KSB PumpDrive 2 Installation instructions
Self-cooling Motor-independent
Frequency Inverter
PumpDrive 2
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual PumpDrive 2
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft, Frankenthal 21/08/2017
Contents
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PumpDrive 2
Contents
Glossary .................................................................................................................................................. 5
1 Safety...................................................................................................................................................... 6
1.1 Key to safety symbols/markings.......................................................................................................................6
1.2 General..............................................................................................................................................................6
1.3 Intended use .....................................................................................................................................................6
1.4 Personnel qualification and training...............................................................................................................7
1.5 Consequences and risks caused by non-compliance with this operating manual........................................7
1.6 Safety awareness ..............................................................................................................................................7
1.7 Safety information for the user/operator.......................................................................................................7
1.8 Safety information for maintenance, inspection and installation ................................................................7
1.9 Unauthorised modes of operation..................................................................................................................8
1.10 Software Changes.............................................................................................................................................8
1.11 Electromagnetic compatibility (EMC)..............................................................................................................8
1.11.1 Interference emission requirements ...................................................................................................8
1.11.2 Line harmonics requirements..............................................................................................................9
1.11.3 Interference immunity requirements .................................................................................................9
2 Transport/Temporary Storage/Disposal............................................................................................. 10
2.1 Checking the condition upon delivery..........................................................................................................10
2.2 Transport.........................................................................................................................................................10
2.3 Storage............................................................................................................................................................11
2.4 Disposal/recycling ...........................................................................................................................................12
3 General.................................................................................................................................................. 13
3.1 Principles .........................................................................................................................................................13
3.2 Target group...................................................................................................................................................13
3.3 Other applicable documents..........................................................................................................................13
3.4 Symbols ...........................................................................................................................................................13
4 Operation.............................................................................................................................................. 14
4.1 Graphical control panel..................................................................................................................................14
4.1.1 Graphical display................................................................................................................................14
4.1.2 Menu keys ..........................................................................................................................................16
4.1.3 Service interface and LED traffic light function...............................................................................21
5 Commissioning report ......................................................................................................................... 23
6 Description............................................................................................................................................ 24
6.1 General description ........................................................................................................................................24
6.2 Designation.....................................................................................................................................................24
6.3 Name plate......................................................................................................................................................26
6.4 Power range and sizes....................................................................................................................................26
6.5 Technical data.................................................................................................................................................27
6.6 Dimensions and weights ................................................................................................................................30
6.7 Mounting options...........................................................................................................................................31
7 Installation at Site................................................................................................................................ 32
7.1 Safety regulations...........................................................................................................................................32
7.2 Checks to be carried out prior to installation...............................................................................................32
7.3 Mounting PumpDrive.....................................................................................................................................32
7.3.1 Motor mounting ................................................................................................................................32
7.3.2 Wall/control cabinet mounting.........................................................................................................32
7.4 Electrical connection ......................................................................................................................................33
7.4.1 Safety regulations ..............................................................................................................................33
7.4.2 Information for planning the system ...............................................................................................34
7.4.3 Electrical connection..........................................................................................................................38
8 Commissioning/Shutdown.................................................................................................................. 64
8.1 Commissioning wizard ...................................................................................................................................64
Contents
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8.2 Control point concept ....................................................................................................................................65
8.3 Setting motor parameters..............................................................................................................................65
8.4 Motor control method ...................................................................................................................................66
8.5 Automatic motor adaptation (AMA) of frequency inverter........................................................................67
8.5.1 Automatic motor adaptation (AMA) of frequency inverter for asynchronous motors.................68
8.5.2 Automatic motor adaptation (AMA) of frequency inverter for KSB SuPremE motors .................69
8.6 Entering the setpoint .....................................................................................................................................70
8.7 Pump operation..............................................................................................................................................72
8.7.1 Single-pump operation......................................................................................................................72
8.7.2 Multiple pump configuration ...........................................................................................................82
8.8 Application functions.....................................................................................................................................87
8.8.1 Aligning the frequency inverter with the pump .............................................................................87
8.8.2 Protective functions ...........................................................................................................................89
8.8.3 Flow rate estimation..........................................................................................................................96
8.8.4 Energy optimisation...........................................................................................................................98
8.8.5 Ramps ...............................................................................................................................................109
8.8.6 Motor standstill heater....................................................................................................................112
8.9 Device functions ...........................................................................................................................................112
8.9.1 Factory and user settings.................................................................................................................112
8.9.2 Read out PumpMeter ......................................................................................................................113
8.9.3 Date and time ..................................................................................................................................114
8.10 Digital and analog inputs/Digital and analog outputs ..............................................................................114
8.10.1 Digital inputs....................................................................................................................................114
8.10.2 Analog inputs...................................................................................................................................118
8.10.3 Relay outputs ...................................................................................................................................120
8.10.4 Analog outputs ................................................................................................................................122
8.10.5 Inputs and outputs of the I/O extension board .............................................................................123
8.11 Parameterising the M12 module.................................................................................................................127
8.12 Parameterising the field bus module..........................................................................................................130
9 Servicing/Maintenance...................................................................................................................... 133
9.1 Safety regulations.........................................................................................................................................133
9.2 Servicing/inspection......................................................................................................................................133
9.2.1 Supervision of operation .................................................................................................................133
9.3 Dismantling...................................................................................................................................................134
9.3.1 Preparing frequency inverter for dismantling ...............................................................................134
10 Parameter List..................................................................................................................................... 135
10.1 Selection lists.................................................................................................................................................188
11 Trouble-shooting................................................................................................................................ 189
11.1 Faults/malfunctions: Trouble-shooting .......................................................................................................189
11.2 Alerts .............................................................................................................................................................190
11.3 Warnings.......................................................................................................................................................193
11.4 Information messages ..................................................................................................................................195
12 Purchase Order Specifications........................................................................................................... 196
12.1 Ordering spare parts ....................................................................................................................................196
12.2 Accessories ....................................................................................................................................................197
12.2.1 Service software ...............................................................................................................................197
12.2.2 Control panels ..................................................................................................................................197
12.2.3 Motor adapter kits...........................................................................................................................197
12.2.4 Adapter for wall and cabinet mounting ........................................................................................199
12.2.5 M12 module .....................................................................................................................................199
12.2.6 Installation options ..........................................................................................................................200
12.2.7 Sensor system ...................................................................................................................................202
12.2.8 Control cabinet mounting...............................................................................................................205
13 EU Declaration of Conformity........................................................................................................... 207
Index ................................................................................................................................................... 208
Glossary
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PumpDrive 2
Glossary
Braking resistor
Takes up the braking power produced during
generator operation.
Hydraulic blockage
Undesirable operating situation in which the
pump cannot supply fluid due to a closed inlet or
outlet.
KSB device bus
Proprietary CAN bus that is used in dual and
multiple pump configurations for facilitating
communication among the frequency inverters.
The KSB device bus cannot be used for external
communication or for communication with the
KSB local bus (PumpDrive 1).
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
RCD
Abbreviation for "residual current device"
1 Safety
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1 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
1.1 Key to safety symbols/markings
Table1: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
1.2 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
1.3 Intended use
▪This product must only be operated within the limit values stated in the technical
product literature for the mains voltage, mains frequency, ambient temperature,
motor rating, fluid handled, flow rate, speed, density, pressure, temperature and
in compliance with any other instructions provided in the operating manual or
other applicable documents.
▪The product must not be used in potentially explosive atmospheres.
1 Safety
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PumpDrive 2
1.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to. The responsibilities, competence and
supervision of all personnel involved in installation, operation, maintenance and
inspection must be clearly defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the product must always be supervised by specialist technical personnel.
1.5 Consequences and risks caused by non-compliance with this operating
manual
▪Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
–Failure of important product functions
–Failure of prescribed maintenance and servicing practices
1.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and legislation (e.g. EN50110-1)
1.7 Safety information for the user/operator
▪The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪Do not remove any contact guards during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
1.8 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪Any work on the product shall only be performed when it has been disconnected
from the power supply (de-energised).
▪Carry out work on the product during standstill only.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
1 Safety
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1.9 Unauthorised modes of operation
Never operate the product outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.
1.10 Software Changes
The software has been specially created for this product and thoroughly tested.
It is impermissible to make any changes or additions to the software or parts of the
software. Software updates supplied by KSB are excluded from this rule.
1.11 Electromagnetic compatibility (EMC)
The Electromagnetic Compatibility Directive 2004/108/EC defines the requirements
concerning the interference immunity and interference emissions of electric and
electronic equipment.
1.11.1 Interference emission requirements
The EN61800-3 EMC product standard is relevant for electric variable speed drives/
control systems. It specifies all pertinent requirements and refers to the relevant
generic standards for complying with the EMC Directive.
Frequency inverters are commonly used by operators as a part of a system, plant or
machine assembly. It should be noted that the operator bears all responsibility for
the final EMC properties of the equipment, plant or installation.
A prerequisite or requirement for complying with the relevant standards or the limit
values and inspection/test levels referenced by them is that all information and
descriptions regarding EMC-compliant installation be observed and followed.
(ðSection7.4,Page33)
In accordance with the EMC product standard, the EMC requirements to be met
depend on the purpose or intended use of the frequency inverter. Four categories
are defined in the EMC product standard:
Table2: Categories of intended use
Category Definition Limits to EN55011
C1 Frequency inverters with a supply voltage under 1000V installed in the
first environment (residential and office areas).
Class B
C2 Frequency inverters with a supply voltage under 1000V installed in the
first environment (residential and office areas) that are neither ready to
be plugged in/connected nor are mobile and must be installed and
commissioned by specialist personnel.
Class A, Group 1
C3 Frequency inverters with a supply voltage under 1000V installed in the
second environment (industrial environments).
Class A, Group 2
C4 Frequency inverters with a supply voltage over 1000V and a nominal
current over 400A installed in the second environment (industrial
environments) or that are envisaged for use in complex systems.
No borderline/
boundary1)
The following limit values and inspection/test levels must be complied with if the
generic standard on interference emissions applies:
Table3: Classification of installation environment
Environment Generic standard Limits to EN55011
First environment (residential and office areas) EN/IEC61000-6-3
for private, business and commercial
environments
Class B
Second environment (industrial environments) EN/IEC61000-6-4
for industrial environments
Class A, Group 1
The frequency inverter meets the following requirements:
1) An EMC plan must be devised.
1 Safety
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PumpDrive 2
Table4: EMC properties of the frequency inverter
Power
[kW]
Cable length
[m]
Category to EN 61800-3 Limits to EN55011
≤ 11 ≤5 C1 ClassB
> 11 ≤50 C2 ClassA, Group 1
The EN61800-3 standard requires that the following warning be provided for drive
systems that do not comply with category C1 specifications:
This product can produce high-frequency interference emissions that may necessitate
targeted interference suppression measures in a residential or office environment.
1.11.2 Line harmonics requirements
The product is a device for professional applications as defined by EN 61000-3-2. The
following generic standards apply when establishing a connection to the public
power grid:
▪EN 61000-3-2
for symmetric, three-phase devices (professional devices with a total power of up
to 1kW)
▪EN 61000-3-12
for devices with a phase current of between 16A and 75A and professional
devices from 1kW up to a phase current of 16 A.
1.11.3 Interference immunity requirements
In general, the interference immunity requirements for a frequency inverter hinge on
the specific environment in which the inverter is installed.
The requirements for industrial environments are therefore higher than those for
residential and office environments.
The frequency inverter is designed such that the immunity requirements for
industrial environments and, thus, the lower-level requirements for residential and
office environments, are met and fulfilled.
The following relevant generic standards are used for the interference immunity test:
▪EN 61000-4-2: Electromagnetic compatibility (EMC)
–Part 4-2: Testing and measurement techniques – Electrostatic discharge
immunity test
▪EN 61000-4-3: Electromagnetic compatibility (EMC)
–Part 4-3: Testing and measurement techniques – Radiated, radio-frequency,
electromagnetic field immunity test
▪EN 61000-4-4: Electromagnetic compatibility (EMC)
–Part 4-4: Testing and measurement techniques – Electrical fast transient/burst
immunity test
▪EN 61000-4-5: Electromagnetic compatibility (EMC)
–Part 4-5: Testing and measurement techniques – Surge immunity test
▪EN 61000-4-6: Electromagnetic compatibility (EMC)
–Part 4-6: Testing and measurement techniques – Immunity to conducted
disturbances, induced by radio-frequency fields
2 Transport/Temporary Storage/Disposal
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2 Transport/Temporary Storage/Disposal
2.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
2.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷Always transport the pump (set) in the specified position.
▷Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷Give due attention to the weight data and the centre of gravity.
▷Observe the applicable local health and safety regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig.1: Transporting a close-coupled pump set
Fig.2: Transporting a horizontal pump set
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