KSB PumpDrive Installation & Operating Manual Download

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Self-cooling Motor-independent Frequency

Inverter

PumpDrive

Installation/Operating Manual

Summary of Contents for PumpDrive

Page 1: ...Self cooling Motor independent Frequency Inverter PumpDrive Installation Operating Manual...

Page 2: ...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...

Page 3: ...ation work 8 2 9 Unauthorised modes of operation 9 2 10 Software Changes 9 2 11 Electromagnetic compatibility 9 3 Transport Temporary Storage Disposal 10 3 1 Checking the condition upon delivery 10 3...

Page 4: ...98 8 2 Maintenance inspection 98 8 3 Dismantling 98 9 Wiring diagrams 99 9 1 Open loop control mode 99 9 2 Closed loop control mode 100 9 3 Multiple pump configuration 101 10 Parameter lists 104 10 1...

Page 5: ...external communication Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional components and accessories PWM Type of modulation...

Page 6: ...technical personnel 1 3 Other applicable documents Table 1 Overview of other applicable documents Document Contents Operating manual Description of proper and safe use of the pump in all phases of op...

Page 7: ...installation operating and maintenance instructions that must be observed to ensure that the product is operated safely as well as to prevent injury and damage to property The safety information in a...

Page 8: ...nd safety regulations Explosion protection regulations Safety regulations for handling hazardous substances Applicable standards and legislation e g EN 50110 1 2 7 Safety information for the user oper...

Page 9: ...ria and methods required to comply with the EMC Directive Table 4 Interference emission Drive kW Interference emission Conducted Radiated 7 5 Unrestricted distribution Limits to EN 55011 class B Restr...

Page 10: ...e 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 Gi...

Page 11: ...Fig 2 Transporting a horizontal pump set Fig 3 Transporting a vertical pump set 3 Transport Temporary Storage Disposal PumpDrive 11 of 162...

Page 12: ...ions 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 hum...

Page 13: ...304lJM0000Z 0105000180 17 4 A 7 5 KW INPUT 3007K50 BH0000 1 2 3 4 Fig 4 Name plate example 1 Enclosure 2 Type series size 3 Ident number 4 Serial number 4 4 Functions Table 7 Functions Functions Desig...

Page 14: ...al8 LON field bus system Optional8 Optional8 Modbus field bus system Accessories6 Accessories6 RS 232 service interface Table 8 Functions Functions Design Basic Advanced S Protective functions Thermal...

Page 15: ...s field bus system Optional8 Optional8 Optional8 LON field bus system Optional8 Optional8 Accessories6 Modbus field bus system Accessories6 Accessories6 Accessories6 RS 232 service interface 4 5 Techn...

Page 16: ...e analog inputs 2 Voltage input 0 2 10 V DC Ri 22 k Current input 0 4 20 mA DC Ri 500 Resolution 10 Bit Analog outputs Number of parameterisable analog outputs 1 toggling 4 output values Voltage outpu...

Page 17: ...power ranges specified apply in full to all mounting options Table 10 Power range for 2 and 4 pole motors or nominal speeds of 1500 rpm and 3000 rpm Size Power kW Maximum nominal motor current A 22 A...

Page 18: ...0 1 5 002K20 2 2 9 003K00 3 B 004K00 4 325 250 170 65 224 307 377 250 180 65 224 357 M6x9 4x 10 005K50 5 5 10 5 007K50 7 5 C 011K00 11 420 320 235 125 283 396 482 320 245 125 283 458 M8x9 4x 23 015K00...

Page 19: ...ns specified in the following table must be observed Table 12 Ambient conditions Operating temperature Temperature C Without power derating 0 C to 40 C With power derating 0 C to 50 C The service life...

Page 20: ...fety regulations DANGER Incorrect electrical installation Danger of death from electric shock Electrical connection to be made by a qualified electrician only Observe the technical connection requirem...

Page 21: ...ctors such as for example the type of connection the ambient conditions and the type of system Power connection cables must be used in accordance with their intended use and the manufacturer specifica...

Page 22: ...5 39 0 41 0 022K00 22 45 0 47 3 D 030K00 30 65 0 M40 M16 M40 M16 68 3 35 037K00 37 80 0 84 0 045K00 45 93 0 97 7 Length of motor connection cable If PumpDrive is not mounted on the motor to be contro...

Page 23: ...ay 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 Separate motor protection i...

Page 24: ...istance 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...

Page 25: ...omprises a V shaped cover for the power and motor connection cable connections and an L shaped cover for the control cable connection 1 Remove the cross recessed head screws on the C shaped cover 2 Re...

