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Multipump
System CFW-08
Software Version V5.0X
Language: English
Document: 0899.5547 / 02
Installation, Conguration and Operation Guide
CFW-08 Frequency Inverter
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MULTIPUMP SYSTEM
INDEX
1. About the Guide ........................................................................................... 05
2. CFW-08 Multipump Compatibility ................................................................... 05
3. CFW-08 Multipump Specification ................................................................... 05
4. Introduction to the Multipump System .............................................................. 05
4.1. About the Multipump System ................................................................... 07
4.2. General Characteristics of the Multipump System ...................................... 07
4.3. Advantages of a Multipump System .......................................................... 08
4.4. CFW-08 Multipump Control ....................................................................08
5. Fixed Control Multipump System ..................................................................... 09
5.1. Electrical Connections .............................................................................09
5.2. Operation of the Fixed Control ................................................................ 09
5.2.1. Rule for Adding a Pump to the System ................................................. 10
5.2.2. Rule for Removing a Pump from the System ......................................... 10
6. Floating Control Multipump System ................................................................. 10
6.1. Electrical Connections ............................................................................11
6.2. Operation of the Floating Control ............................................................ 11
7. Parameterization of the Multipump Control ......................................................12
7.1. Detailed Parameter Description ............................................................... 12
7.1.1. Multipump Read-Only Parameters ...................................................... 12
7.1.2. Multipump System Writing Parameters – General Configuration ............13
7.1.3. Multipump System Writing Parameters – Fault Configuration ................. 14
7.1.4. Multipump System Writing Parameters – Rotation Configuration ............15
7.1.5. Multipump System Writing Parameters – Sleep Mode Configuration ....... 16
7.1.6. Multipump System Writing Parameters – Pump Starting Configuration .... 17
7.1.7. Multipump System Writing Parameters – Pump Stopping Configuration .. 18
7.2. ECC4 Control Board Connections ........................................................... 20
7.3. Modified Parameters at the CFW-08 Multipump ........................................ 21
8. Multipump Control Configuration Tutorial........................................................ 22
9. Errors and Possible Causes ............................................................................. 24
10. Multipump Control Connection Schematics ...................................................25
10.1. Multipump Fixed Control Power Section Electrical Schematic .................... 25
10.2. Multipump Fixed Control Command Connections ................................... 26
10.3. Multipump Floating Control Power Section Electrical Schematic ................ 27
10.4. Multipump Floating Control Command Connections ............................... 28
11. Quick Parameter Reference ......................................................................... 29
11.1. Parameters with Changes in the Factory Default Values ............................ 29
11.2. Parameters with New Functions .............................................................. 30
11.3. Multipump System Parameters................................................................30
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Installation, Configuration and Operation Guide
Multipump System
1. ABOUT THE GUIDE
This guide supplies the necessary description for the operation of the CFW-08 frequency
inverter in multipump system applications. It describes the new parameters and functions
related to the multipump system, and the functions that were changed compared to the
standard CFW-08 user manual.
NOTE!
2. CFW-08 MULTIPUMP COMPATIBILITY
manual, except for the items listed below:
Three relay outputs with normally open contacts;
It does not have analog output;
It is not available in the following models: 1.6-2.6-4.0-7.0A / 200V/240V and
1.0-1.6-2.6-4.0A / 380V/480V.
3. CFW-08 MULTIPUMP SPECIFICATION
for instance, CFW080100B2024POA5Z.
Use this guide together with the CFW-08 user manual.
The CFW-08 Multipump inverter is compatible with the functions described in the user
The CFW-08 Multipump is defined by the code “A5” in the product intelligent code,
The main modifications in this product, compared to the standard, are:
ECC4 control board with more functions than the standard ECC3;
V5.0X software, dedicated to the multipump control, instead of the standard
software.
NOTE!
For more information on the intelligent code, refer to the section 2.4 in the user
manual
4. INTRODUCTION TO THE MULTIPUMP SYSTEM
The CFW-08 Multipump implements a PID regulator together with a logic for the
activation of up to three relay outputs. Those outputs are for activating the pumps connected
to the system. Therefore, the control is able to activate multiple pumps, and one pump
can have the speed controlled throughout the entire operation range while the others are
activated directly (On/Off). The control logic for the activation of the relay outputs monitors
the process variables in order to identify the need of activation or deactivation of pumps
in the system. Refer to the figure 4.2.
The figure 4.1 illustrates the CFW-08 application in a 4 pump system with fixed
control, i.e., the inverter controls the speed of the main pump and commands three other
pumps through the relay outputs. Observe the pressure transducer connection, as well as
the activation of the auxiliary pumps through direct on line start, SSW-07, and star-delta
starter.
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Figure 4.1: Multipump illustrative example
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4.1. About the Multipump System
Multipump, or multiple pumps pumping system, refers to the control of more than one pump
using only one frequency inverter to control the pump speed. The inverter selects which pumps
will operate in order to keep/control the output pressure of a pumping system. An alternation
between their activation is also performed, making it possible an equal use of the pumps.
In order to control the system output pressure a PID controller is used, together with the
auxiliary pumps star/stop logic, according to the figure 4.2.
The system can be controlled in two manners:
Fixed Control, where the pump with variable speed (connected to the inverter) is always
the same one;
Floating Control, where the pump with variable speed (connected to the inverter) is
changed according to the alternating need.
