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VFD-NXL
User Manual
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Carel VFD-NXL User Manual

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Integrated Control Solutions & Energy Savings
VFD - NXL
NXL family
User manual
3
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About the CAREL VFD-NXL family user’s manual
Congratulations for choosing the Smooth Control provided by CAREL VFD­NXL Family frequency converters! The User’s Manual will provide you with the necessary information about the installation, commissioning and operation of CAREL VFD-NXL Frequency Converter. We recommend that you carefully study these instructions before powering up the frequency converter for the fi rst time.
At least the 10 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.
Start-up Quick Guide
1. Check that the delivery corresponds to your order, see Chapter 2 “Receipt
of delivery“ page 9.
2. Before taking any commissioning actions read carefully the safety
instructions in Chapter 1 “Safety“ page 7.
3. Before the mechanical installation, check the minimum clearances around
the unit and check the ambient conditions in Chapter 4 “Installation“ page 13.
4. Check the size of the motor cable, mains cable, mains fuses and check the
cable connections, read Chapter 5 “Cabling and connection“ page 16.
5. Follow the installation instructions, see Chapter 4 “Installation“ page 13.
6. Control cable sizes and the grounding system are explained in paragraph
“Cabling“ page 16.
7. Instructions on using the keypad are given in Chapter 6 “Control keypad“
page 25.
8. All parameters have factory default values. In order to ensure proper
operation, check the rating plate data for the values below and the corresponding parameters of parameter group P2.1. See paragraph “Monitoring values (Control keypad: menu M1)“ page 38:
• nominal voltage of the motor, parameter 2.1.6;
• nominal frequency of the motor, parameter 2.1.7;
• nominal speed of the motor, parameter 2.1.8;
• nominal current of the motor, parameter 2.1.9;
• motor power factor, cos, parameter 2.1.10;
• All parameters are explained in the Manual cod. +030220726 (to be
downloaded from website www.carel.com)
9. Follow the commissioning instructions, see Chapter 7 “Commissioning“
page 37.
10. The CAREL VFD-NXL Frequency Converter is now ready for use.
11. In the end of this manual, you will fi nd a quick help with the default
I/O, control panel menus, monitoring values, fault codes and basic parameters.
CAREL Spa is not responsible for the use of the
frequency converters against the instructions.
Information for users on the correct handling of
waste electrical and electronic equipment (WEEE)
In reference to European Community directive 2002/96/EC issued on 27 January 2003 and the related national legislation, please note that:
1. WEEE cannot be disposed of as municipal waste and such waste
must be collected and disposed of separately;
2. the public or private waste collection systems defi ned by local
legislation must be used. In addition, the equipment can be returned to the distributor at the end of its working life when buying new equipment;
3. the equipment may contain hazardous substances: the improper use
or incorrect disposal of such may have negative eff ects on human health and on the environment;
4. the symbol (crossed-out wheeled bin) shown on the product or
on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 13 August 2005 and that it must be disposed of separately;
5. in the event of illegal disposal of electrical and electronic waste, the
penalties are specifi ed by local waste disposal legislation.
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Indice
1. SAFETY 7
1.1 Warnings ....................................................................................................................7
1.2 Safety instructions ...............................................................................................7
1.3 Earthing and earth fault protection ..........................................................7
1.4 Running the motor .............................................................................................7
1.5 EU Directive .............................................................................................................7
1.6 EMC Directive .........................................................................................................7
2. RECEIPT OF DELIVERY 9
2.1 Codes ...........................................................................................................................9
2.2 Storage ........................................................................................................................9
2.3 Maintenance ...........................................................................................................9
3. TECHNICAL DATA 10
3.1 Introduction..........................................................................................................10
3.2 Power ratings .......................................................................................................11
3.3 Technical data ......................................................................................................12
4. INSTALLATION 13
4.1. Mounting ..............................................................................................................13
4.2 Dimensions ...........................................................................................................13
4.3 Cooling ....................................................................................................................15
4.4 Changing EMC protection class from H to T ...................................15
5. CABLING AND CONNECTIONS 16
5.1 Power connections ..........................................................................................16
5.2 Control unit ...........................................................................................................22
6. CONTROL KEYPAD 25
6.1 Indications on the keypad display ..........................................................25
6.2 Keypad push-buttons .....................................................................................25
6.3 Start-up wizard ...................................................................................................26
6.4 Navigation on the control keypad .........................................................26
7. COMMISSIONING 37
7.1 Safety ........................................................................................................................37
7.2 Commissioning of the frequency converter ....................................37
7.3 Basic parameters ................................................................................................37
8. FAULT TRACING 39
9. DESCRIPTION OF EXPANDER BOARD OPTAA 40
10. DESCRIPTION OF EXPANDER BOARD OPTAI 41
11. FLANGE MOUNTING KIT FOR NXS/P FREQUENCY CONVERTERS FR4FR6 42
11.1 General ..................................................................................................................42
11.2 CAREL fl ange mounting kit contents ................................................42
11.3 Installation ..........................................................................................................43
11.4 Information Sticker ........................................................................................44
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1. SAFETY
ONLY A COMPETENT ELECTRICIAN MAY CARRY OUT THE ELECTRICAL INSTALLATION
1.1 Warnings
1
The components of the power unit of the frequency converter are live when CAREL VFD-NXL is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury. The control unit is isolated from the mains potential.
2
The motor terminals U, V, W (T1, T2, T3) and the DC-link/brake resistor terminals ¬–/+ (in CAREL VFD-NXL ≥1.1 kW) are live when CAREL VFD-NXL is connected to mains, even if the motor is not running.
3
The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when CAREL VFD-NXL is disconnected from mains.
4
The earth leakage current of NXL exceeds 3.5 mA a.c. According to EN61800-5-1, a reinforced protective ground connection must be ensured. See paragraph 1.3 “Earthing and earth fault protection“ page 7
5
If the frequency converter is used as a part of a machine, the machine manufacturer is responsible for providing the machine with a main switch (EN 60204-1).
6 Only spare parts delivered by CAREL can be used.
7
The heat sink of types MF2 and MF3 may be hot when the frequency converter is in use. Coming into contact with the heat sink may cause burns.
1.2 Safety instructions
1
The CAREL VFD-NXL frequency converter is meant for fi xed installations only.
2
Do not perform any measurements when the frequency converter is connected to the mains.
3
After disconnecting the frequency converter from the mains, wait until the fan stops and the indicators on the display go out. Wait 5 more minutes before doing any work on CAREL VFD-NXL connections.
4
Do not perform any voltage withstand tests on any part of CAREL VFD-NXL . There is a certain procedure according to which the tests shall be performed. Ignoring this procedure may result in damaged product.
5
Prior to measurements on the motor or the motor cable, disconnect the motor cable from the frequency converter.
6
Do not touch the IC-circuits on the circuit boards. Static voltage discharge may damage the components.
1.3 Earthing and earth fault protection
The CAREL VFD-NXL frequency converter must always be earthed with an earthing conductor connected to the earthing terminal . The earth leakage current of NX_ exceeds 3.5 mA AC. According to EN61800-5-1, one or more of the following conditions for the associated protective circuit shall be satisfi ed:
a. The protective conductor shall have a cross-sectional area of at least
10 mm2 Cu or 16 mm2 Al, through its total run.
b. Where the protective conductor has a cross-sectional area of less
than 10 mm2 Cu or 16 mm2 Al, a second protective conductor of at least the same cross-sectional area shall be provided up to a point where the protective conductor has a cross-sectional area not less than 10 mm2 Cu or 16 mm2 Al.
c. Automatic disconnection of the supply in case of loss of continuity of
the protective conductor. See chapter 6 “Control keypad“ page 25.
The cross-sectional area of every protective earthing conductor which does not form part of the supply cable or cable enclosure shall, in any case, be not less than:
• 2,5 mm
2
if mechanical protection is provided or
• 4 mm
2
if mechanical protection is not provided. The earth fault protection inside the frequency converter protects only the converter itself against earth faults in the motor or the motor cable. It is not intended for personal safety.
Due to the high capacitive currents present in the frequency converter, fault current protective switches may not function properly.
1.4 Running the motor
Warning symbols: for your own safety, please pay special attention to the instructions marked with the following symbols:
= Dangerous voltage
= General warning
= Hot surface – Risk of burn
Motor run check list
1
Before starting the motor, check that the motor is mounted properly and ensure that the machine connected to the motor allows the motor to be started.
2
Set the maximum motor speed (frequency) according to the motor and the machine connected to it.
3
Before reversing the motor shaft rotation direction make sure that this can be done safely.
4
Make sure that no power correction capacitors are connected to the motor cable.
5
Make sure that the motor terminals are not connected to mains potential.
1.5 EU Directive
CE Marking
The CE marking on the product guarantees the free movement of the product within the EEA (European Economic Area). It also guarantees that the product meets the various requirements placed upon it (such as the EMC Directive and possibly other directives according to the so­called new procedure). CAREL VFD-NXL frequency converters carry the CE label as a proof of compliance with the Low Voltage Directive (LVD) and the Electro Magnetic Compatibility (EMC).
1.6 EMC Directive
General
The EMC Directive provides that the electrical apparatus must not excessively disturb the environment they are used in, and, on the other hand, it shall have an adequate level of immunity toward other disturbances from the same environment.
Technical criteria
EMC compliance is a major consideration for CAREL VFD-NXL drives from the outset of the design. CAREL VFD-NXL frequency converters are marketed throughout the world, a fact which makes the EMC requirements of customers diff erent. All CAREL VFD-NXL frequency converters are designed to fulfi l even the strictest immunity requirements.
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Environments de ned in the product standard EN 61800-3 (2004)
First environment: environment that includes domestic premises, it also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes. Note: houses, apartments, commercial premises or offi ces in a residential building are examples of fi rst environment locations.
Second environment: environment that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for domestic purposes. Note: industrial areas, technical areas of any building fed from a dedicated transformer are examples of second environment locations.
Frequency converter EMC classi cation
NX frequency converters are divided into fi ve classes according to the level of electromagnetic disturbances emitted, the requirements of the power system network and the installation environment. The EMC class of each product is defi ned in the type designation code. Later in this manual the division is made according to the mechanical sizes (MF2, MF3, etc.). The technical data of the diff erent sizes can be found in paragraph 4.3 “Cooling“ page 15.
EMC Class C (MF4 to MF6):
Frequency converters of this class comply with the category C1 requirements of the product family standard EN 61800-3 (2004). The category C1 ensures the best EMC characteristics and it includes converters with rated voltage less than 1000V and intended for use in the fi rst environment.
Class H:
NXL frames MF4 – MF6 are delivered from the factory as class H products with an internal RFI fi lter. The fi lter is available as option for classes MF2 and MF3. With a RFI fi lter NXL frequency converters comply with the category C2 requirements of the product family standard EN 61800-3 (2004). The category C2 includes converters which are in fi xed installations and the rated voltage of which is less than 1000V. The class H frequency converters can be used both in 1st and 2nd environment. Note: if class H converters will be used in the fi rst environment they shall be installed and commissioned only by a professional.
Class T:
Frequency converters of this class fulfi l the product family standard EN 61800-3 (2004) if intended to be used in IT systems. In IT systems, networks are isolated from earth, or connected to earth through high impedance to achieve a low leakage current. Note: if converters are used with other supplies, no EMC requirements are complied with.
Class N:
The drives of this class do not have EMC emission protection and are mounted in enclosures. NXL frames MF2 and MF3 are delivered from the factory without an external RFI fi lter as class N products.
All NX frequency converters fulfi l all EMC immunity requirements of the product family standard EN 61800-3 (2004).
Warning: In a domestic environment this product may cause
radio interference in which case the user may be required to take
adequate measures
Manufacturer’s declaration of conformity
The following page presents the photocopy of the Manufacturer’s Declaration of Conformity assuring the compliance of frequency converters with the EMC-directives.
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2. RECEIPT OF DELIVERY
CAREL VFD-NXL frequency converters have 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 transport damages are to be found on the product and that the delivery is complete (compare the type designation of the product to the code below). Should the drive 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.
2.1 Codes
NXL00
** * * *
EMC emission level N = EMC-level N H = EMC-level H
IP: 1 = IP 20 2 = IP 21 5 = IP 54 + Key Board
Voltage range 2 = line 208-240 V 5 = line 380-500 V
Nominal current xy = nominal current xy Amp.
Fig. 2.a
2.2 Storage
If the frequency converter is to be kept in store before use make sure that the ambient conditions are acceptable:
Storing temperature: –40…+70 °C Relative humidity: <95%, no condensation
2.3 Maintenance
In normal conditions, CAREL VFD-NXL frequency converters are maintenance-free. However, we recommend to clean the heatsink (using e.g. a small brush) whenever necessary. Most CAREL VFD-NXL drives are equipped with a cooling fan, which can easily be changed if necessary.
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3. TECHNICAL DATA
3.1 Introduction
CAREL VFD-NXL is a compact frequency converter with the output ranging from 250 W to 30 kW.
In CAREL VFD-NXL frequency converter the internal microprocessor controls the motor basing on the information it receives through measurements, parameter settings, control I/O and control keypad. The IGBT Inverter Bridge produces a symmetrical, 3-phase PWM-modulated AC-voltage to the motor.
The control keypad constitutes a link between the user and the frequency converter. The control keypad is used for parameter setting, reading status
data and giving control commands. Instead of the control keypad, also a PC can be used to control the frequency converter if connected through a cable and a serial interface adapter (optional equipment).
