Nastec VASCO Operating Manual

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VAriable Speed COntroller

Operating manual

VASCO

manVASCO_eng_05.docx

Index

1. VASCO Introduction ........................................................................................................................................................... 3

2. Safety Instructions ............................................................................................................................................................. 3

3. Technical Characteristics ................................................................................................................................................... 4

3.1 Weight and dimensions .......................................................................................................................................................... 4

4. Electric wiring .................................................................................................................................................................... 5

4.1 Protections ............................................................................................................................................................................... 9

4.2 Electromagnetic compliance .................................................................................................................................................... 9

4.3 Installation with long motor cables ......................................................................................................................................... 9

5. VASCO installation ............................................................................................................................................................10

5. VASCO Installation for constant pressure control ................................................................................................................... 12

5.1.1 Pressure tank .............................................................................................................................................................. 12

5.1.2 Pressure sensor ........................................................................................................................................................... 12

6. VASCO Use and Programming ..........................................................................................................................................13

6.1 VASCO display ....................................................................................................................................................................... 13

6.2 Initial configuration ............................................................................................................................................................... 13

6.3 Initial view ............................................................................................................................................................................. 15

6.4 Menu view............................................................................................................................................................................. 16

6.5 Installer parameters .............................................................................................................................................................. 16

6.6 Advanced parameters ............................................................................................................................................................ 21

7. Protections and alarms .....................................................................................................................................................24

8. Minimum stop frequency at 0 delivery (f min Q=0) during constant pressure control. .....................................................26

9. Auxiliary pumps during constant pressure control ...........................................................................................................26

9.1 DOL pumps ............................................................................................................................................................................ 27

9.2 COMBO function .................................................................................................................................................................... 28

10. Trouble-shooting chart ...................................................................................................................................................30

11. Technical Assistance .......................................................................................................................................................32

1. VASCO Introduction

VASCO is a variable frequency drive designed to control and protect pumping systems by varying the output frequency to the pump. VASCO can be applied to both new and existing pumping systems, and provides:

 energy and cost savings  simplified installation and an overall lower pumping system cost  longer life of the pumping system and relevant components  improved reliability

VASCO, when connected to any pump, manages the system operation to maintain a certain constant physical quantity (pressure, differential pressure, flow, temperature, etc.) regardless of the conditions of use. The pump is operated only when needed thus avoiding unnecessary energy consumption. VASCO at the same time is able to:

 protect the motor from overload and dry running  implement soft start and soft stop to increase the system life and reduce current peaks  provide an indication of current consumption, voltage, and power  maintain a record of run time and display any errors and/or failures reported by the system  control up to two additional pumps at a constant speed (Direct On Line)  connect to other VASCO units for combined operation

Through the use of inductive filters (optional) VASCO eliminates dangerous surges that are induced in long cables, making VASCO suitable for control of submersible pumps.

2. Safety Instructions

The manufacturer strongly suggests carefully reading this operation manual before using and installing its products Any operation (installation, maintenance and repair) must be carried out by trained, skilled, and qualified personnel. Failure to observe and follow the instructions in this manual may result in dangerous and potentially lethal electric shock. Pay attention to all standard safety and accident prevention regulations

The device must be connected to main power supply via a switch to ensure the complete disconnection from the network before any operation on the VASCO itself (including visual inspection) and/or on the connected load.

Disconnect VASCO from the main power supply before commencing any work.

Do not remove, for any reason, the cover and the cable plate without having first disconnected the device from the main power supply and having waited at least 5 minutes.

VASCO and pumping system must be grounded properly before operation. For the entire period VASCO is powered, high voltage is present on the output terminals of the inverter whether or not the pump is running.

Tightening all 4 screws on the cover with washers is recommended before powering the device. Otherwise, there may be a failure to connect the cover to ground, creating the risk of electric shock or even death.

Avoid any shock or significant impact during transport.

Check the VASCO immediately upon delivery and check for damage and/or missing parts. If either occurs, immediately notify the supplier.

Damages due to transport, incorrect installation, or improper use of the device will null and void the warranty.

Tampering or disassembly of any component will automatically void the warranty.

The manufacturer cannot be held responsible for any damages to people and/or property due to improper use of its products.

3. Technical Characteristics

Model

Vin +/- 15%

Max

Vout

Max line

current

Max

motor

current

Typical P2 motor

[V] AC

[V]

[A]

[KW]

[HP]

VASCO 209

1 x 230 VAC

1 x Vin

1.1

1.5

3 x Vin

1.5

VASCO 214

1 x 230 VAC

1 x Vin

1.1

1.5

3 x Vin

11 3 4

VASCO 406

3 x 380-460 VAC

3 x Vin

2,2

VASCO 409

3 x 380-460 VAC

3 x Vin

13,5

9 4 5,5

VASCO 414

3 x 380-460 VAC

3 x Vin

5,5

7,5

VASCO 418

3 x 380-460 VAC

3 x Vin

7,5

VASCO 425

3 x 380-460 VAC

3 x Vin

VASCO 430

3 x 380-460 VAC

3 x Vin

 Power frequency: 50 - 60 Hz (+/- 2%)  Max. ambient temperature at nominal current: 40°C (104 °F)  Max. altitude at nominal current: 1000 m  Grade of protection: IP55 (NEMA 4) *  RS485 serial communication

 PWM configurable: 2.5 ,4, 6, 8, 10 kHz

* auxiliary cooling fan of the VASCO, used in wall mounted applications, has a protection rating of IP20. If you require the version with IP55, please

contact the supplier.

VASCO is able to power the motor with a higher current for a short period of time according to the linear relation: 101% of the nominal current for 10min., 110% nominal current for 1 min.

3.1 Weight and dimensions

Model

Weight *

[Kg]

VASCO 209

VASCO 214

4,3

VASCO 406

4,4

VASCO 409

4,4

VASCO 414

VASCO 418

VASCO 425

VASCO 430

7,2

* Weight without auxiliary cooling fans and without packing.

