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Operating Instructions

1. 3 4 516 Processor Error Check the ground and earth connection 810100 0 0 Software failure and the cabling that no signal cable is Failure code 16 running in parallel with a power cable 1 2 3 4 5 6 Low Water The incoming water flow rate or the O 6 0 0o 0 0 Output pressure is below suction pressure is too low Failure code 26 25 of the required pressure Sensor Error Check cable connection of the internal sensor or changing of the complete pressure measurement device contact your service partner 1 2 3 4 5 6 Over Temperature Motor Ambient temperature is too high or O 0 160 0 0 0 Over Temperature Drive cooling of the motor is not efficient Failure code 36 PTC of the motor has Clean the cover and the motor fan and detected over temperature read the manual of the motor or the Hydrovar Temperature of the handled liquid is too Watercooled has reached high or no flow through the Hydrovar its maximum temperature Watercooled for efficient cooling 1 2 3 4 5 6 Over current Check the power consumption of the O 01010 0 0 Short circuit motor and the working point of the pump Failure code 46 Overload if they do not exceed the max output Output current to te motor power of the Hydrovar Watercooled is too high due to too high nominal power nominal power of the Reduce the flow rate motor or short circuit of 2 Check the connection to the motor phases of the motor or the Pump is blocked or tight due to sol
2. life Operating Instruction 2 Technical Data HYDROVAR Watercooled Power supply Max nominal Type Voltage Freguency motor current HVW 1 07 0 75 kW 220 240 V 15 48 62 Hz 4 2 A System pressure max 6 bar Motor cable length max 20 Meter Overload max 20 Cooling through handled liguid Water Service water Medium temperature max 50 C see diagram below Ambient temperature 0 C 50 C see diagram below Storage temperature 25 C 55 C 70 C during max 24 hours Humidity RH max 50 at 40 C unlimited RH max 90 at 20 C max 30 days per year 75 average per year Class F Condensation is not permitted Air pollution The air may contain dry dust as found in workshops where there is no excessive guantity of dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted Altitude max 1000m above sea level At sites over 1000 m above sea level the maximum output power is derated by 1 for every additional 100m If the installation site is higher than 2000 m above sea level please contact your local distributor Class of protection IP 55 Temperature Medium temperature depends on the ambient temperature 60 5 50 40 30 4 20 Mediums Temperature C 5 30 40 50 Ambient temperature C Means of protection Ask your power supply company which means of protection are required Applicable TN s
3. of the system pressure Description of the LED Signal Bright O Dark O Slow blinking Fast blinking LED Signal Stop Button Start Button Error code Decrease Increase 5 Status signal and required value adjustment After connecting the power supply to the Hydrovar Watercooled the 1 LED is switched on To start the unit press the button Fast blinking of LED 1 Pump is running Slow blinking of LED 1 Required pressure is reached and the unit is in standby mode To stop the unit press the button Auto Start Function Memory Function HVW in operation after a power supply failure HVW will start automatically again HVW in standby after power supply failure HVW will remain in standby mode if the required pressure Is available after pressure is down HVW will start automatically If the unit has been stopped stop button has been pressed before the power supply failure the Hydrovar Watercooled is also stopped after return of the supply power 13 www hydrovar com ITT Industries Engineered for life Operating Instruction Controller mode constant pressure control In this mode the Hydrovar Watercooled is controlling to a constant output pressure independent from the required flow rate but limited to the maximum performances of the pump The integrated low water protection shuts off the pump when the output pressure during operatin
4. ARA s r l Via Lombardi 14 36075 Montechio Maggiore I Vicenza Italien Telefon 39 0444 707111 Telefax 39 0444 492166 E Mail mkt lowara ittind com www lowara com LOWARA Niederlassungen Subsidiaries LOWARA DEUTSCHLAND GMBH Biebigheimer Strasse 12 D 63762 GroBostheim Telefon 0 60 26 943 0 Telefax 0 60 02 943 210 E Mail info de lowara ittind com www lowara de LOWARA FRANCE S A S BP 7311 F 37073 Tours Cedex 2 Tel 33 2 47881717 Fax 33 2 47881700 E Mail info fr lowara ittind com www lowara fr LOWARA FRANCE SAS Agence Sud Z 1 La Sipi re BP 23 13730 Saint Victoret F T l 0033 04 42 10 02 30 Fax 0033 04 42 10 43 75 LOWARA NEDERLAND B V Postbus 54 NL 4180 BB Waardenburg Tel 31 418 655060 Fax 31 418 655061 E Mail info nl lowara ittind com www lowara nl LOWARA PORTUGAL Com rcio de Bombas Lda Praceta da Castanheira 38 P 4475 019 Barca Portugal Tel 351 22 9478550 Fax 351 22 9478570 E Mail info pt lowara ittind com www lowara pt www hydrovar com LOWARA IRELAND Ltd 59 Broomhill Drive Tallaght Industrial Estate Tallaght Dublin 24 Tel 35 31 4520266 Fax 35 31 4520725 e mail sales ir lowara ittind com www lowara ie LOWARA UK Ltd Millwey Rise Industrial Estate Axminster GB Devon EX13 5HU Tel 44 1297 630230 Fax 44 1297 630270 E Mail uksales lowara ittind com www lowara co uk LOWARA UK Ltd Regional sales office Unit 1 By
