BUSCH LM 0530 A User manual

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Retrofit Instructions
DOLPHIN
Variable-Frequency Drive Installation
LM 0530 A, LM 0800 A
LT 0320 A, LT 0430 A, LT 0510 A, LT 0630 A
0870224006/-0001_en / Original instructions / Modifications reserved 16/09/2021

Table of Contents
2 / 24 Installation and Retrofit Instructions DOLPHIN LM 0530-0800 A, LT 0320-0630
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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 without Motor............................................................... 4
3.1.2 Variable-Frequency Drive with Motor.................................................................... 5
3.2 Motor Compatibility......................................................................................................... 8
4 Transport ..................................................................................................................................8
5 Storage .....................................................................................................................................9
6 Installation................................................................................................................................9
6.1 Installation Conditions...................................................................................................... 9
6.1.1 Variable-Frequency Drive Installation Location ...................................................... 10
6.1.2 Line Protection ......................................................................................................10
6.1.3 Ambient Conditions............................................................................................... 10
6.1.4 Preventing Electromagnetic Interferences .............................................................. 11
6.2 Variable-Frequency Drive Installation ............................................................................... 12
6.2.1 Dismantle the Motor Terminal Box ........................................................................ 12
6.2.2 Install Adapter Plate .............................................................................................. 12
6.2.3 Mount Variable-Frequency Drive........................................................................... 13
6.2.4 Connect Variable-Frequency Drive to Motor ......................................................... 14
6.3 Motor & Coupling Installation .......................................................................................... 15
6.4 Electrical Connection ........................................................................................................ 16
7 Commissioning.........................................................................................................................18
8 Troubleshooting .......................................................................................................................19
8.1 LED Flash Codes............................................................................................................... 20
9 Technical Data..........................................................................................................................21

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
Different retrofit kit levels are available and mainly depends on the motor type previously
fitted on the machine.
The retrofit kit without motor is only intended for machines having a compatible motor
with the variable-frequency drive included in this kit, see Motor Compatibility [►8].
3.1.1 Variable-Frequency Drive without Motor
Pos. 1 Pos. 2
Pos. 3
Pos. 7
Pos. 4 Pos. 5
Pos. 6
–Inverter retrofit kit 11 kW (to suit DOLPHIN LT 0320 A)
Kit number: 0999 700 454
Pos. Part Qty Part no.
1 Variable-frequency drive 1 0643 700 406
2 Adapter Plate 1 0360 700 450
3 Countersunk screw 4 906.0MM /006/020
4 Hex head screw 5 914.0MM/008/012
5 Spring lock washer 5 921.2/MM/008
6 Neoprene Rubber Gasket 1 0990 700 520
7 Wiring material 1 0985 700 457
–Inverter retrofit kit 15 kW (to suit DOLPHIN LT 0430 A, LT 0510 A, LM 0530 A)
Kit number: 0999 700455
Pos. Part Qty Part no.
1 Variable-frequency drive 1 0643 700 407
2 Adapter Plate 1 0360 700 450
3 Countersunk screw 4 906.0MM /006/020
4 Hex head screw 5 914.0MM/008/012
5 Spring lock washer 5 921.2/MM/008
6 Neoprene Rubber Gasket 1 0990 700 520
7 Wiring material 1 0985 700 457

Retrofit Kit Description | 3
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–Inverter retrofit kit 22 kW (to suit DOLPHIN LT 0630 A, LM 0800 A)
Kit number: 0999 700456
Pos. Part Qty Part no.
1 Variable-frequency drive 1 0643 700 408
2 Adapter Plate 1 0360 700 450
3 Countersunk screw 4 906.0MM /006/020
4 Hex head screw 5 914.0MM/008/012
5 Spring lock washer 5 921.2/MM/008
6 Neoprene Rubber Gasket 1 0990 700 520
7 Wiring material 1 0985 700 457
3.1.2 Variable-Frequency Drive with Motor
Pos. 400
11kW & 15kW Kits
Pos. 550
Pos. 402
Pos. 403
Pos. 300
Pos. 401
Pos. 450
–Inverter & Motor retrofit kit 11kW (to suit DOLPHIN LT 0320 A)
Kit number: 0999 700 461
Pos. Part Qty Part no.
300 Coupling 1 CO/H110/038/042
400 11kW motor 1 0630 700 013
401 Hexagon head bolt 4 900.0MM/016/045
402 Hexagon head bolt 2 900.0MM/012/040
403 Hexagon head bolt 2 900.0MM/012/050
450 Flange adaptor 1 185.1ML5/RD17022/F
550 11kW retrofit kit with VFD 1 0999 700 454

