Xylem HYDROVAR User Manual

Operating Instructions

HV 2.015 / 2.022

HV 4.022 / 4.030 / 4.040

HV 4.055 / 4.075 / 4.110

HV 4.150 / 4.185 / 4.220

V 2012/03A-V01.4
771079412	Manual HV 2.015-4.220	ENGLISH

			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	Operating ..........................................................................................modes				9
3.2.1 ..........................................................		Actuator (for SINGLE pump operation only!)			9
3.2.2 ................................................................................................................		Controller			9
3.2.3 ..........................................		Cascade Serial / Synchronous (not for SINGLE version)			10
3.2.4 .................................................................		Cascade Relay (not for SINGLE version)			12
4 Type designation ............................................................................................code					13
5 Technical Data.........................................................................................................					14
5.1	General ...............................................................................technical data				15
5.2	EMC requirements ..................................(Electromagnetic compatibility)				16
6 Dimensions and ........................................................................................weights					17
7 Modules 20
8 Mechanical components .........................................................................................					22
8.1	Included ......................................................................mounting material				22
8.2	Optional .................................................................................components				22
8.2.1 ...........................................................................................		Mounting accessories			22
8.2.2 .................................................................................................................		Sensors			22
8.2.3 .....................................................................................................................		Filter			22
•	Line-coils ...........................................................................................................................				22
8.2.4 ......................................................................		Cable entry (only HV4.150 – 4.220)			22
8.2.5 .....................................................................................		Ready - made motor cables			22
8.3	Assembly ................................................................................instructions				23
9 Electrical installation ............................................................................and wiring					25
9.1	Means ...................................................................................of protection				25
9.2	EMC-electromagnetic ...........................................................compatibility				26
9.3	Recommended .......................................................................Cable Types				27
9.4	Wiring .............................................................................and connections				28
9.4.1 .........................................................................................		Main voltage terminals			29
9.4.2 .................................................................................................		Motor connection			30
9.4.3 ......................................................		Power unit		Errore. Il segnalibro non è definito.
	.................................................................................................	9.4.3.1	Solo run		32
	.............................................................................................	9.4.3.2	Addressing		34
9.4.4 ...........................................................................................................		RFI – switch			36
9.4.5 ..........................................................................................................		Control unit			37
	..........................................	9.4.5.1 Control card – HYDROVAR MASTER Inverter			37
	..............................................................................................	9.4.5.2	Relay Card		44

3

	9.4.5.3 Control card – HYDROVAR SINGLE Inverter (not for HV 4.150 – HV
	4.220)	46
10 Programming ........................................................................................................			49
10.1	Display – Control panel of the MASTER / SINGLE Inverter .........................		49
10.2	Function of the push buttons ....................................................................		49
10.3	Display of the BASIC Inverter .....................................................................		50
10.4	Software parameters..................................................................................		51
00 MAIN MENU ....................................................................................................			51
20 SUBMENU STATUS ...........................................................................................			56
40 SUBMENU DIAGNOSTICS .................................................................................			59
60 SUBMENU SETTINGS........................................................................................			60
0100 SUBMENU BASIC SETTINGS .........................................................................			61
0200 SUBMENU CONF INVERTER..........................................................................			64
0300 SUBMENU REGULATION ..............................................................................			72
0400 SUBMENU SENSOR ......................................................................................			74
0500 SUBMENU SEQUENCE CNTR. .......................................................................			77
0600 SUBMENU ERRORS ......................................................................................			82
0700 SUBMENU OUTPUTS ....................................................................................			83
0800 SUBMENU REQUIRED VALUES .....................................................................			84
0900 SUBMENU OFFSET .......................................................................................			86
1000 SUBMENU TEST RUN....................................................................................			89
1100 SUBMENU SETUP		.........................................................................................	90
1200 SUBMENU RS485-INTERFACE.......................................................................			91
11 Failure messages...................................................................................................			92
11.1	BASIC Inverter.............................................................................................		93
11.2	MASTER / SINGLE Inverter ..........................................................................		94
11.3	Internal errors.............................................................................................		97
Maintenance ..............................................................................................................			99
Programming flow chart ........................................................................................			100

Follow the pump operating and maintenance instructions

We reserve the right to alter specifications

4

1 Important safety instructions

Read and follow the operating and safety instructions carefully before starting operations!

All modifications must be done by qualified technicians!

Warning that failure to observe the precaution may cause electric shock

Warning that failure to observe the precaution may cause personal injury or damage to property.

In addition to 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 on the electrical or mechanical part of the system.

Installation, maintenance and repair work may be carried out only by trained, skilled and qualified personnel.

