Danfoss VACON 3000 Operating guide

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Operating Guide

VACON® 3000 Enclosed Drive

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VACON® 3000 Enclosed Drive

Operating Guide

Introduction 9

1.1

Purpose of this Operating Guide 9

Additional Resources 9

1.2

Manual Version 9

1.3

Safety 10

Safety Symbols 10

2.1

Qualified Personnel 10

2.2

Danger and Warnings 10

2.3

Cautions and Notices 12

2.4

Main Circuit Breaker 14

2.5

Safety and Protection Requirements 14

2.5.1

Minimum Requirements for MCB and MCB Control 14

2.5.2

Contents

Product Overview 16

Intended Use 16

3.1

3.2

Product Description 16

3.2.1

AFE Drive 16

3.2.2

12-Pulse Drive 17

3.3

Type Code Description 17

3.4

Available Options 18

Receiving the Delivery 21

4.1

Checking the Delivery 21

4.2

Storage 21

4.3

Lifting and Moving the Enclosed Drive 21

Mechanical Installation 24

5.1

Operating Environment 24

5.2

Cabinet Installation 24

5.3

Dimensions of the Enclosed Drive 25

5.4

Liquid Cooling Requirements 26

5.4.1

Safety in Liquid-cooling 26

5.4.2

General Information on Liquid Cooling 26

5.4.3

Cooling Liquid 27

5.4.3.1

5.4.3.2

5.4.3.3

Quality Requirements for the Purified Water 27

Purified Water as Coolant 27

Antifreeze Mix as Coolant 27

VACON® 3000 Enclosed Drive

Operating Guide

5.4.3.4

5.4.3.5

5.4.4

Cooling System 30

5.4.4.1

5.4.4.2

5.4.4.3

5.5

Cooling and Free Space Around the Enclosed Drive 32

Electrical Installation 34

6.1

Galvanic Isolation Between the MV and LV Sections 34

6.2

Mains and Motor Cable Selection 35

6.3

Mains and Motor Cable Inlet and Termination 35

6.4

Grounding 38

6.4.1

Standard Grounding Configurations 38

6.5

Additional Instructions for Cable Installation 39

Temperature of the Cooling Liquid 28

Condensation 28

Materials 30

Cooling System Overview 31

Cooling Connections to the Enclosed Drive 31

Contents

6.6

Main Circuit Breaker Installation 40

6.7

Cabling of the Power Modules 40

6.7.1

Phase Module L20/L30 Terminals 40

6.7.2

DFE Power Module Terminals 40

6.7.2.1

6.7.3

Power Module Grounding 42

6.7.4

DC-Link Connections 43

6.7.5

Brake Chopper Installation 45

6.7.6

Terminal Screw Tightening Torque Specifications 45

6.7.7

LED Display on the Phase Module 45

6.7.8

LED Display on the DFE Power Module 47

6.8

Low-Voltage Power Supplies 48

6.8.1

Low-Voltage Power Supply Connections 48

6.8.2

Safety Notes for the Precharge Unit 49

6.8.3

Location of the Precharge Unit 49

6.9

Safety Functions 49

DFE Control Terminals 41

6.9.1

Safe Torque Off (STO) 50

6.9.2

Safe Stop 1 (SS1) 50

6.9.3

Safety Considerations 50

6.9.3.1

6.9.4

STO Operating Principle 51

6.9.5

SS1 Operating Principle 51

Diagnostic Test 50

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections 52

Control Interface 52

7.1

7.2

The Control Compartment of the Enclosed Drive 52

Control Unit Components 53

7.3

7.4

Control Unit Cabling 54

7.4.1

Selection of the Control Cables 55

7.4.2

Control Unit Terminals 55

7.5

DIP Switches on the Control Unit 56

7.5.1

Selection of Terminal Functions with DIP Switches 56

7.5.2

Isolation of the Digital Inputs from Ground 57

7.6

Fieldbus Connection 58

7.6.1

Fieldbus Terminals 58

7.6.2

Using Fieldbus through an Ethernet Cable 59

7.6.3

Using Fieldbus through an RS485 Cable 60

Contents

Option Board Installation 62

7.7

7.8

Optical Fiber Connections 63

7.8.1

Selection of Optical Fiber Cables 66

7.8.2

Making Optical Fiber Cables 67

7.9

Encoder Interface 68

7.9.1

Encoder Terminals and Signals 69

7.9.2

Encoder Jumper Configurations 70

7.9.3

Encoder Connection 72

7.10

Battery for the Real-Time Clock (RTC) 73

7.11

Galvanic Isolation Barriers 73

7.12

System and Application Software 73

7.13

Technical Data on Control Connections 73

7.14

Auxiliary I/O Board 75

7.14.1

Connector Locations 75

7.14.2

Connector Specifications 76

7.14.3

LED Display on the Auxiliary I/O Board 80

Commissioning 82

8.1

Safety Checks before Starting the Commissioning 82

8.2

Operating the Grounding Switch 82

8.3

Commissioning the Drive 83

8.3.1

Basic Job Information 83

8.3.2

Before Power-up Checklist 84

8.3.3

Control and Auxiliary Power Commissioning Checklist 87

VACON® 3000 Enclosed Drive

Operating Guide

8.3.4

8.4

Commissioning Procedures 88

8.4.1

8.4.2

8.4.3

8.4.4

8.4.5

8.4.6

8.4.7

8.5

Insulation Resistance Measurements 106

8.5.1

8.5.2

Contents

Medium-Voltage Power Commissioning Checklist 88

Filling the Liquid Cooling System 88

Grid Voltage Feedback Configuration 92

Installing Software on the Control Unit 94

Verifying the Phase Module Connections 97

Commissioning Test 98

8.4.5.1

8.4.5.2

AFE Synchronization Test 101

Encoder Setup 105

Measuring the Switchgear Insulation Resistance 106

Measuring the Cable and Motor Insulation 107

Commissioning Test with HMI Touch Screen 99

Commissioning Test with VACON® Live 100

8.5.2.1

8.5.2.2

8.5.2.3

Maintenance 108

9.1

Preventive Maintenance Recommendations 108

9.2

Maintenance of the Heat Exchanger 110

Fault Tracing 111

10.1

Fault Types 111

10.2

Faults and Alarms 111

10.2.1

Fault Code 1 - Overcurrent 111

10.2.2

Fault Code 2 - Overvoltage 112

10.2.3

Fault Code 3 - Earth Fault 113

10.2.4

Fault Code 5 - Charging Switch 114

10.2.5

Fault Code 7 - Saturation 114

10.2.6

Fault Code 8 - System Fault 114

Insulation Checks of the Motor Cable 107

Insulation Checks of the Mains Cable 107

Insulation Checks of the Motor 107

10.2.7

Fault Code 9 - Undervoltage 122

10.2.8

Fault Code 10 - Input Phase 122

10.2.9

Fault Code 11 - Output Phase Supervision 124

10.2.10

Fault Code 12 - Brake Chopper Supervision 124

10.2.11

Fault Code 13 - AC Drive Undertemperature 125

10.2.12

Fault Code 14 - AC Drive Overtemperature 125

10.2.13

Fault Code 15 - Motor Stall 127

10.2.14

Fault Code 16 - Motor Overtemperature 127

VACON® 3000 Enclosed Drive

Operating Guide

10.2.15

10.2.16

10.2.17

10.2.18

10.2.19

10.2.20

10.2.21

10.2.22

10.2.23

10.2.24

10.2.25

10.2.26

10.2.27

10.2.28

Contents

Fault Code 17 - Motor Underload 127

Fault Code 19 - Power Overload 128

Fault Code 25 - Motor Control Fault 128

Fault Code 26 - Start-up Prevented 129

Fault Code 29 - ATEX Thermistor 129

Fault Code 30 - Safety 129

Fault Code 32 - Fan Cooling 132

Fault Code 33 - Fire Mode Enabled 132

Fault Code 37 - Device Changed (Same Type) 132

Fault Code 38 - Device Added (Same Type) 133

Fault Code 39 - Device Removed 134

Fault Code 40 - Device Unknown 134

Fault Code 41 - IGBT Temperature 135

Fault Code 43 - Encoder Fault 135

10.2.29

Fault Code 44 - Device Changed (Different Type) 137

10.2.30

Fault Code 45 - Device Added (Different Type) 138

10.2.31

Fault Code 46 - Real Time Clock 138

10.2.32

Fault Code 47 - Software Update 139

10.2.33

Fault Code 49 - Precharge 139

10.2.34

Fault Code 50 - AI Low Fault 143

10.2.35

Fault Code 51 - Device External Fault 143

10.2.36

Fault Code 52 - Keypad Communication Fault 144

10.2.37

Fault Code 53 - Fieldbus Communication Fault 144

10.2.38

Fault Code 54 - Slot Fault 144

10.2.39

Fault Code 57 - Identification 145

10.2.40

Fault Code 58 - Mechanical Brake 146

10.2.41

Fault Code 59 - Communication 146

10.2.42

Fault Code 61 - Speed Error Fault 146

10.2.43

Fault Code 63 - Quick Stop 146

10.2.44

Fault Code 65 - PC Communication Fault 147

10.2.45

Fault Code 66 - Thermistor Input Fault 147

10.2.46

Fault Code 67 - Module Test Stand 148

10.2.47

Fault Code 68 - Maintenance Counter 148

10.2.48

Fault Code 69 - Fieldbus Mapping Error 148

10.2.49

Fault Code 76 - Start Prevented 149

10.2.50

Fault Code 77 - >5 Connections 149

10.2.51

Fault Code 78 - Identification Ongoing 149

10.2.52

Fault Code 80 - Fieldbus Watchdog Fault 149

VACON® 3000 Enclosed Drive

Operating Guide

10.2.53

Fault Code 84 - Overspeed Error 149

10.2.54

Fault Code 111 - Temperature Input Fault 1 149

10.2.55

Fault Code 112 - Temperature Input Fault 2 150

10.2.56

Fault Code 114 - User Defined Fault 1 150

10.2.57

Fault Code 115 - User Defined Fault 2 151

10.2.58

Fault Code 200 - Precharge 151

10.2.59

Fault Code 201 - High Humidity/Temperature 152

10.2.60

Fault Code 202 - Encoder 152

10.2.61

Fault Code 203 - STO Fault 153

10.2.62

Fault Code 204 - Output Filter 153

10.2.63

Fault Code 205 - Coolant Temperature 153

10.2.64

Fault Code 300 - Unsupported 153

Specifications 154

11.1

Power Ratings 154

Contents

11.1.1

Power Ratings for Mains Voltage 3300 V 154

11.1.2

Power Ratings for Mains Voltage 4160 V 154

11.1.3

Overload Capability 155

11.2

Technical Data 155

11.2.1

Mains Supply 155

11.2.2

Motor Output 156

11.2.3

Control Properties 156

11.2.4

Drive Properties 157

11.2.5

Ambient Conditions 158

11.2.6

Cooling 159

11.2.7

Source Impedance Specifications 160

11.3

Main Circuit Diagrams 164

11.3.1

VACON® 3000 AFE Main Circuit Diagrams 164

11.3.2

VACON® 3000 12-Pulse Main Circuit Diagrams 166

11.4

Abbreviations 167

Version

Release date

Remarks

29.09.2021

First version

VACON® 3000 Enclosed Drive

Operating Guide

Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.

1.2 Additional Resources

Other resources are available to understand advanced AC drive functions, programming, and options.

•

The VACON® 3000 application guides provide greater detail on how to work with the applications and how to set the parameters of the AC drive.

•

The operating and installation guides for VACON® options give detailed information about specific drive options.

Supplementary publications and manuals are available from Danfoss. See www.danfoss.com for listings.

1.3 Manual Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.

Table 1: VACON® 3000 Enclosed Drive Operating Guide Version

VACON® 3000 Enclosed Drive

Operating Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

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

W A R N I N G

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

C A U T I O N

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

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

Safety

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•

Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

•

Are familiar with the basic regulations concerning health and safety/accident prevention.

•

Have read and understood the safety guidelines given in all manuals, especially the instructions given in the operating guide of the unit.

•

Have good knowledge of the generic and specialist standards applicable to the specific application.

•

Are familiar with the structure and operation of medium-voltage drives and the related risks. Special training for medium-voltage installations may be necessary.

2.3 Danger and Warnings

D A N G E R

SHOCK HAZARD FROM POWER UNIT COMPONENTS

The power unit components are live when the drive is connected to mains. Contact with this voltage can result in death or seri-

ous injury.

Do not touch the components of the power unit when the drive is connected to mains.

Do not do any work on live equipment. Before doing any work on internal drive components, follow proper lock out and tag out procedure. Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

VACON® 3000 Enclosed Drive

Operating Guide

D A N G E R

SHOCK HAZARD FROM TERMINALS

The motor terminals U, V, W, the brake resistor terminals, and the DC-link terminals must be treated as live when the drive is

connected to mains. Contact with this voltage can lead to death or serious injury.

Do not touch the motor terminals U, V, W, the brake resistor terminals, or the DC terminals when the drive is connected to

mains. Do not do any work on live equipment. Before doing any work on the drive, follow proper lock out and tag out procedure. Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

D A N G E R

SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE

The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the

mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to

death or serious injury.

Disconnect the drive from the mains and make sure that the motor has stopped.

Disconnect the motor. Lock out and tag out the power source to the drive. Make sure that no external source generates unintended voltage during work. To ground the drive input and DC link, close the grounding switch. If there is no grounding switch, make sure that the drive input and DC link are grounded for work. Also ground the motor terminals for work. Wait for the DC-link capacitors to discharge fully before opening the cabinet door or the cover of the AC drive. The discharge time is <7 minutes for AFE drives and <21 minutes for 12-pulse drives. Use a measuring device to make sure that there is no voltage.

Safety

W A R N I N G

SHOCK HAZARD FROM CONTROL TERMINALS

The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this voltage

can lead to injury.

Make sure that there is no voltage in the control terminals before touching the control terminals.

W A R N I N G

ACCIDENTAL MOTOR START

When there is a power-up, a power break, or a fault reset, the motor starts immediately if the start signal is active, unless the pulse

control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions (including the

start inputs) can change. If you activate the auto reset function, the motor starts automatically after an automatic fault reset. See

the Application Guide. Failure to ensure that the motor, system, and any attached equipment are ready for start can result in

personal injury or equipment damage.

Disconnect the motor from the drive if an accidental start can be dangerous. Make sure that the equipment is safe to operate

under any condition.

VACON® 3000 Enclosed Drive

Operating Guide

W A R N I N G

ELECTRICAL SHOCK HAZARD - LEAKAGE CURRENT HAZARD >3.5 MA

Leakage currents exceed 3.5 mA. Failure to connect the drive properly to protective earth (PE) can result in death or serious in-

jury.

Ensure reinforced protective earthing conductor according to IEC 60364-5-54 cl. 543.7 or according to local safety regula-

tions for high touch current equipment. The reinforced protective earthing of the drive can be done with:

a PE conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al.

an extra PE conductor of the same cross-sectional area as the original PE conductor as specified by IEC 60364-5-54 with a

minimum cross-sectional area of 2.5 mm2 (14 AWG) (mechanical protected) or 4 mm2 (12 AWG) (not mechanical protected).

a PE conductor completely enclosed with an enclosure or otherwise protected throughout its length against mechanical

damage.

a PE conductor part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2 (14 AWG)

(permanently connected or pluggable by an industrial connector. The multi-conductor power cable shall be installed with an appropriate strain relief).

NOTE: In IEC/EN 60364-5-54 cl. 543.7 and some application standards (for example IEC/EN 60204-1), the limit for requiring

reinforced protective earthing conductor is 10 mA leakage current.

2.4 Cautions and Notices

Safety

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS

Using spare parts that are not from the manufacturer can damage the drive.

Do not use spare parts that are not from the manufacturer.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM CHANGES TO DRIVE COMPONENTS

Doing electrical or mechanical changes to the drive components can cause malfunctions and can damage the AC Drive.

Do not make electrical or mechanical changes to the drive components.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING

Not using a grounding conductor can damage the drive.

Always ground the AC drive with a grounding conductor that is connected to the grounding terminal that is identified with

the PE symbol. If no dedicated transformer is installed, the AC drive is intended for high resistance grounding systems with a resistance grounded neutral point. For operation in an IT network without a dedicated transformer, consult Danfoss.

C A U T I O N

CUT HAZARD FROM SHARP EDGES

There can be sharp edges in the AC drive that can cause cuts.

Wear protective gloves when mounting, cabling, or doing maintenance operations.

C A U T I O N

BURN HAZARD FROM HOT SURFACES

Touching surfaces, which are marked with the 'hot surface' sticker, can result in injury.

Do not touch surfaces which are marked with the 'hot surface' sticker.

VACON® 3000 Enclosed Drive

Operating Guide

N O T I C E

DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE

Some of the electronic components inside the AC drive are sensitive to ESD. Static voltage can damage the components.

Use ESD protection when working with electronic components of the AC drive. Do not touch the components on the circuit

boards without proper ESD protection.

N O T I C E

DAMAGE TO THE AC DRIVE FROM MOVEMENT

Movement after installation can damage the drive.

Do not move the AC drive during operation. Use a fixed installation to prevent damage to the drive.

N O T I C E

DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL

The EMC level requirements for the AC drive depend on the installation environment. An incorrect EMC level can damage the

drive.

Before connecting the AC drive to the mains, make sure that the EMC level of the AC drive is correct for the mains.

Safety

N O T I C E

RADIO INTERFERENCE

In a residential environment, this product can cause radio interference.

Take supplementary mitigation measures.

N O T I C E

MAINS DISCONNECTION DEVICE

If the AC drive is used as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN

60204-1).

N O T I C E

MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES

Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not operate

correctly.

N O T I C E

VOLTAGE WITHSTAND TESTS

If done improperly, doing voltage withstand tests can damage the drive.

Megohmmeter testing is the only recommended test type for field installations.

Only a qualified field service engineer is allowed to perform this test. Refer to the proper high potential/megohmmeter testing instructions in the service guide.

N O T I C E

WARRANTY

If the power modules are opened, the warranty is not valid.

Do not open the power modules.

CB1

CB2

MVD

e30bi562.10

Trip coil: RO from VACON® 3000 (reaction time: 10 ms delay)

Undervoltage release (UVR): IGBT switch from arc flash relay (reaction time: 2 ms delay)

Breaker open: RO from the breaker

Breaker closed: RO from the breaker

Breaker ready (optional): RO from the breaker

CB1

Circuit breaker 1

CB2

Circuit breaker 2

Grid or generator

Motor

MVD

VACON® 3000 medium-voltage drive

VACON® 3000 Enclosed Drive

Operating Guide

Safety

N O T I C E

PERSONAL PROTECTIVE EQUIPMENT AND APPROVED TOOLS

When doing electrical work on the AC drive, always use personal protective equipment (PPE) and tools which are approved for

work with medium-voltage devices.

