Kolmeks NC 209 User manual

VAriable Speed COntroller
Operating manual
NC
manNC_eng_30

2
Index
1. NC Introduction................................................................................................................................................................. 3
2. Safety Instructions............................................................................................................................................................. 3
3. Technical Characteristics ................................................................................................................................................... 4
3.1 Weight and dimensions .......................................................................................................................................................... 5
4. Electric wiring.................................................................................................................................................................... 6
4.1 Protections............................................................................................................................................................................. 12
4.2 Electromagnetic compliance.................................................................................................................................................. 12
4.3 Installation with long motor cables ....................................................................................................................................... 12
5. NC installation ..................................................................................................................................................................13
5.1 NC Installation for constant pressure control........................................................................................................................ 16
5.1.1 Pressure tank .............................................................................................................................................................. 16
5.1.2 Pressure sensor........................................................................................................................................................... 16
5.2 NC installation for differential constant pressure applications ............................................................................................. 17
5.2.1 Sensors wiring ............................................................................................................................................................. 17
5.2.2 Programming............................................................................................................................................................... 17
6. NC Use and Programming.................................................................................................................................................18
6.1 NC display.............................................................................................................................................................................. 18
6.2 Initial configuration............................................................................................................................................................... 18
6.2.1 FOC motor control ...................................................................................................................................................... 20
6.3 Initial view ............................................................................................................................................................................. 22
6.4 Menu view............................................................................................................................................................................. 23
6.5 Control parameters ............................................................................................................................................................... 23
6.6 Motor parameters.................................................................................................................................................................. 27
6.7 IN/OUT parameters................................................................................................................................................................ 30
6.8 Connectivity parameters........................................................................................................................................................ 31
7. Protections and alarms.....................................................................................................................................................31
8. Auxiliary pumps during constant pressure control ...........................................................................................................33
8.1 DOL pumps............................................................................................................................................................................ 34
8.2 COMBO function .................................................................................................................................................................... 35
9. Trouble-shooting chart .....................................................................................................................................................38
10. Technical Assistance .......................................................................................................................................................39

3
1. NC Introduction
NC is a variable frequency drive designed to control and protect pumping systems by varying the output frequency to the
pump.
NC can be applied to both new and existing pumping systems, and provides:
energy and cost savings
simplified installation and an overall lower pumping system cost
longer life of the pumping system and relevant components
improved reliability
NC, when connected to any pump, manages the system operation to maintain a certain constant physical quantity (pressure,
differential pressure, flow, temperature, etc.) regardless of the conditions of use. The pump is operated only when needed
thus avoiding unnecessary energy consumption.
NC at the same time is able to:
protect the motor from overload and dry running
implement soft start and soft stop to increase the system life and reduce current peaks
provide an indication of current consumption, voltage, and power
maintain a record of run time and display any errors and/or failures reported by the system
control up to two additional pumps at a constant speed (Direct On Line)
connect to other NC units for combined operation
Through the use of inductive filters (optional) NC eliminates dangerous surges that are induced in long cables, making NC
suitable for control of submersible pumps.
2. Safety Instructions
The manufacturer strongly suggests carefully reading this operation manual before using and installing its products
Any operation (installation, maintenance and repair) must be carried out by trained, skilled, and qualified personnel.
Failure to observe and follow the instructions in this manual may result in dangerous and potentially lethal electric shock.
Pay attention to all standard safety and accident prevention regulations
The device must be connected to main power supply via a switch to ensure the
complete disconnection from the network before any operation on the NC itself
(including visual inspection) and/or on the connected load.
Disconnect NC from the main power supply before commencing any work.
Do not remove, for any reason, the cover and the cable plate without having first
disconnected the device from the main power supply and having waited at least
5 minutes.
NC and pumping system must be grounded properly before operation.
For the entire period NC is powered, high voltage is present on the output
terminals of the inverter whether or not the pump is running.
Tightening all screws on the cover with washers is recommended before
powering the device. Otherwise, there may be a failure to connect the cover to
ground, creating the risk of electric shock or even death.
Avoid any shock or significant impact during transport. Check the NC immediately upon delivery and check for damage
and/or missing parts. If either occurs, immediately notify the supplier. Damages due to transport, incorrect installation, or
improper use of the device will null and void the warranty. Tampering or disassembly of any component will automatically
void the warranty.The manufacturer cannot be held responsible for any damages to people and/or property due to
improper use of its products.
Devices marked with this symbol cannot be disposed of in household waste but
must be disposed of at appropriate waste drop-off centres. It is recommended
to contact the Waste Electrical and Electronic Equipment drop-off centres
(WEEE) in the area. If not disposed of properly, the product can have potential
harmful effects on the environment and on human health due to certain
substances present within. Illegal or incorrect disposal of the product is subject
to serious administrative and/or criminal penalties.

