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Hydrovar

Pump Control

installation, operation and Maintenance Manual

instruction Manual

IM223R04

Summary of Contents for hydrovar

Page 1: ...Hydrovar Pump Control installation operation and Maintenance Manual Instruction Manual IM223R04...

Page 2: ...hnical data 13 5 2 EMC requirements Electromagnetic compatibility 14 6 Dimensions and Weights 15 7 Additional Components 17 7 1 Cable glands provided 17 7 2 Assembly Instructions All models 18 8 Elect...

Page 3: ...TTINGS 44 0200 SUBMENU CONF INVERTER 47 0300 SUBMENU REGULATION 52 0400 SUBMENU SENSOR 54 0500 SUBMENU SEQUENCE CNTR 56 0600 SUBMENU ERRORS 60 0700 SUBMENU OUTPUTS 61 0800 SUBMENU REQUIRED VALUES 62 0...

Page 4: ...compliance with the operating instructions 1 This manual is intended to assist in the installation operation and repair of the system and must be kept with the system 2 Installation and maintenance MU...

Page 5: ...e N P T threaded fitting for the pressure sensor and properly sized pipe Piping should be no smaller than the pump discharge and or suction connections Piping should be kept as short as possible Avoid...

Page 6: ...alling the Pressure Sensor The pressure sensor requires a FNPT fitting for installation Install the pressure sensor with the electrical connector pointing up to avoid clogging the pressure port with d...

Page 7: ...ol of a single pump with fewer features than the Master controller 3 2 Modes of Operation 3 2 1 Actuator for single pump operation only In this mode the HYDROVAR operates as an actuator with external...

Page 8: ...control of all pumps in the system including automatic alternation of the lead and lag pumps which provides even wear and achieves even operating hours for each pump If the control card of a Master co...

Page 9: ...oller In this mode it is possible to run all pumps in cascade serial mode and synchronous mode as well This configuration allows each pump to become the lead pump This also ensures a proper operation...

Page 10: ...2 03 3 05 5 07 7 5 10 10 15 15 Volts 2 230V 4 460V Phase 1 Single Phase 3 3 Phase Type M Master S Single B Basic Series HV The following applies to this example HV Hydrovar Variable Speed Drive M Mast...

Page 11: ...2 MASTER HVM1202 BASIC HVB1202 SINGLE HVS1202 3 MASTER HVM1203 BASIC HVB1203 SINGLE HVS1203 460 V 3 3 MASTER HVM3403 BASIC HVB3403 SINGLE HVS3403 5 MASTER HVM3405 BASIC HVB3405 SINGLE HVS3405 7 5 MAS...

Page 12: ...6 10 14 HVM3405 5 11 4 15 14 HVM3407 7 5 15 1 20 12 HVM3410 10 19 6 20 10 HVM3415 15 27 8 30 8 Listed catalog numbers are for master drives Details also apply to corresponding basic and single units H...

Page 13: ...y or shutdown the HYDROVAR should remain connected to the power supply but turned off to prevent inadvertant pump run This will maintain power to the internal heater and reduce internal condensation A...

Page 14: ...er drive systems including specific training with respect to EMC requirements Class A environment EN 61800 3 Class C3 Environment that includes all establishments other than those directly connected t...

Page 15: ...nches Drawings are not to scale Dimensions are nominal Type Weight lbs Basic Master Single 2 3 HP 1 Ph 8 8 9 7 3 5 HP 3 Ph a minimum center distance between HYDROVARs 12 b header space for maintenance...

Page 16: ...ngs are not to scale Dimensions are nominal Type Weight lbs Basic Master Single 7 5 10 15 HP 16 9 17 8 3 Ph a minimum centre distance between HYDROVARs 17 b minimum header space for maintenance 12 9 4...

Page 17: ...cover of the HYDROVAR can be mounted and tight ened by the four fastening screws Ensure the integrity of the ground wire connection Failure to properly ground the controller or motor will cre ate an...

Page 18: ...18 7 2 Assembly Instructions All models continued Additional Components...

Page 19: ...ter A suitable protection unit has to be selected according local regulations Ground Fault Circuit Interrupter GFCI When using a GFCI make sure that it also releases in the event of a short circuit in...

