Binder HydroStar BGA 160 User manual

POOL COUNTERFLOW UNIT
BGA 160, BGA 215, BGA 275,
BGA 320, BGA 430, BGA 550

BA-EN-HydroStar V3.1 page 1
Table of contents
1
Manufacturer's address.................................................................................................................... 1
2 General............................................................................................................................................. 2
2.1 Important information.................................................................................................................. 2
2.1.1 Technical data.................................................................................................................... 2
2.1.2 Information for the user / target group ............................................................................... 3
2.1.3 Hazard information ............................................................................................................ 4
2.1.4 Validity ............................................................................................................................... 4
2.1.5 Proper use ......................................................................................................................... 5
2.1.6 Operating conditions.......................................................................................................... 5
2.1.7 General safety and application notes ................................................................................ 6
2.1.8 Disposal ............................................................................................................................. 6
2.1.9 Scope of supply ................................................................................................................. 6
3 HydroStar installation shaft .............................................................................................................. 7
3.1 Scope of supply .......................................................................................................................... 7
3.2 BGA 160/215/275, installation in skimmer or overflow pools ..................................................... 7
3.3 BGA 320/430/550, installation in skimmer or overflow pools ..................................................... 8
3.4 Installing the spring-loaded flange.............................................................................................. 9
3.5 Aligning the turbine................................................................................................................... 10
3.6 Installation of the cover plate.................................................................................................... 10
4 Turbine without HydroStar installation shaft .................................................................................. 11
4.1 Installation example for a BGA turbine..................................................................................... 11
4.2 Dimensions of turbine BGA 160/320 with installation flange.................................................... 11
4.3 Dimensions of turbine BGA 215/430 with installation flange.................................................... 12
4.4 Dimensions of turbine BGA 275/550 with installation flange.................................................... 12
5 HydroStar BGA 160/320/275/550 C for retrofit installation ............................................................ 13
6 PIEZO Tri / PIEZO Tri Square, installation .................................................................................... 14
7 Control unit ..................................................................................................................................... 16
7.1 Connection block diagram ........................................................................................................ 17
7.2 Terminals.................................................................................................................................. 17
7.3 Motor connection ...................................................................................................................... 18
7.4 Extending the motor supply line ............................................................................................... 18
7.5 Connecting the HydroStar PIEZO Tri ....................................................................................... 18
7.6 Connecting an external operating device ................................................................................. 19
7.6.1 Instructions for operation with a smartphone................................................................... 19
8 Start-up........................................................................................................................................... 19
8.1 Remote control operation ......................................................................................................... 19
8.1.1 Switching the turbine on and off ...................................................................................... 20
8.1.2 Water jet control............................................................................................................... 20
9 Optional operation by PIEZO Tri.................................................................................................... 21
10 Optional operation via touch display ........................................................................................ 22
11 End of operation ....................................................................................................................... 23
12 Shutdown / hibernation............................................................................................................. 23
13 Maintenance and repair............................................................................................................ 23
13.1 General................................................................................................................................. 23
13.1.1 Maintenance .................................................................................................................... 23
13.1.2 Repair .............................................................................................................................. 23
13.1.3 Troubleshooting ............................................................................................................... 24
14 Changes ................................................................................................................................... 24
1 Manufacturer's address
BINDER GmbH & Co. KG
Reichardstraße 16, D-31789 Hameln
Tel. [phone] Fax. [phone]
Mail: [e-mail] www.binder24.com

BA-EN-HydroStar V3.1 page 2
2 General
2.1 Important information
Operation
Guarantee
Observance of these operating instructions is essential to ensure trouble-free
operation and in order for any warranty entitlements to be honoured. Therefore,
please carefully read through the operating instructions before working with the
counter current unit.
Intended use
The turbine swimming pool is intended for use in privately used swimming pools
according to DIN EN 16582. It only be used in public swimming pools in special
solutions.
Note
This operating manual includes instructions on storage, assembly, operation and
maintenance of the HydroStar counterflow unit BGA 160, BGA 215, BGA 275,
BGA 320, BGA 430 and BGA 550.
Start-up
Maintenance
Installation
The personnel entrusted with the handling, storage, installation, start-up,
inspection and maintenance of the machine must be qualified for industrial,
mechanical and electrical equipment.
Disposal
The current and regional regulations must be observed for disposal. Grease and
oil must be disposed of in accordance with applicable environmental protection
regulations.
Note
This device is not intended to be used by persons (including children) with limited
physical, sensory or mental aptitude or lack of experience and/or knowledge
unless they are supervised by a person responsible for their safety or have
received instruction from this person as to how the device is used. Children
should be supervised to ensure that they do not play with the device.
Danger If the mains connection cable for this device is damaged, it must be replaced by
the manufacturer or its customer service department, or a similarly qualified
person to prevent any hazard.
2.1.1 Technical data
BGA 160 BGA 320
Supply voltage 230 VAC 230 VAC
Frequency range 47 – 63 Hz 47 – 63 Hz
Rated current 6 A 12 A
Starting current (typical) 60 A 60 A
Rated power 1350 VA 2700 VA
Motor
Motor type 1 Brushless DC motor
(BLDC)
2 Brushless DC motors
(BLDC)
Rated voltage 24 VDC 24 VDC
Rated current 50A 2 x 50A
Rated rotational speed 2400 min
-1
2400 min
-1
Turbine
Discharge rate 50 – 160 m³/h 100 – 320 m³/h
Speed (turbine outlet) 1.0 – 3.2 m/s 1.0 – 3.2 m/s
Water temperature +5° C to +40° C +5° C to +40° C
Immersion depth 0.20 m – 1.00 m 0.20 m – 1.00 m

BA-EN-HydroStar V3.1 page 3
BGA 215 BGA 430
Supply voltage 230 VAC 230 VAC
Frequency range 47 – 63 Hz 47 – 63 Hz
Rated current 8 A 16 A
Starting current (typical) 60 A 60 A
Rated power 1500 VA 3000 VA
Motor
Motor type 1 Brushless DC motor
(BLDC)
2 Brushless DC motors
(BLDC)
Rated voltage 24 VDC 24 VDC
Rated current 40A 2 x 40A
Rated rotational speed 2400 min
-1
2400 min
-1
Turbine
Discharge rate 65 – 215 m³/h 130 – 430 m³/h
Speed (turbine outlet) 1.0 – 3.2 m/s 1.0 – 3.2 m/s
Water temperature +5° C to +40° C +5° C to +40° C
Immersion depth 0.20 m – 1.00 m 0.20 m – 1.00 m
BGA 275 BGA 550
Supply voltage 230 VAC 230 VAC
Frequency range 47 – 63 Hz 47 – 63 Hz
Rated current 8 A 16 A
Starting current (typical) 60 A 60 A
Rated power 1700 VA 3400 VA
Motor
Motor type 1 Brushless DC motor
(BLDC)
2 Brushless DC motors
(BLDC)
Rated voltage 24 VDC 24 VDC
Rated current 50A 2 x 50A
Rated rotational speed 2400 min
-1
2400 min
-1
Turbine
Discharge rate 80 – 275 m³/h 160 – 550 m³/h
Speed (turbine outlet) 1.0 – 3.2 m/s 1.0 – 3.2 m/s
Water temperature +5° C to +40° C +5° C to +40° C
Immersion depth 0.20 m – 1.00 m 0.20 m – 1.00 m
2.1.2 Information for the user / target group
This documentation contains the necessary information for proper use of the products described
therein. It is intended for technically qualified personnel.
Qualified personnel are persons who - because of their education, experience, instructions, and
knowledge about corresponding standards and regulations, rules for the prevention of accidents, and
operating conditions - are authorised by the person responsible for the safety of the machine to
perform the required actions and who are able to recognise and avoid potential hazards (definition of
qualified personnel according to IEC 364)

BA-EN-HydroStar V3.1 page 4
2.1.3 Hazard information
The following directions are for the safety of the service personnel as well as for the safety of the
described products as well as any connected devices.
Danger! Rotating/rotating components.
Failure to observe this can result in death, serious injury or property damage.
•Please note that there are no persons in the inflow and outflow area of the turbine swimming
system before the start!
•Please note that no objects (such as toys), body parts or body-worn accessories are placed in
the openings (suction openings and discharge openings)!
•Never before starting the turbine swimming system, nor during the operation of the turbine
swimming system!
Danger! Dangerous electrical voltage.
Failure to observe this can result in death, serious injury or property damage.
•Isolate supply voltage before installation or removal work as well as in case of fuse
replacement or modifications of the setup.
•Observe the accident prevention and safety regulations that apply to the specific area of use.
•Before putting the machine into operation, check whether the rated voltage coincides with the
local mains voltage.
•Emergency stop devices must remain operational in all modes of operation. Disabling the
emergency stop devices may not cause an uncontrolled restart.
•The electrical connections must be covered!
•Ground wire connections must be checked for fault-free function after installation!
•The conditions described in DIN VDE 0100-702:2003-11 must be observed.
2.1.4 Validity
This document applies to the HydroStar counterflow units from the BGA product line.
Safety information
Adherence to this information is the prerequisite for trouble-free operation and the fulfilment of any
guarantee claims.

BA-EN-HydroStar V3.1 page 5
2.1.5 Proper use
Note: The devices described here are electrical equipment for use in swimming pools and other
pools and may only be used under the following conditions:
Exceptions: The manufacturer has designed the product specifically for other applications and
ambient conditions.
The counterflow unit
•...must only be used for the intended purposes and those confirmed in the shipping
documents.
•... must only be operated under the operating conditions stipulated in the operating
instructions and within the power limits.
•... is a component for use in privately-used swimming pools with a salt content <0.4% (See 
Note below)
•... complies with the valid standards and regulations.
Improper use
•Use in potentially explosive areas
•Use in harsh environments (acids, gases, vapours, dust, oil)
•Use in a sewage area
•Use of the turbine above water
Improper enviroment
•Observe the surrounding material (filling material) of the installation shaft
•Depending on the filling material, the installation shaft must be protected
•When using filler material with high chloride and sulfate fractions, the stainless steel housing
must be protected against these damaging substances with a PE film (protective film)
Note
The HydroStar is a component for use in swimming pools with a salt content <0,4%. It’s forbidden to
put the salt into the swimming pool within a radius of 2 meter around the HydroStar. For applications
with a salt content >0,4% contact company Binder.
2.1.6 Operating conditions
Control box:
Ambient temperature: 0° C to +50° C
Site altitude: up to 1000 m above sea level
Turbine:
Water temperature: +5° C to +40° C
Immersion depth: 0.30m to 1.00m below the surface of the water

BA-EN-HydroStar V3.1 page 6
2.1.7 General safety and application notes
At the time of delivery, the counterflow unit and its components are considered to be state of the art
and fundamentally safe to operate.
All transport, storage, installation/assembly, connection, commissioning, maintenance and
servicing work may only be performed by qualified personnel.
During such work, qualified personnel must observe:
•the supplementary safety instructions in the individual chapters of this documentation.
•the safety instructions in attached supplementary sheets and further documents from
subcontractors.
•this documentation and the circuit diagrams in the control box.
•the warning and safety signs on the devices.
•the machine-specific regulations and requirements.
•the national and regional regulations for safety and accident prevention.
The counterflow unit can pose a risk to persons, the machine itself and other property
belonging to the operator
•... if unqualified personnel work on or with the drive system.
•... if the drive system is used improperly.
•... if the drive system is installed and operated incorrectly.
•... if the following notes are disregarded:
oOnly operate the counterflow unit if it is in perfect working order.
oAs a general rule, any retrofitting, changes or reconstruction of the drive system is prohibited.
The above work may only be performed after consultation with the manufacturer.
oDuring operation and for an extended period afterwards, the components may have live parts,
moving parts and hot surfaces.
oStart-up (start of proper operation) may only be carried out once it has been confirmed that the
machine complies with EMC Directive 2004/108/EC and that the machine conforms to
Machinery Directive 2006/42/EC.
oObserve EN 60204.
Should you have any questions or problems, please contact your representative.
2.1.8 Disposal
The drive unit must be disposed of in compliance with the currently applicable regulations of the
respective country. Grease and oil contained in it must be disposed of in accordance with applicable
environmental protection regulations. Electronic elements and components must be disposed of
through a certified specialised company.
2.1.9 Scope of supply
•Prewired control unit with built-in options in accordance with the specification
•Turbine with a 10m connecting cable
•Additional accessories as listed in the accompanying papers.
After receiving the delivery, check the delivery contents against the accompanying papers to make
sure they are complete.
The manufacturer does not offer warranty for claims regarding missing parts submitted at a later date.
Any transport damage that is discovered must be reported to the shipping agent without delay.

BA-EN-HydroStar V3.1 page 7
3 HydroStar installation shaft
The HydroStar standard installation shaft is suitable for all standard pool types.
3.1 Scope of supply
The HydroStar installation shaft comes complete with all required accessories.
•Installation shaft
•Spring-loaded frame with seals and screws
•Cover plate with fastening bolts
•Additional accessories as listed in the accompanying papers.
After receiving the delivery, check the delivery contents against the accompanying papers to make
sure they are complete.
3.2 BGA 160/215/275, installation in skimmer or overflow pools

BA-EN-HydroStar V3.1 page 8
3.3 BGA 320/430/550, installation in skimmer or overflow pools

BA-EN-HydroStar V3.1 page 9
3.4 Installing the spring-loaded flange
1 Wall penetration
2 Flange with spacer 5
4 Silicon sealing
7 Pool liner
M6 Screws for flange
M5 Screws for cover
•The contact surfaces of the wall penetration (1) must be free of sand and concrete remnants.
•The contact surface must be grease-free by cleaning with an appropriate cleaner.
•Remove the paper on one side of the seal (4)
•Put the adhesive side of the seal on the frame of the wall penetration. Take care not to cover the
attachment holes.
•Put the pool liner (7) on top of the seal and poke holes for the screws.
•Put spring-loaded flange in place and attach with the M6 screws.
•Observe the specified tightening torque (7 - 10 Nm)!

BA-EN-HydroStar V3.1 page 10
3.5 Aligning the turbine
•The turbine is installed with an
adjustment bracket in a hanging
position.
•Attach the adjustment bracket with
the turbine to the stay bolts.
•The top nuts determine the
positioning and also the flow of
the turbine.
•The factory setting for the
discharge angle is approx. 4°. In
most cases, the angle does not
have to be changed.
•Based on pool size, depth, and
user requirements, the angle can
be adjusted by means of stay bolts.
•Then, adjust the height of the
turbine.
•Tighten and lock all nuts
securely.
•The flow plate with the flow aid can
only be installed when the turbine
is correctly aligned.
3.6 Installation of the cover plate
•Align the turbine and do a trial run
•Do not install the cover plate (3) until the turbine is correctly aligned.
•There is a flow aid attached to the inside of the cover plate.
•The cover plate cannot be installed until the turbine is correctly aligned and protrudes into the flow
aid.
•Place the cover plate on the press frame (2) and fix it with the countersunk head screws M5, while
supporting the cover plate with one hand or slightly lifting it to prevent damage to the countersunk
head screws.
•Observe the specified tightening torque (4 - 6 Nm)!

BA-EN-HydroStar V3.1 page 11
4 Turbine without HydroStar installation shaft
•The turbine is designed for use under water.
•It is to be installed under the surface of the water at a suitable location in the swimming pool (Center
turbine 300mm under water level).
•Protective equipment may be necessary to ensure that swimmers do not come into contact with the
turbine.
•It must be ensured that an adequate water quantity is fed in.
•The motor cable must be installed so that it is not drawn in by the water current.
4.1 Installation example for a BGA turbine
  NOTE
The illustration is only given as an example. The machine builder is responsible for the planning and
professional installation as well as installation of any required protective equipment!
4.2 Dimensions of turbine BGA 160/320 with installation flange
  NOTE The turbine may only be fastened to the installation flange!

BA-EN-HydroStar V3.1 page 12
4.3 Dimensions of turbine BGA 215/430 with installation flange
  NOTE The turbine may only be fastened to the installation flange!
4.4 Dimensions of turbine BGA 275/550 with installation flange
  NOTE The turbine may only be fastened to the installation flange!

BA-EN-HydroStar V3.1 page 13
5 HydroStar BGA 160/320/275/550 C for retrofit installation
•These units are ready for installation and manufactured according to order instructions.
•The frame must be securely attached to the pool edge.
•No attachment at the pool floor is necessary.
•The feet should be adjusted so that the unit stands securely and the frame is not perpendicular.
•The motor cable must be installed so that cannot be damaged.
•The installation shaft must be completely under water.
•The unit's suction is on the bottom and front side. It must be ensured that the suction slits are never
clogged and water flow is guaranteed.
NOTE
•Do not climb on the frame or the installation shaft.
•Do not use the installation shaft as a "starting block".
•Do not push-off from the cover plate.

BA-EN-HydroStar V3.1 page 14
6 PIEZO Tri / PIEZO Tri Square, installation
PIEZO Tri, installation in pool wall, installation shaft Ø120
PIEZO Tri, installation shaft Ø120, cover plate Ø130

BA-EN-HydroStar V3.1 page 15
PIEZO Tri Square, installation shaft with cover plate
PIEZO Tri Square, installation shaft 150 x 70 mm

BA-EN-HydroStar V3.1 page 16
7 Control unit
•Observe DIN VDE 0100-702 (Installation of low voltage systems, Section 702: Swimming
pools and other pools).
•The control unit must be installed in area 2 as per DIN VDE 0100-702. The power lead-in must be
equipped with residual current protection (RCD) with a rated residual operating current of ≤30mA.
•The system must have a 16 A inert fuse installed.
•Installation in a dry room in which other technical equipment for operating the swimming pool is
installed. The room should be a maximum of 10 m from the pool.
•The control unit is designed for wall mounting. It is mounted with 4 screws Ø 8 mm (not included in
delivery). It must be fixed in such a way that the cable entries are on the bottom.
Mounting BGA 160/215/275 Mounting BGA 320/430/550
HydroStar BGA 160/215/275 HydroStar BGA 320/430/550
NOTE Please also observe the circuit diagrams included in delivery!

BA-EN-HydroStar V3.1 page 17
7.1 Connection block diagram
The HydroStar BGA 320/430/550 Twin twice the motor terminals.
7.2 Terminals
•Connection is carried out by means of
screwless WAGO terminals
•Please observe the information.
WARNING

The wires for motor feed have a paper casing!
Ensure that the paper casing is completely
removed!

BA-EN-HydroStar V3.1 page 18
7.3 Motor connection
•Insert the motor cable into the M25 threaded cable connection so that the jacket is pushed
through by approximately 50 mm.
•Securely tighten the threaded cable connection.
•Connect the motor supply line to the terminal strip according to the colour coding.
7.4 Extending the motor supply line
NOTE: Observe the minimum cross-section of 16 mm²!
If it is necessary to lengthen the line, observe the motor's rotation direction.
If the turbine is running in the wrong direction, invert the two connection lines.
•Shorten the original motor supply (3 x 6mm²) line to ≤5 m (minimum 2 m)
•Extend up to a total length of 30 m with a cable cross-section of 16 mm² fine wired!
•To extend the turbine cable, the original BINDER 3x16 mm² cable is recommended! (Art.
No.: 5300115)
7.5 Connecting the HydroStar PIEZO Tri
•The connection cable is a 14-wire cable with cross-section of 0.5 mm
2
.
•The cable can be lengthened with an equivalent cable up to 30 m.
•It must be ensured that the wires are connected with the same numbering.
•An underground junction box for cable lengthening must have a watertight seal.
•Terminal strip X2 is used for connection.
•Connect the wire number according to terminal number.
•Please also observe the circuit diagrams included in delivery!

 NOTE: Please also observe the circuit diagrams included in delivery!

BA-EN-HydroStar V3.1 page 19
7.6 Connecting an external operating device
By means of push buttons connected to the X2 terminal strip, the following functions can be
controlled:
•On/Off by closing terminals 1-2
•Turbine acceleration by closing terminals 1-8
•Turbine deceleration by closing terminals 1-11
•Breaking capacity: 24VDC/20mA, maximum cable length 30m
•Please also observe the circuit diagrams included in delivery!
7.6.1 Instructions for operation with a smartphone
The X2 terminal strip can be used as an interface to an overriding control unit (e.g., Loxone). The
terminal assignment can be found in the circuit diagrams included in delivery.
8 Start-up
Turn the unit on using the rotary switch on the front side of the control unit!
ELECTRICAL HAZARD
Before starting the machine up, check the operation of the residual current device (RCD) on the
machine side.
Check all lines for damage and make sure the electrical connections are secure.

 NOTE
Do not perform any trial runs unless the turbine is completely under water! Operating it above water or
only partly in water will cause the drive motor to fail!
8.1 Remote control operation
  DANGER
The radio transmitter and receiver are pre-set to match at the factory and programmed for the
operation of the HydroStar counterflow unit. Any reprogramming or using a second or third-party radio
transmitter may damage the machine or harm people.
Before starting the turbine, make sure that no one is in the flow out area of the turbine. The sudden
flow of water may lead to unpredictable reactions.