Multipump
System CFW-08
Software Version V5.0X
Language: English
Document: 0899.5547 / 02
Installation, Conguration and Operation Guide
CFW-08 Frequency Inverter
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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