Operating Guide

VACON® 3000 Drive Kit

drives.danfoss.com
VACON® 3000 Drive Kit

Operating Guide Contents

Contents
1 Introduction 11
1.1 Purpose of this Operating Guide 11

1.2 Additional Resources 11

1.3 Version History 11

1.4 Disposal 11

2 Safety 12
2.1 Safety Symbols 12

2.2 Qualified Personnel 12

2.3 Danger and Warnings 12

2.4 Cautions and Notices 14

2.5 Main Circuit Breaker 16

2.5.1 Safety and Protection Requirements 16

2.5.2 Minimum Requirements for MCB and MCB Control 16

3 Product Overview 18
3.1 Intended Use 18

3.2 Product Description 18

3.2.1 AFE Drive 18

3.2.2 12-Pulse Drive 19

3.3 Type Code Description 20

3.4 Available Options 20

4 Receiving the Delivery 23

4.1 Checking the Delivery 23

4.2 Storage 23

4.3 Lifting the Drive Components 24

5 Mechanical Installation 25
5.1 Operating Environment 25

5.2 Cabinet Installation 25

5.3 Mounting Rack Installation 25

5.3.1 VACON® 3000 Mounting Racks 25

5.3.2 Mounting Rack and Module Installation Guidelines 26

5.3.3 Assembling the Mounting Racks 27

5.3.4 Installation of the Mounting Rack 30

5.3.5 Grounding of the Mounting Rack 30

5.3.6 Cabling in the Mounting Rack 30

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5.4 Installing Modules in a Mounting Rack 31

5.5 Liquid Cooling Requirements 32

5.5.1 Safety in Liquid-cooling 32

5.5.2 General Information on Liquid Cooling 32

5.5.3 Cooling Liquid 33

5.5.3.1 Quality Requirements for the Purified Water 33

5.5.3.2 Purified Water as Coolant 33

5.5.3.3 Antifreeze Mix as Coolant 33

5.5.3.4 Temperature of the Cooling Liquid 34

5.5.3.5 Condensation 34

5.5.4 Cooling System 36

5.5.4.1 Materials 36

5.5.4.2 Heat Exchanger 37

5.5.4.3 Cooling System Installation 37

5.5.4.4 Power Module Cooling Connections 38

5.6 Air Cooling Requirements 39

6 Electrical Installation 41
6.1 Power Cabling Guidelines 41

6.1.1 MV and LV Sections in the Cabinet 41

6.1.2 Power Cable Selection 42

6.1.3 Cable Inlets Between Cabinet Sections 43

6.1.4 Mains and Motor Cable Selection 44

6.1.5 Mains and Motor Cable Inlet and Termination 44

6.1.6 Grounding 46

6.1.6.1 Standard Grounding Configurations 46

6.1.7 Installation in an IT grid 47

6.1.8 Additional Instructions for Cable Installation 48

6.2 Cabling of the Power Modules 48

6.2.1 Phase Module L20/L30 Terminals 48

6.2.2 DFE Power Module Terminals 49

6.2.2.1 DFE Control Terminals 49

6.2.3 Power Module Grounding 50

6.2.4 DC-Link Connections 51

6.2.5 Brake Chopper Installation 53

6.2.6 Terminal Screw Tightening Torque Specifications 53

6.2.7 LED Display on the Phase Module 53

6.2.8 LED Display on the DFE Power Module 55

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6.3 Single-belt Operation 56

6.4 Main Circuit Breaker Installation 56

6.5 Installation of Auxiliary Components 56

6.5.1 Surge Protection Device Installation 56

6.5.2 Potential Transformer Installation 56

6.5.3 LC Filter Installation 57

6.5.4 Input Common-mode Filter Installation 58

6.5.5 DC Capacitors for DFE Installation 59

6.5.6 Grounding Switch Installation 59

6.5.6.1 Operating the Grounding Switch 60

6.5.7 Common-Mode Capacitor Installation 61

6.5.8 Pre-Charge Unit Installation 61

6.5.8.1 Safety Notes for the Precharge Unit 61

6.5.8.2 Pre-Charge Unit Installation 62

6.5.9 Isolation Transformer Installation 62

6.5.10 Auxiliary Power Supply Installation 63

6.5.11 Cabinet Heater Installation 64

6.5.12 Overtemperature Indicator Installation 64

6.5.13 Leak Detector Installation 64

6.5.14 Arc Flash Detector Installation 64

6.6 Safety Functions 64

6.6.1 Safe Torque Off (STO) 64

6.6.2 Safe Stop 1 (SS1) 64

6.6.3 Safety Considerations 65

6.6.3.1 Diagnostic Test 65

6.6.4 STO Operating Principle 65

6.6.5 SS1 Operating Principle 66

6.6.6 Installation Guidelines 66

6.6.7 Recommended Components 67

6.6.8 Determining the Power Supply Specific STO Delay Time 68

6.6.8.1 Response Time and Fault Reaction Time 68

6.6.9 Safety Relay Wiring 69

6.6.10 Safety-related Data 70

6.7 Mechanical Interlocking System 71

6.7.1 Operating the Interlocking System 72

7 Control Connections 73
7.1 Control Unit Components 73

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Operating Guide Contents

7.2 Control Unit Installation 74

7.3 Control Interface 74

7.4 Control Unit Cabling 75

7.4.1 Selection of the Control Cables 75

7.4.2 Control Unit Terminals 75

7.5 DIP Switches on the Control Unit 76

7.5.1 Selection of Terminal Functions with DIP Switches 76

7.5.2 Isolation of the Digital Inputs from Ground 77

7.6 Fieldbus Connection 78

7.6.1 Fieldbus Terminals 78

7.6.2 Using Fieldbus through an Ethernet Cable 79

7.6.3 Using Fieldbus through an RS485 Cable 80

7.7 Option Board Installation 82

7.8 Optical Fiber Connections 83

7.8.1 Selection of Optical Fiber Cables 86

7.8.2 Making Optical Fiber Cables 87

7.9 Pre-charge and Supply Voltage Feedback Connections 88

7.10 Encoder Interface 89

7.10.1 Encoder Terminals and Signals 90

7.10.2 Encoder Jumper Configurations 91

7.10.3 Encoder Connection 93

7.11 Battery for the Real-Time Clock (RTC) 94

7.12 Galvanic Isolation Barriers 94

7.13 System and Application Software 94

7.14 Technical Data on Control Connections 94

7.15 Auxiliary I/O Board 96

7.15.1 Connector Locations 96

7.15.2 Connector Specifications 97

7.15.3 LED Display on the Auxiliary I/O Board 101

7.15.4 Breaker Enable Signals 102

7.15.5 Breaker Enable Logic 102

7.15.6 Breaker Enable Mapping Examples 103

7.16 HCM Board 106

7.16.1 Connector Locations 106

7.16.2 Installation 106

8 Commissioning 108
8.1 Safety Checks before Starting the Commissioning 108

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8.2 Commissioning the Drive 108

8.2.1 Basic Job Information 108

8.2.2 Before Power-up Checklist 109

8.2.3 Control and Auxiliary Power Commissioning Checklist 112

8.2.4 Medium-Voltage Power Commissioning Checklist 113

8.3 Commissioning Procedures 114

8.3.1 Filling the Liquid Cooling System 114

8.3.2 Grid Voltage Feedback Configuration 116

8.3.3 Installing Software on the Control Unit 117

8.3.4 Verifying the Phase Module Connections 120

8.3.5 Commissioning Test 122

8.3.5.1 Commissioning Test with VACON® Live 123

8.3.6 AFE Synchronization Test 125

8.3.7 Encoder Setup 129

8.4 Insulation Resistance Measurements 130

8.4.1 Measuring the Switchgear Insulation Resistance 130

8.4.2 Measuring the Cable and Motor Insulation 130

8.4.2.1 Insulation Checks of the Motor Cable 130

8.4.2.2 Insulation Checks of the Mains Cable 131

8.4.2.3 Insulation Checks of the Motor 131

9 Maintenance 132
9.1 Preventive Maintenance Recommendations 132

9.1.1 Maintenance Log for Cooling System 134

10 Fault Tracing 135

10.1 Fault Types 135

10.2 Faults and Alarms 135

10.2.1 Fault Code 1 - Overcurrent 135

10.2.2 Fault Code 2 - Overvoltage 136

10.2.3 Fault Code 3 - Earth Fault 137

10.2.4 Fault Code 5 - Charging Switch 137

10.2.5 Fault Code 7 - Saturation 138

10.2.6 Fault Code 8 - System Fault 138

10.2.7 Fault Code 9 - Undervoltage 146

10.2.8 Fault Code 10 - Input Phase 146

10.2.9 Fault Code 11 - Output Phase Supervision 148

10.2.10 Fault Code 12 - Brake Chopper Supervision 148

10.2.11 Fault Code 13 - AC Drive Undertemperature 149

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Operating Guide Contents

10.2.12 Fault Code 14 - AC Drive Overtemperature 149

10.2.13 Fault Code 15 - Motor Stall 151

10.2.14 Fault Code 16 - Motor Overtemperature 151

10.2.15 Fault Code 17 - Motor Underload 151

10.2.16 Fault Code 19 - Power Overload 151

10.2.17 Fault Code 25 - Motor Control Fault 152

10.2.18 Fault Code 26 - Start-up Prevented 152

10.2.19 Fault Code 29 - ATEX Thermistor 152

10.2.20 Fault Code 30 - Safety 153

10.2.21 Fault Code 32 - Fan Cooling 155

10.2.22 Fault Code 33 - Fire Mode Enabled 156

10.2.23 Fault Code 37 - Device Changed (Same Type) 156

10.2.24 Fault Code 38 - Device Added (Same Type) 157

10.2.25 Fault Code 39 - Device Removed 157

10.2.26 Fault Code 40 - Device Unknown 158

10.2.27 Fault Code 41 - IGBT Temperature 158

10.2.28 Fault Code 43 - Encoder Fault 158

10.2.29 Fault Code 44 - Device Changed (Different Type) 160

10.2.30 Fault Code 45 - Device Added (Different Type) 161

10.2.31 Fault Code 46 - Real Time Clock 161

10.2.32 Fault Code 47 - Software Update 162

10.2.33 Fault Code 49 - Precharge 162

10.2.34 Fault Code 50 - AI Low Fault 166

10.2.35 Fault Code 51 - Device External Fault 166

10.2.36 Fault Code 52 - Keypad Communication Fault 167

10.2.37 Fault Code 53 - Fieldbus Communication Fault 167

10.2.38 Fault Code 54 - Slot Fault 167

10.2.39 Fault Code 57 - Identification 168

10.2.40 Fault Code 58 - Mechanical Brake 169

10.2.41 Fault Code 59 - Communication 169

10.2.42 Fault Code 61 - Speed Error Fault 169

10.2.43 Fault Code 63 - Quick Stop 169

10.2.44 Fault Code 65 - PC Communication Fault 170

10.2.45 Fault Code 66 - Thermistor Input Fault 170

10.2.46 Fault Code 67 - Module Test Stand 170

10.2.47 Fault Code 68 - Maintenance Counter 171

10.2.48 Fault Code 69 - Fieldbus Mapping Error 171

10.2.49 Fault Code 76 - Start Prevented 171

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10.2.50 Fault Code 77 - >5 Connections 172

10.2.51 Fault Code 78 - Identification Ongoing 172

10.2.52 Fault Code 80 - Fieldbus Watchdog Fault 172

10.2.53 Fault Code 84 - Overspeed Error 172

10.2.54 Fault Code 111 - Temperature Input Fault 1 172

10.2.55 Fault Code 112 - Temperature Input Fault 2 173

10.2.56 Fault Code 114 - User Defined Fault 1 173

10.2.57 Fault Code 115 - User Defined Fault 2 173

10.2.58 Fault Code 200 - Precharge 174

10.2.59 Fault Code 201 - High Humidity/Temperature 175

10.2.60 Fault Code 202 - Encoder 175

10.2.61 Fault Code 203 - STO Fault 175

10.2.62 Fault Code 204 - Output Filter 176

10.2.63 Fault Code 205 - Coolant Temperature 176

10.2.64 Fault Code 300 - Unsupported 176

11 Specifications 177
11.1 Dimensions 177

11.1.1 Dimensions, Phase Module (L20/L30) 177

11.1.2 Dimensions, DFE Power Module 178

11.1.3 Dimensions, Brake Chopper Unit 179

11.1.4 Dimensions, Control Unit 179

11.1.5 Dimensions, Auxiliary I/O Board 180

11.1.6 Dimensions, HCM Board 180

11.1.7 Dimensions, Pre-Charge Unit 181

11.1.8 Dimensions, LC Filter 182

11.1.9 Dimensions, Input Common-mode Filter 185

11.1.10 Dimensions, Common-Mode Capacitor 189

11.1.11 Dimensions, DC Capacitor for DFE 190

11.1.12 Dimensions, Potential Transformer 194

11.1.13 Dimensions, Isolation Transformer 194

11.1.14 Dimensions, Grounding Switch 195

11.1.15 Dimensions, Surge Protection Device 197

11.1.16 Dimensions, Mounting Rack 197

11.2 Power Ratings 200

11.2.1 Power Ratings for Mains Voltage 3300 V 200

11.2.2 Power Ratings for Mains Voltage 4160 V 200

11.2.3 Overload Capability 201

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Operating Guide Contents

11.3 Technical Data 202

11.3.1 Mains Supply 202

11.3.2 Motor Output 203

11.3.3 Control Properties 203

11.3.4 Drive Properties 204

11.3.5 Ambient Conditions 205

11.3.6 Cooling 205

11.3.7 Source Impedance Specifications 207

11.4 Main Circuit Diagrams 210

11.4.1 VACON® 3000 AFE Main Circuit Diagrams 210

11.4.2 VACON® 3000 12-Pulse Main Circuit Diagrams 213

11.5 Abbreviations 214

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VACON® 3000 Drive Kit

Operating Guide Introduction

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 with the drive.

1.2 Additional Resources

Other resources are available to understand advanced AC drive functions, programming, and options.
• The VACON® 3000 design guide provides technical information to understand the capabilities of the VACON® 3000 drive for
integration into motor control and monitoring systems.
• The VACON® 3000 application guides provide greater detail on how to work with the applications and how to set the parame-
ters of the AC drive.
• The operating and installation guides for VACON® options give detailed information about specific drive options.
Supplementary publications and manuals are available from Danfoss. See www.danfoss.com for listings.

1.3 Version History

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is English.

Table 1: Version History

Version Remarks

A First version

B Updated information for several of the Drive Kit components.

Updated information for safety functions.

1.4 Disposal
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance
with local and currently valid legislation.

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Operating Guide Safety

2 Safety
2.1 Safety Symbols
The following symbols are used in this guide:

D A N G E R
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, as-
semble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably
experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
• Are familiar with the basic regulations concerning health and safety/accident prevention.
• Have read and understood the safety guidelines given in all manuals, especially the instructions given in the operating guide of
the unit.
• Have good knowledge of the generic and specialist standards applicable to the specific application.
• Are familiar with the structure and operation of medium-voltage drives and the related risks. Special training for medium-volt-
age installations may be necessary.

2.3 Danger and Warnings

D A N G E R
SHOCK HAZARD FROM POWER UNIT COMPONENTS
The power unit components are live when the drive is connected to mains. Contact with this voltage can result in death or seri-
ous injury.
- Do not touch the components of the power unit when the drive is connected to mains.
Do not do any work on live equipment.
Before doing any work on internal drive components, follow proper lock out and tag out procedure.
Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

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Operating Guide Safety

D A N G E R
SHOCK HAZARD FROM TERMINALS
The motor terminals U, V, W, the brake resistor terminals, and the DC-link terminals must be treated as live when the drive is
connected to mains. 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.
Do not do any work on live equipment.
Before doing any work on the drive, follow proper lock out and tag out procedure.
Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

D A N G E R
SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE
The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the
mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to
death or serious injury.
- Disconnect the drive from the mains and make sure that the motor has stopped.
Disconnect the motor.
Lock out and tag out the power source to the drive.
Make sure that no external source generates unintended voltage during work.
To ground the drive input and DC link, close the grounding switch. If there is no grounding switch, make sure that the drive
input and DC link are grounded for work. Also ground the motor terminals for work.
Wait for the DC-link capacitors to discharge fully before opening the cabinet door or the cover of the AC drive. The discharge
time is <7 minutes for AFE drives and <21 minutes for 12-pulse drives.
Use a measuring device to make sure that there is no voltage.

W A R N I N G
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.

W A R N I N G
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.

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Operating Guide Safety

W A R N I N G
ELECTRICAL SHOCK HAZARD - LEAKAGE CURRENT HAZARD >3.5 MA
Leakage currents exceed 3.5 mA. Failure to connect the drive properly to protective earth (PE) can result in death or serious in-
jury.
- Ensure reinforced protective earthing conductor according to IEC 60364-5-54 cl. 543.7 or according to local safety regula-
tions for high touch current equipment. The reinforced protective earthing of the drive can be done with:
- a PE conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al.
- an extra PE conductor of the same cross-sectional area as the original PE conductor as specified by IEC 60364-5-54 with a
minimum cross-sectional area of 2.5 mm2 (14 AWG) (mechanical protected) or 4 mm2 (12 AWG) (not mechanical protected).
- a PE conductor completely enclosed with an enclosure or otherwise protected throughout its length against mechanical
damage.
- a PE conductor part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2 (14 AWG)
(permanently connected or pluggable by an industrial connector. The multi-conductor power cable shall be installed with an
appropriate strain relief).
- NOTE: In IEC/EN 60364-5-54 cl. 543.7 and some application standards (for example IEC/EN 60204-1), the limit for requiring
reinforced protective earthing conductor is 10 mA leakage current.

2.4 Cautions and Notices

C A U T I O N
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.

C A U T I O N
DAMAGE TO THE AC DRIVE FROM CHANGES TO DRIVE COMPONENTS
Doing electrical or mechanical changes to the drive components can cause malfunctions and can damage the AC Drive.
- Do not make electrical or mechanical changes to the drive components.

C A U T I O N
DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING
Not using a grounding conductor can damage the drive.
- Always ground the AC drive with a grounding conductor that is connected to the grounding terminal that is identified with
the PE symbol. If no dedicated transformer is installed, the AC drive is intended for high resistance grounding systems with a
resistance grounded neutral point. For operation in an IT network without a dedicated transformer, consult Danfoss.

C A U T I O N
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.

C A U T I O N
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.

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Operating Guide Safety

N O T I C E
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.
- Use ESD protection when working with electronic components of the AC drive. Do not touch the components on the circuit
boards without proper ESD protection.

N O T I C E
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.

N O T I C E
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.

N O T I C E
RADIO INTERFERENCE
In a residential environment, this product can cause radio interference.
- Take supplementary mitigation measures.

N O T I C E
MAINS DISCONNECTION 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).

N O T I C E
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.

N O T I C E
VOLTAGE WITHSTAND TESTS
If done improperly, doing voltage withstand tests can damage the drive.
- Megohmmeter testing is the only recommended test type for field installations.
Only a qualified field service engineer is allowed to perform this test.
Refer to the proper high potential/megohmmeter testing instructions in the service guide.

N O T I C E
WARRANTY
If the power modules are opened, the warranty is not valid.
- Do not open the power modules.

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Operating Guide Safety

N O T I C E
PERSONAL PROTECTIVE EQUIPMENT AND APPROVED TOOLS
When doing electrical work on the AC drive, always use personal protective equipment (PPE) and tools which are approved for
work with medium-voltage devices.

2.5 Main Circuit Breaker

The main circuit breaker (MCB) is an important protection device for the drive. If there is a serious fault in the drive, the MCB imme-
diately disconnects the main supply to the drive. To protect personnel and to prevent further damage to the equipment, the main
supply must be disconnected immediately with an open or trip command from the drive.
If the drive is supplied through a dedicated transformer, install the MCB on the primary side of the supply transformer (see Illustra-
tion 1).

e30bi562.10
2
CB1
CB2 MVD
G
~
M
~

3
4
5
Illustration 1: Overview of the Drive System

1 Trip coil: RO from VACON® 3000 (reaction time: CB1 Circuit breaker 1
10 ms delay)
CB2 Circuit breaker 2
2 Undervoltage release (UVR): IGBT switch from arc
flash relay (reaction time: 2 ms delay) G Grid or generator

3 Breaker open: RO from the breaker M Motor

4 Breaker closed: RO from the breaker MVD VACON® 3000 medium-voltage drive

5 Breaker ready (optional): RO from the breaker

2.5.1 Safety and Protection Requirements

For safety and protection, the MCB must meet the minimum requirements of the specifications of Danfoss medium-voltage drives.
The minimum requirements for the MCB are stated in this manual and in the respective MCB specifications, which are available for
each medium-voltage drive from Danfoss. The system integrator must make sure that the minimum requirements are met.
The safety requirements for the drive are based on the following standards:
• EN ISO 13849-1: Safety of machinery, Safety-related parts of control systems, General principles for design, section 6.2.6 Catego-
ry 3
• UL347A, Edition 1: Standard for Medium Voltage Power Conversion Equipment

2.5.2 Minimum Requirements for MCB and MCB Control

Requirements
To meet the stipulated safety requirements, Danfoss requires the following:
• MCB is equipped with 2 independent opening coils.
• MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage.
• Route the MCB open and trip commands directly from the drive to the MCB.
- Do not route the trip command through any PLC or DCS (distributed control system) which is not certified to meet SIL 3-
level requirements and to fulfill the given timing requirements.
- Opening of the MCB by the drive must be possible at any time. Do not interrupt the open and trip commands, for example,
by a local-remote switch in the MCB.

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Operating Guide Safety

• Closing the MCB locally is not allowed. The drive must have exclusive control of closing the MCB.
• The maximum opening time of the MCB must never exceed the product or project specific maximum time defined in the MCB
specifications.
• Typical maximum protection and safety trip time for the drive: 60 ms
Recommendations
To meet the stipulated safety requirements, Danfoss recommends the following:
• Provide an upstream protection coordination scheme which uses the "breaker failure" (ANSI 50BF) signal to trip the upstream
breaker automatically, in case the MCB does not open.
• After a failure has occurred, the upstream breaker must open within the maximum protection and safety trip time.

