WEG CFW500 Applications Manual
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WEG CFW500 Applications Manual

WEG CFW500 Applications Manual

Solar pump drive
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Motors | Automation | Energy | Transmission & Distribution | Coatings
SOLAR PUMP DRIVE
CFW500
Application Manual
Language: English
Document: 10005553220 / 06

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Summary of Contents for WEG CFW500

  • Page 1 Motors | Automation | Energy | Transmission & Distribution | Coatings SOLAR PUMP DRIVE CFW500 Application Manual Language: English Document: 10005553220 / 06...
  • Page 2 Application Manual Solar Pump Drive Series: CFW500 Language: English Document Number: 10005553220 / 06 Publication Date: 02/2025...

  • Page 3: Table Of Contents

    1.2 SAFETY WARNING IN THE PRODUCT ....................8 1.3 PRELIMINARY RECOMMENDATIONS ....................9 2 PHOTOVOLTAIC WATER PUMPING SYSTEM ........10 2.1 OVERVIEW OF THE CFW500 IN PHOTOVOLTAIC SYSTEMS ............10 2.2 GENERAL CHARACTERISTICS OF THE SOLAR PUMP ..............10 3 INSTALLATION ..................12 3.1 SIZING OF PHOTOVOLTAICS SOLAR MODULES ................

  • Page 4: About The Manual

    This manual provides the necessary information for the configuration of Solar Pump Drive application developed with the CFW500 inverter SoftPLC function. This application manual must be used together with the CFW500 user’s manual, the SoftPLC function manual and the WLP or WPS software manual.

  • Page 5: Quick Parameter Reference

    Quick Parameter Reference, Faults and Alarms QUICK PARAMETER REFERENCE Application Default: User Parameter Description Adjustable Range Prop. Groups Page 60Hz (50Hz) Setting P0100 Acceleration Time 0.1 to 999.0 s 10.0 s BASIC P0101 Deceleration Time 0.1 to 999.0 s 10.0 s BASIC P0133 Minimum Speed...
  • Page 6 Actual Pressure Setpoint / Speed 0.0 to 4000.0 [Eng. Un.1] SPLC P1013 Output Pressure 0.0 to 300.0 SPLC P1014 Operating Time CFW500 0 to 6553.5 h SPLC P1015 Counter kWh 0 to 65535 kWh SPLC Remaining Time to a new Start...

  • Page 7: Faults And Alarms

    The firmware of the product (P0023) is incompatible Incompatible Firmware Version with the Solar Pump Application. with the Solar Pump Application version. Compatible Versions: CFW500 G1 (P0023 < v3.5x -> P1010=v1.xx) CFW500 G2 (P0023 > v3.5x -> P1010=v2.xx) Solar Pump Drive | 7...

  • Page 8: Safety Instructions

    Safety Instructions 1 SAFETY INSTRUCTIONS This manual contains the information necessary for the correct use of the frequency inverter CFW500 applied to photovoltaic systems for water pumping. It was developed to be operated by people with proper technical training or qualification to handle this kind of equipment.

  • Page 9: Preliminary Recommendations

    For the purposes of this manual, qualified persons are those trained and are therefore suitable for: 1. Install, ground, energize and operate the CFW500 in accordance with these manual and legal safety procedures. 2. Wear protective equipment in accordance with established local standards.

  • Page 10: Photovoltaic Water Pumping System

    2.2 GENERAL CHARACTERISTICS OF THE SOLAR PUMP The main characteristic of the Solar Pump Drive developed for the CFW500 inverter SoftPLC function is the control of one pump using a frequency inverter supplied by a photovoltaic system, thus allowing control of the speed of the pump.
  • Page 11 ■ Counter hours of operation and energy produced by the solar modules and consumed by the pump. NOTE! For applications where the cable between motor and inverter is greater than 100 meters, consult the WEG for sizing the output reactance/sine filter. Solar Pump Drive | 11...

