ITT HV 2.022, HV 4.055, HV 2.015, HV 4.040, HV 4.075 Operating Instructions Manual

...

HV 2.015 / 2.022 HV 4.022 / 4.033 / 4.040 HV 4.055 / 4.075 / 4.110

EN: ENGLISH Motor-mounted

DE: GERMAN-DEUTSCH Motormontage IT: ITALIANO Montaggio su motore FR: FRANÇAIS Montée sur moteur NL: NEDERLANDS Montage op de motor PT: PORTUGUÊS Montada em motor ES: ESPAÑOL Motor-Instalado

771079402 Manual HV 2.015-4.110-VL-A

Operating Instructions

HV 2.015 / 2.022 HV 4.022 / 4.033 / 4.040 HV 4.055 / 4.075 / 4.110

Motor-mounted

English

Index

1 Important safety instructions ................................................................................5

2 System Design........................................................................................................8

2.1 Pressure tank............................................................................................8

3 Product Overview...................................................................................................9

3.1 Hardware Configurations ........................................................................9

3.2 Operation Modes .....................................................................................9

3.2.1 Actuator (for single pump operation only!) ............................................................ 9

3.2.2 Controller................................................................................................................ 9

3.2.3 Cascade Relay ....................................................................................................... 10

3.2.4 Cascade Serial....................................................................................................... 11

4 Type designation code.........................................................................................13

5 Technical Data......................................................................................................14

5.1 General Technical Data ..........................................................................15

5.2 EMC (Electromagnetic compatibility) requirements .............................16

6 Dimensions and Weights .....................................................................................17

7 Modules ...............................................................................................................19

8 Mechanical Components .....................................................................................21

8.1 Included mounting material ..................................................................21

8.2 Optional Components............................................................................21

8.2.1 Fittings.................................................................................................................. 21

8.2.2 Sensors ................................................................................................................. 21

8.2.3 Filter ..................................................................................................................... 21

8.2.4 Ready-made Motor cables .................................................................................... 21

8.3 Assemble Instruction .............................................................................22

9 Electrical installation and wiring .........................................................................24

9.1 Means of protection ..............................................................................24

9.2 EMC-electromagnetic compatibility ......................................................25

9.3 Recommended Cable Types ...................................................................26

9.4 Wiring and connections .........................................................................27

9.4.1 Main Voltage Terminals ........................................................................................ 28

9.4.2 Motor connection................................................................................................. 29

9.4.3 Power Unit............................................................................................................ 30

9.4.3.1 Solo Run ................................................................................................ 31

9.4.3.2 Addressing............................................................................................. 33

9.4.4 Control Unit.......................................................................................................... 35

9.4.4.1 Control Card – HYDROVAR Master Inverter............................................ 35

9.4.4.2 Relay Card.............................................................................................. 42

9.4.4.3 Control Card – HYDROVAR Single Inverter ............................................. 44

10 Programming .......................................................................................................47

10.1 Display – Control panel of the Master / Single Inverter ........................47

10.2 Function of the push buttons................................................................47

10.3 Display of the Basic Inverter ..................................................................48

10.4 Software Parameters .............................................................................49

00 Main Menu ........................................................................................49

20 Submenu Status................................................................................54

40 Submenu Diagnostic .........................................................................57

60 Submenu Settings.............................................................................58

0100 Submenu Basic Settings .......................................................59

0200 Submenu Configuration Inverter..........................................62

0300 Submenu Regulation ............................................................68

0400 Submenu Sensor ...................................................................70

0500 Submenu Sequence Control .................................................73

0600 Submenu Errors ....................................................................78

0700 Submenu Outputs.................................................................79

0800 Submenu Required Values....................................................80

0900 Submenu Offset ...................................................................83

1000 Submenu Testrun .................................................................86

1100 Submenu Setups ..................................................................87

1200 Submenu RS485-Interface ....................................................88

11 Failure Messages ..................................................................................................89

11.1 Basic Inverter..........................................................................................90

11.2 Master / Single Inverter..........................................................................91

11.3 Internal Errors ........................................................................................94

12 Maintenance ........................................................................................................96

Follow the Pump Operating and Maintenance Instructions

We reserve the right to alter specifications

1 Important safety instructions

Read and follow the operating instructions and safety

instructions carefully before starting operations!

All modifications must be done by qualified technicians!

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 the instructions contained in 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 only be carried out by trained, skilled and qualified personnel. Unauthorized modifications or changes to the system make all guarantees null and void.

During operation, the motor can be stopped by open a digital input or manually operated, whereby the HYDROVAR and the motor remain under voltage. For safety reasons, the HYDROVAR has to be disconnected from the power supply when carrying out work on the machinery.

When the HYDROVAR is connected to power supply, the components of the power unit as well as certain components of the control unit are connected to the power supply.

Touching these components seriously endangers life!

Before removing the HYDROVAR cover the system must be disconnected from the power supply. After switching off the power supply wait at least 8 minutes before starting work on or in the HYDROVAR (the capacitors in the intermediate circuit are discharged by the installed discharge resistors).

Voltages of up to 800 volts are possible (in case of an error these also can be higher)

All work, carried out at opened HYDROVAR, may only be performed by qualified and authorized staff.

