VARISCO PSDrive 11 User manual

PSDrive
Installation, operation and maintenance manual
Rev50
29/07/2021
EN

Copyright © 2021 Varisco S.r.l.
The information contained in this manual can be changed without notice
Varisco S.r.l., Via Prima Strada, 37, 35129, Padova, Italy, Tel. [phone], Fax , [email protected], varisco.it

Table of Contents
1. Introduction ....................................................................................................................... 5
1.1. Purpose of the manual ............................................................................................. 5
1.2. Product presentation ............................................................................................... 5
2. Safety ............................................................................................................................... 6
2.1. Symbols ................................................................................................................. 6
2.2. Qualified personnel ................................................................................................. 6
2.3. Safety warnings ...................................................................................................... 7
2.4. Acoustic emission ................................................................................................... 9
2.5. Certifications ........................................................................................................... 9
3. Maintenance .................................................................................................................... 10
3.1. Maintenance ......................................................................................................... 10
3.2. Warranty ............................................................................................................... 10
3.3. Spare parts ........................................................................................................... 10
3.4. Disassembly and repair ......................................................................................... 11
3.5. Disposal ............................................................................................................... 11
4. Transport and storage ...................................................................................................... 11
4.1. Transport .............................................................................................................. 11
4.2. Inspection on delivery ............................................................................................ 12
4.3. Handling ............................................................................................................... 12
4.4. Storage ................................................................................................................ 12
5. Technical features ............................................................................................................ 13
5.1. Technical Data ...................................................................................................... 13
5.2. Dimensions and weight .......................................................................................... 14
5.3. Cable entry ........................................................................................................... 14
6. Mechanical installation ..................................................................................................... 14
6.1. Installation environment ......................................................................................... 14
6.2. Cooling ................................................................................................................. 15
6.3. Mechanical assembly of size 2 devices ................................................................... 16
6.4. Motor on-board mounting ....................................................................................... 17
6.5. Wall mounting ....................................................................................................... 20
7. Electrical installation ......................................................................................................... 22
7.1. Grounding ............................................................................................................. 22
7.2. Protective devices ................................................................................................. 22
7.3. Connecting cables ................................................................................................. 23
7.3.1. Power cables ............................................................................................. 23
7.3.2. Control cables ............................................................................................ 24
7.4. Electromagnetic compatibility (EMC) ...................................................................... 24
7.5. Electrical connections ............................................................................................ 25
7.5.1. Power connections ..................................................................................... 26
7.5.2. Control connections .................................................................................... 29
8. Commissioning ................................................................................................................ 30
8.1. Preliminary checks ................................................................................................ 30
8.2. Powering .............................................................................................................. 31
9. Operation and programming ............................................................................................. 31
9.1. Keyboard and display ............................................................................................ 32
9.2. Control via App ..................................................................................................... 32
9.3. Initial display ......................................................................................................... 33
9.4. FOC motor control ................................................................................................. 33
9.4.1. Introduction ................................................................................................ 33
9.4.2. Calibration of the FOC control ..................................................................... 34
9.4.3. Adjustment of the FOC control .................................................................... 35
9.5. Menu .................................................................................................................... 36
9.6. Control parameters ................................................................................................ 37
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9.7. Motor parameters .................................................................................................. 39
9.8. IN/OUT parameters ............................................................................................... 41
9.9. Connectivity parameters ........................................................................................ 42
10. Constant pressure operation ........................................................................................... 43
10.1. Introduction ......................................................................................................... 43
10.2. The pressure tank ............................................................................................... 43
10.3. Electrical connections .......................................................................................... 44
11. Fractioning of the pumping system .................................................................................. 44
11.1. Introduction. ........................................................................................................ 44
11.2. Variable speed pumping group with two or more pumps in COMBO. ....................... 45
11.2.1. Principle of cascade operation. .................................................................. 45
11.2.2. Synchronous operating principle. ............................................................... 45
11.2.3. Electrical connections. ............................................................................... 46
11.2.4. Programming the master unit. .................................................................... 46
11.2.5. Programming of slave units. ...................................................................... 47
11.2.6. Automatic master replacement .................................................................. 47
12. Operation at constant differential pressure ....................................................................... 48
12.1. Introduction ......................................................................................................... 48
12.2. Electrical connections .......................................................................................... 48
12.3. Programming ...................................................................................................... 49
13. Alarms ........................................................................................................................... 49
14. Warnings ....................................................................................................................... 53
15. EC Declaration of Conformity .......................................................................................... 56
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1. Introduction
1.1. Purpose of the manual
The purpose of this manual is to provide users with detailed information on the installation, operation,
and maintenance of the product, paying particular attention to safety regulations.
