calculated VFD output
frequency, Hz

0102 Motor Current 0...2.0*I2hd
Measured Motor Current, A
0103 Motor Power
-2...2*Phd
Motor Power, kW
0104 DC Bus Voltage 0…2.5*Vdn
Measured intermediate circuit

voltage, V
0105 Motor Voltage 0…2.0*Vdn
Calculated motor voltage, V
0106 Drive Temp
0…150º C
VFD Temp, Deg C
0107 VFD On Time
0…9999h
Elapsed time counter; runs

when the drive is powered, Hrs

(since last reset). Re-settable by

parameter 2605.
0108 Run Time
0…9999h
Motor run time counter, Hrs

(since last reset). The counter

runs when the inverter

modulates. Re-settable by

parameter 2605.
0109 KWh Counter
0…9999kWh kWh counter, kWh (since last

reset). Re-settable by parameter

2605.
0110 DI6-1 Status
000000…
Status of digital inputs.

111111
Example: 0000001=DI1 is on,

DI2-DI6 off
0111 AI1
0…100 %
Value of analog input 1, %
0112 AI2 Trnsdcr Fdbk 0…100 %
Value of analog input 2, %
0113 RO3-1 Status
000…111
Status of relay outputs.

Example: 001=RO1 is energized,

RO2 & RO3 are de-energized.
0114 AO1[mA]
0…20 mA
Value of analog output 1, mA
0115 AO2[mA]
0…20 mA
Value of analog output 2, mA
0116 Last Fault
Fault Codes
Last fault code of the drive.
0117 Previous Fault 1 Fault Codes
Previous fault code of the drive.
0118 Previous Fault 2 Fault Codes
Oldest fault code of the drive.
0119 Fault Time 1
0120 Fault Time 2
0121 Speed at Flt
- RPM
Speed at the time of the latest

fault.
0122 Freq at Flt
- Hz
Frequency at the time of the

latest fault.
0123 Voltage at Flt
- V
DC bus voltage at the time of

the latest fault.
➀ NOTE: Group 01 is read-only. Used for monitoring.

PARAMETER LISTINGS
Defaults
Group VFD Signals
Range
Description
01
0124 Current at Flt
- A

0125 Status at Flt
-

0126 DI 6-1 At Fault 000…111

0127 Drive On Time Hi - Days
0128 Drive On Time Lo - Hrs : Min : Sec

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Motor current at the time of
the latest fault.
The drive status word at the
time of the latest fault.
The drive digital input status at
the time of the latest fault.
Drive “on - time in days.
Drive “on - time in hrs/min/secs.

Group Pump Signals
Range
Description
02

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

0201 Set Point
0…max scale Controller set point; unit

determined by parameter 1501.
0202 Actual
0…max scale Actual feedback; unit

determined by parameter 1501.
0203 Pump Speed
0 – 60 Hz
Actual frequency of motor, Hz.
0204 Wire to Water
0…? Hp
Overall hp includes pump,

Power
motor and VFD.
0205 Set Point #1
0…max scale Set Point (reference) #1; unit

determined by parameter 1501.
0206 Set Point #2
0…max scale Set Point (reference) #2; unit

determined by parameter 1501.
0207 Energy Savings 0…65353 USD Calculated AV savings (option 1

or 2) since last reset. Savings are

compared to conventional

system ($). Re-settable by

parameter 26.05.
0208 Pump Number Stopped, Pump Actual pump number in multi
1…Pump 4
pump control mode.
0209 Used Set Point 0…max scale Same value as in 0205 or 0206,

depending on which is in use.
Group Status Words
Range
Description
03

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

0301 FB CMD Word 1
0302 FB CMD Word 2
0303 FB STS Word 1

—
—
—

Low word of drive’s control word
High word of drive’s control word
Low word of drive’s status word

0304
0305
0306
0307
0308
0309

—
—
—
—
—
—

High word of drive’s status word
Fault word 1 of the drive
Fault word 2 of the drive
Fault word 3 of the drive
Alarm word 1 of the drive
Alarm word 2 of the drive

FB STS Word 2
Fault Word 1
Fault Word 2
Fault Word 3
Alarm Word 1
Alarm Word 2

PARAMETER LISTINGS
Defaults
Group Status Words
Range
Description
03
0310
0311
0312
0313
0314
Group
10

AV Alarm Word
AV Fault Word
Comm RO Word
Comm Value 1
Comm Value 2

—
Aquavar Alarm word
—
Aquavar Fault word
—
—
—

Locks/
Range Description
Passwords

1001 Parameter Lock

Open

Locked

(Default)

1002 Pass Code
0…300000

1003 Local Lock

Off (Default)

On
1004 Parameter Save

Done (Default)

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Selects the state of the parameter Locked Locked Locked Locked Locked
lock. The lock prevents
parameters from being changed.
The lock is open. Parameter
values can be changed.
Parameter values cannot be
changed from the keypad. The
lock can be opened by entering
the valid password in parameter
10.02. When the keypad is
locked the AV keypad functionality is limited to starting,
stopping and changing the
reference (set point).
Password setting 66 opens the
0 0 0 0 0
lock and returns the value to
zero on the display. The password relocks when power is
disconnected. To relock the
keypad reset parameter 1001
to “Locked”.
Disables local control on the
Off Off Off Off Off
keypad. WARNING! Before
activating, ensure that the
control panel is not needed for
stopping the drive.
Local control allowed.
Local control disabled.
Saves the parameter values to Done Done Done Done Done
the permanent memory.
Parameters entered via the
keypad are automatically saved.
Parameters are not automatically
saved when altered through the
fieldbus connection.

PARAMETER LISTINGS
Defaults
Group
10

Locks/ Range Description
Passwords

1004 Parameter Save Save

(continued)

1005 New Pass Code 0…300000

1006 Set Point Lock

Off (Default)

On
Group
11

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Used for manually saving
Done
Done Done Done Done
parameters that have been
altered through the fieldbus
connection.
Sets new pass code for
0
0
0
0
0
parameter lock. Returns to 0
after saving.
Disables set point changes
Off
Off
Off
Off
Off
from the keypad.
Local control allowed.
Local control allowed.

Start-Up
Range Description
Data

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

1101 Language
Selects the display language English English English English

English (AM) American English.

(Default)

Español
Spanish (full translation)

Francais
French (full translation)
1102 Application
Selects the application macro
✔
✔
✔
✔
Macro

Single Pump One AV regulating to a set point

(Default)

Synchronous Lag pumps start as needed and

all pumps regulate to the set

point at the same speed. Note:

it is recommended that all

pumps be identical.

Multicontrol
Lag pumps start as needed. The

last lag pump to start regulates

to the set point; the remaining

pumps operate at an enable

sequence speed (2203).

Constant Slave The master unit starts up to

three fixed speed slave units

when needed. See RO1, RO2

and RO3 settings (parameters

1801, 1804 and 1807).

Speed Control AV follows a speed reference

only. Pump protect fault

function is inactive.
1103 Application
No
Resets parameters to default

Restore
Yes
settings.

English

✔

PARAMETER LISTINGS
Defaults
Group
11

Start-Up Range
Description
Data

1104 Motor Nom
11…345V/

Voltage
230…690V

1105 Motor Nom
0.2*I2hd…

Current
2.0*I2hd

1106 Motor Nom Freq 10.0…500Hz

1107 Motor Nom RPM 50…18000

RPM

1108 Motor Nominal 0.2…2.0*Phd

Power

Defines the motor voltage.
230/ 230/ 230/ 230/ 230/
Equal to the value on the
460/ 460/
460/
460/
460/
motor nameplate.
575 575 575 575 575
Defines the motor current.
1.0* 1.0* 1.0* 1.0* 1.0*
Equal to the value on the
I2hd
I2hd
I2hd
I2hd
I2hd
motor nameplate.
Defines the motor nominal
60 60 60 60 60
frequency. Equal to the value
on the motor nameplate.
Defines the motor nominal
3550 3550 3550 3550 3550
speed. Equal to the value on
the motor nameplate.
Defines the motor power (hp). 1.0*Phd 1.0*Phd 1.0*Phd 1.0*Phd 1.0*Phd
Equal to the value on the
nameplate.

Group Start/Stop Range
Description
12
1201 Start/Stop

Keypad

Fieldbus
1202 Auto Restart

Off

1203 Test Run

Not Sel (default)

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Keypad Keypad Keypad Keypad Keypad
Defines the connections and
source of the start/stop
commands.
Comment - DI1= Enable. 0= Disable,
1 = Enable. DI2 = Low Water. 0 = Fault,
1 = OK, DI3 = Estop 0 = Estop, 1 = OK,
After Estop restart from keypad required.
Start/Stop from keypad. After a
fault reset, the drive will restart
only if auto restart (1202) is set
to on. If auto restart is off the
drive must be started from the
keypad.
Start via fieldbus control word
Selects whether the AV will
On On On On On
automatically restart after a
power failure or fault reset.
Not selected
Selected. The AV will automatically restart if conditions permit.
Selects when the drive will
Not Sel Not Sel Not Sel Not Sel Not Sel
perform a test run
Not selected

PARAMETER LISTINGS
Defaults
Group Start/Stop Range
Description
12
1203 Test Run
Automatic

(continued)

Manual

1204 Test Speed % (FL) 0...100%

1205 Test Run Delay
0...3600 Hr

1206 Motor Jog

1209 Manual
Disabled

Override
(Default)

1210 Override
0-60 Hz

Freq
Group
13

Group
14

If selected and the drive has not
run for the test delay (1205) the
drive will start and run at 50%
of maximum speed (1401) for
20 seconds and shutdown.
Auto Restart 1202 must be on.
Once manual is selected the
Not Sel Not Sel Not Sel Not Sel Not Sel
drive will start and run at test
speed (1204) for 20 seconds
and shutdown. Once the
manual test is complete this
parameter will return to
“Not Sel”.
25% 25% 25% 25% 25%
Selects the speed the test runs
at in manual test mode (1203).
Selects how long after the drive 1000 1000 1000 1000 1000
is idle before it will do a test run.
Jogs motor for 10 sec @ 60 RPM Disabled Disabled Disabled Disabled Disabled
to check for motor rotation.
Drive will run at constant speed
as set in Parameter 1210 when
enabled and contact DI5 is active.
Sets motor speed when manual
override is active.

