February 2005

ACS800 Pump Control

Insert image
here

Insert image Insert image

here here
All rights reserved. - 1 -
© Copyright year ABB.

2/10/2005
 Content

1. Backround
2. Basic software features
3. Basic pump applications
4. Pump efficiency
© Copyright year ABB - 2 -
 Flow Control Methods

Throttling by a valve

By-passing by a valve

On-off control of the pump

Variable speed control of the pump

© Copyright year ABB - 3 -

Parallel running of Pumps

 Relative Power Consumption
© Copyright year ABB - 4 -
 History of the Pump control SW

„ Dedicated drive for pump applications was missing from

ABB LV Drives portfolio
„ All these features were made from demand or in co-
operation with our customers in the first place
„ Those features are now standardized and will be
available in one SW package
„ One idea is to control some part of the process without
separate PLC; therefore Adaptive Programming is
included too
„ Also some other equipments can be replaced, like
flowmeter
© Copyright year ABB - 5 -
 Content

1. Backround
2. Basic software features
1. Multipump Control
2. Level Control
3. Anti-jam Function
4. Flow Calculation Function
5. Pump Priority Control
6. Sleep Boost Function
7. Adaptive programming
© Copyright year ABB - 6 -

3. Basic pump applications

4. Pump efficiency
 ACS800 Pump Control features
1. Multipump Control
2. Level Control
3. Anti-jam Function
4. Flow Calculation Function
5. Pump Priority Control
6. Sleep Boost Function
7. Adaptive programming
© Copyright year ABB - 7 -

„ The Intelligent Pump control SW is functionally

backward compatible with Traditional PFC.
 Pump Control benefits in general

„ Replace additional HW & SW

„ Flowmeter
„ External communication modules (Profibus, Ethernet)
„ PLC (SW & HW) -> Pump Control & Application programming
„ Additional I/O modules
„ Boosts energy savings
„ Control panel with clear application and signal texts
„ Includes helpful W&W segment features
„ Level control
© Copyright year ABB - 8 -

„ Pump priority
„ Anti-jam
„ Flush effect
 1a) Traditional PFC

„ Up to 5 pumps are
controlled by one AC
drive
„ PI-control controls only
one pump
„ One pump is regulated PT
and others are stand-by
or running at nominal
speed P1
M P2
„ External contactors and M P3
soft starters needed M
© Copyright year ABB - 9 -
 1a) Traditional PFC (+ and -)

Benefits Notice!
„ Traditional „ Needs external motor control
centre
„ The pump motors must be off
same size
„ Mechanical stress with DOL
motors and pumps
„ Today AC drive prices are
closer to contactors and soft
© Copyright year ABB - 10 -

starters
„ Not redundant
 1. Multipump Control

„ Is used when several pumps are running in the same part

of system and needed flow variates

Frequency

50
p

mp

p
pum

pum

p
pu

m
pu
2nd
1st

3 rd
40

4th
0
© Copyright year ABB - 11 -

Increasing Flow demand Q

Q(ref)
 1b) Multipump Control
„ Each motor is controlled by
AC drive
„ Redundant with star
connection (or by external
power supply to control
board)
„ One is adjusted and rest are
running with constant
frequency (or stand-by)
„ When Master reaches the
100% frequency, next starts
as Master
© Copyright year ABB - 12 -
 1b) Multipump Control (+ and -)

Benefits Notice!
„ Smooth control when „ Notice redundancy with
number of pumps are control connections
increased or decreased -
> no preassure peaks
„ Enables that any pump
can be taken away and
others continue
uninterrupted
„ Different size of pumps
© Copyright year ABB - 13 -

allowed
 1c) Direct Follower Control

„ Each motor is controlled

by AC drive
„ Redundant with star
connection (or by
external power supply
to control board)
„ All Followers follow
Master frequency
reference and all
motors are running all
the time
© Copyright year ABB - 14 -

„ Start/stop + reference
locked to Master
 1c) Direct Follower Control (+ and -)

