ITT HV 2.022, HV 4.055, HV 2.015, HV 4.040, HV 4.075 Operating Instructions Manual
...
HV 2.015 / 2.022
HV 4.022 / 4.033 / 4.040
HV 4.055 / 4.075 / 4.110
EN: ENGLISH Motor-mounted
DE: GERMAN-DEUTSCH Motormontage
IT: ITALIANO Montaggio su motore
FR: FRANÇAIS Montée sur moteur
NL: NEDERLANDS Montage op de motor
PT: PORTUGUÊS Montada em motor
ES: ESPAÑOL Motor-Instalado
771079402 Manual HV 2.015-4.110-VL-A
Operating Instructions
HV 2.015 / 2.022
HV 4.022 / 4.033 / 4.040
HV 4.055 / 4.075 / 4.110
Motor-mounted
English
2
Index
1 Important safety instructions ................................................................................5
2 System Design........................................................................................................8
2.1 Pressure tank............................................................................................8
3 Product Overview...................................................................................................9
3.1 Hardware Configurations ........................................................................9
3.2 Operation Modes .....................................................................................9
3.2.1 Actuator (for single pump operation only!) ............................................................ 9
3.2.2 Controller................................................................................................................ 9
3.2.3 Cascade Relay ....................................................................................................... 10
3.2.4 Cascade Serial....................................................................................................... 11
4 Type designation code.........................................................................................13
5 Technical Data......................................................................................................14
5.1 General Technical Data ..........................................................................15
5.2 EMC (Electromagnetic compatibility) requirements .............................16
6 Dimensions and Weights .....................................................................................17
7 Modules ...............................................................................................................19
8 Mechanical Components .....................................................................................21
8.1 Included mounting material ..................................................................21
8.2 Optional Components............................................................................21
8.2.1 Fittings.................................................................................................................. 21
8.2.2 Sensors ................................................................................................................. 21
8.2.3 Filter ..................................................................................................................... 21
8.2.4 Ready-made Motor cables .................................................................................... 21
8.3 Assemble Instruction .............................................................................22
9 Electrical installation and wiring .........................................................................24
9.1 Means of protection ..............................................................................24
9.2 EMC-electromagnetic compatibility ......................................................25
9.3 Recommended Cable Types ...................................................................26
9.4 Wiring and connections .........................................................................27
9.4.1 Main Voltage Terminals ........................................................................................ 28
9.4.2 Motor connection................................................................................................. 29
9.4.3 Power Unit............................................................................................................ 30
9.4.3.1 Solo Run ................................................................................................ 31
9.4.3.2 Addressing............................................................................................. 33
9.4.4 Control Unit.......................................................................................................... 35
9.4.4.1 Control Card – HYDROVAR Master Inverter............................................ 35
9.4.4.2 Relay Card.............................................................................................. 42
9.4.4.3 Control Card – HYDROVAR Single Inverter ............................................. 44
3
10 Programming .......................................................................................................47
10.1 Display – Control panel of the Master / Single Inverter ........................47
10.2 Function of the push buttons................................................................47
10.3 Display of the Basic Inverter ..................................................................48
10.4 Software Parameters .............................................................................49
00 Main Menu ........................................................................................49
20 Submenu Status................................................................................54
40 Submenu Diagnostic .........................................................................57
60 Submenu Settings.............................................................................58
0100 Submenu Basic Settings .......................................................59
0200 Submenu Configuration Inverter..........................................62
0300 Submenu Regulation ............................................................68
0400 Submenu Sensor ...................................................................70
0500 Submenu Sequence Control .................................................73
0600 Submenu Errors ....................................................................78
0700 Submenu Outputs.................................................................79
0800 Submenu Required Values....................................................80
0900 Submenu Offset ...................................................................83
1000 Submenu Testrun .................................................................86
1100 Submenu Setups ..................................................................87
1200 Submenu RS485-Interface ....................................................88
11 Failure Messages ..................................................................................................89
11.1 Basic Inverter..........................................................................................90
11.2 Master / Single Inverter..........................................................................91
11.3 Internal Errors ........................................................................................94
12 Maintenance ........................................................................................................96
Follow the Pump Operating and Maintenance Instructions
We reserve the right to alter specifications
4
1 Important safety instructions
Read and follow the operating instructions and safety
instructions carefully before starting operations!