Ramps/
Range Description
Windows

1301 Ramp 1 Fast Accel 0…1800 sec
1302 Ramp 2 Fast Decel 0…1800 sec
1303 Ramp 3 Slow Accel 0…1800 sec
1304 Ramp 4 Slow Decel 0…1800 sec
1305 Ramp Hysteresis 0…100 %

1306 Reg Window
0…100 %

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Defines the fast acceleration time.
5
Defines the fast deceleration time.
5
Defines the slow acceleration time.
60
Defines the slow deceleration time.
60
Per cent of window set aside
80
for hysteresis error.
Window around the set point
which the control algorithm
8
operates.

Spd Lim/
Range Description
Strt Lvl

1401 Maximum
Minimum

Frequency/Speed Frequency…

60 Hz

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Defines the allowable maxi-
mum speed. Default setting
is parameter 1106 Motor Nom
Freq. (May want to show RPM
or HZ.)

5
5
60
60
80

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control
60

PARAMETER LISTINGS
Defaults
Group
14

Spd Lim/ Range
Description
Strt/Lvl

1402 Minimum
0…Max

Frequency/Speed Frequency

1403 Config Speed

Min

0 (Default)

Min Freq

1404 Stp Delay
0…1800 s

Min Spd

1405 Restart Value
0…150 %

1406 Restart Delay
0…1800 s

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Defines the minimum speed
6
6
6
6
range. Default setting is 10% of
parameter 1106 Motor Nom
Freq. (May want to show RPM
or HZ.)
Defines the reaction of the drive 0
0
0
0
when the AV tries to regulate at
a speed at or below minimum
frequency (1402).
The drive will stay at Minimum
Frequency until Stp Delay Min
Spd (1404) times out; the unit
will then shutdown.
The AV will stay at this speed
until the transient clears or unit
is manually shutdown; unless a
fault occurs.
The time period the drive will
0
0
0
0
stay at MinSpd (1402) before
stopping. Functions when 1403
is set to 0. Becomes active if set
point would result in regulation
below min spd, closed valve
condition in pressure control
and Secondary Protect A&B.
If the drive is shutdown by
0 0 0 0
Config speed min (1403) due to
no system demand (pressure
control and level control only)
the drive will sleep until the
process actual value drops
below a set restart value (1405)
for longer than the restart delay
(1406). If operating in inverse
mode (2101) the drive will sleep
until the process variable rises
above the restart value. Wakeup level in % of set point value.
To disable the Restart Value
function in both normal and
inverse settings enter “0%”.
Auto Restart (parameter 1202)
does not influence the restart
function. Default = 0.
Time delay for restart value
0
0
0
0
(1405).(Default = 0 sec)

PARAMETER LISTINGS
Defaults
Group
14

Spd Lim/ Range
Description
Strt/Lvl

1407 Priming Delay
0…6000 s

Group
15

When the drive is starting from
0 RPM this parameter delays
pump protection faults (2404
and 2407) for the setting time.
The default setting is “0”. Once
the priming delay time is
complete the protection delay
(parameter 2406) becomes
functional. During the priming
delay the pump runs at the
maximum speed setting
(parameter 1401) since it
cannot achieve the set point.

Transducer
Range Description
Var

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control
0

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

1501 Transducer Unit
Selects the units (default is
Psig
Psig
Psig
Psig

pressure) for the primary process

transmitter feedback located at

AI2. In speed control macro

default unit is RPM.

GPM

Psig (Default)

F Deg

C Deg
1502 Transducer Max 0…6553.5
For single pump and multipump
300
300
300
300

macros this parameter defines

the full-scale feedback (20 mA

setting) of the primary process

transmitter at AI2. This parameter

also correlates to the maximum

value of Reference (set points) 1

and 2. For the Speed Control

macro this parameter scales the

maximum (20 mA or keypad )

speed setting. Note when units

are in Ft, M, In or Cm: AI2 Max

is always based on a specific

gravity = 1 regardless of setting

for parameter 1506. Actual

pressure signals in Ft, M, In or

Cm are corrected for specific

gravity by the firmware. Signal

can be quadratic or linear.

Psig

PARAMETER LISTINGS
Defaults
Group
15

Transducer Range
Description
Var

1503 Transducer Min 0…6553.5

1506 Sensor Min

(Not in Software)

4 mA (Default)

Tuned Value

Tune

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

For single pump and multipump
0
0
0
0
macros this parameter defines
the value (normally zero) of the
4 mA setting for the primary
process transmitter at AI2. This
parameter also correlates to the
minimum value of Reference
(set points) 1 and 2. For the
Speed Control macro this
parameter scales the value
(normally zero) of the 4 mA or
keypad speed setting. Note
when units are in Ft, M, In or
Cm: AI2 Min is always based on
a specific gravity = 1 regardless
of setting for parameter 1506.
Actual pressure signals in Ft, M,
In or Cm are corrected for
specific gravity by the firmware.
Signal can be quadratic or linear.
Defines the value for analog
4 mA 4 mA
4 mA
4 mA
sensor input.
4 mA is selected as the
minimum value.
Select tuned value after the tune
function has been completed.
This will select the tuned value
for the minimum value of
sensor input.
This parameter sets the minimum value of the signal to be
applied to sensor input. When
tune is selected and enter is
pressed the tuned value for
sensor input is set to the actual
sensor input value when the
tune function was activated.
This function is useful for zeroing
out any system hysteresis.

4 mA

PARAMETER LISTINGS
Defaults
Group
16

Reference Range
Description
Select

1601 SP1/SP2 Select

Reference 1

(Default)

DI4

Fieldbus

1602 Set Point 1 Select

Keypad

(Default)

Analog Input

Speed Control

Fieldbus

1603 Set Point 2 Select

Keypad

(Default)

AI 1

Fieldbus

1604 AI 1 Minimum

0-10 VDC

4 – 20 mA

(Default)

Tuned Value

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Defines the source from which Ref 1 Ref 1
Ref 1
Ref 1
Ref 1
the drive reads the signal that
selects the setpoint.
Reference 1 (set point 1) is
being used only.
Digital Input 4 selects set point 1
or set point 2. 0pen = Set Point
1, Closed = Set Point 2.
The set point is sent via Fieldbus
control word.
Selects the signal source for
Keypad Keypad Keypad Keypad Keypad
Reference1 (set point #1).
The set point is selected from
the keypad.
The set point is selected by an
analog input (AI1).
The set point is selected via
Fieldbus control word.
Keypad Keypad Keypad Keypad Keypad
Selects the signal source for
Reference1 (set point #2).
The set point is selected from
the keypad.
The set point is selected by an
analog input (AI1).
The set point is selected via
Fieldbus control word.
Defines the minimum value for 4-20 4-20 4-20 4-20 4-20
analog input AI1.
mA mA mA mA mA
A 0VDC signal will activate a
Sensor Failure fault function
unless 24.01 and 24.02 are
disabled.
4 mA is selected as the
minimum value.
Select tuned value after the tune
function has been completed.
This will select the tuned value
for the minimum value of AI1.

PARAMETER LISTINGS
Defaults
Group
16

Reference Range
Description
Select

1604 AI 1 Minimum
Tune

(continued)

Group
18

This parameter sets the minimum 4-20
4-20
4-20
4-20
value of the signal to be applied mA
mA
mA
mA
to AI1. When tune is selected
and enter is pressed the tuned
value for AI1 is set to the actual
AI1 value when the tune
function was activated. This
function is useful for zeroing
out any system hysteresis.

Relay
Range Description
Outputs

1801 Relay RO1

Output

Not Sel

Run

Ready (Default)

VFD Fault

Low Water

Pump Protect

Start Slave

Stand by

1802 RO1 ON Delay 0...3600 s

1803 RO1 OFF Delay 0…3600 s

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control
4-20
mA

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Selects the AV status to be
Ready Ready Ready
Start
indicated through relay output 1
Slave
(RO1). The relay energizes when
the status meets the setting.
Relay warnings are reset
automatically, faults must be
manually reset.
The output is not used
The output indicates the drive is
running.
The output indicates that power
is supplied to the drive and it is
awaiting a start command.
The drive has faulted
The secondary protection
warning or fault function has
been activated. DI4 is low for
the protection delay setting
(2404). Closed = normal,
Open = Secondary Protect fault
function is active.
The pump protection warning or
fault function has been activated.
Used in multipump macro to
start slave pump only.
Drive is in sleep mode due to no
system demand.
Defines the operation delay for
0
0
0
0
relay output RO1.
Defines the release delay for
0
0
0
0
relay output RO1.