  • Page 12: Installation

    The frequency inverters operate with undervoltage and overvoltage protection, so that if the voltage reaches these limit values, the inverter will interrupt its operation. Table 3.1 shows the inverter operating voltage information, as well as the overvoltage and undervoltage limits. Table 3.1 – Voltage levels of the CFW500 P0296 200-240 Vac...
  • Page 13 Installation To facilitate the understanding of sizing, we use the following system as an example: Figure 3.1 – Example of a photovoltaic pumping system For this example, based on desired flow a motor pump of 3 hp was selected as a reference, the sizing of the system's number of modules follows the equations: MOTORPUMP SIZING CALCULATION OF DAILY HYDRAULIC ENERGY...
  • Page 14 0°C (Voc = 376.7 Vdc). NOTE! The dimensioning values are according to the table 3.1 (within the limits of CFW500). By associating eight solar modules in series, we are inserting steps of 2760 W . To meet the application needs 5.24kW...

  • Page 15: Connections

    The type of connection to be used will be determined by the voltage of the equipment, below are presented the typical connections for each CFW500 Frame, for more details about the connections of the solar panels consult the “Solar Pump Drive Installation Guide”...

  • Page 16: Frames B, C, D, E And F

    Installation 3.2.2 Frames B, C, D, E and F For CFW500 frequency inverters of frames B, C, D, E and F, models with access to the Link DC (Ud + and Ud-) the following connection is recommended. Figure 3.4 – Connection diagram of the water pumping photovoltaic system for inverter frames B, C, D, E...

  • Page 17: Frames B, C, D, E And F With Hybrid Power

    3.2.3 Frames B, C, D, E and F with Hybrid Power For CFW500 frequency inverters of frames B, C, D, E and F, models with access to the Link DC (Ud + and Ud-) and require hybrid power, the following connection is recommended.
  • Page 18 NOTE! Check terminal access Ud- it may be necessary to remove the plastic shield to make the terminal connection. Table 3.4 – Suggested components for external pre-charge CFW500 T4 Charge Contactor KC Pre-Charge Resistor RC By-pass Contactor KB CWB18 – 18A...

  • Page 19: Control Method By Maximum Power Point Tracking

    Parameters Description 4 CONTROL METHOD BY MAXIMUM POWER POINT TRACKING The strategy of control method of variable reference is constantly tracking the maximum power point of the system (MPPT). The maximum power point of a solar module changes according to the solar irradiance incident on the solar cell, as well as the temperature, wind velocity, inclination of the solar photovoltaic module, passing of clouds, thus generating the need of the constant search for maximum power of the system.

  • Page 20: Parameters Description

    Parameters Description 5 PARAMETERS DESCRIPTION The CFW500 inverter parameters (P0000 to P0999) and the SoftPLC function parameters (P1000 to P1059) for the Solar Pump Drive application will be presented next. NOTE! The Solar Pump Drive application only works on CFW500 inverter with firmware version over V2.06.

  • Page 21: Voltage Pid Controller

    Parameters Description 5.1.2 Voltage PID Controller This group of parameters allows the user to configure the PID controller gains for the DC voltage control supplied by the photovoltaic modules. The PID controller always will attempt to search the work point defined by Tracking Setpoint and for this will act on the output frequency of the motor.

  • Page 22: Cloud/Load Controller

    Parameters Description 5.1.3 Cloud/Load Controller This group of parameters allows the programmer to enable and adjust the gain of the cloud/load controller. The controller works together with the DC Voltage PID controller, when the error between the SP voltage and the DC Link voltage is above a threshold (P1038), the controller is enabled and will contribute the DC Voltage PID, adding a value to its output according to a gain setting (P1039).

