57

Pump/Fan control
The PFC (Pump and fan control) macro is specially designed for multimotor pumping
(or compressor, etc.) stations. While directly controlling one motor, the drive is able
to start additional, direct-on-line motors whenever a higher capacity is needed.
There is an Autochange function to alternate between the pumps so all pumps have
an equal duty time, and the Interlocks function enables the drive to detect if any of
the pumps are unavailable (e.g. switched off for maintenance) so the next available
pump is started instead.
See the chapter PFC Application Example. See also the chapter Application macros,
section PFC (Pump and fan control) macro, and the parameter groups listed below.

Settings
Parameter Additional information
Group 14 RELAY Selection of digital outputs for starting and stopping of motors
OUTPUTS
Group 41 PFC Process reference selection, set-up of auxiliary motor start/stop frequencies
CONTROL 1
Group 42 PFC Set-up of auxiliary motors, start delays, Interlocks function and automatic
CONTROL 2 motor alternation (Autochange function)
Group 44 PFC Set-up of PFC protections (pressure monitoring)
PROTECTION

Diagnostics
Actual value Additional information
01.17, 01.40 Status of digital inputs
01.21, 01.41 Status of relay outputs
01.42 Time since latest Autochange

Program features
58

Process PI control
There is a built-in PI controller in the drive. The controller can be used to control
process variables such as pressure, flow or fluid level.
When the process PI control is activated, a process reference (setpoint) is
connected to the drive instead of a speed reference. An actual value (process
feedback) is also brought back to the drive. The process PI control adjusts the drive
speed in order to keep the measured process quantity (actual value) at the desired
level (reference).
The block diagram below right illustrates the process PI control.
The figure on the left shows an application example: The controller adjusts the
speed of a pressure boost pump according to the measured pressure and the set
pressure reference.

Example: PI Control Block Diagram

Pressure boost pump PI
%ref
A C S 6 0 0
40.01
ACS800 40.02 Switch
Actual Values Frequency
A C T P A R F U N C D R IV E

40.03
40.04 .
E N T E R

reference
L O C R E S E T R E F

R E M

..
3
40.15
AI1
Speed
2 0 ...1 0 b a r AI2 PIDmax
reference
4 ...2 0 m A
AI3 PIDmin 99.04 = 0
(DTC)

%ref = external reference EXT REF2 (see

parameter 11.06)

Settings
Parameter Purpose
99.02 Application macro selection
Group 40 PI CONTROL The settings of the process PI controller
32.09 to 32.14 The supervision limits for the process reference REF2 and the variables
ACT1 and ACT2

Diagnostics
Actual Signals Purpose
01.12, 01.24, 01.25 and PID process controller reference, actual values and error value
01.26
Group 14 RELAY Supervision limit exceeded indication through a relay output
OUTPUTS
Group 15 ANALOGUE PID process controller values through standard analogue outputs
OUTPUTS

Program features
 59

Sleep function for process PI control

The block diagram below illustrates the sleep function enable/disable logic.

Compare Select
Motor
Delay
frequency
1 OFF AND Set/Reset
INTERNAL
1<2 DI
t
S 1 = Activate
43.03 2 AND
%refActive
PFCActive & sleeping
43.01 modulating 43.02 S/R 0 = Deactivate
DI1
..
& Or
R sleeping
. 03.02 (b1)

<1 Or
03.02 (b2)
StartRq
<1
Compare Select Delay
Process actual value
(selected by 40.04) 1 OFF
INTERNAL
1<2 DI
t
43.05 2 AND
43.01 43.06
DI1
&
..
.

Motor freq.: Drive output frequency

%refActive: The % reference (EXT REF2) is in use. See Parameter 11.02.
PFCActive: 99.02 is PFC
modulating: The inverter IGBT control is operating

Example: Sleep function for a PI controlled pressure boost pump

Water consumption falls at night. As a consequence, the PI process controller
decreases the motor speed. However, due to natural losses in the pipes and the low
efficiency of the centrifugal pump at low speeds, the motor does not stop but keeps
rotating. The sleep function detects the slow rotation, and stops the unnecessary
pumping after the sleep delay has passed. The drive shifts into sleep mode, still
monitoring the pressure. The pumping restarts when the pressure falls under the
allowed minimum level and the wake-up delay has passed.

Settings
Parameter Additional information
99.02 PFC control activation
Group 43 SLEEP Sleep function settings
FUNCTION

Diagnostics
Warning SLEEP MODE on the panel display.

Program features
60

Program features
 61

Application macros

Chapter overview
This chapter describes the intended use, operation and the default control
connections of the standard application macros. It also describes how to save a user
macro, and how to recall it.

Overview of macros
Application macros are preprogrammed parameter sets. While starting up the drive,
the user can select one of the macros by parameter 99.02.
There are two standard macros and two user macros. The table below contains a
summary of the macros and describes suitable applications.

