BUSCH LM 0180 A User manual

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Retrofit Instructions
DOLPHIN
Variable-Frequency Drive Installation
LM 0180 A, LM 0270 A
LT 0170 A, LT 0220 A
0870232639/-0001_en / Original instructions / Modifications reserved 16/09/2021

Table of Contents
2 / 20 Installation and Retrofit Instructions DOLPHIN LM 0180-0270 A, LT 0170-0220
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Table of Contents
1 Safety .......................................................................................................................................3
2 Introduction..............................................................................................................................3
3 Retrofit Kit Description.............................................................................................................4
3.1 Scope of Delivery ............................................................................................................. 4
3.1.1 Variable-Frequency Drive with Motor.................................................................... 4
3.2 Motor Compatibility......................................................................................................... 5
4 Transport ..................................................................................................................................5
5 Storage .....................................................................................................................................6
6 Installation................................................................................................................................6
6.1 Installation Conditions...................................................................................................... 6
6.1.1 Variable-Frequency Drive Installation Location ...................................................... 7
6.1.2 Line Protection ......................................................................................................7
6.1.3 Ambient Conditions............................................................................................... 7
6.1.4 Preventing Electromagnetic Interferences .............................................................. 8
6.2 Variable-Frequency Drive Installation ............................................................................... 9
6.2.1 Dismantle the Motor Terminal Box ........................................................................ 9
6.2.2 Install Adapter ....................................................................................................... 10
6.2.3 Mount Variable-Frequency Drive........................................................................... 11
6.3 Motor & Coupling Installation .......................................................................................... 12
6.4 Electrical Connection ........................................................................................................ 12
7 Commissioning.........................................................................................................................15
8 Troubleshooting .......................................................................................................................16
8.1 LED Flash Codes............................................................................................................... 17
9 Technical Data..........................................................................................................................18

Safety | 1
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1 Safety
Prior to handling the machine, this instruction manual should be read and understood. If
anything needs to be clarified, please contact your Busch representative.
Read this manual carefully before use and keep for future reference.
This instruction manual remains valid as long as the customer does not change anything
on the product.
The machine is intended for industrial use. It must be handled only by technically trained
personnel.
Always wear appropriate personal protective equipment in accordance with the local
regulations.
The machine has been designed and manufactured according to state-of-the-art meth-
ods. Nevertheless, residual risks may remain. This instruction manual highlights potential
hazards where appropriate. Safety notes and warning messages are tagged with one of
the keywords DANGER, WARNING, CAUTION, NOTICE and NOTE as follows:
DANGER
... indicates an imminent dangerous situation that will result in death or serious injuries if
not prevented.
WARNING
... indicates a potentially dangerous situation that could result in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result in damage to property.
NOTE
... indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
2 Introduction
NOTE
Retrofit kit instructions.
This document is delivered along with a retrofit kit.
It only contains information about the retrofit kit installation as well as additional infor-
mation about changes in the use of the initial product.
Please refer to the original instruction manual of the corresponding machine whose con-
tent remains valid.

3 | Retrofit Kit Description
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3 Retrofit Kit Description
3.1 Scope of Delivery
The retrofit kit with motor is available to suit the DOLPHIN LM 0180 A and LM 0270 A
or LT 0170 A and LT 0220 A.
3.1.1 Variable-Frequency Drive with Motor
Pos. 400
5.5kW & 7.5kW Kits
Pos. 550
Pos. 401
Pos. 402
Pos. 300
Pos. 401
Pos. 450
–Inverter & Motor retrofit kit 5.5kW (to suit DOLPHIN LM 0180 A, LT 0170 A)
Kit number: 0999 700460
Pos. Part Qty Part no.
300 Coupling 1 CO/H110/028/038
400 5.5kW motor 1 0623 700 004
401 Hexagon head bolt 6 900.0MM/012/030
402 Hexagon head bolt 2 900.0MM/012/040
450 Flange adaptor 1 185.1ML4/RD16880/F
550 5.5kW retrofit kit with VFD 1 0999 700 452
–Inverter & Motor retrofit kit 7.5kW (to suit DOLPHIN LM 0270 A, LT 0220 A)
Kit number: 0999 700462
Pos. Part Qty Part no.
300 Coupling 1 CO/H110/028/038
400 7.5kW motor 1 0624 700 005
401 Hexagon head bolt 6 900.0MM/012/030
402 Hexagon head bolt 2 900.0MM/012/040
450 Flange adaptor 1 185.1ML4/RD16880/F
550 7.5kW retrofit kit with VFD 1 0999 700 453

