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HVL 4.220

Xylem HVL 4.220, HVL 2.015 Installation, Operation And Maintenance Manual

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Page 1
Installation, Operation,
and Maintenance Manual
HVL 2.015-4.220
Page 2
Page 3
Table of Contents
1 Introduction and Safety..............................................................................................................4
1.1 Introduction.......................................................................................................................... 4
1.1.1 Qualified personnel......................................................................................................4
1.2 Safety..................................................................................................................................... 4
1.3 User safety.............................................................................................................................5
1.4 Protecting the environment................................................................................................7
1.5 Warranty................................................................................................................................7
1.6 Spare parts............................................................................................................................7
1.7 EU declaration of conformity (No LVD/EMCD05)............................................................8
1.8 EU declaration of conformity..............................................................................................8
2 Transportation and Storage....................................................................................................10
2.1 Inspect the delivery........................................................................................................... 10
2.2 System lifting...................................................................................................................... 10
2.3 Transportation guidelines.................................................................................................11
2.4 Storage guidelines.............................................................................................................11
Table of Contents
3 Product Description................................................................................................................. 12
3.1 System description............................................................................................................ 12
3.2 Product function and use..................................................................................................13
3.3 Applications........................................................................................................................13
3.4 The data plate.................................................................................................................... 14
3.5 Technical Data....................................................................................................................15
3.6 Motor thermal protection................................................................................................. 16
3.7 Dimensions and weights...................................................................................................17
3.8 Design and layout..............................................................................................................18
3.9 Included mounting components..................................................................................... 20
3.10 Optional components.....................................................................................................21
4 Installation................................................................................................................................. 22
4.1 Installation site checklist....................................................................................................22
4.2 Frequency converter and motor pre-installation check list..........................................22
5 Mechanical Installation............................................................................................................ 23
5.1 Cooling................................................................................................................................23
5.2 Lifting...................................................................................................................................23
5.3 Mounting.............................................................................................................................23
6 Electrical Installation................................................................................................................ 26
6.1 Precautions......................................................................................................................... 26
6.2 Protection devices............................................................................................................. 27
6.3 Wire type and ratings........................................................................................................ 29
6.4 EMC compatibility............................................................................................................. 30
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 1
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Table of Contents
6.5 AC mains and motor connection terminals....................................................................32
6.6 Control terminals............................................................................................................... 34
6.7 Premium card terminals.................................................................................................... 38
7 Operation.................................................................................................................................. 40
7.1 Pre-start procedure........................................................................................................... 40
7.2 Pre-startup inspections..................................................................................................... 40
7.3 Apply power....................................................................................................................... 41
7.4 Discharge time................................................................................................................... 41
8 Programming............................................................................................................................ 43
8.1 Display and control panel.................................................................................................43
8.2 Functions of push buttons................................................................................................ 43
8.3 Software parameters......................................................................................................... 44
9 Maintenance..............................................................................................................................98
9.1 General................................................................................................................................98
9.2 Check error codes............................................................................................................. 98
9.3 Check the functions and parameters.............................................................................. 98
10 Troubleshooting.....................................................................................................................99
10.1 No error message on the display.................................................................................. 99
10.2 Error message on the display........................................................................................ 99
10.3 Internal error, on display or red LED ON................................................................... 101
11 Technical Reference............................................................................................................ 102
11.1 Example: P105 ACTUATOR mode..............................................................................102
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Table of Contents
11.2 Example: P200 Ramp Settings.....................................................................................102
11.3 Example: P330 LIFT AMOUNT.................................................................................... 103
11.4 Example: P500 SUBMENU SEQUENCE CNTR.......................................................... 104
11.5 Example: P900 SUBMENU OFFSET............................................................................ 105
11.6 Programming flow charts............................................................................................. 107
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 3
Page 6
1 Introduction and Safety
1 Introduction and Safety
1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
1.1.1 Qualified personnel
WARNING:
This product is intended to be operated by qualified personnel only.
• Correct and reliable transport, storage, installation, operation, and maintenance are required for the trouble-free and safe operation of the frequency converter. Only qualified personnel are allowed to install or operate this equipment.
• Qualified personnel are defined as trained staff, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures that are described in this document.
• Persons with diminished capacities should not operate the product unless they are supervised or have been properly trained by a professional.
• Children must be supervised to ensure that they do not play on or around the product.
1.2 Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
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1.2.1 Safety message levels
About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Definitions
Safety message level Indication
DANGER:
1 Introduction and Safety
A hazardous situation which, if not avoided, will result in death or serious injury
Hot surface hazard
WARNING:
CAUTION:
Electrical Hazard:
NOTICE:
Hot surface hazards are indicated by a specific symbol that replaces the typical hazard level symbols:
CAUTION:
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
The possibility of electrical risks if instructions are not followed in a proper manner
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
1.3 User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 5
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1 Introduction and Safety
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
• Never operate a pump without a properly installed coupling guard.
property.
control.
pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
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Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in eyes
Chemicals or hazardous fluids on skin
1.4 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
1 Introduction and Safety
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
Waste and emissions guidelines
1.5 Warranty
For information about warranty, see the sales contract.
Do not dispose of equipment containing electrical components together with domestic waste.
Collect it separately in accordance with local and currently valid legislation.
1.6 Spare parts
WARNING:
Only use original spare parts to replace any worn or faulty components. The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as void the guarantee.
For more information about the product's spare parts, refer to the Sales and Service department.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 7
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1 Introduction and Safety
1.7 EU declaration of conformity (No LVD/EMCD05)
1. Apparatus model/Product: → data plate
2. Name and address of the manufacturer: Xylem Service Italia S.r.l. Via Vittorio Lombardi 14 36100 Vicenza VI Italy
3. This declaration of conformity is issued under the sole responsibility of the manufacturer.
4. Object of the declaration: Frequency converter (variable speed drive) HYDROVAR® for electric pump in one of the following models
HVL2.015-A0010 HVL4.015-A0010 HVL2.022-A0010 HVL4.022-A0010 HVL2.030-A0010 HVL4.030-A0010 HVL2.040-A0010 HVL4.040-A0010 HVL3.015-A0010 HVL4.055-A0010 HVL3.022-A0010 HVL4.075-A0010 HVL3.030-A0010 HVL4.110-A0010 HVL3.040-A0010 HVL4.150-A0010 HVL3.055-A0010 HVL4.185-A0010 HVL3.075-A0010 HVL4.220-A0010 HVL3.110-A0010
5. The object of the declaration described above is in conformity with the relevant Union harmonisation legislation:
• Directive 2014/35/UE of 26 February 2014 (electrical equipment designed for use within certain voltage limits)
• Directive 2014/30/UE of 26 February 2014 (electromagnetic compatibility)
6. References to the relevant harmonised standards used or references to the other technical specifications in
relation to which conformity is declared:
• EN 61800-5-1:2007
• EN 61800-3:2004+A1:2012 (*), EN 61000-6-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007+A1:2011
(*) Category C3
7. Notified body: -
8. Additional information: -
Signed for and on behalf of: Xylem Service Italia S.r.l. Montecchio Maggiore,18/04/2016 Amedeo Valente
Director of Engineering and R&D
Rev. 00
1.8 EU declaration of conformity
1. Unique identification of the EEE: No HVL
2. Name and address of the manufacturer: Xylem Service Italia S.r.l.
3. This declaration of conformity is issued under the sole responsibility of the manufacturer.
8 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Via Vittorio Lombardi 14 36100 Vicenza VI Italy
Page 11
1 Introduction and Safety
4. Object of the declaration: Frequency converter (variable speed drive) HYDROVAR® for electric pump in one of the following models
HVL2.015-A0010 HVL4.015-A0010 HVL2.022-A0010 HVL4.022-A0010 HVL2.030-A0010 HVL4.030-A0010 HVL2.040-A0010 HVL4.040-A0010 HVL3.015-A0010 HVL4.055-A0010 HVL3.022-A0010 HVL4.075-A0010 HVL3.030-A0010 HVL4.110-A0010 HVL3.040-A0010 HVL4.150-A0010 HVL3.055-A0010 HVL4.185-A0010 HVL3.075-A0010 HVL4.220-A0010 HVL3.110-A0010
5. The object of the declaration described above is in conformity with Directive 2011/65/EU of the European
Parliament and of the Council of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment.
6. References to the relevant harmonised standards used or references to the other technical specifications in
relation to which conformity is declared: -
7. Additional information: -
Signed for and on behalf of: Xylem Service Italia S.r.l. Montecchio Maggiore,18/04/2016 Amedeo Valente
Director of Engineering and R&D
Rev. 01
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 9
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2 Transportation and Storage
2 Transportation and Storage
2.1 Inspect the delivery
2.1.1 Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.1.2 Inspect the unit
1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue.
2.2 System lifting
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
WARNING: Crush Hazard
1) Always lift the unit by its designated lifting points. 2) Use suitable lifting equipment and
ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4) Stay clear of cables and suspended loads.
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Lifting diagrams
HVNG-IOM_LIFTING-1_A_SC
HVNG-IOM_LIFTING-2_A_SC
2 Transportation and Storage
2.3 Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
• Do not damage the cables during transport; do not squeeze, bend or drag the cable.
• Always keep the cable ends dry.
• Secure the unit against tipping over and slipping until it is mounted and fixed in its final location.
• Lift and handle the product carefully, using suitable lifting equipment (stacker, crane, crane mounting device, lifting blocks, sling ropes, etc.).
• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the hose.
2.4 Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 11
Page 14
1
1
1
1
3 Product Description
3 Product Description
3.1 System description
System layout
The images show a typical single-pump and multi-pump system using the unit. When the system is connected directly to the water supply use a low-pressure switch on
the suction side.
Pressure tank
Figure 1: Single-pump system
Figure 2: Multi-pump system
1. Pump with HYDROVAR
2. Diaphragm pressure tank
3. Distribution panel
4. Gate valve
5. Non-return valve
6. Low water control
7. Pressure gauge
8. Pressure sensor
9. Drain tap
A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure in the pipes when there is no water demand. The unit stops the pump from continuing to run at zero demand and reduce the size of the tank that is required for supply purposes.
The tank must be permitted and suitable for systems pressure. The capacity of the tank must be 10% of the maximum system flow rate of the pump or
pumps (0.1 times the flow rate in l/min or gal/min). Turn off the unit to reduce the water pressure to check and set the correct pre-charged pressure.
The pre-charge pressure of the tank can be determined by using the following table:
Required pressure or Start Value when active [bar]
Pre-charge pressure [bar]
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3.2 Product function and use
Description
HYDROVAR is a pump-mounted variable speed, microprocessor-based system controller. It can be mounted onto virtually any model of fan cooled motor and is simple to integrate into BMS systems with ModBus or Bacnet communication as standard.
In a variable speed controlled system, the pump works every time with the speed where it produces at the reduced flow exactly the required head. Therefore there is no wasted energy given to the system like on/off or bypass control.
Intended use
HYDROVAR is made for the following pump applications:
• Pressure, level, and flow regulation
• Closed loop systems
• Irrigation applications with single or multiple pumps
Improper use
The product must not be used for constant torque applications.
Approvals and certifications
3 Product Description
The unit complies with UL508C thermal memory retention requirements.
3.3 Applications
Application alternatives
The application alternatives for the product are the following:
• Actuator
• Controller
• Cascade serial / Synchronous
• Cascade relay
3.3.1 Actuator
This mode is used for a unit in a single pump operation only. The unit operates as an actuator according an external speed signal or continuous operation on either one or two programmed frequencies. This is done by using the corresponding digital input.
3.3.2 Controller
This mode is set as the default operating mode and is used for a unit in a single pump operation.
3.3.3 Cascade serial / Synchronous
In these applications, each of the pumps (up to eight pumps) must be equipped with a unit.
The units are connected via the RS485 interface and communicate via the provided protocol.
The combination of the different units which are used in a multi-pump-system depends on the system requirements.
It is possible to run all pumps in cascade serial mode and synchronous mode as well. If one unit fails, then each pump of the system can become the lead pump and can take control.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 13
Page 16
1
2
.
-
-
3 4 5 6 7 821
.
3 Product Description
3.3.4 Cascade relay
Description
One pump is fitted with the unit and up to five slave pumps can be switched to on/off on demand. The unit uses an additional Premium Card for this purpose.
For switching the slave pumps an external switchboard has to be installed.
Example
The example shows a booster set with four pumps where only one speed-controlled pump and the others are fixed speed.
1. HYDROVAR
2. External panel
3.4 The data plate
Type definition code
Figure 3: Definition code and placement
No. Description Alternatives
1 Brand HVL - HYDROVAR
2 Power supply 2: 1~ 230 VAC
3 Shaft power *10 [kW] 015: 1.5 kW (2.0 HP)
4 Enclosure rate A: IP 55 / Type1
5 Bus communication 0: Standard communication
3: 3~ 230 VAC 4: 3~ 380–460 VAC
022: 2.2 kW (3.0 HP) 030: 3.0 kW (4.0 HP) 040: 4.0 kW (5.0 HP) 055: 5.5 kW (7.5 HP) 075: 7.5 kW (10.0 HP) 110: 11.0 kW (15.0 HP) 150: 15.0 kW (20.0 HP) 185: 18.5 kW (25.0 HP) 220: 22.0 kW (30.0 HP)
14 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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Example
.
-
-
3 4 5 6 7 821
075 A 0 0 1 04HVL
.
3 Product Description
No. Description Alternatives
6 Optional cards 0: No optional cards
7 Internal display 1: Standard internal display installed
8 Other options 0: No other options installed
No. Example Description
1 HVL HYDROVAR
2 4 Power Supply: 3~ 380–460 VAC
3 075 Shaft power: 7.5 kW (10.0 HP)
4 A Enclosure rate: IP 55 / Type1
5 0 Standard communication
6 0 No optional cards installed
7 1 Standard internal display installed
8 0 No other options installed
3.5 Technical Data
Electrical specification
HVL
2.015 2.022 2.030 2.040 3.015 3.022 3.030 3.040 3.055 3.075 3.110 4.015 4.022 4.030 4.040 4.055 4.075 4.110 4.150 4.185 4.220
Input
Mains Supply L N L1 L2 L3 L1 L2 L3
Nominal input voltage (Vin):
Maximum Input Current, continuous [A]:
efficiency,
rated [%], typically:
Output
Output voltage (V)
Maximum output current, continuous [A]:
Output frequency (Hz)
208–240±10% 208–240±10% 380–460±15%
11.6 15.1 22.3 27.6 7.0 9.1 13.3 16.5 23.5 29.6 43.9 3.9 5.3 7.2 10.1 12.8 16.9 24.2 33.3 38.1 44.7
94.0 93.5 93.5 93.5 96.0 96.0 96.0 96.0 96.0 96.0 96.0 96.0 96.5 96.5 96.5 97.0 97.0 97.0 97.0 97.0 97.0
0–240 0–100% of supply voltage 0–100% of supply voltage
7.5 10 14.3 16.7 7.5 10 14.3 16.7 24.2 31 44 4.1 5.7 7.3 10 13.5 17 24 32 38 44
15–70
Environmental specification
Storage temperature -30°C [-22°F] to 70°C [158°F]
Relative humidity 5%-95% - Condensation is not permitted
Operational temperature -10°C [-14°F] to 55°C [131°F]
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 15
100% power rating -10°C [-14°F] to 40°C [104°F] with de-rating 40°C [104°F] to 55°C [131°F]
Page 18
3 Product Description
Air pollution The air may contain dry dust as found in workshops where there is
excessive dust due to machines. Excessive amounts of dust, acids, corrosive gases, salts etc are not permitted.
