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Operating Instructions

1. lift intensity in of set pressure 73 0400 0400 SUBMENU SENSOR In this submenu all actual value sensors which are connected to the HYDROVAR can be configured up to two transducers with current output or voltage signal output It is not possible to install two different transducer types because main configuration is the same for all connected sensors Transducers must be always the same type 0405 pude Dimension unit Possible settings psi m h g min mH20O ft C F l sec l min m sec 9o Chose the desired dimension unit by pressing or V By changing the DIMENSION UNIT you have to consider changing the SENSOR RANGE 0420 according to the new DIMENSION UNIT too 0410 CONF SENSOR 0410 Selection of the sensor Sensor 1 Possible settings Sensor 1 Sensor 2 Auto Switch Dig1 Switch Dig2 Switch Dig3 Switch Dig4 Auto Lower Auto Higher Sensor 1 Sensor 2 This parameter determines how the connected sensors are used and which one is active It is also possible to measure the difference of two connected sensors or to configure an automatic switchover in case of a faulty sensor Sensor 1 is constantly active Sensor 1 0 4 20mA signal connected to X3 2 and X3 3 24V 0 10V signal connected to X3 6 and X3 3 24V Sensor 2 is constantly active Sensor 2 0 4 20mA signal connected to X3 4 and X3 3 24V 0 10V signal
2. uM ac 36 9 4 5 C 37 9 4 5 1 Control card HYDROVAR MASTER 37 94 52 44 9453 Control card HYDROVAR SINGLE Inverter not for HV 4 150 HV 4 220 46 emt ERR 49 10 1 Display Control panel of the MASTER SINGLE Inverter 49 10 2 Function of the push buttons 49 10 3 Display of the BASIC 50 10 4 Software Parameters ees a 51 OO MAIN MENU 51 20 SUBMENU SSTATUS 56 40 SUBMENU DIAGNOSTICS 59 60 SUBMENU SETTINGS lea di aate IE c o Sich Da ale afe RES 60 0100 SUBMENU BASIC SETTINGS 61 0200 SUBMENU CONF INVERTER 64 0300 SUBMENU REGULATION 72 0400 SUBMENU SENSOR bia INO a DR Mou adi 74 0500 SUBMENU SEQUENCE CNTR 12 55 wx SEG CU ER cedro dr ER Fe ves 77 0600 SUBMENU ERRORS 5 uisrRiSuERERDESKEE DIXERVEXERPEREREHKDINES FEXX REUS AR SE SUELE 82 0700 SUBMEN
3. nN3QWans 00 JNOO nN3Wans 00 SONILLAS 5 NNAWENS 00 SONILLAS nN3Wans 09 101 39V43H3LlNI S8Sv SH 00c L 541135 nNa3Nans 0011 15 1 NNAWENs 0001 135440 NNAWENS 006 S3fY1VA nNaNans 008 SLNdLNO NNAWENs 004 5 009 29S lt SS Jd 1VH3dO 410 295 lt SS Jd SELL NVIN NOHIS3L 090 LO ADIAAG 14S 00 0 cA 1954540 00 0 LA 195450 ZH 00 GcOl 816 16 LVNLOV SES Jeq IVA O3H Gc8 L TIV HHOLIONHIO 06 29S JNIL HIS3L 001 19554540 0 1 0201 216 L8N 1VINHOJ TV 19 OL 15008 4153931 910 001 Z13431 86 0 0 LX 195340 16 L 13 31 016 ZH 00 LOYD LYVNLOV 08 Jeq L IVA O3H S10413 199 JNOO 0c8 024 1utodjes MS 918 13H ANOO SIZ NO 13599 919 QHOMSSVd NNYLSAL 0101 1 014 L 53 00 0096 edoun3 0000 LAS AHOLOVZ sinoy 001 N HlSiL ZH 0 001 330 5340 206 1 5330 440 018 295 019 909 ouenbaj 1ndino 50 39V43H3J LNI S
4. M M ER V EI KENNEN ED AIME 22 8 1 Included mounting material 2 poi ibi Log Ee PER PUR 22 8 2 Optional 22 8 2 1 MOUNTING ACCESS ONES E E 22 8 2 2 1 22 8 2 3 Bi d THEATRE Mere 22 GEM RESTORE CEN 22 8 2 4 Cable entry only HV4 150 4 220 22 8 2 5 Ready made Motor cx ee ete een eta ete utto rE 22 8 3 Assembly instructions ioo iio tous Prova PU e oen Uma cu Osa dato usns OE GS a Miei NER 23 9 Electrical Installation and WIFIDQ ee 25 9 1 Means OF protectiolaxis usano re atas ca v c ate be e ar iw cat 25 9 2 EMC electromagnetic eese 26 9 3 Recommended Cable Types 27 9 4 Wiring and connections ese Pour se orveda ides usu nie UE ius 28 9 4 1 Main voltage terminals c ccccceccceecceeccceecceeeceeeeeeeeceeeseueeseeeseeeseeeseeseaeeeaeeeneeesaees 29 9 4 2 REOR TTE 30 9 4 3 POW CRU Errore Il segnalibro non definito 9443 1 25010 FUP on P DERE Kari aaa e aa E OR 32 JAGOGESSSIDG ee ee ee ee 34 9 4 4
5. an 4 r 2 1 Ns 2 ANS E mo f c ter i Ex ae p A 1 2 Power supply L1 L2 L3 3x400 VAC 29 9 4 2 Motor connection Mounting of the PTC Method A Method B motor block terminal block rubber gasket cover of the conduit box The cover of the conduit box must be opened and the terminal block inside removed Fix the PTC Method A or B Replace the terminal block Electrical connection of the motor cables bd dim The PTC must be fixed to the metal body of the motor This is necessary to measure the right temperature of the motor The connection of the motor cable depends on the type of motor and can be done in star or delta connection The right connection of the motor has to be selected as shown on the motor label according to the output voltage of the HYDROVAR star connection delta connection H H U lt n 0 Mm Guo dre Piin D ricca V D w KOR R UOT DZH N DISTAS IC d HONA Y V E d 2 30 9 4 3 Power unit On the power unit two control terminal blocks can be found HV 2 015 2 022 HV 4 022 4 030 4 040 Se fs X7 Terminal for internal fan X8 24 X1 Control terminals power unit PT PTC or thermal switch STA
6. connected to X3 5 and X3 3 24V Auto Automatic switch over in case of a faulty transmitter Switch Dig1 Manual switching by closing digital input 1 X3 9 10 Switch Dig2 Manual switching by closing digital input 2 X3 6 GND Switch Dig3 Manual switching by closing digital input 3 X3 5 GND Switch Dig4 Manual switching by closing digital input 4 X3 15 GND The sensor with the lower actual value or available sensor in case of a faulty sensor is used automatically The sensor with the higher actual value or available sensor in case of a faulty sensor is used automatically Sens 1 Sens 2 The difference of both connected sensors is taken as actual value Auto Lower Auto Higher 74 0415 sd Selection of the sensor type and input terminal Possible settings analog 4 20mA analog 0 20mA analog U 0 10V For correct operation the suitable signal input type regarding to the connected sensor has to be selected Sensor type Terminals analog 4 20mA The actual value is represented by a current X3 2 gt Sensor 1 analog 0 20mA signal connected to following terminals X3 4 gt Sensor 2 The actual value is given from a voltage signal X3 6 gt Sensor 1 aed following terminals X3 5 gt Sensor 2 Sensor 2 15 not available for the SINGLE Inverter configuration 0420 SENS RANGE 0420 20mA 10 00 Bar Sensor range Possible settings 0 00 10000 Determines the end value 20mA or 10V o
7. e adjust Parameter DELAY TIME 0610 if the failure happens only for short time check booster unit adjust parameter DELAY TIME 0610 Parameter ERROR RESET 0615 set to ON to enable 5 restarts e g in empty system FAILURE SENSOR 1 ACT VAL SENSOR 1 ERROR 23 Sensor signal on terminals X3 2 4mA active Sensor WARNING 20 sec gt ERROR non active sensor WARNING ACTUAL VALUE signal pressure transducer faulty wrong connection e Sensor or cable fault check configuration of the sensors in submenu SENSORS 0400 FAILURE SENSOR 2 ACT VAL SENSOR 2 ERROR 24 Sensor signal on terminals X3 4 4mA active Sensor WARNING 20 sec gt ERROR non active Sensor WARNING ACTUAL VALUE signal pressure transducer faulty wrong connection e Sensor or cable fault check configuration of the sensors in submenu SENSORS 0400 SETPOINT 1 I x4mA SETPOINT 1 1 lt 4mA ERROR 25 Current signal input of required values is active but no signal 4 20mA is connected WARNING 20 sec gt ERROR e check external analogue signal on terminals X3 17 18 e check configuration of the required values in Submenu REQUIRED VALUES 0800 SETPOINT 2 lt 4 SETPOINT 2 1 lt 4 ERROR 26 Current signal input of required values is active but no signal 4 20mA is connected WARNING 20 sec gt ERROR e check external analogue signal on termina
8. 03 REQ VAL s D1 X XX Bar Effective required value Shows the current required value that is calculated based on ACTUAL VALUE INCREASE 0505 ACTUAL VALUE DECREASE 0510 and LIFT AMOUNT 0330 If the required value is influenced by an offset signal SUBMENU OFFSET 0900 the current active required value is also shown in this window E g Multi pump application with two pumps REQUIRED VALUE 02 5 00 bar ACT VALUE INCREASE 0505 0 50 bar ACT VALUE DECREASE 0510 0 25 bar gt REQ VAL 03 5 25 bar After starting the second pump the pressure will be increased to a system pressure of 5 25 bar With this parameter you are able to see the calculated new required value c Active MODE 0105 Actuator Frequency XX X Hz a STOP X XX Bar 1 display in Mode actuator If parameter MODE 0105 is set to actuator the parameter REQUIRED VALUE 02 will change to ACTUAT FREQ and is equivalent to parameter 0830 By using this parameter it is possible to run the HYDROVAR up to two pre selected frequencies to manually control the HYDROVAR 02 ACTUAT FRQ 02 D1 XX X Hz Set the desired frequency with either or V The selected frequency in this parameter is only active in the actuator mode The configuration must be done with parameter C REQ VAL 1 0805 or C REQ VAL 2 0810 and parameter SW REQ VAL 0815 For manual setting of the frequency the parameters ACTUATOR FREQUENCY 1 0830 and ACTUATOR FREQU
9. 0505 ACT VAL INC jo 0505 0 35 Bar Lift value Possible settings 0 00 to the pre selected sensor range 0510 ACT VAL DEC 0510 0 15 BAR Drop value x Possible settings 0 00 to the pre selected sensor range 0515 ENABLE FRQ 0515 enable frequency for the next power unit 48 0 Hz K Possible settings 0 0 70 0 Hz Using this parameter the desired release frequency for the following pumps can be selected If a pump in the system reaches this frequency and the system pressure drops below the REQUIRED VALUE 02 ACTUAL VALUE DECREASE 0510 the next pump is started EN 0520 22 5 Enable delay time for cascade relay only Possible settings 0 100 sec If the conditions for starting an assist pump are fulfilled the fix speed pump will start after this selected time 0525 SW DELAY 0525 E ecc Switch delay for cascade relay only Possible settings 100 sec Delay time between two switching actions of the fix speed pump That parameter prevents the system against repeated switching actions caused by the variation of the consumption 0530 DISABLE FRQ 30 Hz Disable frequency for cascade relay only 0530 Possible settings 0 0 120 0 Hz The frequency to switch off the fixed speed pumps in cascade relay mode can be set by this parameter 78 If the MASTER Inverter goes below that frequency for longer than the pre selected DISABLE DLY 0535 and the system pressure is higher than the EFFE
10. Active MODE 0105 Cascade Relay Cascade Serial Cascade Synchron ADRX PX XX XHz n STOP X XX Bar 1 display at mode cascade serial and cascade relay This window shows the status of the HYDROVAR Indicates the HYDROVAR which actually controls the system ADR X Pump address Cascade relay mode Indicates the number of pumps which are running PX e g P3 MASTER 2 fixed speed pumps are running Cascade serial synchron mode Indicates the sequence of the pumps in the system depending on the MASTER PRIORITY 0570 and SWITCH INTERVAL 0555 ON Automatic and external released Stop of the HYDROVAR by pressing V STOP Manually stopped Start of the HYDROVAR by pressing To start up the HYDROVAR close external OFF External release X3 7 8 is open release or bridge terminal X3 7 8 Indication for MODE Controller Cascade Relay Cascade Serial Cascade Synchron 02 02 REQUIRED VAL D1 Bar Set the desired required value with A or V The current REQUIRED VALUE and its source by the additional information are shown in this window D1 internal required value 1 set by parameter 0820 D2 internal required value 2 set by parameter 0825 U1 required value 1 voltage signal input Connected to X3 13 U2 required value 2 voltage signal input Connected to X3 15 I1 required value 1 current signal input Connected to X3 18 I2 required value 2 current signal input Connected to X3 23 52
11. MAX FREQ 0245 0 MAX FREQ 0245 0 MAX FREQ 0245 0 MAX FREQ 0245 The functions thermal protection and external ON OFF remain still active e The functions External ON OFF Motor Overheat Lack of water and all other internal protections still work In the actuator mode it is also possible to work with pre selected frequencies for a manual control of the HYDROVAR It is possible to set two different frequencies in the submenu REQUIRED VALUES 0800 A changeover of these frequencies can be done with parameter SW REQ VAL 0815 f Hz 1 3 2 3 3 3 OFF ON 2 fmax po aii qut 0255 f fmin Fo ue 0255 f gt 0 PIC M qe range of control s Bees PN cid fmin n m m m Te OVdc E f min 10Vdc OmA signal range zeropoint 20mA AmA f max 20mA 62 0106 PUMP ADDR 0106 4 Select desired address for the MASTER Inverter Possible settings 1 8 Set desired address on each MASTER Inverter and press gt button for approx 3 sec and the following massages will appear Addressing E 1220 PUMP ADDR 1220 PUMP ADDR Addressing 1 Addressing done Addressing failed retry When using MASTER and BASIC Inverters together in a multi pump system you have to consider that the BASIC Inverters have their separate address Otherwise a correct function of the system couldn t be guaranteed For detailed Information see chapter 9 4 3 2 Addressing 0110 Set
12. externally via the digital inputs With the following parameters the source of the required values and the change over can be configured 0810 C REQ VAL 2 0810 OFF Configuration required value 2 Possible settings OFF digital analog U 0 10V analog 0 20mA analog 4 20mA OFF Required value 2 is not used digital The internal required value 2 is used Setting in the main menu in Parameter 02 or Parameter 0825 The required value 2 is determined by the value of a voltage anao WN signal 0 10V connected to terminals X3 15 X3 16 GND A5 The required value 2 is determined by the value of a current analog 1 0 20mA 4 20mA or 0 20mA connected to terminals X3 23 X3 22 GND Notice If the incoming current signal falls below 4mA 4 20mA analog 14 20mA gt setting a warning message is shown on the display If the failure is still active after 20 seconds an error message will be shown 84 Ts 0815 SW REQ VAL Switching between required value 1 and 2 Setpoint 1 Possible settings Setpoint 1 Setpoint 2 Switch Dig 1 Switch Dig 2 Switch Dig 3 Switch Dig 4 Setpoint 1 Only required value 1 is active No switching possible Setpoint 2 Only required value 2 is active No switching possible Switch Dig 1 Manual switching by closing digital input 1 X3 9 10 Switch Dig 2 Manual switching by closing digital input 2 X3 6 10 Switch Dig 3 Manual switching by closing digital input 3 X3
