ITT Flygt ACS550 Start-Up Guide_20060615.book
Contents
1. 2203 DECELER TIME 1 0 0 1800 s 01s 4s CHANGED DEFAULT VALUE 2205 ACCELER TIME 2 0 0 1800 s 0 1s 60s REMOVED 2206 DECELER TIME 2 0 0 1800 s 0 1s 60s REMOVED Group 29 Maintenance Trig REMOVED Group 30 Fault Functions 3005 MOT THERM PROT 0 NOT SEL 1 O NOT CHANGED DEFAULT VALUE 1 FAULT SEL uL 2 WARNING The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical amperes at the drive nominal voltage 600 V maximum for 690 V units The drive provides overload protection in accordance with the National Electrical Code US The ITT Flygt version of ACS550 default setting is off and must be activated at start up See User s Manual 3AFE64804588 English for the standard ACS550 01 U1 default setting The drives are to be used in a heated indoor controlled environment see chapter Technical Data section Ambient Conditions User s Manual 3AFE64804588 English for specific limits Brake chopper ABB has brake choppers that when applied with appropriately sized brake resistors will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Proper application of the brake chopper is defined in chapter Technical Data section Brake Components User s Manual SAFE64804588 English This can be applied to a single drive or multiple drives with DC bus connected to allow a sharing of regenerative energy Group 33 I2. 4613 REV RUN TIME Defines the reverse running time in the PCS Range 0 0 100 0 s Resolution 0 1 s Default 7 0 s 4614 REV RUN ACC Defines the reverse acceleration time in the PCS If the actual application demands a longer PCS reverse acceleration time due to fluid mechanical or electrical factors set the parameter to meet the demand ATTENTION No lower value than 2 0 s shall be set since stress on the impeller and shaft increases with reduced acceleration time Range 0 0 100 0 s Resolution 0 1 s Default 2 0 s 4615 REV RUN DEC Defines the reverse deceleration time in the PCS If the actual application demands a longer PCS reverse deceleration time due to fluid mechanical or electrical factors set the parameter to meet the demand Range 0 0 100 0 s Resolution 0 1 s Default 0 3 s Start up 23 Appendix 1 Controlling the PCS What this appendix contains This appendix describes the control principles of the pump cleaning sequence PCS regarding communication between the pump controller and the ITT Flygt version of ACS550 Overview The PCS can be controlled according to 3 0 to 2 different principles Disable the PCS Control principle 0 In order to completely disable the PCS parameters 4601 EXE P CLEAN SEQ and 4602 REQ P CLEAN SEQ must both be set to 0 NOT SEL Pump controller executing the PCS Control principle 1 When parameter 4601 EXE P CLEAN SEQ is set to 1 and param
3. LOC UMAIN MENU PARAMETERS SHOW HIDE CHANGED PAR EXIT ENTER LOC UPAR GROUPS 99 46 PUMP CLEAN SEQ 99 START UP DATA EXIT SEL Start up data Always to be set a Scroll with CANS Y to parameter 9901 LANGUAGE and press EDIT b Scroll with a v to the language to be set then press X LOC U PARAMETERS 9901 LANGUAGE ENGLISH 9902 APPLIC MACRO 9904 MOTOR CTRL MODE 9905 MOTOR NOM VOLT EXIT EDIT LOC UPAR EDIT 9901 LANGUAGE ENGLISH 0 CANCEL SAVE Start up data Always to be set 8 Check the pump data sheet and find the nominal voltage Scroll with CANT to parameter 9905 MOTOR NOM VOLT and press lt b Set the nominal voltage by pressing CANIS w 2 then press xl LOC U PARAMETERS 9901 LANGUAGE 9902 APPLIC MACRO 9904 MOTOR CTRL MODE 9905 MOTOR NOM VOLT 600 v EXIT EDIT LOC UPAR EDIT 9905 MOTOR NOM VOLT V CANCEL SAVE Start up data Always to be set a Check the pump data sheet and find the rated current b Scroll to parameter 9906 MOTOR NOM CURR set the rated current then save LOC UPAR EDIT 9906 MOTOR NOM CURR CANCEL SAVE Start up 14 Step Action Control panel display 6 Start up data Always to be set a Check the pump data sheet and find the nominal frequency LOC UPAR EDIT b Scroll
4. PCS 2 0 cadum kr RR E xeu E ae s 18 Start command in remote control l l ees 18 Interrupting the POS res AA ae nn E E a et EN RES 18 lee Coucou 18 Important parameter settings 0 02 zzz zzz zzz 19 Appendix 1 Controlling the PCS What this appendix contains 0 0 2 cc ns 23 OVOIVIOW y sa pb a re RES REGNO Sad A ert ham Aueh Put ect ber une 23 Disable the PCS Control principle O lille 23 Pump controller executing the PCS Control principle 1 20222020000005 23 ACS550 executing the PCS Control principle 2 2 2 2 2 2 0 eee 24 Testing demonstrating the PCS s du puros ee pared EE Debt ePeracheu tie d wed p a saad 25 Appendix 2 ITT Flygt version of ACS550 parameters What this appendix contains o ooooooo lr 26 Group 99 START UP DATA oooccccccc e nn 26 Group 01 Operating Data i aenst see ge E a ens 26 Group 10 Start Stop Dir z asz ee e eee E A e Ete a aa 26 Group 11 Reference Select i io em naar es HIER DR ie ee PA 27 Group 12 Constant Speeds oococoocooco eeee 27 Group T3 Analogue InpUls 5 23 um oh Aare eee be rt ls vi e ke 27 Group 14 Relay QUIDUls lt a e es 27 Group 15 Analogue OUIDUILS tates rat eee let ee ee eee 27 Group 20 LimltS x2 ero ee da ue pe Bg El o 28 Group 21 Start Stop doe ean seine a eae alae Un aera haart 28 Group 22 AccellDecel socia ah dare be Paraben ats Oe Pao Di rd route t 28 Group 29 Mai
