Franklin Electric VR Spec PAK User manual

franklinwater.com

ENGLISHEN

VR Spec PAK

Owner’s Manual

Table of Contents

PRODUCT INFORMATION - - - - - - - - - 3

Description - - - - - - - - - - - - - - 3

INSTALLATION - - - - - - - - - - - - - - 4

Physical Installation - - - - - - - - - - 4

Electrical Connections- - - - - - - - - 5

DRIVE CONFIGURATION - - - - - - - - - - 6

Multi-Drive Configuration - - - - - - - 6

Pump Discharge Pressure Sensing - - - 6

Pump Suction Pressure Sensing - - - - 6

Master VFD Control HMI Menu Settings 7

OPERATION - - - - - - - - - - - - - - - -14

VFD Discharge Pressure Sensing- - - -14

Assist Pump Speed Parameters - - - -14

Standby Activation Speed- - - - - - -15

VFD PID Setpoint Pressure - - - - - -15

Pre-Start Verifications- - - - - - - - -15

Starting the Package - - - - - - - - -16

SAFETY INSTRUCTIONS

This equipment should be installed and serviced by technically

qualified personnel who are familiar with the correct selection

and use of appropriate tools, equipment, and procedures. Failure

to comply with national and local electrical and plumbing codes

and within Franklin Electric recommendations may result in elec-

trical shock or fire hazard, unsatisfactory performance, or equip-

ment failure.

Know the product’s application, limitations, and potential haz-

ards. Read and follow instructions carefully to avoid injury and

property damage. Do not disassemble or repair unit unless

described in this manual.

Failure to follow installation or operation procedures and all

applicable codes may result in the following hazards:

Risk of death, personal injury, or

property damage due to explosion, fire,

or electric shock.

• Do not use to pump flammable, combustible, or explosive fluids

such as gasoline, fuel oil, kerosene, etc.

• Do not use in explosive atmospheres or hazardous locations as

classified by the NEC, ANSI/NFPA70.

• Do not handle a pump, pump motor, or drive with wet hands or

when standing on a wet or damp surface.

Risk of severe injury or death.

• To reduce risk of electrical shock, disconnect power before work-

ing on or around the system. More than one disconnect switch

may be required to de-energize the equipment before servicing.

• Check local electrical and building codes before installation. The

installation must be in accordance with their regulations as well

as the most recent National Electrical Code (NEC) and the Occu-

pational Safety and Health Act (OSHA).

• Wire pump system for correct voltage.

• Ensure that the system is properly grounded all the way to the

service entrance panel.

• When lifting or moving heavy components, use suitable lifting

equipment, in good condition, rated for at least 5 times the

weight of the materials being moved.

• Capacitors inside the drive can still hold lethal voltage even after

power has been disconnected—ALLOW 5 MINUTES FOR DAN-

GEROUS INTERNAL VOLTAGE TO DISCHARGE BEFORE REMOV-

ING COVER OR WORKING WITH INTERNAL COMPONENTS.

Risk of bodily injury, electric shock, or

equipment damage.

• This equipment must not be used by children or persons with

reduced physical, sensory or mental abilities, or lacking in experi-

ence and expertise, unless supervised or instructed. Children

may not use the equipment, nor may they play with the unit or in

the immediate vicinity.

• Equipment can start automatically. Lockout-Tagout before ser-

vicing equipment.

• Possible hot surfaces. Do not touch pumps during operation.

Allow all package components to cool for 30 minutes before

handling.

• Operation of this equipment requires detailed installation and

operation instructions provided in this manual for use with this

product. Read entire manual before starting installation and oper-

ation. End User should receive and retain manual for future use.

Risk of damage to pump or other equipment.

• Periodically inspect pump and system components. Regularly

check hoses for weakness or wear, making certain that all con-

nections are secure.

PRODUCT INFORMATION

Description

PRODUCT INFORMATION

Description

VR SpecPAK includes two, three, or four VR pumps controlled by separate variable

frequency drives, such as Q-Link Variable Frequency Drives, the Invertek drive, or the

Cerus X Drive.