13. gt button till RESET appears 1130 1130 CLR MOTORH Clear motor hours for selected unit UNIT X or on ALL Cascade Serial Synchron Possible settings 1 8 ALL Set desired unit where the Motor Hours should be cleared or ALL and press button till RESET appears 1135 CLR OPERAT ULE Press gt 3 sec Clear operation time The operation time indicates the total time the HYDROVAR is already connected to power supply For reset the operation time of the current HYDROVAR press button till RESET appears 90 1200 SUBMENU RS485 1200 INTERFACE User Interface The following 3 Parameters are necessary for the communication between the HYDROVAR and an external device e g PLC via standardized Modbus protocol Set desired address Baudrate and Format according the system requirements 1205 ADDRESS 1205 Set desired address for the user interface Possible settings 1 247 1210 LALO Baudrate for user interface 9600 Possible settings 1200 2400 4800 9600 14400 19200 38400 1215 FORMAT 1215 RTU N81 Format for user interface Possible settings RTU N81 RTU N82 RTU E81 RTU 081 ASCII N72 ASCII E71 ASCII O71 Internal Interface If several MASTER Inverters are connected via the internal RS 485 interface max 8 using cascade serial mode each HYDROVAR needs its own allocated pump address number 1 8 Each address may only be used once 1220 221 bid ADDIR Select desired address for the MASTER Inver
14. the pump gt bypass line for circulation pumps 0260 FMIN TIME 0260 0s Delay time before shut off below MIN FREQ Possible settings 0 100 sec After running the pump for this selected time at minimum frequency the pump will stop if parameter CONFIG FMIN 0255 is set to f gt 0 NOTE Problems with shut off the pump at no demand too small or no pressure tank may be solved as the system pressure is increasing during this delay time 0265 BOOST Setting of the motor starting voltage in of 0265 5 connected supply voltage Possible settings 0 25 of the input voltage This parameter determines the characteristics of the voltage frequency curve In particular it refers to the voltage increase during the motor starting stage as a percentage of the nominal voltage Take care that settings are kept as low as possible so that the motor does not become thermally overloaded at lower frequencies If the boost is set too low a failure OVERLOAD may occur because the starting current is too high 0270 KNEE FRQ 216 50 0 Hz Knee frequency Possible settings 30 0 90 0 Hz With this parameter you can set the frequency at which the HYDROVAR should generate its maximum output voltage value of connected input voltage For standard applications this frequency should be set according the MAX FRQ 0245 Default Setting 2 Be careful This parameter should be used for special applications only Incorrect sett
15. voltage power supply network which supplies buildings used for domestic purposes e g Industrial areas technical areas of any building fed from a dedicated transformer are typical examples of second environment locations The HYDROVAR complies with the general EMC regulations and is tested according to the following standards 61800 3 2004 EN 55011 2002 Disturbance voltages Disturbance field strength Second Environment class B class C2 class class Disturbance voltages OK OK OK Warning In a domestic environment this product may cause radio interference in which case supplementary mitigation measures may be required EN 61000 4 2 2001 Electrostatic discharge EN 61000 4 3 2002 Electromagnetic field immunity test EN 61000 4 4 2001 Burst immunity test EN 61000 4 5 2001 Surge immunity test EN 61000 4 6 1996 Immunity of conducted RF Disturbance 6 Dimensions and weights HV 2 015 2 022 HV 4 022 4 030 4 040 In LUE TI All dimensions in millimetres Drawings are not to scale Lifting aids must have the proper dimensions H kg BASIC HV m HV 2 015 5 HV 2 ere HV 4 BM HV 4 BI HV 4 HV 4 040 a minimum centre distance between HYDROVAR units 300 mm b expansion space for maintenance 300 mm HV 4 055 4 075 4 110 All dimensions in millimetres Drawings are not to scale Lifting
16. 5 10 Switch Dig 4 Manual switching by closing digital input 4 X3 15 16 0820 REQ VAL 1 0820 Bar Required value 1 digital Possible settings 0 0 to the pre selected sensor range 0825 REQ VAL 2 e 0825 XX X Bar Required value 2 digital Possible settings 0 0 to the pre selected sensor range Set the desired required value with either or V This pre selected required value is active in all modes except Actuator if parameter C REQ VAL 1 0805 or C REQ VAL 2 0810 is set to digital and parameter SW REQ VAL 0815 is set to setpoint 1 2 or the REQUIRED VALUE 1 2 is selected via digital input This pre selected required value could also be taken over in the main menu with parameter REQUIRED VAL 02 if the current required value is active 0830 ACTUAT FRQ 1 0830 Required frequency 1 for actuator XX X Hz Possible settings 0 0 MAX FREQ 0245 0835 ACTUAT FRQ 2 0835 XX X Hz Required frequency 2 for actuator Possible settings 0 0 MAX FREQ 0245 Set the frequency with either or V The selected frequency in this parameter is only active in the actuator mode if parameter C REQ VAL 1 0805 or C REQ VAL 2 0810 is set to digital and parameter SW REQ VAL 0815 is set to setpoint 1 2 or the ACTUATOR FREQUENCY 1 2 is selected via digital input 85 0900 0900 SUBMENU OFFSET The different analogue inputs on terminals X3 13 24 can be used also to connect a second actual value signal as offset source
17. Password by pressing or V Possible settings 0000 9999 The pre set password 0066 can be changed After the password has been changed it is recommended to note the new password somewhere 0115 ure Po SASI Possible settings with A or V Possible settings ON OFF OFF All parameters in the main menu can be changed without the need of a password ON If the LOCK FUNCTION is activated no changes be done in all the parameters However the HYDROVAR can be started or stopped by using the push buttons A or V In order to change the set value the LOCK FUNCTION must be set to OFF 0120 Display Contrast Possible settings 10 100 Can be adjusted between 10 100 for improved appearance of the display 0125 DISP BRIGHT 0125 100 Display Brightness Possible settings 10 100 The backlight intensity of the display can be adjusted 63 0200 SUBMENU CONF 0200 INVERTER 0202 SOFTWARE 0202 HV VO14 Software version of the control board If a Remote Display is connected also its software version is shown in this window 0202 0202 SW RD 1 0 Software version of the Remote display RD and the HV V01 4 control board HV 0203 Selection of the SW version on the power board 5 00 00 Possible settings 00 02 Manual selection of the required sel and indication of the active act software version on the power board All available versions can be selected if
18. aids must have the proper dimensions mE y 39 492 Weight kg MASTER EIC LI HV 4 HV4 110 minimum centre distance between HYDROVAR units 430 mm expansion space for maintenance 300 mm HV 4 150 4 185 4 220 ees All dimensions in millimetres Drawings are not to scale Lifting aids must have the proper dimensions MASTER Gm EHE 14 00 HV4 220 minimum centre distance between HYDROVAR 550 mm expansion space for maintenance 300 mm itm 16 7 Modules Regarding the application the specific configuration for the HYDROVAR can be chosen Due to this possibility the HYDROVAR can be configured regarding the reliability and cost effectiveness for each type of application HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 m dL MI TM li A 1 ZAA WE WW S HV 4 150 4 185 4 220 20 1 2 3 4 5 6 Power unit Without one of the control cards it can be used as BASIC Inverter or as simple soft starter in a SINGLE pump application When using a SINGLE or MASTER configuration the power unit is fitted with an additional control card 4 Filter card not available for HV4 150 4 220 standard is class A Ensures EMC compliance for domestic environments Class B Mou
19. connection terminals X6 and X7 can be used if optional boards are available E g the additional relay card can be connected to the control card at connection slot X6 X5 Status Relays X4 RS485 Terminal 37 Control terminals All control cables connected to the control card have to be screened See chapter 9 3 recommended cable types External volt free contacts must be suitable for switching 10 VDC NOTE If unscreened control cables are used signal interference may occur and could also interfere incoming signals and the function of the HYDROVAR Do not connect the ground of the control card to other voltage potentials All electronic ground terminals and GND of the RS 485 interface are connected internally Digital and Analogue I O X3 1 GND electronic ground 2 Actual value current input sensor 1 0 20mA 4 20mA Ri 50Q 3 Power supply for external sensors 24VDC max 100mA 4 Actual value current input sensor 2 0 20mA 4 20mA Ri 50Q 6 Actual value voltage input sensor 1 Dig 2 0 10 VDC 7 External ON OFF release Active low 8 GND electronic ground 9 Configurable digital input 1 Dig 1 Active low 10 GND electronic ground 11 Low water Active low 12 GND electronic ground 13 Voltage signal input required value 1 Offset 0 14 GND electronic ground 3 KN 15 Voltage signal input required value 2 Dig 4 o sc Offset 16 GND electronic ground 17 GND elect
20. maintain pressure in the line when there is no water demand This avoids the pump from continuing to run at zero demand With the HYDROVAR no large tanks are required for supply purposes The tank must be permitted and suitable for systems pressure The tank should have a capacity of min 10 of the maximum system flow rate l min of one pump also valid for multi pump system Example Maximum flow rate of the pump 250 litres per minute Minimum volume of the tank 250 0 10 25 litres The pre charge pressure of the tank can be determined by using the following table required pressure bar 1 2 3 4 5 6 7 8 9 10 0 8 1 2 3 4 5 6 7 8 9 pre charge pressure bar NOTICE To check and set the right pre charge pressure please reduce the water pressure to zero by turning the HYDROVAR off 3 Product overview 3 1 Hardware configurations The HYDROVAR modular concept basically consists of two main parts the power unit and the control card In its BASIC configuration consisting of only the power unit the HYDROVAR can be used as so called BASIC Inverter In that configuration the HYDROVAR can be used as a sequence pump in a multi pump system but also as a simple soft starter for SINGLE pump applications By attaching one of the additional control cards to the BASIC Inverter the HYDROVAR can be upgraded either to the so called SINGLE or the MASTER Inverter BASIC Inverter HYDROVAR BASIC unit not available for HV 4 150 4 2
21. or water level switch required Configurable digital input 1 DIG 1 e g for switching between 2 required values or sensors External ON OFF release Actual value voltage input sensor 1 0 10 VDC DIG 2 DIG 3 Actual value current input sensor 2 0 20mA 4 20mA Ri 50Q Actual value voltage input sensor 2 0 10 VDC Sensor supply max 100 mA Actual value current input sensor 1 0 20mA 4 20mA Ri 500 Ground can be used as actual value voltage input and also as digital input Also the voltage signal input on terminal X3 15 can be used as digital input X3 3 and X3 24 gt gt max 100mA 39 Connection examples e Sensor Actual value signal Input Connection of a 2 wire transducer e g standard pressure transducer PA22 Possible connections Actual value signal input 0 4 20mA 24VDC sensor supply Actual value signal input 0 4 20mA Ground Connection of an active actual value signal X3 4 X3 3 X3 2 X3 1 e Switching between two connected sensors External switching between two connected sensors by closing digital input 1 X3 9 10 How to program see SUBMENU SENSORS 0400 22 10 34 Sensor 2 Sensor 1 digital input 1 Standard pressure transducer PA22 brown white e Switching between two different required values External switching between two connected required value signals e g between voltage and current signal input by closing digital input 1
22. over pressure 0225 Ramp 3 Slow acceleration time 70 sec Possible settings 1 1000 sec e Excessively fast running up time may lead to oscillation and or an error OVERLOAD e Excessively slow running up time can cause a drop of the outgoing pressure during variation of the demand 0230 MU ET Ramp 4 Slow deceleration time 70 sec Possible settings 1 1000 sec e Excessively fast running down time leads to oscillation of the HYDROVAR and thereby of the pump e Excessively slow running down time can cause pressure fluctuations during variation of the demand 0235 RAMP FMIN A 0235 Ramp Fi acceleration Possible settings 1 0 25 0 sec Fast running up time to start up the HYDROVAR till the selected MIN FREQUENCY 0250 is reached Beyond the minimum frequency RAMP1 0215 fast acceleration ramp starts to work e Excessively fast running up time may cause an error OVERLOAD during the HYDROVAR starts up 67 0240 RAMP FMIN D 0240 2 0 sec Ramp F deceleration Possible settings 1 0 25 0 sec Fast running down time to stop the HYDROVAR immediately below the selected MIN FREQUENCY 0250 e Excessively fast running down time tends to cause an error OVERVOLTAGE 0245 MAX FRQ ue 50 0 Hz Maximum frequency Possible settings 30 0 70 0 Hz This parameter determines the maximum speed of the pump The standard setting is according to the nominal frequency of the connected mo
23. safety devices which switch off the control element in the event of a fault whereby the motor has zero current but remains energised and comes to a halt The motor can also be halted by mechanical blocking If it is switched off electronically the motor is current less from the mains voltage through the electronics of the HYDROVAR but is not potential free in the circuit In addition voltage fluctuations especially power failures can cause the system to switch itself off Repair of faults can cause the motor to start up again automatically The system may only be put into operation when it has been grounded In addition to that equipotential bonding of all conductive pipes must be ensured Please consider local installation standards High voltage tests of the HYDROVAR or the motor may damage the electronic components Hence bridge the in and outgoing terminals L1 L2 L3 U V W before To avoid incorrect metering by capacitors incorporated in the electronic part isolate the motor from the HYDROVAR 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 Transport handling storage disposal e Check the HYDROVAR immediately after delivery receipt for damage or missing parts e The HYDROVAR unit must be transported carefully e Avoid se
24. supply before any work can be carried out on the electrical or mechanical part of the system Installation maintenance and repair work may be carried out only by trained skilled and qualified personnel Unauthorized modification or changes to the system make all guarantees null and void During operation the motor can be stopped by opening a digital input or manual operation whereby the HYDROVAR and the motor remain under voltage For safety reasons the HYDROVAR has to be disconnected from the power supply when carrying out work on the machinery When the HYDROVAR is connected to the power supply the components of the power unit as well as certain components of the control unit are connected directly to mains Touching these components seriously endangers life Before removing the HYDROVAR 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 the capacitors in the intermediate circuit are discharged by the internal discharge resistors Voltages of up to 800 volts are possible in case of error these also can be higher All work carried out on the HYDROVAR may only be performed by qualified and authorized staff Furthermore take care not to short circuit the neighbouring components when connecting the external control wires All cable ends which are not in use have to be isolated The HYDROVAR contains electronic
