Operating Instructions HV 2.015 / 2.022 HV 4.022 / 4.030 / 4.040 HV 4.055 / 4.075 / 4.110 HV 4.150 / 4.185 / 4.220 V 2012/03A-V01.4 771079412 Manual HV 2.015-4.
Index 1 Important safety instructions ...................................................................................5 2 System design ...........................................................................................................8 2.1 Pressure tank ................................................................................................8 3 Product overview ......................................................................................................9 3.1 3.
9.4.5.3 4.220) Control card – HYDROVAR SINGLE Inverter (not for HV 4.150 – HV 46 10 Programming ........................................................................................................49 10.1 Display – Control panel of the MASTER / SINGLE Inverter .........................49 10.2 Function of the push buttons ....................................................................49 10.3 Display of the BASIC Inverter .....................................................................50 10.
1 Important safety instructions Read and follow the operating and safety instructions carefully before starting operations! All modifications must be done by qualified technicians! Warning that failure to observe the precaution may cause electric shock Warning that failure to observe the precaution may cause personal injury or damage to property. In addition to these operating instructions please pay attention to universal safety and accident prevention regulations.
All work, carried out on the HYDROVAR, may only be performed by qualified and authorized staff. Furthermore, take care not to short circuit the neighbouring components when connecting the external control wires. All cable ends which are not in use have to be isolated. The HYDROVAR contains electronic safety devices which switch off the control element in the event of a fault, whereby the motor has zero current but remains energised and comes to a halt. The motor can also be halted by mechanical blocking.
Transport, handling, storage, disposal: • • • Check the HYDROVAR immediately after delivery/receipt for damage or missing parts The HYDROVAR unit must be transported carefully. Avoid serious impacts NOTICE! Dispose of all packing materials and the HYDROVAR unit in accordance with local regulations. For more detailed information about the recycling of this product, please contact your local authority, your waste disposal service provider or the outlet where you purchased the product.
2 System design The following diagrams show typical SINGLE and multi-pump systems using the HYDROVAR. Connection can be made directly to a water supply. In such a case, the use of a low pressure switch on the suction is recommended. SINGLE pump layout (1) (2) (3) 2.
3 Product overview 3.1 Hardware configurations The HYDROVAR modular concept basically consists of two main parts: the power unit and the control card. In its BASIC configuration (consisting of only the power unit) the HYDROVAR can be used as so called BASIC Inverter. In that configuration the HYDROVAR can be used as a sequence pump in a multi pump system, but also as a simple soft starter for SINGLE pump applications.
3.2.3 Cascade Serial / Synchronous (not for SINGLE version) In these modes various combinations among the versions BASIC and MASTER Inverter are possible. In general each of the pumps needs to be equipped with a HYDROVAR unit. All the units are connected via the RS485 interface and communicate via the standard MODBUSprotocol (9600 Baud, RTU, N81). To realise a fully controlled system at least one MASTER Inverter is needed, the remaining pumps could be fitted just with a BASIC Inverter.
To increase the operating reliability of such a system, also a second MASTER Inverter is recommended: Full-featured possibility: Each pump is equipped with a MASTER Inverter In this mode it is possible to run all pumps in cascade serial mode and synchronous mode as well. This configuration allows each pump of the system to become the lead pump. This also ensures a proper operation if one MASTER Inverter fails. In this case another HYDROVAR takes control.
3.2.4 Cascade Relay (not for SINGLE version) One pump is fitted with a HYDROVAR MASTER Inverter and up to 5 slave pumps can be switched ON and OFF on demand. For this purpose an additional relay card including 5 relays is attached to the MASTER Inverter. However an external switchboard is needed for all the motor relays as the relays in the HYDROVAR are not able to switch the pumps directly (just used as control contacts).
4 Type designation code HV . - - - - - - - . Software version Language 1 = Western Europe resp. all lang. (with V01.
5 Technical Data Incoming power supply (data only for dimensioning of the power supply line and not for calculating the efficiency of the HV) recommended maximum rated Voltage limits nominal line protection cross-section output 48-62 Hz current input [kW] [V] [A] [A] [mm²] HYDROVAR type HV 2.015 2.022 4.022 4.030 4.040 4.055 4.075 4.110 4.150 4.185 4.220 1,5 2,2 2,2 3 4 5,5 7,5 11 15 18,5 22 3~380-460 ± 15% 3~380-460 ± 15% 3x380-460 ± 15% HYDROVAR type HV 2.015 2.022 4.022 4.030 4.040 4.055 4.075 4.
5.1 General technical data Ambient temperature: 0° C ... +40°C At higher temperatures a reduction of the output current or the use of the next HYDROVAR power size is necessary. 110 100 max. output current [%] 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 max.
5.2 EMC requirements (Electromagnetic compatibility) The EMC requirements in general differ between two environments which depending on the intended use. • First environment – class B (EN 61800-3: Class C2) Environment that includes domestic premises, it also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes e.g.
