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Vacon NX User Manual

Liquid-cooled drives
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Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com

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  • Page 1 ® ac drives liquid-cooled drives user manual Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 2 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 3: Table Of Contents

    CE marking........................11 2.2. EMC directive......................... 11 2.2.1. General .......................... 11 2.2.2. Technical criteria ......................11 2.2.3. Vacon frequency converter EMC classification ............11 2.2.4. Explanations of voltage classes..................11 2.2.5. Manufacturer's declaration of conformity..............12 RECEIPT OF DELIVERY ................. 13 3.1.
  • Page 4 • 2 6.1.3. Fuse sizes........................73 6.1.4. Cable installation instructions..................79 6.1.5. Supply busbars for inverter units ................. 81 6.1.6. Installation space ......................82 6.1.7. Earthing of power unit ....................82 6.1.8. Installation of ferrite rings (option) on the motor cable..........83 6.1.9.
  • Page 5 11.4. Brake chopper unit technical data................170 11.5. BCU power ratings ....................173 11.5.1. Vacon NXB; DC voltage 460–800 V ................173 11.5.2. Vacon NXB; DC voltage 640–1100 V ................174 11.6. Vacon brake resistors and brake chopper dimensioning......... 175 11.6.1.
  • Page 6 All parameters are explained in the All in One Application Manual. 9. Follow the commissioning instructions, see Chapter 8. 10. The Vacon NX Liquid-Cooled Frequency Converter is now ready for use. Vacon Plc is not responsible for the use of its products against instructions.
  • Page 7 Congratulations for choosing the Smooth Control provided by Vacon NX_W Liquid Cooled drives! The User's Manual will provide you with the necessary information about the installation, commissioning and operation of Vacon NX Liquid-Cooled drives. We recommend that you carefully study these instructions before powering up the frequency converter for the first time.

  • Page 8: Safety

    9000 emf The motor terminals U, V, W and the DC-link/brake resistor terminals are live when Vacon NX Liquid-Cooled drive is connected to mains, even if the motor is not running. 9000.emf...

  • Page 9: Warnings

    Prior to measurements on the motor or the motor cable, disconnect the motor cable from the frequency converter. Do not lift the Vacon NX Liquid-cooled drive from the plastic handles with an elevat- ing device, such as jib crane or hoist.

  • Page 10: Cautions

    . See page 81. The earth leakage current of Vacon NX_ exceeds 3.5 mA AC. According to EN 61800-5-1, one or more of the following conditions for the associated protective circuit shall be satisfied: a.

  • Page 11: Running The Motor

    SAFETY vacon • 9 Running the motor Warning symbols For your own safety, please pay special attention to the instructions marked with the following symbols: Dangerous voltage 9000.emf General warning 13006.emf Hot surface – Risk of burn Motor run check list...
  • Page 12 • 10 SAFETY NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from website. 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 website.

  • Page 13: Eu Directive

    The CE marking on the product guarantees the free movement of the product within the EEA (European Economic Area). Vacon NX frequency converters carry the CE label as a proof of compliance with the Low Voltage Directive and the Electro Magnetic Compatibility Directive (EMC). The company SGS FIMKO has acted as the Competent Body.

  • Page 14: Manufacturer's Declaration Of Conformity

    TN/TT networks. Should a drive originally purchased for TN/TT networks be used in an IT network, the screw at X41 must be removed. It is strongly recommended that this be done by Vacon personnel. Ask you local distributor for more information.

  • Page 15: Receipt Of Delivery

    RECEIPT OF DELIVERY vacon • 13 RECEIPT OF DELIVERY The standard delivery of Vacon liquid-cooled drives includes all or part of the following components: • Power unit • Choke (not DC-fed inverters, type code I) • Control unit • Control unit mounting kit •...

  • Page 16: Storage And Shipping

    If the storage time exceeds 12 months the electrolytic DC capacitors need to be charged with caution. Therefore, such a long storage time is not recommended. See Chapter 9.3 and the NX Liquid-Cooled Drives Service Manual for instructions on charging. See also Chapter 3.3.

  • Page 17: Technical Data

    The Vacon NX_W Liquid-Cooled product range consists of active front ends, inverters, brake choppers and frequency converters. Figure 1 & Figure 2 presents the block diagram of the Vacon NX Liquid-Cooled inverter and frequency converter. Mechanically, the product consists of two units, the Power Unit and the Control Unit.
  • Page 18 CH3. For CH72 (only 6-pulse) and CH74, it is available as internal option while in all other sizes it is optional but installed externally. Figure 1. Vacon NX Liquid-Cooled converter principal block diagram Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 19 An internal brake chopper belongs to standard equipment in sizes CH3 only, while in all other sizes it is optional but installed externally. Figure 2. Vacon NX Liquid-Cooled inverter principal block diagram Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 20: Power Ratings

    TECHNICAL DATA Power ratings Vacon Liquid-Cooled product range consists of both frequency converters (AC input, AC output) and inverter units (DC input, AC output). The following tables present the drive output values for both and an indication of motor shaft power at I...
  • Page 21 NX Liquid-Cooled drive output power. The enclosure class for all NX Liquid-Cooled frequency converters is IP00. If the motor is continuously (besides start and stop ramps) run at frequencies below 5 Hz, pay attention to the drive dimensioning for low frequencies, i.e. maximum I = 0.66*I...
  • Page 22 DC connections must be connected together otherwise there can be unbalance between the power modules. 4.2.1.2 Vacon NX Liquid-Cooled Frequency Converter – Mains voltage 525—690 VAC Table 4. Power ratings of NX Liquid-Cooled frequency converter (6-pulse), supply voltage 525—690 VAC...
  • Page 23 TECHNICAL DATA vacon • 21 Table 4. Power ratings of NX Liquid-Cooled frequency converter (6-pulse), supply voltage 525—690 VAC Mains voltage 525-690 VAC, 50/60 Hz, 3~, 6-pulse drives 0820_6 17.3/1.0/18.3 CH74 0920_6 19.4/1.1/20.5 CH74 1030_6 1030 1000 21.6/1.2/22.8 CH74 1180_6...
  • Page 24 Closed Loop control mode. All power losses are worst case losses. If some other mains voltage is used, apply the formula P = x Un x In x cosϕ x eff% to calculate the NX Liquid Cooled drive output power.

  • Page 25: Inverter Units

    • 23 4.2.2 Inverter units 4.2.2.1 Vacon NX Liquid-Cooled Inverter Unit – Mains voltage 465—800 VDC Table 7. Power ratings of NX Liquid-Cooled inverter unit, supply voltage 540—675 VDC Mains voltage 465-800 VDC Drive output Power loss Current Motor output power...
  • Page 26 The enclosure class of all inverter units is IP00. 4.2.2.2 Vacon NX Liquid-Cooled Inverter Unit – Mains voltage 640—1100 VDC Table 8. Power ratings of NX Liquid-Cooled inverter unit, supply voltage 710—930 VDC Mains voltage 640-1100 VDC Drive output Power loss...
  • Page 27 I . It is recommended to check the rating with your distributor or Vacon. Drive overrating may also be necessary if the process requires high starting torque. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 28: Technical Data

    Output frequency 0…320 Hz (standard); 7200 Hz (Special software) connection Frequency resolution Application dependent Output filter Vacon liquid cooled NX_8 unit must be equipped with a du/dt- or sine-filter. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 29 TECHNICAL DATA vacon • 27 Table 9. Technical data Control method Frequency control U/f Open Loop Sensorless Vector Control Closed Loop Vector Control Switching frequency NX_5: Up to and including NX_0061: 1…16 kHz; Factory default 10 kHz From NX_0072: 1…12 kHz; Factory default 3.6 kHz NX_6/ 1…6 kHz;...
  • Page 30 • 28 TECHNICAL DATA Table 9. Technical data Ambient operating –10 °C (no frost)…+50 °C (at I temperature The NX Liquid Cooled drives must be used in an heated indoor controlled environment. Installation 0...+70 °C temperature Storage temperature –40 °C…+70 °C; No liquid in heatsink under 0 ºC...
  • Page 31 TECHNICAL DATA vacon • 29 Table 9. Technical data Analogue input voltage 0…+10 V, R = 200 kΩ, (–10 V…+10 V joystick control) Resolution 0.1%, accuracy ±1% Analogue input current 0(4)…20 mA, Ri = 250 W differential Digital inputs (6) Positive or negative logic;...
  • Page 32 • 30 TECHNICAL DATA Table 9. Technical data Allowed cooling agents Drinking water (see specification on page 49). Water-glycol mixture. See derating specifications, Chapter 5.3. Volume See page 51. Temperature of cooling 0…35 °C (I )(input); 35…55 ºC: derating required, agent see Chapter 5.3.