All modifications must be done by qualified technicians!
Warns that failure to observe the precaution may cause electric shock
Warns that failure to observe the precaution may cause personal injury or
damage to property.
In addition to the instructions contained in these operating instructions please pay
attention to universal safety and accident prevention regulations.
Basically the HYDROVAR must be disconnected from the power supply before any work can
be carried out in the electrical or mechanical part of the system.
Installation, maintenance and repair work may only be carried out by trained, skilled and
qualified personnel.
Unauthorized modifications or changes to the system make all guarantees null and void.
During operation, the motor can be stopped by open a digital input or manually operated,
whereby the HYDROVAR and the motor remain under voltage. For safety reasons, the
HYDROVAR has to be disconnected from the power supply when carrying out work on the
machinery.
When the HYDROVAR is connected to power supply, the components of the
power unit as well as certain components of the control unit are connected to
the power supply.
Touching these components seriously endangers life!
Before removing the HYDROVAR cover the system must be disconnected from
the power supply. After switching off the power supply wait
at least 8 minutes before starting work on or in the HYDROVAR (the
capacitors in the intermediate circuit are discharged by the installed discharge
resistors).
Voltages of up to 800 volts are possible (in case of an error these also can be
higher)
5
All work, carried out at opened HYDROVAR, may only be performed by
qualified and authorized staff.
Furthermore, care must be taken not to short circuit the neighbouring
components when connecting the external control wires and all cable ends
which are not in use are isolated.
The HYDROVAR contains electronic safety devices which switch off the control
element in the event of faults, whereby the motor has zero current but
remains energised and comes to a halt. The motor can also be halted by
mechanical blocking. If it is switched off electronically the motor is
disconnected from the mains voltage through the electronics of the
HYDROVAR but is not potential-free in the circuit.
In addition voltage fluctuations, especially power failures can cause the
system to switch off itself.
Repair of faults can cause the motor to start up again!
The system may only be put into operation when it has been grounded.
In addition, equipotential bonding of all conductive pipes must be
ensured.
(Please consider local installation standards!)
High voltage tests of the HYDROVAR or the motor may damage the
electronic components! Hence bridge the in- and outgoing
terminals L1 - L2 - L3 -- U-V-W before.
To avoid incorrect metering by capacitors incorporated in the electronic
part isolate the motor from the HYDROVAR.
The operating instructions must be read, understood and
followed by the operating personnel. We point out that we
accept no liability for damage and operating disorders
which are the result of non-compliance with the operating
instructions.
6
Transport, Handling, Storage, Disposal:
• Check the HYDROVAR immediately upon delivery/receipt of dispatch for damage or
missing parts
• The HYDROVAR unit must be transported carefully and by competent personnel.
• Avoid serious impacts
NOTICE!
The use of the WEEE Symbol indicates that this product may not be treated
as household waste.
Dispose of all packing materials and the HYDROVAR unit in accordance with
local regulations. For more detailed information about the recycling of this
product, please contact your local authority, your household waste disposal
service provider or the shop where you purchased the product.
CAUTION!
CAUTION!
WARNING!
Lifting aids (stacker, crane, crane mounting device, lifting blocks, sling
ropes, etc.) must have the proper dimensions so that they can bear the
weight of the HYDROVAR.
It is not allowed to carry the HYDROVAR around by using the connected
cables.
Do not damage the cable during transport (do not squeeze, bend or drag).
The cable ends must be kept dry.
• Do not stand underneath suspended loads
• take note of the general regulations on prevention of accidents
• The HYDROVAR must be secured against tipping over and slipping until
it has been fixed in its final location.
