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Fuji Electric FRENIC-Eco Series Quick Manual

For pump control and hvac applications
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QUICK GUIDE
PUMP CONTROL
Frequency inverter for pump control and HVAC applications
Date
Version
14/04/2009
1.0.5

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Summary of Contents for Fuji Electric FRENIC-Eco Series

  • Page 1 QUICK GUIDE PUMP CONTROL Frequency inverter for pump control and HVAC applications Date Version 14/04/2009 1.0.5...
  • Page 2 Version Details Date Written Checked Approved English Translation from J. M. Ibáñez J. Català 1.0.3 19/09/08 Spanish version 1.0.3 J. Carreras M. Kitchen 1.0.4 Small changes done 24/10/08 J. Català J. Català 1.0.5 14/04/09 J. Català ROM 1900 functions added Pump Control Quick Guide...
  • Page 3 Thank you for purchasing Fuji Electric’s inverter for pump and fan applications. This guide is structured as follows: CHAPTER 0: Introduction to pressure control systems 9 types of pump control CHAPTER 1: Single pump control Electrical diagram Sleep Function Wake-up Function...
  • Page 4 The target of a pressure control system is to provide a variable flow with a constant pressure for the water system of an apartment building, machine refrigeration systems, mixing liquids in chemical industry, etc. A very typical example is providing the water supply for a residential building. In this case, the flow (water consumption) is greater in the morning than during the night (when it’s almost non-existent) The pressure control system must be able to provide, at the same pressure, both types of consumption (Daytime higher flow, and during the night...
  • Page 5 QUICK GUIDE PUMP CONTROL frequency inverter is able to control single or multiple pumps in mono-regulated or multi- regulated configuration. Several control schemes may be built as shown below: The necessary digital outputs will vary depending on the control type has been chosen (OPC-F1-RY optional card may be necessary).
  • Page 6 Necessary digital outputs Do we need the optional relay card installed? Single pump control When a regulated pump is being controlled, it’s necessary to consider certain parameters in order to allow the inverter to control the pump’s start-up and stop, controlling speed to maintain the desired pressure, etc.

  • Page 7: Sleep Function

    When the “RUN” signal is switched on (either FWD or REV), the inverter will increase the output frequency (always after the period time defined in J38 (sec)). In order to control this rising output, some parameters are available: F23 (Hz) controls the starting frequency, J43 the starting PID frequency and the ramp from one to the other (F07) (sec.).
  • Page 8 Figure 1.2: Speed control behaviour while sleep and wake-up functions are enabled Pump Control Quick Guide...
  • Page 9 The following table (table 1.1), called “Common parameters to the all pump control systems”, shows the common parameters to all pump control systems using , these are known as the basic parameters. In other chapters, Specific Parameters’ table will be shown. These parameters will depend on the chosen control system.
  • Page 10 COMMON PARAMETERS DESCRIPTION Basic Function F02: Run Command This function code defines the way in what the “RUN” signal will be given to the inverter in order to start the pressure control. Usually, “Run Command” is sent to the inverter by means of the digital input (F02 = 1). That is, switching on FWD or REV (control terminals in the inverter) digital inputs enables the inverter output.
  • Page 11 Special Functions H91: C1 Signal disconnection Detection Disconnection of pressure sensor (cable failure). When a value is stored in parameter H91 (between 0.1 and 60.0 seconds) the inverter will generate an alarm (CoF) when it notices that C1 signal current is missing (C1 current < 2mA) during a time longer than the value in H91.
  • Page 12 Necessary digital outputs Do we need the optional relay card Mono-regulated pump control (Mono-joker) installed? 1 auxiliary pump 1 inverter driven pump (ON / OFF) The schematic for a mono-regulated pump control with 1 regulated pump + 1 auxiliary pump by means of inverter is as follows: Please, pay attention to the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 13 Necessary digital outputs Do we need the optional relay card Mono-regulated pump control (Mono-joker) installed? 2 auxiliary pump 1 inverter driven pump (ON / OFF) The schematic for a mono-regulated pump control with 1 regulated pump + 2 auxiliary pumps by means of the inverter is as follows: Please, pay attention to the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 14 Necessary digital outputs Do we need the optional relay card Mono-regulated pump control (Mono-joker) installed? 3 auxiliary pump 1 inverter driven pump (ON / OFF) The schematic for a mono-regulated pump control with 1 regulated pump + 3 auxiliary pumps by means of the inverter is as follows: Please, pay attention to the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 15 Necessary digital outputs Do we need the optional relay card Mono-regulated pump control (Mono-joker) installed? 4 auxiliary pump 1 inverter driven pump (ON / OFF) The schematic for a mono-regulated pump control with 1 regulated pump + 4 auxiliary pumps by means of the inverter is as follows: Please, pay attention to the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 16 Mono-regulated pump control involves a pump exclusively driven by the inverter and other(s) pump(s), working in “On-Off control” mode and directly connected to the commercial power supply. The inverter will connect/disconnect the auxiliary pump(s) to the commercial power supply, in order to achieve the desired pressure.
