Zener ECODRIVE 8000 User guide

SW08020 Application Guide
Pump PID 2: Advanced Pump PID Control
ZENER 8000

Page 1 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Important Warnings:
•ALL PROTECTION PROVIDED BY THE ZENER 8000 IS FOR OPERATIONAL PURPOSES ONLY. SEPARATE
INDEPENDENT METHODS MUST BE EMPLOYED TO PREVENT ECONOMIC LOSS.
•THIS EQUIPMENT CONTAINS HIGH VOLTAGE AND REMAINS CHARGED FOR A PERIOD AFTER POWER IS
REMOVED. ALWAYS ALLOW 15 MINUTES FOR COMPLETE DISCHARGE AND CHECK FOR THE PRESENCE OF
AC OR DC VOLTAGE BEFORE ACCESSING MOTOR PHASE TERMINALS, WIRING OR INTERNAL
COMPONENTS.
Check List: What information you need to know
1. What is the motor nameplate Full Load Current ? __________Amps
2. What is the motor nameplate RPM ? __________rpm
3. What is the desired operating pressure (in kPa) ? __________kPa
4. What is the maximum system pressure allowable (in kPa) ? __________kPa
5. What is the transducer’s pressure rating (ie. @ 20mA) ? __________kPa
6. What is the minimum operating speed of the pump (= X% of 50Hz) ? __________Hz
7. What is the maximum starts per hour rating of the pump/motor? __________
Product Support
www.zener.com.au/support-8r.php
Reference Manual
www.zener.com.au/images/im00140.pdf
Pump PID 2 Application Guide (this document)
www.zener.com.au/images/im00127.pdf

Page 2 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Commissioning Overview
Each step must be completed in order shown before proceeding to the next. Before proceeding to power
the ZENER 8000 and operating the pump, check all wiring is correct and that the pump and plumbing
system is in a state fit for operation. If any parameters are changed it is important to ‘save changes’ when
prompted exiting the menu.
Preparation:
Preliminary Checks:
Operational Check &Fine Tuning:
Read all safety instructions & warnings
Install as per instruction manual and this
‘Application’ guide
Load the application & adjust initial
parameters
Operate in local mode to check direction
Operate in remote mode and check PID.
Calibrate PID if required.
Check pressure transducer feedback
Check & calibrate ‘IDLE’ function
Check & calibrate ‘PIPE FILL’ if required
Check overall operation and protection
Refer to the installation manual
Go to page 3
Go to Page 10
Go to Page 10
Go to Page 11
Go to Page 13
Go to Page 15
Refer to the installation manual and
Page 4 of this guide
Read this application guide carefully and
ensure it meets your requirements
Go to Page 6
Familiarise yourself with operating the ZENER
8000 and application menus
Go to page 5 to 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Save ‘Custom Defaults’ and/or record settings
12.

Page 3 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Application Overview
Part Number: SW08020
App Group: Standard
Description: Advanced PID Pressure Control System No.2
Menu Text: Pump PID 2
Compatibility: ZENER 8000 Firmware 5.2.6ZO or later
Application Guide: IM00127
What is a ZENER ‘Application’
An ‘Application’ is firmware that aims to simplify wiring, programming and the commissioning of a Variable
Speed Drive. An ‘Application’ programs the drive and creates new user friendly menus with the essential
settings. This eliminates timely setups, the reading & interpretation of complex manuals and ensures all
critical protection is installed & set up correctly.
Since the ‘Application’ programs all the parameters required and custom ‘User menus’ created there is
generally no reason to program additional parameters unless there is a variation to the intended operation of
this ‘Application’.
Application Summary:
This application provides an advanced PID Pressure Control System (PCS) using an external pressure
transducer. The ZENER 8000 will maintain a constant pressure with changing water consumption
requirements. This is a pressure control system with an automatic turn off function (idle or sleep) when there
is no demand (or flow). An optional ‘No flow switch’ can also be used to trigger idle mode.
A user configured set point provides the pressure for the system to maintain. As the pressure changes the
ZENER 8000 automatically adjusts the speed to ensure constant pressure is maintained.
When demand decreases the drive will reduce in
speed to reduce pressure accordingly. As the flow
& speed reduces the load (current) also reduces.
When the Load reaches the ‘idle threshold’ for the
‘idle delay’ period, the drive goes into idle mode.
In idle mode the PID & output turns off until it is
told to wake. The ZENER 8000 will automatically
wake when the pressure falls to a specified level.
Pumping will recommence and operate in PID
mode.
A flow switch can be used to trigger
idle mode. This simplifies the setup and
provides a better solution with
multiple or a variable set point.
A ‘Pipe Fill’ feature is also available to
run at a set speed during filling then
automatically changeover to PID
mode when the set pressure is
reached.
This also provides protection for the pump &
motor:
i. Motor Overload protection
ii. Output Short Circuit protection
iii. Loss of transducer signal
iv. High & Low pressure Protection
v. Optional Low Bore level protection