4.2. General Characteristics of the Multipump System
The multipump system developed for the CFW-08 presents the following characteristics:
Control of up to 4 pumps in Fixed Control mode;
Control of up to 3 pumps in Floating Control mode;
Auxiliary pumps activation mode control;
Control of the inverter driven pump change (Floating Control);
Acceleration and deceleration ramp for the inverter driven pump;
Minimum and maximum speed limits for the inverter driven pump;
System pressure setpoint setting via parameter or via analog input;
Selection via digital inputs, of up to four pressure setpoint values;
Whether or not the pump is enabled via digital input;
Gain, offset and filter adjustment for analog inputs;
Sleep mode possibility;
Minimum output pressure fault (pipe breaking);
Maximum output pressure fault (pipe obstruction);
Alternation of pumps according to their operation time.
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4.3. Advantages of a Multipump System
A multipump pumping system presents the following advantages compared to a single
pump:
Energy savings;
Increased life span of the pumping system;
It makes maintenance without operation interruption possible;
It keeps a constant line pressure;
It provides the necessary flow according to the system demand;
System fault diagnosis;
Pump operation time equalization, allowing thus the uniform wearing of them.
4.4. CFW-08 Multipump Control
The multipump control implemented in the CFW-08 frequency inverter is capable of
activating up to 4 pumps with Fixed Control and 3 pumps with Floating Control. The used
PID regulator is the same of the standard product; therefore, in order to adjust this regulator
and the other software functions, it is strictly necessary that this guide be supplied together
with the CFW-08 user manual.
Setpoint
PID
Regulator
Frequency
Consumer
Process
Multipump
Logic
Set of
Pumps
Pressure
CFW-08
Figure 4.2: Simplified schematic of the multipump system
Multipump System
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5. FIXED CONTROL MULTIPUMP SYSTEM
It is characterized by the fact that the inverter always controls the speed of the same pump,
called the main pump. Auxiliary pumps are activated by the CFW-08 inverter digital outputs
(relays). In that way, the more suitable starting technique can be chosen by the user, direct on
line, star-delta, Soft-Starter, etc.
The CFW-08 Multipump Fixed Control is selected through the parameter P203=2, and
makes the operation of up to 4 pumps possible, one connected directly to the inverter and
the other three commanded through the CFW-08 relay outputs.
5.1. Electrical Connections
The suggested power section electrical schematic of the Multipump Fixed Control for the
operation of a main pump and three more auxiliary pumps is presented in the figure 10.1.
Observe the connection of the inverter directly to the main pump, and the auxiliary
pumps started directly on line through 2K1, 3K1 and 4K1 contactors. Note that the inverter
protection is achieved through fuses, and for the auxiliary pumps via circuit breakers 2Q1,
3Q1 and 4Q1.
The figure 10.2 presents the command connections according to the CFW-08 factory
default, i.e., the digital input DI1 enables the inverter with ramp (start/stop), and the other
inputs, DI2, DI3 and DI4, are used for commanding the auxiliary pumps 2M1, 3M1 and
4M1, respectively.
2S2, 3S2 and 4S2 switches allow selecting between Manual / 0 / Automatic positions. The
“Manual” position issues the command for starting the auxiliary pump without the multipump
system control. The “0” position switches off the pump and disables it from the multipump
system. The “Automatic” position enables the auxiliary pump to be used in the multipump
system.
RL1, RL2 and RL3 relay outputs activate respectively 2K1, 3K1 and 4K1 contactors for
starting the auxiliary pumps.
5.2. Operation of the Fixed Control
The Multipump control is implemented based on certain output pressure limits of the system,
on the inverter output frequency, as well as on some time intervals necessary for the process
stabilization. Through the system pressure and inverter output frequency variables, it is possible
to identify the need of adding or removing a pump from the system. Therefore, the continuous
control performed by the main pump has its range amplified through the activation of auxiliary
pumps connected in parallel in the pumping system. The following sections synthesize the two
rules for the operation of the auxiliary pumps:
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5.2.1. Rule for Adding a Pump to the System
The parameters P575, P576 and P577, define the operation point where a pump must
be added to the system. Parameters P575 and P576 determine frequency and pressure,
respectively. The parameter P577, though, corresponds to the time interval (∆t) this condition
must be sustained before the control activates the pump.
Ps < SP - P576
Fs > P575
∆t > P577
Ps > SP+P576
Fs > P575
∆t > P577
Where: Ps = System output pressure (process variable)
Fs = Output frequency
SP = Pressure Setpoint (Keys, AI2 or DIx)
∆t = Time interval
5.2.2. Rule for Removing a Pump from the System
The parameters P580, P581 and P582, define the operation point where a pump must
be removed from the system. Parameters P580 and P581 determine frequency and pressure,
respectively. The parameter P582, though, corresponds to the time interval (∆t) this condition
must be sustained before the control deactivates the pump.
Ps > SP + P581
Fs < P580
∆t > P582
Ps < SP - P581
Fs < P580
∆t > P582
Increments the number of pumps in case of direct PID action
(P527=0).
Increments the number of pumps in case of reverse PID action
(P527=1).
Decrements the number of pumps in case of direct PID action
(P527=0).
Decrements the number of pumps in case of reverse PID action
(P527=1).
