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TECHNICAL MANUAL

888-2625-001
HE Pump Module

HE Pump Module
(Closed Loop)

T.M. No. 888-2625-001 January 21, 2013


Revision E
© Copyright Harris Corporation 2011, 2012, 2013
All rights reserved
ii 888-2625-001 1/22/13
WARNING: Disconnect primary power prior to servicing.
Technical Assistance
Technical and troubleshooting assistance for HARRIS Transmission products is available from
HARRIS Field Service (factory location: Quincy, Illinois, USA) during normal business hours (8:00
AM - 5:00 PM Central Time). Telephone +1-217-222-8200 to contact the Field Service Department;
FAX +1-217-221-7086; or E-mail questions to tsupport@harris.com.
Emergency service is available 24 hours a day, seven days a week, by telephone only.
Online assistance, including technical manuals, white papers, software downloads, and service
bulletins, are available at http://www.broadcast.harris.com (from there, click on Customer Support
Portal under the Services & Support tab drop down menu).
Address written correspondence to Field Service Department, HARRIS Broadcast Communications
Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. For other global service contact
information, please visit: http://www.broadcast.harris.com/contact.
NOTE: For all service and parts correspondence, you will need to provide the Sales Order number,
as well as the Serial Number for the transmitter or part in question. For future reference, record those
numbers here: ___________________/____________________
Please provide these numbers for any written request, or have these numbers ready in the event you
choose to call regarding any Service, or Parts requests. For warranty claims it will be required, and
for out of warranty products, this will help us to best identify what specific hardware was shipped.

Replaceable Parts Service


Replacement parts are available from HARRIS Service Parts Department 7:00 AM to 7:00 PM
Central Time, Monday through Friday, and 8:00 AM to 1:00 PM Central Time on Saturday.
Telephone +1-217-222-8200 or email servicepartsreq@harris.com to contact the Service Parts
Dept.
Emergency replacement parts are available by telephone only, 24 hours a day, seven days a week
by calling +1-217-222-8200.

Unpacking
Carefully unpack the equipment and perform a visual inspection to determine if any apparent
damage was incurred during shipment. Retain the shipping materials until it has been verified that all
equipment has been received undamaged. Locate and retain all PACKING CHECK LISTs. Use the
PACKING CHECK LIST to help locate and identify any components or assemblies which are
removed for shipping and must be reinstalled. Also remove any shipping supports, straps, and
packing materials prior to initial turn on.

Returns And Exchanges


No equipment can be returned unless written approval and a Return Authorization is received from
HARRIS Broadcast Communications Division. Special shipping instructions and coding will be
provided to assure proper handling. Complete details regarding circumstances and reasons for return
are to be included in the request for return. Custom equipment or special order equipment is not
returnable. In those instances where return or exchange of equipment is at the request of the
customer, or convenience of the customer, a restocking fee will be charged. All returns will be sent
freight prepaid and properly insured by the customer. When communicating with HARRIS
Broadcast Communications Division, specify the HARRIS Order Number or Invoice Number.

1/22/13 888-2625-001 iii


WARNING: Disconnect primary power prior to servicing.
Manual Revision History

Pump Module

REV. DATE ECN Pages Affected


5/20/11 DRAFT PRELIMINARY DRAFT
A1 6/14/11 Release
B 10/2011 P51325 Section 2.5 Step 2 and 3.14 added notes for starting w/o Txer
C 11/21/11 P51576 Modified steps in Section 2 to increase clarity.
D 01/24/12 E61171 Changed tables to reflect new low temp settings.
E 01/21/13 E62443 Added Appendix A for remote control panel operation.

iv 888-2625-001 1/22/13
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1/22/13 888-2625-001 MRH-1
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MRH-2 888-2625-001 1/22/13
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Guide to Using Harris Parts List Information
The Harris Replaceable Parts List Index portrays a tree structure with the major items being left most in the
index. The example below shows the Transmitter as the highest item in the tree structure. If you were to look at
the bill of materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output
Cabinet. In the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show up one
indentation level below the Transmitter and implies that they are used in the Transmitter. The Controller Board is
indented one level below the Control Cabinet so it will show up in the bill of material for the Control Cabinet.
The tree structure of this same index is shown to the right of the table and shows indentation level versus tree
structure level.
Example of Replaceable Parts List Index and equivalent tree structure:

Replaceable Parts List Index Part Number Page


Transmitter
Table 7-1. Transmitter 994 9283 001 7-2 994 9283 001
Table 7-2. Control Cabinet 992 9244 002 7-3
Table 7-3. Controller Board 992 8344 002 7-6 Control Cabinet PA Cabinet Output Cabinet
Table 7-4. PA Cabinet 992 9400 002 7-7 992 9244 002 992 9400 002 992 9450 001
Table 7-5. PA Amplifier 994 7894 002 7-9
Table 7-6. PA Amplifier Board 992 7904 002 7-10 Controller Board PA Amplifier
Table 7-7. Output Cabinet 992 9450 001 7-12 992 8344 002 992 7894 002

PA Amplifier Board
992 7904 002
The part number of the item is shown to the right of the description as is the page in the manual where the bill for
that part number starts. Inside the actual tables, four main headings are used:
• Table #-#. ITEM NAME - HARRIS PART NUMBER - this line gives the information that corresponds
to the
• Replaceable Parts List Index entry;
• HARRIS P/N column gives the ten digit Harris part number (usually in ascending order);
• DESCRIPTION column gives a 25 character or less description of the part number;
• REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001,
R102, etc.) that corresponds to the number found in the schematics (C001 in a bill of material is equiva-
lent to C1 on the schematic) or 2) gives added information or further explanation (i.e., “Used for 208V
operation only,” or “Used for HT 10LS only,” etc.).

Inside the individual tables some standard conventions are used:


• A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS col-
umn means that this item is used on or with C001 and is not the actual part number for C001.
• In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has pur-
chased and has not manufactured or modified. If the last three numbers are other than 000, the item is
either manufactured by Harris or is purchased from a vendor and modified for use in the Harris product.
• The first three digits of the ten digit part number tell which family the part number belongs to - for
example, all electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic
(can) capacitor is found to have a 9xx xxxx xxx part number (a number outside of the normal family of
numbers), it has probably been modified in some manner at the Harris factory and will therefore show
up farther down into the individual parts list (because each table is normally sorted in ascending order).
Most Harris made or modified assemblies will have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part
number will show up in a bill that is higher in the tree structure. This is often the case for components
that may be frequency determinant or voltage determinant and are called out in a higher level bill
structure that is more customer dependent than the bill at a lower level.

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viii 888-2625-001 1/22/13
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x 888-2625-001 1/22/13
WARNING: Disconnect primary power prior to servicing.
! WARNING:
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS.
PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUC-
TIONS AND REGULATIONS.

This manual is intended as a general guide for trained and qualified personnel who are aware
of the dangers inherent in handling potentially hazardous electrical/electronic circuits. It is not
intended to contain a complete statement of all safety precautions which should be observed
by personnel in using this or other electronic equipment.

The installation, operation, maintenance and service of this equipment involves risks both to
personnel and equipment, and must be performed only by qualified personnel exercising due
care. HARRIS CORPORATION shall not be responsible for injury or damage resulting from
improper procedures or from the use of improperly trained or inexperienced personnel
performing such tasks. During installation and operation of this equipment, local building
codes and fire protection standards must be observed.

The following National Fire Protection Association (NFPA) standards are recommended as
reference:
- Automatic Fire Detectors, No. 72E
- Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
- Halogenated Fire Extinguishing Agent Systems, No. 12A

! WARNING:
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLO-
SURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS
AND SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE
INTERNAL ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN
ALONE OR WHEN FATIGUED.

Do not remove, short-circuit or tamper with interlock switches on access covers, doors,
enclosures, gates, panels or shields. Keep away from live circuits, know your equipment and
don’t take chances.

! WARNING:
IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.

! WARNING:
IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR
EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR
CASE WHEN THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW
THE UNIT TO COOL DOWN BEFORE ATTEMPTING TO REMOVE THE DEFEC-
TIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR
WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE-
QUENT INJURY.
1/22/13 888-2625-001 xi
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xii 888-2625-001 1/22/13
WARNING: Disconnect primary power prior to servicing.
FIRST-AID

Personnel engaged in the installation, operation, maintenance or servicing of this equipment


are urged to become familiar with first-aid theory and practices. The following information is
not intended to be complete first-aid procedures, it is a brief and is only to be used as a
reference. It is the duty of all personnel using the equipment to be prepared to give adequate
Emergency First Aid and there by prevent avoidable loss of life.

Treatment of Electrical Burns

1. Extensive burned and broken skin


a. Cover area with clean sheet or cloth. (Cleanest available cloth
article.)
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply any salve or ointment.
c. Treat victim for shock as required.
d. Arrange transportation to a hospital as quickly as possible.
e. If arms or legs are affected keep them elevated.

NOTE:
If medical help will not be available within an hour and the victim is conscious and
not vomiting, give him a weak solution of salt and soda: 1 level teaspoonful of salt
and 1/2 level teaspoonful of baking soda to each quart of water (neither hot or
cold). Allow victim to sip slowly about 4 ounces (a half of glass) over a period of
15 minutes. Discontinue fluid if vomiting occurs. (Do not give alcohol.)

2. Less severe burns - (1st & 2nd degree)


a. Apply cool (not ice cold) compresses using the cleanest available
cloth article.
b. Do not break blisters, remove tissue, remove adhered particles of
clothing, or apply salve or ointment.
c. Apply clean dry dressing if necessary.
d. Treat victim for shock as required.
e. Arrange transportation to a hospital as quickly as possible.
f. If arms or legs are affected keep them elevated.