  • Page 33: Installation

    For units with no mounting bracket (see Chapter 5.1.2.1), the best place for hoisting is the hole(s) in the middle of the mounting plate (Lifting point 1). Vacon NX Liquid-Cooled drives consisting of several modules can the most safely and easily be lifted by the holes in the mounting bracket (Lifting point 2) using a screw pin shackle.
  • Page 34 See Figure 4 and Figure 5. The NX liquid cooled drives are equipped with plastic handles and these handles can be used to move and lift drives consisting of one power module (CH61, CH62, & CH72) by hand.
  • Page 35 INSTALLATION vacon • 33 5-6pcs M5 Fixing rail 2pcs M8 2pcs M8 PEM 11313_uk Figure 5. Securing the drive to the cabinet frame Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 36: Nx Liquid-Cooled Dimensions

    Table 10. One-module drive dimensions (mounting base included) Chassis Width Height Depth Weight CH61/62 CH72 1076 *. AC choke excluded. Terminals 11314_uk Figure 6. Vacon NX Liquid-Cooled drive dimensions, CH3 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 37 INSTALLATION vacon • 35 11315_uk Figure 7. Vacon NX Liquid-Cooled drive dimensions (frequency converter), CH4 11316_uk Figure 8. Vacon NX Liquid-Cooled drive dimensions (inverter), CH4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 38 • 36 INSTALLATION 11317_uk Figure 9. Vacon NX Liquid-Cooled dimensions, CH5 frequency converter 11318_uk Figure 10. Vacon NX Liquid-Cooled dimensions, CH5 inverter Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 39 INSTALLATION vacon • 37 11319_uk Figure 11. Vacon Liquid-Cooled frequency converter, CH61 11320_uk Figure 12. Vacon Liquid-Cooled inverter, CH61 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 40 • 38 INSTALLATION 11321_uk Figure 13. Vacon Liquid-Cooled inverter, CH62 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 41 INSTALLATION vacon • 39 11322_uk Figure 14. Vacon Liquid-Cooled frequency converter (6-pulse), CH72 11323_uk Figure 15. Vacon Liquid-Cooled frequency converter (6-pulse) with internal brake chopper Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 42 Figure 16. Vacon Liquid-Cooled frequency converter (12-pulse), CH72 5.1.2.2 Drives consisting of several modules Vacon NX Liquid-Cooled drives consisting of several modules are mounted in a mounting bracket as presented in Figure 17. Table 11. Several-module drive dimensions (mounting bracket incl.)
  • Page 43 INSTALLATION vacon • 41 11326_uk Figure 18. Vacon Liquid-Cooled frequency converter with mounting bracket, CH63 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 44 • 42 INSTALLATION 11327_uk Figure 19. Vacon Liquid-Cooled inverter with mounting bracket, CH63 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 45 INSTALLATION vacon • 43 11328_uk Figure 20. Vacon NX Liquid-Cooled inverter dimensions, CH64, IP00 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 46 • 44 INSTALLATION 11329_uk Figure 21. Vacon NX Liquid-Cooled frequency converter (6-pulse) dimensions, CH74, IP00 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 47 INSTALLATION vacon • 45 11330_uk Figure 22. Vacon NX Liquid-Cooled frequency converter (6-pulse) with internal brake chopper di- mensions, CH74, IP00 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 48 • 46 INSTALLATION 11331_uk Figure 23. Vacon NX Liquid-Cooled frequency converter (12-pulse) with internal brake chopper di- mensions, CH74, IP00 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 49: Cooling

    • 47 Cooling Instead of using air for cooling, Vacon NX Liquid-Cooled drives are cooled with liquid. The liquid circulation of the drive is usually connected to a heat-exchanger (liquid-liquid/liquid-air) which cools down the liquid circulating in the cooling elements of the drive. Because the cooling elements are made of aluminium, the cooling agents allowed to be used are drinking water, demineralized water or a mixture of water and glycol.
  • Page 50 • 48 INSTALLATION Table 12. Drinking water chemical specification Quality Unit Value Boron mg/l Bromate μg/l Cadmium μg/l Chromium μg/l Copper mg/l Cyanides μg/l 1,2-Dichloroethane μg/l Epichlorohydrin μg/l 0.10 Fluoride mg/l Lead μg/l Mercury μg/l Nickel μg/l mg/l Nitrate (NO...
  • Page 51 INSTALLATION vacon • 49 Table 13. Drinking water quality recommendations Quality Unit Max. value Aluminium μg/l mg/l 0.50 Ammonium (NH Ammonium (NH mg/l 0.40 mg/l <100 Chloride Manganese μg/l Iron μg/l <0.5 1] 2] mg/l Sulphate Sodium mg/l Oxidizability mg/l...
  • Page 52 • 50 INSTALLATION Specification: Process water Table 14. Process water specification Quality Unit Value 6…9 Water hardness °dH <20 Electrical conductivity μS/cm <100 mg/l <100 Chlorides (Cl) Iron (Fe) mg/l <0.5 *. The allowed concentration of chloride ions (Cl–): <1000 ppm at 20 °C, < 300 ppm at 50 °C and <...
  • Page 53 26.1ºC 11332_uk Figure 24. Example of cooling system Vacon recommends to equip the cooling system with pressure and flow supervision (FE). The flow supervision can be connected to digital input function External fault. If the coolant flow is found too low, the frequency converter will be stopped.
  • Page 54 • 52 INSTALLATION In tables below you will find the specifications related to the cooling agent and its circulation. See also Table 9 on page 25. Table 15. Information about cooling agent and its circulation Min. liquid flow Max. liquid flow Nom.

  • Page 55: Condensation

    5.2.1 Condensation Condensation on the cooling plate of the NX Liquid-Cooled drive must be avoided. Therefore, the temperature of the cooling liquid must be kept higher than the temperature of the electrical room. Use the graph below to determine if the drive operating conditions (combination of room temperature, humidity and cooling liquid temperature) are safe, or, to choose the allowed temperature for the cooling liquid.