WARNING
Read the manual carefully before installing and using the product.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
NOTE
Keep the manual in a protected place near the installation and easily accessible for con-
sultation. A digital copy of this manual may be downloaded from the manufacturer's web-
site or by scanning the QR code on the product itself.
1.2. Product presentation
PSDrive is a device for the control and protection of pumping systems based on the variation of the
pump supply frequency. It may be applied to both new and old systems, thus ensuring:
• energy and economic savings
• simplified installation and lower system costs
• extension of system life
• improved reliability
PSDrive, when connected to any pump on the market, it manages its operation in order to keep a cer-
tain physical quantity constant (pressure, differential pressure, flow rate, temperature, etc.) as the con-
ditions of use change. In this manner, the pump, or the pump system, is operated only when and as
much as it is needed, thus avoiding unnecessary energy waste and extending its life. At the same time
the device is able to:
• protect the motor from overloads and dry running
• implement soft starts and soft stops to increase system life and reduce absorption peaks
• provide an indication of the current consumption and the supply voltage
• record the operating hours and, based on these, the errors and faults reported by the system
•
• connect to other devices to realize combined operation
Appropriate output filters, available upon request, allow for reducing the dangerous overvoltages that
are generated in very long cables and, therefore, make the device optimal also when controlling sub-
merged pumps.
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2. Safety
2.1. Symbols
TIP
This symbol indicates a TIP or recommendation.
NOTE
This symbol indicates a NOTE or an indication or concept to be emphasised.
CAUTION
This symbol indicates CAUTION, thus an indication which failure to respect can lead to
minor or moderate damage.
WARNING
This symbol indicates a WARNING, thus an indication which, in the event of non-compli-
ance, may lead to serious, even fatal damage to persons or things.
DANGER
This symbol indicates an ELECTRICAL HAZARD, which if not avoided will result in death
or electrocution.
2.2. Qualified personnel
WARNING
The installation, use and maintenance of the product are strictly for qualified personnel
who have undergone appropriate training. Any use by unqualified personnel must be car-
ried out under the approval, responsibility, and close monitoring of the latter.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
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WARNING
Failure to comply with the instructions may lead to loss of warranty.
WARNING
Keep out of the reach of children.
2.3. Safety warnings
WARNING
During installation and use of the product, comply with the general safety regulations,
working in a clean, dry environment, free of hazardous substances and using the appro-
priate accident prevention tools (gloves, helmet, goggles, shoes, and whatever else is
necessary).
WARNING
The product is suitable for installation in industrial environments. In case of installation in
a residential environment, it is recommended to adopt all the safety precautions required
by local regulations.
WARNING
The unsuitable use of the product, non-original spare parts or tampering with the hard-
ware and/or firmware of the product may lead to serious damage to property or persons
in addition to the loss of warranty. The manufacturer waives all liability due to the improp-
er use of its products.
WARNING
Before commissioning the product, ensure that the installation is safe and in accordance
with local regulations.
WARNING
Comply with the provisions to meet EMC requirements.
WARNING
Use cables of the appropriate type and cross-section according to the electrical charac-
teristics of the load, the ambient temperature and local regulations.
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WARNING
Any insulation tests may only be performed in accordance with the manufacturer's in-
structions. Failure to do so may result in damage to the unit.
