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Operating Instructions

1. 54 9 22 2 Fall Value actual value decreasel eene 54 9 22 3 Enable sequence contra 55 9 224 Switch Interval dte Z tals doe te dE RR ERES 55 9 22 5 Source of required value EE 55 9 22 6 Submenu Synchronous Control 56 9 22 6 1 Synchronous meme nennen 56 9 22 6 2 Synchronous WIindOW nemen nnne nennen 56 9 22 7 Pump status nennen nennen nennen 57 9 22 8 Busarbit Diag Counter for interface communication problems 57 9 23 Submenu RS 485 Interface 58 923 1 B mp Address a 58 E legt EE 58 9 24 Frequency Lifting EY an PEERS kw ak EP e EVE E Da 59 9 25 Lift Amounttintensity boue ni dee ie a e n e 59 9 26 Analogue OUTPUT ce kk ve nana kak eer ee ak ak kan speak Si E SEKR 60 9 27 Dimension nib o coto cto ano ese e Ae 60 9 28 Automatic test run 8 nnne nnn ah nnn nns nnns nnne 60 9 29 Submenu for manual test run 61 3 9 29 1 Activate manual test run 61 9 29 2 d 9101000000 61 9 29 3 Boost for manual test run 61 9 30 Submenu Error 8 2 8 88282888883888 83332 383 62 9 30 1 Conveyor EMMI c
2. Press the button to change to the next parameter 51 9 21 2 1 Offset level LEVEL 1 The level 1 is the start level of the 1 Offset XX X Yo Adjustable between 0 and 10096 of the additional analogue input Press the button to change to the next parameter 9 21 3 2 Offset level LEVEL 2 The level 2 is the start level of the 2 Offset XX X Yo Adjustable between 0 and 10096 of the additional analogue input Press the button to change to the next parameter 9 21 4 Intensity 1 INTENSITY 1 Only in combination with Level 1 XX X Yo This is the intensity of the 1 Offset of the required value at the zero point of the second analogue input Setting range 200 up to 200 of the sensor range Press the button to change to the next parameter 9 21 5 Intensity 2 INTENSITY 2 Only in combination vvith Level 21 XX X Yo This is the intensity of the 2 Offset of the required value at the maximum point of the second analogue input Setting range 200 up to 200 of the sensor range To leave the submenu press longer than 3 seconds to change to SUBMENU Press the button to change to the next parameter Offset 52 9 21 6 Example for the Offset SENSOR RANGE 20mA 10 bar REQUIRED VALUE 5 bar LEVEL 1 30 of the Offset signal LEVEL 2 80 of the Offset signal INTENSITY 1 100 5 bar refer to the sensor range INTENSITY 2 20 4 2 bar refer to the sensor range Actual Value i
3. Error memory All errors are only readable in English 4 ERROR 1 Latest error happened on the HYDROVAR Press the button to change to the next parameter 5 ERROR 2 Error happened before the latest error Press the button to change to the next parameter 6 ERROR 3 Error happened before error 2 Press the button to change to the next parameter 7 ERROR 4 Error happened before error 3 Press the button to change to the next parameter 8 ERROR 5 Error happened before error 4 More information about errors see chapter 10 No Error is shovvn if the error memory is empty and no failure happenedl Press the button to change to the next parameter 9 TOTAL RUN TIME Runtime of the motor HYDROVAR This parameter 0000 00 shovvs hovv long the motor vvas povvered by the HYDROVAR Press the button to change to the next parameter 10 SAVE 222 Simultaneously press buttons and until n 11 SAVE appears on the display After five seconds the SAVED display changes back to the 1 display NOTICE All changes has to be saved otherwise they would be lost in case of a disconnection of the power supply 41 9 Parameters of the Secondary Menu Before entering the secondary menu these instructions must be read carefully to prevent incorrect settings which will cause malfunction All parameters can also be set during operation Therefore you should be trained how to use the secondary men
4. HYDROVAR controlled pump reaches the start level the relay will closed fixed speed pump switched ON It will be switched OFF the output frequency drops below the defined stop level Press the button to change to the next parameter 9 21 Submenu Offset The 2 analogue input either could be used as 2 required value or as the source for a recalculation offset of the required value SUBMENU Press for about 3 seconds to enter the submenu Offset Press the button shortly to change to the next parameter chapter 9 22 9 21 1 Source of the Offset input OFFSET INPUT Possible settings with AN or W Off OFF Offset deactivated Offset will be calculated according to the current input 4 20mA connected to terminals X1 12 X1 10 Ground There is also the possibility to connect a 2 actual value sensor to terminals X1 3 supply for the sensor and X1 12 EXT ADC I Notice If the incoming offset signal is belovv 4mA an error message will be shown on the display and a failure is indicated failure relay is closed The failure is also shovvn at a multi pump layout but no failure vvould be indicated failure relay is not closed only the master pump will be exchanged If the offset signal fails at all HYDROVARs the failure would be indicated also EXT ADC U 0 10V Offset will be calculated according to the voltage input 0 10V or 2 EXT ADC U 2 10V 10V connected to terminals X1 13 X1 10 Ground
5. Included mounting material Included Cable gland Cable gland 1 Closing gland Terminals i for max mm components l N N Na NN NW 1e H e 12 16 20 25 40 16 29 12116 16 29 aa diameter 4 5 10 9 17 19 28 9 14 14 25 mm HV type EE 3p a ae 0 sssmr pez 1 T ee 23 13 1 39 Boso eq lE pex p opus xd 1 WEE 330 345e 20 20 Pol tT 111112 5 max available cable entries 5 2 Optional components 5 2 1 Fittings Mounting clamps for motor mounting Mounting ring 4 pieces per set only available for HV 1 15 3 11f Mounting ring Available for the diameters 140 mm 155 mm CAUTION If you use a motor with plastic fan cover you have to use a steel mounting ring Distance bushes Distance bushes which are mounted between the HYDROVAR and the motor fan cover Different bushes are available which depends to the output and the type Q of the motor only necessary for the types HV 3 15 3 22e 16 45 Adapter Available for HV 2 1 3 111 T Remote Display e Available for HV 2 1 3 11f 5 2 2 Bus interface MODBUS for installation in the for external installation Tor external installation HYDROVAR svvitching cabinet vvall mounting 5 2 3 Sensors 4 20mA pressure transducer differential pressure transducer level sensor temperature sensor flovv indicator orifice plate inductive flovv metering 5 2 4 Filt
6. Motor connection cables Output Output output 4x1 5 4x4 4x2 5 4x6 4x6 4x25 4x10 4x25 4x25 4x50 3x35 1x25 4x50 Make sure that the Hydrovar s electrical data match those of the electric pump Improper combinations may cause malfunctions and fail to ensure the protection of the electric motor The rated 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 11096 of the nominal current for max 10 sec before the error Overload will occur Ambient temperature 0 C 40 C At higher temperatures a reduction of the output current or the use of the next HYDROVAR type is necessary 110 4 100 90 5 80 1 70 4 60 5 50 4 401 max output current 30 1 20 10 4 0 0 10 20 30 40 50 60 max ambient temperature C o Protect the HYDROVAR against direct sunlight o Outdoor installation without protection of the HYDROVAR is not permitted Storage temperature 25 C 55 C 70 C during max 24 hours RH max 50 at 40 C unlimited RH max 9096 at 20 C max 30 days per year 75 average per year Class F Condensation is not permitted Humidity The air may contain dry dust as found in workshops where there is no excessive quan
7. SClOCTION EE 37 8 Parameters of the main menu 38 9 Parameters of the Secondary Menu E 42 9 1 JIDEREEN EEN EERSTEN E 42 2 MIM GOW nce IS 43 9 3 Ramp Hystelesls re EES 43 9 4 Ramp 1 Fast acceleration me ENEE 44 2 9 5 Ramp 2 Fast deceleration me ENEE 44 9 6 Ramp 3 Slow acceleration time 44 9 7 Ramp 4 Slow deceleration 44 9 8 Maximum Ftequericy nidi a ADA ARALAR 45 9 9 Minimurmi PREG U GACY oie sad foui ote EE 45 9 10 Operation at minimum frequency 46 9 11 Delay time to shut off below minimum frequency 46 9 12 BOOSU EE 46 9 13 Sensor AGJUSE e eec eee aa edet deos Costo l ee n ts bd li a na 47 9 14 Sensor e EE 47 9 15 Setting of the sensor range EEN 47 9 16 Operation e TE 48 9 17 Regulation friode apeti am AA on ok ta kn ok bol 49 9 18 Start ATTEN 49 9 192 Required KEE 50 9 20 Configuration of the pump running relay X2 4 5 6 51 9 21 Submen cOf seE E 51 9 21 1 Source of the Offset input s s eene nennen nennen 51 9 21 2 T e EE EE 52 9 24 3 2 Offset levelb we cee a ear eter rtt m d si 52 9 21 4 Intensity e ausi D D eni ke a Dana 52 9 21 5 ntensity eebe Ss XEM 52 9 21 6 Example for the Offset 53 9 22 Submenu Sequence ske az sen te tiara ge beoe uaa 54 9 22 1 Lift Value actual value
8. components when connecting the external control wires and that open cable ends which are not in use are isolated The HYDROVAR 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 HYDROVAR 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 grounded 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 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 Transport Handling Storage Disposal e Check the HYDROVAR immediately upon delivery receipt of dispatch for damage or miss
