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vacon nx active front end unit (afe) user manual

1. 46 NN TOME ENOG UNI 22 c 46 elie VEC TTC AM 48 i 50 9 E 93 SU m m 93 57 5 2 3 Arranging ventilation of the enclosure 60 S N SUS SWING TC t 61 SS MEME 64 Pm 64 mi 64 Pwer Any AO 64 CONT o III MEER TR 68 Galvanic ISO ATOM 70 COMTOLR EYDI c 71 6 1 Indicators on the keypad 72 sarip en cre 72 6 1 2 Status LEDs green green red 72 Erb 73 OZ Keypad USM OU s 74 6 3 Navigation on the control 79 6 3 1 Monitoring men MT RT 76 6 3 2 Parameter menu M2
2. 5 LV LdO U 9 JO 51 PL OL 6 8 LV LdO ut DOAPT ZL 40 9 10 127 LO 2 NIVIN SE LO C N N N re N C LO x lt LL e a N re N N ce LO T APPENDICES VACON 9 105 152 144 Dia 4 5 5 mm Screw M4 114 5 11214 emf Figure 82 Dimensions of the door mounting kit 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 106 APPENDICES IL A DC terminal AC Terminal NXA 02615 NXA 01706 NXA 04605 NXA 03256 PE M8x25 NXA 13005 NXA 10306 PE M8x25 11213 emf Figure 83 Terminal sizes for Vacon NX Active Front End units Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW Vacon com Manual authoring Document ID documentation dvacon com Runsorintie 7 65380 Vaasa D P D 9 06 B Finland Rev B Subject to change without prior notice 2015 Vacon Plc Sales code DOC INSNXAFE DLUK
3. 28 28 4 7 1 Connection between control unit and power unit 28 4 7 2 LCL wiring 29 48 Active Front End power ratings Re E ue 39 4 8 1 Vacon DC voltage 380 500 8 8 8 33 4 8 2 Vacon NXA voltage 925 690 npa aal 33 4 9 Active Front End unit 34 LACE 34 4 11 Active Front End unit Fuse selection 35 orenera E E E 35 4 11 2 Fuses mains voltage 380 500 2 35 4 11 3 Fuses mains voltage 525 690 36 4 12 Active Front End unit Circuit breaker selection 38 Main pieno 39 5 15 Cir CUE Nero scm t EM 40 41 415 1 Common pre charging 41 4 15 2 Each Active Front End unit has the pre charging circuit 43 dw LCT WING T eod NET TR Toa itis ges dE 3 24 hour support 358 01201 212 575 Email vacon avacon com VACON 92 MOUNN O
4. 31 55 un pial 64 c t m m c F E 40 I Tel 358 0 201 2121 Fax 358 0 201 212 205 LL WI c um EA E z 9 s E SEE cD TH E n OQ LL ctr sed UU OVAOrZ 1 E 59 32 c 4 Ss HA A 37 JEn a m C2 1 E Oz 6l _ EC Or 2 2 LINDYID NIVIN VACON 95 APPENDICES UOISIADY OU 300 Ou UO2EA 392 45 oT pose 2 bho 5169 4 onu v amg 12VAOYC Bt ON 2608 ON COM 9 ogay SNIT AS 2 LINIJ gt TI m c Z Ph nx za ei at L 4 G4 Iz ZX we zy 12VAOvZ ce 4 2VAOvC ONINOLINOW HOLDVLNOD NIVIW 2GAvC 1VNH3 LX3 X 4 11227 pdf Figure 72 Wiring diagram for control circuit z 5 gt 9 9 gt 0 LLI e LO LO CN C C LO 4 2
5. 2 VACON 96 APPENDICES Earthing bolt back xj Mounting Holes 7 5 i m a 11228 pdf Figure 73 FI9 Dimensions Tel 358 0 201 2121 Fax 358 0 201 212 205 APPENDICES 952 Earthing bolt back I iE vey CET Figure 74 FI 10 Dimensions 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 97 11229 pdf VACON 98 APPENDICES ELT AE ea vt x Mounting holes wm 8 Ted in et 55 1 8 11230 pdf Figure 75 FI 13 Dimensions Tel 358 0 201 2121 Fax 358 0 201 212 205 APPENDICES VACON 99 nm gt dx i 5 5 a gt VL 25 6103 01 a a LCL 170A 690V 261A 500V LCL 325A 690V 460A 500V Dimension drawing Title 454 Material a x 2 2111 z ooo gt M T Q Cc c c c T WAN D _ gt Figure 76 FI9 and FI 10 LCL filter dimensions 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 100 APPENDICES Break out View C
6. Option board or drive added Reset Option board of different type or drive Set the option board parameters of different power rating added again Device added different type Remove fault situation from external device Check board and slot 54 Slot fault Defective option board or slot Temperature limit values set for the PT100 fault PT100 have been exceeded Find the cause of temperature rise KLIXON Status of KLIXON input is LOW Check resistors Check thermistor connection If thermistor input of the option board is not in use it has to be short circuited e External fault Digital input fault The thermistor input of option board 61 Thermistor fault has detected too high resistor temperature Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 83 6 3 6 1 Fault time data record When a fault occurs the information described in Chapter 6 3 4 is displayed By pressing Menu button right you will enter the Fault time data record menu indicated by 1 gt In this menu some selected important data valid at the time of the fault are recorded This feature will help the user or the service person in determining the cause of the fault The data available are Table 28 Fault time recorded data T1 Counted operation days Fault 43 Additional code T2 Counted operation hours hh mm ss Fault 43
7. Change the cooling fans Main fan of the unit Fan of the LCL filter 5 10 years aks the DC bus capacitors if DC voltage ripple It is also recommended to record all actions and counter values with dates and time for follow up of maintenance 24 hour support 358 0 201 212 575 Email vacon avacon com 14 RECEIPT OF DELIVERY 3 6 LIFTING THE MODULES The modules can be lifted by the holes on top Place the lifting hooks symmetrically in at least four holes The maximum allowed lifting angle is 459 For frames FI9 and FI10 see Figure 3 and for the frame 113 see Figure 4 The lifting equipment must be able to carry the weight of the module 11179 emf Figure 3 Lifting points for FI9 and FI 10 modules Tel 358 0 201 2121 Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 9 15 Figure 4 Lifting points FI13 modules 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 16 RECEIPT OF DELIVERY 3 7 LIFTING THE LCL FILTERS The modules can be lifted by the holes on top Place the lifting hooks symmetrically in two holes in the FI9 and F110 LCL filters and four holes in the FI13 LCL filter The maximum allowed lifting angle 15 459 For the FI9 and FI10 LCL filter see Figure 5 and for the F113 LCL filter see Figure 6 11177 emf Figure 5 Lifting points for FI9 and FI 10 LCL filter Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON 17
8. The Vacon NX Active Front End is operable through the nine push buttons of the control keypad Furthermore the buttons can be used in setting parameters and monitoring values The keypad is detachable and isolated from the input line potential 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 72 CONTROL KEYPAD 6 1 INDICATORS ON THE KEYPAD DISPLAY FUN Sor READY 3062 emf Figure 52 Vacon control keypad and drive status indications 6 1 1 DRIVE STATUS INDICATIONS The drive status symbols tell the user the status of the brake chopper In addition they tell about possible irregularities detected by the brake chopper control software in brake chopper functions Indicates that the drive is running STOP Indicates that the drive is not running READY d up when AC power is on In case of a trip the symbol will not light ALARM Indicates that the drive is running outside a certain limit and a warning is given Indicates that unsafe operating conditions were encountered due to which FAULT the drive was stopped 6 1 2 STATUS LEDS GREEN GREEN RED The status LEDs light up in connection with the READY RUN and FAULT drive status indicators _ Lights up with the AC power connected to the drive Simultaneously the drive status D 9 indicator READY is lit up Lights
9. The cautions and warnings are marked as follow Table 1 Warning signs DANGER Dangerous voltage WARNING or CAUTION CAUTION Hot surface 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 6 SAFETY WARNINGS The components of the power unit LCL filter and pre charging circuit are live when the Active Front End is connected to AC supply Coming into contact with this voltage is extremely dangerous and may cause death or severe injury The control unit is isolated from mains potential The control O terminals are isolated from the mains potential However the relay outputs and other l O terminals may have dangerous control voltage present even when the Active Front End Is disconnected from the AC supply SAFETY INSTRUCTIONS Do not touch the components on the circuit boards Static voltage discharge may damage the components The Active Front End LCL filter and optional components are used for fixed installations only e 1 1 2 13006 emf Do not perform any measurements when the Active Front End is connected to the AC supply After having disconnected the Active Front End from the AC supply wait until the fan stops and the indicators on the keypad go out if no keypad is attached see the indica tor through the keypad base Wait 5 more minutes before doing any work on Active Front End connections Do not even open the cover before this time has expired Do not perform any
10. freezing 40 C during operation 10 no freezing 40 C Maximum temperature 50 see Power derating as a function of ambient temperature Ambient conditions Storage temperature 40 C 70 Relative humidity 0 to 95 RH non condensing non corrosive no dripping water Air quality chemicalfumes EN 60721 equipment in operation Class solid particles IEC 721 3 3 equipment in operation Class 352 Elevation of place of 10096 Loadability no derating up to 1000 m operation Maximum elevation 2000 m 525 690 and 4000 m 380 500 VAC Relay 1 0 max 240 V 3000 m max 120 V 4000 m see Power derating as a function of installation altitude See Chapter 4 16 Vibration 9 150 Hz EN50178 EN 60068 2 6 Vibration amplitude 1 mm in frequency range 3 15 8 Hz Max acceleration 1 G in frequency range 15 8 150 Hz Impacts UPS drop test with applicable UPS weights EN 50178 Storage and transport max 15 11 ms packed EN 60068 2 27 00 standard size in the kW HP range immunity 61800 3 279 edition 2004 second settings environment EN 50178 1997 EN 60204 1 1996 2009 EN 60950 2000 3 edition as relevant CE UL cUL Safety FI GOST R IEC EN 61800 5 for approvals see the unit nameplate Tel 358 0 201 2121 Fax 358 0 201 212 205 A
11. RECEIPT OF DELIVERY 11176 emf Figure 6 Lifting points for Fl13 LCL filter 24 hour support 358 0 201 212 575 Email vacon avacon com 18 RECEIPT OF DELIVERY 3 8 WARRANTY Only manufacturing defects are covered by the warranty The manufacturer assumes no responsibility for damages caused during or resulting from transport receipt of the delivery installation commissioning or use The manufacturer shall in no event and under no circumstances be held responsible for damages and failures resulting from misuse wrong installation unacceptable ambient temperature dust corrosive substances or operation outside the rated specifications Neither can the manufacturer be held responsible for consequential damages The Manufacturer s warranty period is 18 months from the delivery or 12 months from the commissioning whichever expires first Vacon PLC general terms and conditions of sale The local distributor may grant a warranty time different from the above This warranty time shall be specified in the distributor s sales and warranty terms Vacon assumes no responsibility for any other warranties than that granted by Vacon itself In all matters concerning the warranty please contact your distributor first Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 19 4 ACTIVE FRONT END CAFE 4 1 INTRODUCTION The Vacon NX Active Front End is used to transfer power be
12. 1 5 Ses TL TE SS ee JcJ LEL 1030A 690V 1300A 500V Dimension drawing Outlet right Title 9 y a oo Fo gt 1 2 gt lt a oo e I Figure 77 FI 13 LCL filter dimensions output connections right Tel 358 0 201 2121 Fax 358 0 201 212 205 APPENDICES VACON 101 Sheet 1 1 1 2 c 9 gt ET VL 25 6133 12 Tolerance Doc no 5 7 1 2 c o x d gt Seal u N gt u EL 2 gt 3 8 5 su ao 79E m 0Z 66 Z8E vere tj 5 4 Material Mass gt 22 a nm m Z lo amp EE goa jg 4 e P 9 8002 1 Z1 Peropdn 5 11233 pdf Figure 78 FI 13 LCL filter dimensions output connections left 24 hour support 358 0 201 212 575 Email vacon avacon com APPENDICES VACON 102 Lio AQ peox22u peuedalg 20 70 7 941 pa13auo2 STATED Ha AIUG 1 uon3ejoud sunjeradiua SnD Jaulo sn ani P lold 90 P A VAN YUN ayy 01 wieje 291 011002 ayy W
13. 3 1 TYPE DESIGNATION CODE FOR THE AFE UNIT In Vacon type designation code for Common DC Bus components the Active Front End Unit is characterised by letter A and number 2 If the Active Front End unit is ordered by number 2 delivery does not include anything else than the unit itself NOTE The delivery does not include the auxiliary devices which are needed for the operation the or DC fuses the fuses bases the main contactor or circuit breaker The customer will take care of the auxiliary devices VACON NX ACTIVE FRONT END TYPE CODE Cw a anne re 5 e Product Generation Module type A AFE Active Front End Nominal current low overload eg 0261 261 A 1030 1030 A etc Nominal supply voltage 5 380 500 VAC 465 800 VDC 6 525 690 VAC 640 1100 VDC Control keypad A standard alpha numeric Enclosure class 0 IP00 FI9 13 EMC emission level T IT networks 61800 3 Internal brake shopper 0 N A no brake chopper Delivery include 2 AFE module 5 Standard air cooled drive U Standard air cooled power unit external supply for main fan Hardware modifications module type S Boards Fiber connection standard boards FI9 FI13 Fiber connection varnished boards FI9 FI13 Option boards each slot is represented by two characters Basic 1 0 board Expander 1 0 board C Fieldbus board D Special board Figure 1 Ty
