OJ Electronics OJ-DV-1013, OJ-DV-1005, OJ-DV-1007, OJ-DV-1011, OJ-DV-3016 Instructions Manual

...

Download

INSTRUCTIONS

OJ-DV

OJ Drives

A DRIVES PROGRAMME DEDICATED TO VENTILATION SOLUTIONS

INSTRUCTIONS OJ-DV

Contents

1. Product presentation ...............................................................3

2. Introduction ......................................................................3

3. Key to symbols....................................................................3

4. Ensuring safety before installation .....................................................3

5. Product use ......................................................................4

6. Prohibition on use .................................................................4

7. EMC – Electromagnetic compatibility ..................................................4

8. Approvals and certiﬁcations..........................................................4

9. Product programme ................................................................5

10. Rating plate ......................................................................6

11. Exploded and dimensioned drawings ..................................................7

12. Mechanical installation..............................................................9

13. Electrical installation...............................................................10

13.1 Dangerous induced voltage (Windmilling) ........................................10

13.2 EMC-compliant installation ...................................................10

13.3 Short-circuit protection - Power supply..........................................10

13.4 Personal protection - use of RCD’s (TT-system), direct current (AC/DC) risk .............10

13.5 Potential equalisation........................................................11

13.6 Grounding hazard (PE) leakage current hazard....................................11

13.7 Cable requirements .........................................................11

13.8 Opening the OJ-DV .........................................................12

13.9 Cable entries – cable glands – strain relief .......................................12

13.10 Spring terminals............................................................13

13.11 Terminal and connector overview ..............................................13

13.12 Motor connection...........................................................13

13.13 Mains voltage connection ....................................................14

13.14 Modbus connection.........................................................14

13.15 A/D control signal connections ................................................15

13.16 Closing of OJ-DV ...........................................................16

14. Checklist – mechanical and electrical installation ........................................17

15. Hand terminal (Hterm) – connection and functions .......................................18

16. PCTool – connection and functions ...................................................18

17. Optional modules – connection and function ...........................................18

18. Functions .......................................................................19

18.1 Analogue/digital control......................................................19

18.2 Modbus control ............................................................19

18.3 Switching frequency ........................................................19

18.4 Braking power .............................................................20

18.5 Fire mode ................................................................20

18.6 Frequency converter mode – for asynchronous motors ............................20

18.7 Electronically commutated mode (EC mode) – for PM and BLDC motors ...............21

19. Built-in protection ................................................................22

20. Alarms .........................................................................22

21. Modbus addressing of OJ-DV ......................................................24

22. Maintenance.....................................................................24

23. Troubleshooting ..................................................................25

24. Disposal ........................................................................27

25. Technical speciﬁcations............................................................28

INSTRUCTIONS OJ-DV | General

1. Product presentation

OJ-DV is a range of controllers suitable for regulating the speed of an electric motor in a wide variety

of applications.

OJ-DV is highly versatile as it can control various motor types, including:

• ACIM - asynchronous induction motors

• PMSM - permanent magnet synchronous motors

• BLDC - brushless DC motors

2. Introduction

• Read this manual thoroughly and follow the instructions it contains before taking OJ-DV into use.

• This manual contains important information and should be used when installing, connecting and commissioning the OJ-DV as well as during maintenance, service and troubleshooting.

• If the instructions contained in this manual are not observed, the liability of the supplier and the warranty shall be voided (see also Section 6. Prohibition on use).

• Technical descriptions, drawings and ﬁgures must not be wholly or partly copied or disclosed to third parties without the permission of the manufacturer.

• All rights are reserved if the product is included in patent rights or other form of registration.

3. Key to symbols

Particular attention should be paid to the sections in these instructions which are marked with

symbols and warnings.

Warning

3.1. This symbol is used where there is a risk of severe or fatal personal injury.

Caution

3.2. This symbol is used where potentially dangerous situations may result in minor or moderate personal

injury. The symbol is also used to warn against unsafe and hazardous conditions.

Note

3.3. This symbol is used to indicate important information and in situations which may result in serious

damage to equipment and property.

Warning

4. Ensuring safety before installation

4.1. OJ-DV must only be installed by qualiﬁed personnel or people who have received appropriate

training and have thus become qualiﬁed to install the product.

4.2. Qualiﬁed personnel have knowledge of the installation practices used and can perform installation in

accordance with relevant local and international requirements, laws and regulations.

4.3. Qualiﬁed personnel are familiar with the instructions and safety precautions described in this manual.

4.4. OJ-DV contains dangerous high voltage when connected to the mains.

4.5. Mains voltage must always be disconnected before any installation, service or maintenance tasks are

performed on the product.

4.6. When OJ-DV is connected to the mains, there is a risk that the motor could start unintentionally,

causing a risk of dangerous situations and personal injuries.

4.7. Unintentional start during programming, service or maintenance may result in serious injury or

damage to equipment and property.

4.8. The motor/fan can be started via an external input signal, Modbus or a connected control panel.

4.9. Before connecting mains voltage to OJ-DV, all OJ-DV, motor and fan components must be properly

ﬁtted.

4.10. Before connecting mains voltage to OJ-DV, all openings, covers and cable glands must be properly

ﬁtted and closed. Unused cable glands must be replaced with blank glands.

INSTRUCTIONS OJ-DV | General

4.11. OJ-DV contains capacitors which become charged during operation. These capacitors can remain

charged even after the power supply has been cut o. There is a risk of severe personal injury if the connection terminals or wire ends are touched before these capacitors have been completely discharged. The discharge time is about 3 minutes under normal conditions.

5. Product use

5.1. OJ-DV is especially used in ventilation applications (fans).

5.2. OJ-DV can also be used in other applications. If OJ-DV is used in applications where it cannot be

positioned directly in a ﬂow of air, impaired OJ-DV cooling must be taken into account. This can be countered by creating additional ventilation around the product or by reducing performance requirements. See Section 25. Technical speciﬁcations.

5.3. OJ-DV is an electronic motor controller used to regulate fan speed. OJ-DV can be used to control AC

asynchronous motors, BLDC motors and PM motors.

5.4. Depending on what is needed, OJ-DV is suitable for stand-alone applications or as part of larger

systems/machines.

5.5. The product can be used under various environmental conditions. See Section 25. Technical

speciﬁcations.

5.6. OJ-DV can be ﬁtted directly to the frame of the fan motor, thus saving space.

5.7. Motor operation can be regulated by commands from an external controller.

5.8. OJ-DV has built-in motor protection.

5.9. OJ-DV can be used in domestic and industrial environments and has a built-in EMC ﬁlter.

5.10. The OJ-DV is developed for use in industry and deﬁned as professional equipment according to

EN 61000-3-2:2014, it is not intended for sales to the general public.

Warning

6. Prohibition on use

• The OJ-DV must not be taken into use until the machine or product into which it is incorporated has in its entirety been declared to be in conformity with all relevant national and international regulations.

• The product must not be energised until the entire installation complies with ALL relevant EU directives.

• The product carries a manufacturer's warranty if installed in accordance with these instructions and applicable installation regulations.

• If the product has been damaged in any way, e.g. during transport, it must be inspected and repaired by authorised personnel before being connected to the power supply.

• If OJ-DV is built into machinery with rotating parts, e.g. a ventilation system, transport system, etc., the entire system must comply with the Machinery Directive.

7. EMC – Electromagnetic compatibility

• OJ-DV has built-in EMC ﬁlter.

8. Approvals and certiﬁcations

CE marking

• OJ Electronics A/S hereby declares under sole responsibility that the product complies with the following European Parliament directives:

• LVD - Low voltage: 2006/95/EU

• EMC - Electromagnetic compatibility: 2004/108/EU

• RoHS - Hazardous substances: 2011/65/EU

Product standard

• In accordance with EN 61800-2 – Adjustable speed electrical power drive systems. Part 2. General requirements.

INSTRUCTIONS OJ-DV | General

Safety

• In accordance with EN 61800-5-1 – Adjustable speed electrical power drive systems. Part 5. Safety requirements – Electrical, thermal and energy.

