Bell & Gossett 193 User Manual
VARIABLE SPEED PUMPING SYSTEMS
INSTRUCTION MANUAL
VARIABLE SPEED PUMP CONTROLLER AND
INTEGRATED AJUSTABLE FREQUENCY DRIVE
WARNING LABEL #S11550
HV 2.1-3.11
INSTALLED IN THIS LOCATION.
IF MISSING IT MUST BE
REPLACED.
INSTRUCTION MANUAL
210 980-2
HV 120-1-ENBG
26.03.2003
HV3.15-3.22
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
DESCRIPTION: Microprocessor based pump
controller and adjustable speed drive for variable
volume pumping systems. The controller consists
of the following components: microprocessor,
operator interface with alphanumeric display, and
membrane keypad.
OPERATIONAL LIMITS: See the control panel
nameplate for operating voltage, current draw, as
well as information on the equipment to be
connected to the control panel.
SAFETY INSTRUCTION
This safety alert symbol will be used in this
manual to draw attention to safety related
instructions. When used, the safety alert
symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTION MAY
RESULT IN A SAFETY HAZARD!
Operating Instruction
Index
1 Important safety instructions ........................................................................5
2 System Design................................................................................................ 7
3 Pressure tank ................................................................................................8
4 Technical Data - Frequency Inverter And General Data................................. 9
5 Dimensions and Weights .............................................................................11
6 Mounting the Technovar..............................................................................12
6.1Mounting the Technovar on the pump.................................................12
6.1.1 Components included............................................................................................ 12
6.1.2 Mounting .............................................................................................................. 13
6.1.3 Mounting the thermistor ....................................................................................... 23
6.2 Electric installation and wiring.............................................................24
6.2.1 Means of protection .............................................................................................. 24
6.2.2 Wiring the Technovar to the motor ....................................................................... 24
6.3 Main Voltage Terminals .......................................................................25
6.4 Control Terminals................................................................................. 26
6.4.1 Control terminals................................................................................................... 27
6.4.2 Dip-Switch on the controller board........................................................................ 28
6.4.3 Main parts from the control card........................................................................... 28
6.5 Front plate............................................................................................ 29
7 Language Selection...................................................................................... 30
8 Typical applications .....................................................................................31
8.1 Control ................................................................................................. 31
8.2 The Main Menu Setting........................................................................ 31
8.3 Single Pump – Pump Protection........................................................... 34
8.3.1 To set run out protection....................................................................................... 34
8.4 Single Pump – System Curve Compensation........................................ 36
8.4.1 Entering the compensation values......................................................................... 37
8.5 Multiple Pump - Constant Pressure and System Curve Compensation 38
9 Parameters of the main menu ..................................................................... 43
10 Settings at Secondary Menu.......................................................................46
10.1 JOG-MODE..........................................................................................46
10.2 Window - %........................................................................................ 47
10.3 Ramp Hysteresis ................................................................................. 47
10.4 Ramp 1: Fast running up time:........................................................... 47
10.5 Ramp 2: Fast running down time:...................................................... 47
10.6 Ramp 3: Slow running up time: ......................................................... 48
10.7 Ramp 4: Slow running down time: ....................................................48
2
Operating Instruction
Ramp – Window.........................................................................................48
10.8 Maximum Frequency.......................................................................... 48
10.9 Minimum Frequency ..........................................................................49
10.10 Operation at the minimum frequency ............................................. 49
10.11 Delay time for shut off at minimum frequency ............................... 49
10.12 Boost ................................................................................................ 49
10.13 Sensor – Adjust................................................................................. 50
10.14 Sensor - Curve .................................................................................. 50
10.15 Setting of the measuring range ....................................................... 50
10.16 Operation Mode ............................................................................... 50
10.17 Control Response ............................................................................. 51
10.18 Start Value........................................................................................ 52
10.19 2nd Required Value............................................................................ 52
10.20 Configuration of 1st relay ................................................................. 53
10.21 Submenu Offset ............................................................................... 53
10.21.1 Source of the Offset input ................................................................................. 53
10.21.2 1
10.21.3 2
10.21.4 INTENSITY 1 ....................................................................................................... 54
10.21.5 INTENSITY 2 ....................................................................................................... 54
st
Offset level.................................................................................................... 53
nd
Offset level ................................................................................................... 54
10.22 Submenu Sequence control ............................................................. 54
