Nastec 4HS User manual

4HS Submersible Pumps
Installation and Operating Manual
man4HS_06_eng.docx LCD 2.24 INV 2.2 H 2.1

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Index
1. Introduction of the 4HS submersible pumps range..................................................................................................3
2. Safety Instructions ....................................................................................................................................................4
3. Stocking conditions ...................................................................................................................................................4
4. Packing content......................................................................................................................................................... 5
5. General technical features....................................................................................................................................5
6. Pump installation ......................................................................................................................................................6
6.1 Installing pump in the well................................................................................................................................ 6
6.2 Pump cable........................................................................................................................................................ 7
7 CM installation ..........................................................................................................................................................8
7.1 Electric wiring....................................................................................................................................................9
8. 4HS pumps installation for constant pressure mode..............................................................................................10
8.1 Pressure tank ..................................................................................................................................................11
8.2 Pressure sensor...............................................................................................................................................11
8.3 Minimum stop frequency at 0 delivery (f min Q=0) during constant pressure control..................................12
9. 4HS pumps performance range ..............................................................................................................................13
10. 4HS use and programming..................................................................................................................................16
10.1 Display.............................................................................................................................................................16
10.2 Initial setting ...................................................................................................................................................16
10.3 Initial view.......................................................................................................................................................18
10.4 Menu display...................................................................................................................................................19
10.5 Installer parameters........................................................................................................................................19
10.6 Advanced parameters.....................................................................................................................................24
11. Protections and alarms ...................................................................................................................................27
12. Trouble-shooting chart .......................................................................................................................................30
13. Technical Assistance ...........................................................................................................................................31

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1. Introduction of the 4HS submersible pumps range
4HS is a 4” high speed centrifugal submersible pump for clean water composed by:
high speed three phase asynchronous motor with wet rotor and canned type resin filled stator.
Built-in inverter on board driven by a dedicated control module (CM) positioned outside the well.
High speed multi stage pump entirely made of AISI 304 stainless steel.
Pump driving made by inverter allows:
Modify the pump speed to grant constant the desired pressure regardless water request. In this way the
pump is operated only and when needed thus avoiding unnecessary waste of energy and granting longer
system life.
implement the soft start and the soft stop to increase the system life and reducing the current peaks.
protect the motor from overloading and dry running , overvoltage, undervoltage and possible abnormal
conditions
4HS is used on residential and industrial sectors for water pressurized systems, granting:
Energy saving
Simplified and quick installation
Long life reliability
4HS: submersible pump
CM: control module

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2. Safety Instructions
NASTEC strongly suggests to reading carefully 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 instruction of this manual may result fatal in dangerous electric shock.
The unit must be connected to the power supply by a switch granting the
complete visual disconnection (separation) from the line before any operation
on the 4HS itself and on the connected load.
Disconnect the unit from the power supply before any operation.
Do not remove for any reason, the cover of the CM and the cable guard
without having visually disconnected the unit from the power supply and
having waited at least 5 minutes.
4HS and pump system must be grounded properly before operation.
For the entire period the CM is powered a high voltage is present on the
output terminals independently if it is running or not the pump.
Do not start the pump for any reason if not completely immersed in water.
Avoid any shock or serious impact during transportation.
Check the 4HS immediately upon delivery and check for damage and/or missing parts. In either case, immediately
notify the supplier.
Damages due to transportation, incorrect installation, or improper use of the device will null and void the warranty.
NASTEC cannot be held responsible for any damage to people and/or property due to improper use of its
products.
3. Stocking conditions
Store the product on its packaging in a dry and well ventilated environment within a temperature range from -20 ° C
and 70 ° C.
If the pump remains in stock for more than a year is recommended to disassemble the rotating parts and test their
functionality. It 'also need to power the electric pump (without running the motor) to allow charging of electrolytic
capacitors of the inverter module.
If the pump has already been put into operation and is then placed in storage, the minimum storage temperature is
4 ° C. Alternatively you need to add anti-freeze fluid.

