Bell & Gossett

INSTRUCTION MANUAL
Document No.: 176U7761
Revision B July 2003

VARIABLE SPEED PUMPING SYSTEMS

INSTRUCTION MANUAL

Technologic 500 Series

and
Technologic 500X Series
Pump Controller
TM

TM

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNERS 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
INSTRUCTIONS
SAFETY

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

ITT Industries
Engineered for life

175R5359

Safety Guidelines

! DANGER

1.

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 considered 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 components. 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.

2.
3.

4.

The drive must be disconnected from the AC line before any

service work is done.
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.
Correct protective grounding of the equipment must be established. The user must be protected against supply voltage and the
motor must be protected against overload in accordance with
applicable national and local regulations.
Ground currents are higher than 3 mA.

Warnings Against Unintended Start

1.

2.
3.

4.

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.
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.
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.
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.

! 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

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 ElectronicThermal 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

Section 5 FEEDBACK TRANSMITTER WIRING .......................................................................................................... 26

5.1
5.2
5.3
5.4

Connecting Feedback Transmitters ................................................................................................................................................................. 26

Single 4 - 20 mA Flow Meter Connection ......................................................................................................................................................... 26
One or Two 4 - 20 mA Feedback Transmitters Connection .............................................................................................................................. 26
Two Feedback Signals and Two Setpoints Connection ................................................................................................................................... 27

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

6.1
6.2
6.3
6.4

Introduction ..................................................................................................................................................................................................... 28
Quick Menu Setup Instructions for Tech 500 .................................................................................................................................................... 29
Setup Instructions for AFD 2 and AFD 3 .......................................................................................................................................................... 30
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

Section 1 GENERAL
1.1 Purpose of Manual

1.4 Backplate

This manual is furnished to acquaint the user with practical ways to

install, operate, and maintain this unit. Read the information and safety
precautions presented here before installation or doing any work on
the unit.

Mount directly to the wall all controllers without a backplate. This

ensures that air flow is in contact with the heatsink all the way from the
bottom of the unit. If this is not possible, a metal plate at least as large as
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 &
Gossett.

The material presented in this manual is arranged for installation, setup

and operation of the equipment. In some instances the equipment may
be installed and programmed for immediate operation. It is still
recommended that the user be familiar with all the content in this
manual. Those users familiar with the product will find sections of this
manual useful for procedural information and reference.

NEMA 1
Backplate Required
Controller Size
Power
5 to 30 HP
200-240 V
15 to 75 HP
380-460 V
150 to 300 HP
380-460 V
15 to 75 HP
550-600 V
200 to 300 HP
550-600 V

1.2 Vertical Installation

The controller must always be installed vertically. To ensure that no
injury or damage occurs, the drive must always be firmly attached to
the wall or the floor before further installation work is carried out.

1.3 Clearances
The controller is cooled by air circulation. For
proper cooling, the minimum distances above
and below the unit must be maintained as
shown in the table below. For units in an
auxiliary enclosure with the controller
mounted on a backpanel, the required
clearances are measured from the top and
bottom of the controller, not the backpanel.

NEMA 12
Backplate Required
Controller Size
Power
1 to 30 HP
200-240 V
1 to 75 HP
380-460 V

Backplate Requirements
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.

Controller Size

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.

Top Clearance

Bottom Clearance

4" (100mm)

4" (100mm)

8" (200mm)

8" (200mm)

9" (225mm)

9" (225mm)

150 to 300 HP, 380-460, 550-600 V

12" (300mm)

12" (300mm)

350 to 600 HP, 380-460 V

16" (400mm)

Floor mount

1 to 3 HP, 200-240 V
1 to 10 HP, 380-460, 550-600 V
5 to 30 HP, 200-240 V
15 to 75 HP, 380-460, 550-600 V
40 to 60 HP, 200-240 V
100 to 125 HP, 380-460, 550-600 V

Mounting Clearances
5

1.5 Grounding Plate

1.7 UL, C-UL, and CE Conformity

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.

All Tech 500 and Tech 500X pump controllers are CE marked, and all
controllers and option packages are UL and C-UL listed.

This tab is located near the AC line terminal strip. Mount the bottom
cover on the control unit.

1.6 Shielded Wires

Wires to control signals should be shielded to reduce radiofrequency
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 shieldedcontrol
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.

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.

