Danfoss Vacon NXP Series User manual

Operating guide
VACON® NXS/NXP Air-cooled
Wall-mounted and Standalone

Contents
1 Introduction 8
1.1 Purpose of this Operating Guide 8
1.2 Additional Resources 8
1.3 Disposal 8
1.4 Type Approvals and Certifications 8
1.5 Start-up Quick Guide 9
2 Safety 11
2.1 Safety Symbols 11
2.2 Danger and Warnings 11
2.3 Cautions and Notices 13
3 Product Overview 15
3.1 Intended Use 15
3.2 Manual Version 15
3.3 Package Label 15
3.4 Description of the Type Code 16
3.5 Enclosure Sizes 19
3.6 Available Protection Ratings 21
3.7 Available EMC Classes 22
3.8 Control Panel 23
3.8.1 Introduction to Control Panel 23
3.8.2 Keypad 23
3.8.3 Display 25
3.8.4 Basic Menu Structure 26
4 Receiving the Delivery 28
4.1 Checking the Delivery 28
4.2 Storing the Product 30
4.3 Lifting the Product 30
4.4 Using the Product Modified Label 30
5 Mounting the Unit 32
5.1 Environmental Requirements 32
5.1.1 General Environmental Requirements 32
5.1.2 High Altitude Installation 32
5.2 Cooling Requirements 33
5.2.1 General Cooling Requirements 33
5.2.2 Cooling of FR4 to FR9 33
5.2.3 Cooling of Standalone AC drives (FR10 to FR11) 36
Contents
Operating guide | VACON® NXS/NXP Air-cooled
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5.3 Installation Sequence 37
5.3.1 Installation Sequence for Wall-mounted AC Drives 37
5.3.2 Installation Sequence for Standalone AC drives 37
6 Electrical Installation 38
6.1 Cable Connections 38
6.1.1 General Cable Requirements 38
6.1.2 UL Standards on Cabling 39
6.1.3 Cable Selection and Dimensioning 39
6.1.4 Cable Selection and Dimensioning, North America 39
6.1.5 Fuse Selection 40
6.1.6 Principle of the Power Unit Topology 40
6.1.7 Brake Resistor Cables 40
6.2 EMC-compliant Installation 41
6.2.1 Installation in a Corner-grounded Network 42
6.3 Grounding 42
6.4 Get Access and Locate the Terminals 44
6.4.1 Get Access and Locate the Terminals for FR4 44
6.4.2 Get Access and Locate the Terminals for FR5 46
6.4.3 Get Access and Locate the Terminals for FR6 48
6.4.4 Get Access and Locate the Terminals for FR7 50
6.4.5 Get Access and Locate the Terminals for FR8 52
6.4.6 Get Access and Locate the Terminals for FR9 54
6.5 Installing the Cables 56
6.5.1 Additional Instructions for Cable Installation 57
6.5.2 Installing the Cables, FR4-FR6 57
6.5.3 Installing the Cables, FR7 60
6.5.4 Installing the Cables, FR8 63
6.5.5 Installing the Cables, FR9 66
6.5.6 Installing the Cables, FR10-FR11 68
6.6 Installation in an IT System 68
6.6.1 Installing the AC drive in an IT System, FR4-FR6 69
6.6.2 Installing the AC Drive in an IT System, FR7 72
6.6.3 Installing the AC Drive in an IT System, FR8-FR11 75
7 Control Unit 76
7.1 Control Unit Components 76
7.2 Control Voltage (+24V/EXT +24V) 76
7.3 Control Unit Cabling 77
7.3.1 Selection of the Control Cables 77
7.3.2 Control Terminals on OPTA1 78
7.3.3 Control Terminals on OPTA2 and OPTA3 81
Contents
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7.4 Installation of Option Boards 83
7.5 Galvanic Isolation Barriers 83
8 Using the Control Panel 85
8.1 Navigating on the Control Panel 85
8.2 Using the Monitoring Menu (M1) 85
8.2.1 Monitored Values 86
8.3 Using the Parameter Menu (M2) 87
8.3.1 Finding the Parameter 87
8.3.2 Selecting Values 88
8.3.3 Editing the Values Digit by Digit 89
8.4 Using the Keypad Control Menu 90
8.4.1 Finding the Keypad Control Menu 90
8.4.2 Keypad Control Parameters M3 91
8.4.3 Changing the Control Mode 91
8.4.4 Keypad Reference 92
8.4.5 Changing the Rotation Direction 92
8.4.6 Disabling the Stop Motor Function 93
