Goulds Aquavar IPC Start Up Genie Programming Guide
Goulds Aquavar IPC Start Up Genie Programming Guide
IM262R00
AQUAVAR ®
TABLE OF CONTENTS
Introduction…………………………………………………………………………………………………………………… 3
Chapter 1: Motor…………………………………………………………………………………………………………… 4
Chapter 2: Application……………………………………………………………………………………………………… 5
2.1. Single Pump………………………………………………………………………………………………………… 5
2.2. Constant Slave……………………………………………………………………………………………………… 6
2.3. Duplex Control……………………………………………………………………………………………………… 7
2.4. Speed Control………………………………………………………………………………………………………… 8
2.5. Test Run Mode……………………………………………………………………………………………………… 8
Chapter 3: Feedback………………………………………………………………………………………………………… 9
Chapter 4: Setpoint………………………………………………………………………………………………………… 10
Chapter 5: Flow Compensation…………………………………………………………………………………………… 10
Chapter 6: Pump Protection………………………………………………………………………………………………… 11
Chapter 7: Digital Input……………………………………………………………………………………………………… 15
Chapter 8: Relay and Analog Output Setup……………………………………………………………………………… 16
Chapter 9: Communication………………………………………………………………………………………………… 17
Chapter 10: Copy to LCP (Local Control Panel)………………………………………………………………………… 19
Chapter 11: Copy from LCP (Local Control Panel)……………………………………………………………………… 19
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CentriPro
Aquavar IPC Start-Up Genie
INTRODUCTION
The proprietary Start-Up Genie guides you through quick and easy commissioning. Take advantage of
the complete Genie with 11 sections to configure applications with pump protections, I/O options, and
communications. For the more straightforward applications set your motor information and operation mode
and “Autoset” the rest of the parameters. With support for the most common control configurations, the Genie
reduces set-up and configuration time to less than 15 minutes.
The Intelligent Pump Controller (IPC) Start-Up Genie allows the end-user to quickly and easily configure the
controller for pump control applications including single pump, constant slave, duplex control, speed control,
and test run mode. The Genie guides users through the 11 sections for controller configuration. The Setup
Selection screen allows the user to configure the motor, application type, inputs, outputs, pump protection
features, flow compensation, and communications.
SETUP SELECTION
1. Motor
2. Application
3. Feedback
Autoset*
4. Setpoint
5. Flow Compensation
6. Pump Protection Setup
7. Digital Input
8. Relay and Analog Output Setup
9. Communication
10. Copy to LCP
11. Copy from LCP
*At this point, the Autoset configuration window will give users the option to set the remaining parameters to the most common settings.
See Table 2.
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CentriPro
Aquavar IPC Start-Up Genie
CHAPTER 1: MOTOR
Allows configuration of the motor parameters; HP, Voltage, Nominal Frequency, Nominal Speed, Motor Current,
Motor Service Factor, and Motor Type. The Motor information for these settings are found on the motor
nameplate.
The Start-Up Genie will begin automatically after the initial power up (Screen 2) or it can be engaged by
selecting Start-Up Genie under Quick Menus. First, select the language for programming (Screen 1), then you
will be led to the Setup Selection screen. Select “Motor” in the Setup Selection screen (Screen 3) and the Genie
will guide you through the following sequence of parameters. Press [OK] to select the parameter and enable
editing. The highlighted area can be modified by using the up and down arrows. For numeric values with more
than one digit, use the left and right keys to select the position within the number. Press [OK] to accept and save
or [Cancel] to disregard the change.