REFERENCE:
ILLINOIS HEART ASSOCIATION
AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY
MANUAL (SECOND EDITION)

1/22/13 888-2625-001 MRH-1


WARNING: Disconnect primary power prior to servicing.
Table of Contents

Section 1 Section 4
Introduction Theory of Operation
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . 1-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
General Description. . . . . . . . . . . . . . . . . . . . . . . . 1-2 Speed Of Electric Induction Motors . . . . . . . . . . . .4-1
Transmitter Cooling System . . . . . . . . . . . . . . . 1-5 Using An Inverter To Control Induction Motor Speed4-
Cooling System Control Panel. . . . . . . . . . . . . 1-6 3
Pump Module. . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Inverter Operated Pump and Cooler Modules . . .4-4
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Transmitter PA Module and Combiner Cold Plates
1-8 Section 5
Glycol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Maintenance and Alignments
General Specifications. . . . . . . . . . . . . . . . . . . . . . 1-8
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Miscellaneous Maintenance . . . . . . . . . . . . . . . . . .5-1
Section 2 Cooling System Checks . . . . . . . . . . . . . . . . . . . .5-1
Heat Exchanger Cleaning . . . . . . . . . . . . . . . . .5-1
Installation / Alternate Pumps. . . . . . . . . . . . . . . . . . . . . . . . .5-2
Initial Turn-On Pump Module Strainer Cleaning . . . . . . . . . . . .5-2
Coolant Level Management: . . . . . . . . . . . . . . .5-3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cooling System Maintenance Notes . . . . . . . . .5-4
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Pump Module Operation Without Transmitter .5-6
Pump Module Drawings. . . . . . . . . . . . . . . . . . . 2-1
Operating Environment and Placement. . . . . . . . . 2-2
AC Mains Requirements . . . . . . . . . . . . . . . . . . . . 2-3 Section 6
Surge Suppression Devices. . . . . . . . . . . . . . . . . 2-3
Ground Requirements. . . . . . . . . . . . . . . . . . . . . 2-4
Diagnostics
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . 2-5 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Charging Closed Loop Cooling Systems . . . . . . 2-10
Charging Closed Loop Cooling Systems with Section 7
Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Parts List
Section 3
Operation Appendix-A
Inverter Setup and Operation . . . . . . . . . . . . . . . . 3-1 Remote Placement of Control Panel
Inverter Pre-programming . . . . . . . . . . . . . . . . . 3-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Verify F700 Setting & Run Command. . . . . . . 3-3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Inverter Programming. . . . . . . . . . . . . . . . . . . . . 3-3
Identifying Parameter Type:. . . . . . . . . . . . . . . 3-4
Changing Basic Parameters . . . . . . . . . . . . . . . 3-4
Changing Extended Parameters: . . . . . . . . . . . 3-5
Clearing Inverter Memory . . . . . . . . . . . . . . . . . 3-5
Manual Fan Control . . . . . . . . . . . . . . . . . . . . . . 3-5

1
Table of Contents (Continued)

2
HE Pump Module

Section 1
Introduction 1
1.1 Purpose of This Manual

This technical manual contains the information pertaining to the Harris HE Pump
Modules with part numbers 9950333001G and 9950333002G.

• Section 1, Introduction, provides general manual layout, frontispiece, equipment


description, block diagram and general specifications.
• Section 2, Installation/Initial Turn-On, provides physical and electrical installation
procedures for the pump module.
• Section 3, Operation, provides operational instructions for inverters.
• Section 4, Theory of Operation, provides detailed theory of operation for the pump
module and sub assemblies.
• Section 5, Maintenance and Alignments, provides preventative and corrective main-
tenance information and applicable field alignment procedures.
• Section 6, Diagnostics, provides detailed fault information and diagnostic proce-
dures.
• Section 7, Parts List, provides pump module parts lists.

1/22/13 888-2625-001 1-1


WARNING: Disconnect primary power prior to servicing.
Section 1 Introduction HE Pump Module

1.2 General Description

This section contains specifications, component locations and a general description of


the Harris HE Pump.Module

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Figure 1-1 Harris HE Pump Module - ISO

1-2 888-2625-001 1/22/13


WARNING: Disconnect primary power prior to servicing.
HE Pump Module Section 1 Introduction

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Figure 1-2 HE Pump Module - Left Side View

1/22/13 888-2625-001 1-3


WARNING: Disconnect primary power prior to servicing.
Section 1 Introduction HE Pump Module

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Figure 1-3 HE Pump Module - Front View

1-4 888-2625-001 1/22/13


WARNING: Disconnect primary power prior to servicing.
HE Pump Module Section 1 Introduction

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Figure 1-4 HE Pump Module - Rear View

1.2.1 Transmitter Cooling System

Liquid cooled broadcast transmitters typically use 50/50 glycol/distilled water coolant
to move heat away from the transmitter. They may also use cabinet air flushing fans to
remove residual cabinet heat. A simplified block diagram of a typical liquid cooling
system is shown in Figure 1-5. The cooling system components normally consists of:

a. Pump Module/Cooling System Control Panel


b. Plumbing (hose or copper tube)
c. Heat Exchanger
d. Transmitter PA Modules and Combiner Cold Plates

1/22/13 888-2625-001 1-5


WARNING: Disconnect primary power prior to servicing.
Section 1 Introduction HE Pump Module

Figure 1-5 Transmitter Liquid Cooling System

1.2.1.1 Cooling System Control Panel

The cooling system control panel is used to control the pump module and heat
exchanger. It also serves as the interface to the transmitter control system. The cooling
system control panel connects to the transmitter for monitoring/control and supplies AC
to the heat exchanger fans.

The control panel, shown in Figure 1-6, has local inverter controls on the front which
allow setup and activation of pump A and B and heat exchanger fans A and B.

It also contains the following controls and indicators:

• Pump A Inverter control


• Pump B Inverter control
• Fan A Inverter control
• Fan B Inverter control
• REMOTE/LOCAL Switch
• Pump B ON/OFF Switch
• Pump A ON/OFF Switch
• Circuit Breakers: Inverters, Pump A & B and Fans A & B

1-6 888-2625-001 1/22/13


WARNING: Disconnect primary power prior to servicing.
HE Pump Module Section 1 Introduction

Inverter Controls

Pump/Fan
AC Breakers

Local
Switches

Figure 1-6 Cooling System Control Panel

Status indications may also be sent to the transmitter for display or for use in remote
control operation.

When in Remote mode, the transmitter is responsible for control of the cooling system,
including ON/OFF, manual pump selection and automatic pump switching in the case
of a failure. Placing the control panel in Local mode allows manual switching of the
pumps using the pump ON/OFF switches on the cooling control panel.

The lower half of the control panel contains AC breakers for the pumps, fans and
inverters. The pump module should be installed with a customer supplied AC
disconnect that can be used to remove all AC power from the pump module. The
control panel is an integral part of the pump module assembly (see Figure 1-1 A) and
normally installed within view of the transmitter (usually next to the transmitter
disconnect panel).

1/22/13 888-2625-001 1-7


WARNING: Disconnect primary power prior to servicing.
Section 1 Introduction HE Pump Module

1.2.1.2 Pump Module

The pump module, shown in Figure 1-1, is a self-contained unit with integrated
expansion tank, pressure gauges, temperature sensor, inlet strainer and dual pumps
(operating in main/standby mode). The pump module is designed for indoor
mounting. There are two versions of pump module, one for 208-240VAC, three phase
operation and the other for 380-415VAC, three phase operation.

1.2.1.3 Heat Exchanger

The heat exchanger, which is typically installed outside, contains 2 fans. The fans are
enabled when the pump module is under transmitter control. A thermistor (temperature
sensor) in the outlet side of the pump module controls the speed of both fans. See 4.3.1
for additional information on fan control.

There are four heat exchanger models. 208-240VAC or 380-480VAC, three phase,
12kW cooling capacity and 208-240VAC or 380-480VAC, three phase, 50kW cooling
capacity. The 12kW models are mounted vertically and the 50kW models can be
mounted either vertically or horizontally depending on configuration of mounting legs.

1.2.1.4 Transmitter PA Module and Combiner Cold Plates

Each PA module has an integrated liquid cooled cold plate which connects to the
cooling system with quick release connectors. There are may also be cold plates inside
the combiners or splitters to which internal combiner reject loads are attached.

1.2.1.5 Glycol

Depending on application either ethylene or propylene glycol are suitable for use in the
HE pump module. Harris recommends a 50/50 mixture of glycol and distilled water for
normal operation. Follow all local and national regulations regarding use and disposal
of glycol. For additional information on glycol products refer to www.dowtherm.com or
www.dowfrost.com.

1.3 General Specifications

NOTE:
Specifications subject to change without notice.

1-8 888-2625-001 1/22/13


WARNING: Disconnect primary power prior to servicing.
HE Pump Module

Section 2
Installation /
Initial Turn-On
2
2.1 Introduction

This section includes information for installation and initial turn on of a Harris HE
Pump Module. Both pump module versions have similar installation and turn on
procedures.

2.2 Documentation

The following is a list of documentation that ships with the pump module. Find and
save all documentation. The top level Document Package for each version of pump
module are shown below:

• Dual pump 208-240 & 380-480VAC 988-2625-001

A Document Package includes:

1. This technical manual 888-2625-001


2. Drawing Package with schematics for the pump module.

2.2.1 Pump Module Drawings

Review the drawing package to become familiar with the available information.
Information on installation and planning is given in the following drawings (see Table
2-1 below for drawing numbers):

a. Outline Drawing - Shows connections for AC, control, coolant lines and gives
overall dimensions.
b. Wiring Diagram - AC and control wiring diagram.

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Section 2 Installation / Initial Turn-On HE Pump Module

c. Performance Data - Flow and Power vs Pressure

Table 2-1 Pump Module Drawing Numbers

Drawing Number Drawing Title

843-5607-068 Outline Drawing, Wiring Diagram, Performance Data

2.3 Operating Environment and Placement

The selection of a proper installation location is essential for equipment longevity and
reliability. Do not install the pump module in places where it may be exposed to
mechanical shocks, excessive vibration, temperature, dust, water, salty air, or corrosive
gas.

Ambient temperature and relative humidity should always range between the following
limits at the installation location:

• Ambient temperature: -33 to +50oC


• Relative humidity: 5 to 95% non-condensing

An electrical control panel is integrated into the pump module assembly. The pump
module and electrical panel are specifically designed for indoor use only and should be
positioned near the transmitter so the pump module control panel can be readily viewed
and is easily accessible.

The pump module should be installed to allow access to the front for maintenance
purposes. Changing pump modules will require access to the front of the unit.
Approximately 1 meter of clearance is recommended at the front. AC mains
connections are on the sides of the unit.

Once in place, the pump module should be securely fastened to the floor using customer
supplied brackets and fasteners. 15.4 mm(1/2 inch) diameter mounting holes are located
on the bottom and sides of the pump module rack.

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WARNING: Disconnect primary power prior to servicing.
HE Pump Module Section 2 Installation / Initial Turn-On

2.4 AC Mains Requirements

There are two versions of pump module, one for 208-240VAC, three phase operation
and the other for 380-480VAC, three phase operation. The desired AC mains voltage
must be provided when order is placed. The voltage ranges noted above are phase to
phase values. A neutral connection is not used in the pump module.