  • Page 56: Cooling System Connections

    • 54 INSTALLATION Example: If the temperature of the electric room is 30 °C, the relative humidity is 40% and the temperature of the cooling liquid is 20 °C (the lowest curve in Figure 26), then the drive operating conditions are safe.
  • Page 57 INSTALLATION vacon • 55 Figure 28. External thread of hose adapter For all other chasses (CH3, CH4), the standard delivery includes fast connectors of type 'Tema', series 1300 or 1900. The fast connectors are available as option also for CH5, CH6, CH7.
  • Page 58 • 56 INSTALLATION 5.2.2.1 Pressure losses Table 18. Pressure losses; CH6x CH6x with standard 1.5m hoses and optional fast connectors TEMA Pressure Pressure loss total loss total Pressure Pressure Pressure Pressure (inflow (Tema, Volume loss; Pressure loss; loss; loss; Tema,...
  • Page 59 About the installation Vacon recommends to mount the flow switch on the inflow side of the system (see Figure 24). Pay attention to the direction of flow. The switch reaches the highest accuracy when it is mounted in...
  • Page 60 • 58 INSTALLATION horizontal position. If mounted vertically, the mechanical sensor is affected by the Earth’s gravity which reduces the accuracy according to the data given in Table 20. 11339_00 Figure 31. Flow switch: Hose connection, fast connector (electrical), fast connector lock screw, ca- ble seal and clamp Table 20.
  • Page 61 INSTALLATION vacon • 59 Coolant outlet Coolant inlet 11340_uk Figure 32. Direction of coolant circulation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 62: Drive Derating

    INSTALLATION Drive derating The tables below state the maximum coolant temperatures for Vacon liquid-cooled drives at given switching frequencies. Drive derating is required if the maximum temperatures are exceeded. NOTE! If the heatsink is nickel-coated you must allow for a 2-degree C derating of values in the tables below.
  • Page 63 INSTALLATION vacon • 61 Table 23. Max temperatures of coolant at switching frequency of 3.6 kHz Supply voltage 525-690 VAC, switching frequency 3,6 kHz Max coolant temperature [°C] Max coolant temperature [°C] Chassis Type Supply voltage 525 V Supply voltage 690 V...

  • Page 64: Input Chokes

    The input chokes are included in the standard delivery of Vacon liquid-cooled frequency converters (not inverters). However, you can also order your frequency converter without the choke. The Vacon chokes listed below are meant for supply voltages of 400-500 V and 525-690 V. Table 25. Input choke dimensioning, 6-pulse supply...

  • Page 65: Installation Of Input Chokes

    5.4.1 Installation of input chokes There are two types of input choke connection in Vacon NX Liquid-Cooled drives. The two smallest sizes (CH31, CH32; up to 61 A) have terminal block connection whereas bigger sizes use busbar connection. Examples of both connections and the choke dimensions below.
  • Page 66 • 64 INSTALLATION Mains Converter 220a.fh8 11342_uk Figure 34. Example of input chokes for Vacon NX Liquid-Cooled. Sizes 87 A…145 A and 590 A Table 27. Choke dimensions; Sizes 23 A…145 A and 590 A Weight Choke type [mm] [mm]...
  • Page 67 CHK1150N6A0 (8 pcs) (36 pcs) If you have ordered the input chokes for Vacon NX Liquid-Cooled separately pay attention to the following instructions: 1. Protect the chokes from dripping water. You may even need to use plexiglass for protection because jets of water may occur when working with the connections.

  • Page 68: Electrical Cabling And Connections

    How the power connections of Vacon NX Liquid-Cooled units are implemented depends on the size of the unit. The smallest NX Liquid-Cooled unit (CH3) has terminal blocks for the connections. In all other units, the connection is established using cables and cable clips or bolting the busbars together.
  • Page 69 ELECTRICAL CABLING AND CONNECTIONS vacon • 67 Table 30. Cable types required to meet standards Cable type Level N/T Mains cable Motor cable Control cable = Power cable intended for fixed installation and the specific mains voltage. Symmetrical shielded cable recommended.
  • Page 70 • 68 ELECTRICAL CABLING AND CONNECTIONS Table 31. Motor cable sizes, 400—500 V Terminal cable size Max. number of Motor cable Main Chassis Type cables/ Earth terminal Cu [mm terminal Bolt size ], max. CH63 0820_5 3*(3*185+95) **** 8/M12...
  • Page 71 ELECTRICAL CABLING AND CONNECTIONS vacon • 69 Table 32. Motor cable sizes, 525—690 V Terminal cable size Max. number of Motor cable Chassis Type cables/ Main terminal Earth terminal Cu [mm Bolt size ], max CH63 0590_6 3*(3*150+70) 8/M12 CH63...
  • Page 72 • 70 ELECTRICAL CABLING AND CONNECTIONS Table 33. Mains cable sizes for frequency converters, 400—500 V Terminal cable size Max. number Chassis Type of cables/ Main terminal Earth terminal Mains cable Bolt size ], max Cu [mm 0105_5 3*50+25 50 Cu 6—70...
  • Page 73 ELECTRICAL CABLING AND CONNECTIONS vacon • 71 See the tightening torques of bolts in Table 35. Table 34. Mains cable sizes, 525—690 V Terminal cable size Max. number Mains cable Chassis Type of cables/ Main terminal Earth terminal Cu [mm Bolt size ], max.

  • Page 74: Drive Protection - Fuses

    • 72 ELECTRICAL CABLING AND CONNECTIONS Table 35. Tightening torques of bolts Tightening torque Max. inward thread length Bolt [Nm] [mm] Earthing bolt 13.5 (see page 82) We recommend a low-impedance earthing of the motor cable shield for better performance.

  • Page 75: Fuse Sizes

    In case you wish to use fuses of other fuse manufacturers, contact Vacon. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 76 • 74 ELECTRICAL CABLING AND CONNECTIONS 6.1.3.1 Frequency converters Table 36. Fuse sizes for Vacon NX Liquid-Cooled (500 V) frequency converters DIN43620 DIN43653 Qty. of Fuse Fuse Chass Fuse fuses per Type aR fuse aR fuse aR fuse catalog...
  • Page 77 ELECTRICAL CABLING AND CONNECTIONS vacon • 75 Table 37. Fuse sizes for Vacon NX Liquid-Cooled (690 V) frequency converters DIN43620 DIN43653 Qty. of Fuse Fuse fuses Fuse Chassis Type aR fuse aR fuse size aR fuse part nr. drive part nr.
  • Page 78 ELECTRICAL CABLING AND CONNECTIONS 6.1.3.2 Fuse sizes, inverters Each DC supply line must be equipped with an aR fuse according to the tables below. Table 38. Fuse sizes for Vacon NX Liquid-Cooled (450—800 V) inverters "TTQF" threaded "TTF" threaded end end size84 or "7X"...
  • Page 79 ELECTRICAL CABLING AND CONNECTIONS vacon • 77 Table 38. Fuse sizes for Vacon NX Liquid-Cooled (450—800 V) inverters "TTQF" threaded "TTF" threaded end end size84 or "7X" DIN43620 "PLAF" 2x84 or size 83 with end with end contacts Chas Fuse...
  • Page 80 • 78 ELECTRICAL CABLING AND CONNECTIONS Table 39. Fuse sizes for Vacon NX Liquid-Cooled (640—1100 V) inverters "TTF" threaded end "TTQF" threaded "7X" end size84 or DIN43620 or size 83 with end "PLAF" 2x84 with Fuse contacts end contacts...

  • Page 81: Cable Installation Instructions

    Before starting the installation, check that none of the components of the frequency converter is live. Vacon NX Liquid-Cooled drive must always be installed in an enclosure, a separate cubicle or an electrical room. Always use a jib crane or similar lifting device to lift the drive. For safe and appropriate lifting, see Chapter 5.1.1.
  • Page 82 ELECTRICAL CABLING AND CONNECTIONS Liquid cooling connection: The standard delivery of the Vacon NX Liquid-Cooled drive includes hoses on the cooling element 1.5 m in length and 15 mm in diameter. The hoses are inserted in 1400-mm UL94V0 approved conduits. Connect the line hose branch to its counterpart (screw or fast connector) on the of the Vacon Liquid-Cooled drive.

  • Page 83: Supply Busbars For Inverter Units

    ELECTRICAL CABLING AND CONNECTIONS vacon • 81 2,3 kN 2,3 kN 2,3 kN 1 kN 2,3 kN 2,3 kN nxw11.fh8 1 kN 2,3 kN AC drives 2,3 kN Maximum terminal stress 2,3 kN 11345_uk Figure 37. Maximum terminal stresses 6.1.5...

