Xylem IM223 User Manual

INSTRUCTION MANUAL

IM223R04

Hydrovar Pump Control

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INDEX

1 Important Safety Instructions ........................................................................................................................................ 4

2 System Design................................................................................................................................................................... 5

2.1 Pressure tank ................................................................................................................................................................ 6

3 Product Overview ............................................................................................................................................................7

3.1 Hardware congurations .............................................................................................................................................7

3.2 Operation modes ......................................................................................................................................................... 7

3.2.1 Actuator (for single pump operation only!) .................................................................................................... 7

3.2.2 Controller ............................................................................................................................................................ 7

3.2.3 Cascade Relay .................................................................................................................................................... 7

3.2.4 Cascade Serial/Synchron .................................................................................................................................. 8

4 Model Number ................................................................................................................................................................ 10

5 Technical Data .................................................................................................................................................................12

5.1 General technical data ..............................................................................................................................................13

5.2 EMC requirements (Electromagnetic compatibility) .............................................................................................14

6 Dimensions and Weights .............................................................................................................................................. 15

7 Additional Components ................................................................................................................................................ 17

7.1 Cable glands provided .............................................................................................................................................17

7.2 Assembly Instructions – All models..........................................................................................................................18

8 Electrical Installation and Wiring ................................................................................................................................ 19

8.1 Equipment protection ............................................................................................................................................... 19

8.2 EMC- electromagnetic compatibility ....................................................................................................................... 21

8.3 Recommended Wire Types .......................................................................................................................................22

8.4 Wiring and connections ............................................................................................................................................ 22

8.4.1 Input voltage terminals ....................................................................................................................................23

8.4.2 Motor connection .............................................................................................................................................24

8.4.3 Power unit..........................................................................................................................................................24

8.4.3.1 Solo run (Hand Mode) ........................................................................................................................ 25

8.4.3.2 Addressing ...........................................................................................................................................27

8.4.4 Control unit ....................................................................................................................................................... 28

INDEX

9 Programming ...................................................................................................................................................................35

9.1 Display – Control panel of the Master / Single Inverter ........................................................................................35

9.2 Function of the push buttons ...................................................................................................................................35

9.3 Basic Drive Display ....................................................................................................................................................36

9.4 Software parameters .................................................................................................................................................36

00 MAIN MENU .......................................................................................................................................................... 37

20 SUBMENU STATUS ...............................................................................................................................................40

40 SUBMENU DIAGNOSTICS ..................................................................................................................................43

60 SUBMENU SETTINGS...........................................................................................................................................44

0100 SUBMENU BASIC SETTINGS .......................................................................................................................... 44

0200 SUBMENU CONF INVERTER ..........................................................................................................................47

0300 SUBMENU REGULATION ................................................................................................................................52

0400 SUBMENU SENSOR ......................................................................................................................................... 54

0500 SUBMENU SEQUENCE CNTR ........................................................................................................................ 56

0600 SUBMENU ERRORS .........................................................................................................................................60

0700 SUBMENU OUTPUTS ......................................................................................................................................61

0800 SUBMENU REQUIRED VALUES ...................................................................................................................... 62

0900 SUBMENU OFFSET .......................................................................................................................................... 64

1000 SUBMENU TEST RUN ......................................................................................................................................66

1100 SUBMENU SETUP ............................................................................................................................................67

1200 SUBMENU RS485-INTERFACE ....................................................................................................................... 67

10 Failure Messages ..........................................................................................................................................................69

10.1 Basic Inverter ..........................................................................................................................................................69

10.2 Master / Single Inverter ........................................................................................................................................70

10.3 Internal errors.........................................................................................................................................................73

11 Maintenance .................................................................................................................................................................75

12 Programming Flow Chart ........................................................................................................................................... 76

Limited Warranty ...............................................................................................................................................................80

DANGER

Hazardous voltage

DANGER

Hazardous Pressure

CAUTION

! SAFETY INSTRUCTIONS

WARNING

CAUTION

Section 1

Important: Read all safety information prior to installation of the Controller.

NOTE

This is a SAFETY ALERT SYMBOL. When you see this symbol on the controller, pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury or property damage. Obey all messages that follow this symbol to avoid injury or death.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Used without a safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

NOTE Indicates special instructions which are very important and must be followed.

NOTE

All operating instructions must be read, understood, and followed by the operating personnel. Xylem Inc. accepts no liability for damages or operating disorders which are the result of non-compliance with the operating instructions.

