Retrofit BrochureRetrofitting the ‘plug and play’ HYDROVAR units to a fixed speed booster set not only eliminates the need for a control panel but also introduces a soft start function, that when combined with the benefits of running a pump at a variable speed, can prolong the life of the pump and the water system. By reducing the in-rush current when the pump is turned on, parts such as motor bearings and pipe fittings are protected from hydraulic shock that can cause cavitation and breakdown.

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Connecting a HYDROVAR couldn’t be simpler; here we demonstrate an installation in just five steps:

Step One: Assessment of the installation site and the current pump activity.

retrofit-step1Before any HYDROVAR installation, the site and its current equipment should be assessed to determine the current level of energy being consumed and the kW of the motor. From here, the installer can calculate how much the booster set or heating pump is costing on an annual basis by calculating 0.22 Euros per hour for each kilowatt of energy consumed. An 11kW single pump will therefore cost €2.42 per hour to run at full speed. Once this cost has been multiplied by the number of pumps that are in use, the installer can explain in monetary terms what an average 50 per cent reduction in energy consumption would save the end user.

Step Two: Clamping the HYDROVAR into place.

The HYDROVAR sits directly onto the pump and utilises the cool air emitted from the fan vents to prevent overheating. This means that there is no need for an additional cooling unit, keeping the footprint of the HYDROVAR to a minimum and not utilising valuable wall space. Fixings are located on the outer casing so no need to remove the casing of the HYDROVAR as previous models. Use the four mounting clamps provided together with the central post pin and secure it to the metal fan cowl of the pump unit. The clamps are designed to fit all IEC motors. Stainless steel ring supports are available for motors fitted with plastic fan cowls. Wall mounted versions are available as an option.


Step Three: Pump Terminal Wiring.

retrofit-step3After attaching the cable glands to the exposed gland plate on the left hand side of the HYDROVAR, unscrew and remove the front of the pump motor terminal box. Take the HYDROVAR connection cables (purchased separately or made using standard wires and connections) and feed the motor terminal end of the cable through the cable entry points, connecting it to the relevant terminals. If you are retrofitting the unit to an existing booster set then the power supply needs to be rerouted directly into the HYDROVAR. No PCT is required and this is now done by the internal software of the HYDROVAR. Once this is done, reattach the terminal front cover, ensuring that the water seal is correctly in place.

Step Four: HYDROVAR wiring.

retrofit-step4Remove the wiring chamber cover and pass the other end of the connection cable through the cable inlet on the left hand side of the HYDROVAR, connecting it to the relevant power supply and signal wires. Once this is done, connect the transducer cable (also called the sensor or pressure transmitter) to the HYDROVAR through the same gland plate. The loose end of the transducer must then be connected to the pipe as close to the pump as possible.

Step Five: Completion and programming.

retrofit-step5After replacing the terminal cover lid of the HYDROVAR unit, programme the required bar pressure using the buttons and the screen. Depending on the number of pumps in the booster set, some very simple programming may be required. This is detailed clearly in the operating instructions manual. The first screen after powering up the unit will be the quick start guide after setting these parameters; the HYDROVAR will automatically begin its soft start and work to the system requirements.