Operating Instructions
Contents
1. ANSWANS NINIWANS f jeg oo0 0 Ajisuaju 10 moo fouenbaJJ 447 DONI J8A MS soo Semos mo ada 500L 50 JOU E MO Bi aur ululJ soo sinou pz sot Hl 0 4 1043 Z ung 15a 15008 EA uis UD ee uuy Duo c ZH ODE ZHODE ZH O S sub O S O 10413 15e fouanbaJJ 15a WWI J40 eAe s TJ bes e qeu3 ubi apay 15009 5 L SOL uU DOLL ASG 50 ZH 009 Jeg SLO 008 ZH 00 ON Q ssaJppwy dung e ag 10413 ung 153 a qeua auey 10suas jur UG SAS ag anjer TUN 515313 5A4 Asuanbas ua C 4 s ar all dl O u 00000 d Jeg 00 0 umog dn abuey jo 1nO bui eubrs 10413 Je8 SLO O S d ZH 005 O awiuny dung jur Joanu Um Lea MEIS ysnipy Josu35 niBijuo sejby SU anjen PU MORUA Asuanbasy MEA c A A A A A e E je fa E e y wi E e E rm m y Fa e D YO A sisoubeig umog dn 9900 40413 unas Josuas sIE 3Y Ja o 3uo2n niA Jajjouquez A J HAU a POMES Eg NNJANANS nepeg pPIonissEd 125 nN3lwans NINEN AK NNANANS IN JW TS nN3alwsrns IN JW TIS nNg3iesns c Jeg ELUJON Jajjou3u02 pajgeuz pajqeuz c E yun uosuawig apoy uone nbay apoy HES ojny aInssalg Buey O OU j SEO Sen HI 3 A SEMI JOS Y O TITI 5 a O c jeg 0S E pagesa 00 00 U Kei v NAINIWANS aJnssag Buinseuuo ony abueu sssJppw un V SOM N O C 2 Ba o We uonein6bijuo7 ssauppy gt e 71 Be E W Q ITT Indust2. 7 P www hydrovar com 15 ITT Industries Engineered for life HYDROVAR Operating Instruction 6 1 3 Mounting the thermistor Variant A motor thermistor terminal block rubber gasket cover of the conduit box Variant B 1 Open the cover of the conduit box and remove also the terminal block inside 2 Fix the thermistor Variant A or B 3 Electrical connection of the motor cables see chapter 6 2 ITT Industries Engineered for life www hydrovar com 16 3 6 1 4 Mounting of the pressure transducer In the delivery of the pressure transducer there are included Pressure transmitter X 2 gasket Viton 1 The transducer has an mechanical connection of G Lait 2 Electrical connection to the Hydrovar see chapter 6 2 www hydrovar com 17 Y ITT Industries Engineered for life HYDROVAR Operating Instruction 6 2 Electric installation and wiring Note All installations and maintenance MUST be performed by trained and qualified personal with proper tools Warning In case of a failure disconnect and lockout electrical power and wait five minutes for capacitor discharge before servicing the Hydrovar 6 2 1 Means of protection Ask your power supply company which means of protection are required Applicable AC and DC current operated circuit breaker FI TN systems protective circuits When using a FI protection switch make sure that it also releases in the event of
3. 202000000200202 NENNEN KK NANANA RR KKK NNN eea NN ANA NAKAKA KNK NANANA NAKAKA KAN 52 15 1 LOW WATER E 52 15 2 OVERHEATING Moon 52 1553 OVERVDETAGE a as saga aaa an a Ga a aa E NAN ee BAN KT A AE MA S 52 1A BS NB e EE 52 Ta CVE ROAD AA 52 15 6 OVERHEATING OF THE HEAT SINK ccccscccecesnccusucvcrcucesesnecusuaveuausesusueuuauaveraususeeueuusuarsusueeesuanarauaaseneaeuss 52 15 7 SENSOR FAULT EE 53 15 8 CONVEYOR IMIT PAUL 53 15 9 ADDITIONAL INTERNAL PROCESSOR ERROR MESSAGES cceccececcesecceceueeceuseceueaueuueusaueusaueusaueaueueaueuuaeeaeaess 53 lo MANTENAN CE iod EE EE 53 Follow the Pump Operating and Maintenance Instructions We reserv the right to alter specifications www hydrovar com 3 e ITT Industries Engineered for life HYDROVAR Operating Instruction 1 Important safety instructions Read and follow the operating instructions and safety instructions carefully before starting operations All modifications must be done by qualified technicians Warns that failure to observe the precaution may cause electric shock Warns that failure to observe the precaution may cause personal injury or damage to property In addition to the instructions contained in these operating instructions please pay attention to universal safety and accident prevention regulations The HYDROVAR drive head must be disconnected from the power supply before any work can
4. If you have selected F 50 the frequency will go F Fmin down to the selected minimum frequency Then the inverter will run for the selected time and after this time the Hydrovar will stop automatically With the selection is F 5F you can not run the pump below the set minimum frequency In the controller actuator and multicontroller mode the pump will never run below the set minimum frequency the pump will only stop with the external on off terminals or in case of a failure Press 3 on the controller to change to 13 5 5 Delay time for Fmin Fmin Time After running the pump for this selected time at Os minimum frequency the pump will stop if parameter CONFIG Fmin it set to F gt 0 Adjustable between O and 100s To leave the submenu press the gt key longer than 3 sec 13 6 Submenu Controller Submenu To enter this menu you have to press the key to Controller leave the menu press the gt key longer than 3 sec www hydrovar com 42 e ITT Industries Engineered for life Operating instruction MYDHOVAR 13 6 1 Window Yo Window This value indicates the max variation of the outgoing 5 96 pressure ref Ramp window Possible setting between 096 10096 of required pressure Press gt on the controller to change to 13 6 2 Ramp Hysteresis Hysteresis Level where the fast ramp changes to the slow 80 ramp within the window Possible setting between 0 100 of the window Press
5. Te www hydrovar com ITT Industries Engineered for life Operating Instruction 1 HYDROVAR NN Vogel Pumpen Manufacturer s Declaration as defined in EC Machinery Directive 98 392 EEC Appendix II B and the EMC Directive 89 336 EEC We herewith declare that the frequency converter of type HDROVAR HV 1 1 1 15 1 2 is intended for assembly with other machines to a machine It is forbidden to start using it until it has been established that the machine on this converter is to be installed or with which this converter is to be assembled complies with the provisions of EC Directives 93 AA EEC and 93 68 EEC Relevant technical standards and specifications especially EN 55011 EN 50082 2 EN 60146 EN 50178 EN 60204 1 d Dir Ing Sacher Pumpenfabrik ERNST VOGEL GmbH A 2000 Stockerau Ernst Vogel Str 2 Stockerau 25 03 03 ITT Industries Engineered for life www hydrovar com 55 amp HFIYDmROVAm W VOGEL PUMPEN Pumpenfabrik ERNST Vogel GmbH A 2000 Stockerau Ernst Vogel Strasse 2 Telefon 02266 604 Telefax 02266 65 311 Internet www vogel pumpen com www hydrovar com A 8054 Graz Seiersberg K rtnerstrasse 518 Telefon 0316 28 6120 Telefax 0316 28 70 42 A 9020 Klagenfurt Schachterlweg 58 Telefon 0463 31 93 20 Telefax 0463 31 93 17 A 4600 Wels Haidestrasse 41 Telefon 07242 66 8 51 52 53 54 Telefax 07242 66 8 51 12 A 6175 Kematen Bahnhofstrasse 31 Telefon 05232 2
6. a DC fault use for each Hydrovar a separate Fl switch 6 2 2 Wiring the Hydrovar to the motor Remove the 3 screws holding the top of the Hydrovar Carefully lift the top loose the earth screw and put the Hydrovar cover aside Now you can see the 2 main parts 1 control card with all terminals for the control signals and the RS485 interface 2 main card with all power components and terminals for power supply and motor ITT Industries Engineered for life www hydrovar com 18 Operating Instruction HYDROVAR 6 2 2 1 Main part overview HV1 1 control card 1 main supply connections Motor connections main board 2 Cable gland for power supply 5 10mm Cable introduction for motor cable at least 11 5mm Cable introduction for control cable at least 5mm HV1 15 1 2 control card 1 main board 2 motor main suppl PP connections connections cable introduction for control cable IT T Industries Engineered for life www hydrovar com 19 amp HYDROVAR Operating Instruction 6 2 2 2 Connecting the power cables a motor cable Locate the motor connections labeled U V W inside the Hydrovar Connect wires to the terminals and rout the cable through the cable gland You must take a motor cable at least 11 5mm if you want protection IP55 only HV1 1 The earth wire of the cable has to be fixed with the screws with the earth symbol to the cooling body of t
