Zenith Pumps ZVD Vector Drive ® Installation And Operation Manual AC Vector Motor Speed Controller
Table of Contents 1 ZVD Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 General Information ....................................................... 1-1 Table 1-1 ZVD Standard Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2.
1. ZVD Description 1.1 Introduction This manual contains easy to follow information and procedures required to complete the initial installation, wiring, and startup operation for the ZVD AC Vector Drive. Be sure to observe all WARNINGS, CAUTIONS, and NOTES prior to proceeding with a particular task. Note: The standard ZVD Vector Drive is prepackaged in a NEMA 12 control cabinet. The controller is mounted and all internal cabinet wiring is complete.
Table 1-1. ZVD Standard Specifications Rated Input Voltage: 230 VAC: 180 – 264 VAC, 3 Phase HP Rating: 1 HP 2 HP 3 HP 5 HP Rated Input Current: 5.7A 7.6A 14.0A 20.6A Rated Output Current: 5.0A 7.0A 11.0A 17.0A Rated Input Voltage: 460 VAC: 342 – 528 VAC, 3 Phase HP Rating: 1 HP 2 HP 3 HP 5 HP Rated Input Current: 3.2A 4.3A 5.9A 11.2A Rated Output Current: 2.7A 4.2A 5.5A 8.
2. ZVD Installation and Wiring 2.1 Installation The ZVD AC vector drive is sold in a NEMA 12 control cabinet and is intended to be part of a Zenith Products Division fluid handling solution. For customers who desire to mount the drive in their own cabinet, the ZVD is also sold as a standalone NEMA 1 drive. 2.1.1 NEMA 1 Standalone If purchased as a NEMA 1 standalone drive, the location and installation of the ZVD should adhere to the following constraints: 2.1.1.
2.2 Wiring (continued) 2.2.1.2 The control cabinet ground must be a single point termination and be at a resistance of less than 1 ohm with relation to true earth. All grounds within the control cabinet must be connected to the single point ground termination. 2.2.1.3 High voltage wiring (> 50 V) must be run in separate conduit from low voltage (<50 V) or signal wiring.
3. ZVD Program Requirements 3.1 General The ZVD program codes are arranged in groups. A program code is designated by its group number, followed by a dash, and then its individual number within that group. For example, the code 05 – 03 indicates it is the third code in the fifth group. For a full discussion on groups and codes, consult the full code listing. 3.2 Accessing Program Codes 3.2.1 To access the program codes, press the PROG/DATA key. The display shows a number on the left.
3.3 Standard Program Code Changes (continued) Code 02 – 02 (Stop Method) = ____________ (Default is 0 (Ramp Stop)) Choices: Ramp Stop (0) or Fast Stop (1) Code 02 – 03 (Carrier Frequency) = 12 (KHz) NOTE: EMI and heat generation are directly affected by carrier frequency. Acoustical noise is inversely affected by carrier frequency. If the motor is located in a space in which acoustical noise is not bothersome, set Code 02 – 03 to 2 KHz.
3.3 Standard Program Code Changes (continued) Code 07 – 02 (Torque Boost) = 0 (Code 00 - 09 = 2 or 3); = 8 (Code 00 – 09 = 0 or 1) Code 07 – 04 (Number of Motor Poles) = 4 (Base Speed = 1800 RPM) Code 07 – 05 (Motor Auto Detection) = 1, then press RUN (To Auto Detect Motor Resistance); = 0 (Normal) Code 07 – 06 (Motor Line-to-line Resistance) = ____________ (Auto Detect through or Measure Using an Ohmmeter) Code 07 – 10 (Current Limit) = 100 (Software Version 3.
4. ZVD Operation NOTE: For all references to wiring, refer to Chapter 2. For all references to programming codes, refer to Chapter 3. 4.1 Local Keypad Operation 4.1.1 Entering Setpoint 4.1.1.1 Press the MODE key until the F or U is lit on the left side of the display. 4.1.1.2 If the F is lit, the setpoint will be entered in frequency. The frequency range is from 0.01 Hz to the value of Code 01-00, which for the standard setup is 60.00 Hz. A setting of 60.00 Hz means that the motor will turn at 1800 RPM.
