PEDROLLO STEADYPRES Variable Frequency Drive Instructions

PEDROLLO STEADYPRES Variable Frequency Drive

Product Usage Instructions

• Specifications
  • Brand: STEADYPRES
  • Model: 12D10274007A
  • Made in: Italy
  • Type: Electronic Frequency Variator (Inverter)
• General Information
  • The STEADYPRES inverter is designed in Italy to regulate frequency electronically.
• Safety Standards
  • Ensure compliance with the safety symbols and warnings provided in the manual to prevent electric shocks or damage to individuals or property.
• Description of the Product
  • The product includes various parts like a control panel, front cover, suction and discharge ports, technical data plate, power cable glands, valve group, and expansion vessel connection.
• Control Panel
  • The control panel features a power on/off button, LED indicators for operation and alarms, pressure increase/decrease buttons, and an operation status LED indicator.
• Technical Data and Usage Limits
  • Specifications include regulation pressure, maximum liquid temperature, ambient temperature, maximum pressure, protection rating, working position, and allowed fluids.
• Parallel Applications
  • The product allows for parallel use of multiple pumps.
• Light Indicators
  • The LED indicators show different statuses such as pump running, pump stopping, and alarms.
• Installation
  • Follow the installation guidelines provided in the manual to ensure proper setup of the STEADYPRES inverter.
• Basic Configuration
  • Adjust the settings of the inverter according to your requirements for frequency and output type (single-phase or three-phase).

FAQs

• Q: What should I do if the LED indicators show an alarm?
  • A: Refer to the user manual to identify the specific issue indicated by the LED alarm and take appropriate action as recommended.
• Q: Can STEADYPRES be used with flammable liquids?
  • A: No, STEADYPRES is not suitable for pumping flammable liquids or operating in explosive environments.

GENERAL INFORMATION

• This manual must always accompany the equipment to which it refers and be kept in an accessible place to be consulted by those involved in system operation and maintenance.
• Installers/users must read the instructions and information in this manual carefully before using the equipment to avoid damaging or misusing it or voiding the warranty.
• This product must not be used by children or people with reduced physical, sensory, or mental capabilities, nor those with inadequate experience and knowledge, except under supervision and instruction. Children should be observed to make sure they do not play with the equipment.
• The manufacturer shall not be held liable in the event of an accident or damage due to negligence or failure to follow the instructions described in this booklet or conditions other than those specified on the rating plate. The manufacturer shall not be held liable for damage due to improper use of the equipment.
• Inspect the goods immediately upon receipt to make sure that the equipment has not been damaged during transport. If any anomalies are found, promptly inform our dealer or the Pedrollo customer service department if purchased directly, no later than 5 days after receipt.
• The indications and instructions in this manual refer to the standard use of the product; for situations, functions, or particular applications not described below, contact the retailer.
• If a request for technical support or spare parts is necessary, specify the code of the model and the serial number outlined in the specific plate.
• Our service department and technical support are available for any requirements you may have.
• Do not stack weights or other boxes on the package.
• The information contained in the manual can vary without prior warning. Any damage caused by these instructions will not be considered since they are approximate. Remember that non-compliance with the instructions outlined by us could cause harm to people or property.
• However, remember that compliance with local provisions and/or legislation in force should be met.

SAFETY STANDARDS

SYMBOLS

The symbols used in this manual are described below.

• RISK OF ELECTRIC SHOCK
  • This symbol warns that failure to observe the instructions will create a risk of electric shock.
• RISK OF DAMAGE TO PEOPLE OR PROPERTY
  • This symbol warns that failure to observe the instructions will create a risk of personal harm or property damage.

WARNINGS

• Please read all parts of this manual carefully before installing and using the product.
• Check that the rating plate data is as required and matches the facilities.
• Only qualified personnel capable of making electrical connections by national regulations may carry out installation and maintenance.
• STEADYPRES must only be used for the purpose and operation for which it was designed. Any other application and use should be considered misused and hazardous.
• In the event of a fire at or near the installation site, do not use water jets, but use suitable extinguishers (powder, foam, carbon dioxide).
• Install the equipment away from heat sources in a dry, covered place with the specified degree of protection(IP).
• Only qualified technicians who are aware of the safety regulations in force may carry out any installation and/or maintenance work.
• Use of non-original spare parts, tampering, or improper use will void the product warranty.
• The manufacturer cannot be held liable for damage deriving from misuse of the product and is not responsible for damage caused by maintenance or repairs carried out by unqualified people and/or using non-original spare parts.

