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Operating Instructions

1. 83 11 Failure Messages is isbancetesventevausetecudelalazectu vedats 84 11 1 85 11 2 Master Single Inverter 86 11 3 Internal ia 89 12 Maintenance anode GDE 91 Follow the pump operating and maintenance instructions We reserve the right to alter specifications 9 TT 1 Important safety instructions Read and follow the operating and safety instructions carefully before starting operations All modifications must be done by qualified technicians N Warns that failure to observe the precaution may cause electric shock Warns that failure to observe the precaution may cause personal injury or damage to property In addition to these operating instructions please pay attention 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 be carried out only by trained skilled and qualified personal Unauthorized modifications or changes to the system make all guarantees null and void During operation the motor can be stopped by opening digital input or manual operation whereby the HY
2. 440 210422222 21 8 2 Optional components 21 8 2 1 Mounting accessories 21 8 2 2 21 8 2 3 EET 21 8 2 4 Ready made motor nennen nnns 21 8 3 Assemble instruction 22 9 Electrical installation and wiring 4 4440422 88 24 9 1 Means of protection Oo ela 24 9 2 EMC electromagnetic compatibility 25 9 3 Recommended cable types eene crine ern 26 9 4 Wiring and connections ter odictor eee eue o 27 9 4 1 Main voltage nnne nnns 28 9 4 2 Motor connection c ee Ee att eios 29 9 4 3 30 9 4 3 1 Solo RUD 31 9 4 9 2 hes 33 9 4 4 GontrolUnit 25 0 8 niu Lapi RR RR 35 9 4 4 1 Control card HYDROVAR Master Inverter 35 9 4 4 2 Relay Card senos REPERIO ERRARE 43 9 4 4 3 Control card HYDROVAR Single 2
3. A V 0 1 1 The mentioned HYDROVAR in this example is specified with following technical data Nominal mains voltage Rated output Hardware configurations Enclosure class EMC filter Optional components Hardware version Language Software version 13 3 3 380 460VAC 4 Motor mounted unit Master Inverter 55 B Filter domestic environment Display Relay Card G A Western Europe V01 1 amp ITT 5 Technical Data HYDROVAR Power supply Type Rated Voltage limits nominal Recommended Maximum output 48 62 Hz current input line protection cross section oe j 20 2 3 380 460 15 13 10 16 3 380 460 15 HYDROVAR Output to the motor Type Rated max output voltage nominal Motor connection cables output current output mm 4x1 5 4x1 5 4 2 5 4x6 Make sure that the HYDROVAR s electrical data match those of the electric pump Improper combinations may cause errors and malfunction and of the protection of the electric motor The nominal current of the motor must be lower than the rated current of the HYDROVAR to prevent overheating or shutdown due to OVERLOAD The max output current of the HYDROVAR could reach 110 of the nominal current for max 60 sec before the error OVERLOAD w
4. All errors including these of the Basic Inverter are shown and saved at the Master Inverter in this menu The errors saved in this menu include the failure message text of the current HYDROVAR where the failure happened and also date and time when the failure occurred For more information about errors see chapter 11 failure messages 26 1st ERROR 26 ERROR XX Latest error happened on selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 27 2nd ERROR 27 ERROR 2nd error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 28 3rd ERROR 28 ERROR XX 3rd error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 29 4th ERROR 29 ERROR 4th error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press A or V to scroll up or down 30 5th ERROR 30 ERROR 5th error of the selected device Message ERROR XX FAILURE TEXT DATE TIME Press or V to scroll up or down 56 9 TT 40 40 SUBMENU DIAGNOSTICS 41 production date of the HYDROVAR only Master In this parameters the current temperature voltage and frequency of the chosen inverter can be monitored even during operation of the HYDROVAR These parameters are only readable 42 SEL INVERTER 42 1 Selection of the desired unit Possible settings
5. On the power unit in its basic form which is used as Basic Inverter in multi pump systems or as a simple soft starter in a single pump application is fitted with two control terminal blocks 2 015 2 022 HV 4 022 4 030 4 040 X1 Control terminals power unit PTC PTC or thermal switch START STOP external release when using a Basic Inverter SL SOLO RUN O 7 2 SsL SOLO RUN PTC 3 1 9 START STOP_PTC To ensure a save operation between the HYDROVAR and the motor if the HYDROVAR is used as Basic Inverter a motor thermo switch or PTC and an external on off switch should be connected to the power unit They must be connected to X1 PTC in serial and will stop the HYDROVAR in case of a failure Also a low water switch or any other protective devices can be connected to these terminals If there aren t connected any external protective devices or they are connected directly to the control card when using a Master Inverter bridge terminals X1 PTC otherwise the HYDROVAR can t be started 30 9 TT 9 4 3 1 Solo run The terminals X1 SL are used to release a Basic Inverter when used a multi pump application when the communication to the Master Inverter fails or even the Master Inverter itself fails or in case the Basic Inverter is just used as simple soft starter e At opened contact X1 SL the HYDROVAR works in standard operation So a Basic Inverter only
6. User Interface The following 3 Parameters are necessary for communication between the HYDROVAR and an external device e g PLC via standardized Modbus protocol Set desired address Baudrate and Format according the system requirements 1205 ADDRESS 1205 1 Set desired address for the user interface Possible settings 1 247 1210 Baudrate for user interface 9600 Possible settings 1200 2400 4800 9600 14400 19200 38400 1215 FORMAT 5 1215 RTU N81 Format for user interface Possible settings RTU N81 RTU N82 RTU E81 RTU O81 ASCII N72 ASCII E71 ASCII O71 Internal Interface If several Master Inverters are connected via the internal RS 485 interface max 8 using cascade serial mode each pump must be allocated its own pump address number 1 8 Each address may only be used once 1220 PUMP ADDR 1220 1 Select desired address for the Master Inverter Possibel settings 1 8 Set desired address for the current Master Inverter and press gt button for approx 5 sec and the following massages will appear Addressing 1220 PUMP ADDR T 1220 PUMP ADDR Addressing ness 1 Addressing done Addressing failed retry When using Master and Basic Inverters together in a multi pump system you have to consider that the Basic Inverters have their separate address Otherwise a correct function of the system couldn t be guaranteed For detailed Information see chapter 9 4 3 2 Addressing 83 9 TT 11 Failure
7. 0440 SENS 2 CALO i NE 0440 0 00 00 bar Sensor 2 zero point calibration Possible settings 10 up to 10 of the sensor range Zero point calibration for Sensor 2 for explanation see Parameter 0430 5 0445 SENS 2 CALx 0445 0 10 00 bar Sensor 2 upper range value calibration Possible settings 10 up to 10 of the sensor range Upper range calibration for Sensor 2 for explanation see Parameter 0435 72 9 TT 0500 SUBMENU 9200 SEQUENCE CNTR Using the parameters of this submenu all necessary settings can be done for running a z multi pump system even in cascade relay and cascade serial mode Application Example 1 Lead pump reaches its ENABLE FREQUENCY 0515 2 Actual value falls and reaches the cut in value of the 1 follow up pump Cut in value REQUIRED VALUE 02 ACT VAL DEC 0510 the 1 follow up pump is switched on automatically 3 After the start up the new required value is calculated in the following way NEW REQUIRED VALUE REQ VAL 02 ACT VAL DEC 0510 ACT VAL INC 0505 The new required value is shown in the main menu as parameter EFF REQ VAL 03 Calculations of the new required value for multi pump applications Number of active pumps 1 k 1 lift value fall value e Lift value Fall value gt Pressure constant independent how many pumps are operation e Lift value gt Fall value gt Pressure rises when lag pump switches o
8. Find the Dip switch which is placed on the power unit see picture next page o Set the desired address for each Inverter e g Address 4 gt Switch 1 is set to OFF Switch 2 and 3 are set to ON o Mount the cover on the HYDROVAR and tighten the four fastening screws o Reconnect HYDROVAR to power supply HV 2 015 2 022 HV 4 055 4 075 4 110 33 9 TT HV 4 022 4 030 4 040 Basic Inverter Basic Inverter Dip Switch 9 TT 9 4 4 Control unit Regarding the hardware configuration of your HYDROVAR there are two different control cards available The control unit of the HYDROVAR Master Inverter basically consists of the control card and the additional boards which are connected to the control card via slot connectors This configuration is able to support all special software features and optional boards The second available control card included in the HYDROVAR Single Inverter is developed just for single pump operation This control card doesn t support any additional boards and includes just the minimum necessary software parameters 9 4 4 1 Control card HYDROVAR Master Inverter The control card is connected to the power unit via a ribbon cable on terminal X8 e The display is connected to terminal X9 The display can be mounted in normal position 0 or upside down 180 e The connection terminals X6 and X7 can be used if optional boards are available e g the additional Relay Card can be connected to
9. If the HYDROVAR is used as Basic Inverter only the power unit the following errors are indicated by the red LED red LED Code Error Probability cause 1 blink UNDERVOLTAGE DC voltage of the HYDROVAR too low 2 blinks OVERCURRENT or Current rise at the output too high or OVERLOAD power limit of the HYDROVAR is reached 3 blinks INVERTER OVERHEAT high temperature inside the HYDROVAR 4 blinks OVERVOLTAGE DC voltage of the HYDROVAR too high 5 blinks CODE ERROR Internal error 6 blinks MOTOR OVERHEAT PTC in the conduit box has reached its release EXTERNAL CONTACT temp or external contact is open Resetting the CODE ERROR and the OVERCURRENT ERROR it is only possible to cut the power supply for gt 60 seconds Reset A reset of all other errors can be done by open close the START STOP PTC input X1 PTC on the power unit If the Basic Inverter is used in combination with a Master Inverter each failure can be indicated on the Master Inverter too and will be saved in the failure memory including date and time when the failure appeared Indication on the Master Inverter For detailed failure information on the specific unit SUBMENU STATUS 20 has to be entered and the affected device has to be selected ERR Basic Addr X When a Master Inverter is used in such a system it is also possible to reset the errors which occurred on the Basic Inverter by the Master with
10. phase failure at the input too low e asymmetry of the phases e check if the addressing of Basic Inverter DIP SW has been done The communication between Check has allocated his COMM LOST the Power Unit and the control card doesn t work correctly own pump address e check if the connection from control card to the power unit is made properly ribbon cable 87 ITT e cutting off the power supply for gt 60 seconds manual reset by closing external ON OFF Terminals X3 7 8 Reset manual reset by pressing 4 and simultaneously for about 5 seconds e Auto reset possible if ERROR RESET 0615 is set to ON incoming pressure or min level to Low water contact is LACK OF WATER X3 11 12 is opened bridge X3 11 12 if there is no ext ERROR 21 low water protection just active if motor is running adjust Parameter DERRE TIME 0610 if the failure happens only for short time Reset e Automatically if low water contact X3 11 12 will be closed MIN THRESHOLD ERROR 22 defined value of parameter MIN THRESHOLD 0605 was not reached during the pre selected DELAY TIME 0610 e check booster unit adjust parameter DELAY TIME 0610 e Parameter ERROR RESET 0615 set to ON to enable 5 restarts e g in empty system FAILURE SENSOR 1 ACT VAL SENSOR 1 ERROR 23 Sensor signal on terminals X3 2 lt 4mA active Sensor WARNING 20 sec
