PUMP CONTROL. AC Variable Speed Drive PUMP CONTROL. Energy efficient pumping with. 0.75kW 250kW / 1HP 350HP V Single & 3 Phase Input

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1 PUMP CONTROL AC Variable Speed Drive PUMP CONTROL Energy efficient pumping with 0.75kW 250kW / 1HP 350HP V Single & 3 Phase Input

2 Energy Efficient Pump Control Energy efficient flow control from reliable, compact drives, ideal for pump systems Car Parks Pumping Stations Treatment Plants Manufacturing Instant Power Savings With variable speed control, Optidrive HVAC immediately reduces power usage compared to fixed speed systems. Variable Speed Optimisation Power Input to fixed speed system Input to Optidrive HVAC variable speed system Energy Savings Calculator Estimate your potential energy savings, CO 2 emissions and financial savings using our free software. Flow (%) Pump systems are often sized to be most efficient at an application's maximum flow rate. In systems with peak rather than continuous demand, Optidrive HVAC matches pump output to the demands of pump systems. This variable speed control offers significant savings by maximising system efficiency at all flow rates. Traditional means of controlling pump output involve dissipating or diverting the output already generated by the pump running at full speed. In comparison, Optidrive HVAC saves energy by generating only the required output. Invertek s philosophy to provide innovative products with easy to use, energy efficient features ensures that time, set up costs and operational (energy) savings are maximised at all times. This results in the shortest possible payback period, namely the time taken to recover the initial product and installation costs through financial savings achieved through installing Optidrive HVAC drives. For simple installation into your pump management system all Optidrive HVAC drives are provided with both BACnet and Modbus RTU as standard across the product range

3 PUMP CONTROL Energy efficient pumping with Save Energy Save Money Save Time Energy optimisation function minimises energy usage in real time under partial load conditions Advanced sleep & wake functions provide maximum energy savings by switching off the pump when not required Advanced pump cleaning ensures maximum operating efficiency technology allows simple operation of multiple pump sets without the need for a PLC Pump blockage detection and cleaning dramatically reduces pump maintenance requirements Built in PLC functionality allows basic programming of customised applications Simple parameter set allows fast commissioning of pump control systems Pump operating curve detection automatically detects and monitors normal pump behaviour and is able to react when pumping conditions change Customisable OLED display provides excellent visibility of drive status and operation in all conditions Controlling Your Pump System Optimising Efficiency Control System Set-point Signal 0-10V Pressure Sensor Energy Optimisation The advanced optimisation function intelligently matches energy usage to the pump load to ensure your pump operates at maximum efficiency. Input Drive Output Feedback Signal 4-20mA Outputs Outputs Energy Monitoring The inbuilt energy consumption meters allow energy consumption to be clearly displayed and savings to be calculated. Outputs Outputs Optidrive HVAC has a PID controller built in that is fully integrated with both pump and energy efficient features and is packaged in a user friendly way to ensure ease of use and fast commissioning. Now in the majority of applications it has become possible to eliminate the need for external controllers. Resonance Avoidance Optidrive HVAC can be easily configured to avoid frequencies that cause resonance in pumping systems, preventing unnecessary noise and mechanical damage to motors and pipework. In-built Sleep Mode with Auto-boost Sleep mode saves energy by detecting when a pump is running inefficiently and producing little useful work. Optidrive HVAC can be programmed to enter into a sleep/disabled mode until the demand increases. To help prevent sleep mode oscillation, Optidrive HVAC can automatically initiate a boost cycle to increase pressure on starting or stopping. 3

4 Multi-pump Control Embedded control technology for multi-pump systems Flexible pump station control with no PLCs or pump control units Setpoint Control Independent pump control system A standard feature on all drives Optiflow communications Feedback signal 4 Total Control Simple Connection Flexible Solution A single Master drive acts to control and monitor system operation. Control connections are made to this drive only, saving installation time and reducing costs. Additional drives connected on the system require a single RJ45 connection and basic commissioning, leading to time savings and simplified installation. The system can operate with up to five pumps in any configuration, e.g. Duty / Assist / Standby. Duty pumps are automatically rotated, ensuring maximum service life and system efficiency.

5 PUMP CONTROL Energy efficient pumping with Summary yy All drives operate at variable speed for maximum energy saving. yy Equal run time sharing across every pump. yy Automatic system reconfiguration in the event of a pump fault (including the master pump). yy Continued system operation when drives are individually powered off (including the master drive). yy Communication and +24V control voltage shared between drives via a standard RJ45 patch lead. yy Independent maintenance indicators for each pump. yy Any pump can be switched to Hand operation a the touch of a button, and will automatically rejoin the network when switched back to Auto. yy For waste water applications each pump can be set for blockage/ragging detection and activate an automatic de-ragging/pump cleaning cycle. yy Optional mains isolator with lock-off for safe pump maintenance. yy Optiflow function configured through simple parameter set-up and intelligent drive self configuration. Consistent Flow Reduced Downtime The required pressure and flow levels are maintained regardless of how many pumps are required. When demand increases, additional pumps are automatically brought on stream to assist and are switched off again when not required. In the event of a fault, or if a pump needs to be isolated for maintenance, the system will automatically continue to operate with the remaining available pumps. The mains power can even be completely isolated from the Master drive without affecting operation of the Slave drives. 5

6 Dedicated to Pump Applications Putting you in control Avoid Pump Downtime Pump Prime Mode Blockage Detect/Clear Optidrive HVAC can detect pump blockages and trigger a programmed cleaning cycle to automatically clear them, preventing downtime. Dry Run Protection Optidrive HVAC can evaluate a pump s speed/power and shut it off or warn when the pump starts to run dry, protecting it from heat/friction damage. Motor Preheat Function Optidrive HVAC features a motor preheat function to help ensure moisture is not permitted to collect on the motor in periods of inactivity and prior to motor start up. In addition, the motor preheat function can be used to keep condensation from developing on the motor as the motor cools down immediately following a stop. The feature is fully configurable, meaning the pump can be always available the instant it is required. Pump Stir Cycle Triggered by a settable period of inactivity, a configurable cleaning cycle can be run to clear sediment, ensuring the pump is ready to run when needed. Pump Prime with Burst Pipe Detection Pump prime mode allows starting of the pump in a safely controlled manner, to ensure consistent filling and pressurisation of pipe work and systems. Low pressure warnings are ignored during priming to allow the system to prime correctly, whilst a failsafe timeout prevents the pump from continuing to run in the event of a failure to prime. This helps to prevent the effects of water hammering (such as bursting water pipes) or damage to fountain / sprinkler heads. The time limit, set for pump prime mode to complete, means that the pressure in the system must reach the minimum level within the set time. Failure of the system to pressurise would indicate a leak or burst pipe within the pump system and result in the Optidrive HVAC shutting down the pump. During normal operation the system pressure is still continuously monitored against the minimum level so that a burst pipe during normal operation will likewise result in the drive tripping low pressure and shutting the pump down. 6

7 PUMP CONTROL Energy efficient pumping with Hand / Auto Allows immediate manual pump control in the event of an automatic control system failure or for simplified commissioning / system checks and when a fast temporary override of the control system is required. Built in Auto Control Selection allows return to automatic system control just as easily. Relay Cascade Control Drive Controlled Bypass Variable speed duty pump with up to 4 assist pumps Optidrive HVAC can be used as the controller in a pump duty assist configuration. Optidrive HVAC will provide automatic operating time monitoring and balancing for assist pumps to share duty cycle. Run time clocks for all fixed speed assist pumps are maintained and visible within the Optidrive HVAC for integration into the pump system maintenance schedules. Intelligent features within the Optidrive HVAC allow a bypass circuit to be implemented. Activation of Bypass mode can be determined intelligently by the Optidrive HVAC drive based on a command from the building management system. The drive can be set to automatically select bypass mode when entering into a trip condition ensuring minimal disruption to service. 3-Phase Mains Input Supply With Additional Relay Module Relay 1 Output Relay 2 Output Relay 3 Output Relay 4 Output Sensor feedback to drive PID Master Pump Slave Pump 1 Slave Pump 2 Slave Pump 3 Slave Pump 4 Sensor Pump Output Channel 7

8 Features & Options Peripherals and factory build options to help integrate Optidrive HVAC with your pumping systems Maintenance interval timer and service indication OLED Display Installed as standard on all IP55 & IP66 models y Clear multi-line text display y Operates to 10 C y Wide viewing angle, effective in dark and light conditions y Customisable display y Multi-language selection Multi-language, high visibility OLED display Enclosure Options Simple user interface with HAND / AUTO select IP20 IP66 IP55 IP40 Sizes 2 & 3 Cabinet mount Sizes 2 & 3 Wall or cabinet mount Sizes 4 7 Wall or cabinet mount Size 8 Free-standing Optional kit is available for through-hole mounting Pluggable control terminals IP66: Protection in Harsh Environments Dust-tight Install in-situ and be sure of protection from dust and contaminants. IP66 Inbuilt isolator option available High quality long life fans Integrated cable management IP20 IP40 IP55/NEMA 12 IP66/NEMA 4X Washdown Ready With a sealed ABS enclosure and corrosion resistant heatsink, IP66 rated drives are ideal for high pressure washdown applications. Corrosion Protection The heat-sink of the IP66 drive is specially coated to protect against attack / corrosion by harsh environments and chemicals. For additional protection in water and waste water applications all HVAC drives can be ordered with full conformal coating of the internal drive electronics. The conformal coating option provides protection to level 3C2 according to IEC Localised conformal coating of critical components is provided as standard. 8

9 PUMP CONTROL Energy efficient pumping with Powerful PC Software Drive commissioning and parameter backup y Real-time parameter editing y Drive network communication y Parameter upload, download and storage y Simple PLC function programming Compatible with Windows XP, Windows Vista & Windows 7 Plug-in Modules Optipad Mains Isolator Extend functionality and communication options Expansion Modules y Extended I/O (3 x Digital In, 1 x Relay Out) y Cascade Control (extended Relay) (3 x Relay Outputs) Fieldbus Interfaces y BACnet/IP y EtherNet/IP y DeviceNet y Profibus Remote Keypad & OLED Display IP55 panel mount operator interface. y Clear multi-line text display y Multiple language select y Customisable displays Optistick Mains Isolator Option Lockable mains isolator option. Can be used with sizes 4-8. Rapid Commissioning Tool Plug-in or wirelessly copy parameter sets between drives. provided as standard 9

10 kw HP Amps Size kw Model Code Product Range Frame Size Supply Voltage Power Rating Generation Input Phases Power Type EMC Filter Brake Transistor Factory Build Options HP Model Code Product Range Frame Size Supply Voltage Power Rating Generation Input Phases Power Type EMC Filter Brake Transistor Factory Build Options IP20 IP40 IP55 IP66 Enclosure IP66 with Isolator Display Factory Build Options 7 Segment LED Display OLED Display PCB Coating Standard Coating Full Conformal Coating V ± 10% 1 Phase Input V ± 10% 3 Phase Input ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 2 -## ODV H F 1 2 -## 2 S T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C V ± 10% 3 Phase Input ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 #-## ODV H F 1 #-## 2 X D S T N C ODV K F 1 2 -## ODV H F 1 2 -## 2 S T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F 1 N- T # ODV H F 1 N- T # N T N C ODV K F T # ODV H F T # 4 T N C ODV K F T # ODV H F T # 4 T N C kw Models: Factory Settings Motor Rated Frequency: 50Hz Motor Rated Voltage: 400V HP Models: Factory Settings Motor Rated Frequency: 60Hz Motor Rated Voltage: 460V Replace # in model code with colour-coded option IP20 units are available with 7 Segment LED Display only NOT TO SCALE H IP20 IP66 IP55 IP40 mm mm mm kg Size Height Width Depth Weight W D