Upon receiving the pump module, measure the AC mains voltage to verify that the
correct version of pump module has been supplied. The inverters and the jumpers in the
pump and fan motors will vary depending on AC mains voltage.

Consult drawing 843-5607-068, sheet two, for information on suggested wiring,


fusing and motor jumper requirements.

! WARNING:
DISABLE AND LOCK OUT PUMP MODULE PRIMARY POWER BEFORE AC MAINS
CABLES ARE CONNECTED TO THE EQUIPMENT. TURN OFF (OPEN) ALL
SWITCHES AND BREAKERS ON THE COOLING CONTROL PANEL, PUMP MODULE
AND HEAT EXCHANGER. THIS WILL ALLOW THEM TO BE TURNED ON (CLOSED)
ONE AT A TIME LATER TO CHECK FOR WIRING PROBLEMS.

! WARNING:
AN EXTERNAL CIRCUIT PROTECTION DEVICE (BREAKER OR FUSE) IS
REQUIRED. THIS IS PROVIDED BY THE CUSTOMER IN ACCORDANCE WITH PRE-
VAILING LOCAL SAFETY NORMS AND DRAWING 843-5607-068.

Install the AC mains wiring in a separate conduit from all control and small signal lines.

2.4.1 Surge Suppression Devices

Harris strongly recommends the use of surge protection devices on the incoming AC
mains lines. These devices protect against damages due to transients arising from both
natural and man-made sources. (e.g. lightning and inductive load switching). Clear
preference is to be given to “series” type surge protection devices -- featuring protection
by both a series inductance / shunt capacitor filter and shunt threshold device -- over
simple shunt-only clamping devices. The surge protector must be sized to handle the
full amperage of the load it is protecting (plus a nominal safety margin) and be
connected to the building ground system by short, direct connections. In the case where

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

the shunt protection elements are protected by a fuse, it is necessary to periodically


check the integrity of the fuse to ensure continued transient protection.

! CAUTION:
FAILURE TO FOLLOW THESE RECOMMENDATIONS MAY LEAD TO
SHORTENED EQUIPMENT LIFE AND REDUCED RELIABILITY.

2.4.2 Ground Requirements

Two separate ground connections are required for the HE pump module: an AC safety
ground and an RF earth ground.

The AC safety ground prevents an electrocution hazard should a dangerous potential


from inside the unit accidentally contact the metal chassis. The AC safety ground works
by providing a secure, uninterrupted path for any wayward electrical current to return to
the source: the secondary winding of the local power-grid transformer (or generator).
This ensures that any exposed metal parts will not simply “float” to a voltage level dan-
gerous to humans in the case of an accidental contact with mains voltage and that suffi-
cient fault current will be drawn to trip any circuit protection devices.

The AC safety ground (green/yellow) wire from the pump module should terminate at a
suitable physical earth (PE) or (PEN) connection at the AC mains entrance/distribution
panel, or as otherwise dictated by safety norms. In those systems with only a direct earth
ground instead of a wired PE connection back to the power source, the use of special
ground-fault sensing circuit protection devices is indicated.

In addition to the equipment chassis, all metal enclosures and conduit pieces potentially
exposed to mains voltages in the case of a fault should have a secure, un-interrupted,
conductive path back to the PE terminal in the mains entrance.

The RF earth ground prevents damage to the equipment during lightning induced
transients by providing a low impedance path for lightning to return to the earth. A
brass RF ground block is located at the rear of the pump module chassis. A copper
ground strap with a minimum width of 5 cm should be used to connect the pump
module rack to the building earth ground system.

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HE Pump Module Section 2 Installation / Initial Turn-On

2.5 Electrical Connections

! CAUTION:
AVOID RUNNING PUMPS WITHOUT COOLANT. RUNNING PUMPS DRY CAN
DAMAGE THEM IN AS LITTLE AS 15 SECONDS.

STEP 1 Install conduit and then connect the AC wiring between the AC mains
panel and pump module. Refer to AC Power Flow Diagrams and
Electrical Installation Diagrams that are part of the transmitter
documentation package. A safety ground wire must also be included and
attached at the location noted in Figure 2-1.

Safety
Ground

3 Phase
AC

Figure 2-1 Pump Module Control Panel AC & Ground Terminals

STEP 2 Install conduit and then connect the AC wiring between the control panel
and heat exchanger fans. Refer to drawing 843-5607-068 in the pump
module documentation package. The rotation of the fans will need to be
checked prior to operation. Fan rotation is checked by momentarily
activating them while monitoring the direction of the fan blades as they
slow down. If blade rotation is oppossite the arrow direction (Figure 2-2
on right) on the fan cover then swap two of the AC lines feeding the
fans. These connections are inside the control panel. Remove control
panel cover and relocate wires in the fan Wago block (see Figure 2-3).
Swap two of the wires (to each fan) to change direction of rotation.

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

NOTE:
If the transmitter is not available to provide control for the heat exchanger fans-
fans, they must be turned on manually. Refer to Section 3.1.4 for instructions on
manual fan control.

Figure 2-2 Pump & Fan Rotation Arrows

AC to Heat
Exchanger Fans
1&2

Figure 2-3 Pump Module Control Panel Fan AC Terminals

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HE Pump Module Section 2 Installation / Initial Turn-On

Heat Exchanger Heat Exchanger


Fan AC Fan AC

Figure 2-4 Heat Exchanger Fan AC Connections

STEP 3 Install conduit and connect the control and status wires between the
cooling control panel and the transmitter with multi-conductor
cable. These low level signals are wired from connector J1 at the top of
the transmitter to terminals J3 or J4 in the cooling control panel. Refer to
the transmitter External Wiring Diagram for details.

Table 2-2 Inputs to Control Panel J3 or J4

Pin Wire Color Signal Conditions

1 BLK GROUND

2 RED NC

3 BLU PUMP INTLK From transmitter, active high. When high, the
transmitter’s RF output is muted and the pumps are
forced to OFF regardless of the LOCAL/REMOTE
setting in the pump cooling control panel. If this
interlock is active, the pumps can’t be turned ON
(even locally). This interlock is driven by the
transmitter or PA cabinet leak detector. If a leak is
detected, this interlock goes to high.

4 WHT PUMP RUN From transmitter, active high to turn on selected


pump.

5 BRN SWITCH PUMP From transmitter, pulsed active high to switch


between Pump A and Pump B.

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

Table 2-2 Inputs to Control Panel J3 or J4

Pin Wire Color Signal Conditions

6 GRY GROUND

7 TAN NC

8 PINK NC

9 ORG PUMP A Pump module output, transmitter input. Active


SELECTED when input is LOW.

10 YEL PUMP B Pump module output, transmitter input. Active


SELECTED when input is LOW.

11 GRN LOCAL STATUS Pump module output, transmitter input. Remote =


LOW, Local = HIGH

12 PUR GROUND

Table Note: NC = Not Connected

NOTE:
Condensation can occur in the conduit leading to the outside heat exchanger from
the control panel. This conduit and connectors should be caulked or sealed after
the system is tested and operational. The goal is to keep warm air from inside the
building out of the conduit which lies outside the building.

Pump Module
Control Wiring
to Transmitter

Figure 2-5 Pump Module Control Panel Control Wiring (goes to transmitter)

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HE Pump Module Section 2 Installation / Initial Turn-On

To Pump Module
Control Panel

Figure 2-6 Transmitter Connection to Pump Module

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

2.6 Charging Closed Loop Cooling Systems

The following instructions assume that the transmitter cabinet, plumbing for cooling
system, pump module and heat exchanger have all been properly installed per
instructions provided in the transmitter documentation package.

! CAUTION:
AVOID RUNNING PUMPS WITHOUT COOLANT. RUNNING PUMPS DRY CAN
DAMAGE THEM IN AS LITTLE AS 15 SECONDS.

STEP 1 Before charging the system with coolant or water use a tire gauge to
check air pressure on the on the expansion tank. Pressure can be checked
by removing the plastic cover on the end of the tank to expose a
Schrader valve. The measured air pressure in the tank should be 12 psi
from the factory. If it is not 12 psi add or release air to achieve 12 psi
bladder pressure.

NOTE:
The 12 psi pressure level is acceptable if the pump module is going to be installed
at the same elevation as the heat exchanger. In situations where the heat
exchanger will be located above the pump module higher initial bladder tank air
pressures will be required.

The following instructions assume that the bladder tank pressure is 12 psi and the heat
exchanger and pump module are located at the same elevation.

STEP 2 Open automatic bleed vents to allow trapped air to bleed from system.
STEP 3 Close supply and return ball valves at transmitter bypass manifold. Open
bypass valve to allow coolant to flow through bypass assembly and
prevent flow through transmitter. Coolant flow through the transmitter is
not desired until system is clean.
STEP 4 Bypass flow through liquid cooled test load and or filter at this time.
Flow through these components is not desired until system is clean.
STEP 5 Charge the system with coolant (use charge pump or circulation pumps)
to an initial static pressure of 15psi. If this is the first fill the initial
charge should be pure water until integrity of system can be checked.

NOTE:
Static pressures are measured with pumps off.

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HE Pump Module Section 2 Installation / Initial Turn-On

NOTE:
If the circulation pump is to be used to charge the system see separate instructions
in "2.7 Charging Closed Loop Cooling Systems with Circulating Pump" on page
2-13.

STEP 6 Momentarily turn on pump A and monitor the rotational direction of the
pump motor fins as they slow down. If the direction is opposed to the
indicator arrow on the motor cowl swap two of the AC lines feeding the
pump motor (after the inverter, U/T1, V/T2 or W/T3 connections).
These connections are inside the inverter and can be accessed by
opening the inverter cover and loosening the terminal screws located at
the rear on the right. The inverter controls the rotation of the pump
motors independent of the mains.
STEP 7 Repeat this process for Pump B motor to verify that it is also rotating in
the right direction.

! CAUTION:
PURE WATER SHOULD BE USED FOR SHORT TERM INITIAL TESTING ONLY. IF
OUTSIDE TEMPERATURES ARE NEAR OR BELOW FREEZING AVOID USING
WATER IN THE SYSTEM FOR PERIODS OF TIME THAT WOULD ALLOW IT TO
FREEZE. FREEZING WATER IN THE COOLING SYSTEM WILL DAMAGE COOLING
SYSTEM COMPONENTS.