Ready

0
0

PARAMETER LISTINGS
Defaults
Group
18

Relay Range Description
Outputs

1804 Relay RO2

Output

Not Sel

Run (Default)

VFD Fault

Low Water

Pump Protect

Start Slave

Stand by

1805 RO2 ON Delay 0…3600 s

1806 RO2 OFF Delay 0…3600 s

1807 Relay RO3

Output

Not Sel (default)

Run

Ready

VFD Fault

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Selects the AV status to be
Run-
Run-
Run-
Start
Runindicated through relay output 2 ning
ning
ning
Slave
ning
(RO2). The relay energizes when
the status meets the setting.
Relay warnings are reset
automatically, faults must be
manually reset.
The output is not used
The output indicates the drive
is running.
The drive has faulted
The secondary protection
warning or fault function has
been activated. DI4 is low for
the protection delay setting
(2404). Closed = normal,
Open = Secondary Protect fault
function is active.
The pump protection warning or
fault function has been activated.
Used in multipump macro to
start slave pump only.
Drive is in sleep mode due to
no system demand.
Defines the operation delay for
0
0
0
0
0
relay output RO2.
Defines the release delay for
0
0
0
0
0
relay output RO2.
Selects the AV status to be
Not
Not
Not
Not
Not
indicated through relay output 3 Used Used
Used
Used
Used
(RO3). The relay energizes when
the status meets the setting.
Relay warnings are reset
automatically, faults must be
manually reset.
The output is not used
The output indicates the drive is
running.
The output indicates that power
is supplied to the drive and it is
awaiting a start command.
The drive has faulted

PARAMETER LISTINGS
Defaults
Group
18

Relay Range Description
Outputs

Low Water

Pump Protect

Start Slave

Stand by

1808 RO3 ON Delay 0…3600 s

1809 RO3 OFF Delay 0… 3600 s

Group
19

The secondary protection
warning or fault function has
been activated. DI4 is low for
the protection delay setting
(2404). Closed = normal,
Open = Secondary Protect fault
function is active.
The pump protection warning or
fault function has been activated.
Used in multipump macro to
start slave pump only.
Drive is in sleep mode due to
no system demand.
Defines the operation delay for
0
0
0
0
relay output RO3.
Defines the release delay for
0
0
0
0
relay output RO3.

Analog
Range Description
Outputs

1901 AO 1 Content Sel

Not Sel (default)

Frequency

Current

Torque

Power

Proc Var/

Actual

Energy Saving

1902 AO1 Content
Various

Min
1903 AO1 Content
Various

Max

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

0
0

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Connects a AV signal to analog Not
Not
Not
Not
output 1 (AO1).
Used Used
Used
Used
Not in use.
Output frequency. 20 mA =
motor nominal frequency (1106).
Output current. 20 mA =
motor nominal current (1105).
Motor torque. 20 mA = 100%
of motor nominal rating.
Motor Power. 20 mA = 100%
of motor power rating.
Actual value of process variable
AI2. 20 mA = Reference 1 Max
(1603).
Calculated energy savings
(option 1 or 2) over a conventional fixed speed system.
20 mA = Savings scale (2603).
Selects the minimum value of the
characterisitc being monitored.
Selects the maximum value of the 4
4
4
4
characteristic being monitored.

Not
Used

PARAMETER LISTINGS
Defaults
Group
19

Analog Range
Description
Outputs

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

1904 Minimum AO1 0.0…20.0 mA

1905 Maximum AO1 0.0…20.0 mA

1906 AO 2 Content Sel

Not Sel (default)

Frequency

Current

Torque

Power

Proc Var/

Actual

Energy Saving

Defines the minimum value of
0.1
0.1
0.1
0.1
AO1. Default = 4 mA.
Defines the maximum value of
20
20
20
20
AO1. Default = 20 mA.
Connects a AV signal to analog
Not
Not
Not
Not
output 2 (AO2).
Used Used
Used
Used
Not in use.
Output frequency. 20 mA =
motor nominal frequency (1106).
Output current. 20 mA =
motor nominal current (1105).
Motor torque. 20 mA = 100%
of motor nominal rating.
Motor Power. 20 mA = 100%
of motor power rating.
Actual value of process variable
AI2. 20 mA = Reference 1 Max
(1603).
Calculated energy savings
(option 1 or 2) over a conventional fixed speed system.
20 mA = Savings scale (2603).

1907 AO2 Content
Various

Min
1908 AO2 Content
Various

Max
1909 Minimum AO2 0.0…20.0 mA

1910 Maximum AO2 0.0…20.0 mA

Selects the minimum value of the
characterisitc being monitored.
Selects the maximum value of the
characteristic being monitored.
Defines the minimum value of
4
4
4
4
AO2. Default = 4 mA
Defines the maximum value of
20
20
20
20
AO2. Default = 20 mA

Group
Regulate Range
Description
21
2101 Regulation Mode

Normal

(Default)

Inverse

0.1
20
Not
Used

4
20

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Selects the type of AV control with Normal Normal Normal Normal Normal
falling process variable signal.
Increases the output speed with
falling process variable signal.
For level control applications the
tank is on the discharge side.
Decreases the output speed with
falling process variable signal.
For level control applications the
tank is on the suction side.

PARAMETER LISTINGS
Defaults
Group
Regulate Range
Description
21
2102 Press Incr Speed 0…60 Hz

2103 Press Incr
0….10000

Group
22

Multipump
Range Description
Control

2201 Value Decrease 0…1000

2202 Value Increase 0….1000

2203 Enable Sequence 0… 60 Hz

2204 Switch Lead Lag 1…100 h

Sets the speed for which
additional pressure is added to
compensate for system frictional
losses at increased flow. Used for
single pump and backup modes
only. Default = 20 Hz.
The pressure increase in selected
units point which is added to the
set point pressure to compensate
for frictional losses at the pressure
increase speed. Used for single
pump and backup modes only.
Note the full set point pressure
increase (%) is achieved at
maximum speed (1401).

Defines how much the actual
can drop before the next lag
pump is started. Used for
multicontrol, synchronous
control and slave modes only.
Defines the increase in set point
when a lag pump starts. This
value is cumulative with each
lag pump that turns on. Used
for multicontrol, synchronous
control and slave modes only.
The default setting for 2202 is
equal to the value set in 2201.
Defines the speed the drive
must be at before multipump
operation is allowed.. Applies to
synchronous, multicontrol and
slave modes only. Default =
98% of 1401 Maximum Speed.
Defines the time the lead unit
will run before a new unit is
deemed the lead unit. Note if
set to 1001 (Not SEL) the
switching function is disabled
(including switching during a
fault). Default setting is 48 hrs.

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control
20 20 20 20 20

0 0 0 0 0

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control
5

PARAMETER LISTINGS
Defaults
Group
22

Multipump Range
Description
Control

2205 Sync Limit
0…60 Hz

2206 Sync Window
0…60 Hz

2207 Pump Address 1…4

2208 Setp2 Source
OFF, 1…4

Group
24

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

Selects the speed at which lag
pump #1 (or slave #1 RO1)
should be turned off. Applies to
synchronous, multicontrol and
slave modes.
The speed step above the sync
limit (2206) used to turn off lag
pump #2 (or slave #2 RO2).
Twice the Sync Window is the
speed step at which lag pump
#3 (or slave #3 RO3) is turned
off. Used for synchronous and
slave modes only.
Defines the pump address for
1
multipump systems.
Defines which pump has the
Off
analog input connected for
second set point.

Fault
Range Description
Functions

Off

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

2401 Keypad Failure
Selects how the AV will react to

a keypad communication break.

Disabled
Protection is inactive

Fault
The drive trips on fault and

the motor coasts to a stop.

A fault message is generated

“Panel Loss”.
2402 Pump Protect
Fault
Actual process value is lower
Dis-
Dis-
Dis-
Dis-

Ctrl
than protection limit (2403) for abled abled abled
abled

protection delay (2404) and AV

is at max speed for the

protection delay.

Disabled
Protection is disabled.

(Default)

Warning
The AV generates a warning

only “Pump Protect”; no other

action is taken.

Warn and
The AV generates a warning

Control
“Pump Protect” and controls

according to the setting of

Config Speed Min (1403).

Disabled

PARAMETER LISTINGS
Defaults
Group
24

Fault Range Description
Functions

Single Synch- Multi- Constant Speed
Pump ronous Control Slave Control

2403 Protection Limit 0…6553.5
This is the protection limit in PSI 0
0
0
0

for the process value at which

Pump Protect Ctrl (2402)

activates when pump is at max

speed for the protection delay.
2404 Protection Delay 0…200 s
This is the protection delay
0
0
0
0

period prior to activation of

Pump Protect Ctrl (2402).

Default setting is “0 sec”.
2405 Low Water
Loss of digital input 2 (DI2) for
Dis-
Dis-
Dis-
Dis-

protection delay (2404).
abled abled abled
abled

Disabled
Protection is disabled.

(Default)

Warn
The AV generates a warning

only “Secondary Protect A”; no

other action is taken.

Warn and
Parameter 1202 Auto Restart

Control
must be set to “On” to

automatically restart once fault

has been reset.
2406 Error Reset
0…9999
Indicates number of fault resets. 0
0
0
0

Note parameter 1202 Auto

Restart must be set to “on”.

When set to “0” Error Reset is

disabled. Time between resets is

parameter 2407 Reset Delay.