7. 44 13 6 8 IPE ALOIS eege 44 13 7 SUBMENU MULTICONTROLLER eI Innen ne nnemennemenre mense sne sa se esse ses sere essa re sas se essere sa rea Ene 45 EX E E EE 45 CYA E lee 45 13 7 E e 0 0 24 LNG NENE a E E ee ee ee eee 46 NA Switch Interval EE 46 13 0 ET ER e RN E 47 13 8 1 Relay Configuration EEN 47 13 8 2 Start frequency or the slave EE 47 13 8 3 Stop frequency of the slave DUImD GG IBIG Fal REUXPROKREDEDOUDDS PEDE PAD DERE 47 13 9 SUBMENU SENSOR 0na aa 47 13 9 1 Sensor E 48 EE E SENSO MA ANU 48 Ke ER SUBMENU TEST PON WE 48 15 70 Start OF manual fest TUTTG ADA NADAAN FP PD PAGG AAN 48 13 10 2 Sequence for automatic test E 46 I3 O TOS RUM FICOUCICy E 46 13 104 Test KUN OOS AAP 49 1511 SUBMENU e E 49 LE MEG I OF EE 49 EE 49 13 12 SET PASSWORD EE 49 13 13 DEFAULT WR 49 13 14 SUBMENU Ee 49 E EE 50 IS TNI ADE EE 50 CN P SE OP NONONG AA AS 50 13 14 4 Software Version nanana NN NDN DAD NDN ND END EKSENA NND EKSENA ND SNN ND eaaa ENG kna anane sa saa aa 50 TN oa RTEA WO AA S AA ARA 50 14 CONTROLLER MENU OF THE PROGRAMMING DEVICE cene nen 50 14 1 CONTROLLER MENU CONFIGURATION 2200000001 000 Sa 51 14 1 1 Automatic connection to the programming device c sccccseccneecseecsueesaeecseessuessesseesaeesaes 51 14 1 2 Software Version of the programming Oevice maana naaa seen 51 14 2 SEENEN 51 TAZ AG cla NG MONA AA AA AAP 51 15 POSSIBLE ERROR MESSAGES
8. ONSEN FJ iN P Vi P X d Vi a Ei Ma U gt W Lf q HYDROVAR e ITT Industries Engineered for life 34 www hydrovar com Operating Instruction HYDROVAR When two three or four Hydrovar speed controlled pumps are connected together in a system via the RS485 interface they can be programmed to work together to maintain system pressure up to the maximum flow rate of all the pumps combined As the first pump reaches its maximum speed and flow the second pump will automatically turn on and so on In addition the sequence of the pump that will run first lead pump can be automatically varied to reduce premature wear on any one pump in the system Instructions Refer to chapter 11 1 setting single pump constant pressure Follow these instructions for setting the required pressure and then continue with the following steps From the 1 display press the 3 button twice until you SUBMENU reach PARAMETER Then press the W button and the display will change to PASSWORD 0000 Password The Password protection prevents untrained personal from accidentally changing the base setting Press the AN button until you reach the number 0066 PASSWORD 0066 Press the gt button repeatedly until you reach SUBMENU MULTICONTROLLER Press the dk button to enter the submenu and change to ACTUAL VALUE INCREASE 0 15 bar ACTUAL PRESSURE INCREASE Lift value This value together with the fall value ACTUAL
9. complies with the general EMC provisions and has been tested according to the following standards e Disturbance voltage EN 55011 e EMC Immunity EN 61000 4 3 and ENV 50204 e Electrostatic discharge EN 61000 4 2 Ambient temperature 5 C 40 C Storage temperature 25 C 55 C 70 C during max 24 hours Humidity rH max 50 at 40 C unlimited rH max 90 at 20 C max 30 days per year Condensation not permitted Air pollution The air may contain dry dust as found in workshops where there is no excessive quantity of dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted Altitude max 1000m above sea level At higher altitudes the max available power has to be reduced Please ask the manufacturer for further details Class of protection IP55 ITT Industries Engineered for life www hydrovar com 10 3 Operating Instruction HYDROVAR 5 1 Dimensions HV1 1 closing cap 120 Weight Kg 27 cable gland le HV1 15 1 2 closing cap cable entries www hydrovar com 11 e ITT Industries Engineered for life HYDROVAR Operating Instruction 6 HYDROVAR mounting 6 1 Mounting the HYDROVAR on the pump 6 1 1 Included components Variant for HV1 1 mounting and distance ring screw cable gland washer Variant for HV1 15 1 2 screw M5x50 cable gland mounting clamp www hydrovar com 12 e IT T Industries Engineered f
10. gt on the controller to change to 13 6 3 Fast acceleration time Time setting at Ramp 1 2 3 or 4 will influence the control of the pump and SHOULD NOT BE CHANGED at normal operation Possible setting for each ramp 0 05 1000 sec Accel High Excessively fast running up time may overload the 4 Sec Inverter Excessively slow running up time may cause a break down of the outgoing pressure Press gt on the controller to change to 13 6 4 Fast deceleration time Decel High Excessively fast running down time tends to cause 4 Sec oscillation or hunting or can cause an error OVERVOLTAGE during pump down of the pump Excessively slow running down time tends to generate over pressure Press gt on the controller to change to 13 6 5 Slow acceleration time Accel Low A too slow running up time during variation of 70 Sec demand the outgoing pressure may break A too fast running up time may lead to over oscillation and or overload of the inverter Press gt on the controller to change to TT Industries Engineered for life www hydrovar com 43 amp HYDROVAR Operating Instruction 13 6 6 Slow deceleration time Decel Low A too fast setting leads to oscillation 70 Sec A too slow setting delays the switching off too much and may generate over pressure Ramp Window eingesteliter Solldruck Druck Drehzahl set rated pressure Pressure speed ARI a A x A In 96 eingestellte Fenstereinstellung 10076 Rampenhyste
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12. possibilities to use the push buttons of the Hydrovar The Pump could be STARTED with the 4 button if Autostart is disabled the pump can be started by pressing the Y button and then the 4 button at the first startup or after a power supply failure or STOPPED with the Y button Both buttons are on the front plate of the Hydrovar e Change pressure without programming device To change the pressure without the external programming device you have to follow 1 Start the pump with the push button J on the front plate of the Hydrovar 2 Then press the 4 and Y buttons together for longer than 3 sec cy The colour of the LED changes to orange 4 Now you can change the pressure with the 4 and Il buttons The only way to check the set pressure is given by a pressure gauge 5 If there is no action for more than 5 sec the HYDROVAR returns to normal operation automatically and the new required pressure is saved ITT Industries Engineered for life www hydrovar com 24 Operating Instruction HYDROVAR 8 Possible indications of the LED on the HYDROVAR Green shining Green slow flashing Green fast flashing Orange shining Orange slow flashing Orange fast flashing Red shining Red flashing www hydrovar com Motor stopped via external stop with terminals X2 4 X2 5 or the unit is stopped with the Y button on the front plate Inverter is active but the motor
13. pressure bar 1 2 3 4 5 6 7 8 9 10 0 8 1 2 3 4 5 6 7 8 9 VorpreBdruck precharge pressure bar Before checking the precharge pressure take care that the tank is pressureless no water inside TT Industries Engineered for life www hydrovar com 7 amp HYDROVAR Operating Instruction 4 Transducer 4 1 Pressure Transmitter Series PA 22 S The sensor of this transmitter is a piezoresistive silicon pressure sensor mounted on a tape TAP freely floating in an oil chamber The pressure is transferred to the sensor by a separate steel diaphragm in the oil chamber Specifications Range FS 10 bar 25 bar other ranges upon request Max pressure P 20 bar 50 bar Class of protection IP 67 Output signal 0 5 4 5 V DC Supply 5 VDC 5 Yo Operating temperature 10 80 C compensated max 40 135 C Storage Temperature 40 4 135 C Cable length 1 2 m connections white analogue output signal Out 1 green Ground GND 2 brown supply voltage VCC 3 Materials Body 1 4435 diaphragm 1 4435 Measures in mm ff cc Ae Gia ITT Industries Engineered for life www hydrovar com 8 amp Operating Instruction HYDROVAR l l l Series PD 39 M 4 2 Differential Pressure Transmitter The sensors of this differential pressure transmitter are two piezoresistive silicon pressure sensors mounted on a tape TAP freely floating in an oil chamber The pressure