VR Series Vertical Multi-Stage Pumps are available in options from 3 to 30 m3/h (16

to 160 GPM) at best efficiency point with all 316 stainless steel internal hydraulics for

superior durability, efficiency, and performance. A small footprint, premium motor,

and rugged components ensure long operating life to provide a water pumping solu-

tion in nearly any tough application. The pumps are suitable for water supply and

pressure boosting systems, irrigation and agriculture, water treatment, and HVAC

applications. For more information and aid during installation or maintenance, refer

to the included VR pump owner’s manual.

The Variable Frequency Drives (VFDs) within the package are designed to control and

protect the pump motors. For more information and aid during installation or main-

tenance, refer to the included VFD owner’s manual.

The package may come with an optional Master VFD Control HMI Screen. With this

control screen, the user has the ability to update parameters to each individual VFD

for ease of controlling the pumps as a package instead of individually. Parameters

include acceleration and deceleration ramp speed, PID information, VFD speed, pres-

sure setpoint, pressure transducer range, pump duty switch over time, standby acti-

vation speed and mode timer, assist pump start, stop and settling speeds, and wake

up differential.

The package as a whole is not under the same warranty. For warranty information, please see the owner’s

manual of each component.

What’s Included

1. VFD parameter listing for pumps

2. Couplings (2)

3. 304SS grooved end caps (2)

4. Variable Frequency Drive (VFD) Owner’s Manual

5. VR Pump Owner’s Manual

6. VR SpecPAK Owner’s Manual

INSTALLATION

Physical Installation

INSTALLATION

Physical Installation

1. Mount the package to a level foundation of suitable mass and rigidity using 0.50” bolts.

• Consult a building professional.

2. Attach the discharge end cap to the opposite side of the discharge header from

the incoming site water connection using one of the provided couplings.

3. Attach the suction end cap to the opposite side of the suction header using the

other coupling.

4. Make piping connections for the site water.

• The suction and discharge can be connected to either end of the manifolds.

5. Install isolation valves near both the inlet and outlet of the packaged assembly.

• These valves aid with startup loads and prevent full discharge draining during

maintenance.

6. Install an appropriately sized pressure relief valve on the discharge side of the

pump.

7. Refer to the VFD Owner’s Manual for setup instructions.

Risk of severe injury or death.

• When lifting or moving heavy components, use suitable lifting equipment, in good condition, rated

for at least 5 times the weight of the materials being moved.

Risk of bodily injury or property damage.

• Pumps can develop very high pressure in some situations. Always install a pressure relief valve able

to pass the full pump flow.

• Install the pressure relief valve near the pressure tank and route to a drain capable of full system

flow.

• Ensure that the foundation is rated to accommodate the operating weight of the package and that it

is sized sufficiently for the weight and loads the package will experience.

• Do not over tighten piping connections on the fittings used to connect the site plumbing to each

header as this could damage the equipment and/or headers.

INSTALLATION

Electrical Connections

• Refer to the VFD Owner’s Manual and the VR Pump Owner’s Manual for proper wiring, installation and

electrical instructions, and hazards.

• The base booster pump package comes with pre-wired VFDs and an

electrical control panel.

• Provide power and ground wiring sized for the voltage, phase and

fuse size listed on the UL 508A labeled panel. Terminate the power

wiring on the panel's fused disconnect and land the ground wire on

the sub panels electrical stud.

HMI Digital Outputs Wiring

NOTE: Some packages come without an HMI and, therefore, do not need wiring to the VFD.

Risk of severe injury or death by electrical shock.

• To minimize risk of electrical shock, disconnect power before working on or around the system.

• Capacitors inside the drive can still hold lethal voltage even after power has been disconnected—

ALLOW 5 MINUTES FOR DANGEROUS INTERNAL VOLTAGE TO DISCHARGE BEFORE REMOVING

COVER OR WORKING WITH INTERNAL COMPONENTS.

• Once site power has been provided to the control panel and those feeds are live, there will be ener-

gized electrical lines in the control panel up to the remote disconnect terminals even when the

panel's remote disconnect switch is off. Always de-energize the site power feeding the control panel

when opening the panel; otherwise, an electrical shock hazard will still exist which can cause serious

injury, death and major property damage.