6 Dimensions and weights HV 2.015 / 2.022 HV 4.022 / 4.030 / 4.040 All dimensions in millimetres! Lifting aids must have the proper dimensions. Type HV 2.015 HV 2.022 HV 4.022 HV 4.030 HV 4.
HV 4.055 / 4.075 / 4.110 All dimensions in millimetres! Lifting aids must have the proper dimensions. Drawings are not to scale! Type HV 4.055 HV 4.075 HV 4.
HV 4.150 / 4.185 / 4.220 All dimensions in millimetres! Lifting aids must have the proper dimensions. Drawings are not to scale! Type HV 4.150 HV 4.185 HV 4.
7 Modules Regarding the application the specific configuration for the HYDROVAR can be chosen. Due to this possibility the HYDROVAR can be configured regarding the reliability and cost effectiveness for each type of application. HV 4.022 / 4.030 / 4.040 HV 4.055 / 4.075 / 4.110 6 4 5 3 2 1 HV 4.150 / 4.185 / 4.
(1) Power unit Without one of the control cards it can be used as BASIC Inverter or as simple soft starter in a SINGLE pump application! When using a SINGLE or MASTER configuration the power unit is fitted with an additional control card (4) (2) Filter card (not available for HV4.150-4.220, standard is class A) Ensures EMC compliance for domestic environments.
8 Mechanical components 8.1 Included mounting material M 12 M 16 M 20 M 25 M 40 7 - 13 9 - 17 15 - 23 2 (3) 2 2.015 – 2.022 2 (3) 4.022 – 4.040 2 2 (3) 4.055 – 4.110 2 4.150 – 4.185 4 (5) 2 4.220 4 (5) 2 ( ) max. available cable entries 8.2 closing glad 4,5 - 10 Cable diameter [mm] Cable gland + Lock nut 3,7 - 7 Included components 2 2 2 2 2 M 12 M 16 3 3 3 4 4 1 1 1 2 2 Motor PTC Mounting clamps Centring bit 1 1 1 1 1 4 4 4 4 4 1 1 1 1 1 M 50 1 1 Optional components 8.2.
8.3 Assembly instructions HV 2.015 – HV 4.110 HV 4.150 – HV 4.
To remove the HYDROVAR – cover, the 4 fastening screws must be opened. • Ensure that there is no liquid on the unit before you open the cover. • Centre the HYDROVAR on the motor fan cover using the rubber centre bit. • If the HYDROVAR is mounted on a motor with plastic fan cover, a stainless steel mounting ring must be used. • The HYDROVAR is installed on the motor fan cover by using the mounting brackets, the four screws and the relevant washers*.
9 Electrical installation and wiring All installations and maintenance has to be performed by properly trained and qualified personnel with proper tools!! Use personal protection equipment. In case of a failure, the electrical power has to be disconnected or switched off. Wait at least 5 minutes for capacitor discharge before servicing the HYDROVAR. Otherwise it can cause shock, burns or death. 9.1 Means of protection Ask your power supply company which means of protection are required.
9.2 EMC-electromagnetic compatibility To ensure the electromagnetic compatibility the following points must be observed for cable installation: Earth / ground to ensure EMC • 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.
Motor cables To ensure the EMC compatibility and minimize noise level and leakage currents, keep the motor cable as short as possible (use shielded cables only if the total length exceeds 1.5 meters). Additional component line choke (coil) Line coils are available as an option and should be mounted between the HYDROVAR and the main fuse. The Line coil should be as near as possible to the HYDROVAR (max. 30cm).
9.4 Wiring and connections Remove the screws holding the top cover of the HYDROVAR. Lift off the top cover. The following parts can be seen on a HYDROVAR MASTER / SINGLE Inverter: HV 2.015 / 2.022 HV 4.022 / 4.030 / 4.040 HV 4.055 / 4.075 / 4.
9.4.1 Main voltage terminals The power supply is connected to the power section: Terminal L + N (1 x 230 VAC, SINGLE-phase) Terminal L1+ L2 + L3 (3 x 400 VAC, three-phase) HV 2.015 / 2.022 L-N 1x230 VAC HV 4.022 / 4.030 / 4.040 L1-L2-L3 3x400 VAC Motor connection U-V-W (Crimp connection 6,3mm) Power supply HV 4.055 / 4.075 / 4.110 HV 4.150 / 4.185 / 4.
9.4.2 Motor connection Mounting of the PTC Method A : Method B : motor block PTC terminal block rubber gasket 1. 2. 3. 4. PTC cover of the conduit box The cover of the conduit box must be opened and the terminal block inside removed Fix the PTC (Method A or B) Replace the terminal block Electrical connection of the motor cables The PTC must be fixed to the metal body of the motor.
9.4.3 Power unit On the power unit two control terminal blocks can be found. HV 2.015/2.022 HV 4.022 / 4.030 / 4.040 HV 4.055 / 4.075 / 4.110 HV 4.150 / 4.185 / 4.