Unauthorized modification or changes to the system make all guarantees null and void.

During operation, the motor can be stopped by opening a digital input or manual operation 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 the power supply, the components of the power unit as well as certain components of the control unit are connected directly to mains.

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 5 minutes before starting work on or in the HYDROVAR (the capacitors in the intermediate circuit are discharged by the internal discharge resistors).

Voltages of up to 800 volts are possible (in case of error these also can be higher)

5

All work, carried out on the HYDROVAR, may only be performed by qualified and authorized staff.

Furthermore, take care not to short circuit the neighbouring

components when connecting the external control wires. All cable ends which are not in use have to be isolated.

The HYDROVAR contains electronic safety devices which switch off the control element in the event of a fault, 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 current less 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 itself off.

Repair of faults can cause the motor to start up again automatically!

The system may only be put into operation when it has been grounded. In addition to that, 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 inand 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 after delivery/receipt for damage or missing parts

•The HYDROVAR unit must be transported carefully.

•Avoid serious impacts

NOTICE!

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 waste disposal service provider or the outlet where you purchased the product.

CAUTION!

Lifting aids (stacker, crane, crane mounting device, lifting blocks, sling ropes, etc.) must be suitable to handle the weight of the HYDROVAR.

CAUTION!

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.

WARNING!

•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 and multi-pump systems using the HYDROVAR. Connection can be made directly to a water supply. In such a case, the use of a low pressure switch on the suction is recommended.

SINGLE pump layout

Multi pump layout

(1)	pump with HYDROVAR	(4)	gate valve	(7)	pressure gauge
(2)	diaphragm tank	(5)	non return valve	(8)	pressure transmitter
(3)	distribution panel	(6)	low water control	(9)	drain tap

2.1Pressure tank

A diaphragm pressure tank is used on the discharge side of the pump to maintain pressure in the line when there is no water demand. This avoids the pump 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]

pre-charge pressure [bar]

NOTICE: To check and set the right pre-charge pressure, please reduce the water pressure to zero by turning the HYDROVAR off.

8

3 Product overview

3.1Hardware configurations

The HYDROVAR modular concept basically consists of two main parts: the power unit and the control card. In its BASIC configuration (consisting of only the power unit) the HYDROVAR can be used as so called BASIC Inverter. In that configuration 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 attaching one of the additional control cards to the BASIC Inverter the HYDROVAR can be upgraded either to the so called SINGLE or the MASTER Inverter.

BASIC Inverter – HYDROVAR BASIC unit (not available for HV 4.150 – 4.220).

Application:

- Sequence pump in a multi pump system, SINGLE pump operation as soft-starter

SINGLE Inverter – HYDROVAR BASIC Inverter with included control card for SINGLE pump operation. This SINGLE Inverter is not able to support any optional modules like the Relay Card.

Application:

- Simple SINGLE pump applications

MASTER Inverter – HYDROVAR BASIC Inverter including the high level control card (supports also the optional modules like the Relay Card and all specific 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

-Control of up to 5 fixed speed pumps when used in combination with the optional relay card

3.2Operating modes

3.2.1 Actuator (for SINGLE pump operation only!)

In this mode the HYDROVAR operates as an actuator according an external speed signal or continuous operation on either one or two programmed frequencies by using the corresponding digital input.

Please consider that this mode is only possible with a HYDROVAR MASTER or SINGLE Inverter and is limited for SINGLE pump operation only

3.2.2 Controller

This mode is set as default operating mode and is used for a HYDROVAR in SINGLE pump operation when there is no connection to any other HYDROVAR via the internal RS485 interface.

9

3.2.3 Cascade Serial / Synchronous (not for SINGLE version)

In these modes various combinations among the versions BASIC and MASTER Inverter are possible.

In general each of the pumps needs to be equipped with a HYDROVAR unit. All the units are connected via the RS485 interface and communicate via the standard MODBUSprotocol (9600 Baud, RTU, N81).

To realise a fully controlled system at least one MASTER Inverter is needed, the remaining pumps could be fitted just with a BASIC Inverter.

The controller in the MASTER Inverter is continuously in communication with all the BASIC Inverters. All failures are indicated on the MASTER including the date and time.

All the control is done by the MASTER Inverter including automatic change over of the lag pumps to provide even wear and achieve even operating hours.

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 (up to 8 pumps) is equipped with a HYDROVAR unit (at least one MASTER Inverter and remaining ones can be BASIC Inverters). All units are connected via the serial interface (RS485).

The combination of the different HYDROVAR units which 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 reliability reasons and 4 BASIC Inverters without control card – or just any other combination).