STEP 8 Turn on the circulation pump and monitor inlet and outlet pressures.
When most air is out of system the inlet pressure should be 5-15 psi
(cold). If necessary charge the system with additional coolant until
approximately 15 psi static pressure is noted.
STEP 9 Run the system for 30 minutes on one pump then switch to the opposite
pump for another 30 minutes. Add coolant as required to keep inlet
pressure between 5-15psi.

NOTE:
Inlet and static pressures may rise above 15 psi if the system coolant is hot.

STEP 10 If the system has been charged with distilled water the system should be
drained and the water should be checked for cleanliness. It the system is
dirty it will need to be flushed. See transmitter manual for flushing
instructions. After cleaning and flushing the system should be charged
with coolant (50/50 mix of glycol/distilled water).
STEP 11 If the system has been charged with coolant (50/50 mix of glycol/
distilled water) run the system for several hours while monitoring the

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

sight glass (if used) for air. A low level of coolant or bubbles in the sight
glass would indicate air in the system and coolant should be added.

NOTE:
Typically the sight glass is located at a high point in the system on the return side
of the transmitter. The air purger and sight glass traps air that is introduced during
transmitter maintenance.

STEP 12 Close system automatic air vents.


STEP 13 Restore flow through transmitter, filter and test load as required.
STEP 14 End of procedure.

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HE Pump Module Section 2 Installation / Initial Turn-On

2.7 Charging Closed Loop Cooling Systems with


Circulating Pump

Properly outfitted closed loop cooling systems can be charged using the system
circulating pump. A separate charge pump is not required.

STEP 1 Turn off the pump breakers A and B on the front of the control panel.
Turn Pump A and B local control switches to the OFF position. Set
pump module system control switch to Local mode.

NOTE:
These actions prevent the pumps from starting before the system is properly
primed.

Figure 2-7 Pump Module Control Panel

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Section 2 Installation / Initial Turn-On HE Pump Module

STEP 2 The pump B intake side must be primed with coolant or water prior to
initial turn on.
STEP 3 Use a 2-7/8" (73 mm) open end or adjustable wrench to disconnect the
inlet connector just below the inlet valve as noted in Figure 2-8. Remove
the inlet valve/strainer assembly.
STEP 4 Attach the fill valve hose shown in Figure 2-9 on page 2-16 and route
the hose to a reservoir containing coolant or clean water. The reservoir
end of the hose should have a screen strainer installed in the hose fitting.
STEP 5 Close the fill valve shown in Figure 2-9 on page 2-16.
STEP 6 Open the pump B inlet valve shown in Figure 2-9 on page 2-16.
STEP 7 Fill the inlet side of the pump module with coolant or with pure water if
this is the first fill (approximately 1/2 gallons, 1.9 liters).
STEP 8 Open the fill valve for a few seconds to allow coolant to flow through the
fill valve hose. When coolant flow from the hose is noted place the hose
end below the fluid level (near the bottom of the reservoir) and close the
fill valve. This step removes air from hose.
STEP 9 Refill the inlet side of the pump module to replace the coolant drained
from the fill hose.
STEP 10 Re-attach the inlet valve/strainer and tighten the fittings.

NOTE:
Water is used for the first fill (new system only) to check the system for leaks.
Once the system is leak free then the system should be drained and refilled
(flushed) as needed to insure that no dirt or debris is retained in the cooling sys-
tem. Finally, the system should be drained and refilled with 50/50% glycol/dis-
tilled water mix using this same procedure.

! CAUTION:
IN COLD ENVIRONMENTS WATER MUST NEVER BE ALLOWED TO STAY IN THE
SYSTEM LONG ENOUGH TO FREEZE. THE SYSTEM MUST BE DRAINED OF
WATER AND FILLED WITH 50/50 GLYCOL/DISTILLED WATER MIX BEFORE BEING
EXPOSED TO FRIGID TEMPERATURES FOR EXTENDED PERIODS.

NOTE:
Adding the water or coolant primer could be done before the pipe/hose is con-
nected to the pump module.

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HE Pump Module Section 2 Installation / Initial Turn-On

Outlet Inlet
Valve Valve

Supply
StrainerSide
Valve

Inlet
Connector

Figure 2-8 Top of Pump Module

STEP 11 Set up a 30 gallon (size varies with system) reservoir (bucket or drum)
filled with pure water (for first fill) or 50/50% glycol/distilled water
mixture for the final fill. If the initial fill of water is contaminated with
dirt and debris several flushing cycles may be needed to insure the
system is clean. The strainer should be cleaned after each flush. The
strainer is cleaned with the pumps off and inlet valve closed to prevent
draining the entire system.
STEP 12 Attach a hose to the pump module strainer valve ( see Figure 2-8) and
route to the reservoir. With this strainer valve open, air and coolant will
be allowed to bleed from the system into the reservoir as the system is
being filled with coolant. When the pump is first activated air bubbles
will rise from strainer valve hose in the reservoir. The flow from this
hose will become a solid coolant stream after air is purged from the
system. Use adequate length to allow end of hose to extend well below
coolant level in reservoir.

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Section 2 Installation / Initial Turn-On HE Pump Module

Fill Valve
Hose

Pump B
Inlet Valve

Fill Valve

Figure 2-9 Fill Valve Hose

STEP 13 Open the plastic vent cap located on top of the pump module air
separator. See Figure 2-10. Also open the vent cap on the system air
purger which is located near the transmitter on the bypass manifold.

Air Separator
Vent Cap

Air Separator

Figure 2-10 Air Seperator Vent

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HE Pump Module Section 2 Installation / Initial Turn-On

STEP 14 Open inlet and oultet valves on top of the pump module to allow coolant
flow when pump is activated.
STEP 15 Apply AC power to the pump module.
STEP 16 Turn on pump B breaker shown in Figure 2-7.
STEP 17 Open the strainer valve and the fill valve.
STEP 18 Fully close pump B inlet valve. This will force the system to draw water
or coolant from the reservoir via the fill hose.
STEP 19 Be prepared to monitor the pump module pressure gauges while
charging the cooling system.
STEP 20 Momentarily turn on pump B and monitor the rotational direction of the
pump motor fins as they slow down. If the direction is opposed to the
indicator arrow on the motor cowl swap two of the AC lines feeding the
pump motor (after the inverter, U/T1, V/T2 or W/T3 connections).
These connections are inside the inverter and can be accessed by
opening the inverter cover and loosening the terminal screws located at
the rear on the right. The inverter controls the rotation of the pump
motors independent of the mains. Repeat this process for Pump A to
verify that it is also rotating in the right direction.
STEP 21 Turn pump B switch to the ON positions. Pump B should automatically
start running and begin to draw coolant from the reservoir into the
cooling lines. Allow the pump to continue running while monitoring the
pressure gauges. Also, monitor for any air bubbles that rise from the
reservoir. The air is being vented from the strainer bleed valve hose.
STEP 22 Use the pump B inverter potentiometer to speed up the pump for more
suction.
STEP 23 Close the strainer valve when a steady coolant stream appears to flow
and no air bubbles rise from the hose into the reservoir.
STEP 24 When the inlet pressure reaches 15 psi, close the fill valve and open
pump B inlet valve. Leave hoses in the reservoir with the ends
submerged. They will be used later to add coolant.
STEP 25 Allow the cooling system to continuously run so any trapped air can be
purged through the air separator vent caps. Periodically switch between
pumps to ensure trapped air is evacuated from the system through the
vent cap. The inlet pressure gauge must maintain a positive reading to
insure adequate coolant flow to the pumps.
STEP 26 Allow the pump module to run continuously and periodically switch
between pumps.

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WARNING: Disconnect primary power prior to servicing.
Section 2 Installation / Initial Turn-On HE Pump Module

NOTE:
Recharge the coolant system if the inlet pressure falls below 5 psi. This can be
accomplished by switching to pump “B”, slowly closing pump B inlet and then
slowly opening the system fill valve. Monitor inlet pressure as outlined in STEP
24.

STEP 27 Close the air separator plastic vent cap once the gauge readings have
stabilized and air is no longer coming out of the vent.
STEP 28 Set the inverter low level (LL) to an initial value of 15 Hz using
instructions provided in 3.1.1 on page 3-2. The pump module ships with
this value set to 45 Hz which may produce too much flow for smaller
transmitters.
STEP 29 Set the transmitter cabinet to the recommended flow rate by adjusting
the pump inverter frequencies (use knob on inverters) one at a time.The
recommended flow rates are listed in Table 3-1 on page 3-3. Record the
frequencies that produce the desired cabinet flow. These frequencies
will be used later to set up the inverter low levels (LL) as described in
3.1.1 on page 3-2.

NOTE:
The flow rate (liters per minute) can be viewed on the transmitter System GUI
screen.

STEP 30 When the inlet and outlet pressure gauge readings hold steady, switch the
active pump OFF and select REMOTE operation. This should turn off
the pump module and the gauge readings will fall to the static pressure
reading. Both gauges will read the same pressure.
STEP 31 Close the pump module and system automatic air vent valves.
STEP 32 Continue to monitor the cooling system pressure readings for several
weeks after the transmitter is brought up to normal operations. You may
need to add some additional coolant by repeating STEP 27. Normally,
the amount of coolant required will be less than 1/2 gallon(1.89 liters).

NOTE:
See Section 3 for inverter setup and operation.

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HE Pump Module

Section 3
Operation 3
3.1 Inverter Setup and Operation

Inverters are used to control pump and fan motors. They control the speed of the motors
as required to achieve operational cooling parameters. The inverters must be properly
programmed prior to system operation. Typically, LL and F202 need to be set on site.

Potentiometer Frequency Hz.


Dial

MODE Key
UP/DOWN Keys
ENTER Key

RUN/STOP Buttons
(not used after programming) Front Panel
Locking Screw

Figure 3-1 VF-S11 Inverter Control Panel

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Section 3 Operation HE Pump Module

The plumbing/cooling system must be installed and filled with coolant before
proceeding with the following steps. In order to program the inverters the pump
frequency needed to achieve the recommended flow rate must be determined. The
optimum pump operating frequency will need to be determined and set up for each
system. This value will then be programmed to the and F202 parameters.

3.1.1 Inverter Pre-programming

The lower limit pump operating frequency is programmed at the factory


to 45 Hz to satisfy larger cooling sytems. The optimum pump frequency should be
determined for each system. This value must then be programmed to the parameters
and F202. Use the following procedure to determine the required pump
frequency.