Macro Suitable Applications

PFC Pump/fan/compressor station with one to four parallel pumps.

Hand/Auto Speed control applications. Switching between two external control devices is
possible.

User The user can save the customised standard macro i.e. the parameter settings
including group 99, and the results of the motor identification into the permanent
memory, and recall the data at a later time. Two user macros are essential when
switching between two different motors is required

Application macros
62

PFC (Pump and fan control) macro

Pump and Fan Control (PFC) macro can operate a pump (or fan or compressor)
station with one to five parallel pumps. The control principle of a two-pump station is
as follows:
• The motor of pump 1 is connected to the drive. The capacity of the pump is
controlled by varying the motor speed.
• The motor of pump 2 is connected direct-on-line. The pump can be switched on
and off by the drive when necessary.
• The process reference and actual value are fed to the PI controller included in the
PFC macro. The PI controller adjusts the speed (frequency) of pump 1 such that
the process actual value follows the reference. When the frequency reference of
the process PI controller exceeds the limit set by the user, the PFC macro
automatically starts pump 2. When the frequency falls below the limit set by the
user, the PFC macro automatically stops pump 2.
• Using the digital inputs of the drive, an interlocking function can be implemented;
the PFC macro detects if a pump is switched off and starts the other pump
instead.
• The PFC macro makes automatic pump alternation possible (not in use in the
example below) so both pumps have an equal duty time. For more information on
the alternation system and other useful features such as the Sleep function,
Constant reference value, Reference steps and Regulator by-pass, see Chapter 6
– Parameters (Groups 41 and 42).
By default, the drive receives process reference (setpoint) through analogue input
AI1, process actual value through analogue input AI2 and Start/Stop commands
through digital input DI6. The interlocks are connected to digital input DI2 (Motor 1)
and digital input DI3 (Motor 2).
The default output signals are given through analogue output AO1 (frequency) and
AO2 (actual value of the process PI controller).
If the Control Panel is in Local control mode (“L” visible on the first row of the
display), the drive follows the frequency reference given from the Panel. The
automatic Pump and Fan Control (PFC) is bypassed: no process PI controller is in
use and the direct-on-line motors are not started.

Application macros
 63

Operation diagram

Mains Supply
3~ 1 L -> 45.0 Hz I
Input Power

ACS 800
ACT VAL1 10.00 bar
Process Act. Value ~
~ CURRENT 80.00 A
PI
Process Ref. Value FREQ 45.00 Hz
+24 V supply Reference, Start/Stop, and Direction
DI3 (Interlock 2)
commands are given from the Control Panel.
DI2 (Interlock 1) ~~ To change to External, press LOC REM.
RO2 RO1

Pump 1
On/Off
1 -> 45.0 Hz I
Pump 1
Regulated speed
ACT VAL1 10.00 bar
Pump 2 CURRENT 80.00 A
On/Off M
3~
FREQ 45.00 Hz
Pump 2
Direct-on-line Reference is read from analogue input AI2.
M
Start/Stop commands are given through digital
3~
input DI6.

+24 V DC ~230 V AC

Note: By default, automatic pump alternation is not in use.

Application macros
64

Default control connections

The figure below shows the external control connections for the PFC macro. The
markings of the standard I/O terminals on the RMIO board are shown.

X20
1 VREF Reference voltage -10 VDC
2 GND 1 kohm < RL < 10 kohm
X21
1 VREF Reference voltage 10 VDC
2 GND 1 kohm < RL < 10 kohm
3 AI1+ External reference 2 (process reference to PI
4 AI1- controller). 0(2) … 10 V, Rin > 200 kohm
5 AI2+ Actual value 1 (process actual value to PI
PT 6 AI2- controller). 0(4) … 20 mA, Rin = 100 ohm
7 AI3+ By default, not in use.
8 AI3- 0(4) … 20 mA, Rin = 100 ohm.
Hz 9 AO1+ Frequency. 0(4) … 20 mA =
10 AO1- 0 … motor nom. speed, RL < 700 ohm
11 AO2+ Actual 1 (PI controller actual value).
12 AO2- 0(4) … 20 mA =
X22
1 DI1 By default, not in use.
2 DI2 Interlock: motor 1 off/on
3 DI3 Interlock: motor 2 off/on
4 DI4 By default, not in use.
5 DI5 By default, not in use.
6 DI6 Stop/Start
7 +24 V +24 VDC, max. 100 mA
8 +24 V
9 DGND1 Digital ground
10 DGND2 Digital ground
11 DI IL Start interlock (0 = stop)
X23
1 +24 V Auxiliary voltage output, non-isolated,
2 GND 24 VDC, 250 mA
X25
1 RO11 Relay output 1
3

