OPERATING INSTRUCTIONS - QUICK START GUIDE VAU 1 ......• The emergency stop facilities according to DIN EN 60204-1; VDE 0113-1:2007-06 must remain operational during all operating

OPERATING INSTRUCTIONS - QUICK START GUIDE

VAU 1.1/1-ACFREQUENCY CONVERTER

MAKE IT BECKER

2 BECKER VAU 1.1/1-AC

TABLE OF CONTENTS

1 SAFETY INFORMATION 3

1.1 WARNING SYMBOLS USED 3

1.2 GENERAL INFORMATION 3

1.3 COMMISSIONING INFORMATION 3

1.4 OPERATING INFORMATION 4

1.5 INTENDED USE 5

2 INSTALLATION 6

2.1 CONNECTION SPACE 6

2.1.1 CONNECTION POWER LINE 7

2.1.2 RELAYS 7

2.1.3 MOTOR CONNECTION 7

2.1.4 FAN CONNECTIONS 7

2.1.5 SIGNAL TERMINALS 8

2.1.6 PTC/BIMETALLIC SWITCH 8

2.2 RS485 INTERFACEE 8

2.3 LOCAL OPERATION AND DISPLAY 9

3 FAULT DETECTION AND REMOVAL 9

3.1 TABLE OF THE LED-FLASH CODES 9

3.2 TABLE OF POSSIBLE ERROR MESSAGES 10

4 TECHNICAL SPECIFICATIONS 12

5 INTERFACES 13

6 CERTIFICATIONS 13

Frequency converter integrated Frequency converter separate with fan

Typ 1 - VAU1.1/1-AC-I Typ 2 - VAU1.1/1-AC-L

BECKER VAU 1.1/1-AC 3

1 SAFETY INFORMATION

1.1 WARNING SYMBOLS USED

Danger (general)

Danger from electric shock and electrical discharge

Danger from hot surfaces!

1.2 GENERAL INFORMATION

i Detailed information can be found in the VAU 1.1/1-AC operating instructions.

Visit our homepage for this: www.becker-international.com

i IMPORTANT INFORMATIONThis quick start guide represents only an excerpt of the VAU 1.1/1-AC operating instructions. The latter should be read thoroughly before initial start-up.

The quick start guide contains safety instructions and helps the user to put the basic model of the frequency converter (FC) into operation and to operate it with the default settings.

The frequency converter can only be operated safely if the required ambient conditions, see chapter 4, have been complied with.

Gebrüder BECKER GmbH will not be liable for damage resulting from the non-observance of these operating instructions.

These operating instructions form a part of the product. They apply exclusively to the frequency converter of the VAU series by Gebr. Becker GmbH. Store the operating instructions well accessible for all users near the frequency converter.

i IMPORTANT INFORMATIONAny work concerning transport, installation and commissioning as well as maintenance may only be carried out by qua-lified specialists (observing IEC 364/CENELEC HD 384/DIN VDE 0100 and IEC 664/DIN VDE 0110 and national accident prevention regulations).

Qualified personnel in the meaning of these operating instructions are electricians who are familiar with the installation, assembly, commissioning and operation of the frequency converter and the related risks. In addition they will have know-ledge of the relevant standards and regulations based on their technical training.

WARNINGMortal danger from fire or electric shock!

Death or serious injury!

Only use the frequency converter as intended.

Do not perform any alterations on the frequency converter.

Only use spare parts and accessories sold or recommended by the manufacturer.

During assembly ensure adequate distance to adjacent components.

CAUTIONRisk of burns from hot surfaces!

Serious skin burns from hot surfaces!

The heat sink and all other metal components can heat up to temperatures exceeding 70°C.

Adequate distance to adjacent components must be kept during assembly.

When working on the components ensure sufficient cooling down times.

1.3 COMMISSIONING INFORMATIONElectrical connection

Frequency converters are equipment items for use in industrial high voltage systems and are operated with voltages which may result in serious injury or death upon contact.

They may only be installed or worked on by qualified electricians and with the equipment switched to zero potential. These individuals must always have access to the operating instructions which must be consistently observed by them.


DANGERMortal danger from electric shock!


Switch the frequency converter to zero potential and protect it against reactivation.

The following terminals may still carry dangerous voltages even with the motor at rest:

• mains connection terminals 1X1: PE, N, L

• motor connection terminals X2: U, V, W

• connection terminals X6, X7: relay contacts relay 1 and 2

• PTC/bimetallic switch connection terminals 1X6: T1/T2

i IMPORTANT INFORMATION• When working on live frequency converters the applicable national accident prevention regulations (e.g. VBG 4) must be observed.

