PumpDrive DPM. Installation and Operating Instructions Dual Pump Module (DPM) /4--10

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1 /4--10 PumpDrive DPM 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 ).

2 Page Contents 1 General Symbols Safety information Function Installation and connection to power supply Removing the control panel Removing the connection cables Attaching the DPM Connection to power supply Setting the DIP switches on the standard control panel Parameter settings Setting/optimising the start and stop limits in 2 Pumps operating mode Operation / Monitoring Standard control panel 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 Fig. 11: DIP switches on control panel Fig. 12: Fastening the control panel Fig. 13: Characteristic curves for defining the start and stop limits Shaded area: permissible range Tables Table 1: Scope of supply of DPM set of accessories... 3 Table 2: Symbols and their meaning... 3 Table 3: Parameter settings Table 4: Start and stop limits in the 2 Pumps operating mode

3 1 General The DPM set of accessories is available for controlling redundant variable speed twin pumps (e. g. Etaline Z PumpDrive) or two identical variable speed pumps operating in parallel. The dual pump module (DPM) is available as a separate accessory/spare part. 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: Quantity Component Use Ident. number Spare part 1 PumpDrive DPM set of accessories 2 Dual pump module (DPM) Communication module to transfer data via X KSB local bus 1 CAN bus cable (purple) Data transfer between the two PumpDrives X via KSB local bus 1 Control cable (grey) Transmission of the measurement signal of the X differential pressure sensor to the second PumpDrive 1 Resistance 500 Ω Conversion of the ma (current) measurement X signal of the differential pressure sensor into V DC voltage values 2 Wire jumper Connection of digital inputs DI1 and DI6 to 24 V DC at X both PumpDrives 3 Cable tie PumpDrive DPM operating instructions See product literature Table 1: Scope of supply of DPM set of accessories Fig. 1: Scope of supply 1.1 Symbols Symbol n Description Prerequisite " Instruction 1. Multi--step instructions Table 2: Result Symbols and their meaning 3

4 2 Safety information This KSB device has been developed using state--of--the--art technology; it is manufactured with the utmost care and subject to continuous 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: Caution 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 ). 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 (see EN ). The manufacturer shall not accept any liability if you fail to comply with the information in these operating instructions. 3 Function The 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 1Pumpoperating 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 supply Danger of death from electric shock! " Before starting any work on PumpDrive, switch off the system and secure it against inadvertent start--up. Note 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 4

5 4.1 Removing the control panel 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. 5

6 4.2 Removing the connection cables Note Two connection cables are attached at the back of the standard control panel. They are not required for operation with 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 DPM Caution Risk 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 Determine the direction of installation of the control panel (see PumpDrive operating instructions, reference No /3, section 6.4.9). 6

7 1 2 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 7

8 3. Use the 3 cross--head screws supplied (see Fig. 5) to mount the DPM. Caution 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 supply Danger of death from electric shock! " Make sure that the system is switched off and secured against inadvertent start--up. Note PumpDrive 1 (with standard control panel and DPM) The PumpDrives must be connected to the power supply before the control panel is inserted. GND 20 DI6 19 DI5 18 DI4 17 DI3 16 DI2 15 DI V 13 AGND 12 AN -OUT 11 P4 GND 20 DI6 19 DI5 18 PumpDrive 2 DI4 17 (with standard DI3 16 control panel and DI2 15 DPM) DI V 13 AGND 12 AN -OUT 11 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

9 PumpDrive 1 (with standard control panel and DPM) PumpDrive 2 (with standard control panel and DPM) SB1_GND SB1+ SB1 - SB1_GND SB1+ SB1 - SB1Z - SB1Z+ SB1_GND SB1+ SB1 - SB1_GND SB1+ SB1 - SB1Z - SB1Z P4 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+ brown SB1-- white SB1_GND green/yellow PumpDrive 1 (with standard control panel and DPM) PumpDrive 2 (with standard control panel and DPM) ABNG P7 AIN1 GND AIN2 +24V NO2 COM2 NO1 COM1 ABNG P7 AIN1 GND AIN2 +24V NO2 COM2 NO1 COM P7 500 Ω 3--wire sensor ma Fig. 9: Connecting the sensors 4. Connect the sensors in parallel (see Fig. 9). -- Use the control cable supplied: 5 G If sensors with ma are used, connect a terminating resistor. Caution 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). or Connect 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) : 9

10 1 -- Remove the cover for the mains and motor connection (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. 10

11 4.5 Setting the DIP switches on the standard control panel Caution Risk 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 mode of the dual pump system. ON OFF Pump changeover (after 24 h) 2 Pumps (2x50 %) P1 P0 1 Pump (2x100 %) Master M Auxiliary Master A4 A3 A2 A1 A0 Not applicable for 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. Note 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 system D Green flashing: Auxiliary Master PumpDrive in a multiple pump system D No display: PumpDrive used as single-pump drive 4. 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. 11

12 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). 12

13 5 Parameter settings The parameter settings of the Master PumpDrive must be checked, either using the KSB Service Software or a graphical control panel. " The parameters must be set as follows: Parameter Description Setting Role in multiple pump configuration Auxiliary main pump for both PumpDrives PumpDrive ID 1 for Master PumpDrive 2 for Aux. Master PumpDrive ) High load function Warning 2) ) Low load function Warning 2) Function Dig In 2 System start for both PumpDrives AI 2 setting Voltage AI2 Low voltage 2V 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. 13

14 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 High load at low motor frequency Defines start--up of additional pump p High load at high motor frequency High load profile Low load at low motor frequency Defines stopping of pumpp Low load at high motor frequency Low load profile High load time delay Identification of the impermissible range and Low load time delay response are time--controlled by way of these parameters Warning: High load function Starting and stopping is enabled by the Warning: Low load function warning Rated motor power Low motor frequency limit High motor frequency limit Maximum output frequency Table 4: Start and stop limits in the 2 Pumps operating mode P max@ ( ) P max@ ( ) P max@ ( ) P max@ ( ) Low Freq ( ) High Freq ( ) Fig. 13: Characteristic curves for defining the start and stop limits Shaded area: permissible range 14

15 6 Operation / Monitoring Caution Any damage to the surface of the PumpDrive control panels by pointed or sharp-edged objects may reduce the degree 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 the setpoint using the setting keys. The operating mode, motor speed and sensor signal are displayed via LEDs Key functions LEDs: traffic light function Display Setpoint or actual value Speed Display of the redundant dual pump control function Display of the operating mode Setting keys Increase Confirm Reduce Operating keys Manual mode User--programmable function key OFF Automatic mode Service interface (RS 232) A blanking plate (ident. number: ) that prevents intervention in the operating mode is available for safety-relevant applications. 15

16 LEDs The traffic light signals provide information about the pump system s operating status. LEDs: D Red: One or more than one alert is active D Amber: One or more than one warning is active D Green: Trouble--free operation LED bar graph display The LED bar graph display can display three different colours. The colours represent the following operating parameters: D Red: Motor frequency D Amber: Actual value sensor signal D Green: Setpoint The current values of these three operating parameters are shown as percentages by means of the five individual LEDs. Each LED represents a particular percentage range of the operating parameter selected: D Min. LED: % D 2. LED: % D 3. LED: % D 4. LED: % D Max. LED: % 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 LED This LED shows the function assigned to the PumpDrive: D Green: Master PumpDrive in a multiple pump system D Green flashing: Auxiliary Master PumpDrive in a multiple pump system D No display. PumpDrive used as single-pump drive Mode LED This LED shows the current operating mode of the PumpDrive: D Red: OFF mode, switched off D Amber: Automatic mode D Green: Manual mode 16

17 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! Down Arrow key: The operating parameters are selected in reverse order to the Up Arrow key. Setpoint specification D 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 keys are 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. 17

18 Operating keys You 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 OFF If the drive is in Manual mode when the voltage supply is interrupted, the drive will switch to the OFF mode once the voltage supply is restored. Automatic mode Parameterisable function key The 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 compensation 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 deactivated. Service interface The service interface allows a PC / Notebook to be connected via a special cable (USB - RS232). The PumpDrive Service Software can 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 Software for parameterisation and data back--up can be ordered under ident. No.:

19 Notes: 19

20 / Subject to technical modification without prior notice. KSB Aktiengesellschaft Frankenthal Johann-Klein-Str Frankenthal (Germany) Tel Fax

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