5. REV RUN DEC 0 0 100 0 s 0 1s 0 3s ADDED Group 81 PFC Control REMOVED Appendix 2 ITT Flygt version of ACS550 parameters vyS968 EV 16A 4 1110 90 ZL VO NA 0 LO OSSSOV JO uosa YHA LLI FLYGT www flygt com
6. Unit and scale defined by REMOVED par 4206 and 4207 0130 PID 1 FBK Unit and scale defined by REMOVED par 4006 4106 and 4007 4107 0131 PID 2 FBK Unit and scale defined by REMOVED par 4206 and 4207 0132 PID 1 DEVIATION Unit and scale defined by REMOVED par 4006 4106 and 4007 4107 0133 PID 2 DEVIATION Unit and scale defined by REMOVED par 4206 and 4207 Group 10 Start Stop Dir 1001 EXT 1 COMMANDS 0 14 CHANGED DEFAULT VALUE 1003 DIRECTION 1 3 CHANGED DIRECTION CANNOT BE REQUESTED IN REMOTE CONTROL MODE AUTOMATIC REVERSE DIRECTION IN THE PUMP CLEANING SEQUENCE Appendix 2 ITT Flygt version of ACS550 parameters 27 Code Name Range Res Default Modifications in ITT Flygt version of ACS550 Group 11 Reference Select 1102 EXT1 EXT2 SEL 6 12 1 0 REMOVED 9 TIMER FUNCTION 1 10 12 TIMER FUNCTION 2 4 1103 REF1 SELECT 0 17 1 CHANGED DEFAULT VALUE 1106 REF2 SELECT 0 19 1 REMOVED 9 TIMER FUNCTION 1 10 12 TIMER FUNCTION 2 4 19 PID1OUT Group 12 Constant Speeds 1201 CONST SPEED 14 19 1 9 REMOVED SEL 15 18 TIMER FUNCTION 1 4 19 TIMER 1 amp 2 1209 TIMED MODE SEL 1 2 1 2 REMOVED Group 13 Analogue Inputs 1304 MINIMUM Al2 0 100 0 1 20 CHANGED DEFAULT VALUE Group 14 Relay Outputs 1401 RELAY OUTPUT
7. a time that exceeds the value set to parameter 4604 TON TORQ The fulfilment of the condition is monitored and analyzed by the drive 2 RUN TIME The request of the PCS is triggered when the actual run time parameter 0114 RUN TIME since the last start command or since the last completed PCS exceeds the reference value set to parameter 4605 RUN TIME REQ The fulfilment of the condition is monitored and analyzed by the drive 3 TORQ OR RUN TIME The request of the PCS is triggered when either the motor torque or run time condition is fulfilled as described above under selection 1 TORQ or 2 RUN TIME 4 P CTRL DI2 The request of the PCS is triggered by the pump controller setting digital input DI2 of the drive from 0 to 1 There are two reasons for using this selection Only the parameters analyzed by the pump controller and the logic programmed to the pump controller are used to control the PCS thus the drive s capability to analyze torque and or run time is not utilized Testing demonstrating the PCS and the logic of the relay output and digital input signals involved with the PCS by simulating that the request of the PCS is coming from the drive as if the torque and or run time condition was really fulfilled as monitored and analyzed by the drive Default 1 4603 TORQ REQ The parameter is used with parameter 4602 REQ P CLEAN SEQ selections 1 and 3 It defines the motor torque reference value in percent of nomina
8. drive to suit the speed regulated wastewater pumping application The ITT Flygt version of ACS550 is designed to be operated by one external pump controller In a typical speed regulated wastewater pumping application several drives are controlled by one external pump controller and each pump is driven by its own drive unit as illustrated in Figure 7 Pump 3 3 controller ACS550 ACS550 Figure 1 ITT Flygt version of ACS550 in speed regulated wastewater pumping application The drive contains one application macro ITT Flygt The main function of the macro is to automatically detect and remove clogging substances from the pump impeller The drive can detect clogging that occurs during operation by monitoring the pump motor torque The actual value is compared to a reference value that has been set to the drive If due to clogging the actual value exceeds the reference value for a certain time period the pump cleaning sequence can be executed The pump cleaning sequence can also be executed at run time intervals set to the drive counting from zero at every pump start Execution of the pump cleaning sequence at run time intervals can be used as a preventive measure and a complement to the automatic detection and removal of clogging in applications that are prone to clogging Description of the ITT Flygt version of ACS550 10 User interface Application By default
9. only parameter groups 46 PUMP CLEAN SEQ and 99 START UP DATA are shown and accessible The reason is to minimize the number of parameters that confront the user All parameters in the drive shown and hidden have default values that are especially fit for speed regulated wastewater pumping If necessary all parameter groups can be shown and accessible by a selection in the submenu SHOW HIDE The ITT Flygt version of ACS550 is equipped with a special control panel The main menu of the control panel features submenu SHOW HIDE which is used to make all parameter groups accessible inaccessible except groups 46 PUMP CLEAN SEQ and 99 START UP DATA who are always shown The control panel does not provide assistants as does the standard ACS550 01 U1 Assistant Control Panel macro ITT Flygt The application macro ITT Flygt is configured for wastewater pumping applications and contains the pump cleaning sequence When the ITT Flygt macro is selected parameter 9902 APPLIC MACRO all drive parameters shown and hidden are reset to default values Pump cleaning sequence PCS The pump cleaning sequence PCS is defined by parameter group 46 PUMP CLEAN SEQ When the PCS is executed it operates as illustrated in Figure 2 where one PCS cycle is shown together with the parameters forming it Refer to section Important parameter settings on page 19 to study all the parameters involved with the PCS as well as particularly important normal ope