25. the above mentioned points and to guarantee EMC compatibility and correct function of the HYDROVAR the recommended cable types should be used Application Recommended cable type Motor cables HV 2 015 2 022 4G1 5 2x 0 75 HV 4 022 4 030 4 040 4G1 5 2x 0 75 HV 4 055 4 075 4G2 5 2x 0 75 HV 4 110 4G4 2 0 75 HV 4 150 4 185 4G6 2 0 75 HV 4 220 4G10 2x0 75 JE Y ST Y BD Control and signal cables JE LIYCY BD Cables connected to RS485 interface JE Y ST Y 2x2 x 0 8 BD 27 9 4 Wiring and connections Remove the screws holding the top cover of the HYDROVAR Lift off the top cover The following parts can be seen on a HYDROVAR MASTER SINGLE Inverter HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 A Power supply B Motor connections C Terminal block START STOP PTC D RS 485 Interface E Status Relays SOLORUN User interface RS 485 Interface Internal interface F optional Relay Card 9 4 1 Main voltage terminals The power supply is connected to the power section Terminal L 1 x 230 SINGLE phase Terminal L1 L2 L3 3 x 400 VAC three phase HV 2 015 2 022 HV 4 022 4 030 4 040 L1 L2 L3 3x400 VAC Motor connection U V W Crimp connection 6 3mm Power supply HV 4 055 4 075 4 110 HV 4 150 4 185 4 220 ees Motor aS er T T connection d ANY m L zi 7
26. the unit should be checked from time to time All modifications must be done by qualified personnel For mounting and repairs at the HYDROVAR qualified service technicians are available Demounting The HYDROVAR must be disconnected from the power supply before any work can be carried out Consider the pump and motor instruction Please wear your personal protection equipment For further information please ask your distributor 99 Programming flow chart SOLLSONSVIG Xx nNaWans Ov H3LH3MANI A XXX H31H3JANIL1OA SNLVLS HOuua ON nNa3Wans 0c douua HLS XX XXXXX SYNOH XX XXXXX HSITON3 ASVNONVI ZH 83 LNdLNO XX YALYAANIYYND HOHH3 ON HLY p jqeu 318VN3 330 LYVLS OLNV 330 JN TVA 1 15 oD XX 96 XX H31H3ANI dii3 L HOHuua ON douua qae 39IA3d SNLVLS TVA 333 LO H31H3ANI 135 HdOuua ON douua LO ADIAAG 123 13S XXQZ XX XX TVA aauino3g XXXX XX XX 1 aoasd SOLLSONSVIG OV HOHH3 ON 151 00000000 SNLVLS SLINN 501715 NNAWENS 0c S E ZH IN31AX 100 HLINO 3ON3nO3S nN3Wans 00S YOSNAS nN3Wans 00v nN3Wans 00 H31H3ANI JNOO nN3Wans 00 SONILLAS 21579 nN3Wans 00 AllHOIlHdlSIN 07S ZH 00 WITHONAS 09S ZH 0 05 ATE
27. to 8 HYDROVARs in a multi pump system minimum 1 MASTER Inverter For the connection to each HYDROVAR via the RS 485 interface the terminals X2 1 3 on the power unit can be used twice Or the terminals X4 4 6 on the control card can be used X2 GND OO SIO C RS485 internal interface sio C C Mechanical connection of the terminal Use recommended cable type see chapter 9 3 Strip the end of the used wire about 5 6mm push down the orange wedges by using a small screwdriver insert the stripped wire remove the screwdriver to fix the wire To remove push down the orange wedges and pull out the wire Connection example using one MASTER and three BASIC Inverters HYDROVAR Master Inverter HYDROVAR Basic inverter HYDROVAR Basic Inverter Control Card Power Unit Power Unit GND 2 SIO 2 SIO A B PoP IPS PSPC SPP PTET Pee Pere S 33 Basic Inverter 9 4 3 2 Addressing When using the cascade serial synchronous mode in a multi pump application where more than one MASTER Inverter or even BASIC Inverters are used the right address must be set to ensure a proper communication within the system MASTER Inverter The desired address of the MASTER Inverter has to be set via the HYDROVAR software In this case for all MASTER Inverters t
28. version of BASIC is production date gt 05 2008 After pressing button for 5 seconds the selected specification is activated and DONE 15 displayed Following parameters 0285 0286 0290 and 0291 are added to the menu only on units 5 5 22kW The required version can only be activated if all devices are updated to the new version else version will be automatically re set to the next lower version Setting 00 all units with production date prior 05 2008 Setting 01 BASIC 1 5 4kW starting with control board software V01 3 see 47 Setting 02 BASIC 5 5 22kW starting with control board software V01 3 0205 MAX UNITS 0205 06 Maximum number of units jo Possible settings 1 8 Select The maximum number of units which can operate at the same time For example Cascade Serial 1 MASTER and 2 BASIC Inverters are installed in a multi pump system reasonable values 1 3 Cascade Relay 1 MASTER Inverter and 3 fixed speed pumps gt reasonable values 2 4 64 0210 INVERTER Selection of the HYDROVAR address for 0210 ALL parameterizing jo Possible settings ALL 1 8 If several HYDROVAR MASTER Inverters and even BASIC Inverters are connected via the RS 485 interface the parameterization of all the settings in SUMBENU 200 can be done via one unit and will be taken over by other units in this group If only a specific unit needs to be programmed you have to press the button for 3 sec and then choose thi
29. 0 e Multiple cable entry M50 8 2 5 Ready made motor cables Available for HV 2 015 4 220 22 8 3 Assembly instructions HV 2 015 HV 4 110 4 screws to fit cover M4x50 M5x20 HYDROVAR top cover M6x70 LL 4screws M5x70 display centering bit fan cover im motor motor conduit box 23 4 screws 4 mounting clamps V motor cable a g A E v actual value sensor IT HV 4 150 HV 4 220 T To remove the HYDROVAR cover the 4 fastening screws must be opened e Ensure that there is no liquid on the unit before you open the cover e Centre the HYDROVAR on the motor fan cover using the rubber centre bit If the HYDROVAR is mounted on a motor with plastic fan cover a stainless steel mounting ring must be used e The HYDROVAR is installed on the motor fan cover by using the mounting brackets the four screws and the relevant washers e The HYDROVAR has to be centred and then the four screws must be tightened e Tighten each fastening screw until the two bottom teeth in the brackets start to grip the fan cover e After the electrical components are connected the top cover of the HYDROVAR can be mounted and tightened by the four fastening screws Make sure of a good connection of ground wire e Ensure HYDROVAR cover gasket is in place before tightening the fastening screws e En
30. 20 Application Sequence pump in a multi pump system SINGLE pump operation as soft starter SINGLE Inverter HYDROVAR BASIC Inverter with included control card for SINGLE pump operation This SINGLE Inverter is not able to support any optional modules like the Relay Card Application Simple SINGLE pump applications MASTER Inverter HYDROVAR BASIC Inverter including the high level control card supports also the optional modules like the Relay Card and all specific software features Application SINGLE pump control including all extended features Multi pump system of MASTER and BASIC Inverters up to 8 pumps Multi pump system equipped with up to 8 MASTER Inverters Control of up to 5 fixed speed pumps when used in combination with the optional relay card 3 2 Operating modes 3 2 1 Actuator for SINGLE pump operation only In this mode the HYDROVAR operates as an actuator according an external speed signal or continuous operation on either one or two programmed frequencies by using the corresponding digital input Please consider that this mode is only possible with a HYDROVAR MASTER or SINGLE Inverter and is limited for SINGLE pump operation only 3 2 2 Controller This mode is set as default operating mode and is used for a HYDROVAR in SINGLE pump operation when there is no connection to any other HYDROVAR via the internal RS485 interface 3 2 3 Cascade Serial Synchronous not for SINGLE version In thes
31. 4 055 HV4 110 Placed at the front side of the HYDROVAR under the control card S1 activation HV filter capacitor Open default setting change of position by the end user only after consultation of your local service partner Closed only for specific requirements referred to RFI S1 WARNING The switch may not be opened in case the HYDROVAR is still connected to the main supply Before changing the position of the switch ON OFF you have to be sure that the HYDROVAR is disconnected from the mains supply 36 9 4 5 Control unit Regarding the hardware configuration of the HYDROVAR two different control cards are available The control unit of the HYDROVAR MASTER Inverter basically consists of the control card and the additional boards which are connected to the control card via slot connectors This configuration is able to support all special software features and optional boards The second available control card included in the HYDROVAR SINGLE Inverter is developed just for SINGLE pump operation This control card doesn t support any additional boards and includes just the necessary software parameters for SINGLE pump applications 9 4 5 1 Control card HYDROVAR MASTER Inverter The control card is connected to the power unit via a ribbon cable on terminal X8 e The display is connected to terminal X9 ET The display can be mounted in normal position 0 or upside down 180 for HV2 015 4 110 e The
32. 4 kW Hardware configurations Motor mounted unit MASTER Inverter Enclosure class IP 55 EMC filter B Filter domestic environment Optional components Display Relay Card Hardware version G Language 1 Western Europe respectively all languages Software version V01 4 13 5 Technical Data HYDROVAR Incoming power supply data only for dimensioning of the power supply line and not for calculating the efficiency of the HV Voltage limits nominal recommended maximum 48 62 Hz current input line protection cross section M N 14 0 1 230 15 3 380 460 15 3 380 460 15 221 25 L 299 3 390 50 3 380 460 15 481 so 25 559 63 HYDROVAR Output to the motor type rated max output voltage nominal motor connection cables output current output 7 0 T 3x U axt 5 4 4 3 0 4 2 5 4x4 pra Make sure that the electrical data of the HYDROVAR match those of the electric pump Improper combinations may cause errors and malfunction of the protection of the electric motor A 20 25 13 13 16 20 25 32 50 50 63 The nominal current of the motor must be lower than the rated current of the HYDROVAR to prevent overheating or shutdown due to OVERLOAD The max output current of the HYDROVAR could reach 110 of the nominal current for max 60 sec before the error OVERLOAD will occur 5 1 General technical data Ambient tem
33. 8v SH 001 541135 nNaWNans 0011 NNYLSAl 0001 1358340 006 008 SLNdLNO NNAWSENs 004 Suouu nNaWans 009 102 XYLEM WATER SOLUTIONS AUSTRIA GMBH Ernst Vogel Strasse 2 2000 Stockerau Osterreich Telefon 43 0 2266 604 Telefax 43 0 2266 65311 e mail info austria xyleminc com web www xylemaustria com Xylem Water Solutions Austria GmbH reserves the right to make modifications without prior notice 2012 Xylem Inc
34. 910 LEVEL 1 0910 Offset active between 0 and LEVEL 1 Possible settings OFFSET RANGE 0912 2d Offset signal value Possible settings LEVEL 1 Designation of the x coordinate as absolute value 0913 OFFSET Y1 0913 0 00 bar Desired value Possible settings 0 standardization of the sensor Desired value designation of the y coordinate as absolute value 0915 LEVEL 2 0915 100 Offset active between LEVEL 2 and OFFSET RANGE Possible settings LEVEL 1 OFFSET RANGE 0917 E Offset signal value 100 Possible settings LEVEL 2 OFFSET RANGE Designation of the x coordinate as absolute value 0918 OFFSET Y2 0918 0 00 bar Desired value Possible settings standardization of the sensor Desired value designation of the y coordinate as absolute value 87 KN EN EN EN Example for using the Offset function Constant pressure system with required value of 5 bar Additionally a flow sensor is connected to the Offset input Parameter 907 Offset Range 160 max range of flow sensor 16m3 h System requirement 1 5 bar constant pressure while the flow rate is between 5m3 h and 12m3 h Below the 5 m3 h the pressure should be decreased with the limitation to have max 2 5 bar at a flow rate of 2m3 h Settings Parameter 0910 Level 1 50 5m3 h first limit where the offset function is active Parameter 0912 Offset X1 20 2mJ h fixed point acc
35. AILURE TEXT DATE TIME Press or V to scroll up or down 2 2nd ERROR 27 ERROR XX 2nd error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 28 3rd ERROR 28 ERROR XX 3rd error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 29 4th ERROR 29 ERROR XX 4th error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 30 5th ERROR 30 ERROR XX 5th error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 58 40 SUBMENU 40 DIAGNOSTICS 41 41 PROD DATE production date of the HYDROVAR MASTER SINGLE only In this parameters the current temperature voltage and frequency of the chosen HYDROVAR can be monitored even during operation of the unit These parameters are only to read 42 SEL INVERTER 42 sq Selection of the desired unit Possible settings 1 8 43 TEMP INVERTER 43 XX Temperature of the selected unit The current value determines the temperature inside the selected HYDROVAR and is shown in C and also in percent of the max allowed temperature 44 CURR INVERTER 44 XXX Current of the selected unit This value determines the output current of the HYDROVAR in percent to max rated current output e 45 VOLT INVERTER 45 XXX
36. CDs e The RCD has to be installed according local regulations Automatic circuit breaker e Use automatic circuit breaker with C type characteristic curve e Rating of the line protection see chapter Technical Data Internal protective devices of the HYDROVAR e The malfunctions short circuit under and overvoltage overload and the overheating of the electronic components are monitored internally by the HYDROVAR External protective devices e Additional protective functions like motor overheat and low water protection are controlled by external equipment 25 9 2 EMC electromagnetic compatibility To ensure the electromagnetic compatibility the following points must be observed for cable installation Earth ground to ensure EMC e Protection earth It is important to connect the HYDROVAR to PE because of the earth leakage current e HF earth connection Ground cables should be as short as possible and with lowest impedance Signal cables Control and signal cables should be screened types to prevent disturbances from outside The screen should be only connected to ground on one end to prevent ground loops The screen should be connected to HYDROVAR GND use pre mounted cable clips For small cable diameters the cable clips can be squeezed to ensure fixing To connect a screen with lowest impedance to ground remove the insulation from the signal cable and connect the screen to ground Signal cables mus
