Xylem Hydrovar Installation, Operation And Maintenance Manual
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Xylem Hydrovar Installation, Operation And Maintenance Manual

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Installation, Operation,
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HVL 2.015-4.220

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  • Page 1 Installation, Operation, and Maintenance Manual HVL 2.015-4.220...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1 Introduction and Safety......................4 1.1 Introduction.......................... 4 1.1.1 Qualified personnel...................... 4 1.2 Safety............................. 4 1.2.1 Safety message levels....................5 1.3 User safety..........................5 1.4 Protecting the environment....................7 1.5 Warranty..........................7 1.6 Spare parts..........................7 1.7 EU declaration of conformity (No LVD/EMCD05)............8 1.8 EU declaration of conformity....................8 2 Transportation and Storage....................
  • Page 4 Table of Contents 6.4.1 EMC requirements......................30 6.4.2 Wiring the cables......................30 6.4.3 RFI switch........................31 6.5 AC mains and motor connection terminals..............32 6.5.1 AC Mains (power supply) connection..............32 6.5.2 Motor connection....................... 33 6.6 Control terminals....................... 34 6.6.1 Motor sensor connection...................35 6.6.2 Input for emergency basic operations..............36 6.6.3 Digital and analog I/O....................36 6.6.4 RS485 connection.......................37...
  • Page 5 Table of Contents 11.2 Example: P200 Ramp Settings..................102 11.3 Example: P330 LIFT AMOUNT..................103 11.4 Example: P500 SUBMENU SEQUENCE CNTR............104 11.5 Example: P900 SUBMENU OFFSET................105 11.6 Programming flow charts..................... 107 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 6: Introduction And Safety

    This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.

  • Page 7: Safety Message Levels

    1 Introduction and Safety 1.2.1 Safety message levels About safety messages It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards: • Personal accidents and health problems •...
  • Page 8 1 Introduction and Safety Safety equipment Use safety equipment according to the company regulations. Use this safety equipment within the work area: • Hard hat • Safety goggles, preferably with side shields • Protective shoes • Protective gloves • Gas mask •...

  • Page 9: Protecting The Environment

    • Clean-up of spills Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon. Recycling guidelines Always follow local laws and regulations regarding recycling.

  • Page 10: Eu Declaration Of Conformity (No Lvd/Emcd05)

    36100 Vicenza VI Italy 3. This declaration of conformity is issued under the sole responsibility of the manufacturer. 4. Object of the declaration: Frequency converter (variable speed drive) HYDROVAR ® electric pump in one of the following models HVL2.015-A0010 HVL4.015-A0010 HVL2.022-A0010...
  • Page 11 1 Introduction and Safety 4. Object of the declaration: Frequency converter (variable speed drive) HYDROVAR ® electric pump in one of the following models HVL2.015-A0010 HVL4.015-A0010 HVL2.022-A0010 HVL4.022-A0010 HVL2.030-A0010 HVL4.030-A0010 HVL2.040-A0010 HVL4.040-A0010 HVL3.015-A0010 HVL4.055-A0010 HVL3.022-A0010 HVL4.075-A0010 HVL3.030-A0010 HVL4.110-A0010 HVL3.040-A0010 HVL4.150-A0010 HVL3.055-A0010...

  • Page 12: Transportation And Storage

    2 Transportation and Storage 2 Transportation and Storage 2.1 Inspect the delivery 2.1.1 Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3.

  • Page 13: Transportation Guidelines

    2 Transportation and Storage Lifting diagrams HVNG-IOM_LIFTING-1_A_SC HVNG-IOM_LIFTING-2_A_SC 2.3 Transportation guidelines Precautions WARNING: • Stay clear of suspended loads. • Observe accident prevention regulations in force. • Do not damage the cables during transport; do not squeeze, bend or drag the cable. •...

  • Page 14: Product Description

    When the system is connected directly to the water supply use a low-pressure switch on the suction side. Figure 1: Single-pump system Figure 2: Multi-pump system 1. Pump with HYDROVAR 2. Diaphragm pressure tank 3. Distribution panel 4. Gate valve 5.

  • Page 15: Product Function And Use

    3.2 Product function and use Description HYDROVAR is a pump-mounted variable speed, microprocessor-based system controller. It can be mounted onto virtually any model of fan cooled motor and is simple to integrate into BMS systems with ModBus or Bacnet communication as standard.