8.4.7 Special Functions in Keypad Control Menu 93
8.5 Using the Active Faults Menu (M4) 94
8.5.1 Finding the Active Faults Menu 94
8.5.2 Examining the Fault Time Data Record 95
8.5.3 Fault Time Data Record 95
8.6 Using the Fault History Menu (M5) 96
8.6.1 Fault History Menu (M5) 96
8.6.2 Resetting the Fault History 97
8.7 Using the System Menu (M6) 97
8.7.1 Finding the System Menu 97
8.7.2 System Menu Functions 97
8.7.3 Changing the Language 100
8.7.4 Changing the Application 100
8.7.5 Copy Parameters (S6.3) 101
8.7.6 Security 104
8.7.7 Keypad Settings 107
8.7.8 Hardware Settings 108
8.7.9 System Info 111
8.8 Using the Expander Board Menu 114
8.8.1 Expander Board Menu 114
8.8.2 Examining the Connected Option Boards 114
8.8.3 Finding the Option Board Parameters 115
8.9 Further Control Panel Functions 115
Contents
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9 Commissioning 116
9.1 Safety Checks before Starting the Commissioning 116
9.2 Commissioning the AC Drive 117
9.3 Measuring the Cable and Motor Insulation 118
9.3.1 Insulation Checks of the Motor Cable 118
9.3.2 Insulation Checks of the Mains Cable 119
9.3.3 Insulation Checks of the Motor 119
9.4 Checks after Commissioning 120
9.4.1 Testing the AC Drive after Commissioning 120
9.4.2 RUN Test without Load 120
9.4.3 Start-up Test 121
9.4.4 Identification Run 121
10 Maintenance 122
10.1 Maintenance Schedule 122
10.2 Reforming the Capacitors 122
11 Fault Tracing 123
11.1 General Information on Fault Tracing 123
11.2 Resetting a Fault 123
11.3 Creating Service Info File 124
12 Specifications 125
12.1 Weights of the AC Drive 125
12.2 Dimensions 125
12.2.1 List of Dimension Information 125
12.2.2 Wall-mounted 126
12.2.3 Flange mounting 130
12.2.4 Standalone 136
12.3 Cable and Fuse Sizes 137
12.3.1 List of Cable and Fuse Size Information 137
12.3.2 Cable and Fuse Sizes for 208–240 V and 380–500 V, FR4 to FR9 137
12.3.3 Cable and Fuse Sizes for 208–240 V and 380–500 V, FR4 to FR9, North America 138
12.3.4 Cable and Fuse Sizes for 525–690 V, FR6 to FR9 140
12.3.5 Cable and Fuse Sizes for 525–690 V (UL Rating 600 V), FR6 to FR9, North America 141
12.3.6 Cable and Fuse Sizes for 380–500 V, FR10 to FR11 142
12.3.7 Cable and Fuse Sizes for 380–500 V, FR10 to FR11, North America 142
12.3.8 Cable and Fuse Sizes for 525–690 V, FR10 to FR11 143
12.3.9 Cable and Fuse Sizes for 525–690 V (UL Rating 600 V), FR10 to FR11, North America 144
12.4 Cable Stripping Lengths 144
12.5 Tightening Torques for Cover Screws 146
12.6 Tightening Torques of the Terminals 146
Contents
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12.7 Power ratings 147
12.7.1 Overload Capability 147
12.7.2 Power Ratings for Mains Voltage 208–240 V 148
12.7.3 Power Ratings for Mains Voltage 208–240 V, North America 149
12.7.4 Power Ratings for Mains Voltage 380–500 V 150
12.7.5 Power Ratings for Mains Voltage 380–500 V, North America 151
12.7.6 Power Ratings for Mains Voltage 525–690 V (UL Rating 600 V) 152
12.7.7 Power Ratings for Mains Voltage 525–690 V (UL Rating 600 V), North America 153
12.8 VACON NXP Technical Data 154
12.9 Brake Resistor Ratings 159
12.9.1 Brake Resistor Ratings 159
12.9.2 Brake Resistor Ratings for Mains Voltage 208–240 V 159
12.9.3 Brake Resistor Ratings for Mains Voltage 380–500 V 160
12.9.4 Brake Resistor Ratings for Mains Voltage 525–690 V 161
12.10 Fault Codes 162
12.11 EU Declaration of Conformity 169
Contents
Operating guide | VACON® NXS/NXP Air-cooled
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1 Introduction