14. 5 4 4 5 pressing the enter button If the Start Up wizard is not active follow the instructions in 8 5 N below 8 Select the language of the keypad from Menu M6 56 1 Instructions on using the keypad i are given in Chapter 6 9 parameters have factory default values To ensure proper operation check the rating 5 3 5 plate data for the values below and the corresponding parameters of parameter group S Nominal voltage of the supply 2 1 1 5 5 Digital input settings according to connections P2 2 1 1 P2 2 1 8 Change control place to 1 0 P3 1 In case of parallel AFE e Set drooping parameter to 596 2 5 1 e Set PWM Synch parameter to Enable 2 5 2 All parameters are explained in the Active Front End AFE Application Manual 5 S 10 Follow the commissioning instructions in the Active Front End Application Manual 11 The Vacon NX Active Front End is now ready for use 5 5 jj NW GG ww ww 6f yy Vacon Plc is not responsible for the use of the Active Front End against the instructions 24 hour support 358 0 201 212 575 Email vacon avacon com 4 ABOUT THE VACON USER S MANUAL Congratulations for choosing Vacon NX Active Front End The User s Manual will provide you with the necessary information about the installation commission
15. Active Front End unit the connection direction can change from right to left see Appendix 77 and Appendix 78 Follow the instruction below 1 2 2 4 9 7 Open fastenings numbered by 1 in Figure 29 Open fastenings numbered by 2 in Figure 29 Remove bus bars Remove the dark grey from the right side and place it in same place to the left Place the bus bars like in Figure 30 Close fastenings numbered by 2 in Figure 30 Close fastenings numbered by 1 in Figure 30 Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON 49 INSTALLATION emf 11185 11186 emf lon de connecti S Left igure 30 F vacon dvacon com 24 hour support 358 0 201 212 575 Ema VACON 50 INSTALLATION 5 1 3 CoNTROL Box The control unit of the Active Front End unit is mounted into a mounting rack which then can be placed inside the enclosure Figure 31 and Figure 32 The control unit should be placed so that it is easy to access Vacon alpha numeric or graphical keypad can be used to control the Active Front End unit The keypad is connected to the control unit The keypad can be mounted on the enclosure door with optional door mounting kit see Appendix 81 In that case the keypad connects to the control unit with an RS232 cable Pay special attention to the earthing of the cable see the instructions below 11188 emf 11187 emf Figure 32 Mounting points of Control Box
16. Language English 11197 emf Figure 59 Selection of language 6 3 8 2 Copy parameters The parameter copy function is used when the operator wants to copy one or all parameter groups from one drive to another All the parameter groups are first uploaded to the keypad then the keypad is connected to another drive and then the parameter groups are downloaded to it or possibly back to the same drive For more information see on 87 Before any parameters can be successfully copied from one drive to another the Active Front End has to be stopped when the parameters are downloaded to it The parameter copy menu S6 3 contains four functions Parameter sets 56 3 1 The user can reload the factory default parameter values and store and load two customised parameter sets all parameters included in the application On the Parameter sets page 56 3 1 press Menu button right to enter the edit mode The text LoadFactDef begins to blink and you can confirm the loading of factory defaults by pressing the Enter button The drive resets automatically Alternatively you can choose any other storing or loading functions with the Browser buttons Confirm with the Enter button Wait until appears on the display Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 87 READY CONFIRM 553 Parameter sets gt Parameter sets Select Load FactDef CANCEL PRE REA
17. VACON 62 1 r Nr a n b OO 4 t Shield 1 11222 jpg Shield 11223 pg Figure 43 Cabinet cooling airflow guides for FI 13 AFE unit and LCL filter The sheet metal airflow guides deflectors marked in green prevents air circulation between different sections of the equipment The shield guides marked in green prevent air circulation inside a section The points marked in red show the exhaust air holes These holes must not be covered nor must anything be placed above them to stop the free exit of warm air from inside the Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 63 equipment The points marked in blue show the cooling air intake holes These holes must not be blocked In any way The materials used for preventing the circulation of air inside the equipment must be fire restraining The edges must be sealed to prevent the formation of gaps When the deflectors are made according to the instructions no separate cooling fan Is required 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 64 INSTALLATION 5 3 POWER CONNECTION 5 3 1 AC CONNECTION The 3 phase input is connected to the input terminals of the LCL filter L1 L2 and L3 The output terminals of the LCL filter U V and are connected to the input terminals of the AFE unit U V and W Figure 8 The AC input of the AFE input group must be protected
18. see Chapter 6 3 5 will appear on the display In addition the indication FAULT or ALARM see Figure 56 or Chapter 6 1 1 is displayed and in case of a FAULT the red LED on the keypad starts to blink If several faults occur simultaneously the list of active faults can be browsed with the Browser buttons The memory of active faults can store a maximum of 10 faults in the order of appearance The display can be cleared with the Reset button and the read out will return to the same state it was in before the fault trip The fault remains active until it is cleared with the Reset button or with a reset signal from the 1 0 terminal NOTE Remove external Start signal before resetting the fault to prevent unintentional restart of the drive 24 hour support 358 0 201 212 575 Email VACON 80 CONTROL KEYPAD READY GE Normal state Active faults no faults FO 11201 emf 6 3 5 FAULT TYPES Vacon NX Active Front End has four types of faults These types differ from each other on the basis of the subsequent behaviour of the drive See Table 26 dm Operation hours 34 21 05 11202 emf Figure 57 Fault display Table 26 Fault types Fault type symbol Meaning A This type of fault is a sign of an unusual operating condition It does ALarm not cause the drive to stop nor does it require any special actions The A fault remains in the display for about 30
19. used Notusd Not used 6 5 KE Em R locking RN Enabled Enabled Change Disabled 56 5 4 Multimonitoring items Change Enabled Enabled EE Disabled RUN MM Lesage Timeouttime 0 3 8 p 567 7 Hardware settings Hardware Hardware settings P6 7 1 Internal brake mE connected resistor Connected P6 7 2 Fan control function Continuous Continuous M LLL T 08 1 mwem pm 8702 Operation orainen _ 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 86 CONTROL KEYPAD 6 3 8 1 Selection of language The Vacon NX control keypad offers you the possibility to control the inverter through the keypad In the language of your choice Locate the language selection page under the System menu It s location indication is S6 1 Press Menu button right once to enter the edit mode As the name of the language starts to blink you can select another language for the keypad texts Confirm with the Enter button The blinking stops and all text information on the keypad are presented in the selected language You can return to the previous menu any time by pressing Menu button left READY 56 GE System Menu Language 519511 English 1
20. 17 6 3 3 Keypad control menu 77 6 3 4 Active fault menu 79 65 c E 80 ioo genet ete eee ee eee eer 81 6 3 7 Fault history menu 5 00 0 0 nmm 83 System menu 84 PEE SIBI ETE 93 Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON 3 AT LEAST THE 11 FOLLOWING STEPS OF THE START UP QUICK GUIDE MUST BE PERFORMED DURING THE INSTALLATION AND COMMISSIONING IF ANY PROBLEMS OCCUR PLEASE CONTACT YOUR LOCAL DISTRIBUTOR 5 5 Start up Quick Guide 1 Check that the delivery corresponds to your order see Chapter 3 2 Before taking any commissioning actions read carefully the safety instructions in 1 Y 3 Beforethe mechanical installation check the minimum clearances around the unit and 5 5 check the ambient conditions in Chapter 5 Y Y 4 Check the size of the supply cable bus bar DC output cable bus bar and mains fuses 5 5 DC fuses and check the cable connections 9 Follow the installation instructions see Chapter 5 6 The sizes and earthing of control connections are explained in Chapter 5 7 If the Start Up wizard is active select the language you want the keypad and confirm by
21. Email vacon avacon com VACON 84 CONTROL KEYPAD cm lt gt 5 ChargeSwitch Operation hours 13 25 43 Gay F5 Fault history lt P 11 Output phase lt gt Operation days H19H3 T1977 PUSH lt to reset 11200 emf Figure 58 Fault history menu 6 3 8 SYSTEM MENU M6 You can enter the System menu from the Main menu by pressing Menu button right when the location indication is visible the first line of the keypad display The controls associated with the general use of the Active Front End such as application selection customised parameter sets or information about the hardware and software are located under the System menu The number of submenus and subpages is shown with the symbol S on the value line The System menu functions are presented in the Table 29 System menu functions Table 29 System menu functions Min Max Unit Default Selections English English Deutsch Suomi Svenska Italiano Load set 1 Store set 2 Load set 2 parameters All but motor parameters Application parameters Load to keypad Cony parameters _ Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 85 Table 29 System menu functions Function Min Max Unit Default Selections S64 4 Parameter comparison Parametercomparison S651 5 1 Password Not used
22. MONITORING MENU M1 You can enter the Monitoring menu from the Main menu by pressing Menu button right when the location indication M1 is visible on the first line of the display Figure 55 shows how to browse through the monitored values The monitored signals carry the indication and they are listed in Table 25 The values are updated once every 0 3 seconds This menu is meant only for signal checking The values cannot be altered here For changing values of parameters see Chapter 6 3 2 Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 77 Ga dD Nie FreqReference 13 95 Hz DA READY DA READY Monitor lt q gt Output frequency 1 gt 14 13 95 Hz 11204 emf Figure 55 Monitoring menu Table 25 Monitored signals Code Signal name Unit Description V1 1 Frequency reference Hz DC link voltage Measured DC link voltage V1 3 Unit temperature C Heat sink temperature Digital input statuses LUN ________ p M mA M1 17 Multimonitoring items Displays three selectable monitoring values See Chapter 6 3 8 4 Multimonitoring items 6 5 4 6 3 2 PARAMETER MENU M2 Parameters are the way of conveying the commands of the user to Vacon NX Active Front End Parameter values can be edited by entering the Parameter Menu from the Main Menu when the location indication M2 is visible on the first line of the displa
23. Menu button right f the page you want to move to by default Is at the third level repeat the procedure Confirm the new default page with the Enter button You can return to the previous menu at any time by pressing Menu button left c Zi zi m CONFIRM CHANGE REPEAT TO SET Default page DEFAULT SUBMENU PAGE 0 0 CANCEL 11195 emf Figure 68 Default page function Default page in the operating menu 6 6 2 Here you can set the location in the Operating menu in special applications only to which the display automatically moves to when the set Timeout time P6 6 3 see Timeout 6 6 3 has expired or the power is switched on to the keypad See how to set the Default page Figure 68 Timeout time 6 6 3 The Timeout time setting defines the time after which the keypad display returns to the Default page 6 6 1 See Default page P6 6 1 Enter the edit mode by pressing Menu button right Set the desired timeout time and confirm it with the Enter button You can return to the previous menu at any time by pressing Menu button left 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 92 CONTROL KEYPAD READY READY 3 25632 CONFIRM CHANGE 4 CANCEL 11196 emf Timeout time gt Timeout time A Timeout time 90 s 0 5 055 L EN Figure 69 Timeout time setting NOTE If the Default page value is 0 the meout time settin
