IVS Sensorless Pump Commissioning Check ... - Armstrong Pumps

FILE NO.: 94.202
DATE: Sep. 14, 2010
SUPERSEDES: 94.202
DATE: June 2, 2010
IVS Sensorless Pump Commissioning Check Sheet
The following is a step-by-step guide to starting up and commissioning an Armstrong IVS Sensorless Pump. One check sheet is to
be completed per pump! You must follow and fill out all fields below to ensure that all aspects of the pump are checked and setup
for proper operation. This sheet must be returned to Armstrong along with the “IVS Startup Data Sheet” for the startup to be
considered as complete! Once complete, this sheet requires that end-user / general contractor sign off on the work rendered as
final approval that the pumps function as intended. Please submit this commissioning check sheet along with your work invoice /
startup claim in order to ensure prompt and timely payment of work rendered!
NO CHECK SHEET + STARTUP DATA SHEET = INCOMPLETE STARTUP!
UNLESS STATED OTHERWISE ALL FIELDS ARE MANDATORY!
ONE SET PER DRIVE+PUMP!
Project Name:
Building Address:
Contractor Name:
Site Contact Name: Site Contact Tel. #:
Your Company:
Your Name:
Pump Model: Pump Tag #:
Pump Serial #: Sales Order #:
NOTES:
- GC = General Contractor
- BAS = Building Automation System
Pre-Startup Package:
Yes No N/A
Do you have the pump Order Annexe
Do you have the pump-specific variable speed curve with duty point indicated
Do you have the Sensorless VFD setup file
Do you have the Sensorless Datafile (csv file)
OPTIONAL: Do you have the pump Installation & Operation Manual
Pre-Startup Arrangements:
Yes No N/A
Verify with GC that water and power is available and ready to the pump
Verify with GC that piping system valves can be opened to 100% to simulate full load
Verify with GC that pumps can be run without damage to system
Verify with GC that BAS is wired to drive and ready to go (IF APPLICABLE)
Verify with GC that BAS contractor will be there on site to meet you (IF APPLICABLE)
Before Power Up Checklist:
Done
Check pump installation for proper mounting as per Pump Installation & Operation Manual instructions
Check incoming voltage across the lines and record here: L1 ________ L2 ________ L3 ________
Note: Voltage should be no more than +/- 10% of design voltage
Check if pump is to be controlled remotely by BAS start / stop contact with BAS contractor:
Option #1: If yes, check if BAS contact is wired across terminals 12 & 18 on VFD
Option #2: If no, check if factory jumper is wired across terminals 12 & 18 on VFD
Note: Contacts close = pump runs. Contacts open = pump stops.
Open up and bleed pump seal flush line to verify no air is locked inside seal / seal lines
Check alignment of pump (horizontally mounted pumps only)
Check if piping system valves are opened to 100% to simulate full design load and that they stay that way
Unit is now safe to turn power on.
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Startup Checklist:
Done
Verify IVS drive has completed proper bootup sequence
Verify IVS drive is in the OFF mode (if not – place in OFF mode)
Note: If this is a Dual Arm, make sure both IVS drives are in OFF!
Check parameter 20-69.0 through 20-69.9 to verify if Sensorless data is programmed (it will show pump
size, serial number, etc.)
Put pump in HAND mode and run at 15Hz and looking from the top of the motor down, verify motor
rotation as per the sticker on the motor (should be clockwise from top of the motor looking down)
Open up and bleed pump seal flush line again to verify no air has travelled into seal / seal lines
Change parameter 0-22 (default value is option 1610 – “Power [kW]”) to option 1654 “Feedback 1 [Unit]”
to display Sensorless pressure readout on the top right corner of screen
FOR DUAL ARMS: Close and secure the flapper valve so that it isolates the pump you are not using
Close the discharge valve at the immediate outlet of the pump to deadhead pump
With pump in HAND mode, increase the speed of the pump to the design speed as per the duty curve in
your startup package. Eg: If your duty speed is 1550 RPM and you have a 1740 RPM, 60Hz motor, you
will need to run at: 1550/1740 x 60Hz = 53.4 Hz
Record the readout from suction and discharge gauges (include units)
SUCTION = DISCHARGE =
Verify the pump dP on deadhead (discharge valve is shut) is the same as shown on the duty curve
Record VFD Sensorless pressure readout (include units)
SENSORLESS PRESSURE =
Verify that VFD Sensorless pressure readout is within +/- 5% compared to gauge readout
Change parameter 0-22 back to option 1610 – “Power [kW]”
Put pump into AUTO mode. The pump should maintain the no-flow pressure as per parameter 22-87
Record VFD Sensorless pressure readout when pump is ramped down to no flow speed.
Reopen discharge valve to 100% open. The pump should now ramp up to design flow and head.