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4. Packing content
Packing includes:
4HS submersible pump with 2,5 meters flat cable length.
CM (control module)
Pressure transducer
Operating Manual
Cable junction kit
5. General technical features
PUMP
Max. temperature of pumped liquid
35 °C (92 °F)
Min. speed of water flow on motor case
0.2 m/s
Characteristics of pumped liquid
clean, non-corrosive, non-explosive, free of particles and
fibers, with a maximum sand content of 50 g/m3
Grade of protection
IP68
Used Materials
Impellers and diffusers in AISI 304 stainless steel
Cable
Flat cable ACS –WRAS
CM
Max. temperatura dell’ ambiente d’ installazione
60 °C (140 °F)
Grade of protection
IP55 (NEMA 4)
Used Materials
Aluminium , LCD membrane with PVC stickers, antipull
plug in polyamide
Analog input
2 x analog input 4-20 mA + 2 settable analog input 4-20
mA or 0-10 V .
Digital input
4 inputs, N.O or N.C settable via software
Digital output
2 output relays 5 A , 250 Vac, N.O. or N.C settable
Auxiliary feeding
24 Vdc (300 mA),10 Vdc (5 mA)
Day and time indication
dater with lithium backup battery (unavailable)
User display
Backlit LCD display with 16 characters x 2 rows , 5
buttons, buzzer for acoustic
Short circuit protection
With fuse (25 Amp)
CERTIFICATIONS
CE
Check the 4HS packing immediately upon delivery and check for damage and/or missing parts; in
either cases immediately notify the supplier

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6. Pump installation
Entire installation procedure must be performed verifying that pump is not connected to the
mains.
Pump can be installed both vertically and horizontally,
but the outlet should never be below the horizontal
line.
If the pump is not installed in a well, to grant a proper
cooling, a cooling sleeve must be used; doing so the
minimum speed of the pumped liquid has to be
granted.
6.1 Installing pump in the well
To reduce noise transmission it is advised to use plastic pipes.
The pump must always be secured in the well through a special rope attached to loop on the pump head.
It is recommended not to drop the pump in the well by using the electric cable, its integrity must be preserved in all
operations. In this regard it is recommended to fix the cable on cable support or on the pipe.
During operation the pump suction must always remains at least 1.5 meters below the dynamic water level.

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Do not drop the pump in the well by using the electric cable
Make sure about the electric cable integrity during all the operations.
Ensure the pump in the well with a stainless steel rope to be fixed to the
hole in the pump head
6.2 Pump cable
4HS are equipped, in their standard configuration, with 5 meter flat cable length.
SINGLE PHASE INPUT POWER
If the distance between the pump and the CM is longer than the supplied cable it is necessary to make a junction
performed by the special kit supplied as standard.
The cable section for additional power conductors must be calculated considering the maximum allowed voltage
drop.
4HS model
type of wire
total cable length
10 –50 m
50 –100 m
100 –150 m
150 –200 m
4HS 02/04
4HS 04/03
4HS 06/02
power
2,5 mm2 (AWG
13)
4mm2 (AWG 11)
6 mm2 (AWG 9)
10 mm2 (AWG 7)
signal
1 mm2 (AWG 17)
1,5 mm2 (AWG 15)
4HS 02/08
4HS 04/05
4HS 06/04
power
4 mm2 (AWG 11)
6mm2 (AWG 9)
10 mm2 (AWG 7)
16 mm2 (AWG 5)
signal
1 mm2 (AWG 17)
1,5 mm2 (AWG 15)
POWER
SIGNAL
blue
brown
ground
red
white

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7CM installation
The CM can be easily fixed to the wall using 2 screws through the holes shown in Figure 2.
Then using the special inserts thus cover can be fixed firmly.
The IP55 protection degree enables the CM installation even in humid and dusty environments. However it is
recommended to protect the CM from the direct exposure to weather and sunlight.
To make the junction is necessary to follow carefully the instructions inside the kit.
At the time of joining and electrical connection is essential to maintain the
correspondence between the signal cables.
After cable joining and placed the pump in the well you must perform, before
connecting to the CM, a test of insulation: join together the two power cables and,
applying a voltage of 500V, an insulation resistance from the ground higher than 100
Mohm must be verified. Join together the two signal cables and, applying a voltage of
500V, an insulation resistance from the ground higher than 100 Mohm must be verified.

