Operating Instructions
Contents
1. ness ERE DER 29 FE remi EE 29 736 SUBMENU ECONOMY dee ace 30 FO COT CIN 30 7 6 2 Rated Doder 30 VA OCA 40114 0 7 RT EE 30 POA C V 30 VN A e ddGejeizq 31 FS SWITCH INTERVAL RETE 31 VES SEV SSN ORD areca sec TUTORIS 31 www hydrovar com 3 e ITT Industries Engineered for life HYDROVAR Operating Instruction SEKR CMNERRRRRRRRRRRRRRRRRRUuu e mmmm 31 E Eb ok MEE 31 7 12 SUBMENU DIAGNOSIS THIS PARAMETER ARE ONLY TOREAD enhn ehe emm men esee serrer msesse sse erre nen 32 PASE EE 32 7 12 2 Pump oo Je CREE 32 POS PEEL EDECR e 32 7 12 4 Software Version vecccccccccccencccensecensetensetensatenstenstensdtensdtensdtunsntenstensntnnsdtensdtnnsntensusensnsesensusensases 32 8 CONTROLLER MENU OF THE PROGRAMMING DEVICE eeeen m n HI mI mI Rh Rh heh hh hme 33 9 1 CONTROLLER MENU CONFIGURATION eege 33 8 1 1 Automatic connection to the programming device isis sese n nnne arn aannnann 33 67 2 50l WNA VASON E 33 OaE BIE A RE S EE 34 82 1 Change OF PUMP ool En 34 92. HYDROVAR Operating Instruction 8 2 Submenu address Submenu To enter this menu you have to press the W button to Address leave the menu press the button longer than 3 sec 8 2 1 Change of pump address Address Change Addresses from 01 to 04 can be set in this 00 gt 00 parameter To change the address it is not necessary to cut the interface connection to other HYDROVARS On the left side there is shown the address of the HYDROVAR which you want to select select the address by using the buttons or WY On the right side you can select a new address also with the buttons ah and de You only can select an address which is not used in the pump group To change between left and right side press button or The star shows the actual used side If you have selected mode MASTER SLAVE it is important that each Hydrovar has it s own address from 01 to 04 To save the new selected address press both buttons and together for 2 sec If it was successfully you will see the same address on both sides To leave the submenu press the key for 3 sec www hydrovar com 34 e ITT Industries Engineered for life Operating instruction 851 1 HYDFOVAR 9 Possible Error messages You have to connect the programming unit to read the error message on the display After the cause has been remedied the malfunction has to be reset by cutting off the power supply for gt 30 seconds The last 3 error messag
3. La Sipi re BP 23 13730 Saint Victoret F T l 0033 04 42 10 02 30 Fax 0033 04 42 10 43 75 LOWARA NEDERLAND B V Postbus 54 NL 4180 BB Waardenburg Tel 4 31 418 655060 Fax 31 418 655061 E Mail info nli lowara ittind com www lowara nl LOWARA PORTUGAL Comercio de Bombas Lda Praceta da Castanheira Lote 6 Barca P 4470 Maia Tel 351 22 9478550 Fax 351 22 9478570 E Mail lowaraportugal mail telepac pt www hydrovar com HYDROVAR LOWARA IRELAND Ltd 59 Broomhill Drive Tallaght Industrial Estate Tallaght Dublin 24 Tel 35 31 4520266 Fax 35 31 4520725 www lowara ie LOWARA UK Ltd Millwey Rise Industrial Estate Axminster GB Devon EX13 5HU Tel 44 1297 630230 Fax 44 1297 630270 E Mail uksales lowara ittind com www lowara co uk LOWARA UK Ltd Regional sales office Unit 1 Byram Industrial Park Low street Brotherton Knottingley WF 11 9 HS West Yorkshire Tel 44 1 977 607 267 Fax 44 1 977 607 226 E mail salesuknorth lowara ittind com www lowara co uk ITT FLUID TECHNOLOGY INT ASIA PACIFIC PTE Ldt 298 Tiong Bahru road 03 04 06 Tiong Bahru Plaza Singapore 168730 Tel 65 2763693 Fax 65 2763685 ITT FLUID TECHN INT AUSTRALIA PTY Ltd 18 Commercial Drive Dandenong South Victoria 3175 AUSTRALIA Tel 61 3 97065066 Fax 61 3 97066065 43 e ITT Industries i Engineered for life HYDROVAR amp VOGEL PUMPEN Pumpenfabrik ERNST Vogel GmbH
4. A 2000 Stockerau Ernst Vogel Strasse 2 Telefon 02266 604 Telefax 02266 65 311 Internet www vogel pumpen com www hydrovar com A 8054 Graz Seiersberg Karntnerstrasse 518 Telefon 0316 28 6120 Telefax 0316 28 70 42 A 9020 Klagenfurt Schachterlweg 58 Telefon 0463 31 93 20 Telefax 0463 31 93 17 A 4600 Wels Haidestrasse 41 Telefon 07242 66 8 51 52 53 54 Telefax 07242 66 8 51 12 A 6175 Kematen Bahnhofstrasse 31 Telefon 05232 20 0 01 Telefax 05232 20 0 03 www hydrovar com Operating Instruction Tochterunternehmen in Europa Subsidiaries in Europa LOWARA VOGEL Szivattyu Kft H 8000 Sz kesfeh rvar Bakony u 8 Telefon 0036 22 512 640 Telefax 0036 22 512 642 Lowara Vogel Polska sp zo o PL 40652 Katowice ul Worcella 16 Telefon 0048 32 202 8904 Telefax 0048 32 202 5452 VOGEL ROCANO SA CH 2087 Cornaux Z l Pr s Bersot Telefon 0041 32 75 87 200 Telefax 0041 32 75 87 200 e ITT Industries i Engineered for life
5. it is important that the motor was running with constant speed to reach the operation temperature Then you can choose between learning the first point and select one of the pre programmed reference curves only by using the external programming unit or learn 3 up to 12 points to run along the optimum system curve a Using one of the pre programmed reference curves 2 7 1 connect the external programming device to select your favourite reference curve 2 Stop the pump while pressing the button Y on the HYDROVAR 3 Press the A and Y buttons together for 5 sec the colour of the LED changes from green to orange The pump is now ready to learn 4 Set now the first system point at flow 0 You can change the speed of the pump by using the button A higher frequency or Y lower frequency Check the difference pressure on an important point of the system to set the required frequency On the display of the programming device you can see the power and the frequency 5 To save the learned point press the A and Y buttons together until the LED will begin to start fast flashing The Hydrovar stops automatically This saved point is now the min point of your selected reference curve but it can be used for all other reference curves also IT T Industries Engineered for life www hydrovar com 21 amp HYDROVAR Operating Instruction b Learning a complete system curve reference curve 0 Default no external programmi