Altitude Max. 1000 m above sea level. For installation over 1000 m above sea
level, the maximum output power has to be de-rated by 1% for every additional 100 m. If the installation site is over 2000 m above sea level, please contact your local distributor or service contact.
Installation specification
Protection Motor drive input have to be protected by an external circuit breaker/
fuse
Motor wire type shielded power cable
Maximum motor cable length (no EMC compliant), screened 50m (164ft)
Maximum motor cable length (no EMC compliant), unscreened 100m (328ft)
EMC compliance
In accordance with IEC 61800-3 and EN 61000 series standards, shield cable will be used for motor drive output and communication.
Installations must be done according EMC correct installations and avoiding pigtails (on the drive side), otherwise EMC cannot be guaranteed.
Class of protection
• IP55, Enclosure Type 1
• Protect the product from direct sunlight
• Protect the product from direct rainfall
• Outdoor installation without protection, to especially keep the temperature limits of the product, is not permitted
3.6 Motor thermal protection
Motor thermal protection can be implemented using various techniques: PTC sensor in motor windings or Software Thermal Control (STC).
Protection against motor overheating comes from par. 290 "STC Motor Protection", which by default is pre-sett to data value "STC trip".
NOTICE: The STC function is initialized at 1.125 x rated motor current and rated motor frequency. The STC function provides class 20 motor overload protection in accordance with the NEC.
Motor thermal protection prevents the motor from overheating. The STC function is an electronic feature that simulates a bimetal relay that is based on internal measurements. The characteristic is shown in the following figure.
16 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 19
The X-axis shows the ratio between Imotor actual and Imotor nominal. The Y-axis shows
216
243
170
205
HVNG-IOM_HVLA_DIMENSIONS_A_SC
the time in seconds before the STC cuts off and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 20% of the nominal speed. The curve shows that at lower speed the STC cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from overheating even at low speed. The STC function calculates the motor temperature that is based on actual current and speed.
The calculated percentage of allowed maximum temperature is visible as a readout in par. 293 "Motor Thermal".
With the STC the motor is protected from being overheated and there is no need for any further motor protection. That means when the motor is heated up the STC timer controls how long the motor can be operated at the high temperature before it is stopped in order to prevent overheating.
Motor thermal protection can also be achieved using an external thermistor: set par. 290 "STC Motor Protection" to data value "Thermistor trip".
3.7 Dimensions and weights
Reading instructions
All measurements are in millimeters (inches). The images are not to scale.
3 Product Description
Free distance
Dimensional drawings
Area Models Free distance
Above the unit All > 300 mm (12 in)
Center-distance between units (to ensure space for cabling):
HVL 2.015 ÷ 2.022 | 3.015 ÷ 3.022 |
4.015 ÷ 4.040
HVL 2.030 ÷ 2.040 | 3.030 ÷ 3.055 |
> 300 mm (12 in)
> 430 mm (17 in)
4.055 ÷ 4.110
HVL 3.075 ÷ 3.110 | 4.150 ÷ 4.220 > 550 mm (21,6 in)
Figure 4: HVL2.015, HVL2.022, HVL3.015, HVL3.022, HVL4.015 ÷ HVL4.040
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 17
Page 20
276
305
185
265
HVNG-IOM_HVLB_DIMENSIONS_A_SC
366
407
200
337
HVNG-IOM_HVLC_DIMENSIONS_A_SC
3 Product Description
Figure 5: HVL2.030, HVL2.040, HVL3.030 ÷ HVL3.055, HVL4.055 ÷ HVL4.110
Figure 6: HVL3.075 ÷ HVL3.110, HVL4.150 ÷ HVL4.220
Weight
Models Maximum Weight
HVL 2.015 ÷ 2.022 | 3.015 ÷ 3.022 | 4.015 ÷ 4.040 5,6 Kg (12,3 lbs)
HVL 2.030 ÷ 2.040 | 3.030 ÷ 3.055 | 4.055 ÷ 4.110 10,5 Kg (23 lbs)
HVL 3.075 ÷ 3.110 | 4.150 ÷ 4.220 15,6 Kg (34,4 lbs)
3.8 Design and layout
Parts and descriptions
The unit can be fitted with the features the application requires.
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4
3
1
2
3 Product Description
Position number Description
1 Power board, heatsink, EMC filter
2 Control board
3 Cover
4 Plastic cover
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 19
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3 Product Description
3.9 Included mounting components
Included
components
Cable Gland(s) and Lock Nut(s)
Entry Thread Reducer
Plug(s) for Cable Gland(s)
Screws M5x30 4
Spade Connector(s) for PE conductors
Spares sealing ring 2
Centering pin 1 1 1
Mounting Clamps 4 4 4
M12 3.5 ÷ 7.0 0.138 ÷
M16 5.0 ÷ 10.0 0.197 ÷
M20 7.0 ÷ 13.0 0.275 ÷
M25 10.0 ÷ 17.0 0.394 ÷
M32 13.0 ÷ 21.0 0.512 ÷
M40 19.0 ÷ 28.0 0.748 ÷
M40 ->
M32
M12 3 3 3
M16 2 2 2
M5x40 4
M6x40 4 4
M6x50 4 4
RF-U 4 2 2
BF-U 4 2 2
GF-U 4 2 2
Cable outer diameter Model
(mm) inches HVL 2.015 ÷ 2.022 |
3.015 ÷ 3.022 | 4.015 ÷ 4.040
3 3 3
0.275
2 2 2
0.394
2
0.512
2
0.669
0.827
2
1.102
HVL 2.030 ÷ 2.040 |
3.030 ÷ 3.055 | 4.055 ÷ 4.110
HVL 3.075 ÷ 3.110 |
4.150 ÷ 4.220
2
2
For HVL 3.075 ÷ 3.110 or HVL 4.150 ÷ 4.220, if the cables outer diameter is incompatible with the included cable glands, use the supplied Entry Thread Reducers (and spares sealing rings).
20 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 23
M40 M40 M40XM32
38X48
M32
HVNG-IOM_HVLC_REDUCER_A_SC
3 Product Description
3.10 Optional components
Components
Component Description
Motor cables The motor cable that is ready to connect to the unit.
Mounting ring If the motor fan is made of plastic, then a mounting ring is used.
Sensors The following sensors can be used with the unit:
Premium Card HYDROVAR Card to control up to five slave pumps and to connect additional
Wi-Fi Card HYDROVAR To connect and interact wireless with HYDROVAR
It is available in two diameters: 140 mm (5.5 in) and 155 mm (6.1 in).
• Pressure-transducer
• Differential pressure-transducer
• Temperature-sensor
• Flow indicator (orifice plate, inductive flow meter)
• Level-sensor
analog and digital I/Os
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 21
Page 24
4 Installation
4 Installation
4.1 Installation site checklist
DANGER:
Never install the system controller in an explosive or flammable environment.
WARNING:
• Always refer to the local and national regulations, legislation, and codes in force regarding selection of installation site, and water and power connections.
• Keep the manual, drawings, and diagrams accessible for detailed installation and operation instructions. It is important that the manual is available for equipment operators.
• Install the unit on the motor fan cover. Keep motor cables as short as possible. Check the motor characteristics for actual tolerances.
• For wall mounting installations with long motor cables, use the output filter option to protect the motor.
• Ensure that the ingress protection rating of Hydrovar (IP55, Type1) is suitable for the installation environment.
CAUTION:
• Ingress protection. IP55 (Type 1) rating can only be guaranteed if the unit is properly closed.
• Make sure that there is no liquid on the unit before opening the plastic cover.
• Ensure all cable glands and unused holes for glands are properly sealed.
• Ensure that the plastic cover is properly closed.
• Device damage through contamination. Do not leave Hydrovar uncovered.
4.2 Frequency converter and motor pre-installation check list
• Compare the model number of the unit on the nameplate to what was ordered to verify the proper equipment.
• Ensure each of the following are rated for same voltage:
– Mains (power) – Frequency converter – Motor
• Ensure that the frequency converter output current rating is equal to or greater than motor service factor current for peak motor performance.
– Motor size and frequency converter power must match for proper overload
protection.
– If frequency converter rating is less than motor, full motor output cannot be
achieved.
22 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 25
5 Mechanical Installation
5.1 Cooling
• The frequency converter is cooled by means of air circulation. To protect the unit from overheating, it must be ensured that the ambient temperature does not exceed the maximum temperature stated for the frequency converter and that the 24-hour average temperature is not exceeded.
• Derating for temperatures between 40°C (104°F) and 50°C (122°F) and elevation 1000 m (3300 ft) above sea level must be considered.
• Improper mounting can result in overheating and reduced performance.
CAUTION:
During the normal operation, the heat sink surfaces may be so hot that only the buttons should be touched to avoid burns.
5.2 Lifting
• Check the weight of the unit to determine a safe lifting method.
• Ensure that the lifting device is suitable for the task.
• If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit.
• For lifting, use hoist rings on the unit, when provided.
5 Mechanical Installation
5.3 Mounting
• Install the unit on the motor fan cover. Keep motor cables as short as possible. Check the motor characteristics for actual tolerances.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 23
Page 26
HVNG-IOM_MOUNT_EXPLOD-1_B_SC
1
3
6
4
8
2
5
7
9
5 Mechanical Installation
1. Actual value sensor
2. Motor conduit box
3. Motor fan cover
4. Motor cable
5. Mounting clamps
6. Centring pin
7. Screws for mounting clamps
8. Plastic cover
9. Screws for plastic cover Refer to callouts in preceding image.
1. Fit the rubber centering pin [6] on the bottom of the HYDROVAR®.
24 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 27
5 Mechanical Installation
NOTICE:
Always use a stainless steel mounting ring if the motors fan cover is made of plastic.
2. Center the unit on the motor fan cover [3] using the centering pin [6].
3. Adjust mounting clamps [5] length for smaller motor sizes, as indicated in the picture that follows.
NOTICE:
Take care about sharp edges and remove them properly.
4. Fasten the unit: a. Fasten the mounting clamps [5] and relative screws [7].
b. Tighten the screws [7] until the two bottom teeth in the brackets grip the fan cover. c. Tighten the screws until the unit is securely fastened.
5. Remove the screws for plastic cover [9].
6. Remove the plastic cover [8].
7. Make the electrical connections.
–
For more information about how to make the electrical connections, see Electrical
Installation.
NOTICE:
You can remove the metal plate to make the electrical installation easier.
Mounting clamps
8. Mount and fasten the plastic cover [8] using 2,0 Nm tightening torque.
Electrical Hazard:
Make sure that all the cable glands are mounted properly and that all the unused cable entries use closing plugs.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 25
Page 28
6 Electrical Installation
6 Electrical Installation
6.1 Precautions
WARNING:
• EQUIPMENT HAZARD. Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. Installation, start­up, and maintenance must be performed by trained and qualified personnel. Failure to follow these guidelines could result in death or serious injury.
Electrical Hazard:
• All electrical wiring must be carried out by an authorized electrician, in accordance with the electrical regulations locally in force.
NOTICE:
WIRING ISOLATION. Run input power, motor wiring and control wiring in three separate metallic conduits or use separated shielded cable for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum frequency converter and associated equipment performance.
For your safety comply with the following requirement:
• Electronic control equipment is connected to hazardous mains voltage. Extreme care should be taken to protect against electrical hazards when applying power to the unit.
Earth (grounding) requirements
WARNING:
For operator safety, it is important to ground the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document. Ground currents are higher than 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury.
NOTICE:
It is the responsibility of the user or certified electrical installer to ensure correct grounding (earthing) of the equipment in accordance with national and local electrical codes and standards.
• Follow all local and national electrical codes to ground electrical equipment properly.
• Proper protective grounding for equipment with ground currents higher the 3.5 mA must be established. See the Leakage current (>3.5 mA) section for details.
• A dedicated ground wire is required for input power, motor power and control wiring.
• Use the clamps provided with the equipment for proper ground connections.
• Do not ground one frequency converter to another in a “daisy chain” fashion.
• Keep the ground wire connections as short as possible.
• Using high-strand wire to reduce electrical noise is recommended.
• Follow motor manufacturer wiring requirements.
Leakage current (>3.5 mA)
Follow national and local codes regarding protective earthing of equipment with a leakage current > 3.5 mA. Frequency converter technology implies high frequency switching at high power. This will generate a leakage current in the earth connection. A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current. The
26 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 29
earth leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.
EN/EC61800–5–1 (Power Drive System Product standard) requires special care if the leakage current exceeds 3.5 mA. Earth grounding must be reinforced in one of the following ways:
• Earth ground wire of at least 8 AWG or 10 mm2 Cu (or 16mm2 Al).
• Two separate earth ground wires of the same cross sectional area.
See EN60364–5–54 section 543.7 for further information. On HYDROVAR, the phase conductor and the corresponding protective earthing
conductor can be of the same cross-sectional area, provided they are made of the same metal (because the cross-sectional area of the phase conductor is less than 16 mm2).
The cross-sectional area of every protective earthing conductor which does not form a part of the supply cable or cable enclosure shall, in any case, be not less than:
• 2.5 mm2 if mechanical protection is provided or
• 4 mm2 if mechanical protection is not provided. For cord-connected equipment, provisions shall be made so that the protective earthing conductor in the cord shall, in the case of failure of the strain-relief mechanism, be the last conductor to be interrupted.
6.2 Protection devices
6 Electrical Installation
Fuses and Circuit Breakers
• An electronically activated function within the frequency converter provides overload protection in the motor. The overload calculates the level of increase to activate timing for the trip (controller output stop) function. The higher the current draw, the quicker the trip response. The overload provides Class 20 motor protection. See Warnings and alarms for details on the trip function.
