KSB PumpDrive 2 Eco Operating Manual

Download

Page 1

Self-cooling, motor-independent frequency inverter

PumpDrive 2 Eco

Installation/Operating Manual

Page 2

Legal information/Copyright

Installation/Operating Manual PumpDrive 2 Eco

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.

Page 3

Contents

3 of 172

PumpDrive 2 Eco

Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 6

1.1 Principles ...........................................................................................................................................................6

1.2 Target group.....................................................................................................................................................6

1.3 Other applicable documents............................................................................................................................6

1.4 Symbols .............................................................................................................................................................6

2 Safety...................................................................................................................................................... 7

2.1 Key to safety symbols/markings.......................................................................................................................7

2.2 General..............................................................................................................................................................7

2.3 Intended use .....................................................................................................................................................7

2.4 Personnel qualification and training...............................................................................................................8

2.5 Consequences and risks caused by non-compliance with this operating manual........................................ 8

2.6 Safety awareness ..............................................................................................................................................8

2.7 Safety information for the user/operator.......................................................................................................8

2.8 Safety information for maintenance, inspection and installation ................................................................8

2.9 Unauthorised modes of operation..................................................................................................................9

2.10 Software Changes.............................................................................................................................................9

2.11 Electromagnetic compatibility (EMC)..............................................................................................................9

2.11.1 Interference emission requirements ...................................................................................................9

2.11.2 Line harmonics requirements............................................................................................................10

2.11.3 Interference immunity requirements ...............................................................................................10

3 Transport/Temporary Storage/Disposal............................................................................................. 11

3.1 Checking the condition upon delivery..........................................................................................................11

3.2 Transport.........................................................................................................................................................11

3.3 Storage............................................................................................................................................................12

3.4 Disposal/recycling ...........................................................................................................................................13

4 Description............................................................................................................................................ 14

4.1 General description ........................................................................................................................................14

4.2 Designation.....................................................................................................................................................14

4.3 Name plate......................................................................................................................................................16

4.4 Power range and sizes....................................................................................................................................16

4.5 Technical data.................................................................................................................................................17

4.6 Dimensions and weights ................................................................................................................................19

4.7 Mounting options...........................................................................................................................................20

5 Installation at Site................................................................................................................................ 21

5.1 Safety regulations...........................................................................................................................................21

5.2 Checks to be carried out prior to installation...............................................................................................21

5.3 Mounting PumpDrive.....................................................................................................................................21

5.3.1 Motor mounting ................................................................................................................................21

5.3.2 Wall/control cabinet mounting.........................................................................................................21

5.4 Electrical connection ......................................................................................................................................22

5.4.1 Safety regulations ..............................................................................................................................22

5.4.2 Information for planning the system ...............................................................................................23

5.4.3 Electrical connection.......................................................................................................................... 27

6 Operation.............................................................................................................................................. 45

6.1 Standard control panel ..................................................................................................................................45

6.1.1 Display ................................................................................................................................................45

6.1.2 Main screen ........................................................................................................................................48

6.1.3 Settings menu ....................................................................................................................................49

6.1.4 Service interface and LED traffic light function...............................................................................52

7 Commissioning/Shutdown.................................................................................................................. 53

7.1 Control point concept ....................................................................................................................................53

Page 4

Contents

4 of 172

PumpDrive 2 Eco

7.2 Setting motor parameters..............................................................................................................................53

7.3 Motor control method ..................................................................................................................................54

7.4 Automatic motor adaptation (AMA) of frequency inverter........................................................................56

7.4.1 Automatic motor adaptation (AMA) of frequency inverter for asynchronous motors.................56

7.4.2 Automatic motor adaptation (AMA) of frequency inverter for KSB SuPremE motors .................57

7.5 Entering the setpoint .....................................................................................................................................58

7.6 Pump operation..............................................................................................................................................59

7.6.1 Single-pump operation......................................................................................................................59

7.6.2 Multiple pump configuration ...........................................................................................................72

7.7 Application functions.....................................................................................................................................78

7.7.1 Aligning the frequency inverter with the pump .............................................................................78

7.7.2 Protective functions ........................................................................................................................... 80

7.7.3 Flow rate estimation.......................................................................................................................... 85

7.7.4 Energy optimisation...........................................................................................................................87

7.7.5 Ramps .................................................................................................................................................94

7.7.6 Motor standstill heater...................................................................................................................... 97

7.8 Device functions .............................................................................................................................................98

7.8.1 Factory and user settings................................................................................................................... 98

7.8.2 Reading out PumpMeter ................................................................................................................... 98

7.8.3 Date and time ....................................................................................................................................99

7.9 Digital and analog inputs/Digital and analog outputs ..............................................................................100

7.9.1 Digital Inputs.................................................................................................................................... 100

7.9.2 Analog inputs................................................................................................................................... 104

7.9.3 Relay output..................................................................................................................................... 107

7.9.4 Analog outputs ................................................................................................................................108

7.9.5 Parameterising the M12 module ....................................................................................................109

7.10 Parameterising the field bus module..........................................................................................................112

8 Servicing/Maintenance...................................................................................................................... 114

8.1 Safety regulations.........................................................................................................................................114

8.2 Servicing/inspection......................................................................................................................................114

8.2.1 Supervision of operation ................................................................................................................. 114

8.3 Dismantling...................................................................................................................................................115

8.3.1 Preparing frequency inverter for dismantling ...............................................................................115

9 Parameter List..................................................................................................................................... 116

9.1 Selection lists.................................................................................................................................................144

10 Trouble-shooting................................................................................................................................ 145

10.1 Faults/malfunctions: Trouble-shooting .......................................................................................................145

10.2 Alerts .............................................................................................................................................................146

10.3 Warnings.......................................................................................................................................................149

10.4 Information messages ..................................................................................................................................151

11 Purchase Order Specifications........................................................................................................... 152

11.1 Ordering spare parts ....................................................................................................................................152

11.2 Accessories ....................................................................................................................................................153

11.2.1 Service software ...............................................................................................................................153

11.2.2 Motor adapter kits........................................................................................................................... 153

11.2.3 Adapter for wall / cabinet mounting..............................................................................................157

11.2.4 M12 module .....................................................................................................................................157

11.2.5 Optional components ...................................................................................................................... 159

11.2.6 Sensor system ...................................................................................................................................160

11.2.7 Control cabinet mounting...............................................................................................................164

12 Commissioning report ....................................................................................................................... 166

13 EU Declaration of Conformity........................................................................................................... 167

Index ................................................................................................................................................... 168

Page 5

Glossary

5 of 172

PumpDrive 2 Eco

Glossary

Braking resistor

Takes up the braking power produced during generator operation.

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"

Page 6

1 General

6 of 172

PumpDrive 2 Eco

1 General

1.1 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.

1.2 Target group

This operating manual is aimed at the target group of trained and qualified specialist technical personnel.

1.3 Other applicable documents

Table1: 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

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.

1.4 Symbols

Table2: 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

Step-by-step instructions

Note Recommendations and important information on how to handle the product

1) Optional

Page 7

2 Safety

7 of 172

PumpDrive 2 Eco

2 Safety

DANGER

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

DANGER

This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

WARNING

This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

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.

2.2 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.

2.3 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.

Page 8

2 Safety

8 of 172

PumpDrive 2 Eco

2.4 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.

2.5 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

2.6 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. EN50110-1)

2.7 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.)

2.8 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.

Page 9

2 Safety

9 of 172

PumpDrive 2 Eco

2.9 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.

2.10 Software Changes

The software has been specially created for this product and thoroughly tested. It is not allowed to make any changes or additions to the software or parts of the software. Software updates supplied by KSB are excluded from this rule.

2.11 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.

2.11.1 Interference emission requirements

The EN61800-3 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.

(ðSection5.4,Page22)

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:

Table4: Categories of intended use

Category Definition Limits to EN55011

C1 Frequency inverters with a supply voltage under 1000V installed in the

first environment (residential and office areas).

Class B

C2 Frequency inverters with a supply voltage under 1000V 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 1000V installed in the

second environment (industrial environments).

Class A, Group 2

C4 Frequency inverters with a supply voltage over 1000V and a nominal

current over 400A installed in the second environment (industrial environments) or that are envisaged for use in complex systems.

No borderline/

boundary

The following limit values and inspection/test levels must be complied with if the generic standard on interference emissions applies:

Table5: Classification of installation environment

Environment Generic standard Limits to EN55011

First environment (residential and office areas) EN/IEC61000-6-3

for private, business and commercial environments

Class B

Second environment (industrial environments) EN/IEC61000-6-4

for industrial environments

Class A, Group 1

The frequency inverter meets the following requirements:

2) An EMC plan must be devised.

Page 10

2 Safety

10 of 172

PumpDrive 2 Eco

Table6: EMC properties of the frequency inverter

Power

[kW]

Cable length

[m]

Category to EN 61800-3 Limits to EN55011

≤ 11 ≤5 C1 Class B

The EN61800-3 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.

2.11.2 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 1kW)

▪ EN 61000-3-12

for devices with a phase current of between 16A and 75A and professional devices from 1kW up to a phase current of 16 A.

2.11.3 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

Page 11

3 Transport/Temporary Storage/Disposal

11 of 172

PumpDrive 2 Eco

3 Transport/Temporary Storage/Disposal

3.1 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.

3.2 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

90L 112M

Fig.2: Transporting a horizontal pump set

Page 12

3 Transport/Temporary Storage/Disposal

12 of 172

PumpDrive 2 Eco

Fig.3: Transporting a vertical pump set

Fig.4: Transporting the motor with frequency inverter

3.3 Storage

If the ambient conditions for storage are met, the function of the control unit is safeguarded even after a prolonged period of storage.

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.

Page 13

3 Transport/Temporary Storage/Disposal

13 of 172

PumpDrive 2 Eco

Table7: 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).

3.4 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.

Page 14

4 Description

14 of 172

PumpDrive 2 Eco

4 Description

4.1 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.

4.2 Designation

Table8: Designation example

Position

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

Table9: Key to the designation

Position Code Description

PumpDrive 2

Eco

PumpDrive2

1-5 Generation

PDRV2 2. PumpDrive generation ✘ ✘

6 Variant

E PumpDrive 2 Eco ✘ -

- PumpDrive2 - ✘

8-13 Power

A 000K37=0,37kW ✘ ✘

000K55=0,55kW ✘ ✘ 000K75=0,75kW ✘ ✘ 001K10=1,1kW ✘ ✘ 001K50=1,5kW ✘ ✘

B 002K20=2,2kW ✘ ✘

003K00=3kW ✘ ✘ 004K00=4kW ✘ ✘

C 005K50=5,5kW ✘ ✘

007K50=7,5kW ✘ ✘ 011K00=11kW ✘ ✘

D 015K00=15kW - ✘

018K50=18,5kW - ✘ 022K00=22kW - ✘ 030K00=30kW - ✘

E 037K00=37kW - ✘

045K00=45kW - ✘ 055K00=55kW - ✘

14 Mounting option

M Motor mounting ✘ ✘ W Wall mounting ✘ ✘ C Cabinet mounting ✘ ✘

16 Motor manufacturer

K KSB ✘ ✘ S Siemens ✘ ✘ C Cantoni ✘ ✘ W Wonder ✘ ✘

Page 15

4 Description

15 of 172

PumpDrive 2 Eco

Position Code Description

PumpDrive 2

Eco

PumpDrive2

17-20 Motor type

1LE1 Siemens 1LE1/ KSB1PC3 ✘ ✘ 1LA7 Siemens 1LA7/ KSB1LA7 ✘ ✘ 1LA9 Siemens 1LA9/ KSB1LA9 ✘ ✘ 1LG6 Siemens 1LG6/ KSB1LG6 ✘ ✘ 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 - ✘

N Profinet - ✘

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.

Page 16

4 Description

16 of 172

PumpDrive 2 Eco

4.3 Name plate

IP55

PumpDrive

3PH 380 - 480 VAC

50-60 Hz

0116033209

25,9 A

11 KW

INPUT:

3PH 0 VIN

0-140 Hz 25 A

OUTPUT:

PDRV21_011K00

1 2

Fig.5: Name plate 1, frequency inverter (example)

1 Mains input frequency 2 Mains input current 3 Mains input voltage 4 Output frequency 5 Nominal output current 6 Output voltage 7 Nominal power 8 Enclosure 9 Type series, size 10 Product certification

IP55

PumpDrive

997257666000010002 ETN 080-065-160 GG A 11GD20150

31.07.2014

PDRV2__-015K00M_S1LE1E2P2_MPIRM

3 4

Fig.6: Name plate 2, frequency inverter (example)

1 PumpDrive type code 2 KSB order number 3 Pump designation 4 Date of manufacture

4.4 Power range and sizes

Table10: Power range4) for 2-pole (3000rpm), 4-pole (1500rpm) and 6-pole (1000) asynchronous motors and KSB SuPremE

Size Nominal electrical power Nominal output current Mains input current

[kW] [A] [A]

Variant for Variant for Variant for

400 V/ 3~ 230 V/1~ 400 V/ 3~ 230 V/1~ 400 V/ 3~ 230 V/1~

A 0,37 - 1,3 - 1,4 -

0,55 0,55 1,8 3,0 2 4,0 0,75 - 2,5 - 2,7 1,10 1,10 3,5 4,5 3,7 6,0 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 -

4) The power ranges specified apply in full to all mounting options.

Page 17

4 Description

17 of 172

PumpDrive 2 Eco

Size Nominal electrical power Nominal output current Mains input current

[kW] [A] [A]

Variant for Variant for Variant for

400 V/ 3~ 230 V/1~ 400 V/ 3~ 230 V/1~ 400 V/ 3~ 230 V/1~

C 7,5 - 18 - 18,7 C 11 - 25 - 25,9 -

4.5 Technical data

Table11: Technical data

Characteristic Value

Mains supply

Mains voltage

1~: 230V AC +/- 15% (0.55 and 1.1kW) 3 ~: 380V AC -10% to 480V AC +10% (0.37 to 11.0kW)

Voltage difference between the three phases

±2% of the supply voltage Mains frequency 50 - 60Hz ± 2 % Mains types TN-S, TN-CS, TN-C, TT and IT mains (to IEC/EN60364)

Output data

Frequency inverter output frequency 0 - 70Hz for asynchronous motors

0 - 140Hz for KSBSuPremE PWM carrier frequency Range: 2 - 8kHz

Factory setting: 4kHz Phase rate of rise dv/dt

5000V/µs max. (depending on the size of the frequency

inverter) Peak voltages 2×1.41×V

eff

Electric cables with a high current-carrying capacity can cause

the voltage to increase up to double the value.

Frequency inverter data

Efficiency 98 % - 95 %

Noise emissions Sound pressure level of pump used + 2.5dB

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 < 1000 m above MSL, or 1% power derating per additional

100m Vibration resistance 16.7m/s2 max. (to EN60068-2-64) Fluid temperature

10)

-90°C to +140°C

EMC

Frequency inverter ≤11kW EN61800-3 C1/EN55011 Class B/cable length ≤ 5m

5) If the mains voltage is low, the nominal torque of the motor will be lower.

6) This information is only relevant for three-phase mains power.

7) The phase rate of rise (dv/dt) depends on the line capacity.

8) The efficiency at the nominal point of the frequency inverter varies between 98 percent for high power outputs and

95percent for low outputs, depending on the inverter's nominal power.

9) The values are for orientation purposes only. The value refers to the nominal duty point (50Hz) 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.

10) Provided the specified ambient temperature limits are complied with.

Page 18

4 Description

18 of 172

PumpDrive 2 Eco

Characteristic Value

Mains feedback 1~: integrated PFC module

3~: integrated line choke

Inputs and outputs

Internal power supply unit 24V ± 10 % Maximum load 600mA DC max., short-circuit and overload-proof Residual ripple <1%

Analog inputs

Number of parameterisable analog inputs 2 (configurable for current or voltage input) Input type Not differential Maximum voltage (with reference to GND) + 10V Current input 0/4 - 20mA

Input impedance 500Ω Accuracy 1% of full-scale value Signal delay < 10ms Resolution 12bit

Voltage input 0/2 - 10V

Input impedance Approx. 160kOhm Accuracy 1% of full-scale value Signal delay < 10ms Resolution 12bit

Reverse polarity protection Not provided

Analog outputs

Number of parameterisable analog outputs 1 (toggling 4 output values) Current output 4-20 mA Maximum external working resistance 850Ω Output PNP transistor Accuracy 2 % of full-scale value Signal delay < 10ms Reverse polarity protection Provided Short-circuit protection and overload protection Provided

Digital inputs

Number of digital inputs 4 in total, 3 of which can be parameterised ON level 15-30V OFF level 0-3V Input impedance Approx. 2kOhm Galvanic isolation Provided, isolation voltage: 500VAC Delay < 10ms Reverse polarity protection Provided

Relay outputs

Number of parameterisable relay outputs 2 normally open contacts Maximum contact rating AC: Max. 250 VAC/0.25A

DC: Max. 30 VDC/2A

PWM carrier frequency

Power derating for increased carrier frequency Sizes A, B and C (at PWM carrier frequency > 4kHz):

Nominal motor current (PWM)

= I

Nominal motor current

×(1 - [f

PWM

- 4kHz]×2.5%)

Page 19

4 Description

19 of 172

PumpDrive 2 Eco

4.6 Dimensions and weights

Fig.7: Dimensions

Table12: Dimensions and weights

Size P Motor-mounted model

[mm]

Wall-/

Cabinet-mounted

model

11)

[mm]

Fastening screws/bolts Weight

12)

[kg]

[kW] a b c d e a b c d e F

A ..000K37.. 0,37 260 171 144 140 141 343 171 144 140 333 M4 × 10 4

..000K55.. 0,55 ..000K75.. 0,75 ..001K10.. 1,1 ..001K50.. 1,5

B ..002K20.. 2,2 290 186 144 155 121 328 186 144 155 318 M4 × 10 5,5

..003K00.. 3 ..004K00.. 4

C .. 005K50.. 5,5 330 255 185 219 205 401 255 185 219 387 M6 × 12 9,5

.. 007K50.. 7,5 ..

0011K00..

11) The dimensions provided refer to PumpDrive including the wall-mounting brackets.

12) Without motor adapter

Page 20

4 Description

20 of 172

PumpDrive 2 Eco

4.7 Mounting options

The frequency inverter is identical in design and configuration for all 3 mounting options.

