KSB PumpDrive 2, PumpDrive 2 Eco Operating Manual
Self-cooling Motor-independent
Frequency Inverter
PumpDrive 2
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual PumpDrive 2
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft, Frankenthal 21/08/2017
Contents
3 of 212
PumpDrive 2
Contents
Glossary .................................................................................................................................................. 5
1 Safety...................................................................................................................................................... 6
1.1 Key to safety symbols/markings.......................................................................................................................6
1.2 General..............................................................................................................................................................6
1.3 Intended use .....................................................................................................................................................6
1.4 Personnel qualification and training...............................................................................................................7
1.5 Consequences and risks caused by non-compliance with this operating manual........................................ 7
1.6 Safety awareness ..............................................................................................................................................7
1.7 Safety information for the user/operator.......................................................................................................7
1.8 Safety information for maintenance, inspection and installation ................................................................7
1.9 Unauthorised modes of operation..................................................................................................................8
1.10 Software Changes.............................................................................................................................................8
1.11 Electromagnetic compatibility (EMC)..............................................................................................................8
1.11.1 Interference emission requirements ...................................................................................................8
1.11.2 Line harmonics requirements..............................................................................................................9
1.11.3 Interference immunity requirements .................................................................................................9
2 Transport/Temporary Storage/Disposal............................................................................................. 10
2.1 Checking the condition upon delivery..........................................................................................................10
2.2 Transport.........................................................................................................................................................10
2.3 Storage............................................................................................................................................................11
2.4 Disposal/recycling ...........................................................................................................................................12
3 General.................................................................................................................................................. 13
3.1 Principles .........................................................................................................................................................13
3.2 Target group...................................................................................................................................................13
3.3 Other applicable documents..........................................................................................................................13
3.4 Symbols ...........................................................................................................................................................13
4 Operation.............................................................................................................................................. 14
4.1 Graphical control panel..................................................................................................................................14
4.1.1 Graphical display................................................................................................................................ 14
4.1.2 Menu keys ..........................................................................................................................................16
4.1.3 Service interface and LED traffic light function...............................................................................21
5 Commissioning report ......................................................................................................................... 23
6 Description............................................................................................................................................ 24
6.1 General description ........................................................................................................................................24
6.2 Designation.....................................................................................................................................................24
6.3 Name plate......................................................................................................................................................26
6.4 Power range and sizes....................................................................................................................................26
6.5 Technical data.................................................................................................................................................27
6.6 Dimensions and weights ................................................................................................................................30
6.7 Mounting options...........................................................................................................................................31
7 Installation at Site................................................................................................................................ 32
7.1 Safety regulations...........................................................................................................................................32
7.2 Checks to be carried out prior to installation...............................................................................................32
7.3 Mounting PumpDrive.....................................................................................................................................32
7.3.1 Motor mounting ................................................................................................................................ 32
7.3.2 Wall/control cabinet mounting.........................................................................................................32
7.4 Electrical connection ......................................................................................................................................33
7.4.1 Safety regulations ..............................................................................................................................33
7.4.2 Information for planning the system ...............................................................................................34
7.4.3 Electrical connection.......................................................................................................................... 38
8 Commissioning/Shutdown.................................................................................................................. 64
8.1 Commissioning wizard ...................................................................................................................................64
Contents
4 of 212
PumpDrive 2
8.2 Control point concept ....................................................................................................................................65
8.3 Setting motor parameters..............................................................................................................................65
8.4 Motor control method ...................................................................................................................................66
8.5 Automatic motor adaptation (AMA) of frequency inverter........................................................................67
8.5.1 Automatic motor adaptation (AMA) of frequency inverter for asynchronous motors.................68
8.5.2 Automatic motor adaptation (AMA) of frequency inverter for KSB SuPremE motors .................69
8.6 Entering the setpoint .....................................................................................................................................70
8.7 Pump operation..............................................................................................................................................72
8.7.1 Single-pump operation......................................................................................................................72
8.7.2 Multiple pump configuration ...........................................................................................................82
8.8 Application functions.....................................................................................................................................87
8.8.1 Aligning the frequency inverter with the pump .............................................................................87
8.8.2 Protective functions ...........................................................................................................................89
8.8.3 Flow rate estimation.......................................................................................................................... 96
8.8.4 Energy optimisation...........................................................................................................................98
8.8.5 Ramps ...............................................................................................................................................109
8.8.6 Motor standstill heater.................................................................................................................... 112
8.9 Device functions ...........................................................................................................................................112
8.9.1 Factory and user settings................................................................................................................. 112
8.9.2 Read out PumpMeter ......................................................................................................................113
8.9.3 Date and time ..................................................................................................................................114
8.10 Digital and analog inputs/Digital and analog outputs ..............................................................................114
8.10.1 Digital inputs.................................................................................................................................... 114
8.10.2 Analog inputs................................................................................................................................... 118
8.10.3 Relay outputs ...................................................................................................................................120
8.10.4 Analog outputs ................................................................................................................................ 122
8.10.5 Inputs and outputs of the I/O extension board .............................................................................123
8.11 Parameterising the M12 module.................................................................................................................127
8.12 Parameterising the field bus module..........................................................................................................130
9 Servicing/Maintenance...................................................................................................................... 133
9.1 Safety regulations.........................................................................................................................................133
9.2 Servicing/inspection......................................................................................................................................133
9.2.1 Supervision of operation .................................................................................................................133
9.3 Dismantling...................................................................................................................................................134
9.3.1 Preparing frequency inverter for dismantling ............................................................................... 134
10 Parameter List..................................................................................................................................... 135
10.1 Selection lists.................................................................................................................................................188
11 Trouble-shooting................................................................................................................................ 189
11.1 Faults/malfunctions: Trouble-shooting .......................................................................................................189
11.2 Alerts .............................................................................................................................................................190
11.3 Warnings.......................................................................................................................................................193
11.4 Information messages ..................................................................................................................................195
12 Purchase Order Specifications........................................................................................................... 196
12.1 Ordering spare parts ....................................................................................................................................196
12.2 Accessories ....................................................................................................................................................197
12.2.1 Service software ...............................................................................................................................197
12.2.2 Control panels ..................................................................................................................................197
12.2.3 Motor adapter kits........................................................................................................................... 197
12.2.4 Adapter for wall and cabinet mounting ........................................................................................ 199
12.2.5 M12 module ..................................................................................................................................... 199
12.2.6 Installation options ..........................................................................................................................200
12.2.7 Sensor system ................................................................................................................................... 202
12.2.8 Control cabinet mounting...............................................................................................................205
13 EU Declaration of Conformity........................................................................................................... 207
Index ................................................................................................................................................... 208
Glossary
5 of 212
PumpDrive 2
Glossary
Braking resistor
Takes up the braking power produced during
generator operation.
