Vacon NXL User manual

vacon nxl
ac drives
user manual
multi-control
application manual
®

AT LEAST THE 11 FOLLOWING STEPS OF THE START-UP QUICK GUIDE MUST BE PERFORMED
DURING THE INSTALLATION AND COMMISSIONING.
IF ANY PROBLEMS OCCUR, PLEASE CONTACT YOUR LOCAL DISTRIBUTOR.
Start-up Quick Guide
1. Check that the delivery corresponds to your order, see Chapter 3.
2. Before taking any commissioning actions read carefully the safety instructions in
Chapter 1.
3. Before the mechanical installation, check the minimum clearances around the unit and
check the ambient conditions in Chapter 5.
4. Check the size of the motor cable, mains cable, mains fuses and check the cable
connections, read Chapter 6.
5. Follow the installation instructions, see Chapter 5.
6. Control cable sizes and the grounding system are explained in Chapter 6.1.1.
7. Instructions on using the keypad are given in Chapter 7.
8. All parameters have factory default values. In order to ensure proper operation, check
the rating plate data for the values below and the corresponding parameters of
parameter group P2.1. See Chapter 8.3.2.
•nominal voltage of the motor, par. 2.1.6
•nominal frequency of the motor, par. 2.1.7
•nominal speed of the motor, par 2.1.8
•nominal current of the motor, par. 2.1.9
•motor power factor, cosϕ, par. 2.1.10
All parameters are explained in the Multi-Control Application Manual.
9. Follow the commissioning instructions, see Chapter 8.
10. The Vacon NXL Frequency Converter is now ready for use.
11. In the end of this manual, you will find a quick help with the default I/O, control panel
menus, monitoring values, fault codes and basic parameters
Vacon Plc is not responsible for the use of the frequency converters against
the instructions.

CONTENTS
VACON NXL USER’S MANUAL
INDEX
1SAFETY
2EU DIRECTIVE
3RECEIPT OF DELIVERY
4TECHNICAL DATA
5INSTALLATION
6CABLING AND CONNECTIONS
7CONTROL KEYPAD
8COMMISSIONING
9FAULT TRACING
10 DESCRIPTION OF BOARD OPT-AA
11 DESCRIPTION OF BOARD OPT-AI
VACON MULTI-CONTROL APPLICATION MANUAL

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ABOUT THE VACON NXL USER'S MANUAL
AND THE MULTI-CONTROL APPLICATION MANUAL
Congratulations for choosing the Smooth Control provided by Vacon NXL frequency converters!
The User's Manual will provide you with the necessary information about the installation,
commissioning and operation of Vacon NXL Frequency Converter. We recommend that you carefully
study these instructions before powering up the frequency converter for the first time.
In the Multi-Control Application Manual you will find information about the application used in the
Vacon NXL Drive.
This manual is available in both paper and electronic editions. We recommend you to use the
electronic version if possible. If you have the electronic version at your disposal you will be able to
benefit from the following features:
The manual contains several links and cross-references to other locations in the manual which
makes it easier for the reader to move around in the manual, to check and find things faster.
The manual also contains hyperlinks to web pages. To visit these web pages through the links you
must have an internet browser installed on your computer.
NOTE: You will not be able to edit the Microsoft Word version of the manual without a valid password.
Open the manual file as a read-only version.
All specifications and information are subject to changes without further notice.

