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

...

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

+ 19 hidden pages

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