6. SPEED FREQUENCY 26 26 26 PUMP PUMP LAST ERROR 2ND ERROR 3RD ERROR SOFTWARE RUNTIME ADDRESS IT T Industries Engineered for life www hydrovar com 40 Operating instruction 85 HYDFOVAR SUBMENU SUBMENU MODE SWITCH SET LEARNING DEFAULT TESTRUN ECONOMY CONTROLLER INTERVAL PASSWORD 30 31 32 32 32 32 32 CURRENCY RATED POWER COSTS KWH CLEAR SAVINGS 31 31 31 31 START TEST ENABLE TEST TEST BOOST TEST RUN RUN FREQUENZY RUN 30 30 30 30 POWER FREQ PASSWORD2 COEFFA COEFF B COEFF C 29 29 29 29 29 WINDOW Fx SHIFT ACCEL HIGH DECEL HIGH ACCEL LOW DECEL LOW 27 27 28 28 28 28 Order no HYDROVAR Pump Note Date Name www hydrovar com 4 amp ITT Industries Engineered for life HYDROVAR Operating Instruction ITT Industries Engineered for life www hydrovar com 42 Operating Instruction LOWARA Hauptsitz Headquarter LOWARA s r l Via Lombardi 14 36075 Montechio Maggiore l Vicenza Italien Telefon 39 0444 707111 Telefax 39 0444 492166 E Mail mkt lowara ittind com www lowara com LOWARA Niederlassungen Subsidiaries LOWARA DEUTSCHLAND GMBH Biebigheimer Strasse 12 D 63762 GroBostheim Telefon 0 60 26 943 0 Telefax 0 60 02 943 210 E Mail info de lowara ittind com www lowara de LOWARA FRANCE S A S BP 7311 F 37073 Tours Cedex 2 Tel 33 2 47881717 Fax 33 2 47881700 E Mail info fr lowara ittind com www lowara fr LOWARA FRANCE SAS Agence Sud Z
7. interference immunity The HV Series frequency converter complies with the general EMC provisions and has been tested according to the following standards e Disturbance voltage EN 55011 e EMC Immunity EN 61000 4 3 and ENV 50204 e Electrostatic discharge EN 61000 4 2 Ambient temperature 5 C 40 C Storage temperature 25 C 55 C 70 C during max 24 hours Humidity rH max 50 at 40 C unlimited rH max 90 at 20 C max 30 days per year Condensation not permitted Air pollution The air may contain dry dust as found in workshops where there is no excessive quantity of dust due to machines Excessive amounts of dust acids corrosive gases salts etc are not permitted Altitude max 1000m above sea level At sites over 1000 m above sea level the maximum output power is derated by 1 for every additional 100m If the installation site is higher than 2000 m above sea level please contact your local distributor Class of protection IP55 www hydrovar com 7 e ITT Industries Engineered for life HYDROVAR Operating Instruction 2 1 Dimensions HVS 1 1 closing cap 5155 65 120 k EE 0 O12 Qj cable gland HVS 1 15 4 70 HVS 1 15 1 2 3 2 3 3 3 4 closing cap cable entries 2x for M20 2x for M16 3x for M12 ITT Industries Engineered for life www hydrovar com 8 amp Operating Instruction FIYDROVAm 3 HYDROVAR mounting 3 1 Mounting the HYDROVAR on the pu
8. 0 25 of maximum output voltage are possible However care should be taken that settings are kept as low as possible so that the motor does not become thermally overloaded 7 2 3 Fixed Speed FIXED SPEED This speed is to run the motor with constant speed 30 0 HZ This speed is activated if the Digital Input X2 2 3 is closed Or if it is a single pump and there is ERROR POWERMEASURE detected This speed should be set to maintain a minimum flow e g night consumption The energy savings are also activated with the Fixed Speed ITT Industries Engineered for life www hydrovar com 25 amp HYDROVAR Operating Instruction 7 3 Submenu Controller Submenu To enter this menu you have to press the W button to Controller leave the menu press the button longer than 3 sec 7 3 1 Function Mode Function Mode Enabled Disabled Enabled Function Mode activated control along a calculated system curve Disabled Interpolation Point to Point control only for special applications 7 3 2 Window Hz Interpolation Window if function mode is disabled 2Hz 7 3 3 Window Fx Function mode Window if Function Mode is enabled 2 96 7 3 4 Shift Function mode Shift Oscillation of the learned system curve if Function 0 0 Hz mode is enabled Required Settings 0 1 5 Hz Settings to high oscillation is possible This function activate an increase and decrease of speed around the actual system point www hydrovar co
