Bell & Gossett INSTRUCTION MANUAL

Document No.: 176U7761

Revision B July 2003
VARIABLE SPEED PUMPING SYSTEMS
INSTRUCTION MANUAL

Technologic 500 Series TM

and
Technologic 500X Series TM

Pump Controller

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

DESCRIPTION: Microprocessor based dedicated pump controller for
variable volume pumping systems. The controller consists of the following
components: microprocessor, operator interface with 4 line display and
membrane key pad, and 24 VDC power supply.
OPERATIONAL LIMITS: See the controller nameplate for operating
voltage and current draw.
! DANGER
SAFETY
INSTRUCTIONS
This safety alert symbol will be used in this manual and on the equipment
Safety Instructions decal to draw attention to safety related instructions.
When used, the safety symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THE
INSTRUCTIONS MAY RESULT IN SAFETY HAZARD.

Bell & Gossett

175R5359
ITT Industries
Engineered for life

! DANGER
Rotating shafts and electrical equipment can
be hazardous. Therefore, it is strongly
recommended that all electrical work conform
to National Electrical Code (NEC) and all local
regulations. Installation, start-up and
maintenance should be performed only by
qualified personnel.
Factory recommended procedures, included in this manual, should be
followed. Always disconnect electrical power before working on the
unit.
Although shaft couplings or belt drives are generally not furnished by
the manufacturer, rotating shafts, couplings and belts must be protected
with securely mounted metal guards that are of sufficient thickness to
provide protection against flying particles such as keys, bolts and
coupling parts. Even when the motor is stopped, it should be consid-
ered “alive” as long as its controller is energized. Automatic circuits may
start the motor at any time. Keep hands away from the output shaft until
the motor has completely stopped and power is disconnected from the
controller.
Motor control equipment and electronic controls are connected to
hazardous line voltages. When servicing drives and electronic controls,
there will be exposed components at or above line potential. Extreme
care should be taken to protect against shock. Stand on an insulating
pad and make it a habit to use only one hand when checking compo-
nents. Always work with another person in case of an emergency.
Disconnect power whenever possible to check controls or to perform
maintenance. Be sure equipment is properly grounded. Wear safety
glasses whenever working on electric control or rotating equipment.
! DANGER
Touching electrical parts may be fatal, even after equipment has
been disconnected from AC line. To be sure that capacitors have
fully discharged, wait 14 minutes for 208 V and 460 V units and 30
minutes for 600 V units after power has been removed before
touching any internal component.
2
Safety Guidelines
1. The drive must be disconnected from the AC line before any
service work is done.
2. The “Stop/Off” key on the local control panel of the drive does not
disconnect the equipment from the AC line and is not to be used as
a safety switch.
3. Correct protective grounding of the equipment must be estab-
lished. The user must be protected against supply voltage and the
motor must be protected against overload in accordance with
applicable national and local regulations.
4. Ground currents are higher than 3 mA.
Warnings Against Unintended Start
1. While the drive is connected to the AC line, the motor can be
brought to a stop by means of external switch closures, serial bus
commands or references. If personal safety considerations make it
necessary to ensure that no unintended start occurs, these stops
are not sufficient.
2. During programming of parameters, the motor may start. Be
certain that no one is in the area of the motor or driven equipment
when changing parameters.
3. A motor that has been stopped may start unexpectedly if faults
occur in the electronics of the drive, or if an overload, a fault in the
supply AC line or a fault in the motor connection or other fault
clears.
4. If the “Local/Hand” key is activated, the motor can only be brought
to a stop by means of the “Stop/Off” key or an external safety
interlock.
Motor Overload Protection
NOTE
It is responsibility of user or person installing
drive to provide proper grounding and branch
circuit protection for incoming power and
motor overload according to National Electrical
Code (NEC) and local codes.
The electronic thermal relay (ETR) in UL listed Tech 500s provides
Class 20 motor overload protection in accordance with the NEC in
single motor applications when parameter 117 is set for ETR TRIP and
parameter 105 is set for rated motor current.
 Table of Contents

Section 1 GENERAL ....................................................................................................................................................... 5

1.1 Purpose of Manual ........................................................................................................................................................................................... 5
1.2 Vertical Installation ............................................................................................................................................................................................. 5
1.3 Clearances ....................................................................................................................................................................................................... 5
1.4 Backplate .......................................................................................................................................................................................................... 5
1.5 Grounding Plate ............................................................................................................................................................................................... 6
1.6 Shielded Wires ................................................................................................................................................................................................. 6
1.7 UL, C-UL, and CE Conformity .......................................................................................................................................................................... 6
1.8 Model Numbers ................................................................................................................................................................................................ 6
1.9 Model Number Description ............................................................................................................................................................................... 7

Section 2 ELECTRICAL CONNECTIONS ....................................................................................................................... 8

2.1 Power Connections .......................................................................................................................................................................................... 8
2.2 Locations of Conduit Entry, Terminal Blocks and Switches — NEMA 1................................................................................................................ 8
2.3 Locations of Conduit Entry, Terminal Blocks and Switches — NEMA 12.............................................................................................................. 9
2.4 Locations of Conduit Entry, Terminal Blocks and Switches — Drives Over 300 HP ........................................................................................... 10
2.5 Input Power Connection ................................................................................................................................................................................. 11
2.6 Motor Wiring Connection ................................................................................................................................................................................. 11
2.7 Grounding ...................................................................................................................................................................................................... 11
2.8 Location of Input Power (Mains) and Output Power (Motor Terminal Blocks) .................................................................................................... 12
2.9 Electrical Installation, Control Wiring ................................................................................................................................................................ 15
2.10 Electronic Thermal Protection ........................................................................................................................................................................ 15
2.11 High Voltage Form C Relay ........................................................................................................................................................................... 15
2.12 Digital Input 33 .............................................................................................................................................................................................. 15
2.13 DIP Switches 1 through 4 ............................................................................................................................................................................. 15
2.14 Ground Leakage Current ............................................................................................................................................................................. 16
2.15 Galvanic Isolation.......................................................................................................................................................................................... 16
2.16 Electrical Noise ............................................................................................................................................................................................. 16
2.17 Terminal Tightening Torque .......................................................................................................................................................................... 17

Section 3 USER INTERFACE ....................................................................................................................................... 20

3.1 Programming through the LCP ........................................................................................................................................................................ 20
3.2 Control Keys for Parameter Setup ................................................................................................................................................................... 20
3.3 Indicator Lamps .............................................................................................................................................................................................. 20
3.4 Local/Off/Remote Switch .................................................................................................................................................................................. 20
3.5 Tech 500/500X Control ................................................................................................................................................................................... 21
3.6 Display Modes ............................................................................................................................................................................................... 21
3.7 Changing Data ............................................................................................................................................................................................... 23
3.8 Enter/Change Quick Menu Parameter Data .................................................................................................................................................... 23
3.9 Example of Changing Parameter Data ............................................................................................................................................................ 24
3.10 Extended Menu ............................................................................................................................................................................................ 24
3.11 Initialization of Parameters ............................................................................................................................................................................. 24
3.12 Uploading/Downloading Parameters ............................................................................................................................................................. 24

Section 4 START UP ..................................................................................................................................................... 25

4.1 Pre-installation Checks .................................................................................................................................................................................... 25
4.2 Installation Checks .......................................................................................................................................................................................... 25
4.3 Apply Power to Controller ............................................................................................................................................................................... 25
4.4 Setting Up Controller for Motor Start ................................................................................................................................................................ 25
4.5 Operational Tests — HAND ............................................................................................................................................................................ 25
4.6 Operational Tests — AUTO ............................................................................................................................................................................. 25
4.7 General Troubleshooting ................................................................................................................................................................................ 25

3
Section 5 FEEDBACK TRANSMITTER WIRING .......................................................................................................... 26
5.1 Connecting Feedback Transmitters ................................................................................................................................................................. 26
5.2 Single 4 - 20 mA Flow Meter Connection ......................................................................................................................................................... 26
5.3 One or Two 4 - 20 mA Feedback Transmitters Connection .............................................................................................................................. 26
5.4 Two Feedback Signals and Two Setpoints Connection ................................................................................................................................... 27

Section 6 TECH 500 CONTROLLER SETUP ............................................................................................................... 28

6.1 Introduction ..................................................................................................................................................................................................... 28
6.2 Quick Menu Setup Instructions for Tech 500 .................................................................................................................................................... 29
6.3 Setup Instructions for AFD 2 and AFD 3 .......................................................................................................................................................... 30
6.4 HP to kW Convertion Table ............................................................................................................................................................................. 30

Section 7 TECH 500X CONTROLLER SETUP ............................................................................................................. 31

7.1 Introduction ...................................................................................................................................................................................................... 31
7.2 Setup Instructions for Tech 500X ..................................................................................................................................................................... 32
7.3 HP to kW Convertion Table ............................................................................................................................................................................. 34

Section 8 STATUS MESSAGES ................................................................................................................................... 35

8.1 Status Messages ............................................................................................................................................................................................. 35
8.2 Table of Status Messages ................................................................................................................................................................................ 35
8.3 Table of Additional B&G Parameters ................................................................................................................................................................ 37
8.4 Table of Changes to Previous Default Parameters ........................................................................................................................................... 37

Section 9 AUTOMATIC BYPASS .................................................................................................................................. 38

9.1 Mode of Operation .......................................................................................................................................................................................... 38
9.1.1 Setup A1 ...................................................................................................................................................................................................... 38
9.1.2 Setup B3 ..................................................................................................................................................................................................... 39
9.1.3 Setup C4/D4 ............................................................................................................................................................................................... 40
9.2 Options ........................................................................................................................................................................................................... 41

Section 10 PUMP ALTERNATION AND RELAY STATUS ............................................................................................ 42

10.1 Technologic 500 Pump Alternation ................................................................................................................................................................. 42
10.1.1 Pump Alternation with Automatic Bypass ...................................................................................................................................................... 42
10.1.2 Duty Standby ............................................................................................................................................................................................ 42
10.1.3 Pump On Time .......................................................................................................................................................................................... 42
10.1.4 Pump Cycles ............................................................................................................................................................................................. 42
10.1.5 Display Information .................................................................................................................................................................................... 42
10.2 Technologic 500X Pump Alternation .............................................................................................................................................................. 42
10.3 Relay Status ................................................................................................................................................................................................. 42

Section 11 WARNINGS AND ALARMS ......................................................................................................................... 43

11.1 Warning and Alarm Displays.......................................................................................................................................................................... 43
11.2 Description and Remedy ............................................................................................................................................................................... 43
11.3 Table of Alarms and Warnings ....................................................................................................................................................................... 44
11.4 Table of Alarm/Warning Voltage Limits ............................................................................................................................................................ 49

4
 Section 1 GENERAL

1.1 Purpose of Manual 1.4 Backplate

This manual is furnished to acquaint the user with practical ways to Mount directly to the wall all controllers without a backplate. This
install, operate, and maintain this unit. Read the information and safety ensures that air flow is in contact with the heatsink all the way from the
precautions presented here before installation or doing any work on bottom of the unit. If this is not possible, a metal plate at least as large as
the unit. the back of the unit must be firmly mounted to the back of the controller
(see tables below). A backplate assembly is available from Bell &
The material presented in this manual is arranged for installation, setup Gossett.
and operation of the equipment. In some instances the equipment may
be installed and programmed for immediate operation. It is still
NEMA 1
recommended that the user be familiar with all the content in this Backplate Required
manual. Those users familiar with the product will find sections of this
Controller Size Power
manual useful for procedural information and reference.
5 to 30 HP 200-240 V
1.2 Vertical Installation 15 to 75 HP 380-460 V
The controller must always be installed vertically. To ensure that no 150 to 300 HP 380-460 V
injury or damage occurs, the drive must always be firmly attached to 15 to 75 HP 550-600 V
200 to 300 HP 550-600 V
the wall or the floor before further installation work is carried out.

1.3 Clearances
NEMA 12
The controller is cooled by air circulation. For
Backplate Required
proper cooling, the minimum distances above X Controller Size Power
and below the unit must be maintained as
1 to 30 HP 200-240 V
shown in the table below. For units in an 1 to 75 HP 380-460 V
auxiliary enclosure with the controller
mounted on a backpanel, the required Backplate Requirements
clearances are measured from the top and
bottom of the controller, not the backpanel. X

All controllers can be mounted with no side clearance. Sufficient space

must be provided in front of the controller for door swing for units with a
hinged door. Controllers 350 HP and above require 25 inches (605
mm) front space for access. In addition, sufficient room must be
available for installation and service access. On units with an auxiliary
enclosure, the auxiliary enclosure door will have a greater door swing
than the controller. See the dimensional drawings of the auxiliary
enclosure which are included with the unit.
Units without a backplate must be mounted
directly to a solid wall with no spacers between
the controller and the wall. Free-standing units
without a backplate require a backplate to be
mounted.