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7.1 Electric wiring
Input power line (LINE):
L1,L2 power line
GND ground
Output power line (PUMP):
M1,M2 terminals
GND ground
Pump signal:
S+ (red)
S- (white)
Analog inputs:
AN1 (4-20 mA or 0-10 V)
AN2 (4-20 mA or 0-10 V)
0V
+24V
AN3 (4-20 mA)
AN4 (4-20 mA)
0V
+24V
10V
0V
AN1 o AN2 terminals can be set as
voltage input (V) or current input (I)
through J5 e J9 selector.
Digital inputs:
IN1
0V
IN2
0V
IN3
0V
IN4
0V
Communication
auxiliary (RS485):
S1+
S1-
Digital outputs (relays):
RELAY1: pump run signal
NO: normally opened
COM: common
NC: normally closed
RELAY2: alarm signal
NO: normally opened
COM: common
NC: normally closed
Relays of digital outputs are free
contacts relays (no voltage) Max
voltage is 250 V AC and max
current is 5 A.
L1

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Read carefully the Guidelines for safety before installing the device.
At the end of the installation check that no other objects are inside the CM or
deposited on the electronic board.
It is recommended to tighten all 4 screws with washers of the cover before
powering the device. Otherwise, you may fail to connect to ground the cover
with a risk of electric shock or even death.
8. 4HS pumps installation for constant pressure mode
CM can manage the rotation speed of pump to maintain constant the pressure in a point of plant regardless the
water demand of the user.
The basic scheme of a line of pumping system capable of achieving this operation is as follows:

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8.1 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 CM 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 1 bar (15 psi) less 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 bar
If the set-pressure of the system is 60 psi, the pre-charge pressure of the tank should be 45 psi
8.2 Pressure sensor
It is possible to use pressure sensor with a linear output signal with range 4 –20 mA.
Pressure transducer will be powered by any range of DC voltage including the value 24 V.
It is necessary to set the pressure sensor characteristics in the initial configuration menu or in the installer menu
(please check the relevant chapter on setting parameters).
The connection of the pressure sensor is through the analog input terminals
0V (signal GND, if available)
+24V (power supply 24 V dc)
AN1 (signal 4-20 mA)
CM accepts the signal of an additional pressure transducer to be activated automatically if the first transducer fails;
it is enough to connect the wires of the additional pressure transducer to pin AN2 (signal 4-20 mA) and +24V (power
supply 24 V dc).

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8.3Minimum stop frequency at 0 delivery (f min Q=0) during constant pressure control.
Minimum stop frequency is the minimum frequency value that, while maintaining the p_set, water delivery is zero.
Below scheme graphically shows the function:
Progressively closing the water delivery valve reduces flow, causing CM to reduce the pump speed by reducing the
output frequency, to maintain a constant pressure (i.e. 3 bar).
Once the water flow stops (output completely closed), pump will run at minimum frequency to maintain the set
pressure.
Upon determining that the water requirement has stopped, CM stops the pump to save energy. Thus, the pump will
be stopped when minimum frequency is reached.
Once the pump is stopped at min. frequency value, set pressure is maintained in the system.
To maintain the pressure on the pump output line, it is necessary to install a small pressure tank able to compensate
for minor water leakage and to limit the number of pump restarts.
It is important to pinpoint that a particular set pressure corresponds to a single value of min. stop frequency.
To stabilize the pressure control operated by the CM module, it is suggested to put the
pressure sensor near the well exit, after the check valve.
Pressure sensor and power cables can be close but it is suggested to use a shield cable
connecting the shield to the sensor ground pin.
If the end user wants to change the set pressure, a new value of min. stop frequency
should also be set.
100 Hz
40 Hz
Q
H
76 Hz
p_set (es: 3 bar)
80 Hz

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9. 4HS pumps performance range

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15

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10. 4HS use and programming
CM 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
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
A second and different password is required; improper setting of these advanced parameters could
compromise the integrity and the life of CM 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).
10.1 Display
Screen is a back-lit LCD displaying 2 rows of 16 digits each. Alarms are indicated by an audible signal.
10.2 Initial setting
When the 4HS is switched on for the first time, the initial setting menu is displayed for the initial setting of
parameters to configure pumps and plant characteristics.
If the initial setting procedure is not ended properly, it is impossible to run the pump.
Initial setting procedure can be repeated.
STOP motor
Menu exit
Alarms reset
START motor
ENTER
Scroll up
Scroll down

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The CM software suggests default values for each parameter. If you wish to change the suggested value, press
ENTER button, wait for the value blinks and act on the scroll keys. Press ENTER again to set the new value that will
end to flash.
A detailed description of parameters of initial setting will follow:
parameter
default
description
English
End user communication language.
bar
Select Pressure unit.
Control mode: Constant pressure
16
Set max pressure of pressure transducer;
Set the pressure value of the transducer when output signal is
20 mA equivalent to the higher value of pressure range.
Zero point adjustment of the transducer (4mA) as offset
compensation; automatically done by pressing Enter.
If the transducer is not connected or wrongly connected the
signal PRESS. SENSOR OFF is activated.
10
It’s the maximum pressure suitable in the system. If the
pressure goes over an alarm occurs and pump is stopped.
Pump is automatically restart if the pressure goes below the
maximum value for time of at least 5 seconds.
3
It is the pressure value to be kept constant.
OFF
If ON is selected, after a lack of voltage, 4HS returns to its
normal status; if 4HS was powering the pump before voltage
drop, it returns to feed the pump without any kind of advise.
Warning, read again the advice of the chapter 1.
Once the Setting procedure is completed you will get this
indication on the display; set parameters are recorded by 4HS;
these parameters can be singly set up in the INSTALLER
Parameters menu or ADVANCED Parameters menu. If you
with to reset to initial parameters use the DEFAULT
Parameters menu.
INITIAL SET UP
COMPLETED
Auto restart
ON/OFF
Set pressure
p = XX.X [bar]
Max alarm pres.
p = XX.X [bar]
Offset sensors
Press ENT for tuning
F.s. press. sensor
20mA = XXX.X [bar]
Unit
bar/psi
Language
Italiano / English

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10.3 Initial view
When powering the CM LCD display shows: model, release of digit display software (LCD =X.XX) and the release of
inverter software (INV = X.XX) as shown below:
The following End User messages are displayed by pushing the scroll buttons:
p_m is the pressure value read by the pressure transducer
By pressing ENTER the pressure set value is displayed.
Holding more than 5 seconds the ENTER button you can change the pressure set
value.
f value is the supply frequency to the motor; by pressing ENTER you can change
the f value manually (word “set” is displayed) , pressing again ENTER you exit this
set possibility (word “set” disappeared).
V_in is the voltage supplied to the motor. This value is displayed only if motor is
off; if motor is ON, I value appears , equivalent to the absorbed motor current.
cosphi index means the angle phi between the voltage and current absorbed by
the motor.
P is the power in W supplied to the pump.
NORMAL status means no alarms.
If an alarm occurs a message blinks on the display and an audible signal is
activated.
By pushing ENTER accesses: inverter lifetime, pump lifetime, alarm list.
PUMP lifetime is increasing when pump is powered.
To come back to previous views press ENTER.
Return to MENU list by pressing ENTER.
First row gives the 4HS status:
Inv:ON XXX.X Hz CM is powered and feeding the 4HS showing its frequency.
Inv:ON Mot: OFF CM is powered but 4HS is not running (i.e. motor/pump was stopped due to minimum
frequency being reached).
Inv:OFF Mot: OFF 4HS is not controlled.
Menu
ENT to enter
ALL. XXXXXXXXXXXXX
XXXXXXX h : XX m
Motor Life
xxxxx h : xx m
Inverter Life
xxxxx h : xx m
Inv: ON/OFF Mot: ON/OFF
STATUS:NORMAL/ALARM
Inv: ON/OFF Mot: ON/OFF
P = XXXXX [W]
Inv: ON/OFF Mot: ON/OFF
cosphi = X.XX
Inv: ON/OFF Mot: ON/OFF
V_in=XXX [V] / I=XX.X [A]
Inv: ON/OFF Mot: ON/OFF
f = XXX.X [Hz]
Inv: ON/OFF Mot: ON/OFF
p_m=XX.X [bar]
www.nastec.eu
4HS
www.nastec.eu
LCD = X.XX
www.nastec.eu
INV = X.XX