24. NXA 1030 6 19050 Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 57 5 2 2 LCL FILTER Enough free space must be left around the LCL filter to ensure sufficient air circulation and cooling You will find the required dimensions for free space in the Table 23 You will find the required cooling air minimum air holes and heat dissipation in the Table 24 When planning the cooling for the space take into consideration that the LCL filter heat loss is approx 1 of the nominal capacity Air flow see Figure 37 and Figure 38 Table 23 Mounting space dimensions Dimensions mm LCL0261 5 LCLO170 6 LCLO460 5 LCL1300 5 free space above the LCL filter B distance between LCL filter and cabinet wall 11217 emf Figure 36 Installation space 24 hour support 358 0 201 212 575 Email vacon avacon com INSTALLATION VACON 58 11220 jpg Figure 37 Cooling airflow for FI9 and FI 10 LCL filters LO C N N N re N C LO x LL e N re N h N LO INSTALLATION VACON 59 lt gt 54 7 lt lt SE 5 ed 11239 jpg Figure 38 Cooling airflow guides for FI 13 LCL filter Table 24 Power losses and required cooling air for the LCL filters Heat dissipation Cooling air required Minimum air holes on Type TT 3 switchgear and
25. Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 51 1 If the keypad sits in its place on the control unit remove the keypad 2 Connect the male end of the keypad cable to the D connector of the control unit Use Vacon RS232 cable included in the delivery Figure 1 3 the cable over the top of the box and secure with plastic band on the backside Figure 2 4 Earthing of keypad cable Earth the keypad cable in the mounting box frame by fixing the branch cable with a screw underneath the control unit See Figures 3 and 4 9 Mount the control unit mounting box in the front left corner of the enclosure using two screws as shown in Figure 5 NOTE Do not install the mounting box floating with e g plastic screws 6 Connect the optical cables the flat cable to the power unit See Chapter 4 7 1 Connection between control unit and power unit and Figures 6 7 7 Connect the female end of the keypad cable to keypad on the enclosure door Figure 8 Usea cable channel for the cable run Figure 9 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 52 INSTALLATION Figure 4 Figure 6 Figure 7 Figure 8 Figure 9 Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 53 5 2 COOLING 5 2 1 ACTIVE FRONT END UNIT Enough free space must be left around the Active Front End unit to ensure sufficient air circulation and cooling You
26. against short circuit The fuses suitable for protection are shown in Chapter 4 11 A circuit breaker can also be used for protection see Chapter 4 12 The best short circuit protection is achieved by using fuses The short circuit protection must be on the input side when seen from the LCL filter Figure 8 A cable or busbar designed for the purpose must be used to make the connection The connection must be dimensioned according to the nominal current rating of the Active Front End unit The necessary overloading allowance must also be used The connection must also have the same short circuit capacity as the whole system The connecting cable or busbar may be of copper or aluminium When aluminium is used steps must be taken to prevent corrosion dimensions of the terminals in the unit are indicated in Appendix 82 and their locations are shown in Appendix 73 Appendix 74 and Appendix 75 Locations of terminals in the LCL filter are shown in Appendix 76 and Appendix 77 5 3 2 DC CONNECTION The DC connection of the Active Front End unit is connected to the terminals at the top The terminals are marked as B for connection to DC and B for connection to DC The DC connection must be protected using DC fuses see Chapter 4 11 The terminal dimensions are shown in Appendix 82 5 3 3 LCL FILTER FAN POWER SUPPLY Two types of power supplies are available for the LCL filter cooling fan The cooling fan can be supplied from an external power
27. delivery includes the cable for the control connection The length of the standard cable is 1 6 m The over temperature protection can be wired directly to the control unit or to the DC DC power supply The over temperature protection must be connected to protect the filter for protect the filter in case of over temperature NOTE By default the over temperature protection is not activated If itis not activated the LCL can be damaged in case of over temperature Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 65 If the over temperature protection is connected to a digital input the wires to be removed from the terminal X52 The 1 0 wiring has to be connected to the terminals 1 and 4 on the terminal X52 see Appendix 80 If the over temperature protection is connected to the 1 0 of the Active Front End unit it can be programmed The parameter 2 2 1 3 has to be set to choose the digital input to which the over temperature monitoring is connected The parameter P2 7 3 allows one to select the response to an over temperature alarm as wanted If the over temperature protection is connected to the DC DC power supply the jumper has to be removed from the terminal X3 The cable from the terminal X52 should be connected to the terminal X3 By default the jumper is connected to the terminal X3 see Figure 45 The delivery includes the cable for connecting the terminals X52 and X3 The wiring diagram can be seen
28. du Double Insulated Double Insulated Double Insulated Double Insulated 11166 emf Figure 22 Active Front End units parallel connection with own pre charging circuits 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 44 ACTIVE FRONT END 4 16 DERATING The output power has to be derated if one of following cases e Ambient temperature is more than 40 C e Installation altitude is more than 1000 m 4 16 1 AMBIENT TEMPERATURE The power rating of the Active Front End unit is valid for an ambient temperature of 40 C If the device is to be used in higher ambient temperatures its power rating must be subjected to derating The derating coefficient is 1 5 1 C for ambient temperatures not exceeding 50 C The reduced power 15 calculated using the formula P 10096 40 9C X 100 Pa nominal power of the unit t ambient temperature x derating coefficient Derating as a function of ambient temperature Loadability 96 Loadability 20 30 40 Ambient temperature C 11167 emf Figure 23 Derating as the ambient temperature 4 16 2 INSTALLATION ALTITUDE The standard power ratings of the Active Frond End unit are valid for a maximum installation altitude of 1 000 m If the device is to be used in higher installation altitudes its power ratings must be subjected to derating The derating coefficient is 1 596 per 100 m Th
29. for 3 seconds when the Active Front End is running modulating The keypad will become the active control place Select the keypad as the active control place by pressing for 3 seconds when the Active Front End is stopped modulating The keypad will become the active control place NOTE that if you are in any other than menu M3 these functions will not work If you are in some other than menu M3 and try to start the Active Front End by pressing the START button when the keypad is not selected as the active control place you will get an error message Keypad Control NOT ACTIVE 6 3 3 1 Selection of control place There are three different places sources where the Active Front End can be controlled from For each control place a different symbol will appear on the alphanumeric display Control place Keypad panel Keypad You can change the control place by entering the edit mode with Menu button right The options can then be browsed with the Browser buttons Select the desired control place with the Enter button See the diagram on the next page See also Chapter 6 3 3 above 6 3 4 ACTIVE FAULT MENU M4 You can enter the Active faults menu from the Main menu by pressing Menu button right when the location indication M4 is visible on the first line of the keypad display When a fault brings the brake chopper to a stop the location indication F1 the fault code a short description of the fault and the fault type symbol
30. in Table 2 Short circuit protection is implemented by protecting the input of the DC power with fuses When required the cooling fan can be controlled on off by installing a contactor in the DC power supply input and controlling that depending on whether the main switch is open or closed The over temperature protection of the LCL filter must always be wired from contacts 1 and 4 of terminal X52 to a digital input of the control unit see Appendix 81 and from contacts 1 and 2 of terminal X51 to a digital input of the control unit The wiring of the circuit is shown in Figure 48 LCL filter with external DC DC supply LCL filter X51 4 AFE unit rature 1 Over temperature Switch protection switch 2 Over temperature protection switch 3 DC supply 4 DC supply Over tempera ture protection Tempe rature nI dis X52 4 1 Over temperature protection switch temperature 4 Over temperature Control unit 7 I protection switch DC supply 48 Vdc Figure 48 Wiring diagram of external DC power 24 hour support 358 0 201 212 575 Email VACON 68 INSTALLATION 5 4 CONTROL UNIT The control unit of Vacon NX Active Front End consists of the control board and option boards see Figure 49 and Figure 50 connected to the five slot connectors A to E on the control board The control board is connect
31. intermediate circuit has to be double insulated NOTE Enough space must be reserved around the resistors to ensure sufficient cooling Don t place any heat sensitive components near the resistors Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 41 4 15 PARALLELING The power of the input group can be increased by connecting several Active Front End units in parallel Paralleling refers to Active Front End units connected in the same input transformer Active Front End units of different power ratings can also be connected in parallel No communication bet ween the units is required they work independently Vacon s standard LCL filters must be used for paralleling If filters other than Vacon s standard LCL filters are used in Active Front End units connected in parallel too large circulation currents may be generated between the Active Front End units Parameter P2 1 4 Parallel AFE must be set to 1 yes for all parallel AFE units This parameter will also set DC Droopingto 4 The value of DC Drooping can be also modified manually with parameter P2 2 2 Each Active Front End unit connected in parallel must have its own short circuit protection on AC and DC sides The fuses are selected in accordance with Section 4 11 When paralleling attention must be paid to the sufficient short circuit capacity of the system The derating of Active Front End units connected in parallel is 596 of the DC power th
32. output LCL0261 5 2350 1100 30000 LCLO170 6 2050 LCL0A60 5 3180 1100 30000 LCL0325 6 3290 LCL1300 5 6330 1300 42000 LCL1030 6 8680 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 60 INSTALLATION 5 2 3 ARRANGING VENTILATION OF THE ENCLOSURE The enclosure door must be provided with air gaps for air intake To achieve sufficient cooling inside the cabinet the dimensions for the total area of free openings for incoming air given in Table 22 and Table 24 must be followed For instance there could be two screened gaps as presented in Figure 39 Vacon s recommendation This layout ensures a sufficient air flow to the module fans as well as cooling of the additional components Air outlet gaps must be situated on top of the cabinet The minimum effective air outlet area per unit frame is given in Table 22 and Table 24 The cooling arrangements inside the cabinet must be such that they prevent hot output air from mixing with the incoming fresh air see Chapter 5 2 4 The ventilation gaps must fulfill the requirements set by the selected IP class The examples in this manual apply to protection class IP21 During operation air is sucked in and circulated by a fan blower at the bottom of the power unit the power unit is placed in the upper part of the cabinet the fan blower will be in the mid of the cabinet at the height of the upper ventilation grid In case of LCL filter air inlet 1 1 in Figure 39 cannot