4. Electric wiring

Power board VASCO 209,214

Power supply: LINE: L1, L2, earth It is recommended to use cable lugs

Output:

3 ph motor: earth ,U,V,W, 1 ph motor: earth, U (running), V (common)

It is recommended to use cable lugs.

230 V AC auxiliary fans (wall mounting kit)

FAN: F1, F2

Recommended line and motor cables stripping

Power board VASCO 406,409

Power supply:

LINE: GND , L1, L2, L3,

It is recommended to use cable lugs.

Motor output:

MOTOR: U, V, W, GND

It is recommended to use cable lugs.

12 V dc auxiliary fan (wall mounting kit) :

0VE, + VE WARNING: respect the polarity.

Cable stripping recommended for line input and output to the motor.

Power board VASCO 414,418,425,430

Power supply:

LINE: L1, L2, L3, GND

It is recommended to use cable lugs.

Motor output:

MOTOR: U, V, W, GND

It is recommended to use cable lugs.

12 V dc auxiliary fans (wall mounting kit)

VENT: +, WARNING: respect the polarity.

Cable stripping recommended for line input and output to the motor.

Control board

Analog inputs (10 or 15 Vdc):

1. AN1: 4-20 mA: pressure sensor

2. AN2: 4-20 mA: auxiliary

pressure sensor

3. AN3: 4-20 mA / 0 - 10 Vdc

(settable by jumper C.C.): flow sensor or temperature sensor

4. AN4: 4-20 mA / 0 - 10 Vdc

(settable by C.C.): trimmer for frequency regulation

Digital outputs:

 motor run signal:

NO1, COM1: closed contact with motor running. NC1,COM1: closed contact with motor stopped.

 alarm signal

NO2,COM2: opened contact without alarm. NC2,COM2: closed contact without alarm.

 DOL1 pump relay:

NO3,COM3: closed contact with DOL1 running. NC3,COM3: opened contact with DOL1 running.

 DOL2 pump relay:

NO4,COM4: closed contact with DOL2 running. NC4,COM4: opened contact with DOL2 running.

Relays are no voltage contacts. Max. voltage to the contacts is 250 V with max current of 5 A.

RS485:

 S+  S-  G

It is recommended to respect the polarity linking more VASCOs in series.

Digital inputs:

 IN1  IN2  IN3  IN4  0V

We recommend using only no voltage contacts. Opening or closing the digital

contacts (depending on software configuration set (see inst. parameters) you can start or stop the motor.

4.1 Protections

The protections required upstream each VASCOs depends on the type of installation, and local regulations. We recommend to use overload protection with the characteristic curve of type C and type B circuit breaker, sensitive to both AC and DC current.

4.2 Electromagnetic compliance

To ensure electromagnetic compatibility (EMC) of the system, it is necessary to apply the following measures:

 Always connect the device to ground  Use shielded signal cables by placing the screen at one end.  Use motor cable as short as possible (<1 m / <3 ft). For longer lengths, it is recommended to use shielded cables

connecting the screen at both ends.

 Separate signal, motor, and power supply cables.

Note: To enable the restoration of the display screen when there are electromagnetic interference, VASCO periodically provides some fast "refresh" of the display.

4.3 Installation with long motor cables

With long motor cables it’s recommended to decrease the

commutation frequency from 10 kHz (default) to 2.5 kHz (advanced parameters). This reduces the probability of voltage spikes in the motor windings which may damage the insulation.

For motor cable lengths up to 50 meters it’s recommended

to place between VASCO and motor a dv / dt reactance, available on request.

For motor cable lengths greater than 50 meters it’s

recommended to place between VASCO and motor a sinusoidal filter, available on request.

5. VASCO installation

VASCO can be installed directly on the fan cover of the motor or mounted on the wall.

Motor mounting kit

In this application VASCO is cooled by the motor fan. Motor kit (available upon request) allows a solid coupling of the two units and it is composed of:

VASCO 209,214,406,409

VASCO 414,418,425,430

 n.°4 rods  n.°4 M5 nuts  n.° 4 hooks  n.° 1 cooling ring

 n.° 4 M5 screws.  n.° 4 clamps  n.° 4 clips to add if necessary  n.°1 centre pin

Use the cooling ring for best cooling of VASCO during operation. Warning: when using the cooling ring, the cooling air of the motor is slightly warmer than without the VASCO; if the resulting motor temperature exceeds the indicated maximum allowable value, remove the cooling ring, leaving the VASCO to be cooled by itself.

Wall mounting kit

In this application VASCO is cooled independently by its auxiliary cooling fan integrated in the radiator. Wall-mounted kit is composed of:

VASCO 209,214,406,409

VASCO 414,418,425

 n.° 1 auxiliary fan 230V AC (VASCO 209,214)

or 12 VDC (VASCO 406,409)

 n.° 4 screws to fix cooling fan  n.° 1 protection grill  n.° 1 metal bracket in AISI 304

 n.° 4 screws to fix VASCO to wall bracket

 n.° 2 12 V DC fans.  n.° 1 fans cover.  n.° 2 fans cover fixing screws  n.° 2 wall fixing brackets  n.° 4 M5 screws for VASCO fixing to the brackets  n.°1 holes reference sheet

Make sure the manufacturer that the electric motor is suited for operation in the inverter Make sure to properly attach the grid of the auxiliary cooling fan. Make sure to remove the auxiliary cooling fan if VASCO is coupled to a motor. Failure to do so creates a high risk of overheating the motor and VASCO unit.

5. VASCO Installation for constant pressure control

VASCO controls the pump speed to maintain constant pressure at a set point independent of the water demand in the system. A basic schematic is shown below:

5.1.1 Pressure tank

Installation of a pressure tank in the hydraulic system is recommended to compensate leakage of water in the system (or during minimum water demand) and to avoid continuous start/stop cycling of the pump (check the appendix for more information). Selecting the proper volume and pre-charge pressure of the tank is very important; smaller tank volumes will not compensate adequately for minimum water usage or leakage, while larger volumes make it more difficult for VASCO to control the pressure evenly.