• The local regulations for the installation of electrical systems and accident prevention regulations must be observed.

• The electrical installation must be carried out in accordance with relevant regulations (e.g. observe conductor cross sections, fuses, earth connections).

• If personal and fire protection is required when using the frequency converter, all-current sensitive fault current protection switches (residual current devices of type B) must be used (in accordance with DIN VDE 0160 and EN 50178). These offer reliable protection for the high frequency alternating currents occurring during FC operation and smooth and pulsating direct fault currents. Common fault current protection switches of type A are not approved.

• Only use permanently wired mains connections.

• Earth the frequency converter in accordance with DIN EN 61140; VDE 0140-1.

• Contact currents > 3.5 mA may occur in the VAU. In this case an additional protective earth conductor with the same cross section as the original earth conductor must be installed in accordance with DIN EN 61800-5-1. Whether the equipment concerned must be additionally earthed can be determined from the respective equipment instructions. A second protective earth conductor can be connected on the outside of the device below the control cable feed. A suitable M4x10 screw (2.0 Nm torque) is included in the scope of delivery.

• When using different voltage levels (e.g. +24V/ 230 V) crossing cables must always be avoided! The user must also ensure that the applicable regulations are complied with (e.g. double or reinforced insulation in accordance with DIN EN 61800-5-1)!

• The circuit boards contain highly sensitive MOS semiconductor elements which are particularly sensitive to static electricity. Please avoid, therefore, touching the strip conductors or components with your hands or with metal objects. When connecting the conductors, only the screws of the terminal strips may be touched with insulated screwdrivers.

i • In a residential environment this product may cause high frequency interference necessitating interference suppression measures!

• Information on the EMC-compliant installation, such as shielding, earthing and cable routing, can be found in the documentation of the frequency converters. This information must also be always observed for frequency converters bearing the CE mark. Adherence to the limits required by EMC legislation is the responsibility of the manufacturer of the plant or machine.

1.4 OPERATING INFORMATION

DANGERMortal danger from electric shock!


2 mimDue to charged capacitors the device might still carry dangerous voltage for up to 2 minutes after disconnection from the mains.

Touching exposed or open terminals, conductors and device components can lead to serious injury or death!

Therefore, opening the device or removing the covers or control panel is only permitted 2 minutes after the device has been switched to zero potential.

Even with the motor at rest (e.g. on account of an electronic lock, blocked drive or short circuited output terminal) the mains connection terminals, motor terminals and terminals for the brake resistance may still carry dangerous voltage. A shut down motor does not equate to an electrical separation from the mains.


DANGERMortal danger from rotating mechanical components!


Under certain configurations the converter might automatically start after activation of the mains.

Systems with frequency converters installed might need to be equipped with additional protective devices in accordance with the respective applicable safety regulations (e.g. laws on technical equipment, accident prevention regulations etc.).

If the required covers are removed without authorisation or with incorrect use, installation or operation there is a risk of serious personal injury or property damage.

All covers must be kept closed during operation.

i IMPORTANT INFORMATIONPlease note the following information during operation:

• The frequency converter operates with high voltages.

• When operating electrical equipment, some components of this equipment inevitably carry dangerous voltages.

• The emergency stop facilities according to DIN EN 60204-1; VDE 0113-1:2007-06 must remain operational during all operating modes of the control device. Resetting the emergency stop facility must not lead to uncontrolled or undefined reactivation.

• To ensure safe disconnection from the mains the mains supply cable to the frequency converter must be disconnected synchronously and at all poles.

• A pause of 1 to 2 min. must be adhered to between successive mains connections.

• Certain parameter settings may cause the frequency converter to automatically restart after a supply voltage failure.

• For a sound motor overload protection the motor parameters, in particular the I2t settings, must be configured correctly.

• The frequency converter does not provide internal motor overload protection. Motor overload protection can also be ensured using an external PCT/bimetallic switch.

• The frequency converter must not be used as an „emergency stop facility“ (see DIN EN 60204-1; VDE 0113-1:2007-06).

• If the air is dusty, the cooling surfaces must be regularly cleaned.

1.5 INTENDED USE

i IMPORTANT INFORMATION• The VAU frequency converter is a device for the speed control of three phase rotary current motors.

• The frequency converter can be integrated into the device or used separately.

• Frequency converters are components intended for installation in electrical systems or machinery.

