Westinghouse MA7200-2003-N1 Thru MA7200-2040-N1 Quick start manual

MA7200 PLUS INVERTER
SERIES
PID Quick Start Manual
For Fan and Pump Applications
3 to 75 HP
Models- MA7200-2003-N1 Thru MA7200-2040-N1 (230V)
&
MA7200-4003-N1 Thru MA7200-4075-N1 (460V)
speed
time
Rev. 1.3 - May 27th 2008
MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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PID Quick Start Guide for Fan and Pump Applications
PID is a control method that can be used for the purpose of automatically regulating flow or
pressure in fan and pump applications. Following steps 1 through 13 listed below in this guide will
simplify the start up of the MA7200 PLUS Inverter series for fan and pump applications using PID
control. Some of the steps are specific to pump applications only and will be so noted. The guide is
not intended to replace the MA7200 PLUS Installation and Operation Manual, and the user is urged
review this manual.
The PID method of control covered by this guide will consist basically of a set-point (operating point,
e.g. flow, pressure etc.) entered through the keypad and an analog transducer feedback signal (0 –
10 VDC or 4 - 20 mA). These two signals are then compared, and through PID processing, correct for
any load or environmental changes to maintain the set-point. Only the (P) proportional and (I)
integral parameters will be set and adjusted through the keypad to optimize performance. The
parameter (D) derivative will not be discussed or used in this guide as the factory setting is usually
sufficient for fan and pump applications. Actual values will be used to provide a realistic example of
setting up PID control.
Although the inverter can be controlled via serial communication, it is beyond the scope of this guide
and the user is referred to the MA7200 PLUS Installation and Operating Manual for further
information on this subject.
Step 1 – Before starting the inverter –Safety First!
Step 2 – Apply power to the drive.
Step 3 – Set drive to run mode.
Step 4 – Check fan or pump motor operation.
Step 5 – Making external digital input / output and analog feedback control wiring connections.
Step 6 – Select stop / start method of control.
Step 7 – Setting minimum speed in pump applications. (Pump applications only)
Step 8 – Select PID control and feedback input
Step 9 – Select engineering units.
Step 10 – Setting PID parameters
Step 11 – Setting acceleration and deceleration. (Note 1)
Step 12 – Setting PID sleep functions. (Pump applications only)
Step 13 – Testing the system.
Note 1 – The acceleration and deceleration parameters are not specific to PID control but are
included as part of the PID set-up.
SAFETY FIRST!
Step 1 - Before Starting the Inverter
• Referring to the MA7200 PLUS Instruction Manual, please review and verify that the correct
inverter size for the motor was received free of damage. To ensure personnel safety and to avoid
equipment damage, follow the precautions and the installation procedures for mounting, wiring,
and operating environment.
CAUTION - To avoid damage to the inverter when removing the inverter cover
and/or LCD Operator, refer to Appendix B for the proper procedure.
• In accordance with applicable codes make electrical connections to the motor and input power
terminals. (Refer to the block diagram, Fig. 4). No other external connections should be made at
this time, as the initial control will be from the keypad.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 2 - Apply Power to the Drive
• Apply AC power to the Inverter and observe the LCD Display Line 1; it should read
“Freq. Cmd 000.00Hz”. Line 2 should read “TECO”. The red LED on the STOP key should be on.
The DRIVE and FWD LED’s should be on. (See Fig. 1 below)
Step 3 - Set Drive to Run Mode
• If the red DRIVE LED is not on with AC power up, press the PGRM / DRIVE key until the red
Drive LED is on. The Inverter is now in the RUN mode.
Step 4 - Check Fan or Pump Motor Operation
•
Enter 10.00Hz for the frequency reference and set parameter Sn-08 = 1 to disable Reverse
Direction Operation. Note: The output from the inverter is displayed in Hz as factory default. If
desired, the output may be displayed in other units such as (%) of full speed, PSI etc. (see
Step 9)
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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•
Press the RUN key, and check the fan or pump direction of rotation. If the direction is not correct,
press the STOP key and wait until the fan or pump has come to a complete STOP. Next, power
down the inverter.
