venotec Abyzz A400 IPU User manual

Operating Manual
A400 IPU

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© 2020 venotec GmbH
venotec GmbH
Am Nordkreuz 36
26180 Rastede
Deutschland
www.venotec.de
Any claims against venotec in relation to the products described in this manual shall
be handled exclusively as per the guarantee conditions of the manufacturer. The
product specifications may deviate from the information in this manual due to technical
improvements and innovations.
Valid as of: 28.05.2020!
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Table of contents
Page
Preface
4
Scope of delivery
5
Function descriprion
6
Warnings
7
Proper use and general information
8
Installation of driver
9
Installation of pump
10
Commissioning
11
Run-in phase
12
Description of control elements
13
Operation
14
Maintenance
17
Guarantee
24
Troubleshooting
26
Disposal
27
Technical data
28
Dimensions
29
Materials
30
Spare parts list
31
Flow charts
32
Declaration of conformity
33
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Preface
Thank you for buying an Abyzz pump! By buying this powerful product, you have
acquired a highly efficient, fully variable pump that was developed and manufactured
in Germany to meet the most stringent quality and performance requirements. This
manual aims to help you to start using the product and to make the required settings.
In order to reap the benefits of this product for as long as possible, please read this
manual carefully and observe our recommendations.
Should the quality of the product not meet your expectations, please contact the
dealer who sold you the pump or contact us directly. We recommend that you use the
provided form to register your product with us so that we can provide you with the best
possible service. Please make sure that the serial number on your product remains
legible and be ready to provide us with this number if asked.
Legend
This symbol indicates particularly important information.
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Scope of delivery
1 Abyzz A400 pump with 3m or 10m cable
1 Abyzz A400 driver incl. mounted power cord (1.5m)
1 Registration form!
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Functional Description
The heart of the Abyzz pumps is a sinusoidal three-phase synchronous motor. The
efficiency of the engine is over 90%, making it one of the most efficient engines. The
integrated bearing rinse offers optimum protection against calcification and ensures
low-maintenance operation.
The processed materials are designed for a long service life and meet the highest
requirements and quality standards. The products were developed and manufactured
in Germany. That's our understanding of:
„Made in Germany“
The electronic control offers optimal operating characteristics. These include in
particular:
-Variable speed range (0.0 - 100.0%)
-Precise speed adjustment in steps of 0.1%
-Integrated programming to generate waves, bursts and random flow patterns,
with additional BOOSTMODE to override actual programming (MCFS - Menu
Controlled Flow Sequencer)
-Comprehensive safety functions, such as dry run warning, temperature alert,
overcurrent protection, speed zero alert)
-Soft startup
-Auxiliary port for peripheral devices (e.g. interfacing to external controllers)
-High quality lockable IP65 motor cable connector
-Low-noise operation
-Pump cable 3 or 10 meters (extension with Abyzz Range Extender possible)
-Display color changeable
-Splash water protected driver (IP65)
-Wide range input with active power factor correction
-Optimized heat sink design
-Child-proof lock of operations controls
-High durability
-Low thermal power loss (extra low heat transfer into the water)
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Warnings
-Always disconnect the mains plug before working on the pump!"
-Attention high voltage: An opening of the electronics (Abyzz driver) is
prohibited and only to be carried out by the manufacturer!"
-Never disconnect the motor supply line from the driver during operation!"
-Only connect clearly associated parts with each other!"
-Keep the leads, connectors and drivers dry and protect the components
from damage."
-Do not work with wet hands on the wiring or on the driver."
-Operate the product only when there are no persons in the water or persons
in contact with the water."
-Inspect the product for possible damage and never use a visibly damaged
product."
-Only connect Abyzz devices to suitable, standard-compliant sockets with
earthing contact, which are protected by a residual current device (RCCB).!
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Intended use and general instructions
The product is suitable for pumping liquids (sea water, fresh water,
brackish water, chlorinated water and other non-aggressive liquids) at a
temperature of + 2 ° C to + 40 ° C. A list of the parts in contact with the
medium to be pumped can be found in the appendix, for non o.a.
Media please ensure the compatibility with the specified components
before use.
The product can deliver both clear and polluted water up to a particle size of 1mm.
When used in dirty water, regular cleaning and the use of a pre-filter to protect the
pump are required. Especially the internal flushing channel has to be cleaned.