11 PUMP CONTROL Drive Specification Input Ratings Supply Voltage Supply Frequency V ± 10% V ± 10% 48 62Hz Control Specification Control Method PWM Frequency Variable Torque V/F Variable Torque Energy Optimised V/F 4 32kHz Effective Control Features Fire Mode Broken Belt Detection Selectable direction Selectable speed reference Under load monitoring with autotune configuration Displacement Power Factor Phase Imbalance Inrush Current Power Cycles Output Ratings Output Power Ambient Conditions Enclosure Programming Overload Capacity Output Frequency Typical Efficiency Temperature Altitude Humidity Ingress Protection Keypad Display PC > % Maximum allowed < rated current 120 per hour maximum, evenly spaced 230V 1 Phase Input: kW (1 3HP) 230V 3 Phase Input: kW (1 100HP) 400V 3 Phase Input: kW 460V 3 Phase Input: 1 350HP 110% for 60 seconds 0 120Hz, 0.1Hz resolution 98% IP20: 50 C IP40: 40 C IP55: 40 C IP66: 40 C Up to 1000m ASL without derating Up to 2000m maximum UL approved Up to 4000m maximum (non UL) Above 1000m : Derate by 1% per 100m 95% Max, non-condensing IP20 (Frame sizes 2 & 3) IP66 (Frame sizes 2 & 3; up to 7.5kW) IP55 (Frame sizes 4 7) IP40 (Frame size 8) Built-in keypad as standard Optional remote mountable keypad Built-in multi language OLED display (except IP20) LED display (IP20 only) OptiTools Studio I/O Specification Ramp to Stop: Stopping Mode User Adjustable seconds Coast to Stop Braking Motor Flux Braking Skip Frequency Single point, user adjustable Setpoint Control Power Supply Programmable Inputs Digital Inputs Analog Inputs Programmable Outputs Relay Outputs Analog Signal Digital Optional 0 to 10 Volts 10 to 0 Volts 10 to +10 Volts 0 to 20mA 20 to 0mA 4 to 20mA 20 to 4 ma Motorised Potentiometer (Keypad) Modbus RTU BACnet BACnet/IP, Profibus DP, DeviceNet, EtherNet/IP 24 Volt DC, 100mA, Short Circuit Protected 10 Volt DC, 5mA for Potentiometer 5 Total as standard (Optional additional 3) 3 Digital (Optional additional 3) 2 Analog / Digital Selectable Volt DC, internal or external supply, NPN Response time : < 4ms Resolution : 12 bits Response time : < 4ms Accuracy : < 1% full scale Parameter adjustable scaling and offset 4 Total (Optional additional 3) 2 Analog / Digital 2 Relays (Optional additional 3) Maximum Voltage : 250 VAC, 30 VDC Switching Current Capacity : 6A AC, 5A DC Pump Control Features Maintenance & Diagnostics Standards Compliance PID Control Pump Blockage Detection Pump Cleaning Multi-pump Control Pump Stir Fault Memory Data Logging Maintenance Indicator Monitoring EN :2004 Internal PID control with feedback display Pump load monitoring with autotune function, user configurable Adjustable Pump Cleaning Cycle operation Control of fixed speed assist pumps via optional cascade control module Control of Duty, Assist and Standby variable speed pumps via internal Master Slave network Automatic pump stir function Last 4 Trips stored with time stamp Logging of data prior to trip for diagnostic purposes : Output Current, Drive Temperature, DC Bus Voltage Maintenance Indicator with user adjustable maintenance interval Onboard service life monitoring Hours Run Meter Resettable & Non Resettable kwh meters Adjustable speed electrical power drive systems. EMC requirements. Analog Outputs 0 to 10 Volt 0 to 20mA 4 to 20mA Model Code Guide Connection Diagram Product Family ODV KF1#-## Generation Frame Size V = 2 Supply V = 4 Voltage Power Rating Code Single Phase = 1 Input 3 Phase = 3 Phases kw = K Power Type HP = H Internal EMC Filter = F EMC Filter No Brake Transistor = 1 Brake Transistor IP20 = 2 Enclosure IP40 = 4 IP55 = N IP66 Non-switched = X IP66 with Isolator = D OLED Text Display = T Display LED Display = S Standard Coating = N Full Conformal Coating = C PCB Coating Function Default Setting 12 Volt DC Output, 100mA max / 24 Volt DC Input Digital Input 1 Drive Enable Digital Input 2 Analog / Preset Speed 1 Select Digital Input 3 Local / Remote Reference Select +10 Volt Power Supply 5mA Analog Input 1 Local Speed Reference 0 Volt Analog Output 1 Motor Speed 0 Volt Analog Input 2 Remote Speed Reference Analog Output 2 Motor Current Safe Torque Off Input Safe Torque Off Input Output Relay 1 Drive Healthy / Fault Output Relay 2 Drive Running 11

12 PUMP CONTROL Optidrive HVAC +44 (0) Saving Energy / Reducing CO 2 With large scale increases in global energy costs and the introduction of taxes and legislation relating to the Industrial production of CO 2 gases the needed to reduce energy consumption and save money has never been greater. The Optidrive HVAC can be used with environmental sensors to reduce pump speed in pumping applications without compromising the required output of the system. Easy Installation Compact and modern design utilising the latest available technology have accumulated in a robust HVAC drive with small dimensions and innovative mounting and cabling features Simple Set-up & Rapid Commissioning Optidrive HVAC was developed from concept for easy of use. A handful of parameters configure the drive for basic pump applications. A short, concise product data means the drive is running in seconds. Advanced powerful functionality is equally easily accessible. UK Head Office, Welshpool Invertek Drives Ltd is dedicated to the design, manufacture and marketing of electronic variable speed drives. The state of the art UK headquarters houses specialist facilities for research & development, manufacturing and global marketing. All company operations are accredited to the exacting customer focused ISO 9001:2008 quality standard. The company's products are sold globally in over 65 different countries. Invertek Drives' unique and innovative drives are designed for ease of use and meet with recognised international design standards. Imaginative Enclosure Design With Enclosure design from IP20 all the way up to IP66 the Optidrive HVAC is well suited to harsh environments, or where cabinet and cabling costs need to be reduced. Advanced Pump Control Functions The key pump control functionality required for your application is inbuilt into the Optidrive HVAC and packaged to be both quick and simple to active. Added to this is the drives own PLC programming flexibility that makes drive functionality virtually limitless. Global Pump Solutions Invertek Drives operate at the heart of pumping systems around the world Options for Flexibility Optidrive HVAC combines both peripheral and factory built options to ensure you get the right drive, scaled to suit your application. With inbuilt BACnet and Modbus, and a host of communication options the Optidrive can integrate easily into your Industrial network of choice. IRELAND Maintaining pressure at pumping stations HOLLAND ITALY Hot water pumping across district network Cooling system control in steel foundry IRELAND Storm water pumping in Dublin Port Tunnel Optidrive HVAC User Guide Scan to download or visit the Invertek Drives website / optidrive-hvac INVERTEK DRIVES LIMITED UK HEAD OFFICE Offa s Dyke Business Park, Welshpool, Powys. UK SY21 8JF Tel: +44 (0) Fax: +44 (0) [email protected] 2012 Invertek Drives Ltd. All rights reserved. 85-PUMPB-IN V1.02