10. to parameter 9907 MOTOR NOM FREQ set the nominal 9907 MOTOR_NOM FREQ frequency then save 0 0 Hz CANCEL SAVE 7 Start up data Always to be set a Check the pump data sheet and find the nominal speed LOC UPAR EDIT b Scroll to parameter 9908 MOTOR NOM SPEED set the nominal 9908 MOTOR NOM SPEED speed then save rpm CANCEL SAVE 8 Start up data Always to be set a Check the pump data sheet and find the rated power LOC UPAR EDIT b Scroll to parameter 9909 MOTOR NOM POWER set the rated power 9909 MOTOR NOM POWER then save CANCEL SAVE _ 9 Parameter 4601 Set depending on the pump cleaning sequence PCS control principle LOC U PARAMETERS For description of the parameter see page 19 If another selection than ep es default is to be set 9909 MOTOR NOM POWER a Scroll with CANS w 2 to parameter 4601 b Press X select by pressing CANIS w 7 then press wl EXIT EDIT 10 Parameter 4602 Set depending on the PCS control principle For the parameter description see page 20 If another selection than default is to be set Scroll to the parameter set it and save the selection 11 Parameters 4604 4615 Normally not to be set The parameters are described on pages 20 to 22 If any default value is not suitable to the actual application scroll to the parameter set it and save the value Start up 15 Step Action Control panel display 12 Hidden parameters Normally not to be set For complete parame
11. 1 0 45 1 2 ADDED 46 PCS REQ 47 PCS EXE REMOVED 30 PID SLEEP 31 PFC 32 AUTOCHANGE CHANGED DEFAULT VALUE 1402 RELAY OUTPUT 2 0 45 1 46 ADDED 46 PCS REQ 47 PCS EXE REMOVED 30 PID SLEEP 31 PFC 32 AUTOCHANGE CHANGED DEFAULT VALUE 1403 RELAY OUTPUT 3 0 45 1 47 ADDED 46 PCS REQ 47 PCS EXE REMOVED 30 PID SLEEP 31 PFC 32 AUTOCHANGE CHANGED DEFAULT VALUE Group 15 Analogue Outputs 1501 AO1 CONTENT 99 199 1 106 CHANGED DEFAULT VALUE SEL 1502 AO1 CONTENT 0 kw CHANGED DEFAULT VALUE MIN 1504 MINIMUM AO1 0 0 20 0 0 1 m 4mA CHANGED DEFAULT VALUE 1507 AO2 CONTENT 99 199 1 105 CHANGED DEFAULT VALUE SEL 1510 MINIMUM AO2 0 0 20 0 0 1mA 4mA CHANGED DEFAULT VALUE Appendix 2 ITT Flygt version of ACS550 parameters 28 Code Name Range Res Default Modifications in ITT Flygt version of ACS550 Group 20 Limits 2007 MINIMUM FREQ 500 500 Hz 0 1 Hz 35 Hz CHANGED DEFAULT VALUE Group 21 Start Stop 2101 START FUNCTION 1 5 1 CHANGED DEFAULT VALUE 2102 STOP FUNCTION 1 COAST 1 CHANGED DEFAULT VALUE 2 RAMP 2103 DC MAGN TIME 0 10s 0 01s 1s CHANGED DEFAULT VALUE Group 22 Accel Decel 2201 ACC DEC 1 2 SEL 0 7 1 6 1 5 REMOVED 2202 ACCELER TIME 1 0 0 1800 s 01s 2s CHANGED DEFAULT VALUE
12. PCS is executed both relay outputs RO2 and RO3 of the drive energize During the PCS both RO2 and RO3 remain energized When the last cycle of the PCS ends both RO2 and RO3 deenergize and normal operation continues Control principle 2 is applied when only the drive s capability to monitor and analyze torque and or run time is to control the PCS thus the parameters analyzed by the pump controller and the logic programmed to the pump controller are not utilized Appendix 1 Controlling the PCS 25 Control principle 2 including the order of events is illustrated in Figure 6 Pump controller 1 PCS Requested 2 PCS Executed DI2 DI3 RO2 RO3 ACS550 Figure 6 Control principle 2 PCS Pump cleaning sequence DI Digital input RO Relay output Testing demonstrating the PCS When parameter 4601 EXE P CLEAN SEQ is set to 1 or 2 and parameter 4602 REQ P CLEAN SEQ to 4 the pump controller can set digital input DI2 of the drive from 0 to 1 to simulate that the request of the PCS is coming from the drive as if the torque and or run time condition was really fulfilled as monitored and analyzed by the drive When DI2 is set from 0 to 1 the drive energizes relay output RO2 Depending on whether parameter 4601 EXE P CLEAN SEQ is set to 1 or 2 the PCS can then be executed according to Control principle 1a or 2 respectively When parameter 4601 EXE P CLEAN SEQ is set to 1 and paramet
13. and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive or the pump motor Read the safety instructions before working on the drive The chapters of this guide are briefly described below About this guide describes the guide Description of the ITT Flygt version of ACS550 describes the ITT Flygt version of the ACS550 drive Start up describes the start up procedure of the drive Controlling the pump cleaning sequence describes the different principles of controlling the pump cleaning sequence ITT Flygt version of ACS550 parameters is a list of standard ACS550 01 U1 parameters which are modified for the ITT Flygt version of ACS550 added with special ITT Flygt parameter group 46 PUMP CLEAN SEQ About this guide Other related manuals ACS550 01 U1 User s Manual 3AFE64804588 English The manual contains Quick Start Guide complete installation instructions control panel use complete parameter descriptions maintenance instructions and technical data for the standard ACS550 01 U1 drive Where necessary the ACS550 01 U1 User s Manual 3AFE64804588 English can be consulted parallel to this Start Up Guide However the modifications done to the ITT Flygt version of ACS550 compared to the standard ACS550 01 U1 as presented in Appendix 2 ITT Flygt version of ACS550 parameters must be noticed to avoid confusion Installation and commissioning overview Table 1 show
