Xylem hydrovar hv 1.1 User manual

Operating Instructions
HV 1.1-HV 1.2
Incl. RS 485 - interface
771079212 MANUAL HV1_1-1_2-EN ENGLISH
V 2012/03A

3
Index
1 IMPORTANT SAFETY INSTRUCTIONS ............................................................................................5
2 SYSTEM DESIGN...........................................................................................................................7
3 PRESSURE TANK ..........................................................................................................................8
4 TRANSDUCER ...............................................................................................................................9
4.1 PRESSURE TRANSMITTER SERIES PA-21 R ..........................................................................................9
4.2 DIFFERENTIAL PRESSURE TRANSMITTER SERIES PD 39 M .....................................................................10
5 TECHNICAL DATA - FREQUENCY INVERTER AND GENERAL DATA..............................................11
5.1 DIMENSIONS ................................................................................................................................12
6 HYDROVAR MOUNTING .............................................................................................................13
6.1 MOUNTING THE HYDROVAR ON THE PUMP .......................................................................................13
6.1.1 Included components...........................................................................................................13
6.1.2 Mechanical mounting ..........................................................................................................14
6.1.3 Mounting the thermistor (4) ................................................................................................17
6.1.4 Mounting of the pressure transducer..................................................................................18
6.2 ELECTRIC INSTALLATION AND WIRING..................................................................................................19
6.2.1 Means of protection ............................................................................................................19
6.2.2 Wiring the Hydrovar to the motor........................................................................................19
6.2.3 Control.................................................................................................................................22
6.2.4 Terminals .............................................................................................................................22
6.3 FRONT PLATE ................................................................................................................................24
7 OPERATION WITHOUT EXTERNAL PROGRAMMING DEVICE.......................................................25
8 POSSIBLE INDICATIONS OF THE LED ON THE HYDROVAR ..........................................................26
9 OPERATION IN THE MAIN MENU................................................................................................27
10 CONNECTING THE EXTERNAL PROGRAMMING DEVICE TO THE HYDROVAR .............................28
11 TYPICAL APPLICATIONS..............................................................................................................29
11.1 SETTING SINGLE PUMP CONSTANT PRESSURE .......................................................................................29
11.2 SINGLE PUMP -PUMP PROTECTION ....................................................................................................30
11.3 SINGLE PUMP –SYSTEM CURVE COMPENSATION ..................................................................................32
11.4 ENTERING COMPENSATION VALUES ...................................................................................................33
MULTIPLE PUMP CONSTANT PRESSURE AND SYSTEM COMPENSATION....................................................................35
12 SETTINGS AT THE INVERTERMENU.............................................................................................40
13 SETTINGS AT THE SUBMENU-PARAMETER .................................................................................41
13.1 PRESSURE CHANGE.........................................................................................................................41
13.2 AUTO START .................................................................................................................................41
13.3 MODE.........................................................................................................................................42
13.4 CONTROL RESPONSE.......................................................................................................................42
13.4.1 Dimension unit ...................................................................................................................42
13.5 SUBMENU INVERTER .......................................................................................................................42
13.5.1 Maximum Frequency...........................................................................................................42
13.5.2 Minimum frequency............................................................................................................43
13.5.3 Boost ..................................................................................................................................43
13.5.4 Operation of the minimum frequency.................................................................................43
13.5.5 Delay time for Fmin.............................................................................................................43
13.6 SUBMENU CONTROLLER ..................................................................................................................44
13.6.1 Window - %........................................................................................................................44
13.6.2 Ramp Hysteresis..................................................................................................................44