EMC - Electromagnetic compatibility

Table 8.1

OJ-DV size Motor cable length Intended use PDS of category

EN-61800-3

0.55…..1.3 kW <5.0 m First environment C1 & C2 EN-61000-6-2 EN-61000-6-3

1.5…..3.0 kW <5.0 m First environment C1 & C2 EN-61000-6-2 EN-61000-6-3

4.0…..7.5 kW <5.0 m First environment C1 & C2 EN-61000-6-2 EN-61000-6-3

11.0 kW <5.0 m First environment C1 & C2 EN-61000-6-2 EN-61000-6-3

15.0 kW <4.0 m First environment C1 & C2 EN-61000-6-2 EN-61000-6-3

11.0…..15.0k W >4.0 Second environment C3 EN-61000-6-2 EN-61000-6-4

• In accordance with EN 61800-3 – Adjustable speed electrical power drive systems. Part 3. EMC requirements and speciﬁc test methods. See table 8.1

• The OJ-DV product line fulﬁls the “residential level” for emissions as per EN-61000-6-3 and the “industrial level” for immunity as per EN-61000-6-2 with up to 5 metre shielded motor cables. (15kW is limited to up to 4 metre motor cables).

• Longer motor cables can be used. Industrial level for both immunity and emissions can be fulﬁlled, depending on the cable capacity as well as the motor capacity.

By reducing the motor cable length, it is possible to install up to 6 OJ-DVs in the same unit with EN-618003 C1 & C2 still being fulﬁlled. RoHS compatible

• Contains no hazardous substances according to the RoHS Directive.

Immunity Emission

9. Product programme

• OJ-DV is available in four dierent enclosures, whose size depends on the rated power of the

OJ-DV.

• The product programme contains 12 power sizes ranging from 0.55 kW to 15.0 kW, see table 9.

• Enclosures are designated ”H1”…”H5”, where ”H1” is the smallest and ”H5” is the largest.

• All enclosures are made of die-cast aluminium.

Table 9

Product name Enclosure Power Supply voltage Dimensions (w, h, d) OJ-DV-1005 H1 0.55 kW 1 x 230 V 185 x 230.5 x 90 mm OJ-DV-1007 H1 0.75 kW 1 x 230 V 185 x 230.5 x 90 mm OJ-DV-1011 H1 1.1 kW 1 x 230 V 185 x 230.5 x 90 mm OJ-DV-1013 H1x 1.3 kW 1 x 230 V 185 x 265 x 125 mm OJ-DV-3016 H3 1.6 kW 3 x 400 V 185 x 265 x 100 mm OJ-DV-3024 H3 2.4 kW 3 x 400 V 185 x 265 x 100 mm OJ-DV-3030 H3 3.0 kW 3 x 400 V 185 x 265 x 100 mm OJ-DV-3040 H4 4.0 kW 3 x 400 V 220 x 294 x 107 mm OJ-DV-3055 H4 5.5 kW 3 x 400 V 220 x 294 x 107 mm OJ-DV-3065 H4 6.5 kW 3 x 400 V 220 x 294 x 107 mm OJ-DV-3075 H4 7.5 kW 3 x 400 V 220 x 294 x 107 mm OJ-DV-3110 H5 11.0 kW 3 x 400 V 244 x 399 x 144 mm OJ-DV-3150 H5 15.0 kW 3 x 400 V 244 x 399 x 144 mm

All 3x400V versions can also be connected to 3x230V. The power output (kW) will, however, be limited to max. 58% (1/√3) of the rated power output at 3x400V.

INSTRUCTIONS OJ-DV | General

Caution

With enclosure sizes H3 ... H5, OJ-DV operating and motor parameters are set for connection to a supply voltage of 3x400V. If these types are connected to a 3x230V power supply, operating and motor parameters must therefore be changed for optimum operation. Motor parameters can be changed by the installer via the hand terminal (OJ-DV Hterm), OJ-Drives-Tool or OJ-DV PCTool. Conﬁguration parameters can only be changed by the manufacturer.

10. Rating plate

10.1. OJ-DV is equipped with a silver-coloured rating

plate.

See the example in ﬁg. 10.1 and explanation in

table 10.2.

Check that the information speciﬁed on the rating

plate is as expected.

10.2. Rating plate, information and explanation

10.3. Explanation of product code

Each and every OJ-DV is given its own product

code during manufacture.

The product code (see table 10.3) gives precise

information on the speciﬁc OJ-DV.

The product code contains the following

information:

Table 10.3

Week number

W W B B B B B S S S S S Y Y

Week of production

Batch Serial no. Year

Manufacturer's order number

Unit number

Year of manufacture

Figure 10.1

Table 10.2

1 Product ID = see table 10.4. 2 Shaft power at nominal voltage 3 Max. input voltage, Hz/A 4 Max. output voltage/Hz/A 5 Product code = see table 10.3. 6 Enclosure rating 7 Weight 8 Temperature range, operating 9 Manufacturer's logo 10 Manufacturer's web address 11 Manufacturer's postal address 12 Country of manufacture 13 CE approved, logo 14 Disposal, logo 15 Bar code 16 EAC approved, logo

10.4. The product ID consists of a combination of 14

numbers and letters, each of which provides information about the speciﬁc product, see ﬁg.

10.4 and table 10.4.

Table 10.4

1 2 3 4 5 6 7 8 9 10 11 12 13

Manufacturer's initials

Product type

Electrical connection

Controller power/size

Optional module type Cable entry Integrated cooling fan

INSTRUCTIONS OJ-DV | Installation

Figure 10.4

Type: “V”: Ventilation “R”: Rotor “C”: Conveyor

11. Exploded and dimensioned drawings

Figure 11.1

BR1014A21b

Table 11.1

No. Description No. Description 1 Motor connection terminals 5 RJ12 Modbus connectro (2 x xslave/1 x Master) 2 Connections for future use 6 3-point stain relief for Modbus connector cable (ribbon cable) 3 Connector for optional modules 7 Power terminals (H1=L, N, PE); (H3, H4, H5=L1, L2, L3, PE) 4 Terminal strip for Modbus and A/D control signals 8 Connector for the earth (PE) protective conductor

BR1014A21b

INSTRUCTIONS OJ-DV | Installation

Dimensioned drawings

Figure 11.2

Figure 11.4

Figure 11.3

52.25

40.5

185

52.25

230.5

40.5

185

52.25

BR1014A25a

8.5

265.5

8.5

100

52.25

40.5

BR1014A25a

BR1014A23a

8.5

BR1014A23a

Figure 11.5

29.5

66.5

BR1014A22b

8.5

54.5

34.5

20.7

BR1014A24a

8.5

107.5

Figure 11.6

399

220

55.222

144

BR1014A24a

50 52.25

40.5

265.5

8.5

BR1014A43a

21.5

68.5

244

8.5

BR1014A22b

125

40.5

52.25

8.5

184.5

BR1014A43a

INSTRUCTIONS OJ-DV | Installation

12. Mechanical installation

Incorrect mechanical installation may cause overheating and impaired performance.

Warning

• OJ-DV must only be installed by trained/experienced personnel.

• To ensure proper cooling of the OJ-DV, it must be positioned in such a way that the passing air ﬂow (> 3 m/s turbulent air speed) can cool the OJ-DV cooling ﬁns. (3 m/s turbulent air speed is equivalent to 6.5 m/s laminar air speed). If the OJ-DV is installed in a reduced air ﬂow (< 3 m/s turbulent air speed) or mounted outside a direct airstream, the output power (kW) will be reduced. External on-board cooling fan can be added.

• Only OJ-DV-1013 can be installed without considering the above requirements for sucient air ﬂow over the cooling ﬁns. OJ-DV-1013 is supplied with extra large cooling ﬁns and can therefore be mounted in still air with an air temperature of max. 40°C.

See Section 25: Technical Speciﬁcations.

• To facilitate future service and maintenance tasks, ensure that there is sucient space around the unit after it has been installed.

• To achieve the speciﬁed enclosure rating, the cable glands must not point upwards (see ﬁg. 12.4).

• To prevent water from entering OJ-DV via cables and cable glands, ensure that connection is performed in such a way that water is prevented from accumulating around the cable in the gland. See ﬁg. 12.5.

• Check that the surface to which OJ-DV is attached is capable of supporting the entire weight of the unit.

• OJ-DV can be mounted vertically, horizontally or at an incline. See ﬁg. 12.4.

• OJ-DV must be installed on a ﬂat solid surface.

• To avoid unnecessarily long motor cables (max. 5 m), OJ-DV should be installed as close to the motor as possible.

• Use only the pre-cut installation holes/screw holes to secure OJ-DV in place.

• Dimensioned drawings, see ﬁgs 11.2 to 11.6.

Figure 12.4

BR1014A05a

Figure 12.5

BR1014A26a

INSTRUCTIONS OJ-DV | Installation

13. Electrical installation

Warning

• OJ-DV must only be installed and commissioned by trained/qualiﬁed personnel.