CAUTION
Electronic boards and components may be damaged by electrostatic discharge. We
therefore, recommend to don't touch the components.
CAUTION
Take care during installation and electrical connection that no foreign bodies enter into the
device.
DANGER
During the entire period in which the device is powered, regardless of whether it is operat-
ed or remains in stand-by (digital shutdown), high voltage is present inside the device and
at the input and output terminals.
DANGER
The device, previously in stand-by condition, may suddenly start up following the reset of
an alarm or changed system conditions. This may result in serious mechanical and elec-
trical danger to the operator who, upon seeing the device stopped, may have intervened
on it, on the load or on the system in which it is installed.
DANGER
Disconnect the device from the power supply, check that the load is completely stopped,
and wait at least 15 minutes before working on it or on the load applied to it.
DANGER
If the motor is of permanent magnet type, the device may be energised by the passive
rotation of the motor. In this case, it is recommended to disconnect both the power supply
and the load before working on the device itself.
DANGER
Ensure that the device is fully closed and all fixing screws are properly tightened before
supplying power. Do not remove the protective parts for any reason while the device is
powered on.
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DANGER
It is recommended to install the appropriate protection devices upstream of the device,
such as a circuit breakers, fuses and a residual current device (RCD).
DANGER
Make sure that the device and the loads connected to it are properly grounded with the
appropriate connection terminals before commissioning.
Ensure that the grounding system is compliant and refer to local regulations for grounding
devices.
Each load must be fitted with its own earthing cable, the length of which must be as short
as possible. Do not make interconnected grounding connections.
Leakage currents may exceed 3.5 mA. It is recommended to use the reinforced ground
connection if necessary.
CAUTION
During device operation, some surfaces may reach high temperatures that may cause
burns upon contact with skin. Be very careful when touching the device!
Avoid contact with flammable products.
WARNING
Do not place any interrupting or switching devices between the inverter and the load. In-
terruption or switching during motor operation may cause serious damage to the device.
WARNING
Do not perform insulation tests on the load or power cable without first disconnecting
them from the device.
2.4. Acoustic emission
The device has a noise emission:
< 65 dB at a distance of 1 meter with the cooling fans at maximum speed.
2.5. Certifications
The product has the following certifications:
• CE
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3. Maintenance
3.1. Maintenance
WARNING
Before carrying out any work on the device, read the chapter carefully Safety [6] reported
in the manual.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
WARNING
Failure to comply with the instructions may lead to loss of warranty.
The device requires the following maintenance:
Intervention Interval
Check that the unit is properly cooled, that the fans are functioning and that the cooling surfa-
ces are clean
Every 12 months or in the pres-
ence of a temperature alarm
Check for alarms Every 12 months
Check the correct tightening of the power terminals Every 12 months
Verification of the maintenance of the degree of protection (ingress of dust or water) by check-
ing the tightening of the screws in the mechanical closing parts, checking the gaskets, check-
ing the cable glands.
Every 6 months
3.2. Warranty
The warranty conditions may be found in the sales documents. Contact your dealer for more informa-
tion.
3.3. Spare parts
The manufacturer provides spare parts for the device. Contact your dealer for more information.
WARNING
It is recommended to use only original spare parts.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
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WARNING
Failure to comply with the instructions may lead to loss of warranty.
3.4. Disassembly and repair
If it is necessary to disassemble and repair the device, it is recommended that the safety instructions be
strictly observed.
WARNING
The installation, use and maintenance of the product are strictly for qualified personnel
who have undergone appropriate training. Any use by unqualified personnel must be car-
ried out under the approval, responsibility, and close monitoring of the latter.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
WARNING
Failure to comply with the instructions may lead to loss of warranty.
3.5. Disposal
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 may have po-
tential harmful effects on the environment and on human health due to certain substances present with-
in. Illegal or incorrect disposal of the product is subject to severe administrative and/or criminal penal-
ties.
4. Transport and storage
4.1. Transport
Avoid subjecting the product to severe shocks or extreme weather conditions during transport. The
packaging must remain dry and at a temperature between -20°C (-4°F) and +70°C (+158°F). Do not
stack packages without first checking feasibility with the manufacturer.
