Ksb-pumpdrive Iom

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PumpDrive DPM 4070.83/4--10 Installation and Operating Instructions Dual Pump Module (DPM) These installation and operating instructions are not valid on their own. They must always be applied in conjunction with the PumpDrive operating instructions (reference No. 4070.81).

description

Centrifugal pumps from Ksb Germany.For HVAC applications, firefighting, irrigation, and municipal and waste water treatment.

Transcript of Ksb-pumpdrive Iom

Page 1: Ksb-pumpdrive Iom

PumpDrive DPM4070.83/4--10

Installation and Operating InstructionsDual Pump Module (DPM)

These installation and operating instructions are not valid on their own. They must always be applied in conjunction with thePumpDrive operating instructions (reference No. 4070.81).

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Contents

1 General 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Function 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Installation and connection to power supply 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Removing the control panel 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Removing the connection cables 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Attaching the DPM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Connection to power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Setting the DIP switches on the standard control panel 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Parameter settings 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Setting/optimising the start and stop limits in “2 Pumps” operating mode 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Operation / Monitoring 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Standard control panel 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figures

Fig. 1: Scope of supply 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 2: Removing the control panel 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 3: Connection cables 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 4: Attaching the DPM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 5: Fixing the DPM using 3 cross--head screws 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 6: DIP switch on DPM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 7: Connecting the digital inputs 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 8: Connecting the KSB local bus interface 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 9: Connecting the sensors 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 10: Connecting the terminating resistor 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 11: DIP switches on control panel 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 12: Fastening the control panel 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. 13: Characteristic curves for defining the start and stop limits

Shaded area: permissible range 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tables

Table 1: Scope of supply of DPM set of accessories 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 2: Symbols and their meaning 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 3: Parameter settings 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 4: Start and stop limits in the 2 Pumps operating mode 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 GeneralThe DPM set of accessories is available for controlling redundant variable speed twin pumps (e. g. Etaline Z PumpDrive) or twoidentical variable speed pumps operating in parallel. The dual pump module (DPM) is available as a separate accessory/sparepart.The dual pump module (DPM) can only be used in combination with the PumpDrive Basic model and the standard control panel.It cannot be used in combination with the blanking plate or the graphical control panel.

Scope of supply of PumpDrive DPM set of accessories:

Quan-tity

Component Use Ident. number Sparepart

1 PumpDrive DPMset of accessories

01 131 684

2 Dual pump module (DPM) Communication module to transfer data viaKSB local bus

47 121 257 X

1 CAN bus cable (purple) Data transfer between the two PumpDrivesvia KSB local bus

01 131 429 X

1 Control cable (grey) Transmission of the measurement signal of thedifferential pressure sensor to the second PumpDrive

01 131 430 X

1 Resistance 500 Ω Conversion of the 4--20 mA (current) measurementsignal of the differential pressure sensor into

0--10 V DC voltage values

01 127 044 X

2 Wire jumper Connection of digital inputs DI1 and DI6 to 24 V DC atboth PumpDrives

01 131 428 X

3 Cable tie 01 114 578

1 PumpDrive DPMoperating instructions

See productliterature

Table 1: Scope of supply of DPM set of accessories

Fig. 1: Scope of supply

1.1 Symbols

Symbol Description

n Prerequisite

" Instruction

1. Multi--step instructions

Result

Table 2: Symbols and their meaning

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2 Safety informationThis KSB device has been developed using state--of--the--art technology; it is manufactured with the utmost care and subject tocontinuous quality control.These operating instructions contain important information and precautions.

Warning of a risk of fatal injury:

Warning of a risk of electric shocks:

Warning of a risk of damage to property:

These installation and operating instructions are not valid on their own. They must always be applied in conjunction with thePumpDrive operating instructions (reference No. 4070.81).The installation and operating instructions must be read and understood before performing any work on the device.

The dual pump module must only be fitted in devices of the PumpDrive product family by skilled, properly trained personnel (seeEN 50110--1).The manufacturer shall not accept any liability if you fail to comply with the information in these operating instructions.

3 FunctionThe DPM serves to control two identical pumps equipped with the PumpDrive Basic model with standard control panel.One of the pumps is defined to be the main pump (master), the other is the auxiliary pump (auxiliary master).The dual pump system can be set to two operating modes:D In 1 Pump operating mode, the dual pump system is designed to achieve the setpoint with one pump operating at rated values

(2x100 %).D In 2 Pumps operating mode, the system’s rated operating point is achieved with both pumps operating at rated values

(2x50 %).