Hydraulic blockage
Undesirable operating situation in which the
pump cannot supply fluid due to a closed inlet or
outlet.
KSB device bus
Proprietary CAN bus that is used in dual and
multiple pump configurations for facilitating
communication among the frequency inverters.
The KSB device bus cannot be used for external
communication or for communication with the
KSB local bus (PumpDrive 1).
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
RCD
Abbreviation for "residual current device"
1 Safety
6 of 212
PumpDrive 2
1 Safety
!
DANGER
All the information contained in this section refers to hazardous situations.
1.1 Key to safety symbols/markings
Table1: Definition of safety symbols/markings
Symbol Description
!
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
1.2 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
1.3 Intended use
▪ This product must only be operated within the limit values stated in the technical
product literature for the mains voltage, mains frequency, ambient temperature,
motor rating, fluid handled, flow rate, speed, density, pressure, temperature and
in compliance with any other instructions provided in the operating manual or
other applicable documents.
▪ The product must not be used in potentially explosive atmospheres.
1 Safety
7 of 212
PumpDrive 2
1.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to. The responsibilities, competence and
supervision of all personnel involved in installation, operation, maintenance and
inspection must be clearly defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the product must always be supervised by specialist technical personnel.
1.5 Consequences and risks caused by non-compliance with this operating
manual
▪ Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
1.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and legislation (e.g. EN50110-1)
1.7 Safety information for the user/operator
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
1.8 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Any work on the product shall only be performed when it has been disconnected
from the power supply (de-energised).
▪ Carry out work on the product during standstill only.
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
1 Safety
8 of 212
PumpDrive 2
1.9 Unauthorised modes of operation
Never operate the product outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.
1.10 Software Changes
The software has been specially created for this product and thoroughly tested.
It is impermissible to make any changes or additions to the software or parts of the
software. Software updates supplied by KSB are excluded from this rule.
1.11 Electromagnetic compatibility (EMC)
The Electromagnetic Compatibility Directive 2004/108/EC defines the requirements
concerning the interference immunity and interference emissions of electric and
electronic equipment.
1.11.1 Interference emission requirements
The EN61800-3 EMC product standard is relevant for electric variable speed drives/
control systems. It specifies all pertinent requirements and refers to the relevant
generic standards for complying with the EMC Directive.
Frequency inverters are commonly used by operators as a part of a system, plant or
machine assembly. It should be noted that the operator bears all responsibility for
the final EMC properties of the equipment, plant or installation.
A prerequisite or requirement for complying with the relevant standards or the limit
values and inspection/test levels referenced by them is that all information and
descriptions regarding EMC-compliant installation be observed and followed.
(ðSection7.4,Page33)
In accordance with the EMC product standard, the EMC requirements to be met
depend on the purpose or intended use of the frequency inverter. Four categories
are defined in the EMC product standard:
Table2: Categories of intended use
Category Definition Limits to EN55011
C1 Frequency inverters with a supply voltage under 1000V installed in the
first environment (residential and office areas).
Class B
C2 Frequency inverters with a supply voltage under 1000V installed in the
first environment (residential and office areas) that are neither ready to
be plugged in/connected nor are mobile and must be installed and
commissioned by specialist personnel.
Class A, Group 1
C3 Frequency inverters with a supply voltage under 1000V installed in the
second environment (industrial environments).
Class A, Group 2
C4 Frequency inverters with a supply voltage over 1000V and a nominal
current over 400A installed in the second environment (industrial
environments) or that are envisaged for use in complex systems.
No borderline/
boundary
1)
The following limit values and inspection/test levels must be complied with if the
generic standard on interference emissions applies:
Table3: Classification of installation environment
Environment Generic standard Limits to EN55011
First environment (residential and office areas) EN/IEC61000-6-3
for private, business and commercial
environments
Class B
Second environment (industrial environments) EN/IEC61000-6-4
for industrial environments
Class A, Group 1
The frequency inverter meets the following requirements:
1) An EMC plan must be devised.