9. could communicate via the standardized Modbus protocol with an external control device e g PLC A MEE UR Power i 24VDC supply PIT In RS i fan connection EX B 5V GND s GND Sch l sio S10 Ali so X5 X6 HV RS 485 The terminal HV RS485 is the RS485 interface to the HYDROVAR SIO SIO and GND must be connected with the corresponding terminals of the RS 485 interface of the HYDROVAR Caution GND must be connected because it is the ground connection for the whole interface For the power supply of the interface you have to connect the terminal of the fan on the Modbus interface and the HYDROVAR see chapter 6 3 The second terminal on the Modbus could be used to connect a fan 33 6 4 Selection of the switching frequency Before changing the switching frequency disconnect the power supply otherwise the HYDROVAR power module could be destroyed A switching frequency of 8kHz only should be selected if the HYDROVAR is mounted directly on the motor in order to reduce the noise level In case of longer motor cables the switching frequency should be decreased to reduce losses in the cable as well as the temperature in the motor For applications with submersible pumps select 2 5kHz switching frequency SW switching 1 2 ON S OFF OFF 8kHz standard l ON OFF 5kHz LI 3 OFF ON 4kHz 2 n ON ON 2 5kHz HV 2 1f 3 11f HV 3 15e 3 45e See i DIP Switch t
10. ground Low water 5VDC Ri 10kOhm e g incoming pressure switch or water level switch 8 Thermal switch or PTC mounted in the motor terminal box 5VDC Ri 10kOhm 9 Thermal switch or PTC 10 GND electronic ground 11 Analogue output 0 10 VDC max 2mA to show actual value or actual frequency 12 Current signal input 4 20mA to determine the required value or the offset 13 Voltage signal input 0 10VDC or 2 10VDC to determine the required value or the offset 14 Digital input for 2 Required value o Terminal X2 1 NC EE Max 250VAC 0 3A resistive load 4 NC Max 220VDC 0 3A resistive load 5 P mp russinrelsy CC Max 30VDC 2A resistive load 6 NO NOTICE In case of no error the fault relay X2 2 X2 3 is closed Terminal X5 and X6 1 RS485 SIO LOW 2 RS485 SIO HIGH 3 RS485 GND 4 RS485 5VDC max 20mA supply of external interface converter 29 RS 485 4 5V GND SIO SIO 3 2 l Li 2 NM XI N X6 Li 2 Li a e 2 DV GND SIO SIO RS 485 Pump running signal Fault signal Digital input Voltage signal input 0 2 10V Current signal input 4 20mA Analogue output 0 10V Ground Motor thermoswitch or PTC Low Water External on off 15 VDC Transducer supply Actual value signal input 4 20mA Ground 30 6 3 3 1 Connection example
11. incoming pressure or min level to less bridge X1 6 7 if there is no ext low water protection adjust Parameter DELAY TIME if the failure happens only for short time Conveyer Limit adjustable value of Parameter CONVEYER LIMIT is not reached check booster unit adjust Parameter DELAY TIME Parameter ERROR RESET set to ON to enable 5 restarts e g in empty system Motor overheat PTC in the conduit box has reached its release temperature close X1 8 9 if there is no PTC available e g submersible pumps no proper motor cooling outside temperature too high MOTOR OVERLOAD check star delta connection Inverter overheat too high temperature inside the HYDROVAR no proper cooling contamination of the motor vents ambient temperature too high Over voltage DC voltage of the HYDROVAR too high Parameter Ramp 2 too fast Power supply too high Voltage peaks too high Solution Line filters Line inductance RC Element Under voltage DC voltage of the HYDROVAR too low supply voltage too low phase failure at the input asymmetry of the Phases Overloaded shown on the display but HYDROVAR keeps on running Power limit of the HYDROVAR is reached check Parameter settings and operation point of the motor input povver too high check characteristics of the HYDROVAR Overload Povver limit of the HYDROVAR is exceeded check Parameter Ramp 1 2 too shor
12. start ENABLE SEQ CTL Adjustable from 0 0 Hz to 70 Hz 48 0 Hz In general this release frequency should be set 1 2 Hz lower than the max frequency If the following pump s are not necessary to cover a higher demand but want to be used for automatic change over to provide even wear or in case of a failure the release frequency must be set higher than the max frequency This parameter is used also to start a fixed speed pump when Simple Multicontr is set When this frequency level is reached the dry contact of the relay X2 5 X2 6 will be closed With the parameter Stop Delay Fmin chapter 9 11 you could select a delay time Press the button to change to the next parameter 9 22 4 Switch Interval This parameter allows an automatic change over of the master pump and the following pumps in order to provide even wear and achieve even operating hours of the pumps This is the interval of time after which the starting sequence of the pumps is automatically switched in order to ensure the uniform use of all the pumps available the interval is based on the operating time of the pumps MOTOR HOURS parameter SWITCH INTERVAL Adjustable between 1 and 100 hours 12 hours If an interval of more than 100 hours is selected the automatic changeover is disabled Manual change of the master pump in the 1 display with the button Press the button to change to the next parameter 9 22 5 Source of required value SOURCE REQ
13. the 4 pump All 4 pumps are running with an output frequency SYNCHRON LIMIT 2xSYNCHRON WINDOW To leave the submenu press longer than 3 seconds to change to 56 SUBMENU Press the button to change to the next parameter Synch Control 9 22 7 Pump status indication PUMP SEQUENCY Shows the status of the individual HYDROVAR in a Adr disabled multipump system adjustable between addresses 1 to 4 The following diagnosis parameters can be also be read in this display window Address of the pump that is being read EE is shown for the address of the current used pump hold Px Pump is stopped by the system external on off closed run Px Pump is running stop Px Pump is stopped because f lt start frequency of the previous pump disabled 1 Pump not ready to start external on off opened manually stopped Error HYDROVAR error Fault Polling failure RS 485 interface connection wrong or not connected detected 1 Polling successful RS 485 To check the communication between the HYDROVAR and a connected Adr5 external unit fault detected X indicates the selected pump 1 4 Press the button to change to the next parameter 9 22 8 Busarbit Diag Counter for interface communication problems BUSARBIT DIAG Shows the number of errors happened during the 0 communication attempts on the RS 485 interface At rising values a malfunction of the RS 485 interfa
14. the frequency when the pump reaches the set pressure at zero flow Can be found out by using the JOG MODE Press the button to change to the next parameter 9 25 Lift Amount Intensity LIFT AMOUNT Adjustable from 0 to 199 9 0 0 96 This value states how much the set value should be continually increased till the maximum speed maximum volume is reached Application example 1 Enter the set pressure see main menu 2 Find out the frequency where set pressure is reached at zero demand see Jog Mode and enter this value in parameter FREQU LIFTING 3 Set desired lift at maximum speed in of the set pressure in the parameter LIFT AMOUNT H 100 A set pressure B window 1121 T 3 dap C lift intensity in of set N z l Asse B pressure Log Tr d l TS AP LI Q Press the button to change to the next parameter 59 9 26 Analogue Output ANALOG OUT Analogue output 0 10 VDC 0 10096 max 2 mA Actual value at terminal X1 11 X2 10 ground Possible settings Actual value signal at terminal X1 2 Output frequency 0 fmax Press the button to change to the next parameter 9 27 Dimension Unit DIMENSION UNIT Can be changed with or W Bar Adjustable units bar psi m h g min ft mH20O 96 or without unit By changing the DIMENSION UNIT the SENSOR RANGE see chapter 9 15
15. value of the 2 pump REQUIRED VALUE ACTU VALUE DEC 2 Pump 2 is switched on automatically 3 The required value is calculated new after starting the 2 pump in the following way NEW REQUIRED VALUE REQUIRED VALUE ACTU VALUE DEC ACU VALUE INC Q Calculation of the new required value for multi pumps application Multicontroller Mode k Number of active pumps k 1 p k 1 llift value fall value e Lift value Fall value Pressure constant even all pumps are in operation e Lift value gt Fall value Pressure rises when lag pump switches on Lift value lt Fall value gt Pressure falls when lag pump switches on The following 3 parameters are responsible for switching ON OFF the lag pumps and for the calculation of the new required value as well 9 22 1 Lift Value actual value increase ACTU VALUE INC Adjustable between 0 to the pre selected Sensor range 0 35 Bar Press the button to change to the next parameter 9 22 2 Fall Value actual value decrease ACTU VALUE DEC Adjustable between 0 to the pre selected Sensor range 0 15 BAR Press the button to change to the next parameter 54 9 22 3 Enable sequence control With this parameter you can select the desired start value for the following pumps If a pump in the system reaches this release frequency and the system pressure drops below the Required value actual value decrease the next pump will
16. will be automatically calculated according to the new unit Therefore after changing the UNIT you have to check the setting of the SENSOR RANGE Press the button to change to the next parameter 9 28 Automatic test run TEST RUN Adjustable between 10 100 operating hours after 100 h The test run starts the pump at the set time after the last stop for 20 seconds to a speed of 30 Hz Deactivating test run Set 100 hours gt keep button 4 depressed shortly press the button W in addition gt deactivated appears on the display e To reactivate the test run set the desired hours using the W button The test run is only active when the pump is stopped and external on off is closed Press the button to change to the next parameter 60 9 29 Submenu for manual test run SUBMENU Press for about 3 seconds to enter the submenu TEST RUN man Press the button shortly to change to the next parameter chapter 9 30 9 29 1 Activate manual test run TEST RUN man By simultaneously pressing ah a test run will be A W started The HYDROVAR speeds up to the test frequency with Ramp1 and then decreases the speed till stop with Ramp2 Press the button to change to the next parameter 9 29 2 Test Frequency TEST FREQUENCY Frequency for manual test run 30 0 Hz Can be set from 6 0 Hz up to 70 0 Hz Press the button to change to the next parameter 9 29 3 Boost for manual test run BOOST TEST RUN Setting of th