11. 1 8 43 E ERTER Temperature of the selected unit XX XX C The current value determines the temperature inside the selected unit and is shown in C and also in percent of the max allowed temperature 44 CURR INVERTER 44 XXX Current of the selected unit This value determines the output current of the HYDROVAR in percent to the max rated current output 45 VOLT INVERTER 45 XXX V Voltage of the selected unit This value determines the output voltage 46 OUTPUT FREQ 26 XX X Hz Output frequency of the selected unit This value determines the output frequency supplied from the HYDROVAR at the moment 57 9 TT 60 SUBMENU SETTINGS Before entering the submenu settings these instructions must be read carefully to prevent incorrect settings which will cause malfunction All parameters can also be set during operation Therefore different parameters in the extended submenu should be used only by trained and qualified persons It is suggested stopping the HYDROVAR by pressing in the main menu during changing parameters 61 gj iM entering password 0066 Default by pressing A or V NOTICE The password must be entered at each entry into the submenu 61 PASSWORD Confirm by pressing and the first window of the sub 0066 menu is shown 62 JOG 0 0Hz Both current output frequency and actual value are 62 X XX Bar shown e By pressing A or V in this menu the internal controller of the HYDROVAR is deactivate
12. 9 TT 9 4 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 2 015 2 022 4 022 4 030 4 040 L1 L2 L3 3x400 VAC L1 N 1x230 VAC Motor connection U V W Power supply Crimp connection 6 3mm HV 4 055 4 075 4 110 Power supply Motor L1 L2 L3 connection 3x400 VAC U V W 28 9 TT 9 4 2 Motor connection Mounting of the PTC Variant A Variant B Motor block PTC Terminal block Rubber gasket Cover of the conduit box The cover of the conduit box must be opened and the terminal block inside removed Fix the PTC Variant A or B Remounting of the terminal block Electrical connection of the motor cables Je Cl The PTC must 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 of the motor has to be selected as shown on the motor label according to the output voltage of the HYDROVAR star connection delta connection 20 1 29 9 TT 9 4 3 Power unit
13. Application Single pump control including all extended features Multi pump system of Master and Basic Inverters up to 8 pumps Multi pump system equipped with up to 8 Master Inverters in combination with the optional Relay Card up to 5 fixed speed pumps can be controlled Single Inverter HYDROVAR with control card developed only for single pump operation and less features in comparison with the Master Inverter Therefore the Single Inverter isn t able to support any optional modules like the Relay Card Application Single pump control 3 2 Operation modes 3 2 1 Actuator for single pump operation only In this mode the HYDROVAR operates as an actuator with external speed signal or switching between 2 programmed frequencies by using the corresponding digital input For this application the HYDROVAR operates like a standard frequency converter when an external controller is used Please consider that this mode is only possible by using a HYDROVAR Master or Single Inverter and is limited for single pump operation only 3 2 2 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 Typical single pump operation 9 TT 3 2 3 Cascade Relay 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 with 5 relays is used in th
14. asynchronous motors which are responsible for a voltage drop 2096 of the line voltage EMC summary Install potential equalization according local regulations Don t install the power cable in parallel to signal cables Use screened signal cables Connect both ends of the screen of the motor cable to ground Connect only one end of the screen of a signal cable to ground Motor cable as short as possible Pigtails should be prevented 9 3 Recommended Cable Types To ensure the above mentioned points to guarantee EMC compatibility and a correct function of the HYDROVAR the mentioned cable types should be used Application Recommended cable type Motor cables HV 2 015 2 022 4G1 5 2 x 0 75 FDF HV 4 022 4 040 4G1 5 2 x 0 75 FDF HV 4 055 4 075 4G2 5 2 x 0 75 FDF HV 4 110 4G4 2 0 75 FDF JE Y ST Y BD Control and signal cables JE LIYCY BD Cables connected to RS485 interface JE Y ST Y 2x 2x 0 8 BD 26 9 TT 9 4 Wiring and connections Remove the screws holding the top cover of the HYDROVAR Lift off the top cover The following parts can be seen on a HYDROVAR Master Single Inverter HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 A Power supply B Motor connections C Terminal block START STOP PTC D RS 485 Interface E Status Relays SOLORUN User interface RS 485 Interface Internal interface F optional Relay Card 27
15. gt ERROR non active sensor WARNING ACTUAL VALUE signal pressure transducer faulty wrong connection Sensor or cable fault check configuration of the sensors in submenu SENSORS 0400 FAILURE SENSOR 2 ACT VAL SENSOR 2 ERROR 24 Sensor signal on terminals X3 4 lt 4mA active Sensor WARNING 20 sec gt ERROR non active Sensor WARNING ACTUAL VALUE signal pressure transducer faulty wrong connection Sensor or cable fault check configuration of the sensors in submenu SENSORS 0400 SETPOINT 1 1 4 SETPOINT 1 1 lt 4 ERROR 25 Current signal input of required values is active but no signal 4 20mA is connected WARNING 20 sec gt ERROR e check external analogue signal on terminals X3 17 18 e check configuration of the required values in Submenu REQUIRED VALUES 0800 FA 88 TT SETPOINT 2 1 lt 4mA Current signal input of required 2 Sigmako values is active but no signal e check configuration of the required SETPOINT 2 I lt 4mA 4 20mA is connected 1 values in Submenu REQUIRED 1 ERROR 26 WARNING 20 sec gt ERROR VALUES 0800 e cutting off the power supply for gt 60 seconds manual reset by closing External ON OFF Terminals X3 7 8 manual reset by pressing lt and simultaneously for about 5 Reset seconds e Auto reset possible if ERROR RESET 0615 is se
16. EFF REQ VAL 03 D1 X XX Bar Effective required value Shows the current required values which is calculated based on ACTUAL VALUE INCREASE 0505 ACTUAL VALUE DECREASE 0510 and LIFT AMOUNT 0330 The required value is considering by an offset signal SUBMENU OFFSET 0900 the current active required value is shown in this window e g Multi pump application with two pumps REQUIRED VALUE 02 5 00 bar ACT VALUE INCREASE 0505 0 50 bar ACT VALUE DECREASE 0510 0 25 bar gt REQ VAL EFF 03 5 25 bar After starting the second pump the pressure would be increased to a system pressure of 5 25 bar With this parameter you are able to see the calculated new required value c Active MODE 0105 Actuator Frequency XX X Hz e STOP X XX Bar 1 display in Mode actuator If parameter MODE 0105 is set to actuator the parameter REQUIRED VALUE 02 will change to ACTUAT FREQ 1 and is equivalent to parameter 0830 REQUIRED VALUE EFFECTIVE 03 will change to ACTUAT FREQ 2 Parameter 0835 By using these parameters it is possible to run the HYDROVAR with the two pre selected frequencies for manual control of the HYDROVAR 02 ACTUAT FRQ 1 Hz Set the desired frequency with either A or V The selected frequency in this parameter is only active in the actuator mode if parameter C REQ VAL 1 0805 is set to digital and Parameter SW REQ VAL 0815 is set to setpoint 1 or ACTUATOR FREQUENCY 1 select
17. X2 RS485 Interface Power Unit 4 Internal interface SIO Internal SIO interface SIO for multi pump systems GND GND electronic ground X2 SIO Internal SlO interface SIO p Parameter not available for HYDROVAR Single Inverter The internal RS 485 Interface on the power unit is used for the communication between up to 8 HYDROVARs in a multi pump system minimum 1 Master Inverter For the connection to each HYDROVAR via the RS 485 interface the terminals X2 1 3 on the power unit can be used twice Even the terminals X4 4 6 on the control card can be used X2 GND OO SIO O O RS485 internal interface Mechanical connection of the terminal Use recommended cable type see chapter 9 3 Strip the end of the used wire about 5 6mm push down the orange wedges by using a small screwdriver insert the stripped wire ee remove the screwdriver to fix the wire Wey To remove push down the orange wedges and pull out the wire Connection example using one Master and three Basic Inverters HYDROVAR Master Inverter HYDROVAR Basic Inverter HYDROVAR Basic Inverter HYDROVAR Basic Inverter Control Card UT S Power Unit Power Unit Power Unit GND SIO SIO 32 9 TT 9 4 3 2 Addressing When using the cascade serial mode in multi pump application where more than one Master Inverters
18. 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 66 9 TT 0270 KNEE FRQ 2248 50 0 2 Knee frequency Possible settings 30 0 70 0 Hz With this parameter you can set the frequency at which the HYDROVAR should deliver its maximum output voltage for special applications only For standard applications this frequency should be set according the MAX FRQ 0245 Default Setting 50 2 Be careful This parameter should be used for special applications only Incorrect setting can cause an overload error and even a damage of the motor 0275 pete ee Reduction of the maximum output current Possible settings 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 OFF 100 85 75 50 2 015 7 5 95 5 25 3 5 2 022 10 8 50 7 50 5 00 4 022 5 7 4 85 4 28 2 85 4 030 7 3 6 21 5 48 3 65 4 040 9 7 65 6 75 4 5 4 055 13 5 11 48 10 13 6 75 4 075 17 14 45 12 75 8 5 4 110 23 19 55 17 25 11 5 0280 EDU Selection of the switching frequency Possible settings Auto 8 kHz 4 kHz e Auto default setting In standard operation the HYDROVAR works with a switching frequency of 8kHz in order
19. as pump running or fault signal relay For this application see connection example below How to program see parameters CONF REL 1 0715 and CONF REL 2 0720 Connection examples Pump running signal Fault signal Ext 250VAC 220VDC Ext 250VAC 220VDC X5 X5 2 v 9 X5 1 3 closed X5 4 and 6 closed motor run indication if there is a fault error 41 e ITT 9 4 4 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 1 X10 Terminals Relay Card 6 lt __ Terminal block Notice When using the relay contacts for switching external contactors a corresponding RC snubber circuit or varistor is necessary to prevent disturbances arising during a switching action of the relay X10 Relay Card 1 Relay 1 2 Relay 2 max 250VAC 0 25A 3 Relay 3 max 220VDC 0 25A 4 Relay 4 max 30VDC 0 25A 5 Relay 5 6 COMMON nr Fe P X10 6 COM 5 Relay 5 4 Relay 4 Relay 3 2 Relay 2 Relay 1 Contacts switching the fixed speed pumps Please consider that the fixed speed pumps can t be switched directly by the Relay card an external panel for the contactors of the D O L or STAR DELTA starters is necessary 42 9 TT Conn
20. following standards EN 61800 3 2005 EN 55011 2002 Disturbance voltages Disturbance field strength First environment Second Environment class B class C2 class class C3 Disturbance voltages OK OK Disturbance field strength m OK Warning In a domestic environment this product may cause radio interference in which case supplementary mitigation measures may be required EN 61000 4 2 2001 Electrostatic discharge EN 61000 4 3 2002 Electromagnetic field immunity test EN 61000 4 4 2001 Burst immunity test EN 61000 4 5 2001 Surge immunity test EN 61000 4 6 1996 Immunity of conducted RF Disturbance EN 61000 4 11 2001 Voltage dips and interruptions 16 9 TT 6 Dimensions and weights HV 2 015 2 022 HV 4 022 4 030 4 040 eS a All dimensions in millimetres Drawings are not in scale Lifting aids must have the proper dimensions Weight kg Single HV 4 040 a Minimum centre distance between HYDROVARs 300 mm b expansion space for maintenance 110 mm TT HV 4 055 4 075 4 110 170 1 All dimensions in millimetres Drawings are not in scale Lifting aids must have the proper dimensions Master Single HV 4 055 HV 4 075 7 70 8 10 a minimum centre distance between HYDROVARs 430 mm b expansion space for maintenance 110 mm 9 TT 7 Modules Regarding t