Manual intervention is required

if fault is still active after set

number of resets has been

achieved. The drive reaction to

the fault will be according to

parameter 1405 Config Speed

Min setting. Reset is applicable

to parameters 2404 and 2405.
2407 Reset Delay
1…250 s
Defines the time that the AV will 60 s
60
60
60

wait after an alarm and control

condition before attempting an

error reset.
2408 Run Enable
DI1 has to be closed for drive to

be able to run.

Disable
Run Enable is not in use

Enable
DI1 is used for Run Enable

Function.

Disabled

PARAMETER LISTINGS
Defaults
Group
24

Fault Range Description
Functions

2409 Comm Fault

Function

Not Selected

Fault

Last Speed

2410 Comm Fault
0…60.0s

Time

Group
25

Group
26

Selects how the drive reacts in a Last
Last
Last
Last
fieldbus comm break i.e.; if the Speed Speed Speed Speed
drive fails to receive command
word or reference. The time delays is given by parameter 2410.
No response
Drive Faults and coasts to stop
Drive displays a warning and
remains running at last speed
reference.
Defines the time delay for the
3.0 s
3
3
3
control word or reference
supervision.

Automatic
Range Description
Reset

2501 NR of Trials
0…5

2502 Trial Time
1.0…600.0 s

2503 Delay Time
0.0…120.0 s

2504 AR Overcurrent

Disable
2505 AR Overvoltage

Disable
2506 AR Undervoltage

Disable
2507 AR AI 2002 MAXIMUM SPEED.
• 2007 MINIMUM FREQ > 2008 MAXIMUM FREQ.
• 2001 MINIMUM SPEED / 9908 MOTOR NOM SPEED > 128 (or < -128).
• 2002 MAXIMUM SPEED / 9908 MOTOR NOM SPEED > 128 (or < -128).
• 2007 MINIMUM FREQ / 9907 MOTOR NOM FREQ > 128 (or < -128).
• 2008 MAXIMUM FREQ / 9907 MOTOR NOM FREQ > 128 (or < -128).
Parameter values are inconsistent. Check for the following:
• 2007 MINIMUM FREQ is negative.
Parameter values are inconsistent. Check for any of the following:
• 1503 TRANSDUCER MIN > 1502 TRANSDUCER MAX.
Parameter values are inconsistent. Check for any of the following:
• 1904 AO 1 MIN > 1905 AO 1 MAX.
• 1909 AO 2 MIN > 1910 AO 2 MAX.

FAULTS/ALARMS
Fault Fault Name
Code In Panel
1005 PAR PCU 2

1007 PAR FBUS

1009 PAR PCU 1

Description and Recommended Corrective Action
Parameter values for power control are inconsistent: Improper motor nominal
kVA or motor nominal power. Check for the following:
• 1.1 ≤ (1104 MOTOR NOM CURR * 1103 MOTOR NOM VOLT * 1.73 / PN) ≤ 2.6
• Where: PN = 1000 * 1107 MOTOR NOM POWER (if units are kW)
or PN = 746 * 1107 MOTOR NOM POWER (if units are HP, e.g. in US)
Parameter values are inconsistent. Check for and correct:
• A parameter is set for fieldbus control (e.g. 1201 START/STOP = Fieldbus),
but 3001 COMM PROT SEL = 0.
Parameter values for power control are inconsistent: Improper motor nominal
frequency or speed. Check for both of the following:
• 1 ≤ (60 * 1105 MOTOR NOM FREQ / 1106 MOTOR NOM SPEED ≤ 16
• 0.8 ≤ 1106 MOTOR NOM SPEED / (120 * 1105 MOTOR NOM FREQ / Motor Poles)
≤ 0.992

Fault Resetting
The AQUAVAR can be configured to automatically reset certain faults. Refer to parameter
Group 24: Fault Functions and Group 25: Automatic Reset.
Warning! If an external source for start command is selected and it is active, the
AQUAVAR may start immediately after fault reset.
Flashing Red LED
To reset the drive for faults indicated by a flashing red LED:
• Turn the power off for 5 minutes.
Red LED
To reset the drive for faults indicated by a red LED (on, not flashing), correct the problem and
do one of the following:
• From the control panel: Press RESET
• Turn the power off for 5 minutes.
NOTE: In some cases a fault reset “soft key” will appear on the display. Press this button to
reset, then press the start key.
• When the fault has been removed, the motor can be started.
Fault History
For reference, the last three fault codes are stored in Group 01: VFD Signals. Specifically parameters 0116…0118. The Aquavar CPC stores additional fault data, which helps the operator
identify operating conditions at the time of fault. (Parameters 0119…0126).
To clear the fault history, go to PAR GROUPS 01, VFD SIGNALS. Press the SEL key. Down arrow
to 0116 LAST FAULT, then press the EDIT key. Next press the UP and DOWN arrow at the
same time until NO RECORD shows on the display. This clears all the faults in the history.

119

FAULTS/ALARMS
Correcting Alarms
The recommended corrective action for alarms is:
• Determine if the Alarm requires any corrective action (action is not always required).
• Use “Alarm Listing” below to find and address the root cause of the problem.
• Press the reset key (when available) or turn the power off for at least 5 minutes.
Alarm Listing
The following table lists the alarms by code number and describes each.
Alarm
Code

Display Description

2001 Reserved
2002
2003
2004 DIR LOCK
The change in direction being attempted is not allowed. Either:

• Do not attempt to change the direction of motor rotation.
2005
I/O COMM
Fieldbus communication has timed out. Check for and correct:

• Fault setup (2411 COMM FAULT FUNC and 2412 COMM FAULT TIME).

• Communication settings (Group 31 or 32 as appropriate).

• Poor connections and/or noise on the line.
2006
AI1 LOSS
Analog Input 1 is lost, or value is less than the minimum setting.

Check:

• Input source and connections

• Parameter that sets the minimum (1604)
2007 TRANSDUCER Analog Input 2 is lost, or value is less than the minimum setting.
LOSS Check:

• Transducer, connection and wiring

• Input source and connections

• Parameter that sets the minimum (1506)
2008 PANEL LOSS
Panel communication is lost and either:

• Drive is in local control mode (the control panel displays LOC), or

• Drive is in remote control mode (REM) and is parameterized to accept

start/stop, direction or reference from the control panel.

To correct check:

• Communication lines and connections

• Parameter 2401 KEYPAD FAILURE
2009 RESERVED

120

FAULTS/ALARMS
Alarm
Code

Display Description

2010 MOT
OVERTEMP

2011 UNDERLOAD

2012 MOTOR STALL

Motor is hot, based on either the drive’s estimate or on temperature feedback.
This alarm warns that a Motor Underload fault trip may be near. Check:
• Check for overloaded motor, pump.
Motor load is lower than expected. This alarm warns that a Motor Underload
fault trip may be near. Check:
• Motor and drive ratings match (motor is NOT undersized for the drive).
Motor is operating in the stall region. This alarm warns that a Motor Stall fault
trip may be near. Check motor connections.

2013
AUTORESET
(note 1)

2015
ALARM 2015

PUMP

PROTECT

2016
LOW WATER
2017
NOT USED
2023
E-STOP
FAULT

This alarm warns that the drive is about to perform an automatic fault reset,
which may start the motor.
• To control automatic reset, use parameter Group 12 AUTOMATIC RESET.
Pump protection has been triggered via parameter 2403 (protection limit)
and 2404 (protection delay). This protection is enabled when the pump
reaches maximum frequency and cannot maintain system set point for the
specific delay time. Check for air entrainment, plugged impeller, blocked
suction, lack of NPSHa, pump run-out.
Check DI2 contact or suction switch continuity.
Check jumper / connection, between Terminal 10 and 15 (DI3).

121

MAINTENANCE (Frame Sizes R1-R6)
WARNING! Read “Safety” on page 7 before performing any maintenance on
the equipment. Ignoring the safety instructions can cause injury or death.

Maintenance Intervals
If installed in an appropriate environment, the drive requires very little maintenance. This table
lists the routine maintenance intervals recommended by CentriPro.
Maintenance

Interval

Depends on the dustiness of the
environment (every 6…12 months).

Instruction

Heatsink Temperature
Check and Cleaning

Main Cooling
Every five years
Fan Replacement

See “Main Fan Replacement”
on pages 122, 123, 126 and 127

Internal Enclosure
Every three years
Cooling Fan Replacement
(IP 54/UL Type 12 units)

See “Internal Enclosure Fan
Replacement” on page 123

Capacitor Change
Every ten years
(Frame size R5 and R6)

See “Capacitors” on page 124

Replace Battery in Advanced
Control Panel

See “Battery” on page 124

Every ten years

See “Heatsink” on page 122

Heatsink
The heatsink fins accumulate dust from the cooling air. Since a dusty heatsink is less efficient
at cooling the drive, overtemperature faults become more likely. In a “normal” environment
(not dusty, clean) check the heatsink annually, in a dusty environment check more often.
Clean the heatsink as follows (when necessary):
1. Remove power from drive
2. Remove the cooling fan (see section “Main Fan Replacement” below)
3. Blow clean compressed air (not humid) from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of the dust entering adjoining equipment, perform the cleaning in
another room.
4. Replace the cooling fan
5. Restore power

Main Fan Replacement
The drive’s main cooling fan has a life span of about 60,000 operating hours at maximum
rated operating temperature and drive load. The expected life span doubles for each 10º C
(18º F) drop in the fan temperature (fan temperature is a function of ambient temperatures
and drive loads).
Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise
in the heatsink temperature in spite of heatsink cleaning. If the drive is operated in a critical
part of a process, fan replacement is recommended once these symptoms start appearing.
Replacement fans are available from the factory. Do not use other than factory specified spare
parts.
122