Transport | 4
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3.2 Motor Compatibility
NOTICE
Non-compatible motor
Risk of damage to the machine and the variable-frequency drive
• Make sure to use a compatible motor and approved by Busch.
The variable-frequency drive is only compatible with the following motor(s):
Motor type Power / Voltage Size Part no.
Three-phase 5.5kW / 400V AC 132M / B5-300 0624 700 004
Three-phase 7.5kW / 400V AC 132M / B5-300 0624 700 005
Recommended motor rating (4-pole asynchronous motor) is specified on the 400V AC
supply voltage.
NOTE
Refer to the motor nameplate for specific technical information.
4 Transport
WARNING
Suspended load.
Risk of severe injury!
• Do not walk, stand or work under suspended loads.
Motor + VFD weight:
approx. 63 kg
VFD weight: 8.7 kg
• Check the motor for transport damage.

5 | Storage
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5 Storage
NOTICE
Long storage time.
Risk of damage to the variable-frequency drive!
Due to a long storage time the capacitors of the variable-frequency drive can lose effi-
ciency because of electrochemical processes. In worst case it can lead to a short circuit
and therefore to a damage to the variable-frequency drive.
• Connect the variable-frequency drive every 2 years for 30 minutes to the mains.
• Store the motor with the variable-frequency drive indoor, dry, dust free and if possible
in the original packaging preferably at temperature between -20 … 60 °C.
6 Installation
DANGER
Carry out any work on the variable-frequency drive and motor.
Risk of electrical shock!
• Electrical installation work must only be executed by qualified personnel.
DANGER
The installation conditions are not respected.
Risk of electrical shock!
Risk of severe injury!
• Take care that the installation conditions are met.
CAUTION
The machine can start immediately when power is supplied.
Risk of inadvertent start-up!
• Make sure that a start-up will not lead to a dangerous situation.
6.1 Installation Conditions
• Make sure that the variable-frequency drive is de-energised.
• Make sure that the variable-frequency drive is grounded in accordance with DIN EN
61140; VDE 0140, NEC and other relevant standards.
• Make sure that unused open cable ends in the motor terminal box are insulated.
• Make sure that mains connections are hardwired.
• Make sure to use suitable line circuit breakers with the prescribed nominal current be-
tween the mains and the variable-frequency drive, see Line Protection [►7].
• Make sure that the ambient conditions are complied with, see Ambient Conditions
[►7].

Installation | 6
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6.1.1 Variable-Frequency Drive Installation Location
• Make sure that the variable-frequency drive is located as below:
6.1.2 Line Protection
• Make sure that the cross-section of the supply line is designed according to the trans-
fer category and the maximum permitted current. The contractor commissioning the
device must ensure protection for the power line.
Nominal motor rating 5.5 kW and 7.5 kW
Mains current [A] 14.8 A (150% overload for 60s - 22.2 A)
Line circuit breaker
(recommendation)
C 25
Characteristics C = line circuit breaker
tripping between 6 … 10 times In
6.1.3 Ambient Conditions
• Make sure that the housing type (protection class) is suitable for the operating envi-
ronment.
• Ensure that the seal between the motor and the adapter plate is inserted correctly
• All unused cable screw connections must be sealed.
• Check that the cover of the drive controller is closed and bolted down tightly (4 x M4
x 28) 2 Nm.
• Ensure that the seal between the motor and the adapter plate is inserted correctly.
• All unused cable screw connections must be sealed.
• Make sure that no condensate from the motor can enter the drive controller during
and after installation.
• Make sure to comply with the following ambient conditions:
Altitude of the installation
location
up to 1000 m above sea level / over 1000 m with reduced
performance (1 % per 100 m) (max. 2000m)
Ambient temperature Inverter allowable -25 °C to +50 °C.
Relative humidity ≤ 90 % at 30°C, condensation not permitted. Inverter is
IP55 rated for active cooling version or IP65 rated for
passive cooling version.
Resistance to vibration and
shock
DIN EN 60068-2-6 severity 2 (vibration from transport)
DIN EN 60068-2-27 (vertical impact test)
2 … 200 Hz for sinusoidal vibrations.