4.1 Local Keypad Operation (continued) 4.1.6.3 Press the MODE key until no LED’s are lit on the left side of the display. This is the multi-function display and will indicate the parameter selected by Code 00 – 04. 4.1.6.3.1 If the action indicated in paragraph 4.1.6.2.1 has been performed, the display will show the last parameter viewed. Calling up Code 00 – 04 will reflect this new parameter. NOTE: To view encoder RPM, Code 00 – 04 must be set back to 11. 4.1.7 Faults 4.1.7.
5. ZVD Troubleshooting and Fault Information The ZVD motor drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages. Once a fault is detected, the corresponding protective functions will be activated to shut down the drive output. Below are the fault descriptions for a fault shown on the digital keypad display. The four most recent faults can be read on the digital keypad display (codes 06-08 through 06-11.
Fault Name Fault Descriptions 1. The AC drive detects excessive drive output current. Note: The AC drive can withstand up to 150% of the rated current for a maximum of 60 seconds. Internal electronic overload trip Corrective Actions 1. Check whether the motor is overloaded. 2. Reduce torque compensation setting as set in Pr.7-02. 3. Increase the AC drive’s output capacity. 1. Check for possible motor overload. 2. Check electronic thermal overload setting. 3. Increase motor capacity. 4.
Fault Name Fault Descriptions The external terminal EF-GND goes from OFF to ON. Corrective Actions 1. When external terminal EF-GND is closed, the output will be turned off. (under N.O. E.F.) 2. Press RESET after fault has been cleared Emergency stop. Press RESET after fault has been cleared. When the multifunction input terminals (MI1 to MI6) stop, AC drive stops any output. Internal memory IC can not be programmed. 1. Return to the factory. Internal memory IC can not be read. 1.
APPENDIX A: ZVD Part Numbers Standalone Part Numbers (NEMA 1) Description Part Number 1 HP, 230 VAC, 3 Phase . . . . . . . . . . . . . . . . . . . 68-16817-0108-0 NEMA 12 Part Numbers with EMI filter installed Description Part Number 2 HP, 230 VAC, 3 Phase . . . . . . . . . . . . . . . . . . . 68-16817-0109-0 1 HP, 230 VAC, 3 Phase . . . . . . . . . . . . . . . . . . . 68-16814-0705-0 1 HP, 460 VAC, 3 Phase . . . . . . . . . . . . . . . . . . . 68-16817-0110-0 2 HP, 230 VAC, 3 Phase . . . . . . . .
APPENDIX B: ZVD Program Code 00-05 Examples Example (1): User Defined Units in Pump RPM Given: Code 01 – 00 = 60 Hz Motor RPM @ 60 Hz = 1800 RPM Reducer Ratio = 21.420 : 1 Example (5): User Defined Units in Flow Rate (gm / minute) Given: Code 01 – 00 = 60 Hz Motor RPM @ 60 Hz = 1800 RPM Reducer Ratio = 22.585 : 1 Then: Pump RPM @ 60 Hz = 1800 / 21.420 = 84.03 RPM Code 00 – 05 = Pump RPM / Code 01 – 00 Pump Capacity = 1.2 cc / revolution Fluid Specific Gravity = 1.1 gm / cc Code 00 – 05 = 84.03 / 60 = 1.
APPENDIX C: ZVD Program Codes Gear Reducer: Size __________ Ratio __________ The below listed program codes have been changed from the ZVD default program codes. If the drive has been reset to factory default for any reason, these codes must be changed to the entry listed for the drive to operate as it did when first received Code Code Description 00-03 . . . . . . . . . . Startup Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-04 . . . . . . .
APPENDIX D: ZVD Summary of Default Program Codes ★ Can be set during operation Group 0: User Parameters Parameters Explanation Settings 0-00 0-01 0-02 Identity Code of Drive Rated Current Display Parameter Reset 0-03 Start-up Display of AC Drive ★ Read-only Read-only d10: reset parameter to factory setting d0: F (setting frequency) d1: H (actual frequency) d2: u (user-defined unit) d3: Multi Function Display d4: FWD/REV d0: Display output current (A) d1: Display Counter Value (C) d2: Display Process
APPENDIX D: ZVD Summary of Default Program Codes Group 1: Basic Parameters Parameters 01-00 01-01 01-02 01-03 01-04 Explanation Maximum Output Freq. (Fo,max) Maximum Voltage Frequency (Base Freq) (Fmax) Maximum Output Voltage (Vmax) Mid-Point Frequency (Fmid) Mid-Point Voltage (Vmid) 01-07 01-08 01-09 01-10 01-11 01-12 01-13 01-14 Minimum Output Frequency (Fmin) Minimum Output Voltage (Vmin) Upper bound of freq. Lower bound of freq.