7
2 System Design
The following diagrams show typical single pump and multi-pump systems using the
HYDROVAR control unit. Connection can be made directly to a water supply. In such a case,
a pressure switch on the suction side should be used.
Single Pump Layout Multi Pump Layout
(1) pump with HYDROVAR
(2) diaphragm tank
(3) distribution panel
(4) gate valve
(5) non return valve
(6) low water control
(7) pressure gauge
(8) pressure transmitter
(9) drain tap
2.1 Pressure tank
A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure
in the line when there is no demand. This will keep the pumps from continuing to run at
zero demand. With the HYDROVAR, no large tanks are required for supply purposes.
The tank must be permitted and suitable for systems pressure. The tank should have a
capacity of min. 10% of the maximum system flow rate [l/min] of one pump (also valid for
multi-pump system).
Example:
Maximum flow rate of the pump = 250 litres per minute
Minimum volume of the tank = 250 x 0.10 = 25 litres
The pre-charge pressure of the tank can be determined by using the following table:
required pressure (bar) (system pressure)
precharge pressure (bar) (air pressure)
NOTICE:
To check and set the right pre-charge pressure, please make the tank
pressure less before.
8
3 Product Overview
3.1 Hardware Configurations
The HYDROVAR Modul Concept consists mechanically of two main parts, the Power Unit
and the Control Card. In its basic configuration (consists only of the Power Unit) the
HYDROVAR can be used as “Basic Inverter” without the need of the Control Card. In that
form the HYDROVAR can be used as a sequence pump in a multi pump system, but also as
a simple soft starter for single pump applications.
By extending this “Basic Inverter” with the additional Control Card, the HYDROVAR is able
to work in different modes and can be extended by the implementation of different
modules.
General Versions:
Basic Inverter – HYDROVAR in its simplest configuration, consists only of the power unit.
Application: Single pump operation as soft-starter, sequence pump in a multi pump system
Master Inverter – Full featured HYDROVAR including the high level Control Card (supports
also the optional modules like the optional “Relay Card” and all special software features).
Application:
- Single pump control including all extended features
- Multi pump system of “Master” and “Basic Inverters” (up to 8 pumps)
- Multi pump system equipped with up to 8 “Master Inverters”
- in combination with the optional “Relay Card” up to 5 fixed speed pumps can be
controlled with this kind of configuration
Single Inverter – HYDROVAR with Control Card developed only for Single pump operation
and less features in comparison with the Master Inverter. Additionally the Single Inverter
isn’t able to support any optional Modules like the Relay Card.
Application:
- Single pump control
3.2 Operation Modes
3.2.1 Actuator (for single pump operation only!)
In this mode the HYDROVAR operates as an Actuator with external speed signal or
switching between 2 programmed frequencies by using the corresponding digital input.
For this application the HYDROVAR operates like a standard frequency converter when an
external controller is used.
!!! Please consider that this mode is only possible by using a HYDROVAR Master or
Single Inverter and is limited for single pump operation only!!!
3.2.2 Controller
This mode should be selected if only one HYDROVAR pump is in operation and there is no
connection to any other HYDROVAR via RS485 interface.
9
3.2.3 Cascade Relay
One pump is fitted with a HYDROVAR “Master Inverter” and up to 5 full speed slave pumps
can be switched ON and OFF on demand. For this purpose an additional relay card with 5
relays is used in the “Master Inverter”. Each Relay can be activated or deactivated
depending on how many pumps are connected.
Basically an external panel is needed for all the motor relays, because the relays in the
HYDROVAR can’t switch the pumps directly as they are just used as switch contacts.
Also an automatic change over of the fixed speed pumps to provide even wear and achieve
even operating hours is possible in this mode.
This configuration would be a simple alternative compared with other solutions using
VFD’s on each pump, but in any case care has to be taken due to the lower operating
safety of such a system.
