Vacon NX series, NXA series User Manual

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vacon nx

ac drives

active front end unit (afe)

air cooled

user manual

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TABLE OF CONTENTS

Document: DPD00906D

Version release date: 1/2/18

1. Safety...............................................................................................................5

1.1 Warnings ............................................................................................................................6

1.2 Cautions .............................................................................................................................6

1.3 Grounding and earth fault protection ................................................................................7

1.4 Electro-magnetic compatibility (EMC)...............................................................................8

1.5 Using an RCD or an RCM device ........................................................................................8

2. EU Directive .....................................................................................................9

2.1 CE marking.........................................................................................................................9

2.2 EMC directive .....................................................................................................................9

2.2.1 Introduction........................................................................................................................9

2.2.2 Technical criteria ...............................................................................................................9

2.2.3 VACON® Active Front End EMC classification ..................................................................9

2.2.4 Manufacturer’s declaration of conformity.........................................................................9

3. Receipt of delivery .........................................................................................11

3.1 Type designation code for the AFE unit ...........................................................................11

3.2 Type designation code for the LCL filter .........................................................................12

3.3 Type designation code for the pre-charging components ..............................................13

3.4 Storage .............................................................................................................................14

3.4.1 Capacitor reforming.........................................................................................................14

3.5 Maintenance.....................................................................................................................15

3.6 Lifting the modules ..........................................................................................................16

3.7 Lifting the LCL filters .......................................................................................................18

3.8 Disposal............................................................................................................................20

4. Active Front End (AFE) ...................................................................................21

4.1 Introduction......................................................................................................................21

4.2 Active Front End Unit block diagram...............................................................................23

4.3 Active Front End enclosure sizes ....................................................................................24

4.4 Active Front End unit technical data................................................................................26

4.5 LCL filter technical data ..................................................................................................29

4.6 Application........................................................................................................................30

4.7 Diagrams ..........................................................................................................................30

4.7.1 Connection between control unit and power unit ...........................................................30

4.7.2 LCL wiring diagram..........................................................................................................32

4.8 Active Front End power ratings .......................................................................................36

4.8.1 VACON® NXA; DC voltage 380–500 V..............................................................................36

4.8.2 VACON® NXA; DC voltage 525–690 V..............................................................................37

4.9 Active Front End unit – Dimensions ................................................................................38

4.10 LCL filter – Dimensions ...................................................................................................38

4.11 Active Front End unit – Fuse selection ............................................................................39

4.11.1 Introduction......................................................................................................................39

4.11.2 Fuses; mains voltage 380–500 V......................................................................................39

4.11.3 Fuses; mains voltage 525–690 V......................................................................................42

4.12 Active Front End unit – Circuit breaker selection ...........................................................44

4.13 Main contactor .................................................................................................................45

4.14 Pre-Charging circuit ........................................................................................................46

4.15 Paralleling........................................................................................................................47

4.15.1 Common pre-charging circuit .........................................................................................47

4.15.2 Each Active Front End unit has the pre-charging circuit................................................49

4.16 Derating............................................................................................................................50

4.16.1 Ambient Temperature......................................................................................................50

Rev. D

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4.16.2 High altitude installation..................................................................................................51

5. Installation.....................................................................................................52

5.1 Mounting...........................................................................................................................52

5.1.1 Active Front End Unit .......................................................................................................52

5.1.2 LCL filter ..........................................................................................................................54

5.1.3 Control Box.......................................................................................................................56

5.2 Cooling..............................................................................................................................59

5.2.1 Active Front End unit........................................................................................................59

5.2.2 LCL filter ..........................................................................................................................63

5.2.3 Arranging ventilation of the enclosure ............................................................................66

5.2.4 Steering air flow...............................................................................................................67

5.3 Power connection.............................................................................................................70

5.3.1 AC connection ..................................................................................................................70

5.3.2 DC connection ..................................................................................................................70

5.3.3 Cable installation and the UL standards .........................................................................70

5.3.4 LCL filter Fan power supply.............................................................................................70

5.4 Control unit ......................................................................................................................75

5.4.1 Control unit components .................................................................................................75

5.4.2 Control voltage (+24V/EXT +24V)......................................................................................75

5.4.3 Control unit cabling..........................................................................................................76

5.5 Galvanic isolation barriers...............................................................................................82

6. Control Keypad ..............................................................................................83

6.1 Indicators on the keypad display .....................................................................................84

6.1.1 Drive status indications....................................................................................................84

6.1.2 Status LEDs (green – green – red) ..................................................................................84

6.1.3 Text Lines .........................................................................................................................85

6.2 Keypad push-buttons .......................................................................................................85

6.2.1 Buttons descriptions........................................................................................................86

6.3 Navigation on the control keypad ....................................................................................87

6.3.1 Monitoring menu (M1)......................................................................................................88

6.3.2 Parameter menu (M2).....................................................................................................89

6.3.3 Keypad control menu (M3)...............................................................................................91

6.3.4 Active fault menu (M4) .....................................................................................................91

6.3.5 Fault types........................................................................................................................92

6.3.6 Fault codes.......................................................................................................................93

6.3.7 Fault history menu (M5)...................................................................................................95

6.3.8 System menu (M6) ..........................................................................................................96

7. Appendices...................................................................................................106

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 3

AT LEAST THE 11 FOLLOWING STEPS OF THE START-UP QUICK GUIDE MUST BE PERFORMED DURING THE INSTALLATION AND COMMISSIONING.

IF ANY PROBLEMS OCCUR, CONTACT YOUR LOCAL DISTRIBUTOR.

Start-up Quick Guide

1. Check that the delivery corresponds to your order, see Chapter 3.

2. Before taking any commissioning actions, read carefully the safety instructions in Chapter 1.

3. Before the mechanical installation, check the minimum clearances around the unit and check the ambient conditions in Chapter 5.

4. Check the size of the supply cable/bus bar, DC output cable/bus bar, and mains fuses, DC fuses and check the cable connections.

5. Follow the installation instructions, see Chapter 5.

6. The sizes and grounding of control connections are explained in Chapter 5.

7. If the Start-Up wizard is active, select the language you want the keypad and confirm by pressing the enter button. If the Start-Up wizard is not active, follow the instructions in 8 below.

8. Select the language of the keypad from Menu M6, S6.1. Instructions on using the keypad are given in Chapter 6.

9. All parameters have factory default values. To ensure proper operation, check the rating plate data for the values below and the corresponding parameters of parameter group G2.1.

• Nominal voltage of the supply (P2.1.1)

• Digital input settings according to connections (P2.2.1.1-P2.2.1.8)

• Change control place to I/O (P3.1)

In case of parallel AFE:

• Set drooping parameter to 5% (P2.5.1)

• Set PWM Synch parameter to Enable (P2.5.2)

All parameters are explained in the VACON

NX Active Front End (AFE) Application

Manual.

10. Follow the commissioning instructions in the VACON

NX Active Front End Application

Manual.

11. The VACON

NX Active Front End is now ready for use.

Vacon Ltd is not responsible for the use of the Active Front End against the instructions.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 4

ABOUT THE VACON® NX AFE USER'S MANUAL

Congratulations for choosing VACON

NX Active Front End!

The User's Manual will provide you with the necessary information about the installation, commissioning and operation of VACON

NX Active Front End. We recommend that you carefully

study these instructions before powering up the active front end for the first time. In the VACON

NX Active Front End Application Manual you will find information about the Active Front End application. Should that application not meet the requirements of your process, contact the manufacturer for information on special application.

This manual is available in both paper and electronic editions. We recommend you to use the electronic version if possible. If you have the electronic version at your disposal, you will be able to benefit from the following features:

The manual contains several links and cross-references to other locations in the manual, which makes it easier to move around in the manual. The reader can thus easily find and check things.

The manual also contains hyperlinks to web pages. To visit these web pages through the links, you must have an internet browser installed on your computer.

This manual is applicable only for Active Front End units, LCL filters and optional components that are introduced in this manual.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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1. SAFETY

This manual contains warnings and cautions, which are identified with safety symbols. The warnings and cautions give important information on how to prevent injury and damage to the equipment or your system.

Read the warnings and cautions carefully and obey their instructions.

The cautions and warnings are marked as follows:

Table 1. Warning signs

WARNING!

CAUTION!

CAUTION! Hot surface

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1.1 Warnings

Do not touch the components of the power unit, LCL filter or pre-charging circuit when the drive is connected to Mains, or the DC-link when DC-link is powered. The components are live when the drive is connected to mains or the DC-link is powered. A contact with this voltage is very dangerous.

Do not touch the line-in terminals U, V, W or the DC terminals when the drive is connected to mains or DC-link when DC-link is powered. These terminals are live when the drive is connected to mains or DC-link when DC-link is powered, also when the system does not operate.

Do not touch the control terminals. They can have a dangerous voltage also when the drive is disconnected from mains or DC-link when DC- link is powered.

Before you do electrical work on the drive, disconnect the drive from the mains and make sure that the system has stopped. Lock out and tag out the power sources to the drive. Make sure that no external source generates unintended voltage during work. Note that also the load side of the drive can generate voltage.

Wait 5 minutes before you open the cabinet door or the cover of the AC drive. Use a measuring device to make sure that there is no voltage. The terminal connections and the components of the drive can be live 5 minutes after it is disconnected from the mains and the system has stopped.

Before you connect the drive to mains, make sure that the front cover and the cable cover of the drive are closed. The connections of the AC drive are live when the drive is connected to mains.

When there is a power-up, a power break or a fault reset, the system 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.

Wear protective gloves when you do mounting, cabling or maintenance operations. There can be sharp edges in the AC drive that can cause cuts.

1.2 Cautions

Do not move the AC drive, LCL filter or the optional components. Use a fixed installation to prevent damage to the drive.

Do not make measurements when the AC drive is connected to mains. It can cause damage to the drive.

Make sure that there is reinforced protective ground connection. It is mandatory, because the touch current of the AC drives is more than 3.5 mA AC (refer to EN 61800-5-1). See Chapter 1.3 "Grounding and earth fault protection".

Before you do any work on the Common DC Bus, make sure that the system is grounded.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

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After having disconnected the Active Front End from the AC supply, wait until the fan stops and the indicators on the keypad go out (if no keypad is attached see the indicator through the keypad base). Wait 5 more minutes before doing any work on Active Front End connections. Do not even open the cover before this time has expired.

Do not use spare parts that are not from the manufacturer. Using other spare parts can cause damage to the drive.

Do not touch the components on the circuit boards. Static voltage can cause damage to these components.

Prevent radio interference. The AC drive can cause radio interference in a domestic environment.

NOTE!

If you activate the autoreset function, the system starts automatically after an automatic fault reset. See the VACON

NX AFE Application Manual.

If you use the AC drive as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN 60204-1).

1.3 Grounding and earth fault protection

The AC drive must always be grounded with a grounding conductor that is connected to the grounding terminal that is identified with the symbol .

Not using a grounding conductor can cause damage to the drive.

The touch current of the drive is more than 3.5 mA AC. The standard EN 61800-5-1 tells that 1 or more of these conditions for the protective circuit must be true.

The connection must be fixed.

a) The protective grounding conductor must have a cross-sectional area of minimum 10 mm 16 mm

Al. OR

b) There must be an automatic disconnection of the mains, if the protective grounding conductor breaks. See Chapter 5 "Installation". OR

Cu or

c) There must be a terminal for a second protective grounding conductor in the same crosssectional area as the first protective grounding conductor.

Table 2. Protective grounding conductor cross-section

Cross-sectional area of the phase

conductors (S) [mm

]

The minimum cross-sectional area of the

protective grounding conductor in question [mm

S ≤ 16 S

16 < S ≤ 35 16

35 < S S/2

The values of the table are valid only if the protective grounding conductor is made of the same metal as the phase conductors. If this is not so, the cross-sectional area of the protective grounding

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

]

vacon • 8 Safety

conductor must be determined in a manner that produces a conductance equivalent to that which results from the application of this table.

The cross-sectional area of each protective grounding conductor that is not a part of the mains cable or the cable enclosure, must be a minimum of:

•2.5 mm

•4 mm sure that the protective grounding conductor in the cord is the last conductor to be interrupted, if the strain-relief mechanism breaks.

Obey the local regulations on the minimum size of the protective grounding conductor.

if there is mechanical protection, and

if there is not mechanical protection. If you have cord-connected equipment, make

NOTE!

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

Do not do voltage withstand tests on the AC drive. The manufacturer has already done the tests. Doing voltage withstand tests can cause damage to the drive.

1.4 Electro-magnetic compatibility (EMC)

The drive must obey the standard IEC 61000-3-12. To obey it, the short-circuit power SSC must be a minimum of 120 R that you connect the drive and the motor to mains with a short-circuit power S of 120 R

. If necessary, contact your mains operator.

SCE

at the interface point between your mains and the public mains. Make sure

SCE

that is a minimum

1.5 Using an RCD or an RCM device

The drive can cause a current in the protective grounding conductor. You can use a residual currentoperated protective (RCD) device, or a residual current-operated monitoring (RCM) device to give protection against a direct or an indirect contact. Use a type B RCD or RCM device on the mains side of the drive.

NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from

http://drives.danfoss.com/knowledge-center/technical-documentation/.

REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site http://drives.danfoss.com/knowledge-center/technical-documentation/ .

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

EU Directive vacon • 9

2. EU DIRECTIVE

2.1 CE marking

The CE marking on the product guarantees the free movement of the product within the EEA (European Economic Area). It also guarantees that the product complies with applicable directives (for example, the EMC Directive and other possible so-called new method directives). VACON Active Front End carries the CE label as a proof of compliance with the Low Voltage Directive (LVD), Electro Magnetic Compatibility (EMC) Directive and RoHS Directive.

2.2 EMC directive

2.2.1 Introduction

The EMC Directive provides that the electrical apparatus must not excessively disturb the environment it is used in, and, on the other hand, it shall have an adequate level of immunity toward other disturbances from the same environment.

The compliance of VACON Construction Files (TCF) and checked and approved by SGS FIMKO, which is a Notified Body. The Technical Construction Files are used to authenticate the conformity of VACON with the Directive because it is impossible to test such a large product family in a laboratory environment and because the combinations of installation vary greatly.

