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hydrovar® X for industrial systems

In industrial environments, pumps do much more than simply move water: they are an integral part of production processes. They supply washing, cooling, and filtration systems, handle process fluids, and manage recovery and recycling circuits. Any interruption or instability in one of these areas can quickly spread throughout the entire production line, impacting quality, timing, and costs. For this reason, pump control must be precise, reliable, and fully integrated with plant automation systems.

With hydrovar® X, we are not simply talking about a pump inverter, but about an integrated system composed of the eXM motor and the HVX inverter, designed to equip pumps and booster systems in modern industrial plants. This combination ensures optimized speed control, higher efficiency compared to traditional IE3 motors, compact dimensions, and intelligent, connected, and scalable operation capable of adapting to changing operating conditions without requiring continuous manual interventions.

“Precise flow and pressure control reduces process variability and helps maintain stable and repeatable operations — a key element in production lines.”
Massimo Rovoletto, product owner, AW, Italy

How hydrovar® X meets industrial requirements

hydrovar® X enables precise control of pump speed and system pressure, ensuring that the pump always operates as close as possible to its optimal operating point, even when load conditions change throughout the production day or as the number of active users on the line varies. This makes processes more stable and predictable, reducing fluctuations that could compromise product quality or production continuity. In industries where even minimal variations in pressure or flow can affect a washing cycle, a cooling process, or a filtration phase, this level of control becomes a decisive factor in ensuring repeatable end results.

Intelligent multi-pump management

One of hydrovar® X’s key strengths is its ability to manage multi-pump systems with up to eight units, distributing the workload evenly among connected pumps rather than concentrating it on a single reference unit. In the event of maintenance or temporary shutdown of one pump, the load is automatically redistributed across the remaining units without interrupting the production process. This functionality makes it possible to:

  • balance the operating time of each unit and reduce wear
  • avoid single points of failure within the system
  • ensure greater operational continuity, even during maintenance or when a pump is temporarily out of service

The result is a significant improvement in overall plant reliability, particularly important for applications where unplanned downtime is not acceptable.

Integration with industrial automation systems

hydrovar® X is designed for seamless integration with industrial control and supervision systems without requiring dedicated communication architectures or complex proprietary solutions. Through standard communication protocols such as Modbus and BACnet, the pumping system can be connected to factory automation platforms, SCADA systems, and advanced monitoring and diagnostic solutions, enabling centralized management and full visibility of plant performance. In this way, the pump is no longer an isolated component but becomes an integral part of the plant’s digital ecosystem, communicating with other control systems in real time.

Integrated protection and advanced diagnostics

To reduce the risk of unexpected downtime, hydrovar® X includes several protection and monitoring functions:

  • complete motor protection against overloads and critical operating conditions
  • system protection functionalities against dry running, overpressure, underpressure, and water hammer; the Setpoint Shift function allows the operating point to vary according to external conditions (for example, low suction pressure), enabling the system to continue operating even under critical conditions
  • integrated THDi filters, which improve power quality by reducing harmonic distortion fed back into the electrical network
  • compatibility with condition monitoring systems, helping identify anomalies before they develop into actual failures
  • an extended error log that enables comprehensive analysis of operating anomalies

These capabilities support the transition from reactive maintenance, based on intervention after failure, to a more preventive and predictive approach, where interventions are planned according to the actual condition of components rather than fixed maintenance intervals.

Benefits for industrial applications

Thanks to precise flow and pressure control, hydrovar® X makes processes more stable, repeatable, and reliable, reducing unwanted system fluctuations. Automatic pump management and integrated protection functions also help minimize unplanned downtime: the system can quickly respond to abnormal conditions and maintain plant operation even in critical situations. Furthermore, integration with supervision systems allows operators to monitor performance, operating parameters, and pump status in real time, improving operational efficiency and decision-making quality.

Optimizing Total Cost of Ownership (TCO)

One of hydrovar® X’s main objectives is reducing the Total Cost of Ownership (TCO). Thanks to intelligent speed control and efficient pump management, the system avoids running units at fixed speed when the process does not require it, adapting operation to actual demand rather than nominal conditions. This results in significant energy savings, reduced maintenance costs due to less mechanical stress on components, and longer equipment lifespan. Over time, these benefits translate into a measurable and tangible economic return that goes beyond the initial purchase cost of the system.

Massimo Rovoletto
Product Owner, AW, Italy