• Check that the data speciﬁed on the rating plate of the motor matches the data speciﬁed on the OJ-DV rating plate.

• Incorrect electrical installation may cause a risk of severe or fatal personal injury.

Warning

13.1 Dangerous induced voltage (Windmilling)

• If natural drafts through the duct system cause the fan to rotate even when it has not received an operating signal (called windmilling), there is a risk that the motor will induce voltage on the OJ-DV motor terminals, making them dangerous to touch.

Caution

13.2 EMC-compliant installation

• Always use shielded cables as motor cables.

• Shielded cable is not necessary for I/O signal cables and Modbus cables.

• Cable shields must always be electrically connected to the earthed product enclosure.

• Use the internal, factory-ﬁtted cable clamps to ensure proper shield connection.

• Never convey mains voltage, motor connections and control signals in the same cable.

• The +24 VDC from the OJ-DV is not intended to be used as power supply for third party products. If the +24 is used for power supply to third party products, the product might not fulﬁll the EMC regulations.

Note

13.3 Short-circuit protection – Power supply

• Short-circuit protection for the supply side of OJ-DV is not provided together with the product.

• Correct short-circuit protection at the power supply input side on the OJ-DV must always be used in accordance with local and international regulations.

• Short-circuit protection equipment must as a minimum have a tripping curve “C” conforming to IEC 60898-1.

• Short-circuit protection is supplied by the installer.

Warning

13.4 PERSONAL PROTECTION - USE OF RCDs (TT-system), DIRECT CURRENT (AC/DC) RISK

This product can cause a DC current in the ground protective conductor in the event of a ground

fault.

If the 3 phases to the OJ-DV are not switched in at exactly the same time, then there will be a

generated current in the earthing/ground conductor during the switching time until all 3 phases are connected.

Take notice of the following precautions:

• If a residual current device (RCD) is used for extra personal protection, use only an RCD of Type B on the supply side of this product (B type, for alternating and/or pulsating current with DC components and continuous fault current).

• RCDs of type B must comply with all provisions of IEC 61008/9

• Protective earthing of the OJ-DV in combination with the use of RCDs must always be performed in accordance with the relevant local and international requirements, laws and regulations

• Failure to follow these precautions can lead to severe or fatal injuries to persons and animals.

INSTRUCTIONS OJ-DV | Installation

Warning

13.5 Potential equalisation

• There is a risk of electrical interference if the ground potential between the OJ-DV and the air handling unit or duct dier from each other. In the event of potential dierences between system components, an equalisation conductor must always be ﬁtted.

• Recommended cable cross section: 10 mm2.

• Lugs should be used, and the equalisation conductor should be attached to the OJ-DV enclosure via one of the screws used to mechanically install the unit.

Warning

13.6 GROUNDING HAZARD (PE) LEAKAGE CURRENT HAZARD

Follow national and local regulations regarding protective earthing of equipment with a leakage current

exceeding 3.5 mA.

The OJ-DV technology causes switching at high frequency. This will generate a leakage current in the

earth/grounding connection, PE. (PE=Protective Earth).

This ground leakage current is dependant on the dierent conﬁgurations, including RFI ﬁltering, shielded

motor cables and the motor type.

EN/IEC61800-5-1 (Power Drive System Product Standard) requires special emphasis because the

leakage current in the OJ-DV possibly exceeds 3.5 mA. See EN60364-5-54 paragraph 543.7 (Reinforced protective conductors for protective conductor currents exceeding 10 mA) for further information.

Earth/grounding connection must be made in one of the following 3 ways:

• When connecting only one (1) PE conductor, the minimum cross-section should be at least 10 mm2,

• When connecting 2 separate ground conductors, both should comply with the dimensioning rules.

• If 2 conductors are used, they must be connected to individual earth/grounding connectors in the OJ-

DV controller.

• External grounding connection. If the machine housing is approved as a grounding connector, then

the OJ-DV can be grounded to the machine.

• Grounding connectors must always be made in accordance with applicable local and international

standards and directives.

• Follow all local and national electrical regulations for earth/grounding the OJ-DV properly.

• Establish well-executed protective grounding for this OJ-DV that has a leakage current exceeding 3.5 mA.

• A dedicated ground conductor is required for input power, motor power and control wiring.

• Use the clamps and connectors on the OJ-DV for proper ground connections.

• Do not “daisy chain” the ground connection between 2 or more OJ-DV controllers.

• Keep the ground conductor connections as short as possible.

• Always use shielded cables between the OJ-DV and motor, to reduce electrical noise.

• Follow motor manufacturer wiring requirements.

Note

13.7 Cable requirements

• All cables and conductors used in connection with the OJ-DV must comply with local and national rules and regulations.

• The OJ-DV product line fulﬁls the “residential level” for emissions as per EN-61000-6-3 and “industrial level” for immunity as per EN-61000-6-2 with up to 5 metre shielded motor cables. (15 kW is limited to up to 4 metre motor cables). Longer motor cables can be used but it is the installer’s responsibility to ensure the standards in EN-61000-6-2 are complied with. Industrial level for both immunity and emissions can be fulﬁlled, depending on the cable capacity as well as the motor capacity.

• A 6-core, unshielded, 30 AWG/0.066 mm² telecommunications cable can be used as a Modbus cable.

• Generally, cable types with copper conductors are recommended.

• For recommended cable dimensions, see table 13.7.

INSTRUCTIONS OJ-DV | Installation

Table 13.7

Power cable

Cable gland Cable diameter Cable size, min. Cable size, max. Core sleeve/stripped min.

H1/H1x M20 6-12 mm 3x1.5 mm H3 M20 6-12 mm 4x1.5 mm H4 M20 6-12 mm 4x1.5 mm H5 M25 11-18 mm 4x2.5 mm

Motor cable

Cable gland Cable diameter Cable size, min. Cable size, max. Core sleeve/stripped min.

H1/H1x M20 6-12 mm 3x1.5 mm H3 M20 6-12 mm 4x1.5 mm H4 M20 6-12 mm 4x1.5 mm H5 M25 11-18 mm 4x2.5 mm

A/D control cable

Cable gland Cable diameter Cable size, min. Cable size, max. Core sleeve/stripped min.

H1/H1x M20 6-12 mm 2x2x0.7 mm H3 M20 6-12 mm 2x2x0.7 mm H4 M20 6-12 mm 2x2x0.7 mm H5 M20 6-12 mm 2x2x0.7 mm

Modbus round cable

Cable gland Cable diameter Cable size, min. Cable size, max. Core sleeve/stripped min.

H1/H1x M16 4-8 mm 3x2x0.7 mm H3 M16 4-8 mm 3x2x0.7 mm H4 M16 4-8 mm 3x2x0.7 mm H5 M16 4-8 mm 3x2x0.7 mm

Modbus ribbon cable

H1 ... H5: Telecommunication cable/ribbon cable, 6-core, unshielded, 30 AWG/0.066 mm²

3x2.5 mm 4x2.5 mm 4x4 mm 4x10 mm

10x2x0.7 mm 10x2x0.7 mm 10x2x0.7 mm 10x2x0.7 mm

10 mm 10 mm 10-15 mm 10-18 mm

10 mm 10 mm 10 mm 10 mm

13.8 Opening the OJ-DV

• Check that the voltage supply to OJ-DV has been disconnected before opening the cover.

• Wait approx. 3 minutes after disconnecting mains voltage before removing the cover.

• OJ-DV is opened by loosening the six Torx 20 screws holding the plastic cover in place.

• Carefully remove the loosened cover.

13.9 Cable entries – cable glands – strain relief

Figure 13.9

• The factory-ﬁtted cable glands should be used when inserting power, motor and control cables into OJ-DV.

• Remember to re-tighten the cable glands to ensure

OJ-DV låg

ingress protection and strain relief.

• If Modbus communication is based on 6-core, unshielded, 30 AWG/0.066 mm² telecommunication

Gummipakning

Modbus kabel

cable, the cable must be inserted through the purpose-moulded rubber seal. See ﬁg. 13.9.

• The rubber seal has a cut insertion slit and assure

the product enclosure rating if properly ﬁtted. See ﬁg. 13.9.

• The Modbus cable entry features 3-point strain relief, which must be used.

OJ-DV låg

-DA

BR1014A06a

BR1014A07a

INSTRUCTIONS OJ-DV | Installation

Control signals

13.10 Spring terminals

• If multi-core cables/leads are used, core sleeves/ end sleeves must always be used.