Page 26: ...1 Route the mains or motor connection cables through the cable glands and connect to the specified terminals 2 Connect the line for a PTC connection PTC thermistor to terminal strips 5 6 If the sensor...

Page 27: ...ury due to electric shock De energise PumpDrive before opening the housing or when working on the terminals of the inputs and outputs Fig 9 Establishing the power supply and motor connections sizes A...

Page 28: ...erminal block Braking resistor P3 terminal block Sensor connection P5 terminal block PTC connection P5 terminal block Motor connection P4 terminal block Motor PTC Connect the cores for a PTC connectio...

Page 29: ...cable entry for transport Ferrites are separated before cable entry 1 Position the ferrite cores around the power cable near the PumpDrive terminals and close them by pressing the upper and lower par...

Page 30: ...5 4 3 4 Establishing an earth connection PumpDrive must be earthed Observe the following when establishing the earth connection Ensure that the cable lengths are as short as possible Use different ear...

Page 31: ...cting the field bus module To ensure radio frequency shielding use shielded cables for LON and Profibus and install these in accordance with EMC requirements Use cable type 0 5 mm AWG 24 e g G Y st Y...

Page 32: ...24V NO2 COM2 NO1 COM1 10 9 3 1 2 4 5 6 7 8 P4 P7 P8 P5 P9 P6 Fig 17 Control terminals P4 P4 terminal strip P5 Service interface RS232 P6 LED traffic light function P7 P7 terminal strip P8 Field bus mo...

Page 33: ...4 V DC voltage source to a digital input Terminal strip P4 terminals 11 and 12 PumpDrive is equipped with an analog output whose output value can be parameterised via the control panel Analog signals...

Page 34: ...do not assign the input on terminal strip P7 6 5 4 3 7 Connecting the control panel DANGER Improper handling Damage to PumpDrive Only connect or remove the control panel when it is de energised CAUTIO...

Page 35: ...phical control panel and tighten the fastening screws by applying 0 5 Nm of torque Changing the installation position of the control panel Table 21 Possible installation positions for the control pane...

Page 36: ...que to ensure compliance with IP 55 enclosure protection requirements 1 Position the V shaped cover while ensuring that the gasket is seated correctly 2 Tighten the cross head screws of the cover by a...

Page 37: ...etpoint and actual value via LEDs 3 Navigation keys Setpoint specification 4 Operating keys Toggling operating modes 5 Service interface PumpDrive configuration and parameterisation via PC notebook 6...

Page 38: ...have the following meaning The maximum motor frequency e g 50 Hz 100 has been reached The full scale value of the sensor e g 6 bar 100 has been reached The setpoint specified in open loop control mode...

Page 39: ...ssure compensation function is activated when this key is pressed When the OK key is pressed the percentage of the setpoint compensation of the dynamic pressure compensation function is displayed in t...

Page 40: ...the Func parameterisable function key Display of the dynamic pressure setpoint compensation function is deactivated 6 2 Graphical control panel 1 2 4 3 5 6 Fig 22 Graphical control panel Table 30 Desc...

Page 41: ...Sprache LCD Beleuchtung Leuchtdauer 1 2 3 4 5 6 Fig 23 Graphical display example Table 32 Description of display Item Description Explanation 1 Parameter No Displays the selected parameter No 2 Main...

Page 42: ...K key Confirm settings Confirm menu selection Move to the next digit when entering numerals Alert reset Help key Displays a help text for each selected menu option 6 2 4 Operating keys Table 34 Assign...

Page 43: ...unauthorised intervention in the operating mode of PumpDrive Table 36 Parameters for setting the operating key functions Parameter Description Possible settings Factory setting 3 1 4 1 Enable disable...

Page 44: ...ow keys 3 Press OK 4 Select the operating parameter required from the list of possible operating parameters 5 Press OK to confirm As soon as a parameter is defined the relevant parameter is displayed...

Page 45: ...he amber or red LED A flashing message is output in the last line of the control panel display If more than one message is output the last one is displayed Alerts have priority over warnings To displa...

Page 46: ...talian Table 41 Language parameters Parameter Description Possible settings Access Factory setting 3 1 1 1 Display language German French English Italian Customer English 6 2 5 3 2 Access levels Four...

Page 47: ...meter 3 3 2 5 Nominal Speed 1 First digit of parameter number 3 3 2 5 Press the Settings menu key 3 1 appears in the top left of the screen 2 Second digit of parameter number 3 3 2 5 Press the arrow k...

Page 48: ...ion are listed here 6 3 Service interface CAUTION Improper use of service interface Damage to connected laptop PC Only use the connection cable approved by KSB USB RS232 The service interface allows a...