1.9 Model Number Description

230 Volt Input

Model Number Max. Nominal Max. Drive
Output HP Output Current

208 Volt Input

Model Number Max. Nominal
Max. Drive
Output HP Output Current
6002
6002
6003
6004
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062

1
1
2
3
5
7
10
15
20
25
30
40
50
60

4.6
6.6
7.5
10.6
16.7
24.2
30.8
46.2
59.4
74.8
88
114
143
169

460 Volt Input

Model Number Max. Nominal
Max. Drive
Output HP Output Current
6002
6002
6003
6004
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062
6075
6100
6102
6122
6125
6150
6175
6225
6275
6350
6400
6500
6550

1
1
2
3
5
7
10
15
20
25
30
40
50
60
75
100
100
125
125
150
200
250
300
350
450
500
600

2.1
3.0
3.4
4.8
8.2
11.0
14
21
27
34
40
52
65
77
106
130
130
160
160
190
240
302
361
443
540
590
678

6002
6002
6003
6004
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062

1
1
2
3
5
7
10
15
20
25
30
40
50
60

4.2
6.6
7.5
10.6
16.7
24.2
30.8
46.2
59.4
74.8
88
104
130
154

380 Volt Input

Model Number Max. Nominal Max. Drive
Output HP Output Current
6002
6003
6004
6005
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062
6075
6100
6125
6150
6175
6225
6275

1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
200

3.0
4.1
5.6
7.2
10
13
16
24
32
37.5
44
61
73
90
106
147
177
212
260
315
368

600 Volt Input

Model Number Max. Nominal
Max. Drive
Output HP Output Current
6002
6003
6004
6005
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062
6072
6100
6125
6150
6175
6225
6275

1
2
3
4
5
7
10
15
20
25
30
40
50
60
75
100
125
150
200
250
275

2.4
2.7
3.9
4.9
6.1
9
11
17
22
27
32
41
52
62
77
99
125
144
192
242
289

Section 2 ELECTRICAL CONNECTIONS

2.1 Power Connections
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 metalgrounding 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.

NEMA 1
NEMA 1

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
the auxiliary enclosure. See the drawings supplied with the Tech 500
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

6006-6062, 200 to 240 V; 6016-6075, 6102, 6122, 380 to 460 V;

6100-6150, 550-600 V

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

2.3 Locations of Conduit Entry, Terminal Blocks

and Switches, NEMA 12

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

and Switches, Drives Over 300 HP

6350-6550, 380 to 460 V

10

NEMA 1 and NEMA 12

2.5 Input Power Connection

Drive Input Maximum

Current
AWG
2.2
10
2.5
10
3.6
10
4.6
10
5.7
10
8.4
10
10.3
10
16.6
6
20.5
6
25.2
6
29.9
2
38.3
2
48.5
1/0
57.9
1/0
71.8
1/0
92
4/0
117
4/0
134
4/0
179
2 x 4/0
226
2 x 4/0
270
2 x 4/0

For drives with no auxiliary enclosure, connect input power to drive

terminals L1, L2, and L3, (terminal numbers 91, 92, and 93). If an auxiliary
enclosure is provided, input power connections are made in the auxiliary
enclosure. Refer to the connection diagrams shipped with the unit.
Size wiring to the input current as shown in the tables below. Maximum
AWG wire size is also provided.

! CAUTION
Incoming power, motor wiring and control
wiring should be run in three separate conduits
or raceways.
Enclosures for larger drives and auxiliary
enclosures are made of metal. To avoid getting
metal chips into electronics, do not drill any
holes after unit has been installed in a vertical
position.
Drive Input Maximum
Current
AWG
5.0
10
7.0
10
10.0
10
16.0
10
23.0
6
30.0
6
46.0
6
59.2
2
74.8
2
88.0
0
101.3
1/0
126.6
3/0
149.9
4/0

Maximum
AWG
10
10
10
10
10
10
6
6
6
6
2
2
2
1/0
2/0
3/0
2x1/0
2x1/0
2x3/0
2x4/0
3x1/0
3x3/0
3x3/0
3x4/0

6002
6003
6004
6005
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062
6072
6100
6125
6150
6175
6225
6275

600 VAC Input Current/Wire Gage

Model
6002
6003
6004
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062

All current ratings are in amps.

208 VAC Input Current/Wire Gage

Drive Input
Current
2.5
3.4
4.8
8.3
10.6
14
21
27.6
34
41
53
64
77
103
145
174
206
256
317
366
443
540
590
678

Model

Model
6002
6003
6004
6006
6008
6011
6016
6022
6027
6032
6042
6052
6062
6075
6100
6125
6150
6175
6225
6275
6350
6400
6500
6550

2.6 Motor Wiring Connection

! WARNING

Connecting input power to motor terminals will

result in drive failure when power is applied.
Output motor cables from multiple drives must
be run in separate conduits or raceways.
For drives with no auxiliary enclosure, connect the motor to drive
terminals U, V, and W (terminal numbers 96, 97, and 98). Terminal 99
is earth ground. If an auxiliary enclosure is provided, refer to the
connection diagrams shipped with the unit. Ground the shield on the
motor wire, if used, at both the drive and the motor.

2.7 Grounding

! DANGER

For operator safety, it is important to ground

drive properly.
Ground the drive properly. Use a ground wire at least 7 AWG (10mm2).
Connect the ground wire directly to a reliable earth ground. Do not use
the conduit connecting to the drive as a replacement for a ground wire. Do
not ground one drive to another in a daisy chain fashion.