NX Active Front End with the EMC Directive is verified with Technical

NX Ac tive Front End

2.2.2 Technical criteria

Our basic idea was to develop a range of VACON usability and cost efficiency. EMC compliance was a major consideration from the outset of the design.

2.2.3 VACON

Factory delivered VACON immunity requirements (standard EN 61800-3).

Class T: Class T equipment have a small earth leaking current and can be used with floating DC input.

2.2.4 Manufacturer’s declaration of conformity

The following page presents the photocopy of the Manufacturer's Declaration of Conformity assuring the compliance of VACON

Active Front End EMC classification

NX Active Front End are Class T equipment, which fulfills all EMC

NX Active Front End with the EMC-directives.

NX Active Front End offering the best possible

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 10 EU Directive

Date Issued by Date Approved by

15-04-2016 Signature

Name: Kimmo Syvänen Title: Director, Premium Drives

15-04-2016 Signature

Name: Timo Kasi Title: VP, Design Center Finland and Italy

Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated into any other language, the translator concerned shall be liable for the correctness of the translation.

ID No: DPD01844 Revision No: A Page

1of 1

Danfoss A/S

DK-6430 Nordborg Denmark CVR nr.: 20 16 57 15

Telephone: +45 7488 2222 Fax: +45 7449 0949

EU DECLARATION OF CONFORMITY

Danfoss A/S

Vacon Ltd

declares under our sole responsibility that the

Product(s) Vacon NX Common DC bus Products

Type(s) Vacon NXI 0004 5… to 2700 5 Vacon NXI 0004 6… to 2250 6 Vacon NXA 0004 5… to 2700 5 Vacon NXA 0004 6… to 2250 6 Vacon NXN 0400 5… to 0650 5 Vacon NXN 0400 6… to 0650 6 Vacon NXB 0004 5… to 2700 5 Vacon NXB 0004 6… to 2250 6

Covered by this declaration is in conformity with the following directive(s), standard(s) or other normative document(s), provided that the product is used in accordance with our instructions.

Safety: EN 61800-5-1:2007 EN 60204-1:2006+A1:2009 (as relevant)

EMC: EN 61800-3:2004+A1:2012

and conforms to the relevant safety provisions of Low Voltage Directive 2006/95/EC (until April 19th, 2016), 2014/35/EU (from April 20th, 2016) and EMC Directive 2004/108/EC (until April 19th, 2016), 2014/30/EU (from April 20th, 2016).

The year the CE marking was affixed: 2005

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Receipt of delivery vacon • 11

3. RECEIPT OF DELIVERY

VACON® NX Active Front End has undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transportation damage are to be found on the product and that the delivery is complete (compare the type designation of the product to the codes below, See Table 3, Table 4, Table 5).

Should the product have been damaged during the shipping, contact primarily the cargo insurance company or the carrier.

If the delivery does not correspond to your order, contact the supplier immediately.

3.1 Type designation code for the AFE unit

In VACON® type designation code for Common DC Bus components, the Active Front End Unit is characterised by letter A and number 2. If the Active Front End unit is ordered by number 2 delivery does not include anything else than the unit itself.

NOTE! The delivery does not include the auxiliary devices, which are needed for the operation (the AC or DC fuses, the fuses bases, the main contactor or circuit breaker, etc.). The customer will take care of the auxiliary devices.

Table 3. Type designation code for the VACON® Active Front End

Code Description

NX Product Generation

AAAA

Module type A = AFE Active Front End

Nominal current (low overload) e.g. 0261 = 261 A, 1030 = 1030 A, etc.

Nominal supply voltage 5 = 380-500 VAC / 465-800 VDC 6 = 525-690 VAC / 640-1100 VDC

Control keypad A = Standard alpha-numeric display (LCD) B = No local control panel F = Dummy panel G = Graphical panel

Enclosure class 0 = IP00, FI9-13

EMC emission level T = IT networks (EN61800-3)

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Internal brake shopper 0 = N/A (no brake chopper)

Delivery include 2 = AFE module

S = Standard air cooled drive O = DC fan external power supply

F = Fiber connection, standard boards, FI9-FI13 G = Fiber connection, varnished boards, FI9-FI13 N = IP54 Control Unit for OPT-AF, Fiber connection, standard boards, FI9-FI13 O = IP54 Control Unit for OPT-AF, Fiber connection, varnished boards, FI9-FI13

vacon • 12 Receipt of delivery

Table 3. Type designation code for the VACON® Active Front End

Code Description

Option boards; each slot is represented by two characters:

A1 A2 00 00 00

00 = the slot is not used A = Basic I/O board B = Expander I/O board C = Fieldbus board D = Special board E = Fieldbus board

3.2 Type designation code for the LCL filter

LCL filters has two versions of cooling fan power supply, one without the integrated DC/DC power supply and one with it. The LCL filter is characterized without the integrated DC/DC power supply by letter A and with the integrated DC/DC power supply by letter B in version column, Table 4.

Table 4.

Code Description

LCL

AAAA

R Reserve 0 Reserve 1 Reserve

Type designation code for the LCL filters

Product range LCL = LCL filter for AFE

Nominal current (low overload) E.g. 0261 = 261 A,0460 = 460 A and so on.

Voltage class 5 = 380-500 VAC 6 = 525-690 VAC

Version (hardware) A = DC fan without DC/DC power supply B = DC fan with integrated DC/DC power supply

Enclosure class: 0 = IP00

Cooling fan type 1 = DC fan

Manufacturer T = Trafotek

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Receipt of delivery vacon • 13

3.3 Type designation code for the pre-charging components

The pre-charging components can be ordered separately. The pre-charging resistors are optimized for each Active Front End unit. Components of the pre-charging circuit are 2 pcs charging resistors, the contactor, the diode bridge and the snubber capacitor, see Table 5. Each pre-charging circuit has maximum charging capacity, see Table 26.

Table 5. Type designation code for the pre-charging components

FI9 AFE/CHARGING-AFE-FFE-FI9

Item Q’ty Description Manufacturer Product Code

1 1 Diode Bridge Semikron SKD 82 2 2 Charging resistors Danotherm CAV150C47R 3 1 Snubber capacitor Rifa PHE448 4 1 Contactor Telemecanique LC1D32P7

FI10 AFE/CHARGING-AFE-FFE-FI10

Item Q’ty Description Manufacturer Product Code

1 1 Diode Bridge Semikron SKD 82 2 2 Charging resistors Danotherm CBV335C20R 3 1 Snubber capacitor Rifa PHE448 4 1 Contactor Telemecanique LC1D32P7

FI13 AFE/CHARGING-AFE-FFE-FI13

Item Q’ty Description Manufacturer Product Code

1 1 Diode Bridge Semikron SKD 82 2 2 Charging resistors Danotherm CAV335C11R 3 1 Snubber capacitor Rifa PHE448 4 1 Contactor Telemecanique LC1D32P7

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vacon • 14 Receipt of delivery

3.4 Storage

If VACON® NX Active Front End is to be stored before use, make sure that the ambient conditions are acceptable:

Storage temperature –40…+70 °C (-40...+158°F) Relative humidity 0 to 95%, no condensation

If you must keep the VACON power to the VACON

We do not recommend a long storage time. If the storage time is more than 12 months, you must charge the electrolytic DC capacitors with caution. To reform the capacitors, obey the instructions in Chapter 3.4.1 Capacitor reforming.

3.4.1 Capacitor reforming

After a long storage time, it is necessary to reform the capacitors to prevent damage to the capacitors. To make sure that the possible high leakage current through the capacitors stays in minimum, use a DC-power supply with an adjustable current limit.

1. Set the current limit to 300-800mA to agree with the size of the drive.

2. Connect the DC-power supply to the B+/Bterminals (DC+ to B+, DC- to B-) of the DC-link or directly to the capacitor terminals.

3. Set the DC-voltage to the nominal DC-voltage level of the Active Front End (1.35*Un AC) and keep the power on for 1 hour, at minimum. If the Active Front End was in store for much longer than 12 months and the capacitors were not charged, speak to the factory to get instructions before you connect the power.

NX Active Front End in storage for a long time, you must connect the

NX Active Front End each year. Keep the power on for a minimum of 2 hours.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Receipt of delivery vacon • 15

3.5 Maintenance

All technical devices, drives as well, need a certain amount of care-taking and failure preventive maintenance. To maintain trouble-free operation of the VACON environmental conditions, as well as load, line power, process control, etc. have to be within specifications, determined by manufacturer.

If all conditions are in accordance with the manufacturer's specifications, there are no other concerns, but to provide a cooling capacity high enough for the power- and control circuits. This requirement can be met by making sure, that the cooling system works properly. Operation of cooling fans and cleanness of the heat sink should be verified regularly.

Regular maintenance is recommended to ensure trouble free operation and long lifetime of VACON maintenance.

NX Active Front End. At least the following things should be included in the regular

Table 6. Maintenance interval

Interval Maintenance

12 months (if unit is stored) Capacitor reforming, see Chapter 3.4.

Check tightening torque of the input and output terminals and I/O terminals.

Clean the heat sink.

NX Active Front End,

6 - 24 months (The interval is different in

different environment.)

5 - 7 years

5 - 10 years

It is also recommended to record all actions and counter values with dates and time for follow up of maintenance.

Clean the cooling tunnel.

Check operation of the cooling fan, check for corrosion on terminals, bus bars and other surfaces.

Check the door filters. Change the cooling fans.

• Main fan of the unit.

• Fan of the LCL filter.

• Internal IP54 (UL Type 12) fan.

• Cabinet cooling fan/filter.

Change the DC bus capacitors if DC voltage ripple is high.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 16 Receipt of delivery

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3.6 Lifting the modules

The modules can be lifted by the holes on top. Place the lifting hooks symmetrically in at least four holes. The maximum allowed lifting angle is 45º. For enclosure sizes FI9 and FI10, see Figure 1 and for the enclosure size FI13, see Figure 2.

The lifting equipment must be able to carry the weight of the module.

Figure 1. Lifting points for FI9 and FI10 modules

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Figure 2. Lifting points for FI13 modules

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vacon • 18 Receipt of delivery

45º

11177A_00

3.7 Lifting the LCL filters

The modules can be lifted by the holes on top. Place the lifting hooks symmetrically in two holes in the FI9 and FI10 LCL filters and four holes in the FI13 LCL filter. The maximum allowed lifting angle is 45º. For the FI9 and FI10 LCL filter, see Figure 3 and for the FI13 LCL filter, see Figure 4.

Figure 3. Lifting points for FI9 and FI10 LCL filter

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Receipt of delivery vacon • 19

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Figure 4. Lifting points for FI13 LCL filter

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vacon • 20 Receipt of delivery

3.8 Disposal

When the drive is at the end of its operation life, do not discard it as a part of municipal waste. You can recycle the primary components of the drive. You must disassemble some components before you can remove the different materials. Recycle the electrical and electronic components as waste.

To make sure that the waste is recycled correctly, send the waste to a recycling centre. You can also send the waste back to the manufacturer. Obey the local and other applicable regulations.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 21

NFE*

FFE*

INU

BCU

AFE*

alternative

2 2 2

11168.emf

Common DC bus

4. ACTIVE FRONT END (AFE)

4.1 Introduction

The VACON® NX Active Front End is used to transfer power between the AC input and intermediate

DC circuit. The VACON is transferred from the AC input to the intermediate DC circuit, the VACON

NX Active Front End has a two-way function. This means that when power

NX Active Front End

rectifies the alternating current and voltage. When power is transferred from the intermediate DC

circuit to the AC input, the VACON The difference between VACON

low current distortion (THDI). In a typical VACON

NX Active Front End inverts the direct current and voltage.

NX Active Front End and other Front Ends is that the unit creates

NX Active Front End configuration, the desired

number of Inverters, Figure 5, are connected to the intermediate DC circuit. The Active Front End configuration consists of the unit itself, LCL filter, pre-charging circuit, control

unit, AC fuses, main contactor (or circuit-breaker) and DC fuses, Figure 6.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Figure 5. Typical Active Front End configuration

vacon • 22 Active Front End (AFE)

11169.emf

UUVVW

L1 L2 L3

+LCL-U1

+AFE-U1

NXA

XXXXX

B+ B-

-F2,1

-X1

-R -R

-X1

-K3

-V3

4 5 6

1 2 3

2 4 6

1 3 5

-Q3

4 5 6

1 2 3

DC+ DC-

-K1

-F1,1

-Q1

-Q2

21 22

Double Insulated

Main Circuit

Figure 6. VACON® Active Front End Single Unit connections

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 23

B+

B-

U/T1

V/T2

W/T3

RS-232

11170.emf

Power Module

Control Module Keypad

Control

Driver

Measurements

Power

supply

Fan

ASIC

IGBT

bridge

I/O

slot E

I/O

slot D

I/O

slot C

I/O

slot A

I/O

slot B

4.2 Active Front End Unit block diagram

Figure 7. NXA block diagram

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 24 Active Front End (AFE)

11175.emf

11174.emf

4.3 Active Front End enclosure sizes

Figure 8. VACON® NXA, FI9. Protection class IP00

Figure 9. VACON

NXA, FI10. Protection class IP00

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 25

11173.emf

Figure 10. VACON® NXA, FI13. Protection class IP00

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 26 Active Front End (AFE)

4.4 Active Front End unit technical data

Table 7. Technical specification for VACON® NXA Active Front End unit

AC input connection

DC output

connection

Control

characteristics

Ambient conditions

Voltage U

Frequency f

380...500 Vac; 525...690 Vac; UL rating up to 600 V, –10%…+10%

48–63 Hz

Starting delay FI9–FI13: 5 s

FI9_5 : 4950F; FI9_6 : 3733F

DC bank capacitance

FI10_5: 9900F; FI10_6: 7467F FI13_5: 29700F; FI13_6: 22400F

Voltage

1.35 x U 110%).

: Ambient temperature +40 °C (104 °F),

x 1.1 (default DC link voltage boosting is

overloadability 1.5 x I

• For 40 - 50 °C (104 - 122°F), the ambient temperatures use derating factor IH*1.5%/1

Continuous output current

°C (°F).

• For 50 – 55 °C (122 - 131°F), the ambient temperatures use derating factor IH*2.5% /1 °C (°F).