14. to 13 10 4 Test Run Boost Start voltage in of rated voltage in order to ensure 10 0 that the motor starts safely Adjustable between 096 and 25 To leave the submenu press the gt key longer than 3 sec 13 11 Submenu Error Submenu To enter this menu you have to press the N key to Error leave the menu press the gt key longer than 3 sec 13 11 1 Conveyor Limit Conveyor Limit Disabled or adjustable between O and 10 bar of the 0 0 bar analogue input signal range 0 0 bar means disabled conveyor limit An adjusted value 50 has to be reached till the programmed ERROR DELAY time Doesn t this value be reached the failure ERROR WATER will be indicated and the pump stops Press gt on the controller to change to 13 11 2 Error Delay Error Delay Adjustable between 0 100 sec 10 Sec Delayed switch off in the event of low water Terminal X2 6 X2 7 and also for the conveyor limit To leave the submenu press the key for 3 sec 13 12 Set Password Set Password The pre set password can be changed if necessary 0066 with the and keys Press gt on the controller to change to 13 13 Default Settings Default To load DEFAULT PARAMETER press buttons 4 d ni together till the timer is run down Press gt on the controller to change to 13 14 Submenu Diagnosis Submenu To enter this menu you have to press the N key to Diagnosis leave the menu press the gt key longer than 3 sec
15. www hydrovar com 49 e ITT Industries Engineered for life HYDROVAR Operating Instruction 13 14 1 Pump Runtime Pump Runtime Shows the running hours of the pump 0000 Std Press gt on the controller to change to 13 14 2 Pump Address Pump Address This window shows the adjustment of the pump 1 address only read Press gt on the controller to change to 13 14 3 Error memory The last three error messages are always stored in an internal memory The error signals can not be deleted Last Error Shows the last error 2 Error Shows the Error before the last error 3 Error Shows the Error before Error 2 Press gt on the controller to change to 13 14 4 Software Version Software In this parameter there is shown the used software CP VOG 004 version of the HYDROVAR To leave the submenu press the gt key for 3 sec 13 15 Set Password Password Here the set or changed password must be O K confirmed 14 Controller menu of the programming device To reach the controller menu you have to press gt on the controller for longer than 3 sec when the 1 display PRESS X X bar The actual input value bar and the actual output SPEED X X Hz frequency Hz are displayed is shown Then the display will change to ITT Industries Engineered for life www hydrovar com 50 3 Operating instruction MYDROVAR Address 01 The actual pump address is shown Detected Then press on the contro
16. 0 0 01 Telefax 05232 20 0 03 www hydrovar com 56 Operating Instruction Tochterunternehmen in Europa Subsidiaries in Europa LOWARA VOGEL Szivatty Kft H 8000 Sz kesfeh rv r Bakony u 8 Telefon 0036 22 512 640 Telefax 0036 22 512 642 Lowara Vogel Polska sp zo o PL 40652 Katowice ul Worcella 16 Telefon 0048 32 202 8904 Telefax 0048 32 202 5452 VOGEL ROCANO SA CH 2087 Cornaux Z l Pr s Bersot Telefon 0041 32 75 87 200 Telefax 0041 32 75 87 200 e ITT Industries Engineered for life
17. 0 seconds acknowledgement 15 4 Undervoltage XXX Possible cause Check mains supply faulty Error Undervolt fuse or phase Unsymmetry Disconnect the power supply for gt 30 seconds acknowledgement 15 5 Overload XXX Possible causes false data settings or the Error Overload pump is working at a capacity significantly in excess of its performance data Ramp 1 to fast Max frequency to high Boost to low Disconnect the power supply for gt 30 seconds acknowledgement 15 6 Overheating of the heat sink XXX The thermal sensor mounted on the cooling Error KK Temp body of the HYDROVAR indicates over ITT Industries Engineered for life www hydrovar com 52 Operating Instruction HYDROWAR temperature Possible causes insufficient cooling ambient temperature is too high or motor overloaded After the cause has been remedied the malfunction has to be reset by cutting off the power supply for gt 30 seconds 15 7 Sensor fault XXX The voltage level of the incoming analogue Sensor Fault input signal is supervised If the signal falls below the 0 5VDC level an Error will be displayed Possible causes break of the sensor cable or the sensor itself bad connection of the plug of the sensor After the cause has been remedied the malfunction has to be reset by cutting off the power supply for gt 30 seconds 15 8 Conveyor limit fault XXX The value of the programmed Conveyor limit Error Water is not reached within the
18. 13 5A4 Asuanbas LIA he A A A A A E e d ra e wi p m e m E 30 sisoubeig umog dn 9900 10413 uniisal Josuas sIe aH Ja o3uo2nniA Ja jou3uo Japanu pJOMSS Ed nN3lWwsns meja PJOMSSEd 135 NNJWANS ANNANS NANJNANS NNIJWANS NNIJWANS NINIWANS IN 3mNans V E d d Ak es 4 a E Jeg EWON Ja o43u02 pajqeug pajqeug 9900 yun uoisuawig apo uonenBay apo Hes ONY ainssaid abueu puomsseg F WIYDON SAMS SEMI JOS A d d y H Jeg OS J pejqesic DO lt a DO nNaWans aunssald Bulpauuo gt ony aBuey gt ssauppy r A uoneunbijuo ssaJppy niN3l sns NINIWANS umog dn abueg jo INO IA Duugufte 10413 II Jeg silo 1605 J ZH OOS uny 352 HEIS isnipy Josuas NByuo gt sie ay 2u anyeA TI AVODUIAN Aouanbai NEI pa 32 www hydrovar com ITT Industries Engineered for life Operating Instruction HYDROVAR Instructions From the 1 display press the 3 button twice until you SUBMENU reach PARAMETER Then press the W button and the display will change to PASSWORD 0000 Password The Password protection prevents untrained personal from accidentally changing the base setting Press the AN button until you reach the number 0066 PASSWORD 0066 Press the gt button repeatedly until you reach SUBMENU CONTROLLER Press the W button to enter the submenu and change to WINDOW 5 0 Yo Now press the button until you re
19. A VLLL GH CL Sf E u 00000 Jeg 0070 umog dn abuey jo MO bui eubrs 10413 Je8 SLO 96 O S ZH 005 awiuny dung jur Janua Un 153 HEIS ysnipy Josu35 nBijuo sejby SU am now MAOpUlAA Asuanbas4 Xe A A A A A A sisoubeig umog dn 9900 10413 unsal 105135 SIEH 38 0MJUO3N N N awo J3 J3AU NNIWANS jnejeg piomssed jas NINIWANS NINIWANS NINIWANS NINIWANS nNawans ANIWANS NINIWANS ewon s9onuo pageu3 pege3 9900 apoy uonejnbay apo WES olny aunssa4g 3BUrY PJOMSSEd 7 F INBYDONS181 MS a SJEMJOS A Fa Y d Lee pagesi D0 lt lt 00 ZH 0 OS paads mwee Jeg OS niN3al vans anssalg Jeg X X SSalg buipeuuo ony abueu sssuppy P d 3 e EC LO ssaJppy uenemBuuos ssaJppwv nNaWwsens nNawans NO N www hydrovar com ITT Industries Engineered for life Operating instruction HYDROVAR General for working with the external programming device With and gt you can select the different parameters in the menu To enter a submenu press the we button To leave the submenu you have to press the buttons or gt for longer than 3 sec With or you can change the parameters Each change in the settings is saved after leaving this parameter with the buttons or 3 When you have changed a parameter and you leave it the LCD shows you the following message SAVE for about 2 se
20. DC When there is used a transmitter with another signal range you can also choose an input signal of 0 5 2 5VDC for example a 4 20mA transmitter with an external load resistor of 125 ohm 0 25W with the buttons Y To leave the submenu press the gt key longer than 3 sec 13 10 Submenu Test Run Submenu To enter this menu you have to press the N key to Testrun leave the menu press the gt key longer than 3 sec 13 10 1 Start of manual test run Start Test Run By simultaneously pressing 4 N a test run will be Ai released even if the test cycle is not set After starting this test run the pump will speed up with the fasten ramp 1 to the in the parameter 13 10 3 setted speed and then will ramp down with the fasten ramp 2 Press 3 on the controller to change to 13 10 2 Sequence for automatic test run Time Test Run Adjustable between 1 100 hours 100 h The test run starts the pump at the set time after the last stop for 20 seconds with the in parameter 13 10 3 set speed Deactivating test run Set O hours by using ah and V Repeating the test run Select test run and set the desired hours using the key Press gt on the controller to change to 13 10 3 Test Run Frequency Test Frequency Frequency for manual and automatic test run 30 0 Hz Can be set from 0 Hz up to 70 Hz ITT Industries Engineered for life www hydrovar com 48 Operating Instruction HYDROVAR Press gt on the controller to change
