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Zener 8000 Application Manual

Pump pid 2: advanced pump pid control
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ZENER 8000
SW08020
Application Guide
Pump PID 2: Advanced Pump PID Control

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Summary of Contents for Zener 8000

  • Page 1 ZENER 8000 SW08020 Application Guide Pump PID 2: Advanced Pump PID Control...

  • Page 2: Important Warnings

    Application SW08020: Pump PID 2 [Advanced Pump PID Control] Important Warnings: • ALL PROTECTION PROVIDED BY THE ZENER 8000 IS FOR OPERATIONAL PURPOSES ONLY. SEPARATE INDEPENDENT METHODS MUST BE EMPLOYED TO PREVENT ECONOMIC LOSS. • THIS EQUIPMENT CONTAINS HIGH VOLTAGE AND REMAINS CHARGED FOR A PERIOD AFTER POWER IS REMOVED.

  • Page 3: Commissioning Overview

    Each step must be completed in order shown before proceeding to the next. Before proceeding to power the ZENER 8000 and operating the pump, check all wiring is correct and that the pump and plumbing system is in a state fit for operation. If any parameters are changed it is important to ‘save changes’ when prompted exiting the menu.

  • Page 4: Application Overview

    This application provides an advanced PID Pressure Control System (PCS) using an external pressure transducer. The ZENER 8000 will maintain a constant pressure with changing water consumption requirements. This is a pressure control system with an automatic turn off function (idle or sleep) when there is no demand (or flow).

  • Page 5: System Requirements

    Control Wiring: Note: All control wiring should be screened. ************************************************************************* Ensure the ZENER 8000 is in local mode (remove link in terminal 5) to prevent operation while programming and performing preliminary checks.. Page 4 Document: IM00127 RevB...

  • Page 6: Operation Displays

    Application SW08020: Pump PID 2 [Advanced Pump PID Control] Operation Displays The operational displays show the operating state of the ZENER 8000. The six operational displays are: Speed /  Reference Display, Meter Display, PID Display, PID / Meter Display and kWhr / Hours Run Display. Press (ENTER) to step through each display.

  • Page 7: Loading An Application

    Reloading and Application: Factory defaults must be restored and the application reloaded. To restore defaults follow the procedure below. NOTE: To restore defaults the ZENER 8000 must not be Pump PID2 in REMOTE mode. Remove terminal 5. User Menu ▼...
  • Page 8 Application SW08020: Pump PID 2 [Advanced Pump PID Control] Application ‘CONFIG’ & ‘USER’ Menu: There are now 2 additional menu’s created with this application, a ‘CONFIG MENU’ and a ‘USER MENU’. CONFIG MENU USER MENU The ‘CONFIG MENU’ is created for initial The ‘USER MENU’...

  • Page 9: Config Menu Parameters

    ▼ PRESS TO STEP THROUGH APPLICATION PARAMETERS 22.0Amps PRESS ENTER TO EDIT AND SAVE CHANGES Ensure the ZENER 8000 is in local mode (remove terminal 5) or will not operate. Initial parameters to adjust: Parameter Default Explanation Rated Motor Amps ?? Amps.
  • Page 10 Application SW08020: Pump PID 2 [Advanced Pump PID Control] Parameter Default Explanation Low Trip Level 250.0 kPa Adjust if required. Adjust the level for ‘low pressure’ trip (in kPa) Low Trip time 30 sec Adjust if required. Adjust the low pressure trip time to allow the pipes to fill and pressure to increase above the trip level.
  • Page 11 Use the ▲ to increase the speed above the minimum speed level. If the motor shaft or pump rotates in the wrong direction remove the input power, wait for the ZENER 8000 to discharge and swap any two motor phase wires. Re-apply input power and recheck direction Check pressure transducer feedback: Close the discharge valve and press FWD/ ▲...

  • Page 12: Check The Following

    Check the following: 1. The ZENER 8000 operates and stabilises at a speed where the PV = SV. 2. The pressure (ie. PV) indicated on the ZENER 8000 is correct. If not correct turn the pump off and investigate. 3. Check that the control is stable and responds to changes. Refer to PID tuning guide if unstable.

  • Page 13: Pid Tuning Guide

    Halve the value of H01 Proportional band (avoid adjustments below 10%) Stop & restart the ZENER 8000 & pump. Observe the time it takes to reach pressure (or reacts to changes) Repeat if the response is slow. Keep halving H01 Proportional band until overshoots or starts to oscillate then proceed to step 2.
  • Page 14 When the pressure drops due to returned period of time ‘Idle Delay’ and then goes into ‘Idle Mode’ (sleep). Or ; The input from the optional demand the ZENER 8000 wakes automatically and operates in PID mode. Flow Switch indicating ‘No Flow’ for the ‘Idle Delay’.
  • Page 15 (‘load % threshold’ is not used). When the flow switch provides an ‘open contact’ (no flow) into D3 (terminal 35) for the ‘Idle delay’ period, the ZENER 8000 will enter idle mode. It will operate in conjunction with the above ‘load %’ method if configured.

  • Page 16: Important Note

    Application SW08020: Pump PID 2 [Advanced Pump PID Control] Check the Idle function: Operate the ZENER 8000 in PID mode and while pumping turn various valves or taps on and off to check that it goes in and out of idle as required.

  • Page 17: Thermistor Input

    Parameters that you may want adjustment include: Idle Boost: Idle Boost provides a boost in pressure before the ZENER 8000 goes into ‘Idle’ mode. There are 2 parameters: Idle Boost: Set the pressure to ‘boost to’ in the current units (eg. Kpa) ESC to Menu>...
  • Page 18 Application SW08020: Pump PID 2 [Advanced Pump PID Control] Set point Variable: The set point in this application is a preset value. It is possible to alter this to another source such as; • Potentiometer • Multiple speed • Analogue reference signal (0-5V, 0-10V, 4-20mA) •...
  • Page 19 Application SW08020: Pump PID 2 [Advanced Pump PID Control] Parameters programmed by the Application: The following parameters are automatically programmed by the ‘Application’ when it is loaded. They are listed below for reference purposes only. Application Menu: Other Preset Parameters 1.

  • Page 20: Troubleshooting Guide

    Set point changed so incorrect ‘Load %’ setting. ‘Load %’ will need checking/adjustment if set point is changed. May need a flow switch fitted. More Information or Assistance: For details on all the features and parameters available refer to the ZENER 8000 Reference Manual available on the ZENER website: www.zener.com.au...
  • Page 21 ZENER AUSTRALIAN DISTRIBUTORS New South Wales Queensland Sydney Regional NSW Zener Varidrive Solutions Zener Varidrive Solutions Zener Electric Queensland Pty Ltd 366 Horsley Road 1 William Street Unit 23, 28 Burnside Road Milperra NSW 2214 Maryville NSW 2293 Yatala QLD 4207...

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