: Ambient temperature +40 °C(104 °F),

overloadability 1.1 x I

Control system Open Loop Vector Control

Switching frequency

Ambient temperature during operation

NXA_xxxx 5: 3.6 kHz NXA_xxxx 6: 3.6 kHz

: –10°C (-14 °F) (no frost)…+40°C (104 °F)

H/IL

Maximum temperature +55 °C (131 °F), see Power derating as a function of ambient temperature.

(1 min./10 min.).

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 27

Table 7. Technical specification for VACON

Storage temperature -40 °C (-104 °F)...+70 °C (158 °F)

Relative humidity

Air quality:

- chemical fumes

-solid particles

Elevation of place of operation

Vibration IEC/EN 61800-5-1/ EN 60068-2-6

Impacts EN 50178, EN 60068-2-27

0 to 95% RH, non-condensing, non-corrosive, no dripping water.

Designed according to

• IEC 60721-3-3, AC drive in operation, class 3C2

• IEC 60721-3-3, AC drive in operation, class 3S2 100% loadability (no derating) up to 1000 m.

Maximum elevation 2000 m (525-690 VAC) and 4000 m (380-500 VAC), Relay I/O: max. 240 V: 3000 m; max. 120 V: 4000 m, see Power derating as a function of installation altitude. See Chapter 4.16.

5…150 Hz. FI9:

FI10-13:

UPS drop test (with applicable UPS weights) Storage and transport: max. 15 G, 11 ms (packed).

NXA Active Front End unit

• Vibration amplitude 1 mm (peak) in frequency range 5…15.8 Hz.

• Max. acceleration 1 G in frequency range

15.8…150 Hz.

• Vibration amplitude 0.25 mm (peak) in frequency range 5…31Hz.

• Max. acceleration 1 G in frequency range 31…150 Hz.

EMC (using factory

settings)

Noise level

Safety standards

Approvals

Enclosure class IP00/Open type standard size in the kW/HP range.

Immunity

Average noise level (cooling fan) in dB(A)

IEC/EN 61800-3:2004+A1:2012, second environment

FI9: 76 FI10: 76 FI13: 81

IEC/EN 61800-5-1, UL 508C, CSA C22.2 No.274 T-level, see chapter 2.2.3.

CE, cULus, RCM, KC, EAC, UA. (See the nameplate of the drive for more approvals.) Marine approvals: LR, BV, DNV, GL, ABS, RMRS, CCS,KR.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 28 Active Front End (AFE)

Table 7. Technical specification for VACON

Control connections

NXA Active Front End unit

Analogue input voltage

Analogue input current Digital inputs (6) Positive or negative logic; 18…30 VDC

Auxiliary voltage +24 V, ±15%, max. 250 mA Reference voltage,

output

Analogue output (1)

Digital outputs Open collector output, 50 mA / 48 V.

Relay outputs

Overvoltage protection Undervoltage protection

Earth fault protection

0…+10 V, R Resolution 0.1% (12-bit), accuracy ±1%

0(4)…20 mA, R

+10 V, +3%, max. load 10 mA

0(4)…20 mA; R Accuracy ±2%

2 programmable changeover relay outputs Switching capacity (resistive): 24 VDC / 8 A, 250 VAC / 8 A, 125 VDC / 0.4 A. Min. switching load: 5 V / 10 mA.

NXA_5: 911 VDC; NXA_6: 1200 VDC NXA_5: 333 VDC; NXA_6: 461 VDC

In case of earth fault in the supply cable, the earth fault protection only protects the NX-AFE itself.

= 200 kΩ.

= 250 Ω differential

max. 500 Ω; Resolution 10 bit;

Protection

Input phase monitoring Trips if any of the input phases is missing. Overcurrent protection Yes Unit over-temperature

protection Short-circuit protection

of +24 V and +10 V reference voltages

Yes

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 29

4.5 LCL filter technical data

Table 8. Technical specifications for VACON® LCL filter for Active Front End units

AC connections

Cooling fan With

integrated DC/DC-

power supply

Cooling fan with

external DC-power

supply

EMC (using factory

settings)

Safety Same as the unit

Voltage U Frequency f Continuous output current Same as the unit

Switching frequency

Input voltage U Power consumption 220 W

Losses 20…30 W Short-circuit protection DC fuses on the input side Input voltage U

Current 5 A

Short-circuit protection

Immunity Same as the unit

Ambient temperature during operation

Same as the unit 50 or 60 Hz +2%

LCLxxxx 5: 3.6 kHz LCLxxxx 6: 3.6 kHz

333...911 Vdc; 460...1200 Vdc

48 Vdc; -10...+10%

AC fuses on the input side of the external power supply.

Same as the unit

Ambient conditions

Protection

Storage temperature Same as the unit Relative humidity Same as the unit Air quality:

- Chemical fumes

- Solid particles Elevation of place of operation Same as the unit Vibration

EN 50178/EN 60068-2-6 Impacts

EN 50178, EN 60068-2-27 Dissipation power Approximately 1% Cooling fan rotation monitoring Yes (with integrated DC/DC power supply) Over-temperature monitoring Yes

Same as the unit

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 30 Active Front End (AFE)

4.6 Application

The VACON® NX Active Front End needs special application software, which is delivered with the NX AFE unit. More information on the application can be found in VACON

NX AFE Application Manual.

4.7 Diagrams

4.7.1 Connection between control unit and power unit

The communication connections between the Active Front End power unit and the control unit is established using optical cable, Figure 11. The standard cable length of the optical cable is 1.5 m. For optional the optical cables can get different lengths. The maximum length of the optical cable is 10 m. The adapter board is located back side of the control unit, see Figure 12. ASIC board terminals located in the unit under the black cover, Figure 13. To open black cover two screws at left and right side should be opened.

Figure 11. Optical cable adapter board

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 31

Figure 12. Optical cable adapter board

Figure 13. Optical cable terminals in the unit (FI13 example)

Optical terminals on adapter board

H1 Gate control enable

H2 Phase U control

H3 Phase V control

H4 Phase W control

H5 ADC synchronization

H6 VaconBus data from control board to ASIC

H7 VaconBus data from ASIC to control board

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 32 Active Front End (AFE)

LCL FILTER

-R1 -R4

-L1

-L2.1

-L2.2

-L2.3

U V W

-C1

-C2

-C3

L1 L2 L3

-C1.1 -C1.2

-C2.2-C2.1

-C3.1 -C3.2

-C4.1

-C4.2

-C5.1 -C5.2

-C6.1

-C6.2

-R2 -R5

-R3 -R6

11181.emf

Other terminals on adapter board

X1 Control board connection

Supply voltage 24 V

•Max. current 1A

• Terminal #1: +

(from power unit ASIC)

(customer);

• Terminal #2: –

NOTE! The minimum fibre cable bending radius is 50 mm. NOTE! Terminals

X2 and X3 can be in use simultaneously. However, if the +24 V supply from the

control I/O terminals (e.g. from board OPT-A1) is used, this terminal must be protected with a diode.

4.7.2 LCL wiring diagram

The LCL filter contains a choke on the mains side, capacitors and a choke on the AFE side, Figure 14. The LCL also includes capacitors connected against ground potential. There are resistors connected across the capacitors for discharging them when the LCL filter is disconnected from the input power. The discharging resistors are 10 MΩ, 500 V and 0.5 W.

4.7.2.1

If the LCL filter is used in a network fitted with an earth fault protection relay, these discharging

Removing discharging resistors

Figure 14. VACON

resistors should be removed. If the discharging resistors are not removed, the earth fault

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

LCL filter wiring diagram

Active Front End (AFE) vacon • 33

7101A_uk

monitoring device might indicate a very low leakage resistance. The resistors must be connected so that the capacitors are discharged when disconnecting from the input power. The wiring diagram of an alternative discharging circuit can be seen in Figure 16. Figure 15 shows the default wiring of the LCL filter. The discharging resistors should be 10 kΩ, 500 V and 2 W. Failure to ensure the discharging of capacitors results in a risk of electric shock! Without the discharge resistors, the capacitors take a very long time to discharge.

Figure 17 (for FI9 and FI10) and Figure 18 (for FI13) have a blue marking on the lead that has to be removed from each capacitor if the discharge resistor is not to be used.

Warning! If you do not allow a total discharge of the system before starting the modification, it is likely that you will get an electric shock in spite of the fact the system is disconnected from the power supply.

Figure 15. Wiring diagram of the default LCL filter

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 34 Active Front End (AFE)

7102A_uk

Figure 16. Wiring diagram of LCL and AFE circuit when used in installations which have earth fault

protection relay or when used in IT network or when AFE of other manufacturer is connected to same

transformer secondary supply

4.7.2.2

If a PWM modulated rectifier from another manufacturer is connected to the same input transformer, the HF capacitor must be removed, because the HF capacitors will be filtering the high frequency disturbances from another manufacturer’s active front ends. It is recommended to always use own transformers if more than one manufacturer’s AFEs are used.

Figure 17 (for FI9 and FI10) and Figure 18 (for FI13) have a red marking on the lead that has to be removed from each capacitor if the HF capacitors are not to be used. Removing the lead disconnects the capacitors from ground potential.

Removing HF capacitors

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 35

11253B_uk

11254B_uk

Figure 17. HF capacitors in FI9 and FI10 LCL filter

Figure 18. HF capacitors in FI13 LCL filter

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 36 Active Front End (AFE)

4.8 Active Front End power ratings

4.8.1 VACON® NXA; DC voltage 380–500 V

Table 9. Pow er r atin gs of VACON® NXA, supply voltage 380–500 VAC

Unit

Low overload

(AC current)

High overload

(AC current)

DC Power

(continuous)

Type

Code

Enclosure

size

L-cont [A]I1min [A]

H-cont

[A]

1min [A]

400 V mains

P [kW]

500 V mains

P [kW]

NXA_0168 5 FI9 170 187 140 210 114 143 NXA_0205 5 FI9 205 226 170 255 138 172 NXA_0261 5 FI9 261 287 205 308 175 220 NXA_0385 5 FI10 385 424 300 450 259 323

AFE

NXA_0460 5 FI10 460 506 385 578 309 387 NXA_1150 5 FI13 1150 1265 1030 1545 773 966 NXA_1300 5 FI13 1300 1430 1150 1725 874 1092

For dimensions of NXA units, see Table 11 and LCL filters Table 12.

NOTE! The rated currents in a given ambient (+40 °C) temperature are achieved only when the switching frequency is equal to the factory default.

NOTE! The motor output power: P

= AFEs DC power

= efficiency of the inverter

INU

= efficiency of the motor

Motor

out=Pdc

x (η

INU

x η

Motor

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 37

4.8.2 VACON® NXA; DC voltage 525–690 V

Table 10. Power ratings of VACON® NXA, supply voltage 525–690 VAC (UL 525-600V)

Unit

Low overload

(AC current)

High overload

(AC current)

DC Power

(continuous)

Type

Code

Enclosure

size

L-cont [A]I1min [A]IH-cont [A]I1min [A]

690 V mains

P [kW]

NXA_0125 6 FI9 125 138 100 150 145 NXA_0144 6 FI9 144 158 125 188 167 NXA_0170 6 FI9 170 187 144 216 197

AFE

NXA_0261 6 FI10 261 287 208 312 303 NXA_0325 6 FI10 325 358 261 392 377 NXA_0920 6 FI13 920 1012 820 1230 1067 NXA_1030 6 FI13 1030 1133 920 1380 1194

For dimensions of NXA units, see Table 11 and LCL filters Table 12.

NOTE! The rated currents in a given ambient (+40 °C) temperature are achieved only when the switching frequency is equal to the factory default.

NOTE! The motor output power: P

= AFEs DC power

= efficiency of the inverter

INU

= efficiency of the motor

Motor

out=Pdc

x (η

INU

x η

Motor

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 38 Active Front End (AFE)

4.9 Active Front End unit – Dimensions

Table 11. The NXA unit dimensions

Module Module Dimension

Type

AFE

NOTE! More detailed dimensions can be found Appendix 77, Appendix 78 and Appendix 79.

Enclosure

size

FI9 1030 239 372 67 FI10 1032 239 552 100 FI13 1032 708 553 306

Height [mm] Width [mm] Depth [mm] Weight [kg]

4.10 LCL filter – Dimensions

Table 12. LCL filter dimensions

Module Module Dimension

Type

LCL

Enclosure

size

FI9 1775 291 515 241/245 FI10 1775 291 515 263/304 FI13 1442 494 525 477/473

Height [mm] Width [mm] Depth [mm] Weight [kg]

NOTE! Weight is different for 500 V/690 V other dimensions are same for both voltage classes.

NOTE! More detailed dimensions can be found Appendix 80 and Appendix 81.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 39

4.11 Active Front End unit – Fuse selection

4.11.1 Introduction

AC fuses are used to protect the input network in case the Active Front End unit or the LCL filter is faulty. DC fuses are used to protect the Active Front End unit and the LCL filter in case there is a short circuit in the DC buses. If DC fuses are not used, short-circuit in the DC buses will cause a loading of the Active Front End unit. Vacon Ltd will not assume any responsibility for damages caused by insufficient protection.