2.5 Main Circuit Breaker

The main circuit breaker (MCB) is an important protection device for the drive. If there is a serious fault in the drive, the MCB immediately disconnects the main supply to the drive. To protect personnel and to prevent further damage to the equipment, the main supply must be disconnected immediately with an open or trip command from the drive.

If the drive is supplied through a dedicated transformer, install the MCB on the primary side of the supply transformer (see Illustra-

tion 1).

Illustration 1: Overview of the Drive System

2.5.1 Safety and Protection Requirements

For safety and protection, the MCB must meet the minimum requirements of the specifications of Danfoss medium-voltage drives. The minimum requirements for the MCB are stated in this manual and in the respective MCB specifications, which are available for each medium-voltage drive from Danfoss. The system integrator must make sure that the minimum requirements are met.

The safety requirements for the drive are based on the following standards:

•

EN ISO 13849-1: Safety of machinery, Safety-related parts of control systems, General principles for design, section 6.2.6 Category 3

•

UL347A, Edition 1: Standard for Medium Voltage Power Conversion Equipment

2.5.2 Minimum Requirements for MCB and MCB Control

Requirements

To meet the stipulated safety requirements, Danfoss requires the following:

•

MCB is equipped with 2 independent opening coils.

•

MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage.

•

Route the MCB open and trip commands directly from the drive to the MCB.

Do not route the trip command through any PLC or DCS (distributed control system) which is not certified to meet SIL 3level requirements and to fulfill the given timing requirements.

Opening of the MCB by the drive must be possible at any time. Do not interrupt the open and trip commands, for example, by a local-remote switch in the MCB.

VACON® 3000 Enclosed Drive

Operating Guide

•

Closing the MCB locally is not permitted. When the MCB is in the service position, the drive must have exclusive control of closing the MCB.

•

The maximum opening time of the MCB must never exceed the product or project specific maximum time defined in the MCB specifications.

•

Typical maximum protection and safety trip time for the drive: 60 ms

Recommendations

To meet the stipulated safety requirements, Danfoss recommends the following:

•

Provide an upstream protection coordination scheme which uses the "breaker failure" (ANSI 50BF) signal to trip the upstream breaker automatically, in case the MCB does not open.

•

After a failure has occurred, the upstream breaker must open within the maximum protection and safety trip time.

Safety

e30bg963.10

VACON® 3000 Enclosed Drive

Operating Guide

Product Overview

3 Product Overview

3.1 Intended Use

VACON® 3000 is a liquid-cooled AC drive for stepless speed or torque control of medium-voltage induction motors. VACON® 3000 Enclosed Drive is a complete medium-voltage drive installed in a cabinet.

VACON® 3000 Enclosed Drive is available for industrial applications with motor voltages of 3300 V and 4160 V, and in a power range starting from 2 MW. Basic configurations have a power of 2 MW or 3 MW. These configurations can be paralleled for systems of 4 MW and above.

Two different drive configurations are available:

•

Regenerative, with an active front-end (AFE)

•

Non-regenerative, with a 12-pulse diode front-end (DFE)

Illustration 2: Example of the VACON® 3000 Enclosed Drive

3.2 Product Description

3.2.1 AFE Drive

An example diagram of the regenerative VACON® 3000 Enclosed Drive is shown in Illustration 3. The main components of the drive are:

•

The active front-end (AFE) unit includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are installed in parallel to make a 3-phase converter. The AFE converts the supplied AC voltage to DC voltage. It also enables the supply of power to the supply network when the motor is braking.

•

The inverter unit (INU) includes 3 or 6 of the same liquid-cooled 1-phase modules, which are used in the AFE. The INU converts the DC voltage to the AC voltage and frequency supplied to the motor.

•

The LC filter (FLC) limits harmonic current on the supply network.

•

The pre-charge unit (PRC) charges the DC-link capacitors.

•

The AFE and INU control units (CNU-AFE/CNU-INU) are connected to the power conversion units with optical fibers.

•

The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV section of the cabinet.

The basic VACON® 3000 AFE drive is intended for installations, where the system is supplied by a dedicated transformer and the source impedance is small. These installations are usually on land. The drive includes an LC filter instead of an LCL filter, because the supply side inductance is included in the dedicated transformer.

It is recommended to install a dedicated transformer for the drive. If the drive is not supplied by a dedicated transformer (that is, there are other loads than the drive on the same supply):

CCM

LGI LCM LCV

CNU-AFE CNU-INU

3 x PCU

PRC

CSH

INUAFEFLC+PICM

MV~

+PODU

+POSI

Motor

LV~

e30bg606.10

AXU-IOB

CCM

Motor

CDC

PCU

3 x PCU

CNU-INU

AXU-IOB

PRC

MV~

LV~

MV~

12P-DFE

INU

+PODU

+POSI

e30bg607.10

VACON® 3000 Enclosed Drive

Operating Guide

•

Install the drive in a high resistance grounding system with a resistance grounded neutral point.

•

Install an input common-mode filter (option +PICM).

Product Overview

If the source impedance is high, select the +PHSI option. See 11.2.7 Source Impedance Specifications. For operation in an IT network without a dedicated transformer, contact Danfoss. For the full main circuit diagrams, see 11.3.1 VACON® 3000 AFE Main Circuit Diagrams.

Illustration 3: Example Main Circuit Diagram of a VACON® 3000 AFE Drive

3.2.2 12-Pulse Drive

An example diagram of the 12-pulse non-regenerative VACON® 3000 Enclosed Drive is shown in Illustration 4. The main components of the drive are:

•

The diode front-end unit (DFE) is a liquid-cooled 12-pulse power conversion unit (PCU), which changes the supplied AC voltage to DC voltage. The 12-pulse configuration is used to limit harmonics on the supply network.

•

The inverter unit (INU) includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are installed in parallel to make a 3-phase converter. The INU converts the DC voltage to the AC voltage and frequency supplied to the motor.

•

The pre-charge unit (PRC) charges the DC-link capacitors.

•

The INU control unit (CNU-INU) is connected to the inverter units with optical fibers.

•

The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV section of the cabinet.

The 12-pulse DFE must be supplied by a dedicated transformer with two secondary windings. For the full main circuit diagrams, see 11.3.2 VACON® 3000 12-Pulse Main Circuit Diagrams.

Illustration 4: Example Main Circuit Diagram of a VACON® 3000 12-Pulse Drive

3.3 Type Code Description

The type code for VACON® 3000 has five basic parts (1–5) and option codes (6).

5 6

ACON3000 - ED - 4Q - 0425 - 03 +XXXX +YYYY +ZZZZ

e30bg964.10

Input voltage [V]

3300

4160

Output current [A]

0425

0340

0640

0510

0820

0650

1230

0980

Option Code

Option Description

+PICM

(1)

Input common-mode filter The option is only available for AFE drives. Always include the input common-mode filter in VACON® 3000 AFE installations, which are not supplied by a

dedicated transformer.

+PODU

(1)

dU/dt output filter

+POSI

(1)

Sine-wave output filter

+POCM

(1)

Output common-mode filter Contact Danfoss to check the common-mode capacitor option selection.

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 5: VACON® 3000 Type Code Structure

Product Overview

1. Product series

VACON® 3000. This part of the code is always the same.

2. Product class

The VACON® 3000 product.

•

ED: Enclosed Drive

3. Drive type

There are two different drive types available. All kits include an inverter unit (INU) as default. The front-end type is specified in the type code.

•

4Q: A regenerative drive with an active front end (AFE) and an LC input filter, supplied through a dedicated transformer. If the drive is not supplied by a dedicated transformer, install a common-mode filter (available with option code +PICM).

•

12: A non-regenerative drive with a 12-pulse diode front end (DFE) rectifier and external DC capacitors. A dedicated transformer with 2 secondary windings is necessary.

4. Nominal output current

See the available output currents in

Table 2.

Table 2: Available Output Current Ratings

5. Nominal input voltage

Nominal supply voltage: 03 = 3300 V or 04 = 4160 V.

6. Option codes

Optional components. See the available codes in 3.4 Available Options.

3.4 Available Options

Table 3: Available Options for VACON® 3000 Enclosed Drive

Option Code

Option Description

+DBCU

(1)

Brake chopper unit for dynamic braking The option does not include a brake resistor. The option is for 12-pulse drives. If a brake chopper is required for an AFE drive, contact Danfoss.

+PHSI

High source impedance Option for installation locations with high source impedances (~10–15% SI). For example, marine applications

usually have a high source impedance. The option affects the size of the input filters. The default installation location has small source impedance (SSI).

This option is only available for AFE drives. Examine each application one by one. To see if this option is necessary, find out the source impedance and see

11.2.7 Source Impedance Specifications. If necessary, consult Danfoss.

+SC__ +SD__ +SE__

C, D, and E slot option boards Default: No option boards in slots C, D, and E. See the available option boards in Table 4.

+QSTO

Safe torque off functionality. Only available for AFE drives.

+QFV1 +QFV2

Control and fan supply voltage 115 V (default for 4160 V) 230 V (default for 3300 V)

+PGDR +PGDN

Grounding of the heat sink and connection of the grounding resistor in power modules R: DC neutral-to-ground resistor connected (default) N: DC neutral-to-ground resistor not connected

+PLIN +PLDI

Liquid cooling options IN: Industrial water and grounded heat sink DI: Deionized water and floating heat sink

+PUFE

Short-circuit current rating: 40 kA, for 100 ms. Available only for AFE drives.

+PGC0

Common-mode capacitor to ground removed

+PLCT

Coolant input from the top

+PHET +PH00

Heat exchanger option ET: Titanium liquid-to-liquid heat exchanger included 00: Liquid-to-liquid heat exchanger not included

+QP24 +QP40 +QP48

Precharge input voltage 240 V 400 V (default for 3300 V) 480 V (default for 4160 V)

+GAUL

cUL certificate

+GACE

EU declaration, CE approval

+GADN

Marine approval DN: Det Norske Veritas

VACON® 3000 Enclosed Drive

Operating Guide

Product Overview

Option Code

Option Description

+GALR

LR: Lloyd's Register

Slot C

Slot D

Slot E

Option Board

(1)

+SCB1

+SDB1

+SEB1

I/O board OPTB1: 6 x Digital input/digital output, programmable

+SCB2

+SDB2

+SEB2

I/O board OPTB2: 1 x relay output (NO/NC), 1 x relay output (NO), Thermistor

+SCB4

+SDB4

+SEB4

I/O board OPTB4: 1 x analog input, 2 x analog output (isolated)

+SCB5

+SDB5

+SEB5

I/O board OPTB5: 3 x relay output

+SCB9

+SDB9

+SEB9

I/O board OPTB9: 1 x relay output, 5 x digital input (42–240 V AC)

+SCBF

+SDBF

+SEBF

I/O board OPTBF: 1 x analog output, 1 x digital output, 1 x relay output

+SCBH

+SDBH

+SEBH

I/O board OPTBH: 3 x Temperature measurement (support for PT100, PT1000, NI1000, KTY84-130, KTY84-150, KTY84-131 sensors)

+SDD3

+SED3

Adapter board OPTD3: RS232 adapter

+SDE3

+SEE3

Fieldbus board OPTE3: PROFIBUS DP-V1 (Screw connector)

+SDE5

+SEE5

Fieldbus board OPTE5: PROFIBUS DP-V1 (D9 connector)

+SDE6

+SEE6

Fieldbus board OPTE6: CANopen

+SDE7

+SEE7

Fieldbus board OPTE7: DeviceNet

+SDE9

+SEE9

Fieldbus board OPTE9: 2-port Ethernet

+SDEA

+SEEA

Fieldbus board OPTEA: Advanced 2-port Ethernet

+SDEC

+SEEC

Fieldbus board OPTEC: EtherCAT

VACON® 3000 Enclosed Drive

Operating Guide

The nominal current and voltage selected in the type code of the VACON® 3000 affect this option. The correct size and number of parts is supplied

automatically. If a different size or number of parts is needed, an order for separate parts is possible.

Table 4: Available Option Boards for Slots C, D, and E

Product Overview

For a 12-pulse drive, the option includes one board. For an AFE drive, the option includes two boards, one for the AFE control unit and one for the

INU control unit. If the drive also has the brake chopper option (+DBCU), the option includes one more board for the brake chopper control unit.

VACON® 3000 Enclosed Drive

Operating Guide

Receiving the Delivery

4 Receiving the Delivery

4.1 Checking the Delivery

After removing the packaging, examine the drive for transport damages.

If the drive was damaged during the shipping, speak to the cargo insurance company or the carrier.

To make sure that the delivery is correct, compare the type code for the order to the type code on the package label. The type code specifies the drive type, nominal output current, nominal input voltage, and option codes. See 3.3 Type Code

Description.

If the delivery does not agree with the order, speak to the vendor immediately.

4.2 Storage

N O T I C E

LIQUID IN THE HEAT SINK

If the cooling liquid is not removed from the heat sink before storage or shipping, the liquid can freeze and damage the drive.

Always remove the cooling liquid from the heat sink before storage or shipping.

If the AC drive is kept in storage, keep it in controlled conditions.

•

Storage temperature: -40…+70°C (-40... +158°F). If the storage temperature is below 0°C (+32°F), make sure that there is no cooling liquid in the heat sink.

•

Relative humidity: < 96%, no condensation

Keep the equipment sealed in its packaging until installation.

4.3 Lifting and Moving the Enclosed Drive

W A R N I N G

LIFTING HEAVY EQUIPMENT

Follow local safety regulations for lifting heavy weights. Failure to follow recommendations and local safety regulations can result

in death or serious injury.

Ensure that the lifting equipment is in proper working condition.

The cabinets must be moved vertically. Always refer to the shipping marks on the package for more information. Do not remove the package material before installing the AC drive.

To lift the cabinets, use a lifting device that can lift the weight of the cabinets. There are lifting holes on the top of the cabinets. Use these holes to lift the cabinets and to move them to the installation location. The minimum angle between the cabinets and the chain is 60°.

To divide the weight of the cabinets equally, and to prevent damage to the equipment, always use 4 lifting holes. Align the lifting locations with the horizontal center of gravity.

e30bg965.10

>60°

e30bg966.10

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 6: Lifting the Cabinets

Receiving the Delivery

You can use rollers, for example, to move the cabinets. Move the cabinets carefully. Switchgear parts can easily fall because their center of gravity is high up at the back of the cabinets.

Illustration 7: Moving the Cabinets

When the cabinet is in the installation location, it can be necessary to make small adjustments to the position of the cabinet. Use a crowbar to move the cabinet from the special hooks on the cabinet base.

Remove the moving hooks from the base of the cabinet before installation.

e30bg967.10

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 8: Hooks on the Cabinet Base for Adjusting the Position of the Cabinet

Receiving the Delivery

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

5 Mechanical Installation

5.1 Operating Environment

N O T I C E

CONDENSATION

Moisture can condense on the electronic components and cause short circuits.

Avoid installation in areas subject to frost.

Install space heaters to warm the air inside the cabinets. Before powering the drive, run the cooling pumps to warm up the components, until the drive is warmer than the ambient air.

N O T I C E

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. For specifications regarding ambient conditions, see 11.2.5 Ambient Conditions.

5.2 Cabinet Installation

Installation guidelines:

•

Locate the drive as near to the motor as possible.

•

Ensure unit stability by mounting the enclosure on a solid surface.

•

Make sure that the level of the floor is in permitted limits. The maximum deviation from the basic level can be no more than 5 mm (0.197 in) along a 3 m (9.84 ft) distance. The maximum permitted height difference between the cabinet front and rear edges is 2 mm (0.079 in).

•

Ensure that the strength of the mounting location supports the unit weight.

•

It is not recommended to install the cabinet directly against a wall.

•

Attach the cabinet to the floor. There are holes in the base of the cabinet which can be used for the installation.

•

Ensure that there is enough space around the unit for proper cooling.

•

Ensure that there is enough room to open the cabinet doors and for working on the equipment.

•

Remove the moving hooks from the base of the cabinet before installation.

A C

e30bg968.10

A–C

See the dimensions in Table 5.

Type code

Dimension A

Dimension B

Dimension C

VACON3000ED-4Q-0425-03

2400 mm (7 ft 10.5 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0640-03

2600 mm (8 ft 6.4 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0820-03

3800 mm (12 ft 5.6 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-1230-03

4400 mm (14 ft 5.2 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0340-04

2400 mm (7 ft 10.5 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0510-04

2600 mm (8 ft 6.4 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0650-04

3800 mm (12 ft 5.6 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-4Q-0980-04

4400 mm (14 ft 5.2 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0425-03

2400 mm (7 ft 10.5 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0640-03

2600 mm (8 ft 6.4 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0820-03

3400 mm (11 ft 1.9 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-1230-03

3800 mm (12 ft 5.6 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

5.3 Dimensions of the Enclosed Drive

Illustration 9 and Table 5 show the dimensions of the basic VACON® 3000 Enclosed Drive. Some options can affect the total width or

height of the cabinet. Always refer to the delivery-specific information for the accurate dimensions.

Illustration 9: Dimensions of the VACON® 3000 Enclosed Drive

Table 5: Dimensions of the VACON® 3000 Enclosed Drive

Type code

Dimension A

Dimension B

Dimension C

VACON3000ED-12-0340-04

2400 mm (7 ft 10.5 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0510-04

2600 mm (8 ft 6.4 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0650-04

3400 mm (11 ft 1.9 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON3000ED-12-0980-04

3800 mm (12 ft 5.6 in)

2130 mm (6 ft 11.9 in)

1000 mm (3 ft 3.4 in)

VACON® 3000 Enclosed Drive

Operating Guide

5.4 Liquid Cooling Requirements

5.4.1 Safety in Liquid-cooling

W A R N I N G

POISONOUS COOLANTS

Glycols and inhibitors are poisonous. If touched or consumed, they can cause injury.

Prevent the coolant from getting into the eyes. Do not drink the coolant.

C A U T I O N

HOT COOLANT

Hot coolant can cause burns.

Avoid contact with the hot coolant.

Mechanical Installation

C A U T I O N

PRESSURIZED COOLING SYSTEM

Sudden release of pressure from the cooling system can cause injury.

Be careful when operating the cooling system.

N O T I C E

INSUFFICIENT COOLING CAPACITY

Insufficient cooling can cause the product to become too hot and thus become damaged.

To make sure that the cooling capacity of the cooling system stays sufficient, make sure that the cooling system is vented

and that the coolant circulates properly.

5.4.2 General Information on Liquid Cooling

VACON® 3000 drives are liquid-cooled. The liquid circulation of the drive is connected to a heat-exchanger that cools down the liquid circulating in the cooling elements of the drive. The power modules have aluminum heat sinks, which give good and safe temperature control. Because the cooling elements are made of aluminum, the cooling liquids allowed to be used are inhibited pure water, inhibited demineralized water, or an inhibited mixture of water and glycol.

The inductors of the input and output filters use air-to-liquid heat exchanger units for forced air cooling. The heat exchangers decrease the heat losses to the air and thus decreases the number of fans necessary for cooling the cabinet.

There are two types of cooling systems: open systems and closed systems. An open system has no pressure but the hydrostatic and pumping pressure. It allows free contact between the cooling liquid and

air. Air is continuously dissolved into the cooling liquid. In a closed system, the piping is air-tight and there is a preset pressure inside the pipes. The pipes must be made of metal, or a

specific plastic or rubber that includes an oxygen barrier that limits the diffusion of oxygen. Minimizing of oxygen content in the cooling liquid decreases the risk of corrosion of the metal parts. Closed systems usually have an expansion vessel that allows for a safe change of volume of the cooling liquid due to temperature changes.

Always use a closed system with Danfoss liquid-cooled drives.

Property

Required value

6...8

Chlorides

≤ 25 ppm

Sulphate ions

≤ 25 ppm

Maximum particle size

≤ 50 µm

Total dissolved solids

≤ 200 ppm

Total hardness (CaCO3)

3…4.6 dH° (53…80 ppm)

Hydrogen carbonate

≤ 50 ppm

Electrical conductivity

≤ 500 µS/cm

VACON® 3000 Enclosed Drive

Operating Guide

5.4.3 Cooling Liquid

5.4.3.1 Quality Requirements for the Purified Water

N O T I C E

DAMAGE TO SYSTEM FROM THE USE OF HYDROCARBONS

Hydrocarbons damage the rubber seals of the cooling system.

Do not use hydrocarbons (for example mineral oil) as coolant. Do not mix hydrocarbons to coolant.

Table 6: Requirements for the Purified Water

Mechanical Installation

5.4.3.2 Purified Water as Coolant

Purified water can be used as coolant if there is no risk of freezing. Freezing water permanently damages the cooling system. Purified water is demineralized, deionized, or distilled water.

Always use an inhibitor Cortec VpCI-649 with 1.0% of volume with purified water.

C A U T I O N

CORROSION HAZARD WITH DRINKING WATER

Some components are made of aluminum, which has limited corrosion resistance against high chloride concentrations. Drinking

water can have a chloride concentration of 250 ppm, which increases the aluminum corrosion rate. High chloride concentration

exposes aluminum especially to pitting corrosion which can damage the system relatively quickly.

Use purified (demineralized, deionized, or distilled) water with corrosion inhibitors.

5.4.3.3 Antifreeze Mix as Coolant

The following antifreeze products are a good general solution for liquid cooling since they provide freeze protection and corrosion protection.

The allowed antifreeze coolants are the following ethylene glycols and propylene glycols.

Ethylene glycols

•

DOWCAL 100

•

Clariant Antifrogen N

Propylene glycols

•

DOWCAL 200

•

Clariant Antifrogen L

These glycols already include corrosion inhibitors. Do not add any other inhibitor. Do not mix different glycol qualities because there can be harmful chemical interactions.

VACON® 3000 Enclosed Drive

Operating Guide

The glycol concentration of the coolant must be 25–55% by volume, according to the specified ambient temperature. Higher concentration reduces cooling capacity. Lower concentration results in biological growth and inadequate amount of corrosion inhibitors. Antifreeze must be mixed with purified water according to 5.4.3.1 Quality Requirements for the Purified Water.

Mechanical Installation

5.4.3.4 Temperature of the Cooling Liquid

To gain full performance of the product, the temperature of the cooling liquid entering the drive components must be a maximum of 43°C (109°F) and above the dew point. While circulating inside the cooling element, the liquid transfers the heat produced by the power semiconductors and other components. The temperature rise of the cooling liquid during the circulation is typically less than 4°C (7.2°F). Typically, more than 95% of the power losses are dissipated in the cooling liquid. It is recommended to equip the cooling circulation with temperature supervision.

The secondary circuit maximum temperature must always be lower than the primary circuit temperature. The temperature difference must be at least 5°C (9°F) with equal flow. The temperature difference is necessary for the correct operation of the heat exchanger.

There are 3 external causes that affect the nominal temperature of the primary circuit:

•

The maximum ambient temperature at the drive installation location.

•

The maximum relative humidity at the drive installation location.

•

The maximum secondary circuit liquid temperature.

All these causes must be examined when calculating the primary circuit temperature. The primary circuit temperature can be different for each installation.

5.4.3.5 Condensation

Condensation must be avoided. Always keep the temperature of the cooling liquid a minimum 2°C (3.6°F) above the dew point. Use the graph in Illustration 10 to see if the conditions (combination of room temperature, humidity, and cooling liquid temperature) are safe for the drive to operate.

The conditions are safe when the point is below the related (cooling liquid temperature) curve. If they are not, decrease the ambient temperature or the relative humidity. Also the cooling liquid temperature can be increased. Note, that if the cooling liquid temperature is increased above the figures in loadability charts, it decreases the nominal output current of the drive. The curves in Illustra-

tion 10 are valid at sea level altitude (1013 mbar/14.69 psi).

If the temperature of the liquid in the secondary circuit is lower than the ambient temperature and the relative humidity is high, condensation can occur on the secondary circuit pipes and the plate heat exchanger in the HX unit. The condensation is not dangerous, but it is not recommended. If there is condensation in the HX unit, it can cause the leak sensor in the cabinet to give a leak alarm. If a leak alarm occurs again and again, install insulation in the secondary circuit pipes and the plate heat exchanger. The insulation stops the condensation and thus prevents the incorrect leak alarms.

0 (32)

10 (50)

20 (68)

30 (86)

40 (104)

50 (122)

60 (140)

e30bg701.10

100

amb

, °C (°F)

Tc, °C (°F)

RH (%)

45 (113) 40 (104) 38 (100) 35 (95) 30 (86) 25 (77) 20 (68)

Relative humidity

amb

Ambient temperature

TcCooling liquid temperature

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

Illustration 10: Safe Operating Conditions in Relation to Condensation

Example Safe Operating Conditions

If the ambient temperature is +30°C (+86°F), the relative humidity is 40% and the cooling liquid temperature is +20°C (+68°F, the lowest curve in Illustration 10), then the drive operation conditions are safe.

If the ambient temperature increases to +35°C (+95°F) and the relative humidity to 60%, then the operation conditions of the drive are not safe. To get safe operation conditions, the ambient temperature must be decreased to +28°C (+82°F) or below. If it is not possible to lower the ambient temperature, then the cooling liquid temperature can be increased to +25°C (+77°F) or above.

Example Dew Point and Primary Circuit Temperature

If the ambient temperature and the maximum relative humidity at the drive installation location is known, the dew point chart (see

Illustration 11) can be used to find the correct temperature for the primary circuit.

•

Ambient temperature = 35°C (95°F)

•

Maximum relative humidity = 60%

According to the diagram in Illustration 11, the dew point for the given values is 26°C (78.8°F). Always keep the temperature of the cooling liquid a minimum 2°C (3.6°F) above the dew point. Thus the primary circuit minimum temperature is set to 28°C (82.4°F).

The secondary circuit maximum temperature must always be 5°C (9°F) lower than the primary circuit temperature. Thus, in this example, the secondary circuit temperature must be below 23°C (73.4°F) during operation.

Notice, that these conditions are valid for the starting of the drive. After the start, the temperature inside the cabinet starts to increase and the humidity decreases.

Tamb (°C/°F)

2364396438461050125414571661186420682272247526792882308632903493369738

100401044210844111461154811850122°C°F

°C °F

100

10 50

15 59

20 68

25 77

30 86

35 95

104

113

122

Tc (°C/°F)

RH (%)

e30bg702.10

Relative humidity

amb

Ambient temperature

TcPrimary circuit temperature

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

Illustration 11: Dew Point Diagram for Ambient Temperatures between +10°C...+50°C (+50°F...+122°F) at 1013 mbar (14.69 psi)

5.4.4 Cooling System

5.4.4.1 Materials

COPPER OR COPPER ALLOY PARTS DAMAGE THE SYSTEM

Using copper or copper alloy pipes or parts in contact with the cooling liquid damages the system.

Do not use pipes made of copper or alloys that include copper. If metallic pipes are used in the cooling system, use alumi-

num or stainless steel pipes.

Allowed materials in the cooling system

These materials are allowed in the cooling system if they are compatible with the cooling liquid:

•

Aluminum (EN-AW6060, EN-AW6063, or EN-AW6082)

•

Stainless steel (AISI 304/316)

•

Plastic*

•

Elastomers (EPDM, NBR, FDM)*

* If plastic or elastomers are used, check material compatibility within the temperature range of the cooling liquid. See the specifications in 11.2.6 Cooling.

Do not use PVC, copper, brass, or other materials not compatible with the heat sink material or cooling liquid.

Recommended material for pipes

C A U T I O N

= =

≈

≈≈

AFE

Bleeding

Filling

Temperature control

Drain

Liquid to air

heat exchangers

INU

≈

≈ ≈

e30bg969.10

Heat exchanger

Level indication

Level switch

Motor

Pump

Pressure indication

Pressure transmitter

TankTTTemperature transmitter

VACON® 3000 Enclosed Drive

Operating Guide

•

PA11

•

PA12

•

PEX with oxygen barrier

•

PEX-AL-PEX

Mechanical Installation

The electrical resistance of the plastic and rubber pipes must be >109 Ω.

5.4.4.2 Cooling System Overview

The cooling system has a bypass valve in the primary line and valves at each power module inlet. They make it possible to open and clean the cooling system. Open the bypass valve and close the valves to the AC drive when cleaning the system. While commissioning the system, close the bypass valve and open the valves to the AC drive.

The cooling system has temperature, pressure, and leak supervision. They can be connected to the External fault digital input function. If the cooling liquid flow or pressure is too low, the temperature too high or of there is a leak, the supervision stops the drive.

Illustration 12: The Cooling System of the VACON® 3000 Enclosed Drive

5.4.4.3 Cooling Connections to the Enclosed Drive

Connect the cooling pipes to the heat exchanger at the top on the right side of the cabinet. See the locations of the input and output pipe connections in Illustration 13.

e30bg970.10

Cooling liquid input

Cooling liquid output

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

Illustration 13: Locations of the Cooling Connections

5.5 Cooling and Free Space Around the Enclosed Drive

The VACON® 3000 Enclosed Drive is a liquid-cooled AC drive, but in a liquid-cooled drive system, there are always some heat losses to the air. The heat losses come from

•

busbars,

•

filters,

•

inductors,

•

other auxiliary components.

The AC drive uses liquid-to-air heat exchangers to cool the hot air from the inductors and other components. Fans in the cabinet walls move the air between the cabinet sections. The structure of the cabinet is such, that the air can move freely through the cabinet.

There must be a minimum of 20 cm (7.87 in) of space above the cabinet without structures that can stop the airflow. Make sure that the hot air goes out of the cabinet and does not come back into the cabinet. Some free space in front of the drive is also necessary for maintenance.

The power loss of the AC drive can change significantly, when the load, the output frequency or the switching frequency changes. It is useful to know the power loss, when planning the cooling equipment in an electrical room.

VACON® 3000 Enclosed Drive

Operating Guide

Mechanical Installation

e30bg713.11

Illustration 14: The Liquid-to-Air Heat Exchangers and Fans Used to Cool the Components in the Cabinets

AFE

CSH

INU

CCM CCM

+PODU

+POSI

GSW

PTR

400/

480V

e30bg978.10

230/

120V

CNU-AFE

Aux I/O

CNU-INU

AIT

APS

PCU

LCVLGIMCB

LCM

Arc

flash

detector

SPD

Cab

heater

Cab

heater

Cabinet

over temp

indicator

Cabinet

over temp

indicator

24 V - 20 A

Panel

lighting

Panel service socket

L N PE

LSI

LCV

LCM

LGI

PRC

GSW

MCB

COT COT

DSI

Door safety

interlocks

HXLA

4160/ 3300V

Motor

LOW-VOLTAGE SECTIONMEDIUM-VOLTAGE SECTION

Liq to air

Power module

cabinet

Thermostat

Humidity

Magnetics

cabinet

Magnetics

cabinet

Magnetics

cabinet

PRC

Humidity

HX Run O

I HX OK

Leak

detector

PS-BRK

MTR

ESW

HMI

O - MX Start

I - KMX Status

I - VCB Status

O - VCB Close

O - MX Permissive

I - Power On I - Power Off I - GND SW Unlock I - Arc Guard Online I - Arc Guard Trip I - HX OK I - User Interlock

APS

24 V-10 A

Liq to airHXLiq to air

Door safety

interlocks

Relay

Logic

L N

Galvanic isolation between the MV and LV sections

LV supply for the isolation transformer (AIT)

Optical fiber connections

Supply voltage feedback from the potential transformer (PTR) to the AFE control unit

LV supply for the pre-charge unit (PRC)

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6 Electrical Installation

6.1 Galvanic Isolation Between the MV and LV Sections

There is galvanic isolation between the low-voltage (LV) and medium-voltage (MV) sections of the cabinet. The insulation between the sections gives the devices in the LV section protection from the MV section voltages. Illustration 15 shows which components are installed in the MV and LV sections.

All connections between the LV and MV sections are done with optical fiber cables. The only LV connections between the MV and LV sections are:

•

The LV supply for the pre-charge unit (PRC)

•

The LV supply for the isolation transformer (AIT)

•

The supply voltage feedback from the potential transformer (PTR) to the AFE control unit

Illustration 15: Connections between the MV and LV Sections of the Cabinet

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VACON® 3000 Enclosed Drive

Operating Guide

Illustration 16: Locations of the Low-Voltage Sections in the VACON® 3000 Enclosed Drive

Electrical Installation

6.2 Mains and Motor Cable Selection

C A U T I O N

UNEQUAL LOAD

If the cable installation is not symmetrical, unequal load can occur in AC drives with parallel inputs or outputs. The unequal load

can decrease loadability or damage the drive.

In drives with parallel inputs or outputs, make sure that the cable size, cable length, cable type, and routing is the same for all

parallel cables.

Use cables with a nominal voltage U0/U of 3.6/6 kV and maximum voltage 7.2 kV. The size and type of the cable depends on the application of the drive. The cable size is also affected by:

•

The current at continuous load,

•

the permitted short-circuit current,

•

the installation conditions.

To decrease EMI, use shielded 3-phase cables for the motor connection. If single-core cables are used in the input or output, they must be shielded.

When selecting the cable, refer to the input voltage and the load current of the drive. Obey all applicable standards and local safety regulations.

Example Mains Cables for the VACON® 3000 4160 V 510 A AFE Drive

The recommendation for the VACON® 3000 4160 V 510 A AFE drive, is to use two 240 mm2 (500 kcmil) M2N type cables (available from Liban Cables/Nexans) for each phase. The cables are 3.6/6 kV copper cables with one core, XLPE insulation, a PVC cover, shielded, and unarmored.

6.3 Mains and Motor Cable Inlet and Termination

There are cable entries at the top and bottom of the cabinet sections for the mains and motor cables. If an output filter option is installed, cabling from the bottom is not possible.

W V U

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The mains terminals (L1, L2, L3)

The motor terminals (U, V, W)

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 17: The Mains and Motor Terminal Locations

Electrical Installation

Connect the mains cables to terminals L1, L2, and L3 in the mains input section. Connect the motor cables to the inverter section terminals U, V, and W. Make openings for the cables in the grommets on the bottom or top of the cabinet and push through the cables. Use cable clamps to attach the cables. Always connect the PE conductors of the mains and motor cables to the PE busbar.

In units with parallel motor outputs, do not connect the motor cables together in the AC drive end. Always connect the parallel motor cables together in the motor end only. The minimum motor cable length is 5 m (16.4 ft).

Use medium-voltage cable lugs to connect the cables to the busbar terminals. Use heat shrink or cold shrink cable termination kits on the cables, for example, the kits HIT1.1204L or CIT1.1204L available from Ensto.

The output cables to the motor must be 360° EMC grounded, for example, by installing EMC grounding clamps at the cable inlet. To make a 360° connection with the grounding clamps and the cable shield, strip the cables. The EMC grounding clamps must be the correct size to give a 360° contact with the cable shield.

e30bg732.10

Cable grommet

Cable clamp

360° EMC grounding

PE busbar

Cable termination

Cable lug

e30bh726.10

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

Illustration 18: Example of a 1-phase Motor Cable Inlet to the Cabinet

Illustration 19: Example of a 3-phase Motor Cable Inlet to the Cabinet

Cable entry seal with 360° EMC grounding

PE busbar

Cable termination

Cable lug

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VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6.4 Grounding

Ground the AC drive in accordance with applicable standards and directives. In the specified ground fault conditions, the current density in the grounding conductor, if of copper, must not be more than:

•

200 A/mm2 for a short circuit of 1 s, and

•

125 A/mm2 for a short circuit of 3 s.

But, the cross-sectional area of the grounding conductor must not be less than 30 mm2 (AWG2). Refer to IEC62271-200.

There is a protective earthing (PE) busbar at the bottom front of the cabinets. Connect the PE rail to an external ground at the installation location as is approved in the applicable regulations. Obey the local regulations on the minimum size of the protective earthing conductor.

Illustration 20: The Grounding Busbar

The power module grounding terminals, the DC link neutral point, the grounding switch, and the transient voltage suppressors are connected to the PE rail. Also the frames of the inductors and capacitors are grounded.

Always connect the PE conductors of the mains and motor cables to the PE busbar. The output cables to the motor must be 360° EMC grounded. To make a 360° connection with the grounding clamps and the cable shield, strip the cables. Ground the motor cable shield at the drive and motor ends of the cable.

6.4.1 Standard Grounding Configurations

CLF

CAB

3 3 3 3

DC+ DC0 DC-

MVC

CCM

GND

GND GND

e30bh722.10

CAB

Drive cabinet frame

MV circuit breaker or fused contactor

CCM

Grounding capacitor

CLF

CL filter

GND

Grounding busbar

MV motor

MVC

MV cable

MV transformer (secondary side ungrounded)

LCL

CCM

LCM

CAB

DC+ DC0 DC-

MVC

MVS

GND

GND GND

M 3~

e30bh723.10

CAB

Drive cabinet frame

MV circuit breaker or fused contactor

CCM

Common-mode capacitor network (used in gridconnected systems only)

GND

Grounding busbar

LCL

LCL filter

LCM

Common-mode inductor

MV motor

MVC

MV cable

MVS

MV source (ungrounded or impedance grounded only)SPStar point of shunt capacitor

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 21: Grounding of Transformer-Isolated Drives

Electrical Installation

Illustration 22: Grounding of Grid-Connected Drives

6.5 Additional Instructions for Cable Installation

•

Before starting the installation, make sure that none of the components of the AC drive is live. Read carefully the warnings in the Safety section.

•

Make sure that the motor cables are sufficiently far from other cables.

•

The motor cables must go across other cables at an angle of 90°.

•

If it is possible, do not put the motor cables in long parallel lines with other cables.

•

Only use symmetrically EMC shielded motor cables.

•

Make sure that there is sufficient clearance (approximately 25 mm/1 in) between the cables in the cabinet and between the cables and conductor materials.

•

If cable insulation checks are necessary, see 8.5.2 Measuring the Cable and Motor Insulation.

B C D

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~, phase input (AFE) / motor output (INU), size M10

- , DC minus, size M10

0, DC link neutral point, size M10

+, DC plus, size M10

Heat sink terminal, size M6

Ground terminal, size M6

Cooling liquid terminal in (AFE) / out (INU)

Cooling liquid terminal in (INU) / out (AFE)

Optical fiber A

Optical fiber B

24 V supply for control

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6.6 Main Circuit Breaker Installation

Install a main circuit breaker for the short-circuit protection of the AC drive. Use, for example, a fast vacuum circuit breaker. When selecting the size of the mains circuit breaker, refer to the available short circuit power, continuous current, and supply voltage.

The VACON® 3000 AFE drive has a maximum short-circuit current of 31.5 kA. The operation time of the circuit breaker must not be longer than 4 cycles (50 Hz: 80 ms, 60 Hz: 67 ms).

The function of the circuit breaker is to give short-circuit protection. For ground fault protection, install a protection relay and resistors.

6.7 Cabling of the Power Modules

6.7.1 Phase Module L20/L30 Terminals

To make access and installation easy, all terminals are located in the front of the phase modules. Phase, DC, neutral, and ground terminals have sufficient space between them and creepage walls on each side. To make the terminals compatible with different cable lugs, the terminals can be changed by removing screws from the front.

See the functions of the AFE/INU phase module terminals in Illustration 23. If the phase module operates as an AFE or INU, some of the terminals have different functions.

Illustration 23: AFE/INU Phase Module Terminals

6.7.2 DFE Power Module Terminals

In the DFE power module, all terminals are at the front of the module, except the AC input terminals, which are at the back of the module. DC, neutral, and ground terminals have sufficient space between them and creepage walls on each side. To make the DC

B C

e30bi551.10

- , DC minus, size M10

N, DC neutral, size M10

+, DC plus, size M10

Optical fibers

Optical fibers A and B

24 V supply

Cooling liquid terminal in

Cooling liquid terminal out

Heat sink terminal, size M6

Ground terminal, size M6

1L1, phase input

1L2, phase input

1L3, phase input

2L1, phase input

2L2, phase input

2L3, phase input

VACON® 3000 Enclosed Drive

Operating Guide

terminals compatible with different cable lugs, the terminals can be changed by removing screws from the front. The AC terminals have knife type busbar connections for 10 mm (0.39 in) thick busbars.

The functions and locations of the DFE power module terminals are shown in Illustration 24.

Electrical Installation

Illustration 24: Terminals in the Front (left) and Back (right) of the DFE Power Module

6.7.2.1 DFE Control Terminals

The DFE power module has specific terminals for controlling the crowbar circuit in the module. Optical fiber terminals A and B are for Powerbus connection to the auxiliary I/O board.

The optical crowbar circuit control connectors:

•

T: Crowbar TX

•

R: Crowbar RX

•

O: Crowbar fire out

•

FIRE: External crowbar fire in

•

GOOD: Main circuit breaker enable out

To avoid unintentional crowbar firing, protect unused optical connectors with matching covers.

N O T I C E

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e30bg718.10

Grounding terminal

Heat sink terminal

Heat sink grounding jumper

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 25: Control Terminals of the DFE Power module

6.7.3 Power Module Grounding

Electrical Installation

C A U T I O N

GROUNDING THE HEAT SINK

In the power modules, do not remove the grounding jumper between the heat sink terminal and the ground terminal.

Ground all the power modules. Also the heat sinks of all power modules must be grounded. Make sure that the grounding jumper is connected between the heat sink terminal and the ground terminal (see Illustration 26).

Illustration 26: AFE/INU Phase Module Grounding Terminals and Jumper

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Grounding terminal

Heat sink terminal

Heat sink grounding jumper

e30bg719.10

Grounding terminals

Grounding connection busbar

Grounding busbar

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 27: DFE Power Module Grounding Terminals and Jumper

Electrical Installation

Use a busbar to connect all the grounding terminals of the phase modules and power modules to the same grounding busbar. See the example in Illustration 28.

Illustration 28: Phase Module Grounding Connection Busbar Example

6.7.4 DC-Link Connections

The VACON® 3000 power modules and DC capacitors for DFE have three DC terminals: plus (+), minus (-) and neutral (N). Busbars or cables can be used to make the DC-link connections.

DC-link connections in AFE drives

CCM

+ 0

PCU

AFE

PCU

~ ~

+ 0

PCU

INU

PCU

+ 0

CDC

DFE

+ 0

PCU

INU

PCU

1L1 1L2 1L3

PCU

2L1 2L2 2L3

A B

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AFE drive

12-pulse drive

CCM

3 x PCU 3 x PCU 3 x PCU

CDC

DFE

CCM

LCV

2 x CSH

LCV

U V

L1 L2 L3

1L1 1L2 1L3

2L1 2L2 2L3

e30bg721.11

AFE drive

12-pulse drive

VACON® 3000 Enclosed Drive

Operating Guide

•

Connect the output DC terminals of the AFE phase modules to the DC-input terminals of the INU phase modules.

•

Connect the DC-plus terminals of the phase modules together and the DC-minus terminals of the phase modules together.

•

Connect the DC-link neutral points of the phase modules and ground them through the common-mode capacitor (CCM).

•

See circuit diagram A in Illustration 29.

Electrical Installation

DC-link connections in 12-pulse drives

•

Connect the output DC terminals of the DFE power module to the plus (+), minus (-), and neutral (N) terminals of the DC capacitor for DFE (CDC).

•

Connect the DC terminals of the INU phase modules to the plus (+), minus (-), and neutral (N) terminals of the CDC.

•

Ground the DC-link neutral point through the common-mode capacitor (CCM).

•

See circuit diagram B in Illustration 29.

Illustration 29: DC-Link Connections in VACON® 3000 Drives

DC-link connections in VACON® 3000 drives with parallel power circuits

•

Connect the plus, minus, and neutral terminals of the parallel DC links.

•

See the circuit diagrams in

Illustration 30.

Illustration 30: DC-Link Connection Examples for VACON® 3000 Drives with Parallel Power Circuits

CCM

+ 0

PCU

INU

PCU

+ 0

+DBCU

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Brake resistor

Terminal

Size

Tightening Torque

Power terminals

M10

24.5 Nm (217 lb-in)

Ground terminals

5 Nm (44 lb-in)

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6.7.5 Brake Chopper Installation

The brake chopper module is an L20 or L30 phase module. Thus, the electrical and control interface is the same as in AFE and INU phase modules. See 6.7.1 Phase Module L20/L30 Terminals.

•

Ground the brake chopper module in the same way as the other power modules. See 6.7.3 Power Module Grounding.

•

Make the DC-link connections in the same way as for the INU phase modules. See 6.7.4 DC-Link Connections.

Brake resistor connections

•

Connect the brake resistor between the output terminal (~) of the brake chopper unit (+DBCU) and the DC-link neutral point.

The brake resistor is not included in the brake chopper option (+DBCU) delivery. The resistor can be ordered with a separate order code.

Illustration 31: DC-Link and Brake Resistor Connections of the Brake Chopper Unit

6.7.6 Terminal Screw Tightening Torque Specifications

Table 7: Power Module Terminal Screw Tightening Torque Specifications

6.7.7 LED Display on the Phase Module

VOLTAGE INDICATION

The voltage indicators on the phase module are not safety approved. Even if the voltage indicators are off, there can be a danger-

ous voltage in the module. A contact with this voltage can lead to death or serious injury.

In the front of the phase module, there is a four letter LED display and four LED indicators: BBP, BBN, LED1 and LED2. BBP and BBN show if there is voltage in the DC link plus and minus busbars. The functions of LED1 and LED2 are not set.

The LED indicators BBP and BBN use the power from the DC link to operate. That is, if the 24 V supply to the phase modules stops, the LEDs show if the DC link is charged. The LEDs are on when the capacitor DC-link half voltages are >500 V. They start to blink as the voltage drops to <500 V. If the voltages drop to <25 V, the LEDs turn off.

D A N G E R

Even if the voltage indicators are off, before touching the module: Short circuit the DC-link terminals and connect them to ground. Do measurements and make sure that there is no voltage.

BBP BBN LED1 LED2

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Four character LED display

LED indicators

6A 6B

e30bg618.10

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 32: LEDs in the front of the phase module

Electrical Installation

LED Display Operation

The phase module start up sequence starts when the connection between the phase module and control unit is disconnected. Usually the start up occurs when 24 V DC is supplied to the module. Also, the start up sequence occurs during a software update.

LED display modes during phase module start up:

•

1. Reset mode: The display is empty.

•

2. Phase module software setup: The phase module sets up local software.

•

3. Phase module communication setup: After the software setup, the phase module enables communication to the control unit. When the phase module receives the first message from the control unit, the PCU moves to the next mode.

•

4. Control unit setup: Set up between the control unit and the phase module. If the setup is a success, the phase module moves to the next mode.

•

5. Network setup: The last step in the setup. When the phase module receives approval from the control unit, the phase module moves to the operation mode.

•

6. Operation: In the operation mode, the LED display view changes at an interval of 3 s. The display changes between the belt information indicator (6A) and the module information indicator (6B).

Illustration 33: LED Display Modes During Start Up

Belt information: The belt information indicator tells the number of the AFE or INU unit (or belt of three modules) in which the PCU

is installed (see

7.8 Optical Fiber Connections).

The belt information indicator is of type: [ ] [ ] [B] [belt number 1–4].

•

The first two digits are empty.

•

The last two digits show the belt number (B1–B4).

e30bi884.10

Four character LED display

VACON® 3000 Enclosed Drive

Operating Guide

Module information: The module information indicator tells the identification number of the PCU, the unit type (AFE/INU), and the

phase of the module. The module information indicator is of type: [PowerID N_] [PowerID _N] [L = AFE, 'blank' = INU] [1, 2, 3 for AFE; U, V, W for INU].

•

The first two digits show the ID of the phase module.

•

The last two digits show the phase.

AFE: L1, L2, or L3.

INU: _U, _V, or _W.

BCU: RA, RB, or RC.

The PowerID is a 2-digit identification number for each phase module. The ID can be mapped directly to the HMI fault source indication.

Belt and module information examples (see 6A/6B in Illustration 33):

•

[ ] [ ] [B] [1] <-> [ ] [2] [ ] [U] = phase module ID 2, U phase INU in belt 1

•

[ ] [ ] [B] [1] <-> [ ] [4] [ ] [W] = phase module ID 4, W phase INU in belt 1

•

[ ] [ ] [B] [3] <-> [1] [0] [ ] [W] = phase module ID 10, W phase INU in belt 3

•

[ ] [ ] [B] [1] <-> [ ] [2] [L] [1] = phase module ID 2, L1 phase AFE in belt 1

•

[ ] [ ] [B] [1] <-> [ ] [4] [L] [3] = phase module ID 4, L3 phase AFE in belt 1

Electrical Installation

6.7.8 LED Display on the DFE Power Module

There is a four character LED display on the front of the DFE power module. The display functions in the same principle as the display on the phase modules, but the shown belt and module information is different. See 6.7.7 LED Display on the Phase Module.

Illustration 34: LEDs on the Front of the DFE Power Module

Belt information: The belt information indicator tells the number of the channel on the control unit to which the power module is

connected, in this case C5 (see 7.8 Optical Fiber Connections). The belt information indicator is of type: [ ] [ ] [C] [5].

•

The first two digits are empty.

•

The last two digits show the number of the channel.

Module information: The module information indicator tells the identification number of the power module. The number of the first installed DFE power module is 22, the second is 23, and so on.

The module information indicator is of type: [PowerID N_] [PowerID _N] [ ] [ ].

e30bg974.10

Cable entry for low-voltage power supply cables.

Low-voltage power supply connectors.

VACON® 3000 Enclosed Drive

Operating Guide

•

The first two digits show the ID of the power module.

•

The last two digits are empty.

Electrical Installation

6.8 Low-Voltage Power Supplies

6.8.1 Low-Voltage Power Supply Connections

Low-voltage power supplies are necessary for the auxiliary components of the VACON® 3000 Enclosed Drive.

•

3-phase 400/480 V, 50/60 Hz supply for the pre-charge unit and the heat exchanger unit. In drives with parallel power circuits, a separate pre-charge unit is necessary for each parallel circuit. The low-voltage supply to the pre-charge units must be able to supply a power of 10 kVA for each pre-charge unit.

•

1-phase 120 V, 50/60 Hz supply for the control units and auxiliary components in the LV section of the cabinet.

•

1-phase 120 V, 50/60 Hz supply for the auxiliary components in the MV section of the cabinet.

Make sure that the input AC voltage level selection for the pre-charge unit is correct. Ground the cable shields of the LV supply cables.

Illustration 35: The Location of the Low-Voltage Cable Entry and the Power Supply Connectors

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Precharge unit

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6.8.2 Safety Notes for the Precharge Unit

D A N G E R

SHOCK HAZARD FROM THE PRECHARGE UNIT

The precharge unit can supply dangerous high voltages from its low-voltage source (215 V to 480 V AC). A contact with this volt-

age can lead to death or serious injury.

Do not try to energize the precharge unit before the system installation is completed!

Do not bypass the control unit and energize the precharge unit! Make sure that correct lock out and tag out procedures are applied to the low-voltage input of the precharge unit.

C A U T I O N

RISK OF OVERHEATING

Successive precharge operations can overheat the transformer of the precharge unit.

To allow the transformer enough time to cool down, ensure a minimum of 30 minutes between successive precharge opera-

tions.

The correct selection of the voltage selection board prevents the application of incorrect voltage to the transformer input. If there is a fault condition, the 2-pole circuit breaker on top of the precharge unit opens. The breaker opens only in fault conditions

in which inspection or maintenance is necessary. The control unit monitors the DC-link voltage during the precharge sequence and if it senses an unusual condition, stops the se-

quence. Because of the monitoring, do not bypass these protection steps during the commissioning or troubleshooting of the drive. Precharge timeout:

•

The control unit automatically limits the frequency of start ups to a safe value.

6.8.3 Location of the Precharge Unit

The precharge unit or units are typically installed at the top of the output section of the enclosed drive. The location can differ depending on the drive type and configuration.

Illustration 36: The Location of the Precharge Unit

6.9 Safety Functions

The information in this section is valid only if the drive is equipped with the STO option (+QSTO).

VACON® 3000 Enclosed Drive

Operating Guide

Electrical Installation

6.9.1 Safe Torque Off (STO)

Safe Torque Off (STO) is a hardware-based safety function to prevent the drive from generating torque on the motor shaft. The STO safety function has been designed for use in accordance with the following standards:

•

EN 61800-5-2 STO SIL3

•

ENISO 13849-1 PL “e” Category 4

•

EN 62061 SILCL3

•

IEC 61508 SIL3

•

The function also corresponds to an uncontrolled stop in accordance with stop category 0, EN 60204-1.

The STO function is not the same as the prevention of unexpected start-up function. For fulfilling those requirements, more external components are required according to appropriate standards and application requirements. Required external components can be for example:

•

Appropriate lockable switch

•

A safety relay providing a reset function

6.9.2 Safe Stop 1 (SS1)

The SS1 safety function is realized in compliance with type C of the drives safety standard EN 61800-5-2 (Type C: "The PDS(SR) initiates the motor deceleration and initiates the STO function after an application specific time delay").

The SS1 safety function has been designed for use in accordance with the following standards:

•

EN 61800-5-2 Safe Stop 1 (SS1) SIL3

•

EN ISO 13849-1 PL"e" Category 4

•

EN 62061: SILCL3

•

IEC 61508 SIL3

•

The function also corresponds to a controlled stop in accordance with the stop category 1, EN 60204-1.

6.9.3 Safety Considerations

Designing of safety-related systems requires special knowledge and skills. Only qualified personnel are permitted to install and set up the STO functionality.

The use of STO or other safety functions does not in itself ensure safety. An overall risk evaluation is required to make sure that the commissioned system is safe. The safety devices must be correctly incorporated into the entire system. The entire system must be designed in compliance with all relevant standards within the field of industry.

Standards such as EN 12100 (Part 1/Part 2) and ISO 14121-1 provide methods for designing safe machinery and for carrying out a risk assessment.

The information in this manual provides guidance on the use of the STO safety function together with the VACON® 3000 Enclosed Drive. This information is in compliance with accepted practice and regulations at the time of writing. However, the end product/ system designer is responsible for ensuring that the system is safe and in compliance with relevant regulations.

The STO function does not electrically isolate the drive output from the mains supply. If electrical work is to be carried out on the drive, the motor or the motor cabling, the drive has to be isolated from the mains supply. Use, for example, an external mediumvoltage disconnecting switch (optionally as part of the main circuit breaker, see 6.6 Main Circuit Breaker Installation). In addition, the grounding switch must be closed or an alternative grounding according to applicable standards must be provided (see 8.2 Operat-

ing the Grounding Switch).

6.9.3.1 Diagnostic Test

Performing a diagnostic test is mandatory. The achievable SIL performance level/category for STO/SS1 depends on the testing interval.

Test/ diagnostic interval

(1)

EN 61800-5-2

ENISO 13849-1

EN 62061

1 day

SIL3

PL “e” Category 4

SILCL3

3 months

SIL3

PL “e” Category 3

SILCL3

1 year

SIL2

PL “d” Category 3

SILCL2

Frequency

Time

SS1

request

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Time delay

Safe Torque Off (STO)

actual

Motor deceleration

VACON® 3000 Enclosed Drive

Operating Guide

Table 8: SIL Performance Level/Category Based on Diagnostic Test Interval

Time between tests.

To perform the test, follow this procedure.

•

Start with a powered-on system. Connection to the MV grid is not required.

•

Press S1 (STO/SS1 button).

•

Wait until the STO diagnostic lamp is continuously on.

•

Reset S1.

•

If available, push reset button S2.

•

The STO diagnostic lamp should go off, and the drive should be operational again after less than 1 minute.

Note: A diagnostic test is also automatically executed as part of any regular STO/SS1 cycle.

Electrical Installation

6.9.4 STO Operating Principle

The STO safety function allows the drive output to be disabled so that the drive cannot generate torque in the motor shaft. The STO safety function is achieved by stopping the drive operation. The drive operation is stopped by removing the 24 V supply to

the inverter units. When the 24 V supply is removed, the drive stops operation and does not generate torque in the motor shaft.

6.9.5 SS1 Operating Principle

After receiving a safe stop command, the motor starts decelerating and the SS1 safety function initiates the STO function after a user-set time delay.

Illustration 37: The Principle of Safe Stop 1 (EN 61800-5-2, SS1 Type C)

The system designer/user is responsible for understanding and setting the time delay of the safety relay, as it is process/machine dependent.

•

The time delay of the relay must be set to a greater value than the deceleration time of the drive. If there is a single failure or malfunctioning of the drive system, the drive may not ramp down as requested, but is always put to a safe STO state after the configured time delay of the relay. The motor deceleration time is process/machine dependent.

•

The stop function of the drive must be correctly set for the process/machine. Activating the SS1 safety function must execute the configured stop in the drive, using the undelayed relay output signal "SS1 NOT ACTIVATED". In the application software, it is recommended to use the "Quick Stop" functionality for this purpose.

e30bg977.10

e30bg976.10

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

7 Control Connections

7.1 Control Interface

When the drive is connected to the mains, it must be possible to monitor the drive, reset faults, and set parameters to the drive without opening the cabinet. These actions can all be done with the door-mounted PLC touch screen.

Illustration 38: PLC Touch Screen on the Cabinet Door

7.2 The Control Compartment of the Enclosed Drive

VACON® 3000 Enclosed Drive has a control compartment, a separate section which includes the control units and other auxiliary components. The components of the control compartment shown in Illustration 39 can differ depending on the drive type and configuration. For example, the AFE drive has two control units and the 12-pulse drive has one. Drives with the brake chopper option (+DBCU) also have a control unit for the brake chopper.

Illustration 39: Components in the Control Compartment

AFE control unit

INU control unit

Diode module for the 24 V power supplies

Fiber optic converter

24 V power supplies for the control units

Terminals for control connections and auxiliary devicesGMCBs and relays for the auxiliary devices

PLCIIndustrial Ethernet switch

Terminals for the PLC

PLC touch screen

Signal indicator lights and push buttons

Cabinet light

230 V socket

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VACON® 3000 Enclosed Drive

Operating Guide

7.3 Control Unit Components

Control Connections

Illustration 40: The Components of the Control Unit

The control terminals for the default I/O connections

The Ethernet connection

The relay terminals for 3 relay outputs or 2 relay outputs and a thermistor

The option boards

DIP switch for the RS485 bus termination

DIP switch for the signal selection of analog output

DIP switch for the isolation of the digital inputs from ground

DIP switch for the signal selection of analog input 2

DIP switch for the signal selection of analog input 1

The status indicator of the Ethernet connection

Cooling fan

The battery for the real-time clock

Control unit power supply terminal

Encoder terminals (only used in INU control units)

Digital inputs and outputs for pre-charge

Optical fiber inputs for external breaker enable

Supply voltage feedback

Optical fiber interface to phase modules

Encoder configuration jumpers

Cable clamps

Ground points

Color/status of the LED

Status of the drive

Blinking slowly

Ready

Green

Run

Red

Fault

Orange

Alarm

Blinking fast

Downloading software

VACON® 3000 Enclosed Drive

Operating Guide

On delivery of the AC drive, the control unit contains the default control interface (control panel with graphical display). If special options were selected in the order, the option boards are included loose in the delivery. On the next pages, there is information on the terminals and general wiring examples.

The control unit can be started with a 24 V DC ±5%, 3 A power source with external overload protection. This voltage is sufficient to keep the control unit on and for setting the parameters. The measurements of the main circuit (for example, the DC-link voltage, and the unit temperature) are not available when the drive is not connected to the mains.

The status indicator on the control unit shows the status of the drive. The status indicator is on the control panel, below the keypad, and it can show five different statuses.

Control Connections

Table 9: Control Unit LED Status Definitions

7.4 Control Unit Cabling

Install the control cables in the low-voltage section of the cabinet. Keep the cables away from high voltages and possible electrical arcs. Make the control connections between the control units and power units with optical fiber cables.

There are cable entries at the top and bottom of the cabinet. A VACON® 3000 12-pulse drive has one control unit, the INU control unit. Install all the I/O and relay cables to the INU control unit.

A VACON® 3000 AFE drive has two control units, the AFE control unit and the INU control unit. The I/O and relay cable installation is application-specific and both the AFE and INU control units can be used.

Terminal

Terminal screw size

Tightening torque (Nm)

Tightening torque (lbin)

All the terminals of the I/O board and the relay board

0.5

4.5

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

7.4.1 Selection of the Control Cables

N O T I C E

CABLE SELECTION

Obey regional low-voltage standards in the cable selection.

The control cables must be a minimum of 0.5 mm2 (AWG20) multi-core shielded cables. The terminal wires must be a maximum of

2.5 mm2 (AWG13) for the relay board terminals and other terminals.

Table 10: The Tightening Torques of the Control Cables

7.4.2 Control Unit Terminals

Here is the basic description of the terminals of the default I/O and relay board. The standard I/O board has 22 fixed control terminals and 8 relay board terminals.

Some terminals are assigned for signals that have optional functions that can be used with the DIP switches. For more information, see 7.5 DIP Switches on the Control Unit.

DI4

DI5

Modbus RTU,

N2, BACnet

FAULT

RUN

AO1-

+24Vin

24Vout

GND

DI1

DI2

DI3

DI4

DI5

DI6

RO1/1 NC

RO1/2 CM

RO1/3 NO

RS485

RO2/1 NC

RO2/2 CM

RO2/3 NO

RO3/2 CM

RO3/3 NO

Standard I/O board

Terminal Signal Description

+10Vref

AI1+

AI1-

AI2+

AI2-

24Vout

Reference output

Analog input 1+

Analog input 1-

Analog input 2+

Analog input 2-

24 V auxiliary voltage

I/O ground

Digital input 1

Digital input 2

Digital input 3

Digital input 4

Digital input 5

Digital input 6

Common for DI1-DI6

Common for DI1–DI6

24 V auxiliary voltage

I/O ground

Analog output 1+

Analog output 1-

24 V auxiliary input voltage

Output

frequency

(0...20 mA)

READY

Serial bus, negative

Serial bus, positive

Relay output 1

Relay output 2

Relay output 3

FAULT

Fault reset

AO1+

Frequency reference (default 0...10 V)

Frequency reference (Default 4...20 mA)

Start forward

Start reverse

External fault

Freq. ref.

Open Closed Open Closed

Open Open Closed Closed

Analog input 1 Preset Freq. 1 Preset Freq. 2 Preset Freq. 3

Referencepotentiometer

1...10 kΩ

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VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

Illustration 41: The Signals of the Control Terminals on the Default I/O Board and the Default Control Connections for the VACON® 3000 INU

Application

7.5 DIP Switches on the Control Unit

7.5.1 Selection of Terminal Functions with DIP Switches

Two selections for specified terminals can be done with the DIP switches. The switches have two positions: up and down. See the location of the DIP switches and the possible selections in Illustration 42.

A B

AI1

AO1

RS485

OFF

AI2

e30bg737.10

The voltage signal (U), 0–10 V input

The current signal (I), 0–20 mA input

OFFDONEThe RS485 bus termination

The DIP switch

The default position

AI1UAI2IAO1IRS485 bus termination

OFF

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

Illustration 42: The Selections of the DIP Switches

Table 11: The Default Positions of the DIP Switches

7.5.2 Isolation of the Digital Inputs from Ground

It is possible to isolate from ground the digital inputs (terminals 8–10 and 14–16) on the standard I/O board. To do this, change the position of a DIP switch on the control board.

e30bg738.10

The digital inputs

Floating

Connected to ground (default)

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 43: Change the Position of This Switch to Isolate the Digital Inputs from Ground

Control Connections

7.6 Fieldbus Connection

7.6.1 Fieldbus Terminals

The drive can be connected to fieldbus with an RS485 or an Ethernet cable.

•

If an RS485 cable is used, connect it to terminals A and B of the default I/O board.

•

If an Ethernet cable is used, connect it to the Ethernet terminal.

In a VACON® 3000 AFE drive, connect the fieldbus to both the AFE and INU control units.

e30bg739.10

RS485 terminal A = Data -

RS485 terminal B = Data +

RS485 DIP switch

The Ethernet terminal

The control terminals

Cable clamps

Item

Description

Plug type

Shielded RJ45 plug, maximum length 40 mm (1.57 in)

Cable type

CAT5e STP

Cable length

Maximum 100 m (328 ft)

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

Illustration 44: The Ethernet and RS485 Connections

7.6.2 Using Fieldbus through an Ethernet Cable

Table 12: Ethernet Cable Data

Ethernet Cabling

Connect the Ethernet cable to its terminal.

See more in the installation guide of the used fieldbus.

Item

Description

Plug type

2.5 mm2 (AWG13)

Cable type

STP (shielded twisted pair), Belden 9841 or similar

Cable length

So that it agrees with the fieldbus. See the fieldbus manual.

e30bg841.10

15 mm

e30bg842.10

e30bg843.10

VACON® 3000 Enclosed Drive

Operating Guide

7.6.3 Using Fieldbus through an RS485 Cable

Table 13: RS485 Cable Data

RS485 Cabling

Remove approximately 15 mm (0.59 in) of the gray shield of the RS485 cable. Do this for the two fieldbus cables.

Strip the cables for approximately 5 mm (0.20 in) to put them in the terminals. Do not keep more than 10 mm (0.39 in) of the cable outside the terminals.

Control Connections

Strip the cable at such a distance from the terminal that it can be attached to the frame with the grounding clamp for the control cable. Strip the cable at a maximum length of 15 mm (0.59 in). Do not remove the aluminum shield of the cable.

Connect the cable to the default I/O board of the drive, in terminals A and B.

•

A = negative

•

B = positive

e30bg844.10

e30bg845.10

e30bg846.10

VACON® 3000 Enclosed Drive

Operating Guide

Attach the shield of the cable to the frame of the drive with a grounding clamp for the control cable to make a grounding connection.

Illustration 45: Grounding the Cable with a Grounding Clamp

If the drive is the last device on the fieldbus line, set the bus termination. Set the bus termination for the first and the last device of the fieldbus line. It is recommended that the first device on the fieldbus is the master device.

Find the DIP switches on the left side of the control unit of the drive.

Control Connections

Set the DIP switch of the RS485 bus termination to the ON position.

The termination resistors are placed at both ends of the fieldbus line to decrease signal reflections on the line. Biasing is built in the bus termination resistor. The termination resistance is 220 Ω.

Illustration 46: Setting the Bus Termination for a Fieldbus Line

The termination is activated

The termination is deactivated

The termination is activated with a DIP switch

The bus termination. The resistance is 220 Ω.EThe fieldbus

OPT

e30bg847.10

The slot coding

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

N O T I C E

LOSS OF TERMINATION RESISTANCE

If the last device on the fieldbus line is powered down, the termination resistance is lost. The loss of termination resist-

ance causes signal reflections on the line, which can disrupt the fieldbus communication.

Do not power down the last device on the fieldbus line while the fieldbus is active.

7.7 Option Board Installation

W A R N I N G

SHOCK HAZARD FROM CONTROL TERMINALS

The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this voltage

can lead to injury.

Make sure that there is no voltage in the control terminals before touching the control terminals.

N O T I C E

INCOMPATIBLE OPTION BOARDS

It is not possible to install option boards that are not compatible with the drive.

If the installed board is an OPTB or an OPTC option board, make sure that the label on it says "dv" (dual voltage). This marking shows that the option board is compatible with the drive.

Illustration 47: Label on the Option Board

Installation Procedure

e30bg848.10

e30bg849.10

The slot coding

The option slots

VACON® 3000 Enclosed Drive

Operating Guide

To get access to the option slots, open the cover of the control unit.

Install the option board into the correct slot: C, D, or E.

The option board has a slot coding, because of which it is not possible to install the option board in an incorrect slot.

Control Connections

Illustration 48: Installing the Option Boards

Close the cover of the control unit.

7.8 Optical Fiber Connections

The VACON® 3000 drive has a high-speed Powerbus optical fiber interface for internal connections. The control unit has six optical fiber connections: four for phase modules, one for the connection between the control units and one for an auxiliary board. The two terminals used for the control of the INU or AFE phase modules are shown in Illustration 49.

F01

F02

F03

F04

F05

F06

e30bg740.11

F01

Terminal for phase module connections (belt 1)

F02

Terminal for phase module connections (belt 2)

F03

Terminal not used

F04

Terminal not used

F05

Terminal for auxiliary I/O board connection

F06

Terminal not used

A B

PCU L1 / U

F01

PCU L2 / V

PCU L3 / W

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VACON® 3000 Enclosed Drive

Operating Guide

Illustration 49: Optical Fiber Terminals

Control Connections

Connect the phase modules of each AFE or INU in series (see Illustration 50).

•

Connect the optical fiber from connector A of the phase module L1/U to connector F01 on the control unit.

•

Connect the optical fiber from connector A of the phase module L2/V to connector B on phase module L1/U.

•

Connect the optical fiber from connector A of the phase module L3/W to connector B on phase module L2/V.

Illustration 50: Optical Fiber Connections between Control Unit and Phase Modules

Two parallel AFE or INU units can be connected to one control unit. The first AFE or INU unit (Belt 1, series connection of three phase modules) is connected to control unit connector F01 and the second (B2) to connector F02.

PCU / L1

PCU / L2

PCU / L3

F01 F02 F03 F04 F05 F06

CH2

CH1

F05 F06

CNU-AFE

F01 F02 F03 F04

CNU-INU

AFE / B1

PCU / L1

PCU / L2

PCU / L3

AFE / B2

PCU / U

PCU / V

PCU / W

INU / B1

PCU / U

PCU / V

PCU / W

INU / B2

AUX I/O

e30bg742.11

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

If a brake chopper is installed (option +DBCU), there is a separate control unit for the brake choppers. Connect the brake chopper modules in series as shown in Illustration 51. A maximum of three modules can be connected in series. Brake choppers can also be connected to the control unit one by one (BCU1 to connector FO1, and BCU2 to FO2).

Illustration 51: Parallel Optical Fiber Connections in an AFE Drive

F05 F06 F05 F06

F01 F02 F03 F04

CNU-BCU

F01 F02 F03 F04

CNU-INU

PCU / U

PCU / V

PCU / W

INU / B1

PCU / U

PCU / V

PCU / W

INU / B2

PCU

BCU / B1

PCU

BCU / B2

PCU

DFE

e30bi782.10

CH2

CH1

AUX I/O

Item

Specification

Operation temperature

-40...+85°C (-40...+185°F)

Minimum bend radius

25 mm (1 in)

Cable size (outer dimensions)

2.2 x 4.4 mm (0.087 x 0.173 in)

Fiber size

d = 1 mm (0.04 in)

Cover material

Flame resistant PE or PVC

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

Illustration 52: Parallel Optical Fiber Connections in a 12-pulse Drive with BCU Option

7.8.1 Selection of Optical Fiber Cables

SI-POF duplex cables are recommended for all optical fiber connections. The connector type must be LC duplex. The specifications in Table 14 are for cables manufactured by Firecomms. The cable assemblies (POF and connectors) are available from Firecomms resellers with type code FD-XXX-LDB, where XXX is the length of the cable, XXC in centimeters, and XXM in meters.

Table 14: Optical Fiber Cable Specifications

Item

Specification

UL flame resistance

VW-1

Cable standard

Compatible with IEC 60793-2-40 class A4a

Plastic optical fiber type

Duplex optical fiber, 1 mm (0.04 in) high-purity core. The core and cladding are surrounded by a

2.2 mm (0.082 in) polyethylene (PE) jacket. Firecomms type code: FC-500-0DB

Connector type

Firecomms type code: FP-00C-LD0

Connector standard

Compatible with IEC 61754-20 edition 2

30–40

(1.25–1.5)

(1.0)

e30bj243.10

VACON® 3000 Enclosed Drive

Operating Guide

Recommended tools (from FiberFin):

•

LC Duplex crimp tool, 2.60 mm hex, PEW 8 (FiberFin type code: FF-CRMP-LC-WL)

•

Ultra Low Loss finishing tool, LC Connector (FiberFin type code: FF-LC-RZR1)

•

Installer kit, including finishing tool and crimping tool (FiberFin type code: FF-STDLCINST-K)

Control Connections

7.8.2 Making Optical Fiber Cables

The fiber optic cables most likely to need replacement are the ones connected to the phase modules. During the installation or replacement of modules, it is possible to damage the fiber optic cables accidentally. This procedure describes how to make new cables.

These tools and equipment are required:

•

Specialized tool kit for fiber optics

Wire stripper

Wire cutter

Crimper tool

•

Fiber optic wire

•

Connectors

For details, see 7.8.1 Selection of Optical Fiber Cables.

Procedure

Cut the required length of fiber optic wire. Use a wire cutter to make sure that the cuts are clean.

Use the stripper tool to strip the wires approximately 25 mm (1 in) at both ends.

Illustration 53: Stripping and Splitting the Cable

Split the wires apart 30–40 mm (1.25–1.5 in) from both ends.

See Illustration 53.

Place a connector into the crimper tool.

1.6

(0.63)

e30bj244.10

VACON® 3000 Enclosed Drive

Operating Guide

Push the fibers into the connector. Make sure that the fibers are fully pushed in. The fibers must come out of the end of the

Control Connections

connector approximately 1.6 mm (0.63 in).

Illustration 54: Installing the Connectors on the Cable

When the wires and connector are fully in position, firmly close the crimper grip.

Install the connector on the other end of the cable. Notice the labels A and B on the connectors. When making the connection for the other end of the wire, B goes to the A slot and A to B.

See Illustration 54.

Check the cable by shining an LED on one end of the cable and verifying that the other end is lit. For example, shine on wire A on one end, and verify that B is lit on the other end.

7.9 Encoder Interface

The VACON® 3000 control unit includes a 2-encoder interface. The encoder interface is only used in the INU control unit, not in AFE or BCU control units.

The encoder interface is designed for HTL (High-voltage Transistor Logic) type encoders (voltage output type Push-pull HTL, open collector output type HTL) which provide input signal levels dependent on the supply voltage of the encoder.

The encoder properties include:

•

Cross-connected optically isolated feedback for good noise limits

•

150 kHz maximum frequency

•

Different encoder line driver voltage levels (24 V, 15 V, 5 V)

•

Different encoder supply voltage levels (+24 V, +15 V) with current limits

•

Differential encoder duplicator option from one of the encoder interfaces

•

Master/follower selection

•

Two qualifier inputs (1Q, 2Q) for position detection or pulse tachometer applications

If absolute encoder functionality is required, contact Danfoss.

DE C

e30bg744.10

Encoder terminal, channel A

Encoder terminal, channel B

Encoder output voltage selection jumpers, channel A

Encoder output voltage selection jumpers, channel BEMaster/follower selection jumpers

Encoder input voltage selection jumpers

e30bg745.10

Terminal

Signal

Signal Description

A1+

Channel A pulse input A1+ (differential); voltage range +5 V…+24 V

A1-

Channel A pulse input A1- (differential); voltage range +5 V…+24 V

B1+

Channel A pulse input B1+ (differential); voltage range +5 V…+24 V; 90° delay from A1+

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

Illustration 55: Encoder Interface of the Control Unit

7.9.1 Encoder Terminals and Signals

Illustration 56: Encoder Terminals

Encoder channel A is usable only for motor control.

Table 15: Channel A Terminals and Signals

Terminal

Signal

Signal Description

B1-

Channel A pulse input B1- (differential); voltage range +5 V…+24 V; 90° delay from A1-

Z1+

Channel A pulse input Z1+ (differential); voltage range +5 V…+24 V; One pulse/revolution

Z1-

Channel A pulse input Z1- (differential); voltage range +5 V…+24 V; One pulse/revolution

71QQualifier/position input; Single-ended signal (to ground)

82QQualifier/position input; Single-ended signal (to ground)

GND

Ground for control and inputs 1Q and 2Q

Vcc

Encoder supply voltage (selection with jumpers X11 and X15)

Terminal

Signal

Signal Description

A2+

Channel B pulse input A2+ (differential); voltage range +5 V…+24 V

A2-

Channel B pulse input A2- (differential); voltage range +5 V…+24 V

B2+

Channel B pulse input B2+ (differential); voltage range +5 V…+24 V; 90° delay from A2+

B2-

Channel B pulse input B2- (differential); voltage range +5 V…+24 V; 90° delay from A2-

Z2+

Channel B pulse input Z2+ (differential); voltage range +5 V…+24 V; One pulse/revolution

Z2-

Channel B pulse input Z2- (differential); voltage range +5 V…+24 V; One pulse/revolution

7a+Pulse output a+ (differential); Made internally from channel 1 or channel 2 (selection with jumper X21); Output voltage +24 V

8a-Pulse output a- (differential); Made internally from channel 1 or channel 2 (selection with jumper X21); Output voltage +24 V

9b+Pulse output b+ (differential); Made internally from channel 1 or channel 2 (selection with jumper X22); Output voltage +24 V

10b-Pulse output b- (differential); Made internally from channel 1 or channel 2 (selection with jumper X22); Output voltage +24 V

VACON® 3000 Enclosed Drive

Operating Guide

Table 16: Channel B Terminals and Signals

Control Connections

7.9.2 Encoder Jumper Configurations

See the locations of the jumpers in Illustration 57 and the jumper pin sequence in Illustration 58. The available encoder jumper configurations:

•

Encoder input voltage selection, jumpers X11 and X15, see Table 17.

•

Master/follower selection, jumpers X21 and X22, see Table 18.

•

Encoder output voltage selection for channel A, jumpers X23-X25, see Table 19.

•

Encoder output voltage selection for channel B, jumpers X26-X28, see Table 20.

X21 X22

X28

X26

X27

X23 X24

X25

X11 X15

e30bg746.10

1 3 5

2 4 6

1 3 5

2 4 6

e30bg747.10

Jumper Selection

Pins to connect, Jumper X11

Pins to connect, Jumper X15

+15 V (default)

1-2

open

+24 V

open

1-2

Jumper Selection

Pins to connect

Master (default)

3-5 and 4-6

Follower

1-3 and 2-4

Jumper Selection

Pins to connect, Jumper X23 (input A1)

Pins to connect, Jumper X24 (input B1)

Pins to connect, Jumper X25 (input Z1)

+24 V

open

+15 V (default)

1-3 and 2-4

+5 V

3-5 and 4-6

Jumper Selection

Pins to connect, Jumper X26 (input A2)

Pins to connect, Jumper X27 (input B2)

Pins to connect, Jumper X28 (input Z2)

+24 V

open

+15 V (default)

1-3 and 2-4

+5 V

3-5 and 4-6

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 57: Encoder Jumper Locations

Control Connections

Illustration 58: Jumper Pin Sequence and Connection Example (Pins 1-3 and 2-4 Connected)

Table 17: Encoder Input Voltage Selection, Jumpers X11 and X15

Table 18: Master/Follower Selection, Jumpers X21 and X22

Table 19: Encoder Output Voltage Selection, Channel A

Table 20: Encoder Output Voltage Selection, Channel B

GND

A-

B-

15/24 V

Encoder Control unit

Channel 1

A+

B+

1: A1+ 2: A1-

3: B1+ 4: B1-

9: GND 10: Vcc

e30bi919.10

GND

Encoder Control unit

Channel 1

A+

B+

1: A1+ 2: A1-

3: B1+ 4: B1-

9: GND 10: Vcc

e30bi920.10

GND

A-

B-

Encoder Control unit

Channel 1

1: A1+ 2: A1-

3: B1+ 4: B1-

9: GND 10: Vcc

e30bi921.10

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

7.9.3 Encoder Connection

Ground the encoder cable shields only at the AC drive end to avoid circulating current in the shield. Isolate the shield at the encoder end.

If possible, use double shielded cable for encoder connection. A high pulse frequency combined with a high cable capacitance places a considerable load on the encoder. Therefore, apply as low

a voltage as possible for the encoder supply. Use +15 V encoder voltage input, if allowed in the voltage range specification of the encoder.

If external voltage supply is used, connect the ground of the external supply to terminal 9 in channel A of the encoder interface and to the encoder ground.

Differential Connection

Illustration 59: HTL Type Encoder Connection with Differential Inputs

Single-ended Connection

Illustration 60: HTL Type Encoder Connection (Open Source) with Single-ended Inputs

Illustration 61: HTL Type Encoder Connection (Open Collector) with Single-ended Inputs

GND

A-

B-

15/24 V

Encoder Control unit 1

Channel 1

Channel 2

A+

B+

A-

B-

A+

B+

1: A1+ 2: A1-

3: B1+ 4: B1-

7: a+ 8: a-

9: b+ 10: b-

9: GND 10: Vcc

Control unit 2

Channel 1

1: A1+ 2: A1-

3: B1+ 4: B1-

e30bi922.10

Terminal

Signal

Technical Information

Reference output

+10 V, 0%...+3%, maximum current: 10 mA

Analog input, voltage, or current

Analog input channel 1

0...+10 V (Ri = 200 kΩ) 4–20 mA (Ri =250 Ω) Resolution 0.1%, accuracy ±1% Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP

switches in the Operating Guide).

Analog input common (current)

Differential input if not connected to ground Allows ±20 V common-mode voltage to GND

VACON® 3000 Enclosed Drive

Operating Guide

Chain Connection

Illustration 62: Chain Connection with Duplicated Differential Inputs

Control Connections

7.10 Battery for the Real-Time Clock (RTC)

To use the real-time clock (RTC), a battery must be installed in the left side of the control unit. See 7.2 The Control Compartment of

the Enclosed Drive. Use a ½ AA battery with 3.6 V and a capacity of 1000–1200 mAh. Use, for example, a Vitzrocell SB-AA02 battery.

The battery lasts approximately 10 years. See more about the functions of the RTC in the application guides.

7.11 Galvanic Isolation Barriers

The control connections are isolated from the mains. The ground terminals are permanently connected to the I/O ground. The digital inputs on the standard I/O board can be galvanically isolated from the I/O ground. To isolate the digital inputs, use the

DIP switch that has the positions FLOAT and GND. See 7.5.2 Isolation of the Digital Inputs from Ground.

7.12 System and Application Software

The VACON® 3000 control unit comes with AFE or INU system and application software. There is also separate application software for the brake chopper control unit.

The application software is specific to the VACON® 3000 and comes installed on the drive. For more information, see the VACON® 3000 Application guides.

7.13 Technical Data on Control Connections

Table 21: The Standard I/O Board

Terminal

Signal

Technical Information

Analog input, voltage, or current

Analog input channel 2 Default: 4–20 mA (Ri =250 Ω)

0...+10 V (Ri = 200 kΩ) Resolution 0.1%, accuracy ±1% Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP

switches in the Operating Guide).

Analog input common (current)

Differential input if not connected to ground Allows ±20 V common-mode voltage to GND

24 V auxiliary voltage

+24 V, ±10%, maximum voltage ripple < 100 mV rms Maximum 250 mA Short-circuit protected

I/O ground

Ground for reference and controls (connected internally to frame ground through 1 MΩ)

Digital input 1

Positive or negative logic Ri = min. 5 kΩ 0–5 V = 0 15–30 V = 1

Digital input 2

Digital input 3

Common A for DIN1DIN6

Digital inputs can be disconnected from ground. See chapter Isolation of digital inputs from ground in the Operating Guide.

24 V auxiliary voltage

+24 V, ±10%, maximum voltage ripple < 100 mV rms Maximum 250 mA Short-circuit protected

I/O ground

Ground for reference and controls (connected internally to frame ground through 1 MΩ)

Digital input 4

Positive or negative logic Ri = min. 5 kΩ 0–5 V = 0 15–30 V = 1

Digital input 5

Digital input 6

Common A for DIN1DIN6

Digital inputs can be disconnected from ground. See chapter Isolation of digital inputs from ground in the Operating Guide.

Analog signal (+output)

Analog output channel 1, selection 0 -20 mA, load <500 Ω Default: 0–20 mA 0–10 V Resolution 0.1%, accuracy ±2% Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP

switches in the Operating Guide) Short-circuit protected

Analog output common

24 V auxiliary input voltage

Can be used as external power back-up for the control unit A

RS485

Differential receiver/transmitter Set bus termination with DIP switches (see chapter Selection of terminal functions with DIP

switches in the Operating Guide). Termination resistance = 220 Ω

RS485

VACON® 3000 Enclosed Drive

Operating Guide

Control Connections

•

Terminal

Signal

Technical information

Relay output 1

(1)

Change-over switch (SPDT) relay. 5.5 mm isolation between channels. Switching capacity

24 V DC / 8 A

250 V AC / 8 A

125 V DC / 0.4 A

Minimum switching load

5 V / 10 mA

222324

Relay output 2

(1)

Change-over switch (SPDT) relay. 5.5 mm isolation between channels. Switching capacity

24 V DC / 8 A

250 V AC / 8 A

125 V DC / 0.4 A

Minimum switching load

5 V / 10 mA

252632

Relay output 3

(1)

Normally-open (NO or SPST) switch relay. 5.5 mm isolation between channels. Switching capacity

24 V DC / 8 A

250 V AC / 8 A

125 V DC / 0.4 A

Minimum switching load

5 V / 10 mA

VACON® 3000 Enclosed Drive

Operating Guide

Table 22: The Standard Relay Board (+SBF3)

Control Connections

If 230 V AC is used as control voltage from the output relays, the control circuitry must be powered with a separate isolation transformer to limit

the short-circuit current and the overvoltage spikes. This is to prevent welding on the relay switches. Refer to standard EN 60204-1, section 7.2.9.

7.14 Auxiliary I/O Board

7.14.1 Connector Locations

H12J14 J15 H40 H60J12 J13

S15 S10 S9 S13 S5 S2 S18 S4 S3 S8 S7

S16

S17

S12

S11

S14

H161

H160

H24

H23

J11 J10 J2 X5

J4 J3H13

e30bi609.10

H12

Breaker enable fiber optic input 2

H13

Breaker enable fiber optic input 1

H23

External breaker enable fiber optic TX2

H24

External breaker enable fiber optic RX2

H40

Communication channel 1 (PBHS)

H60

Communication channel 2 (PBHS)

H160

External breaker enable fiber optic TX1

H161

External breaker enable fiber optic RX1

Grid voltage measurement, 3 channels

Grid current measurement, 3 channels

Analog voltage (0–10 V)/analog current (4–20 mA) measurement, 4 channels

Digital inputs (24 V, 0.5 A), 8 channels

J10

Relay outputs, 4 channels

J11

Relay outputs, 5 channels

J12

Digital inputs (24 V, 0.5 A), 8 channels

J13

Digital inputs (24 V, 0.5 A), 8 channels

J14

Breaker enable digital inputs, 4 channels

J15

24 V pull-up for sensors

S1–S18

Control switches

24 V input

Connector

Signal Name

Input Disable Switch

Description

H12

Breaker enable 2

S12

When light is present, the breaker is enabled. Switch in position (1-2) disables the input.

H13

Breaker enable 1

S11

When light is present, the breaker is enabled. Switch in position (1-2) disables the input.

VACON® 3000 Enclosed Drive

Operating Guide

Illustration 63: The Connectors and Switches on the Auxiliary I/O Board

Control Connections

7.14.2 Connector Specifications

Table 23: Connectors H12/H13, Breaker Enable Optical Fiber Signals

Connector

Signal Name

Input Disable Switch

Description

H23

Ext Brk TX 2

–

Transmit breaker enable signal to other boards.

H24

Ext Brk RX 2

Receive breaker enable signal from other boards. Switch position (1-2) disables external signal.

H160

Ext Brk TX 1

–

Transmit breaker enable signal to other boards.

H161

Ext Brk RX 1

Receive breaker enable signal from other boards. Switch position (1-2) disables external signal.

Connector

Signal Name

Description

J2-1

Phase A

120/127 V phase A grid voltage input (LN peak -170 V)

J2-2

Phase B

120/127 V phase B grid voltage input (LN peak -170 V)

J2-3

Phase C

120/127 V phase C grid voltage input (LN peak -170 V)

J2-4

Reference

Neutral/return/artificial neutral

Connector

Signal Name

Switch Control

Description

J3-1

CT Supply

–

+16 V, positive supply output for hall effect sensor

J3-2

CT Supply

–

-16 V, negative supply output for hall effect sensor

J3-3

Analog Input 5 +

S2 switch position (1-2) grounds Input 1P

J3-4

Analog Input 5 -

S18

S18 switch position (1-2) connects burden resistor

J3-5

Analog Input 6 +

S4 switch position (1-2) grounds Input 2P

J3-6

Analog Input 6 -

S3 switch position (1-2) connects burden resistor

J3-7

Analog Input 7 +

S8 switch position (1-2) grounds Input 3P

J3-8

Analog Input 7 -

S7 switch position (1-2) connects burden resistor

Connector

Signal Name

Switch Control

Description

J4-1

Analog Input 1

S10

Voltage/current input 1 (single ended). Switch toggles between current and voltage.

J4-2

Analog Input 2

Voltage/current input 2 (single ended). Switch toggles between current and voltage.

J4-3

Analog Input 3

S13

Voltage/current input 3 (single ended). Switch toggles between current and voltage.

J4-4

Analog Input 4

Voltage/current input 4 (single ended). Switch toggles between current and voltage.

J4-5

Common

–

Return for analog voltage signals.

VACON® 3000 Enclosed Drive

Operating Guide

Table 24: Connectors H23/H24 and H160/H161, External Breaker Enable Optical Fiber Inputs/Outputs

Table 25: Connector J2, Grid Voltage (120/127 V) Measurement (Copper Wire) Analog Signals

Control Connections

Table 26: Connector J3, Grid Current Measurement (Copper Wire) Analog Signals

Table 27: Connector J4, General Purpose Voltage/Current Measurement (Copper Wire) Analog Signals

Connector

Signal Name

Description

J8-1

Digital input 1

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-2

Digital input 2

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-3

Digital input 3

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-4

Digital input 4

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-5

Digital input 5

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-6

Digital input 6

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-7

Digital input 7

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-8

Digital input 8

24 V, 0.5 A optically isolated digital input (signal bank A)

J8-9

Common A

Signal return for bank A

Connector

Signal Name

Description

J9-1

Digital input 9

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-2

Digital input 10

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-3

Digital input 11

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-4

Digital input 12

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-5

Digital input 13

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-6

Digital input 14

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-7

Digital input 15

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-8

Digital input 16

24 V, 0.5 A optically isolated digital input (signal bank B)

J9-9

Common B

Signal return for bank B

Connector

Signal Name

Description

J10-1

Relay output 1 CM

Relay is disabled when breaker enable network is not satisfied.

J10-2

Relay output 1 NO

Relay is disabled when breaker enable network is not satisfied.

J10-3

Relay output 2 CM

Relay is disabled when breaker enable network is not satisfied.

J10-4

Relay output 2 NO

Relay is disabled when breaker enable network is not satisfied.

J10-5

Relay output 3 CM

Relay is disabled when breaker enable network is not satisfied.

J10-6

Relay output 3 NO

Relay is disabled when breaker enable network is not satisfied.

J10-7

Relay output 4 CM

Relay is disabled when breaker enable network is not satisfied.

J10-8

Relay output 4 NO

Relay is disabled when breaker enable network is not satisfied.

VACON® 3000 Enclosed Drive

Operating Guide

Table 28: Connector J8, 24 V/0.5 A Digital Input (Copper Wire) Signals

Table 29: Connector J9, 24 V/0.5 A Digital Input (Copper Wire) Signals

Control Connections

Table 30: Connector J10, Relay Outputs

Connector

Signal Name

Description

J11-1

Relay output 5 CM

Relay is disabled when breaker enable network is not satisfied.

J11-2

Relay output 5 NO

Relay is disabled when breaker enable network is not satisfied.

J11-3

Relay output 6 CM

Relay is disabled when breaker enable network is not satisfied.

J11-4

Relay output 6 NO

Relay is disabled when breaker enable network is not satisfied.

J11-5

Relay output 7 CM

Relay is disabled when breaker enable network is not satisfied.

J11-6

Relay output 7 NO

Relay is disabled when breaker enable network is not satisfied.

J11-7

Relay output 8 CM

Relay is disabled when breaker enable network is not satisfied.

J11-8

Relay output 8 NO

Relay is disabled when breaker enable network is not satisfied.

J11-9

Relay output 9 CM

Relay is disabled when breaker enable network is not satisfied.

J11-10

Relay output 9 NO

Relay is disabled when breaker enable network is not satisfied.

Connector

Signal Name

Description

J12-1

Digital input 17

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-2

Digital input 18

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-3

Digital input 19

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-4

Digital input 20

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-5

Digital input 21

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-6

Digital input 22

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-7

Digital input 23

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-8

Digital input 24

24 V, 0.5 A optically isolated digital input (signal bank C)

J12-9

Common C

Signal return for bank C

Connector

Signal Name

Description

J13-1

Digital input 25

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-2

Digital input 26

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-3

Digital input 27

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-4

Digital input 28

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-5

Digital input 29

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-6

Digital input 30

24 V, 0.5 A optically isolated digital input (signal bank D)

VACON® 3000 Enclosed Drive

Operating Guide

Table 31: Connector J11, Relay Outputs

Table 32: Connector J12, 24 V/0.5 A Digital Input (Copper Wire) Signals

Control Connections

Table 33: Connector J13, 24 V/0.5 A Digital Input (Copper Wire) Signals

Connector

Signal Name

Description

J13-7

Digital input 31

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-8

Digital input 32

24 V, 0.5 A optically isolated digital input (signal bank D)

J13-9

Common D

Signal return for bank D

Connector

Signal Name

Input Disable Switch

Description

J14-1

Breaker enable 3

S14

When the signal is high, the breaker is enabled. Switch position (1-2) disables the input.

J14-2

Breaker enable 4

S15

When the signal is high, the breaker is enabled. Switch position (1-2) disables the input.

J14-3

Breaker disable 1

S16

When the signal is high, the breaker is disabled. Switch position (1-2) disables the input.

J14-4

Breaker disable 2

S17

When the signal is high, the breaker is disabled. Switch position (1-2) disables the input. J14-5

Return

–

Return for breaker enable signals

Connector

Signal Name

Description

J15-1

24V

Current limited 24 V pull-up voltage (2 mA)

J15-2

24V

Current limited 24 V pull-up voltage (2 mA)

J15-3

GND

Return for current limited 24 V

J15-4

GND

Return for current limited 24 V

Connector

Signal Name

Description

X5-1

24V

24 V positive supply voltage

X5-2

GND

Ground (return for 24 V supply voltage)

X5-3PEProtective earth

VACON® 3000 Enclosed Drive

Operating Guide

Table 34: Connector J14, Breaker Enable, Copper Wire Signals (FK-MCP 1.5/5-ST-3.81)

Control Connections

Table 35: Connector J15, 24 V Pull-up

Table 36: Connector X5, Power Supply

7.14.3 LED Display on the Auxiliary I/O Board

There is a four character LED display on the auxiliary I/O board. The display functions in the same principle as the display on the phase modules, but the shown belt and module information is different. See 6.7.7 LED Display on the Phase Module.

Belt information: The belt information indicator tells the number of the channel on the control unit to which the auxiliary I/O board is connected, in this case C5 (see 7.8 Optical Fiber Connections).

The belt information indicator is of type: [ ] [ ] [C] [5].

•

The first two digits are empty.

•

The last two digits show the number of the channel.

Module information: The module information indicator tells the identification number of the auxiliary I/O board. The number of the first installed board is 14, the second is 15, and so on.

The module information indicator is of type: [PowerID N_] [PowerID _N] [ ] [ ].

VACON® 3000 Enclosed Drive

Operating Guide

••The first two digits show the ID of the auxiliary I/O board.

The last two digits are empty.

Control Connections

VACON® 3000 Enclosed Drive

Operating Guide

Commissioning

8 Commissioning

8.1 Safety Checks before Starting the Commissioning

Before starting the commissioning, read these warnings.

D A N G E R

SHOCK HAZARD FROM POWER UNIT COMPONENTS

The power unit components are live when the drive is connected to mains. A contact with this voltage can lead to death or seri-

ous injury.

Do not touch the components of the power unit when the drive is connected to mains. Before connecting the drive to mains,

make sure that the covers of the drive are closed.

D A N G E R

SHOCK HAZARD FROM TERMINALS

The motor terminals U, V, W, the brake resistor terminals, or the DC terminals are live when the drive is connected to mains, also

when the motor does not operate. A contact with this voltage can lead to death or serious injury.

Do not touch the motor terminals U, V, W, the brake resistor terminals, or the DC terminals when the drive is connected to

mains. Before connecting the drive to mains, make sure that the covers of the drive are closed.

D A N G E R

SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE

The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the

mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to

death or serious injury.

Disconnect the drive from the mains and make sure that the motor has stopped.

8.2 Operating the Grounding Switch

D A N G E R

SHOCK HAZARD FROM THE DC LINK

A contact with the DC-link voltage can lead to death or serious injury.

After the AC drive is disconnected from the mains, wait for the DC link to discharge.

Use a measuring device to make sure that there is no voltage.

Turn off the AFE and INU and disconnect the AC drive from the mains (DC link begins to discharge).

Lock out/tag out the MV power source.

Wait for the DC link to discharge below 50 V DC.

The discharge time is:

•

<7 minutes for AFE drives.

•

<21 minutes for 12-pulse drives.

If more DC capacitance than normal is installed, the discharge time can be longer.

Customer

Country

Project number

Location

Start date (mm/dd/yy)

Customer ID

End date (mm/dd/yy)

Drive serial number

Company personnel

Drive type code

End customer

Application

Motor Nominal Voltage (V AC)

Motor Nominal Frequency (Hz)

Motor Nominal Speed (RPM)

Motor Nominal Current (A AC)

Motor Power Factor (0–1)

Motor Nominal Power (kW)

Transformer Specifications (MVA, Secondary V RMS, %Z)

VACON® 3000 Enclosed Drive

Operating Guide

Measure and make sure that the DC link is discharged before unlocking the grounding switch.

Unlock the grounding switch.

There is a safety solenoid on the grounding switch. The solenoid makes sure that the switch does not close while the DC link is energized or if the mains power is on.

Close the grounding switch.

Open the power module cabinet.

Make sure that the DC-link voltage indication lights on the front of the phase modules are not on.

See 6.7.7 LED Display on the Phase Module.

Make sure that all the blades of the grounding switch are correctly closed.

8.3 Commissioning the Drive

Before starting the commissioning, read the warnings and safety instructions in this manual.

•

Fill in the basic information about the job and the motor nameplate data.

•

Go through each item in the commissioning checklists.

Before power-up.

Control and auxiliary power commissioning.

Medium-voltage power commissioning.

•

Write down any findings or measured values in the comment fields.

•

Once each task is completed, mark the completion date and the name of the responsible employee.

Commissioning

8.3.1 Basic Job Information

Table 37: Basic Job Information

Table 38: Motor Nameplate Data

•

Item

Comments

Date completed (mm/dd/yy)

Employee

Confirm that the ambient conditions are within the specification.

See 11.2.6 Cooling.

Perform system lockout/tagout and grounding of the drive according to specific customer installation procedure.

Make sure that the mains and motor cables are selected according to the requirements.

See 6.2 Mains and Motor Cable Selection.

Make sure that the MV input/supply cables are connected according to the system schematic and are properly torqued.

Make sure that the output/motor cables are connected according to the system schematic and are properly torqued.

Confirm that a wire check of the MV input and output cables has been completed.

Confirm the proper grounding of the MV cable shields, motor, transformer, and drive cabinet.

See 6.4 Grounding.

Per local electrical codes, verify that the MV drive cabinet is grounded to the earth ground of the facility.

Confirm that the drive cabinet ground busbars are connected in all sections.

See 6.4 Grounding.

Check the resistances of the grounding connections. Measure both polarities.

Resistances to check:

Control system grounding

System safety grounding

Cabinet support

External housing of the cooling fans

Door locks/handles

The resistances should be approximately ≤0.5 Ω.

Confirm that the MV input and output cables have been insulation tested according to local regulations.

Confirm that there are no power factor correction capacitors connected to the motor cable.

Check that the optical fiber cables are in good condition and the routing is done in a way, that does not damage the cables. For example, make sure that the maximum bending radius of the cables (25 mm/1 in) is not exceeded.

VACON® 3000 Enclosed Drive

Operating Guide

8.3.2 Before Power-up Checklist

Table 39: Checklist of Commissioning Tasks to Do Before Power-up

Commissioning

•

•••

•

Item

Comments

Date completed (mm/dd/yy)

Employee

AFE drive systems

Make sure that the phase modules (INU/AFE) are installed correctly:

Cabling/busbars are properly torqued.

Fiber optic wires are connected in correct order.

24 V DC plug is connected.

12-pulse drive systems

Make sure that the phase modules (INU) and DFE module are installed correctly:

Cabling/busbars properly are torqued.

Fiber optic wires are connected in correct order.

24 V DC plug is connected.

12-pulse drive systems

Make sure that the DC-link capacitors for DFE are installed correctly:

Cabling/busbars are properly torqued.

Overpressure switch is connected to control.

Confirm that there is a minimum of 76 mm (3.0 in) from an exposed MV terminal to ground.

Confirm that there is a minimum of 34 mm (1.35 in) from an exposed MV terminal to opposite polarity.

Check that the main circuit wiring has correct clearance to ground and no insulated MV cabling (SIWO-KUL) is in contact with opposite phases or the drive enclosure.

Verify that the INU/AFE phase modules and DFE power module are connected to the correct corresponding input/ output busbar terminals (U -> U, L1 -> L1, and so on).

See 6.7 Cabling of the Power Modules.

Check that all cooling hoses are connected from the manifold to the phase modules, DFE module, and inductor heat exchangers.

See 5.4.4.2 Cooling System Overview.

Make sure that the MV drive cooling system has been filled and pressurized with no leaks.

See the specifications in 11.2.6 Cooling. See the instructions in 8.4.1 Filling the Liquid Cooling Sys-

tem.

If applicable, make sure that all cooling valves are opened.

Make sure that the single-phase control power cables (120/240 V) are connected according to the system schematic in a separate conduit from the MV cabling.

VACON® 3000 Enclosed Drive

Operating Guide

Commissioning

Item

Comments

Date completed (mm/dd/yy)

Employee

Make sure that the auxiliary (400–480 V AC) power cables are connected according to the system schematic in a separate conduit from the MV cabling.

Torque all control and auxiliary input power cables after they are connected.

See 7.4 Control Unit Cabling and 6.8.1 Low-Voltage Power

Supply Connections.

Confirm that the pre-charge voltage selection board that is installed matches the supplied auxiliary voltage level.

See 6.8.3 Location of the Precharge Unit.

Connect the required customer communication cables and I/O including main breaker control to the MV drive.

See the customer drive schematic and 2.5 Main Circuit

Breaker.

AFE drive systems

Verify the proper setup of grid voltage feedback. See 8.4.2 Grid Voltage Feedback Configuration.

AFE drive systems

Verify that the PT and TVS fuses are in working condition.

Confirm that the customer cooling connection is made to the drive cabinet heat exchanger.

See 5.4.4.3 Cooling Connections to the Enclosed Drive.

Make sure that the temperature of the liquid in the secondary circuit is at least 5°C below the temperature level in the primary cooling circuit of the MV drive. The absolute maximum for the secondary circuit liquid temperature is 38°C.

See 5.4.3.4 Temperature of the Cooling Liquid.

Make sure that the flow rate of the customer cooling is greater than or equal to the required flow of the MV Drive.

See 11.2.6 Cooling.

Confirm that the unit is clean and free from any foreign objects (such as nuts, washers, bolts, tools, metal shavings).

Confirm that there is no condensation inside the drive. See 5.4.3.5 Condensation.

VACON® 3000 Enclosed Drive

Operating Guide

Commissioning

•

Item

Comments

Date completed (mm/dd/yy)

Employee

Remove the control and auxiliary power lockout/tagout so that these LV supplies can be energized.

Apply 120/240 V single-phase control power. Verify that the voltages are within specification. Record the measurement.

Control voltage: ________ V AC

Apply 400–480 V AC three-phase power. Verify that the voltages are within specification. Record the measurement.

Auxiliary voltage: ________ V AC

Verify that the INU/AFE (if applicable), and HX control units are powered on and communicating.

If required, install software to the AFE/INU/BCU control units.

See 8.4.3 Installing Software on the Control Unit. Record the software revision details.

System software revision: ______________ Application: ______________

Verify that all the power module LED displays show the correct phase and belt information.

See 8.4.4 Verifying the Phase Module Connections. Correct the fiber optic cable sequence if necessary.

Operate the cooling system manually.

If needed, purge air from the system.

Check for leaks.

Check the liquid temperature.

Check the flow rate.

See the cooling specification details in 11.2.6 Cooling.

Flow rate: __________ l/min Static pressure: __________ bar (psi)

Test the customer I/O signals. Verify that the external customer interlocks operate as in-

tended.

Make sure that the digital input ground is connected to the digital system ground when floating, or to the control terminal ground.

See 7.5.2 Isolation of the Digital Inputs from Ground.

Perform the commissioning test. See 8.4.5 Commissioning Test.

VACON® 3000 Enclosed Drive

Operating Guide

8.3.3 Control and Auxiliary Power Commissioning Checklist

Table 40: Checklist of Control and Auxiliary Power Commissioning Tasks

Commissioning

Item

Comments

Date completed (mm/dd/yy)

Employee

Remove the main power lockout/tagout, so that the main power can be applied.

AFE drive systems

Perform the AFE synchronization test and tuning. See 8.4.6

AFE Synchronization Test.

12-pulse drive systems

Issue the start command to the drive, therefore energizing the DC link through the 12-pulse input.

Verify the charging of the DC link to the rated level in an acceptable time (below the value programmed for the DClink timeout: ≤60 s)

Pre-charge time: ________ s Discharge time: ________ s

Confirm that the INU control unit is giving the "Online and ready" signal.

Check that the motor parameters have been set in the INU control unit.

Perform the Motor ID Run (P3.1.2.8.1) with or without rotation.

For details, see the VACON® 3000 Application Guide.

If applicable, make sure that the encoder is connected and configured properly.

See 8.4.7 Encoder Setup.

To verify correct rotation, operate the motor (with the load uncoupled).

Operate the motor (with the load uncoupled) and incrementally increase the output up to the maximum rated frequency.

Operate the motor under load. Verify the operation up to full load.

Tune the control parameters as necessary to achieve the required operational specifications of the application.

VACON® 3000 Enclosed Drive

Operating Guide

8.3.4 Medium-Voltage Power Commissioning Checklist

Table 41: Checklist of Medium-Voltage Power Commissioning Tasks

Commissioning

8.4 Commissioning Procedures

8.4.1 Filling the Liquid Cooling System

Before operating a drive, the cooling system must be filled, pressurized, and purged of air. For this procedure, it is assumed that the system is empty of cooling liquid and must be filled. Under normal situations, the system has already been tested before shipping out and typically has some fluid.

Note:

e30bi799.10

VACON® 3000 Enclosed Drive

Operating Guide

•

Accessibility to certain components of the cooling system can be an issue depending on the layout of the drive and/or the heat

Commissioning

exchanger unit.

•

This guide is not intended to be used as a reference for commissioning cooling systems which are not installed in a VACON® 3000 enclosed drive.

•

Operation and maintenance instructions for Adwatec heat exchangers are available for download at Danfoss product materials

– Adwatec.

To access the inlet and outlet cooling manifolds, locate the cabinet in which the cooling system is installed.

The location of the manifolds varies depending on the internal layout of the cabinet. Sometimes there might not be access to install quick disconnects to the manifolds. In these cases, it is necessary to connect straight to one of the hoses on the power module instead of the manifold.

In the example illustration, the inlet and outlet manifolds are easily accessible. The inlet hoses on the manifold are marked with blue tape and the outlet hoses with red tape.

Illustration 64: Cooling Liquid Inlet and Outlet Manifolds

Connect the cooling fluid pump assembly to the inlet and outlet manifolds with quick connects (if available). Open the valves.

Before filling the system with glycol, verify that all cooling hoses throughout the system are firmly connected and/or torqued. Make certain that any hoses with valves connected to a module have their valves in the open position.

Make sure that the automatic air purger on the main heat exchanger is uncapped and its valve is open.

The air purger is on the main heat exchanger, behind the HX control cabinet. Its location varies depending on the cabinet and heat exchanger design.

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Operating Guide

Illustration 65: Air Purger Location

Begin running the standalone pump and fill the system. Water should be flowing into the inlet while a combination of water and air pockets/bubbles are flowing out from the outlet. If any leak is detected, immediately shut off the pump.

The power of the pump and size of the cooling system dictates the flow rate and how quickly the air can be purged from the system. Use an appropriately sized pump. A pump of at least 0.5 hp or greater is ideal.

Commissioning

When air bubbles/pockets flowing out of the outlet hose are no longer visible, stop the pump.

Close the inlet and outlet valves.

Slowly open the air bleeders on the pumps. Air bubbles out. When the bubbling starts becoming only fluid seeping out, close off the bolts to seal the pumps.

The air bleeders are in the front of the pump, just below the motor. There is one on each of the motor pumps.

Illustration 66: Air Bleeders on the Pumps

Open the inlet and outlet valves and start to run the standalone pump from the glycol tank again.

Run the pump for at least 5 minutes before shutting off.

Close the inlet and outlet valves.

Repeat step 8. There should be fewer air bubbles this time around.

Move to step 10.

10.

Pressurize the system.

Open the inlet valve.

Activate the standalone glycol pump.

AUTO 0 SERVICE

MAIN SWITCH

RUN FAULT ALARM

RESET

2 3

P2 P1+P2

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Wait for the pressure to build up to approximately 1.2 bar.

Close the inlet valve and turn off the pump.

11.

Run the heat exchanger.

Verify that the HX is in ready state (blinking green light).

There are two knobs on the HX control panel. Set the right knob to P1+P2 and the left knob to Service.

The drive of the HX starts to run one of the pumps.

Run the pump for about 5 minutes and stop by turning the left knob back to 0 position.

The HX cooling system requires 480 V AC to run.

Commissioning

Illustration 67: Heat Exchanger Control Panel

12.

Wait ~2 minutes after stopping. Briefly open and close the outlet valve. More air bubbles should come out. Repeat this several times until the pressure is no longer enough to force out any more air pockets.

Illustration 68: Removing the Air

13.

Run the standalone pump again.

Open the inlet valve.

Start to operate the standalone pump and open the outlet valve.

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Air filling tank

Fluid level gauge

Nozzle

VACON® 3000 Enclosed Drive

Operating Guide

14.

When the air has been purged, pressurize the system to 1.2 bar with the standalone pump again.

15.

Check the fluid level gauge.

There is a tank labeled “Air Filling” to the rear of the cooling system cabinet. The fluid level gauge is connected to this tank. On this gauge, is a marker labeled “nominal level”.

Commissioning

Repeat steps 10–12. After the 2nd cycle, the number of air pockets that are purged should be reduced. Repeat the cycle until there are only few small air bubbles remaining. It is not possible to eliminate all the air bub-

bles.

Illustration 69: Location of the Fluid Level Gauge

If the fluid level is above the nominal line: To release excess fluid back into the glycol tank, open the outlet valve. The pressure drops from the 1.2 bar. If the fluid level is still above the “nominal” line after the pressure drops to 0, add air to the “air filling” tank until the fluid level drops to the “nominal” marker.

If the fluid level is below the nominal line: Bleed air out of the tank by pressing the pin on the nozzle. The fluid level on the gauge climbs while the pressure decreases from 1.2 bar. Operate the standalone pump and repressurize. The goal is to be at or slightly above the nominal marker while having 1.2 bar of pressure.