17. 3 11f MEE 185 oo e Sale LA All dimensions in millimetres Dravvings are not in scale a centre distance between the HYDROVAR 430 mm b expansion space for maintenance 120 mm Wall mounting version high 305 mm width 280 mm depth 280 mm fn I AI Mounting space around the HYDROVAR 150 mm HV 3 15 3 18 3 22 e i 385 300 from the fan cover All dimensions in millimetres 350 x350 29 00 Type Weight HV VVM Kit ik ikg 40 00 Drawings are not in scale a centre distance between the HYDROVAR 550 mm b expansion space for maintenance 300 mm max diameter of the motor fan cover 385 mm Wall mounting version 400 di a 10 E Mounting space 132 5 132 5 n 4 above beside below 300 mm 200 mm 150 mm 14 Wall mounting version mm High 430 wide 365 deep 361 HV 3 30 3 37 3 45 e Not available as motor mounted version 600 350 _ 200 610 All dimensions in millimetres Weight Drawings are not in scale EE kg Mounting space above 500 mm Beside and below the HYDROVAR 150 mm 15 5 Mechanical mounting of the HYDROVAR unit on the motor 5 1
18. Change to previous parameter in the menu k Long pressing Enter the submenu or change back to the main menu A Saving of all settings K AS Long pressing The auxiliary texts of the actual parameter is shown or language selection in the first window short Change to faster scrolling down of the value ah short Vv Change to faster scrolling up of the value x YW RESET of a failure by pressing all three buttons simultaneously for about 5 seconds 7 3 Language Selection The information on the display and all parameters can be called up in the following languages e German e French e Dutch e English e Spanish e Italian e Portuguese To select the desired language proceed as follows Shortly press k simultaneously in 1 display 5 The actual language will now appear in the second line The desired language can be selected with the button or W e After the language has been selected shortly press the button and the display will change back to the first vvindovv of the main menu e The selection of the language vvill be saved automatically 37 8 Parameters of the main menu After connecting the HYDROVAR to the power supply the following index will be shown SW Ver VOG 120 The current software version with the date of Date XXXX programming is displayed for about 3 seconds If the connection of terminal X1 4 X1 5 external release contact is open the following message appears INVERTER L
19. DOW ca 20 and RAMPHYSTERESIS ca 99 Problem ACTUAL VALUE can t be hold Parts to check Solution Ramphysteresis too big RAMPHYSTERESIS 90 99 Submersible pumps Problem motor cables are too long Solution reduce SWITCHING FREQUENCY BOOST 10 20 General Problem pressure fluctuations analogue signal not constant Solution e check cables and connection of the screen e check earth connection of the Transmitter e use screened cables 68 11 RS 485 Interface Standardised Bus Interface for communication between the HYDROVAR and or an overruling external control system The data protocol complies with ISO 1745 for RS 485 interfaces and contains the following configurations Data rate 9600 Baud 1 Start Bit 8 Data 1 Stop Bit An interface inverter RS 232 RS 485 is necessary in case communication with a 24V interface of a PC or another external control system is vvanted The vvhole interface protocol can be obtained upon request 12 Auxiliary Texts These are available for all parameters To call them up press the buttons Each auxiliary text then appears as running text in the second line of the vvindovv 13 Maintenance The HYDROVAR does not requlre special maintenance Hovvever the cooling fan and the vents should be freed of dust occasionally Also the temperature around the unit should be checked from time to time All modifications must be don
20. IRED VALUE will change to MANUAL CONTROL in the main menu where the actual frequency and the actual value are displayed according to the JOG MODE in the submenu Now the frequency can be changed with the 4 and buttons The speed of the pump will change along the fast Ramps After selecting the right frequency it can be saved in the standard SAVE window After a supply failure the pump will run with this selected frequency depending on the parameter AUTO START automatically In the 1 display the actual frequency is shown CONFIG FMIN will not work in this mode Attention Driving the pump in a not allowed speed range can damage the motor or the HYDROVAR Press the button to change to the next parameter 9 17 Regulation mode 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 at constant suction pressure or at constant level Press the button to change to the next parameter 9 18 Start Value START VALUE This parameter gives you the start value after pump stop disabled in percentage of the required value Adjustable between disabled and sensor range e g required value 5 0 bar start value 2 5 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 grows up and the press
21. MP 1 Excessively fast running up time may cause an error 4 0 Sec OVERLOAD during the HYDROVAR is starting Excessively slow running up time may cause a drop of the outgoing pressure during operation Press the button to change to the next parameter 9 5 Ramp 2 Fast deceleration time RAMP 2 Excessively fast running down time tends to cause an 4 0 Sec error OVERVOLTAGE e Excessively slow running down time tends to generate over pressure Press the button to change to the next parameter 9 6 Ramp 3 Slow acceleration time RAMP 3 A too fast running up time may lead to oscillation 70 Sec and or an error OVERLOAD A too slow running up time can cause a drop of the outgoing pressure during variation of the demand Press the button to change to the next parameter 9 7 Ramp 4 Slow deceleration time RAMP 4 e A too fast running down time leads to oscillation of 70 Sec the HYDROVAR and thereby of the pump A too slow running down time can cause pressure fluctuations during variation of the demand Press the button to change to the next parameter 44 9 8 Maximum Frequency This parameter determines the maximum speed of the pump and at which output frequency the HYDROVAR has its max output voltage The standard setting is according to the nominal frequency of the connected motor MAX FREQUENCY Possible setting between 40 and 70 Hz 50 0 Hz Attention Settings higher than 50 Hz may overload th
22. Mode MODE Select with the 4 and W buttons Controller Possible Settings Controller This mode should be selected if only one HYDROVAR pump is in operation and there is no connection to any other HYDROVAR via RS485 interface Multicontroller If more than one pump should operate together via the RS485 interface follow up pump control this mode must be set Advantages If the pumps are connected via RS485 interface there are the possibilities of automatic svvitch over because of pumps being out of order eyclic change of lead and lag pumps or automatic start and stop of lag pumps follovving the actual demand Synchronous Controller The Synchronous Controller mode is vvorking in the same vvay like the Multicontroller 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 are running with a better efficiency Actuator The Actuator application is only used if you have an external controller and the HYDROVAR is used like a standard frequency converter In the Actuator Mode the internal controller is shut off and the output frequency is proportional to the input signal X1 2 2 4 20 mA 0 f The frequency changes with the programmed Ramps 1 and 2 The functions of low water thermal protection and external ON OFF are still working Sensor Fault 48 Manual Control IF MANUAL CONTROL is selected the parameter REQU
23. OCKED enable inverter To start the HYDROVAR bridge these two terminals or close the external ON OFF switch If any other error occurs see chapter 10 Error messages The following two windows 1 Window and Required value depend on the selected mode see chapter 9 16 a Active MODE Controller Default setting 1 ITT INDUSTRIES 1 display at Mode Controller XX X BAR Press the button to change to the next parameter 2 REQUIRED VALUE 1 Set the desired required pressure with either 4 or v X XX BAR and then shortly press the k button Default setting 3 5 bar If you want to change to the 2 Required Value you have to close the external contact at terminals X1 10 X1 14 After closing this contact the display changes from REQUIRED VALUE 1 to 2 1 REQUIRED VALUE 2 In this window the configuration of the 2 f required ADC X XX X BAR value is shown see chapter 9 19 ADC X or INT shows the source of the external or internal Required Value 2 XX X Bar shows the actual value of the Required Value 2 Press the button to change to the next parameter menu 3 38 b Active MODE Actuator 1 ITT INDUSTRIES 1 display at Mode Actuator Frequency XX X Hz e In this mode an external controller is used so the HYDROVAR will not control the set value but will only be responsible for running the connected motor at a frequency proportional to the value of the analogue input signal originating from the external sou
