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1. Starting frequency of a new Above this frequency and after the time delay for Hz 013 to auxiliary pump starting a pump 003 another auxiliary pump High starts Speed HSP 013 FrqAuxPumpOff Stopping frequency of an Below this frequency and after the time delay for Hz Low auxiliary pump stopping an auxiliary pump 004 the pump is speed stopped LSP to 012 014 Pr adj coeff Pressure adjustment coefficient Coefficient used to adjust the pressure reference or 1 0 to feedback to compensate for loss of head when the 32767 hydraulic circuit is long 2 015 Sleep thresh Sleep threshold This threshold activates the sleep time delay when Hz 0 to the frequency is below that set by the parameter High speed HSP 016 WUp thresh Wake up threshold Activates the variable pump and pressure regulation 1 0 to 9999 when the installation has been in sleep state 017 Time base Modification of the time base of If 017 150 time 008 changes from hours to 0 to 150 008 minutes enabling quick checking of the changeover of the pumps during the debug or demonstration phase 018 V pumpSwFr Frequency below which Determines the frequency below which changeover Hz 0 to changeover of variable pumps of the variable pump is possible if the relative High is permitted operating time differential is reached speed If 018 0 0Hz the changeover can only be HSP performed if the installation is in sleep state
2. WUp thresh 016 Wake up threshold a few below the PID reference Time base 017 Modifying the time base of Lim Rel Time 008 switches from a time base of hours to minutes enabling quick checking of the changeover of the pumps during the debug or demonstration phase V pumpSwFr 018 Frequency below which changeover of variable pumps is permitted 28 1765272 10 2011 Setup 9 Set the PI regulator 1 7 APPLICATION FUNCT FUn menu PID REGULATOR Pid 0 00Hz REM U 1 SIMPLY START 2 MONITORING 3 SETTINGS 4 MOTOR CONTROL 5 INPUTS OUTPUTS CFG RDY App 0 00Hz REM RDY App 0 00Hz REM MAIN MENU ENT 6 COMMAND ENT 1 7 APPLICATION FUNCT 1 DRIVE MENU 1 7 APPLICATION FUNCT PID REGULATOR 2 ACCESS LEVEL 8 FAULT MANAGEMENT PID PRESET REFERENCES 3 OPEN SAVE AS 9 COMMUNICATION SLEEPING WAKE UP 10 DIAGNOSTICS TORQUE LIMITATION 11 IDENTIFICATION 2nd CURRENT LIMIT 12 FACTORY SETTINGS 6 MONITORING CONFIG 13 USER MENU 7 DISPLAY CONFIG 14 PROGRAMMABLE CARD Example with a 0 10 bar sensor Min PID feedback PIF1 0 Max PID feedback PIF2 10 000 in order to have the best possible resolution The maximum reference value for the process is 5 bar Min PID reference PIP1 0 Max PID reference PIP2 5 000 It can be adjusted from 0 to 5 000 Example for a 4 bar reference The reference is given by Internal PID ref rPI To have a 4 bar reference rPI must
3. gt 7 1 USER PARAMETERS gt select the parameters in 1 2 MONITORING SUP choose PID reference rPC and PID feedback rPF 0 00Hz REM MAIN MENU 1 DRIVE MENU 2 ACCESS LEVEL 3 OPEN SAVE AS RDY App 0 00Hz REM 7 1 USER PARAMETERS ENT H a PARAMETER SELECTION 7 2 USER MENU CUSTOMIZED SELECTION 7 3 PARAMETER ACCESS USER MENU NAME DEVICE NAME Code lt lt gt gt T K PARAMETER SELECTION 1 2 MONITORING RDY App 0 00Hz REM PARAMETER SELECTION Power on time 7 1 USER PARAMETERS 1 DRIVE MENU IGBT alarm counter Return std name No 1 1 SIMPLY START PID reference ESC ESC PARAMETER SELECTION ENT 2 MONITORING PID feedback CUSTOMIZED SELECTION 1 3 SETTINGS PID error USER MENU NAME 1 4 MOTOR CONTROL DEVICE NAME 1 5 INPUTS OUTPUTS CFG T K List RDY App 0 00Mz REM RDY Term 0 00Hz REM Rdy App 0 00Hz REM CUSTOMIZED SELECTION PID feedback PID reference User name ENT ENT u gt PID feedback Unit Standard __ uy Multiplier 1 T K Quick Divisor 7 Offset 0 00 Ray App 0 00Hz REM RDY App _ 0 00Hz REM PID feedback PID reference User name ESC ESC ESC ESC ESC 1 250 mbar Multiplier Divisor Offset PID feedback 1200 mbar T K Quick 32 1765272 10 2011 Setup 14 Save the configuration The configuration that
4. 1 The unit is determined by the Min PID feedback PIF1 and Max PID feedback PIF2 parameters which are used to calibrate the PID feedback sensor range See example on page 14 2 This coefficient allows to adjust the pressure reference up to the version V1 1IE02 and the PID feedback from the version V1 21E02 The parametrization of the pump switching card with PC Software is possible only in connected mode 1765272 10 2011 21 22 Architecture of the booster station Single variable mode with 5 PUMPS 1 variable speed pump and 4 fixed speed pumps auxiliary pumps z 4 fixed speed auxiliary pumps io van Andie CGA u nel D D e BTE K we Mes DS Variable pump S ee ALS WSF CP ATV61 gt A S ER N USS Pressure sensor 1765272 10 2011 Connection diagrams Example of single variable diagram with 5 pumps 3 phase supply Pumps A KM5 KM4 Each pump is controlled by a logic output Pump 1 control via logic output LO51 Pump 2 control via logic output LO52 Pump 3 control via logic output LO53 Pump 4 control via logic output LO54 Pump 5 control via logic output LO55 Pl feedback Pl reference Start stop Pump status OLI55 24V U V W leet eo pee ese Q1 oo L1 L213 Altivar 61 VW3A3502 Ale LO51 pCOM 109 LO53 Al1 LO54 10 LOSS I N i LI oLl51