33. output current Same as the unit Switching frequency LCLxxxx 5 3 6 kHz 6 3 6 kHz Input voltage Uin 333 911 460 1200 Cooling fan With integrated DC DC Input voltage Ui 48 Vdc 10 10 Cooling fan with external DC power supply Short circuit protection AC fuses on the Input side of the external power supply immunity 61800 3 274 edition 2004 second settings environment AME UU Ambient temperature during Same as the unit operation Storage temperature Same as the unit Relative humidity Same as the unit Air quality Same as the unit Chemical fumes Ambient conditions Solid particles Elevation of place of operation Same as the unit Vibration Same as the unit EN 50178 EN 60068 2 6 Impacts Same as the unit EN 50178 EN 60068 2 27 Dissipation power Approximately 190 Cooling fan rotation monitoring Yes with integrated DC DC power supply Protection Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE 27 4 6 APPLICATION The Vacon NX Active Front End needs special application software which is delivered with the NX AFE unit More information on the application can be found in Application User s Manual 4 7 DIAGRAMS 4 7 1 CONNECTION BETWEEN CONTROL UNIT AND POWER UNIT The communication connections between the Active Front End power unit and the control unit is es
34. supply or an integrated DC DC power supply 5 3 3 1 LCL filter with integrated DC DC power supply for fan The DC DC power supply is integrated in the structure of the LCL filter Figure 44 and Figure 45 The integrated DC DC power supply takes its input voltage from the intermediate circuit Appendix 79 The input of the DC DC power supply must be protected against short circuit using DC fuses type Ferraz Shawmut 8 A if the length of the supply cable does not exceed 2 m The fuses be installed in holders type Ferraz Shawmut US1021 2 pole to allow the easy disconnection of the DC DC power supply from the supply If the length of the supply cable exceeds 2 m fuses type Ferraz Shawmut D100gRB008VI 8 must be used The fuses should be installed in holders The high DC voltage must be taken into account when wiring the supply suitable cables leads must be used The DC DC power supply is monitored and controlled by the Active Front End unit The DC DC power supply connections are shown in Figures 44 45 and Appendix 79 and Appendix 80 The control connection has to be taken from the Active Front End unit The control cable has to be connected to the terminal X51 on the LCL filter see Figure 44 and Figure 45 The control cable has to be connected to the terminal X3 on the Active Front End unit see Figure 47 The terminal X3 can be found under the black cover In the 13 the terminal X3 is located in the left most unit The
35. voltage withstand tests on any part of Active Front End There is a certain procedure according to which the tests shall be performed Ignoring this procedure may result in damaged product Before connecting the Active Front End to AC supply make sure that the Active Front End front and cable covers are closed Before doing any work on Common DC bus system shall be earthen 1 3 EARTHING The Active Front End unit and LCL filter must always be earthed with an earthing conductor connected to the earthing terminal Tel 358 0 201 2121 Fax 358 0 201 212 205 EU DIRECTIVE VACON 97 2 EU DIRECTIVE 2 1 MARKING The marking on the product guarantees the free movement of the product within the EEA European Economic Area It also guarantees that the product complies with applicable directives for example the EMC Directive and other possible so called new method directives Vacon NX Active Front End carries the CE label as a proof of compliance with the Low Voltage Directive LVD Electro Magnetic Compatibility Directive and RoHS Directive 565 FIMKO has acted as the Notified Body 2 2 EMC DIRECTIVE 2 2 1 INTRODUCTION The EMC Directive provides that the electrical apparatus must not excessively disturb the environment it is used in and on the other hand it shall have an adequate level of immunity toward other disturbances from the same environment The compliance of Vacon NX Active Front E
36. 38 2 Table 17 Bussman DC fuse selection mains voltage 640 1100 Vdc Module Bussman type aR NOTE All fuses are flush end type If some other type is needed please contact Vacon ncm mui ss 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 38 ACTIVE FRONT END AFE 4 12 ACTIVE FRONT END UNIT CIRCUIT BREAKER SELECTION The Active Front End can also be protected by a circuit breaker The recommended types of circuit breakers are shown in Table 18 circuit breaker from another manufacturer is used it must be equivalent to the circuit breakers shown Further information on the circuit breakers shown is available from the manufacturer Circuit breakers do not provide the same level of protection as fuses Acircuit breaker can be used without a main contactor In this case the Active Front End unit controls the circuit breaker instead of the contactor The circuit breakers shown are suitable for equipment rated at 380 V 500 V or 525 V 690 V Table 18 Circuit breaker for Vacon NXA T5HAO00FF3LS T5HA00FF3LS MCCB 1SDA054349R1 MOE230V T4 5 Motor 1SDA054897R1 UVRC230V T4 5 Undervoltage rel cabled 1SDA054891R1 ES 6 T5 Spreaded ext term incl PB100 1SDA055038R1 AUX C3 1 T4 5 Aux alarm cont cabled 1SDA054911R1 PB100 T4 5 3P Phase separators for upper lower 1SDA054970R1 AUX SA1 S51 1 T4 5 terminals 1SDA064518R1 S51 NC T5H630FF3LS TSH
37. 575 Email VACON 88 CONTROL KEYPAD Automatic parameter backup 6 3 4 On this page you can activate or inactivate the parameter backup function Enter the edit mode by pressing Menu button right Select Yes No with the Browser buttons When the Parameter backup function is activated Vacon NX control keypad makes a copy of the parameters of the presently used application When applications are changed you will be asked if you wish the parameters of the new application to be uploaded to the keypad If you want to do this press the Enter button you wish to keep the copy of the parameters of the previously used application saved in the keypad press any other button Now you will be able to download these parameters to the Active Front End following the instructions given in Chapter 6 3 8 2 If you want the parameters of the new application to be automatically uploaded to the keypad you have to do this for the parameters of the new application once on page the Upload parameters to keypad To keypad 56 3 2 as instructed Otherwise the panel will always ask for the permission to upload the parameters NOTE Parameters saved in the parameter settings on page the Parameter sets 56 3 1 will be deleted when applications are changed If you want to transfer the parameters from one application to another you have to upload them first to the keypad 6 3 8 3 Parameter comparison In the Parameter co
38. 630FF3LS MCCB 1SDA054412R1 MOE230V T4 5 Motor 1SDA054897R1 UVRC230V T4 5 Undervoltage rel cabled 1SDA054891R1 ES 6 T5 Spreaded ext term incl PB100 1SDA055038R1 AUX C3 1 T4 5 Aux alarm cont cabled 1SDA054911R1 PB100 T4 5 3P Phase separators for upper lower 1SDA054970R1 AUX SA1 S51 1 T4 5 terminals 1SDA064518R1 S51 NC T7S16FF3PR231LS Spring chargin motor 220 250 V SPRING CHARGING MOTOR 1SDA062116R1 AC DC AUX 2Q 400 V AC AUX CONTACT 1SDA062102R1 SOR 220 240 V AC DC SHUNT OPENING RELEASE 1SDA063548R1 T7S16FF3PR231LS MOULDED CASE CIRCUIT BREAKER 1SDA063010R1 UVR 220 240 V AC DC UNDER VOLTAGE RELAY 1SDA063552R1 SCR 220 240 V AC DC SHUNT CLOSING RELEASE 1SDA063550R1 AUX RTC 250 V AC DC READY TO CLOSE 1SDA062109R1 Trip reset 200 240 V AC DC TRIP RESET UNIT 1SDA062119R1 AUX SA 1 S51 T7 T7M AUX SA 1 S51 T7 T7M 1SDA063553R1 Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 39 4 13 CONTACTOR If a main contactor 15 to be used the types shown in Table 19 are recommended If a contactor from another manufacturer is used it must be equivalent to the types shown Further information on the contactors shown is available from the manufacturer Table 19 Recommended main contactor types FI9 Contactor 500 V FID A210 30 11 80 Contactor 350 A 690 V AC3 110 KW 400 V 230 VAC Coil Type FI9 Contactor 690 V 9 A185 30 11 80 Contactor 275 A 690 V 132 KW 690V 230
39. AFEs are used Figure 19 for FI and FI10 and Figure 20 for FI13 have a red marking on the lead that has to be removed from each capacitor if the HF capacitors are not to be used Removing the lead disconnects the capacitors from ground potential 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 32 ACTIVE FRONT END f de m A 1 7 1 11253 A emf Figure 19 HF capacitors in FI9 and FI 10 LCL filter 11254 A emf Figure 20 HF capacitors in FI 13 LCL filter Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 33 4 8 ACTIVE FRONT END POWER RATINGS 4 8 1 VACON NXA DC VOLTAGE 380 500 V Table 6 Power ratings of Vacon NXA supply voltage 380 500 VAC Low oveload High oveload DC Power AC current AC current continuous Unit 400 V mains 500 V mains Code Frame li A lamin A lH cont A limin A P kW P kW For dimensions of NXA units see Table 8 and LCL filters Table 9 NOTE The rated currents in a given ambient 40 C temperature are achieved only when the switching frequency is equal to the factory default NOTE The motor output power Pout Pde X niNU X NMotor AFEs DC power NU efficiency of the inverter TIMotor efficiency of the motor 4 8 2 Vacon NXA DC VOLTAGE 525 690 V Table 7 Power ratings of Vacon NXA supply voltag
40. CTIVE FRONT END AFE VACON 25 Table 4 Technical specification for Vacon NXA Active Front End unit Analogue input voltage 0 10 V 200 Resolution 0 1 accuracy 1 Analogue input current 0 4 20 mA 250 Q differential Digital inputs 6 Positive or negative logic 18 30 VDC Auxiliary voltage 24 V 1595 max 250 mA Reference voltage 10 V 3 max load 10 mA Control connections Analogue output 1 0 4 20 mA max 500 Q Resolution 10 bit Accuracy 2 Digital outputs Open collector output 50 mA 48 V Relay outputs 2 programmable changeover relay outputs Breaking capacity 24 8 A 250 8 A 125 VDC 0 4 A Min switching load 5 V 10 mA Overvoltage protection NXA 5 911 VDC NXA 6 1200 VDC Undervoltage protection NXA 5 333 VDC NXA 6 460 VDC Earth fault protection In case of earth fault in the supply cable the earth fault protection only protects the NX AFE itself Input phase monitoring if any of the input phases 15 missing Protection Short circuit protection Yes of 24 V and 10 V reference voltages 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 26 ACTIVE FRONT END 4 5 LCL FILTER TECHNICAL Table 5 Technical specifications for Vacon LCL filter for Active Front End units Voltage Same as the unit Frequency fin 50 or 60 Hz 2 Aids Mil Continuous
41. Counted operation days T3 Output frequency Hz Fault 43 Counted operation hours hh mm ss V ge DC voltage Lo ww 1 7 wem j Real time record If real time is set to run on the brake chopper the data items T1 and T2 will appear as follows T 1 Counted operation days yyyy mm dd Counted operation hours 6 3 7 FAULT HISTORY MENU M5 You can enter the Fault history menu from the Main menu by pressing Menu button right when the location indication M5 is visible on the first line of the keypad display All faults are stored in the Fault history menu where you can browse them with the Browser buttons Additionally the Fault time data record pages see Chapter 6 3 6 1 are accessible for each fault You can return to the previous menu any time by pressing Menu button left memory of the Active Front End can store a maximum of 30 faults in order of appearance The number of faults currently in the fault history is shown on the value line of the main page 1 The order of the faults is indicated by the location indication in the upper left corner of the display The latest fault is indicated by F5 1 the one before that by F5 2 and so on If there are 30 uncleared faults in the memory the next fault will erase the oldest fault from the memory Pressing the Enter button for about 2 to 3 seconds resets the whole fault history The symbol will change to 0 24 hour support 358 0 201 212 575
42. DY 55 3 1 6 3 m Parameter sets Parameter sets Wait OK 11198 emf Figure 60 Storing and loading of parameter sets Upload parameters to keypad To keypad 56 3 2 This function uploads all existing parameter groups to the keypad provided that the drive is stopped Enter the To keypad page S6 3 2 from the Parameter copy menu Pressing Menu button right takes you to the edit mode Use the Browser buttonsto select the option A parameters and press the Enter button Wait until appears on the display READY a READY 663 6530 422 6532 CONFIRM Copy Parameters to keypad gt Up to keypad Select All param 1 CANCEL READY 5632 6532 GE Up to keypad Up to keypad Walt OK 11199 emf Figure 61 Parameter copy to keypad Download parameters to drive From keypad S6 3 3 This function downloads one or all parameter groups uploaded to the keypad to a drive provided that the drive is in STOP status Enter the To keypad page S6 3 2 from the Parameter copy menu Pressing the Menu button right takes you to the edit mode Use the Browser buttons to select either parameters All but motor parameters or Application parameters and press the Enter button Wait until appears the display The procedure to download the parameters from keypad to Active Front End is similar to that of from Active Front End to keypad See Figure 60 24 hour support 358 0 201 212