• Motor HP: Enter the rated motor power in HP from the motor nameplate data.*
• Motor Voltage: Set the rated motor voltage from the motor nameplate data.*
• Motor Frequency: Select the motor frequency from the motor nameplate data.*
• Motor Nominal Speed: Enter the rated motor speed from the motor nameplate
data.*
• Motor Current: Enter the rated motor current value from the motor nameplate
data.*
• Current Limit: Set the Current Limit equal to (Service Factor Amps/Full Load
Amps). For example, if the Motor Current (FLA) indicated on the motor nameplate
is 5.6A and the Motor Service Factor Current (SFA) is 6.4A, enter 114% for Current
Limit (%). Be sure to properly set the Motor Current (FLA) and Current Limit. These
parameters will configure the motor overload protection feature.
• Motor Type: Select Submersible for borehole application or Surface for above
ground motors. Based on selection, the following parameters will be backfilled:
PARAMETER SUBMERSIBLE SURFACE
Motor Speed Low Limit [4-12] 30Hz --
Compressor Start Max Speed [1-78] 29Hz Default
Starting Ramp Up Time [3-82] 1s 3s
Function at Stop [1-80] Coast Coast
Min Speed for Function at Stop [1-82] 10Hz 10Hz
• Sleep Frequency/Low Limit: Enter the minimum limit for motor speed. The motor
speed low limit can be set to correspond to the minimum output frequency of the
motor shaft. The motor speed low limit must not exceed Motor Frequency listed
above.
* Changing this parameter will affect settings of other parameters.
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CentriPro
Aquavar IPC Start-Up Genie
CHAPTER 2: APPLICATION
Allows the user to configure varying operating modes, units, and ramps. Changing operating modes will
overwrite drive or motor size independent parameters.
OPERATING MODE:
2.1. Single Pump (default): 1 pump/1 controller for constant pressure, level
control, or flow control applications
• APPLICATION TYPE:
• Constant Pressure: Pressure control using a pressure transducer or other
external feedback device with analog signal
• Flow Control: Flow control using a flow meter or other external feedback
device with analog signal
• CONTROL UNITS: Select the appropriate control units for the application
(psi, GPM, ft., etc.).
• RAMP TIME: The Ramp Time is the time to transition from stop to full speed.
• Fast = 5s accelerate and 3s decelerate.
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• APPLICATION TYPE:
• Constant Pressure: Pressure control using a pressure transducer or other
external feedback device with analog signal
• Flow Control: Flow control using a flow meter or other external feedback
device with analog signal
• CONTROL UNITS: Select the appropriate control units for the application
(psi, GPM, ft., etc.).
• RAMP TIME: The Ramp Time is the time to transition from stop to full speed.
• Fast = 5s accelerate and 3s decelerate.
• Medium = 10s accelerate and 5s decelerate.
• Slow = 20s accelerate and 10s decelerate.
• NUMBER OF PUMPS: Set the total number of pumps including the variable
speed pump.
• RUN TIME EQUALIZATION: Enabling this parameter will stage and destage
the fixed speed pumps to provide equal run time for each fixed speed
pump.
• PRESSURE CONTROL UNITS: Select the appropriate control units for the
application (psi, bar, etc.)
• RAMP TIME: The Ramp Time is the time to transition from stop to full speed.
• Fast = 5s accelerate and 3s decelerate.
• Medium = 10s accelerate and 5s decelerate.
• Slow = 20s accelerate and 10s decelerate.
• LAG PUMP START FREQUENCY: This parameter defines the speed which
the lead pump needs to achieve before the lag pump will be started. Setting
Start and Stop frequencies too close together will cause frequent starts and
stops of the lag pump.
• LAG PUMP STOP FREQUENCY: This parameter defines the speed to which
system needs to drop before stopping the lag pump. Setting Start and Stop
frequencies too close together will cause frequent starts and stops of the
lag pump.
• ALTERNATION: When enabled, this parameter will alternate the lead pump
after the elapsed time specified in Alternate Time.
• ALTERNATION TIME: Time setting for the amount of elapsed time (not run
time) between lead pump alternations.
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• SPEED REFERENCE SOURCE: Set the source for the speed command. For
analog inputs 53 and 54. Be sure to properly set the configuration switches
A53 and A54 behind the keypad. Switch set to “I” for mA transducer; switch
set to “U” for voltage transducer”
• TEST RUN SPEED: Set the Test Run Speed as the speed the pump will run
when test mode is enabled.