▪ Motor mounting

For the motor mounting option, the frequency inverter is mounted to the motor via an adapter or to the pump for the Movitec configuration. Adapters for subsequent conversion to motor mounting for existing pump systems are available as accessories.

▪ Wall mounting

The installation kit required for the wall-mounted model is included in the scope of supply. Installation kits for subsequent conversion to wall mounting for existing pump systems are available as accessories.

▪ Cabinet mounting

The installation kit required for the cabinet-mounted model is included in the scope of supply. Installation kits for subsequent conversion to cabinet mounting for existing pump systems are available as accessories.

Page 21

5 Installation at Site

21 of 172

PumpDrive 2 Eco

5 Installation at Site

5.1 Safety regulations

DANGER

Incorrect installation

Danger to life!

▷ Install the frequency inverter in a flood-proof location. ▷ Never use the frequency inverter in potentially explosive atmospheres.

5.2 Checks to be carried out prior to installation

Place of installation

The standard configuration has IP55 enclosure protection and may only be used in environments for which its enclosure provides adequate protection.

The place of installation must meet the following requirements:

▪ Well ventilated ▪ No direct sunlight ▪ Protected from weather ▪ Sufficient clearance for ventilation and dismantling ▪ Flood-proof

Ambient conditions

▪ Operating temperature: -10 °C to +50°C

The service life of the frequency inverter is reduced if an average temperature of +35°C/24h is exceeded or if the inverter is operated at temperatures below 0°C or above +40°C.

The frequency inverter switches off automatically if excessively high or low temperatures occur.

NOTE

Contact the manufacturer if the device is to be used under ambient conditions other than those described above.

Outdoor installation

Provide the frequency inverter with suitable protection when installed outdoors to prevent condensation on the electronic equipment and exposure to excessive sunlight.

5.3 Mounting PumpDrive

Depending on the selected mounting option, an adapter or installation kit is required.

5.3.1 Motor mounting

The frequency inverter for the motor-mounted model is supplied, together with the pump, already mounted to the motor via an adapter. Adapters for subsequent conversion to the motor mounting configuration for existing pump systems are available from KSB.

5.3.2 Wall/control cabinet mounting

The wall-mounted model is supplied with the installation kit required for wall mounting as standard. Installation kits for subsequent conversion to the wall mounting configuration for existing pump systems are available from KSB.

Page 22

5 Installation at Site

22 of 172

PumpDrive 2 Eco

The frequency inverter should rest flush against the wall so that the air flow of the fans is directed through the heat sink.

Make sure to prevent exhaust air produced by other equipment from entering the device's air intake in order to ensure adequate cooling of the device. The following minimum distances must be observed:

Table13: Minimum distances for control cabinet mounting

Minimum distance from other devices Distance [mm]

Top and bottom 100 Side 20

The power dissipated in the form of heat when the frequency inverter is operated at nominal duty values varies between 98percent for high power outputs and 95percent for low outputs, depending on the frequency inverter's nominal power.

5.4 Electrical connection

5.4.1 Safety regulations

DANGER

Incorrect electrical installation

Risk of fatal injury due to electric shock!

▷ Always have the electrical connections installed by specialist personnel. ▷ Observe the technical specifications of the local and national energy supply

companies.

DANGER

Unintentional start-up

Risk of fatal injury due to electric shock!

▷ Disconnect the frequency inverter from the mains before carrying out any

maintenance and installation work.

▷ Prevent the frequency inverter from being re-started unintentionally when

carrying out any maintenance and installation work.

DANGER

Contact with live components

Risk of fatal injury due to electric shock!

▷ Never remove the centre housing part from the heat sink. ▷ Mind the capacitor discharge time.

After switching off the frequency inverter, wait 10minutes until dangerous voltages have discharged.

WARNING

Direct connection between power supply and motor connection (bypass)

Damage to the frequency inverter!

▷ Never establish a direct connection between the power supply and motor

connection (bypass) of the frequency inverter.

Page 23

5 Installation at Site

23 of 172

PumpDrive 2 Eco

WARNING

Simultaneous connection of several motors to the frequency inverter output

Damage to the frequency inverter! Fire hazard!

▷ Never simultaneously connect several motors to the frequency inverter output.

CAUTION

Improper dielectric test

Damage to the frequency inverter!

▷ Never carry out dielectric tests on frequency inverter components. ▷ Only carry out dielectric tests on the motor, motor connection cable, or power

cable after having disconnected the frequency inverter connections.

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.

The frequency inverter is equipped with electronic safety devices, which in case of a disturbance or malfunction, trip and de-energise the inverter, causing it to stop.

Use only the available cable gland holes (if necessary, in combination with double cable glands) for establishing the cable connections. Any additional drilling could generate metal chips and damage the equipment.

5.4.2 Information for planning the system

5.4.2.1 Power/connection cables

Selecting the power/connection cables

The type of connection cable you choose depends on various factors such as, for example, the type of connection, the ambient conditions and the type of system.

Connection cables must be used in accordance with their intended use, and the manufacturer specifications regarding nominal voltage, current, operating temperature and thermal effects must be observed.

Power/connection cables must not be routed across or near hot surfaces unless they have been designed for this kind of application.

When they are used in mobile system components, flexible or highly flexible power/ connection cables must be employed.

The cables used for connections to permanently installed devices should be as short as possible and be properly connected to these devices.

Different earth bus bars should be used for control and power/motor connection cables.

Power cable

Unshielded cables can be used as power cables. The power cables must be designed with a cross-section suitable for the nominal

mains current. If a mains contactor is used in the power cable (before the frequency inverter), this

must be configured for an AC1 duty rating; the rated current values of the frequency inverters used are added and the result is increased by 15%.

Motor connection cable

Shielded cables must be used as motor connection cables.

Control cable

Shielded cables must be used as control cables.

Page 24

5 Installation at Site

24 of 172

PumpDrive 2 Eco

NOTE

Lines of type J-Y (ST) Y are not suitable for used as control cables.

1 2 3

Fig.8: Structure of electric cable

1 Wire end sleeve 2 Core 3 Cable

Table14: Cable cross-sections of control terminals

Control terminal Core cross-section [mm²] Cable diameter

13)

[mm]

Rigid cores Flexible cores Flexible cores with

wire end sleeves

Terminal strip A, B 0,2-1,5 0,2-1,0 0,25-0,75 M16: 5,0-10,0

Table15: Power cable properties

Size

Power

Cable gland for Mains input current

14)

Maximum

core cross-

section

Cable cross-

section

KSBmotor cable

Mains power

cable

Sensor cable

Motor

connection cable

PTC thermistor

[A]

Variant for

[kW] 400V/ 3~ 230V/1~ [mm²]

A .. 000K37 .. 0,37 M20 M16 M20 M16 1,4 - 2,5 2,5

.. 000K55 .. 0,55 2,0 4,0 .. 000K75 .. 0,75 2,7 -

..001K10.. 1,1 3,7 6,0

B .. 001K50 .. 1,5 M25 M16 M25 M16 5,2 - 2,5

.. 002K20 .. 2,2 6,3 .. 003K00 .. 3 8,4 .. 004K00 .. 4 10,4 -

C ..005K500.. 5,5 M32 M16 M32 M16 14,6 - 16 4

..007K500.. 7,5 18,7 ..011K000.. 11 25,9 - 6

Length of motor connection cable

If the frequency inverter is not mounted on the motor to be controlled, longer motor connection cables may be required. The stray capacitance of the connection cables may result in high-frequency discharge currents flowing to ground. The sum of the discharge currents and motor current may exceed the output-side rated current of the frequency inverter. This will activate the frequency inverter's protection equipment and the motor will be stopped. The following motor connection cables are recommended depending on the power range:

13) Impairment of protection provided by enclosure when cable diameters other than those specified are used.

14) Observe the information on the use of line chokes provided in the Accessories section.

Page 25

5 Installation at Site

25 of 172

PumpDrive 2 Eco

Table16: Length of motor connection cable

Power range Cable length Stray capacitance

Max.

[kW] [m] [nF]

≤ 11 (Class B) 5 ≤ 5 ≥ 15(Class A, Group 1) 50 ≤ 5

Table17: Length of motor connection cable

Power range [kW]

Maximum cable length

[m]

Stray capacitance

[nF]

≤ 11 (Class B) 5 ≤ 5

Output filter

If the length or stray capacitance of the power cable exceed the values indicated, we recommend installing a suitable output filter between the frequency inverter and the motor to be controlled. These filters reduce the voltage ramp-up time of the frequency inverter output voltages and limit their peaks.

5.4.2.2 Electrical protection equipment

Back-up fuses

Provide three fast-acting fuses in the mains power supply line to the frequency inverter. The fuse size must be suitable for the nominal mains current supplied to the frequency inverter.

Motor protection switch

Separate motor protection is not required because the frequency inverter has its own safety devices (e.g. electronic overcurrent trip). Available motor protection switches must be dimensioned in accordance with the nominal motor current.

Residual current device

If fixed connections and appropriate supplementary earthing are used (cf. DINVDE0160), residual current devices (RCDs) are not mandatory for frequency inverters.

If residual current devices are used, three-phase frequency inverters must in accordance with DIN VDE 0160 be connected via universal AC/DC sensitive RCDs, as potential direct-current components may cause standard AC sensitive RCDs to either fail to respond or respond erroneously.

Table18: Residual current device to be selected

Size Rated current [mA]

A, B and C 150

If you use a long shielded cable for the mains/motor connection, the residual-current monitoring device may be triggered by the discharge current that flows to earth

(triggered by the carrier frequency). Remedies: Replace the RCD (residual current device) or lower the response limit.

5.4.2.3 Information on electromagnetic compatibility

Electromagnetic interference from other electrical devices can affect the frequency inverter. Interference can also be emitted by the frequency inverter itself, however.

The interference emitted by the frequency inverter is generally conducted through the motor connection cables. The following measures are proposed for RFI suppression:

▪ Shielded motor connection cables for line lengths >70cm

(especially recommended for frequency inverters with low power ratings)

▪ Metal cable ducts made from a single piece with a minimum coverage of 80% (if

shielded connection cables cannot be used)

Installation at site/

environment

For more effective shielding, install the frequency inverter in a metal cabinet. When installing the power components in the control cabinet, make sure they are

not too close to other devices (control and monitoring devices). Maintain a minimum distance of 0.3metres between the cabling and power

components as well as other cabling in the control cabinet.

Connecting cables

Use different earth bus bars for the control cable and power/motor connection cable.

Page 26

5 Installation at Site

26 of 172

PumpDrive 2 Eco

The shield on the power/connection cable must consist of a single piece and be earthed at both ends either just on the appropriate earth terminal or on the earth bus bar (do not connect it to the earth bus bar in the control cabinet).

The shielded cable ensures that the high-frequency current, which normally flows as a discharge current from the motor housing to earth or between the individual conductors, now flows through the shielding.

The shield for the control cable (connection on frequency inverter side only) also serves as protection against radiated emissions and must be connected to the designated connection points in the control cable terminal housing.

In applications with long shielded motor cables, additional reactive resistors or output filters must be provided to compensate the capacitive stray current to earth and reduce the rate of voltage rise on the motor. These measures help reduce radio frequency interference further. Using just ferrite rings or reactive resistors does not ensure compliance with the limit values defined in the EMC directive.

NOTE

If you are using shielded cables that are longer than 10 m, check the stray capacitance to ensure that the diffusion between the phases or to earth is not excessive, which could cause the frequency inverter to stop.

Routing cables

Route control cable and power/motor connection cable in separate cable ducts. When routing the control cable observe a minimum distance of 0.3metres between

the control cable and the power/motor connection cables. If you cannot avoid crossing control and power/motor connection cables, you should

cross them at 90degrees to each other.

5.4.2.4 Earth connection

The frequency inverter must be properly earthed. To ensure greater interference immunity, a wide contact face is required for the

different earth connections. In the case of cabinet mounting, use two separate copper earth bus bars (mains

power supply/motor connection and control connection bar) with a suitable size and cross-section for earthing the frequency inverter. All the earth connections are connected to these.

The bars are connected to the earthing system at one point only. The control cabinet is then earthed via the mains earthing system.

5.4.2.5 Line chokes

The line input currents indicated are for orientation only; they refer to operation at nominal rating. These currents may vary depending on the actual line impedance. In low-impedance mains, higher currents may occur. To limit the line input current, external line chokes can be used alongside the line chokes already integrated (in the power range up to and including 45 kW). Line chokes also reduce mains feedback and improve the power factor. The scope of DINEN 61000-3-2 must be heeded.

Appropriate line chokes are available from KSB. (ðSection11.2.7,Page164)

5.4.2.6 Output filter

The maximum cable lengths must be maintained in order to meet RFI suppression requirements to EN55011. Output filters are required if the maximum cable lengths are exceeded.

Technical data available on request. (ðSection11.2.7,Page164)

Page 27

5 Installation at Site

27 of 172

PumpDrive 2 Eco

5.4.3 Electrical connection

5.4.3.1 Removing the housing cover

DANGER

Contact with live components

Risk of fatal injury due to electric shock!

▷ Never remove the centre housing part from the heat sink. ▷ Mind the capacitor discharge time.

After switching off the frequency inverter, wait 10minutes until dangerous voltages have discharged.

The terminal wiring compartment is covered by a screwed-on housing cover. The terminals of the power and motor connection cables are additionally guarded by a protective cover to prevent them from being touched.

Housing cover

Fig.9: Housing cover

1. Remove the cross recessed head screws on the cover.

2. Remove the cover.

Protective cover

Fig.10: Prying open the protective cover

1. The protective cover for connecting the power and motor connection cables is push fit. Before connecting the power and motor connection cables, carefully pry open the protective cover using a wide screwdriver.

Fig.11: Removing the protective cover

2. Remove the protective cover.

Page 28

5 Installation at Site

28 of 172

PumpDrive 2 Eco

5.4.3.2 Overview of terminal strips

400V/ 3~ variant with

1relay

DIE

+ 2 4 V

G ND

DI 3

DI2D

+ 2 4 V

DIC

N D

A I

N 2

N O

+ 24

COM+24V

B1B2B3B

4B5B6

B8B

B1 0

A 1A2A3A4A5A6A7

A 9

A 1 0

GNDG

N D

AI N1

+2 4

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

Fig.12: Overview of terminal strips for 400V/ 3~ variant with 1relay

1 Mains power supply and motor

connection

2 Control cables

NOTE

The new frequency inverter generation is equipped with a second relay.

400V/ 3~ variant with

2relays

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

DI-EN

+24V

GND

DI3

DI2

DI1

+24V

DICOM

AO-GND

AIN2

NO1

+24V

GND

COM1

+24V

B 8

B10

GND

AIN1

+24V

C 3

GND

B2B3B4

B 5

A1A2A3

A5A6A7

A 10

C 4

Fig.13: Overview of terminal strips for 400V/ 3~ variant with 2relays

1 Mains power supply and motor

connection

2 Control cables

230V/ 1~ variant

L N

LINE

PE U V W

MOTOR

PTC

MOTOR

DI-EN

+24V

GND

DI 3

DI2

DI 1

+ 24

DICOM

AO-GND

A O

AIN

NO1

+24

GND

COM

+ 24

B 7

B10

GND

AIN1+

24 V

NO2

COM

+24V

C2C

GND

B 2

B 4

B5B

A 1

A 3

A4A5

A6A7A

A10

Fig.14: Overview of terminal strips for 230V/ 1~ variant

1 Mains power supply and motor

connection

2 Control cables

Page 29

5 Installation at Site

29 of 172

PumpDrive 2 Eco

5.4.3.3 Connection to mains power supply and motor

DANGER

Touching or removing the terminals and connectors of the braking resistor

Risk of fatal injury due to electric shock!

▷ Never open or touch the terminals and connectors of the braking resistor.

CAUTION

Incorrect electrical installation

Damage to the frequency inverter!

▷ Never fit a contactor (in the motor connection cable) between the motor and

the frequency inverter.

1. Route the connection cable for the mains power supply and/or the motor connection cable through the cable glands and connect the cable(s) to the specified terminals.

2. Connect the line for a PTC connection/PTC thermistor to the PTC terminal strip (3).

NOTE

In the event of a short circuit in the winding (short circuit between phase and PTC), a fuse trips and prevents carryover of low voltages to the low-voltage level. In the case of a fault or malfunction, this fuse can only be replaced by KSB service personnel.

Size A

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

L1 L2 L3

Fig.15: Establishing the mains power supply and motor connections, sizeA, 400V/3~ variant

① Mains connection ② Motor connection ③ PTC connection ④ Braking resistor ⑤ Motor PTC ⑥ Jumper for IT mains

Page 30

5 Installation at Site

30 of 172

PumpDrive 2 Eco

L N

LINE

PE U V W

MOTOR

PTC

MOTOR

Fig.16: Establishing the mains power supply and motor connections, sizeA, 230V/1~ variant

① Mains connection ② Motor connection ③ PTC connection ④ Braking resistor ⑤ Motor PTC ⑥ Jumper for IT mains

Size B

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

L1 L2 L3

Fig.17: Establishing the mains power supply and motor connections, sizeB

① Mains connection ② Motor connection ③ PTC connection ④ Braking resistor ⑤ Motor PTC ⑥ Jumper for IT mains

Page 31

5 Installation at Site

31 of 172

PumpDrive 2 Eco

Size C

L1 L2 L3

LINE

PE U V W

MOTOR

PTC

MOTOR

L1 L2 L3

Fig.18: Establishing the mains power supply and motor connections, sizeC

① Mains connection ② Motor connection ③ PTC connection ④ Braking resistor ⑤ Motor PTC ⑥ Jumper for IT mains

Connecting motor

monitoring devices (PTC/

PTC thermistor)

Connect the cores for a PTC connection/PTC thermistor to the PTC terminal strip (3). If no PTC connection is available on the motor side, parameter 3-2-3-1 (PTC Analysis) must be deactivated.

NOTE

IP55 enclosure protection as specified in the technical data is only provided if the cover has been fitted properly.

IT mains

DANGER

Contact with live components

Risk of fatal injury due to electric shock!

▷ Never remove the centre housing part from the heat sink. ▷ Mind the capacitor discharge time.

After switching off the frequency inverter, wait 10minutes until dangerous voltages have discharged.

Jumper in IT mains

If the frequency inverter is to be used in an IT mains, the relevant IT mains jumpers (See Fig. "Establishing the mains power supply and motor connections") must be removed.