HMI Relay Output HMI Terminals VFD #

O 1 1 & 2 1

O 2 3 & 4 2

O 3 5 & 6 3

O 4 7 & 8 4

DRIVE CONFIGURATION

Multi-Drive Configuration

DRIVE CONFIGURATION

Multi-Drive Configuration

• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary.

• The VFDs are configured to act as the central command structure for the package. One VFD is desig-

nated as the Master to provide cascade and speed control for all other VFD units.

• Master status can be switched between the VFDs by setting the correct parameter when the drive is in

Hand Mode and turned off.

• The package is configured to operate the pumps in a Lead/Lag fashion. Lead and lag roles are set by

the Master VFD.

• The lead pump designation will rotate so all VFDs will run about the same amount of time and not

exceed the hours set in the Pump Duty Switch Over Time parameter. Refer to “VFD Parameter Screens 1

& 2” on page 9 to modify this parameter with the Master VFD Control HMI Menu.

Pump Discharge Pressure Sensing

The pump discharge pressure is measured using one of the pressure transducers installed (per pump) and

wired into one of the analog inputs (AI). Refer to the VFD manual provided for the specific input terminal

number.

• For VFD discharge pressure sensing during operation, refer to “VFD Discharge Pressure Sensing”

on page 14.

• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary.

Pump Suction Pressure Sensing

To prevent pump damage during periods of abnormally low suction pressure, each pump circuit is equipped

with a Low Pressure Switch (LPS) on the inlet side to the pump(s). The LPS is normally open and closes

above 5 PSI.

• The switch is wired into the enable circuit on each VFD control terminal connection block (digital

input) to keep the string powered and the VFD enabled as long as the switch reads pressures

above 5 PSI.

• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary.

DRIVE CONFIGURATION

Master VFD Control HMI Menu Settings

Some units are equipped with a color touchscreen mounted to the

Master VFD Control HMI face.

• The touchscreen acts as an operating interface to control all VFD

programming and displays system conditions, trending informa-

tion, and alarm information.

• The Master VFD Control HMI communicates with the Master VFD

via Modbus and can read/write information to all VFDs.

• While PID control of the VFDs is still provided by the Master VFD,

PID control constants can be set in the Master VFD Control HMI

and written to the VFDs.

Master VFD Control HMI Function Keys

The function keys along the bottom will display the following screens:

1. Main Screen

2. VFD Parameter Screen 1

3. VFD Parameter Screen 2

4. Pump Status and Alarm Point Setting

5. Main Screen

NOTE: With the exception of the Main Screen, all screens require entry of the system passcode before view-

ing. Refer to “System Passcode” on page 12 for more details.

Risk of damage to equipment.

• Only use fingers or proper pointing devices, which have rubber tips, for pressing against the Master

VFD Control HMI touchscreen. Using pencils, pens, and screwdrivers could result in damaging the

screen.

12 3 4 5

DRIVE CONFIGURATION

Master VFD Control HMI Menu Settings

Master VFD Control HMI Main Screen

The main screen is displayed on power up or by pressing the F1 button.

1. System Status: shows whether the overall package is on or off.

• Pressing the red “OFF” button sends a disable command to the VFDs.

• Pressing the green “ON” button sends an enable command to the pump VFDs.

• A text field is shown above the button to indicate the overall state the On/Off button.

NOTE: Enabling the pump does not make it run, but allows the pump to run when the system pressure

is below the setpoint if the VFD is not in a fault condition.

2. Alarm System Information: displays an alarm or warning with errors.

• For alarms, an “Active Shutdown Alarms” icon displays along with a text icon describing the fault.

For example, “Lo Lo Pressure” is displayed in the figure above.

• Refer to “Alarm Settings” on page 10.

3. Alarm Log Button: refer to “Alarm Log Screen” on page 13.

4. Alarm Acknowledge Button: stops the alarm buzzer when pressed.

5. Individual Pump Enable Buttons: enables or disables the specified pump when pressed.

IMPORTANT: The enable buttons follow the order of the pumps on the physical rack. If the left pump is

changed from master status, the enable buttons will not move on the screen. The leftmost enable but-

ton will always control the leftmost pump.