5. 19 Menus Parameter Setting Parameters in the 1 14 Multi pump En menu 001 Op mode Selecting the operating mode 0 Pumps off 0t08 1 Single variable 2 Multiple variable 3 Single variable with changeover of auxiliary pumps 4 Multiple variable with changeover of auxiliary pumps 5 Single variable with limited relative operating time 6 Multiple variable with limited relative operating time 7 Single variable with changeover of auxiliary pumps and limited relative operating time 8 Multiple variable with changeover of auxiliary pumps and limited relative operating time 002 No of pumps Total number of pumps connected Includes the auxiliary pumps and the variable pump 0t05 003 Pump Delay On Time delay before starting an This time is necessary to avoid the effects of 0 to 300 auxiliary pump transient pressure fluctuation and thus prevent oscillation starting stopping of the pump 004 Pump Delay Off Time delay before the request to This time is necessary to avoid the effects of 0 to 300 stop an auxiliary pump transient pressure fluctuation and thus prevent oscillation stopping starting of the pump 005 SleepFunctDel Sleep function time delay If the frequency is below the sleep threshold after 0 to 3000 this time the sleep function is activated 006 Acc Aux Pump Time delay for reaching the Allows the auxiliary pump to reach its nominal speed 0 t
6. L COM OLI52 6LI53 dLI54 P24 4 l ei CP5 CP4 CP3 CP2 CP1 Pump control ji External 24 V ipower supply 6 The state of each pump must be sent back to the pump switching card via a logic input 1 the pump is ready to operate 0 the pump is faulty State of pump 1 on logic input LI51 State of pump 2 on logic input LI52 State of pump 3 on logic input L153 State of pump 4 on logic input LI54 State of pump 5 on logic input LI55 Example of single variable diagram with 5 pumps continued CP1 CP2 E_ KM1 KM2 el Pump 1 Pump 2 For pumps 3 to 5 same diagrams incrementing the indices KMx CPx 1765272 10 2011 23 Connection diagrams Example of multiple variable diagram with 5 pumps 3 phase supply J Q oo L1 L2 13 Altivar 61 VW3A3502 PI feedback SA2 Los1 i LO52 Pl reference LAs tees S440 LO55 CP5 CP4 CP3 CP2 CP1 Start stop LM EEE Sn Tai ea a Da ae hal AR COM oov oLI52 External 24 V ump status oLI53 Pump control ipower supply OLI54 P24 Q O24 V i Q5 KM5 KD5 KM4 KD4 KM3 KD3 KM2 KD2 KM1 KD1 Each pump is controlled by a logic output Pumps Pump 1 control via logic output LO51 Pump 2 control via logic output LO52 Pump 3 control via logic output LO53 Pump 4 control via logic output LO54 Pump 5 control via logic
7. PID references PID reference gt Time Auxiliary pump 1 Stop Auxiliary pump 2 Stop l i I Auxiliary pump 3 Stop e Compensation for loss of head is active when the Pr adj coeff 014 parameter is other than 0 The new PID regulator reference is generated using PID preset reference 2 Preset ref PID 2 rP2 The Preset ref PID 2 rP2 parameter is controlled by the pump switching card It is therefore not possible to use the PID preset references function with the Compensation for loss of head function Example of using the PID regulator with an internal reference Internal PID ref rPI 400 internal reference Min PID feedback PIF1 200 Max PID feedback PIF2 1000 Pr adj coeff 014 50 Each time an auxiliary pump is started the reference becomes variable pump 1 auxiliary pump new reference 450 variable pump 2 auxiliary pumps new reference 500 variable pump 3 auxiliary pumps new reference 550 14 1765272 10 2011 Operating Principle Compensation for loss of head up to the version V1 1IE02 continued Arvo Dr Al2 gt User feedback PIF Al2 j Variable Pump PID speed setpoint en AM User reference Fr1 Al1 ait rPC gt UVW rP2 Y Pr2 C415 See eee oe PERENA ee a EEEE Se a a u a pe De a an a a VW3 A3 502 A A Y L
8. be set to 4000 10 Start the application The PID regulator gains remain at their factory settings and the application can be started The PID starts smoothly with the Acceleration 2 AC2 ramp 5 seconds default setting The process can now be debugged If the process is not fast enough or if there is an error in steady state increase the gain Set the auxiliary pump activation and deactivation thresholds to avoid cascaded starts and stops when there are minor variations in demand 1765272 10 2011 29 Setup 11 Customize the display Create a graph display with the following parameters PID reference rPC and PID feedback rPF 6 MONITORING CONFIG menu App 0 00Hz REM MAIN MENU 1 DRIVE MENU 2 ACCESS LEVEL 3 OPEN SAVE AS RDY App 0 00Mz REM 6 MONITORING CONFIG Code T K ENT 6 1 PARAM BAR SELECT 6 MONITORING CONFIG 6 2 MONITOR SCREEN TYPE 7 DISPLAY CONFIG 6 3 COM MAP CONFIG Code lt lt gt gt T K 6 2 MONITOR SCREEN TYPE Selection of parameters displayed in the centre of the screen and the display mode digital values or bar graph format Deselect the current parameters and select PID reference rPC and PID feedback rPF Select digital values display RUN App 35 00Hz REM PID reference 1250 PID feedback 1200 Code lt lt gt gt T K 30 1765272 10 2011 Setup 12 Create a user menu with the parameters necessary for adjusti