  • Page 84: Installation Space

    • 82 ELECTRICAL CABLING AND CONNECTIONS 6.1.6 Installation space Enough free space shall be left above and below the frequency converter/inverter to ensure practical and appropriate electrical and cooling connections. The minimum dimensions are given in the table below. The space left and right to the drive may be 0 mm.

  • Page 85: Installation Of Ferrite Rings (Option) On The Motor Cable

    The Vacon delivery includes fixed sets of ferrite rings. When ferrite rings are used to...

  • Page 86: Cable And Motor Insulation Checks

    • 84 ELECTRICAL CABLING AND CONNECTIONS 6.1.10 Cable and motor insulation checks 1. Motor cable insulation checks Disconnect the motor cable from terminals U, V and W of the frequency converter and from the motor. Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor.

  • Page 87: Control Unit

    ELECTRICAL CABLING AND CONNECTIONS vacon • 85 Control unit The control unit of Vacon NX Liquid-Cooled frequency converter/inverter is installed into a mounting box. It contains the control board and additional boards (see Figure 41 and Figure 42) slot connectors connected to the five (A to E) of the control board.
  • Page 88 • 86 ELECTRICAL CABLING AND CONNECTIONS Usually, when the frequency converter is delivered from the factory, the control unit includes at least the standard compilation of two basic boards (I/O board and relay board) which are normally installed in slots A and B. On the next pages you will find the arrangement of the control I/O and the relay terminals of the two basic boards, the general wiring diagram and the control signal descriptions.

  • Page 89: Control Board Power-Up

    ELECTRICAL CABLING AND CONNECTIONS vacon • 87 6.2.1 Control board power-up The control board can be powered (+24 V) in two different ways: either 1) directly from the power board ASIC, terminal X10 or/and 2) externally using the customer’s own power source. The two ways of supplying the board can be used simultaneously.
  • Page 90 • 88 ELECTRICAL CABLING AND CONNECTIONS RO1/1 RO1/3 ac/dc Switching: RO2/1 <8A/24Vdc, <0.4A/125Vdc, RO2/3 <2kVA/250Vac Continuously: <2Arms Basic relay board OPT-A2 NX6_6.fh8 11355_uk Figure 45.General wiring diagram of the basic relay board (OPT-A2) 6.2.2.1 Control cables The control cables shall be at least 0.5 mm screened multicore cables, see Table 30.
  • Page 91 ELECTRICAL CABLING AND CONNECTIONS vacon • 89 Gate drivers 10Vref L1 L2 L3 +24V Control I/O ground AI2+ AI2 - Control DIN1... panel Digital input DIN3 group A DIN4... Digital input DIN6 group B Control Power Analogue AO1+ board board...

  • Page 92: Control Terminal Signals

    • 90 ELECTRICAL CABLING AND CONNECTIONS 6.2.3 Control terminal signals Table 41. Control I/O terminal signals Terminal Signal Technical information OPT-A1 +10 Vref Reference voltage Maximum current 10 mA AI1+ Analogue input, Selection V or mA with jumper block X1 (see...
  • Page 93 ELECTRICAL CABLING AND CONNECTIONS vacon • 91 Table 41. Control I/O terminal signals Terminal Signal Technical information OPT-A2 RO1/1 Relay output 1 Max. switching voltage 250 VAC, 125 VDC RO1/2 Max. switching current 8 A/24 VDC, 0.4 A/250 VDC RO1/3 Min.
  • Page 94 • 92 ELECTRICAL CABLING AND CONNECTIONS 6.2.3.2 Jumper selections on the OPT-A1 basic board The user is able to customise the functions of the frequency converter to better suit his needs by selecting certain positions for the jumpers on the OPT-A1 board. The positions of the jumpers determine the signal type of analogue and digital inputs.
  • Page 95 ELECTRICAL CABLING AND CONNECTIONS vacon • 93 Jum per block X 1 : Jum per block X 2 : AI1 m ode AI2 m ode AI1 mode: 0...20mA; Current input AI2 mode: 0...20mA; Current input AI1 mode: Voltage input; 0...10V AI2 mode: Voltage input;...

  • Page 96: Control Unit Mounting Box

    6.2.4.1 Installing the control unit mounting box The control unit of Vacon NX Liquid-Cooled drive is mounted into a metal box which then can be placed inside the enclosure. Vacon alpha-numeric or graphical keypad can be used to control the drive.
  • Page 97 Figure 5. NOTE! Do not install the mounting box floating (with e.g. plastic screws). To ensure a proper grounding of the control unit box assembly, Vacon recommends that an additional grounding cable be drawn from the mounting box and connected to the cabinet frame.

  • Page 98: Internal Connections

    • 96 ELECTRICAL CABLING AND CONNECTIONS Internal connections As a general rule, all internal electrical and communications connections are made at the factory. However, if modules have to be moved, for example, and the connections therefore removed, you the Power Unit ASIC...
  • Page 99 ELECTRICAL CABLING AND CONNECTIONS vacon • 97 DC- DC+ X9 X15 H1H2H3H4H5H6H7 ASIC board X3 X4 X5 Driver board, Driver board, phase U phases V&W Module 1 Module 2 Internal fan Internal fan 11370_uk Figure 53. Terminals and connections between ASIC and driver boards (CH63)
  • Page 100 • 98 ELECTRICAL CABLING AND CONNECTIONS DC- DC+ X9 X15 H1H2H3H4H5H6H7 ASIC board X3 X4 X5 Driver board, Driver board, Driver board, phase U phase V phase W Internal fan Internal fan Internal fan Module 3 Module 1 Module 2 11371_uk Figure 54.

  • Page 101: Connections Between Power Unit Asic And The Control Unit

    6.3.2 Connections between power unit ASIC and the control unit control The communication connections between the NX Liquid-Cooled drive power unit and the unit (see Chapter 6.2) can be established using either the conventional round cable (standard in chassis CH3, CH4 and CH5) or optical cable (all chassis). Note that for chassis CH61 and greater, only optical cables can be used.
  • Page 102 • 100 ELECTRICAL CABLING AND CONNECTIONS Min bending radius 50 mm 11310_uk Figure 56. Connecting the power supply and control cables to the control unit, Ch6x Min bending radius 50 mm 11297_uk Figure 57. Connecting the power supply and control cables to the control unit, Ch7x Each fibre optic cable has a number 1...7 marked on the cable shield at both cable ends.
  • Page 103 ELECTRICAL CABLING AND CONNECTIONS vacon • 101 Optical terminals on Optical cable adapter board: Gate control enable Phase U control Phase V control Phase W control ADC synchronization VaconBus data from control board to ASIC VaconBus data from ASIC to control board...
  • Page 104 • 102 ELECTRICAL CABLING AND CONNECTIONS The control unit uses 24 VDC supplied from the ASIC board, which is located on the left side of the power unit 1. To access the board, remove the protective cover in front of the power module. Con- nect the power supply cable to the X10 connector on the ASIC board and to the X2 connector on the rear side of the control unit.

  • Page 105: Connections Between Mains Device And Inverter Power Module

    The dimensions in the table below shall be taken into account if some kind of mains device (e.g. fuse, switch fuse, contactor) is used in the input line between the mains and the Vacon Liquid- Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 106 • 104 ELECTRICAL CABLING AND CONNECTIONS Cooled inverter. Table 42. Connections from mains device to drive Connection Chassis Type Conductor cross section Busbar size Busbar size (flexible connection) (bare Cu) 0016_5 0022_5 0031_5 0038_5 0045_5 0061_5 0072_5 0087_5 0105_5...
  • Page 107 ELECTRICAL CABLING AND CONNECTIONS vacon • 105 Table 43. Connections from mains device to drive Connection Conductor cross Chassis Type Busbar size (flexible Busbar size section [mm connection) (bare Cu) CH61 0170_6 2*24*1 0208_6 0261_6 CH62 0325_6 2*70 5*32*1 0385_6...

  • Page 108: Control Keypad

    CONTROL KEYPAD CONTROL KEYPAD The control keypad is the link between the Vacon frequency converter 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).

  • Page 109: Control Place Indications

    CONTROL KEYPAD vacon • 107 7.1.2 Control place indications The symbols I/O term, Keypad Bus/Comm (see Figure 60) indicate the choice of control place made in the Keypad Control Menu (see Chapter 7.3.3). I/O term = I/O terminals are the selected control place; i.e. START/STOP commands or reference values etc.

  • Page 110: Keypad Push-Buttons

    • 108 CONTROL KEYPAD Keypad push-buttons The Vacon alphanumeric control keypad features 9 push-buttons that are used for the control of the frequency converter (and motor), parameter setting and value monitoring. 3063_00 Figure 61. Keypad push-buttons 7.2.1 Button descriptions = This button is used to reset active faults (see Chapter 7.3.4).

  • Page 111: Navigation On The Control Keypad

    CONTROL KEYPAD vacon • 109 = Stop button. Pressing this button stops the motor (unless disabled by parameter R3.4/R3.6). See Chapter 7.3.3. 7.2.1.1 Swap between keypad control and another control as active control place With the I/O terminals or fieldbus selected as the active control place, it is also possible to change the control to the local keypad and back to the original control place.

  • Page 112: Monitoring Menu (M1)

    • 110 CONTROL KEYPAD READY READY R EADY R EADY R EADY R EADY I/Oterm I/Oterm I/Ote rm I/Ote rm I/Oterm I/Oterm Expander boards Expander boards A:NXOPTA1 A:NXOPTA1 Parameters Parameters G1 G1 G1 G1 P1 P3 P1 P3 G1 G5...
  • Page 113 CONTROL KEYPAD vacon • 111 R EADY Lo ca l FreqReference 13.95 Hz READY READY Local Local Monitor Output frequency V1 V14 13.95 Hz 11376_uk Figure 63. Monitoring menu Table 44. Monitored signals Code Signal name Unit Description V1.1 Output frequency Frequency to the motor V1.2...

  • Page 114: Parameter Menu (M2)

    • 112 CONTROL KEYPAD 7.3.2 Parameter menu (M2) Parameters are the way of conveying the commands of the user to the frequency converter. The Parameter Menu Main Menu parameter values can be edited by entering the from the when the location indication M2 is visible on the first line of the display.

  • Page 115: Keypad Control Menu (M3)

    CONTROL KEYPAD vacon • 113 Ke ypa d Input signals READY READY READY Keypad Keypad Keypad Parameters Basic parameters Min Frequency P1 P18 G1 G8 13.95 Hz READY READY Keypad Keypad Min Frequency Min Frequency enter 13.95 Hz 14.45 Hz 11377_uk Figure 64.
  • Page 116 • 114 CONTROL KEYPAD 7.3.3.1 Selection of control place There are three different places (sources) which the frequency converter can be controlled from. For each control place, a different symbol will appear on the alphanumeric display: Control place symbol...

  • Page 117: Active Faults Menu (M4)

    CONTROL KEYPAD vacon • 115 7.3.3.4 Stop button activated By default, pushing the STOP button will always stop the motor regardless of the selected control place. You can disable this function by giving parameter 3.4 the value 0. If the value of this parameter is 0, the STOP button will stop the motor only when the keypad has been selected as the active control place.
  • Page 118 CONTROL KEYPAD 7.3.4.1 Fault types In the NX frequency converter, there are four different types of faults. These types differ from each other on the basis of the subsequent behaviour of the drive. See Table 46. I/Ote rm Operation hours...

  • Page 119: Fault History Menu (M5)

    CONTROL KEYPAD vacon • 117 7.3.4.2 Fault codes The fault codes, their causes and correcting actions are presented in Table 55. The shadowed faults are A faults only. The items written in white on black background present faults for which you can program different responses in the application.

  • Page 120: System Menu (M6)

    • 118 CONTROL KEYPAD The memory of the frequency converter can store a maximum of 30 faults in the order of appearance. The number of faults currently in the fault history is shown on the value line of the main page (H1H#).
  • Page 121 CONTROL KEYPAD vacon • 119 Table 48. System menu functions Code Function Unit Default Cust Selections Basic Application Standard Application Local/Remote control Appl. Basic Multi-Step Application S6.2 Application selection Applica- PID Control Application tion Multi-Purpose Control Appl. Pump and Fan Control Appl.
  • Page 122 Contact factory for more details. 7.3.6.1 Language selection The Vacon control keypad offers you the possibility to control the frequency converter through the keypad in the language of your choice. System menu Locate the language selection page under the .
  • Page 123 Pushing any other button leaves the parameters of the previously used application saved in the keypad. For more information, see Chapter 7.3.6.3. For more information about the Application Package, see Vacon NX Application Manual. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 124 The parameter copy menu (S6.3) embodies four functions: Parameter sets (S6.3.1) The Vacon NX frequency converter features a possibility for the user to load back the factory default parameter values and to store and load two customised parameter sets (all parameters included in the application).
  • Page 125 CONTROL KEYPAD vacon • 123 READY READY enter CONFIRM Parameter sets Parameter sets Select LoadFactDef CANCEL READY READY Parameter sets Parameter sets Wait... 11384_uk Figure 70. Storing and loading of parameter sets Upload parameters to keypad (To keypad, S6.3.2) This function uploads all existing parameter groups to the keypad provided that the drive is stopped.
  • Page 126 . Choose with the When the Parameter backup function is activated Vacon NX control keypad makes a copy of the parameters of the presently used application. Every time a parameter is changed the keypad backup is automatically updated.
  • Page 127 CONTROL KEYPAD vacon • 125 7.3.6.5 Security Security submenu NOTE! The is protected with a password. Store the password in a safe place! Password (S6.5.1) The application selection can be protected against unauthorised changes with the Password function (S6.5.1). By default, the password function is not in use. If you want to activate the function, enter the edit...
  • Page 128 • 126 CONTROL KEYPAD Start-up Wizard (P6.5.3) The Start-up Wizard is a feature on the control keypad to facilitate the commissioning of the frequency converter. If selected active (default), the Start-up Wizard prompts the operator for the language and application of his/her choice plus for the values for a set of parameters common to all applications as well as for a set of application-dependent parameters.
  • Page 129 CONTROL KEYPAD vacon • 127 Multimonitoring items (P6.5.4) Vacon alpha-numeric keypad features a display where you can monitor even three actual values at Monitoring values the same time (see Chapter 7.3.1 and Chapter in the manual of the application you are using). On page P6.5.4 of the System Menu you can define if it is possible for the operator to replace the values monitored with other values.
  • Page 130 • 128 CONTROL KEYPAD Default page in the operating menu (P6.6.2) Operating menu Here you can set the location (page) in the (in special applications only) to which Timeout time the display automatically moves as the set (see below) has expired or as the power is switched on to the keypad.
  • Page 131 CONTROL KEYPAD vacon • 129 Example: • Transfer delay between the frequency converter and the PC = 600 ms • The value of par. 6.7.3 is set to 1200 ms (2 x 600, sending delay + receiving delay) • The corresponding setting shall be entered in the [Misc]-part of the file NCDrive.ini:...
  • Page 132 • 130 CONTROL KEYPAD Table 49. Counter pages Page Counter Example 1.013 C6.8.1.2. Power On day counter Value on display is . The drive has operated for 1 year and 13 days. C6.8.1.3. Power On hour counter Value on display is 7:05:16. The drive has operated for 7 hours 5 minutes and 16 seconds.
  • Page 133 CONTROL KEYPAD vacon • 131 Table 51. Software information pages Page Content 6.8.3.2 System software version 6.8.3.3 Firmware interface 6.8.3.4 System load Applications (S6.8.4) Applications submenu At location S6.8.4 you can find the containing information about not only the application currently in use but also all other applications loaded into the frequency converter. The information available is: Table 52.

  • Page 134: Expander Board Menu (M7)

    • 132 CONTROL KEYPAD Hardware (S6.8.5) Hardware information page provides information on the following hardware-related topics: Table 53. Hardware information pages Page Content 6.8.5.1 Power unit type code 6.8.5.2 Nominal voltage of the unit 6.8.5.3 Brake chopper 6.8.5.4 Brake resistor Expander boards (S6.8.6)
  • Page 135 CONTROL KEYPAD vacon • 133 Menu button right Enter the following menu level (G#) with the . At this level, you can browse through slots (see page 84) A to E with the Browser buttons to see what expander boards are connected.

  • Page 136: Further Keypad Functions

    • 134 CONTROL KEYPAD Further keypad functions The Vacon NX control keypad embodies additional application-related functions. See Vacon NX Application Package for more information. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 137: Commissioning

    9000.emf The motor terminals U, V, W and the DC-link/brake resistor terminals B–, B+/R+, R– are live when Vacon NX Liquid-Cooled drive is connected to mains, even if the motor is not running. 9000.emf The control I/O-terminals are isolated from the mains potential.

  • Page 138: Commissioning Of The Frequency Converter

    6. Check that all Start/Stop switches connected to the I/O terminals are in Stop-position. 7. Connect the frequency converter to mains. 8. Set the parameters of group 1 (See Vacon All in One Application Manual) according to the requirements of your application. At least the following parameters should be set:...
  • Page 139 COMMISSIONING vacon • 137 Monitoring menu (M1) d) Check in the that the value of Output frequency changes according to the change of frequency reference. e) Push the Stop button on the keypad. 10. Run the start-up tests without the motor being connected to the process, if possible. If this is not possible, secure the safety of each test prior to running it.

  • Page 140: Fault Tracing

    • 138 FAULT TRACING FAULT TRACING Fault codes When a fault is detected by the frequency converter control electronics, the drive is stopped and the symbol F together with the ordinal number of the fault, the fault code and a short fault description Reset button appear on the display.
  • Page 141 FAULT TRACING vacon • 139 Table 55. Fault codes Fault Fault Possible cause Correcting measures code System fault component failure Reset the fault and restart. faulty operation Should the fault re-occur, Note exceptional fault data record. contact your local distributor.
  • Page 142 • 140 FAULT TRACING Table 55. Fault codes Fault Fault Possible cause Correcting measures code Frequency 3) Heatsink temperature is over 70 °C. Cause 1): converter Overtemperature warning is issued when Check that values for Ith overtemperature the heatsink temperature exceeds 65 °C.
  • Page 143 FAULT TRACING vacon • 141 Table 55. Fault codes Fault Fault Possible cause Correcting measures code Microprocessor faulty operation Reset the fault and restart. watchdog fault component failure Should the fault re-occur, Subcodes: contact your distributor. S1 = CPU watchdog timer S2 = ASIC reset Startup prevented Start-up of the drive has been prevented.
  • Page 144 • 142 FAULT TRACING Table 55. Fault codes Fault Fault Possible cause Correcting measures code Device added Option board added. Reset. Device is ready for (same type) Subcodes: use. S1 = Control board Old board settings will be S4 = Control unit used.
  • Page 145 The data connection between the field- Check installation. bus Master and the fieldbus board is bro- If installation is correct ken. contact the nearest Vacon distributor. Slot fault Defective option board or slot. Check board and slot. Contact the nearest Vacon distributor.

  • Page 146: Load Test With Motor

    • 144 FAULT TRACING Table 55. Fault codes Fault Fault Possible cause Correcting measures code Speed error Motor speed is unequal to reference. Check encoder connection. PMS motor has exceeded the pull out torque. Run disable Run enable signal is low.

  • Page 147: Dc Link Test (Without Motor)

    FAULT TRACING vacon • 145 DC link test (without motor) NOTE! There will be dangerous voltages present during this test! 1. Read carefully the safety instructions in Chapter 1 and follow them. 2. Connect a variable DC power supply to DC+ and DC– terminals. Make sure that all polarities are correct.

  • Page 148: Active Front End (Nxa)

    10.1 Introduction The Vacon NX Active Front End is used to transfer power between the AC input and intermediate DC circuit. The Vacon NX Active Front End has a two-way function. This means that when power is transferred from the AC input to the intermediate DC circuit, the Vacon NX Active Front End rectifies the alternating current and voltage.

  • Page 149: Type Designation Code

    ACTIVE FRONT END (NXA) vacon • 147 10.3 Type designation code In Vacon type designation code, the Active Front Unit is characterized by the characters NXA and number 2, for example: NXA 0300 5 A1A2000000 POWER MODULE U/T1 IGBT V/T2...

  • Page 150: Active Front End Unit Technical Data

    • 148 ACTIVE FRONT END (NXA) 10.4 Active Front End unit technical data The technical data for the active front end unit, see table below. *) NX_8 AC drives only available as Ch6x AFE/BCU/INU units. Table 56. Technical data Input voltage U NX_5: 400…500 VAC (–10%…+10%);...
  • Page 151 • 149 Table 56. Technical data Ambient operating –10 °C (no frost)…+50 °C (at I temperature The NX Liquid Cooled drives must be used in an heated indoor controlled environment. Installation 0...+70 °C temperature Storage temperature –40 °C…+70 °C; No liquid in heatsink under 0 ºC...
  • Page 152 • 150 ACTIVE FRONT END (NXA) Table 56. Technical data Analogue input 0…+10 V, R = 200 kΩ, (–10 V…+10 V joystick control) voltage Resolution 0.1%, accuracy ±1% Analogue input 0(4)…20 mA, Ri = 250 W differential current Digital inputs (6) Positive or negative logic;...
  • Page 153 ACTIVE FRONT END (NXA) vacon • 151 Table 56. Technical data Allowed cooling Drinking water (see specification on page 49) agents Water-glycol mixture See derating specifications, Chapter 5.3. Volume See page 51. Temperature of 0…35 °C (I )(input); 35…55 ºC: derating required, cooling agent see Chapter 5.3.

  • Page 154: Power Ratings

    • 152 ACTIVE FRONT END (NXA) 10.5 Power ratings Table 57. Power ratings of NX Liquid Cooled AFE unit, supply voltage 400-500 VAC Vacon NX Liquid Cooled Front End; DC Bus voltage 465–800 VDC Active Power loss Chassis AC Current...
  • Page 155 ACTIVE FRONT END (NXA) vacon • 153 Table 58. Power ratings of NX Liquid Cooled AFE unit, supply voltage 525-690 VAC Vacon NX Liquid Cooled Front End; DC Bus voltage 640–1100 VDC ***) Active Power loss Chassis AC Current DC power...

  • Page 156: Liquid Cooled Rlc Filters

    10.6.1 Introduction Vacon‘s Liquid Cooled AFE units can be used with either Liquid Cooled or Air Cooled LCL filters. The standard Liquid Cooled LCL filters are named RLC filter. The RLC filter type codes can be seen from Table 57. The RLC filters are not included in the standard delivery of the AFE units and therefor they need to be ordered reparately.