24. RESET This parameter allovvs an automatic restart for 5 times in disabled case of a failure To activate this function a certain delay time 0 250sec has to be selected by pressing the 4 button not for internal error 1 9 After the 5 restart the HYDROVAR will shut off definitely and an error message is shovvn The internal counter of the automatic error reset vvould be decreased after each operating hour so if an error could be reset after 3 restarts there are 3 restarts possible after an hour 4 after tvvo hours and 5 automatic restarts after 3 operating hours To deactivate this parameter press the W button until disabled appears Press the button to change to the next parameter CLEAR ERRORS The error memory can be deleted by entering a 0000 password 2 UJ e B Q o m m Vd For more information contact your distributor To leave the submenu press longer than 3 seconds to change to SUBMENU Press the button to change to the next parameter ERRORS 62 9 31 Operating Hours OPPERATING HOURS Total time the HYDROVAR is connected to the power 0000 h supply Reset press and Y together till TIMER RESET appears In parallel the TOTAL RUN TIME of the motor in the main menu would be reset Press the button to change to the next parameter 9 32 Display Contrast DISP CONTRAST Can be adjusted between 10 and 100 for improved 50 Yo clarity of the display depending on the ins
25. Solutions Austria GmbH reserves the right to make modifications without prior notice 2012 Xylem Inc
26. VALUE By using a 2 required value in a multi pump system OFF there are different options to set the source of this value For selecting you have to choose the desired pump address which should be the source of the required value Following adjustments are possible OFF ADR1 ADR2 ADR3 and ADR4 If an additional analogue input is active you have to enter the address where this input is connected If the right address is selected the additional input is active for the whole system which means that only one input is necessary also for a multi pump system At active Multicontroller or Synch Controller mode the active value required value 1 or 2 is shovvn in the centre of the display in the first line of the first vvindovv see chapter 8c If 27 is shown in the second line of the display the pump will work with a required value from another pump in the multi pump system On the pump which is the source of the required value no is shown If the source of the required value is set to OFF no 2 required value is used or the source for this value is always taken of the actual master Press the button to change to the next parameter 55 9 22 6 Submenu Synchronous Control By using the synchronous control all pumps in the system maintain the set pressure by running on the same frequency The 2 pump starts when the 1 pump reaches the release frequency ENABLE SEQ CONTR and both pumps will run synchronousl
27. a voltage signal 0 10V or 2 10V connected to terminals X1 13 X1 10 Ground The max value of the analogue signal is equal to the defined SENSOR RANGE see chapter 9 15 Setting the 2 required value The active required value is shown in the actual display of the parameter Required value If the 2 required value is enabled digital input terminal X1 14 closed there is shown Required value 2 in the first line The second line will shown the source of the 2 required value selected in the parameter CONFIG REQ VAL 2 and also the actual value of this input as well INT setting according the existing required value in the main menu EXT only display of the value of the 2 analogue input signal In case of saving both required values will be saved automatically Press the button to change to the next parameter 50 9 20 Configuration of the pump running relay X2 4 5 6 Possible selection with 4 and W Run Motor e Simple Multicontr Allows to start stop a fixed speed pump e Run Motor motor run indication via the relay If you have selected Simple Multicontroller the following parameters will have new additional functions The start level of the lag pump you enter at the parameter Enable Seg Ctl and the stop value in the parameter Synchron Limit Using the parameter Stop Delay Fmin you are able to svvitch on the lag pump after a selectable delay time e g if the
28. all the gaskets of the fastening screvvs o Ensure that the mounting of the cable glands is done properly and use closing glands for cable bushings which aren t used 19 HV 3 15e HV 3 22e 422 622 HYDROVAR cover L i Display unit 8 fixing screws ES d li 4 screws to fix the cover 1 Motor cover 4 fixing screws Motor Motorcable Motor conduit box Pressure transmitter 4 NO L D e Position the HYDROVAR at the motor try to centre it as good as possible and prepare the boreholes for the fixing screws o Ensure that the position of the display is correct If it is necessary Display is changeable by 180 VVorking process to turn the control board to turn the control board you have to disconnect the connection to the povver board open the 4 hexagonal bolts use a 7mm socket wrench and turn the control board mount the control board and connect the 40 pin plug to the power board o remove the motor fan cover if you have to install the HYDROVAR horizontal e Mount the HYDROVAR by using the suitable fixing screws M8 distance bushes and screw nuts this should be self locking at the motor fan cover o If the HYDROVAR is mounted horizontal a additional bracing may be required 21 6 Electrical installation and wiring All installations and maintenance have to be performed by properly trained and qualified personal with proper too
29. bmenu DEFAULT VALUES Press the button shortly to change to the next parameter gt chapter 9 37 You reset all settings to the default settings for two different areas EUROPE or USA If you suspect you made a mistake by entering parameter settings but are unable to identify the location you can start again from the beginning by reloading the factory settings 9 36 1 Default Values Europe DEFAULT EUROPE Load the DEFAULT PARAMETERS for Europe by A pressing the for approx 5 seconds max frequency 50 Hz display unit bar Press the button to change to the next parameter 9 36 2 Default Values USA DEFAULT USA Load the DEFAULT PARAMETER for the USA by A pressing the 4 for approx 5 seconds max frequency 60 Hz display unit psi IMPORTANT After reloading the default settings the display is flashing To deactivate the flashing you have to save this change see next parameter To leave the submenu press longer than 3 seconds and change to SUBMENU Press the button to change to the next parameter DEFAULT VALUES 9 37 Saving SAVE All values must be saved stored in an EEPROM after A changing If they aren t saved all changes will be lost in case of a power failure Saving Press till the message SAVED is shown on the display After saving the display changes automatically to the 1 display after a few seconds 64 10 Error Signals The active Error messages a
30. ce could be possible To leave the submenu press longer than 3 seconds to change to SUBMENU Press the button to change to the next parameter Seq Control 57 9 23 Submenu RS 485 Interface SUBMENU Press for about 3 seconds to enter the submenu RS 485 Interface Press the button shortly to change to the next parameter chapter 9 24 9 23 1 Pump Address PUMP ADDRESS If only one pump is used the setting remains OFF OFF If several pumps are connected via the RS 485 interface max 4 each pump must be allocated its own pump address number 1 4 Address 5 is reserved for an external control device Each address may only be used once Press the button to change to the next parameter 9 23 2 ADC Reference ADC REFERENCE Reference for the local ADC Analogue Digital Converter Local or SIO RS485 interface Possible Settings LOCAL Actual value sensor Terminal X1 1 2 REMOTE Actual value via RS 485 Terminal X5 or X6 1 2 3 To leave the submenu press longer than 3 seconds to change to SUBMENU Press the button to change to the next parameter RS 485 Interface 58 9 24 Frequency Lifting Control according to a system curve increase of the set pressure depending upon the delivery rate or speed FREQU LIFTING Adjustable between 6 Hz and the set MAXIMUM 30 0 Hz FREQUENCY The setting determines the output frequency where the set pressure starts to be increased The right setting should be
31. e by qualified technicians 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 Look at the pump and motor instruction Notes VVhen replacing the control card in a plant vvith more than one pump ensure that the softvvare hardvvare is compatible vvith all other control cards For further information please ask your distributor 69 0 Berg 1iquesng Aty YSN nejaq ZHOZ ne Lipy 75 MODUIM UOIYDUAS u nb s dung Aty edoun3 1jnejeq E ZH 070 1onuo youAs 0000 Mun uosyouAs J NNAWENs 510413 410 00 p lqesip Yo 001 anjeA bay nos z Ayisuayu LI Aty sanjeA 3jnejeq yasay 1043 uny 1591 1500g NEE ii anes nNawans iiis S F sinoy 21 9600 295 2 ZH 0102 JeAi91U YMS L Atsuauut 27 27757 0 ZH 087 Yo 070 NO 440 pajqesip Aty 112 b s c Big Guneay uoun 4207 r ao4 Auo2 uny 1591 et e207 Jeg S10 Yo 00 aouasaja
32. e motor Settings of 10 above nominal frequency cause a 33 higher power consumption Press the button to change to the next parameter 9 9 Minimum Frequency MIN FREQUENCY Possible setting between OHz and Max frequency 0 0 Hz At operation below the right min frequency the HYDROVAR works with the fast Ramps Attention The min frequency depends on the selected pump type Especially for borehole applications the min frequency must be set to 30Hz Press the button to change to the next parameter 45 9 10 Operation at minimum frequency CONFIG FMIN Possible setting f gt 0 or f gt f f gt fmin f gt 0 After reaching the required pressure the frequency will go down to the selected MINIMUM FREQUENCY and the HYDROVAR will keep running for the selected STOP DELAY time see next parameter After this time the HYDROVAR will stop automatically f 5 fan With these setting the pump will never stop automatically Only the frequency will go down to the selected MINIMUM FREQUENCY To stop the pump you have to open the external ON OFF terminals X1 4 and 5 or press the W button Applications circulation systems The setting f gt fmin can overheat the pump when there is no flow through the pump gt bypass line for circulation pumps Press the button to change to the next parameter 9 11 Delay time to shut off below minimum frequency STOP DELAY FMIN Possible setting between 0 and 100s 55 e After ru
33. e motor starting voltage in Yo of rated input 10 0 96 voltage 0 2596 of maximum input voltage is possible To leave the submenu press longer than 3 seconds to change to SUBMENU Press the button to change to the next parameter TEST RUN man 61 SUBMENU Press for about 3 seconds to enter the submenu ERRORS Press the button shortly to change to the next parameter chapter 9 31 5 UJ e c o 3 o 3 c m 9 30 1 Conveyor Limit CONVEYOR LIMIT Adjustable between 0 00 and max SENSOR RANGE disabled e To disable the conveyor limit press W till disabled is shown on the display Obar e An adjusted value gt 0 has to be reached till the programmed DELAY TIME If this value can t be reached the HYDROVAR stops and the failure VAL RANGE CONTR vvill be indicated Press the button to change to the next parameter DELAY TIME Adjustable between 0 100 Sec 2 Sec w o N o o zi 3 D Delay time to switch off the HYDROVAR in case the actual value drops below the conveyor limit or a connected external low water protection opens the terminals X1 6 X1 7 Notice The Conveyor Limit function is also active during the start period of the pump Therefore the delay time has to be set higher than the duration till the pump reaches this value also during the start of the pump Press the button to change to the next parameter 9 30 3 Automatic Error reset ERROR
34. e 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 maintain pressure in the line when there is no demand This will keep the pumps from continuing to run at zero demand With the HYDROVAR it isn t necessary to have a large tank 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 x 0 10 25 litres The pre charge pressure of the tank can be determined in the following table required pressure bar 1 2 3 4 5 6 7 8 9 10 8 1 2 3 A 5 6 7 8 9 precharge pressure bar NOTICE To check and set the right pre charge pressure please make the tank pressure less before 3 Technical Data HYDROVAR Povver Supply Voltage limits Rated line protection Maximum 48 62 Hz current input max connection 20 3x380 460 15 3 5f 5 5 376 75 3x380 460 1596 3 11f 11 3 21 2 2 6 3 13 32f 22 SE 3x380 460 1596 10 3x380 460 15 10 HYDROVAR Output to the motor Type Rated Max Voltage Rated Current
35. er Motor coils e Line coils EMC Filter see chapter 6 2 EMV 5 2 5 Motor cables for direct installation Available for HV 2 1f 3 22e 17 5 3 Assemble Instruction HV 2 1f HV 3 11f i Ad 3 screws to fix the cover Gasket HYDROVAR cover Display changeable by 180 4 Screws M5x60 ect 62 Centre bit 4 Mounting clamps A i d Motorcable Motor Motor conduit box Pressure transmitter To remove the HYDROVAR cover open the 3 fastening screws o Be careful not to lose the small gaskets o Ensure that there is no water on the unit before you open the cover o Be careful not to damage the connecting cablel e Position the HYDROVAR on the motor fan cover e Try to centre it as good as possible using the rubber centre bit o If you use a motor with plastic fan cover you have to use a steel mounting ring e Install the HYDROVAR on the motor fan cover by using the mounting brackets the four screvvs and the related vvashers Make sure the converter is vvell centred and then tighten the four screvvs e Tighten each fastening screw until the two bottom teeth in the brackets start to grip the fan cover After connecting the electrical components mount the cover on the HYDROVAR and tighten the three fastening screvvs o Make sure of a good connection of the connecting cable and the ground vvire o Control the gasket of the HYDROVAR and don t forget to inst
36. esis Yo Window setting 5 in 96 of the 100 Set hysteresis Yo required value W W I JOE EDT ZE R1 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 ttime 9 2 Window WINDOW e Determines the band where the slow Ramp changes to 596 the fast Ramp Possible setting between 096 10096 of required value for steep pump curves and closed loop systems 20 3096 Press the button to change to the next parameter 9 3 Ramp Hysteresis RAMP HYSTERESIS e Determines the band where the fast Ramp changes to 80 the slow Ramp or rather the change between the slow Ramps e Possible setting between 0 100 for an accurate controlling without automatic shut off 99 Press the button to change to the next parameter 43 Ramp settings Time setting of the Ramps vvill influence the control of the pump and shouldn t be changed at standard operation Possible setting of each Ramp 0 05 1000 sec The fast Ramps 1 and 2 are determined by the type povver of the HYDROVAR Default 4 sec depending on the power of the HYDROVAR you should increase the time up to 15s The Ramps 3 and 4 determine the speed of the internal HYDROVAR controller and depend on the system that has to be controlled Default 70 sec To adjust the Ramps press or W 9 4 Ramp 1 Fast acceleration time RA
37. ing parts e The HYDROVAR unit must be transported carefully and by competent personnel e Avoid serious impacts NOTICE Ge CAUTION gt CAUTION gt WARNING gt The use of the WEEE Symbol indicates that this product may not be treated as household waste Dispose of all packing materials and the unit in accordance with local regulations For more detailed information about the recycling of this product please contact your local authority your household waste disposal service provider ort he shop where you purchased the product Lifting aids stacker crane crane mounting device lifting blocks sling ropes etc must have the proper dimensions so that they can bear the weight of the HYDROVAR 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 e Do not stand underneath suspended loads e take note of the general regulations on prevention of accidents e The HYDROVAR must be secured against tipping over and slipping until it has been fixed in its final location 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 In such a case a pressure switch on the suction side should be used Single Pump Layout Multi Pump Layout 1 pump with HYDROVAR 4 gat
38. ls In case of a failure disconnect or switch off electrical power and wait 5 minutes for capacitor discharge before servicing the HYDROVAR Otherwise it can cause shock burns or death 6 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 there can be a current to earth due to the capacitors in the input filter A suitable protection unit has to be selected according local regulations Residual current device RCD 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 RCDs 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 3 Technical Data Internal protective devices of the HYDROVAR e The malfunctions short circuit under and over voltage and the overheating of the electronic components overload are controlled by the HYDROVAR External protective devices e Additional protective functions like motor overheat and low water protection are controlled by external equipment 22 6 2 EMC elect
39. nal filter capacity the earth leakage current will increase if the filter is activated Therefore in case of using ELCB relays earth leakage circuit breakers RCD they must be suitable for VFDs suitable for protecting equipment with a DC content in the faulty current as well as suitable for a high leakage current gt 300mA HV 2 11 2 21 HV 3 21 3 111 HV 3 15f 3 22f Switch contact Opened RFI filter function deactivated default setting Closed RFI filter function activated for wall mounted version VVARNING The svvitch may not be operated in case the HYDROVAR is still connected to the mains supply Before changing the position of the switch ON OFF you have to be sure that the HYDROVAR is disconnected from the mains supply 35 7 Programming 7 1 Display control panel HV 2 1f 3 11f ON OFF Select Power Run Fault HV 3 15e 3 22e HV 3 30e 3 45e inside OFF ON Select POWER Alo fk RUN Power 45 Pa HYDROVAR 2 PRESSURE DRUCK fk gt A z f8 AUTOSTART on or Y gt f ERRORS FEHLER gt sE TOTAL RUN TIME BETRIEBSSTUNDEN gt D SAVE SPEICHERN 0 START GI e STOP m 36 7 2 Function of the push buttons Start of the HYDROVAR or increase the value in the menu v Stop of the HYDROVAR or decrease the value in the menu Short pressing Change to next parameter in the menu SEN
40. nning the pump for this selected time at minimum frequency the pump will stop if parameter CONFIG FMIN is set to f gt 0 NOTICE Problems with shut off the pump at O demand too small or no pressure tank may be solved by exceeding the required value during this delay time e f the limit of the parameter ENABLE SEQUENCE CONTROL is exceeded and the relay configuration is set to SIMPLE MULTICONTROLLER see chapter 9 20 the pump running relay X2 4 5 6 will be closed after running the pump for this selected time Press the button to change to the next parameter 9 12 Boost BOOST Setting of the motor starting voltage in Yo of rated 5 0 96 voltage 0 2596 of maximum input voltage is possible This value 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 Press the button to change to the next parameter 46 9 13 Sensor Adjust Zero point adjustment 4mA of the transducer Necessarily required for multi pump applications SENSOR ADJUST Make sure that the system is not pressurized A v Press buttons W simultaneously until a new message appears This mes