Recommended tank volume is equal to the 10% of the maximum water flow of the system (expressed in volume unit/min)

Example: if the max water flow is 50 liters/min, the pressure tank should have a capacity of 5 liters If the max water flow is 20 gpm, the pressure tank should have a capacity of 2 gallons

Pre-charge pressure of the pressure tank should be at least 80% than the set-pressure of the system.

Example: if the set-pressure of the system is 4 bar, the pre-charge pressure of the tank should be 3.2 bar If the set-pressure of the system is 60 psi, the pre-charge pressure of the tank should be 48 psi

5.1.2 Pressure sensor

VASCO requires a pressure sensor with a linear output signal within the range 4 – 20 mA. The pressure transducer can be powered by any range of DC Voltage which includes the value 15 V dc. It is necessary to set the pressure sensor characteristics in the initial configuration menu or in the installer menu (please check the relevant chapter on setting parameters). Connect the sensor cable wires to the analog input terminals as follows:

 0V: GND signal (if available)  AN1: signal 4-20 mA (-)

 +15: 15 Vdc (+)

VASCO accepts the signal of a second pressure sensor in order to:

 realize constant differential pressure (AN1 – AN2).  substitute first pressure sensor when it fails

 0V: GND signal (if available)  AN2: signal 4-20 mA (-)

 +15: 15 Vdc (+)

VASCO

1 2 3

1: pump

2: check valve

3: pressure tank

4: valve

5: valve

6: pressure sensor

6. VASCO Use and Programming

VASCO software is extremely simple to use, but allows a wide variety of parameters to be set for ideal system calibration. Setting Parameters are organized in 2 levels:

1: Installer level A password is required for this level; these parameters are adjustable by trained professionals

Default password: 001 From the menu a different password can be set up.

2. Advanced level A second and different password is required; improper setting of these advanced parameters could compromise the integrity and the life of VASCO and pump;

Default password 002 It is possible to set up a different password.

Installer and Advanced levels can be entered only with the correct password; otherwise, it is impossible to set up and/or modify any parameters (they can be only displayed).

6.1 VASCO display

Screen is a back-lit LCD displaying 2 rows of 16 digits each. Alarms are indicated by an audible signal.

6.2 Initial configuration

When VASCO is switched on for the first time, the initial setting menu is displayed for the initial setting of parameters to configure pump characteristics, pressure sensor range, and system characteristics. If the initial setting procedure is not completed properly, it is impossible to run the pump. Initial setting procedure can be repeated if necessary. The initial setting procedure can be repeated (by using the 2rd level password) to reconfigure VASCO or if VASCO is installed in a different system. A brief description of parameters and their allowable ranges are listed below:

STOP motor

Menu exit

Alarms reset

START motor

ENTER

Scroll up

Scroll down

Parameter

Default

Description

XXXX

End user communication language

bar

Pressure unit

threephase

Type of motor connected (VASCO 209,214)

Rated current of the motor per it’s nameplate indication increased by

10%. The voltage drop caused by the inverter leads to higher input current than nominal. Make sure motor is capable of accepting increased current.

Rated frequency of the motor per its nameplate.

Control mode: Constant pressure

Maximum pressure of pressure transducer; Set the pressure value of the transducer when output signal is 20 mA equivalent to the highest value of pressure range (i.e. 0 – 10 bars transducer range) 10 bars = 20 mA

If the transducer is not connected or connected improperly, the signal SENS. PRESS OFF is activated when pressing ENTER.

Maximum pressure allowed in the system. If the pressure goes over this value, an alarm occurs and the pump is stopped. Pump is automatically restarted if the pressure goes below the maximum value for a period of at least 5 seconds.

Press START/STOP to run a test at rated frequency

Warning: make sure to run the system without damaging pump and system

--->

If, during the test, the motor runs in reverse, it is possible to change the wiring sequence via software without physically changing wires at the terminals.

The pressure value to be kept constant.

OFF

If ON is selected, after a lack of voltage, VASCO returns to its normal status; if VASCO was powering the pump before the voltage drop, it resumes powering the pump automatically. Warning, review the advice in chapter 1

Once the Setting procedure is completed you will get this indication on the display; setting parameters are recorded by VASCO; these parameters can be set up individually in the INSTALLER Parameters menu or ADVANCED Parameters menu.

INITIAL SETUP

COMPLETED

Autorestart

ON/OFF

Set pressure

p = XX.X [bar]

Rotation sense

---> / <---

Motor test

START/STOP

Max alarm press.

p = XX.X [bar]

Sensor test

Press ENT

F.s. press.sensor

20mA = XX.X [bar]

Rated motor freq

f = XXX [Hz]

Rated motor Amp.

I = XX.X [A]

Motor type

singlephase/threephase

Unit

bar/psi

Language

XXXXXX

6.3 Initial view

When first powering the VASCO, the display shows : release of display software (LCD = X.XX) and the release of inverter software (INV = X.XX) as shown below:

The following End User messages are displayed by pushing the scroll buttons:

p_m is the pressure value read by the pressure transducer By pressing ENTER the pressure set value is displayed. Keeping pressed ENTER button more than 5 second, is possible to modify the set pressure on real time.

f value is the supply frequency to the motor; by pressing ENTER you can change the f

value manually (word “set” is displayed) , press ENTER again to exit parameter setting (word “set” disappeared)

V is the voltage supplied to the motor. This value is displayed only if motor is OFF; if motor is ON, A value equal to the absorbed motor current is displayed

cosphi index means the angle phi between the voltage and current absorbed by the motor

P is the power in Watts supplied to the pump.