Page 4 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
System Requirements:
1. ZENER 8000 with the Application: Pump PID 2 and an option board (AQ/AF08001) fitted.
2. A pressure transducer and a pressure gauge (for calibration purposes) located between the pump and
any discharge valves.
3. A 4-20mA pressure transducer. However different devices can be used by varying the appropriate
parameters.
4. Non return valve required on the suction side of the pump. All non-return valves are functioning
correctly and there are no leaks in the pipework. With all field taps and valves turned off the pressure
holds.
5. The motor & pump are in good working order.
6. Any non-return valve on the discharge side of the pump must be located between the pump and the
transducer.
7. The internal high & low pressure trips are for operational purposes only. Separate and independent
methods must be employed to prevent economic loss. A pressure relief valve is recommended.
8. Optional control input available for ‘Bore level’. External level sensing device required.
9. Optional control input available for ‘Flow Switch’. This provides a more direct idle control. A flow
switch may be required with multiple set points or a variable set point.
Control Wiring:
Note: All control wiring should be screened.
*************************************************************************
Ensure the ZENER 8000 is in local mode (remove link in terminal 5) to prevent
operation while programming and performing preliminary checks..

Page 5 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Operation Displays
The operational displays show the operating state of the ZENER 8000. The six operational displays are: Speed /
Reference Display, Meter Display, PID Display, PID / Meter Display and kWhr / Hours Run Display. Press

(ENTER) to step through each display.
Speed / Reference Display
The top line displays the operating output frequency
and the second line displays the speed reference and
the drive status
Meter Display
The top line displays the operating output frequency
and power and the second line displays motor load and
output current.
PID Display
The top line displays the process variable (PV) with its
units and the second line displays set-point variable
(SV) expressed with the same units.
PID / Meter Display
The top line displays the operating output frequency
and process variable (PV) and the second line displays
output current and motor speed.
kWhr / Hours Run Display
The top line displays the kWhrs consumed by the motor
and the second line displays accumulated running time
of the motor
Display Messages
Message
Meaning
REM
REMOTE MODE: Start/stop control from digital inputs.
LOC
LOCAL MODE: Start/stop control from local console.
PID-A ON (OFF)
PID ON (or OFF): PID controller is operating or not.
FWD or REV
Forward or Reverse direction selected from local console or Digital inputs or internal
PV-A OOR
‘Out of Regulation’: A warning that PID is operating and the PV is not equal to the SV.
-DRY-
Bore level switch is indicating a low bore and/or in the timeout period before
Idle
PID is active and currently in Idle Mode and will wake based on pressure level set.
Filling
Pipe Fill Mode is active. When set pressure is reached will switch to PID mode.
Fill T/out
Alarm: The fill time has lapsed and pressure has not reach required level
35.0 Hz
35.0 FWD LOC
35.0Hz 6.1kW
0% 8.0A
P
V500.0 kPa
S
V500.0 PIDO N
35.0Hz 500.0kPa
0% 750rpm
(Meter Display)
(PID Display)
(PID / Meter Display)
ENTER
ENTER
ENTER
ENTER
ENTER
(Speed / Reference Display)
0 kWhrs
0 hours
(kWhr / Hours Run Display)






Page 6 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Loading an Application:
Loading an Application will program the drive for you
and create a unique menu with the parameters you
need to adjust.
If ‘APPLICATION <NONE>’ is displayed this means there
is no Application loaded.
If ‘APP: Pump PID2’ is displayed this means this an
application has been loaded. The application will be
displayed.
If it is the incorrect application loaded go to page 6 for
instructions how to re-load an application.
To load the application:
Reloading and Application:
Factory defaults must be restored and the
application reloaded. To restore defaults
follow the procedure below.
Application
<NONE>
A00 DEFAULTS
ESC
ENTER
&
DOWN
Application
<NONE>
ENTER
PRESS
▼
DOWN TO FIND THE DESIRED APPLICATION
Application
Pump PID 2
OR
Application
Pump PID 2
Load factory
defaults?
a
Pump PID2
User Menu
ESC
ENTER
ENTER
CAUTION MAY START WITHOUT
NOTICE CHECK WIRING. CONTINUE ?
ENTER
Load Complete ?
Press ESC and ENTER to SAVE CHANGES when prompted.
Power Down the ZENER 8000 completely and then
REPEAT the procedure to load the application.
ENTER TO SELECT & LOAD
This will take you direct to the ‘CONFIG MENU’.
Go to page 8
a
A00 DEFAULTS
CONTINUE WITH
FACTORY DEFAULTS
▼
DOWN
NOTE:
To restore defaults the ZENER 8000 must not be
in REMOTE mode. Remove terminal 5.
This should be performed in LOCAL MODE as
the pump may run. (Remove link in terminal 5)