  • Page 16: Cascade Relay

    3.4 The data plate Type definition code Figure 3: Definition code and placement Description Alternatives Brand HVL - HYDROVAR Power supply 2: 1~ 230 VAC 3: 3~ 230 VAC 4: 3~ 380–460 VAC Shaft power *10 [kW] 015: 1.5 kW (2.0 HP) 022: 2.2 kW (3.0 HP)

  • Page 17: Technical Data

    1: Standard internal display installed Other options 0: No other options installed Example Example Description HYDROVAR Power Supply: 3~ 380–460 VAC Shaft power: 7.5 kW (10.0 HP) Enclosure rate: IP 55 / Type1 Standard communication No optional cards installed Standard internal display installed No other options installed 3.5 Technical Data...

  • Page 18: Motor Thermal Protection

    3 Product Description Air pollution The air may contain dry dust as found in workshops where there is excessive dust due to machines. Excessive amounts of dust, acids, corrosive gases, salts etc are not permitted. Altitude Max. 1000 m above sea level. For installation over 1000 m above sea level, the maximum output power has to be de-rated by 1% for every additional 100 m.

  • Page 19: Dimensions And Weights

    3 Product Description The X-axis shows the ratio between Imotor actual and Imotor nominal. The Y-axis shows the time in seconds before the STC cuts off and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 20% of the nominal speed.

  • Page 20: Design And Layout

    3 Product Description HVNG-IOM_HVLB_DIMENSIONS_A_SC Figure 5: HVL2.030, HVL2.040, HVL3.030 ÷ HVL3.055, HVL4.055 ÷ HVL4.110 HVNG-IOM_HVLC_DIMENSIONS_A_SC Figure 6: HVL3.075 ÷ HVL3.110, HVL4.150 ÷ HVL4.220 Weight Models Maximum Weight HVL 2.015 ÷ 2.022 | 3.015 ÷ 3.022 | 4.015 ÷ 4.040 5,6 Kg (12,3 lbs) HVL 2.030 ÷...
  • Page 21 3 Product Description Position number Description Power board, heatsink, EMC filter Control board Cover Plastic cover HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 22: Included Mounting Components

    3 Product Description 3.9 Included mounting components Included Cable outer diameter Model components (mm) inches HVL 2.015 ÷ 2.022 | HVL 2.030 ÷ 2.040 | HVL 3.075 ÷ 3.110 | 3.015 ÷ 3.022 | 4.015 3.030 ÷ 3.055 | 4.055 4.150 ÷...

  • Page 23: Optional Components

    • Flow indicator (orifice plate, inductive flow meter) • Level-sensor Premium Card HYDROVAR Card to control up to five slave pumps and to connect additional analog and digital I/Os Wi-Fi Card HYDROVAR To connect and interact wireless with HYDROVAR HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 24: Installation

    • For wall mounting installations with long motor cables, use the output filter option to protect the motor. • Ensure that the ingress protection rating of Hydrovar (IP55, Type1) is suitable for the installation environment. CAUTION: •...

  • Page 25: Mechanical Installation

    5 Mechanical Installation 5 Mechanical Installation 5.1 Cooling • The frequency converter is cooled by means of air circulation. To protect the unit from overheating, it must be ensured that the ambient temperature does not exceed the maximum temperature stated for the frequency converter and that the 24-hour average temperature is not exceeded.
  • Page 26 7. Screws for mounting clamps 8. Plastic cover 9. Screws for plastic cover Refer to callouts in preceding image. ® 1. Fit the rubber centering pin [6] on the bottom of the HYDROVAR HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...
  • Page 27 5 Mechanical Installation NOTICE: Always use a stainless steel mounting ring if the motors fan cover is made of plastic. 2. Center the unit on the motor fan cover [3] using the centering pin [6]. 3. Adjust mounting clamps [5] length for smaller motor sizes, as indicated in the picture that follows.

  • Page 28: Electrical Installation

    6 Electrical Installation 6 Electrical Installation 6.1 Precautions WARNING: • EQUIPMENT HAZARD. Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. Installation, start- up, and maintenance must be performed by trained and qualified personnel. Failure to follow these guidelines could result in death or serious injury.