21. is open releaser bridge terminal X307 8 49 9 TT b Active MODE 0105 Cascade Relay Cascade Serial ADRX PX XX X Hz o STOP X XX Bar 1 display at mode cascade serial and cascade relay This window shows the status of the HYDROVAR x Indicates the regulation Master ADR X Pump address Cascade relay mode Indicates the number of pumps which are running PX e g P3 Master 2 fixed speed pumps are running Cascade serial mode Indicates the sequence of the pumps in the system depending on the MASTER PRIORITY 0570 and SWITCH INTERVAL 0555 ON Manually and external released Stop of the HYDROVAR by pressing V STOP Manually stopped Start of the HYDROVAR by pressing A To start up the HYDROVAR close external OFF External release X3 7 8 is open release or bridge terminal X378 Valid for MODE Controller Cascade Relay Cascade Serial 02 REQUIRED VAL 02 D1 X XX Bar Set the desired required value with A or V The current REQUIRED VALUE and its source by the additional information are shown in this window D1 internal required value 1 specified parameter 0820 D2 internal required value 2 specified parameter 0825 U1 required value 1 voltage signal input Connected to X3 13 U2 required value 2 voltage signal input Connected to X3 15 I1 required value 1 current signal input Connected to X3 18 I2 required value 2 current signal input Connected to X3 23 50 9 TT 03
22. not used 23 STATUS DEVICE 23 Status of the selected device Stopped Possible messages Running Stopped Disabled OFF Mode Cascade Serial relay on relay off Mode Cascade Relay Preparing Solorun Faulted Shows the status of the device 4 Mode CASCADE RELAY relay on gt Relay contact is closed gt fixed speed pump is running relay off gt Relay contact is opened gt fixed speed pump is stopped Mode CASCADE SERIAL Running gt Pump is running Stopped gt Pump is stopped because there is no request Disabled gt Pump is stopped manually Stopped with buttons or disabled with parameter ENABLE DEVICE 24 or by external device external on off contact open OFF gt Pump is not connected to power supply Pump is not connected via RS485 interface Preparing gt A new unit is connected to the multi pump system and Data is transferred Solorun gt Solorun is activated X1 SL closed Faulted gt A failure occurred on the current unit 24 25 oc at Enable Disable of the selected device Possible settings Enable Disable EN The selected device can be enabled or disabled manually Either in cascade relay or cascade serial mode 55 TT 25 MOTOR HOURS 25 Motor runtime of the selected device Total time how long the motor is being powered by the HYDROVAR and basis for the switching order of the follow up pumps How to reset see parameter CLR MOTORH 1130 Error memory
23. permitted and suitable for systems pressure The tank should have a capacity of min 1096 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 by using the following table required pressure bar 1 2 3 4 5 6 7 8 9 10 0 8 1 2 3 4 5 6 7 8 9 precharge pressure bar NOTICE To check and set the right pre charge pressure please make the tank unpressurised before 9 TT 3 Product overview 3 1 Hardware configurations The HYDROVAR modul concept basically consists 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 Basic Inverter In that configuration the HYDROVAR can be used as a sequence pump in a multi pump system but also as a simple soft starter for single pump applications By extending this Basic Inverter with the additional control card the HYDROVAR is able to work in different modes and can be extended additional Basic Inverter HYDROVAR in its simplest configuration Application Single pump operation as soft starter sequence pump in a multi pump system Master Inverter Full featured HYDROVAR including the high level control card supports also the optional modules like the Relay Card and all special software features
24. required value 1 Offset 0 20 4 20mA Ri 50Q 19 10V internal ref for analogue output 10 00VDC max 3mA 20 Analogue output 1 0 10VDC max 2mA 21 Analogue output 2 4 20 22 GND electronic ground 23 Current signal input required value 2 Offset 0 20 4 20mA 500 24 24V power supply for control inputs 24VDC max 100mA 6 Terminals 5 and 6 be used as actual value voltage input and also as digital input Also the voltage signal input on terminal X3 15 can be used as digital input TE X3 3 and X3 24 gt 100mA Offset These terminals can be used as required value or offset signal input Configuration see submenu REQUIRED VALUES 0800 and submenu OFFSET 0900 36 ITT 595955906059 605965596059 X3 12 41 10 1 Le 3 24V 55959590609 VOVOVO Additional power supply max 100 mA Current signal input required val 2 0 20mA 4 20mA 500 To determine the required value or the offset Analogue output 2 4 20mA Analogue output 1 0 10 VDC Current signal input required val 1 0 20mA 4 20 Ri 500 To determine the required value or the offset Voltage signal input required value 2 0 10 vbC DIG 4 To determine the required value or the offset Voltage signal input required value 1 0 10 VDC To determine the required value or the offset Low water e g incoming pressure switch or water level switch Configurable digi
25. 0000000 Status of all units This parameter gives a quick overview about the status of the connected units In Cascade serial mode the status of all max 8 connected units is shown whereas 1 activated 0 deactivated In Cascade relay mode Master is equipped with additional Relay Card the status of the 5 Relay switching contacts is shown e g Mode Cascade serial 21 STATUS UNITs 1 11001000 Unit 1 2 and 5 are running e g Mode Cascade relay 21 STATUS UNITS Relay Contact 1 and 3 are closed 10100 22 Select device Possible settings 01 08 Check the current status the motor hours and the last failures which occurred The selection is depending on the selected mode 105 Select desired unit by pressing A or V Mode CASCADE SERIAL The selection specifies the address of the single units e g Device 01 gt Master Inverter with pre selected address 1 Device 02 gt Basic Inverter with pre selected address 2 Device 03 gt Basic Inverter with pre selected address 3 For selecting desired address on a Basic Inverter see chapter addressing To set the address on a Master Inverter see submenu 1200 RS485 Interface 54 itt Mode CASCADE RELAY Device enabled by 01 Master Inverter 02 fixed speed pump Relay 1 X10 1 03 fixed speed pump Relay2 10 2 04 fixed speed pump Relay3 X10 3 05 fixed speed pump Relay4 X10 4 06 fixed speed pump Relay 5 X10 5 07 not used 08
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27. 02 5 1135 DISVS 5 00 HO AlRIORIdISIM 025 2H 008 084 3190510 OES 184 00 0b 0 X 195 ZSHJS Str Jeq 00 0 0 0 195 DSHAS 028 00 LHNOWY 1311 OEE OUSMS TAS 082 39s 0 090 0 bc 298 HOLAS 525 Jeq 00 0 0 0 195 2 5 45 Ott SHAS Szr 2H 0 0 141170944 Scc 340 duudMOd Siz 0 lt SSZ 01 Scc 00L 1 999 510 521 5 555 39s 6 184 00 0 1 550 X 195 bSHAS 4eq 0070 SHAS ewou J00 2H 0709 0344 33H3 2H 0 p O2 diHOD dSI 055 026 022 021 Jeq 000 StS 2H 8t 0184 515 5 35 515 5 35 dHOD 019 08 51548 315 SIE 9 15008 592 2H 0709 0384 XVI V diva 212 340 LOHNA 201 SLL ZH 0 O33 4eq 9 0 0 5 DAT WALOY 015 Josuas Ob MOCHA 32s 0 0 05 11 4 012 135 011 gas 6 A10 319 510 525 Jeq 6 0 SHPWWA LOY 505 109 LINMSHAWIG 505 32s 0 V HINA SEZ 9 5 SOZ J00W 501 ULHO 5 NWAWANS
28. 1 or the ACTUATOR FREQUENCY 1 is selected via digital input 0835 ACTUAT FRQ 2 0839 XX X Hz Required frequency 2 for actuator Possible settings 0 0 MAX FREQ 0245 Set the frequency with either A or V The selected frequency in this parameter is only active in the actuator mode if parameter C REQ VAL 2 0810 is set to digital and parameter SW REQ VAL 0815 is set to setpoint 2 or the ACTUATOR FREQUENCY 2 is selected via digital input 81 TT 1100 SUBMENU 100 SETUP 1120 TEORA NORDE Enter password by pressing or V 0000 The below mentioned parameters are available after entering the password For more information contact your distributor 1125 1125 CLR ERRORS Clear error memory of selected unit UNIT X or ALL units Cascade Serial Possible settings 1 8 ALL To clear the error memory either of one specific unit 1 8 or ALL units can be selected For reset press button till RESET appears 1130 1130 CLR MOTORH Clear motor hours for selected unit UNIT X or for ALL Cascade Serial Possible settings 1 8 ALL Set desired unit where the Motor Hours should be cleared or ALL and press button till RESET appears 1135 CLR OPERAT 1135 Clear operation time The operation time indicates the total time the HYDROVAR is connected to power supply For reset the operation time of the current HYDROVAR press button till RESET appears 82 9 TT 1200 SUBMENU 1289 RS485 INTERFACE
29. 2 0 44 1 0 Programming te euh 47 ITT 10 1 Display Control panel of the Master Single Inverter 47 10 2 Function of the push 47 10 3 Display of the Basic Inverter 48 10 4 Software Parameters 49 00 Main Menu ase 49 20 Submenu Status 5 reir i seca chaste weaved AREA SER 54 40 Submenu 5 iet ise estesa iudi eyelet 57 GO Submenu Settings en terere tus quoe pea ETE E 58 0100 Submenu Basic Settings 2 2 59 0200 Submenu Configuration 62 0300 Submenu Regulation 68 0400 Submenu Sensor oii kx en Kan Ed ow eer Dui 70 0500 Submenu Sequence Control 73 0600 Submenu Y ke a PR 78 0700 Submenu cives sve avs 79 0800 Submenu Required Values 80 1100 Submenu Setups vce 82 1200 Submenu RS485 Interface
30. A 10bar 0 4 bar differential pressure transducer gt 20mA 0 4 bar Flowmeter Flowrate 36m3 h gt 20mA 36m3 h 0425 Uae SEU E Sensor curve linear Possible settings linear quadratic Internal calculation based on the actual value Possible Setting and its application e linear Pressure control differential pressure control level temperature and flow control inductive or mechanical e quadratic Flow control using an orifice plate together with a differential pressure transmitter 71 TT 0430 SENS 1 CALO Lu E 0430 0 00 00 bar Sensor 1 zero point calibration Possible settings 10 up to 10 of the sensor range 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 of the sensor range e g DIMENS UNIT 0405 bar SENS RANGE 0420 10 00 bar SENS 1 CALO 0430 2 gt 00 20 bar 0435 SENS 1 CALx s 0435 0 10 00 bar Sensor 1 upper range value calibration Possible settings 10 up to 10 of the sensor range To set the calibration for the upper range value of sensor 1 this parameter can be used After setting the right dimension unit and sensor range the upper range value can be adjusted between 10 and 10 of the sensor range e g DIMENS UNIT 0405 bar SENS RANGE 0420 10 00 bar SENS 1 CALO 0430 2 gt 09 80 bar
31. AL 1 0820 XX X Bar Required value 1 digital Possible settings 0 0 to the pre selected Sensor range Set the required value with either A or V This pre selected required value is active in mode cascade relay and cascade serial if parameter C REQ VAL 1 0805 is set to digital and parameter SW REQ VAL 0815 is set to setpoint 1 or the REQUIRED VALUE 1 is chosen via digital input This pre selected required value could also be taken over in the main menu with parameter REQUIRED VAL 02 if the current required value is active 0825 REQ VAL 2 9825 XX X Bar Required value 2 digital Possible settings 0 0 to the pre selected sensor range Set the desired required value with either A or This pre selected required value is active in mode cascade relay and cascade serial if parameter C REQ VAL 2 0810 is set to digital and parameter SW REQ VAL 0815 is set to setpoint 2 or the REQUIRED VALUE 2 is selected via digital input This pre selected required value could also be taken over in the main menu with parameter REQUIRED VAL 02 if the current required value is active 80 9 TT 0830 ACTUAT FRQ 1 0830 XX X Hz Required frequency 1 for actuator Possible settings 0 0 MAX FREQ 0245 Set the frequency with either A or V The selected frequency in this parameter is only active in the actuator mode if parameter C REQ VAL 1 0805 is set to digital and parameter SW REQ VAL 0815 is set to setpoint
32. DROVAR and the motor remain under voltage For safety reasons the HYDROVAR has to be disconnected from the power supply when carrying out work on the machinery When the HYDROVAR is connected to the power supply the components of the power unit as well as certain components of the control unit are connected directly to mains Touching these components seriously endangers life Before removing the HYDROVAR cover the system must be disconnected from the power supply After switching off the power supply wait at least 5 minutes before starting work on or in the HYDROVAR the capacitors in the intermediate circuit are discharged by the internal discharge resistors Voltages of up to 800 volts are possible in case of error these also can be higher All work carried out at opened HYDROVAR may only be performed by 5 e ITT qualified and authorized staff Furthermore it has to be taken care not to short circuit the neighboured 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 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 current less from the mains voltage through the electronics of the HYDROVAR but is not potential free in the