Page 7 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Application ‘CONFIG’ & ‘USER’ Menu:
There are now 2 additional menu’s created with this application, a ‘CONFIG MENU’ and a ‘USER
MENU’.
Always remember to press ‘ENTER’ when
prompted to save changes.
Do not remove power while saving!!
Set Pressure
500.0 kPa
ESC
ENTER
Pump PID 2
config (Default)
A00 DEFAULTS
ESC
ENTER
&
DOWN
ENTER
CONFIG MENU
The ‘CONFIG MENU’ is created for initial
setup. This can be found in the A00 DEFAULT’
Menu and has all the parameters required.
General access to this menu can be locked
out.
USER MENU
The ‘USER MENU’ is created for the operator.
In this application it provides access to the ‘Set
pressure’ only. Access to other settings can be
locked out.
APP: Pump PID 2
user (Default)
PARAMETERS IN MENU:
Set Pressure
PARAMETERS IN MENU:
Rated Motor Amps
Overload Amps
Motor RPM
Transducer Scale
Set Pressure
Minimum Speed (Hz)
Idle Threshold %
Time before Idle
Resume @ PV
Low Trip Level
Low Trip time
High Trip Level
Pipe Fill
Pipe Fill Speed (Hz)
Fill Level
Fill time (s)
Low Bore timeout
ENTER to edit
and
ENTER to save
changes
SAVE CHANGES
ENTER=YES ESC=NO
ENTER
ESC
“WHEN EXITING MENU”
Pump PID 2
user (Default)
DOWN
Rated Motor Amps
20 Amps
DOWN

Page 8 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
CONFIG MENU Parameters:
After loading the application the CONFIG MENU will appear. Modify the following parameters. If the CONFIG
menu does not appear read page 7.
Ensure the ZENER 8000 is in local mode (remove terminal 5) or will not operate.
Initial parameters to adjust:
Parameter Default Explanation
1. Rated Motor Amps ?? Amps. Enter Motor nameplate full load current.
2. Overload Current ?? Amps. Enter Motor nameplate full load current.
3. Rated Motor rpm 1470 rpm Enter Motor nameplate speed in rpm.
4. Transducer Scale 1000.0 Enter the rating of the pressure transducer at
20mA, in kPa.
5. Set Pressure 500.0kPa Enter the desired operating pressure.
IDLE MODE Adjustments Adjust later. Go to page 13 for an explanation on Idle Mode
6. MIN Speed (Hz) 0 Hz Leave at 0Hz (or minimum pump speed) to check
pump rotation. This should be at least the minimum operating
speed for the pump. Eg. 30Hz. When started the pump will run
to this speed.
7. Idle Threshold % 20% Leave at 20% (or 0% for OFF) and adjust later.
Enter the Load% under ‘No flow’ or ‘dead head’ condition
which the ZENER 8000 must go into idle.
8. Time before Idle 5sec 5 seconds is a good starting point.
Enter the time period at the ‘Idle Threshold %’ before going
into idle Mode.
9. Resume @ PV 25% below SV Leave at 25% for moment.
Enter the pressure to wake from idle mode. This is entered as a
value in % below the set pressure.
Motor Rated Amps
22.0Amps
PUMP PID 2
config (defaults)
ENTER
PRESS
▼
TO STEP THROUGH APPLICATION PARAMETERS
PRESS ENTER TO EDIT AND SAVE CHANGES

Page 9 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Parameter Default Explanation
10. Low Trip Level 250.0 kPa Adjust if required.
Adjust the level for ‘low pressure’ trip (in kPa)
11. Low Trip time 30 sec Adjust if required.
Adjust the low pressure trip time to allow the pipes to fill and
pressure to increase above the trip level.
12. High Trip Level 800.0 kPa Adjust if required .
Adjust level for ‘high pressure’ trip (in kPa). The trip time
(default 0 seconds) can be adjusted in another menu if
required ( Refer to User Alarm 1).
13. Pipe Fill OFF Leave OFF for the moment.
Pipe fill mode runs the pump at a fixed speed until the pipes fill
and the pressure begins to build. When the ‘Fill to Level’
pressure is reached it automatically switches to PID mode.
Select ‘PV Threshold’ for pipe fill based on pressure.
14. Pipe Fill Speed (Hz) 40 Hz Leave for the moment.
This is the operating speed for pipe fill mode
15. Fill to Level 300.0 kPa Leave for the moment.
This is the pressure level to change from Pipe Fill to PID mode
16. Fill Time 40 sec Leave for the moment.
This is the time period for the pipe fill to reach pressure before
an alarm occurs.
17. Low Bore timeout 0 sec Leave at 0 sec for moment.
This feature requires an external bore level switch. Link
terminal 1 to Terminal D1(31) if no bore level switch installed.
Enter the time to restart after the ‘Low Bore’ switch contact
returns to the closed position. “– DRY-“ is displayed during the
timeout period.” Link terminal 1 to Terminal D1(31) if no bore
level switch available.
When back to the beginning (first parameter ‘Set Pressure’), press ESC until:
SAVE CHANGES
ENTER=YES ESC=NO
ENTER
ESC
Pump PID 2
config (Default)
A00 DEFAULT
ESC
PV 0.0 kPa
SV 500