STEP 1 Make sure the pump module control switch is in LOCAL mode and both
pumps are off.
STEP 2 Set the basic parameter to 15 Hz. See 3.1.2.2 for
instructions on setting basic parameters.
STEP 3 Fully open the transmitter inlet and outlet coolant control valves
allowing flow through transmitter cabinet.
STEP 4 Turn one of the pumps on. The potentiometer dial on the inverter front
panel will be used to change the pump frequency.
STEP 5 Use the transmitter TCU GUI screens to determine actual coolant flow
rate and then use the inverter pot to adjust the pump frequency until the
recommended flow rate in Table 3-1 is achieved. Do not use
frequencies below 15Hz. Record this value. The inverter will be
programmed with this value using the and F202
parameters.

NOTE:
The recommended flow rates given in Table 3-1 are lower than those given in the
transmitter outline drawing and technical manual. The settings here represent the
lowest recommended coolant flow. The HE pumps will increase speed automati-
cally at higher ambient temperatures and increase flow above these levels as
needed.

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HE Pump Module Section 3 Operation

Table 3-1 Typical Transmitter Flow Rates

Quantity of PA Minimum Coolant Recommended Typical Pump


Modules Flow Rate Trip Point Coolant Flow Rate Frequency Range
(LPM) (LPM) (Hz)

2 10 14 15-20

3 19 27 15-20

4 23 32 15-25

6 31 43 20-30

8 38 53 25-35

10 46 65 TBD

12 53 75 TBD

16 70 100 TBD

3.1.1.1 Verify F700 Setting & Run Command

If the inverter has been previously programmed, inverter programming may be locked.
This setting prohibits parameter values from changing. To enable programming, set
extended parameter F700 to 0. To prohibit programming, set F700 to 1. See 3.1.2.3 for
detailed instructions on changing extended parameters.

Many parameters cannot be changed while the inverter is receiving the RUN
command. This command can be disabled by unplugging the inverter control connector
from the pump control board. If the inverter has not been previously programmed, the
RUN and STOP keys on the inverter front panel are used to control the inverter. Simply
press the STOP key to cancel the RUN command. Verify that the motor has stopped.

3.1.2 Inverter Programming

Inverters for fans and pumps are programmed with different parameter values. Refer to
Table 3-2 for pump inverter settings. Refer to Table 3-3 for fan inverter settings. It is
recommended that the parameters be programmed in the order shown in Table 3-2 and
Table 3-3 . Programming parameters in a different order will not affect the inverters

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Section 3 Operation HE Pump Module

operation. The F700 parameter locks programming of parameters, and must be the last
parameter programmed.

3.1.2.1 Identifying Parameter Type:

Two types of parameters need to be changed for the inverter to interface properly with
the transmitter:

Basic parameters – parameters that are changed often. Basic parameter names
typically contain all letters. Basic parameters:

Extended Parameters – parameters that begin with F followed by three digits (F100 –
F999). Extended parameters are accessed by selecting in the basic
parameter menu. 

3.1.2.2 Changing Basic Parameters

Figure 3-1 shows the inverter control panel keys used to change parameter values.

Pressing the MODE key several times during programming will return to the initial
display.

Initial press of the MODE key once will display “AUH”.

Use the UP/DOWN keys to select the desired basic parameter, such as .

Press the Enter key. The current value of the selected basic parameter should be
displayed.

Use the UP/DOWN keys to select the desired new value for the parameter.

If the UP/DOWN keys won’t change the parameter value, programming might be
locked on the inverter. See 3.1.1.1 to enable programming.

Press the ENTER key to save the new value. The parameter name and new value should
flash on the display.

Use the UP/DOWN and ENTER keys to modify more basic parameters if needed.
Otherwise, press the MODE key several times until the display returns to 0.0 Hz.

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HE Pump Module Section 3 Operation

3.1.2.3 Changing Extended Parameters:

Figure 3-1 shows the inverter keys used to change parameter values. Pressing the
MODE key several times will cause a return to the frequency display.

Press the MODE key. The inverter should display “AUH”.

Use the UP/DOWN keys to select the extended parameter list:

Press the Enter key. You should see the first extended parameter F100.

Use the UP/DOWN keys to select the desired extended parameter such as F115.

Press the ENTER key. You will see the current value of the selected parameter.

Use the UP/DOWN keys to change the parameter value to the desired value.

If the UP/DOWN keys won’t change the parameter value, programming might be
locked on the inverter. See 3.1.1.1 to enable programming.

Press the ENTER key to save the new value. The parameter name and new value should
flash on the display.

You can use the UP/DOWN and ENTER keys to modify more extended parameters if
needed. Otherwise, press the MODE key until the display returns to 0.0 Hz.

3.1.3 Clearing Inverter Memory

The basic parameter allows the inverter to be reset to factory default


values. If the inverter has been improperly programmed it may be useful to clear inveter
memory and then reporgram it.

To clear all inverter parameters, set the basic parameter to 3. All inverter
parameters will need to be reprogrammed. See 3.1.2.2 for detailed instructions for
programming basic parameters. See Table 3-2 or 3-3 for parameters.

3.1.4 Manual Fan Control

After the fan inverters have been properly programmed according to Table 3-3,
frequency setting (fan speed) will be controlled by a temperature sensor in the pump
module. The inverter potentiometer will not change the fan motor speed.

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Section 3 Operation HE Pump Module

Should it become necessary to allow manual frequency control (fan activation) via the
built in inverter potentiometers additional jumpers inside the inverter will be needed.

To enable the built in potentiometer for manual frequency control (manual fan
activation):

STEP 1 Turn off the AC breaker going to the inverter.


STEP 2 Open the front panel of the inverter. To open the front panel the locking
screw shown in Figure 3-1 needs to be turned counterclockwise.
STEP 3 Place a jumper wire between the S2 terminal and one of the CC
terminals on the inverter terminal board as indicated in Figure 3-2. This
jumper allows potentiometer control.Ok to add jumper to existing
wire in terminal.
STEP 4 If there is no inverter enable signal is coming from the transmitter then
another jumper is needed to allow manual operation of the inverter.
Place the additional jumper between terminals F and CC. This jumper
allows fan activation when transmitter is not installed or can’t be
activated.Ok to add jumper to existing wire in terminal.

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HE Pump Module Section 3 Operation

S2

CC
CC

Figure 3-2 Fan Inverter Potentiometer Jumper

Table 3-2 Pump Inverter Settings

Programming Parameter Setting Description Selection


Order

Command mode
1 0 Terminal board
selection

Frequency mode
2 0 Built-in potentiometer
selection

3 1 Acceleration time 10 seconds

See Section
4 Lower limit frequency Hz
3.1.1

5 1 V/F selection mode Variable torque

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Section 3 Operation HE Pump Module

Table 3-2 Pump Inverter Settings

Programming Parameter Setting Description Selection


Order

Input terminal selection Frequency command


6 F115 38 5 (S2) forced switching

VIA input point 1


7 F201 50 setting
50%

Set to same VIA input point 1


8 F202 value as LL. frquency
Hz

VIA input point 2


9 F203 100 setting
100%

Frequency setting mode


10 F207 1 selection 2
VIA

Auto-restart control Auto-restart after


11 F301 1 selection. momentary stop

Operation starting
12 F242 1 frequency (hysteresis)
1 Hz

13 F303 10 Retry selection 10 times

Panel operation
14 F733 1 prohibition (RUN/STOP Prohibited
keys)

Prohibition of panel
15 F734 1 emergency stop Prohibited
operation

Prohibition of change of
16 F700 1 parameter settings
Prohibited

Table 3-3 Fan Inverter Settings

Programming Parameter Setting Description Selection


Order

0 Command mode Terminal board


1 selection

1 Frequency mode VIA


2 selection

3 1 Acceleration time 10 seconds

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HE Pump Module Section 3 Operation

Table 3-3 Fan Inverter Settings

Programming Parameter Setting Description Selection


Order

4 10 Lower limit frequency 10 Hz

5 1 V/F selection mode Variable torque

38 Input terminal selection Frequency command


6 F115 5 (S2) forced switching

30 VIA input point 1 30%


7 F201 setting

10 VIA input point 1 10Hz


8 F202 Frequency

60 VIA input point 2 60%


9 F203 setting

0 Frequency setting mode Built-in potentiometer


10 F207 selection 2

10 Operation starting 10Hz


frequency. Turns
11 F241 inverter off when fluid
<30 o C.

1 Auto-restart control Auto-restart after


12 F301 selection momentary stop

10 Retry selection 10 times


13 F303
1 Panel operation Prohibited
14 F733 prohibition (RUN/STOP
keys)

1 Prohibition of panel Prohibited


15 F734 emergency stop
operation

1 Prohibition of change of Prohibited


16 F700 parameter settings

1/22/13 888-2625-001 3-9


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Section 3 Operation HE Pump Module

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WARNING: Disconnect primary power prior to servicing.
HE Pump Module

Section 4
Theory of
Operation
4
4.1 Introduction

Liquid cooling system pump and fan modules were previously operated with single
speed AC motors, which have two operating conditions, on or off.

The volume of coolant flow was determined by he the pump size and associated
plumbing, flow rate was determined by the worst case cooling requirements.

Cooling of the liquid was controlled by the heat exchanger, where single speed fans
sucked air across a chiller core. Cooling was controlled by two temperature settings,
which are as follows:

• Below the low temperature setting, both fans were off.


• When the temperature was between the low and high settings one fan
operates.
• When the temperature was above the high setting, both fans operate.

Pump, fan and core sizes were determined by the worst case cooling requirements

An alternate concept in cooling systems involves the use of variable speed induction
motors on pumps and fans to more adequately control coolant flow, temperature, and
reduce the cost of operation.

4.2 Speed Of Electric Induction Motors

In the past, a DC motor was the only convenient way to easily have a continuously
variable motor speed.

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Section 4 Theory of Operation HE Pump Module

AC induction motor speed is determined by the AC line frequency, the number of field
coils, and the amount of speed reduction due to load (this is called the slip speed). For
example, an induction motor which operates on 60 Hz and has four field coils (2 pairs
of field coils) and has a slip speed of 50 RPM would have the following speed in
revaluations per minute (RPM).

F  60  2 60  60  2
RPM = ------------------------- – S = --------------------------- – 50 = 1750
N 4

Where: F = AC line frequency.


N = Number of poles.
S = Slip speed, which is the slowing of the motor speed due to its load.

The current drawn by an induction motor is determined by three factors, which are:

• The dc resistance of its coils.