Controller Size Top Clearance Bottom Clearance

1 to 3 HP, 200-240 V
4" (100mm) 4" (100mm)
1 to 10 HP, 380-460, 550-600 V
5 to 30 HP, 200-240 V
8" (200mm) 8" (200mm)
15 to 75 HP, 380-460, 550-600 V
40 to 60 HP, 200-240 V
9" (225mm) 9" (225mm)
100 to 125 HP, 380-460, 550-600 V
150 to 300 HP, 380-460, 550-600 V 12" (300mm) 12" (300mm)
350 to 600 HP, 380-460 V 16" (400mm) Floor mount

Mounting Clearances

5
1.5 Grounding Plate
Controllers up to 3 HP, 200 to 240 V, up to 10 HP, 380 to 460 V and
550 to 600 V with a NEMA 1 enclosure have a plastic bottom cover with
provision for conduit entry. To meet UL requirements, the metal
grounding plate must be in place above the plastic bottom cover. The
plate must be grounded to the chassis, and the conduit grounded to the
plate. If the grounding plate is not factory installed, it must be installed in
the units that have a plastic bottom panel to ensure proper grounding of
the conduit to the enclosure. Connect the ground wire from the
grounding plate to the ground tab marked with the ground symbol.
This tab is located near the AC line terminal strip. Mount the bottom
cover on the control unit.
1.7 UL, C-UL, and CE Conformity
All Tech 500 and Tech 500X pump controllers are CE marked, and all
controllers and option packages are UL and C-UL listed.
1.8 Model Numbers
The specific installation instructions may vary depending upon the
model of Technologic 500 or Technologic 500X series being installed.
When this occurs, the model can be identified by a 6XXX number. This
number can be found on the red nameplate on the outside left side of
the controller enclosure, or the outside right side of a controller with an
auxiliary enclosure. A model identification description can be found on
the next page.

1.6 Shielded Wires

Wires to control signals should be shielded to reduce radio frequency
noise interference. When RFI is a concern, shielded cable should be
used between the drive and the motor.

If unshielded control wires are used, control inputs are subject to signal
disturbances. Such disturbances may affect drive operation. Extreme
noise levels may disturb the microprocessor of the control card.

The shield of the control wires must be grounded at the cable clamp at
the bottom of the controller, but the shield must continue with the cable
all the way up to the control card. The shield is not to be connected to
any of the terminals on the control card. For safety reasons, the
insulation around the shield should only be removed where it is
connected to the cable clamp. The insulation should be left on the shield
between the clamp and the terminals.

Generally speaking, all conductors coming from a shielded control

cable must be as short as possible. Long conductor ends attract noise.
The shield must be connected to the chassis by means of the cable
clamp. Long pigtails on the shield reduce the effectiveness of the shield.

6
1.9 Model Number Description 230 Volt Input

Model Number Max. Nominal Max. Drive

Output HP Output Current
208 Volt Input 6002 1 4.2
6002 1½ 6.6
6003 2 7.5
Model Number Max. Nominal Max. Drive
6004 3 10.6
Output HP Output Current
6006 5 16.7
6002 1 4.6
6008 7½ 24.2
6002 1½ 6.6
6011 10 30.8
6003 2 7.5
6004 3 10.6 6016 15 46.2
6006 5 16.7 6022 20 59.4
6008 7½ 24.2 6027 25 74.8
6011 10 30.8 6032 30 88
6016 15 46.2 6042 40 104
6022 20 59.4 6052 50 130
6027 25 74.8 6062 60 154
6032 30 88
6042 40 114
6052 50 143 380 Volt Input
6062 60 169
Model Number Max. Nominal Max. Drive
Output HP Output Current
6002 1.1 3.0
6003 1.5 4.1
6004 2.2 5.6
460 Volt Input
6005 3 7.2
6006 4 10
Model Number Max. Nominal Max. Drive 6008 5.5 13
Output HP Output Current 6011 7.5 16
6002 1 2.1 6016 11 24
6002 1½ 3.0 6022 15 32
6003 2 3.4 6027 18.5 37.5
6004 3 4.8 6032 22 44
6006 5 8.2 6042 30 61
6008 7½ 11.0 6052 37 73
6011 10 14
6062 45 90
6016 15 21
6075 55 106
6022 20 27
6027 25 34 6100 75 147
6032 30 40 6125 90 177
6042 40 52 6150 110 212
6052 50 65 6175 132 260
6062 60 77 6225 160 315
6075 75 106 6275 200 368
6100 100 130
6102 100 130 600 Volt Input
6122 125 160
6125 125 160 Model Number Max. Nominal Max. Drive
6150 150 190 Output HP Output Current
6175 200 240
6002 1½ 2.4
6225 250 302
6003 2 2.7
6275 300 361
6004 3 3.9
6350 350 443
6005 4 4.9
6400 450 540
6006 5 6.1
6500 500 590
6008 7½ 9
6550 600 678
6011 10 11
6016 15 17
6022 20 22
6027 25 27
6032 30 32
6042 40 41
6052 50 52
6062 60 62
6072 75 77
6100 100 99
6125 125 125
6150 150 144
6175 200 192
6225 250 242
6275 275 289

7
 Section 2 ELECTRICAL CONNECTIONS
NEMA 1
2.1 Power Connections NEMA 1
1. Make all power connections with 75o C rated copper wiring.
2. Conduit entry must be from the bottom on all drives. Conduit
entries are provided on smaller drives. For drives with
auxiliary enclosures, refer to the dimensional drawings
provided for conduit entry locations.
3. To meet UL requirements, install the metal grounding plate in all
drives that have a plastic bottom. Install the grounding plate just
above the plastic bottom. Ground the metal plate to the chassis
and ground the conduit to the metal plate.
4. The conduit entries provide strain relief for the wires in drives
mounted in NEMA 1 or NEMA 12 enclosures. With chassis
mounted drives, the power and control wires must have strain
relief supplied by the installer. DO NOT rely on the terminal
blocks to provide strain relief.

2.2 Locations of Conduit Entry, Terminal Blocks

and Switches, NEMA 1
The following drawings illustrate the locations of the conduit entry,
control terminal blocks, the auxiliary relay connections, input and output
power terminal blocks, and the internal switches. On drives with an
auxiliary enclosure, some or all of the power connections at the drive
will be factory made. Custom input and output terminals may be inside 6006-6062, 200 to 240 V; 6016-6075, 6102, 6122, 380 to 460 V;
the auxiliary enclosure. See the drawings supplied with the Tech 500 6100-6150, 550-600 V
pump controller for details on custom terminal blocks and conduit entry
locations for the auxiliary enclosure.

6002-6004, 200 to 240 V

6002-6011, 380 to 460 V
6002-6011, 550 to 600 V 6100, 6125-6275, 380 to 460 V; 6175-6275, 550-600 V

8
2.3 Locations of Conduit Entry, Terminal Blocks NEMA 12
and Switches, NEMA 12

6002-6005, 200 to 240 V; 6002-6011, 380 to 460 V 6006-6032, 200 to 240 V; 6016-6075, 6102, 6122, 380 to 460 V

6042-6062, 200 to 240 V; 6100, 6125, 380 to 460 V 6150-6275, 380 to 460 V

9
2.4 Locations of Conduit Entry, Terminal Blocks NEMA 1 and NEMA 12
and Switches, Drives Over 300 HP

6350-6550, 380 to 460 V

10
2.5 Input Power Connection Drive Input Maximum
Model
Current AWG
For drives with no auxiliary enclosure, connect input power to drive 2.2 10 6002
terminals L1, L2, and L3, (terminal numbers 91, 92, and 93). If an auxiliary 2.5 10 6003
enclosure is provided, input power connections are made in the auxiliary 3.6 10 6004
4.6 10 6005
enclosure. Refer to the connection diagrams shipped with the unit. 5.7 10 6006
8.4 10 6008
Size wiring to the input current as shown in the tables below. Maximum 10.3 10 6011
AWG wire size is also provided. 16.6 6 6016
20.5 6 6022
25.2 6 6027
! CAUTION 29.9
38.3
2
2
6032
6042
Incoming power, motor wiring and control 48.5 1/0 6052
wiring should be run in three separate conduits 57.9 1/0 6062
71.8 1/0 6072
or raceways. 92 4/0 6100
117 4/0 6125
Enclosures for larger drives and auxiliary 134 4/0 6150
enclosures are made of metal. To avoid getting 179 2 x 4/0 6175
226 2 x 4/0 6225
metal chips into electronics, do not drill any 270 2 x 4/0 6275
holes after unit has been installed in a vertical
position.
600 VAC Input Current/Wire Gage
Drive Input Maximum
Model
Current AWG
5.0 10 6002
7.0 10 6003 All current ratings are in amps.
10.0 10 6004
16.0 10 6006
23.0 6 6008
30.0 6 6011 2.6 Motor Wiring Connection
46.0 6 6016

! WARNING
59.2 2 6022
74.8 2 6027
88.0 0 6032 Connecting input power to motor terminals will
101.3 1/0 6042
126.6 3/0 6052 result in drive failure when power is applied.
149.9 4/0 6062 Output motor cables from multiple drives must
be run in separate conduits or raceways.
208 VAC Input Current/Wire Gage
For drives with no auxiliary enclosure, connect the motor to drive
Drive Input Maximum
Current AWG
Model terminals U, V, and W (terminal numbers 96, 97, and 98). Terminal 99
2.5 10 6002 is earth ground. If an auxiliary enclosure is provided, refer to the
3.4 10 6003
connection diagrams shipped with the unit. Ground the shield on the
4.8 10 6004
8.3 10 6006 motor wire, if used, at both the drive and the motor.
10.6 10 6008
14 10 6011 2.7 Grounding
21 6 6016

! DANGER
27.6 6 6022
34 6 6027
41 6 6032 For operator safety, it is important to ground
53 2 6042
64 2 6052
drive properly.
77 2 6062
103 1/0 6075 Ground the drive properly. Use a ground wire at least 7 AWG (10mm2).
145 2/0 6100
174 3/0 6125 Connect the ground wire directly to a reliable earth ground. Do not use
206 2x1/0 6150 the conduit connecting to the drive as a replacement for a ground wire. Do
256 2x1/0 6175
317 2x3/0 6225
not ground one drive to another in a “daisy chain” fashion.
366 2x4/0 6275
443 3x1/0 6350
540 3x3/0 6400
590 3x3/0 6500
678 3x4/0 6550

460 VAC Input Current/Wire Gage

11
2.8 Location of Input Power (Mains) and Output
Power (Motor Terminal Blocks)
Connect input power to the terminals identified as L1, L2 and L3.
Connect the motor leads to the terminals identified as U, V and W.

! WARNING
Connecting input power to motor terminals will
result in drive failure when the power is applied.

NEMA 1
6042-6062, 200-240 V
6100, 6125, 380-460 V
6100-6150, 550-600 V

NEMA 1 and NEMA 12

6002-6005, 200-240 V
6002-6011, 380-460 V
6002-6011, 550-600 V

NEMA 1
6006-6032, 200-240 V NEMA 1
6016-6075, 6102, 6122, 380-460 V 6150-6275, 380-460 V
6016-6072, 550-600 V 6175-6275, 550-600 V

12
2.8 Location of Input Power (Mains) and Output
Power (Motor Terminal Blocks), continued
Connect input power to the terminals identified as L1, L2 and L3.

NEMA 12
6006-6032, 200-240 V
6016-6062, 380-460 V

NEMA 12
6150-6275, 380-460 V

NEMA 12
6042-6062, 200-240 V
6075-6125, 380-460 V

13
2.8 Location of Input Power (Mains) and Output
Power (Motor Terminal Blocks), continued
Connect input power to the terminals
identified as L1, L2 and L3.

NEMA 1 and NEMA 12, 6350-6550, 380-460 V

without disconnector and mains fuses

NEMA 1 and NEMA 12, 6350-6550, 380-460 V

with disconnector and mains fuses

14
2.9 Electrical Installation, Control Wiring
! CAUTION
Incoming power, motor wiring and control
wiring should be run in three separate conduits
or raceways.
Torque: 5 - 6 in-lbs (0.6 - 0.7 Nm)
Screw size: M3
Shielded control wires are recommended. To reduce interference from
electrical noise, ground the cable shield at a cable clamp, as shown
below, at both ends. Connect the shield to the grounded clamp. Very
long control wires may create 60 Hz interference. To resolve this,
connect one end of the shield to earth with a 0.1 µF capacitor, keeping
the leads as short as possible. If interference persists, disconnect the
grounded shield connection at the end opposite to the drive.
2.12 Digital Input 33
A spare digital input terminal number 33 is available and programmed
through parameter 307, Digital Input 33. Thirteen preset functions are
available including reset, freeze reference, hand start, auto start and
others.
2.13 DIP Switches 1 through 4
DIP switches are located on the control card.
They are used for serial communication and the common of digital
inputs 16 through 33. The switch positions shown are the factory
settings.
Switch 1 is not used.

Switches 2 and 3 are used for terminating serial communication. On the

first and last drive in a multiple device network, or on the only drive of a
single drive network, switches 2 and 3 must be ON (the default setting).
On all other drives in a multiple device network, set switches 2 and 3 to
OFF.

2.10 Electronic Thermal Protection Switch 4 separates the common for the internal 24 VDC supply from the
The electronic thermal relay is UL approved for single motor thermal common of the external 24 VDC supply. Normally this switch is ON and
protection as long as the following is complied with: the power supply is present at terminals 12 and 13. Set Switch 4 to the
OFF position when an external 24 VDC supply is used.
1. Parameter 117, Thermal Protection, is set to ETR TRIP.
2. Parameter 105, Motor Current, is set for the full-load nameplate
motor current.