1. This manual is intended to assist in the installation, operation and repair of the system and must be kept with the system.

2. Installation and maintenance MUST be performed by properly trained and qualied personnel.

3. Review all instructions and warnings prior to performing any work on the system.

4. Any safety decals MUST be left on the controller and/or pump system.

5. The system MUST be disconnected from the main power supply before removing the cover or

attempting any operation or maintenance on the electrical or mechanical part of the system. Failure to disconnect electrical power before attempting any operation or maintenance can result in electrical shock, burns, or death.

6. When in operation, the motor and pump could start unexpectedly and cause serious injury.

Section 1A

Review Hydrovar components and ensure that all parts are included. Inspect all components supplied for shipping damage.

Included Hydrovar components:

1. Hydrovar motor mount variable 4. 4 Attachment brackets, (bottom hook, speed drive extender, and screws)

2. Pressure transducer with cable 5. Precision screwdriver.

3. Conduit plate caps and reducers 6. Instruction and Operation Manual

Hazardous Pressure

CAUTION

SYSTEM DESIGN

Section 2

The following diagrams show typical single and multi-pump systems using the HYDROVAR Variable Speed Drive. Connect directly to water supply. Use of a low suction pressure switch is recommended.

NOTE

Systems MUST be designed by qualied technicians only and meet all applicable state and local code requirements.

Single Pump Layout Multi-Pump Layout

67 7

445

4 45

(1) pump with HYDROVAR (4) gate valve (7) pressure gauge

(2) diaphragm tank (5) check valve or ball valve (8) pressure transducer

(3) fusible disconnect (6) low suction pressure switch (9) pressure relief valve

General

NOTE

All plumbing work must be performed by a qualied technician. Always follow all local, state and provincial

codes.

A proper installation requires a pressure relief valve, a ¼" female N.P.T. threaded tting for the pressure sensor, and properly sized pipe. Piping should be no smaller than the pump discharge and/or suction connections. Piping should be kept as short as possible. Avoid the use of unnecessary ttings to minimize friction losses.

Some pump and motor combinations supplied with this system can create dangerous pressure. Select pipe and ttings according to your pipe suppliers’ recommendation. Consult local codes for piping requirements in your area.

All joints must be airtight. Use Teon tape or another type of pipe sealant to seal threaded connections. Use caution when using thread sealant as any excess that gets inside the pipe may plug the pressure sensor.

Galvanized ttings or pipe should never be connected directly to the stainless steel discharge head or casing as galvanic corrosion may occur. Barb type connectors should always be double clamped.

Hazardous Pressure

CAUTION

SYSTEM DESIGN

Pressure Tank, Pressure Relief Valve and Discharge Piping

Use only “pre-charged” tanks on this system. Do not use galvanized tanks. Select an area that is always above 34º F (1.1º C) in which to install the tank, pressure sensor and pressure relief valve. If this is an area where a water leak or pressure relief valve blow-off may damage property, connect a drain line to the pressure relief valve. Run

the drain line from the pressure relief valve to a suitable drain or to an area where water will not damage property.

Pressure Tank, System Pressure

Sizing – A diaphragm tank (not included) is used to cushion the pressure system during start-up and shut-down.

It should be sized to at least 20% of the total capacity of your pump. Example: If your pump is sized for 100 GPM then size your tank for at least 20 gal. total volume, not draw down. Pre-charge your bladder tank to 15-20 PSI below your system pressure. The controller is pre-set for 50 PSI at the factory. Therefore a 35-40 PSI pre-charge in your tank would be required. Use the higher tank pre-charge setting if the system drifts over 5 PSI at a constant ow rate. NOTE: Pre-charge your tank before lling with water!

CAUTION

Maximum working pressure of HydroPro diaphragm tank is 125 psi.

Installing the Pressure Sensor

The pressure sensor requires a ¼" FNPT tting for installation. Install the pressure sensor with the electrical connector pointing up to avoid clogging the pressure port with debris. Install the pressure sensor in a straight run of pipe away from elbows or turbulence. For optimum pressure control install the pressure sensor in the same straight run of pipe as the pressure tank. Ensure the pressure sensor is within 10 feet of the pressure tank. Installing the pressure sensor far away from the pressure tank may result in pressure oscillations. Do not install the pressure sensor in a location where freezing can occur. A frozen pipe can cause damage to the pressure

sensor.

