It is the installer’s responsibility to ensure the configuration and installation of the PC PUMP VFD System meets the requirements of any site specific, local and national electrical regulations.
•
The PC PUMP VFD System operates from HIGH VOLTAGE, HIGH ENERGY ELECTRICAL SUPPLIES. Stored charge may be present in the system after the main power has been switched off.
•
For safety reasons the enclosure door must be closed at all times.
•
Some features of the PC PUMP VFD System may cause the motor to start automatically after power failure.
SERVICING WARNINGS: •
Service only by qualified personnel.
•
Always isolate and allow to discharge before servicing.
•
Never replace fuses with higher rating. Always replace fuses with proper rating.
•
VFD uses static sensitive components. Use static safe procedures when handling these components.
•
Never work on live equipment alone.
•
Observe all recommended practices.
STELLAR TECH PC PUMP VFD System Technical Manual 070613 1
REVISION HISTORY Date
Revision
Revision Comments
STELLAR TECH PC PUMP VFD System Technical Manual 070613 2
CONTENTS IMPORTANT APPLICATION NOTES SAFETY WARNINGS: SERVICING WARNINGS:
1 1 1
REVISION HISTORY
2
1
INTRODUCTION TO THE PC PUMP VFD SYSTEM
5
1.1 1.1.1 1.1.2 1.1.3
THE PC PUMP VFD SYSTEM TYPES Variable Frequency Drive Type Options Enclosure Type Options System Configuration Options
UNPACKING OF YOUR PC PUMP VFD SYSTEM Unpacking the PC PUMP VFD System Disposal of Packing INSTALLATION OF YOUR PC PUMP VFD SYSTEM Installation Environment Installation Methods Spacing CONNECTING THE PC PUMP VFD SYSTEM Power Wiring Control Wiring
COMMISSIONING REPORT PRE-POWER-UP CHECKS POWERED CHECKS Power Supply Check Software Programming Before Running the Motor Motor Rotation Check Motor Current Input and Output Signals Operator Switched and Indicator Lights If Something Does Not Work COMMISSIONING WRAP-UP
9 9 10 10 10 10 10 10 11 11 11 11
STANDARD PC PUMP VFD SYSTEMS
12
4.1 4.2 4.2.1 4.2.2 4.3 4.3.1
INTRODUCTION MODES OF OPERATION FOR “ON / OFF” SELECTOR SWITCH Operation in “OFF” Position Operation in “ON” Position TROUBLESHOOTING When the motor does not operate
12 12 12 12 12 13
2
3
4
STELLAR TECH PC PUMP VFD System Technical Manual 070613 3
5
PC PUMP VFD SYSTEM WITH CUSTOM OPTIONS
15
ROUTINE MAINTENANCE
16
6.2 6.3
Every six (6) months if continuous operation, every three (3) months if operated less than 24 hours a day Every twelve (12) months Every two (2) years
16 16 16
7.1 7.2 7.2.1 7.2.2 7.3 7.4
WARRANTY TERMS WARRANTY PERIOD Standard Warranty Extended Warranty NOT COVERED BY WARRANTY ON-SITE WARRANTY REPAIRS
6 6.1
7
WARRANTY 17 17 17 17 17 17
APPENDIX A B C
PC PUMP VFD SYSTEM COMMISSIONING REPORT QUICK START GUIDE DELAY-ON TIMER SETTING
STELLAR TECH PC PUMP VFD System Technical Manual 070613 4
18 19 20
1 1.1
INTRODUCTION TO THE PC PUMP VFD SYSTEM THE PC PUMP VFD SYSTEM TYPES
Each system is unique to the application the units were designed for. This will result in minor differences between each model and the combinations of differences are virtually limitless. Therefore it is impossible to cover all the features in the PC PUMP VFD System in this manual. Please refer to the electrical drawing(s) and supplemental documents for details.
1.1.1
Variable Frequency Drive Type Options
The STELLAR TECH PC PUMP VFD System uses Mitsubishi variable frequency drives. For a detailed VFD software parameter description please refer to the VFD manufacturer’s manual.
1.1.2
Enclosure Type Options
The PC PUMP VFD System may be manufactured with one of following enclosure types: • • • • • •
NEMA 1 NEMA 12 NEMA 3R NEMA 4 NEMA 4X or any other enclosure types requested.
Each enclosure type will be selected depending on the system requirements.
1.1.3
System Configuration Options
The PC PUMP VFD System may be manufactured with one of following System Configurations: • •
Standard System Custom Configuration
Each System Configuration type will be selected depending on the system requirements.
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2
UNPACKING, INSTALLATION, AND CONNECTION
2.1
UNPACKING OF YOUR PC PUMP VFD SYSTEM
2.1.1
Unpacking the PC PUMP VFD System
The PC PUMP VFD System is packed in a wooden crate for transportation. (NOTE: Some units may be shipped on a skid for local shipments) Before unpacking, check that the PC PUMP VFD System has not been damaged during transportation. If the PC PUMP VFD System appears damaged file a report with the carrier immediately.
2.1.2
Disposal of Packaging
Packaging materials are made from cardboard, plastic, styrofoam, or wood and they can be recycled at your local recycling center.
2.2
INSTALLATION OF YOUR PC PUMP VFD SYSTEM
2.2.1
Installation Environment
The external ambient temperature of the enclosure must not exceed 40ºC (104ºF). The enclosure must have enough space around it to ensure adequate cooling. Do not install the unit in the vicinity of any source of water, corrosive and conductive material, gas or debris. This can result in catastrophic failure if such material enters the enclosure. If the unit is installed in such an environment additional protection such as a drip shield or enclosure (i.e. NEMA 3R, 4, or 4X) must be provided.
2.2.2
Installation Methods
The PC PUMP VFD System may be of “Wall-Mount” or “Floor-Mount” type. In either case, the unit must be securely installed. Secure the unit to an area that can support the weight of the unit. Install supports for earthquake protection if necessary.
2.2.3
Spacing
There must be adequate space around the unit for cooling. Refer to the Figure 2.1 and Table 2.1 for the minimum spacing required. Regional regulations may require adequate room for the door to open completely. - NOTE -
Do not mount the PC PUMP VFD Package above a heat source such as heater, transformer, or another VFD. Failure to comply will cause cooling capacity of the top unit be greatly reduced and may cause premature failure.
STELLAR TECH PC PUMP VFD System Technical Manual 070613 6