Danger
After the power has been turned OFF, wait at least 5 minutes until the charge
indicator extinguishes completely before touching any wiring, circuit boards or
components.
•
Reverse any two of the fan or pump motor connections at the inverter ( U(T1),V(T2), or W(T3) ).
Next, following STEP 2, power-up the inverter; the motor direction should now be correct.
Step 5 – Making External Digital Input/Output and Analog Feedback
Control wiring Connections
•
Before removing any covers or making any external control connections, power down the
inverter.
Danger
After the power has been turned OFF, wait at least 5 minutes until the charge
indicator extinguishes completely before touching any wiring, circuit boards, or
components.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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•
In this step the external wiring connections will be made for the various control functions. To do
this, the method of control and feedback used in your particular application must be determined.
In the following pages are wiring examples for (digital input) Start / Stop, and (analog)
Feedback. Also included are E-Stop, (digital output) Restart, and Fault indication connections.
DIGITAL INPUT / OUTPUT terminal connections
Fig’s 2a, 2b, and 2c below show the terminal connections for input control functions. The
connections shown are typical and the user is referred to the MA7200 PLUS Manual if
additional information is required. Fig.2d shows an example for the use of the Fault Output
Relay.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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ANALOG FEEDBACK terminal connections
Fig’s 3a,3b, and 3c, show the analog feedback schemes for 0-10VDC or 4-20mA devices to
control flow, level, pressure etc.
•
After all of the external wiring has been completed and secure, replace all covers and
power up the inverter.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 6 – Select Start / Stop Method of Control (Sn-04)
•
•
•
Before selecting this parameter, ensure the inverter is in the STOP mode.
The set-point is selected by the keypad (Sn-05=0), and the start / stop method can be from the
keypad or external contact (see Fig. 2a). NOTE: The set-point can also be set from an external
source but commonly it is set from the keypad.
The parameter (Sn – 04) is set to = 0 (keypad), as factory default. If external contact is desired,
follow the navigation procedure below to set (Sn-04 = 1).
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 7 – Setting Minimum Speed in Pump Applications
(NOTE: In the case of a fan application skip this step and go to Step 8)
•
•
In the case of pump applications it is normally required to limit the minimum speed that the
pump will operate regardless of the input speed command. The pump minimum speed is
usually specified either by the pump manufacturer or the application. Once this value has
been established, the minimum output frequency of the inverter and thus the minimum
motor (pump) speed can be set by parameter Cn-19. This parameter sets the minimum
inverter frequency output, and thus a minimum motor (pump) speed to a percentage of the
maximum output command frequency.
The following is an example of setting the minimum motor (pump) speed to 1800 RPM,
which is 50% of the maximum pump speed, 3600 RPM.
To set parameter Cn-19 = 050%
(Minimum pump speed )
Keypad Steps
key
An – 01 Freq. Cmd. 1
key 3 times
Cn-01
Input Voltage
PRGM
1 - Press the
DRIVE
2 - Press the
DSPL
Resulting Display
Cn-19
key until the display shows
3 - Press the
Freq Cmd Low Bound
Flashing
4 - Press the
EDIT
ENTER
Cn-19 = 000%
key
Freq Cmd Low Bound
Flashing
5 - Press the
RESET
key twice; then the
key 5 times
Cn-19 = 050%
Freq Cmd Low Bound
6 - Press the
EDIT
ENTER
key to save.
Entry Accepted
2 Seconds
Flashing
Cn-19 = 050%
7 - Press the
PRGM
DRIVE
Freq Cmd Low Bound
key to return to the main display.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 8– Select PID control (Sn-64), and Feedback input (Sn – 24) [4 – 20 mA
or 0 – 10 Vdc]
•
•
•
•
Before selecting the parameter(s), ensure the inverter is in the STOP mode.
To activate PID control parameter (Sn-64) must be set to =1.
The Feedback Input parameter (Sn –24) is set to = 1 (AIN, 4-20 mA), as factory default. To
select (VIN, 0-10 Vdc), (Sn-24) must be set to 0. (See Figs. 3a, 3b and 3c for feedback
connections)
To set the parameter(s), follow the navigation procedure as shown next.