  • Page 29: Protection Devices

    The overload provides Class 20 motor protection. See Warnings and alarms for details on the trip function. • Hydrovar must be provided with short-circuit and over-current protection to avoid overheating of the cables in the installation. Input fusing and/or circuit breakers are required to provide this protection.
  • Page 30 6 Electrical Installation Fuse Circuit breaker Non UL Voltage supply Bussmann Edison Littelfuse Ferraz- Fuse Shawmut Type T Type gG MCB S200 3.015 JJN-15 TJN (15) JLLN 15 A3T15 S203-C16 3.022 JJN-15 TJN (15) JLLN 15 A3T15 S203-C16 3.030 JJN-20 TJN (20) JLLN 20 A3T20...

  • Page 31: Wire Type And Ratings

    6 Electrical Installation 6.3 Wire type and ratings • All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements. • Use cables with a minimum heat resistance of +70 °C (158 °F); to obey the UL (Underwriters Laboratories) regulations, it is recommended that all power connections be made with a minimum 75°C rated copper wire of the following types: THW, THWN.

  • Page 32: Emc Compatibility

    Hydrovar fulfills the product standard EN61800-3:2004 + A1:2012, which defines categories (C1 to C4) for device application areas. Depending on the motor cable length, a classification of Hydrovar by category (based on EN61800-3) is reported in the following table: Table 5: EMC categories Hydrovar classification by categories based on 61800-3 2.015 ÷...

  • Page 33: Rfi Switch

    RFI filter of Hydrovar, by unscrewing the RFI switch depicted in the following image. WARNING: Do not make changes on Hydrovar when it is connected to mains: Make sure that the unit is disconnected from the power supply before removing the screw. HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 34: Ac Mains And Motor Connection Terminals

    SWITCH HVNG-IOM_RFI-SWITCH_A_SC 6.5 AC mains and motor connection terminals Unscrew the dedicated 6 screws and remove the plastic cover of Hydrovar, in order to proceed wiring the power supply and the motor terminal, as described in the following paragraphs. 6.5.1 AC Mains (power supply) connection 1.

  • Page 35: Motor Connection

    • Comply with local and national electrical codes • Do not install power factor correction capacitors between the frequency converter and the motor • Do not wire a starting or pole-changing device between Hydrovar and the motor HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 36: Control Terminals

    MOT_CONN_A-SC 6.6 Control terminals Unscrew the dedicated 6 screws and remove the plastic cover of the Hydrovar, in order to proceed wiring the control terminals, as described in the following paragraphs; for reference, the wiring harness scheme is reported on the backside of the plastic cover too.

  • Page 37: Motor Sensor Connection

    6 Electrical Installation COVER_B-SIDE_A_SC Figure 7: Cover Do not connect the ground of the control card to other voltage potentials. All ground terminals and ground of the RS485 connection are connected internally. HVNG-IOM_CONTROL-BOARD_A_SC Figure 8: Control board 6.6.1 Motor sensor connection Terminals X1/7 and X1/8 are used to connect a motor sensor (PTC or thermal switch) to stop the unit in case of failure;...

  • Page 38: Input For Emergency Basic Operations

    6 Electrical Installation Table 6: PTC terminals Terminals Description X1/7 PTC or thermal switch input X1/8 PTC or thermal switch input (Ground) 6.6.2 Input for emergency basic operations Terminals X1/20 and X1/21 are used to connect an external switch which forces (when closed) Hydovar to perform a manual start-up till reaching the maximum frequency (fixed speed) set by par.

  • Page 39: Rs485 Connection

    Terminals X1/11, X1/12 and X1/13 are used for the communication among up to 8 Hydrovar in a multi-pump application; a dedicated termination resistor switch (BUS1, see image below) is made available to add a parallel terminator resistor to this RS485 port: if the resistor is needed put BUS1 switch on ON position.

  • Page 40: Premium Card Terminals

    6 Electrical Installation Table 10: Status relays Terminals Description Comments X2/1 Status Relay 2: NO Status Relay 2 Maximum 250 VAC, 0.25 A X2/2 Status Relay 2: NC Maximum 220 VDC, 0.25 A X2/3 Status Relay 2: CC Maximum 30 VDC, 2 A X2/4 Status Relay 1: NO Status Relay 1...
  • Page 41 6 Electrical Installation Table 12: Relay terminals Terminals Description Comments X4/1 Relay 1: NO Maximum 250 VAC, 0.25 A Maximum 220 VDC, 0.25 A X4/2 Relay 2: NO Maximum 30 VDC, 0.25 A X4/3 Relay 3: NO X4/4 Relay 4: NO X4/5 Relay 5: NO X4/6...

