Frequency converter VAU 4/4 VAU(w) 7.5/3 VAU 11-22/3
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1 operating instructions Quick start guide Frequency converter VAU 4/4 VAU(w) 7.5/3 VAU 1122/ /15 1
2 Table of Contents 1. Safety information Warning symbols used General information Commissioning information Operating information Intended use Installation Connection space Connection Power line Signal terminals Relays RS485 interface Local operation and display Fault detection and removel Table of the LEDflash codes Table of possible error messages Technical specifications Interfaces Certifications Safety information 1.1 Warning symbols used Danger (general) Danger from electric shock and electrical discharge Danger from hot surfaces! 1.2 General information i i Detailed information can be found in the VAU 4/4, VAU(w) 7.5/3, VAU 1122/3 operating instructions.. Visit our homepage for this: IMPORTANT INFORMATION This quick start guide represents only an excerpt of the VAU 7.5/3 operating instructions. The latter should be read thoroughly before initial startup. The quick start guide contains safety instructions and helps the user to put the basic model of the VAU 7.5/3 into operation and to operate it with the default settings. The frequency converter can only be operated safely if the required ambient conditions, see chapter 4, have been complied with. Gebrüder BECKER GmbH will not be liable for damage resulting from the nonobservance of these operating instructions. These operating instructions form a part of the product. They apply exclusively to the frequency converter of the VAU series by Gebrüder BECKER GmbH. Store the operating instructions well accessible for all users near the frequency converter. 2
3 i IMPORTANT INFORMATION Any work concerning transport, installation and commissioning as well as maintenance may only be carried out by qualified specialists (observing IEC 364/CENELEC HD 384/DIN VDE 0100 and IEC 664/DIN VDE 0110 and national accident prevention regulations). Qualified personnel in the meaning of these operating instructions are electricians who are familiar with the installation, assembly, commissioning and operation of the frequency converter and the related risks. In addition they will have knowledge of the relevant standards and regulations based on their technical training. WARNING Mortal danger from fire or electric shock! Death or serious injury! Only use the frequency converter as intended. Do not perform any alterations on the frequency converter. Only use spare parts and accessories sold or recommended by the manufacturer. During assembly ensure adequate distance to adjacent components. CAUTION Risk of burns from hot surfaces! Serious skin burns from hot surfaces! The heat sink and all other metal components can heat up to temperatures exceeding 70 C. Adequate distance to adjacent components must be kept during assembly. When working on the components ensure sufficient cooling down times. Install a contact protection where appropriate. 1.3 Commissioning information Electrical connection Frequency converters are equipment items for use in industrial high voltage systems and are operated with voltages which may result in serious injury or death upon contact. They may only be installed or worked on by qualified electricians and with the equipment switched to zero potential. These individuals must always have access to the operating instructions which must be consistently observed by them. DANGER Mortal danger from electric shock! Death or serious injury! Switch the frequency converter to zero potential and protect it against reactivation. The following terminals may still carry dangerous voltages even with the motor at rest: mains connection terminals X1: L1, L2, L3 motor connection terminals X2: U, V, W connection terminals X6, X7: relay contacts relay 1 and 2 PTC/bimetallic switch connection terminals T1/T2 3