You can have your CAREL VFD-NXL drive equipped with control I/O boards OPT-AA, OPT-AI, OPT-B_ or OPT-C_.
All other sizes but MF2 have an internal brake chopper. The input EMC fi lters are available as options externally for MF2 and MF3. In other sizes the fi lters are internal and included as standard.
=
=
L1 L2 L3
U V W
3~
3~
nxlk57
Mains
Motor
Brake Chopper*
Measure­ments
Gate Drivers
Motor Control μP
Motor and Application Control
Control Keypad
Fan
Current Sensors***
Rectifier
IGBT Inverter
Brake resistor*
Power Supply
Control I/O
1)
2)
3)
Integrated input module**
*Brake chopper belongs to the standard equipment in classes MF3 to MF6, brake resistor is available as option **Classes MF4 and bigger have an integrated input module ***This measuring method only in classes MF5 and bigger
Control module
Power module
Cha rg.res.
Op tio n boar d
Fig. 3.a
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3.2 Power ratings
CAREL VFD-NXL – Mains voltage 208 – 240 V
Mains voltage 208-240 V, 50/60 Hz, 1~/3~ Series NXL
Frequency converter type
Loadability Motor shaft power
Nominal input
current 1~/3~
Mechanical size
Enclosure and
protection class
Dimensions
WxHxD
Weight
(kg)
Low High Low High
Rated continuous
current IL (A)
10% overload
current (A)
Rated continuous
current IH (A)
50% overload
current (A)
40 °C
P(kW)
50 °C
P(kW)
EMC-levelN
NXL 0002 2* 2.4 2.6 1.7 2.6 0.37 0.25 4.8/-- MF2/IP20 60x130x150 1.0 NXL 0003 2* 3.7 4.1 2.8 4.2 0.75 0.55 7.4/5.6 MF3/IP20 84x220x172 2.0 NXL 0004 2* 4.8 5.3 3.7 5.6 1.1 0.75 9.6/7.2 MF3/IP20 84x220x172 2.0 NXL 0006 2* 6.6 7.3 4.8 7.2 1. 1.1 13.2/9.9 MF3/IP20 84x220x172 2.0
Tab. 3.a
Nota: NXL 0002 2 is suitable for single phase supply only
CAREL VFD-NXL - Mains voltage 380 – 500 V
Mains voltage 380-500 V, 50/60 Hz, 3~ Series NXL
Frequency converter type
Loadability Motor shaft power
Nom. input
current
Mechanical
size Enclosure
and protection
class
Dimensions
WxHxD
Weight
(kg)
Low High 380 V supply 500 V supply
Rated
continuous
current IL (A)
10%
overload
current (A)
Rated
continuous
current IH (A)
50%
overload
current (A)
10%
overload
40 °C P(kW)
50%
overload
50 °C P(kW)
10%
overload
40 °C P(kW)
50%
overload
50 °C P(kW)
EMC-level N
NXL 0001 5* 1.9 2.1 1.3 2 0.55 0.37 0.75 0.55 2.9 MF2/IP20 60x130x150 1.0 NXL 0002 5* 2.4 2.6 1.9 2.9 0.75 0.55 1.1 0.75 3.6 MF2/IP20 60x130x150 1.0 NXL 0003 5* 3.3 3.6 2.4 3.6 1.1 0.75 1.5 1.1 5.0 MF3/IP20 84x220x172 2.0 NXL 0004 5* 4.3 4.7 3.3 5 1.5 1.1 2.2 1.5 6.5 MF3/IP20 84x220x172 2.0 NXL 0005 5* 5.4 5.9 4.3 6.5 2.2 1.5 3 2.2 8.1 MF3/IP20 84x220x172 2.0
EMC-level H/C
NXL 0007 5* 7.6 8.4 5.6 8.4 3 2.2 4 3 7.6 MF4/IP21,IP54 128x292x190 5 NXL 0009 5* 9 9.9 7.6 11.4 4 3 5.5 4 9 MF4/IP21,IP54 128x292x190 5 NXL 0012 5* 12 13.2 9 13.5 5.5 4 7.5 5.5 12 MF4/IP21,IP54 128x292x190 5 NXL 0016 5* 16 17.6 12 18 7.5 5.5 11 7.5 16 MF5/IP21,IP54 144x391x214 8.1 NXL 0023 5* 23 25.3 16 24 11 7.5 15 11 23 MF5/IP21,IP54 144x391x214 8.1 NXL 0031 5* 31 34 23 35 15 11 18.5 15 31 MF5/IP21,IP54 144x391x214 8.1 NXL 0038 5* 38 42 31 47 18.5 15 22 18.5 38 MF6/IP21, IP54 195x519x237 18..5 NXL 0046 5* 46 51 38 57 22 18.5 30 22 46 MF6/IP21, IP54 195x519x237 18.5 NXL 0061 5* 61 67 46 69 30 22 37 30 61 MF6/IP21, IP54 195x519x237 18.5
Tab. 3.b
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3.3 Technical data
Mains connection
Input voltage Uin
380 - 500V, -15%...+10% 3~ 208…240V, -15%...+10% 3~
208…240V, -15%...+10% 1~ Input frequency 45…66 Hz Connection to mains Once per minute or less (normal case)
Motor connection
Output voltage 0 - Uin
Continuous output current
IH: Ambient temperature max. +50 °C, overload 1.5 x IH (1min/10min)
IL: Ambient temperature max. +40 °C, overload 1.1 x IL (1min/10min) Starting torque 150% (Low overload); 200% (High overload) Starting current 2 x IH 2 s every 20 s, if output frequency <30Hz and temperature of heatsink <+60 °C Output frequency 0…320 Hz Frequency resolution 0,01 Hz
Control characteristrics
Control method
Frequency Control V/f
Open Loop Sensorless Vector Control Switching frequency (See parameter 2.6.8) 1...16 kHz; Factory default 6 kHz Frequency reference Analogue input Keypad reference
Resolution 0.1% (10 bit), accuracy ±1%
Resolution 0.01 Hz Field weakening point 30…320 Hz Acceleration time 0.1…3000 sec Deceleration time 0.1…3000 sec Braking torque DC-brake: 30%*TN (without brake option)
Ambient conditions
Ambient operating temperature
–10°C (no frost)…+50 °C: IH
–10 °C (no frost)…+40 °C: IL Storage temperature –40 °C…+70 °C Relative humidity 0…95% rH, non-condensing, non-corrosive, no dripping water Air quality:
- chemical vapours
- mechanical particles
IEC 721-3-3, unit in operation, class 3C2
IEC 721-3-3, unit in operation, class 3S2
Altitude
100% load capacity (no derating) up to 1000 m
1-% derating for each 100 m above 1000 m.
Maximum altitudes:
NX_2: 3000 m
NX_5 (380...400 V): 3000 m
NX_5 (415...500 V): 2000 m
NX_6: 2000 m
Vibration: EN50178/EN60068-2-6
5...150 Hz
Displacement amplitude 1(peak) mm at 5...15.8 Hz
Max acceleration amplitude 1 G at 15.8...150 Hz
Shock EN50178, IEC 68-2-27
UPS Drop Test (for applicable UPS weights)
Storage and shipping: max 15 G, 11 ms (in package) Enclosure class IP20; MF2 and MF3. IP21/IP54; MF4 – MF6
EMC
Immunity Fulfi ls EN 61800-3 (2004), fi rst and second environment
Emissions
Depend on EMC class, see chapters 1.6.2 and 1.6.3
EN 61800-5-1 (2003); CE, cUL, C-TICK; (see unit nameplate for more detailed approvals)
Safety
Control connections
Analogue input voltage 0...+10 V, Ri = 200 kΩ, Resolution 10 bit, accuracy ±1% Analogue input current 0(4)…20 mA, Ri = 250 Ω diff erential Digital inputs 3 positive logic; 18…24 Vdc Auxiliary voltage +24 V, ±15%, max. 100 mA Output reference voltage +10 V, +3%, max. load 10 mA Analogue output 0(4)…20 mA; RL max. 500 Ω; resolution 16 bit; accuracy ±1%
Relay outputs
1 programmable change over relay output
Switching capacity: 24 Vdc/8 A, 250 Vac/8 A, 125 Vdc/0.4 A
Protections
Overvoltage protection NXL_2: 437 Vdc; NXL_5: 911 Vdc Undervoltage protection NXL_2: 183 Vdc; NXL_5: 333 Vdc Earth-fault protection In case of earth fault in motor or motor cable, only the frequency converter is protected Unit overtemperature protection Yes Motor overload protection Yes Motor stall protection Yes Motor underload protection Yes Short-circuit protection of +24 V and +10 V reference voltages
Yes
Overcurrent protection Trip limit 4,0*IH instantaneously
Tab. 3.c
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4. INSTALLATION
4.1. Mounting
MF2 and MF3
There are two possible positions in the wall mounting for the frames MF2 and MF3. The NXL type MF2 is mounted with two screws using the middle holes of the mounting plates. If an RFI fi lter is used, the upper mounting plate shall be attached with two screws. MF3 and bigger types are always mounted with four screws.
X
X
X
X
X
MF2 without a filter
MF2 with a filter
Fig. 4.a Fig. 4.b
4.2 Dimensions
W1
Ø
H2
H3
H8
H5
D1
D2
H1
H4
H6
H7
W2
nxlk7.fh8
Fig. 4.c
Type
Dimensions (mm)
W1 W2 H1 H2 H3 H4 H5 H6 H7 H8 D1 D2 Ø
MF2 30 60 172 152 140 130 80 42 11 6 150 144 6
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W2
W3
H5
Ø
D2
D1
H3
H4
H2
H1
H6
W1
H7
nxlk8.fh8
Fig. 4.d
Type
Dimensions (mm)
W1 W2 W3 H1 H2 H3 H4 H5 H6 H7 D1 D2 Ø
MF3 84 35 23 262 235 223 199 193 184 220 172 166 6
MF4 – MF6
The frequency converter shall be fi xed with four screws (or bolts, depending on the unit size). Enough space shall be reserved around the frequency converter in order to ensure a suffi cient cooling. Also see to that the mounting plane is relatively even.
W1
W2
H1 H2
Ø
D1
H3
fr5ip21.fh8
Ø
E1
Ø
E2
Ø*
Type
Dimensions
W1 W2 H1 H2 H3 D1 Ø E1Ø E2Ø*
MF4 128 100 327 313 292 190 7 3 x 28.3 MF5 144 100 419 406 391 214 7 2 x 37 1 x 28.3 MF6 195 148 558 541 519 237 9 3 x 37
Fig. 4.e
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4.3 Cooling
Forced air fl ow cooling is used for frames MF4, MF5, MF6 and higher powers of MF3. Enough free space shall be left above and below the frequency converter to ensure suffi cient air circulation and cooling. You will fi nd the required dimensions for free space in the table below.
C
A
NK5_2
D
B
A
B
Fig. 4.f
Type
Dimensions [mm]
ABCD
NXL 0002-0006 2* 10 10 100 50 NXL 0001-0005 5* 10 10 100 50 NXL 0007-0012 5* 20 20 100 50 NXL 0016-0032 5* 20 20 120 60 NXL 0038-0061 5* 30 20 160 80
Tab. 4.x
A. clearance around the freq. converter (see also B) B. distance from one frequency converter to another or distance to
cabinet wall
C. free space above the frequency converter D. free space underneath the frequency converter
Type Cooling air required (m3/h)
NXL 0003—0012 5* 70 NXL 0016—0031 5* 190 NXL 0038—0061 5* 425
4.4 Changing EMC protection class from H to T
The EMC protection class of CAREL VFD-NXL frequency converter types MF4 – MF6 can be changed from class H to class T with a simple procedure presented in the fi gure:
Remove
t
his screw
Fig. 4.g.a
Remove this screw
Fig. 4.g.b
Remove these screws
Fig. 4.g.c
Note: Do not attempt to change the EMC-level back to class H.
Even if the procedure above is reversed, the frequency converter
will no longer fulfi l the EMC requirements of class H!
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5. CABLING AND CONNECTIONS
5.1 Power connections
Fig. 5.a.a
Fig. 5.a.b
Fig. 5.a.c
Cabling
Use cables with heat resistance of at least +70 °C. The cables and the fuses must be dimensioned according to the tables below. Installation of cables according to UL regulations is presented in paragraph “Cable installation and the UL standards“ page 22. The fuses function also as cable overload protection. These instructions apply only to cases with one motor and one cable connection from the frequency converter to the motor. In any other case, ask the factory for more information.
1st environment
(restricted distribution)
2nd environment
Cable type Level H/C Level L Level T Level N
Mains cable 1 1 1 1 Motor cable 3* 2 1 1 Control cable 4 4 4 4
Tab. 5.a
Level C
EN 61800-3+A11, 1st environment, unrestricted distribution EN 61000-6-3
Level H
EN 61800-3+A11, 1st environment, restricted distribution EN 61000-6-4
Level L EN61800-3, 2nd environment
Level T:
see paragraph: “Environments defi ned in the product standard EN 61800-3 (2004)“ page 8
Level N:
see paragraph: “Environments defi ned in the product standard EN 61800-3 (2004)“ page 8 1 Power cable intended for fi xed installation and the specifi c mains
voltage. Shielded cable not required. (NKCABLES/MCMK or similar recommended)
2 Power cable equipped with concentric protection wire and
intended for the specifi c mains voltage. (NKCABLES /MCMK or similar recommended).