MAINTENANCE (Frame Sizes R1-R6)
Frame Size R1…R4
To replace the fan:
1. Remove power from drive
2. Remove drive cover
3. For Frame Size:
• R1, R2: Press together the retaining clips on the fan cover sides
and lift.
• R3, R4: Press in on the lever located on the left side of the fan
mount and rotate the fan up and out.
4. Disconnect the fan cable.
5. Install the fan in reverse order
6. Restore power
Frame Size R5 and R6
To replace the fan:
1. Remove power from drive
2. Remove the screws attaching the fan
3. Disconnect the fan cable.
4. Install the fan in reverse order
5. Restore power

Internal Enclosure Fan Replacement
IP 54 / UL Type 12 enclosures have an additional internal fan
to circulate air inside the enclosure.
Frame Size R1 to R4
To replace the internal enclosure fan in frame sizes R1 to R4:
1. Remove power from drive
2. Remove the front cover
3. The housing that holds the fan in place has barbed retaining
clips at each corner. Press all four clips toward the center to
release the barbs.
4. When the clips/barbs are free, pull the housing up to remove
from the drive.
5. Disconnect the fan cable
6. Install the fan in reverse order
• The fan air flow is up (refer to arrow on fan)
• The fan wire harness is toward the front
• The notched housing barb is located in the right-rear corner
• The fan cable connects just forward of the fan at the top of
the drive
123

MAINTENANCE (Frame Sizes R1-R6)
Frame Size R5 and R6
To replace the internal enclosure fan in frame sizes R5 or R6:
1. Remove power from drive
2. Remove the front cover
3. Lift the fan out and disconnect the cable
4. Install the fan in reverse order
5. Restore power

Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their life span is from
35,000…90,000 hours depending on drive loading and ambient temperature. Capacitor life
can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a input
power fuse failure or a fault trip. Contact factory if capacitor failure is suspected. Replacements for frame size R5 and R6 are available from the factory. Do not use other than factory
specified spare parts.

Control Panel
Cleaning
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the
display window.
Battery
A battery is only used in control panels that have the clock function available and enabled.
The battery keeps the clock operating in memory during power interruptions. To remove the
battery, use a coin to rotate the battery holder on the back of the control panel. Replace the
battery with type CR2032.

124

MAINTENANCE (Frame Sizes R7-R8)
Layout
The layout stickers of the drive are shown below. The stickers show all possible components
concerning maintenance activities. Not all of them are present in each delivery.

Designation
Component

A49
Control Panel

A41
Motor Control and I/O Board (OMIO)

Y41
Cooling Fan
_
C Capacitors

125

MAINTENANCE (Frame Sizes R1-R6)
Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. In a “normal” environment (not dusty, not clean) the
heatsink should be checked annually, in a dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section “Fan” below).
2. Blow dry clean compressed air from bottom to top and simultaneously use a vacuum
cleaner at the air outlet to trap the dust. Note: Prevent dust from entering adjoining
equipment.
3. Replace the cooling fan

Fan
The life span of the cooling fan of the drive is about 50,000 (R7) and 60,000 (R8) hours. The
actual life span depends on the running time of the fan, ambient temperature and dust concentration. See the appropriate Aquavar CPC User Manual for the actual signal which indicates the running time of the cooling fan.
Replacement fans are available from CentriPro. Do not use other than factory specified spare
parts.

Replacing the Fan (R7)
1. Remove the upper front cover and disconnect the control panel cables.
2. Disconnect the discharging resistor wire.
4
3

3
3

DCDC+

2
7
3
8

5
3
3
3

126

DC+

DC-

MAINTENANCE (Frame Sizes R7-R8)
3. Remove the DC capacitor pack by undoing the black fixing screws.
4. Disconnect the fan supply wires (detachable terminal).
5. Disconnect the fan capacitor wires.
6. Undo the black fixing screws of the fan cassette.
7. Press the snap-on holders to release the side cover.
8. Lift from the handle and pull the fan cassette out.
9. Install the fan in reverse order to the above and replace the fan capacitor.

Replacing the Fan (R8)
1. Remove the upper front cover.
2. Remove the OMIO board.
3. Disconnect the fan capacitor and power supply wires. Replace the starting capacitor.
4. Undo the black fastening screws of the plastic side cover of the fan and lift the cover off.
5. Undo the black fastening screws of the fan.
6. Lift the fan out of the cabinet.
7. Install the fan in reverse order to the above.

127

MAINTENANCE (Frame Sizes R1-R6)
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their life span is at
least 90,000 hours depending on the operating time of the drive, loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by damage
to the unit and an input cable fuse failure or a fault trip. Contact your CentriPro authorized
Aquavar CPC distributor or the factory.

Replacing the Capacitor Pack (R7)
Replace the capacitor pack as described in section “Replacing the Fan (R7)” on page 126.

Replacing the Capacitor Pack (R8)
1. Remove the upper front cover and the side plate equipped with control panel mounting slot.
2. Disconnect the discharging resistor wire.
3. Undo the fastening screws.
4. Lift the capacitor pack out.
5. Install the capacitor pack in reverse order to the above.

128

MAINTENANCE (Frame Sizes R7-R8)
LEDs
This table describes LEDs of the drive.

Where

OMIO Board

LED
Red (blinking)
Green

When the LED is lit
Drive in fault state.
The power supply on the board is OK.

Control Panel
Red
Mounting Platform
Green

Drive in fault state.
The main +24 V power supply for the control
panel and the OMIO board is OK.

OITF Board
V204 (green)

V309 (red)

V310 (green)

+5 V voltage of the board is OK.
Prevention of unexpected start is ON.
IGBT control signal transmission to the gate
driver control boards is enabled.

Control Panel
Cleaning
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the
display window.
Battery
A battery is only used in Assistant Control Panels that have the clock function available and
enabled. The battery keeps the clock operating in memory during power interruptions.
The expected life for the battery is greater than ten years. To remove the battery, use a coin
to rotate the battery holder on the back of the control panel. Replace the battery with type
CR2032.

129

TECHNICAL DATA
Sizing
The current ratings are the same regardless of the supply voltage within one voltage range.
To achieve the rated motor power given in the table, the rated current of the drive must be
higher than or equal to the rated motor current.
Note 1: The maximum allowed motor shaft power is limited to 1.5 · ATimes Rated HP. If
the limit is exceeded, motor torque and current are automatically restricted. The function
protects the input bridge of the drive against overload.
Note 2: The ratings apply in ambient temperature of 40º C (104º F).
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000
meters (3300 ft), or if the ambient temperature exceeds 40º C (104º F) or if 8 kHz switching
frequency (parameter 5001) is used.
Temperature Derating
In the temperature range +40º C…50º C (+104º F…122º F) the rated output current is decreased 1% for every 1º C (1.8º F) above +40º C (+104º F). The output current is calculated by
multiplying the current given in the rating table by the derating factor.
Example: If the ambient temperature is 50º C (+122º F) the derating factor is
100% - 1%/ºC x 10º C = 90% or 0.90.
The output current is then 0.90 x I2N or 0.90 x I2hd.
Altitude Derating
The derating is 1% for every 100 m (330 feet) above 3300 feet. If the installation site is higher
than 2000 m (6600 feet) above sea level, please contact the factory for assistance.
Single Phase Supply Derating
For 208…240 Volt series drives, a single phase supply can be used. In that case, the derating
is 50%, for the maximum amps and corresponding power rating of the three phase drive at
208-230 Volt input.
Switching Frequency Derating
If the 8 kHz switching frequency (parameter 5001) is used, derate HP and current output to
80%.

130

TECHNICAL DATA
Cable Sizing/Ratings
208…240 Volt Drives
The following tables provide current, horsepower, frame size and recommended cable sizes
for the Aquavar CPC.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Output
Frame
Voltage Phase
Base
Load
DUTY

Cable
Size
Size2 Min. AWG1

Model
Amps HORSEPOWER
CPC20171 8.5
2
R1
14
CPC20241 12
3
R2
12
CPC20311 15.5
5
R2
12
CPC20461 23
7.5
R3
10
CPC20591 29.5
10
R3
8
230
1 CPC20881 44.0
15
R4
6
CPC21141 57.0
20
R4
4
CPC21431 71.5
25
R6
3
CPC21781 89.0
30
R6
2
CPC22211 110.5
40
R6
1/0
CPC22481 124.0
50
R6
2/0
CPC20121 11.8
3
R1
14
CPC20171 16.7
5
R1
10
CPC20241 24.2
7.5
R2
8
CPC20311 30.8
10
R2
8
CPC20461 46.2
15
R3
6
CPC20591 59.4
20
R3
4
230
3 CPC20751 74.8
25
R4
3
CPC20881 88.0
30
R4
2
CPC21141 114.0
40
R4
1/0
CPC21431 143.0
50
R6
3/0
CPC21781 178.0
60
R6
4/0
CPC22211 221.0
75
R6 300MCM
CPC22481 248.0
100
R6 350MCM

Input
Cable Size
Min. AWG1
10
8
8
6
4
2
1/0
3/0
4/0
300MCM
350MCM
14
10
8
8
6
4
3
2
1/0
3/0
4/0
300MCM
350MCM

(1) Recommended AWG Size based on NEC table 310.16, 40º C ambient, 90º C, UL type copper wire. For other
wire sizes or types, consult local, state or NEC codes.
(2) Frame sizes R7 and R8, the Aquavar CPC will have multiple conductor terminals for each phase. Consult
technical section (CABLE TERMINALS).