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Where: Ps = System output pressure (process variable)
Fs = Output frequency
SP = Pressure Setpoint (Keys, AI2 or DIx)
∆t = Time interval
6. FLOATING CONTROL MULTIPUMP SYSTEM
In the Floating Control Multipump System the inverter can be connected to any of the
pumps, whereas the others operate as auxiliary pumps. This is possible because of the
interlocking between the pump commands combined to the CFW-08 relay command logic,
which allows any of the pumps to be connected to the inverter or to the line, according to
a pre-defined relay output activation sequence.
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Starting from the point where all the CFW-08 relay outputs are off, the first one that is
activated connects the CFW-08 to the respective pump, which operates as the main pump.
The other relay outputs activated in the sequence start their respective pumps direct on line,
and they operate as the auxiliary pumps.
6.1. Electrical Connections
The suggested electrical schematic for the power section of the Multipump Floating Control
for the operation of three pumps is presented in the figure 10.3.
Observe that the schematic with 6 contactors makes it possible that the inverter be
connected to any of the pumps, i.e., 1K1, 2K1 and 3K1 contactors connect the respective
pumps to the CFW-08 power output terminals. On the other hand, 1K2, 2K2 and 3K2
contactors perform a direct on-line start of their respective pumps. Note that 1K2, 2K2 and
3K2 starters must not necessarily be contactors, they can be Soft Starters for instance.
The figure 10.4 presents the command connections according to the CFW-08 factory
default, i.e., the digital input DI1 enables the inverter with ramp (start/stop), and the other inputs,
DI2, DI3 and DI4, are used for commanding the pumps 1M1, 2M1 and 3M1, respectively.
1S2, 2S2 and 3S2 switches allow selecting between Manual / 0 / Automatic positions. The
“Manual” position issues the command for starting the auxiliary pump without the multipump
system control. The “0” position switches off the pump and disables it from the multipump
system. The “Automatic” position enables the auxiliary pump to be used in the multipump
system.
RL1, RL2 and RL3 relay outputs activate respectively 1K1, 2K1 and 3K1 contactors for
starting the pumps. Note that in this schematic there is no representation of the auxiliary or main
pumps, because the first started one is the main pump and the others will be auxiliaries.
6.2. Operation of the Floating Control
The Floating Multipump Control is identical to the Fixed Control regarding the decision
making process for adding or removing pumps from the system, according to the section 5.2.
The interlocking presented in the figure 10.4, however, allows that any of the three pumps
be connected to the inverter output. Therefore, opposite to the Fixed Control, the pump
controlled by the inverter can be changed by another, thus balancing the operation time
among all the system pumps. The moment for changing the pump driven by the CFW-08 is
totally programmable in a way that the user defines the system operation point, as well as the
maximum time interval between changes.
According to the figures 10.3 and 10.4 schematics, the pump connected to the frequency
inverter is always the first to be activated; the pumps that are activated next are connected
directly to the line as auxiliary pumps. Therefore, in opportune moments, such as when the
inverter is disabled or in sleep mode, or the system capacity is below a specific pre-defined
point, then the inverter is able to switch off all the pumps and reinitiate the operation connecting
itself to another pump of the system.
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7. PARAMETERIZATION OF THE MULTIPUMP CONTROL
The CFW-08 Multipump Control was devised in order to support both multipump
applications, with fixed and floating control. The section 7.1 presents the CFW-08 new
parameters for the Multipump Control.
7.1. Detailed Parameter Description
7.1.1. Multipump Read-Only Parameters
P540 – System Pressure
Adjustable
0 to P552 Unit: - Default: -
Range:
Description:
Process variable or multipump system output pressure, with the scale defined by P552. The
process variable and the parameters linked to it have no unit, so that the user can work
with the unit system that better suits the application.
P541 – B
Adjustable
Pump Operation Time
RL1
0.0 to 3000 Unit: x10h Default: -
Range:
Description:
It totalizes the operation time of the pump linked to the relay output RL1.
P542 – B
Adjustable
Pump Operation Time
RL2
0.0 to 3000 Unit: x10h Default: -
Range:
Description:
It totalizes the operation time of the pump linked to the relay output RL2.
P543 – B
Adjustable
Pump Operation Time
RL3
0.0 to 3000 Unit: x10h Default: -
Range:
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Description:
It totalizes the operation time of the pump linked to the relay output RL3.
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P544 – CFW-08 Operation Time
Adjustable
0.0 to 3000 Unit: x10h Default: -
Range:
Description:
It totalizes the operation time of the frequency inverter CFW-08.
7.1.2. Multipump System Writing Parameters – General Configuration
P550 – Number Auxiliary Pumps
Adjustable
0 to 3 Unit: - Default: 3
Range:
Description:
It defines the number of auxiliary pumps for the Multipump Fixed Control (P203=2), or
the number of pumps for the Multipump Floating Control (P203=3).
P551 – Activation of the Auxiliary Pumps
Adjustable
Range:
0 = In a sequence
1 = With rotation
Unit: - Default: 1
Description:
It determines the mode of activating the pumps:
In sequence (P551=0) → the multipump control activates the pumps in the sequential
order B
B
RL3
, B
RL1
and B
RL2
, B
and B
RL2
order.
RL1
and deactivates them, according to the system needs, in the
RL3
With rotation (P551=1) → the multipump control activates the auxiliary pumps
according to their operation times stored in P541, P542 and P543, in order to equalize
these times.
P552 – Pressure Sensor Scale
Adjustable
0.00 to 300.0 Unit: - Default: 10.00
Range:
Description:
It adjusts the pressure sensor full scale. This value is also used as the full scale for the
parameters linked to the system pressure.