3 Power cable equipped with compact low-impedance shield and
intended for the specifi c mains voltage. (NKCABLES /MCCMK, SAB/ÖZCUY-J or similar recommended). *360º earthing of both motor and FC connection required to meet the standard
4
Screened cable equipped with compact low-impedance shield (NKCABLES /jamak, SAB/ÖZCuY-O or similar).
Types MF4 – MF6: a cable entry fl ange should be used when installing the motor cable at both ends in order to reach the EMC levels.
Note: The EMC requirements are fulfi lled at factory defaults of
switching frequencies (all frames).
Cable and fuse sizes
Frame Type IL [A] Fuse [A] Mains cable Cu (mm2)
Terminal cable size (min/max)
Main terminal (mm2) Earth terminal (mm2) Control terminal (mm2) Relay terminal (mm2)
MF2 0002 2 10 2*1.5+1.5 0.5-2.5 0.5-2.5 0.5-1.5 0.5-2.5 MF3 0003-0006 3-6 16 2*2.5+2.5 0.5-2.5 0.5-2.5 0.5-1.5 0.5-2.5
Tab. 5.b
Frame Type IL [A] Fuse [A] Mains cable Cu (mm2)
Terminal cable size (min/max)
Main terminal (mm2) Earth terminal (mm2) Control terminal (mm2) Relay terminal (mm2)
MF2 0001-0002 1-2 10 3*1.5+1.5 0.5-2.5 0.5-2.5 0.5-1.5 0.5-2.5 MF3 0003-0005 3-5 10 3*1.5+1.5 0.5-2.5 0.5-2.5 0.5-1.5 0.5-2.5 MF4 0007-0009 7-9 10 3*1.5+1.5 1-4 1-2.5 0.5-1.5 0.5-2.5 MF4 0012 12 16 3*2.5+2.5 1-4 1-2.5 0.5-1.5 0.5-2.5 MF5 0016 16 20 3*4+4 1-10 1-10 0.5-1.5 0.5-2.5 MF5 0023 22 25 3*6+6 1-10 1-10 0.5-1.5 0.5-2.5 MF5 0031 31 35 3*10+10 1-10 1-10 0.5-1.5 0.5-2.5 MF6 0038-45 38-45 50 3*10+10 2.5-50 Cu- 6-50 Al 6-35 0.5-1.5 0.5-2.5 MF6 0061 61 63 3*16+16 2.5-50 Cu- 6-50 Al 6-35 0.5-1.5 0.5-2.5
Tab. 5.c
Note: The earth leakage current of NXL exceeds 3.5mA a.c. According to EN61800-5-1, a reinforced protective ground connection must be ensured.
See paragraph 1.3 “Earthing and earth fault protection“ page 7.
17
ENG
Mounting of cable accessories
Enclosed to your CAREL VFD-NXL frequency converter you have received a plastic bag containing components that are needed for the installation of the mains and motor cables in the frequency converter.
1
2
6
3
4
5
7
8
Fig. 5.b
Components:
Ref.1 Grounding terminals (MF4, MF5) (pcs 2) Ref.2 Cable clamps (pcs 3) Ref.3 Rubber grommets (sizes vary from class to class) (pcs 3) Ref.4 Cable entry gland (pcs 1) Ref.5 Screws, M4x10 (pcs 5) Ref.6 Screws, M4x16 (pcs 3) Ref.7 Grounding cable clamps (MF6) (pcs 2) Ref.8 Grounding screws M5x16 (MF6) (pcs 4)
Note: The cable accessories installation kit for frequency
converters of protection class IP54 includes all components
except 4 and 5.
Mounting procedure
A. Make sure that the plastic bag you have received contains all
necessary components.
B. Open the cover of the frequency converter (Fig. 5.c.a). C. Remove the cable cover. Observe the places for
a. the grounding terminals (MF4/MF5) (Fig. 5.c.b). b. the grounding cable clamps (MF6) (Fig. 5.c.c).
D. Re-install the cable cover. Mount the cable clamps with the three
M4x16 screws as shown in Fig. 5.c.d. Note that the location of the grounding bar in FR6/MF6 is diff erent from what is shown in the picture.
E. Place the rubber grommets in the openings as shown in Fig. 5.c.e. F. Fix the cable entry gland to the frame of the frequency converter with
the fi ve M4x10 screws (Fig. 5.c.f). Close the cover of the frequency converter.
Fig. 5.c.a
Fig. 5.c.b
Fig. 5.c.c
Fig. 5.c.d
Fig. 5.c.e
Fig. 5.c.f
18
ENG
Installation instructions
1. Before starting the installation, check that none of the components
of the frequency converter is live.
2. The NXL frequency converter types MF2 and MF3 shall be installed
inside a switchgear, separate cubicle or electrical room because of the protection class IP20 and the fact that the cable terminals are not protected.
3. Place the motor cables suffi ciently far from other cables:
• Avoid placing the motor cables in long parallel lines with other
cables
• If the motor cables runs in parallel with other cables, note the
minimum distances between the motor cables and other cables given in table below.
• The given distances also apply between the motor cables and
signal cables of other systems.
• The maximum length of the motor cables is 30 m (MF2-MF3), 50 m
(MF4) and 300 m (MF5 – MF6).
• The motor cables should cross other cables at an angle of 90
degrees.
distance between cables (m) schielded cable (m)
0.3 ≤20
1.0 ≤50
4. If cable insulation checks are needed, see paragrapher “Cable and
motor insulation checks“ page 22.
5. Connect the cables:
• Strip the motor and mains cables as advised in table 5.d and fi gure
5.e.
6. Connect the mains, motor and control cables into their respective
terminals. For Information on cable installation according to UL regulations see paragrapher “Cable installation and the UL standards“ page 22.
• Make sure that the control cable wires do not come in contact
with the electronic components of the unit.
• If an external brake resistor (option) is used, connect its cable to
the appropriate terminal.
• Check the connection of the earth cable to the motor and the
frequency converter terminals marked with.
• Connect the separate shield of the motor cable to the earth plate
of the frequency converter, motor and the supply centre.
• Ensure that the control cables or the cables of the unit are not
trapped between the frame and the protection plate.
Stripping lengths of motor and mains cables
Fig. 5.d
Frame A1 B1 C1 D1 A2 B2 C2 D2
MF2 7 35 7 20 7 50 7 35 MF3 7 40 7 30 7 60 7 40 MF4 15 35 10 20 7 50 7 35 MF5 20 40 10 30 20 60 10 40 MF6 20 90 15 60 20 90 15 60
Tab. 5.d
Installation of cables to CAREL VFD-NXL
Note: In case you want to connect an external brake resistor (MF3
and bigger sizes), see separate Brake Resistor Manual.
Earth ter minal
Contro l cable
Motor cable
Mains cable
Fig. 5.e.a Fig. 5.e.b
19
ENG
Control cable
Motor cable
Mains cable
Earth te rminal
Brake resistor terminals
BR+
BR -
Fig. 5.f.a Fig. 5.f.b
Note: MF2-MF3: It is advisable to connect fi rst the cables to the
terminals and earthing plate, and then attach the terminals and
earthing plate to the unit.
Installation of an external RFI fi lter to MF2 and MF3
The EMC protection class of CAREL VFD-NXL frequency converters MF2 and MF3 can be changed from N to H with an optional external RFI fi lter. Install the power cables in terminals L1, L2 and L3 and the grounding cable in terminal PE of the fi lter. See the fi gures below. See also mounting instructions of MF2.
Note: Leagage current is more than 3.5mA a.c. Reinforced
protective ground connection must be ensured according to EN61800-5-1. See paragraph 1.3 “Earthing and earth fault protection“ page 7.
MF2
MF3
nxlk1.fh11
BR+
BR-
L1
U/T1
V/T2
W/T3
L2
L3
L1 L2 L3
PE
L1
U/T1
V/T2
W/T3
L2
L3
PE
RFI filter
Mains cable
Earthing cable
RFI filter cable
Ground
Additional earthing cable. See chapter 1.3
MF2
MF3
rfi2.fh11
NL
PE
L1
U/T1
V/T2
W/T3
L2
BR+
BR-
L1
U/T1
V/T2
W/T3
L2
L3
PE
RFI filter
Mains cable
Earthing cable
RFI filter cable
Ground
Additional earthing cable. See chapter 1.3
Fig. 5.g Fig. 5.h.a Fig. 5.h.b
RFI Filter type Dimensions (wxhxd - mm)
NXARF08500 (RFI-0008-5-1) (footprint type) 60x252x35 NXARF13200 (RFI-0013-2-1) (footprint type) 60x252x35
Tab. 5.e
20
ENG
Earth terminals
Mains cable
Motor cable
Brake resistor
ter minals
DC ter minals
Fig. 5.i.a Fig. 5.i.b
Note for MF4: Two protective conductors are required for MF4
according to EN61800-5-1. See paragraph 1.3 “Earthing and earth
fault protection“ page 7 and fi gure 6.r.
Fig. 5.j.a Fig. 5.j.b
21
ENG
Mains cable Motor cable
Earth terminals
Brake resistor
terminals
DC terminals
Fig. 5.k.a Fig. 5.k.b
Note for MF5: Reinforced protective ground connection must be
ensured according to standard EN61800-5-1. See paragraph 1.3 “Earthing and earth fault protection“ page 7.
Brake resistor
ter mi n a ls
Mains cable
Motor cable
Earth terminals
DC
ter mi n a ls
Fig. 5.l.a Fig. 5.l.b
Note for MF6: Reinforced protective ground connection must be
ensured according to standard EN61800-5-1. See paragraph 1.3 “Earthing and earth fault protection“ page 7.
22
ENG
Cable installation and the UL standards
To meet the UL (Underwriters Laboratories) regulations, a UL-approved copper cable with a minimum heat-resistance of +60/75°C must be used. The tightening torques of the terminals are given in the following table.
Frame Tightening torque (Nm) Tightening torque in-lbs.
MF2 0.5-0.6 4-5 MF3 0.5-0.6 4-5 MF4 0.5-0.6 4-5 MF5 1.2-1.5 10-13 MF6 4 35
Tab. 5.f
Cable and motor insulation checks
1. Motor cable insulation checks: Disconnect the motor cable from
terminals U, V and W of the frequency converter and from the motor. Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1MΩ.
2. Mains cable insulation checks: Disconnect the mains cable from
terminals L1, L2 and L3 of the frequency converter and from the mains. Measure the insulation resistance of the mains cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1MΩ.
3. Motor insulation checks: Disconnect the motor cable from the
motor and open the bridging connections in the motor connection box. Measure the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed 1000 V. The insulation resistance must be >1MΩ.
5.2 Control unit
MF2 – MF3
The control unit of the CAREL VFD-NXL frequency converter is integrated with the power unit and consists roughly of the control board and one optional board, which can be connected to the slot connector of the control board.
MF4 – MF6
In frames MF4-MF6 (NXL control hardware revisions JA, L or newer) there are two option board connectors SLOT D and SLOT E (see Figure 5.m). Software version NXL00005V250 or newer supports hardware with two board slots. Also older software versions can be used, but they will not support hardware with two board slots.
Sl ot D: F ieldbus boards
Sl ot E: I/O boa rds , fie ldbus boards and ex pander s
D
E
Fig. 5.m
Allowed option boards in MF4 – MF6:
See below for the allowed option boards in the two slots on NXL MF4 – MF6 frequency converters:
SLOT D C2 C3 C4 C6 C7 C8 CI CJ SLOT E AA AI B1 B2 B4 B5 B9 C2 C3 C4 C6 C7 C8 CI CJ
When two option boards are used, the one in slot E has to be OPT-AI or OPT-AA. It is not allowed to use two OPT-B_ or OPT-C_ boards. Also combinations of OPT-B_ and OPT-C_ –boards are prohibited. See descriptions for OPT-AA and OPT-AI option boards in chapters 9 and 10 page 40 and 41.
Control connections
The basic control connections are shown below. The signal descriptions are presented in paragraph “Control I/O“ page
23.
nxlk13.fh8
21 22 23
910111819A B
12345678
30
Fig. 5.n.a
nxlk49.fh8
30
910111819 A B
21 22 23
12345678
Fig. 5.n.b
23
ENG
Control I/O
Reference potentiometer 1 to 10 kΩ
Terminal Signal Description
1 +10 Vref Reference output Voltage for potentiometer, etc. 2 AI1+ Analogue input, voltage range 0 to 10 Vdc. Voltage input frequency reference 3 AI1- I/O Ground Ground for reference and controls 4 AI2+ Analogue input, current range 0 to 20 mA Current input frequency reference 5 AI2-/GND 6 +24V Control voltage output Voltage for switches, etc. max 0.1 A 7 GND I/O ground Ground for reference and controls 8 DIN1 Start forward (programmable) Contact closed = start forward 9 DIN2 Start reverse (programmable) Contact closed = start reverse 10 DIN3 Multi-step speed selection 1 (programmable) Contact closed = multi-step speed 11 GND I/O ground Ground for reference and controls 18 AO1+ Output frequency
Analogue output
Programmable Range 0 to 20 mA/RL, max. 500 Ω
19 AO1­A RS485 Serial bus Rx/Tx- Diff erential receiver/transmitter B RS485 Serial bus Rx/Tx+ Diff erential receiver/transmitter 30 +24 V 24 V aux. input voltage Control power supply backup 21 RO1 Relay output 1
FAULT
Programmable22 RO1
23 RO1
Tab. 5.f
Terminal Signal Description
1 +10Vref Reference output Voltage for potentiometer, etc.