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10.4 Menu display
Pressing ENTER where you are in *MENU’ / ENT to access] in initial display, the following MENUs are displayed:
Password required to enter (default 001)
Password required to enter (default 002)
Installer password required to enter (default 001)
It is possible to return to original default set parameters (Change Init. Set.)
Password required to enter (default 002)
To exit the Menu level and return to INITIAL DISPLAY is enough to press STOP button
10.5 Installer parameters
Most of the installer parameters are already set up during the initial configuration (chapter 6.2 Settings). Through
this menu is possible to change again the previous parameters or enable further parameters allowing a perfect
calibration of the pumping system in relation to the plant.
parameter
default
desciption
Constant press.
Fix speed
Const.press.2val
Fix speed 2 val.
External speed
Constant temp.
Constant flow
Const. press.
Mode of control:
Constant pressure: CM changes the speed of pump to keep the
pressure constant, independent of water demand
Fixed frequency: CM feeds the pump a set frequency, so the speed of
motor is kept constant.
Constant pressure control with two values; the two values are
selected by opening or closing the digital input 2.
Fixed frequency control with two values to be selected by opening or
closing the digital input 2.
External speed: control motor frequency by using analogical input 4-
20 mA connected to input AN4.
Constant temp.: CM changes the speed of pump to keep the
temperature constant. An analogical signal 4-20 mA coming from a
temperature sensor must be connected to input AN3.
Constant flow: CM changes the speed of pump to keep the flow
constant. An analogical signal 4-20 mA coming from a flow sensor
must be connected to input AN3.
Control mode
Constant press.
Fix speed
Const.press.2val
Fix speed 2 val.
External speed
Constant temp.
Const. flow
MENU’
Change Init. Set.
MENU
Retrieve Init. Set.
MENU
Advanced param.
MENU
Instal. param.

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parameter
default
desciption
Constant press.
Fix speed
Const.press.2val
Fix speed 2 val.
External speed
Constant temp.
Constant flow
bar
Pressure unit


°C
Temperature unit

16
Maximum pressure of pressure transducer;
Set the pressure value of the transducer
when output signal is 20 mA equivalent to the
highest value of pressure range
(i.e. 0 –10 bars transducer range) 10 bars =
20 mA





100
Full scale of the temperature sensor.
From the plate data of the sensor can read the
temperature at which the sensor provides
output 20 mA.

0
Full scale of the temperature sensor.
From the plate data of the sensor can read the
temperature at which the sensor provides
output 4 mA.

100
Full scale of the flow sensor.
From the plate data of the sensor can read the
flow at which the sensor provides output 20
mA.

Zero point adjustment of the transducer
(4mA) as offset compensation; automatically
done by pressing Enter.
If the transducer is not connected or
connected improperly, the signal an alarm 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.







0
Minimum pressure allowed in the system. If
the pressure goes lower than the set value, an
alarm occurs and the pump is stopped. Pump
is automatically restarted if the pressure goes
higher than the minimum value for a period of
at least 5 seconds. This parameter is
particularly useful in the event a system pipe
breaks. It is suggested to set a value higher
than 0.







Min alarm pres.
p = XX.X [bar]
Max alarm pres.
p = XX.X [bar]
Offset sensors
Press ENT
F.s. flow sensor
20mA = XXX.X [m3/h]
Min temp. sensor
4mA = - XXX.X [°C]
F.s. temp.sensor
20mA = XXX.X [°C]
F.s. press.sensor
20mA = XX.X [bar]
Unit
°C / °F
Unit
bar/psi