Related Manuals for Xylem HYDROVAR HV2.1f
Summary of Contents for Xylem HYDROVAR HV2.1f
- Page 1 Operating Instructions HV2.1f – HV3.11f HV3.15e – HV3.22e HV3.30e-HV3.45e V 2012/03A 771079342 English HV2_1-3_45-V-EN-6A...
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Page 2: Table Of Contents
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...................... - Page 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 –...
- Page 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 –...
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Page 5: Important Safety Instructions
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. - Page 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.
- Page 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.
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Page 8: System Design
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 pump with HYDROVAR... -
Page 9: Technical Data
3 Technical Data HYDROVAR Power Supply Type Rated Voltage limits Rated line protection Maximum max. connection output 48-62 Hz current input [kW] [mm²] 2.1f 12,7 1x220-240 -10% +15% 2.2f 16,5 3.2f 3x380-460 ± 15% 3.3f 3.4f 3.5f 12,6 3x380-460 ± 15% 3.7f 16,3 3.11f... - Page 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°...
- Page 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)
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Page 12: Dimensions And Weights
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 6,80 HV 2.2f 5,80 HV 3.2f 8,40 HV 3.3f HV 3.4f All dimensions in millimetres! Drawings are not in scale! a … centre-distance between the HYDROVAR 300 [mm] b …... - Page 13 HV 3.5/3.7/3.11 f Type Weight HV + WM-Kit [kg] [kg] HV 3.5f 10,00 12,60 HV 3.7f HV 3.11f 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]...
- Page 14 HV 3.15/3.18/3.22 e Type Weight HV + WM-Kit [kg] [kg] HV 3.15e 40,00 29,00 HV 3.18e 40,00 HV 3.22e 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.
- Page 15 HV 3.30/3.37/3.45 e Not available as motor-mounted version! Type Weight All dimensions in millimetres! Drawings are not in scale! [kg] HV 3.30e 57,00 HV 3.37e 57,00 HV 3.45e 60,00 Mounting space above: 500 [mm] Beside and below the HYDROVAR: 150 [mm]...
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Page 16: Mechanical Mounting Of The Hydrovar Unit On The Motor
5 Mechanical mounting of the HYDROVAR unit on the motor 5.1 Included mounting material Included Cable gland Cable gland Closing gland Center- Terminals components Motor piece for max. [mm²] PG PG 12 16 16 Cable diameter 3,5-7 4,5-10 7-13 9-17 19-28 9-14 14-25... -
Page 17: Bus Interface
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 for external installation for external installation – HYDROVAR – switching cabinet wall mounting 5.2.3 Sensors (4-20mA) •... -
Page 18: Assemble Instruction
5.3 Assemble Instruction HV 2.1f – HV 3.11f 3 screws (to fix the cover) HYDROVAR - cover Gasket Display (changeable by 180°) 4 Screws M5x60 Centre bit 4 Mounting clamps Motor fan cover Motorcable Motor Motor conduit box Pressure transmitter... - Page 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! •...
- Page 20 HV 3.15e – HV 3.22e HYDROVAR - cover Display-unit (8 fixing- screws) 4 screws (to fix the cover) Motor fan cover 4 fixing screws Motor Motorcable Motor conduit box Pressure transmitter...
- Page 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...
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Page 22: Electrical Installation And Wiring
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. -
Page 23: Emc-Electromagnetic Compatibility
6.2 EMC-electromagnetic compatibility To ensure the electromagnetic compatibility the following points must be observed for cable installation: Earth / ground to ensure EMC • Protection earth It is important to connect the HYDROVAR to PE, because of the earth leakage current. •... - Page 24 HYDROVAR line filter motorcoil motor/pump max. 30cm max. 2 m Supply Screened cable max. 100 m Additional component line choke (coil) Line coils are available as an option and should be mounted between the HYDROVAR and the main fuse. The Line coil should be as near as possible at the HYDROVAR (max. 30 cm distance) Advantages: •...
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Page 25: Wiring And Connections
6.3 Wiring and connections Remove the screws holding the top cover of the HYDROVAR. (Caution: At HV3.15e - 3.22e also the 8 screws of the display have to be removed!) Lift off the top cover and you could see the following parts. HV 2.1f –... -
Page 26: Main Voltage Terminals
6.3.1 Main Voltage Terminals The power supply is connected to the power section: terminal L1+N (1 x 230 VAC, single-phase) terminal L1+ L2 + L3 (3 x 400 VAC, three-phase) HV 2.1f / 2.2f HV3.2f - 3.11f Power Supply Power Supply Motor connection Motor connection 1x230 VAC... - Page 27 HV 3.30e – HV 3.45e Control card Optional: Impedance coils Motor connection Power supply L1,L2,L3 with 400VAC Impedance coils Motor connection without Impedance coils Mounting the distance bolts to enable the HYDROVAR operating with closed panel door. This should be done before mounting the unit on the wall: 1) Affix the adhesive label on the outside of the panel door 2) Open the door and mount the adhesive label for the display and the control buttons 3) Justify the distance bolts (three pieces are included) on the control buttons you want to...
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Page 28: Motor Connection
6.3.2 Motor connection Mounting of the PTC Variant A : Variant B : Motor block Terminal block Rubber gasket Cover of the conduit box 1. Open the cover of the conduit box and remove also the terminal block inside 2. Fix the PTC (Variant A or B) 3. -
Page 29: Control Terminals
6.3.3 Control Terminals All control cables which are connected to the control- or RS485-terminal have to be screened. If unscreened control cables are used, signal interference may occur and could interfere to the function and signals of the HYDROVAR. Don’t connect the ground of the control card to different voltage potentials. All electronic ground terminals and GND of the RS 485-interface are connected internally. - Page 30 RS 485 Pump running signal Fault signal Digital input Voltage signal input 0/2 - 10V Current signal input 4 - 20mA Analogue output 0 - 10V Ground Motor thermoswitch or PTC Low Water External on/off +15 VDC Transducer supply Actual-value-signal input 4 – 20mA Ground...
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Page 31: Connection Examples
6.3.3.1 Connection examples Terminal X1 • Transducer – Actual-value- signal input o Connection of a 2-wire transducer (e.g. standard pressure transducer PA22) o Connection of an active actual-value-signal • Actual value – Frequency indicator (how to program see chapter 9.26) e.g.: to display the actual motor frequency •... - Page 32 Terminal X2 • Pump running signal (how to program see chapter 9.20) Ext. 250VAC / 220VDC X2/ 5 and 6 closed: motor run indication or start/stop of a fixed speed pump • Fault signal Ext. 250VAC / 220VDC X2/ 1 and 2 closed: if there is an Fault / Error or power supply of the HYDROVAR is cut of...
- Page 33 Terminal X5 / X6 For multi-pump applications (synch. or multicontroller) you have to connect each HYDROVAR (max. 4) via the RS 485 interface. (Use screened cables!) HYDROVAR 4 Using the optional Modbus interface, one or more HYDROVAR could communicate via the standardized Modbus-protocol with an external-control-device (e.g.
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Page 34: Selection Of The Switching-Frequency
6.4 Selection of the switching-frequency Before changing the switching frequency, disconnect the power supply, otherwise the HYDROVAR power module could be destroyed. A switching-frequency of 8kHz only should be selected if the HYDROVAR is mounted directly on the motor in order to reduce the noise level. In case of longer motor cables the switching-frequency should be decreased to reduce losses in the cable as well as the temperature in the motor. -
Page 35: Rfi - Switch
6.6 RFI - switch For the HYDROVAR types HV2.1 – HV3.22 there are installed new additional filter capacitors, which provides an improved filter characteristic in order to avoid RFI (Radio Frequency Interferences) when mounting the HYDROVAR on the wall and using longer cables between the HYDROVAR and the motor. -
Page 36: Programming
7 Programming 7.1 Display – control panel HV 2.1f – 3.11f ON/+ OFF/- Select Power Fault HV 3.15e – 3.22e HV 3.30e – 3.45e - inside OFF/- ON/+ Select Power Fault... -
Page 37: Function Of The Push Buttons
7.2 Function of the push buttons Start of the HYDROVAR or increase the value in the menu Stop of the HYDROVAR or decrease the value in the menu Short pressing: Change to next parameter in the menu Change to previous parameter in the menu Long pressing: Enter the submenu or change back to the main menu Saving of all settings Long pressing: The auxiliary texts of the actual parameter is shown... -
Page 38: Parameters Of The Main Menu
8 Parameters of the main menu After connecting the HYDROVAR to the power supply the following index will be shown: SW-Ver: VOG 120 The current software version with the date of Date: xxxx programming is displayed for about 3 seconds If the connection of terminal X1/4-X1/5 (external release contact) is open, the following message appears: INVERTER LOCKED... - Page 39 b) Active MODE = Actuator: ITT INDUSTRIES display at Mode Actuator Frequency XX.X Hz • In this mode an external controller is used, so the HYDROVAR will not control the set value but will only be responsible for running the connected motor at a frequency proportional to the value of the analogue input signal originating from the external source.
- Page 40 d) Active MODE = Manual Control: ITT INDUSTRIES display at Mode Manual Control local. Frequency XX.X Hz Continue by pressing the -button MANUAL CONTROL Set the desired set pressure with either X.X Hz X.XX BAR then shortly press the -button. Press the button to change to the next parameter (menu 3) The following parameters of the main menu are valid for all selected Modes!
- Page 41 Error memory All errors are only readable in English. E R R O R 1 Latest error, happened on the HYDROVAR ......Press the button to change to the next parameter E R R O R 2 Error, happened before the latest error ......
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Page 42: Parameters Of The Secondary Menu
9 Parameters of the Secondary Menu Before entering the secondary menu these instructions must be read carefully to prevent incorrect settings which will cause malfunction. All parameters can also be set during operation. Therefore you should be trained how to use the secondary menu. -
Page 43: Window
The parameters Window and Ramp Hysteresis and the Ramp settings as well are responsible for the control characteristic of the HYDROVAR and also guarantee the stop of the pumps at 0 demand in boosters and water supply stations. set rated required value Pressure, speed Set hysteresis % Window setting... -
Page 44: Ramp 1: Fast Acceleration Time
Ramp settings: • Time setting of the Ramps will influence the control of the pump and shouldn’t be changed at standard operation. • Possible setting of each Ramp 0,05 - 1000 sec. • The fast Ramps 1 and 2 are determined by the type (power) of the HYDROVAR. (Default = 4 sec.;... -
Page 45: Maximum Frequency
9.8 Maximum Frequency This parameter determines the maximum speed of the pump and at which output frequency the HYDROVAR has its max. output voltage. The standard setting is according to the nominal frequency of the connected motor. MAX. FREQUENCY Possible setting between 40 and 70 Hz 50.0 Hz Attention: Settings higher than 50 Hz may overload the motor! Settings of 10% above nominal frequency cause a 33% higher power... -
Page 46: Operation At Minimum Frequency
9.10 Operation at minimum frequency CONFIG FMIN Possible setting: f->0 or f->f f => fmin f->0: After reaching the required pressure the frequency will go down to the selected MINIMUM FREQUENCY and the HYDROVAR will keep running for the selected “STOP DELAY” time (see next parameter). -
Page 47: Sensor – Adjust
9.13 Sensor – Adjust Zero point adjustment (4mA) of the transducer: Necessarily required for multi pump applications. SENSOR ADJUST Make sure that the system is not pressurized. Press buttons simultaneously until a new message appears … SENSOR ADJUST This message confirms the calibration of the Adjusted transmitter’s zero point by associating the minimum value of the transmitter’s output signal (4mA) for... -
Page 48: Operation Mode
9.16 Operation Mode MODE: Select with the buttons Controller Possible Settings: Controller: This mode should be selected if only one HYDROVAR pump is in operation and there is no connection to any other HYDROVAR via RS485 interface. Multicontroller: If more than one pump should operate together via the RS485 interface (follow-up pump control), this mode must be set. -
Page 49: Regulation Mode
Manual Control: If MANUAL CONTROL is selected, the parameter REQUIRED VALUE will change to MANUAL CONTROL in the main menu, where the actual frequency and the actual value are displayed (according to the JOG-MODE in the submenu). • Now the frequency can be changed with the buttons •... -
Page 50: Nd Required Value
9.19 2 Required Value CONFIG. REQ. VAL.2 With this parameter a 2 independent required value can be selected and at the same time the source of it will be determined. The changeover between 1 and the 2 required value can be done via the digital input, terminal X1/14 on the control card. -
Page 51: Submenu Offset
9.20 Configuration of the pump running relay (X2/4-5-6) RELAY CONFIG. Possible selection with Run Motor • Simple Multicontr. ⇒ Allows to start/stop a fixed speed pump. • Run Motor ⇒ motor run indication (via the relay) If you have selected Simple Multicontroller, the following parameters will have new additional functions: The start level of the lag pump you enter at the parameter “Enable Seg. -
Page 52: St Offset Level
9.21.2 1 Offset level LEVEL 1 The level 1 is the start level of the 1 Offset. XX.X % Adjustable between 0 and 100% of the additional analogue input. Press the button to change to the next parameter 9.21.3 2 Offset level LEVEL 2 The level 2 is the start level of the 2... -
Page 53: Example For The Offset
9.21.6 Example for the Offset 20mA ≙ 10 bar SENSOR RANGE: REQUIRED VALUE: 5 bar LEVEL 1: 30% of the Offset signal LEVEL 2: 80% of the Offset signal -100% ≙ -5 bar (refer to the sensor range) INTENSITY 1: +20% ≙... -
Page 54: Submenu Sequence Control
9.22 Submenu Sequence control Using the parameters in that submenu all necessary settings can be done for running a multi- pump system. Each parameter within this submenu must be changed only on one HYDROVAR of the system, because it will be transferred via the RS485 interface to each connected HYDROVAR. -
Page 55: Enable Sequence Control
9.22.3 Enable sequence control With this parameter you can select the desired start-value for the following pumps. If a pump in the system reaches this release-frequency and the system pressure drops below the “Required value” - “actual value decrease”, the next pump will start. ENABLE SEQ. -
Page 56: Submenu Synchronous Control
9.22.6 Submenu Synchronous Control By using the synchronous control all pumps in the system maintain the set pressure by running on the same frequency. The 2 pump starts, when the 1 pump reaches the release frequency (ENABLE SEQ. CONTR.) and both pumps will run synchronously. The follow-up pump will be stopped, when the frequency drops below the set SYNCHRON. -
Page 57: Pump Status Indication
S U B M E N U Press the button to change to the next parameter Synch. Control 9.22.7 Pump status indication PUMP – SEQUENCY Shows the status of the individual HYDROVAR in a Adr1 disabled multipump system (adjustable between addresses 1 to 4) The following diagnosis parameters can be also be read in this display window: Address of the pump that is being read AdrX *... -
Page 58: Submenu - Rs 485 Interface
9.23 Submenu - RS 485 Interface S U B M E N U Press for about 3 seconds to enter the submenu RS 485-Interface Press the button shortly to change to the next parameter (-> chapter 9.24) 9.23.1 Pump Address PUMP-ADDRESS If only one pump is used, the setting remains OFF. -
Page 59: Frequency Lifting
9.24 Frequency Lifting Control according to a system curve (increase of the set pressure, depending upon the delivery rate or speed). FREQU. – LIFTING Adjustable between 6 Hz and the set MAXIMUM 30.0 Hz FREQUENCY. The setting determines the output-frequency where the set pressure starts to be increased. The right setting should be the frequency when the pump reaches the set pressure at zero flow. -
Page 60: Analogue - Output
9.26 Analogue - Output ANALOG - OUT Analogue output 0 – 10 VDC = 0 - 100% (max. 2 mA) Actual value (at terminal X1/11, X2/10=ground) Possible settings: ♦ Actual value (signal at terminal X1/2) ♦ Output frequency (0 - f Press the button to change to the next parameter 9.27 Dimension Unit... -
Page 61: Submenu For Manual Test Run
9.29 Submenu for manual test run S U B M E N U Press for about 3 seconds to enter the submenu TEST RUN man. Press the button shortly to change to the next parameter (-> chapter 9.30) 9.29.1 Activate manual test run TEST RUN man. -
Page 62: Submenu - Error
9.30 Submenu - Error S U B ME N U Press for about 3 seconds to enter the submenu ERRORS Press the button shortly to change to the next parameter (-> chapter 9.31) 9.30.1 Conveyor Limit CONVEYOR-LIMIT Adjustable between 0.00 and max. SENSOR RANGE. disabled •... -
Page 63: Operating Hours
9.31 Operating Hours OPPERATING HOURS Total time the HYDROVAR is connected to the power 0000 h. supply. Reset: press together, till “TIMER-RESET” appears. In parallel, the TOTAL RUN TIME of the motor, in the main menu would be reset. Press the button to change to the next parameter 9.32 Display –... -
Page 64: Setting Default Values
9.36 Setting Default Values S U B M E N U Press for about 3 seconds to enter the submenu DEFAULT VALUES Press the button shortly to change to the next parameter ( -> chapter 9.37) You reset all settings to the default settings for two different areas (EUROPE or USA). If you suspect you made a mistake by entering parameter-settings but are unable to identify the location, you can start again from the beginning by reloading the factory settings. -
Page 65: Error Signals
10 Error Signals The active Error messages are shown in the selected language, but the last 5 Error messages stored in the Error memory (main menu) are displayed in English language only! After the cause has been remedied, the error can be reset by cutting off the power supply for >60 seconds, or pressing all three buttons ( , ) together for about 5 seconds. - Page 66 Motor overheat PTC in the conduit box has • close X1/8 - 9 if there is no PTC reached its release available (e.g. submersible pumps) temperature • no proper motor cooling • outside temperature too high • MOTOR OVERLOAD • check star/delta connection Inverter overheat too high temperature inside •...
- Page 67 To quit the following errors you have to cut he power supply for >30 seconds. If the error signal should appear again, contact customer service and provide a detailed description of the error. Internal errors Error-message on the Display - red LED on EEPROM-ERROR Reset - after repeated error-message ERROR 1...
- Page 68 Examples Booster unit Problem: no stop of the HYDROVAR Parts to check Solution • existing demand • check pipes and valves • non return valve is not closed • change non return valve • pre charge pressure in the pressure tank •...
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Page 69: Rs 485 - Interface
11 RS 485 - Interface Standardised Bus-Interface for communication between the HYDROVAR and/or an overruling external control system. The data protocol complies with ISO 1745 for RS 485 interfaces and contains the following configurations: Data rate: 9600 Baud (1 Start Bit, 8 Data, 1 Stop Bit) An interface inverter RS 232/RS 485 is necessary in case communication with a 24V interface of a PC or another external control system is wanted. - Page 71 Notes: “ITT” and „Engineered for life“ are registered trademarks of ITT Industries, Inc. All other trademarks or registered trademarks are property of their respective owners.
- Page 72 Ernst-Vogel Strasse 2 2000 Stockerau Österreich 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 modifications without prior notice. © 2012 Xylem, Inc...