  • Page 17 In the following, the requirements or conditions to activate an auxiliary pump are shown: • Connection of an auxiliary pump If the regulated pump’s output frequency is higher than the level established by J34 during the time specified in J35, the inverter will understand that using the regulated pump is not enough to maintain the required pressure, and the inverter is ready to connect an auxiliary pump to the commercial power supply.
  • Page 18 In the following the requirements or conditions to deactivate an auxiliary pump are shown: • Disconnection of an auxiliary pump If the output frequency level of the regulated pump gets lower than the value stored in J36 during a time longer than J37, the inverter will understand that the auxiliary pump is no longer needed and will begin a disconnection process.
  • Page 19 The following table (Table 2.1), “Common parameters to all the pump control systems”, shows the common parameters to all of the control systems using inverter. These are known as the basic parameters. In addition to the following table, there is also a specific parameters table. If you are adjusting the inverter by means of the TP-E1 keypad, it is recommended to set E52 to “2”, in order to be able to access to all of the inverter’s menus.
  • Page 20 The following table (Table 2.2) shows the specific function codes for a good control system with 1 regulated pump + 1, 2, 3, or 4 auxiliary pumps: Specific Function Codes , mono-regulated pump control with 1 regulated pump + 1, 2, 3 or 4 auxiliary pumps For 1 For 2 For 3...
  • Page 21 J26, J27, J28, J29: Motor 1 mode, Motor 2 mode, Motor 3 mode, Motor 4 mode Function codes J26, J27, J28 and J29 define: J26 = 0 Pump 1 unavailable J26 = 1 Pump 1 available J26 = 2 Pump 1 connected to commercial power supply J27 = 0 Pump 2 unavailable J27 = 1 Pump 2 available J27 = 2 Pump 2 connected to commercial power supply...
  • Page 22 Necessary digital Do we need the optional relay Mono-regulated pump control (Mono-joker) outputs card installed? 1 regulated 4 auxiliary pumps 1 additional pump pump (On-Off control) (On-Off control) The schematic to implement a mono-regulated pump control with 1 regulated pump + 4 auxiliary pumps + 1 additional pump with a inverter is as follows: Please, pay attention on the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 23 This control system consists on a regulated pump controlled exclusively by the inverter and other 5 pumps working in “On-Off control” mode connected directly to the commercial power supply (4 auxiliary pumps + 1 additional pump). The inverter will connect/disconnect the auxiliary pumps to the commercial power supply in order to achieve the desired pressure.
  • Page 24 The following table (Table 3.1), called “Common parameters to all the pump control systems”, shows the common parameters to all of the control systems using the inverter, these are the basic parameters. Additional to the common function codes’ table, there is also a table with specific function codes. If you are adjusting the inverter by means of the TP-E1 keypad, it is recommended to set E52 to “2”, in order to be able to access all inverter menus.
  • Page 25 Condition for frequencies where auxiliary pumps are connected/disconnected Condition for the connection of the additional pump Using this control topology, it can be necessary to delay the disconnection of the motor from the commercial power supply (J37), in order to prevent the simultaneous disconnection of the auxiliary and the additional pumps.
  • Page 26 DESCRIPTION OF SPECIFIC PARAMETERS FOR A MONO-REGULATED PUMP CONTROL + 4 AUXILLIARY PUMPS + 1 ADDITIONAL PUMP Outputs Set-up E22: Status Signal Assignment to Y3 The function code E22 defines the signal assigned to digital output Y3. In order to implement a mono-regulated pump control system with an additional pump, the Y3 terminal’s signal must be set to 2, corresponding to FDT function.
  • Page 27 Multi-regulated pump Control (Multi-Joker) Necessary digital outputs Do we need the optional relay card installed? 2 Regulated pumps The schematic to implement a multi-regulated pump control with 2 regulated pumps by means of inverter is as follows: Please, pay attention on the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 – 20 mA).
  • Page 28 Multi-regulated pump control (Multi-Joker) Necessary digital outputs Do we need the optional relay card installed? 3 regulated pumps The schematic to implement a multi-regulated pump control with 3 regulated pumps by means of inverter is as follows: Please, pay attention on the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 – 20 mA).