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Vacon NXL User's Manual
Document code: DPD01446A
Table of contents Date: 24.02.2014
1. SAFETY............................................................................................................................. 7
1.1 Warnings ................................................................................................................................... 7
1.2 Safety instructions.................................................................................................................... 7
1.3 Earthing and earth fault protection ......................................................................................... 8
1.4 Running the motor.................................................................................................................... 9
2. EU DIRECTIVE ................................................................................................................ 10
2.1 CE marking ............................................................................................................................. 10
2.2 EMC directive .......................................................................................................................... 10
2.2.1 General............................................................................................................................ 10
2.2.2 Technical criteria............................................................................................................ 10
2.2.3 Environments defined in the product standard EN 61800-3:2004+A1:2012................. 10
2.2.4 Vacon frequency converter EMC classification ............................................................. 10
2.2.5 Manufacturer's declaration of conformity..................................................................... 11
3. RECEIPT OF DELIVERY................................................................................................... 13
3.1 Type designation code ............................................................................................................ 13
3.2 Storage.................................................................................................................................... 14
3.3 Maintenance............................................................................................................................ 14
3.4 Warranty.................................................................................................................................. 15
4. TECHNICAL DATA .......................................................................................................... 16
4.1 Introduction............................................................................................................................. 16
4.2 Power ratings.......................................................................................................................... 18
4.2.1 Vacon NXL – Mains voltage 208 – 240 V......................................................................... 18
4.2.2 Vacon NXL – Mains voltage 380 – 500 V......................................................................... 18
4.3 Technical data......................................................................................................................... 19
5. INSTALLATION............................................................................................................... 21
5.1 Mounting ................................................................................................................................. 21
5.1.1 MF2 and MF3 .................................................................................................................. 21
5.1.2 MF4 – MF6....................................................................................................................... 24
5.2 Cooling .................................................................................................................................... 25
5.3 Changing EMC protection class from H to T.......................................................................... 26
6. CABLING AND CONNECTIONS ....................................................................................... 27
6.1 Power connections ................................................................................................................. 27
6.1.1 Cabling ............................................................................................................................ 28
6.1.1.1 Cable and fuse sizes............................................................................................... 29
6.1.2 Mounting of cable accessories....................................................................................... 30
6.1.3 Installation instructions ................................................................................................. 32
6.1.3.1 Stripping lengths of motor and mains cables ....................................................... 33
6.1.3.2 Installation of cables to Vacon NXL ....................................................................... 34
6.1.4 Cable installation and the UL standards ....................................................................... 42
6.1.5 Cable and motor insulation checks ............................................................................... 42
6.2 Control unit ............................................................................................................................. 43
6.2.1 MF2 – MF3....................................................................................................................... 43

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6.2.2 MF4 – MF6....................................................................................................................... 43
6.2.2.1 Allowed option boards in MF4 – MF6:.................................................................... 43
6.2.3 Control connections ....................................................................................................... 44
6.2.4 Control I/O....................................................................................................................... 45
6.2.5 Control terminal signals ................................................................................................ 46
6.2.5.1 Jumper selections on Vacon NXL basic board...................................................... 47
6.2.6 Motor thermistor (PTC) connection ............................................................................... 50
7. CONTROL KEYPAD ......................................................................................................... 51
7.1 Indications on the Keypad display.......................................................................................... 51
7.1.1 Drive status indications.................................................................................................. 51
7.1.2 Control place indications................................................................................................ 52
7.1.3 Numeric indications ....................................................................................................... 52
7.2 Keypad push-buttons.............................................................................................................. 53
7.2.1 Button descriptions ........................................................................................................ 53
7.3 Start-up wizard ....................................................................................................................... 54
7.4 Navigation on the control keypad........................................................................................... 55
7.4.1 Monitoring menu (M1) .................................................................................................... 58
7.4.2 Parameter menu (P2)..................................................................................................... 61
7.4.3 Keypad control menu (K3).............................................................................................. 63
7.4.3.1 Selection of control place ...................................................................................... 63
7.4.3.2 Keypad reference ................................................................................................... 64
7.4.3.3 Keypad direction..................................................................................................... 64
7.4.3.4 Stop button activation............................................................................................. 64
7.4.4 Active faults menu (F4)................................................................................................... 65
7.4.4.1 Fault types .............................................................................................................. 65
7.4.4.2 Fault codes ............................................................................................................. 66
7.4.5 Fault history menu (H5).................................................................................................. 68
7.4.6 System menu (S6)........................................................................................................... 69
7.4.6.1 Copy parameters .................................................................................................... 71
7.4.6.2 Security ................................................................................................................... 71
7.4.6.3 Keypad settings ...................................................................................................... 72
7.4.6.4 Hardware settings.................................................................................................. 73
7.4.6.5 System information ................................................................................................ 74
7.4.6.6 AI mode ................................................................................................................... 77
7.4.7 Modbus interface............................................................................................................ 78
7.4.7.1 Modbus RTU protocol............................................................................................. 78
7.4.7.2 Termination Resistor.............................................................................................. 79
7.4.7.3 Modbus address area............................................................................................. 79
7.4.7.4 Modbus process data ............................................................................................. 79
7.4.7.5 Fieldbus parameters.............................................................................................. 81
7.4.8 Expander board menu (E7)............................................................................................. 83
7.5 Further keypad functions ....................................................................................................... 83
8. COMMISSIONING............................................................................................................ 84
8.1 Safety....................................................................................................................................... 84
8.2 Commissioning of the frequency converter........................................................................... 84
8.3 Basic parameters ................................................................................................................... 87
8.3.1 Monitoring values (Control keypad: menu M1).............................................................. 87
8.3.2 Basic parameters (Control keypad: Menu P2 B2.1).................................................. 88
9. FAULT TRACING............................................................................................................. 90