  • Page 23: Solar Detector

    The solar photovoltaic detector consists of a small power photovoltaic module suitably sized (Pmax=5W, Vmp=16.8V, Imp=0.3A, Voc=21V, Isc=0.39A) to be connected to analog input 2 (AI2 ) of the CFW500 through a signal conditioner (Solar Detector), whose function is to inform the instantaneous irradiation.
  • Page 24 The use of the Solar Detector is optional, but its use is recommended if a more autonomous system is desired. NOTE! See the CFW500-KDS accessory manual/installation guide for more information on the solar detector. The documents are available on the WEG website. P0236 – AI2 Signal Function Adjustable 0 a 18 ->...
  • Page 25 Parameters Description P1048 – DOx Normally Closed Adjustable 0 to 1 Application Default Setting: Range: Properties: Access groups via HMI: SPLC Description: This parameter defines the DOx operation mode. Value “0” for normally open contact and value “1” for normally closed contact.
  • Page 26 Parameters Description Solar Pump Drive | 26...

  • Page 27: Pressure Controller

    Parameters Description 5.2 PRESSURE CONTROLLER This group of parameters allows the user to configure the conditions of operation of the pressure controller. The pressure controller should receive the pressure return of the system by connecting a pressure transducer to the analogic input (AI1) and perform the pump speed control, when the user defined pressure is reached and the solar radiation conditions allow it.

  • Page 28: Pressure Pid Controller

    Parameters Description P1031 – Pressure Sensor Scale Adjustable 0.0 to 300.0 Application Default Setting: 10.0 Range: Properties: Access groups via HMI: SPLC Description: This parameter defines the full-scale value of the pressure sensor connected to the analog input 1 (AI1). 5.2.1 Pressure PID Controller This group of parameters allows the user to configure the PID controller gains for the pressure control.

  • Page 29: Sleep Mode

    P1035 in order for sleep mode to be activated and the pump to be stopped. NOTE! The alarm message "A750: Sleep Mode Active" will be generated on the HMI of the CFW500 inverter to alert that the Solar Pump Drive is in sleep mode.

  • Page 30: Dry Pump

    Parameters Description 5.3.1 Dry Pump This group of parameters allows the user to configure dry pump detection, to protect the inverter driven pump. P1040 – Time Delay for Dry Pump Fault (F765) Adjustable 0 to 65000 s Application Default Setting: Range: Properties: Access groups via HMI: SPLC...

  • Page 31: Minimum Output Pressure

    Parameters Description 5.3.2 Minimum Output Pressure This parameter group allows the user to configure the minimum output pressure detection for pump protection activated by the CFW500 frequency inverter. P1044 – Minimum Output Pressure Adjustable 0.0 to 300.0 Factory Setting: 0.0...

  • Page 32: Control Setpoint

    Parameters Description NOTE! The system will stop if a fault message is generated. The value of this parameter at "0" disables the fault. 5.4 CONTROL SETPOINT This group of parameters allows the user to adjust the speed or pressure setpoint required for the system to function.

  • Page 33: Reset Of P1014 (Operating Time) And P1015 (Kwh)

    Access groups via HMI: SPLC Description: This parameter allows to reset the parameters P1014 (operating time of the CFW500) and P1015 (kWh counter). These parameters can be useful for counting the number of monthly or weekly hours that the system is operating and the kWh generated.

  • Page 34: Reading Parameters

    Parameters Description 5.6 READING PARAMETERS P1010 – Solar Pump Drive Application Version Adjustable 0.00 to 10.00 Application Default Setting: Range: Properties: Access groups via HMI: SPLC Description: This parameter indicates the version of the ladder application software developed for the Solar Pump Drive. P1011 –...
  • Page 35 Range: Properties: Access groups via HMI: SPLC Description: This parameter displays the kWh value produced by the CFW500 and consumed by the pump. P1016 – Remaining Time to a New Start Attempt Adjustable 0 to 3200 s Application Default Setting:...

  • Page 36: Power Up And Start Up

    4. Energize input; 5. Check the general parameters in the CFW500 (Quick Parameter Reference, Page 5), and adjust the parameters according to the technical characteristics of the water pump and the inverter; 6. Execute the oriented start-up routine (P0317=1) and adjust the values according to the motor characteristics;...

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