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TIP
It is advisable to always indicate FRAGILE on the packaging
4.2. Inspection on delivery
Check upon receipt of the product:
• the integrity of the packaging
• the integrity of the content
• the presence of all components
In case of problems, notify the forwarder immediately.
WARNING
The manufacturer declines all responsibility for damage to the product due to transport
4.3. Handling
The product must be handled by hand or using suitable lifting equipment in relation to its weight and the
regulations in force.
If necessary, use dedicated handling equipment (cranes, ropes, trolleys), using the lifting points provi-
ded in the product.
During handling it is recommended to:
• Handle with care
• keep away from suspended loads
• always wear accident prevention equipment
• be careful not to damage electrical cables
Do not handle the product using electrical cables as lifting gear.
WARNING
Failure to follow the instructions may result in damage to the product, the system in which
it is installed and, in the worst cases, damage to property or persons with even fatal con-
sequences.
4.4. Storage
The product must be stored in its packaging in a dry place, without sudden changes in humidity and
temperature and protected from mechanical (weights, vibrations), thermal and chemical agents.
The temperature of the storage environment must be between -20°C (-4°F) and 70°C (+158°F) with a
maximum relative humidity of 85% (non-condensing).
If the product remains in stock for more than 24 months from the manufacturing date shown on the
packaging, it is necessary to check the mechanical integrity of its parts and supply power to it at least
once every 12 months.
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If the product is put back into storage after it has been used, it is advisable to contact the manufacturer
for further information on storage.
5. Technical features
5.1. Technical Data
Electrical specifications by model:
Model Vin +/- 15%
[VAC]
Max V out
[VAC]
Max I
in [A]
Max I
out [A]
Typical
motor P2
[kW]
Maximum
efficiency
[%]
Size
PSDrive 11 3 x 380 - 460 3 x Vin 3,7 4 1,1 96 1
PSDrive 22 3 x 380 - 460 3 x Vin 5,4 6 2,2 96 1
PSDrive 40 3 x 380 - 460 3 x Vin 8 9 4 96 1
PSDrive 55 3 x 380 - 460 3 x Vin 13,5 14 5,5 97 2
PSDrive 75 3 x 380 - 460 3 x Vin 17,5 18 7,5 97 2
PSDrive 110 3 x 380 - 460 3 x Vin 24 25 11 97 2
PSDrive 150 3 x 380 - 460 3 x Vin 29 30 15 97 2
PSDrive 185 3 x 380 - 460 3 x Vin 36 38 18,5 97 2
PSDrive 220 3 x 380 - 460 3 x Vin 42 44 22 97 2
General electrical specifications:
Power supppy frequency 50 - 60 Hz (+/- 2%)
Voltage unbalance between the power supply phases +/- 2%
Maximum output frequency 300 Hz
EMC compliance EN61800-3 C1 for single-phase models, C2 for three-phase
models
Energy efficiency class (according to EN61800-9-2) IE2
Ambient specifications:
Relative humidity of the operating environment 5 - 95% non-condensing
Working environment temperature 10°C (14°F) to 60°C (140°C)
Maximum ambient working temperature at nominal load 40°C (104 °F)
Power derating above maximum temperature -2.5% each °C (-1.4% each °F)
Maximum altitude at nominal load 1000 m (3280 ft)
Power derating beyond maximum altitude - 1% per 100 m (328 ft)
Mechanical Specifications:
Degree of protection IP66 (NEMA 4X)
Resistance to vibrations EN60068-2-6:2008, EN60068-2-27:2009, EN60068-2-64:2008,
WARNING
Protect the device from direct exposure to sunlight and weather.