Page 32

5 Installation at Site

32 of 172

PumpDrive 2 Eco

5.4.3.3.1 Directly connect motor cable without motor connector (for sizes A and B only)

DANGER

Improper electrical connection

Risk of fatal injury due to electric shock!

▷ Never simultaneously use the motor connector with a motor cable that is

directly connected to the motor terminals.

▷ Never touch terminals and connectors of the motor connector.

When directly connecting a motor line to the designated motor terminals (U, V, W), the motor connector fitted at the factory must first be removed.

Fig.19: Disconnecting the cores of the motor connector

1. Disconnect the cores of the motor connector at terminals U, V and W.

Fig.20: Removing the motor connector

2. Remove the motor connector from the heat sink.

Fig.21: Inserting and fastening cover

3. Close the opening in the heat sink using the kit accompanying the frequency inverter (comprising a cover, gasket and bolts/screws).

NOTE

IP55 enclosure protection as specified in the technical data is only provided if the cover has been fitted properly.

Page 33

5 Installation at Site

33 of 172

PumpDrive 2 Eco

5.4.3.3.2 Retrofitting a frequency inverter for a KSB SuPremE B2 motor (for sizes C only)

Fig.22: Plug

The heat sink is closed with a plug. The following steps must be carried out to retrofit for a KSB SuPremE B2 motor.

1. Remove screwed-in plug.

Fig.23: Removing the plug

2. Remove the nut from the plug inside the frequency inverter.

NOTE

IP55 enclosure protection as specified in the technical data is only provided if the Oring has been fitted properly.

Fig.24: Inserting the O-ring

3. Place O-ring onto adapter.

DANGER

Pinching of power and motor connection cables

Risk of fatal injury due to electric shock!

▷ Never damage the insulation of the power and motor connection cables when

inserting into the opening of the frequency inverter.

Page 34

5 Installation at Site

34 of 172

PumpDrive 2 Eco

Fig.25: Inserting motor cables

4. Place the frequency inverter onto the motor adapter of the KSB SuPremE B2 motor and insert the motor cables of the KSB SuPremE B2 motor into the opening of the frequency inverter.

5. Connect the motor cables as described.

Fig.26: Connecting the motor cables

6. Connect the PTC cables that are supplied as standard with the KSB SuPremE B2 motor.

7. Close the frequency inverter with the protective cover and the housing cover.

5.4.3.4 Establishing an earth connection

The frequency inverter must be earthed. Observe the following when establishing the earth connection:

▪ Ensure that the cable lengths are as short as possible. ▪ Use different earth bus bars for the control and power/motor connection cables. ▪ The earth bus bar of the control cable must not be affected by currents from the

power/motor connection cables since this could be a source of interference.

Connect the following to the earth bus bar of the power/motor connection cable:

▪ Motor earthing connections ▪ Housing of the frequency inverter ▪ Shielding of the power/motor connection cable

Connect the following to the earth bus bar of the control cable:

▪ Shielding of the analog control connections ▪ Shielding of the sensor cables ▪ Shielding of the field bus connection cable

Installing multiple

frequency inverters

Fig.27: Establishing an earth connection If you are installing more than one frequency inverter, the star configuration is

recommended.

5.4.3.5 Installing an M12 module

The M12 module can be used to connect two frequency inverters to implement dual pump configurations. The M12 module also allows PumpMeter to be connected to the frequency inverter via Modbus.

Page 35

5 Installation at Site

35 of 172

PumpDrive 2 Eco

Fig.28: M12 module

Connection for dual pump configurations (KSB device bus)

C, D

2 Connection for PumpMeter (Modbus) A 3 Connector for the bus cable crosslink (Modbus) B

▪ Can be retrofitted ▪ Internal T-connector (bus looped through) [uninterruptible even in the event of a

frequency inverter power failure]

▪ Pre-configured cables (ðSection11.2,Page153) ▪ Connector for self assembly (ðSection11.2,Page153)

The M12 slot module can be fitted in an available slot of the frequency inverter.

Page 36

5 Installation at Site

36 of 172

PumpDrive 2 Eco

Blind cover

Fig.29: Blind cover

1 Blind cover

1. Unscrew the cross recessed head screws in the blind cover.

2. Remove the blind cover.

M12 module

Fig.30: Inserting the M12 module

1. Carefully insert the slot module into the open slot. The plug-in module is guided on rails until it engages in the contact.

Fig.31: Securing the M12 module

2. Secure the plug-in module using the 4 cross recessed head screws. IP55 enclosure protection is not provided until the screws have been tightened.

CAUTION

Incorrect assembly

Impairment of protection provided by the enclosure (protection may be compromised)!

▷ Cover unused M12 sockets of the M12 module with a cap (included in the scope

of supply).

Page 37

5 Installation at Site

37 of 172

PumpDrive 2 Eco

Connecting dual pump configurations

Designing dual pump configurations via a cable pre-configured especially for this connection (see Accessories)

21 3

Fig.32: Connecting M12 modules in dual pump configurations

1 Connection for dual pump configuration, PumpDrive No.1 2 Pre-configured bus cable for dual and multiple pump configuration

(colour: light purple, connector: angled, connector: angled)

3 Connection for dual pump configuration, PumpDrive No.2

NOTE

Terminating resistors (refer to KSB accessories) that can be connected to the unassigned M12 connector (C or D) at the M12 module are required for the bus terminator.

Connecting PumpMeter in single-pump configurations

Use pre-configured cables to connect PumpMeter (ðSection11.2,Page153)

NOTE

Connect PumpMeter (Modbus) to the M12 module, input A.

Fig.33: Connecting the M12 module to PumpMeter in single-pump configurations

1 PumpMeter: Modbus connection 2 Pre-configured bus cable for connecting PumpMeter to M12 module

(colour: black, socket: straight, connector: angled)

3 M12 module: Connection for PumpMeter (Modbus)

Connecting PumpMeter in dual and multiple pump configurations

Pre-configured crosslink cables can be used to switch the PumpMeter Modbus signal from frequency inverter to frequency inverter. (ðSection11.2,Page153)

Page 38

5 Installation at Site

38 of 172

PumpDrive 2 Eco

1 2

5 6

9 1010

Fig.34: Connecting PumpMeter in dual and multiple pump configurations

1 PumpMeter: Modbus connection 2 Pre-configured bus cable for connecting PumpMeter to M12 module

(colour: black, socket: straight, connector: angled) 3 M12 module, socket A: Connection for PumpMeter (Modbus) 4 M12 module, socket B: Connection for bus cable crosslink (Modbus) 5 Pre-configured bus cable crosslink for redundant connection of PumpMeter

(colour: black, connector: angled; connector: angled) 6 M12 module, socket A: Connection for bus cable crosslink (Modbus) 7 Connection for dual/multiple pump configuration, PumpDrive No.1 8 Pre-configured bus cable for dual and multiple pump configuration

(colour: light purple, connector: angled, connector: angled) 9 Connection for dual/multiple pump configuration, PumpDrive No.2 10 Terminating resistor

Pin assignment

4 3

Fig.35: M12 module standard assignment for M12 socket as viewed looking at the mating face

Table19: Pin assignment, M12 module, input A/B

Pin Conductor colour coding M12 socket A assignment

parameterised for

PumpMeter Modbus

M12 socket B assignment

parameterised for

PumpMeter Modbus

M12 socket A and B

assignment

parameterised as analog

input

1 Brown 24 V output (supply to

PumpMeter)

24 V output (supply to

PumpMeter)

24 V output (supply to

PumpMeter) 2 Blue 0V 0V 0V 3 White D- D+ Input (4 - 20 mA) 4 Grey D+ D- 5 - - - Vent opening

Table20: Pin assignment, M12 module, input C/D

Pin Conductor colour coding M12 socket C and D assignment

1 - Shielding 2 Red 3 Black CAN GND 4 White CAN H

Page 39

5 Installation at Site

39 of 172

PumpDrive 2 Eco

Pin Conductor colour coding M12 socket C and D assignment

5 Blue CAN L Thread - Shielding

5.4.3.6 Installing and connecting the field bus module

The available field bus module is a plug-in Modbus RTU module. The field bus module has the following properties:

▪ Can be retrofitted ▪ Internal T-connector (bus looped through) [uninterruptible even in the event of a

frequency inverter power failure]

▪ Pre-configured cables (ðSection11.2,Page153) ▪ Connector for self assembly (ðSection11.2,Page153)

Installing the field bus module

The field bus module can be fitted in an available slot of the frequency inverter.

Page 40

5 Installation at Site

40 of 172

PumpDrive 2 Eco

Blind cover

Fig.36: Blind cover

1 Blind cover

1. Unscrew the cross recessed head screws in the blind cover.

2. Remove the blind cover.

Field bus module

Fig.37: Inserting the field bus module

1. Carefully insert the field bus module into the open slot. The plug-in module is guided on rails until it engages in the contact.

Fig.38: Securing the field bus module

2. Secure the field bus module using the 4 cross recessed head screws. IP55 enclosure protection is not provided until the screws have been tightened.

CAUTION

Incorrect assembly

Impairment of protection provided by the enclosure (protection may be compromised)!

▷ Cover unused M12 sockets with a cap (included in the scope of supply).

Page 41

5 Installation at Site

41 of 172

PumpDrive 2 Eco

Connecting the field bus module

Observe the following when connecting the field bus module:

▪ Before the bus connection is established among the nodes, potential equalisation

must have been implemented and checked.

▪ To ensure high-frequency shielding, use suitable, shielded cables for the

respective field bus and install them in accordance with EMC requirements.

▪ A minimum distance of 0.3metres is recommended between such cables and

other electric conductors.

▪ Do not use the bus cable to make any further connections in addition to the field

bus module (for example, 230 V alert and 24 V start).

CAUTION

Incorrect installation

Damage to the field bus module!

▷ Never supply the field bus module with voltage using the M12 connector or the

M12 socket.

BA BA

Fig.39: Connecting the field bus module

Table21: Connecting the field bus module

Item Design M12 connector

1 Frequency inverter 1 M12 connector A: Coming

M12 socket B: Going

2 Frequency inverter 2 M12 connector A: Coming

M12 socket B: Going

Field bus control must be activated in the frequency inverter when using the field bus module .

NOTE

The frequency inverter is reset when a field bus module is replaced or retrofitted. Menu 3-12 for setting the parameters of the field bus module is then enabled.

5.4.3.7 Connecting the control cable

1 2 3

Fig.40: Structure of electric cable

1 Wire end sleeve 2 Core 3 Cable

Page 42

5 Installation at Site

42 of 172

PumpDrive 2 Eco

Table22: Cable cross-sections of control terminals

Control terminal Core cross-section [mm²] Cable diameter

15)

[mm]

Rigid cores Flexible cores Flexible cores with

wire end sleeves

Terminal strip A, B 0,2-1,5 0,2-1,0 0,25-0,75 M16: 5,0-10,0

Table23: Control terminal assignment for variant with 1 relay

Terminal strip Terminal Signal Description

B10 DI-EN Digital enable input B9 +24V +24 V DC voltage source B8 GND Ground B7 DICOM Ground for digital inputs B6 DI3 Digital input 3 B5 DI2 Digital input 2 B4 DI1 Digital input 1 B3 +24V +24 V DC voltage source B2 AO-GND Ground for AN-OUT B1 AO1 Analog current output A10 +24V +24 V DC voltage source A9 AIN2 Analog input 2 A8 GND Ground A7 +24V +24 V DC voltage source A6 AIN1 Analog input 1 A5 GND Ground A4 GND Ground A3 NO Relay, NO contact A2 COM1 Relay, reference (COM) A1 +24V +24 V DC voltage source

NOTE

The new frequency inverter generation is equipped with a second relay.

15) Impairment of protection provided by enclosure when cable diameters other than those specified are used.

Page 43

5 Installation at Site

43 of 172

PumpDrive 2 Eco

Table24: Control terminal assignment for variant with 2 relays

Terminal strip Terminal Signal Description

DI-EN +24V GND

DI3

DI2 DI1 +24V

DICOM

AO-GND

AIN2

NO1

+24V

GND

COM1

+24V

B10

GND

AIN1

+24V

NO2

COM

+24V

GND

Digital inputs

▪ The frequency inverter is equipped with 4 digital inputs. ▪ Digital input DI-EN is permanently programmed and is used to enable the

hardware.

▪ The functions of digital inputs DI1 to DI3 can be parameterised as required.

The digital inputs are electrically isolated. The DICOM reference ground for the digital inputs is thus also electrically isolated. If the internal 24V source is used, the internal GND must also be connected to the electrically isolated DICOM ground of the digital inputs. A wire jumper can be used between GND and DICOM for this purpose.

Page 44

5 Installation at Site

44 of 172

PumpDrive 2 Eco

CAUTION

Differences in potential

Damage to the frequency inverter!

▷ Never connect an external +24 V DC voltage source to a digital input.

Analog outputs

▪ The frequency inverter is equipped with an analog output whose output value

can be parameterised via the control panel.

▪ Analog signals to a higher-level control station must be electrically isolated when

they are transmitted, for example by using isolating amplifiers.

Relay outputs

▪ The function of the volt-free relays (NO1 and NO2) can be parameterised via the

Service Tool.

Analog inputs

▪ Analog signals from a higher-level control station must be electrically isolated

when they are transmitted to the frequency inverter, for example by using isolating amplifiers.

▪ If an external voltage or current source is used for the analog inputs, the ground

of the setpoint or sensor sources is applied to terminal A5 or A8.

▪ The +24 V DC voltage source (terminal A7 or A10) serves as a power supply for

the sensors connected to the analog inputs.

5.4.3.8 Connecting the control panel

CAUTION

Electrostatic charging

Damage to the electronics!

▷ Personnel must ensure that they are free of electrostatic charges before the

control panel is opened (in the event that the wireless module is retrofitted).

Mounting the graphical control panel to the frequency inverter

The standard control panel is screwed to the housing cover with 4 screws.

1. Undo the screws on the standard control panel.

2. Carefully lift the standard control panel.

3. Position the standard control panel and fasten with screws.

Changing the installation position of the control panel

Table25: Possible installation positions for the control panel

Standard Rotated 180°

The standard control panel can be rotated 180degrees if required.

Page 45

6 Operation

45 of 172

PumpDrive 2 Eco

6 Operation

6.1 Standard control panel

AUTO

1/min

Fig.41: Standard control panel

Table26: Description of standard control panel

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. 3 Display Displays information on frequency inverter operation 4 Operating keys Toggling operating modes 5 Navigation keys Navigation and parameter setting

6.1.1 Display

OFFOFF

MAN

AUTO

1/min

m h kW

A V Hz

% °C bar

1 2

Fig.42: Main screen (example)

1 Operating point display 2 Type of control 3 Display of the current operating mode

Page 46

6 Operation

46 of 172

PumpDrive 2 Eco

4 Units 5 Menu, parameter number, parameter values 6 Log in as customer 7 Active wireless connection

The wireless icon illuminates when the Bluetooth module is inserted. The

wireless icon flashes when communication takes place. 8 Single/dual pump 9 Rotational speed 0-100%

Table27: Menu, parameter number, parameter values, messages

Display Function

AUTO

Menu example: Open-loop Control

Menu example: Open-loop Control (1-3):

▪ The letter S is used as the first character to identify a menu.

▪ The second character identifies the first menu level, i.e. Operation S1-x-x-x,

Diagnosis S2-x-x-x, Settings S3-x-x-x and Information S4-x-x-x.

▪ The wrench icon shows that you have logged in as a customer.

AUTO

bar

Parameter number example: Setpoint (Closed-loop Control)

Parameter number example: Setpoint (Closed-loop Control) (1-3-2):

▪ The letter P is used as the first character to identify a parameter number.

▪ The following characters show the parameter number.

▪ The wrench icon shows that you have logged in as a customer.

AUTO

bar

Parameter value example: Setpoint (Closed-loop Control)

Parameter value example: Setpoint (Closed-loop Control) (1-3-2) set to 4 bar:

▪ If a parameter value can be edited, the digit flashes.

▪ The wrench icon shows that you have logged in as a customer.

AUTO

1/min

Message example: Dry running

Message example: Dry running (E13):

▪ A message is identified by the letter E (Error) and a unique number.

Page 47

6 Operation

47 of 172

PumpDrive 2 Eco

Table28: Assignment of keys

Key Function

Arrow keys:

▪ Move up/down in the menu options. ▪ Increase/decrease a numerical value. (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 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.

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.

Manual mode via control panel

NOTE

After a power failure, the frequency inverter reverts to the OFF operating mode. Manual mode must be restarted.

Table29: 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 1-3-10 must be set to Local.

▪ When switching the operating mode from OFF to MAN, the frequency inverter operates

at minimum speed. The control point 1-3-10 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.

Arrow keys:

▪ Pressing the arrow keys changes and immediately accepts the control value (Manual)

1-3-5. 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

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.

Page 48

6 Operation

48 of 172

PumpDrive 2 Eco

6.1.2 Main screen

The main screen shows factory default operating values.

AUTO

1/min

AUTO

1/min

AUTO

A Hz

ESC

1 2

Fig.43: Selecting and displaying operating values on the main screen

1 Parameter number for speed (1-2-1-1) 2 Current speed [rpm] 3 Parameter number for motor input power (1-2-1-2) 4 Current power input of motor in kW 5 Parameter number for motor current (1-2-1-5) 6 Current motor current in A

Page 49

6 Operation

49 of 172

PumpDrive 2 Eco

7 Parameter number for output frequency (1-2-1-7) 8 Current output frequency in Hz

If a message (alert, warning or information) is currently active, it will be displayed on the main screen.

AUTO

1/min

Fig.44: Message display A message is identified by the letter E (Error) and a unique number (see list of all

messages in the Annex). The traffic light function shows whether the message is an alert (red LED), a warning (amber LED) or just information (green LED).

Messages are acknowledged by pressing OK. Acknowledged and gone messages are listed in the message history in Menu 2 – Diagnosis.

NOTE

If the motor standstill heater has been switched on, the display alternates between the measured value and the letter H.

6.1.3 Settings menu

NOTE

The standard control panel is designed to be used for simple settings only (e.g. setting the setpoint). We recommend using the Service Tool for more extensive configuration tasks.

Opening the Settings menu: Press and hold the ESC key and press OK.