6 | Installation
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Electromagnetic compatibili-
ty
Immune to interference acc. to DIN EN 61800-3
Cooling Active cooling & Passive
* Do not cover/block cooling outlets.
6.1.4 Preventing Electromagnetic Interferences
Where possible use shielded lines for control circuits.
The shielding should be applied to the line end with special care and without laying the
leads across longer stretches without shielding.
Ensure that no parasitic currents (compensating currents etc.) can flow via the analogue
cable's shielding.
Route the control lines as far away as possible from the power lines. Under certain cir-
cumstances, separate power ducts should be used.
If lines do cross, an angle of 90° should be observed.
Upstream circuit elements, such as protector switches and brake coils, or circuit elements
that are operated via the outputs of the drive controller have to be interference-sup-
pressed. RC circuits are suitable as AC voltage protector switches, while free-wheeling
diodes or varistors are usually used as DC voltage protector switches. These interference
suppression devices are attached directly to the protector switch coils.
NOTE
Where possible, the power for a mechanical brake should be supplied in a separate ca-
ble.
Power connections between the drive controller and motor should always be shielded or
reinforced, and the shielding must have large-scale grounding at both ends! The use of
EMC cable screw connections is recommended. These are not part of the scope of deli-
very.
Wiring suitable for EMC must be ensured.

Installation | 6
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6.2 Variable-Frequency Drive Installation
NOTICE
Sealing not correctly mounted.
Loss of the protection class!
• Make sure during assembly tasks to correctly mount all sealing.
• Replace any worn or damaged seal.
6.2.1 Dismantle the Motor Terminal Box
• Ensure that the motor is isolated before beginning.
Reuse under
terminal box gasket.
Scrap lid and gasket,
terminal box, terminal block.
• Remove the original terminal motor box from the motor.
• Disconnect the earth connection.
• Scrap the parts which will be no longer necessary.
•Memorize or write down the connection sequence before beginning.
• Disconnect the wires from the connection terminal block, pair the wires together as
they are currently bridged into pairs by brass link bars, this can be done by tape.
• Refer to nameplate if unsure, the connection sequence should be Wye ‘Y’.

6 | Installation
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6.2.2 Install Adapter
• Use new provided gasket located on the top of the motor inline with the x4 tapped
holes.
• Taking the adaptor plate begin to position on top of the rubber gasket, carefully pass
motor wires through the center and place onto motor top where the adaptor place
will mount.
• Feed loose motor wires through opening in adaptor module, ensure the adaptor mod-
ule is in the correct orientation, with the ‘U’ section facing towards the motor fan end.
• Secure adapter once step 1 & 2 are completed, using (x 4 qty) M5 Hex Head Screw
and Spring Washers to 5Nm.
• Connect motor wires in the correct sequence as pairs on the x3 terminal pins for U, V,
W, (as per step 7.2.1) according to the shown terminal markings.
• Please carefully look at the terminal pins on the PCB board there are small identifica-
tion markings for U, V, W.
Note: Should the electrical phases not be assembled in the required direction of motor
rotation, this can be altered later if the Inverter software is provided.

Installation | 6
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6.2.3 Mount Variable-Frequency Drive
pos. 1
X4
pos. 6
pos. 5
pos. 3
pos. 4
pos. 2
• Remove the four screws and the housing cover of the variable-frequency drive to ac-
cess the internal parts, beware the earth connection cable between the cover and the
housing.
• Disconnect spade earth connector from housing lid.
• Ensure pos.5 (x 4 qty) are screwed partially into the thread bosses located in 4 places
on the side of the adaptor plate, these will secure the inverter top box.
• Before proceeding, ensure all motor wires are correctly secured to the individual termi-
nals as designated.
• Check the rubber O Ring is seated on the inverter drive shoulder, this is typically pre-
installed on the adaptor module.
• Taking pos.6 the main inverter drive box, position over the adaptor plate, ensure the
fan extraction end of the inverter drive is facing away from the flanged end of the
motor.
• Carefully place the inverter drive onto the adaptor module
• Check the inverter is seated onto the adaptor, then fully screw pos.5 (x4 qty) into the
chamfered holes located onto the side 4Nm.
See Electrical Connection [►12]
DANGER
Risk of death due to electrical shock!
Death or serious injury!
• De-energise drive controller and secure it against being restarted.