Furthermore, care must be taken not to short circuit the neighbouring components when connecting the external control wires and all cable ends which are not in use are isolated.

The HYDROVAR contains electronic safety devices which switch off the control element in the event of faults, whereby the motor has zero current but remains energised and comes to a halt. The motor can also be halted by mechanical blocking. If it is switched off electronically the motor is disconnected from the mains voltage through the electronics of the HYDROVAR but is not potential-free in the circuit.

In addition voltage fluctuations, especially power failures can cause the system to switch off itself. Repair of faults can cause the motor to start up again!

The system may only be put into operation when it has been grounded. In addition, equipotential bonding of all 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.

Transport, Handling, Storage, Disposal:

• Check the HYDROVAR immediately upon delivery/receipt of dispatch for damage or missing parts

• The HYDROVAR unit must be transported carefully and by competent personnel.

• Avoid serious impacts

NOTICE!

The use of the WEEE Symbol indicates that this product may not be 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, please contact your local authority, your household waste disposal service provider or the shop where you purchased the product.

CAUTION!

WARNING!

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.

• Do not stand underneath suspended loads

• take note of the general regulations on prevention of accidents

• The HYDROVAR must be secured against tipping over and slipping until

it has been fixed in its final location.

2 System Design

The following diagrams show typical single pump and multi-pump systems using the HYDROVAR control unit. Connection can be made directly to a water supply. In such a case, a pressure switch on the suction side should be used.

Single Pump Layout Multi Pump Layout

(1) pump with HYDROVAR (2) diaphragm tank (3) distribution panel

(4) gate valve (5) non return valve (6) low water control

(7) pressure gauge (8) pressure transmitter (9) drain tap

2.1 Pressure tank

A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure in the line when there is no demand. This will keep the pumps from continuing to run at zero demand. With the HYDROVAR, no large tanks are required for supply purposes. The tank must be permitted and suitable for systems pressure. The tank should have a capacity of min. 10% of the maximum system flow rate [l/min] of one pump (also valid for multi-pump system).

Example: Maximum flow rate of the pump = 250 litres per minute Minimum volume of the tank = 250 x 0.10 = 25 litres

The pre-charge pressure of the tank can be determined by using the following table:

required pressure (bar) (system pressure)

precharge pressure (bar) (air pressure)

NOTICE:

To check and set the right pre-charge pressure, please make the tank pressure less before.

3 Product Overview

3.1 Hardware Configurations

The HYDROVAR Modul Concept consists mechanically of two main parts, the Power Unit and the Control Card. In its basic configuration (consists only of the Power Unit) the HYDROVAR can be used as “Basic Inverter” without the need of the Control Card. In that form 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 by the implementation of different modules.

General Versions:

Basic Inverter – HYDROVAR in its simplest configuration, consists only of the power unit.

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 optional “Relay Card” and all special software features).

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 with this kind of configuration

Single Inverter – HYDROVAR with Control Card developed only for Single pump operation and less features in comparison with the Master Inverter. Additionally 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.

3.2.3 Cascade Relay

One pump is fitted with a HYDROVAR “Master Inverter” and up to 5 full speed slave pumps can be switched ON and OFF on demand. For this purpose an additional relay card with 5 relays is used in the “Master Inverter”. Each Relay can be activated or deactivated depending on how many pumps are connected. Basically an external panel is needed for all the motor relays, because the relays in the HYDROVAR can’t switch the pumps directly as they are just used as switch 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 would be a simple alternative compared with other solutions using VFD’s on each pump, but in any case care has to be taken due to the lower operating safety 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.

External panel

max. 5 fixed speed units

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-Format (fixed with 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 informed about the status and a possible failure of the “Basic Inverters” all the time. All possible failures will be indicated on the Master unit, including also the date and real time when the failure happened.

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 will be possible .

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 (extended 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 safety 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”

RS 485

connection

extended up to 8 pumps

To increase the operating safety of such a system, also a second “Master Inverter” could be used:

RS 485

connection

extended up to 8 pumps

Full-featured Possibility: Each pump is equipped with a “Master Inverter”

RS 485

connection

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 a lead pump. This ensures a proper operation if one “Master Inverter” fails, either another one is used to take the “full responsibility” and a steady control of the system. That ensures that the operating hours of each separate pump will be on the same level to ensure even wear of the pumps.

4 Type designation code

HV . - - - - - - - .

Software Version

A = Western Europe

B = Eastern Europe

C = Northern Europe

Hardware Version

Optional Components

Relay Card (0= without / R= included)

Display (0= without / 1= included)

EMC Protection Filter

A = A- Filter (industrial environment)

B = B- Filter (domestic environment)

Language

Optional Card

Bus Card

Enclosure Class (IP Class)

2= IP 21 5= IP 55

Hardware Configurations

M = Motor mounted Unit W = Wall mounted Unit

1= Basic Inverter 2= Single Inverter 3= Master Inverter

Rated Output

022= 2,2 kW 055= 5,5 kW 030= 3,0 kW 075= 7,5 kW

040= 4,0 kW 110= 11kW

Nominal mains voltage

1= 1~/1~ 230VAC 3= 3~/3~ 230VAC

2= 1~/3~ 230VAC 4= 3~/3~ 380-460VAC

Example

HV 4 . 0 4 0 - M 3 - 5 - B - 1 0 R 0 - G- A - V 0 1 . 1

The mentioned HYDROVAR in this example is specified with following technical data: Nominal mains voltage: 3~/3~