• The connection terminals are spring loaded and the stripped wire can be easily inserted into the terminal by carefully pushing the wire into the terminal without using tools. Alternatively, the terminal spring can be loosened by pressing it lightly with a screwdriver or similar implement. See ﬁg. 13.10.

• Solid and multi-core cables/leads can be used.

• Stripped wire ends or end sleeves must be between 8 and 15 mm.

• Wires can be removed by carefully loosening the terminal spring by pressing lightly with a screwdriver or similar implement. See ﬁg. 13.10.

13.11 Terminal and connector overview

Figure 13.11

OJ-DV

Motor

Future use

Open collector

BR-

BR+

Modbus

Gnd

+10Vdc

0-10Vin

Gnd

Din2

Din1

Dout1

Gnd

-V+

Adr.Pin1

-Add. Pin1

-Bus B

-Bus A

Adr.Pin2

-Add. Pin2

-Gnd

Adr.Pin1

-Add. Pin1

-Bus B

-Bus A

Adr.Pin2

-Add. Pin2

-Gnd

-V+

-Gnd

-Bus B

-Bus A

-V+

-Gnd

Figure 13.10

3-Phase connection

RJ12 Modbus Slave

RJ12 Modbus Master e.g. PTH/VOC

BR1014A01a

BBR1014A01a

-GB

BR1014A03c

13.12 Motor connection

• The motor cable must be connected to the

• When the stripped wire is properly inserted into

• IMPORTANT! The motor cable must always be

• Remember to re-tighten the cable glands to

terminals marked ”U”, ”V”, ”W” and ”PE”.

the terminal (see section 13.10), the terminal tensions automatically with the correct torque.

a shielded cable and the shield must be ended in the clamp intended for that purpose. See ﬁg.

13.12.

ensure ingress protection and strain relief.

Figure 13.12

BR1014A09a

8-15mm

BR1014A09a

Motor

BR- BR+

INSTRUCTIONS OJ-DV | Installation

13.13 Mains voltage connection

• With 3-phase OJ-DV units, connect the power cable to the terminals marked ”L1”, ”L2”, ”L3” and ”PE”. See ﬁg. 13.13.1. On 1-phase OJ-DV units, the terminals are marked ”L”, ”N” and ”PE”. See ﬁg.

13.13.2.

• Pay special attention to section 13.6 in these instructions, in particular:

• Earth/grounding connection must be made in one

of the following 3 ways:

• When connecting only one (1) PE conductor,

the minimum cross-section should be at least 10 mm2, or

• When connecting 2 separate ground

conductors, both should comply with the dimensioning rules.

• If 2 conductors are used, they must be

connected to individual earth/grounding connectors in the OJ-DV controller.

• External grounding connection. If the

machine housing is approved as a grounding connector, then the OJ-DV can be grounded to the machine.

• Grounding connectors must always be made

in accordance with applicable local and international standards and directives.

• It is recommended that the PE wire is 20 mm longer than the other wires in the cable. If the cable is accidentally pulled out of the OJ-DV while there is voltage on the cable and terminals, the PE wire will then be the last to be disconnected. OJ-DV is thus prevented from causing electric shock.

• When the stripped wire is properly inserted into the terminal (see section 13.10), the terminal tensions automatically with the correct torque.

• Remember to re-tighten the cable glands to ensure ingress protection and strain relief.

Figure 13.13.1

L2 L3

MAINS

8-15mm

BR1014A08b

Figure 13.13.2

BR1014A08b

MAINS

12mm

BR1014A27b

13.14 Modbus connection

• OJ-DV is equipped with four connectors for Modbus connection.

• It also features 3 x RJ12 connectors and one strip of spring terminals.

• On the terminal strip with spring terminals for control signals (A/D I/O), the terminals for connecting Modbus are marked ”Bus A”, ”Bus B” and ”GND”. See ﬁg. 13.14.1.

• If wanted, a round cable can be used for Modbus communication, connected to terminals marked ”Bus A” and ”Bus B” on the OJ-DV terminal strip.

• The Modbus terminals are internally connected in parallel to the Modbus pins in the RJ12 connectors marked ”A” and ”B”.

• The three 3 RJ12 connectors are marked ”A”, ”B” and ”C”.

• ”A”: Modbus connection, slave, +24 V voltage in

connector.

Figure 13.14.1

Bus A

Bus B

GND

+10Vdc

-V+

-Add. Pin1

-Bus B

-Bus A

-Add. Pin2

-Gnd

-Add. Pin1

-Bus B

-Bus A

-Add. Pin2

-Gnd

-V+

-Gnd

-Bus B

-Bus A

-V+

-Gnd

BR1014A16a

INSTRUCTIONS OJ-DV | Installation

• ”B”: Modbus connection, slave, no +24 V voltage in connector.

• ”C”: Modbus connection, Master, external equipment, e.g. PTH/VOC. See ﬁg. 13.11.

• A 6-core, unshielded, 30 AWG/0.066 mm² telecommunications cable or similar type of ribbon cable can also be used for Modbus communication.

• Attach RJ12 connectors to both ends using a special-purpose tool.

• The OJ-DV is prepared to be installed in Modbus networks either in daisy chain or star

networks. Every OJ-DV has a preinstalled Modbus termination resistor of size 1 kΩ, which in most applications would be sucient.

• Extra Modbus termination resistor is not to be used, except in installations where the Modbus

exceeds >100 m in a daisy chain Modbus connection.

• If the Modbus exceeds >100 m, it might be necessary to install an extra Modbus termination

resistor of size 180 Ω. This resistor is only to be installed in the last OJ-DV in the chain.

• In Modbus star connection installations, a Modbus termination resistor is mostly not to be used.

Note

IMPORTANT! RJ12 connectors must be ﬁtted to the ends in such a way that both connectors have the same colour sequence as the cable. See ﬁg. 13.14.2.

13.15 A/D control signal connections

• Connect A/D control signals to the terminal strip, see ﬁg. 13.15.1

• For further information on using the spring terminals, see section 13.10.

• The function/programming of A/D inputs and outputs can be changed via Modbus.

For further information on the Modbus protocol,

contact OJ Electronics A/S

• +10Vdc = Constant + 10 VDC for control signal

and NOT intended as power supply for other purposes.

• Short-circuit proof also short-circuit between

+24 VDC and +10 VDC

• Tolerance ± 3%

• 0-10V In = Analogue 0-10V control input for

speed

• Potentiometer, electrical connection, see ﬁg.

13.15.2.

Figure 13.14.2

Figure 13.15.1

Bus A

Bus B

GND

+10Vdc

0-10V In

GND

Din2

Din1

Dout1

GND

Figure 13.15.2

Bus A

Bus B

GND

+10Vdc

0-10V In

GND

Din2

Din1

Dout1

GND

Same colour sequence

Samme farverækkefølge

8-15mm

-V+

-Add. Pin1

-Bus B

-Bus A

-Add. Pin2

-Gnd

-Add. Pin1

-Bus B

-Bus A

-Add. Pin2

-Gnd

-V+

-Gnd

-Bus B

-Bus A

-V+

-Gnd

BR1014A02a

BR1014A15a

BR1014A20a

INSTRUCTIONS OJ-DV | Installation

• Potentiometer: min. 500 Ω, recommended

4.7kΩ

• Internal input impedance: 60 kΩ

• External controller, electrical connection,

see ﬁg. 13.15.3

• GND = Ground (-)

• Din2 = Alarm reset (factory setting)

• Digital input

• Internal input impedance: 60 kΩ

• Electrical connection, see ﬁg. 13.15.4

• Din1 = Start/Stop (factory setting)

• Digital input

• Internal input impedance: 60 kΩ

• Electrical connection, see ﬁg. 13.15.4

• Dout1 = Tacho Out; Open Collector (factory

setting)

• Digital output

• Pull-up resistance range 1.5-22 kΩ

• Pull-up voltage range 0-24 V DC

• Pull-up current range 1-20 mA

• Logical low for high stability after 1 ms

• If EMC sensitive equipment is to be connected,

then an external RC ﬁlter must be mounted with a time constant of 1 µs.

• Electrical connection, see ﬁg. 13.15.5

• GND = Ground (-).

Figure 13.15.3

Bus A

Bus B

GND

+10Vdc

0-10V In

GND

Din2

Din1

Dout1

GND

Figure 13.15.4

Bus A

Bus B

GND

+10Vdc

0-10V In

GND

Din2

Din1

Dout1

GND

Figure 13.15.5

+10Vdc

0-10V In

Bus A

Bus B

GND

Din2

Din1

Dout1

GND

Controller

+Vout

GND

Controller

+24V

BR1014A18a

AoutX

BR1014A18a

BR1014A19a

DoutX

BR1014A19a

BR1014A17a

RΩ

BR1014A17a

13.16 Closing of OJ-DV

• When all electrical connections have been correctly mounted, OJ-DV can be closed again

• Fasten the blue plastic cover with the associated 6 TX20 screws.

