Franklin Electric VR Spec PAK Pressure Boosting System Owner’s Manual

Franklin Electric VR Spec PAK Pressure Boosting System

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:

DANDER: 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.

WARNING: 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.

CAUTION: 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.

NOTICE: 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

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
WARNING: 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.

CAUTION: 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.

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.

Electrical Connections

WARNING: 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.
• 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.

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.

Master VFD Control HMI Menu Settings

NOTICE: 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.

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.

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”

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

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:

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

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.

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”

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
• W: 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”

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.

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.

Trend Screen

• This screen provides a graph of the setpoint pressure value and the measured discharged pressure cur-rently and historically.
• The setpoint values are plotted in green, while the measured pressure values are in red.
• To navigate to the screen, refer to “Master VFD Control HMI Main Screen” on page 8.

To customize the screen:

1. Press the “Hide Press SP Trend” button to hide or display the pressure setpoint.
2. Press the “Hide Press PV Trend” to hide or display the discharge pressure reading.
3. Change the min and max scale values along the vertical axis by selecting the desired graph line and then pressing on the respective upper and lower numbers.
   • A prompt to enter a new value will display.
   • The new value will update after pressing the return key.
4. Show or hide the horizontal grid lines by pressing the “G” button.
5. View historic graph views by pressing the “M” button.
   • Arrow toggle buttons will appear for navigation to the desired time period.

System/Project Info Screen

To navigate to this screen, refer to “Master VFD Control HMI Main Screen” on page 8.

1. Change Password button: validates and alters the new passcode entered. Refer to “System Passcode” on page 12 to change the system passcode.
2. Project Info button: displays a screen with customizable information provided at the time of purchase.
   • Screen headings include “Project Information” and “Spare Parts”.
3. “Press until Calibrate Screen appears” button: refer to “Calibrate Screen”

System Passcode

• When accessing any of the setup screens, a passcode screen will appear.
• The factory preset passcode is “0” (zero).
• For security purposes, the value shown in the “Passcode” field always displays as “0” and does not rep-resent the actual value.

To update the system passcode:

1. Press the display field to the right of the “Current Pass-code” text label to bring up the “Passcode Change” input screen.

2. Enter the current passcode on the input screen that appears.

3. Hit the return key.

4. Press the display field to the right of the “New Pass-code” text lable to bring up the “New Passcode” screen.

5. Enter the new passcode on the input screen.
   Hit the return key.

   • Refer to step 3 and the graphic.

6. Press the Change Password button on the System/Project Info screen.
   NOTE: The new passcode is accepted if the values in both fields return to “0” on the screen.

Calibrate Screen

1. Enter Info Mode button: secured access to Info Mode where advanced system settings such as memory bits, system integers, and time zones are set. For entry, adjustments and more details, consult the fac-tory or Technical Support.
2. Calibrate Touchscreen button: brings up a screen to coordinate the screen buttons with the user’s physical touch. Small buttons will appear one at a time on the screen for the user to press so the touch-screen accurately represents the system information and responds to input. To exit before fully cali-brated, press the ESC button.
3. ESC button: exits the screen.

Alarm Log Screen

• This screen provides an overview of present and historical faults registered by the system.
• The alarms are listed by group.
• To navigate to the screen, refer to “Master VFD Control HMI Main Screen”

1. Search button: displays detailed fault information, including a list of specific alarms registered and whether it was acknowledged.
   • Further information can be viewed by pressing the button again.
2. Reset button: clears the alarm count.
3. Refresh button: alarm log page is refreshed.
4. ESC button: exits the screen.
   •  The screen can also be exited using any of the function keys.

OPERATION

VFD Discharge Pressure Sensing

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

• The pump system maintains a set discharge pressure by comparing it to a user defined setpoint. Then the system adjusts the speed of the pump motor VFDs to achieve that setpoint.

• During no flow periods, the VFDs will stop the pump motors and enter standby mode. The system will stay in the ready state until the discharge pressure drops and water demand resumes. Refer to
  “Standby Activation Speed” on page 15.

• The lead pump will be the first pump dispatched to meet the pressure setpoint established in the VFD.

• The pump motor speed will be bounded by the minimum and maximum speed settings established in VFD parameters the speed driven by the PID control algorithm in the VFD.

Assist Pump Speed Parameters

Three factory preset VFD parameters control the speed at which additional assist pumps are activated or deactivated to aid the lead pump. Refer to the VFD Owner’s Manual for additional details as setup instruc-tions will vary. Within the Master VFD Control HMI they are:

1. Assist Pump Settling Time: the wait period, in seconds, before assist pumps are activated or deacti-vated.
2. Assist Pump Start Speed: the maximum speed the lead pump will run without more assistance before the Assist Pump Settling Time is reached.
   • If the lead pump is operated above the Assist Pump Start Speed for a period of time exceeding the Pump Settling Time, the Master VFD will start a lag pump and drive both at the same speed.
   • In Triplex and Quad packages, additional pumps will be activated to assist if needed.
3. Assist Stop Speed: the minimum speed at which the assist pumps will run before the Assist Pump Set-tling Time is reached.
   • Once the pumps operate at a speed lower than the Assist Pump Stop Speed for a period of time exceeding the Pump Settling Time, assist pumps are deactivated one at a time.
   • This parameter may be adjusted to have the assist pumps stay on longer or shut down sooner.