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Operating Guide Product Overview

3 Product Overview
3.1 Intended Use
VACON® 3000 is a liquid-cooled AC drive for stepless speed or torque control of medium-voltage induction motors. The VACON®
3000 Drive Kit is a modular MV drive that offers a new dimension of application engineering for industrial applications with motor
voltages of 3300 V or 4160 V. It enables the complete customization of the enclosure to meet the unique needs, restrictions, and
characteristics of various applications, including applications with limited space and in harsh conditions.
The VACON® 3000 Drive Kit is available in a power range starting from 2 MW. Basic configurations have a power of 2 MW or 3 MW.
These configurations can be paralleled for systems of 4 MW and above.
The VACON® 3000 Drive Kit includes all the main parts for the drive:
• Power modules,
• pre-charge unit,
• control unit,
• filters.
The modules and accessories are used to make different medium-voltage AC drive solutions, such as regenerative and non-regener-
ative drives. The VACON® 3000 Drive Kit accommodates flexible arrangements, straightforward system integration, and easy main-
tenance. The protection rating of the modules is IP00, and thus the modules have to be installed in a cabinet.
Two different drive configurations are available:
• Regenerative, with an active front-end (AFE)
• Non-regenerative, with a 12-pulse diode front-end (DFE)

e30bg602.11

Illustration 2: Example of the VACON® 3000 Drive Kit

3.2 Product Description

3.2.1 AFE Drive

An example diagram of the regenerative VACON® 3000 is shown in Illustration 3. The main components of the drive are:
• The active front-end (AFE) unit includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are
installed in parallel to make a 3-phase converter. The AFE converts the supplied AC voltage to DC voltage. It also enables the
supply of power to the supply network when the motor is braking.
• The inverter unit (INU) includes 3 or 6 of the same liquid-cooled 1-phase modules, which are used in the AFE. The INU converts
the DC voltage to the AC voltage and frequency supplied to the motor.
• The LC filter (FLC) limits harmonic current on the supply network.

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• The pre-charge unit (PRC) charges the DC-link capacitors.

• The AFE and INU control units (CNU-AFE/CNU-INU) are connected to the power conversion units with optical fibers.
• The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV
section of the cabinet.
The basic VACON® 3000 AFE drive is intended for installations, where the system is supplied by a dedicated transformer and the
source impedance is small. These installations are usually on land. The drive includes an LC filter instead of an LCL filter, because the
supply side inductance is included in the dedicated transformer.
It is recommended to install a dedicated transformer for the drive. If the drive is not supplied by a dedicated transformer (that is,
there are other loads than the drive on the same supply):
• Install the drive in a high resistance grounding system with a resistance grounded neutral point.
• Install an input common-mode filter (option +PICM).
If the source impedance is high, select the +PHSI option. See 11.3.7 Source Impedance Specifications.
For operation in an IT network without a dedicated transformer, contact Danfoss.
For the full main circuit diagrams, see 11.4.1 VACON® 3000 AFE Main Circuit Diagrams.

e30bg606.10
CNU-AFE CNU-INU

AXU-IOB

CCM CCM
LV~
CSH PRC

+ +
MV~ o o Motor
- -

LGI LCM LCV 3 x PCU 3 x PCU

+PODU
+PICM FLC AFE INU +POSI
Illustration 3: Example Main Circuit Diagram of a VACON® 3000 AFE Drive

3.2.2 12-Pulse Drive

An example diagram of the 12-pulse non-regenerative VACON® 3000 Drive Kit is shown in Illustration 4. The main components of
the drive are:
• The diode front-end unit (DFE) is a liquid-cooled 12-pulse power conversion unit (PCU), which changes the supplied AC voltage
to DC voltage. The 12-pulse configuration is used to limit harmonics on the supply network.
• The inverter unit (INU) includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are installed
in parallel to make a 3-phase converter. The INU converts the DC voltage to the AC voltage and frequency supplied to the mo-
tor.
• The pre-charge unit (PRC) charges the DC-link capacitors.
• The INU control unit (CNU-INU) is connected to the inverter units with optical fibers.
• The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV
section of the cabinet.
The 12-pulse DFE must be supplied by a dedicated transformer with two secondary windings.
For the full main circuit diagrams, see 11.4.2 VACON® 3000 12-Pulse Main Circuit Diagrams.

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Operating Guide Product Overview

e30bg607.10
AXU-IOB CNU-INU

LV~
PRC

MV~ + + +
Y
Δ 0 0 0 Motor
Δ - - -
MV~
CDC 3 x PCU
CCM
PCU +PODU
12P-DFE INU +POSI

Illustration 4: Example Main Circuit Diagram of a VACON® 3000 12-Pulse Drive

3.3 Type Code Description

The type code for VACON® 3000 has four basic parts (1–4) and option codes (5).

VACON3000 - 4Q - 0425 - 03 +XXXX +YYYY +ZZZZ

e30bg670.10

1 2 3 4 5
Illustration 5: VACON® 3000 Type Code Structure

1. Product series
VACON® 3000. This part of the code is always the same.
2. Drive type
There are two different drive types available. All kits include an inverter unit (INU) as default. The front-end type is specified in the
type code.
• 4Q: A regenerative drive with an active front end (AFE) and an LC input filter, supplied through a dedicated transformer. If the
drive is not supplied by a dedicated transformer, install an input common-mode filter (available with option code +PICM).
• 12: A non-regenerative drive with a 12-pulse diode front end (DFE) rectifier and external DC capacitors. A dedicated transformer
with 2 secondary windings is necessary.
• 24: A non-regenerative drive with a 24-pulse diode front end (DFE) rectifier and external DC capacitors. A dedicated transformer
with 4 secondary windings is necessary.
3. Nominal output current
See the available output currents in Table 2.

Table 2: Available Output Current Ratings

Motor voltage [V] 3300 4160

Output current [A] 0425 0340

0640 0510

0820 0650

1230 0980

4. Nominal input voltage

Nominal supply voltage: 03 = 3300 V or 04 = 4160 V.
5. Option codes
Optional components.
See the available codes in 3.4 Available Options.

3.4 Available Options

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Table 3: Available Options for VACON® 3000 Drive Kit

Option Code Option Description

+PICM Input common-mode filter

(1) The option is only available for AFE drives.
Always include the input common-mode filter in VACON® 3000 AFE installations, which are not supplied by a
dedicated transformer.

+DBCU Brake chopper unit for dynamic braking

(1) The option includes one brake chopper module. The option does not include a brake resistor.
The option is for 12-pulse drives. If a brake chopper is required for an AFE drive, contact Danfoss.

+PHSI High source impedance

Option for installation locations with high source impedances (~10–15% SI). For example, marine applications
usually have a high source impedance. The option affects the size of the input filters. The default installation lo-
cation has small source impedance (SSI).
This option is only available for AFE drives.
Examine each application one by one. To see if this option is necessary, find out the source impedance and see
11.3.7 Source Impedance Specifications. If necessary, consult Danfoss.

Filter inductors
+PFCH Inductors included
+PFC1 Inductors included without heat exchanger and fan
+PFC0 No inductors included

+SC__ C, D, and E slot option boards

+SD__ Default: No option boards in slots C, D, and E.
+SE__ See the available option boards in Table 4.

+HMDR Door keypad mounting kit with drive side IP54 protection and a cable length of 3 m (9.84 ft)

+QAIT Isolation transformer

Isolated auxiliary transformer for the power section, 120/240 V input voltage, 120 V output voltage, 3 kVA
The option is recommended to separate the low-voltage devices in the low-voltage section and the devices in
the medium-voltage section.

+QGSW Grounding switch

This option is recommended.
A 5-pole switch is supplied for AFE drives, and a 2-pole switch for 12-pulse drives.

+QPTR Potential transformer for input voltage measurement

+QSPD Surge protection device

The option is recommended for AFE drives with a high probability of large transient overvoltages at the drive
input.

+PMRK Mounting rack for power modules and the DC capacitors for DFE
(1)

+SAXB Additional auxiliary I/O board for the power section.

One auxiliary I/O board is included in the kit by default.

+HGAS Gasket sealing for increased dust protection of power modules

Control and fan supply voltage

115 V (default for 4160 V)

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Option Code Option Description

+QFV1 230 V (default for 3300 V)
+QFV2

Grounding of the heat sink and connection of the grounding resistor in power modules
+PGDR R: DC neutral-to-ground resistor connected (default)
+PGDN N: DC neutral-to-ground resistor not connected

Precharge input voltage

+QP24 240 V
+QP40 400 V (default for 3300 V)
+QP48 480 V (default for 4160 V)

+QGSK Mechanical interlocking system

Included by default with option +GAUL.

+GAUL cUL certificate

+GACE EU declaration, CE approval

1The nominal current and voltage selected in the type code of the VACON® 3000 affect this option. The correct size and number of parts is supplied
automatically. If a different size or number of parts is needed, an order for separate parts is possible.

Table 4: Available Option Boards for Slots C, D, and E

Slot C Slot D Slot E Option Board(1)

+SCB1 +SDB1 +SEB1 I/O board OPTB1: 6 x Digital input/digital output, programmable

+SCB2 +SDB2 +SEB2 I/O board OPTB2: 1 x relay output (NO/NC), 1 x relay output (NO), Thermistor

+SCB4 +SDB4 +SEB4 I/O board OPTB4: 1 x analog input, 2 x analog output (isolated)

+SCB5 +SDB5 +SEB5 I/O board OPTB5: 3 x relay output

+SCB9 +SDB9 +SEB9 I/O board OPTB9: 1 x relay output, 5 x digital input (42–240 V AC)

+SCBF +SDBF +SEBF I/O board OPTBF: 1 x analog output, 1 x digital output, 1 x relay output

+SCBH +SDBH +SEBH I/O board OPTBH: 3 x Temperature measurement (support for PT100, PT1000, NI1000, KTY84-130,
KTY84-150, KTY84-131 sensors)

+SDD3 +SED3 Adapter board OPTD3: RS232 adapter

+SDE3 +SEE3 Fieldbus board OPTE3: PROFIBUS DP-V1 (Screw connector)

+SDE5 +SEE5 Fieldbus board OPTE5: PROFIBUS DP-V1 (D9 connector)

+SDE6 +SEE6 Fieldbus board OPTE6: CANopen

+SDE7 +SEE7 Fieldbus board OPTE7: DeviceNet

+SDE9 +SEE9 Fieldbus board OPTE9: 2-port ethernet

+SDEA +SEEA Fieldbus board OPTEA: Advanced 2-port ethernet

+SDEC +SEEC Fieldbus board OPTEC: EtherCAT

1
For a 12-pulse drive, the option includes one board. For an AFE drive, the option includes two boards, one for the AFE control unit and one for the
INU control unit. If the drive also has the brake chopper option (+DBCU), the option includes one more board for the brake chopper control unit.

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Operating Guide Receiving the Delivery

4 Receiving the Delivery

4.1 Checking the Delivery
1. After removing the packaging, examine the drive for transport damages.
- If the drive was damaged during the shipping, speak to the cargo insurance company or the carrier.
2. To make sure that the delivery is correct, compare the type code for the order to the type code on the package label. The
type code specifies the drive type, nominal output current, nominal input voltage, and option codes. See 3.3 Type Code
Description.
- If the delivery does not agree with the order, speak to the vendor immediately.

The contents of the delivery are different for each type of drive kit. Below are the components, which are always included
in the delivery.
AFE drive
- LC filter (AFE shunt capacitor and AFE converter side inductor)
- Common-mode capacitor
- AFE phase modules
- AFE control unit
- Auxiliary I/O board
- INU phase modules
- INU control unit
- Pre-charge unit
12-pulse drive
- DFE power module
- Auxiliary I/O board
- DC capacitors for DFE
- Common-mode capacitor
- INU phase modules
- INU control unit
- Pre-charge unit

4.2 Storage

N O T I C E
LIQUID IN THE HEAT SINK
If the coolant is not removed from the heat sink before storage or shipping, the liquid can freeze and damage the drive.
- Always remove the coolant from the heat sink before storage or shipping. Plug or seal the inlet and outlet coolant connec-
tors.

If the AC drive or drive components are kept in storage, keep them in controlled conditions.
• Storage temperature: -40…+70 °C (-40... +158 °F). If the storage temperature is below 0 °C (+32 °F), make sure that there is no
coolant in the heat sinks.
• Relative humidity: < 95%, no condensation
Keep the equipment sealed in its packaging until installation.

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Operating Guide Receiving the Delivery

4.3 Lifting the Drive Components

W A R N I N G
LIFTING HEAVY EQUIPMENT
Follow local safety regulations for lifting heavy weights. Failure to follow recommendations and local safety regulations can result
in death or serious injury.
- Ensure that the lifting equipment is in proper working condition.

The VACON® 3000 phase modules and other components, such as inductors, capacitors, and transformers are heavy. Use a lifting
device to move the heavy components.
The power modules have 13 mm (0.51 in) holes on top of the units, where lifting rings can be installed. The lifting rings are not
included in the delivery.
Before lifting the inductors, remove the heat exchanger from the top of the inductor. Lift the inductors from the lifting rings on top
of the components.
Put the lifting hooks symmetrically in two or more lifting rings. Make sure that the lifting device can lift the weight of the equip-
ment. The maximum lifting angle is 90°.

e30bg669.10
≤90° ≤90°

Illustration 6: Lifting a VACON® 3000 Phase Module and an Inductor

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Operating Guide Mechanical Installation

5 Mechanical Installation
5.1 Operating Environment

N O T I C E
CONDENSATION
Moisture can condense on the electronic components and cause short circuits.
- Avoid installation in areas subject to frost.
Install space heaters to warm the air inside the cabinets.
Before powering the drive, run the cooling pumps to warm up the components, until the drive is warmer than the ambient
air.

N O T I C E
EXTREME AMBIENT CONDITIONS
Hot or cold temperatures compromise unit performance and longevity.

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the
installation environment. For specifications regarding ambient conditions, see 11.3.5 Ambient Conditions.

5.2 Cabinet Installation

The VACON® 3000 power modules and other components have the protection rating IP00. Therefore, the drive must be installed in
a metal cabinet or other enclosure which is applicable for medium-voltage applications. The enclosure must have the correct level
of protection against the ambient conditions in the installation area. Make sure that the cabinet gives protection against:
• Water
• Humidity
• Dust
• Other contaminations
The cabinet must also be sufficiently strong for the weight of the drive components and auxiliary devices. When preparing the in-
stallation, obey the applicable local regulations.
The cabinet assembly must have sufficient space for all the drive components, the power and control cables, and auxiliary devices.
There must also be sufficient space to make the cable connections. Make sure that it is also possible to do service work, for example:
• Replace the fans,
• make inspections,
• tighten terminal screws.
The enclosure must obey the EMC requirements of the second environment, class 2. See the standard IEC 61800-3.
Installation guidelines:
• Locate the drive enclosure as near to the motor as possible.
• Ensure unit stability by mounting the enclosure on a solid surface.
• Ensure that the strength of the mounting location supports the unit weight.
• Ensure that there is enough space around the unit for proper cooling.
• Ensure that there is enough room to open the cabinet doors and for working on the equipment.

5.3 Mounting Rack Installation

5.3.1 VACON® 3000 Mounting Racks

The installation of phase modules, DFE power modules, DC capacitors for DFE and brake chopper units in a cabinet is easy with the
mounting racks supplied by Danfoss.
The mounting racks are easy to use. The modules are pushed in the mounting rack and mounted with screws from the front of the
module. The easy installation also makes the removal and maintenance of the modules fast and easy.
Mounting racks are supplied in different sizes and they can contain a different number of modules.

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Operating Guide Mechanical Installation

• Mounting racks for AFE + INU systems usually hold six phase modules, but also racks with 3 slots are available.
• Mounting rack for DFE + INU systems contain 6 slots (1xDFE + 3xINU + 1xDC capacitor + one slot for BCU or extra DC capacitor).
• The mounting racks are available in two different widths: one for the L20 size modules and one for the L30 size modules.
The mounting racks are available as option +PMRK.
The mounting racks are delivered as a kit and require assembly.

5.3.2 Mounting Rack and Module Installation Guidelines

To keep the busbar connections between the modules as short as possible, follow these guidelines when assembling the mounting
racks and installing the modules in the racks.
AFE Drives
In AFE drives, install the AFE and INU phase modules next to each other in the 6-slot or 3-slot racks. If the drive has parallel power
circuits, install the AFE phase modules in one rack and the INU phase modules in the other rack.

e30bj433.10
AFE AFE INU

AFE AFE INU

AFE AFE INU

INU AFE INU AFE INU

INU AFE INU AFE INU

INU AFE INU AFE INU

1 2 3
Illustration 7: Mounting Rack Configuration Examples for AFE Drives

1 AFE/INU phase modules in 6-slot rack 3 AFE/INU phase modules in two 6-slot racks

2 AFE/INU phase modules in two 3-slot racks

12-pulse Drives
In 12-pulse drive installations, follow these guidelines:
• Install the DFE module at the top or at the bottom, and next to the DC capacitor.
• Install the INU phase modules next to each other, and next to the DC capacitor.
• If the drive uses a 7-terminal DC capacitor (which is larger than a 6-terminal capacitor), use the rack with a specific slot for the
capacitor.
• In 6-slot racks, the extra slot can be used for a brake chopper unit or an extra DC capacitor.
• If an extra DC capacitor is required, install it next to the other DC capacitor.
• If the extra slot in the rack is not required, a 5-slot rack can be used. The extra slot can also be left empty. In this case, it is
recommended to leave the empty slot at the top of the rack, so that the center of gravity of the assembly is lower.
• If the drive has parallel power circuits, and the modules for each circuit are installed in separate racks side-by-side, the configu-
ration in both racks must be the same.

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e30bj434.11
BCU INU
DFE DFE
INU INU INU INU
CDC CDC
INU INU INU INU
INU CDC
INU CDC INU INU
INU INU
CDC CDC CDC CDC
INU INU
DFE DFE DFE DFE
BCU INU
1 2 3 4 5 6
Illustration 8: Mounting Rack Configuration Examples for 12-pulse Drives

1 DFE module at the top and BCU in extra slot 4 DFE module at the bottom and CDC in extra slot

2 DFE module at the top and CDC in extra slot 5 DFE module at the bottom and extra slot empty

3 DFE module at the bottom and BCU in extra slot 6 5-slot rack with DFE module at the bottom

Drives with Parallel Power Circuits

In drives with parallel power circuits in side-by-side racks, make the DC-link connection between the racks:
• AFE: In the middle of the AFE/INU phase modules (between 3rd and 4th module in a 6-slot rack).
• DFE: At the DC capacitor.
For details of the DC-link connections, see 6.2.4 DC-Link Connections.

5.3.3 Assembling the Mounting Racks

These assembly instructions apply to all mounting racks. The example illustrations are of a mounting rack for 12-pulse (DFE) drives.

Procedure
1. Attach the slides to all the racks with M4x10 flat head screws. Make sure that the slides are level with the front of the rack.
e30bj442.10

Illustration 9: Mounting the Slides on the Racks

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

2. Set down 3 horizontal beams.

e30bj443.10
Illustration 10: The Horizontal Beams

3. Set one rack on the horizontal beams and align them.

e30bj444.10

Illustration 11: Aligning the First Rack with the Horizontal Beams

4. Assemble the vertical beams to the horizontal part and align with the holes on the rack. Make sure that the slotted holes in
the vertical beams are at the top. Mount the vertical beam to the rack with M8x20 torx pan head screws. Tighten the screws
by hand only.
e30bj445.10

Illustration 12: Assembling the Vertical Beams

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Operating Guide Mechanical Installation

5. Mount the vertical beams to the horizontal beams with M8 nuts. Tighten the nuts by hand only.

e30bj446.10
Illustration 13: Mounting the Vertical Beams to the Horizontal Beams

6. Stack the other racks on top of the first rack and align them.
e30bj447.10

Illustration 14: Stacking the Racks

7. Attach the vertical beams to the other racks, like the first one.
8. Mount the 3 horizontal beams on top of the rack assembly with M8 nuts. Tighten the nuts by hand only.
e30bj448.10

Illustration 15: Mounting the Horizontal Beams at the Top

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

9. Mount the clips to the back of the rack assembly with M6 screws. There are 2 clips per rack slot.

Illustration 16: Mounting the Clips e30bj449.10

10. Tighten all the fasteners.

Table 5: Tightening Torques

Screw size Torque (Nm)

M4 3

M6 6

M8 9

5.3.4 Installation of the Mounting Rack

Attach the mounting rack tightly at the bottom in all installations. The mounting rack can also be attached from the top. Always
attach the mounting rack at the top in locations where vibration of the cabinet is possible.
See the dimensions of the mounting racks in 11.1.16 Dimensions, Mounting Rack.

5.3.5 Grounding of the Mounting Rack

The mounting rack has a copper ground bar installed to the right side to make it easy to ground each power module. Connect the
mounting rack ground to the primary ground bar of the cabinet. Use the hole at the bottom of the copper bar in the right side of
the mounting rack.

5.3.6 Cabling in the Mounting Rack

There is a wire duct in the mounting rack, on top of the ground bar. Use the wire duct for the 24 V DC power cables and optical
fibers to the phase modules.

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5.4 Installing Modules in a Mounting Rack

Installing the Modules in a Mounting Rack
1. Lift the module in the mounting rack.

e30bg838.10

Illustration 17: L20 Phase Module and a Mounting Rack for Six Modules

2. Push the module in the mounting rack as far as it goes.

e30bg839.10

Illustration 18: L20 Phase Module Pushed in the Mounting Rack

3. Attach the module to the mounting rack with screws in the front of the module. The screws are included in the delivery.
e30bg840.11

1 1

1 1

Illustration 19: Locations of the Mounting Screws in the L20 Phase Module

A Mounting screws

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Operating Guide Mechanical Installation

5.5 Liquid Cooling Requirements

5.5.1 Safety in Liquid-cooling

W A R N I N G
POISONOUS COOLANTS
Glycols and inhibitors are poisonous. If touched or consumed, they can cause injury.
- Prevent the coolant from getting into the eyes. Do not drink the coolant.

C A U T I O N
HOT COOLANT
Hot coolant can cause burns.
- Avoid contact with the hot coolant.

C A U T I O N
PRESSURIZED COOLING SYSTEM
Sudden release of pressure from the cooling system can cause injury.
- Be careful when operating the cooling system.

N O T I C E
INSUFFICIENT COOLING CAPACITY
Insufficient cooling can cause the product to become too hot and thus become damaged.
- To make sure that the cooling capacity of the cooling system stays sufficient, make sure that the cooling system is vented
and that the coolant circulates properly.

N O T I C E
DAMAGE TO COOLING SYSTEM
If the coolant circulation is stopped too soon, high temperature components can cause rapid local increase in the coolant tem-
perature, which can damage the cooling system.
- Do not stop the cooling system when stopping the drive. Keep the coolant circulation flowing for 2 min after the drive has
been stopped.

