PropaGator Start-up & Operational Sequence
PropaGator
Start-up
Start-up and calibration of the PropaGator is a simple 10-step process. Following the steps that below sequentially will ensure the simplest and most efficient route to getting the equipment up and running. Following the initial start-up, only slight adjustments to the Load Current Level setting might be necessary to fine-tune the pump off point. This setting determines the point at which the pump is allowed to turn off and should set at a no-flow condition to minimize pump cycling at low flow conditions. This is the most direct method for determining the actual work required of the VFD. Fine tuning this setting should only be done after the system has become operational and considerable load (flow) has been placed on the equipment.
Start-up Procedure:
1. With cover off of drive, set minimum run timer (Time Sensor Dial) to zero by turning dial on the timer board to the full counter clockwise position.
2. Using the drive’s digital keypad, set the OL1 level (parameter: E34) to 2.75.
3. From the drive’s digital keypad, set the pressure setpoint to 10psig below the design system setpoint. The actual pressure and setpoint are displayed on the drive’s LED display.
4. Turn pump into “Hand” and allow pump to run to maintain the new setpoint.
5. Now adjust the Pressure Start Setpoint (Level Dial) on the timer board so the FWD signal drops in/out. You can see this occur by monitoring the remote I/O through the drive’s digital keypad display. This point is now the pump’s Pressure Start Setpoint.
6. Turn pump off and adjust the pressure setpoint to the design system setpoint for normal operation.
7. Set minimum run timer (Time Sensor Dial) to the 2 minute maximum by turning dial on the timer board to the full clockwise position.
8. Turn pump into “Hand” and close isolation valve to obtain a no-flow condition.
9. Using the drive’s digital keypad display, monitor the load current level at the no-flow condition. This will determine the initial “off” setpoint.
10. Using the drive’s digital keypad, set the OL1 level (parameter: E34) to this value divided by 0.9. Round up to the next 0.1 amp. This determines the on/off load current deadband for pressure maintenance mode and the off setpoint after an irrigation cycle.
Fine Tuning Procedure:
1. After a substantial load has been placed on the equipment, the load current at no-flow should be checked again to be sure the pump is turning off at its minimum load condition. This will occur at no-flow. Following steps 9-10 above, run the pump into the irrigation system (isolation valve open) when there is no demand for water. Ideally, this will occur prior to shutdown following an irrigation cycle. Once the irrigation system is charged the no-flow condition should occur and this load current visibly evident. If this load current level needs adjustment, follow step 10 for the new setting.
Operational Sequence
The pump starts on a drop in pressure of approximately 10psig below the system setpoint. When this point is reached, the pump will start and run at the required speed to maintain the system setpoint. Once started, the pump will continue to run until the setpoint is maintained, the load on the pump has decreased to (at or near a no flow condition) the off setpoint, and the minimum run timer has expired. When all of these conditions have been met, the drive will stop until the start sequence is repeated.
In pressure maintenance mode (typically between 5 and 10% of the system capacity), the pump will cycle more frequently to maintain pressure. Once the load exceeds the pressure maintenance mode setpoint, the irrigation mode is engaged and the load will be required to decrease to the load off setpoint, as explained above.
VFD Display
The VFD LED displays system pressure by default. The system setpoint can be viewed by pressing the UP ARROW key once on the display keypad. Once displayed, the setpoint can be adjusted by pressing the UP or DOWN ARROW keys to reach the desired setting. When the desired setting is reached, it can be stored by pressing the FUNC|DATA key. This will be the new system setpoint. Pressing the PROG key once will return the LED to the system pressure display. The setting can be verified by the system pressure gauge when the pumping is running.
Alarms
The PropaGator has been equipped with a standard low system pressure alarm. The low system pressure switch should be set 10-20psig below the system pressure setpoint (it should not be set above the pressure start setpoint). When a low system pressure condition exists and the drive is indicating a maximum speed condition, the low system pressure alarm timer will activate. Once the alarm delay has expired, the drive will be stop immediately and indicate an external alarm condition with an OH2 message on its LED display. The alarm can be cleared and the drive reset by pressing the RESET key on the drive keypad display or the RESET pushbutton on the optional Operator Station. If the Operator Station is provided, an alarm condition light will be illuminated to indicate the alarm condition.
If the optional high pump temperature alarm has been provided, the alarm will operate in the same manner as the low system pressure alarm, except there is no alarm activation delay (the alarm activates immediately upon occurrence).