4 i IMPORTANT INFORMATION When working on live frequency converters the applicable national accident prevention regulations (e.g. VBG 4) must be observed. The local regulations for the installation of electrical systems and accident prevention regulations must be observed. The electrical installation must be carried out in accordance with relevant regulations (e.g. observe conductor cross sections, fuses, earth connections). If personal and fire protection is required when using the frequency converter, allcurrent sensitive fault current protection switches (residual current devices of type B) must be used (in accordance with DIN VDE 0160 and EN 50178). These offer reliable protection for the high frequency alternating currents occurring during FC operation and smooth and pulsating direct fault currents. Common fault current protection switches of type A are not approved. Only use permanently wired mains connections. Earth the frequency converter in accordance with DIN EN 61140; VDE Contact currents > 3.5 ma may occur in the VAU. In this case an additional protective earth conductor with the same cross section as the original earth conductor must be installed in accordance with DIN EN Whether the equipment concerned must be additionally earthed can be determined from the respective equipment instructions. The option for connecting a second protective earth conductor is found below the mains supply connection (marked with a mass symbol) on the outside of the equipment. The scope of delivery of the adapter plate includes a suitable M6x15 screw for the connection (torque 4.0 Nm). When using different voltage levels (e.g. +24V/ 230 V) crossing cables must always be avoided! The user must also ensure that the applicable regulations are complied with (e.g. double or reinforced insulation in accordance with DIN EN )! The circuit boards contain highly sensitive MOS semiconductor elements which are particularly sensitive to static electricity. Please avoid, therefore, touching the strip conductors or components with your hands or with metal objects. When connecting the conductors, only the screws of the terminal strips may be touched with insulated screwdrivers. In a residential environment this product may cause high frequency interference necessitating interference suppression measures! Information on the EMCcompliant installation, such as shielding, earthing and cable routing, can be found in the documentation of the frequency converters. This information must also be always observed for frequency converters bearing the CE mark. Adherence to the limits required by EMC legislation is the responsibility of the manufacturer of the plant or machine. 4
5 1.4 Operating information DANGER Mortal danger from electric shock! Death or serious injury! Due to charged capacitors the device might still carry dangerous voltage for up to 2 minutes 2 mim after disconnection from the mains. Touching exposed or open terminals, conductors and device components can lead to serious injury or death! Therefore, opening the device or removing the covers or control panel is only permitted 2 minutes after the device has been switched to zero potential. Even with the motor at rest (e.g. on account of an electronic lock, blocked drive or short circuited output terminal) the mains connection terminals, motor terminals and terminals for the brake resistance may still carry dangerous voltage. A shut down motor does not equate to an electrical separation from the mains. DANGER Mortal danger from rotating mechanical components! Death or serious injury! Under certain configurations the converter might automatically start after activation of the mains. Systems with frequency converters installed might need to be equipped with additional protective devices in accordance with the respective applicable safety regulations (e.g. laws on technical equipment, accident prevention regulations etc.). If the required covers are removed without authorisation or with incorrect use, installation or operation there is a risk of serious personal injury or property damage. All covers must be kept closed during operation. i IMPORTANT INFORMATION Please note the following information during operation: The frequency converter operates with high voltages. When operating electrical equipment, some components of this equipment inevitably carry dangerous voltages. The emergency stop facilities according to DIN EN ; VDE 01131: must remain operational during all operating modes of the control device. Resetting the emergency stop facility must not lead to uncontrolled or undefined reactivation. To ensure safe disconnection from the mains the mains supply cable to the frequency converter must be disconnected synchronously and at all poles. For VAU 1122/3 a pause of 1 to 2 min. must be adhered to between successive mains connections. Certain parameter settings may cause the frequency converter to automatically restart after a supply voltage failure. For a sound motor overload protection the motor parameters, in particular the I2T settings, must be configured correctly. The frequency converter does not provide internal motor overload protection. Motor overload protection can also be ensured using an external PCT/bimetallic switch. The frequency converter must not be used as an emergency stop facility (see DIN EN ; VDE 01131:200706). If the air is dusty, the cooling surfaces must be regularly cleaned. 5