380-460VAC

Rated Output: 4 kW Hardware Configurations: Motor mounted unit - Master Inverter Enclosure Class: IP 55 EMC-filter: B - Filter (domestic environment) Optional Components: Display, Relay-Card Hardware Version: G Language: A: Western Europe (DE, EN, FR, NL, IT, ES, PT) Software Version: V01.1

5 Technical Data

HYDROVAR Power Supply

Type Rated

output

Voltage limits

48-62 Hz

Rated current

input

Recommended

line protection

Maximum

connection

HV [kW] [V] [A] [A] [mm²]

2.015 1,5 14,0 20

2.022 2,2

1~230 ± 15%

20,0 25

4.022 2,2 7,6 13

4.030 3 9,1 13

4.040 4

3~380-460 ± 15%

11,4 16

4.055 5,5 15,1 20

4.075 7,5 19,6 25

4.110 11

3~380-460 ± 15%

27,8 32

HYDROVAR Output to the motor

Type Rated

Output

Max. Voltage Output Rated Current

output

Motor connection cables

HV [kW] [V] [A] mm²

2.015 1,5 7

2.022 2,2

3~ Uin

4x1,5 – 4x4

4.022 2,2 5,7

4.030 3 7,3

4.040 4

3~ Uin

4x1,5 – 4x4

4.055 5,5 13,5

4.075 7,5 17

4.110 11

3~ Uin

4x2,5 – 4x6

Make sure that the HYDROVAR’s electrical data match those of the electric pump. Improper combinations may cause malfunctions and fail to ensure the protection of the electric motor.

The rated current of the motor must be lower than the rated current of the HYDROVAR to prevent overheating or shutdown due to “OVERLOAD”.

The max. output current of the HYDROVAR could reach 110% of the nominal current for max. 60 sec. before the error “OVERLOAD” will occur.

5.1 General Technical Data

Ambient temperature:

0° C ... +40°C At higher temperatures a reduction of the output current or the use of the next HYDROVAR type is necessary.

110

100

max. output current [%]

0 102030405060

max. ambient temperature [°C]

o Protect the HYDROVAR against direct sunlight! o Outdoor installation without protection of the

HYDROVAR is not permitted!

Storage temperature:

Humidity:

Air pollution:

Altitude:

Class of protection:

-25° .C ... +55° C (+70°C during max. 24 hours.)

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 / 4.033 / 4.040 IP 55, NEMA 4 (Indoor only) HV 4.055 / 4.075 / 4.110

Certifications:

CE, UL, C-Tick, cUL

5.2 EMC requirements (Electromagnetic compatibility)

The EMC requirements differ between two environments which depending on the intended use.

• First environment – class B (EN 61800-3: Class C2)

Environment that includes domestic premises, it also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes.

E.g. 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.

• 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 following standards: EN 61800-3/2005

EN 55011 (2002) Disturbance voltages / Disturbance field strength

First environment

– class B / class C2

Second Environment

– class A / class C3

Disturbance voltages OK OK Disturbance field stength *) 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

6 Dimensions and Weights

HV 2.015 / 2.022 HV 4.022 / 4.030 / 4.040

All dimensions in millimetres! Drawings are not in scale!

Lifting aids must have the proper dimensions.

Type Weight [kg]

Basic

Master/

Single

HV 2.015 HV 2.022 HV 4.022

4,00 4,40 HV 4.030 HV 4.040

a … minimum centre-distance between the HYDROVAR 300 [mm] b … expansion space for maintenance 110 [mm]

HV 4.055 / 4.075 / 4.110

All dimensions in millimetres! Drawings are not in scale!

Lifting aids must have the proper dimensions.

Type Weight [kg]

Basic

HV 4.055 HV 4.075

7,70 8,10

HV 4.110

a … minimum centre-distance between the HYDROVAR 430 [mm] b … expansion space for maintenance 110 [mm]

Master/

Single

1 2 3 6 1 2 3 5 4 6 5

7 Modules

Regarding to 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 operation safety and cost effectiveness for your specific application.

HV 4.022 / 4.033 / 4.040 HV 4.055 / 4.075 / 4.110

(1)

(2)

(3)

(4)

(5)

Relay Card

The optional Relay Card allows to control up to 5 fixed speed pumps (can be only used in combination with the Master Inverter).

Control Card

The control card is used for the Master/Single Inverter and includes the I/O’s for the digital and analogue signals (i.e. actual value input, run/fault relay output) and the Display unit.

Display Unit

Depending to the installation position the display can be turned to your prefered position! (The push-buttons will change automatically when turning the display!)

Filter Card

Optional Filter Card to ensure EMC regulations for domestic environments.

Mounting Kit

The Mounting Kit consists of the Metal and the Plastic Cover. On the Plastic Cover there are fixed the Control Card, the Display and also the additional Relay Card if used. 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.

(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!

