Becker VariAir VAU 7.5/3 User manual

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28100241401 11/12
operating instructions
Frequency converter
VAU 7.5/3
QUICK START GUIDE

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Safety information
Warning of electrical shock! Danger to life!
Electrical shock can cause serious injury or even death of persons. The frequency converter
can be damaged as well.
Warning of danger of other types! Risk of injury!
Further sources of danger that can cause serious injury of persons. The frequency converter
can be damaged as well.
Warning of hot surfaces! Risk of injury!
Warning of automatic start-up of the machine!
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Detailed information can be found in the VAU 7.5/3 operating instructions.
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VAU 7.5/3 → First steps
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This quick start guide represents only an excerpt of the VAU 7.5/3 operating instructions. The
latter should be read thoroughly before initial start-up.
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.
Intended use
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Frequencyconvertersarecomponentsthatareintendedforinstallationintoelectricalsystems
or machines.
When being installed into machines, the commissioning of the converters (i.e. running in
normal operation) is not permitted until it has been determined that the machine at the date
ofcommissioningcomplieswiththe relevant machinery directive including the EMC directive;
EN 60204 must be observed.
The frequency converters comply with EC Machinery Directive 2006/42/EC.
The technical data as well as the specications of the technical connection conditions can be
found both on the specication plate and in this manual and must be observed.

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Preparatory measures
Alltasksfortransport,installationandcommissioningaswellasforservicingshouldbecarried
out by qualied technicians (IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664
or DIN VDE 0110 and national accident prevention regulations) .
Qualied technicians are persons that are familiar with the setting up, assembly, commis-
sioning and operation of the product and have the appropriate qualications for their tasks.
Setting up The setting up and the cooling of the devices need to be done according to the directives of
the corresponding pump documentation.
Thefrequencyconvertersneedto be protected against excessive strain. In particular, compo-
nentsmust neither be bent nor insulationdimensions changed during transport and handling.
Avoid touching electronic components and contacts.
Frequency converters contain electrostatically-endangered components that can be easily
damagedbyimproperhandling.Electricalcomponentsmustneither be damaged mechanically
nor destroyed (possible health hazard!).
Electrical connection
Frequency converters are components for use in industrial high-voltage systems and are
operated with voltages that can cause serious injuries or even death if touched.
Installations and maintenance may only be done by qualied electricians and when the
device is free of voltage. The operating instructions have to be available for these persons
at all times and be dutifully observed by them.
On the circuit boards there are highly sensitive MOS semiconductor devices that are es-
pecially sensitive to static electricity. Therefore, please avoid touching the circuit boards or
components with your hands or with metallic objects. Only the screws of the terminal strips
may be touched by insulated screwdrivers when wires are connected.
Thefrequency converter is intended forpermanent connection only and maynot be operated
without an effective earth connection that complies with the local regulations for high leakage
currents
(> 3.5 mA). VDE 0160 prescribes the laying of a second earth line or an earth cross-section
of at least 10 mm2.
If personal or re protection is required when using the FC, all-current sensitive residual-
current devices (type B RCD) must be used (in accordance with VDE 0664). They provide
reliable protection for the high-frequency AC currents and the smooth and pulsating DC re-
sidual currents that occur during FC operation. Conventional typeAresidual-current devices
are not suitable for this purpose.
When working on frequency converters that are electrically charged, the relevant national
accident prevention regulations must be observed.
The local regulations on installing electrical systems as well as the accident prevention re-
gulations must be observed.
The electrical installation is to be carried out according to the applicable regulations (e.g.
cable cross-sections, fuses, earth lines).
Information on EMC-compliant installation – such as insulation, earthing, arrangement of lters
and the laying of lines – can be found in the documentation for the frequency converters.
Always observe these instructions also with CE-marked frequency converters. The responsi-
bility of complying with the limits required by the EMC regulations lies with the manufacturer
of the system or machine.