  • Page 157: Power Rating And Dimensions

    ACTIVE FRONT END (NXA) vacon • 155 10.6.3 Power rating and dimensions Table 59. Vacon RLC ratings, drive suitable and dimensions Vacon NX Liquid Cooled regenerative line filters - IP00 Dimensions Suitability Dimensions Thermal Power loss Ldrive, 1pcs Dimensions Total...
  • Page 158 525-690V In/Out (L_in2/L_out2) out2 3070A_uk Figure 89. Example of L choke of a Vacon RLC filter 3072_00 Figure 90. Example of capacitor bank (C ) of a Vacon RLC filter bank Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 159: Technical Data

    Protection terminals 10 and 15. Relay contact type: normally closed. Switching temperature: 150 °C. Table 60. Vacon RLC technical data 10.6.5 Removing discharging resistors If the filter is used in a network fitted with an earth fault protection relay, the discharging resistors should be removed.
  • Page 160 • 158 ACTIVE FRONT END (NXA) 3074_uk Figure 91. Wiring diagram of the alternative discharging circuit configuration Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 161: Removing Hf Capacitors

    ACTIVE FRONT END (NXA) vacon • 159 10.6.6 Removing HF capacitors If a PWM modulated rectifier from another manufacturer is connected to the same input transformer, the capacitors must be removed! Otherwise the capacitors must not be removed. Figure 92 and Figure 93 have a red marking on the lead that has to be removed from each capacitor if the interference suppression capacitors are not to be used.

  • Page 162: Active Front End - Fuse Selection

    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 Plc will not assume any responsibility for damages caused by insufficient protection. The warranty becomes void if the drive is not equipped with appropriate fuses.
  • Page 163 CH64 2300 2300 DIN3 PC73UB69V1250PA PC33UD69V1250TF PC47UD70V36CP50 9 (3 Table 62. Fuse sizes for Vacon NX AFE units (525—690 V) DIN43620 TTF threaded TTF threaded end Qty. of end "7X" or size Chassis Type contacts in size 83 fuses /...

  • Page 164: Pre-Charcing Circuit

    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 Vacon's standard pre-charging circuits are shown in Table 63. Pre-charging circuits are suitable for 380-500 Vac and 525-690 Vac.
  • Page 165 ACTIVE FRONT END (NXA) vacon • 163 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 circuit-breaker or contactor as well as the pre-charging circuit contactor must be connected as shown in Figure 94.
  • Page 166 • 164 ACTIVE FRONT END (NXA) 3078.emf 11402 uk Figure 95. Wiring diagram for control unit Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 167: Parelling

    Vacon's standard LCL filters must be used for paralleling. If filters other than Vacon's 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.

  • Page 168: Common Pre-Charging Circuit

    • 166 ACTIVE FRONT END (NXA) 10.10 Common pre-charging circuit In case of paralleled Active Front End units, one common pre-charging circuit can be used, see Figure 96. Standard pre-charging circuits can be used if the capacitance of the intermediate circuit not exceeds maximum value.

  • Page 169: Each Active Front End Unit Has The Pre-Charcing Circuit

    ACTIVE FRONT END (NXA) vacon • 167 10.11 Each Active Front End unit has the pre-charcing circuit Each Active Front End can have an own pre-charging circuit, and each unit is controlling it’s own pre-charging and main contactor, see Figure 97. One control switch can be used but if an Active Front End unit needs to be controlled independently, separate switches are needed.

  • Page 170: Brake Chopper Unit (Nxb)

    11.1 Introduction The Vacon NXB (Brake chopper unit) is a unidirectional power converter for the supply of excessive energy from a common DC bus drive line-up to resistors where the energy is dissipated as heat. External resistors are needed. The NXB improves the DC-link voltage controllability as well as enhances the motor drives performance in dynamic applications.

  • Page 171: Nxb Topologies And Connection

    V/L2 Resistor Unnecessary energy is burnt off W/L3 11403_uk Figure 99. Brake chopper unit topology Resistor U/T1 V/T2 W/T3 Resistor 11404_uk Figure 100. Vacon Brake Chopper Unit connections Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 172: Brake Chopper Unit Technical Data

    BRAKE CHOPPER UNIT (NXB) 11.4 Brake chopper unit technical data *) NX_8 AC drives only available as Ch6x AFE/BCU/INU units. Table 65. Technical specification for Vacon NXB liquid-cooled brake chopper unit Input voltage U NX_5: 400…500 VAC (–10%…+10%); 465…800 VDC (–0%…+0%) NX_6: 525…690 VAC (–10%…+10%);...
  • Page 173 BRAKE CHOPPER UNIT (NXB) vacon • 171 Table 65. Technical specification for Vacon NXB liquid-cooled brake chopper unit Vibration 5…150 Hz EN 50178/EN 60068-2-6 Displacement amplitude 0.25 mm (peak) at 3…31 Hz Max acceleration amplitude 1 G at 31…150 Hz...
  • Page 174 • 172 BRAKE CHOPPER UNIT (NXB) Table 65. Technical specification for Vacon NXB liquid-cooled brake chopper unit Allowed cooling agents Drinking water (see specification on page 46) Water-glycol mixture See derating specifications, Chapter 5.3. Volume See page 51. Temperature of cooling 0…35 °C (Ibr)(input);...

  • Page 175: Bcu Power Ratings

    BRAKE CHOPPER UNIT (NXB) vacon • 173 11.5 BCU power ratings 11.5.1 Vacon NXB; DC voltage 460–800 V Table 66. Power ratings of Vacon NXB, supply voltage 460–800 Vdc Braking voltage 460-800 VDC Loadability Braking capacity BCU rated Rated min...

  • Page 176: Vacon Nxb; Dc Voltage 640-1100 V

    • 174 BRAKE CHOPPER UNIT (NXB) 11.5.2 Vacon NXB; DC voltage 640–1100 V Table 67. Power ratings of Vacon NXB, supply voltage 640–1100 Vdc Braking voltage 640-1100 VDC ***) Loadability Braking capacity BCU rated Rated min Rated min Rated Rated cont.

  • Page 177: Vacon Brake Resistors And Brake Chopper Dimensioning

    • 175 11.6 Vacon brake resistors and brake chopper dimensioning 11.6.1 Braking energy and losses Table 68. Vacon standard brake resistors and NXB energy, mains voltage 465–800 Vdc Mains voltage 465-800 VDC BCU output Chassis Power loss at full...

  • Page 178: Braking Power And Resistance, Mains Voltage 380-500 Vac/600-800 Vdc

    • 176 BRAKE CHOPPER UNIT (NXB) c = power loss into coolant; a = power loss into air; T = total power loss; power losses of input chokes not included. All power losses obtained using max. supply voltage and switching frequency of 3.6 kHz and Closed- Loop control mode.
  • Page 179 BRAKE CHOPPER UNIT (NXB) vacon • 177 Table 72. Minimum resistance Minimum resistance at DC-link voltages [ohm] Thermal Chassis NXB unit current [Ith] NXB 0031_5 19,5 20,6 21,6 22,6 23,6 24,7 25,7 NXB 0061_5 10,4 11,0 11,5 12,0 12,5 13,1...

  • Page 180: Braking Power And Resistance, Mains Voltage 525-690 Vac/840-1100 Vdc

    • 178 BRAKE CHOPPER UNIT (NXB) 11.6.3 Braking power and resistance, mains voltage 525–690 Vac/ 840–1100 Vdc Table 74. Voltage levels Default +18% DC-link voltage level for braking Voltage 708,8 742,5 776,3 850,5 931,5 +18% 1004 1051 1099 Table 75. Maximum braking power...
  • Page 181 BRAKE CHOPPER UNIT (NXB) vacon • 179 Table 77. Maximum resistance Maximum resistance at DC-link voltages [ohm] Thermal Chassis NXB unit current [Ith] 1004 1051 1099 1136 * Ch62 NXB 0325_6 12,9 13,5 14,1 14,7 15,4 16,2 16,9 17,5 Ch62...

