Xylem HVS 1.1 User Manual
Operating Instructions
HVS 1.1 - HVS 1.2
HVS 3.2 - HVS 3.4
Sensorless
V 201203A
771079102 Manual HVS1.3-3.4 ENGLISH
HYDROVAR sensorless
The idea is to control the pump speed
Energysavings
according to the power consumption of
the motor instead to the head of the
pump.
Each working point at a defined speed on
the curve of required pump head in the
hydraulic diagram (A,B,C) has also a
corresponding point in the electric
performance diagram (D,E,F).
Each of these points is defined by the
power consumption at the same speed.
All these points of power consumption at
different speeds results in a pretended
curve of power consumption at different
speeds.
If the controller varies the speed of the
pump at different flow values so that the
power consumption moves along this
curve and the working point of the pump
in the hydraulic diagram will also move
along the corresponding curve of pump
head but without measuring this head.
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Index
1. IMPORTANT SAFETY INSTRUCTIONS ................................................................................................6
2. TECHNICAL DATA - HYDROVAR SENSORLESS AND GENERAL DATA................................................8
2.1 DIMENSIONS ............................................................................................................................................9
3. HYDROVAR SENSORLESS MOUNTING............................................................................................10
3.1 MOUNTING THE HYDROVAR SENSORLESS ON THE PUMP ..........................................................................................10
3.1.1 Included components ................................................................................................................10
3.1.2 Mechanical mounting ................................................................................................................11
3.1.3 Mounting the Thermistor...........................................................................................................13
3.2 ELECTRIC INSTALLATION AND WIRING.....................................................................................................................14
3.2.1 Means of protection ..................................................................................................................14
3.2.2 Wiring the Hydrovar sensorless to the motor.............................................................................14
3.3 MAIN PART OVERVIEW .......................................................................................................................................15
3.4 CONNECTING THE POWER CABLES .........................................................................................................................16
3.4.1 Control Terminals.......................................................................................................................17
3.5 FRONT PLATE .................................................................................................................................................19
4 FUNCTION BUTTONS OF THE HYDROVAR SENSORLESS.................................................................20
5 LEARNING A SYSTEM CURVE TO ADAPT THE SYSTEM’S REQUIREMENTS......................................21
6 SETTINGS AT THE SUBMENU – PROGRAMMING DEVICE ...............................................................23
7 SETTINGS AT THE SUBMENU-PARAMETER .................................................................................................24
7.1 AUTO START .................................................................................................................................................24
7.2 SUBMENU INVERTER..........................................................................................................................................25
7.2.1 Maximum Frequency..................................................................................................................25
7.2.2 Boost .........................................................................................................................................25
7.2.3 Fixed Speed ...............................................................................................................................25
7.3 SUBMENU CONTROLLER .....................................................................................................................................26
7.3.1 Function Mode...........................................................................................................................26
7.3.2 Window Hz - Interpolation ........................................................................................................26
7.3.3 Window Fx - Function mode ......................................................................................................26
7.3.4 Shift – Function mode................................................................................................................ 26
7.3.5 Accel high..................................................................................................................................27
7.3.6 Decel high..................................................................................................................................27
7.3.7 Accel Low ..................................................................................................................................27
7.3.8 Decel Low. .................................................................................................................................27
7.4 SUBMENU REFERENCE CURVE ..............................................................................................................................28
7.4.1 Reference Curve.........................................................................................................................28
7.4.2 Power / Frequency .....................................................................................................................28
7.4.3 Coefficients A / B / C .................................................................................................................. 28
7.5 SUBMENU TEST-RUN .........................................................................................................................................29
7.5.1 Start Test Run ............................................................................................................................29
7.5.2 Enable Test Run .........................................................................................................................29
7.5.3 Test Frequency...........................................................................................................................29
7.5.4 Boost Test Run...........................................................................................................................29
7.6 SUBMENU ECONOMY ........................................................................................................................................30
7.6.1 Currency ....................................................................................................................................30
7.6.2 Rated Power ..............................................................................................................................30
7.6.3 Costs / kWh................................................................................................................................30
7.6.4 Clear Savings .............................................................................................................................30
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7.7 MODE CONTROLLER .......................................................................................................................................... 31
7.8 SWITCH INTERVAL.............................................................................................................................................31
7.9 SET PASSWORD................................................................................................................................................31
7.10 LEARNING .................................................................................................................................................31
7.11 DEFAULT .................................................................................................................................................31
7.12 SUBMENU DIAGNOSIS – “READ ONLY” PARAMETERS ..............................................................................................32
7.12.1 Pump Runtime .........................................................................................................................32
7.12.2 Pump Address..........................................................................................................................32
7.12.3 Error memory...........................................................................................................................32
7.12.4 Software Version .....................................................................................................................32
8 CONTROLLER MENU OF THE PROGRAMMING DEVICE ..................................................................33
8.1 CONTROLLER MENU CONFIGURATION ....................................................................................................................33
8.1.1 Automatic connection to the programming device....................................................................33
8.1.2 Software Version .......................................................................................................................33
8.2 SUBMENU ADDRESS ..........................................................................................................................................34
8.2.1 Change of pump address...........................................................................................................34
9 POSSIBLE ERROR MESSAGES .........................................................................................................35
9.1 OVERHEATING – MOTOR ....................................................................................................................................35
9.2 OVERVOLTAGE .................................................................................................................................................35
9.3 UNDERVOLTAGE ............................................................................................................................................... 35
9.4 OVERLOAD .................................................................................................................................................35
9.5 OVERHEATING OF THE HEAT SINK..........................................................................................................................36
9.6 ERROR POWER MEASUREMENT.............................................................................................................................36
9.7 ADDITIONAL INTERNAL PROCESSOR ERROR MESSAGES: ..............................................................................................36
10 POSSIBLE INDICATIONS OF THE LED ON THE HYDROVAR SENSORLESS...................................................37
11 MAINTENANCE .........................................................................................................................................38
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1. Important safety instructions
Read and follow the operating instructions
and safety instructions carefully before
starting operations! All modifications must be
done by qualified technicians!
In addition to the instructions contained in these operating instructions please pay
attention to universal safety and accident prevention regulations.
Warns that failure to observe the precaution may cause electric shock.
Warns that failure to observe the precaution may cause personal injury
or damage to property.
The HYDROVAR sensorless has to be disconnected from the power supply before any work
can be carried out in the electrical or mechanical part of the system.
Installation, maintenance and repair work may only be carried out by trained, skilled and
qualified personnel.
Unauthorised modifications or changes to the system make all guarantees null and void.
When in operation the motor can be stopped by remote control, where by the HYDROVAR
sensorless and the motor remain under voltage. For safety reasons, the unit must be
disconnected from the power supply when carrying out work on the machinery as locking
out the equipment by switching off the release mechanism or set value cannot prevent
accidental starting of the motor.
When the HYDROVAR sensorless is connected to power supply, the
components of the power unit as well as certain components of the master
control unit are also connected to the power supply.
Touching these components seriously endangers life!
Before removing the HYDROVAR sensorless cover the system must be
disconnected from the power supply. After switching off the power supply
wait at least 5 minutes before starting work on or in the HYDROVAR
sensorless (the capacitors in the intermediate circuit have to be discharged
by the installed discharge resistors first).
Voltages of up to 400 volts are possible (if there are faults it can be higher).
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All work carried out when the HYDROVAR sensorless is open may only be
performed by qualified authorised staff.
Furthermore, care must be taken not to short circuit the neighbouring
components when connecting the external control wires and that open
cable ends which are not in use are insulated.
The HYDROVAR sensorless contains electronic safety devices which switch
off the control element in the event of faults, whereby the motor has zero
current but remains energised and comes to a halt. The motor can also be
halted by mechanical blocking. If it is switched off electronically the motor
is disconnected from the mains voltage through the electronics of the
HYDROVAR sensorless but is not potential-free in the circuit.
In addition voltage fluctuations, especially power failures can cause the
system to switch off itself.
Repair of faults can cause the motor to start up again.
The system may only be put into operation when it has been earthened. In addition,
equipotential bonding of all pipes must be ensured.
The operating instructions have to be read, understood and followed by the operating
personnel. We point out that we accept no liability for damage and operating disorders
which are the result of non-compliance with the operating instructions.
NOTICE!
High voltage tests of the inverter or the motor may damage the
electronic components! Hence bridge before the in- and outgoing
terminals L -N -- U- V-W.
To avoid incorrect metering by capacitors incorporated in the
electronic part isolate the motor from the HYDROVAR sensorless.
Preliminary Inspection
Visual Inspection
Upon delivery, check the integrity of the packaging.
After you have removed the external packaging, visually inspect the converter to make sure
it has suffered no damage during transport. If any damage is visible, inform your
distributor within 8 days from the delivery date.
Handling and Storage
The product must be lifted and handled carefully.
During transport and storage, protect the converter from humidity and mechanical damage
caused by impacts, falls, etc...
ATTENTION:
Dispose of all packing materials and the unit in accordance with local regulations.
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2. Technical Data - Hydrovar sensorless and General Data
HYDROVAR
sensorless
Type
HVS
Rated
output
Hydrovar sensorless
output to the Motor
Voltage Max.
current
Supply Voltage (Uin) Prefuse
min.
Mains frequency
[A] Ampere
48-62 [Hz]
1.1 1,1 kW 3x0-Uin 4,8 A 1x220-240V ±15% 10
1.15 1,5 kW 3x0-Uin 7,0 A 1x220-240V ±15% 16
1.2 2,2 kW 3x0-Uin 10,0 A 1x220-240V ±15% 20
3.2 2,2 kW 3x0-Uin 5,7 A 3x380-460V ±15% 10
3.3 3 kW 3x0-Uin 7,3 A 3x380-460V ±15% 13
3.4 4 kW 3x0-Uin 9 A 3x380-460V ±15% 16
Output voltage: 3x 0...Uin VAC / 0-70 Hz
(depends on the input voltage)
Min. frequency: 0 – max. frequency
Electrical efficiency: > 95%
Protection against: Short circuit, over- and undervoltage, overheating of the
electronics (overload) and additional external protective functions
via PTC (motor temperature) and low water switch.
A mains filter is fitted to ensure interference immunity.
The Hydrovar sensorless complies with the general EMC provisions and has been tested
according to the following standards:
• Disturbance voltage: EN 55011
• EMC – Immunity: EN 61000-4-3 and ENV 50204
• Electrostatic discharge: EN 61000-4-2
Ambient temperature: 5° C ... + 40°C
Storage temperature: -25° C ... + 55° C
(+70°C during max. 24 hours.)
Humidity: rH max. 50% at 40°C, unlimited
rH max. 90% at 20°C, max. 30 days per year
Condensation not permitted !
Air pollution:
The air may contain dry dust as found in workshops where
there is no excessive quantity of dust due to machines.
Excessive amounts of dust, acids, corrosive gases, salts etc.
are not permitted
Altitude: max. 1000m above sea level
At sites over 1000 m above sea level, the maximum output
power is derated by 1% for every additional 100m.
If the installation site is higher than 2000 m above sea level,
please contact your local distributor.
Class of protection: IP55
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∅
∅
2.1 Dimensions
HVS 1.1:
closing cap
HVS 1.15/1.2/3.2/3.3/3.4
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7
cable
gland
closing cap
Type: WM-Kit
Weight Weight
[Kg] [Kg]
HVS 1.1 2,00 1
HVS 1.15 4,70 1
HVS 1.2 4,70 1
HVS 3.2 4,70 1
HVS 3.3 4,70 1
HVS 3.4 4,70 1
cable entries
2x for M20
2x for M16
3x for M12
Dimensions for Hydrovar sensorless with wall mounting unit
Type High Wide Deep
[mm] [mm] [mm]
HVS1.1 235 155 155
HVS1.15-1.2 235 155 155
HVS3.2-3.4 265 195 195
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p
3. HYDROVAR sensorless mounting
3.1 Mounting the HYDROVAR sensorless on the pump
3.1.1 Included components
Variant for HVS 1.1:
mounting and distance ring
screw
washer
Variant for HVS 1.15/HVS 1.2/HVS 3.2/HVS 3.3/HVS 3.4:
thermistor
cable gland
screw M5x50
thermistor
cable gland
mounting clam
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sensorless
3.1.2 Mechanical mounting
Variant for HVS 1.1
Hydrovar
1. Remove the motor fan cover from
your 3-phase motor by removing the
mounting screws.
2. Put the mounting and distance ring
(1) between the fan cover and the
Hydrovar sensorless and fix them
together with the screw (3) by using
the included washer (2).
3. Use the fan cover screws to mount
(1) mounting
and distance
ring
the fan cover/Hydrovar sensorless
combination to the motor
motor fan
cover
(2) washer
(3) screw
CAUTION!:
Don’t forget the washer between the screw and the motor fan cover!
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Variant for HVS 1.15/HVS 1.2/HVS 3.2/HVS 3.3/HVS 3.4:
Screws with
Gasket
4 screws
M5x50
Centre bit
4 mounting
clamps
CAUTION!
Don’t forget the gaskets
for the 3 screws.
Ensure that there is no
water on the unit before you
open the cover.
Connection
Motor conduit box
Thermistor
Mounting ring
CAUTION!
If you use a motor with plastic fan cover, you have to
a mounting ring.
use
Mounting:
Remove the 3 screws holding the HVS
cover.
Place the centre bit in the HVS fan cover.
Place the HVS fan cover on the motor.
Hang the 4 clamps by the motor fan
cover and fix them with the 4 screws.
Mount the cover with the 3 screws.
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