6. Current Running State: shows the specific VFD field address and status.

• When the pump is running, the icon will turn green and the text “ON” appears.

• When the pump is off, the icon will be red and the text “OFF” will appear.

• The VFD address number is displayed in the upper right corner on the VFD display screen.

7. Boost Button: when enabled (“BOOST ON”), the lead pump will run at a frequency 3 Hz higher than

the Standby Activation Speed for 2 seconds. Then it will go into standby mode.

8. Live Operating Information: displays the system’s pressure setpoint (PSI), output frequency (HZ), out-

put current (A), and discharge pressure (PSI).

9. Trend Screen Button: refer to “Trend Screen” on page 11.

10. System/Project Info Button: refer to “System/Project Info Screen” on page 12.

DRIVE CONFIGURATION

Master VFD Control HMI Menu Settings

VFD Parameter Screens 1 & 2

• VFD Parameter Screen 1 and 2 are viewed by pressing F2 or F3 respectively.

• Access to either screen requires entering the system passcode. Refer to “System Passcode” on page 12.

• The current settings dictating VFD performance are shown in the Column marked CURRENT.

To update system operating values for either screen:

1. Press the applicable button under the NEW column.

2. Enter the new value in the input screen. Press the return button.

• If the input is beyond the allowable range, the return button will not operate.

3. Verify the updated value is shown in the NEW column.

• The value will be written into each of the VFDs.

• Once the value has been read back by the Master VFD Control HMI, the CURRENT column will

update.

VFD Parameter Locations:

*NOTE: These parameters are preset in the factory.

**NOTE: Wake Up Differential represents the percentage of pressure transducer range to be used to trigger

the wake-up call.

Screen Parameter

VFD Parameter Screen 1

Acceleration Ramp Speed

Deceleration Ramp Speed

PID Proportional Gain

PID Integral Time

PID Differential Time

Minimum VFD Speed

Maximum VFD Speed

*Pressure Setpoint (in PSI)

VFD Parameter Screen 2

Pressure Transducer Range

*Pump Duty Switch Over Time

Standby Activation Speed

Standby Mode Timer

*Assist Pump Start Speed

*Assist Pump Stop Speed

*Assist Pump Settling Time

**Wake Up Differential

DRIVE CONFIGURATION

Master VFD Control HMI Menu Settings

Extended VFD Parameters and Alarm Settings Screen

Viewed by pressing the F4 button, this screen shows additional information about VFD read parameters and

system alarm settings.

Access the screen requires entering the system passcode. Refer to “System Passcode” on page 12.

Extended VFD Read Parameters

This section of the screen shows current details of the VFD read parameters, including:

• Drive status: STOPPED (red) or RUNNING (green)

• Healthy/Trip

• Auto/Hand: current mode

• Drive Temp: internal drive temperature in Celsius

• kW: instantaneous power draw by drive in KW

• Run Time Hrs: actual VFD operating run time in hours

Alarm Settings

When a fault occurs, the Master VFD Control HMI Main screen will display the fault type and the alarm

buzzer will sound.

• Warnings do not stop pump operation.

• Alarm trips disable pump operation. The system will not enable the pumps again until the condi-

tion is corrected.

• To silence the alarm buzzer, press the “Alarm Acknowledge” button on the Main Screen. Refer to

“Master VFD Control HMI Main Screen” on page 8.

The current alarm timers and levels are displayed and can be updated by pressing the corresponding button

of the desired setting.

• Time settings are the amount of seconds that the pressure settings (PSI) needs to be exceeded

before the fault condition is triggered.

Fault Fault Type Description

Hi Hi Pressure Trip The discharge pressure reading is above the set level. The program regis-

ters a HIGH PRESSURE ALARM and disables the pump.

Hi Pressure Warning The discharge pressure reading is above the set level. The program regis-

ters a HIGH PRESSURE WARNING. Pump operation is not stopped.

Lo Pressure Warning The discharge pressure reading is below the set level. The program regis-

ters a LOW PRESSURE WARNING. Pump operation is not stopped.

Lo Lo Pressure Trip The discharge pressure reading is below the set level. The program regis-

ters a LOW PRESSURE ALARM and disables the pump.

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