37. CTIVE REQ VALUE 03 REQUIRED VALUE 02 ACTUAL VAL INC 0505 the first assist pump stops 0535 DISABLE DLY 0535 DRE Disable delay time for cascade relay only Possible settings 0 100 sec Delay time before switching off the assist up pumps in cascade relay mode 0540 DROP FRQ uen 42 Hz Drop frequency for cascade relay only Possible settings 0 0 70 0 Hz This parameter is used to prevent the system from pressure hammers Before a following pump starts up the MASTER Inverter will drop to the selected frequency If the DROP FREQUENCY is reached the follow up pump gets released and the MASTER Inverter will continue with normal operation 0545 dors p Overvalue for cascade relay only Possible settings OFF pre selected sensor range If this selected value is reached an immediate shut off of the follow up pumps is executed E g REQUIRED VALUE 02 5 00 bar OVERVALUE 0545 7 50 bar If three pumps are running 1 MASTER Inverter 2 follow up pumps and a system pressure of 7 50 bar is reached one after another assist pump is switched off This parameter prevents the system against overpressure in case the HYDROVAR has been parameterized incorrectly 0550 y Cors Overvalue delay for cascade relay only Possible settings 0 0 10 0 sec Delay time to switch off an assist pump in case the actual value exceeds the OVERVALUE 0545 limit 79 0555 SWITCH INTV Switch interv
38. DROVAR is fitted with an additional Relay Card in selected mode Cascade Relay To switch the fixed speed pumps via the internal Relay Card an external panel for the contactors of the D O L or STAR DELTA starters and optional A 0 M switch is required In the example below 3 fixed speed pumps are connected to the Relay Card For such an application an optional HAND OFF AUTO switch SW1 SW2 and SW3 is recommended During normal operation the switch is set to AUTO so the Relay Card of the HYDROVAR starts and stops the connected pumps The HAND position allows a manual operation of the pumps f one of the additional switches is in OFF position the related relay must be disabled in the submenu STATUS 20 to ensure correct operation of the multi pump system Mains 3 3x 400VAC Ext Power Supply COM 4 AlS Relay 5 Z 4 Relay 4 4 Relay3 2 Relay 2 i Relay 1 4 45 9 4 5 3 Control card HYDROVAR SINGLE Inverter not for HV 4 150 HV 4 220 The control card is connected to the power unit via a ribbon cable on terminal X8 The display is connected to terminal X9 The display can be mounted in normal position 0 or upside down 180 X5 Status Relays X3 Digital Analogue 1 O RS485 Terminal 46 Control Terminals control cables connected to the control unit have to be screened See chap
39. ENCY 2 0835 can be used For detailed information how to run the HYDROVAR by manual control see submenu REQUIRED VALUES 0800 Parameter 03 is not shown in Mode Actuator 53 04 START VALUE 04 OFF Regulation Restart Value Possible settings 0 99 96 OFF This parameter defines the start value after pump stop in percentage of the required value E g REQUIRED VALUE 02 5 0 bar START VALUE 04 80 96 gt 4 0 bar If the pump system has reached the required pressure of 5 0 bar and there is no more consumption the HYDROVAR shuts off the pump When the consumption increases and the pressure drops the pump normally starts If a START VALUE 04 of 4 0 bar has been selected the pump won t start until the pressure drops below The following parameters in the main menu are valid for all selected modes 05 E Language selection ENGLISH Possible settings To select the desired language press A or V The information on the display and all parameters are available in various languages The languages available are split in different language blocks which support different language sets For detailed information see chapter 4 With the following two parameters the current date and time can be set This is used to display failure messages with accurate date and time when the failure occurred 06 DATE 06 DD YYYY Current date Set the date by pressing for approx 3 sec P to set current DAY MONT
40. H and YEAR 07 TIME 07 HH MM Current time Set the time by pressing for approx 3 sec to set current HOUR and MINUTE 54 08 AUTO START 08 Auto Start ON Possible settings ON OFF Select ON with A or OFF with the V button If AUTO START ON the HYDROVAR starts automatically in case of demand after reconnection of power following disconnection If AUTO START OFF the HYDROVAR won t start automatically after reconnection of power following disconnection After remedy of the failure or reconnection of the power supply the following message is shown AUTO START OFF XYLEM XX X Hz STOP Bar Press to restart the HYDROVAR 09 OPERAT TIME 09 0000 h Operating hours Total operating hours How to reset see parameter CLR OPERAT 1135 55 20 20 SUBMENU STATUS Status of all units within a pump group Using this submenu it is possible to check the status including failures and motor hours of 21 STATUS UNITs all connected units 21 Status of all units 00000000 4 This parameter gives a quick overview about the status of the connected units In Cascade serial synchron mode the status of all max 8 connected units is shown whereas 1 activated O deactivated In Cascade relay mode MASTER is equipped with additional Relay Card the status of the 5 Relay switching contacts is shown E g Mode Cascade serial synchron 21 STATUS UNITs 11001000 e Unit 1 2 and 5 are run
41. QUIRED VALUE 02 Set HYSTERESIS 0315 in Set HYSTERESIS 0315 in ONS RES a 4Q4 p a ddp ina 7 77 777 5z 7 7 WINDOW 0310 1 a setting in 9o of P O P Tm m TTE ud UEM T MAN ma rn cd E the required nene FMIN TIME 0260 MIN FREQ 0250 e t s acceleration sene Actual Value deceleration Output Frequency Ramp 1 speed ramp fast increase R2 Ramp 2 speed ramp fast decrease R3 Ramp 3 speed ramp slow increase R4 Ramp 4 speed ramp slow decrease RA Ramp F RD Ramp F min min 66 0215 RAMP 1 0215 dec Ramp 1 Fast acceleration time Possible settings 1 250 1000 sec e Excessively fast running up time may cause an error OVERLOAD during the HYDROVAR starts up e Excessively slow running up time may cause a drop of the outgoing pressure during operation 0220 Ramp 2 Fast deceleration time Possible settings 1 250 1000 sec e Excessively fast running down time tends to cause an error OVERVOLTAGE e Excessively slow running down time tends to generate
42. RT STOP external release when using a BASIC Inverter SOLO RUN S L st E SOLO RUN 4 7 E A PTC n START STOP PTC 31 To ensure safety operation between the HYDROVAR and the motor a motor thermo switch or PTC should be connected to the power unit Additionally this input can be used as an external ON OFF signal when using the HYDROVAR just as BASIC Inverter Both the signals must be connected to X1 PTC in series and will stop the HYDROVAR in case of a failure Also a low water switch or any other protective devices can be connected to these terminals If there is no use of this input terminals X1 PTC have to be bridged otherwise the HYDROVAR will not start automatically 9 4 3 1 Solo The terminals X1 SL are used to release a BASIC Inverter when used in a multi pump application when the communication to the MASTER Inverter fails or even the MASTER Inverter fails itself or in case the BASIC Inverter is just used as a simple soft starter e By opened contact X1 SL the HYDROVAR works in standard operation So a BASIC Inverter only starts up if it is released and requested by a MASTER Inverter via the serial RS485 Interface e When contact X1 SL is closed the HYDROVAR starts up to pre selected MAX FREQUENCY fixed speed 0245 using Ramp 1 and 2 and even the fast ramps FminA and FminD X1 PTC must be closed too all external connected safety devices are still active A ma
43. U OUTPUTS rec PEE Ea FORE SR ES UR 83 0800 SUBMENU REQUIRED VALUES 84 0900 SUBMENU OFESET a5 etsi bor a eae iene 86 1000 SUBMENU TEST 89 1100 SUBMENU SETUP 5 tea d ta ea ric Er ete ra cS Va ed candies 90 1200 SUBMENU 5485 nennen nnn nennen nnn nnn 91 T ToFalure niessdQg8s mua DN P 92 Tit BASIC INVE arna 93 11 27 MASTER SINGLE lnVertet 94 11 3 cda Eel T 97 MaintellaliC G5 99 Programming TOW E E EUN UEM 100 Follow the pump operating and maintenance instructions We reserve the right to alter specifications 1 Important safety instructions Read and follow the operating and safety instructions carefully before starting operations All modifications must be done by qualified technicians Warning that failure to observe the precaution may cause electric shock Warning that failure to observe the precaution may cause personal injury or damage to property In addition to these operating instructions please pay attention to universal safety and accident prevention regulations Basically the HYDROVAR must be disconnected from the power
44. V Voltage of the selected unit This value determines the input voltage connected to the HYDROVAR e 46 OUTPUT FREQ ge XX X Hz Output frequency of the selected unit This value determines the output frequency generated from the HYDROVAR 47 Specification version of the selected device This parameter gives information about the software version of the BASIC drive located on the main board Possible indications 00 All power sizes HV2 015 4 110 prior production 05 2008 Power sizes HV2 015 4 040 related to control board software V01 3 and above Power sizes HV4 055 4 220 related to control board software V01 3 and above 59 60 60 SUBMENU SETTINGS Before entering the submenu settings these instructions must be read carefully to prevent incorrect settings which will cause malfunction All parameters can also be set during operation Therefore different parameters in the extended submenu should be used only by trained and qualified persons It is suggested stopping the HYDROVAR by pressing V in the main menu during changing parameters 61 d jede entering password 0066 Default by pressing or V NOTICE If the submenu is opened with the correct password it will remain open for a time period of 10 minutes without the need of enter the password again to access the secondary menu 61 PASSWORD Confirm by pressing and the first window of the sub 0066 menu is shown 62 JOG 0 0Hz Both current
45. VAR Master Inverter HYDIRONAR Basic Inverter HYDROVAR Basic Inverter HYDROVAR Basic Inverter POPP PCCP ee tr 0 5 5 Q WENEENRERMTESEEETEENRAEMSMAERENMTATEMTMEENMEMETNM REWEREMHTEEEEEETENREANEASEMMATENTMEMEMEETTEENT Control Card Power Unit Power Unit Power Unit GND 2 SIO Z 5 SIO A PoP IPS PSEC SPP PTET Pere eee Pe S By using the RS485 User interface on the control card one or more HYDROVAR can communicate via the standardized Modbus protocol with an external control device e g PLC This interface can be used for parameterization and controlling the HYDROVAR via external devices Also active for HYDROVAR SINGLE Inverter configuration Do not use the internal interface as user interface and vice versa HYDROVAR User Interface PLC aM EMAEEESTEREEERATATARTRTATEMEATEETEATEEATTEERETATATARTETEETETSEREMEETEM Pit tit Pee 42 X5 Status Relays X5 CC Status Relay 1 NC NO CC Status Relay 2 NC NO Max 250VAC 0 25A Max 220VDC 0 25A Max 30VDC 2A B W N Status Relay 1 Status Relay 2 AD XS Notice P When using the relay contacts for 3 6 NO griving an external relay a i A 2 NC E 92 5 NC corresponding RC snubber circuit or varistor 15 necessary to prevent CC Z CC disturbance of the HYDROVAR Both Status Relays on the control card can be used regarding the programmed config
46. VSIG 069 xx xx 9650 X IVOcSN3IS Gry Jeq xx x 960 0 IVO ISN3S 0 00 INNOWV 141 OEE 001 ony Oud MSIS 08c ZH 08 295 p Occ 001 1 9199 51 ZH sinoy pz ALNI HOLIMS 295 HOLIMS xx x Q 0 cSN3S SN3S ZH 0 05 1311099 330 330 Gad ZH 09 295 p l dINVU GL H LNOO dSIQ oes 0 0 A1d IVAH3AO ZH O et 295 G O3Hd dOHd Ors A da3a 18vsig pajqesip ANIWAYSAO 1eq G 0 ONI IVA LOV 91 0 OAGIWA LOV OLS 295 G ZH 8r 318VN3 0 X 1VO ISN3S 1050965 Jeq HOSN3S JNOO 017 00 01 Dojeue JONVY SN3S HOSN3S 917 08 01 AGOW SISSUSLSAH SIE MOQNIM 016 ZH 00 ZH 00 410 OHddDIS 982 0 lt ZH 09 9 99S 0 JINX 15009 G9C NIINS 09c NIN ANOO oes 0 295 04 V NINA SEC dINVd oes 0 AH JHvMldOS TIV 9 LO LO 195 SLINN ON A901 MSSVd 135 011 901 JAQON c e 0000 ZH SOF c9 QuyOMSSVd ANI USA 13S HLNO 32 5 NNAWENS 00S YOSNAS NN3AWENs 00v
47. X3 9 10 In ACTUATOR mode it is possible to switch between two different frequencies by the digital inputs The connected input signals current or voltage are proportional to the frequency How to program see SUBMENU REQUIRED VALUES 0800 3 n3 QA Digital Input 1 Qs 4 8 2 19 OQ Required value 1 external current signal Required value 2 external voltage signal X3 e Actual value frequency indicator e g to display the actual motor frequency How to program see SUBMENU OUTPUTS 0700 Possible connections oret Analogue output 1 0 10V X3 20 97 Analogue output 2 4 20mA X3 21 es 4l 41 X4 RS485 Interface XA 1 User SIO Interface SIO User SIO Interface SIO GND electronic ground 4 Internal SIO Interface SIO 5 Internal SIO Interface SIO 6 GND electronic ground User interface for external communication Internal interface for multi pump systems RS 485 Internal interface RS 485 User interface 6 GND GND 2 5 X0 2 SIO 2 4 so 2 1 so The internal RS 485 Interface is used for the communication between up to 8 HYDROVAR in a multi pump application For the connection of each HYDROVAR the RS 485 interface the terminals X4 4 6 on the control card and either the terminals X2 1 3 on the power unit can be used Connection example using one MASTER and three BASIC Inverters N HYDRO
48. ached its e For detailed information how the release temperature terminal X1 PTC could be used see chapter 9 4 3 Gn amp lissearthepewsrsupsly e check power supply under full load PHASELOSS has been lost gt automatic pies SEIS pH ERROR 16 power reduction just available for the units 4 055 4 220 visual inspection of points at the input terminals e supply voltage too low UNDERVOLTAGE DC voltage of the HYDROVAR phase failure at the input COMM LOST too low The communication between the Power Unit and the control card doesn t work correctly 95 asymmetry of the phases check if the addressing of BASIC Inverter DIP SW has been done correctly retry e check if each unit has allocated its own pump address e check if the connection from control card to the power unit is made properly ribbon cable LACK OF WATER ERROR 21 MIN THRESHOLD ERROR 22 cutting off the power supply for gt 60 seconds manual reset by closing external ON OFF Terminals X3 7 8 manual reset by pressing lt and gt simultaneously for about 5 seconds Auto reset possible if ERROR RESET 0615 is set to ON Low water contact X3 11 12 is opened just active if motor is running defined value of parameter MIN THRESHOLD 0605 was not reached during the pre selected DELAY TIME 0610 incoming pressure or min level too low bridge X3 11 12 if there is no ext low water protection
49. al for cyclic Pied edid 2A hours for cascade serial synchron only Possible settings 0 250 hours This parameter allows an automatic change over of the MASTER pump and the assist pumps in order to provide even wear and achieve even operating hours of the pumps The switch interval is used for HYDROVAR MASTER Inverters only connected via the RS 485 interface by using operation mode Cascade Serial or Cascade Synchron Synchronous Control By using the synchronous control mode all pumps in the system maintain the set pressure by running at the same frequency The 2 pump starts when the 1 pump reaches the ENABLE 0515 and the system pressure drops below ACTU VAL DEC 0510 gt both pumps will run synchronously The assist pump will stop when the frequency drops below the set SYNCHR LIMIT 0560 This function creates a hysteresis effect which prevents the assist pump against a frequent on off operation To find out the right setting e Start the first pump in JOG Mode 62 Increase the frequency till you reach the required value Check the frequency f at zero consumption e Set the synchronous limit 2 3 Hz e Set the synchronous window between 1 or 2 Hz depending on the pump curve and set point 0560 SYNCHR LIM 0560 0 0 Hz Frequency limit for synchronous control This parameter is used for switching off the first assist pump in synchronous mode So if the frequency of both pumps drop
50. cy centre Skip frequency range 0 0 5 0 Hz Current limit functionality OFF ON Current limit 10 0 100 Following parameters 0285 0291 are limited for power ratings starting from 5 5kW Size 2 and Size 3 with production date 05 08 and control board software V01 3 or above otherwise they are not visible and therefore not active 71 0300 SUBMENU 0300 REGULATION 0305 JOG 0 0Hz Both the current output frequency and actual value 0305 X XX Bar are shown e By pressing or V in this menu the internal controller of the HYDROVAR is deactivated and it changes to manual mode e Using the A and V buttons any constant speed can be set without further control to achieve the set point e f this value becomes 0 00 Hz the HYDROVAR stops e As soon as the window is left by pressing lt or the HYDROVAR returns to the selected mode 0310 WINDOW 0310 5o range of ramp control Possible settings 0 100 of required value e Determines the band where the slow ramp changes to the fast ramp e for steep pump curves and closed loop systems 20 30 0315 HYSTERESIS 0315 30 Hysteresis for ramp switching Possible settings 0 100 e Determines the band where the normal regulation is done change between the slow ramps accurate control without automatic shut off 99 e g constant flow control 0320 REG MODE 0320 Regulation mode normal Possible settings normal invers
51. de even wear and achieve even operating hours is possible in this mode This configuration is a cost effective alternative compared with other solutions using VFD s on each pump but in any case care has to be taken due to the lower reliability of such a system Application example Booster sets up to 6 pumps where only one pump is speed controlled by the HYDROVAR and the others are fixed speed 1 HYDROVAR MASTER Inverter 5 fixed speed max 5 fixed speed pumps External panel 12 4 Type designation code Software version Language 1 Western Europe resp all lang with VO1 4 3 Eastern Northern Europe Hardware version Optional components Optional card Relay Card 02 without R included Bus card Display 02 without 1 included EMC protection filter A Filter industrial environment B B Filter domestic environment Enclosure class IP Class 2 21 5 55 Hardware configurations M Motor mounted unit W Wall mounted unit 1 BASIC Inverter 2 SINGLE Inverter MASTER Inverter Rated output 0222 2 2 kW 055 5 5 kW 030 3 0OkW 075 2 7 5 kW 040 4 0 kW 1102 11kW 150215 0kW 185 18 5kW 220 22 0kW Nominal mains voltage 1 1 1 230VAC 3 3 3 230VAC 2 1 3 230VAC 4 3 3 380 460VAC Example The mentioned HYDROVAR in this example is specified with following technical data Nominal mains voltage 3 3 380 460VAC Rated output
52. dr 2 Adr 3 MASTER BASIC BASIC BASIC BASIC BASIC MASTER MASTER 81 0600 0600 SUBMENU ERRORS 0605 0605 Hs Lux ERG minimum threshold limit disabled Possible settings disabled max SENSOR RANGE e An adjusted value gt 0 00 has to be reached within the programmed DELAY TIME 0610 e f this value can t be reached the HYDROVAR stops with the failure message MIN THRESHOLD ERROR eTo disable the minimum threshold limit press W till disabled is shown on the display 0610 DELAY TIME 0610 minimum threshold limit delay time 2 Sec Possible settings 1 100 sec Delay time to switch off the HYDROVAR in case the actual value drops below the min threshold limit or a connected external low water protection at terminals X3 11 12 has been opened Notice The min threshold function is also active during start up of the pump Therefore the delay time has to be set higher than the duration that is needed to reach a value above the limit G 0615 vede jn REINES Automatic error reset Possible settings ON OFF ON Allows an automatic restart for 5 times in case of a failure If the failure is still active after the 5 restart the HYDROVAR will shut off and the appropriate error message is shown The internal counter of the automatic error reset is decreased by 1 after each operating hour so if an error could be reset after 3 restarts there are 3 further restarts possible after one hour 4 after two hours and 5 automatic r
53. e Normal Speed is increased with falling actual value signals control at constant output pressure Inverse Speed is reduced with falling actual value signal control at constant suction pressure or at constant level on the suction side 72 0325 0325 30 0 Hz Frequency limit for required lift value Possible settings 0 0 Hz 70 0 Hz Control according to a system curve increase of the set pressure depending on the flow rate speed to cover friction losses The setting determines the output frequency where the set pressure starts to be increased The right setting should be equal to the frequency when the pump reaches the set pressure at zero flow Can be determined by using the JOG MODE 0305 0330 ee Lift amount for required lift value Possible settings 0 0 200 0 This value states how much the set value should be continually increased till the maximum speed maximum volume is reached Application example _ f 100 1 Enter the set pressure see main menu il parameter REQ VAL 02 2 Find out the frequency where set a Lg Dl oS I Eesti pressure is reached at zero demand FII TIN eT use JOG MODE 0305 and set the value in parameter FREQU LIFTING 3 Set desired lift at maximum speed in 96 of the set pressure in the parameter LIFT AMOUNT 0330 A set pressure y window
54. e modes various combinations among the versions BASIC and MASTER Inverter are possible In general each of the pumps needs to be equipped with a HYDROVAR unit All the units are connected via the RS485 interface and communicate via the standard MODBUS protocol 9600 Baud RTU N81 To realise a fully controlled system at least one MASTER Inverter is needed the remaining pumps could be fitted just with a BASIC Inverter The controller in the MASTER Inverter is continuously in communication with all the BASIC Inverters All failures are indicated on the MASTER including the date and time All the control is done by the MASTER Inverter including automatic change over of the lag pumps to provide even wear and achieve even operating hours If the control card of a MASTER Inverter fails each of the BASIC Inverters can be manually started by an external switch manual operation in order to ensure an emergency operation of the system Application Example Each pump of the system up to 8 pumps is equipped with a HYDROVAR unit at least one MASTER Inverter and remaining ones can be BASIC Inverters All units are connected via the serial interface RS485 The combination of the different HYDROVAR units which are used in a multi pump system depends on the system requirements i e in a 6 pump system 2 MASTER Inverters can be used due to reliability reasons and 4 BASIC Inverters without control card or just any other combination Minimum
55. estarts after 3 operating hours A manual reset can be done by switching an external ON OFF X3 7 8 contactor Not each error can be reset automatically For detailed information see chapter 11 failure messages OFF if the ERROR RESET is set to OFF each failure would be shown on the display directly and must be reset manually 82 0700 0700 SUBMENU OUTPUTS 0705 ANALOG OUT1 0705 Analogue output 1 Analogue output 0 10V 0 100 Terminal X3 20 Possible settings Actual value Output frequency 0 fmax 0710 Analogue output 2 Actual value Actual Value Output frequency Terminal X3 21 Possible settings Analogue output 4 20mA 0 100 Possible settings Actual value Output frequency 0 fmax 0715 nio Configuration of the status relay 1 5 1 2 3 Running 0720 BER Configuration of the status relay 2 X5 4 5 6 Possible settings Power Errors Warnings StandBy Errorreset Errors of BASICs Warnings BASICs EN config explanation of status Action if status YES Relay 1 X5 1 3 closed Power HYDROVAR is connected to power supply Relay 2 X5 4 6 closed Runnin Motor is runnin Ber E posee 9 9 Relay 2 X5 4 6 closed Eror An error is indicated on the HYDROVAR Relay 1 X5 1 2 closed incl power failure Relay 2 X5 4 5 closed uw Relay 1 X5 1 2 closed Warnings A warning is indicated on the HYDROVAR Relay 2 X5 4 5 closed StandB Pum
56. f all other errors can be done by open close the START STOP_ PTC input X1 PTC on the power unit If the BASIC Inverter is used in combination with a MASTER Inverter each failure can be indicated on the MASTER Inverter too and will be saved in the failure memory including date and time when the failure appeared Indication on the MASTER Inverter For detailed failure information on the specific unit SUBMENU STATUS 20 has to be entered and the affected device has to be selected with it s pump address ERR BASIC Addr X If MASTER Inverter is used in such a system the errors which occurred on the BASIC Inverter can be reset by the MASTER without interfere the operation of the other HYDROVAR units in the system also valid for automatic Error reset 93 11 2 MASTER SINGLE Inverter Each error is shown on the display in plain text and saved in the error memory The errors can be reset automatically depending on the setting in parameter ERROR RESET 0615 or manually in following ways e cutting the power supply for gt 60 seconds e pressing lt and gt simultaneously for about 5 seconds open and close the External ON OFF Terminals X3 7 8 No error message on the display no AUTOSTART after Parameter AUTOSTART 08 is power failure set to OFF Check parameter AUTOSTART 08 Pressure higher than the start No operation even system value or REGULATION MODE check parameter START VALUE 04 pressu
57. f the connected sensor The maximum sensor range gt 20mA 100 of the sensor range must be set For example 10 bar pressure sensor gt 20mA 10bar 0 4 bar differential pressure sensor gt 20mA 0 4 bar Flowmeter Flowrate 36m3 h gt 20mA 36m3 h 0425 Dum SEI CURVE Sensor curve linear Possible settings linear quadratic Internal calculation based on the actual value Possible setting and its application e linear Pressure control differential pressure control level temperature and flow control inductive or mechanical e quadratic Flow control using an orifice plate together with a differential pressure sensor 75 0430 d Sensor 1 zero point calibration 0 actual value Possible settings 1096 up to 10 This parameter is used to calibrate the minimum value of Sensor 1 After setting the dimension unit and the sensor range the zero point for this sensor can be adjusted Adjustable range between 10 and 10 0435 SENS 1 CAL X 0 actual value Sensor 1 upper range value calibration Possible settings 10 up to 10 To set the calibration for the upper range value of sensor 1 this parameter can be used After setting the right dimension unit and sensor range the upper range value can be adjusted between 10 and 10 0440 SENS 2 CAL 0 0 actual value 0440 Sensor 2 zero point calibration Possible settings 10 up to 10 Zero point calibration for Sensor 2 for explanat
58. for the required value 0905 OFFS INPUT 0905 OFF Selection of the Offset Input Possible settings OFF analog U1 0 10V analog U2 0 10V analog 11 0 20mA 4 20mA analog 12 0 20mA 4 20mA OFF Offset disabled analog U 1 Offset will be calculated according to the voltage signal 0 10V 0 10V connected to terminals X3 13 Required Value 1 X3 14 GND analog U 2 Offset will be calculated according to the voltage signal 0 10V 0 10V connected to terminals X3 15 Required Value 2 X3 16 GND analog 11 Offset will be calculated according to the current signal 4 20mA 0 4 20mA 0 20mA connected to terminals X3 18 Required Value 2 X3 17 GND analog 12 Offset will be calculated according to the current signal 4 20mA or 0 4 20mA 0 20mA connected to terminals X3 23 Required Value 2 X3 22 GND e Notice If the incoming current signal drops below 4mA a warning message is shown on the display but the HYDROVAR keeps operating without the Offset function 0907 OFFSET RANGE 0907 100 Representation of the sensor range Possible settings 0 10000 The Offset Range can be set to a number between and 10000 Its value depends on the maximum range of the connected offset sensor Settings of the x axis are shown in the chart below E 9 16 bar sensor can be set as range 16 160 1600 The higher the set offset ranges the higher is the resolution on the signal input 86 0
59. he below shown dip switch on the power unit must be set to address 1 default setting BASIC Inverter not standard use for HV 4 150 4 220 when using a BASIC Inverter in a multi pump system it is necessary to set the dip switches on the power unit in order to get a separate address for each Inverter within your pump group Pls consider reserved addresses for the MASTER Inverters Example Multi pump system with 3 MASTER and 4 BASIC Inverters e Set address 1 3 for the MASTER Inverters via appropriate software parameters See submenu CONF INVERTER 0200 or submenu RS485 INTERFACE 1200 e Address 4 7 for the BASIC Inverters via dip switch The pre selected address is also responsible for the pump sequence Switch Switch Switch 1 2 3 OFF OFF OFF Address 1 default setting Required setting for the use with control card OFF OFF ON Address 2 OFF ON OFF Address 3 Address ON OFF ON ON Address 4 i I ON OFF OFF Address 5 ON OFF ON Address 6 1234 ON ON OFF Address 7 ON ON ON Address 8 switch 4 not used Setting of the correct address HYDROVAR must be disconnected from power supply at least for 5 minutes before removing the top cover open four fastening screws o Use the dip switch which is on the power unit see picture next page o the desired address for each HYDROVAR E g Address 4 gt switch 1 is set to OFF switch 2 and 3 are set to ON o Mount the cover on the HYDROVAR and
60. he installation site is over 2000 m above sea level please contact your local distributor or service contact HV 2 015 2 022 HV 4 022 4 030 4 040 IP 55 NEMA 4 indoor use only HV 4 055 4 075 4 110 HV 4 150 4 185 4 220 CE UL C Tick cUL 5 2 EMC requirements Electromagnetic compatibility The EMC requirements in general differ between two environments which depending on the intended use e First environment class EN 61800 3 Class C2 Environment that includes domestic premises it also includes establishments directly connected without intermediate transformers to a low voltage power supply network which supplies buildings used for domestic purposes e g houses apartments commercial premises or offices in a residential building are typical examples of first environment locations Be careful The relevant EMC regulations for which the HYDROVAR is tested in the first environment consider that the HYDROVAR is a restricted available product That means the voltage of the inverter is less than 1000 V it is neither a plug in device nor a movable device and when used in the first environment is intended to be installed and commissioned only by a person or an organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects e Second environment class A EN 61800 3 Class C3 Environment that includes all establishments other than those directly connected to a low
61. including the high level control card which supports also the optional modules like the optional Relay Card and all specific software features When using a HYDROVAR SINGLE Inverter HYDROVAR with control card only for SINGLE pump operation there are less software features in comparison to the HYDROVAR MASTER Inverter All parameters which are not active for a HYDROVAR SINGLE Inverter are marked with the following symbol Parameter not available for a HYDROVAR SINGLE Inverter Parameters which are transferred automatically within the whole group of HYDROVAR units are marked with the following symbol Global parameter interchanged on all HYDROVAR within one system NOTICE All changes will be saved automatically especially in case of a disconnection of the power supply 00 00 MAIN MENU The 1 window REQUIRED VALUE 02 and EFFECTIVE REQUIRED VALUE 03 depend on the selected mode which has been chosen with parameter MODE 0105 The differences within the windows in the different modes are shown below a Active MODE 0105 Controller Default setting XYLEM XX X Hz Spe STOP X XX Bar 1 display at mode Controller This window shows the status of the HYDROVAR ON Automatic and external released Stop of the HYDROVAR by pressing V STOP Manually stopped Start of the HYDROVAR by pressing To start up the HYDROVAR close external OFF External release X3 7 8 is open release or bridge terminal X3 7 8 51 b
62. ing can cause an overload error and even a damage of the motor 69 0275 Possible settings If a motor with lower nominal power is used the maximum output current should be adjusted accordingly 0275 POWER REDUCT OFF OFF 85 75 50 Reduction of the maximum output current The reduction of the maximum output current also affects the overload detection Output current A HV type OFF 100 85 75 50 2 015 7 00 5 95 5 25 3 50 2 022 10 00 8 50 7 50 5 00 4 022 5 70 4 85 4 28 2 85 4 030 7 30 6 21 5 48 3 65 4 040 9 00 7 65 6 5 4 50 4 055 13 50 11 48 10 13 6 5 4 075 17 00 14 45 12 75 8 50 4 110 23 00 19 55 17 25 11 50 4 150 30 00 25 50 22 50 15 00 4 185 37 00 31 45 27 75 18 50 4 220 43 00 36 55 32 25 21 50 0280 AEO SEE Selection of the switching frequency g Auto Possible settings Auto 8 kHz 4 kHz e Auto default setting In standard operation the HYDROVAR works with a switching frequency of 8kHz in order to reduce the noise level At rising temperature inside the HYDROVAR the switching frequency is decreased to 4kHz automatically e 8 kHz Selection with lowest noise level but without decrease at rising temperature e 4 kHz Reduce the temperature in the HYDROVAR 70 0285 SKIPFRQ CTR pese 0 0 Hz Possible settings 0286 SKIPFRQ RNG EE 0 0 Hz Possible settings 0290 CURR LIMIT 0290 OFF Possible settings 0291 CURR LIMIT 100 Possible settings Skip frequen
63. ion see Parameter 0430 0445 SENS 2 CAL X 0 actual value Sensor 2 upper range value calibration Possible settings 10 up to 10 Upper range calibrations for Sensor 2 for explanation see Parameter 0435 76 0500 SUBMENU 0500 SEQUENCE CNTR Using the parameters of this submenu all necessary settings can be done for running a multi pump system even in cascade relay and cascade serial synchron mode Application Example 1 Lead pump reaches its ENABLE FREQUENCY 0515 2 Actual value falls and reaches the cut in value of the 1 assist pump Cut in value 2 REQUIRED VALUE 02 ACT VAL DEC 0510 the 1 assist pump is switched on automatically 3 After the start up the new required value is calculated in the following way NEW REQUIRED VALUE REQ VAL 02 ACT VAL DEC 0510 ACT VAL INC 0505 The new required value is shown in the main menu as parameter EFF REQ VAL 03 0 0 Q Calculations of the new required value for multi pump applications number of active pumps k 1 p p k 1 lift value fall value e Lift value Fall value gt Pressure constant independent how many pumps are in operation e Lift value gt Fall value Pressure rises when assist pump switches on e Lift value Fall value Pressure falls when assist pump switches on 77 The following 3 parameters are responsible for starting the assist pumps and to calculate the new required value as well
64. ls X3 22 23 e check configuration of the required values in Submenu REQUIRED VALUES 0800 4 96 cutting off the power supply for gt 60 seconds manual reset by closing External ON OFF Terminals X3 7 8 manual reset by pressing lt and gt simultaneously for about 5 seconds Auto reset possible if ERROR RESET 0615 is set to ON 11 3 Internal errors To quit the following errors you have to cut the power supply for gt 60 seconds If the error message is still shown on the display contact customer service and provide a detailed description of the error Internal errors Error message on the display red LED on ERROR 1 EEPROM ERROR Reset after repeated error message data block malfunction change control card ERROR 4 Button error e check push buttons e g jammed key e Display board may be defective EPROM error Reset after repeated error message ERROR 5 Checksum error change control card Program error Reset after repeated error message ERROR 6 Watchdog error change control card Program error Reset after repeated error message ERROR 7 Processor pulse error gt change control card e check the installation of the cables connection of the screen and Code error potential equalization S ESI invalid processor command check earth ground e install additional inductances for the signal cables e g ferrites 97 Examples Problem no sto
65. lue selection of the submenu v Decrease of a value selection of the submenu short V Change to faster scrolling up of a value V short A Change to faster scrolling down of a value Short pressing enter submenu Change to next parameter in the menu Short pressing leave submenu Change to previous parameter in the menu Long Pressing Acknowledgement of a determined action Long Pressing Change back to the main menu 49 10 3 Display of the BASIC Inverter green OK red Error 1 Blink Undervoltage Constant Motor stop 2 Blinks Overcurrent Overload Standby 3 Blinks Inverter Overheat 4 Blinks Overvoltage 5 Blinks Code Error Blinking 6 Blinks Motor Overheat External Contact m gt W Status LED green Constant Motor stopped Standby Blinking Motor run Error LED red The type of error is indicated by the blinking code of the ERROR LED Undervoltage 2 blinks Overcurrent Overload Inverter overheat Overvoltage Code Error Motor overheat external contact is open For detailed information see chapter 11 Failure messages 50 10 4 Software parameters In the following chapters all available parameters of the main and secondary menu are listed The upper window shows the factory setting and the line below the possible range of settings The general parameter description is written for the HYDROVAR MASTER Inverter Full featured HYDROVAR
66. ning E g Mode Cascade relay 21 STATUS UNITs 10100 e Relay Contact 1 and 3 are closed EN 22 ee E Select device Possible settings 1 8 Check the current status the motor hours and the last failures which occurred The selection is depending on the selected mode 105 Select desired unit by pressing or V Mode CASCADE SERIAL SYNCHRON The selection specifies the address of the HYDROVAR units E g Device 1 gt MASTER Inverter with pre selected address 1 Device 2 gt BASIC Inverter with pre selected address 2 Device 3 gt BASIC Inverter with pre selected address 3 For set the address on a BASIC Inverter see chapter addressing To set the address on a MASTER Inverter see parameter 106 or submenu 1200 RS485 Interface 56 Mode CASCADE RELAY Device enabled by 1 MASTER Inverter 2 fixed speed pump Relay 1 10 1 3 fixed speed pump Relay2 10 2 4 fixed speed pump Relay 3 X10 3 5 fixed speed pump 4 10 4 6 fixed speed pump Relay 5b 10 5 7 not used 8 not used 23 23 STATUS DEVICE CN a Stopped us of the selected device Possible messages Running Stopped Disabled OFF Preparing Mode Casc Serial Synchr relay on relay off Mode Cascade Relay Solorun Faulted all Modes Shows the status of the device Mode CASCADE RELAY relay on gt Relay contact is closed gt fixed speed pump is running relay off gt Relay contact is opened gt fixed speed
67. nting Kit Consists of the metal and plastic cover to fix the control card and the display and the additional Relay Card if used By the pre mounted cable clips the screen of all signal cables has to be connected to HYDROVAR ground to avoid any interferences on the signals Control card either for MASTER or SINGLE Inverter Display unit 2 line plain text indication for programming and read out Relay Card The optional Relay Card allows to control up to 5 fixed speed pumps can be only used in combination with the MASTER Inverter 21 8 Mechanical components 8 1 Included mounting material Included Cable gland closing glad components Lock nut M M _ 12 16 20 25 40 12 16 50 Cable diameter mm d 2015 2022 29 2 2 53 11 ol od races Gee ERR EEEE 4 055 4 110 2 3 2 2 3 1 1 4 1 grow LT re T 4 220 4 5 2 2 4 2 1 1 4 1 max available cable entries 8 2 Optional components 8 2 1 Mounting accessories Mounting ring Avallable for diameters 140 mm CAUTION If the HYDROVAR is mounted on a motor with a plastic fan cover a stainless steel mounting ring must be used to support the weight of the Mountina HYDROVAR 8 2 2 Sensors e pressure transducer e temperature sensor e differential pressure transducer e flow indicator level sensor orifice plate inductive flow meter 8 2 3 Filter e Line coils 8 2 4 Cable entry only HV4 150 4 22
68. nual start up is always possible even the HYDROVAR is equipped with a control card For example if it is necessary because of safety reasons to operate the BASIC Inverters when the MASTER Inverters fail it is possible to equip this terminal with an AUTO MANUAL switch Connection Example gt gt External switch to enable the 2 ab aem SOLO RUN I SL SW 1 anual for example External release or 4 PTC 4 Low water switch PTC or thermo switch mounted in the motor terminal box Recommended connections of external protective devices BASIC Inverter PTC or thermal switch X1 PTC External release X1 PTC Placed on the power unit Low water switch 1 MASTER Inverter PTC or thermal switch X1 PTC Placed on the power unit External release X3 7 8 GAL AE X3 11 12 Placed on the control card 32 If the HYDROVAR is used as a BASIC Inverter in a multi pump system the internal interface on the power unit is used for the serial RS 485 connection to the other HYDROVAR units in the system Be careful Internal interface is not available in SINGLE Inverter configuration X2 RS485 Interface Power Unit X2 SIO Internal SIO interface SIO Internal SIO interface SIO GND GND electronic ground Internal interface for multi pump systems TN Parameter not available for a HYDROVAR SINGLE Inverter The internal RS 485 Interface on the power unit is used for the communication between up
69. ontact X3 7 8 is closed 1010 TESTRUN FRQ 30 0 Hz Frequency for manual and automatic test run Possible settings 0 Fmax 1015 do egi oval Setting of the motor starting voltage in 96 of input voltage Possible settings 0 25 of maximum input voltage is possible 1020 Ieee IME Test Run time 5 sec Possible settings 0 180 sec 1025 25 p DOE Select Inverter for manual test run Possible settings 01 08 1030 WAN Manual Test Run Confirm test run for selected unit Press 3 sec With this parameter it is possible to perform a manual Test Run for one selected unit Even fixed speed pumps in Cascade Relay Mode can be included into the test run function By pressing gt button for approx 3 sec a test run will be started 89 1100 1100 SUBMENU SETUP 1110 1110 EUROPE Restores the HV to factory setting Possible settings EUROPE USA To restore the HYDROVAR to factory settings select Europe or USA For reset press button till DONE appears 1120 Diod Enter password by pressing A or V The below mentioned parameters are available after entering the right password For more information pls contact your local distributor 1125 1125 CLR ERRORS Clear error memory of selected unit UNIT X or on ALL units Cascade Serial Synchron Possible settings 1 8 ALL To clear the error memory either 1 8 for one specific unit or ALL for all units can be selected For reset press
70. ording the requirements Parameter 0913 Offset Y1 2 5 2 5bar max allowed pressure at this flow rate System requirement 2 5 bar constant pressure while the flow rate is between 5m3 h and 12m3 h Above the 12 m h the pressure should be increased with the limitation to have max 6 0 bar at max flow rate of 16m3 h Settings Parameter 915 Level 2 2 120 2 12m3 h second limit where the offset function is active Parameter 917 Offset X2 160 16m3 h fixed point according the requirements Parameter 918 Offset Y2 6 6bar required pressure at this flow rate Required Value Sollwertverlauf Offseteinfluss 16 14 12 5 10 7 F 5 12m3 h gt 8 OFFSET X2 5 6 VM l OFFSET X1 OFFSET Y2 2 OFFSETY1 0 i 0 20 40 60 80 100 120 140 160 2m3 h Level 1 Offset Level 2 88 1000 1000 SUBMENU TEST RUN 1005 TEST RUN 1005 after 100 hrs Automatic test run Possible settings OFF 100 h The Automatic Test Run starts up the pump after the last stop to prevent the pump from blocking Test Run Time Frequency and Boost can be selected in the parameters below To disable the automatic test run press V until OFF appears on the display The test run is only active when the HYDROVAR is stopped but manually released and external ON OFF c