4.11.2 Fuses; mains voltage 380–500 V

4.11.2.1

Type Code

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

AC fuses

Table 13. Mersen AC fuse selection, mains voltage 380–500 Vac

Module AC fuses

Enclosure

size

NXA_0168 5 FI9 PC32UD69V400TF 690 400 32 3 NXA_0205 5 FI9 PC32UD69V400TF 690 400 32 3 NXA_0261 5 FI9 PC32UD69V400TF 690 400 32 3 NXA_0385 5 FI10 PC33UD69V700TF 690 700 33 3 NXA_0460 5 FI10 PC33UD69V700TF 690 700 33 3 NXA_1150 5 FI13 PC44UD75V18CTQ 750 1800 44 3 NXA_1300 5 FI13 PC44UD75V18CTQ 750 1800 44 3

Table 14. Bussman AC fuse selection, mains voltage 380–500 Vac

Mersen

type [aR]*

UN [V]

[A]

Size Q'ty

Module AC fuses

Type Code

NXA_0168 5 FI9 170M8602 1000 400 3BKN/75 3 NXA_0205 5 FI9 170M8602 1000 400 3BKN/75 3 NXA_0261 5 FI9 170M8604 1000 500 3BKN/75 3

AFE

NOTE! Fuses for FI9 and FI10 are blade type and for FI13 flush-end type. If some other type is needed, contact

your distributor.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

NXA_0385 5 FI10 170M8607 1000 700 3BKN/75 3 NXA_0460 5 FI10 170M8608 1000 800 3BKN/75 3 NXA_1150 5 FI13 170M7082 690 2000 4BKN/65 3 NXA_1300 5 FI13 170M7082 690 2000 4BKN/65 3

Enclosure

size

Bussman

type [aR]*

UN [V]

[A]

Size Q'ty

vacon • 40 Active Front End (AFE)

Table 15. Mersen AC fuse selection, mains voltage 380–500 Vac, North-America

Module AC fuses

Type Code

NXA_0168 5 FI9 PC32UD69V400TF 690 400 32 3 NXA_0205 5 FI9 PC32UD69V400TF 690 400 32 3 NXA_0261 5 FI9 PC32UD69V400TF 690 400 32 3

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

4.11.2.2 DC fuses

Type Code

NXA_0385 5 FI10 PC33UD69V700TF 690 700 33 3 NXA_0460 5 FI10 PC33UD69V700TF 690 700 33 3 NXA_1150 5 FI13 PC44UD75V18CTQ 750 1800 44 3 NXA_1300 5 FI13 PC44UD75V18CTQ 750 1800 44 3

Table 16. Mersen DC fuse selection, mains voltage 465–800 Vdc

Module DC fuses

NXA_0168 5 FI9 PC73UD13C400TF 1250 400 73 2 NXA_0205 5 FI9 PC73UD13C400TF 1250 400 73 2 NXA_0261 5 FI9 PC73UD13C500TF 1250 500 73 2

Enclosure

size

Enclosure

size

Mersen

type [aR]*

Mersen type [aR]*

UN [V]

[A]

Size Q'ty

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

NXA_0385 5 FI10 PC73UD13C800TF 1250 800 73 2 NXA_0460 5 FI10 PC73UD95V11CTF 950 1100 73 2 NXA_1150 5 FI13 PC84UD11C22CTQ 1100 2200 84 2 NXA_1300 5 FI13 PC84UD11C24CTQ 1100 2400 84 2

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 41

Table 17. Bussman DC fuse selection, mains voltage 465–800 Vdc

Module DC fuses

Type Code

NXA_0168 5 FI9 170M6458 690 500 3BKN/50 2 NXA_0205 5 FI9 170M6458 690 500 3BKN/50 2 NXA_0261 5 FI9 170M6462 690 800 3BKN/50 2

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

Type Code

AFE

NXA_0385 5 FI10 170M6466 690 1250 3BKN/50 2 NXA_0460 5 FI10 170M6466 690 1250 3BKN/50 2 NXA_1150 5 FI13 170M7084 690 3000 4BKN/65 2 NXA_1300 5 FI13 170M7084 690 3000 4BKN/65 2

Table 18. Bussman DC fuse selection, mains voltage 465–800 Vdc, North-America

Module DC fuses

NXA_0168 5 FI9 170M1777 800 400 FU/70 2 NXA_0205 5 FI9 170M1777 800 400 FU/70 2 NXA_0261 5 FI9 170M1781 800 630 FU/70 2 NXA_0385 5 FI10 170M6499 1200 1100 3BKN/90 2

Enclosure

size

Enclosure

size

Bussman

type [aR]*

Bussman

type [aR]*

UN [V]

[A]

Size Q'ty

NXA_0460 5 FI10 170M6499 1200 1100 3BKN/90 2 NXA_1150 5 FI13 170M6499 1200 1100 3BKN/90 3x2 NXA_1300 5 FI13 170M6499 1200 1100 3BKN/90 3x2

NOTE! Fuses for FI9 is fuse links type and for FI10 and FI13 are flush-end type. If some other type is needed, contact your distributor.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 42 Active Front End (AFE)

4.11.3 Fuses; mains voltage 525–690 V

4.11.3.1

Type Code

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

AC fuses

Table 19. Mersen AC fuse selection, mains voltage 525–690 Vac (UL 525-600V)

Module AC fuses

Enclosure

size

NXA_0125 6 FI9 PC71UD13C250TF 1250 250 71 3 NXA_0144 6 FI9 PC71UD13C250TF 1250 250 71 3 NXA_0170 6 FI9 PC71UD13C250TF 1250 250 71 3 NXA_0261 6 FI10 PC73UD13C450TF 1250 450 73 3 NXA_0325 6 FI10 PC73UD13C450TF 1250 450 73 3 NXA_0920 6 FI13 PC44UD75V16CTQ 750 1600 44 3 NXA_1030 6 FI13 PC44UD75V16CTQ 750 1600 44 3

Table 20. Bussman AC fuse selection, mains voltage 525–690 Vac (UL 525-600V)

Mersen

type [aR]*

UN [V]

[A]

Size Q'ty

Module AC fuses

Type Code

NXA_0125 6 FI9 170M4954 1000 315 1BKN/75 3 NXA_0144 6 FI9 170M4954 1000 315 1BKN/75 3 NXA_0170 6 FI9 170M4954 1000 315 1BKN/75 3

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

NXA_0261 6 FI10 170M8604 1000 500 3BKN/75 3 NXA_0325 6 FI10 170M8607 1000 700 3BKN/75 3 NXA_0920 6 FI13 170M7081 690 1600 4BKN/65 3 NXA_1030 6 FI13 170M7081 690 1600 4BKN/65 3

Enclosure

size

Bussman

type [aR]*

[V]

[A]

Size Q'ty

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Active Front End (AFE) vacon • 43

4.11.3.2 DC fuses

Table 21. Mersen DC fuse selection, mains voltage 640–1100 Vdc

Module DC fuses

Type Code

NXA_0125 6 FI9 PC71UD13C315TF 1250 315 71 2 NXA_0144 6 FI9 PC71UD13C315TF 1250 315 71 2 NXA_0170 6 FI9 PC71UD13C400TF 1250 400 71 2

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

Type Code

NXA_0261 6 FI10 PC73UD13C500TF 1250 500 73 2 NXA_0325 6 FI10 PC73UD13C630TF 1250 630 73 2 NXA_0920 6 FI13 PC84UD12C18CTQ 1150 1800 84 2 NXA_1030 6 FI13 PC84UD11C20CTQ 1100 2000 84 2

Table 22. Bussman DC fuse selection, mains voltage 640–1100 Vdc

Module DC fuses

NXA_0125 6 FI9 170M4956 1250 400 1BKN/75 2 NXA_0144 6 FI9 170M4956 1250 400 1BKN/75 2

Enclosure

size

Enclosure

size

Mersen type [aR]*

Bussman

type [aR]*

UN [V]

[A]

Size Q'ty

NXA_0170 6 FI9 170M4956 1250 400 1BKN/75 2

AFE

NOTE! All fuses are flush-end type. If some other type is needed, contact your distributor.

Type Code

AFE

NXA_0261 6 FI10 170M8607 1250 700 3BKN/75 2 NXA_0325 6 FI10 170M8607 1250 700 3BKN/75 2 NXA_0920 6 FI13 170M7640 1000 2500 4BKN/95 2 NXA_1030 6 FI13 170M7658 1000 2700 4BKN/95 2

Table 23. Bussman DC fuse selection, mains voltage 640–1100 Vdc, North-America

Module DC fuses

Enclosure

size

NXA_0125 6 FI9 170M1831 1000 400 FU/90 2 NXA_0144 6 FI9 170M1831 1000 400 FU/90 2 NXA_0170 6 FI9 170M1831 1000 400 FU/90 2 NXA_0261 6 FI10 170M6496 1200 800 3BKN/90 2 NXA_0325 6 FI10 170M6496 1200 800 3BKN/90 2 NXA_0920 6 FI13 170M6496 1200 800 3BKN/90 3x2 NXA_1030 6 FI13 170M6498 1200 1000 3BKN/90 3x2

Bussman

type [aR]*

UN [V]

[A]

Size Q'ty

NOTE! Fuses for FI9 is fuse links type and for FI10 and FI13 are flush-end type. If some other type is needed, contact your distributor.

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vacon • 44 Active Front End (AFE)

4.12 Active Front End unit – Circuit breaker selection

The Active Front End can also be protected by a circuit-breaker. The recommended types of circuitbreakers are shown in Table 24. If a circuit-breaker from another manufacturer is used, it must be equivalent to the circuit-breakers shown. Further information on the circuit-breakers shown is available from the manufacturer. Circuit-breakers do not provide same level of protection as fuses, therefore, fuses are always recommended to be used. A circuit-breaker can be used without a main contactor. In this case, the Active Front End unit controls the circuit-breaker instead of the contactor. The circuit-breakers shown are suitable for equipment rated at 380 V–500 V or 525 V–690 V.

Table 24. Circuit breaker for VACON

Type T5H400FF3LS

T5H400FF3LS MOE230V/T4-5 UVRC230V/T4-5

FI9

ES-6/T5 AUX-C3+1/T4-5 PB100/T4-5-3P AUX-SA1-S51+1/T4-5

Type T5H630FF3LS

T5H630FF3LS MOE230V/T4-5 UVRC230V/T4-5

FI10

ES-6/T5 AUX-C3+1/T4-5 PB100/T4-5-3P AUX-SA1-S51+1/T4-5

Type T7S16FF3PR231LS

MCCB Motor Undervoltage rel. (cabled) Spreaded ext. term. incl. PB100 Aux./alarm cont. (cabled) Phase separators for upper/lower terminals S51 NC

NXA

1SDA054349R1 1SDA054897R1 1SDA054891R1 1SDA055038R1 1SDA054911R1 1SDA054970R1 1SDA064518R1

1SDA054412R1 1SDA054897R1 1SDA054891R1 1SDA055038R1 1SDA054911R1 1SDA054970R1 1SDA064518R1

E1.2N 1600A Ekip Dip LI 3p F-F M E1.2 220-250Vac/dc YR 250Vac/dc E1.2 RTC 250V E1.2

FI13

YO E1.2 220-240Vac/dc YC E1.2 220-240Vac/dc YU E1.2 220-240Vac/dc PB Separators H=200mm 4pz E1.2 F 3P

1SDA070881R1 Spring charging Motor Reset coil Ready to close auxiliary contact Opening coil Closing coil Undervoltage coil Phase separators

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1SDA073711R1

1SDA073746R1

1SDA073770R1

1SDA073674R1

1SDA073687R1

1SDA073700R1

1SDA073879R1

Active Front End (AFE) vacon • 45

4.13 Main contactor

If a main contactor is to be used, the types shown in Table 25 are recommended. If a contactor from another manufacturer is used, it must be equivalent to the types shown. Further information on the contactors shown is available from the manufacturer.

Table 25. Recommended main contactor types

Type FI9 Contactor / 500 V

FI9 A210-30-11-80 Contactor, 350 A/690 V, AC3 110 KW/400 V, 230 VAC-Coil

Type FI9 Contactor / 690 V

FI9 A185-30-11-80 Contactor, 275 A/690 V, AC3 132 KW/690V, 230 VAC-Coil

Type

FI10

Type

FI10

Type FI13 Contactor / 500 V

FI13 AF1650-30-11-70 Contactor, 1650 A/500 V, AC3 560 KW/400 V, 100…250 V AC/DC coil

Type FI13 Contactor / 690 V

FI13 AF1350-30-11-70 Contactor, 1350 A/690 V, AC3 --- KW/400 V, 100…250 V AC/DC coil

AF400-30-11-70 Contactor, 600 A/500 V, AC3 200KW/400V, 100…250 V AC/DC coil

AF300-30-11-70 Contactor, 500 A/690 V, AC3 250 KW/690 V, 100…250 V AC/DC coil

FI10 Contactor / 500 V

FI10 Contactor / 690 V

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vacon • 46 Active Front End (AFE)

4.14 Pre-Charging circuit

The Active Front End unit requires an external pre-charging circuit. The purpose of the pre-charging unit is to charge the voltage in the intermediate circuit to a level sufficient for connecting the Active Front End unit to the mains. The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors. The technical specifications of our standard precharging circuits are shown in Table 26. Pre-charging circuits are suitable for 380-500 Vac and 525690 Vac.

The Active Front End unit must not be connected to mains without pre-charging. In order to ensure the correct operation of the pre-charging circuit, the input circuit-breaker or contactor, as well as the pre-charging circuit contactor, must be controlled by the Active Front End unit. The input circuitbreaker or contactor as well as the pre-charging circuit contactor must be connected as shown in Appendix 74.

Table 26. Capacitance Min and Max value for Pre-charging circuit

Enclosure

size

FI9 2x47R 4950 µF 30000 µF

FI10 2x20R 9900 µF 70000 µF

FI13 2x11R 29700 µF 128000 µF

If the capacitance of the intermediate circuit in the system exceeds the values shown, contact your nearest distributor.

The example shown in Appendix 74 uses a spring-return switch. The switch has positions 0-1START. The spring returns the switch from position START to position 1. To start the pre-charging, the switch is turned from position 0 via 1 to START. When pre-charging starts, the switch can be released and it returns to position 1. No other control measures are required. The Active Front End application controls the main contactor of the system with Relay Output RO2, see Appendix 76. When pre-charging of the intermediate circuit is ready the main contactor will be closed. The status of the main contactor is monitored via digital input (Default is DIN4). As a default the main contactor monitoring is ON but it can be set OFF with parameter. The main contactor should not be possible close without pre-charging.

To open the main contactor, simply turn the switch to 0. The contactor should not be opened under load. Opening the contactor under load will shorten its service life.

Resistance

Capacitance

Min Max

NOTE! Wirings that are used for connecting the pre-charging circuit to the intermediate circuit has to be double-insulated (example: NSGAFÖU 1.8/3kV (IEC), NSHXAFÖ 3kV (IEC Halogen free), MULTI-STANDARD SC 2.2 (UL)).

NOTE! Enough space must be reserved around the resistors to ensure sufficient cooling. Don’t place any heat sensitive components near the resistors.

