Vacon OPT-A2, OPT-A1, OPT-B8 User Manual

user's manual

brake chopper unit (bcu)

application

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9

2 • vacon

Vacon Brake Chopper Unit application

Software: ABFIFF01 V1.01

INDEX Document code: ud01138a
Date: 1.11.2006

1. INTRODUCTION .................................................................................................................................3

1.1 Operation principle of BCU....................................................................................................... 3

1.2 Quick start instructions ............................................................................................................ 5

2. CONTROL I/O ...................................................................................................................................6

3. BRAKE CHOPPER APPLICATION – PARAMETER LISTS ........................................................................... 7

3.1 Monitoring values (Control keypad: menu M1)........................................................................ 7

3.2 Basic parameters (Control keypad: Menu G2 Æ G2.1)............................................................ 8

3.3 Input signals (Control keypad: Menu G2 Æ G2.2).................................................................... 8

3.4 Output signals (Control keypad: Menu G2 Æ G2.3) ................................................................. 9

3.5 BCU In parallel (Control keypad: Menu G2 Æ G2.4)................................................................ 9

3.6 Fieldbus parameters (Control keypad: Menu G2 Æ G2.5)..................................................... 10

3.7 Protections (Menu G2 Æ G2.6) ............................................................................................... 11

3.8 Keypad control (Control keypad: Menu M3)........................................................................... 11

3.9 System menu (Control keypad: Menu M6)............................................................................. 11

3.10 Expander boards (Control keypad: Menu M7) ....................................................................... 11

4. DESCRIPTION OF PARAMETERS.........................................................................................................12

4.1 Basic parameters ................................................................................................................... 12

4.2 Input signals............................................................................................................................ 13

4.3 Output signals......................................................................................................................... 15

4.4 BCU In Parallel ....................................................................................................................... 17

4.5 Fieldbus parameters .............................................................................................................. 17

4.6 Protections.............................................................................................................................. 18

4.7 Keypad control........................................................................................................................ 18

5. FIELDBUS PROFILE FOR VACON BRAKE CHOPPER UNIT ....................................................................... 19

6. FAULT CODES ................................................................................................................................. 21

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Introduction vacon • 3

1. INTRODUCTION

1.1 Operation principle of BCU

When you want to slow down a running asynchronous motor fed by a frequency converter it turns
into a generator, feeding energy back into the frequency converter. The energy increases the voltage
in the DC-link. The frequency converter compensates for this increase by increasing the output
frequency, decreasing the instantaneous slip and increasing the motor load. The deceleration is, in
this case, dependent on the power losses in the converter and in the motor. This is usually sufficient
in most cases, for pumps, fans, conveyors etc. where the kinetic energy in the load is small or the
braking time is not critical.

When you have to brake down the motor faster than the losses allow, you have to use BCU module
and an external brake resistor (or resistors) for energy dissipation. The extra energy from the load
is turned into heat in the brake resistor. If the DC link voltage increases too much, the BCU turns on
and discharges the capacitors through the brake resistor. Applications where dynamic braking is
usually needed include centrifuges, cranes, some conveyors and drives requiring very fast
reversing.

Modules can be connected parallel with other BCU modules in order to increase braking capacity
(Figure 1).

In BCU application you can use either Analogue input or OPT-B8 option board for PT100 sensor
connection.

Start-up sequence of BCU application has been illustrated in Figure 2.

Figure 1. BCU in common DC bus system

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4 • vacon Introduction

Init

Softwar e Ini t

complete

Read y to
switch on

DC link voltage

OK?

No

Yes

RunEna ble from I/O (P2.2.1.3)

No

or fieldbus (MCW,bit 1)

Ready to Run

(Ready led is on)

Fault?

Yes

BCU Ru nning

(Run le d is on )

Figure 2. Start-up sequence

Yes

No

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Introduction vacon • 5

1.2 Quick start instructions

NOTE! Before taking any commissioning actions read carefully the safety instructions in Vacon NX

User's Manual, chapter 1.

1. Check installations (see Figure 3, Table 2-1 and Table 2-2).

2. Check resistor(s) max. temperature durability.

3. Switch power on.

4. Set PT-100 parameters (P2.2.2.1, P2.2.2.2 and P2.6.1 – P2.6.3) or KLIXON input settings
(P2.2.1.4).

5. Set brake chopper operation level to preferred value (P2.1.2).

6. In case of parallel BCU set Drooping (P2.4.1) = 5%.

7. Set Digital input parameters (P2.2.1.1 – P2.2.1.4) according to connections.

8. Test BCU.

9. If fault occurs see chapter 6.

DC+
DC-

-R1

-U1

DC+

-F1

BCU

UVW

DC-

-R2

Figure 3. Resistor connections

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6 • vacon Control I/O

2. CONTROL I/O

OPT-A1

Terminal Signal Description
1 +10V
2 AI1+ Analogue input 1, voltage or

3 AI1- Analogue input common Ground for reference and controls
4 AI2+
5 AI2­6 +24V Control voltage output Voltage for switches, etc. max 0.1 A
7 GND I/O ground Ground for reference and controls
8 DIN1 Digital input 1
9 DIN2 Digital input 2