Abrasive ingredients increase wear - damage resulting from this is excluded from the
warranty.
The pump is not self-priming and must therefore always be mounted below the water
level.
Please always observe the generally applicable national and international regulations
during installation.
The maximum working pressure must not exceed 2.5 bar.
Prior to storage, the product must be thoroughly cleaned with fresh water and suitable
cleaning agents (such as Abyzz Pump Cleaner), otherwise residues may accumulate
in the pump.
When using, please make sure that the intake duct is adequately protected, otherwise
animals or objects will get into the pump to avoid damage.
When laying piping, make sure there is sufficient compensation for temperature
fluctuations in the pipe sections.
Use sufficient pipe diameter, we recommend minimum diameter of 50mm at the
suction and 40mm at the pressure side.
The product has a dry run warning. If the pump is dry running over 50% of speed the
controller gives an alarm. The pump has to be switched off immediately to make sure
no permanent damage is done. The user is responsible for the pump not running dry.!
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Installation of driver
Mounting:
The product must not be installed outside. The mounting wall must be dry and
protected from splashes of water and damp. A suitable power outlet should be
available at an appropriate distance. Please keep a distance from ceilings of at least
20cm.
Wiring:
When laying the wires, make sure that no drips of water can reach the electronics via
the wires.
Please note that due to the driver switch-on current, you must not switch on multiple
drivers on the same fuse at the same time. Do not use multi-socket strips and do not
exceed the permitted connected load of your supply line under any circumstances.
Ambient temperature and cooling:
The product can be used at ambient temperatures of 2 ° C to + 40 ° C. Depending on
the required performance, the temperature protection of the driver may give a warning,
in which case better cooling is to be ensured. The driver automatically reduces power
as the temperature continues to rise. Overheating will cause the driver to switch off.
To ensure sufficient cooling, the driver should be at least 20
cm away from any other objects (walls, ceilings, cable ducts,
pipes etc.). The cooling element must not be covered. We
recommend that you do not expose the driver to any additional
heat source (heating system, lighting, sunlight) and ensure
sufficient ventilation if using it in cupboards or on racks.
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Electrical connection:
The Abyzz driver requires a voltage of 100 ... 240V / 50 ... 60Hz.
The connection must be made to a suitable, properly installed earthed socket, which is
protected by a circuit breaker in accordance with DIN VDE 0100T739 (residual current
circuit breaker). We recommend that you do not connect more than one controller to a
supply line (16A fuse).
The driver has a fuse for fire protection inside. This is to be exchanged exclusively by
the service. Inside the device are no user-servicable elements.
Installation of pump
The Abyzz pump can be operated submerged to a depth of 2 meters or in a dry
position.
The mounting position has to be horizontally as a standard.
For all other possible mounting positions the user is responsible for the safe operation
of the pump. It has to be made sure, that the pump is always filled with the medium
completely. Abyzz cannot be held responsible for damages to the pump, which result
from inappropriate mounting other than the recommended standard.
Make sure there is a free, unobstructed water supply at the connection line of the
suction side and protect the inlet with a suitable sieve to keep coarse particles (sand,
threads from filter wadding or similar) away from the impeller. When piping you should
make sure to install at least 50cm of straight piping on the suction side, so that the
water can flow in straight. These measures optimize the efficiency and ensure a clear
noise reduction. For the highest possible efficiency, please use sufficient pipe
diameters for larger pipe systems (Recommended: suction side 50mm (2"), pressure
side 40mm (1 1/4“)).
When using adhesive fittings, be sure to use an adhesive suitable for the material
(PVC).
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Installation outside a sump:
Look for a suitable place where only a few power losses occur due to angles or bends
and cable routing. If possible, always use bends instead of angles and connect the
pump as far as possible without mechanical stress in order to avoid vibrations on
connection lines, which could lead to leaks in the course of time due to screw
connections or adhesions.
With these measures you have made optimal arrangements for a trouble-free and
quiet operation.
Installation inside a sump:
Place the pump in the filter sump and connect it to your piping system as mechanically
as possible without tension to avoid noise and vibration.
Commissioning
After proper installation, the Abyzz pump can be put into operation. To do this, connect
the motor connection cable to the driver. The plug is coded and can only be connected
in one position. The plug used meets the highest requirements for tightness and
safety. Screw the plug to ensure these characteristics. Connect the Abyzz power cable
to the grounded receptacle.