To ensure safety operation between the HYDROVAR and the motor a motor-thermo-switch or PTC should be connected to the power unit. Additionally this input can be used as an external ON / OFF signal when using the HYDROVAR just as BASIC Inverter.
If the HYDROVAR is used as a BASIC Inverter in a multi-pump system, the internal interface on the power unit is used for the serial RS-485 connection to the other HYDROVAR units in the system. (Be careful: Internal interface is not available in SINGLE Inverter configuration!) X2 RS485-Interface – Power Unit X2/ SIO SIO + GND S Internal SIO-interface: SIOInternal SIO-interface: SIO+ GND, electronic ground Internal interface for multi-pump-systems S …….
9.4.3.2 Addressing When using the cascade serial/synchronous mode in a multi-pump-application (where more than one MASTER Inverter or even BASIC Inverters are used), the right address must be set to ensure a proper communication within the system. MASTER Inverter – The desired address of the MASTER Inverter has to be set via the HYDROVAR-software. In this case for all MASTER Inverters the below shown dip-switch on the power unit must be set to address 1 (default setting).
HV 2.015 / 2.022 HV 4.022 / 4.030 / 4.040 BASIC Inverter HV 4.055 / 4.075 / 4.110 BASIC Inverter Dip- switch Dip- switch HV 4.150 / 4.185 / 4.220 Terminal for external LED (X22) possibility to connect a LED to show the status without display operation.
9.4.4 RFI – switch For HYDROVAR HV4.055 – HV4.220 additional filter capacitors are included, which provide an improved filer characteristic in order to avoid RFI (Radio Frequency Interfaces) when the HYDROVAR is used as wall mounted device with longer motor cables between the HYDROVAR and the motor. In general the default settings should not be changed and remain in default position. NOTE: Due to the additional filter capacity the earth leakage current will increase, if the filter is active.
9.4.5 Control unit Regarding the hardware configuration of the HYDROVAR two different control cards are available. The control unit of the HYDROVAR MASTER Inverter basically consists of the control card and the additional boards which are connected to the control card via slot connectors. This configuration is able to support all special software features and optional boards. The second available control card included in the HYDROVAR SINGLE Inverter is developed just for SINGLE pump operation.
Control terminals All control cables connected to the control card have to be screened (See chapter 9.3 recommended cable types). External volt free contacts must be suitable for switching <10 VDC. NOTE: If unscreened control cables are used, signal interference may occur and could also interfere incoming signals and the function of the HYDROVAR. Do not connect the ground of the control card to other voltage potentials.
Additional power supply ** max. 100 mA Current signal input (required val. 2) 0-20mA / 4-20mA [Ri=50Ω] To determine the required value or the offset Analogue output 2 4-20mA Analogue output 1 0-10 VDC Current signal input (required val.
Connection examples: • Sensor–Actual-value-signal Input Connection of a 2-wire transducer (e.g.
• Switching between two different required values External switching between two connected required value signals (e.g.: between voltage and current signal input) by closing digital input 1 (X3/9-10). In ACTUATOR mode it is possible to switch between two different frequencies by the digital inputs. The connected input signals (current or voltage) are proportional to the frequency. How to program see SUBMENU REQUIRED VALUES [0800].
X4 RS485-Interface X4/ 1 2 3 4 5 6 User SIO-Interface: SIOUser SIO-Interface: SIO+ GND, electronic ground Internal SIO-Interface: SIOInternal SIO-Interface: SIO+ GND, electronic ground User interface for external communication Internal interface for multi-pump-systems RS-485 – Internal interface RS-485 - User interface The internal RS-485 Interface is used for the communication between up to 8 HYDROVAR in a multi-pump application.
X5 Status-Relays X5/ 1 2 3 4 5 6 Status Relay 1 Status Relay 2 Status Relay 1 CC NC NO CC NC NO [Max. 250VAC] [0,25A] [Max. 220VDC] [0,25A] [Max. 30VDC] [2A] Status Relay 2 Notice: When using the relay contacts for driving an external relay, a corresponding RC-snubber-circuit or varistor is necessary, to prevent disturbance of the HYDROVAR! Both Status-Relays on the control card can be used regarding the programmed configuration.
9.4.5.2 Relay Card This optional component can be used only in combination with a HYDROVAR MASTER Inverter. The Relay Card is connected to the control card using connection slot X6 (See chapter 9.4.4.1). Terminal block Notice: When using the relay contacts for switching external contactors, a corresponding RC-snubbercircuit or varistor is necessary, to prevent disturbances arising during a switching action of the relay! Terminals Relay Card X10 Relay Card X10/ 1 Relay 1 2 Relay 2 [max.