• The inductive reactance, which is determined by the number of turns of the
coil and the amount of magnetic material in the frame and rotor.
• The back EMF (electromotive force) generated as a function of the motor’s
speed.

When the rotor of motor is locked, its line current is extremely high, being limited by
the dc resistance and inductive reactance (the impedance) of its coils. As the motor
speed increases, it generates a back EMF which is proportional to the motor speed. The
back EMF cancels part of the applied voltage, the difference voltage applied to the coil
impedance determines the AC current draw. When the slip speed is zero RPM, the
motor is rotating at its ideal speed, 1800 RPM in the above example, and the back EMF
equals the applied voltage.Therefore, the AC current of the motor is zero. In the real
world even an unloaded motor has some friction losses, therefore, it will have some slip
speed and draw some current.

A speed of a given induction motor can be reduced by lowering the applied AC


frequency, but, unless the motor was designed for such use, it would draw higher AC
current at any given load. This is due mainly to the decrease of back EMF generated due
to its slower operating speed and to a somewhat less effect because of its lower
inductive reactance. Both of these detrimental effects can be reduced by use ing more
magnetic material in the motor (heavier frame) and possibly increasing the number of
turns of the coils.

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HE Pump Module Section 4 Theory of Operation

4.3 Using An Inverter To Control Induction Motor Speed

The heart of the variable speed induction motor is the high efficiency inverter module.
This module operates as follows. The incoming AC is rectified to DC and stored in
large capacitors. Solid state circuitry, using off/on switching, creates a simulated AC
sine wave at the desired voltage and frequency.

To reduce the AC current draw as the line frequency and motor speed are reduced, the
applied voltage is reduced in proportion to the line frequency. For example, a 240 Vac
motor designed for 60 Hz will require 40 Vac at 10Hz. This is calculated by the
following formula.

Rated AC Voltage 240


Applied Voltage = --------------------------------------------------  Applied Frequency = ---------  10 = 40 Vac
Rated AC Frequency 60

NOTE:
The applied voltage may be varied slightly to obtain optimum performance.

Figure 4-1 Three Phase Inverter Simplified Diagram

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WARNING: Disconnect primary power prior to servicing.
Section 4 Theory of Operation HE Pump Module

4.3.1 Inverter Operated Pump and Cooler Modules

Inverters and variable speed pumps and fans are used in the Harris liquid cooling
systems. These systems use three phase AC power.

The temperature of the pump module output coolant, which is the input coolant to the
transmitter, is monitored and changed to a control voltage which is proportional to the
temperature. This control voltage controls the output frequency of the inverters, which
controls the pump and fan speed. Two temperature thresholds are used.

Fans:
The range of the control voltage is 0 to 10 Vdc. At the low temperature threshold the
control voltage is approximately 3 Vdc, and at the high temperature threshold, the
control voltage is approximately 6 Vdc. When the control voltage is at or below 3 Vdc,
the inverters turn off. This reduces fan speeds which provides minimum air flow and
cooling. When the control voltage is  6 Vdc, the inverters output a 60 Hz frequency at
the input AC line voltage. This operates the fans at maximum speed which provides
maximum coolant flow and cooling. When control voltage is between 3-6vdc,
frequency is variable.

Pumps:
Pumps operate at LL frequency for  5Vdc then begin to increase frequency.

The inverter, pump motor, and fan motor have two AC voltage ratings, which are 200 to
240 Vac or 380 to 500 Vac.

When the correct AC rotation is established between the inverter and the pump or fan
motors, The direction of rotation is independent of the rotation of the input three phase
AC power. The inverter will operate properly if one phase of the AC input power is lost,
however, long term operation with a lost phase is not recommended and will reduce
inverter life.

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WARNING: Disconnect primary power prior to servicing.
HE Pump Module

Section 5
Maintenance and
Alignments
5
5.1 Introduction

This section contains all of the maintenance and alignment procedures for HE pump
module and associated cooling system components. Consult the transmitter technical
manual for more detailed cooling system maintenance information.

5.2 Miscellaneous Maintenance

5.2.1 Cooling System Checks

Inspect the cooling system weekly for coolant leaks and check the coolant level.

5.2.1.1 Heat Exchanger Cleaning

The heat exchanger fins and pump motor housing fins should be examined for dust and
dirt buildup monthly. Clean as necessary with low pressure water hose, soft bristled
brush or compressed air.

! CAUTION:
TAKE CARE NOT TO DAMAGE THE FINS. DO NOT CLEAN WITH HIGH PRESSURE
WATER, WIRE BRUSH OR OTHER METHODS THAT MIGHT DAMAGE THE FINS.

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Section 5 Maintenance and Alignments HE Pump Module

5.2.1.2 Alternate Pumps

Every two months select the opposite pump in order to keep both pumps in a proper
working state. Switching the pumps can be accomplished via the GUI screen (with
pump module in REMOTE mode) by pressing SYSTEM then press the GUI button to
select the inactive pump. This may also be a good time to manually operate (open and
close them several times) all valves to assure proper movement and closure.

NOTE:
See the cooling system drawings, manufacturers component manuals, transmitter
technical manual for additional details.

5.2.1.3 Pump Module Strainer Cleaning

The strainer is shown on drawing 843-5607-068 which shows a ball valve above the
strainer and additional ball valves at the pump inputs. The strainer is located on the
pump module in the return line. The strainer should be inspected several times during
the start up process and cleaned following the final flush. The frequency of inspection
after initial installation may vary depending on site conditions but in most cases annual
inspection and cleaning of the cooling system strainer is recommended. The strainer
must be disassembled and cleaned when the transmitter is off the air since the coolant
flow must be disrupted prior to opening the strainer assembly. Follow the steps that
follow to clean the strainer:

a. Turn off the transmitter and pump module.


b. Close the ball valves on both sides of the strainer.

! CAUTION:
WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN
REMOVING THE STRAINER CAP. LOOSEN THE CAP SLOWLY SINCE THE
COOLANT MAY BE UNDER PRESSURE. THE COOLANT MAY ALSO BE HOT.

c. Remove strainer housing cap.

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HE Pump Module Section 5 Maintenance and Alignments

StrainerAssy.

Screen

Plug/Drain.

NOTE:
A small amount of liquid will still be present in the pipe and strainer housing, and
a receptacle (bucket) will be necessary to contain the spillage.

d. Pull strainer screen


e. Inspect and clean strainer as needed
f. Replace the strainer, and perform the above steps in reverse order to restore the
cooling system to normal operation.

5.2.1.4 Coolant Level Management:

The HE pump module is used in a closed (pressurized) cooling system. The system
contains a pressurized expansion tank with a bladder that separates the system coolant
from pressurized air. The expansion tank is pressurized (with air) at the factory and
should not need pressurization on site. The coolant level is checked by viewing the
coolant passing through the sight glass located on the air purger at the highest point in

1/22/13 888-2625-001 5-3


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Section 5 Maintenance and Alignments HE Pump Module

the cooling system. The presence of air bubbles or lack of fluid in the sight glass is an
indication that the system needs to be charged with additional coolant.

Air
Purger
Sight
Glass

Figure 5-1 Air Purger and Sight Glass

5.2.1.5 Cooling System Maintenance Notes

5.2.1.5.1 Coolant Checks:

The pH level of the 50/50 glycol/water mixture should be above 8.0. A PH level that is
below 8.0 indicates that the inhibitors in the glycol are ineffective. Should the PH level
of the mixture drop below 8.0 either additives must be added or the coolant should be
changed. The PH level should be checked regularly with either pH paper or with a pH
meter. If these test items are not available a sample of the coolant can be sent to an
independent service provider for analysis. The pH level should be checked at 3 month
intervals.

The 50/50 glycol/water mixture should be checked at 3 month intervals as well. Drain a
sample of coolant from the system and check the 50/50 mixture. Use a conventional
float hydrometer and jar (for ethylene glycol only) or a MISCO DFR 200 or equivalent
digital refractometer to verify the 50/50 mixture (for ethylene or propylene glycol).

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HE Pump Module Section 5 Maintenance and Alignments

5.2.1.5.2 Changing Pumps:

a. Turn off the transmitter and pump module (if possible). Turn off all breakers and
switches on the pump module (if possible). If the transmitter must remain on air
during the pump change turn off the breakers for the bad pump.
b. Close the ball (isolation) valves on either side of the pump that is to be changed.
c. Disconnect the fittings on either side of the pump.

NOTE:
A small amount of liquid will still be present in the pipe and pump housing, and a
receptacle (bucket) will be necessary to contain the spillage.

! WARNING:
WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN REMOV-
ING. LOOSEN THE CAP SLOWLY SINCE THE COOLANT MAY BE UNDER PRES-
SURE. THE COOLANT MAY ALSO BE HOT.

d. Remove and replace the pump. Take care to install the pump so flow is
maintained in the proper direction.

! CAUTION:
USE PIPE JOINT COMPOUND OR TEFLON TAPE ON MALE THREADED FITTINGS
AS REQUIRED PRIOR TO REINSTALLATION OF PUMP. USE JOINT COMPOUND
SPARINGLY TO AVOID CONTAMINATION OF COOLANT. IF FITTINGS WITH O-RING
SEALS ARE USED THE O-RINGS SHOULD NOT BE REUSED. USE A NEW O-RING
AND LUBRICATE IT LIGHTLY WITH SILICON GREASE.

e. Perform the above steps in reverse order to restore the cooling system to normal
operation.
f. Once pump operation is restored check the sight glass to be sure that air bubbles
are not present and that the level of coolant is adequate. Charge system as
required to maintain coolant level.

1/22/13 888-2625-001 5-5


WARNING: Disconnect primary power prior to servicing.
Section 5 Maintenance and Alignments HE Pump Module

5.2.1.6 Pump Module Operation Without Transmitter

The pump module can be operated independently, without being attached to the
transmitter, by selecting the LOCAL mode on the pump module/heat exchanger cooling
control panel.

! CAUTION:
SELECTION OF LOCAL WILL ALSO ALLOW THE PUMP MODULE/HEAT
EXCHANGER TO BE OPERATED FROM THE CONTROL PANEL AS LONG AS THE
PUMP INTERLOCK IS NOT ACTIVE.

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WARNING: Disconnect primary power prior to servicing.
HE Pump Module

Section 6
Diagnostics 6
6.1 Inverter

The ToshibaVF-S11 industrial inverter display a wide range of error and failure codes
that may aid in troubleshooting. Refer to the Toshiba Inverter Technical Manual which
contains tabulated fault listings and troubleshooting help.This manual ships with the
pump module and is also available on line.