Application Example
Booster sets up to 6 pumps where only one pump is speed controlled by the HYDROVAR
and the others are fixed speed (1 HYDROVAR Master Inverter+5 fixed speed). This should
be the standard configuration when the additional “Relay Card” is used.
External panel
External panel
External panel
External panel
max. 5 fixed
speed units
10
3.2.4 Cascade Serial
In this mode there are various possibilities to combine the different versions of the
HYDROVAR, which will be explained on the following pages.
In general each of the pumps is equipped with a HYDROVAR unit. All units are connected
via the RS485 interface and are communicating via standard MODBUS-Format (fixed with
9600 Baud, RTU, N81).
To realise a fully controlled system at least one “Master Inverter” is needed, the other
pumps could be fitted just with a “Basic Inverter”.
The controller in the “Master Inverter” is informed about the status and a possible failure
of the “Basic Inverters” all the time. All possible failures will be indicated on the Master
unit, including also the date and real time when the failure happened.
The complete control will be done via the “Master Inverter” every time, but also an
automatic change over of the lag pumps to provide even wear and achieve even operating
hours will be possible .
If the Control Card of a “Master Inverter” fails, each of the “Basic Inverters” can be
manually started by an external switch (manual operation) in order to ensure an
“emergency operation” of the system.
Application Example
Each pump of the system (extended up to 8 pumps) is equipped with a HYDROVAR unit (at
least one “Master Inverter” and the others can be “Basic Inverters” in order to ensure a
proper control of the system) which are connected via the serial interface.
The combination of the different HYDROVAR units that are used in a multi-pump-system
depends on the system requirements (i.e. in a 6 pump system 2 “Master Inverters” can be
used due to safety reasons and 4 “Basic Inverters” without Control Card – or just any other
configuration)
Minimum requirement: 1 “Master Inverter” and the others equipped with “Basic Inverters”
RS 485
connection
extended up
to 8 pumps
11
To increase the operating safety of such a system, also a second “Master Inverter” could be
used:
RS 485
connection
extended up
to 8 pumps
Full-featured Possibility: Each pump is equipped with a “Master Inverter”
RS 485
connection
extended up
to 8 pumps
In this mode it is possible to run all pumps in multi-controller mode and synchronous mode
as well!
This configuration allows each pump of the system to become a lead pump. This ensures a
proper operation if one “Master Inverter” fails, either another one is used to take the “full
responsibility” and a steady control of the system. That ensures that the operating hours of
each separate pump will be on the same level to ensure even wear of the pumps.
12
4 Type designation code
HV . - - - - - - - .
Software Version
A = Western Europe
B = Eastern Europe
C = Northern Europe
Hardware Version
Optional Components
Relay Card (0= without / R= included)
Display (0= without / 1= included)
EMC Protection Filter
A = A- Filter (industrial environment)
B = B- Filter (domestic environment)
Language
Optional Card
Bus Card
Enclosure Class (IP Class)
2= IP 21
5= IP 55
Hardware Configurations
M = Motor mounted Unit
W = Wall mounted Unit
1= Basic Inverter
2= Single Inverter
3= Master Inverter
Rated Output
022= 2,2 kW 055= 5,5 kW
030= 3,0 kW 075= 7,5 kW
040= 4,0 kW 110= 11kW
Nominal mains voltage
1= 1~/1~ 230VAC 3= 3~/3~ 230VAC
2= 1~/3~ 230VAC 4= 3~/3~ 380-460VAC
Example
HV 4 . 0 4 0 - M 3 - 5 - B - 1 0 R 0 - G- A - V 0 1 . 1
The mentioned HYDROVAR in this example is specified with following technical data:
Nominal mains voltage: 3~/3~
380-460VAC
Rated Output: 4 kW
Hardware Configurations: Motor mounted unit - Master Inverter
Enclosure Class: IP 55
EMC-filter: B - Filter (domestic environment)
Optional Components: Display, Relay-Card
Hardware Version: G
Language: A: Western Europe (DE, EN, FR, NL, IT, ES, PT)
Software Version: V01.1
13
5 Technical Data
HYDROVAR Power Supply
Type Rated
output
Voltage limits
48-62 Hz
Rated current
input
Recommended
line protection
Maximum
connection
HV [kW] [V] [A] [A] [mm²]
2.015 1,5 14,0 20
2.022 2,2
1~230 ± 15%
20,0 25
10
4.022 2,2 7,6 13
4.030 3 9,1 13
4.040 4
3~380-460 ± 15%
11,4 16
10
4.055 5,5 15,1 20
4.075 7,5 19,6 25
4.110 11
3~380-460 ± 15%
27,8 32
10
HYDROVAR Output to the motor
Type Rated
Output
Max. Voltage Output Rated Current
output
Motor connection cables
HV [kW] [V] [A] mm²
2.015 1,5 7
2.022 2,2
3~ Uin
10
4x1,5 – 4x4
4.022 2,2 5,7
4.030 3 7,3
4.040 4
3~ Uin
9
4x1,5 – 4x4
4.055 5,5 13,5
4.075 7,5 17
4.110 11
3~ Uin
23
4x2,5 – 4x6
Make sure that the HYDROVAR’s electrical data match those of the electric
pump. Improper combinations may cause malfunctions and fail to ensure the
protection of the electric motor.
The rated current of the motor must be lower than the rated current of the HYDROVAR
to prevent overheating or shutdown due to “OVERLOAD”.
The max. output current of the HYDROVAR could reach 110% of the nominal current for
max. 60 sec. before the error “OVERLOAD” will occur.
14
5.1 General Technical Data
Ambient temperature:
0° C ... +40°C
At higher temperatures a reduction of the output current or
the use of the next HYDROVAR type is necessary.
110
100
90
80
70
60
50
40
max. output current [%]
30
20
10
0
0 102030405060
max. ambient temperature [°C]
o Protect the HYDROVAR against direct sunlight!
o Outdoor installation without protection of the
HYDROVAR is not permitted!
Storage temperature:
Humidity:
Air pollution:
Altitude:
Class of protection:
-25° .C ... +55° C (+70°C during max. 24 hours.)
RH max. 50% at 40°C, unlimited
RH max. 90% at 20°C, max. 30 days per year
75% average per year (Class F)
Condensation is not permitted!
The air may contain dry dust as found in workshops where
there is no excessive quantity of dust due to machines.
Excessive amounts of dust, acids, corrosive gases, salts etc.
are not permitted
max. 1000m above sea level
At sites over 1000 m above sea level, the maximum output
power has to be derated by 1% for every additional 100m.
If the installation site is higher than 2000 m above sea level,
please contact your local distributor.
HV 2.015 / 2.022
HV 4.022 / 4.033 / 4.040 IP 55, NEMA 4 (Indoor only)
HV 4.055 / 4.075 / 4.110
Certifications:
CE, UL, C-Tick, cUL
15
5.2 EMC requirements (Electromagnetic compatibility)
The EMC requirements differ between two environments which depending on the intended
use.
• First environment – class B (EN 61800-3: Class C2)
Environment that includes domestic premises, it also includes establishments directly
connected without intermediate transformers to a low-voltage power supply network
which supplies buildings used for domestic purposes.
E.g. Houses, apartments, commercial premises or offices in a residential building are typical
examples of first environment locations.
Be careful
: The relevant EMC regulations for which the HYDROVAR is tested in the first
environment consider that the HYDROVAR is a restricted available product. That means the
voltage of the inverter is less than 1 000 V, it is neither a plug in device nor a movable
device and, when used in the first environment, is intended to be installed and
commissioned only by a person or an organisation having necessary skills in installing
and/or commissioning power drive systems, including their EMC aspects.