9. Mounting ring CAUTION If you use a motor with plastic fan cover you have to use a mounting ring 3 1 3 Mounting the Thermistor Variant A Motor Thermistor Terminal block Rubber gasket Cover of the conduit box www hydrovar com 12 ITT Industries Engineered for life Operating instruction 5 MYDFOVAR Variant B Thermistor 1 Open the cover of the conduit box and remove also the terminal block inside 2 Fix the Thermistor Variant A or B 3 Electrical connection of the motor cables 3 2 Electric installation and wiring NOTICE All installations and maintenance have to be performed by trained and qualified personnel with proper tools WARNING In case of a failure disconnect and lockout electrical power and wait five minutes for capacitor discharge before servicing the Hydrovar Otherwise it can cause shock burns or death 3 2 1 Means of protection Ask your power supply company which means of protection are required Applicable AC and DC current operated circuit breaker Fl TN systems protective circuits When using a Fl protection switch make sure that it also releases in the event of a DC fault use for each Hydrovar a separate Fl switch www hydrovar com 13 e ITT Industries Engineered for life HYDROVAR Operating Instruction 3 2 2 Wiring the Hydrovar to the motor Remove the 3 screws holding the top of the Hydrovar Carefully lift the top loose the earth screw and put
10. Operating Instructions HYDROVAR HVS 1 1 HVS 1 2 HVS 3 2 HVS 3 4 SENSORLESS e i dM I Wh Au S English 771079102 HVS1 1 3 4 VL EN e ITT Industries Engineered for life HYDROVAR HYDROVAR sensorless mu Energysavings www hydrovar com Operating Instruction The idea is to control the puMp speed according to the power consumption of the motor instead to the head of the pump Each working point at a defined speed on the curve of required pump head in the hydraulic diagram A B C has also a corresponding point in the electric performance diagram D E F Each of these points is defined by the power consumption at the same speed All these points of power consumption at different speeds results in a pretended curve of power consumption at different speeds If the controller varies the speed of the pump at different flow values so that the power consumption moves along this curve and the working point of the pump in the hydraulic diagram will also move along the corresponding curve of pump head but without measuring this head e ITT Industries Engineered for life Operating instruction 1 wmHYDROVAR Index Y IMPORTANT SAFETY INSTRUCTIONS KKK NNN n nnn nne ENNEN NNN ENEE REENEN NEEN 5 2 TECHNICAL DATA FREQUENCY INVERTER AND GENERAL DATA ccccceceeceeceeeeeceueeeceeaeeneeeneeneeneenenas 7 2 1 PINE NSIOINS ances cscnacancesnataschanasanasanesesasascid ase ee S
11. POSSIBLE ERROR MESSAGES 44 encre NNN RENE REE NNE NERE RENEE ERNE NNN EE RRE NN ERR EEKNN SNE ERNE NEN NERE NES ERE 35 d Seite eh e 35 D2 OVEN O C eee ee ee eee ee ae ene eee eee Sete ete eee EEN 35 Ds IND ER OUTAGE ens OO ONEONOUOU 35 SX OVERHOAD EEN 35 9 5 OVERHEATING OF THE HEAT SINK e ehm eme eme eme hme hne nnne rra ee es resa serrer seems ssesse EET serene 36 9 6 ERROR POWERMEASUREMENT G ssseeeeeeeeeeee kst kk kk kk kk REE REE REE E ES EET TEE LEE E LERNER REELLE ERE REEL REELT EET LETTE Eee rer En 36 9 7 ADDITIONAL INTERNAL PROCESSOR ERROR MESSAGES ccccceccceccececucecacecaceueeeneeeueeeaeesaetuaeesnetnaeegeenaeenaetnaetgneegnenanenanes 36 10 POSSIBLE INDICATIONS OF THE LED ON THE HYDROVAR c cccccceeeccececeeecceeceneeeeeeeesuseeenueeeenueeeaas 37 TI MAINIENAN 38 www hydrovar com 4 e ITT Industries Engineered for life Operating instruction wmHYDROVAR 1 Important safety instructions Read and follow the operating instructions and safety instructions carefully before starting operations All modifications must be done by qualified technicians In addition to the instructions contained in these operating instructions please pay attention to universal safety and accident prevention regulations Warns that failure to observe the precaution may cause electric shock Warns that failure to ob
12. ber 0066 0066 Hold the 3 button down to reach the next display www hydrovar com 23 e ITT Industries Engineered for life HYDROVAR Operating Instruction 7 Settings at the Submenu Parameter IMPORTANT i Before entering the secondary menu these instructions must be read carefully to prevent incorrect settings which will cause malfunction Parameter settings on the end of the manual with the number of the side and place for the changing Parameters 7 1 Auto start Auto Start You can select between Y Disabled and Enabled Enabled Autostart Enabled means that the pump starts again automatically after an interruption of the power supply power failure If Autostart Disabled is set the pump has to be restarted manually after a power failure by pressing Wand ab www hydrovar com 24 e ITT Industries Engineered for life Operating instruction HYDFOVAR 7 2 Submenu Inverter Submenu To enter this menu you have to press the button to Inverter leave the menu press the button longer than 3 sec 7 2 1 Maximum Frequency Max Frequency Possible setting between min 40 and max 70 Hz 50 0 Hz Attention Settings higher than 50 Hz may overload the motor Settings of 10 above nominal frequency cause 33 more power consumption 7 2 2 Boost BOOST The stated value determines the course of the 5 0 96 U f curve Setting of the motor starting voltage in 96 of rated voltage Settings of