The pressure sensor cable is 30' as standard. The cable can be shortened for a cleaner installation. Longer cable lengths are available, consult factory. Maximum recommended pressure sensor cable length is 300 feet. Avoid leaving a coil of pressure sensor cable as this can induce unwanted transient voltages and noise into the system. Do not run the pressure sensor cable alongside the input or output wiring. Maintain a distance of at least 8” between the pressure sensor cable and input or output wiring.

WARNING

Discharge pressure within the piping system prior to removing pressure transducer or disconnecting any part of the piping system. Open a valve until pressure on an external gauge reads 0 psi.

PRODUCT OVERVIEW

Section 3

3.1 Hardware Congurations

The HYDROVAR variable speed drive consists of two separate components: the power unit and the control card. In its basic conguration (consisting of only the power unit) the HYDROVAR can be used as a Basic Inverter. In that conguration the HYDROVAR can be used as a sequence pump in a multi pump system, or as a simple soft starter for single pump applications.

By extending this Basic controller with the additional control card, the HYDROVAR is able to work in different modes and can be used for multipump applications.

Three types of drives are available. They are each capable of different levels of control. They are:

Master controller:

• Full variable speed controller of itself in a single pump conguration, with more features than the Single

controller

• Full variable speed control of the attached motor and up to 7 additional Master or Basic controllers.

• Full variable speed control of the attached motor and on/off, xed speed control of up to 5 additional pumps.

(This requires an additional relay card.)

Basic controller:

• Single pump soft start control

• Full variable speed control when connected to a Master controller

Single controller:

• Full variable speed control of a single pump with fewer features than the Master controller

3.2 Modes of Operation

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.

NOTE

This mode can only be programmed with a Master or Single controller, and is for single pump systems 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.

→ Typical single pump operation

3.2.3 Cascade Relay

One pump is tted with a HYDROVAR Master controller and up to 5 xed speed pumps can be switched ON and OFF on demand. For this purpose an additional Relay Card with 5 relays is used in the Master controller.

Separate motor starters are needed for each motor relay, because the relays in the HYDROVAR are control contacts only.

Lead/Lag switching of the xed speed pumps to provide even wear and achieve even operating hours can be programmed in this mode.

This conguration is a cost effective alternative compared with other solutions using VFD’s on each pump, but additional equipment is required, and you only have xed speed control of the pumps.

PRODUCT OVERVIEW

Application Example

Booster sets up to 6 pumps where only one pump is speed controlled by the HYDROVAR and the others are xed speed (1 HYDROVAR Master Inverter+5 xed speed). This should be the standard conguration when the additional Relay Card is used.

3.2.4 Cascade Serial and Cascade Synchron

In these modes each of the pumps is equipped with a HYDROVAR unit. All units are connected and communicate via the RS485 interface.

At least one Master controller is used. The other pumps can be controlled by Basic or Master drives. The Master controller continually reads the status and failures of the Basic controllers. All failures are indicated on the master unit, including the date and time.

The Master controller has complete control of all pumps in the system, including automatic alternation of the lead and lag pumps, which provides even wear and achieves even operating hours for each pump.

If the control card of a Master controller fails, each of the Basic controllers can be manually started by an external switch (manual operation) for “emergency operation” of the system.

Application Example

Each pump, (up to 8 pumps), is equipped with a HYDROVAR unit. At least one Master controller will be connected to up to seven Basic controllers. All units are connected via the serial interface (RS485).

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 or more Master controllers can be used to increase reliability,

and up to 4 Basic controllers without control card.

Minimum requirement: 1 Master controller and the other pumps equipped with Basic controllers.

PRODUCT OVERVIEW

To increase the reliability of a system, (in the event of a Master controller failure) a second Master controller can be used.

Full-featured possibility: Each pump is equipped with a Master controller.

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

This conguration allows each pump to become the lead pump. This also ensures a proper operation if one Master controller 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.