43. O 2 Table 13 Bussman DC fuse selection mains voltage 465 800 Vdc ER zz Gui Module DC fuses Bussman type aR Nxao2s15 F9 SOKN SU 2 NX 04605 0 150 2 00 150 2_ NOTE All fuses are flush end type If some other type is needed please contact 4 11 3 FUSES MAINS VOLTAGE 525 690 V 4 11 3 1 AC fuses Table 14 Ferraz Shawmut AC fuse selection mains voltage 525 690 Vac Module AC fuses Ferraz Shawmut type aR NEL T 0788 PCHSUDISCENPA 750 80 3 _ Hrs 5 NOTE Fuses for FI and FI10 are blade type and for F113 flush end type If some other type is needed please contact Vacon Table 15 Bussman AC fuse selection mains voltage 525 690 Vac Module fuses Bussman type aR ee mo mmes in snr 5 10 NOTE All fuses are blade type If some other type is needed please contact Vacon Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 9 37 4 11 3 2 DC fuses Table 16 Ferraz Shawmut DC fuse selection mains voltage 640 1100 Vdc Module DC fuses Ferraz Shawmut type aR 05256 FU PCTaUDTaCEIOTF 1250 530 3 Xi 10906 Fns PCRADDTICHICTG A
44. VAC Coil Type FI10 Contactor 500 V EN AF400 30 11 70 Contactor 600 A 500 V 200KW 400V 100 250 V AC DC coil FI10 Contactor 690 V FI10 AF300 30 11 70 Contactor 500 A 690 V AC3 250 KW 690 V 100 250 V AC DC coil FI13 Contactor 500 V AF1650 30 11 70 Contactor 1650 500 V 560 KW 400 V 100 250 V AC DC coil Type FI13 Contactor 690 V AF1350 30 11 70 Contactor 1350 690 V KW 400 V 100 250 V AC DC coil 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 40 ACTIVE FRONT END 4 14 PRE CHARGING CIRCUIT The Active Front End unit requires an external pre charging circuit The purpose of the pre charging unit is to charge the voltage in the intermediate circuit to a level sufficient for connecting the Active Front End unit to the mains The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors technical specifications of Vacon s standard pre charging circuits are shown in Table 20 Pre charging circuits are suitable for 380 500 Vac and 525 690 Vac The Active Front End unit must not be connected to mains without pre charging In order to ensure the correct operation of the pre charging circuit the input circuit breaker or contactor as well as the pre charging circuit contactor must be controlled by the Active Front End unit The input circuit breaker or contactor a
45. VACON NX AC DRIVES ACTIVE FRONT END UNIT AFE USER MANUAL VACON DRIVEN BY DRIVES 9 1 TRBLE CONTENTS Document DPD00906B Rev B Version release date 18 5 15 1 yet c M 5 e m 6 EA TSO NERO 6 2 rr 6 DC Rec 7 MIG AME eiu 7 PARA Tem 7 8 EROR 2 2 3 Vacon Active Front End classification 7 2 2 4 Manufacturer s declaration of conformity 7 3 PREC IDC OF CUI 10 3 1 designation code for the AFE unit 10 3 2 Type designation code for the LCL filter 11 3 3 designation code for the pre charging components 12 Sr MV vigo RED T Tm 13 2 MR m 14 Sm iR Rm 19 971 2B TI Ci E 17 o NEU uias 19 APE 20 TO Nom 20 4 2 Active Front End Unit block diagram 0 000 22 Front End fame 23 4 4 Active Front End unit technical data 25 Be LC Ter Pei INCA 27 PRU SOU spa E
46. VE FRONT END AFE VACON 21 4 2 ACTIVE FRONT END UNIT BLOCK DIAGRAM Power Module Measure Dr ae river Control Module RS 232 I O I O I O slot slot B slot E Figure 9 NXA block diagram 11170 emf 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 22 ACTIVE FRONT END 4 3 ACTIVE FRONT END FRAME SIZES 11175 emf Figure 11 Vacon NXA 110 Protection class POO Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 23 11173 emf Figure 12 Vacon 113 Protection class POO 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 24 ACTIVE FRONT END 4 4 ACTIVE FRONT END UNIT TECHNICAL Table 4 Technical specification for Vacon NXA Active Front End unit Voltage 380 500 Vac 525 690 Vac 10 10 in 1 Frequency f 48 63 Hz Starting delay FI9 FI13 5 s Voltage 1 35 x Ui x 1 1 default DC link voltage boosting is 11090 DC output Continuous output Ambient temperature 40 C connection current overloadability 1 5 x lj 1 min 10 Ambient temperature 40 C overloadability 1 1 x lj 1 min 10 Control Control system Open Loop Vector Control Switching frequency NXA xxxx 5 3 6 kHz NXA xxxx 3 6 kHz Ambient temperature 1029
47. alance Subcode in T14 Should the fault re occur contact your Warning only Ede nen uH fames local distributor 52 DC Voltage unbalance IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current IGBT temperature hardware Contact your distributor If you are Application Problem in application software application programmer check the application program Option board or control unit changed Same type of board or same power rating of drive Device changed same type Reset Device is ready for use Old parameter settings will be used Option board or drive added Drive of same power rating or same type of board added Device removed PD on Reset Device longer available Drive removed Unknown option board or drive Subcode in T 14 Device unknown 51 Unknown device 52 Power not same type as Power2 Device added same type Reset Device is ready for use Old board settings will be used Contact the distributor near to you e IGBT Inverter Bridge overtemperature IGBT temperature protection has detected too high a gt short term overload current Reset Set the option board parameters again If option bard changed Set converter parameters again if power unit changed Option board or control unit changed Option board of different type or dif ferent power rating of drive Device changed different type
48. as been stored much longer than 1 year de energized consult factory before connecting the power Tel 358 0 201 2121 Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 13 3 5 MAINTENANCE All technical devices drives as well need a certain amount of care taking and failure preventive maintenance To maintain trouble free operation of the Vacon NX Active Front End environmental conditions as well as load line power process control etc have to be within specifications determined by manufacturer If all conditions are in accordance with the manufacturer s specifications there are no other concerns but to provide a cooling capacity high enough for the power and control circuits This requirement can be met by making sure that the cooling system works properly Operation of cooling fans and cleanness of the heat sink should be verified regularly Regular maintenance Is recommended to ensure trouble free operation and long lifetime of Vacon NX Active Front End At least the following things should be included in the regular maintenance Table 3 Maintenance interval 12 months if unit is stored Capacitor reforming see seperate instructions Check tightening torque of the input and output terminals and 1 0 terminals Clean the cooling tunnel 6 24 months depending on environment Check operation of the cooling fan check for corrosion on terminals bus bars and other surfaces Check the door filters
49. aximum charging capacity see Table 20 Table 2 Type designation code for the pre charging components 219 AFE CHARGING AFE FFE FI9 2110 AFE CHARGING AFE FFE F110 Description Product Code 02 Charging resistors CBV335C20R Snubber capacitor PHE448 FI13 AFE CHARGING AFE FFE F113 Description Manufacturer Product Code 2 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 9 12 RECEIPT OF DELIVERY 3 4 STORAGE If Vacon9 NX Active Front End is to be stored before use make sure that the ambient conditions are acceptable Storage temperature 40 70 C Relative humidity 9595 no condensation When the Active Front End unit is stored without voltage being applied the recharging of the capacitors should be done at least once a year by connecting voltage into the unit and keeping it powered at least for 1hour If the storing time is much longer than one year the recharging of the capacitors has to be carried out so that the possible high leakage current through the capacitors is limited The best alternative is to use DC power supply with adjustable current limit Current limit has to be set for example to 300 500 mA and DC power supply has to be connected to the B B terminals DC supply terminals DC voltage must be adjusted up to nominal DC voltage level of the unit 1 35 U AC and shall be supplied at least for 1 hour If DC power supply with current limiting is not available and unit h
50. be used 11221 jpg Figure 39 Cabinet openings for cooling 1 Cooling air inlets 2 Hot air exhaust Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 61 5 2 4 STEERING AIR FLOW Cooling air must be taken in through the ventilation gaps on the door and blown out at the top of the enclosure To steer the hot air from the power unit to the outlet at the top of the enclosure and prevent it from circulating back to the fan blower use either of the following arrangements A Install a closed air duct from the power unit to the outlet on top of the enclosure A in Figure 40 B Install shields in the gaps between the power unit and the cabinet walls B in Figure 40 Place the shields above the air outlet gaps at the sides of the module A Air duct 3 A ra e p e s gmp r i atw roama r a P a SS a Nc gt 254 5 5 JP E e Sheet metal a 55 2 lt J Shields n Mr s SM Touch protections Mesh type touch protection 11224 jpg Figure 40 Cabinet cooling airflow guides NOTE If a flat roof is used mount a V shaped air guide on the underside of the roof to direct the air flow horizontally See Figure 41 11216 emf Figure 41 Roof structure seen from the side 24 hour support 358 0 201 212 575 Email vacon avacon com INSTALLATION
51. e 525 690 Low oveload High oveload DC Power AC current AC current continuous 690 V mains lamin A lH cont A lamin A P kW ew ws 9s 99 C For dimensions of NXA units see Table 8 and LCL filters Table 9 NOTE The rated currents in a given ambient 440 temperature are achieved only when the switching frequency is equal to the factory default NOTE The motor output power Pout PdcX X Motor AFEs DC power efficiency of the inverter NMotor efficiency of the motor 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 34 ACTIVE FRONT END AFE 4 9 ACTIVE FRONT END UNIT DIMENSIONS Table 8 The NXA unit dimensions Module Module Dimension Frame Height mm Width mm ih mm m kg NOTE More detailed dimensions can be found Appendix 73 Appendix 74 and Appendix 75 4 10 LCL FILTER DIMENSIONS Table 9 LCL filter dimensions Module Module Dimension Frame Height mm Width mm Depth mm Weight kg NOTE Weight is different for 500 V 690 V other dimensions are same for both voltage classes NOTE More detailed dimensions can be found Appendix 76 and Appendix 77 Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 9 35 4 11 ACTIVE FRONT END UNIT FUSE SELECTION 4 11 1 INTRODUCTION AC fuses are used to protect the input network in case the Active Fron
52. e power rating of the device can be reduced to a maximum installation altitude of 4000 m 500 V and 2000 m 690 V The reduced power can be calculated using the formula Pde Pn 100 Ainst 7 XI A 00 P nominal power of the unit hing Intended installation altitude hbase 1 000 m x derating coefficient Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 45 Derating as a function of installation altitude Loadability o o gt 2 1000 1500 2000 2500 3000 3500 Installation altitude 11255 emf Figure 24 Derating as the installation altitude 380 500 V Derating as a function of installation altitude Loadability Loadability 1000 1500 Installation altitude m 11256 emf Figure 25 Derating as the installation altitude 525 690 V NOTE If higher installation altitude is considered please contact Your nearest Vacon office 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 46 INSTALLATION 5 INSTALLATION 5 1 MOUNTING The equipment mounting must be sturdy enough to carry the weight of the equipment The enclosure class of the equipment will depend on the mounting and solutions to be used The equipment mounting must provide sufficient shielding for contact of the live parts 2 The installation and mountin
