CG Emotron VFXR46-250-CL User manual

Emotron AFE Drives
Slim-LC Liquid cooled drives
Hardware manual
English

CG Drives & Automation 01-7694-01r0 1
Safety Instructions
Congratulations for choosing a product from CG Drives &
Automation!
Before you begin with installation, commissioning or
powering up the unit for the first time it is very important
that you carefully study this Instruction manual.
Following symbols can appear in this instruction or on the
product itself. Always read these first before continuing.
Handling the AC drive
Installation, commissioning, demounting, taking
measurements, etc, of or on the AC drive may only be
carried out by personnel technically qualified for the task.
A number of national, regional and local regulations govern
handling, storage and installation of the equipment. Always
observe current rules and legislation.
Opening the AC drive
Always take adequate precautions before opening the AC
drive. Although the connections for the control signals and
the switches are isolated from the main voltage, do not
touch the control board when the AC drive is switched on.
Incorrect connection
The AC drive is not protected against incorrect connection
of the mains voltage, and in particular against connection of
the mains voltage to the motor outlets U, V and W. The AC
drive can be damaged in this way. Risk for personal injury.
Precautions to be taken with a
connected motor
If work must be carried out on a connected motor or on the
driven machine, the mains voltage must always be
disconnected from the AC drive first. Wait at least 7minutes
before starting work.
Earthing
The AC drive must always be earthed via the mains safety
earth connection.
Earth leakage current
Residual current device (RCD)
compatibility
This product cause a DC current in the protective
conductor. Where a residual current device (RCD) is used
for protection in case of direct or indirect contact, only a
Type B RCD is allowed on the supply side of this product.
Use RCD of 300 mA minimum.
EMC Regulations
In order to comply with the EMC Directive, it is absolutely
necessary to follow the installation instructions. All
installation descriptions in this manual follow the EMC
Directive.
NOTE: Additional information as an aid to avoid
problems.
CAUTION!
Failure to follow these instructions can result
in malfunction or damage to the AC drive.
Warning!
Failure to follow these instructions can result
in serious injury to the user in addition to
serious damage to the AC drive.
HOT SURFACE!
Failure to follow these instructions can result
in injury to the user.
WARNING!
Always switch off the mains voltage before
opening the AC drive and wait at least
7 minutes to allow the capacitors to
discharge.
!
CAUTION!
This AC drive has an earth leakage current
which does exceed 3.5 mA AC. Therefore the
minimum size of the protective earth
conductor must comply with the local safety regulations
for high leakage current equipment which means that
according to the standard IEC61800-5-1 the protective
earth connection must be assured by one of following
conditions:
PE conductor cross-sectional area shall for phase cable
size < 16 mm2(6 AWG) be >10 mm2Cu (16 mm2Al) or
use a second PE conductor with same area as original
PE conductor.
For cable size above 16 mm2(6 AWG) but smaller or
equal to 35mm2 (2 AWG) the PE conductor cross-
sectional area shall be at least 16mm2
(6 AWG).
For cables >35 mm2(2 AWG) the PE conductor cross-
sectional area should be at least 50 % of the used phase
conductor.
When the PE conductor in the used cable type is not in
accordance with the above mentioned cross-sectional
area requirements, a separate PE conductor should be
used to establish this.
!