1 Safety
9 of 212
PumpDrive 2
Table4: EMC properties of the frequency inverter
Power
[kW]
Cable length
[m]
Category to EN 61800-3 Limits to EN55011
≤ 11 ≤5 C1 ClassB
> 11 ≤50 C2 ClassA, Group 1
The EN61800-3 standard requires that the following warning be provided for drive
systems that do not comply with category C1 specifications:
This product can produce high-frequency interference emissions that may necessitate
targeted interference suppression measures in a residential or office environment.
1.11.2 Line harmonics requirements
The product is a device for professional applications as defined by EN 61000-3-2. The
following generic standards apply when establishing a connection to the public
power grid:
▪ EN 61000-3-2
for symmetric, three-phase devices (professional devices with a total power of up
to 1kW)
▪ EN 61000-3-12
for devices with a phase current of between 16A and 75A and professional
devices from 1kW up to a phase current of 16 A.
1.11.3 Interference immunity requirements
In general, the interference immunity requirements for a frequency inverter hinge on
the specific environment in which the inverter is installed.
The requirements for industrial environments are therefore higher than those for
residential and office environments.
The frequency inverter is designed such that the immunity requirements for
industrial environments and, thus, the lower-level requirements for residential and
office environments, are met and fulfilled.
The following relevant generic standards are used for the interference immunity test:
▪ EN 61000-4-2: Electromagnetic compatibility (EMC)
– Part 4-2: Testing and measurement techniques – Electrostatic discharge
immunity test
▪ EN 61000-4-3: Electromagnetic compatibility (EMC)
– Part 4-3: Testing and measurement techniques – Radiated, radio-frequency,
electromagnetic field immunity test
▪ EN 61000-4-4: Electromagnetic compatibility (EMC)
– Part 4-4: Testing and measurement techniques – Electrical fast transient/burst
immunity test
▪ EN 61000-4-5: Electromagnetic compatibility (EMC)
– Part 4-5: Testing and measurement techniques – Surge immunity test
▪ EN 61000-4-6: Electromagnetic compatibility (EMC)
– Part 4-6: Testing and measurement techniques – Immunity to conducted
disturbances, induced by radio-frequency fields
2 Transport/Temporary Storage/Disposal
10 of 212
PumpDrive 2
2 Transport/Temporary Storage/Disposal
2.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
2.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Give due attention to the weight data and the centre of gravity.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig.1: Transporting a close-coupled pump set
Fig.2: Transporting a horizontal pump set
2 Transport/Temporary Storage/Disposal
11 of 212
PumpDrive 2
Fig.3: Transporting a vertical pump set
Fig.4: Transporting the motor with frequency inverter
Fig.5: Transporting the frequency inverter with lifting gear
2.3 Storage
If the ambient conditions for storage are met, the function of the control unit is
safeguarded even after a prolonged period of storage.
2 Transport/Temporary Storage/Disposal
12 of 212
PumpDrive 2
CAUTION
Damage during storage by humidity, dirt or vermin
Corrosion/contamination of the control unit!
▷ For outdoor storage cover the (packed or unpacked) control unit and
accessories with water-proof material.
Table5: Ambient conditions for storage
Ambient condition Value
Relative humidity 85% max. (non-condensing)
Ambient temperature -10°C to + 70°C
▪ Store the control unit in dry, vibration-free conditions and, if possible, in its
original packaging.
▪ Store the control unit in a dry room where the level of atmospheric humidity is as
constant as possible.
▪ Prevent excessive fluctuations in atmospheric humidity (see table on ambient
conditions for storage).
2.4 Disposal/recycling
The product is classified as special waste due to several installed components:
1. Dismantle product.
2. Separate materials
e.g.:
- Aluminium
- Plastic cover (recyclable plastic)
- Line chokes with copper windings
- Copper lines for internal wiring
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
PCBs, power electronics, capacitors and electronic components are all special
waste.
3 General
13 of 212
PumpDrive 2
3 General
3.1 Principles
This manual is supplied as an integral part of the type series indicated on the front
cover. The manual describes the proper and safe use of this equipment in all phases
of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
3.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
3.3 Other applicable documents
Table6: Overview of other applicable documents
Document Contents
Operating manual Description of the proper and safe use of the
pump in all phases of operation
Wiring diagram Description of the electrical connections
Supplementary operating
manual
2)
Description of the proper and safe use of
supplementary product components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
3.4 Symbols
Table7: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
2) Optional
4 Operation
14 of 212
PumpDrive 2
4 Operation
4.1 Graphical control panel
OK
MAN
ESC
?
AUTO FUNC
OFF
3
1
2
3
4
Fig.6: Graphical control panel
Table8: Description of graphical control panel
Position Description Function
1 Graphical display Displays information on frequency inverter operation
2 Menu keys Accessing the elements of the first menu level (Operation,
Diagnosis, Settings and Information)
3 Navigation keys Navigation and parameter setting
4 Operating keys Toggling operating modes
4.1.1 Graphical display
The main screen breaks down into 6areas.
C M
H
1-2-1-1
2893
rpm
17.48 m³/h
4.62 bar 642.9 V
RUN
AUTO
Speed
8
1
4
5
7
6
3
2
Fig.7: Main screen (example)
1 Motor standstill heater is switched on
2 The wireless icon illuminates when the Bluetooth module is inserted. The
wireless icon flashes when communication takes place.
3 Display of the master and login level
4 Display of up to four (4)operating values: One operating value is displayed in
large format. Three (3) operating values are displayed in small format. The
operating values scroll through cyclically.