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Active Front End (AFE) vacon • 47

4.15 Paralleling

The power of the input group can be increased by connecting several Active Front End units in parallel. Paralleling refers to Active Front End units connected in the same input transformer. Active Front End units of different power ratings can also be connected in parallel. No communication between the units is required; they work independently. Our standard LCL filters must be used for paralleling. If filters other than our standard LCL filters are used in Active Front End units connected in parallel, too large circulation currents may be generated between the Active Front End units. Parameter P2.1.4 Parallel AFE must be set to “1/yes” for all parallel AFE units. This parameter will also set DC Drooping to 4%. The value of DC Drooping can be also modified manually with parameter P2.2.2.

Each Active Front End unit connected in parallel must have its own short-circuit protection on AC and DC sides. The fuses are selected in accordance with Section 4.11. When paralleling, attention must be paid to the sufficient short-circuit capacity of the system.

The derating of Active Front End units connected in parallel is 5% of the DC power; this should be taken into account when selecting the input unit.

If a device is to be isolated from the AC and DC voltages, and other Active Front End units connected in parallel are also to be used, separate isolators are required in the AC input and DC output. The AC input can be isolated using a compact circuit-breaker, an ordinary circuit-breaker or a fuse switch. Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position. The DC output can be isolated using a fuse switch. The pre-charging circuit must also be isolated from the AC input. A load isolation switch or safety isolation switch can be used for this. The device can also be connected to mains even when the other devices connected in parallel are already connected and running. In such a case, the isolated deice must first be pre-charged. When that is done, the AC input can be switched on. After this, the device can be connected to the interediate DC circuit.

4.15.1 Common pre-charging circuit

In case of paralleled Active Front End units, one common pre-charging circuit can be used, see Figure 19. Standard pre-charging circuits can be used if the capacitance of the intermediate circuit not exceeds maximum value. For example if three FI10 Active Front End units are connected parallel, the pre-charging circuit for FI13 Active Front End unit can be used. If all paralleled Active Front End units have a common circuit breaker, the breaker can be controlled by one of the Active Front End units. If each paralleled Active Front End unit has its own circuit-breaker, each Active Front End controls it’s own circuit. The circuit diagram for control, see Appendix 74 and Appendix 76.

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vacon • 48 Active Front End (AFE)

11165.emf

+LCL-U1

+AFE-U1 NXA xxxx x

DC+

DC-

+LCL-U2

+AFE-U2 NXA xxxx x

Main Circuit

Double Insulated

Figure 19. Active Front End units parallel connection with one common pre-charging circuit

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Active Front End (AFE) vacon • 49

+LCL-U1

+LCL-U2

11166.emf

+AFE-U1 NXA xxxx x

+AFE-U2 NXA xxxx x

DC+ DC-

Main Circuit

Double Insulated

4.15.2 Each Active Front End unit has the pre-charging circuit

Each Active Front End can have its own pre-charging circuit. Each unit controls its own pre-charging and main contactor. See Figure 20. One control switch can be used, but if an Active Front End unit needs to be controlled independently, separate switches are needed. With this the system is more redundant than with a common pre-charging circuit. The circuit diagram for control, see Appendix 74 and Appendix 76.

Figure 20. Active Front End units parallel connection with own pre-charging circuits

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vacon • 50 Active Front End (AFE)

11167A_00

20%

40%

60%

80%

100%

120%

4.16 Derating

The output power has to be derated if one of following cases:

• Ambient temperature is more than 40 ºC (104 °F).

• Installation altitude is more than 1000 m.

4.16.1 Ambient Temperature

The power rating of the Active Front End unit is valid for an ambient temperature of 40 ºC (104 °F). If the device is to be used in higher ambient temperatures, its power rating must be subjected to derating. The derating coefficient from 40 °C to 50 °C, use derating factor 1.5 %/1 °C, and from 50 °C to 55 °C, use derating factor 2.5 %/1 °C, for ambient temperatures not exceeding 55 °C (131 °F). The reduced power is calculated using the formula:

= Pn *((100% - (t - 40 ºC)*X)/100)

= nominal power of the unit

t = ambient temperature x = derating coefficient

A Ambient temperature, °C BLoadability, % CLoadability %

Figure 21. Derating as the ambient temperature

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Active Front End (AFE) vacon • 51

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

10%

30%

50%

70%

20%

40%

60%

80%

90%

100%

110%

4.16.2 High altitude installation

The density of air decreases when the altitude increases and the pressure decreases. When the air density decreases, the thermal capacity decreases (i.e. less air removes less heat) and the resistance to electric field (breakdown voltage / distance) decreases.

The full thermal performance of VACON

NX AC drives is designed for installation up to 1000 m altitude and the electric insulation is designed for installations up to 2000 m altitude. Higher installation locations are possible, when you obey the derating guidelines in this chapter.

NOTE! 690V units maximum installation altitude is 2000m. Above 1000 m, you must decrease the limited maximum load current by 1% for each 100 m. Thus,

for example, at 2500 m altitude, you must decrease the load current down to 85% of the rated output current (100% – (2500 m – 1000 m) / 100 m x 1% = 85%).

When you use fuses at high altitudes, the cooling effect of the fuse decreases as the density of the atmosphere decreases.

When you use fuses above 2000 meters, the continuous rating of the fuse:

I = I

*(1- (h-2000)/100*0.5/100)

I = Current rating at high altitude I

= Rated current of a fuse

h = Altitude in meters

Figure 22. Loadability in high altitudes

For permitted maximum altitudes, see Table 7. For information on option boards and I/O signals and relay outputs, see VACON

Manual.

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NX I/O Boards User

vacon • 52 Installation

5. INSTALLATION

5.1 Mounting

The equipment mounting must be sturdy enough to carry the weight of the equipment. The enclosure class of the equipment will depend on the mounting and solutions to be used. The equipment mounting must provide sufficient shielding for contact of the live parts (IPXXB). The installation and mounting must comply with local laws and regulations.

5.1.1 Active Front End Unit

The Active Front End can be mounted in a vertical position on the back plane of a cubicle. Enough space must be reserved around the Active Front End to ensure sufficient cooling, see Figure 30. Follow the minimum dimensions for installation, see Table 27. Required cooling air capacity and minimum air holes on the switchgear, see Table 28. Also make sure that the mounting plane is relatively even. The Active Front End is fixed with four bolts, Figure 23, Figure 24 and Figure 25.

Figure 23. Mounting points of FI9 AFE unit

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Installation vacon • 53

Figure 24. Mounting points of FI10 AFE unit

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vacon • 54 Installation

Figure 25. Mounting points of FI13 AFE unit

5.1.2 LCL filter

The LCL filter can only be mounted in a vertical position on the floor of a cubicle. Enough space must be reserved around the LCL filter to ensure sufficient cooling, see Figure 33. Follow the minimum dimensions for installation, see Table 29. Required cooling air capacity and minimum air holes on the switchgear, see Table 30. LCL filters cooling air airflow is present in Figure 34 and Figure 35. Also make sure that the floor is relatively even. The LCL filter must be attached properly so it can not move.

In the LCL filter for the FI13 Active Front End unit, the connection direction can change from right to left, see Appendix 81 and Appendix 82. Follow the instruction below:

1. Open fastenings numbered by 1 in Figure 26.

2. Open fastenings numbered by 2 in Figure 26.

3. Remove bus bars.

4. Remove the (dark grey) from the right side and place it in same place to the left.

5. Place the bus bars like in Figure 27.

6. Close fastenings numbered by 2 in Figure 27.

7. Close fastenings numbered by 1 in Figure 27.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Installation vacon • 55

11185.emf

11186.emf

Figure 26. Right-side connection

Figure 27. Left-side connection

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 56 Installation

11188.emf

11187.emf

4 pcs Ø 5

308

8.5

300

126

7.5

8.5

5.1.3 Control Box

The control unit of the Active Front End unit is mounted into a mounting rack which then can be placed inside the enclosure, Figure 28 and Figure 29. The control unit should be placed so that it is easy to access. VACON

alpha-numeric or graphical keypad can be used to control the Active Front End unit. The keypad is connected to the control unit. The keypad can be mounted on the enclosure door with optional door mounting kit, see Appendix 85. In that case the keypad connects to the control unit with an RS232 cable. Pay special attention to the grounding of the cable, see the instructions below.

Figure 28. Control unit installed into the mounting box; Left: front; Right: back

Figure 29. Mounting points of Control Box

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Installation vacon • 57

1. If the keypad sits in its place on the control unit, remove the keypad. Connect the male end of the keypad cable to the D-connector of the control unit. Use our

2. RS232 cable included in the delivery. Figure 1.

3. Run the cable over the top of the box and secure with plastic band on the backside. Figure 2. Grounding of keypad cable

4. branch cable with a screw underneath the control unit. See Figures 3 and 4.

Mount the control unit mounting box in the front-left corner of the enclosure using two screws

5. as shown in Figure 5. NOTE! Do not install the mounting box floating (with e.g. plastic screws).

Connect the optical cables (or the flat cable) to the power unit. See Chapter 4.7.1 Connection

6. between control unit and power unit and Figures 6 - 7.

Connect the female end of the keypad cable to keypad on the enclosure door, Figure 8. Use a

7. cable channel for the cable run, Figure 9.

: Earth the keypad cable in the mounting box frame by fixing the

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 58 Installation

Figure 1. Figure 2. Figure 3.

Figure 4. Figure 5. Figure 6.

Figure 7. Figure 8. Figure 9.

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Installation vacon • 59

5.2 Cooling

5.2.1 Active Front End unit

Enough free space must be left around the Active Front End unit to ensure sufficient air circulation and cooling. You will find the required dimensions for free space in the Table 27. You will find the required cooling air, minimum air holes and heat dissipation in the Table 28.

When planning the cooling for the space, take into consideration that the Active Front End unit heat loss is approx. 2% of the nominal capacity. Air flow, see Figure 31 and Figure 32.

Table 27. Mounting space dimensions

Dimensions [mm]

Type

NXA_0168 - 0261 5 NXA_0125 - 0170 6

NXA_0385 - 0460 5 NXA_0261 - 0325 6

NXA_1150 - 1300 5 NXA_0920 - 1030 6

A B B

200 0 0 100

200 00100

A = free space above the unit

B = distance between inverter and cabinet wall

B2 = distance between two units

C = free space underneath of the units

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vacon • 60 Installation

2x FI9/FI10

FI9/FI10

11215.emf

Figure 30. Installation space for FI9, FI10 and FI13

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Installation vacon • 61

Figure 31. Cooling airflow for FI9 and FI10 units

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vacon • 62 Installation

Table 28. Power losses and required cooling air for the Active Front End units

Type

NXA_0168 - 0261 5 NXA_0125 - 0170 6

NXA_0385 - 0460 5 NXA_0261 - 0325 6

NXA_1150 - 1300 5 NXA_0920 - 1030 6

Figure 32. Cooling airflow for the FI13 unit

Enclosure

size

FI9

FI10

FI13

Heat dissipation

(W)

3540 3320

6160 6070

17920 19050

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Cooling air required

1150

1400

4200

/h)

Minimum air holes on

switchgear (mm

Inlet: 55000 Outlet: 30000

Inlet: 65000 OUtlet: 40000

Inlet: 195000 OUtlet 105000

)

Installation vacon • 63

11217.emf

5.2.2 LCL filter

Enough free space must be left around the LCL filter to ensure sufficient air circulation and cooling. You will find the required dimensions for free space in the Table 29. You will find the required cooling air, minimum air holes and heat dissipation in the Table 30.

When planning the cooling for the space, take into consideration that the LCL filter heat loss is approx. 1% of the nominal capacity. Air flow, see Figure 34 and Figure 35.

Table 29. Mounting space dimensions

Dimensions [mm]

Type

LCL0261 5 LCL0170 6

LCL0460 5 LCL0325 6

LCL1300 5 LCL1030 6

A B B

350 0 20 0

350 0200

A = free space above the LCL filter

B = distance between LCL filter and cabinet wall

Figure 33. Installation space

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vacon • 64 Installation

11220A_00

Figure 34. Cooling airflow for FI9 and FI10 LCL filters

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Installation vacon • 65

Figure 35. Cooling airflow guides for FI13 LCL filter

Table 30. Power losses and required cooling air for the LCL filters

Type

LCL0261 5 LCL0170 6

LCL0460 5 LCL0325 6

LCL1300 5 LCL1030 6

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Heat dissipation

(W)

2350 2050

3180 3290

6330 8680

Cooling air required

/h)

1100 30000

1300 42000

Minimum air holes on switchgear

(input and output) (mm

)

vacon • 66 Installation

5.2.3 Arranging ventilation of the enclosure

The enclosure door must be provided with air gaps for air intake. To achieve sufficient cooling inside the cabinet, the dimensions for the total area of free openings for incoming air given in Table 28 and Table 30 must be followed. For instance, there could be two screened gaps as presented in Figure 36 (our recommendation). This layout ensures a sufficient air flow to the module fans as well as cooling of the additional components.

Air outlet gaps must be situated on top of the cabinet. The minimum effective air outlet area per unit frame is given in Table 28 and Table 30. The cooling arrangements inside the cabinet must be such that they prevent hot output air from mixing with the incoming fresh air (see Chapter 5.2.4).

The ventilation gaps must fulfill the requirements set by the selected IP class. The examples in this manual apply to protection class IP21.

During operation, air is sucked in and circulated by a fan blower at the bottom of the power unit. If the power unit is placed in the upper part of the cabinet, the fan blower will be in the mid of the cabinet, at the height of the upper ventilation grid. In case of LCL filter air inlet 1.1 in Figure 36 cannot be used.

Figure 36. Cabinet openings for cooling

1. Cooling air inlets

2. Hot air exhaust

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Installation vacon • 67

Shields

Sheet metal

Touch

Mesh type touch

Air duct

protection

protections

11216.emf

5.2.4 Steering air flow

Cooling air must be taken in through the ventilation gaps on the door and blown out at the top of the enclosure. To steer the hot air from the power unit to the outlet at the top of the enclosure and prevent it from circulating back to the fan blower, use either of the following arrangements:

Install a closed air duct from the power unit to the outlet on top of the enclosure

(A in Figure 37). Install shields in the gaps between the power unit and the cabinet walls (B in Figure 37).

Place the shields above the air outlet gaps at the sides of the module.