10.22.1 Lift Value ........................................................................................................... 55
10.22.2 Fall Value ........................................................................................................... 55
10.22.3 Release frequency of the following controller.................................................... 56
10.22.4 Switch Interval................................................................................................... 56
10.22.5 Source of required value.................................................................................... 57
10.22.6 Synchronous Control ......................................................................................... 57
10.22.7 Pump status indication ...................................................................................... 58
10.22.8 Error Signals for Data Bus Interruptions............................................................. 58
10.23 Submenu - RS 485 Interface ............................................................. 59
10.23.1 Pump Address.................................................................................................... 59
10.23.2 ADC Reference................................................................................................... 59
10.24 Compensation Frequency................................................................. 59
10.25 Lift-Intensity.....................................................................................60
10.26 Analog - Output ............................................................................... 60
10.27 Unit...................................................................................................61
10.28 Automatic test run ........................................................................... 61
10.29 Submenu for manual test run.......................................................... 61
10.29.1 Activate manual test run.................................................................................... 61
10.29.2 Test Frequency................................................................................................... 61
10.29.3 Boost ................................................................................................................. 61
10.30 Submenu - Error ............................................................................... 62
10.30.1 Conveyor Limit................................................................................................... 62
10.30.2 Delay Time......................................................................................................... 62
3
Operating Instruction
10.30.3 Automatic Error reset......................................................................................... 62
10.30.4 Erase Error memory ........................................................................................... 63
10.31 Operating Hours............................................................................... 63
10.32 Display - Contrast............................................................................. 63
10.33 Set Password .................................................................................... 63
10.34 Operating Lock .................................................................................63
10.35 Internal Heater ................................................................................. 63
10.36 Setting Default Values......................................................................64
10.36.1 Default Values Europe ....................................................................................... 64
10.36.2 Default Values USA............................................................................................ 64
10.37 Saving...............................................................................................64
11 Error Signals................................................................................................ 65
11.1 Low Water .......................................................................................... 65
11.2 Conveyor Control ...............................................................................65
11.3 Overheating – Motor .......................................................................... 65
11.4 Overheating – Inverter ....................................................................... 65
11.5 Over voltage.......................................................................................65
11.6 Under voltage..................................................................................... 66
11.7 Limit ................................................................................................... 66
11.8 Short Circuit ....................................................................................... 66
11.9 Overload............................................................................................. 66
11.10 Pressure Sensor Error I < 4 mA ...................................................... 66
11.11 Additional Error signals:................................................................... 67
12 RS 485 - Interface........................................................................................ 67
13 Auxiliary Texts.............................................................................................68
14 Maintenance ...............................................................................................73
14.1 Notes.................................................................................................. 73
Follow the Pump Operating and Maintenance Instructions
We reserve the right to alter specifications
4
Operating Instruction
1 Important safety instructions
In addition to the instructions contained in these operating instructions please pay
attention to universal safety and accident prevention regulations.
The TECHNOVAR drive head must be disconnected from the power supply before any work
can be carried out in the electrical or mechanical part of the system.
Installation, maintenance and repair work may only be carried out by trained, skilled and
qualified personnel.
Unauthorized modifications or changes to the system make all guarantees null and void.
When in operation, the motor can be stopped by remote control, whereby the drive head and
the motor remain under voltage. For safety reasons, the unit has to 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 TECHNOVAR drive
head (the capacitors in the intermediate circuit have to be discharged by the
installed discharge resistors first).
Voltages of up to 800 volts are possible (if there are faults it can be higher)
All work, carried out when the frequency inverter is open, may only be
performed by qualified authorized 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 isolated.
5
Operating Instruction
The TECHNOVAR 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 energized 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 potentialfree 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.
Warns that failure to observe the precautions may cause electrical shock.
Failure to follow these instructions could result in serious personal injury or death.