2 RO12 M1 START
230 V AC
3 RO13
A2

A1

X26
1 RO21 Relay output 2
3

2 RO22 M2 START
230 V AC
3 RO23
A2

A1

X27
1 R031 Relay output 3
2 R032 FAULT
230 V AC
3 R033

Application macros
 65

Hand/Auto macro
Start/Stop and Direction commands and reference settings can be given from one of
two external control locations, EXT1 (Hand) or EXT2 (Auto). The Start/Stop/Direction
commands of EXT1 (Hand) are connected to digital input DI1, and the reference
signal is connected to analogue input AI1. The Start/Stop/Direction commands of
EXT2 (Auto) are connected to digital input DI6, and the reference signal is
connected to analogue input AI2. The selection between EXT1 and EXT2 is
dependent on the status of digital input DI5. The drive is frequency-controlled.
The frequency reference and Start/Stop and Direction commands can also be given
from the control panel.
The frequency reference in Auto Control (EXT2) is given as a percentage of the
maximum frequency of the drive.
Two analogue and three relay output signals are available on terminal blocks. The
default signals on the display of the control panel are FREQUENCY, CURRENT and
CTRL LOC.

Operation diagram

1 L -> 45.0 Hz I
Input FREQ 45.00 Hz
EXT1 (Hz) = Power
Hand Control CURRENT 80.00 A
CTRL LOC LOCAL
Local control: Reference, Start/Stop
commands are given from the Control Panel.
Hz Frequency
Hand/Auto To change to External, press LOC REM.
A Current

Relay
PLC Outputs 1 -> 45.0 Hz I
or FREQ 45.00 Hz
automation CURRENT 80.00 A
EXT2 (%) = CTRL LOC EXT1
Auto Control
M External control (Hand): Reference is read
3∼
from analogue input AI1. Start/Stop commands
are given through digital input DI1.
Motor

Application macros
66

Default control connections

The figure below shows the external control connections for the Hand/Auto macro.
The markings of the standard I/O terminals on the RMIO board are shown.

X20
1 VREF Reference voltage -10 VDC
2 GND 1 kohm < RL < 10 kohm
X21
1 VREF Reference voltage 10 VDC
2 GND 1 kohm < RL < 10 kohm
3 AI1+ External reference 1 (Hand control).
4 AI1- 0(2) … 10 V, Rin > 200 kohm
5 AI2+ External reference 2 (Auto control).
6 AI2- 0(4) … 20 mA, Rin = 100 ohm
7 AI3+ By default, not in use.
8 AI3- 0(4) … 20 mA, Rin = 100 ohm.
Hz 9 AO1+ Motor frequency. 0(4) … 20 mA =
10 AO1- 0 … motor nom. speed, RL < 700 ohm
A 11 AO2+ Motor current.
12 AO2- 0(4) … 20 mA =
X22
1 DI1 Stop/Start (EXT1)
2 DI2 By default, not in use.
3 DI3 By default, not in use.
4 DI4 By default, not in use.
5 DI5 EXT1 (Hand) / EXT2 (Auto) selection*
6 DI6 Stop/Start (Auto)
7 +24 V +24 VDC, max. 100 mA
8 +24 V
9 DGND1 Digital ground
10 DGND2 Digital ground
11 DI IL Start interlock (0 = stop) 4)
X23
1 +24 V Auxiliary voltage output, non-isolated,
2 GND 24 VDC, 250 mA
X25
1 RO11 Relay output 1
2 RO12 READY
3 RO13
X26
1 RO21 Relay output 2
2 RO22 RUNNING
3 RO23
X27
1 R031 Relay output 3
Fault 2 R032 INVERTED FAULT
3 R033

Application macros
 67

User macros
In addition to the standard application macros, it is possible to create two user
macros. The user macro allows the user to save the parameter settings including
Group 99, and the results of the motor identification into the permanent memory, and
recall the data at a later time. The panel reference and the control location setting
(Local or Remote) are also saved.
To create User Macro 1:
• Adjust the parameters. Perform the motor identification if not performed yet.
• Save the parameter settings and the results of the motor identification by
changing parameter 99.02 to USER 1 SAVE (press ENTER). The storing takes
approximately 20 to 60 seconds.
To recall the user macro:
• Change parameter 99.02 to USER 1 LOAD.
• Press ENTER to load.
The user macro can also be switched via digital inputs (see parameter 16.05).

Note: User macro load restores also the motor settings in group 99 START-UP
DATA and the results of the motor identification. Check that the settings correspond
to the motor used.

Example: The user can switch the drive between two motors without having to
adjust the motor parameters and to repeat the motor identification every time the
motor is changed. The user needs only to adjust the settings and perform the motor
identification once for both motors and then to save the data as two user macros.
When the motor is changed, only the corresponding User macro needs to be loaded,
and the drive is ready to operate.

Application macros
68

Application macros