NORMAL status means no alarms. If an alarm occurs, a message blinks on the display and an audible signal is activated. Pressing ENTER accesses: VASCO lifetime, PUMP lifetime, alarm list. PUMP lifetime is recorded while pump is powered.

To return to previous views, press ENTER.

First row gives the VASCO status:

 Inv: ON XXX.X Hz VASCO is powered and is powering the motor showing its frequency.  Inv: ON Mot: OFF VASCO is powered but motor is not running (i.e. motor/pump was stopped due to minimum

frequency being reached)

 Inv: OFF Mot: OFF VASCO is not powered

If COMBO function is activated, the VASCO address is placed close to indication “Inv”.

Menù

ENT to access

XXXXXXXXXXXXXXX

XXXXXXX h : XX m

Motor Life

xxxxx h : xx m

Inverter Life

xxxxx h : xx m

Inv: ON/OFF Mot: ON/OFF

STATUS: NORMAL

Inv: ON/OFF Mot: ON/OFF

P = XXXXX [W]

Inv: ON/OFF Mot: ON/OFF

cosphi = XXX

Inv: ON/OFF Mot: ON/OFF

V = X.XX [V] I= XX.X [A]

Inv: ON/OFF Mot: ON/OFF

f = XXX [Hz]

Inv: ON/OFF Mot: ON/OFF

p_m = XX.X [bar]

LCD = X.XX

INV = X.XX

6.4 Menu view

Pressing ENTER when you are in [MENU’ / ENT to access] in initial display, will display the following MENUs:

Installer password required to enter level 1 (default 001)

Advanced password required to enter level 2 (default 002)

Installer password required to enter level 1 (default 001) It is possible to return to original set parameters.

Advanced password required to enter level 2 (default 002)

To exit the Menu level and return to initial display, press STOP button.

6.5 Installer parameters

Many of the Installer parameters are set during the Initial Configuration (chapter 6.2 Initial Configuration). However, through the Installer Parameters menu, it is possible to change the set parameters or set others in order to perfect the calibration of VASCO to the pumping system.

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

Const. press.

Mode of control:

 Constant pressure: VASCO changes the speed of pump to keep the

pressure constant, independent of water demand

 Fixed frequency: VASCO feeds the pump a set frequency, so the speed of

motor is kept constant.

 Constant pressure control with two values; the two values are selected by

opening or closing the digital input 2.

 Fixed frequency control with two values to be selected by opening or

closing the digital input 2.

 External speed: control motor frequency by using analogical input .  Constant temp.: VASCO changes the speed of pump to keep the

temperature constant. An analogical signal coming from a temperature sensor must be connected.

 Constant flow: VASCO changes the speed of pump to keep the flow

constant. An analogical signal coming from a flow sensor must be connected.

Control mode

 Constant press.  Fix speed  Const.press.2val  Fix speed 2 val.  External speed  Constant temp.  Const. flow

MENU’

Change init.set.

MENU’

Retrive init.set

MENU’

Advanced. param.

MENU’

Install. param.

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

bar

Pressure unit



°C

Temperature unit



100

Full scale of the temperature sensor. From the plate data of the sensor can read the temperature at which the sensor provides output 20 mA. (or 10 V)



Full scale of the temperature sensor. From the plate data of the sensor can read the temperature at which the sensor provides output 4 mA. (or 0 V)



100

Full scale of the flow sensor. From the plate data of the sensor can read the flow at which the sensor provides output 20 mA. (or 10 V)



20%

Zero point adjustment. (20 mA x 20% = 4 mA).



Minimum pressure allowed in the system. If the pressure goes lower than the set value, an alarm occurs and the pump is stopped. Pump is automatically restarted if the pressure goes higher than the minimum value for a period of at least 5 seconds. This parameter is particularly useful in the event a system pipe breaks. It is suggested to set a value higher than 0.



0.65

If the pump goes into dry-running, the cosphi reaches its lowest level. To set this value, contact the pump manufacturer or test by closing the suction and checking the value on the VASCO display; a value can be set by assuming a dry cosphi equivalent to 60% of the rated cosphi specified by the manufacturer.



Dry run cosphi

cosphi = X.XX

Min alarm pres.

p = XX.X [bar]

Max alarm pres.

p = XX.X [bar]

Offset sensors

x = XX.X [%]

F.s. flow sensor

20mA = XXX.X [m3/h]

Min temp. sensor

4mA = - XXX.X [°C]

F.s. temp.sensor

20mA = XXX.X [°C]

F.s. press.sensor

20mA = XX.X [bar]

Unit

°C / °F

Unit

bar/psi

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

The pressure value to be kept constant.



Pressure compensation at the maximum frequency for each pump. Acting on the green button you can reverse the sign.



The pressure value to be kept constant.



Pressure compensation at the maximum frequency for each pump. Acting on the green button you can reverse the sign.



Time to update p set for losses compensation.



To ensure proper operation of pressure control is recommended to place the sensor near the pump. To compensate the pressure loss in the pipes (proportional to flow) it is possible to vary the pressure set in a linear relation with respect to frequency. If Q = 0, Set pressure is granted while at the max output frequency will be granted the Set pressure + p loss compens.

It can perform the following test to verify the correct value of p loss compensation:

1. install a pressure gauge away from the pressure sensor

2. open completely the valve

3. check the pressure gauge

--> Set the value of p loss compens. equal to the difference of the values from the two gauges. When using a group of pumps, the pressure compensation to be applied to each pump is equal to the total pressure compensation (when all the pumps are running at full speed) divided by the number of pumps in the group.

Press. set update

t = XX [s]

p loss compens. 2

p = XX.X [bar]

Set pressure 2

p = XX.X [bar]

p loss compens.

p = XX.X [bar]

Set pressure

p = XX.X [bar]

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

Set the frequency value (or the speed) to feed the pump.



Set the frequency value (or the speed) to feed the pump.



Temperature value to be maintained constant.



Flow value to be maintained constant.



Minimum frequency below which the pump must stop.