  • Page 42: Operation

    7 Operation 7 Operation 7.1 Pre-start procedure Electrical Hazard: If input and output connections have been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge capacitors within the frequency converter, even when disconnected from mains input.

  • Page 43: Apply Power

    7 Operation Item to Inspect Description Checked Grounding (earthing) • Check for good earth connections (ground connections) that are tight and free of oxidation. • Grounding (earthing) to conduit is not a suitable ground (earth) . Input and output power •...
  • Page 44 7 Operation Minimum waiting times (min) 3.075 ÷ 3.110 4.015 ÷ 4.110 4.150 ÷ 4.220 High voltage may be present even when the warning LED indicator lights are off. HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 45: Programming

    8 Programming 8 Programming Notice NOTICE: Read and follow the operating instructions carefully before you start programming. This is to prevent incorrect settings which cause malfunction. All modifications must be done by qualified technicians! 8.1 Display and control panel HVNG-IOM_BUTTONS_A_SC.DRW 1.

  • Page 46: Software Parameters

    • OUTPUT FREQ.: current frequency supplied by the drive to the motor • ENTER/PREV/NEXT: actual functions of the related push buttons Referring to the second set (those parameters configuring HYDROVAR), each of them is presented with an image of the display containing (for example) the following information: P09 OPERAT.TIME...

  • Page 47: M00 Main Menu

    • Actual value: is the input signal supplied by the selected transducer (set by menu 400) • Status HV: is the HYDROVAR status (ON / OFF / STOP) depending on manual setting on push buttons and external contact X1/18-19) •...
  • Page 48 8 Programming • Status HV: is the HYDROVAR status (ON / OFF / STOP) depending on manual setting on push buttons and external contact X1/18-19) • Output frequency: current frequency supplied by the drive to the motor • PREV/START/STOP/NEXT: actual functions of the related push buttons When.
  • Page 49 8 Programming • Output frequency: current frequency supplied by the drive to the motor • Left/Up/Down/Right: actual functions of the related push buttons When parameter 105 MODE is set to Actuator, display shows the following information: P02 ACTUAT.FRQ. xx.x Hz Actual Value Output Freq.
  • Page 50 8 Programming P04 START VALUE P04 START VALUE 100% Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. This parameter defines, in percentage (0-100%) of the required value (P02 REQUIRED VAL.), the start value after pump stops. If P02 REQUIRED VAL.

  • Page 51: M20 Status

    P08 AUTO-START Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. If AUTO-START = On, then the HYDROVAR starts automatically (in case of demand) following a power disconnection. P09 OPERAT.TIME P09 OPERAT.TIME 0000h Actual Value Output Freq.
  • Page 52 Up fct. Down fct. Right fct. where (HYDROVAR is equipped with additional Premium Card) the status of the 5 Relay- switching contacts is shown. (where as 1=activated / 0=deactivated). P22 SELECT DEVICE This parameter lets the user select a specific unit (1-8) in a cascade system, so that current status, motor hours and last failures occurred can be checked.
  • Page 53 "Enabled" or "Disabled". P25 MOTOR HOURS This parameter shows the operation time in hours of the selected device. Thus, the time period during which HYDROVAR has powered the motor. P25 MOTOR HOURS XXXXX h Actual Value Output Freq.

  • Page 54: M40 Diagnostics

    8 Programming P26 thru P30: ERROR memory These parameters hold the error memory information. All errors are saved and shown in these parameters. P26 1ST ERROR XX Error Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. The errors include the following information: •...
  • Page 55 8 Programming P42 SEL.INVERTER Select the desired inverter unit (1-8). P42 SEL.INVERTER Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. P43 TEMP.INVERTER Shows the temperature inside the selected (by mean of parameter 42) unit, P43 TEMP.INVERTER XX% XX°C Actual Value Output Freq.

  • Page 56: M60 Settings

    8 Programming P46 OUTPUT FREQ. X.XX Hz Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. P47 VER.INVERTER : POWER Shows information about the software version of the power board for the selected (by means of parameter 42) unit. P47 VER.INVERTER 1.00 Actual Value...

  • Page 57: M100 Basic Settings

    Cascade Synchron All pumps operate on the same frequency Actuator 1 Hydrovar The Actuator mode is used if the HYDROVAR is a standard VFD with: • Fixed speed requirements or • An external speed signal is connected. For more information, see Example: P105 ACTUATOR mode (page 102).
  • Page 58 If several MASTER inverters are connected via the internal RS-485 interface (maximum eight in Cascade Serial mode), then the following must apply: • Each HYDROVAR needs an individual pump-address (1–8) • Each address can only be used once. P110 SET PASSW.