  • Page 29 This control consists of 2/3 pumps regulated by the inverter. In Multi-regulated pump Control, all of the system pumps are driven by means of the inverter. The inverter controls the pump and connects/disconnects each pump to/from the commercial power supply according to the application requirements.
  • Page 30 The following is an explanation of the requirements or conditions to connect a regulated pump to the commercial power supply, and to disconnect a pump from the commercial power supply: • Connection of a regulated pump to the main supply If the regulated pump’s output frequency rises above the level stored in J34 during the time established in J35, the inverter will understand that the regulated pump is not enough to maintain the required pressure and will get ready to connect the pump to the commercial power supply.
  • Page 31 J37 (sec) J36 (Hz) Figure 4.5: Increase of the pump’s speed to disconnect the pump from the main supply The exact point where the inverter will disconnect the pump from the main supply can be defined with function code J41. The equation to find this point is: ...
  • Page 32 The following table (Table 4.1), called “Common Parameters to all the pump control systems”, shows the common parameters to all the control systems using the inverter, these are the basic function codes. In addition to the common function codes’ table, there is a table with the specific function codes. If you are adjusting the inverter by means of the TP-E1 keypad, it is recommended to set E52 to “2”, in order to be able to access all the inverter menus.
  • Page 33 The following table (table 4.2) shows the specific function codes for multi-regulated pump control system with 2/3 regulated pumps: Specific Parameters for Multi-regulated pump control with 2 / 3 regulated pumps For 2 regulated pumps For 3 regulated pumps Name Default value User’s Value (without OPC-F1-RY)
  • Page 34 The other modes can be useful for: Mode 0: The pump is omitted. Can be useful to disconnect, software disable, a pump from the system without modifying the wires. Mode 2: Can be useful to check the rotation direction of the pumps, because they will be connected to the commercial power supply as soon as this mode is activated.
  • Page 35 Necessary digital outputs Do we need the optional relay card Multi-regulated pump Control (Multi-Joker) installed? 1 additional pump 3 regulated pumps (“On-Off control”) The schematic for a multi-regulated pump control with 3 regulated pumps + 1 additional pump by means of the inverter is as follows: Please, pay attention on the pressure transducer’s wiring, connected to the inverter’s analog input C1 (4 –...
  • Page 36 In Multi-regulated pump Control, all the system pumps are regulated by means of the inverter. The inverter controls the pump and connects/disconnects each pump to/from the commercial power supply according to the application requirements. The control system explained in this chapter consists of 3 pumps regulated by means of the inverter plus an additional pump working in “On-Off control”...
  • Page 37 In the same way as the multi-regulated pump control with 2/3 regulated pumps (chapter 4), if the pressure demand cannot be satisfied with only one pump, the inverter will connect it to the commercial power supply to gain control of pump 2 as a regulated pump. If there is still not enough pressure, pump 2 will be connected to the main supply and pump 3 will become the new regulated pump.
  • Page 38 CONDITIONS TO ACHIEVE GOOD CONTROL IN MULTI-REGULATED PUMP CONTROL WITH 3 REGULATED PUMPS+ 1 ADDITIONAL PUMP Please follow the instructions below if it is necessary to change function codes data: Condition for Sleep/wake up frequencies Condition for frequencies where auxiliary pumps are connected/disconnected Condition for the connection of an additional pump With this topology, it may be necessary to extend the disconnection time of the motor from the commercial power supply (J37), to prevent the additional and the regulated pumps could be disconnected...
  • Page 39 DESCRIPTION OF SPECIFIC PARAMETERS OF MULTI-REGULATED PUMP CONTROL WITH 3 REGULATED PUMPS + 1 ADDITIONAL PUMP Outputs Set-up E21: Status Signal Assignment to Y2 Parameter E21 defines the function assigned to digital output Y2. For a multi-regulated pump control system with 3 regulated pumps + 1 additional pump, this output must be set to 2, corresponding to the FDT function.
  • Page 40 Dry well function (Related function codes -> E80, E81) Target: to make the inverter enter a STOP state, displaying an error code, when motor torque decreases below a set level for a specified period of time. Digital Inputs to use: X5 (with “Enable External alarm Trip” command assigned to it) •...
  • Page 41 Overpressure alarm (related function codes -> J11, J12 y J13) Target: make the inverter enter a STOP state and display an error code, when the process value (Feedback – pressure transducer) rises above a certain level. Digital Input to use: X4 (with “Enable External alarm Trip” command assigned to it) •...