6 | Installation
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6.3 Motor & Coupling Installation
• Refer to coupling manufacturer’s manual for details of coupling fitment to motor and
pump shafts.
• Install motor adaptor to motor pedestal then install motor onto motor adaptor.
6.4 Electrical Connection
DANGER
Risk of death due to electrical shock!
Death or serious injury!
• Be sure that the power supply provides the correct voltage and is designed for the re-
quired current.
• Use suitable circuit breakers with the prescribed nominal current between the mains
and drive controller.
• Use suitable fuses with appropriate current values between the mains and drive con-
troller (see technical data).
• The drive controller must be grounded with the motor according to relevant regula-
tions. Noncompliance may result in serious injury.
WARNING
DAMAGE TO PROPERTY POSSIBLE!
If the information is not observed, the drive controller could be damaged and destroyed
during subsequent commissioning.
Commissioning may only be performed by qualified staff.
Safety precautions and warnings must always be observed.

Installation | 6
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1.
2.
3.
4.

6 | Installation
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Please refer to
motor nameplate &
datasheet for technical
information.
Hardware enable
** (see diagram “Hardware enable, sizes A – D”)
5. 6.
7.
8.
9.
10.
NOTICE
Incorrect direction of rotation.
Risk of damage to the machine!
• Operation in the wrong direction of rotation can destroy the machine in a short time!
Prior to start-up, ensure that the machine is operated in the right direction.
Hardware Enable Required:
Connect En.HW to 24V Out on Terminal Relay Block X5 before attempting a motor jog.
• Determine the intended direction of rotation with the arrow (stuck on or cast).
• Jog the motor briefly.
• Watch the fan wheel of the motor and determine the direction of rotation just before
the fan wheel stops.

Commissioning | 7
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If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
NOTE
To change the motor phase wire, refer to the chapter Variable-Frequency Drive Installa-
tion [►9].
7 Commissioning
NOTE: PC - Ensure you are using the latest software version.
Once the retrofit kit installation achieved, the machine can operate between the follow-
ing frequency ranges (factory settings):
Machine type Motor frequency RPM
LM 0180 A
34 - 60 Hz 1000 to 1780 rpm
LM 0270 A
LT 0170 A
LT 0220 A
Remote speed control and parametrisation are only possible via the remote control and
the PC-Software. Contact your Busch representative for more information.
NOTICE
Frequent starts and stops by connecting and disconnecting from the power supply.
Risk of damage to the machine!
Starting the machine by connecting and disconnecting the power supply is permitted
max. 12 starts per hour.
Mains cycle of operation/restart every 2 minutes.
Between disconnecting and connecting at least 1 to 2 minutes must have been passed. If
the process requires more frequent starts/stops of the machine:
• Use the digital start signal.
• Refer to the original instruction manual of the corresponding machine for the com-
plete commissioning procedure.
• Maximum permissible number of starts by using the digital signal: unlimited
As soon as the machine is operated under normal operating conditions:
• Measure the mains current or read it via PC-Software or controller.

8 | Troubleshooting
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8 Troubleshooting
DANGER
Carry out any work on the variable-frequency drive and motor.
Risk of electrical shock!
• Electrical installation work must only be executed by qualified personnel.
Problem Possible Cause Remedy
The machine does not start. The variable-frequency drive
(VFD) is not supplied with
the correct voltage.
• Check the power supply.
No start signal. • Check the connection.
The motor or the variable
frequency drive (VFD) is de-
fective.
• Check the LED on the
variable-frequency drive
display, if red, it is faulty
(contact Busch or read er-
ror with software).
En. HW has not been
connected.
• Using a jumper cable
from terminal relay box
X5 - 24V Out to En. HW.
Incorrect or loose wiring. • Re-check wiring dia-
grams, check terminal
connections are correctly
tightened and conductor
ends are contacting termi-
nal points.

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8.1 LED Flash Codes
When an error occurs, the LEDs on the variable-frequency drive display a flashing code
that allows the errors to be diagnosed.
The following table contains an overview:
Red LED Green LED State
Boot loader active (flashing in turn)
Ready for operation (activate En_HW for operation)
Operation / ready
Warning
Error
Identification of motor data
Initialisation
Firmware update
Bus error operation
Bus error ready for operation
Key
LED off LED on
LED flashing LED flashing quickly

9 | Technical Data
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9 Technical Data
Below additional technical data once the variable-frequency drive has been installed on
the motor.
The technical datas of the machine in the original instruction manual remain valid after
the retrofitting.
LM 0180-0270 A with VFD - LT 0170-0220 A with VFD
Allowed frequency range 34 – 60 Hz
Installation altitude 100% load capacity (no derating) up to 1000 m;
Derating 1% / 100 m at 1000 … 2000 m
Supply network TN- and TT-network
(cannot be used with corner grounded networks)
Immunity EN 61800-3, 2nd environment
Emissions EN 61800-3, category C2 as standard

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