ITT HYDROVAR Series User manual

771079402 Manual HV 2.015-4.110-VL-A
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

Operating Instructions
English
HV 2.015 / 2.022
HV 4.022 / 4.033 / 4.040
HV 4.055 / 4.075 / 4.110
Motor-mounted

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3
Index
1Important safety instructions ................................................................................5
2System Design........................................................................................................8
2.1 Pressure tank............................................................................................8
3Product 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
4Type designation code.........................................................................................13
5Technical Data......................................................................................................14
5.1 General Technical Data ..........................................................................15
5.2 EMC (Electromagnetic compatibility) requirements .............................16
6Dimensions and Weights .....................................................................................17
7Modules ...............................................................................................................19
8Mechanical 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
9Electrical 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

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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

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1Important 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)

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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.

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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!
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.
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.

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2System 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:
NOTICE: To check and set the right pre-charge pressure, please make the tank
pressure less before.
required pressure (bar) (system pressure)
precharge pressure (bar) (air pressure)

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3Product 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.

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External panel
max. 5 fixed
speed units
External panel
External panel External panel
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.

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extended up
to 8 pumps
RS 485
connection
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”

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RS 485
connection
extended up
to 8 pumps
RS 485
connection
extended up
to 8 pumps
To increase the operating safety of such a system, also a second “Master Inverter” could be
used:
Full-featured Possibility: Each pump is equipped with a “Master Inverter”
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.

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4Type designation code
Software Version
Language
A = Western Europe
B = Eastern Europe
C = 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
Nominal mains voltage
1= 1~/1~ 230VAC 3= 3~/3~ 230VAC
2= 1~/3~ 230VAC 4= 3~/3~ 380-460VAC
Example
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
HV . - - - - - - - .
HV 4 . 0 4 0 - M 3 - 5 - B - 1 0 R 0 - G- A - V 0 1 . 1

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5Technical 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.

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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.
oProtect the HYDROVAR against direct sunlight!
oOutdoor installation without protection of the
HYDROVAR is not permitted!
Storage temperature: -25° .C ... +55° C (+70°C during max. 24 hours.)
Humidity:
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!
Air pollution:
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
Altitude:
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.
Class of protection:
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
0
10
20
30
40
50
60
70
80
90
100
110
0 102030405060
max. ambient temperature [°C]
max. output current [%]

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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

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6Dimensions 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
HV 4.030
HV 4.040
4,00 4,40
a … minimum centre-distance between the HYDROVAR 300 [mm]
b … expansion space for maintenance 110 [mm]

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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
Master/
Single
HV 4.055
HV 4.075
HV 4.110
7,70 8,10
a … minimum centre-distance between the HYDROVAR 430 [mm]
b … expansion space for maintenance 110 [mm]

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7Modules
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
1
2
3
6
1
2
3
5
4
6
5