  • Page 42 PID Display units set-up (related function codes -> E40, E41) In order to display the values of PID control (SV, PV, MV, etc.) in engineering units, adjustment of the value in E40 to the sensor range is needed. So, the user will be able to enter the Command Value in user units, instead of percentage of PID. For example, if the transducer in use is 4-20 mA (160 bars), the function code E40 must be set to 160.
  • Page 43 Note: Function codes from J48 to J52 contain the accumulated run time of each pump. These values can be reset (set the time to “0”). It can be useful in case of replacement of an old pump for a newer one. Using both solutions the pump’s working time can be fairly distributed between all the pumps of the system.
  • Page 44 Dead Band (related function code -> J42) Function code J42 can be used to avoid the connection/disconnection (undesired) of any auxiliary pump, when the frequency of the regulated pump is close to the switching between commercial/inverter-driven frequencies. If the difference between the PID Feedback and PID Set point is less than the percentage stored in J42, the inverter won’t make a connection/disconnection of the pump.
  • Page 45 If you want to make this repetition slower (to make longer the time between sleep and wake-up), the functions codes J23 and J24 can be useful (two additional conditions to wake up the regulated pump are added). Normally, by means of using these function codes it’s possible to separate the sleep and wake-up actions. The idea is to increment J23 (% of error) until the time between sleep and wake-up is long enough.
  • Page 46 2. Holding integral PID component during the process (anti-reset wind-up) J10 function code can be used to hold the integral PID component. The integral component will be active only when the margin between process value (PV) and set point (SV), that is the error, is inside the limits defined by J10 function code. If bigger than J10, current integral PID component will be held.
  • Page 47 Name Data setting range Default setting Current Value Data protection 0: Disable data protection (Fuction code data can be edited) 1: Enable data protection Frequency command 1 0: Enable arrow keys on the keypad 1: Enable voltage input to terminal [12] (0 to 10 V DC) 2: Enable current input to terminal [C1] (4 to 20 mA) 3: Enable sum of voltage and current inputs to terminals [12] and [C1] 5: Enable voltage input to terminal [V2] (0 to 10 V DC)
  • Page 48 Name Data Range Default Setting Current value Command Assignment to: X1 Selecting function code data assigns the corresponding function to terminals [X1] to [X5] as listed below. Setting the value Command Assignment to: X2 of 1000s in parentheses ( ) shown below assigns a negative logic input to a terminal. Command Assignment to: X3 Note: In the case of (THR) and (STOP), data (1009) and (1030) are for normal logic, and "9"...
  • Page 49 Default Setting Name Data Range Current value LED monitor Speed item 0: Output frequency 3: Motor speed in r/min 4: Load shaft in r/min 7: Display speed in % 30.00 Coefficient for speed indication 0.01 to 200.00 Display coefficient for input 0.000: Cancel / reset 0.010 watt-hour data...
  • Page 50 Default Setting Name Data Range Current value Motor No. Of Poles 2 to 22 Rated Capacity 0.01 to 1000 kW (If P99 is 0, 3 or 4) Rated capacity of the motor 0.01 to 1000 HP (If P99 is 1) Rated Current 0.00 to 2000 A Rated current of Fuji standard motor...
  • Page 51 Default Setting Name Data Range Current value DC braking (braking response mode) 0: Slow 1: Quick STOP key priority/start check function STOP key priority Start check function 0: Disable Disable 1: Enable Disable 2: Disable Enable 3: Enable Enable Clear alarm data Setting H97 data to "1"...
  • Page 52 Default Setting Current value Name Data Range RS485 communication Station address 1 to 255 (standard) Communications error 0: Immediately trip with alarm ErP processing 1: Trip with alarm ErP after running for the period specified by timer y13 2: Retry during the period specified by timer y13. If retry fails, trip and alarm ErP. If it succeeds, continue to run 3: Continue to run 2.0 s Error processing timer...
  • Page 53 The keypad consists of 4 digit LED monitor, 5 LED indicators and 6 keys, as shown in the figure. The keypad allows you to start and stop the motor, monitor running status and switch to the menu mode. In the menu mode you may set the function code data, monitor I/O signal states check...
  • Page 54 The relay card is an option card with 3 additional relays of 3 contacts – 2 positions. This card is essential in order to implement the following pump control systems: Multi-pump control with 3 regulated pumps Multi-regulated pump control with 3 regulated pumps + 1 additional pump The functions that can be assigned to these relays are: 60 (1060): Sequenced start motor 1, inverter-driven (M1_I)