P553 – Setpoint 2 via Digital Input
Adjustable
0.00 to P552 Unit: - Default: 3.00
Range:
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P554 – Setpoint 3 via Digital Input
Adjustable
0.00 to P552 Unit: - Default: 4.00
Range:
P555 – Setpoint 4 via Digital Input
Adjustable
0.00 to P552 Unit: - Default: 5.00
Range:
Description:
The PID regulator setpoint can be selected via digital inputs (DIx) in a similar way to the
Multispeed function. The parameters P525, P553, P554 and P555 define the four possible
setpoint values for the selection via digital inputs. Once the setpoint via DIx is active, the
PID regulator assumes this value regardless of the local or remote reference programmed
in the inverter. Refer to the table 7.1.
Table 7.1: Setpoint via DIx combinations
DI3 (SP1) DI4 (SP0) Setpoint
Off Off P525
Off On P553
On Off P554
On On P555
P556 – Operation Time Reset
Adjustable
Range:
0 = Without reset
1 = B
2 = B
3 = B
4 = CFW-08 operation time
pump time reset
RL1
pump time reset
RL2
pump time reset
RL3
Unit: - Default: 0
reset
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Description:
It allows the operation time reset of every pump of the system.
7.1.3. Multipump System Writing Parameters – Fault Configuration
P560 – Pressure Sensor Signal Failure (E52)
Adjustable
Range:
Description:
It enables the monitoring of the pressure sensor 4 to 20 mA signal. If the sensor current is
less or equal to 2 mA, the inverter disables all the pumps and indicates E52.
0 = Disables the function
1 = Enables the function
Unit: - Default: 0
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P561 – Minimum Output Pressure (E54)
Adjustable
Range:
P562 – Maximum Output Pressure (E54)
Adjustable
Range:
P563 – Time for Output Pressure Failure (E54)
Adjustable
Range:
Description:
When the output pressure is below P561, the inverter output frequency is higher than
P580 and all the auxiliary pumps enabled via the DIx are running, in this case, once
the condition is kept during the interval programmed in P563, the inverter is disabled
indicating E54 and it switches off all the pumps. On the other hand, when the output
pressure is above P562, the inverter output frequency is lower than P575 and all the
enabled pumps are switched off, the inverter will be switched off indicating E54 if this
condition is kept during the P563 interval. In this way, the E54 error is able to detect
breaking or obstruction in the pipes.
7.1.4. Multipump System Writing Parameters – Rotation Configuration
0.00 to P552 Unit: - Default: 0.0
0.00 to P552 Unit: - Default: 10.00
0.0 to 999
0.0 = Disables the
function
Unit: s Default: 0.0
P565 – Number of Pumps Activated for Performing Rotation
Adjustable
Range:
P566 – Rotation Interval
Adjustable
Range:
P567 – Rotation Frequency
Adjustable
Range:
0 to P550
0 = Disabled
rotation
0.0 to 3000 Unit: x10h Default: 7.2
0.0 = Test (every 60 s)
0.00 to P134 Unit: Hz Default: 50.00
Unit: - Default: 0
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Description:
The parameters P565, P566 and P567 only have functions in the Multipump Floating
Control (P203=3), because they define the conditions for the rotation of the pump
connected to the frequency inverter.
By definition, rotation is the change of the pump controlled by the frequency inverter by
another available on the system. The criteria for the connection of the other pump also
takes into account the operation time in P541, P542 and P543, in order to equalize
these times when P551=1.
The rotation occurs naturally while the inverter is disabled or in the sleep mode. If these
events do not occur before the P566 interval, then the inverter performs the commutation
switching all the pumps off and starting the system again. In order that this commutation
event occurs, it is necessary that the number of running pumps be less or equal to P565,
and output frequency of pump controlled less to P567. In this way the user defines the
system operation criteria for the rotation event execution by means of the P566 timing.
7.1.5. Multipump System Writing Parameters – Sleep Mode Configuration
P570 – Sleep Mode Activation Frequency
16
Adjustable
Range:
0.00 to P134
0.00 = Disables sleep
Unit: Hz Default: 30.00
function
Description:
It is the frequency value that starts the P571 timing, in order to activate the sleep mode.
P571 – Sleep Mode Activation Time
Adjustable
0.0 to 999 Unit: s Default: 10.00
Range:
Description:
If no auxiliary pump is on and the output frequency is lower than P570, and keeping this
condition for a minimum interval given by P571, the inverter enters the sleep mode by
deactivating the PWM pulses at the output and indicating “Srdy” on the display. The sleep
function can be deactivated adjusting P570 in 0.00 Hz. Refer to the figure 7.1.
P572 – Wake up Pressure Deviation
Adjustable
0 to P552 Unit: - Default: 0.20
Range:
P573 – Wake up Time
Adjustable
0.0 to 999 Unit: s Default: 0.0
Range:
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Description:
The parameter P572 defines the pressure value above or below the setpoint, depending on
the PID action set in P527, where the inverter leaves the sleep mode and restarts controlling
the system again after the P573 interval, as illustrated in the figure 7.1 for P573=0.0 s. This
pressure limit determined by P572 will be below the setpoint if the PID controller action is
direct (P527=0) or above the setpoint if the action is reverse (P527=1).
