4.15 Paralleling ........................41 Common pre-charging circuit ..................41 4.15.1 Each Active Front End unit has the pre-charging circuit ..........43 4.15.2 4.16 Derating ..........................44 Ambient Temperature ......................44 4.16.1 Installation altitude ......................44 4.16.2 Installation .....................46 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 2 Mounting ...........................46 5.1.1 Active Front End Unit .......................46 5.1.2 LCL filter ..........................48 5.1.3 Control Box ........................50 Cooling ..........................53 5.2.1 Active Front End unit ......................53 5.2.2 LCL filter ..........................57 5.2.3 Arranging ventilation of the enclosure ................60 5.2.4 Steering air flow .......................61 Power connection ......................64...
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10. Follow the commissioning instructions in the Active Front End Application Manual. ® 11. The Vacon NX Active Front End is now ready for use. Vacon Plc is not responsible for the use of the Active Front End against the instructions. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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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.
Please read the information included in cautions and warnings carefully. The cautions and warnings are marked as follow: Table 1. Warning signs DANGER! Dangerous voltage 9000.emf WARNING! or CAUTION! 13006.emf CAUTION! Hot surface 9001.emf 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 6 Safety Warnings The components of the power unit, LCL filter and pre-charging circuit are live when the Active Front End is connected to AC supply. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury. The control unit is isolated from mains potential.
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 NX Active Front End 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.
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Product name: Vacon NX Common DC bus Products Model designation: Vacon NXA 0004 5… to 2700 5 Vacon NXA 0004 6… to 2250 6 has been designed and manufactured in accordance with the following standards: Safety:...
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.
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, Figure 2. VACON LCL FILTERS FOR AFE - TYPE CODE VACON...
• 12 Receipt of delivery 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 Relative humidity <95%, no condensation When the Active Front End unit is stored without voltage being applied, the recharging of the capacitors should be done at least once a year by connecting voltage into the unit and keeping it powered at least for 1hour.
® Regular maintenance is recommended to ensure trouble free operation and long lifetime of Vacon NX Active Front End. At least the following things should be included in the regular maintenance. Table 3. Maintenance interval Interval...
• 14 Receipt of delivery 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 frames FI9 and FI10, see Figure 3 and for the frame FI13, see Figure 4.
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Receipt of delivery vacon • 15 11178.emf Figure 4. Lifting points for FI13 modules 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 16 Receipt of delivery 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.
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Receipt of delivery vacon • 17 11176.emf Figure 6. Lifting points for FI13 LCL filter 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
(Vacon PLC general terms and conditions of sale). The local distributor may grant a warranty time different from the above. This warranty time shall be specified in the distributor's sales and warranty terms. Vacon assumes no responsibility for any other warranties than that granted by Vacon itself.
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.
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• 20 Active Front End (AFE) Main Circuit -F1,1 +LCL-U1 +AFE-U1 XXXXX B+ B- -F2,1 11169.emf Figure 8. Vacon Active Front End Single Unit connections Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
IGBT V/T2 bridge W/T3 Power Measure- Driver supply ments ASIC Keypad Control Module RS-232 Control slot A slot B slot C slot D slot E 11170.emf Figure 9. NXA block diagram 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 22 Active Front End (AFE) Active Front End frame sizes 11174.emf Figure 10. Vacon NXA, FI9. Protection class IP00 11175.emf Figure 11. Vacon NXA, FI10. Protection class IP00 Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
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Active Front End (AFE) vacon • 23 11173.emf Figure 12. Vacon NXA, FI13. Protection class IP00 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 24 Active Front End (AFE) Active Front End unit technical data ® Table 4. Technical specification for Vacon NXA Active Front End unit Voltage U 380...500 Vac; 525...690 Vac; –10%…+10% AC input connection Frequency f 48–63 Hz Starting delay FI9–FI13: 5 s...
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NX-AFE itself. Input phase monitoring Trips if any of the input phases is missing. Protection Overcurrent protection Unit overheat protection Yes Short-circuit protection of +24 V and +10 V reference voltages 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 26 Active Front End (AFE) LCL filter technical data Table 5. Technical specifications for Vacon LCL filter for Active Front End units Voltage U Same as the unit Frequency f 50 or 60 Hz +2% AC connections Continuous output current...
• 27 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 Application User’s Manual. Diagrams 4.7.1 Connection between control unit and power unit...
• 28 Active Front End (AFE) Figure 15. Optical cable terminals in the unit (FI13 example) Optical terminals on adapter board Gate control enable Phase U control Phase V control Phase W control ADC synchronization VaconBus data from control board to ASIC...
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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. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 30 Active Front End (AFE) -FC1 MAINS I> I> I> BREAKER I>> I>> I>> -FC2.1 -FC2.2 GND/PE -FC2.3 SC FUSES -RF4 -FCD1 -FCD2 GND/PE GND/PE GND/PE -TB1 H1..H7 -FC3.1 -FC3.3 -FC3.5 -FC3.2 -FC3.4 -FC3.6 DC_BUS 7101.emf Figure 17. Wiring diagram of the default LCL filter...
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Figure 19 (for FI9 and FI10) and Figure 20 (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. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 32 Active Front End (AFE) Remove Remove 11253_A.emf Figure 19. HF capacitors in FI9 and FI10 LCL filter Remove Remove 11254_A.emf Figure 20. HF capacitors in FI13 LCL filter Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
Active Front End (AFE) vacon • 33 Active Front End power ratings 4.8.1 Vacon NXA; DC voltage 380–500 V Table 6. Power ratings of Vacon NXA, supply voltage 380–500 VAC Low oveload High oveload DC Power Unit (AC current) (AC current)
• 34 Active Front End (AFE) Active Front End unit – Dimensions Table 8. The NXA unit dimensions Module Module Dimension Type Frame Height [mm] Width [mm] Depth [mm] Weight [kg] 1030 FI10 1032 FI13 1032 NOTE! More detailed dimensions can be found Appendix 73, Appendix 74 and Appendix 75.
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.
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NXA_1300 5 FI13 170M6566 1250 3GKN/50 NOTE! All fuses are flush-end type. If some other type is needed, please contact Vacon. 4.11.3 Fuses; mains voltage 525–690 V 4.11.3.1 AC fuses Table 14. Ferraz Shawmut AC fuse selection, mains voltage 525–690 Vac...
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170M4926 1250 1GKN/75 NXA_0325 6 FI10 170M8507 1250 3GKN/75 NXA_1030 6 FI13 170M8510 1100 1000 3GKN/75 NOTE! All fuses are flush-end type. If some other type is needed, please contact Vacon. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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 18. Circuit breaker for Vacon NXA Type T5H400FF3LS...
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 20. Pre-charging circuits are suitable for 380-500 Vac and 525-690 Vac.
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 Parallel AFE between the Active Front End units.
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• 42 Active Front End (AFE) Main Circuit +LCL-U1 +LCL-U2 +AFE-U1 +AFE-U2 NXA xxxx x NXA xxxx x 11165.emf Figure 21. Active Front End units parallel connection with one common pre-charging circuit Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
Derating as a function of ambient tempera- ture +LCL-U2 +LCL-U1 +AFE-U1 +AFE-U2 NXA xxxx x NXA xxxx x 11166.emf Figure 22. Active Front End units parallel connection with own pre-charging circuits 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 44 Active Front End (AFE) 4.16 Derating The output power has to be derated if one of following cases: • Ambient temperature is more than 40 ºC. • 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.
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Loadability % 1000 1500 2000 2500 Installation altitude, m 11256.emf Figure 25. Derating as the installation altitude 525-690 V NOTE! If higher installation altitude is considered please contact Your nearest Vacon office. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 46 Installation NSTALLATION 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 (IP2x). The installation and mounting must comply with local laws and regulations.
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Installation vacon • 47 Figure 27. Mounting points of FI10 AFE unit 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 48 Installation Figure 28. 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 36. Follow the minimum dimensions for installation, see Table 23.
Figure 31 and Figure 32. 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 81.
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1. If the keypad sits in its place on the control unit, remove the keypad. 2. Connect the male end of the keypad cable to the D-connector of the control unit. Use Vacon RS232 cable included in the delivery. Figure 1.
NXA01300 5 NXA01030 6 A = free space above the unit = distance between inverter and cabinet wall = distance between two units C = free space underneath of the units 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 54 Installation 2x FI9/FI10 FI9/FI10 11215.emf Figure 33. Installation space for FI9, FI10 and FI13 Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
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Installation vacon • 55 Figure 34. Cooling airflow for FI9 and FI10 units 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 56 Installation Figure 35. Cooling airflow for the FI13 unit Table 22. Power losses and required cooling air for the Active Front End units Minimum air holes on Heat dissipation Cooling air required Type switchgear (input and output)
Table 22 and Table 24 must be followed. For instance, there could be two screened gaps as presented in Figure 39 (Vacon's recommendation). This layout ensures a sufficient air flow to the module fans as well as cooling of the additional components.
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 41. 11216.emf Figure 41. Roof structure seen from the side 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 62 Installation Sheet metal Shield Shield Front Shield Figure 42. Cabinet cooling airflow guides for FI9 and FI10 AFE unit and LCL filter Sheet metal Shield Front Shield Back Figure 43. Cabinet cooling airflow guides for FI13 AFE unit and LCL filter The sheet metal airflow guides (deflectors) marked in green prevents air circulation between different sections of the equipment.
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The materials used for preventing the circulation of air inside the equipment must be fire- restraining. 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. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 64 Installation 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 8.