14. er 4602 REQ P CLEAN SEQ to 4 the PCS can also be executed without any preceding simulated request by DI2 according to Control principle 1b Appendix 1 Controlling the PCS 26 Appendix 2 ITT Flygt version of ACS550 parameters What this appendix contains This appendix contains Table 4 which presents the parameters that are modified in the ITT Flygt version of ACS550 compared to the standard ACS550 01 U1 The right hand side column describes the modification For a complete standard ACS550 01 U1 parameter list with descriptions of the parameters refer to ACS550 01 U1 User s Manual 3AFE64804588 English Table 4 ITT Flygt version of ACS550 parameters Code Name Range Res Default Modifications in ITT Flygt version of ACS550 Group 99 START UP DATA 9902 APPLIC MACRO 20 ITT Flygt 1 1 ADDED APPLIC MACRO ITT Flygt REMOVED ALL STANDARD ACS550 APPLIC MACROS CHANGED DEFAULT VALUE 9904 MOTOR CONTROL 3 SCALAR 1 3 REMOVED MODE 1 VECTOR SPEED 2 VECTOR TORQUE 9910 MOTOR ID RUN 0 OFF 1 ON 1 0 REMOVED Group 01 Operating Data 0114 RUN TIME R 0 9999 h 1h Oh CHANGED RESET TO 0 AT EVERY STOP COMMAND AND EVERY COMPLETED CLEANING SEQUENCE 0126 PID 1 OUTPUT 1000 1000 0 1 REMOVED 0127 PID 2 OUTPUT 100 100 0 1 REMOVED 0128 PID 1 SETPNT Unit and scale defined by REMOVED par 4006 4106 and 4007 4107 0129 PID 2 SETPNT
15. eter 4602 REQ P CLEAN SEO to 1 2 or 3 the drive requests the pump controller to execute the PCS when the torque and or run time condition is fulfilled as monitored and analyzed by the drive The drive requests the PCS by energizing relay output RO2 When the pump controller receives the energized RO2 signal from the drive the pump controller takes the decision when to execute the PCS depending on what logic is programmed to the pump controller When the pump controller decides to execute the PCS the pump controller sets digital input DI3 of the drive from 0 to 1 When DI3 is set from 0 to 1 the PCS is executed and the drive energizes also relay output RO3 The very moment that the pump controller receives the energized RO3 signal from the drive the pump controller must reset DI3 from 1 to 0 During the PCS both RO2 and RO3 remain energized When the last cycle of the PCS ends both RO2 and RO3 deenergize and normal operation continues Control principle 1a including the order of events is illustrated in Figure 4 ACS550 DI2 2 Execute PCS Pump 1 PCS Requested controller la TESTES os 3 PCS Executed RO3 Figure 4 Control principle 1a PCS Pump cleaning sequence DI Digital input RO Relay output Appendix 1 Controlling the PCS 24 When parameter 4601 EXE PCLEAN SEQ is set to 1 and parameter 4602 REQ P CLEAN SEQ to 1 2 3 or 4 it is also possible for the pump controlle
16. firm the change OK Control panel display LOC USHOW HIDE show all par Show ITT Flygt par EXIT SEL 13 Check the direction of rotation a Press ey repeatedly until the control panel display reaches the output mode Set the maximum frequency reference to the drive by pressing A until the maximum frequency reference indicated in the upper right corner of the control panel display is reached b Start the pump by pressing C gt Check that the rotating arrow that indicates the direction of rotation in the upper left part of the control panel display is rotating clockwise If the arrow is rotating counter clockwise press EP to change to the clockwise direction c Check the flow or head delivered by the pump to make sure that the pump is running in the forward direction If the pump is running in the forward direction proceed to step 14 Ifthe pump is running in the reverse direction proceed to step 13 d d Stop the drive by pressing C455 Power off the drive and switch two phases on the output of the drive Apply power to the drive and repeat commissioning from step 13 a Torque test 14 ATTENTION When parameter 4602 REQ P CLEAN SEQ is set to 1 or 3 itis strongly recommended that parameter 4603 TORQ REQ is set to a non default value that suits the actual application In order to do so a torque test is done as follows a Make sure that the dr