AUTO

ESC

OKESC

AUTO

1/min

1 2

Fig.45: Opening the Settings menu

1 Main screen 2 Settings menu

The wrench icon shows that you are in the Settings menu or that a value can be changed.

The parameter numbers identify 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.

Page 50

6 Operation

50 of 172

PumpDrive 2 Eco

6.1.3.1 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

6.1.3.1.1 Access levels

Three access levels have been defined to prevent accidental or unauthorised access to frequency inverter parameters:

Table30: 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.

Table31: Access level parameters

Parameter Description Possible settings Factory setting

1-1-1 Customer Login

0000...9999 0000

Customer service parameters can only be accessed using the Service Tool and the appropriate dongle.

NOTE

If no keys are pressed for five minutes, the system will automatically return to the standard access level.

The password can be changed after entering the factory default password.

Table32: Parameter for changing the password (requires use of the Service Tool)

Parameter Description Possible settings Factory setting

1-1-5 Customer Access ID

Changing the customer access ID

0000...9999 -

6.1.3.2 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.

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.

Page 51

6 Operation

51 of 172

PumpDrive 2 Eco

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.

Overview of warnings and alerts (ðSection10,Page145) Messages can be acknowledged as follows:

Table33: 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 30seconds 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 30seconds. The time intervals are 1second, 5seconds, 20seconds, 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.

6.1.3.3 Menu: Settings

General settings can be made or the settings for the process optimised in the Settings section.

Locking operating keys

Table34: Parameters for setting the control panel

Parameter Description Possible settings Factory setting

3-1-2-2 Control Keys Require Login

The MAN, OFF, AUTO and FUNC keys are locked without a valid login (customer).

▪ 0 = OFF ▪ 1 = ON

0 = OFF

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.

Page 52

6 Operation

52 of 172

PumpDrive 2 Eco

6.1.3.4 Menu: Information

All direct information about the frequency inverter is provided in the Information section. Important details regarding the firmware version are listed here.

6.1.4 Service interface and LED traffic light function

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.

Table35: 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

Page 53

7 Commissioning/Shutdown

53 of 172

PumpDrive 2 Eco

7 Commissioning/Shutdown

Ensure that the following requirements are met prior to commissioning:

▪ The pump has been vented and primed with the fluid to be handled. ▪ Flow through the pump is in the design direction specified in order to avoid

generator operation of the frequency inverter.

▪ A sudden start-up of the motor or pump set does not result in personal injury or

damage to machinery.

▪ No capacitive loads, for example for reactive current compensation, are

connected to the outputs of the device.

▪ The mains voltage is in the range approved for the frequency inverter. ▪ The frequency inverter has been properly connected to the power supply

(ðSection5.4,Page22) .

▪ All enable and start commands that can start the frequency inverter are

deactivated (refer to digital inputs, DI-EN Digital Enable Input and DI1 System Start).

▪ No voltage is applied to the power supply module of the frequency inverter. ▪ The frequency inverter and/or the pump set must not be loaded above the

permissible nominal power.

▪ The flow rate estimation function activated at the factory is required for many

pump-related functions such as starting and stopping pumps. It is therefore recommended that the flow rate estimation function be left on.

7.1 Control point concept

Possible control points are the control panel, digital/analog inputs, field buses, radio remote control or the Service Tool. These control points are grouped into three categories:

▪ Based on one-off event: Control panel, radio remote control, Service Tool ▪ Based on cyclic events: Field buses ▪ Based on permanent/continuous state: Digital/analog inputs

The following control functions can be realised via a control point:

▪ System start / stop ▪ Setpoint in closed-loop control mode ▪ Control value in open-loop control mode ▪ Control value in manual mode ▪ Toggling individual frequency inverters between Manual, OFF and Automatic ▪ Toggling between normal and alternative setpoint/control value

The Control Point parameter (3-6-2) only distinguishes between field bus and local operation (control panel, radio remote control or Service Tool).

Digital and analog inputs

Digital and analog inputs are treated in a special manner: A digital or analog input can be configured for each of the control functions mentioned. Digital and analog inputs have the highest priority. For this type of control, all other control points (e.g. control panel) are disabled, even if the control function is configured for a field bus. When the control point is changed, the values last set remain intact until they are also changed.

Specifications for digital and analog inputs are defined at the active master control device (= master). Exceptions are fixed speeds, as well as the Digital Potentiometer Manual and OFF parameter options, which only apply to the respective control function.

7.2 Setting motor parameters

The motor parameters are typically preset at the factory. The factory default motor parameters must be compared with the data provided on the motor name plate and adjusted, if required.

Page 54

7 Commissioning/Shutdown

54 of 172

PumpDrive 2 Eco

NOTE

Motor parameters cannot be changed while the motor is in operation.

NOTE

If the motor parameters are changed, the Automatic Motor Adaptation function must be subsequently called up in conjunction with the vector control method (Motor Control Method parameter 3-3-1).

Table36: Motor parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-2-1-1 Nominal Motor Power

Nominal power of motor as per name plate

Minimum to maximum limit of value range set

Dependent on size/ motor

3-2-1-2 Nominal Motor Voltage

Nominal voltage of motor as per name plate

Minimum to maximum limit of value range set

Dependent on size/ motor

3-2-1-3 Nominal Motor Frequency

Nominal frequency of motor as per name plate

Minimum to maximum limit of value range set

Dependent on size/ motor

3-2-1-4 Nominal Motor Current

Nominal current of motor as per name plate

Minimum to maximum limit of value range set

Dependent on size/ motor

3-2-1-5 Nominal Motor Speed

Nominal speed of motor as per name plate

Minimum to maximum limit of value range set

Dependent on size/ motor

3-2-1-6 Nominal Cos Phi Value

Cos phi of motor at nominal power

0,00…1,00 Dependent on size/

motor

3-2-2-1 Minimum Motor Speed

Minimum motor speed

0…4200 rpm Motor-specific

3-2-2-2 Maximum Motor Speed

Maximum motor speed

0…4200 rpm Motor-specific

3-2-3-1 PTC Data Analysis

Motor temperature monitoring

▪ 0 = OFF ▪ 1 = ON

Motor-specific

3-2-3-2 Thermal Motor Protection Behaviour

Behaviour for detection of excessive motor temperature

▪ Non-self-acknowledging ▪ Self-acknowledging

Non-selfacknowledging

3-2-4-1 Motor Direction of Rotation

Setting the direction of rotation of the motor with respect to the motor shaft

▪ 0 = Clockwise ▪ 1 = Anti-clockwise

0 = Clockwise

7.3 Motor control method

The frequency inverter gives you a choice of several motor control methods:

▪ Vector control method for the KSB SuPremE motor ▪ Vector control method for the asynchronous motor ▪ V/f control method for the asynchronous motor

The V/f control method can be selected for basic applications. For more complex applications, the vector control method can be used, which offers considerably higher speed and torque accuracy than the V/f control method. The motor control method can be set using the Motor Control Method parameter (3-3-1).

Page 55

7 Commissioning/Shutdown

55 of 172

PumpDrive 2 Eco

Table37: Parameters for analog output (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-3-1 Motor Control Method

Selecting the control method

▪ SuPremE Vector Control ▪ Asynchronous Motor Vector

Control

▪ Asynchronous Motor V/f

Control

Asynchronous Motor V/f Control

Vector control method

No additional settings or adjustments are required for vector control methods. The extended motor data required for the vector control method is determined by automatic motor adaptation.

V/f control method

If the V/f control method is selected using the Motor Control Method parameter (3-3-1), it may be necessary to adapt the preset V/f characteristic (3-3-2), depending on the application scenario.

By changing the V/f characteristic in accordance with the pump characteristic, the motor current can be adjusted in line with the required load torque (squared load torque). By default, the frequency inverter is set to a linear V/f characteristic.

By increasing the first voltage data point V0 (boost voltage), a higher torque can be generated if a higher breakaway torque is required.

Fig.46: V/f characteristic

Table38: Parameters for changing the V/f characteristic (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-3-2-1 V/f Voltage 0

Data points for the V/f characteristic

0,00...15,00 % 3-2-1-2 2

3-3-2-2 V/f Voltage 1

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-2 20

3-3-2-3 V/f Frequency 1

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-3 20

3-3-2-4 V/f Voltage 2

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-2 40

3-3-2-5 V/f Frequency 2

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-3 40

3-3-2-6 V/f Voltage 3

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-2 80

3-3-2-7 V/f Frequency 3

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-3 80

3-3-2-8 V/f Voltage 4

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-2 100

3-3-2-9 V/f Frequency 4

Data points for the V/f characteristic

0,0...100,00 % 3-2-1-3 100

Page 56

7 Commissioning/Shutdown

56 of 172

PumpDrive 2 Eco

7.4 Automatic motor adaptation (AMA) of frequency inverter

Automatic motor adaptation (AMA) is a method that calculates or measures the extended electrical parameters of the motor to ensure optimum motor output and efficiency. Automatic motor adaptation is used in conjunction with the vector control methods.

NOTE

Before starting automatic motor adaptation, ensure that the motor name plate data was parameterised correctly.

NOTE

Automatic motor adaptation can only be started from the Auto Stop state. For this purpose, the frequency inverter must be in automatic mode and the System Start / Stop parameter (1-3-1) must be set to Stop.

NOTE

Carry out AMA only when the motor is cold to adapt the frequency inverter. If standard AMA and extended AMA are used in conjunction with long motor connection cables, measurement errors can occur when identifying the extended motor data. This, in turn, can prevent the motor from being operated in an optimal fashion or prevent it from being operated at all. In such scenarios, it is recommended that you use offline AMA.

7.4.1 Automatic motor adaptation (AMA) of frequency inverter for asynchronous motors

Three (3) types of AMA are available to carry out automatic motor adaptation for asynchronous motors:

▪ Offline calculation:

Using the nominal data of the motor as a basis, the extended motor data required for vector control is calculated.

▪ Standard AMA:

The extended motor data is determined by taking a measurement with the motor being at a standstill.

▪ Extended AMA:

The extended motor data is determined by taking a measurement with the motor running at approximately 10percent of its nominal speed.

The extended AMA option is the most accurate method for determining the extended motor data and ensures very good control of the motor. Offline calculation is the simplest method available and is sufficient for basic applications.

After starting AMA using the Start Automatic Motor Adaptation parameter (3-3-3-1), you can select one of the above-mentioned types for automatic motor adaptation. The motor is disabled while AMA is being carried out.

NOTE

Carrying out standard AMA and extended AMA in particular can take several minutes, depending on the size of the motor.

NOTE

If the extended motor data cannot be determined using the AMA option, an AMA Fault alert is output. In this scenario, the extended motor data is not saved and AMA must be restarted.

Page 57

7 Commissioning/Shutdown

57 of 172

PumpDrive 2 Eco

NOTE

If a different alert is output while AMA is being carried out, the AMA process is interrupted and the AMA Fault alert is output. In this scenario, the extended motor data is not saved and AMA must be restarted.

The following extended motor data (3-3-3-2 to 3-3-3-5) is calculated or measured depending on the AMA type selected under Start Automatic Motor Adaptation (3-3-3-1):

Table39: Parameters for automatic motor adaptation for asynchronous motors (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-3-3-1 Start Automatic Motor Adaptation

Function used to start automatic motor adaptation (AMA).

1. Offline Calculation: Using the nominal

data of the motor as a basis, the extended motor data is calculated.

2. Standard AMA: The extended motor

data is determined by taking a measurement with the motor being at a standstill.

3. Extended AMA: The extended motor

data is determined by taking a measurement with the motor running at approximately 10percent of its nominal speed.

▪ Offline Calculation ▪ Standard AMA – Motor at

Standstill

▪ Extended AMA – Motor

Running

Offline Calculation

3-3-3-2 Rs Motor Stator Phase Resistance

Extended motor data:

Stator phase resistance

0,0...5000,000 Dependent on motor

3-3-3-3 LS – Motor Stator Phase Inductance

Extended motor data: Stator phase inductance

0,0...5000,0 Dependent on motor

3-3-3-4 TR – Rotor Time Constant

Extended motor data: Rotor time constant

0,0...5000,0 Dependent on motor

3-3-3-5 Km – Magnetisation Coefficient of Stator

and Rotor

Extended motor data: The magnetisation coefficient describes the magnetic coupling between the stator and rotor of the motor.

0,0000 ... 100,0000 Dependent on motor

7.4.2 Automatic motor adaptation (AMA) of frequency inverter for KSB SuPremE motors

Automatic motor adaptation for the KSB SuPremE motor is started using the Update Motor Parameters (3-3-4-1) parameter. Using the nominal motor data as a basis, the extended motor data is determined which ensures very good control of the KSB SuPremE motor.

Page 58

7 Commissioning/Shutdown

58 of 172

PumpDrive 2 Eco

Table40: Parameters for automatic motor adaptation for asynchronous motors (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-3-4-1 Update Motor Parameters

Function used to start automatic motor adaptation (AMA) for the KSB SuPremE motor.

Using the nominal motor data as a basis, the extended motor data is determined which ensures very good control of the KSB SuPremE motor.

Run Dependent on motor

3-3-4-2 Selected Motor

SuPremE motor variant currently selected

Power Range of KSB SuPremE Motors

Dependent on motor

NOTE

If the extended motor data for the KSB SuPremE motor cannot be determined, a No Matching Motor Data Available alert is output. The name plate data of the KSB SuPremE motor should be checked and verified.

7.5 Entering the setpoint

NOTE

The parameter values and value ranges/units entered are mutually dependent. This is why the first step in parameterising the frequency inverter is always to specify the applicable value range and units (refer to parameter 3-11). If the value range or unit is subsequently changed, all dependent parameters must be checked for correctness again.

One of the control points is used to define the setpoint and control value:

▪ Setpoint in closed-loop control mode ▪ Control value in open-loop control mode ▪ Control value in manual mode

NOTE

When specifying several setpoints/control values, mind the priority of the control points.

Page 59

7 Commissioning/Shutdown

59 of 172

PumpDrive 2 Eco

Table41: Specifying a setpoint/manual-mode control value via the control panel

Parameter Description Possible settings Refers to Factory setting

1-3-2 Setpoint (Closed-loop Control)

Configurable setpoint. This parameter is disabled if the setpoint is specified via DIGIN/ANIN. Otherwise, the setpoint source is selected via the Control Point parameter (Local/Field Bus).

Minimum to maximum limit of measuring range

3-11 0,00

1-3-3 Control Value (Open-loop

Control)

Configurable control value for speed in open-loop control mode

Minimum to maximum speed of motor

3-11 3-2-2-1

1-3-4 Control Value (Manual)

When manual mode is activated, the current operating speed is accepted; otherwise, minimum speed is used. The speed can then be set in manual mode.

Minimum to maximum speed of motor

3-11 3-2-2-1

System start

The system start function for starting/stopping the system in automatic mode can be specified via a digital input or the control panel.

NOTE

When using the system start via a digital input, the start option must not be simultaneously specified via the System Start / Stop parameter (1-3-1), as the system start would then remain active via this parameter (1-3-1) when the digital input is deactivated.

Table42: System start parameters

Parameter Description Possible settings Factory setting

1-3-1 System Start / Stop

This function is used to start the system.

▪ 0 = Stop ▪ 1 = Start

0 = Stop

3-8-6-1 Digital Input 1 Function

Configurable function of digital input 1

▪ No Function ▪ System Start

System Start

7.6 Pump operation

7.6.1 Single-pump operation

7.6.1.1 Open-loop control mode

Open-loop control mode is selected via the Type of Control parameter(3-6-1) for pumps in automatic mode (AUTO key). In open-loop control mode, the pump is operated at the specified speed. This speed is specified using the Control Value (Open-loop Control) parameter 1-3-3 or via an analog input .

The frequency inverter starts in automatic mode if digital input 1 is supplied with +24V DC (terminal strip C2/C1) or the system start is activated via the System Start/ Stop parameter (1-3-1).

Page 60

7 Commissioning/Shutdown

60 of 172

PumpDrive 2 Eco

7.6.1.1.1 Open-loop control mode using external standard signal

NOTE

A control value can be defined in automatic mode using an external standard signal.

D I

-E N

+ 24V

G ND

D I

D I2

D I

+ 24

D I

C O M

AO-G

A O

A I

N 2

N O

+ 24

G N D

C O M

+ 2 4 V

B 9

B1 0

A 2

A 5

A 8A9

A 1

G N D

A I

+2 4

0V (GN

D )

0 .

10 V

Fig.47: Terminal wiring diagram, open-loop control mode, for variant with 1 relay (dashed line = optional)

1 Start / Stop 2 External setpoint signal 3 Signal relay 1 4 Digital enable input 5 Ground for digital inputs

NOTE

The new frequency inverter generation is equipped with a second relay.

Page 61

7 Commissioning/Shutdown

61 of 172

PumpDrive 2 Eco

0 V

(

GND)

0... 10

3 1 456

Fig.48: Terminal wiring diagram, open-loop control mode, for variant with 2 relays (dashed line = optional)

1 Start / Stop 2 External setpoint signal 3 Signal relay 1 4 Digital enable input 5 Ground for digital inputs 6

Example

At analog input 1, a control value of 2000 rpm should be set via a 0 - 10V voltage signal. 6.66 V then corresponds to a speed of 2000rpm for a 2-pole motor. The minimum speed set is not undershot. The system start takes place via digital input1.

Table43: Example of open-loop control mode using external standard signal (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Open-loop Control) is selected.

0 = OFF (Open-loop Control)

- -

3-2-2-1 Minimum Motor Speed 500 1/min 3-11 500 1/min 3-2-2-2 Maximum Motor Speed 3000 1/min 3-11 2100 1/min 3-8-1-1 Analog Input Signal

Sensor signal at analog input 1

4=0-10 V - 0 = OFF

3-8-1-2 Analog Input 1 Function

Internal operating values cannot be used as an actual value source.

1 = Alternative Setpoint/ Control Value (Auto)

- 0 = OFF

3-8-1-3 Analog Input 1 Lower Limit Minimum to maximum

limit of measuring range

- 0,00

3-8-1-4 Analog Input 1 Upper Limit Minimum to maximum

limit of measuring range

- 100,00

1-3-1 System Start / Stop

This function is used to start the system.

0 = Stop - 0 = Stop

Page 62

7 Commissioning/Shutdown

62 of 172

PumpDrive 2 Eco

NOTE

The System Start/ Stop parameter (1-3-1) must be set to Stop if the system start takes place via the digital input.

7.6.1.1.2 Open-loop control mode via control panel

NOTE

The control value for automatic mode can be specified using the control panel. If a control value is simultaneously specified via the analog input, this value has a higher priority.

Example

A 2-pole motor is to run with a speed of 2000 rpm. To this end, a control value of 2000rpm must be set via the control panel using the Control Value (Open-loop Control) parameter (1-3-3). The system start is activated by the System Start / Stop (1-3-1) parameter. The frequency inverter then starts as soon as it is set to automatic or manual mode and the enable is given via DI-EN.

Table44: Example of open-loop control mode via control panel (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Open-loop Control) is selected.

0 = OFF (Open-loop Control)

- -

3-2-2-1 Minimum Motor Speed 500 rpm 3-11 500 rpm 3-2-2-2 Maximum Motor Speed 3000 rpm 3-11 2100 rpm 1-3-1 System Start / Stop

This function is used to start the system.

1 = Start - 0 = Stop

1-3-3 Control Value (Open-loop

Control)

Configurable control value for speed in open-loop control mode

2000 rpm - 500 rpm

7.6.1.2 Closed-loop control mode

The frequency inverter has a process controller to detect and adjust or compensate for changes in hydraulic processes. Controlled variables such as discharge pressure, differential pressure, flow rate and temperature are recorded and compared with the setpoint specified. Based on the current control deviation, a new control variable is calculated that is implemented as the new speed for the drive.

Page 63

7 Commissioning/Shutdown

63 of 172

PumpDrive 2 Eco

Overall structure of the process controller

3-6-3

3-6-2

3-6-1 3-6-4-2 3-6-4-3 3-6-4-4 3-6-4-8

3-6-4-6

3-6-4-5

Controlled variable

Control deviation

Setpoint

Control variable

Operating point

Setpoint ramp time

Drive and

hydraulic process

Setpoint ramp

Process controller

Fig.49: Overall structure of the process controller The hydraulic process to be controlled, influenced by the speed of the frequency

inverter, represents the controlled system. The measured controlled variable, or in the case of sensorless differential pressure control, the internally calculated controlled variable, is subtracted from the setpoint to form the control deviation. The control deviation is supplied to the actual process controller. The time taken to achieve the setpoint can be prolonged via a setpoint ramp.

Selecting the type of control

To activate the process controller, the type of process to be controlled must be selected via the Type of Control parameter (3-6-1). When OFF (Open-loop Control) is selected, the process controller is deactivated and the frequency inverter runs in open-loop control mode.

Table45: Selecting the type of control

Parameter Description Possible settings Factory setting

3-6-1 Type of Control

Selecting the control process. The controller is deactivated when OFF (Openloop Control) is selected.

▪ 0 = OFF (Open-loop Control) ▪ 1 = Discharge Pressure ▪ 2 = Suction Pressure ▪ 3=Differential Pressure ▪ 4 = Differential Pressure

(Sensorless)

▪ 5 = Flow Rate ▪ 6 = Temperature (Cooling) ▪ 7 = Temperature (Heating) ▪ 8 = Suction-side Level ▪ 9 = Discharge-side Level ▪ 10 = Differential Pressure

(Sensorless)

0 = OFF (Open-loop Control)

The response of the frequency inverter to a positive or negative control deviation is defined by the controller's control direction. For a normal control direction and positive control deviation, the speed is increased; for an inverted control direction and positive control deviation, the speed is decreased. The control direction of the controller is implicitly defined by the type of control selected.

Page 64

7 Commissioning/Shutdown

64 of 172

PumpDrive 2 Eco

Table46: Control direction

Type of control Control direction Comment

Discharge pressure, differential pressure, differential pressure (sensorless), flow rate, temperature (heating), discharge-side level

Normal Increase in speed for

positive control deviation

Suction pressure, temperature (cooling), suction-side level

Inverted Decrease in speed for

positive control deviation

Setting the setpoint or control value

Parameter (3-6-2) is used to define the source of the setpoint for an activated process controller or the source of the control value for a deactivated process controller. When Local is selected, an analog input or the control panel may be used as the source. When Field Bus is selected, the source of the field bus device is used.

Changes in the setpoint are ramped along the setpoint ramp .

Setting the actual value

Parameter (3-6-3) is used to define the source of the actual value. When Local is selected, an analog input or the control panel may be used as the source. When Field Bus is selected, the source of the field bus device is used.

Setting the process controller

NOTE

The PID process controller is set using the following parameters: Parameter (3-6-4-2) defines the proportional constant of the controller. The control deviation is transferred to the control value, amplified by the proportional gain.

To avoid a permanent control deviation, an integrating controller constant is required for many hydraulic processes. For this purpose, parameter (3-6-4-3) is used to define the integral time of the integral constant. The control deviation is integrated over time, weighted in relation to the integral time selected and added to the control value. Reducing the integral time leads to faster adjustment or compensation for the control deviation. When an integral time of 0s is selected, the integral constant is deactivated.

By leveraging the differential constant, the controller can respond to a quick change in the control deviation. Whether a differential constant is necessary is a function of the dynamics of the hydraulic process; for typical centrifugal pump applications, it is not required. When a rate time of 0s is selected, the differential constant of the process controller is deactivated. The rate time of the differential constant is defined using parameter (3-6-4-4). By increasing the rate time, the response to quick changes in the control deviation is intensified. The Differential Constant Limitation parameter (3-6-4-8) is used to define the maximum differential gain, which will help limit the effect of measurement noise on the control value. Decreasing the limitation value restricts the influence of the differential constant at high frequencies, and the influence of measurement noise can be suppressed.

Page 65

7 Commissioning/Shutdown

65 of 172

PumpDrive 2 Eco

Table47: Parameters of the PID controller

Parameter Description Possible settings Factory setting

3-6-4-2 Proportional Constant

Setting the proportional constant of the controller

0,01...100,00 1,00

3-6-4-3 Integral Time (Integral Constant)

Setting the integral constant of the controller

0,0 to 9999,9 s 0,2 s

3-6-4-4 Rate Time (Differential Constant)

Setting the differential constant of the controller

0,00... 100,00s 0,00s

3-6-4-8 Differential Constant Limitation

The maximum differential gain is limited in order to suppress measurement noise, for example.

1,00...20,00 3,00

Automatic determination of controller parameters

The parameters of the process controller can be determined automatically while the hydraulic process is underway. To this end, a test sequence involving speed changes is carried out and evaluated automatically. The test sequence is started as follows:

1. Operate the single-pump system or multiple pump system with the type of control required using a PI controller and the relevant setpoint.

2. Run up the hydraulic system to reach the typical operating conditions in terms of pressure and flow rate.

3. Once an adjusted and largely stable operating point is reached, start the test sequence for automatically determining the controller parameters via parameter 3-6-4-1-1.

ð The display now shows the Automatic Determination of Controller

Parameters Active message.

After the test sequence has been completed, the values determined for the proportional constant, integral time and, if required, the rate time of the controller are written to the respective parameters. In addition, the Operating Point parameter (3-6-4-5) is als set to the current speed. The display now shows the Automatic Determination of Controller Parameters Finished message.

The single-pump system or multiple pump system continues to operate uninterrupted with the new controller parameters. If the process of determining the controller parameters could not be completed correctly, the display shows the Automatic Determination of Controller Parameters Cancelled message. The single-pump system or multiple pump system then continues to operate with the unchanged controller parameters.

The process of automatically adapting the controller parameters can be modified if required. This is done by three parameters:

▪ The extent of the speed changes during the test sequence is defined via the

Amount of Sudden Speed Change parameter (3-6-4-1-2). Typical values lie in the range of 5 to 15% of the pump nominal speed.

▪ The Controller Type parameter (3-6-4-1-3) specifies whether the controller

parameters should be determined for a PI controller or a PID controller.

▪ The Process Response Time parameter (3-6-4-1-4) defines the time that lapses

after a speed change until the controlled variable exhibits almost no change at all. After this time the controlled variable has reached approximately 95% of its full-scale value. The default value defined is sufficient for the majority of pressure or flow rate control tasks. Especially when very slow processes are involved, such as those of temperature control, a sufficiently long test sequence must be ensured via this value. The duration of determining the controller parameters automatically directly relates to the time specified here.

Page 66

7 Commissioning/Shutdown

66 of 172

PumpDrive 2 Eco

Table48: Automatic determination of controller parameters

Parameter Description Possible settings Factory setting

3-6-4-1-1 Start Test Sequence

Starts the test sequence for automatically determining the controller parameters

Run

3-6-4-1-2 Amount of Sudden Speed Change

Extent of speed changes during the test sequence for automatic determination of the controller parameters.

0…3-2-2-2 1/min 150 rpm

3-6-4-1-3 Controller Type

Selection of the controller type: PI or PID

▪ PI ▪ PID

3-6-4-1-4 Process Response Time

Time that lapses after a speed change until the controlled variable exhibits almost no change at all (after this time, the controlled variable has reached approximately 95percent of its full-scale value)

0,1…10000 s 3s

7.6.1.2.1 Closed-loop control mode via control panel

NOTE

E N

+ 2 4 V

G N D

DI3

D I2

DI 1

+2 4V

DIC

AO-GND

A O

A I

N 2

N O

+ 2 4 V

G ND

CO M

+ 2 4 V

B 3

B 6

B 7

B10

A 1

A2A

3A4A5A6

A 8A9

A 1

GNDG

AIN1

+ 24V

3 1 45

Fig.50: Terminal wiring diagram, closed-loop control mode, for variant with 1 relay (dashed line = optional)

1 Start/stop 2 2 Feedback value transmitter 3 Signal relay 1

Page 67

7 Commissioning/Shutdown

67 of 172

PumpDrive 2 Eco

4 Digital enable input 5 Ground for digital inputs

NOTE

The new frequency inverter generation is equipped with a second relay.

3 1 45

Fig.51: Terminal wiring diagram, closed-loop control mode, for variant with 2 relays (dashed line = optional)

1 Start/stop 2 2 Feedback value transmitter 3 Signal relay 1 4 Digital enable input 5 Ground for digital inputs 6

Example

The frequency inverter is to control the system to achieve a setpoint of 6.7bar in a differential pressure control process. For this purpose, a differential pressure sensor (4 - 20mA) with a measuring range of 0 to 10bar is connected to analog input 2 of the frequency inverter. The setpoint is specified using the control panel. The system start is activated by the System Start / Stop (1-3-1) parameter. The frequency inverter starts as soon as it is set to automatic or manual mode and the enable is given via DIEN.

Table49: Example of closed-loop control mode with setpoint specification via the control panel (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Openloop Control) is selected.

3=Differential Pressure -

3-11-2-1 Minimum Pressure

Minimum limit of measuring range

0,00 -1,00 bar

3-11-2-2 Maximum Pressure

Maximum limit of measuring range

10,0 1000,0 bar

3-11-2-3 Pressure Unit

Configurable unit for pressure 1

bar bar

Page 68

7 Commissioning/Shutdown

68 of 172

PumpDrive 2 Eco

Parameter Description Possible settings Factory setting

1-3-2 Setpoint (Closed-loop Control)

Configurable setpoint. This parameter is disabled if the setpoint is specified via DIGIN/ANIN. Otherwise, the setpoint source is selected via the Control Point parameter (Local/Field Bus).

6,7 bar 0,00 bar

3-8-2-1 Analog Input 2 Signal

Sensor signal at analog input 2

1 = 4-20 mA 0 = OFF

3-8-2-2 Analog Input 2 Function

Function of analog input2. Internal operating values cannot be used as an actual value source.

6 = Differential Pressure 0 = OFF

3-8-2-3 Analog Input 2 Lower Limit 0,00 0,00 3-8-2-4 Analog Input 2 Upper Limit 10,00 100,00 1-3-1 System Start / Stop

This function is used to start the system.

1 = Start 0 = Stop

NOTE

The System Start/ Stop parameter (1-3-1) must be set to Stop if the system start takes place via the digital input.

7.6.1.2.2 Closed-loop control mode with external setpoint signal

The setpoint can be specified via an external setpoint signal. If a setpoint is simultaneously specified via the control panel, the setpoint via the analog input has a higher priority .

NOTE

Page 69

7 Commissioning/Shutdown

69 of 172

PumpDrive 2 Eco

D I

E N

+ 2 4 V

G N D

DI3

D I2

DI 1

+2 4

DI C

A O

-GND

A O

A I

N 2

N O

+ 2 4 V

G ND

CO M

+ 2 4 V

B 3

B 6

B 7

B10

A 1

A2A

3A4A5A6

A 8A9

A 1

GNDG

AIN1

+ 24V

0 V

(

G N D )

0. .

1 0V

3 1 45

Fig.52: Terminal wiring diagram, closed-loop control mode, for variant with 1 relay (dashed line = optional)

1 Start/stop 2 2 External setpoint signal 3 Signal relay 1 4 Digital enable input 5 Ground for digital inputs 6 Feedback value transmitter

NOTE

The new frequency inverter generation is equipped with a second relay.

Page 70

7 Commissioning/Shutdown

70 of 172

PumpDrive 2 Eco

0V (

GND

)

0... 10

3 1 45

Fig.53: Terminal wiring diagram, closed-loop control mode, for variant with 2 relays (dashed line = optional)

1 Start/stop 2 2 External setpoint signal 3 Signal relay 1 4 Digital enable input 5 Ground for digital inputs 6 Feedback value transmitter

Example

The frequency inverter is to control the system to achieve a setpoint of 6.7bar in a differential pressure control process. For this purpose, a differential pressure sensor (4 - 20mA) with a measuring range of 0 to 10bar is connected to analog input 2 of the frequency inverter. The setpoint specification is made as an external setpoint signal (4 - 20mA) via analog input1. For the desired setpoint of 6.7bar, 10.7mA must be applied at analog input1. The system start is activated by the System Start / Stop parameter (1-3-1). The frequency inverter starts as soon as it is set to automatic or manual mode and the enable is given via DI-EN.

Table50: Example of closed-loop control mode with setpoint specification via external setpoint signal (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Openloop Control) is selected.

3 = Differential Pressure -

3-11-2-1 Minimum Pressure

Minimum limit of measuring range

0,00 -1,00 bar

3-11-2-2 Maximum Pressure

Maximum limit of measuring range

10,0 1000,0 bar

3-11-2-3 Pressure Unit

Configurable unit for pressure 1

bar bar

3-8-1-1 Analog Input 1 Signal

Sensor signal at analog input 1

1 = 4-20 mA 0 = OFF

Page 71

7 Commissioning/Shutdown

71 of 172

PumpDrive 2 Eco

Parameter Description Possible settings Factory setting

3-8-1-2 Analog Input 1 Function

Function of analog input1. Internal operating values cannot be used as an actual value source.

1 = Alternative Setpoint/Control Value (Auto)

0 = OFF

3-8-1-3 Analog Input 1 Lower Limit 0,00 0,00 3-8-1-4 Analog Input 1 Upper Limit 10,00 100,00 3-8-2-1 Analog Input 2 Signal

Sensor signal at analog input 2

1 = 4-20 mA 0 = OFF

3-8-2-2 Analog Input 2 Function

Function of analog input2. Internal operating values cannot be used as an actual value source.

6 = Differential Pressure 0 = OFF

3-8-2-3 Analog Input 2 Lower Limit 0,00 0,00 3-8-2-4 Analog Input 2 Upper Limit 10,00 100,00 1-3-1 System Start / Stop

This function is used to start the system.

1 = Start 0 = Stop

NOTE

The System Start/ Stop parameter (1-3-1) must be set to Stop if the system start takes place via the digital input.

7.6.1.2.3 Sensorless differential pressure control

Sensorless differential pressure control enables control to achieve a constant differential pressure of the pump without the use of pressure sensors in a singlepump configuration. The procedure is based on the characteristic curves of the pump. Steep power curves are conducive to high process accuracy. The process is suitable to a limited extent if sections of the power curve are constant over the flow rate or the pump operates outside the permissible operating range. It is activated by setting the Type of Control parameter (3-6-1) to Differential Pressure (Sensorless). Setting the setpoint.

NOTE

To facilitate sensorless differential pressure control, all parameters of the pump characteristic curves (3-4-1, 3-4-3-1 to 3-4-3-22) and the inside pipe diameters at the pressure measuring points (3-5-2-1 and 3-5-2-2) must have been entered.

Table51: Parameters for sensorless differential pressure control

Parameter Description Possible settings Factory setting

3-6-1 Type of Control 4 = Differential Pressure

(Sensorless)

7.6.1.2.4 Sensorless flow rate control

Sensorless flow rate control enables control to achieve a constant flow rate of the pump or multiple pump system without the use of a flow rate sensor. The method is based on the characteristic curves of the pump. Steep power curves are conducive to high process accuracy. It is activated by setting the Type of Control parameter (3-6-1) to Flow Rate (Sensorless), with flow rate estimation being active (3-9-8-1 set to ON).

The time response of the control process is influenced not only by the designated control parameters (3-6-4-2 to 3-6-4-4), but significantly by the Attenuation of Flow Rate Estimation parameter (3-9-8-1). The larger and more "sluggish" a hydraulic system is, the higher the value that must be assigned to this parameter. The value should roughly coincide with the system's response time. The response time of the system refers to the time that lapses after a change in speed until the flow rate exhibits almost no change at all.

Page 72

7 Commissioning/Shutdown

72 of 172

PumpDrive 2 Eco

NOTE

To facilitate sensorless flow rate control, all parameters of the pump characteristic curves (3-4-1, 3-4-3-1 to 3-4-3-22) and the inside pipe diameters at the pressure measuring points (3-5-2-1 and 3-5-2-2) must have been entered.

NOTE

For power curves with sections of the curve being constant over the flow rate (flat characteristic curve), signals must be made available for the suction pressure and discharge pressure of the pump.

Table52: Sensorless flow rate estimation parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-9-8-1 Flow Rate Estimation ▪ 0 = OFF

▪ 1 = ON

1 = ON

3-9-8-2 Attenuation of Flow Rate Estimation

Time constant for attenuation of flow rate estimation. Higher values will result in greater attenuation.

0…600 s 5 s

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Openloop Control) is selected.

▪ 0 = OFF (Open-loop Control) ▪ 1 = Discharge Pressure ▪ 2 = Suction Pressure ▪ 3=Differential Pressure ▪ 4 = Differential Pressure

(Sensorless)

▪ 5 = Flow Rate ▪ 6 = Temperature (Cooling) ▪ 7 = Temperature (Heating) ▪ 8 = Suction-side Level ▪ 9 = Discharge-side Level ▪ 10 = Differential Pressure

(Sensorless)

7.6.2 Multiple pump configuration

7.6.2.1 Multiple pump configuration in open-loop control mode

Open-loop control mode is selected via the Type of Control parameter(3-6-1) for pumps in automatic mode (AUTO key). In open-loop control mode, all running pumps are operated at the specified speed. The number of running pumps is defined via the Maximum Number of Pumps Running parameter (3-7-2). The speed is specified using the Control Value (Open-loop Control) parameter (1-3-3) (ðSection7.6.1.1.2,Page62) or via an analog input (ðSection7.6.1.1.1,Page60) .

Page 73

7 Commissioning/Shutdown

73 of 172

PumpDrive 2 Eco

Table53: Parameters for multiple pump configuration in open-loop control mode

Parameter Description Possible settings Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Openloop Control) is selected.

0 = OFF (Open-loop Control) 0 = OFF (Open-loop

Control)

3-7-2 Maximum Number of Pumps Running

Maximum number of pumps running simultaneously in a multiple pump configuration

1…2 1

1-3-3 Control Value (Open-loop Control)

Configurable control value for speed in open-loop control mode

Minimum to maximum speed of motor

500

7.6.2.2 Multiple pump configuration in closed-loop control mode

7.6.2.2.1 Role of the drives in multiple pump configurations

In multiple pump configurations, one of the frequency inverters assumes the function of master control. The master control device starts and stops pumps and manages open-loop and closed-loop control of the multiple pump system. All signals required to control the system must be connected to the master control device. The master control role is assigned to a frequency inverter via the Role in Multiple Pump System parameter (3-7-1).

Several master control devices can be assigned to improve the availability of the multiple pump system. One of them serves as the active master control device, while the others act as redundant devices. The active master control device is identified by an "M" for "master" in the second header of the control panel. In the event that the active master control device fails, its tasks will be assumed by a redundant master control device. To ensure that this takes place, all signals required for open-loop and closed-loop control must also be connected to the redundant master control devices.

NOTE

If the master control device fails and a redundant master control device assumes its tasks, a temporary drop in pressure can occur.

The maximum number of pumps running simultaneously is limited via the Maximum Number of Pumps Running parameter (3-7-2).

Page 74

7 Commissioning/Shutdown

74 of 172

PumpDrive 2 Eco

Table54: Multiple pump configuration parameters

Parameter Description Possible settings Factory setting

3-7-1 Role in Multiple Pump System

Selecting the role of the frequency inverter in a multiple pump configuration. The active master control device is responsible for starting and stopping pumps, as well as for open-loop and closed-loop control. All input variables required for open-loop or closed-loop control must be connected to the master control device and all redundant master control devices. The redundant master control device which is to serve as the active master control is selected automatically based on a configurable transfer time. Auxiliary control devices and redundant master control devices receive their control value from the master control device.

▪ 0 = Master Control ▪ 1= Auxiliary Control

0 = Master Control

3-7-2 Maximum Number of Pumps Running

Maximum number of pumps running simultaneously in a multiple pump configuration

1...2 1

7.6.2.2.2 Starting and stopping

NOTE

System flow rate availability is a prerequisite for starting and stopping pumps. If the flow rate has not been measured, flow rate estimation, parameter 3-9-8-1, must be enabled.

Pumps are started and stopped in line with current requirements via the switching limits displayed in diagrams 1 and 2. If the current operating point of the multiple pump system shifts such that one of these switching limits is passed, a pump is started or stopped. Switching limits are defined using the parameters listed in the "Start/stop parameters" table. These switching limits are parameterised for changing over from one to two pumps. Switching limits for starting and stopping additional pumps are calculated automatically and do not need to be defined.

Table55: Parameters for starting and stopping (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-7-3-3 Start Speed

A pump is started when the start speed is reached.

0…140 % Nominal

pump speed

100 %

3-7-3-4 Stop Speed

A pump is stopped when the stop speed is reached (only required for pumps with flat characteristic curves).

0…90 % Nominal

pump speed

50 %

3-7-3-5 Start Flow Rate

Start flow rate for starting a second pump at nominal speed. Value provided in % of maximum flow rate Q6. Switching limits for starting additional pumps are derived from this value.

0…100 % Maximum

flow rate

95 %

3-7-3-6 KSB PumpDynamicControl

Shift between energy-efficient (0%) and dynamic operating mode (100%)

1…100 % - 30 %

Page 75

7 Commissioning/Shutdown

75 of 172

PumpDrive 2 Eco

Parameter Description Possible settings Refers to Factory setting

3-7-3-1 Min. Time Start

Minimum period of time between two starts

0.0…600.0s - 10 s

3-7-3-2 Min. Time Stop

Minimum period of time between two stops

0.0…600.0s - 20 s

3-2-2-1 Minimum Motor Speed 0…4200 rpm - 500 rpm 3-4-3-30 Low Flow Limit Flow Rate in %

opt

Flow rate for low flow limit at nominal speed

0…100 % Best

efficiency point Q

opt

30 %

3-7-3-7 Time Delay_Trigger Criterion

Period of time for which a start or stop condition (speed and/or flow rate limit) must be continually violated before a pump is started or stopped.

0.1…600 s - 5 s

Detailed parameter description

NOTE

Frequency inverters that are parameterised at the factory for the pump set are provided with parameters that have already been optimised for starting and stopping.

The following diagram shows the switching limits of a running pump in a multiple pump system and the associated parameters in the head / flow rate diagram.

3-7-3-5

3-7-3-3

3-7-3-4

3-2-2-1

3-4-3-30

Fig.54: Switching limits of a running pump in a multiple pump system

1 Characteristic head curve of a running pump 2 Characteristic head curve of two running pumps

Stop limits: Stopping a running pump

Start limits: Starting the second pump

Page 76

7 Commissioning/Shutdown

76 of 172

PumpDrive 2 Eco

Arrows Effective direction of the switching limits Coloured area Operating range of a running pump

Start Speed (3-7-3-3):

If the speed of a pump exceeds this value, an additional pump is started if available. The diagram shows the start speed (3-7-3-3) plotted as a curve that limits, or restricts, the operating range of the single pump. Above or to the right of this line, two pumps are running. If the start speed (3-7-3-3) is also plotted as a curve, see the "Switching limits of two running pumps in a multiple pump system" diagram, which limits, or restricts, the operating range of two running pumps. Above or to the right of this line, three pumps are running.

Start Flow Rate (3-7-3-5): The start flow rate defines a point on the characteristic head curve where an additional start limit intersects. It limits the operating range of the single pump. Below or to the right of this line, two pumps are running. The start flow rate optimised for efficiency equates to approximately 95% of the maximum flow rate (factory setting) for most pumps.

Low Flow Limit (3-4-3-30):

When the low flow limit is reached, a (one) pump is stopped. Even if only one pump is running, it is stopped provided that standby mode (sleep mode) is active . If standby mode is not active, the last pump is not stopped. A warning message is output, however.

Stop Speed (3-7-3-4):

When the stop speed is reached, a (one) pump is stopped. Even if only one pump is running, it is stopped provided that standby mode (sleep mode) is active. If standby mode is not active, the last pump is not stopped. The minimum speed (3-2-2-1) cannot be undershot, however.

The "Switching limits of two running pumps in a multiple pump system" diagram shows the switching limits of two running pumps in a multiple pump system and the associated parameters in the head/flow rate diagram.

3-7-3-3

3-7-3-6

3-7-3-3

3-4-3-30

3-7-3-4

Fig.55: Switching limits of two running pumps in a multiple pump system

1 Characteristic head curve of a running pump 2 Characteristic head curve of two running pumps

Stop limits: Stopping the second pump

Start limits: Starting the third pump

Arrows Effective direction of the switching limits Coloured area Operating range of two running pumps

Page 77

7 Commissioning/Shutdown

77 of 172

PumpDrive 2 Eco

KSB PumpDynamicControl (3-7-3-6):

This parameter determines the position of the stop limits relative to the start limits; see "Switching limits of two running pumps in a multiple pump system" diagram and greatly impacts the dynamic response and energy efficiency of the system. The parameter can be defined anywhere from 0% for maximum energy efficiency to 100% for maximum dynamic response.

Low values mean that only the number of pumps required from a practical energy perspective operate, or run. Fast, extensive changes in demand may possibly be responded to with a delay as switching operations occur relatively frequently. Values which are set too low, however, can lead to unstable starting and stopping cycles.

High values enable quick response to fast, extensive changes in demand as a relatively large number of pumps run and switching operations do not occur as frequently. High values can also lead to high energy consumption, however. The following procedure is recommended for setting this parameter: Starting with a low value (e.g. 10%), the parameter is gradually increased until the response time of the multiple pump system suits the application. If this is already the case with the initial value set, decreasing the value may prove even more beneficial.

Minimum Time Between Starts (3-7-3-1):

This parameter defines the minimum period of time that must lapse before a subsequent start is carried out. Setting this parameter can prevent a second pump from being started while a pump that was started just before is still running up to its target speed along the start ramp. The minimum period of time between two starts (3-7-3-1) should therefore be coordinated with the start ramp time (3-3-5-1). An appropriate setting is achieved by selecting roughly the same times.

Minimum Time Between Stops (3-7-3-2):

This parameter defines the minimum period of time that must lapse before a subsequent stop is carried out. Setting this parameter can prevent a second pump from being stopped while a pump that was stopped just before is still running down along the stop ramp. The minimum period of time between two stops (3-7-3-2) should therefore be coordinated with the stop ramp time (3-3-5-1). An appropriate setting is achieved by selecting roughly the same times.

Time Delay_Trigger Criterion (3-7-3-7): This parameter is used to define the sensitivity of starting and stopping to the respective application. This is the period of time for which a start or stop condition must be continually fulfilled before a pump is started or stopped. Reducing the time leads to greater sensitivity. Starting and stopping occur more quickly, and the risk of switching operations triggered by measurement outliers increases. Extending the time leads to reduced sensitivity. Starting and stopping occur more slowly, and the risk of switching operations triggered by measurement outliers decreases.

7.6.2.3 Automatic Pump Changeover

In multiple pump configurations, an automatic pump changeover for equalising the load placed on the pumps can be activated by configuring parameter 3-7-4-1. When the Runtime setting has been selected, pumps are changed after the defined runtime (3-7-4-2). When the Runtime with Time of Day setting has been selected, the changeover takes place at the time set (3-7-4-3) only if the pump has run for at least the defined runtime. If the pump is stopped, the runtime for this pump is reset.

Page 78

7 Commissioning/Shutdown

78 of 172

PumpDrive 2 Eco

Table56: Automatic pump changeover parameters

Parameter Description Possible settings Factory setting

3-7-4-1 Automatic Pump Changeover

If this parameter is enabled, pump changeover will take place after a defined operating time.

▪ 0 = OFF ▪ 1 = Runtime ▪ 2 = Runtime with Time of

Day

OFF

3-7-4-2 Pump Runtime

Runtime of pump up to the next pump changeover. If the pump is stopped, the runtime is reset.

0…168 h 24 h

3-7-4-3 Pump Changeover Time

Time at which pumps are changed when the runtime is exceeded.

0:00-23:59 0:00

7.7 Application functions

7.7.1 Aligning the frequency inverter with the pump

The characteristic curves of the pump are described by parameters 3-4-3-1 to 3-4-3-22 and apply at the nominal speed of the pump 3-4-1. The characteristic curves provide the basis for the following functions:

▪ Flow rate estimation ▪ Operating point monitoring ▪ Stand-by mode (sleep mode) ▪ Sensorless differential pressure control ▪ Dual pump configuration

If the frequency inverter is parameterised at the factory, all pump-specific parameters are already specified.

3-4-3-16 3-4-3-17

3-4-3-22

3-4-3-1 3-4-3-2 3-4-3-7

...

Q5Q

Fig.56: Characteristic head curve with seven data points and the relevant parameters Flow rate Q0, i.e. parameter (3-4-3-1), is always zero. Flow rate Q6 (3-4-3-7) describes

the end of the characteristic curves and also represents the maximum permissible flow rate of the pump.

Page 79

7 Commissioning/Shutdown

79 of 172

PumpDrive 2 Eco

3-4-3-9

3-4-3-10

3-4-3-15

3-4-3-1 3-4-3-2 3-4-3-7

...

Q5Q

Fig.57: Power curve with seven data points and the relevant parameters The same flow rate values are used for the power curves as for the characteristic

head curve.

NOTE

The power curve is not converted to account for the density of the fluid handled (3-5-1). A power curve that is consistent with the density of the fluid handled must therefore be entered.

The optimum operating point of the pump at nominal speed is defined via the Flow Rate Q

opt

parameter (3-4-3-8). The low flow limit of the pump at nominal speed is defined via the Low Flow Limit Flow Rate parameter (3-4-3-30). This is a percentagebased specification that refers to the optimum operating point.

Table57: Parameters for matching PumpDrive to the pump (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-4-3-1 Förderstrom Q_0 Minimum to maximum flow rate Pump-specific 3-4-3-2 Flow Rate Q_1 Minimum to maximum flow rate Pump-specific 3-4-3-3 Flow Rate Q_2 Minimum to maximum flow rate Pump-specific 3-4-3-4 Flow Rate Q_3 Minimum to maximum flow rate Pump-specific 3-4-3-5 Flow Rate Q_4 Minimum to maximum flow rate Pump-specific 3-4-3-6 Flow Rate Q_5 Minimum to maximum flow rate Pump-specific 3-4-3-7 Flow Rate Q_6 Minimum to maximum flow rate Pump-specific 3-4-3-8 Flow Rate Q_

opt

Minimum to maximum flow rate Pump-specific

3-4-3-9 Pump Input Power P_0 Minimum to maximum flow rate Pump-specific 3-4-3-10 Pump Input Power P_1 Minimum to maximum flow rate Pump-specific 3-4-3-11 Pump Input Power P_2 Minimum to maximum flow rate Pump-specific 3-4-3-12 Pump Input Power P_3 Minimum to maximum flow rate Pump-specific 3-4-3-13 Pump Input Power P_4 Minimum to maximum flow rate Pump-specific 3-4-3-14 Pump Input Power P_5 Minimum to maximum flow rate Pump-specific 3-4-3-15 Pump Input Power P_6 Minimum to maximum flow rate Pump-specific 3-4-3-16 Head H_0 00,00...1000,00 Pump-specific 3-4-3-17 Head H_1 00,00...1000,00 Pump-specific 3-4-3-18 Head H_2 00,00...1000,00 Pump-specific 3-4-3-19 Head H_3 00,00...1000,00 Pump-specific 3-4-3-20 Head H_4 00,00...1000,00 Pump-specific 3-4-3-21 Head H_5 00,00...1000,00 Pump-specific

Page 80

7 Commissioning/Shutdown

80 of 172

PumpDrive 2 Eco

Parameter Description Possible settings Factory setting

3-4-3-22 Head H_6 00,00...1000,00 Pump-specific 3-4-3-23 NPSH_0 00,00...1000,00 Pump-specific 3-4-3-24 NPSH_1 00,00...1000,00 Pump-specific 3-4-3-25 NPSH_2 00,00...1000,00 Pump-specific 3-4-3-26 NPSH_3 00,00...1000,00 Pump-specific 3-4-3-27 NPSH_4 00,00...1000,00 Pump-specific 3-4-3-28 NPSH_5 00,00...1000,00 Pump-specific 3-4-3-29 NPSH_6 00,00...1000,00 Pump-specific 3-4-3-30 Low Flow Limit Flow Rate in % Qopt 0...100 Pump-specific

7.7.2 Protective functions

7.7.2.1 Activating/deactivating thermal motor protection

Thermal overload results in immediate tripping and an alert message is output. Restarting will only be possible after the motor has cooled down sufficiently. The stop threshold value is set at the factory for monitoring with a PTC sensor or a thermal circuit breaker. If other thermocouples are used, the value has to be set by KSB Service.

NOTE

Thermal motor protection cannot be activated/deactivated while the motor is in operation.

Table58: Thermal motor protection (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-2-3-1 PTC Data Analysis

Motor temperature monitoring

▪ 0 = OFF ▪ 1 = ON

1 = ON

3-2-3-2 Thermal Motor Protection Behaviour

Behaviour for detection of excessive motor temperature

▪ Non-self-acknowledging ▪ Self-acknowledging

Non-self-acknowledging

7.7.2.2 Electrical motor protection by overvoltage/undervoltage monitoring

The frequency inverter monitors the mains voltage. If it falls below 380 V -10 % or exceeds 480 V +10%, this results in tripping and an alert is output. The alert must be acknowledged before the drive can be restarted.

7.7.2.3 Stop due to Overcurrent

NOTE

Should the Overcurrent and Short Circuit faults occur, the frequency inverter is automatically reset (after 2s – 4s - 6s). If the fault still cannot be acknowledged, the frequency inverter switches off for safety reasons, and fault messages A5 (Short circuit)/A9 (Overcurrent) and A6 (Hardware fault) are output. The combination of these faults indicates to the operator that all components of the system and their electrical connections must be thoroughly checked. The frequency inverter can only be restarted with a voltage reset after the fault present has been rectified.

If the Max. Motor Current in % of Nominal Motor Current (3-3-7-1) limit value is exceeded by 5%, the partially self-acknowledging Overcurrent alert is output that causes the motor to be stopped. The drive remains disabled as long as this event is active. The Motor Disabled status is displayed on the control panel.

Page 81

7 Commissioning/Shutdown

81 of 172

PumpDrive 2 Eco

7.7.2.4 Dynamic overload protection by speed limitation

The frequency inverter is equipped with current sensors that record and limit the motor current. When the defined overload limit is reached, the speed is lowered to reduce the power (I²t control). The frequency inverter then no longer operates in closed-loop control mode but maintains the operative function at a lower speed.

Based on the values set in the I²t Triggering Characteristic (3-3-7-5) and the Max. Motor Current in % of Nominal Motor Current (3-3-7-1) parameters, a dynamic time period is calculated during which the motor may be operated at a current higher than the Nominal Motor Current (3-2-1-4) until I²t control takes over. The more the motor exceeds its nominal current, the faster the I²t control mode is activated.

The first time dynamic overload protection (I²t counter=0) is activated and the motor current is at 110% of the nominal motor current (3-2-1-4), it will take 60seconds (3-3-7-5) for I²t control to take over as defined in the default factory settings. If the overload current is below the maximum motor current, the dynamic time period calculated is extended by a corresponding amount. If the motor continues to operate at its nominal current following operation in overload mode, the I²t control mode remains active. If the current drops to a value below the nominal current of the motor (3-2-1-4), the I²t counter is reset. This process can take up to 10minutes, depending on the current at which the motor is currently operating.

As soon as I²t control is activated, the Dynamic Overload Protection warning is displayed. This warning is self-acknowledging and is reset when I²t control is deactivated.

When the I²t stop speed (3-3-7-6) is undershot, the partially self-acknowledging Dynamic Overload Protection alert is output and the motor is stopped. The motor is disabled. After the I²t threshold value is undershot, the motor restarts after a maximum disable time of 10seconds has lapsed, depending on the size of the motor.

Table59: Parameters for dynamic overload protection by speed limitation (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-2-1-4 Nominal Motor Current

Nominal current of motor as per name plate

0.00 ... 150.00 A - Dependent on size

3-3-7-1 Max. Motor Current in % of

Nominal Motor Current

Configuring the maximum motor current permissible

0 ... 150 % 3-2-1-4 110 %

3-3-7-5 I²t Triggering Characteristic

Based on the I²t triggering characteristic, a period of time is calculated dynamically during which the motor may be operated at a higher current until I²t control is activated.

1 .. 60 s - 60 s

3-3-7-6 I²t Stop Speed

This speed limit causes a Dynamic Overload Protection alert to be output, at which time the motor is stopped.

Minimum to maximum speed of motor

- 500 rpm

7.7.2.5 Tripping at phase failure and short circuit

Phase failure and short circuit result in direct tripping (without stop ramp). This protective function does not need to be parameterised.

7.7.2.6 Broken wire detection (live zero)

The control system monitors all analog inputs at which a sensor has already been detected or for which a sensor has been permanently set for broken wire (live zero).

Page 82

7 Commissioning/Shutdown

82 of 172

PumpDrive 2 Eco

A prerequisite are signals with 4 - 20 mA or 2 - 10 V. If the lower voltage or current value is defined as 0 V or 0 mA, cable integrity monitoring is not carried out for the corresponding analog input. If the value falls below 4 mA or 2 V, a parameterisable response is initiated after a parameterisable time delay.

If the sensor relates to the actual value source and dedicated control is no longer possible due to a lack of redundancy, the No Master Control alert is output (or otherwise, the Failure of Actual Value warning).

A Broken Wire warning is output if no control function is active. The alerts and warnings are self-acknowledging. In the event of an alert (control no longer possible), a configurable response is implemented:

▪ Stop all pumps ▪ Maintain speed ▪ Configurable speed

Table60: Broken wire detection (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-9-1-1 Response to Failure

Operating behaviour of frequency inverter upon Failure of Actual Value alert

▪ All Pumps OFF ▪ Fixed Speed

All Pumps OFF

3-9-1-2 Time Delay

Time delay before the message (warning or alert) is triggered. In a redundant system, only a warning is output as the auxiliary master can assume the function. Only if the actual value also fails at the auxiliary master is an alert output, which then triggers the specified response to actual value failure (pump changeover).

0,0…10,0s 0,5s

3-9-1-3 Speed During Failure

Fixed speed that is activated when the actual value fails.

Minimum to maximum speed of motor

500rpm

7.7.2.7 Suppressing a frequency range

In the case of critical system conditions, a frequency range can be suppressed to prevent resonance. An upper and lower speed limit value can be parameterised for this purpose. If the upper and lower limit speeds have the same rpm setting, suppression does not occur.

NOTE

Suppressing a frequency range does not take effect in manual mode.

Suppressing a frequency range in closed-loop control mode

If the closed-loop control value exceeds the lower limit speed or undershoots the upper limit speed, the control system transitions through the resonance range. Before the resonance range is passed again, the closed-loop control value must have left it once. In this way, oscillation is reduced when a controller is set to respond slowly. The effect cannot be avoided altogether, however, if the setpoint is reached within the confines of the resonance range. In the event that several transitions occur in closed-loop control mode, a Resonance Range warning is output. This warning is displayed for 60seconds after the last transition.

Suppressing a frequency range in open-loop control mode

If the open-loop control value is below the mean value between both limit speeds, the motor remains at the lower limit speed. If the open-loop control value is above the mean value between both limit speeds, the motor remains at the upper limit speed. If the mean value is exceeded or undershot, the control system overcomes the resonance range along the motor protection ramp.

Page 83

7 Commissioning/Shutdown

83 of 172

PumpDrive 2 Eco

Table61: Upper and lower limit speed (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-9-12-1 Lower Limit

Lower speed limit for suppressing the resonance range in Hz. If the lower and upper limit frequency are assigned the same values, there is no suppression. This function is not supported in manual mode.

Minimum to maximum speed of motor

0 rpm

3-9-12-2 Upper Limit

Upper speed limit for suppressing the resonance range in Hz. If the lower and upper limit frequency are assigned the same values, there is no suppression. This function is not supported in manual mode.

Minimum to maximum speed of motor

0 rpm

7.7.2.8 Operating point monitoring

Operating point monitoring generates warning messages if the pump operates outside the permissible operating range. Excessively low flow rates produce the Low Flow warning. Excessively high flow rates produce the Overload warning. The underlying limits can be matched to the pump via the parameters listed (refer to table on parameters for operating point monitoring). Operating point monitoring is activated together with flow rate estimation via parameter (3-9-8-1).

NOTE

Operating point monitoring will only function properly if the Inside Pipe Diameters at Discharge Pressure Measuring Points (3-5-2-1 and 3-5-2-2) parameters have been entered.

3-4-3-30 3-4-3-31

Fig.58: Head / flow rate diagram

Permissible operating range

1 Nominal speed 2 Minimum speed 3 Low flow limit 4 Overload limit

Page 84

7 Commissioning/Shutdown

84 of 172

PumpDrive 2 Eco

Table62: Operating point monitoring parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-4-3-30 Low Flow Limit Flow Rate in % of Q

opt

Flow rate for low flow limit at nominal speed

0..100% 3-4-3-8 30%

3-4-3-31 Overload Limit Flow Rate in % of Q

max

Flow rate for the overload limit at nominal speed

0..100% 3-4-3-7 98 %

7.7.2.9 Functional check run

When a pump is stopped for an extended period of time, the pump can be operated cyclically to prevent the pump from seizing up.

NOTE

The functional check run is only performed in automatic mode. The functional check run also remains active if system start has not been activated for the respective pump. The pump will start up.

The speed that is used for the functional check run can be set via the Speed for Functional Check Run parameter (3-9-2-5). The duration of the functional check run (3-9-2-4) is extended by ramp times. The functional check run also works for pumps that were stopped by standby mode (sleep mode). If a functional check run is in progress, it can be interrupted, or cancelled, at any time by changing to the OFF mode.

Functional check run after idle period

After a configurable idle period has passed (3-9-2-1), a functional check is performed on the pumps in automatic mode. For this purpose, the Automatic Functional Check Run (3-9-2-1) parameter must be set to After Idle Period. The Functional Check Run Duration (3-9-2-4) parameter is used to specify the duration of the functional check run.

Table63: Parameters for functional check run after idle period

Parameter Description Possible settings Refers to Factory setting

3-9-2-1 Automatic Functional Check Run

For a functional check run, a pump is started, run at a configurable frequency for a configurable period of time and then stopped again. During this period, the pump is not available for closed-loop control operation.

1 = After Idle Period - 0 = OFF

3-9-2-2 Idle Period before Functional

Check Run

A functional check run is performed for a pump if it has not been started for the defined period of time.

0…168 h - 24 h

3-9-2-4 Functional Check Run Duration

Runtime of pump during the functional check run at the set speed

0.0…600.0 s - 5.0 s

3-9-2-5 Speed for Functional Check Run

Speed for functional check run

Minimum to maximum speed of motor

3-11 500 rpm

Functional check run after idle period at defined time

The frequency inverter performs a functional check run when a specific time has been reached. If the function is activated, the idle period of the pump must first have passed, at which point the functional check run is delayed until a specific configurable time is reached.

Page 85

7 Commissioning/Shutdown

85 of 172

PumpDrive 2 Eco

Table64: Parameters for functional check run after idle period at defined time

Parameter Description Possible settings Refers to Factory setting

3-9-2-1 Automatic Functional Check Run

2 = After Idle Period at Defined Time

- 0 = OFF

3-9-2-2 Idle Period before Functional

Check Run

A functional check run is performed for a pump if it has not been started for the defined period of time.

0…168 h - 24 h

3-9-2-3 Time for Functional Check Run

When a time has been defined, the functional check run after idle period is delayed until the defined time is reached.

00:00…23:59 - 00:00

3-9-2-4 Functional Check Run Duration

Runtime of pump during the functional check run at the set speed

0.0…600.0 s - 5 s

3-9-2-5 Speed for Functional Check Run

Speed for functional check run

Minimum to maximum speed of motor

3-11 500 rpm

7.7.2.10 Individual monitoring functions

An upper and lower limit value (parameters 3-10-1-1 to 3-10-11-3) can be defined for the following operating values:

▪ Power ▪ Current ▪ Speed ▪ Setpoint ▪ Actual Value ▪ Flow rate ▪ Suction pressure ▪ Discharge pressure ▪ Differential pressure ▪ Frequency ▪ Temperature

When these limit values are undershot or overshot, a warning is triggered after a continuous time delay that is defined (3-10) has lapsed.

7.7.3 Flow rate estimation

The flow rate and head estimation is based on the characteristic curves of the pump and the operating data determined by the frequency inverter with regard to pump input power and speed. Flow rate estimation is activated by the Flow Rate Estimation parameter (3-9-8-1). The characteristic curves are entered as described in (ðSection7.7.1,Page78) . If no pressure sensors are installed close to the pump for improving flow rate estimation accuracy, a monotonically increasing power curve is required.

Page 86

7 Commissioning/Shutdown

86 of 172

PumpDrive 2 Eco

NOTE

The actual characteristic curves of a pump can differ from the documented ones as a result of manufacturing tolerances. Inaccuracies then arise for flow rate estimation. Higher accuracies can be reached by using the characteristic curves obtained from a pump acceptance test.

Improving accuracy with pressure sensors installed close to the pump

Signals sent from pressure sensors installed close to the pump can be used to improve the accuracy of flow rate and head estimations. They should only be used, however, if the pressure loss between the pump nozzle and pressure measuring point is negligible both on the suction and discharge side (< 1% of the sensor measuring range). If this requirement is not met, the Pressure Measuring Point Positions parameter (3-5-2-4) must be set to the Distant from Pump value to deactivate the influence of the pressure signals on flow rate estimation. Otherwise, the Close to Pump default setting with activated accuracy improvement function applies. The pressure measuring points must be described by parameters (refer to table on flow rate estimation parameters).

Pressures that are recorded via analog inputs with the Suction Pressure_Internal, Discharge Pressure_Internal or Differential Pressure_Internal function are only used to improve the accuracy of the flow rate and head estimation. They are always regarded as "close to pump" sensors, regardless of the Pressure Measuring Point Positions (3-5-2-4) parameter.

Multiple pump systems

Fig.59: Conditions for improving accuracy with pressure sensors installed close to the pump in multiple pump systems

The following additional conditions must be fulfilled for multiple pump systems in which pressure measurements are only taken in collecting lines (or headers/ manifolds):

▪ All of the pumps are identical in design. ▪ Suction and discharge nozzles of the pumps have the same diameter (in-line

pumps).

▪ Suction and discharge-side collecting lines have the same diameter. ▪ The total flow rate is largely distributed equally across the individual pumps.

If these requirements are not met, the pressure signals may not be used to improve the accuracy of the flow rate and head calculation. The Pressure Measuring Point Positions parameter (3-5-2-4) must be set to the Distant from Pump value.

Table65: Flow rate estimation parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-9-8-1 Flow rate estimation 1 = ON 0 = OFF 3-5-2-1 Pipe Diameter_Suction Pressure

Measuring Point

0...1000mm 0,0mm

Page 87

7 Commissioning/Shutdown

87 of 172

PumpDrive 2 Eco

Parameter Description Possible settings Factory setting

3-5-2-2 Pipe Diameter_Discharge Pressure

Measuring Point

0...1000mm 0,0mm

3-5-2-3 Height Difference_Pressure Measuring

Points

-10...10m 0,0m

3-5-2-4 Pressure Measuring Point Positions ▪ Close to Pump

▪ Distant from Pump

Close to Pump

7.7.4 Energy optimisation

7.7.4.1 Pressure/differential pressure control with dynamic pressure compensation

Dynamic pressure compensation makes it possible to supply a distant consumer with largely constant pressure, irrespective of the flow, when pump-end pressure sensors are used. This is achieved by increasing the pump's pressure setpoint as the flow rate increases in order to compensate for the rising pressure losses in the piping.

Open piping system

∆p

Fig.60: Pressure control with dynamic pressure compensation in open system

1 Pump set with diagram of flow rate-dependent setpoint 2 Piping with diagram of pressure losses 3 Consumer with diagram of inlet pressure

The discharge pressure of the pump (1) can be used in open piping systems to achieve an almost constant pressure upstream of the consumer (3).

Page 88

7 Commissioning/Shutdown

88 of 172

PumpDrive 2 Eco

Closed piping system

∆p

Fig.61: Differential pressure control with dynamic pressure compensation in closed system

1 Pump set with diagram of flow rate-dependent setpoint 2 Piping with diagram of pressure losses 3 Consumer with differential pressure diagram

The differential pressure of the pump (1) can be used in closed systems to achieve an almost constant differential pressure at the consumer (3).

Two dynamic pressure compensation methods are available: "Dynamic pressure compensation based on flow rate" and "Dynamic pressure compensation based on speed".

NOTE

Based on flow rate

Dynamic pressure compensation is best realised based on the measured or estimated flow rate. To this end, the Dynamic Pressure Compensation Method parameter (3-9-3-1) is set to Flow Rate. The following diagram shows the setpoint compensation curve (solid line) as a function of the flow rate and relevant parameters.

Page 89

7 Commissioning/Shutdown

89 of 172

PumpDrive 2 Eco

3-9-3-4

3-9-3-2

Fig.62: Setpoint compensation curve for dynamic pressure compensation based on flow rate

1 Flow rate independent setpoint 2 Setpoint compensation 3 Compensated setpoint

The compensated setpoint (3) is the sum of the flow rate independent setpoint (1) and setpoint compensation (2). The flow rate independent setpoint (1) is configured as described in (ðSection7.5,Page58) . Setpoint compensation (2) starts at flow rate Q = 0 and reaches the value defined under Setpoint Compensation (3-9-3-4) at the Dyn Press Comp Q Data Point (3-9-3-2) flow rate. Beyond that, setpoint compensation continues along the parabola shown.

The relatively small pressures in the lower flow rate range may not be sufficient to open installed swing check valves. In order to achieve the pressure required in this range, parameter (3-9-3-5) can be used to define a minimum setpoint compensation value. The following diagram shows the influence of minimum setpoint compensation on the setpoint compensation curve.

3-9-3-4

3-9-3-5

3-9-3-2

Fig.63: Setpoint compensation curve for dynamic pressure compensation based on flow rate with minimum setpoint compensation (3-9-3-5)

1 Flow rate independent setpoint 2 Setpoint compensation 3 Compensated setpoint

Based on speed (for closed hydraulic circuits)

If neither the measured nor estimated flow rate is available, dynamic pressure compensation can be realised based on speed. This is only possible for closed hydraulic circuits and single-pump configurations, however. To this end, the Dynamic Pressure Compensation Method parameter (3-9-3-1) is set to Speed.

The following diagram shows the setpoint compensation curve (solid line) as a function of the speed and relevant parameters.

Page 90

7 Commissioning/Shutdown

90 of 172

PumpDrive 2 Eco

3-9-3-4

3-9-3-3

Fig.64: Setpoint compensation curve for dynamic pressure compensation based on speed

1 Flow rate independent setpoint 2 Setpoint compensation 3 Compensated setpoint

The compensated setpoint (3) is the sum of the flow rate independent setpoint (1) and setpoint compensation (2). The flow rate independent setpoint (1) is configured as described in (ðSection7.5,Page58) . Setpoint compensation starts at speed n = 0 and reaches the value defined under Setpoint Compensation (3-9-3-4) at the Dyn Press Setpoint Comp n Data Point (3-9-3-3) speed. Setpoint compensation continues along the parabola shown. The Minimum Setpoint Compensation parameter (3-9-3-5) can be used to define a minimum setpoint compensation value for opening swing check valves.

Table66: Parameters for pressure/differential pressure control with dynamic pressure compensation (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-9-3-1 Dynamic Pressure Compensation Method

Selecting the dynamic differential pressure compensation method (DFS). Dynamic pressure compensation based on speed can only be used for systems without a geodetic head (e.g. in closed systems).

▪ 0 = OFF ▪ 1 = Speed ▪ 2 = Flow Rate

0 = OFF

3-9-3-2 Dyn Press Comp Q Data Point

The setpoint compensation value is reached at this point. Beyond that, the setpoint is further increased with respect to the specified value.

Minimum to maximum flow rate Dependent on the unit

set

3-9-3-3 Dyn Press Comp n Data Point

The setpoint compensation value is reached at this point. Beyond that, the setpoint is further increased with respect to the specified value. Data is entered in % referred to Maximum Motor Speed (3-2-2-2).

Referred to parameter 3-2-2-2 Maximum Motor Speed

0 %

3-9-3-4 Setpoint Compensation

Configurable setpoint compensation at data point 3-9-3-2 or 3-9-3-3

Minimum to maximum limit of measuring range

Dependent on the unit set

3-9-3-5 Minimum Setpoint Compensation

Minimum setpoint compensation for opening the swing check valve in the case of low pump flow rates.

Minimum to maximum limit of measuring range

Dependent on the unit set

Page 91

7 Commissioning/Shutdown

91 of 172

PumpDrive 2 Eco

Sensorless differential pressure control with dynamic pressure compensation (Sensorless Dyn Press Comp)

∆p

Fig.65: Differential pressure control with dynamic pressure compensation in closed system

1 Pump set with diagram of flow rate-dependent setpoint 2 Piping with diagram of pressure losses 3 Consumer with differential pressure diagram

In a closed hydraulic system, an almost constant differential pressure can be achieved at the consumer through sensorless dynamic pressure compensation, without the need for pressure sensors. The method is based on the characteristic curves of the pump. Steep power curves are conducive to high process accuracy. The process is suitable to a limited extent if sections of the power curve are constant over the flow rate. It is activated by setting the Type of Control parameter (3-6-1) to Differential Pressure (Sensorless) and setting the Dynamic Pressure Compensation Method (3-9-3-1) to Flow Rate.