4
3. Technical Characteristics
Model
Vin +/- 15% [V]
Max V out
[V]
Max I in
[A]
Max I out
[A]
P2 motor
power*
[kW]
Size
NC 209
1 x 230
1 x Vin
15
9
1,1
1
3 x Vin
7
1,5
1
NC 214
1 x 230
1 x Vin
20
9
1,1
1
3 x Vin
11
3
1
NC 218
1 x 230
3 x Vin
38
18
4
2
NC 225
1 x 230
3 x Vin
53
25
5,5
2
NC 306
3 x 230
3 x Vin
10
6
1,1
1
NC 309
3 x 230
3 x Vin
13,5
9
2,2
1
NC 314
3 x 230
3 x Vin
13,5
14
3
2
NC 318
3 x 230
3 x Vin
17,5
18
4
2
NC 325
3 x 230
3 x Vin
24
25
5,5
2
NC 330
3 x 230
3 x Vin
29
30
7,5
2
NC 338
3 x 230
3 x Vin
42
38
9,2
3
NC 348
3 x 230
3 x Vin
52
48
11
3
NC 365
3 x 230
3 x Vin
68
65
15
3
NC 375
3 x 230
3 x Vin
78
75
18,5
3
NC 385
3 x 230
3 x Vin
88
85
22
3
NC 406
3 x 380 - 460
3 x Vin
10
6
2,2
1
NC 409
3 x 380 - 460
3 x Vin
13,5
9
4
1
NC 414
3 x 380 - 460
3 x Vin
13,5
14
5,5
2
NC 418
3 x 380 - 460
3 x Vin
17,5
18
7,5
2
NC 425
3 x 380 - 460
3 x Vin
24
25
11
2
NC 430
3 x 380 - 460
3 x Vin
29
30
15
2
NC 438
3 x 380 - 460
3 x Vin
42
38
18,5
3
NC 448
3 x 380 - 460
3 x Vin
52
48
22
3
NC 465
3 x 380 - 460
3 x Vin
68
65
30
3
NC 475
3 x 380 - 460
3 x Vin
78
75
37
3
NC 485
3 x 380 - 460
3 x Vin
88
85
45
3
Power frequency: 50 - 60 Hz (+/- 2%)
Max. ambient temperature at nominal current: 40°C (104 °F)
Max. altitude at nominal current: 1000 m
Grade of protection: IP55 (SIZE 1,2) , IP54 (SIZE 3) *
RS485 serial communication
* auxiliary cooling fan of the NC, used in wall mounted applications, has a protection rating of IP54.
NC is able to power the motor with a higher current for a short period of time according to the linear relation: 101%
of the nominal current for 10min., 110% nominal current for 1 min.

5
3.1 Weight and dimensions
Model
Weight *
Size
[Kg]
NC 209
4
1
NC 214
4,3
1
NC 218
7,2
2
NC 225
7,2
2
NC 306
4,4
1
NC 309
4,4
1
NC 314
7
2
NC 318
7
2
NC 325
7
2
NC 330
7,2
2
NC 338
33
3
NC 348
33
3
NC 465
34
3
NC 375
34
3
NC 385
34
3
NC 406
4,4
1
NC 409
4,4
1
NC 414
7
2
NC 418
7
2
NC 425
7
2
NC 430
7,2
2
NC 438
33
3
NC 448
33
3
NC 465
34
3
NC 475
34
3
NC 485
34
3
* Weight without packing.
SIZE 1
SIZE 2
SIZE 3