Page 10 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Preliminary Checks
The following should be performed with the ZENER 8000 in local mode to provide better control to carry out
the checks. Ensure the motor and pump is ready and safe to operate.
To operate in local mode:
Remove the link in terminal 5, this
selects local or remote/PID mode.
REM= REMOTE OR PID MODE [Control using terminal inputs]
LOC = LOCAL MODE [Control using push buttons]
Top display: Actual Speed in Hz (50Hz = full speed)
Bottom Display: Set speed
Press FWD/ ▲to start
Press FWD/▲to increase the speed
Press STOP to stop the pump
Note: If there is a minimum speed set it will go straight to that
speed. To increase above this speed you will need to hold down the
UP button until it goes above the minimum speed setting.
Check motor/pump direction:
Press FWD/ ▲to start and increase the motor speed sufficient to test the direction. If a minimum speed is set
it will go to that speed. Use the ▲to increase the speed above the minimum speed level.
If the motor shaft or pump rotates in the wrong direction remove the input power, wait for the ZENER 8000 to
discharge and swap any two motor phase wires. Re-apply input power and recheck direction
Check pressure transducer feedback:
Close the discharge valve and press FWD/ ▲to start & increase the motor speed until the desired operating
pressure is indicated on the pressure gauge. Press STOP to stop the pump and check that the pressure holds. If
the pressure does not hold there is a problem and must be rectified to operate correctly. If there is a small drop
this must be allowed for in the wake control. ie.‘resume @PV’ or implement an ‘Idle Boost’
Press

(ENTER) to scroll through the operator displays (see page 5) to the PID display shown below.
Check that the top display (PV) is displaying the correct pressure as
per the pressure gauge. If this is not correct (within acceptable
tolerance) than investigate and rectify. The service menu can be
used to display the mA being received from the transducer.



ESC
EXIT
FWD
REV
ENTER
STOP
25.0 Hz
35.0 FWD LOC
P
V500.0 kPa
=

Page 11 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Checking the PID operation
Ensure the system is ready to pump and discharge valve is open for flow required. Re-install the wire in
terminal 5 to operate in Remote/PID Mode and apply power to the ZENER 8000.
Find the PID display to monitor the performance:
Check the following:
1. The ZENER 8000 operates and stabilises at a speed where the PV = SV.
2. The pressure (ie. PV) indicated on the ZENER 8000 is correct. If not correct turn the pump off
and investigate.
3. Check that the control is stable and responds to changes. Refer to PID tuning guide if unstable.
These parameters are found in the following menu:
4. Open & close additional taps/valves to check pressure is maintained and the system respond
sufficiently. Refer to tuning guide if response is slow or over shooting occurs.
5. Progress to next step and enable ‘Idle Mode’ if this feature is required.
H00 PID CONTROL
Pump PID 2
User (defaults)
ESC
DOWN
ENTER
PID-A Controller
ENTER
H01 Prop Band
300 %
ENTER TO EDIT & SAVE
DOWN
PV 0 kPa
SV 500 PID ON
Process Variable is the pressure feedback from the transducer
Set Point Variable is the desired operating pressure
Operating Status: Refer to Page 5
PID ON = Pressure control active
OOR = a warning only that the PV is a set % from the SV
-DRY- = Low Bore input or time out period is active
H02 Integ. time
2.00 sec/r
DOWN to “Integ Time & Diff Time

Page 12 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
PID Tuning Guide
The Proportional gain:amplifies the difference between the set point reference and feedback signals. The H01
Prop. Band value is the proportion of input required to generate 100% at the output of the PID control. For
example H01 Prop. Band is 300.0%, the proportional gain is 100/300 = 0.333. That is 3 units of input will
generate 1 unit of output. The higher the % value, the lower the ‘proportional gain’.
The integral time: The integral action adds a corrective component to reduce a constant error difference
between set point and feedback signals. The greater the error, the quicker the gain increases. The H02 Integ.
time value sets the time to ‘repeat’ the error difference between set point and feedback signals - This assumes
the Proportional gain is equal to 1.
A low H02 Integ. time value attempts to regulate the process variable quickly. However if excessively low, over
shooting and under shooting will be more prominent.
A high H02 Integ. time value diminishes over shooting and under shooting. However regulation takes longer to
achieve.
Guide to PID Tuning:
Step
Problem
Action
1.
The plumbing is set for typical flow but the
system responds too slowly
1.1 Stop the ZENER 8000 & pump
1.2 Halve the value of H01 Proportional band (avoid adjustments below
10%)
1.3 Stop & restart the ZENER 8000 & pump.
1.4 Observe the time it takes to reach pressure (or reacts to changes)
1.5 Repeat if the response is slow. Keep halving H01 Proportional band
until overshoots or starts to oscillate then proceed to step 2.
2.
The system starts to overshoot or oscillate
2.1 Stop the ZENER 8000
2.2 Double the value H01 Proportional band
2.3 Observe the time it takes to reach pressure (or reacts to changes)
2.4 Repeat if the system still overshoots or oscillates proceed to step 3.
3.
The system still responds slowly
(after adjusting H01 Proportional band )
3.1 Halve the H02 Integral Time
3.2 Observe the time it takes to reach the pressure (or reacts to changes)
3.3 Repeat if the response is still slow (half Again) otherwise proceed to
step 4.”
4.
The system starts to overshoot or oscillate
(after adjusting H01 Proportional band )
4.1 Double the H02 Integral Time
4.2 Observe the time it takes to reach the pressure (or reacts to changes)
4.3 Repeat if the system still overshoots or oscillates (half Again)