Minimum requirement: 1 MASTER Inverter and the other pumps equipped with BASIC Inverters

10

To increase the operating reliability of such a system, also a second MASTER Inverter is recommended:

Full-featured possibility: Each pump is equipped with a MASTER Inverter

In this mode it is possible to run all pumps in cascade serial mode and synchronous mode as well.

This configuration allows each pump of the system to become the lead pump. This also ensures a proper operation if one MASTER Inverter fails. In this case another HYDROVAR takes control. This ensures that the operating hours of each pump will be the same to ensure even wear of the pumps.

11

3.2.4 Cascade Relay (not for SINGLE version)

One pump is fitted with a HYDROVAR MASTER Inverter and up to 5 slave pumps can be switched ON and OFF on demand. For this purpose an additional relay card including 5 relays is attached to the MASTER Inverter.

However an external switchboard is needed for all the motor relays as the relays in the HYDROVAR are not able to switch the pumps directly (just used as control 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 is a cost effective alternative compared with other solutions using VFD’s on each pump, but in any case care has to be taken due to the lower reliability 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).

12

4 Type designation code

HV

.

-

-

-

-

-

-

-

.

Software version

Language

1 = Western Europe resp. all lang. (with V01.4)

3 = Eastern/Northern Europe

Hardware version

Optional components

Optional card Relay Card (0= without / R= included)

Bus card Display (0= without / 1= included)

EMC protection filter

A = A- Filter (industrial environment) B = B- Filter (domestic environment)

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
150=15,0kW	185=18,5kW	220=22,0kW

		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 - 1 -

V

0

1

. 4

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:	1 (Western Europe) respectively all languages
Software version:	V01.4
	13

5 Technical Data

	HYDROVAR		Incoming power supply (data only for dimensioning of the power
			supply line and not for calculating the efficiency of the HV)
	type	rated	Voltage limits	nominal	recommended	maximum
		output	48-62 Hz	current input	line protection	cross-section
	HV	[kW]	[V]	[A]	[A]	[mm²]
	2.015	1,5	1~230 ± 15%	14,0	20	4
	2.022	2,2		20,0	25
	4.022	2,2		7,4	13
	4.030	3	3~380-460 ± 15%	9,1	13	4
	4.040	4		11,7	16
	4.055	5,5		17,5	20
	4.075	7,5	3~380-460 ± 15%	22,1	25	4
	4.110	11		29,9	32
	4.150	15		39,0	50
	4.185	18,5	3x380-460 ± 15%	48,1	50	25
	4.220	22		55,9	63

HYDROVAR			Output to the motor
type	rated	max. output voltage		nominal	motor connection cables
	output			current output
HV	[kW]	[V]		[A]	mm²
2.015	1,5	3x Uin		7,0	4x1,5 – 4x4
2.022	2,2			10,0
4.022	2,2			5,7
4.030	3	3x Uin		7,3	4x1,5 – 4x4
4.040	4			9,0
4.055	5,5			13,5
4.075	7,5	3x Uin		17,0	4x2,5 – 4x4
4.110	11			23,0
4.150	15			30,0	4x6 – 4x25
4.185	18,5	3x Uin		37,0
4.220	22			43,0	4x10 – 4x25

Make sure that the electrical data of the HYDROVAR match those of the electric pump. Improper combinations may cause errors and malfunction of the protection of the electric motor.

The nominal 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

5.1General technical data

Ambient temperature:

Storage temperature:

Humidity:

Air pollution:

Altitude:

Class of protection:

Certifications:

0° C ... +40°C

At higher temperatures a reduction of the output current or the use of the next HYDROVAR power size is necessary.

	110
	100
	90
[%]	80
	70
current
	60
output	50
	40
max.
	30
	20
	10
	0
	0	10	20	30	40	50	60

max. ambient temperature [°C]

The insulation rating of the HYDROVAR is IP55 however and in common with other IP55 equipment, please note the following:

•Protect the HYDROVAR from direct sunlight!

•Protect the HYDROVAR from direct rainfall

•Outdoor installation without protection to keep especially the temperature limits of the HYDROVAR is not permitted!

-25° C ... +55° C (+70°C during 24 hours max.)

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!

During long periods of inactivity or shutdown, the HYDROVAR should remain connected to the power supply but the ext on/off inhibited to prevent running of the pump. This will maintain power to the internal heater and reduce internal condensation. The air may contain dry dust as found in workshops where there is excessive dust due to machines.

Excessive amounts of dust, acids, corrosive gases, salts etc. are not permitted

Max. 1000m above sea level

For installations over 1000 m above sea level, the maximum output power has to be de-rated by 1% for every additional 100m.