NOTE : Assist Stop Speed should be higher than the Standby Activation Speed setting. Refer to “Standby Activation Speed”

All three parameters can be viewed or modified in the VFD Parameter Screen 2 of the Master VFD Control HMI. When setting the parameters, be sure to consider pump efficiency curves, pump operating ranges, and any constraints to minimize pump run times. Refer to “VFD Parameter Screens 1 & 2”  Refer to the VFD Owner’s Manual for setting the speed parameters individually.

Standby Activation Speed

The Standby Activation Speed is the speed representing a no flow condition of the pump preset at the fac-tory. It can be determined by dead heading the lead pump and recording the pump speed. Refer to the VFD Owner’s Manual for additional details as setup instructions will vary. The parameter can be updated in the VFD Parameter Screen 2 of the Master VFD Control HMI. Refer to “VFD Parameter Screens

NOTE: Programming a Standby Activation Speed of 1-3 HZ above the value has the VFD go into standby mode during no flow periods.

When the lead pump motor is operated at a speed lower than the Standby Activation Speed for a period of time exceeding the Standby Mode Timer, the lead pump is taken off-line and placed in a standby status. The lead pump will remain in standby until the Master VFD measures a pressure less setpoint minus the PID Restart Error Level.

• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary.
• To set the Standby Mode Timer or the PID Restart Error Level via the Master VFD Control HMI, refer to “VFD Parameter Screens 1 & 2”

Boost Function

A boost function can be enabled so that the lead pump will run at a higher speed for a period of time before going into standby mode. This can be set up by programming a boost Speed Time for a value greater than 0 (this value is the seconds the boost will operate at) and setting the boost speed in the Preset Speed.

• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary.
• To activate the boost feature via the Master VFD Control HMI Menu, refer to “Master VFD Control HMI Main Screen”

VFD PID Setpoint Pressure

• The VFD PID reference parameter represents the pressure transducer range.
• The setpoint pressure is calculated internally by the VFD by dividing Pressure Setpoint by Pressure Transducer Range. Refer to “VFD Parameter Screens 1 & 2” on page 9 to change these parameters via the Master VFD Control HMI Menu.
• Refer to the VFD Owner’s Manual for additional details as setup instructions will vary for individual drives.
• If a replacement drive is installed without this function block programming, the discharge pressure set-point will need to be manually entered in the VFD. Refer to the owner’s manual for instructions.

Pre-Start Verifications

1. Check electrical incoming voltage meets requirements and an adequate ground connection exists.
2. Inspect the overall system for damage during installation.
3. Pressurize the system with the site water to remove any trapped air.
4. If there are any water leaks in the piping, isolate the location and tighten the connections.
   • If the leaks are at the threaded connections in the piping circuits, tighten each fitting so the suction and discharge manifolds equally distanced.

Starting the Package

1. Power on the VFDs, switching their disconnect switches to the ON position.
   • Refer to the VFD Owner’s Manual.
   • Each VFD should be in Hand Mode and turned off. Refer to the VFD Owner’s Manual for details on Hand and Auto Mode.
2. Make sure the VFD Setpoint Pressure for the unit is correct. Refer to “VFD PID Setpoint Pressure” on page 15.
3. Verify the Standby Activation Speed is correct.
   • Refer to “Standby Activation Speed” on page 15.
   • Isolate out the pumps to find the dead head speed corresponding to the site pressure setpoint.
   • Add 1-3 HZ to that number to find the speed at which the pumps go into standby mode if they operate at this frequency for the time period set in the Standby Mode Timer.
   • If the number calculated is different, update the Standby Activation Speed to the new value. Refer to “VFD Parameter Screens 1 & 2” on page 9 for entry via the Master VFD Control HMI Menu.
4. Verify Assist Pump Start and Stop speeds are correct. Refer to “Assist Pump Speed Parameters” on page 14.
5. Place each VFD in Auto Mode and turn on. Refer to the VFD Owner’s Manual.
6. Verify that the pump rotates clockwise when looking down at the motor.
   • If rotation is incorrect, change the phasing in the parameter setting at the VFD.
   • Refer to the VFD Owner’s Manual.
7. If needed, place each VFD in Hand mode and turn off to adjust the PID Proportional Gain, PID Integral Time, and PID Differential Time parameters to optimize pump performance for system demand changes.
   • Refer to “VFD Parameter Screens 1 & 2” on page 9 for entry via the Master VFD Control HMI Menu.

NOTE: For maintenance and troubleshooting of the VFDs and pumps, refer to their owner’s manuals.

References

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