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On the keypad, the fault “32 Fan Cooling” will be shown. Figure 44. Integrated DC/DC-power in the FI9 and FI10 LCL filter 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 66 Installation Figure 45. Integrated DC/DC-power in the FI13 LCL filter LCL filter with integrated DC-DC supply AFE unit (V phase in FI13) Tempe- X51: (4-pin) rature ...
Over- 4 = Over-temperature Control unit temperature protection protection switch DIN2 DIN3 DC supply 11164.emf (48 Vdc) Figure 48. Wiring diagram of external DC-power 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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® The control unit of Vacon NX Active Front End consists of the control board and option boards (see Figure 49 and Figure 50) connected to the five slot connectors (A to E) on the control board. The control board is connected to the power unit through a D connector (1).
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I/O and the relay terminals of the two basic boards, the general wiring diagram and the control signal descriptions. The I/O boards mounted at the factory are indicated in the type code. For more information on the option boards, see Vacon NX option board manual (ud741).
• 70 Installation Galvanic isolation barriers The control connections are isolated from the mains potential and the GND terminals are permanently connected to ground. See Figure 51. 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).
® The Vacon NX Active Front End is operable through the nine push-buttons of the control keypad. Furthermore, the buttons can be used in setting parameters and monitoring values. The keypad is detachable and isolated from the input line potential.
3062.emf Figure 52. 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.
= 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. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 74 Control Keypad Keypad push-buttons The Vacon NX alphanumeric control keypad has 9 push-buttons that are used for controlling ® Vacon NX Active Front End, setting parameters, and monitoring values. reset sele ct enter 11208.emf Figure 53. Keypad push-buttons 6.2.1...
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. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
• 76 Control Keypad READY R EADY R EADY I/Oterm I/O te rm I/O term Expander boards A:NXOPTA1 Parameters G1 G1 P1 P3 STOP R EADY STOP R EADY Change I/O te rm I/Ote rm enter...
6.3.2 Parameter menu (M2) ® Parameters are the way of conveying the commands of the user to Vacon NX Active Front End. 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 56.
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Pressing takes you back to the previous menu. Several parameters are locked, i.e. cannot be edited, when Vacon NX Active Front End is in RUN *Locked* status. If you try to change the value of such a parameter the text will appear on the display.
The fault remains active until it is cleared with the or with a reset signal from the I/O terminal. NOTE! Remove external Start signal before resetting the fault to prevent unintentional restart of the drive. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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 26. 11202.emf Figure 57. Fault display Table 26. Fault types...
- Check the correct amount and flow Overtemperature warning is issued of cooling air. overtemperature when the heatsink temperature - Check the heatsink for dust. exceeds 85 °C. - Check the ambient temperature. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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External fault Digital input fault. device. Check board and slot. Slot fault Defective option board or slot Contact the nearest Vacon distributor. Temperature limit values set for the PT100 fault Find the cause of temperature rise. PT100 have been exceeded. KLIXON Status of KLIXON input is LOW.
Enter button Pressing the for about 2 to 3 seconds resets the whole fault history. The symbol H# will change to 0. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 84 Control Keypad I/O term I/O ter m 5 ChargeSwitch Operation hours 13:25:43 READY READY READY I/Oterm I/Oterm I/Oterm Operation days Fault history 11 Output phase PUSH to reset enter 11200.emf Figure 58. Fault history menu 6.3.8...
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Fan control function Continuous Continuous Temperature P6.7.3 HMI acknowledgment 5000 P6.7.4 HMI: no. of retries S6.8 System information S6.8.1 Total counters C6.8.10.1. MWh counter C6.8.10.2. Operation day counter C6.8.1.3. Operation hour counter 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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.
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. Wait until 'OK' appears on the display. The procedure to download the parameters from keypad to Active Front End is similar to that of from Active Front End to keypad. See Figure 60. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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Select with the When the Parameter backup function is activated Vacon NX control keypad makes a copy of the parameters of the presently used application. When applications are changed, you will be asked if you wish the parameters of the new application to be uploaded to the keypad. If you want to do this,...
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Enter the edit mode by pressing Use the to change the Enter button parameter lock status. Confirm the change with the or go back to the previous level by pressing Menu button left. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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Figure 65. Activation of Start-up wizard Multimonitoring items (P6.5.4) Vacon NX alphanumeric keypad features a display where you can monitor up to three actual values at the same time (see Chapter 6.3.1 and Chapter Monitoring values in the manual of the application you are using).
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Menu button right . Set the desired timeout time and confirm it with Enter button Menu button left . You can return to the previous menu at any time by pressing 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
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• 92 Control Keypad READY READY READY CONFIRM CHANGE enter Timeout time Timeout time Timeout time CANCEL 90 s 90 s. 60 s. 11196.emf Figure 69. Timeout time setting Default page Timeout time NOTE! If the value is 0 the setting has no effect.
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