The LED is flashing. You can start and stop the pump in any mode (except external
controls) by pressing the Start / Stop button.
If the pump suddenly runs dry with more than one-third of your power, a dry-running
warning is activated. This switches off the pump and reports an error ("DRYRUN!" And
acoustic signal). After a few seconds, the pump starts up again automatically and,
once the dry run has been completed, resumes operation. Several start attempts are
started. If the dry run persists, the pump stops for self-protection and must be
restarted manually.
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Run in phase"
Despite very high precision, minimal manufacturing tolerances can not be avoided in
the manufacture of the bearings. This condition may generate noise during the start-
up phase of the pump. However, this is normal and does not pose a long-term
problem. During post-fabrication testing, all pumps are tested for performance,
concentricity and noise. The start-up phase can take a few days, depending on the
operating mode. The following figure clearly shows the difference between a brand
new bearing (left) and a bearing after the break-in phase (right). After the break-in
phase, these operating noises will almost disappear.
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new
after use

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Description of control elements
Display:
The display informs you about the operating status of the pump. The display goes into
a sleep mode after 3 minutes for maximum life and lowest power consumption.
Pressing a button turns the display on again. The overview changes every 2 seconds
as follows and displays the operating data such as energy use, mode of operation,
speed setting etc.
Die Anzeige der ersten Zeile ändert sich von „Stopped“ zu „Running“, wenn Sie die
Drehzahl erhöhen und die Pumpe einschalten:
LED:
The LED indicates a correct function via a flashing signal.
Keyboard:
The keyboard allows direct operation and in the menu the programming of the pump.
In the operating mode "Permanent" (delivery state) you can start or stop the motor
with the "Start / Stop" button and change the speed with the "up" and "down" buttons.
If you want to store the new speed permanently, press the "M" key and the last value
set will be retained. The "Start / Stop" setting is automatically saved, so that the pump
automatically returns to its original operating mode after a loss of operating voltage. If
you want to enter the menu to display operating data or to program the pump, press
the "M" key.
You get to the menu and the current operating mode is displayed. Press the "up" and
"down" keys to navigate in the menu. The current software status, operating hours and
operating mode are displayed consecutively.
The contrast of the display can be adjusted in the corresponding overview by holding
down the "Start / Stop" button and pressing the "up" or "down" buttons.
If you would like to change the operating mode, press the "Start / Stop" key when the
operating mode is displayed. You can now set the operating mode with the "up" and
"down" keys. The different operating modes are:
- Permanent: The pump runs permanently at a fixed speed.
- Wave: The pump changes in adjustable times between two fixed speeds.
- Random: The pump changes the speed within an adjustable time within a set
minimum and maximum value
- Random 2: Same as Random mode, but also the time between changes is chosen
randomly.
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- BOOST MODE: When the BOOST MODE is activated, the pump generates a
separate interval regardless of the programmed operating state, e.g. to stir up dirt.
If you have selected the operating mode, press "Start / Stop". You will then be asked
to enter the corresponding data (minimum and maximum power, time interval). Finally
confirm each setting with "Start / Stop". Finally, the settings are saved automatically
and you get back to the overview.
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© 2020, Abyzz by venotec GmbH
Running at:30% AuxMod:None
Running at:30% ABYZZ A400IPU
Running at:30% Power:80W
Running at:30% Boost mode: OFF
Running at:30% Saving 20,28 /M
Running at:30% Mode:Perm
Mode:Permanent
(UP/DOWN/SS)
Min:0.0%
(UP/DOWN/SS)
Max:0.0%
(UP/DOWN/SS)
RND Time:0.50s
(UP/DOWN/SS)
Min:0.0%
(UP/DOWN/SS)
Max:0.0%
(UP/DOWN/SS)
Min.Time:0.50s
(UP/DOWN/SS)
Max.Time:0.50s
(UP/DOWN/SS)
Min:0.0%
(UP/DOWN/SS)
Max:0.0%
(UP/DOWN/SS)
Mode:Permanent
Speed:450rpm S↕
Operating for:
30h32m24s ↕
LCD Contrast:
20 S↕
Boost mode: OFF
S↕
Energy cost /kWh
25ct S↕
Used Energy:
0.56kWh ↕
Boost Power:
90% S↕
Boost time:
20s S↕
Boost every
24 hours S↕
Running at:30% Status:OK
Running @ 30.0% Temp L:26C/R:28C
0
3
4
5
6
Feeding Time:
30s S↕
7
Factory Reset:
NO S↕
8
LCD Background:
Abyzz Orange S↕
9
10
Dynamic Control:
100% S↕
11
Speed Zero Alert
OFF S↕
12
AuxMod Settings:
No Module S↕
13
Child Lock:
OFF S↕
14
Display Service
Info S↕
15
1
Firmware: V3.2.1
0528b ↕
2
41
Boost mode:
ON ↕
40
42
43
20
Mode:Wave
(UP/DOWN/SS)
20
21
22
23
24
20
Mode:Random
(UP/DOWN/SS)
60
61
62
Mode:Random 2
(UP/DOWN/SS)
20
70
71
Feeding Break:
29s M↕
50
1:0000:0000:0000 0032:0032:0000-M
100
2:0000:0032:0000 0000:0000:01-M
3:00:64:012:0000 00000003:0000 -M
4:A400IPU:321 0528b U=264.2V-M
5:G07E0D00001 T0000M0000S0000M
101
102
103
104
Error:0014 NO SYNC M=OK
250
Abyzz IPU Driver Programming Reference Guide Firmware V3.2.1
M
↑+↓
Error
Condition
SS
Usage
Use „UP“ and „DOWN“ buttons to navigate within menus or to change values. The number on the top right of each display screen is the menu item number. Menu item 0 (zero) is the overview, the lower line will automatically scroll through different informations. Values like e.g. LCD Contrast are modified by using the „UP“ and „DOWN“ buttons while keeping „Start/Stop“ pressed.
↑+↓
Press „UP“ and „DOWN“ simultaneously
M
Press „M“ button
SS
Press „Start/Stop“ button
SS
SS

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Maintenance
Danger - strong magnetic field !
-Danger to life for people with pacemakers!
-Do not bring rotors near pacemakers, credit cards, data carriers or similar items
that are sensitive to magnetic fields!
-Danger of injury due to clamping!
-Do not place metal parts near the rotor!"
"
Abyzz pumps are virtually maintenance-free when used properly."
"
If the flow rate decreases, dirt particles may have caught in the impeller and
must be removed. Even slight vibrations can be an indication of contamination
of the impeller."
"
For cleaning, disconnect the pump head from the motor (screws on the front,
see illustration) and clean the impeller."
"
If disassembly of the impeller is necessary, loosen the retaining screw with a
suitable Allen key and pull the impeller off the shaft. This screw is made of
titanium and must not be replaced by another screw!
If further disassembly is necessary, please contact the service.
O-rings and rubber parts are subject to unavoidable aging and should be replaced if
necessary. These parts can be obtained by mentioning the part number as spare
parts.
Carefully place the rotor in the engine block and push the assembly into the bearing
seat until the bearing shield is flush with the flange.
Screw the pump head back to the engine block, tightening the screws crosswise to
apply even pressure to the O-ring seal and ensure tightness!
The pump should be decalcified at regular intervals in installations that are constantly
and intensively limed (eg stone coral pools). We recommend this process at least
once a year.!
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!
Fig. 1: Pump with pump head (A200)
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!
Fig. 2: Loosening of impeller components (rotor unit)
!
Fig. 3: Disassemly of impeller components (rotor unit)
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!
!
Fig. 4 a/b: Removed impeller component and close-up of bearing (left)
If you need to disassemble the impeller wheel, use a suitable Allen wrench to undo the
retaining screw (fig. 5) and pull the impeller wheel off the shaft. This screw is made of
titanium and must not be replaced by another screw.
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!
Fig. 5: Disassembly of impeller wheel
When assembling the pump (fig. 6 and 7), please make sure that the guide lug (A) fits
into the corresponding opening on the magnetic impeller plate and that the flushing
opening (C) is in the right place. Make sure that the bearing (B) is in the correct
position inside the motor. If necessary, push the bearing into position with a blunt
object (e.g. the handle of a screwdriver). Make sure that the O-ring for the vibration
isolation and sealing (fig. 10) is in the right position before reassembling the pump.
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