• Hydrovar must be provided with short-circuit and over-current protection to avoid overheating of the cables in the installation. Input fusing and/or circuit breakers are required to provide this protection. Fuses and Circuit Breakers must be provided by the installer as part of installations.
• Use recommended fuses and/or circuit breakers on the supply side as protection in case of component breakdown inside the adjustable frequency drive (first fault). Use of recommended fuses and circuit breakers ensures possible damage to the adjustable frequency drive is limited to damages inside the unit. For other circuit breaker types, ensure that the energy into the adjustable frequency drive is equal to or lower than the energy provided by recommended types.
• The fuses below are suitable for use on a circuit capable of delivering 100,000 Ams (symmetrical), 480V maximum. With the proper fusing the adjustable frequency drive Short Circuit Current Rating (SCCR) is 100,000 Ams.
Table 1: Recommended fuses and circuit breakers
Voltage
supply
1~ 230 VAC
Fuse Circuit
breaker
HVL
2.015 JJN-20 TJN (20) JLLN 20 A3T20 20 S201-C20
2.022 JJN-25 TJN (25) JLLN 25 A3T25 25 S201-C25
2.030 JJN-35 TJN (35) JLLN 35 A3T35 35 S201-C32
2.040 JJN-35 TJN (35 JLLN 35 A3T35 35 S201-C40
Bussmann Edison Littelfuse Ferraz-
UL Non UL
Fuse ABB
Shawmut
Type T Type gG MCB S200
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 27
Page 30
6 Electrical Installation
Voltage
supply
3~ 230 VAC
3~ 380–460
VAC
Fuse Circuit
breaker
HVL
Bussmann Edison Littelfuse Ferraz-
UL Non UL
Fuse ABB
Shawmut
Type T Type gG MCB S200
3.015 JJN-15 TJN (15) JLLN 15 A3T15 16 S203-C16
3.022 JJN-15 TJN (15) JLLN 15 A3T15 16 S203-C16
3.030 JJN-20 TJN (20) JLLN 20 A3T20 16 S203-C20
3.040 JJN-25 TJN (25) JLLN 25 A3T25 25 S203-C25
3.055 JJN-30 TJN (30) JLLN 30 A3T30 25 S203-C32
3.075 JJN-50 TKN (50) JLLN 50 A3T50 50 S203-C50
3.110 JJN-60 TJN (60) JLLN 60 A3T60 63 S203-C63
4.015 JJS-10 TJS (10) JLLS 10 A6T10 10 S203-C10
4.022 JJS-10 TJS (10) JLLS 10 A6T10 10 S203-C13
4.030 JJS-15 TJS (15) JLLS 15 A6T15 16 S203-C13
4.040 JJS-15 TJS (15) JLLS 15 A6T15 16 S203-C16
4.055 JJS-20 TJS (20) JLLS 20 A6T20 20 S203-C20
4.075 JJS-20 TJS (20) JLLS 20 A6T20 20 S203-C25
4.110 JJS-30 TJS (30) JLLS 30 A6T30 30 S203-C32
4.150 JJS-50 TJS (50) JLLS 50 A6T50 50 S203-C50
4.185 JJS-50 TJS (50) JLLS 50 A6T50 50 S203-C50
4.220 JJS-60 TJS (60) JLLS 60 A6T60 63 S203-C63
Type gG fuses in the table are reporting the fuses rated current.
Residual Current Devices, RCDs (GFCIs)
Where Ground Fault Circuit Interrupters (GFCIs) and residual current devices (RCDs), also know as earth leakage circuit breakers (ELCDs), are used, comply with the following:
• for HVL 2.015 ÷ 2.040, use GFCIs (RCDs) which are capable of detecting AC currents and pulsating currents with DC components. These GFCIs (RCDs) are marked with the
following symbol:
• for HVL 3.015 ÷ 3.110 and 4.015 ÷ 4.220, use GFCIs (RCDs) which are capable of detecting AC and DC currents. These GFCIs (RCDs) are marked with the following
symbols:
• Use GFCIs (RCDs) with an inrush delay to prevent faults due to transient earth currents.
• Dimension GFCIs (RCDs) according to the system configuration and environmental considerations.
NOTICE:
When an earth leakage circuit breaker or ground fault circuit interrupter is selected, the total leakage current of all the electrical equipment in the installation must be taken into account.
28 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 31
6.3 Wire type and ratings
• All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements.
• Use cables with a minimum heat resistance of +70 °C (158 °F); to obey the UL (Underwriters Laboratories) regulations, it is recommended that all power connections be made with a minimum 75°C rated copper wire of the following types: THW, THWN.
Table 2: Recommended power connections cables
HVL Power supply input cable + PE Motor output cables + PE
Wire numbers x Max.
copper section
2.015 3 x 2mm
2.022
2.030 3 x 6mm
2.040
3.015 4 x 2mm
3.022
3.030 4 x 6mm
3.040
3.055
3.075 4 x 16mm
3.110
4.015 4 x 2mm
4.022
4.030
4.040
4.055 4 x 6mm
4.075
4.110
4.150 4 x 16mm
4.185
4.220
6 Electrical Installation
Wire numbers x Max.
AWG
2
2
2
2
2
2
2
2
3 x 14AWG 4 x 2mm
3 x 10AWG 4 x 6mm
4 x 14AWG 4 x 2mm
4 x 10AWG 4 x 6mm
4 x 5AWG 4 x 16mm
4 x 14AWG 4 x 2mm
4 x 10AWG 4 x 6mm
4 x 5AWG 4 x 16mm
Wire numbers x Max.
copper section
2
2
2
2
2
2
2
2
Wire numbers x Max.
AWG
4 x 14AWG
4 x 10AWG
4 x 14AWG
4 x 10AWG
4 x 5AWG
4 x 14AWG
4 x 10AWG
4 x 5AWG
Table 3: Tightening torques for power connections
HVL
2.015 ÷ 2.022
3.015 ÷ 3.022
4.015 ÷ 4.040
2.030 ÷ 2.040
3.030 ÷ 3.055
4.055 ÷ 4.110
3.075 ÷ 3.110
4.150 ÷ 4.220
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 29
Tightening torque
Mains and motor cable terminals Earth conductor
Nm lb-in Nm lb-in
0.8 7.1 3 26.6
1.2 10.6 3 26.6
1.2 10.6 3 26.6
Page 32
6 Electrical Installation
Control cables
All control cables that are connected to the control board must be screened. External volt free contacts must be suitable for switching < 10 VDC.
NOTICE:
If unscreened control cables are used, then signal interference with the incoming signals and the function of the unit can be compromised.
Table 4: Recommended control cables
Hydrovar Control Cables
All I/O conductors 0.2 ÷ 1.6 25÷ 16 0.5–0.6 4.5–5.4
6.4 EMC compatibility
6.4.1 EMC requirements
Hydrovar fulfills the product standard EN61800-3:2004 + A1:2012, which defines categories (C1 to C4) for device application areas.
Depending on the motor cable length, a classification of Hydrovar by category (based on EN61800-3) is reported in the following table:
Table 5: EMC categories
HVL Hydrovar classification by categories based on 61800-3
2.015 ÷ 2.040 C1 (*)
3.015 ÷ 3.110 C2 (*)
4.015 ÷ 4.220 C2 (*)
(*) 0,75 motor cable length; contact Xylem for further information NOTICE: No external EMC filters are required to make Hydrovar compliant with the limit
values of each category reported in the preceding table; motor cable shall be shielded.
Copper section Tightening torque
2
mm
AWG Nm lb-in.
6.4.2 Wiring the cables
To ensure electromagnetic compatibility the following points must be observed for cable installation:
• Ground cables should be as short as possible and with lowest impedance.
• Signal cables should be screened types to prevent disturbances from outside. Connect the shield to ground on one end only (to prevent ground loops), preferably to HYDROVAR GND using the pre mounted cable-clips; to connect a shield with lowest impedance to ground, remove the insulation from the signal cable and connect the shield to ground, as shown in the following image.
• Shielded Motor cable should be as short as possible; connect the shield to ground on both ends!
30 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 33
HVNG-IOM_FIX-CAVI_A_SC
6 Electrical Installation
6.4.3 RFI switch
NOTICE:
Signal cables must be installed separate both from motor cable and power supply cable. If signal cables are installed in parallel to power supply cable or to motor cable for a longer distance, the distance between these cables should be more than 200mm. Do not cross power cables and control cables - if this is not possible, cross them only in an angle of 90°.
In case mains power supply is impedance-grounded (IT), the AC drive must have the EMC protection level C4 as per product standard EN61800-3:2004 + A1:2012: it is then necessary to deactivate the RFI filter of Hydrovar, by unscrewing the RFI switch depicted in the following image.
WARNING:
Do not make changes on Hydrovar when it is connected to mains: Make sure that the unit is disconnected from the power supply before removing the screw.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 31
Page 34
U V W
L1/L L2 L3/N
RFI
SWITCH
HVNG-IOM_RFI-SWITCH_A_SC
SWITCH
RFI
HVNG-IOM_SUPPLY-CABLE-1F_A_SC
U V W
L1/L L2 L3/N
RFI
SWITCH
L1/L L2 L3/N
6 Electrical Installation
6.5 AC mains and motor connection terminals
Unscrew the dedicated 6 screws and remove the plastic cover of Hydrovar, in order to proceed wiring the power supply and the motor terminal, as described in the following paragraphs.
6.5.1 AC Mains (power supply) connection
1. Size wiring based upon the input current of Hydrovar Comply with local and national electrical codes for cable sizes.
2. Connect 1–phase AC input power wiring to terminals L and N: make sure phase and neutral are properly aligned to provided terminals L and N.
32 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 35
3. Connect 3–phase AC input power wiring to terminals L1, L2, and L3.
HVNG-IOM_SUPPLY-CABLE-3F_A_SC
U V W
L1/L L2 L3/N
RFI
SWITCH
L1/L L2 L3/N
HVNG-IOM_2ND_EARTHPOINT_A_SC
6 Electrical Installation
4. Ground the cable in accordance with grounding instructions provided.
5. If a double earthing is necessary, use the earth terminal under the heatsink of the drive.
6.5.2 Motor connection
WARNING:
INDUCED VOLTAGE. Run output motor cables from multiple frequency converters separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately could result in death or serious injury.
• Comply with local and national electrical codes
• Do not install power factor correction capacitors between the frequency converter and the motor
• Do not wire a starting or pole-changing device between Hydrovar and the motor
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 33
Page 36
HVNG-IOM_MOTOR-SUPPLY_A_SC
U V W
L1/L L2 L3/N
RFI
SWITCH
U V W
U V W
U V W
H Y D R O V A R
H Y D R O V A R
U
V
W
U
V
W
MOT_CONN_A-SC
6 Electrical Installation
• Connect 3–phase motor wiring to terminals U, V, and W.
• Ground the cable in accordance with grounding instructions provided
• Torque terminals in accordance with the informations provided.
• Follow motor manufacturer wiring requirements
• The connection of the motor cable depends on the type of 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.
• The connection of the motor cable shield can be done using a pigtail connected to a PE screw (see image below), or by using a metallic cable gland in case of motor with metallic conduit box connected to PE.
6.6 Control terminals
Unscrew the dedicated 6 screws and remove the plastic cover of the Hydrovar, in order to proceed wiring the control terminals, as described in the following paragraphs; for
34 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
reference, the wiring harness scheme is reported on the backside of the plastic cover too.
Page 37
COVER_B-SIDE_A_SC
Figure 7: Cover
HVNG-IOM_CONTROL-BOARD_A_SC
6 Electrical Installation
Do not connect the ground of the control card to other voltage potentials. All ground terminals and ground of the RS485 connection are connected internally.
Figure 8: Control board
6.6.1 Motor sensor connection
Terminals X1/7 and X1/8 are used to connect a motor sensor (PTC or thermal switch) to stop the unit in case of failure; any other protective device can be connected to these terminals.
As described in par. 3.6 Motor thermal protection, this input can be enabled by setting par. 290 "STC Motor Protection" to data value "Thermistor trip".
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 35
Page 38
6 Electrical Installation
Table 6: PTC terminals
Terminals Description
X1/7 PTC or thermal switch input
X1/8 PTC or thermal switch input (Ground)
6.6.2 Input for emergency basic operations
Terminals X1/20 and X1/21 are used to connect an external switch which forces (when closed) Hydovar to perform a manual start-up till reaching the maximum frequency (fixed speed) set by par. 245 "Maximum Frequency
Table 7: SL terminals
Terminals Description
X1/20 External switch (SOLO RUN) input
X1/21 External switch (SOLO RUN) input (Ground)
6.6.3 Digital and analog I/O
Several terminals, from X1/1 to X1/24, are used to connect analog and digital I/Os to correspondent input signals, most of them configurable by specific parameters.
Table 8: I/O terminals
Item Terminals Description Comments
X1/1 Power supply for external
24VDC, Σ max. 100mA
sensor 1
Sensor 1
X1/2 Actual value current/voltage
input sensor 1
0-20mA / 4-20mA / 0-10 VDC / 2-10 VDC
X1/3 Ground for external sensor1GND, electronic ground (for
X1/2)
X1/4 Power supply for external
24VDC, Σ max. 100mA
sensor 2
Sensor 2
X1/5 Actual value current/voltage
input sensor 2
0-20mA / 4-20mA / 0-10 VDC / 2-10 VDC
X1/6 Ground for external sensor2GND, electronic ground (for
X1/5)
X1/9 Auxiliary voltage supply 10VDC, max. 3mA
Auxiliary
X1/10 Ground for auxiliary voltage
supply
GND, electronic ground (for X1/9)
X1/14 Configurable digital input 1 Active low
Digital Input
X1/15 Ground for configurable
digital input 1
GND, electronic ground (for X1/14)
X1/16 Low water input Active low
Low water
X1/17 Ground for low water input GND, electronic ground (for
X1/16)
X1/18 External ON/OFF input Active low
External ON/OFF
External fan (Not to be
used: only for Wall
Mounting kit connection!)
X1/19 Ground for external ON/OFF
input
X1/22 External fan control
X1/23 Ground for external fan
control
GND, electronic ground (for X1/18)
GND, electronic ground (for X1/22)
36 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 39
6.6.4 RS485 connection
Terminals X1/11, X1/12 and X1/13 are used for the communication among up to 8 Hydrovar in a multi-pump application; a dedicated termination resistor switch (BUS1, see image below) is made available to add a parallel terminator resistor to this RS485 port: if the resistor is needed put BUS1 switch on ON position.