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
6016-6075, 6102, 6122, 380-460 V
6016-6072, 550-600 V

12

NEMA 1
6150-6275, 380-460 V
6175-6275, 550-600 V

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.

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

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 0.1F capacitor, keeping
the leads as short as possible. If interference persists, disconnect the
grounded shield connection at the end opposite to the drive.

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

The electronicthermal relay is UL approved for single motor thermal
protection as long as the following is complied with:
1.
2.

Parameter 117, Thermal Protection, is set to ETR TRIP.

Parameter 105, Motor Current, is set for the full-load nameplate
motor current.

Switch 4 separates the common for the internal 24 VDC supply from the
common of the external 24 VDC supply. Normally this switch is ON and
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.

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

2.16 Electrical Noise

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.

In general, electrical noise can be divided into two forms: wire-borne

electromagnetic interference (EMI), and radiating radio frequency
interference (RFI).

2.15 Galvanic Isolation

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.

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.

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 shields impedance at higher
frequencies, which reduces the shields 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.

Galvanic Isolation

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.

Paths of Normal Current Leakage to Ground

16

2.17 Terminal Tightening Torque

Tighten terminals connecting the controller input power, output to the
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
amps and less, have removable terminal blocks with screws. Larger units
have fixed bolts. (See the controller nameplate for maximum drive output
current.)

380 to 460 VAC Terminal Tightening Torque

Max. Drive
Output Current

Torque
in-lbs (Nm)

Max. Drive
Output Current

to 10
16
24
32
37.5
44
61
73
90
106

5 (0.6)
5 (0.6)
17 (1.8)
17 (1.8)
17 (1.8)
28 (3.0)
28 (3.0)
28 (3.0)
28 (3.0)
100 (11.3)

147
177
212
260
315
368
487
594
649
746

200 to 240 VAC Terminal Tightening Torque

Max. Drive
Output Current
6.6
7.5
10.6
16.7
24.2
30.8
46.2
59.4
74.8
88
114
143
169

Torque
in-lbs (Nm )
5 (0.6)
5 (0.6)
5 (0.6)
5 (0.6)
17 (1.8)
17 (1.8)
28 (3.0)
28 (3.0)
28 (3.0)
35 (4.0)
100 (11.3)
100 (11.3)
100 (11.3)

Torque
in-lbs (Nm)
100
100
100
100
100
100
372
372
372
372

(11.3)
(11.3)
(11.3)
(11.3)
(11.3)
(11.3)
(42.0)
(42.0)
(42.0)
(42.0)

550 to 600 VAC Terminal Tightening Torque

Max. Drive
Output Current

Torque
in-lbs (Nm)

to 11
27
41
77
144
289

5 (0.6)
17 (1.8)
28 (3.0)
35 (4.0)
100 (11.3)
100 (11.3)

All current ratings are in amps.

200 to 208 VAC Auxiliary Control Panel Tightening Torques

200-208 V Max
Output

Overload
Relay

In/Out Power
Terminal

CTK Breaker

Main Disco
Switch

Drive Disco
Switch

MN/BYP Fuse
BLK

Drive Fuse
BLK

Ground
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
Output

Overload
Relay

In/Out Pow er
Term inal

CTK Breaker

Main Disco
Sw itch

Drive Disco
Sw itch

MN/BYP Fuse
BLK

Drive Fuse
BLK

Ground
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
Output

Overload
Relay

In/Out Power
Terminal

CTK Breaker

Main Disco
Switch

Drive Disco
Switch

MN/BYP Fuse
BLK

Drive Fuse
BLK

Ground
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
Output

Overload
Relay

In/Out Power
Terminal

CTK Breaker

Main Disco
Switch

Drive Disco
Switch

MN/BYP Fuse
BLK

Drive Fuse
BLK

Ground
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.

[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

[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.

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

[EXTEND MENU] gives access to all drive parameters,

including Quick Menu items.

20

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.

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

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
Tech500/500X 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].

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

VAR 2

P1
P2
STATUS

SETUP

1
P3

21

Operating data options for the first and second line of the LCP display:
Data Item:

Unit:

Resulting reference, %
Resulting reference, unit
Frequency
% of maximum output frequency
Motor current
Power
Power
Output energy
Hours run
Used-defined readout
Setpoint 1
Setpoint 2
Feedback 1
Feedback 2
Feedback
Motor voltage
DC-link voltage
Thermal load on motor
Thermal load on drive
Input status, digital input
Input status, analog terminal 53
Input status, analog terminal 54
Input status, analog terminal 60
Output status, relay status
Pulse reference
External reference
Heat sink temperature
User-defined text
PID output
FB analog input 60

%
[unit]
Hz
%
A
kW
HP
kWh
hours
[unit]
[unit]
[unit]
[unit]
[unit]
[unit]
V
V
%
%
[binary code]
V
V
mA
[binary code]
Hz
%
C
[-]
[unit]
[mA]

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.

3.6.1 Display Mode I

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
with Pump 3 running and Pump 1 off.
The text in line 1, FREQUENCY, describes the meter shown in the
large display. Line 2 (large display) shows the current output
frequency (40.0 Hz), direction of rotation (reverse arrow), and active
setup (1). Line 3 reports pump status. Line 4 is the status line and the
information is automatically generated for display by the drive in
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.

3.6.2 Display Mode II

This display mode shows three operating data values in the top line
programmed via parameters 007, 008, and 009. Pressing the
[DISPLAY MODE] key toggles between Display Modes I and II.

10.0U 10.0U 500U

50.0Hz

P2:R
AUTO

P3:R

REMOTE

40.0Hz

SETUP

P2:R
P3:R P1:O
AUTO REMOTE RUNNING

22

P1:O

RUNNING

3.6.3 Display Mode III

Press and hold the [DISPLAY MODE] key while in ModeII. Mode III is
visible as long as the key is depressed. The top line changes to identify
the data names and units displayed. Lines 2 and 4 are unchanged.
When the key is released, the display returns to Mode II.

FEED 1

FEED 2 FLOW

60.0Hz

SETUP

P1:R
P2:R P3:O
AUTO REMOTE RUNNING

3.6.4 Display Mode IV

This display mode is used for local operation, where the local speed
reference is given from the keypad. In this display mode, the reference
is determined via the [+] and [-] keys. Control is carried out through the
bottom keys on the keypad. The first line indicates the required
reference. The third line gives the relative value of the output
frequency in the form of a bar graph in relation to the maximum
frequency.

USE +/FREQUENCY

SETUP

40Hz

40.0Hz

SETUP

HAND LOCAL RUNNING

3.7 Changing Data

3.7.3 Changing Listed Numeric Values

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.

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.

The procedure for changing data depends on whether the selected

parameter represents a numerical data value or a function.

Enter or change parameter data or settings in accordance with the

following procedure.

3.7.1 Changing Numeric Values

1.
2.
3.
4.
5.

If the chosen parameter represents a number value, the flashing digit

can be changed by means of the [+]and [-] keys. Position the cursor
by using the tand u keys, then change the data value using the [+]
and [-] keys.

3.8 Enter/Change Quick Menu Parameter Data

6.

FREQUENCY

24.2Hz

Press [QUICK MENU] key.

Use t and u keys to find parameter group to edit.
Use [+] and [-] keys to find parameter to edit.
Press [CHANGE DATA] key.
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.
Press [CANCEL] key to disregard change, or press [OK] key to
accept change and enter new setting.

SETUP

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

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 ramp up time to 100 seconds in accordance with the following
procedure.

The local control panel (LCP) has the capability to store and transfer all
the parameters programmed into the Tech 500/500X controller. Setup
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
reestablish initial parameter settings, if so desired.

1.
2.
3.
4.
5.
6.
7.
8.

Press [QUICK MENU] key.

Press [+] key until you reach Parameter 206, Ramp Up Time.
Press [CHANGE DATA] key.
Press t key twice hundreds digit will flash.
Press [+] key once to change hundreds digit from 0 to 1.
Press u key to move cursor to tens digit.
Press [-] key until 6 counts down to 0 and setting for Ramp Up
Time reads 100 s.
Press [OK] key to enter new value into drive controller.
NOTE
Programming parameter functions available
through Extended Menu key is done in
accordance with same procedure described for
Quick Menu functions.

3.10 Extended Menu

In some applications, the Quick Menu will not access additional
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

This feature is also useful when setting up multiple drives. LCPs are
removable and interchangeable. Once setup information has been
uploaded from the drive, the LCP may be connected to another drive
and all parameter setting downloaded to quickly program additional
drives with identical settings.
To upload data, use the Extended Menu to find parameter 004, LCP
Copy. Select Upload All Parameters to store parameter settings
(including motor data) into the LCP. LCP Copy will be displayed while
data is uploading. This may take a minute or two. To download data,
select either Download All Parameters or Download
Power-independent Parameters (to exclude motor data entered in
parameters 102 through 106).
Manually initializing the drive using parameter 620, Operating Mode,
does not change the values stored in the LCP.

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 STARTController has tripped off and is in process of
automatically restarting.
TRIPController has tripped off. Press RESET to start.
TRIP LOCKEDController 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 24VDC,
200mA 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
413
414
314
315
316

Description
MIN. FEEDBACK
MAX. FEEDBACK
AI [mA] 60 FUNCT
AI 60 SCALE LOW
AI 60 SCALE HIGH

Setting
0
100
FEEDBACK
4 mA
20 mA

 

If the transmitter is capable of producing 10V at 20 mA, the value of the

resistor to use is:
R=

10 V
= 500
20 mA

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

26

Parameter

Description

Setting

415
413
414
417
308
309
310
311
312
313

REF./FDBK UNIT
MIN. FEEDBACK
MAX. FEEDBACK
2 FEEDBACK CALC.
AI [V] 53 FUNCT.
AI 53 SCALE LOW
AI 53 SCALE HIGH
AI [54] 54 FUNCT.
AI 54 SCALE LOW
AI 54 SCALE HIGH

PSI
0
100
2 ZONE MIN.
FEEDBACK
2V
10 V
NO OPERATION
2V
10 V

5.4 Two Feedback Signals and Two Setpoints

Connection
Similar to two feedback signals and one setpoint, the need for two
feedback signals with two setpoints is frequently encountered.
Whenever two critical zones do not have the same setpoint value, two
feedback with two setpoint control is required. Many pumping systems
require the monitoring and control of two loads that differ in size and
pressure drop.
To enable this setup, the feedback function in parameter 417, Feedback
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.

Parameter

Description

Factory Setting

415
413
414
417
308
309
310
311
312
313

REF./FDBK UNIT
MIN. FEEDBACK
MAX. FEEDBACK
2 FEEDBACK CALC.
AI [V] 53 FUNCT.
AI 53 SCALE LOW
AI 53 SCALE HIGH
AI [54] 54 FUNCT.
AI 54 SCALE LOW
AI 54 SCALE HIGH

PSI
0
100
2 ZONE MIN.
FEEDBACK
2V
10 V
NO OPERATION
2V
10 V

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

The quick menu items for programming the Tech 500 are arranged in
the following sequence (see block diagram):

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.

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 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 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 Setup1.
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
09
10
11
12

Motor Power
Motor Voltage
Motor Frequency
Motor Current
Motor Rated Speed

MICROPROCESSOR

TECH 500 SETTINGS

PUMP
15 Pump Combination
16 Max. Pump Flow
17 Alternation Time
18 Pumps Active During AZF
19 Low Suction Cut Out Time
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

01 Setpoint 1
02 Setpoint 2
03 Max. Feedback
04 Max. Reference
07 Max. Feedback 60
13 Min. Frequency
14 Max. Frequency

OUTPUT
05 AO Terminal 42 Output
06 AO Terminal 45 Output

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
Menu
Number
01

Para.
Number

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

04

05

Name

Units

Range

Factory Setting

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.

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.
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.
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
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.)
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.

09

10

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

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.
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.
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).
763
Max Pump Flow
GPM
0 to 999,999.999
Disabled
Set the value for End of Curve (EOC) pump protection.

14

15

16

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.

17

770
Alternation Time
Hours
0 to 999
Set the time between automatic pump alternation cycles.

Only Manual

18

772

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.

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).

29

Quick
Menu
Number
20

21

Para.
Number

Name

Units

Factory Setting

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.
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
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
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

27

28

29

Off

Off

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 t.
For example, if a time constant of 0.1 s is programmed, the cut off frequency for the lowpass filter will
be 1/[2 (.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

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
drive must be programmed with the nameplate data from the motor it
controls. For normal operation, all other parameter settings must remain
at factory default settings or match the settings in the Tech500.
1. Program AFD 2 and AFD 3 drives for operation by entering motor
data for parameters 102 through 106, in sequence.
2. Ensure that parameter 100, Configuration, is set for Open Loop.
3. Ensure that the setting for Min. Frequency (parameter 201) and
Max. Frequency (parameter 202) match those of the Tech 500
pump controller Min. Frequency and Max. Frequency.
4. Ensure that terminal 17 (parameter 301) is set for Pulse Output.

30

Range

6.4 HP to kW Convertion Table

)1
0.4
0.5
0.75
1.0
1.5
2
3
4
5
7.5
10
15
20
25
30
40

L8
0.25
0.37
0.55
0.75
1.10
1.50
2.20
3.00
4.00
5.50
7.50
11
15
18.5
22
30

)1
50
60
75
100
125
150
200
250
300
350
400
420
450
500
540
600

L8
37
45
55
75
90
110
132
160
200
250
300
315
355
400
450
500

Section 7 TECH 500X CONTROLLER SETUP

NOTE

7.1 Introduction
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 Setup1.
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
103
104
105
106

Motor Power
Motor Voltage
Motor Frequency
Motor Current
Motor Rated Speed

CONTROLLER

CONTROLLER SETTINGS

PUMP
712
713
714
715
716
717
718
721
762
776
777
778
779
780
781
782
783
784

Pump Combination
Staging Bandwidth
SBW Stage OFF Delay Timer
SBW Stage ON Delay Timer
Override Bandwidth
OBW Timer
Transition Frequency
Destage Timer
Max. Feedback 60
NFSD Proof Timer
Min. Speed Proof Timer
Restart PV Drop
Min. Run Timer
Pump Min. Frequency for NFSD
Pump Max. Frequency for NFSD
NF Power at Min. Frequency
NF Power at Max. Frequency
Multiplier for NF Detection

418
419
417
414
201
202
205
723

Setpoint 1
Setpoint 2
Feedback Calculation
Max. Feedback
Min. Frequency
Max. Frequency
Max. Reference
Mode Select

PID CONTROLLER TUNING

422
423
424
427

PID Start-up Frequency

PID Proportional Gain
PID Integrator Time
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

105

Motor Current

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.

Amps

Nine options

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

723

Mode Select

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.
Master/Slave or Standard
Control
Select Standard Control for operation with the Tech 500X with fixed speed pumps.

32

Master/Slave

7.2 Setup Instructions for Tech 500X (continued)

Para.
Number
712

Name
Pump Combinations

Units

Range

Factory Setting

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

30

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

Off

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

Off

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

781

Pump Max. Frequency for

Hz
0 to 9999
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 controllers 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 controllers 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.
Number
422

Name

Units

PID Start-up Frequency

Hz

Range

Factory Setting

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
t. For example, if a time constant of 0.1 s is programmed, the cut off frequency for the lowpass
filter will be 1/[2 (.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

0.4
0.5
0.75
1.0
1.5
2
3
4
5
7.5
10
15
20
25
30
40

34

L8

0.25
0.37
0.55
0.75
1.10
1.50
2.20
3.00
4.00
5.50
7.50
11
15
18.5
22
30

)1

50
60
75
100
125
150
200
250
300
350
400
420
450
500
540
600

L8

37
45
55
75
90
110
132
160
200
250
300
315
355
400
450
500

Section 8 STATUS MESSAGES

80.0% 5.08A 2.15kW

8.1 Status Messages

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
the drive.
B. The center part of the status line indicates the REFERENCE
LOCATION.
C. The last part of the status line gives the present DRIVE STATUS.
The table below defines the status massage display words.

8.2 Table of Status Messages

40.0 Hz

P1:R

SETUP

P2:R P3:0

AUTO REM. RUNNING

HAND LOCAL STOP
RAMPING
OFF
B
JOGGING
A
.
.
.
.
STANDBY
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.
Parameter 208, Automatic Ramp, is enabled. The drive is attempting to
AUTO RAMP
avoid a trip from overvoltage by extending its decel ramp time.
The boost function in parameter 406, Boost Setpoint, is enabled. This
SLEEP.BST
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
WORD
RUN REQ.

DESRIPTION

! DANGER

When in Run Request mode, motor may restart at any time

without warning.

JOG
JOG REQ.

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 has been enabled via a digital input or via serial communication.

! DANGER

When in Jog Request mode, motor may restart at any time

without warning.

FRZ.OUT
FRZ.REQ

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

! DANGER

When in Freeze Request mode, motor may restart at any time

without warning.

START F/R

AMA RUN
AMA STOP

STANDBY
STOP
DC STOP
UN.READY
CTR.READY
NOT READY
START IN.
XXXX

36

A start command has been given, but the motor will remain stopped until a
Run Permission signal is received via a digital input.
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.
Automatic motor adaptation has been enabled in parameter 107, Automatic
Motor Adaptation, AMA.
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.
The drive is able to start the motor when a start command is received.
The motor has been stopped via a stop signal from serial communication.
The DC brake has been enabled in parameters 114 through 116.
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.
This status is only active when a Profibus option card is installed.
The drive is not ready for operation, because of a trip or because OFF1,
OFF2 or OFF3 is a logic 0.
This status will only be displayed if, in parameter 599, Profidrive [1] has been
selected and OFF2 or OFF3 is a logic 0.
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.

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

750
751
752
753
754
755
760
761
764
765
766
767
768
769
771
780
781
782
783
784
785
786
787
788

B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G
B&G

%
sec
sec
%
sec
%
GPM
GPM
sec
%
sec
GPM
sec
sec
sec
Hz
Hz
W
W
none
none
none
none
none

0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0 .7 5
0
0
D is a b le
D is a b le

100
999
999
100
999
100
39
0
999
100
999
100
999
60
200
9999
9999
1 6 ,0 0 0
1 6 ,0 0 0
2 .0 0
2
2
E n a b le
E n a b le

P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.
P a r.

F a c to ry D e fa u lt
95
30
60
85
30
50
22
0
30
45
30
0
0
20
10
0
0
0
0
1 .2
0 (D is a b le d )
0
D is a b le
D is a b le

8.4 Table of Changes to Previous Default Parameters

Parameter
No.
111
301

Start Delay
Terminal 17 Digital Input

302

Terminal 18 Digital Input

303

Terminal 19 Digital Input

304

Terminal 27 Digital Input

305

Terminal 29 Digital Input

306

Terminal 32 Digital Input

317

All Zone Fail Proof Time

319

Terminal 42 Output

Title

Changes
Changed default value from 0 to 20 sec.
System Start/Stop: removing control voltage
initiates a sequenced stop. The PID controller
is stopped and reinitializes.
Programming Lock: applying control voltage
prevents programming the drive from the
keypad. Data Change Locked is displayed
when the [CHANGE DATA] key is pressed.
AFD-1 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
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.
AFD-2 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
AFD-3 Input: receiving control voltage confirms
the AFD is running for drive failure detection.
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.
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
controller to run directly from input line power. The Tech 500 has three
available configurations as standard.

TECH 500 controller

The active setup is displayed on the keypad display under the word
setup. Setup is selected in parameter 002, Active Setup. The following
parameters must be programmed for automatic bypass operation.
Range

Default
value

785
786
787

1-2
0-2
Disable/Enable

1
0 (disable)
Disable

A1

B3

1
1
1
1
Disable Disable

A1 constant speed
bypass drive

Three-contactor
bypass

In the event of drive failure detection, the pump controller can

automatically start the pump across the line. For a motor or pump
failure, the controller can automatically shut down the system. Reset the
controller manually after the fault has been cleared. The
Drive/Off/Bypass/Test switch can be used to manually select system
operation in bypass from line power (bypass), from the controller
(drive), or to shut the system off.

Setup A1
Setup B3
Setup C4/D4

Parameter

One 100%
pump

C4

D4

2
1
Disable

2
2
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"

Motor/Pump/DP-switch

Relay 2
"Running"

DIGITAL INPUT

+24V

16: (RESET)
17: (SYSTEM START)

NO
switch

18: (PROGRAM LOCK)

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
6B

Select pump 1

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
controller

Slave
drive

Two 100%
pumps (C4)
Two 50%
pumps (D4)

D4 Automatic linepowered bypass drive

Two two-contactor
bypasses

In the event of drive failure detection, the pump controller can automatically 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.

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.

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.
Slave drive

Master including TECH500

TECH500 controller
9A
9B

Bypass pump2

NO contact

8A

Bypass pump1

8B

7A
7B

6A
6B

Start slave 1

U/V/W
output

U/V/W
output

Relay 2
"Running"

Main Input Power

Main Input Power

Relay 2
"Running"

D4 Bypass unit
Slave - DIGITAL INPUT

Master - DIGITAL INPUT

18: (START)

16: (RESET)
17: (SYSTEM START)
18: (PROGRAM LOCK)
Motor/Pump/

19: (AFD-1 INPUT)

Motor/Pump/

DP-switch

27: (LOW SUCTION CUTOUT)

DP-switch

29: (AFD-2 INPUT)

32: (PUMP 1 INPUT)
33: (PUMP 2 INPUT)

+24V
NO
switch
"Pump 1"

+24V
NO
switch
"Pump 2"

C4/D4 Automatic Bypass Setup Block Diagram

40

The bypass architecture for the Tech 500 controller allows for a variety
of optional control, indicator, and protective features.

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 fuseddisconnect or bypass enclosure.

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 singledrive configuration this switch is mounted on the fused-disconnect
enclosure door.

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.

9.2 Options

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.

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 overloads normally open auxiliary contact is
factory-wired to the pump 1 digital input of the controller.

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 fuseddisconnect or bypass enclosure.
Bypass Running Light
A light mounted on the bypass enclosure door indicates that the motor is
running in bypass.

41

Section 10 PUMP ALTERNATION AND RELAY STATUS

10.1 Technologic 500 Pump Alternation
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 pump3.
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 Tech500 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.

10.1.2 Duty Standby

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
the failed pump until manual reset of the system. The standby pump
complies with the pump alternation characteristics described in 10.1,
with or without automatic bypass. Standby applies to the last pump in
the current alternation sequence.

10.1.3 Pump On Time

Parameter 724: Pump 1
Parameter 725: Pump 2
Parameter 726: Pump 3

A timer accumulates hours the pump has run. The counter is updated
10 times per hour which means that cycles less than 6 minutes are not
registered. The hours can be reset to zero when a pump is replaced.
42

10.1.4 Pump Cycles

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.

RELAY STATUS

101000

SETUP

P1:R
P2:R P3:O
AUTO REMOTE RUNNING
Relay open: 0
Relay closed: 1
NOTE

For readout via serial communication, parameter

537 must be used.
Bit 7 = Relay 01
Bit 6 = Relay 02
Bits 5 - 4 = Relays 06 - 07

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
number. The explanation is displayed on the top (line 1).

The table in 8.3 Table of Alarms and Warnings gives Tech 500/500X
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.
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
also describes the common remedies for the fault condition.

LOW SUCTION CUT OUT

WARN.72

SETUP

P1:R
P2:R P3:R
AUTO REMOTE RUNNING

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
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
number. The explanation is displayed on line 3 or on lines 3 and 4.

TRIP (RESET)

ALARM 72

SETUP

LOW SUCTION CUT OUT

1)
2)
3)

Pressing the RESET key on the keypad

Digital input
Serial communication input

Where an X is placed under both warning and alarm in the table in

8.3, this means that a warning precedes the alarm. After a trip, the
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

UNDER 10 VOLTS

Alarm
(Trip)

Trip
Lock

Description and Remedy

The 10 V voltage from terminal 50 on the control
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 .
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.