Connection example: The following wiring diagram shows a standard cascade control system where the HYDROVAR is fitted with an additional Relay Card, in selected mode Cascade Relay. To switch the fixed speed pumps via the internal Relay Card, an external panel for the contactors of the D.O.L or STAR/DELTA starters (and optional A/0/M – switch) is required. In the example below 3 fixed speed pumps are connected to the Relay Card.
9.4.5.3 Control card – HYDROVAR SINGLE Inverter (not for HV 4.150 – HV 4.220) The control card is connected to the power unit via a ribbon cable on terminal X8. The display is connected to terminal X9 The display can be mounted in normal position (0°) or upside down (180°).
Control Terminals All control cables connected to the control-unit have to be screened (See chapter 9.3 recommended cable types). External volt free contacts must be suitable for switching <10 VDC. NOTE: If unscreened control cables are used, signal interference may occur and could interfere with incoming signals and the function of the HYDROVAR. Don’t connect the ground of the control card to other voltage potentials. All electronic ground terminals and GND of the RS 485-interface are connected internally.
X5 Status-Relays X5/ 1 2 3 4 5 6 Status Relay 1 Status Relay 2 Status Relay 1 CC NC NO CC NC NO [Max. 250VAC] [0,25A] [Max. 220VDC] [0,25A] [Max. 30VDC] [2A] Status Relay 2 Notice: When using the relay contacts for driving an external relay, a corresponding RC-snubber-circuit or varistor is recommended, to prevent disturbances arising during a switching action of the relay! Both Status-Relays on the control card can be used regarding the programmed configuration.
10 Programming Read and follow the operating instructions carefully before you start programming to prevent incorrect settings which will cause malfunction! All modifications must be done by qualified technicians! 10.1 Display – Control panel of the MASTER / SINGLE Inverter Power Run Error LEFT UP DOWN RIGHT 10.
10.3 Display of the BASIC Inverter Status LED - green Constant Blinking Motor stopped (Standby) Motor run Error LED - red The type of error is indicated by the blinking-code of the ERROR LED. 1 blink 2 blinks 3 blinks 4 blinks 5 blinks 6 blinks Undervoltage Overcurrent / Overload Inverter overheat Overvoltage Code Error Motor overheat (external contact is open) For detailed information see chapter 11 Failure messages.
10.4 Software parameters In the following chapters all available parameters of the main and secondary menu are listed. The upper window shows the factory setting and the line below the possible range of settings. The general parameter description is written for the HYDROVAR MASTER Inverter (Full featured HYDROVAR including the high level control card which supports also the optional modules like the optional Relay Card and all specific software features).
b) Active MODE [0105] = Cascade Relay / Cascade Serial / Cascade Synchron * ADR X STOP PX XX.X Hz X.XX Bar 1st display at mode cascade serial and cascade relay S This window shows the status of the HYDROVAR. * Indicates the HYDROVAR which actually controls the system ADR X Pump address PX Cascade relay mode: Indicates the number of pumps which are running e.g.: P3 ….
03 03 EFF REQ VAL D1 X.XX Bar Effective required value Shows the current required value that is calculated based on ACTUAL VALUE INCREASE [0505], ACTUAL VALUE DECREASE [0510] and LIFT AMOUNT [0330]. If the required value is influenced by an offset signal (SUBMENU OFFSET [0900]) the current active required value is also shown in this window. E.g. Multi-pump-application with two pumps REQUIRED VALUE [02]: 5.00 bar ACT. VALUE INCREASE [0505]: 0.50 bar ACT. VALUE DECREASE [0510]: 0.
04 04 START VALUE OFF Possible settings: Regulation Restart Value G 0 – 99 % – OFF This parameter defines the start value after pump stop in percentage of the required value. E.g. REQUIRED VALUE [02]: 5.0 bar START VALUE [04]: 80 % --> 4.0 bar If the pump system has reached the required pressure of 5.0 bar and there is no more consumption, the HYDROVAR shuts off the pump. When the consumption increases, and the pressure drops the pump normally starts. If a START VALUE [04] of 4.
08 08 AUTO - START ON Possible settings: Auto Start ON – OFF Select ON with ▲ or OFF with the ▼ button. If AUTO-START = ON the HYDROVAR starts automatically (in case of demand) after reconnection of power following disconnection. If AUTO-START = OFF the HYDROVAR won’t start automatically after reconnection of power following disconnection. After remedy of the failure or reconnection of the power supply the following message is shown: AUTO START = OFF XYLEM STOP 09 XX.X Hz X.XX Bar 09 OPERAT.
20 20 SUBMENU STATUS Status of all units within a pump group Using this submenu it is possible to check the status (including failures and motor hours) of all connected units. 21 21 STATUS UNITs 00000000 Status of all units G S This parameter gives a quick overview about the status of the connected units - In Cascade serial/synchron mode the status of all (max.