Page 49: ...operation 7 1 1 1 Setting motor parameters Motor mounted PumpDrive model The motor parameters have been set at the factory Cabinet mounted or wall mounted PumpDrive model The factory set motor paramet...

Page 50: ...oint below 50 is specified PumpDrive always operates at its minimum frequency of 25 Hz 50 Table 46 Units for setpoint specification Parameter Description Unit 3 2 2 1 Setpoint unit Selection list III...

Page 51: ...9 Page 99 GND DI6 DI5 DI4 DI3 DI2 DI1 24V AGND AN OUT 20 19 18 17 16 15 14 13 12 11 1 AGND AIN1 GND AIN2 24V NO2 C OM2 NO1 C OM1 10 9 3 1 2 4 5 6 7 8 P4 P7 2 0V S ignal 3 4 Fig 25 Terminal wiring diag...

Page 52: ...ltage Current 3 8 2 2 Analog IN 1 Low voltage 0 0 3 8 2 3 Analog IN 1 High voltage 10 10 3 8 2 6 Unit of Analog IN 1 3 8 2 7 Low value for Analog IN 1 0 0 3 8 2 8 High value for Analog IN 1 100 100 3...

Page 53: ...ital inputs are used for this purpose Table 52 Parameters for open loop control mode via digital potentiometer function Parameter Description Settings Input 3 7 1 4 Function of Digital IN 4 Preset Set...

Page 54: ...ve has been set at the factory so that it will automatically recognise a sensor connected to analog input 2 and will then automatically activate closed loop control mode in the following cases A senso...

Page 55: ...Table 54 Closed loop control mode Function Input connection Specification Setting range parameter value Setpoint specification P7 terminal strip Analog input 1 P7 9 10 5 10 V DC 25 50 Hz Graphical con...

Page 56: ...ted PumpDrive detects it as a sensor signal and following a restart system reboot automatically PI Auto 3 9 1 6 Activated switches to closed loop control mode PI Mode 3 9 1 1 Enabled without the need...

Page 57: ...he PI Process Type parameter 3 9 1 5 is defaulted to Variable Pressure at the factory If a different controller type is required change the selection to suit requirements The Variable Pressure process...

Page 58: ...on and response speed of the closed control loop can be optimised using the PI Prop Gain 3 9 1 2 and PI Integral Tm 3 9 1 3 parameters When beginning to optimise the controller the values for PI Prop...

Page 59: ...alue Setpoint 3 9 1 3 Value too large 3 9 1 3 Value optimal 3 9 1 3 Value too small Time Point in time at which a sudden change in setpoint occurs dashed line Fig 36 Setting the integral term 7 1 1 4...

Page 60: ...1 terminal P7 9 AIN1 and 10 AGND P7 is set as the setpoint source 3 5 4 1 A direct voltage of 0 to 10 V 0 to 100 is expected as the signal If a current signal e g 4 20 mA 0 100 is to be used the Al 1...

Page 61: ...parameter 3 5 4 3 has already been set to Remote Setpoint for this purpose However the bus module needs to be enabled after installation by using the Field Bus parameter 3 2 1 5 so that the setpoint c...

Page 62: ...lel in a multiple pump configuration The defined master PumpDrive Advanced controls the slave PumpDrives PumpDrive Basic to ensure that they are utilised optimally If the master fails or malfunctions...

Page 63: ...f all PumpDrives have to be connected to a 24 V supply Digital input 1 Enables the respective PumpDrive If digital input 1 is not connected to 24 V the relevant PumpDrive in a multiple pump configurat...

Page 64: ...alue has to be entered for each further PumpDrive This also applies to PumpDrives used as slaves 3 1 7 4 Backup Guard Tm Time value for identifying the PumpDrive as the active master control panel 1 0...

Page 65: ...the main pump set after voltage has been applied simultaneously The lowest time value set activates the respective PumpDrive as the main pump drive This time value has to be set on Pump 1 The remaini...

Page 66: ...type the parameters for the speed and power may have to be adapted in order to achieve optimal starting and stopping in the system The Tm Cons Add Pum 3 12 5 3 and Tm Stop Pump 3 12 5 4 parameters al...

Page 67: ...main pump an auxiliary main pump and a slave pump The PumpDrives used are equipped as follows Table 62 Multiple pump configuration example PumpDrive Role Control panel 1 Main pump with active master...

Page 68: ...ters must be set as described in Section 7 1 1 4 Page 54 In particular the PI Mode parameter 3 9 1 1 must be set to Enabled In a multiple pump configuration the settings for closed loop control mode h...

Page 69: ...In multiple pump configurations the PumpDrives must be connected via an internal KSB local bus The active master control panel then controls all other connected PumpDrives via the KSB local bus The ma...