Delay for which the pump will stop once the minimum frequency is reached (f min Q=0)



Ramp time from freq min Q=0 to motor freq min. If, during this time, the p checked goes below the (p_set -delta start pres), VASCO powers the motor again; otherwise, VASCO will stop the pump following the min freq. of motor ramp.



0.3

This value represents the pressure drop below the set pressure required to start the pump.



Delta start pres

p = XX.X [bar]

Ramp Q=0

t = XX [s]

Stop delay Q=0

t = XX [s]

Set f. min Q=0

fmin = XXX [Hz]

Flow set

Q = XXX.X [m3/h]

Temperature set

T = XXX.X [°C]

Operating freq. 2

f = XXX [Hz]

Operating freq.

f = XXX [Hz]

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

0.5

It's the increase of pressure respect to pressure set which must be passed so that there is a forced shutdown of the pump.



0.5

The common parameters than you should get the temperature above the temperature set so that the pump, arrested earlier, are restarted.



It's the temperature rise compared to temperature set which must be passed so that there is a forced shutdown of the pump.



0.5

This value represents the flow drop below the set flow required to start the pump.



It's the increase of flow respect to flow set which must be passed so that there is a forced shutdown of the pump.



Kp and Ki parameters allow the dynamic control of system by VASCO; set values (Ki=50, Kp=005) are usually enough to get a valid dynamic control; if the set pressure do not consent a valid control, proceed as follows; increase or reduce Ki while keeping Kp constant; if the problem persists, increase Kp value and increase or reduce the Ki value again till a good dynamic control is reached.



OFF

Function to activate (ON) the first auxiliary pump DOL 1 (Direct On Line pump).



OFF

Function to activate (ON) the second auxiliary pump DOL 2 (Direct On Line pump).



OFF

Function to allow alternating starting priority between the DOL pumps in order to allow equal use of them.



delay time with which the pumps DOL start after the variable speed pump has reached the maximum frequency and the pressure value has fallen below set pressure – delta start pressure



OFF

Function to enable multiple VASCO’s to work in

parallel as described in the technical appendix (see the relevant chapter). Up to 8 VASCO units can be connected in parallel. VASCO’s communication through RS 485 gates is granted by a private protocol.



Direct

Direct: increasing misured pressure, VASCO decreases motor frequency. Inverse: increasing misured pressure, VASCO increase motor frequency.



PI control

Direct/Reverse

COMBO

ON/OFF

Start delay AUX

t = XX [s]

Alternance

ON/OFF

Pump DOL 2

ON/OFF

Pump DOL 1

ON/OFF

XXX

Delta stop flow

Q = XXX.X [m3/h]

Delta start flow

Q = XXX.X [m3/h]

Delta stop temp.

T = XXX.X [°C]

Delta start temp.

T = XXX.X [°C]

Delta stop press

p = XX.X [bar]

parameter

default

desciption

Constant press.

Fix speed

Const.press.2val

Fix speed 2 val.

External speed

Constant temp.

Constant flow

--->

If, during the test, the motor runs in reverse, it is possible to change the wiring sequence via software without physically changing wires at the terminals.



N.O.

By selecting N.A. (normally open) VASCO runs the motor if the digital input 1 is open; motor will be stopped if the digital input 1 is closed. By selecting N.C. (normally closed) VASCO runs the motor if the digital input 1 is closed; motor will be stopped if the digital input 1 is opened.



N.O.

By selecting N.A. (normally open) VASCO runs the motor if the digital input 2 is open; motor will be stopped if the digital input 2 is closed. By selecting N.C. (normally closed) VASCO runs the motor if the digital input 2 is closed; motor will be stopped if the digital input 2 is opened.



N.O.

By selecting N.A. (normally open) VASCO runs the motor if the digital input 3 is open; motor will be stopped if the digital input 3 is closed. By selecting N.C. (normally closed) VASCO runs the motor if the digital input 3 is closed; motor will be stopped if the digital input 3 is opened.



N.O.

By selecting N.A. (normally open) VASCO runs the motor if the digital input 4 is open; motor will be stopped if the digital input 4 is closed. By selecting N.C. (normally closed) VASCO runs the motor if the digital input 4 is closed; motor will be stopped if the digital input 4 is opened.



Digital input IN2 and IN3 delay. Digital input IN1 and IN4 have 1 second fix delay.



Pressing ENT allows the installer level password (1st level) (default 001) to be changed.



6.6 Advanced parameters

All the advanced parameters, due to their importance, are already set during initial setup (cap. 6.2 Initial Configuration). However, it is always possible to modify individual parameters or modify the password 2:

Parameters

Default

Description

XXX

Motor rated voltage (as shown in the motor plate) Average voltage drop due to the inverter is between 20 V and 30 Vrms based on load condition.

Refers to the voltage increase during the start up of the motor. Warning: An excessive value can seriously damage the motor. Contact the motor manufacturer for further information. If a single-phase motor is used, a value of 1% is suggested to increase the

Voltage boost

V = XX [%]

Rated motor Volt.

V = XXX [V]

Change PASSWORD1

ENT

Dig.In.2/3 delay

t= XX [s]

Digital input 4

N.O. / N.C.

Digital input 3

N.O. / N.C.

Digital input 2

N.O. / N.C.

Digital input 1

N.O. / N.C.

Rotation sense

---> / <---

starting torque.

Rated current of the motor per it’s nameplate indication increased by 10%.

The voltage drop caused by the inverter leads to higher input current than nominal. Make sure motor is capable of accepting increased current.

Rated frequency of the motor per its nameplate.

Maximum frequency of the motor. Note: by reducing the maximum frequency of the motor, maximum current will be reduced as well.

Minimum frequency of the motor. Note: depends on the selected pump type; for submersible pumps with water filled motors, is not advisable to set minimum frequency lower than 30 Hz in order to protect the integrity of the thrust bearings.