5. Operating Instructions Hydrovar Watercooled ENGLISH 771079012 Manual HVW1 07 VL EN C X ITT Industries Operating Instruction www hydrovar com ITT industries Operating Instruction Contents 1 Important safety instructions 20 Oopvvenrcen ba Govier Oela lvl viaal 4 2 Technical Data AES 6 3 Mounting and ACCESSONIGS 11040 taha isamaaliste tia Su alia valida aada 7 4 Electrical connection control terminals and Display unit rrmennns 12 5 Status signal and required value adjustment nneennnnennennnnnannennn naa 13 6 a ae MESSAGES 4 ise mnt Miret ai TAA A E altai ila eki liilia 15 2 Maintenance and Notes st ei mttnttindaesi avesta aveeeuevacdeesterseewdcebeeneteealieewedts 16 Follow the Pump Operating and Maintenance Instructions We reserve the right to alter specifications 3 www hydrovar com ITT Industries Engineered for life Operating Instruction 1 Important safety instructions Read and follow the operating instructions and safety instructions carefully before starting operation All modifications must be done by qualified technicians In addition to the instructions contained in this service manual please pay attention to universal safety and accident preventing regulations Warns that failure to observe the precaution may cause electric shock Warns that failure to observe the precaution may cause personal injury or damage to property The Hydrovar Wa
6. WARA VOGEL Szivattyu Kft H 8000 Sz kesfeh rvar Bakony u 8 Telefon 0036 22 512 640 Telefax 0036 22 512 642 Lowara Vogel Polska sp zo o PL 40652 Katowice ul Worcella 16 Telefon 0048 32 202 8904 Telefax 0048 32 202 5452 ITT Industries Engineered for life
7. chanically blocked Clean or change the check valve Wrong parameter setting Increase the control window setting contact customer service Air in the suction pipe or in the pump Check the suction pipe and ventilate the whole system Flexible or too long suction line Larger pressure tank necessary 7 Maintenance and Notes The HYDROVAR Watercooled does not require any special maintenance For further information please contact your distributor www hydrovar com 16 KR ITT Industries W Engineered for life Operating Instruction Manufacturer s Declaration as defined in EC Machinery Directive 98 37 EEC Appendix II B and the EMC Directive 89 336 EEC We herewith declare that the frequency converter of type Hydrovar Watercooled HVW1 07 is intended for assembly with other machines to a machine It is forbidden to start using it until it has been established that the machine on this converter is to be installed or with which this converter is to be assembled complies with the provisions of EC Directives Relevant technical standards and specifications especially EN 61000 4 EN 55011 Dir Ing Manfred Sacher Pumpenfabrik ERNST VOGEL GmbH A 2000 Stockerau Ernst Vogel Str 2 Stockerau 30 08 04 www hydrovar com K ITT Industries Engineered for life Operating Instruction 18 www hydrovar com ITT industries Operating Instruction LOWARA Hauptsitz Headguarter LOW
8. drovar com ITT industries Operating Instruction The Hydrovar Watercooled contains electronic safety devices which switch off the control element in the event of a fault whereby the motor has zero current but remains energized and comes to a halt The motor can also be halted by mechanical blocking If it is electronically switched off the motor is disconnected from the mains voltage through the electronics of the Hydrovar Watercooled but is not potential free in the circuit In addition voltage fluctuations especially power failures can cause the system to switch off itself Repair of faults can cause the motor to start up again The system may only be put into operation when it has been earthened In addition eguipotential bonding of all pipes must be ensured The operating instructions must be read understood and followed by the operating personnel We point out that we accept no liability for damage and operating disorders which are the result of non compliance with the operating instructions Transportation Handling Check the Hydrovar Watercooled immediately upon delivery receipt of dispatch for damage or missing parts If any damage is visible inform your distributor within 8 days from the delivery date The unit must be transported carefully and by competent personnel Avoid serious impacts Attention Dispose of all packing materials in accordance with local regulations www hydrovar com ITT Industries Engineered for
9. g of the pump is below 25 of the stored required pressure for longer than 20 seconds In that case the controller will shut off the pump and will show Error code 26 Lack of water This kind of failure will be reset automatically for 3 times with a delay of another 20 seconds After the 3 try the Hydrovar Watercooled has to be reset by removing the power supply Adjustment of the required pressure Press and together for 3 seconds till all LEDs are illuminated 1 2 3 4 5 6 0 010 0105 0 The reguired pressure setting is now active and will be indicated by shining of LED 1 and 6 LEDs 3 and 4 inthe centre of the LED bar are blinking alternately Reguired pressure can be changed Press increase or decrease to set the reguired pressure The changing of the operating pressure of the pump is shown on the manometer If no button is pressed for more than 10 seconds the new setting will be saved automatically 14 ITT Industries Engineered for life www hydrovar com Operating Instruction 6 Error Messages LED Indication Failure reason Possible solution 1 2 3 1 4 5 6 Under Voltage Check the cable and the terminals on O0O 0 0 0 0 0 Supply voltage is too low the supply side of the Hydrovar Failure code 06 1 2
10. id motor cable parts inside the pump 1 2 3 4 5 6 Over voltage Check the supply voltage level and all O O O O0O Supply voltage is too high connections Failure code 56 or spikes on the supply side If there are spikes on the supply line use special filters on the input side After remedy of the failure reason it is necessary to switch on the Hydrovar Watercooled Please contact your distributor if the same failure occurs more often Give a detailed description of the error the failure code and the serial number of the Hydrovar Watercooled Bright Dark O Slow blinking Fast blinking www hydrovar com 15 KR ITT Industries W Engineered for life Operating Instruction Other failures and possible causes Failure Possible cause Solution Oscillation of the pressure Wrong pre charge pressure in the pressure tank Adjust pre charge pressure according to the required pressure or the start pressure when active Wrong parameter setting Optimize control parameters contact customer service Dirty or blocked sensor Clean the internal sensor piping and connection contact customer service Pump does not stop Wrong pre charge pressure in the pressure tank Adjust pre charge pressure according to the required pressure or the start pressure when active Check valve is leaky or me
11. ipe of the Hydrovar Watercooled e g at pumping of service or rain water we recommend a filter before the unit 10 www hydrovar com ITT industries Operating Instruction Dimensions all measures are in MM Motor connection U V W Voltage Control supply terminals L N PE Ground PE Ground 11 www hydrovar com ITT Industries Engineered for life Operating Instruction 4 Electrical connection control terminals and Display unit Do the hydraulic assembling first before starting the electrical connection a Openthe 4 screws of the cover and remove the top cover b Connect the motor cable and the supply cable c If reguired connect the control cable for the external release contact and the thermistor PTC If they are not used these inputs have to be bridged Cable gland type Suitable cable Pieces diameter M20x1 5 7 13 mm 1 M16x1 5 4 5 10 mm 2 M12x1 5 3 5 7 mm 1 Do not connect the electronic ground with the other voltage potentials There is only single isolation of the control voltage Between ground and GND of the control voltage there can occur voltage levels gt 100VAC Connected relays or switches therefore have to have double isolated contacts Terminals X4 1 GND 2 External release On Off 3 GND 4 Thermistor 12 amp www hydrovar com CY ITT Industries Engineered for life Operating Instruction Front label 1 HYDROVAR Display
12. pumps and a maximum system pressure of 6 bars The variable speed drive can be used for service water water supply from a well or as a booster station The requirement for using this variable speed drive is a capable pump with an asynchronous motor suitable for a 3x230VAC supply and isolation class F Mounting into the pressure line with pressure tank For applications as water supply or booster with automatic shutoff it is necessary to mount a check valve and a pressure tank To measure or control the actual system pressure it is necessary that the check valve is mounted before the Hydrovar Watercooled The pressure tank can be mounted before or after the Hydrovar Watercooled or of the not used pipe connection Between pressure tank and Hydrovar Watercoo ed it is not allowed to mount a check valve or a pressure reduction valve to ensure storing the pressure in the system at zero demand With the Hydrovar Watercooled it is not necessary to have a large pressure tank for supply purposes For selecting a pressure tank make sure it is approved and suitable for the maximum system pressure The pressure tank should have a capacity of more than 10 of the maximum system flow rate l min of the pump Example Maximal capacity of the pump 70 Liter per minute Minimum volume of the pressure tank 70x0 10 7 Liter A certain pre charge pressure has to be in the pressure tank when there is no water in the tank determined by the required pre
13. ram Industrial Park Low street Brotherton Knottingley WF 11 9 HS West Yorkshire Tel 44 1 977 607 267 Fax 441 977 607 226 E mail salesuknorth lowara ittind com www lowara co uk ITT FLUID TECHNOLOGY INT ASIA PACIFIC PTE Ldt 298 Tiong Bahru road 03 04 06 Tiong Bahru Plaza Singapore 168730 Tel 65 2763693 Fax 65 2763685 ITT FLUID TECHN INT AUSTRALIA PTY Ltd 18 Commercial Drive Dandenong South Victoria 3175 AUSTRALIA Tel 61 3 97065066 Fax 61 3 97066065 19 ITT Industries Engineered for life Operating Instruction VOGEL PUMPEN Hauptsitz Headquarter Pumpenfabrik ERNST Vogel GmbH A 2000 Stockerau Ernst Vogel Strasse 2 Telefon 02266 604 Telefax 02266 65 311 Internet www vogel pumpen com www hydrovar com VOGEL Niederlassungen Subsidiaries A 8054 Graz Seiersberg Kartnerstrasse 518 Telefon 0316 28 6120 Telefax 0316 28 70 42 A 9020 Klagenfurt Schachterlweg 58 Telefon 0463 31 93 20 Telefax 0463 31 93 17 A 4600 Wels Haidestrasse 41 Telefon 07242 66 8 51 52 53 54 Telefax 07242 66 8 51 12 A 6175 Kematen Bahnhofstrasse 31 Telefon 05232 20 0 01 Telefax 05232 20 0 03 Engineered for life is a registered trademark of ITT Industries 2003 All other trademarks or registered trademarks are property of their respective owners All data subject to change without notice www hydrovar com Tochterunternehmen in Europa Subsidiaries in Europa LO
14. ssure or the start value when activated Solldruck required pressure 1 2 3 4 5 6 7 8 9 10 0 8 1 2 3 4 5 6 7 8 9 VorpreBdruck precharge pressure bar Special application Constant pressure control with external release contact For irrigation systems the Hydrovar Watercooled can be mounted without check valve and pressure tank if the Hydrovar Watercooled will be activated with an external release contact The Hydrovar Watercooled keeps the system pressure constant while the external contact is closed irrigation is on and is switched off by the external contact when the irrigation system is not in use www hydrovar com ITT Industries Engineered for life Operating Instruction Notice To protect the pump against air inlet from the suction side or working below an allowed incoming pressure level it is necessary to connect an external protection unit to the release contact terminals of the unit The Hydrovar Watercooled shuts off when the contact will be opened and turns on if the contact will be closed When there is an application of sucking out water from a well or a tank there has to be used a level probe or a float switch as the low water protection For booster stations a pressure switch has to be mounted for low water protection When the pressure switch opens the contact of the Hydrovar Watercooled will detect low water and the pump will be stopped For protection against contamination inside the cooling p
15. tercooled must be disconnected from the power supply before any work can be carried out in the electrical or mechanical part of the system Installation maintenance and repair work may only be carried out by trained skilled and qualified personnel Unauthorized modifications or changes to the system make all guarantees null and void When in operation the motor can be stopped by remote control whereby the Hydrovar Watercooled and the motor remain under voltage For safety reasons the unit has to be disconnected from the power supply when carrying out work on the machinery as locking out the equipment by switching off the release mechanism or set value cannot prevent accidental starting of the motor When the Hydrovar Watercooled is connected to power supply the components of the power unit as well as certain components of the master control unit are also connected to the power supply Touching these components seriously endangers life Before removing the Hydrovar Watercooled cover the system must be disconnected from the power supply After switching off the power supply wait at least 5 minutes before starting work on or in the Hydrovar Watercooled the capacitors in the intermediate circuit are discharged by the installed discharge resistors first Notice Furthermore care must be taken not to short circuit the neighboring components when connecting the external control wires Isolate open cable ends which are not in use www hy
16. ystems protective circuits Fl pulse current circuit breaker 6 amp www hydrovar com CY ITT Industries Engineered for life Operating Instruction 3 Mounting and accessories The Hydrovar Watercooled has to be directly mounted in the pressure line The cooling of the unit is done through the handled liquid The Hydrovar Watercooled has two connections with 1 female thread and one connection with 1 male thread The direction of the flow can be chosen in any direction The 3 unused connection can either be closed use incl closing cup or can be used as the connection for the pressure tank Direct mounting on the pressurized side of a dry pump Indirect mounting in the pipe work with a submersible pump www hydrovar com ITT Industries Engineered for life Operating Instruction Assembly possibilities Max 45 left Horizontal assembly Max 45 right Vertical assembly a kud f Day D gt Possibilities for wrong mounting r E WRONG M There is no flow through the Hydrovar Watercooled KD Inefficient cooling of the A WRONG Check valve is mounted after the Hydrovar Watercooled Wrong measuring point for the system pressure and therefore no automatic stop of the pump at zero demand unit www hydrovar com ITT industries Operating Instruction General information about the System The Hydrovar Watercooled is suitable for constant pressure control of

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