6 1.5 Intended use i IMPORTANT INFORMATION The VAU frequency converter is a device for the speed control of three phase rotary current motors. The frequency converter can be used integrated into the motor (with standard adapter plate) or in close proximity to the motor (with wall mounting adapter plate). Frequency converters are components intended for installation in electrical systems or machinery. This frequency converter is not approved for operation in explosive areas! When they are installed in machinery, the commissioning of the frequency converters (i.e. the start of their intended operation) is prohibited until it has been determined that the machine complies with the provisions of applicable machinery directive including the EMC directive at the time of commissioning; EN60204 must be observed. The harmonised standards of the DIN EN 50178; VDE 0160: series in conjunction with DIN EN ; VDE : are applicable to this frequency converter. The frequency converters meet the requirements of the EC machinery directive 2006/42/EC. The technical data and information relating to the connection conditions can be found on the rating plate and in these instructions and must always be adhered to. Repairs may only be carried out by authorised repair centres. Independent unauthorised interventions may lead to death, personal injury and property damage. Such cases invalidate the warranty by Gebrüder BECKER GmbH. No external mechanical loads, e.g. stepping onto the housing, are permitted! VAU 4/4, VAU(w) 7.5/3, VAU 1122/3 First steps 2. Installation 2.1 Connection space After opening the terminal box cover you will find all the connection terminals of the frequency converter in the connection area. VAU 4/4 VAU(w) 7.5/3 Cable gland Mains cable connection L1, L2, L3, PE Brake module connection Relay Rel.2: Collective fault message (standard) Rel.1: Collective operating message (standard) Control terminal EMC cable gland RS485interface Connection socket for: PC (KombiTool) manual control unit (MMI) 6
7 VAU 1122/3 Cable gland Mains cable connection L1, L2, L3, PE Relay Rel.2: Collective fault message (standard) Rel.1: Collective operating message (standard) Motor connection U, V, W, PE PTC/bimetallicswitch connection Control terminal EMC cable gland RS485Interface Connection socket for: PC (KombiTool) manual control unit (MMI) Connection Power line VAU 4/4 und VAU(w) 7.5/3 Conductor crosssection of the mains power supply: 0,25 4 mm 2 (wireend ferrule with plastic shroud) Stripping length: 15 mm VAU 1122/3 Conductor crosssection of the mains power supply: 1,5 25 mm 2 (wireend ferrule with plastic shroud) Terminal Connection L1, L2, L3 Mains power supply phase L1, L2, L3 PE Mains power supply earth line PE Signal terminals Conductor crosssection of the signal lines: 0,51,0 mm 2 (wireend ferrule with plastic shroud) Stripping length: 910 mm Connection terminals of the bottom row of the doubledecker terminal block: Terminal Connection 10 V Out Int. voltage supply 24 V IN Ext. voltage supply GND (In) Ground (ext. voltage supply) GND Ground Analog Out 2 (0 V 10 V) Analog voltage output GND Ground GND Ground GND Ground Analog In 3 Analog input 3 Analog In 4 Analog input 4 7
8 Connection terminals of the top row of the doubledecker terminal block: Terminal Connection 24V Out Int. voltage supply Dig In 1 Digital input 1 (enable) Dig In 2 Digital input 2 Dig In 3 Digital input 3 Analog Out 1 (0V...10V) Analog voltage output 1 Analog Out 1 (0mA...20mA) Analog current output 1 RS 485 A(+) Serial interface RS485 line A RS 485 B() Serial interface RS485 line B Analog In 2 Analog input 2 Analog In 1 Analog input Relays Function Description The relays can be parametrised with different functions. Relay 1 Aggregated operation message (standard), AOM NO NC COM Relay 2 AEM Device stands still: The device is turning at a speed > 0: Aggregated error message (standard), Faultfree operation: Malfunction: COM NC COM NO COM NC COM NO NOTE All control voltages refer to a common reference potential (GND). 24 V can be taken from the respective terminals. The sum of the currents may not exceed 100 ma. 2.2 RS485 interface The RS485 interface is designed as a twowire model acc. to EIA RS485 (data lines A and B) and provides the communication with the frequency converter. Pin assignment M12 Description 4 3 M12: 1 24 V 2 RS 485 A(+) 3 GND RS 485 B() Pin (bus in) 8