MODEL NUMBER CODE

Section 4

Hydrovar Variable Speed Drive Type and Catalog Number

Hydrovar Example Product Code

HV M 3 4 20 0

Filter (optional): Standard = 0, (no lter) Residential = B

HP Rating: 02 = 2 03 = 3 05 = 5 07 = 7.5 10 = 10 15 = 15

Volts: 2 = 230V 4 = 460V

Phase: 1 = Single Phase 3 = 3 Phase

Type: M - Master

S - Single B - Basic

Series: HV

The following applies to this example:

HV - Hydrovar Variable Speed Drive

M - Master Drive, (full control and communications)

3 - 3 Phase input power

4 - 460 Volt input power

20 - 20 Horsepower rated

Blank: Standard Commercial Filter, (not residential)

MODEL NUMBER CODE

Section 4 (continued)

Hydrovar Product Numbering Chart

Voltage Phase Normal Duty HP Drive Type Model Number

MASTER HVM1202

230 V 1

460 V 3

7.5

BASIC HVB1202

SINGLE HVS1202

MASTER HVM1203

BASIC HVB1203

SINGLE HVS1203

MASTER HVM3403

BASIC HVB3403

SINGLE HVS3403

MASTER HVM3405

BASIC HVB3405

SINGLE HVS3405

MASTER HVM3407

BASIC HVB3407

SINGLE HVS3407

MASTER HVM3410

BASIC HVB3410

SINGLE HVS3410

MASTER HVM3415

BASIC HVB3415

SINGLE HVS3415

TECHNICAL DATA

Section 5

Hydrovar Power Supply

Rated Output Voltage Limits 48-62 HZ

Cat #* HP V Amps Amps AWG

HVM1202 2

HVM1203 3 20 25 10

HVM3403 3

HVM3405 5 11.4 15 14

HVM3407 7.5 15.1 20 12

HVM3410 10 19.6 20 10

HVM3415 15 27.8 30 8

* Listed catalog numbers are for master drives. Details also apply to corresponding basic and single units.

1 Ph, 220-240V -10%,

+15%

3 Ph, 380-460V

+-15%

Rated Current

Input

14 20 14

7.6 10 14

Hydrovar Output to the Motor

Rated Output Voltage Limits 48-62 HZ Rated Current Output Motor Connection Wires

Cat #* HP V Amps AWG

HVM1202 2

HVM1203 3 10 14

HVM3403 3

HVM3405 5 9 14

HVM3407 7.5 13.5 14

HVM3410 10 17 12

HVM3415 15 23 10

3 Ph, 240V

3 Ph, 480V

Recommended

Line Protection

7 14

5.7 14

Maximum

Wire Size

TECHNICAL DATA

5.1 General Technical Data

Ambient temperature: 0° C ... +40° C, 32º F... +104º F At higher temperatures reduce the output current as shown below or upsize to the next largest HYDROVAR.

110

100

Maximum Output Current (%)

0102030405

Maximum Ambient Temperature (ºC)

The enclosure rating of the HYDROVAR is IP55 however, please note the following:

• Protect the HYDROVAR from direct sunlight!

• Protect the HYDROVAR from direct rainfall

• Outdoor installation without protection from sun will void warranty!

Storage temperature: -25° C ... +55° C, -10º F ... +130º F

Humidity: RH maximum 50% at 104º F, unlimited

RH maximum 90% at 70º F, maximum 30 days per year 75% average per year (class F) Condensation is not allowed and will void warranty!

During long periods of inactivity or shutdown, the HYDROVAR should remain connected to the power supply but turned off to prevent inadvertant pump run. This will maintain power to the internal heater and reduce internal condensation.

Air pollution: 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

Altitude: Maximum 1000 m, 3280 feet above sea level. At sites over 1000 m above sea level, the maximum output power should be de-rated by 1% for every additional 100 m. For installations higher than 2000 m above sea level, please contact your local distributor.

Class of protection: IP 55, NEMA 4 (Indoor use only)

Certications: CE, UL, C-Tick, cUL

TECHNICAL DATA

5.2 EMC Requirements (Electromagnetic Compatibility)

The EMC requirements depend on the intended use.

Class B environment (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. Examples of class B environments include houses, apartments, commercial premises or ofces in a residential building.

CAUTION: The relevant EMC regulations for which the HYDROVAR was tested in class B environments is based on the restricted use of the product and the following limitations:1) the drive voltage is less than 1000 V; 2) it is neither a plug in device nor a movable device and, 3) when used in the class B environment, it is intended to be installed and utilized by technicians with the necessary training and skills required for installing and/or using power drive systems, including specic training with respect to EMC requirements.

