Xylem HVL 2.015-4.220 User Manual

Installation, Operation,
and Maintenance Manual
HVL 2.015-4.220

Xylem HVL 2.015-4.220 Specifications

General

Brand	Xylem
Model	HVL 2.015-4.220
Category	Water System
Language	English

Summary

Introduction and Safety

1.1.1 Qualified personnel

Product is intended for operation by qualified personnel only.

1.2 Safety

WARNINGs regarding physical injury and equipment damage.

1.2.1 Safety message levels

Definitions of DANGER, WARNING, CAUTION, NOTICE levels.

1.3 User safety

General safety rules to follow in work area.

Electrical connections

Connections must be made by certified electricians.

Transportation and Storage

2.2 System lifting

WARNING: Lift equipment only at specified lifting points.

Product Description

3.2 Product function and use

Description, intended use, and approvals for HYDROVAR controller.

3.3 Applications

Application alternatives for the product.

3.3.3 Cascade serial / Synchronous

Multi-pump operation via RS485 interface.

3.3.4 Cascade relay

One pump controls up to five slave pumps via an additional Premium Card.

3.5 Technical Data

Electrical specifications, environmental, and installation data.

3.6 Motor thermal protection

Implementation of PTC sensor or Software Thermal Control (STC).

Installation

4.1 Installation site checklist

DANGER/WARNING regarding installation environment.

4.2 Frequency converter and motor pre-installation check list

Check model numbers, voltage, and current ratings before installation.

Mechanical Installation

5.3 Mounting

Install unit on motor fan cover, keep motor cables short.

Electrical Installation

6.1 Precautions

WARNINGs for equipment hazards and electrical safety.

6.2 Protection devices

Information on recommended fuses and circuit breakers.

6.3 Wire type and ratings

Recommended power and control cable types and tightening torques.

6.4 EMC compatibility

Requirements and guidelines for electromagnetic compatibility.

6.4.1 EMC requirements

Hydrovar classification by categories based on EN61800-3.

6.4.2 Wiring the cables

Guidelines for ensuring electromagnetic compatibility during wiring.

6.5 AC mains and motor connection terminals

Instructions for wiring AC mains power supply and motor connections.

6.5.1 AC Mains (power supply) connection

Connect 1-phase AC input power wiring to terminals L and N.

6.5.2 Motor connection

WARNING about induced voltage from output motor cables.

6.6 Control terminals

Wiring instructions for control terminals.

6.6.1 Motor sensor connection

Connecting a motor sensor (PTC or thermal switch).

6.6.2 Input for emergency basic operations

Connect external switch for manual start-up.

6.6.3 Digital and analog I/O

Details of digital and analog I/O terminals and their functions.

6.6.4 RS485 connection

Terminals for multi-pump communication and external control devices.

6.6.5 Status relays

Terminals for making available Status Relay 1 and 2 contacts.

6.7.1 Digital and analog I/O (X3)

Connection of additional analog and digital I/Os.

Operation

7.1 Pre-start procedure

Electrical Hazard: Ensure power is OFF before proceeding with connections.

7.2 Pre-startup inspections

Check auxiliary equipment, cable routing, cooling, EMC, and fuses.

7.3 Apply power

NOTICE: HIGH VOLTAGE. Ensure safety covers are in place before applying power.

7.4 Discharge time

WARNING: Disconnect power and wait for capacitor discharge time.

Programming

8.3 Software parameters

Parameters are organized in two distinct groups: menu definition and configuration.

8.3.1 M00 MAIN MENU

Menu scope includes Home, language, date/time setup, and operating hours.

P02 REQUIRED VAL.

Sets the required value for the system, e.g., pressure in bar.

P03 EFF.REQ.VAL.

Shows current required value considering lift amount and offset signals.

P04 START VALUE

P08 AUTO-START

8.3.2 M20 STATUS

Check status (failures, motor hours) of connected units.

P21 STATUS UNITS

P22 SELECT DEVICE

P23 STATUS DEVICE

P24 ENABLE DEVICE

P26 thru P30: ERROR memory

Parameters hold error memory information.

8.3.3 M40 DIAGNOSTICS

Submenu for production date, temperature, current, voltage, frequency, software version.

P42 SEL.INVERTER

8.3.4 M60 SETTINGS

Submenu includes PASSWORD and JOG parameters.

P61 PASSWORD

P62 JOG

8.3.5 M100 BASIC SETTINGS

Submenu for operation mode, pump address, password, lock function, display.

P105 MODE

Selects operation mode: Controller, Cascade, Actuator.

P106 PUMP ADDR.

8.3.6 M200 CONF.INVERTER

Submenu includes Software, Units, Ramp, Motor, Frequency, STC settings.

P215 RAMP 1

P220 RAMP 2

P225 RAMP 3

P230 RAMP 4

P235 RAMP FMIN A

P240 RAMP FMIN D

P245 MAX.FREQ.