• TEST RUN RAMP TIME: Set the Test Run Ramp Time as the time ramp used
when starting and stopping the pump in Test Run Mode.
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CentriPro
Aquavar IPC Start-Up Genie
CHAPTER 3: FEEDBACK
Feedback Setup allows the configuration of analog inputs (sensors) and other feedback sources.
• Control Feedback Sources: Select the number of feedbacks that are used to
controlling the process variable. The feedbacks referred to are for control, not
for monitoring.
• Feedback 1 Sensor Fault: If enabled, Sensor Fault will display a fault when
sensor voltage or current drops to less than 50% of the minimum value
programmed for that input.
AUTOSET
For basic applications, users are able to set motor information, operation mode and “Autoset” the rest of
the parameters. With support for the most common control configurations, the Genie reduces setup and
configuration time to less than 15 minutes. Autoset parameters vary with application type.
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CentriPro
Aquavar IPC Start-Up Genie
CHAPTER 4: SETPOINT
This setup allows configuration of up to 2 setpoints.
• Number of set points: Select the number of setpoints used in the application. If
multiple setpoints are used, the setpoint can be selected by the state of DI 33.
• Setpoint 1: This is the target value for the control loop. If multiple setpoints are
enabled, active when DI 33 = open.
• Setpoint 2: This is the target value for the control loop. If multiple setpoints are
enabled, active when DI 33 = closed.
• Is the speed at the design point known?: Enable the Work Point Calculation
if the speed at the design point is known. This information is most commonly
known in closed loop circulating systems
• Speed at Design Point: Set the motor speed in Hz at which System Design
Working Point is achieved.
• Speed at No Flow: Set the motor speed in Hz at which flow is zero and
minimum pressure is achieved.
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• Flow at Rated Speed: Set the flow value corresponding to flow at rated speed.
• Flow at Design Point: Set the flow value corresponding to flow at design point
• Dual Pump Value Increase: Defines the increase in setpoint when a lag pump
starts. This value is entered as a % of the Maximum Reference
• Sleep Mode: Sleep Mode allows the pump to stop when a no flow condition is
detected. A no flow condition means that the setpoint has been satisfied and the
pump is running at the sleep frequency.
• Minimum/Sleep Frequency: Enter the minimum limit for the motor speed.
The motor speed low limit can be set to correspond with the minimum output
frequency of the motor shaft. The Motor Speed Low Limit must not exceed the
Motor Frequency.
• Sleep Delay: The sleep delay time is the time the pump must stay at the sleep
frequency before going to sleep.
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CentriPro
Aquavar IPC Start-Up Genie
• Flow Check Window: Flow check window is the amount of pressure increase
used in the flow check function.
• Flow Check Low Time: Flow check low time defines how long the controller will
run at the setpoint during the flow check function.
• Flow Check High Time: Flow check high time defines how long the controller
will run at Flow Check Window + setpoint during the flow check function.
• Run the No Flow Power Calibration Setup: Start of auto setup of power data for No-Flow Power tuning.
22-39
design flow and at no flow. Scaled
• The first screen prompts to ensure the Sleep Frequency/Low Limit and
Motor Frequency have been set. If these points are not set the No Flow Power
Calibration will not operate properly.
• The next screen prompts to close all discharge valves and to press [Hand On] to
begin the No Flow Power Calibration process. Doing this ensures the pump will
operate at no flow/shutoff. If the pump does not operate at no flow during the
setup, the calibration data will be invalid.