1.1 Purpose of this Operating Guide
This operating guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions
and general warnings. Always keep this operating guide available with the drive.
1.2 Additional Resources
Other resources are available to understand advanced AC drive functions and programming.
• The VACON®NX All-in-One Application Manual provides greater detail on working with parameters and shows many application
examples.
• The VACON®NX I/O Boards User Manual gives more information on the I/O boards and their installation.
• Instructions for operation with option boards and other optional equipment.
Supplementary publications and manuals are available from Danfoss.
NOTE! Download the English and French product manuals with applicable safety, warning and caution information from https://
www.danfoss.com/en/service-and-support/.
REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l'ensemble des informations
de sécurité, avertissements et mises en garde applicables sur le site https://www.danfoss.com/en/service-and-support/.
1.3 Disposal
Context:
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with
local and currently valid legislation.
1.4 Type Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
Introduction
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089
NOTICE
The specific approvals and certification for the drive are on the nameplate of the drive. For more information, contact the local
Danfoss office or partner.
1.5 Start-up Quick Guide
Context:
Do at minimum these procedures during the installation and commissioning.
If there are problems, speak to the local distributor.
Vacon Ltd is not responsible for the use of the AC drives against the instructions.
Introduction
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Procedure
1. Check that the delivery agrees to the order, see 4.1 Checking the Delivery.
2. Before starting the commissioning, read carefully the safety instructions in 2.2 Danger and Warnings and 2.3 Cautions and Notices.
3. Before the mechanical installation, check the minimum clearances around the AC drive ( 5.2.2 Cooling of FR4 to FR9 and 5.2.3
Cooling of Standalone AC drives (FR10 to FR11)) and check the ambient conditions in 12.8 VACON NXP Technical Data.
4. Check the dimensions of the motor cable, mains cable, mains fuses and check the cable connections. Read 6.1 Cable Connections,
6.2 EMC-compliant Installation and 6.3 Grounding.
5. Obey the installation instructions, see 6.5 Installing the Cables.
6. Find information on the control connections in 7.3.2 Control Terminals on OPTA1.
7. If the start-up wizard is active, select the language of the control panel and the application. Accept the selections with the Enter
button. If the start-up wizard is not active, obey the instructions a and b.
ASelect the language of the control panel from the Menu M6, page 6.1. For instructions, see 8.7.3 Changing the Language.
BSelect the application from the Menu M6, page 6.2. For instructions, see 8.7.4 Changing the Application.
8. All parameters have factory default values. To make sure that the AC drive operates correctly, make sure that these group G2.1
parameters have the same data as the nameplate. For more information on the parameters in the list, see the VACON®All in One
Application Manual.
• Nominal voltage of the motor
• Nominal frequency of the motor
•Nominal speed of the motor
• Nominal current of the motor
• Motor cos phi
9. Obey the commissioning instructions, see 9.2 Commissioning the AC Drive.
The VACON®NXS/NXP AC drive is ready for operation.