2.11 High Voltage Form C Relay

The connections for the high-voltage relay are terminals 01, 02, 03.
The high-voltage relay is programmed in parameter 323, Relay
Output 1.
1+3 normally closed, 1+2 normally open
Max. 240 VAC, 2 Amp
Min. 24 VDC, 10 mA or
24 VAC, 100 mA
Max. wire gage: 10 AWG (4 mm2)
Terminal Torque: 5 in-lbs (0.6 Nm)

15
2.14 Ground Leakage Current
It is normal for there to be some leakage current from the drive to earth
ground. Paths of current leakage are shown on the drawing below.
The leakage current will exceed 3.5 mA.
2.15 Galvanic Isolation
Galvanic isolation offers protection from electric shock. All control
terminals of all Tech 500 pump controllers, and terminals 1 through 3 of
the relay output, offer galvanic isolation as long as the RFI switch (if
provided) is in the ON position. The galvanic isolation in the Tech 500
conforms to the European standard EN 50178.
The components that make up the galvanic isolation are:
1. Power supply, including signal isolation.
2. Gate drive for IGBTs, trigger transformers and optocouplers.
3. Output current Hall effect transducers.
Galvanic Isolation
Paths of Normal Current Leakage to Ground
16
2.16 Electrical Noise
In general, electrical noise can be divided into two forms: wire-borne
electromagnetic interference (EMI), and radiating radio frequency
interference (RFI).
Using shielded motor cables reduces RFI but increases EMI. This is
because shielded wires have a greater capacitance than unshielded
wires. Unshielded input power connections to the drive generate more
noise in the radio frequency range on the AC line. The shield reduces
the radiated noise, but increases the low-frequency electromagnetic
noise on the AC line. But, since the noise current is taken back to the
unit through the shield, only a small electromagnetic field is generated
from shielded motor wires.
With an EMI filter, the noise level on the AC line will be reduced to about
the same level for shielded and unshielded wires alike.
Connect the motor wiring shield, if used, in the enclosure of the drive as
well as at the motor. Use shield brackets to avoid “pigtail” shield ends.
Even short “pigtails” increase the shield’s impedance at higher
frequencies, which reduces the shield’s effect and increases the noise
produced.
It is generally easier and less complicated to use unshielded motor
wires than shielded cables. If unshielded wires are used, the RFI will
be greater. But, since the strength of the radiated signal decreases with
distance from the signal source, radiated noise is generally not a
problem.
To reduce the noise level from the total system (drive + installation)
make the motor wiring as short as possible.
Provide separate conduits, or raceways, for power, motor and control
wiring to provide the greatest immunity from distortion.
2.17 Terminal Tightening Torque
Tighten terminals connecting the controller input power, output to the 380 to 460 VAC Terminal Tightening Torque
motor(s) and ground to the values shown in the tables below. Units with
200 to 240 volts of 88 amps and less, and units with 380 to 600 volts of 90
Max. Drive Torque Max. Drive Torque
amps and less, have removable terminal blocks with screws. Larger units
Output Current in-lbs (Nm) Output Current in-lbs (Nm)
have fixed bolts. (See the controller nameplate for maximum drive output
to 10 5 (0.6) 147 100 (11.3)
current.)
16 5 (0.6) 177 100 (11.3)
24 17 (1.8) 212 100 (11.3)
32 17 (1.8) 260 100 (11.3)
37.5 17 (1.8) 315 100 (11.3)
44 28 (3.0) 368 100 (11.3)
61 28 (3.0) 487 372 (42.0)
200 to 240 VAC Terminal Tightening Torque 73 28 (3.0) 594 372 (42.0)
90 28 (3.0) 649 372 (42.0)
Max. Drive Torque 106 100 (11.3) 746 372 (42.0)
Output Current in-lbs (Nm )
6.6 5 (0.6)
7.5 5 (0.6)
10.6 5 (0.6)
16.7 5 (0.6)
550 to 600 VAC Terminal Tightening Torque
24.2 17 (1.8)
30.8 17 (1.8) Max. Drive Torque
46.2 28 (3.0) Output Current in-lbs (Nm)
59.4 28 (3.0)
74.8 28 (3.0) to 11 5 (0.6)
88 35 (4.0) 27 17 (1.8)
114 100 (11.3) 41 28 (3.0)
143 100 (11.3) 77 35 (4.0)
169 100 (11.3) 144 100 (11.3)
289 100 (11.3)
All current ratings are in amps.

200 to 208 VAC Auxiliary Control Panel Tightening Torques

200-208 V Max Overload In/Out Power Main Disco Drive Disco MN/BYP Fuse Drive Fuse Ground
CTK Breaker
Output Relay Terminal Switch Switch BLK BLK Terminal

4.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

6.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

7.5 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

10.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

16.7 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

24.2 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

30.8 A 17 (1.9) 35 (4.0) 22 (2.5) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

46 A 40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 45 (5.1) 45 (5.1) 50 (5.6)

59.4 A 40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 120 (13.6) 120 (13.6) 50 (5.6)

74.8 A 40 (4.5) 175 (19.8) 44 (5) 55 (6.2) 55 (6.2) 120 (13.6) 275 (30.1) 50 (5.6)

88 A 40 (4.5) 175 (19.8) 44 (5) 70 (7.9) 70 (7.9) 120 (13.6) 275 (30.1) 50 (5.6)

114 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

143 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

169 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 450 (50.8) N/A 275 (30.1)

All current ratings are in amps. All torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

17
2.17 Terminal Tightening Torque (continued)

230 to 240 VAC Auxiliary Control Panel Tightening Torques

230-240 V Max Overload In/Out Pow er Main Disco Drive Disco MN/BYP Fuse Drive Fuse Ground
CTK Breaker
Output Relay Term inal Sw itch Sw itch BLK BLK Term inal

4.2 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

6.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

7.5 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

10.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

16.7 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

24.2 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

30.8 A 17 (1.9) 35 (4.0) 22 (2.5) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

46.2 A 40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 45 (5.1) 45 (5.1) 50 (5.6)

59.4 A 40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 120 (13.6) 120 (13.6) 50 (5.6)

74.8 A 40 (4.5) 175 (19.8) 44 (5) 55 (6.2) 18 (2) 120 (13.6) 275 (30.1) 50 (5.6)

88 A 40 (4.5) 175 (19.8) 275 (30.1) 70 (7.9) 55 (6.2) 275 (31.1) 275 (30.1) 50 (5.6)

104 A 40 (4.5) 175 (19.8) 275 (30.1) 375 (42.4) 70 (7.9) 275 (31.1) N/A 50 (5.6)

130 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

154 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 450 (50.8) N/A 275 (30.1)

380 to 460 VAC Auxiliary Control Panel Tightening Torques

380-460 V Max Overload In/Out Power Main Disco Drive Disco MN/BYP Fuse Drive Fuse Ground
CTK Breaker
Output Relay Terminal Switch Switch BLK BLK Terminal

2.1 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

3.0 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

4.1 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

5.6 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

8.2 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

11.0 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

16 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

24 A 17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

32 A 17 (1.9) 35 (4.0) 22 (2.5) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

37.5 A 17 (1.9) 35 (4.0) 22 (2.5) 18 (2) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

44 A 40 (4.5) 35 (4.0) 22 (2.5) 18 (2) 18 (2) 45 (5.1) 45 (5.1) 50 (5.6)

61 A 40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 45 (5.1) 120 (13.6) 50 (5.6)

73 A 40 (4.5) 175 (19.8) 44 (5) 55 (6.2) 18 (2) 120 (13.6) 120 (13.6) 50 (5.6)

90 A 40 (4.5) 175 (19.8) 44 (5) 70 (7.9) 55 (6.2) 120 (13.6) 275 (30.1) 50 (5.6)

106 A 40 (4.5) 175 (19.8) 275 (30.1) 375 (42.4) 70 (7.9) 275 (31.1) N/A 50 (5.6)

147 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

177 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 275 (30.1)

212 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 450 (50.8) 500 (56.5) 275 (30.1)

260 A 200 (22.6) 375 (42.4) 275 (30.1) 500 (56.8) 500 (56.8) 450 (50.8) 500 (56.5) 275 (30.1)

315 A 375 (42.4) 375 (42.4) 275 (30.1) 500 (56.8) 500 (56.8) 450 (50.8) 275 (30.1) 275 (30.1)

368 A 375 (42.4) 375 (42.4) 275 (30.1) 500 (56.8) 500 (56.8) 375 (42.4) 375 (42.4) 275 (30.1)

Current ratings are in amps. Torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

18
2.17 Terminal Tightening Torque (continued)

550 to 600 VAC Auxiliary Control Panel Tightening Torques

550-600 V Max Overload In/Out Power Main Disco Drive Disco MN/BYP Fuse Drive Fuse Ground
CTK Breaker
Output Relay Terminal Switch Switch BLK BLK Terminal

1.7 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

2.4 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

2.7 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

3.9 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

6.1 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

9.0 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

11.0 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 25 (2.8) 45 (5.1)

17 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

22 A 17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

27 A 17 (1.9) 35 (4.0) 50 (5.6) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

32 A 17 (1.9) 35 (4.0) 50 (5.6) 18 (2) 18 (2) 45 (5.1) 120 (13.6) 45 (5.1)

41 A 40 (4.5) 35 (4.0) 50 (5.6) 18 (2) 18 (2) 45 (5.1) 120 (13.6) 50 (5.6)

52 A 40 (4.5) 175 (19.8) 50 (5.6) 70 (7.9) 55 (6.2) 120 (13.6) 120 (13.6) 50 (5.6)

62 A 40 (4.5) 175 (19.8) 50 (5.6) 70 (7.9) 55 (6.2) 120 (13.6) 120 (13.6) 50 (5.6)

77 A 40 (4.5) 175 (19.8) 275 (30.1) 70 (7.9) 55 (6.2) 120 (13.6) 120 (13.6) 50 (5.6)

99 A 40 (4.5) 175 (19.8) 275 (30.1) 375 (42.4) 70 (7.9) 275 (31.1) 275 (30.1) 50 (5.6)

125 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

144 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 275 (30.1)

192 A 200 (22.6) 275 (30.1) 275 (30.1) 375 (42.4) 375 (42.4) 450 (50.8) N/A 275 (30.1)

242 A 375 (42.4) 375 (42.4) 275 (30.1) 500 (56.8) 500 (56.8) 450 (50.8) 500 (56.5) 275 (30.1)

289 A 375 (42.4) 375 (42.4) 275 (30.1) 500 (56.8) 500 (56.8) 375 (42.4) 275 (30.1) 275 (30.1)

Current ratings are in amps. Torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

19
 Section 3 USER INTERFACE
3.1 Programming through the LCP
The combined display and keypad on the front of the Tech 500 is called
the Local Control Panel (LCP). The LCP is the user interface to the
pump controller.
The LCP has several user functions: programming the controller;
displaying operational data, along with warnings and cautions; to reset
the controller after a fault; to manually alternate pump selection; and, in
local control, to start/stop and control the speed of the Tech 500.
3.2 Control Keys for Parameter Setup
The keys are divided into groups by function. The keys between the
display and indicator lamps are used for parameter setup, selecting the
display indication during normal operation and controlling the drive
speed during local speed control operation.
[DISPLAY/MODE] is used to change display modes or
to return to the Display mode from either the Quick
Menu or the Extend Menu mode.
[QUICK MENU] gives access to the programming
parameters in the Quick Menu. These are the most
commonly used parameters in setting up the drive and
controller functions.
[EXTEND MENU] gives access to all drive parameters,
including Quick Menu items.
20
[CHANGE DATA] is used for changing a parameter
setting selected in either the Extend Menu or the Quick
Menu mode.
[CANCEL] is used if a change to a selected parameter
is not to be carried out.
[OK] is used for confirming a change to a selected
parameter.
[+] and [-] are used to scroll through parameters and
for changing a selected parameter. These keys can
also be used to change the drive speed as a function
of the local reference. In addition, the keys are used in
Display mode to switch between readouts.
[<>] are used when selecting a parameter group and
for moving the cursor to the desired digit when
changing numerical values. These keys are also used
to alternate pump selection.
3.3 Indicator Lamps
At the bottom of the control panel are three indicator lamps: a red alarm
lamp, a yellow warning lamp, and a green voltage (power on) lamp.
red yellow green
If pre-determined threshold values are exceeded, the alarm and/or
warning lamp is activated, and a status or alarm text is displayed. The
power-on light is activated when the Tech 500 receives voltage.
3.4 Local/Off/Remote Switch
The Local/Off/Remote switch provides a drive start command in Local,
a contact closure on terminal 17 for a remote start signal in Remote,
and an Off position. The drive must be in Auto Start mode for this to
function.
OFF
LOCAL REMOTE
3.5 Tech 500/500X Control
The keys below the indicator lamps are used for Start/Stop control
and selection of the operating site. Keys for control of the drive are
described below.
The [HAND START] key is used if the drive is to be
started from the control panel. Pressing [HAND START]
will give a start command to the drive. The
Tech 500/500X controller will not operate in this mode
and pump staging will not occur.
! WARNING
Motor will start when HAND START is activated.
The following control signals are active on the control
terminals when HAND START is activated:
• Hand Start - Off Stop - Auto Start - Reset
• Setup select lsb - Setup select msb
• Jog
• Run permissive
• Lock for data change
• Stop command from serial communication
[OFF/STOP] is used for stopping the connected
motor in Hand or Auto mode. If the stop function is
activated, the main display will flash. This key can
be disabled in parameter 013.
[AUTO START] is used if the Tech 500/500X is to
be controlled through the control terminals. When a
start signal is active on the control terminals and/or
serial bus, the unit will start.
! WARNING
Tech 500/500X can start at anytime with a start
signal through digital inputs. Digital inputs have
higher priority than control keys [HAND START]
and [AUTO START].
RESET is used for manually resetting the drive after a
fault trip (alarm) or pump/AFD fail. In this case, the top
line of the display will show TRIP (RESET). If the top
line of the display shows TRIP (AUTO START), the
drive will automatically restart. If the top line of the
display shows TRIPLOCK (DISC. MAINS), input power
to the drive must be removed before the trip can be
reset.
3.6 Display Modes
In Auto operational mode, information is displayed in any of three
programmable displays. Pressing the [DISPLAY MODE] key enters
display mode and toggle between modes I and II. While in Display
Mode, the [+] and [-] keys scroll through all data display options. When
in Mode II, holding down the [DISPLAY MODE] key enters Mode III
which identifies the units on the top line that the display is showing.
Mode IV is available only in local Hand operation and displays the
local speed reference.
In normal operation, three data readouts can be shown on the first
(top) line of the display. One readout is available for line 2 (the large
display). Parameters 008, 009 and 010 select the data displayed on
the top line. Parameter 007, Large Display Readout, selects the data
displayed on line 2. The list on the next page defines the operating data
that can be selected for the display readouts.
Line 3 displays pump status beginning with the lead pump in the left of
the three positions. Status indicators are: O=off, R=run, F=failed,
B=bypass. Pump alternation is reflected in the order pumps 1 through 3
are displayed. At start, “System Start Delay” is displayed for 20
seconds in line 3.
Line 4 (bottom line) automatically displays the operating status of the
drive (see 6.5 Status Messages).
The active setup number and an arrow indicating the direction of motor
rotation is shown. Clockwise indicates forward and counterclockwise
indicates reverse. The arrow body is removed if a stop command is
given or if the output frequency falls below 0.01 Hz.
Warnings and alarms (fault trips) will also be displayed. During an
alarm, ALARM and the alarm number is shown on the large display. An
explanation is given in line 3 or in lines 3 and 4. For a warning,
WARN. and the warning number is shown with an explanation in line 1.
Both alarms and warnings cause the display to flash.
VAR1.1 VAR1.2 VAR1.3
P1
VAR 2
P2 P3
SETUP
STATUS
21
Operating data options for the first and second line of the LCP display: 3.6.2 Display Mode II
This display mode shows three operating data values in the top line
Data Item: Unit:
Resulting reference, % %
programmed via parameters 007, 008, and 009. Pressing the
Resulting reference, unit [unit] [DISPLAY MODE] key toggles between Display Modes I and II.
Frequency Hz
% of maximum output frequency %
Motor current A
Power kW
Power HP 10.0U 10.0U 500U
Output energy kWh
Hours run
Used-defined readout
Setpoint 1
hours
[unit]
[unit]
50.0Hz SETUP