Mode CASCADE RELAY: Device 1 2 3 4 5 6 7 8 enabled by MASTER Inverter fixed speed pump fixed speed pump fixed speed pump fixed speed pump fixed speed pump not used not used 23 STATUS DEVICE Stopped 23 Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 X10 /1 X10 /2 X10 /3 X10 /4 X10 /5 Status of the selected device G S Possible messages: Running, Stopped, Disabled, OFF, Preparing (Mode Casc.
25 25 MOTOR HOURS XXXXX h Motor-runtime of the selected device G Total time how long the motor is being powered by the HYDROVAR. How to reset see parameter CLR MOTORH. [1130]. Error memory All errors, including these of the BASIC Inverter are shown and saved at the MASTER Inverter in this menu. The errors saved in this menu include the failure message text of the current HYDROVAR where the failure happened, and also date and time when the failure occurred.
40 40 SUBMENU DIAGNOSTICS 41 41 PROD. DATE XX.XX.XXXX production date of the HYDROVAR (MASTER /SINGLE only) In this parameters the current temperature, voltage and frequency of the chosen HYDROVAR can be monitored even during operation of the unit. These parameters are only to read! 42 42 SEL. INVERTER * 1 * Possible settings: 43 43 TEMP.
60 SUBMENU SETTINGS Before entering the submenu settings these instructions must be read carefully to prevent incorrect settings which will cause malfunction. All parameters can also be set during operation. Therefore different parameters in the extended submenu should be used only by trained and qualified persons.
0100 0100 SUBMENU BASIC SETTINGS 0105 0105 MODE Controller Selection of the operation mode Possible settings: Controller, Cascade Relay, Cascade Serial, Cascade Synchron, Actuator Controller (Default Setting): This mode should be selected if only one HYDROVAR MASTER /SINGLE Inverter is used and no connection to any other HYDROVAR via RS-485 interface is needed.
Actuator: (For SINGLE pump operation only!) The actuator mode has to be used if a fixed speed setting is required or an external speed signal is connected and the HYDROVAR is just used like a standard VFD. In this case, the internal controller is shut off, so the HYDROVAR does not control the set value but runs the connected motor at a frequency proportional to the input signal which is connected to the analogue inputs or is set directly on the HYDROVAR.
0106 0106 PUMP ADDR. * 1 * Possible settings: Select desired address for the MASTER Inverter S 1-8 Set desired address on each MASTER Inverter and press ► button for approx. 3 sec. and the following massages will appear: Addressing -> Addressing 1220 PUMP ADDR. or 1220 PUMP ADDR. * 1 * - 1 - Addressing done Addressing failed - retry When using MASTER and BASIC Inverters together in a multi-pump-system you have to consider that the BASIC Inverters have their separate address.
0200 0200 SUBMENU CONF INVERTER 0202 0202 SOFTWARE HV V01.4 Software version of the control board If a Remote Display is connected also its software version is shown in this window. 0202 0202 SW RD V01.0 HV V01.4 Software version of the Remote display (RD) and the control board (HV) 0203 0203 SET VER.INV sel:00 act:00 Selection of the SW version on the power board Possible settings: G 00 - 02 Manual selection of the required (sel.) and indication of the active (act.
0210 0210 INVERTER ALL Possible settings: Selection of the HYDROVAR address for parameterizing G S ALL, 1-8 If several HYDROVAR MASTER Inverters and even BASIC Inverters are connected via the RS-485 interface, the parameterization of all the settings in SUMBENU [200] can be done via one unit and will be taken over by other units in this group. If only a specific unit needs to be programmed you have to press the ► button for 3 sec.
Ramp settings: • Time settings of the ramps influence the control of the pump. • The fast ramps 1 and 2 are determined by the type (power) of the HYDROVAR and the type of the pump. Default = 4 sec.; depending on the power of the HYDROVAR they should be increased up to 15s for higher power ratings to avoid overload error.
0215 0215 RAMP 1 4 sec Possible settings: • • 0220 RAMP 2 4 sec Possible settings: 0225 RAMP 3 70 sec Possible settings: 0230 RAMP 4 70 sec Possible settings: • Ramp 2: Fast deceleration time G 1 – 250 (1000) sec Ramp 3: Slow acceleration time G 1 – 1000 sec Excessively fast running up time may lead to oscillation and/or an error (OVERLOAD). Excessively slow running up time can cause a drop of the outgoing pressure during variation of the demand.
0240 0240 RAMP FMIN D 2.0 sec Possible settings: Ramp Fmin deceleration G 1.0 – 25.0 sec Fast running down time, to stop the HYDROVAR immediately below the selected MIN. FREQUENCY [0250]. • Excessively fast running down time tends to cause an error (OVERVOLTAGE) 0245 0245 MAX. FRQ. 50.0 Hz Possible settings: Maximum frequency G 30.0 – 70.0 Hz This parameter determines the maximum speed of the pump. The standard setting is according to the nominal frequency of the connected motor.
f->fmin With this setting the pump will never stop automatically. Only the frequency will go down to the selected MINIMUM FREQUENCY [0250]. To stop the pump the external ON/OFF must be opened or the ▼ button must be pressed. Applications: circulation systems The setting f->fmin can overheat the pump, when there is no flow through the pump => bypass line for circulation pumps! 0260 0260 FMIN TIME 0s Possible settings: Delay time before shut off below MIN. FREQ.