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13.6.3 Fast acceleration time .........................................................................................................44
13.6.4 Fast deceleration time.........................................................................................................44
13.6.5 Slow acceleration time........................................................................................................44
13.6.6 Slow deceleration time .......................................................................................................45
RAMP WINDOW ......................................................................................................................................45
13.6.7 Compensation Frequency....................................................................................................45
13.6.8 Lift-Intensity........................................................................................................................46
13.7 SUBMENU MULTICONTROLLER ..........................................................................................................47
13.7.1 Lift Value ............................................................................................................................47
13.7.2 Fall Value ............................................................................................................................48
13.7.3 Release – Follow up pump ..................................................................................................48
13.7.4 Switch Interval ....................................................................................................................49
13.8 SUBMENU RELAY ...........................................................................................................................49
13.8.1 Relay Configuration ............................................................................................................49
13.8.2 Start frequency of the slave pump......................................................................................49
13.8.3 Stop frequency of the slave pump ......................................................................................49
13.9 SUBMENU SENSOR.........................................................................................................................50
13.9.1 Sensor – Adjust ...................................................................................................................50
13.9.2 SensorMax-Adjust...............................................................................................................50
13.10 SUBMENU TEST-RUN ......................................................................................................................50
13.10.1 Start of manual test run....................................................................................................50
13.10.2 Sequence for automatic test run.......................................................................................51
13.10.3 Test Run: Frequency .........................................................................................................51
13.10.4 Test Run: Boost.................................................................................................................51
13.11 SUBMENU ERROR...........................................................................................................................51
13.11.1 Conveyor Limit..................................................................................................................51
13.11.2 Error Delay........................................................................................................................51
13.12 SET PASSWORD .............................................................................................................................52
13.13 DEFAULT SETTINGS.........................................................................................................................52
13.14 SUBMENU DIAGNOSIS.....................................................................................................................52
13.14.1 Pump Runtime ..................................................................................................................52
13.14.2 Pump Address...................................................................................................................52
13.14.3 Error memory....................................................................................................................52
13.14.4 Software Version ..............................................................................................................53
13.15 SET PASSWORD .............................................................................................................................53
14 CONTROLLER MENU (OF THE PROGRAMMING DEVICE) ............................................................53
14.1 CONTROLLER MENU CONFIGURATION .................................................................................................53
14.1.1 Automatic connection to the programming device.............................................................54
14.1.2 Software Version of the programming device.....................................................................54
14.2 SUBMENU ADDRESS........................................................................................................................54
14.2.1 Change of pump address....................................................................................................54
15 POSSIBLE ERROR MESSAGES......................................................................................................55
15.1 LOW WATER.................................................................................................................................55
15.2 OVERHEATING –MOTOR .................................................................................................................55
15.3 OVERVOLTAGE ..............................................................................................................................55
15.4 UNDERVOLTAGE ............................................................................................................................55
15.5 OVERLOAD...................................................................................................................................55
15.6 OVERHEATING OF THE HEAT SINK .......................................................................................................56
15.7 SENSOR FAULT ..............................................................................................................................56
15.8 CONVEYOR LIMIT FAULT...................................................................................................................56
15.9 ADDITIONAL INTERNAL PROCESSOR ERROR MESSAGES: ...........................................................................56
16 MAINTENANCE...........................................................................................................................57
Follow the Pump Operating and Maintenance Instructions
We reserv the right to alter specifications

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1Important safety instructions
Read and follow the operating instructions
and safety instructions carefully before
starting operations! All modifications must be
done by qualified technicians!
In addition to the instructions contained in these operating instructions please pay
attention to universal safety and accident prevention regulations.
The HYDROVAR drive head must be disconnected from the power supply before any work
can be carried out in the electrical or mechanical part of the system.
Installation, maintenance and repair work may only be carried out by trained, skilled and
qualified personnel.
Unauthorised modifications or changes to the system make all guarantees null and void.
When in operation the motor can be stopped by remote control, whereby the drive head
and the motor remain under voltage. For safety reasons, the unit must be disconnected
from the power supply when carrying out work on the machinery as locking out the
equipment by switching off the release mechanism or set value cannot prevent accidental
starting of the motor.
When the drive head is connected to power supply, the components of the
power unit as well as certain components of the master control unit are also
connected to the power supply.
Touching these components seriously endangers life !
Before removing the frequency inverter cover the system must be
disconnected from the power supply. After switching off the power supply
wait at least 5 minutes before starting work on or in the HYDROVAR drive
head (the capacitors in the intermediate circuit have to be discharged by the
installed discharge resistors first).
Voltages of up to 400 volts are possible (if there are faults it can be higher).
All work carried out when the frequency inverter is open may only be
performed by qualified authorised staff.
Furthermore, care must be taken not to short circuit the neighbouring
components when connecting the external control wires and that open
cable ends which are not in use are insulated.

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The HYDROVAR drive head contains electronic safety devices which switch off
the control element in the event of faults, whereby the motor has zero current
but remains energised and comes to a halt. The motor can also be halted by
mechanical blocking. If it is switched off electronically the motor is
disconnected from the mains voltage through the electronics of the frequency
converter but is not potential-free in the circuit.
In addition voltage fluctuations, especially power failures can cause the
system to switch off itself.
Repair of faults can cause the motor to start up again.
The system may only be put into operation when it has been earthened. In addition,
equipotential bonding of all pipes must be ensured.
The operating instructions must be read, understood and followed by the operating
personnel. We point out that we accept no liability for damage and operating disorders
which are the result of non-compliance with the operating instructions.
Please
note:
High voltage tests of the inverter or the motor may damage the
electronic components! Hence bridge before the in- and outgoing
terminals L -N -- U- V-W.
To avoid incorrect metering by capacitors incorporated in the
electronic part isolate the motor from the Hydrovar Drive head.

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2System Design
The following diagrams show typical single pump and multi-pump systems using the
Hydrovar control unit. Connection can be made directly to a water supply or water
can be drawn from a break tank or well. In the case of break tanks and wells, level
switches, should be used to shut down the pumps when water is low. In the direct
connection, a pressure switch on the suction side should be used.
Single pump layout
Multiple pump Layout
(1) pump with drive head
(2) diaphragm tank
(3) distribution panel
(4) gate valves
(5) non return valves
(8) incoming pressure switch
(9) pressure gauges
(14) pressure transmitter

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3Pressure tank
A diaphragm pressure tank is used on the discharge side of the pump or pumps to
maintain pressure in the line when there is no demand. This will keep the pumps from
continuing to run. With the Hydrovar control unit, it is not necessary to have a large tank
for supply purposes. In selecting a tank, make sure it can withstand systems pressure. The
tank should have a capacity of more than 10% of the maximum system flow rate l/min of
one pump.
Ask of required certificates needed for your country!
Precharge the tank to the following:
Before checking the precharge pressure, take care, that the tank, is
pressureless (no water inside).
Solldruck / required pressure [bar]

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4Transducer
4.1 Pressure Transmitter Series PA-21 R
The sensor of this transmitter is a piezoresistive silicon pressure sensor, mounted
on a tape (TAP) freely floating in an oil chamber. The pressure is transferred to
the sensor by a separate nickel diaphragm in the oil chamber.
Specifications
Range (FS): 10 bar (other ranges upon request)
Max. pressure-Pmax: 20 bar
Class of protection : IP 67
Output signal: 0,5 – 4,5 V DC (ratiometric)
Supply: 5 VDC +/- 5 %
Operating temperature: -20...+80°C
Storage Temperature: -40...+100°C
connections:
+ VCC ⇒brown = supply voltage
+ Out ⇒white = analogue output signal
GND ⇒green = Ground
Materials:
Body: steel and brass
diaphragm: nickel
Pressure Transmitter:
Plug:

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4.2 Differential Pressure Transmitter
Series PD 39 M
The sensors of this differential pressure transmitter are two piezoresistive silicon pressure
sensors, mounted on a tape (TAP) freely floating in an oil chamber. The pressure is
transferred to the sensor by a separate steel diaphragm in the oil chamber.
Specifications
Range(FS): 4 bar differential
Over-pressure- Pmax: 16 bar single-sided
Class of protection : IP 65
Output Signal: 0,5 – 4,5 V DC (ratiometric)
Supply: 5 VDC +/- 10 %
Load Resistance: > 5 kΩ
Linearity:: ±0.20 % FS; max. ±0.5% FS
Stability: ±0.1 % FS; max. ±0.2% FS
Operating temperature: -10...+80°C
Storage Temperature: -40...+80°C
Material: Body and diaphragm: 1.4435 Stainless steel
Screw joint and cover: Steel electroplated for Emetorpipe d=8mm
Plug: mPm 193
Incl. 2m cable:
Out (white)
+ Vcc (brown)
GND (green)
Screen
P -
P +

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5 Technical Data - Frequency Inverter And General Data
HYDROVAR Hydrovar output to
the Motor
Supply Voltage (Uin) Prefuse
min.
Type Rated
output
Voltage Max.
current
Mains frequency
48-62 Hz
HV 1.1 1,1 kW 3x 230 V 4,8 A 1x 220-240 V±15% 10 Ampere
HV 1.15 1,5 kW 3x 230V 7,0 A 1x 220-240 V ±15% 10 Ampere
HV 1.2 2,2 kW 3x 230V 10,0 A 1x 220-240 V ±15% 16 Ampere
Output voltage: 3x 0...Uin VAC / 0-70 Hz
(depends on the input voltage)
Min. frequency: 0 – max. frequency
Electrical efficiency: > 95%
Protection against: Short circuit, over- and undervoltage, overheating of the
electronics (overload) and additional external protective functions
via PTC (motor temperature) and low water switch.
A mains filter is fitted to ensure interference immunity.
The HV Series frequency converter complies with the general EMC provisions and has
been tested according to the following standards:
•Disturbance voltage: EN 55011
•EMC – Immunity: EN 61000-4-3 and ENV 50204
•Electrostatic discharge: EN 61000-4-2
Ambient temperature: 5° C ... + 40°C
Storage temperature: -25° C ... + 55° C
(+70°C during max. 24 hours.)
Humidity: rH max. 50% at 40°C, unlimited
rH max. 90% at 20°C, max. 30 days per year
Condensation not permitted !
Air pollution: The air may contain dry dust as found in workshops where
there is no excessive quantity of dust due to machines.
Excessive amounts of dust, acids, corrosive gases, salts etc.
are not permitted
Altitude:: max. 1000m above sea level
At higher altitudes the max. available power has to be
reduced. Please ask the manufacturer for further details.
Class of protection : IP55