2CG Drives & Automation 01-7694-01r0
Mains voltage selection
The AC drive may be ordered for use with the mains voltage
range listed below.
FDUL46/VFXR46/AFR46: 380-460 V, +10%/-15%
FDUL69/VFXR69/AFR69: 480-690 V, +6%/-15%
Voltage tests (Megger)
Do not carry out voltage tests (Megger) on the motor, before
all the motor cables have been disconnected from the AC
drive.
Condensation
If the AC drive is moved from a cold (storage) room to a
room where it will be installed, condensation can occur.
This can result in sensitive components becoming damp. Do
not connect the mains voltage until all visible dampness has
evaporated.
Power factor capacitors for improving
cosϕ
Remove all capacitors from the motor and the motor outlet.
Precautions during Autoreset
When the automatic reset is active, the motor will restart
automatically provided that the cause of the trip has been
removed. If necessary take the appropriate precautions.
Transport
To avoid damage, keep the AC drive in its original
packaging during transport. This packaging is specially
designed to absorb shocks during transport.
IT Mains supply
The AC drives can be modified for an IT mains supply,
(non-earthed neutral), please contact your supplier for
details.
Alarms
Never disregard an alarm. Always check and remedy the
cause of an alarm.
Heat warning
DC-link residual voltage
HOT SURFACE!
Be aware of specific parts on the AC drive
having high temperature.
WARNING!
After switching off the mains supply,
dangerous voltage can still be present in the
AC drive. When opening the AC drive for
installing and/or commissioning activities
wait at least 7 minutes. In case of malfunction a
qualified technician should check the DC-link or wait for
one hour before dismantling the AC drive for repair.

CG Drives & Automation, 01-7694-01r0 3
Table of contents
Safety Instructions ......................................... 1
Table of contents............................................ 3
1. Introduction..................................................... 5
1.1 Software manual ....................................................... 5
1.2 Delivery and unpacking ............................................ 5
1.3 Using of the instruction manual............................... 5
1.4 Warranty .................................................................... 6
1.5 Standards .................................................................. 6
1.6 Dismantling and scrapping....................................... 8
1.7 Glossary ..................................................................... 8
1.8 Single line diagrams FDUL/VFXR and AFR.............. 8
1.9 General description................................................... 8
1.10 AC drive types ............................................................ 9
1.11 Emotron single drive cabinet concept ................... 11
1.12 Emotron AFR/AFG concept..................................... 12
2. Mounting ...................................................... 13
2.1 Lifting instructions................................................... 13
3. Control Connection ..................................... 17
3.1 Control board location ............................................ 17
3.2 Control board........................................................... 18
3.3 Terminal connections ............................................. 19
3.4 Configuration with jumpers and switches ............. 20
3.5 Connection example ............................................... 22
4. Installation ................................................... 23
4.1 Connection of motor and mains cables................. 23
4.2 Cables ...................................................................... 24
4.3 Cable specifications................................................ 24
5. Water cooling............................................... 29
5.1 Connection with cooling section ............................ 29
5.2 Connection without cooling section ....................... 30
6. Troubleshooting........................................... 31
6.1 Trip conditions, causes and remedial action ........ 31
6.2 Maintenance ........................................................... 32
6.3 Fault messages from software............................... 32
7. Technical Data............................................. 33
7.1 Drive data ................................................................ 33
7.2 Power losses and flow ............................................ 36
7.3 General electrical specifications............................ 38
7.4 Dimensions and Weights........................................ 39
7.5 Derating ................................................................... 41
7.6 Environmental conditions....................................... 41
7.7 Water cooling........................................................... 42
7.8 DC fuses for VSI units ............................................. 44

4CG Drives & Automation, 01-7694-01r0

CG Drives & Automation 01-7694-01r0 Introduction 5
1. Introduction
1.1 Software manual
Refer to manual Emotron AFR/AFG 2.1 manual
01-7690-01 regarding the software.
1.2 Delivery and unpacking
Check for any visible signs of damage. Inform your supplier
immediately of any damage found. Do not install the AC
drive if damage is found.
Check that all items are present and that the type number is
correct.
1.3 Using of the instruction
manual
Within this instruction manual the abbreviation “AC drive”
is used to indicate the complete variable speed drive as a
single unit.
Check that the software version number on the first page of
this manual matches the software version in the AC drive.
With help of the index and the table of contents it is easy to
track individual functions and to find out how to use and set
them.
The Quick Setup Card can be put in a cabinet door, so that
it is always easy to access in case of an emergency.
1.3.1 Instruction manuals for
optional equipment
In the following table we have listed available options and
the name of the Instruction manual or data sheet/
Instruction plus document number. Further in this main
manual we are often referring to these instructions.
Ta b l e 1 Av a i l a b l e o p tions and documents
Option Valid instruction manual/
document number
I/O board I/O board 2.0, instruction
manual / 01-5916-01
Encoder board
Emotron Encoder board
2.0, Instruction manual /
01-5917-01
PTC/PT100 board
PTC/PT100 board 2.0,
instruction manual /
01-5920-01
CRIO board (VFX) Emotron AC Drive Crane
option 2.0, Instruction
manual
Crane interface (VFX)
Fieldbus - Profibus
Fieldbus Option,
Instruction manual /
01-3698-01
Fieldbus - DeviceNet
Fieldbus - CANopen
Ethernet - Modbus TCP
Ethernet - EtherCAT
Ethernet - Profinet IO 1-port
Ethernet - Profinet IO 2-port
Ethernet - EtherNet/IP 2-port
Safe Torque Off board
Option Safe Torque Off
OSTO – 100 option board
01-7513-11