8 Mechanical Components

8.1 Included mounting material

Included

components

M M M M M M 12 16 20 25 12 16

Cable

diameter

[mm]

2.015- 2.022 2 (3) 2 2 3 1 1 4 1 10

4.022- 4.040 2 (3) 2 2 3 1 1 4 1 10

4.055- 4.110 2 (3) 2 2 3 1 1 4 1 10 ( ) max. available cable entries

3,5-7 4,5-10 7-13 9-17

Cable gland Closing gland Motor PTC Mounting

clamps

Center-

piece

Terminals

for max.

[mm²]

8.2 Optional Components

8.2.1 Fittings

Mounting ring

Available for the diameters: 140 mm 155 mm

Mounting ring

CAUTION!

If the HYDROVAR is mounted on a motor with plastic fan cover, a stainlesssteel mounting ring must be used.

8.2.2 Sensors

• pressure-transducer • temperature-sensor

• differential-pressure-transducer • flow indicator

• level-sensor

(orifice plate, inductive flow meter)

8.2.3 Filter

• Line-coils

8.2.4 Ready-made Motor cables

Available for HV 2.015 – 4.110

8.3 Assemble Instruction

HV 2.015 – HV 4.110

4 Screws M5x60

4 screws (to fix the cover)

HYDROVAR - cover

Display

Centre bit

4 Mounting clamps

Motor fan cover

Motor

Motorcable

Motor conduit box

PTC

Pressure transmitter

To remove the HYDROVAR – cover, the 4 fastening screws must be opened.

o Ensure that there is no water on the unit before you open the cover.

• The HYDROVAR has to be positioned on the motor fan cover (check if the mounting of the motor fan cover is done properly).

• Try to centre it as good as possible using the rubber centre bit.

If the HYDROVAR is mounted on a motor with plastic fan cover, a stainless steel mounting ring must be used.

• The HYDROVAR is installed on the motor fan cover by using the mounting brackets, the four screws and the related washers.

• The HYDROVAR has to be centred and then the four screws must be tightened.

• Tighten each fastening screw until the two bottom teeth in the brackets start to grip the

fan cover.

• After the electrical components are connected, the top cover on the HYDROVAR can be mounted and tightened by the four fastening screws.

o Make sure of a good connection of the ground wire. o Control the gasket of the HYDROVAR before tighten the fastening screws. o Ensure that the mounting of the cable glands is done properly and use closing

glands for cable-bushings which aren’t used.

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 8 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:

• protective earthing

• AC and DC residual current operated protective devices (RCD)

• TN systems

Protective earthing:

• 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):

• 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 => use pulse sensitive RCDs o three phase HYDROVAR => use AC/DC sensitive RCDs

• The RCD has to be installed according local regulations!

Automatic circuit breaker:

• Use automatic circuit breaker with C-type characteristic curve

• Rating of the line-protection (see chapter Technical Data)

Internal protective devices of the HYDROVAR:

• 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:

• Additional protective functions like motor overheat and low water protection, are controlled by external equipment.

9.2 EMC-electromagnetic compatibility

To ensure the electromagnetic compatibility the following points must be observed for cable installation:

Earth / ground to ensure EMC

• Protection earth

It is important to connect the HYDROVAR to PE, because of the earth leakage current.

• HF earth connection

Ground cables should be as short as possible and with lowest impedance.

Signal cables

Control and signal cables should be screened types to prevent disturbances from outside.

The screen should be only connected to ground on one side; otherwise it is possible that the screen has a ground current. The screen should be extensively connected with cableclips 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°.

Motor cables

To ensure the EMC compatibility and minimize noise level and leakage currents, keep the motor cable as short as possible.

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.

Advantages:

• better efficiency

• reduction of harmonic currents

For the following applications additional line chokes are strongly recommended:

• high short circuit currents

• compensation-plants without a coil

• asynchronous motors which are responsible for a voltage drop >20% 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 only one end of the screen of a signal-cable to ground

• If screened motor-cables are used, both ends of the screen have to be connected 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 HV 4.022-4.040

HV 4.055-4.075 HV 4.110

- Control- and Signal- Cables

4G1,5 + (2 x 0.75) FDF 4G1,5 + (2 x 0,75) FDF 4G2,5 + (2 x 0,75) FDF 4G 4 + (2 x 0,75) FDF JE-Y(ST)Y … BD JE-LiYCY … BD

- Cables connected to RS485 interface JE-Y(ST)Y 2 x 2 x 0,8 BD

B C

F C E

A B

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 / 4.033 / 4.040

(A) Power supply (D) Status-Relays (F) Terminal block:

- START/STOP_PTC

(B) Motor connections (E) RS-485 Interface - SOLORUN

- User Interface - RS-485 Interface

HV 4.055 / 4.075 / 4.110

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 HV 4.022 / 4.033 / 4.040

L1-N

L1-L2-L3

3x400 VAC

1x230 VAC

Power Supply

HV 4.055 / 4.075 / 4.110

Motor Connection

U-V-W

(Crimp connection 6,3mm)

Power Supply

L1-L2-L3

3x400 VAC

Motor

Connection

U-V-W

Y D R O

9.4.2 Motor connection

Mounting of the PTC

Variant A : Variant B :

Motor block

PTC

Terminal block

Rubber gasket

Cover of the

1. The cover of the conduit box must be opened and the terminal block inside removed

2. Fix the PTC (Variant A or B)

3. Remounting of the terminal block

4. Electrical connection of the motor cables

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

H Y D R O V A

U V W

V A

U V

PTC

9.4.3 Power Unit

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 terminalblocks.