4 Operation
15 of 212
PumpDrive 2
5 Display of operating status
6 Display of the current operating mode
7 Parameter number of the operating value displayed in the centre
8 Name of the operating value displayed in the centre
Table9: Assignment of keys
Key Function
Operation menu key
Diagnosis menu key
Settings menu key
Information menu key
Arrow keys:
▪ Move up/down in the menu options.
▪ Increase/decrease the value displayed when you are entering numerals. (When an arrow
key is pressed and held down, the response repeats in ever shorter intervals.)
ESC
Escape key:
▪ Delete/reset entry
(the entry is not saved).
▪ Move up one menu level.
OK
OK key:
▪ Confirm settings.
▪ Confirm menu selection.
▪ Move to the next digit when entering numerals.
▪ Message display: Acknowledge alert.
▪ Measured value display: Go to Favourites menu.
?
Help key:
▪ Displays a help text for each selected menu option.
MAN
MAN operating key:
▪ Starts the frequency inverter in manual operating mode.
OFF
OFF operating key:
▪ Stops the frequency inverter.
AUTO
AUTO operating key:
▪ Switches to automatic operating mode.
FUNC
FUNC operating key:
▪ Parameterisable function key
Manual mode via control panel
NOTE
After a power failure, the frequency inverter reverts to the OFF operating mode.
Manual mode must be restarted.
4 Operation
16 of 212
PumpDrive 2
Table10: Assignment of keys for manual mode
Key Function
MAN
MAN operating key:
▪ When switching the operating mode from AUTO to MAN, the current operating speed is
used as control value (Manual) 1-3-4 and is displayed accordingly. The control point 3-6-2
must be set to Local.
▪ When switching the operating mode from OFF to MAN, the frequency inverter operates
at minimum speed. The control point 3-6-2 must be set to Local.
▪ If the control value (Manual) 1-3-4 is defined via an analog input, the analog input speed
is accepted. (ðSection8.2,Page65)
Arrow keys:
▪ Pressing the arrow keys changes and immediately accepts the control value (Manual)
1-3-4. Making a change using the arrow key has a direct effect even when not confirmed
with OK. The speed can only be changed between the set minimum speed and the
maximum speed.
ESC
OK
ESC/OK key:
▪ Press the OK or ESC key to go from digit to digit. Press the ESC key to go back. Changes
are rejected. Pressing the OK key for the right-hand digit takes you back to the main
screen.
4.1.2 Menu keys
The menu keys allow you to directly access the first menu level (Operation 1-x-x-x,
Diagnosis 2-x-x-x, Settings 3-x-x-x, and Information 4-x-x-x).
The parameter numbers contain the navigation path, which helps you find a
particular parameter quickly and easily. The first digit of the parameter number
indicates the first menu level, which is called up directly via the four menu keys.
C M
STOP
3-6-1
AUTO
OFF (Open-loop Control)
Discharge Pressure
Suction Pressure
Differential Pressure
Flow Rate
Temperature (Cooling)
Type of Control
1
2
3
4
5
6
Fig.8: Menu display
1 Name of current menu/parameter
2 Parameter number of parameter selected in selection list
3 Display of the current operating mode
4 Display of the master and login level
5 Parameter/submenu selection list
6 Display of operating status
4 Operation
17 of 212
PumpDrive 2
4.1.2.1 Menu: Operation
The Operation section contains all information required for operating the machine
and the process. This includes:
▪ Login to device with password
▪ Operating and measured values for motor, frequency inverter, pump and system
▪ Setpoints and control values
▪ Energy meter and operating hours
4.1.2.1.1 Access levels
Three access levels have been defined to prevent accidental or unauthorised access to
frequency inverter parameters:
Table11: Access levels
Access level Description
Standard (No Login) Access without password entry.
Customer Access level for the expert user with access to all parameters required for
commissioning
Customer service Access level for service personnel.
If a parameter's access level is not explicitly specified, the parameter is always
assigned the customer access level.
Table12: Access level parameters
Parameter Description Possible settings Factory setting
1-1-1 Customer Login
Log in as customer
0000...9999 0000
1-1-2 Service Login
Log in for access to special parameters for KSB
Service
0000...9999 -
1-1-4 Logout
Log out of all access levels
Run -
NOTE
If no keys are pressed for ten minutes, the system will automatically return to the
standard access level.
The password can be changed after entering the factory default password.
Table13: Parameters for changing passwords
Parameter Description Possible settings Factory setting
1-1-5 Customer Access ID
Changing the customer access ID
0000...9999 -
1-1-6 Service Access ID
Changing the service access ID
0000...9999 -
4.1.2.1.2 Operating values for input and output signals
The status of the digital inputs/relay outputs is displayed via the Digital Inputs
(1-2-4-6) and Digital Outputs (1-2-4-7) parameters.
Table14: Example of status of digital inputs (1-2-4-6). 24V is applied to digital input 1: System Start
Optional IO card Standard
Digital input DI8 DI7 DI6 DI5 DI4 DI3 DI2 DI1
Bit pattern on display 0 0 0 0 0 0 0 I
4 Operation
18 of 212
PumpDrive 2
Table15: Example of status of digital outputs (1-2-4-7). The following is reported via relay output 1: General fault
message (configurable)
Optional IO card Standard
Digital output R8 R7 R6 R5 R4 R3 DO2 D01 R2 R1
Bit pattern on
display
0 0 0 0 0 0 0 0 0 I
4.1.2.2 Menu: Diagnosis
In the Diagnosis section, the user is provided with information about faults and
warning messages that pertain to the pump set or process. The frequency inverter
can be in fault (standstill) or warning (operational) status. The user can also find
previous messages in the history.