APPENDIX D: ZVD Summary of Default Program Codes Group 2: Operation Method Parameters Parameters 02-00 02-01 02-02 02-03 02-04 02-05 D-3 Explanation Source of Frequency Command Source of Operation Command Stop Method PWM Carrier Frequency Reverse Operation 2-wire/3-wire Operation Control Mode Selection 2-06 Line Start Lockout 02-07 Loss of ACI Settings d0: d1: d2: d3: d4: d0: d1: Digital keypad 0 to +10V from AVI 4 to 20mA from ACI Potentiometer control (-10 to +10Vdc) RS-485 communication
APPENDIX D: ZVD Summary of Default Program Codes Group 3: Output Function Parameters Parameters Explanation 03-00 Multi-Function Output1 (Relay Output) 03-01 Multi-Function Output2 (Photocoupler Output) 03-02 Multi-Function Output3 03-03 Multi-Function Output4 03-04 Desired Freq. Attained 03-05 Analog Output Signal 03-06 03-07 03-08 03-09 03-10 Analog Output Gain ★ Digital Output Gain ★ Terminal Count Value Preliminary Count Value Desired Freq.
APPENDIX D: ZVD Summary of Default Program Codes Group 4: Input Function Parameters Parameters Explanation 04-00 04-01 04-02 04-03 04-04 Potentiometer Bias Frequency ★ Potentiometer Bias Polarity ★ Potentiometer Frequency Gain ★ Potentiometer Reverse Motion Enable Multi-Function Input Terminal 1 (MI0, MI1) 04-05 04-06 04-07 Multi-Function Input Terminal 4 (MI4) 04-08 Multi-Function Input Terminal 5 (MI5) 04-09 Multi-Function Input Terminal 6 (MI6) 04-10 D-5 Multi-Function Input Terminal 2 (MI2)
APPENDIX D: ZVD Summary of Default Program Codes Group 5: Multi-Step Speed and PLC Parameters Parameters Factory Default Setting Explanation Settings 05-00 05-01 05-02 05-03 05-04 05-05 05-06 05-07 05-08 05-09 05-10 05-11 05-12 05-13 05-14 1st Step Speed Freq. 2nd Step Speed Freq. 3rd Step Speed Freq. 4th Step Speed Freq. 5th Step Speed Freq. 6th Step Speed Freq. 7th Step Speed Freq. 8th Step Speed Freq. 9th Step Speed Freq. 10th Step Speed Freq. 11th Step Speed Freq. 12th Step Speed Freq.
APPENDIX D: ZVD Summary of Default Program Codes Group 6: Protection Parameters Parameters 06-00 06-01 06-02 06-03 06-04 06-05 06-06 06-07 06-08 D-7 Factory Default Setting Explanation Settings Over-Voltage Stall Prevention Over-Current Stall Prevention during Accel Over-Current Stall Prevention during Operation d0: Disable d1: Enable 01 20 to 250% 170 20 to 250% 170 Over-Torque Detection Mode Over-Torque Detection Level Continuous Output Time Limit Electronic Thermal Overload Relay Electro
APPENDIX D: ZVD Summary of Default Program Codes Group 6: Protection Parameters (Cont.) Parameters 06-11 06-12 Explanation Fourth Most Recent Fault Record Over-voltage Stall Level Settings d14: Lv d15: CF1 d16: CF2 d17: Base Block (B.B.
APPENDIX D: ZVD Summary of Default Program Codes Group 8: Special Parameters Parameters Explanation Settings 0.0 to 100% 08-03 DC Braking Current Level DC Braking Time during Start-Up DC Braking Time during Stopping Start-Point for DC Braking 08-04 Momentary Power Loss 08-00 08-01 08-02 08-08 08-09 08-10 08-11 08-12 08-13 08-14 Maximum Allowable Power Loss Time B.B.
APPENDIX D: ZVD Summary of Default Program Codes Group 9: Communication Parameters Parameters Explanation Settings 09-00 Communication Address ★ 09-01 Transmission Speed ★ 09-02 Transmission Fault Treatment ★ 09-03 Overtime Detection 09-04 Communication Protocol ★ 1 to 254 d0: Baud Rate 4800bps d1: Baud Rate 9600bps d2: Baud Rate 19200bps d3: Baud Rate 38400bps d0: Warn and keep Operating d1: Warn and RAMP to Stop d2: Warn and COAST to Stop d3: No warning and keep Operating d0: Disable d1: Enab
APPENDIX D: ZVD Summary of Default Program Codes Group 10: PID Control Parameters Parameters 10-00 Input terminal for Frequency 10-01 10-02 10-03 10-04 10-06 10-07 10-08 Gain over Frequency Input Proportional Gain (P) Integral Gain (I) Derivative Control (D) Upper Bound for Integral Control Derivative Filter time Constant PID Output Freq Limit Feedback Signal Detection time 10-09 Transmission Fault Treatment 10-10 PG Pulse Range 10-11 PG Input 10-12 10-13 Proportional Speed control (P) Integral
APPENDIX D: ZVD Summary of Default Program Codes Group 11: Fan & Pump Control Parameters Parameters 11-00 11-01 11-02 11-03 11-04 Explanation Settings V/F Curve Selection d0: V/F Curve determined by Pr.01-00 to Pr.01-06 d1: 1.5 Power Curve d2: 1.7 Power Curve d3: Square Curve d4: Cube Curve Start Frequency of the Auxiliary Motor Stop Frequency of Auxiliary Motor Time Delay before Starting the Auxiliary Motor Time Delay before Stopping the Auxiliary Motor Factory Default Setting 0 0.00 to 120.
E-1 H RUN JOG STOP RESET PROG DATA MODE RUN STOP JOG FWD REV F H U HP 1 2 3 5 1 2 3 5 230 230 230 230 460 460 460 460 D 64-16814-0693-1 64-16814-0694-1 64-16814-0699-1 64-16814-0702-1 64-16814-0695-1 64-16814-0696-1 64-16814-0700-1 64-16814-0703-1 16" x 12" x 8" 16" x 12" x 8" 24" x 16" x 8" 24" x 20" x 12" 16" x 12" x 8" 16" x 12" x 8" 24" x 16" x 8" 24" x 20" x 12" 68-16814-0705-0 68-16814-0706-0 68-16814-0707-0 68-16814-0708-0 68-16814-0709-0 68-16814-0710-0 68-16814-0711-0 68-16814-0712-0
E-2 RUN 17 16 15 CUSTOMER'S FUSED 230 OR 460 VAC 3 START OPTIONAL EMI FILTER 0-10VDC 4-20MA SPEEN 5KΩ 24 23 22 21 20 19 18 17 16 15 JUMPER (NOTE 1) CBL1 P2 P1 PGI CARD MULTI FUNCTION AFM (GRN) ACI (BRN) ACM (BLK) AVI (WHT) +10V (RED) MI2 DCM EF FWD T S R 4 6 1 3 (BLK) DCM RC RB RA 11 10 6 5 4 9 8 7 14 13 OPTIONAL INTRINSICALLY SAFE BARRIER CBL2 CBL3 12 2 5 P2 (NOTE1) P1 T3 T2 T1 (RED) VP (CLR) A DCM MI1 W V U 1.
E-3 7 8 9 4 5 6 4 5 6 1 2 3 CUSTOMER'S 230 VAC OR 460VAC 3 PHASE INPUT POWER MULTI-FUNCTION STATUS OUTPUT NORMALLY OPEN NORMALLY CLOSED COMMON GND T4 T7 MOTOR POWER CONNECTIONS 1 - 5 HP, 460 VAC, 3 PHASE GND T4 T5 T6 MOTOR POWER CONNECTIONS 1 - 5 HP, 230 VAC, 3 PHASE L1 L20 L3 GND 15 16 17 15 16 17 12 13 14 10 11 1 - 5 HP, 230 VAC OR 460 VAC, 3 PHASE REMOTE START REMOTE STOP REMOTE RUN CONTACT CLOSE TO RUN OPEN TO STOP WHT (CLR) RED BLK SHEILD HALL EFFECT SENSOR P1 Wiring diagram T
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