Introduction
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2 Safety
2.1 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a property damage message.
2.2 Danger and Warnings
DANGER
SHOCK HAZARD FROM POWER UNIT COMPONENTS
The power unit components are live when the drive is connected to mains. A contact with this voltage can lead to death or
serious injury.
-Do not touch the components of the power unit when the drive is connected to mains. Before connecting the drive to
mains, make sure that the covers of the drive are closed.
DANGER
SHOCK HAZARD FROM TERMINALS
The motor terminals U, V, W, the brake resistor terminals, or the DC terminals are live when the drive is connected to mains, also
when the motor does not operate. A contact with this voltage can lead to death or serious injury.
-Do not touch the motor terminals U, V, W, the brake resistor terminals, or the DC terminals when the drive is connected to
mains. Before connecting the drive to mains, make sure that the covers of the drive are closed.
Safety
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DANGER
SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE
The terminal connections and the components of the drive can be live 5 minutes after the drive is disconnected from the mains
and the motor has stopped. Also the load side of the drive can generate voltage. A contact with this voltage can lead to death
or serious injury.
-Before doing electrical work on the drive:
•Disconnect the drive from the mains and make sure that the motor has stopped.
• Lock out and tag out the power source to the drive.
• Make sure that no external source generates unintended voltage during work.
• Wait 5 minutes before opening the cabinet door or the cover of the AC drive.
• Use a measuring device to make sure that there is no voltage.
WARNING
SHOCK HAZARD FROM CONTROL TERMINALS
The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this
voltage can lead to injury.
-Make sure that there is no voltage in the control terminals before touching the control terminals.
WARNING
ACCIDENTAL MOTOR START
When there is a power-up, a power break, or a fault reset, the motor starts immediately if the start signal is active, unless the
pulse control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions
(including the start inputs) can change. If you activate the auto reset function, the motor starts automatically after an automatic
fault reset. See the Application Guide. Failure to ensure that the motor, system, and any attached equipment are ready for start
can result in personal injury or equipment damage.
-Disconnect the motor from the drive if an accidental start can be dangerous. Make sure that the equipment is safe to
operate under any condition.
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.
-Ensure the correct grounding of the equipment by a certified electrical installer.
WARNING
SHOCK HAZARD FROM PE CONDUCTOR
The drive can cause a DC current in the PE conductor. Failure to use a residual current-operated protective (RCD) device Type B
or a residual current-operated monitoring (RCM) device can lead to the RCD not providing the intended protection and
therefore can result in death or serious injury.
-Use a type B RCD or RCM device on the mains side of the drive.
Safety
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2.3 Cautions and Notices
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT MEASUREMENTS
Doing measurements on the AC drive when it is connected to mains can damage the drive.
-Do not do measurements when the AC drive is connected to mains.
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS
Using spare parts that are not from the manufacturer can damage the drive.
-Do not use spare parts that are not from the manufacturer.
CAUTION
DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING
Not using a grounding conductor can damage the drive.
-Make sure that the AC drive is always with a grounding conductor that is connected to the grounding terminal that is
identified with the PE symbol.
CAUTION
CUT HAZARD FROM SHARP EDGES
There can be sharp edges in the AC drive that can cause cuts.
-Wear protective gloves when mounting, cabling, or doing maintenance operations.
CAUTION
BURN HAZARD FROM HOT SURFACES
Touching surfaces, which are marked with the 'hot surface' sticker, can result in injury.
-Do not touch surfaces which are marked with the 'hot surface' sticker.
NOTICE
DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE
Some of the electronic components inside the AC drive are sensitive to ESD. Static voltage can damage the components.
-Remember to use ESD protection always when working with electronic components of the AC drive. Do not touch the
components on the circuit boards without proper ESD protection.