21. DECREASE 0 15 bar After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Press the gt button to change to ENABLE SEQ CONTROL 48 Hz The follow up pump only starts when the start value is reached and the lead pump has reached the programmed release frequency Adjustable from 0 0 Hz to 70 Hz Normally this start frequency is set 1 to 2Hz lower than the MAX FREQUENCY If you don t want to start a following pump this value has to be set higher than the MAX FREQUENCY see application example on previous page ENABLE SEQUENCE CONTROL Enter the required value by pressing the ah and Y button ENABLE SEQ CONTROL 49 Hz After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Press the gt button to change to SWITCH INTERVAL 24 HOURS This time determines the interval of the changeover of the master pump in order to achieve even operating hours of all pumps in the system Adjustable between 0 and 250 hours SWITCH INTERVAL Enter the required value by pressing the ah and Y button SWITCH INTERVAL 24 HOURS e ITT Industries Engineered for life www hydrovar com 37 HYDROVAR Operating Instruction After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARA
22. JJ 15a Jur 430 BARS io bes sjqeu3 L sol Y 001 ASt S0 zHoos egen ssaJppwy dung e aq 10413 ung 153 ajqeu3 auey sosuas yuu UO SAB S Sag anjer DI o Ct L a 1 1 u 00000 k Jeg 000 umog dn auey jo Ino Buyjeubis song Jeg slo awiuny dung jur Janua ung 153 HEIS ysnipy 10suas nuog sey JU an EA iow A A A A A y w Ne fe Ph e Th Pa Le m Pag We ES ai 30 a sIsouBbelg lumogrdn 9900 10413 unijsal Josuas SIE 3H EIST KIT DIOAASSB nNaewans ines PIOMSSE ed Jos NN SWS NINEN LAK IN JW TIS nN3lwsrns nN3IWSS E Lu IF un Fj I 3 j Ia i P i E A E L Jeg L JELUION LI Ja jou3uo02 pajqeu3 pajqeu3 9900 D yun UDISU SUNG apoy UONEnbang apo 11615 O NY aunssaig abueu PIOMSSEY d CX e Mk ET Ka AA Xx d x d d A gt JayaweIe Jeg OS CH ZHO 0S paads O nN3awans aJnssaJg Jeg X X ssald pasatan LO sseJppiy 1e8 000 Ausuayul 1n 4 zH Q O fousenba Um p so OL MOT Soa 50 04 s0 M0 BON aul UM sot HI 0 4 ubiH aag uuy ruo A pi E Lu 4 ER A sub O S ubi Jawan 15009 008 ZH 0 0 st sisa SAH Asuanbas LIA NO he FEES 4 4 ra 96 O S 1 ZH Op AAODUIAA Aauanbaly Xey onu susu NNIWENS NNAWENS5 W3HDONSISA MS SJEM JOS pe qesic D0 ss OO Bunseuuo oy ebueu sait uoneunBijuo 11 5581ppy L 1 La nN3INSIS nN3INSIS ki 00 o UT QM
23. METER for a short time when the new setting is saved Use the settings of this submenu lift value fall value enable sequence control and switch interval for each pump in the Hydrovar system Hold the 3 button down for 3 seconds to return to SUBMENU CONTROLLER Hold the 3 button down again for 3 seconds to return to PRESSURE x x bar the 1 display SPEED xx Hz If you set the addresses in a multiple pump system the first time connect only the Hydrovar unit where you want to set the address to power supply otherwise all Hydrovars in the system connected over the RS485 interface will change their address too In the following section you will give the pump an address number Generally the first programmed pump will be number 1 the second will be number 2 and so on The purpose of this is to help the Hydrovar sequence the start and stop activity of the pumps in the system including the selection of the lead and lag pumps From the 1 display hold the 3 button for longer than 3 Address 01 sec to get the display where the actual address is shown Detected or When there is no active address there is shown Address 01 LOST Then press the button twice to change to Submenu Address Press the dk button to enter the submenu and change to Address Change 00 gt 00 Addresses from 01 to 04 and also 00 can be set in this parameter To change the address it is not necessary to cut the interface connection to other HYDROVARS On t
24. Operating Instructions HYDROVAR HV 1 1 HV 1 2 Incl RS 485 interface English 771079202 Manual HV1 1 1 2 V EN Vogel Pumpen K ITT Industries Engineered for life HYDROVAR Operating Instruction Index 1 1 IMPORTANT SAFETY INSTRUCTIONS 0222x0000000 LA heIttkhnetkhrxtnk kr manna kanns 4 2 SYSTEM DESIGN i sou aaa aaa ag aana a Ma da ag aaa n E MEME AA 6 3 PRESSURE TANE dee 7 4 TRANSDUCER ernieren EEE A AEE 8 4 1 PRESSURE TRANSMITTER SERIES PA 21 Reeg Seege 8 4 2 DIFFERENTIAL PRESSURE TRANSMITTER SERIES PD Z0OM RII mehrerer rrr rers 9 5 TECHNICAL DATA FREQUENCY INVERTER AND GENERAL DATA eem 10 5 1 BIS ISI KEE 11 6 HYDROVAR Lei RH Hl LEE 12 6 1 MOUNTING THE HYDROVAR ON THE PUMP 222200000000406 eR mehrerer rere rre er rre sers serere 12 6 1 1 Included COMPONENTS cccscccscccnecceeccecseccsecceessuessuessessuenseessesseeeseesessuenseeseusseensesseesseesseses 12 NEE han ola UNG APP PAPA KA ANAA APA IN GG A I 13 Gila Mounting e 16 6 14 Mounting OF the pressure e DE 17 6 2 ELECTRIC INSTALLATION AND WIRING a a eee eee m e IR IR hm ehh ehh NBA ANAN NAAN 18 GA MGA NEO EE 18 6 2 2 Wiring the Hydrovar to the motor sensns sa nsns sn asesinar nsa anna ns 18 AGO O il pL DIDI iL ILL ILE ILLI Iii EE 21 524 TO EE 21 oM TRON E NEE 23 7 OPERATION WITHOUT EXTERNAL PROGRAMMING DEVICE A 24 8 POSSIBLE INDICATIONS OF THE LED ON THE HYDROVAR a 25 9 OPERATION IN THE MAIN MENU eennnnmI RI III HII tI IIttheIe
25. TI NL AT iiftintensty eingestellter LR a NT LALA oi MN soc FAN NAN M set pressure see To leave the submenu press the gt key longer than 3 sec 13 7 Submenu Multicontroller Submenu To enter this menu you have to press the key to Multicontroller leave the menu press the gt key longer than 3 sec 13 7 1 Lift Value ACTU VALUE INC Adjustable between 0 and 2 5 bar 0 15 BAR This value together with the fall value determines the increase of the required value after starting of the following pumps Press gt on the controller to change to 13 7 2 Fall Value For scaling the required value for 1 to 4 pumps www hydrovar com 45 e ITT Industries or life Engine HYDROVAR Operating Instruction Actu Value Dec Adjustable between O and 2 5 bar 0 15 bar This value determines the start value of the 2 and the other following pumps Start Value REQUIRED VALUE ACT VALUE DEC Application example 1 Pump 1 reaches f maximum speed 2 Pressure falls and reaches the start value of the 2 pump REQUIRED VALUE ACTU VALUE DEC 3 Pump 2 is switched on automatically 4 The required value is calculated new after the start of the 2 pump in the following way New required value REQUIRED VALUE ACTU VALUE DEC ACU VALUE INC Generally k Number of active pumps P P k 1 lift value fall value e Lift value Fall value gt Pressure
26. VALUE DECREASE determines the increase of the required value after starting of the following pumps see attached application example on next page ITT Industries Engineered for life www hydrovar com 35 amp HYDROVAR Operating Instruction Generally a slight pressure drop is allowed on the first pump before the next is started This allows for brief systems fluctuations without pump cycling Once the next pump starts however you will want the system to resume its normal set pressure To do this enter the amount of pressure drop you will allow before the next pump starts value of parameter ACTUAL VALUE DECREASE The diagram shows the pressure drop and increase To increase the pressure even more to compensate for system loss at higher flows enter the total of the system drop allowed before next pump starts and the increased pressure ACTUAL VALUE INCREASE desired For example if the pressure drop allow 0 35 bar before the next pump starts and the increased pressure needed to compensate for system losses is 0 2 bar you would enter 0 35 0 20 0 55 bar calculated value of the parameter ACTUAL VALUE INCREASE to compensate for both system pressure drop and compensation requirements Application example 1 Pump 1 reaches the speed of ENABLE SEQ CONTROL 2 Pressure falls and reaches the start value of the 2 pump REQUIRED VALUE ACTUAL VALUE DECREASE 3 Pump 2 is switched on automatically 4 The requ
27. ach the parameter LIFT LIFT FREQUENCY FREQUENCY 30 Hz LIFT FREQUENCY This indicates the frequency at which the increase of the set pressure should begin It should be the speed at which the pump works at the set pressure and at delivery rate of 0 m3 h On a 50 Hz system there is virtually no flow below about 30 Hz on a 60 Hz system about 40Hz Press the 4 and N button until you reach desired frequency LIFT FREQUENCY 30 Hz After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Now press the button to change to LIFT INTENSITY 0 0 bar LIFT INTENSITY This value states how much the required value should be continually increased till the maximum speed maximum volume is reached Press the and N button until you reach desired value LIFT INTENSITY 0 0 bar After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Hold the gt button down for 3 seconds to return to SUBMENU CONTROLLER Hold the 3 button down again for 3 seconds to return to PRESSURE x x bar the 1 display SPEED xx Hz ITT Industries Engineered for life www hydrovar com 33 amp WIDA SAMS MPAYLOS A D L jeg EWON Ja jo 3u02