• Second environment – class A (EN 61800-3: Class C3)
Environment that includes all establishments other than those directly connected to a low
voltage power supply network which supplies buildings used for domestic purposes
E.g. Industrial areas, technical areas of any building fed from a dedicated transformer are
typical examples of second environment locations.
The HYDROVAR complies with the general EMC regulations and is tested according
to the following standards: EN 61800-3/2005
EN 55011 (2002) Disturbance voltages / Disturbance field strength
First environment
– class B / class C2
Second Environment
– class A / class C3
Disturbance voltages OK OK
Disturbance field stength *) OK
*) Warning - In a domestic environment, this product may cause radio interference, in which case
supplementary mitigation measures may be required.
EN 61000-4-2 (2001) Electrostatic Discharge
EN 61000-4-3 (2002) Electromagnetic field immunity test
EN 61000-4-4 (2001) Burst Immunity Test
EN 61000-4-5 (2001) Surge Immunity Test
EN 61000-4-6 (1996) Immunity of Conducted RF-Disturbance
EN 61000-4-11 (2001) Voltage dips and interruptions
16
6 Dimensions and Weights
HV 2.015 / 2.022
HV 4.022 / 4.030 / 4.040
All dimensions in millimetres! Drawings are not in scale!
Lifting aids must have the proper dimensions.
Type Weight [kg]
Basic
Master/
Single
HV 2.015
HV 2.022
HV 4.022
4,00 4,40
HV 4.030
HV 4.040
a … minimum centre-distance between the HYDROVAR 300 [mm]
b … expansion space for maintenance 110 [mm]
17
HV 4.055 / 4.075 / 4.110
All dimensions in millimetres! Drawings are not in scale!
Lifting aids must have the proper dimensions.
Type Weight [kg]
Basic
HV 4.055
HV 4.075
7,70 8,10
HV 4.110
a … minimum centre-distance between the HYDROVAR 430 [mm]
b … expansion space for maintenance 110 [mm]
Master/
Single
18
1 2 3 6 1 2 3 5 4 6 5
7 Modules
Regarding to your application the needed configuration which is available for the
HYDROVAR can be selected. Due to this possibility the HYDROVAR can be configured
regarding the operation safety and cost effectiveness for your specific application.
HV 4.022 / 4.033 / 4.040 HV 4.055 / 4.075 / 4.110
4
19
(1)
(2)
(3)
(4)
(5)
Relay Card
The optional Relay Card allows to control up to 5 fixed speed pumps (can be only
used in combination with the Master Inverter).
Control Card
The control card is used for the Master/Single Inverter and includes the I/O’s for
the digital and analogue signals (i.e. actual value input, run/fault relay output)
and the Display unit.
Display Unit
Depending to the installation position the display can be turned to your prefered
position!
(The push-buttons will change automatically when turning the display!)
Filter Card
Optional Filter Card to ensure EMC regulations for domestic environments.
Mounting Kit
The Mounting Kit consists of the Metal and the Plastic Cover. On the Plastic Cover
there are fixed the Control Card, the Display and also the additional Relay Card if
used. The Pre-mounted cable-clips, which are necessary to connect the screen of
all signal cables to HYDROVAR-ground, are placed on the Metal Cover.
(6)
Power Unit
In its standard form it will be used as Basic Inverter or as simple soft starter in a
single pump application!
When using a Master configuration the power unit is fitted with an additional
control card!
20
8 Mechanical Components
8.1 Included mounting material
Included
components
M M M M M M
12 16 20 25 12 16
Cable
diameter
[mm]
2.015- 2.022 2 (3) 2 2 3 1 1 4 1 10
4.022- 4.040 2 (3) 2 2 3 1 1 4 1 10
4.055- 4.110 2 (3) 2 2 3 1 1 4 1 10
( ) max. available cable entries
3,5-7 4,5-10 7-13 9-17
Cable gland Closing gland Motor PTC Mounting
clamps
Center-
piece
Terminals
for max.