6
4. Electric wiring
Power board NC 209,214
Power supply:
LINE: L1, L2,GND
It is recommended to use
cable lugs
Output:
3 ph motor:
GND,U,V,W,
1 ph motor:
earth, U (running), V (common)
It is recommended to use cable lugs.
230 V AC auxiliary fans
(wall mounting kit)
FAN: F1, F2
Recommended line and motor cables stripping

7
Power board NC 218, 225
Power supply:
LINE: L1, L2, GND
It is recommended to use cable
lugs.
Motor output:
MOTOR: U, V, W, GND
It is recommended to use cable
lugs.
12 V dc auxiliary fans (wall
mounting kit)
VENT: +, -
WARNING: respect the polarity.
Cable stripping recommended for line input and output to the motor.

8
Power board NC 306,309,406,409
Power supply:
LINE: GND , L1, L2, L3,
It is recommended to use cable
lugs.
Motor output:
MOTOR: U, V, W, GND
It is recommended to use cable
lugs.
12 V dc auxiliary fan (wall
mounting kit) :
0VE, + VE
WARNING: respect the polarity.
Cable stripping recommended for line input and output to the motor.

9
Power board NC 314,318,325,330,414,418,425,430
Power supply:
LINE: L1, L2, L3, GND
It is recommended to use cable
lugs.
Motor output:
MOTOR: U, V, W, GND
It is recommended to use cable
lugs.
12 V dc auxiliary fans (wall
mounting kit)
VENT: +, -
WARNING: respect the polarity.
Cable stripping recommended for line input and output to the motor.

10
Power board NC 338,348,365,375,385,438,448,465,475,485
Power supply:
LINE: L1, L2, L3, P.E.
It is recommended to use
cable lugs.
Motor output:
MOTOR: U, V, W, P.E.
It is recommended to use
cable lugs.
Cable stripping recommended for line input and output to the motor.
LINE
L2
L1
P.E.
W
P.E
L3
V
U
MOTOR

11
Control board
Analog inputs (10 or 15 Vdc):
1. AN1: 4-20 mA: sensor 1
2. AN2: 4-20 mA: sensor 2
3. AN3: 4-20 mA / 0 - 10 Vdc (settable
by jumper C.C.): external set
4. AN4: 4-20 mA / 0 - 10 Vdc (settable
by C.C.): trimmer for frequency
regulation / external set 2
Digital outputs:
motor run signal:
NO1, COM1: closed contact with motor running.
NC1,COM1: closed contact with motor stopped.
alarm signal
NO2,COM2: closed contact without alarm.
NC2,COM2: closed contact with alarm or no power
supply.
DOL1 pump relay:
NO3,COM3: closed contact with DOL1 running.
NC3,COM3: opened contact with DOL1 running.
DOL2 pump relay:
NO4,COM4: closed contact with DOL2 running.
NC4,COM4: opened contact with DOL2 running.
Relays are no voltage contacts. Max. voltage to the
contacts is 250 V with max current of 5 A.
RS485 for COMBO:
S1+
S1-
G
It is recommended to
respect the polarity
linking more NCs in
series.
Digital inputs:
IN1 : motor start & stop
IN2: value set 1 & 2 switching
IN3: sensor 1 & 2 switching
IN4 : motor start & stop + alarms
reset
0V
We recommend using only no voltage
contacts.
Opening or closing the digital contacts
(depending on software configuration
set (see IN/OUT. parameters) you can
start or stop the motor.
RS485 for MODBUS:
S2+
S2-
G
It is recommended to
respect the polarity.