• This frequency converter is not approved for operation in explosive areas!

• When they are installed in machinery, the commissioning of the frequency converters (i.e. the start of their intended operation) is prohibited until it has been determined that the machine complies with the provisions of applicable machinery directive including the EMC directive at the time of commissioning; EN60204 must be observed.

• The harmonised standards of the DIN EN 50178; VDE 0160:1998-04 series in conjunction with DIN EN 60439-1; VDE 0660-500:2005-01 are applicable to this frequency converter.

• The frequency converters meet the requirements of the EC machinery directive 2006/42/EC.

• The technical data and information relating to the connection conditions can be found on the rating plate and in these instructions and must always be adhered to.

• Repairs may only be carried out by authorised repair centres. Independent unauthorised interventions may lead to death, personal injury and property damage. Such cases invalidate the warranty by Gebr. Becker GmbH.

• No external mechanical loads, e.g. stepping onto the housing, are permitted!


VAU 1.1/1-AC → First steps

2 INSTALLATION

2.1 CONNECTION SPACE After opening the terminal box cover you will find all the connection terminals of the frequency converter in the connection area.

Mains supply PE, N, L

PTC/bimetallic switch

Enable bridge24V Out & Dig In 1

Fan fuse RelayRel.2: Collective fault message (standard)Rel.1: Fan control (standard)

Control terminal RS485-interfaceConnection socket for:- PC (KombiTool)- manual control unit (MMI)

Fan connections

Motor connectionU, V, W,

EMC - cable gland

PE Cover PE Motor


2.1.1 CONNECTION POWER LINEConductor cross-section of the mains power supply: 0,25 -4 mm2 (wire-end ferrule with plastic shroud)

Stripping length: 12 mm

Terminal Connection

PE, N, L Mains supply - Conductor PE, N, L

2.1.2 RELAYSFunction Description

The relays can be parametrised with different functions.

COMNONC

Relay 2

AEM

Aggregated error message (standard),

Fault-free operation:

Malfunction:

COM - NC

COM - NO

Relay 1 Reserved for fan control

2.1.3 MOTOR CONNECTIONConductor cross-section of the engine connection: 1,5-2,5 mm2

Terminal Connection

U, V, W Conductor U, V, W

PE Motor feed line PE

2.1.4 FAN CONNECTIONSTerminal Connection

+ Fan FC (only for version with separate FC)

- Fan FC (only for version with separate FC)

+ Fan VASF

- Fan VASF


2.1.5 SIGNAL TERMINALSConductor cross-section of the signal lines: 0,5-1,0 mm2 (wire-end ferrule with plastic shroud)

Stripping length: 9-10 mm

Connection terminals of the bottom row of the double-decker terminal block:

Terminal Connection

10V Out Int. voltage supply 10V

24V IN Ext. voltage supply

GND (In) Ground (ext. voltage supply)

GND Ground

Analog Out 2 (0V...10V) Analog voltage output

GND Ground

GND Ground

GND Ground

Analog In 3 Analog input 3


Connection terminals of the top row of the double-decker terminal block:

Terminal Connection

24V Out Int. voltage supply 24V

Dig In 1 Digital input 1 (enable)

Dig In 2 Digital input 2

Dig In 3 Digital input 3

Analog Out 1 (0V...10V) Analog voltage output 1

Analog Out 1 (0mA...20mA) Analog current output 1

RS 485 A(+) Serial interface RS485 line A

RS 485 B(-) Serial interface RS485 line B



NOTE • All control voltages refer to a common reference potential (GND).

• 24 V can be taken from the respective terminals. The sum of the currents may not exceed 100 mA.

2.1.6 PTC/BIMETALLIC SWITCHTerminal Connection

T1 Temperature monitoring 1

T2 Temperature monitoring 2

2.2 RS485 INTERFACEEThe RS485 interface is designed as a two-wire model acc. to EIA RS485 (data lines A and B) and provides the communication with the frequency converter.

Pin assignment M12 Description

1

4 3

2

Pin (bus in)

1 24V

2 RS 485 A(+)

3 GND

4 RS 485 B(-)


2.3 LOCAL OPERATION AND DISPLAYThe local operation of the device is done on the operating panel as shown.

Acknowledge buttonMalfunktion

RS485 interfacePotentionmeter for adjusting the setpoint

LEDs indicate the converter status

Using the potentiometer (scale 0...100%), the current setpoint value can be increased or decreased.

A malfunction can be acknowledged by pressing the Acknowledgement button.

The two LEDs indicate the current converter state.

3 FAULT DETECTION AND REMOVAL

3.1 TABLE OF THE LED-FLASH CODESRed LED Green LED Status

Operation

With optional BUS module: BUS operation (active BUS connection)

Malfunction - further information see chapter 3.2

With optional BUS module: BUS module is ready for operation

Initialisation

Legend: LED off, LED on, LED flashes, LED flashes quickly

fault see → following table of possible fault messages

→ KombiTool diagnosis or read out P1011...1014

→ Display handheld (MMI)


3.2 TABLE OF POSSIBLE ERROR MESSAGESIn case of a fault (red LED is permanently lit), the error is indicated via an extended flash code of the green LED.

The green LED briefly flashes 1-10 times. At the end of the flash code there is a pause of 5 seconds before the code is repeated. The table below provides an overview.

Error group Error no. KombiTool

LED MMI Name Description Cause

1x

1 4096 13 Cable break

Analogue In 1

(4..20mA / 2 - 10V

Current or voltage below the lower limit of analogue input 1

Cable break, faulty or unconnected external sensor

1 8192 14 Cable break

Analogue In 2

(4..20mA / 2 - 10V)

Current or voltage below the lower limit of analogue input 2

Cable break, faulty external sensor

1 32768 16 Alarm 1 system fault Customer-specific fault via the func-tion of the digital inputs

dependent on the application

2 1 17 Alarm 2 system fault Customer-specific fault via the func-tion of the digital inputs

dependent on the application

2 64 23 External fault 1 The parametrised error input (digital input) is active

2 128 24 External fault 2 The parametrised error input (digital input) is active

2x

3 1 32 IGBT tripped Protection of the IGBT module against overcurrent has tripped

Short circuit in the motor or motor supply cable / regulator settings

3 128 39 Monitoring Maximum output current of the con-verter exceeded

Cooling insufficient / low speed and high torque / cycle frequency too high / ramp times too short / brake not released

3x

2 2 18 FC overtemperature Internal temperature too high Cooling insufficient, low speed and high torque, cycle frequency too high.

3 8 35 Motor overtempe-rature

Motor temperature monitoring with PTC/bimetallic switch has tripped

Motor overload (e.g. high torque at low speed / ambient temperature too high)

3 64 38 IGBT module over-temperature

Power module / IGBT module over-temperature

Cooling insufficient, low speed and high torque, cycle frequency too high

3 256 40 FC overtemperature Internal temperature too high Cooling insufficient / low speed and high torque / cycle frequency too high / permanent overload

4x

3 16 36 Grid interruption A phase is missing/ mains voltage interrupted

3 2048 43 Earth leakage Earth leakage of a motor phase Insulation fault

3 8192 45 Motor connection interrupted

No motor currecnt in spite of excita-tion by the FC

No Motor connected or motor not fully connected.

5x

2 16 21 Bus Timeout Setpoint specification via bus. No response from bus node or MMI / PC

Bus cable interrupted

2 32 22 Max auto-acknow-ledgements

The number of max. automatic acknowledgements (1,182) has been exceeded

6x

1 16384 15 Blockage Motor blocked Mechanical fault or overload

7x

3 1024 42 I2t motor protection shut-down

The internal I2t motor protection has tripped

Permanent overload

4 2 49 Overload Max. overload of the frequency converter exceeded for more than 60 sec.

Legend: LED flashes, LED flashes quickly


Error group Error no. KombiTool

LED MMI Name Description Cause

8x

3 2 33 Intermediate circuit overvoltage

The maximum intermediate circuit voltage has been exceeded

Return feed from motor during ge-nerator operation / mains voltage too high / incorrect speed regulator configuration / brake resistance not connected or faulty / ramp times too short

3 4 34 Intermediate circuit undervoltage

The minimum intermediate circuit voltage has been fallen below

Mains voltage too low / mains con-nection faulty

9x

1 1 1 24V undervoltage Supply voltage below 15V 24V supply overload

1 2 2 24V overvoltage Supply voltage greater than 31V Internal 24V supply faulty or external supply faulty

1 1024 11 System fault No voltage is present at the power component

Operation with 24 V without mains supply

10x

3 System fault contact BECKER in case of this fault





1 128 8 Internal application The internal communication is faulty EMC faults










1 512 10 Distributor parame-ters

The internal distribution of the para-meters during initialisation has failed

Parameter record is incomplete

3 16384 46 Motor parameters Plausibility check of motor parame-ters has failed

Parameter record faulty

3 32768 47 Frequency conver-ter parameters

Plausibility check of frequency con-verter parameters has failed

Parameter record faulty

4 1 48 Rating plate data No valid motor rating plate data Motor rating plate data not yet ente-red (delivery state)