Safety
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NOTICE
DAMAGE TO THE AC DRIVE FROM MOVEMENT
Movement after installation can damage the drive.
-Do not move the AC drive during operation. Use a fixed installation to prevent damage to the drive.
NOTICE
DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL
The EMC level requirements for the AC drive depend on the installation environment. An incorrect EMC level can damage the
drive.
-Before connecting the AC drive to the mains, make sure that the EMC level of the AC drive is correct for the mains.
NOTICE
RADIO INTERFERENCE
In a residential environment, this product can cause radio interference.
-Take supplementary mitigation measures.
NOTICE
MAINS CONNECTION DEVICE
If the AC drive is used as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN
60204-1).
NOTICE
MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES
Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not
operate correctly.
NOTICE
VOLTAGE WITHSTAND TESTS
Doing voltage withstand tests can damage the drive.
-Do not do voltage withstand tests on the AC drive. The manufacturer has already done the tests.
Safety
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3 Product Overview
3.1 Intended Use
The drive is an electronic motor controller intended for:
• Regulation of motor speed in response to system feedback or to remote commands from external controllers. A power drive
system consists of the AC drive, the motor, and equipment driven by the motor.
• System and motor status surveillance.
The drive can also be used for motor overload protection.
Depending on the configuration, the drive can be used in standalone applications or form part of a larger appliance or installation.
The drive is allowed for use in residential, industrial, and commercial environments in accordance with local laws and standards.
NOTICE
In a residential environment, this product can cause radio interference, in which case supplementary mitigation measures can
be required.
Foreseeable misuse
Do not use the drive in applications which are non-compliant with specified operating conditions and environments. Ensure
compliance with the conditions specified in 12.8 VACON NXP Technical Data.
3.2 Manual Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
Table 1: Manual and Software Version
Edition Remarks
DPD00910G Package label and type code information changed in 3.3 Package Label and 3.4 Description of the Type Code.
Information on removing the jumper X10-1 added in 6.6.1 Installing the AC drive in an IT System, FR4-FR6.
Information on creating a service info file added in 11.3 Creating Service Info File.
Structure of the manual changed.
3.3 Package Label
The package label gives detailed information about the delivery.
Product Overview
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A B
H
G
F
E
D
C
I
e30bf961.10
1003322235
V00001687465
NXP00875-A2H1SSS-A1A2000000
171208
B.ID :
S/ N:
Type:
AC DRI VE
V00001687465
7DP-008752-116SC8
Made in Finland
Danfoss A/S, 6430 Nordborg, Denmark
135X9219
87A 40°C / 72A 50°C
87A 40°C / 72A 50°C
45kW:400V / 60HP:480V
IP21/Type1
3~AC,0-Uin, 0-320Hz,
Uin:3~AC,380-500V, 50/60Hz,
POWER :
OUTPUT:
INPUT:
Danfoss Limited
0018131571
NXP00002V195
Ma rks:
Cust. Or d. No :
Appl icat ion :
Firm w are :
7DP-008752-116SC8
Code:
AThe batch ID
CThe type code
EThe mains voltage
GThe protection rating
IThe order number of the customer
BThe order number of VACON®
DThe serial number
FThe nominal output current
HThe firmware code
Illustration 1: Package Label of VACON®NXS/NXP AC Drives
3.4 Description of the Type Code
The type designation code of VACON®is made of standard codes and optional codes. Each part of the type designation code agrees to
the data in the order.
Example:
The code can have this format, for example:
•NXP00035-A2H1SSS-A1A2C30000+DNOT
Product Overview
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Table 2: Description of the Type Code
Code Description
VACON This part is same for all the products.
NXP The product range:
• NXP = VACON®NXP
•NXS = VACON®NXS
0003 The drive rating in amperes. For example, 0003 = 3 A
5 The mains voltage:
• 2 = 208–240 V
•5 = 380–500 V
• 6 = 525–600 V (IEC)
525–600 V (cULus)
A The control panel:
•A = standard (text display)
•B = no local control panel
• F = dummy keypad
• G = graphic display
2 The protection rating:
•0 = IP00
• 2 = IP21 (UL Type 1)
• 5 = IP54 (UL Type 12)
• T = flange-mounted (through-hole mounted)
H The EMC emission level:
•C = complies with the category C1 of standard IEC/EN 61800-3 + A1, 1st environment, and nominal voltage less
than 1000 V
•H = complies with the category C2 of standard IEC/EN 61800-3 + A1, fixed installations, and nominal voltage
less than 1000 V
• L = complies with the category C3 of standard IEC/EN 61800-3 + A1, 2nd environment, and nominal voltage less
than 1000 V
• T = complies with the standard IEC/EN 61800-3 + A1 when used in IT networks (C4).
• N = No EMC emission protection. An external EMC filter is necessary.
1The brake chopper:(1)
•0 = No brake chopper
•1 = Internal brake chopper
• 2 = Internal brake chopper and resistor, available for:
- 208–240 V (FR4-FR6)
- 380–500 V (FR4-FR6)
Product Overview
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Code Description
SSS The hardware changes:
• The supply, the first letter (Xxx):
- S = 6-pulse connection (FR4 to FR11)
- B = Additional DC-connection (FR8 to FR11)
- J = FR10 to 11 stand-alone with main switch and DC-link terminals
• The mounting, the second letter: (xXx):
- S = Air-cooled drive
• The boards, the third letter (xxX):
- S = Standard boards (FR4 to FR8)
- V = Coated boards (FR4 to FR8)
- F = Standard boards (FR9 to FR11)
- G = Coated boards (FR9 to FR11)
- A = Standard boards (FR10 to FR11 standalone drives)
- B = Coated boards (FR10 to FR11 standalone drives)
- N = separate IP54 (UL Type 12) control box, standard boards (FR9 IP00, ≥ FR10)
- O = separate IP54 (UL Type 12) control box, coated boards (FR9 IP00, ≥ FR10)
- X = separate IP00 control box, standard boards (FR9 IP00)
- Y = separate IP00 control box, coated boards (FR9 IP00)
A1A2C30000 The option boards. 2 characters for each slot. 00 = the slot is not used
The option board abbreviations:
•A = basic I/O board
•B = expander I/O board
• C = fieldbus board
• D = special board
• E = fieldbus board
For example, C3 = PROFIBUS DP
+DNOT The optional codes. There are many options.
The options that are related to ordering of paper manuals are:
•+DNOT = No paper manuals, only Quick Guide and Safety Guide
•+DPAP = With English paper manuals
• +DPAP+DLDE = With German paper manuals
1A brake resistor is available as an option for external installation for 208–240 V (FR7-FR11), 380–500 V (FR7-FR11), and 525–690 V (all enclosure sizes).
Product Overview
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3.5 Enclosure Sizes
Example:
The codes for nominal current and nominal mains voltage are part of the type code (see 3.4 Description of the Type Code) on the
package label (see 3.3 Package Label). Use these values to find out the enclosure size of the AC drive from the table.
In the example "NXP00035-A2H1SSS-A1A2C30000+DNOT", the code for nominal current is 0003 and the code for nominal mains
voltage is 5.
Table 3: Enclosure Sizes
Nominal mains voltage Nominal current Enclosure size
2 (208–240 V) 0003 FR4
0004
0007
0008
0011
0012
0017 FR5
0025
0031
0048 FR6
0061
0075 FR7
0088
0114
0140 FR8
0170
0205
0261 FR9
0300
Product Overview
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Nominal mains voltage Nominal current Enclosure size
5 (380–500 V) 0003 FR4
0004
0005
0007
0009
0012
0016 FR5
0022
0031
0038 FR6
0045
0061
0072 FR7
0087
0105
0140 FR8
0168
0205
0261 FR9
0300
0385 FR10
0460
0520
0590 FR11
0650
0730
Product Overview
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