33. OR 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 5 M Digital Input 1 20 2 8 19 2 7 Required value 1 external current signal Required value 2 external voltage signal 995609066655 X3 Actual value frequency indicator e g to display the actual motor frequency How to program see SUBMENU OUTPUTS 0700 Possible connections 20 0721 Analogue output 1 0 10V X3 20 72 Analogue output 2 4 20mA 3 21 4 39 9 TT X4 RS485 Interface X4 1 User SIO Interface SIO SIO Interface e for external communication 3 GND electronic ground 4 Internal SIO Interface SIO 5 Internal SIO Interface 510 6 electronic ground gai RS 485 Internal interface RS 485 User interface 7 6 GND 2 3 GND 2 5 SIO 2 2 0 2 so 2 so LLLI The internal RS 485 Interface is used for the communication between up to 8 HYDROVARs in a multi pump application For the connection of each HYDROVAR via the RS 485 interface the terminals X4 4 6 on the control card and either the terminals X2 1 3 on the power unit can be used Connection example using one Master and three Basic Inverters HYDROVAR Maste
34. Overvalue delay for cascade relay only Possible settings 0 0 10 0 sec Delay time to switch off a follow up pump in case the actual value exceeds the OVERVALUE 0545 limit 0555 SWITCH INTV Switch interval for cyclic changeover 0555 24 hours for cascade serial only Possible settings 0 250 hours 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 The switch interval is valid for HYDROVAR Master Inverters only connected via the RS 485 interface and using operation mode Cascade Serial 0570 0570 MSTPRIORITY Master priority ON for cascade serial only Possible settings ON OFF This parameter determines the switching order when master and Basic Inverters are used together In such a case you have to choose if the master or the Basic Inverters should be switched on first ON All Master Inverters in the system are released unless it is stopped by a failure or manually before the first Basic Inverter gets released For example Address 1 3 Master Inverters Address 4 8 Basic Inverters Switching order Adr 1 Adr 2 Adr 3 Adr 4 Adr 5 Adr 6 Adr 7 Adr 8 Master Master Master Basic Basic Basic Basic Basic OFF One master which is responsible for the controlling according the set value is running With rising consumption all Basic Inverters have to be released before any other Master star
35. VAR is exceeded check Parameter RAMP 1 2 0215 0220 too short and BOOST 0265 too low check motor connection star delta and cable Pump blocked Motor turns in the wrong direction before running Non return valve defect Not allowed operation point or MAX FREQUENCY 0245 too high check also the BOOST 0265 OVERVOLTAGE ERROR 13 DC voltage of the HYDROVAR too high Parameter RAMP 2 0220 too fast Power supply too high Voltage peaks too high Solution Line filters Line inductance RC element INVERT OVERHEAT ERROR 14 too high temperature inside the HYDROVAR no proper cooling e contamination of the motor vents ambient temperature too high THERMO MOT EXT An external protective device connected to terminal X1 PTC close X1 PTC if there is no external protective device connected close external on off switch if ERROR 15 has released e g PTC which is connected to these terminals connected has reached its e For detailed information how the release temperature terminal X1 PTC could be used see chapter 9 4 3 One phases of the power e check power supply under full load PHASELOSS supply has been lost gt if phase failure at the input ERROR 16 automatic power reduction check circuit breakers just available for the units e visual inspection of points at the HV4 055 4 110 input terminals e supply voltage too low UNDERVOLTAGE DC voltage of the HYDROVAR
36. W REQ VAL 0815 0110 oio nd Set Password by pressing A or V Possible settings 0000 9999 The pre set password 0066 can be changed After the password has been changed it is recommended to make some notes about the new password 01151 mere Scena Possible settings with A or V Possible settings ON OFF OFF All parameters in the main menu can be changed without the need of a password ON If the LOCK FUNCTION is activated no changes can be done in the main menu The HYDROVAR can be just started or stopped by using the push buttons or In order to change the set value the LOCK FUNCTION must be reset to OFF 60 TT 0120 DISP CONTR 0120 75 96 Display Contrast Possible settings 10 10096 Can be adjusted between 10 100 for improved readability of the display depending on he installation position 0125 DISP BRIGHT 0125 100 96 Display Brightness Possible settings 10 10096 The backlight intensity of the display can be adjusted 61 9 TT 0200 SUBMENU 920g CONF INVERTER 0205 0203 is Maximum number of units Possible settings 01 08 Select The maximum number of units which operate at the same time For example Cascade Serial 1 Master and 2 Basic Inverters are installed in a multi pump system gt reasonable values 1 3 Cascade Relay 1 Master Inverter and 3 fixed speed pumps gt reasonable values 2 4 0210 0249 monum Selection of the Power Unit for p
37. able are split in different language blocks which support different language sets For detailed information see chapter 4 With the following two parameters the current date and time can be set That is necessary to save and display failure messages with the accurate date and time when the failure happened 06 DATE 06 DD MM YYYY Current date Set the date by pressing for approx 5 sec to set current DAY MONTH and YEAR 07 TIME 07 HH MM Current time Set the time by pressing for approx 5 sec Enter the submenu by pressing to set current HOUR and MINUTE 52 itt 08 ps nob SU Auto Start Possible settings ON OFF Select ON with A or OFF with the V button If AUTO START ON the HYDROVAR starts automatically in case of demand after 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 ITT XX X Hz STOP X XX Bar Press A to restart the HYDROVAR 09 OPERAT TIME 09 0000 h Operating hours Total operatin hours How to reset see parameter CLR OPERAT 1135 53 TT 20 SUBMENU irae 20 STATUS Status of all units ina pump group Using this submenu it is possible to check the status including failures and motor hours of all connected units 21 STATUS UNITs 21 0
38. als All control cables connected to the control unit have to be screened See chapter 9 3 recommended cable types NOTE If unscreened control cables are used signal interference may occur and could interfere the incoming signals and the function of the HYDROVAR Don t connect the ground of the control card to other voltage potentials All electronic ground terminals and GND of the RS 485 interface are connected internally Digital and Analogue I O X3 GND electronic ground 1 GND electronic ground 2 Actual value input sensor 1 0 10VDC or 0 20mA 4 20mA Ri 500 3 Power supply for external sensors 24VDC max 100mA 4 User SIO Interface SIO 5 User SIO Interface SIO User Interface for external usage 6 GND electronic ground 7 External ON OFF release active low 8 GND electronic ground 9 Configurable digital input 1 active low 10 GND electronic ground 11 Low water active low 12 Low water e g incoming pressure switch or water level switch X3 595559609 L I Configurable digital input 1 e g to enable 2nd required value External ON OFF release GND electronic ground User SIO Interface SIO User SIO Interface SIO Sensor supply max 100 mA Actual value input sensor 1 0 10V or 0 20mA 4 20mA Ri 50Q 7 6 GND 5 SIO 4 SIO 3 24V 2 E ou Ground 45 9 TT X5 Status R
39. arameterizing Possible settings ALL 1 8 If several HYDROVAR Master Inverters and even Basic Inverters are connected via the RS 485 interface the parameterization of the volumes of SUMBENU 200 can be done via one unit and will be taken over by other units in this group If only a specific unit has to be programmed you have to push the button for 5 sec and chose afterwards this unit 1 8 for which the parameterization should be done At setting ALL every device in the group is addressed Be careful if you change back to ALL the configuration of this set will be reloaded 62 9 TT Ramp settings e Time settings of the ramps influence the control of the pump and shouldn t be changed for standard operation e The fast ramps 1 and 2 are determined by the type power of the HYDROVAR and the type of the pump Default 4 sec depending on the power of the HYDROVAR they should be increased up to 15s for higher power ratings to avoid overload switch off e The slow ramps 3 and 4 determine the regulation speed of the internal HYDROVAR controller for small devices or constant consumption and depend on the system which has to be controlled Default 70 sec e The Ramps FminA and FminD are used for a start up and shut off These parameters allow fast acceleration and deceleration and especially should be used for applications where pumps or other devices are powered which shouldn t work below a determined frequency for a certa
40. ase contact your local authority your household waste disposal service provider or the 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 9 TT 2 System design The following diagrams show typical single pump and multi pump systems using the HYDROVAR 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 gate valve 7 pressure gauge 2 diaphragm tank 5 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 water demand This avoids the pump from continuing to run at zero demand With the HYDROVAR no large tanks are required for supply purposes The tank must be
41. by closing digital input 2 X3 6 GND Switch Dig3 Manual switching by closing digital input 3 X3 5 GND Switch Dig4 Manual switching by closing digital input 4 X3 15 GND The sensor with the lower actual value or available sensor in case of a faulty sensor is used automatically The sensor with the higher actual value or available sensor in case of a faulty sensor is used automatically Sens 1 Sens 2 difference of both connected sensors is taken as actual value Auto Lower Auto Higher 70 TT 0415 puo Selection of the sensor type and input terminal Possible settings analog 4 20mA analog 0 20mA analog U 0 10V For correct operation the suitable signal input type regarding to the connected sensor has to be selected Sensor type Terminals analog 4 20mA actual value is represented by a current X3 2 gt Sensor 1 analog 0 20mA signal connected to following terminals X3 4 gt Sensor 2 The actual value is given from a voltage signal X3 6 gt Sensor 1 connected to following terminals X3 5 gt Sensor 2 _ Sensor 2 isn t available for the Single Inverter configuration 0420 SENS RANGE 0420 20mA 10 00 Bar Sensor range Possible settings 0 00 10000 Determines the end value 20mA or 10V of the connected sensor The maximum sensor range gt 20mA 100 of the sensor range must be set For example 10 bar pressure transducer gt 20m
42. ccording the diagram set WINDOW 0310 ca 10 and HYSTERESIS 0315 80 50 set RAMP 2 0220 to 4 15 sec the MINIMUM FREQUENCY 0250 should be activated for pressure increase at 0 demand Control on constant flow Problem control fluctuations Parts to check measure control characteristics are set to low enlarger WINDOW 0310 and set HYSTERESIS 0315 to 99 to control with RAMP 3 and 4 Circulating pump Problem oscillation of the motor speed Parts to check measure control settings too fast e increase RAMP 3 0225 and 4 0230 100 200sec e WINDOW 0310 ca 20 and HYSTERESIS 0315 ca 99 Problem ACTUAL VALUE can t be hold Parts to check measure HYSTERESIS is set too big HYSTERESIS 0315 90 99 General Problem pressure fluctuations analogue signal not constant Solution e use screened cables e check cables and connection of the screen e check earth connection of the transmitter cable 90 9 TT 12 Maintenance The HYDROVAR does not require any special maintenance However 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 done by qualified personnel For mounting and repairs at the HYDROVAR qualified service technicians are available Demounting The HYDROVAR must be discon