NOTE! If a flat roof is used, mount a V-shaped air guide on the underside of the roof to direct the air flow horizontally. See Figure 38.

Figure 37. Cabinet cooling airflow guides

Figure 38. Roof structure seen from the side

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vacon • 68 Installation

Sheet metal

Shield

Front

Shield

Front

Shield

Back

Sheet metal

Figure 39. Cabinet cooling airflow guides for FI9 and FI10 AFE unit and LCL filter

Figure 40. Cabinet cooling airflow guides for FI13 AFE unit and LCL filter

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Installation vacon • 69

The sheet metal airflow guides (deflectors) marked in green prevents air circulation between different sections of the equipment. The shield guides marked in green prevent air circulation inside a section. The points marked in red show the exhaust air holes. These holes must not be covered, nor must anything be placed above them to stop the free exit of warm air from inside the equipment. The points marked in blue show the cooling air intake holes. These holes must not be blocked in any way.

The materials used for preventing the circulation of air inside the equipment must be firerestraining. The edges must be sealed to prevent the formation of gaps. When the deflectors are made according to the instructions, no separate cooling fan is required.

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vacon • 70 Installation

5.3 Power connection

5.3.1 AC connection

The 3-phase input is connected to the input terminals of the LCL filter (L1, L2 and L3). The output terminals of the LCL filter (U, V and W) are connected to the input terminals of the AFE unit (U, V and W), Figure 6. The AC input of the AFE input group must be protected against short circuit. The fuses suitable for protection are shown in Chapter 4.11. A circuit breaker can also be used for protection, see Chapter 4.12. The best short-circuit protection is achieved by using fuses. The short-circuit protection must be on the input side when seen from the LCL filter, Figure 6.

A cable or busbar designed for the purpose must be used to make the connection. The connection must be dimensioned according to the nominal current rating of the Active Front End unit. The necessary overloading allowance must also be used. The connection must also have the same short-circuit capacity as the whole system. The connecting cable or busbar may be of copper or aluminium. When aluminium is used, steps must be taken to prevent corrosion. The dimensions of the terminals in the unit are indicated in Appendix 86 and their locations are shown in Appendix 77, Appendix 78 and Appendix 79. Locations of terminals in the LCL filter are shown in Appendix 80 and Appendix 81.

5.3.2 DC connection

The DC connection of the Active Front End unit is connected to the terminals at the top. The terminals are marked as B+ for connection to DC+ and B- for connection to DC-. The DC connection must be protected using DC fuses, see Chapter 4.11. The terminal dimensions are shown in Appendix 86.

5.3.3 Cable installation and the UL standards

To meet the UL (Underwriters Laboratories) regulations, a UL-approved copper cable with a minimum heat-resistance of 90 C must be used.

Use Class 1 wire only. The units are suitable for use on a circuit capable of delivering not more than 100,000 rms

symmetrical amperes, 600 V maximum, or equivalent when protected by class J, T or Semiconductor fuses.

5.3.4 LCL filter Fan power supply

Two types of power supplies are available for the LCL filter cooling fan. The cooling fan can be supplied from an external power supply or an integrated DC/DC power supply.

5.3.4.1

The DC/DC power supply is integrated in the structure of the LCL filter, Figure 41 and Figure 42. The integrated DC/DC power supply takes its input voltage from the intermediate circuit, Appendix 83. The input of the DC/DC power supply must be protected against short circuit using DC fuses type Ferraz Shawmut ATQ8 (8 A) if the length of the supply cable does not exceed 2 m. The fuses can be installed in holders type Ferraz Shawmut US102I (2-pole), to allow the easy disconnection of the DC/ DC power supply from the supply. If the length of the supply cable exceeds 2 m, fuses type Ferraz Shawmut D100gRB008VI (8 A) must be used. The fuses should be installed in holders.

LCL filter with integrated DC/DC power supply for fan

The DC- power supply should be wired from the AFE power module DC-connectors. Wires should be connected between the main DC- fuses and AFE module (see Figure 43). With FI13, the power supply can be taken from the V- phase.

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Installation vacon • 71

The high DC voltage must be taken into account when wiring the supply; suitable cables/leads must be used.

The DC/DC power supply is monitored and controlled by the Active Front End unit. The DC/DC power supply connections are shown in Figures 41 - 42 and Appendix 83 and Appendix 84.

The control connection has to be taken from the Active Front End unit. The control cable has to be connected to the terminal X51 on the LCL filter, see Figure 41 and Figure 42. The control cable has to be connected to the terminal X3 on the Active Front End unit, see Figure 44. The terminal X3 can be found under the black cover. In the FI13, the terminal X3 is located in the left-most unit. The delivery includes the cable for the control connection. The length of the standard cable is 1.6 m.

The over-temperature protection can be wired directly to the control unit or to the DC/DC power supply. The over-temperature protection must be connected to protect the filter for protect the filter in case of over-temperature.

NOTE! By default, the over-temperature protection is not activated. If it is not activated, the LCL can be damaged in case of over-temperature.

If the over-temperature protection is connected to a digital input, the wires have to be removed from the terminal X52. The I/O wiring has to be connected to the terminals 1 and 4 on the terminal X52, see Appendix 84. If the over-temperature protection is connected to the I/O of the Active Front End unit, it can be programmed. The parameter P2.2.1.3 has to be set to choose the digital input to which the over-temperature monitoring is connected. The parameter P2.7.3 allows one to select the response to an over-temperature alarm as wanted.

If the over-temperature protection is connected to the DC/DC power supply, the jumper has to be removed from the terminal X3. The cable from the terminal X52 should be connected to the terminal X3. By default, the jumper is connected to the terminal X3, see Figure 42. The delivery includes the cable for connecting the terminals X52 and X3. The wiring diagram can be seen in Appendix 84. If over-temperature monitoring is connected to the DC/DC power supply, the Active Front End unit will monitor over-temperature. The response to an over-temperature alarm cannot be selected. In this case, the over-temperature fault message will be same as the fan fault of the unit. On the keypad, the fault “32 Fan Cooling” will be shown.

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vacon • 72 Installation

Figure 41. Integrated DC/DC-power in the FI9 and FI10 LCL filter

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Installation vacon • 73

DC-DC+

X81

X51

X53

X52

X70

11163A_uk

Main fuse

AFE unit (V phase in FI13)

Fan supply DC/DC

LCL filter with integrated DC-DC supply

X51: (4-pin) 1 = (fan alarm) 2 = DC- (fuse base connection) 3 = (fan control) 4 = +16.5 V

X52: (4-pin) 1 = Over-temperature protection switch 4 = Over-temperature protection switch

X53: (3-pin) + = DC+ (supply)

- = DC- (supply)

Fan

Temperature Switch

Fan supply DC/DC

DC supply

Figure 42. Integrated DC/DC-power in the FI13 LCL filter

Figure 43. Wiring diagram of integrated DC/DC-power

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vacon • 74 Installation



     



 



      



X51



DIN2 DIN3





11164.emf

LCL filter with external DC/DC supply

DC supply (48 Vdc)

Control unit

AFE unitLCL filter

X51: (4-pin) 1 = Over-temperature protection switch 2 = Over-temperature protection switch 3 = DC- (supply) 4 = DC+ (supply)

X52: (4-pin) 1 = Over-temperature protection switch 4 = Over-temperature protection switch

Tem pe -

rature Switch

Tem pe -

rature

Switch

Fan

Over-temperature protection

Overtemperature protection

Figure 44. Terminal X3 (U-phase in FI13) in the unit

5.3.4.2

LCL filter without DC/DC power supply for fan

The LCL filter is supplied without an integrated DC/DC power supply. In this case, the customer must procure the power supply separately. The requirements for the DC power supply are shown in Table 5. Short-circuit protection is implemented by protecting the input of the DC power with fuses. When required, the cooling fan can be controlled on/off by installing a contactor in the DC power supply input and controlling that depending on whether the main switch is open or closed. The over-

temperature protection of the LCL filter must always be wired from contacts 1 and 4 of terminal X52 to a digital input of the control unit (see Appendix 85) and from contacts 1 and 2 of terminal X51 to a digital input of the control unit. The wiring of the circuit is shown in Figure 45.

Figure 45. Wiring diagram of external DC-power

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Installation vacon • 75

5.4 Control unit

5.4.1 Control unit components

The control unit of the VACON

NX Active Front End contains the control board and additional boards (see the figure below) connected to the 5 slot connectors (A to E) of the control board. The control board is connected to the power unit through a Dconnector or fibre optic cables.

Figure 46. Basic and option board connections on the control board

When you receive the VACON interface. If you included special options in your order, the VACON

NX Active Front End, the control unit contains the standard control

NX Active Front End is as in your order. On the next pages, you can find information on the terminals and general wiring examples. The type code shows the I/O boards that are installed at the factory. For more information on the option boards, see VACON

For instructions on how to install the control unit that is not attached to the power unit, see VACON

NX I/O Boards User manual.

NXP IP00 Drives Installation Manual.

5.4.2 Control voltage (+24V/EXT +24V)

It is possible to use the drive with an external power source with these properties: +24 VDC ±10%, minimum 1000 mA. You can use it to externally power-up the control board, and the basic and expander boards.

Connect the external power source to one of the 2 bidirectional terminals (#6 or #12), see Figure 48. With this voltage, the control unit stays on and you can set 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 mains.

NOTE! If you supply the AC drive with external 24 V DC power, you must use a diode in terminal #6 (or #12) to prevent the current to flow in opposite direction. Put a 1 A fuse in 24 V DC line for each AC drive. The maximum current consumption of each drive is 1 A from the external power supply.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 76 Installation

Ext +24VDC

Power Supply

-G1

-F1

PE/GND

-F2 1A

gG/

Class CC

-Q1 3A

#6 #7 #6 #7 #6 #7 #6 #7 #6 #7 #6 #7

-F3 1A

gG/

Class CC

-Q2

-F4 1A

gG/

Class CC

-Q3 3A

-F5

gG/

Class CC

-Q4

-F6

gG/

Class CC

-Q5

-F7 1A

gG/

Class CC

-Q6

Figure 47. Parallel connection of 24 V inputs with many AC drives

NOTE! The control unit I/O ground is not isolated from the chassis ground / protective earth. In the installation, take into account the potential differences between the grounding points. We recommend that you use galvanic isolation in the I/O and 24V circuitry.

NOTE! Analogue outputs and inputs do not work with only +24V supplied to the control unit. If there is a +24V/EXT+24V output on the board, it is locally short-circuit protected. If one of the +24V/

EXT+24V outputs short-circuits, the others remain powered because of the local protection.

5.4.3 Control unit cabling

The OPTA1 basic board has 20 control terminals, and the relay board has 6 or 7. You can see the standard connections of the control unit and the descriptions of signals in Figure 48.

5.4.3.1

Selection of the control cables

The control cables must be a minimum of 0.5 mm2 (20 AWG) screened multicore cables. The terminal wires must be a maximum of 2.5 mm

1.5 mm

(16 AWG) for other terminals.

(14 AWG) for the terminals of the relay board and

Table 31. The tightening torques of the control cables

The tightening torque

Nm lb-in.

The terminal

screw

Relay and thermistor terminals M3 0.5 4.5 Other terminals M2.6 0.2 1.8

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Installation vacon • 77

5.4.3.2 Control terminals on OPTA1

Here you see the basic description of the terminals of the I/O board and the relay board. For more information, see Jumper selections on the OPTA1 basic board. For more information on control

terminals, see VACON

All in One Application manual.

Reference potentiometer,

1-10kΩ

Standard I/O board

Terminal Signal Description

+10V

ref

AI1+

GND/AI1-

AI2+

GND/AI2-

+24V

GND

DIN1 DIN2

DIN3

CMA

+24V

GND

DIN4

DIN5

DIN6

CMB

AO1+

AO1-

DO1

Reference voltage

Analogue input, voltage or current

Analogue input common

Analogue input, voltage or current

Analogue input common

24 V aux. voltage

I/O ground

Digital input 1

Digital input 2

Digital input 3

Common A for DIN1—DIN3

Control voltage output

I/O ground

Digital input 4

Digital input 5

Digital input 6

Common B for DIN4-DIN6

Analogue signal (+output)

Analogue output common

Open collector output

Maximum current 10 mA

Selection V/mA with jumper block X1 (*)

0...+10 V (Ri = 200 kΩ) (-10V...+10V Joystick ctrl, sel. with jumper) 0-20 mA (Ri =250 Ω)

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

Selection V/mA with jumper block X1 (*)

0...+10 V (Ri = 200 kΩ) (-10V...+10V Joystick ctrl, sel. with jumper) 0-20 mA (Ri =250 Ω)

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

±15%, max. 250 mA (all boards total) 150 mA (from single board) Can also be used as external power backup for the control unit (and fieldbus)

Ground for reference and controls

Ri = min. 5 kΩ 18-30 V = 1

Digital inputs can be disconnected from ground (*)

Same as terminal #6

Same as terminal #7

Ri = min. 5 kΩ 18-30 V = 1

Must be connected to GND or 24 V of I/O term. or to ext.24 V or GND Selection with jumper block X3 (*)

Output signal range: Current 0(4)-20 mA, RL max 500 Ω or Voltage 0-10 V, RL >1kΩ Selection with jumper block X6 (*)

Maximum Uin = 48 VDC Maximum current = 50 mA

Figure 48. The control terminal signals in OPTA1

*) See Fig. 26 Jumper blocks on OPTA1.

Parameter references for I/O on keypad and NCDrive are: An.IN:A.1, An.IN:A.2, DigIN:A.1, DigIN:A.2, DigIN:A.3, DigIN:A.4, DigIN:A.5, DigIN:A.6, AnOUT:A.1 and DigOUT:A.1.

To use the control voltage output +24V/EXT+24V:

• you can wire the +24V control voltage to digital inputs through an external switch.

• you can use the control voltage to power up external equipment, such as encoders and auxiliary relays.

Note that the specified total load on all available +24V/EXT+24V output terminals must not exceed 250mA. The maximum load on the +24V/EXT+24V output per board is 150mA.

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vacon • 78 Installation

# Reference # Reference

A Max. 150 mA C Max. 250 mA

B+24V out

Figure 49. Maximum loads on +24V/EXT+24V output

Digital input signal inversions

The active signal level is different when the common inputs CMA and CMB (terminals 11 and 17) are connected to +24 V or to ground (0 V). See Fig. 25. The 24 V control voltage and the ground for the digital inputs and the common inputs (CMA, CMB) can be internal or external.