0275 0275 POWER REDUCT. OFF Possible settings: Reduction of the maximum output current G OFF, 85%, 75%, 50% If a motor with lower nominal power is used, the maximum output current should be adjusted accordingly. The reduction of the maximum output current also affects the overload-detection! Output current [A] HV type 2.015 2.022 4.022 4.030 4.040 4.055 4.075 4.110 4.150 4.185 4.220 0280 OFF = 100% 7,00 10,00 5,70 7,30 9,00 13,50 17,00 23,00 30,00 37,00 43,00 0280 SEL.SW.FRQ.
0285 0285 SKIPFRQ CTR 0,0 Hz Possible settings: 0286 0286 SKIPFRQ RNG 0,0 Hz Possible settings: 0290 0290 CURR. LIMIT OFF Possible settings: 0291 0291 CURR. LIMIT 100 % Possible settings: Skip frequency centre G fmin - fmax Skip frequency range G 0,0 – 5,0 Hz Current limit functionality OFF - ON Current limit 10,0 - 100 % Following parameters [0285] - [0291] are limited for power ratings starting from 5,5kW (Size 2 and Size 3) with production date 05/08 and control board software V01.
0300 0300 SUBMENU REGULATION 0305 0305 JOG 0.0Hz X.XX Bar Both the current output frequency and actual value are shown. • By pressing ▲ or ▼ in this menu, the internal controller of the HYDROVAR is deactivated and it changes to manual mode. • Using the ▲ and ▼ buttons any constant speed can be set without further control to achieve the set point! • If this value becomes 0.00 Hz the HYDROVAR stops. • As soon as the window is left by pressing ◄ or ►, the HYDROVAR returns to the selected mode.
0325 0325 FRQ. LIFT 30.0 Hz Possible settings: Frequency limit for required lift value G 0.0 Hz – 70.0 Hz Control according to a system curve (increase of the set pressure, depending on the flow rate/speed to cover friction losses). The setting determines the output-frequency where the set pressure starts to be increased. The right setting should be equal to the frequency when the pump reaches the set pressure at zero flow (Can be determined by using the JOG MODE [0305]). 0330 0330 LIFT AMOUNT 0.
0400 0400 SUBMENU SENSOR In this submenu all actual value sensors which are connected to the HYDROVAR can be configured, (up to two transducers with current output or voltage signal output). It is not possible to install two different transducer types because main configuration is the same for all connected sensors. Transducers must be always the same type. 0405 0405 DIMENS.
0415 SENSOR TYPE 4 – 20mA 0415 Possible settings: Selection of the sensor type and input terminal - analog I 4-20mA - analog I 0-20mA - analog U 0-10V For correct operation the suitable signal input type regarding to the connected sensor has to be selected.
0430 0430 SENS 1 CAL 0 0% = actual value Possible settings: Sensor 1 zero point calibration - 10% up to +10% This parameter is used to calibrate the minimum value of Sensor 1. After setting the dimension unit and the sensor range the zero point for this sensor can be adjusted. Adjustable range between -10 % and +10 %.
0500 S 0500 SUBMENU SEQUENCE CNTR. Using the parameters of this submenu, all necessary settings can be done for running a multi-pump system (even in cascade relay and cascade serial / synchron mode). Application Example: 1) Lead pump reaches its ENABLE FREQUENCY [0515] 2) Actual value falls and reaches the cut in-value of the 1st assist pump Cut in-value = REQUIRED VALUE [02] – ACT. VAL. DEC.
The following 3 parameters are responsible for starting the assist pumps and to calculate the new required value as well. 0505 0505 ACT.VAL.INC. 0.35 Bar Possible settings: 0510 0510 ACT.VAL.DEC. 0.15 BAR Possible settings: 0515 0515 ENABLE FRQ 48.0 Hz Possible settings: Lift value G S 0.00 – to the pre selected sensor range Drop value G S 0.00– to the pre selected sensor range enable frequency for the next power unit G S 0.0 – 70.
If the MASTER Inverter goes below that frequency for longer than the pre-selected DISABLE DLY [0535] and the system pressure is higher than the EFFECTIVE REQ. VALUE [03] (REQUIRED VALUE [02] + ACTUAL VAL. INC [0505]), the first assist pump stops. 0535 0535 DISABLE DLY 5 sec Possible settings: Disable delay time (for cascade relay only!) S 0 – 100 sec Delay time before switching off the assist up pumps in cascade relay mode.
