Xylem HYDROVAR HV 2.015 Operating Instructions Manual Download Page 1

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Operating Instructions

V 2012/03A-V01.4

771079412 Manual HV 2.015-4.220

ENGLISH

HV 2.015 / 2.022

HV 4.022 / 4.030 / 4.040
HV 4.055 / 4.075 / 4.110
HV 4.150 / 4.185 / 4.220

Summary of Contents for HYDROVAR HV 2.015

Page 1: ...Operating Instructions V 2012 03A V01 4 771079412 Manual HV 2 015 4 220 ENGLISH HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 HV 4 150 4 185 4 220...

Page 2: ......

Page 3: ...Mechanical components 22 8 1 Included mounting material 22 8 2 Optional components 22 8 2 1 Mounting accessories 22 8 2 2 Sensors 22 8 2 3 Filter 22 Line coils 22 8 2 4 Cable entry only HV4 150 4 220...

Page 4: ...NU BASIC SETTINGS 61 0200 SUBMENU CONF INVERTER 64 0300 SUBMENU REGULATION 72 0400 SUBMENU SENSOR 74 0500 SUBMENU SEQUENCE CNTR 77 0600 SUBMENU ERRORS 82 0700 SUBMENU OUTPUTS 83 0800 SUBMENU REQUIRED...

Page 5: ...authorized modification or changes to the system make all guarantees null and void During operation the motor can be stopped by opening a digital input or manual operation whereby the HYDROVAR and the...

Page 6: ...t In addition voltage fluctuations especially power failures can cause the system to switch itself off Repair of faults can cause the motor to start up again automatically The system may only be put i...

Page 7: ...service provider or the outlet where you purchased the product CAUTION Lifting aids stacker crane crane mounting device lifting blocks sling ropes etc must be suitable to handle the weight of the HYDR...

Page 8: ...ain pressure in the line when there is no water demand This avoids the pump from continuing to run at zero demand With the HYDROVAR no large tanks are required for supply purposes The tank must be per...

Page 9: ...he Relay Card Application Simple SINGLE pump applications MASTER Inverter HYDROVAR BASIC Inverter including the high level control card supports also the optional modules like the Relay Card and all s...

Page 10: ...R Inverter including automatic change over of the lag pumps to provide even wear and achieve even operating hours If the control card of a MASTER Inverter fails each of the BASIC Inverters can be manu...

Page 11: ...his mode it is possible to run all pumps in cascade serial mode and synchronous mode as well This configuration allows each pump of the system to become the lead pump This also ensures a proper operat...

Page 12: ...ble to switch the pumps directly just used as control contacts Also an automatic change over of the fixed speed pumps to provide even wear and achieve even operating hours is possible in this mode Thi...

Page 13: ...E Inverter 3 MASTER Inverter Rated output 022 2 2 kW 055 5 5 kW 030 3 0 kW 075 7 5 kW 040 4 0 kW 110 11kW 150 15 0kW 185 18 5kW 220 22 0kW Nominal mains voltage 1 1 1 230VAC 3 3 3 230VAC 2 1 3 230VAC...

Page 14: ...d output max output voltage nominal current output motor connection cables HV kW V A mm 2 015 1 5 7 0 2 022 2 2 3x Uin 10 0 4x1 5 4x4 4 022 2 2 5 7 4 030 3 7 3 4 040 4 3x Uin 9 0 4x1 5 4x4 4 055 5 5 1...

Page 15: ...tdown the HYDROVAR should remain connected to the power supply but the ext on off inhibited to prevent running of the pump This will maintain power to the internal heater and reduce internal condensat...

Page 16: ...aving necessary skills in installing and or commissioning power drive systems including their EMC aspects Second environment class A EN 61800 3 Class C3 Environment that includes all establishments ot...

Page 17: ...ns in millimetres Drawings are not to scale Lifting aids must have the proper dimensions Type Weight kg BASIC MASTER SINGLE HV 2 015 HV 2 022 HV 4 022 HV 4 030 HV 4 040 4 00 4 40 a minimum centre dist...

Page 18: ...metres Drawings are not to scale Lifting aids must have the proper dimensions Type Weight kg BASIC MASTER SINGLE HV 4 055 HV 4 075 HV 4 110 7 70 8 10 a minimum centre distance between HYDROVAR units 4...

Page 19: ...ons in millimetres Drawings are not to scale Lifting aids must have the proper dimensions Type Weight kg MASTER HV 4 150 HV 4 185 HV 4 220 14 00 a minimum centre distance between HYDROVAR 550 mm b exp...