28. ad TT Industries Engineered for life www hydrovar com 5 8o HYDROVAR Operating Instruction 2 System Design The following diagrams show typical single pump and multi pump systems using the Hydrovar control unit Connection can be made directly to a water supply or water can be drawn from a break tank or well In the case of break tanks and wells level switches should be used to shut down the pumps when water is low In the direct connection a pressure switch on the suction side should be used PX E VA X gt 1 pump with drive head 5 2 diaphragm tank 3 distribution panel 4 gate valves Single pump layout 5 non return valves 8 incoming pressure switch 9 pressure gauges 14 pressure transmitter Multiple pump Layout ITT Industries Engineered for life www hydrovar com 6 amp Operating instruction 85 1 78 MYDROVAR 3 Pressure tank A diaphragm pressure tank is used on the discharge side of the pump or pumps to maintain pressure in the line when there is no demand This will keep the pumps from continuing to run With the Hydrovar control unit it is not necessary to have a large tank for supply purposes In selecting a tank make sure it can withstand systems pressure The tank should have a capacity of more than 1096 of the maximum system flow rate l min of one pump Ask of required certificates needed for your country Precharge the tank to the following Solldruck required
29. age is shown during the connecting when CONNECTION AUTOCONNECTING is enabled In this time the Hydrovar searches for the given or entered address Then the display changes to the 1 display PRESS X X bar The actual input value bar and the actual SPEED X X Hz output frequency Hz are displayed 11 Typical applications 11 1 Setting Single Pump Constant Pressure At the first startup Change Pressure and Autostart of the external programming unit are enabled After connecting on the display of the programming unit there is shown Scan This message is shown when the external Connection programming device is set up to the Hydrovar and scanning a valid pump address After a few seconds the display changes automatically to the 1 display Press x x bar This window showss the actual values of the Speed x x Hz Hydrovar a required pressure of 3 5 bar is previously set Press gt on the controller to change to Pressure To select required pressure use the xx x bar buttons and we After changing of the value you have to confirm with the button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved After changing of the value you have to confirm with the 3 button Then press on the controller to change back to the 1 display Press x x bar Speed x x Hz ITT Industries Engineered for life www hydrovar com 28 3
30. alogues indication the amount of friction E WAON loss that can be expected in various sizes of Cl pumps at different flow rates Use these ENT Anhubintensitat TM d in des tables to determine the friction loss for the i NJ sue pipe size you are using at maximum flow KL LA lift intensity in of rate eingestellter Gaan jai K set pressure Solldruck E Ml dL AL NG Ba anak set pressure E N CO ITNA LI Kt fat II BBS 238 YUL LLLA tt Q This Diagram shows a typical system curve The system pressure set point is shown at shutoff and pressure increase is shown for increasing flow Calculate the pressure required to overcome friction loss at maximum flow ITT Industries Engineered for life www hydrovar com 31 amp Operating Instruction DONI 18A MS SJEAMIJOS 10413 E 10413 7 LK 10413 15e L sol ssauppy dung Aejag 10413 CI d 4 00000 ieg 000 aunjung dung jur Joanu oS 11 4 Entering Compensation Values HYDROVAR Jeg 000 Aysuaiu 447 zH 00E Au nbasy Vu 5004 mo aag n 500L H MOT Bi aul UI 96 001 sinoypz sot Hl o 4 uny 45a 15009 Jeau yaus UD ee uiu Duuo ZH OO ZH OD ZH O S 5 OT O S fouenbaJJ 15al WWI JJO BAG S po bes ajqeu3 ubi Jawan 15009 Y DOL AGt S0O ZH 00S Jeg SL O 008 ZH 00 ung 153 ajqeu3 auey sosuas WWI UD SAe S sag anjer DI 5153
31. be carried out in the electrical or mechanical part of the system Installation maintenance and repair work may only be carried out by trained skilled and qualified personnel Unauthorised modifications or changes to the system make all guarantees null and void When in operation the motor can be stopped by remote control whereby the drive head and the motor remain under voltage For safety reasons the unit must be disconnected from the power supply when carrying out work on the machinery as locking out the equipment by switching off the release mechanism or set value cannot prevent accidental starting of the motor When the drive head is connected to power supply the components of the power unit as well as certain components of the master control unit are also connected to the power supply Touching these components seriously endangers life Before removing the frequency inverter 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 drive head the capacitors in the intermediate circuit have to be discharged by the installed discharge resistors first ITT Industries Engineered for life www hydrovar com 4 amp Operating instruction 8 MYDROVAR Voltages of up to 400 volts are possible if there are faults it can be higher All work carried out when the frequency inverter is open may only be performed by qualif
32. c PARAMETER 10 Connecting the external programming device to the HYDROVAR After connection of the HYDROVAR head to the power supply and plug in of the external programming device there can be shown two different messages 1 If the AUTOCONNECTION is disabled standard you reach Address 01 This message is shown when the Remote Control is Lost new connected At this time the Hydrovar searches for an available address If address 01 is available the display changes to Address 01 The actual pump address is shown Detected Statusinformations by systems with activated Multicontroller P1 Masterpump P2 Slavepump P3 Slavepump P4 Slavepump P Follownumber is not useful Hold pump stops through the pressure transmitter Run pump runs Stop pump stops through the leadpump Disabled pump stops through the stopbutton or the terminal block Error pump stops through an error V Follow pump stopped Regulator from the follow pump is release Pump don t work at the follow pump TT Industries Engineered for life www hydrovar com 27 amp HYDROVAR Operating Instruction If the actual pump address 01 is not available the display does not change and you will see again Address 01 Then you could change the address with and ve Lost and confirm the selected address with 3 Press gt on the controller and you enter the INVERTERMENU 2 If the AUTOCONNECTION is enabled following message is shown SCAN This mess
33. constant when pumps switch on e Lift value gt Fall value gt Pressure rises when lag pump switches on e Lift value Fall value Pressure falls when lag pump switches on P1 P2 P3 Press 3 on the controller to change to 13 7 3 Release Follow up pump Enable Seq Ctl The follow up pump only starts when the start 48 0 Hz value is reached and the lead pump has reached the programmed release frequency Adjustable from 0 0 Hz to 70 Hz If you don t want to start a following pump this value has to be set higher than the MAX FREQUENCY Press gt on the controller to change to 13 7 4 Switch Interval Switch Interval For changing the master pump and follow up 24 hours pump in order to achieve even operating hours of www hydrovar com 46 e ITT Industries Engineered for life Operating Instruction HYDROVAR the pumps Adjustable between 0 and 250 hours To leave the submenu press the gt key longer than 3 sec 13 8 Submenu Relay Submenu To enter this menu you have to press the key to Relay leave the menu press the gt key longer than 3 sec 13 8 1 Relay Configuration Relay Configu Possible selections with buttons W and Simple Multicnt Simple Multicnt allows to start a following simple multi constant speed pump controller Run Signalling Run indication over the relay Error Signalling fault indication over the relay Warning Max contact load 500mA 125V Press 3 on the controller to c