If the installation site is over 2000 m above sea level, please contact your local distributor or service contact.

HV 2.015 / 2.022

HV 4.022 / 4.030 / 4.040 IP 55, NEMA 4 (indoor use only) HV 4.055 / 4.075 / 4.110

HV 4.150 / 4.185 / 4.220 CE, UL, C-Tick, cUL

15

5.2EMC requirements (Electromagnetic compatibility)

The EMC requirements in general 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 1000 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 61800-3/2004

EN 55011	(2002)	Disturbance voltages / Disturbance field strength
				Second Environment
			First environment
			– class B / class C2	– class A / class C3
Disturbance voltages			OK	OK
Disturbance field strength			*)	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

16

6 Dimensions and weights

HV 2.015 / 2.022

HV 4.022 / 4.030 / 4.040

All dimensions in millimetres!	Drawings are not to 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 HYDROVAR units				300 [mm]
b … expansion space for maintenance				300 [mm]

17

HV 4.055 / 4.075 / 4.110

All dimensions in millimetres!	Drawings are not to scale!
Lifting aids must have the proper dimensions.

	Type	Weight [kg]
		BASIC		MASTER /
				SINGLE
	HV 4.055
	HV 4.075	7,70		8,10
	HV 4.110
a … minimum centre-distance between HYDROVAR units			430 [mm]
b … expansion space for maintenance			300 [mm]

18

HV 4.150 / 4.185 / 4.220

All dimensions in millimetres!	Drawings are not to scale!
Lifting aids must have the proper dimensions.

Type	Weight [kg]
	MASTER
HV 4.150
HV 4.185	14,00
HV 4.220

a … minimum centre-distance between HYDROVAR	550 [mm]
b … expansion space for maintenance	300 [mm]

19

7 Modules

Regarding the application the specific configuration for the HYDROVAR can be chosen. Due to this possibility the HYDROVAR can be configured regarding the reliability and cost effectiveness for each type of application.

HV 4.022 / 4.030 / 4.040

HV 4.055 / 4.075 / 4.110

6

4

5 3

2

1

HV 4.150 / 4.185 / 4.220

6

4

1

5

20

Power unit

Without one of the control cards it can be used as BASIC Inverter or as simple soft

(1) starter in a SINGLE pump application!

When using a SINGLE or MASTER configuration the power unit is fitted with an additional control card (4)

	(2)	Filter card (not available for HV4.150-4.220, standard is class A)
		Ensures EMC compliance for domestic environments. (Class B)
		Mounting Kit
	(3)	Consists of the metal and plastic cover to fix the control card and the display (and
		the additional Relay Card if used). By the pre-mounted cable-clips, the screen of all

signal cables has to be connected to HYDROVAR-ground to avoid any interferences on the signals

(4)

(5)

Control card

either for MASTER or SINGLE Inverter

Display unit

2 line plain text indication for programming and read out.

Relay Card

(6) The optional Relay Card allows to control up to 5 fixed speed pumps (can be only used in combination with the MASTER Inverter).

21

8 Mechanical components

8.1Included mounting material

Included		Cable gland +					closing glad				Motor	Mounting	Centring
components		Lock nut									PTC	clamps	bit
	M	M	M		M	M	M	M		M
	12	16	20		25	40	12	16		50
Cable diameter	3,7- 7	-4,510	13-7		17-9	-1523
[mm]
2.015 – 2.022	2 (3)	2	2				3	1			1	4	1
4.022 – 4.040	2 (3)	2	2				3	1			1	4	1
4.055 – 4.110	2 (3)	2			2		3	1			1	4	1
4.150 – 4.185	4 (5)	2				2	4	2		1	1	4	1
4.220	4 (5)	2				2	4	2		1	1	4	1

( ) max. available cable entries

8.2	Optional components
8.2.1	Mounting accessories
Mounting ring
Available for diameters:		140 mm
		155 mm

Mounting

8.2.2 Sensors

•pressure-transducer

•differential-pressure-transducer

•level-sensor

8.2.3 Filter

•Line-coils

8.2.4Cable entry (only HV4.150 – 4.220)

• Multiple cable entry (M50)

8.2.5Ready-made motor cables

Available for HV 2.015 – 4.220

CAUTION!

If the HYDROVAR is mounted on a motor with a plastic fan cover, a stainless-steel mounting ring must be used to support the weight of the HYDROVAR.