• Tightening torque on the screws in the blue cover is 2 Nm. To ensure that the product constantly maintains the IP enclosure rating speciﬁed for the product, it must be ensured that the 6 TX20 screws are suciently tightened to the tightening torque. At the same time, it must be ensured that the tightening torque is not so high that the blue plastic cover is deformed.

INSTRUCTIONS OJ-DV | Installation

14. Checklist – mechanical and electrical installation

• Before OJ-DV is energized for the ﬁrst time, installation and connection must be checked.

• Use the table below as a checklist.

Item to be checked Description of check √

Completion Check that the entire installation is ready to be commissioned, both electrically and mechanically, before

Product conformity Check that the mains voltage on the supply terminals corresponds to the rated input voltage of the OJ-

Mechanical installation

Ambient conditions Check that requirements on the surrounding environment have been met.

Cabling Check that all cabling has been ﬁtted correctly and that motor and control cables are kept apart in

Electrical installation Check that cables have been correctly inserted into OJ-DV and that the cable glands have been correctly

energizing the installation.

Check that no people or animals are present in the vicinity of moving parts.

DV.

Check the rating plates of the motor and OJ-DV to ensure that the units have been sized correctly. Check that OJ-DV is correctly and securely attached to a ﬂat surface.

See Section 12 in this manual. Check that there is a free, unobstructed passage of air to the cooling ﬁns.

See Section 12 in this manual. Check that the blue plastic cover on OJ-DV is correctly mounted and that all screws are suciently

tightened before switching the power on to the product. Tightening torque on the screws is 2 Nm. Check that all unused cable glands and other unused openings are appropriately blanked o in

accordance with the applicable enclosure rating.

Check that temperature and other environment speciﬁcations are observed.

See technical speciﬁcations, Section 25 in this manual.

separate cable conduits. Check that the motor cable is a shielded cable and that its length is no longer than 5 metres. Check that all cables are securely attached and relieved of tension and torsion.

tightened. Check that the OJ-DV voltage supply terminals have been connected to the correct mains voltage level.

Check that all cables are correctly ended and securely attached. Check that all cables are free of visible damage throughout their length. Check whether there are any loose connections, which may cause overheating and serious damage to

the product and property.

Mains voltage Check that the mains voltage wires have been correctly ﬁtted to the supply terminals: one-phase on

Motor connection Check that motor cables are correctly connected to ”U”, ”V”, ”W” and ”PE” – and check that tightening

Control and signal wires

Shield Check that the motor cable shield is ended correctly and use continuity measurement to check that the

Fuses and circuit breakers

Earthing Check that all earth connections in the motor and OJ-DV are correctly connected and free of oxidation.

terminals ”L”, ”N” and ”PE” and three-phase on terminals ”L1”, ”L2”, ”L3” and ”PE”. Check by means of voltage measurement that there is the correct voltage on the terminals. Check short-circuit protection and supplementary protection.

torque is correct on the spring terminals of the motor. Check that control cables are ended correctly and securely attached. Check that both ends of the Modbus cable have been attached to the correct connectors.

shield is connected to an active earth connection at both ends. Check that active short-circuit protection has been correctly ﬁtted and sized. Check that all safety equipment is operative and set correctly.

Check by means of continuity measurement that the earth connection is active and that the contact resistance complies with applicable local and international directives and regulations.

INSTRUCTIONS OJ-DV | Operation

15. Hand terminal (Hterm) – connection and functions

• The OJ-DV range can be connected to an OJ-DV Hterm hand terminal via Modbus RJ12 connector ”A”. See ﬁg. 15.1.

• If an OJ-DV Hterm is connected, the hand terminal will act as master and the OJ-DV as slave.

• Only one master at a time can be connected to the RJ12 connectors marked ”A” and ”B”. It is thus not possible to connect both a hand terminal to connector ”A” and an active Modbus communication cable to connector ”B” at the same time.

• OJ-DV Hterm has the following menu options:

• Status: Control and operating parameters

for connected OJ-DV

• Setup: Setting application parameters

• Alarm: Read-out of alarm log for connected

OJ-DV

• Modbus: Changing Modbus settings for OJ-

• About: Read-out of software version no.

and type for connected OJ-DV

• Conﬁg: Changing OJ-DV/motor settings

Note

For further information on OJ-DV Hterm operation and menus, contact OJ Electronics A/S.

Figure 15.1

-V+

-Add. Pin2

-Bus B

-Bus A

-Add. Pin2

-Gnd

-Add. Pin2

-Bus B

-Bus A

-Add. Pin2

-Gnd

-V+

-Gnd

-Bus B

-Bus A

-V+

-Gnd

BR1014A11a

16. PCTool – connection and functions

• The OJ-DV range can be conﬁgured using OJ-DV PCTool, which must be connected to Modbus RJ12 connector ”B”.

• OJ-DV PCTool allows motor and controller parameters to be viewed and set, including:

• Status: Control and operating parameters for connected OJ-DV

• Setup: Setting application parameters

• Alarm: Read-out of alarm log for connected OJ-DV

• Modbus: Changing Modbus settings for OJ-DV

• About: Read-out of software version no. and type for connected OJ-DV

• Conﬁg: Changing OJ-DV/motor settings

• Log data: Read-out of log ﬁles

• Firmware: Updating ﬁrmware

• Motor: Conﬁguring motor parameters

• Fan: Conﬁguring fan parameters

• Hardware: Conﬁguring OJ-DV hardware

OJ-DV PCTool is used solely by fan and system manufacturers. For further information on OJ-DV PCTool operation and menus, contact OJ Electronics A/S.

17. Optional modules – connection and function

• Various optional modules can be connected to OJ-DV, providing extra versatility where the unit is to be built into systems and applications that require additional inputs and outputs.

For further information on the possibilities oered by optional modules, contact OJ Electronics A/S.

INSTRUCTIONS OJ-DV | Functions

18. Functions

18.1 Analogue/digital control

• OJ-DV can be controlled via analogue/digital (A/D) inputs or via Modbus.

• The factory setting is analogue/digital (A/D) control.

• Connect A/D control signals to the terminal strip, see section 13.15.1.

0-10V In

• Is used to control motor speed in relation to a 0-10V signal.

Note

• With A/D control, functions such as alarm read-out and acknowledgement are still possible via Modbus even though "Modbus control" is not activated.

• The relationship between the 0-10V control signal and motor speed depends on the settings for min./max. speed and ramp up/ramp down times. See ﬁgs 18.1 and 18.2.

• The ”+10Vdc”, ”0-10V In” and ”GND” terminals can be connected to a potentiometer, see electrical connection in ﬁg.13.15.2.

The function of the digital inputs and outputs has been deﬁned by OJ Electronics A/S as follows:

• Din1 = Start/Stop (1 = Start)

• Din2 = Alarm reset (1 = Alarm reset)

• Dout1 = Tacho Out (1 pulse per motor revolution)

Note

The digital inputs and outputs can be given alternative functions via Modbus.

Relationship between control signal (0-10V In) and speed – see ﬁg. 18.1.

The control signal regulates motor speed between the set minimum and maximum speeds (AC motor=Hz; PM/BLDC motor=rpm) and the set ramp times – see ﬁg.18.2.

18.2 Modbus control

• OJ-DV can be controlled via Modbus

commands according to the Modbus protocol.

• Control of motor speed via Modbus

communication is factory disabled.

• If OJ-DV is to be controlled via Modbus,

Coil Stat Bit register 8 must be set to ”0” = ”Modbus control”.

• Other functions, such as alarm read-out

and acknowledgement, are still possible via Modbus even though "Modbus control" is not activated.

• NOTE! Contact OJ Electronics A/S if you

require the Modbus protocol.

•

18.3 Switching frequency

Switching frequency is crucial in determining the

amount of audible acoustic noise emitted by OJ-DV.

The higher the switching frequency, the less audible

noise will be emitted by OJ-DV. At the same time, however, internal losses will be increased, reducing eciency.