6Introduction CG Drives & Automation 01-7694-01r0
1.4 Warranty
The warranty applies when the equipment is installed,
operated and maintained according to instructions in this
instruction manual. Duration of warranty as per contract.
Faults that arise due to faulty installation or operation are
not covered by the warranty.
1.5 Standards
The AC drives described in this instruction manual comply
with the standards listed in table 2. For the declarations of
conformity and manufacturer’s certificate, contact your
supplier for more information or visit www.emotron.com/
www.cgglobal.com.
1.5.1 Product standard for EMC
Product standard EN (IEC) 61800-3, second edition of
2018 defines the:
First Environment (Extended EMC) as environment that
includes domestic premises. It also includes establishments
directly connected without intermediate transformers to a
low voltage power supply network that supplies buildings
used for domestic purposes.
Category C2: Power Drive System (PDS) of rated
voltage<1.000 V, which is neither a plug in device nor a
movable device and, when used in the first environment, is
intended to be installed and commissioned only by a
professional.
Second environment (Standard EMC) includes all other
establishments.
Category C3: PDS of rated voltage <1.000 V, intended for
use in the second environment and not intended for use in
the first environment.
Category C4: PDS or rated voltage equal or above 1.000 V,
or rated current equal to or above 400 A, or intended for use
in complex systems in the second environment.
The AC drive complies with the product standard
EN(IEC) 61800-3 Ed. 2.0:2018 (Any kind of metal
screened cable may be used). The standard AC drive is
designed to meet the requirements according to category
C3, for a motor cable length of maximum 80 m.
By using the optional “Extended EMC” filter the AC drive
fulfils requirements according to category C2.
WARNING!
In a domestic environment this product may
cause radio interference, in which case it
may be necessary to take adequate
additional measures.
WARNING!
The standard AC drive, complying with
category C3, is not intended to be used on a
low-voltage public network which supplies
domestic premises; radio interference is
expected if used in such a network. Contact
your supplier if you need additional
measures.

CG Drives & Automation 01-7694-01r0 Introduction 7
Ta b l e 2 St a n d a rd s
Market Standard Description
European
EMC Directive 2014/30/EU
Low Voltage Directive 2014/35/EU
WEEE Directive 2012/19/EU
All
EN 60204-1 Safety of machinery - Electrical equipment of machines
Part 1: General requirements.
EN(IEC) 61800-3 Ed. 2.0:
2018
Adjustable speed electrical power drive systems
Part 3: EMC requirements and specific test methods.
EMC Directive: Declaration of Conformity and CE marking
EN(IEC)61800-5-1 Ed. 2.0
Adjustable speed electrical power drive systems Part 5-1.
Safety requirements - Electrical, thermal and energy.
Low Voltage Directive: Declaration of Conformity and CE marking
IEC 60721-3-3
Classification of environmental conditions. Air quality chemical vapours, unit in
operation. Chemical gases 3C2, Solid particles 3S2.
Optional with coated boards
Unit in operation. Chemical gases Class 3C3, Solid particles 3S2.
North & South
America
ULC508C UL Safety standard for Power Conversion Equipment
USL USL (United States Standards - Listed) complying with the requirements of
UL508C Power Conversion Equipment
UL 840
UL Safety standard for Power Conversion Equipment.
Insulation coordination including clearances and creepage distances for
electrical equipment.
CNL CNL (Canadian National Standards - Listed) complying with the requirements
of CAN/CSA C22.2 No. 14-10 Industrial Control Equipment.
Russian EAC For all sizes.