5.5.2 General Information on Liquid Cooling

VACON® 3000 drives are liquid-cooled. The liquid circulation of the drive is connected to a heat-exchanger that cools down the
liquid circulating in the cooling elements of the drive. The power modules have aluminum heat sinks, which give good and safe
temperature control. Because the cooling elements are made of aluminum, the cooling liquids allowed to be used are inhibited
pure water, inhibited demineralized water, or an inhibited mixture of water and glycol.
The inductors of the input and output filters use air-to-liquid heat exchanger units for forced air cooling. The heat exchangers de-
crease the heat losses to the air and thus decreases the number of fans necessary for cooling the cabinet.
There are two types of cooling systems: open systems and closed systems.
An open system has no pressure but the hydrostatic and pumping pressure. It allows free contact between the cooling liquid and
air. Air is continuously dissolved into the cooling liquid.
In a closed system, the piping is air-tight and there is a preset pressure inside the pipes. The pipes must be made of metal, or a
specific plastic or rubber that includes an oxygen barrier that limits the diffusion of oxygen. Minimizing of oxygen content in the
cooling liquid decreases the risk of corrosion of the metal parts. Closed systems usually have an expansion vessel that allows for a
safe change of volume of the cooling liquid due to temperature changes.
Always use a closed system with Danfoss liquid-cooled drives.

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5.5.3 Cooling Liquid

5.5.3.1 Quality Requirements for the Purified Water

N O T I C E
DAMAGE TO SYSTEM FROM THE USE OF HYDROCARBONS
Hydrocarbons damage the rubber seals of the cooling system.
- Do not use hydrocarbons (for example mineral oil) as coolant. Do not mix hydrocarbons to coolant.

Table 6: Requirements for the Purified Water

Property Required value

pH 6...8

Chlorides ≤ 25 ppm

Sulphate ions ≤ 25 ppm

Maximum particle size ≤ 50 µm

Total dissolved solids ≤ 200 ppm

Total hardness (CaCO3) 3…4.6 dH° (53…80 ppm)

Hydrogen carbonate ≤ 50 ppm

Electrical conductivity ≤ 500 µS/cm

5.5.3.2 Purified Water as Coolant

Purified water can be used as coolant if there is no risk of freezing. Freezing water permanently damages the cooling system. Puri-
fied water is demineralized, deionized, or distilled water.
Always use an inhibitor Cortec VpCI-649 with 1.0% of volume with purified water.

C A U T I O N
CORROSION HAZARD WITH DRINKING WATER
Some components are made of aluminum, which has limited corrosion resistance against high chloride concentrations. Drinking
water can have a chloride concentration of 250 ppm, which increases the aluminum corrosion rate. High chloride concentration
exposes aluminum especially to pitting corrosion which can damage the system relatively quickly.
- Use purified (demineralized, deionized, or distilled) water with corrosion inhibitors.

5.5.3.3 Antifreeze Mix as Coolant

The following antifreeze products are a good general solution for liquid cooling since they provide freeze protection and corrosion
protection.
The allowed antifreeze coolants are the following ethylene glycols and propylene glycols.
Ethylene glycols
• DOWCAL 100
• Clariant Antifrogen N
Propylene glycols
• DOWCAL 200
• Clariant Antifrogen L
These glycols already include corrosion inhibitors. Do not add any other inhibitor. Do not mix different glycol qualities because
there can be harmful chemical interactions.

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

The glycol concentration of the coolant must be 25–55% by volume, according to the specified ambient temperature. Higher con-
centration reduces cooling capacity. Lower concentration results in biological growth and inadequate amount of corrosion inhibi-
tors. Antifreeze must be mixed with purified water according to 5.5.3.1 Quality Requirements for the Purified Water.

5.5.3.4 Temperature of the Cooling Liquid

To gain full performance of the product, the temperature of the cooling liquid entering the drive components must be a maximum
of 43°C (109°F) and above the dew point. While circulating inside the cooling element, the liquid transfers the heat produced by the
power semiconductors and other components. The temperature rise of the cooling liquid during the circulation is typically less than
4°C (7.2°F). Typically, more than 95% of the power losses are dissipated in the cooling liquid. It is recommended to equip the cooling
circulation with temperature supervision.
The secondary circuit maximum temperature must always be lower than the primary circuit temperature. The temperature differ-
ence must be at least 5°C (9°F) with equal flow. The temperature difference is necessary for the correct operation of the heat ex-
changer.
There are 3 external causes that affect the nominal temperature of the primary circuit:
• The maximum ambient temperature at the drive installation location.
• The maximum relative humidity at the drive installation location.
• The maximum secondary circuit liquid temperature.
All these causes must be examined when calculating the primary circuit temperature. The primary circuit temperature can be differ-
ent for each installation.

5.5.3.5 Condensation
Condensation must be avoided. Always keep the temperature of the cooling liquid a minimum 2°C (3.6°F) above the dew point. Use
the graph in Illustration 20 to see if the conditions (combination of room temperature, humidity, and cooling liquid temperature)
are safe for the drive to operate.
The conditions are safe when the point is below the related (cooling liquid temperature) curve. If they are not, decrease the ambient
temperature or the relative humidity. Also the cooling liquid temperature can be increased. Note, that if the cooling liquid tempera-
ture is increased above the figures in loadability charts, it decreases the nominal output current of the drive. The curves in Illustra-
tion 20 are valid at sea level altitude (1013 mbar/14.69 psi).
If the temperature of the liquid in the secondary circuit is lower than the ambient temperature and the relative humidity is high,
condensation can occur on the secondary circuit pipes and the plate heat exchanger in the HX unit. The condensation is not dan-
gerous, but it is not recommended. If there is condensation in the HX unit, it can cause the leak sensor in the cabinet to give a leak
alarm. If a leak alarm occurs again and again, install insulation in the secondary circuit pipes and the plate heat exchanger. The
insulation stops the condensation and thus prevents the incorrect leak alarms.

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Operating Guide Mechanical Installation

e30bg701.10
Tamb , °C (°F)

60 (140)

50 (122)

Tc , °C (°F)
40 (104)
45 (113)

40 (104)
30 (86) 38 (100)

35 (95)

30 (86)
20 (68)
25 (77)

20 (68)
10 (50)

0 (32)
100 90 80 70 60 50 40 30 20 10 0

RH (%)
Illustration 20: Safe Operating Conditions in Relation to Condensation

RH Relative humidity T c Cooling liquid temperature

T amb Ambient temperature

Example
Safe Operating Conditions
If the ambient temperature is +30°C (+86°F), the relative humidity is 40% and the cooling liquid temperature is +20°C (+68°F, the
lowest curve in Illustration 20), then the drive operation conditions are safe.
If the ambient temperature increases to +35°C (+95°F) and the relative humidity to 60%, then the operation conditions of the drive
are not safe. To get safe operation conditions, the ambient temperature must be decreased to +28°C (+82°F) or below. If it is not
possible to lower the ambient temperature, then the cooling liquid temperature can be increased to +25°C (+77°F) or above.

Example
Dew Point and Primary Circuit Temperature
If the ambient temperature and the maximum relative humidity at the drive installation location is known, the dew point chart (see
Illustration 21) can be used to find the correct temperature for the primary circuit.
• Ambient temperature = 35°C (95°F)
• Maximum relative humidity = 60%
According to the diagram in Illustration 21, the dew point for the given values is 26°C (78.8°F). Always keep the temperature of the
cooling liquid a minimum 2°C (3.6°F) above the dew point. Thus the primary circuit minimum temperature is set to 28°C (82.4°F).
The secondary circuit maximum temperature must always be 5°C (9°F) lower than the primary circuit temperature. Thus, in this ex-
ample, the secondary circuit temperature must be below 23°C (73.4°F) during operation.
Notice, that these conditions are valid for the starting of the drive. After the start, the temperature inside the cabinet starts to in-
crease and the humidity decreases.

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

e30bg702.10
Tamb (°C/°F)
10 15 20 25 30 35 40 45 50 °C
50 59 68 77 86 95 104 113 122 °F
100

95

90

85

80

75

70

65
RH (%)

60

55

50

45

40

35

30

25

20
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 °C
36 39 43 46 50 54 57 61 64 68 72 75 79 82 86 90 93 97 100 104 108 111 115 118 122 °F
Tc (°C/°F)
Illustration 21: Dew Point Diagram for Ambient Temperatures between +10°C...+50°C (+50°F...+122°F) at 1013 mbar (14.69 psi)

RH Relative humidity T c Primary circuit temperature

T amb Ambient temperature

5.5.4 Cooling System

5.5.4.1 Materials

C A U T I O N
COPPER OR COPPER ALLOY PARTS DAMAGE THE SYSTEM
Using copper or copper alloy pipes or parts in contact with the cooling liquid damages the system.
- Do not use pipes made of copper or alloys that include copper. If metallic pipes are used in the cooling system, use alumi-
num or stainless steel pipes.

Allowed materials in the cooling system

These materials are allowed in the cooling system if they are compatible with the cooling liquid:
• Aluminum (EN-AW6060, EN-AW6063, or EN-AW6082)
• Stainless steel (AISI 304/316)
• Plastic*
• Elastomers (EPDM, NBR, FDM)*
* If plastic or elastomers are used, check material compatibility within the temperature range of the cooling liquid. See the specifica-
tions in 11.3.6 Cooling.
Do not use PVC, copper, brass, or other materials not compatible with the heat sink material or cooling liquid.
Recommended material for pipes

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

• PA11
• PA12
• PEX with oxygen barrier
• PEX-AL-PEX
The electrical resistance of the plastic and rubber pipes must be >109 Ω.

5.5.4.2 Heat Exchanger

The heat exchanging equipment can be located outside the electrical room in which the AC drives are. The connections between
these two are made on site. To minimize the pressure drops, the piping must be made as short and straight as possible. It is also
recommended to install a regulating valve that is equipped with a flow rate measurement point. This makes it possible to measure
and regulate the cooling liquid circulation in the commissioning phase.
The highest point of the piping must be equipped with either an automatic or a manual venting device. The material of the piping
must comply with at least AISI 304 (and AISI 316 is recommended). Before connecting the pipes, clean the bores thoroughly. If
cleaning with water is not possible, use pressured air to remove all loose particles and dust.
The VACON® 3000 Drive Kit does not include a heat exchanger unit, but Danfoss supplies a range of applicable liquid-to-liquid heat
exchangers. It is recommended to use Adwatec CCE-series cooling modules. Suitable pump sizes depending on the required cool-
ing power are 10-4, 15-3, or 32-2.

5.5.4.3 Cooling System Installation

Install the power modules and liquid-to-air heat exchangers to the cooling system in parallel. Do not install the modules in series!
Incorrect installation of the liquid cooling system can lead to overheating of the drive components and can damage the equipment.
See Illustration 22 for examples of the cooling system and the connections between the AC drive components and the cooling sys-
tem.

Primary circuit Secondary circuit

e30bg703.11
To power Bleeding
modules

< 43°C HX
PT
PI
LI
Tank

M3 Raw
LS
water
Temprerature control

LS PI
M1
TT
P1
PT
M2 Drain
Liquid-to-air AFE INU From power TT Filling
modules P2
Heat exchangers

Illustration 22: Cooling System Example

HX Heat exchanger PI Pressure indicator

LI Level indicator PT Pressure transmitter

LS Level switch Px Pump

Mx Motor TT Temperature transmitter

Recommended Components
Valves
Install a bypass valve in the primary or secondary line, and valves at each PCU inlet. The bypass valves make it possible to open and
clean the cooling system. Open the bypass valve and close the valves to the AC drive when cleaning the system. While commission-
ing the system, close the bypass valve and open the valves to the AC drive.
Pressure and flow supervision

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

Install pressure and flow supervision (FE) in the cooling system. The flow supervision can be connected to the External fault digital
input function. If the cooling liquid flow is too low, the flow supervision stops the AC drive.
Flow restrictors
If there is a wide range of input pressure and if it is not sure, that there is an equal pressure difference, install flow restrictors in the
outputs of all the power modules and the liquid-to-air heat exchangers for the inductors.

5.5.4.4 Power Module Cooling Connections

C A U T I O N
INCORRECT COOLING CONNECTIONS
Incorrect installation of the liquid cooling connectors can lead to overheating of the power modules and can damage the equip-
ment.
- Do the cooling connections correctly. Make sure that the connections are tight and that there are no leaks.

The phase modules and DFE power modules have an easy inlet-outlet piping configuration in the front for connection to the heat
exchanger unit. The L20/L30 power module heat sink has G1/2 holes with threads (BSPP: ISO/DIN 1179-1). The D22 power module
has G3/4 size holes.
Do the sealing of the heat sink threads (BSPP G1/2) with bonded sealing washers (Dowty washers). Do not use sealing tape or com-
pound on the threads.
The tightening torques for the cooling connections:
• G1/2 Dowty washer: 40–65 Nm.
• G3/4 Dowty washer: 70–110 Nm.
The cooling hoses are connected differently in AFE and INU phase modules. See Illustration 23 and Table 7. In brake chopper units,
the connection order of the cooling hoses can be selected freely.
e30bg704.11

1 2
AFE
INU
Illustration 23: Cooling Hose Terminals on the L20 Phase Module

1 Cooling hose terminal 1

2 Cooling hose terminal 2

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VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

e30bi552.10
1

Illustration 24: Cooling Hose Terminals on the D22 Power Module

1 Cooling hose terminal 1

2 Cooling hose terminal 2

Table 7: Power Module Cooling Connections

Power Module Type Cooling Terminal 1 Cooling Terminal 2

AFE IN OUT

INU OUT IN

DFE IN OUT

BCU IN/OUT IN/OUT

5.6 Air Cooling Requirements

VACON® 3000 is a liquid-cooled AC drive, but in a liquid-cooled drive system, there are always some heat losses to the air. The heat
losses come from the busbars, filters, inductors, and other auxiliary components. While installing the drive modules and other com-
ponents to a cabinet, it must be ensured that there is sufficient airflow in each cabinet section. When designing the cooling system,
refer to the highest possible continuous temperature and load.
The ambient conditions in each cabinet section must be in line with the specifications for VACON® products. Make sure that the
temperature of the cooling air does not become higher than the maximum ambient temperature or lower than the minimum ambi-
ent temperature of the drive. If the AC drive becomes too hot again and again, it puts the operation at risk and decreases the life
time of the installed components.
Liquid-to-air heat exchangers can be used to cool the hot air from the inductors and other components. Fans can be installed in the
cabinet walls to move the air between the cabinet sections. The structure of the cabinet must be such, that the air can move freely
through the cabinet.

Danfoss A/S © 2022.11 AQ286660482920en-000201 / DPD01895 | 39

VACON® 3000 Drive Kit

Operating Guide Mechanical Installation

e30bg713.11
Illustration 25: Example of Liquid-to-Air Heat Exchangers Used for Cabinet Cooling

If only fans are used to cool the cabinet, the cabinet door or bottom part of the cabinet must have air gaps for air intake and outlet
air gaps on top of the cabinet. The inlet and outlet air gaps must obey the requirements set by the selected protection rating. The
structure in the cabinet must move the hot air to the outlet at the top of the enclosure. The structure must also make sure that the
hot air cannot turn back to the fans and the drive components.
The air must move freely through the cabinet. There must be a minimum of 20 cm (7.87 in) of space above the cabinet without
structures that can stop the airflow. Make sure that the hot air goes out of the cabinet and does not come back into the cabinet.

40 | Danfoss A/S © 2022.11 AQ286660482920en-000201 / DPD01895

VACON® 3000 Drive Kit

Operating Guide Electrical Installation

6 Electrical Installation
6.1 Power Cabling Guidelines

6.1.1 MV and LV Sections in the Cabinet

In the cabinet installation, make a clear separation between the low-voltage (LV) and medium-voltage (MV) sections. There must be
galvanic isolation between the LV and MV sections. The insulation between the sections gives the devices in the LV section protec-
tion from the MV section voltages. The example in Illustration 26 shows which components to install in the MV and LV sections.
Make all connections between the LV and MV sections with optical fiber cables. The only approved LV connections between the MV
and LV sections are:
• The LV supply for the pre-charge unit (PRC)
• The LV supply for the isolation transformer (+QAIT)
• The supply voltage feedback from the potential transformer (+QPTR) to the AFE control unit
Be careful with the installation of the pre-charge unit, the isolation transformer, and potential transformer. Make sure that the LV
supply cables are not near parts with medium voltage and have protection from possible arc flashes.

+QGSW

e30bg753.11
PRC E
400/
CCM CCM 480V
CSH

PCU PCU +PODU O HX Run

MCB LGI LCM LCV AFE INU +POSI I HX OK
+ +
L1 o o U
- - ESW
4160/ HMI
Motor

L2 V MTR
3300V
L3 W HX

C CNU-INU

APS
+QSPD 24 V-10 A
TB
+QPTR LSI
PRC
LCV Aux I/O D CNU-AFE
LCM
GSW 24 V-10 A
LGI
MCB
Leak LD
detector
Cabinet
over temp
COT
COT
C
Cabinet
indicator over temp DSI
Door safety I - VCB Status
indicator interlocks Humidity
L N
I - KMX Status
HXLA O - MX Start
PS-BRK APS O - MX Permissive
Cab
heater 24 V - 20 A O - VCB Close Relay
Arc
Power module Magnetics Magnetics Magnetics flash
Logic
cabinet cabinet cabinet cabinet detector
Liq to air Liq to air Liq to air Cab
I - Power On
HX HX HX heater Thermo- Door safety I - Power Off
stat 24 V - 20 A interlocks I - GND SW Unlock
L N I - Arc Guard Online
I - Arc Guard Trip
I - HX OK
Humidity I - User Interlock
Thermo-
stat
+QAIT

230/
Panel
service
120V
socket
L N PE

B Panel
lighting

A
MEDIUM-VOLTAGE SECTION LOW-VOLTAGE SECTION
Illustration 26: Example of the MV and LV Sections

A Galvanic isolation between the MV and LV sections D Supply voltage feedback from the potential trans-
former (+QPTR) to the AFE control unit
B LV supply for the isolation transformer (+QAIT)
E LV supply for the pre-charge unit (PRC)
C Optical fiber connections

Danfoss A/S © 2022.11 AQ286660482920en-000201 / DPD01895 | 41

VACON® 3000 Drive Kit

Operating Guide Electrical Installation

6.1.2 Power Cable Selection

When selecting the busbars and cables for the power connections between the drive components and auxiliary components, refer
to the highest possible continuous temperature and load. All the recommended cable dimensions are for copper cables. It is recom-
mended to use, for example, Nexans SIWO-KUL B10 6.6/7.2 kV copper cables in the medium-voltage sections of the cabinet.
The recommended cable sizes apply to cables with a maximum operation temperature of +120°C (+248°F).

+QGSW 3 4

e30bg729.11
PRC
2
CCM CCM LV
2
CSH
2 2
1 2
PCU PCU +PODU
MCB LGI LCM LCV AFE INU +POSI
+ +
o o MTR
L1 - -
U

Motor
MV L2 V HX
L3 W

3 1
3 1 1 1 1 1
+QSPD CNU-AFE
+QPTR

Illustration 27: Recommended Cable Sizes for VACON® 3000 AFE Drives

1 See Table 8

2–4 See Table 9

e30bg730.11
3 4
+QGSW
2 2 PRC

CCM LV

DFE
2 +PODU
CDC INU +POSI
MV~ + + + U
Motor

o o o V
- - - W
MV~ HX

5 1 1 1 1

Illustration 28: Recommended Cable Sizes for VACON® 3000 12-Pulse Drives

1 See Table 8 5 See Table 10

2–4 See Table 9

Table 8: The Recommended 6.6 kV Main Circuit Cable Sizes for VACON® 3000 AFE and 12-pulse drives

Drive Nominal Voltage Drive Nominal Current Cable Size, Cu Part Number(1)

3300 V 425 A 185 mm2 (350 kcmil) 10148885

640 A 240 mm2 (500 kcmil) 10148947

820 A 2×185 mm2 (2×350 kcmil) 10148885

1230 A 2×240 mm2 (2×500 kcmil) 10148947

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VACON® 3000 Drive Kit

Operating Guide Electrical Installation

Drive Nominal Voltage Drive Nominal Current Cable Size, Cu Part Number(1)

4160 V 340 A 185 mm2 (350 kcmil) 10148885

510 A 240 mm2 (500 kcmil) 10148947

650 A 2×185 mm2 (2×350 kcmil) 10148885

980 A 2×240 mm2 (2×500 kcmil) 10148947

1
Cu-cable SIWO-KUL B10 6.6/7.2 kV from Nexans

Table 9: The recommended sizes for the cables 2, 3, and 4

Cable Cable Size, Cu Part Number(2)

2 70 mm2 (AWG00) 10148773

3 16 mm2 (AWG6) 10148769

4 6 mm2 (AWG10) 10148778

2 Cu-cable SIWO-KUL from Nexans

Table 10: AC Busbars for DFE Module of VACON® 3000 12-pulse drives

Drive Nominal Voltage Drive Nominal Current Busbar thickness Busbar width

3300 V 425–1230 A 8 mm (0.315 in)(1) 80 mm (3.15 in)(2)

4160 V 340–980 A

1 Fixed due to DFE connector size.

2 Sized according to VACON3000-12-1230-03.

6.1.3 Cable Inlets Between Cabinet Sections

It is recommended to use cable installation kits to make sure that there is sufficient clearance (approximately 25 mm / 1 in) between
the cables and between the cables and conductor materials.
Use insulation plates that have grommets made of insulating material or non-magnetic metal (for example aluminum) for each ca-
ble inlet.
e30bg731.10

C B

Illustration 29: Example of Cable Installation Kits and a Cable Inlet

A Cable installation kits C Grommets made of insulating material

B Insulation plate

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VACON® 3000 Drive Kit

Operating Guide Electrical Installation

6.1.4 Mains and Motor Cable Selection

C A U T I O N
UNEQUAL LOAD
If the cable installation is not symmetrical, unequal load can occur in AC drives with parallel inputs or outputs. The unequal load
can decrease loadability or damage the drive.
- In drives with parallel inputs or outputs, make sure that the cable size, cable length, cable type, and routing is the same for all
parallel cables.

Use cables with a nominal voltage U0/U of 3.6/6 kV and maximum voltage 7.2 kV. The size and type of the cable depends on the
application of the drive. The cable size is also affected by:
• The current at continuous load,
• the permitted short-circuit current,
• the installation conditions.
To decrease EMI, use shielded 3-phase cables for the motor connection. If single-core cables are used in the input or output, they
must be shielded.
When selecting the cable, refer to the input voltage and the load current of the drive. Obey all applicable standards and local safety
regulations.
Example
Mains Cables for the VACON® 3000 4160 V 510 A AFE Drive
The recommendation for the VACON® 3000 4160 V 510 A AFE drive, is to use two 240 mm2 (500 kcmil) M2N type cables (available
from Liban Cables/Nexans) for each phase. The cables are 3.6/6 kV copper cables with one core, XLPE insulation, a PVC cover, shiel-
ded, and unarmored.

6.1.5 Mains and Motor Cable Inlet and Termination

The bottom or top sections of the enclosure must have cable entries which have flanges with rubber gaskets, grommets, or equiva-
lent sealing for the cable entry.
Connect the mains cables to terminals L1, L2, and L3 in the mains input section. Connect the motor cables to the inverter section
terminals U, V, and W. Make openings for the cables in the grommets on the bottom or top of the cabinet and push through the
cables. Use cable clamps to attach the cables. Always connect the PE conductors of the mains and motor cables to the PE busbar.
In units with parallel motor outputs, do not connect the motor cables together in the AC drive end. Always connect the parallel
motor cables together in the motor end only. The minimum motor cable length is 5 m (16.4 ft).
Use medium-voltage cable lugs to connect the cables to the busbar terminals. Use heat shrink or cold shrink cable termination kits
on the cables, for example, the kits HIT1.1204L or CIT1.1204L available from Ensto.
The output cables to the motor must be 360° EMC grounded, for example, by installing EMC grounding clamps at the cable inlet. To
make a 360° connection with the grounding clamps and the cable shield, strip the cables. The EMC grounding clamps must be the
correct size to give a 360° contact with the cable shield.

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VACON® 3000 Drive Kit

Operating Guide Electrical Installation

e30bg732.10
A

Illustration 30: Example of a 1-phase Motor Cable Inlet to the Cabinet

A Cable grommet D PE busbar

B Cable clamp E Cable termination

C 360° EMC grounding F Cable lug

e30bh726.10

Illustration 31: Example of a 3-phase Motor Cable Inlet to the Cabinet

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VACON® 3000 Drive Kit

Operating Guide Electrical Installation

A Cable entry seal with 360° EMC grounding C Cable termination

B PE busbar D Cable lug

6.1.6 Grounding
Ground the AC drive in accordance with applicable standards and directives.
Unless local wiring regulations state otherwise, the cross-sectional area of the PE conductor must be at least ½ times the phase
conductor and made of the same material, according to IEC 61800-5-1. The connection must be fixed.
Where relevant, refer to the grounding instructions in Article 250 of the National Electrical Code® (NEC®).
Install a protective earthing (PE) rail, for example, at the bottom front of the cabinets. Connect the PE rail to an external ground at
the installation location as is approved in the applicable regulations. Obey the local regulations on the minimum size of the protec-
tive earthing conductor.
Connect the phase module grounding terminals to the PE rail. Also ground the frames of the inductors and capacitors. Use a copper
grounding conductor with a cross-sectional area of minimum 2 x 35 mm2 (2 x AWG2) for each power module or a cable which obeys
the local regulations for grounding conductors.
Make sure that the ground connection to the frame of the inductors and capacitors is good. If the component is painted, remove
the paint from the connection point.
Always connect the PE conductors of the mains and motor cables to the PE busbar. The output cables to the motor must be 360°
EMC grounded. To make a 360° connection with the grounding clamps and the cable shield, strip the cables.
Grounding the cable shields:
• 3-phase cables: Ground the mains and motor cable shields at the drive, transformer, and motor ends of the cables.
• 1-phase cables: Ground the mains and motor cable shields only at the drive ends of the cables.

M e30bh724.10
3 3 3 3 3~

Illustration 32: Grounding the Cable Shields of 3-phase Cables

e30bh725.10

M
3~

Illustration 33: Grounding the Cable Shields of 1-phase Cables

6.1.6.1 Standard Grounding Configurations

e30bh722.10

TR CB
CLF DC+
DC0 M
3 3 3 DC- 3 3 3~

3
GND MVC GND 3

CCM

GND
CAB

Illustration 34: Grounding of Transformer-Isolated Drives

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VACON® 3000 Drive Kit

Operating Guide Electrical Installation

CAB Drive cabinet frame GND Grounding busbar

CB MV circuit breaker or fused contactor M MV motor

CCM Grounding capacitor MVC MV cable

CLF CL filter TR MV transformer (secondary side ungrounded)

e30bh723.10
MVS CB LCL LCM
DC+
DC0 M
3 3 3 3 DC- 3 3 3~

3 SP MVC
GND GND 3

MVC CCM

GND
CAB

Illustration 35: Grounding of Grid-Connected Drives

CAB Drive cabinet frame LCM Common-mode inductor

CB MV circuit breaker or fused contactor M MV motor

CCM Common-mode capacitor network (used in grid- MVC MV cable

connected systems only)
MVS MV source (ungrounded or impedance grounded
GND Grounding busbar only)

LCL LCL filter SP Star point of shunt capacitor

6.1.7 Installation in an IT grid

The VACON® 3000 phase modules have in-built ground fault monitoring. In networks where the mains is impedance-grounded (IT),
there is often separate ground fault monitoring equipment. This external equipment usually has limitations on the minimum
grounding resistance or the maximum grounding capacitance of the AC drive.
By default, the drive has a 25 µF common-mode capacitor installed between DC neutral and ground (see 6.5.7 Common-Mode Ca-
pacitor Installation). If this grounding capacitance is too high for the ground fault monitoring equipment, it can be replaced with a
smaller capacitance. Contact Danfoss for further information.
For ground voltage measurement, each phase module has 12 MΩ grounding resistance between DC neutral and ground. This resist-
ance cannot be removed. However, each phase module has also a 190 kΩ (for 3300 V) or 300 kΩ (for 4160 V) resistor installed to
ground. It is possible to order the phase modules with this grounding resistor disconnected (option +PGDN).

GND DC- PH~ DC+

e30bi526.10

2 MΩ 2 MΩ 2 MΩ 2 MΩ

2 MΩ 2 MΩ 2 MΩ 2 MΩ

2 MΩ 2 MΩ 2 MΩ 2 MΩ
190/300 kΩ
2 MΩ 2 MΩ 2 MΩ 2 MΩ

2 MΩ 2 MΩ 2 MΩ 2 MΩ

2 MΩ 2 MΩ 2 MΩ 2 MΩ
DCN
Illustration 36: Grounding Resistance in the Phase Modules

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Example
A 4160 V, 2 MW or 3 MW VACON® 3000 AFE drive has 6 phase modules. Therefore, the total grounding resistance is approximately
300 kΩ/6 = 50 kΩ (neglecting the 12 MΩ/6 = 2 MΩ of the phase modules).

6.1.8 Additional Instructions for Cable Installation

• Before starting the installation, make sure that none of the components of the AC drive is live. Read carefully the warnings in the
Safety section.
• Make sure that the motor cables are sufficiently far from other cables.
• The motor cables must go across other cables at an angle of 90°.
• If it is possible, do not put the motor cables in long parallel lines with other cables.
• Only use symmetrically EMC shielded motor cables.
• Make sure that there is sufficient clearance (approximately 25 mm/1 in) between the cables in the cabinet and between the
cables and conductor materials.
• If cable insulation checks are necessary, see 8.4.2 Measuring the Cable and Motor Insulation.

6.2 Cabling of the Power Modules

6.2.1 Phase Module L20/L30 Terminals

To make access and installation easy, all terminals are located in the front of the phase modules. Phase, DC, neutral, and ground
terminals have sufficient space between them and creepage walls on each side. To make the terminals compatible with different
cable lugs, the terminals can be changed by removing screws from the front.
See the functions of the AFE/INU phase module terminals in Illustration 37. If the phase module operates as an AFE or INU, some of
the terminals have different functions.
e30bg716.10

A B C D E F

G H I J K
Illustration 37: AFE/INU Phase Module Terminals

A ~, phase input (AFE) / motor output (INU), size M10 G Cooling liquid terminal in (AFE) / out (INU)

B - , DC minus, size M10 H Cooling liquid terminal in (INU) / out (AFE)

C 0, DC link neutral point, size M10 I Optical fiber A

D +, DC plus, size M10 J Optical fiber B

E Heat sink terminal, size M6 K 24 V supply for control

F Ground terminal, size M6

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6.2.2 DFE Power Module Terminals

In the DFE power module, all terminals are at the front of the module, except the AC input terminals, which are at the back of the
module. DC, neutral, and ground terminals have sufficient space between them and creepage walls on each side. To make the DC
terminals compatible with different cable lugs, the terminals can be changed by removing screws from the front. The AC terminals
have knife type busbar connections for 10 mm (0.39 in) thick busbars.
The functions and locations of the DFE power module terminals are shown in Illustration 38.

1 2 3

e30bi551.11
7

4 14
8
5 9 11
6
15

10 12

16

13

Illustration 38: Terminals in the Front (left) and Back (right) of the DFE Power Module

1 - , DC minus, size M10 9 Heat sink terminal, size M6

2 N, DC neutral, size M10 10 Ground terminal, size M6

3 +, DC plus, size M10 11 1L1, phase input

4 Optical fibers 12 1L2, phase input

5 Optical fibers A and B 13 1L3, phase input

6 24 V supply 14 2L1, phase input

7 Cooling liquid terminal in 15 2L2, phase input

8 Cooling liquid terminal out 16 2L3, phase input

6.2.2.1 DFE Control Terminals

The DFE power module has specific terminals for controlling the crowbar circuit in the module. Optical fiber terminals A and B are
for Powerbus connection to the auxiliary I/O board.
The optical crowbar circuit control connectors:
• T: Crowbar TX
• R: Crowbar RX
• O: Crowbar fire out
• FIRE: External crowbar fire in
• GOOD: Main circuit breaker enable out

N O T I C E
To avoid unintentional crowbar firing, protect unused optical connectors with matching covers.

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e30bi563.10
Illustration 39: Control Terminals of the DFE Power module

6.2.3 Power Module Grounding

C A U T I O N
GROUNDING THE HEAT SINK
- In the power modules, do not remove the grounding jumper between the heat sink terminal and the ground terminal.

Ground all the power modules. Also the heat sinks of all power modules must be grounded. Make sure that the grounding jumper is
connected between the heat sink terminal and the ground terminal (see Illustration 40).

1 2 3
e30bg718.11

Illustration 40: AFE/INU Phase Module Grounding Terminals and Jumper

1 Heat sink terminal 3 Grounding terminal

2 Heat sink grounding jumper

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e30bi550.11
1

Illustration 41: DFE Power Module Grounding Terminals and Jumper

1 Heat sink terminal 3 Grounding terminal

2 Heat sink grounding jumper

Use a busbar to connect all the grounding terminals of the phase modules and power modules to the same grounding busbar. See
the example in Illustration 42.
e30bg719.10

Illustration 42: Phase Module Grounding Connection Busbar Example

A Grounding terminals C Grounding busbar

B Grounding connection busbar

6.2.4 DC-Link Connections

The VACON® 3000 power modules and DC capacitors for DFE have three DC terminals: plus (+), minus (-) and neutral (N).
Busbars or cables can be used to make the DC-link connections.
DC-link connections in AFE drives

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• Connect the output DC terminals of the AFE phase modules to the DC-input terminals of the INU phase modules.
• Connect the DC-plus terminals of the phase modules together and the DC-minus terminals of the phase modules together.
• Connect the DC-link neutral points of the phase modules and ground them through the common-mode capacitor (CCM).
• See circuit diagram A in Illustration 43.
DC-link connections in 12-pulse drives
• Connect the output DC terminals of the DFE power module to the plus (+), minus (-), and neutral (N) terminals of the DC capaci-
tor for DFE (CDC).
• Connect the DC terminals of the INU phase modules to the plus (+), minus (-), and neutral (N) terminals of the CDC.
• Ground the DC-link neutral point through the common-mode capacitor (CCM).
• See circuit diagram B in Illustration 43.

A B

e30bg720.11
AFE INU DFE INU
PCU PCU PCU
+ + +
L1 ~ 0 0 ~ U 0 ~ U
- - PCU -
1L1 ~ CDC
PCU PCU PCU
1L2 ~
+ + 1L3 ~ + + + +
L2 ~ 0 0 ~ V 0 0 0 0 ~ V
- - 2L1 ~ - - - -
2L2 ~
PCU PCU 2L3 ~ PCU
+ + +
L3 ~ 0 0 ~ W 0 ~ W
- - -

CCM CCM

PE PE

Illustration 43: DC-Link Connections in VACON® 3000 Drives

A AFE drive

B 12-pulse drive

DC-link connections in VACON® 3000 drives with parallel power circuits

• Connect the plus, minus, and neutral terminals of the parallel DC links.
• See the circuit diagrams in Illustration 44.

A B
e30bg721.11

PE CCM PE CCM
2 x CSH

+ + + + +
o o o o o
- - - - -
1L1
LCV 3 x PCU 3 x PCU 1L2 CDC 3 x PCU
L1 U + U
V 1L3 o V
L2
W 2L1 - W
L3 2 x CSH
2L2
+ + 2L3 + + +
o o DFE o o o
- - - - -

LCV 3 x PCU 3 x PCU CDC 3 x PCU

Illustration 44: DC-Link Connection Examples for VACON® 3000 Drives with Parallel Power Circuits

A AFE drive

B 12-pulse drive

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6.2.5 Brake Chopper Installation

The brake chopper module is an L20 or L30 phase module. Thus, the electrical and control interface is the same as in AFE and INU
phase modules. See 6.2.1 Phase Module L20/L30 Terminals.
• Ground the brake chopper module in the same way as the other power modules. See 6.2.3 Power Module Grounding.
• Make the DC-link connections in the same way as for the INU phase modules. See 6.2.4 DC-Link Connections.
Brake resistor connections
• Connect the brake resistor between the output terminal (~) of the brake chopper unit (+DBCU) and the DC-link neutral point.
The brake resistor is not included in the brake chopper option (+DBCU) delivery. The resistor can be ordered with a separate order
code. e30bg722.10

INU
PCU
+ +
0 0 ~ U
- -
PCU
+
0 ~ V
-
PCU
+
0 ~ W
-

+DBCU
+
0 ~
-
R

CCM

PE

Illustration 45: DC-Link and Brake Resistor Connections of the Brake Chopper Unit

R Brake resistor

6.2.6 Terminal Screw Tightening Torque Specifications

Table 11: Power Module Terminal Screw Tightening Torque Specifications

Terminal Size Tightening Torque

Power terminals M10 24.5 Nm (217 lb-in)

Ground terminals M6 5 Nm (44 lb-in)

6.2.7 LED Display on the Phase Module

D A N G E R
VOLTAGE INDICATION
The voltage indicators on the phase module are not safety approved. Even if the voltage indicators are off, there can be a danger-
ous voltage in the module. A contact with this voltage can lead to death or serious injury.
- Even if the voltage indicators are off, before touching the module:
Short circuit the DC-link terminals and connect them to ground.
Do measurements and make sure that there is no voltage.

In the front of the phase module, there is a four letter LED display and four LED indicators: BBP, BBN, LED1 and LED2. BBP and BBN
show if there is voltage in the DC link plus and minus busbars. The functions of LED1 and LED2 are not set.
The LED indicators BBP and BBN use the power from the DC link to operate. That is, if the 24 V supply to the phase modules stops,
the LEDs show if the DC link is charged. The LEDs are on when the capacitor DC-link half voltages are >500 V. They start to blink as
the voltage drops to <500 V. If the voltages drop to <25 V, the LEDs turn off.

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e30bg617.10
A

BBP BBN LED1 LED2

Illustration 46: LEDs in the front of the phase module

A Four character LED display

B LED indicators

LED Display Operation

The phase module start up sequence starts when the connection between the phase module and control unit is disconnected. Usu-
ally the start up occurs when 24 V DC is supplied to the module. Also, the start up sequence occurs during a software update.
LED display modes during phase module start up:
• 1. Reset mode: The display is empty.
• 2. Phase module software setup: The phase module sets up local software.
• 3. Phase module communication setup: After the software setup, the phase module enables communication to the control unit.
When the phase module receives the first message from the control unit, the PCU moves to the next mode.
• 4. Control unit setup: Set up between the control unit and the phase module. If the setup is a success, the phase module moves
to the next mode.
• 5. Network setup: The last step in the setup. When the phase module receives approval from the control unit, the phase module
moves to the operation mode.
• 6. Operation: In the operation mode, the LED display view changes at an interval of 3 s. The display changes between the belt
information indicator (6A) and the module information indicator (6B).
e30bg618.10

2 4

3 5

6A 6B

Illustration 47: LED Display Modes During Start Up

Belt information: The belt information indicator tells the number of the AFE or INU unit (or belt of three modules) in which the PCU
is installed (see 7.8 Optical Fiber Connections).
The belt information indicator is of type: [ ] [ ] [B] [belt number 1–4].
• The first two digits are empty.
• The last two digits show the belt number (B1–B4).

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Module information: The module information indicator tells the identification number of the PCU, the unit type (AFE/INU), and the
phase of the module.
The module information indicator is of type: [PowerID N_] [PowerID _N] [L = AFE, 'blank' = INU] [1, 2, 3 for AFE; U, V, W for INU].
• The first two digits show the ID of the phase module.
• The last two digits show the phase.
- AFE: L1, L2, or L3.
- INU: _U, _V, or _W.
- BCU: RA, RB, or RC.
The PowerID is a 2-digit identification number for each phase module. The ID can be mapped directly to the HMI fault source indica-
tion.
Belt and module information examples (see 6A/6B in Illustration 47):
• [ ] [ ] [B] [1] <-> [ ] [2] [ ] [U] = phase module ID 2, U phase INU in belt 1
• [ ] [ ] [B] [1] <-> [ ] [4] [ ] [W] = phase module ID 4, W phase INU in belt 1
• [ ] [ ] [B] [3] <-> [1] [0] [ ] [W] = phase module ID 10, W phase INU in belt 3
• [ ] [ ] [B] [1] <-> [ ] [2] [L] [1] = phase module ID 2, L1 phase AFE in belt 1
• [ ] [ ] [B] [1] <-> [ ] [4] [L] [3] = phase module ID 4, L3 phase AFE in belt 1

6.2.8 LED Display on the DFE Power Module

There is a four character LED display on the front of the DFE power module. The display functions in the same principle as the dis-
play on the phase modules, but the shown belt and module information is different. See 6.2.7 LED Display on the Phase Module.
e30bi884.11

Illustration 48: LEDs on the Front of the DFE Power Module

1 Four character LED display

Belt information: The belt information indicator tells the number of the channel on the control unit to which the power module is
connected, in this case C5 (see 7.8 Optical Fiber Connections).
The belt information indicator is of type: [ ] [ ] [C] [5].
• The first two digits are empty.
• The last two digits show the number of the channel.
Module information: The module information indicator tells the identification number of the power module. The number of the
first installed DFE power module is 22, the second is 23, and so on.
The module information indicator is of type: [PowerID N_] [PowerID _N] [ ] [ ].
• The first two digits show the ID of the power module.
• The last two digits are empty.

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6.3 Single-belt Operation

VACON® 3000 drives with parallel power circuits (dual-belt drives) can be configured for single-belt operation. If there is a fault in
one of the phase modules, single-belt operation can be used temporarily to bypass one of the parallel power circuits and run the
drive at lower capacity.
If single-belt operation is required, contact Danfoss.

6.4 Main Circuit Breaker Installation

Install a main circuit breaker for the short-circuit protection of the AC drive. Use, for example, a fast vacuum circuit breaker. When
selecting the size of the mains circuit breaker, refer to the available short circuit power, continuous current, and supply voltage.
The operation time of the circuit breaker must not be longer than 4 cycles (50 Hz: 80 ms, 60 Hz: 67 ms).
The function of the circuit breaker is to give short-circuit protection. For ground fault protection, install a protection relay and resis-
tors.

N O T I C E
CONNECTION TO ARC FLASH PROTECTION
Connect the circuit breaker to the arc flash detection system in the AC drive cabinet.

6.5 Installation of Auxiliary Components

6.5.1 Surge Protection Device Installation

Installation in an AFE Drive with an Input Common-Mode Filter
Install the surge protection device (SPD) in the drive cabinet near the input section. Install the SPD on the supply side of the input
common-mode filter with one metal oxide varistor (MOV) between each phase and ground.
Connect the SPD grounding terminal to ground. The conductor size must be a minimum 16 mm2 (AWG6).

CCM CCM
e30bg759.10

(+PICM)
CSH
LGI LCM
(+PICM) (+PICM) LCV AFE
+
MV~ o
-

+QSPD

Illustration 49: Installation of the SPD option (+QSPD) in an AFE Drive with an Input Common-Mode Filter (+PICM)

Installation in an AFE Drive Supplied by a Dedicated Transformer

C A U T I O N
COMMON-MODE VOLTAGES
An AFE installation which is supplied by a dedicated transformer does not require an input common-mode filter. In this case,
however, there are common-mode voltages between the supply transformer and the AFE drive. These voltages could damage
the SPD.
- Because of common-mode voltages, do not install the SPD between the supply transformer and the AFE drive if there is no
input common-mode filter. Instead, install the SPD on the supply side of the supply transformer.

6.5.2 Potential Transformer Installation

Connect the potential transformer on the supply side of the main circuit breaker (MCB). If there is a dedicated supply transformer,
install the potential transformer on the supply side.
Connect the phases L1, L2, and L3 to terminals A, B, and C on the potential transformer. Connect the terminals X1, X2, and X3 to the
AFE control unit (CNU-AFE). See 7.9 Pre-charge and Supply Voltage Feedback Connections.

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A X1

e30bg761.11
B
X2
C X3

+QPTR CNU-AFE

MCB
L1
L2
MV~
L3

Illustration 50: Potential Transformer (+QPTR) Installation

The potential transformer available as option +QPTR can only be used for nominal primary side voltages up to 4160 V. For higher
supply voltages, a different transformer is required. The transformer secondary voltages must be 120 V.
If the AC drive must fulfill the requirements of IEC 61800-5-1 and the potential transformer is to be installed inside the drive enclo-
sure, then the transformer must fulfill the protective separation requirements for decisive voltage class D. The potential transformer
available as option +QPTR does not fulfill this requirement, and must be installed outside the drive enclosure.
If the drive must fulfill the requirements of UL347A, there are no protective separation requirements.
If the potential transformer is to be installed inside the drive enclosure, install it in the low-voltage section of the cabinet. Make sure
that there is a minimum of 40 mm (1.5 in) between the transformer frame and grounded cabinet parts. See the dimensions of the
potential transformer in 11.1.12 Dimensions, Potential Transformer.

40
e30bg762.10

(1.5)

Illustration 51: Recommended Free Space Around the Potential Transformer in mm (in)

6.5.3 LC Filter Installation

The LC filter contains an AFE side inductor (LCV) and shunt capacitors (CSH).
Install the filter between the supply network and the AFE unit in the medium-voltage section of the cabinet.
Installation of the AFE Side Inductor
Install the AFE side inductor (LCV) before the input to the AFE unit. If the input common-mode filter option (+PICM) is selected,
install the LCV between the common-mode inductor and the AFE unit input.
Connect the thermal switch of the inductor to the auxiliary I/O board.