Figure 18.1

Frequency/revolutions

Frekvens/ omdrejninger

Max. Hz/Rpm

Min. Hz/Rpm

0% 0V

Figure 18.2

Speed out

Max. Speed

Min. Speed

Setpoint

100%

Up Ramp

100%

9.5V

Down Ramp

-DA

BR1014A13a

Setpoint

BR1014A13a

-GB

BR1014A12a

Time

BR1014A12a

INSTRUCTIONS OJ-DV | Functions

OJ-DV can be set to operate constantly with a switching frequency of either 4 kHz or 8 kHz, or it

can be set to change switching frequency automatically depending on motor speed (AUTO setting). Switching frequency (switching mode) is set via Modbus:

• Setting ”4kHz” = Constant 4kHz switching frequency

• Setting ”8kHz” = Constant 8kHz switching frequency

• Setting ”AUTO” = Switching frequency is changed automatically:

• At motor speeds higher than 60% of rated speed, switching frequency is changed to 4 kHz

• At motor speeds lower than 50% of rated speed, switching frequency is changed to 8 kHz

18.4 Braking power

• The electronics within OJ-DV can as a starting point supply braking power corresponding to its own consumption. It is expected that an air ﬂow capable of maintaining typically up to 30% of nominal fan speed can be braked by this function.

18.5 Fire mode

• Fire mode designates a function in which OJ-DV is kept operating by an emergency program which disables the alarm monitor.

• The ﬁre mode function can be activated via Modbus or via digital input.

• Among other things, the function can be used in connection with smoke extraction from a burning property. When ﬁre mode is activated, an extraction fan will continue to remove smoke from the property for as long as possible.

• In ﬁre mode, OJ-DV is able to maintain operation for at least an hour even when OJ-DV and the fan motor are overheated (max. 70°C).

• Upon activation of ﬁre mode operation the output signal to the motor remains the same value as it was just before the ﬁre mode condition was activated, and any alarms will be suppressed.

• During ﬁre mode operation the output signal to the motor will at any time be the selected voltage of 0-10V input, or if the OJ-DV is controlled via Modus, it will be the control signal from a potential Modbus Master. If there is a communication failure on the Modbus, the output signal to the motor will be the same value as it was just before the Modbus communication was disconnected.

• If the motor is not operating when ﬁre mode is activated, the motor will remain stopped upon activation of ﬁre mode.

18.6 Frequency converter mode – for asynchronous motors

The OJ-DV factory-set to frequency converter mode for

standard asynchronous induction motors (AC-IM) and the control mode is 0-10VDC input.

This can be changed using the OJ-DV-PCTool or OJ-

DCV-HTERM (Hand terminal).

If you use the OJ-DV in frequency converter mode, you

must connect a standard 3 phase~ AC-IM motor. Pay special attention to the information that you will ﬁnd on the nameplate of the motor.

The voltage output from the OJ-DV is for the OJ-

DV-1005…..OJ-DV-1011 maximum 250 VAC.

For the OJ-DV-3015…..OJ-DV-3150 the maximum

voltage output is 364 VAC.

If the supply voltage is higher than the rated voltage of

the single windings in the connected motor, then the motor will be damaged.

Pay special attention if the motor is connected in “star”

or “delta” connections.

On a standard AC-IM motor, the “star”/“delta”

connection often can be changed by rearranging the jumpers on the motor terminal, see ﬁgure 18.6. With the OJ-DV in frequency converter mode, it is the installer’s responsibility to enter the correct control and motor parameters.

Figure 18.6.1

BR1014A41a

INSTRUCTIONS OJ-DV | Functions

Pay special attention to the following parameters:

Minimum frequency Even if the control signal is e.g. 0% or 0.0V and the OJ-DV has an activated start signal, the motor will not

run slower than the value in this parameter.

Maximum frequency Even if the control signal is e.g. 100% or 10.0V and the OJ-DV has an activated start signal, the motor will

not run faster than the value in this parameter.

Ramp-up time Ramp-up time is the time (in seconds) from when the OJ-DV gets the start signal until the speed has been

reached according to the setpoint. The ramp-up time is used to avoid overload and damage to the controller and motor. The ramp-up time is also used in upward jumps between speed setpoints. If this ramp-up is too short, the OJ-DV could possibly trigger a current limit alarm

Ramp-down time. Ramp-down time is the time (in seconds) from when the OJ-DV receives a stop signal until the motor comes

to a halt. The ramp-down time is used to avoid overload and damage to the controller and motor. Rampdown time is also used in connection with downward jumps between speed setpoints. If this ramp-down is too short, the OJ-DV will use power to stop or slow down the motor. This could possibly trigger a current limit alarm from the OJ-DV.

Switch frequency Switch frequency is a parameter that has an inﬂuence on the eciency and the audible noise from the con-

nected motor and/or the OJ-DV controller. In the OJ-DV it is possible to select “Auto”, “4 kHz” or “8 kHz”. Activating the “Extra high” Modbus parameter makes it possible to select “Auto”, “4 kHz” or “10 kHz”. The higher the switch frequency, the lower the audible noise from the OJ-DV controller system, but the consequence of lower audible noise is decreasing eciency of the OJ-DV controller system. In “Auto” the OJ-DV will automatically switch between “4 kHz” and “8/10 kHz”. During start-up from 0 – 60% speed, the switch frequency will be “8/10 kHz” and this will make for less audible noise from the connected motor and/or the OJ-DV controller. When the speed has increased and passes 60%, the switch frequency will then switch to “4 kHz”. The noise from the fan and airﬂow will now drown out the audible noise from the OJ-DV controller system. In the speed-down sequence, the OJ-DV will switch to “8/10 kHz” when the speed of the motor passes 50% downwards. It is also possible to select a ﬁxed switch frequency of “4 kHz” or “8/10 kHz”.

U-min Hz This parameter selects the voltage to the motor at minimum frequency. Freq U-max This parameter selects the frequency to the motor at maximum voltage. V/F characteristic The “V/F characteristic” parameter is a parameter

that makes it possible to change the ratio between voltage and frequency for the motor. The “V/F characteristic” is factory-set to the value 0 (zero), which means that the ratio between the voltage and the frequency is linear. At the other end, the value “100” is equal to a parabolic relation between voltage and frequency. For a standard fan application, the value of the “V/F characteristic” should be 75. AC motors with poor eciency require a higher “V/F characteristic”.

Figure 18.6.2

For further information about parameters in the OJ-DV, see OJ-DV Modbus protocol.

18.7 Electronically commutated mode (EC mode) – for PM and BLDC motors

The OJ-DV factory-set to frequency converter mode for standard asynchronous induction motors

(AC-IM) and the control mode is 0-10 VDC input. This can be changed using the OJ-DV-PCTool or OJ-DCV-HTERM (Hand terminal). The dierence between an AC-IM motor and a PM-SM/BLDC is basically the rotor. In the PM-SM/BLDC motor, the windings in the rotor are replaced with permanent magnets, but

the control system has to be and is very dierent. Due to the permanent magnets in the rotor, they

will induce voltage in the stator windings as they rotate and as a result also voltage back to the

controller. This is what is called back EMF (EMF = electromotive force) and describes an important

and special characteristic of the motor. The controller has to be able to handle this back EMF and that is why you cannot control a PM-SM/

BLDC motor with an OJ-DV controller in frequency converter mode.

INSTRUCTIONS OJ-DV | Functions

Before operation, select and load the correct fan and motor parameter ﬁles using the OJ-DV

Handterminal or OJ-DV-PCTool. It is the installer’s responsibility to enter the correct control and

motor parameters. Pay special attention to the following parameters:

Minimum rpm Even if the control signal is e.g. 0% or 0.0V and the OJ-DV has an activated start signal, the motor will not

run slower than the value in this parameter.

Maximum rpm Even if the control signal is e.g. 100% or 10.0V and the OJ-DV has an activated start signal, the motor will

not run faster than the value in this parameter.

Ramp-up time Ramp-up time is the time (in seconds) between the OJ-DV gets the start signal until the speed has been

reached according to the setpoint. The ramp-up time is used to avoid overload and damage to the controller and motor. The ramp-up time is also used in upwards jumps between speed setpoints. If this ramp up is too short, the OJ-DV possibly could trigger an current limit alarm.