53. ed by one of the Active Front End units If each paralleled Active Front End unit has its own circuit breaker each Active Front End controls it s own circuit The circuit diagram for control see Appendix 70 and Appendix 72 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 42 ACTIVE FRONT END AFE Main Circuit 10 L1 L2 Yos EE L3 PE ind K2 1 15 LCL U1 AFE U1 AFE U2 xxxx x Double Insulated I 11165 emf Figure 21 Active Front End units parallel connection with one common pre charging circuit Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 43 4 15 2 EACH ACTIVE FRONT END UNIT HAS THE PRE CHARGING CIRCUIT Each Active Front End can have its own pre charging circuit Each unit controls its own pre charging and main contactor See Figure 22 One control switch can be used but if an Active Front End unit needs to be controlled independently separate switches are needed With this the system 15 more redundant than with a common pre charging circuit The circuit diagram for control see Appendix 70 and Appendix 72 Main Circuit 20 Ambient temperature Loadability Huc of ambient tempen 11 we 3 5 K1 1 Mrd E L gt gt Hn AFE UT 72 4 2 AFE U2 NXA XXXX X X
54. ed to the power unit through a D connector 1 ze sce MELT fui d uu br uc LEN L ooc oo0nnn nonno 1111111 E G preme EL n E ER at ie Te 441 E 1 2 Pure 0 6600006565566066505n20 oOonooo Ve 11210 emf Figure 49 Control board Figure 50 Basic and option board connections on the control board Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 69 When Vacon NX Active Front End is delivered from the factory the control unit usually includes two basic boards I O board and relay board which are normally installed in slots A and B On the next pages you will find the arrangement of the control 1 0 and the relay terminals of the two basic boards the general wiring diagram and the control signal descriptions The 1 0 boards mounted at the factory are indicated in the type code For more information on the option boards see Vacon NX option board manual 741 The control board can be powered externally 424 by connecting the external power source to bidirectional terminal 6 This voltage 15 sufficient for parameter setting and for keeping the fieldbus active NOTE If the 24 V input of several brake choppers or other loads are connected in parallel we recommend to use a diode in t
55. el consists of menus M1 to M7 and is called the Main menu The user can navigate in the Main menu with the Browser buttons up and down The desired submenu can be entered from the Main menu with the Menu buttons When there still are pages to enter under the currently displayed menu or page you can see an arrow in the lower right corner of the display and can reach the next menu level by pressing Menu button right The control keypad navigation chart is shown on the next page Please note that menu M1 is located in the lower left corner From there you will be able to navigate your way up to the desired menu using the menu and browser buttons You will find more detailed descriptions of the menus later in this chapter 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 9 76 CONTROL KEYPAD a cm E 5711 2 Expander boards Parameters G19G5 STOP READY 5 System Menu 51959 mmm value READY 5 Operation days 17 Fault history H12H3 F mcm 11 Output phase 1177 Active faults iet M3 mm P3 m Keypad control _ Control Place Terminal Change Browse value wm d Parameters Basic parameters lt gt Min Frequency 01909 P1 gt P15 13 95 Hz Browse Change Monitor p Output frequency A NO editing V12V15 13 95Hz 11205 emf Figure 54 Keypad navigation chart 6 3 1
56. erminal 6 to avoid the current to flow in opposite direction which might damage the control board 7 m 6 7 6 6 11212 emf 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 70 INSTALLATION 5 5 GALVANIC ISOLATION BARRIERS The control connections are isolated from the mains potential and the GND terminals are permanently connected to ground See Figure 51 The digital inputs are galvanically isolated from the I O ground The relay outputs are additionally double isolated from each other at 300 50178 See Figure 51 L1 L2 L3 Control 1 0 grou nd 029 9 Control Digital input panel Digital input group B Control board Digital output N CMS NEY Sd 11209 emf Figure 51 Galvanic isolation barriers Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 71 6 CONTROL KEYPAD The control keypad is the link between Active Front End and the user The Vacon NX control keypad features an alphanumeric display with seven indicators for the Run status RUN C READY STOP ALARM FAULT and three indicators for the control place 1 0 term Keypad BusComm There are also three Status Indicator LED s green green red see Chapter 6 1 2 The control information i e the menu number description of the menu or the displayed value and the numeric information are presented on three text lines
57. g has no effect Contrast adjustment P6 6 4 In case the display is unclear you can adjust it s contrast through the same procedure as for the timeout time setting see Timeout time 6 6 3 Backlight time P6 6 5 By giving a value for the Backlight time you can determine how long the backlight stays on before going out You can select any time between 1 and 65535 minutes or Forever For the value setting procedure see Timeout time 6 6 3 Tel 358 0 201 2121 Fax 358 0 201 212 205 VACON 93 APPENDICES APPENDICES 7 45 UOISIA9M ou AQ uo2eA OLI PUP ola 34V 3 71612 Jawojsng wopesg 2945 TIENI 4 d Beg onu p fosd 072 N QGdilvifnsNi 318nod C 2000 VXN D ifr33v 9 S F o mae ens e Dur 22 2 HN EYI ET EX 072 1 INIDYVHO NIVIN HOLOVINOO HOLOVINOO LI NIVIN n 11225 pdf Figure 70 Wiring diagram for FI9 and FI 10 24 hour support 358 0 201 212 575 Email vacon avacon com APPENDICES VACON 9 94 ER jn3415 Jawn 201 EG ani N 388 j N 8 9 90 8 0 J g
58. g must comply with local laws and regulations 5 1 1 ACTIVE FRONT END UNIT The Active Front End can be mounted in a vertical position on the back plane of a cubicle Enough space must be reserved around the Active Front End to ensure sufficient cooling see Figure 33 Follow the minimum dimensions for installation see Table 21 Required cooling air capacity and minimum air holes on the switchgear see Table 22 Also make sure that the mounting plane is relatively even The Active Front End is fixed with four bolts Figure 26 Figure 27 and Figure 28 Figure 26 Mounting points of FI9 AFE unit Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 47 Figure 27 Mounting points of FI10 AFE unit 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 48 INSTALLATION 11257 jpg Figure 28 Mounting points of FI13 AFE unit 5 1 2 LCL FILTER The LCL filter can only be mounted in a vertical position on the floor of a cubicle Enough space must be reserved around the LCL filter to ensure sufficient cooling see Figure 36 Follow the minimum dimensions for installation see Table 23 Required cooling air capacity and minimum air holes on the switchgear see Table 24 LCL filters cooling air airflow is present in Figure 37 and Figure 38 Also make sure that the floor is relatively even The LCL filter must be attached properly so it can not move In the LCL filter for the
59. in Appendix 80 If over temperature monitoring is connected to the DC DC power supply the Active Front End unit will monitor over temperature response to an over temperature alarm cannot be selected In this case the over temperature fault message will be same as the fan fault of the unit On the keypad the fault 32 Fan Cooling will be shown m E iai 11237 jpg Figure 44 Integrated DC DC power in the FI9 and FI 10 LCL filter 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 66 INSTALLATION 11238 Figure 45 Integrated DC DC power in the FI 13 LCL filter LCL filter with integrated DC DC supply AFE unit V phase in F113 Lemper X51 4 rature LO Switch 1 fan alarm 2 DC fuse base connection 3 fan control 4 165V X52 4 pin 1 Over temperature protection switch 4 Over temperature protection switch X53 3 pin DC supply DC supply 7 1 BE supply 11163 emf Figure 46 Wiring diagram of integrated DC DC power Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION 67 11242 jpg Figure 47 Terminal X3 U phase in FI13 in the unit 5 3 3 2 LCL filter without DC DC power supply for fan The LCL filter is supplied without an integrated DC DC power supply In this case the customer must procure the power supply separately The requirements for the DC power supply are shown
60. in menu M6 see Chapter 6 3 8 4 Parameter lock 6 5 2 You can return to the Main menu any time by pressing Menu button left for 1 to 2 seconds You will find the parameter lists from the Active Front End Application manual Once in the last parameter of a parameter group you can move directly to the first parameter of that group by pressing Browser button up See the diagram for parameter value change procedure in Figure 56 NOTE You can connect power to the control board by connecting the external power source to the bidirectional terminal 6 on the board see Chapter 5 4 The external power source can also be connected to the corresponding 24 V terminal on any option board This voltage is sufficient for parameter setting and for keeping the fieldbus active em Input signals G123G8 READY READY READY Me pe aD Parameters 4 Basic parameters 4 Min Frequency G129G8 Pi gt P18 15 95 Gi Min Frequency 413 95 Hz Figure 56 Parameter value change procedure Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 79 6 3 3 KEYPAD CONTROL MENU M3 In the Keypad Control Menu you can choose the control place You can enter the submenu level by pressing Menu button right NOTE There are some special functions that can be performed in menu M3 Select the keypad as the active control place by pressing
61. ing and operation of Vacon NX Active Front End We recommend that you carefully study these instructions before powering up the active front end for the first time In the Active Front End Application Manual you will find information about the Active Front End application Should that application not meet the requirements of your process please contact the manufacturer for information on special application This manual is available in both paper and electronic editions We recommend you to use the electronic version if possible If you have the electronic version at your disposal you will be able to benefit from the following features The manual contains several links and cross references to other locations in the manual which makes it easier to move around in the manual The reader can thus easily find and check things The manual also contains hyperlinks to web pages visit these web pages through the links you must have an internet browser installed on your computer This manual 15 applicable only for Active Front End units LCL filters and optional components that are introduced in this manual Tel 358 0 201 2121 Fax 358 0 201 212 205 SAFETY VACON 5 1 This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid unintentional damage to the product or connected appliances Please read the information included in cautions and warnings carefully
62. is function does not prevent unauthorised editing of parameter values Enter the edit mode by pressing Menu button right Use the Browser buttons to change the parameter lock status Confirm the change with the Enter button or go back to the previous level by pressing Menu button left 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 90 CONTROL KEYPAD cD cD d ME 555 5552 System Menu Security gt Parameter Lock 51959 P1 gt P4 ChangeEnable READY 5552 GS Parameter Lock Parameter Lock Change Enabl ChangebDisabl 11191 emf Figure 64 Parameter locking Start up wizard 6 5 3 The Start up wizard facilitates the commissioning of Vacon NX Active Front End If active the Start up wizard prompts the operator for the language and application of his her choice and then displays the first menu or page Activating the Start up wizard In the System Menu find page P6 5 3 Press Menu button right once to enter the edit mode Use the Browser buttons select Yes and confirm the selection with the Enter button you want to deactivate the function follow the same procedure and give the parameter value Vo P553 GD P553 CONFIRM Startup wizard Startup wizard 4 Yes 11192 emf Figure 65 Activation of Start up wizard Multimonitoring items P6 5 4 Vacon NX alphanumeric keypad features a display where you can monitor up t