A B

+24 V

GND

DIN1

DIN2

DIN3

CMA

GND

+24 V

DIN1

DIN2

DIN3

CMA

# Reference # Reference

Positive logic (+24 V is the

active signal) = the input is active when the switch is

closed.

Negative logic (0 V is the active signal) = the input is active when the switch is closed. You must set the jumper X3 to the position 'CMA/CMB isolated from ground'.

Figure 50. The Positive/Negative logic

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Installation vacon • 79

X6X2X1

ABCD ABCD ABCD

Jumper selections on the OPTA1 basic board

You can change the functions of the AC drive to make them better agree with your requirements. To do this, change some positions for the jumpers on the OPTA1 board. The positions of the jumpers set the signal type of analogue and digital inputs.

On the A1 basic board, there are 4 jumper blocks: X1, X2, X3 and X6. Each jumper block contains 8 pins and 2 jumpers. See the possible jumper selections in the figure below.

Figure 51. Jumper blocks on OPTA1

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vacon • 80 Installation

Jumper block X1:

AI1 mode

ABCD

AI1 mode: 0...20mA; Current input

ABCD

AI1 mode: Voltage input; 0...10V AI2 mode:Voltage input; 0...10V

ABCD

AI1 mode: Voltage input; 0...10V

differential

ABCD

AI1 mode: Voltage input; -0...10V AI2 mode: Voltage input; -10...10V

AI1 mode: 0...20mA; Current input

AI2 mode: Voltage input; 0...10V

Jumper block X2:

AI2 mode

ABCD

differential

ABCD

Jumper block X6:

AO1 mode

ABCD

AO1 mode: 0....20mA; Current output

ABCD

AO1 mode: Voltage output; 0...10V

Jumper block X3:

CMA and CMB grounding

CMB connected to GND CMA connected to GND

CMB isolated from GND CMA isolated from GND

CMB and CMA internally connected together, isolated from GND

= Factory default

Figure 52. Jumper selections for OPTA1

NOTE! If you change the AI/AO signal contents, also change the related board parameter in menu M7.

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Installation vacon • 81

DigOUT:B.1 *)

DigOUT:B.2 *)

OPTA2

RO1/1

RO1/2

RO1/3

RO2/1

RO2/2

RO2/3

Relay output 1

Relay output 2

Switching capacity

• 24 VDC/8 A

• 250 VAC/8 A

• 125 VDC/0.4 A Minimum switching load

• 5 V/10 mA

Switching capacity

• 24 VDC/8 A

• 250 VAC/8 A

• 125 VDC/0.4 A Minimum switching load

• 5 V/10 mA

21 22 23 24 25 26

5.4.3.3 Control terminals on OPTA2

Figure 53. The control terminal signals on relay boards OPTA2

*) Parameter reference on keypad and NCDrive.

Figure 54. OPTA2

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vacon • 82 Installation

L1 L2 L3

UVW

RO1/1 RO1/2

RO1/3

RO2/3

RO2/2

RO2/1

10Vref GND

GND

+24V

AI1 AI2+

AI2 -

DIN1... DIN3 CM A

DIN4... DIN6 CM B

AO1+ AO2 -

DO1

k6_1 5

TI1+ TI1-

Control I/O ground

Digital input group A

Digital input group B

Analogue outp ut

Digital outp ut

Control board

Control

panel

Gat e dri vers

Powe r board

11209.emf

5.5 Galvanic isolation barriers

The control connections are isolated from the mains potential and the GND terminals are permanently connected to ground. See Figure 55.

The digital inputs are galvanically isolated from the I/O ground. The relay outputs are additionally double-isolated from each other at 300 VAC (EN-50178). See Figure 55.

Figure 55. Galvanic isolation barriers

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Control Keypad vacon • 83

6. CONTROL KEYPAD

The control keypad is the link between VACON®NX Active Front End and the user. The VACON® NX control keypad features an alphanumeric display with seven indicators for the Run status (RUN,

, READY, STOP, ALARM, FAULT) and three indicators for the control place (I/O term/ Keypad/

BusComm). There are also three Status Indicator LED’s (green – green – red), see Chapter 6.1.2. The control information, i.e. the menu number, description of the menu or the displayed value and

the numeric information are presented on three text lines. The VACON

Furthermore, the buttons can be used in setting parameters and monitoring values. The keypad is detachable and isolated from the input line potential.

NX Active Front End is operable through the nine push-buttons of the control keypad.

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vacon • 84 Control Keypad

READY

FAULTSTOP

RUN

Bus/Comm

Keypad

I/Oterm

ALARM

run

ready

fault

1 2 3 4 5 6

a bIc

3062.emf

enter

reset

select

12345

III

6.1 Indicators on the keypad display

Figure 56. VACON® control keypad and drive status indications

6.1.1 Drive status indications

The drive status symbols tell the user the status of the brake chopper. In addition, they tell about possible irregularities detected by the brake chopper control software in brake chopper functions.

RUN = Indicates that the drive is running.

STOP = Indicates that the drive is not running.

READY =

ALARM =

FAULT =

Lights up when AC power is on. In case of a trip, the symbol will not light up.

Indicates that the drive is running outside a certain limit and a warning is given.

Indicates that unsafe operating conditions were encountered due to which the drive was stopped.

6.1.2 Status LEDs (green – green – red)

The status LEDs light up in connection with the READY, RUN and FAULT drive status indicators.

Lights up with the AC power connected to the drive. Simultaneously, the drive status

indicator READY is lit up.

= Lights up when the drive is running (modulating).

Lights up when unsafe operating conditions were encountered due to which the drive was stopped (Fault Trip). Simultaneously, the drive status indicator FAULT

blinks on the display and the fault description can be seen.

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Control Keypad vacon • 85

enter

reset

sele ct

11208.emf

6.1.3 Text Lines

The three text lines (•, ••, •••) provide the users with information on their present location in the keypad menu structure as well as with information related to the operation of the drive.

Location indicator; displays the symbol and number of the menu, parameter, etc.

•

Example: M2 = Menu 2 (Parameters); P2.1.3 = Acceleration time.

••

•••

6.2 Keypad push-buttons

The VACON® NX alphanumeric control keypad has 9 push-buttons that are used for controlling VACON

= Description line; Displays the description of the menu, value or fault.

Value line; Displays the numerical and textual values of references, parameters, etc.

and the number of submenus available in each menu.

NX Active Front End, setting parameters, and monitoring values.

Figure 57. Keypad push-buttons

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vacon • 86 Control Keypad

reset

select

enter





6.2.1 Buttons descriptions

= This button is used to reset active faults. See Chapter 6.3.4.

This button is used to switch between the two latest displays. This may be useful

when you want to see how the changed new value influences some other value. The enter button is used for:

1) confirmation of selections.

2) fault history reset (2…3 seconds). Browser button up.

Browse the main menu and the pages of different submenus. Edit values.

Browser button down.

Browse the main menu and the pages of different submenus. Edit values.

Menu button left Move backward in menu.

Move cursor left (in parameter menu). Exit edit mode.

Menu button right Move forward in menu.

Move cursor right (in parameter menu). Enter edit mode.

Start button

Pressing this button starts VACON pad is the active control place. See Chapter 6.3.3.

Stop button

Pressing this button stops VACON parameter R3.4/R3.6). See Chapter 6.3.3.

NX Active Front End (modulation) if the key-

NX Active Front End (unless disabled by

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Control Keypad vacon • 87

Descriptio

available



V14

READY

Local

RUN

Monitor

11206.emf

6.3 Navigation on the control keypad

The data on the control keypad is arranged in menus and submenus. The menus are used for the display and editing of measurement and control signals, parameter settings (see Chapter 6.3.2) and reference value and fault displays (see Chapter 6.3.4). Through the menus, you can also adjust the contrast of the display (see Chapter 6.3.8.5).

Location

Number of items

The first menu level consists of menus M1 to M7 and is called the Main menu. The user can navigate in the Main menu with the Browser buttons up and down. The desired submenu can be entered from the Main menu with the Menu buttons. When there still are pages to enter under the currently displayed menu or page, you can see an arrow ( ) in the lower right corner of the display and can reach the next menu level by pressing Menu button right.

The control keypad navigation chart is shown on the next page. Note that menu M1 is located in the lower left corner. From there you will be able to navigate your way up to the desired menu using the menu and browser buttons.

You will find more detailed descriptions of the menus later in this chapter.

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vacon • 88 Control Keypad

FT1T7

STOP FAULT

I/Oterm

STOP

I/Oterm

FAULT

H1H3

READY

I/Oterm

T1T7

I/Oterm

READY

I/O t e rm

READY

S1S9

STOP READY

I/Oterm

STOP READY

I/Oterm

enter

G1G5

READ Y

I/Oterm

A:NXOPTA1

READY

I/Oterm

G1G1

READY

I/O te rm

V1V15

READY

I/Oterm

RUN

13.95 Hz

READY

I/Oterm

RUN

G1G9

READY

I/Oterm

P1P15

READY

I/Oterm

13.95 Hz

READY

Local

P1P3

READY

I/Oterm

STOP

READY

I/Oterm

STOP

enter

STOP FAULT

I/Oterm

Parameters Basic parameters Min Frequency

11 O utput phase Operation days

Fault history 11 Output phas e Operation days

System Menu Langua g e

Change

value

Browse

Expander boards

Parameters

P1P3

Monitor Output freq uency

No editing!

Keypad control

Cont rol P la ce

I/O Terminal

Change

value

Change

value

Browse

Active faults

English

or:

11205.emf

6.3.1 Monitoring menu (M1)

You can enter the Monitoring menu from the Main menu by pressing Menu button right when the

Figure 58. Keypad navigation chart

location indication M1 is visible on the first line of the display. Figure 59 shows how to browse through the monitored values.

The monitored signals carry the indication V#.# and they are listed in Table 32. The values are updated once every 0.3 seconds.

This menu is meant only for signal checking. The values cannot be altered here. For changing values of parameters, see Chapter 6.3.2.

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Control Keypad vacon • 89



V14

READY

Local

13.95 Hz

READY

Local

13.95 Hz

READY

Loca l

RUN RUN

RUN

Monito r Output frequency

FreqReference

11204.emf

Figure 59. Monitoring menu

Table 32. Monitored signals

Code Signal name Unit Description

V1.1 Frequency reference Hz

V1.2 DC-link voltage V Measured DC-link voltage

V1.3 Unit temperature ºC Heat sink temperature

V1.4 Voltage input V AI1

V1.5 Current input mA AI2

V1.6 DIN1, DIN2, DIN3 Digital input statuses

V1.7 DIN4, DIN5, DIN6 Digital input statuses

V1.8 DO1, RO1, RO2 Digital and relay output statuses

V1.9 Analogue output current mA AO1

M1.17 Multimonitoring items

6.3.2 Parameter menu (M2)

Displays three selectable monitoring values. See Chapter 6.3.8.4, Multimonitoring items (P6.5.4).

Parameters are the way of conveying the commands of the user to VACON Parameter values can be edited by entering the Parameter Menu from the Main Menu when the location indication M2 is visible on the first line of the display. The value editing procedure is presented in Figure 60.

Pressing Menu button right once takes you to the Parameter Group Menu (G#). Locate the desired parameter group by using the Browser buttons and press Menu button right again to see the group and it‘s parameters. Use the Browser buttons to find the parameter (P#) you want to edit. Pressing

NX Active Front End.

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vacon • 90 Control Keypad

11203.emf

Menu button right takes you to the edit mode. As a sign of this, the parameter value starts to blink. You can now change the value in two different ways:

• Set the desired value with the Browser buttons and confirm the change with the Enter button. Consequently, the blinking stops and the new value are visible in the value field.

• Press Menu button right once more. Now you will be able to edit the value digit by digit. This may come in handy, when a relatively greater or smaller value than that on the display is desired. Confirm the change with the Enter button.

The value will not change unless the Enter button is pressed. Pressing Menu button left takes you back to the previous menu.

Several parameters are locked, i.e. cannot be edited, when VACON status. If you try to change the value of such a parameter the text *Locked* will appear on the display. The Active Front End must be stopped to edit these parameters.

The parameter values can also be locked using the function in menu M6 (see Chapter 6.3.8.4, Parameter lock (P6.5.2)).

You can return to the Main menu any time by pressing Menu button left for 1 to 2 seconds.

You will find the parameter lists from the VACON

NX Active Front End Application manual.

NX Active Front End is in RUN

Once in the last parameter of a parameter group, you can move directly to the first parameter of that group by pressing Browser button up.

See the diagram for parameter value change procedure in Figure 60. NOTE! You can connect power to the control board by connecting the external power source to the

bidirectional terminal #6 on the NXOPTA1 board (see Chapter 5.4). The external power source can also be connected to the corresponding +24 V terminal on any option board. This voltage is sufficient for parameter setting and for keeping the fieldbus active.

Figure 60. Parameter value change procedure

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Control Keypad vacon • 91

I/O ter m

Keypad

Bus/ Comm

6.3.3 Keypad control menu (M3)

In the Keypad Control Menu, you can choose the control place. You can enter the submenu level by pressing Menu button right.

NOTE! There are some special functions that can be performed in menu M3:

Select the keypad as the active control place by pressing for 3 seconds when the Active

Front End is running (modulating). The keypad will become the active control place.

Select the keypad as the active control place by pressing for 3 seconds when the Active

Front End is stopped (modulating). The keypad will become the active control place.

NOTE! that if you are in any other than menu M3 these functions will not work. If you are in some other than menu M3 and try to start the Active Front End by pressing the START button when the keypad is not selected as the active control place, you will get an error message: Keypad Control NOT ACTIVE.

6.3.3.1

There are three different places (sources) where the Active Front End can be controlled from. For each control place, a different symbol will appear on the alphanumeric display:

You can change the control place by entering the edit mode with Menu button right. The options can then be browsed with the Browser buttons. Select the desired control place with the Enter button. See the diagram on the next page. See also Chapter 6.3.3 above.