Page 20: ...AMP Rating Part Number Voltage Rating HFD512C1 230 1 60 OT25F3 2 HP 25A 18 8AWG 7 IN LB Bussman 20 KTK R 20 600V HFD512E1 230 1 60 OT40F3 3 HP 40A 18 8AWG 7 IN LB Bussman 30 KTK R 30 600V HFD534A1 460...

Page 21: ...rolled signals as twisted pairs especially if voltage 48 V Relay controlled signals using less than 48 V can be run in the same cables as digital input signals Note Never mix 24 VDC and AC power signa...

Page 22: ...holding the top cover of the HYDROVAR Lift off the top cover The following parts can be seen on a HYDROVAR Master Single Drive 1 Ph 2 3 HP 3 Ph 3 5 HP 3 Ph 7 5 10 15 HP A Power supply B Motor connecti...

Page 23: ...ut Voltage Terminals The power supply is connected to the power section Terminal L N 230 VAC single phase Terminal L1 L2 L3 460 VAC three phase 2 3 HP 1 3 5 HP 3 7 5 10 15 HP 3 Electrical Installation...

Page 24: ...he terminal block if necessary 4 Wire the motor according to the motor manufacturer s instructions Note The thermistor must be attached to the motor This is required to measure the motor temperature 8...

Page 25: ...he HYDROVAR will not start 8 4 3 1 Solo Run Hand Mode Terminals X1 SL are used to enable a Basic drive when used in a multi pump application when the commu nication from the Master drive fails or if t...

Page 26: ...erial RS 485 connection to the other HYDROVAR units in the system Note Internal interface is not available on Single Inverters X2 RS485 Interface Power Unit X2 SIO Internal SIO interface SIO Internal...

Page 27: ...en using a Basic drive in a Multi pump system the dip switches must be set to the appropri ate address for each drive in the system The addresses for the Basic drives start after the last address of t...

Page 28: ...ection 8 2 for recommended wire types External voltage free contacts must be suitable for switching 10 VDC Note If unscreened control wires are used signal interference may occur and could interfere w...

Page 29: ...uired value 2 Dig 3 Offset 0 10VDC 16 GND electronic ground 17 GND electronic ground 18 Current signal input required value 1 Offset 0 20mA 4 20mA Ri 50 19 10V internal ref for analogue output 10 00VD...

Page 30: ...switch required or jumper Configurable digital input 1 DIG 1 for switching between 2 required values or sensors External ON OFF E Stop Connect through switch or jumper Actual value voltage input senso...

Page 31: ...nsor 2 24VDC sensor supply X3 3 brown Actual value signal input 0 4 20mA X3 2 Sensor 1 white Ground X3 1 screen shield Switching between two individual sensors External switching between two sensors b...

Page 32: ...tor frequency How to program see SUBMENU OUTPUTS 0700 Possible connections Analogue output 1 0 10V X3 20 Analogue output 2 4 20mA X3 21 X4 RS485 Interface X4 1 User SIO Interface SIO User interface 2...

Page 33: ...stan dard Modbus protocol with an external control device e g PLC This interface can be used for controlling the HYDROVAR with external devices Also available on HYDROVAR Single drives Do not use the...

Page 34: ...s 1 and 3 Status Relay 2 is programmed for Fault when closed between 4 and 5 Factory setting The output relays are used to signal pump running or fault signal See connection example below To program s...

Page 35: ...ngle Drive 9 2 Function of the Push Buttons Start the HYDROVAR Stop the HYDROVAR and Reset pressing both buttons simultaneously for 5 seconds Increase a value selection in the submenu Decrease a value...

Page 36: ...l parameters of the main menu and submenus are listed The upper window shows the factory setting and the line below the possible range of settings The general parameter descrip tion is written for the...

Page 37: ...dow shows the current run status of the drive ON Running Stop the HYDROVAR by pressing STOP Manually stopped Start the HYDROVAR by pressing OFF E Stop X3 7 8 is open To start the HYDROVAR close E Stop...

Page 38: ...based on ACTUAL VALUE INCREASE 0505 ACTUAL VALUE DE CREASE 0510 and LIFT AMOUNT 0330 If the required value is influenced by an offset signal SUBMENU OFFSET 0900 the current active required value is al...

Page 39: ...t until the pressure drops below 40 PSI 80 of 50 PSI The following parameters in the main menu are valid for all selected modes 05 05 LANGUAGE Language selection ENGLISH Possible settings To select th...

Page 40: ...ng hours To reset to 0 see parameter CLR OPERAT 1135 20 20 SUBMENU STATUS Status of all units within a pump group Use this submenu to check the status including failures and motor hours of all connect...

Page 41: ...pump Relay 2 X10 2 4 fixed speed pump Relay 3 X10 3 5 fixed speed pump Relay 4 X10 4 6 fixed speed pump Relay 5 X10 5 7 not used 8 not used 23 23 STATUS DEVICE Status of the selected device Stopped P...

Page 42: ...and time when the failure occurred For more information about errors see chapter 10 failure mes sages 26 26 1st ERROR Most recent error on the selected drive ERROR XX Message ERROR XX FAILURE TEXT DAT...

Page 43: ...e 44 44 CURR INVERTER Current of the selected unit XXX This value determines the output current of the HYDROVAR in percent to the maximum rated current output 45 45 VOLT INVERTER Input Voltage of the...

Page 44: ...out entering the password again to access the secondary menu 61 PASSWORD Confirm by pressing and the first window of the sub menu is shown 0066 62 62 JOG 0 0Hz Both current output frequency and actual...

Page 45: ...scade Serial mode Actuator For single pump operation only Actuator mode is used if a fixed speed setting is required or an external speed signal is connected to con trol the speed of the drive In this...

Page 46: ...ng 1 1 Address Set Address failed retry When using Master and Basic drives together in a multi pump system the Basic Inverters have separate ad dresses For detailed Information see chapter 8 4 3 2 Add...

Page 47: ...and HV V01 3 the control board HV 0203 0203 SET VER INV Activate additional settings Contact factory to use sel 01 act 01 Possible settings 00 02 Activates skip frequency parameter and current limit...

Page 48: ...d increased up to 15 seconds for higher horsepower drives to avoid overload er ror The slow ramps 3 and 4 determine the acceleration deceleration rates of the drive when the pressure is within the hys...

Page 49: ...ay cause a drop in outgoing pressure during varying demand 0230 0230 RAMP 4 Ramp 4 Slow acceleration time 70 sec Possible settings 1 1000 sec Rapid deceleration may lead to pump oscillation Slow decel...

Page 50: ...s time the HYDROVAR will stop automatically f fmin The pump will never stop automatically The frequency will only drop down to the selected MINI MUM FREQUENCY 0250 To stop the pump the external ON OFF...

Page 51: ...ld be adjusted accordingly The reduction of the maximum output current also affects the overload detection HV Horsepower Output current A OFF 100 85 75 50 230V 2 HP 7 5 95 5 25 3 5 230V 3 HP 10 8 50 7...

Page 52: ...shown X XX PSI By pressing or in this menu the internal controller of the HYDROVAR is deactivated and it changes to manual mode Using the and buttons any constant speed can be set without further con...

Page 53: ...output frequency where the set pressure starts to be increased The right set ting should be equal to the frequency when the pump reaches the set pressure at zero flow Can be deter mined by using the J...

Page 54: ...ne 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 is constantly active Sensor 1 0 4 20mA s...

Page 55: ...mA 300 PSI 0425 0425 SENS CURVE Sensor curve linear Possible settings linear quadratic Internal calculation based on the actual value Possible setting and its application Linear Pressure control diffe...

Page 56: ...arameter 0435 0500 0500 SUBMENU SEQUENCE CNTR This submenu defines parameters for multi pump systems Application Example 1 Lead pump reaches its ENABLE FREQUENCY 0515 2 Actual value falls and reaches...

Page 57: ...2 PSI Possible settings 0 00 to the pre selected sensor range 0515 0515 ENABLE FRQ Enable frequency for the next drive 48 0 Hz Possible settings 0 0 70 0 Hz Sets the frequency for the next pump to tur...

Page 58: ...s Before a following pump starts up the Master Inverter will drop to the selected frequency If the DROP FREQUENCY is reached the follow up pump gets released and the Master Inverter will continue with...

Page 59: ...mp in JOG Mode 62 Increase the frequency till you reach the required value Check the frequency f0 at zero consumption Set the synchronous limit f0 2 3 Hz Set the synchronous window between 1 or 2 Hz d...

Page 60: ...ess till disabled is shown on the display 0610 0610 DELAY TIME Minimum threshold limit delay time 2 Sec Possible settings 1 100 sec Delay time to switch off the HYDROVAR if the actual value drops belo...

Page 61: ...Errorreset Errors of Basics Warnings Basics Config Explanation of status Action if status YES Power HYDROVAR is connected to power supply Relay 1 X5 1 3 closed Relay 2 X5 4 6 closed Running Motor is...

Page 62: ...between the 1st and the 2nd required 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 b...

Page 63: ...ed 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 digita...

Page 64: ...the connected offset sensor E g 300 PSI sensor can be set as range 300 3000 30000 The higher the offset range the higher the resolution on the signal input 0910 0910 LEVEL 1 Offset active between 0 an...

Page 65: ...imit where the offset function is active Parameter 0912 Offset X1 20 8 GPM fixed point according the requirements Parameter 0913 Offset Y1 2 5 36 PSI max allowed pressure at this flow rate System requ...

Page 66: ...010 TESTRUN FRQ Frequency for manual and automatic test run 30 0 Hz Possible settings 0 Fmax 1015 1015 TESTR BOOST Setting the motor starting voltage boost in 10 0 of rated input voltage Possible sett...

Page 67: ...tton till RESET appears 1130 1130 CLR MOTORH Clear motor hours for selected unit UNIT X or on ALL units Cascade Serial Synchron Possible settings 1 8 ALL Set desired unit where the Motor Hours should...

Page 68: ...R needs its own allocated pump address number 1 8 Each address may only be used once 1220 1220 PUMP ADDR Select desired address for the Master Inverter 1 Possible settings 1 8 Set desired address for...

Page 69: ...1 2 3 or X5 4 5 6 depending on the configuration How to program see parameter CONF REL 1 0715 and CONF REL 2 0720 10 1 Basic Inverter The Basic Hydrovar power unit only may indicate the following erro...

Page 70: ...START after Parameter AUTOSTART 08 is Check parameter AUTOSTART 08 power failure set to OFF No operation when system Pressure higher than the start Check parameter START VALUE 04 pressure set pressure...

Page 71: ...f ERROR 15 connected has reached its connected to these terminals release temperature For detailed information see chapter 8 4 3 Check power supply under full load PHASELOSS One phase of the power sup...

Page 72: ...signal on terminals ACTUAL VALUE signal pressure FAILURE SENSOR 2 X3 2 4mA transducer faulty Active Sensor Poor connection ACT VAL SENSOR 2 WARNING 20 sec ERROR Sensor or cable fault ERROR 24 Non acti...

Page 73: ...rol card ERROR 6 Program error Reset after repeated error message Watchdog error change control card ERROR 7 Program error Reset after repeated error message Processor pulse error change control card...

Page 74: ...otor speed Cause Check Increase RAMP 3 0225 and 4 0230 Control settings too fast 100 200sec WINDOW 0310 20 and HYSTERESIS 0315 99 Problem ACTUAL VALUE can t be maintained Cause Check HYSTERESIS is set...

Page 75: ...me All modifications must be done by qualified personnel For mounting and repairs only qualified service technicians should attempt Disconnecting The HYDROVAR must be disconnected from the power suppl...

Page 76: ...UNITS 00000000 41 PROD DATE xx xx xxxx 26 1ST ERROR NO ERROR 3 EFF REQ VAL 50 PSI 7 TIME xx xx 23 STATUS DEVICE running 43 TEMP INVERTER x xx xx C 4 START VALUE OFF 8 AUTO START OFF 24 ENABLE DEVICE e...

Page 77: ...520 ENABLE DLY 5 sec 550 OVERVAL DLY 0 sec 420 SENS RANGE 300 PSI 325 FRQ LIFT 30 0 Hz 525 SWITCH DLY 2 sec 555 SWITCH INTV 24 hours 425 SENS CURVE linear 330 LIFT AMOUNT 0 0 530 DISABLE FRQ 30 0 Hz 5...

Page 78: ...110 FACTORY SET USA 905 OFFS INPUT OFF 1205 ADDRESS 1 615 ERROR RESET ON 1015 TESTR BOOST 10 715 CONF REL 1 Running 815 SW REQ VAL Setpoint 1 1125 CLR ERRORS ALL 910 LEVEL 1 0 915 LEVEL 2 100 1020 TES...

Page 79: ...79 NOTES...

Page 80: ...osts of replacement equipment d Consequential damages of any kind and e Reimbursement for loss caused by interruption of service For purposes of this warranty the following terms have these definition...

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