2 AI1+ or DIN 4 Analogue input, voltage range 0 to 10 Vdc
Voltage input frequency reference (MF2-3) Voltage/current input frequency reference (MF4-
MF6). Can be programmed as DIN4. 3 AI1- I/O Ground Ground for reference and controls 4 AI2+ Analogue input, voltage range 0 to 10 Vdc
or current range 0 to 20 mA
Voltage or current input frequency reference 5 AI2-/GND
6 + 24 V Control voltage output 7 GND I/O ground Ground for reference and controls
Tab. 5.g
Control terminal signals
Terminal Signal Technical information
1 +10 Vref Reference voltage Maximum current 10 mA
2 AI1+
Analogue input, voltage (MF4 and bigger: voltage or current)
MF2-MF3: Voltage input MF4-MF6 Selection V or mA with jumper block X8 (see chapter 6.2.6):
Default: 0 to 10 V (Ri = 200 kΩ)
0 to 20 mA (Ri = 250 Ω)
3 AI1– Analogue input common
Diff erential input if not connected to ground; Allows ±20V diff erential mode voltage to GND
4 AI2+ Analogue input, voltage or current
Selection V or mA with jumper block X4(MF2-MF3) and X13 (MF4-MF6)
Default: 0 to 10 V (Ri = 200 kΩ)
0 to 20 mA (Ri = 250 Ω)
5 AI2– Analogue input common
Diff erential input;
Allows ±20 V diff erential mode voltage to GND 6 24 Vout 24 V auxiliary output voltage ±10%, maximum current 100 mA 7 GND I/O ground Ground for reference and controls 8 DIN1 Digital input 1 Ri = min. 5 kΩ 9 DIN2 Digital input 2 10 DIN3 Digital input 3 11 GND I/O ground Ground for reference and controls
18 AO1+ Analogue signal (+output)
Output signal range:
Current 0(4)–20mA, RL max 500Ω or 19 AO1–/GND Analogue output common A RS 485 Serial bus Rx/Tx- Diff erential receiver/transmitter, bus impedance 120 Ω B RS 485 Serial bus Rx/Tx+ Diff erential receiver/transmitter, bus impedance 120 Ω 30 +24V 24V auxiliary input voltage Control power supply backup 21 RO1/1 Relay output 1
Switching capacity: 24 Vdc/8 A
250 Vac/8 A 125 Vdc/0,4 A
Relay output terminals are galvanically isolated from the I/O ground
22 RO1/2
23 RO1/3
Tab. 5.h
mA
24
ENG
Jumper selections on CAREL VFD-NXL basic board
The user is able to customise the functions of the frequency converter to better suit his needs by selecting certain positions for the jumpers on the NXL board. The positions of the jumpers determine the signal type of analogue input (terminal #2) and whether the termination resistor RS485 is used or not. The following fi gures present the jumper selections of NXL frequency converters:
Jumper block X4 in MF3:
Vol tag e in put; 0 . ..1 0V
Termination resistor RS 4 8 5 is in use
0...20mA; Current input
Voltage input; 0...10V
= Factory default
0...20mA; Current input
Termination resistor RS 4 8 5 is not used
Jumper block X4 in MF2:
Jumper block X 7 in MF3:
Termination resistor RS 4 8 5 is in use
Termination resistor RS 4 85 is not used
Termination resistor
prog ramming
Analogue input
prog ra mming
Analogue input
prog ramming
Termination resistor
prog ramming
Fig. 5.o.a
Jumper block X9:
Voltage input; 0...10V
0...20mA; Current input
Jumper block X8:
AI1 mode
Termination resistor RS 4 85 is in use
Termination resistor RS 485 is not used
Jum pe r block X13:
AI2 mode
0...20mA; Current input
Volta ge input; 0...10V
Voltage input; 0 ...10 V
(differential)
Fig. 5.o.b
Warning: If using a serial connection to the pCO controller, the
jumper for selecting the terminal resistance must be left in the “RS 485 TERMINAL RESISTANCE NOT USED” position. Check the correct positions of the jumpers. Running the motor with signal settings diff erent from the jumper positions will not harm the frequency converter but may damage the motor.
Note: If you change the AI signal content also remember to change
the corresponding parameters (S6.9.1, 6.9.2) in System Menu.
Jumper blo ck X4
Jumper blo ck X4
Jumper block X7
Fig. 5.p
X8
X13
X9
Fig. 5.q
Motor thermistor (PTC) connection
There are three possibilities to connect a PTC resistor to CAREL VFD-NXL:
1. With optional board OPT-AI. (Recommended method)
CAREL VFD-NXL equipped with OPT-AI fulfi lls IEC 664 if the motor thermistor is insulated (= eff ective double insulation).
2. With optional board OPT-B2.
CAREL VFD-NXL equipped with OPT-B2 fulfi lls IEC 664 if the motor thermistor is insulated (= eff ective double insulation).
3. With the digital input (DIN3) of NXL.
The DIN3 is galvanically connected to other I/O’s of NXL. This is why reinforced or double insulation of the thermistor (IEC
664) is absolutely required outside the frequency converter (in the motor or between the motor and the frequency converter).
+24 V (terminal 6)
DIN3 (terminal 10, par.2.1.18 = 14)
nxlk60.fh8
External PTC Resistor
GND (terminal 11)
External resistor
4.7 k...5.6 k 
Fig. 5.r
Note: The NXL trips when PTC impedance exceeds 4,7 kΩ
Warning: It is strongly recommended to use OPT-AI or OPT-B2
board for motor thermistor connection. If the motor thermistor is connected to DIN3, the instructions above must be followed, otherwise a serious safety hazard may result from the connection.
25
ENG
6. CONTROL KEYPAD
The control keypad is the link between the CAREL frequency converter and the user. The CAREL VFD-NXL control keypad features a seven­segment display with seven indicators for the Run status (RUN,
, READY, STOP, ALARM, FAULT) and three indicators for the control place (I/O term, Keypad, Bus/Comm). The control information, i.e. the number of menu, the displayed value and the numeric information are presented with numeric symbols. The frequency converter is operable through the seven push-buttons of the control keypad. Furthermore, the keypad serves the purposes of parameter setting and value monitoring. The keypad is detachable and isolated from the input line potential.
6.1 Indications on the keypad display
Fig. 6.a
Drive status indications
The drive status indications tell the user what the status of the motor and the drive is.
Motor is running; Blinks when the stop command has been given but the frequency is still ramping down.
and
Indicate the direction of motor rotation. Indicates that the drive is not running. Lights when AC power is on. In case of a fault, the symbol will not
light up. 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 the drive was stopped.
Tab. 6.a
Control place indications
The symbols I/O term, Keypad and Bus/Comm indicate the choice of control place made in the Keypad control menu.
I/O terminals are the selected control place; i.e. START/STOP commands or reference values are given through the I/O terminals. Control keypad is the selected control place; i.e. the motor can be started or stopped and its reference values altered from the keypad. The frequency converter is controlled through a Fieldbus.
Tab. 6.b
Numeric indications
The numeric indications provide the user with information on his present location in the keypad menu structure as well as with information related to the operation of the drive.
6.2 Keypad push-buttons
The CAREL seven-segment control keypad features 7 push-buttons that are used for the control of the frequency converter (and motor) and parameter setting.
Fig. 6.b
Button descriptions
There are two operations integrated in this button. The button operates mainly as reset button except in the parameter edit mode. The button operation is shortly described below.
The Enter button serves for:
1) confi rmation of selections
2) fault history reset (2…3 seconds)
This button is used to reset active faults. Note! The motor may start immediately after resetting the faults.
Browser button up Browse the main menu and the pages of diff erent submenus. Edit values.
Browser button down Browse the main menu and the pages of diff erent submenus. Edit values.
Menu button left Move backward in menu. Move cursor left (in parameter edit mode). Exit edit mode. Hold down for 2…3 seconds to return to main menu. Menu button right Move forward in menu. Move cursor right (in parameter edit mode). Enter edit mode.
Start button. Pressing this button starts the motor if the keypad is the active control place. See paragraph “Selection of control place“ page 29.
Stop button. Pressing this button stops the motor (unless disabled by parameter P3.4). Stop button serves also for activating the Start-up Wizard (see below)
Tab. 6.c
26
ENG
6.3 Start-up wizard
CAREL VFD-NXL has a built-in start-up wizard, that speeds up the programming of the drive. The wizard helps you choose between four diff erent operating modes, Standard, Fan, Pump and High Performance. Each mode has automatic parameter settings optimised for the mode in question. The programming wizard is started by pressing the Stop button for 5 seconds, when the drive is in stop mode. See the fi gure below for the procedure:
Fig. 6.c
6.4 Navigation on the control keypad
The data on the control keypad are arranged in menus and submenus. The menus are used for example for the display and editing of measurement and control signals, parameter settings (paragraph 7.3 “Parameter menu (P2)“ page 28), reference values (paragraph “Keypad control menu (K3)“ page 29 and “Selection of control place“ page 29) and fault displays (chapter 8 page 39).
Fig. 6.d
The fi rst menu level consists of menus M1 to E7 and is called the Main menu. The user can navigate in the main menu using the Browser buttons up and down. The desired submenu can be entered from the main menu using the Menu buttons. When there still are pages to enter under the currently displayed menu or page, the last digit of the fi gure on the display is blinking and by pressing the Menu button right, you can reach the next menu level.
STOP
READY
I/O t erm
enter
enter
reset
enter
STOP
I/O te rm
READY
STOP I/O ter m
READY
STOP
I/O ter m
READY
STOP
I/O t erm
READY
STOP
I/O te rm
READY
STOP
I/O term
READY
STOP
I/O te rm
READY
STOP
I/O te rm
READY
STOP
I/O term
READY
STOP
I/O te rm
READY
STOP
I/O te rm
READY
STOP
I/O term
READY
STOP
I/O te rm
READY
STOP
I/O te rm
READY
I/O term
READY
STOP
I/O te rm
READY
STOP
I/O te rm
READY
STOP
I/O term
READY
STOP
I/O t erm
READY
Hz
STOP
No editing!
Change
value
Change
value
Browse
Browse
Browse
Press to reset
Fig. 6.e
The control keypad navigation chart is shown on Chapter 6 “Keypad control“ page 25. Please note that the 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. More detailed descriptions of the menus you will fi nd later in this Chapter.
Location
27
ENG
Menu functions:
Code Menu Min Max Selections
M1 Monitoring menu V1.1 V1.24 See chapter 7.4.1 for the monitoring
values
P2 Parameter menu P2.1 P2.10 P2.1 = Basic parameters
P2.2 = Input signals P2.3 = Output signals P2.4 = Drive control P2.5 = Prohibit frequencies P2.6 = Motor control P2.7 = Protections P2.8 = Autorestart P2.9 = PID control P2.10=Pump and fan control
K3 Keypad control
menu
P3.1 P3.6 P3.1 = Selection of control place
R3.2 = Keypad reference P3.3 = Keypad direction P3.4 = Stop button activation P3.5 = PID reference 1
P3.6 = PID reference 2 F4 Active faults menu Shows the active faults and their types H5 Fault history menu Shows the fault history list S6 System menu S6.3 S6.10 S6.3 = Copy parameters
S6.5 = Security
S6.6 = Keypad settings
S6.7 = Hardware settings
S6.8 = System info
S6.9 = AI mode
S6.10 = Fieldbus parameters
Parameters are described in chapter
7.4.12
E7 Expander board
menu
E7.1 E7.2 E7.1 = Slot D
E7.2 = Slot E
Tab. 6.d
Monitoring menù (M1)
You can enter the Monitoring menu from the Main menu by pushing the Menu button right when the location indication M1 is visible on the display. How to browse through the monitored values is presented down. The monitored signals carry the indication V#.# and they are listed in the table 6.e. The values are updated once every 0.3 seconds.
Fig. 6.f
This menu is meant only for value checking. The values cannot be altered here. For changing values of parameters see paragrafo “Monitoring value” page 38.
28
ENG
Code Signal name Unit ID Description
V1.1 Output frequency Hz 1 Frequency to the motor V1.2 Frequency reference Hz 25 V1.3 Motor speed rpm 2 Calculated motor speed V1.4 Motor current A 3 Measured motor current V1.5 Motor torque % 4 Calculated actual torque/nominal torque of the motor V1.6 Motor power % 5 Calculated actual power/nominal power of the motor V1.7 Motor voltage V 6 Calculated motor voltage V1.8 DC-link voltage V 7 Measured DC-link voltage V1.9 Unit temperature ºC 8 Heat sink temperature V1.10 Analogue input 1 13 AI1 V1.11 Analogue input 2 14 AI2 V1.12 Analogue output current mA 26 AO1 V1.13 Analogue output current 1, expander board mA 31 V1.14 Analogue output current 2, expander board mA 32 V1.15 DIN1, DIN2, DIN3 15 Digital input statuses V1.16 DIE1, DIE2, DIE3 33 I/O expander board: Digital input statuses V1.17 RO1 34 Relay output 1 status V1.18 ROE1, ROE2, ROE3 35 I/O exp. board: Relay output statuses V1.19 DOE 1 36 I/O exp. board: Digital output 1 status V1.20 PID Reference % 20 In percent of the maximum process reference V1.21 PID Actual value % 21 In percent of the maximum actual value V1.22 PID Error value % 22 In percent of the maximum error value V1.23 PID Output % 23 In percent of the maximum output value V1.24 Autochange outputs 1,2,3 30 Used only in pump and fan control V1.25 Mode 66 Shows the current drive confi guration mode selected with startup wizard:
0 = No mode selected (Default) 1 = Standard 2 = Fan 3 = Pump 4 = High performance
Tab. 6.e
Parameter menu (P2)
Parameters are the way of conveying the commands of the user to the frequency converter. The parameter values can be edited by entering the Parameter Menu from the Main Menu when the location indication P2 is visible on the display. The value editing procedure is presented in Fig. 6.g. Push the Menu button right once to move into the Parameter Group Menu (G#). Locate the parameter group desired by using the Browser buttons and push the Menu button right again to enter the group and its parameters. Use again the Browser buttons to fi nd the parameter (P#) you want to edit. Pushing the 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 diff erent manners:
1. Just set the new desired value with the Browser buttons and confi rm
the change with the Enter button. Consequently, the blinking stops and the new value is visible in the value fi eld.