Messages
All monitoring and protective functions trigger warnings or alerts. These are
signalled via the amber or red LED of the LED traffic light function.
A corresponding message is output on the control panel display. If more than one
message is output, the last one is displayed. Alerts have priority over warnings.
AUTO
17.48 m³/h
4.62 bar2893 rpm
W57
rpm
C M
RUN
Low flow
1
5
2
3
4
Fig.9: Message display
1 Name of the message displayed in the centre
2 Display of the master and login level
3 Display of the message: The most recently received message is displayed in
large format on the main screen. Three operating values are displayed in small
format.
4 Display of operating status
5 Displays the current operating mode
Pending messages
If a message has occurred and been acknowledged but has not gone, this message
will be listed in the Pending Messages menu. All current messages can be displayed in
the Diagnosis menu under Pending Messages (2-1). Active warnings and alerts can
also be connected to the relay outputs.
Message history
Only messages that have come, been acknowledged, and gone are listed in the
message history. The message history can be viewed by selecting the Message History
parameter 2-2. The last 100 messages are listed here. You can use the arrow keys and
the OK key to select an entry from the list.
Acknowledging and resetting messages
NOTE
Depending on the combination of settings, the frequency inverter could
conceivably restart automatically after acknowledgement/reset or when the cause
of the malfunction or fault has been eliminated.
Acknowledgement
You can acknowledge the message once the cause has been rectified. Messages can
be acknowledged separately in the Diagnosis menu. A message can also be
acknowledged via a digital input. Digital input 2 is defaulted for this purpose.
4 Operation
19 of 212
PumpDrive 2
Overview of warnings and alerts (ðSection11,Page189)
Messages can be acknowledged as follows:
Table16: Acknowledgement types for messages
Property of message Type of acknowledgement
Self-acknowledging Message self-acknowledges if condition for message has gone.
Self-acknowledging
(configurable)
Users can choose between self-acknowledging and acknowledging manually.
Partially selfacknowledging
Alerts that are partially self-acknowledging carry out self-acknowledgement in
increasingly large intervals after the alarm condition has gone. If the alert occurs
repeatedly within a specific time window, no additional self-acknowledgement is
carried out.
As soon as the alarm condition of a pending alert no longer exists, the time interval is
started. When this interval expires, automatic acknowledgement takes place.
If the alert occurs again within 30seconds after the time interval has started, the
interval is extended by one increment. Should this not be the case, the previous
(shorter) time interval is reverted to and corresponding action is taken again in
30seconds. The time intervals are 1second, 5seconds, 20seconds, and endless (i.e.
manual acknowledgement is required). When the 20-second interval is extended, selfacknowledgement no longer takes place.
Non-self-acknowledging Must be acknowledged manually.
Time stamp
If a message is not acknowledged and its condition comes and goes several times in
this time window, the first occurrence of the message is always used for the Message
Come time stamp. The Message Condition Gone time stamp, however, always shows
the last time the message condition was no longer active.
4.1.2.3 Menu: Settings
General settings can be made or the settings for the process optimised in the Settings
section.
4.1.2.3.1 Setting the display language
The display ships from the factory with support for 4languages (language package).
A language package can be changed using the KSB Service Tool:
Table17: Parameters for display language
Parameter Description Possible settings Factory setting
3-1-1 Language
Configurable display language
Depending on the language package:
▪ English, German, French, Italian
▪ English, French, Dutch, Danish
▪ English, Spanish, Portuguese, Turkish
▪ English, Norwegian, Swedish, Finnish
▪ English, Estonian, Latvian, Lithuanian
▪ English, Polish, Hungarian, Czech
▪ English, Slovenian, Slovakian, Croatian
▪ English, Russian, Romanian, Serbian
English, German,
French, Italian
4 Operation
20 of 212
PumpDrive 2
4.1.2.3.2 Setting the control panel
Table18: Parameters for setting the control panel
Parameter Description Possible settings Factory setting
3-1-2-1 Operating Values on Main Screen
Display of current operating values on the main
screen
Main screen selection list -
3-1-2-2 Control Keys Require Login
Direct access to the MAN, OFF, AUTO and FUNC
operating keys can be disabled via this parameter.
▪ OFF
▪ ON
OFF
3-1-2-3 Function Key Assignment
Assigning a freely selectable function to the FUNC
key
▪ No Function
▪ System Start / Stop
▪ Setpoint (Closed-loop
Control)
▪ Control Value (Open-loop
Control)
▪ Alternative Setpoint (Closed-
loop Control)
▪ Alternative Control Value
(Open-loop Control)
▪ Immediate Pump
Changeover
▪ Immediate Functional Check
Run
▪ Language
▪ Fixed Speed 1
▪ PumpMeter Upload
▪ Remote/Local Control Point
Language
3-1-2-4 Display Contrast
Configurable contrast for the display
0...100 50
3-1-2-5 Display Backlight
Configuring the display backlight
▪ OFF
▪ ON
▪ Automatic
Automatic
3-1-2-6 Display Backlight Duration
Duration of display backlight on period in
automatic mode
0...600 30
Operating Values on Main
Screen
Up to 4operating values are simultaneously displayed on the main screen. An
operating value is displayed in large format with the associated parameter name,
parameter number and unit. Three (3) operating values are displayed in smaller
format with the associated unit. The arrow keys can be used to cycle through the
operating values. Each operating value passes through all display areas. Up to
10operating values can be selected from the predefined list for the display. The
sequence of the selection list determines the sequence of the operating values on the
main screen. If more than 4parameters are selected, the hidden parameters are also
cycled through in the background.