Ramp-down time Ramp-down time is the time (in seconds) from when the OJ-DV receives a stop signal until the motor comes

Switch frequency Switch frequency is a parameter that has an inﬂuence on the eciency and the audible noise from the con-

nected motor and/or the OJ-DV controller. In the OJ-DV it is possible to select “Auto”, “4 kHz” and “8 kHz”. The higher the switch frequency, the lower the audible noise from the OJ-DV controller system, but the consequence of lower audible noise is decreasing eciency of the OJ-DV controller system. In “Auto” the OJ-DV will automatically switch between “4 kHz” and “8 kHz”. During start-up from 0 - 60% speed, the switch frequency will be “8kHz” and this will make for less audible noise from the connected motor and/or the OJ-DV controller. When the speed has increased and passes 60%, the switch frequency will then switch to “4 kHz”. The noise from the fan and airﬂow will now drown out the audible noise from the OJ-DV controller system. In the speed-down sequence, the OJ-DV will switch to “8 kHz” when the speed of the motor passes 50% downwards. It is also possible to select a ﬁxed switch frequency of “4 kHz” or “8 kHz”. In the speed-down sequence, the OJ-DV will switch to “8/10 kHz” when the speed of the motor passes 50% downwards. It is also possible to select a ﬁxed switch frequency of “4 kHz” or “8/10 kHz”.

For further information about parameters in the OJ-DV, see OJ-DV Modbus protocol.

19. Built-in protection

• If the temperature inside OJ-DV exceeds 95°C, OJ-DV will attempt to reduce its internal heat

generation by reducing motor speed (rpm).

• OJ-DV has built-in current limitation for the protection of motor and cables and cannot therefore

supply more current than it is set to.

• In the event of lacking phase on the supply input, OJ-DV will reduce speed and activate a non-

critical alarm.

• The OJ-DV motor output terminals are short-circuit protected against phase-to-phase short

circuiting.

20. Alarms

• OJ-DV has a built-in alarm monitor, which monitors optimal fault-free operation and triggers an

alarm if operating or performance problems are observed.

• Alarms are either ”Critical” alarms or ”Non-critical” alarms.

• ”Critical” alarms stop the motor.

• ”Non-critical” alarms reduce motor performance.

• The built-in alarm monitor stops the OJ-DV.

• If the alarm situation passes, the alarm is automatically reset and OJ-DV restarted.

• If the maximum number of restarts (5 times/60 min) is exceeded, the alarm must be reset

manually.

INSTRUCTIONS OJ-DV | Alarms

• The alarm can be reset by means of a Modbus command.

• The alarm is automatically reset if the power is disconnected for longer than 60 seconds.

• Alarms can be read via Modbus, see Modbus protocol.

• Alarm overview, see table 20.

Table 20 Alarm overview Trigger Alarm priority Motor operation/

response

Supply voltage too low

Supply voltage too high The motor’s power use is too high

Internal temperature in OJ-DV too high (>95 °C)

Phase error; one or more phases disconnected (L1, L2, L3)

Blocked rotor

Motor power has reached it’s limit

Earth fault (Only OJ-DV-3110 & OJ-DV-3150)

Running in the wrong direction

Fault in internal EEPROM circuit

Stopped after 5 re-start attempts within 60min N/A Phase error in motor supply (U, V, W)

Internal communication fault

Ripple voltage too high External 24VDC supply overloaded.

✓ Supply voltage to OJ-DV is too low. ✓ OJ-DV is mistakenly connected to

mains voltage 3 x 230VAC.

✓ Supply voltage to OJ-DV is too high. ✓ Short circuit in motor cable.

✓ Short circuit in one or more motor

windings.

✓ Cooling of OJ-DV enclosure too low. ✓ Insucient air circulation around

OJ-DV.

✓ Air temperature around OJ-DV is

too high.

✓ Missing phase in supply voltage to

OJ-DV

✓ Large imbalance in supply voltage. ✓ The rotor is unable to rotate due to

a mechanical blockage of the rotor or fan.

✓ OJ-DV has reached the limit for

maximum output power.

✓ The connected motor is larger than

allowed for the chosen OJ-DV

✓ The load is too big for the

connected motor.

✓ Earth fault on motor cables or motor

windings

✓ Windmilling in the opposite direction

during the start up process.

✓ Incorrectly chosen conﬁguration ﬁle

- tried to download a conﬁguration ﬁle which is not contained in OJ-DV

✓ OJ-DV is defective.

✓ One or more motor phases / motor

cables is disconnected.

✓ One or more motor windings is

disconnected.

✓ During the process of updating

the MOC conﬁguration ﬁle, communication was inadvertently disconnected.

✓ If the alarm goes o during normal

operation, it usually indicates a defective OJ-DV.

✓ Imbalance on voltage supply. ✓ Overloading or short circuit on +24V

voltage supply.

”NC” ”RP”

”C” ”SA5”

”NC” ”RP”

”C” ”SA5”

”NC” ”RP”

”C” ”SA5”

”NC” ”RP”

”C” ”S”

”C” ”SA5”

”NC” ”RP”

Abbreviations:

”C”=Critical alarm ”NC”=Non-critical alarm ”RP”=Reduced performance ”SA5”=Motor stops after 5 restarts caused by same fault within 60 min ”S”=Motor stops immediately

INSTRUCTIONS OJ-DV | Maintenance and troubleshooting

LED indications

• OJ-DV is equipped with a two-colour LED which

Figure 18.5

LED

indicates operating status.

• The LED is located on the underside of OJ-DV

beside the entry for the mains cable.

See ﬁg. 18.5.

• Lights constantly green when mains voltage is

connected

• Flashes green when Modbus communication is

active

• Lights constantly red when at least one critical

alarm is active

• Flashes red when at least one non-critical

alarm is active

21. Modbus addressing of OJ-DV

Modbus addressing of OJ-DV can be accomplished in two dierent ways.

• Via the addressing pins of the ”A” or ”B” connectors – see ﬁg. 13.14.1 and table 20.1.

Table 20.1

Add.

Pin. no.

0X36 (54 dec) 0X37 (55 dec) 0X38 (56 dec) 0X39 (57 dec)

BR1014A06a

Add.Pin1

Add.Pin2

= No connection between ”GND” and Add.Pin1/ Add.Pin2

= Connection between ”GND” and Add.Pin1/ Add.Pin2

• Via OJ-DV PCTool, where OJ-DV can be set to other Modbus addresses – see instructions for OJ-

DV PCTool.

Modbus protocol

• Contact OJ Electronics A/S if you require a complete Modbus protocol.

22. Maintenance

22.1. OJ-DV is maintenance free under normal operating conditions and load proﬁles.

22.2. The cooling ﬁns must be kept free of dust, dirt and other foreign matter so that air can pass freely

over them. Deposits of dust, dirt or other foreign matter on and between the cooling ﬁns will prevent

cooling of the OJ-DV and thus impair performance.

Caution

22.3. The cooling ﬁns may become very hot. (Max. 95°C under normal operating conditions.)

Warning

22.4. OJ-DV cannot be repaired on site. Never attempt to repair a defective unit. Contact your supplier to

obtain a replacement.

22.5. Additional technical data are available on request from OJ Electronics A/S.

INSTRUCTIONS OJ-DV | Maintenance and troubleshooting

23. Troubleshooting

Warning

23.1. Before opening OJ-DV, the mains voltage must be disconnected for at least 3 minutes to ensure

there is no risk of dangerous residual currents in electronic circuits or capacitors.

23.2. If natural drafts through the duct system cause the fan to rotate even though it has received no

operating signal, there is a risk that the motor will induce voltage on the OJ-DV motor terminals,

making them dangerous to touch.

23.3. Troubleshooting when OJ-DV is controlled via A/D signals:

Symptom Cause Action

Motor inoperative Lacking supply voltage Check the voltage supply to OJ-DV terminals ”L” and ”N” on 230V

models (H1) or terminals ”L1”, ”L2” and ”L3” on 3x400V and 3x230V models (H3…H5). (Nominal supply voltage is stated on the rating plate.)

Check whether short-circuit protection has been activated.

Check that the voltage supply to OJ-DV has not been cut o by other components.

Poor electrical connections Check electrical connections.

Wrong motor for OJ-DV setup Check that the correct motor settings have been read into and stored

in the OJ-DV setup.

Lacking operating signal A/D control:

Check that OJ-DV can receive an operating signal. With A/D control, OJ-DV must have a signal connected to the "Start/ Stop" input – digital input Din1 or Din2 depending on the setup.

Lacking 0-10VDC control signal Check that an operating signal is connected to ”0-10V In”.

Potentiometer control: Check that the potentiometer is correctly connected to terminals ”+10Vdc”, ”0-10V In” and ”GND” on the terminal strip.

Active alarm Read out active alarms and remedy their cause.

The motor has been stopped 5 times by the built-in motor protector because of overloading or other alarm

Defective OJ-DV controller Replace OJ-DV.

Defective motor Replace motor.

Motor running in wrong direction

Symptom Cause Action

OJ-DV noisier than acceptable

Wrong phase sequence in motor cable

Switching frequency too low Increase switching frequency.