71. output frequency and actual value are 62 X XX Bar shown e By pressing A or V in this menu the internal controller of the HYDROVAR 15 deactivated and it changes to manual mode e Using the A and V buttons any constant speed can be set without further control to achieve the set point e f this value becomes 0 00 Hz the HYDROVAR stops e As soon as the window is left by pressing lt or gt the HYDROVAR returns to the selected mode 60 0100 SUBMENU BASIC 0100 SETTINGS 0105 V rds Selection of the operation mode Controller Possible settings Controller Cascade Relay Cascade Serial Cascade Synchron Actuator Controller Default Setting This mode should be selected if only one HYDROVAR MASTER SINGLE Inverter is used and no connection to any other HYDROVAR via RS 485 interface is needed Cascade Relay The standard application for this mode is one MASTER Inverter fitted with an additional Relay Card to control up to 5 fixed speed pumps No connection to any other HYDROVAR via RS 485 Interface possible Advantages costs realizing of simple systems Disadvantage quality of regulation reliability Cascade Serial Has to be selected if more than one HYDROVAR controlled pump operate together via the RS 485 interface The standard application for this mode is a multi pump system with up to 8 pumps each fitted with a HYDROVAR MASTER Inverter or a combination of MASTER and BASIC Inverters Advantages reliability swi
72. p is released manually and by external release no Relay 1 X5 1 3 closed y error warning is indicated and HYDROVAR doesn t run Relay 2 X5 4 6 closed TT If Parameter ERRORRESET 0615 is activated and a Relay 1 X5 1 3 closed Warning occurs 5 times Error gt Relay 2 X5 4 6 closed Error of Relay 1 X5 1 2 closed BASICs A failure is indicated at least on one BASIC Relay 2 X5 4 5 closed Warnings warning is indicated on the HYDROVAR or atleast Relay 1 X5 1 2 closed BASICs on one BASIC Relay 2 X5 4 5 closed 83 0800 SUBMENU 0800 REQUIRED VALUES 0805 C REQ VAL 1 alius Configuration required value 1 0805 Possible settings digital analog U 0 10V analog 0 20mA analog 4 20mA EN The internal required value 1 is used 9 Setting in the main menu in Parameter 02 parameter 0820 The required value 1 is determined by the value of a voltage signal 0 10V connected to terminals X3 13 X3 14 GND The required value 1 is determined by the value of a current signal analog 1 0 20mA 4 20mA or 0 20mA connected to terminals X3 18 X3 17 GND Notice If the incoming current signal drops below 4mA 4 20mA analog 1 4 20mA setting a warning message is shown on the display If the failure is still active after 20 seconds an error message will be shown analog U 0 10V The changeover between the 1 and the 2 required value can be done either internally or
73. p of the HYDROVAR Parts to check measure e existing demand e check pipes and valves e non return valve is not closed e change non return valve e pre charge pressure in the pressure tank e adjust according the diagram e set WINDOW 0310 ca 10 and e incorrect setting of WINDOW and HYSTERESIS 0315 80 50 RAMPHYSTERESIS e set RAMP 2 0220 to 4 13 sec e shut down ramp too slow e the MINIMUM FREQUENCY 0250 should be e suction line too long activated for pressure increase at 0 demand Control on constant flow Problem control fluctuations Parts to check measure enlarger WINDOW 0310 and set control characteristics are set too low HYSTERESIS 0315 to 9996 to control with RAMP 3 and 4 Circulating pump Problem oscillation of the motor speed Parts to check measure e increase RAMP 0225 and 4 0230 100 200sec e WINDOW 0310 ca 20 and HYSTERESIS 0315 ca 99 control settings too fast Problem ACTUAL VALUE can t be hold Parts to check measure HYSTERESIS is set too big HYSTERESIS 0315 90 99 Problem pressure fluctuations analogue signal not constant Solution check cables and connection of the screen e check earth connection of the transmitter cable e use screened cables 98 Maintenance The HYDROVAR does not require any special maintenance However the cooling fan and the vents should be free of dust Also the temperature around
74. perature 0 40 C Storage temperature Humidity Air pollution Altitude Class of protection Certifications At higher temperatures a reduction of the output current or the use of the next HYDROVAR power size is necessary max output current 96 0 10 20 30 40 50 60 max ambient temperature The insulation rating of the HYDROVAR is IP55 however and in common with other IP55 equipment please note the following e Protect the HYDROVAR from direct sunlight e Protect the HYDROVAR from direct rainfall e Outdoor installation without protection to keep especially the temperature limits of the HYDROVAR is not permitted 25 55 C 70 C during 24 hours max RH max 5096 at 40 C unlimited RH max 90 at 20 max 30 days per year 75 average per year class F Condensation is not permitted During long periods of inactivity or shutdown the HYDROVAR should remain connected to the power supply but the ext on off inhibited to prevent running of the pump This will maintain power to the internal heater and reduce internal condensation The air may contain dry dust as found in workshops where there Is excessive dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted Max 1000m above sea level For installations over 1000 m above sea level the maximum output power has to be de rated by 196 for every additional 100m If t
75. pump is stopped Mode CASCADE SERIAL SYNCHRON running gt Pump 15 running stopped gt Pump is stopped because there is no request disabled gt Pump is stopped manually Stopped with buttons or disabled with parameter ENABLE DEVICE 24 or by external device external on off contact open OFF gt Pump is not connected to power supply Pump is not connected via RS485 interface preparing gt A new unit is connected to multi pump system and Data is transferred solo run gt Solorun is activated X1 SL closed faulted gt A failure occurred on the current unit 24 ENABLE DEVICE 24 Enable Enable Disable of the selected device aJa Possible settings Enable Disable The selected device can be enabled or disabled manually Either in cascade relay serial synchron or controller mode 57 25 MOTOR HOURS 25 XXXXX h Motor runtime of the selected device Total time how long the motor is being powered by the HYDROVAR How to reset see parameter CLR MOTORH 1130 Error memory All errors including these of the BASIC Inverter are shown and saved at the MASTER Inverter in this menu The errors saved in this menu include the failure message text of the current HYDROVAR where the failure happened and also date and time when the failure occurred For more information about errors see chapter 11 failure messages 26 1st ERROR 26 Latest error happened on selected device ERROR XX Message ERROR XX F
76. r which can occur on the HYDROVAR even on the MASTER SINGLE and the BASIC Inverter Additionally the possible countermeasures to reset these errors are described Please note that an automatic error reset can be activated in SUBMENU ERRORS to reset an occurred failure automatically for 5 times For more information about this function see parameter ERROR RESET 0615 All error signals and warnings can be indicated via the two status relays on terminals X5 1 2 3 or X5 4 5 6 depending on the configuration How to program see parameter CONF REL 1 0715 and CONF REL 2 0720 92 11 1 BASIC Inverter The HYDROVAR in configuration BASIC Inverter only the power unit is able to indicate the following errors by the red LED red LED Code MEM HN probable cause 1 blink UNDERVOLTAGE DC DC voltage of the HYDROVAR too low DC voltage of the HYDROVAR too low the HYDROVAR too low 2 blinks OVERCURRENT or Current rise at the output too high or mri power limit of the HYDROVAR is reached Blinks Blinks INVERTER INVERTER OVERHEAT Too Too high temperature inside the HYDROVAR temperature Too high temperature inside the HYDROVAR the HYDROVAR 4 blinks OVERVOLTAGE DC voltage of the HYDROVAR too high 6 blinks MOTOR OVERHEAT IPTC in the conduit box has reached its release EXTERNAL CONTACT temp or external contact is open To reset the CODE ERROR and the OVERCURRENT ERROR the power supply has to be cut gt 60 seconds A reset o
77. re lt set pressure has been changed to and or REGULATION MODE 0320 INVERSE Error message on the display check connection terminals of the HYDROVAR check the connection terminal of OVERCURRENT Current rise at the output too ERROR 11 high the motor and the motor cable check the windings of the motor Reset e cutting of the power supply for gt 60 seconds automatic Error reset not possible for that kind of failure 94 OVERLOAD ERROR 12 OVERVOLTAGE ERROR 13 INVERT OVERHEAT ERROR 14 THERMO MOT EXT Power limit of the HYDROVAR Is exceeded DC voltage of the HYDROVAR too high too high temperature inside the HYDROVAR An external protective device connected to terminal X1 PTC check Parameter RAMP 1 2 0215 0220 too short and BOOST 0265 too low check motor connection star delta and cable Pump blocked Motor turns in the wrong direction before running Non return valve defect Not allowed operation point or MAX FREQUENCY 0245 too high check also the BOOST 0265 Parameter RAMP 2 0220 too fast Power supply too high Voltage peaks too high Solution Line filters Line inductance RC element no proper cooling contamination of the motor vents ambient temperature too high close X1 PTC if there is no external protective device connected close external on off switch if ERROR 15 has released e g PTC which is connected to these terminals connected has re
78. requirement 1 MASTER Inverter and the other pumps equipped with BASIC Inverters HV Master HV Basic HV Basic HV Basic extended up J RS 485 to 8 pumps n connection I Ud AMI To increase the operating reliability of such a system also a second MASTER Inverter is recommended HV Master HV Master HV Basic HV Basic extended up to 8 pumps DU See eee eee eee sees eens Full featured possibility Each pump is equipped with a MASTER Inverter HV Master HV Master HV Master HV Master extended up D 3 10 8 pumps In this mode it is possible to run all pumps in cascade serial mode and synchronous mode as well This configuration allows each pump of the system to become the lead pump This also ensures a proper operation if one MASTER Inverter fails In this case another HYDROVAR takes control This ensures that the operating hours of each pump will be the same to ensure even wear of the pumps 11 3 2 4 Cascade Relay not for SINGLE version One pump is fitted with a HYDROVAR MASTER Inverter and up to 5 slave pumps can be switched ON and OFF on demand For this purpose an additional relay card including 5 relays is attached to the MASTER Inverter However an external switchboard is needed for all the motor relays as the relays in the HYDROVAR are not able to switch the pumps directly just used as control contacts Also an automatic change over of the fixed speed pumps to provi
79. rious impacts NOTICE Dispose of all packing materials and the HYDROVAR unit in accordance with local regulations For more detailed information about the recycling of this product please contact your local authority your waste disposal service provider or the outlet where you purchased the product CAUTION Lifting aids stacker crane crane mounting device lifting blocks sling ropes etc must be suitable to handle the weight of the HYDROVAR gt CAUTION It is not allowed to carry the HYDROVAR around by using the connected cables Do not damage the cable during transport do not squeeze bend or drag The cable ends must be kept dry gt WARNING Do not stand underneath suspended loads Take note of the general regulations on prevention of accidents The HYDROVAR must be secured against tipping over and slipping until it has been fixed in its final location gt 2 System design The following diagrams show typical SINGLE and multi pump systems using the HYDROVAR Connection can be made directly to a water supply In such a case the use of a low pressure switch on the suction is recommended SINGLE pump layout Multi pump layout 1 pump with HYDROVAR 4 gate valve 7 pressure gauge 2 diaphragm tank 5 non return valve 8 pressure transmitter 3 distribution panel 6 low water control 9 drain tap 2 1 Pressure tank A diaphragm pressure tank is used on the discharge side of the pump to
80. ronic ground 18 Current signal input required value 1 Offset 0 20mA 4 20mA Ri 50Q 19 10V internal ref for analogue output 10 00VDC max 3mA x Analogue output 1 0 10VDC max 2mA Analogue output 2 4 20mA B GND electronic ground 23 Current signal input required value 2 Offset 0 20mA 4 20mA Ri 50Q 24 24V power supply for control inputs 24VDC max 100mA n Terminals 5 and 6 can be used as actual value voltage input and also as digital input Also the voltage signal input on terminal X3 15 can be used as digital input X3 3 3 24 gt gt 100mA Offset These terminals can be used as required value or offset signal input Configuration see submenu REQUIRED VALUES 0800 and submenu OFFSET 0900 38 X3 9999999999985 SOVON 5 5 Terminals X3 5 and 6 10 4 8 4 2 a Ld 68 PL Additional power supply max 100 mA Current signal input required val 2 0 20mA 4 20mA Ri 2500 To determine the required value or the offset Analogue output 2 4 20mA Analogue output 1 0 10 VDC Current signal input required val 1 0 20mA 4 20mA Ri 2500 To determine the required value or the offset Voltage signal input required value 2 0 10 vbC DIG 4 To determine the required value or the offset Voltage signal input required value 1 0 10 VDC To determine the required value or the offset Low water e g incoming pressure switch
81. s below this selected value the first assist pump stops Possible settings 0 0 Hz Max frequency 0565 SYNCHR WND 0565 20Hz Frequency window for synchronous control 4 Possible settings 0 0 10 Hz Frequency limit for switching off the next assist pump E g switching off the 39 pump All 3 pumps are running at a frequency SYNCHR LIM 0560 SYNCHR WIN 0565 or switching off the 4 pump All 4 pumps are running at a frequency SYNCHR LIM 0560 2x SYNCHR WIN 0565 80 0570 MSTPRIORITY MASTER priority 0570 for cascade serial synchron only m 5 Possible settings ON OFF This parameter determines the alternation order when MASTER and BASIC Inverters are used within one system In such a case you have to select if either the MASTER or the BASIC Inverters should be switched on first ON all MASTER Inverters in the system are released unless it is stopped by a failure or manually before the first BASIC Inverter gets released For example Address 1 3 MASTER Inverters Address 4 8 BASIC Inverters Switching order Adr 1 Adr 2 Adr 3 Adr4 Adr5 Adr6 Adr8 MASTER MASTER MASTER BASIC BASIC BASIC BASIC BASIC OFF One MASTER which is responsible for the controlling according the set value is running With rising consumption all BASIC Inverters have to be released before any other MASTER starts running Switching order Adr 1 Adr4 Adr5 Adr6 8 A