(Turn on PID control)
1 - Press the
key
2 - Press the
key twice
3 - Press the
key until display shows
Flashing
4 - Press the
0
key
Flashing
1
5 - Press the
key
6 - Press the
key to
.
2 Seconds
Flashing
1
7 - Press the
key to return to the main display.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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To set the parameter Sn-24 = 0
(VIN, 0 – 10 VDC)
Keypad Steps
PRGM
1 - Press the
DRIVE
2 - Press the
DSPL
Resulting Display
An – 01 Freq. Cmd. 1
key
Sn – 01 -
key twice
Inverter Capacity
3 - Press the
Sn – 24
key until display shows
External Input
Flashing
4 - Press the
EDIT
ENTER
Sn – 24 = 1
CMD. AIN
key
Flashing
5 - Press the
6 - Press the
Sn – 24 = 0
key
EDIT
ENTER
CMD. VIN
key to save.
Entry Accepted
2 Seconds
Flashing
Sn – 24 = 0
CMD. VIN
PRGM
7 - Press the
DRIVE
key to return to the main display.
Step 9 – Select Feedback Engineering Units (P1-01) and Scaling (P1-02)
•
Initially the display will read output frequency in (Hz) as the factory default and is set by
parameter (Cn-28=0). If (Cn-28) is changed to (=1), then the display will read out in (%). The
setting of (Cn-28) is only valid if (P1-01=0), which is the factory default. Other engineering units
may be selected by parameter setting (P1-01) as described on the following page.
•
In this step, the feedback engineering units that the system is controlling such as CPM in fan
applications or PSI in the case of pumps can be selected by parameter (P1-01). (See Appendix
A for additional selections). The maximum value that the engineering units will be in any given
application is set by parameter (P1-02). These selections will now be displayed on the digital
operator.
Example: A pump application that has a feeedback transducer with a maximum value of
200 PSI i.e 200 PSI = 20mA or 10 Vdc, can be set as shown next.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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(Engineering Units)
1 - Press the
key
2 - Press the
key 4 times
Flashing
3 - Press the
key
0
key twice
2
Flashing
4 - Press the
5 - Press the
key to
2 Seconds
.
Flashing
2
Note: Once P1-01 is set to a non-zero value, then Cn-28 is no longer valid.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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(Maximum value of Engineering Units)
1 - Press the
2 - Press the
key
key
Flashing
3 - Press the
0
key
Flashing
4 - Press the
1
key
Flashing
5 - Press the
0
key
Flashing
6 - Press the
key; then the
7 - Press the
key to
key twice
2
.
2 Seconds
Flashing
2
8 - Press the
key to return to the main display.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 10 – Setting PID Parameters; Proportional Gain (Bn-17) and
•
•
Integral Time (Bn-18)
After all external connections have been made and the protective covers have been
replaced, power up the inverter but do not run at this point.
Parameters Bn-17 = 1.0 (Proportional Gain) and Bn-18 = 10.0s (Integral Time) are factory
set to the values shown. However, a good starting point for these values is setting the
Proportional Gain Bn-17 = 2.0 and the Integral Time Bn-18 = 5.0s. To change these
parameters, follow the keypad navigation procedure below.
To set parameter Bn-17 = 02.0
(Proportional Gain )
Keypad Steps
Resulting Display
1 - Press the
DRIVE
key
An – 01 Freq. Cmd. 1
2 - Press the
DSPL
key
Bn-01
Acc. Time 1
PRGM
Bn-17
key until the display shows
3 - Press the
PID P_ Gain
Flashing
4 - Press the
EDIT
ENTER
Bn-17 = 01.00
key
PID P_ Gain
Flashing
5 - Press the
6 - Press the
RESET
EDIT
ENTER
key twice; then the
key
Bn-17 = 02.00
PID P_ Gain
key to save.