2. Push the Menu button right once again. Now you will be able to
edit the value digit by digit. This editing manner may come in handy, when a relatively greater or smaller value than that on the display is desired. Confi rm the change with the Enter button.
The value will not change unless the Enter button is pushed. Pressing the Menu button left takes you back to the previous menu.
Several parameters are locked, i.e. not editable, when the drive is in RUN status. The frequency converter must be stopped in order to edit these parameters. The parameters values can also be locked using the function in menu S6 (see paragraph “Parameter lock“ page 32). You can return to the Main menu anytime by pressing the Menu button left for 1 to 2 seconds. The basic parameters are listed in paragraph 7.3 “Basic parameter“ page
37. You will fi nd the complete paremeter lists and descriptions in the +030220726 manual (that can be download from website www.carel. com). Once in the last parameter of a parameter group, you can move directly to the fi rst parameter of that group by pushing the Browser button up.
enter
STOP
I/ O term
READY
STOP
I/O term
READY
STOP I/ O te rm
READ Y
STOP
I/ O term
READY
STOP
I/ O term
READY
STOP
I/ O term
READY
STOP
I/O ter m
REA DY
nxl k17 . fh8
HzHz
Hz
Fig. 6.g
29
ENG
Keypad control menu (K3)
In the Keypad Controls Menu, you can choose the control place, edit the frequency reference and change the direction of the motor. Enter the submenu level with the Menu button right.
Parameters in Menu K3 Selections
P3.1 = Selection of control place
1 = I/O terminals 2 = Keypad 3 = Fieldbus
R3.2 = Keypad reference
P3.3 = Keypad direction
0 = Forward 1 = Reverse
P3.4 = Stop button activation
0 = Limited function of Stop button
1 = Stop button always enabled P3.5 = PID reference 1 P3.6 = PID reference 2
Tab. 6.f
Selection of control place
There are three diff erent places (sources) which the frequency converter can be controlled from. For each control place, a diff erent symbol will appear on the alphanumeric display:
Control place Symbol
I/O terminals I/O term Keypad (panel) Keypad Fieldbus Bus/Comm
Tab. 6.g
Change the control place by entering the edit mode with the Menu button right. The options can then be browsed through with the Browser buttons. Select the desired control place with the Enter button. See the paragraph “Keypad control menù (K3)“ page 29.
ente r
STOP I/O term
READY
STOP I/O term
READY
STOP I/O term
READY
STOP I/O term
READY
STOP I/ O t e r m
READY
Fig. 6.h
Note: With the I/O terminals or fi eldbus selected as the active
control place, it is also possible to change the control to the local keypad and back to the original control place by pressing for fi ve seconds.
Keypad reference
The keypad reference submenu (R3.2) displays and allows the operator to edit the frequency reference. The changes will take place immediately. This reference value will not, however, infl uence the rotation speed of the motor unless the keypad has been selected as the active control place. Note: The maximum diff erence between the output frequency and the keypad reference is 6 Hz. The software monitors the keypad frequency automatically. See Figure 6.g for how to edit the reference value (pressing the Enter button is not, however, necessary).
Keypad direction
The keypad direction submenu displays and allows the operator to change the rotating direction of the motor. This setting will not, however, infl uence the rotation direction of the motor unless the keypad has been selected as the active control place. See Fig. 6.h for how to change the rotation direction.
Stop button activation
By default, pushing the STOP button will always stop the motor regardless of the selected control place. You can disable this function by giving parameter 3.4 the value 0. If the value of this parameter is 0, the STOP button will stop the motor only when the keypad has been selected as the active control place. See Fig. 6.h for how to change the value of this parameter.
Active faults menu (F4)
The Active faults menu can be entered from the Main menu by pushing the Menu button right when the location indication F4 is visible on the keypad display. The memory of active faults can store the maximum of 5 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 before the fault trip. The fault remains active until it is cleared with the Reset button or with a reset signal from the I/O terminal.
Note: Remove external Start signal before resetting the fault to
prevent unintentional restart of the drive.
Normal state, no faults:
Fault types
In the NXL frequency converter, there are two diff erent types of faults. These types diff er from each other on the basis of the subsequent behaviour of the drive. See Table 6.h. Fault types.
OP I/O t
erm
STOP I/O t
erm
STOP I/O t
erm
nxlk19.fh8
Fig. 6.i
30
ENG
Fault type symbol Meaning
A (Alarm)
This type of fault is a sign of an unusual operating condition. It does not cause the drive to stop, nor does it require any special actions. The ‘A fault’ remains in the display for about 30 seconds.
F (Fault)
An ‘F fault’ is a kind of fault that makes the drive stop. Actions need to be taken in order to restart the drive.
Tab. 6.h
Fault code
Fault Possible cause Correcting measures
1 Overcurrent
Frequency converter has detected too high a current (>4*In) in the motor cable:
- sudden heavy load increase
- short circuit in motor cables
- unsuitable motor
Check loading. Check motor size. Check cables.
2 Overvoltage
The DC-link voltage has exceeded the limits defi ned in Table 4.c:
- too short a deceleration time
- high overvoltage spikes in supply
Make the deceleration time longer.
3 Earth fault
Current measurement has detected that the sum of motor phase current is not zero.
- insulation failure in cables or motor
Check motor cables and motor.
8 System fault
- component failure
- faulty operation
Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.
9 Undervoltage
DC-link voltage is under the voltage limits defi ned in Table 4-3.
- most probable cause: too low a supply voltage
- frequency converter internal fault
In case of temporary supply voltage break reset the fault and restart the frequency converter. Check the supply voltage. If it is adequate, an internal failure has occurred. Contact the distributor near to you.
11 Output phase supervision
Current measurement has detected that there is no current in one motor phase.
Check motor cable and motor.
13
Frequency converter undertemperature
Heatsink temperature is under –10 °C
14
Frequency converter overtemperature
Heatsink temperature is over 90 °C. Overtemperature warning is issued when the heatsink temperature exceeds 85 °C.
Check the correct amount and fl ow of cooling air. Check the heatsink for dust. Check the ambient temperature (p2.6.8). Make sure that the switching frequency is not too high in relation to ambient temperature and motor load.
15 Motor stalled Motor stall protection has tripped. Check motor.
16 Motor overtemperature
Motor overheating has been detected by frequency converter motor temperature model. Motor is overloaded.
Decrease the motor load. If no motor overload exists, check the temperature model parameters.
17 Motor underload Motor underload protection has tripped.
22 EEPROM checksum fault
Parameter save fault
- faulty operation
- component failure
Contact the distributor near to you
24 Counter fault Values displayed on counters are incorrect
25
Microprocessor watchdog fault
- faulty operation
- component failure
Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.
29 Thermistor fault
The thermistor input of option board has detected increase of the motor temperature
Check motor cooling and loading Check thermistor connection (If thermistor input of the option board is not in use it has to be short circuited)
34
Internal bus communication
Ambient interference or defective hardware
Reset the fault and restart Should the fault re-occur, contact the distributor near to you.
35 Application fault Selected application does not function. Contact the distributor near to you.
39 Device removed
Option board removed. Drive removed.
Reset
40 Device unknown Unknown option board or drive. Contact the distributor near to you.
41 IGBT temperature
IGBT Inverter Bridge overtemperature protection has detected too high a motor current.
Check loading. Check motor size.
44 Device change
Option board changed. Option board has default settings.
Reset
45 Device added Option board added. Reset
50
Analogue input Iin<4mA (selected signal range 4 to 20 mA)
Current at the analogue input is < 4mA.
- control cable is broken or loose
- signal source has failed
Check the current loop circuitry.
51 External fault
Digital input fault. Digital input has been programmed as external fault input and this input is active.
Check the programming and the device indicated by the external fault information. Check also the cabling of this device.
52
Keypad communication fault
The connection between the control keypad and the frequency converter is broken.
Check keypad connection and possible keypad cable.
53 Fieldbus fault
The data connection between the fi eldbus Master and the fi eldbus board is broken
Check installation. If installation is correct contact the nearest CAREL distributor
54 Slot fault Defective option board or slot Check board and slot.; Contact the nearest CAREL distributor
55 Actual value supervision
Actual value has exceeded or fallen below (depending on par. 2.7.22) the actual value supervision limit (par. 2.7.23)
Tab. 6.i
Fault codes
The fault codes, their causes and correcting actions are presented in the table below. The shadowed faults are A faults only. The items written in white on black background present faults for which you can program diff erent responses in the application. See parameter group Protections. Note! When you contact the factory or the distributor due to a fault, it is advisable to write down all fault texts and codes that appear on the keypad
31
ENG
Fault history menu (H5)
The Fault history menu can be entered from the Main menu by pushing the Menu button right when the location indication H5 is visible on the keypad display. All faults are stored in the Fault history menu in which you can browse through them using the Browser buttons. You can return to the previous menu anytime by pushing the Menu button left. The memory of the frequency converter can store a maximum of 5 faults in the order of appearance. The latest fault carries the indication H5.1, the second latest H5.2 etc. If there are 5 uncleared faults in the memory the next occurring fault will erase the oldest from the memory. Pressing the Enter button for about 2 to 3 seconds resets the whole fault history.
S T O P I / O
t e r m
R E A D Y
S T O P I / O
t e r m
R E A D Y
S T O P I / O
t e r m
R E A D Y
n x l k 2 0 . f h 8
P u s h
E n t e r
t o
r e s e t !
Fig. 6.j
System menu (S6)
The System menu can be entered from the main menu by pushing the Menu button right when the location indication S6 is visible on the display. The controls associated with the general use of the frequency converter, such as keypad settings, customised parameter sets or information about the hardware and software are located under the System menu. Below you will fi nd a list of the functions available in the System menu.
Functions in the System menu
Code Function Min Max Unit Default Cust Selections
S6.3 Copy parameters
P6.3.1 Parameter sets
0 = Select; 1 = Store set 1; 2 = Load set 1; 3 = Store set 2; 4 = Load set 2;
5 = Load factory defaults; 6 = Fault; 7 = Wait; 8 = OK S6.5 Security P6.5.2 Parameter lock 0 1 0 0 = Change Enabled; 1 = Change Disabled S6.6 Keypad settings P6.6.1 Default page 0 1.1 P6.6.3 Timeout time 5 65535 s 1200 S6.7 Hardware settings P6.7.2 Fan control 0 0 0 = Continuous; 1 = Temperature (only sizes MF4 and bigger) P6.7.3 HMI acknowledg. timeout 200 5000 ms 200 P6.7.4 HMI number of retries 1 10 5 S6.8 System info S6.8.1 Counters menu C6.8.1.1 Mwh counter KWh C6.8.1.2 Operating days counter hh:mm: ss C6.8.1.3 Operating hours counter hh:mm: ss S6.8.2 Trip counters T6.8.2.1 MWh trip counter kWh P6.8.2.2 Clear MWh trip counter 0 = No action 1 = Clear MWh trip counter T6.8.2.3 Operating days trip counter T6.8.2.4 Operating hours trip counter hh:mm: ss P6.8.2.5 Clear operating time counter 0 = No action; 1 = Clear T6.8.2.3, T6.8.2.4 S6.8.3 Software info I6.8.3.1 Software package Scroll information with menu button right I6.8.3.2 System SW version I6.8.3.3 Firmware interface I6.8.3.4 System load % S6.8.4 Application info S6.8.4.1 Application A6.8.4.1.1 Application id A6.8.4.1.2 Application version A6.8.4.1.3 Firmware interface S6.8.5 Hardware info I6.8.5.2 Unit voltage V I6.8.5.3 Brake chopper 0=Not present; 1=Present S6.8.6 Options S6.8.6.1 Slot E OPT- Note! the submenus are not showing if no option board is installed I6.8.6.1.1 Slot E Status 1 5 1=Connection lost; 2=Initializing; 3=Run; 5=Fault I6.8.6.1.2 Slot E Program version S6.8.6.2 Slot D OPT- Note! the submenus are not showing if no option board is installed I6.8.6.2.1 Slot D Status 1 5 1=Connection lost; 2=Initializing; 3=Run; 5=Fault I6.8.6.2.2 Slot D Program version S6.9 AI mode P6.9.1 AIA1 mode 0 1 0 0=Voltage input; 1=Current input (Types MF4 – MF6)
32
ENG
Code Function Min Max Unit Default Cust Selections
P6.9.2 AIA2 mode 0 1 1 0=Voltage input; 1=Current input S6.10 Fieldbus parameters I6.10.1 Communication status P6.10.2 Fieldbus protocol 1 1 1 0=Not used; 1=Modbus protocol P6.10.3 Slave address 1 255 1 Addresses 1 – 255
P6.10.4 Baud rate 0 8 5
0=300 baud; 1=600 baud; 2=1200 baud; 3=2400 baud; 4=4800 baud
5=9600 baud; 6=19200 baud; 7=38400 baud; 8=57600 baud P6.10.5 Stop bits 0 1 0 0=1; 1=2 P6.10.6 Parity type 0 2 0 0=None; 1=Odd; 2=Even P6.10.7 Communication timeout 0 300 s 0 0=Not used; 1=1 second; 2=2 seconds, etc
Tab. 6.j
Copy parameters
The Copy parameters submenu (S6.3) is located under the System menu. The CAREL NX frequency converter features a possibility for the user to store and load two customised parameter sets (all parameters included in the application, not the system menu parameters) and to load back the factory default parameter values.
Parameter sets (S6.3.1)
On Parameter sets page (S6.3.1), push the Menu button right to enter the Edit menu. You can store or load two customised parameter sets or load back the factory defaults. Confi rm with the Enter button. Wait, until 8 (=OK) appears on the display.
enter
STOP
I/O te rm
READY
STOP
I/O te rm
READY
STOP I/ O
term
READY
STOP I/ O
term
READY
Fig. 6.k
Security
The Security submenu (S6.5) under the system menu has a function that allows the user to prohibit changes to the parameters.
Parameter lock (P6.5.2)
If the parameter lock is activated the parameter values cannot be edited.
Note: This function does not prevent unauthorised editing of
parameter values.
Enter the edit mode by pushing the Menu button right. Use the Browser buttons to change the parameter lock status (0 = changes enabled, 1 = changes disabled). Accept the change with the Enter button or return to the previous level with the Menu button left.
enter
STOP I/O term
READY
STO P I/O t erm
READY
STOP I/O term
READY
STOP I/O term
READY
STO P I/O t erm
READY
nxlk22.fh8
Fig. 6.l
Keypad settings
In the submenu S6.6 under the System menu you can further customise your frequency converter operator interface. Locate the Keypad settings submenu (S6.6). Under the submenu, there are two pages (P#) associated with the keypad operation, Default page (P6.6.1) and Timeout time (P6.6.3)
33
ENG
Default page (P6.6.1)
Here you can set the location (page) to which the display automatically moves as the Timeout time (see below) has expired or as the power is switched on to the keypad. Press the Menu button right once to enter the edit mode. Pressing the Menu button right once again makes you able to edit the number of the
HMI acknowledge timeout (P6.7.3)
This function allows the user to change the timeout of the HMI acknowledgement time.
Note: If the frequency converter has been connected to the PC
with a normal cable, the default values of parametres 6.7.3 and
6.7.4 (200 and 5) must not be changed. If the frequency converter has been connected to the PC via a modem and there is delay in transferring messages, the value of par. 6.7.3 must be set according to the delay as follows: Example:
• Transfer delay between the frequency converter and the PC = 600 ms
• The value of par. 6.7.3 is set to 1200 ms (2 x 600, sending delay +
receiving delay)
• The corresponding setting shall be entered in the [Misc]-part of the
fi le NCDrive.ini:
- Retries = 5
- AckTimeOut = 1200
- TimeOut = 6000
It must also be considered that intervals that are shorter than the AckTimeOut-time cannot be used in NC-Drive monitoring. Enter the edit mode by pushing the Menu button right. Use the Browser buttons to change the acknowledgement time. Accept the change with the Enter button or return to the previous level with the Menu button left. See Fig. 6.m - for how to change the HMI acknowledgement timeout.
submenu/page digit by digit. Confi rm the new default page value with the Enter button. You can return to the previous step anytime by pushing the Menu button left.
Note: If you set a page that does not exist in the menu, the display
will automatically move to the last available page in the menu.
enter
STOP I/O term
READY
STO P I/O t erm
READY
STOP I/O term
READY
STOP I/O term
READY
STO P I/O t erm
READY
nxlk22.fh8
Fig. 6.m
Timeout time (P6.6.3)
The Timeout time setting (Fig. 6.m) defi nes the time after which the keypad display returns to the Default Page (P6.6.1), see above. Move to the Edit menu by pressing the Menu button right. Set the timeout time you want and confi rm the change with the Enter button.
You can return to the previous step anytime by pushing the Menu button left.
Note: This function cannot be disabled.
enter
STOP I/O term ST OP I/O te r m STOP I/ O te r m
nxl k24. fh8
ss
CANC EL
CO NF IR M CH A NG E
Fig. 6.n
Hardware settings
In the Hardware settings submenu (S6.7) you can further customise the settings of the frequency converter with three parameters: Fan control, HMI acknowledgement timeout and HMI retry.
Fan control (P6.7.2)
Note! Only the higher power modules of MF3 have been equipped with a cooling fan, in lower power modules of MF3 the cooling fan is available as optional equipment. If the cooling fan has been installed in MF3 it runs continuously, when the power is switched on.
Sizes MF4 and bigger:
This function allows you to control the frequency converter’s cooling fan. You can set the fan to run continuously when the power is switched on or depending on the temperature of the unit. If the latter function has been selected the fan is switched on automatically when the heat sink temperature reaches 60 °C. The fan receives a stop command when the heat sink temperature falls to 55 °C. However the fan runs for about a minute after receiving the stop command, as well as after changing the value from 0 (Continuous) to 1 (Temperature). Enter the edit mode by pushing the Menu button right. The present mode shown starts to blink. Use the Browser buttons to change the fan.
34
ENG
en ter
STOP
I/ O te rm
READY
STOP
I/O t e rm
RE ADY
ss
STOP
I/ O te rm
READY
Fig. 6.o
Number of retries to receive HMI acknowledgement (P6.7.4)
With this parameter you can set the number of times the drive will try receive acknowledgement if this does not succeed within the acknowledgement time (P6.7.3). Enter the edit mode by pushing the Menu button right. The present value shown starts to blink. Use the Browser buttons to change the amount of retries. Accept the change with the Enter button or return to the previous level with the Menu button left.
System information
In the submenu S6.8 under the System menu you can fi nd frequency converter-related hardware and software information as well as operation­related information. Enter the Info menu by pressing the Menu button right. Now you can browse through the information pages with the Browser buttons.
Counters submenu (S6.8.1)
In the Counters submenu (S6.8.1) you can fi nd information related to the frequency converter operation times, i.e. the total numbers of MWh, operation days and operation hours passed so far. Unlike the counters in the trip counters menu, these counters cannot be reset.
Note: The operation time counter (days and hours) runs always,
when the power is on.
Page Counter
C6.8.1.1 MWh counter C6.8.1.2 Operation day counter C6.8.1.3 Operation hour counter
Tab. 6.k
Trip counters submenu (S6.8.2)
Trip counters (menu S6.8.2) are counters the values of which can be reset i.e. restored to zero. You have the following resettable counters at your disposal:
Page Counter
T6.8.2.1 MWh counter P6.8.2.2 Clear mWh counter T6.8.2.3 Operation day counter T6.8.2.4 Operation hour counter P6.8.2.5 Clear operation time counter
Tab. 6.l
Note: The trip counters run only when the motor is running.
enter
STOP
I/O
term
READY
STOP
I/O
term
READY
STOP I/O term
READY
STOP I/O term
READY
Fig. 6.p
Example: When you want to reset the operation counters, you should do
the following:
Software info submenu (S6.8.3)
The following information can be found under the Software info submenu (S6.8.3):
Page Content
I6.8.3.1 Software package I6.8.3.2 System software version I6.8.3.3 Firmware interface I6.8.3.4 System load
Tab. 6.m
Application information submenu (S6.8.4)
You can fi nd the following information from the Application info submenu (S6.8.4)
Page Content
A6.8.4.1 Application D6.8.4.1.1 Application id D6.8.4.1.2 Version D6.8.4.1.3 Firmware interface
Tab. 6.n
Hardware information submenu (S6.8.5)
You can fi nd the following information from the Hardware info submenu (S6.8.5)
Page Content
I6.8.5.2 Unit voltage I6.8.5.3 Brake chopper
Tab. 6.o
Connected options submenu (S6.8.6)
The Connected options submenu (S6.8.6) shows the following information on the option board connected to the frequency converter:
Page Content
S6.8.6.1 Slot E Option board I6.8.6.1.1 Slot E Option board status I6.8.6.1.2 Slot E Program version S6.8.6.2 Slot D Option board I6.8.6.2.1 Slot D Option board status I6.8.6.2.2 Slot D Program version
Tab. 6.p
In this submenu you fi nd information about the option board connected to the control board (see chapter 5.2 “Control unit“ page 22). You can check the status of the slot by entering the board submenu with the Menu button right and using the Browser buttons. Push the Menu button right again to display the status of the board. The selections are shown in Table 7-5. The keypad will also display the program version of the respective board when you push either one of the Browser buttons. For more information on the expander board-related parameters, see paragraph “Expanded board menu (E7)“ page 36.
Fig. 6.q
35
ENG
AI mode
The parameters P6.9.1 and P6.9.2 selects the analogue input mode. P6.9.1 appears only in classes MF4 – MF6.
0 = voltage input (par. 6.9.1 default) 1 = current input (par. 6.9.2 default)
Note Make sure that the jumper selections correspond to the
selections of this parameter.
Modbus interface
NXL has a built-in Modbus® RTU bus interface. The signal level of the interface is in accordance with the RS485 standard.
RS-485 Tr ansceiver Control terminal
RS-485 A
RS-485 B
Terminal resistor 120 X7 -> MF2-MF3 X9 -> MF4-MF6
Fig. 6.r
Protocol: Modbus® RTU Baud rates: 300, 600, 1200, 2400, 4800, 9600, 19200, 38700, 57600 (bit/s) Signal level: RS-485 ( TIA/EIA-485-A) Input impedance: 2 kΩ
Modbus® RTU protocol
Modbus RTU protocol is a simple but eff ective fi eldbus protocol. Modbus® network has a bus topology, where every device has an individual address. With the help of the individual bus addresses the commands are directed to the single devices within the network. Modbus® supports also broadcast - type messages, that are received by every device of the bus. Broadcast messages are sent to the address “0” which is reserved for these messages. The protocol includes CRC error detection and parity check for preventing the handling of messages containing errors. In Modbus® the data is transferred in hex mode asynchronically and a break of approximately 3,5 characters is used as an end character. The length of the break depends on the used baud rate.
Function code Function name Address
Broadcast messages
03 Read Holding Register All ID numbers No 04 Read Input Register All ID numbers No 06 Preset Single Register All ID numbers Yes 16 Preset Multiple Register All ID numbers Yes
Tab. 6.q
Termination Resistor
The RS485 bus is terminated with 120 Ω termination resistors in both ends. NXL has a built-in termination resistor which is switched off as a default. See the jumper selections in paragraph “Jumper selection on CAREL VFD-NXL basic board“ page 24.
Modbus® address area
The Modbus® bus of NXL uses the ID numbers of the application as addresses. The ID numbers can be found in the parameter tables. When several parameters/monitoring values are read at a time they must be consecutive. 11 addresses can be read and the addresses can be parameters or monitoring values.
Modbus® process data
Process data is an address area for fi eldbus control. Fieldbus control is active when the value of parameter 3.1 (Control place) is 3 (=fi eldbus). The contents of the process data has been determined in the application. The following tables present the process data contents.
Output Process data
Addr. Modbus register Name Scale Type
2101 32101, 42101 FB Status Word - Binary coded 2102 32102, 42102 FB General Status Word - Binary coded 2103 32103, 42103 FB Actual Speed 0,01 % 2104 32104, 42104 Motor speed 0,01 +/- Hz 2105 32105, 42105 Motor speed 1 +/- Rpm 2106 32106, 42106 Motor current 0,1 A
2107 32107, 42107 Motor Torgue 0,1
+/- % (of nominal)
2108 32108, 42108 Motor Power 0,1
+/- % (of
nominal) 2109 32109, 42109 Motor Voltage 0,1 V 2110 32110, 42110 DC Voltage 1 V 2111 32111, 42111 Active Fault - Fault code
Tab. 6.r
Input Process data
Addr. Modbus register Name Scale Type
2001 32001, 42001 FB Control Word - Binary coded 2002 32002, 42002 FB General Control Word - Binary coded 2003 32003, 42003 FB Speed Reference 0,01 % 2004 32004, 42004 PID Control Reference 0,01 % 2005 32005, 42005 PID Actual Value 0,01 % 2006 32006, 42006 - - ­2007 32007, 42007 - - ­2008 32008, 42008 - - ­2009 32009, 42009 - - ­2010 32010, 42010 - - ­2011 32011, 42011 - - -
Tab. 6.s
Status Word
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
--------FZAREF W FLT DIR RUN RDY
Information about the status of the device and messages is indicated in the Status word. The Status word is composed of 16 bits the meanings of which are described in the table under.
Actual speed
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
MSB LSB
This is actual speed of the frequency converter. The scaling is –10000...10000. In the application, the value is scaled in percentage of the frequency area between set minimum and maximum frequency.
Control word
1514131211109876543 2 1 0
-------------RSTDIRRUN
The three fi rst bits of the control word are used to control the frequency converter.
Speed reference
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
MSB LSB
This is the Reference 1 to the frequency converter. Used normally as Speed reference. The allowed scaling is –10000...10000. In the application, the value is scaled in percentage of the frequency area between the set minimum and maximum frequencies.