Ramp-up time to reach the speed required to achieve the set pressure (or frequency value). Longer times delay the system reaching the preset value but better protect system components. Excessively long ramp-up times can create difficulties in VASCO setup, and can also cause false overload alarms.

Ramp-down time to reach zero speed. Longer times keep the system pressurized, while protecting the system components. Excessively long ramp-down times can create difficulties in VASCO setup. Excessively short ramp-down times can cause false overload alarms.

Time to reach the minimum frequency of the motor and vice versa.

When VASCO is used to control a water filled submersible motor it’s

important to keep this time at 1 second.

Carrier frequency (switching frequency). It is possible to chose PWM in the range of 2.5 ,4, 6, 8, 10 kHz . Higher values give a more sinusoidal wave with fewer losses. If long cables are used (>20 m / >76 ft) (submersible pump) it is recommended to install an inductive filter between VASCO and the motor (available upon request) and

PWM

f = XX [kHz ]

Ramp f min mot.

t = XX [sec]

Ramp down time

t = XX [sec]

Ramp up time

t = XX [sec]

Min motor freq.

f = XXX [Hz]

Max motor freq.

f = XXX [Hz]

Rated motor freq

f = XXX [Hz]

Rated motor Amp.

I = XX.X [A]

to set the value of PWM to 2.5 kHz. This reduces the risk of voltage spikes, which can damage motor and cable insulation.

This parameter allows you to change the V / f characteristic with which VASCO feeds the engine. The linear characteristic corresponds to constant torque with variable speed. The quadratic characteristic is normally used with centrifugal pumps. The selection of torque characteristic should be done ensuring a smooth operation, a reduction of energy consumption and a lower level of heat and acoustic noise.

Indipendent

Function logic for analog input AN1,AN2.

OFF

Pressing ENT allows the advanced level password (2st level) (default 002) to be changed.

Change PASSWORD2

ENT

Autorestart

ON/OFF

AN1,AN2 function

XXXXXX

V/f lin. --> quad.

XXX %

7. Protections and alarms

Anytime a protection occurs a blinking message is displayed together with an audible alarm; on STATUS in the initial view, the protection is displayed; by pressing the STOP button. Only from this position (STATUS) in the initial view is it possible to try to reset the alarm; if VASCO does not reset the alarm it is displayed again together an audible sound.

ALARM MESSAGE

ALARM DESCRIPTION

POSSIBILE SOLUTIONS

OVERCURRENT MOT.

Motor overload: input current of the motor is higher than the rated motor current setting parameter.

Motor voltage drop caused by the inverter causes the motor input current to be higher than rated. Contact motor manufacturer to check if motor is capable of accepting this current.

 Make sure that the motor current setting

parameter is higher than rated.

 Check other possible causes of over current

UNDER VOLTAGE

Supply voltage too low

Check possible causes of undervoltage

OVER VOLTAGE

Supply voltage too high

Check possible causes of overvoltage

OVER TEMP. INV.

Inverter over temperature

 Make sure than ambient temperature is less

than 40 °C (104 °F).

 Check if auxiliary cooling fan is working

properly and if mounting space is adequate for proper cooling.

 Reduce the PWM value (Advance Parameter

Menu)

NO LOAD

No load

 Check if load is properly connected to the

VASCO terminals

NO WATER

(DRY RUN COSPHI)

Motor cosphi is lower than the set value of dry running cosphi

 Check if the pump is primed  Check the set value of dry running cosphi.

Dry running cosphi is approximately 60% of the rated cosphi (at rated frequency) listed on the motor plate.

If pump’s cosphi is lower than the set dryrunning cosphi for at least 2 seconds, VASCO stops the pump. VASCO tries to run the pump every 10, 20, 40, 80, 160 minutes and then the pump is stopped.

WARNING: if dry running protection occurs, VASCO will try to start the pump automatically. Be sure to cut power supply to VASCO before performing any maintenance.

PRESS.SENS.FAULT

Pressure sensor error

 Check the pressure transducer  Check the wiring of transducer

FLOW SENS. FAULT

flow sensor error

 Check the flow transducer  Check the wiring of transducer

TEMP. SENS. FAULT

temperature sensor error

 Check the temperature transducer  Check the wiring of transducer

OVER PRESSURE

Measured pressure value has reached the maximum pressure accepted by the system.

 Check possible causes of reaching max

pressure

 Check the max pressure value setting

UNDER PRESSURE

Measured pressure value has reached the lowest pressure accepted by the system.

 Check possible causes reaching min pressure

(i.e. broken pipe, open pressure relief valve, etc.)

 Check the min pressure value setting.

OVERLOAD INV.

The current drawn by the load exceeds the capacity of VASCO. VASCO is still able to continue to power the load for 10 minutes with an output current of 101% of nominal and for 1 minute with an output current of 110% of nominal

 Increase the ramp-up time  Make sure that the load current is at least

10% below the VASCO nominal current

 Check the voltage drop along the supply

cable to the motor

COMMUNICATION

Communication between Master and slave(s) has been interrupted

 Check the wiring connections  Make sure the Master is not in the Menu

level; if so, exit from the level.

 In the STATUS of the slave (where the alarm

is displayed) try to reset the alarm by pushing STOP button.

ADDRESS ERROR

Same address as other VASCOs in the group

 The address of each VASCO needs to be

different

KEYBOARD FAULT

A Button on the keyboard has been pressed for more than 150 seconds

 Make sure buttons are not depressed  Call service assistance

DIGITAL INPUT

Digital input opened /closed

 Check the input digital configuration (under

Installer Parameters menu )

ALARM SLAVE XX

slave XX error detected by master

 check the status of the slave

If pumps cosphi is lower than the dry-running cosphi for at least 2 seconds, VASCO will stop the pump. VASCO will try to run the pump every 10, 20, 40, 80, 160 minutes and then the pump is stopped. ATTENTION: if dry-running protection occurs, VASCO will try to start the pump automatically. Be sure to cut power supply before attempting maintenance VASCO will stop the pump if the input motor current is higher than the set motor current for an extended time. By pressing the START button it is possible to run the pump again. VASCO will stop the pump if the input voltage is higher than the set voltage for an extended time. By pressing the START button it is possible to run the pump again. VASCO will stop the pump if the input voltage is lower than the set voltage for an extended time. By pressing the START button it is possible to run the pump again.