1
Setpoint 2 [unit] P2:R P3:R P1:O
Feedback 1 [unit]
Feedback 2 [unit] AUTO REMOTE RUNNING
Feedback [unit]
Motor voltage V
DC-link voltage V
Thermal load on motor %
Thermal load on drive % 3.6.3 Display Mode III
Input status, digital input [binary code] Press and hold the [DISPLAY MODE] key while in Mode II. Mode III is
Input status, analog terminal 53 V
Input status, analog terminal 54 V visible as long as the key is depressed. The top line changes to identify
Input status, analog terminal 60 mA the data names and units displayed. Lines 2 and 4 are unchanged.
Output status, relay status [binary code]
Pulse reference Hz When the key is released, the display returns to Mode II.
External reference %
Heat sink temperature °C
User-defined text [-]
PID output [unit]
FB analog input 60 [mA] FEED 1 FEED 2 FLOW
Three operating data values can be shown in the first display line and
one in the large display line, programmed via parameters 007, 008,
009, and 010.
60.0Hz SETUP

1
P1:R P2:R P3:O
3.6.1 Display Mode I AUTO REMOTE RUNNING
In Display mode I, the drive is in Auto mode with reference and control
determined via the control terminals. Below is an example in which the
drive is running in setup 1, in Auto mode, with a remote reference, and
at an output frequency of 40 Hz. Pump 2 is currently the lead pump 3.6.4 Display Mode IV
with Pump 3 running and Pump 1 off. This display mode is used for local operation, where the local speed
reference is given from the keypad. In this display mode, the reference
The text in line 1, FREQUENCY, describes the meter shown in the is determined via the [+] and [-] keys. Control is carried out through the
large display. Line 2 (large display) shows the current output bottom keys on the keypad. The first line indicates the required
frequency (40.0 Hz), direction of rotation (reverse arrow), and active reference. The third line gives the relative value of the output
setup (1). Line 3 reports pump status. Line 4 is the status line and the frequency in the form of a bar graph in relation to the maximum
information is automatically generated for display by the drive in frequency.
response to its operation. It shows that the drive is in auto mode, with a
remote reference, and that the motor is running. See Status Messages
section for a detailed description of line 4 data.
USE +/- 40Hz

FREQUENCY 40.0Hz SETUP

P2:R
40.0Hz
P3:R P1:O
SETUP

1 HAND LOCAL RUNNING

AUTO REMOTE RUNNING

22
3.7 Changing Data
Regardless of whether a parameter has been selected under the Quick
Menu or the Extend Menu, the procedure for changing data is the
same. Pressing the [CHANGE DATA] key gives access to changing the
selected parameter. Line 3 displays the parameter number and title.
The underlined function or number flashing in line 4 on the display is
subject to change.
The procedure for changing data depends on whether the selected
parameter represents a numerical data value or a function.
3.7.3 Changing Listed Numeric Values
A few parameters offer numeric lists of values that can be selected from
or changed. This means that if the numeric value is not listed, a value
may be entered using the procedure for changing numeric values. This
applies to parameter 102, Motor power; parameter 103, Motor voltage;
and parameter 104, Motor frequency.
3.8 Enter/Change Quick Menu Parameter Data
Enter or change parameter data or settings in accordance with the
following procedure.

3.7.1 Changing Numeric Values 1. Press [QUICK MENU] key.

If the chosen parameter represents a number value, the flashing digit 2. Use t and u keys to find parameter group to edit.
can be changed by means of the [+] and [-] keys. Position the cursor 3. Use [+] and [-] keys to find parameter to edit.
by using the t and u keys, then change the data value using the [+] 4. Press [CHANGE DATA] key.
and [-] keys. 5. Use [+] and [-] keys to select correct parameter setting. Or, to
move to digits within a number, use t and u arrows. Flashing
cursor indicates digit selected to change.
6. Press [CANCEL] key to disregard change, or press [OK] key to
FREQUENCY accept change and enter new setting.

24.2Hz SETUP

1
205 MAX.REFERENCE
000060.000 Hz

The selected digit is indicated by a flashing cursor. The bottom display

line gives the data value that will be entered (saved) by pressing the
[OK] button. Use [CANCEL] to ignore the change.

3.7.2 Changing Functional Values

If the selected parameter is a functional value, the selected text value
can be changed by means of the [+] and [-] keys.

MOTOR CURRENT

3.90 A SETUP

1
210 REFERENCE TYPE
SUM

The functional value flashes until signing off by pressing the [OK]
button. The functional value has then been selected. Use [CANCEL] to
ignore the change.

23
3.9 Example of Changing Parameter Data 3.12 Uploading/Downloading Parameters
Assume Parameter 206, Ramp Up Time, is set at 60 seconds. Change The local control panel (LCP) has the capability to store and transfer all
the ramp up time to 100 seconds in accordance with the following the parameters programmed into the Tech 500/500X controller. Setup
procedure. data stored in the LCP is useful as a backup for preserving initial
setting. This data can be downloaded from the LCP to the drive to
1. Press [QUICK MENU] key.
reestablish initial parameter settings, if so desired.
2. Press [+] key until you reach Parameter 206, Ramp Up Time.
3. Press [CHANGE DATA] key. This feature is also useful when setting up multiple drives. LCPs are
4. Press t key twice – hundreds digit will flash. removable and interchangeable. Once setup information has been
5. Press [+] key once to change hundreds digit from ‘0’ to ‘1.’ uploaded from the drive, the LCP may be connected to another drive
6. Press u key to move cursor to tens digit.
and all parameter setting downloaded to quickly program additional
7. Press [-] key until ‘6’ counts down to ‘0’ and setting for Ramp Up
drives with identical settings.
Time reads ‘100 s.’
8. Press [OK] key to enter new value into drive controller. To upload data, use the Extended Menu to find parameter 004, LCP
Copy. Select Upload All Parameters to store parameter settings
NOTE (including motor data) into the LCP. LCP Copy will be displayed while
Programming parameter functions available data is uploading. This may take a minute or two. To download data,
through Extended Menu key is done in select either Download All Parameters or Download
accordance with same procedure described for
Power-independent Parameters (to exclude motor data entered in
Quick Menu functions.
parameters 102 through 106).
3.10 Extended Menu Manually initializing the drive using parameter 620, Operating Mode,
In some applications, the Quick Menu will not access additional does not change the values stored in the LCP.
parameters necessary to set up the drive. To access all parameters,
including Quick Menu items, use the Extended Menu. The Extended
Menu is enabled by pressing the [EXTEND. MENU] key.

3.11 Initialization of Parameters

! CAUTION
Initialization using parameter 620, Operating
Mode, will reset drive to default parameters. Any
special application programming performed at
factory, during start-up or thereafter, will be lost.

It is possible to reset all parameters back to their original default values

at once. To reset the drive parameters to their read only default values,
select Initialize in parameter 620, Operating Mode, and cycle power to
the drive. The bottom line of the display will read “Initialized.” After
initialization, parameter 620 defaults back to Normal Operation.

These parameters are not reset by initialization:

Parameter 600 Operating hours
Parameter 601 Hours run
Parameter 602 kWh counter
Parameter 603 Number of power-ups
Parameter 604 Number of overtemperatures
Parameter 605 Number of overvoltages

24
 Section 4 START UP
4.1 Pre-installation Checks
1. Compare drive model number to what was ordered.
2. Ensure each of following are rated for same voltage:
• Controller
• Power line
• Motor
3. Record following motor data:
• Voltage
• Frequency
• Full load current
• Full load speed
• Power — convert HP to kW (See conversion table in this
manual.)
4. Ensure that rated controller current is equal to or greater than total
full load current.
• For multiple motor operations, add up full load current ratings of
all motors.
• Controller can be at most one size smaller than motor.
• If rating is less than motor, full motor output cannot be achieved.
5. Check motor wiring:
• Any disconnect between controller and motor should be
interlocked to safety interlock circuit to avoid unwanted trips.
• No power factor correction capacitors can be connected between
controller and motor.
• Two speed motors must be wired permanently for full speed.
• Y-start, r-run motors must be wired permanently for run.
4.2 Installation Checks
1. Input fusing in power supply for all controllers must be provided.
2. Environmental concerns — for standard NEMA 1 drive:
• Clean air supply
• Dry air (max 95% relative humidity, non-condensing)
• 14oF to 104oF ambient temperature operating range, or as rated
• 3,300 foot maximum elevation with no derating
3. Mounting
• Vertical
• Controllers with heat sink fins exposed in back of unit must be
mounted against a solid surface (see Clearances section in this
manual).
• Keep any construction dirt out of controller.
4. Wiring
• Wire controller in accordance with instructions and diagrams
received with unit.
• Separate conduits must be provided to controller for input power,
output power, and control wiring.
• Note that safety interlock and remote run/stop circuitry is 115 VAC
for controllers with bypasses.
• Use knockouts or conduit entry plates. Avoid metal shavings in cabinet.
• Protect signal wires from noise.
• Ground each controller and drive individually.
• Double check input and output power wiring for correct location.
! WARNING
Ensure that all safety instructions in this manual
as well as all local safety requirements have
been satisfied prior to applying power to unit.
4.3 Apply Power to Controller
Installation, start-up and maintenance should only be performed by
qualified personnel.
4.4 Setting Up Controller for Motor Start
Enter motor nameplate data into controller parameters in the following
sequence:
08 MOTOR POWER, parameter 102 (in kW) (See conversion table in
this manual.)
09 MOTOR VOLTAGE, parameter 103
10 MOTOR FREQUENCY, parameter 104
11 MOTOR CURRENT, parameter 105
12 MOTOR SPEED, parameter 106
Press HAND START key to initiate operation in local control.
4.5 Operational Tests, HAND
1. Check motor rotation from drive. If incorrect, disconnect input
power from drive and reverse two leads between drive and motor.
2. If a bypass is provided, check motor rotation in bypass mode. If
incorrect, disconnect input power from drive and reverse two input
power leads.
3. Accelerate motor quickly to full speed and verify operation.
4. Decelerate motor quickly to stop and verify operation.
5. Operate motor over entire speed range while closely checking for
resonance.
4.6 Operational Tests, AUTO
1. Ensure that controller follows run/stop and safety interlock
commands from system.
2. Ensure controller follows speed reference or feedback from system.
4.7 General Troubleshooting
1. Display Messages:
• AUTO START—Controller has tripped off and is in process of
automatically restarting.
• TRIP—Controller has tripped off. Press RESET to start.
• TRIP LOCKED—Controller has tripped off. Remove and apply
power before restarting with RESET.
2. Refer to Warnings and Alarms section in this manual.
3. Check tightness of all connections and wires for proper location.
4. Measure input signals.
5. Check controller input and output for balanced voltage and current.
25
 Section 5 FEEDBACK TRANSMITTER WIRING
5.1 Connecting Feedback Transmitters
Terminals 12 and 13 of the controller provide access to a 24 VDC,
200 mA power supply. This can be used to power remote transmitters,
so an external power supply is generally not needed. See Section 3
User Interface for procedures on accessing and setting drive
parameters.
5.2 Single 4 - 20 mA Flow Meter Connection
5.3 One or Two 4 - 20 mA Feedback
Transmitters Connection
When two feedback signals are used, the Tech 500 requires that they
both be connected to its analog voltage inputs, terminals 53 and 54.
Transmitters that produce a current signal can be used by adding two
resistors.