NOTE

Sensorless differential pressure control with dynamic pressure compensation does not work if the Dynamic Pressure Compensation Method (3-9-3-1) parameter has been set to Speed.

3-9-3-4

3-9-3-2

Fig.66: Setpoint compensation curve for dynamic pressure compensation based on flow rate

1 Flow rate independent setpoint 2 Setpoint Compensation 3 Compensated setpoint

Page 92

7 Commissioning/Shutdown

92 of 172

PumpDrive 2 Eco

The diagram shows the setpoint compensation curve (solid line) as a function of the flow rate and relevant parameters. The compensated setpoint (3) is the sum of the flow rate independent setpoint (1) and setpoint compensation (2). The flow rate independent setpoint (1) is configured as described in (ðSection7.5,Page58) . Setpoint compensation (2) starts at flow rate Q = 0 and achieves the value defined under Setpoint Compensation (3-9-3-4) at the Dyn Press Comp Q Data Point (3-9-3-2) flow rate. Setpoint compensation also continues along the parabola shown. A minimum pressure increase as for dynamic pressure compensation with pressure sensors is not possible.

NOTE

To facilitate sensorless differential pressure control, all parameters of the pump characteristic curves (3-4-1, 3-4-3-1 to 3-4-3-22) must be entered.

Table67: Parameters for sensorless pressure/differential pressure control with dynamic pressure compensation (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-6-1 Type of Control

Selecting the control method. The controller is deactivated when OFF (Openloop Control) is selected.

4 = Differential Pressure (Sensorless)

3-9-3-1 Dynamic Pressure Compensation Method

Selecting the dynamic differential pressure compensation method (DFS). Dynamic pressure compensation based on speed can only be used for systems without a geodetic head (e.g. in closed systems).

2 = Flow Rate 0 = OFF

3-9-3-2 Dyn Press Comp Q Data Point

The setpoint compensation value is reached at this point. Beyond that, the setpoint is further increased with respect to the specified value.

Minimum to maximum flow rate 0 m³/h

3-9-3-4 Setpoint Compensation

Configurable setpoint compensation at data point 3-9-3-2 or 3-9-3-3

Minimum to maximum limit of measuring range

0 %

7.7.4.2 Stand-by mode (sleep mode)

NOTE

In sleep mode, PumpDrive may start up without any warning if the actual value exceeds the Maximum Control Deviation for Restart (3-9-4-5).

Sleep mode can be used for the following control tasks:

▪ Controlling the discharge pressure or differential pressure (including sensorless

control)

▪ Controlling the temperature for heating ▪ Controlling the level for filling

Sleep mode allows the single or multiple pump system to be started and stopped as required. If sleep mode is activated, the frequency inverter stops the pump in the case of low flow rates, i.e. should the low flow limit be continuously undershot (3-4-3-30) or the stop speed be continuously undershot (3-9-8-4). In pressure control applications, an accumulator can be filled during brief operation with an increased setpoint (3-9-4-2) prior to stopping. If a drop in pressure and, thus, a flow rate requirement are detected, the pump restarts.

Sleep mode only takes effect in closed-loop control mode. In multiple pump systems, sleep mode only takes effect if just one pump is running. Sleep mode is activated via parameter (3-9-4-1).

Page 93

7 Commissioning/Shutdown

93 of 172

PumpDrive 2 Eco

Sleep mode with setpoint increase

This sleep mode variant is active if a value larger than 0 is selected for the Setpoint Increase parameter (3-9-4-2).

∆p

(3-7-3-4)

∆p

ist

∆p

ist

∆p

soll

3-9-4-3

3-9-4-7

3-9-4-4

3-9-4-5

3-9-4-2

Fig.67: Sleep mode with setpoint increase (shown here by example after the stop speed has been undershot)

Δp

actual

Actual value reaches increased setpoint

Δp

actual

Actual value does not reach increased setpoint

If the low flow limit (3-4-3-30) or stop speed (3-9-4-8) of the pump is undershot due to minimum withdrawal over the specified period (3-9-4-3), setpoint increase starts (t1). In the process, the setpoint is increased along a ramp until it reaches the target setpoint increase (3-9-4-2) and is maintained at a constant level. The ramp time is defined by the Ramp-up Time for Setpoint Increase parameter (3-9-4-7). The total duration of setpoint increase is limited by parameter (3-9-4-4). Control now targets the increased setpoint. If the increased setpoint is reached within this time, stop is triggered (t2). If the actual value does not reach the increased setpoint within this time, the setpoint is reset and the stop attempt cancelled. The pump then operates for a configurable minimum time (3-9-4-6) before another stop attempt can be started.

Restarting

Pressure drops as soon as fluid is withdrawn. If the configurable limit value for the Maximum Control Deviation for Restart (3-9-4-5) is achieved, the pump starts up again (t3).

NOTE

In a multiple pump system, starting of an additional pump cancels the stop attempt.

Page 94

7 Commissioning/Shutdown

94 of 172

PumpDrive 2 Eco

Sleep mode without setpoint increase

This sleep mode variant is active if the value 0 is selected for the Setpoint Increase parameter (3-9-4-2).

If the low flow limit (3-4-3-30) or stop speed (3-9-4-8) of the pump is undershot due to minimum withdrawal over the specified period (3-9-4-3), the pump is stopped.

Pressure drops as soon as fluid is withdrawn. If the configurable limit value for the Maximum Control Deviation for Restart (3-9-4-5) is achieved, the pump restarts.

NOTE

Table68: Parameters for stand-by (sleep) mode (parameterisation using the Service Tool)

Parameter Description Possible settings Refers to Factory setting

3-9-4-1 Sleep Mode

Sleep mode ON/OFF

▪ 0 = OFF ▪ 1 = ON

- 0 = OFF

3-9-4-2 Setpoint Increase

Pressure increase required for tank filling

Minimum to maximum limit of value range

- 0

3-9-4-3 Monitoring Period

Configurable monitoring period until setpoint increase or stop

0,0…600,0 - 30,0 s

3-9-4-4 Duration of Setpoint Increase

Maximum duration of setpoint increase. Stop is triggered if the setpoint is reached within this window. The duration of the setpoint increase must exceed the time of the ramp defined for the increase.

0,0…600,0 - 100,0s

3-9-4-5 Permissible Deviation

Maximum permissible control deviation for restart

Minimum to maximum limit of value range

- 1,0bar

3-9-4-6 Minimum Runtime

Minimum period of time between two stop attempts in sleep mode

0,0...600,0 - 60,0s

3-9-4-7 Ramp-up Time for Setpoint

Increase

Ramp-up time during which the setpoint is increased

0,0...1000,0 - 30,0s

3-9-4-8 Stop Speed

The pump is stopped if the low flow limit or stop speed of the pump is undershot due to minimal withdrawal over period 3-9-4-3.

Minimum to maximum limit of value range

- 3-2-2-1

7.7.5 Ramps

Start and stop ramps (open-loop control mode/manual mode, closed-loop control mode)

Starting and stopping take place via speed ramps. A distinction is made between a start ramp and a stop ramp. The ramps are defined via parameters 3-3-5-1, 3-3-5-2 and 3-2-2-2. In open-loop control mode, the start ramp is left when the control value

Page 95

7 Commissioning/Shutdown

95 of 172

PumpDrive 2 Eco

is reached. In closed-loop control mode, the start ramp is left when the speed defined by the controller is reached. The stop ramp is activated as soon as a stop signal is issued.

WARNING

Stop ramp time set exceeded in the case of steep stop ramps in conjunction with pronounced mass inertia. (A "Limited Stop Ramp" warning is output.)

Hazard to operating personnel caused by rotating machine parts!

▷ Always keep a safe distance from rotating parts until the machine has come to

a complete standstill.

NOTE

In the event of a stop via the DI-EN digital input, the motor is not stopped by the stop ramp, but coasts to a standstill. The amount of time this process takes depends on the mass moment of inertia of the system. The drive remains disabled during coasting. The Motor Disabled status is displayed on the control panel.

[min-1]

[s]

3-3-5-1

3-2-2-2

3-3-5-2

Fig.68: Start ramp (left) and stop ramp (right)

n Speed t Time

Table69: Start and stop ramp parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-3-5-1 Start Ramp Time

Time defining the start ramp

1 - 600 s 3 s

3-3-5-2 Stop Ramp Time

Time defining the stop ramp

1 - 600 s 3 s

3-2-2-2 Maximum Motor Speed 1 - 4000 rpm 2100 rpm

Operating ramp (open-loop control mode/manual mode)

To avoid spontaneous changes in speed in open-loop control mode/manual mode, operating ramps limit the change velocity of the speed. If a speed change curve is flatter than the operating ramp, no limitation occurs.

Parameters 3-2-2-2 and 3-3-5-3 are used for defining the operating ramp.

Page 96

7 Commissioning/Shutdown

96 of 172

PumpDrive 2 Eco

[min-1]

[s]

3-3-5-3

3-2-2-2

3-3-5-3

Fig.69: Operating ramp

n Speed t Time

Table70: Operating ramp parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-3-5-3 Operating Ramp Time

Time defining the ramps for speed changes in open-loop control mode or in manual mode

1 - 600 s 3s

3-2-2-2 Maximum Motor Speed 1 - 4000 rpm 2100 rpm

[s]

3-3-5-1

3-2-2-2

3-3-5-23-3-5-3

Fig.70: Example speed curve in open-loop control mode The illustration shows, by example, a speed curve in open-loop control mode as a

solid line. The control value (speed setting) is displayed as a dotted line. The start command takes effect at time 2. The speed increases along the start ramp until the control value (1) is reached and maintained. The control value increases spontaneously at time3. The speed increases along the operating ramp until the increased control value is reached and maintained. The stop command takes effect at time 4. The speed decreases along the stop ramp until the machine comes to a standstill.

Setpoint ramp (closed-loop control mode)

In closed-loop control mode, setpoint changes are made along the setpoint ramp. This, in turn, avoids spontaneous changes in speed and system oscillations. The inclination of the setpoint ramp is defined by parameter 3-6-4-6 and control range Δx as shown in Figure 4. Control range Δx results from Type of Control 3-6-1 and the settings in the Value Ranges and Units menu 3-11. Two examples:

Example 1

Control targets constant discharge pressure:

The Type of Control parameter (3-6-1) is set to Discharge Pressure. Accordingly, control range Δx is limited by the Minimum Pressure (3-11-2-1) and Maximum Pressure (3-11-2-2) parameters.

Example 2

Control targets constant temperature: The Type of Control parameter (3-6-1) is set to Temperature (Heating). Accordingly, control range Δx is limited by the Minimum Temperature (3-11-4-1) and Maximum Temperature (3-11-4-2) parameters.

Page 97

7 Commissioning/Shutdown

97 of 172

PumpDrive 2 Eco

[s]

3-6-4-6

Δx

3-6-4-6

Fig.71: Setpoint ramp

x Controlled variable t Time Δx Control range

Table71: Setpoint ramp parameters (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-6-4-6 Setpoint Ramp Time

Time defining the setpoint ramp

1 - 600 s 3 s

7.7.6 Motor standstill heater

The frequency inverter is equipped with a parameterisable motor standstill heater. When the motor standstill heater is activated, a direct current is applied to the motor windings while the motor is stopped in relation to the cool-down behaviour of the motor winding. This ensures that sufficient heat is generated to prevent condensation from building inside the motor as well as rules out frost damage that can occur when the motors are stopped in a cold ambient environment.

NOTE

The motor standstill heater can only be activated at a standstill and in the OFF or Auto Stop operating modes of the frequency inverter. If the frequency inverter is in the "disabled" status due to e.g. an alert or another function, the standstill heater is not switched on. In addition, to safeguard the operative performance of the motor standstill heater, the PTC monitoring device of the motor must be activated via the frequency inverter using parameter 3-2-3-1. If the PTC analysis function is deactivated when the motor standstill heater is activated, PTC analysis automatically becomes inactive.

The motor standstill heater can be activated or deactivated via the Motor Standstill Heater parameter (3-2-5-1). The current status of the motor standstill heater is displayed as an information message in the control panel of the frequency inverter. The amount of heating current applied can be changed via the Heating Current parameter (3-2-5-2). This parameter is a service parameter as it should only be changed by qualified staff. The motor standstill heater usually operates with the factory default settings. As soon as the system start procedure has been carried out and the motor starts up, the motor standstill heater is automatically switched off.

Table72: Motor standstill heater parameters

Parameter Description Possible settings Factory setting

3-2-5-1 Motor Standstill Heater

Heating the motor via the motor windings

▪ 0 = OFF ▪ 1 = ON

OFF

3-2-5-2 Heating Current

Heating current in % of nominal motor current

0,00…50,00 20,00

Page 98

7 Commissioning/Shutdown

98 of 172

PumpDrive 2 Eco

7.8 Device functions

7.8.1 Factory and user settings

NOTE

If the system has been commissioned/started up before, restoring the factory settings will cause all parameter settings made so far to be deleted if they have not been backed up using the service software or user settings.

Two additional user settings can be saved and loaded in the frequency inverter. The factory settings cannot be overwritten and can be loaded with parameter (3-1-3-5).

NOTE

In a multiple pump configuration, Load Factory Settings (3-1-3-5) must be carried out separately on all frequency inverters. It is sufficient to save the settings on just one frequency inverter in the system. This approach must also be adopted when loading and saving user settings.

Table73: Factory and user settings (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-1-3-1 Load User Settings 1 Run - 3-1-3-2 Load User Settings 2 Run - 3-1-3-3 Save User Settings 1 Run - 3-1-3-4 Save User Settings 2 Run - 3-1-3-5 Load Factory Settings

This function is used to reset the drive or system to the factory settings.

Run -

7.8.2 Reading out PumpMeter

If the frequency inverter is not parameterised at the factory, all relevant data (motor data, characteristic curves of the pump) can be loaded into the frequency inverter from PumpMeter, provided that PumpMeter is connected via Modbus to input A of the M12 module.

NOTE

When loading data from PumpMeter, the data set at the factory is overwritten. The data in the frequency inverter could be more recent. Reloading the factory data is possible by using the default factory configuration.

Reading out the name plate

In order to read parameters such as pump characteristic curve and motor data from PumpMeter, the Function M12 Module Input A (3-8-4-1) parameter must be set to PMtr Suction / Discharge Pressure or PMtr Suction / Discharge Pressure_Internal. The frequency inverter must be in OFF or Auto Stop mode for this.

NOTE

When changing parameter 3-8-4-1 to one of the above-mentioned values (in particular in retrofit applications) a 24 V voltage reset is triggered, which is required for initialisation of the bus connection to PumpMeter.

Only then will it be possible to read out the name plate. If reading out the name plate is interrupted before data transmission has been

completed or if no communication can be established, the PumpMeter Communication warning will be output and none of the parameters already transmitted will be accepted. As motor data can also be changed by the read process,

Page 99

7 Commissioning/Shutdown

99 of 172

PumpDrive 2 Eco

Automatic Motor Adaptation (AMA) needs to be started once again. Once the read process has been completed, the PumpMeter Upload Completed message is output. Motor parameters changed! Run AMA!

NOTE

When PMtr Suction / Discharge Pressure has been selected, parameter 3-8-4-1 needs to be reset to OFF after reading out the name plate, if the analog input is to be used as the source for control.

Table74: Reading out PumpMeter (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

3-8-4-1 Function M12 Module Input A

Function of M12 module, inputA. Internal operating values cannot be used as an actual value source.

1 = PMtr Suction / Discharge Pressure

0 = OFF

3-13-1 Read Out Name Plate

Transfers the name plate information from PumpMeter to the frequency inverter

Run -

3-13-2 Address

Modbus address of PumpMeter device connected

1...247 247

3-13-3 Baud Rate

Modbus baud rate of PumpMeter device connected

▪ 9600 ▪ 19200 ▪ 38400 ▪ 115200

38400

3-13-4 System Bus Monitoring Period

Modbus time-out setting

1...180s 15

7.8.3 Date and time

The frequency inverter is equipped with a real-time clock. The output format can be selected.

NOTE

Automatic toggling between summer and winter time is not possible.

Table75: Parameters for setting the date and time (parameterisation using the Service Tool)

Parameter Description Possible settings Factory setting

1-5-1 System Time

Current time of system

- Current CET Time

1-5-2 System Date

Current date of system

- Current CET Date

3-1-4-1 Set Date

Setting the date

01.01.2000 ... 31.12.2099 Current CET Date

3-1-4-2 Set Time

Setting the time of day

00:00…23:59 Current CET Time

3-1-4-3 Time Format

Selecting the format for displaying the time

▪ AM ▪ PM ▪ 24h

Page 100

7 Commissioning/Shutdown

100 of 172

PumpDrive 2 Eco

7.9 Digital and analog inputs/Digital and analog outputs

7.9.1 Digital Inputs

The frequency inverter is equipped with four digital inputs. Digital input DI-EN is assigned a fixed function:

Digital input DI-EN can be used to deactivate the pulse width modulation (PWM) of the frequency inverter. In the event of a stop (DI-EN = Low), the motor is not stopped by the stop ramp, but coasts to a standstill. The amount of time this process takes depends on the mass moment of inertia of the system. The drive remains disabled during coasting. The Motor Disabled status is displayed on the control panel. In the most basic scenario, a +24V (C9) wire jumper on DI-EN can enable PWM.

NOTE

WARNING

Rotating machine parts

Risk of injury to operating personnel!

▷ Always keep a safe distance from rotating parts until the machine has come to

a complete standstill.

Three of these digital inputs (DI1 to DI3) can be freely parameterised. The following functions can be selected:

▪ No function ▪ System start ▪ Digital potentiometer (faster/slower) ▪ Dry running protection ▪ Reset alert ▪ Output control of analog input ▪ Process an external message (e.g. door open – response: pump off) ▪ Toggle OFF/Automatic/Fixed speed/External OFF ▪ Pump changeover ▪ Start functional check run

KSB PumpDrive 2 Eco Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual