4070.

83/4--10

PumpDrive DPM
Installation and Operating Instructions
Dual Pump Module (DPM)

These installation and operating instructions are not valid on their own. They must always be applied in conjunction with the
PumpDrive operating instructions (reference No. 4070.81).

PumpDrive DPM
Page

Contents
1
1.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4
4.1
4.2
4.3
4.4
4.5

Installation and connection to power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching the DPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the DIP switches on the standard control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
5.1

Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setting/optimising the start and stop limits in 2 Pumps operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6
6.1

Operation / Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Standard control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4
5
6
6
8
11

Figures
Fig. 1:
Fig. 2:
Fig. 3:
Fig. 4:
Fig. 5:
Fig. 6:
Fig. 7:
Fig. 8:
Fig. 9:
Fig. 10:
Fig. 11:
Fig. 12:
Fig. 13:

Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching the DPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixing the DPM using 3 cross--head screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP switch on DPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the KSB local bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the terminating resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIP switches on control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristic curves for defining the start and stop limits
Shaded area: permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
5
6
7
7
8
8
9
9
10
11
12

Scope of supply of DPM set of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols and their meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start and stop limits in the 2 Pumps operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
13
14

14

Tables
Table 1:
Table 2:
Table 3:
Table 4:

PumpDrive DPM
1

General

The DPM set of accessories is available for controlling redundant variable speed twin pumps (e. g. Etaline Z PumpDrive) or two
identical variable speed pumps operating in parallel. The dual pump module (DPM) is available as a separate accessory/spare
part.
The dual pump module (DPM) can only be used in combination with the PumpDrive Basic model and the standard control panel.
It cannot be used in combination with the blanking plate or the graphical control panel.
Scope of supply of PumpDrive DPM set of accessories:
Quantity

Component

1
2

PumpDrive DPM
set of accessories
Dual pump module (DPM)

CAN bus cable (purple)

Control cable (grey)

Resistance 500

Wire jumper

Use

Ident. number
01 131 684

Communication module to transfer data via

KSB local bus
Data transfer between the two PumpDrives
via KSB local bus
Transmission of the measurement signal of the
differential pressure sensor to the second PumpDrive
Conversion of the 4--20 mA (current) measurement
signal of the differential pressure sensor into
0--10 V DC voltage values

47 121 257

01 131 429

01 131 430

01 127 044

Connection of digital inputs DI1 and DI6 to 24 V DC at

both PumpDrives

01 131 428

Cable tie

01 114 578

PumpDrive DPM
operating instructions

See product
literature

Table 1:

Fig. 1:

1.1

Spare
part

Scope of supply of DPM set of accessories

Scope of supply

Symbols

Symbol

Description

Prerequisite

"

Instruction

1.

Multi--step instructions

Table 2:

Result
Symbols and their meaning

PumpDrive DPM
2

Safety information

This KSB device has been developed using state--of--the--art technology; it is manufactured with the utmost care and subject to
continuous quality control.
These operating instructions contain important information and precautions.
Warning of a risk of fatal injury:

Warning of a risk of electric shocks:

Warning of a risk of damage to property:

Caution
These installation and operating instructions are not valid on their own. They must always be applied in conjunction with the
PumpDrive operating instructions (reference No. 4070.81).
The installation and operating instructions must be read and understood before performing any work on the device.
The dual pump module must only be fitted in devices of the PumpDrive product family by skilled, properly trained personnel (see
EN 50110--1).
The manufacturer shall not accept any liability if you fail to comply with the information in these operating instructions.

Function

The DPM serves to control two identical pumps equipped with the PumpDrive Basic model with standard control panel.
One of the pumps is defined to be the main pump (master), the other is the auxiliary pump (auxiliary master).
The dual pump system can be set to two operating modes:
D In 1 Pump operating mode, the dual pump system is designed to achieve the setpoint with one pump operating at rated values
(2x100 %).
D In 2 Pumps operating mode, the systems rated operating point is achieved with both pumps operating at rated values
(2x50 %).

Installation and connection to power supply

Danger of death from electric shock!

"

Before starting any work on PumpDrive, switch off the system and secure it against inadvertent start--up.

Note

Each of the two PumpDrives of the dual pump system must be fitted with a DPM.

n Required tools:
-- Cross--tip (Phillips) screwdriver: PH1x80
-- Flat--head screwdriver: 2 mm

PumpDrive DPM
4.1

Removing the control panel

1
2
6
5

3
4

Fig. 2:

Removing the control panel

1. Undo the six cross--head screws of the control panel (see Fig. 2).
2. Carefully remove the control panel.

PumpDrive DPM
4.2

Removing the connection cables

Two connection cables are attached at the back of the standard control panel. They are not required for operation
with the DPM and must be removed completely.

Note

Fig. 3:

Connection cables

1. Remove the data cable (1):

-- Unplug both ends of the cable.
2. Remove the power supply cable (2):
-- Unplug the cable end on the back of the control panel.
-- Undo the cable end on the PumpDrives terminal strip using a flat--head screwdriver.

4.3

Attaching the DPM

Caution
"

"
"

Risk of damage to property by electrostatic charges!

Make sure that there are no electrostatic charges before taking the dual pump module out of the plastic bag:
-- To do so, touch an earthed metallic object (piping, radiator, etc.) with the full palm of your hand..
Do not touch electronic components.
Only touch the DPM as shown in Fig. 4.

1. Determine the direction of installation of the control panel (see PumpDrive operating instructions, reference No. 4070.81/3,
section 6.4.9).

PumpDrive DPM

1
2

Fig. 4:

Attaching the DPM

2. Attach the DPM in the appropriate direction of installation:

-- Use slot 1 or 2 (see Fig. 4).

Fig. 5:

Fixing the DPM using 3 cross--head screws

PumpDrive DPM
3. Use the 3 cross--head screws supplied (see Fig. 5) to mount the DPM.
Risk of damage to property by wrong setting of DIP switches!

Caution
"

Make sure that the DIP switches on the DPM are set to ON for both the drives.

Fig. 6:

DIP switch on DPM

4. Set the DIP switches on the DPM to ON for both drives (see Fig. 6).
5. If field bus modules are installed on PumpDrive, set the DIP switches on the field bus modules to OFF.

4.4

Connection to power supply

Danger of death from electric shock!

"

Make sure that the system is switched off and secured against inadvertent start--up.
The PumpDrives must be connected to the power supply before the control panel is inserted.

Note

PumpDrive 1
(with standard
control panel
and DPM)

GND 20
DI6 19
DI5 18
DI4 17
DI3 16
DI2 15
DI1 14
+24V 13
AGND 12
AN--OUT 11

System start

P4
GND 20
DI6 19
DI5 18
PumpDrive 2
DI4 17
(with standard
DI3 16
control panel and
DI2 15
DI1 14
DPM)
+24V 13
AGND 12
AN--OUT 11

Fig. 7:

Connecting the digital inputs

1. Connect the digital input DI1 and the digital input DI6 on each PumpDrive to the 24 V power supply (see Fig. 7).
-- Use the wire jumpers supplied.
2. Connect the DI2 digital inputs of the two PumpDrives (see Fig. 7).
-- Use the control cable supplied: 5 G 0.5.

PumpDrive DPM
SB1_GND 10
SB1+ 9
SB1-- 8
7
6
SB1_GND 5
SB1+ 4
SB1-- 3
SB1Z-- 2
SB1Z+ 1

PumpDrive 1
(with standard
control panel
and DPM)

P4

PumpDrive 2
(with standard
control panel and
DPM)

Fig. 8:

SB1_GND 10
SB1+ 9
SB1-- 8
7
6
SB1_GND 5
SB1+ 4
SB1-- 3
SB1Z-- 2
SB1Z+ 1

Connecting the KSB local bus interface

3. Connect the KSB local bus interfaces for both PumpDrives (see Fig. 8).
Use the CAN bus cable supplied.
-- Colour coding:
SB1+
brown
SB1-white
SB1_GND
green/yellow
ABNG P7 10
AIN1 9
8
GND 7
AIN2 6
+24V 5
NO2 4
COM2 3
NO1 2
COM1 1

PumpDrive 1
(with standard
control panel
and DPM)

P7
PumpDrive 2
(with standard
control panel and
DPM)

Fig. 9:

ABNG P7 10
AIN1 9
8
GND 7
AIN2 6
+24V 5
NO2 4
COM2 3
NO1 2
COM1 1

3--wire
sensor
4--20 mA

500

Connecting the sensors

4. Connect the sensors in parallel (see Fig. 9).

-- Use the control cable supplied: 5 G 0.5.
5. If sensors with 4..20 mA are used, connect a terminating resistor.

Caution
"

Risk of damage to property as a result of incorrect sensor signal!

Connect the terminating resistor supplied to only one of the two drives.

6. Connect the terminating resistor to terminal strip P7 (terminals 6 and 7; see Fig. 9).
or
Connect the terminating resistor to terminal strip P5 (terminals 2 and 3; see Fig. 10). To do so, proceed as follows:
-- Remove the L-shaped cable cover (1) :

PumpDrive DPM

-- Remove the cover for the mains and motor connection (2).

-- Connect the terminating resistor with 500 to terminals 2 and 3.

Fig. 10:

Connecting the terminating resistor

-- Re-mount the cover for the mains and motor connection, using 3 cross-head screws.
-- Re-mount the L-shaped cable cover, using 3 cross-head screws.

10

PumpDrive DPM
4.5

Setting the DIP switches on the standard control panel

Caution
"

Risk of damage to property by wrong setting of DIP switches!

Make sure that the P0 and P1 DIP switches on the back of the control panel are set identically for both drives.

There are 8 DIP switches on the back of the control panel. The 3 P0, P1 and M DIP switches are used to set the operating mode
of the dual pump system.

Pump changeover
(after 24 h)
2 Pumps (2x50 %)

ON OFF

Master

P1
P0 1 Pump (2x100 %)
M Auxiliary Master
A4
A3
A2

Not applicable
for DPM

A1
A0

Fig. 11:

DIP switches on control panel

1. Set the appropriate role for each PumpDrive via the M DIP switch:
-- Set the main pump to be the Master.
-- Set the auxiliary pump to be the Auxiliary Master.
2. Set the operating mode via the P0 DIP switch:
-- Set P0 to ON if in normal operating mode both pumps are to run.
-- Set P0 to OFF if in normal operating mode just one pump is to run.
If P1 is set to ON, P0 should be set to OFF.
Note
3. Set pump changeover via the P1 DIP switch:
-- Set P1 to ON for pump changeover after 24 operating hours.
The role of the PumpDrive is shown by the LED on the control panel:
D Green: Master PumpDrive in a multiple pump system
D Green flashing: Auxiliary Master PumpDrive in a multiple pump system
D No display: PumpDrive used as single-pump drive
4. Insert the control panel into PumpDrive in the appropriate direction of assembly.
Make sure that the 9--pin DSUB plug on the back of the control panel fits in the socket provided for this purpose on PumpDrive.

11

PumpDrive DPM

1
2

6
5

3
4

Fig. 12:

Fastening the control panel

5. Insert the 6 screws of the control panel and tighten to a torque of 0.5 Nm (see Fig. 12).

12

PumpDrive DPM
5

Parameter settings

The parameter settings of the Master PumpDrive must be checked, either using the KSB Service Software or a graphical control
panel.
"

The parameters must be set as follows:

Parameter

Description

Setting

3--2--1--1

Role in multiple pump configuration

Auxiliary main pump for both PumpDrives

3--2--1--2

PumpDrive ID

1 for Master PumpDrive

2 for Aux. Master PumpDrive

3--6--4--51)

High load function

Warning2)

3--6--4--101)

Low load function

Warning2)

3--7--1--2

Function Dig In 2

System start for both PumpDrives

3--8--3--1

AI 2 setting

Voltage

3--8--3--2

AI2 Low voltage

2V

3--9--1--1

PI Mode

Active

Table 3:

Parameter settings

1) For 2 Pumps (2x50 %) operating mode only.

2) The parameter must be set as a function of the pump type and system curve.

13

PumpDrive DPM
5.1
"

Setting/optimising the start and stop limits in 2 Pumps operating mode

Define and set the values for the following parameters. See Table 4 and Fig. 13.

Parameter

Description

Function

3--6--4--1

High load at low motor frequency

Defines start--up
p of additional pump
p p

3--6--4--2

High load at high motor frequency

3--6--4--3
3--6--4--6

High load profile

Low load at low motor frequency

3--6--4--7

Low load at high motor frequency

3--6--4--8
3--6--4--4

Low load profile

High load time delay

3--6--4--9

Low load time delay

3--6--4--5

Warning: High load function

3--6--4--10

Warning: Low load function

3--3--2--1
3--6--1--2
3--6--1--3
3--11--4--1

Rated motor power

Low motor frequency limit
High motor frequency limit
Maximum output frequency

Table 4:

Defines stopping
pp g of p
pump
p

Identification of the impermissible range and

response are time--controlled
time controlled by way of
these parameters
Starting
g and stopping
pp g is enabled byy the
warning.

Start and stop limits in the 2 Pumps operating mode

Pmax@3--6--1--3 (3--6--4--2)

Pmax@3--6--1--3 (3--6--4--7)
Pmax@3--6--1--2 (3--6--4--1)
Pmax@3--6--1--2 (3--6--4--6)
Low Freq
(3--6--1--2)
Fig. 13:

14

High Freq
(3--6--1--3)

Characteristic curves for defining the start and stop limits

Shaded area: permissible range

PumpDrive DPM
6

Operation / Monitoring
Caution

6.1

Any damage to the surface of the PumpDrive control panels by pointed or sharp-edged objects may reduce the
degree of protection provided by the enclosure.

Standard control panel

The standard control panel features an LED bar graph display, keys and a service interface.
With the standard control panel, users can change between the Manual, OFF and Automatic operating modes and specify the
setpoint using the setting keys. The operating mode, motor speed and sensor signal are displayed via LEDs.
6.1.1

Key functions

LEDs:
traffic light function

Display
Setpoint or actual value
Speed
Display of the
redundant dual pump
control function

Display of the
operating mode
Setting keys
Increase
Confirm
Reduce
Operating keys

Manual mode

User--programmable
function key

OFF

Automatic mode

Service interface (RS 232)

A blanking plate (ident. number: 47 106 619) that prevents intervention in the operating mode is available for safety-relevant
applications.

15

PumpDrive DPM
LEDs
The traffic light signals provide information about the pump systems operating status.
LEDs:
D Red: One or more than one alert is active
D Amber: One or more than one warning is active
D Green: Trouble--free operation
LED bar graph display
The LED bar graph display can display three different colours. The colours represent the following operating parameters:
D Red:
Motor frequency
D Amber:
Actual value sensor signal
D Green:
Setpoint
The current values of these three operating parameters are shown as percentages by means of the five individual LEDs. Each
LED represents a particular percentage range of the operating parameter selected:
D Min. LED:
0--19 %
D 2. LED:
20--39 %
D 3. LED:
40--59 %
D 4. LED:
60--79 %
D Max. LED:
80--100 %
The end value of 100 % represents:
D The maximum motor frequency (e.g. 50 Hz 100 %)
D The full-scale value of the sensor (e.g. 6 bar 100 %)
D The specified setpoint in open-loop control mode (e.g. 50 Hz 100 % setpoint)
D The specified setpoint in closed-loop control mode (full-scale value of the sensor 100% setpoint)
DPM LED
This LED shows the function assigned to the PumpDrive:
D Green:
Master PumpDrive in a multiple pump system
D Green flashing:
Auxiliary Master PumpDrive in a multiple pump system
D No display.
PumpDrive used as single-pump drive
Mode LED
This LED shows the current operating mode of the PumpDrive:
D Red:
OFF mode, switched off
D Amber:
Automatic mode
D Green:
Manual mode

16

PumpDrive DPM
Setting keys
Operating parameter display (monitoring)
This function is only available in manual or automatic mode. The actual value can only be displayed if a sensor is connected.
Up Arrow key:
D Pressing key once:
The motor frequency is displayed (red LEDs of the bar graph display)
D Pressing key twice:
The actual value is displayed (amber LEDs of the bar graph display)
D Pressing key three times:
The setpoint is displayed (green LEDs of the bar graph display)
The actual value can only be displayed if a sensor is connected!
6.1.1.1 Down Arrow key:
The operating parameters are selected in reverse order to the Up Arrow key.
Setpoint specification
D Use the
or
keys to switch to the setpoint display (green LEDs).
D Press OK key.
The green LEDs of the LED bar graph display start flashing.
D Use the
or
keys to increase / reduce the setpoint.
Each time a key is pressed, the value will be changed by an increment of 0.5 Hz or 1.0 % (factory default setting). If the keys
are pressed continuously, the setpoint is increased / reduced continuously.
D Press OK key again.
The LED bar graph display returns to operating parameter display mode, i.e. the LEDs are steadily lit.

17

PumpDrive DPM
Operating keys
You can use the operating keys to select the Automatic, Manual or OFF operating modes.
The parameterisable Func key is only available in Automatic or Manual mode.
OK key also serves as alert reset key

Manual mode
OFF
If the drive is in Manual mode when the voltage supply is interrupted, the drive will switch to the OFF
mode once the voltage supply is restored.
Automatic mode
Parameterisable function key
The dynamic pressure compensation function is activated when this key is pressed.
When the OK key is pressed, the percentage of the setpoint compensation of the dynamic pressure compensation function is displayed in the bar display by flashing yellow LEDs.
When the parameterisable function key is pressed again, the display of the setpoint compensation is deactivated.
Service interface
The service interface allows a PC / Notebook to be connected via a special cable (USB - RS232). The PumpDrive Service Software
can be used to configure and parameterise the pump system if you do not have access to a control panel.
You cannot implement a software update for PumpDrive with the standard control panel. The customer version of the Service Software for parameterisation and data back--up can be ordered under ident. No.: 47 121 211.

18

PumpDrive DPM
Notes:

19

4070.83/4-10

09.09.2010

Subject to technical modification

without prior notice.

PumpDrive DPM

KSB Aktiengesellschaft
67225 Frankenthal Johann-Klein-Str. 9 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 Fax +49 6233 86-3401 www.ksb.com