13. d We Repeating the test run Select the test run and set the desired hours using the 4 button 7 5 3 Test Frequency Test Frequency Frequency for manual and automatic test run 30 0 Hz Can be set from 0 Hz up to 70 Hz 7 5 4 Boost Test Run BOOST Test Run Start voltage in 9o of rated voltage in order to ensure 10 0 96 that the motor starts safely www hydrovar com 29 e ITT Industries Engineered for life HYDROVAR Operating Instruction 7 6 Submenu Economy Submenu To enter this menu you have to press the button to Economy leave the menu press the button longer than 3 sec 7 6 1 Currency CURRENCY Change the currency using or V EUR This parameter allows you to change between EUR USD GBP CHF This function is only important to show the right cost savings 7 6 2 Rated Power RATED POWER Maximum Power Rate of the used Hydrovar Xx KW To measure the correct energy savings it is necessary to input the maximum power rate of the unit 7 6 3 Costs kWh COSTS KWH Energy costs per kWh Xx EURO Input the correct energy costs for 1 kWh 7 6 4 Clear Savings CLEAR SAVING Press both buttons to reset the actual energy saving to and V 0 www hydrovar com 30 e ITT Industries Engineered for life Operating instruction wmHYDROVAR 7 7 Mode Controller MODE Single pump Single Select with the 8 and dk Single Single pump or Master Slave up to 4 pumps 7 8 Switch Interval Switch Interva
14. e programming device you are now able to change ramps and windows for a better controlling www hydrovar com 22 e ITT Industries Engineered for life Operating instruction 8 HYDFOVAR 6 Settings at the Submenu Programming Device You are always able to connect the programming device to HYDROVAR The LED will change the colour to orange when connection was successful POWER X X The actual Power 96 and the actual output SPEED X X Hz frequency Hz are displayed POWER SAVING Shows the actually saved energy kW X XX KW TOTAL SAVINGS Shows the whole saved energy costs XX XX EUR in EUR USD GBP CHF General for operating with the external programming device With and you can select the different parameters in the menu To enter a submenu press the We button To leave the submenu you have to press the buttons or 3 for longer than 3 sec With 4 or V you can change the parameters Each change in the settings is saved after leaving this parameter with the buttons or 3 When you have changed a parameter and you leave it the LCD shows you the following message SAVE for about 2 sec PARAMETER SUBMENU From the 1 display press the gt button to reach PARAMETER PASSWORD Then press the button and the display will change to 0000 NOTICE The Password protection prevents untrained personnel from accidentally changing the base settings PASSWORD Press the button until you reach the num
15. es are saved in SUBMENU DIAGNOSIS 9 1 Overheating Motor XXX Error Mot Temp Possible causes insufficient cooling ambient temperature is too high or motor overloaded 9 2 Overvoltage XXX Error Overvolt Possible causes Check mains supply supply voltage too high peak voltage owing to switch heavy loads on the network or RAMP 2 is to fast Find the cause and take countermeasures e g network filter RC elements 9 3 Undervoltage XXX Error Undervolt Possible cause Check mains supply faulty fuse or phase unsymmetry 9 4 Overload XXX Error Overload Possible causes false data settings or the pump is working at a capacity significantly in excess of its performance data Ramp 1 to fast Max frequency to high Boost to low ITT Industries Engineered for life www hydrovar com 35 amp HYDROVAR Operating Instruction 9 5 Overheating of the heat sink XXX Error KK Temp The thermal sensor mounted on the cooling body of the HYDROVAR indicates over temperature Possible causes insufficient cooling ambient temperature is too high or motor overloaded 9 6 Error Power measurement XXX Error Powermeas No detected signal from the power measurement Possible causes wrong connection on the control card 9 7 Additional internal processor Error messages ERROR 1 EEPROM ERROR corresponding data block malfunction ERROR 2 Not used ERROR 3 Processor RAM error ERROR 4 i Not used ERROR 5 Proces
16. ess button Y to stop pump 2 Press the A and Y buttons together for more than 10 sec the colour of the LED changes to orange after 5 seconds and after further 5 seconds the LED changes to orange fast flashing 3 Now you can change the speed of the pump by using the button A higher frequency or Y lower frequency If the external programming device is connected with HYDROVAR the power as well as the frequency is shown on the display and you can also change the frequency with the A and e buttons of the programming device 4 When you have selected the right frequency don t press a button for 5 seconds and that speed is saved automatically Also after power supply fault the pump will run on this speed 5 Press the A and Y buttons together for 5 seconds the pump will stop If you have stored system points the HYDROVAR start with automatic mode www hydrovar com 20 e ITT Industries Engineered for life Operating instruction HYDFOVAR 5 Learning a System Curve to adapt the system s requirements CAUTION Before you start the system the pump has to be filled and all wiring and piping has to be done The learning of the system s required curve depends on the saved system points It is necessary to start at flow 0 and to save at least four system points up to a maximum of 12 points HYDROVAR FN sensorless Loge Difference Pressure Differenzdruckrmessunc Learning Before you start to learn