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5.1 Dimensions
HV1.1:
HV1.15,1.2:
closing cap
∅7
∅
12
Type: Weight
[Kg]
HV 1.1 2,00
HV 1.15 4,70
HV 1.2 4,70
closing cap
cable entries
cable gland

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6 HYDROVAR mounting
6.1 Mounting the HYDROVAR on the pump
6.1.1 Included components
Variant for HV1.1:
Variant for HV1.15-1.2:
mounting and distance ring
washer
screw
cable
g
land
thermistor
thermistor
cable gland
screw M5x50
mountin
g
clam
p

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6.1.2 Mechanical mounting
Variant for HV1.1
1. Remove the motor fan cover from
your 3-phase motor by removing the
mounting screws.
2. Put the mounting and distance ring
(1) between the fan cover and the
Hydrovar and fix them together with
the screw (3) by using the included
washer(2).
3. Use the fan cover screws to mount
the fan cover/Hydrovar combination
to the motor
Attention:
Don’t forget the washer between the screw and the motor fan cover!
Hydrovar
(1) mounting
and distance
ring
motor fan
cover
(2) washer
(3) screw

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Variant for HV1.15-1.2:
Gasket
Thermistor
Transducer
Connection
Motor conduit box
4 mounting clamps
Center bit
4 screw
M5x50
Don’t forget the gaskets for the 3 screws .
Ensure that there is no water on the unit before you open the cover.
Mounting:
uRemove the 3 screws from the
Hydrovar cover.
uPlace the centre bit in the
Hydrovar fan cover.
uPlace the Hydrovar fan cover on
the motor .
uHang the 4 clamps by the
Motor fan cover and mounted
with the 4 screws.
uMounted the cover with the
3 screws.

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If you use a motor with plastic fan cover, you must use
a mountingring.
Mountingring

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6.1.3 Mounting the thermistor (4)
Variant A:
Variant B:
1. Open the cover of the conduit box and remove also the terminal block inside.
2. Fix the thermistor (Variant A or B)
3. Electrical connection of the motor cables see chapter 7.3.
motor
thermistor
terminal block
rubber gasket
cover of the
conduit box
Thermistor

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6.1.4 Mounting of the pressure transducer
In the delivery of the pressure transducer there are included:
1. The transducer has an mechanical connection of G ¼”. If it is necessary put the reducer
(3/8” – 1/4”) into the pump or pipe by using included gaskets.
2. Electrical connection to the Hydrovar see chapter (6.2.4)
(1) pressure transducer
(2) gasket
(3) reducer 3/8“ – ¼“
(4) brass gasket
(4)
(1)
(2)
(3)

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6.2 Electric installation and wiring
6.2.1 Means of protection
Ask your power supply company which means of protection are required.
Applicable: AC and DC current-operated circuit breaker (FI), TN systems, protective
circuits.
When using a FI protection switch, make sure that it also releases in the event of
a DC fault, use for each Hydrovar a separate FI-switch!
6.2.2 Wiring the Hydrovar to the motor
Remove the 3 screws holding the top of the Hydrovar. Carefully lift the top, loose the earth
screw and put the Hydrovar cover aside.
Now you can see the 2 main parts
(1) control card with all terminals for the control signals and the RS485
interface
(2) main card with all power components and terminals for power supply
and motor
Note:
All installations and maintenance MUST be performed by
trained and qualified personal with proper tools!!
Warning:
In case of a failure, disconnect and lockout electrical power and wait
five minutes for capacitor discharge before servicing the Hydrovar.
Otherwise it can cause shock, burns, or death.

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6.2.2.1 Main part overview
HV1.1:
HV1.15, 1.2:
6.2.2.2 Connecting the power cables
Motor connections
main supply
connections
Cable gland (for
power supply 5-
10mm)
control card (1)
main board (2)
Cableintroduction
for motor cable (at
least 11,5mm)
Cableintroduction for control
cable (at least 5mm)
motor connections
main supply connections
control card
(
1
)
main board
(
2
)
cable introduction for
control cable