  • Page 59: M200 Conf.inverter

    HVL and HV 2.015-4.220 multi-pump communication protocol are not compatible! Thus in a multi-pump application where there is present at least one previous generation HYDROVAR (HV 2.015-4.220), all the other HVL model shall be forced in backward compatibility mode. For further information check the dedicated HVL Backward compatibility Set-up and programming guide.
  • Page 60 Down fct. Right fct. Reasonable values are: Value MODE 1–8 Cascade Serial 2–6 Cascade Relay P210 INVERTER Select the HYDROVAR address for parameterization. P210 INVERTER Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Possible settings are: Setting Description All units in the group are programmed at the same time;...
  • Page 61 Down fct. Right fct. This parameter adjusts the fast acceleration time, and it effects the control of the pump; the ramp depends on the type of HYDROVAR and the type of pump. Possible setting (sec) Default setting (sec) 2.015 ÷ 2.040 1–250...
  • Page 62 Down fct. Right fct. This parameter adjusts the slow acceleration time, thus determining: • The regulation speed of the internal HYDROVAR controller for small changes in demand. • The constant outgoing pressure. The ramp (default value 70 sec, possible setting 1–1000 sec) depends on the system which has to be controlled.
  • Page 63 Right fct. This parameter (default value 2.0 sec, possible setting 1.0- 25.0 sec) sets the ramp Fmin deceleration (fast running down time), and it stops HYDROVAR when it gets below P250 MIN.FREQ. For more information, see Example: P200 Ramp Settings.
  • Page 64 -> 0 Once the required pressure is reached and no further consumption is needed, the frequency goes down to the selected P250 MIN.FREQ.: HYDROVAR will then keep running for the selected P260 FMIN TIME and after this time stops automatically.
  • Page 65 Output Freq. Left fct. Up fct. Down fct. Right fct. P265 MOTOR NOM.POWER Sets the nominal power of the motor coupled with HYDROVAR, as reported in the motor nameplate. P265 MOTOR NOM.POWER 1.5 kW Actual Value Output Freq. Left fct.
  • Page 66 Down fct. Right fct. P268 MOTOR NOM.CURR. Sets the motor nominal current, as reported in the motor nameplate, according to • the chosen motor connection • the output voltage of the HYDROVAR P268 MOTOR NOM.CURR. 7.5 A Actual Value Output Freq.
  • Page 67 • For the best adaptation of HYDROVAR, run AMPI on a cold motor • AMPI cannot be performed while the motor runs • AMPI cannot be performed on a motor with a bigger power rating than HYDROVAR that is, when a 5.5 kW motor is coupled with a 4 kW drive •...
  • Page 68 Down fct. Right fct. This parameter (default value 50 Hz, possible setting 30.0- 90.0 Hz) sets the knee frequency, where HYDROVAR generates its maximum output voltage. For standard applications, set this value according to nominal frequency of the motor. P283 SEL.SW.FREQ.
  • Page 69 10 kHz Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. HYDROVAR, in any case, can decrease automatically the switching frequency applying the derating criteria. Possible settings are: Possible setting Default 2,015 Random 2 kHz 5 kHz...
  • Page 70 8 Programming P284MIN.SW.FREQ. This parameter sets the minimum switching frequency HYDROVAR can generate. P284 MIN.SW.FREQ 2 kHz Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. This parameter is useful to force HYDROVAR to generate: • switching frequencies in a certain bandwidth (upper limit defined by P283 - lower limit defined by P284) •...

  • Page 71: M300 Regulation

    This parameter (default value 110%, possible setting 10–300%) sets the current limit for motor (in % of rated motor current) If the set value is higher than HYDROVAR maximum rated output, then current is still limited to the maximum rated output.
  • Page 72 8 Programming P305 JOG x.xx Hz Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Where: • JOG: is the parameter description • X.XX: is the current parameter value (0Hz - P245 MAX.FREQ.); at 0.0 Hz, the unit stops. •...