8Introduction CG Drives & Automation 01-7694-01r0
1.6 Dismantling and scrapping
The enclosures of the drives are made from recyclable
material as aluminium, iron and plastic. Our AC-drives
comply to RoHS II directive, and contain electronic waste
(e-waste). Any local or national regulations in force for the
disposal and recycling of e-waste must be complied with.
1.6.1 Disposal of old electrical and
electronic equipment
This symbol on the product or on its packaging indicates
that this product shall be taken to the applicable collection
point for the recycling of electrical and electronic
equipment. By ensuring this product is disposed of correctly,
you will help prevent potentially negative consequences for
the environment and human health, which could otherwise
be caused by inappropriate waste handling of this product.
The recycling of materials will help to conserve natural
resources. For more detailed information about recycling
this product, please contact the local distributor of the
product.
1.7 Glossary
1.7.1 Abbreviations
In this manual the following abbreviations are used:
1.8 Single line diagrams
FDUL/VFXR and AFR
1.9 General description
The Emotron active front end (AFE) is a regenerative active
front end unit designed to be used either in combination
with Emotron motor inverter (VSIs) i.e. VFX/FDU or
without Emotron motor inverter (VSIs). The main objective
of the Emotron AFE is to rectify the supply AC voltage into
DC voltage to be fed to or regenerated from the VSIs. This
is achieved with the minimal impact on the supply by the
control of the active rectifier module which provides
sinusoidal input currents with a very low harmonic content,
typically a THD(I) below 5%. Different variants of
Emotron active front end drives are: AFR, FDUL and
VFXR.
Table 3 Abbreviations
Abbreviation/
symbol Description
AC drive Frequency converter
AFR Regenerative, low harmonic active front end
without Emotron motor inverter.
AnIn Analogue input
AnOut Analogue output
DigIn Digital input
DigOut Digital output
FDUL
Non-regenerative, low harmonic drive includ-
ing active front end (AFR) together with Emo-
tron motor inverter FDU.
IGBT Insulated Gate Bipolar Transistor
PEBB Power Electronic Building Block
SELV Safety Extra Low Voltage
VFXR
Regenerative, low harmonic drive including
active front end (AFR) together with Emotron
motor inverter VFX.
CAUTION!
Always consult CG Drives & Automation
before connecting an Emotron AFR/AFG to a
standard VSI.
!

CG Drives & Automation 01-7694-01r0 Introduction 9
1.10 AC drive types
1.10.1 Standard AC drive (as comparison)
A standard AC drive consists of a rectifier module and an
inverter module. The rectifier module (front-end) consists of
a 6-pulse diode bridge, i.e. diode front-end (DFE) while the
inverter module (VSI) consists of IGBTs with anti-parallel
free wheeling diodes, see Fig. 1. The main advantages of
DFEs are the simple and robust design together with their
high efficiency, i.e. low losses. The main disadvantages are
unidirectional power flow and the high harmonic content in
the line current, typically THD 30- 40%.
Fig. 1 Standard AC drive.
1.10.2 AC drive with AFR or AFG (FDUL/VFXR/FDUG/VFXG)
An AFE unit is basically a VSI towards the supply (via a
filter) where the IGBTs are used as an active rectifier, see
Fig. 2. The main advantages are inherent 4Q-operation, i.e.
bi-directional power flow, and sinusoidal supply currents,
i.e. low harmonics, regeneration and improved power factor.
The AFE unit is controlled in such a way to keep the energy
between motor and supply in balance. This is achieved by
controlling the DC-link voltage (Udc). Other features are
the possibility for reactive power compensation and boosted
DC-link voltage.
Fig. 2 VSI with AFR/AFG.
AFE
VSI
AFR/AFG = AFE + LCL-filter
FDUL/VFXR = AFR + VSI (FDU/VFX)
AFR/AFG
FDUG/VFXG = AFG + VSI (FDU/VFX)