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Bit defi nitions
Bit Description
Value = 0 Value = 1 RUN Stop Run DIR Clockwise Counterclockwise
RST
Rising edge of this
bit will reset active fault RDY Drive not ready Drive ready FLT No fault Fault active W No warning Warning active AREF Ramping Speed reference reached Z - Drive is running at zero speed F - Flux Ready
Tab. 6.t
Fieldbus parameters
RS485 communication status (I6.10.1) With this function you can check the status of the RS 485 bus. If the bus is not in use, this value is 0.
xx.yyy
xx = 0 – 64 (Number of messages containing errors) yyy = 0 – 999 (Number of messages received correctly)
Fieldbus protocol (P6.10.2)
With this function you can select the fi eldbus communications protocol. 0 = Not used 1 = Modbus protocol
Slave address (P6.10.3)
Set here the slave address for the modbus protocol. You can set any address between 1 and 255.
Baud rate (P6.10.4)
Selects the baud rate used with the modbus communication. 0 = 300 baud 1 = 600 baud 2 = 1200 baud 3 = 2400 baud 4 = 4800 baud 5 = 9600 baud 6 = 19200 baud 7 = 38400 baud 8 = 57600 baud
Stop bits (P6.10.5)
Set the number of stop bits used in Modbus communication 0 = 1 stop bit 1 = 2 stop bits
Parity type (P6.10.6)
Here you can select the type of parity checking used with the modbus communication. 0 = None 1 = Odd 2 = Even
Communication time-out (P6.10.7)
If communication between two messages is broken for a longer time than that defi ned by this parameter, a communication error is initiated. If the value of this parameter is 0, the function is not used. 0 = Not used 1 = 1 second 2 = 2 seconds, etc
Expander board menu (E7)
The Expander board menu makes it possible for the user:
1. to see which expander board is connected to the control board and
2. to reach and edit the parameters associated with the expander board.
Enter the following menu level (E#) with the Menu button right. You can view and edit the parameter values in the same way as described in paragraph “Parameter menu (P2)“ page 28.
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7. COMMISSIONING
7.1 Safety
Before commissioning, note the following directions and warnings:
1
Internal components and circuit boards of the frequency converter (except for the galvanically isolated I/O terminals) are live when CAREL VFD-NXL is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.
2
The motor terminals U, V, W and the DC-link/brake resistor terminals ¬–/+ are live when CAREL VFD-NXL is connected to mains, even if the motor is not running.
3
The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when CAREL VFD-NXL is disconnected from mains.
4
Do not make any connections with the frequency converter connected to the mains.
5
After having disconnected the frequency converter from the mains, wait until the fan stops and the indicators on the keypad go out (if no keypad is attached see the indicator through the keypad base). Wait 5 more minutes before doing any work on CAREL VFD-NXL connections. Do not even open the cover before this time has expired.
6
Before connecting the frequency converter to mains make sure that the CAREL VFD-NXL front cover is closed.
7
The heat sink of types MF2 and MF3 may be hot when the frequency converter is in use. Coming into contact with the heat sink may cause burns.
Tab. 7.a
7.2 Commissioning of the frequency converter
1. Read carefully the safety instructions in Chapter 5 “Cabling and
connections“ page 16 and above and follow them.
2. After the installation, make sure that:
• both the frequency converter and the motor are grounded.
• the mains and motor cables comply with the requirements given
in paragraph “Cabling“ page 16.
• the control cables are located as far as possible from the power
cables (see paragraph “Cable and fusible dimensions” page 16, step
3) , the shields of the shielded cables are connected to protective earth
. The wires may not touch the electrical components of
the frequency converter.
• For option boards only: make sure that the common ends of digital
input groups are connected to +24V or ground of the I/O terminal or the external supply.
3. Check the quality and quantity of cooling air (paragraph 4.3 “Control
unit“ page 22).
4. Check the inside of the frequency converter for condensation.
5. Check that all Start/Stop switches connected to the I/O terminals are
in Stop-position.
6. Connect the frequency converter to mains.
7. Set the parameters of group 1 according to the requirements of your
application. At least the following parameters should be set:
• motor nominal voltage
• motor nominal frequency
• motor nominal speed
• motor nominal current
• You will fi nd the values needed for the parameters on the motor
rating plate.
• NOTE! You can also run the Start-up Wizard. See paragraph 6.3
”Start-up wizard” page 26 for more information.
8. Perform run test without motor
Perform either Test A or Test B:
A. Controls from the I/O terminals:
a. Turn the Start/Stop switch to ON position. b. Change the frequency reference (potentiometer) c. Check in the Monitoring menù (M1) that the value of Output
frequency changes according to the change of frequency reference.
d. Turn the Start/Stop switch to OFF position.
B. Control from the control keypad:
a. Change the control from the I/O terminals to the keypad as
advised in paragraph “Selection of control place“ page 29.
b. Push the Start button on the keypad . c. Move over to the Keypad Control Menu (K3) and Keypad
Reference submenu and change the frequency reference using the Browser buttons
.
d. Check in the Monitoring menù (M1) that the value of Output
frequency changes according to the change of frequency reference.
e. Push the Stop button on the keypad .
9. Run the start-up tests without the motor being connected to the
process, if possible. If this is not possible, secure the safety of each test prior to running it. Inform your co-workers of the tests.
• Switch off the supply voltage and wait up until the drive has
stopped as advised at paragraph 7.1 “Safety“ page 37, step 5.
• Connect the motor cable to the motor and to the motor cable
terminals of the frequency converter.
• See to that all Start/Stop switches are in Stop positions.
• Switch the mains ON
• Repeat test 8A or 8B.
10. Connect the motor to the process (if the startup test was run without
the motor being connected)
• Before running the tests, make sure that this can be done safely.
• Inform your co-workers of the tests.
• Repeat test 8A or 8B.
7.3 Basic parameters
On the next pages you will fi nd the list of parameters that are essential for the commissioning of the frequency converter. You will fi nd more details of these and other special parameters in the +030220726 manual (that can be download from website www.carel.com). Note! If you wish to edit the special parameters, you must set the value of par. 2.1.22 to 0.
Column explanations:
Code Location indication on the keypad; Shows the operator the present
param. number
Parameter Name of parameter Min Minimum value of parameter Max Maximum value of parameter Unit Unit of parameter value; Given if available Default Value preset by factory Cust Customer’s own setting ID ID number of the parameter (used with PC tools)
On the parameter code: parameter value can only be changed after the FC has been stopped.
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Monitoring values (Control keypad: menu M1)
The monitoring values are the actual values of parameters and signals as well as statuses and measurements. Monitoring values cannot be edited.
Code Parameter Unit ID Description
V1.1 Output frequency Hz 1 Frequency to the motor V1.2 Frequency reference Hz 25 V1.3 Motor speed rpm 2 Calculated motor speed V1.4 Motor current A 3 Measured motor current V1.5 Motor torque % 4 Calculated actual torque/nominal torque of the unit V1.6 Motor power % 5 Calculated actual power/nominal power of the unit V1.7 Motor voltage V 6 Calculated motor voltage V1.8 DC-link voltage V 7 Measured DC-link voltage V1.9 Unit temperature ºC 8 Heat sink temperature V1.10 Analogue input 1 V 13 AI1 V1.11 Analogue input 2 14 AI2 V1.12 Analogue output current 26 AO1 V1.13 Analogue output current 1, expander board mA 31 V1.14 Analogue output current 2, expander board mA 32 V1.15 DIN1, DIN2, DIN3 15 Digital input statuses V1.16 DIE1, DIE2, DIE3 33 I/O expander board: Digital input statuses V1.17 RO1 34 Relay output 1 status V1.18 ROE1, ROE2, ROE3 35 I/O exp. board: Relay output statuses V1.19 DOE 1 36 I/O exp. board: Digital output 1 status V1.20 PID Reference % 20 In percent of the maximum frequency V1.21 PID Actual value % 21 In percent of the maximum actual value V1.22 PID Error value % 22 In percent of the maximum error value V1.23 PID Output % 23 In percent of the maximum output value V1.24 Autochange outputs 1, 2, 3 30 Used only in pump and fan control
V1.25 Mode 66
Shows the current operating mode selected with the Startup Wizard: 1=Standard, 2= Fan, 3= Pump, 4= High Performance
Tab. 7.b
Basic parameters (Control keypad: Menu P2 B2.1)
Code Parameter Min Max Unit Default Cust ID Note
P2.1.1 Min frequency 0,00 Par. 2.1.2 Hz 0,00 101
P2.1.2 Max frequency Par. 2.1.1 320,00 Hz 50,00 102
NOTE: If fmax > than the motor synchronous speed, check
suitability for motor and drive system P2.1.3 Acceleration time 1 0,1 3000,0 s 1,0 103 P2.1.4 Deceleration time 1 0,1 3000,0 s 1,0 104
P2.1.5 Current limit 0,1 x IL 1,5 x IL A IL 107
NOTE: Formulas apply approximately for frequency converters up
to MF3. For greater sizes, consult the factory.
P2.1.6 Nominal voltage of the motor 180 690 V
NXL2:230V NXL5:400V
110
P2.1.7 Nominal frequency of the motor 30,00 320,00 Hz 50,00 111 Check the rating plate of the motor
P2.1.8 Nominal speed of the motor 300 20 000 rpm 1440 112
The default applies for a 4-pole motor and a nominal size
frequency converter. P2.1.9 Nominal current of the motor 0,3 x IL 1,5 x IL A IL 113 Check the rating plate of the motor P2.1.10 Motor cos 0,30 1,00 0,85 120 Check the rating plate of the motor P2.1.11 Start function 0 1 0 505 0=Ramp; 1=Flying start P2.1.12 Stop function 0 1 0 506 0=Coasting; 1=Ramp P2.1.13 U/f optimisation 0 1 0 109 0=Not used; 1=Automatic torque boost
P2.1.14 I/O reference 0 5 0 117
0=AI1; 1=AI2; 2=Keypad reference; 3=Fieldbus reference
(FBSpeedReference); 4=Motor potentiometer; 5=AI1/AI2 selection
P2.1.15 AI2 signal range 1 4 2 390
Not used if AI2 Custom min > 0% or AI2 custom max. < 100% 1= 0
mA to 20 mA; 2= 4 mA to 20 mA; 3= 0 V to 10 V; 4= 2 V to 10 V
P2.1.16 Analogue output function 0 12 1 307
0= Not used; 1= Output freq. (0 - fmax); 2= Freq. reference (0 -
fmax); 3= Motor speed (0 - Motor nominal speed); 4= Output
current (0 - InMotor); 5= Motor torque (0 - TnMotor); 6= Motor
power (0 - PnMotor); 7= Motor voltage (0 - UnMotor); 8= DC-link
volt (0 - 1000 V); 9=PI controller ref. value; 10= PI contr. act. value 1;
11= PI contr. error value; 12= PI controller output
P2.1.17 DIN2 function 0 10 1 319
0= Not used; 1= Start Reverse; 2= Reverse; 3= Stop pulse; 4=
External fault, cc; 5= External fault, oc; 6= Run enable; 7= Preset
speed 2; 8= Motor pot. UP (cc); 9= Disable PID (Direct freq.
reference); 10= Interlock 1
P2.1.18 DIN3 function 0 17 6 301
0= Not used; 1= Reverse; 2= External fault, cc; 3= External fault, oc;
4= Fault reset; 5= Run enable; 6= Preset speed 1; 7= Preset speed
2; 8= DC-braking command; 9= Motor pot. UP (cc); 10= Motor
pot. DOWN (cc); 11= Disable PID (PID control selection); 12= PID
Keypad ref. 2 selection; 13= Interlock 2; 14= Thermistor input (See
Chapter 6.2.4); 15= Force CP to I/O; 16= Force CP to Fieldbus; 17=
AI1/AI2 selection P2.1.19 Preset speed 1 0,00 Par. 2.1.2 Hz 10,00 105 P2.1.20 Preset speed 2 0,00 Par. 2.1.2 Hz 50,00 106 P2.1.21 Automatic restart 0 1 0 731 0= Not used; 1=Used
P2.1.22 Parameter conceal 0 1 0 115
0= All parameters and menus visible; 1=Only group P2.1 and
menus M1 – H5 visible
Tab. 7.c
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8. FAULT TRACING
When a fault is detected by the frequency converter control electronics, the drive is stopped and the symbol F together with the ordinal number of the fault and the fault code appear on the display. The fault can be reset with the Reset button on the control keypad or via the I/O terminal. The faults are stored in the Fault history menu (H5) which can be browsed. The diff erent fault codes you will fi nd in the table below. The fault codes, their causes and correcting actions are presented in the table below. The shadowed faults are A faults only. The items written in white on black background present faults for which you can program diff erent responses in the application. See parameter group Protections.
Fault code
Fault Possible cause Correcting measures
1
Overcurrent
- sudden heavy load increase
- short circuit in motor cables
- unsuitable motor
Frequency converter has detected too high a current (>4*In) in the motor cable:
Check loading. Check motor size. Check cables.
2
Overvoltage
- too short a deceleration time
- high overvoltage spikes in utility
The DC-link voltage has exceeded the limits defi ned in. Make the deceleration time longer.
3
Earth fault
- insulation failure in cables or motor
Current measurement has detected that the sum of motor phase current is not zero.
Check motor cables and motor.
8 System fault
- component failure
- faulty operation
Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.
9
Undervoltage
- most probable cause: too low a supply voltage
- frequency converter internal fault
DC-link voltage is under the voltage limits defi ned in.