Page 70: ...ND SB1 SB1 SB1Z SB1Z Sensor 4 20mA AGND AIN1 GND AIN2 24V NO2 COM2 NO1 COM1 10 9 3 1 2 4 5 6 7 8 Sensor 4 20mA AGND AIN1 GND AIN2 24V NO2 COM2 NO1 COM1 10 9 3 1 2 4 5 6 7 8 P4 P4 P4 P4 P4 P4 P7 P7 P7...

Page 71: ...iple pump operation Digital input 6 P4 19 24 V for switching PumpDrive to multiple pump operation Establishing a sensor connection If a sensor with a 4 20 mA signal is used a 500 ohm resistor must be...

Page 72: ...re sensor 7 2 Application functions 7 2 1 PumpDrive protective functions If the Advanced control panel fails the Advanced protective functions can no longer be ensured The Advanced protective function...

Page 73: ...999 A Depending on the size 7 2 1 4 Current limitation If the current limit value defined in the MotMod Curr Lim parameter 3 6 1 4 is exceeded PumpDrive reduces the speed until the limit value is no l...

Page 74: ...7 2 and then the lower limit to prevent resonant frequencies Lo Bypass Freq 3 3 7 1 have to be entered Table 72 Parameters for suppressing a frequency range Parameter Description Possible settings Re...

Page 75: ...e the function all the values in the load curve parameters 3 12 2 2 to 3 12 2 9 must be set to zero The Learn Time parameter 3 12 2 10 specifies for how long PumpDrive will record measured values per...

Page 76: ...raulic blockage 100 No reduction 0 100 85 3 12 4 8 Time delay for hydraulic blockage 0 1000 s 10 s 3 12 4 9 Load curve reduction for dry running 100 No reduction 0 100 70 3 12 4 10 Time delay for dry...

Page 77: ...t to match PumpDrive to the driven pump Refer to the pump product literature for the values to be set When using multistage pumps make sure that the power data set using parameters 3 12 3 21 to 3 12 3...

Page 78: ...ed by two methods Measured Via a flow rate sensor Estimated Based on the pump characteristic curve parameterised H Q or P Q For parameterising the pump characteristic curve flow rate estimation Sectio...

Page 79: ...Lim Low Flow Qopt Q Lim High Flow and Qmax for the driven pump Q Lim Low Flow must not be lower than Qmin and Q Lim High Flow must not be higher than Qmax Table 75 Parameters for characteristic curve...

Page 80: ...rate estimation is to be used in a multiple pump configuration make sure that the maximum number of pumps running simultaneously 3 12 5 1 is set properly to match requirements The following restricti...

Page 81: ...alog input 1 and the discharge side pressure sensor 0 2 5 bar 4 20 mA must be connected to analog input 2 The maximum flow rate as per the pump characteristic curve Q 100 Qmax is 24 5 m3 h Table 77 Pa...

Page 82: ...Hi Current 20 20 3 8 2 6 AN IN 1 unit m h 3 8 2 7 AN IN 1 Low 0 0 3 8 2 8 AN IN 1 High 30 0 3 8 2 11 AI 1 descriptor Q Process 3 8 3 11 AI 2 descriptor Process Process 3 12 1 1 Q measurement Measured...

Page 83: ...t every 15 min 2 10 s 60 s 5 min Monitoring of the motor current and output frequency Table 82 Parameters for monitoring the motor current and output frequency Parameter Description Possible settings...

Page 84: ...log IN 2 Unit 3 8 3 6 100 Table 84 Parameters for monitoring the setpoint and actual value Parameter Description Possible settings Factory setting 3 6 5 1 Lower limit Setpoint monitoring 0 to Maximum...

Page 85: ...th the signal of a pressure or differential pressure sensor and the current flow rate as reference input variables for the dynamic pressure setpoint compensation function The method used for determini...

Page 86: ...te Estimated 3 4 1 3 Calibration for Q measurement p 100 value Full scale value of pressure differential pressure sensor 3 4 2 1 Q compensation point As required by system conditions 3 4 2 2 Setpoint...

Page 87: ...p 100 value 0 9999 in physical unit of pressure 3 2 2 3 0 3 4 2 1 Q compensation point 0 100 0 3 4 2 2 Setpoint compensation 0 9999 in physical unit of setpoint 3 2 2 1 0 The parameters for setting t...

Page 88: ...Possible settings Factory setting 3 8 2 11 AI 2 descriptor Process Pressure P1 Pressure P2 Q Temperature Process 3 8 3 11 AI 2 descriptor Process The parameters must be set as follows Table 93 Paramet...

Page 89: ...2 descriptor Q 7 2 4 2 Stand by mode sleep mode NOTE In stand by sleep mode PumpDrive may start up without any warning if the actual pressure exceeds the defined hysteresis for closed loop control mod...