Legend: LED flashes, LED flashes quickly


4 TECHNICAL SPECIFICATIONS

Description \ size VAU 1.1/1-AC

Typical motor output [kW] to be connected (4 pole asynchronous motor)

1,1

Mains voltage [V] 1~ 100VAC -10% ... 230VAC +10%

Mains frequency [Hz] 47 to 63

Grid configuration TN / TT

Mains current [A] 9,2

FC output current, eff. [A]

[IN at 8 kHz]

5,2

Max. overload 150 % of nominal current for 60 sec

Switching frequency [kHz] 4, 8, 16, (factory setting 8)

Rotary field frequency [Hz] 0 - 400

Protection function Over- and undervoltage, I2t limitation, short circuit, motor/frequency converter temperature, tilt protection, stall protection

Recommendations for LS switches 2) C 10

Property C = line safety switch

Caution: The cross section of the supply line must be designed according to the installation type and maximum permitted current. The contractor commissioning the device must ensure protection for the mains power line.

Dimensions

[L x W x H] mm

VAU 1.1/1-AC-I

319 x 176 x 110

VAU 1.1/1-AC-F

330 x 176 x 158

Weight [kg] 3,8 5,0

Cooling: via the attached pump via the fan integrated in the FC

Degree of protection [IPxy] 55

EMC complied with according toDIN EN 61800-3

Interference emission: 1st environment category C2

Interference immunity: 2nd environment

Vibration and shock resistance: DIN EN 60068-2-6 severity level 2 (vibration during transport)

DIN EN 60068-2-27 (vertical impact test)

2…200 Hz for sinusoidal oscillations.

Ambient temperature [° C] - 10 (without condensation) to + 40 (without derating)

Relative humidity: ≤ 96%, condensation not permissible

Altitude of installation location: up to 1000 m above MSL/ more than 1000 m with reduced output

(1% per 100 m) (max. 2000 m)

Technical data equipment (technical modifications reserved)

1) Approx. 50 % reduced supply feed possible (reduced output power)

2) For the exact information on the pre-fuse for individual devices, please refer to the device data sheet or the operating instructions of the device.


5 INTERFACES

Inputs and outputs Description

Digital input 1...3 • Switching level Low < 5 V / High > 15 V

• Imax

(bei 24 V) = 3 mA

• Rin = 8,6 kOhm

Analog input 1...4 • In 0 – 10 V or 0 – 20 mA

• In 2 – 10 V or 4 – 20 mA

• Resolution 10 Bit

• Tolerance +/- 2 %

• Voltage input: Rin = 10 kOhm

• Current input: Load = 500 Ohm

Relay 1; 2 Change over contact (NO/NC/COM)

Max. switching power

• for resistive load (cos φ = 1): 5 A at ~ 230 V or = 30 V

• for inductive load(cos φ = 0,4 und L/R = 7 ms): 2 A at ~ 230 V or = 30 V

Max response time: 7 ms ± 0,5 ms

Electrical lifetime: 100 000 switching cycles

Analog output 1

(current)

• Short circuit proof

• Iout

= 0.. 20 mA

• Load = 500 Ohm


Analog output1, 2

(voltage)


• Uout

= 0..10 V

• Imax

= 10 mA


24 V DC fixed voltage output • Auxiliary voltage U = 24 V DC


• Imax

= 100 mA

• external supply of 24 V possible

10 V DC fixed voltage output • Auxiliary voltage U = 10 V DC


• Imax

= 30 mA

The frequency converters include the option to connect a motor temperature monitoring (PTC/bimetal).

Interface specification

6 CERTIFICATIONSEuropean EMC guidelinesIf the frequency converters of the VAU-series are installed and operated according to the recommendations of these operating instructions, they fulfils all requirements of the EMC regulations according to the EMC product standards for motor driven systems EN 61800-3.

MAKE IT BECKER

28

100

242

65

1 |

20

20

-01-

27

| A

ll r

igh

ts r

ese

rve

d

Documents

OPERATING INSTRUCTIONS - QUICK START GUIDE VAU 1 ......• The emergency stop facilities according to DIN EN 60204-1; VDE 0113-1:2007-06 must remain operational during all operating