131

TECHNICAL DATA
Cable Sizing/Ratings
380…480 Volt Drives
The following table provides Aquavar CPC rating information and
recommended wire sizing for the input and output cables.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Output
Input
Frame
Voltage Phase
Base
Load
DUTY

Cable
Size
Cable
Size
Size2 Min. AWG1 Min. AWG1

Model
Amps HORSEPOWER
CPC40061 6.9
3
R1
14
14
CPC40081 8.8
5
R1
14
14
CPC40121 11.9
7.5
R1
14
14
CPC40151 15.4
10
R2
12
12
CPC40231 23
15
R2
12
12
CPC40311 31
20
R3
10
8
CPC40381 38
25
R3
8
8
CPC40451 45
30
R3
8
6
CPC40591 59
40
R4
6
4
CPC40721 72
50
R4
4
3
CPC40771 77
60
R4
4
3
460
3 CPC40971 97
75
R4
3
1
CPC41251 125
100
R5
1
2/0
CPC41571 157
125
R6
2/0
3/0
CPC41801 180
150
R6
3/0
4/0
CPC42451 245
200
R7 350MCM 350MCM

CPC43161
316
250
R7
2 X 250MCM 2 X 250MCM

CPC43681
368
300
R8
2 X 300MCM 2 X 300MCM

CPC44141
414
350
R8
2 X 400MCM 2 X 400MCM

CPC44861
486
400
R8
2 X 500MCM 2 X 500MCM

CPC45261
526
450
R8
2 X 350MCM 2 X 350MCM

CPC46021
602
500
R8
2 X 500MCM 2 X 500MCM

CPC46451
645
550
R8
2 X 500MCM 2 X 500MCM
(1) Recommended AWG Size based on NEC table 310.16, 40º C ambient, 90º C, UL type copper wire. For other
wire sizes or types, consult local, state or NEC codes.
(2) Frame sizes R7 and R8, the Aquavar CPC will have multiple conductor terminals for each phase. Consult
technical section (CABLE TERMINALS) for maximum wire diameter and torque values.

132

TECHNICAL DATA
Fuse Sizing/Ratings
208…240 Volt Drives
Branch circuit protection must be provided by the end user, electrical contractor or distributor, sized per local, state or local National Electrical Codes. Recommendations for fused
circuit protection are in the following tables.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Input
Frame
Fuse Type3
Voltage Phase
Base
Load
DUTY
Current
Size
JJN

Model
Amps HORSEPOWER
Amps
CPC20171 8.5
2
R1 17.3
20
CPC20241 12
3
R2 24.5
30
CPC20311 15.5
5
R2
31.6
40
CPC20461 23
7.5
R3 46.9
60

CPC20591
29.5 10 R3
60.2 70
230
1 CPC20881 44.0
15
R4
89.8
110
CPC21141 57.0
20
R4 116.3
150
CPC21431 71.5
25
R6 145.9
175
CPC21781 89.0
30
R6 181.6
225
CPC22211 110.5
40
R6
225.4
300
CPC22481 124.0
50
R6
252.9
300
CPC20121 11.8
3
R1
12.0
15
CPC20171 16.7
5
R1
17.0
25
CPC20241 24.2
7.5
R2
24.7
30

CPC20311
30.8 10 R2
31.4 40

CPC20461
46.2 15 R3
47.1 60

CPC20591
59.4 20 R3
60.6 70

230
3
CPC20751
74.8 25 R4
76.3 90
CPC20881 88.0
30
R4
89.8
110
CPC21141 114.0
40
R4
116.3
150
CPC21431 143.0
50
R6
145.9
175
CPC21781 178.0
60
R6
181.6
225
CPC22211 221.0
75
R6
225.4
300

CPC22481
248.0 100 R6
252.9 300
(3) UL Class T fuses are recommended for short circuit protection. Very fast acting Bussmann* T-tron type
JJN and JJS are shown in the Aquavar CPC tables. Other manufaturers are acceptable if they meet fuse
requirements.
* Bussmann is a registered trademark of Cooper Industries Inc.

133

TECHNICAL DATA
Fuse Sizing/Ratings
380…480 Volt Drives
The following table provides Aquavar CPC rating information and recommended fuse sizing
for the input short circuit protection. Branch circuit protection must be provided by the end
user, contractor or distributor. Sized according to local or applicable NEC codes.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Input
Frame
Fuse Type3
Voltage Phase
Base
Load
DUTY
Current
Size
JJN

Model
Amps HORSEPOWER
Amps
CPC40061 6.9
3
R1
7.0
10
CPC40081 8.8
5
R1
9.0
15
CPC40121 11.9
7.5
R1
12.1
15

CPC40151
15.4 10 R2
15.7 20
CPC40231 23
15
R2 23.5
30
CPC40311 31
20
R3 31.6
40
CPC40381 38
25
R3 38.8
45
CPC40451 45
30
R3 44.9
60
CPC40591 59
40
R4 60.2
70
CPC40721 72
50
R4 73.4
90
CPC40771 77
60
R4 78.5
90
460
3 CPC40971 97
75
R4
98.0
125
CPC41251 125
100
R5 126.5
150
CPC41571 157
125
R6 160.1
200
CPC41801 180
150
R6 183.6
225
CPC42451 245
200
R7 250.0
300
CPC43161 316
250
R7 322.3
400
CPC43681 368
300
R8 375.4
450
CPC44141 414
350
R8 422.3
500
CPC44861 486
400
R8 495.8
600
CPC45261 526
450
R8 536.5
800
CPC46021 602
500
R8 614.0
800
CPC46451 645
550
R8 658.0
800
(3) UL Class T fuses are recommended for short circuit protection. Very fast acting Bussmann* T-tron type
JJN and JJS are shown in the Aquavar CPC tables. Other manufaturers are acceptable if they meet fuse
requirements.

134

TECHNICAL DATA
Cable Terminals (Frames R1-R6)
Mains and motor cable maximum sizes (per phase) accepted at the cable
terminals and the tightening torques are listed below.

U1, V1, W1
Earthing PE
Control Wire

U2, V2, W2
“Ground”
Frame

Maximum Torque Maximum Torque Maximum Torque
Size

Wire Size
Wire Size
Wire Size
mm2 AWG Nm lb-ft mm2 AWG Nm lb-ft mm2 AWG Nm lb-ft
R1
6
8 1.4 1.0 4 10 1.4 1.0

R2 10
6
1.4
1.0
10
8
1.4
1.0

R3 25
3
1.8
1.3
16
6
1.8
1.3
2

2.0 1.5 1.5 16 0.4 0.3

50 1/0 2.0 1.5 35

70 2/0 15 11.1 70 2/0 15 11.1

R6 185 350 40 29.5 95 4/0 8 5.9
MCM

Cable Terminals (Frames R7-R8)
Mains and motor cable maximum sizes (per phase) accepted at the cable terminals and the
tightening torques are listed below.

U1, V1, W1, U2, V2, W2
Earthing PE

Number

Frame
Cable
Tightening
Tightening

of holes

Size
Diameter Screw Screw
Torque
Torque
per

phase mm in Nm lb-ft Nm lb-ft

R7➀
R8➀

2
3

58
58

2.28
2.28

M12 50…75 35…55
M12 50…75 35…55

M8
M8

15…22 10…16
15…22 10…16

➀ NOTE: Maximum AWG size for R7 Frame is (2) x 500MCM.

Maximum AWG size for R8 Frame is (3) x 500MCM.

135

TECHNICAL DATA
Input Power (Mains) Connection

Input Power (Mains) Connection Specifications

Voltage (U1)

208/220/230/240 VAC 3-phase (1-phase) +10%-15% for CPC2XXXX.
400/415/440/460/480 VAC 3-phase +10%-15% for CPC4XXXX.

Prospective Short-Circuit
Current (IEC 629)

Maximum allowed prospective short-circuit current in the supply is
65 kA in a second providing that the mains cable of the drive is
protected with appropriate fuses. US: 65,000 AIC.

Frequency

48…63 Hz

Imbalance

Max. ±3% of nominal phase to phase input voltage.

Fundamental Power
Factor (cos phi1)

0.98 (at nominal load)

Cable Temperature
Rating

90º C (194º F) rating minimum

Motor Connection

Motor Connection Specifications

Voltage (U2) 0…U1, 3-phase symmetrical, Umax at the field weakening point.
Frequency
0…500 Hz
Frequency Resolution
0.01 Hz
Current
See “Ratings” on pages 131-134
Power Limit
1.5 x Rated HP
Field Weakening Point
10…60 Hz
Switching Frequency
Selectable: 1, 4 or 8 kHz
Cable Temperature
90º C (194º F) rating minimum
Rating

Maximum Motor Cable Length
Frame Size

fsw = 1 or 4 kHz
fsw = 8 kHz
Maximum Motor
R1
100 m
50 m
Cable Length
R2 - R4
200 m
100 m

R5 - R6
300 m
150 m

R7 - R8
300 m
NA

WARNING! Using a motor cable longer than specified in the chart above may cause
permanent damage to the drive or motor.
WARNING! Use of an output load filter or reactor is required when motor leads
exceed the above recommendations. Consult motor manufacturer on required use
of inverter drives.