9. 051 y activation Loss of head _ 102 compensation Pumps LO5S 1765272 10 2011 Operating Principle Compensation for loss of head from the version V1 2IE02 An additional step Pr adj coeff 014 is automatically substracted from the PID feedback each time an auxiliary pump is started These reference steps compensate for a loss of pressure loss of head in the pipework due to an increase in flow rate PID feedback PID feedback Compensated PID feedback I I I Time Run j l Auxiliary pump 1 l l Stop i I l l l Run i l Auxiliary pump 2 i i Stop I l l I Run l Auxiliary pump 3 Stop Compensation for loss of head is active when the Pr adj coeff 014 parameter is other than 0 The new PID feedback is generated using the virtual analog input Network Al AlU1 The Network Al AlU1 parameter is controlled by the pump switching card It is therefore not possible to use the virtual analog input with the Compensation for loss of head function 16 1765272 10 2011 Operating Principle Compensation for loss of head from the version V1 2IE02 continued ATV6r ae l Al1 gt User reference FR1 Al1 gt Variable Pump PID speed setpoint AI2 le feedback in uvw AIC1 APP PIF AIV1 ee BEREEHUGEREA
10. 1 3 SETTINGS 1 4 MOTOR CONTROL 1 5 INPUTS OUTPUTS CFG e Leave the pumping ventilation macro configuration factory setting Enter data from the motor rating plate Standard mot freq bFr Rated motor power nPr Rated motor volt UnS Rated mot current nCr Rated motor freq FrS Rated motor speed nSP parameters Perform an auto tune operation Auto tuning tUn parameter In order to perform the auto tuning operation the Op mode 001 parameter in the 1 14 Multi pump En menu must be 0 and a check must be carried out to ensure continuity of wiring between the drive and the motor if there is an output contactor it must be closed 2 Configure the pressure feedback must be input Al2 Al2 is automatically assigned by the pump switching card 1 5 INPUTS OUTPUTS CFG I O menu 0 00Hz REM 1 1 SIMPLY START 1 2 MONITORING RDY App 0 00Hz REM 1 3 SETTINGS RUN App 0 00Hz REM MAIN MENU 1 4 MOTOR CONTROL 1 5 INPUTS OUTPUTS CFG 1 DRIVE MENU 1 5 INPUTS OUTPUTS CFG Al2 CONFIGURATION 2 ACCESS LEVEL Code lt lt gt gt T K 3 OPEN SAVE AS Configure Al2 according to the pressure sensor being used Example 4 20 mA 3 Configure the PID regulator reference The macro configuration Pumps Fans assigns automatically the PID reference to Al1 The factory configuration of Al1 is O 10V The PID reference can be given by an internal reference In the 1 7 A
11. 1765272 Altivar 61 Pump switching card User s manual VW3 A3 502 10 2011 Schneider www schneider electric com ES Electric Contents Important information 4 Before you begin 5 Documentation structure 6 Description 7 Description of the terminals 8 Characteristics 9 Data backup battery 10 Operating Principle 11 General did Choosing a variable speed pump 12 Choosing an auxiliary pump fixed speed 12 Operation using limited relative operating time 12 Special cases 12 Selecting the operating mode 18 Controlling an auxiliary pump 13 Sleep function Wake up function 13 Compensation for loss of head up to the version V1 11E02 14 Compensation for loss of head up to the version V1 1IE02 continued 15 Compensation for loss of head from the version V1 21E02 16 Compensation for loss of head from the version V1 2IE02 continued 17 Menus Parameter Setting 18 Using the graphic display terminal or the setup software in connected to drive mode 18 1 14 Multi pump En menu 18 Parameters in the 1 14 Multi pump En menu 20 Architecture of the booster station 22 Connection diagrams 23 Setup 26 1765272 10 2011 3 Important information PLEASE NOTE Please read these instructions carefully and examine the device in order to familiarize yourself with it before installation operation or maintenance The specific messages whic
12. 4 4 KQ Maximum voltage 30 V Switching thresholds State 0 if lt 5 V or logic input not wired State 1 if gt 11 V Common point for all the card I O 2 Logic outputs LO51 L056 Six 24 V logic outputs positive logic open collector type source compatible with level 1 PLC standard IEC 65A 68 Maximum switching voltage 30 V Maximum current 200 mA Common point for all the card I O 2 I O connection Type of contact Screw at intervals of 3 81 mm Maximum capacity mm 1 5 AWG 16 Tightening torque Nm 0 25 Lithium battery Life 8 years S 1 If the power consumption table does not exceed 200 mA this card can be powered by the drive Otherwise an external 24 V power supply must be used 2 This common point is also the drive 0 V COM 1765272 10 2011 Hardware setup Data backup battery The pump switching card has a non volatile RAM NVRAM which is needed to store variables A lithium battery is mounted on this non volatile RAM to avoid this data being lost when the card is turned off O Lithium battery Important When installing the pump switching card in the drive make sure that this battery is present It takes the form of a rectangular block clipped onto the non volatile RAM see schematic opposite The battery life is 8 years The battery has a re