17. he control panel display shall indicate REM in the upper 0 kw left corner 0 a 0 A hts i 0 0 The drive is now commissioned and ready to be controlled by the pump i o controller DIR MENU Start up 18 Basic operating rules for the PCS Basic operating rules for controlling the PCS are described below For detailed descriptions of the control principles of the PCS refer to Appendix 1 Controlling the PCS Start command in remote control The drive must be in remote control given a start command DI1 1 and run indicated by energized relay output RO1 to accept a request and execution of the PCS In local control the PCS cannot be requested executed at all whereas in remote control the PCS can be requested executed provided there is a preceding start command Consequently If a request of the PCS is not answered by executing the PCS before a stop command DI1 0 indicated by de energized relay output RO1 is given the request of the PCS is cancelled Interrupting the PCS When the PCS is executed it will interrupt before completion if the drive is given a stop command This means that the pump is actually stopped However the pump can be restarted to normal operation immediately by a new start command Blocked PCS Request and execution of the PCS are blocked for 3 seconds after every given start command and after every completed PCS This way normal dynamic motor load during accelerati
18. ion of the proneness to clogging in the actual application the higher the proneness to clogging the lower the value Range 1 100 h Resolution 1 h Default 2 h 4606 NUM OF CYCLES Defines the number of cycles that the PCS performs at each execution Set a high enough value to render the PCS a fair chance to fully clean the impeller in one execution only If the PCS fails to fully clean the impeller at the first execution the PCS will be requested anew provided that the condition for the request is fulfilled Range 1 10 Resolution 1 Default 2 4607 FWD RUN FREQ Defines the forward running frequency in the PCS in percent of the maximum motor frequency parameter 2008 MAXIMUM FREQ Range 0 0 100 0 Resolution 0 1 Default 100 0 4608 FWD RUN TIME Defines the forward running time in the PCS Range 0 0 100 0 s Resolution 0 1 s Default 7 s 4609 FWD RUN ACC Defines the forward acceleration time in the PCS If the actual application demands a longer PCS forward acceleration time due to fluid mechanical or electrical factors set the parameter to meet the demand Range 0 0 100 0 s Resolution 0 1 s Default 0 3 s 4610 FWD RUN DEC Defines the forward deceleration time in the PCS If the actual application demands a longer PCS forward deceleration time due to fluid mechanical or electrical factors set the parameter to meet the demand Note The default value is valid for lift pump stations i e s
19. ircuit common 14 10V Reference voltage 10 VDC DH 5 AI2 Frequency reference 4 20 mA T 6 JAGND Analog input circuit common p 47 A01 Power 4 20 mA OH 8 AO2 Torque 4 20 mA 19 AGND Analog output circuit common 10 24V Auxiliary voltage output 24 VDC 11 GND Auxiliary voltage output common 12 DCOM Digital input common for all 13 D Start Stop Activate to start 14 DI2 Request pump cleaning sequence Pulse until RO3 is energized 15 DIS Execute pump cleaning sequence Pulse until RO3 is energized 16 DI4 Not used 17 DIS Not used 18 DI6 Not used 19 RO1C Relay output 1 programmable 20 RO1A Default operation 21 RO1B Running gt 19 connected to 21 22 RO2C Relay output 2 programmable Default operation 23 RO2A fal 24 RO2B Pump cleaning sequence requested gt 22 connected to 24 25 RO3C Relay output 3 programmable 26 RO3A Default operation 27 RO3B D Pump cleaning sequence executed gt 25 connected to 27 Figure 3 Drive input output from to pump controller Description of the ITT Flygt version of ACS550 12 Start up What this chapter contains This chapter describes the start up procedure of the drive Start up procedure By default only parameter groups 46 PUMP CLEAN SEQ and 99 START UP DATA are shown and accessible All parameters in the drive shown and hidden have default values that are especially fit for soeed regulated
20. ive is in local control started indicating clockwise direction of rotation set to the maximum frequency reference Start up 17 Step Action Control panel display b Make sure that the pump is running in the forward direction LOC U 60 0Hz pumping at a relevant physical level in the sump according to the 1 1 kw pumping strategy to be used in the actual application 2 9 A delivering a stable flow 50 0 DIR MENU c Read the motor torque level percentage value on the third row of the control panel display e g 50 d Multiply the value by 1 2 e g 50 x 1 2 60 The factor 1 2 corresponds to a torque contribution that can be expected when clogging occurs e Stop the drive by pressing lt P gt Proceed to step 15 to set the result of step 14 d to parameter 4603 TORQ REQ 15 Set the torque reference value a Enter the main menu Scroll to and enter submenu PARAMETERS Loc v 0 0Hz 0 0 kw 0 0 A 0 0 DIR b Scroll to and select parameter group 46 PUMP CLEAN SEQ LOC UPAR GROUPS 99 46 PUMP CLEAN SEQ 99 START UP DATA EXIT SEL c Scroll to parameter 4603 Set and save the resulting value from step 14 d e g 60 LOC UPAR EDIT 4603 TORO REO 60 0 CANCEL SAVE 16 Press EP repeatedly until the control panel display reaches the output mode showing the status information Switch to remote control by Nay U 0 0Hz pressing E T