9 2.3 Local operation and display The local operation of the device is done on the operating panel as shown. LEDs indicate the converter status RS485 interface Acknowledge button Malfunktion Potentionmeter for adjusting the setpoint Using the potentiometer (scale %), the current setpoint value can be increased or decreased. A malfunction can be acknowledged by pressing the Acknowledgement button. The two LEDs indicate the current converter state. 3. Fault detection and removal 3.1 Table of the LEDflash codes Red LED Green LED Status Operation With optional BUS module: BUS operation (active BUS connection) Malfunction further information see chapter 3.2 With optional BUS module: BUS module is ready for operation Initialisation Legend: fault see LED off, LED on, LED flashes, LED flashes quickly following table of possible fault messages KombiTool diagnosis or read out P Display handheld (MMI) 9
10 3.2 Table of possible error messages In case of a fault (red LED is permanently lit), the error is indicated via an extended flash code of the green LED. The green LED briefly flashes 110 times. At the end of the flash code there is a pause of 5 seconds before the code is repeated. The table below provides an overview. Error Error no. group KombiTool LED MMI Name Description Cause Cable break Current or voltage below Cable break, faulty or unconnected Analogue In 1 external sensor the lower limit of analogue (4..20mA/ 2 10V) input 1 1x 2x 3x 4x Cable break Analogue In 2 (4..20mA/ 2 10V) Alarm 1 system fault Alarm 2 system fault Current or voltage below the lower limit of analogue input 2 Customerspecific fault via the function of the digital inputs Customerspecific fault via the function of the digital inputs External fault 1 The parametrised error input (digital input) is active External fault 2 The parametrised error input (digital input) is active IGBT tripped Protection of the IGBT module against overcurrent has tripped Monitoring Maximum output current of the converter exceeded FC application overtemperature Motor overtemperature IGBT module overtemperature FC overtemperature Internal temperature too high Motor temperature monitoring with PTC/bimetallic switch has tripped Power module / IGBT module overtemperature Internal temperature too high Cable break, faulty external sensor dependent on the application dependent on the application Short circuit in the motor or motor supply cable / regulator settings Cooling insufficient / low speed and high torque / cycle frequency too high / ramp times too short / brake not released Cooling insufficient, low speed and high torque, cycle frequency too high. Motor overload (e.g. high torque at low speed / ambient temperature too high) Cooling insufficient, low speed and high torque, cycle frequency too high Cooling insufficient / low speed and high torque / cycle frequency too high / permanent overload Grid interruption A phase is missing/ mains voltage interrupted Earth leakage Earth leakage of a motor Insulation fault phase Motor connection interrupted No motor currecnt in spite of excitation by the FC No Motor connected or motor not fully connected. Legend: LED flashes, LED flashes rapidly 10
11 Error Error no. group KombiTool LED MMI Name Description Cause Bus Timeout Setpoint specification via Bus cable interrupted bus. No response from bus node or MMI / PC 5x Max autoacknowledgementmatic acknowledgements The number of max. auto (1,182) has been exceeded Blockage Motor blocked Mechanical fault or overload 6x 7x 8x 9x I2t motor protection shutdown The internal I2t motor protection has tripped Overload Max. overload of the frequency converter exceeded for more than 60 sec Intermediate circuit overvoltage Intermediate circuit undervoltage The maximum intermediate circuit voltage has been exceeded The minimum intermediate circuit voltage has been fallen below Supply voltage of application below 15V Supply voltage of application greater than 31V V application undervoltage V application overvoltage System fault No voltage is present at the power component Permanent overload Return feed from motor during generator operation / mains voltage too high / incorrect speed regulator configuration / brake resistance not connected or faulty / ramp times too short Mains voltage too low / mains connection faulty 24V supply overload Internal 24V supply faulty or external supply faulty Operation with 24 V without mains supply Legend: LED flashes, LED flashes rapidly 11