Selecting operating values for the main screen
1. Open parameter 3-1-2-1 in the Settings menu.
2. Using the arrow keys, select the operating value to be displayed from the list.
3. Press OK key.
4. Select additional, required operating values from the list and confirm by
pressing the OK key.
4 Operation
21 of 212
PumpDrive 2
C M
RUN
AUTO
3-1-2-1
Speed
Motor Input Power
Motor Current
Output Frequency
Pump Suction Pressure
Pump Discharge Pressure
Operating Values on Main Scr...
Fig.10: Selecting multiple parameters from the selection list
Locking operating keys
The operating keys of the control panel can be locked via the 3-1-2-2 parameter to
prevent unauthorised operation or unauthorised acknowledgement of alerts.
Function key assignment
The FUNC operating key can be preassigned a function from a selection list.
NOTE
When the FUNC operating key is used in the System Start / Stop role, the system
must be restarted via the FUNC operating key every time the voltage is reset.
Favourites menu
Press the OK key on the main screen to call up the favourites menu, where you can
select various parameters and quickly adapt their configuration settings.
4.1.2.4 Menu: Information
All direct information about the frequency inverter is provided in the Information
section. Important details regarding the firmware version are listed here.
4.1.3 Service interface and LED traffic light function
2
1
Fig.11: Service interface and traffic light LEDs
Item Description Function
1 Service interface Optical interface
2 LED traffic light function The traffic light function provides information about the
system's operating status.
Service interface
The service interface allows a PC/notebook to be connected via a special cable (USB –
optical).
The following action can be taken:
▪ Configuring and parameterising the frequency inverter with the service software
▪ Software update
▪ Saving and documenting set parameters
LED traffic light function
The LED traffic light function provides information about the current PumpDrive
operating status.
4 Operation
22 of 212
PumpDrive 2
Table19: LED description
LED Description
Red
One or more than one alert is active
Amber
One or more than one warning is active
Green
Steady light: Trouble-free operation
5 Commissioning report
23 of 212
PumpDrive 2
5 Commissioning report
Report number: ...................................................
Purchaser
Order number ........................................................................................................................................
Customer ........................................................................................................................................
Installation location ........................................................................................................................................
Contact ........................................................................................................................................
Product
Pump type .................................................................................................................................................................
Pump works number 1. ................................................. 2. .................................................
3. ................................................. 4. .................................................
5. ................................................. 6. .................................................
Motor data ................. [kW] ..................... [A] ........................ [V] .................... [cos phi] ................... [rpm]
Type code 1. ................................................. 2. .................................................
3. ................................................. 4. .................................................
5. ................................................. 6. .................................................
Serial number 1. ................................................. 2. .................................................
(Name plate), frequency
inverter
3. ................................................. 4. .................................................
5. ................................................. 6. .................................................
Operating mode
Manual mode Application: Pressure/differential pressure/flow rate/temperature
Open-loop control mode Setpoint .......................... [Source] ............. [Unit] ................. [Value]
Closed-loop control mode Sensor .............................[sensor full-scale value]
Multiple pump
configuration
Number of frequency inverters ..... [Quantity] Number of HMIs..... [Quantity]
Master control device Number of master control devices ..... [Quantity]
Bus connection Field bus type ...................... Number of modules ..... [Quantity]
Comments
.................................................................................................................................................................................................
.................................................................................................................................................................................................
.................................................................................................................................................................................................
.................................................................................................................................................................................................
........................................................................................ ........................................................................................
KSB Customer Service/name Client/name
........................................................................................ ........................................................................................
Place, date, signature Place, date, signature
6 Description
24 of 212
PumpDrive 2
6 Description
6.1 General description
PumpDrive is a modular, self-cooling frequency inverter which enables the motor
speed to be varied continuously by means of analog standard signals, a field bus or
the control panel.