6.3.4 Active fault menu (M4)

You can enter the Active faults menu from the Main menu by pressing Menu button right when the location indication M4 is visible on the first line of the keypad display.

Selection of control place

Control place Symbol

I/O terminals

Keypad (panel)

Fieldbus

When a fault brings the brake chopper to a stop, the location indication F1, the fault code, a short description of the fault, and the fault type symbol (see Chapter 6.3.5) will appear on the display. In addition, the indication FAULT or ALARM (see Figure 60 or Chapter 6.1.1) is displayed and, in case of a FAULT, the red LED on the keypad starts to blink. If several faults occur simultaneously, the list of active faults can be browsed with the Browser buttons.

The memory of active faults can store a maximum of 10 faults in the order of appearance. The display can be cleared with the Reset button and the read-out will return to the same state it was in before the fault trip. The fault remains active until it is cleared with the Reset button or with a reset signal from the I/O terminal.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 92 Control Keypad

Normal state, no faults

READY

I/Oterm

Active faults

11201.emf

11202.emf

NOTE! Remove external Start signal before resetting the fault to prevent unintentional restart of the drive.

6.3.5 Fault types

VACON

NX Active Front End has four types of faults. These types differ from each other on the basis

of the subsequent behaviour of the drive. See Table 33.

Figure 61. Fault display

Table 33. Fault types

Fault type symbol Meaning

(Alarm)

(Fault)

(Fault Autoreset)

(Fault Trip)

This type of fault is a sign of an unusual operating condition. It does not cause the drive to stop, nor does it require any special actions. The 'A fault' remains in the display for about 30 seconds.

An 'F fault' makes the drive stop. Actions need to be taken to restart the drive.

If an 'AR fault' occurs the drive will stop immediately. The fault is reset automatically and the drive tries to restart the motor. Finally, if the restart is not successful, a fault trip (FT, see below) occurs.

If the drive is unable to restart the motor after an AR fault an FT fault occurs. The 'FT fault' has basically the same effect as the F fault: the drive is stopped.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Control Keypad vacon • 93

6.3.6 Fault codes

The fault codes, their causes and correcting actions are presented in the Table 34. The shadowed faults are A faults only. The items in white on black background are faults for which you can program different responses in the application. See parameter group Protections.

NOTE! When contacting the distributor or factory because of a fault condition, always write down all texts and codes visible on the keypad display.

Table 34. Fault codes

Fault

code

Fault Possible cause Correcting measures

Overcurrent

Overvoltage

Saturation trip

System fault

Undervoltage

AFE undertemperature

AFE overtemperature

AFE has detected too high current (>4*IH) in the resistor cables:

The DC-link voltage has exceeded the limit: 911 V for 500 V AFE 1200 V for 690 V AFE

Various causes:

- Defective component.

- Brake resistor short-circuit oroverload.

- Component failure

- Faulty operation

Note exceptional fault data record Subcode in T.14: S1 = Reserved S2 = Reserved S3 = Reserved S4 = Reserved S5 = Reserved S6 = Reserved S7 = Charging switch S8 = No power to driver card S9 = Power unit communication (TX) S10 = Power unit communication (Trip) S11 = Power unit communication (Measurement)

DC-link voltage is under the AFE fault voltage limit: 333 VDC for 500 V AFE 460 VDC for 690 V AFE

- Most probable cause: too low supply voltage in the system.

- AFE internal fault.

Heatsink temperature is under –10 °C

Heatsink temperature is over 90 °C. Overtemperature warning is issued when the heatsink temperature exceeds 85 °C.

- Check cables.

- Check resistors.

- Cannot be reset from the keypad.

- Switch off power.

- DO NOT RE-CONNECT POWER!

- Contact your local distributor.

Reset the fault and restart. Should the fault re-occur, contact your local distributor.

- In case of temporary supply voltage break, reset the fault and restart the AC drive.

- Check the supply voltage.

- If it is adequate, an internal failure has occurred.

- Contact your local distributor.

- Check the correct amount and flow of cooling air.

- Check the heatsink for dust.

- Check the ambient temperature.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 94 Control Keypad

Table 34. Fault codes

Fault

code

Fault Possible cause Correcting measures

Unbalance between power modules in

Unbalance (Warning only)

Thermistor fault

IGBT temperature (hardware)

Application Problem in application software

Device changed (same type)

Device added (same type)

Device removed

Device unknown

IGBT temperature

Device changed (different type)

Device added (different type)

External fault

Slot fault Defective option board or slot

PT100 fault

Cooling fault

paralleled units. Subcode in T.14: S1 = Current unbalance S2 = DC-Voltage unbalance

The thermistor input of option board has detected too high resistor temperature.

IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current

Option board or control unit changed. Same type of board or same power rating of drive.

Option board or drive added. Drive of same power rating or same type of board added.

Option board removed. Drive removed.

Unknown option board or drive. Subcode in T.14: S1 = Unknown device S2 = Power1 not same type as Power2

IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current

Option board or control unit changed. Option board of different type or different power rating of drive.

Option board or drive added. Option board of different type or drive of different power rating added.

Digital input fault.

Temperature limit values set for the PT100 have been exceeded.

The cooling circulation of the liquid cooled drive has failed.

Should the fault re-occur, contact your local distributor.

Check resistors. Check thermistor connection (If thermistor input of the option board is not in use it has to be short circuited).

Contact your distributor. If you are application programmer check the application program.

Reset. Device is ready for use. Old parameter settings will be used.

Reset. Device is ready for use. Old board settings will be used.

Reset. Device no longer available.

Contact the distributor near to you.

Reset. Set the option board parameters again if option bard changed. Set converter parameters again if power unit changed.

Reset. Set the option board parameters again.

Remove fault situation from external device.

Check board and slot. Contact your nearest distributor.

Find the cause of temperature rise.

Check the reason for the cooling failure from the external system.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Control Keypad vacon • 95

6.3.6.1 Fault time data record

When a fault occurs, the information described in Chapter 6.3.4 is displayed. By pressing Menu button right, you will enter the Fault time data record menu indicated by T.1T.#. In this menu, some selected important data valid at the time of the fault are recorded. This feature will help the user or the service person in determining the cause of the fault.

The data available are;

Table 35. Fault time recorded data

T.1

T.2

T.3

T.8 DC voltage V

T.9 Unit temperature °C

T.10 Run status

T.11 Direction

T.12 Warnings

Real time record

If real time is set to run, the data items T1 and T2 will appear as follows:

T.1 Counted operation days yyyy-mm-dd

Counted operation days

(Fault 43: Additional code)

Counted operation hours

(Fault 43: Counted operation days)

Output frequency

(Fault 43: Counted operation hours)

(hh:mm:ss)

(d)

(d) Hz

T.2 Counted operation hours hh:mm:ss,sss

6.3.7 Fault history menu (M5)

You can enter the Fault history menu from the Main menu by pressing Menu button right when the location indication M5 is visible on the first line of the keypad display.

All faults are stored in the Fault history menu where you can browse them with the Browser buttons. Additionally, the Fault time data record pages (see Chapter 6.3.6.1) are accessible for each fault. You can return to the previous menu any time by pressing Menu button left. The memory of the Active Front End can store a maximum of 30 faults in order of appearance. The number of faults currently in the fault history is shown on the value line of the main page (H1H#). The order of the faults is indicated by the location indication in the upper left corner of the display. The latest fault is indicated by F5.1, the one before that by F5.2 and so on. If there are 30 uncleared faults in the memory, the next fault will erase the oldest fault from the memory.

Pressing the Enter button for about 2 to 3 seconds resets the whole fault history. The symbol H# will change to 0.

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

vacon • 96 Control Keypad

H1H3

READY

I/Oterm

T1T7

I/Oterm

READY

I/Oterm

READY

13:25: 43

I/O te r m

enter

Fau lt history 11 O utput p hase

5ChargeSwitch

Operation days

Operationhours

PUSH to reset

11200.emf

Figure 62. Fault history menu

6.3.8 System menu (M6)

You can enter the System menu from the Main menu by pressing Menu button right when the location indication M6 is visible on the first line of the keypad display.

The controls associated with the general use of the Active Front End, such as application selection, customised parameter sets or information about the hardware and software are located under the System menu. The number of submenus and subpages is shown with the symbol S (or P) on the value line.

The System menu functions are presented in the Table 36.

System menu functions

Table 36. System menu functions

Code Function Min Max Unit Default Selections

English Deutsch

S6.1 Selection of language English

Suomi Svenska Italiano

Active Front

S6.2 Application selection

End

application

S6.3 Copy parameters

S6.3.1 Parameter sets

S6.3.2 Up to keypad All parameters

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Load factory defaults Store set 1 Load set 1 Store set 2 Load set 2

Control Keypad vacon • 97

Table 36. System menu functions

Code Function Min Max Unit Default Selections

All parameters

S6.3.3 Down from keypad

P6.3.4 Autom. BackUp Yes

S6.4 Parameter comparison S6.5 Security

S6.5.1 Password Not used 0 = Not used

P6.5.2 Parameter locking

S6.5.3 Start-up wizard

S6.5.4 Multimonitoring items

P6.5.5 OPTAF Remove

S6.6 Keypad settings

Change

Enabled

Change

Enabled

All but motor parameters Application parameters

No Yes

Change Enabled Change Disabled

No Yes

Change Enabled Change Disabled

P6.6.1 Default page P6.6.2 Default page/OM P6.6.3 Timeout time 0 65535 s 30 P6.6.4 Contrast 0 31 18 P6.6.5 Backlight time Always 65535 min 10

S6.7 Hardware settings

P6.7.1

P6.7.2 Fan control function Continuous

P6.7.3 HMI acknowledgment 200 5000 ms 200 P6.7.4 HMI: no. of retries 1 10 5

P2.6.7.5 Sine Filter

P2.7.6 Pre-Charge Mode

S6.8 System information

S6.8.1 Total counters

Internal brake

resistor

Connected

Not connected Connected

Continuous Temperature First Start Calc temp

Not connected Connected

Normal FC Ext. ChSwitch

T6.8.1.1. MWh counter kWh T6.8.1.2. PwOn Day Counter T6.8.1.3. PwOn Hour Count.

S6.8.2 Trip counters

T6.8.2.1 MWh counter

T6.8.2.2 Clr MWh Counter

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Not Reset Reset

vacon • 98 Control Keypad

Table 36. System menu functions

Code Function Min Max Unit Default Selections

T6.8.2.3 PwOn Day Counter T6.8.2.4 PwOn Hour Count.

T6.8.2.5 Clr Optime cntr

S6.8.3 Software I6.8.3.1 Software package I6.8.3.2 SystemSw version I6.8.3.3 Firmware interf. I6.8.3.4 System load

S3.8.4 Applications

S6.8.5 Hardware

S6.8.5.1 Power unit S6.8.5.2 Unit Voltage S6.8.5.3 Brake Chopper S6.8.5.4 Brake Resistor

Not Reset Reset

S6.8.5.5 Serial number

A: B:

S6.8.6 Expander boards

S6.8.7 Debug I6.8.7.1 System Load I6.8.7.2 Parameter Log

S6.9 Power Monitor

S6.11 Power multimon.

6.3.8.1 Selection of language

The VACON® NX control keypad offers you the possibility to control the inverter through the keypad in the language of your choice.

Locate the language selection page under the System menu. It‘s location indication is S6.1. Press Menu button right once to enter the edit mode. As the name of the language starts to blink you can select another language for the keypad texts. Confirm with the Enter button. The blinking stops and all text information on the keypad are presented in the selected language.

C: D: E:

IU filtered IV filtered IW filtered

Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/

Vacon NX series, NXA series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. SAFETY

1.1 Warnings

1.2 Cautions

1.3 Grounding and earth fault protection

1.4 Electro-magnetic compatibility (EMC)

1.5 Using an RCD or an RCM device

2. EU DIRECTIVE

2.1 CE marking

2.2 EMC directive

2.2.1 Introduction

2.2.2 Technical criteria

2.2.4 Manufacturer’s declaration of conformity

3. RECEIPT OF DELIVERY

3.1 Type designation code for the AFE unit

3.2 Type designation code for the LCL filter

3.3 Type designation code for the pre-charging components

3.4 Storage

3.4.1 Capacitor reforming

3.5 Maintenance

3.6 Lifting the modules

3.7 Lifting the LCL filters

3.8 Disposal

4. ACTIVE FRONT END (AFE)

4.1 Introduction

4.2 Active Front End Unit block diagram

4.3 Active Front End enclosure sizes

4.4 Active Front End unit technical data

4.5 LCL filter technical data

4.6 Application

4.7 Diagrams

4.7.1 Connection between control unit and power unit

4.7.2 LCL wiring diagram

4.8 Active Front End power ratings

4.8.1 VACON® NXA; DC voltage 380–500 V

4.8.2 VACON® NXA; DC voltage 525–690 V

4.9 Active Front End unit – Dimensions

4.10 LCL filter – Dimensions

4.11 Active Front End unit – Fuse selection

4.11.1 Introduction

4.11.2 Fuses; mains voltage 380–500 V

4.11.3 Fuses; mains voltage 525–690 V

4.12 Active Front End unit – Circuit breaker selection

4.13 Main contactor

4.14 Pre-Charging circuit

4.15 Paralleling

4.15.1 Common pre-charging circuit

4.15.2 Each Active Front End unit has the pre-charging circuit

4.16 Derating

4.16.1 Ambient Temperature

4.16.2 High altitude installation

5. INSTALLATION

5.1 Mounting

5.1.1 Active Front End Unit

5.1.2 LCL filter

5.1.3 Control Box

5.2 Cooling

5.2.1 Active Front End unit

5.2.2 LCL filter

5.2.3 Arranging ventilation of the enclosure

5.2.4 Steering air flow

5.3 Power connection

5.3.1 AC connection

5.3.2 DC connection

5.3.3 Cable installation and the UL standards

5.3.4 LCL filter Fan power supply

5.4 Control unit

5.4.1 Control unit components

5.4.2 Control voltage (+24V/EXT +24V)

5.4.3 Control unit cabling

5.5 Galvanic isolation barriers

6. CONTROL KEYPAD

6.1 Indicators on the keypad display

6.1.1 Drive status indications

6.1.2 Status LEDs (green – green – red)

6.1.3 Text Lines

6.2 Keypad push-buttons