136

TECHNICAL DATA
Control Connection

Control Connection Specifications

Analog Inputs
and Outputs

See table heading “Hardware Description” on page 29.

Digital Inputs

Digital input impedance 1.5 kΩ. Maximum voltage for digital
inputs is 30 V.

Relays
(Digital Outputs)

• Maximum contact voltage: 30 V DC, 250 V AC
• Maximum contact current / power: 6 A, 30 V DC; 1500 VA, 250 V AC
• Maximum. continuous current: 2 A rms (cos ϕ = 1), 1 A rms
(cos ϕ = 0.4)
• Minimum load: 500 mW (12 V, 10 mA)
• Contact material: Silver-nickel (AgN)
• Isolation between relay digital outputs, test voltage:
2.5 kV rms, 1 minute

Cable Specifications

See “Control Cables” on page 17.

Efficiency (Frames R1-R8)
Approximately 98% at nominal power level.

Cooling (Frames R1-R6)

Method

Requirement

Cooling Specifications
Internal fan, flow direction from bottom to top.
Free space around the unit:
• 200 mm (8 in) above and below the unit.
• 25 mm (1 in) along each side of the unit.

137

TECHNICAL DATA
Cooling (Frames R7-R8)
Installation Procedure
Choose the mounting orientation (a, b, c or d).
a)

c)
Lifted from above

Symbols:
required free space
air inlet surface
wall fixing point (recommended)
control panel mounting slot

Required Free Space Around the Unit for
Frame Mounting
Mounting, Maintenance, Service and Cooling*
Size Orientation
Front
Side
Above
mm in mm in mm in

a,d
500
20
–
–
200 7.9

b
– – 500 20 200 7.9
R7

lifting lifting
c
–
– 200** 7.9**
space space

a,d 600 24 – – 300 12

b
– – 600 24 300 12
R8

lifting lifting
c
–
– 300** 12**
space space

* Space for the installer not included.
** Space for the fan and capacitor replacement not included.

Mounting orientations a and b
Make holes in the wall (recommended):
1. Lift the unit against the wall into the mounting place.
2. Mark the locations for the two fixing points in the wall.
3. Mark the bottom edges of the unit to the floor.

138

TECHNICAL DATA
Air Flow, 380…480 Volt Drives
The following table lists heat loss and air flow data for 380…480 Volt drives.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Heat Loss Air
Frame
Voltage Phase
Base
Load
DUTY
Flow
Size

Model
Amps HORSEPOWER
Watts BTU/HR CFM
CPC40061 6.9
3
R1 97 331 26
CPC40081 8.8
5
R1 127 433 26
CPC40121 11.9
7.5
R1 172 587 26
CPC40151 15.4
10
R2 232 792 52
CPC40231 23
15
R2 337 1150 52
CPC40311 31
20
R3 457 1560 79
CPC40381 38
25
R3 562 1918 79
CPC40451 45
30
R3 667 2276 165
CPC40591 59
40
R4 907 3096 165
CPC40721 72
50
R4 1120 3820 165
CPC40771 77
60
R4 1295 4420 168
460
3 CPC40971 97
75
R4 1440 4915 168
CPC41251 125
100
R5 1940 6621 239
CPC41571 157
125
R6 2310 7884 239
CPC41801 180
150
R6 2810 9590 239
CPC42451 245
200
R7 3850 13144 319
CPC43161 316
250
R7 6850 23386 319
CPC43681 368
300
R8 6850 23386 721
CPC44141 414
350
R8 7850 26800 721
CPC44861 486
400
R8 7850 26800 721
CPC45261 526
450
R8 7600 25946 721
CPC46021 602
500
R8 8100 27653 721
CPC46451 645
550
R8 9100 31067 721

139

TECHNICAL DATA
Air Flow, 208…240 Volt Drives
The following table lists heat loss and air flow data for 208…240 Volt drives.
CENTRIPRO AQUAVAR CPC

NEMA 1
Full
NORMAL

Heat Loss Air
Frame
Voltage Phase
Base
Load
DUTY
Flow
Size

Model
Amps HORSEPOWER
Watts BTU/HR CFM
CPC20171 8.5
2
R1 161 551 26
CPC20241 12
3
R2 227 776 52
CPC20311 15.5
5
R2 285 373 52
CPC20461 23
7.5
R3 420 1434 79
CPC20591 29.5
10
R3 536 1829 79
230
1 CPC20881 44.0
15
R4 786 2685 165
CPC21141 57.0
20
R4 1014 3463 165
CPC21431 71.5
25
R6 1268 4431 238
CPC21781 89.0
30
R6 1575 5379 238
CPC22211 110.5
40
R6 1952 6666 238
CPC22481 124.0
50
R6 2189 7474 238
CPC20121 11.8
3
R1 116 404 26
CPC20171 16.7
5
R1 161 551 26
CPC20241 24.2
7.5
R2 227 776 52
CPC20311 30.8
10
R2 285 373 52
CPC20461 46.2
15
R3 420 1434 79
CPC20591 59.4
20
R3 536 1829 79
230
3 CPC20751 74.8
25
R4 671 2290 165
CPC20881 88.0
30
R4 786 2685 165
CPC21141 114.0
40
R4 1014 3463 165
CPC21431 143.0
50
R6 1268 4431 238
CPC21781 178.0
60
R6 1575 5379 238
CPC22211 221.0
75
R6 1952 6666 238
CPC22481 248.0
100
R6 2189 7474 238

140

TECHNICAL DATA
Dimensions and Weights
Frames R1-R6
The dimensions and mass for the AQUAVAR depend on the frame size and enclosure type.
If unsure of frame size, first, find the “Type” code on the drive labels. Then look up that type
code in the “Technical Data” on page 142, to determine the frame size. A complete set of dimensional drawings for AQUAVAR drives is located in the Technical Data section.
Units with UL Type 1 Enclosures
Outside Dimensions

UL Type 1 – Dimensions for each Frame Size

R1 R2 R3 R4 R5 R6
Ref.
mm in mm in mm in mm in mm in mm in

W
H
H2
H3
D

125 4.9 125 4.9 203 8.0 203 8.0 265 10.4 300 11.8
330 13.0 430 16.9 490 19.3 596 23.4 602 23.7 700 27.6
315 12.4 415 16.3 478 18.8 583 23.0 578 22.8 698 27.5
369 14.5 469 18.5 583 23.0 689 27.1 739 29.1 880 34.6
212 8.3 222 8.7 231 9.1 262 10.3 286 11.3 400 15.8

NOTE: Enclosures are standard NEMA 1, indoor use only.

141

TECHNICAL DATA
Frames R1-R6
Mounting Dimensions

UL Type 1 – Dimensions for each Frame Size

R1 R2 R3 R4 R5 R6
Ref.
mm in mm in mm in mm in mm in mm in
W1* 98.0 3.9 98.0 3.9 160 6.3 160 6.3 238 9.4 263 10.4
W2* — — — — 98.0
3.9
98.0
3.9
— — — —
H1* 318 12.5 418 16.4 473 18.6 578 22.8 588 23.2 675 26.6

a
5.5 0.2 5.5 0.2 6.5 0.25 6.5 0.25 6.5 0.25 9.0 0.35

b 10.0 0.4 10.0 0.4 13.0 0.5 13.0 0.5 14.0 0.55 14.0 0.55

c 5.5 0.2 5.5 0.2 8.0 0.3 8.0 0.3 8.5 0.3 8.5 0.3

d 5.5 0.2 5.5 0.2 6.5 0.25 6.5 0.25 6.5 0.25 9.0 0.35
* Center to center dimension.

Weight

UL Type 1 – Weight for each Frame Size

R1 R2 R3 R4 R5 R6

kg lb. kg lb. kg lb. kg lb. kg lb. kg lb.
6.1 13.4 8.9 19.5 14.7 32.4 22.8 50.2 37 82 78 176

142

TECHNICAL DATA
Units with IP 54 / UL Type 12 Enclosures
Outside Dimensions

IP 54 / UL Type 12 – Dimensions for each Frame Size

R1 R2 R3 R4 R5 R6
Ref.
mm in mm in mm in mm in mm in mm in

W
W2
H3
D

215 8.5 215 8.5 257 10.1 257 10.1 369 14.5 410 16.1
225 8.9 225 8.9 267 10.5 267 10.5 369 14.5 410 16.1
441 17.4 541 21.3 604 23.8 723 28.5 776 30.5 924 36.4
238 9.37 245 9.6 276 10.9 306 12.0 309 12.2 423 16.6

Mounting Dimensions
Mounting dimensions are the same as for the IP 21 / UL Type 1 Enclosure. See “Mounting
Dimensions” on page 144.
Weight

IP 54 / UL Type 12 – Weight for each Frame Size

R1 R2 R3 R4 R5 R6

kg lb. kg lb. kg lb. kg lb. kg lb. kg lb.
8.4 18.6 11.5 25.4 18.1 40.0 26.6 58.7 42 93 86 190

143

Top View

TECHNICAL DATA

E2
X2

Weights and Dimensions

Frames R7-R8
E1

Top View

E2
X2

H1
D

NEMA 1 Enclosure

H1
W2 Depth Weight E1
E2
Frame
mm in mm in mm in kg lb. mm in mm in

R8 2130 83.86 800 31.5 585 23.03 375 827 92 3.62 250 9.84

1503 59.17 609 23.98 495 19.49 195 430 92 3.62 250 9.84

Drawing is not for engineering purposes.