  • Page 73: M400 Sensor

    8.3.8 M400 SENSOR MENU SCOPE In this submenu it is possible to configure all actual-value sensors that are connected to the HYDROVAR. However, the following limitations apply: • It is possible to have maximum two transducers with current output or voltage-signal output.
  • Page 74 8 Programming P405 DIMENSION UNIT Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. In case a change of this parameter is needed, consider to change P420 SENSOR RANGE to the corresponding dimension unit too! P410 CONF.SENSOR Sets how the connected sensors are used and which sensor is active.
  • Page 75 8 Programming P415 SENSOR TYPE 4-20 mA Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Possible setting are: Table 14: Selection of the sensor type and input terminal Setting Input Terminals Actual Value • Analog I 4 - 20 mA •...

  • Page 76: M500 Sequence Contr

    8 Programming P430 SENS.1 CAL.0 This parameter is used to calibrate the minimum value of Sensor 1. P430 SENS.1 CAL.0 Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. After setting P405 DIMENSION UNIT and P420 SENSOR RANGE, the zero point for this sensor can be adjusted between -10 % and +10 %.
  • Page 77 8 Programming • Actual value (increase, decrease) • Frequency (enable, disable, drop) • Delay (enable, switch, disable) • Overvalue • Overvalue delay • Switch intervals • Synchronous frequency limit and window For example and more information, see P500 Example: P500 SUBMENU SEQUENCE CNTR.
  • Page 78 8 Programming P520 ENABLE DLY. 5 sec Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. It sets the enable delay time: the fixed-speed pump starts after the selected time. P525 SWITCH DLY. This parameter only applies to cascade relay! P525 SWITCH DLY.
  • Page 79 Up fct. Down fct. Right fct. This parameter prevents the system against overpressure in case the HYDROVAR has been parameterized incorrectly: if this selected value is reached, an immediate shut-off of the follow-up-pumps is executed. Possible settings are "Off" (default) or P420 SENSOR RANGE.

  • Page 80: M600 Error

    8 Programming P560 SYNCHR.LIM. 0.0 Hz Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. This parameter sets the frequency limit: the first assist pump shuts off if the frequency goes below this parameter's value. For information about how to find the correct setting, see Example: P500 SUBMENU SEQUENCE CNTR.

  • Page 81: M700 Outputs

    Up fct. Down fct. Right fct. Selects the delay time of the minimum threshold limit: it shuts off the HYDROVAR if the actual value drops below P605 MIN.THRESH. or if a low-water protection (at terminals X1/16–17) becomes open. P615 ERROR RESET...
  • Page 82 Selects the status relay 1 (X2/4 - 5 - 6). Possible settings are: Setting Description Action if status = YES Power HYDROVAR is connected to the power Relay 1: X2/ 4 - 6 closed supply. Running The motor is running...

  • Page 83: M800 Required Values

    StandBy The pump is released manually and Relay 2: X2/ 1 - 3 closed by external release, no error/warning is indicated and the HYDROVAR does not run. Errorreset If the parameter P615 ERROR RESET Relay 2: X2/ 1 - 3 closed is activated and a warning occurs five times - >...
  • Page 84 8 Programming Setting Description Connected to terminals (Premium Card) Required value 2 not used. Digital The internal required value 2 is used. For setting, see P02REQUIRED VAL. or Digital P825 REQ.VAL.2 Analog U 0-10V The required value 2 is set by the X3/11-12 value of voltage signal.

  • Page 85: M900 Offset

    8 Programming P825 REQ.VAL.2 P825 REQ.VAL.2 XX.X bar Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Sets the digital required value 2 in bar (possible setting 0.0 - P420 SENSOR RANGE). The value is active in all operation mode (but not Actuator mode), if the following applies: •...
  • Page 86 X3/10-11 (Required Value 2) If the incoming current signal drops to below 4 mA, a warning message is shown on the display; however, HYDROVAR continues to operate without the offset function. P907 OFFSET RANGE P907 OFFSET RANGE Actual Value Output Freq.
  • Page 87 8 Programming Selects the first level until the offset function 1 is active. For an example of the offset function and more information, see Example: P900 SUBMENU OFFSET (page 105). P912 OFFSET X1 P912 OFFSET X1 Actual Value Output Freq. Left fct.

  • Page 88: M1000 Test Run

    (possible setting are "Off" or "After 100 hrs". Automatic test run is only active when both of the following occur: • HYDROVAR is stopped but manually released. • The external ON/OFF contact (X1/18 - 19) is closed.