HV 2.015/2.022 HV 4.022 / 4.033 / 4.040

HV 4.055 / 4.075 / 4.110

X1 Control Terminals – Power Unit

PTC PTC or Thermal switch

START/STOP (external release) when using a Basic Inverter

SL SOLO RUN

SOLO RUN

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.

9.4.3.1 Solo Run

The Terminals X1/SL are used to release a Basic Inverter (when used in 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.

• At opened contact X1/SL the HYDROVAR works in standard operation. So a Basic Inverter only starts up, if it is released and requested by a Master Inverter via the serial RS485Interface.

• 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

SOLO RUN

for example:

External release or Low water switch

PTC or Thermo-switch

(mounted in the motor terminal box)

Recommended connections of external protective devices:

Basic Inverter:

External release X1/PTC

PTC or Thermal switch X1/PTC

Placed on the Power Unit

Low water switch X1/PTC

Master Inverter:

External release X3/7-8 Low water switch X3/11-12

PTC or Thermal switch X1/PTC Placed on the Power Unit

Placed on the Control Card

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 HYDROVAR in the system. (Be careful: Internal Interface is not active for Single Inverter configuration!)

X2 RS485-Interface – Power Unit

X2/

SIO SIO + GND

Internal SIO-Interface: SIOInternal SIO-Interface: SIO+ GND, electronic ground

Internal Interface for multi-pump-systems

……. Parameter not available for a 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.

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

- remove the screwdriver to fix the wire

- To remove, push down the orange wedges and pull out the wire!

Connection example using one Master- and three Basic - Inverters:

9.4.3.2 Addressing

When using the Cascade Serial Mode in a Multi-pump-application where more than one Master Inverters, 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 HYDROVAR-Software. So 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

• Set Address 1-3 for the Master Inverters via appropriate Software Parameters (See Submenu RS485-INTERFACE [1200])

• Address 4-7 for the Basic Inverters via Dip-Switch

The pre-selected Address is also responsible for the pump sequence.

Switch 1 Switch 2 Switch

OFF OFF OFF

Address 1 (Default Setting)

(Required setting for the use with Control Card)

OFF OFF ON Address 2 OFF ON OFF Address 3 OFF ON ON Address 4

ON OFF OFF Address 5 ON OFF ON Address 6 ON ON OFF Address 7 ON ON ON Address 8

Address

Switch 4 is not used!

Setting of the correct Address:

o The HYDROVAR must be disconnected from power supply at least for 8 minutes

before removing the top-cover (open four fastening screws)!

o 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 -> 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 4.022 / 4.033 / 4.040

HV 4.055 / 4.075 / 4.110

Basic Inverter Basic Inverter

Dip-switch

9.4.4 Control Unit

Regarding the Hardware configuration of your HYDROVAR there are available two different Control Cards.

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 also 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 with a ribbon cable on terminal X8.

• The display is connected to terminal X9 (the connection depends to the installation position).

• The connection terminals X6 and X7 can be used if optional boards are available. e.g. The additional Relay Card can be connected to the Control Card at connection slot X6.

X5- Status- Relays

X3- Digital / Analogue –I /O

X4- RS485 - Terminal

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 interfere the incoming signals and the function of the HYDROVAR.

Don’t connect the ground of the Control Card to different voltage potentials. All electronic ground terminals and GND of the RS 485-interface are connected internally.

X3 Digital and Analogue I/O

X3/

GND, electronic ground

Actual value current input Sensor 1

Power supply for external sensors

Actual value current input Sensor 2

Actual value voltage input Sensor 2

Actual value voltage input Sensor 1

External ON/OFF (release)

GND, electronic ground

Configurable Digital Input 1

GND, electronic ground

Low water

GND, electronic ground

0-20mA / 4-20mA [Ri=50Ω] 24VDC, ** max. 100mA 0-20mA / 4-20mA [Ri=50Ω] *Dig 3 0-10 VDC *Dig 2 0-10 VDC Active Low

Dig 1 Active Low

Active Low

Voltage signal input (Required Value 1)

GND, electronic ground

Voltage signal input (Required Value 2)

GND, electronic ground

Current signal input (Required Value 1)

+10V Internal Ref. for Analogue Output

Analogue Output 1

Analogue Output 2

GND, electronic ground

Current signal input (Required Value 2)

+24V Power supply for control inputs

(Offset) 0-10VDC (Offset) *Dig 4 0-10VDC (Offset) (Offset) (Offset) 0-20mA / 4-20mA [Ri=50Ω] 10,00VDC, max. 3mA 0-10VDC, max. 2mA 4-20mA [Ri=50Ω] (Offset) (Offset) 0-20mA / 4-20mA [Ri=50Ω] 24VDC, ** max. 100mA

* Terminals 5 and 6 can be used as actual value voltage input and even as

Digital Input without any additional configuration.

Also the voltage signal input on terminal X3/15 can be used as Digital Input. ** X3/3 and X3/24 – 24VDC and ∑ max. 100mA (Offset) These terminals could be used as Required Value and Offset Signal Input.

The configuration could be done in Submenu REQUIRED VALUES [0800] and Submenu OFFSET [0900].