•temperature-sensor

•flow indicator

(orifice plate, inductive flow meter)

22

8.3Assembly instructions

HV 2.015 – HV 4.110

HV 4.150 – HV 4.220

4 screws (to fit cover) M4x50 M5x20

HYDROVAR – top cover

4 screws M6x70

4 screws M5x70

display

centering bit

4 mounting clamps

motor cable

motor fan cover

motor

motor conduit box

PTC

actual value sensor

23

To remove the HYDROVAR – cover, the 4 fastening screws must be opened.

•Ensure that there is no liquid on the unit before you open the cover.

•Centre the HYDROVAR on the motor fan cover using the rubber centre bit.

•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 relevant 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 of the HYDROVAR can be mounted and tightened by the four fastening screws.

•Make sure of a good connection of the ground wire.

•Ensure HYDROVAR cover gasket is in place before tightening the fastening screws.

•Ensure that the mounting of the cable glands is done properly and use closing plugs for cable entries which are not in use.

*For HV4.150-4.220: Measure the right distance with the acceptance, the clamp and the screw together

			Max. Length			Adjust the length for smaller motor
						sizes
Adjust the length for smaller motor sizes
					take care about sharp edges and them properly
					Please	remove

24

9 Electrical installation and wiring

All installations and maintenance has to be performed by properly trained and qualified personnel with proper tools!!

Use personal protection equipment.

In case of a failure, the electrical power has to be disconnected or switched off. Wait at least 5 minutes for capacitor discharge before servicing the HYDROVAR.

Otherwise it can cause shock, burns or death.

9.1Means 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 an 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, underand overvoltage, 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.

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9.2EMC-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 end; to prevent ground loops. The screen should be connected to HYDROVAR GND (use pre mounted cable-clips).

For small cable diameters the cable clips can be squeezed to ensure fixing.

Pre-mounted cable-clips

To connect a screen with lowest impedance to ground, remove the insulation from the signal cable and connect the screen to ground.

Signal cables must be installed separate from motorand powersupply 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.

Do not cross power cables and 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 (use shielded cables only if the total length exceeds 1.5 meters).

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 (max. 30cm).

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 to local regulations

•Do not install the power-cables in parallel to signal-cables

•Use screened signal-cables

•Connect both ends of the screen of the motor cable to ground

•Connect only one end of the screen of a signal-cable to ground

•Motor-cable as short as possible

•Pigtails should be prevented

9.3Recommended Cable Types

To ensure the above mentioned points and to guarantee EMC compatibility and correct function of the HYDROVAR the recommended cable types should be used.

	Application		Recommended cable-type
	- Motor-cables HV 2.015-2.022		4G1,5 + (2 x 0.75)
	HV 4.022 – 4.030- 4.040		4G1,5 + (2 x 0,75)
	HV 4.055-4.075		4G2,5 + (2 x 0,75)
	HV 4.110		4G 4 + (2 x 0,75)
	HV 4.150 – 4.185		4G6 + (2 x 0,75)
	HV 4.220		4G10 + (2 x 0,75)
	- Controland signalcables		JE-Y(ST)Y … BD
			JE-LiYCY … BD
	- Cables connected to RS485 interface		JE-Y(ST)Y 2 x 2 x 0,8 BD
		27

9.4Wiring 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 / 4.030 / 4.040

HV 4.055 / 4.075 / 4.110

F

F

E

E

D

D

C

C

A

A

B

B

(A)

Power supply

(B)

Motor connections

(C) Terminal block:

- START/STOP_PTC

(D)

RS-485 Interface

(E)

Status-Relays

- SOLORUN

- User interface

- RS-485 Interface

- Internal interface

(F) optional Relay Card

F

E

C

D A B

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9.4.1 Main voltage terminals

The power supply is connected to the power section: Terminal L + 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 / 4.030 / 4.040

L1-L2-L3

3x400 VAC

L - N

1x230 VAC

Motor connection U-V-W

(Crimp connection 6,3mm)

Power supply

HV 4.055 / 4.075 / 4.110

HV 4.150 / 4.185 / 4.220

Motor connection U-V-W

Power supply L1-L2-L3

3x400 VAC

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9.4.2 Motor connection

Mounting of the PTC

Method A : Method B :

motor block

PTC

terminal block

PTC

rubber gasket cover of the

conduit box

1.The cover of the conduit box must be opened and the terminal block inside removed

2.Fix the PTC (Method A or B)

3.Replace the terminal block

4.Electrical connection of the motor cables

The PTC must be fixed to the metal body 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 motor and can be done in staror 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		U			H	U
					Y
Y		V
					D	V
D		W	U				U
					R	W
R			V
					O		V
O
					V
V			W				W
					A
A
					R
R
			PTC				PTC
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