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Operation During operation, frequency converters can have – depending on their type of protection –
electrically charged, uncovered, and possibly even moving or rotating parts, as well as hot
surfaces.
The device is charged with dangerous voltage for up to 5 minutes after being switched off.
Opening the device or removing the covers or the operating unit is not permitted until 5 mi-
nutes after the voltage to the device has been switched off. Before switching on the power
supply voltage all covers need to be reattached.
Even if the motor is at a standstill (for instance because of electronic blockage, blocked drive
or output terminal short circuit) the power cable terminals, motor terminals and terminals for
the brake resistor may still carry dangerous voltages. A motor standstill does not mean that
there is a galvanic separation from the mains.
Notice, under certain settings, the converter can start up automatically when switched on
from the mains side.
Systems into which the frequency converters are installed must, if necessary, be equipped
withadditionalmonitoring and protective devices according to the relevantsafetyregulations,
i.e. laws for technical tools and appliances, accident preventions regulations, and so forth.
Thereisariskof serious injury for persons or material damage if requiredcoversareremoved
without authorisation, if the device or its components are used improperly, or if installed or
operated incorrectly.
Electrically charged parts and line connections must not be touched directly after frequency
converters are disconnected from the supply voltage, as the capacitors may be charged.
Observe the corresponding signs about this on the frequency converters.
During operation all covers must be kept closed.
The frequency converter is maintenance-free under normal operating conditions. If the air is
dusty, the cooling surfaces should be cleaned regularly with compressed air.
WARNING! DANGER TO LIFE!
The power pack may still be charged with voltage for up to 5 minutes after being switched
off from the mains. Converter terminals, motor feeder lines and motor terminals may carry
voltage.
Touching open or exposed terminals, lines and device parts can cause serious injuries
and even death!
CAUTION
Children and the general public are prohibited from accessing the device.
The device may be used only as intended by the manufacturer. Unauthorised modications
and use of spare parts and auxiliaries that are not sold or recommended by the manufac-
turer of the device can cause res, electrical shocks and injuries.
Store these operating instructions where they are easily accessible and place them in
every user's hands.
The heat sink and other metallic parts can reach temperatures of more than 70 °C.
Keep sufcient space to neighbouring components.
When working on the components allow for sufcient cooling time.
Warning: This is a product of the limited sales class acc. to IEC 61800-3. In a residential environ-
ment this product can cause high-frequency interferences, in which case the user can be
required to take suitable measures.
A suitable measure would be the employment of a recommended line lter.

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Commissioning
After opening the terminal box cover you will nd all the connection terminals of the frequency converter
in the connection area.
Connection
Power line
L1, L2, L3, PE
Signal terminals
Relay
Aggregated error message Rel.2
Aggregated operation message Rel.1
Connection Power line
Maximum wire cross-section of the mains power supply: 4 mm2 (wire-end 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
Maximum connection cross-section of the signal lines: 1.5 mm2 (wire-end ferrule with plastic shroud)
Minimum connection cross-section of the signal lines: 0.25 mm2 (wire-end ferrule with plastic shroud)
Connection terminals of the bottom row of the double-decker 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

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Connection terminals of the top row of the double-decker terminal block:
Terminal Connection
24 V Out Int. voltage supply
Dig In 1 Setpoint value enable
Dig In 2 Programmable P 156
Dig In 3 Programmable P 157
Analog Out 1 (0 V…10 V) Analog voltage output
AnalogOut1(4 mA…20 mA) Analog current output
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 1
Relais
Function Description
COMNO
NC
Relay 1
AOM Aggregated operation message.
Device stands still:
The device is turning at a speed > 0: COM - NC COM - NO
Relay2
AEM Aggregated error message.
Fault-free operation:
Malfunction: 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.

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RS485 interface
The RS485 interface is designed as a two-wire model acc. to EIA RS485 (data lines A and B) and
provides the communication with the frequency converter.
Pin assignment
M12: M12 Description
1
43
2
Pin (bus in)
1 24 V
2RS 485 A(+)
3 GND
4 RS 485 B(-)
The local operation of the device is done on the operating panel as shown.
Acknowledge button
Malfunktion
RS485 interface Potentionmeter for
adjusting the setpoint
LEDs indicate the
converter status
Using the potentiometer, the current setpoint value can be increased or decreased.
A malfunction can be acknowledged by pressing the Acknowledgement button.
A red LED indicates a malfunction.
Table of the LED-ash codes
Red LED Green LED Status
Initialisation
Operation
Malfunction
With optional BUS module:
BUS module is ready for operation
With optional BUS module:
BUS operation (active BUS connection)
Legend: LED off, LED on, LED ashes, LED ashes quickly
fault see →KombiTool diagnosis or read out P01011...1014
→Display handheld

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Malfunction, Fault message
Kombi Tool Handheld,
Error no. fault
Error group 1 P1011
1 1 Undervoltage 24V electronic
2 2 Overvoltage 24V electronic
128 8 Internal communication not ok
512 10 Parameter set not complete
1024 11 System error, missing mains voltage
4096 13 Cable breakage Analog In 1 (4-20mA /2-10V)
8192 14 Cable breakage Analog In 2 (4-20mA / 2 -10V)
16384 15 Blockage
32768 16 Alarm 1 (DigIn parameterised)
Error group 2 P1012
1 17 Alarm 2 (DigIn parameterised)
16 21 Bus Timeout
32 22 Max. automatic fault acknowledge exceed
64 23 External error 1
128 24 External error 2
Error group 3 P1013
1 32 Short circuit
2 33 Overvoltage intermediate circuit
4 34 Undervoltage intermediate circuit
8 35 Overtemperature motor
16 36 Mains interruption
64 38 Overtemperature powermodul FC
128 39 Over current FC
256 40 Inner temperature FC too high
1024 42 I2T motor protection cut off
2048 43 Earth fault
8192 45 Motor connection defective
16384 46 Motor parameter not ok
32768 47 Controller parameter not ok
Error group 4 P1014
1 48 No motor data (delivery status)
2 49 Overload
Technical specications
Function Description
Rated motor power [kW] 7,5
Mains voltage 3 AC 400V-15%...480V+10%, 50/60 Hz
Rated / input current [A] 17,8
Short time max. current [A] 26,7 (150% IN) for 60 sec.
Output frequency [Hz] 0 - 400
Protection functions overvoltage, undervoltage, I2t- limitation,
short circuit, motor temperature, FC tem-
perature, motor current limitation
Ambient temperature at rated power [°C] -10...+50
Altitude Up to 1000 m over sea level
over1000 m with reduced power
(1% per 100 m) (max. 2000 m)

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Function Description
Protection class IP55
Dimensions (L x W x H) [mm] 307x233x181
Weight incl. adapter plate [kg] 8,7
Switching frequency of the power stage [kHz] 4, 8, 16, (default setting 8)
EMC certicates
according to DIN EN 61800-3;
VDE 0160-103:2005-07
C2
Inputs and outputs Description
Digital input 1...3 Switching level Low < 5V / High > 15V
Imax(at 24V) = 3mA;
Rin = 8,6kΩ
Analog input 1...4 0 /2 … 10V oder 0 /4 … 20mA
resolution 10 Bit;
Rin = 10kΩ
Relay 1; 2 Change over contact (NO/NC)
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 ati ~ 230 V or = 30 V
Max response time: 7 ms ± 0,5 ms
Electrical lifetime: 100 000 switching cycles
Analog output 1(current) - Short circuit proof
- I out = 0..20mA
- Load = 500Ω
Analog output1 (voltage) - Short circuit proof
- U out = 0..10V
- Imax = 10mA
24 V DC xed voltage output - Auxiliary voltage U = 24V DC
- Short circuit proof
- Imax = 100mA
- external supply of 24 V possible
10 V DC xed voltage output - Auxiliary voltage U = 10V DC
- Short circuit proof
- Imax = 30mA
The VAU7.5/3 frequency converter is equipped with a motor temperature monitoring (PTC).
Certications
European EMC guidelines
If the VAU7.5/3 frequency converter is installed and operated according to the recommenda-
tions of these operating instructions, it fulls all requirements of the EMC regulations according
to the EMC product standards for motor driven systems EN 61800-3.

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SERVICE
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