10 Introduction CG Drives & Automation 01-7694-01r0
1.10.3 AFR
AFR consists of Emotron power electronic module (AFE)
connected to grid through LCL filter as shown in Fig. 3.
The main objective of the Emotron AFR is to rectify the
supply AC voltage into the DC voltage to be fed to or
regenerated from the VSIs (motor inverter). It also keeps the
harmonic content of the current exchanged with grid at low
level, maintaining the THD(I) below 5%. AFR offers
standard AFE functionality such as:
-Activepowercontrol.
- Reactive power control.
- Low harmonic operation.
Fig. 3 AFR
AFE VSI
AFR= AFE + LCL filter
AFR
LCL
AFE
Udc

CG Drives & Automation 01-7694-01r0 Introduction 11
1.11 Emotron single drive cabinet concept
1.11.1 FDUL/VFXR/FDUG/VFXG (single drive) applications
The Emotron low harmonic and regenerative AC drive i.e.
FDUL/VFXR/FDUG/VFXG is comprised by an AFR or
AFG unit i.e. AFE and filters and a VSI, i.e. Emotron VFX
or FDU. The concept is designed as a cabinet solution, see
Fig. 4.
Fig. 4 Single drive in cabinet
where
• Cabinet - IP54 cabinet with fans
• Q1 - Main switch *
• K1 - Main contactor *
•RFI-EMCfilter
•LCL-LCLfilter
• F2 - MCB (Miniature circuit breaker) for pre-charge
circuit
• AFE - Emotron AFE module with 24V standby supply
board, voltage measurement board, brake chopper
switch (optional) and integrated pre-charge circuit
(K2,D2,R2)
• AFR/AFG - Emotron AFE and filters
• VSI - DC-voltage fed VSI module, i.e. Emotron VFX or
FDU
• CB - Control board
• Lo - Output coil
* For larger units, Q1 Main switch and K1 Main contact are
replaced by Q1 Motorized circuit breaker.
1.11.2 Common DC-bus applications
For common DC-bus applications, the cabinet will contain
only the AFR/AFG part of Fig. 4, i.e. all except the VSI &
Lo.
AFR/AFG
CB CB
AFR/AFG = AFE + LCL
FDUL/VFXR = AFR + VSI (FDU/VFX)
FDUG/VFXG = AFG + VSI (FDU/VFX)
NOTE:
For AFG/FDUG/VFXG, supply voltage measurement
board (SVMB) is mandatory. It is mounted and
connected internally to K2.

12 Introduction CG Drives & Automation 01-7694-01r0
1.12 Emotron AFR/AFG concept
Emotron also offers only AFR/AFG solution for the
applications where complete FDUL/VFXR/FDUG/VFXG
drive train is not required. In this concept, the DC power
load/source is connected to the DC-terminals of AFR/AFG.
AFR/AFG consists of AFE power electronic module and
LCL filters as main components along with other necessary
components. AFR/AFG concept is shown in Fig. 5.
Fig. 5 AFR/AFG concept
where
• Cabinet - outer cabinet (for example IP54)
• Q1 - Main switch *
• K1 - Main contactor *
•RFI-EMCfilter
•LCL-LCLfilter
• F2 - MCB (Miniature circuit breaker) for pre-charge
circuit
• AFE - Emotron AFE module with 24V standby supply
board, voltage measurement board, optional brake
chopper switch and integrated pre-charge circuit (K2,
D2, R2)
• AFR/AFG - Emotron AFE and filters
• DC source/load - External DC power source or load
based on the application.
• CB - Control board
* For larger units, Q1 Main switch and K1 Main contact
are replaced by Q1 Motorized circuit breaker.
Cabinet
DC
source/load
Q1 K1
F2
RFI L2
AFR/AFG AFE
Udc
K2 D2 R2
CB & PPU
C
DC+
DC-
NOTE:
For AFG/FDUG/VFXG, supply voltage measurement
board (SVMB) is mandatory. It is mounted and
connected internally to K2.