8. Minimum stop frequency at 0 delivery (f min Q=0) during constant pressure control.

Minimum stop frequency is the minimum frequency value that, while maintaining the p_set , water delivery is zero. Below scheme graphically shows the function:

Progressively closing the water delivery valve reduces flow, causing VASCO to reduce the pump speed by reducing the output frequency, to maintain a constant pressure (i.e. 3 bar). Once the water flow stops (output completely closed), pump will run at minimum frequency to maintain the set pressure. Upon determining that the water requirement has stopped, VASCO stops the pump to save energy. Thus, the pump will be stopped when minimum frequency is reached. Once the pump is stopped at min. frequency value, set pressure is maintained in the system. To maintain the pressure on the pump output line, it is necessary to install a small pressure tank able to compensate for minor water leakage and to limit the number of pump restarts. It is important to pinpoint that a particular set pressure corresponds to a single value of min. stop frequency. So, if the end user wants to change the set pressure, a new value of min. stop frequency should also be set.

9. Auxiliary pumps during constant pressure control

When the water needs vary considerably, it is advisable to share the water request between several pumps ensuring better efficiency and reliability. A first method consists of a single pump driven directly by VASCO and another 1 or 2 pumps directly connected to the mains DOL (Direct On Line); DOL pumps are controlled by VASCO and connected to the mains through 1 or 2 contactors.

In this method, DOL pumps are not started and stopped smoothly with the corresponding increase in energy consumption and mechanical wear (startup current). Also note that DOL pumps are not protected by VASCO. A second method of sharing water demand (named COMBO mode) consists of using additional pumps in parallel (up to 8), with each one driven by a VASCO.

In this method, energy consumption and reliability of the pumping system is maximized: VASCO monitors and protects each pump. It is possible to assemble a booster system composed of pumps connected in COMBO mode and another 1 or 2 DOL pumps to cover additional water demand (menaged only by master).

9.1 DOL pumps

Each DOL pump is switched on by a contactor controlled by the digital output DOL1 and DOL2 present in the VASCO.

Two pumps are connected in parallel, with one pump (pump 1, P1) run by the inverter, while the second pump (pump 2, P2)

is directly connected to the main power (“Direct On Line” connection). Start/Run of the second pump is controlled by the

relay DOL1 (allowing a third pump to be controlled by the relay DOL2).

If pump 1 (P1) is already running to maintain the desired set pressure (red line) , an additional water request changes the system curve from C1 to C2 ; since pump 1 (P1) is running at maximum speed, it is not possible to maintain the set pressure by increasing the speed, so the system pressure will drop till reaching the new working point 2. If pressure at the point 2 is (p_set – delta start pres), VASCO will run the DOL by relay DOL1. The DOL pump will run at its nominal speed while the pump 1 will drop it speed equal to the P1 pattern to maintain set pressure. If water demands decreases, returning to the system curve C1, pump 1 will reduce the pump speed to maintain constant pressure in the system. When pump 1 reaches a frequency equivalent to the minimum frequency, while still maintaining set pressure, the DOL pump will be switched off and pump 1 will increase the speed to maintain the p_set in the system.

VASCO relays driving the DOL pumps are relays with no voltage contacts. Max voltage to the contacts is 250 V, max current 5 A.

P1@f min Q=0

P1+P2

delta start pres.

If two pumps are connected in parallel, the first driven by VASCO and the second with a DOL

connection, it is necessary makes sure that the value “delta pressure restart” will be sufficiently high

to ensure the first pump, once the DOL pump is switched on, will reach a frequency higher than its minimum frequency value. By proper setting of the minimum frequency, excessive pump ON/OFF cycling is avoided, thus preventing damage to the DOL pump.

9.2 COMBO function

In the “Installer parameters” menu it is possible to enable the COMBO function that allows serial communication between up

to 8 VASCOs, each one connected to a pump. The operating principle (switch on/off) of pumps is similar to as stated in chapter 9.1.

To achieve the COMBO function in a system consisting of several interconnected VASCOs, use a pressure sensor connected to each VASCO. The value of the set pressure is communicated to the slaves via the serial port. To prevent the shutdown of the system due to pressure sensor failure, connecting a 2nd pressure sensor to the VASCO; make sure that the two pressure sensors are identical. Remember to perform the offset operation of the sensors in each VASCO (Installer Parameters menu) . As a further help, you can connect another two DOL pumps to the VASCO Master to cover additional water demand; they will be operated only when all the COMBO pumps are already in operation.

RS485 serial connection

VASCO’s communication is made through a private protocol using the RS485 port. Each VASCO must be connected to each other by using a tripolar cable (0,5 mm2) wired on S+,S-,G pins on control board.

MASTER: address 00

SLAVE 1: address 01

SLAVE 2: address 02

Master setup

1. Supply power to the VASCO master.

2. If not yet completed, perform the initial configuration as described on chapter 6.2

3. Initial view is shown:

4. Scroll until:

5. Press ENT

6. Press ENT

7. Insert password (default 001).

8. Scroll until:

9. Set ON

10. Set:

VASCO’s address in parallel operation.

 00 : VASCO master

OFF

Function to allow alternating between the VASCOs connected in parallel in order to allow equal use of each pump in the group; in this way Master will reorganize the starting priority of the pumps by checking the life of each of them.

Delay time with which the slaves start after the variable speed pump has reached the maximum frequency and the pressure value has fallen below set pressure – delta start pressure

11. Press STOP (red button)

12. Press STOP again

Start delay AUX

t = XX [s]

Alternance

ON/OFF

Address

Combo

ON/OFF

MENU’

Param. install.