CCM
e30bg763.11

CCM
(+PICM)
CSH
LGI LCM
(+PICM) (+PICM) LCV AFE
+
MV~ o
-
Aux I/O

Illustration 52: Installation of the AFE Side Inductor (LCV)

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Installation of the Shunt Capacitors

D A N G E R
SHOCK HAZARD FROM CAPACITOR
The capacitor has bleed resistors. The discharge time to < 50 V DC is 5 minutes. A contact with this voltage can lead to death or
serious injury.
- Do not touch the capacitor before it has been discharged. Use a measuring device to make sure that there is no voltage.

C A U T I O N
COMMON-MODE VOLTAGE
Common-mode voltages can damage the shunt capacitors.
- If there is no input common-mode filter installed, do not connect the shunt capacitors to ground.

Install the shunt capacitors (CSH) between the phases L1, L2, and L3. If the input common-mode filter option (+PICM) is selected,
ground the CSH through the common-mode capacitor (CCM). If there is no input common-mode filter, do not connect the CSH to
ground.
Connect the shunt capacitors to the phases L1, L2, and L3 on the supply network side of the LCV. If the input common-mode filter
option (+PICM) is selected, connect the CSH between the grid side AFE inductor (LGI) and common-mode inductor (LCM).
If 2 shunt capacitors are necessary, connect them in parallel. See the circuit diagram examples in Illustration 53.
If it is necessary to route the cables to the CSH through a cabinet wall, put the 3-phase cables and the wye connector through the
same cable inlet.

e30bg764.10
A B
CCM CCM CCM
CCM (+PICM)
(+PICM)
C
CSH C 2 x CSH

+ +
MV~ o MV~ o
- -
LGI LCM LCV AFE LGI LCM LCV AFE
(+PICM) (+PICM) (+PICM) (+PICM)

Illustration 53: Installation of the Shunt Capacitors

A LC Filter with 1xCSH C CSH ground connection

B LC Filter with 2xCSH

6.5.4 Input Common-mode Filter Installation

The input common-mode (CM) filter includes a grid side AFE inductor (LGI), a common-mode inductor (LCM), and a common-mode
capacitor (CCM).
Install the CM filter between the supply network and the AFE unit in the medium-voltage section of the cabinet.
Installation of the Grid Side AFE Inductor and Common-mode Inductor
Install the grid side AFE inductor (LGI) and the common-mode inductor (LCM) in series, with the LGI on the supply network side.
Install the inductors on the supply side of the AFE side inductor (LCV). The shunt capacitor connection must be between the LGI and
LCM.
Connect the thermal switches of the inductors to the auxiliary I/O board.

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CCM CCM

e30bg765.11
(+PICM)
CSH
LGI LCM
(+PICM) (+PICM) LCV AFE
+
MV~ o
-
Aux I/O Aux I/O

Illustration 54: Input Common-mode Filter (+PICM) Installation in a VACON® 3000 AFE Drive

Installation of the Common-mode Capacitor

Install the common-mode capacitor (CCM) of the input common-mode filter between the shunt capacitors (CSH), the common-
mode capacitor (CCM), and the ground. For more information, see 6.5.7 Common-Mode Capacitor Installation.

6.5.5 DC Capacitors for DFE Installation

Install the DC capacitors (CDC) between the DFE power module and the INU phase modules.
• Connect the DC+ connectors to terminals 1 and 2.
• Connect the neutral point to terminals 3 and 4.
• Connect the DC- connectors to terminals 5 and 6
In drives with parallel inverter units, install the DC capacitors in parallel.
See the circuit diagram examples in Illustration 55.
Connect the overpressure switch of the capacitor to the auxiliary I/O board.
The DC capacitors can be installed in the mounting racks, which are available as an option (+PMRK).

CDC INU

e30bg766.11
+ +
o o
DFE DFE - -
1L1 CDC INU 1L1
1L2 + + 1L2
1L3 o o 1L3
Motor Motor
2L1 - - 2L1
2L2 2L2 CDC INU
2L3 2L3 + +
o o
- -

A B
Illustration 55: DC Capacitor (CDC) Installation in a 12-Pulse Drive

A 12-Pulse drive with one INU

B 12-Pulse drive with two parallel inverter units

6.5.6 Grounding Switch Installation

Installing the grounding switch (GSW) is recommended. The grounding switch is available as option +QGSW. If a grounding switch
is not installed, make sure that the grounding is done correctly.
Always install the grounding switch in the medium-voltage section of the cabinet. See the dimensions of the grounding switch in
11.1.14 Dimensions, Grounding Switch.
Installation in AFE Drives
The grounding switch connects the three input phases and the DC-link plus and minus to ground. In drives with parallel power
circuits, both DC-link circuits are connected to the GSW.
Connect the auxiliary switches of the GSW to the auxiliary I/O board.

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+QGSW

e30bg767.11
Aux I/O

CCM CCM
(+PICM) CSH

LGI LCM LCV AFE INU

(+PICM) (+PICM)
+ +
0 0 Motor
MV~
- -

Illustration 56: Grounding Switch Installation in an AFE Drive

Installation in 12-Pulse Drives

The grounding switch connects the DC-link plus and minus to ground. The grounding switch does not ground the input phases. In
drives with parallel power circuits, both DC-link circuits are connected to the GSW.
Connect the auxiliary switches of the GSW to the auxiliary I/O board.

+QGSW

e30bg768.11
Aux I/O

CCM
DFE
INU
CDC
MV~ + + +
0 0 0 Motor
- - -
MV~

Illustration 57: Grounding Switch Installation in a 12-Pulse Drive

6.5.6.1 Operating the Grounding Switch

D A N G E R
SHOCK HAZARD FROM THE DC LINK
A contact with the DC-link voltage can lead to death or serious injury.
- After the AC drive is disconnected from the mains, wait for the DC link to discharge.
Use a measuring device to make sure that there is no voltage.

1. Turn off the AFE and INU and disconnect the AC drive from the mains (DC link begins to discharge).
2. Lock out/tag out the MV power source.
3. Wait for the DC link to discharge below 50 V DC.

The discharge time is:

- <7 minutes for AFE drives.
- <21 minutes for 12-pulse drives.
If more DC capacitance than normal is installed, the discharge time can be longer.

4. Measure and make sure that the DC link is discharged before unlocking the grounding switch.
5. Unlock the grounding switch.

There is a safety solenoid on the grounding switch. The solenoid makes sure that the switch does not close while the DC
link is energized or if the mains power is on.

6. Close the grounding switch.

7. Open the power module cabinet.

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8. Make sure that the DC-link voltage indication lights on the front of the phase modules are not on.

See 6.2.7 LED Display on the Phase Module.

9. Make sure that all the blades of the grounding switch are correctly closed.

6.5.7 Common-Mode Capacitor Installation

D A N G E R
SHOCK HAZARD FROM CAPACITOR
The capacitor has bleed resistors. The discharge time to < 50 V DC is 5 minutes. A contact with this voltage can lead to death or
serious injury.
- Do not touch the capacitor before it has been discharged. Use a measuring device to make sure that there is no voltage.

N O T I C E
OPERATION WITHOUT A COMMON-MODE CAPACITOR
If operation without a common-mode capacitor is necessary, consult Danfoss.

Install the common-mode capacitor (CCM) between the DC-link neutral point and ground. Install this capacitor in all VACON® 3000
drives.
The input common-mode filter option (+PICM) includes a second common-mode capacitor. Install the common-mode capacitor of
the CM filter between the shunt capacitors (CSH), the first common-mode capacitor (CCM), and the ground.

e30bg769.10
CCM
(+PICM) CCM
CSH

+ +

MV~ o o Motor
- -

LGI LCM LCV AFE INU

(+PICM) (+PICM)

Illustration 58: Common-Mode Capacitors (CCM) Installed in a VACON® 3000 AFE Drive

6.5.8 Pre-Charge Unit Installation

6.5.8.1 Safety Notes for the Precharge Unit

D A N G E R
SHOCK HAZARD FROM THE PRECHARGE UNIT
The precharge unit can supply dangerous high voltages from its low-voltage source (215 V to 480 V AC). A contact with this volt-
age can lead to death or serious injury.
- Do not try to energize the precharge unit before the system installation is completed!
Do not bypass the control unit and energize the precharge unit!
Make sure that correct lock out and tag out procedures are applied to the low-voltage input of the precharge unit.

C A U T I O N
RISK OF OVERHEATING
Successive precharge operations can overheat the transformer of the precharge unit.
- To allow the transformer enough time to cool down, ensure a minimum of 30 minutes between successive precharge opera-
tions.

The correct selection of the voltage selection board prevents the application of incorrect voltage to the transformer input.

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If there is a fault condition, the 2-pole circuit breaker on top of the precharge unit opens. The breaker opens only in fault conditions
in which inspection or maintenance is necessary.
The control unit monitors the DC-link voltage during the precharge sequence and if it senses an unusual condition, stops the se-
quence. Because of the monitoring, do not bypass these protection steps during the commissioning or troubleshooting of the drive.
Precharge timeout:
• The control unit automatically limits the frequency of start ups to a safe value.

6.5.8.2 Pre-Charge Unit Installation

The pre-charge unit (PRC) is a medium-voltage device. Install it in the medium-voltage section of the cabinet (never in the low-
voltage section). Installing the pre-charge unit in the same section as the input filters is recommended. See the dimensions of the
precharge unit in 11.1.7 Dimensions, Pre-Charge Unit.
• Connect the low voltage input to the pre-charge unit terminals 1 and 3. L goes to terminal 3, and N to terminal 1.
• In AC Drives with parallel power circuits, a separate pre-charge unit is necessary for each parallel circuit. The low-voltage supply
to the pre-charge units must be able to supply a power of 10 kVA for each pre-charge unit.
- If there are multiple pre-charge units, make sure that all units are wired correctly and working. Pre-charging with fewer units
than required can overheat the pre-charge units.
• Ground the cable shield of the LV supply cable.
• Connect the pre-charge control signals to the auxiliary I/O board and to the control unit. In AFE drives the AFE control unit
controls the pre-charge and in 12-pulse drives the control comes from the INU control unit.
• The pre-charge unit has 3 medium-voltage terminals for the DC-link connection: DC(+), DC(0), and DC(-). Connect these termi-
nals to the DC link.
• Install a circuit breaker at the low-voltage input to the PRC. The circuit breaker type/rating must be higher than the rating of the
PRC circuit breaker. Install the circuit breaker in the low-voltage section of the cabinet.
TB2-4
TB2-3
TB2-2
TB2-1
TB1-4
TB1-3
TB1-2
TB1-1

3 1

DC(+) e30bh373.10

DC(0)

DC(-)

Illustration 59: Locations of the Pre-Charge Unit Terminals

6.5.9 Isolation Transformer Installation

Install the isolation transformer in the medium-voltage section together with the 24 V auxiliary supply for the phase modules. Do
not install the transformer in the same cabinet with the control unit.
If the system is to be certified according to standard IEC61800-5-1:
• Install isolation transformers for the INU and AFE low-voltage supplies.
• The isolation transformers must provide protective separation for Decisive Voltage Class D (DVC D) according to IEC61800-5-1
for the respective system voltage.
• The transformers must have a coupling capacitance between primary and secondary of maximum 120 pF.
If the system is to be certified according to standard UL347A:
• Isolation transformers for the INU and AFE low-voltage supplies are not required.

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If the Safe torque off (STO) function is required from the drive, see the additional requirements for the isolation transformers in 6.6.6
Installation Guidelines.

6.5.10 Auxiliary Power Supply Installation

Auxiliary 24 V DC power supplies are required for:
• The power electronics.
• The AFE phase modules.
• The DFE power module.
• The INU phase modules.
• The brake chopper unit.
• The control units.
• The auxiliary I/O boards.
Install the power supplies for the control units in the low-voltage section of the cabinet.
Install the power supplies for the phase modules in the medium-voltage section of the cabinet. Supply these power supplies
through an isolation transformer (+QAIT).
Installation Guidelines for the MV Section
• Connect the neutral of the 24 V DC supply to the neutral point of the DC link.
• Connect the neutral of the DC output and the neutral of the AC input of the power supplies.
• Connect the PE and frame of the power supplies to the neutral connector.
• Since the power supplies are tied to the DC neutral, isolate them from other live parts and from ground.
The creepage and clearance distances between the DC-neutral connection, ground (basic insulation), and other parts of the LV cir-
cuit (DVC A, B, or C) must be according to standards IEC61800-5-1 and UL347A.
If the system is to be certified according to standard IEC61800-5-1:
• Install isolation transformers for the INU and AFE low-voltage supplies.
• The isolation transformers and the potential transformer must fulfill the protective separation requirements of IEC61800-5-1.
• Connect the neutral of the 24 V DC supplies for INU and AFE modules to the neutral point of the DC link.
If the system is to be certified according to standard UL347A:
• Isolation transformers for the INU and AFE low-voltage supplies are not required.
• Connect the minus of the 24 V DC supply to ground.
• The neutral of the 24 V DC supply for the AFE and INU modules can be connected to ground.
If a solution with floating 24 V supplies is used, then 24 V monitoring of the floating 24 V supplies is not possible. Thus, redundant
power supplies are not recommended in such a solution.
If the Safe torque off (STO) function is required from the drive, see the additional requirements for the power supplies in 6.6.6 Instal-
lation Guidelines.
Example
Auxiliary Power Supplies for VACON3000-4Q-0425-03
The VACON3000-4Q-0425-03 is an AFE drive. It includes three AFE and three INU phase modules. A 24 V DC, 3 A power supply is
necessary for each phase module. To energize the phase modules, a 24 V DC, 20 A power supply can be used, but it is recommen-
ded to install two power supplies in parallel and supply the phase modules through a diode redundancy module. Thus, if there is a
failure in one of the two power supplies, the power supply continues.
An AFE drive also includes two control units for the AFE and INU phase modules. A 24 V DC, 3 A power supply is necessary for each
control unit. To energize the control units, a 24 V DC, 10 A power supply can be used, but it is recommended to install two power
supplies in parallel and supply the control units through a diode redundancy module. Thus, if there is a failure in one of the two
power supplies, the power supply continues.

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APS +QAIT

e30bg771.11
APS

Illustration 60: Installation Example of Auxiliary Power Supplies (APS) in the Medium-Voltage Section of the Cabinet

6.5.11 Cabinet Heater Installation

It is recommended to install cabinet heaters in these sections of the cabinet assembly:
• The power module section.
• The LC filter and input common-mode filter section.
• The control compartment.
Install thermostats in the cabinets to start and stop the cabinet heaters. Supply the cabinet heaters through the isolation transform-
ers (+QAIT).

6.5.12 Overtemperature Indicator Installation

Install overtemperature indicators in the top part of the cabinets. Setting the indicators to 70°C (158°F) is recommended.

6.5.13 Leak Detector Installation

Install leak detectors in all the cabinets with liquid-cooled components and in the cabinet with the heat exchanger.

6.5.14 Arc Flash Detector Installation

Arc flash detectors sense the light from an arc flash and send a trip signal to the drive control unit.
Install arc flash detectors in all the medium-voltage sections of the cabinet. Use for example, PGR-8800 from Littelfuse. Only use
optical fibers to make the connections between the LV and MV sections of the cabinet.

N O T I C E
CONNECTION TO THE MAINS CIRCUIT BREAKER
It is recommended to connect the arc flash detection system to the mains circuit breaker.

6.6 Safety Functions

6.6.1 Safe Torque Off (STO)

Safe Torque Off (STO) is a hardware-based safety function to prevent the drive from generating torque on the motor shaft. The STO
safety function has been designed for use in accordance with the following standards:
• EN 61800-5-2 STO SIL3
• ENISO 13849-1 PL “e” Category 4
• EN 62061 SILCL3
• IEC 61508 SIL3
• The function also corresponds to an uncontrolled stop in accordance with stop category 0, EN 60204-1.
The STO function is not the same as the prevention of unexpected start-up function. For fulfilling those requirements, more external
components are required according to appropriate standards and application requirements. Required external components can be
for example:
• Appropriate lockable switch
• A safety relay providing a reset function

6.6.2 Safe Stop 1 (SS1)

The SS1 safety function is realized in compliance with SS1-t of the drives safety standard EN 61800-5-2 (SS1-t: "The PDS(SR) initiates
the motor deceleration and performs the STO function after an application-specific time delay").
The SS1 safety function has been designed for use in accordance with the following standards:

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• EN 61800-5-2 Safe Stop 1 (SS1) SIL 3

• EN ISO 13849-1 PL"e" Category 4
• EN 62061: SILCL3
• IEC 61508 SIL 3
• The function also corresponds to a controlled stop in accordance with the stop category 1, EN 60204-1.

6.6.3 Safety Considerations

Designing of safety-related systems requires special knowledge and skills. Only qualified personnel are permitted to install and set
up the STO functionality.
The use of STO or other safety functions does not in itself ensure safety. An overall risk evaluation is required to make sure that the
commissioned system is safe. The safety devices must be correctly incorporated into the entire system. The entire system must be
designed in compliance with all relevant standards within the field of industry.
Standards such as EN 12100 (Part 1/Part 2) and ISO 14121-1 provide methods for designing safe machinery and for carrying out a
risk assessment.
The information in this manual provides guidance on the use of the STO safety function together with the VACON® 3000 Drive Kit.
This information is in compliance with accepted practice and regulations at the time of writing. However, the end product/system
designer is responsible for ensuring that the system is safe and in compliance with relevant regulations.
The STO function does not electrically isolate the drive output from the mains supply. If electrical work is to be carried out on the
drive, the motor or the motor cabling, the drive has to be isolated from the mains supply. Use, for example, an external medium-
voltage disconnecting switch (optionally as part of the main circuit breaker, see 6.4 Main Circuit Breaker Installation). In addition, the
grounding switch must be closed or an alternative grounding according to applicable standards must be provided (see 6.5.6.1 Op-
erating the Grounding Switch).

6.6.3.1 Diagnostic Test

Performing a diagnostic test is mandatory. The achievable SIL performance level/category for STO/SS1 depends on the testing inter-
val.

Table 12: SIL Performance Level/Category Based on Diagnostic Test Interval

Test/ diagnostic interval(1) EN 61800-5-2 ENISO 13849-1 EN 62061

1 day SIL3 PL “e” Category 4 SILCL3

3 months SIL3 PL “e” Category 3 SILCL3

1 year SIL2 PL “d” Category 3 SILCL2

1 Time between tests.

To perform the test, follow this procedure.
• Start with a powered-on system. Connection to the MV grid is not required.
• Press S1 (STO/SS1 button).
- See the diagrams in 6.6.9 Safety Relay Wiring.
• Wait until the STO diagnostic lamp is continuously on.
• Reset S1.
• If available, push reset button S2.
• The STO diagnostic lamp should go off, and the drive should be operational again after less than 1 minute.
Note: A diagnostic test is also automatically executed as part of any regular STO/SS1 cycle.

6.6.4 STO Operating Principle

The STO safety function allows the drive output to be disabled so that the drive cannot generate torque in the motor shaft.
The STO safety function is achieved by stopping the drive operation. The drive operation is stopped by removing the 24 V supply to
the inverter units. When the 24 V supply is removed, the drive stops operation and does not generate torque in the motor shaft.
To stop the 24 V supply to the power modules, use a safety relay and a sensor. See 6.6.6 Installation Guidelines.
The activation time of the STO function depends on the holdup time of the 24 V supply. There is internal capacitance in the power
supply, which causes a delay in cutting the supply to the power modules. Thus, the maximum STO delay time can only be specified

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for specific power supplies. When using the recommended 24 V power supplies, the maximum STO delay is below 1 s. For a sugges-
ted method for determining the delay time with a specific power supply, see 6.6.8 Determining the Power Supply Specific STO De-
lay Time.

6.6.5 SS1 Operating Principle

After receiving a safe stop command, the motor starts decelerating and the SS1 safety function initiates the STO function after a
user-set time delay.

Frequency SS1 Motor

e30bi927.10
request deceleration
factual

Safe Torque Off (STO)

Time delay
0 Time
Illustration 61: The Principle of Safe Stop 1 (EN 61800-5-2, SS1-t)

The system designer/user is responsible for understanding and setting the time delay of the safety relay, as it is process/machine
dependent.
• The time delay of the relay must be set to a greater value than the deceleration time of the drive. If there is a single failure or
malfunctioning of the drive system, the drive may not ramp down as requested, but is always put to a safe STO state after the
configured time delay of the relay. The motor deceleration time is process/machine dependent.
• The stop function of the drive must be correctly set for the process/machine. Activating the SS1 safety function must execute
the configured stop in the drive, using the undelayed relay output signal "SS1 NOT ACTIVATED". In the application software, it is
recommended to use the "Quick Stop" functionality for this purpose.

6.6.6 Installation Guidelines

The STO functionality is implemented with a relay and a sensor to stop the 24 V DC supply to the inverter units. Install these parts in
the low-voltage section of the drive enclosure. The STO/SS1 components must be installed in an IP54 enclosure.
The input voltage for the safety relay must be 24 V ±5%.
The undelayed output of the relay (STO not activated) is connected to the digital input (DI) of the INU control unit. See 6.6.9 Safety
Relay Wiring.
In the STO safety relay, set the delay time to 100 ms. The delay ensures, that there is sufficient time to notify the control unit before
the 24 V at the INU modules are stopped. This allows the control unit to suppress the faults that a 24 V loss of the power modules
normally generates.
For SS1, set the time delay to 0.5–30 s. This is normally the next higher relay time setting after the deceleration is guaranteed to be
complete. Manual or automatic reset of the safety relay can be selected with a wiring option (see 6.6.9 Safety Relay Wiring). After the
reset of the safety relay, the control unit needs >30 s for a drive reset before the drive can be started again.
STO/SS1 diagnostic output is available from the digital output of the INU control unit.
• 1 Hz flashing immediately after STO/SS1 activation.
• Continuous once INU is confirmed to be powered off.
• Caution: The diagnostic output is not a safety function. Do not rely on it to ensure an STO state.
The motor contactors must be rated according to the isolation transformer inrush current.
General Wiring Instructions
The maximum allowed cable length between the STO safety relay inputs (S11/S12 and S21/S22) and the STO/SS1 push button (S1) is
500 m (1640 ft). If cables with a conductor cross-sectional area smaller than 1.5 mm2 (16 AWG) are used, reduce the cable length to
account for increased voltage drop in the cables.
Illustration 62 and Illustration 63 show example wiring diagrams of the STO installation for VACON® 3000 AFE and 12-pulse drives.
The wiring of the STO safety relay and contactors is shown in more detail in 6.6.9 Safety Relay Wiring.