41. nput Level 1 Level 2 100 80 Intensity 2 20 Required 5 bar Value 1 DORMI SEAT ep eae ee 40 Intensity 1 100 20 Offset signal 0 bar 5 0 20 40 60 80 100 I 1 E 1 096 4mA 0V 2V 10096 20mA 10V At the parameter Level 7 you have entered the required value in percent from the Offset signal input 30 also proceed with the second level 80 Intensity one and two are depending on the Sensor range of the external value signal The Intensity 1 that you have entered is valid till you reach Level 1 after reaching Level 1 the Required Value has no offset The standard Required Value will be valid till you reach the Level 2 After reaching level 2 the new value depending on the Intensity 2 is valid Press the button to change to the next parameter 53 9 22 Submenu Sequence control Using the parameters in that submenu all necessary settings can be done for running a multi pump system Each parameter within this submenu must be changed only on one HYDROVAR of the system because it will be transferred via the RS485 interface to each connected HYDROVAR Up to four pumps can be connected using the integrated RS 485 interface SUBMENU Press for about 3 seconds to enter the submenu Seq Control Press the button shortly to change to the next parameter chapter 9 23 Application Example 1 Pump 1 reaches fmax maximum speed 2 Pressure falls and reaches the start
42. ntion to universal safety and accident prevention regulations Basically the HYDROVAR must be disconnected from the power supply before any work can be carried out in the electrical or mechanical part of the system Installation maintenance and repair work may only be carried out by trained skilled and qualified personnel Unauthorized modifications or changes to the system make all guarantees null and void During operation the motor can be stopped by open a digital input or manually operated 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 power supply the components of the power unit as well as certain components of the master control unit are also connected to the power supply Touching these components seriously endangers life Before removing the HYDROVAR 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 installed discharge resistors first Voltages of up to 800 volts are possible if there are faults it can be higher All work carried out at opened HYDROVAR may only be performed by qualified and authorized staff Furthermore care must be taken not to short circuit the neighbouring
43. o select the switching frequency SW 30 SW 31 DIP Switches to decrease the max output current 6 5 Reduction of the maximum output current When a motor with lower nominal power is used the max output current should be adjusted accordingly Only possible for HV 2 1 f 3 11 f Possible SW30 SW30 SW31 SW31 setting A B A B 100 ON OFF OFF OFF Output current A 7 10096 85Yo 65 Yo 50 2 1 7 00 5 95 4 55 3 50 85 OFF ON OFF OFF 2 2 10 00 8 50 6 50 5 00 65 OFF OFF ON OFF 32 5 70 4 85 3 71 2 85 50 OFF OFF OFF ON 3 3 7 00 5 95 4 55 3 50 34 900 765 585 450 reduction of the maximum output 35 13 50 1148 878 675 current also affects the Overload detection 3 7 17 00 14 45 11 05 8 50 3 41 23 00 19 55 14 95 11 50 34 6 6 RFI switch For the HYDROVAR types HV2 1 HV3 22 there are installed new additional filter capacitors which provides an improved filter characteristic in order to avoid RFI Radio Frequency Interferences when mounting the HYDROVAR on the wall and using longer cables between the HYDROVAR and the motor This filter element is switch able and is deactivated in the default setting switch contact opened because for standard mounting version motor mounted and using standard motor cable length the filter is not required The filter should be only activated in case of separate mounting Wall mounted versions of the HYDROVAR NOTE Due to the additio
44. of the motor cables PWN cra The PTC should be fixed to the metal compound 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 the motor and can be done in star or delta connection The right connection for 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 o Sr o s U Te a OHS ere D W U TO R Ena R KOH ox a On o V y A R o o R TTT T n PTC 28 6 3 3 Control Terminals All control cables which are connected to the control or RS485 terminal have to be screened If unscreened control cables are used signal interference may occur and could interfere to the function and signals of the HYDROVAR Don t connect the ground of the control card to different voltage potentials All electronic ground terminals and GND of the RS 485 interface are connected internally Terminals X1 1 GND electronic ground 2 Actual value input 4 20mA Ri 50 Ohm 3 Power supply for external sensor 15VDC max 100mA 4 GND electronic ground 5 External on off release 5VDC Ri 10kOhm contacts suitable for switching lt 10VDC are necessary GND electronic
45. only one end of the screen of a signal cable to the ground Motor cable as short as possible Use a motor coil if the cable is longer than 20 meters max 100 meters motor cable e Pigtails should be prevented 24 6 3 Wiring and connections Remove the screws holding the top cover of the HYDROVAR Caution At HV3 15e 3 22e also the 8 screws of the display have to be removed Lift off the top cover and you could see the following parts HV 2 1f 3 11f Connection to power board DIP switch Connection to 241114444441141111133443 8 ettitit WE emei g 24VDC output ii max 800mA Sa 3 for external 4 fan modbus z 2 LU uui RS 485 terminals Power supply Control terminal blocks Motor connections 3x400 VAC HV3 15e HV3 45e LCD Display push buttons Indication LEDs RS 485 terminals es Control terminal blocks 24VDC output max 1A for external fan modbus 6 28055 Connection to power board 25 6 3 1 Main Voltage Terminals The power supply is connected to the power section terminal L1 N 1 x 230 VAC single phase terminal L1 L2 L3 3 x 400 VAC three phase HV 2 1f 2 2f HV3 2f 3 111 Povver Supply Motor connection Povver Supply Motor connection 1x230 VAC 3x400 VAC HV 3 15e 3 22e Power Supply 3x 400VAC 26 HV 3 30e HV 3 45e Motor connec
46. onnection of the screen e Pigtails should be prevented because they raise the impedance of the screen and affect the shielding effect at a high frequency e The power cable and the motor cable should be installed as distant as possible For motor cable lengths from 20 to 100 meters it is necessary to install an output filter between the HYDROVAR and the motor as shown in the diagram below The filter has to be mounted as close as possible to the HYDROVAR max distance 2 meters For further information contact our sales or service department 23 line filter HYDROVAR max 30cm max 2m motorcoil motor pump EN EE DUU DUU keannnnnnnnnnnnne TP L Gup Screened cable max 100 m 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 at the HYDROVAR max 30 cm distance Advantages e better efficiency e reduction of current harmonics Applications e high short circuit currents e compensation plants without a coil e asynchronous motors who are responsible for a voltage drop 2095 of the line voltage EMC summary e Install potential equalization according local regulations Don t install the motor cable in parallel to the signal cable or the power cable e Use screened motor and signal cables Connect both ends of the screen of the motor cable to the ground Connect
47. quired Value you have to close the external contact connected to X1 10 X1 14 After closing this contact the display changes from REQUIRED VALUE 1 to 2 1 REQUIRED VALUE 2 This window shows the condition of the second ADC X XX X BAR required value see chapter 9 19 ADC X or INT shows the source of the external or internal Required Value 2 XX X Bar shows the actual value of the Required Value 2 Press the button to change to the next parameter menu 3 39 d Active MODE Manual Control 1 ITT INDUSTRIES 1 display at Mode Manual Control local Frequency XX X Hz Continue by pressing the button 2 MANUAL CONTROL Set the desired set pressure with either AN or and X X Hz X XX BAR then shortly press the button Press the button to change to the next parameter menu 3 The following parameters of the main menu are valid for all selected Modes 3 AUTO START Select ON with AN or OFF with the W button ON IF AUTO START ON the HYDROVAR starts automatically after a remedy of a failure or disconnection of the power supply IF AUTO START OFF the HYDROVAR won t start automatically after a remedy of a failure or disconnection of the power supply After remedy of the failure or reconnection of the power supply the following message is shown 3 1 NO AUTOSTART To restart the HYDROVAR press W to quit and A to disable inverter restart Press the button to change to the next parameter 40
48. r Reset after repeated error message ERROR 6 Watchdog error 5 change control card Program error Reset after repeated error message ERROR 7 Processor pulse error 5 change control card e check the installation of the cables connection of the screen and ERROR 8 Program error potential equalization invalid processor command e check earth ground install additional inductances for the signal cables e g ferrites ERROR 9 Counter of operation time Reset after repeated error message 5 change control card 67 Examples Booster unit Problem no stop of the HYDROVAR Parts to check Solution 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 no correct settings of WINDOW and e set WINDOW ca 10 and RAMPHYSTERESIS RAMPHYSTERESIS 80 50 e shut down RAMP too slow e set RAMP 2 to 4 15 sec e suction line too long e the MINIMUM FREQUENCY should be activated for pressure increase at 0 demand Control on constant flow Problem control fluctuations Parts to check Solution enlarger WINDOW and RAMPHYSTERESIS to 99 to control with RAMP 3 and 4 control characteristics are set to low Circulating pump Problem oscillation of the motor speed Parts to check Solution e increase RAMP 3 and 4 100 200sec control settings too fast e WIN