Figure 7.1: Example of the Sleep Mode behavior
7.1.6. Multipump System Writing Parameters – Pump Starting Configuration
P575 – Auxiliary Pump Starting Frequency
Adjustable
Range:
Description:
It defines the frequency above which the inverter will be able to start an auxiliary pump
in order to increase the system pressure.
P576 – Auxiliary Pump Starting Pressure Deviation
Adjustable
Range:
Description:
It defines the pressure deviation regarding to the setpoint, at which the inverter will be able
to start an auxiliary pump in order to increase the system pressure. This pressure deviation
will be below the setpoint if the PID controller action is direct (P527=0) or above the setpoint
if the action is reverse (P527=1).
P133 to P134 Unit: Hz Default: 49.00
0.0 a P552 Unit: - Default: 0.20
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P577 – Auxiliary Pump Starting Time
Adjustable
Range:
Description:
An auxiliary pump is started in the system if the P575 and P576 conditions remain during
the time window defined in P577. If there is more than one auxiliary pump available and
the pump rotation is active through P551, the inverter will activate the one with the shortest
operation time among P541, P542 and P543.
P578 – Auxiliary Pump Starting Transition Delay
Adjustable
Range:
Description:
The parameter P578 has the purpose of reducing the pressure transient when an auxiliary
pump is activated, reducing the output frequency to the value of the Auxiliary Pump
Stopping Frequency – P580. Thus, if P578 is properly adjusted the impact of starting an
auxiliary pump is minimized. Besides this, in some auxiliary starter types, as Soft-Starters
and star-delta, the moment of the reduction must be controlled. At the transition moment
the PID regulator output is ignored and the inverter follows the second ramp (P103) until
the output frequency reaches P580. After this, the PID regulator retakes the control of the
inverter output frequency normally.
7.1.7. Multipump System Writing Parameters – Pump Stopping
Configuration
0.0 to 999 Unit: s Default: 3.0
0.0 to 100.0
100.0 = without
transition
Unit: s Default: 100.0
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P580 – Auxiliary Pump Stopping Frequency
Adjustable
Range:
Description:
It defines the frequency below which the inverter will be able to stop an auxiliary pump in
order to reduce the system pressure.
P581 – Auxiliary Pump Stopping Pressure Deviation
Adjustable
Range:
Description:
It defines the pressure deviation regarding to the setpoint, at which the inverter will be
able to stop an auxiliary pump in order to decrease the system pressure. This pressure
deviation will be above the setpoint if the PID controller action is direct (P527=0) or below
the setpoint if the action is reverse (P527=1).
P133 to P134 Unit: Hz Default: 30.00
0.00 to P552 Unit: - Default: 0.00
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P582 – Auxiliary Pump Stopping Time
Adjustable
0.0 to 999 Unit: s Default: 3.0
Range:
Description:
An auxiliary pump is stopped in the system if the P580 and P581 conditions remain during
the time window defined in P582. If there is more than one auxiliary pump available and the
pump rotation is active through P551, the inverter will deactivate the one with the longest
operation time among P541, P542 and P543.
P583 – Auxiliary Pump Stopping Transition Delay
Adjustable
Range:
0.0 a 100,0
100.0 = without
Unit: s Default: 100.0
transition
Description:
The parameter P583 has the purpose of reducing the pressure transient when an auxiliary
pump is deactivated, increasing the output frequency to the value of the Auxiliary Pump
Starting Frequency – P575. Thus, the impact of stopping an auxiliary pump is minimized
if P583 is properly adjusted. Besides this, in some auxiliary starter types, as Soft-Starters
and star-delta, the moment of the reduction must be controlled. At the transition moment
the PID regulator output is ignored and the inverter follows the second ramp (P102) until
the output frequency reaches P575. After this, the PID regulator retakes the control of the
inverter output frequency normally.
The figure 7.2 presents an example of auxiliary pump commutation using the Multipump
Fixed Control with three auxiliary pumps, so that the active B
after some time the B
the others. The description of the figure 7.2 steps is listed next.
pump is activated, because it has an operation time shorter than
RL3
pump is deactivated, and
RL1
T0-T1 interval: Normal operation without any timing, only the PID regulator is acting in
the system, and the pressure is increasing while the frequency is going down. At the T1
instant the frequency and pressure values trigger the P582 timer;
T1-T2 interval: P577 timing, at T2 the inverter begins the frequency reduction;
T2-T3 interval: The inverter decelerates with the 2nd ramp down to P580 without delay
(P578=100.0);
T3-T4 interval: The PID regulator retakes the control of the output frequency which
stabilizes at T4;
T4-T5 interval: Normal operation without any timing, only the PID regulator is acting
in the system;
T5-T6 interval: The pressure goes up and the frequency goes down;
T6-T7 interval: At T7 the P582 timing switches off the B
T7-T8 interval: The inverter accelerates with the 2nd ramp up to P575 without delay
pump;
RL1
(P583 = 100.0);
T8-T9 interval: The PID regulator retakes the control of the output frequency which
stabilizes at T9.
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Figure 7.2.: Commutation example for the multipump control
7.2. ECC4 Control Board Connections
The ECC4 control board for the CFW-08 multipump is similar to the ECC3 of the standard
CFW-08, however, instead of two relay outputs it has three relay outputs, and all of them are
NO (Normally Open) with a common point at terminal XC1:11. The third relay output is located
at the terminal XC1:9 in the place of the former analog output. Therefore, all the functions
related to this output are disabled. The figure 7.3 presents the control connections (analog and
digital inputs and outputs) made at the ECC4 control board terminal strip XC1, considering
a multipump system with three auxiliary pumps, factory default programming, two-wire (4 to
20) mA sensor, and using the KDC-24V-CFW08 (24 V/100 mA supply) accessory.