43. 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 automatically The system may only be put into operation when it has been grounded In addition to that equipotential bonding of all conductive pipes must be ensured Please consider local installation standards High voltage tests of the HYDROVAR or the motor may damage the electronic components Hence bridge the in and outgoing terminals L1 L2 L3 U V W before To avoid incorrect metering by capacitors incorporated in the electronic part isolate the motor from the HYDROVAR The operating instructions must be read understood and followed by the operating personnel We point out that we accept no liability for damage and operating disorders which are the result of non compliance with the operating instructions ITT Transport handling storage disposal e Check the HYDROVAR immediately after delivery receipt for damage or missing parts e The HYDROVAR unit must be transported carefully e Avoid serious impacts NOTICE zd CAUTION gt CAUTION gt WARNING gt The use of the WEEE symbol indicates that this product may not treated as household waste Dispose of all packing materials and the HYDROVAR unit in accordance with local regulations For more detailed information about the recycling of this product ple
44. d and the inverter changes to manual mode Using the and V buttons any constant speed can be set without influence of the actual value of the control signal e f this value becomes 0 00 Hz the HYDROVAR stops As soon as the window will be left by pressing lt gt the HYDROVAR enters the selected mode 58 9 TT 0100 SUBMENU 9198 BASIC SETTINGS 0105 Ports Selection of the operation mode Controller Possible settings Controller Cascade Relay Cascade Serial Actuator Controller Default Setting This mode should be selected if only one HYDROVAR Master Inverter is in operation and there is no connection to any other HYDROVARs via RS 485 interface Cascade Relay The standard application for this mode is one Master Inverter fitted with an additional Relay Card to control up to 5 fixed speed pumps No connection to any other HYDROVAR via RS 485 Interface possible Advantages costs realizing of simple systems Disadvantage quality of regulation reliability Cascade Serial If more than one speed controlled pump has to operate together via the RS 485 interface this mode must be selected The standard application for this mode is a multi pump system with up to 8 pumps each fitted with a HYDROVAR Master Inverter or a combination of Master and Basic Inverters Advantages reliability switchover for operating hours optimizing switching over in case of a failure 59 9 TT Actuator For single p
45. e HYDROVAR on the motor fan cover using the rubber centre bit If the HYDROVAR is mounted a motor with plastic fan cover a stainless steel mounting ring must be used e The HYDROVAR is installed on the motor fan cover by using the mounting brackets the four screws and the related washers e The HYDROVAR has to be centred and then the four screws must be tightened e Tighten each fastening screw until the two bottom teeth in the brackets start to grip the fan cover e After the electrical components are connected the top cover of the HYDROVAR can be mounted and tightened by the four fastening screws Make sure of a good connection of the ground wire Control the gasket of the HYDROVAR before tighten the fastening screws Ensure that the mounting of the cable glands is done properly and use closing glands for cable entries which aren t used 23 ITT 9 Electrical installation and wiring All installations and maintenance have to be performed by properly trained and qualified personnel with proper tools Use personally protection equipment In case of a failure the electrical power has to be disconnected or switched off Wait at least 5 minutes for capacitor discharge before servicing the HYDROVAR Otherwise it can cause shock burns or death 9 1 Means of protection Ask your power supply company which means of protection are required Applicable e protective earthing AC and DC residual current o
46. e Master Inverter Basically an external switchboard is needed for all the motor relays because the relays in the HYDROVAR are not able to switch the pumps directly as they are just used as control contacts Also an automatic change over of the fixed speed pumps to provide even wear and achieve even operating hours is possible in this mode This configuration is a cost effective alternative compared with other solutions using VFD s on each pump but in any case care has to be taken due to the lower reliability of such a system Application example Booster sets up to 6 pumps where only one pump is speed controlled by the HYDROVAR and the others are fixed speed 1 HYDROVAR Master Inverter 5 fixed speed This should be the standard configuration when the additional Relay Card is used HV Master max 5 fixed speed pumps External panel 10 9 TT 3 2 4 Cascade Serial In this mode there are various possibilities to combine the different versions of the HYDROVAR which will be explained on the following pages In general each of the pumps is equipped with a HYDROVAR unit All units are connected via the RS485 interface and are communicating via standard MODBUS protocol 9600 Baud RTU N81 To realise a fully controlled system at least one Master Inverter is needed the other pumps could be fitted just with a Basic Inverter The controller in the Master Inverter is continuously informed about the status and failures of
47. ection 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 switch is required In the example below 3 fixed speed pumps are connected to the Relay Card For such an application an optional HAND OFF AUTO switch SW1 SW2 and SW3 is recommended During normal operation the switch is set to AUTO so the Relay Card of the HYDROVAR starts and stops the connected pumps The HAND position allows a manual operation of the pumps If one of the additional switches is in OFF position the related relay must be disabled in the submenu STATUS 20 to ensure correct operation of the multi pump system Mains 3 3x 400VAC Ext Power Supply gt 6 4 2 7 5 Relay 5 Z Relay 4 2 Relay 3 V m Relay 2 Relay 1 4 43 9 TT 9 4 4 3 Control card HYDROVAR Single Inverter The control card is connected to the power unit via a ribbon cable on terminal X8 The display is connected to terminal X9 The display can be mounted in normal position 0 or upside down 180 X5 Status Relays 1 12 X3 Digital Analogue 1 O RS485 Terminal 44 9 TT Control Termin
48. ed via digital input For detailed information how to run the HYDROVAR by manual control see submenu REQUIRED VALUES 0800 02 ACTUAT FRQ 1 92 Hz Set the desired frequency with either or V The selected frequency in this parameter is only active in the actuator mode if parameter C REQ VAL 2 0810 is set to digital and Parameter SW REQ VAL 0815 is set to setpoint 2 or ACTUATOR FREQUENCY 1 selected via digital input For detailed information how to run the HYDROVAR by manual control see submenu REQUIRED VALUES 0800 Non valid for Mode Actuator 51 9 TT 04 28 Regulation Restart Value Possible settings 0 100 OFF This parameter defines the start value after pump stop in percentage of the required value e g REQUIRED VALUE 02 5 0 bar START VALUE 04 80 96 gt 4 0 bar If the pump system has reached the required pressure of 5 0 bar and there is no more consumption the HYDROVAR shuts off the pump When the consumption increases and the pressure drops the pump normally starts If a START VALUE 04 of 4 0 bar has been selected the pump won t start before the pressure drops below The following parameters in the main menu are valid for all selected modes 05 Language selection ENGLISH guag Possible settings To select the desired language press or V The information on the display and all parameters are available in various languages The languages avail
49. elays X5 CC Status Relay 1 NC NO Status Relay 2 NC NO 250VAC 0 25A Max 220VDC 0 25A Max 30VDC 2A A WIN Status Relay 1 Status Relay 2 5 X5 Pato 18 C Both Status Relays on the control card can be used regarding the programmed configuration Notice When using the relay contacts for driving an external relay a 6 NO corresponding RC snubber circuit is or 5 varistor recommended to prevent disturbances arising during a switching 4 CC action of the relay ISSS Factory setting The two relays are used as pump running or fault signal relay For this application see connection example below How to program see parameters CONF REL 1 0715 and CONF REL 2 0720 Connection examples Pump running signal Fault signal Ext 250VAC 220VDC Ext 250VAC 220VDC OSO X5 1 and 3 closed X5 4 and 5 closed motor run indication if there is a fault error 46 9 TT 10 Programming Read and follow the operating instructions carefully before 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 SCH 60 65 2 2 Run Error LEFT UP DOWN RIGHT 10 2 Function of the push buttons A Start of the HYDROVAR
50. ency Possible settings f gt 0 or f gt f min f gt 0 After reaching the required pressure and consumption 0 the frequency will go down to the selected MINIMUM FREQUENCY 0250 and the HYDROVAR will keep running for the selected FMIN TIME 0260 After this time the HYDROVAR will stop automatically f gt f in 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 gt f can overheat the pump when there is no flow through the pump gt bypass line for circulation pumps 0260 259 pus TIME Delay time to shut off below minimum frequency Possible settings 0 100 sec After running the pump for this selected time at minimum frequency the pump will stop if parameter CONFIG FMIN 0255 is set to f gt 0 NOTICE Problems with shut off the pump at 0 demand too small or no pressure tank may be solved as the system pressure is increasing during this delay time 0265 BOOST Setting of the motor starting voltage in of 0265 5 96 connected supply voltage Possible settings 0 25 of the input voltage This parameter determines the characteristics of the voltage frequency curve In particular it refers to the voltage increase during the motor starting stage as a percentage of the nominal voltage Take care that settings
51. ensors which are connected to the HYDROVAR can be configured Either two transducers with current signal input or voltage signal input It isn t possible to install two different transducer types because configurations are the same for all connected sensors 0405 paon eee ui Dimension unit Possible settings bar psi m h g min mH20 ft C F l sec l min m sec Chose the desired Dimension Unit by pressing A or V By changing the DIMENSION UNIT you have to consider to change the SENSOR RANGE 0420 according to the new DIMENSION UNIT too 0410 0210 CONT Selection of the sensor Sensor 1 Possible settings Sensor 1 Sensor 2 Auto Switch Dig1 Switch Dig2 Switch Dig3 Switch Dig4 Auto Lower Auto Higher Sensor 1 Sensor 2 This parameter determines how the connected sensors are used and which one is active It is also possible to measure the difference of two connected sensors or to configure an automatic switchover in case of a faulty sensor Sensor 1 is constantly active Sensor 1 0 4 20mA signal connected to X3 2 and X3 3 24V 0 10V signal connected to X3 6 and X3 3 24V Sensor 2 is constantly active Sensor 2 0 4 20mA signal connected to X3 4 and X3 3 24V 0 10V signal connected to X3 5 and X3 3 24V Auto Automatic switch over in case of a faulty transmitter Switch Dig1 Manual switching by closing digital input 1 X3 9 10 Switch Dig2 Manual switching
52. er Inverter HV Master HV Master HV Master HV Master extended up to 8 pumps In this mode it is possible to run all pumps in multi controller mode and synchronous mode as well This configuration allows each pump of the system to become the lead pump This ensures a proper operation if one Master Inverter fails In this case another HYDROVAR takes control That ensures that the operating hours of each separate pump will be on the same level to ensure even wear of the pumps 12 e ITT 4 Type designation code Eis GEER EERE EE EE Example LJ 1 1 1 230VAC 2 1 3 230VAC Software version Language A Western Europe B Eastern Europe C Northern Europe Hardware version Optional components Optional card Relay Card 0 without R included Bus card Display 0 without 1 included EMC protection filter A A Filter industrial environment B B Filter domestic environment W Enclosure class IP Class 2 IP 21 5 IP 55 Hardware configurations M Motor mounted unit Wall mounted unit 1 2 3 Basic Inverter Single Inverter Master Inverter Rated output 0222 2 2 kW 055 5 5 kW 030 3 0 075 7 5 kW 040 4 0 kW 1103 11kW Nominal mains voltage 3 3 3 230VAC 4 3 3 380 460VAC HV 41 0 4 0 3 5 B 1 0 R 0 G