When pump is stabilized, record pump speed, Sensorless pressure, Sensorless flow on startup data sheet
Reopen discharge valve to 100% open. The pump should now ramp up to pressure setpoint in the drive
on parameter 20-21
If the pump goes to full speed and does not hit the pressure setpoint, this is most likely because the
system is oversized and has less resistance than designed for.
Option #1: Work with general contractor and engineer to determine whether more flow and less head is
acceptable. If this is, change parameter 20-21 to the new pressure setpoint, parameter 22-87 to a value
that is 40% of the new setpoint and parameter 22-89 to the new flow based on the pressure setpoint
according to the duty curve. RECORD THESE VALUES ON THE STARTUP DATA SHEET.
Option #2: If available, try to balance the system using an Armstrong FlowTrex Valve on discharge of the
pump to increase backpressure and put the pump back on the design curve
Notes Regarding Dual Arm Pumps:
If parameter # 5-31 on Pump #1 / Master is set to “Running / No Warning” and if both pumps are set to AUTO
mode, putting one of the pumps in OFF mode will start the other pump up.
If pump overlap is required when switching duty / standby pumps, go to SETUP #2 on both pumps and increase
the ramp down time on parameter # 3-42. Default time is 60 seconds.
Checking for resonance:
If you notice piping or accessories attached to the pump are vibrating at a specific frequency / speed of the pump, you
can adjust the IVS drive to bypass this frequency by giving it a range of frequencies it needs to skip.
Set the beginning of the range in parameter # 4-61 “Bypass Speed From” and the end of the range on parameter # 4-
62 “Bypass Speed To”. RECORD THESE VALUES IN THE STARTUP DATA SHEET.
Keep in mind that the drive does not “jump” past this range. It will just not stay within it (it will still move through it).
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PID Loop Autotuning:
Done
Place the pump in OFF mode
Verify all system valves are at 100% or a 100% load situation is recreated and nothing will change during
this tuning.
Change parameter 0-22 (default value is option 1610 – “Power [kW]”) to option 1654 “Feedback 1 [Unit]”
to display Sensorless pressure readout on the top right corner of screen
Record parameter 20-93 “PID Proportional Gain” in the Startup Data Sheet
Record parameter 20-94 “PID Integral Time” in the Startup Data Sheet
Verify parameter 20-95 “PID Differentiation Time” is set to “OFF”
Go to parameter 20-79 “PID Auto Tuning” and change this to “ENABLE”. Follow the on-screen
instructions.
When the screen asks you to select a run speed where to auto tune the VFD to, use the
UP/DOWN/LEFT/RIGHT keys to enter a speed where the Sensorless pressure readout (on the top right
corner of the screen) is the same as the desired setpoint in parameter 20-21
Press OK to begin the auto tune procedure (this can take 2-5 minutes)
Press OK when auto tune is complete to accept new PID loop tuning
Record NEW value in parameter 20-93 “PID Proportional Gain” in the Startup Data Sheet
Record NEW value in parameter 20-94 “PID Integral Time” in the Startup Data Sheet
Verify parameter 20-95 “PID Differentiation Time” is set to “OFF”
Change parameter 0-22 back to option 1610 – “Power [kW]”
Place the pump back into AUTO mode and then open / close discharge isolation valves to test new pump
ramp up / down speeds. If acceptable, move on.
BAS / BMS Communications: Yes – Type: ________________ No
If the BAS/BMS is communicating to the drive via Modbus, Metasys or FLN:
Check parameter # 8-30 and change it accordingly to the BAS / BMS comm. Type
Check parameter # 8-31, 8-32 and 8-33 and change the address, baud rate and parity/stop bits in accordance to
the BAS/BMS contractor instructions
If the BAS/BMS is communicating to the drive via Lonworks or BACNet RTU, the drive is factory up already and good
to go.
SIGNOFF:
By signing off on this startup checklist, both parties hereby accept that the equipment listed in this checklist has been
properly verified to be fully operational and functioning as per the sales order for the equipment listed.
Startup Technician Name (Please print):
Startup Technician Signature:
Customer Name (Please print):
Customer Signature:
Date (mm/dd/yyyy):
/ / / /
Date (mm/dd/yyyy):
Submit complete documents to Armstrong via fax at 416-759-9101 or via email at warrantyclaims@armlink.com.
S. A. Armstrong Limited Armstrong Pumps Inc. Armstrong Integrated Limited
23 Bertrand Avenue 93 East Avenue Wenlock Way
Toronto, Ontario North Tonawanda, New York Manchester
Canada, M1L 2P3 U.S.A. 14120-6594 United Kingdom, M12 5JL
T: 416-755-2291 T: 716-693-8813 T: +44 (0) 8444 145 145
F: 416-759-9101 F: 716-693-8970 F: +44 (0) 8444 145 146 © S.A. Armstrong Limited 2010
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