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XC1 terminal strip ECC4 – Default functions for the Multipump System
Sensor
4..20mA
+
-
Comando
Bomba 2
Comando
Bomba 3
Fase rede
Comando
Comando
Bomba 1
1 DI1 Digital input 1: CFW-08 inverter enabling (start-stop)
2 DI2 Digital input 2: B
3 DI3 Digital input 3: B
4 DI4 Digital input 4: B
pump enabling
RL1
pump enabling
RL2
pump enabling
RL3
5 GND 0 V Reference
4...20mA
Sensor
6 AI1
Analog input 1 (4-20 mA): System pressure feedback for the
PID control
7 +10V +10 Vdc Reference for potentiometer
Pump 3
Command
Pump 2
Command
Command
voltage
Pump 1
Command
8 AI2 Analog input 2: Digital input DI6 (no function)
9 RL3 Relay output 3: B
10 RL2 Relay output 2: B
pump activation
RL3
pump activation
RL2
11 COM Common point for the relay outputs
12 RL1 Relay output 1: B
pump activation
RL1
XC16 terminal strip KDC-24V-CFW08 Accessory
0V GND 24Vdc power supply 0 V reference
24V +24 Vdc 24Vdc power supply output
Figure 7.3: Connections at the CFW-08 Multipump control board
NOTE!
In order to enable 4-20 mA current reading at the analog input 1, select the S1.3 switch
in ON. Refer to the CFW-08 frequency inverter manual for more information.
7.3. Modified Parameters at the CFW-08 Multipump
In order to facilitate the inverter parameterization some parameters suffered modification in
their factory default values, regarding the user manual. The table in the section 11.1 presents
the parameters that suffered modification in the factory default.
In the Multipump CFW-08 the parameters P525 and P040 indicate their values in the
pressure sensor scale, P552, instead of the percentage value indicated in the standard CFW-08
user manual.
Some parameters received new functions, which are not described in the user manual, in
the Multipump inverter software, according to the section 11.2 table.
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The digital input function “B
command according to the schematics of sections 10.2 and 10.4. If a B
have a digital input programmed for its command, the controls assumes that this pump will
Pump Enable” configures the referred DIx for the Multipump
RLX
pump does not
RLX
always be enabled for the multipump command.
The “SP1 Setpoint” function configures the DI3 for selecting the setpoint via DIx, according
to the section 7.1.
The “SP0 Setpoint” function configures the DI4 for selecting the setpoint via DIx, according
to the section 7.1.
Parameters P277 and P279 received the new option 4 that configures the relay output
RLx for the Multipump control.
8. MULTIPUMP CONTROL CONFIGURATION TUTORIAL
A multipump control configuration sequence, with tips and examples, for applying the
Multipump CFW-08 inverter in pumping systems, starting from the factory default, is showed
in the next items.
Step 1 – Factory Default Configuration
The factory default is the starting point for this tutorial. The default values are loaded by
setting P204=5. The factory default values are presented in the quick parameter reference
tables of this guide and of the user manual.
The multipump factory default presents the following configurations:
Local and remote commands via terminals (DI1 = start/stop, DI2 = B
DI3 = B
Local and remote reference via keypad (PID setpoint via P525 = 2.00);
Pump Enable, DI4 = B
RL2
Pump Enable);
RL3
Pump Enable,
RL1
Multipump Floating Control for the operation of three pumps;
Pump rotation enabled for every 72 hours;
0 to 10.00 bar/4 to 20 mA pressure sensor;
Inactive faults (E52 and E54).
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Step 2 – Multipump Control Type
Adjust P203 in 2 or 3 for fixed control or floating control, respectively. Refer to the sections
6 and 7.
Step 3 – Analog Input Configuration
Verify the used pressure sensor specification and configure the parameter P235 accordingly,
as well as the S1.3 switch on the ECC4 control board. Refer to the Chapter 3 – Installation,
on the user manual.
Observe the pressure sensor connection to the CFW-08 terminal strip XC1. The figure
7.3 shows the connection of a two-wire sensor using the optional 24 V power supply. These
connections are identical in the case of an external 24 V power supply.
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Step 4 – General Configuration of the Multipump Control
Set the number of pumps in P550, for the fixed control (P203=2) this number refers to the
number of auxiliary pumps. However, in the case of floating control (P203=3) this number
is equal to the total of pumps.
The pressure sensor scale can be adjusted in P552, from 0.00 to 300.0. This scale is used
for the analog inputs and other parameters related to the output pressure. Therefore, the user
is free to choose the pressure unit system that better suits the application.
If necessary, the pressure setpoint can be forced to a value pre-defined in P553, P554 or
P555. This function may be useful in systems were the operation pressure must be changed
frequently.
Step 5 – Fault Configuration
The factory default parameterization disables the Multipump fault indications. The fault
indications may be activated after the multipump control is operating in a satisfactory manner.
Leave the fault settings for the end of the configuration.
The faults implemented in the CFW-08 Multipump are expressed by the E52 and E54
errors, and they can diagnose the following faults:
Fault in the pressure sensor (4 to 20 mA);
Input and output pipe break;
The absence of liquid in the pipes.