53. eters of the secondary menu are listed The first window shows the factory setting and the line below the possible 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 special software features When using a HYDROVAR Single Inverter HYDROVAR with control card developed only for single pump operation there are less software features in comparison to the HYDROVAR Master Inverter All parameters which are not active for a HYDROVAR Single Inverter are marked with the following symbol sae mas Parameter not available for a HYDROVAR Single Inverter NOTICE All changes will be saved automatically especially in case of a disconnection of the power supply 00 00 MAIN MENU 1 window REQUIRED VALUE 02 and EFFECTIVE REQUIRED VALUE 03 depend on the selected mode which has been chosen with parameter MODE 0105 The difference between the windows in the different modes is shown below a Active MODE 0105 Controller Default setting ITT XX X Hz STOP Bar 1 display at mode controller This window shows the status of the HYDROVAR ON Manually and external released Stop of the HYDROVAR by pressing V STOP Manually stopped Start of the HYDROVAR by pressing A To start up the HYDROVAR close external OFF External release X3 7 8
54. further restarts possible after one hour 4 after two hours and 5 automatic restarts after 3 operating hours A manual reset can be done by switching an external ON OFF X3 7 8 contactor Not each error can be reset automatically For detailed information see chapter 11 failure messages OFF if the ERROR RESET is set to OFF each failure would be shown on the display directly and must be reset manually 77 TT 0700 SUBMENU 9799 OUTPUTS 0705 ANALOG OUT1 Output Frequency Analoge output 1 Analogue output 0 10V 0 100 Possible settings Actual value Output frequency 0 fmax 0710 ANALOG OUT2 oag Actual value Analoge output 2 Possible settings Analogue output 4 20mA 0 100 Possible settings Actual value Output frequency 0 fmax 0715 CONF REL 1 0715 Running 0720 CONF REL 2 0720 Errors Possible settings Terminal X3 20 Actual Value Output frequency Terminal 3 21 Configuration of the Status Relay 1 X5 1 2 3 Configuration of the Status Relay 2 X5 4 5 6 Power Errors Warnings StandBy Errorreset Both Status Relays can be used to indicate the current status and fault condition of the HYDROVAR Config Explanation Power HYDROVAR is connected to power supply Running Motor is running Errors An error is indicated on the HYDROVAR Warnings A warning is indicated on the HYDROVAR StandB Pump 15 released manually and by external release no y error wa
55. h 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 to prevent grand loops The screen should be extensively connected with cable clips to HYDROVAR GND use pre mounted cable clips Pre mounted cable clips To connect a screen with lowest impedance to ground remove the isolation from the signal cable and connect the screen extensive to ground Signal cables must be installed separate from motor and power supply cables If signal cables are installed in parallel to power supply cables motor cables for a longer distance the distance between these cables should be more than 200mm Don t cross power cables with control cables if this is not possible cross them only in an angle of 90 25 9 TT Motor cables To ensure the EMC compatibility and minimize noise level and leakage currents keep the motor cable as short as possible and use shielded cables only Additional component line choke coil Line coils are available as an option and should be mounted between the HYDROVAR and the main fuse The Line coil should be as near as possible to the HYDROVAR max 30cm Advantages e better efficiency e reduction of harmonic currents For the following applications additional line chokes are strongly recommended e high short circuit currents compensation plants without a coil
56. ill occur 14 9 TT 5 1 General technical data Ambient temperature Storage temperature Humidity Air pollution Altitude Class of protection Certifications 0 40 C At higher temperatures a reduction of the output current or the use of the next HYDROVAR power size is necessary 110 4 100 90 5 80 5 70 4 604 50 4 40 4 max output current 304 204 10 4 0 0 10 20 30 40 50 60 max ambient temperature C o Protect the HYDROVAR from direct sunlight o Outdoor installation without protection of the HYDROVAR is not permitted 25 C 55 C 70 C during 24 hours max RH max 50 at 40 C unlimited RH max 90 at 20 C max 30 days per year 75 average per year class F Condensation is not permitted The air may contain dry dust as found in workshops where there is no excessive quantity of dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted max 1000m above sea level At sites over 1000 m above sea level the maximum output 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 HV 2 015 2 022 HV 4 022 4 030 4 040 55 NEMA 4 Indoor use only 4 055 4 075 4 110 CE UL C Tick 15 9 TT 5 2 requirements Electromagnetic com
57. in the 1st Window v Stop of the HYDROVAR in the 1st Window Reset by pressing of both buttons simultaneously for 5 seconds A Increase of a value selection of the submenu v Decrease of a value selection of the submenu short V Change to faster scrolling up of a value V short A Change to faster scrolling down of a value Short pressing enter submenu Change to next parameter in the menu lt Short pressing leave submenu Change to previous parameter in the menu gt Long Pressing Acknowledgement of an determined action lt Long Pressing Change back to the main menu 47 9 TT 10 3 Display of the Basic Inverter green e 4 red Error 1Blink X Undervoltage Constant Motor stop 2 Blinks Overcurrent Overload Standby 3Blinks Inverter Overheat 4 Blinks Overvoltage dor 5 Blinks Code Error Blinking Motor run 6 Blinks Motor Overheat External Contact SCH 60 67 Status LED green Constant Motor stopped Standby Blinking Motor run Error LED red The type of error is indicated by the blinking code of the ERROR LED 1 blink Undervoltage 2 blinks Overcurrent Overload 3 blinks Inverter overheat 4 blinks Overvoltage 5 blinks Code Error 6 blinks Motor overheat external contact is open For detailed information see chapter 11 Failure messages 48 9 TT 10 4 Software parameters In the following chapters all available param
58. in time to prevent damages or decrease abrasion To adjust the Ramps press A or V set rated REQUIRED VALUE 02 WINDOW 0310 setting in of the required Ramp F acceleration Actual Value RD Ramp Deceleration Output Frequency 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 63 TT 0215 xad Ramp 1 Fast acceleration time Possible settings 1 250 sec e Excessively fast running up time may cause an error OVERLOAD during the HYDROVAR starts up e Excessively slow running up time may cause a drop of the outgoing pressure during operation 0220 us 2 Ramp 2 Fast deceleration time Possible settings 1 250 sec e Excessively fast running down time tends to cause an error OVERVOLTAGE e Excessively slow running down time tends to generate over pressure 0225 RAMES Ramp 3 Slow acceleration time 70 Sec Possible settings 1 250 sec e Excessively fast running up time may lead to oscillation and or an error OVERLOAD e Excessively slow running up time can cause a drop of the outgoing pressure during variation of the demand 0230 nds Ramp 4 Slow deceleration time 70 Sec Possible settings 1 250 sec e Excessively fast running down time leads to oscillation of the HYDROVAR and thereby of the pump e Excessively slow running down time can cause pressure fluctua
59. itt Operating Instructions HYDmROVAmR HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 V 200710A 771079412 Manual HV 2 015 4 110 ENGLISH Engineered for life ITT Index 1 Important safety instructions Rcx el Kl EXP EVA RA REN YR Vx x RE VR NA 5 2 System design for booster sets 8 2 1 Pressure eroe E Eie E redeo scd ese Re 8 3 Product OVOrVIGW i erate utu dee ae Medus dcs uiua cds des 9 3 1 Hardware 44 0 9 3 2 Operation MOUS n Es iz 9 3 2 1 Actuator for single pump operation only 9 3 2 2 ite it extet al baad tn 9 3 2 3 DE 10 3 2 4 Gascade Serial i ottenendo 11 4 Type designation a rede ede 13 5 Technical duca 14 5 1 General technical 15 5 2 EMC Electromagnetic compatibility requirements 16 Dimensions 25 2222252 21122 252422 21458 24 52 entes 17 NWIGCI GS DC 19 Mechanical compoblents iiec 21 8 1 Included mounting
60. message will be shown analog U 0 10V 0810 C REQ VAL 2 0810 OFF Configuration required value 2 Possible settings OFF digital analog U 0 10V analog 0 20mA analog 4 20mA OFF Required value 2 is not used digital The internal required value 2 is used Setting in the main menu in Parameter 02 or Parameter 0825 The required value 2 is determined by the value of a voltage signal 0 10V connected to terminals X3 15 X3 16 GND The required value 2 is determined by the value of a current analog 0 20mA signal 4 20mA or 0 20mA connected to terminals X3 23 X3 22 GND Notice If the incoming current signal falls below 4mA 4 20mA analog 4 20mA setting a warning message is shown on the display If the failure is still active after 20 seconds an error message will be shown analog U 0 10V PY PA 79 TT 0815 DUUM Switching between required value 1 and 2 Possible settings Setpoint 1 Setpoint 2 Switch Dig 1 Switch Dig 2 Switch Dig 3 Switch Dig 4 Setpoint 1 Only required value 1 is active No switching possible Setpoint 2 Only required value 2 is active No switching possible Switch Dig 1 Manual switching by closing digital input 1 X3 9 10 Switch Dig 2 Manual switching by closing digital input 2 X3 6 10 Switch Dig 3 Manual switching by closing digital input 3 X3 5 10 Switch Dig 4 Manual switching by closing digital input 4 X3 15 16 0820 REQ V
61. 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 but it is possible that the HYDROVAR keeps running depends to the different warnings If a warning is active and the cause is not remedied within 20 seconds an error will be shown Errors are indicated on the HYDROVAR and by the red failure LED placed on the control panel and the connected motor is stopped immediately All errors are shown on the display and saved in the error memory including date and time when the failure appeared The below mentioned points describe each error which can occur on the HYDROVAR even on the Master and the Basic Inverter Also the possible countermeasures to reset these errors are described Please notice that an automatic error reset can be activated in SUBMENU ERRORS to reset an occurred failure automatically for 5 times For more information about this function see parameter ERROR RESET 0615 All error signals and warnings can be also indicated at the two status relays on terminals X5 1 2 3 or X5 4 5 6 depending on the configuration How to program see parameter CONF REL 1 0715 and CONF REL 2 0720 84 9 TT 11 1 Basic Inverter
62. n e Lift value lt Fall value Pressure falls when lag pump switches on 73 9 TT The following 3 parameters are responsible for starting the lag pumps and for calculation of the new required value as well 0505 ACT VAL INC 0505 0 35 Bar Lift value Possible settings 0 00 to the pre selected sensor range 0510 ACT VAL DEC 0510 0 15 BAR Fall value Possible settings 0 00 to the pre selected sensor range 0515 ENABLE FR 0515 48 0 Hz enable frequency for the next power unit Possible settings 0 0 70 0 Hz Using this parameter the desired release frequency for the following pumps can be selected If a pump in the system reaches this frequency and the system pressure drops below the REQUIRED VALUE 02 ACTUAL VALUE DECREASE 0510 the next pump is started 0520 0520 oun Enable delay time for cascade relay only Possible settings 0 100 sec If the conditions for switching on a follow up pump are satisfied the follow up pump will start after this selected time 0525 SW DELAY 0525 pees Switch delay for cascade relay only Possible settings 0 100 sec Delay time between two switching actions of the follow up pumps That parameter prevents the system against repeated switching actions caused by the variation of the consumption 74 9 TT 0530 DISABLE FRQ 30 Hz Possible settings 0 0 120 0 Hz s The frequency to switch off the fixed speed pumps in cascade relay mode can be set by this parame