1/22/13 888-2625-001 6-1


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Section 6 Diagnostics HE Pump Module

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WARNING: Disconnect primary power prior to servicing.
Section 7
Parts List 7
Replaceable Parts List Index
Table 7-1 ASSY, LOW VOLTAGE PUMP MODULE, HE - - - - - 9950333001G (C) 7-2
Table 7-2 ASSY, PUMP MODULE, BASIC, HE - - - - - - - - - 981 5607 001 (K) 7-2
Table 7-3 ASSY, INPUT PLUMBING, PUMP MODULE, HE - - 943 5607 449 (E) 7-2
Table 7-4 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE - 943 5607 450 (H) 7-3
Table 7-5 KIT, INVERTERS, LOW VOLTAGE, 240V - - - - - - 981 5607 003 (A) 7-3

Table 7-6 ASSY, HIGH VOLTAGE PUMP MODULE, HE - - - - - 9950333002G (B) 7-4
Table 7-7 ASSY, PUMP MODULE, BASIC, HE - - - - - - - - - 981 5607 001 (K) 7-4
Table 7-8 ASSY, INPUT PLUMBING, PUMP MODULE, HE - - 943 5607 449 (E) 7-4
Table 7-9 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE - 943 5607 450 (H) 7-4
Table 7-10 ASSY, CONTROL UNIT, PUMP MODULE, HE- - - - 971 5607 003 (K) 7-5
Table 7-11 KIT, INVERTERS, HIGH VOLTAGE, 480V - - - - - - 981 5607 002 (C) 7-5

For table above and in tables that follow in this section the (X) or (XX) after the table
title part number is the revision level of that bill of material and is for reference only.

1/22/13 888-2625-001 7-1


WARNING: Disconnect primary power prior to servicing.
Section 7 Parts List HE Pump Module

Table 7-1 ASSY, LOW VOLTAGE PUMP MODULE, HE - 9950333001G (C)


Harris PN Description Qty UM Reference Designators
981 5607 001 ASSY, PUMP MODULE, BASIC, HE 1 EA
981 5607 003 KIT, INVERTERS, LOW VOLTAGE, 240V 1 EA

Table 7-2 ASSY, PUMP MODULE, BASIC, HE - 981 5607 001 (K)
Harris PN Description Qty UM Reference Designators
021 7510 002 HOSE, 1/2'' ID, BLUE 1.5 FT
021 7510 004 HOSE, GEN PURPOSE, EPDM, 1.25" ID, RED 1.13 FT
336 1254 000 *HOSE CLAMP, (MINI) SST, SAE-6 2 EA
354 0190 000 NUT WIRE 8 EA
358 1036 000 *HOSE CLAMP, SST, SAE-152 1 EA
358 1316 000 HOSE CLAMP, SST, SAE-24 9 EA
358 3025 000 HOSE BARB, 0.50H X 0.50MPT 1 EA
358 3185 000 PLUG WHT 1.093/1.125 HOLE 4 EA
359 1154 000 BUSHING, 1/2 X 1/4 MALE TO 1 EA
359 1476 000 HOSE BARB, PUSH-LOC, BRASS 2 EA
359 1617 000 VALVE, BLOWDOWN BALL 2 EA
359 1619 000 VALVE, PRESSURE RELIEF 75 PSI 1 EA
359 1621 000 VALVE, AUTOMATIC AIR VENT 1 EA
359 1625 000 FITTING, CROSS PIPE 1/2" NPT 1 EA
359 1631 000 ELBOW, MXF STREET 90 DEG 1/2 IN 1 EA
359 1632 000 ADAPTER 1/4" F TO 1/4" M BRASS 2 EA
359 1634 000 ELBOW 1.25"ID HOSE X 1.25"MNPT 2 EA
359 1635 000 HOSE BARB, 0.50H X 0.50FPT 1 EA
424 0677 000 HOSE, RUBBER 6' W/3/4" CPLGS 2 EA
629 0202 000 GAUGE, PRESSURE, 0-100 PSI 2 EA
638 0075 000 SENSOR, THERMISTR NTC 100K OHM 1 EA
843 5607 068 WIRING DIAGRAM HE COOLING SYSTEM ULX/VLX0 DWG
943 5607 435 BRACKET, TANK 1 EA
943 5607 436 BACK 1 EA
943 5607 437 BASE 1 EA
943 5607 449 ASSY, INPUT PLUMBING, PUMP MODULE, HE 1 EA
943 5607 450 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE1 EA
943 5607 631 LABEL KIT, PUMP MODULE 1 EA
359 1620 000 TANK, EXPANSION IN-LINE 2 GAL 1 EA
708 0061 020 MOTOR PUMP 126, 2HP 2 EA
971 5607 003 ASSY, CONTROL UNIT, PUMP MODULE, HE 1 EA

Table 7-3 ASSY, INPUT PLUMBING, PUMP MODULE, HE - 943 5607 449 (E)
Harris PN Description Qty UM Reference Designators
0038020050A *TUBE, COPPER 1.625 OD (TYPE M) 3.52 FT
843 5607 449 ASSY INSTR, INPUT PLUMBING 0 DWG
359 1611 000 VALVE, BALL 1.5" W/UNION 2 EA
359 0418 000 ELBOW CU 90DEG 1.500C X 1.500FTG 4 EA
359 0274 000 TEE CU 1.500C X 1.500C X 1.500C 1 EA
359 1622 000 TEE CU 1.500C X 1.500C X 2.000C 1 EA
359 1616 000 VALVE, BALL 1-1/2" W/STRAINER/UNION 1 EA
359 1623 000 REDUCER, FITTING 2 X 1/2 1 EA
359 0106 000 ADAPTER, FTGXM 0.500 X 0.500 COPPER 1 EA

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HE Pump Module Section 7 Parts List

Table 7-4 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE - 943 5607 450 (H)
Harris PN Description Qty UM Reference Designators
0038020050A *TUBE, COPPER 1.625 OD (TYPE M) 2.6 FT
843 5607 450 ASSY INSTR, OUTPUT PLUMBING 0 DWG
359 1630 000 VALVE, BALL / UNION NT-EFC-O 1 EA
359 1603 150 VALVE, BALL 1.500 SWEAT 2 EA
359 1629 000 VALVE, CHECK 1-1/2" BRONZE RING 2 EA
359 0274 000 TEE CU 1.500C X 1.500C X 1.500C 1 EA
359 0418 000 ELBOW CU 90DEG 1.500C X 1.500FTG 4 EA
943 5601 724 FITTING, 1-1/4 HOSE BARB TO 1.5 FTG 2 EA

Table 7-5 KIT, INVERTERS, LOW VOLTAGE, 240V - 981 5607 003 (A)
Harris PN Description Qty UM Reference Designators
736 0467 000 INVERTER DRIVE, 240V 3PH 1HP 2 EA
736 0468 000 INVERTER DRIVE, 240V 3PH 2HP 2 EA
943 5607 445 BRACKET, INVERTER 1 EA

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WARNING: Disconnect primary power prior to servicing.
Section 7 Parts List HE Pump Module

Table 7-6 ASSY, HIGH VOLTAGE PUMP MODULE, HE - 9950333002G (B)


Harris PN Description Qty UM Reference Designators
981 5607 001 ASSY, PUMP MODULE, BASIC, HE 1 EA
981 5607 002 KIT, INVERTERS, HIGH VOLTAGE, 480V 1 EA

Table 7-7 ASSY, PUMP MODULE, BASIC, HE - 981 5607 001 (K)
Harris PN Description Qty UM Reference Designators
021 7510 002 HOSE, 1/2'' ID, BLUE 1.5 FT
021 7510 004 HOSE, GEN PURPOSE, EPDM, 1.25" ID, RED 1.13 FT
336 1254 000 *HOSE CLAMP, (MINI) SST, SAE-6 2 EA
354 0190 000 NUT WIRE 8 EA
358 1036 000 *HOSE CLAMP, SST, SAE-152 1 EA
358 1316 000 HOSE CLAMP, SST, SAE-24 9 EA
358 3025 000 HOSE BARB, 0.50H X 0.50MPT 1 EA
358 3185 000 PLUG WHT 1.093/1.125 HOLE 4 EA
359 1154 000 BUSHING, 1/2 X 1/4 MALE TO 1 EA
359 1476 000 HOSE BARB, PUSH-LOC, BRASS 2 EA
359 1617 000 VALVE, BLOWDOWN BALL 2 EA
359 1619 000 VALVE, PRESSURE RELIEF 75 PSI 1 EA
359 1621 000 VALVE, AUTOMATIC AIR VENT 1 EA
359 1625 000 FITTING, CROSS PIPE 1/2" NPT 1 EA
359 1631 000 ELBOW, MXF STREET 90 DEG 1/2 IN 1 EA
359 1632 000 ADAPTER 1/4" F TO 1/4" M BRASS 2 EA
359 1634 000 ELBOW 1.25"ID HOSE X 1.25"MNPT 2 EA
359 1635 000 HOSE BARB, 0.50H X 0.50FPT 1 EA
424 0677 000 HOSE, RUBBER 6' W/3/4" CPLGS 2 EA
629 0202 000 GAUGE, PRESSURE, 0-100 PSI 2 EA
638 0075 000 SENSOR, THERMISTR NTC 100K OHM 1 EA
843 5607 068 WIRING DIAGRAM HE COOLING SYSTEM ULX/VLX0 DWG
943 5607 435 BRACKET, TANK 1 EA
943 5607 436 BACK 1 EA
943 5607 437 BASE 1 EA
943 5607 449 ASSY, INPUT PLUMBING, PUMP MODULE, HE 1 EA
943 5607 450 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE1 EA
943 5607 631 LABEL KIT, PUMP MODULE 1 EA
359 1620 000 TANK, EXPANSION IN-LINE 2 GAL 1 EA
708 0061 020 MOTOR PUMP 126, 2HP 2 EA
971 5607 003 ASSY, CONTROL UNIT, PUMP MODULE, HE 1 EA

Table 7-8 ASSY, INPUT PLUMBING, PUMP MODULE, HE - 943 5607 449 (E)
Harris PN Description Qty UM Reference Designators
0038020050A *TUBE, COPPER 1.625 OD (TYPE M) 3.52 FT
843 5607 449 ASSY INSTR, INPUT PLUMBING 0 DWG
359 1611 000 VALVE, BALL 1.5" W/UNION 2 EA
359 0418 000 ELBOW CU 90DEG 1.500C X 1.500FTG 4 EA
359 0274 000 TEE CU 1.500C X 1.500C X 1.500C 1 EA
359 1622 000 TEE CU 1.500C X 1.500C X 2.000C 1 EA
359 1616 000 VALVE, BALL 1-1/2" W/STRAINER/UNION 1 EA
359 1623 000 REDUCER, FITTING 2 X 1/2 1 EA
359 0106 000 ADAPTER, FTGXM 0.500 X 0.500 COPPER 1 EA

