Hydrovar pump regulator repair

Hydrovar pump controller repair is part of our service offering, as these devices are often used in critical applications. The Hydrovar is a pump controller that is sold by several companies. Its task is to regulate the pump output as required. To make this possible, it has an integrated frequency converter.

As it is technically a combination of control unit and frequency inverter, both components need to be analysed specifically in the event of a fault. Our experience in the Frequency converter repair helps us to efficiently rectify even complex error patterns.

The Hydrovar is used in water supply, irrigation, heating control, fire extinguishing systems and pressure boosting systems, among others. In the event of a fault, we specifically analyse the control and power electronics, replace worn components and carry out extensive functional tests. In our article on Industrial electronics repair you will find more information about our working methods and our quality standards.

Operating modes of the Hydrovar pump controller

Thanks to the integrated Control and regulation the Hydrovar pump controller offers a wide range of possible applications in a variety of areas, such as building services engineering, industry or water management. For this reason, it supports several operating modes that ensure maximum efficiency and needs-based pump performance depending on the area of application. As part of a Hydrovar pump regulator repair an understanding of these operating modes is helpful in order to analyse and rectify faults in a targeted manner. Some of the most common operating modes are presented in the following section.

Manual mode

In actuator mode, the Hydrovar works purely as a power adjuster. It is controlled via an external frequency signal or by switching between two fixed speeds. The internal control remains inactive. This operating mode is usually used in combination with an external controller, which specifies the control commands and takes over the higher-level control.

Regular operation

In control mode, the Hydrovar assumes the function of both the actuator and the controller. The internal electronics enable fully automatic control of the pump performance - without the need for an additional control device. This simplifies installation and is ideal for applications where independent pressure or flow control is required.

Cascade operation

Several Hydrovar pump controllers can be networked with each other in cascade mode. Depending on the system configuration, there can be one or more masters. If only one master is used, it takes over complete control of the connected units. With several master devices, the system is designed to be fail-safe: If one master fails, another automatically takes over control. This function is particularly advantageous for systems with high availability requirements.

Error with the Hydrovar pump controller

Hydrovar pump controllers are available in power ranges from 1.5 to 22 kilowatts. Despite the different variants, the technical design is largely identical, which is why typical error patterns are often the same. Models with a display show errors via corresponding error codes, while devices without a display use a flashing code.

Many faults can be reset by completely disconnecting the power supply for at least 60 seconds. If the fault persists after this, it is referred to as a permanent fault. If, on the other hand, the fault only occurs occasionally, it is a sporadic or recurring fault.

Finding the cause of a Hydrovar pump controller repair can be challenging, especially in the case of sporadic problems, as the fault cannot always be reliably reproduced on the test bench. In such cases, experience, targeted analysis and, if necessary, the use of special test methods are crucial.

Error analysis in the exclusion procedure

If an error occurs permanently or repeatedly, the wiring and the connected sensors should be checked carefully first. If no abnormalities can be found there, you can use the error code or its meaning as the basis for a repair enquiry with us. We will be happy to assist you with further diagnosis and repair of the affected device.

Problems currently known to us

The most common problem we are currently aware of is the complete failure of the Hydrovar. In this case, the device no longer responds and both the power LED and the RUN LED remain dark. The Hydrovar shows no function at all. For further information, please contact us at 02826-88198 call or via the Contact form .