3 | Retrofit Kit Description
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Pos. 400
11kW & 15kW Kits
Pos. 550
Pos. 402
Pos. 403
Pos. 300
Pos. 401
Pos. 450
–Inverter & Motor retrofit kit 15kW (to suit DOLPHIN LT 0430 A, LT 0510 A,
LM 0530 A). Kit number: 0999 700463
Pos. Part Qty Part no.
300 Coupling 1 CO/H110/038/042
400 15kW motor 1 0632 700 014
401 Hexagon head bolt 4 900.0MM/016/045
402 Hexagon head bolt 2 900.0MM/012/040
403 Hexagon head bolt 2 900.0MM/012/050
450 Flange adaptor 1 185.1ML5/RD17022/F
550 15kW retrofit kit with VFD 1 0999 700 455

Retrofit Kit Description | 3
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Pos. 400
22kW Kit
Pos. 550
Pos. 401
Pos. 402
Pos. 300
Pos. 403 Pos. 404
–Inverter & Motor retrofit kit 22kW (to suit DOLPHIN LT 0630 A, LM 0800 A)
Kit number: 0999 700464
Pos. Part Qty Part no.
300 Coupling 1 CO/H150/038/048
400 22kW motor 1 0633 700 016
401 Hexagon head bolt 2 900.0MM/016/065
402 Hexagon head bolt 2 900.0MM/016/075
403 Nut 4 920.0MM/016
404 Washer 4 921.0MM/016
550 22kW retrofit kit with VFD 1 0999 700 456

4 | Transport
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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 11kW / 400V AC 160L / B5-350 0632 700 013
Three-phase 15kW / 400V AC 160L / B5-350 0632 700 014
Three-phase 22kW / 400V AC 180L / B5 0633 700 016
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.):
DOLPHIN LT 0320 A = 134kg
DOLPHIN LM 0530 A, LT 0430 A or LT 0510 A = 180kg
DOLPIN LT 0630 A or LM 0800 A = 195kg
VFD weight: 21 kg
• Check the motor for transport damage.

Storage | 5
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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.
• Make sure that the ambient conditions are complied with, see Ambient Conditions.

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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 Up to 11 kW and 15 kW
Mains current [A] 28.2
Rated line current [A] 53
Line circuit breaker
(recommendation)
C 50
Characteristics C = line circuit breaker
tripping between 6 … 10 times In
Grid Frequency 50/60hz +/- 6%
Overload for 60 sec. in % 150 (42.3 A)
Nominal motor rating Up to 22 kW
Mains current [A] 39.9
Rated line current [A] 53
Line circuit breaker
(recommendation)
C 63
Characteristics C = line circuit breaker
tripping between 6 … 10 times In
Grid Frequency 50/60hz +/- 6%
Overload for 60 sec. in % 130 (51.87 A)
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 M6
x 28) 4 Nm.
• 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:

Installation | 6
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Altitude of the installation
location
If the machine is installed at an altitude greater than 1000
meters above sea level:
*Contact your Bush representative, the motor should be
derated or the ambient temperature limited.
Ambient temperature Inverter allowable -25 °C to +50 °C.
Relative humidity ≤ 90 % at 30°C, condensation not permitted. Inverter is
IP55 rated.
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.
Electromagnetic compatibili-
ty
Immune to interference acc. to DIN EN 61800-3
Cooling with integrated fans, with active cooling.
40m3/h to 60m3h airflow required
*Do not cover fan/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 deliv-
ery.
Wiring suitable for EMC must be ensured.

6 | Installation
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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.
Parts to be scrapped
Leave inner terminal
block in place
• Remove the original terminal motor box from the motor.
• Disconnect the earth connection.
• Scrap the parts which will be no longer necessary.
6.2.2 Install Adapter Plate
pos. 3 pos. 2 pos. 6