Entry Accepted
2 Seconds
Flashing
Next set Bn-18 = 005.00
Cn-19 = 050%
Freq Cmd Low Bound
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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To set parameter Bn-18 = 005.00
(Integral Time )
Keypad Steps
Resulting Display
Bn-18
key
1 - Press the
PID I_ Time
Flashing
2 - Press the
EDIT
ENTER
Bn-18 = 010.00 s
key
PID I_ Time
Flashing
3 - Press the
RESET
key twice; then the
key
Bn-18 = 000.00 s
PID I_ Time
Flashing
4 - Press the
RESET
key ; then the
key 5 times
Bn-18 = 005.00 s
PID I_ Time
6 - Press the
EDIT
ENTER
key to save.
Entry Accepted
2 Seconds
Flashing
Bn-18 = 005.00 s
7 - Press the
PRGM
DRIVE
key to return to the main display.
PID I_ Time
Word About PID Control-
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 11 – Setting parameters acceleration (Bn-01) and deceleration (Bn-02)
times
•
Acceleration and Deceleration times as well as the PID control [(P) Proportional Gain
and/or the (I) Integral Time (see STEP 11) directly control the system dynamic response.
The longer the acceleration and deceleration time, the slower the system response, and the
shorter time, the faster the response. An excessive amount of time can result in sluggish
system performance while too short of a time may result in system instability.
The starting values suggested by this guide normally result in good system performance for
the majority of fan and pump applications. If the values need to be adjusted, caution
should be exercised, and the changes should be in small increments to avoid system
instability.
•
Parameters Bn-01 (Acceleration) and Bn-02 (Deceleration) are both set at the factory for
10.0 seconds. For fan and pump applications, the recommended starting values are 30
seconds. To change these parameters, follow the keypad navigation procedure as shown
next.
To set parameter Bn-01 = 30.0 s
(Acceleration Time )
Keypad Steps
Resulting Display
1 - Press the
DRIVE
key
An – 01 Freq. Cmd. 1
2 - Press the
DSPL
key
Bn-01
Acc. Time 1
PRGM
Flashing
3 - Press the
EDIT
ENTER
Bn-01 = 0010.0
Acc. Time 1
key
Flashing
4 - Press the
5 - Press the
RESET
EDIT
ENTER
key 3 times; then the
Key twice
Bn-01 = 0030.0
Acc. Time 1
key to save.
Entry Accepted
2 Seconds
Flashing
Next set Bn-02 = 0030.0
Bn-01 = 0030.0
Acc. Time 1
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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To set parameter Bn-02 =30.0
(deceleration Time )
Keypad Steps
Resulting Display
Bn-02
key
1 - Press the
Dec. Time 1
Flashing
2 - Press the
EDIT
Bn-02 = 0010.0 s
key
ENTER
Dec. Time 1
Flashing
3 - Press the
4 - Press the
RESET
key 3 times; then the
EDIT
ENTER
key twice
Bn-02 = 0030.0 s
Dec. Time 1
key to save.
Entry Accepted
2 Seconds
Flashing
Bn-02 = 0030.0 s
5 - Press the
PRGM
DRIVE
Dec. Time 1
key to return to the main display.
Step 12 – Setting PID Sleep Function parameters (P1-04), (P2-01),
(P2-02), (P2-03) and (P2-04).
(NOTE: In the case of a Fan application skip this step and go to Step13)
•
The PID Sleep function is turned on by parameter (P1-04) when set to (=1). This allows the
system to turn off the PID and thus the inverter output so that the pump does not run when
the system level (PSI) is above the set-point. This sleep start level is set by parameter (P201) in a range from 0 – 100% of the maximum inverter output. When the system level drops
below a value (the units are selected by Step 8) set by parameter (P2-03), the sleep
wakeup level, the output of the inverter will turn on. Parameters (P2-02) and (P2-04)
provide delay times in seconds for sleep start level and sleep wakeup level respectively.
Fig. 4 will serve to illustrate this.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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•
To further cover the PID Sleep function, the following is an example of the various
parameter settings that could be used. In this example the system will have the following
specifications:
- Max. Pump Motor Speed : 3600 RPM.