82. s unit 1 8 for which the parameterization should be done With setting ALL each HYDROVAR in the group is programmed Be careful if you change back to ALL the new settings will be copied to all units The following parameters in Submenu 200 do have different factory settings depending on the power rating Therefore the factory setting shown in the document may differ to the factory settings of the unit itself All factory settings shown in the document are related to power ratings up to 4kW whereas higher power ratings use other settings 65 Ramp settings e Time settings of the ramps influence the control of the pump e The fast ramps 1 and 2 are determined by the type power of the HYDROVAR and the type of the pump Default 4 sec depending on the power of the HYDROVAR they should be increased up to 15s for higher power ratings to avoid overload error e The slow ramps 3 and 4 determine the regulation speed of the internal HYDROVAR controller for small devices or constant consumption and depend on the system which has to be controlled Default 70 sec e The Ramps FminA and FminD are used for a start up and shut off These parameters allow fast acceleration and deceleration and especially should be used for applications where pumps or other devices are powered which shouldn t work below a determined frequency for a certain time to prevent damages or decrease abrasion To adjust the Ramps press or V A set rated RE
83. sure that the mounting of the cable glands is done properly and use closing plugs for cable entries which are not in use For HV4 150 4 220 Measure the right distance with the acceptance the clamp and the screw together Max Length Adjust the length for smaller motor sizes 3 D 2 aS am ap m remove them properly 24 9 Electrical installation and wiring All installations and maintenance has to be performed by properly trained and qualified personnel with proper tools Use personal protection equipment In case of a failure the electrical power has to be disconnected or switched off Wait at least 5 minutes for capacitor discharge before servicing the HYDROVAR Otherwise it can cause shock burns or death 9 1 Means of protection Ask your power supply company which means of protection are required Applicable e protective earthing AC and DC residual current operated protective devices RCD e TN systems Protective earthing e Please note that a current to earth can occur due to the capacitors in the input filter suitable protection unit has to be selected according local regulations Residual current device RCD RCCB e When using an RCD make sure that it also releases in the event of a short circuit inside the DC part of the HYDROVAR to earth o SINGLE phase HYDROVAR gt use pulse sensitive RCDs o three phase HYDROVAR gt use AC DC sensitive R
84. t be installed separate from motor and power supply cables If signal cables are installed in parallel to power supply cables motor cables for a longer distance the distance between these cables should be more than 200mm Do not cross power cables and control cables if this is not possible cross them only in an angle of 90 26 Motor cables To ensure the EMC compatibility and minimize noise level and leakage currents keep the motor cable as short as possible use shielded cables only if the total length exceeds 1 5 meters Additional component line choke coil Line coils are available as an option and should be mounted between the HYDROVAR and the main fuse The Line coil should be as near as possible to the HYDROVAR max 30cm Advantages e better efficiency e reduction of harmonic currents For the following applications additional line chokes are strongly recommended e high short circuit currents e compensation plants without a coil e asynchronous motors which are responsible for a voltage drop gt 20 of the line voltage EMC summary Install potential equalization according to local regulations Do not install the power cables in parallel to signal cables Use screened signal cables Connect both ends of the screen of the motor cable to ground Connect only one end of the screen of a signal cable to ground Motor cable as short as possible Pigtails should be prevented 9 3 Recommended Cable Types To ensure
85. tch over for operating hours optimizing switch over in case of a failure duty standby and automatic duty assist Cascade Synchron The Synchronous Controller mode is working in the same way like the cascade serial mode The only difference is that all pumps in the multi pump system are running at the same frequency Advantages In the synchronous mode the pumps can operate in a better efficiency range and the system is able to provide additional energy saving compared to standard Cascade Serial mode 61 Actuator For SINGLE pump operation only The actuator mode has to be used if a fixed speed setting is required or an external speed signal is connected and the HYDROVAR is just used like a standard VFD In this case the internal controller is shut off so the HYDROVAR does not control the set value but runs the connected motor at a frequency proportional to the input signal which is connected to the analogue inputs or is set directly on the HYDROVAR X3 13 Voltage signal input Required value 1 X3 15 Voltage signal input Required value 2 X3 18 Current signal input Required value 1 X3 23 Current signal input Required value 2 e A manual switching between the analogue inputs is possible by using the corresponding digital inputs e The frequency varies along the programmed Ramps 1 accelerative and 2 declarative 0 10V 0 10V 4 20mA 0 20mA 4 20mA 0 20mA 0 MAX FREQ 0245 0 MAX FREQ 0245 0
86. ter Possible settings 1 8 Set desired address for the current MASTER Inverter and press button for approx sec and the following massages will appear Addressing a 1220 PUMP ADDR or 1220 PUMP ADDR Addressing UNS 1 Addressing done Addressing failed retry When using MASTER and BASIC Inverters together in a multi pump system you have to consider that the BASIC Inverters have their separate address Otherwise a correct function of the system couldn t be guaranteed For detailed Information see chapter 9 4 3 2 Addressing 91 11 Failure messages If the HYDROVAR is stopped by an error warning the HYDROVAR as well as the motor remain under voltage Before any work is carried out on the electrical or mechanical part of the system the HYDROVAR must be disconnected from power supply Difference between warnings and errors Warnings are shown on the display and even by the red failure led If a warning is active and the cause is not remedied within 20 seconds an error will be shown and the HYDROVAR stops However it is possible that the HYDROVAR keeps running depends to the different warnings Errors are indicated on the HYDROVAR display and by the red failure LED placed on the control panel In case of an error the connected motor is stopped immediately errors are shown in plain text and saved in the error memory including date and time when the failure appeared The following information describes each erro
87. ter 9 3 recommended cable types External volt free contacts must be suitable for switching 10 VDC NOTE If unscreened control cables are used signal interference may occur and could interfere with incoming signals and the function of the HYDROVAR Don t connect the ground of the control card to other voltage potentials All electronic ground terminals and GND of the RS 485 interface are connected internally Digital and Analogue I O X3 1 GND electronic ground 2 Actual value input sensor 1 0 10VDC or 0 20mA 4 20mA Ri 50Q 3 Power supply for external sensors 24VDC max 100mA 4 User SIO Interface SIO 5 User SIO Interface SIO 4 User Interface for external usage 6 GND electronic ground 7 External ON OFF release active low 8 GND electronic ground 10 GND electronic ground 11 Low water active low 12 GND electronic ground Low water e g incoming pressure switch or water level switch required I 10 2 3 Configurable digital input 1 e g to enable 2nd required value S e E External ON OFF release zu 7 GND GND electronic ground 5 SIO User SIO Interface 510 4 SIO User SIO Interface SIO 2 Actual value input sensor 1 0 10V or 0 20mA 4 20mA Ri 50Q e 92 3 424V supply max 100 mA 2 e 3 Ground X5 Status Relays X5 CC Status Relay 1 NC NO CC Status Relay 2 NC NO Max 250VAC 0 25A Max 220VDC 0 25A Ma
88. tighten the four fastening screws o Reconnect HYDROVAR to power supply 34 HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 BASIC Inverter BASIC Inverter Terminal for external LED X22 Dip switch for addressing S1 possibility to connect a LED to show the S2 reserved for changing the switching status without display operation frequency function not active 35 9 4 4 RFI switch For HYDROVAR HV4 055 HV4 220 additional filter capacitors are included which provide an improved filer characteristic in order to avoid RFI Radio Frequency Interfaces when the HYDROVAR is used as wall mounted device with longer motor cables between the HYDROVAR and the motor In general the default settings should not be changed and remain in default position NOTE Due to the additional filter capacity the earth leakage current will increase if the filter is active Therefore in case of using ELCB relays earth leakage circuit breakers RCD they must be suitable for VFD s see also chapter 9 1 HV4 150 HV4 220 switch S1 and S2 S1 used only for internal high voltage testin Closed default setting should not be MMC be the end user Open only for tests done by the manufacturer S2 activation HF filter capacitor Closed default setting RFI filter active for symmetric power supply net standard in mainly all countries Open RFI filter deactivated for asymmetric power supply net e g USA HV
89. tor Settings higher than standard may overload the motor Settings of 10 above nominal frequency cause 3396 higher power consumption 0250 MIN FREQ 0239 20 0 Hz Minimum frequency Possible settings 0 0 f 0 0 30 0 Hz if 203 is 00 default max At operation below the set min frequency the HYDROVAR operates with the fast ramps 0235 0240 As per default the max setting of this parameter is limited to 30Hz To enable the MIN FREQ for settings 30Hz first the parameter 203 must be changed to setting 01 or 02 gt see page 64 for more detailed information The min frequency depends on the selected pump type and application Especially for borehole applications the min frequency must be set to 30Hz 0255 CONF FMIN 0255 0 Operation at minimum frequency Possible settings f gt 0 or f 5f f 20 After reaching the required pressure and no further consumption the frequency is going down to the selected MINIMUM FREQUENCY 0250 and the HYDROVAR will keep running for the selected FMIN TIME 0260 After this time the HYDROVAR will stop automatically 68 1 gt 1 With this setting the pump will never stop automatically Only the frequency will go down to the selected MINIMUM FREQUENCY 0250 To stop the pump the external ON OFF must be opened or the W button must be pressed Applications circulation systems The setting f gt f can overheat the pump when there 15 no flow through min
90. uration Factory setting The two relays are used as pump running or fault signal relay For this application see connection example below How to program see parameters CONF REL 1 0715 and CONF REL 2 0720 Connection examples Pump running signal Fault signal Ext 250VAC 220VDC Ext 250VAC 220VDC X5 PAL X5 1 and 3 closed X5 4 and 5 closed motor run indication If there is a fault error 43 9 4 5 2 Relay Card This optional component can be used only in combination with a HYDROVAR MASTER Inverter The Relay Card is connected to the control card using connection slot X6 See chapter 9 4 4 1 Notice When using the relay contacts for switching external contactors a corresponding RC snubber circuit or varistor is necessary to prevent disturbances arising during a switching action of the relay Terminals Relay Card X10 Relay Card Relay 1 Relay 2 max 250VAC 0 25A Relay 3 max 220VDC 0 25A Relay 4 max 30VDC 0 25A Relay 5 COMMON GND EN Z 2 s Relay 5 Contacts for switching the fixed speed pumps 92 4 Relay 4 7 Relay 3 Please consider that the fixed speed pumps palsy can t be switched directly by the Relay card 2 2 y an external panel for the contactors of the 92 Relay 1 D O L or STAR DELTA starters is necessary x 44 Connection example The following wiring diagram shows a standard cascade control system where the HY
91. x 30VDC 2A B W N Status Relay 1 Status Relay 2 Notice AS X5 When using the relay contacts for gt driving an external relay a 3 NO 2 6 corresponding RC snubber circuit or A 2 NC 92 5 NC varistor is recommended to prevent disturbances arising during a switching 0 92 4 CC action of the relay Both Status Relays on the control card can be used regarding the programmed configuration Factory setting The two relays are used as pump running or fault signal relay For this application see connection example below How to program see parameters CONF REL 1 0715 and CONF REL 2 0720 Connection examples Pump running signal Fault signal Ext 250VAC 220VDC Ext 250VAC 220VDC ames X5 1 and 3 closed X5 4 and 5 closed motor run indication If there is a fault error 48 10 Programming Read and follow the operating instructions carefully before you start programming to prevent incorrect settings which will cause malfunction All modifications must be done by qualified technicians 10 1 Display Control panel of the MASTER SINGLE Inverter 2 o I ue Power Run Error LEFT UP DOWN RIGHT 10 2 Function of the push buttons Start of the HYDROVAR in the 1st Window v Stop of the HYDROVAR in the 1st Window and Reset by pressing of both buttons simultaneously for 5 seconds A Increase of a va
92. xylem Operating Instructions HYDROVAR HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 HV 4 150 4 185 4 220 V 2012 03A V01 4 771079412 Manual HV 2 015 4 220 ENGLISH 1 Important safety Instructions eio piu 5 Pd GESIG ERR T 8 21 Pressure LANA ecoregion ea aque 8 3 Product OVEIVICW PNE T E 9 3 1 Hardware configurations ciiin Sub eO Use 9 3 2 Operating MOG CS ic sss ssectc ruta sa esuv a acus sena sc pu sese aos sues ps Eai 9 3 2 1 Actuator for SINGLE pump operation only 9 3 2 2 GON 9 3 2 3 Cascade Serial Synchronous not for SINGLE 10 3 2 4 Cascade Relay not for SINGLE version scccssceceecceeeeeeeeeeeeeeeeeeeeeseeeeeeeeeneeseeess 12 4 Type designation Rina aes Sie 13 5 Technical a ado ee Ie a 14 5 1 General technical data 15 5 2 EMC requirements Electromagnetic compatibility 16 6 Dimensions and weights 17 7 Modules 20 8 Mechanical components bei EN

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