Installation | 6
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• Unscrew the temperature wire block from motor.
• Mount the adapter plate (pos. 2) with the flat gasket (pos. 6) and the four screws
(T40 M6x16) (pos. 3) (torque: 25NM).
6.2.3 Mount Variable-Frequency Drive
4x
4x
pos. 5 Flat gasket
VFD (pos. 1)
Lower part
VFD (pos. 1)
pos. 4
pos. 2
Pos. 7
• Remove the four screws and the housing cover of the variable-frequency drive to ac-
cess to the internal parts, beware the earth connection cable between the cover and
the housing.
• Disconnect spade earth connector from housing lid.
• Dissociate the lower part of the variable-frequency drive (pos. 1) from the housing by
unscrewing two M8 screws.
• Motor connection wires need to be completed before installing the lower VFD part.
• Use the wiring material (pos. 7) for motor connection.
• Mount the lower part and the flat gasket of the variable-frequency drive to the adapt-
er plate (pos. 2) with the four socket head screws and spring washers (pos. 4 and 5),
ensure supplied earth (PE) cable ring connector is secured on one of the screws.
• Reassemble the housing of the variable-frequency drive with the two screws (Torque
spec. M8: 25.0 NM) previously removed without forgetting the O-ring seal.
• Keep the variable-frequency drive's housing cover open for wiring.
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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6.2.4 Connect Variable-Frequency Drive to Motor
• Connect the variable-frequency drive to the motor by using the wiring materials (pos.
7) delivered in the retrofit kit as follows:
Motor connection assignment
Connect all cables to the following connections:
(3) "Mains terminal [X1]"
• Unscrew the four screws from the drive control's housing cover and take off the cov-
er.
• Guide the mains connection cable through the cable screw connection and connect
the phases with the L1, L2, L3 contacts for 400 V and the ground cable with the PE
contact on the connection terminal. The cable screw connection provides strain relief,
and the PE connection cable must be connected in a leading fashion (considerably
longer)!
• When connecting a brake resistor to an optional braking module, cables with shielding
and double insulation must be used!
• The inverter drive also has the option of being equipped with terminals for connecting
a brake resistor. The configuration may vary depending on the version.
(4) "Brake resistor [X2] (optional)"
Terminal no. Designation Assignment
1 B+ Connection for brake resistor (+)
2 B- Connection for brake resistor (-)
(5) "Motor terminal [X4]"
• Unscrew the four screws from the drive control's housing cover and take off the cov-
er.
• Using the wiring materials for pos.7, connect the wiring cables to motor pin terminals
(as per nameplate connection configuration) L1, L2, L3 to the Invertor [X4] U, V, W
Terminal (unscrew terminals) ensure the correct phase colour/identifications are in
place. The ground cable (PE) should already be fixed in place as per Section 6.2.3.
connected this cable to the invertor [X4] PE Terminal.
• When connecting a brake resistor to an optional braking module, cables with shielding
and double insulation must be used!
(6) "Motor PTC/Klixon [X11]" (optional)
PE UVW
Terminal no. Designation Assignment
1 PE Earth connection
2 U Motor phase 1
3 V Motor phase 2
4 W Motor phase 3

Installation | 6
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Motor temperature switch connection
Terminal no. Designation Assignment
1 T1 Connection temp. switch (+)
2 T2 Connection temp. switch (-)
• Mount the cover on the housing of the variable-frequency drive with the four screws
to a torque of 4 Nm.
• Make sure that the earth connection cable between the cover and the housing is cor-
rectly in place.
• Make sure that all unused cable glands are sealed.
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 | Installation
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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.
4x
If the variable-frequency drive’s housing is not open:
• Remove the four screws and the housing cover, beware the earth connection ca-
ble between the cover and the housing.
• Guide the mains connection cable through the cable gland.
• Connect the cables to the terminals as follows:

Installation | 6
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3 x 400 VAC terminal assignment
L1 L2 L3 PE
Terminal no. Designation Assignment
1 L1 Mains phase 1
2 L2 Mains phase 2
3 L3 Mains phase 3
4 PE Earth connection
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.
If the rotation of the motor must be changed:
• Switch any two of the motor phase wires.
(or within the software parameter 1.150).
NOTE
To change the motor phase wire, refer to the chapter Variable-Frequency Drive Installa-
tion [►12].

7 | Commissioning
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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 Inverter output kW Motor frequency RPM
LM 0530 A 15
34 - 60 Hz 1000 to 1780 rpm
LM 0800 A 22
LT 0320 A 11
LT 0430 A 15
LT 0510 A 15
LT 0630 A 22
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.
Appropriate measures to prevent pump flooding or running dry should be taken, when
using a cycle operation.
Contact your Busch representative for more information if unsure.

Troubleshooting | 8
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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.
NOTICE
Variable-frequency drive maintenance.
Risk of damage to the variable-frequency drive!
• Maintenance and adjustment 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.

8 | Troubleshooting
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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