Page 13 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Implementing ‘Idle mode’
What is Idle Mode ?
Idle mode is a feature that automatically switches the pump off when a ‘no flow’ condition is detected. The
pump will then restart based on pressure (‘% below SV’) or PID output (‘output frequency’).
There are 2 methods in which the ‘Idle Mode’ can be configured.
1. “LOAD %” [DEFAULT] Monitoring the ‘load %’ to indicate when the pump load represents a no flow
situation. Idle mode is triggered when the load drops to the preset level for the preset time.
Depending on the pump performance and operating conditions a flow switch may be required. Eg.
Multiple set points.
2. FLOW SWITCH [DEFAULT] Connect an external flow switch that triggers ‘idle mode’ when no flow for
the preset ‘idle delay’. The switch is connected to digital input on the option board D3(35). The default
setting requires a contact that opens on ‘no flow’. This input is always active so a link is required when
a flow switch is not fitted. A flow switch is the best method to use when operated with a variable or
multiple set point. The flow switch provides a more simple setup process as the ‘load % threshold’ is
not used.
3. OTHER [CUSTOM] Use an internal logic function or other external device to trigger idle mode.
NOTE: Both the ’load %’ and the ‘flow switch’ methods can be used simultaneously, with the same ‘idle delay’.
Idle based on ‘ % Load’
This is detected by a drop in ‘Load%’ for a set period of time. For this to operate it is important to find the %
load under a ‘No Flow’ or ‘Dead head’ condition. Pumping will resume when the pressure falls below a
specified % below the Set point. A flow switch can also be installed to trigger the idle mode.
To ensure correct operation the ‘Idle’ function must be checked and configured for all possible conditions.
For installations where multiple or variable set points the load% method may not operate under all
conditions and require a flow switch to be installed.
time
PV feedback
Output Speed
%Load
PV feedback
H104 RESUME AT
PV threshold
H100 IDLE %LOAD
H101 IDLE DELAY
ZENER 8000 is idle
IDLE:
%Load decreases with reduced flow to a level for a
period of time ‘Idle Delay’ and then goes into ‘Idle
Mode’ (sleep). Or ; The input from the optional
Flow Switch indicating ‘No Flow’ for the ‘Idle Delay’.
WAKE:
When the pressure drops due to returned
demand the ZENER 8000 wakes automatically
and operates in PID mode.

Page 14 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Idle Mode based on Flow Switch Input
This application configures a digital input D3(35) for a flow switch input. The flow switch provides a more
simple setup process (‘load % threshold’ is not used). When the flow switch provides an ‘open contact’ (no
flow) into D3 (terminal 35) for the ‘Idle delay’ period, the ZENER 8000 will enter idle mode. It will operate in
conjunction with the above ‘load %’ method if configured.
NOTE: If there is no switch available or installed a link must be fitted between terminal 1 & 35.
Idle Mode Adjustments
The following steps will help find the settings for Idle Mode.
STEP 1. Select the operator display that displays the following
[Press ENTER to step through the displays]
Note: You may also need to set the minimum speed to 30Hz or less to do the following test
STEP 2. Select one of the following methods to determine the initial idle settings.
Method 1: Operate the ZENER 8000 in PID Mode and close the discharge valve. The speed should decrease and
the pressure should remain at the set point. Take the Load % and the speed reading. Stop the Pump
or open the discharge valve.
Method 2: Operate the ZENER 8000 in local mode. Close the discharge valve. Press the FWD/▲button to start
and increase the speed until the set pressure is reached. Take the Load % and the speed reading. Stop
the pump.
MIN Speed (Hz) 0 (default) Adjust to value equal to or higher than the minimum
operating speed for the pump. This must be less than the
Speed (Hz) value recorded in step 2 for “idle” to operate. This
must be set to a level which will allow a ‘no flow’ condition (eg.
Flow switch operation’).
Idle Threshold % 20% (default) Set at approximately 2-3% higher than the above recorded
‘load%’ value. Eg. Load % = 32% at dead head, set to 35%
This is not required if using a flow switch. To turn Idle
operation OFF adjust this to 0%.
Time before Idle 5 sec (defaut) Increase / decrease if required
This must be longer than the time for the ‘idle trigger’ to
indicate a flow. ie. flow switch or ‘Load %’
Resume Pumping @ 25% below SV Adjust if required.
Reduce the value if required to ‘wake’ at a higher pressure.
Increase the value if required to ‘wake’ at a lower pressure.
28.0Hz 400.0kPa
36% 800 rpm
Speed in Hz
Actual Pressure PV
% Load
30.0Hz 500kPa
36% 800 rpm
Note this value: ________%
Note this value: ________Hz
Adjust the ‘Idle’ Settings.
Refer to page 15