Class A environment (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 class A 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 eld strength

First environment Second Environment

– class B / class C2 – class A / class C3 Disturbance voltages OK OK

Disturbance eld 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 eld 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

DIMENSIONS AND WEIGHTS

Section 6

HVM1202, HVM1203, HVM3403, 3405

8.9

8.2

7.9

3.353.35

6.7

7.9

7.4

All dimensions in inches! Drawings are not to scale! Dimensions are nominal

Basic Master / Single

Weight [lbs]

Type

2, 3 HP

1 Ph

3, 5 HP

3 Ph

8.8 9.7

a … minimum center-distance between HYDROVARs 12"

b … header space for maintenance 12"

DIMENSIONS AND WEIGHTS

HVM3407, HVM3410, HVM3415

10.9

10.2

9.9

3.35

6.7

3.35

10.2

9.4

All dimensions in inches! Drawings are not to scale! Dimensions are nominal

Weight [lbs]

Type

Basic Master / Single

7.5, 10, 15 HP

3 Ph

16.9 17.8

a … minimum centre-distance between HYDROVARs 17"

b … minimum header space for maintenance 12"

ADDITIONAL COMPONENTS

Section 7

7.1 Cable Glands Provided

Included

components

Gland sizer

Cable

size

AWG

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

( ) maximum available cable entries

12 16 20 25 12 16

#8-#1 4,5-10 7-1 3 9-17

Cable gland and lock nut

M M M M M M

Conduit

plugs

Thermistor

Mounting

clamps

Centring - bit

7.2 Assembly Instructions – All models

To remove the HYDROVAR cover, loosen the 4 fastening screws.

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

• The HYDROVAR is installed on the motor fan cover using the mounting brackets, the four screws and the relevant washers.

• Center the HYDROVAR and tighten the four screws holding the brackets.

• Tighten each 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.

• Ensure the integrity of the ground wire connection. Failure to properly ground the controller or motor will create an electrical shock hazard.

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

• Ensure cable glands are properly installed and close conduit openings that are not being used with conduit plugs.

ADDITIONAL COMPONENTS

7.2 Assembly Instructions – All models (continued)

ELECTRICAL INSTALLATION AND WIRING

Section 8

NOTE

All installations and maintenance must be performed by properly trained and qualied

personnel. Use personal protection equipment.

NOTE

In case of a failure, the electrical power must be disconnected or switched off. Wait at least 5 minutes for capacitor discharge before servicing the HYDROVAR. Shock, burns or death are possible hazards if the capacitor discharges during maintenance, repair, or assembly.

8.1 Equipment Protection

Follow state, and local codes for proper equipment protection.

Applicable: • proper grounding

• AC and DC Ground Fault Circuit Interrupter (GFCI)

Proper grounding:

• Please note that leakage to ground can occur due to the capacitors in the input lter.

• A suitable protection unit has to be selected (according local regulations).

Ground Fault Circuit Interrupter (GFCI):

• When using a GFCI, make sure that it also releases in the event of a short circuit inside the DC-part of the HYDROVAR to ground!

• single phase HYDROVAR => use pulse sensitive GFCI's

• three phase HYDROVAR => use AC/DC sensitive GFCI's

• The GFCI should be installed according to local regulations!

Fuses:

• Use Very fast acting Class T fuses

• Bussman T-tron type JJN and JJS fuses are acceptable (or equal)

Internal equipment protection:

• The Hydrovar has internal protections against the following malfunctions: short circuit; under and over-voltage, overload and the overheating of the electronic components.

External protective devices:

• Additional protective functions like motor overheat and low water protection are controlled by separate equipment.

ELECTRICAL INSTALLATION AND WIRING

Fused Disconnect Box:

DISCONNECT

SINGLE

PHASE

CUSTOMER SUPPLIED

VOLTAGE

THREE PHASE

CUSTOMER SUPPLIED

VOLTAGE

Disconnect

Part Number

Input

Voltage

GND

DISCONNECT

GND

Disconnect

HP / AMP

Rating

HFD512C1 230/1/60 OT25F3 2 HP / 25A

HFD512E1 230/1/60 OT40F3 3 HP / 40A

HFD534A1 460/3/60 OT16F3 3 HP / 16A

HFD534B1 460/3/60 OT16F3 3 HP / 16A

HFD534C1 460/3/60 OT25F3 3 HP / 25A

HFD534C2 460/3/60 OT25F3 3 HP / 25A

HFD534E2 460/3/60 OT40F3 3 HP / 40A

12 AWG

Wire

Range

#18-

8AWG

#18-

8AWG

#18-

8AWG

#18-

8AWG

#18-

8AWG

#18-

8AWG

#18-

8AWG

FUSE BLOCK

Tightening

Torque

Supplier

7 IN/LB Bussman 20 KTK-R-20 600V

7 IN/LB Bussman 30 KTK-R-30 600V

7 IN/LB Bussman 10 KTK-R-10 600V

7 IN/LB Bussman 15 KTK-R-15 600V

7 IN/LB Bussman 20 KTK-R-20 600V

7 IN/LB Bussman 30 KTK-R-30 600V

CUSTOMER SUPPLIED

HYDROVAR

16 AWG

GND

CUSTOMER SUPPLIED

HYDROVAR

16 AWG

GND

Fuse

AMP

Rating

GND

Part

Number

MTR

Voltage

Rating

NOTE: Recommended protection (not included with drive only). This fused disconnect is available as part of the PHV series packaged

Hydrovar, see price book.

MOTOR

ELECTRICAL INSTALLATION AND WIRING

8.2 EMC – Electromagnetic Compatibility

To ensure electromagnetic compatibility the following points must be observed for cable installation:

Control Cables

General Recommendations

Use shielded cables, temperature rated at 60º C (140º F) or above:

• Control cables must be multi-core cables with a braided copper wire screen.

Double Shielded Single Shielded

Example: JAMAK by Draka NK Cables Example: NOMAK by Draka NK Cables

• The screen must be twisted together into a bundle not longer than ve times its width and connected to terminal X1-1 (for digital and analog I/O cables) or to either X1-28 or X1-32 (for RS485 cables).

Route control cables to minimize radiation to the cable:

• Route as far away as possible from the input power and motor cables (at least 20 cm (8 in)).

• Where control cables must cross power cables make sure they are at an angle as near 90º as possible.

• Stay at least 20 cm (8 in) from the sides of the drive.

Use care in mixing signal types on the same cable:

• Do not mix analog and digital input signals on the same cable.

• Run relay-controlled signals as twisted pairs (especially if voltage > 48 V). Relay-controlled signals using less than 48 V can be run in the same cables as digital input signals.

NOTE! Never mix 24 VDC and AC power signals in the same cable.

Motor Wires

To ensure the EMC compatibility and minimize noise level and leakage currents, use the shortest possible motor wires. Use shielded wires only if the total length exceeds 6 feet.)

Line Reactors

Line reactors are available as an option and should be mounted between the HYDROVAR and the main fuse. The Line reactor should be as close to the HYDROVAR as possible, (max. 12").

Advantages:

• more efcient

• reduction of harmonic currents

For the following applications additional line reactors 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 proper grounds according to local codes and regulations

• Do not install the power wires in parallel to control wires

• Use screened control cables

• Connect both ends of the motor wire screen to ground

• Connect only one end of the control wire screen to ground

• Motor wires should be as short as possible

ELECTRICAL INSTALLATION AND WIRING

8.3 Recommended Wire Types

For maximum 40º C ambient temperature, recommend use of 75º C wire of the following types: RHW, THHW, THW, THWN, XHHW, USE, ZW.

8.4 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 Drive:

1 Ph / 2, 3 HP 3 Ph / 3, 5 HP 3 Ph / 7.5, 10, 15 HP

(A) Power supply (B) Motor connections (C) Terminal block:

- START/STOP (D) RS-485 Interface (E) Status-Relays - SOLORUN (hand mode)

- User interface - RS-485 Interface

- Internal interface (F) Optional Relay Card

ELECTRICAL INSTALLATION AND WIRING

8.4.1 Input Voltage Terminals

The power supply is connected to the power section:

Terminal L + N (230 VAC, single-phase) Terminal L1+ L2 + L3 (460 VAC, three-phase)

2, 3 HP / 1Ø 3, 5 HP / 3Ø

7.5, 10, 15 HP / 3Ø

ELECTRICAL INSTALLATION AND WIRING

8.4.2 Motor Connection

Attaching the Thermistor

Method A : Method B :

1. Remove conduit box cover

2. Attach the thermistor (Method A or B)

3. Replace the terminal block, if necessary

4. Wire the motor according to the motor manufacturer's instructions.

NOTE! The thermistor must be attached to the motor. This is required to measure the motor temperature!

8.4.3 Power Unit

The basic drive has two control terminal blocks.

HVB 1202, 1203

HVB 3403, 3405

HVB 3407, 3410, 3415

+ 56 hidden pages