6.2 Designation
Table20: Designation example
Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
P D R V 2 E - 0 1 1 K 0 0 M _ S 1 L E 1 E 2 P 2 _ M O O R O
Table21: Key to the designation
Item Code Description
PumpDrive 2
Eco
PumpDrive2
1-4 Generation
PDRV2 2. PumpDrive generation ✘ ✘
6 Variant
E PumpDrive 2 Eco ✘ -
- PumpDrive2 - ✘
8-13 Power
A 000K37=0,37kW ✘ ✘
000K55=0,55kW ✘ ✘
000K75=0,75kW ✘ ✘
001K10=1,1kW ✘ ✘
001K50=1,5kW ✘ ✘
B 002K20=2,2kW ✘ ✘
003K00=3kW ✘ ✘
004K00=4kW ✘ ✘
C 005K50=5,5kW ✘ ✘
007K50=7,5kW ✘ ✘
011K00=11kW ✘ ✘
D 015K00=15kW - ✘
018K50=18,5kW - ✘
022K00=22kW - ✘
030K00=30kW - ✘
E 037K00=37kW - ✘
045K00=45kW - ✘
055K00=55kW - ✘
14 Mounting option
M Motor mounting ✘ ✘
W Wall mounting ✘ ✘
C Cabinet mounting ✘ ✘
16 Motor manufacturer
K KSB ✘ ✘
S Siemens ✘ ✘
C Cantoni ✘ ✘
W Wonder ✘ ✘
6 Description
25 of 212
PumpDrive 2
Item Code Description
PumpDrive 2
Eco
PumpDrive2
17-20 Motor type
1LE1 Siemens 1LE1/ KSB1PC3 ✘ ✘
1LA7 Siemens 1LA7/ KSB1LA7 ✘ ✘
1LA9 Siemens 1LA9/ KSB1LA9 ✘ ✘
1LG6 Siemens 1LG6/ KSB1LG6 ✘ ✘
SUPB KSB SuPremE B ✘ ✘
DMC KSB(DM) Cantoni ✘ ✘
DMW KSB(DM) Wonder ✘ ✘
21-22 Efficiency class
E1 IE1 ✘ ✘
E2 IE2 ✘ ✘
E3 IE3 ✘ ✘
E4 IE4 ✘ ✘
23-24 Number of motor poles
P2 2 poles ✘ ✘
P4 4 poles ✘ ✘
P6 6 poles ✘ ✘
26 M12 module
O None ✘ ✘
M M12 module ✘ ✘
27 Field bus module
O None ✘ ✘
L LON - ✘
P Profibus DP - ✘
M Modbus RTU ✘ ✘
B BACnet MS / TP - ✘
3)
N Profinet - ✘
3)
E Ethernet - ✘
3)
28 Optional component 1
O None ✘ ✘
I I/O extension board - ✘
29 Optional component 2
O None ✘ ✘
R Bluetooth module ✘ ✘
30 Optional component 3
O None ✘ ✘
M Master switch - ✘
3) Consult the manufacturer.
6 Description
26 of 212
PumpDrive 2
6.3 Name plate
IP55
PumpDrive
3PH 380 : 480 VAC
50-60 Hz
0105000180
18,0 A
7,5 KW
INPUT:
P D R V 2 _ _ 0 0 7K50
1
2
3
4
5
6
Fig.12: Name plate 1, frequency inverter (example)
1 Enclosure 2 Type series, size
3 Nominal power 4 Nominal current
5 Mains frequency 6 Mains voltage
IP55
PumpDrive
997257666000010002
ETN 080-065-160 GG A 11GD20150
31.07.2014
PDRV2__-015K00M_S1LE1E2P2_MPIRM
3
4
1
2
Fig.13: Name plate 2, frequency inverter (example)
1 PumpDrive type code 2 KSB order number
3 Pump designation 4 Date of manufacture
6.4 Power range and sizes
Table22: Power range4) for 2-pole (3000rpm), 4-pole (1500rpm) and 6-pole (1000) asynchronous motors and KSB
SuPremE
Size Nominal electrical power Nominal output current Mains-side input current
[kW] [A] [A]
A 0,37 1,3 1,4
0,55 1,8 2
0,75 2,5 2,7
1,10 3,5 3,7
1,50 4,9 5,2
B 2,2 6 6,3
3,0 8 8,4
4,0 10 10,4
C 5,5 14 14,6
7,5 18 18,7
11 25 25,9
D 15 33 34,1
18,5 42 43,3
22 51 52,4
30 66 67,7
E 37 81,5 83,4
4) The power ranges specified apply in full to all mounting options.
6 Description
27 of 212
PumpDrive 2
Size Nominal electrical power Nominal output current Mains-side input current
[kW] [A] [A]
E 45 97 99
55 120 122,4
6.5 Technical data
Table23: Technical data of frequency inverter
Characteristic Value
Mains supply
Mains voltage
5)
3 ~ 380VAC - 10% to 480VAC +10%
Voltage difference between the three phases ±2% of the supply voltage
Mains frequency 50 - 60Hz ± 2 %
Mains types TN-S, TN-CS, TN-C, TT and IT mains (to IEC/EN60364)
Output data
Frequency inverter output frequency 0 - 70 Hz for asynchronous motors
0 - 140Hz for KSBSuPremE
PWM carrier frequency Range: 2 - 8 kHz
(Factory setting: 4kHz)
Phase rate of rise dv/dt
6)
5000 V/µs max. (depending on the size of the frequency
inverter)
Peak voltages 2×1,41×V
eff
Lines with a high current-carrying capacity can cause the
voltage to increase up to double the value.
Frequency inverter data
Efficiency 98 % - 95 %
7)
Noise emissions Sound pressure level of pump used + 2.5dB
8)
Environment
Enclosure IP55 (to EN 60529)
In-service ambient temperature -10°C to +50°C
In-storage ambient temperature -10 °C to +70 °C
Relative humidity Operation: 5% to 85% (non-condensing)
Storage: 5% to 95%
Transport: 95%max.
Installation altitude < 1000m above MSL, or 1 % power derating per additional
100m
Vibration resistance 16.7m/s2 max. (to EN60068-2-64)
Fluid temperature -30°C to +140°C
EMC
Frequency inverter ≤11kW EN61800-3 C1/EN55011 Class B/cable length ≤ 5m
Frequency inverter ≥ 15 kW EN 61800-3 C2/EN 55011 Class A, Group 1/cable length ≤50m
Mains feedback Integrated line chokes
Inputs and outputs
Internal power supply unit 24V ± 10 %
Maximum load 600mA DC max., short-circuit and overload-proof
5) If the mains voltage is low, the nominal torque of the motor will be lower.
6) The phase rate of rise (dv/dt) depends on the line capacity.