63. is should be taken into account when selecting the input unit If a device is to be isolated from the AC and DC voltages and other Active Front End units connected in parallel are also to be used separate isolators are required in the AC input and DC output The AC input can be isolated using a compact circuit breaker an ordinary circuit breaker or a fuse switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position The DC output can be isolated using a fuse switch The pre charging circuit must also be isolated from the AC input A load isolation switch or safety isolation switch can be used for this The device can also be connected to mains even when the other devices connected in parallel are already connected and running In such a case the isolated deice must first be pre charged When that is done the AC input can be switched on After this the device can be connected to the interediate DC circuit 4 15 1 COMMON PRE CHARGING CIRCUIT In case of paralleled Active Front End units one common pre charging circuit can be used see Figure 21 Standard pre charging circuits can be used if the capacitance of the intermediate circuit not exceeds maximum value For example if three 10 Active Front End units are connected parallel the pre charging circuit for F113 Active Front End unit can be used If all paralleled Active Front End units have a common circuit breaker the breaker can be controll
64. mparison submenu 56 4 you can compare the actual parameter values to the values of your customised parameter sets and those loaded to the control keypad You can compare the parameter by pressing Menu button right in the Compare parameters Submenu The actual parameter values are first compared to those of the customised parameter Set1 If no differences are detected 0 is displayed on the lowermost line If any of the parameter values differ from those of Set1 the number of the deviations is displayed together with symbol P for example P1 P5 five deviating values By pressing Menu button right once more you can enter pages where you can see both the actual value and the value it was compared to In this display the value on the description line in the middle is the default value and the one on the value line lowermost is the edited value Furthermore you can also edit the actual value with the Browser buttons in the edit mode which you can enter by pressing Menu button right once 554 ParamComparison 5 1 0 gt gt 2 1 2 50 0 6 5654 m A EDIT VALUE v CONFIRM CHANGE 11189 emf Figure 62 Parameter comparison Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 89 6 3 8 4 Safety NOTE The Security submenu S6 5 is protected with a password Store the password in a safe place Password S6 5 1 The application selection can be p
65. nd with the EMC Directive is verified with Technical Construction Files and checked and approved by 565 which is a Notified Body The Technical Construction Files are used to authenticate the conformity of Vacon NX Active Front End with the Directive because it is impossible to test such a large product family in a laboratory environment and because the combinations of installation vary greatly 2 2 2 TECHNICAL CRITERIA Our basic idea was to develop a range of Vacon NX Active Front End offering the best possible usability and cost efficiency EMC compliance was a major consideration from the outset of the design 2 2 3 VACON ACTIVE FRONT END CLASSIFICATION Factory delivered Vacon NX Active Front End are Class T equipment which fulfills all EMC immunity requirements standard EN 61800 3 Class T Class T equipment have a small earth leaking current and can be used with floating DC input 2 2 4 MANUFACTURER S DECLARATION OF CONFORMITY The following page presents the photocopy of the Manufacturer s Declaration of Conformity assuring the compliance of Vacon NX Active Front End with the EMC directives 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 8 EU DIRECTIVE VACON DRIVEN BY DRIVES EC DECLARATION OF CONFORMITY We Manufacturer s name Vacon Manufacturer s address 25 Runsorintie 7 FIN 65381 Vaasa Finland hereby declare that the prod
66. o three actual values at the same time see Chapter 6 3 1 and Chapter Monitoring values in the manual of the application you are using On page P6 5 4 of the System Menu you can define whether the operator can replace the values monitored with other values See Figure 66 Po SY GE PESH Multimon items items items ChangeEnable hangeEnable ChangeDisable 11193 emf Figure 66 Disabling the change of multimonitoring items Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 91 6 3 8 5 Keypad settings In the Keypad settings submenu under the System menu you can further customise your Active Front End operator interface Locate the Keypad setting submenu 56 6 Under the submenu there are four pages associated with the keypad operation 566 m Keypad settings lt Default page P1 gt P5 11194 emf Figure 67 Keypad settings submenu Default page 6 6 1 Here you can set the location page to which the display automatically moves when the Timeout time P6 6 3 see Timeout time 6 6 3 has expired or the power is switched on to the keypad If the Default page 15 0 the function is not activated i e the latest displayed page remains the keypad display Pressing Menu button righttakes you to the edit mode Change the number of the Main menu with the Browser buttons To edit the number of the submenu page press
67. oke on the AFE side Figure 16 The LCL also includes capacitors connected against ground potential There are resistors connected across the capacitors for discharging them when the LCL filter is disconnected from the input power The discharging resistors are 10 MQ 500 V and 0 5 W Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 29 r LCL FILTER L1 nnl lll 11181 emf Figure 16 Vacon LCL filter wiring diagram 4 7 2 1 Removing discharging resistors If the LCL filter is used in a network fitted with an earth fault protection relay these discharging resistors should be removed If the discharging resistors are not removed the earth fault monitoring device might indicate a very low leakage resistance The resistors must be connected so that the capacitors are discharged when disconnecting from the input power The wiring diagram of an alternative discharging circuit can be seen in Figure 18 Figure 17 shows the default wiring of the LCL filter The discharging resistors should be 10 500 V and 2 W Failure to ensure the discharging of capacitors results in a risk of electric shock Without the discharge resistors the capacitors take a very long time to discharge Figure 19 for FI and 10 and Figure 20 for 13 have a blue marking on the lead that has to be removed from each capacitor if the discharge resistor is not to be used Warning If you do not allow a total di
68. oy 9 LV LdO Ut 9L JO 51 PL 0 6 8 euius LV LdO ut DOAPZ 21 10 9 eumua NIVIN 11234 pdf Figure 79 Circuit diagram for DC DC power supply if over temperature protection is connected to the I O LO C N N N re N C LO x LL e N b N N LO VACON 9 103 APPENDICES jawod 20 20 o S3ATHO A8 s uoqgoejoud asmesdwa jerjsn N 5U A Pood ay wos uey gt 9 91 Figure 80 Circuit diagram for DC DC power supply if over temperature protection 2 2 en JO C O O 24 hour support 358 0 201 212 575 Email APPENDICES VACON 9 104 pelaeuoo sn 5 UOISIAaM AO i uonaejo4d aunjesadwiay 1917517 rr peg Jawn 11236 pdf Figure 81 Circuit diagram for LCL filter without integrated DC DC power supply X XXXX 1 33 LV LdO UI 91 JO 61 1701 6 8 LV LdO ut DOAPT L 20 9 euius Ajddns Ajddns
69. pe designation code for the Active Front End 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 9 10 RECEIPT OF DELIVERY 3 2 TYPE DESIGNATION CODE FOR THE LCL FILTER LCL filters has two versions of cooling fan power supply one without the integrated DC DC power supply and one with it The LCL filter is characterized without the integrated DC DC power supply by letter A and with the integrated DC DC power supply by letter B in version column Figure 2 VACON LCL FILTERS FOR AFE TYPE CODE y Productrange LCL LCL filter for AFE Nominal current Low overload eg 0460 460 A 1300 130 A etc Voltage class 5 380 500 VAC 6 525 690 Version hardware DC fan without DC DC power supply B DC fan with integrated DC DC power supply Enclosure class 0 IP00 Reserve Reserve Reserve Cooling fan type 1 DC fan Manufacturer T Trafotek Figure 2 Type designation code for the LCL filters Tel 358 0 201 2121 Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 11 3 3 TYPE DESIGNATION CODE FOR THE COMPONENTS The pre charging components can be ordered separately The pre charging resistors are optimized for each Active Front End unit Components of the pre charging circuit are 2 pcs charging resistors the contactor the diode bridge and the snubber capacitor see Table 2 Each pre charging circuit has m
70. rotected against unauthorised changes with the Password function 56 5 1 By default the password function is not in use If you want to activate the function enter the edit mode by pressing Menu button right A blinking zero appears in the display and you can seta password with the Browser buttons The password can be any number between 1 and 65535 NOTE that you can also set the password by digits In the edit mode push Menu button right again and Timeout time P6 6 3 another zero appears on the display Set ones first To set the tens press Menu button right and so on Confirm the password with the Enter button After this you have to wait until the Timeout P6 6 3 see Timeout time 6 6 3 has expired before the password function Is activated If you try to change applications or the password itself you will be prompted for the current password Enter the password with the Browser buttons You can deactivate the password function by entering the value 0 READY READY 555 5 56 5 ep Password Password Not in use gt 00 11190 Figure 63 Password setting NOTE Store the password in a safe place No changes can be made unless a valid password is entered Parameter lock P6 5 2 This function allows the user to prohibit changes to the parameters If the parameter lock is activated the text ocked will appear on the display if you try to edit a parameter value NOTE Th
71. s This may be useful when you want to see how the changed new value influences some other value The enter button is used for 1 confirmation of selections 2 fault history reset 2 3 seconds Browser button up Browse the main menu and the pages of different submenus Edit values Browser button down Browse the main menu and the pages of different submenus Edit values Menu button left Move backward in menu Move cursor left in parameter menu Exit edit mode Menu button right Move forward in menu Move cursor right in parameter menu Enter edit mode Start button Pressing this button starts Vacon NX Active Front End modulation if the keypad is the active control place See Chapter 6 3 3 Stop button Pressing this button stops Vacon NX Active Front End unless disabled by parameter R3 4 R3 6 See Chapter 6 3 3 Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 9 75 6 3 NAVIGATION ON THE CONTROL KEYPAD The data on the control keypad is arranged in menus and submenus The menus are used for the display and editing of measurement and control signals parameter settings see Chapter 6 3 2 and reference value and fault displays see Chapter 6 3 4 Through the menus you can also adjust the contrast of the display see Chapter 6 3 8 5 Location CDA Gy Description _ Monitor Number of items V1 gt V 4 available 11206 emf The first menu lev
72. s well as the pre charging circuit contactor must be connected as shown in Appendix 70 Table 20 Capacitance Min and Max value for Pre charging circuit Capacitance 4950 uF 30000 uF Frame size Resistance 2x20R 9900 uF 70000 uF 2x11R 29700 128000 If the capacitance of the intermediate circuit in the system exceeds the values shown please contact the nearest Vacon office The example shown in Appendix 70 uses a spring return switch The switch has positions 0 1 START The spring returns the switch from position START to position 1 To start the pre charging the switch is turned from position 0 1 to START When pre charging starts the switch can be released and it returns to position 1 No other control measures are required Active Front End application controls the main contactor of the system with Relay Output RO2 see Appendix 72 When pre charging of the intermediate circuit is ready the main contactor will be closed The status of the main contactor is monitored via digital input Default is DINA4 As a default the main contactor monitoring is ON but it can be set OFF with parameter The main contactor should not be possible close without pre charging To open the main contactor simply turn the switch to 0 The contactor should not be opened under load Opening the contactor under load will shorten its service life NOTE Wirings what are used for connecting the pre charging circuit to the