Table 7-9 ASSY, OUTPUT PLUMBING, PUMP MODULE, HE - 943 5607 450 (H)
Harris PN Description Qty UM Reference Designators
0038020050A *TUBE, COPPER 1.625 OD (TYPE M) 2.6 FT
843 5607 450 ASSY INSTR, OUTPUT PLUMBING 0 DWG
359 1630 000 VALVE, BALL / UNION NT-EFC-O 1 EA

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HE Pump Module Section 7 Parts List

359 1603 150 VALVE, BALL 1.500 SWEAT 2 EA


359 1629 000 VALVE, CHECK 1-1/2" BRONZE RING 2 EA
359 0274 000 TEE CU 1.500C X 1.500C X 1.500C 1 EA
359 0418 000 ELBOW CU 90DEG 1.500C X 1.500FTG 4 EA
943 5601 724 FITTING, 1-1/4 HOSE BARB TO 1.5 FTG 2 EA

Table 7-10 ASSY, CONTROL UNIT, PUMP MODULE, HE - 971 5607 003 (K)
Harris PN Description Qty UM Reference Designators
055 0120 227 CONDUIT FLEXIBLE 1/2 IN. 7 FT
055 0120 231 CONN, STRAIGHT 1/2 2 EA
055 0120 373 CONN 1/2 IN. 90 DEG 2 EA
250 0387 000 CABLE, 6C 20AWG STRD 6 FT
354 0792 000 LUG, TERMINAL 6-14 AWG 2 EA
358 3637 000 PLATE, END STOP, DIN RAIL MTG 2 EA
606 1137 100 CKT BRKR 10 AMPS 3P 480VAC 4 EA
612 2156 006 PLUG, 6C 1ROW VERTICAL 4 EA
615 0007 000 TERM BLK, THRU, 2-POLE, GREY (264) 6 EA
615 0008 000 TERM BLK, GROUND, 4-POLE, GRN/YEL (264) 1 EA
901 0227 101 PWA, PUMP CONTROL 1 EA
943 5607 446 BRACKET, BREAKER 1 EA
952 9253 260 CABLE HE PUMP MODULE 1 EA
971 0053 312 ASSY, BUSBAR 3P 4-BRKR (12TAP) 1 EA
943 5607 440 CHASSIS, CONTROL ENCLOSURE 1 EA
350 0046 000 RIVET 0.156 DIA, DOME HEAD, OPEN END 2 EA
943 5607 438 COVER, CONTROL ENCLOSURE 1 EA

Table 7-11 KIT, INVERTERS, HIGH VOLTAGE, 480V - 981 5607 002 (C)
Harris PN Description Qty UM Reference Designators
736 0469 000 INVERTER DRIVE, 460V 3PH 2HP 2 EA
736 0465 000 INVERTER DRIVE, 460V 3PH 1HP 2 EA

1/22/13 888-2625-001 7-5


WARNING: Disconnect primary power prior to servicing.
Section 7 Parts List HE Pump Module

7-6 888-2625-001 1/22/13


WARNING: Disconnect primary power prior to servicing.
HE Pump Module

Appendix A Remote Placement of Control Panel

A.1 Introduction

The 9950333005 HE Pump Module Conversion Kit facilitates remote placement of HE


control panel on 9950333001G, 9950333002G, and 99500333004G HE pump module
assemblies.

Note: The HE pump module control panel is designed for indoor use only. The pumps
can be used outdoors if cover (included in remote mounting kit) is installed as described
in Installation Drawing 843-5607-072 (sheet 7)

Tools:

• #2 Phillips Screwdriver
• Diagonal cutter
• Wire stripper
• Pliers

A.2 Procedure
STEP 1 Turn pump control panel breakers and switches to off positions
(Figure A-1).
STEP 2 Turn off AC mains supply to pump module.
STEP 3 Set cooling control panel Remote/Local switch to Local.
STEP 4 Remove two Phillips screws from front, bottom of control panel
(Figure A-1); then lift cover upward to remove.

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HE Pump Module

Figure A-1 Cooling Control Front Panel

STEP 5: Use a #2 Phillips to disconnect AC mains and safety ground wiring


from cooling control panel breakers and frame (Figure A-2).

STEP 6: Remove pump module AC mains input cable and conduit from
control panel (Figure A-2).

Figure A-2 Cooling Control Panel AC Mains Connections

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HE Pump Module

STEP 7: Disconnect transmitter control connector (WAGO) from controller


board (Figure A-2). Read note below. Use a WAGO extractor tool to
remove colored wires from connector. Place WAGO connector back on
board for later reuse.

NOTE:
The transmitter control connector wires may not have to be removed from con-
nector if the control panel is to be relocated closer to TX. The connector will fit
through the hole in control chassis allowing the cable to be removed with the
connector (if desired).

STEP 8: Remove transmitter control cable and conduit from control panel .

STEP 9: Use a WAGO extractor to disconnect fan AC wires from lower part
of terminal block (Figure A-3).

Figure A-3 AC to Fans

STEP 10: Remove AC fan cables and conduit from control panel.

STEP 11: Disconnect thermistor wire WAGO connector (Figure A-4); use
WAGO extractor tool to remove wires, then place WAGO connector
back on board (for later reuse).

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HE Pump Module

Figure A-4 Thermistor Wire

STEP 12 Trace thermistor wires to rear of unit and use diagonal cutter to
remove tie wraps.
STEP 13 Remove thermistor wire clamp and pad (Figure A-5); retain for later
reuse.

Figure A-5 Thermistor Wire, Sensor, Pad, and Clamp

STEP 14 Use a #2 Phillips screwdriver to turn the inverter controller cover


fastener ¼ turn CCW to release the locking mechanism, allowing
the hinged front cover to open (Figure A-6).

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HE Pump Module

Figure A-6 Inverter/Controller Front Panel Fasteners

STEP 15 Access the inverter AC terminal board by removing the plastic


snap-in terminal board cover at the bottom of the open inverter
(Figure A-7).

Figure A-7 Terminal Board Cover and Inverter Connections

STEP 16 Use a #2 Phillips screwdriver to remove the three AC output wires


(blue) from each pump inverter (Figure A-8); also remove the safety
ground wire (green/yellow). Save the hardware for later reuse when
control panel is remotely mounted.

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HE Pump Module

Figure A-8 Inverter AC Output Wiring

STEP 17 Remove tie wraps as required to free the blue AC output wires and
green/yellow ground wires (inside the control panel) that go to the
pumps. The wires will need to slide through the holes in the bottom of
the control panel when it is removed from the pump module chassis.

Figure A-9 Cooling Control Panel Conduit Fittings

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HE Pump Module

STEP 18 Remove control panel conduit lock nuts from both pump AC supply
lines (Figure A-9) allowing conduits and AC wiring to pull free of
control panel when removed.

Figure A-10 AC Cable to Fans

STEP 19 Use a #2 Phillips to loosen the top two control box mounting screws
on each side of the control panel (Figure A-10).
STEP 20 Use a #2 Phillips to remove the lower mounting screw on each side of
the control panel (Figure A-10).
STEP 21 Remove control panel assembly from pump module chassis.
STEP 22 Refer to installation drawing 8435607072 (sheet 7). Mount the cooling
control panel indoors, in a dry location, preferably within sight of
the transmitter. M8 (5/16”) hardware is suitable for mounting the
control panel. Drill holes as required in the cooling control back panel to
facilitate wall mounting. Mount the panel to allow ventilation on all
sides. Unistrut sections (supplied by customer) can be mounted to the
wall and the back of the control panel can be affixed to unistrut sections.
STEP 23 Install pump A and B isolator switches (provided in kit) on the
pump side of the pump module chassis opposite, and in-between, the

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HE Pump Module

copper supply and return line pipes. Use self tapping screws to mount
the switches; take care not to screw into the rigid copper tubes that lie on
the opposite side of the mounting partition.
STEP 24 Install the AC mains conduit and wiring from the customer mains
panel or disconnect to the remote cooling control panel.
STEP 25 Install the pump module AC conduits and wiring from the remotely
located control panel to the isolator switches. Attach the AC supply
wires and safety grounds to the isolator switches. Attach the existing
pump AC wires and conduit to the isolator switches.
STEP 26 Install the fan AC conduits and wiring between the cooling control
panel (inside the building) to the customer supplied AC fan
disconnects (located outside) near the heat exchanger fans.
STEP 27 Install the fan AC conduits and wiring between the AC disconnect
(outside the building) to the heat exchanger isolator switches on the
heat exchanger chassis.
STEP 28 Affix the thermistor wire and temperature sensor on the pump
module return side copper pipe or on the transmitter copper bypass
assembly (transmitter outlet side) inside the building. Route the
thermistor wire (use customer provided conduit) back to the control
panel and attach the thermistor wires to the WAGO connector
(previously used).

NOTE:
50’ of audio wire and connectors (used to connect thermistor to control panel
connector) are provided in the remote control panel kit (see Figure A-11). The
temperature sensor is non-polar and can't be hooked up backwards. Shield and
drain wire in audio cable are not used.

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HE Pump Module

Figure A-11 Thermistor Sensor, Wire and Connectors

STEP 29 Route and install the cooling control wires between the transmitter
(pump module connector on top of cabinet) and the control board
inside the cooling control panel. Use customer provided conduit.
Wiring is described in the pump module manual 888-2625-001 (Section
2) and in the external wiring diagram (843-5601-705 single cabinet,
843-5601-296 dual cabinet, or 843-5601-305 three cabinet) supplied
with the transmitter documentation package.

NOTE:
Do not run control and monitoring wires in the same conduit as AC supply.

STEP 30 Install HE pump cover (provided with kit). The extension panel
attached to the top cover should be removed and reversed to cover the
isolator switches. Insert the hold down pin in each side of the cover to
keep it in place on the pump module chassis.

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HE Pump Module

NOTE:
Refer to the transmitter ULX TM 888-2628-001, VLX TM 888-2610-001 and
HE pump module manual 888-2625-001 for instructions on cooling system
installation, charging, and operation.

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