63. nected from the power supply before any work can be carried out Consider at the pump and motor instruction Please take your personal protection equipment For further information please ask your distributor 2008 ITT Industries Inc all rights reserved ITT and Engineered for life are registered trademarks of ITT Industries Inc All other trademarks or registered trademarks are property of their respective owners All data subject to change without notice 91 ITT S2ILSOND VIG ZH XXX NWAWENS OF 0303 1 41 0 A XXX snivis NWAWENS 02 Youd OH HLS 5 HOLOMN 192340 HSIT9H3 39vn5Hv 1 n XX youd paiqesip 4D1A40 3 18vH3 340 1 915 oinv 00 3n vA 14915 oD XX Y XX OH IJAJU 501915 184 96 TWA OJA 443 510 135 OH 00 1937135 72 3190 109 lt lt TA 03 XXXX XX XX 3190 OH uoi 151 00000000 SLINN 501915 164 SE ZH SOLLSOHD VIG NWAWENS 08 501915 5 02 92 32 30035 805 005 YOSHAS NWAWANS OOF HOLLY Ifl9 34 NHAWENS 002 YILYJAHI 805 0
64. o your application the needed configuration which is available for the HYDROVAR can be selected Due to this possibility the HYDROVAR can be configured regarding the reliability and cost effectiveness for your specific application HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 e ITT 1 2 3 4 5 6 Power unit In its standard form it will be used as Basic Inverter or as simple soft starter in a single pump application When using a Master configuration the power unit is fitted with an additional control card This is the basic part for all configurations and always used Filter card Optional filter card to ensure EMC regulations for domestic environments Class B Mounting Kit The Mounting Kit consists of the metal and the plastic cover On the plastic cover the control card is fixed if used also the display and the additional Relay Card is there mounted The pre mounted cable clips which are necessary to connect the screen of all signal cables to HYDROVAR ground are placed on the metal cover Control card The control is used for the Master Single Inverter and includes the I O s for the digital and analogue in and out signals the display unit and the push buttons Display unit Depending to the installation position horizontal or vertical the display can be turned to your preferred position The push button assignment will change automatically when turning the display Rela
65. or additional to Master Inverters also Basic Inverters are used the right address must be set to guarantee the correct function of this system Master Inverter The desired addresses of the Master Inverter have 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 Basic Inverter When using a Basic Inverter in a Multi pump system it is necessary to set the Dip Switches on the power unit in order to get a separate address for each Inverter within your pump group pls consider reserved addresses for the Master Inverters for example Multi pump system with 3 Master and 4 Basic Inverters e Set address 1 3 for the Master Inverters via appropriate software parameters see submenu RS485 INTERFACE 1200 e Address 4 7 for the Basic Inverters via Dip Switch The pre selected address is also responsible for the pump sequence Switch Switch Switch 1 2 3 Address 1 default setting OFF 244 Required setting for the use with control OFF OFF ON Address 2 OFF ON OFF Address 3 Address ON OFF ON ON Address 4 ON OFF OFF Address 5 ON OFF ON Address 6 1234 ON ON OFF Address 7 ON ON ON Address 8 Switch 4 is not used Setting of the correct address o The HYDROVAR must be disconnected from power supply at least for 5 minutes before removing the top cover open four fastening screws
66. out interfere the operation of the other Inverters in the system also valid for automatic Error reset 85 9 TT 11 2 Master Single Inverter Each error is shown on the display in plain text and saved in the error memory The errors can be reset automatically depending on the setting in parameter ERROR RESET 0615 or manually in different ways e cutting the power supply for gt 60 seconds by pressing lt and gt gt simultaneously for about 5 seconds e via External ON OFF Terminals X3 7 8 No error message on the display Error probable cause measure no AUTOSTART after Parameter AUTOSTART 08 is powertailure set to OFF Check parameter AUTOSTART 08 Pressure higher than the start value or REGULATION MODE has been changed to INVERS No operation even system pressure set pressure check parameter START VALUE 04 and or REGULATION MODE 0320 Error message on the display Error Probability cause measure e check connection terminals of the HYDROVAR e check the connection terminal of the motor and the motor cable e check the windings of the motor OVERCURRENT Current rise at the output too ERROR 11 high e disconnect from off the power supply for gt 60 seconds Reset an automatic Error reset isn t possible for that kind of failure ITT Error Probability cause measure OVERLOAD ERROR 12 Power limit of the HYDRO
67. patibility The EMC requirements differ between two environments which depending on the intended use e 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 houses apartments commercial premises or offices in a residential building are typical examples of first environment locations Be careful The relevant EMC regulations for which the HYDROVAR is tested in the first environment consider that the HYDROVAR is a restricted available product That means the voltage of the inverter is less than 1 000 V it is neither a plug in device nor a movable device and when used in the first environment is intended to be installed and commissioned only by a person or an organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects e Second environment class A EN 61800 3 Class C3 Environment that includes all establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes e g Industrial areas technical areas of any building fed from a dedicated transformer are typical examples of second environment locations The HYDROVAR complies with the general EMC regulations and is tested according to the
68. perated protective devices RCD e TN systems Protective earthing e Please note that a current to earth can occur due to the capacitors in the input filter A suitable protection unit has to be selected according local regulations Residual current device RCD RCCB e When using a 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 The RCD has to be installed according local regulations Automatic circuit breaker e Use automatic circuit breaker with C type characteristic curve e Rating of the line protection see chapter Technical Data Internal protective devices of the HYDROVAR e The malfunctions short circuit under and over voltage overload and the overheating of the electronic components are monitored internally by the HYDROVAR External protective devices e Additional protective functions like motor overheat and low water protection are controlled by external equipment 24 9 TT 9 2 EMC electromagnetic compatibility To ensure the electromagnetic compatibility the following points must be observed for cable installation Earth ground to ensure EMC e Protection earth It is important to connect the HYDROVAR to PE because of the earth leakage current e HF earth connection Ground cables should be as short as possible and wit
69. r Inverter HYDROVAR Basic Inverter HYDROVAR Basic Inverter HYDROVAR Basic Inverter Control Card ded Power Unit Power Unit i i Power Unit GND SIO SIO By using the RS 485 User interface on the control card one or more HYDROVAR can communicate via the standardized Modbus protocol with an external control device e g PLC This interface can be used for parameterization and controlling the HYDROVAR via external devices Also active for HYDROVAR Single Inverter Configuration Do not use the internal interface as user interface and vice versa Nes User Interface PLC 98888 848989888988889088888800888800008808888898889888888888888808 0 004 00 0 0 0 0 60 0 000 40 40 0000 40 TT X5 Status Relays X5 CC Status Relay 1 NC NO Status Relay 2 NC NO 250VAC 0 25A Max 220VDC 0 25A 30VDC 2A OU WN Status Relay 1 Status Relay 2 X5 X5 212 Hoke C Both Status Relays on the control card can be used regarding the programmed configuration Notice When using the relay contacts for 6 NO driving an external relay a 5 corresponding RC snubber circuit or varistor is necessary to prevent CC disturbance of the HYDROVAR ISSS Factory setting The two relays are used
70. rning is indicated and HYDROVAR doesn t run If Parameter ERRORRESET 0615 is activated and a Errorreset Warning occurs 5 times Error gt 78 Relay1 Relay2 Relay1 Relay2 Relay1 Relay2 Relay1 Relay2 Relay1 Relay2 Relay1 Relay2 Action X5 1 3 closed X5 4 6 closed X5 1 3 closed X5 4 6 closed X5 1 3 closed X5 4 6 closed X5 1 3 closed X5 4 6 closed X5 1 3 closed X5 4 6 closed X5 1 3 closed X5 4 6 closed itt 0800 SUBMENU REQUIRED VALUES The changeover between 1 and the 274 required value be done internally or externally via the digital inputs With the following parameters the source of the required values and the change over can be configured 0805 C REQ VAL 1 0805 digital Configuration required value 1 Possible settings digital analog U 0 10V analog 0 20mA analog 4 20mA Digital The internal required value 1 is used 9 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 The required value 1 is determined by the value of a current signal analog 120 20mA 4 20mA or 0 20mA connected to terminals X3 18 X3 17 GND Notice If the incoming current signal falls below 4mA 4 20mA analog 1 4 20mA setting a warning message is shown on the display If the failure is still active after 20 seconds an error
71. s 0 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 on the suction side 68 9 TT 0325 FRQ LIFT 0255 30 0 2 Frequency limit for required lift value Possible settings 0 0 Hz 70 0 Hz Control according to a system curve increase of the set pressure depending on the delivery rate or 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 5253 c Lift amount for required lift value 0 Possible settings 0 0 200 0 This value states how much the set value should be continually increased till the maximum speed maximum volume is reached Application example 1 Enter the set pressure see main menu parameter REQ 21 2 Find out the frequency where set pressure is reached at zero demand use JOG MODE 0305 and set the value in parameter FREQU LIFTING 3 Set desired lift at maximum speed in 96 of the set pressure in the parameter LIFT AMOUNT 0330 A set pressure window C lift intensity in 9o of set pressure 69 TT 0400 SUBMENU 0290 SENSOR In this submenu all actual value s
72. starts up if it is released and requested by a Master Inverter via the serial R 485 Interface e When contact X1 SL is closed the HYDROVAR starts up to pre selected MAX FREQUENCY 0245 using Ramp 1 and 2 and even the fast ramps FminA and FminD X1 PTC must be closed too all external connected safety devices are still active A manual start up is always possible even the HYDROVAR is equipped with a control card For example if it is necessary because of safety reasons to operate the Basic Inverters when the Master Inverters fail it is possible to equip this terminal with an AUTO MANUAL switch Connection Example External switch to enable the j SL SW 1 SOLO RUN Manual for example PTC 2 External release or Low water switch PTC or thermo switch mounted in the motor terminal box Recommended connections of external protective devices Xl Basic Inverter PTC or thermal switch X1 PTC External release X1 PTC Placed on the power unit Low water switch X1 PTC Master Inverter PTC or thermal switch X1 PTC Placed on the power unit External release X3 7 8 Bow BEBE eah 11 12 Placed on the control card 31 9 TT If the HYDROVAR is used as 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 HYDROVARs in the system Be careful Internal interface is not active for Single Inverter configuration
73. t to ON 11 3 Internal errors To quit the following errors you have to cut the power supply for gt 60 seconds If the error message is still Shown on the display contact customer service and provide a detailed description of the error Internal errors Error message on the display red LED on ERROR 1 EEPROM ERROR Reset after repeated error message data block malfunction change control card ERROR 4 Button error e check push buttons e 9 jammed key e Display board may be defect EPROM error Reset after repeated error message ERROR 5 Checksum error change control card Program error Reset after repeated error message ERROR 6 Watchdog error change control card Program error Reset after repeated error message ERROR 7 Processor pulse error change control card e check the installation of the cables connection of the screen and Code error potential equalization CPOE ERRAR invalid processor command je check earth ground e install additional inductances for the signal cables e g ferrites 89 w ITT Examples Booster unit Problem no stop of the HYDROVAR Parts to check measure e existing demand non return valve is not closed e pre charge pressure in the pressure tank no correct settings of WINDOW RAMPHYSTERESIS e shut down ramp too slow suction line too long check pipes and valves change non return valve adjust a