  • Page 182: Brake Chopper Unit - Fuse Selection

    • 180 BRAKE CHOPPER UNIT (NXB) 11.7 Brake chopper unit – Fuse selection Table 78. BCU fuse selection, mains voltage 465–800 Vdc "TTF" threaded end "TTQF" threaded end DIN43620 "7X" or size 83 with end size84 or "PLAF" 2x84 Min res.
  • Page 183 BRAKE CHOPPER UNIT (NXB) vacon • 181 Table 79. BCU fuse selection, mains voltage 640–1100 Vdc "TTF" threaded end "TTQF" threaded end DIN43620 "7X" or size 83 with size84 or "PLAF" 2x84 Min res. end contacts with end contacts Chass...

  • Page 184: Appendices

    • 182 APPENDICES APPENDICES Appendix 1 Vacon NXW frequency converter and inverter main circuit and control diagrams CH3, FC B+ / R+ DC + U / T1 Skiip Skiip V / T2 81...83 81...83 W / T3 DC -...
  • Page 185 APPENDICES vacon • 183 CH5, FC SKiM 5 U / T1 V / T2 W / T3 X10 X11 X13 MEASUREMENTS K1, K2, K3 DC + + 24 V DC - RECTIFIER BOARD POWER BOARD FIBER ADAPTER BOARD H1...H7 CONTROL BOARD...
  • Page 186 • 184 APPENDICES CH61, FC, CONTROL ASIC BOARD DC + DC - RECT / X13 CONTROL UNIT DRIVER / X13 CONTROL DRIVER / X14 PANEL DRIVER / X15 DRIVER / H4 DRIVER / H5 DRIVER / H6 OPTO DRIVER / H7...
  • Page 187 APPENDICES vacon • 185 CH61, INVERTER, CONTROL ASIC BOARD DC + DC - CONTROL UNIT DRIVER / X13 CONTROL DRIVER / X14 PANEL DRIVER / X15 DRIVER / H4 DRIVER / H5 DRIVER / H6 OPTO DRIVER / H7 ADAPTER...
  • Page 188 • 186 APPENDICES CH62, INVERTER, CONTROL ASIC BOARD DC + DC - CONTROL UNIT DRIVER / X13 CONTROL DRIVER / X14 PANEL DRIVER / X15 DRIVER / H4 DRIVER / H5 DRIVER / H6 OPTO DRIVER / H7 ADAPTER...
  • Page 189 APPENDICES vacon • 187 CH63, FC, MODULE 2 V / T2 W / T3 MEASUREMENT BOARD 2 MEASUREMENT BOARD 3 DRIVER BOARD V DRIVER BOARD W With SPU-024 option only X1/+ and X15/+: connected to DC+ if SPU-024 not in use...
  • Page 190 • 188 APPENDICES U / T1 CH63, INVERTER, MODULE 1 MEASUREMENT BOARD 1 DRIVER BOARD U 11417_uk V / T2 W / T3 CH63, INVERTER, MODULE 2 MEASUREMENT BOARD 2 MEASUREMENT BOARD 3 DRIVER BOARD V DRIVER BOARD W...
  • Page 191 APPENDICES vacon • 189 CH63, INVERTER, CONTROL ASIC BOARD DC + DC - CONTROL UNIT DRIVER U / X6 CONTROL DRIVER V / X2 PANEL DRIVER W / X6 DRIVER U / H15 DRIVER U / H16 DRIVER V / H2...
  • Page 192 • 190 APPENDICES CH64, INVERTER, CONTROL ASIC BOARD DC + DC - Charge fb PHASE DRIVER / X1 MODULE CONTROL UNIT DRIVER / H2 CONTROL DRIVER / H4 PANEL DRIVER / X1 PHASE MODULE DRIVER / H2 DRIVER / H4...
  • Page 193 APPENDICES vacon • 191 CH72, FC, CONTROL ASIC BOARD DC + DC - RECT / X13 DRIVER / X13 CONTROL UNIT CONTROL DRIVER / X14 PANEL DRIVER / X15 DRIVER / H4 DRIVER / H5 DRIVER / H6 OPTO DRIVER / H7...
  • Page 194 • 192 APPENDICES ASIC CH74, FC, CONTROL BOARD DC + DC - Charge fb RECT / X13 PHASE DRIVER / X1 MODULE CONTROL UNIT DRIVER / H2 CONTROL DRIVER / H4 PANEL DRIVER / X1 PHASE MODULE DRIVER / H2...
  • Page 195 APPENDICES vacon • 193 Appendix 2 OETL2500 + OFAX3 + Charging circuit for NX liquid-cooled inverters 1640_5 to 2300_5 (3 dia- grams) MAIN CIRCUIT 500V 400 VAC aux L1 aux L2 -F2.1 /5-3C DC+ /5-3C DC- DC+ DC- DC+ DC-...
  • Page 196 • 194 APPENDICES CONTROL UNIT /1-1B 24 VDC SUPPLY -KENTTÄ-Q2 -W13 +10Vref AIA1+ AIA1- AIA2+ AIA2- +24V DIN1 DIN2 DIN3 +24V DIN4 DIN5 DIN6 AOA1+ AOA1- DOA1 ABCD ABCD -A16 -A11 VACON-03-A1: RO1 NC RO1 C RO1 NO RO2 C...
  • Page 197 The physical size of the fuse is chosen on the basis of the fuse current: Current < 400 amps (size 2 fuse or smaller), current < 400 amps (size 3 fuse). Table 80. Fuse sizes (Bussman aR) for Vacon NX Liquid-Cooled (500 V) frequency converters DIN43653 DIN43653 Qty.
  • Page 198 • 196 APPENDICES Table 80. Fuse sizes (Bussman aR) for Vacon NX Liquid-Cooled (500 V) frequency converters DIN43653 DIN43653 Qty. of DIN43620 Fuse Fuse (80mm) (110mm) fuses per Chassis Type Ith phase aR fuse Fuse aR fuse Fuse aR fuse...
  • Page 199 APPENDICES vacon • 197 Table 81. Fuse sizes (Bussman aR) for Vacon NX Liquid-Cooled (690 V) frequency converters DIN43653 DIN43653 Qty. of DIN43620 (80mm) (110mm) Fuse Fuse fuses Chassis Type aR fuse Fuse aR fuse Fuse aR fuse Fuse phase part nr.
  • Page 200 • 198 APPENDICES Table 82. Fuse sizes (Bussman aR) for Vacon NX Liquid-Cooled (450—800 V) inverters DIN43653 DIN43653 DIN43620 Fuse Fuse Qty. of (80mm) (110mm) Chassis Type fuses/ aR fuse Fuse aR fuse Fuse aR fuse Fuse pole part nr.
  • Page 201 APPENDICES vacon • 199 Table 83. Fuse sizes (Bussman aR) for Vacon NX Liquid-Cooled (640—1100 V) inverters DIN43620 DIN43653 (110mm) Fuse Fuse Qty. of fuses/ Chassis Type aR fuse Fuse aR fuse pole Fuse size part nr. size part nr.
  • Page 202 • 200 APPENDICES Table 84. Fuse sizes (Bussman aR) for Vacon NX AFE units (380—500 V) DIN43653 DIN43653 DIN43620 Fuse Fuse Qty. of (80mm) (110mm) Chassis Type fuses / aR fuse Fuse aR fuse Fuse aR fuse Fuse phase 3~ part nr.
  • Page 203 APPENDICES vacon • 201 Table 85. Fuse sizes (Bussman aR) for Vacon NX AFE units (525—690 V) DIN43620 DIN43653 (110mm) Qty. of Fuse Fuse Type fuses / aR fuse Fuse aR fuse Chassis Fuse size phase 3~ part nr. size part nr.
  • Page 204 • 202 APPENDICES Table 86. Brake chopper unit fuse selection (Bussman aR), mains voltage 465–800 Vdc DIN43620 Min resistor Qty. of Braking Fuse Fuse Chassis Type value, 2* fuses per aR fuse Fuse current [ohm] pole part nr. size...
  • Page 205 Document ID: Rev. D Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

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