Step 6 – Sleep Mode Configuration
The multipump characteristic of adapting itself to the system consumption makes it possible
that during zero consumption periods the inverter disables the pulses, entering the “sleep” mode
(Srdy). When the consumption is no longer null, the inverter works normally again (awakes).
This allows significant energy savings in systems with large load variation.
The sleep function is activated when the conditions defined by the parameters P570 to
P573 are fulfilled and all the pumps are off.
Step 7 – Auxiliary Pump Activation Configuration
Set the parameter P575 for a frequency slightly below the nominal frequency of the driven
motors. The P576 value must be adjusted between 2% and 5% of the value defined as the
setpoint, allowing main pump operation up to the nominal frequency, at the expense of a
small deviation in the output pressure (P576) regarding the setpoint.
The auxiliary pump starting time defines the desired rapidity in taking actions with auxiliary
pumps; however, a too low value of P577 may result in excessive activations of auxiliary
pumps.
The P578 transition delay is more effective in the cases where the auxiliary pumps are
activated by starters with transport delay, which is the case of Soft-Starters and star-delta
starters.
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Step 8 – Auxiliary Pump Deactivation Configuration
Depending on the pump constructive form, there is a minimum frequency below which
the pump does not produce mechanical work. P580 value must be slightly above this point
so that the controller switches off an auxiliary pump allowing thus the main pump to operate
above this undesired operation point.
Set P580 initially at 50% of the motor nominal frequency, and after observing the system
response, find out the optimal point for switching off an auxiliary pump when the controlled
pump is no longer influencing the output pressure. Note that this point varies with the output
pressure; therefore, by changing the setpoint a new adjustment may be necessary.
The parameters P581, P582 and P583 have functions similar to those of P576, P577 and
P578, however, applied to the deactivation.
Step 9 – PID Regulator Configuration
In pumping system controls, a PI regulator is enough to produce a good performance
control. The proportional “KP” (P520) and the integral “KI” (P521) gains must be changed if
the controller response is not satisfactory, i.e., if there are oscillations around the setpoint value
in the output pressure, if the response time is too slow, or if there is a constant error regarding
the setpoint. For the majority of the multipump applications the factory default values should
suffice for a good PID regulator response.
Below are some suggestions for adjusting the regulator:
a) Oscillation in the output pressure – In the majority of the cases this is caused by excessive
gains in the PID controller. Reduce the KP and KI gains gradually and observe the
response;
b) Too low response time – By increasing the KP gain the system must respond faster, however,
above a certain limit the system may present overshoots.
c) Constant error at the output – In this case, by increasing the KI gain the error at the output,
i.e., when the output is not able to match the setpoint, is eliminated. An excessive KI gain
may generate output oscillations; in such case reduce the KP gain in order to reduce the
total gains keeping the KI gain value.
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9. ERRORS AND POSSIBLE CAUSES
The table 9.1 presents the error codes generated by the CFW-08 for the Multipump
control, the other error codes are presented in the user manual chapter 7 - Diagnostics and
Troubleshooting.
Table 9.1: Errors generated by the CFW-08 multipump
MULTIPUMP CONTROL ERRORS
ERROR RESET POSSIBLE CAUSES CORRECTIVE ACTIONS
E52:
Pressure sensor
signal failure
E54:
Exceeded
pressure limit
Power-on;
HMI key;
Auto reset via DIx.
Power-on;
HMI Key;
Auto reset via DIx.
Interrupted pressure sensor
wire;
Analog input programming
error.
Pipe break;
Pressure sensor failure.
Refer to the item 3.2.5 – Control
Wiring, (selection switches) in the
user manual;
Verify P560, P235 and P239.
Verify P235, P561, P562 and
P563;
Verify the pipes and the pressure
sensor.