• The controller will now begin running the pump while monitoring the power. In the first two steps the pump
is operated at 85% of maximum speed defined at Motor Speed High Limit [Hz] and the power to the pump
is monitored and saved. The pump then operates at 50% of maximum speed and the power is monitored
and saved. The no flow power curve is then constructed within the controller based on these 2 points using
the affinity laws. The No Flow Power Calibration Set-up is now complete. The power data can be saved by
pressing [OK] and then the down arrow. If any issues were encountered during the calibration process
discard the data by pressing [Cancel] and repeat the calibration process.
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Aquavar IPC Start-Up Genie
• Under Pressure Delay: Under Pressure Delay Time sets the delay before the
action set occurs when an Under Pressure condition in detected.
Given:
• Under Pressure Delay = 10 seconds
• Under Pressure Difference = 10%
• Setpoint = 50 psi
• High Feedback 1 Value = 300 psi.
When the system pressure falls below 20 psi (50 psi – (10% * 300 psi))
for more than 10 seconds, the controller will issue an Under Pressure Alarm or Warning.
• Pump Protect Delay: Pump Protect Delay sets the time between detection of a
Pump Protect Alarm condition and the issue of the Pump Protect Alarm.
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Aquavar IPC Start-Up Genie
• Terminal 19, 27, and 33 Digital Input: If not already set for Pump Protection or Dual Setpoint, select the
function from the available digital input range.
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Aquavar IPC Start-Up Genie
• Relay Function: To modify the relay function, first press OK and use the up and
down arrows to select the correct index. Selecting [0] allows modification of
Relay 1, [1] allows modification of Relay 2. Press OK to save the index and allow
editing of the relay function. Press OK to save the Relay Function setting. The
default setting for Relay 1 is to activate on No Alarm which can be used to detect
alarms, including loss of power. The default setting for Relay 2 is to activate on
Run.
• Relay on Delay: This is the delay time from when the relay function is triggered
to when the relay transitions its state. To modify the relay delay time first press
OK and use the up and down to select the correct index. Selecting [0] allows
modification of Relay 1, [1] allows modification of Relay 2. Press OK to save the
index and allow editing of the delay time. Press OK to save the Relay on Delay
setting.
• Terminal 42 Output Min: Scale the minimum output of the selected analog
signal at terminal 42, as a percentage of the maximum signal value. E.g. if OmA
of (0 Hz) is desired at 25% of the maximum output value, then program 25%.
• Terminal 42 Output Max: Scale the maximum output of the selected analog
signal at terminal 42.
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CentriPro
Aquavar IPC Start-Up Genie
CHAPTER 9: COMMUNICATION
This setup configures the on board fieldbus communications.
• Address: Enter the address for the FC port. The valid range depends on the
protocol.
• Parity/Stop Bits: Parity and stop bits selection for the FC ports.
• Minimum Response Delay: Specify the minimum delay time between receiving
a request and transmitting a response. This is used for overcoming modem
turnaround delays.
• Maximum Response Delay: Specify the maximum permissible delay time
between transmitting a request and receiving a response. Exceeding this delay
time will cause control time-out.
• Coasting Select: Select control of the coasting function via the terminals and/or
via the bus.
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• BACnet Device Instance: Enter a unique ID number for the BACnet device.
• MS/TP Max Masters: Define the address of the master which holds the highest
address in this network. Decreasing this value optimizes polling for the token.
• Control Timeout Time: enter the maximum time expected to pass between the
receptions of two consecutive telegrams. If this time is exceeded, it indicates
that the serial communication has stopped and the function selected will then
be carried out.
• Control Timeout Function: Select the time-out function. The time-out function
activates when the control word and reference fails to be updated within the
time period specified.
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Aquavar IPC Start-Up Genie
• Copy Setup to LCP for the transfer to other drive: To easily copy setup to
another drive, select “Yes” to copy setup to LCP then transfer LCP to another
drive and select “Copy from LCP” in the Start-Up Genie.
• Copy Setup from LCP: Select “All” to copy all parameters in all set-ups from the
LCP to the drive. Select “Application Only” to copy all parameters in all set-ups
except for size dependent parameters.
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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. IM262R00 October 2014