17. fe www hydrovar com 5 amp HYDROVAR Operating Instruction All work carried out when the frequency inverter is open may only be performed by qualified authorised staff Furthermore care must be taken not to short circuit the neighbouring components when connecting the external control wires and that open cable ends which are not in use are insulated The HYDROVAR drive head contains electronic safety devices which switch off the control element in the event of faults whereby the motor has zero current but remains energised and comes to a halt The motor can also be halted by mechanical blocking If it is switched off electronically the motor is disconnected from the mains voltage through the electronics of the frequency converter but is not potential free in the circuit In addition voltage fluctuations especially power failures can cause the system to switch off itself Repair of faults can cause the motor to start up again The system may only be put into operation when it has been earthened In addition equipotential bonding of all pipes must be ensured The operating instructions have to 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 NOTICE High voltage tests of the inverter or the motor may damage the electronic components Hence bridge before the in and outg
18. ine hi nasa sees neta seni sah EEEE 8 3 Adieu LEE 9 3 1 MOUNTING THE HYDROVAR ON THE BUMP eee kk tt kk RE ERNE ERR RE ERNE REE N RE ERR REE ENES ERNE REE NR TEEN ETERN REE RR EL ERNE LERNER TERRE ERNE LERNER EN 9 AT MENE DE COLIIDODBITS ee 9 mc Mer omn a mo ee 10 3 1 3 Mounting the thermistor seii sees aee Er nnns EEEE E EREEREER EEEE EREEREER ADEE EE EERE TEREE 12 3 2 ELECTRIC INSTALLATION AND WIRING eese mme meme m nehme nem sese se esse es eser ess ess e esse esse esse esse esee eren 13 3 2 1 Means of protection isiiseiisssisesi sees sans an hnanhnnassna nean ssas stas ssa a ssa asas suas saa assa assa sss assa ss aa assa s nes 13 9 2 2 WINING the Hyarovar tO TNC MOLE ico sszacuencusnceseeuanoseaneeeiveravenavecesaegeaeenaueseeauaaeesneeanauaodbbnds 14 CN NP ART OVERVIEW RTT TT UU T T 15 3 4 CONNECTING THE POWER CABLES ceseesen I kk me e ehe he messe sese kisses es esse ke esses es usse sse esses essere sess es essere nnns 16 LU EE qoam LEN NN m 17 ROI PUP Ui Rc 19 4 FUNCTION BUTTONS OF THE HYDROVAR cccccceceeeeeceeeeeseecceeneceeeceeaeecenaeeneuaeeaeeaueaneaneaneeueeneuaneueuannas 20 5 LEARNING A SYSTEM CURVE TO ADAPT THE SYSTEM S REQUIREMENTS enn 21 6 SETTINGS AT THE SUBMENU PROGRAMMING DEVICE eere m Immer mnm nnnm nnn 23 7 SETTINGS AT THE SUBMENU PARAMIETER eene nehmen hmm nn
19. l For changing the MASTER pump 0024 Adjustable between 0 de activated and 250 hours 7 9 Set Password Set Password The pre set password can be changed if necessary 0066 with the and buttons 7 10 Learning Learning Enabled you allow to learn system points Enabled Disabled Disabled Learn mode is deactivated 7 11 Default Default To load DEFAULT PARAMETER press buttons 4 V MWY together till the timer is run down www hydrovar com 31 e ITT Industries Engineered for life HYDROVAR Operating Instruction 7 12 Submenu Diagnosis read only Parameters Submenu To enter this menu you have to press the button to Diagnosis leave the menu press the button longer than 3 sec 7 12 1 Pump Runtime Pump Runtime Shows the running hours of the pump 0000 Std 7 12 2 Pump Address Pump Address This window shows the adjustment of the pump 1 address only readable 7 12 3 Error memory The last three error messages are always saved in an internal memory The error signals can not be deleted Last Error Shows the last error 2 Error Shows the Error before the last error Shows the Error before Error 2 7 12 4 Software Version Software This parameter shows you the used software version CP VOG 004 of the HYDROVAR www hydrovar com 32 e ITT Industries Engineered for life Operating Instruction 851 HMYDFOVAR 8 Controller menu of the programming device To reach the contro
20. ller menu you have to press gt on the controller for longer than 3 sec when the 1 display POWER X X The actual values are displayed SPEED X XHz is shown Then the display will change to Address 01 The actual pump address is shown P1 run P1 Master run HVS running P2 Slave disabled HVS is not ready extern on off P not active stop HVS is ready but not running Error Error message or no supply voltage Then press on the controller to change to 8 1 Controller menu Configuration Submenu To enter this menu you have to press the button to Configuration leave the menu press the button longer than 3 sec 8 1 1 Automatic connection to the programming device Auto Connecting Only valid for programming device Enabled Auto connecting enabled after plug in the programming device it changes automatically to the inverter menu During this auto connection the programming device is looking for a valid address and SCAN CONNECTION is shown on the display Auto connecting disabled there is no automatic connecting with the pump choose the address Auto connecting will be saved after leaving the submenu Configuration 8 1 2 Software Version Software In the second line of the display there is shown the Software VOGREM XXX version of the software of the programming device and also the date of programming of this software ITT Industries Engineered for life www hydrovar com 33 amp
21. m 26 e ITT Industries Engineered for life Operating Instruction 8 HYDFOVAR Time setting will influence the control of the pump and SHOULD NOT BE CHANGED at normal operation Possible settings for each ramp 0 05 1000 sec 7 3 5 Accel high Accel High Excessively fast running up time may overload the 10 Sec Inverter 7 3 6 Decel high Excessively fast running down time tends to cause 10 Sec oscillation or hunting or can cause an error OVER VOLTAGE during pump down of the pump Excessively slow running down time tends to generate over pressure 7 3 7 Accel Low Accel Low Excessively fast running up time tends to cause 70 Sec oscillation 7 3 8 Decel Low Decel Low A too fast setting leads to oscillation 70 Sec www hydrovar com 27 e ITT Industries Engineered for life HYDROVAR Operating Instruction 7 4 Submenu Reference Curve Submenu To enter this menu you have to press the W button to Reference Curve leave the menu press the button longer than 3 sec 7 4 1 Reference Curve Change the curve by pressing or V 0 7 This parameter allows selecting different pre programmed curves 0 Learned curve with 3 up to 12 system points 1 previous learned system curve 2 Selection A 7 By using reference curve 2 7 it is only necessary to 3 Selection B learn one point at zero flow You are also able to 4 Selection C change the reference curve while pump is running to 5 Selecti
22. mp 3 1 1 Included components Variant for HVS 1 1 M A J NN NR p e thermistor screw cable gland Variant for HVS 1 15 HVS 1 2 HVS 3 2 HVS 3 3 HVS 3 4 thermistor screw M5x50 m 49 cable gland mounting clamp www hydrovar com 9 e ITT Industries Engineered for life HYDROVAR Operating Instruction 3 1 2 Mechanical mounting Variant for HVS 1 1 Hydrovar 1 Remove the motor fan cover from your 3 phase motor by removing the mounting screws 2 Put the mounting and distance ring 1 between the fan cover and the Hydrovar and fix them together with the screw 3 by using the included washer 2 and distance 3 Use the fan cover screws to mount ring the fan cover Hydrovar combination to the motor motor fan cover lt ____ 2 washer O 3 screw CAUTION Don t forget the washer between the screw and the motor fan cover ITT Industries Engineered for life www hydrovar com 10 Operating Instruction 8 oHwHYDROVAR Variant for HVS 1 15 HVS 1 2 HVS 3 2 HVS 3 3 HVS 3 4 S It crews with j CAUTION Gasket Don t forget the gaskets for the 3 screws Ensure that there is no water on the unit before you open the cover 4 screws M5x50 Centre bit m Ce es Ch 4 mounting clamps Connection Motor conduit box Thermistor www hydrovar com 11 e ITT Industries Engineered for life HYDROVAR Operating Instruction e
23. ng device required 1 Stop the pump while pressing the button Y on the HYDROVAR 2 Press the A and Y buttons together for 5sec the colour of the LED changes from green to orange The pump is now ready to learn 3 Set now the first system point at flow 0 You can change the speed of the pump by using the button A higher frequency or Y lower frequency Check the difference pressure on an important point of the system to set the required frequency If external programming device is connected with HYDROVAR you can see the power and the frequency on the display 4 To save the learned point press the A and Y buttons together until the LED will begin to start fast flashing 5 Increase now the flow of the pump up to 20 30 of the maximum flow Increase also the frequency by using the button A higher frequency or Y lower frequency to reach the required value 6 To save this point press the A and Y buttons together gt 4 Learn now the next points up to the maximum flow 7 To save the last system point and to end the learning mode you have to press the A and v button together after setting the last frequency until the pump stops automatically and the LED starts shining green Now the required system curve is stored 8 If Autostart function is disabled start the automatic mode by pressing button A The Hydrovar increases now the speed till it reaches the right point depending on the system curve With th
24. nm ENNEN E ER 24 FM WO SUR T T 24 DEAS a INVERTER oe E 25 PAPA ILE nHldoU cisE 25 LEE 121 SE 25 E EET AAEE Er 25 7 3 SUBMENU CONTROLLER sssssssssusessnsunusrrnnrunrrrnnnnrrrnnnurernn nurt rn unur rr runn rrrNENRErENANAREENANNEEENANAEEENNREEENENACEEEEENREEEE ENEE E Ennn Enne 26 v s ERE T IV EE 26 7 3 2 Window Hz Interpolation wea eccscccsccacecsecnnecnsueneeesueneeneneneeseeeneeeaeeneeenensauenaesnensanasaussaensesanssansaneses 26 7 3 3 Window F Ff nction MODE E 26 7 3 4 Shift Function mode 26 ERE ve BU EE EF 27 E AAAA SES E E EE E A eee 27 VIE AP E a a a aan AN AE EAT OEE EET EE Ee A E 27 EE AEREE EEEE EEEE EEEE E 27 7 4 SUBMENU REFERENCE CURWE sek kk tk kk REE ERNE REE EEN NERE LER NERE LER NNE ETERN REEL ERNE REE RR REEL ERR REEL EEN REEL ER REEL ERNE R ELLER REEL LERNER LEE 28 7 4 1 Reference Curtke ictceccccccccncncenedenenenncnensonsedenentanensonandedenennanantanaadenensnnanedadenennanensonansensnenenennanentes 28 TP POW C7 FICO UCC J RERERERERE NERE NERE REED 28 728 30 DELUECIEnIS AJ BC EE 28 Fe Bits NES LU RT 29 VES TC Ig TEE a 9 Pn 29 Po oh ge 6 ae S T P PN IERRT RR mAmmmmmET A 8mmmmB 29 PESE Isque