Terminals X1/24, X1/25 and X1/26 are used for the communication (via Modbus or Bacnet protocol) with an external-control-device (e.g. PLC, BMS or a PC too); a dedicated termination resistor switch (BUS2, see image below) is made available to add a parallel terminator resistor to this RS485 port: if the resistor is needed put BUS2 switch on ON position.
6 Electrical Installation
Table 9: RS485 ports
6.6.5 Status relays
Terminals X2/4, X2/5 and X2/6 are used to make available Status Relay 1 contacts, for driving an external relay used as pump status configurable indicator.
Terminals X2/1, X2/2 and X2/3 are used to make available Status Relay 2 contacts, for driving an external relay used as pump status configurable indicator.
Terminals Description Comments
X1/11 RS485 port 1: RS485-1N
X1/12 RS485 port 1: RS485-1P
X1/13 GND, electronic ground
RS485 port 1 for multi-pump systems
BUS1 Termination resistor for port 1
X1/24 RS485 port 2: RS485-2N
X1/25 RS485 port 2: RS485-2P
RS485 port 2 for external
X1/26 GND, electronic ground
BUS2 Termination resistor for port 2
communication
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 37
Page 40
6 Electrical Installation
Table 10: Status relays
Terminals Description Comments
X2/1 Status Relay 2: NO Status Relay 2
X2/2 Status Relay 2: NC
X2/3 Status Relay 2: CC
X2/4 Status Relay 1: NO Status Relay 1
X2/5 Status Relay 1: NC
X2/6 Status Relay 1: CC
6.7 Premium card terminals
6.7.1 Digital and analog I/O (X3)
Several terminals, from X3/1 to X3/12, are used to connect additional analog and digital I/Os to correspondent input signals, most of them configurable by specific parameters.
Table 11: PC I/O terminals
Item Terminals Description Comments
Digital Input
Signal 1
Signal 2
Sensor 3
Sensor 4
Maximum 250 VAC, 0.25 A Maximum 220 VDC, 0.25 A
Maximum 30 VDC, 2 A
Maximum 250 VAC, 0.25 A Maximum 220 VDC, 0.25 A
Maximum 30 VDC, 2 A
X3/1 Configurable digital input 2 Active low
X3/2 Ground for configurable
digital input 2
X3/3 Analog output signal 1 4-20mA
X3/4 Ground for analog output
signal 1
X3/5 Analog output signal 2 0-10 VDC
X3/6 Ground for analog output
signal 2
X3/7 Power supply for external
sensor 3
X3/8 Actual value current/voltage
input sensor 3
X3/9 Ground for external sensor3GND, electronic ground (for
X3/10 Power supply for external
sensor 4
X3/11 Actual value current/voltage
input sensor 4
X3/12 Ground for external sensor4GND, electronic ground (for
GND, electronic ground (for X3/1)
GND, electronic ground (for X3/3)
GND, electronic ground (for X3/5)
24VDC, Σ max. 100mA
0-20mA / 4-20mA / 0-10 VDC / 2-10 VDC
X3/8)
24VDC, Σ max. 100mA
0-20mA / 4-20mA / 0-10 VDC / 2-10 VDC
X3/11)
6.7.2 Relays (X4)
Several terminals, from X4/1 to X4/6, are used to connect up to 5 fixed speed pumps through an external panel.
38 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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6 Electrical Installation
Table 12: Relay terminals
Terminals Description Comments
X4/1 Relay 1: NO Maximum 250 VAC, 0.25 A
X4/2 Relay 2: NO
X4/3 Relay 3: NO
Maximum 220 VDC, 0.25 A
Maximum 30 VDC, 0.25 A
X4/4 Relay 4: NO
X4/5 Relay 5: NO
X4/6 Ground for relays
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 39
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7 Operation
7 Operation
7.1 Pre-start procedure
Electrical Hazard:
If input and output connections have been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge capacitors within the frequency converter, even when disconnected from mains input. For initial start up, make no assumptions about power components. Follow pre-start procedures. Failure to follow pre-start procedures could result in personal injury or damage to equipment.
1. Make sure input power to unit is OFF and locked out. Do not rely on the frequency converter disconnect switches for input power isolation.
2. In case of 1–phase AC input power, verify that there is no voltage on input terminals L and N, phase-to-phase and phase-to-ground.
3. In case of 3–phase AC input power, verify that there is no voltage on input terminals L1, L2 and L3, phase-to-phase and phase-to-ground.
4. Verify that there is no voltage on output terminals U, V and W, phase-to-phase and phase-to-ground.
5. Confirm continuity of the motor by measuring ohm values on U-V, V-W and W-U.
6. Check for proper grounding of the frequency converter as well as the motor.
7. Inspect the frequency converter for loose connections on terminals.
8. Record the following motor-nameplate data: power, voltage, frequency, full load current, and nominal speed. These values are needed to program motor nameplate data later.
9. Confirm that the supply voltage matches voltage of frequency converter and motor.
7.2 Pre-startup inspections
Item to Inspect Description Checked
Auxiliary equipment • Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may
reside on input power side of the frequency converter or output side to motor. Ensure they are ready for full speed operation.
• Check function and installation of any sensors used for feedback to the frequency converter.
• Remove power factor correction caps on motor(s), if present.
Cable routing • Ensure that input power, motor wiring and control wiring are separated or in three separate
metallic conduits for high frequency noise isolation.
Control wiring • Check for broken or damaged wires and connections.
• Check that control wiring is isolated from power and motor wiring for noise immunity.
• Check the voltage source of the signals, if necessary.
• The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly.
Cooling clearance • Measure that top and bottom clearance is adequate to ensure proper air flow for cooling.
EMC considerations • Check for proper installation with regard to electromagnetic capability.
Environmental conditions • See equipment tech label for the maximum ambient operation temperature limits.
• Humidity levels must be 5–95% non-condensing.
Fusing and circuit breakers • Check for proper fusing or circuit breakers.
• Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are in the open position.
40 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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7 Operation
Item to Inspect Description Checked
Grounding (earthing) • Check for good earth connections (ground connections) that are tight and free of oxidation.
• Grounding (earthing) to conduit is not a suitable ground (earth) .
Input and output power wiring
Switches • Ensure that all switch and disconnect settings are in the proper positions.
Vibration • Check that the unit is mounted solidly.
• Check for loose connections.
• Check that motor and mains are in separate conduit or separated screened cables.
• Check for an unusual amount of vibration.
Checked by: Date:
7.3 Apply power
NOTICE:
• HIGH VOLTAGE. Frequency converters contain high voltage when connected to AC mains. Installation, start-up and maintenance should be performed by qualified personnel only. Failure to comply could result in death or serious injury.
• UNINTENDED START. When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to comply could result in death, serious injury, equipment, or property damage.
• POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE! Risk of personal injury when the frequency converter is not properly closed. Before applying power, ensure all safety covers are in place and securely fastened.
1. Confirm that the input voltage is balanced with 3%. If not, correct voltage imbalance before proceeding. Repeat this procedure after the voltage correction.
2. Ensure that optional equipment wiring, if present, matches the installation application.
3. Ensure that all operator and start enable devices are in the OFF position. Panel doors should be closed or cover mounted.
4. Apply power to the unit. DO NOT start the frequency converter at this time. For units with a disconnect switch, turn to the ON position to apply power to the frequency converter.
7.4 Discharge time
WARNING:
Disconnect and lock out electrical power and wait for the minimum waiting time specified below. Failure to wait the specified time after power has been removed before performing service or repair could result in death or serious injury.
Frequency converters contain DC-link capacitors that can remain charged even when the frequency converter is not powered. To avoid electrical hazards, disconnect:
• AC mains
• Any permanent magnet type motors
• Any remote DC-link power supplies, including battery backups, ups and DC-link connections to other frequency converters.
Wait for the capacitors to discharge completely before performing any service or repair work. Refer to the following table for wait times:
HVL Minimum waiting times (min)
2.015 ÷ 2.040 15
3.015 ÷ 3.055 4
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 41
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7 Operation
HVL Minimum waiting times (min)
3.075 ÷ 3.110 15
4.015 ÷ 4.110 4
4.150 ÷ 4.220 15
High voltage may be present even when the warning LED indicator lights are off.
42 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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8 Programming
1 2 345 6 7
HVNG-IOM_BUTTONS_A_SC.DRW
Notice
NOTICE:
Read and follow the operating instructions carefully before you start programming. This is to prevent incorrect settings which cause malfunction. All modifications must be done by qualified technicians!
8.1 Display and control panel
8 Programming
1. Power
2. Run
3. Error
4. Left
5. Up
6. Down
7. Right
8.2 Functions of push buttons
Push button Description
▲ Start of the unit in the 1st window.
▼ Stop of the unit in the 1st window.
◄ and ► Reset: press both buttons simultaneously for 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 press ► Enter submenu / change to next parameter in the menu.
Short press ◄ Leave submenu / change to previous parameter in the menu.
Long press ◄ Change back to main menu.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 43
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M20 STATUS
MENU
Actual value Output Freq.
ENTER PREV NEXT ENTER
P09 OPERAT.TIME
xxxxx.xx
Actual value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
Functions associated to each push button may change, but they are shown in every moment, for reference, on the lowest row of the display.
8.3 Software parameters
Parameters are organized in 2 distinct groups:
• The set of parameters only defining menus
• The set of parameters necessary for HYDROVAR configuration
Referring to the first set (those parameters defining menus), each of them is presented with an image of the display containing (for example) the following information:
where:
• M20: is the Menu number
• STATUS: is the Menu name
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• OUTPUT FREQ.: current frequency supplied by the drive to the motor
• ENTER/PREV/NEXT: actual functions of the related push buttons
Referring to the second set (those parameters configuring HYDROVAR), each of them is presented with an image of the display containing (for example) the following information:
where:
• P09: is the parameter number
• OPERAT.TIME: is the parameter name
• XXXXX.XX: is the current parameter value
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right fct.: actual functions of the related push buttons
The parameters are applicable for all HYDROVAR with the following exceptions:
• If a setting is transferred automatically on all HYDROVAR within one system, this is marked with the symbol (Global):
• If a parameter is read-only, this is marked with the symbol (Read-only):
44 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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8.3.1 M00 MAIN MENU
CONTROLLER
Actual Value
Status HV Output Freq.
PREV START STOP NEXT
ACTUATOR
Actual Value
Status HV Output Freq.
PREV START STOP NEXT
CASCADE RELAY #1+4
Actual Value
Status HV Output Freq.
PREV START STOP NEXT
Menu scope
This submenu includes the following software parameters:
• Home
• Selection of required value
• Regulation restart value
• Language selection
• Date and time setup
• Auto - start
• Operating hours
HOME
The information shown on the display depends on the selection done in parameter 105 MODE; for more details, see P105 MODE (page 55)
When P105 MODE is set to Controller or Actuator, display shows the following information:
8 Programming
where:
• Actual value: is the input signal supplied by the selected transducer (set by menu 400)
• Status HV: is the HYDROVAR status (ON / OFF / STOP) depending on manual setting on push buttons and external contact X1/18-19)
• Output frequency: current frequency supplied by the drive to the motor
• PREV/START/STOP/NEXT: actual functions of the related push buttons
When parameter 105 MODE is set to Cascade Relay, display shows the following information:
where:
• Cascade Relay: is the value of parameter 105
• #1+4: is the indication that the system is running with 1 Master (#1) and, for example, 4 fixed speed pumps (+4)
• Actual value: is the input signal supplied by the selected transducer (set by menu 400)
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CASCADE SERIAL @1-P4
Actual Value
Status HV Output Freq.
PREV START STOP NEXT
CASCADE SYNCHRON @1-P4
Actual Value
Status HV Output Freq.
PREV START STOP NEXT
G
P02 REQUIRED VAL. D1
xxx.xx bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
• Status HV: is the HYDROVAR status (ON / OFF / STOP) depending on manual setting on push buttons and external contact X1/18-19)
• Output frequency: current frequency supplied by the drive to the motor
• PREV/START/STOP/NEXT: actual functions of the related push buttons
When. 105 MODE is set to Cascade Serial or Cascade Synchron, display shows the following information:
P02 REQUIRED VAL.
where:
• Cascade Serial or Cascade Synchron: is the value of parameter 105
• @1: shows, for example, the value of parameter 1220 (PUMP ADDR.)
• P4: shows, for example, the address of the pump which is currently acting as Master of the cascade, depending on settings of menu 500
• Actual value: is the input signal supplied by the selected transducer (set by menu 400)
• Status HV: is the HYDROVAR status (ON / OFF / STOP) depending on manual setting on push buttons and external contact X1/18-19)
• Output frequency: current frequency supplied by the drive to the motor
• PREV/START/STOP/NEXT: actual functions of the related push buttons
The information shown on the display depend on the selection done in parameter 105; for more details, see P105 MODE (page 55)
When parameter 105 MODE is set to Controller, Cascade Relay, Cascade Serial or Cascade Synchron, display shows the following information:
where:
• REQUIRED VAL.: is the parameter description
• D1: is (for example) the selected source for the parameter, set by submenu 800
• XXX.XX: is the current parameter value
• bar: is the dimension unit set by parameter 405
• Actual value: is the input signal supplied by the selected transducer (set by submenu
46 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
400), expressed with the dimension unit set by parameter 405
Page 49
P02 ACTUAT.FRQ. D1
xx.x Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P03 EFF.REQ.VAL D1
xxx.xx bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right: actual functions of the related push buttons
When parameter 105 MODE is set to Actuator, display shows the following information:
where:
• ACTUAT.FRQ.1.: is the parameter description
• D1: is (for example) the selected source for the parameter, set by submenu 800
• XX.X: is the current parameter value
• Hz: is the dimension unit
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right: actual functions of the related push buttons
P03 EFF.REQ.VAL.
The information shown on the display depends on the selection done in par. 105; for more details, see P105 MODE (page 55)
When parameter 105 MODE is set to Controller, Cascade Relay, Cascade Serial or Cascade Synchron, display shows the following information:
where:
• EFF.REQ.VAL.: is the parameter description
• D1: is (for example) the selected source for the parameter, set by submenu 800
• XXX.XX: is the current parameter value
• bar: is the dimension unit set by parameter 405
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right:actual functions of the related push buttons
When parameter 105 MODE is set to Actuator, P03 is not shown! Parameter 03 EFF.REQ.VAL. shows the current required value that is calculated based on
parameter 505 ACT.VAL.INC., parameter 510 ACT.VAL.DEC. and parameter 330 LIFT AMOUNT. If the required value is influenced by an offset signal (set by submenu 900), then the current active required value is also shown in this window.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 47
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G
P04 START VALUE
100%
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P05 LANGUAGE
English
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P06 DATE
XX.XX.20XX
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P07 TIME
HH.MM
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P04 START VALUE
P05 LANGUAGE
This parameter defines, in percentage (0-100%) of the required value (P02 REQUIRED VAL.), the start value after pump stops.