  • Page 89: M1100 Setup

    8 Programming P1015 TEST R.BOOST P1015 TEST R.BOOST 10.0 % Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Sets the motor starting voltage (possible setting 0 -25%) as a percentage of the rated input voltage. P1020 TEST R.TIME P1020 TEST R.TIME 5 sec Actual Value...
  • Page 90 8 Programming • Clear motor hours • Clear operation time P1110 FACTORY SET P1110 FACTORY SET Europe Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Restores the factory settings. Possible settings are: Setting Offset calculation Europe Restore the factory setting for European versions.

  • Page 91: M1200 Rs-485 Interface

    Up fct. Down fct. Right fct. Clear the operation time, which stores the total time the HYDROVAR is connected to power supply. For this parameter please note that, once entered into edit mode (by pressing the provided push button), the user can confirm the new value by pressing for 3 sec the right (►) push button.
  • Page 92 8 Programming P1203 PROTOCOL P1203 PROTOCOL Modbus RTU Actual Value Output Freq. Left fct. Up fct. Down fct. Right fct. Sets the desired communication protocol. Possible settings are: • Disabled • Modbus RTU • Modbus ASCII • BACNet MS/TP P1205 ADDRESS P1205 ADDRESS Actual Value Output Freq.
  • Page 93 Right fct. This parameter shows the identification number of the Wi-Fi network generated when the wireless module is assembled into HYDROVAR. In particular, the network name will be: "hydrovar__P1225__", where P1225 is the value of this parameter, expressed as an 8 character word.

  • Page 94: M1300 Start-Up

    Output Freq. Left fct. Up fct. Down fct. Right fct. This parameter set the nominal power of the motor coupled with HYDROVAR, as reported on the motor nameplate. For possible setting, see P265 MOTOR NOM.POWER (page 63) P1303 MOTOR NOM.VOLT.
  • Page 95 50Hz (without Motor Filter): in this case, the motor's electrical parameters are already available to HYDROVAR, so the start-up procedure skips to P1308 STC MOTOR PROT.. By selecting "NO", the user is declaring the use of any other motor: in this case the motor's electrical parameters need to be set into HYDROVAR, so the start-up procedure goes to the next step (P1305 MOTOR NOM.CURR.)
  • Page 96 Up fct. Down fct. Right fct. This parameter selects an address (1-8) for each HYDROVAR. If several MASTER inverters are connected via the internal RS-485 connection (maximum eight in Cascade serial mode), then the following must apply: • Each HYDROVAR needs an individual pump-address (1–8) •...
  • Page 97 8 Programming This parameter sets the pressure control mode for the pump system (single and multi pump): depending on the setting ("Constant" or "Differential") a set of further parameters are automatically configured. Whenever P1311 CONTROL MODE is set to a new value, each parameter in the below table is overwritten to its own specified value, regardless of previous different settings.
  • Page 98 Up fct. Down fct. Right fct. Selects the delay time of the minimum threshold limit: it shuts off the HYDROVAR if the actual value drops below P1317 MIN.THRESH. or if a low-water protection (at terminals X1/16–17) becomes open. HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...
  • Page 99 If the user configured the whole application by selecting “YES” then the HYDROVAR will not make available the Start-up menu at every power-on. By selecting "NO" at next power-on, the HYDROVAR will offer to the user the start-up procedure. P1323 ADDRESS...

  • Page 100: Maintenance

    9 Maintenance 9 Maintenance 9.1 General Electrical Hazard: Before any service or maintenance disconnect the system from the power supply and wait at least 5 minutes before starting work on or in the unit (the capacitors in the intermediate circuit are discharged by the internal discharge resistors). The unit does not require any special maintenance.

  • Page 101: Troubleshooting

    10 Troubleshooting 10 Troubleshooting Precaution NOTICE: • Always disconnect the unit from the power supply before you perform any installation and maintenance tasks. Warnings and errors • Warnings and errors are shown on the display and/or by the red LED. •...
  • Page 102 10 Troubleshooting Error Cause Check the following: Power limit exceeded - motor • Is the parameter P215/P220 RAMP 1/RAMP 2 OVERLOAD current too high (slow rise too short and P265 BOOST too low? ERROR 12 detected). • Do the cables and connection work? •...

  • Page 103: Internal Error, On Display Or Red Led On

    10 Troubleshooting Error Cause Check the following: Sensor signal on terminals • The Actual value signal from the pressure FAILURE SENSOR 2, X3/4 is less than 4 mA which transducer is faulty. ACT. VAL. SENSOR 2 an active sensor must deliver. •...