- Set Point: 150 PSI.
- Feedback Transducer Range: 0 – 200 PSI.
- Pump System Sleep Level: 2160RPM or 60% of max. speed set by
(P21-01=060.00). Sleep Level Delay Time: 10 sec. set by (P2-02=010.0 ).
- Pump System Wakeup Level: 100 PSI set by (P2-03=0100). Wakeup Time: 5 sec.
set by (P2-04=005.0).
•
Referring to Step 9, set the engineering units to PSI (P1-01=02) and then the range to 200
(P1-02=0200).
On the following pages the keypad navigation sequence is shown in setting the PID
parameters.
NOTE: The inverter must be in the Stop mode in order to turn on the sleep function.
•
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Set parameter P1-04 = 1
(Turn on sleep function)
Resulting Display
Keypad Steps
PRGM
1 - Press the
DRIVE
2 - Press the
DSPL
An – 01 Freq. Cmd. 1
key
P1-04
PID Sleep Function
key 4 times
Flashing
3 - Press the
EDIT
ENTER
P1-04 = 0
PID Sleep Invalid
key
Flashing
4 - Press the
5 - Press the
P1-04 = 1
key
EDIT
ENTER
PID Sleep Valid
key to save.
Entry Accepted
2 Seconds
Flashing
P1-04 = 1
Next set P2-01 = 60%
PID Sleep Valid
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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(Sleep Start Level Delay Time)
1 - Press the
key twice; then the
key
Flashing
2 - Press the
0
key
Flashing
3 - Press the
1
key
key twice; then the
Flashing
4 - Press the
key ; then the
5 - Press the
key to
0
key
2 Seconds
.
Flashing
0
(Sleep wakeup Level)
1 - Press the
key twice; then the
key
Flashing
2 - Press the
0
key
Flashing
3 - Press the
4 - Press the
key twice; then the
key to
key
1
2 Seconds
.
Flashing
1
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Step 13 – Testing The System
•
•
The system can now be tested for performance. To do this, set the set-point through the
keypad and run the drive at some low level and check that the motor is operating properly
and that the feedback signal level and polarity are correct.
Check the system for dynamic operation and make any adjustments necessary for optimum
performance. This may require making adjustments to parameters Bn-17 proportional
gain and Bn-18 Integral Time. (Refer to Step 10)
NOTE: Parameters Bn-17 and Bn-18 may be changed through the keypad while the
system is operating.
A word of CAUTION ! - the parameter changes should be made in small increments
and the results checked to avoid highly unstable and possibly damaging
conditions.
•
This should complete the installation.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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MA7200 PLUS BLOCK DIAGRAM
Fig. 5 is an overall basic electrical connection diagram for the MA7200 PLUS. It is used in
conjunction with the other sections of this guide to give the user the ability to successfully start up
a fan or pump application. More detailed information is available in the MA7200 PLUS Manual to
which the user is referred, if further information is required.
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MA7200 PLUS Inverter 3 to 75 HP PID Fan and Pump Quick Start Manual
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Appendix AEngineering Units Selected by P1-01=
Setting
Unit
0
Description
----
Setting
Unit
Description
13
MPM
meter / minute
1
%
%
14
CMM
meter3 / minute
2
PSI
PSI
15
W
W
3
GPH
gallon / hour
16
kW
kW
4
GPM
gallon / minute
17
°C
°C
5
InW
Inch water
18
m
meter
6
FPM
feet / minute
19
A
A
3
7
CFM
feet / minute
20
RPM
RPM
8
In
inch
21
SPM
stroke/minute
9
Ft
feet
22
/s
unit / s
10
HP
HP
23
/m
unit / m
11
°F
°F
24
/h
unit / h
12
m/s
meter / second
25
none
Appendix B Removing the LCD Digital Operator and Inverter Cover(s)
Remove the (2) screws
LCD Operator
RJ11 connector
Gently Lift
the
LCD Operator and remove the
connecting cable (RJ11) by
unplugging it from the back of
the LCD Operator.
Connecting cable
Gently remove the
cover(s).
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