KSB PumpDrive Istruzioni per l'installazione
Self-cooling Motor-independent Frequency
Inverter
PumpDrive
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual PumpDrive
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 01.10.2015
Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ........................................................................................................... 6
1.2 Target group ..................................................................................................... 6
1.3 Other applicable documents ............................................................................ 6
1.4 Symbols ............................................................................................................. 6
2 Safety .....................................................................................................7
2.1 Key to safety symbols/markings ....................................................................... 7
2.2 General .............................................................................................................. 7
2.3 Intended use ..................................................................................................... 7
2.4 Personnel qualification and training ............................................................... 8
2.5 Consequences and risks caused by non-compliance with this operating
manual .............................................................................................................. 8
2.6 Safety awareness .............................................................................................. 8
2.7 Safety information for the user/operator ....................................................... 8
2.8 Safety information for maintenance, inspection and installation work ....... 8
2.9 Unauthorised modes of operation .................................................................. 9
2.10 Software Changes ............................................................................................. 9
2.11 Electromagnetic compatibility ......................................................................... 9
3 Transport/Temporary Storage/Disposal .............................................10
3.1 Checking the condition upon delivery .......................................................... 10
3.2 Transport ......................................................................................................... 10
3.3 Storage ............................................................................................................ 12
3.4 Disposal/recycling ........................................................................................... 12
4 Description ..........................................................................................13
4.1 General description ........................................................................................ 13
4.2 Designation ..................................................................................................... 13
4.3 Name plate ...................................................................................................... 13
4.4 Functions ......................................................................................................... 13
4.5 Technical data ................................................................................................. 15
4.6 Power range .................................................................................................... 17
4.7 Sizes ................................................................................................................. 17
4.8 Dimensions and weights ................................................................................ 18
4.9 Mounting options ........................................................................................... 18
5 Installation at Site ...............................................................................19
5.1 Safety regulations ........................................................................................... 19
5.2 Checks to be carried out prior to installation ............................................... 19
5.3 Mounting PumpDrive ..................................................................................... 19
5.4 Electrical connection ...................................................................................... 20
Contents
PumpDrive 3 of 162
6 Operation ............................................................................................37
6.1 Standard control panel .................................................................................. 37
6.2 Graphical control panel .................................................................................. 40
6.3 Service interface ............................................................................................. 48
7 Commissioning/shutdown ..................................................................49
7.1 Pump operation .............................................................................................. 49
7.2 Application functions ..................................................................................... 72
7.3 Device functions ............................................................................................. 94
7.4 Digital and analog inputs/Digital and analog outputs ................................ 94
8 Maintenance/inspection .....................................................................98
8.1 Safety regulations ........................................................................................... 98
8.2 Maintenance/inspection ................................................................................. 98
8.3 Dismantling ..................................................................................................... 98
9 Wiring diagrams .................................................................................99
9.1 Open-loop control mode ............................................................................... 99
9.2 Closed-loop control mode ............................................................................ 100
9.3 Multiple pump configuration ...................................................................... 101
10 Parameter lists ..................................................................................104
10.1 Selection list .................................................................................................. 129
11 Trouble-shooting ..............................................................................131
11.1 Faults/Malfunctions: Trouble-shooting ....................................................... 131
11.2 Warnings ....................................................................................................... 132
11.3 Alerts ............................................................................................................. 134
12 Purchase Order Specifications ..........................................................138
12.1 Ordering spare parts .................................................................................... 138
12.2 Accessories .................................................................................................... 138
13 Commissioning report ......................................................................157
14 EC Declaration of Conformity ..........................................................158
Index ..................................................................................................159
Contents
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Glossary
Braking resistor
Takes up the braking power produced during
generator operation.
CAN bus
CAN bus (Controller Area Network) is an
asynchronous, serial bus system.
KSB local bus
Proprietary CAN bus that is used in dual and
multiple pump configurations for facilitating
communication among the PumpDrives. The
KSB local bus cannot be used for external
communication.
Pump
Machine without drive, additional components
or accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
PWM
Type of modulation that utilises the AC voltage
of the power supply mains to generate an AC
voltage with variable frequency and amplitude
for directly supplying electrical machinery such
as three-phase motors. The changes in
frequency and amplitude alter the operating
speed of the motor.
RCD
Abbreviation for "residual current device"
Glossary
PumpDrive 5 of 162
1 General
1.1 Principles
This manual is supplied as an integral part of the type series indicated on the front
cover. The manual describes the proper and safe use of this equipment in all phases
of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Operating manual Description of proper and safe use of the pump in
all phases of operation
Wiring diagram Description of electrical connections
Supplementary operating
manual1)
Description of proper and safe use of additional
product components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) Optional
1 General
6 of 162 PumpDrive
2 Safety
All the information in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: 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.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure that the product is operated safely as well as to
prevent injury and damage to property.
The safety information in all sections of this manual must be complied with.
The manual must be read and fully understood by the specialist personnel/operators
responsible prior to installation and commissioning.
The contents of this 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 manual.
2.3 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.
!DANGER
2 Safety
PumpDrive 7 of 162
2.4 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.
2.5 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
2.6 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 and legislation (e.g. EN 50110-1)
2.7 Safety information for the user/operator
▪Fit contact guards supplied by the operator for hot, cold or 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.)
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations 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 all maintenance, inspection and installation work 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/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning.
2 Safety
8 of 162 PumpDrive
2.9 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.
2.10 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.
2.11 Electromagnetic compatibility
The EMC Directive sets out the requirements concerning the interference immunity
and the RFI emissions of electrical equipment.
2.11.1 Requirements to EN 61800-3 – Interference emission
The EN 61800-3 EMC product standard is relevant for electric variable speed drives/
control systems. It describes all the criteria and methods required to comply with the
EMC Directive.
Table 4: Interference emission
Drive
[kW]
Interference emission
Conducted Radiated
≤ 7,5 Unrestricted distribution
Limits to EN 55011 class B
Restricted distribution
Limits to EN 55011 class A1
> 7,5 Restricted distribution
Limits to EN 55011 class A1
Restricted distribution
Limits to EN 55011 class A1
The following warning applies (to EN 61800-3/A11: 2000-01, section 6.3):
PumpDrive is a product with restricted distribution.
This product may cause radio interference in the domestic environment; in this case,
the user / company operating the device may have to take appropriate preventive
measures.
2.11.2 Requirements to EN 61800-3-2 – Line harmonics
The product is a device for professional applications as defined by EN 61000-3-2.
If the product is connected to the public low-voltage mains, appropriate measures
must be taken or a connection approval be obtained from the local energy supply
company.
No connection approval is required when connecting to an industrial power supply.
Drives ≤ 1000 W
Drives > 1000 W
2 Safety
PumpDrive 9 of 162
3 Transport/Temporary Storage/Disposal
3.1 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.
3.2 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
3 Transport/Temporary Storage/Disposal
10 of 162 PumpDrive
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