  • Page 104: Technical Reference

    11 Technical Reference 11 Technical Reference 11.1 Example: P105 ACTUATOR mode Graph f [Hz] fmax (0255)f->fmin (0255)f->0 fmin 0Vdc 10Vdc 20mA 20mA Position numbers 1. Signal range * (f ) + zeropoint 2. Range of control 11.2 Example: P200 Ramp Settings Graph H [bar] t [s]...

  • Page 105: Example: P330 Lift Amount

    Follow these instructions to set the lift amount. 1. Enter the set pressure. P02 REQUIRED VAL. (page 46). 2. Close all valves in the system and start the HYDROVAR ® to read the frequency displayed. Another possibility to find out the frequency for the set pressure at zero demand is to use the P305 JOG mode.

  • Page 106: Example: P500 Submenu Sequence Cntr

    11 Technical Reference Graph Position numbers f = 100 % 1. The pressure at zero demand (all valves closed). 2. The pressure plus lift amount to compensate the friction loss. 11.4 Example: P500 SUBMENU SEQUENCE CNTR. Graph Calculation process for the sequence centre value 1.

  • Page 107: Example: P900 Submenu Offset

    11 Technical Reference p = p + (k–1) * (P505 ACT.VAL.INC - P510 ACT.VAL.DEC) • P505 ACT.VAL.INC = P510 ACT.VAL.DEC → Pressure constant, independent of how many pumps are in operation. • P505 ACT.VAL.INC > P510 ACT.VAL.DEC→ Pressure rises when assist pump switches •...
  • Page 108 11 Technical Reference Graph See graph below for more details. 12m³/h 5m³/h 2m³/h Position numbers 1. LEVEL 1 2. LEVEL 2 3. OFFSET X1 4. OFFSET X2 5. OFFSET Y1 6. OFFSET Y2 HVL 2.015-4.220 Installation, Operation, and Maintenance Manual...

  • Page 109: Programming Flow Charts

    11 Technical Reference 11.6 Programming flow charts Submenu 0 – 40 Submenu 0–40 Name Example menu MAIN HOME HOME Actual value REQUIRED VAL. 3,5 bar EFF.REQ.VAL. 3,5 bar START VALUE LANGUAGE English DATE xx.xx.20xx TIME xx:xx AUTO-START OPERAT.TIME xxxxx:xx STATUS STATUS UNITS 00000000 SELECT DEVICE...
  • Page 110 11 Technical Reference Submenu 60 – 300 Submenu 60–300 Name Example menu SETTINGS PASSWORD 0000 xx.x Hz 3,5 bar BASIC SETTINGS MODE Controller PUMP ADDR. SET PASSW. 0066 LOCK FUNCT. DISP.CONTR. 75 % DISP.BRIGHT. 100 % CONF.INVERTER 210 215 SOFTWARE HV V01.4 240 245 MAX.UNITS...
  • Page 111 11 Technical Reference Submenu 60–300 Name Example menu WINDOW 10 % HYSTERESIS 80 % REG.MODE Normal FRQ.LIFT 30,0 Hz LIFT AMOUNT 0,0 % Submenu 400 – 500 Submenu 400–500 Name Example menu SENSOR 415 420 DIMENSION UNIT CONF.SENSOR Sensor 1 SENSOR TYPE Analog I 4 - 20 mA SENSOR RANGE...
  • Page 112 11 Technical Reference Submenu 600 – 1200 Submenu 600–1200 Name Example menu ERROR MIN.THRESH. Disabled DELAY-TIME 2 sec ERROR RESET OUTPUTS ANALOG OUT.1 Output frequency ANALOG OUT.2 Actual value CONF.REL.1 Running CONF.REL.2 Errors REQUIRED VALUES C.REQ.VAL.1 Digital C.REQ.VAL.2 SW.REQ.VAL. Setpoint 1 REQ.VAL.1 3,5 bar REQ.VAL.2...
  • Page 113 11 Technical Reference Submenu 1300 Submenu 1300 Name Example menu 1300 START-UP 1300 1301 1302 1303 1304 1305 1301 LANGUAGE English 1302 MOTOR NOM.POWER 1303 MOTOR NOM.VOLT. 1306 1307 1308 1309 1310 1304 PRE-SET MOTOR ? 1305 MOTOR NOM.CURR. 1311 1312 1313 1314...
  • Page 116 For more information on how Xylem can help you, go to xyleminc.com Xylem Service Italia S.r.l. Visit our Web site for the latest version of this document...

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