Additional Power supply ** max. 100 mA

Current signal input (Required Val. 2) 0-20mA / 4-20mA

[Ri=50Ω] To determine the required value or the offset

Analogue Output 2 4-20mA [Ri=500Ω]

Analogue Output 1 0-10 VDC

Current signal input (Required Val. 1) 0-20mA / 4-20mA

[Ri=50Ω] To determine the required value or the offset

Voltage signal input (Required Value 2) 0-10 VDC *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 Digital 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 0-20mA / 4-20mA [Ri=50Ω]

Sensor supply ** max. 100 mA Actual-value-current input Sensor 1

0-20mA / 4-20mA [Ri=50Ω]

Ground

* Terminals X3/5 and 6 can be used as actual value voltage input and even as Digital Input without any

additional configuration. Also the voltage signal input on terminal X3/15 can be used as Digital Input.

** X3/3 and X3/24 – 24VDC and ∑ max. 100mA

Connection examples:

• Sensor–Actual-value-signal Input

Connection of a 2-wire transducer

(e.g. standard pressure transducer PA22)

Connection of an active actual-value-signal

Possible connections:

Standard Pressure Transducer PA22:

Actual-value-signal input 0/4-20mA: X3/4 … Sensor 2 +24VDC Sensor Supply: X3/3 brown Actual-value-signal input 0/4-20mA: X3/2 … Sensor 1 white Ground: X3/1

• Switching between two connected sensors

Manual switching between two connected Sensors by closing Digital Input 1 (X3/9-10). How to program see SUBMENU SENSORS [0400].

Digital Input 1

• Switching between two different required values

Manual switching between two connected required value signals (e.g.:1voltage and 1 current signal input) by closing Digital Input 1 (X3/9-10).

In ACTUATOR Mode it is possible to switch between two different frequencies by the Digital Inputs. The connected input signals (current or voltage) are proportional to the frequency.

How to program see SUBMENU REQUIRED VALUES [0800].

Digital Input 1

Required Value 1

- external current signal

Required Value 2

- external voltage signal

• Actual value – Frequency Indicator

e.g. to display the actual motor frequency How to program see SUBMENU OUTPUTS [0700].

Possible connections: Analogue Output 1 (0-10V): X3/20 Analogue Output 2 (4-20mA): X3/21

X4 RS485-Interface

User SIO-Interface: SIO-

X4/

User SIO-Interface: SIO+

2 3 GND, electronic ground

Internal SIO-Interface: SIO-

Internal SIO-Interface: SIO+

5 6 GND, electronic ground

User Interface for external usage

Internal Interface for multi-pump-systems

RS-485 – Internal Interface RS-485 - User Interface

The internal RS-485 Interface is used for the communication between up to 8 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 even the terminals X2/1-3 on the power unit can be used. (Connection example: using one Master- and three Basic -

Inverters.)

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 parameterising 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!

X5 Status-Relays

X5/

1 2 3 4 5 6

Status Relay 1

Status Relay 2

CC NC NO CC NC NO

[Max. 250VAC] [Max. 220VDC] [Max. 30VDC]

[0,25A general use] [0,25A general use] [2A general use]

Status Relay 1 Status Relay 2

Please Note:

When using the relay contacts for driving an external relay, a corresponding RC-snubber-circuit is recommended, to prevent disturbances arising during a switching action of the relay!

Both Status-Relays on the Control Card can be used regarding the programmed configuration.

Depending to the programming, both relays can be used to indicate the current status and failure messages of the HYDROVAR. For example 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

X5/ 1 and 3 closed:

- motor run indication

Ext. 250VAC / 220VDC

X5/ 4 and 5 closed:

- if there is a Fault/Error

- if the supply of the HYDROVAR is cut off

9.4.4.2 Relay Card

Optional Component can be used only in combination with a HYDROVAR Master Inverter.

The Relay Card is connected to the Control Card using connection slot X6 (See chapter 9.4.4.1).

Terminal Block

Please Note:

When using the relay contacts for switching external contactors, a corresponding RC-snubber-

circuit is recommended, to prevent disturbances

Connector to Control Card

arising during a switching action of the relay!

Terminals Relay Card

X10 Relay Card

X10/

Relay 1

Relay 2 [Max. 250VAC] [1A general use]

Relay 3

Relay 4 [Max. 30VDC] [1A general use]

Relay 5

COMMON

COM Relay 5

Contacts for switching the fixed speed pumps.

Relay 4 Relay 3 Relay 2 Relay 1

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).

Connection example:

The following wiring diagram shows a standard cascade control system where the HYDROVAR is fitted with an additional Relay card, in selected mode “Cascade Relay”.

To switch the fixed speed pumps via the internal relay card, an external panel for the contactors of the D.O.L or STAR/DELTA starters (and optional A/0/M – switch) is required.

In the example below 3 fixed speed pumps (motors) are connected to the Relay Card. For such an application, an optional HAND/OFF/AUTO switch (SW1, SW2, SW3) is recommended.

- During normal operation the switch is set to AUTO, so the Relay Card of the HYDROVAR would start and stop the follow-up 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.

9.4.4.3 Control Card – HYDROVAR Single Inverter

The Control Card is connected to the power unit with a ribbon cable on terminal X8.

• The display is connected to terminal X9

(The connection depends to the installation position).