Degrees of Protection
Available enclosures:
• IP 21 / UL Type 1 Enclosure. The site must be free of airborne dust, corrosive gases or
liquids, and conductive contaminants such as condensation, carbon dust and metallic particles. Indoor use only.
• IP 54 / UL Type 12 Enclosure. This enclosure provides protection from airborne dust and
light sprays or splashing water from all directions. Indoor use only.
• UL Type 3R- Enclosures are intended for outdoor use to provide a degree of protection
from falling rain. Undamaged by the formation of ice on the enclosure. May be cooled
by forced air and louvers for vents. This rating is met by placing the drive into a NEMA 3R
Enclosure.
Compared to the IP 21 / UL Type 1 Enclosure, the IP 54 / UL Type 12 Enclosure has:
• The same internal plastic shell as the IP 21 Enclosure.
• A different outer plastic cover.
• An additional internal fan to improve cooling.
• Larger dimensions.
• The same rating (does not require a derating).
• Plastic gasketed cover for keypad.

144

TECHNICAL DATA
Ambient Conditions
The following table lists the AQUAVAR environmental requirements.
Ambient Environment Requirements

Storage and Transportation
Installation Site

in the protective package

• 0…1000 m (0…3,300 ft)

Altitude1

• 1000…2000 m (3,300…6,600 ft)
if PN and I2 derated 1% every
100 m above 1000 m
(300 ft above 3,300 ft).

Ambient
Temperature2

• -15…40º C (5…104º F)
• Max. 50º C (122º F) if PN and I2
derated to 90%.

Relative humidity

< 95% (non-condensing)

• No conductive dust allowed.

• The ACS550 should be installed

in clean air according to
Contamination
enclosure classification.
levels
• Cooling air must be clean, free
(IEC 721-3-3)

from corrosive materials and free
from electrically conductive dust.
• Chemical gases: Class 3C2
• Solid particles: Class 3S2

Sinusoidal
Vibration

• Mechanical conditions: Class 3M4
(IEC 60721-3-3)
• 2…9 Hz 3.0 mm (0.12 in)
• 9…200 Hz 10 m/s2 (33 ft/s2)

-40…70º C (-40…158º F)

Storage
• No conductive dust allowed.
• Chemical gases: Class 1C2
• Solid particles: Class 1S2
Transportation
• No conductive dust allowed.
• Chemical gases: Class 2C2
• Solid particles: Class 2S2
In accordance with ISTA-1A and 1B
specifications.

Shock
Not allowed
(IEC 68-2-29)

Maximum 100 m/s2 (330 ft/s2),
11ms (36 ft)

Free Fall3
Not allowed

• 76 cm (30 in), frame size R1
• 61cm (24 in), frame size R2
• 46 cm (18 in), frame size R3
• 31 cm (12 in), frame size R4
• 25 cm (10 in), frame size R5
• 15 cm (6 in), frame size R6

(1) Consult factory above 6600’ altitude.
(2) Derate drive one HP size from motor for higher temperatures (e.g. motor HP = 10 HP; use 15 HP Aquavar in
temperature up to 122º F).
(3) R7-R8 not allowed for free fall any distance.

145

TECHNICAL DATA
Materials
Materials Specifications

Drive
Enclosure

Package

Disposal

• PC/ABS 2.5 mm, color NCS 1502-Y (RAL 90021 / PMS 420 C and 425 C)
• Hot-dip zinc coated steel sheet 1.5…2 mm, thickness of coating 100 micrometers.
• Cast aluminium AlSi
• Extruded aluminium AlSi
Corrugated board (drives and option modules), expanded polystyrene.
Plastic covering of the package: PE-LD, bands PP or steel.
The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are
marked with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors contain electrolyte and the printed circuit
boards contain lead, both of which will be classified as hazardous waste within the EU.
They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling
instructions, please contact your local recycler.

Applicable Standards
The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standards EN 50178 and EN 60204-1.
Applicable Standards
EN 50178 (1997)
EN 60204-1
(1997)

EN 60529: 1991
(IEC 529), IEC
60664-1 (1992)
EN 61800-3
(1996) +
Amendment
A11 (2000)
UL 508C

146

Electronic equipment for use in power installations.
Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for
installing:
• An emergency-stop device
• A supply disconnecting device
Degrees of protection provided by enclosures (IP code).

EMC product standard including specific test methods.

UL Standard for Safety, Power Conversion Equipment, second edition.

TECHNICAL DATA
UL Markings
The AQUAVAR is suitable for use on a circuit capable of delivering not more than 65,000 RMS
symmetrical amperes, 480 V maximum. The AQUAVAR has an electronic motor protection
feature that complies with the requirements of UL 508C. When this feature is selected and
properly adjusted, additional overload protection is not required unless more than one motor
is connected to the drive or unless additional protection is required by applicable safety
regulations.
The drives are to be used in a controlled environment. See section “Ambient Conditions” on
page 145 for specific limits.
Liability Limits
The manufacturer is not responsible for:
• Any costs resulting from a failure if the installation, commissioning, repair, alteration
or ambient conditions of the drive do not fultill the requirements specified in the
documentation delivered with the unit and other relevant documentation.
• Units subjected to mususe, negligence or accident.
• Units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special,
indirect, incidental or consequential damages, losses or penalties.
If you have any questions concerning your product, please contact the local distributor or
CentriPro. The technical data, information and specifications are valid at the time of printing.
The manufacturer reserves the right to modifications without prior notice.

147

APPENDIX

PRESSURE TRANSDUCER
300 PSI 4-20 mA
P/N 9K515
(To order sensor with 200 inch (16 ft.) cable, use P/N 9K391)

Packard 3-pin
Metri-Pack
Series 150
Output
White
3/16” Dia
sphere of
silicon
grease at
base of
terminals

3.25
Snubber
added

+Supply
Brown

3
1

No
Connection

1/4 MNPT
0.875” HEX

LABEL
CentriPro
www.centripro.com

0300SB

PART#: 9K515
LISTED
79BN
PRESSURE: 0-300PSI
INPUT: 10-28VDC
MADE IN USA
OUTPUT: 4-20mA
SERIAL #: AXXXXXX
YYMMDD

SPECIFICATIONS
Parameter
Value
Pressure Range
300 PSI
Output (0 - 100%)
4-20 mA
Supply Voltage
10-28 VDC
Burst Pressure Minimum
5x rated
Pressure Overload Maximum
2x rated
Supply Current Maximum
<22mA
Pressure Cycles Minimum
100 million
Accuracy (combined lin/hyst/rep)
< 0.5% BFSL
Zero Offset Maximum
< 1% of FS / ºC
Span Tolerance Maximum
< 2% of FS / ºC
148

Parameter
Value
Operating Temp. Range
-40 to 85°C
Compensation Temp. Range
0 to 55°C
Zero Thermal Error Maximum
< .035% of FS
Span Thermal Error Maximum
< .035% of FS
Pressure Port Material
17-4 PH
Housing Material
304 stainless steel
Isolation Voltage Minimum
500VDC
Seal Material
N/A

UL cUL 508
Listings

CE ENG/326

9K515
9K516
9K517

A00462C 2
A00462C 4

9K514

A00462C 1
A00462C 3

K No.

Part No.

A00439C 4

A00439C 3

A00439C 2

A00439C 1

0-1000 PSI

0-500 PSI

0-300 PSI

0-150 PSI

Transducer Part
Pressure Range
No.

A00436C 360

Cable Part
No.

APPENDIX

Transducer Data/Specifications

149

150
A00436C 100
A00436C 50
A00436C 30
A00436C 16

100
50
30
16
(standard)

NOTE: Not available in 200 feet.

Drawing
Number
A (ft)

9K400

9K399

9K398

9K397

K No.

APPENDIX

Transducer Cable Specification

APPENDIX
Spare Parts List

Part Number

Description

64732048

Control Panel (Keypad) Connector

CPCCPA

Control Panel (Keypad)

0CAT01

Control Panel Extension Cable 8 ft.

CPCB01

Control Board (OMIO) fits all sizes.

0FANR1

Fan Kit, R1 Frame Size, Aquavar CPC

0FANR2

Fan Kit, R2 Frame Size, Aquavar CPC

0FANR3

Fan Kit, R3 Frame Size, Aquavar CPC

0FANR4

Fan Kit, R4 Frame Size, Aquavar CPC

0FANR5

Fan Kit, R5 Frame Size, Aquavar CPC

0FANR6

Fan Kit, R6 Frame Size, Aquavar CPC

0FANR7

Fan Kit, R7 Frame Size, Aquavar CPC

64391658

Fan Kit, R8 Frame Size, Aquavar CPC

CPCEXTKIT

Control Panel Mounting Kit

151

CENTRIPRO LIMITED WARRANTY
This warranty applies to all Aquavar CPC controllers manufactured by Xylem, Inc.
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 CentriPro distributor from whom the controller was purchased and furnish complete details
regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the CentriPro Customer 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 CentriPro and the dealer in purchases,
consignments or contracts for sale of the subject controllers.
(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing controllers to
customers.
(3) “Customer” means any entity who buys or leases the subject controllers 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.

Xylem Inc.
2881 East Bayard Street Ext., Suite A
Seneca Falls, NY 13148
Phone: (800) 453-6777
Fax: (888) 322-5877
www.centripro.com
CentriPro and Aquavar are trademarks of Xylem Inc. or one of its subsidiaries.
© 2014 Xylem Inc.

IM167 Revision 8

December 2014

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544607 3 Aquavar CPC Manual

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