0555 0555 SWITCH INTV 24 hours Possible settings: Switch interval for cyclic changeover (for cascade serial / synchron only!) G S 0 – 250 hours This parameter allows an automatic change over of the MASTER pump and the assist pumps, in order to provide even wear and achieve even operating hours of the pumps. The switch interval is used for HYDROVAR MASTER Inverters only (connected via the RS-485 interface) by using operation mode Cascade Serial or Cascade Synchron.
0570 0570 MSTPRIORITY ON Possible settings: G MASTER priority (for cascade serial / synchron only!) S ON - OFF This parameter determines the alternation order when MASTER and BASIC Inverters are used within one system. In such a case you have to select if either the MASTER or the BASIC Inverters should be switched on first. ON- all MASTER Inverters in the system are released (unless it is stopped by a failure or manually) before the first BASIC Inverter gets released.
0600 0600 SUBMENU ERRORS 0605 0605 MIN. THRESH. disabled Possible settings: minimum threshold limit disabled - max. SENSOR RANGE • An adjusted value >0.00 has to be reached within the programmed DELAY TIME [0610] • If this value can’t be reached, the HYDROVAR stops with the failure message MIN. THRESHOLD ERROR. • To disable the minimum threshold limit, press ▼ till disabled is shown on the display.
0700 0700 SUBMENU OUTPUTS 0705 0705 ANALOG OUT1 Output Frequency Analogue output 0 – 10V = 0 - 100% Possible settings: - Actual value - Output frequency (0 - fmax) 0710 0710 ANALOG OUT2 Actual value Possible settings: S Analogue output 1 Terminal: X3/20 S Analogue output 2 Actual Value, Output frequency Analogue output 4 – 20mA = 0 - 100% Possible settings: - Actual value - Output frequency (0 - fmax) Terminal: X3/21 0715 0715 CONF REL 1 Running Configuration of the status relay 1 (X5/1-2-3)
0800 0800 SUBMENU REQUIRED VALUES 0805 0805 C.REQ.VAL 1 digital Possible settings: Digital analog U=0 – 10V analog I=0 – 20mA analog I=4 – 20mA Configuration required value 1 - digital - analog I 0-20mA - analog U 0-10V - analog I 4-20mA S The internal required value 1 is used. Setting in the main menu in Parameter 02 or parameter [0820]. The required value 1 is determined by the value of a voltage signal (0 – 10V) connected to terminals X3/13- X3/14 (GND).
0815 0815 SW REQ.
0900 S 0900 SUBMENU OFFSET The different analogue inputs on terminals X3/13-24 can be used also to connect a second actual value signal as offset source for the required value. 0905 0905 OFFS.
0910 0910 LEVEL 1 0 Possible settings: 0912 0912 OFFSET X1 0 Possible settings: Offset active between 0 and LEVEL 1 S 0 – OFFSET RANGE Offset signal value S 0 – LEVEL 1 Designation of the x – coordinate as absolute value 0913 0913 OFFSET Y1 0,00 bar Possible settings: Desired value S 0 – standardization of the sensor Desired value; designation of the y – coordinate as absolute value 0915 0915 LEVEL 2 100 Possible settings: 0917 0917 OFFSET X2 100 Possible settings: Offset active between
Example for using the Offset function: Constant pressure system with required value of 5 bar. Additionally a flow sensor is connected to the Offset input. Parameter [907] - Offset Range = 160 (max. range of flow sensor = 16m³/h) System requirement 1: 5 bar constant pressure while the flow rate is between 5m³/h and 12m³/h. Below the 5 m³/h the pressure should be decreased with the limitation to have max. 2,5 bar at a flow rate of 2m³/h.
1000 1000 SUBMENU TEST RUN 1005 1005 TEST RUN after 100 hrs Possible settings: G Automatic test run OFF – 100 h. The Automatic Test Run starts up the pump after the last stop to prevent the pump from blocking. Test Run Time, Frequency and Boost can be selected in the parameters below. To disable the automatic test run, press ▼ until OFF appears on the display.
1100 1100 SUBMENU SETUP 1110 1110 FACTORY SET EUROPE Possible settings: Restores the HV to factory setting EUROPE, USA To restore the HYDROVAR to factory settings select Europe or USA. For reset press ► button till DONE appears. 1120 1120 PASSWORD 2 0000 Enter password by pressing ▲ or ▼ The below mentioned parameters are available after entering the right password! For more information, pls.
1200 1200 SUBMENU RS485INTERFACE User Interface The following 3 Parameters are necessary for the communication between the HYDROVAR and an external device (e.g. PLC) via standardized Modbus-protocol. Set desired address, Baudrate and Format according the system requirements.
11 Failure messages If the HYDROVAR is stopped by an error (warning), the HYDROVAR as well as the motor remain under voltage. Before any work is carried out on the electrical or mechanical part of the system, the HYDROVAR must be disconnected from power supply. Difference between warnings and errors: • Warnings are shown on the display and even by the red failure led. If a warning is active and the cause is not remedied within 20 seconds an error will be shown and the HYDROVAR stops.
11.