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AFE (3×PCU) INU (3×PCU)

e30bg979.11
DC+

4160/
3 3 DCN 3 M
DC- 3~
3300 V CNU-INU
STO/SS1
MCB FLC Diagnostics
DO

DI

CNU-AFE
3

PTR

STO/SS1
Reset
+24V APS AIT
+ L 2 2
- N
240/
120 V
PE STO safety
relay +
contactors
APS AIT
+24V + L 2
- N

PE

Medium-voltage section Low-voltage section

Illustration 62: Example STO Installation Wiring Diagram for a VACON® 3000 AFE Drive

DFE (PCU) INU (3×PCU)

e30bi479.10
DC+
2 x 1850/ 3 DCN 3 M
2 x 2360 V DC- 3~
CNU-INU

DO
STO/SS1
DI Diagnostics

STO/SS1
Reset
+24V APS AIT
+ L 2 2
- N 240/
120 V
PE STO safety
relay +
contactors
APS AIT
+24V + L 2
- N

PE

Medium-voltage section Low-voltage section

Illustration 63: Example STO Installation Wiring Diagram for a VACON® 3000 12-pulse Drive

6.6.7 Recommended Components

The following components are recommended for implementing the STO/SS1 function in VACON® 3000 Drive Kit configurations.
STO Safety relay (manufacturer Phoenix Contact):
• PSR-SCP-24DC/ESD/4X1/30, type code 2981800 (screw connection terminal blocks)
• PSR-SPP-24DC/ESD/4X1/30, type code 2981813 (spring-cage connection terminal blocks)
The relays can be used for both STO and SS1 with SIL 3.

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Isolation transformer (manufacturer Stangenes):

• 120-240/120-240 V AC, 500 VA, type code SIT30-500
24 V DC power supply (manufacturer Phoenix Contact):
• For 3 INU modules: QUINT-PS/1AC/ 24DC/10, type code 2866763
• For 6 INU modules: QUINT-PS/1AC/ 24DC/20, type code 2866776
Motor contactors (manufacturer Schneider Electric):
• 4 kW, 9 A, 24 V DC coil, type code LC1D09BD
STO/SS1 push button and contacts (manufacturer Schneider Electric):
• Emergency switching off push button XB4, type code ZB4BS844
• Single contact block XB4/XB5, 1 NC, type code ZBE102
There are no special requirements for the STO reset switch. See S2 in 6.6.9 Safety Relay Wiring.

C A U T I O N
OPERATING CONDITIONS
Incorrect ambient operating conditions can cause the components to malfunction.
- Mount the components in such a way that the requirements for the ambient operating conditions are fulfilled. Specifically,
the safety relay PSR-XXX-24DC/ESD/4X1/30 has an operating temperature range of -20...+45 °C (-4...+113 °F).

Other condition requirements:

• Storage temperature: -40...+70 °C (-40...+158 °F)
• Electromagnetic environment: IEC 61800-5-2:2016 Annex E

6.6.8 Determining the Power Supply Specific STO Delay Time

The following procedure can be used to determine the maximum STO delay time with a specific 24 V power supply.
• If the LV supply for the 24 V power supply can have variable voltage levels, execute the test (also) at the highest input voltage
level. The highest input voltage level is expected to yield the longest hold-up times.
• If a short STO delay time is needed, consider using only a single (non-redundant) power supply. In this case, also keep the power
rating of the supply close to the minimum requirement.
• In applications where the maximum STO delay is critical, consider sufficient margin to account for variances including specifical-
ly of the 24 V power supply.

Procedure
1. Measure the voltage of K5 or K6 and the 24 V output current of the 24 V power supply with an oscilloscope.

See 6.6.9 Safety Relay Wiring.

2. Power up the control compartment only.

The MV supply remains off and grounded.

3.
Reset the safety relay when the manual restart is configured.
4.
Validate that 24 V is applied across K5 and K6, and current is flowing out of the 24 V power supply.
5.
Trigger the oscilloscope on a negative edge on the channel showing K5/K6 voltage.
6.
Push the STO button (S1).
7.
Measure the time 'td24V' from the beginning of the voltage drop across K5/K6 to the time when the output current of the
24 V power supply drops to 0 A for the first time. Further high frequency oscillations can be ignored.
The maximum STO delay time is 'td24V' + 0.34 s.
The 0.34 s accounts for the maximum delay of the safety relay at the 100 ms setting (100 ms +40%) and the maximum shutdown
delay within the INU Power Modules (200 ms). The delay of the contactors K5/K6 is already included in the time 'td24V' based on the
described procedure.

6.6.8.1 Response Time and Fault Reaction Time

STO safety function:

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• The response time is no more than 1 s.

• The fault reaction time is no more than the response time.
SS1 safety function:
• The response time can be selected, but is no more than 30 s with ±40% tolerance.
• The fault reaction time is no more than the response time.
To ensure the correct response time and fault reaction time, follow the procedure in 6.6.3.1 Diagnostic Test.

6.6.9 Safety Relay Wiring

24 V L N

e30bg980.11
STO

S1

A1 S11 S12 S21 S22 <0.1 13 23 37 47 K5

(Clock) ( ) (Clock) ( ) 0.5
1
CNU-INU
PSR-ESD-30 3
5
( ) ( ) 10
20
A2 S34 S35 30 14 24 38 48 DI DO K6

S2
Reset STO NOT
ACTIVATED AIT
STO
K5 K5 Diagnostics
APS
K6 K6

0V 24 V to INU

Illustration 64: Safety Relay Wiring Diagram for STO with Manual Reset

24 V L N
e30bi928.10

STO

S1

A1 S11 S12 S21 S22 <0.1 13 23 37 47 K5

(Clock) ( ) (Clock) ( ) 0.5
1
CNU-INU
PSR-ESD-30 3
5
( ) ( ) 10
20
A2 S34 S35 30 14 24 38 48 DI DO K6

STO NOT
ACTIVATED AIT
STO
K5 K5 Diagnostics
APS
K6 K6

0V 24 V to INU

Illustration 65: Safety Relay Wiring Diagram for STO with Automatic Reset

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24 V L N

e30bi929.10
SS1

S1

A1 S11 S12 S21 S22 <0.1 13 23 37 47 K5

(Clock) ( ) (Clock) ( ) 0.5
1
CNU-INU
PSR-ESD-30 3
5
( ) ( ) 10
20
A2 S34 S35 30 14 24 38 48 DI DO K6

S2
STO NOT
Reset ACTIVATED AIT
SS1 NOT
ACTIVATED STO
K5 K5 Diagnostics
APS
K6 K6

0V 24 V to INU

Illustration 66: Safety Relay Wiring Diagram for SS1 with Manual Reset

24 V L N

e30bi930.10
SS1

S1

A1 S11 S12 S21 S22 <0.1 13 23 37 47 K5

(Clock) ( ) (Clock) ( ) 0.5
1
CNU-INU
PSR-ESD-30 3
5
( ) ( ) 10
20
A2 S34 S35 30 14 24 38 48 DI DO K6

STO NOT
ACTIVATED AIT
SS1 NOT
ACTIVATED STO
K5 K5 Diagnostics
APS
K6 K6

0V 24 V to INU

Illustration 67: Safety Relay Wiring Diagram for SS1 with Automatic Reset

6.6.10 Safety-related Data

The values in Table 13 are used as the basis for the safety-related data calculation.
Table 13: Calculation Basis for the Safety-Related Data

Quantities Values

Mean operation, dop 365.25 days/year

Mean operation, hop 24 h/day

Mean operation time between successive cycles, tCycle 3600 s

Mission time 20 years

The safety-related data for STO/SS1 in VACON® 3000 drives, based on the values in Table 13, and the components listed in 6.6.7
Recommended Components, is given in Table 14.

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Table 14: Safety-Related Data for STO/SS1

Standards Safety parameters Values

IEC 61800-5-2:2016 SIL 3

PFH 1.9×10-8 1/h

HFT 1

EN 62061/A2:2015 SILCL 3

PFH 1.9×10-8

HFT 1

EN ISO 13849-1:2015 PL E

MTTFd 107 years

DCavg High

Category 4

IEC 61508:2010 SIL 3

PFH 1.9×10-8 1/h

HFT 1

PFD 1.9×10-4
(low demand mode, SIL 3)

6.7 Mechanical Interlocking System

The interlocking system ensures that the lock-out/tag-out process is followed and cannot be bypassed. UL- and CSA-certified VA-
CON® 3000 Drive Kit (option +GAUL) are equipped with a mechanical interlocking system (Type F Isolation Interlock from Kirk Key
Interlock Company LLC) by default. For other drives the mechanical interlocking system is available as an option (+QGSK).
The Kirk Key Interlock is mounted inside the cabinet as part of the grounding switch assembly. The locking bolt locks the grounding
switch in the open position (not grounded) and the key can be removed at this position. When a matching safety-locking system is
used with the upstream circuit breaker feeding the drive, the lock-out/tag-out method with trapped key interlock (TKI) can be im-
plemented.
e30bk275.10

Illustration 68: Mechanical Interlock

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1 Pad-lockable latches 3 Handle of grounding switch

2 Clear cover 4 Lock and locking bolt

Instructions for installing the safety-locking system for the upstream circuit breaker are available from the manufacturer of the cir-
cuit breaker.
The coded key number used in the safety-locking system of the drive is included in the product delivery. Alternatively, if the cus-
tomer already has a safety-locking system in place, the existing key number can be used at the ordering phase.

N O T I C E
Danfoss strongly promotes the full use of the benefits offered by this advanced lock-out/tag-out method. It is the responsibility of
the customer to make sure that the VACON® 3000 Drive Kit is installed according to the instructions from the manufacturer and
local safety regulations. Using safe working methods, such as following lockout/tagout and TKI procedures, are the responsibili-
ties of the user/operator.

6.7.1 Operating the Interlocking System

This procedure describes how to perform a lock-out/tag-out procedure correctly with the trapped key interlock (TKI) system.
When the process and the drive are running, the upstream breaker is closed, and the key is trapped at the breaker.

Procedure
1. Start the lock-out/tag-out procedure and shut down the process.
2. Stop the drive and wait until it is safe to ground the drive.
3. Once it is safe to open the upstream breaker, open, rack out, and ground the breaker.
4. Remove the key from the upstream breaker, so that the breaker cannot be operated.
5. Check that there is no voltage in the supply cables of the drive.
6. Unlock the grounding switch of the drive with the key.

 The key is trapped at the drive.

7. Turn the grounding switch to ground the drive.
8. To create electrically safe working conditions, finish the lock-out/tag-out procedure.
To restart the drive and the process, follow the procedure in reverse order.

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7 Control Connections
7.1 Control Unit Components

e30bg735.10
I

H
K
L

A
R

J
T

Q F
U
E
B
C
P

D
O
U

U T

N U T M
Illustration 69: The Components of the Control Unit

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A The control terminals for the default I/O connections L The battery for the real-time clock

B The Ethernet connection M Control unit power supply terminal

C The relay terminals for 3 relay outputs or 2 relay out- N Encoder terminals (only used in INU control units)
puts and a thermistor
O Digital inputs and outputs for pre-charge
D The option boards
P Optical fiber inputs for external breaker enable
E DIP switch for the RS485 bus termination
Q Supply voltage feedback
F DIP switch for the signal selection of analog output
R Optical fiber interface to phase modules
G DIP switch for the isolation of the digital inputs from
ground S Encoder configuration jumpers

H DIP switch for the signal selection of analog input 2 T Cable clamps

I DIP switch for the signal selection of analog input 1 U Ground points

J The status indicator of the Ethernet connection

K Cooling fan

On delivery of the AC drive, the control unit contains the default control interface (control panel with graphical display). If special
options were selected in the order, the option boards are included loose in the delivery. On the next pages, there is information on
the terminals and general wiring examples.
The control unit can be started with a 24 V DC ±5%, 3 A power source with external overload protection. This voltage is sufficient to
keep the control unit on and for setting the parameters. The measurements of the main circuit (for example, the DC-link voltage,
and the unit temperature) are not available when the drive is not connected to the mains.
The status indicator on the control unit shows the status of the drive. The status indicator is on the control panel, below the keypad,
and it can show five different statuses.

Table 15: Control Unit LED Status Definitions

Color/status of the LED Status of the drive

Blinking slowly Ready

Green Run

Red Fault

Orange Alarm

Blinking fast Downloading software

7.2 Control Unit Installation

Install the VACON® 3000 control units in the low-voltage section of the cabinets. Use the four mounting holes on the control unit
frame. See the dimensions of the control unit in 11.1.4 Dimensions, Control Unit.

7.3 Control Interface

When the drive is connected to the mains, it must be possible to monitor the drive, reset faults, and set parameters to the drive
without opening the cabinet. The drive can be controlled with a control panel or a PC connected to the control unit. The control
panel can be installed on the cabinet door or outside the cabinets. A door keypad mounting kit is available as option +HMDR.
VACON® 3000 AFE drives have two control units, for the AFE and the INU. AC drives with the brake chopper option (+DBCU) also
have a control unit for the brake chopper. It must be clear, which of the control units controls the AFE, INU and brake chopper.
Identify the control units clearly.
More information about the control interface functionality is available in the VACON® 3000 Application Guides.

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7.4 Control Unit Cabling

Install the control cables in the low-voltage section of the cabinet. Keep the cables away from high voltages and possible electrical
arcs. Make the control connections between the control units and power units with optical fiber cables.
There are cable entries at the top and bottom of the cabinet.
A VACON® 3000 12-pulse drive has one control unit, the INU control unit. Install all the I/O and relay cables to the INU control unit.
A VACON® 3000 AFE drive has two control units, the AFE control unit and the INU control unit. The I/O and relay cable installation is
application-specific and both the AFE and INU control units can be used.

7.4.1 Selection of the Control Cables

N O T I C E
CABLE SELECTION
Obey regional low-voltage standards in the cable selection.

The control cables must be a minimum of 0.5 mm2 (AWG20) multi-core shielded cables. The terminal wires must be a maximum of
2.5 mm2 (AWG13) for the relay board terminals and other terminals.

Table 16: The Tightening Torques of the Control Cables

Terminal Terminal screw size Tightening torque Tightening torque (lb-

(Nm) in)

All the terminals of the I/O board and the relay board M3 0.5 4.5

7.4.2 Control Unit Terminals

Here is the basic description of the terminals of the default I/O and relay board. The standard I/O board has 22 fixed control termi-
nals and 8 relay board terminals.
Some terminals are assigned for signals that have optional functions that can be used with the DIP switches. For more information,
see 7.5 DIP Switches on the Control Unit.

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Standard I/O board

e30bg736.11
Terminal Signal Description

1 +10Vref Reference output

Reference-
potentio- 2 AI1+ Analog input 1+
meter Frequency reference
1...10 kΩ (default 0...10 V)
3 AI1- Analog input 1-

4 AI2+ Analog input 2+ Frequency reference

(Default 4...20 mA)
5 AI2- Analog input 2-
6 24Vout 24 V auxiliary voltage
7 GND I/O ground
8 DI1 Digital input 1 Start forward
9 DI2 Digital input 2 Start reverse
10 DI3 Digital input 3 External fault
11 CM Common for DI1-DI6
12 24Vout 24 V auxiliary voltage
13 GND I/O ground
DI4 DI5 Freq. ref.
14 DI4 Digital input 4 Open Open Analog input 1
Closed Open Preset Freq. 1
Open Closed Preset Freq. 2
15 DI5 Digital input 5 Closed Closed Preset Freq. 3
16 DI6 Digital input 6 Fault reset
17 CM Common for DI1–DI6

18 AO1+ Analog output 1+ Output

mA frequency
19 AO1- Analog output 1- (0...20 mA)

24 V auxiliary
30 +24Vin
input voltage
A RS485 Serial bus, negative Modbus RTU,
B RS485 Serial bus, positive N2, BACnet
21 RO1/1 NC Relay output 1
RUN
22 RO1/2 CM RUN
23 RO1/3 NO
24 RO2/1 NC Relay output 2
FAULT 25 RO2/2 CM FAULT
26 RO2/3 NO
32 RO3/2 CM Relay output 3
READY
33 RO3/3 NO
Illustration 70: The Signals of the Control Terminals on the Default I/O Board and the Default Control Connections for the VACON® 3000 INU
Application

7.5 DIP Switches on the Control Unit

7.5.1 Selection of Terminal Functions with DIP Switches

Two selections for specified terminals can be done with the DIP switches. The switches have two positions: up and down. See the
location of the DIP switches and the possible selections in Illustration 71.

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e30bg737.10
A B

AI1
U

AI2
U

B AO1
U

RS485
OFF

ON

D E

Illustration 71: The Selections of the DIP Switches

A The voltage signal (U), 0–10 V input D ON

B The current signal (I), 0–20 mA input E The RS485 bus termination

C OFF

Table 17: The Default Positions of the DIP Switches

The DIP switch The default position

AI1 U

AI2 I

AO1 I

RS485 bus termination OFF

7.5.2 Isolation of the Digital Inputs from Ground

It is possible to isolate from ground the digital inputs (terminals 8–10 and 14–16) on the standard I/O board. To do this, change the
position of a DIP switch on the control board.

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e30bg738.10
A
B

Illustration 72: Change the Position of This Switch to Isolate the Digital Inputs from Ground

A The digital inputs C Connected to ground (default)

B Floating

7.6 Fieldbus Connection

7.6.1 Fieldbus Terminals

The drive can be connected to fieldbus with an RS485 or an Ethernet cable.
• If an RS485 cable is used, connect it to terminals A and B of the default I/O board.
• If an Ethernet cable is used, connect it to the Ethernet terminal.
In a VACON® 3000 AFE drive, connect the fieldbus to both the AFE and INU control units.

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e30bg739.10
E

F B

Illustration 73: The Ethernet and RS485 Connections

A RS485 terminal A = Data - D The Ethernet terminal

B RS485 terminal B = Data + E The control terminals

C RS485 DIP switch F Cable clamps

7.6.2 Using Fieldbus through an Ethernet Cable

Table 18: Ethernet Cable Data

Item Description

Plug type Shielded RJ45 plug, maximum length 40 mm (1.57 in)

Cable type CAT5e STP

Cable length Maximum 100 m (328 ft)

Ethernet Cabling
1. Connect the Ethernet cable to its terminal.

See more in the installation guide of the used fieldbus.

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7.6.3 Using Fieldbus through an RS485 Cable

Table 19: RS485 Cable Data

Item Description

Plug type 2.5 mm2 (AWG13)

Cable type STP (shielded twisted pair), Belden 9841 or similar

Cable length So that it agrees with the fieldbus. See the fieldbus manual.

RS485 Cabling
1. Remove approximately 15 mm (0.59 in) of the gray shield of the RS485 cable. Do this for the two fieldbus cables.
- a. Strip the cables for approximately 5 mm (0.20 in) to put them in the terminals. Do not keep more than 10 mm (0.39
in) of the cable outside the terminals.
e30bg841.10
10

- b. Strip the cable at such a distance from the terminal that it can be attached to the frame with the grounding clamp
for the control cable. Strip the cable at a maximum length of 15 mm (0.59 in). Do not remove the aluminum shield
of the cable.
e30bg842.10

mm
15

2. Connect the cable to the default I/O board of the drive, in terminals A and B.

- A = negative
- B = positive
e30bg843.10

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3. Attach the shield of the cable to the frame of the drive with a grounding clamp for the control cable to make a grounding
connection.

e30bg844.10
Illustration 74: Grounding the Cable with a Grounding Clamp

4. If the drive is the last device on the fieldbus line, set the bus termination. Set the bus termination for the first and the last
device of the fieldbus line. It is recommended that the first device on the fieldbus is the master device.
- a. Find the DIP switches on the left side of the control unit of the drive.

e30bg845.10

- b. Set the DIP switch of the RS485 bus termination to the ON position.

The termination resistors are placed at both ends of the fieldbus line to decrease signal reflections on the line.
Biasing is built in the bus termination resistor. The termination resistance is 220 Ω.
e30bg846.10

D
A

C
E B
Illustration 75: Setting the Bus Termination for a Fieldbus Line

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A The termination is activated D The bus termination. The resistance is 220

Ω.
B The termination is deactivated
E The fieldbus
C The termination is activated with a DIP
switch

N O T I C E
LOSS OF TERMINATION RESISTANCE
If the last device on the fieldbus line is powered down, the termination resistance is lost. The loss of termination resist-
ance causes signal reflections on the line, which can disrupt the fieldbus communication.
- Do not power down the last device on the fieldbus line while the fieldbus is active.

7.7 Option Board Installation

W A R N I N G
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.

N O T I C E
INCOMPATIBLE OPTION BOARDS
It is not possible to install option boards that are not compatible with the drive.

If the installed board is an OPTB or an OPTC option board, make sure that the label on it says "dv" (dual voltage). This marking shows
that the option board is compatible with the drive.
e30bg847.10
OPT
dv

A
Illustration 76: Label on the Option Board

A The slot coding

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Installation Procedure
1. To get access to the option slots, open the cover of the control unit.

e30bg848.10

2. Install the option board into the correct slot: C, D, or E.

The option board has a slot coding, because of which it is not possible to install the option board in an incorrect slot.
e30bg849.10

A
B

Illustration 77: Installing the Option Boards

A The slot coding

B The option slots

3. Close the cover of the control unit.

7.8 Optical Fiber Connections

The VACON® 3000 drive has a high-speed Powerbus optical fiber interface for internal connections. The control unit has six optical
fiber connections: four for phase modules, one for the connection between the control units and one for an auxiliary board. The two
terminals used for the control of the INU or AFE phase modules are shown in Illustration 78.

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e30bg740.11
F01 F02 F03 F04 F05 F06
Illustration 78: Optical Fiber Terminals

F01 Terminal for phase module connections (belt 1) F04 Terminal not used

F02 Terminal for phase module connections (belt 2) F05 Terminal for auxiliary I/O board and DFE connec-
tions
F03 Terminal not used
F06 Terminal not used

Connect the phase modules of each AFE or INU in series (see Illustration 79).
• Connect the optical fiber from connector A of the phase module L1/U to connector F01 on the control unit.
• Connect the optical fiber from connector A of the phase module L2/V to connector B on phase module L1/U.
• Connect the optical fiber from connector A of the phase module L3/W to connector B on phase module L2/V.
e30bg741.10

A B PCU F01
L1 / U

A B PCU
L2 / V

A B PCU
L3 / W

Illustration 79: Optical Fiber Connections between Control Unit and Phase Modules

Two parallel AFE or INU units can be connected to one control unit. The first AFE or INU unit (Belt 1, series connection of three phase
modules) is connected to control unit connector F01 and the second (B2) to connector F02.