21. l motor torque The actual motor torque parameter 0105 TORQUE must exceed the reference value due to clogging before request of the PCS can be triggered ATTENTION It is strongly recommended that this parameter is set to a non default value that suits the actual application as described in Table 2 Step 14 and 15 Range 0 0 200 0 Resolution 0 1 Default 120 4604 TON TORQ The parameter is used with parameter 4602 REQ P CLEAN SEQ selections 1 and 3 It defines the time for which the actual motor torque parameter 0105 TORQUE must exceed the motor torque reference value parameter 4603 TORQ REQ before request of the PCS can be triggered Parameter 4604 TON TORQ ensures that the PCS does not become oversensitive and react to normal dynamic motor load during acceleration at every pump start or to minor disturbances during normal operation Range 0 100 s Resolution 1 s Default 5 s Start up 21 Code Name Description 4605 RUN TIME REQ The parameter is used with parameter 4602 REQ P CLEAN SEQ selections 2 and 3 It defines the run time reference value that the actual run time parameter 0114 RUN TIME must exceed since the last start command or completed PCS before request of the PCS can be triggered Parameter 0114 RUN TIME is reset to 0 at every stop command and after every completed PCS Set the value to parameter 4605 RUN TIME REQ based on knowledge and percept
22. nformation 3301 FW VERSION 0000 FFFF hex 1 Firm ware version 3302 LP VERSION 0000 FFFF hex 1 0 ADDED ITT Flygt LOADING PACKAGE REMOVED STANDARD ACS550 LOADING PACKAGE Group 34 Panel Display Process Variables 3401 SIGNAL 1 PARAM 100 199 1 106 CHANGED DEFAULT VALUE Group 36 Timer Functions REMOVED Group 40 Process PID Set 1 REMOVED Group 41 Process PID Set 2 REMOVED Group 42 Ext Trim PID REMOVED Appendix 2 ITT Flygt version of ACS550 parameters 29 Code Name Range Res Default Modifications in ITT Flygt version of ACS550 Group 46 PUMP CLEAN SEQ ADDED 4601 EXE P CLEAN SEQ 0 NOT SEL 1 1 ADDED 1 P CTRL DIS 2 ACS550 4602 REQ P CLEAN SEQ 0 NOT SEL 1 1 ADDED 1 TORQ 2 RUN TIME 3 TORQ OR RUN TIME 4 PCTRLDI2 4603 TORQ REQ 0 0 200 0 0 1 120 0 ADDED 4604 TON TORQ 0 100 s 1s 5s ADDED 4605 RUN TIME REQ 0 100 h 1h 2h ADDED 4606 NUM OF CYCLES 0 10 1 2 ADDED 4607 FWD RUN FREQ 0 0 100 0 0 1 100 0 ADDED 4608 FWD RUN TIME 0 0 100 0 s 0 1s 7 0s ADDED 4609 FWD RUN ACC 0 0 100 0 s 0 1s 0 3s ADDED 4610 FWD RUN DEC 0 0 100 0 s 0 18 2 0s ADDED 4611 ZERO SPEED 0 0 100 0 s 0 1s 7 0s ADDED PAUSE 4612 REVRUN FREQ 0 0 100 0 0 1 80 0 ADDED 4613 REV RUN TIME 0 0 100 0 s 0 1s 7 0s ADDED 4614 REVRUN ACC 0 0 100 0 s 0 1s 2 0s ADDED 4615
23. ntenance Tigh cy besa e ra RR ey bw Sia Rey Rec Kane ende 28 Group 30 Fault Functions Si 42 04 nern Diane 28 Group 332 Information s tse er ase exer a AS eo es etin 28 Group 34 Panel Display Process Variables llli elles 28 Group 36 Timer Functions 0 0 0 0 00 hans 28 Group 40 Process PID Set 1 uds wA Rn Bir PR E ut E a 28 Group 41 Process PID Set 2 0 szelt ee k ell 28 Group 42 Ext Trim PID denenan oie a eA ee RR e ehh 28 Group 46 PUMP CLEAN SEQ wini ea e a a E eee 29 Group 81 PEG Control onere rs eh er ra e OE RR ten 29 About this guide What this chapter contains This chapter describes the guide in short Use of this guide Start up the ITT Flygt version of ACS550 drives according to the instructions given in this guide The guide contains an installation and commissioning overview Table 7 with references to other manuals and chapters in this guide Target reader Safety A Contents The guide is intended for people who plan the installation install commission use and service the drive Read the guide before working on the drive The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Only qualified specialists are allowed to install commission and maintain the drive WARNING Follow the safety instructions given in ACS550 01 U1 User s Manual 3AFE64804588 English when installing operating
24. on is not able to request or execute the PCS Start up 19 Important parameter settings Table 3 lists the parameters whose settings are particularly important in order to achieve reliable speed regulated wastewater pumping Parameters marked with are described in ACS550 01 U1 User s Manual 3AFE64804588 English Parameters numbered from 4601 to 4615 are dedicated to the ITT Flygt version of ACS550 Note All default values are related to ITT Flygt pumps exclusively Table 3 Particularly important parameter settings to achieve reliable speed regulated wastewater pumping Code Name Description 2007 MINIMUM FREQ ATTENTION No lower value than 35 0 Hz shall be set since the risk of clogging increases with reduced speed Default 35 0 Hz 2008 MAXIMUM FREQ ATTENTION No higher value than nominal frequency shall be set otherwise the pump motor may overheat Default Nominal frequency 2202 ACCELER TIME 1 If the actual application demands a longer normal operation non PCS acceleration time due to fluid mechanical or electrical factors set the parameter to meet the demand ATTENTION No lower value than 2 0 s shall be set since stress on the impeller and shaft increases with reduced acceleration time Default 2 0 s 2203 DECELER TIME 1 Ifthe actual application demands a longer normal operation non PCS deceleration time due to fluid mechanical or electrical factors set the parame
25. r to execute the PCS at any time without any preceding request from the drive Again the pump controller executes the PCS by setting digital input DI3 of the drive from 0 to 1 When the PCS is executed both relay outputs RO2 and RO3 energize The very moment that the pump controller receives the energized RO3 signal from the drive the pump controller must reset DI3 from 1 to 0 During the PCS both RO2 and RO3 remain energized When the last cycle of the PCS ends both RO2 and RO3 deenergize and normal operation continues The setting of parameter 4601 EXE P CLEAN SEQ to 1 and parameter 4602 REQ P CLEAN SEQ to 4 is applied when only the parameters analyzed by the pump controller and the pump controller logic are to control the PCS thus the drive s capability to analyze torque and or run time is not utilized Control principle 1b including the order of events is illustrated in Figure 5 ACS550 DI2 1 Execute PCS EHE 2 PCSR d i controller ag FCS Requested t 3 PCS Executed RO3 Figure 5 Control principle 1b PCS Pump cleaning sequence DI Digital input RO Relay output ACS550 executing the PCS Control principle 2 When parameter 4601 EXE P CLEAN SEQ is set to 1 and parameter 4602 REQ P CLEAN SEQ to 1 2 or 3 the drive requests itself to directly execute the PCS when the torque and or run time condition is fulfilled as monitored and analyzed by the drive The very moment that the
26. ration parameters A Forward speed Normal PCS performs the number of cycles set to 4606 Normal operation j operation acc 4609 dec 4610 4611 4608 4611 4613 i 4611 gt a gt gt lt gt Reverse speed Figure 2 Continuous line Pump cleaning sequence PCS Dashed line Normal operation The PCS is controlled in a way that is referred to as request and execute The control is defined by the combination of the settings of parameters 4601 EXE P CLEAN SEQ and 4602 REQ P CLEAN SEQ Refer to Table 3 for description of the parameters For detailed descriptions of the control principles of the PCS refer to Appendix 1 Controlling the PCS Description of the ITT Flygt version of ACS550 11 The PCS can be executed by the pump controller at detection of clogging by the drive and or by the pump controller at regular run time intervals set to the drive and or bythe pump controller at any time depending on what parameters are analyzed by the pump controller and what logic is programmed to the pump controller or bythe drive itself at detection of clogging and or at regular run time intervals set to the drive Drive input output from to pump controller X1 T SCR Signal cable shield screen de Al Not used 3 AGND Analog input c
27. rig Start Up Guide ACS550 Equipped with ITT Flygt Application Program Flygt ITT Industries 896544 03 Engineered for life ACS550 Equipped with ITT Flygt Application Program Start Up Guide Table of contents About this guide What this chapter contains 0 0 ccc es 7 B omui Acc P e 7 Target reader ced km AAA AA ii he 7 Sigla sce a ntur rn ee EE ER REA rear de 7 Contents a an qr IN Motte out sce Ea S S a Ohm ales Ar tinea Rec MUR WARP EN LDAP ACE EA oL se S eR 7 Other related Manuals xica e eve estes med c ENT Ce ER C te EU ERO QE AUS 8 ACS550 01 U1 User s Manual 3AFE64804588 English 0 0 0 e ee eee 8 Installation and commissioning overview lees 8 Abbreviatioris xs eue tese To x e cc sae mt Mae oxi RE ge UR EUR E ERU RR E were 8 Description of the ITT Flygt version of ACS550 What this chapter contains ooooococoocoo Res 9 BASICS vos das ias tow d das 19 a EO eR HT Bp BE ERI gun DO SOS DE DoD dun CO aes an P d 9 FUNCOM esz e LETT 9 Ser Interface vnd eos ttu bao em EC Dc uot rette Peur IO RC AP CS diac t 10 Application Macro CET Eg is eset sc eng Sende eres a a a CR A A 10 Pump cleaning sequence PCS ceci le iw tee etm ann ala 10 Drive input output from to pump controller 00 2c 11 Start up What this chapter contains 0 0 0 0 ccc cette een 12 Start UP PrOcedure iicet pe REG pur ue debes Bleed BAGG CEU e ERE 12 Basic operating rules forthe
28. s an overview of the tasks in installing and commissioning the drive Table 1 Overview of the tasks in installing and commissioning Step Task Reference 1 Identify the frame size of your drive R2 R3 R4 R5 or R6 Chapter Technical data in ACS550 01 U1 User s Manual 3AFE64804588 English Plan the installation Check the ambient conditions ratings required cooling air flow input power con nection compatibility of the motor motor connection and other technical data Select the cables Quick Start Guide and chapters Installation and Technical Data in ACS550 01 U1 User s Manual 3AFE64804588 English Option manual if optional equipment is included Install the drive mechanical installation input and output power wiring control wiring between the pump controller and the drive Quick Start Guide and chapters Installation and Technical Data in ACS550 01 U1 User s Manual 3AFE64804588 English Drive input output from to pump controller page 11 Commission the drive Start up page 12 ACS550 01 U1 User s Manual SAFE64804588 English Abbreviations PCS Pump Cleaning Sequence About this guide Description of the ITT Flygt version of ACS550 What this chapter contains Basics Function This chapter describes the ITT Flygt version of ACS550 in short The ITT Flygt version of ACS550 is customized from the standard ACS550 01 U1