 



 
  

   
 

 

 


 
 
 



  
  
 
   
 

   







   

 

 
 
 
   
 



Parameter Description Setting   

413 MIN. FEEDBACK 0

414 MAX. FEEDBACK 100 If the transmitter is capable of producing 10V at 20 mA, the value of the
314 AI [mA] 60 FUNCT FEEDBACK resistor to use is:
315 AI 60 SCALE LOW 4 mA 10 V
R= = 500Ω
316 AI 60 SCALE HIGH 20 mA 20 mA

The input scaling of the Tech 500 analog inputs in this case would have
to be 2 - 10 Volt.

Parameter Description Setting

415 REF./FDBK UNIT PSI

413 MIN. FEEDBACK 0
414 MAX. FEEDBACK 100
417 2 FEEDBACK CALC. 2 ZONE MIN.
308 AI [V] 53 FUNCT. FEEDBACK
309 AI 53 SCALE LOW 2V
310 AI 53 SCALE HIGH 10 V
311 AI [54] 54 FUNCT. NO OPERATION
312 AI 54 SCALE LOW 2V
313 AI 54 SCALE HIGH 10 V

26
5.4 Two Feedback Signals and Two Setpoints Parameter Description Factory Setting
Connection
415 REF./FDBK UNIT PSI
Similar to two feedback signals and one setpoint, the need for two
413 MIN. FEEDBACK 0
feedback signals with two setpoints is frequently encountered. 414 MAX. FEEDBACK 100
Whenever two critical zones do not have the same setpoint value, two 417 2 FEEDBACK CALC. 2 ZONE MIN.
feedback with two setpoint control is required. Many pumping systems 308 AI [V] 53 FUNCT. FEEDBACK
require the monitoring and control of two loads that differ in size and 309 AI 53 SCALE LOW 2V
310 AI 53 SCALE HIGH 10 V
pressure drop.
311 AI [54] 54 FUNCT. NO OPERATION
312 AI 54 SCALE LOW 2V
To enable this setup, the feedback function in parameter 417, Feedback
313 AI 54 SCALE HIGH 10 V
Function, is selected. When selecting 2-zone Minimum in parameter
417, the drive will regulate the system so the feedbacks are equal to or
greater than their associated setpoints. If 2-zone Maximum is selected,
the feedbacks will be equal to or less than their associated setpoints.

Feedback 1 is associated with Setpoint 1 and Feedback 2 is associated

with Setpoint 2. The two independent groupings are continuously
monitored to satisfy both zones requirements.

The transmitters are connected to the Tech 500 in the same way as
shown in 5.3 Two 4 - 20 mA Feedback Transmitters Connection with
1 setpoint and 2 feedbacks. The feedback connected to terminal 53 is
assigned to setpoint 1 and the one connected to terminal 54 to setpoint
2. Both transmitters must have the same output signal and range.

27
 Section 6 TECH 500 CONTROLLER SETUP

6.1 Introduction
A quick menu list is activated by pressing the Quick Menu key on the
controller keypad. The 29 item quick menu allows programming the
Tech 500 controller, basic pump functions, and fine tuning the internal
PID controller. For programming a Tech 500X pump controller, see
Section 7.
The items on the quick menu are arranged in order for sequencial
programming. Review the factory settings prior to programming since
these settings frequently meet operational requirements. Many of the
Tech 500 programming features may already be set.
The quick menu items for programming the Tech 500 are arranged in
the following sequence (see block diagram):
01 – 07, 13 and 14 setup basic controller options for Tech 500
operation.
08 – 12 establish basic motor settings.
15 - 25 set pump parameters for system control.
26 - 29 provide instructions for fine tuning the PID controller for
operation after system start.
The remaining drives are programmed by entering data for quick menu
items 08 - 14 in sequence into each drive.

To program the Tech 500 for typical operation, scroll through the quick
menu items and enter the appropriate data required. Additional
parameter settings are available which can be selected through the
extended menu. The quick menu is designed to provide access to
those items most commonly used in setup and system operation. See
Section 3 User Interface for procedures on accessing and setting drive
parameters.
The Tech 500 has four independent setups that can be programmed.
The initial programming in this chapter is stored as Setup 1.
The Tech 500 has been programmed with factory settings typical for
operation. These settings may be satisfactory for initial start up of the
system.

MOTOR
08 Motor Power
09 Motor Voltage
10 Motor Frequency
11 Motor Current
12 Motor Rated Speed

MICROPROCESSOR

TECH 500 SETTINGS

01 Setpoint 1
PUMP 02 Setpoint 2
15 Pump Combination 03 Max. Feedback OUTPUT
16 Max. Pump Flow 04 Max. Reference
05 AO Terminal 42 Output
17 Alternation Time 07 Max. Feedback 60
06 AO Terminal 45 Output
18 Pumps Active During AZF 13 Min. Frequency
19 Low Suction Cut Out Time 14 Max. Frequency
20 High System Pressure
21 High System Proof Timer
22 NFSD Proof Timer
23 Min. Speed Proof Timer
24 Restart PV Drop
25 Min. Run Timer

PID CONTROLLER TUNING

26 PID Start-up Frequency
27 PID Proportional Gain
28 PID Integrator Time
29 PID Lowpass Filter Time

Tech 500 Controller Setup Block Diagram

28
6.2 Quick Menu Setup Instructions for Tech 500
See 3.7 Enter/Change Quick Menu Parameter Data for instructions on
entering and changing parameter data.
Quick Para. Name Units Range Factory Setting
Menu Number
Number
01 418 Setpoint 1 PSI Min. Ref. to Max. Ref. 0
Set the desired setpoint 1 value within the range of Min. Reference to Max. Reference.

02 419 Setpoint 2 PSI Min. Ref. to Max. Ref. 0

Set the desired setpoint 2 value within the range of Min. Reference to Max. Reference.

03 414 Maximum Feedback PSI Min. FB to 36

999,999.999
Set the value to display on the LCP when the feedback signal is at maximum. This display does not
effect the speed of the drive.
04 205 Maximum Reference PSI Min. Ref. to Max. FB 36
Set the maximum value for the sum of all references. The maximum reference is ignored when local
reference is active.
05 319 AO 42 Function - [0] – [44] PID Pulse Output
Select PID Pulse Output for the function of analog output terminal 42.

06 321 AO 45 Function - [0] – [44] Output Freq. 4-20 mA

Select Frequency Output 4 – 20 mA for the function of analog output terminal 45.

07 762 Maximum Feedback 60 0 to 999,999.999 0

Set the maximum value of the flow meter for input terminal 60.

08 102 Motor Power kW 0.25 to 500 Depends on drive size

Select the motor power in kW that equals the HP nameplate value of the motor. (See the HP to kW
conversion table in 6.4.)
09 103 Motor Voltage Volts 200 to 600 Depends on drive
Select the motor voltage that equals the voltage nameplate value of the motor (regardless of the AC
input voltage).
10 104 Motor Frequency Hz 50 / 60 60
Select the motor frequency in Hz that equals the nameplate value of the motor.

11 105 Motor Current Amps 0.01 to VLT rating Depends on drive and
motor settings.
Set the motor current value in amps that equals the nameplate value of the motor.

12 106 Motor Nominal Speed RPM 100 to 60,000 Depends on drive and
motor settings.
Set the rated motor speed value in RPM that equals the nameplate value of the motor.

13 201 Min. Frequency Hz 0.0 to Max. Freq. 18

Set the minimum drive output frequency value in Hz. The drive will be unable to run continuously below
this limit in any mode.
14 202 Max. Frequency Hz Min. Freq. to 120/1000 60
Set the maximum drive output frequency value in Hz. This value should correspond to the maximum
motor speed. The drive will be unable to run continuously above this limit in any mode.
15 712 Pump Combinations - 1 to 3 Master Only
Set the number of pumps operating in the system: Master Only; R6 @100% (AFD 2 on relay 6);
or R6, R7 @ 100% (AFD 2 on relay 6, and AFD 3 on relay 7).
16 763 Max Pump Flow GPM 0 to 999,999.999 Disabled
Set the value for End of Curve (EOC) pump protection.

17 770 Alternation Time Hours 0 to 999 Only Manual

Set the time between automatic pump alternation cycles.

18 772 Number of Pumps Active --- 1 to 3 1

During All Zone Fail
Enter the number of pumps that should operate in the event that all zones fail (AZF).

19 773 Low Suction Cut Out Time Sec. 0 to 999 Disabled

Set the Low Suction Alarm proof time delay in seconds upon receipt of low suction digital input.

29
 Quick Para. Name Units Range Factory Setting
Menu Number
Number
20 774 High System Pressure Units 0 to 999,999.999 Disable
Set the value when High System Pressure Alarm will be activated. A value of 0 will disable the high
system pressure function.
21 775 High System Proof Timer Sec. 0 to 999 0
Set the proof time prior to high system pressure shutdown.

22 776 NFSD Proof Timer Sec. 0 to 9999 Off

Set the no flow shut down proof time delay in seconds.

23 777 Min. Speed Proof Timer Sec. 0 to 9999 30

Set the minimum speed the drive will operate at during no flow shut down sequence.

24 778 Restart PV Drop PSI 0 to 999,999.999 Off

Enter the system pressure prior to restart after no flow shut down.

25 779 Min. Run Timer Sec. 60 to 600 (60=OFF) 600

Set the time period to ignore the no flow shut down sequence after restart from no flow shut down.

PID Controller Tuning

26 422 PID Start-up Frequency Hz Min. Freq. to Max. 15.0
Freq.
Set the desired start-up frequency between Min. Frequency and Max. Frequency. Each time the
drive is given a start command, the drive accelerates to the start-up frequency before PID control is
activated.
27 423 PID Proportional Gain Factor 0.00 to 10.0 7.0
1. With the motor started, set the PID Proportional Gain to 0.3 and increase it until the feedback
signal becomes unstable.
2. Reduce the value until the feedback signal has stabilized.
3. Lower the proportional gain by about half (40% to 60%).
28 424 PID Integrator Time Sec. 0.01 to 9999.0 20.0
1. With the motor started, set PID Integration Time to 20 seconds and reduce the value until the
feedback signal becomes unstable.
2. Increase the integration time until the feedback signal stabilizes.
3. Increase the integration time from 15% to 50%.
29 427 PID Lowpass Filter Time Sec. 0.01 to 10.00 0.02
Set the desired time constant (t).
Noise on the feedback signal can be reduced by the lowpass filter. The cut off frequency equals ½πt.
For example, if a time constant of 0.1 s is programmed, the cut off frequency for the lowpass filter will
be 1/[2π (.1)] = 1.6 Hz. The PID controller will then only respond to changes in the feedback signal
with a frequency less than 1.6 Hz.

6.3 Setup Instructions for AFD 2 and AFD 3 6.4 HP to kW Convertion Table
AFD 2 and AFD 3 drives run in open loop mode and receive stop/start
and speed reference commands from the Tech 500 controller. Each )1 L8 )1 L8
drive must be programmed with the nameplate data from the motor it 0.4 0.25 50 37
controls. For normal operation, all other parameter settings must remain 0.5 0.37 60 45
at factory default settings or match the settings in the Tech 500. 0.75 0.55 75 55
1.0 0.75 100 75
1. Program AFD 2 and AFD 3 drives for operation by entering motor 1.5 1.10 125 90
data for parameters 102 through 106, in sequence. 2 1.50 150 110
2. Ensure that parameter 100, Configuration, is set for Open Loop. 3 2.20 200 132
3. Ensure that the setting for Min. Frequency (parameter 201) and
4 3.00 250 160
Max. Frequency (parameter 202) match those of the Tech 500
5 4.00 300 200
pump controller Min. Frequency and Max. Frequency.
7.5 5.50 350 250
4. Ensure that terminal 17 (parameter 301) is set for Pulse Output.
10 7.50 400 300
15 11 420 315
20 15 450 355
25 18.5 500 400
30 22 540 450
40 30 600 500

30
 Section 7 TECH 500X CONTROLLER SETUP

7.1 Introduction NOTE

Items for standard mode operation (one Tech 500X controller and one
or two constant speed pumps) are arranged in order for quick and
easy programming. The Tech 500X has four independent setups that
can be programmed. The initial programming in this chapter is stored
as Setup 1.
The Tech 500X has been programmed with factory settings typical for
operation. These settings may be satisfactory for initial start up of the
system.
Enter motor data in sequence for parameters 102
through 106 since some data points automatically
change subsequent values.
The menu items for programming the Tech 500X are arranged in the
sequence of controller, motor, pump, and fine tuning the PID controller
(see block diagram).