73. scharge of the system before starting the modification it is likely that you will get an electric shock in spite of the fact the system is disconnected from the power supply 24 hour support 358 0 201 212 575 Email vacon avacon com VACON ACTIVE FRONT END 4 af af MAINS BREAKER ds ay m 1 1 FCD a GND PE GND PE 2 2 PE PE E 1 1 1 1 1 1 Ga 0 DC A A A A gt _______ ___ ___ ______ 7101 emf Figure 17 Wiring diagram of the default LCL filter Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTIVE FRONT END AFE VACON 9 31 CL 4 a MAINS 1 1 FCDhy FCDA 8A Y 8A Y GND PE 2 2 PE 1 1 1 1 1 1 M DC C C C C 7102 emf Figure 18 Wiring diagram of LCL and AFE circuit when used in IT network or when AFE of other manufacturer is connected to same transformer secondary supply 4 7 2 2 Removing HF capacitors If a PWM modulated rectifier from another manufacturer is connected to the same input transform er the HF capacitor must be removed because the HF capacitors will be filtering the high frequen cy disturbances from another manufacturer s active front ends It is recommended to always use own transformers if more than one manufacturer s
74. seconds F An F fault makes the drive stop Actions need to be taken to restart Fault the drive AR If an AR fault occurs the drive will stop immediately The fault is Fault Autoreset reset automatically and the drive tries to restart the motor Finally if the restart is not successful a fault trip FT see below occurs FT If the drive is unable to restart the motor after an AR fault an FT fault Fault Trip occurs he FT fault has basically the same effect as the F fault the drive is stopped Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 81 6 3 6 FAULT CODES The fault codes their causes and correcting actions are presented in the Table 27 The shadowed faults are A faults only The items in white on black background are faults for which you can program different responses in the application See parameter group Protections NOTE When contacting the distributor or factory because of a fault condition always write down all texts and codes visible on the keypad display Table 27 Fault codes Fault AFE has detected too high current Check cables 4 IH in the resistor cables Check resistors The DC link voltage has exceeded the Overvoltage dE 911 V for 500 V AFE 1200 V for 690 V AFE Various causes Cannot be reset from the keypad Defective component Switch off power Brake resistor short circuit DO NOT RE CONNECT POWER oroverload Contact your local di
75. stributor Possible cause Correcting measures Fault Saturation trip Component failure Faulty operation Note exceptional fault data record Subcode in 1 14 51 Reserved 52 Reserved 53 Reserved 54 Reserved Reset the fault and restart System fault S5 Reserved Should the fault re occur contact your 56 Reserved local distributor 57 Charging switch 58 No power to driver card S9 Power unit communication TX 510 Power unit communication Trip 511 Power unit communication Measurement DC link voltage is under the AFE fault In case of temporary supply voltage voltage limit break reset the fault and restart the 333 VDC for 500 V AFE frequency converter Undervoltage 460 VDC for 690 V AFE Check the supply voltage Most probable cause too low f it is adequate an internal failure supply voltage in the system has occurred AFE internal fault Contact your local distributor undertemperature Heatsink temperature is over 90 C Check the correct amount and flow AFE Overtemperature warning is issued of cooling air overtemperature when the heatsink temperature Check the heatsink for dust exceeds 85 C Check the ambient temperature 1 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 82 CONTROL KEYPAD Table 27 Fault codes Possible cause Correcting measures code Unbalance between power modules In paralleled units i Unb
76. t End unit or the LCL filter is faulty DC fuses are used to protect the Active Front End unit and the LCL filter in case there is a short circuit in the DC buses If DC fuses are not used short circuit in the DC buses will cause a Loading of the Active Front End unit Vacon Plc will not assume any responsibility for damages caused by insufficient protection 4 11 2 FUSES MAINS VOLTAGE 380 500 V 4 11 2 1 AC fuses Table 10 Ferraz Shawmut AC fuse selection mains voltage 380 500 Vac Module AC fuses Ferraz Shawmut type aR 04805 WHUDENBEUN 690 80 3 Paos Fns T0 3 NOTE Fuses for FI9 and FI10 are blade type and for F113 flush end type If some other type is needed please contact Vacon ERES ee eee Table 11 Bussman AC fuse selection mains voltage 380 500 Vac Module fuses Bussman type aR NXA NXA 04605 5 FO 170M6277 1250 1000 3 1005 10 SSHT 38 NOTE All fuses are blade type If some other type is needed please contact Vacon mel mum perna WRIT SHT 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 36 ACTIVE FRONT END 4 11 2 2 DC fuses Table 12 Ferraz Shawmut DC fuse selection mains voltage 465 800 Vdc Module DC fuses Ferraz Shawmut type aR 04805 PCHNUDSSVHICTF 3 NXiINUS Pns PCRADDTICHCT
77. tablished using optical cable Figure 13 The standard cable length of the optical cable is 1 5 m For optional the optical cables can get different lengths The maximum length of the optical cable is 10 m The adapter board is located back side of the control unit see Figure 14 ASIC board terminals located in the unit under the black cover Figure 15 To open black cover two screws at left and right side should be opened ASIC board X26 immi VH WH WLX3 X4 X5 11252 jpg Figure 13 Optical cable adapter board 4 eus r7 rx ien Figure 14 Optical cable adapter board E 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 28 ACTIVE FRONT END 11180 29 Figure 15 Optical cable terminals in the unit FI13 example Optical terminals on adapter board Gate control enable H7 OH VaconBus data from ASIC to control board Other terminals on adapter board Control board connection Supply voltage 24 customer e Max current 1A Terminal 1 e Terminal 2 NOTE The minimum fibre cable bending radius is 50 mm NOTE Terminals X2 and X3 can be in use simultaneously However if the 24 V supply from the control 1 0 terminals e g from board is used this terminal must be protected with a diode 4 7 2 LCL WIRING DIAGRAM The LCL filter contains a choke on the mains side capacitors and a ch
78. tween the AC input and intermediate DC circuit The Vacon NX Active Front End has a two way function This means that when power Is transferred from the AC input to the intermediate DC circuit the Vacon NX Active Front End rectifies the alternating current and voltage When power Is transferred from the intermediate DC circuit to the AC input the Vacon NX Active Front End inverts the direct current and voltage The difference between Vacon NX Active Front End and other Front Ends is that the unit creates low current distortion THDI In a typical Vacon NX Active Front End configuration the desired number of Inverters Figure 7 are connected to the intermediate DC circuit The Active Front End configuration consists of the unit itself LCL filter pre charging circuit control unit AC fuses main contactor circuit breaker and DC fuses Figure 8 Common DC bus 11168 emf Figure 7 Typical Active Front End configuration 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 20 ACTIVE FRONT END Main Circuit 16 L1 L2 2 30 L3 f PE PEQ NENE HH 4 esa 1 2 3 13 15 Q2 214 6 4 5 6 LCL U1 1 05 2 22 1 2 3 AFE U1 NXA xxxxx AP R R OF Double Insulated gt DC 11169 emf Figure 8 Vacon Active Front End Single Unit connections Tel 358 0 201 2121 Fax 358 0 201 212 205 ACTI
79. uct Product name Vacon NX Common DC bus Products Model designation Vacon 0004 5 to 2700 5 Vacon NXA 0004 6 to 2250 6 has been designed and manufactured in accordance with the following standards Safety EN 60204 1 2009 as relevant EN 61800 5 1 2007 Low Voltage Directive 2006 95 EC EMC Factory delivered Vacon NX inverter modules comply with the requirements of category 4 equipment according to EN 61800 3 2004 EMC Directive 2004 108 EC It is ensured through internal measures and quality control that the product conforms at all times to the requirements of the current Directive and the relevant standards In Vaasa 25 of September 2009 WY Vesa Laisi President The year the CE marking was affixed 2005 11240 pdf Tel 358 0 201 2121 Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 9 3 RECEIPT OF DELIVERY Vacon NX Active Front End has undergone scrupulous tests and quality checks at the factory before they are delivered to the customer However after unpacking the product check that no signs of transportation damage are to be found on the product and that the delivery is complete compare the type designation of the product to the codes below See Figure 1 Figure 2 Table 2 Should the product have been damaged during the shipping please contact primarily the cargo Insurance company or the carrier If the delivery does not correspond to your order contact the supplier immediately
80. up when the drive is running modulating Lights up when unsafe operating conditions were encountered due to which the um drive was stopped Fault Trip Simultaneously the drive status indicator FAULT blinks on the display and the fault description can be seen Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL KEYPAD VACON 73 6 1 3 TEXT LINES The three text lines e ee eee provide the users with information on their present location in the keypad menu structure as well as with Information related to the operation of the drive Location indicator displays the symbol and number of the menu parameter etc e Example M2 Menu 2 Parameters P2 1 3 Acceleration time ee Description line Displays the description of the menu value or fault eee Value line Displays the numerical and textual values of references parameters etc and the number of submenus available in each menu 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 74 CONTROL KEYPAD 6 2 KEYPAD PUSH BUTTONS The Vacon NX alphanumeric control keypad has 9 push buttons that are used for controlling Vacon NX Active Front End setting parameters and monitoring values 11208 emf Figure 53 Keypad push buttons 6 2 1 BUTTONS DESCRIPTIONS enter lt 106 This button is used to reset active faults See Chapter 6 3 4 This button is used to switch between the two latest display
81. will find the required dimensions for free space in the Table 21 You will find the required cooling air minimum air holes and heat dissipation in the Table 22 When planning the cooling for the space take into consideration that the Active Front End unit heat loss is approx 2 of the nominal capacity Air flow see Figure 34 and Figure 35 Table 21 Mounting space dimensions Dimensions mm NXA0261 5 NXA0170 6 NXA0460 5 NXA0325 6 free space above the unit B distance between inverter and cabinet wall distance between two units free space underneath of the units 24 hour support 358 01201 212 575 Email vacon avacon com VACON 54 INSTALLATION 11215 Figure 33 Installation space for FI9 FI 10 and FI 13 Tel 358 0 201 2121 Fax 358 0 201 212 205 INSTALLATION VACON 55 11218 jpg Figure 34 Cooling airflow for FI9 and FI10 units 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 56 INSTALLATION BS i EN S 11219 jpg Figure 35 Cooling airflow for the FI 13 unit Table 22 Power losses and required cooling air for the Active Front End units 2252 Minimum air holes Heat dissipation Cooling air required TT m3 h switchgear input and output mm NXA_0261 5 3540 1150 50000 NXA_0170 6 3320 NXA_0460 5 6160 1400 60000 NXA_0325 6 6070 13005 17920 4200 180000
82. y The value editing procedure Is presented in Figure 56 Pressing Menu button right once takes you to the Parameter Group Menu Locate the desired parameter group by using the Browser buttons and press Menu button right again to see the group and it s parameters Use the Browser buttons to find the parameter you want to edit Pressing Menu button right takes you to the edit mode As a sign of this the parameter value starts to blink You can now change the value in two different ways 24 hour support 358 0 201 212 575 Email vacon avacon com VACON 78 CONTROL KEYPAD e Set the desired value with the Browser buttons and confirm the change with the Enter button Consequently the blinking stops and the new value are visible in the value field e Press Menu button right once more Now you will be able to edit the value digit by digit This may come in handy when a relatively greater or smaller value than that on the display Is desired Confirm the change with the Enter button The value will not change unless the Enter button 15 pressed Pressing Menu button left takes you back to the previous menu Several parameters are locked i e cannot be edited when Vacon NX Active Front End is in RUN status If you try to change the value of such a parameter the text Z ocked will appear on the display The Active Front End must be stopped to edit these parameters The parameter values can also be locked using the function

vacon nx active front end unit (afe) user manual

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