49. r ves 2 euet et e e RE kk a kok kk kk sel uba 62 RAPERE 62 9 30 3 Automatic Error 4 62 9 30 4 S s s n n s d dinh ine a ara EDRTR a ii 62 9 31 Operating HOUES occi aet a ki n l Geen 63 E 63 9 33 Set PASSWWONG ki ete akite laz 63 9 34 Lock Functon sa adalar 63 9 35 Internal Heater ive Pra dio Fed v da d Ta a Eege 63 9 36 Setting Default on ea e ea e 64 9 36 1 Default Values Europe 64 9 36 2 Default Values USA title taa etat ss annn nhn hn nnn 64 E e EE 64 TO n ak a ia di adan 65 17 AE Ee Tt WEE 69 12 Aux llary E E 69 12 Maintenance EE 69 Follow the Pump Operating and Maintenance Instructions VVe reserve the right to alter specifications 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 VVarns 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 atte
50. rce e In the Actuator mode the output frequency is proportional to the input signal on terminal X1 2 4 20 mA 0 max frequency e The frequency varies with fast RAMPS 1 and 2 e The functions Lack of water Motor overheat external ON OFF and all other internal protections still work Press the button to change to the next parameter menu 3 c Active MODE Synch Controller or Multi controller m ADRX x PX 1 display at the Synch Controller or Multicontroller XX X Bar mode ADR X Pump address see chapter 9 23 1 x Indicates the source of the required value It is always shovvn at the current HYDROVAR which delivers the active required value To select the source see chapter 9 22 5 1 required value 1 of the active HYDROVAR 2 gt required value 2 of the active HYDROVAR PX Indicates the current pump positioning within the system where as P1 Master pump P2 1 lag pump and so on Press the button to change to the next parameter 2 REQUIRED VALUE 1 Set the desired set pressure with either 4N or W and X XX BAR then shortly press the button If several HYDROVARS are connected via the RS 485 interface one unit must be ready for operation when the set pressure is changed otherwise the set value will not be accepted by the follow up pumps Afterwards the new required pressure has to be saved see parameter SAVE in all pumps If you want to change to the 2 Re
51. re shown in the selected language but the last 5 Error messages stored in the Error memory main menu are displayed in English language only After the cause has been remedied the error can be reset by cutting off the power supply for gt 60 seconds or pressing all three buttons f and together for about 5 seconds All error signals are indicated at terminal X2 1 2 3 failure relay If no Error is active the relay switches on and terminals X2 2 and X2 3 are closed NOTICE If AUTO START is ON and automatic ERROR RESET is enabled the HYDROVAR can start again automatically after a power failure Error picture No error message on the display No red LED no AUTOSTART after power failure Parameter AUTOSTART is set to OFF Check Parameter AUTOSTART Display shows INVERTER LOCKED ENABLE INVERTER external ON OFF contact is opened check if switch or external contact is closed or bridge X1 4 and X1 5 EXT ADC I lt 4mA is blinking on the display Either 2 Required Value or OFFSET is active but no signal 4 20mA connected check external analogue signal on terminals X1 10 12 No operation even system pressure set pressure Pressure higher than the start value regulation mode isn t set to NORMAL check parameter START VALUE and or REGULATION MODE Error message on the Display red LED on Lack of water Low water contact is open e protection of
52. romagnetic 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 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 side otherwise it is possible that the screen has a ground current The screen should be connected with cable clips extensive to HYDROVAR GND Signal cables should be installed separate from motor and power supply cables If signal cables are installed in parallel to motor cables or to power supply cables for a longer distance the distance between these cables should be more than 200mm Don t cross power cables with control cables if this is not possible cross them only 90 Motor cables To prevent EMC and capacitive currents we advise to install the HYDROVAR directly at the motor If the HYDROVAR is mounted separately keep the motor cable as short as possible We recommend using a screened cable or one protected by a metal sheath t is necessary to connect both ends of the screen to ground but these connections couldn t replace the potential equalization We suggest a cable clip for an optimal c
53. s Terminal X1 e Transducer Actual value signal input o Connection of a 2 vvire transducer e g standard pressure transducer PA22 Actual value Frequency indicator how to program see chapter 9 26 9 1i e g to display the actual motor frequency jio r 2 Required value how to program see chapter 9 19 to enable the 2 required value close the switch external voltage signal or external current signal SSSSS e Offset hovv to program see chapter 9 21 0 2 10V external voltage signal or external current signal SSSSS or EZ 2 actual value sensor 4 20mA Terminal X2 e Pump running signal how to program see chapter 9 20 Ext 250VAC 220VDC ls 2 e ol X2 5 and 6 closed 9 motor run indication gt or start stop of a fixed speed pump e Fault signal Ext 250VAC 220VDC gt if there is an Fault Error or power supply of the HYDROVAR is cut of X2 1 and 2 closed 32 Terminal X5 X6 For multi pump applications synch or multicontroller you have to connect each HYDROVAR max 4 via the RS 485 interface Use screened cables HYDROVAR 1 HYDROVAR 2 HYDROVAR 3 5V SIO 50 2 i so gt BM JE GND SIO e Gi A Z X6 x SSSS HYDROVAR 4 Using the optional Modbus interface one or more HYDROVAR
54. sage confirms the calibration of the Adjusted transmitter s zero point by associating the minimum value of the transmitter s output signal 4mA for example to a pressure of zero bar This message appears when the presence of residual out of range pressure in the system does not enable the calibration of the zero point Depressurize the system completely and change the adjustment Press the button to change to the next parameter 9 14 Sensor Curve SENSOR CURVE Internal calculation base of the actual value 4 20mA Linear Possible Setting and its application e linear Pressure control differential pressure control level temperature and flow control inductive or mechanical e quadratic Flow control with an orifice plate together with a differential pressure transmitter Press the button to change to the next parameter 9 15 Setting of the sensor range Before changing the senor range you have to select the right dimension unit see 9 27 SENSOR RANGE Determines the end value 20mA of the measuring 20mA 10 0Bar transmitter e g 10 0 bar pressure transmitter Adjustable range 20mA 100 of the sensor range Following values corresponds to the possible adjustable ranges Bar 0 2 100 bar psi 2 9 1450 5 psi m3 h 4 2400m h g min 17 10560g min ft max 6 3345ft mH20 max 1019 5mH20 without unit 2 1000 Yo 0 100 Yo Press the button to change to the next parameter 47 9 16 Operation
55. t and BOOST too lovv check motor connection star delta and cable Pump blocked Motor turns in the vvrong direction before running Non return valve defect Not allovved operation point or Parameter Max frequency too high check Parameter BOOST in the menu MANUAL TEST RUN Output short Current rise at the output too high check connection terminals of the HYDROVAR check the connection terminal of the motor check the motor cable check the vvindings of the motor Act Value Sensor Data signal on terminals X1 2 c4mA ACTUAL VALUE signal pressure transducer faulty wrong connection Sensor Transducer fault faulty Transducer cable 66 To quit the following errors you have to cut he power supply for 30 seconds If the error signal should appear again contact customer service and provide a detailed description of the error Internal errors Error message on the Display red LED on EEPROM ERROR Reset after repeated error message ERROR 1 corresponding data block ET EE malfunction Security error Reset after repeated error message ERROR 2 l Software protection error change control card ERROR 3 RAM error Reset after repeated error message 5 change control card ERROR 4 Button error e check push buttons e g jammed key Display board may be defect ERROR 5 EPROM error Reset after repeated error message 5 change control card Program erro
56. tallation position Press the button to change to the next parameter 9 33 Set Password SET PASSWORD The pre set password 0066 can be changed if necessary 0066 Set Password by pressing 4 or W If the password will be modified it is recommended to make some notes about the new password Press the button to change to the next parameter 9 34 Lock Function LOCK FUNCTION Possible settings with AN or V OFF FF All parameters in the main menu can be changed without the need of a passvvord N If the LOCK FUNCTION is activated it s not possible to make any changes in the main menu The HYDROVAR be just started or stopped by using the buttons and W n order to change the set value the LOCK FUNCTION must be reset to OFF Press the button to change to the next parameter o o 9 35 Internal Heater HEATING Internal heating during standstill to prevent ON condensation in the HYDROVAR If ON is selected should be the general configuration a heating resistance approx 10 vvatt is svvitched on vvhen the motor is at a standstill and the supply of the HYDROVAR is O K Notice If the HYDROVAR is cut from the supply the internal heater doesn t work So if the HYDROVAR isn t used for a longer time e g vvinter season it shouldn t be disconnected from the power supply Press the button to change to the next parameter 63 9 36 Setting Default Values SUBMENU Press for about 3 seconds to enter the su