Page 90: ...Enable disable sleep mode Disabled Enabled Disabled 3 4 3 2 Difference between feedback and setpoint to start 0 9999 in physical unit of setpoint 3 2 2 1 0 3 4 3 3 Start delay sleep mode 0 1 60 s 1 s...

Page 91: ...ond as follows If none of the digital inputs configured for fixed speed is connected PumpDrive will control pump operation in line with the given process variables Once the digital inputs configured f...

Page 92: ...5 600 s 3 3 3 6 2 Defines together with 3 11 4 1 the gradient of ramp 1 Up 0 5 600 s 3 3 3 6 3 Defines together with 3 11 4 1 the gradient of ramp 1 Down 0 5 600 s 3 3 3 6 4 Defines together with 3 1...

Page 93: ...data point f2 0 100 3 3 2 3 40 3 3 1 6 Voltage data point V3 0 100 3 3 2 2 64 3 3 1 7 Frequency data point f3 0 100 3 3 2 3 80 3 3 1 8 Voltage data point V4 0 100 3 3 2 2 100 3 3 1 9 Frequency data po...

Page 94: ...configuration The functions of inputs 2 to 5 are user defined Table 101 Parameters for the digital inputs Parameter Description Possible settings Factory setting 3 7 1 2 Function of Digital IN 2 Sele...

Page 95: ...V to Analog IN 1 High voltage 3 8 2 3 0 3 8 2 3 Analog IN 1 High voltage Analog IN 1 Low voltage 3 8 2 2 to 10 V 10 3 8 2 4 Analog IN 1 Low current 0 to Analog IN 1 High current 3 8 2 5 mA 4 3 8 2 5 A...

Page 96: ...t the analog output Table 106 Parameters for analog output Parameter Description Possible settings Factory setting 3 8 4 1 Source 1 for Analog OUT 1 No None 2 Setpoint 10 V 100 3 Feedback 10 V 100 4 N...

Page 97: ...the operating parameter in accordance with source 1 is output The maximum switch over speed between the individual sources for the analog output is 100 ms 10 Hz Table 107 Analog output sources Bit 1 B...

Page 98: ...housing part from the heat sink Mind the capacitor discharge time After switching off PumpDrive wait five minutes until dangerous voltages have discharged NOTE All maintenance service and installatio...

Page 99: ...Analog input 2 Terminal box Terminal box Option Customer spec setpoint 0 10 V or 2 10 V 4 20 mA Option Option Option Option Repair switch Pump Pump ON OFF Fig 49 Connection example for open loop contr...

Page 100: ...nal box Option Repair switch Terminal box Option Customer spec setpoint 0 10 V or 2 10 V 4 20 mA Option Option Option Analog input 2 Sensor Fig 50 Connection example for closed loop control mode 9 Wir...

Page 101: ...tion Terminal box Option Repair switch Pump Option Option Customer spec setpoint 0 2 10 V or 4 20mA Analog input 2 Fig 51 Connection example for multiple pump operation PumpDrive 1 Master 9 Wiring dia...

Page 102: ...Terminal box Option Repair switch Pump Analog input 2 Fig 52 Connection example for multiple pump operation PumpDrive 2 AuxMaster 9 Wiring diagrams 102 of 162 PumpDrive...

Page 103: ...switch Pump Analog input 2 Fig 53 Connection example for multiple pump operation PumpDrive 4 Slave jumper 1 2 on terminal strip P4 only if slave without control panel CAN bus terminator 9 Wiring diag...

Page 104: ...ng Hours Display of operating hours 0 0 0 0 h All 1 1 1 3 kWh Counter Display of energy consumption 0 0 0 0 kWh All 1 1 1 4 No of Power ups Number of starts 0 0 0 0 All 1 1 1 5 Rst kWh Counter Reset e...

Page 105: ...nding unit 0 0 0 0 3 8 3 6 All 1 3 1 7 Pressure P1 Display of pressure P1 0 0 0 0 3 2 2 3 All 1 3 1 8 Pressure P2 Display of pressure P2 0 0 0 0 3 2 2 3 All 1 3 1 9 Q Unit Display of flow rate Q in co...

Page 106: ...Alarm Word Alert word 0 0 0 0 hex Customer 1 4 3 3 Warning Word Warning word 0 0 0 0 hex Customer 1 4 3 4 Status Word Status word 0 0 0 0 hex Customer 1 5 Pump Menu for pump 1 5 1 Flow Rate Meas Subme...

Page 107: ...al value of power of pump 6 0 0 0 0 kW All 1 5 3 Pump Status Submenu for displaying pump status 1 5 3 1 Status Pump 1 Display of status of pump 1 0 0 0 0 hex All 1 5 3 2 Status Pump 2 Display of statu...

Page 108: ...Display of high motor current 0 0 0 0 h All 2 4 1 5 Mot Current Lo Display of low motor current 0 0 0 0 h All 2 4 1 6 Mot Power High Display of high motor power 0 0 0 0 h All 2 4 1 7 Mot Power Low Dis...

Page 109: ...c PDrive Display of identifier of PumpDrive selected 0 0 Customer 3 1 2 Set up Submenu for settings 3 1 2 1 Set up Version User defined version number 1 01 0 1 99 99 Customer 3 1 3 Display Config Subm...

Page 110: ...ll OFF Start 3 1 5 9 HMI all PDrive Transfer settings from HMI to all PumpDrives 1 1 Customer OFF Start 3 1 5 10 System Stop Stop system 1 1 All OFF Start 3 1 5 11 System Start Start system 1 1 All OF...

Page 111: ...r displaying basic settings 3 2 1 1 MultiPump Role Selection of role in multiple pump configuration 1 2 Customer Standard slave Auxiliary main pump 3 2 1 2 PumpDrive ID PumpDrive ID 0 0 0 6 Customer 3...

Page 112: ...3 3 1 6 V f Voltage 3 Selection of V f voltage 3 64 64 0 100 Customer 3 3 1 7 V f Frequency 3 Selection of V f frequency 3 80 80 0 100 Customer 3 3 1 8 V f Voltage 4 Selection of V f voltage 4 100 10...

Page 113: ...protection 83 5 83 5 0 100 Service 3 3 6 Ramps Ramps 3 3 6 1 Ramp 0 up down Ramp used to reach minimum frequency from 0 and vice versa 3 3 0 5 600 s Customer 3 3 6 2 Ramp 1 Up tm Ramp 1 used to go fro...

Page 114: ...of flow rate value for Q measurement estimation 0 0 0 9999 3 2 2 2 Customer 3 4 1 3 p 100 Value Selection of pressure value for Q measurement estimation 0 0 0 9999 3 2 2 3 Customer 3 4 2 Setpoint Com...

Page 115: ...omer 3 5 Setpoint Menu for setpoint 3 5 1 General Settngs Submenu for general setpoint settings 3 5 1 1 Setpoint Scale Scale of setpoint 1 1 0 5 2 Customer 3 5 1 2 Min Setpoint Specification of minimu...

Page 116: ...ource of setpoint 2 4 4 Customer None Analog IN 1 Analog IN 2 Configurable Setpoint Remote Setpoint RS232 Setpoint 3 5 4 3 Setp Source 3 Selection of source of setpoint 3 5 5 Customer None Analog IN 1...

Page 117: ...lower limit value for frequency monitoring 0 0 0 3 6 2 6 Customer 3 6 2 6 Hi Out Freq Wrn Selection of upper limit value for frequency monitoring 100 100 3 6 2 5 100 Customer 3 6 2 7 Freq Wrn Tm Dly...

Page 118: ...90 3 6 4 1 100 Customer 3 6 4 3 Hi Load Profile Selection of overload profile 1 1 Customer Linear Square Cubic 3 6 4 4 Hi Load Tm Dly Selection of overload time delay 5 5 0 30 s Customer 3 6 4 5 High...

Page 119: ...oring 5 5 0 60 s Customer 3 6 6 4 Fdbk Wrn Func Selection of actual value monitoring function 1 1 Customer No Function Warning Stop Trip 3 7 Digital IN OUT Menu for digital inputs and outputs 3 7 1 Di...

Page 120: ...og inputs and outputs 3 8 1 Analog IO Mode Submenu 3 8 1 1 Live Zero TmDly Time delay after live zero detection 3 3 0 1 60 s Customer 3 8 1 2 Live Zero Fnc Live zero function 1 1 Customer No Function...

Page 121: ...Voltage Analog IN 2 Low current 0 0 0 3 8 3 3 V Customer 3 8 3 3 AI2 Hi Voltage Analog IN 2 High current 10 10 3 8 3 2 10 V Customer 3 8 3 4 AI2 Lo Current Unit of Analog IN 2 4 4 0 3 8 3 5 mA Custom...

Page 122: ...nk Voltage 3 8 4 4 AO Source 4 Source 4 for Analog OUT 1 1 Customer No Setpoint Feedback Nominal Powerr Motor Voltage Motor Current Motor Speed Output Frequency DC Link Voltage 3 8 4 5 AO Lo Voltage A...

Page 123: ...Guard Tm Threshold value for control word time monitoring 4 4 2 10 s Customer 3 10 1 2 Ctrl Wd Wrn Fnc Perform function upon control word timeout 1 1 Service 3 10 1 3 Aux main Grd Tm Time at which au...

Page 124: ...pDrive power class 3 3 1 16 Customer 3 11 5 2 Offset DC Link Offset DC link voltage 350 350 200 365 V Factory 3 12 Adv Pump Ctrl Menu for Advanced Pump Control 3 12 1 Flow Rate Meas Submenu for flow r...

Page 125: ...point 30 30 30 500 s Customer 3 12 2 11 learn meas fail Permissible measuring error in percent outside a predefined tolerance band 5 5 2 20 Customer 3 12 3 Q P H Curves Submenu for displaying H P Q c...

Page 126: ...9 m3 h Customer 3 12 3 14 H_0 Data point H P Q curve H_0 at nominal speed 0 0 0 9999 m Customer 3 12 3 15 H_1 Data point H P Q curve H_1 at nominal speed 0 0 0 9999 m Customer 3 12 3 16 H_2 Data point...

Page 127: ...20 0 120 s Customer 3 12 4 3 Q Hi Timeout Fn Perform function when overload occurs 1 1 Customer No Function Warning Stop Trip 3 12 4 4 Q Lim Low Flow Limit value for minimum flow stop for Q 100 100 0...

Page 128: ...bus Module Profibus module 4 Information Main menu information 4 1 PDrive Info Menu for displaying PumpDrive information 4 1 1 PDrive ID Submenu for displaying PumpDrive ID 4 1 1 1 Device Ser No Seria...

Page 129: ...0 Selection list Selection value Selection list I II III IV V 1 None No Function None OFF 1 0 kHz 2 Reset reset after alert CAUTION Possible restart PDrive Ready 2 5 1 5 kHz 3 Start System system star...

Page 130: ...wer Too Low W m2 19 An IN1 Range m s 20 An IN1 Too High ft s 21 An IN1 Too Low l s 22 An IN2 Range l min 23 An IN2 Too High l h 24 An IN2 Too Low kg s 25 Thermal Warn kg min 26 Rdy No Temp Wrn kg h 27...

Page 131: ...ble consultation with KSB s customer service is required Mains fuse rating too small for the nominal mains current PumpDrive does not start PumpDrive runs unevenly Max speed not reached PumpDrive runn...

Page 132: ...Section 7 2 3 Page 82 Out Freq High Output frequency exceeds upper limit Section 7 2 3 Page 82 Out Curr High Output current below lower limit Section 7 2 3 Page 82 Out Curr High Output current exceeds...

Page 133: ...unning Check mains voltage quality Fluctuating DC link voltage 1 4 1 1 when pump operates at rated values Check mains voltage quality Incorrect motor current measurement 1 2 1 5 Measure current using...

Page 134: ...age Impermissible undervoltage mains Stop High Voltage Impermissible overvoltage mains Stop Over Current Impermissible overcurrent Section 7 2 3 Page 82 Breakover Curre Internal overcurrent for exampl...

Page 135: ...e PumpDrive output current set too low Slightly increase 3 6 1 4 to enable higher PumpDrive output current Motor voltage output is too low at rated load 1 2 1 3 380 V at rated load Check line input vo...

Page 136: ...r current Wrong device ordered mount larger PumpDrive model Motor voltage too low Change V f characteristic to Linear Section 7 2 6 2 Page 93 Ramp times too short Select longer ramp times Wrong direct...

Page 137: ...t connected Connect digital input 6 to 24 V DC check system configuration Stop and Trip An event has been classified as a Stop Trip event Check Stop Trip settings Section 7 1 1 Page 49 read out alert...

Page 138: ...gn Mat No kg KD Automation Service Software Customer version The software can be downloaded from the KSB web site free of charge CD ROM with instructions RS232 parameterisation cable and USB RS232 ada...

Page 139: ...2 parameterisation cable to a laptop PC with a USB interface 01111255 0 1 12 2 2 Control panels Table 117 Accessories Control panels Description Design Mat No kg Standard control panel for PumpDrive B...

Page 140: ...adapter kits An adapter is required if PumpDrive is to be mounted on the motor Select the adapter required based on the motor size and the type of construction used Table 118 Motor adapter kits access...

Page 141: ...its accessories for KSB Siemens standardised motor Types 1LA7 1LA9 and 1LG6 Description Design Mat No kg For mounting PumpDrive to a KSB Siemens standardised motor Including connection cable and bolts...

Page 142: ...KSB SuPremE motor Description Design Mat No kg for mounting PumpDrive to KSB SuPremE motors including connection cable and screws Size 71M type A PumpDrive size A 01373974 1 7 Size 80M type A PumpDri...