X5- Status- Relays

X3- Digital / Analogue –I /O RS485 - Terminal

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 interfere the incoming signals and the function of the HYDROVAR.

Don’t connect the ground of the Control Card to different voltage potentials. All electronic ground terminals and GND of the RS 485-interface are connected internally.

X3 Digital and Analogue I/O

X3/

Actual value input Sensor 1

Power supply for external sensors

User SIO-Interface: SIO-

User SIO-Interface: SIO+

0-10VDC or 0-20mA / 4-20mA [Ri=50Ω] 24VDC, max. 50mA

User Interface for external usage

GND, electronic ground

6 GND, electronic ground

External ON/OFF (release)

GND, electronic ground

Configurable Digital Input 1

GND, electronic ground

Low water

GND, electronic ground

Active Low

Low water

e.g. incoming pressure switch or water level switch

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. 50 mA Actual-value input Sensor 1

0-10V or 0-20mA / 4-20mA [Ri=50Ω]

Ground

X5 Status-Relays

X5/

1 2 3 4 5 6

Status Relay 1

Status Relay 2

CC NC NO CC NC NO

[Max. 250VAC] [Max. 220VDC] [Max. 30VDC]

[0,25A general use] [0,25A general use] [2A general use]

Status Relay 1 Status Relay 2

Please Note:

When using the relay contacts for driving an external relay, a corresponding RC-snubber-circuit is recommended, to prevent disturbances arising during a switching action of the relay!

Both Status-Relays on the Control Card can be used regarding the programmed configuration.

Connection examples:

Pump running signal Fault signal

X5/ 1 and 3 closed:

- motor run indication

Ext. 250VAC / 220VDC

X5/ 4 and 5 closed:

- if there is a Fault/Error

- if the supply of the HYDROVAR is cut off

Ext. 250VAC

220VDC

10 Programming

10.1 Display – Control panel of the Master / Single Inverter

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!

Power

10.2 Function of the push buttons

Run

Fault

▲ Start of the HYDROVAR in the 1st Window ▼ Stop of the HYDROVAR in the 1st Window

◄ and ► Reset: by pressing of both buttons simultaneously for about 5 seconds

Increase of a value / selection of the submenu

▲ ▼ Decrease of a value / selection of the submenu ▲ + short ▼ Change to faster scrolling up of a value ▼ + short ▲ Change to faster scrolling down of a value

► Short pressing: Enter Submenu / Change to next parameter in the menu ◄ Short pressing: Leave Submenu / Change to previous parameter in the menu

►

Long Pressing: Acknowledgement of an determined action

◄ Long Pressing: Change back to the main menu

10.3 Display of the Basic Inverter

Status LED - green

Constant Motor stopped (Standby) Blinking Motor run

Error LED - red

The Type of shown error which occurred 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 concerning the possible reason and how to reset each error, see chapter 11 Failure Messages.

10.4 Software Parameters

In the following chapters all available parameters of the secondary menu are listed. On the Index window there is shown the factory setting and in 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:

……. Parameter not available for a HYDROVAR Single Inverter

NOTICE! All changes will be saved automatically in case of a disconnection of the

power supply!

00 MAIN MENU

The 1st 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 X.XX Bar

1st display at Mode Controller

This window shows the status of the HYDROVAR.

ON Manually and external released

STOP Manually stopped

OFF External release (X3/7-8) is open

Stop of the HYDROVAR by pressing ▼

Start of the HYDROVAR by pressing ▲

To start up the HYDROVAR close external release or bridge terminal X3/7-8

b) Active MODE [0105] = Cascade Relay / Cascade Serial

* ADR X PX XX.X Hz

STOP X.XX Bar

1st display at Mode Cascade Serial and Cascade Relay

This window shows the status of the HYDROVAR.

ADR X Pump address

Cascade Relay Mode: Indicates the number of pumps which are running

P X

Cascade Serial Mode: Indicates the sequence of the pumps in the system,

e.g.: P3 …. Master + 2 fixed speed pumps are running

depending on the MASTER PRIORITY [0570] and SWITCH INTERVAL [0555]

* Indicates the Regulation Master

ON Manually and external released

STOP Manually stopped

OFF External release (X3/7-8) is open

Stop of the HYDROVAR by pressing ▼

Start of the HYDROVAR by pressing ▲

To start up the HYDROVAR close external release or bridge terminal X3/7-8

Valid for MODE – Controller / Cascade Relay / Cascade Serial

02 REQUIRED VAL

D1 X.XX Bar

Set the desired required value with ▲ or ▼

The current REQUIRED VALUE and its source (by the additional information) is shown in this window.

D1 Internal - Required Value 1 (pre-selection with Parameter 0820) D2 Internal - Required Value 2 (pre-selection with Parameter 0825) U1 Voltage Signal Input - Required Value 1 (Connected to X3/13) U2 Voltage Signal Input - Required Value 2 (Connected to X3/15) I1 Current Signal Input – Required Value 1 (Connected to X3/18) I2 Current Signal Input – Required Value 2 (Connected to X3/23)

03 EFF REQ VAL D1 X.XX Bar

Effective Required Value

Shows the current required values which is calculated regarding to ACTUAL VALUE INCREASE [0505], ACTUAL VALUE DECREASE [0510] and LIFT AMOUNT [0330]. Even if the required value is recalculated by an offset signal (SUBMENU OFFSET [9000]) 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

-> 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

STOP X.XX Bar

1st 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 and is equivalent to Parameter 0835.