Page 20: ...configuration for the HYDROVAR can be chosen Due to this possibility the HYDROVAR can be configured regarding the reliability and cost effectiveness for each type of application HV 4 022 4 030 4 040 H...

Page 21: ...nts Class B 3 Mounting Kit Consists of the metal and plastic cover to fix the control card and the display and the additional Relay Card if used By the pre mounted cable clips the screen of all signal...

Page 22: ...ax available cable entries 8 2 Optional components 8 2 1 Mounting accessories Mounting ring Available for diameters 140 mm 155 mm CAUTION If the HYDROVAR is mounted on a motor with a plastic fan cover...

Page 23: ...2 015 HV 4 110 HV 4 150 HV 4 220 display actual value sensor motor conduit box 4 mounting clamps centering bit 4 screws M5x70 motor cable HYDROVAR top cover 4 screws to fit cover M4x50 M5x20 PTC motor...

Page 24: ...stening screw until the two bottom teeth in the brackets start to grip the fan cover After the electrical components are connected the top cover of the HYDROVAR can be mounted and tightened by the fou...

Page 25: ...input filter A suitable protection unit has to be selected according local regulations Residual current device RCD RCCB When using an RCD make sure that it also releases in the event of a short circui...

Page 26: ...nected to ground on one end to prevent ground loops The screen should be connected to HYDROVAR GND use pre mounted cable clips For small cable diameters the cable clips can be squeezed to ensure fixin...

Page 27: ...the line voltage EMC summary Install potential equalization according to local regulations Do not install the power cables in parallel to signal cables Use screened signal cables Connect both ends of...

Page 28: ...s can be seen on a HYDROVAR MASTER SINGLE Inverter HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 A Power supply B Motor connections C Terminal block START STOP_PTC D RS 485 Interface E Stat...

Page 29: ...N 1 x 230 VAC SINGLE phase Terminal L1 L2 L3 3 x 400 VAC three phase HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 HV 4 150 4 185 4 220 L1 L2 L3 3x400 VAC Motor connection U V W Crimp conne...

Page 30: ...dy of the motor This is necessary to measure the right temperature of the motor The connection of the motor cable depends on the type of motor and can be done in star or delta connection The right con...

Page 31: ...d HV 2 015 2 022 HV 4 022 4 030 4 040 HV 4 055 4 075 4 110 HV 4 150 4 185 4 220 X7 Terminal for internal fan X8 24V X1 Control terminals power unit PTC PTC or thermal switch START STOP external releas...

Page 32: ...ASIC Inverter only starts up if it is released and requested by a MASTER Inverter via the serial RS485 Interface When contact X1 SL is closed the HYDROVAR starts up to pre selected MAX FREQUENCY fixed...

Page 33: ...485 Interface on the power unit is used for the communication between up to 8 HYDROVARs in a multi pump system minimum 1 MASTER Inverter For the connection to each HYDROVAR via the RS 485 interface t...

Page 34: ...BASIC Inverters Set address 1 3 for the MASTER Inverters via appropriate software parameters See submenu CONF INVERTER 0200 or submenu RS485 INTERFACE 1200 Address 4 7 for the BASIC Inverters via dip...

Page 35: ...nverter BASIC Inverter HV 4 150 4 185 4 220 Terminal for external LED X22 Dip switch for addressing S1 possibility to connect a LED to show the status without display operation S2 reserved for changin...

Page 36: ...ly for internal high voltage testing Closed default setting should not be changed be the end user Open only for tests done by the manufacturer S2 activation HF filter capacitor Closed default setting...

Page 37: ...n This control card doesn t support any additional boards and includes just the necessary software parameters for SINGLE pump applications 9 4 5 1 Control card HYDROVAR MASTER Inverter The control car...

Page 38: ...l ON OFF release Active low 8 GND electronic ground 9 Configurable digital input 1 Dig 1 Active low 10 GND electronic ground 11 Low water Active low 12 GND electronic ground 13 Voltage signal input re...

Page 39: ...he required value or the offset Voltage signal input required value 2 0 10 VDC DIG 4 To determine the required value or the offset Voltage signal input required value 1 0 10 VDC To determine the requi...

Page 40: ...ble connections Standard pressure transducer PA22 Actual value signal input 0 4 20mA X3 4 Sensor 2 24VDC sensor supply X3 3 brown Actual value signal input 0 4 20mA X3 2 Sensor 1 white Ground X3 1 Swi...

Page 41: ...frequencies by the digital inputs The connected input signals current or voltage are proportional to the frequency How to program see SUBMENU REQUIRED VALUES 0800 Actual value frequency indicator e g...