34. e pressure setting bar at which you want the pump to shutoff 0 bar Typically a setting of about 1 bar less than the standard pressure setting would be entered After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Press the gt button to change to ERROR DELAY 10s www hydrovar com 30 e ITT Industries Engineered for life Operating Instruction HYDROVAR ERROR DELAY Adjustable between 0 100 sec Delayed switch off in the event of low water terminal X2 6 X2 7 and also for the conveyor limit By pressing the 8 and de button you will be entering the ERROR DELAY amount of time sec that the pump will run at the 10s programmed conveyor limit before it automatically shuts off After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Hold the 3 button down for 3 seconds and you will be SUBMENU returned to ERROR Hold the gt button down again for 3 seconds to return to PRESSURE x x bar the 1 display SPEED xx Hz 11 3 Single Pump System Curve Compensation The Hydrovar can automatically compensate for system friction losses due to increased EN flow Tables are available in most pump A fenster f cat
35. hange to 13 8 2 Start frequency of the slave pump Slave On Limit Here you can set the frequency of the speed 50 0 Hz controlled HYDROVAR pump when the full speed slave pump should start if simple multicontroller is set in the parameter Relay configuration In this case the slave pump runs with full speed and the HYDROVAR pump controls the additional demand Press gt on the controller to change to 13 8 3 Stop frequency of the slave pump Slave Off Limit Here you can set the frequency of the speed 30 0 Hz controlled HYDROVAR pump where the full speed slave pump should stop if simple multicontroller is set in the parameter Relay configuration To leave the submenu press the gt key longer than 3 sec 13 9 Submenu Sensor Submenu To enter this menu you have to press the key to Sensor leave the menu press the gt key longer than 3 sec www hydrovar com 47 e ITT Industries Engineered for life HYDROVAR Operating Instruction 13 9 1 Sensor Adjust SENSOR ADJUST Zero adjustment of the transmitter Out of range Depressurise the system and press keys N simultaneously After adjustment adjusted appears on the display If out of range is shown on the display no adjustment is possible e g when pressure is in the system Press gt on the controller to change to 13 9 2 SensorMax Adjust SENSORMAX ADJUST The analogue input terminal X2 2 is prepared for a 0 5 4 5 V transmitter signal of 0 5 4 5V
36. has stopped gt Motor runs required pressure can be changed without the programming device with the buttons 4 and Y or the external programming device is connected and the pump is stopped with the button Y on the Hydrovar or with the external release input terminals X2 4 and X2 5 connected remote control and the inverter is released but the pump is not running because of the required pressure is reached connected external programming device and the pump is running error signalling type of the Error is shown on the display of the external programming device signalling of a fatal error HYDROVAR has to be cut from the power supply 25 e ITT Industries Engineered for life Operating Instruction in the main menu ION In Operat 9 HYDROVAR HO PUOMSSEY seg PUN uomusu Menu overview Fj gopo Aysuaju 17 zHOO0E fousenbaJ 447 DONI J8AMS 5004 aJeM J05 AAO ac SO OC 0 Joug E MO BO aur WIWI opp sinoypz sort II o lt s 1043 2 un 1531 15008 EAJSJU yaus UD Tea Uu Bruo F V Fi Ng 7 Pi LS zH ODE H 0 DE H O Sp SOP O S J0413 158 fAauanbaJJ 15a iur 44O eAe s pa bes ajqeug ubi aoo 15009 l 5 OL Y OOL ASt S0 zH OOS Jeg SLO 0 08 HOOD ssaJppwy dung Abad 10413 ung 153 a qeua auey 10suas yuu uc anes sag anjer DI si5aJ215 H Asuanbas LIA 1 LLL
37. he Hydrovar Connections in the conduit box The connection of the motor cable depends on the type of the motor and can be done in star or delta connection you have to use the connection for a motor voltage of 3x230V shown on the motor label Star connection Delta connection See b supply cable The main power cable is connected to the terminals labelled L1 N for the 230 VAC single phase input shown in the diagram 6 2 2 1 ITT Industries Engineered for life www hydrovar com 20 3 Operating Instruction HYDROVAR 6 2 3 Control By using the HYDROVAR drive head for constant pressure control together with a pressure or differential pressure transmitter or if required according to external manual control by reference of 0 5 4 5VDC this external signal has to be connected to the terminals X2 1 X2 2 and X2 3 of the control terminals terminals of the RS485 interface E BAON a control terminals HV1 15 1 2 6 2 4 Terminals All externally used cables have to be shielded Do not connect the mass of the electronic components to other higher potentials All electronic ground and GND of the RS 485 interface are internally connected For external off on and low water switch contacts suitable for lt 10 V are necessary The control cable must be at least 5mm If unshielded control cables are used signal interference may occur and interfere with the function of the inve
38. he left side there is shown the address of the HYDROVAR which you are actually speaking select the address by using the buttons or WY On the right side then you can give the HYDROVAR a new address also with the buttons and You only can give an address which is not used in the pump group To change between left and right side press button or gt The star shows the actual used side To save the new selected address press both buttons and gt together for 2 sec If it was successfully you will see the same address on both sides TT Industries Engineered for life www hydrovar com 38 Operating Instruction HYDROVAR Example To change the Hydrovar with address 01 to address 04 press the button to change the to the left side Address Change 00 gt 00 Select the address of the Hydrovar you want to change the Address Change address with the 4 and Y button 01 gt 00 press the 3 button to change the to the right side Address Change 01 5 00 Select the address you want to give this Hydrovar with the Address Change and Y button 01 gt 04 To confirm and save the new selected address press both buttons and gt together for 2 sec If it was successfully you will see the same address on both sides Address Change 04 gt 04 The definition of the address you have to do for each pump in the system Hold the button down for 3 seconds to return to SUBMENU Address Hold the bu
39. ich you want to speak select the address by using the buttons or dei On the right side then you can give the HYDROVAR a new address also with the buttons and N You only can give an address which is not used in the pump group To change between left and right side press button or The star shows the actual used side To save the new selected address press both buttons and together for 2 sec If it was successfully you will see the same address on both sides TT Industries Engineered for life www hydrovar com 51 amp HYDROVAR Operating Instruction To leave the submenu press the gt key for 3 sec 15 Possible Error messages 15 1 Low Water XXX Remedy Error Water Check incoming pressure If incoming pressure is normal the unit restarts itself If there is no external low water protection e g circulating systems you have to bridge terminals X2 6 and X2 7 15 2 Overheating Motor XXX Possible causes insufficient cooling Error Mot Temp ambient temperature is too high or motor overloaded After the cause has been remedied the malfunction has to be reset by cutting off the power supply for gt 30 seconds 15 3 Overvoltage XXX Possible cause Check mains supply supply Error Overvolt voltage too high peak voltage owing to switch heavy loads on the network or RAMP 2 is to fast Find the cause and take countermeasures e g network filter RC elements Disconnect the power supply for gt 3
40. ied authorised staff Furthermore care must be taken not to short circuit the neighbouring components when connecting the external control wires and that open cable ends which are not in use are insulated The HYDROVAR drive head contains electronic safety devices which switch off the control element in the event of faults 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 disconnected from the mains voltage through the electronics of the frequency converter but is not potential free in the circuit In addition voltage fluctuations especially power failures can cause the system to switch off itself Repair of faults can cause the motor to start up again The system may only be put into operation when it has been earthened In addition equipotential bonding of all pipes must be ensured The operating instructions must be read understood and followed by the operating personnel We point out that we accept no liability for damage and operating disorders which are the result of non compliance with the operating instructions Please High voltage tests of the inverter or the motor may damage the note electronic components Hence bridge before the in and outgoing terminals L N U V W To avoid incorrect metering by capacitors incorporated in the electronic part isolate the motor from the Hydrovar Drive he