Benefits Notice!
„ Very fast control method „ With slow speed
„ Disturbance-free system efficiency of the system is
in critical places. If one low (pump efficiency
pump is down, others curve)
adjust themselves
immediately for the new
demand per pump
„ Simple tool for running
and testing in start-up
© Copyright year ABB - 15 -
 2. Level Control (Patent pending)

„ Designed for waste water

applications
„ Integrated level control logic
in the drive
„ Each motor is controlled by
AC drive, no contactors
„ Water level is the controlled
variable by level transmitter
„ Can be used for emptying or
© Copyright year ABB - 16 -

fill in control in storage tanks

 2. Level Control, benefits

„ Energy savings
„ One level transmitter needed; 0-100% by AI signal to AC
drive
„ No external PLC needed – Level control is software
inside the drive
„ Remote control with Profibus gateway or with Ethernet
connection
„ Fast ramp in every start and fixed speeds make a flush
effect
© Copyright year ABB - 17 -

„ Prevents sediment formation in pipelines, common problem in

waste water stations with AC drive (slow speed regulation)
 2. Level Control, benefits

„ Flexible tank level control

„ Application function changes randomly the actual liquid level in
the tank. The actual level varies between the preset levels.
„ Prevents sediment formation on the walls of the tank
„ Together with Anti-jam Control makes the use of pumps
in the harsh environment reliable
© Copyright year ABB - 18 -
 2. Level Control, Example
„ 3 Preset levels
„ Pumping out from
the tank / free
flow into tank
„ Common stop
mode in this
example
„ Also possible for
stable stop mode
(own stop level
© Copyright year ABB - 19 -

for each pump)

 3. Anti-jam Function

„ Prevention of jam or rust in pump,

preventive maintenance
Speed
„ Cleaning up the pump in congested
status
„ Different triggering conditions:
1. Starts if current level rises over the
set limit, so then there might be
something jamming the pump
2. Run-on-time sequence
3. Service switch connected to DI < one anti-jam step >
signal
Time
© Copyright year ABB - 20 -

„ Very effective together with Level

Control mode
 3. Anti-jam Function (+ and -)

Benefits Notice!
„ Active preventive „ Possible risk to pipes and
maintenance -> Easy pump with aggressive
way to maximize ramps and negative
operating time speeds
„ With parallel pumps no „ Adjust ramps and min/max
speed to limit mechanical
downtime for whole
stress
system
© Copyright year ABB - 21 -
 4. Flow Calculation Function (Patent pending)

„ Calculation is based on pump

characteristics and pressure
measurements in normal
pump operating range
„ Independent of pump
manufacturer
„ Purpose is to have needed PT PT

flow measurement accuracy

without expensive flow meter
„ Deviation ± 5…10%
© Copyright year ABB - 22 -

„ Parameter for actual flow and

for total flow measurements
 4. Flow Calculation Function (+ and -)

Benefits Notice!
„ Flow measurement „ Not accurate enough for
without expensive flow invoicing purposes
meter in normal pump „ For single pump only
operating area
„ Deviation is bigger if
„ Less components in speed of the pump is low,
pump system or if flow is throttled
„ With DTC accurate „ Pump curves needed for
calculations accurate results
© Copyright year ABB - 23 -
 5. Pump Priority Function

„ Automatically balances the

running time of pumps in
the system
„ 4 priority classes for
pumps
„ Priority order can be set
„ by priority classes, for
example; 1st class during
day 2nd class during night
„ by preset time intervals to
© Copyright year ABB - 24 -

stabilize running hours

 5. Pump Priority Function (+ and -)

Benefits Notice!
„ Programmable wear and „ Wear and tear balanced
tear for all pumps in a long run, not
„ Easier to do preventive dynamic to avoid
maintenance. unnecessary starts and
stops
„ Service to all pumps at the
same time or one by one „ Time input via DI, no
„ Very useful when several internal calendar in
pumps are in parallel ACS800
© Copyright year ABB - 25 -
 6. Sleep Boost Function

„ Before shutting
down, pump is
boosting pressure
or water level to
extend sleep time
„ Saves energy and
mechanical stress
by preventing
unnecessary starts
and stops
© Copyright year ABB - 26 -
 New parameter groups

„ 47 Level control
„ 46 Anti-jam
„ 45 Flow calculation function
„ 60 Multipump & classes
„ 43 Sleep boost
„ Apr. 100 new parameters
© Copyright year ABB - 27 -
 Useful ACS800 basic features

„ As a standard
„ Extensive, programmable
I/O
„ 3 Analogue Inputs and 2
Outputs
„ 7 Digital Inputs and 3 (relay)
Outputs

„ As an option:
„ 2+2 Analogue or 3+2 Digital
I/Os with Extension module
„ Connectivity to major
automation systems with
© Copyright year ABB - 28 -

optional Profibus module

„ Coated boards and IP54
„ External NETA-01 module
for Ethernet connection
 NETA-01 Ethernet Adapter module

„ Device for browser-based remote monitoring of ABB

drives via Ethernet
„ Up to 9 drives can be connected through the DDCS
Branching Unit or using ring topology
„ It is possible to monitor and control the drive
© Copyright year ABB - 29 -
 ACS800 Pump Control Variants

„ ACS800 Traditional PFC for 5 pump’s

„ ACS800 Multipump Control for 8 pump’s

© Copyright year ABB - 30 -

„ ACS800 Level Control for 3 pump’s

 Limitations

„ Features which cannot be activated at the same time:

„ Multipump and Level control
„ Traditional PFC and Pump Priority Control
„ With Anti-jam cycles, please note group 20 min and max
speed (safety limitations)
„ Please note the limitations of pump and pipeline system
(negative speed, ramps, pressure peaks)
© Copyright year ABB - 31 -
 Content

1. Backround
2. Basic software features
3. Basic pump applications
4. Pump efficiency
© Copyright year ABB - 32 -
 Rainwater pump station

Set-up Useful Pump Control features

„ To pump rainwater out of town „ Level control
„ Parallel pumps „ Anti-jam
„ Storage tank „ Remote access by Ethernet
„ Level measurement module

„ Remote and automatic control

„ Average pump power 100 kW
© Copyright year ABB - 33 -
 Pressure boosting station

Set-up Useful Pump control features

„ In large networks to increase „ Multipump control
pipeline pressure „ Flow measurement
„ Parallel pumps „ Pump priorisation
„ Actual pressure measurement
„ Continuous PI control
© Copyright year ABB - 34 -
 Pilots
„ Example from Pietarsaari rain water pumping station (Finland)

The ACS800 drives and level control software will take care
of the rain water and lift up the level one meter to an other
open channel for ending in the sea.
© Copyright year ABB - 35 -

The place for the two KSB pump’s 80kW .

 Content

1. Backround
2. Basic software features
3. Basic pump applications
4. Pump efficiency
© Copyright year ABB - 36 -
 EU study, pump efficiency

„ February 2001 EU made a study of

energy efficiency of pumps
„ “Pumps are the single largest user of
electricity in Industry in the European
Union, consuming 160 TWhpa of
electricity, accounting for 79 Mton CO2.”
„ “This report recommends policy options
to improve the selection and
maintenance of pumps to reduce these
emissions.”
„ “It it is recognised that the largest
© Copyright year ABB - 37 -

energy savings are to be made

through the better design and control
of pump systems.”
 Pump efficiency, example
„ AHLSTAR™ A_P44-
200 pump
„ System curve with
25m statistic head
„ Efficiency 70…83%
when flow 80…260l/s
and power 40…220kW
„ 13% gap in efficiency
in normal operating
area
„ Optimizing efficiency
© Copyright year ABB - 38 -

also maximize the

lifetime of the pump
 Other system components, savings

„ Examples of equipments which can be replaced by Pump Control

SW features.
„ NOTICE! Check the system configuration and needs!
„ Flowmeter,
„ price for unit to ∅ 100mm pipe is ~2000 €, flow 10...100m3/h
„ price for unit to ∅ 300mm pipe is ~3000 €, flow 100...1000m3/h
„ need for direct pipeline 3 x ∅ before and after the meter
„ PLC, HW & SW, ABB Advant Controller 31
„ Small control units (series 40...50) 500 €
„ Compact control units (series 90) 2000 €
© Copyright year ABB - 39 -

„ SW programming 1000...3000 €
„ Panels 500 €