LIVE ZERO ERROR

MAINS PHASE LOSS

DC LINK VOLTAGE HIGH

The intermediate DC circuit voltage is higher

than Voltage Warning High, see table in 8.4. The
drive is still controlling the motor.

DC LINK VOLTAGE LOW

The intermediate DC circuit voltage is lower than

Voltage Warning Low, see table in 8.4. The drive
is still controlling the motor.

DC LINK OVERVOLT

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.

DC LINK UNDERVOLT

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.

Phase missing on the input power. Check the

supply voltage to the drive.

The voltage will be stated in the display. Check

whether the supply voltage matches the drive
rating.

44

11.3 Table of Alarms and Warnings (continued)

No.

Title

Warn

Alarm
(Trip)

Trip
Lock

Description and Remedy

INVERTER TIME

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

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

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

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

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

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

15

SWITCH MODE FAULT

Warn

Alarm
(Trip)

Trip
Lock

Description and Remedy

Fault in the switch mode power supply (internal
15 V supply).
Contact the Bell & Gossett service department.

16

CURR.SHORT CIRCUIT

There is a short circuit in the output from the

drive.
Remove power to the drive and correct the short
circuit.

17

STD BUSTIMEOUT

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

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.

46

19

EE ERROR POWER

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

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.

11.3 Table of Alarms and Warnings (continued)

No.

Title

Warn

Alarm
(Trip)

22

AMA FAULT

29

HEAT SINK OVERTEMP.

Trip
Lock

Description and Remedy

A fault has been found during automatic motor
adaptation. The text shown in the display
indicates a fault message.

The heatsink temperature became too high. For

NEMA 1 drives, the limit is 90C. For NEMA 12
drives, the limit is 80C. The tolerance is 5C.
The fault cannot be reset until the temperature of
the heatsink has fallen below 60C.
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

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

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

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

35

OUT FREQ RNG/ROT LIM

37

GATE DRIVE FAULT

The serial communication on the communication

option card is not working.
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.

An output IGBT or the power card is defective.

Contact the Bell & Gossett service department.

47

11.3 Table of Alarms and Warnings (continued)

48

No.

Title

Warn

Alarm
(Trip)

39

CHECK P.104 & P.106

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

Parameter 103, Motor Voltage, or 105, Motor

Current, has not been set correctly. Correct the
setting and run AMA again.

41

MOTOR TOO BIG

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

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

The output frequency is lower than parameter

223, Warning: Low Frequency.

62

FOUT >FHIGH

The output frequency is higher than parameter

224, Warning: High Frequency.

63

I MOTOR <I LOW

64

I MOTOR >I HIGH

The output current is higher than parameter 222,

Warning: High Current.

65

FEEDBACK <FDB LOW

The resulting feedback value is lower than

parameter 227, Warning: Low Feedback.

66

FEEDBACK >FDB HIGH

The resulting feedback value is higher than

parameter 228, Warning: High Feedback.

67

REF.<REF.LOW

The remote controlled reference is lower than

parameter 225, Warning: Low Reference.

68

REF.>REF.HIGH

The remote controlled reference is higher than

parameter 226, Warning: High Reference.

Trip
Lock

Description and Remedy

The output current is lower than parameter 221,

Warning: Low Current. Select the required
function in parameter 409, Function in Case of
No Load.

11.3 Table of Alarms and Warnings (continued)

No.

Title

Warn

Alarm
(Trip)

Trip
Lock

69

TEMP.AUTO DERATE

The heat sink temperature has exceeded the

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

70

PUMP/DRIVE FAILED

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

73

ALL ZONE FAILURE

74

HIGH SYS. PRESSURE

75

NO FLOW SHUT DOWN

The system pressure is satisfied with no pump

running. Check auto reset.

76

ONE FEEDBACK ONLY

The controller is not receiving an expected zone

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

77

PUMP X FAILED

Low input to pump identified in warning.

78

AUTOMATIC BYPASS

Indicates pump is running in automatic bypass.

99

UNKNOWN ALARM

Description and Remedy

Low suction pressure has been detected. Check

the suction pressure and suction pressure switch
setting.
The controller is not receiving any zone sensor
signal(s). Check wiring, polarity, piping and
continuity.

High pressure detected in the system. Check

parameter 774 (quick menu item 19).

An unknown fault has occurred. Contact the Bell

& Gossett service department.

11.4 Table of Alarm/Warning Voltage Limits

Drive
Undervoltage alarm
Voltage warning, low
Voltage warning, high
Overvoltage alarm

208 to 230 volt

VDC
VAC
211
151
222
159
384
276
425
305

380 to 460 volt

VDC
VAC
402
289
423
304
777
530
798
550

550 to 600 volt

VDC
VAC
557
413
613
443
943
667
975
689

49