25. oing terminals L N U V W To avoid incorrect metering by capacitors incorporated in the electronic part isolate the motor from the Hydrovar Drive head Preliminary Inspection Visual Inspection Upon delivery check the integrity of the packaging After you have removed the external packaging visually inspect the converter to make sure it has suffered no damage during transport If any damage is visible inform your distributor within 8 days from the delivery date Handling and Storage The product must be lifted and handled carefully During transport and storage protect the converter from humidity and mechanical damage caused by impacts falls etc ATTENTION Dispose of all packing materials in accordance with local regulations ITT Industries Engineered for life www hydrovar com 6 amp Operating instruction mHYDROVAR 2 Technical Data Frequency Inverter and General Data the Motor min HVS output current 48 62 Hz 1 1 1 1 kw 3x0 U 4 8 A 1x220 240V 15 10 133 1 1kW 3x0 U 48A 1x220 240V 15 10 1 15 Output voltage 3x O U VAC 0 70 Hz depends on the input voltage Min frequency 0 max frequency Electrical efficiency gt 95 Protection against Short circuit over and undervoltage overheating of the electronics overload and additional external protective functions via PTC motor temperature and low water switch A mains filter is fitted to ensure
26. on D find the best suitable curve Pup Section The different curves depending on the type of pum 7 Selection F P J yP pump and the duty point 7 4 2 Power Frequency POWER xxx Check the learned points by using and de FREQ xx x HZ Learned points 1 12 This parameter allows only the control of the learned points 7 4 3 Coefficients A B C These coefficients define the actual reference curve 0 7 To change the coefficients it is necessary to know a special password A changing without knowledge about pump curve and power will produce a malpractice of the pump COEFF A B C Change value using and W Press the gt button X XXX to save and change to next coefficient ITT Industries Engineered for life www hydrovar com 28 Operating Instruction 8 HYDFOVAR 7 5 Submenu Test Run Submenu To enter this menu you have to press the W button to Testrun leave the menu press the button longer than 3 sec 7 5 1 Start Test Run Start Test Run By simultaneously pressing 4 dk a test run will be A released even if the test cycle is not set After starting this test run the pump will speed up with the fasten ramp 1 to the set speed and then will ramp down with the fasten ramp 2 7 5 2 Enable Test Run Enable Test Run Adjustable between 1 100 hours 100 h The test run starts the pump at the set time after the last stop for 20 seconds with the set speed Deactivating test run Set 0 hours by using an
27. power measurement To run with Fixed Speed Electronic Ground 1 close X2 2 and X2 3 N x lt 4 5V SIO 3 GND SCC RS 485 Interface Connect X3 1 2 3 to Master Slave unit 1 SIO ET x lt ITT Industries Engineered for life www hydrovar com 18 Operating Instruction HYDROVAR 3 5 Front plate HVS 1 1 1 2 HVS 3 2 3 3 3 4 indication LED connection of the programming device START STOPP WARNINGLIGHT Motor run Motor off Controller stop HYDROVAR ITT Industries Engineered for life www hydrovar com ITT Industries Engineered for life www hydrovar com 19 amp HYDROVAR Operating Instruction 4 Function buttons of the HYDROVAR CAUTION Before you start the system the pump has to be filled and all wiring and piping has to be done The Hydrovar is delivered with the following settings as default Learning enabled allows to learn a reference curve Auto Start enabled after power supply automatic start Other possibilities to use the push buttons of the Hydrovar START Press A button if Autostart is disabled the pump can be started by pressing the Y button and then the A button at the first start up or after a power supply failure or STOP Press the Y button Both buttons are located on the front plate of the Hydrovar e Set Frequency for constant speed For changing the speed without the external programming device you have to do the following 1 Pr
28. serve the precaution may cause personal injury or damage to property The HYDROVAR drive head has to be disconnected from the power supply before any work can be carried out in the electrical or mechanical part of the system Installation maintenance and repair work may only be carried out by trained skilled and qualified personnel Unauthorised modifications or changes to the system make all guarantees null and void When in operation the motor can be stopped by remote control where by the drive head and the motor remain under voltage For safety reasons the unit must be disconnected from the power supply when carrying out work on the machinery as locking out the equipment by switching off the release mechanism or set value cannot prevent accidental starting of the motor When the drive head is connected to power supply the components of the power unit as well as certain components of the master control unit are also connected to the power supply Touching these components seriously endangers life Before removing the frequency inverter cover the system must be disconnected from the power supply After switching off the power supply wait at least 5 minutes before starting work on or in the HYDROVAR drive head the capacitors in the intermediate circuit have to be discharged by the installed discharge resistors first Voltages of up to 400 volts are possible if there are faults it can be higher ITT Industries Engineered for li