CG Drives & Automation 01-7694-01r0 Mounting 13
2. Mounting
This chapter describes how to mount the AC drive.
Before mounting it is recommended that the installation is
planned out first.
• Be sure that the AC drive suits the mounting location.
• The mounting site must support the weight of the AC
drive.
• Will the AC drive continuously withstand vibrations
and/or shocks?
• Consider using a vibration damper.
• Check ambient conditions, ratings, required cooling air/
water flow, compatibility of the motor, etc.
• Know how the AC drive will be lifted and transported.
2.1 Lifting instructions
2.1.1 Transport by crane
All enclosures are suitable for transporting by crane, either as
free-standing enclosures or as bayed suites.
With eyebolts
Individual enclosures are safely transported using the
eyebolts.
For symmetrical loads, the following maximum permissible
overall loads apply:
Fig. 6 Lifting enclosures with eyebolts.
Note: To prevent personal risks and any damage to the
unit during lifting, it is advised that the lifting methods
described below are used.
Ta b l e 4
Cable/chain angle A Permitted load (F)
45 ° 4 800 N (1080 lbf)
60 ° 6 400 N (1439 lbf)
90 ° 13 600N (3057 lbf)
Note: Calculated load F as F [N] = m [kg] x 9.81.
F
F
F
F
F
F
A

14 Mounting CG Drives & Automation 01-7694-01r0
With combination angle
For the enclosure combination with internal baying brackets
and combination angles shown here, the load capacity with a
cable pull angle of 60° is as follows:
F1 = 7000 N
F2 = 7000 N
Fig. 7 Enclosure combination with internal brackets.
For the enclosure combination with internal baying brackets
and combination angles shown here, the load capacity with a
cable pull angle of 60° is as follows:
F1 = 7000 N
F2 = 14000 N
F3 = 7000 N
Fig. 8 Enclosure combination with internal brackets.
F1 F2
F1 F2 F3

CG Drives & Automation 01-7694-01r0 Mounting 15
2.1.2 Transport by fork-lift truck
When transporting individual and bayed enclosures, please take care to ensure that the base/plinth trim panels are fitted, and
loads are restricted to the immediate vicinity of the base/plinth corner pieces.
Transport of individual enclosures
Fig. 9 Transport of individual enclosure with fork-lift truck.
Transport of bayed enclosure suites
For the enclosure combination with internal baying brackets
the following load capacities are supported:
Fig. 10 Transport of enclosure combination with fork-lift truck.
FF
FFF
Max. 15000 N
Max. 15000 N
Max. 7000 N
Max. 14000 N
Max. 7000 N

16 Mounting CG Drives & Automation 01-7694-01r0

CG Drives & Automation 01-7694-01r0 Control Connection 17
3. Control Connection
3.1 Control board location
Fig. 11 Control board location (example FDUL46-1710-CL (left side AFR, right side VSI)

18 Control Connection CG Drives & Automation 01-7694-01r0
3.2 Control board
Fig. 12 shows the layout of the control board which is where
the parts most important to the user are located. Although
the control board is galvanically isolated from the mains, for
safety reasons do not make changes while the mains supply
is on!
Fig. 12 Control board layout.
WARNING!
Always switch off the mains voltage and wait
at least 7 minutes to allow the DC capacitors
to discharge before connecting the control
signals or changing position of any switches. If the
option External supply is used, switch of the mains to
the option. This is done to prevent damage on the
control board.
X8
X2
X3
X1
S1
X5X4 X6 X7
UI
S2
S3
S4
S5
1
12 22
11
41 42 43
31 32 33 51 52
23 4 567 8 910
13 14 15 16 17 18 19 20 21
AO1 AO2 DI4 DI5 DI6 DI7 DO1 DO2 DI8
+24VDI3
DI2
DI1-10V
AI4
AI3AI2
AI1+10V
NC
NC
NO
NO NO
C
CC
R01
R02
R03
X11
A+
B-
OFF
PE
ON
Relay outputs
Control signals
AnIn jumpers
Option
Control
Panel
Communication
Standby supply
Termination switch, RS485