Vacon NXL series User 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
1 SAFETY
2 EU DIRECTIVE
3 RECEIPT OF DELIVERY
4 TECHNICAL DATA
5 INSTALLATION
6 CABLING AND CONNECTIONS
7 CONTROL KEYPAD
8 COMMISSIONING
9 FAULT 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.

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Vacon NXL User's Manual
Document code: ud00791M
Index Date:22.03.2006
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...................................................................................................................... 8
2. EU DIRECTIVE ....................................................................................................................9
2.1 CE marking ................................................................................................................................. 9
2.2 EMC directive .............................................................................................................................. 9
2.2.1 General.............................................................................................................................. 9
2.2.2 Technical criteria..............................................................................................................9
2.2.3 Vacon frequency converter EMC classification ............................................................... 9
2.2.4 Manufacturer's declaration of conformity......................................................................10
3. RECEIPT OF DELIVERY..................................................................................................... 12
3.1 Type designation code .............................................................................................................. 12
3.2 Storage...................................................................................................................................... 13
3.3 Maintenance.............................................................................................................................. 13
3.4 Warranty.................................................................................................................................... 14
4. TECHNICAL DATA ............................................................................................................ 15
4.1 Introduction............................................................................................................................... 15
4.2 Power ratings............................................................................................................................ 17
4.2.1 Vacon NXL – Mains voltage 208 – 240 V..........................................................................17
4.2.2 Vacon NXL – Mains voltage 380 – 500 V..........................................................................17
4.3 Technical data........................................................................................................................... 18
5. INSTALLATION................................................................................................................. 20
5.1 Mounting ................................................................................................................................... 20
5.1.1 MF2 and MF3 ...................................................................................................................20
5.1.2 MF4 – MF6........................................................................................................................23
5.2 Cooling ...................................................................................................................................... 24
5.3 Changing EMC protection class from H to T............................................................................ 25
6. CABLING AND CONNECTIONS ......................................................................................... 26
6.1 Power connections ................................................................................................................... 26
6.1.1 Cabling .............................................................................................................................27
6.1.1.1 Cable and fuse sizes................................................................................................28
6.1.2 Mounting of cable accessories........................................................................................29
6.1.3 Installation instructions ..................................................................................................31
6.1.3.1 Stripping lengths of motor and mains cables ........................................................32
6.1.3.2 Installation of cables to Vacon NXL ........................................................................33
6.1.4 Cable installation and the UL standards ........................................................................40
6.1.5 Cable and motor insulation checks ................................................................................40
6.2 Control unit ............................................................................................................................... 41
6.2.1 MF2 – MF3........................................................................................................................41

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6.2.2 MF4 – MF6........................................................................................................................41
6.2.2.1 Allowed option boards in MF4 – MF6:.....................................................................41
6.2.3 Control connections ........................................................................................................42
6.2.4 Control I/O........................................................................................................................43
6.2.5 Control terminal signals .................................................................................................44
6.2.5.1 Jumper selections on Vacon NXL basic board .......................................................45
6.2.6 Motor thermistor (PTC) connection ................................................................................48
7. CONTROL KEYPAD ........................................................................................................... 49
7.1 Indications on the Keypad display............................................................................................ 49
7.1.1 Drive status indications...................................................................................................49
7.1.2 Control place indications.................................................................................................50
7.1.3 Numeric indications ........................................................................................................50
7.2 Keypad push-buttons................................................................................................................ 51
7.2.1 Button descriptions .........................................................................................................51
7.3 Start-up wizard ......................................................................................................................... 52
7.4 Navigation on the control keypad............................................................................................. 53
7.4.1 Monitoring menu (M1) .....................................................................................................56
7.4.2 Parameter menu (P2)......................................................................................................58
7.4.3 Keypad control menu (K3)...............................................................................................60
7.4.3.1 Selection of control place .......................................................................................60
7.4.3.2 Keypad reference ....................................................................................................61
7.4.3.3 Keypad direction......................................................................................................61
7.4.3.4 Stop button activation..............................................................................................61
7.4.4 Active faults menu (F4)....................................................................................................62
7.4.4.1 Fault types ...............................................................................................................62
7.4.4.2 Fault codes ..............................................................................................................63
7.4.5 Fault history menu (H5)...................................................................................................65
7.4.6 System menu (S6)............................................................................................................66
7.4.6.1 Copy parameters .....................................................................................................68
7.4.6.2 Security ....................................................................................................................68
7.4.6.3 Keypad settings .......................................................................................................69
7.4.6.4 Hardware settings...................................................................................................70
7.4.6.5 System information .................................................................................................71
7.4.6.6 AI mode....................................................................................................................74
7.4.7 Modbus interface.............................................................................................................75
7.4.7.1 Modbus RTU protocol..............................................................................................75
7.4.7.2 Termination Resistor...............................................................................................76
7.4.7.3 Modbus address area..............................................................................................76
7.4.7.4 Modbus process data ..............................................................................................76
7.4.7.5 Fieldbus parameters...............................................................................................78
7.4.8 Expander board menu (E7)..............................................................................................80
7.5 Further keypad functions ......................................................................................................... 80
8. COMMISSIONING.............................................................................................................. 81
8.1 Safety......................................................................................................................................... 81
8.2 Commissioning of the frequency converter............................................................................. 81
8.3 Basic parameters ..................................................................................................................... 84
8.3.1 Monitoring values (Control keypad: menu M1)...............................................................84
8.3.2 Basic parameters (Control keypad: Menu P2 B2.1)...................................................85