29. sor ROM error ERROR 6 Watchdog error ERROR 7 Timer error quartz ERROR 8 i Programme error These ERROR signals are acknowledged by disconnecting the power supply for gt 30 seconds If the error signal should appear again contact customer service and provide a detailed description of the error ITT Industries Engineered for life www hydrovar com 36 Operating Instruction HYDROVAR 10 Possible indications of the LED on the HYDROVAR Green shining Green slow flashing Green fast flashing Motor stopped via external stop with terminals X2 4 X2 5 or the unit is stopped with the Y button on the front plate gt Inverter is active but the motor has stopped gt Motor runs Orange green flashing connected external programming device Orange shining Orange fast flashing Red shining Red flashing www hydrovar com gt LEARNING change speed with the buttons A and Y or the external programming device is connected and the pump is stopped with the button Y on the Hydrovar or with the external release input terminals X2 4 and X2 5 EMERGENCY MODE speed can be changed with the buttons A and Y error signalling type of the Error is shown on the display of the external programming device signalling of a fatal error HYDROVAR has to be disconnected from the power supply 37 e ITT Industries i Engineered for life HYDROVAR Operating In
30. struction 11 Maintenance The Hydrovar control unit does not require special maintenance However the cooling fan and the vent should be freed of dust occasionally Fur further information please ask your distributor www hydrovar com 38 e ITT Industries i Engineered for life Operating instruction 85 HYDFOVAR Manufacturer s Declaration as defined in EC Machinery Directive 98 37 EEC Appendix II B and the EMC Directive 89 336 EEC We herewith declare that the frequency converter of type HYDROVAR HVS 1 1 1 15 1 2 HYDROVAR HVS 3 2 3 3 3 4 is intended for assembly with other machines to a machine It is forbidden to start using it until it has been established that the machine on this converter is to be installed or with which this converter is to be assembled complies with the provisions of EC Directives Relevant technical standards and specifications especially EN 55011 Class B EN 61000 6 EN 60146 EN 50178 EN 60204 1 Dir Ing Sacher Pumpenfabrik ERNST VOGEL GmbH A 2000 Stockerau Ernst Vogel Str 2 Stockerau 20 08 03 www hydrovar com 39 e ITT Industries Engineered for life HYDROVAR Operating Instruction 12 Parameter POWER POWER TOTAL SUBMENU SPEED SAVING SAVINGS PARAMETER SUBMENU PASSWORD AUTOSTART SUBMENU SUBMENU SUBMENU DIAGNOSIS INVERTER CONTROLLER REFERENCE gt CURVE Seite 33 24 25 26 27 29 REFERENCE CURVE 29 FUNCTION WINDOW HZ MODE 27 27 MAX BOOST FIXED
31. the Hydrovar cover aside Now you can see the 2 main parts 1 control card with all terminals for the control signals and the RS485 interface 2 main card with all power components and terminals for power supply and motor ITT Industries Engineered for life www hydrovar com 14 Operating Instruction HYDROVAR 3 3 Main part overview HVS 1 1 control card 1 main supply connections Motor connections main board 2 Cable introduction for Cable gland motor cable for power at least supply 5 10mm 11 5mm Cable introduction for control cable at least 5mm HVS 1 15 HVS 1 2 HVS 3 2 HVS 3 3 HVS 3 4 control card 1 main board 2 motor main suppl i des connections connections cable introduction for control cable www hydrovar com 15 e ITT Industries Engineered for life HYDROVAR Operating Instruction 3 4 Connecting the power cables a motor cable Locate the motor connections inside the Hydrovar Connect wires to the terminals and rout the cable through the cable gland You must take a motor cable at least 11 5mm if you want protection IP55 only HVS 1 1 The earth wire of the cable has to be fixed with the screws with the earth symbol to the cooling body of the Hydrovar b Connections in the conduit box The connection of the motor cable depends on the type of the motor and can be done in star or delta connection you have to use the connection for a motor
32. voltage of 3x230V shown on the motor label Star connection Delta connection c supply cable The main power cable is connected to the terminals labelled L1 N for the 230 VAC single phase unit or L1 L2 L3 for the 3x400VAC three phase unit IT T Industries Engineered for life www hydrovar com 16 Operating Instruction FIYDROVAm Control terminals terminals of the RS485 interface Power supply 220V HVS 1 15 1 2 3 4 1 Control Terminals All external used cables have to be shielded Do not connect the mass of the electronic components to other higher potentials All electronic ground and GND of the RS 485 interface are connected internal For external off on and low water switch contacts suitable for 10 V are necessary The control cable must be at least 5mm If unshielded control cables are used signal interference may occur and interfere with the function of the inverter IT T Industries Engineered for life www hydrovar com 17 amp HYDROVAR Operating Instruction Control Terminals SC RS Error relay X2 10 and 11 CC X2 11 is closed if there is an error or no power supply max 500mA 125V AY SS SS DNDNDNDNDNDN DN DNDNDNDNDN 10 NC L Motor Thermistor Internal connected to 7 White wire Internal Power measurement a Black wire Power measurement External ON OFF XR NE O 5V 3 7 Red wire X2 3 is used for internal Fixed Speed 2
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