Menù

ENT to access

Inv: ON/OFF Mot: ON/OFF

p_mis=XX.X [bar]

Slave setup

Follow Master setup until point 11.

In case of failure of master in a Combo system, will be replaced by slave. As a consequence, all parameters must be setup independently on each inverter, master mode.

1. Set:

VASCO’s address in parallel operation.

 01 --> 07: VASCO slaves

2. Press STOP (red button).

3. In the advanced parameters verify that Autorestart is set ON.

4. Press STOP (red button).

5. Press STOP again.

Whenever the user accesses the Menu screen of the VASCO master, the communication between VASCOs is automatically interrupted.

In case of alarm or failure of a pump in a Combo system, this pump’s operation will be replaced (temporary or

permanently) by another pump.

In case of failure of master in a Combo system, it will be replaced by the next slave. As a consequence of this, all parameters must be setup independently on each inverter as master mode.

10. Trouble-shooting chart

LCD does not switch on after powering the VASCO

 Check the connecting flat cable between the LCD board (attached to the

cover) and the control board

 Check the fuses  Check that the power cables are properly connected.

Power line of VASCO is interrupted by the differential protection contactor

 Check the leakage current to ground of EMC filter  Following a rapid off/on the power supply, the differential contactor can

interrupt the power. After turning off the VASCO it is recommended to wait at least 1 minute before restarting.

When performing the Offset operation of the pressure device, SENS.PRESS.OFF alarm occurs

 Check that the sensor cable is properly connected to the sensor device

and to the VASCO.

 Make sure that the sensor and its cable are not damaged.  Check that the operating range of pressure sensor is of 4 -20 mA type

and the value of 15 V is within the voltage feed range of the sensor

Frequency and pressure oscillation on constant pressure control mode

 Check if the water tank and its air pressure are correctly set. It may be

necessary to increase the tank volume or reduce the pre-charge pressure.

 Check the ki & kp parameters (Installer Parameters menu). At first, it is

suggestable to increase the Ki value. If it not enough reduce of one unit the Kp value.

During constant pressure control, pump stops and starts continuously.

 Make sure that the value f min Q=0 (minimum frequency with Q=0)

(Installer Parameters menu) is properly set up. Otherwise repeat the procedure.

 Increase the value of parameter stop delay (Installer Parameter menu)

Address

 Increase the time value ramp Q=0 parameter (Installer Parameters

value).

DOL pump stops and starts continuously

 Increase delta start pressure in accordance with chapter 9.1.  Check to see if the water tank and it’s air pressure are correctly set. It

may be necessary to increase the tank volume or reduce the pre-charge pressure.

Measured pressure p_mis drops too much before VASCO starts the pump.

 Decrease the delta start pressure (Installer Parameters menu) .  Check to see if the water tank and it’s air pressure are correctly set. It

may be necessary to increase the tank volume or reduce the pre-charge pressure.

 Modify the value of ki & kp parameters (Installer Parameters menu).

At first, it is suggestable to reduce the Ki value. If it is not enough increase of one unit the Kp value.

11. Technical Assistance

For more technical information contact the authorized reseller providing the following information. The solution to the problem will be found faster and easier if full information is provided.

Model/Serial Code

LCD version (shown when VASCO is power supplied) LCD = _.__

INV version (shown when VASCO is power supplied) INV = _.__

Line Voltage: ___ [V]

Line Frequency: 50 Hz 60 Hz

description of problem:

installation type: wall mounted on motor fan cover

motor type: single phase three phase

submersible surface

if submersible: cable lenght [m]: _____

if sommersible: cable section [mm2]:____

P2 motor [kW]:____

rated motor Volt [V]:___

rated motor Amp [A]:__

rated motor Hz:___

if single phase: capacitor _____ [UF]

if singlephase: starting Amp I st = _____ [A]

pump performances Q = ____ [l/min] H = ____ [m]

tank volume: _____ [liters]

precharge pressure: _____ [bar]

number of DOL pumps: ___

number of COMBO pumps: ___

medium ambient temperature: _____ [°C]

pressure sensor

4 mA = ___ [bar] 20 mA = ___[bar]

digital inputs used:

digital ouputs used:

electric and hydraulic scheme of the system (more detailed as possible)

set parameters: please fill the instal. param. and adv. param columns in the software scheme.

DICHIARAZIONE DI CONFORMITA’

Secondo:

Direttiva Macchine 2006/42/CE

Direttiva EMC 2004/108/CE

VASCO 209,214,406,409,414,418,425,430 è un dispositivo elettronico da collegare ad altre macchine elettriche con le quali

viene a formare singole unità. E’ necessario, pertanto, che la messa in servizio di questa unità (corredata di tutti i suoi organi ausiliari) sia effettuata da personale qualificato.

Il prodotto è conforme alle seguenti normative:

EN 55011 Classe A EN 61000 EN 60146 EN 50178 EN 60204-1

Ing. Marco Nassuato Operation Manager

DECLARATION OF CONFORMITY

In according with:

Machine Directive 2006/42/EC

EMC Directive 2004/108/CE

VASCO 209,214,406,409,414,418,425,430 is an electronic device to be connected to other electrical equipment with which it

is to form individual units. It must, therefore, that the putting into service of this unit (with all its subsidiary equipments) to be performed by qualified personnel.

The product conforms to the following regulations:

EN 55011 Class A EN 61000 EN 60146 EN 50178 EN 60204-1

Ing. Marco Nassuato Operation Manager

NOTE

Copyright NASTEC srl 2012 Nastec si riserva il diritto di modificare le informazioni contenute in questo manuale senza alcun preavviso.

Nastec srl, Via della Tecnica, 8, 36024, Mossano, Vicenza, Italy, Tel. +39 0444 886289, Fax +39 0444 776099, www.nastec.eu,

info@nastec.eu

Nastec VASCO Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual