Danfoss VACON NXP Air cooled User guide

user manual

non-regenerative front end unit (nfe)

ac drives

vacon

®

nxn

AT LEAST THE 11 FOLLOWING STEPS OF THE

START-UP QUICK GUIDE

MUST BE PERFORMED DUR-

ING THE INSTALLATION AND COMMISSIONING.

IF ANY PROBLEMS OCCUR, PLEASE CONTACT YOUR LOCAL DISTRIBUTOR.

Start-up Quick Guide

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

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

in Chapter 1.2

3. Before the mechanical installation, check the minimum clearances around the

unit and check the ambient conditions in Chapter 5

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

fuses, DC fuses and check the cable connections.

5. Follow the installation instructions, see Chapter 5.

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

7. All parameters have factory default values. No any changes need to make for

proper operation.

8. The VACON

®

NX Non-Regenerative Front End is now ready for use.

Vacon Ltd is not responsible for the use of the Non-Regenerative Front End against

the instructions.

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Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

CONTENTS

VACON

®

NXN USER MANUAL

INDEX

1 SAFETY

2 EU DIRECTIVE

3 RECEIPT OF DELIVERY

4 Non-REGENERATIVE FRONT END UNIT (NFE)

5 INSTALLATION

6 CONTROL KEYPAD

7 APPENDICES

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1

ABOUT THE VACON

®

NXN USER'S MANUAL

Congratulations for choosing VACON

®

NX Non-Regenerative Front End!

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

and operation of VACON

®

NX Non-Regenerative Front End. We recommend that you carefully study these

instructions before powering up the Non-Regenerative Front End for the first time.

In the Non-Regenerative Front End Application Manual you will find information about the Non-

regenerative Front End application. Should that application not meet the requirements of your process,

please contact the manufacturer for information on special application.

This manual is available in both paper and electronic editions. We recommend you to use the electronic

version if possible. If you have the electronic version at your disposal, you will be able to benefit from the

following features:

The manual contains several links and cross-references to other locations in the manual, which makes it

easier to move around in the manual. The reader can thus easily find and check things.

The manual also contains hyperlinks to web pages. To visit these web pages through the links, you must

have an internet browser installed on your computer.

This manual is applicable only for Non-Regenerative Front End unit, AC choke and optional components

that are introduced in this manual.

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Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

VACON

®

NXN User Manual

Table of contents

Document code: DPD01172C

Date edited: 30.01.2019

1. Safety ............................................................................................................................ 6

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

1.2 Safety Instructions ........................................................................................................................ 6

1.3 Grounding ...................................................................................................................................... 6

1.4 Warning symbols ........................................................................................................................... 7

2. EU directive ................................................................................................................... 8

2.1 CE marking .................................................................................................................................... 8

2.2 EMC directive ................................................................................................................................. 8

2.2.1 Introduction........................................................................................................................... 8

2.2.2 Technical criteria .................................................................................................................. 8

2.2.3 VACON

®

Non-Regenerative Front End EMC classification ............................................... 8

2.2.4 .......................................................................... 8

3. Receipt of delivery ....................................................................................................... 10

3.1 Type designation code for the NFE unit ..................................................................................... 10

3.2 Type designation code for the AC choke .................................................................................... 12

3.3 Storage ......................................................................................................................................... 12

3.4 Maintenance ................................................................................................................................ 12

3.5 Lifting the modules ..................................................................................................................... 13

3.6 Lifting the AC choke .................................................................................................................... 14

3.7 Warranty ...................................................................................................................................... 14

4. Non-Regenerative Front End (NFE) .............................................................................. 15

4.1 Introduction ................................................................................................................................. 15

4.2 Non-Regenerative Front End enclosure sizes .......................................................................... 17

4.3 Non-Regenerative Front End unit technical data ..................................................................... 18

4.4 Application ................................................................................................................................... 19

4.5 Diagrams...................................................................................................................................... 19

4.5.1 Connection between control unit and power unit ............................................................ 19

4.6 Non-Regenerative Front End power ratings ............................................................................. 20

4.6.1 VACON

®

NXN; DC voltage 460 800V ................................................................................. 20

4.6.2 VACON

®

NXN; DC voltage 640 1100V ............................................................................... 20

4.7 Non-Regenerative Front End unit Dimensions ...................................................................... 20

4.8 AC choke Dimensions .............................................................................................................. 20

4.9 Non-Regenerative Front End Fuse selection ......................................................................... 21

4.9.1 Introduction......................................................................................................................... 21

4.9.2 Fuses; mains voltage 380 690V ........................................................................................ 21

4.9.2.1 AC fuses........................................................................................................................ 21

4.9.2.2 DC fuses ....................................................................................................................... 21

4.10 Non-Regenerative Front End unit Circuit breaker selection ................................................ 21

4.11 Non-Regenerative Front End unit Main contactor ................................................................. 22

4.12 Pre-Charging and start up.......................................................................................................... 22

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1

4.13 Paralleling ................................................................................................................................... 22

4.14 12-pulse solution ......................................................................................................................... 23

4.15 Derating ....................................................................................................................................... 23

4.15.1 As the Ambient Temperature ............................................................................................ 23

4.15.2 As the Installation altitude ................................................................................................. 25

5. Installation .................................................................................................................. 27

5.1 Mounting ...................................................................................................................................... 27

5.1.1 Non-Regenerative Front End Unit..................................................................................... 27

5.1.2 AC choke ............................................................................................................................. 28

5.1.3 Control Box ......................................................................................................................... 29

5.2 Cooling ......................................................................................................................................... 29

5.2.1 Non-Regenerative Front End unit .................................................................................... 29

5.2.2 AC choke ............................................................................................................................. 31

5.2.3 Arranging ventilation of the enclosure ............................................................................. 32

5.2.4 Steering air flow ................................................................................................................. 34

5.3 Power connection ........................................................................................................................ 35

5.3.1 AC connection ..................................................................................................................... 35

5.3.2 DC connection ..................................................................................................................... 36

5.4 Cable installation and the UL standards ................................................................................... 36

5.5 I/O terminals and I/O signals ...................................................................................................... 37

6. Control keypad ............................................................................................................. 40

6.1 Navigation .................................................................................................................................... 41

6.1.1 Monitoring menu ................................................................................................................ 41

6.1.2 Parameter menu ................................................................................................................ 42

6.1.3 Fault history menu ............................................................................................................. 44

6.1.4 System menu ...................................................................................................................... 46

7. Appendices .................................................................................................................. 47

Safety vacon 6

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1

1. SAFETY

1.1 Warnings

WARNING

1

The components of the power unit circuit are live when the Non-

Regenerative 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.

2

The control I/O-terminals are isolated from the mains potential. Howev-

er, the relay outputs and other I/O-terminals may have dangerous control

voltage present even when the Non-Regenerative Front End is discon-

nected from the AC supply.

3

Do not touch the components on the circuit boards. Static voltage dis-

charge may damage the components.

1.2 Safety Instructions

1

The Non-Regenerative Front End, AC choke and optional components are

meant for fixed installations only.

2

Do not perform any measurements when the Non-Regenerative Front

End is connected to the AC supply.

3

After having disconnected the Non-Regenerative Front End from the AC

supply, wait until the fan stops. Wait 5 more minutes before doing any

work on the Non-Regenerative Front End connections. Do not even open

the cover before this time has expired.

4

Do not perform any voltage withstand tests on any part of the Non-

Regenerative Front End. There is a certain procedure according to which

the tests must be performed. Ignoring this procedure may result in dam-

aged product.

5

Before connecting the Non-Regenerative Front End to AC supply, make

sure that the Non-Regenerative Front End front and cable covers are

closed.

6

Before doing any work on Common DC bus, system must be grounded.

1.3 Grounding

The Non-Regenerative Front End unit and AC choke must always be grounded with an grounding

conductor connected to the grounding terminal.

ONLY A COMPETENT ELECTRICIAN MAY CARRY OUT

THE ELECTRICAL INSTALLATION

!

vacon 7 Safety

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1

1.4 Warning symbols

For your own safety, please pay special attention to the instructions marked with the following sym-

bols:

=

Dangerous voltage

WARNING

=

General warning

HOT SURFACE

=

Hot surface Risk of burn

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

and caution information from https://www.danfoss.com/en/service-and-support/.

REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit

sur le site https://www.danfoss.com/en/service-and-support/.

EU directive vacon 8

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

2

2. EU DIRECTIVE

2.1 CE marking

The CE marking on the product guarantees the free movement of the product within the EEA (Euro-

pean Economic Area). It also guarantees that the product complies with applicable directives (for

example, the EMC directive and other possible so-called new method directives). VACON

®

NX Non-

Regenerative Front End carries the CE label as a proof of compliance with the Low Voltage Directive

(LVD) and the Electro Magnetic Compatibility (EMC) directive. SGS FIMKO has acted as the Notified

Body.

2.2 EMC directive

2.2.1

Introduction

The EMC Directive provides that the electrical apparatus must not excessively disturb the environ-

ment it is used in, and, on the other hand, it must have an adequate level of immunity toward other

disturbances from the same environment.

The compliance of VACON

®

NX Non-Regenerative Front End with the EMC directive is verified with

Technical 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 Non-

Regenerative Front End with the Directive because it is impossible to test such a large product fami-

ly in a laboratory environment and because the combinations of installation vary greatly.

2.2.2

Technical criteria

Our basic idea was to develop a range of VACON

®

NX Non-Regenerative Front End offering the best

possible usability and cost efficiency. EMC compliance was a major consideration from the outset of

the design.

2.2.3

VACON

®

Non-Regenerative Front End EMC classification

Factory delivered VACON

®

NX Non-Regenerative Front End are Class T equipment, which fulfills all

EMC immunity requirements (standard EN 61800-3).

Class T:

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

2.2.4

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

the compliance of VACON

®

NX Non-Regenerative Front End with the EMC-directives.

Warning: This product is of the restricted sales distribution class according to IEC 61800-3. In resi-

dential areas, this product may cause radio interference in which case the user may be required to

take adequate measures.

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2

Receipt of delivery vacon 10

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3

3. RECEIPT OF DELIVERY

VACON

®

NX Non-Regenerative Front End has undergone scrupulous tests and quality checks at the

factory before they are delivered to the customer. However, after unpacking the product, check that

no signs of transportation damage are to be found on the product and that the delivery is complete

(compare the type designation of the product to the codes below, see Figure 3-1 and Figure 3-2).

Should the product have been damaged during the shipping, please contact primarily the cargo in-

surance company or the carrier.

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

3.1 Type designation code for the NFE unit

In VACON

®

type designation code for Common DC Bus components, the Non-Regenerative Front End

Unit is characterized by letter N and letter N or S. If the Non-Regenerative Front End unit is ordered

by letter N delivery is not include anything else than the unit itself. If letter S is used delivery include

the unit, the AC choke.

NOTE! Delivery does NOT include any auxiliary devices which are needed for proper operation (the

AC or DC fuses, the fuses bases, the main contactor or circuit breaker etc.) The customer must take

care of them.

vacon 11 Receipt of delivery

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3

Figure 3-1. Type designation code for the Non-Regenerative Front End.

Receipt of delivery vacon 12

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3

3.2 Type designation code for the AC choke

AC choke has one version which is suitable for 380-500V and 525-690V voltages.

Figure 3-2. Type designation code for the AC choke.

3.3 Storage

If VACON

®

NX Non-Regenerative Front End is to be stored before use, make sure that the ambient

conditions are acceptable:

Storage temperature °C

Relative humidity <95%, no condensation

3.4 Maintenance

All technical devices, drives as well, need a certain amount of care-taking and failure preventive

maintenance. To maintain trouble-free operation of the VACON

®

NX Non-Regenerative Front End,

environmental conditions, as well as load, line power, process control, etc. have to be within specifi-

cations, determined by manufacturer.

If all conditions are in accordance with the manufacturer's specifications, there are no other con-

cerns, but to provide a cooling capacity high enough for the power- and control circuits. This re-

quirement can be met by making sure, that the cooling system works properly. Operation of cooling

fans and cleanness of the heat sink should be verified regularly.

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

®

NX Non-Regenerative Front End. At least the following things should be included in the regular

maintenance.

vacon 13 Receipt of delivery

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

3

Table 3-1. Maintenance interval

It may also be necessary to check the tightening torques of terminals at certain intervals.

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

maintenance. It may also be necessary to check the tightening torques of terminals at certain inter-

vals.

3.5 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 45 degrees. For enclosures FI9, see Figure 3-3.

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

Figure 3-3. Lifting points for FI9 module.

Receipt of delivery vacon 14

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3

3.6 Lifting the AC choke

The AC choke can be lifted by the holes on top. Place the lifting hooks symmetrically in two holes.

The maximum allowed lifting angle is 45 degrees. Lifting points for the AC choke, see Figure 3-4.

Figure 3-4. Lifting points for AC choke.

3.7 Warranty

Only manufacturing defects are covered by the warranty. The manufacturer assumes no responsibil-

ity for damages caused during or resulting from transport, receipt of the delivery, installation, com-

missioning or use.

The manufacturer shall in no event and under no circumstances be held responsible for damages

and failures resulting from misuse, wrong installation, unacceptable ambient temperature, dust,

corrosive substances or operation outside the rated specifications.

Neither can the manufacturer be held responsible for consequential damages.

The Manufacturer's warranty period is 18 months from the delivery or 12 months from the commis-

sioning whichever expires first (General delivery terms NL92/Orgalime S92).

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. The manufacturer assumes no responsibility

for any other warranties than that granted by the manufacturer itself.

In all matters concerning the warranty, please contact your distributor first.