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5.2. Dimensions and weight
39
248
337 mm
97 mm33
211 mm
150 27
76 114 mm
Size Maximum weight [kg]
1 2,5
2 10
5.3. Cable entry
Cable gland Tightening torque
[Nm]
Cable diameter
[mm]
Size
1
Size
2
PSDrive 185 , PSDrive 220
M12 1,5 3,5-7 3 6 6
M16 3 5-10 - 2 2
M20 6 7-13 2 - -
M25 8 10-17 - 2 -
M40 13 19 -28 - - 2
6. Mechanical installation
WARNING
Read the safety chapter carefully before continuing.
6.1. Installation environment
WARNING
The environmental specifications stated in the technical data of the product must be strict-
ly adhered to.
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WARNING
Do not install the device in environments with risk of explosion, flooding, or the presence
of flammable fluids or solids. Ensure sufficient ventilation in the room.
Refer to local regulations when selecting the appropriate installation location.
WARNING
The degree of protection of the device is only ensured if, at the end of the installation, the
cover screws and the cable glands have been properly tightened. Close the holes of un-
used cable glands with the appropriate plugs.
Protect the device from direct exposure to weather and sunlight.
Do not leave the device installed without cover or with the cable glands open, even if not
connected to the power supply. The infiltration of dust, water or humidity may irreparably
damage the device.
WARNING
To ensure continuity of operation, the device is able to gradually and automatically reduce
performance before shutting down due to over-temperature. However, prolonged opera-
tion above the rated temperature leads to a reduction in the life of the device.
6.2. Cooling
The device is cooled primarily by forced air circulation through the heat sink element.
In addition to the heat sink, the device also uses the remaining surfaces to cool itself. It is therefore nec-
essary to ensure sufficient space around the device during installation.
In particular, the suction and discharge side of the heat sink must have at least the following distances
from other surfaces:
• 150 mm for current ratings up to 18 A
• 200 mm for current ratings up to 30 A
• 250 mm for current ratings up to 44 A
On the other sides, it is recommended to maintain a minimum distance of 100 mm to allow for cooling
and to make installation and maintenance operations easier.
During operation, the surfaces of the device may become so hot that burns may occur. It is advisable not
to touch.
In the case of installation inside electric cabinet, it is necessary to guarantee the appropriate air flow for
the heat dissipation of all the components. The heat released by the device may be calculated from its
conversion efficiency.
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WARNING
Do not place any heat-generating elements (outlet filters) on the suction side of the de-
vice. Otherwise, dangerous overheating may occur.
6.3. Mechanical assembly of size 2 devices
The size 2 devices are equipped with a quick connection system that allows to make both power and
signal electrical connections on the fixed part, called "base", while the mobile part, called "power", is
applied later.
This allows to work easily during electrical connections without running the risk of damaging the power
part. It also facilitates quick power replacement in case of failure without the need to remove connec-
tions.
To open the device, please follow the instructions shown in the figure and proceed with caution.
In size 2 devices, the earth connection between the base and the power is made by means of four met-
al pins on the power side that engage into four special holes on the base with spring contacts. At the
same time these metal pins serve as a guide for a correct coupling between the base and the heat sink.
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DANGER
Be careful not to damage or remove the four metal pins, as this will not only compromise
the mechanical coupling between the base and the power, but also the ground connec-
tion.
6.4. Motor on-board mounting
The device may be installed in place of the motor terminal cover in both horizontal and vertical posi-
tions. It is necessary to check the compatibility of fixing the base of the device to the motor case with
the motor manufacturer.
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The seal on the base of the device provides protection against the access of water and dust. It is rec-
ommended to drill the gasket only at the level of the four fixing holes to the motor case. It is possible to
use the same screws and washers with which the terminal cover was fastened to the motor case.
Please refer to the following instructions when attaching the device to the motor.
DANGER
At the end of the installation, check for ground continuity between the base of the device
and the motor casing.
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On-board mounting for size 1 devices
63
63
73
73
5.5
65
65
60
4.5
U
V
W
P.E.
12
34
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On-board mounting for size 2 devices
71
(max 100)
71 (max 100)
100
100
65
65
5.5
132
132
75
116
12
34
6.5. Wall mounting
The device is mounted to the wall by means of a special metal bracket available upon request.
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