29. ter description refer to Appendix 2 ITT Flygt version of ACS550 parameters and ACS550 01 U1 User s Manual 3AFE64804588 English If any default value is not suitable to the actual application proceed to step 12 a to change the value Otherwise proceed to step 13 a Press CZ repeatedly until the control panel display reaches the output mode Enter the main menu by pressing SC Scroll to and enter ENTER submenu SHOW HIDE by pressing ST b Select Show all par by pressing SS Confirm the change by pressing SS EXIT x c Press to reach the main menu Scroll to and enter submenu PARAMETERS d Scroll to the parameter set and save the non default selection value If all parameter groups except 46 PUMP CLEAN SEQ and 99 START UP DATA are to be hidden inaccessible again proceed to step 12 e Otherwise proceed to step 13 LOC U 0 0Hz 0 kw 0 0 A 0 0 DIR MENU LOC UMAIN MENU PARAMETERS SHOW HIDE CHANGED PAR EXIT ENTER LOC U SHOW HIDE Show all par Show ITT Flygt par EXIT SEL LOC USHOW HIDE Visibility changed to all par EXIT OK LOC UMAIN MENU PARAMETERS SHOW HIDE CHANGED PAR EXIT ENTER Start up 16 Step Action e Press EP repeatedly until the control panel display reaches the output mode Enter the main menu Scroll to and enter submenu SHOW HIDE Select Show ITT Flygt par and con
30. ter to meet the demand Note The default value is valid for lift pump stations i e systems with limited discharge line length As a rule of thumb all discharge systems longer than 400 m should be analyzed from a water hammer point of view in such an analysis of transients anumber of system parameters have to be considered in these cases please consult ITT Flygt for assistance with setting the parameter to a correct value ATTENTION No lower value than 4 0 s shall be set since stress on the impeller and shaft increases with reduced deceleration time Default 4 0 s 4601 EXE PCLEAN SEQ Defines how the PCS is executed Upon execution the drive relay output RO3 energizes RO3 remains energized during the PCS Range 0 1 2 0 NOT SEL The PCS is not executed 1 P CTRL DI3 The PCS is executed by the pump controller setting the drive digital input DI3 from 0 to 1 2 ACS550 The PCS is executed by the drive itself Default 1 Start up 20 Code Name Description 4602 REQ P CLEAN SEQ Defines what triggers a request of the PCS Upon request the drive relay output RO2 energizes RO2 remains energized until the execution of the PCS starts and during the PCS Range 0 1 2 3 4 0 NOT SEL The PCS is not requested 1 TORQ The request of the PCS is triggered when the actual motor torque parameter 0105 TORQUE exceeds the reference value set to parameter 4603 TORQ REQ for
31. wastewater pumping It is strongly recommended that section Important parameter settings on page 19 is studied before commissioning the drive To commission the drive step by step refer to Table 2 Table 2 Step by step commissioning of the drive Step Action Control panel display 0 Apply power to the drive The ITT Flygt logo will shortly appear before the output mode is displayed in the control panel me nn P FLYGT 1 At the very first power up the drive will be in remote control as indicated by REM in the upper left corner of the control panel display The display Hay v 0 0Hz shows the status information REFERENCE FREQUENCY Hz 0 0 kw POWER kW CURRENT A and TORQUE 96 of nominal torque 0 0 A 0 DIR MENU a Switch to local control by pressing e Local control is indicated by LOC in the upper left corner of the control panel display v 35 0Hz 0 kw 0 A 0 0 DIR MENU E MENU b Enter the main menu by pressing ST Note concerning heavy inflow conditions In case pumping must be done LOC U 35 0Hz before the commissioning of the drive can be completed do steps 13 0 kw and 14 a and b before steps from 2 to 12 a 0 0 0 DIR Start up 13 Step Action Control panel display a Scroll to submenu PARAMETERS by pressing AN or amp w P then press b Scroll with A y amp w 2 to parameter group 99 START UP DATA then press Ex
32. ystems with limited discharge line length As a rule of thumb all discharge systems longer than 400 m should be analyzed from a water hammer point of view in such an analysis of transients a number of system parameters have to be considered in these cases please consult ITT Flygt for assistance with setting the parameter to a correct value ATTENTION No lower value than 2 0 s shall be set since stress on the impeller and shaft increases with reduced deceleration time Range 0 0 100 0 s Resolution 0 1 s Default 2 0 s Start up 22 Code Name Description 4611 ZERO SPEED Defines the zero speed pause time in the PCS PAUSE Note The default value is valid for lift pump stations i e systems with limited discharge line length As a rule of thumb all discharge systems longer than 400 m should be analyzed from a water hammer point of view in such an analysis of transients anumber of system parameters have to be considered in these cases please consult ITT Flygt for assistance with setting the parameter to a correct value Range 0 0 100 0 s Resolution 0 1 s Default 7 0 s 4612 REV RUN FREQ Defines the reverse running frequency in the PCS in percent of the maximum motor frequency parameter 2008 MAXIMUM FREQ ATTENTION No higher value than 80 shall be set since stress on the impeller and shaft increases with increased frequency Range 0 0 100 0 Resolution 0 1 Default 80 0
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