8.4.2 Grid Voltage Feedback Configuration

Grid voltage feedback is a critical component of AFE drives. It must be correctly connected and configured for an AFE drive to be able to properly synchronize with the MV input supply voltage of the drive.

Grid voltage feedback is also necessary to perform the commissioning test. For the commissioning test to be done safely, it must be able to detect whether there is mains power applied to the drive (that it is not powered).

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Operating Guide

Locate the grid voltage feedback connector on the AFE control unit. It is located next to the FO1–FO6 fiber optic slots.

Illustration 70: Grid Voltage Feedback Connector on the AFE Control Unit

Identify the type of potential transformer that is connected from the MV supply to the drive. The feedback configuration is either Wye or Delta.

Connect the grid voltage feedback to the AFE control unit based on the PT type.

If the PT is WYE configured:

Connect phase A to CH1.

Connect phase B to CH2.

Connect phase C to CH3.

Connect the reference to CHR.

Go to the 2.1.1 Line Configuration menu and do these parameter settings:

Grid Voltage FBK Ch A: AN phase voltage

Grid Voltage FBK Ch B: BN phase voltage

Grid Voltage FBK Ch C: CN phase voltage

If the PT is Delta configured:

Connect phase A to CH1.

Connect phase B to CHR.

Connect phase C to CH3.

Leave CH2 empty.

Go to the 3.1.1 Line Configuration menu and do these parameter settings:

Grid Voltage FBK Ch A: AB line voltage

Grid Voltage FBK Ch B: Ground/reference

Grid Voltage FBK Ch C: CB line voltage

Set the other parameters in the 3.1.1 Line Configuration menu.

Nominal Grid Voltage/Frequency: Set to the rated input voltage/frequency of the drive.

Grid Voltage FBK Mode: Set to "Source Voltage".

Grid Voltage FBK Scale: Set based on the expected voltage on the PT secondary. For example, a 35:1 PT ratio at

4160 V equals ≈ 118.8 V secondary voltage. Filter Topology: Set to "LCL".

Regen Filter Select: Select based on the type of phase modules used in the drive.

Commissioning

For example, L20.4, where L20 is the phase module size (L20 or L30) and 4 stands for the input voltage (3=3300 V and 4=4160 V).

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Operating Guide

Special Filter Index: Set to 21000.

Commissioning

8.4.3 Installing Software on the Control Unit

To install the software, each control unit must be connected to separately. After finishing one software installation, disconnect the cable and move it to the next control unit. Make sure that the correct control unit (AFE/INU/BCU) is connected to the PC.

Items required for the software installation:

•

RS485 to USB cable.

•

PC or laptop.

•

The VACON® Live PC tool.

Download VACON® Live from .

Verify that the control unit is powered (the screen on the control panel is on).

Verify that the indicator light on the control unit is green (there are no faults).

If the indicator light is green, skip to step #3.

If the indicator light is red, check the number of the fault. If the fault code is 59 (communication fault), one or more of

the power modules is likely disconnected.

Before opening the cover of the power module section to check the connections, verify that medium voltage is locked out.

Check the modules and verify that the fiber optic cables and the 24 V DC supply are properly connected.

Verify that all the indicator lights are lit on each of the modules.

When the communication fault is cleared, continue to the next step.

If there are still issues with the fault, refer to *INU and AFE phasing* procedure for troubleshooting.

To access the RS485 port, remove the control panel from the control unit.

Connect the RS485 end of the cable to the port on the control unit and the USB end to a PC.

Open the VACON® Live PC tool. When prompted for startup mode, select Online.

After VACON® Live completes searching for connected drives, select the drive, and click Connect to Selected.

Illustration 71: Connecting to the Drive with VACON® Live

After VACON® Live opens, save the current parameter settings.

Open the File menu and select Save file as….

Select an appropriate file name (for example, customer name_drive identity_date).

Save the file into a folder/location that coincides with the contents of the file.

Obtain an up-to-date software build directly from the Danfoss server or request one from the Danfoss software team.

The software build is a file with a ".vcx" extension.

Click this file, and VACON® Loader opens automatically. If VACON® Live is still open, you are prompted to close it.

10.

Click Next to begin.

11.

The same procedure as in VACON® Live for connecting to the drive occurs (step 6). After searching for connected drives is completed, select the drive, and click Connect to Selected.

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Commissioning

12.-Select the appropriate modules to be installed. The modules selected vary depending on the control unit and the drive

type.

Illustration 72: Selecting the Modules to Install in VACON® Loader

Modules to install for AFE control unit in AFE drive

Control firmware

Control firmware (part2)

Select appropriate language

AFE AVUS1253AFE application

M-star firmware

Network configuration

Filter parameters

Belt 1 A phase firmware

Belt 1 B phase firmware

Belt 1 C phase firmware

If the AFE drive has a parallel module configuration, also select the following modules:

Belt 2 A phase firmware

Belt 2 B phase firmware

VACON® 3000 Enclosed Drive

Operating Guide

Belt 2 C phase firmware

If the AFE drive has an Auxiliary I/O board, select the following modules:

Channel 4 Index 1 AUX firmware

No position 2 firmware

No position 3 firmware

If the AFE drive has no Auxiliary I/O board, select the following modules:

No position 1 firmware

No position 2 firmware

No position 3 firmware

Modules to install for INU control unit in AFE drive

Control firmware

Control firmware (part2)

Select appropriate language

INU AVUS1252INU application

M-star firmware

Network configuration

Filter parameters

Belt 1 A phase firmware

Belt 1 B phase firmware

Belt 1 C phase firmware

If the drive has a parallel module configuration, select the following modules:

Belt 2 A phase firmware

Belt 2 B phase firmware

Belt 2 C phase firmware

For the INU control unit of an AFE drive, there are no Auxiliary I/O board settings since the Auxiliary I/O board is already connected to the AFE control unit. Select the modules:

No position 1 firmware

No position 2 firmware

No position 3 firmware

Modules to install for INU control unit in 12-pulse drive

Control firmware

Control firmware (part2)

Select appropriate language

INU AVUS1252INU application

M-star firmware

Network configuration

Filter parameters

Belt 1 A phase firmware

Belt 1 B phase firmware

Belt 1 C phase firmware

If the drive has a parallel module configuration, select the following modules:

Belt 2 A phase firmware

Belt 2 B phase firmware

Belt 2 C phase firmware

If the 12-pulse drive has an Auxiliary I/O board, select the following modules:

Commissioning

VACON® 3000 Enclosed Drive

Operating Guide

Channel 4 Index 1 AUX firmware

No position 2 firmware

No position 3 firmware

Also select the following modules:

Channel 4 Index 1 CBL firmware

No position 2 firmware

No position 3 firmware

Modules to install for CBU control unit in 12-pulse drive (optional)

Control firmware

Control firmware (part2)

Select appropriate language

BCU AVUS1260BCU application

Single unit network configuration

Belt 1 A phase firmware

13.

When the appropriate modules are selected, click Next to begin the installation.

The loading time takes upwards of 30 minutes to complete depending on how many modules are loaded.

Commissioning

14.

After the loading is completed, click Yes to close VACON® Loader.

If the loading fails to reach 100% completion and stops, try again starting from step 8. Before attempting to reinstall:

15.

Check that the core board is fully seated on the auxiliary I/O board.

Check that the fiber cable from the auxiliary I/O board to the appropriate control unit is connected in the correct

ports at both ends.

After the software loading is completed, perform a parameter compare between the new parameter set and the parameter

16.

settings saved in step 7.

See the instructions for comparing the parameters in the VACON® 3000 Application Guides.

8.4.4 Verifying the Phase Module Connections

Before running the drive for the first time, verify the phasing of the INU and/or AFE modules. The verification is done both physically (cabling, busbars) and electrically (identified with 24 V DC control power and fiber optic communication cables).

Obtain a copy of the mechanical drawings of the drive and identify the locations of the phase modules.

Perform a continuity check of the phase module terminal connections.

For INU modules, check the continuity of the connections from the output on the phase module to its correspond-

ing output busbar terminal. For AFE modules, check the continuity of the connections from the output to the L1, L2, L3 busbars where the

main input supply voltage cables are mounted. For dual-belt drives, do the same for the other belt.

Verify, that the fiber optic cables are connected properly between the control units and phase modules.

The fiber from the FO1 slot on the control unit connects to the fiber connector A on either the INU U-phase module or the AFE L1-phase module. The control unit automatically designates the phase module connected to FO1 as a U-phase module (if INU control unit) or L1-phase module (if AFE control unit).

See

7.8 Optical Fiber Connections.

For the remaining module-to-module connections, connect the optical fiber from connector B of the U-phase module to connector A of the next module (which is then designated as V-phase). Then connect the optical fiber from connector B of the V-phase module to connector A of the next module (W-phase). Leave connector B of the last module (W-phase) empty.

The AFE connections are the same, except the designations for the modules are L1, L2, and L3.

If the connections are correct and control power is applied, then the phase modules show the correct belt and phase information on the 4-character LED displays.

In the operation mode, the LED display view changes at an interval of 3 s. The display changes between the belt information indicator and the module information indicator. See 6.7.7 LED Display on the Phase Module.

VACON® 3000 Enclosed Drive

Operating Guide

INU, belt 1

Module 1: __B1 and _2_U

Module 2: __B1 and _3_V

Module 3: __B1 and _4_W

INU, belt 2 (if applicable)

Module 4: __B2 and _5_U

Module 5: __B2 and _6_V

Module 6: __B2 and _7_W

AFE, belt 1

Module 1: __B1 and _2L1

Module 2: __B1 and _3L2

Module 3: __B1 and _4L3

AFE, belt 2 (if applicable)

Module 4: __B2 and _5L1

Module 5: __B2 and _6L2

Module 6: __B2 and _7L3

Confirm that the identification on the LED displays matches the correct input or output terminal that the phase module is connected to.

Commissioning

8.4.5 Commissioning Test

The commissioning test verifies that the drive can be successfully operated without applying medium voltage to the main power terminals (L1, L2, L3). The purpose of the test is to verify operation of the system interlocks and that the pre-charge circuit can close the contactor that supplies medium voltage to the drive.

•

This test does not power up the drive.

•

This test does not run if:

Medium voltage is detected on the input to the mains contactor.

The pre-charge unit has 480 V AC supply power and is connected to the circuit.

•

If either of these two conditions is present, the control unit generates a fault.

The following procedures must be completed before performing the commissioning test:

•

INU/AFE module installation.

•

INU/AFE phasing (see 8.4.4 Verifying the Phase Module Connections).

•

Software download (see 8.4.3 Installing Software on the Control Unit).

•

Cooling fluid addition (see 8.4.1 Filling the Liquid Cooling System).

•

Insulation test of the MV input and output cables.

•

Grid voltage feedback configuration (see 8.4.2 Grid Voltage Feedback Configuration).

Remove power from the input to the main supply power contactor or main circuit breaker (MCB). The drive controls switchgear external to the drive to supply utility voltage to the drive. There is no main circuit breaker internal to

the drive that opens/closes the voltage on the supply terminals (L1, L2, L3). The lockout/tagout procedure must be properly performed.

To prevent accidental charging of the DC link, open the circuit breaker that supplies 480 V AC to the pre-charge unit.

The circuit breaker is in the control compartment. See the wiring diagrams delivered with the drive.

Verify that there was no mistake in the control power wiring and that there is no shock hazard.

On the INU phase modules, disconnect the 24 V DC connector.

See 6.7.1 Phase Module L20/L30 Terminals.

Use a DMM in V AC mode and measure from the +24 V and 0 V terminals to GND.

BYPASS

FR1

FR2

LED

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Operating Guide

Verify that the "breaker enable" DIP switches are in the correct position.

The DIP switches (S1) are on the INU/AFE control unit between fiber optic connectors FR1 and FR2. These two fiber optic inputs are used for the "breaker enable" function. If the DIP switches are in the correct position, a green LED next to the switches is on.

Commissioning

Illustration 73: "Breaker Enable" Connectors, DIP Switches, and LED

If the "breaker enable" function is not used, the fiber optic connectors are plugged. Check that both DIP switches are in the "bypass" position.

If one or both of the "breaker enable" inputs are used, then the corresponding DIP switches must be in the "on" position.

In VACON® Live, make sure that “PCC Gating Enabled” is checkmarked in the Precharge Status Word. If the breaker enable is not properly set, then the commissioning test fails due to failure to receive MX close feedback.

Location of PreCharge Status Word in the menu:

INU application: V2.12.4

•

AFE application: V2.10.4

•

Set the Commissioning test mode parameter to Enable.

Parameter location in the menu:

AFE drives: P3.3.5.3

•

12-pulse drives (INU application): P3.17.5.3

•

The commissioning test can then be performed with the HMI touch screen or with the VACON® Live PC tool.

Commissioning test with the HMI touch screen, see

Commissioning test with the VACON® Live PC tool, see 8.4.5.2 Commissioning Test with VACON® Live.

8.4.5.1 Commissioning Test with HMI Touch Screen.

8.4.5.1 Commissioning Test with HMI Touch Screen

Select the Start Cond tab on the HMI, and check that all the interlocks are made. The power-up sequence starts only if all boxes are highlighted in green.

If a condition is not met, the box is solid black and it must be addresses before the test can be performed.

Give the system a Power On command.

The location of the Power On command in the menu varies depending on the type of drive (12-pulse or AFE).

Check that the cooling system starts. The drive of the heat exchanger runs and the HX circulates the cooling liquid.

Check the PLC Status. It should show Charging, but the DC-link voltage should not charge (should be 0 V DC).

VACON® 3000 Enclosed Drive

Operating Guide

Check that the main contactor closes after the DC pre-charge timeout has elapsed.

The location of the DC Precharge Timeout parameter:

•

AFE application: P3.3.4.9

•

INU application (12-pulse): P3.17.4.9

After the mains contact has been closed, give the system a Power Off command.

Set the Commissioning Test Mode parameter to Disabled.

8.4.5.2 Commissioning Test with VACON® Live

In VACON® Live, go to the Precharge monitoring menu. To see if the drive is ready to attempt a commissioning test, check the monitoring values Precharge State and PowerOn State.

AFE application:

•

Precharge monitoring menu: M2.10

•

Precharge State monitoring value: V2.10.1

•

PowerOn State monitoring value: V2.10.5.1

INU application (12-pulse):

•

Precharge monitoring menu: M2.12

•

Precharge State monitoring value: V2.12.1

•

PowerOn State monitoring value: V2.12.5.1

Commissioning

If either of the two values is not in "ready" state, then an interlock is active and must be resolved before the com-



missioning test can be attempted. Determine what is missing (which unchecked box must be checked), and check the hardware and/or I/O settings of the device which is failing to give the required feedback.

Right-click the PowerOn State parameter, select To Monitoring, and then New Monitor. This value is then used to determine whether the commissioning test is completed successfully.

If Precharge State and PowerOn State are both "ready", then PowerOn State has a value of "3" when viewed with



the monitoring function.

Give the system a "power on" command.

Go to the Internal Control menu.

Change the value of parameter Power Off to "DigIN Slot0.2".

Change the value of parameter Power On to "DigIN Slot0.2".

AFE application:

•

Internal Control menu: M3.3.2.2

•

Power Off parameter: P3.3.2.2.2

•

Power On parameter: P3.3.2.2.1

INU application (12-pulse):

•

Internal Control menu: M3.17.2.2

•

Power Off parameter: P3.17.2.2.2

•

Power On parameter: P3.17.2.2.1

Check that the cooling system starts.

Check that the drive of the heat exchanger runs and the HX circulates the cooling liquid.

Check that the PowerOn State changes to "4" when the HX starts.

Keep monitoring PowerOn State. After a while, the system starts to pre-charge the DC link. In reality, there is no voltage being generated in the DC link. The value set in parameter DC Precharge Timeout starts to count down. PowerOn State shows a value of "5" during the countdown.

The location of the DC Precharge Timeout parameter:

Danfoss VACON 3000 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Introduction

1.1 Purpose of this Operating Guide

1.2 Additional Resources

1.3 Manual Version

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Danger and Warnings

2.4 Cautions and Notices

2.5 Main Circuit Breaker

2.5.1 Safety and Protection Requirements

2.5.2 Minimum Requirements for MCB and MCB Control

3 Product Overview

3.1 Intended Use

3.2 Product Description

3.2.1 AFE Drive

3.2.2 12-Pulse Drive

3.3 Type Code Description

3.4 Available Options

4 Receiving the Delivery

4.1 Checking the Delivery

4.2 Storage

4.3 Lifting and Moving the Enclosed Drive

5 Mechanical Installation

5.1 Operating Environment

5.2 Cabinet Installation

5.3 Dimensions of the Enclosed Drive

5.4 Liquid Cooling Requirements

5.4.1 Safety in Liquid-cooling

5.4.2 General Information on Liquid Cooling

5.4.3 Cooling Liquid

5.4.3.1 Quality Requirements for the Purified Water

5.4.3.2 Purified Water as Coolant

5.4.3.3 Antifreeze Mix as Coolant

5.4.3.4 Temperature of the Cooling Liquid

5.4.3.5 Condensation

5.4.4 Cooling System

5.4.4.1 Materials

5.4.4.2 Cooling System Overview

5.4.4.3 Cooling Connections to the Enclosed Drive

5.5 Cooling and Free Space Around the Enclosed Drive

6 Electrical Installation

6.1 Galvanic Isolation Between the MV and LV Sections

6.2 Mains and Motor Cable Selection

6.3 Mains and Motor Cable Inlet and Termination

6.4 Grounding

6.4.1 Standard Grounding Configurations

6.5 Additional Instructions for Cable Installation

6.6 Main Circuit Breaker Installation

6.7 Cabling of the Power Modules

6.7.1 Phase Module L20/L30 Terminals

6.7.2 DFE Power Module Terminals

6.7.2.1 DFE Control Terminals

6.7.3 Power Module Grounding

6.7.4 DC-Link Connections

6.7.5 Brake Chopper Installation

6.7.6 Terminal Screw Tightening Torque Specifications

6.7.7 LED Display on the Phase Module

6.7.8 LED Display on the DFE Power Module

6.8 Low-Voltage Power Supplies

6.8.1 Low-Voltage Power Supply Connections

6.8.2 Safety Notes for the Precharge Unit

6.8.3 Location of the Precharge Unit

6.9 Safety Functions

6.9.1 Safe Torque Off (STO)

6.9.2 Safe Stop 1 (SS1)

6.9.3 Safety Considerations

6.9.3.1 Diagnostic Test

6.9.4 STO Operating Principle

6.9.5 SS1 Operating Principle

7 Control Connections

7.1 Control Interface

7.2 The Control Compartment of the Enclosed Drive

7.3 Control Unit Components

7.4 Control Unit Cabling