MOTOR
102 Motor Power
103 Motor Voltage
104 Motor Frequency
105 Motor Current
106 Motor Rated Speed

CONTROLLER

CONTROLLER SETTINGS

418 Setpoint 1
PUMP 419 Setpoint 2
417 Feedback Calculation
712 Pump Combination 414 Max. Feedback
713 Staging Bandwidth 201 Min. Frequency
714 SBW Stage OFF Delay Timer 202 Max. Frequency
715 SBW Stage ON Delay Timer 205 Max. Reference
716 Override Bandwidth 723 Mode Select
717 OBW Timer
718 Transition Frequency
721 Destage Timer
762 Max. Feedback 60
776 NFSD Proof Timer
777 Min. Speed Proof Timer
778 Restart PV Drop
779 Min. Run Timer PID CONTROLLER TUNING
780 Pump Min. Frequency for NFSD
781 Pump Max. Frequency for NFSD 422 PID Start-up Frequency
782 NF Power at Min. Frequency 423 PID Proportional Gain
783 NF Power at Max. Frequency 424 PID Integrator Time
784 Multiplier for NF Detection 427 PID Lowpass Filter Time

Tech 500X Controller Setup Block Diagram

31
7.2 Setup Instructions for Tech 500X
Set parameter data in the order listed since some selections entered
change options available for items later in the list. See 3.7
Enter/Change Quick Menu Parameter Data for instructions on entering
and changing parameter data.

Para. Name Units Range Factory Setting

Number
418 Setpoint 1 PSI Min. Ref. to Max. Ref. 0
Set the desired Setpoint 1 value within the range of Min. Reference to Max. Reference.

419 Setpoint 2 PSI Min. Ref. to Max. Ref. 0

Set the desired Setpoint 2 value within the range of Min. Reference to Max. Reference.

417 Feedback Function — Nine options Two-zone

minimum
Use Two-zone Minimum with two feedback signals for the controller to calculate the difference
between Setpoint 1 and Feedback 1 as well as Setpoint 2 and Feedback 2. The controller will regulate
its output speed based upon the larger difference. Select Feedback 1 Only when only one feedback
signal is associated with Setpoint 1, read from terminal 53. Select Feedback 2 Only when only one
feedback signal is associated with Setpoint 2, read from terminal 54.
414 Maximum Feedback PSI Min. FB to 999,999.999 100
Set the value to display on the keypad display when the feedback signal is at maximum. This display
does not effect the speed of the drive.
201 Min. Frequency Hz 0.0 to Max. Freq. 18
Set the minimum drive output frequency value in Hz. The drive will be unable to run continuously
below this limit in any mode.
202 Max. Frequency Hz Min. Freq. to 120/1000 60
Set the maximum drive output frequency value in Hz. This value should correspond to the maximum
motor speed. The drive will be unable to run continuously above this limit in any mode.
205 Maximum Reference PSI Min. Ref. to Max. FB 36
Set the maximum value for the sum of all references. Max. Reference is ignored when local reference
is active.
102 Motor Power kW 0.25 to 500 Depends on
drive size
Select the motor power in kW that equals the HP nameplate value of the motor. (See the HP to kW
conversion table at the end of this table.)
103 Motor Voltage Volts 200 to 600 Depends on
drive.
Select the motor voltage that equals the voltage nameplate value of the motor (regardless of the AC
input voltage).
104 Motor Frequency Hz 50 / 60 60
Select the motor frequency in Hz that equals the nameplate value of the motor.

105 Motor Current Amps 0.01 to VLT rating Depends on

drive and motor
settings.
Set the motor current value in amps that equals the nameplate value of the motor.

106 Motor Nominal Speed RPM 100 to 60,000 Depends on

drive and motor
settings.
Set the rated motor speed value in RPM that equals the nameplate value of the motor.

723 Mode Select — Master/Slave or Standard Master/Slave

Control
Select Standard Control for operation with the Tech 500X with fixed speed pumps.

32
7.2 Setup Instructions for Tech 500X (continued)

Para. Name Units Range Factory Setting

Number
712 Pump Combinations — 1 to 3 Master Only
Set the number of pumps operating in the system: Master Only; R6 @100% (one slave pump on relay
6); R6, R7 @ 100% (one slave pump on relay 6, and one slave pump on relay 7); or R6 @ 100% R7
@ 200% (one pump of flow equal to the master on relay 6 and one pump with 200% flow on relay 7).
713 Staging Bandwidth (SBW) % 0% (OFF) to 100% 0
Percent
Set the pump staging bandwidth in percent of setpoint. The system will run within this range without
pump staging.
714 SBW Stage OFF Delay Sec. 0 (OFF) to 3,000 30
Timer
Set the delay time for staging off pumps when SBW is exceeded.

715 SBW Stage ON Delay Timer Sec. 0 (OFF) to 3,000 30

Set the delay time for staging on pumps when SBW is exceeded.

716 Override Bandwidth (OBW) % 2% to 100% (OFF) OFF

Set the override bandwidth in percent of setpoint that will ignore the SBW delay for immediate pump
staging.
NOTE: To avoid unintended staging during commissioning and controller fine
tuning, leave OBW at factory setting (OFF). After system tuning, set desired
value.

717 Override Bandwidth Timer Sec. 0 (OFF) to 300 10

Set the time duration the OBW timer will prevent pump staging after an override to allow the system to
stabilize.
718 Transition Frequency % 0% to 120% of Max. 90
Frequency
Set the percentage of Max. Frequency the controller will ramp to prior to staging pumps on or off to
prevent momentary pressure destabilization during staging activity.
721 Destage Timer Sec. 0 to 301 (OFF) 15
Set the time duration the variable speed pump will run at minimum speed before staging off a constant
speed pump.
762 Maximum Feedback 60 0 to 999,999.999 999,999.000
Set maximum value of the flow meter for input terminal 60.

776 NFSD Proof Timer Sec. 0 to 9999 Off

Set the time duration delay before no flow shut down in seconds.

777 Min. Speed Proof Timer Sec. 0 to 9999 30

Set the time duration the controller will operate at minimum speed during no flow shut down sequence.

778 Restart PV Drop PSI 0 to 999,999.999 Off

Enter the system pressure prior to restart after no flow shut down.

779 Min. Run Timer Sec. 60 to 600 600

Set the time period to ignore the no flow shut down sequence after restart following no flow shut down.

780 Pump Min. Frequency for Hz 0 to 9999 0

NFSD
Set this value equal to the controller Min. Frequency set in parameter 201.

781 Pump Max. Frequency for Hz 0 to 9999 0

NFSD
Set this value equal to the controller Max. Frequency set in parameter 202.

782 No Flow Power at Min. W 0 to 16000 0

Frequency
With the controller running in Hand Mode at Min. Frequency, determine the power delivered to the
motor when its outlet valve is closed. Power is displayed on the controller’s keypad display. Enter
that value here.
783 No Flow Power at Max. W 0 to 16000 0
Frequency
With the controller running in Hand Mode at Max. Frequency, determine the power delivered to the
motor when its outlet valve is closed. Power is displayed on the controller’s keypad display. Enter
that value here.
784 Multiplier for No Flow — 0.01 to 9.99 1.2
Detection
Set the multiplier to apply to the calculated no-flow power at any speed to determine whether no-flow
shutdown should be initiated.

33
7.2 Setup Instructions for Tech 500X (continued)
PID Tuning

Para. Name Units Range Factory Setting

Number
422 PID Start-up Frequency Hz Min. Freq. to Max. 15.0
Freq.
Set the desired start-up frequency between Min. Frequency and Max. Frequency. Each time the
drive is given a start command, the drive accelerates to the start-up frequency before PID control is
activated.
423 PID Proportional Gain Factor 0.00 to 10.0 7.0
1. With the motor started, set the PID Proportional Gain to 0.3 and increase it until the
feedback signal becomes unstable.
2. Reduce the value until the feedback signal has stabilized
3. Lower the proportional gain by about half (40% to 60%).
424 PID Integrator Time Sec. 0.01 to 9999.0 20.0
1. With the motor started, set PID Integration Time to 20 seconds and reduce the value until
the feedback signal becomes unstable.
2. Increase the integration time until the feedback signal stabilizes.
3. Increase the integration time from 15% to 50%.
427 PID Lowpass Filter Time Sec. 0.01 to 10.00 0.02
Set the desired time constant (t).
Noise on the feedback signal can be reduced by the lowpass filter. The cut off frequency equals
½πt. For example, if a time constant of 0.1 s is programmed, the cut off frequency for the lowpass
filter will be 1/[2π (.1)] = 1.6 Hz. The PID controller will then only respond to changes in the
feedback signal with a frequency less than 1.6 Hz.

7.3 HP to kW Convertion Table

)1
L8
)1
L8

0.4 0.25 50 37
0.5 0.37 60 45
0.75 0.55 75 55
1.0 0.75 100 75
1.5 1.10 125 90
2 1.50 150 110
3 2.20 200 132
4 3.00 250 160
5 4.00 300 200
7.5 5.50 350 250
10 7.50 400 300
15 11 420 315
20 15 450 355
25 18.5 500 400
30 22 540 450
40 30 600 500

34
 Section 8 STATUS MESSAGES

8.1 Status Messages 80.0% 5.08A 2.15kW

Status messages are generated automatically and appear in the fourth
(bottom) line of the display as shown.

A. The first part of the status line indicates the CONTROL POINT of P1:R
40.0 Hz P2:R P3:0
SETUP

the drive. AUTO REM. RUNNING

B. The center part of the status line indicates the REFERENCE
HAND LOCAL STOP
LOCATION.
OFF B RAMPING
C. The last part of the status line gives the present DRIVE STATUS.
A JOGGING
.
.
The table below defines the status massage display words. .
.
STANDBY
8.2 Table of Status Messages
C
DISPLAY DESRIPTION
WORD
CONTROL POINT
AUTO The drive is in Auto mode, which means that Run/Stop control is carried out
via the control terminals and/or serial communication.
HAND The drive is in Hand mode, which means that Run/Stop control is carried out
via the keys on the keypad
OFF OFF/STOP is activated either by means of the keypad, or by the digital
inputs Hand Start and Auto Start, both being a logic ‘0.’
REFERENCE LOCATION
REM. If REMOTE has been selected, the reference is set via the control terminals
or via serial communication.
LOCAL If LOCAL has been selected, the reference is set via the [+] and [-] keys on
the keypad.
DRIVE STATUS
RUNNING The motor speed now corresponds to the resulting reference.
RAMPING The output frequency is changing.
AUTO RAMP Parameter 208, Automatic Ramp, is enabled. The drive is attempting to
avoid a trip from overvoltage by extending its decel ramp time.
SLEEP.BST The boost function in parameter 406, Boost Setpoint, is enabled. This
function can only be enabled in Closed Loop operation.
SLEEP
! DANGER
When in Sleep mode, motor may restart at any time without
warning.

The energy saving function in parameter 403, Sleep Mode Timer, is enabled.
This status message shows that at present the motor has been stopped by
sleep mode. It can restart automatically.
START DEL
! DANGER
When in Start Delay mode, motor may restart at any time
without warning.

A start delay time has been programmed in parameter 111, Start Delay.
When the delay has passed, the drive will start and ramp up to the reference
frequency.

35
8.2 Table of Status Messages (continued)

DISPLAY DESRIPTION
WORD
RUN REQ.

! DANGER
When in Run Request mode, motor may restart at any time
without warning.

A start command has been given, but the motor will not be started until a
Run Permission signal is received via a digital input.
JOG Jog has been enabled via a digital input or via serial communication.
JOG REQ.

! DANGER
When in Jog Request mode, motor may restart at any time
without warning.

A start command has been given, but the motor will remain stopped until a
Run Permission signal is received via a digital input.
FRZ.OUT The output frequency has been frozen.
FRZ.REQ

! DANGER
When in Freeze Request mode, motor may restart at any time
without warning.

A start command has been given, but the motor will remain stopped until a
Run Permission signal is received via a digital input.
START F/R Reversing and start on terminal 19, parameter 303, Digital Inputs, and Start
on terminal 18, parameter 302, Digital Inputs, are enabled at the same time.
The motor will remain stopped until one of the signals becomes a logic ‘0.’
AMA RUN Automatic motor adaptation has been enabled in parameter 107, Automatic
Motor Adaptation, AMA.
AMA STOP Automatic motor adaptation has been completed. The drive is now ready for
operation after the Reset signal has been given. Note that the motor will start
after the drive has received the Reset signal.
STANDBY The drive is able to start the motor when a start command is received.
STOP The motor has been stopped via a stop signal from serial communication.
DC STOP The DC brake has been enabled in parameters 114 through 116.
UN.READY The drive is ready for operation, but terminal 27 is a logic ‘0’ and/or a
Coasting Command has been received via the serial communication.
CTR.READY This status is only active when a Profibus option card is installed.
NOT READY The drive is not ready for operation, because of a trip or because OFF1,
OFF2 or OFF3 is a logic ‘0.’
START IN. This status will only be displayed if, in parameter 599, Profidrive [1] has been
selected and OFF2 or OFF3 is a logic ‘0.’
XXXX The microprocessor of the control has stopped and the drive is not
operating. The cause may be noise on the power line, motor leads or control
wires.