[mm²]
8.2 Optional Components
8.2.1 Fittings
Mounting ring
Available for the diameters: 140 mm
155 mm
Mounting ring
CAUTION!
If the HYDROVAR is mounted on a motor with plastic fan cover, a stainlesssteel mounting ring must be used.
8.2.2 Sensors
• pressure-transducer • temperature-sensor
• differential-pressure-transducer • flow indicator
• level-sensor
(orifice plate, inductive flow meter)
8.2.3 Filter
• Line-coils
8.2.4 Ready-made Motor cables
Available for HV 2.015 – 4.110
21
8.3 Assemble Instruction
HV 2.015 – HV 4.110
4 Screws
M5x60
4 screws (to fix the cover)
HYDROVAR - cover
Display
Centre bit
4 Mounting clamps
Motor fan cover
Motor
Motorcable
Motor conduit box
PTC
Pressure transmitter
22
To remove the HYDROVAR – cover, the 4 fastening screws must be opened.
o Ensure that there is no water on the unit before you open the cover.
• The HYDROVAR has to be positioned on the motor fan cover (check if the mounting of
the motor fan cover is done properly).
• Try to centre it as good as possible using the rubber centre bit.
o
If the HYDROVAR is mounted on a motor with plastic fan cover, a stainless steel
mounting ring must be used.
• The HYDROVAR is installed on the motor fan cover by using the mounting brackets, the
four screws and the related washers.
• The HYDROVAR has to be centred and then the four screws must be tightened.
• Tighten each fastening screw until the two bottom teeth in the brackets start to grip the
fan cover.
• After the electrical components are connected, the top cover on the HYDROVAR can be
mounted and tightened by the four fastening screws.
o Make sure of a good connection of the ground wire.
o Control the gasket of the HYDROVAR before tighten the fastening screws.
o Ensure that the mounting of the cable glands is done properly and use closing
glands for cable-bushings which aren’t used.
23
9 Electrical installation and wiring
All installations and maintenance have to be performed by properly
trained and qualified personnel with proper tools!!
Use personally protection equipment.
In case of a failure, the electrical power has to be disconnected or
switched off. Wait at least 8 minutes for capacitor discharge before
servicing the HYDROVAR.
Otherwise it can cause shock, burns or death.
9.1 Means of protection
Ask your power supply company which means of protection are required.
Applicable:
• protective earthing
• AC and DC residual current operated protective devices (RCD)
• TN systems
Protective earthing:
• Please note that a current to earth can occur due to the capacitors in the input filter.
• A suitable protection unit has to be selected (according local regulations).
Residual current device (RCD/RCCB):
• When using a RCD, make sure that it also releases in the event of a short circuit inside
the DC-part of the HYDROVAR to earth!
o single phase HYDROVAR => use pulse sensitive RCDs
o three phase HYDROVAR => use AC/DC sensitive RCDs
• The RCD has to be installed according local regulations!
Automatic circuit breaker:
• Use automatic circuit breaker with C-type characteristic curve
• Rating of the line-protection (see chapter Technical Data)
Internal protective devices of the HYDROVAR:
• The malfunctions short circuit, under- and over-voltage, overload and the
overheating of the electronic components are monitored internally by the
HYDROVAR.
External protective devices:
• Additional protective functions like motor overheat and low water protection, are
controlled by external equipment.
24
9.2 EMC-electromagnetic compatibility
To ensure the electromagnetic compatibility the following points must be observed for
cable installation:
Earth / ground to ensure EMC
• Protection earth
It is important to connect the HYDROVAR to PE, because of the earth leakage
current.
• HF earth connection
Ground cables should be as short as possible and with lowest impedance.
Signal cables
Control and signal cables should be screened types to prevent disturbances from outside.
The screen should be only connected to ground on one side; otherwise it is possible that
the screen has a ground current. The screen should be extensively connected with cableclips to HYDROVAR GND (use pre mounted cable-clips).
Pre-mounted cable-clips
To connect a screen with lowest impedance to ground, remove the isolation from the
signal cable and connect the screen extensive to ground.