Reset the alarm by short-circuiting the ”Alarm reset” input – digital input Din1 or Din2 depending on the setup. The alarm can also be reset by disconnecting the power supply to the OJ-DV and reconnecting it after approx. 60 seconds.

Never attempt to repair a defective OJ-DV controller. Contact your supplier for replacement/repair.

Interchange two phase wires on the motor or the OJ-DV terminal strip.

0 = Auto 1 = Low = 4 kHz 2 = High = 8 kHz Increasing switching frequency increases losses within OJ-DV, thus reducing eciency. OJ-DV switching frequency can be changed via OJ-DV Hterm or via Modbus.

INSTRUCTIONS OJ-DV | Maintenance and troubleshooting

Symptom Cause Action

OJ-DV cuts out due to an alarm

At least one alarm active Use OJ-DV Hterm to view the alarm and determine which alarm has

stopped the controller/motor. Reset the alarm by short-circuiting the ”Alarm reset” input – digital

input Din1 or Din2 depending on the setup. The alarm can also be reset by disconnecting the power supply to the OJ-DV and reconnecting it after approx. 60 seconds.

The alarm is re-activated after reset Use OJ-DV PCTool to view the alarm and determine which alarm has

stopped the controller/motor. Remedy the cause of repeated alarm activation.

23.4. Troubleshooting when OJ-DV is controlled via Modbus:

Symptom Cause Action

Motor inoperative Lacking supply voltage Check the voltage supply to OJ-DV terminals ”L” and ”N” on 230V

models (H1) or terminals ”L1”, ”L2” and ”L3” on 3x400V and 3x230V models (H3…H5). (Nominal supply voltage is stated on the rating plate.)

Check whether short-circuit protection has been activated.

Check that the voltage supply to OJ-DV has not been cut o by other components.

Poor electrical connections Check electrical connections.

Wrong motor for OJ-DV setup Check that the correct motor settings have been read into and stored

in the OJ-DV setup.

Lacking operating signal Check that OJ-DV can receive an operating signal.

Coil Stat Bits Register 0X0001: Motor start/stop (1=On).

Lacking % control signal from Modbus controller

The motor has been stopped 5 times by the built-in motor protector because of overloading

Defective OJ-DV controller Replace OJ-DV.

Defective motor Replace motor.

Check the Modbus control signal at Modbus address: Holding registers; Register 3X0001: PrcSet 0-10000 (0-100%).

Reset alarm: Coil Stat Bits Register 0X0002: Reset (1 pulse = Reset). The alarm can also be reset by disconnecting the power supply to the OJ-DV and reconnecting it after approx. 60 seconds.

Never attempt to repair a defective OJ-DV controller. Contact your supplier for replacement/repair.

Motor running in wrong direction

OJ-DV noisier than acceptable

OJ-DV cuts out due to an alarm

Wrong phase sequence in motor cable

Switching frequency too low Increase switching frequency.

At least one alarm active Use OJ-DV Hterm to view the alarm and determine which alarm has

The alarm is re-activated after reset Read out the alarm via Modbus registers and determine which alarm

Interchange two phase wires on the motor or the OJ-DV terminal strip.

stopped the controller/motor. Reset the alarm by short-circuiting the ”Alarm reset” input – digital

input Din1 or Din2 depending on the setup. The alarm can also be reset by disconnecting the power supply to the OJ-DV and reconnecting it after approx. 60 seconds.

has stopped the controller/motor. Remedy the cause of repeated alarm activation.

INSTRUCTIONS OJ-DV | Maintenance and troubleshooting

24. Disposal

• OJ-DV contains electronic components and must not be disposed of together with

household waste.

• OJ-DV must be disposed of in accordance with applicable local rules and regulations.

• OJ-DV meets the requirements on marking of electronic waste contained in the

European WEEE Directive 2012/19/EU.

INSTRUCTIONS OJ-DV | Technical speciﬁcations

25. Technical speciﬁcations

Type DV-1005 DV-1007 DV-1011 DV-1013 DV-3015 DV-3024 DV-3030 DV-3040 DV-3055 DV-3065 DV-3075 DV-3110 DV-3150

Enclosure H1 H1x H3 H4 H5 Power size kW 0.5 0.75 1.1 1300 1.5 2.4 3.0 4.0 5.5 6.5 7.5 11 15 Eciency % > 94% > 96,5% > 96,5% > 97%

Power supply

Voltage VAC 1 x 230 VAC 50/60 Hz +/-10% 3 x 400 VAC 50/60 Hz +/-10% Supply current at max. load A 3.0 4.4 6.5 8.5 3.1 5.0 6.3 8.4 11.5 13.6 15.7 24.4 33 Power factor

(cos-phi) at max. load

Motor output

Nominal motor power (on shaft) *1 kW 0.5 0.8 1.15 1.3 1.5 2.4 3.0 4.0 5.5 6.5 7.5 11 15 Frequency Hz AC motor: 0-120 | PM motor: 0-400 Max. output voltage Vrms 3 x 0 - 250 VAC 3 x 0 - 364 VAC Max. output current Arms 2 3.2 4.5 5.2 4.5 6.4 8.0 10.0 12.0 15.0 19.0 27 35.0

Protection

Max. fuse A 16 32 Motor output Short-circuit protected between phases Motor Protected by current limit Impulse protection Protected against transient voltages by VDR Over-voltage protection Yes, 400 V (PTC) Yes, 565 V Overload protection Current and temperature overload protection

Environment

Operating temperature °C -40°C to +50°C Starting temperature °C -40°C to +50°C Storage temperature °C -40°C to +70°C

Dimensions mm 185 x 230.5 x 90 mm

Protection rating IP 54 & 65 Enclosure material Aluminium Front cover Plastic Weight kg 2.0 3.6 3.0 3.9 9.5 Humidity % rh 10-95% rh, non-condensing

Surface Corrosion resistant to EN/ISO 12944-2:1998 Category C4

Air ﬂow / cooling

Interfaces

Digital communication MODBUS RTU RS485 (baud rate: 9.6, 19.2, 38.4, 115.2 Kbaud) Digital communication Slave 2 x RJ12 & 2 x spring terminals Digital communication Master 1 x RJ12 connection Analogue In1 0-10 VDC, 100% @ 9.5 V DC +/-2% Analogue Out1 +10 VDC Digital In1 Start/stop with internal pull-up Digital In2 Alarm reset Digital Out1 Tacho: 1 pulse/revolution | Alarm/running signal Green LED Lit: Power connected | Flashing: Active communication Red LED Flashing: Alarm but still running | Constantly lit: Critical alarm - stop motor

Features

Technology Sinusoidal back-EMF signal controlled via FOC (Field Oriented Control) Flying start Yes, < 30% of max. speed Ramp-up time sec. 15-300 Ramp-down time sec. 15-300 Alarm Yes Alarm reset Via digital input, MODBUS or powering down for more than 60 seconds Fan stop sec. The braking system stops the fan as quickly as possible. Braking time will depend on the inertia of the fan. Service data log Operating hours, alarms, loads, software version, max. temp., max. motor voltage, max. motor current, max. ripple voltage, max. ripple current Software updating Yes, via serial interface Motor parameters Preprogrammed by OJ or on-site conﬁguration Fire mode Nominal power for 1 hour at 70°C ambient temperature Field weakening Yes Short-circuit protection Ye s Integrated EMC ﬁlters Ye s

Approvals

EMC EN 61800-3 (C1 & C2) LVD EN 61800-5-1 Product standard EN 61800 Part 2 RoHS Directive Yes Product approvals CE Data are valid at: nominal supply voltage, +25°C and sucient air ﬂow

Note 1: Motor Power Factor = 0.8 and eciency = 90%

> 0.99 (Active PFC) > 0.9

185 x 265 x 125 mm

Turbulent air speed of min. 3 m/s to achieve max. output power at max. ambient temperature.

Turbulent air speed below 3m/s and higher ambient temperature might lead to reduced output power.

185 x 265 x 100 mm 220 x 294 x 107 mm 244 x 399 x 144 mm

(3m/s turbulent air speed is equivalent to 6,5m/s laminar air speed)

OJ Electronics A/S

Stenager 13B • DK-6400 Sønderborg

Tel. : +45 73 12 13 14 • Fax +45 73 12 13 13

oj@ojelectronics.com • www.ojelectronics.com

OJ Electronics OJ-DV-1013, OJ-DV-1005, OJ-DV-1007, OJ-DV-1011, OJ-DV-3016 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual