HYDROVAR
Operating Instructions
HV2.1f – HV3.11f HV3.15e – HV3.22e
HV3.30e-HV3.45e
V 2012/03A
771079342
HV2_1-3_45-V-EN-6A
English
2
Index
1 Important safety instructions...........................................................................5
2 System Design...................................................................................................8
2.1 Pressure tank............................................................................................8
3 Technical Data...................................................................................................9
4 Dimensions and Weights ................................................................................12
5 Mechanical mounting of the HYDROVAR unit on the motor.........................16
5.1 Included mounting material ..................................................................16
5.2 Optional components ............................................................................16
5.2.1 Fittings ..................................................................................................................16
5.2.2 Bus interface.......................................................................................................... 17
5.2.3 Sensors (4-20mA) .................................................................................................. 17
5.2.4 Filter ...................................................................................................................... 17
5.2.5 Motor cables for direct-installation........................................................................ 17
5.3 Assemble Instruction .............................................................................18
6 Electrical installation and wiring....................................................................22
6.1 Means of protection ..............................................................................22
6.2 EMC-electromagnetic compatibility ......................................................23
6.3 Wiring and connections .........................................................................25
6.3.1 Main Voltage Terminals ......................................................................................... 26
6.3.2 Motor connection.................................................................................................. 28
6.3.3 Control Terminals .................................................................................................. 29
6.3.3.1 Connection examples................................................................................ 31
6.4 Selection of the switching-frequency....................................................34
6.5 Reduction of the maximum output current ..........................................34
6.6 RFI - switch .............................................................................................35
7 Programming ..................................................................................................36
7.1 Display – control panel ..........................................................................36
7.2 Function of the push buttons................................................................37
7.3 Language Selection................................................................................37
8 Parameters of the main menu ........................................................................38
9 Parameters of the Secondary Menu ...............................................................42
9.1 JOG-MODE..............................................................................................42
9.2 Window ..................................................................................................43
9.3 Ramp Hysteresis .....................................................................................43
9.4 Ramp 1: Fast acceleration time..............................................................44
3
9.5 Ramp 2: Fast deceleration time .............................................................44
9.6 Ramp 3: Slow acceleration time ............................................................44
9.7 Ramp 4: Slow deceleration time............................................................44
9.8 Maximum Frequency..............................................................................45
9.9 Minimum Frequency ..............................................................................45
9.10 Operation at minimum frequency .......................................................46
9.11 Delay time to shut off below minimum frequency .............................46
9.12 Boost ....................................................................................................46
9.13 Sensor – Adjust ....................................................................................47
9.14 Sensor - Curve ......................................................................................47
9.15 Setting of the sensor range .................................................................47
9.16 Operation Mode...................................................................................48
9.17 Regulation mode..................................................................................49
9.18 Start Value ...........................................................................................49
9.19 2
nd
Required Value ...............................................................................50
9.20 Configuration of the pump running relay (X2/4-5-6)..........................51
9.21 Submenu Offset ...................................................................................51
9.21.1 Source of the Offset input ................................................................................... 51
9.21.2 1
st
Offset level...................................................................................................... 52
9.21.3 2
nd
Offset level..................................................................................................... 52
9.21.4 Intensity 1............................................................................................................ 52
9.21.5 Intensity 2............................................................................................................ 52
9.21.6 Example for the Offset......................................................................................... 53
9.22 Submenu Sequence control.................................................................54
9.22.1 Lift Value (actual value increase).......................................................................... 54
9.22.2 Fall Value (actual value decrease)......................................................................... 54
9.22.3 Enable sequence control...................................................................................... 55
9.22.4 Switch Interval..................................................................................................... 55
9.22.5 Source of required value...................................................................................... 55
9.22.6 Submenu Synchronous Control ........................................................................... 56
9.22.6.1 Synchronous Limit .................................................................................. 56
9.22.6.2 Synchronous Window............................................................................. 56
9.22.7 Pump status indication ........................................................................................ 57
9.22.8 Busarbit-Diag. - Counter for interface communication problems......................... 57
9.23 Submenu - RS 485 Interface ................................................................58
9.23.1 Pump Address...................................................................................................... 58
9.23.2 ADC Reference..................................................................................................... 58
9.24 Frequency Lifting .................................................................................59
9.25 Lift- Amount (Intensity) .......................................................................59
9.26 Analogue - Output ...............................................................................60
9.27 Dimension Unit ....................................................................................60
9.28 Automatic test run...............................................................................60
9.29 Submenu for manual test run .............................................................61
4
9.29.1 Activate manual test run...................................................................................... 61
9.29.2 Test Frequency..................................................................................................... 61
9.29.3 Boost for manual test run.................................................................................... 61
9.30 Submenu - Error...................................................................................62
9.30.1 Conveyor Limit..................................................................................................... 62
9.30.2 Delay Time........................................................................................................... 62
9.30.3 Automatic Error reset .......................................................................................... 62
9.30.4 Clear Errors.......................................................................................................... 62
9.31 Operating Hours...................................................................................63
9.32 Display – Contrast ................................................................................63
9.33 Set Password........................................................................................63
9.34 Lock Function .......................................................................................63
9.35 Internal Heater .....................................................................................63
9.36 Setting Default Values .........................................................................64
9.36.1 Default Values Europe ......................................................................................... 64
9.36.2 Default Values USA.............................................................................................. 64
9.37 Saving...................................................................................................64
10 Error Signals..................................................................................................65
11 RS 485 - Interface..........................................................................................69
12 Auxiliary Texts...............................................................................................69
13 Maintenance .................................................................................................69
Follow the Pump Operating and Maintenance Instructions
We reserve the right to alter specifications
5
1 Important safety instructions
Read and follow the operating instructions and safety
instructions carefully before starting operations!
All modifications must be done by qualified technicians!
Warns that failure to observe the precaution may cause electric shock
Warns that failure to observe the precaution may cause personal injury or
damage to property.
In addition to the instructions contained in these operating instructions please pay
attention to universal safety and accident prevention regulations.
Basically the HYDROVAR must be disconnected from the power supply before any work can
be carried out in the electrical or mechanical part of the system.
Installation, maintenance and repair work may only be carried out by trained, skilled and
qualified personnel.
Unauthorized modifications or changes to the system make all guarantees null and void.
During operation, the motor can be stopped by open a digital input or manually operated,
whereby the HYDROVAR and the motor remain under voltage. For safety reasons, the
HYDROVAR has to be disconnected from the power supply when carrying out work on the
machinery.
When the HYDROVAR is connected to power supply, the components of the
power unit as well as certain components of the master control unit are also
connected to the power supply.
Touching these components seriously endangers life!
Before removing the HYDROVAR cover the system must be disconnected from
the power supply. After switching off the power supply wait
at least 5 minutes before starting work on or in the HYDROVAR (the
capacitors in the intermediate circuit are discharged by the installed discharge
resistors first).
Voltages of up to 800 volts are possible (if there are faults it can be higher)
6
All work, carried out at opened HYDROVAR, may only be performed by
qualified and authorized staff.
Furthermore, care must be taken not to short circuit the neighbouring
components when connecting the external control wires and that open cable
ends which are not in use are isolated.
The HYDROVAR contains electronic safety devices which switch off the control
element in the event of faults, whereby the motor has zero current but
remains energised and comes to a halt. The motor can also be halted by
mechanical blocking. If it is switched off electronically the motor is
disconnected from the mains voltage through the electronics of the
HYDROVAR but is not potential-free in the circuit.
In addition voltage fluctuations, especially power failures can cause the
system to switch off itself.
Repair of faults can cause the motor to start up again!
The system may only be put into operation when it has been grounded.
In addition, equipotential bonding of all pipes must be ensured.
The operating instructions must be read, understood and followed by the
operating personnel. We point out that we accept no liability for damage
and operating disorders which are the result of non-compliance with the
operating instructions.
High voltage tests of the HYDROVAR or the motor may damage the
electronic components! Hence bridge the in- and outgoing
terminals L1 - L2 - L3 - U- V-W before.
To avoid incorrect metering by capacitors incorporated in the electronic
part isolate the motor from the HYDROVAR.
7
Transport, Handling, Storage, Disposal:
• Check the HYDROVAR immediately upon delivery/receipt of dispatch for damage or
missing parts
• The HYDROVAR unit must be transported carefully and by competent personnel.
• Avoid serious impacts
NOTICE!
The use of the WEEE-Symbol indicates that this product may not be treated as
household waste.
Dispose of all packing materials and the unit in accordance with local
regulations.
For more detailed information about the recycling of this product, please
contact your local authority, your household waste disposal service provider
ort he shop where you purchased the product.
CAUTION!
Lifting aids (stacker, crane, crane mounting device, lifting blocks, sling ropes,
etc.) must have the proper dimensions so that they can bear the weight of the
HYDROVAR.
CAUTION!
It is not allowed to carry the HYDROVAR around by using the connected
cables.
Do not damage the cable during transport (do not squeeze, bend or drag).
The cable ends must be kept dry.
WARNING!
• Do not stand underneath suspended loads
• take note of the general regulations on prevention of accidents
• The HYDROVAR must be secured against tipping over and slipping until it
has been fixed in its final location.
8
2 System Design
The following diagrams show typical single pump and multi-pump systems using the
HYDROVAR control unit. Connection can be made directly to a water supply. In such a case, a
pressure switch on the suction side should be used.
Single Pump Layout Multi Pump Layout
(1) pump with HYDROVAR
(2) diaphragm tank
(3) distribution panel
(4) gate valve
(5) non return valve
(6) low water control
(7) pressure gauge
(8) pressure transmitter
(9) drain tap
2.1 Pressure tank
A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure in
the line when there is no demand. This will keep the pumps from continuing to run at zero
demand. With the HYDROVAR, it isn’t necessary to have a large tank for supply purposes.
The tank must be permitted and suitable for systems pressure. The tank should have a
capacity of min. 10% of the maximum system flow rate [l/min] of one pump (also valid for
multi-pump system).
Example:
Maximum flow rate of the pump = 250 litres per minute
Minimum volume of the tank = 250 x 0.10 = 25 litres
The pre-charge pressure of the tank can be determined in the following table:
NOTICE:
To check and set the right pre-charge pressure, please make the tank
pressure less before.
required pressure (bar)
precharge pressure (bar)
9
3 Technical Data
HYDROVAR Power Supply
Type Rated
output
Voltage limits
48-62 Hz
Rated
current input
line protection
max.
Maximum
connection
HV [kW] [V] [A] [A] [mm²]
2.1f 1,5 12,7 20
2.2f 2,2
1x220-240 -10% +15%
16,5 25
10
3.2f 2,2 6,3 13
3.3f 3 7.4 13
3.4f 4
3x380-460 ± 15%
9,5 16
10
3.5f 5,5 12,6 20
3.7f 7,5 16,3 25
3.11f 11
3x380-460 ± 15%
23,2 32
10
3.15e 15 31,6 40
3.18e 18,5 39 50
3.22e 22
3x380-460 -15% +10%
46,3 63
25
3.30e 30 61 80
3.37e 37 74,7 100
3.45e 45
3x380-460 -15% +10%
89,5 125
50
HYDROVAR Output to the motor
Type Rated
Output
Max. Voltage
Output
Rated Current
output
Motor connection cables
HV [kW] [V] [A] mm²
2.1f 1,5 7
2.2f 2,2
3x U
in
10
4x1,5 – 4x4
3.2f 2,2 5,7
3.3f 3 7
3.4f 4
3x U
in
9
4x1,5 – 4x4
3.5f 5,5 13,5
3.7f 7,5 17
3.11f 11
3x U
in
23
4x2,5 – 4x6
3.15e 15 30
3.18e 18,5 37
4x6 – 4x25
3.22e 22
3x U
in
43 4x10 - 4x25
3.30e 30 58 4x25 – 4x50
3.37e 37 71
3.45e 45
3x U
in
85
3x35+1x25 – 4x50
Make sure that the Hydrovar’s electrical data match those of the electric pump.
Improper combinations may cause malfunctions and fail to ensure the protection
of the electric motor.
10
The rated current of the motor must be lower than the rated current of the Hydrovar to
prevent overheating or shutdown due to “OVERLOAD”.
The max. output current of the HYDROVAR could reach 110% of the nominal current for
max. 10 sec. before the error “Overload” will occur.
Ambient temperature:
0° C ... +40°C
At higher temperatures a reduction of the output current or
the use of the next HYDROVAR type is necessary.
o Protect the HYDROVAR against direct sunlight!
o Outdoor installation without protection of the
HYDROVAR is not permitted!
Storage temperature:
-25° .C ... +55° C (+70°C during max. 24 hours.)
Humidity:
RH max. 50% at 40°C, unlimited
RH max. 90% at 20°C, max. 30 days per year
75% average per year (Class F)
Condensation is not permitted!
Air pollution:
The air may contain dry dust as found in workshops where
there is no excessive quantity of dust due to machines.
Excessive amounts of dust, acids, corrosive gases, salts etc.
are not permitted
Altitude:
max. 1000m above sea level
At sites over 1000 m above sea level, the maximum output
power has to be derated by 1% for every additional 100m.
If the installation site is higher than 2000 m above sea level,
please contact your local distributor.
Class of protection:
HV2.1 - HV3.11f IP 55 (NEMA 4)
HV3.15 - HV3.45e IP 54 (NEMA 12)
Certifications:
CE, UL, C-Tick, cU
L
0
10
20
30
40
50
60
70
80
90
100
110
0 102030405060
max. ambient temperature [°C]
max. output current [%]
11
The HYDROVAR complies with the general EMC regulations and is tested according to the
following standards:
• High Frequency Field Interference
ENV 50204
• Electrostatic Discharge
EN 61000-4
• Radio interference Suppression
EN 61000-6-1 (2002)
EN 61000-6-2 (2002)
EN 61000-6-3 (2002)
EN 61000-6-4 (2002)
12
4 Dimensions and Weights
HV 2.1/2.2/3.2/3.3/3.4 f
Type Weight HV +
WM-Kit
[kg] [kg]
HV 2.1f
HV 2.2f
6,80
HV 3.2f
HV 3.3f
HV 3.4f
5,80
8,40
All dimensions in millimetres! Drawings are not in scale!
a … centre-distance between the HYDROVAR 300 [mm]
b … expansion space for maintenance 120 [mm]
Wall-mounting version:
high: 265 [mm] width: 195 [mm] depth: 195 [mm]
Mounting space around the HYDROVAR:
150 [mm]
13
HV 3.5/3.7/3.11 f
Type Weight HV +
WM-Kit
[kg] [kg]
HV 3.5f
HV 3.7f
HV 3.11f
10,00 12,60
All dimensions in millimetres! Drawings are not in scale!
a … centre-distance between the HYDROVAR 430 [mm]
b … expansion space for maintenance 120 [mm]
Wall-mounting version:
high: 305 [mm] width: 280 [mm] depth: 280 [mm]
Mounting space around the HYDROVAR: 150 [mm]
14
HV 3.15/3.18/3.22 e
Type Weight HV +
WM-Kit
[kg] [kg]
HV 3.15e 40,00
HV 3.18e 40,00
HV 3.22e
29,00
40,00
All dimensions in millimetres! Drawings are not in scale!
a … centre-distance between the HYDROVAR 550 [mm]
b … expansion space for maintenance 300 [mm]
max. diameter of the motor fan cover 385 [mm]
Wall-mounting version:
Mounting space: - above: 300 [mm]
- beside: 200 [mm]
- below: 150 [mm]
Wall-mounting
version
[mm]
High 430
wide 365
deep 361
15
HV 3.30/3.37/3.45 e
Not available as motor-mounted version!
Type Weight
[kg]
HV 3.30e 57,00
HV 3.37e 57,00
HV 3.45e 60,00
Mounting space above:
Beside and below the HYDROVAR:
500 [mm]
150 [mm]
All dimensions in millimetres!
Drawings are not in scale!
16
5 Mechanical mounting of the HYDROVAR unit on the motor
5.1 Included mounting material
Included
components
Cable gland Cable gland
Closing gland PTC
Motor
Center-
piece
Terminals
for max.
[mm²]
M M M M M PG PG M M PG
PG
12 16 20 25 40 16 29 12
16
16
29
Cable
diameter
[mm]
3,5-7 4,5-10 7-13 9-17 19-28
9-14 14-25
HV-type
2.1-3.4 f 2 (3) 2 2 3 1 1 1 10
3.5-3.11 f 2 (3) 2 2 3 1 1 1 10
3.15-3.22 e 0 (2)
1 (2) 1 1 1 25
3.30-3.45 e 2 (3) 2 (2) 2 (2)
3 1 1 50
( ) max. available cable entries
5.2 Optional components
5.2.1 Fittings
Mounting clamps for motor-mounting
4 pieces per set
(only available for HV 1.15-3.11f)
Mounting ring
Available for the diameters: 140 mm
155 mm
CAUTION!
If you use a motor with plastic fan cover, you have to use a steel mounting
ring.
Distance-bushes
Distance - bushes which are mounted between the HYDROVAR and the motor fan
cover. Different bushes are available, which depends to the output and the type
of the motor. (only necessary for the types HV 3.15-3.22e)
Mounting ring
17
45° Adapter
Available for HV 2.1 – 3.11f
Remote Display
Available for HV 2.1 – 3.11f
5.2.2 Bus interface
MODBUS
for installation in the
HYDROVAR
for external installation
– switching cabinet
for external installation –
wall mounting
5.2.3 Sensors (4-20mA)
• pressure-transducer
• differential-pressure-transducer
• level-sensor
• temperature-sensor
• flow indicator
(orifice plate, inductive flow metering)
5.2.4 Filter
• Motor-coils
• Line-coils
• EMC Filter (see chapter 6.2 EMV)
5.2.5 Motor cables for direct-installation
Available for HV 2.1f – 3.22e
18
5.3 Assemble Instruction
HV 2.1f – HV 3.11f
Gasket
Display
(changeable by 180°)
Pressure transmitter
Motor conduit box
4 Mountin
g
clam
p
s
Centre bit
4 Screws
M5x60
Motorcable
HYDROVAR -
cover
3
screws (to fix the cover)
PTC
Motor fan cover
Motor
19
To remove the HYDROVAR – cover, open the 3 fastening screws.
o Be careful not to lose the small gaskets!
o Ensure that there is no water on the unit before you open the cover.
o Be careful not to damage the connecting cable!
• Position the HYDROVAR on the motor fan cover.
• Try to centre it as good as possible using the rubber centre bit.
o
If you use a motor with plastic fan cover, you have to use a steel mounting ring.
• Install the HYDROVAR on the motor fan cover by using the mounting brackets, the four
screws and the related washers.
• Make sure the converter is well centred and then tighten the four screws.
• Tighten each fastening screw until the two bottom teeth in the brackets start to grip the
fan cover.
• After connecting the electrical components, mount the cover on the HYDROVAR and
tighten the three fastening screws.
o Make sure of a good connection of the connecting cable and the ground wire.
o Control the gasket of the HYDROVAR and don’t forget to install the gaskets of the
fastening screws.
o Ensure that the mounting of the cable glands is done properly and use closing glands
for cable-bushings which aren’t used.
20
HV 3.15e – HV 3.22e
Motor
Motorcable
Motor conduit bo
x
Motor fan cover
4 fixing screws
Displa
y
-unit (8 fixing- screws)
HYDROVAR -
cover
4
screws (to fix the cover)
Pressure transmitter
21
• Position the HYDROVAR at the motor, try to centre it as good as possible and prepare the
boreholes for the fixing screws.
o Ensure that the position of the display is correct
If it is necessary, Display is changeable by 180°
Working process to turn the control-board:
- to turn the control-board you have to disconnect the connection to the
power- board
- open the 4 hexagonal bolts (use a 7mm socket wrench) and turn the
control-board
- mount the control-board and connect the 40 pin-plug to the power-board
o remove the motor-fan-cover if you have to install the HYDROVAR horizontal
• Mount the HYDROVAR by using the suitable fixing screws (M8), distance bushes and screw-
nuts (this should be self-locking) at the motor-fan-cover
o If the HYDROVAR is mounted horizontal, a additional bracing may be required
22
6 Electrical installation and wiring
All installations and maintenance have to be performed by properly trained
and qualified personal with proper tools!!
In case of a failure, disconnect or switch off electrical power and wait
5 minutes for capacitor discharge before servicing the HYDROVAR.
Otherwise it can cause shock, burns or death.
6.1 Means of protection
Ask your power supply company which means of protection are required.
Applicable:
• protective earthing
• AC and DC residual current operated protective devices (RCD)
• TN systems
Protective earthing:
• Please note that there can be a current to earth due to the capacitors in the input filter.
• A suitable protection unit has to be selected (according local regulations).
Residual current device (RCD):
• When using an RCD, make sure that it also releases in the event of a short circuit inside the
DC-part of the HYDROVAR to earth!
o single phase HYDROVAR => use pulse sensitive RCDs
o three phase HYDROVAR => use AC/DC sensitive RCDs
• The RCD has to be installed according local regulations!
Automatic circuit breaker:
• Use automatic circuit breaker with C-type characteristic curve
• Rating of the line-protection (see chapter 3. Technical Data)
Internal protective devices of the HYDROVAR:
• The malfunctions short circuit, under- and over-voltage and the overheating of the
electronic components (overload) are controlled by the HYDROVAR.
External protective devices:
• Additional protective functions like motor overheat and low water protection, are
controlled by external equipment.
Loading...