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4

4. NON-REGENERATIVE FRONT END (NFE)

4.1 Introduction

The VACON

®

NX Non-Regenerative Front End is used to transfer power between the AC input and

intermediate DC circuit. The VACON

®

NX Non-Regenerative Front End has only a one-way function.

This means that power can only be transferred from the AC input to the intermediate DC circuit. If

braking is needed, brake chopper has to be connected to the intermediate DC circuit.

In a typical VACON

®

NX Non-Regenerative Front End configuration, the desired number of Inverters,

Figure 4-1, are connected to the intermediate DC circuit.

The Non-Regenerative Front End configuration consists of the unit itself, AC choke, AC fuses, main

contactor and DC fuses, Figure 4-2.

Figure 4-1. Typical Non-Regenerative Front End configuration.

NFE*

3

FFE*

3

2

3

INU

2

3

INU

2

3

INU

2

BCU

AFE*

Common DC bus

* alternative

2 2 2

Non-Regenerative Front End (NFE) vacon 16

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4

Figure 4-2. VACON

®

Non-Regenerative Front End Single Unit connections

CLOSE

-RO2

26

24

25

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4

4.2 Non-Regenerative Front End enclosure sizes

Figure 4-3. VACON

®

NXN, FI9. Protection class IP00

Non-Regenerative Front End (NFE) vacon 18

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4

4.3 Non-Regenerative Front End unit technical data

Mains connection

Input voltage Uin

380 - 690 Vac; -15%...+10%, EN 60204-1

Input frequency

45…66 Hz

Continuous input current

IH: Ambient temperature max. +40°C,

overload 1.5 x IH (1 min./10 min.)

IL: Ambient temperature max. +40°C,

overload 1.1 x IL (1 min./10 min.)

Connection to mains

Unlimited (internal overload protections)

Current THD

Depend on additional chokes ( normal case < 40%)

Starting delay

Depend on dc bus capacitance (max 10 s)

Unexpected input power

break

Shorter breaks than 40ms works normally if DC does not drop

remarkably. Longer break means normal starting operation

(charging current varies according to load).

DC

connection

Output voltage Uout

465...800Vdc ( 380-500 Vac);

640...1100Vdc ( 525-690 Vac);

Efficiency

>98%

DC bank capasitance

6.8µF (included 10 M discharging resistor)

Control charac-

teristics

Control method

NFE is an independent power unit. Charging and protections

controlled by NFE itself.

Ambient condi-

tions

Ambient operating tempera-

ture

H

L

Storage temperature

–40°C…+70°C

Relative humidity

0 to 95% RH, non-condensing, non-corrosive,

no dripping water

Air quality:

- chemical vapours

- mechanical particles

IEC 721-3-3, unit in operation, class 3C2

IEC 721-3-3, unit in operation, class 3S2

Altitude

100% load capacity (no derating) up to 1,000 m

1-% derating for each 100m above 1000.; max. 2000m

Vibration

EN50178/EN60068-2-6

Displacement amplitude 0.

Shock

EN50178, EN60068-2-27

UPS Drop Test (for applicable UPS weights)

Storage and shipping: max 15 G, 11 ms (in package)

Cooling air required

1150 m

3

/h

Enclosure class

IP00/Open type standard size in the kW/HP range

EMC

(at default set-

tings)

Immunity

Fulfil all EMC immunity requirements. Can be chosen N-, L- or

T-level.

Safety

CE, UL, CUL

EN 61800-5-1 (2003); (see unit nameplate for more detailed

approvals)

Control connec-

tions

Display

LCD

Trip information

Relay I/O

Auxiliary voltage

+24 V, +/- 20%, max. load 50 mA

Analogue output

0(4)-20 mA, RL=500 Ohm

Digital output

Open collector, max. Load 48V/50 mA

Relay outputs

Max switching load: 250Vac/2A or 250Vdc/0.4 A

Protections

Unit over temperature pro-

tection

Trips if temperature rising over trip level (default)

Current measurement

Trips if current over trip level (default)

Supply phase supervision

Trips if any of the output phases is missing (default)

Table 4-1. Technical specification for VACON

®

NX Non-Regenerative Front End unit

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4

4.4 Application

The VACON

®

NX Non-Regenerative Front End needs a special application. The unit is delivered with

that application. If application code is needed please contact please contact the manufacturer. More

information about application can be found from this manual.

4.5 Diagrams

4.5.1

Connection between control unit and power unit

The communication connections between the Non-Regenerative Front End power unit and the

con-

trol unit

is established using serial cable, Figure 4-4. The control unit is located under the front cov-

er of the power unit. The control unit cannot place outside of the power unit.

Figure 4-4. NFE power and control connections.

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