Warns that failure to follow these instructions could result in serious personal
injury or death as well as property damage.
6
Operating Instruction
2 System Design
The following diagrams show typical single pump and multi-pump systems using the
Technovar control unit. Connection can be made directly to a water supply or water can be
drawn from a break tank or well. In the case of break tanks and wells, level switches, should
be used to shut down the pumps when water is low. In the direct connection, a pressure
switch on the suction side should be used.
(1) pump with drive head
(2) diaphragm tank
(3) distribution panel
(4) gate valve
(5) non return valve
Single Pump Layout
(8) incoming pressure control
(9) pressure gauge
(14) pressure transmitter
3
Multiple Pump Layout
7
Operating Instruction
3 Pressure tank
A diaphragm pressure tank is used on the discharge side of the pump or pumps to maintain
pressure in the line when there is no demand. This will keep the pumps from continuing to
run. With the Technovar control unit, it is not necessary to have a large tank for supply
purposes.
In selecting a tank, make sure it is permit and suitable for systems pressure. The tank should
have a capacity of more than 10% of the maximum system flow rate g/min of one pump (also
in a multiple pump system!).
Pre charge the tank to the following:
Required pressure
Pre charge pressure (psi)
Note:
De-pressurize the tank prior to charging to ensure accuracy of the
pre-charged pressure.
8
Operating Instruction
4 Technical Data - Frequency Inverter And General Data
TECHNOVAR Technovar
Supply Voltage
output to
the Motor
Model
No.
nominal
Horsepower
HV 2.1 2 7 A
HV 2.2 3 10 A
Max. Current
*1x220...240VAC ±15%
*1x220...240VAC ±15%
HV 3.2 3 5,7 A 3x380...460VAC ±15%
HV 3.3 4 7,3 A 3x380...460VAC ±15%
HV 3.4 5 9 A 3x380...460VAC ±15%
HV 3.5 7.5 13,5 A 3x380...460VAC ±15%
HV 3.7 10 17 A 3x380...460VAC ±15%
HV 3.11 15 23 A 3x380...460VAC ±15%
HV 3.15 20 30 A 3x380...460VAC ±15%
HV 3.18 25 37 A 3x380...460VAC ±15%
HV 3.22 30 43 A 3x380...460VAC ±15%
Note: Consult local authorities in your jurisdiction for fuse sizing.
* Output voltage is 3 phase and requires a motor suitable for 220-240V/3/60 input power
Mains frequency: 48....62 Hz
Max. frequency: See chapter 10.8
Min. frequency: 0 – f-max see chapter 10.9
Electrical efficiency: > 95%
Please
Note!
If the motor and control unit are assembled separately keep the
motor cable as short as possible in order to avoid electromagnetic
emissions and capacitive currents. The length may not exceed 66 m.
and a shielded cable has to be used.
Protection against: Short circuit, under- and over voltage, overheating of the electronics
(overload) and additional external protective functions via PTC (motor temperature) and
low water switch.
A mains filter is fitted to ensure interference immunity.
9
Operating Instruction
The HV-series frequency converter complies with the general EMV provisions and has been
tested according to the following standards:
· Radio Interference Suppression EN 50082 Part 2
EN 55011
· High Frequency Field Interference ENV 50204
· Electrostatic Discharge EN 61000-4
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
75% average per year (Class F, DIN 40 040)
Condensation is 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. 3280 ft. above sea level At higher altitudes the max. available
power has to be reduced. Please ask the manufacturer for further
details.
Class of protection : IP 54 3.15-3.22
Nema 4 bis 3.11
10
Operating Instruction
5 Dimensions and Weights
HV2.1/2.2/3.2/3.3/3.4 HV 3.5/3.7/3.11
Motorfancover max. 7.9 Ø
HV 3.15/ 3.18/ 3.22
Type: Weight: Type: Weight:
[lbs] [lbs]
HV 2.1 13 HV 3.4 13
HV 2.2 13 HV 3.5 22
HV 3.2 13 HV 3.7 22
HV 3.3 13 HV 3.11 22
Type Weight
[lbs]
HV3.15 64
HV3.18 64
HV3.22 64
all measurements in inches
Motorfancover max. 15.2 Ø
11
Operating Instruction
6 Mounting the Technovar
6.1 Mounting the Technovar on the pump
6.1.1 Components included
Thermal resistorScrew M5x90
cable gland
Mounting clamp
12
Operating Instruction
y
6.1.2 Mounting
HV2.1-3.11
Displa
changeable
to 180°
4 Screws
M5x90
Mounting:
u Remove the 3 screws from the
Technovar cover.