Page 42: ...ation For the connection of each HYDROVAR via the RS 485 interface the terminals X4 4 6 on the control card and either the terminals X2 1 3 on the power unit can be used Connection example using one M...

Page 43: ...revent disturbance of the HYDROVAR Both Status Relays on the control card can be used regarding the programmed configuration Factory setting The two relays are used as pump running or fault signal rel...

Page 44: ...or is necessary to prevent disturbances arising during a switching action of the relay Terminals Relay Card X10 Relay Card 1 Relay 1 2 Relay 2 max 250VAC 0 25A 3 Relay 3 max 220VDC 0 25A 4 Relay 4 max...

Page 45: ...h is required In the example below 3 fixed speed pumps are connected to the Relay Card For such an application an optional HAND OFF AUTO switch SW1 SW2 and SW3 is recommended During normal operation t...

Page 46: ...4 150 HV 4 220 The control card is connected to the power unit via a ribbon cable on terminal X8 The display is connected to terminal X9 The display can be mounted in normal position 0 or upside down...

Page 47: ...GND electronic ground 2 Actual value input sensor 1 0 10VDC or 0 20mA 4 20mA Ri 50 3 Power supply for external sensors 24VDC max 100mA 4 User SIO Interface SIO 5 User SIO Interface SIO 6 GND electroni...

Page 48: ...nces arising during a switching action of the relay Both Status Relays on the control card can be used regarding the programmed configuration Factory setting The two relays are used as pump running or...

Page 49: ...hange to faster scrolling up of a value short Change to faster scrolling down of a value Short pressing enter submenu Change to next parameter in the menu Short pressing leave submenu Change to previo...

Page 50: ...rror LED red The type of error is indicated by the blinking code of the ERROR LED 1 blink Undervoltage 2 blinks Overcurrent Overload 3 blinks Inverter overheat 4 blinks Overvoltage 5 blinks Code Error...

Page 51: ...vailable for a HYDROVAR SINGLE Inverter Parameters which are transferred automatically within the whole group of HYDROVAR units are marked with the following symbol Global parameter interchanged on al...

Page 52: ...e HYDROVAR by pressing STOP Manually stopped Start of the HYDROVAR by pressing OFF External release X3 7 8 is open To start up the HYDROVAR close external release or bridge terminal X3 7 8 Indication...

Page 53: ...ve MODE 0105 Actuator Frequency XX X Hz STOP X XX Bar 1st display in Mode actuator If parameter MODE 0105 is set to actuator the parameter REQUIRED VALUE 02 will change to ACTUAT FREQ and is equivalen...

Page 54: ...n the main menu are valid for all selected modes 05 05 LANGUAGE ENGLISH Language selection Possible settings To select the desired language press or The information on the display and all parameters a...

Page 55: ...ng disconnection If AUTO START OFF the HYDROVAR won t start automatically after reconnection of power following disconnection After remedy of the failure or reconnection of the power supply the follow...

Page 56: ...ron 21 STATUS UNITs 11001000 Unit 1 2 and 5 are running E g Mode Cascade relay 21 STATUS UNITs 10100 Relay Contact 1 and 3 are closed 22 22 SELECT DEVICE 1 Select device Possible settings 1 8 Check th...

Page 57: ...ntact is opened fixed speed pump is stopped Mode CASCADE SERIAL SYNCHRON running Pump is running stopped Pump is stopped because there is no request disabled Pump is stopped manually Stopped with butt...

Page 58: ...e chapter 11 failure messages 26 26 1st ERROR ERROR XX Latest error happened on selected device Message ERROR XX FAILURE TEXT DATE TIME Press or to scroll up or down 27 27 2nd ERROR ERROR XX 2nd error...

Page 59: ...This value determines the output frequency generated from the HYDROVAR This parameter gives information about the software version of the BASIC drive located on the main board Possible indications 00...

Page 60: ...the submenu is opened with the correct password it will remain open for a time period of 10 minutes without the need of enter the password again to access the secondary menu 61 PASSWORD 0066 Confirm...

Page 61: ...egulation reliability Cascade Serial Has to be selected if more than one HYDROVAR controlled pump operate together via the RS 485 interface The standard application for this mode is a multi pump syste...

Page 62: ...larative The functions thermal protection and external ON OFF remain still active The functions External ON OFF Motor Overheat Lack of water and all other internal protections still work In the actuat...

Page 63: ...ressing or Possible settings 0000 9999 The pre set password 0066 can be changed After the password has been changed it is recommended to note the new password somewhere 0115 0115 LOCK FUNCT OFF Possib...

Page 64: ...cification is activated and DONE is displayed Following parameters 0285 0286 0290 and 0291 are added to the menu only on units 5 5 22kW The required version can only be activated if all devices are up...

Page 65: ...e to press the button for 3 sec and then choose this unit 1 8 for which the parameterization should be done With setting ALL each HYDROVAR in the group is programmed Be careful if you change back to A...

Page 66: ...avoid overload error The slow ramps 3 and 4 determine the regulation speed of the internal HYDROVAR controller for small devices or constant consumption and depend on the system which has to be contro...

Page 67: ...ing up time may lead to oscillation and or an error OVERLOAD Excessively slow running up time can cause a drop of the outgoing pressure during variation of the demand 0230 0230 RAMP 4 70 sec Ramp 4 Sl...

Page 68: ...ettings 0 0 fmax 0 0 30 0 Hz if 203 is 00 default At operation below the set min frequency the HYDROVAR operates with the fast ramps 0235 0240 As per default the max setting of this parameter is limit...

Page 69: ...settings are kept as low as possible so that the motor does not become thermally overloaded at lower frequencies If the boost is set too low a failure OVERLOAD may occur because the starting current i...

Page 70: ...75 4 50 4 055 13 50 11 48 10 13 6 75 4 075 17 00 14 45 12 75 8 50 4 110 23 00 19 55 17 25 11 50 4 150 30 00 25 50 22 50 15 00 4 185 37 00 31 45 27 75 18 50 4 220 43 00 36 55 32 25 21 50 0280 0280 SEL...

Page 71: ...0290 CURR LIMIT OFF Current limit functionality Possible settings OFF ON Possible settings 10 0 100 Following parameters 0285 0291 are limited for power ratings starting from 5 5kW Size 2 and Size 3 w...

Page 72: ...ble settings 0 100 of required value Determines the band where the slow ramp changes to the fast ramp for steep pump curves and closed loop systems 20 30 0315 0315 HYSTERESIS 80 Hysteresis for ramp sw...

Page 73: ...be determined by using the JOG MODE 0305 0330 0330 LIFT AMOUNT 0 0 Lift amount for required lift value Possible settings 0 0 200 0 This value states how much the set value should be continually increa...

Page 74: ...are used and which one is active It is also possible to measure the difference of two connected sensors or to configure an automatic switchover in case of a faulty sensor Sensor 1 Sensor 1 is constan...

Page 75: ...10 00 Bar Sensor range Possible settings 0 00 10000 Determines the end value 20mA or 10V of the connected sensor The maximum sensor range 20mA 100 of the sensor range must be set For example 10 bar p...

Page 76: ...ossible settings 10 up to 10 To set the calibration for the upper range value of sensor 1 this parameter can be used After setting the right dimension unit and sensor range the upper range value can b...

Page 77: ...mp is switched on automatically 3 After the start up the new required value is calculated in the following way NEW REQUIRED VALUE REQ VAL 02 ACT VAL DEC 0510 ACT VAL INC 0505 The new required value is...

Page 78: ...drops below the REQUIRED VALUE 02 ACTUAL VALUE DECREASE 0510 the next pump is started 0520 0520 ENABLE DLY 5 sec Enable delay time for cascade relay only Possible settings 0 100 sec If the conditions...

Page 79: ...ency If the DROP FREQUENCY is reached the follow up pump gets released and the MASTER Inverter will continue with normal operation 0545 0545 OVERVALUE OFF Overvalue for cascade relay only Possible set...

Page 80: ...tion creates a hysteresis effect which prevents the assist pump against a frequent on off operation To find out the right setting Start the first pump in JOG Mode 62 Increase the frequency till you re...

Page 81: ...s stopped by a failure or manually before the first BASIC Inverter gets released For example Address 1 3 MASTER Inverters Address 4 8 BASIC Inverters Switching order Adr 1 MASTER Adr 2 MASTER Adr 3 MA...

Page 82: ...mp Therefore the delay time has to be set higher than the duration that is needed to reach a value above the limit 0615 0615 ERROR RESET ON Automatic error reset Possible settings ON OFF ON Allows an...

Page 83: ...er HYDROVAR is connected to power supply Relay 1 X5 1 3 closed Relay 2 X5 4 6 closed Running Motor is running Relay 1 X5 1 3 closed Relay 2 X5 4 6 closed Errors An error is indicated on the HYDROVAR i...

Page 84: ...red value can be done either internally or externally via the digital inputs With the following parameters the source of the required values and the change over can be configured 0810 0810 C REQ VAL 2...

Page 85: ...elected sensor range Set the desired required value with either or This pre selected required value is active in all modes except Actuator if parameter C REQ VAL 1 0805 or C REQ VAL 2 0810 is set to d...

Page 86: ...Offset will be calculated according to the current signal 4 20mA or 0 20mA connected to terminals X3 18 Required Value 2 X3 17 GND analog I 2 0 4 20mA Offset will be calculated according to the curre...

Page 87: ...n of the sensor Desired value designation of the y coordinate as absolute value 0915 0915 LEVEL 2 100 Offset active between LEVEL 2 and OFFSET RANGE Possible settings LEVEL 1 OFFSET RANGE 0917 0917 OF...

Page 88: ...xed point according the requirements Parameter 0913 Offset Y1 2 5 2 5bar max allowed pressure at this flow rate System requirement 2 5 bar constant pressure while the flow rate is between 5m h and 12m...

Page 89: ...Frequency for manual and automatic test run Possible settings 0 Fmax 1015 1015 TESTR BOOST 10 0 Setting of the motor starting voltage in of rated input voltage Possible settings 0 25 of maximum input...

Page 90: ...cted unit or on ALL units Cascade Serial Synchron Possible settings 1 8 ALL To clear the error memory either 1 8 for one specific unit or ALL for all units can be selected For reset press button till...

Page 91: ...ernal Interface If several MASTER Inverters are connected via the internal RS 485 interface max 8 using cascade serial mode each HYDROVAR needs its own allocated pump address number 1 8 Each address m...

Page 92: ...ailure LED placed on the control panel In case of an error the connected motor is stopped immediately All errors are shown in plain text and saved in the error memory including date and time when the...

Page 93: ...the CODE ERROR and the OVERCURRENT ERROR the power supply has to be cut 60 seconds A reset of all other errors can be done by open close the START STOP_PTC input X1 PTC on the power unit If the BASIC...

Page 94: ...TART after power failure Parameter AUTOSTART 08 is set to OFF Check parameter AUTOSTART 08 No operation even system pressure set pressure Pressure higher than the start value or REGULATION MODE has be...

Page 95: ...eased e g PTC which is connected has reached its release temperature close X1 PTC if there is no external protective device connected close external on off switch if connected to these terminals For d...

Page 96: ...n terminals X3 2 4mA active Sensor WARNING 20 sec ERROR non active sensor WARNING ACTUAL VALUE signal pressure transducer faulty wrong connection Sensor or cable fault check configuration of the senso...

Page 97: ...d LED on ERROR 1 EEPROM ERROR data block malfunction Reset after repeated error message change control card ERROR 4 Button error e g jammed key check push buttons Display board may be defective ERROR...

Page 98: ...demand Control on constant flow Problem control fluctuations Parts to check measure control characteristics are set too low enlarger WINDOW 0310 and set HYSTERESIS 0315 to 99 to control with RAMP 3 an...

Page 99: ...ime to time All modifications must be done by qualified personnel For mounting and repairs at the HYDROVAR qualified service technicians are available Demounting The HYDROVAR must be disconnected from...

Page 100: ...D DATE xxxxx xx xxxxx xx DATE TIME xx xx xx xx 20xx OFF START VALUE LANGUAGE AUTO START OPERAT TIME ENGLISH OFF SUBMENU SELECT DEVICE ENABLE DEVICE STATUS UNITS STATUS DEVICE MAIN MENU REQUIRED VAL EF...

Page 101: ...WITCH DLY DISABLE FRQ SWITCH INTV CONF INVERTER ALL SKIPFRQ RNG CURR LIMIT CURR LIMIT MIN FREQ OFF SENSOR ENABLE DLY ACT VAL INC ACT VAL DEC ENABLE FREQ SENS1 CAL X SYNCH WIN MSTPRIORITY SYNCH LIM SUB...

Page 102: ...TRUN TESTRUN MAN SUBMENU SETUPS SUBMENU RS485 INTERFACE RS485 INTERFACE TESTR TIME SEL DEVICE SUBMENU OFFSET CLR MOTORH FACTORY SET CLR ERRORS SUBMENU TESTRUN TESTRUN FREQ TESTR BOOST SUBMENU ERRORS S...

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Page 104: ...rasse 2 2000 Stockerau sterreich Telefon 43 0 2266 604 Telefax 43 0 2266 65311 e mail info austria xyleminc com web www xylemaustria com Xylem Water Solutions Austria GmbH reserves the right to make m...

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