11.2 MASTER / SINGLE Inverter Each error is shown on the display in plain text and saved in the error memory.
Error probable cause OVERLOAD ERROR 12 Power limit of the HYDROVAR is exceeded OVERVOLTAGE ERROR 13 DC voltage of the HYDROVAR too high INVERT. OVERHEAT ERROR 14 THERMO MOT/EXT ERROR 15 too high temperature inside the HYDROVAR An external protective device connected to terminal X1/PTC has released (e.g. PTC which is connected has reached its release temperature) PHASELOSS ERROR 16 One phase of the power supply has been lost -> automatic power reduction (just available for the units HV4.055-4.
Reset: LACK OF WATER ERROR 21 Reset: • cutting off the power supply for >60 seconds • manual reset by closing external ON/OFF (Terminals X3/7-8) • manual reset by pressing ◄ and ► simultaneously for about 5 seconds • Auto-reset possible if ERROR-RESET [0615] is set to ON • incoming pressure or min. level too low Low water contact • bridge X3/11-12, if there is no ext.
Reset: • cutting off the power supply for >60 seconds • manual reset by closing External ON/OFF (Terminals X3/7-8) • manual reset by pressing ◄ and ► simultaneously for about 5 seconds • Auto-reset possible if ERROR-RESET [0615] is set to ON 11.3 Internal errors To quit the following errors you have to cut the power supply for >60 seconds. If the error message is still shown on the display, contact customer service and provide a detailed description of the error.
Examples: Booster unit Problem: no stop of the HYDROVAR Parts to check measure • existing demand • check pipes and valves • non return valve is not closed • change non return valve • pre charge pressure in the pressure tank • adjust according the diagram • set WINDOW [0310] (ca.10%) and • incorrect setting of WINDOW and HYSTERESIS [0315] (80-50%) RAMPHYSTERESIS • set RAMP 2 [0220] to 4...13 sec.
Maintenance The HYDROVAR does not require any special maintenance. However, the cooling fan and the vents should be free of dust. Also the temperature around the unit should be checked from time to time. All modifications must be done by qualified personnel! For mounting and repairs at the HYDROVAR, qualified service technicians are available. Demounting: The HYDROVAR must be disconnected from the power supply before any work can be carried out. Consider the pump- and motor-instruction.
SUBMENU 40.1 DIAGNOSTICS 40 20.1 SUBMENU 20 STATUS MAIN MENU 0 xx-xx-xxxx PROD. DATE NO ERROR 41 1ST ERROR 26 00000000 STATUS UNITS 3,5 bar xx.x Hz 26.1 21 ITT XYLEM 42 27 22 6 2 * 01 * SEL. INVERTER NO ERROR 2ND ERROR * 01 * SELECT DEVICE x: 43 28 23.3 23 7 xx % xx C° TEMP.INVERTER NO ERROR 3RD ERROR running STATUS DEVICE xx:xx TIME xx-xx-20xx DATE EFF REQ VAL 3,5 bar 3 3,5 bar REQUIRED VAL x: x: 46 44 29 23.2 24 4.1 8 4.1 4 xx.
SUBMENU SUBMENU SUBMENU SENSOR SEQUENCE CNTR 500.1 500 400.1 400 SUBMENU REGULATION 300.1 300 535 505 405 305 bar 5 sec DISABLE DLY 0,35 bar ACT.VAL.INC bar DIMENS.UNIT 3,5 JOG Hz CONF. FMIN 255 f->0 RAMP 3 70 sec HV V01.3 SOFTWARE Controller MODE 0000 PASSWORD 225 202 CONF INVERTER 200.1 SUBMENU 200 105 61 105.1 SUBMENU SETTINGS BASIC SETTINGS 100.1 100 60.1 60 bar Hz 10 % WINDOW 0 sec FMIN TIME RAMP 4 70 sec act.
SUBMENU OFFSET SUBMENU SETUPS SUBMENU RS485-INTERFACE 1200 1100.1 1100 TESTRUN 1000.1 1000 900.1 1205 1110.1 1110 1005 905 900 SUBMENU 805.1 REQUIRED VALUES 800.1 805 1 ADDRESS Europe FACTORY SET 100 hours TESTRUN OFF OFFS.INPUT digital C.REQ.VAL.1 Output frequency 800 SUBMENU disabled MIN.THRESH. 705 ANALOG OUT1 23.1 605 705.1 OUTPUTS SUBMENU ERRORS SUBMENU 700.1 700 600.1 600 2 sec DELAY TIME 915 910 815.1 815 715.
XYLEM WATER SOLUTIONS AUSTRIA GMBH Ernst-Vogel Strasse 2 2000 Stockerau Österreich Telefon: +43 (0) 2266 / 604 Telefax: +43 (0) 2266 / 65311 e-mail: info.austria@xyleminc.com web: www.xylemaustria.com Xylem Water Solutions Austria GmbH reserves the right to make modifications without prior notice.