74. tal input 1 DIG 1 e g for switching between 2 required values or sensors External ON OFF release Actual value voltage input sensor 1 0 10 VDC DIG 2 Actual value voltage input sensor 2 0 10 VDC DIG 3 Actual value current input sensor 2 0 20 4 20mA Ri 500 Sensor supply max 100 mA Actual value current input sensor 1 0 20mA 4 20mA Ri 500 Ground Terminals X3 5 and 6 can be used as actual value voltage input and also as digital input Also the voltage signal input on terminal X3 15 can be used as digital input Vid X3 3 and X3 24 gt 100mA 37 9 TT Connection examples e Sensor Actual value signal Input Connection of a 2 wire transducer e g standard pressure transducer PA22 Possible connections Actual value signal input 0 4 20mA 24VDC sensor supply Actual value signal input 0 4 20mA Ground Connection of an active actual value signal X3 4 X3 3 X3 2 X3 1 e Switching between two connected sensors External switching between two connected sensors by closing digital input 1 X3 9 10 How to program see SUBMENU SENSORS 0400 22 2 10 1 X3 Standard pressure transducer PA22 Sensor 2 brown Sensor 1 white digital input 1 9 TT e Switching between two different required values External switching between two connected required value signals e 9 between voltage and current signal input by closing digital input 1 X3 9 10 In ACTUAT
75. ter 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 follow up pump stops 0530 Disable frequency for cascade relay only 0535 DISABLE DLY 0535 51222 Disable delay time for cascade relay only Possible settings 0 100 sec Delay time before switching off the follow up pumps cascade relay mode 0540 DROP FRQ 42 Hz Possible settings 0 0 70 0 Hz Ls This parameter is used to prevent the system from pressure hammers Before a following pump starts up the Master Inverter will drop to the selected frequency If the DROP FREQUENCY is reached the follow up pump gets released and the Master Inverter will continue with normal operation 0540 Drop frequency for cascade relay only 0545 Wee CE Overvalue for cascade relay only Possible settings OFF pre selected Sensor range s If this selected value is reached an immediate shut off of the follow up pumps is executed e g REQUIRED VALUE 02 5 00 bar OVERVALUE 0545 7 50 bar If three pumps are running 1 Master Inverter 2 follow up pumps and a system pressure of 7 50 bar is reached one after another follow up pumps shuts off This parameter prevents the system against overpressure in case the HYDROVAR has been parameterized incorrectly 75 TT 0550 OVERVAL DLY 0550 NE
76. the Basic Inverters All failures are indicated on the master unit including also the date and time stamp The complete control will be done via the Master Inverter every time but also an automatic change over of the lag pumps to provide even wear and achieve even operating hours is provided If the control card of a Master Inverter fails each of the Basic Inverters can be manually started by an external switch manual operation in order to ensure an emergency operation of the system Application Example Each pump of the system up to 8 pumps is equipped with a HYDROVAR unit at least one Master Inverter and the others can be Basic Inverters in order to ensure a proper control of the system which are connected via the serial interface The combination of the different HYDROVAR units that are used in a multi pump system depends on the system requirements i e in a 6 pump system 2 Master Inverters can be used due to reliability reasons and 4 Basic Inverters without control card or just any other configuration Minimum requirement 1 Master Inverter and the others equipped with Basic Inverters HV Master HV Basic HV Basic HV Basic extended up to 8 pumps 11 9 TT To increase the operating reliability of such a system also a second Master Inverter is recommended HV Master HV Master HV Basic HV Basic extended up to 8 pumps Full featured Possibility Each pump is equipped with a Mast
77. the control card at connection slot X6 13 X3 24 pooooooooooq 1 12 X3 Digital Analogue lI O X4 RS485 Terminal 35 e ITT Control terminals All control cables connected to the control unit have to be screened See chapter 9 3 recommended cable types NOTE If unscreened control cables are used signal interference may occur and could interference the incoming signals and the function of the HYDROVAR Don t connect the ground of the control card to other voltage potentials All electronic ground terminals and GND of the RS 485 interface are connected internally Digital and Analogue I O X3 1 GND electronic ground 2 Actual value current input sensor 1 0 20 4 20mA Ri 50Q 3 Power supply for external sensors 24VDC max 100mA 4 Actual value current input sensor 2 0 20mA 4 20mA Ri 2500 5 Actual value voltage input sensor 2 Dig 3 0 10 VDC 6 Actual value voltage input sensor 1 Dig 2 0 10 VDC 7 External ON OFF release Active low 8 GND electronic ground 9 Configurable digital input 1 Dig 1 _ Active low 10 GND electronic ground 11 Low water Active low 12 GND electronic ground 13 Voltage signal input required value 1 Offset 0 10VDC 14 GND electronic ground 15 Voltage signal input required value 2 Dig 4 0 10VDC 16 GND electronic ground 17 GND electronic ground 18 Current signal input
78. tions during variation of the demand 64 9 TT 0235 0235 RAMP FMIN A Ramp F 2 0 Sec acceleration Possible settings 1 0 25 0 sec Fast running up time to start up the HYDROVAR till the selected MIN FREQUENCY 0250 is reached Above the minimum frequency RAMP1 0215 fast acceleration ramp starts to work e Excessively fast running up time may cause an error OVERLOAD during the HYDROVAR starts up 0240 Ramp Fmin deceleration 2 0 Sec Possible settings 1 0 25 0 sec Fast running down time to stop the HYDROVAR immediately below the selected MIN FREQUENCY 0250 e Excessively fast running down time tends to cause an error OVERVOLTAGE 0245 MAX FRQ 0245 50 0 2 Maximum frequency Possible settings 30 0 70 0 Hz This parameter determines the maximum speed of the pump The standard setting is according to the nominal frequency of the connected motor Settings higher than standard setting may overload the motor Settings of 10 above nominal frequency cause 33 higher power consumption 0250 MIN FRQ 0250 15 0 Hz Minimum frequency Possible settings 0 0 30 0Hz At operation below the set min frequency the HYDROVAR operates with the fast ramps 0235 0240 The min frequency depends on the selected pump type and application Especially for borehole applications the min frequency must be set to 30Hz 65 9 TT 0255 CONF FMIN 0255 ERA Operation at minimum frequ
79. to reduce the noise level At rising temperature inside the HYDROVAR the switching frequency is decreased to 4kHz automatically 8kHz Selection with lowest noise level but without decrease at rising temperature 2 Reduce the temperature in the motor and even inside the inverter 67 TT 0300 SUBMENU 93989 REGULATION 0305 JOG 0 0Hz Both current output frequency and actual value are 0305 X XX Bar shown By pressing A or V in this menu the internal controller of the HYDROVAR will be shut off and the inverter changes to manual mode With the and V buttons any constant speed be set without influence of the actual value of the control signal e f this value becomes 0 00 Hz the HYDROVAR stops As soon as the window will be left by pressing lt or gt the HYDROVAR restart normal mode 0310 22 e regulation Window 0 Possible settings 0 100 of required value e Determines the band where the slow ramp changes to the fast ramp for steep pump curves and closed loop systems 20 30 0315 HYSTERESIS 0315 80 ramp Hysterics Possible settings 0 100 Determines the band where the normal regulation is done change between the slow ramps accurate control without automatic shut off 99 e g constant flow control 0320 Regulation mode normal Possible settings normal invers Normal Speed is increased with falling actual value signal
80. ts running Switching order Adr 1 Adr4 Adr5 Adr6 Adr7 Adr8 Adr2 Adr3 Master Basic Basic Basic Basic Basic Master Master 76 9 TT 0600 SUBMENU 0600 ERRORS 000 e ees SUN TERESE sss nisse uso ac disabled Possible settings disabled max SENSOR RANGE e adjusted value 70 00 has to be reached within the programmed DELAY TIME 0610 elf this value can t be reached the HYDROVAR stops and indicates the failure message MIN THRESHOLD ERROR disable the minimum threshold limit press V till disabled is shown on the display 0610 minimum threshold limit delay time Possible settings 0 100 sec Delay time to switch off the HYDROVAR in case the actual value drops below the min threshold limit or a connected external low water protection at terminals X3 11 12 has been opened Notice The min threshold function is also active during start up of the pump Therefore the delay time has to be set higher than the duration that is needed to reach a value higher than that 0615 DOME ite SERE Automatic error reset Possible settings ON OFF ON Allows an automatic restart for 5 times in case of a failure If the failure is still active after the 5 restart the HYDROVAR will shut off and the appropriate error message is shown The internal counter of the automatic error reset is decreased by 1 after each operating hour so if an error could be reset after 3 restarts there are 3
81. ump operation only The actuator mode has to be used if an external speed signal is available and the HYDROVAR is just used like a standard frequency converter In this case the internal controller is shut off so the HYDROVAR won t control the set value but it is responsible for running the connected motor at a frequency proportional to the input signal connected to the analogue inputs X3 13 Voltage signal input Required value 1 0 10 MIN FREQ 250 MAX FREQ 245 X3 15 Voltage signal input Required value 2 0 10V MIN FREQ 250 MAX FREQ 245 X3 18 Current signal input Required value 1 4 20 MIN FREQ 250 MAX FREQ 245 0 20mA MIN FREQ 250 MAX FREQ 245 X3 23 Current signal input Required value 2 4 20mA MIN FREQ 250 MAX FREQ 245 0 20mA MIN FREQ 250 MAX FREQ 245 e A manual switching between the analogue inputs is possible by using the corresponding digital inputs e The frequency varies not faster than the programmed Ramps 1 accelerative and 2 declarative The functions thermal protection and external ON OFF remain still active e The functions External ON OFF Motor Overheat Lack of water and all other internal protections still work In the actuator mode it is also possible to work with pre selected frequencies for a manual control of the HYDROVAR It is possible to set two different frequencies in the submenu REQUIRED VALUES 0800 A changeover of these frequencies can be done with parameter S
82. y Card The optional Relay Card allows to control up to 5 fixed speed pumps can be only used in combination with the Master Inverter 20 9 TT 8 Mechanical components 8 1 Included mounting material Included Cable gland Closing gland Motor PTC Mounting centring components t lock nut clamps bit aa eg diameter 4 5 10 9 1 mm 2 121211 1 4022 4040 20 2 2 3 1 1 4 4405 4110 120 2 213111 1 4 max available cable entries 8 2 Optional components 8 2 1 Mounting accessories Mounting ring Available for diameters 140 mm 155 mm CAUTION If the HYDROVAR is mounted on a motor with plastic fan cover a stainless steel mounting ring must be used to support the weight of the motor I ring 8 2 2 Sensors pressure transducer e temperature sensor differential pressure transducer e flow indicator level sensor orifice plate inductive flow meter 8 2 3 Filter e Line coils 8 2 4 Ready made Motor cables Available for HV 2 015 4 110 21 itt 8 3 Assemble instruction HV 2 015 HV 4 110 4 screws to fix the cover F M4x50 HYDROVAR cover 4 Screws M5x60 Display Motorcable Motor fan cover Motor Motor conduit box PTC Pressure transmitter itt 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 e Centre th

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