57. tion vvith Impedance coils Power supply L1 L2 L3 400VAC Motor connection without Impedance coils Mounting the distance bolts to enable the HYDROVAR operating with closed panel door This should be done before mounting the unit on the wall 1 Affix the adhesive label on the outside of the panel door 2 Open the door and mount the adhesive label for the display and the control buttons 3 Justify the distance bolts three pieces are included on the control buttons you want to control from outside when the panel door is closed 4 Close the door of the switchboard and press the control buttons to affix the distance on the outside adhesive label Cable entry On the bottom side of the HYDROVAR there are holes for 2xM40 screwed cable gland for motor and power supply cable and 3xM12 and 2xM16 screwed cable gland for control cables Cooling Both fans inside the HYDROVAR start when the motor is running The fans on the backside of the cooling body are controlled with an NTC and start when the temperature of the power module reaches 50 C 27 6 3 2 Motor connection Mounting of the PTC Variant A Variant B Motor block PTC wol THO E wey OH Rubber gasket Cover of the conduit box Open the cover of the conduit box and remove also the terminal block inside Fix the PTC Variant A or B Remounting of the terminal block Electrical connection
58. tity of dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted Air pollution max 1000m above sea level At sites over 1000 m above sea level the maximum output Altitude power has to be derated by 1 for every additional 100m If the installation site is higher than 2000 m above sea level please contact your local distributor HV2 1 HV3 11f IP 55 NEMA 4 HV3 15 HV3 45e IP 54 NEMA 12 Certifications CE UL C Tick cU Class of protection 10 The HYDROVAR complies with the general EMC regulations and is tested according to the following standards High Frequency Field Interference ENV 50204 Electrostatic Discharge EN 61000 4 Radio interference Suppression EN 61000 6 1 2002 EN 61000 6 2 2002 EN 61000 6 3 2002 EN 61000 6 4 2002 4 Dimensions and Weights HV 2 1 2 2 3 2 3 3 3 4 f Eod Weight HV VVM Kit eg H HV 2 1f EX HV3 2f mena SE All dimensions in millimetres Drawings are not in scale a centre distance between the HYDROVAR 300 mm b expansion space for maintenance 120 mm Wall mounting version high 265 mm width 195 mm depth 195 mm m Wi II MI Ill Mounting space around the HYDROVAR 150 mm HV 3 5 3 7 3 11 1 2280 man Type HV an kg Lg HV 3 5f HV3Jf 10 00 12 60 HV
59. u We suggest stopping the HYDROVAR by pressing W OFF during the first start up INVERTER STOP Press for 3 seconds to change to ON START PASSWORD Set Password 0066 Default by pressing or W 0000 NOTICE The password must be entered at each entry into the submenu PASSWORD Confirm by pressing and the first window of the sub 0066 menu is shown J O G MODE 0 0Hz Bar In the following chapters all available parameters of the secondary menu are listed on the index window there is shown the European default setting 9 1 JOG MODE JOG MODE Both Actual output frequency and actual value are 0 0Hz X XX Bar shovvn By pressing or W in this menu the internal controller of the HYDROVAR will be shut off and the inverter changes to manual mode With the buttons 4 and Y you can set any constant speed with no influence of the actual value of the control signal If this value becomes 0 Hz the HYDROVAR stop Ifyou set a frequency above 0 0 Hz the HYDROVAR will start operating normally again in automatic mode as soon as you change vvindovv Press the button to change to the next parameter 42 The parameters Window and Ramp Hysteresis and the Ramp settings as well are responsible for the control characteristic of the HYDROVAR and also guarantee the stop of the pumps at 0 demand in boosters and water supply stations Pressure speed set rated required value b Am 8922 10096 Set hyster
60. ure goes down the pump will normally start If you have selected a START VALUE of 2 5bar the pump will start after the pressure drops below Press the button to change to the next parameter 49 9 19 2 Required Value CONFIG REQ VAL 2 With this parameter a 2 independent required value OFF can be selected and at the same time the source of it will be determined The changeover between 1 and the 2 required value can be done via the digital input terminal X1 14 on the control card If this input is connected to Ground X1 10 the 2 required value will be active Possible settings with 4N or W OFF 2 required value is not active Using only standard set point INT Internal 2 required value setting according to existing required value in the main menu but at closed digital input X1 14 EXT ADC I The 2 required value is given from the value of a current signal 4 20mA connected to terminals X1 12 X1 10 Ground Notice If the incoming current signal is below 4mA an error message will be shown on the display and a failure is indicated failure relay is closed The failure is also shown at a multi pump layout but no failure would be indicated failure relay is not closed only the master pump will be exchanged If the current signal fails at all HYDROVARs the failure would be indicated also EXT ADC U 0 10V or EXT ADC U 2 10V The 2 required value is given from the value of
61. xylem Operating Instructions HYDROVAR HV2 1f HV3 11f HV3 15e HV3 22e V 2012 03A 771079342 HV2 1 3 45 V EN 6A English 1 Important safety ihstructionse asiz re rb tn kas anka adadan 5 2 System DOSION E 8 2 1 Pressure Un 8 3 Technical Data EE 9 4 Dimensions and Welghts ua sayl ke n a kk a a l a ka ni e 12 5 Mechanical mounting of the HYDROVAR unit on the motor 16 5 1 Included mounting material REENEN 16 5 2 Optional MET 16 a PAPAA DW eg EE 16 5 2 2 Bus Imtertace ne errans nennen errasse nnne 17 5 2 3 Sensors 4 20mA see eee Re enr R nennen aene denen a anna n 17 EE 17 5 2 5 Motor cables for drect Jnstallatton nnns 17 5 3 Assemble a E dee d EE 18 6 Electrical installation and wiring EE 22 6 1 Means of protection REENEN 22 6 2 EMC electromagnetic compatibility 23 6 3 Wiring and Connections 25 6 3 1 Main Voltage Terminal 26 6 3 2 MOO CONNEC UOM mee e eege een Deet ENNEN ENNEN NEEN 28 6 3 3 Control Terminals 29 6 3 3 1 Connection examples ete 31 6 4 Selection of the 5 25 34 6 5 Reduction of the maximum output current 34 6 6 REL SWA ME 35 EERSTEN PERRO TE EE IIT ELS 36 7 1 Display 36 7 2 Function of the push 5 2 37 7 3 Language
62. y The follow up pump will be stopped when the frequency drops below the set SYNCHRON LIMIT This function creates a hysteresis effect which prevents the follow up against a frequent on off operation SUBMENU Press for about 3 seconds to enter the submenu Synch Control Press the button shortly to change to the next parameter chapter 9 22 7 9 22 6 1 Synchronous Limit Tip to find out the right Setting 1 Start the first pump in JOG Mode 1st Window in the submenu increase the frequency till you reach the required value Check the frequency f at zero consumption 2 Set the synchronous limit fy 2 3 Hz 3 Set the synchronous window between 1 or 2 Hz depending on the pump curve and set point SYNCHRON LIMIT Frequency limit adjustable between 0 Hz and the set 0 0 Hz maximum frequency Switch off limit of the first follow up pump So if the frequency of both pumps is lower than this selected value the first follovv up pump will be switched off This parameter is also used for the stop value using an external fixed speed pump with activated Simple Multicontroller in the parameter CONFIGURATION RELAY Press the button to change to the next parameter 9 22 6 2 Synchronous Window SYNCHRON WINDOW Adjustable between 0 10 Hz 2 0 Hz Frequency limit for switching off the next follow up pump Switching of the 3 pump All 3 pumps are running with an output frequency SYNCHRON LIMIT SYNCHRON WINDOW Switching of
63. y DAY 290 anjeA moy 1 A 1 e A s E N CG 9900 Yo 0S Y 0000 10119 L uel uny saj 440 Jeg SEO 440 pJOMSSed 19S 1sesuo deg sinoy Gunelado nNawans ANawans ssaJppy duing 2u anjeA ny andui 19540 f q U 001 Jaye Jeg anjeA jenpy Yo 00 e epelu e ten 01305 bas 18syo f JOJO Un uny 1591 un uolsuawig no bojeuy qunowy 17 nnawans nNawans nNawans Gyuoj LI 440 pajqesip LI J9 0J300 198 001 vwoz Jeour abue jo no Yo 0 S 425 0 0 4 Z TEA bay Gyuoj J anjeA HBS apow uonejn ay apow abuey Josuas 9A1n5 JOsUas 3sn py Josuas 1s00g uwy kejaq dois J ulw Gyuoj M LI ZH 070 ZH 0 08 28504 285 0 es Q v 225 077 08 Yo S Jeg Xxx ZH 0 0S 0000 Aduanbad4 uN fouenboJ4 xev y dwey g dwey J z dwey duiey sisi491s H dwey MOpUIA apow 5Of pJoMssed Se 2 Ne A V Aty 00 0000 NO Jeg OS E degxxx ti anes oul ung eyoj 1043 p 10413 J 40413 g 10113 10113 Meis oiny L enjeA pasinbay SAIMLSNGNI 111 neis 70 Notes ITT and Engineered for life are registered trademarks of ITT Industries Inc All other trademarks or registered trademarks are property of their respective ovvners 71 xylem 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

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