Page 143: ...9 Size 225M type A PumpDrive size D 01374118 10 9 Table 121 Motor adapter kits accessories for Movitec Description Design Mat No kg For mounting PumpDrive to KSB Movitec A pump sets Including connecti...

Page 144: ...on the pump The holes for fastening the adapters are not drilled in the pump at the factory for retrofit configurations Size 0 37 0 55 kW PumpDrive size A 48896489 4 2 Size 0 75 1 1 kW PumpDrive size...

Page 145: ...size D 48897652 23 Table 122 Accessories Connection cables Description Design Mat No kg 740 Ferrit 20 100 100 30 700 30 120 20 M4 M4 M 4 Connection cable for motors Shielded includes cable for connect...

Page 146: ...th standard control panel for redundant operation of two PumpDrives in operating mode 2 x 50 or 2 x 100 01131684 0 6 Table 125 Set of accessories Dual pump module DPM Quantity Component Use Mat No 2 D...

Page 147: ...via KSB local bus CAN with wire end sleeves Included in 01131684 but can also be ordered separately Cable 2 x 2 x 0 22 mm length approx 1 m 01131429 0 3 CAN bus cable Bus cable cut to length for multi...

Page 148: ...10CH length approx 1 m 01131430 1 Measuring resistor 500 Ohm Conversion of the 0 4 20 mA current measurement signal of the differential pressure sensor into 0 2 10 V DC voltage values 01127044 2 Wire...

Page 149: ...d in the LON field bus module literature for PumpDrive refer to the Product Catalogue on the KSB web site The LON literature is based on the LONMARK Functional Profile Pump Controller V 0 93 SFPTpumpC...

Page 150: ...module including software and operating manual on CD ROM Scope of supply of Profibus set of accessories Modbus module for PumpDrive PumpDrive Modbus module operating manual The modular plug on Modbus...

Page 151: ...egment IP 66 enclosure Dimensions in mm see illustration Operating temperature 40 to 85 C 01150961 0 3 19 64 58 Profibus branch switch For connecting PumpDrive to a Profibus network via a spurwith ter...

Page 152: ...For general applications for liquid and gaseous fluids 0 to 80 C measuring accuracy smaller than or equal to 1 2 5 max at 80 C G1 4B process connection with Cu joint ring IP 67 2 wire output 4 to 20...

Page 153: ...ccuracy 0 5 of measuring range G1 2B EN837 connection Flush diaphragm NBR O ring IP65 enclosure 2 wire output 4 20 mA 3 wire output 0 10 V DC Maximum line cross section of 1 5 mm Outer line diameter o...

Page 154: ...n Mat No kg Flow sensor 3 300 cm s For filter loss compensation control cost effective flow control Measuring range 3 300 cm s process connection with internal thread output 4 20 mA 01150960 0 3 Plug...

Page 155: ...P40 housing IP20 terminals 22 5 x 82 x 118 2 mm B x H x T 01085905 1 2 Potential separator For volt free signal transmission between PumpDrive and external controllers Differences in potential can dam...

Page 156: ...er for PumpDrive Line chokes for reducing electromagnetic interference emissions IP20 enclosure Reduction of current peaks in long motor power cables Max motor cable length 80 m 16 kHz 18 5 22 kW Type...

Page 157: ...Application Pressure Differential pressure Flow rate Temperature Open loop control mode Setpoint Source Unit Value Closed loop control mode Sensor Sensor full scale value Multiple pump configuration N...

Page 158: ...declares that the following harmonised international standards have been applied EN 61800 3 7 5 kW EN 61000 6 3 7 5 kW EN 6100 6 2 EN 55011 A1 A2 EN 61000 3 2 EN 61000 3 3 EN 61000 3 11 EN 61000 6 1 E...

Page 159: ...g the installation position 35 Mounting the graphical control panel 35 Mounting the standard control panel 34 Control terminal 22 32 Controller optimisation 58 Controller types 57 Cover L shaped 25 36...

Page 160: ...arnings 132 Monitoring 14 15 Motor connection cable 19 23 Connect 25 26 EMC 23 Length 23 Route 23 Motor mounting 18 Motor protection switch 23 Motor temperature sensors 26 28 Multiple pump configurati...

Page 161: ...73 Warning 133 Standard control panel 37 139 Start and stop limits Power polygon 66 Start menu 44 Stop Trip 83 Storage 12 T Technical data 15 Terminal strip 26 Cable cross section 22 32 P4 control ter...

Page 162: ...4070 81 08 EN 01096999 KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Str 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 3401 www ksb com...

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KSB PumpDrive, Installation & Operating Manual

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