The PropaGator also comes equipped with standard drive protective features such as overcurrent, undervoltage, etc.. For specific information concerning these alarm refer to the drive manual.
Factory Default Settings
Factory default settings are made for both general operational purposes and system specific control. This section addresses settings other than the system setpoint, which is described above. The general operational settings should never need modification except in the rare occurrence of drive replacement. The system specific settings are set from design information provided at time of purchase. These settings can be modified to a degree to accommodate changing or unexpected site conditions.
All settings are saved either electronically within the drives non-volatile memory (Digital) or through an adjustable relay/timer card within the drive (Analog).
Operational Settings
Digital:
Run Latch (E02) = 6
Alarm Reset (E04) = 8
Low System Pressure Alarm (E06) = 9
High Pump Temperature Alarm {Optional} (E07) = 9
Drive Stop (E09) = 7
Max. Speed Reach (E20) = 31
Min. Load Reach (E24) = 7
Inverse Relay Mode (E25) = 1
Max. Speed Reach Deadband (E30) = 2.5Hz.
Min. Speed Reach (E31) = 41Hz.
Min. Speed Reach Deadband (E32) = 0.9Hz.
Load Current Indication (E33) = 1
Min. Load Current Delay (E35) = 5.0s
Max. Speed Level (E36) = 59Hz.
Power Fail Restart (F14) = 4
Min. Speed Level (F16) = 40Hz.
Feedback Function (F31) = 7
Alarm Condition Relay (F36) = 0
PID Mode (H20) = 2
PID Feedback Signal (H21) = 1
PID P-gain (H22) = 1.00
PID I-gain (H23) = 1.0s
PID D-gain (H24) = 10.00s
Analog:
Min. Run Timer (Time Sensor Dial) = 2min. (0-2min. range)
Low System Pressure Alarm Delay (Time Switch Dial) = 2min. (0-2min. range)
System Specific
Digital:
Load Current Level (E34) = (No Flow Current)/0.90
Keypad Operation (F02) = 2 (1 w/o Op. Station)
Analog:
Pressure Start Setpoint (Level Dial) = 10psig below setpoint (0-10Volt range)
Drive navigation keys:
PROG: used to change menus and LCD display information.
FUNC|DATA: used to save settings and select menu options.
UP ARROW: used to scroll through menus and increase setting values.
DOWN ARROW: used to scroll through menus and decrease setting values.
SHIFT RIGHT ARROW: used to change places within a setting value.
RESET: used to reset drive alarms.
STOP: used to stop the drive (active only when Operator Station is not included).
FWD: not active.
REV: not active.
Drive Display Screens
Operation Mode: This screen displays current operation conditions.
Program Menus:
DATA SETTING: allows drive setting values to be modified.
DATA CHECK: view drive settings values.
OPR MNTR: monitor various operating parameters.
I/O CHECK: view drive I/O status.
MAINTENANCE: view inverter status and maintenance information.
LOAD FCTR: view maximum and average current as a function of the drive load.
ALM INF: monitor recent alarm status.
ALM CAUSE: view alarm history information.
DATA COPY: Factory use only.
Additional Features
Cooling Fans: Each PropaGator is equipped with cabinet cooling fans. The cooling fans are controlled directly by a thermostat installed on an interior wall of the cabinet. These cooling fans are design to keep the enclosed space within the cabinet at a safe operating temperature. The thermostat should be set to activate the cooling fans at no higher than 104°F, but not too low that they remain on continuously even during off periods. A recommended setting range is between 90°F and 104°F to protect the electronic equipment.
Pressure Gauges: Each PropaGator is supplied with a system pressure gauge and a suction pressure gauge. These gauges are installed on the package piping, easily viewable from the cabinet access door.
Service Disconnect Switch: Each PropaGator is equipped with a service disconnect switch located on the exterior of the cabinet. This disconnect switch is provided to disconnect power whenever necessary for equipment servicing. The switch is also rated as an outdoor service entrance device suitable for use as a service connection point.
Operator Station: Offered as an option, the operator station is installed on the interior wall of the cabinet as a convenient way for an operator to select operation modes, reset alarms and receive a visual indication of an alarm occurrence. The operation mode (Hand-Off-Auto) can be selected from the selector switch provided. Alarms are indicated and can be reset by the alarm condition light and reset push button, respectively. As an additional option, a flow meter/totalizer is installed on the operator station to record flow rate and the accumulated total flow.