36
8.3 Table of Additional B&G Parameters

No. N am e U n its L o w L im it H ig h L im it F a c to ry D e fa u lt

750 B&G P a r. % 0 100 95

751 B&G P a r. sec 0 999 30
752 B&G P a r. sec 0 999 60
753 B&G P a r. % 0 100 85
754 B&G P a r. sec 0 999 30
755 B&G P a r. % 0 100 50
760 B&G P a r. GPM 0 39 22
761 B&G P a r. GPM 0 0 0
764 B&G P a r. sec 0 999 30
765 B&G P a r. % 0 100 45
766 B&G P a r. sec 0 999 30
767 B&G P a r. GPM 0 100 0
768 B&G P a r. sec 0 999 0
769 B&G P a r. sec 0 60 20
771 B&G P a r. sec 1 200 10
780 B&G P a r. Hz 0 9999 0
781 B&G P a r. Hz 0 9999 0
782 B&G P a r. W 0 1 6 ,0 0 0 0
783 B&G P a r. W 0 1 6 ,0 0 0 0
784 B&G P a r. none 0 .7 5 2 .0 0 1 .2
785 B&G P a r. none 0 2 0 (D is a b le d )
786 B&G P a r. none 0 2 0
787 B&G P a r. none D is a b le E n a b le D is a b le
788 B&G P a r. none D is a b le E n a b le D is a b le

8.4 Table of Changes to Previous Default Parameters

Parameter
No. Title Changes
111 Start Delay Changed default value from 0 to 20 sec.
301 Terminal 17 Digital Input System Start/Stop: removing control voltage
initiates a sequenced stop. The PID controller
is stopped and reinitializes.
302 Terminal 18 Digital Input Programming Lock: applying control voltage
prevents programming the drive from the
keypad. Data Change Locked is displayed
when the [CHANGE DATA] key is pressed.
303 Terminal 19 Digital Input AFD-1 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
304 Terminal 27 Digital Input Add Low Suction Cut Out: a normally closed
pressure switch opens when pressure is
available; a timer issues a warning and trips
the drive at time out expiration.
305 Terminal 29 Digital Input AFD-2 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
306 Terminal 32 Digital Input AFD-3 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
317 All Zone Fail Proof Time All Zone Failure Timeout: low feedback signals
on terminals 53 and 54 issues an alarm and
the drives ramp to a preset user-defined speed.
One low signal causes a warning to be issued
with continued system operation.
319 Terminal 42 Output PID Pulse Output: the PID controller exports a
0 - 5000 Hz pulse for speed reference. The
reference output continues in drive stop mode.

37
 Section 9 AUTOMATIC BYPASS
9.1 Mode of Operation 9.1.1 Setup A1
The automatic bypass option allows for bypassing the Tech 500 TECH 500 controller One 100% A1 constant speed Three-contactor
controller to run directly from input line power. The Tech 500 has three pump bypass drive bypass

available configurations as standard. In the event of drive failure detection, the pump controller can
automatically start the pump across the line. For a motor or pump
Setup A1
failure, the controller can automatically shut down the system. Reset the
Setup B3
controller manually after the fault has been cleared. The
Setup C4/D4
Drive/Off/Bypass/Test switch can be used to manually select system
The active setup is displayed on the keypad display under the word operation in bypass from line power (bypass), from the controller
setup. Setup is selected in parameter 002, Active Setup. The following (drive), or to shut the system off.
parameters must be programmed for automatic bypass operation.

Parameter Range Default A1 B3 C4 D4

value
785 1-2 1 1 1 2 2
786 0-2 0 (disable) 1 1 1 2
787 Disable/Enable Disable Disable Disable Disable Disable

Master including TECH500

TECH500 controller

9A

9B
NO contact

8A
Bypass
8B

7A

7B

6A

6B

U/V/W

Main Input Power

A1 Bypass
"PUMP 1"

DIGITAL INPUT Relay 2 Motor/Pump/DP-switch

"Running"
16: (RESET) +24V

17: (SYSTEM START)

NO
18: (PROGRAM LOCK) switch

19: (AFD-1 INPUT)

27: (LOW SUCTION CUTOUT)

29: (NO OPERATION)

32: (PUMP 1 INPUT)

33: (NO OPERATION)

A1 Automatic Bypass Setup Block Diagram

(shown without manual HOA switch)

38
9.1.2 Setup B3

TECH 500 controller Two 100% B3 automatic line-powered

pumps bypass drive
Three-contactor
bypass
Two additional contactors enable the drive or bypass output to alternate
(manually or automatically) between the two motors. The two pumps do
not operate in parallel under normal operation. In the event of drive
failure detection, the pump controller can automatically start the pump
across the line. The variable speed pump will be stopped and wait a
built-in 13 second delay before line starting to allow the shaft to stop
rotating. For a motor or pump failure, the controller can automatically
start a standby pump after a 13 second delay following destaging the
failed pump. The standby pump will then be run in variable speed. With
a subsequent drive/pump failure, the pump will be line started after the
same destaging and delay sequence. In all cases, reset the controller
manually after the fault has been cleared.

Master including TECH500

TECH500 controller

9A

9B
NO contact

8A
Bypass
8B

7A
Select pump 2
7B

6A
Select pump 1
6B

U/V/W

Relay 2 Main Input Power

"RUNNING"

B3 Bypass unit

DIGITAL INPUT
"Pump 1"
16: (RESET)
Motor/Pump/
17: (SYSTEM START)
DP-switch
18: (PROGRAMMING LOCK)

19: (AFD-1 INPUT)

27: (LOW SUCTION CUTOUT) +24V

29: ()
NO
32: (PUMP 1 INPUT) switch

33: (PUMP 2 INPUT)

"Pump 2"

Motor/Pump/
DP-switch

+24V

NO
switch

B3 Automatic Bypass Setup Block Diagram

39
9.1.3 Setup C4/D4

TECH 500 Slave Two 100% D4 Automatic line- Two two-contactor

controller drive pumps (C4) powered bypass drive bypasses
Two 50%
pumps (D4)
The two pumps do not operate in parallel under normal operation. The
C4 configuration alternates drives and can automatically switch either of
the motors to AC line operation based on the Tech 500 logic. The D4
has the ability to stage on the second drive as needed to satisfy load
conditions, alternate the lead drive, and automatically switch either
motor to the AC line. The D4 can also stage motors in the bypass
mode. The Tech 500 logic controls the operation of drives and
bypasses. Components and circuitry for both bypasses are contained
in one common bypass enclosure, with the drives located on each side
and all mounted on a common back panel.
In the event of drive failure detection, the pump controller can automati-
cally start the second drive/pump combination for operation in variable
speed. The failed drive/pump will be destaged and wait a built-in 13
seconds delay before staging on the second drive/pump combination.
With a subsequent drive/pump failure, a standby pump will be line
started after the same destaging and delay sequence.
Parameter 785 allows selecting the number of drives to fail and
parameter 786 allows selecting a corresponding number of pumps to
be automatically started across the line in the event of failure of the
selected number of drives in parameter 785.
In all cases, reset the controller manually after the fault has been
cleared.

Master including TECH500 Slave drive

TECH500 controller

9A
Bypass pump2
9B
NO contact

8A
Bypass pump1
8B

7A

7B

6A
Start slave 1
6B

U/V/W U/V/W Relay 2

output output "Running"

Main Input Power Main Input Power

Relay 2
"Running"

D4 Bypass unit

Master - DIGITAL INPUT Slave - DIGITAL INPUT

16: (RESET) 18: (START)

17: (SYSTEM START)

18: (PROGRAM LOCK)

19: (AFD-1 INPUT) Motor/Pump/ Motor/Pump/

27: (LOW SUCTION CUTOUT) DP-switch DP-switch

29: (AFD-2 INPUT)

32: (PUMP 1 INPUT)

33: (PUMP 2 INPUT) +24V +24V

NO NO
switch switch

"Pump 1" "Pump 2"

C4/D4 Automatic Bypass Setup Block Diagram

40
9.2 Options
The bypass architecture for the Tech 500 controller allows for a variety
of optional control, indicator, and protective features.
Local/Off/Remote Switch
The Local/Off/Remote switch controls power to the Tech 500 system. In
the Local position, the system will be ON (connected to terminal 17 on
the Tech 500 controller). In the OFF position, the system will be OFF.
In Remote, the Tech 500 system is ON or OFF based on a contact
closure, such as from a building management system. In the single-
drive configuration this switch is mounted on the fused-disconnect
enclosure door.
Drive/Off/Bypass Switch (Two-contactor bypass)
A manual three-position Drive/Off/Bypass switch for each two-contactor
bypass is mounted on the bypass enclosure door to electrically select
whether a motor is powered from the Tech 500 controller (Drive), the
AC line (Bypass), or is disconnected from both (Off).
Drive/Off/Bypass/Test Switch (Three-contactor bypass)
A manual four-position switch mounted on the bypass enclosure door
electrically selects whether the motor is powered by the drive, the AC
line or is disconnected from both. In the Test mode, the motor is
disconnected from the controller and powered by the line, but power is
also applied to the controller for test purposes.
Fused Drive Disconnect Switch
A drive disconnect with drive input fuses allows manual switching of
input power to the Tech 500 controller and provides the controller with
short-circuit protection. The switch and fuses are mounted below the
controller in a separate fused-disconnect enclosure.
Main Panel Disconnect Switch
A main ON/OFF disconnect switch for switching input power for the
entire panel is mounted on the bypass enclosure.
Hi/Low Select (Optional)
A Hi/Low Select option increases the number of analog inputs from 2 to
4, and allows two of those inputs to be selected as analog inputs to the
controller. The component(s) for this option is housed in the fused-
disconnect or bypass enclosure.
Bypass Running Light
A light mounted on the bypass enclosure door indicates that the motor is
running in bypass.
Single-point Power Connection
A single incoming power connection supplies power for all drives and
bypasses, when supplied. The terminals mount in the Tech 500 fused-
disconnect or bypass enclosure.
Master Drive Failure Protection (Optional)
This option monitors the Tech 500 for functionality. If the
Drive/Off/Bypass switch is in the Drive position and voltage is not being
supplied to the drive (two or three drive fuses are cleared), the unit is
hardwired to JOG all available drives. The component(s) for this
function are mounted in the Tech 500 fused-disconnect or bypass
enclosure option.
Motor 1/Auto/Motor 2 Switch (B3 bypass only)
A manual three-position Motor 1/Auto/Motor 2 selector switch mounted
on the option enclosure door electrically selects which motor is
operated. In the Auto mode, the Tech 500 pump controller determines
which motor is operated via two of its Form C relays. The Motor 1 or
Motor 2 positions of the manual switch determine which respective
motor is operated.
Drive Input Fuses
Fast-acting, semiconductor input drive fuses provide short-circuit
protection to the drive.
Bypass Fuses
Dual-element, time-delay fuses provide short-circuit protection to the
motor while running in bypass. These fuses mount in the bypass
enclosure.
Motor Overload
The drive itself offers overload protection for one motor. A separate
overload must be used with the bypass and is mounted in the bypass
enclosure. The overload’s normally open auxiliary contact is
factory-wired to the pump 1 digital input of the controller.
41
 Section 10 PUMP ALTERNATION AND RELAY STATUS

10.1 Technologic 500 Pump Alternation 10.1.4 Pump Cycles

Pump alternation is available for both automatic and manual operation
in the Tech 500 (see 10.2 for Tech 500X operation). In automatic pump
alternation (with less than all pumps operating), an alternation timer
activates pump switching after a user-defined run interval. Alternation
sequence is pump 1 (with Tech 500 controller), pump 2, and pump 3.
During alternation, the current lead pump can run in parallel with the
new lead pump before staging off. The transition time for running in
parallel is 20 seconds by default. Transition time is adjustable between
0 and 60 seconds in parameter 769.
For manual control (with less than all pumps operating), the left and
right arrows on the LCP keypad alter pump operation. Pressing the left
arrow t sequences from pump 1 to pump 3 and pump 2. Pressing the
right arrow u sequences from pump 1 to pump 2 and pump 3. After
manual switching in automatic mode, the timer resets. In either mode,
pumps run in parallel during staging for a user-defined interval.
10.1.1 Pump Alternation with Automatic Bypass
The Tech 500 supports automatic bypass in both the B3 and C4/D4
configurations. In automatic pump alternation (with less than all pumps
operating), an alternation timer activates pump switching after a
user-defined run interval. For B3 and C4, when the alternation time
has expired, the lead pump executes a normal ramp down. After a 13
second delay, the new lead pump stages on. Alternation sequence is
pump 1 (with the Tech 500 controller), to pump 2. For the D4, the PID
controller remains active and receives sensor feedback. When the
alternation time expires, the new lead pump will run in parallel with the
old lead pump, and then the old lead pump drops out and stops.
For manual control with automatic bypass, the left and right arrows on the
LCP keypad alter pump operation. Pressing the left arrow t switches
from lead to pump 1. Pressing the right arrow u switches from lead to
pump 2. After manual switching in automatic mode, the timer resets.
Parameter 728: Pump 1
Parameter 729: Pump 2
Parameter 730: Pump 3
The Tech 500 controller counts the number of times each relay (pump)
is switched on. The cycle counter can be reset to zero when a pump is
replaced.
10.1.5 Display Information
B&G parameters 724 through 738 provide operational information
including the number of hours run, cycles, and the state of the relay for
each pump. See Section 3 User Interface for procedures on accessing
and setting drive parameters.
10.2 Technologic 500X Pump Alternation
The Tech 500X alternates pump operation of equal sized motors based
upon pump run time. The pump with the least number of operating
hours is staged on. Pump alternation only occurs at staging and manual
operation is not supported.
10.3 Relay Status
The display panel on the Tech 500/500X allows reading the status of
the relays.
Press the [DISPLAY MODE] key. Use the [+] and [-] keys to scroll
through the list to RELAY STATUS. The relay status readout consists of
8 binary bits. The first bit (starting from left) indicates the status of relay
01 which is located in the power section of the drive. The second digit
is relay 02 which is located on the drive control card. Digits 3 - 6
indicate the four controller relays (relays 06, 07, 08 and 09) located on
the Tech 500/500X board. Digits 7-8 are reserved for future use.
The readout can be very useful during commissioning to see how
many pumps are in operation.