u Place the Technovar fan cover on
4 Mounting
clamps
the motor .
u Hang the 4 clamps by the
Motor fan cover and mounted
with the 4 screws.
u Mounted the cover with the
3 screws.
Don’t forget the gaskets for the 3 screws .
Ensure that there is no water on the unit before you open the cover.
Fix the display with the 4 Screws.
Thermistor
13
Operating Instruction
Mounting ring
If you use a motor with bis HV2,2kW, you have to use a
mounting ring.
14
Operating Instruction
A
Wall mounting kit HV2.1-3.11
Included components for wallmounted kit HV2.1-3.11
1 mounting plate with fan Picture 1 A
4 M3x 8mm screws (self threading) for kit HV2.1-3.4 Picture 2 B
or M4x15mm screws (self threading) for kit HV3.5-3.11 Picture 2 B
1 Molex connector Mod. 6471-021 Picture 2 C
1 Cable gland M12x1,5 Picture 2 D
1 counter nut M12x1,5 Picture 2 E
not included: Dowels and mounting screws for mounting the kit on the wall.
Recommended diameter for this screws: Æ 5-6mm for kit HV2.1-3.4
Æ 6-8mm for kit HV3.5-3.11
Picture 1 Picture 2
BCD E
15
Operating Instruction
Picture 3 Picture 4
Screw M3x8mm or
M4x15mm
(self threading)
Open
Picture 5
red
+ plus pole
black
Picture 6 Picture 7
Molex connector
cable gland for
fan cable
plus pole/ red
Black / minus
Picture 8 Picture 9
16
Operating Instruction
Free space for wallmounting
Note: You have to leave a free space in front of the Technovar for
configuration and for dismounting the cover.
free space required for cooling and mounting
MOUNTING INSTRUCTIONS
BEFORE REMOVING THE FREQUENCY INVERTER COVER THE SYSTEM MUST BE DIS-CONNECTED
FROM THE POWER SUPPLY. AFTER SWITCHING OFF THE POWER SUPPLY WAIT AT LEAST 5
MINUTES BEFORE STARTING WORK ON OR IN THE TECHNOVAR DRIVE HEAD.
Mounting the mounting plate on the HV 2.1-3.11
Place the heat sink of the Technovar on the mounting plate and fix them together by using the 4 self
threading M3x8mm respective M4x15mm screws (Picture 3).
Connecting the fan-cable
Remove the 3 screws holding the top cover of the Technovar and lift it carefully (picture 4).
NOTE: Take care with the connection cable to the display and the Ground-cable!
Left the cover aside.
Mount the included cable gland (Picture 2D/2E) on the cover plate and put the cable through the cable
gland. (Picture 7).
Connect the fan cable with the Molex connector (Picture 5) and then plug it into the right connection
on the control card (Picture 6).
NOTE: Take care of at the correct polarity: Red cable – plus pole
Black cable – minus pole
Fix the length of the cable inside the Technovar and tighten the cable gland to have ensure the IP55
class of protection.
17
Operating Instruction
Afterwards replace the top cover and be careful with the connection cable to the display and the
Earth-cable. At last fix the 3 screws of the top cover.
In Pictures 8 and 9 you can see the Technovar with the mounted wallmounting-kit.
Mark the 4 holes according to the dimension drawing (see next page) on the wall and drill it with a
drilling machine. Mount the whole Technovar unit on the wall by using suitable screws.