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If a brake chopper is installed (option +DBCU), there is a separate control unit for the brake choppers. Connect the brake chopper
modules in series as shown in Illustration 80. A maximum of three modules can be connected in series. Brake choppers can also be
connected to the control unit one by one (BCU1 to connector FO1, and BCU2 to FO2).

e30bg742.11
CNU-AFE CNU-INU

F01 F02 F03 F04 F05 F06 F01 F02 F03 F04 F05 F06

AFE / B1 INU / B1
CH1 CH2
A A
PCU / L1 B
AUX I/O PCU / U B

A A
PCU / L2 B PCU / V B

A A
PCU / L3 B PCU / W B

AFE / B2 INU / B2

A A
PCU / L1 B PCU / U B

A A
PCU / L2 B PCU / V B

A A
PCU / L3 B PCU / W B

Illustration 80: Parallel Optical Fiber Connections in an AFE Drive

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e30bi782.10
CNU-INU CNU-BCU

F01 F02 F03 F04 F05 F06 F01 F02 F03 F04 F05 F06

INU / B1
CH1 CH2
A
PCU / U B
AUX I/O

A
PCU / V B

DFE BCU / B1

A A A
PCU / W B
PCU B
PCU B

INU / B2

A
PCU / U B

A
PCU / V B

BCU / B2

A A
PCU / W B
PCU B

Illustration 81: Parallel Optical Fiber Connections in a 12-pulse Drive with BCU Option

7.8.1 Selection of Optical Fiber Cables

SI-POF duplex cables are recommended for all optical fiber connections. The connector type must be LC duplex. The specifications
in Table 20 are for cables manufactured by Firecomms. The cable assemblies (POF and connectors) are available from Firecomms
resellers with type code FD-XXX-LDB, where XXX is the length of the cable, XXC in centimeters, and XXM in meters.

Table 20: Optical Fiber Cable Specifications

Item Specification

Operation temperature -40...+85°C (-40...+185°F)

Minimum bend radius 25 mm (1 in)

Cable size (outer dimensions) 2.2 x 4.4 mm (0.087 x 0.173 in)

Fiber size d = 1 mm (0.04 in)

Cover material Flame resistant PE or PVC

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Item Specification

UL flame resistance VW-1

Cable standard Compatible with IEC 60793-2-40 class A4a

Plastic optical fiber type Duplex optical fiber, 1 mm (0.04 in) high-purity core. The core and cladding are surrounded by a
2.2 mm (0.082 in) polyethylene (PE) jacket.
Firecomms type code: FC-500-0DB

Connector type Firecomms type code: FP-00C-LD0

Connector standard Compatible with IEC 61754-20 edition 2

Recommended tools (from FiberFin):

• LC Duplex crimp tool, 2.60 mm hex, PEW 8 (FiberFin type code: FF-CRMP-LC-WL)
• Ultra Low Loss finishing tool, LC Connector (FiberFin type code: FF-LC-RZR1)
• Installer kit, including finishing tool and crimping tool (FiberFin type code: FF-STDLCINST-K)

7.8.2 Making Optical Fiber Cables

The fiber optic cables most likely to need replacement are the ones connected to the phase modules. During the installation or
replacement of modules, it is possible to damage the fiber optic cables accidentally. This procedure describes how to make new
cables.

These tools and equipment are required:

• Specialized tool kit for fiber optics
- Wire stripper
- Wire cutter
- Crimper tool
• Fiber optic wire
• Connectors
For details, see 7.8.1 Selection of Optical Fiber Cables.
Procedure
1. Cut the required length of fiber optic wire. Use a wire cutter to make sure that the cuts are clean.
2. Use the stripper tool to strip the wires approximately 25 mm (1 in) at both ends.

30–40
e30bj243.10

(1.25–1.5)

25
(1.0)
Illustration 82: Stripping and Splitting the Cable

3. Split the wires apart 30–40 mm (1.25–1.5 in) from both ends.

See Illustration 82.

4. Place a connector into the crimper tool.

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5. Push the fibers into the connector. Make sure that the fibers are fully pushed in. The fibers must come out of the end of the
connector approximately 1.6 mm (0.63 in).

A B

e30bj244.10
B A
1.6
(0.63)
Illustration 83: Installing the Connectors on the Cable

6. When the wires and connector are fully in position, firmly close the crimper grip.
7. Install the connector on the other end of the cable. Notice the labels A and B on the connectors. When making the connec-
tion for the other end of the wire, B goes to the A slot and A to B.

See Illustration 83.

8. Check the cable by shining an LED on one end of the cable and verifying that the other end is lit. For example, shine on wire
A on one end, and verify that B is lit on the other end.

7.9 Pre-charge and Supply Voltage Feedback Connections

The control unit has specific terminals for the DC-link pre-charge function. See Illustration 84.
• 3 digital inputs and 3 digital outputs for the operation of the DC-link pre-charge function.
• 2 optical fiber inputs from external sources, for example, an arc flash detector.
• A 3-phase input for supply voltage feedback. The feedback voltage is supplied to the control unit by a potential transformer.

e30bg743.11
ON

1 2
S1

1 2 3 4 5

Illustration 84: Terminals for Pre-charge I/O and Supply Voltage Feedback

1 Supply voltage feedback (L1, L2, L3) 4 Digital outputs (DO1, DO2, DO3) for the operation of
the DC-link pre-charge function
2 Optical fiber inputs for Breaker enable 1 (FR1) and
Breaker enable 2 (FR2) 5 Digital inputs (DI1, DI2, DI3) for the operation of the
DC-link pre-charge function
3 Breaker enable bypass switch (S1)

If the breaker enable fiber connections are not used, set the corresponding bypass switch to the ON position.

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• Switch S1.1 = Bypass for Breaker enable 1 (FR1)

• Switch S1.2 = Bypass for Breaker enable 2 (FR2)

Table 21: The Digital Inputs and Outputs for External Pre-charge Control

Terminal Signal(1) Technical information

DO1 Breaker start SPDT, SPST-NO

Switching capacity
DO2 Breaker enable
• 24 V DC / 8 A
DO3 Pre-charge permissive
• 250 V AC / 8 A
• 125 V DC / 0.15 A
Maximum switching capacity
• 2000 VA / 150 W
Minimum switching load
• 5 V DC / 10 mA

DI1 Pre-charge contactor feedback 24–48 V DC, optically isolated

DI2 Breaker status

DI3 Pilot relay status

1 The digital inputs/outputs are configurable.

7.10 Encoder Interface

The VACON® 3000 control unit includes a 2-encoder interface. The encoder interface is only used in the INU control unit, not in AFE
or BCU control units.
The encoder interface is designed for HTL (High-voltage Transistor Logic) type encoders (voltage output type Push-pull HTL, open
collector output type HTL) which provide input signal levels dependent on the supply voltage of the encoder.
The encoder properties include:
• Cross-connected optically isolated feedback for good noise limits
• 150 kHz maximum frequency
• Different encoder line driver voltage levels (24 V, 15 V, 5 V)
• Different encoder supply voltage levels (+24 V, +15 V) with current limits
• Differential encoder duplicator option from one of the encoder interfaces
• Master/follower selection
• Two qualifier inputs (1Q, 2Q) for position detection or pulse tachometer applications
If absolute encoder functionality is required, contact Danfoss.

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e30bg744.10
E D C F

B A
Illustration 85: Encoder Interface of the Control Unit

A Encoder terminal, channel A D Encoder output voltage selection jumpers, channel

B
B Encoder terminal, channel B
E Master/follower selection jumpers
C Encoder output voltage selection jumpers, channel
A F Encoder input voltage selection jumpers

7.10.1 Encoder Terminals and Signals

e30bg745.10

Illustration 86: Encoder Terminals

Encoder channel A is usable only for motor control.

Table 22: Channel A Terminals and Signals

Terminal Signal Signal Description

1 A1+ Channel A pulse input A1+ (differential); voltage range +5 V…+24 V

2 A1- Channel A pulse input A1- (differential); voltage range +5 V…+24 V

3 B1+ Channel A pulse input B1+ (differential); voltage range +5 V…+24 V; 90° delay from A1+

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Terminal Signal Signal Description

4 B1- Channel A pulse input B1- (differential); voltage range +5 V…+24 V; 90° delay from A1-

5 Z1+ Channel A pulse input Z1+ (differential); voltage range +5 V…+24 V; One pulse/revolution

6 Z1- Channel A pulse input Z1- (differential); voltage range +5 V…+24 V; One pulse/revolution

7 1Q Qualifier/position input; Single-ended signal (to ground)

8 2Q Qualifier/position input; Single-ended signal (to ground)

9 GND Ground for control and inputs 1Q and 2Q

10 Vcc Encoder supply voltage (selection with jumpers X11 and X15)

Table 23: Channel B Terminals and Signals

Terminal Signal Signal Description

1 A2+ Channel B pulse input A2+ (differential); voltage range +5 V…+24 V

2 A2- Channel B pulse input A2- (differential); voltage range +5 V…+24 V

3 B2+ Channel B pulse input B2+ (differential); voltage range +5 V…+24 V; 90° delay from A2+

4 B2- Channel B pulse input B2- (differential); voltage range +5 V…+24 V; 90° delay from A2-

5 Z2+ Channel B pulse input Z2+ (differential); voltage range +5 V…+24 V; One pulse/revolution

6 Z2- Channel B pulse input Z2- (differential); voltage range +5 V…+24 V; One pulse/revolution

7 a+ Pulse output a+ (differential); Made internally from channel 1 or channel 2 (selection with jumper X21); Out-
put voltage +24 V

8 a- Pulse output a- (differential); Made internally from channel 1 or channel 2 (selection with jumper X21); Out-
put voltage +24 V

9 b+ Pulse output b+ (differential); Made internally from channel 1 or channel 2 (selection with jumper X22); Out-
put voltage +24 V

10 b- Pulse output b- (differential); Made internally from channel 1 or channel 2 (selection with jumper X22); Out-
put voltage +24 V

7.10.2 Encoder Jumper Configurations

See the locations of the jumpers in Illustration 87 and the jumper pin sequence in Illustration 88.
The available encoder jumper configurations:
• Encoder input voltage selection, jumpers X11 and X15, see Table 24.
• Master/follower selection, jumpers X21 and X22, see Table 25.
• Encoder output voltage selection for channel A, jumpers X23-X25, see Table 26.
• Encoder output voltage selection for channel B, jumpers X26-X28, see Table 27.

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e30bg746.10
X26 X27 X28

X21 X22 X23 X24 X25 X11 X15

Illustration 87: Encoder Jumper Locations

e30bg747.10

1 2 1 2

3 4 3 4

5 6 5 6

Illustration 88: Jumper Pin Sequence and Connection Example (Pins 1-3 and 2-4 Connected)

Table 24: Encoder Input Voltage Selection, Jumpers X11 and X15

Jumper Selection Pins to connect, Jumper X11 Pins to connect, Jumper X15

+15 V (default) 1-2 open

+24 V open 1-2

Table 25: Master/Follower Selection, Jumpers X21 and X22

Jumper Selection Pins to connect

Master (default) 3-5 and 4-6

Follower 1-3 and 2-4

Table 26: Encoder Output Voltage Selection, Channel A

Jumper Selection Pins to connect, Jumper X23 (in- Pins to connect, Jumper X24 (in- Pins to connect, Jumper X25 (in-
put A1) put B1) put Z1)

+24 V open open open

+15 V (default) 1-3 and 2-4 1-3 and 2-4 1-3 and 2-4

+5 V 3-5 and 4-6 3-5 and 4-6 3-5 and 4-6

Table 27: Encoder Output Voltage Selection, Channel B

Jumper Selection Pins to connect, Jumper X26 (in- Pins to connect, Jumper X27 (in- Pins to connect, Jumper X28 (in-
put A2) put B2) put Z2)

+24 V open open open

+15 V (default) 1-3 and 2-4 1-3 and 2-4 1-3 and 2-4

+5 V 3-5 and 4-6 3-5 and 4-6 3-5 and 4-6

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7.10.3 Encoder Connection

Ground the encoder cable shields only at the AC drive end to avoid circulating current in the shield. Isolate the shield at the encoder
end.
If possible, use double shielded cable for encoder connection.
A high pulse frequency combined with a high cable capacitance places a considerable load on the encoder. Therefore, apply as low
a voltage as possible for the encoder supply. Use +15 V encoder voltage input, if allowed in the voltage range specification of the
encoder.
If external voltage supply is used, connect the ground of the external supply to terminal 9 in channel A of the encoder interface and
to the encoder ground.
Differential Connection

Encoder Control unit

e30bi919.10
Channel 1
A+ 1: A1+
A- 2: A1-
B+ 3: B1+
B- 4: B1-
GND 9: GND
15/24 V 10: Vcc

Illustration 89: HTL Type Encoder Connection with Differential Inputs

Single-ended Connection

Encoder Control unit e30bi920.10

Channel 1
A+ 1: A1+
GND 2: A1-
B+ 3: B1+
GND 4: B1-
GND 9: GND
+ 10: Vcc

Illustration 90: HTL Type Encoder Connection (Open Source) with Single-ended Inputs

Encoder Control unit

e30bi921.10

Channel 1
+ 1: A1+
A- 2: A1-
+ 3: B1+
B- 4: B1-
GND 9: GND
+ 10: Vcc

Illustration 91: HTL Type Encoder Connection (Open Collector) with Single-ended Inputs

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Chain Connection

Encoder Control unit 1

e30bi922.10
Channel 1
A+ 1: A1+
A- 2: A1-
B+ 3: B1+
B- 4: B1-
GND 9: GND
15/24 V 10: Vcc

Channel 2
7: a+
8: a-
9: b+
10: b-

Control unit 2
Channel 1
A+ 1: A1+
A- 2: A1-
B+ 3: B1+
B- 4: B1-

Illustration 92: Chain Connection with Duplicated Differential Inputs

7.11 Battery for the Real-Time Clock (RTC)

To use the real-time clock (RTC), a battery must be installed in the left side of the control unit. See 7.1 Control Unit Components. Use
a ½ AA battery with 3.6 V and a capacity of 1000–1200 mAh. Use, for example, a Vitzrocell SB-AA02 battery.
The battery lasts approximately 10 years. See more about the functions of the RTC in the application guides.

7.12 Galvanic Isolation Barriers

The control connections are isolated from the mains. The ground terminals are permanently connected to the I/O ground.
The digital inputs on the standard I/O board can be galvanically isolated from the I/O ground. To isolate the digital inputs, use the
DIP switch that has the positions FLOAT and GND. See 7.5.2 Isolation of the Digital Inputs from Ground.

7.13 System and Application Software

The VACON® 3000 control unit comes with AFE or INU system and application software. There is also separate application software
for the brake chopper control unit.
The application software is specific to the VACON® 3000 and comes installed on the drive. For more information, see the VACON®
3000 Application guides.

7.14 Technical Data on Control Connections

For more detailed information about the standard I/O board and optional I/O boards, see the VACON® 100 I/O Boards User Manual.
Table 28: The Standard I/O Board

Termi- Signal Technical Information

nal

1 Reference output +10 V, 0%...+3%, maximum current: 10 mA

2 Analog input, volt- Analog input channel 1

age, or current 0...+10 V (Ri = 200 kΩ)
4–20 mA (Ri =250 Ω)
Resolution 0.1%, accuracy ±1%
Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP
switches in the Operating Guide).

3 Analog input com- Differential input if not connected to ground

mon (current) Allows ±20 V common-mode voltage to GND

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Termi- Signal Technical Information

nal

4 Analog input, volt- Analog input channel 2

age, or current Default: 4–20 mA (Ri =250 Ω)
0...+10 V (Ri = 200 kΩ)
Resolution 0.1%, accuracy ±1%
Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP
switches in the Operating Guide).

5 Analog input com- Differential input if not connected to ground

mon (current) Allows ±20 V common-mode voltage to GND

6 24 V auxiliary voltage +24 V, ±10%, maximum voltage ripple < 100 mV rms
Maximum 250 mA
Short-circuit protected

7 I/O ground Ground for reference and controls (connected internally to frame ground through 1 MΩ)

8 Digital input 1 Positive or negative logic

Ri = min. 5 kΩ
9 Digital input 2
0–5 V = 0
10 Digital input 3 15–30 V = 1

11 Common A for DIN1- Digital inputs can be disconnected from ground. See chapter Isolation of digital inputs from
DIN6 ground in the Operating Guide.

12 24 V auxiliary voltage +24 V, ±10%, maximum voltage ripple < 100 mV rms
Maximum 250 mA
Short-circuit protected

13 I/O ground Ground for reference and controls (connected internally to frame ground through 1 MΩ)

14 Digital input 4 Positive or negative logic

Ri = min. 5 kΩ
15 Digital input 5
0–5 V = 0
16 Digital input 6 15–30 V = 1

17 Common A for DIN1- Digital inputs can be disconnected from ground. See chapter Isolation of digital inputs from
DIN6 ground in the Operating Guide.

18 Analog signal (+out- Analog output channel 1, selection 0 -20 mA, load <500 Ω
put) Default: 0–20 mA
19 Analog output com- 0–10 V
mon Resolution 0.1%, accuracy ±2%
Selection V/mA with DIP switches (see chapter Selection of terminal functions with DIP
switches in the Operating Guide)
Short-circuit protected

30 24 V auxiliary input Can be used as external power back-up for the control unit
voltage

A RS485 Differential receiver/transmitter

Set bus termination with DIP switches (see chapter Selection of terminal functions with DIP
B RS485
switches in the Operating Guide). Termination resistance = 220 Ω

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Table 29: The Standard Relay Board (+SBF3)

Terminal Signal Technical information

21 Relay output 1(1) Change-over switch (SPDT) relay. 5.5 mm isolation between channels.
Switching capacity
22
• 24 V DC / 8 A
23
• 250 V AC / 8 A
• 125 V DC / 0.4 A
Minimum switching load
• 5 V / 10 mA

24 Relay output 2(1) Change-over switch (SPDT) relay. 5.5 mm isolation between channels.
Switching capacity
25
• 24 V DC / 8 A
26
• 250 V AC / 8 A
• 125 V DC / 0.4 A
Minimum switching load
• 5 V / 10 mA

32 Relay output 3(1) Normally-open (NO or SPST) switch relay. 5.5 mm isolation between channels.
Switching capacity
33
• 24 V DC / 8 A
• 250 V AC / 8 A
• 125 V DC / 0.4 A
Minimum switching load
• 5 V / 10 mA

1 If 230 V AC is used as control voltage from the output relays, the control circuitry must be powered with a separate isolation transformer to limit
the short-circuit current and the overvoltage spikes. This is to prevent welding on the relay switches. Refer to standard EN 60204-1, section 7.2.9.

7.15 Auxiliary I/O Board

7.15.1 Connector Locations

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J11 J10 J2 X5

e30bi609.10
J8

H23
H24 S1

J9 S6
S17 S16 S15 S10 S9 S13 S5 S2 S18 S4 S3 S8 S7
H160
H161

J12 J13 J14 J15 S14 S12 S11 H13 H12 H40 H60 J4 J3
Illustration 93: The Connectors and Switches on the Auxiliary I/O Board

H12 Breaker enable fiber optic input 2 J8 Digital inputs (24 V, 0.5 A), 8 channels

H13 Breaker enable fiber optic input 1 J9 Digital inputs (24 V, 0.5 A), 8 channels

H23 External breaker enable fiber optic TX2 J10 Relay outputs, 4 channels

H24 External breaker enable fiber optic RX2 J11 Relay outputs, 5 channels

H40 Communication channel 1 (PBHS) J12 Digital inputs (24 V, 0.5 A), 8 channels

H60 Communication channel 2 (PBHS) J13 Digital inputs (24 V, 0.5 A), 8 channels

H160 External breaker enable fiber optic TX1 J14 Breaker enable digital inputs, 4 channels

H161 External breaker enable fiber optic RX1 J15 24 V pull-up for sensors

J2 Grid voltage measurement, 3 channels S1–S18 Control switches

J3 Grid current measurement, 3 channels X5 24 V input

J4 Analog voltage (0–10 V)/analog current (4–20 mA)

measurement, 4 channels

7.15.2 Connector Specifications

Table 30: Connectors H12/H13, Breaker Enable Optical Fiber Signals

Con- Signal Name Input Disa- Description

nector ble Switch

H12 Breaker ena- S12 When light is present, the breaker is enabled. Switch in position (1-2) disables the input.
ble 2

H13 Breaker ena- S11 When light is present, the breaker is enabled. Switch in position (1-2) disables the input.
ble 1

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Table 31: Connectors H23/H24 and H160/H161, External Breaker Enable Optical Fiber Inputs/Outputs

Con- Signal Input Description

nector Name Disable
Switch

H23 Ext Brk TX – Transmit breaker enable signal to other boards.

2

H24 Ext Brk RX S1 Receive breaker enable signal from other boards. Switch position (1-2) disables external sig-
2 nal.

H160 Ext Brk TX – Transmit breaker enable signal to other boards.

1

H161 Ext Brk RX S6 Receive breaker enable signal from other boards. Switch position (1-2) disables external sig-
1 nal.

Table 32: Connector J2, Grid Voltage (120/127 V) Measurement (Copper Wire) Analog Signals

Connector Signal Name Description

J2-1 Phase A 120/127 V phase A grid voltage input (LN peak -170 V)

J2-2 Phase B 120/127 V phase B grid voltage input (LN peak -170 V)

J2-3 Phase C 120/127 V phase C grid voltage input (LN peak -170 V)

J2-4 Reference Neutral/return/artificial neutral

Table 33: Connector J3, Grid Current Measurement (Copper Wire) Analog Signals

Connector Signal Name Switch Control Description

J3-1 CT Supply – +16 V, positive supply output for hall effect sensor

J3-2 CT Supply – -16 V, negative supply output for hall effect sensor

J3-3 Analog Input 5 + S2 S2 switch position (1-2) grounds Input 1P

J3-4 Analog Input 5 - S18 S18 switch position (1-2) connects burden resistor

J3-5 Analog Input 6 + S4 S4 switch position (1-2) grounds Input 2P

J3-6 Analog Input 6 - S3 S3 switch position (1-2) connects burden resistor

J3-7 Analog Input 7 + S8 S8 switch position (1-2) grounds Input 3P

J3-8 Analog Input 7 - S7 S7 switch position (1-2) connects burden resistor

Table 34: Connector J4, General Purpose Voltage/Current Measurement (Copper Wire) Analog Signals

Connec- Signal Name Switch Description

tor Control

J4-1 Analog Input 1 S10 Voltage/current input 1 (single ended). Switch toggles between current and voltage.

J4-2 Analog Input 2 S9 Voltage/current input 2 (single ended). Switch toggles between current and voltage.

J4-3 Analog Input 3 S13 Voltage/current input 3 (single ended). Switch toggles between current and voltage.

J4-4 Analog Input 4 S5 Voltage/current input 4 (single ended). Switch toggles between current and voltage.

J4-5 Common – Return for analog voltage signals.