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9. FAULT TRACING............................................................................................................... 87
10. DESCRIPTION OF EXPANDER BOARD OPT-AA................................................................. 90
11. DESCRIPTION OF EXPANDER BOARD OPT-AI.................................................................. 91

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1. SAFETY
1.1 Warnings
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 frequency converter has a large capacitive leakage current.
5 If the frequency converter is used as a part of a machine, the machine
manufacturer is responsible for providing the machine with a main
switch (EN 60204-1).
6 Only spare parts delivered by Vacon can be used.
HOT SURFACE 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.
4 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.
5 Prior to measurements on the motor or the motor cable, disconnect the
motor cable from the frequency converter.
6 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 fault protection inside the frequency converter protects only the converter itself against
earth faults in the motor or the motor cable.
Due to the high capacitive currents present in the frequency converter, fault current protective
switches may not function properly. If fault current protective switches are used they must be tested
with the drive with earth fault currents that are possible to arise in fault situations.
1.4 Running the motor
Warning symbols
For your own safety, please pay special attention to the instructions marked with the following
symbols:
= Dangerous voltage
WARNING =
General warning
HOT SURFACE =
Hot surface – Risk of burn
MOTOR RUN CHECK LIST
1 Before starting the motor, check that the motor is mounted properly and
ensure that the machine connected to the motor allows the motor to be
started.
2 Set the maximum motor speed (frequency) according to the motor and
the machine connected to it.
3 Before reversing the motor shaft rotation direction make sure that this
can be done safely.
4 Make sure that no power correction capacitors are connected to the
motor cable.
5 Make sure that the motor terminals are not connected to mains
potential.
WARNING

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2. EU DIRECTIVE
2.1 CE marking
The CE marking on the product guarantees the free movement of the product within the EEA
(European Economic Area). It also guarantees that the product meets the various requirements
placed upon it (such as the EMC Directive and possibly other directives according to the so-called
new procedure).
Vacon NXL frequency converters carry the CE label as a proof of compliance with the Low Voltage
Directive (LVD) and the Electro Magnetic Compatibility (EMC). The company SGS FIMKO has acted as
the Competent Body.
2.2 EMC directive
2.2.1 General
The EMC Directive provides that the electrical apparatus must not excessively disturb the
environment they are used in, and, on the other hand, it shall have an adequate level of immunity
toward other disturbances from the same environment.
The compliance of Vacon NXL frequency converters with the EMC directive is verified with Technical
Construction Files (TCF) checked and approved by SGS FIMKO, which is a Competent Body.
2.2.2 Technical criteria
EMC compliance is a major consideration for Vacon NXL drives from the outset of the design. Vacon
NXL frequency converters are marketed throughout the world, a fact which makes the EMC
requirements of customers different. All Vacon NXL frequency converters are designed to fulfil even
the strictest immunity requirements.
2.2.3 Vacon frequency converter EMC classification
Vacon NXL frequency converters are divided into two classes according to the level of
electromagnetic disturbances emitted. Later in this manual the division is made according to the
mechanical sizes (MF2, MF3, etc.). The technical data of the different sizes can be found in Chapter
4.3.

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Class C (MF4 to MF6):
Frequency converters of this class fulfil the requirements of the product standard EN 61800-
3+A11 for the 1st environment (unrestricted distribution) and the 2nd environment.
The emission levels correspond to the requirements of EN 61000-6-3.
Class N:
No EMC emission protection. Vacon NXL frames MF2 and MF3 are delivered from the factory
without an external RFI filter as class N products.
Class H:
Vacon NXL frames MF4 – MF6 are delivered from the factory as class H products with an internal
RFI filter. The filter is available as option for classes MF2 and MF3. With a RFI filter Vacon NXL
frequency converters fulfil the requirements of the product standard EN 61800-3 + A11 for the
1st environment restricted distribution and the 2nd environment.
The emission levels correspond to the requirements of EN 61000-6-4.
Class T:
The T-class converters have a small earth current and can be used with IT supplies only. If they are
used with other supplies no EMC requirements are complied with.
All Vacon NX frequency converters fulfil all EMC immunity requirements (standards EN 61000-
6-1, 61000-6-2 and EN 61800-3).
2.2.4 Manufacturer's declaration of conformity
The following page presents the photocopy of the Manufacturer's Declaration of Conformity assuring
the compliance of Vacon frequency converters with the EMC-directives.