41. ired value is calculated new after the start of the 2 pump in the following way New required value REQUIRED VALUE ACTUAL VALUE DECREASE ACTUAL VALUE INCREASE Generally k Number of active pumps P P k 1 lift value fall value e Lift value Fall value gt Pressure constant when pumps switch on e Lift value gt Fall value gt Pressure rises when lag pump switches on e Lift value lt Fall value gt Pressure falls when lag pump switches on Note This value is cumulative An extra 0 2 bar will be added to the total system pressure with each additional pump which turns on For example if the initial system pressure was 3 5 bar pump two would create 3 7 bar pump three would create 3 9 bar and pump four would create 4 1 bar system pressure ITT Industries Engineered for life www hydrovar com 36 3 Operating Instruction HYDROVAR ACTUAL VALUE INCREASE 0 15 bar After changing of the value you have to confirm with the 3 button Then you will get the message SAVE PARAMETER for a short time when the new setting is saved Enter the required value by pressing the 4 and Y button Press the gt button to change to ACTUAL VALUE DECREASE 0 15 bar This value determines amount of pressure drop you will allow before the next pump starts see application example on previous page ACTUAL PRESSURE DECREASE Fall value Enter the required value by pressing the 4 and Y button ACTUAL VALUE
42. is transferred to the sensor by a separate steel diaphragm in the oil chamber Specifications Range FS 4 bar differential Over pressure Pmax 16 bar single sided Class of protection IP 65 Output Signal 0 5 4 5 V DC ratiometric Supply 5 VDC 10 9o Load Resistance gt 5 kQ Linearity 10 20 Yo FS max 0 5 FS Stability 0 1 Yo FS max 0 2 FS Operating temperature 10 80 C Storage Temperature 40 80 C Material Body and diaphragm 1 4435 Stainless steel Screw joint and cover Steel electroplated for Emetorpipe d 8mm Plug mPm 193 Incl 2m cable Out white Vcc brown GND green Screen ITT Industries Engineered for life www hydrovar com 9 amp HYDROVAR Operating Instruction Technical Data Frequency Inverter And General Data the Motor MF 1 AR 1 output Cu m 48 62 Hz HV 1 1 1 1 kW 3x 230V 1x 220 240 V 15 10 Ampere HV 1 15 1 5kW 3x230V 1x 220 240 V 15 10 Ampere HV 1 2 2 2 kW 3x230V 10 0A 1x220 240V 15 16 Ampere Output voltage 3x 0 Uin VAC 0 70 Hz depends on the input voltage Min frequency 0 max frequency Electrical efficiency gt 95 Protection against Short circuit over and undervoltage overheating of the electronics overload and additional external protective functions via PTC motor temperature and low water switch A mains filter is fitted to ensure interference immunity The HV Series frequency converter
43. ller to change to 14 1 Controller menu Configuration Submenu To enter this menu you have to press the N key to Configuration leave the menu press the gt key longer than 3 sec 14 1 1 Automatic connection to the programming device Only valid for programming device Enabled Auto connecting enabled that after plug in of the programming device it changes automatically to the inverter menu During this auto connection the programming device is looking for a valid address and SCAN CONNECTION is shown on the display Auto connecting will be stored after leaving the submenu Configuration Auto connecting disabled there is no automatic connecting with the pump choose the address Press gt on the controller to change to 14 1 2 Software Version of the programming device Software In the second line of the display there is shown the Software VOGREM 004 version of the software of the programming device and also the date of programming of this software To leave the submenu press the gt key for 3 sec 14 2 Submenu address Submenu To enter this menu you have to press the N key to Address leave the menu press the gt key longer than 3 sec 14 2 1 Change of pump address Address Change Addresses from 01 to 04 and also 00 can be set in 00 5 00 this parameter To change the address it is not necessary to cut the interface connection to other HYDROVARS On the left side there is shown the address of the HYDROVAR wh
44. or life 6 1 2 Mechanical mounting Variant for HV1 1 Hydrovar 1 Remove the motor fan cover from your 3 phase motor by removing the mounting screws 2 Put the mounting and distance ring 1 between the fan cover and the Hydrovar and fix them together with the screw 3 by using the included washer 2 mounting 3 Use the fan cover screws to mount and distance the fan cover Hydrovar combination ring to the motor motor fan cover 2 washer 3 screw Note N Don t forget the washer between the screw and the motor fan cover IT T Industries Engineered for life www hydrovar com 13 amp HYDROVAR Variant for HV1 15 1 2 Operating Instruction Don t forget the gaskets for the 3 screws Ensure that there is no water on the unit before you open the cover Gasket i 4 screw Ihi x M5x50 Center bit vex 4 mounting clamps Connection Motor conduit box Thermistor Transducer www hydrovar com 14 Mounting Remove the 3 screws from the Hydrovar cover Place the centre bit in the Hydrovar fan cover Place the Hydrovar fan cover on the motor Hang the 4 clamps by the Motor fan cover and mounted with the 4 screws Mounted the cover with the 3 screws e ITT Industries Engineered for life Operating Instruction HYDROVAR Mounting ring O a mounting ring If you use a motor with plastic fan cover you must use
45. programmed delay time Error Delay Possible causes can be break of the pipe before or after the pump closed valve before the pump air in the pump After the cause has been remedied the malfunction has to be reset by cutting off the power supply for gt 30 seconds 15 9 Additional internal processor Error messages ERROR 1 EEPROM ERROR corresponding data block malfunction ERROR 2 Not used ERROR 3 e Processor RAM error ERROR 4 l Not used ERROR 5 Processor ROM error ERROR 6 Watchdog error ERROR 7 l Clock error quarz ERROR 8 Programme error These ERROR signals are acknowledged by disconnecting the power supply for gt 30 seconds If the error signal should appear again contact customer service and provide a detailed description of the error 16 Maintenance The HV1 1 1 2 control unit does not require special maintenance However the cooling fan and the vent should be freed of dust occasionally Notes When replacing the control card in a plant with more than one pump ensure that the same control card version is used in all Hydrovar units Fur further information please ask your distributor ITT Industries Engineered for life www hydrovar com 53 amp Operating Instruction DOA anms SIE JOS Joug E 001 snoupz 10413 7 ur 1sa 15009 Jeau Uas zZH OOE ZHODE ZH O S 30413 15e fAauanba
46. rese IN des Solldruckes Set hysteresis See T 596 ES In 96 eingestellte Window setting in x 100 Rampenhysterese Of rated pressure APP v Sef hysteresis Y R1 Rampe 1 schnelle Hochlauframpe speed ramp fast increase R2 Rampe 2 schnelle Tieflauframpe speed ramp fast decrease R3 Rampe 3 langsame Hochlauframpe speed ramp slow increase R4 Rampe 4 langsame Tieflauframpe speed ramp slow decrease t Zeit time R2 A RA Press 3 on the controller to change to 13 6 7 Compensation Frequency Control according to a system curve increase of the set pressure depending on the delivery rate or speed Adjustable between GHz and the set MAXIMUM 30 0 Hz FREQUENCY this setting states at which frequency the set pressure should be increased That is the speed at which the pump works at the set pressure and at delivery rate 0 Press gt on the controller to change to 13 6 8 Lift Intensity LIFT INTENS Adjustable from 0 to 100 of the range of the used 0 0 bar pressure transmitter This value states how much the required value should be continually increased till the maximum speed maximum volume is reached www hydrovar com 44 e ITT Industries Engineered for life Operating Instruction HYDROVAR Figure Lift Intensity mm em TUT II IL mm mm c mm mm a aan wm d mm Sa Anhubintensitat in des HITS NT a aten b Pp 4 Solldruckes lel LEKI
47. ries Engineered for life HYDROVAR Operating Instruction Note Low no suction depends on the installation of a suction line pressure switch or float switch for a tank This is connected to the Hydrovar as described earlier in the Electrical Installation section The cut off setting for this switch should be the maximum NPSH required by the pump To set run out protection Warning Run out protection is available for one pump systems and multiple pump systems with a common suction pipe In multiple pump systems with separate suction pipes you can not avoid dry running by measuring the system pressure because the pressure is produced from another pump in the system From the 1 display press the 3 button twice until you SUBMENU reach PARAMETER Then press the W button and the display will change to PASSWORD 0000 Password The Password protection prevents untrained personal from accidentally changing the base setting Press the AN button until you reach the number 0066 PASSWORD 0066 Press the gt button repeatedly until you reach SUBMENU ERROR Press the dk button to enter the submenu and change to CONVEYOR LIMIT 0 0 bar CONVEYOR LIMIT 0 0 bar means disabled conveyor limit An adjusted value 50 has to be reached till the programmed ERROR DELAY time Doesn t this value be reached the failure CONVEYOR CONTROL ERROR will be indicated and the pump stops By pressing the and button enter th
48. rter When connecting together the variable speed pumps max 4 pumps via the interface RS 485 the terminals X3 1 and X3 2 and X3 3 are to be connected in parallel by means of a shielded cable to every HYDROVAR drive head and programmed accordingly ITT Industries Engineered for life www hydrovar com 21 amp HYDROVAR Operating Instruction Control Terminals Lin cc max 500mA 125V gt Motor thermo Thermistor low water Ld A External release Ri 10kOhm 5VDC use gold External on off plated contact Cl Cl Q9 G9 G9 Q9 Cl 9 CN Ps 4 4 2 15 V Ub Power supply for external control 5VDC 2 actual value signal 0 5 4 5 VDC 3 4 Screen Ground not earthened O 4 45V Pls GND RS 485 L 2 SIO A v Li SIO IT T Industries Engineered for life www hydrovar com 22 Operating Instruction HYDROVAR 6 3 Front plate HV 1 1 1 2 indication LED push buttons WARNINGLIGHT Motor run Motor off Controller stop HYDROVAR M a ITT Industries MV Engineered for life www hydrovar com ITT Industries Engineered for life www hydrovar com 23 amp HYDROVAR Operating Instruction 7 Operation without external programming device Warning Before you start the system the pump must be filled and all wiring and piping have to be done A Note The Hydrovar is delivered with these settings as standard Change Pressure enabled Auto Start enabled Other
49. tton down again for 3 seconds to return to PRESSURE x x bar the 1 display SPEED xx Hz 12 Settings at the Invertermenu 1 display PRESS X X bar The actual input value bar and the actual SPEED X X Hz output frequency Hz are displayed Press gt on the controller to change to PRESSURE There you can set required pressure XX X bar with the buttons and V Press gt on the controller to change to SUBMENU To enter the submenu Parameter PARAMETER press de button Press gt on the controller to change to 1 display ITT Industries Engineered for life www hydrovar com 39 amp HYDROVAR Operating Instruction 13 Settings at the Submenu Parameter must be read carefully to prevent incorrect settings which will cause malfunction Warning Before entering the secondary menu these instructions After entering the SUBMENU PARAMETER the display ill ch t PASSWORD will change to 0000 Set Password 0066 by pressing and V SR 0066 Note The password must be entered at each entry Confirm by pressing and the first Change Pressure parameter of the sub menu is shown Enabled 13 1 Pressure change Change Pressure You can decide between Enabled or NW Enabled Disabled If the pressure setting is enabled you can change the required pressure on the Hydrovarhead with decrease and increase see chapter 7 without an external programming device Press 3 on the controller to change to 13 2 Auto start Auto Start Yo
50. ttteImettthtevftktrxt kk mra kr rra 26 10 CONNECTING THE EXTERNAL PROGRAMMING DEVICE TO THE HYDROWVAR 27 11 TYPICAL APPLICATIONS 0022700j0110 0H I I II III III hne hhnmehhhnmrakrirak i amesa arsa iren armen nnns 28 11 1 SETTING SINGLE PUMP CONSTANT PRESSURE II III I AA 28 11 2 SINGLE PUMP PUMP We e ET 29 11 3 SINGLE PUMP SYSTEM CURVE LOMPENSATION IR II SELA AN NA 31 11 4 ENTERING COMPENSATION KAMERA 32 MULTIPLE PUMP CONSTANT PRESSURE AND SYSTEM COMPENSATION 34 12 SETTINGS AT THE INVERTERMENU eesssemmnnn aa 39 13 SETTINGS AT THE SUBMENU PARAMETER eeesemm aaa 40 13 1 PRESSURE CHANGE EE 40 E e PRU OST OR EE 40 CC BA AY L6 1 AAN 40 1344 KONTROL ANA nga 41 d FACTS IOI WIDI EE 41 UE SBP TIN EE 41 13 5 7 IVI F EGUEN AA 41 TZ UA TO CNG EE 42 13 5 3 a AA 42 13 5 4 Operation of the minimum Treguenck aaa 42 EE CIA IAS E 11 AP PA 42 1260 IER OI Kee Uu et KE 42 www hydrovar com 2 e ITT Industries Engineered for life Operating instruction 8 HMYDHOVAR 13 6 1 Window EE 43 15 62 HAND FIV SUP CSIS saaan BA ga aeng a aaa antaga aaa aapa aa ak a Ka BB E DIKE ga IR a aa Na BE aana eaaa nden naa 43 13 6 3 Fast acceleration time AA 43 13 6 4 Fast deceleration Ume esses hehehe nnne nnn nenhe neuere tessatea sakura sata sa aa sa aa aa aa 43 13 56 59 Slow acceleration EE 43 LE E ere ef EE 44 ALAALA Be EEN 44 3 0 COIDensation FT CO nga scs a aa an aaa a EEA
51. u can select between Disabled and AN Enabled Enabled Autostart Enabled means that the pump starts again automatically after an interruption of the power supply power failure If Autostart Disabled is set the pump has to be restarted manually after a power failure by pressing MY and BJ Press gt on the controller to change to 13 3 Mode ITT Industries Engineered for life www hydrovar com 40 Operating telen HYDROVAR Select with buttons W and A between Controller Multicontroller gt sequence control for max 4 pumps Controller pressure control for a single pump If only one HYDROVAR pump is in operation set Controller If more than one HYDROVAR pumps are working together via the RS485 interface the Multicontroller must be selected Actuator external frequency setting The application Actuator is only used if you have an external controller and the HYDROVAR works like a standard frequency converter external frequency signal 0 5 4 5VDC to the terminals X2 1 and X2 2 Press 3 on the controller to change to 13 4 Control Response Regulation Mode Normal Speed is increased with falling actual value Normal Signals e g Control at constant output pressure Inverse Speed is reduced with falling actual value signal e g Control of constant suction pressure or at constant level before the pump Press gt on the controller to change to 13 4 1 Dimension unit Dimension unit Here you could choose yo
52. ur favourite unit with Bar buttons W and AN Bar psi or for the 1 display Press gt on the controller to change to 13 5 Submenu Inverter Submenu To enter this menu you have to press the N key to Inverter leave the menu press the gt key longer than 3 sec Press gt on the controller to change to 13 5 1 Maximum Frequency Max Frequency Possible setting between min 40 and max 70 Hz 50 0 Hz Attention Settings higher than 50 Hz may overload the motor Settings of 10 above nominal frequency cause 33 more power consumption Press gt on the controller to change to ITT Industries Engineered for life www hydrovar com 4 amp HYDROVAR Operating Instruction 13 5 2 Minimum frequency Min Frequency Here you can set the minimum frequency 0 0 Hz Attention If there is set F gt Fmin in the parameter CONFIG FMIN the pump will not stop in the normal mode It will keep running with the set minimum frequency Possibility of overheating of the pump Press gt on the controller to change to 13 5 3 Boost BOOST The stated value determines the course of the 5 0 96 U f curve Setting of the motor starting voltage in Yo of rated voltage Settings of 0 25 of maximum output voltage are possible However care should be taken that settings are kept as low as possible so that the motor does not become thermally overloaded Press gt on the controller to change to 13 5 4 Operation of the minimum frequency
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