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10. MULTIPUMP CONTROL CONNECTION SCHEMATICS
10.1. Multipump Fixed Control Power Section Electrical Schematic
Figure 10.1: Multipump fixed control power section electrical schematic
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10.2. Multipump Fixed Control Command Connections
26
Figure 10.2: Multipump fixed control command connections
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10.3. Multipump Floating Control Power Section Electrical Schematic
Figure 10.3: Multipump floating control power section electrical schematic
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10.4. Multipump Floating Control Command Connections
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Figure 10.4: Multipump floating control command connections
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11. QUICK PARAMETER REFERENCE
11.1. Parameters with Changes in the Factory Default Values
Parameter Description Adjustable Range Unit Default
P101 Deceleration Time Ramp 1 0.1 to 999 s 5.0
P102 Acceleration Time Ramp 2 0.1 to 999 s 1.0
P103 Deceleration Time Ramp 2 0.1 to 999 s 1.0
P133 Minimum Frequency 0.0 to P134 Hz 20.0
P134 Maximum Frequency P133 to 300.0 Hz 50.0
P203 Special Function Selection 0 = No function
1 = PID Regulator
2 = Multipump Fixed Control
3 = Multipump Floating Control
P235 Analog Input AI1 Signal 0 = (0 to 10)V / (0 to 20)mA
1 = (4 to 20)mA
2 = DI5 PNP
3 = DI5 NPN
4 = DI5 TTL
5 = PTC
P239 Analog Input AI2 Signal 0 = (0 to 10)V / (0 to 20)mA
1 = (4 to 20)mA
2 = DI5 PNP
3 = DI5 NPN
4 = DI5 TTL
5 = PTC
P263 Digital Input DI1 Function 0 to 14 - 9
P264 Digital Input DI2 Function 0 to 14 - 11
P265 Digital Input DI3 Function 0 to 16 - 11
P266 Digital Input DI4 Function 0 to 16 - 11
P277 Relay Output RL1 Function 0 to 7 - 4
P279 Relay Output RL2 Function 0 to 7 - 4
P525 Setpoint via Keypad (Setpoint 1) 0.00 to P555 - 2.0
P536 Automatic Setting of P525 0 = Active
1= Inactive
- 3
- 1
- 3
- 1
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11.2. Parameters with New Functions
Parameter Description New Functions Default Value
P203 Special Function Selection 2 = Multipump Fixed Control
3
3 = Multipump Floating Control
P264 Digital Input DI2 Function
11 = B
P265 Digital Input DI3 Function 11 = B
12 = SP1 Setpoint (MSB)
P266 Digital Input DI4 Function 11 = B
12 = SP0 Setpoint (LSB)
P268 Digital Input DI6 Function 11 = B
12 = B
P277 Relay Output RL1 Function
P279 Relay Output RL2 Function
4 = B
4 = B
Pump Enable
RL1
Pump Enable
RL2
Pump Enable
RL3
Pump Enable
RL2
Pump Enable
RL3
Pump Command
RL1
Pump Command
RL2
11
11
11
14
4
4
11.3. Multipump System Parameters
Multipump Read-Only Parameters
Parameter Description Adjustable Range Unit Default Page
P540 System Pressure 0 a P552 - - 12
P541 B
P542 B
P543 B
P544 CFW-08 Operation Time 0.0 a 3000 (x10h) - 13
Parameter Description Adjustable Range Unit Default Page
P550 Number of Auxiliary Pumps 0 to 3 - 3 13
P551 Activation of the Auxiliary Pumps 0 = In a sequence
P552 Pressure Sensor Scale 0.00 to 300.0 - 10.00 13
P553 Setpoint 2 via Digital Input 0.00 to P552 - 3.00 13
P554 Setpoint 3 via Digital Input 0.00 to P552 - 4.00 14
P555 Setpoint 4 via Digital Input 0.00 to P552 - 5.00 14
P556 Operation Time Reset 0 = Without reset
Parameter Description Adjustable Range Unit Default Page
P560 Pressure Sensor Signal Failure
P561 Minimum Output Pressure (E54) 0.00 to P552 - 0.00 15
P562 Maximum Output Pressure (E54) 0.00 to P552 - 10.00 15
P563 Time for Output Pressure Failure
Pump Operation Time 0.0 a 3000 (x10h) - 12
RL1
Pump Operation Time 0.0 a 3000 (x10h) - 12
RL2
Pump Operation Time 0.0 a 3000 (x10h) - 12
RL3
Multipump System Writing Parameters – General Configuration
- 1 13
1 = With rotation
- 0 14
1 = B
Pump time reset
RL1
2 = B
Pump time reset
RL2
3 = B
Pump time reset
RL3
4 = CFW-08 operation
time reset
Multipump System Writing Parameters – Fault Configuration
(E52)
(E54)
0 = Disables the function
1 = Enables the Function
0.0 to 999
0.0 = Disables the function
- 0 14
s 0.0 15
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Multipump System Writing Parameters – Rotation Configuration
(1)
Parameter Description Adjustable Range Unit Default Page
P565 Number of Pumps Activated for
Performing Rotation
P566 Rotation Interval 0.0 to 3000
0 to P550
0 = Disabled rotation
- 0 15
(x10h) 7.2 15
0.0 = Test (every 60 s)
P567 Rotation Frequency 0.00 to P134 Hz 50.00 15
Multipump System Writing Parameters – Sleep Mode Configuration
Parameter Description Adjustable Range Unit Default Page
P570 Sleep Mode Activation Frequency 0.00 to P134
Hz 30.00 16
0.00 = Disables Sleep
Mode Function
P571 Sleep Mode Activation Time 0.0 to 999 s 10.0 16
P572 Wake up Pressure Deviation 0.00 to P552 - 0.20 16
P573 Wake up Time 0.0 a 999 s 0.0 16
Multipump System Writing Parameters – Pump Starting Configuration
Parameter Description Adjustable Range Unit Default Page
P575 Auxiliary Pump Starting
P133 to P134 Hz 49.00 17
Frequency
P576 Auxiliary Pump Starting Pressure
0.00 to P552 - 0.20 17
Deviation
P577 Auxiliary Pump Starting Time 0.0 to 999 s 3.0 18
P578 Auxiliary Pump Starting Transition
Delay
0.0 to 100.0
100.0 = without transition
s 100.0 18
Multipump System Writing Parameters – Pump Stopping Configuration
Parameter Description Adjustable Range Unit Default Page
P580 Auxiliary Pump Stopping
P133 to P134
Hz 30.00 18
Frequency
P581 Auxiliary Pump Stopping Pressure
0.00 to P552
- 0.00 18
Deviation
P582 Auxiliary Pump Stopping Time
P583 Auxiliary Pump Stopping
Transition Delay
0.0 to 999
0.0 a 100.0
100.0 = without transition
s 3.0 19
s 100.0 19
(1) Valid only for Floating Control.
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