Sets the maximum frequency and pump speed.

P250 MIN.FREQ.

Sets the minimum frequency for operation.

P265 MOTOR NOM.POWER

P266 MOTOR NOM.VOLT.

P267 MOTOR NOM.FRQ.

P268 MOTOR NOM.CURR.

P269 MOTOR NOM.SPEED

P275 AMPI

Activates Automatic Motor Parameter Identification.

P280 SWITCHING CONTROL

P290 STC MOTOR PROT.

Sets protection technique against motor overheating.

P295 CURR.LIM.FUNCT.

P296 CURR.LIMIT SET

8.3.7 M300 REGULATION

Submenu includes Jog, Window, Hysteresis, Regulation mode, Lift settings.

P305 JOG

P325 FRQ.LIFT

P330 LIFT AMOUNT

8.3.8 M400 SENSOR

Configure all actual-value sensors connected to HYDROVAR.

P410 CONF.SENSOR

8.3.9 M500 SEQUENCE CONTR.

Configure parameters for running a multi-pump system.

P505 ACT.VAL.INC.

P510 ACT.VAL.DEC.

P515 ENABLE FRQ.

8.3.10 M600 ERROR

Submenu includes minimum threshold limit, delay time, auto error reset.

P605 MIN.THRESH.

P610 DELAY-TIME

P615 ERROR RESET

Selects automatic reset of errors.

8.3.11 M700 OUTPUTS

Submenu for analog output and status relay configuration.

P715 CONF.REL.1

P720 CONF.REL.2

8.3.12 M800 REQUIRED VALUES

Configure required value and switch between them.

P805 C.REQ.VAL.1

P810 C.REQ.VAL.2

P815 SW.REQ.VAL.

P830 ACTUAT.FRQ1

P835 ACTUAT.FRQ2

8.3.13 M900 OFFSET

Submenu includes offset (input, range) and level parameters.

P905 OFFS.INPUT

8.3.14 M1000 TEST RUN

Parameters for automatic and manual test runs.

P1005 TEST RUN

P1030 TEST RUN MAN.

8.3.15 M1100 SETUP

Submenu for factory settings, password, and error memory.

8.3.16 M1200 RS-485 INTERFACE

Parameters for communication via Modbus or BACnet protocol.

P1203 PROTOCOL

8.3.17 M1300 START-UP

Parameters for quick start-up: Language, Motor Config, Pump Config, Required Value.

P1304 PRE-SET MOTOR ?

P1307 AMPI

P1308 STC MOTOR PROT.

Sets protection technique against motor overheating.

P1309 MODE

P1311 CONTROL MODE

Sets pressure control mode: Constant or Differential.

P1316 START VALUE

P1317 MIN.THRESH.

P1318 DELAY-TIME

P1321 AUTO-START

Maintenance

9.1 General

Electrical Hazard: Disconnect power before service. Unit requires no special maintenance.

9.2 Check error codes

Troubleshooting

10.1 No error message on the display

Troubleshooting for issues like AUTO-START failure or unsteady pressure.

10.2 Error message on the display

Detailed error codes, causes, and remedies for display errors.

OVERLOAD ERROR 12

Cause: Power limit exceeded. Check ramp settings, connections, pump, motor rotation.

OVERVOLTAGE ERROR 13

Cause: Voltage too high. Check ramp speed, supply, peaks. Consider line filters.

INVERT. OVERHEAT ERROR 14

Cause: Unit temperature too high. Check cooling, vents, ambient temp.

THERMO MOT/EXT ERROR 15

Cause: PTC sensor reached release temp. Check external protective device.

PHASELOSS ERROR 16

Cause: One phase of power supply does not work. Check power supply, circuit breakers.

UNDERVOLTAGE

Cause: Voltage too low. Check supply voltage, phase failure, asymmetry.

COMM LOST

LACK OF WATER ERROR 21

Cause: Low water sensor connection open. Adjust delay time or bridge terminals.

MIN. THRESHOLD ERROR 22

Cause: Minimum threshold not reached within delay time. Adjust delay time or enable auto-reset.

FAILURE SENSOR 1, ACT. VAL. SENSOR 1 ERROR 23

Cause: Sensor signal low. Check transducer, connection, configuration.

FAILURE SENSOR 2, ACT. VAL. SENSOR 2 ERROR 24

Cause: Sensor signal low. Check transducer, connection, configuration.

SETPOINT 1 I<4mA, SETPOINT 1 I < 4 mA ERROR 25

SETPOINT 2 I < 4 mA, SETPOINT 2 I < 4 mA ERROR 26

10.3 Internal error, on display or red LED ON

Troubleshooting for internal errors like EEPROM, EPROM, Watchdog, Processor, Code errors.