By using the following two parameters it is possible to run the HYDROVAR with the two pre-selected frequencies for manual control of the HYDROVAR.

02 ACTUAT.FRQ. 1

XX.X Hz

Set the desired frequency with either ▲ or ▼

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 the ACTUATOR FREQUENCY 1 is selected via digital input.

03 ACTUAT.FRQ. 2

XX.X Hz

Set the desired frequency with either ▲ or ▼

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.

For detailed information how to run the HYDROVAR by manual control, see Submenu REQUIRED VALUES [0800].

Non –valid for Mode - Actuator

04 START VALUE

OFF

Regulation Restart Value

Possible settings: 0 – 100 % – OFF This parameter determines the start value after pump stop in percentage of the required

value. e.g. REQUIRED VALUE [02]: 5.0 bar START VALUE [04]: 80 % --> 4.0 bar

If the pump system has reached the required pressure of 5.0 bar and there is no more consumption, the HYDROVAR shuts off the pump. When the consumption increases, and the pressure drops the pump normally starts. If a START VALUE [04] of 4.0 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

ENGLISH

Language selection

Possible settings: To select the desired language press ▲ or ▼

The information on the display and all parameters can be called up in various languages. The languages available are split in different blocks which support different languages.

Which of the available region block is included in your HYDROVAR could be seen in the Type designation code. For detailed information see chapter 4.

With the following two parameters the current date and time, has to be set. That is necessary to save and display failure messages with the accurate date and time when the failure happened.

06 DATE

DD.MM.YYYY

Current Date

Set the date by pressing ► for approx. 3 sec.

After Pressing ► you will enter a Submenu where the current DAY / MONTH / and YEAR can be set.

07 TIME

HH:MM

Current Time

Set the time by pressing ► for approx. 3 sec.

Enter the submenu by pressing ► to set current HOUR and MINUTE.

08 AUTO - START

Auto Start

Possible settings: ON – OFF

Select ON with ▲ or OFF with the ▼ 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 ▲ to restart the HYDROVAR.

09 OPERAT. TIME

0000 h.

Operating Hours

Total time the HYDROVAR is being connected to the power supply. How to reset see Parameter CLR OPERAT. [1135].

20 SUBMENU

STATUS

Status of all units in a pump group

Using this submenu it is possible to check the status (including failures and motor hours) of all connected units.

21 STATUS UNITs

00000000

Status of all Units

This parameter gives a quick overview beyond 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 fitted with additional relay card) the status of the

5 Relay- switching contacts is shown.

e.g. Mode – Cascade Serial

21 STATUS UNITs

11001000

Unit 1, 2 and 5 are running

e.g. Mode – Cascade Relay

21 STATUS UNITs

10100 - - -

Relay Contact 1 and 3 are closed

22 SELECT DEVICE

* 1 *

Select device

Possible settings: 01-08

If you would like to check the following parameters which show the current status, the

motor hours and the last failures which occurred, you have to select the desired unit which should be checked. Regarding to the selected MODE [0105] the desired unit can be chosen:

Mode CASCADE SERIAL:

The number of the device depends to the pre-selected Address. e.g. Device 01 -> Master Inverter with pre-selected Address 1 Device 02 -> Basic Inverter with pre-selected Address 2 Device 03 -> Basic Inverter with pre-selected Address 3

For selecting desired address on a Basic Inverter, see chapter 9.4.3.2 Addressing. To set the address on a Master Inverter, see Submenu 1200 RS485-Interface.

Mode CASCADE RELAY:

Device enabled by

01 Master Inverter 02 fixed speed pump Relay 1 X10 / 1 03 fixed speed pump Relay 2 X10 /2 04 fixed speed pump Relay 3 X10 /3 05 fixed speed pump Relay 4 X10 /4 06 fixed speed pump Relay 5 X10 /5 07 not used 08 not used

23 STATUS DEVICE

Stopped

Status of the selected device

Readable: Running, Stopped, Disabled, OFF (Mode: Cascade Serial) relay on, relay off (Mode: Cascade Relay) Preparing, Solorun, Faulted

Shows the status of the individual device in the system

Mode CASCADE RELAY:

relay on -> Relay contact is closed -> fixed-speed-pump is running relay off -> Relay contact is opened -> fixed-speed-pump is stopped

Mode CASCADE SERIAL:

Running -> Pump is running Stopped -> Pump is stopped, because there is no request Disabled -> Pump is stopped manually

(Stopped with buttons or disabled with Parameter ENABLE DEVICE [24])

or by external device (external on/off contact open)

OFF -> Pump is not connected to power supply Pump is not connected via RS485 interface

Preparing -> A new unit is connected to the multi-pump system at the moment and prepeares the required data Solorun -> Solorun is activated (X1/SL closed) Faulted -> A Failure occurred on the current unit

24 ENABLE DEVICE

Enable

Enable – Disable of the selected device

Possible settings: Enable - Disable

The selected Device can be enabled or disabled manually. (Even in Cascade Relay and Cascade Serial Mode).

25 MOTOR HOURS

XXXX h

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

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

ERROR XX

Latest error happened on selected device