If P02 REQUIRED VAL. is met and there is no more consumption, then the pump stops. The pump starts again when the pressure drops below P04 START VALUE.
Value 100% makes this parameter not effective (100%=off)!
P06 DATE
P07 TIME
This parameter selects the display language.
This parameter set current date.
This parameter set current time.
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P08 AUTO-START
G
P08 AUTO-START
ON
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P09 OPERAT.TIME
0000h
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P21 STATUS UNITS
11001000
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P09 OPERAT.TIME
8 Programming
If AUTO-START = On, then the HYDROVAR starts automatically (in case of demand) following a power disconnection.
This parameter shows the total operating time (in hours). For an instruction on how to reset the counter, see P1135 CLR.OPERAT..
8.3.2 M20 STATUS
MENU SCOPE
Using this submenu it is possible to check the status (including failures and motor hours) of all connected units.
P21 STATUS UNITS
This parameter gives a overview about the status of the connected units. The information shown on the display depend on the selection done in parameter 105
MODE; for more details, see P105 MODE (page 55). When parameter 105 MODE is set to Cascade Serial or Cascade Synchron, display shows
(for example) the following information:
where the status of all (max. 8) connected units is shown (whereas 1=activated / 0=deactivated).
When parameter 105 MODE is set to Cascade Relay, display shows (for example) the following information:
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P21 STATUS UNITS
10100
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P22 SELECT DEVICE
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P23 STATUS DEVICE
Stopped
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P22 SELECT DEVICE
where (HYDROVAR is equipped with additional Premium Card) the status of the 5 Relay­switching contacts is shown. (where as 1=activated / 0=deactivated).
This parameter lets the user select a specific unit (1-8) in a cascade system, so that current status, motor hours and last failures occurred can be checked.
The information shown on the display depends on the selection done in parameter 105 MODE; for more details, see P105 MODE (page 55).
P23 STATUS DEVICE
When P105 MODE is set to Cascade Serial or Cascade Synchron, the value selected for P22 SELECT DEVICE specifies the address of the HYDROVAR units,
When P105 MODE is set to Cascade Relay, the value selected for P22 SELECT DEVICE follows the subsequent table:
Device enabled by
1 MASTER Inverter
2 fixed speed pump Relay 1 X4 /1
3 fixed speed pump Relay 2 X4 /2
4 fixed speed pump Relay 3 X4 /3
5 fixed speed pump Relay 4 X4 /4
6 fixed speed pump Relay 5 X4 /5
7 N/A N/A
8 N/A N/A
This parameter shows the status of the selected device (by means of parameter 22 SELECT DEVICE).
The information shown on the display depend on the selection done in parameter 105 MODE; for more details, see P105 MODE (page 55).
When P105 MODE is set to Cascade Serial or Cascade Synchron, display shows (for example) the following information:
50 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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G
P24 ENABLE DEVICE
Enabled
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P25 MOTOR HOURS
XXXXX h
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
where the value displayed may change as per the following table:
Displayed value Description
Running The pump runs.
Stopped The pump is stopped since the pump is not requested.
Disabled The pump is manually stopped using the: - buttons -
parameter P24 ENABLE DEVICE- external device
OFF The pump is not connected to the power supply or the
RS485.
Preparing A new unit is connected to the system and data is
transferring.
Fault A failure that occurred on the current unit.
When P105 MODE is set to Cascade Relay, the value displayed may change as per the following table:
Displayed value Description
Relay On The relay contact is closed and the fixed-speed pump
operates.
Relay Off The relay contact is open and the fixed-speed pump is
stopped
Fault A failure that occurred on the current unit.
P24 ENABLE DEVICE
P25 MOTOR HOURS
By using this parameter, the user can manually enable and disable the selected device (by means of parameter 22 SELECT DEVICE).
When parameter 105 MODE is set to Controller, Cascade Relay, Cascade Serial or Cascade Synchron, display shows the following information:
where possible settings are "Enabled" or "Disabled".
This parameter shows the operation time in hours of the selected device. Thus, the time period during which HYDROVAR has powered the motor.
For information about how to reset the count, see parameter 1130 CLR.MOTOR H.
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G
P26 1ST ERROR
XX Error
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P35 KWH COUNTER
XXXXX kWh
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P41 PROD.DATE
20YYWW
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P26 thru P30: ERROR memory
These parameters hold the error memory information. All errors are saved and shown in these parameters.
The errors include the following information:
• XX = error code / Error = description
• Date and time of when the error occurred
P35 KWH COUNTER
This parameter registers the power consumption of the motor as a mean value over 1 hour.
For information about how to reset the counter, see parameter 1140 CLR.KWH CNT.
8.3.3 M40 DIAGNOSTICS
MENU SCOPE
This submenu includes the following software parameters:
• Production date
• Actual temperature
• Actual output current
• Actual input voltage
• Actual output frequency
• Software version of the Power Board
During operation, the information in these parameters is read-only. No changes are permitted.
P41 PROD.DATE
Shows the production date of the control board; the display format is YYYYWW (year, week).
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P42 SEL.INVERTER
G
P42 SEL.INVERTER
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P43 TEMP.INVERTER
XX% XX°C
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P44 CURR.INVERTER
XXX %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P45 VOLT.INVERTER
XXX V
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P43 TEMP.INVERTER
8 Programming
Select the desired inverter unit (1-8).
Shows the temperature inside the selected (by mean of parameter 42) unit,
P44 CURR.INVERTER
P45 VOLT.INVERTER
with the following data:
• Temperature inside (°C)
• % of the maximum temperature
Shows the output current in percentage of the maximum rated current for the selected (by mean of parameter 42) unit.
Shows the input voltage (V) for the selected (by mean of parameter 42) unit.
P46 OUTPUT FREQ.
Shows the output frequency (Hz) for the selected (by mean of parameter 42) unit.
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P46 OUTPUT FREQ.
X.XX Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P47 VER.INVERTER
1.00
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P61 PASSWORD
XXXX
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P47 VER.INVERTER : POWER
Shows information about the software version of the power board for the selected (by means of parameter 42) unit.
For details, see table below.
Displayed value Versions (power sizes) Additional information
1.00 All First Release 12/2015
8.3.4 M60 SETTINGS
MENU SCOPE
This submenu includes the following software parameters:
• PASSWORD
• JOG
CAUTION:
Read these instructions carefully before changing any parameter in this sub menu. The settings must be carried out by trained and qualified persons. Incorrect settings will cause malfunction.
It is possible to change all parameters during operation, but it is highly recommended that the unit is stopped when changing parameters.
P61 PASSWORD
Enter the system password, which gives access to all system parameters: default setting is
00066.
When a correct password is entered, the system remains unlocked for 10 minutes. For this parameter please note that, once entered into edit mode (by pressing the
provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
54 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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P62 JOG
P62 JOG
x.xx Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P105 MODE
Controller
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
This parameter deactivates the internal controller of HYDROVAR and changes to manual mode. Display shows the following information:
Where:
• JOG: is the parameter description
• X.XX: is the current parameter value (0Hz - P245 MAX.FREQ.); at 0.0 Hz, the unit stops.
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right fct.: actual functions of the related push buttons
8.3.5 M100 BASIC SETTINGS
MENU SCOPE
This submenu includes the following software parameters:
• Operation mode
• Pump address
• Password
• Lock function
• Display contrast
• Display brightness
8 Programming
P105 MODE
By using this parameter, the user can select an operation mode.
where possible settings are:
MODE Operable unit(s)
Controller (Default )
Cascade Relay 1 Hydrovar and Premium Card
Cascade Serial More than one pump
Cascade Synchron All pumps operate on the same frequency
Actuator 1 Hydrovar
The Actuator mode is used if the HYDROVAR is a standard VFD with:
• Fixed speed requirements or
• An external speed signal is connected.
For more information, see Example: P105 ACTUATOR mode (page 102).
1 Hydrovar
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 55
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P106 PUMP ADDR.
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P110 SET PASSW.
00066
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P115 LOCK FUNCT.
Off
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P120
DISP.CONTR.
75 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P106 PUMP ADDR.
P110 SET PASSW.
Selects an address (1-8) for each HYDROVAR
If several MASTER inverters are connected via the internal RS-485 interface (maximum eight in Cascade Serial mode), then the following must apply:
• Each HYDROVAR needs an individual pump-address (1–8)
• Each address can only be used once.
Set a system password (00000 - 09999); default setting is 00066.
P115 LOCK FUNCT.
P120 DISP.CONTR.
By using this parameter, the user can lock or unlock parameter settings in the main menu.
where possible settings are:
Setting Description
ON No parameters can be changed without the system
password.
OFF All parameters in the main menu can be changed.
Adjust the display contrast (10 - 100%)
P125 DISP.BRIGHT.
56 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Adjust the backlight brightness of the display (10 - 100%)
Page 59
P125 DISP.BRIGHT.
100 %
Actual Value Output Freq.
Left fct. Up fct.
Down fct.
Right fct.
P130 DISP.ROTATION
P130 DISP.ROTATION
FALSE
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P135 BACK.COMP.
NO
Actual Value Output Freq.
Left fct. Up fct.
Down fct.
Right fct.
This parameter enables the rotation, by 180°, of display and push buttons relative to standard position.
P135 BACK.COMP.
8 Programming
This parameter activates the Backward Compatibility mode: when set to YES, it forces HYDROVAR to work in a multi-pump application acting and communicating as the previous generation HYDROVAR (HV 2.015-4.220).
HVL and HV 2.015-4.220 multi-pump communication protocol are not compatible! Thus in a multi-pump application where there is present at least one previous generation HYDROVAR (HV 2.015-4.220), all the other HVL model shall be forced in backward compatibility mode. For further information check the dedicated HVL Backward compatibility Set-up and programming guide.
8.3.6 M200 CONF.INVERTER
MENU SCOPE
This submenu includes the following software parameters:
• Software
• Number of units
• Ramp settings
• Motor settings
• Frequency settings
• STC protection
P202 SOFTWARE
Shows information about the software version of the control board.
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P202 SOFTWARE
1.00
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P205 MAX.UNITS
6
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P210 INVERTER
All
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
P205 MAX.UNITS
For details, see the table below.
Displayed value Additional information
1.00 First Release 12/2015
Set the maximum number of units that operate simultaneously.
P210 INVERTER
Reasonable values are:
Value MODE
1–8 Cascade Serial
2–6 Cascade Relay
Select the HYDROVAR address for parameterization.
Possible settings are:
Setting Description
All All units in the group are programmed at the same time;
in any case all new settings are copied to all units.
1– 8 Used if one specific unit is programmed. Select that unit
(1– 8).
P215 RAMP 1
NOTICE:
• Fast running up time can cause errors (overload) during the startup.
• Slow running up time can cause a drop of the outgoing operating pressure.
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P215 RAMP 1
4 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P220 RAMP 2
4 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
This parameter adjusts the fast acceleration time, and it effects the control of the pump; the ramp depends on the type of HYDROVAR and the type of pump.
HVL Possible setting (sec) Default setting (sec)
2.015 ÷ 2.040 1–250 4
3.015 ÷ 3.040
4.015 ÷ 4.040
3.055 ÷ 3.110 1–1000 8
4.055 ÷ 4.110
4.150 ÷ 4.220 1–1000 12
For more information, see Example: P200 Ramp Settings (page 102).
P220 RAMP 2
NOTICE:
• Fast running down time often causes overvoltage.
• Slow running down time often causes over-pressure.
This parameter adjusts the fast deceleration time, and it effects the control of the pump; the ramp depends on the type of HYDROVAR and the type of pump.
HVL Possible setting (sec) Default setting (sec)
2.015 ÷ 2.040 1–250 4
3.015 ÷ 3.040
4.015 ÷ 4.040
3.055 ÷ 3.110 1–1000 8
4.055 ÷ 4.110
4.150 ÷ 4.220 1–1000 12
For more information, see Example: P200 Ramp Settings (page 102).
P225 RAMP 3
NOTICE:
• Fast running up time can cause oscillation and overload.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 59
• Slow running up time can cause a drop of the outgoing operating pressure, during variation of the demand.
Page 62
P225 RAMP 3
70 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P230 RAMP 4
70 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P235 RAMP FMIN A
2.0 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P230 RAMP 4
This parameter adjusts the slow acceleration time, thus determining:
• The regulation speed of the internal HYDROVAR controller for small changes in demand.
• The constant outgoing pressure.
The ramp (default value 70 sec, possible setting 1–1000 sec) depends on the system which has to be controlled. For more information, see Example: P200 Ramp Settings (page 102).
NOTICE:
• Fast running down time can cause oscillation of the unit and the pump
• Slow running down time can cause pressure fluctuations during variation of the demand.
P235 RAMP FMIN A
This parameter adjusts the slow deceleration time, thus determining:
• The regulation speed of the internal HYDROVAR controller for small changes in demand.
• The constant outgoing pressure.
The ramp (default value 70 sec, possible setting 1–1000 sec) depends on the system which has to be controlled. For more information, see Example: P200 Ramp Settings (page 102).
NOTICE:
Fast running up time can cause errors (overload) during start.
This parameter (default value 2.0 sec, possible setting 1.0- 25.0 sec) sets the ramp Fmin acceleration (fast running up time), and it operates HYDROVAR until the selected P250 MIN.FREQ. is reached; after Fmin is passed, P215 RAMP 1 starts to work. For more information, see Example: P200 Ramp Settings (page 102).
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P240 RAMP FMIN D
G
P240 RAMP FMIN D
2.0 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P245 MAX.FREQ.
50.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P250 MIN.FREQ.
20.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P245 MAX.FREQ.
8 Programming
NOTICE:
Fast running down time often causes overvoltage.
This parameter (default value 2.0 sec, possible setting 1.0- 25.0 sec) sets the ramp Fmin deceleration (fast running down time), and it stops HYDROVAR when it gets below P250 MIN.FREQ. For more information, see Example: P200 Ramp Settings.
NOTICE:
Settings higher than standard can cause overload of the motor.
P250 MIN.FREQ.
P255 CONF.FMIN
This parameter (default value 50 Hz, possible setting 30.0- 70.0 Hz) sets the maximum frequency, and thus the maximum speed of the pump; the standard setting according to the nominal frequency of the connected motor.
NOTICE:
The minimum frequency depends on the selected pump type and application. For borehole applications in particular, the minimum frequency must be set to ≥ 30 Hz*.
This parameter (default value 20 Hz, possible setting 0.0 Hz- P245 MAX.FREQ.) sets the minimum frequency; operations below this value are done with P235 RAMP FMIN A and P240 RAMP FMIN D.
This parameter defines the operation at minimum frequency.
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P255 CONF.FMIN
f -> 0
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P260 FMIN TIME
0 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P261 SKIP FRQ.CTR.
20.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
Possible settings are:
Setting Description
f -> 0 Once the required pressure is reached and no further
consumption is needed, the frequency goes down to the selected P250 MIN.FREQ.: HYDROVAR will then keep running for the selected P260 FMIN TIME and after this time stops automatically.
f -> fmin With this setting the pump never stop automatically: the
frequency goes down to the selected P250 MIN.FREQ.. To stop the pump the external ON/OFF must be opened or the provided push button must be pressed.
NOTICE:
For circulation systems, the setting "f -> fmin" can overheat the pump in case there is no flow through it!
P260 FMIN TIME
P261 SKIP FRQ.CTR.
This parameter (default value 0 sec, possible setting 0-100 sec) sets the delay time before a shut-off below P250 MIN.FREQ. occurs.
It is used to prevent problems with a shut off of the pump at no demand (too small or no pressure tank), as the system pressure increases during this delay time. This parameter is only active if P255 CONF.FMIN is set to "f -> 0".
This parameter (possible setting P250 MIN.FREQ. - P245 MAX.FREQ.) sets the skip frequency center.
P262 SKIP FRQ.RNG.
62 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
This parameter (possible setting 0.0 - 5.0 Hz) sets the skip frequency range.
Page 65
P262 SKIP FRQ.RNG.
0.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P265 MOTOR NOM.POWER
P265 MOTOR NOM.POWER
1.5 kW
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
Sets the nominal power of the motor coupled with HYDROVAR, as reported in the motor nameplate.
Possible settings are:
HVL Undersized motor 2 Undersized motor 1 Default Oversized motor
2,015 0.75 kW - 1.0 hp 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp
2,022 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp
2,030 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp
2,040 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp
3,015 0.75 kW - 1.0 hp 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp
3,022 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp
3,030 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp
3,040 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp
3,055 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp
3,075 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp 11.0 kW - 15.0 hp
3,110 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp 11.0 kW - 15.0 hp 15.0 kW - 20.0 hp
4,015 0.75 kW - 1.0 hp 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp
4,022 1.1 kW - 1.5 hp 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp
4,030 1.5 kW - 2.0 hp 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp
4,040 2.2 kW - 3.0 hp 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp
4,055 3.0 kW - 4.0 hp 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp
4,075 4.0 kW - 5.0 hp 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp 11.0 kW - 15.0 hp
4,110 5.5 kW - 7.5 hp 7.5 kW - 10.0 hp 11.0 kW - 15.0 hp 15.0 kW - 20.0 hp
4,150 7.5 kW - 10.0 hp 11.0 kW - 15.0 hp 15.0 kW - 20.0 hp 18.5 kW - 25.0 hp
4,185 11.0 kW - 15.0 hp 15.0 kW - 20.0 hp 18.5 kW - 25.0 hp 22.0 kW - 30.0 hp
4,220 15.0 kW - 20.0 hp 18.5 kW - 25.0 hp 22.0 kW - 30.0 hp 30.0 kW - 40.0 hp
8 Programming
P266 MOTOR NOM.VOLT.
Sets the motor nominal voltage, as reported in the motor nameplate, according to
• the chosen motor connection
• the output voltage of the HYDROVAR
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P266 MOTOR NOM.VOLT.
230 V
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P267 MOTOR NOM.FRQ.
50.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P268 MOTOR NOM.CURR.
7.5 A
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P269 MOTOR NOM.SPEED
3000 rpm
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
Possible settings are:
HVL Possible setting (V) Default setting (V)
2.015 ÷ 2.040 208–240 230
3.015 ÷ 3.110 208–240 230
4.015 ÷ 4.220 380–460 400
P267 MOTOR NOM.FRQ.
Sets the motor nominal frequency, as reported in the motor nameplate
P268 MOTOR NOM.CURR.
Sets the motor nominal current, as reported in the motor nameplate, according to
• the chosen motor connection
• the output voltage of the HYDROVAR
P269 MOTOR NOM.SPEED
Sets the motor nominal speed, as reported in the motor nameplate
P270 MOTOR POLES
This parameter (possible setting 2 or 4) sets the number of motor poles (display showing, for example, the following information)
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P270 MOTOR POLES
2
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P275 AMPI
P275 AMPI
Full
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P280 SWITCHING CONTROL
HVC
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
NOTICE:
• For the best adaptation of HYDROVAR, run AMPI on a cold motor
• AMPI cannot be performed while the motor runs
• AMPI cannot be performed on a motor with a bigger power rating than HYDROVAR that is, when a 5.5 kW motor is coupled with a 4 kW drive
• Avoid generating external torque during AMPI.
This parameter activates the Automatic Motor Parameter Identification; possible settings are "Off" (AMPInot active), "Full" or "Reduced" (procedure to be performed only in case LC filters are applied on the motor cable).
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
P280 SWITCHING CONTROL
Once the AMPI procedure is activated (when either "Full" or "Reduced" option is selected), it takes up to 3 min for the identification of the motor: during this period HYDROVAR prevents the user from any action ("Running" message on the display, push­buttons deactivated).
Possible outcomes are "OK" (AMPI succeeded in self-configuring the motor) or "Fault" (AMPI result unsuccessful): once one of these two messages is displayed, HYDROVAR unlocks the push buttons to standard related functions.
Sets the motor control method. Possible settings are "V/f" or "HVC" (default) "V/f" represents the Scalar Control: the open loop volts/hertz control of an induction
motor is by far most popular method of speed control because of its simplicity. "HVC" represents the HYDROVAR Vector Control: this method improves dynamic and
stability, both when speed reference is changed and in relation to the load torque. This type of control is adaptive to motor load and adaptation to speed and torque changes is less than 3 milliseconds. Motor torque can remain constant regardless to speed changes.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 65
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G
P281 BOOST
5 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P282 KNEE FREQ.
50.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
P281 BOOST
NOTICE:
• If this parameter is set too low or too high, then there is a risk for overload due to too high starting current.
• Keep the settings as low as possible to reduce the risk of thermal overload of the motor at lower frequencies.
This parameter (possible setting 0-25%) sets the motor starting voltage in % of connected supply voltage, thus determining the characteristics of the voltage/frequency curve.
The default value depends on the type of HYDROVAR:
HVL Default setting (%)
2.015 ÷ 2.040
53.015 ÷ 3.040
4.015 ÷ 4.040
3.055 ÷ 3.110
4.055 ÷ 4.110
4.150 ÷ 4.220 10
8
P282 KNEE FREQ.
P283 SEL.SW.FREQ.
NOTICE:
This parameter must be used for special applications only. An incorrect setting can cause overload or damage of the motor.
This parameter (default value 50 Hz, possible setting 30.0- 90.0 Hz) sets the knee frequency, where HYDROVAR generates its maximum output voltage. For standard applications, set this value according to nominal frequency of the motor.
This parameter sets the switching frequency.
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P283 SEL.SW.FREQ.
10 kHz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
HYDROVAR, in any case, can decrease automatically the switching frequency applying the derating criteria. Possible settings are:
Possible setting
HVL Default
2,015 Random
~5 kHz
2,022 Random
~5 kHz
2,030 Random
~5 kHz
2,040 Random
~5 kHz
3,015 Random
~5 kHz
3,022 Random
~5 kHz
3,030 Random
~5 kHz
3,040 Random
~5 kHz
3,055 Random
~5 kHz
3,075 2 kHz 4 kHz 8 kHz 10 kHz 16 kHz
3,110 2 kHz 4 kHz 8 kHz 10 kHz 16 kHz
4,015 Random
~5 kHz
4,022 Random
~5 kHz
4,030 Random
~5 kHz
4,040 Random
~5 kHz
4,055 Random
~5 kHz
4,075 Random
~5 kHz
4,110 Random
~5 kHz
4,150 2 kHz 4 kHz 8 kHz 10 kHz 16 kHz
4,185 2 kHz 4 kHz 8 kHz 10 kHz 16 kHz
4,220 2 kHz 4 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
2 kHz 5 kHz 8 kHz 10 kHz 16 kHz
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G
P284 MIN.SW.FREQ
2 kHz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P290 STC MOTOR PROT.
STC Trip
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P284MIN.SW.FREQ.
This parameter sets the minimum switching frequency HYDROVAR can generate.
This parameter is useful to force HYDROVAR to generate:
• switching frequencies in a certain bandwidth (upper limit defined by P283 - lower limit defined by P284)
• a fixed switching frequency (when P283 = P284).
Possible settings are:
HVL Default
2,015 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
2,022 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
2,030 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
2,040 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,015 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,022 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,030 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,040 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,055 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
3,075 2 kHz 4 kHz 8 kHz 10 kHz 16kHz
3,110 2 kHz 4 kHz 8 kHz 10 kHz 16kHz
4,015 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,022 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,030 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,040 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,055 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,075 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,110 2 kHz 5 kHz 8 kHz 10 kHz 16kHz
4,150 2 kHz 4 kHz 8 kHz 10 kHz 16kHz
4,185 2 kHz 4 kHz 8 kHz 10 kHz 16kHz
4,220 2 kHz 4 kHz 8 kHz 10 kHz 16kHz
P290 STC MOTOR PROT.
This parameter sets the protection technique against motor overheating.
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Possible settings are "Thermistor trip" or "STC trip" (default).
P291 STC MOTOR THERMAL
77 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P295 CURR.LIM.FUNCT.
OFF
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P296 CURR.LIMIT SET
110 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P291 STC MOTOR THERMAL
This parameter shows the calculated percentage of allowed maximum temperature (for the motor) calculated by STC, based on actual current and speed.
P295 CURR.LIM.FUNCT.
This parameter activates (ON) or deactivates (OFF, default) the current limit functionality.
8 Programming
P296 CURR.LIMIT SET
This parameter (default value 110%, possible setting 10–300%) sets the current limit for motor (in % of rated motor current)
If the set value is higher than HYDROVAR maximum rated output, then current is still limited to the maximum rated output.
8.3.7 M300 REGULATION
MENU SCOPE
This submenu includes the following software parameters:
• Jog
• Window
• Hysteresis
• Regulation mode
• Lift settings
P305 JOG
This parameter deactivates the internal controller of HYDROVAR and changes to manual mode.
Display shows the following information:
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P305 JOG
x.xx Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P310 WINDOW
10 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P315 HYSTERESIS
80 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P320 REG.MODE
Normal
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P310 WINDOW
Where:
• JOG: is the parameter description
• X.XX: is the current parameter value (0Hz - P245 MAX.FREQ.); at 0.0 Hz, the unit stops.
• Actual value: is the input signal supplied by the selected transducer (set by submenu
400), expressed with the dimension unit set by parameter 405
• Output frequency: current frequency supplied by the drive to the motor
• Left/Up/Down/Right fct.: actual functions of the related push buttons
P315 HYSTERESIS
P320 REG.MODE
This parameter (default value 10%, possible setting 0-100%) sets the range for ramp control; from slow to fast.
This parameter (default value 80%, possible setting 0-100%) sets the hysteresis for ramp switching. It determines where the normal regulation is done; value = 99% indicates an accurate control without automatic shut-off.
This parameter selects the regulation mode.
Possible setting are:
70 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Setting Description
Normal Increased speed with falling actual value signal.
Page 73
P325 FRQ.LIFT
G
P325 FRQ.LIFT
30.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P330 LIFT AMOUNT
0.0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P330 LIFT AMOUNT
8 Programming
Setting Description
Inverse Reduced speed with falling actual value signal.
This parameter (default value 30.0 Hz, possible setting 0.0-70.0 Hz) sets the frequency limit for the required lift value where the required pressure starts to be increased.
The correct frequency is when the pump reaches the set pressure at zero flow. This can be determined by using P305 JOG.
This parameter (default value 0.0 %, possible setting 0.0-200.0%) sets the lift amount for the required lift value in HVAC systems or for compensation of friction losses in long pipe work.
8.3.8 M400 SENSOR
MENU SCOPE
P405 DIMENSION UNIT
It determines the increase of the set value until the maximum speed (and maximum volume) is reached.
For an application example, see Example P330 LIFT AMOUNT.
In this submenu it is possible to configure all actual-value sensors that are connected to the HYDROVAR. However, the following limitations apply:
• It is possible to have maximum two transducers with current output or voltage-signal output.
• The transducer types: it is not possible to install two different transducer types because the main configuration is the same for all connected sensors.
This submenu includes the following software parameters:
• Dimension unit
• Configuration
• Type of sensor
• Sensor range
• Sensor curve
• Calibration
Selects the unit of measure for the system.
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P405 DIMENSION UNIT
bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P410 CONF.SENSOR
Sensor 1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P410 CONF.SENSOR
In case a change of this parameter is needed, consider to change P420 SENSOR RANGE to the corresponding dimension unit too!
Sets how the connected sensors are used and which sensor is active. It is also possible to measure the difference of two connected sensors or to configure an
automatic switch-over in case of a faulty sensor.
Possible setting are:
Table 13: Possible settings
Setting Property Description
Sensor 1 Constantly active 0/4 - 20 mA signal: connected to X1/2
and X1/1 (+24V)
0/2 - 10 V signal: connected to X1/2, X1/1 (+24V) and X1/3 (GND)
Sensor 2 Constantly active 0/4 - 20 mA signal: connected to X1/5
and X1/4 (+24V)
0/2 - 10 V signal: connected to X1/5, X1/4 (+24V) and X1/6 (GND)
Auto Automatic switch over In case of faulty sensor
Switch Dig1 Manual switching Close digital input 1 (X1/14 - X1/15)
Switch Dig2 Manual switching Close digital input 2 (X3/1 - X3/2, on
Premium Card)
Switch Dig3 Manual switching Close digital input 3 (X3/5 - GND)
Switch Dig4 Manual switching Close digital input 4 (X3/15 - 16)
Auto Lower Automatic switch over The sensor with the lower actual value
is active
Auto Higher Automatic switch over The sensor with the highest actual
value is active
Sens.1 - Sens.2 - The difference of the connected
sensors as actual value
P415 SENSOR TYPE
Selects the sensor type and the input terminal.
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P415 SENSOR TYPE
4-20 mA
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
Possible setting are:
G
P420 SENSOR RANGE
20mA - 10.00bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P425 SENSOR CURVE
Linear
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
Table 14: Selection of the sensor type and input terminal
Setting Input Terminals Actual Value
• Analog I 4 - 20 mA
• Analog I 0- 20 mA
Analog U 0-10 V • X1/2:
• X1/2: Sensor 1
• X1/5: Sensor 2
Sensor 1
• X1/5: Sensor 2
It is determined by a current signal connected to the given input terminal.
It is determined from a voltage signal connected to the given input terminal.
8 Programming
P420 SENSOR RANGE
Sets the end range value (20 mA or 10 V) of the connected sensor.
In particular, the end range value (20mA or 10V) shall be always equal to the 100% of the sensor range (i.e. for a 0.4bar differential pressure sensor, will be 20mA=0.4bar)
P425 SENSOR CURVE
Sets the mathematical function (curve) to determine the Actual Value based on the Sensor signal.
Possible setting are:
Setting Application
Linear • Pressure control
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 73
Quadratic • Flow control (using an orifice plate with a differential
• Differential Pressure control
• Level
• Temperature
• Flow control (inductive or mechanical)
pressure sensor)
Page 76
P430 SENS.1 CAL.0
0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P435 SENS.1 CAL.X
0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P440 SENS.2 CAL.0
0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P445 SENS.2 CAL.X
0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P430 SENS.1 CAL.0
P435 SENS.1 CAL.X
This parameter is used to calibrate the minimum value of Sensor 1.
After setting P405 DIMENSION UNIT and P420 SENSOR RANGE, the zero point for this sensor can be adjusted between -10 % and +10 %.
This parameter is used to calibrate the upper range value of sensor 1.
P440 SENS.2 CAL.0
P445 SENS.2 CAL.X
After setting P405 DIMENSION UNIT and P420 SENSOR RANGE, the upper range value can be adjusted between -10 and +10%.
This parameter is used to calibrate the minimum value of Sensor 2.
After setting P405 DIMENSION UNIT and P420 SENSOR RANGE, the zero point for this sensor can be adjusted between -10 % and +10 %.
This parameter is used to calibrate the upper range value of sensor 2.
After setting P405 DIMENSION UNIT and P420 SENSOR RANGE, the upper range value can be adjusted between -10 and +10%.
8.3.9 M500 SEQUENCE CONTR.
MENU SCOPE
In this submenu it is possible to configure parameters for running a multi-pump system.
74 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
This submenu includes the following software parameters:
Page 77
P505 ACT.VAL.INC.
G
P505 ACT.VAL.INC.
0.35 bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P510 ACT.VAL.DEC.
0.15 bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P515 ENABLE FRQ.
48.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
• Actual value (increase, decrease)
• Frequency (enable, disable, drop)
• Delay (enable, switch, disable)
• Overvalue
• Overvalue delay
• Switch intervals
• Synchronous frequency limit and window
For example and more information, see P500 Example: P500 SUBMENU SEQUENCE
CNTR. (page 104).
Sets the lift value on the range 0.00 - P420 SENSOR RANGE.
P510 ACT.VAL.DEC.
P515 ENABLE FRQ.
Sets the drop value on the range 0.00 - P420 SENSOR RANGE.
This parameter (default value 48.0Hz, possible setting 0.0-70.0Hz) sets the desired release frequency for the following pumps.
The next pump starts when this value is reached and the system pressure drops below the difference (P02 REQUIRED VAL. - P510 ACT.VAL.DEC.).
P520 ENABLE DLY.
This parameter only applies to cascade relay!
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 75
Page 78
P520 ENABLE DLY.
5 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P525 SWITCH DLY.
5 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P530 DISABLE FRQ.
30 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P535 DISABLE DLY.
5 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P540 DROP FRQ.
42 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P525 SWITCH DLY.
It sets the enable delay time: the fixed-speed pump starts after the selected time.
This parameter only applies to cascade relay!
It sets the switch delay time, thus avoiding repeated switching caused by consumption variation.
P530 DISABLE FRQ.
P535 DISABLE DLY.
This parameter only applies to cascade relay!
It sets the frequency to switch off the fixed speed pumps. If the MASTER Inverter goes below this frequency for longer time than the pre-selected P535 DISABLE DLY. and the system pressure is higher than P03 EFF.REQ.VAL., the MASTER stops another assist pump.
This parameter only applies to cascade relay!
It sets the delay time before switching off the assist pumps.
P540 DROP FRQ.
This parameter only applies to cascade relay!
76 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 79
P545 OVERVALUE
P545 OVERVALUE
OFF
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P550 OVERVAL.DLY.
0.0 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P555 SWITCH INTV.
24 hours
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P550 OVERVAL.DLY.
8 Programming
It is used to prevent the system from pressure hammers. Before the MASTER starts a new assist pump, it drops to this frequency and then (when the frequency is reached) the assist pump is started; at that point the MASTER Inverter returns to normal operation.
This parameter only applies to cascade relay!
This parameter prevents the system against overpressure in case the HYDROVAR has been parameterized incorrectly: if this selected value is reached, an immediate shut-off of the follow-up-pumps is executed.
Possible settings are "Off" (default) or P420 SENSOR RANGE.
This parameter only applies to cascade relay!
P555 SWITCH INTV.
P560 SYNCHR.LIM.
This parameter sets the delay time to switch off an assist pump in case the actual value exceeds P545 OVERVALUE limit.
This parameter only applies to cascade serial and synchronous!
This parameter sets the switch interval for the cyclic change-over: it allows an automatic change-over of the MASTER pump and the assist pumps.
As soon as the switch time is reached the next pump becomes MASTER and the counter restarts; this gives even wear and similar operating hours to all pumps. The switch interval is active as long as the MASTER does not stop.
For information about how to find the correct setting, see Example: P500 SUBMENU
SEQUENCE CNTR. (page 104).
This parameter only applies to cascade synchronous!
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 77
Page 80
P560 SYNCHR.LIM.
0.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P565 SYNCHR.WND.
2.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P605 MIN.THRESH.
Disabled
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
8 Programming
P565 SYNCHR.WND.
This parameter sets the frequency limit: the first assist pump shuts off if the frequency goes below this parameter's value.
For information about how to find the correct setting, see Example: P500 SUBMENU
SEQUENCE CNTR. (page 104).
This parameter only applies to cascade synchronous!
This parameter sets the frequency window: the limit for switching off the next assist pump. For information about how to find the correct setting, see Example: P500 SUBMENU
SEQUENCE CNTR. (page 104).
8.3.10 M600 ERROR
MENU SCOPE
This submenu includes the following software parameters:
• Minimum threshold limit
• Delay time
• Automatic error reset
P605 MIN.THRESH.
Selects the minimum threshold limit: if an adjusted value > 0.00 is not reached within the P610 DELAY-TIME, the unit stops (failure message: MIN.THRESH.ERROR).
P610 DELAY-TIME
NOTICE:
The minimum threshold function is also active during the start-up of the pump. Therefore, the delay time must be set higher than the time required to start up the pump and fill the system.
78 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 81
P610 DELAY-TIME
2 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P615 ERROR RESET
G
P615 ERROR RESET
ON
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P705 ANALOG OUT.1
Output frequency
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
Selects the delay time of the minimum threshold limit: it shuts off the HYDROVAR if the actual value drops below P605 MIN.THRESH. or if a low-water protection (at terminals X1/16–17) becomes open.
Selects automatic reset of errors; if a manual reset is selected, switch an external ON/OFF contactor to the terminal X1/18-19. Possible setting are:
Setting Description
ON • Allows an automatic restart five times when an error
OFF • Each error shown on the display.
8.3.11 M700 OUTPUTS
MENU SCOPE
This submenu includes the following software parameters:
• Analog output 1 and 2
• Configuration of status relay 1 and 2
P705 ANALOG OUT.1
occurs
• Shuts off the unit after the fifth restart.
• The internal counter is decreased by one after each operating hour.
• Each error must be reset manually.
Selects the first analog output, which is connected to terminal X3/3-4 on the Premim Card (analogue output 0 – 10 V = 0 - 100%).
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 79
Page 82
P710 ANALOG OUT.2
Actual value
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P715 CONF.REL.1
Running
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P720 CONF.REL.2
Errors
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P710 ANALOG OUT.2
Selects the second analog output, which is connected to terminal X3/5-6 on the Premim Card (analog output 4 – 20 mA = 0 - 100%).
P715 CONF.REL.1
Selects the status relay 1 (X2/4 - 5 - 6). Possible settings are:
P720 CONF.REL.2
Setting Description Action if status = YES
Power HYDROVAR is connected to the power
supply.
Running The motor is running Relay 1: X2/ 4 - 6 closed
Errors An error is indicated on HYDROVAR
(including power failure).
Warnings A warning is indicated in the
HYDROVAR
StandBy The pump is released manually and
by external release, no error/warning is indicated and the HYDROVAR does not run.
Errorreset If the parameter P615 ERROR RESET
is activated and a warning occurs five times - > Error - >
Relay 1: X2/ 4 - 6 closed
Relay 1: X2/ 5 - 6 closed
Relay 1: X2/ 5 - 6 closed
Relay 1: X2/ 4 - 6 closed
Relay 1: X2/ 4 - 6 closed
Selects the status relay 2 (X2/1 - 2 - 3). Possible settings are:
Setting Description Action if status = YES
Power HYDROVAR is connected to the power
Running The motor is running Relay 2: X2/ 1 - 3 closed
80 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Errors An error is indicated on HYDROVAR
Relay 2: X2/ 1 - 3 closed
supply.
Relay 2: X2/ 2 - 3 closed
(including power failure).
Page 83
Setting Description Action if status = YES
P805 C.REQ.VAL.1
Digital
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P810 C.REQ.VAL.2
OFF
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
Warnings A warning is indicated in the
StandBy The pump is released manually and
Errorreset If the parameter P615 ERROR RESET
8.3.12 M800 REQUIRED VALUES
MENU SCOPE
This submenu includes the following software parameters:
• Configuration of the required value
• Switching between required values
• Required frequencies for Actuator mode
For an example, see Example: P105 ACTUATOR mode (page 102).
P805 C.REQ.VAL.1
8 Programming
Relay 2: X2/ 2 - 3 closed
HYDROVAR
Relay 2: X2/ 1 - 3 closed by external release, no error/warning is indicated and the HYDROVAR does not run.
Relay 2: X2/ 1 - 3 closed is activated and a warning occurs five times - > Error - >
P810 C.REQ.VAL.2
Configures the required value 1. Possible setting are:
Setting Description Connected to terminals (Premium
Card)
Digital The internal required value 1 is used.
For setting, see P02 REQUIRED VAL. or P820 REQ.VAL.1
Analog U 0-10V The required value 1 is set by the
value of voltage signal.
Analog I 0-20mA The required value 1 is set by the
value of current signal.
Analog I 4-20mA The required value 1 is set by the
value of current signal.
Configures the required value 2. Possible settings are:
-
X3/8-9
X3/7-8
X3/7-8
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Page 84
P815 SW.REQ.VAL.
Setpoint 1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P820 REQ.VAL.1
XX.X bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P815 SW.REQ.VAL.
Setting Description Connected to terminals (Premium
Card)
Off Required value 2 not used. -
Digital Digital
Analog U 0-10V The required value 2 is set by the
Analog I 0-20mA The required value 2 is set by the
Analog I 4-20mA The required value 2 is set by the
The internal required value 2 is used. For setting, see P02REQUIRED VAL. or P825 REQ.VAL.2
value of voltage signal.
value of current signal.
value of current signal.
-
X3/11-12
X3/10-11
X3/10-11
P820 REQ.VAL.1
Configure the switching between required value 1 and 2. Possible setting are:
Setting Switching possibilities Action
Setpoint 1 No Only required value 1 is active
Setpoint 2 No Only required value 2 is active
Switch Dig 1 Manual Close digital input 1 (X1/14-15)
Switch Dig 2 Manual Close digital input 2 (X3/1-2) on
Premium Card
Sets the digital required value 1 in bar (possible setting 0.0 - P420 SENSOR RANGE). The value is active in all operation mode (but not Actuator mode), if the following applies:
• P805 C.REQ.VAL.1 is set to Digital.
• P815 SW.REQ.VAL. is set to Setpoint 1 or the REQUIRED VALUE 1 is selected via digital input (open).
If the current required value is active, P02 REQUIRED VAL. can override the pre-selected required value.
82 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 85
P825 REQ.VAL.2
P825 REQ.VAL.2
XX.X bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P830 ACTUAT.FRQ1
0.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P835 ACTUAT.FRQ2
0.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P830 ACTUAT.FRQ1
8 Programming
Sets the digital required value 2 in bar (possible setting 0.0 - P420 SENSOR RANGE). The value is active in all operation mode (but not Actuator mode), if the following applies:
• P810 C.REQ.VAL.2 is set to Digital.
• P815 SW.REQ.VAL. is set to Setpoint 1 or the REQUIRED VALUE 2 is selected via digital input (open).
If the current required value is active, P02 REQUIRED VAL. can override the pre-selected required value.
Set the required frequency 1 for Actuator mode (possible setting 0.0 Hz - P245 MAX.FREQ.).
The selected frequency is only active in Actuator mode, if the following applies:
• P805 C.REQ.VAL.1 is set to Digital.
• P815 SW.REQ.VAL. is set to Setpoint 1 or the ACTUATOR FREQUENCY 1 is selected via digital input (open).
P835 ACTUAT.FRQ2
Set the required frequency 2 for Actuator mode (possible setting 0.0 Hz - P245 MAX.FREQ.).
The selected frequency is only active in Actuator mode, if the following applies:
• P810 C.REQ.VAL.2 is set to Digital
• P815 SW.REQ.VAL. is set to Setpoint 2 or the ACTUATOR FREQUENCY 2 is selected via digital input (closed).
8.3.13 M900 OFFSET
Menu scope
This submenu includes the following software parameters:
• Offset (input, range)
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 83
• Level (1, 2)
Page 86
P905 OFFS.INPUT
OFF
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P907 OFFSET RANGE
100
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P910 LEVEL 1
0
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P905 OFFS.INPUT
• Offset (X1, Y1)
• Offset (X2, Y2)
For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
Selects the offset input. Possible setting are:
Setting Offset calculation
Off Disabled
An. U1 0-10V Calculated from the voltage signal (0 - 10 V) connected to
the terminals X3/7-8-9 (Required Value 1)
An. U2 0-10V Calculated from the voltage signal (0 - 10 V) connected to
the terminals X3/10-11-12 (Required Value 2)
An. I1 0-20mA Calculated from the current signal (0 - 20 mA) connected
to the terminals X3/7-8 (Required Value 1)
An. I1 4-20mA Calculated from the current signal (4 - 20 mA) connected
to the terminals X3/7-8 (Required Value 1)
An. I2 0-20mA Calculated from the current signal (0 - 20 mA) connected
to the terminals X3/10-11 (Required Value 2)
An. I2 4-20mA Calculated from the current signal (4 - 20 mA) connected
to the terminals X3/10-11 (Required Value 2)
P907 OFFSET RANGE
P910 LEVEL 1
If the incoming current signal drops to below 4 mA, a warning message is shown on the display; however, HYDROVAR continues to operate without the offset function.
Set the representation of the sensor range: the value depends on the maximum range of the connected offset sensor. A higher offset range gives a higher signal input resolution.
For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
84 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 87
P912 OFFSET X1
P912 OFFSET X1
0
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P913 OFFSET Y1
0.00 bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P915 LEVEL 2
100
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P917 OFFSET X2
100
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P913 OFFSET Y1
8 Programming
Selects the first level until the offset function 1 is active. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
Sets the offset signal value (X1), which is a fixed point. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
P915 LEVEL 2
P917 OFFSET X2
Set the maximum allowed pressure at P912 OFFSET X1. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
Selects the second limit where the offset function 2 starts to be active. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
Sets the offset signal value (X2), which is a fixed point. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 85
Page 88
P918 OFFSET Y2
0.00 bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P1005 TEST RUN
After 100 hrs
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P1010 TEST RUN FRQ.
30.0 Hz
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P918 OFFSET Y2
Set the required pressure at this flow rate. For an example of the offset function and more information, see Example: P900
SUBMENU OFFSET (page 105).
8.3.14 M1000 TEST RUN
Menu scope
This submenu includes the following software parameters:
• Automatic test run
• Test run frequency
• Test run boost
• Test run time
• Selecting Inverter for test run
• Manual test run
P1005 TEST RUN
Controls the automatic test run, which starts up the pump after the last stop, to prevent the pump from blocking (possible setting are "Off" or "After 100 hrs".
Automatic test run is only active when both of the following occur:
P1010 TEST RUN FRQ.
• HYDROVAR is stopped but manually released.
• The external ON/OFF contact (X1/18 - 19) is closed.
Sets the frequency for manual and automatic test run.
86 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 89
P1015 TEST R.BOOST
G
P1015 TEST R.BOOST
10.0 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
G
P1020 TEST R.TIME
5 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1025 SEL.DEVICE
* 1 *
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1030 TEST RUN MAN.
Press > for 3 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1020 TEST R.TIME
8 Programming
Sets the motor starting voltage (possible setting 0 -25%) as a percentage of the rated input voltage.
Sets the time for the test run.
P1025 SEL.DEVICE
Selects the inverter for the manual test run.
P1030 TEST RUN MAN.
Performs a manual test run for the unit selected by P1025 SEL.DEVICE: this function is also valid for fixed-speed pumps in Cascade relay mode.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
8.3.15 M1100 SETUP
MENU SCOPE
This submenu includes the following software parameters:
• Restore factory setting
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 87
• Password 2
• Clear error memory
Page 90
P1110 FACTORY SET
Europe
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1120 PASSWORD 2
0000
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1125 CLR.ERRORS
ALL
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P1110 FACTORY SET
P1120 PASSWORD 2
• Clear motor hours
• Clear operation time
Restores the factory settings. Possible settings are:
Setting Offset calculation
Europe Restore the factory setting for European versions.
USA Restore the factory setting for US versions.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
P1125 CLR.ERRORS
Enter the system password, which gives access to factory parameters. For this parameter please note that, once entered into edit mode (by pressing the
provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
Used to clear the error memory either (1-8) for one specific unit or ALL for all units in Cascade Serial or Synchronous.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
88 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
Page 91
P1130 CLR.MOTOR H.
P1130 CLR.MOTOR H.
ALL
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1135 CLR.OPERAT.
Press ► 3 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1140 CLR.KWH CNT.
ALL
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
Used to clear the motor hours either (1-8) for one specific unit or ALL for all units in Cascade Serial or Synchronous.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
P1135 CLR.OPERAT.
8 Programming
Clear the operation time, which stores the total time the HYDROVAR is connected to power supply.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
P1140 CLR.KWH CNT.
Used to clear the kilowatt-hours counter either (1-8) for one specific unit or ALL for all units in Cascade Serial or Synchronous.
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
8.3.16 M1200 RS-485 INTERFACE
MENU SCOPE
This submenu includes the following software parameters:
• User interface (address, baudrate, format)
• Internal interface (pump address)
The following parameters are necessary for the communication between HYDROVAR and an external device (e.g. PLC) via standardized Modbus-protocol. Set desired address, Baudrate and Format according the system requirements.
HVL 2.015-4.220 Installation, Operation, and Maintenance Manual 89
Page 92
P1203 PROTOCOL
Modbus RTU
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1205 ADDRESS
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1210 BAUD RATE
9600
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P1203 PROTOCOL
P1205 ADDRESS
Sets the desired communication protocol. Possible settings are:
• Disabled
• Modbus RTU
• Modbus ASCII
• BACNet MS/TP
P1210 BAUD RATE
Sets the desired address (possible setting 1 - 247) for the user interface.
Set the BAUD RATE for the user interface. Possible settings are:
• 1200
• 2400
• 4800
• 9600
• 14400
• 19200
• 38400
• 57600
• 76800
• 115200
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P1215 FORMAT
P1215 FORMAT
8, N, 1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1220 PUMP ADDR.
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1221 BACNET DEV.ID
84001
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1225 SSID NUMBER
01234567
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
Set the data FORMAT for the communication port, depending on the value of P1203 PROTOCOL
Possible settings are:
• 8, E, 1
• 8, O, 1
• 8, N, 2
• 8, N, 1
• 7, E, 1
• 7, O, 1
• 7, N, 2
• 7, N, 1
P1220 PUMP ADDR.
Selects an address for each inverter.
P1221 BACNET DEV. ID
Sets Bacnet Device Object ID
P1225 SSID NUMBER
This parameter shows the identification number of the Wi-Fi network generated when the wireless module is assembled into HYDROVAR.
In particular, the network name will be: "hydrovar__P1225__", where P1225 is the value of
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this parameter, expressed as an 8 character word.
Page 94
P1226 SEC.KEY NUMBER
01234567
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1301 LANGUAGE
English
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1302 MOTOR NOM.POWER
1.5 kW
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1303 MOTOR NOM.VOLT.
230 V
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
Example: if P1225 = a1b2c3d4, wifi network name = "hydrovara1b2c3d4"
P1226 SEC.KEY NUMBER
This parameter shows the security key number to access the Wi-Fi network generated when the wireless module is assembled into HYDROVAR.
In particular, the security key number will be: "xylem__P1226__", where P1226 is the value of this parameter, expressed as an 8 character word.
Example: if P1226 = b5c6d7e8, security key number = "xylemb5c6d7e8"
8.3.17 M1300 START-UP
MENU SCOPE
This submenu includes all the parameters necessary for a quick start-up of HYDROVAR:
• Language
• Motor Configuration (Power, Voltage, …)
• Single/Multi Pump configuration
• Required Value
P1301 LANGUAGE
This parameter selects the display language.
P1302 MOTOR NOM.POWER
This parameter set the nominal power of the motor coupled with HYDROVAR, as reported on the motor nameplate. For possible setting, see P265 MOTOR NOM.POWER (page 63)
P1303 MOTOR NOM.VOLT.
92 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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Sets the motor nominal voltage, as reported in the motor nameplate, according to
P1304 PRE-SET MOTOR ?
YES
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1305 MOTOR NOM.CURR.
7.5 A
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1306 MOTOR NOM.SPEED
3000 rpm
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1307 AMPI
Full
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
• the chosen motor connection
• the output voltage of the HYDROVAR
For possible setting, see P266 MOTOR NOM.VOLT. (page 63)
P1304 PRE-SET MOTOR ?
By selecting "Yes", the user is declaring the use of a Lowara IE3 surface 2-poles motor 50Hz (without Motor Filter): in this case, the motor's electrical parameters are already available to HYDROVAR, so the start-up procedure skips to P1308 STC MOTOR PROT..
By selecting "NO", the user is declaring the use of any other motor: in this case the motor's electrical parameters need to be set into HYDROVAR, so the start-up procedure goes to the next step (P1305 MOTOR NOM.CURR.)
P1305 MOTOR NOM.CURR.
8 Programming
P1306 MOTOR NOM.SPEED
P1307 AMPI
Sets the motor nominal current, as reported in the motor nameplate, according to
• the chosen motor connection
• the output voltage of the HYDROVAR
Sets the motor nominal speed, as reported in the motor nameplate.
This parameter activates the Automatic Motor Parameter Identification; possible settings are "Off" (AMPI not active), "Full" or "Reduced" (procedure to be performed only in case LC filters are applied on the motor cable).
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P1308 STC MOTOR PROT.
STC Trip
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1309 MODE
Controller
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1310 PUMP ADDR.
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1311 CONTROL MODE
Constant
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
For further information, see P275 AMPI (page 65)
P1308 STC MOTOR PROT.
This parameter sets the protection technique against motor overheating; possible the settings are "Thermistor trip" or "STC trip" (default).
P1309 MODE
This parameter selects which operating mode to set the unit to. For possible setting, see P105 MODE (page 55).
P1310 PUMP ADDR.
This parameter selects an address (1-8) for each HYDROVAR. If several MASTER inverters are connected via the internal RS-485 connection (maximum eight in Cascade serial mode), then the following must apply:
• Each HYDROVAR needs an individual pump-address (1–8)
• Each address can only be used once.
P1311 CONTROL MODE
For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
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This parameter sets the pressure control mode for the pump system (single and multi
P1312 DIMENSION UNIT
bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1313 START-UP COMPLETED?
No
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1314 SENSOR RANGE
20mA - 10.00bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
pump): depending on the setting ("Constant" or "Differential") a set of further parameters are automatically configured.
Whenever P1311 CONTROL MODE is set to a new value, each parameter in the below table is overwritten to its own specified value, regardless of previous different settings.
P1311 = Constant P1311 = Differential
P225 RAMP 3 70 sec 90 sec
P230 RAMP 4 70 sec 90 sec
P250 MIN.FREQ. 20 Hz 25 Hz
P255 CONF.FMIN f -> 0 f -> fmin
P260 FMIN TIME 0 sec 3 sec
P315 HYSTERESIS 80% 90%
P410CONF.SENSOR Sensor 1 Sens.1 - Sens.2
P1312 DIMENSION UNIT
Selects the unit of measure for the system.
8 Programming
For further information, see P405 DIMENSION UNIT (page 71)
P1313 START-UP COMPLETED?
If the application the is a multi-pump, then the startup procedure for the first [N-1] pumps is stopped here when selecting Yes.
If the application the is a single-pump or the last pump of a Multi-pump, then select No .
P1314 SENSOR RANGE
Sets the end range value (20 mA or 10 V) of the connected sensor. In particular, the end range value (20 mA or 10 V) must be always equal to the 100% of the sensor range (that is, for a 0.4 bar differential pressure sensor, is 20 mA=0.4 bar).
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Page 98
P1315 REQUIRED VAL.
XXXXX bar
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1316 START VALUE
100 %
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1317 MIN.THRESH.
Disabled
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1318 DELAY-TIME
2 sec
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
8 Programming
P1315 REQUIRED VAL.
For further information, see P02 REQUIRED VAL. (page 46).
P1316 START VALUE
Sets the end range value (20 mA or 10 V) of the connected sensor. In particular, the end range. This parameter defines, in percentage (0-100%) of the required value (P1314 REQUIRED VAL.), the start value after pump stops.
If P1315 REQUIRED VAL. is met and there is no more consumption, then the pump stops. The pump starts again when the pressure drops below P04 START VALUE. Value 100% makes this parameter not effective (100%=off)!
P1317 MIN.THRESH.
P1318 DELAY-TIME
Selects the minimum threshold limit: if an adjusted value > 0.00 is not reached within the P1317 DELAY-TIME, then the unit stops (failure message: MIN.THRESH.ERROR).
Selects the delay time of the minimum threshold limit: it shuts off the HYDROVAR if the actual value drops below P1317 MIN.THRESH. or if a low-water protection (at terminals X1/16–17) becomes open.
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P1319 DATE
P1319 DATE
XX.XX.20XX
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1320 TIME
HH.MM
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1321 AUTO-START
ON
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1322 START-UP COMPLETED?
No
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1323 ADDRESS
1
Actual Value Output Freq.
Left fct. Up fct. Down fct. Right fct.
P1320 TIME
P1321 AUTO-START
8 Programming
Using this parameter current date can be set.
Using this parameter current time can be set.
If AUTO-START = ON, then the HYDROVAR starts automatically (in case of demand) after reconnection of power following disconnection.
P1322 START-UP COMPLETED?
If the user configured the whole application by selecting “YES” then the HYDROVAR will not make available the Start-up menu at every power-on.
By selecting "NO" at next power-on, the HYDROVAR will offer to the user the start-up procedure.
P1323 ADDRESS
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Sets the desired address (possible setting 1 - 247) for the user interface.
Page 100
9 Maintenance
9 Maintenance
9.1 General
Electrical Hazard:
Before any service or maintenance disconnect the system from the power supply and wait at least 5 minutes before starting work on or in the unit (the capacitors in the intermediate circuit are discharged by the internal discharge resistors).
The unit does not require any special maintenance.
Check list
• Make sure that the cooling fan and the vents are free from dust.
• Make sure that the ambient temperature is correct according to the limits of the unit.
• Make sure that qualified personal perform all modifications of the unit.
• Make sure that the unit is disconnected from the power supply before any work is carried out. Always consider the pump- and motor-instruction.
For further information, contact the local distributor.
9.2 Check error codes
Check the error codes in parameters P26 – P30 on a regular basis. For more information about the parameters, see P26 thru P30: ERROR memory (page 52) . For detailed information about the error codes, see Warnings and errors (page 99).
9.3 Check the functions and parameters
If the hydraulic system is changed then follow this procedure.
1. Make sure that all functions and parameters are correct.
2. Adjust the functions and parameters if necessary.
98 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual
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