Grundfos RSI User manual

RSI, 1.5 - 37 kW
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
CONTENTS Page
1. Grundfos RSI 3
1.1 Specific functions of Grundfos RSI 3
2. Safety 4
2.1 Danger 4
2.2 Warnings 4
3. Startup 5
3.1 First Start-up 5
3.2 Description of the applications 7
3.2.1 Standard application 10
3.2.2 Local/Remote application 11
3.2.3 Multi-step application 11
3.2.4 PID Control application 12
3.2.5 Multi-purpose application 14
3.2.6 Motor potentiometer application 16
4. User Interfaces 17
4.1 Keypad of the drive 17
4.1.1 Buttons 17
4.1.2 Display 17
4.1.3 Navigation on keypad 17
4.1.4 RSI graphical keypad 18
4.1.5 RSI Text keypad 24
4.2 Grundfos PC tool 27
4.2.1 Quick setup 28
4.2.2 Monitor 28
4.2.3 Parameters 29
4.2.4 Diagnostics 29
4.2.5 I/O and hardware 32
4.2.6 User settings 42
4.2.7 Favorites 43
4.2.8 User levels 43
4.3 Example of control connections 44
4.3.1 Relay and thermistor input terminals 45
4.3.2 Safe Torque off (STO) terminals 45
5. Monitoring Menu 46
5.1 Monitor group 46
5.1.1 Multi-monitor 46
5.1.2 Trend curve 46
5.1.3 Basic 48
5.1.4 I/O 48
5.1.5 Extras & advanced 49
5.1.6 Timer functions 51
5.1.7 PID Controller 51
5.1.8 ExtPID Controller 51
5.1.9 Mainten. counters 52
5.1.10 Fieldbus data 52
5.1.11 Solar 53
5.1.12 Flow 53
6. Parameters 54
6.1 Application parameter lists 54
6.1.1 Column explanations 55
6.1.2 Group 3.1: Motor settings 55
6.1.3 Group 3.2: Start/Stop setup 59
6.1.4 Group 3.3: References 60
6.1.5 Group 3.4: Ramps And Brakes 62
6.1.6 Group 3.5: I/O Config 63
6.1.7 Group 3.6: Fieldbus DataMap 70
6.1.8 Group 3.7: Prohibit Frequencies 71
6.1.9 Group 3.8: Supervisions 71
6.1.10 Group 3.9: Protections 72
6.1.11 Group 3.10: Automatic reset 78
6.1.12 Group 3.11: Appl. Settings 78
6.1.13 Group 3.12: Timer functions 79
6.1.14 Group 3.13: PID Controller 83
6.1.15 Group 3.14: ExtPID Controller 91
6.1.16 Group 3.16: Maintenance Counters 94
6.1.17 Group 3.21: Pump Control 94
6.1.18 Group 3.22: Solar 95
6.1.19 Group 3.23: Flow meter 96
6.2 Additional parameter information 96
6.2.1 Motor Control 96
6.2.2 Open Loop 101
6.2.3 Start/Stop Setup 103
6.2.4 References 106
6.2.5 Preset Freqs 106
6.2.6 Motor Potentiometer 107
6.2.7 Ramps And Brakes 108
6.2.8 Flux Braking 108
6.2.9 Digital inputs 109
6.2.10 Analog inputs 109
6.2.11 Digital Outputs 114
6.2.12 Analog outputs 116
6.2.13 Prohibit Freq 118
6.2.14 Protections 120
6.2.15 Automatic Reset 125
6.2.16 Feedbacks 126
6.2.17 FeedForward 127
6.2.18 Sleep Function 128
6.2.19 Feedback Superv. 129
6.2.20 Press.Loss.Comp 130
6.2.21 Soft fill 132
6.2.22 Auto-Cleaning 132
6.2.23 Solar 133
7. Fault 136
7.1 Fault Tracing 136
7.2 Fault appears 136
7.3 Fault History 137
7.4 Fault codes 138

English (GB)
3
1. Grundfos RSI
The Grundfos RSI contains a preloaded Grundfos
motor library for instant use.
1.1 Specific functions of Grundfos RSI
The dedicated application software was developed
to drive a Solar Pump with an optimized MPPT
(Maximum Power Point Tracking) for RSI supplied by
Solar Panels.
The MPPT is based on 4 parallel algorithms:
• Feed-Forward Controller (to follow the radiation
variations)
• Correction Controller (to compensate the
temperature variations)
• Oscillation Damping Regulator (to prevent the
panel entering in the "current source" branch of
the characteristic)
• Local Maxima logic (to prevent the regulator from
being trapped in a local maximum lower than
absolute maximum)
Features
• The MPP Tracker controls DC voltage reference
in order to find the maximum power.
• Extensive wizards for start-up, PID-control used
to facilitate commissioning
• "Funct" button for easy change between Local
(keypad) and Remote control place. The remote
control place is selectable by parameter (I/O or
Fieldbus)
• 8 preset frequencies
• Motor potentiometer functions
• 2 programmable ramp times, 2 supervisions and
3 ranges of prohibited frequencies
• Control page for easy operation and monitoring
of the most essential values.
• Fieldbus data mapping
• Automatic reset
• Different pre-heat modes used to avoid
condensation problems
• Maximum output frequency 320 Hz
• Real-time clock and timer functions available
(optional battery required). Possible to program 3
time channels to achieve different functions on
the drive (e.g. Start/Stop and Preset frequencies)
• External PID-controller available. Can be used to
control e.g. a valve using the AC drive's I/O
• Sleep mode function which automatically enables
and disables drive running with user defined
levels to save energy.
• 2-zone PID-controller (2 different feedback
signals; minimum and maximum control)
• Two setpoint sources for the PID-control.
Selectable with digital input
• PID setpoint boost function
• Feedforward function to improve the response to
the process changes
• Process value supervision
• Maintenance counter
• Underload protection can be managed by
measuring Motor torque (standard sensorless
mode) or by measuring the water flow with a flow
meter sensor. This sensor can be an analogue
signal or a digital input. With this sensor it is
possible to measure the water flow [litres/min]
and the total volume of the water flow [m3].
• Sleep mode can be enabled or disabled with a
parameter.
Digital inputs can be used to measure water levels
(minimum and maximum).

English (GB)
4
2. Safety
This manual contains clearly marked warning
information which is intended for your personal
safety and to avoid any unintentional damage to the
product or connected appliances.
Before installing, commissioning or using the
frequency converter, please read the warning
information contained in RSI Installation Manual.
Please read the following additional safety
instructions carefully.
Only authorized, trained and qualified personnel are
allowed to install, operate and maintain the drive.
2.1 Danger
These warnings are intended to personnel
responsible for grounding the frequency converter.
2.2 Warnings
Ignoring the following instructions can
be extremely dangerous and may
cause death or severe injury.
Ground the frequency converter to
ensure personnel safety and to
reduce electromagnetic interference.
After disconnecting the AC drive from
the mains or from the DC input supply,
wait until the indicators on the keypad
go out (if no keypad is attached, see
the indicators on the cover). Wait an
additional 30 seconds before starting
any work on the connections of RSI.
After expiration of this time, use
measuring equipment to absolutely
ensure that no voltage is present.
Always ensure absence of voltage
before starting any electrical work!
The touch current of RSI exceeds 3.5
mA AC. According to standard
EN61800-5-1, a reinforced protective
ground connection must be ensured.
See RSI Installation Manual for further
information.
Never work on the photovoltaic
generator or frequency converter and
its input/output cables when the
frequency converter is connected to
the mains or to the photovoltaic
generator.
Before performing any measurement
on the frequency converter,
disconnect or isolate the mains supply
voltage or the DC input supply.
Do not touch the components on the
frequency converter or on the string
box cabinet that have high DC
voltage.
The photovoltaic generator cells
exposed to light supply DC voltage
even at low light intensity.

English (GB)
5
3. Startup
3.1 First Start-up
In the Startup Wizard, you will be prompted for
essential information needed by the drive so that it
can start controlling your process. In the Wizard, you
will need the following keypad buttons:
Once you have connected power to your RSI, follow
these instructions to easily set up your drive.
NOTE: You can have your AC drive equipped with a
keypad with either a graphical or a text keypad.
1These questions appear if battery is installed
Push the OK button unless you want to set all
parameter values manually.
Left/Right arrows. Use these to easily
move between digits and decimals.
Up/Down arrows. Use these to move
between options in menu and to
change value.
OK button. Confirm selection with this
button.
Back/Reset button. Pressing this
button, you can return to the previous
question in the Wizard. If pressed at
the first question, the Startup Wizard
will be cancelled.
1 Language selection (P6.1) Depends on language package
2 Daylight saving1(P5.5.5)
Russia
US
EU
OFF
3 Time* (P5.5.2) hh:mm:ss
4 Year* (P5.5.4) yyyy
5 Date* (P5.5.3) dd.mm.
6 Run Startup Wizard? Yes
No

English (GB)
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If you set Motor Type to Induction Motor, you see the
next question. If your selection is PM Motor, the
value of parameter P3.1.1.5 Motor Cos Phi is set to
1.00 and the wizard goes directly to question 18.
To continue to the application wizard, set the
selection to Yes and push the OK button.
After these selections, the Start-up wizard is
completed. To start the Start-up wizard again, you
have 2 alternatives. Go to the parameter P6.5.1
Restore Factory Defaults or to the parameter B1.1.2
Start-up Wizard. Then set the value to Activate.
7Make a selection of an application (P1.2
Application,ID212)
Standard
Local/Remote
Multi-step speed
PID control
Multi-purpose
Motor potentiometer
8Set a value for P3.1.2.2 Motor Type (so that
it agrees with the nameplate) PM motor Induction motor
9Set value for P3.1.1.1 Motor Nom Voltg
(according to nameplate) Range: Varies
10 Set value for P3.1.1.2 Motor Nom Freq
(according to nameplate) 8.00...320.00 Hz
11 Set value for P3.1.1.3 Motor Nom Speed
(according to nameplate) Range: 24...19.200 rpm
12 Set value for P3.1.1.4 Motor Nom Currnt
(according to nameplate) Range: Varies
13 Set value for P3.1.1.5 Motor Cos Phi
(according to nameplate) Range: 0.30...1.00
14 Set value for P3.3.1.1 Minimum frequency
reference Range: 0.00...50.00 Hz
15 Set value for P3.3.1.2 MaxFreqReference Range: 0.00...320.00 Hz
16 Set value for P3.4.1.2 Accel Time 1 Range: 0.1...300.0 s
17 Set value for P3.4.1.3 Decel Time 1 Range: 0.1...300.0 s
18 Set value for P3.3.1.1 MinFreqReference Range: 0.00...50.00 Hz
19 Set value for P3.3.1.2 MaxFreqReference Range: 0.00...320.00 Hz
20 Set value for P3.4.1.2 Accel Time 1 Range: 0.1...300.0 s
21 Set value for P3.4.1.3 Decel Time 1 Range: 0.1...300.0 s
22 Run the Application wizard? Yes
No

English (GB)
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3.2 Description of the applications
Use the parameter P1.2 (Application) to make a
selection of an application for the drive. Immediately
when the parameter P1.2 changes, a group of
parameters get their preset values.
M1 Quick setup parameter group
In the Quick Setup parameter group you will find the
different wizards of the RSI Solar Pump Application.
The wizards help you to quickly set up your drive for
use prompting you for a number of essential data.
Code Parameter Min Max Unit Default ID Description
B1.1 Startup wizard 0 1 0 1170
0 = Do not activate
1 = Activate
Choosing Activate initiates the Startup
Wizard (see chapter 3.1 First Start-up).
P1.2 Application 0 5 0 212
0 = Standard
1 = Local/Remote
2 = Multi-Step Speed
3 = PID Control
4 = Multi-Purpose
5 = Motor
Potentiometer
P1.3 MinFreqReference 0.00 P1.4 Hz 0.00 101 Minimum allowed frequency reference
P1.4 MaxFreqReference P1.3 320.00 Hz 50.00 102 Maximum allowed frequency reference
P1.5 Accel Time 1 0.1 300.0 s 5.0 103 Defines the time required for the output frequency to increase from zero
frequency to maximum frequency
P1.6 Decel Time 1 0.1 300.0 s 5.0 104 Defines the time required for the output frequency to decrease from maximum
frequency to zero frequency
P1.7 Current limit Varies Varies A Varies 107 Maximum motor current from AC drive
P1.8 Motor type 0 1 0 650 0 = Induction motor
1 = PM motor
P1.9 Motor Nom Voltg Varies Varies V Varies 110 Find this value Unon the rating plate of
the motor. Note also used connection
(Delta/Star).
P1.10 Motor Nom Freq 8.00 320.00 Hz Varies 111 Find this value fnon the rating plate of the
motor.
P1.11 Motor Nom Speed 24 19200 rpm Varies 112 Find this value nnon the rating plate of
the motor.
P1.12 Motor Nom Currnt Varies Varies A Varies 113 Find this value Inon the rating plate of the
motor.
P1.13 Motor Cos Phi 0.30 1.00 0.74 120 Find this value on the rating plate of the
motor
P1.14 Energy
optimization 0 1 0 666
The drive searches for the minimum
motor current in order to save energy and
to lower the motor noise. This function
can be used e.g. in fan and pump
applications
0 = Disabled
1 = Enabled
P1.15 Identification 0 1 0 631
The identification run calculates or
measures the motor parameters that are
necessary for a good control of the
motor and speed.
0 = No action
1 = At standstill
2 = With rotation
Before you do the identification run, you
must set the motor nameplate
parameters.
P1.16 Start function 0 1 0 505 0 = Ramping
1 = Flying start

English (GB)
8
P1.17 Stop function 0 1 0 506 0 = Coasting
1 = Ramping
P1.18 Automatic reset 0 1 0 731 0 = Disabled
1 = Enabled
P1.19 External fault 0 3 2 701
0 = No action
1 = Alarm
2 = Fault (Stop according to stop mode)
3 = Fault (Stop by coasting)
P1.20 AI Low Fault 0 5 0 700
Response when an analogue signal in
use goes below 50 % of the minimum
signal range. 0 = No action
1 = Alarm
2 = Alarm, Preset Freq
3 = Alarm, Previous Freq
4= Fault (Stop according to stop mode)
5 = Fault (Stop by coasting)
P1.21 Rem.Ctrl. Place 0 1 0 172
Selection of remote control place (start/
stop). Can be used to change back to
remote control e.g. in case of a broken
panel.
0 = I/O control
1 = Fieldbus control
P1.22 I/O A Ref sel 1 9 5 117
Selection of ref source when control place
is I/O A
1 = Preset Frequency 0
2 = Keypad reference
3 = Fieldbus
4 = AI1
5 = AI2
6 = AI1 + AI2
7 = PID reference
8 = Motor potentiometer
9 = Max Power
P1.23 Keypad Ref sel 1 9 2 121 Selection of ref source when control place is keypad:
See P1.22
P1.24 Fieldbus Ref sel 1 9 3 122 Selection of ref source when control place is Fieldbus:
See P1.22
P1.25 AI1 signal range 0 1 0 379 0 = 0…10 V / 0…20 mA
1 = 2…10 V / 4…20 mA
P1.26 AI2 signal range 0 1 1 390 0 = 0…10 V / 0…20 mA
1 = 2…10 V / 4…20 mA
Code Parameter Min Max Unit Default ID Description

English (GB)
9
P1.27 RO1 function 0 51 2 11001
Function selection for Basic R01:
0 = None
1 = Ready
2 = Run
3 = General fault
4 = General fault inverted
5 = General alarm
6 = Reversed
7 = At speed
8 = Thermistor fault
9 = Motor regulator active
10 = Start signal active
11 = Keypad control active
12 = I/O B control activated
13 = Limit supervision 1
14 = Limit supervision 2
15 = No fucntion
16 = No fucntion
17 = Preset speed active
18 = No fucntion
19 = PID in Sleep mode
20 = PID soft fill active
21 = PID supervision limits
22 = Ext. PID superv. limits
23 = Input press. alarm/fault
24 = Frost prot. alarm/fault
25 - 30 = No fucntion
31 = RTC time chnl 1 control
32 = RTC time chnl 2 control
33 = RTC time chnl 3 control
34 = FB ControlWord B13
35 = FB ControlWord B14
36 = FB ControlWord B15
37 = FB ProcessData1.B0
38 = FB ProcessData1.B1
39 = FB ProcessData1.B2
40 = Maintenance alarm
41 = Maintenance fault
42 = No fucntion
43 = No fucntion
44 = Block Out.1
45 = Block Out.2
46 = Block Out.3
47 = Block Out.4
48 = Block Out.5
49 = Block Out.6
50 = Block Out.7
51 = Block Out.8
52 = Block Out.9
53 = Block Out.10
54 = No function
55 = No function
56 = Auto-cleaning active
57 = Motor Switch Open
58 = TEST (Always Closed)
59 = No function
P1.28 Basic R02 function 0 46 3 11004 See P1.27
Code Parameter Min Max Unit Default ID Description

English (GB)
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3.2.1 Standard application
You can use the Standard application in speed-
controlled processes where no special functions are
necessary, for example pumps, fans, or conveyors.
It is possible to control the drive from the keypad,
Fieldbus or I/O terminal.
When you control the drive with the I/O terminal, the
frequency reference signal is connected to AI1
(0…10 V) or AI2 (4…20 mA). The connection
depends the type of the signal. There are also 3
preset frequency references available. You can
activate the preset frequency references with DI4
and DI5. The start/stop signals of the drive are
connected to DI1 (start forward) and DI2 (start
reverse).
It is possible to configure all the drive outputs freely
in all the applications. There are 1 analogue output
(Output Frequency) and 3 relay outputs (Run, Fault,
Ready) available on the basic I/O board.
M1.31 Standard
P1.30 AO1 function 0 19 2 10050
0 = TEST 0 % (Not used)
1 = TEST 100 %
2 = Output freq (0 -fmax)
3 = Freq reference (0-fmax)
4 = Motor speed (0 - Motor nominal
speed)
5 = Output current (0-InMotor)
6 = Motor torque (0-TnMotor)
7 = Motor power (0-PnMotor)
8 = Motor voltage (0-UnMotor)
9 = DC link voltage (0-1000 V)
10 = PID1 output (0-100 %)
11 = Ext.PID output (0-100 %)
12 = ProcessDataIn1 (0-100 %)
13 = ProcessDataIn2 (0-100 %)
14 = ProcessDataIn3 (0-100 %)
15 = ProcessDataIn4 (0-100 %)
16 = ProcessDataIn5 (0-100 %)
17 = ProcessDataIn6 (0-100 %)
18 = ProcessDataIn7 (0-100 %)
19 = ProcessDataIn8 (0-100 %)
Code Parameter Min Max Unit Default ID Description
Code Parameter Min Max Unit Default ID Description
P1.31.1 Preset Freq 1 P1.3 P1.4 Hz 10.0 105 Make the selection of a preset frequency with the
digital input DI4.
P1.31.2 Preset Freq 2 P1.3 P1.4 Hz 15.0 106 Make the selection of a preset frequency with the
digital input DI5.
P1.31.3 Preset Freq 3 P1.3 P1.4 Hz 20.0 126 Make the selection of a preset frequency with the
digital input DI4 and DI5.