Dimension drawing (HV2.1-3.4) (inches)
Dimension drawing (HV3.5-3.11)
18
Operating Instruction
A
Wall mounting – kit 15/22kW
Included Components for wallmounted kit
4 long screw M6x25 Picture 1 A
4 washer Picture 1 B
4 short screw M6x12 Picture 1 C
4 washer Picture 1 D
1 AC-fan incl. connection cable Picture 2
1 fan board incl. 3 fuses T 1A/500V Picture 3 and 3 G
2 cable connector Picture 7
1 2 wire cable with connector Picture 7 and 8
1 cable gland for fan-cable Picture 12
1 wallmounted component Picture 13
Picture 1 Picture 2
B D
C
F
E
F
19
Operating Instruction
G
Picture 3 Picture 4
L3
L2
L1
Picture 5 Picture 6
L1
L2
L3
Picture 7 Picture 8
Picture 9 Picture 10
U2
V2
W2
20
Operating Instruction
Picture 11 Picture 12
12
Picture 13 Picture 14
Mounting the wallmounted kit on the Technovar
BEFORE REMOVING THE FREQUENCY INVERTER COVER THE SYSTEM MUST BE DIS-CONNECTED
FROM THE POWER SUPPLY. AFTER SWITCHING OFF THE POWER SUPPLY WAIT AT LEAST 5
MINUTES BEFORE STARTING WORK ON OR IN THE TECHNOVAR DRIVE HEAD.
Mounting the fan-board
Loosen the 4 main screws from the Technovar cover and also the 8 screws holding the
control-card.
Then remove the Technovar cover carefully. (Take care with the control-card and the GNDCable.)
Picture 3 shows you the fan-board (incl. the 3 fuses 1A/500V- picture 3/G) that you can fix
with the 3 plastic-distances in the 3 holes which are made for. (Picture 4)
The power supply for the fan-board comes from the connections L1, L2, L3 on the primaryside from the rectifier-board.
Please fasten the connection screw as well and connect the right cable with the right
connection
Compare the cable number and the connection number. (Picture 5).
Connecting the control-cable
21
Operating Instruction
Connect the included 2-wire.black cable with the fan-board (Picture 6) an take it upside to
the internal fan. Then place the cable beside the internal fan and fix it with the two cableconnectors which are shown in Picture 7.
Next put the cable through the hole at the front of the Technovar and pull it below the
control card at the bottom (Picture 8).
On the frontside of the control-card is an connector for plug in the control cable what you see
in Picture 9.
Mounting the fan on the Technovar
Place the Technovar at the AC-fan that you can see the LCD-Display at the front and the
pieces for the wallmounted component are on the side (Picture 11).
Then put the fan-cable through the hole and fix it with the included cable gland from picture
12. Look that the cable goes between the heat sink and isn´t fixed from it (Picture 12).
Connect the fan-cable at the connection clamps U2, V2, W2 on the fan board and screw the
GND-cable with the GND screw (Picture 10).
Next take the four long screws M6x25mm and the lock washers (see picture 1/A and B) and fix
the Technovar on the AC-fan with the nuts you can see in picture 2/E.
At least put the wall mounted component (Picture 13) behind the Technovar and fix this 2
components with the four short screws M6x12mm and the lock washers (see Picture 1/C and
D) what you see in picture 14.
!! PLEASE NOTE: The fan is only running with the TECHNOVAR (Run Signal).
Connect the fan cable so that the fan can blow from the carriersheed through the heat sink.
Dimension drawing
22
Operating Instruction
k
6.1.3 Mounting the thermistor
Variant A:
motor
thermistor
terminal bloc
rubber gasket
cover of the
conduit box
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 see chapter 6.2.
4. Electrical connection to the Technovar see chapter 6.2
23
Operating Instruction
6.2 Electric installation and wiring
6.2.1 Means of protection
Ask your power supply company which means of protection are required.
Applicable: AC and DC current-operated circuit breaker (FI), TN systems, protective
circuits.
When using a FI protection switch, make sure that it also releases in the event of
a DC fault, use for each Technovar a separate FI-switch!
6.2.2 Wiring the Technovar to the motor
Remove the 3 screws holding the top cover of the Technovar. Lift off the top carefully, take
off the connection cable to the display carefully remove the ground screw and left aside.
On the next page you can see:
(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
connections
24
Loading...