12
4.1 Protections
The protections required upstream each NCs depends on the type of installation, and local regulations. We recommend to
use overload protection with the characteristic curve of type C and type B circuit breaker, sensitive to both AC and DC
current.
4.2 Electromagnetic compliance
To ensure electromagnetic compatibility (EMC) of the system, it is necessary to apply the following measures:
Always connect the device to ground
Use shielded signal cables by placing the screen at one end.
Use motor cable as short as possible (<1 m / <3 ft). For longer lengths, it is recommended to use shielded cables
connecting the screen at both ends.
Separate signal, motor, and power supply cables.
Note: To enable the restoration of the display screen when there are electromagnetic interference, NC periodically
provides some fast "refresh" of the display.
4.3 Installation with long motor cables
With long motor cables it’s recommended to decrease the
commutation frequency from 10 kHz (default) to 2.5 kHz
(Motor parameters). This reduces the probability of voltage
spikes in the motor windings which may damage the
insulation.
To prevent dangerous overheating of dv / dt and sinusoidal
filters it is recommended to set the correct PWM value in
relation to the cable length.
For motor cable lengths up to 50 meters it’s recommended
to place between NC and motor a dv / dt reactance,
available on request.
For motor cable lengths greater than 50 meters it’s
recommended to place between NC and motor a sinusoidal
filter, available on request.

13
5. NC installation
NC can be installed directly on the fan cover of the motor or mounted on the wall.
Motor mounting kit
In this application NC is cooled by the motor fan. Motor kit (available upon request) allows a solid coupling of the two units
and it is composed of:
NC SIZE 1
NC SIZE 2
n.°4 rods
n.°4 M5 nuts
n.° 4 hooks
n.° 1 cooling ring
n.° 4 M5 screws.
n.° 4 clamps
n.° 4 clips to add if necessary
n.°1 centre pin
Use the cooling ring for best cooling of NC during
operation. Warning: when using the cooling ring, the
cooling air of the motor is slightly warmer than without
the NC; if the resulting motor temperature exceeds the
indicated maximum allowable value, remove the cooling
ring, leaving the NC to be cooled by itself.

14
NC SIZE 3
n.° 1 motor feet adaptor for MEC160,180,200,225
n.° 4 M8 bolts,
n.° 4 M10 bolts, nuts and washer

15
Wall mounting kit
In this application NC is cooled independently by its auxiliary cooling fan integrated in the radiator.
Wall-mounted kit is composed of:
NC SIZE 1
NC SIZE 2
n.° 1 auxiliary fan 230V AC (NC 209,214) or 12
VDC (NC 306,309,406,409)
n.° 4 screws to fix cooling fan
n.° 1 protection grill
n.° 1 metal bracket in AISI 304
n.° 4 screws to fix NC to wall bracket
n.° 2 12 V DC fans.
n.° 1 fans cover.
n.° 2 fans cover fixing screws
n.° 2 wall fixing brackets
n.° 4 M5 screws for NC fixing to the brackets
n.°1 holes reference sheet
Make sure the manufacturer that the electric motor is suited for operation in the inverter
Make sure to properly attach the grid of the auxiliary cooling fan.
Make sure to remove the auxiliary cooling fan if NC is coupled to a motor. Failure to do so creates a
high risk of overheating the motor and NC unit.

16
5.1 NC Installation for constant pressure control
NC controls the pump speed to maintain constant pressure at a set point independent of the water demand in the system. A
basic schematic is shown below:
5.1.1 Pressure tank
Installation of a pressure tank in the hydraulic system is recommended to compensate leakage of water in the system (or
during minimum water demand) and to avoid continuous start/stop cycling of the pump (check the appendix for more
information). Selecting the proper volume and pre-charge pressure of the tank is very important; smaller tank volumes will
not compensate adequately for minimum water usage or leakage, while larger volumes make it more difficult for NC to
control the pressure evenly.
Recommended tank volume is equal to the 10% of the maximum water flow of the system (expressed in volume unit/min)
Example: if the max water flow is 50 liters/min, the pressure tank should have a capacity of 5 liters
If the max water flow is 20 gpm, the pressure tank should have a capacity of 2 gallons
Pre-charge pressure of the pressure tank should be at least 80% than the set-pressure of the system.
Example: if the set-pressure of the system is 4 bar, the pre-charge pressure of the tank should be 3.2 bar
If the set-pressure of the system is 60 psi, the pre-charge pressure of the tank should be 48 psi
5.1.2 Pressure sensor
NC requires a pressure sensor with a linear output signal within the range 4 –20 mA. The pressure transducer can be
powered by any range of DC Voltage which includes the value 15 V dc.
NC accepts the signal of a second pressure sensor in order to:
realize constant differential pressure (AN1 –AN2).
substitute first pressure sensor when it fails
switch pressure sensor by closing digital input IN2
SENSOR 1
AN1: 4-20 mA (-) signal
+15V: 15 Vdc (+) power supply
SENSOR 2
AN2: 4-20 mA (-) signal
+15V: 15 Vdc (+) power supply
NC
1
2
3
5
4
1: pump
2: check valve
3: pressure tank
4: valve
5: valve
6: pressure sensor
6

17
5.2 NC installation for differential constant pressure applications
NC can manage the pump speed in order to keep constant the pressure difference between the dischage and suction side of
the pump in circulation systems. To do this, it is usually installed a differential pressure sensor. Alternatively, it is possible to
use two identical pressure sensors: one in suction side and one in discharge side of the pump. The difference of values is
performed by the NC itself.
.
N.B. If during the operation it is expected that the pressure in the suction side falls below the atmospheric pressure, it is
necessary to use absolute pressure sensors and not relative ones.
5.2.1 Sensors wiring
The NC can be connected to linear pressure sensors with 4 - 20 mA output. The supply voltage range of the sensors must
include the 15 VDC with which the NC feeds the analog inputs.
If you are using a differential pressure sensor it is necessary to connect the sensor to the analog input 1:
DIFFERENTIAL SENSOR
AN1: 4-20 mA (-) signal
+15V: 15 Vdc (+) supply
In case two pressure sensors are used, the pressure sensor in the discharge side must be connected to the analog input 1
while the pressure sensor in the suction side must be connected to the analog input 2:
SENSOR 1 (discharge)
AN1: 4-20 mA (-) signal
+15V: 15 Vdc (+) supply
SENSOR 2 (suction)
AN2: 4-20 mA (-) signal
+15V: 15 Vdc (+) supply
In the IN/OUT parameters menu it is therefore necessary to set the logic AN1, AN2 as "difference".
5.2.2 Programming
In circulation systems pump starting and stopping is usually controlled by an external contact that can be connected to the
digital input 1 (IN1, 0V) and configured as N.O or N.C in the IN/OUT parameters menu. It is then recommended to set the
following parameters:
Control parameter
Recommended value
Freq. min control
Same as minimum motor frequency
Delta control
0 bar
Delta start
0 bar
Stop delay
99 sec
IN/OUT parameter
Recommended value
Function AN1,AN2
Difference 1-2
Constant differential pressure
The "set value" corresponds to the differential pressure to be kept constant.
Set the "set value" equal to the pressure difference measured between the discharge and the suction side of the pump at
maximum load (all utilities opened) and at maximum frequency (50 Hz).
Proportional differential pressure
In case it is needed to use a control logic based on proportional differential pressure (in order to achieve a further energy
saving), it is necessary to set the "set value" equal to the pressure difference between the discharge and suction side of the
pump at minimum frequency (20 Hz ) and "compensation" in order to reach the maximum set value at maximum frequency
(50 Hz) and maximum load (all utilities opened).

18
6. NC Use and Programming
NC software is extremely simple to use, but allows a wide variety of parameters to be set for ideal system calibration.
Setting Parameters are organized in 2 levels:
1: Installer level (MENU’ CONTROL PARAMETERS, MENU’ IN/OUT PARAMETERS, MENU’ CONNECTIVITY PARAM.)
A password is required for this level; these parameters are adjustable by trained professionals
Default password: 001
From the menu a different password can be set up.
2. Advanced level (MENU’ MOTOR PARAMETERS)
A second and different password is required; improper setting of these advanced parameters could compromise the
integrity and the life of NC and pump;
Default password 002
It is possible to set up a different password.
Installer and Advanced levels can be entered only with the correct password; otherwise, it is impossible to set up
and/or modify any parameters (they can be only displayed).
6.1 NC display
Screen is a back-lit LCD displaying 2 rows of 16 digits each. Alarms are indicated by an audible signal.
6.2 Initial configuration
When NC is switched on for the first time, the initial setting menu is displayed for the initial setting of parameters to
configure pump characteristics, pressure sensor range, and system characteristics.
If the initial setting procedure is not completed properly, it is impossible to run the pump. Initial setting procedure can be
repeated if necessary.
The initial setting procedure can be repeated (by using the 2rd level password) to reconfigure NC or if NC is installed in a
different system.
A brief description of parameters and their allowable ranges are listed below:
STOP motor
Menu exit
Alarms reset
START motor
ENTER
Scroll up
Scroll down

19
Parameter
Default
Description
XXXX
End user communication language
bar
Unit
three-phase
Type of motor connected:
single phase (NC 209, 214)
asynchronous three-phase
synchronous PM (permanent magnets)
XX
Rated current of the motor per it’s nameplate indication increased
by 10%. The voltage drop caused by the inverter leads to higher
input current than nominal. Make sure motor is capable of
accepting increased current.
50
Rated frequency of the motor per its nameplate.
Control mode: Constant value [bar]
16
Sensor full scale.
If the transducer is not connected or connected improperly, the
signal SENSOR OFF is activated when pressing ENTER.
10
Maximum pressure allowed in the system. If the pressure goes over
this value, an alarm occurs and the pump is stopped. Pump is
automatically restarted if the pressure goes below the maximum
value for a period of at least 5 seconds.
3
The pressure value to be kept constant.
If the device is "FOC-ready", motor calibration must be carried out
before commissioning.
Carefully read the pertinent chapter.
Press START/STOP to run a test at rated frequency
Warning: make sure to run the system without damaging pump
and system
--->
If, during the test, the motor runs in reverse, it is possible to change
the wiring sequence via software without physically changing wires
at the terminals.
OFF
Activation or deactivation of COMBO operation.
Language
XXXXXX
Unit
XXXXX
Motor type
XXXXXX
Rated motor Amp.
I = XX.X [A]
Rated motor freq
f = XXX [Hz]
F. scale sensor
p = XX.X [bar]
Sensor test
Press ENT
Max alarm value
p = XX.X [bar]
Set value
p = XX.X [bar]
MOTOR TUNING
press ENT
Motor test
START/STOP
Rotation sense
---> / <---
COMBO
ON/OFF

20
OFF
If ON is selected, after a lack of voltage, NC returns to its normal
status; if NC was powering the pump before the voltage drop, it
resumes powering the pump automatically.
Warning, review the advice in chapter 1
Once the Setting procedure is completed you will get this indication
on the display; setting parameters are recorded by NC; these
parameters can be set up individually in the parameters menu.
6.2.1 FOC motor control
Introduction
FOC (Field Oriented Control) motor control implemented in FOC-ready inverters provides the following advantages compared
to traditional control:
Optimal control of the current at each work point.
Quick and precise speed adjustment.
Lower energy consumption.
Reduction of torque oscillations (vibrations) for smoother and more regular operation throughout the frequency
range and lower system noise.
Lower mechanical stress on the motor, pump and hydraulic system.
FOC control of FOC-ready devices can be used with:
Asynchronous three-phase motors
Permanent magnet three-phase synchronous motors
The control is sensorless, i.e. not requiring the use of any sensors.
Calibration of the FOC control
To enable the device to perform FOC control, it is necessary to:
1. Perform all system wiring. Connect the load (pump) to the inverter with a cable of appropriate length and possible
presence of a dV/dt or sinusoidal filter.
2. Power the system and follow the initial configuration procedure by specifying:
a) Motor type: three-phase asynchronous or permanent magnet synchronous.
b) Rated voltage of the motor.
c) Rated frequency of the motor.
d) Rated current of the motor increased by 5%.
3. Perform the Auto tuning process to allow the inverter to learn the electrical information of the load connected to it
(motor, cable and any filter). The calibration process can take up to one minute.
4. Wait for the calibration process to complete successfully.
During the calibration process the motor remains stationary but is powered for the entire
calibration period.
Disconnect the device from the power supply before any intervention on the equipment and on
the loads connected to it.
Carefully follow the safety instructions in the installation and operating manual of the device.
Autorestart
ON/OFF
INITIAL SETUP
COMPLETED