13. AERGEN vw3a3so2 S Y LO51 5 activation Loss of head 1052 compensation Pumps __ 11053 5 1765272 10 2011 Menus Parameter Setting The various menus the configuration the settings and file transfers are accessed in the same way as with the standard drive using the information given in the Programming Manuals with the addition of the following special features Using the graphic display terminal or the setup software in connected to drive mode If the VW3 A3502 card is present in the drive some of the drive parameters which are necessary for the specific functions of the card are automatically preconfigured It also brings up a new 1 14 Multi pump En menu with new specific parameters to be configured If the display terminal or setup software is used presence of the card is displayed in the IDENTIFICATION menu The following parameters are automatically configured by the card and cannot be modified Assignment of logic inputs LI1 Start stop the installation LI51 LI52 LI53 LI54 LI55 LO51 LO52 LO53 LO54 LO55 Stop Key priority PSt No nO Non nO Profile CHCF Separate SEP Separate SEP Cmd switching CCS ch1 active Cd1 ch1 active Cd1 Cmd channel 1 Cd1 Prog card APP Prog card APP Cmd channel 2 Cd2 Prog card APP Prog card APP Ref 2 switchi
14. E e Read and understand this manual in full before installing or operating the variable speed drive Installation adjustment repair and maintenance must be performed by qualified personnel e The user is responsible for compliance with all international and national electrical standards in force concerning protective grounding of all equipment e Many parts of this variable speed drive including the printed circuit boards operate at the line voltage DO NOT TOUCH Use only electrically insulated tools DO NOT touch unshielded components or terminal strip screw connections with voltage present DO NOT short across terminals PA and PC or across the DC bus capacitors e Install and close all the covers before applying power or starting and stopping the drive e Before servicing the variable speed drive Disconnect all power Place a DO NOT TURN ON label on the variable speed drive disconnect Lock the disconnect in the open position e Disconnect all power including external control power that may be present before servicing the drive Wait for the charging LED to go off WAIT 15 MINUTES for the DC bus capacitors to discharge Then follow the procedure for measuring the DC bus voltage given in the Installation Manual The drive LEDs are not accurate indicators of the absence of DC bus voltage Failure to follow these instructions will result in death serious injury or equipment damage A CAUTION DAMAGED EQUIPMEN
15. PPLICATION FUNCT FUn menu select the PID REGULATOR Pld function and the Act internal PID ref PII Yes YES parameter The PID reference is then given by the Internal PID ref rPI parameter 26 1765272 10 2011 Setup 4 Check the wiring of the pumps 1 2 MONITORING SUP menu RUN App _ 0 00Hz REM 1 2 MONITORING VO MAP ENT a Controller Inside O MAP Pump switching card I O COMMUNICATION MAP Alarm groups HMI Frequency ref The presence of the pumps can be checked via the state of the logic inputs on the pump switching card LI51 LI52 LI53 L154 LI55 Pump switching card I O RUN App ___ 50 00Hz_REM Move from one screen to another from C INSIDE CARD LI MAP to Controller inside AO MAP C INSIDE CARD LI MAP a an Gul Controller inside Al MAP Yung INeinavigation Dullon C INSIDE CARD LO MAP Controller inside AO MAP State 0 RUN App 50 00Hz REM PROG CARD LI MAP LI51 LI52 LI53 LI54 LI55 LI56 LI57 LI58 m m M State 1 0 LI59 LI60 1 om E The pump feedback logic inputs are used to ascertain the state of the pumps In the above diagram Pumps No 1 No 2 and No 3 are present 5 Check the direction of rotation of the variable pump The direction of rotation of the variable pump can be checked by switching to control via graphic display terminal mode Press the T K key F4 default T K assignment Set a low speed referenc
16. RJ45 connector not used 2 9 way male SUB D connector for connection to the CANopen bus not used 3 Connector with removable screw terminals 6 contacts at intervals of 3 81 for the 24 V power supply and 4 logic inputs 4 3 connectors with removable screw terminals 6 contacts at intervals of 3 81 for 6 logic inputs 6 logic outputs 2 analog inputs 2 analog outputs and 2 commons Some inputs and outputs are not used as detailed on the next page 5 5 LEDs comprising e 1 to indicate the presence of the 24 V power supply e 1 to indicate a program execution fault e 2 to indicate the CANopen bus communication status e 1 controlled by the application program 6 Block of 4 configuration switches not used 1765272 10 2011 Hardware setup Description of the terminals AO52 COM AO51 Al52 COM SLA AFA AIS1 LO52 LO51 LI60 LI59 LI58 LI57 LI56 L 0 fA T LI55 LO56 LO55 LO54 LO53 IROL UDO l 24V COM LI51 LI52 LI53 LI54 24V Power supply for the pump switching card logic outputs and analog outputs If allowed by the power consump
17. T Do not install or operate any drive that appears damaged Failure to follow this instruction can result in bodily injury and or equipment damage 1765272 10 2011 Documentation structure Installation Manual This manual describes e How to assemble the drive e How to connect the drive Programming manual This manual describes e The functions e The parameters e Use of the drive terminal integrated display terminal and graphic display terminal Communication Parameters Manual This manual describes e The drive parameters with specific information addresses formats etc for use via a bus or communication network e The operating modes specific to communication state chart e The interaction between communication and local control Communication bus and network manuals Modbus CANopen Ethernet Profibus INTERBUS DeviceNet etc These manuals describe e Connection to the bus or network e Configuration of the parameters specific to communication via the integrated display terminal or the graphic display terminal e Diagnostics e Software setup e The protocol communication services Altivar 38 compatibility manual This manual describes the differences between the Altivar 61 and the Altivar 38 It explains how to replace an Altivar 38 including how to replace drives communicating on a bus or network 6 1765272 10 2011 Description Mau s 1
18. altime clock for timestamping faults The precision of the clock is 3 76 seconds per day The date and time on this clock are checked and set from a special sub menu in the 1 14 Multi pump En customizable menu in the graphic display terminal The date and time need to be set on receipt of the pump switching card or after replacing its lithium battery The lithium battery must only be replaced when the drive and the pump switching card are turned off During this operation the data saved in the NVRAM 4 Kwords is lost Spare part reference does not exist for the battery because of a problem of time storage So it is necessary to order it by your self The reference of the baterry is TIMEKEEPER SNAPHAT M4T28 BR12SH1 48mAh 1765272 10 2011 Operating Principle General The main object is to control a complete pumping installation using a single ATV61 drive providing Constant pressure in the system whatever the flow rate A simple method for setting up and diagnosing the installation via the ATV61 The system is operated using several fixed soeed pumps maximum of 4 and one variable speed pump which is unable to provide the full flow range required on its own A PI regulator is used for pump control The pressure sensor provides system feedback To avoid systematic wear of the same pumps a function is provided that allows switching of the pumps according to their operating time The variable pump can also be includ
19. e and give a run command in order to check the direction of rotation of the variable pump All of the wiring must be checked in order to ensure that the direction of rotation of the auxiliary pumps is identical 6 Check the pressure sensor stay in control via graphic display terminal mode 1 2 MONITORING SUP menu I O MAP RUN App 50 00Hz REM VO MAP RUN App 50 00Hz REM LOGIC INPUT MAP ANALOG INPUTS IMAGE Rotate the pump in order to check that the pressure feedback varies according ANALOG INPUTS IMAGE LOGIC OUTPUT MAP ANALOG OUTPUTS IMAGE FREQ SIGNAL IMAGE Code T K All 9 87 V Al2 2 35 mA to the motor speed Code lt lt gt gt T K 1765272 10 2011 27 Setup 7 Determine the cavitation threshold See the characteristics of the pump If the cavitation threshold is not known it can be determined in the following way In control via graphic display terminal mode set the speed reference to the nominal speed of the variable pump The speed reference must then be gradually lowered carry out tests at different initial flow rates The flow rate decreases gradually then abruptly reaches the cavitation point the speed of the pump no longer has any effect on the flow rate In regulation mode run the variable pump then gradually close the shutoff valve The flow rate decreases the pressure tends to increase but the pressure regulation gradually reduces t
20. ed in this changeover procedure The variable speed pump PV is called a variable pump The fixed speed pumps are called auxiliary pumps Application example with 3 fixed pumps The auxiliary pumps are turned on and off according to the flow rate required by the installation The variable pump is controlled so as to ensure continuity in the flow rate variations Card Control of auxiliary pumps VW3A3502 Pressure measurement PV variable pump Flow rate at P1 P2 P3 auxiliary pumps constant pressure Flow 4 rate PV Py P3 PV P2 P2 E P1 Pi P PV 5 5 3 Number of pumps 1765272 10 2011 11 Operating Principle The Altivar 61 controls the pumps via logic outputs LO51 LO52 LO53 etc according to the operating mode that has been programmed The logic inputs indicate the state of the pumps to the Altivar 61 Ll 1 the pump is ready to operate LI 0 the pump is faulty Hour counters are used to determine the total operating time of each pump Choosing a variable speed pump Single variable In this mode the same variable pump is always used It is always controlled by the drive Multiple variable In this mode all the pumps can be variable one at a time The variable pump is chosen according to its operating time stored by the Altivar 61 the pump with the shortest operating time is selected The variable pump can only be changed over if all the auxiliary
21. h follow can appear in the documentation or on the device They warn you of potential dangers or draw your attention to information which can clarify or simplify a procedure The presence of this symbol on a danger or warning label indicates that there is a risk of electrocution which can cause bodily injury if the instructions are not followed A This is the symbol for a safety warning It warns you of a potential danger of bodily injury Follow all the safety instructions accompanying this symbol to avoid any situation that can result in injury or death A DANGER DANGER indicates a dangerous situation resulting in death serious injury or equipment damage A WARNING WARNING indicates a situation involving risks that can cause death serious injury or equipment damage A CAUTION CAUTION indicates a potentially dangerous situation that can result in bodily injury or equipment damage IMPORTANT NOTE The maintenance of electrical equipment must only performed by qualified personnel Schneider Electric can in no way be held responsible for the consequences of using this documentation This document is not intended to be used as a guide by persons who have received no training 2011 Schneider Electric All rights reserved 4 1765272 10 2011 Before you begin Read and understand these instructions before performing any procedure on this drive A DANGER RISK OF DANGEROUS VOLTAG
22. h pump must be sent back to the pump switching card via a logic input 1 the pump is enabled and ready to operate 0 the pump is faulty or disabled State enabling of pump 1 on logic input LI51 State enabling of pump 2 on logic input LI52 State enabling of pump 3 on logic input LI53 State enabling of pump 4 on logic input LI54 State enabling of pump 5 on logic input LI55 Example of multiple variable diagram with 5 pumps with manual automatic switching continued KD5 KD4 KD3 KD2 KM1 e at cP2 i Q2 J E J E sos 585 Z0 KD1 7 Sn ie ia gt ems KD5 f i Bi I ae KD4 f S ok E E KD2 o Pump 1 Pump 2 For pumps 3 to 5 same diagrams incrementing the indices Qx KAx KDx KMx CPx 1765272 10 2011 25 Setup A WARNING RISK OF IMPROPER DRIVE OPERATION The parameters in the 1 14 Multi pump En menu must be only modified when the drive is locked i e when logic input LI1 is at 0 This procedure must also be carried out in the following cases Transferring configuration files Saving a configuration file Writing a parameter via the RS485 serial link Failure to follow these instructions can result in death serious injury or equipment damage 1 Enter via the 1 1 SIMPLY START SIM menu RDY App 0 00Hz REM RDY App 0 00Hz REM MAIN MENU 1 DRIVE MENU 1 DRIVE MENU 1 1 SIMPLY START 2 ACCESS LEVEL 1 2 MONITORING 3 OPEN SAVE AS
23. has been created can be saved in the graphic display terminal App _ 0 00Hz REM MAIN MENU RUN App 0 00Hz REM 3 OPEN SAVE AS 1 DRIVE MENU 2 ACCESS LEVEL ENT 3 OPEN SAVE AS 4 PASSWORD 5 LANGUAGE Code In the MAIN MENU screen select SAVE AS To download the current drive configuration to the graphic display terminal ENT App 0 00Hz SAVE AS REM 1765272 10 2011 33 34 1765272 10 2011 ATV61_carte_multi_pump_EN_1765272_04 1765272 10 2011
24. he speed of the pump to keep the pressure at the reference value Read the frequency value when the flow rate approaches zero flow rate before cavitation Adjust Low speed LSP to 1 or 2 Hz above the point at which the flow rate drops The default value can be around 30Hz for a standard centrifugal pump 8 Set the parameters of the pump switching application Check first that the wiring diagram corresponds to the selected mode 1 14 Multi pump En menu Set the values in parentheses are given for information only they depend on the characteristics of the pumps and the hydraulic system Op mode 001 Selection of the operating mode No of pumps 002 Total number of pumps connected Pump Delay On 003 Time delay before starting an auxiliary pump 3 to 5 s Pump Delay Off 004 Time delay before the request to stop an auxiliary pump 3 to 5 s SleepFunctDel 005 Sleep function time delay 30 s Acc Aux Pump 006 Time delay for reaching the nominal speed of an auxiliary pump 1 to 2 s Dec Aux Pump 007 Time delay for stopping an auxiliary pump 1 to 2 s Lim Rel Time 008 Limited relative operating time FrqAuxPumpOn 012 Starting frequency of a new auxiliary pump High speed HSP 2Hz FrqAuxPumpOff 013 Stopping frequency of an auxiliary pump High speed HSP 12 Hz Pr adj coeff 014 Pressure adjustment coefficient Sleep thresh 015 Sleep threshold 3 to 4 Hz above Low speed LSP
25. ing threshold a pump is stopped When the stop command is sent a time delay Dec Aux Pump 007 parameter is started to allow the pump to reach an effective stop before stopping another pump avoids oscillation Sleep function Wake up function This function is used to stop the variable pump when the flow rate is zero all the auxiliary pumps are off In this case if the frequency of the variable pump is below the sleep threshold Sleep thresh 015 parameter a time delay SleepFunctDel 005 parameter is started If after this time delay SleepFunctDel 005 the frequency remains below the Sleep thresh 015 threshold the variable pump then stops The installation is in sleep state To switch to wake up state the pressure feedback must drop to below the wake up threshold WUp thresh 016 parameter The variable pump is then started Pl feedback WUp thresh 016 Motor frequency Sleep thresh 015 LSP a SleepFunctDel 005 3 Sleep threshold operating time gt 1765272 10 2011 13 Operating Principle Compensation for loss of head up to the version V1 1IE02 An additional step Pr adj coeff 014 is automatically added to the reference value each time an auxiliary pump is started These reference steps compensate for a loss of pressure loss of head in the pipework due to an increase in flow rate PID regulator reference Compensated
26. ng rFC ch1 active Fr1 ch1 active Fr1 Ref 2 channel Fr2 No nO No nO Copy channel 1 lt gt 2 COP No nO No nO PID feedback ass PIF AI2 Al2 Network Al AlU1 Ramp switch ass rPS C411 C411 C411 C411 2 preset PID ref Pr2 C415 C415 Low speed time out tLS 0 0 0 0 Al net channel AICI Prog card APP All the parameters are described in the Programming Manual 1 14 Multi pump En menu The parameters in the 1 14 Multi pump En menu are coded OXX XX varying from 01 to 20 see the list of parameters on the following pages 1765272 10 2011 Operation using the graphic display terminal Setting the date and time In the 1 14 Multi pump En menu DATE TIME SETTINGS submenu the following can be set Year Month Day Hours Minutes Hour Minutes Month Day Year Quick Note The date and time are not refreshed on this settings screen The current date and time Date Time CLO can be displayed in the 1 2 MONITORING SUP menu Note It is not possible to change either the date or time format The date cannot be displayed in the year month day format e The time cannot be displayed in the 10 42 pm format only in the 22 42 format Note It is not possible to configure changes between winter and summer time 1765272 10 2011
27. ng the application Switch to Advanced mode Go to the MAIN MENU and select 2 ACCESS LEVEL LAC Advanced AdU RDY App 0 00Hz REM RDY App 0 00Hz REM 2 ACCESS LEVEL MAIN MENU Basic 1 DRIVE MENU Standard 2 ACCESS LEVEL Advanced 3 OPEN SAVE AS 4 PASSWORD 5 LANGUAGE Code Go to the 7 DISPLAY CONFIG menu then 7 2 USER MENU to select the parameters required in the 1 13 USER MENU Usr 0 00Hz REM MENU 1 DRIVE MENU 2 ACCESS LEVEL 3 OPEN SAVE AS RDY App 0 00Hz REM 7 DISPLAY CONFIG 6 MONITORING CONFIG ENT 7 1 USER PARAMETERS 7 DISPLAY CONFIG pa 7 3 PARAMETER ACCESS Code lt lt gt gt T K In the 1 7 APPLICATION FUNCT FUn menu select PID REGULATOR Pld gt PID prop gain rPG and PID integral gain rlG The following 2 parameters now appear in the 1 13 USER MENU USr PID prop gain rPG PID integral gain rlG RDY App 0 00Hz REM 1 13 USER MENU PID integral gain 1 00 PID prop gain 1765272 10 2011 31 Setup 13 Create a display in customer units for the PID reference rPC and PID feedback rPF parameters Example with a 0 10 bar sensor Min PID feedback PIF1 0 Max PID feedback PIF2 10 000 in order to have the best possible resolution in the operating range Change the unit of the PID reference rPC and PID feedback rPF parameters and select mbar MAIN MENU gt 7 DISPLAY CONFIG
28. o 300 nominal speed of an auxiliary before starting another pump avoids oscillation pump 007 Dec Aux Pump Time delay for stopping an Allows the auxiliary pump to reach its zero flow rate 0 to 300 auxiliary pump before stopping another pump avoids oscillation 008 Lim Rel Time Limited relative operating time If the total operating time of a running auxiliary pump 0 to 3000 and a stopped pump differs by more than the time set in 008 the first pump is stopped and replaced by the second The unit can be changed from hours to minutes via the O17 parameter see next page in order to control operation 009 ResetOpTime Resets the operating counter of a Select the pump number using this parameter Oto5 pump Press ENT The operating time of the pump is reset and the parameter automatically returns to 0 Use when replacing a pump 010 Pump no Number of the pump with If 010 0 parameter 011 indicates the value of the 0to5 operating time displayed in O11 pressure feedback 011 Op time Display of the operating time of If 010 0 this parameter indicates the value of the 0 to the pump selected by 010 pressure feedback 1 65535 1 The unit is determined by the Min PID feedback PIF1 and Max PID feedback PIF2 parameters which are used to calibrate the PID feedback sensor range See example on page 14 20 1765272 10 2011 Menus Parameter Setting 012 FrqAuxPumpOn
29. output LO55 The state of each pump must be sent back to the pump switching card via a logic input 1 the pump is ready to operate 0 the pump is faulty State of pump 1 on logic input LI51 State of pump 2 on logic input LI52 State of pump 3 on logic input L153 State of pump 4 on logic input L154 State of pump 5 on logic input LI55 Example of multiple variable diagram with 5 pumps continued CP1 CP2 KD5 KD1 KD1 i KD5 KD4 i KD3 KD4 KD5 KD3 KD4 KD2 KD3 KM1 KM2 f KD2 E KD2 C J KM2 Pump 1 Pump 2 For pumps 3 to 5 same diagrams incrementing the indices KDx KMx CPx 24 1765272 10 2011 Connection diagrams Example of multiple variable diagram with 5 pumps with manual automatic switching 3 phase supply Pumps 7 Q I L1 L2 13 Altivar 61 VW3A3502 PI feedback Aa LOS L952 LO53 Pl reference LAM LOSA 10 LO55 Start stop un PE cP4 CP3 CP2 CP1 u ae a ur GER is oe SOV nara y External 24 V Pum l i ao oLI53 Pump control ipower supply OLI54 P24 0 24V i Q5 KM5 KD5 KM4 KD4 KM3 KD3 KM2 KD2 KM1 KD1 Each pump is controlled by a logic output Pump 1 control via logic output LO51 Pump 2 control via logic output LO52 Pump 3 control via logic output LO53 Pump 4 control via logic output LO54 Pump 5 control via logic output LO55 The state and enabling of eac
30. pumps are off Choosing an auxiliary pump fixed speed 2 options The auxiliary pumps are started in ascending order of the logic outputs example LO51 then LO52 then LO53 then LO54 then LO55 The auxiliary pumps are stopped in descending order of the logic outputs example LO55 then LO54 then LO53 then LO52 then LO51 Switching the auxiliary pumps Starting up an auxiliary pump the pump with the shortest operating time stored in the drive is selected Stopping an auxiliary pump the pump with the longest operating time stored in the drive is selected Operation using limited relative operating time A relative operating time differential between each pump can be programmed to ensure better distribution of operating times thereby limiting pump wear If the total operating time differential between an operating auxiliary pump and one which is off exceeds the programmed differential the first pump is stopped and replaced by the second one The variable pump can only be replaced if all the auxiliary pumps are off and if its operating frequency is below the programmed threshold V pumpSwFr 018 Special cases If a pump is shown as faulty LI 0 it is not taken into account by the Altivar 61 and the starting and stopping conditions apply only to the other pumps 12 1765272 10 2011 Operating Principle Selecting the operating mode The pump switching card provides 9 possible operating modes These modes combine
31. the choice of variable pump the choice of auxiliary pump and limitation of relative operating time The mode is selected using the Op mode 001 parameter 1 14 Multi pump En menu Controlling an auxiliary pump The PI regulator output frequency reference of the variable pump is used to control starting or stopping of an auxiliary pump with hysteresis as shown in the figure below Frequency of the variable pump Startup 4 of an auxiliary pump HSP Leto 2 22222 So ee sce N ee Starting 45 oo eo et frequency Stop of an Frequenc auxiliary pump a x corresponding to the flow rate of an auxiliary pump Stopping frequency Flow rate of the installation When the frequency exceeds the starting threshold FrqAuxPumpOn 012 parameter a time delay Pump Delay On 003 parameter is started to avoid the effects of transient flow fluctuations If after this time delay the frequency remains higher than the starting threshold another pump is started When the start command is sent a time delay Acc Aux Pump 006 parameter is started to allow the pump to reach its nominal speed before starting another pump avoids oscillation When the frequency is below the stopping threshold FrqAuxPumpOff 013 parameter a time delay is started Pump Delay Off 004 parameter to avoid the effects of transient flow fluctuations If after this time delay the frequency remains below the stopp
32. tion table for example if outputs are not being used the pump switching card can be powered by the 24 V power supply in the drive If you are using an external power supply The pump switching card must be turned on before the drive is turned on or at the same time as the drive is turned on If this order is not followed the drive will lock in a card fault ILF This fault cannot be reset and the only way to acknowledge it is to turn off the drive e Catalog number for a Schneider Electric power supply 24 V 2A ABL7 RE 24 02 COM Common ground and electrical OV of the pump switching card power supply logic inputs Llee outputs LOee analog 3 terminals inputs Alee and analog outputs AOee This ground and electrical OV are common with the drive ground and electrical OV There is therefore no point in connecting this terminal to the OV terminal on the drive control terminals LI51 to LI60 24 V logic inputs LI56 to LI60 Not used LO51 to LO56 24 V logic outputs LO56 Not used Al51 and Al52 0 20mA analog inputs Not used AO51 and AO52 0 20mA analog outputs Not used 1765272 10 2011 Hardware setup Characteristics Electrical characteristics Power supply Voltage V 24 min 19 max 30 Current Maximum A 2 consumption No load mA 80 Using logic output mA 200 maximum 1 Logic inputs LI51 LI60 Impedance

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