12 Error Error no. group KombiTool LED MMI Name Description Cause 3 System fault contact BECKER in case of 4 System fault contact BECKER in case of 5 System fault contact BECKER in case of 6 System fault contact BECKER in case of 7 System fault contact BECKER in case of Application The internal communication EMC faults communication<> power between the application and power circuit boards is faulty 9 System fault contact BECKER in case of 12 System fault contact BECKER in case of 10x 19 System fault contact BECKER in case of 20 System fault contact BECKER in case of 25 System fault contact BECKER in case of 37 System fault contact BECKER in case of 41 System fault contact BECKER in case of 44 System fault contact BECKER in case of 50 System fault contact BECKER in case of Distributor parameters Motor parameters Frequency converter parameters The internal distribution of the parameters during initialisation has failed Plausibility check of motor parameters has failed Plausibility check of frequency converter parameters has failed Rating plate data No valid motor rating plate data Legend: LED flashes, LED flashes rapidly Parameter record is incomplete Parameter record faulty Parameter record faulty Motor rating plate data not yet entered (delivery state) 12
13 4. Technical specifications Description \ size VAU 4/4 VAU(w) 7.5/3 VAU 1122/3 Typical motor output [kw] to be connected (4 pole asynchronous motor) 4 7, ,5 22 Mains voltage [V] 3~ % % 1) Mains frequency [Hz] 47 bis 63 Grid configuration TN / TT Mains current [A] 7,9 14,8 23,2 28,2 33,2 39,8 FC output current, eff. [A] [I N at 8 khz / 400 V] 9,5 17,8 28,0 34,0 40,0 48,0 Min. brake resistance [Ω] Max. overload 150 % of nominal current for 60 sec 130 % Switching frequency [khz] 4, 8, 16, (factory setting 8) Rotary field frequency [Hz] Protection function Over and undervoltage, I2t limitation, short circuit, motor/frequency converter temperature, tilt protection, stall protection Dimensions 270 x 189 x x223x x 294 x 232 [L x W x H] mm VAUw (307x223x155) Weight incl. adapter plate [kg] 5,0 8,7 21,0 Degree of protection [IPxy] EMC complied with according todin EN Interference emission: 1st environment category C2 Interference immunity: 2nd environment Vibration and shock resistance: DIN EN severity level 2 (vibration during transport) DIN EN (vertical impact test) Hz for sinusoidal oscillations. Ambient temperature [ C] 25 (without condensation) to + 50 (without derating) Cooling: Surface cooling: VAU 4/4 and VAU 7.5/3: free convection; VAU 7.5/3: optionally with integrated fan; VAU 1122/3: with integrated fan. Water cooling: VAUw 7.5/3: with integrated water cooler Relative humidity: 96%, condensation not permissible Altitude of installation location: up to 1000 m above MSL/ more than 1000 m with reduced output (1% per 100 m) (max m) Technical data for 400 V equipment (technical modifications reserved) 1) Approx. 50 % reduced supply feed possible (reduced output power) 13
14 5. Interfaces Inputs and outputs Digital input Analog input Relay 1; 2 Analog output 1 (current) Analog output1, 2 (voltage) Description Switching level Low < 5 V / High > 15 V I max (bei 24 V) = 3 ma R in = 8,6 kohm In +/ 10 V or 0 20 ma In 2 10 V or 4 20 ma Resolution 10 Bit Tolerance +/ 2 % Voltage input: R in = 10 kohm Current input: Load = 500 Ohm Change over contact (NO/NC/COM) Max. switching power for resistive load (cos φ = 1): 5 A at ~ 230 V or = 30 V for inductive load(cos φ = 0,4 und L/R = 7 ms): 2 A at ~ 230 V or = 30 V Max response time: 7 ms ± 0,5 ms Electrical lifetime: switching cycles 24 V DC fixed voltage output 10 V DC fixed voltage output Interface specification Short circuit proof I out = ma Load = 500 Ohm Tolerance +/ 2 % Short circuit proof U out = V Imax = 10 ma Tolerance +/ 2 % Auxiliary voltage U = 24 V DC Short circuit proof I max = 100 ma external supply of 24 V possible Auxiliary voltage U = 10 V DC Short circuit proof I max = 30 ma The frequency converters include the option to connect a motor temperature monitoring (PTC / bimetal). 6. Certifications European EMC guidelines If the frequency converters of the VAUseries are installed and operated according to the recommendations of these operating instructions, they fulfils all requirements of the EMC regulations according to the EMC product standards for motor driven systems EN
Frequency converters VAU 4/4 VAU(w) 7.5/3 VAU 11-22/3
Operating Instructions Frequency converters VAU 4/4 VAU(w) 7.5/3 VAU 11-22/3 28100241500 05/15 Contents 1 General information...4 1.1 Notes relating to the documentation...4 1.1.1 Warnings...4 1.1.2 Warning
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