Page 15 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Check the Idle function:
Operate the ZENER 8000 in PID mode and while pumping turn various valves or taps on and off to check that it
goes in and out of idle as required.
Make adjustment as required. If the ‘Load % ‘ method does not provide the desired ‘idle mode’ operation a
flow switch will need to be installed.
Continual Idle cycling: Check if the pressure drops when the pump stops investigate reason and/or increase
the ‘Resume @ PV: X % below SV’ setting. A pressure tank may be required if not fitted or adjust the
parameter ‘pre-idle boost’. This will increase the pressure before switching off. Refer to page 16.
Ensure the idle delay is adequate and flow switch (if fitted) is operating correctly.
Important Note:
Since the dynamics of the system can vary at different operating pressures and conditions, the system should
be tested under all foreseeable conditions to ensure proper operation and operation within the pump
manufacturers specification.
Remaining Parameters:
The remaining parameters to implement & adjust if required are:
Pipe Fill:
The pipe fill option allows the ZENER 8000 to operate at a reduced speed to fill the pipes on start. Pipe
fill is only activated when a start/run command is first given.
Pipe Fill DISABLED To Enable, set to ‘PV Threshold’. This will provide an automatic
changeover to PID when a pressure level is reached.
Pipe Fill Speed (Hz) 40 Adjust the speed to operate during pipe fill mode
Pipe Fill Level 400 kPa Adjust the level to switch from ‘Pipe Fill Mode’ to ‘PID mode’
Pipe Fill time (s) 40 Adjust to the time required to reach the ‘Pipe Fill Level’ pressure
before an alarm occurs
Bore Level Timeout:
Low Bore timeout 0 Enter a time period to restart after a ‘Low Bore’ is detected or
install link if a ‘Bore level switch’ is not installed.
This feature requires a bore level switch to be installed.
When an ‘open contact’ is present on input D1( terminal 31) the
ZENER 8000 stops and displays the warning ‘–DRY-’. When the
contact closes there is a delay before the pump restarts.
The bore level timeout should be set to limit the number of starts per
hour within the pump/motor specifications.
Note:
1. If no ‘Bore Level switch’ is installed fit a bridging link between terminal 1 and 31.
2. If operated with a start/stop switch the low bore switch will stop the pump and not allow a restart until
the time-out period has lapsed.

Page 16 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Variations & Other Adjustments:
Other parameters may need to be adjusted because:
•The setup may vary from the intended application Eg. Use different set point source/reference such as
a potentiometer.
•Additional requirements which the application does not include. Eg. An additional alarm for over
current.
Parameters that you may want adjustment include:
Idle Boost:
Idle Boost provides a boost in pressure before the ZENER 8000 goes into ‘Idle’ mode.
There are 2 parameters:
Idle Boost:
Set the pressure to ‘boost to’ in the current units (eg. Kpa)
ESC to Menu> <DOWN>>> H00 PID PARAMETER <ENTER>PID-A Controller<ENTER><DOWN>>
<H10 Idle Function><ENTER ><<UP/DOWN>> <H105 Idle Boost><ENTER to edit><UP/DOWN to adjust> and<ENTER to save><ESC>
Boost Time:
Set the time period to operate at the boost pressure
<H105 Idle Boost><DOWN><Boost time><ENTER to edit><UP/DOWN to adjust> and<ENTER to save><ESC>
Change Ramp Times:
Ramp types: C030 Accel Time & C031 Decel time = ramp time above minimum speed
C032 S-time = ramp time to minimum speed
ESC to Menu> <DOWN>>> C00 PERFORMANCE <ENTER><DOWN>>>C03 RAMP<ENTER to edit><UP/DOWN to select ramp
type>>and<ENTER to save><ESC> (‘ramp time’ is time taken from 0 to 50Hz)
Note: The time entered is the time from 0 – Max Hz.
Thermistor Input:
Allows a thermistor input for motor protection into terminals 40 and 42 on the option board. This function
needs to be enabled if required.
ESC to Menu> <DOWN>>> G00 INPUT/OUTPUT <ENTER><DOWN>>>G09 Thermistor<ENTER to edit><<UP/DOWN to select
enable>>and<ENTER to save><ESC>

Page 17 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Set point Variable:
The set point in this application is a preset value. It is possible to alter this to another source such as;
•Potentiometer
•Multiple speed
•Analogue reference signal (0-5V, 0-10V, 4-20mA)
•Or other
ESC to Menu> <DOWN>>> H00 PID PARAMETER <ENTER>PID-A Controller<ENTER><DOWN>>>H06 SV Choice<ENTER to
edit><<UP/DOWN>> and <ENTER to save><ESC>
Potentiometer:
To select Analogue input for SV Choice:
ESC to Menu> <DOWN>>> H00 PID PARAMETER <ENTER>PID-A Controller<ENTER><DOWN>>
>H06 SV Choice<ENTER to edit><<Select AI(10,11)>> and <ENTER to save><ESC>
To configure Potentiometer input for 0-5Vdc:
ESC to Menu> <DOWN>>> G00 INPUT/OUTPUT <ENTER> <DOWN>>>Analogue Inputs<ENTER to edit><<Select
AI(10,11)><ENTER><Select 0-5V><ENTER. <ESC>
Others:
For other Set point variable sources refer to the reference manual for details on connection, wiring and the
input parameters required.
Max Hz:
To reduce or increase the maximum speed output. The Motor volts may also be required to ensure the correct
Volts per Hz.
•To operate higher than the motors rated speed.
•To operate a 60Hz motor
•To limit the maximum speed
ESC to Menu> <DOWN>>> C00 PERFORMANCE <ENTER><DOWN>>>C02 MAX Hz<ENTER to edit><<UP/DOWN>>and<ENTER to
save><ESC>
Motor Volts & Hz:
Adjust the output voltage and frequency to suit the motor and ensure the correct volts/Hz ratio is applied.
ESC to Menu> <DOWN>>> B00 MOTOR <ENTER><DOWN>>>B01 MOTOR VOLTS <ENTER to edit><<UP/DOWN>>and<ENTER to
save><ESC>
ESC to Menu> <DOWN>>> B00 MOTOR <ENTER><DOWN>>>B03 MOTOR HZ <ENTER to edit><<UP/DOWN>>and<ENTER to
save><ESC>
Adjust Transducer feedback Zero/Span:
If there is a slight error in the PV reading it may be necessary to make minor adjustment to the input signal for
the transducer feedback. Adjust the ‘Ref @ MIN in’ and/or ‘Ref @ MAX in’.
ESC to Menu> <DOWN>>> G00 INPUT/OUTPUT <ENTER> <DOWN>>>Analogue Inputs<ENTER to edit><<Select
AI(32,34)><ENTER><DOWN>G103 ref @ MIN in><ENTER><UP/DOWN to adjust><ENTER to save><ESC>
<DOWN>G104 ref @ MAX in><ENTER><UP/DOWN to adjust><ENTER to save><ESC>

Page 18 Document: IM00127 RevB 18/04/18
Application SW08020: Pump PID 2 [Advanced Pump PID Control]
Parameters programmed by the Application:
The following parameters are automatically programmed by the ‘Application’ when it is loaded. They are
listed below for reference purposes only.
Application Menu:
1. "Rated Motor Amps"
B02 = ?
2. " Overload current"
D020 = ?
3. "Rated Motor RPM"
B04 = 1470
4. "Transducer Scale" = 1000 (default)
H09 = 1000
5. "Set Pressure" = 500 kPa
F100 = 50.0
6. "Min. Speed (Hz)” = 0
C01 = 0Hz
7. "Idle Threshold %" = 20
H100 = 20
8. "Time before Idle" = 5
H101 = 5
9. "Resume @ PV" = 25% “Below SV”
H104 = 25%
10. "Low Trip Level" = 250.0 kPa
H110 = 250.0
11. "Low Trip time" = 30Sec
G252 = 30
12. "High Trip Level" = 800 kPa
H111 = 800
13. "Pipe Fill" = DISABLED
H120 = 0
14. " Fill Speed (Hz)" = 40
H123 = 40Hz
15. "Fill to Level" = 300kPa
H122 = 300
16. “Fill Time (s)” = 40
H121 = 40
17. “Low Bore Timeout” = 0 secs
G070 = 0
Other Preset Parameters
C030 [Accel] = 1 Sec
C031 [Decel] = 1 sec
C032 [S time] = 0.5 Sec
C033 [Dual Ramp] = Enabled
F010 [Remote Ref] = PID-A Opt
F1001 [PRESET 1 units] = PID A
-High Pressure Trip Config.-
G108 [AI 32,33,Config] = 4-20mA
G230 = [UA1 trip[ Always active
G231 = [UA1 Signal] PVA-Over
G233 = [UA1 msge] HI PRESSURE
-Signal Loss Trip-
G106 [AI 32,34, cmp lo thres] = 2.0 mA
G240 [UA2 Trip] = active with Run cmd
G241 [UA2 Signal] = Lo AI(32,34)
G243 [UA2 msge] = SIGNAL LOST
-Low Pressure trip-
G250 = [UA3 Trip] Active with loop control
G251 = [UA3 Signal] PVA –Under
G253 = [UA3 msge] : LO PRESSURE
-Fill time out trip-
G260 = [UA4 Trip] Run command
G261 = [UA4 Signal] pipe fill timer
G262 = [UA4 Delay] 1 sec
G263 = [UA4 msge] FILL T/O
-Low Bore Customer-
G271 = `TMR 1
G272 = -DRY-
G01 Digital Input Config = CUSTOM
I02 = Logic Block 1
I201 = D2(3)
I202 = TMR 1
I203 = LB1 Logic LLLHLLLH
G071 = [TMR 1 Mode] Delay ON Init.
G0720 = TMR 1 IN2 = ON
G0721 = TMR 1 IN1 = D4(37)
-PID Config.-
H01 [Proportional Band] =200%
H02 = [ Integrator time] = 2.00
H06 = [PID-A SV] = PRESET 1
H07 = [PID-A PV] = AI(32,34]
H08 = PID-A units] = kPa
H102 = Resume by PV threshold
H107 [No Flow Sw] = ~D3(35)
J02 = [Display] = PID Display

Page 19 Document:
Application SW080 : Basic Pump Pressure Control
Trouble Shooting Guide:
The following assumes all standard configurations programmed by the Application without any changes.
Symptom
Checks/Remedy
No Application ‘Pump PID 2’ Menu
is present
1. If you have not loaded the ‘Application’ following the instructions on page 6
2. If you have loaded the Application and no menu, restore defaults and reload
following the instructions on page 6
Pump running wrong direction
3. Swap two motor cables on the ZENER 8000 output or at the motor
PV display is 0 when gauge indicates
pressure
4. Check the application has been loaded. Refer to page 6
5. Check transducer scale has been entered and is correct.
6. In the service menu, check analogue input AI(32,34) is reading correct mA
7. If not reading correct mA, check transducer wiring & polarity
8. Measure DC mA in transducer wiring
PV reading is not correct
9. Check transducer scale has been entered and is correct.
10. In the service menu, check analogue input AI(32,34) is reading the correct mA
11. Measure & check DC mA in transducer wiring is correct and transducer is operating
correctly
12. If only a small error may need to adjust AI(32,34) to read correctly
Pump does not start
13. In the service menu, check digital inputs have ‘1’ on terminals 2,3,4,5 & 6. If a start
push button is used, check it provides a ‘1’ on terminal 4 when pushed. If not, check
input wiring.
14. Is the ‘SV’ on the display indicating the ‘Set pressure’ entered in the ‘Application’
Menu. Eg. 500Kpa.
15. Is the PV reading the correct pressure (as per pressure gauge)
16. If a trip is displayed investigate & rectify. Will need to reset trip.
17. If pipe fill is enabled, check ‘Pipe Fill Speed’ entered is not 0Hz.
18. If Idle is displayed, see below.
-DRY- is displayed and will not start
19. Bore level is low
20. Check Bore level switch operating correctly and connections.
21. If no bore level switch, check bridging link is fitted between terminal 1 and 37.
‘Idle‘ displayed and will not start
22. Check optional ‘no flow switch’ operation and connections. If no switch installed
ensure bridging link is in fitted between terminal 1 and 35.
23. Pressure not dropping to ‘Resume Pumping @ % below SV’ or set too low.
Cycles between ‘run’ and ‘idle’
24. Check ‘Idle’ settings, ‘idle time’ too short or idle % load to high
25. If flow switch is fitted, check correct logic and operation.
Pressure does not build up to the ‘Set
Pressure’.
26. Ensure PV display is correct
27. Motor/Pump rotating wrong direction. Check & rectify.
28. If Pipe fill is enabled check ‘Fill speed (Hz)’is not too low. Disable Pipe fill and check
again
29. If the drive is not running at 50Hz, check motor current in all 3 phases and drive is not
indicating ‘current limit’
30. If running at 50Hz check pump and plumbing.
PID/ pressure control is unstable
31. Ensure Pressure Transducer is operating correctly and the feedback (PV) is stable
when the pump is not running and also running in local mode at a fixed speed.
32. Tune the PID using the parameters and guide on page 11
Current limit is displayed
33. Check the motor current and the drive is correctly matched to the motor & pump.
34. Check the current in each motor phase to ensure balanced
Continually in Pipe Fill Mode
35. Pipe Fill Speed too low, insufficient flow and pressure not reaching pipe fill level.
36. Problem with pump/motor not increasing pressure to pipe fill level. Check
Pump/motor
Will not go into idle, when discharge
valve closed or no flow
37. Minimum speed too high and unable to reach Idle % Load or flow switch to operate
(if fitted)
38. Load % set too low. Repeat procedure ‘Idle Mode Adjustments’ on page 14
39. Set point changed so incorrect ‘Load %’ setting. ‘Load %’ will need
checking/adjustment if set point is changed. May need a flow switch fitted.
More Information or Assistance:
For details on all the features and parameters available refer to the ZENER 8000 Reference Manual available on
the ZENER website: www.zener.com.au