10.1.2 Duty Standby RELAY STATUS

When duty standby is enabled in parameter 788, the lag pump will act
as a standby pump. The standby pump will not stage on during normal
operation, but, in the event of duty pump failure, will take the place of
101000 SETUP

1
P1:R P2:R P3:O
the failed pump until manual reset of the system. The standby pump
complies with the pump alternation characteristics described in 10.1, AUTO REMOTE RUNNING
with or without automatic bypass. Standby applies to the last pump in
the current alternation sequence.
Relay open: 0
10.1.3 Pump On Time Relay closed: 1
Parameter 724: Pump 1 NOTE
Parameter 725: Pump 2 For readout via serial communication, parameter
Parameter 726: Pump 3 537 must be used.
A timer accumulates hours the pump has run. The counter is updated Bit 7 = Relay 01
10 times per hour which means that cycles less than 6 minutes are not Bit 6 = Relay 02
registered. The hours can be reset to zero when a pump is replaced. Bits 5 - 4 = Relays 06 - 07

42
 Section 11 WARNINGS AND ALARMS
11.1 Warning and Alarm Displays 11.2 Description and Remedy
A warning will flash on the large display line along with the warning The table in 8.3 Table of Alarms and Warnings gives Tech 500/500X
number. The explanation is displayed on the top (line 1). warnings and alarms and indicates whether the fault trip-locks the
drive. An alarm is issued when the drive is tripped (discontinues
operation). A warning is issued when an alarm condition is impending.
LOW SUCTION CUT OUT After a trip-lock fault, the input power must be removed, the cause of the
fault corrected, and input power restored to reset the drive. Table 8.3

WARN.72
P1:R P2:R P3:R
SETUP

1
also describes the common remedies for the fault condition.

If the Tech 500/500X trips, the controller will continue to operate and
will not perform a sequenced stop providing power is supplied to the
AUTO REMOTE RUNNING
Tech 500/500X card.

A trip-lock fault can be reset in any one of three ways:

An alarm will flash on the large display line along with the alarm 1) Pressing the RESET key on the keypad
number. The explanation is displayed on line 3 or on lines 3 and 4. 2) Digital input
3) Serial communication input

Where an “X” is placed under both warning and alarm in the table in
TRIP (RESET)
8.3, this means that a warning precedes the alarm. After a trip, the

ALARM 72
LOW SUCTION CUT OUT
SETUP

1
motor will be coasting and the drive warning and alarm indications will
flash. If the fault is removed, only the alarm will flash. After a reset, the
drive will be ready to start operation again.

The Descriptions and Remedy column defines the warnings and

alarms and offers common suggestions that typically clear the fault
condition.

43
11.3 Table of Alarms and Warnings
No. Title Warn
1 UNDER 10 VOLTS X The 10 V voltage from terminal 50 on the control
2 LIVE ZERO ERROR
4 MAINS PHASE LOSS
5 DC LINK VOLTAGE HIGH
6 DC LINK VOLTAGE LOW
7 DC LINK OVERVOLT
8 DC LINK UNDERVOLT
44
Alarm Trip Description and Remedy
(Trip) Lock
card is below 10 V.
Remove some of the load from terminal 50, as
the 10 volts supply is overloaded. Maximum load
is 17 mA, minimum resistance is 590 Ω.
X X The current or voltage signal on terminal 53, 54
or 60 is below 50% of the value preset in
parameters 309, 312 and 315 Terminal,
Minimum Scaling.
X X X Phase missing on the input power. Check the
supply voltage to the drive.
X The intermediate DC circuit voltage is higher
than Voltage Warning High, see table in 8.4. The
drive is still controlling the motor.
X The intermediate DC circuit voltage is lower than
Voltage Warning Low, see table in 8.4. The drive
is still controlling the motor.
X X If the intermediate circuit voltage (DC) is higher
than the Overvoltage Limit of the drive (see table
in 8.4), the drive will trip after a fixed period. The
length of this period depends upon the unit.
X X If the intermediate circuit voltage (DC) drops
below the Undervoltage Limit of the drive
inverter(see table in 8.4), the drive will trip after a
fixed period. The length of the period depends
upon the unit.
The voltage will be stated in the display. Check
whether the supply voltage matches the drive
rating.
11.3 Table of Alarms and Warnings (continued)

No. Title Warn Alarm Trip Description and Remedy

(Trip) Lock

9 INVERTER TIME X X The electronic thermal inverter protection reports

that the drive is about to trip because of an
overload. The counter for electronic thermal
inverter protection gives a warning at 98% and
trips at 100% showing an alarm. The drive
cannot be reset until the counter drops below
90%. Activate ASFM (Automatic Switching
Frequency Modulation) in parameter 408,
Interference Reduction Method, or reduce the
carrier frequency in parameter 407, Switching
Frequency.

10 MOTOR TIME X X According to the electronic thermal protection,

the motor is overheated. The fault is that the
motor is overloaded to more than 100% of the
preset rated motor current for too long. Check
that the motor parameters 102 through 106 have
been set correctly.

11 MOTOR THERMISTOR X X The thermistor or the thermistor connection has

been disconnected. Check that the thermistor
has been correctly connected between terminal
53 or 54 (analog voltage input) and terminal 50
(+10 V supply).

12 CURRENT LIMIT X X The current is higher than the value in parameter

215, Current Limit, and the drive trips after the
time set in parameter 412, Trip Delay
Overcurrent, has passed. Run AMA in parameter
107, Automatic Motor Adaptation.

13 OVERCURRENT X X The inverter peak current limit, approximately

200% of the rated current, has been exceeded.
The warning will last approximately 1 or 2
seconds, and then the drive will trip and signal
an alarm.

Turn off the drive and check for free rotation of

the motor shaft and other causes of the overload.
Run AMA in parameter 107, Automatic Motor
Adaptation.

14 EARTH FAULT X X There is current leakage from the output phases

to ground, either in the leads between the drive
and the motor or in the motor itself.

Remove power to the drive and correct the

ground fault.

45
11.3 Table of Alarms and Warnings (continued)

No. Title Warn Alarm Trip Description and Remedy

(Trip) Lock

15 SWITCH MODE FAULT X X Fault in the switch mode power supply (internal
±15 V supply).

Contact the Bell & Gossett service department.

16 CURR.SHORT CIRCUIT X X There is a short circuit in the output from the

drive.

Remove power to the drive and correct the short

circuit.

17 STD BUSTIMEOUT X X There is no serial communication with the drive.

This warning will only be enabled if parameter

510, Bus Time Interval Function, has been set to
a value different from OFF.

If parameter 510, Bus Time Interval Function,

has been set to Stop and Trip [5], the drive will
first give off an alarm, then ramp down and finally
trip while giving an alarm. It is possible to
increase parameter 509, Bus Time Interval.

18 HPFB TIMEOUT X X There is no serial communication with the

communication option card in the drive.

The warning will only be enabled if parameter

804, Bus Time Interval Function, has been set to
anything but OFF. If parameter 804, Bus Time
Interval Function, has been set to Stop and Trip,
the drive will first give an alarm, then ramp down
and finally trip while giving an alarm.

Parameter 803, Bus Time Interval could possibly

be increased. Parameter 803 is only available
when a communication option card is installed in
the drive.

19 EE ERROR POWER X There is a fault on the power card EEPROM. The

drive will continue to function, but is likely to fail
at the next power-up. Contact the Bell & Gossett
service department.

20 EE ERROR CONTROL X There is a fault in the EEPROM on the control

card. The drive will continue to function, but is
likely to fail at the next power-up. Contact the
Bell & Gossett service department.

46
11.3 Table of Alarms and Warnings (continued)

No. Title Warn Alarm Trip Description and Remedy

(Trip) Lock

22 AMA FAULT X A fault has been found during automatic motor

adaptation. The text shown in the display
indicates a fault message.

29 HEAT SINK OVERTEMP. X X The heatsink temperature became too high. For
NEMA 1 drives, the limit is 90°C. For NEMA 12
drives, the limit is 80°C. The tolerance is ±5°C.
The fault cannot be reset until the temperature of
the heatsink has fallen below 60°C.

The fault could be due to the following:

♦ Ambient temperature too high
♦ Air obstructed
♦ Cooling fan(s) not operating
♦ Motor leads too long
♦ Too high a switching frequency
30 MISSING MOT.PHASE U X Motor phase U, as indicated by the letters on the
output terminal block, is missing or has a high
impedance.

Remove power to the drive and check motor

phase U.

31 MISSING MOT.PHASE V X Motor phase V, as indicated by the letters on the

output terminal block, is missing or has a high
impedance.

Remove power to the drive and check motor

phase V.

32 MISSING MOT.PHASE W X Motor phase W, as indicated by the letters on the

output terminal block, is missing or has a high
impedance.

Remove power to the drive and check motor

phase W.

34 HPFB COMM.FAULT X X The serial communication on the communication

option card is not working.

35 OUT FREQ RNG/ROT LIM X This warning will occur if the output frequency
has reached its Output Frequency Low Limit ,
parameter 201, or Output Frequency High Limit,
parameter 202. If the drive is in Closed Loop,
parameter 100, the warning will show in the
display.

37 GATE DRIVE FAULT X X An output IGBT or the power card is defective.

Contact the Bell & Gossett service department.

47
11.3 Table of Alarms and Warnings (continued)

No. Title Warn Alarm Trip Description and Remedy

(Trip) Lock

39 CHECK P.104 & P.106 X Parameters 104, Motor Frequency, or 106,

Rated Motor Speed, have probably not been set
correctly. Correct the setting and run AMA again.

40 CHECK P.103 & P.106 X Parameter 103, Motor Voltage, or 105, Motor
Current, has not been set correctly. Correct the
setting and run AMA again.

41 MOTOR TOO BIG X The motor used is probably too large for AMA to
be carried out. The setting in parameter 102,
Motor Power, may not match the motor. Check
the motor and select Continue or press [STOP]
key.

42 MOTOR TOO SMALL X The motor used is probably too small for AMA to
be carried out. The setting in parameter 102
Motor Power, may not match the motor. Check
the motor and select Continue or press [STOP]
key.

61 FOUT <FLOW X The output frequency is lower than parameter

223, Warning: Low Frequency.

62 FOUT >FHIGH X The output frequency is higher than parameter

224, Warning: High Frequency.

63 I MOTOR <I LOW X X The output current is lower than parameter 221,
Warning: Low Current. Select the required
function in parameter 409, Function in Case of
No Load.

64 I MOTOR >I HIGH X The output current is higher than parameter 222,
Warning: High Current.

65 FEEDBACK <FDB LOW X The resulting feedback value is lower than

parameter 227, Warning: Low Feedback.

66 FEEDBACK >FDB HIGH X The resulting feedback value is higher than

parameter 228, Warning: High Feedback.

67 REF.<REF.LOW X The remote controlled reference is lower than

parameter 225, Warning: Low Reference.

68 REF.>REF.HIGH X The remote controlled reference is higher than

parameter 226, Warning: High Reference.

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11.3 Table of Alarms and Warnings (continued)

No. Title Warn Alarm Trip Description and Remedy

(Trip) Lock

69 TEMP.AUTO DERATE X The heat sink temperature has exceeded the

maximum value and the auto derating function in
parameter 411 is active.

70 PUMP/DRIVE FAILED X The controller is not receiving a closed drive run

signal or a closed dip switch signal from devices
indicated. For drives with a bypass, bypass
operation will initiate a warning 70. The [RESET]
key on the Master drive may have to be pressed
to clear the warning after drives are switched out
of bypass.

72 LOW SUCTION CUT OUT X X Low suction pressure has been detected. Check
the suction pressure and suction pressure switch
setting.

73 ALL ZONE FAILURE X The controller is not receiving any zone sensor
signal(s). Check wiring, polarity, piping and
continuity.

74 HIGH SYS. PRESSURE X X X High pressure detected in the system. Check

parameter 774 (quick menu item 19).

75 NO FLOW SHUT DOWN X The system pressure is satisfied with no pump

running. Check auto reset.

76 ONE FEEDBACK ONLY X The controller is not receiving an expected zone

sensor signal. Check wiring, polarity, piping and
continuity.

77 PUMP “X” FAILED X Low input to pump identified in warning.

78 AUTOMATIC BYPASS X Indicates pump is running in automatic bypass.

99 UNKNOWN ALARM X X An unknown fault has occurred. Contact the Bell

& Gossett service department.

11.4 Table of Alarm/Warning Voltage Limits

Drive 208 to 230 volt 380 to 460 volt 550 to 600 volt
VDC VAC VDC VAC VDC VAC
Undervoltage alarm 211 151 402 289 557 413
Voltage warning, low 222 159 423 304 613 443
Voltage warning, high 384 276 777 530 943 667
Overvoltage alarm 425 305 798 550 975 689

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