In case of temporary supply voltage break reset the fault and restart the frequency converter. Check the supply voltage. If it is ade¬quate, an internal failure has occurred. Contact the distributor near to you.
11 Output phase supervision
Current measurement has detected that there is no current in one motor phase.
Check motor cable and motor.
13 Frequency converter undertemperature Heatsink temperature is under –10 °C
14 Frequency converter overtemperature
Heatsink temperature is over 90 °C. Overtemperature warning is issued when the heatsink temperature exceeds 85 °C.
Check the correct amount and fl ow of cooling air. Check the heatsink for dust. Check the ambient temperature. Make sure that the switching frequency is not too high in relation to ambient temperature and motor load.
15 Motor stalled Motor stall protection has tripped. Check motor.
16 Motor overtemperature
Motor overheating has been detected by frequency converter motor temperature model. Motor is overloaded.
Decrease the motor load. If no motor overload exists, check the temperature model parameters.
17 Motor underload Motor underload protection has tripped.
22
EEPROM checksum fault
- faulty operation
- component failure
Parameter save fault Contact the distributor near to you
24 Counter fault Values displayed on counters are incorrect
25 Microprocessor watchdog fault
- faulty operation
- component failure
Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.
29 Thermistor fault
The thermistor input of option board has detected increase of the motor temperature
Check motor cooling and loading Check thermistor connection (If thermistor input of the option board is not in use it has to be short circuited)
34 Internal bus communication Ambient interference or defective hardware
Should the fault re-occur, contact the distributor near to you.
35 Application fault Selected application does not function. Contact the distributor near to you.
39 Device removed
Option board removed. Drive removed.
Reset
40 Device unknown Unknown option board or drive. Contact the distributor near to you.
41 IGBT temperature
IGBT Inverter Bridge overtemperature protection has detected too high a motor current.
Check loading. Check motor size.
44 Device change
Option board changed. Option board has default settings.
Reset
45 Device added Option board added. Reset
50
Analogue input Iin < 4mA (selected signal range 4 to 20 mA)
- control cable is broken or loose
- signal source has failed
Current at the analogue input is < 4mA. Check the current loop circuitry.
51 External fault
Digital input fault. Digital input has been programmed as external fault input and this input is active.
Check the programming and the device indicated by the external fault information. Check also the cabling of this device.
52 Keypad communi¬cation fault
The connection between the control keypad and the frequency converter is broken.
Check keypad connection and possible keypad cable.
53 Fieldbus fault
The data connection between the fi eldbus Master and the fi eldbus board is broken
Check installation. If installation is correct contact the nearest CAREL distributor.
54 Slot fault Defective option board or slot Check board and slot.
55 Actual value supervision
Actual value has exceeded or fallen below (depending on par. 2.7.22) the actual value supervision limit (par. 2.7.23)
Tab. 8.a
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9. DESCRIPTION OF EXPANDER BOARD OPTAA
Note: check the Carel price list, to verify if the options are
available.
Fig. 9.a
Description: I/O expander board with one relay output, one open
collector output and three digital inputs.
Allowed slots: CAREL VFD-NXL board slot E Type ID: 16705 Terminals: Two terminal blocks; Screw terminals (M2.6 and M3);
No coding
Jumpers: None Board parameters: None
I/O terminals on OPT-AA
Terminal Parameter setting Description X3
1 +24V Control voltage output; voltage for
switches etc, max. 150 mA 2 GND Ground for controls, e.g for +24 V and DO 3 DIN1 DIGIN:x.1 Digital input 1 4 DIN2 DIGIN:x.2 Digital input 2 5 DIN3 DIGIN:x.3 Digital input 3 6 DO1 DIOUT:x.1 Open collector output, 50mA/48V
X5
24 RO1/NC DIOUT:x.2 Relay output 1 (NO)
Switching capacity:
24 Vdc/8 A
250 Vac/8 A
125 Vdc/0,4 A
25 RO1/C 26 RO1/NO
Tab. 9.a
Note: The +24 V control voltage terminal can also be used to
power the control module (but not the power module).
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10. DESCRIPTION OF EXPANDER BOARD OPTAI
Note: per la disponibilità delle opzioni previste, consultare il listino
CAREL.
Fig. 10.a
Description: I/O expander board with one relay output (NO), three
digital inputs and one thermistor input for CAREL VFD­NXL frequency converters
Allowed slots: CAREL VFD-NXL board slot E Type ID: 16713 Terminals: Three terminal blocks; Screw terminals; No coding Jumpers: None Board parameters: None
I/O terminals on OPT-AA
Terminal Parameter setting Description X4
12 +24V
Control voltage output; voltage for switches etc, max. 150 mA
13 GND
Ground for controls, e.g for
+24 V and DO 14 DIN1 DIGIN:B.1 Digital input 1 15 DIN2 DIGIN:B.2 Digital input 2 16 DIN3 DIGIN:B.3 Digital input 3
X2
25 RO1/ Common
DigOUT:B.1 Relay output 1 (NO)
Switching capacity:
24 Vdc/8 A
250 Vac/8 A
125 Vdc/0,4 A
26 RO1/ Normal Open
X3
28 TI+ DIGIN:B.4
Thermistor input;
Rtrip = 4.7 kΩ (PTC) 29 TI-
Tab. 10.a
Note: The +24 V control voltage terminal can also be used to
power the control module (but not the power module).
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11. FLANGE MOUNTING KIT FOR NXS/P FREQUENCY CONVERTERS FR4FR6
11.1 General
Using the CAREL Flange Mounting Kit, you can mount your CAREL NX frequency converter through the cabinet wall so that the control unit of the drive remains inside the cabinet.
The correct installation of the Flange Mounting Kit aff ects the IP protection class of the frequency converter. After the installation, the control unit is protected according to IP21 and the power unit according to IP54 (unless the frequency converter was originally IP21-protected). See fi gure below.
Cabinet
IP54
IP21
Fig. 11.a
According to standard IEC 60529 (EN 60529), the IP54 frequency converter enclosure provides protection against dust and water sprayed from all directions. Limited ingress of both is permitted.
Flange mounting kit list code:
Carel code Description
NXATHR4000 THR-FR4 Flange for FR4 NXATHR5000 THR-FR5 Flange for FR5 NXATHR6000 THR-FR6 Flange for FR6 NXATHR7000 THR-FR4-54 Flange for FR4, IP54 NXATHR8000 THR-FR5-54 Flange for FR5, IP54 NXATHR9000 THR-FR6-54 Flange for FR6, IP54
Tab. 11.a
11.2 CAREL fl ange mounting kit contents
The contents of the Flange Mounting Kits for diff erent frames are shown in the following pictures.
FR4 (Type designation code: THR-FR4)
Fig. 11.b
1 Flange, top 5 Screws (4*16) 2 Flange, bottom 6 Screws (4*10) 3 Fan & protection plate 7 Sealing tape 4 Plastic sealing
FR5 (Type designation code: THR-FR5)
Fig. 11.c
1 Flange, top 4 Screws (4*16) 2 Flange, bottom 5 Rubber sealing 3 Fan & protection plate 6 Sealing tape
FR6 (Type designation code: THR-FR6)
Fig. 11.d
1 Flange, top 5 Cable ties 2 Flange, bottom 6 Screws (6*12) 3 Fan 7 Sealing tape 4 Rubber sealings
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11.3 Installation
These instructions guide you through the installation of the Flange Mounting Kit that you have purchased for your FR4, FR5 or FR6 size frequency converter. Please note the white triangles in the lower left corners of the installation pictures. They designate the frame(s) the picture applies to. If no triangles exist, the step is applicable to all frames.
1234
Open the control cable cover and remove the cable entry fl ange
Detach the protection plate. Keep the plate and the screws to hand, they will still be needed.
Attach the bottom fl ange to its place with screws. Do not tighten the screws yet.
Place the cable entry fl ange between the frame and the bottom fl ange. Now tighten the screws.
5 6a 6b 7 8
Detach the fan. 6.a Insert the plastic sealing (#4).
6.b Insert the rubber sealings (#5).
Fix the top fl ange to its place. Attach the protection plate with
fan (#3) with the screws you set aside at step 2.
9 10a 10b 11
Detach the grounding rack from the protection plate you removed at step 2 and fi x it to the plate with fan using the screws from the old rack.
Remove the plastic cover of the frequency converter and open the small lid on the power unit cover. Leave the opening uncovered.
Remove the plastic cover of the frequency converter and open the small lid on the power unit cover. Set the screws aside for later use.
Seal the air inlets with the rubber sealings (#4). Leave the opening uncovered.
12 13 14 15
Fix the lid with fan (#3) on the power unit cover using the screws set aside at step 10b.
Carefully re-install the fan ensuring that the connector clip fi ts accurately. Do not slam, do not force!
Attach the adhesive-backed mounts (#7) as shown in the picture and use the ties (#5) to fi x the cables on the power unit.
Connect the fan cables to terminals #6 (red) and #7 (black) of the basic I/O board (NXOPTA1 or NXOPTA8)*
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Apply the sealing tape attached around the opening along the edge. The kit contains a greater amount of tape than what you might need. Only use such an amount of tape required by the dimensions of the opening. See Figure 11.e. Fit the frequency converter in the opening.
Sealing tape
Fig. 11.e
Note: The frequency converter will not fi t in the opening in a
straight position. Tip the converter positioning the lower end fi rst
in the opening. See Figures 11.f and 11.g.
Fig. 11.f
Fig. 11.g
11.4 Information Sticker
Each Flange Mounting Kit delivered by the factory includes a sticker (shown below). Please check IP54/Collar (1) and mark the installation date (2) on the sticker. Finally, attach the sticker on the drive.
Drive modified:
Option board:
N XO PT................
IP 54 up gr a de / C olla r
in s lot:
D a te:. .... ..... .. .. .... .
A B C D E
EM C le ve l m o d ified : H to T / T to H
D a te:. .... ..... .. .. .... .
D a te:. .... ..... .. .. .... .
RFI EMC Filters for size MF2 and MF3
Carel Code NXARF08500 NXARF13200 NXARF12200 NXALR03500 NXALR05200
Type RFI-0008-5-1 RFI EMC fi lter
Amp. 08
RFI-0013-2-1 RFI EMC fi lter, Amp. 13
RFI-0012-2-1 RFI EMC fi lter, Amp. 12
LRF-0003-5-1 LRF EMC fi lter, Amp. 03
LRF-0005-2-1 LRF EMC
fi lter, Amp. 05 Model RFI-0008-5-1 RFI-0013-2-1 RFI-0012-2-1 LRF-0003-5-1 LRF-0005-2-1 Rated current at an ambient temperature
8A / 50 °C 13 A / 50 °C 12 A / 50 °C 3 A / 50 °C 5 A / 50 °C
Rated voltage 3 x 500 V 50/60 Hz 250 V 50/60 Hz 250 V 50/60 Hz 3 x 500 V 50/60 Hz 250 V 50/60 Hz Operational leakage current Calculation with C-tol.
I max 12,5 mA Between P-E / Frequency 500 Vac/50 Hz Non symmetrical voltage (IEC 1000-2-4)
I max 4,1 mA Between P-E / Frequency 230 Vac/50 Hz
I max 4 mA 230 Vac/50 Hz
I max 12,5 mA Between P-P / Frequency 500 Vac/50 Hz Non symmetrical voltage (IEC 1000-2-4)
I max 4,1 mA
Between P-E / Frequency
230 Vac/50 Hz
DC-resistance Max. 3x18 mOhm Max. 2x10 mOhm Max. 2x10,5 mOhm Max. 3x10 mOhm Max. 1 Ohm (L-Line) Temperature range -25 °C…100 °C@25 °C -25 °C…100 °C@25 °C -25 °C…100 °C@25 °C -25 °C…100 °C@25 °C -25 °C…100 °C@25 °C Dimension Fig. 1 Fig. 2 Fig. 3 Fig. 1 Fig. 4
Tab. 11.b
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Code NXARF08500 and code NXALR03500
terminal block 4 mm
2
Ø6 (4 pcs)
M5x0.8 - 6 (5 pcs)
Wires 4x1.5 mm
2
209
2406
7. 5
15
7 ±1
Ferrule
L1, L2, L3
PE
load
30 ±5
60 ±5
187 ±15
140.5 193
252
12
1.25
12.535
60
30
7 ±1
13
35
PE L1 L2 L3
Fig. 11.h
NXARF13200
Ø6 (4 pcs)
M5x0.8 - 6 (5 pcs)
Wires 4x1.5 mm
2
2406
7. 5
15
7 ±1
Ferrule
N, L
PE
load
30 ±5
60 ±5
187 ±15
140.5 193
252
12.535
60
30
7 ±1
13
35
PE N L
Fig. 11.i
Code NXARF12200
Fig. 11.j
46
All trademarks hereby referenced are the property of their respective owners. CAREL is a registered trademark of CAREL Industries in Italy and/or other countries.
© CAREL Industries 2008 all rights reserved
CAREL reserves the right to modify the features of its products without prior notice.
ENG
Code NXALR05200
17 6
400 ±25
200
18 8
12
6
13
50 10
LINE
LOAD
Ø 5.5
Wires 3x1.5 mm
2
Terminal block 6 mm
2
Fig. 11.k
Agenzia / Agency:
CAREL INDUSTRIES HQs
Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 0499 716611 - Fax (+39) 0499 716600 carel@carel.com - www.carel.com
VFD +030220721 rel. 2.2 - 10.05.2011
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