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10. DESCRIPTION OF EXPANDER BOARD OPT-AA............................................................... 93
11. DESCRIPTION OF EXPANDER BOARD OPT-AI................................................................ 94

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1. SAFETY
1.1 Warnings
HOT SURFACE
1
The components of the power unit of the frequency converter are
live
when Vacon NXL is connected to mains potential.
Coming into contact
with this voltage is extremely dangerous and may cause death or
severe injury.
The control unit is isolated from the mains potential.
2
The motor terminals U, V, W (T1, T2, T3) and the DC-link/brake resistor
terminals –/+ (in Vacon NXL ≥1.1 kW) are
live
when Vacon NXL is
connected to mains,
even if the motor is not running
.
3
The control I/O-terminals are isolated from the mains potential.
However, the relay outputs and other I/O-terminals may have a
dangerous control voltage present even when Vacon NXL is disconnected
from mains.
4
The earth leakage current of Vacon NXL
exceeds 3.5mA a.c
. According
to EN61800-5-1, a reinforced protective ground connection must be
ensured
.
See Chapter 1.3.
5
If the frequency converter is used as a part of a machine, the machine
manufacturer is responsible for providing the machine with a
disconnecting device (EN60204-1).
6
Only spare parts delivered by Vacon can be used.
7
The heat sink of types MF2 and MF3 may be hot when the frequency
converter is in use.
Coming into contact with the heat sink may cause
burns
.
1.2 Safety instructions
1
The Vacon NXL frequency converter is meant for fixed installations only.
2
Do not perform any measurements when the frequency converter is
connected to the mains.
3
After disconnecting the frequency converter from the mains, wait until
the fan stops and the indicators on the display go out. Wait 5 more
minutes before doing any work on Vacon NXL connections.
5
Do not perform any voltage withstand tests on any part of Vacon NXL.
There is a certain procedure according to which the tests shall be
performed. Ignoring this procedure may result in damaged product.
6
Prior to measurements on the motor or the motor cable, disconnect the
motor cable from the frequency converter.
7
Do not touch the IC-circuits on the circuit boards. Static voltage
discharge may damage the components.
ONLY A COMPETENT ELECTRICIAN MAY CARRY OUT
THE ELECTRICAL INSTALLATION
WARNING

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1.3 Earthing and earth fault protection
The Vacon NXL frequency converter must always be earthed with an earthing conductor connected to
the earthing terminal .
The earth leakage current of Vacon NX_ exceeds 3.5mA AC. According to EN61800-5-1, one or more
of the following conditions for the associated protective circuit shall be satisfied:
a. The protective conductor shall have a cross-sectional area of at least 10 mm2Cu or 16 mm2Al,
through its total run.
b. Where the protective conductor has a cross-sectional area of less than 10 mm2Cu or 16 mm2Al, a
second protective conductor of at least the same cross-sectional area shall be provided up to a
point where the protective conductor has a cross-sectional area not less than 10 mm2Cu or 16
mm2Al.
c. Automatic disconnection of the supply in case of loss of continuity of the protective conductor. See
chapter 6.
The cross-sectional area of every protective earthing conductor which does not form part of the
supply cable or cable enclosure shall, in any case, be not less than:
-2,5mm2 if mechanical protection is provided or
-4mm2 if mechanical protection is not provided.
The earth fault protection inside the frequency converter protects only the converter itself against
earth faults in the motor or the motor cable. It is not intended for personal safety.
Due to the high capacitive currents present in the frequency converter, fault current protective
switches may not function properly.