DURING THE FIRST INSTALLATION PHASE AND IN THE EVENT OF MAINTENANCE, ensure that:

• THERE IS NO LIVE VOLTAGE on the electricity mains.
• The system IS NOT PRESSURISED
• The electrical power mains are equipped with safety devices and, in particular, a high sensitivity differential switch (30 mA in class F and B) suitable to protect against fault currents, alternating type, unipolar button, continuous with high frequency. Also, check that the earthing complies with the regulations.
• Before removing the cover of the inverter or starting interventions on it, disconnect the system from the electrical mains for at least 5 minutes so that the capacitors have the time to discharge using the built-in discharge capacitors;
• Having carried out the electrical connection on the system, check the settings of the inverter.
• Do not remove the cover and/or disconnect power if the inverter is running.
• CAUTION: In out-of-service status, the STEADYPRES remains live; before any intervention, you must disconnect the voltage from the unit.

EMERGENCY STOP

• While STEADYPRES is running, you can make an emergency stop by disconnecting the power supply to the unit. If intervention is being carried out, ensure there is no VOLTAGE on the electricity mains. Make sure that the system is NOT PRESSURISED.
• In the presence of low voltage (rated value -10%), overcurrents can occur at start-up and at maximum power.
• STEADYPRES IS NOT SUITABLE for pumping flammable liquids or working in environments with danger of explosion.

AUTO-LIMITATION FOR OVERLOAD

If the current detected by the inverter or the temperature of the inverter components exceed the safety limits, STEADYPRES proceeds with a progressive reduction in operating frequency until the values exceeding the limits have returned within them (automatism inside inverter).

PRODUCT DESCRIPTION

• STEADYPRES is an electronic command and control device for a surface or submerged pump, based on the inverter technology.
• It is applied to the delivery of the electric pump and, by adjusting the frequency of the current, allows you to vary the rotation speed of the motor based on the quantity of water required, guaranteeing constant pressure on the system.
• The pressure is easily adjusted by the user using two keys + and – is placed on the control panel with a value between 1 and 9 bar.
• A versatile product that, with a unique device, can combine with a SINGLE-PHASE or THREE-PHASE electric pump thanks to a selector inside which allows selection of the output phases.
• It protects the electric pump from dry running, overcurrent, short circuit or current dispersion, and low voltage power supply.
• It can be equipped with an expansion board, which allows working parallel with other inverters in the pumping unit and management of an input and an output signal.

LIST OF PARTS

1. Control panel
2. Front cover
3. Extraction inlet
4. Delivery inlet
5. Technical data plate
6. Cable glands for power supply/electric pump
7. Cable glands for electric signals
8. Check valve unit
9. Connection for expansion tank (1”)

CONTROL PANEL

1. ON/OFF key
2. Operating and alarm LED indicators
3. Pressure increase key
4. Pressure decrease key
5. Operating status LED indicator

TECHNICAL DATA AND USE LIMITATIONS

STEADYPRES USE METHOD| S/S (Single-phase / Single- phase)| S/T (Single-phase / Three-phase)
---|---|---
Power supply voltage| 1 ~ 230 V (1 ~ 115 V)| 1 ~ 230 V (1 ~ 115 V)
Electric pump motor voltage| 1 ~ 230 V (1 ~ 115 V)| 3 ~ 230 V (3 ~ 115 V)
Permitted voltage variation| ±10%| ±10%
Power frequency| 50Hz or 60Hz| 50Hz or 60Hz
Maximum electric pump motor current| 8.5 A| 7.0 A
Maximum electric pump motor power| 1.5 HP (1.1 kW)| 1.5 HP (1.1 kW)
| |
Adjustment pressure| 1÷9 bar|
Maximum liquid temperature| +40 °C|
Ambient temperature| 0°C ÷ 40 °C|
Maximum pressure| 10 Bar|
Degree of protection| IP 65|

PARALLEL APPLICATIONS

• In parallel applications, there is a MASTER inverter and a SLAVE inverter, controlled by the MASTER. The recognition ofthe MASTER inverter from the SLAVE inverter is given by the LED of the operating status of the SLAVE inverter that flashes BLUE every second.
• The MASTER receives parameter programming controls the operating data, and activates and deactivates the SLAVE as needed.
• If the MASTER is switched off, the SLAVES are again autonomous and continue to operate independently.
• When working in parallel configuration with other inverters, STEADYPRES manages the alternation of starts, to standardize the use of electric pumps

LIGHT SIGNALS

INSTALLATION AND SETTINGS

INSTALLATION COMPULSORY

• Install STEADYPRES in a vertical position.
• If STEADYPRES is equipped with 3-point joints, do not use seals inside the three-point joint; there is already a sealing OR there.
• Install STEADYPRES so that no harmful vibrations or mechanical stress arrive from the connecting tubing
• If the temperature goes under 0 °C, empty water from the STEADYPRES. Freezing of the water contained in STEADYPRES would cause irreversible damage.
• It is indispensable for the installation of an EXPANSION TANK system downstream of the inverter, especially if there are small leaks.
  • Accumulates pressurized water to reduce electric pump start-up to a minimum.
  • Absorbs any excess pressure from the system.
  • The minimum volume necessary, in liters (for membrane models), is approximately equal to 10% of the maximum flow rate of the individual pump, expressed in l/min.

Example of standard application:

• Qmax = 80 l/min V = 80 x 10% = 8 litres (rounded in excess to commercial size)
• Inflation (system with no load): 1 bar less in working pressure:
• Example: Pset = 4 bar Pinflation = 3 bar

RECOMMENDED

• Install STEADYPRES in premises protected against external agents, ventilated, and free of humidity or excess dust.
• Install STEADYPRES as close as possible to the electric pump
• If there are long cables between STEADYPRES and the electric pump (e.g. submerged electric pump), you are advised to apply a sine filter to protect the motor and the STEADYPRES from voltage peaks.

STEADYPRES BASIC CONFIGURATION

Before carrying out connections, ensure there is no voltage on the terminals of the line conductors. Also ensure the electrical power supply mains is equipped with safety devices and in particular a high sensitivity differential switch (30 mA, in class F or B) and a ground compliant with standards.

• Using the STEADYPRES DIP SWITCHES (selectors), you can:
  • set the output frequency at 50 Hz or at 60 Hz.
  • or have the SINGLE PHASE (MM) or THREE PHASE 230V (ST) output

STEADYPRES by default set with the frequency at 50 Hz and with the ST (THREE PHASE 230 V)

• Through the TRIMMER, STEADYPRES has the possibility of setting the current protection threshold
• To access the configuration DIP SWITCHES (A) and TRIMMER (B), remove the front cover by unscrewing the four locking screws.

VERTICAL DIP SWITCHES (A)

PROTECTION CURRENT ADJUSTMENT TRIMMER (B)

SETTING THE ADVANCED PARAMETERS

• These configurations are exclusively intended for qualified staff.
• STEADYPRES can be programmed by default to adapt to the most common types of system, without needing any advanced parameters.

In particular, the advanced parameters and the relevant default settings are:

• In particular cases, it is convenient to edit the advanced parameters to better adapt to the existing system. Remove the front cover to access the settings.
• STEADYPRES avails of 6 DIP SWITCH (horizontal selectors) – (C) to adjust the advanced parameters.

HORIZONTAL SELECTORS (C)

ELECTRICAL CONNECTION

Before carrying out connections, ensure there is no voltage on the terminals of the line conductors. Also ensure the electrical power supply mains is equipped with safety devices and in particular a high sensitivity differential switch (30 mA, in class F or B) and a ground compliant with standards.

• Check the electricity mains power supply voltage corresponds to the voltage indicated in the STEADYPRES plate and the motor, therefore connect the ground before every other connection.
• The voltage of the STEADYPRES power line can vary in a range between +/-10% of the plate power voltage.
• Check the rated current absorbed by the STEADYPRES unit is compatible with the plate data.
• The power line must be protected by a differential circuit breaker switch, with the characteristics listed above.
• Secure the electrical cables in the corresponding terminals using a tool of suitable size to avoid damaging the clamping screws. Take extra care when using an electric screwdriver.
• Do not use multicore cables containing both conductors connected to inductive power loads and signal conductors such as sensors and digital inputs.
• Make connection cables as short as possible, and avoid forming them into a spiral shape as inductive effects could damage the electronics.
• All the conductors used in the cabling must be appropriately proportioned to support the load they must power.

STEADYPRES automatically recognizes the power supply voltage (230 V or 115 V). To access the terminals of the electrical connections remove the cover of the STEADYPRES.
Inside the STEADYPRES, there is a:

• POWER INPUT terminal board (1)
• electric pump motor OUTPUT terminal board (2)
• CONNECTION OF ELECTRICAL SIGNALS terminal board (3) inbound and outbound (optional).

INSTALLATION OF FERRITES

• The provided ferrites (4a and 4b) reduce EMC noise and should be installed at the time of electrical connection.
• Prepare the POWER and MOTOR cables by removing the outer sheath as shown in Fig.➊
• Insert the longer-length ferrite (4a) into the POWER cable and the shorter-length ferrite (4b) into the MOTOR cable, as shown in Fig.➋
• STEADYPRES can be prepared, on request, with metal power cable glands, connected to the ground, for passage of a shielded cable against EMC disturbance.

STEADYPRES CONNECTION CONFIGURED AS S/S (single phase output)

• SINGLE PHASE power supply 230 V / 115 V – 50 Hz or 60 Hz
  • Connect the power cable to the power input terminals N and L of the STEADYPRES.
• SINGLE PHASE electric pump output 230 V / 115 V – 50 Hz or 60 Hz
  • Connect the cable of the motor to the terminals W and V of the STEADYPRES.

STEADYPRES CONNECTION CONFIGURED AS S/T (three-phase output)

• SINGLE PHASE power supply 230 V – 115 V – 50 Hz or 60 Hz
  • Connect the power cable to the power input terminals N and L of the STEADYPRES.
• THREE PHASE electric pump output 400 V | 200 V – 50 Hz or 60 Hz
  • Connect the motor cable to the power output terminals W, V, and U of the STEADYPRES.
  • The 230/400 V three-phase motor must be connected in DELTA.

Ensure the pump connected to the STEADYPRES has the voltage corresponding to the power supply of the STEADYPRES:

• STEADYPRES power supply at 230 V electric pump at 230 V
• STEADYPRES power supply at 115 V electric pump at 115 V

SUBMERGED SINGLE PHASE ELECTRIC PUMP CONNECTION (with 4 CABLES)

INSTALLING THE EXPANSION BOARD (optional)

Disconnect the voltage to the inverter and wait 2 minutes to discharge the capacitors.

• Remove the front cover to access the board compartment.
• Install the board (1) in position, correctly connecting the connector (2) in its compartment.
• Tighten the three fastening screws (3).
• Re-assemble the front cover correctly.

CONNECTION OF ELECTRIC SIGNALS (optional)

• Only for STEADYPRES equipped with an expansion board.
• For installation of the expansion board, see the chapter on INSTALLING THE EXPANSION BOARD.

• Use cable entry/exit points A and B to pass the signal cables to connect to the expansion card.

DESCRIPTION OF TERMINAL FUNCTIONS

FUNCTIONALITY

CONNECTION OF THE SIGNAL BETWEEN THE INVERTERS (RS485) Connect:

• the terminals 3 of the various inverters (RS 485 –)
• the terminals 4 of the various inverters (RS 485 +)

CONNECTION OF THE ALARM SIGNAL – OUTPUT outwards

• (in the applications with the inverter parallel, the wiring must be carried out with the MASTER inverter)
• Logic NO (normally open)
• Connect the signal cable to the terminals 5 and 6
• The maximum connectable load is 0.5 A at 250 Vac

CONNECTION OF LEVEL SIGNAL (or another input signal) – INPUT from outside

• Connect the signal cable to the terminals 7 and 8 (clean contact)
• In the applications with the inverter parallel, the wiring must be carried out with the MASTER inverter

START-UP

• Before starting, it is essential to have carefully read this manual and follow the instructions; you can thereby prevent wrong settings and maneuvers that could cause operating faults.
• Before the start-up of the system, it is essential to carry out any priming of the pumps (filling and purging air) see chapter “OPERATION IN MANUAL MODE (test and priming)”.
• When STEADYPRES is powered, it will be:
  • IN SERVICE if at the time of last switch off, it was IN SERVICE.
  • OUT OF SERVICE if at the time of last switch off, it was OUT OF SERVICE.
• In the event of accidental contact with the voltage, if STEADYPRES was IN SERVICE, on resetting the mains, it returns IN SERVICE.
• To start STEADYPRES, press the ON/OFF key on the control panel and press it again to place it out of service.

ADJUSTING THE WORKING PRESSURE

The WORKING PRESSURE is displayed via the GREEN LEDS that light up on the control panel, and which range from a minimum of 1 bar to a maximum of 9 bar.

• A fixed GREEN LED indicates a full bar
• A flashing GREEN LED indicates a 0.5 bar

To adjust the WORKING PRESSURE:

• Press the key + to display the working pressure.
• Press the keys + to increase or decrease the WORKING PRESSURE.
• On each press of the key + you – increase or decrease the value in steps of 0.5 bar.

EXAMPLE

• Press the key + to display the working pressure.
• With the green LEDs on, as in the figure, the working pressure is 2.5 bar
• Each press of the key + increases the pressure by 0.5 bar.
• For example, to bring the working pressure from the current 2.5 bar to 4 bar, press the key three times +
• The value increases by 1.5 bar (0.5 + 0.5 + 0.5 bar)
• The LEDs switch on as illustrated in the figure.
• Working pressure 4 bar

WORKING PRESSURE (test and priming)

These operations are exclusively intended for qualified staff.

From the OUT OF SERVICE status, you can manually start the electric pump, for TESTING and PRIMING.

• Press the set of keys for 5 seconds (all the LEDs flash to indicate the STEADYPRES is ready to start in manual mode)
• Press the ON/OFF button
• The pump starts at a minimum speed.
• On the control panel, the LEDs assume the status in continuous rotation, and the status LED is fixed green.

To read the PRESSURE

• Press the key + to display the working pressure.
• The status LED turns GREEN.
• Press the keys + or – to increase or decrease the WORKING PRESSURE (steps of 0.5 bar).

To read the CURRENT

• Simultaneously press the keys + and – for 1 second.
• The status LED turns RED.
• Press the keys + or – to increase or decrease the CURRENT (steps of 0.5 A).

To read the FREQUENCY or PRIME the pump

• Simultaneously press the keys + and – for 1 second.
• The status LED turns BLUE.
• Press the keys + or – to increase or decrease the FREQUENCY (steps of 5 Hz. The first LED has a value of 30 Hz).
• To prime the pump, increase the frequency up to 50 Hz to have the maximum priming capacity.
• If priming does not take place approximately within 4 minutes, the procedure interrupted, and all the hydraulic and mechanical checks should be carried out in this case.

EXAMPLE

GREEN status led

• 1 LED fixed = 1 bar
• 1 LED flashing = 0.5 bar

RED status led

• 1 LED fixed = 1 A
• 1 LED flashing = 0.5 A

BLUE status led

• LED 1 fixed = 30 Hz
• Subsequent LEDs fixed = 5 Hz

ALARMS

TROUBLESHOOTING

• Check the inverter is correctly connected to the power line.
• Check the electric pump is correctly connected to the inverter.
• Check all the cables and connections are working.

RECORD

• STEADYPRES does not require any type of routine maintenance if used within the use limitations and in compliance with the instructions outlined in this manual.
• Only authorized service centers may carry out reactive maintenance or repairs.
• Use only original spare parts for repairs. The manufacturer cannot be held in any way liable for damage to people, animals, or property due to maintenance interventions carried out by unauthorized staff or using non-original materials.

REPLACING THE FUSES

• Disconnect the voltage to the inverter and wait 2 minutes to discharge the capacitors.
• Remove the front cover.
• Unscrew and remove the three screws (1).
• Unscrew and remove the four spacers (2).
• Disconnect the connectors (3) and (4).
• If present, remove the expansion board (5).
• Remove the internal cover (6).
• Replace the fuse (7) with one of the same capacity (16 A).
• Re-assemble everything correctly following the operations in reverse order

DIMENSIONS

DISPOSAL

• For disposal of the parts composing the STEADYPRES comply with the standards and legislation in force in the country in which the unit is used.
• Do not dispose of polluting parts in the environment. Correct disposal of WEEE (DIRECTIVE 2012/19/EU)

DECLARATION OF CONFORMITY.

We hereby declare, under our sole responsibility, that this product complies with the provisions of the following EU Directives, including the latest amendments, and with the relevant national transposing legislation:

• 2014/35/EU Low Voltage Directive
• 2011/65/EU Hazardous substances in electronic equipment (RoHS)
• 2012/19/EU and 2003/108/EEC Hazardous substances in electronic equipment (RoHS)
• 2014/30/EU Electromagnetic Compatibility Directive (EMC)
• UK legislation: 2016 No. 1101, 2012 No. 3032, 2016 No. 1091
• San Bonifacio, 16/01/2023

Correct disposal of WEEE (DIRECTIVE 2012/19/EU)

CONTACT

• PEDROLLO S.p.A.
• Via E. Fermi, 7 37047 San Bonifacio (VR) – Italia
• Tel. +39 045 6136311
• Fax +39 045 7614663
• E-Mail: sales@pedrollo.com
• www.pedrollo.com.

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