4 Installation and connection to power supplyDanger of death from electric shock!

" Before starting any work on PumpDrive, switch off the system and secure it against inadvertent start--up.

Each of the two PumpDrives of the dual pump system must be fitted with a DPM.

n Required tools:-- Cross--tip (Phillips) screwdriver: PH1x80-- Flat--head screwdriver: 2 mm

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4.1 Removing the control panel

1

2

3

4

5

6

Fig. 2: Removing the control panel

1. Undo the six cross--head screws of the control panel (see Fig. 2).2. Carefully remove the control panel.

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4.2 Removing the connection cablesTwo connection cables are attached at the back of the standard control panel. They are not required for operationwith the DPM and must be removed completely.

1 2

Fig. 3: Connection cables

1. Remove the data cable (1):-- Unplug both ends of the cable.

2. Remove the power supply cable (2):-- Unplug the cable end on the back of the control panel.-- Undo the cable end on the PumpDrive’s terminal strip using a flat--head screwdriver.

4.3 Attaching the DPMRisk of damage to property by electrostatic charges!

" Make sure that there are no electrostatic charges before taking the dual pump module out of the plastic bag:-- To do so, touch an earthed metallic object (piping, radiator, etc.) with the full palm of your hand..

" Do not touch electronic components." Only touch the DPM as shown in Fig. 4.

1. Determine the direction of installation of the control panel (see PumpDrive operating instructions, reference No. 4070.81/3,section 6.4.9).

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12

Fig. 4: Attaching the DPM

2. Attach the DPM in the appropriate direction of installation:-- Use slot 1 or 2 (see Fig. 4).

Fig. 5: Fixing the DPM using 3 cross--head screws

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3. Use the 3 cross--head screws supplied (see Fig. 5) to mount the DPM.

Risk of damage to property by wrong setting of DIP switches!

" Make sure that the DIP switches on the DPM are set to “ON” for both the drives.

Fig. 6: DIP switch on DPM

4. Set the DIP switches on the DPM to “ON” for both drives (see Fig. 6).5. If field bus modules are installed on PumpDrive, set the DIP switches on the field bus modules to “OFF”.

4.4 Connection to power supplyDanger of death from electric shock!

" Make sure that the system is switched off and secured against inadvertent start--up.

The PumpDrives must be connected to the power supply before the control panel is inserted.

P4

PumpDrive 1(with standardcontrol paneland DPM)

PumpDrive 2(with standardcontrol panel andDPM)

20191817161514131211

20191817161514131211

GNDDI6DI5DI4DI3DI2DI1

+24VAGND

AN--OUT

GNDDI6DI5DI4DI3DI2DI1

+24VAGND

AN--OUT

System start

Fig. 7: Connecting the digital inputs

1. Connect the digital input DI1 and the digital input DI6 on each PumpDrive to the 24 V power supply (see Fig. 7).-- Use the wire jumpers supplied.

2. Connect the DI2 digital inputs of the two PumpDrives (see Fig. 7).-- Use the control cable supplied: 5 G 0.5.

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P4

PumpDrive 1(with standardcontrol paneland DPM)

PumpDrive 2(with standardcontrol panel andDPM)

10987654321

SB1_GNDSB1+SB1--

SB1_GNDSB1+SB1--SB1Z--SB1Z+

10987654321

SB1_GNDSB1+SB1--

SB1_GNDSB1+SB1--SB1Z--SB1Z+

Fig. 8: Connecting the KSB local bus interface

3. Connect the KSB local bus interfaces for both PumpDrives (see Fig. 8).Use the CAN bus cable supplied.-- Colour coding:SB1+ brownSB1-- whiteSB1_GND green/yellow

10987654321

ABNG P7AIN1

GNDAIN2+24VNO2

COM2NO1

COM1

10987654321

ABNG P7AIN1

GNDAIN2+24VNO2

COM2NO1

COM1

3--wiresensor4--20 mA

500 Ω

PumpDrive 1(with standardcontrol paneland DPM)

PumpDrive 2(with standardcontrol panel andDPM)

P7

Fig. 9: Connecting the sensors

4. Connect the sensors in parallel (see Fig. 9).-- Use the control cable supplied: 5 G 0.5.

5. If sensors with 4..20 mA are used, connect a terminating resistor.

Risk of damage to property as a result of incorrect sensor signal!

" Connect the terminating resistor supplied to only one of the two drives.

6. Connect the terminating resistor to terminal strip P7 (terminals 6 and 7; see Fig. 9).orConnect the terminating resistor to terminal strip P5 (terminals 2 and 3; see Fig. 10). To do so, proceed as follows:-- Remove the L-shaped cable cover (1) :

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1

-- Remove the cover for the mains and motor connection (2).

2

-- Connect the terminating resistor with 500 Ω to terminals 2 and 3.

Fig. 10: Connecting the terminating resistor

-- Re-mount the cover for the mains and motor connection, using 3 cross-head screws.-- Re-mount the L-shaped cable cover, using 3 cross-head screws.

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4.5 Setting the DIP switches on the standard control panelRisk of damage to property by wrong setting of DIP switches!

" Make sure that the P0 and P1 DIP switches on the back of the control panel are set identically for both drives.

There are 8 DIP switches on the back of the control panel. The 3 P0, P1 and M DIP switches are used to set the operating modeof the dual pump system.

2 Pumps (2x50 %)

Pump changeover(after 24 h)

Master

P1

P0 1 Pump (2x100 %)

M Auxiliary Master

A4

A3

A2

A1

A0

ON OFF

Not applicablefor DPM

Fig. 11: DIP switches on control panel

1. Set the appropriate role for each PumpDrive via the M DIP switch:-- Set the main pump to be the “Master”.-- Set the auxiliary pump to be the “Auxiliary Master”.

2. Set the operating mode via the P0 DIP switch:-- Set P0 to “ON” if in normal operating mode both pumps are to run.-- Set P0 to “OFF” if in normal operating mode just one pump is to run.

If P1 is set to “ON”, P0 should be set to “OFF”.

3. Set pump changeover via the P1 DIP switch:-- Set P1 to “ON” for pump changeover after 24 operating hours.

The role of the PumpDrive is shown by the LED on the control panel:D Green: Master PumpDrive in a multiple pump systemD Green flashing: Auxiliary Master PumpDrive in a multiple pump systemD No display: PumpDrive used as single-pump drive4. Insert the control panel into PumpDrive in the appropriate direction of assembly.Make sure that the 9--pin DSUB plug on the back of the control panel fits in the socket provided for this purpose on PumpDrive.

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1

2

3

4

5

6

Fig. 12: Fastening the control panel

5. Insert the 6 screws of the control panel and tighten to a torque of 0.5 Nm (see Fig. 12).

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5 Parameter settingsThe parameter settings of the Master PumpDrive must be checked, either using the KSB Service Software or a graphical controlpanel.

" The parameters must be set as follows:

Parameter Description Setting

3--2--1--1 Role in multiple pump configuration “Auxiliary main pump” for both PumpDrives

3--2--1--2 PumpDrive ID “1” for Master PumpDrive“2” for Aux. Master PumpDrive

3--6--4--51) High load function Warning2)

3--6--4--101) Low load function Warning2)

3--7--1--2 Function Dig In 2 “System start” for both PumpDrives

3--8--3--1 AI 2 setting Voltage

3--8--3--2 AI2 Low voltage 2 V

3--9--1--1 PI Mode Active

Table 3: Parameter settings

1) For 2 Pumps (2x50 %) operating mode only.2) The parameter must be set as a function of the pump type and system curve.

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5.1 Setting/optimising the start and stop limits in “2 Pumps” operating mode

" Define and set the values for the following parameters. See Table 4 and Fig. 13.

Parameter Description Function

3--6--4--1 High load at low motor frequency Defines start--up of additional pump3--6--4--2 High load at high motor frequency

p p p

3--6--4--3 High load profile3--6--4--6 Low load at low motor frequency Defines stopping of pump3--6--4--7 Low load at high motor frequency

pp g p p

3--6--4--8 Low load profile3--6--4--4 High load time delay Identification of the impermissible range and

response are time controlled by way of3--6--4--9 Low load time delay

response are time--controlled by way ofthese parameters

3--6--4--5 Warning: High load function Starting and stopping is enabled by the3--6--4--10 Warning: Low load function

g pp g ywarning.

3--3--2--1 Rated motor power3--6--1--2 Low motor frequency limit3--6--1--3 High motor frequency limit3--11--4--1 Maximum output frequency

Table 4: Start and stop limits in the 2 Pumps operating mode

Pmax@3--6--1--3 (3--6--4--2)

Pmax@3--6--1--3 (3--6--4--7)

Pmax@3--6--1--2 (3--6--4--1)Pmax@3--6--1--2 (3--6--4--6)

Low Freq(3--6--1--2)

High Freq(3--6--1--3)

Fig. 13: Characteristic curves for defining the start and stop limitsShaded area: permissible range

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6 Operation / MonitoringAny damage to the surface of the PumpDrive control panels by pointed or sharp-edged objects may reduce thedegree of protection provided by the enclosure.

6.1 Standard control panel

The standard control panel features an LED bar graph display, keys and a service interface.With the standard control panel, users can change between the Manual, OFF and Automatic operating modes and specify thesetpoint using the setting keys. The operating mode, motor speed and sensor signal are displayed via LEDs.

6.1.1 Key functions

User--programmablefunction key

DisplaySetpoint or actual valueSpeedLEDs:

“traffic light” function

Service interface (RS 232)

Reduce

Increase

Setting keys

Manual mode

OFF Automatic mode

Operating keys

Confirm

Display of theredundant dual pumpcontrol function

Display of theoperating mode

A blanking plate (ident. number: 47 106 619) that prevents intervention in the operating mode is available for safety-relevantapplications.

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LEDsThe “traffic light” signals provide information about the pump system’s operating status.LEDs:D Red: One or more than one alert is activeD Amber: One or more than one warning is activeD Green: Trouble--free operation

LED bar graph displayThe LED bar graph display can display three different colours. The colours represent the following operating parameters:D Red: Motor frequencyD Amber: Actual value sensor signalD Green: Setpoint

The current values of these three operating parameters are shown as percentages by means of the five individual LEDs. EachLED represents a particular percentage range of the operating parameter selected:D Min. LED: 0--19 %D 2. LED: 20--39 %D 3. LED: 40--59 %D 4. LED: 60--79 %D Max. LED: 80--100 %

The end value of 100 % represents:

D The maximum motor frequency (e.g. 50 Hz≙ 100 %)

D The full-scale value of the sensor (e.g. 6 bar≙ 100 %)

D The specified setpoint in open-loop control mode (e.g. 50 Hz≙ 100 % setpoint)

D The specified setpoint in closed-loop control mode (full-scale value of the sensor≙ 100% setpoint)

DPM LEDThis LED shows the function assigned to the PumpDrive:D Green: Master PumpDrive in a multiple pump systemD Green flashing: Auxiliary Master PumpDrive in a multiple pump systemD No display. PumpDrive used as single-pump drive

Mode LEDThis LED shows the current operating mode of the PumpDrive:D Red: OFF mode, switched offD Amber: Automatic modeD Green: Manual mode

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Setting keys

Operating parameter display (monitoring)This function is only available in manual or automatic mode. The actual value can only be displayed if a sensor is connected.

Up Arrow key:D Pressing key once:

The motor frequency is displayed (red LEDs of the bar graph display)D Pressing key twice:

The actual value is displayed (amber LEDs of the bar graph display)D Pressing key three times:

The setpoint is displayed (green LEDs of the bar graph display)The actual value can only be displayed if a sensor is connected!

6.1.1.1 Down Arrow key:The operating parameters are selected in reverse order to the Up Arrow key.

Setpoint specificationD Use the or keys to switch to the setpoint display (green LEDs).D Press OK key.

The green LEDs of the LED bar graph display start flashing.D Use the or keys to increase / reduce the setpoint.

Each time a key is pressed, the value will be changed by an increment of 0.5 Hz or 1.0 % (factory default setting). If the keysare pressed continuously, the setpoint is increased / reduced continuously.

D Press OK key again.The LED bar graph display returns to operating parameter display mode, i.e. the LEDs are steadily lit.

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Operating keysYou can use the operating keys to select the Automatic, Manual or OFF operating modes.The parameterisable Func key is only available in Automatic or Manual mode.

OK key – also serves as alert reset key

Manual mode

OFFIf the drive is in Manual mode when the voltage supply is interrupted, the drive will switch to the OFFmode once the voltage supply is restored.

Automatic mode

Parameterisable function keyThe dynamic pressure 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 compen-sation function is displayed in the bar display by flashing yellow LEDs.When the parameterisable function key is pressed again, the display of the setpoint compensation is deacti-vated.

Service interfaceThe service interface allows aPC /Notebook to be connected via a special cable (USB -RS232). ThePumpDrive ServiceSoftwarecan be used to configure and parameterise the pump system if you do not have access to a control panel.You cannot implement a software update for PumpDrive with the standard control panel. The customer version of the Service Soft-ware for parameterisation and data back--up can be ordered under ident. No.: 47 121 211.

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Notes:

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KSB Aktiengesellschaft

67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)

Tel. +49 6233 86-0 • Fax +49 6233 86-3401 • www.ksb.com

Subjecttotechnicalm

odification

withoutpriornotice.

09.0

9.20

104070.83/

4- 10

PumpDrive DPM