7) The efficiency at the nominal point of the frequency inverter varies between 98 percent for high power outputs and
95percent for low outputs, depending on the inverter's nominal power.
8) The values are for orientation purposes only. The value refers to the nominal duty point (50Hz) only. Also refer to the
pump's noise characteristics. They, too, are documented for nominal duty operation. Other values may occur during
variable speed operation.
6 Description
28 of 212
PumpDrive 2
Characteristic Value
Residual ripple <1%
Analog inputs
Number of parameterisable analog inputs 2 (configurable for current or voltage input)
Input type Differential
Maximum voltage (with reference to GND) ± 10V
Current input 0/4 - 20mA
Input impedance 500Ohm
Accuracy 1% of full-scale value
Signal delay < 10ms
Resolution 12bit
Voltage input 0/2 - 10V
Input impedance ca. 40kOhm
Accuracy 1% of full-scale value
Signal delay < 10ms
Resolution 12bit
Reverse polarity protection Positive and negative polarity reversal possible
Analog outputs
Number of parameterisable analog outputs 1 (toggling 4 output values)
Current output 4-20mA
Maximum external working resistance 850Ohm
Output PNP transistor
Accuracy 2 % of full-scale value
Signal delay < 10ms
Reverse polarity protection Provided
Short-circuit protection and overload protection Provided
Digital inputs
Number of digital inputs 6 in total, 5 of which can be parameterised
ON level 15-30V
OFF level 0-3V
Input impedance Approx. 2 kOhm
Electrical isolation Provided, insulation voltage: 500VAC
Delay < 10ms
Reverse polarity protection Provided
Relay outputs
Number of parameterisable relay outputs 2 changeover contacts
Maximum contact rating AC: Max. 250 VAC/0.25A
DC: Max. 30 VDC/2A
PWM carrier frequency
Power derating for increased carrier frequency
Sizes A, B and C (at PWM carrier frequency > 4kHz):
I
Nominal motor current (PWM)
= I
Nominal motor current
×(1 - [f
PWM
- 4kHz]×2.5 %)
Table24: Technical data of I/O extension board
Characteristic Value
Analog inputs
Number of parameterisable analog inputs 1
Input type Differential
Maximum voltage (with reference to GND) + 10V
Current input 0/4 – 20mA
6 Description
29 of 212
PumpDrive 2
Characteristic Value
Input impedance 500Ohm
Accuracy 1% of full-scale value
Signal delay < 10ms
Resolution 11bit
Voltage input 0/2 - 10V
Input impedance ca. 40kOhm
Accuracy 1% of full-scale value
Signal delay < 10ms
Resolution 11 bit + 1 bit sign
Reverse polarity protection Provided
Analog outputs (current output or voltage output)
Number of parameterisable analog outputs 1 (toggling 4 output values)
Current output 4 – 20mA
Maximum external working resistance 850Ohm
Output PNP transistor
Accuracy 2 % of full-scale value
Signal delay < 10ms
Reverse polarity protection Provided
Short-circuit protection and overload
protection
Provided
Voltage output 2 – 10V
Maximum output current 25mA
Output NPN transistor
Accuracy 2 % of full-scale value
Signal delay < 10ms
Reverse polarity protection Provided
Short-circuit protection and overload
protection
Provided
Digital inputs
Number of digital inputs 3 (all parameterisable)
ON level 15-30V
OFF level 0 - 3V
Input impedance Approx. 2 kOhm
Electrical isolation Provided, insulation voltage: 500VAC
Delay < 10ms
Reverse polarity protection Provided
Digital outputs
Number of digital outputs 2
Output PNP transistor
ON level 24V ±10 %
OFF level < 2V
Output current Max. 40 mA
Differential current < 100µA
Reverse polarity protection Provided
Short-circuit protection and overload protection Provided
Relay outputs
Number of parameterisable relay outputs 1 changeover contacts
5 NO contact
6 Description
30 of 212
PumpDrive 2
Characteristic Value
Changeover contact, maximum contact rating AC: Max. 250 VAC/0.25A
DC: Max. 30 VDC/3A
NO contact, maximum contact rating AC: Max. 250 VAC/0.25A
DC: Max. 30 VDC/1A
Suitable for switching operations of contactors with a
maximum start-up current of 10A.
6.6 Dimensions and weights
a
b
c
d
e
F
Fig.14: Dimensions
Table25: Dimensions and weights
Size P Motor-mounted model
[mm]
Wall-/
Cabinet-mounted
model
9)
[mm]
Fastening screws/bolts Weight
10)
[kg]
[kW] a b c d e a b c d e F
A ..000K37.. 0,37 260 190 166 140 141 343 190 166 140 333 M4×10 5
..000K55.. 0,55
..000K75.. 0,75
..001K10.. 1,1
..001K50.. 1,5
B ..002K20.. 2,2 290 211 166 155 121 328 211 166 155 318 M4×10 6,5
..003K00.. 3
..004K00.. 4
C ..005K500.. 5,5 330 280 210 219 205 401 280 210 219 387 M6×12 12,5
..007K500.. 7,5
..011K000.. 11
D ..15K000.. 15 460 350 290 280 309 582 350 290 280 565 M8×14 36
..18K500.. 18,5
..22K00.. 22
..30K00.. 30
E ..37K00.. 37 700 455 340 375 475 819 455 340 375 800 M8×14 60
..45K00.. 45
..55K00.. 55
9) The dimensions provided refer to PumpDrive including the wall-mounting brackets.
10) Without motor adapter
Loading...