10 DIN3 Digital input 3

11 CMA Common for DIN 1—DIN 3 Connect to GND or +24V

12 +24V Control voltage output Voltage for switches (see #6)
13 GND I/O ground Ground for reference and controls
14 DIN4 Digital input 4
15 DIN5 Digital input 5
16 DIN6 Digital input 6

17 CMB Common for DIN4—DIN6 Connect to GND or +24V
18 AO1+
19 AO1­20 DO1 Digital output

Reference voltage Maximum current 10 mA

ref

current

Analogue input 2 Same as A1 but default is 0-20mA.

Fault Reset (Par. P2.2.1.1)

Run enable (Par. P2.2.1.3)

Analogue output 1 Programmable

READY (Par. P2.2.5)

Default: 0– +10V (Ri = 200 kΩ)
(-10V…..+10V Joy-stick control,
selected with a jumper)
0– 20mA (Ri = 250 Ω)

Ri = min. 5kΩ 18…30V = "1"

Ri = min. 5kΩ 18…30V = "1"

.

Range 0—20 mA/R
Programmable
Open collector, I≤50mA, U≤48 VDC

, max. 500Ω

L

OPT-A2

21 RO1
22 RO1
23 RO1

24 RO2
25 RO2
26 RO2

Relay output 1

Running

Relay output 2

Fault

Switching capacity
24VDC/8A
250VAC/8A
125VDC/0.4A
Min. switching load 5V/10mA
Switching capacity
24VDC/8A
250VAC/8A
125VDC/0.4A
Min. switching load 5V/10mA

Table 2- 1. Default I/O configuration.

OPT-B8

Terminal Signal Technical information
1 R1 + AnIN:X.1
2 Rm1
3 R1 -
4 R2 + AnIN:X.2
5 Rm2
6 R2 -
7 R3 + AnIN:X.3
8 Rm3
9 R3 -

10 NC Not connected

PT100 Input, -30…200°C, one sensor.
Accuracy ≤ 1°C.
Sensor current 10 mA.
PT100 Input, -30…200°C, one sensor.
Accuracy ≤ 1°C.
Sensor current 10 mA.
PT100 Input, -30…200°C, one sensor.
Accuracy ≤ 1°C.
Sensor current 10 mA.

Table 2- 2. I/O terminals on OPT-B8

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Brake Chopper Application – Parameter lists vacon • 7

3. BRAKE CHOPPER APPLICATION – PARAMETER LISTS

On the next pages you will find the lists of parameters within the respective parameter groups.

Column explanations:

Code = Location indication on the keypad; Shows the operator the present parameter
number
Parameter = Name of parameter
Default = Value preset by factory
Min = Minimum value of parameter
Max = Maximum value of parameter
Unit = Unit of parameter value; given if available
ID = ID number of the parameter (used with PC tools and fieldbus)
Note = Description of parameter

3.1 Monitoring values (Control keypad: menu M1)

The monitoring values are the actual values of parameters and signals as well as statuses and
measurements. Monitoring values cannot be edited.

See Vacon NX User's Manual, Chapter 7 for more information.

Code Parameter Unit ID Note

V1.1 Total Current A 1104 Filtered braking current in Amperes.
V1.2 Power kW 1106 Braking power in kW.
V1.3 DC-link Voltage V 1108 DC intermediate voltage in Volts
V1.4 Unit Temperature °C 1109 Unit temperature C-degrees.
V1.5 ANALOG OUTPUT 1 % 1112 Analog Output 1 in%
V1.6 DIN1, DIN2, DIN3 15 Digital Inputs A1, A2 and A3 Status (sum)
V1.7 DIN4, DIN5, DIN6 16 Digital Inputs B4, B5 and B6 Status (sum)
V1.8 DO1, RO1, RO2 17 Digital Output and Relay 1&2 Status (sum)
V1.9 Unit Nom Voltage V 111 Nominal voltage rating of the Frequency

V1.10 Unit Nom Current A 1118 Nominal current rating of Frequency Converter.
V1.11 DC Nom Voltage V 1120 Nominal value of Dc-link voltage in Volts.
V1.12 MainControlWord 1160 See the chapter 5
V1.13 MainStatusWord 1162 See the chapter 5
V1.14 Active Fault 37 Active fault code
V1.15 PT100(1) Temperature °C 50 Temperature measured with PT100 sensor 1
V1.16 PT100(2) Temperature °C 51 Temperature measured with PT100 sensor 2

V1.17 PT100(3) Temperature °C 52 Temperature measured with PT100 sensor 3

Table 3-1. Monitoring values

Converter.

(only when OPT-B8 is used)

(only when OPT-B8 is used)

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