Signal cables must be installed separate from motor- and power- supply cables
If signal cables are installed in parallel to power supply cables (motor cables) for a longer
distance, the distance between these cables should be more than 200mm.
Don’t cross power cables with control cables-if this is not possible, cross them only in an
angle of 90°.
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Motor cables
To ensure the EMC compatibility and minimize noise level and leakage currents, keep the
motor cable as short as possible.
Additional component line choke (coil)
Line coils are available as an option and should be mounted between the HYDROVAR and
the main fuse. The Line coil should be as near as possible to the HYDROVAR.
Advantages:
• better efficiency
• reduction of harmonic currents
For the following applications additional line chokes are strongly recommended:
• high short circuit currents
• compensation-plants without a coil
• asynchronous motors which are responsible for a voltage drop >20% of the line
voltage
EMC summary
• Install potential equalization according local regulations
• Don’t install the power-cable in parallel to signal-cables
• Use screened signal-cables
• Connect only one end of the screen of a signal-cable to ground
• If screened motor-cables are used, both ends of the screen have to be connected to
ground
• Motor-cable as short as possible
• “Pigtails” should be prevented
9.3 Recommended Cable Types
To ensure the above mentioned points to guarantee EMC compatibility and a correct
function of the HYDROVAR the mentioned cable types should be used.
Application Recommended Cable-Type
- Motor-cables HV 2.015-2.022
HV 4.022-4.040
HV 4.055-4.075
HV 4.110
- Control- and Signal- Cables
4G1,5 + (2 x 0.75) FDF
4G1,5 + (2 x 0,75) FDF
4G2,5 + (2 x 0,75) FDF
4G 4 + (2 x 0,75) FDF
JE-Y(ST)Y … BD
JE-LiYCY … BD
- Cables connected to RS485 interface JE-Y(ST)Y 2 x 2 x 0,8 BD
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A
B C
F C E
A B
9.4 Wiring and connections
Remove the screws holding the top cover of the HYDROVAR.
Lift off the top cover. The following parts can be seen on a HYDROVAR Master / Single
Inverter:
HV 2.015 / 2.022 HV 4.022 / 4.033 / 4.040
D
E
(A) Power supply (D) Status-Relays (F) Terminal block:
- START/STOP_PTC
(B) Motor connections (E) RS-485 Interface - SOLORUN
- User Interface - RS-485 Interface
(C) Optional Relay Card - Internal Interface
HV 4.055 / 4.075 / 4.110
D
F
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9.4.1 Main Voltage Terminals
The power supply is connected to the power section:
terminal L1 + N (1 x 230 VAC, single-phase)
terminal L1+ L2 + L3 (3 x 400 VAC, three-phase)
HV 2.015 / 2.022 HV 4.022 / 4.033 / 4.040
L1-N
L1-L2-L3
3x400 VAC
1x230 VAC
Power Supply
HV 4.055 / 4.075 / 4.110
Motor Connection
U-V-W
(Crimp connection 6,3mm)
Power Supply
L1-L2-L3
3x400 VAC
Motor
Connection
U-V-W
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Y D R O
9.4.2 Motor connection
Mounting of the PTC
Variant A : Variant B :
Motor block
PTC
Terminal block
Rubber gasket
Cover of the
1. The cover of the conduit box must be opened and the terminal block inside removed
2. Fix the PTC (Variant A or B)
3. Remounting of the terminal block
4. Electrical connection of the motor cables
The PTC must be fixed to the metal compound of the motor. This is necessary to
measure the right temperature of the motor!
The connection of the motor cable depends on the type of the motor and can be done in
star- or delta connection.
The right connection of the motor has to be selected as shown on the motor label
according to the output voltage of the HYDROVAR.
star - connection delta - connection
H
Y
D
R
O
V
A
U
V
W
U
V
W
H
V
A
U
V
U
V
W
PTC
PTC
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