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Table 35: Connector J8, 24 V/0.5 A Digital Input (Copper Wire) Signals

Connector Signal Name Description

J8-1 Digital input 1 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-2 Digital input 2 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-3 Digital input 3 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-4 Digital input 4 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-5 Digital input 5 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-6 Digital input 6 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-7 Digital input 7 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-8 Digital input 8 24 V, 0.5 A optically isolated digital input (signal bank A)

J8-9 Common A Signal return for bank A

Table 36: Connector J9, 24 V/0.5 A Digital Input (Copper Wire) Signals

Connector Signal Name Description

J9-1 Digital input 9 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-2 Digital input 10 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-3 Digital input 11 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-4 Digital input 12 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-5 Digital input 13 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-6 Digital input 14 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-7 Digital input 15 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-8 Digital input 16 24 V, 0.5 A optically isolated digital input (signal bank B)

J9-9 Common B Signal return for bank B

Table 37: Connector J10, Relay Outputs

Connector Signal Name Description

J10-1 Relay output 1 CM Relay is disabled when breaker enable network is not satisfied.

J10-2 Relay output 1 NO Relay is disabled when breaker enable network is not satisfied.

J10-3 Relay output 2 CM Relay is disabled when breaker enable network is not satisfied.

J10-4 Relay output 2 NO Relay is disabled when breaker enable network is not satisfied.

J10-5 Relay output 3 CM Relay is disabled when breaker enable network is not satisfied.

J10-6 Relay output 3 NO Relay is disabled when breaker enable network is not satisfied.

J10-7 Relay output 4 CM Relay is disabled when breaker enable network is not satisfied.

J10-8 Relay output 4 NO Relay is disabled when breaker enable network is not satisfied.

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Table 38: Connector J11, Relay Outputs

Connector Signal Name Description

J11-1 Relay output 5 CM Relay is disabled when breaker enable network is not satisfied.

J11-2 Relay output 5 NO Relay is disabled when breaker enable network is not satisfied.

J11-3 Relay output 6 CM Relay is disabled when breaker enable network is not satisfied.

J11-4 Relay output 6 NO Relay is disabled when breaker enable network is not satisfied.

J11-5 Relay output 7 CM Relay is disabled when breaker enable network is not satisfied.

J11-6 Relay output 7 NO Relay is disabled when breaker enable network is not satisfied.

J11-7 Relay output 8 CM Relay is disabled when breaker enable network is not satisfied.

J11-8 Relay output 8 NO Relay is disabled when breaker enable network is not satisfied.

J11-9 Relay output 9 CM Relay is disabled when breaker enable network is not satisfied.

J11-10 Relay output 9 NO Relay is disabled when breaker enable network is not satisfied.

Table 39: Connector J12, 24 V/0.5 A Digital Input (Copper Wire) Signals

Connector Signal Name Description

J12-1 Digital input 17 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-2 Digital input 18 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-3 Digital input 19 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-4 Digital input 20 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-5 Digital input 21 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-6 Digital input 22 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-7 Digital input 23 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-8 Digital input 24 24 V, 0.5 A optically isolated digital input (signal bank C)

J12-9 Common C Signal return for bank C

Table 40: Connector J13, 24 V/0.5 A Digital Input (Copper Wire) Signals

Connector Signal Name Description

J13-1 Digital input 25 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-2 Digital input 26 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-3 Digital input 27 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-4 Digital input 28 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-5 Digital input 29 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-6 Digital input 30 24 V, 0.5 A optically isolated digital input (signal bank D)

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Connector Signal Name Description

J13-7 Digital input 31 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-8 Digital input 32 24 V, 0.5 A optically isolated digital input (signal bank D)

J13-9 Common D Signal return for bank D

Table 41: Connector J14, Breaker Enable, Copper Wire Signals (FK-MCP 1.5/5-ST-3.81)

Con- Signal Name Input Dis- Description

nector able
Switch

J14-1 Breaker enable S14 When the signal is high, the breaker is enabled. Switch position (1-2) disables the input.
3

J14-2 Breaker enable S15 When the signal is high, the breaker is enabled. Switch position (1-2) disables the input.
4

J14-3 Breaker disa- S16 When the signal is high, the breaker is disabled. Switch position (1-2) disables the input.
ble 1

J14-4 Breaker disa- S17 When the signal is high, the breaker is disabled. Switch position (1-2) disables the input.
ble 2

J14-5 Return – Return for breaker enable signals

Table 42: Connector J15, 24 V Pull-up

Connector Signal Name Description

J15-1 24V Current limited 24 V pull-up voltage (2 mA)

J15-2 24V Current limited 24 V pull-up voltage (2 mA)

J15-3 GND Return for current limited 24 V

J15-4 GND Return for current limited 24 V

Table 43: Connector X5, Power Supply

Connector Signal Name Description

X5-1 24V 24 V positive supply voltage

X5-2 GND Ground (return for 24 V supply voltage)

X5-3 PE Protective earth

7.15.3 LED Display on the Auxiliary I/O Board

There is a four character LED display on the auxiliary I/O board. The display functions in the same principle as the display on the
phase modules, but the shown belt and module information is different. See 6.2.7 LED Display on the Phase Module.
Belt information: The belt information indicator tells the number of the channel on the control unit to which the auxiliary I/O board
is connected, in this case C5 (see 7.8 Optical Fiber Connections).
The belt information indicator is of type: [ ] [ ] [C] [5].
• The first two digits are empty.
• The last two digits show the number of the channel.
Module information: The module information indicator tells the identification number of the auxiliary I/O board. The number of the
first installed board is 14, the second is 15, and so on.
The module information indicator is of type: [PowerID N_] [PowerID _N] [ ] [ ].

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• The first two digits show the ID of the auxiliary I/O board.
• The last two digits are empty.

7.15.4 Breaker Enable Signals

The Breaker Enable signal requires several lower level feedback signals to be OK. Only then it allows closing the MV switchgear that
supplies MV input power to the drive (or conversely, opens the MV switchgear to cut the MV supply power).
See the locations of the connectors in 7.15.1 Connector Locations.
The Breaker Enable signal descriptions:
• Breaker Enable optical fiber signals, see Table 30
• External Breaker Enable optical fiber inputs/outputs, see Table 31
• Breaker Enable copper wire signals, see Table 41

7.15.5 Breaker Enable Logic

Breaker Enable In 1 (SW)

e30bj790.10
Breaker Enable In 2 (SW)
Breaker Enable In 3 (SW)
Breaker Enable In 4 (SW)
Breaker Disable In 1 (SW)
Breaker Disable In 2 (SW)
Breaker Enable RX 1 (SW)
Breaker Enable RX 2 (SW)
Vcc
System Good (WD)
Breaker Enable In 1 (FO)
Breaker Enable In 2 (FO)
Breaker Enable In 3 (CU) AND
Breaker Enable In 4 (CU)
Breaker Enable In 1 (CU)
Breaker Enable In 2 (CU)

AND Breaker Enable TX 2 (FO)

Breaker Enable RX 1 (FO)

AND Breaker Enable Out (SW)

Breaker Enable RX 2 (FO)

AND Breaker Enable TX 1 (FO)

Relay In 1 (SW)
AND Breaker Enable Gated Relay Out 1

Relay In 2 (SW)
AND Breaker Enable Gated Relay Out 2

Relay In 3 (SW) Relay Out 3

Illustration 94: Flowchart Diagram of the Breaker Enable Function

The signals in the flowchart correspond to the following signals on the Auxiliary I/O board:
• Breaker Enable Input 1 and 2 (FO) correspond to H12 and H13 (optical fiber signals).
• Breaker Enable Input 3 and 4 (CU) correspond to J14-1 and J14-2 (copper wire).
• Breaker Disable Inputs 1 and 2 (CU) correspond to J14-3 and J14-4.
• Breaker Enable TX 1 and 2 (FO) correspond to H12 and H13.
• All signals with (SW) denote internal software.
All the input signals of the 7 input AND gate are not necessarily used. Bypass the inputs which are not used by setting their input
disable switches (S1, S6, S11–S17) to disable, which forces a logical 1 to the input of the AND gate.
The positions on the input disable switches are:
• 1 = Off/Bypass
• 2 = On/Enable

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Downstream of the 7 input AND gate are two 2-input AND gates that correspond to the external breaker enable function. Breaker
Enable RX1 and RX2 are disabled/bypassed in any single auxiliary I/O board system setup (S1 and S6 set to bypass). Breaker Enable
TX1 (H12) or TX2 (H13) is used as the final “Breaker Enable OK” signal that goes to the breaker enable FO port (either H23 or H24) on
the control unit. When “healthy”, the green LED to the right of the optical fiber is lit.
Notice that the breaker enable switch setting is reversed on the control unit. The ON position means that the signal is bypassed.

7.15.6 Breaker Enable Mapping Examples

12-pulse drives

e30bj791.10
MV section LV section
DFE
MV Breaker
OC relay Arc
SEL CU/ Flash
GOOD FIRE
FO Relay
Trip 1
PBHS

J14-4 H12
P P
AXU-IOB B B
H
CNU-INU
Safety H
relay J14-1 H160 S S H24
HCM Breaker Enable Breaker Enable

Illustration 95: Breaker Enable Mapping in 12-pulse Drives

Table 44: Breaker Enable Mapping in 12-pulse Drives

Connector Description

J14-1 HCM feedback

J14-2 Not used (set in bypass)

J14-3 Not used (set in bypass)

J14-4 SEL trip relay

H12 CLB “Good” feedback

H13 Not used (set in bypass)

H160 Feedback to INU control unit breaker enable (H24)

H161 Not used (set in bypass)

H23 Not used (set in bypass)

H24 Set (S1 switch on) to receive breaker enable from auxiliary I/O board (H160)

In this setup 3 signals are required for Breaker Enable to achieve the ready state. These 3 signals need to be “healthy” in order to
send a logical 1. Healthy conditions for the 3 signals are as follows:
• HCM board detects voltage below trip threshold (can be set between 25–48 V DC).
• SEL relay is not tripped (caused by overcurrent on motor).
• Crowbar Logic Board is “good” (not in undervoltage, overvoltage, triggered, or voltage imbalance state).

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AFE drives with UFES

e30bj792.10
MV section LV section
UFES CCA REA MV Breaker
X10 R REA
T X9 HS02
GOOD
READY X11 PBHS X8

H12
J14-1 P P
AXU-IOB B B
H
CNU-AFE DO1
Safety H
relay J14-2 H160 S S H24
HCM Breaker Enable Breaker Enable

Illustration 96: Breaker Enable Mapping in AFE Drives with UFES

Table 45: Breaker Enable Mapping in AFE Drives with UFES

Connector Description

J14-1 UFES ready

J14-2 HCM feedback

J14-3 Not used (set in bypass)

J14-4 Not used (set in bypass)

H12 CLB “Good” feedback

H13 Not used (set in bypass)

H160 Feedback to AFE control unit breaker enable (H24)

H161 Not used (set in bypass)

H23 Not used (set in bypass)

H24 Set (S1 switch on) to receive breaker enable from auxiliary I/O board (H160)

In this setup, HCM has the same function. UFES Ready depends on the OK signal from arc flash detection. CCA is healthy as long as
the DC link has not experienced a major dU/dt event (sudden dip or spike in voltage) that would likely precede an arc flash.

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AFE drives without UFES

e30bj793.10
MV section LV section
CCA MV Breaker
Arc
CU/
GOOD FIRE
FO
Flash
PBHS
Relay

H12
P P
AXU-IOB B B
H
CNU-AFE DO1
Safety H
relay J14-2 H160 S S H24
HCM Breaker Enable Breaker Enable

Illustration 97: Breaker Enable Mapping in AFE Drives without UFES

Table 46: Breaker Enable Mapping in AFE Drives without UFES

Connector Description

J14-1 Not used (set in bypass)

J14-2 HCM feedback

J14-3 Not used (set in bypass)

J14-4 Not used (set in bypass)

H12 CLB “Good” feedback

H13 Not used (set in bypass)

H160 Feedback to AFE control unit breaker enable (H24)

H161 Not used (set in bypass)

H23 Not used (set in bypass)

H24 Set (S1 switch on) to receive breaker enable from auxiliary I/O board (H160)

In this setup, there is one less feedback (no UFES) to monitor.

Table 47: Device Descriptions

Device Ac- Full Name Function

ronym

CCA Crowbar control assembly Clamps DC-link voltage when potential arc flash conditions are detected (in
AFE drives).

CLB Crowbar logic board Clamps DC-link voltage during arc flash event to mitigate damage in drive
cabinet (in 12-pulse drives).

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Device Ac- Full Name Function

ronym

HCM Heat sink capacitance monitor Detect voltage between INU/AFE module heat sinks and earth ground. Trips
at 48 V DC.

SEL Schweitzer Engineering Laborato- Monitors output current and sends trip signal when overcurrent is detected.
ries

UFES Ultra fast earthing switch Shorts MV supply voltage to earth ground when triggered.

7.16 HCM Board

7.16.1 Connector Locations

e30bj520.10
J7

J1
J5

J6

Illustration 98: Connectors on the HCM Board

J1 Aux (AO2) J6 Ground

J5 Heat sink (MV AI) J7 Relay (AO1)

7.16.2 Installation
The HCM board is only included in VACON® 3000 Drive Kits with option code +GAUL.
The HCM board can be mounted on a DIN 35 rail.
Install an external overvoltage relay with the HCM board. The recommended relay type is RM22UA33MR from Schneider Electric.
Use these settings for the relay:
• Operating mode = >U, no memory
• Voltage threshold setting (U value) = 10%
• Hysteresis/Window mode (Hys/>U>) = 5%
• Time delay (Tt) = 0.1

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e30bj521.10
24 V
+

X5.1: LP24
X5.2: L24
HS

A1
A2
J5.2 J7.2 E1

22 J15.4: L24
M 21 J14.1: BRKEN_3
HCM Relay
24 J15.1: LP24

J15.3: L24
J14.5: COME

J1.2 J3.3: AIN1_P

J6
J3.4: AIN1_N

GND
AXU-IOB

Illustration 99: HCM Board Wiring Diagram

24 V 24 V supply HS Phase module heat sinks

GND Ground

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8 Commissioning
8.1 Safety Checks before Starting the Commissioning
Before starting the commissioning, read these warnings.

D A N G E R
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 seri-
ous 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.

D A N G E R
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.

D A N G E R
SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE
The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the
mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to
death or serious injury.
- Disconnect the drive from the mains and make sure that the motor has stopped.
Disconnect the motor.
Lock out and tag out the power source to the drive.
Make sure that no external source generates unintended voltage during work.
To ground the drive input and DC link, close the grounding switch. If there is no grounding switch, make sure that the drive
input and DC link are grounded for work. Also ground the motor terminals for work.
Wait for the DC-link capacitors to discharge fully before opening the cabinet door or the cover of the AC drive. The discharge
time is <7 minutes for AFE drives and <21 minutes for 12-pulse drives.
Use a measuring device to make sure that there is no voltage.

8.2 Commissioning the Drive

Before starting the commissioning, read the warnings and safety instructions in this manual.
• Fill in the basic information about the job and the motor nameplate data.
• Go through each item in the commissioning checklists.
- Before power-up.
- Control and auxiliary power commissioning.
- Medium-voltage power commissioning.
• Write down any findings or measured values in the comment fields.
• Once each task is completed, mark the completion date and the name of the responsible employee.

8.2.1 Basic Job Information

Table 48: Basic Job Information

Customer Country

Project number Location

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Start date (mm/dd/yy) Customer ID

End date (mm/dd/yy) Drive serial number

Company personnel Drive type code

End customer Application

Table 49: Motor Nameplate Data

Motor Nominal Voltage (V AC)

Motor Nominal Frequency (Hz)

Motor Nominal Speed (RPM)

Motor Nominal Current (A AC)

Motor Power Factor (0–1)

Motor Nominal Power (kW)

Transformer Specifications (MVA, Secondary V RMS, %Z)

8.2.2 Before Power-up Checklist

Table 50: Checklist of Commissioning Tasks to Do Before Power-up

Item Comments Date completed Employee

(mm/dd/yy)

Confirm that the ambient conditions are within the specifi-

cation.
See 11.3.6 Cooling.

Perform system lockout/tagout and grounding of the drive

according to specific customer installation procedure.

Make sure that the mains and motor cables are selected ac-
cording to the requirements.
See 6.1.4 Mains and Motor Cable Selection.

Make sure that the MV input/supply cables are connected

according to the system schematic and are properly tor-
qued.

Make sure that the output/motor cables are connected ac-

cording to the system schematic and are properly torqued.

Confirm that a wire check of the MV input and output ca-

bles has been completed.

Confirm the proper grounding of the MV cable shields, mo-

tor, transformer, and drive cabinet.
See 6.1.6 Grounding.

Per local electrical codes, verify that the MV drive cabinet is

grounded to the earth ground of the facility.

Confirm that the drive cabinet ground busbars are connec-

ted in all sections.
See 6.1.6 Grounding.

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Item Comments Date completed Employee

(mm/dd/yy)

Check the resistances of the grounding connections. Meas-

ure both polarities.
Resistances to check:
• Control system grounding
• System safety grounding
• Cabinet support
• External housing of the cooling fans
• Door locks/handles
The resistances should be approximately ≤0.5 Ω.

Confirm that the MV input and output cables have been in-
sulation tested according to local regulations.

Confirm that there are no power factor correction capaci-

tors connected to the motor cable.

Make sure that the optical fiber cables are selected accord-
ing to the requirements.
See 7.8.1 Selection of Optical Fiber Cables.

Check that the optical fiber cables are in good condition

and the routing is done in a way that does not damage the
cables. For example, make sure that the maximum bending
radius of the cables (25 mm/1 in) is not exceeded.

AFE drive systems

Make sure that the phase modules (INU/AFE) are installed
correctly:
• Cabling/busbars are properly torqued.
• Fiber optic wires are connected in correct order.
• 24 V DC plug is connected.

12/24-pulse drive systems

Make sure that the phase modules (INU) and DFE module
are installed correctly:
• Cabling/busbars properly are torqued.
• Fiber optic wires are connected in correct order.
• 24 V DC plug is connected.

12/24-pulse drive systems

Make sure that the DC-link capacitors for DFE are installed
correctly:
• Cabling/busbars are properly torqued.
• Overpressure switch is connected to control.

Confirm that there is a minimum of 76 mm (3.0 in) from an

exposed MV terminal to ground.

Confirm that there is a minimum of 34 mm (1.35 in) from

an exposed MV terminal to opposite polarity.

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Item Comments Date completed Employee

(mm/dd/yy)

Check that the main circuit wiring has correct clearance to

ground and no insulated MV cabling (SIWO-KUL) is in con-
tact with opposite phases or the drive enclosure.

Verify that the INU/AFE phase modules and DFE power

module are connected to the correct corresponding input/
output busbar terminals (U -> U, L1 -> L1, and so on).
See 6.2 Cabling of the Power Modules.

Check that all cooling hoses are connected from the mani-
fold to:
• Phase modules
• DFE module
• Inductor heat exchangers
• Output filter (if installed)
See 5.5.4.3 Cooling System Installation.

Make sure that the MV drive cooling system has been filled
and pressurized with no leaks.
See the specifications in 11.3.6 Cooling.
See the instructions in 8.3.1 Filling the Liquid Cooling Sys-
tem.

If applicable, make sure that all cooling valves are opened.

Make sure that the single-phase control power cables

(120/240 V) are connected according to the system sche-
matic in a separate conduit from the MV cabling.

Make sure that the auxiliary (400–480 V AC) power cables

are connected according to the system schematic in a sep-
arate conduit from the MV cabling.

Torque all control and auxiliary input power cables after

they are connected.
See 7.4 Control Unit Cabling and 6.5.10 Auxiliary Power
Supply Installation.

Confirm that the pre-charge voltage selection board that is

installed matches the supplied auxiliary voltage level.
See 6.5.8.2 Pre-Charge Unit Installation.

Connect the required customer communication cables and

I/O including main breaker control to the MV drive.
See the customer drive schematic.

AFE drive systems

Verify the proper setup of grid voltage feedback.
See 8.3.2 Grid Voltage Feedback Configuration.

AFE drive systems

Verify that the PT and TVS fuses are in working condition.

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Item Comments Date completed Employee

(mm/dd/yy)

Confirm that the customer cooling connection is made to

the drive cabinet heat exchanger.

Make sure that the temperature of the liquid in the secon-

dary circuit is at least 5 °C below the temperature level in
the primary cooling circuit of the MV drive. The absolute
maximum for the secondary circuit liquid temperature is
38 °C.
See 5.5.3.4 Temperature of the Cooling Liquid.

Make sure that the flow rate of the customer cooling is

greater than or equal to the required flow of the MV Drive.
See 11.3.6 Cooling.

Confirm that the unit is clean and free from any foreign ob-
jects (such as nuts, washers, bolts, tools, metal shavings).

Confirm that there is no condensation inside the drive.

See 5.5.3.5 Condensation.

8.2.3 Control and Auxiliary Power Commissioning Checklist

Table 51: Checklist of Control and Auxiliary Power Commissioning Tasks

Item Comments Date completed Employee

(mm/dd/yy)

Remove the control and auxiliary power lockout/tagout so

that these LV supplies can be energized.

Apply 120/240 V single-phase control power. Control voltage:

Verify that the voltages are within specification. ________ V AC
Record the measurement.

Apply 400–480 V AC three-phase power. Auxiliary voltage:

Verify that the voltages are within specification. ________ V AC
Record the measurement.

Verify that the INU/AFE (if applicable), and HX control units

are powered on and communicating.

If required, install software to the AFE/INU/BCU control System software revision:

units. ______________
See 8.3.3 Installing Software on the Control Unit. Application:
Record the software revision details. ______________

Verify that all the power module LED displays show the
correct phase and belt information.
See 8.3.4 Verifying the Phase Module Connections.
Correct the fiber optic cable sequence if necessary.

Operate the cooling system manually. Flow rate:

__________ l/min
Static pressure:

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Item Comments Date completed Employee

(mm/dd/yy)
• If needed, purge air from the system. __________ bar (psi)
• Check for leaks.
• Check the liquid temperature.
• Check the flow rate.
See the cooling specification details in 11.3.6 Cooling.

Test the customer I/O signals.

Verify that the external customer interlocks operate as in-
tended.

Make sure that the digital input ground is connected to the

digital system ground when floating, or to the control ter-
minal ground.
See 7.5.2 Isolation of the Digital Inputs from Ground.

Perform the commissioning test.

See 8.3.5 Commissioning Test.

8.2.4 Medium-Voltage Power Commissioning Checklist

Table 52: Checklist of Medium-Voltage Power Commissioning Tasks

Item Comments Date completed Employee

(mm/dd/yy)

Remove the main power lockout/tagout, so that the main

power can be applied.

AFE drive systems

Perform the AFE synchronization test and tuning. See 8.3.6
AFE Synchronization Test.

12/24-pulse drive systems

Issue the start command to the drive, therefore energizing
the DC link through the 12/24-pulse input.

Verify the charging of the DC link to the rated level in an Pre-charge time:
acceptable time (below the value programmed for the DC- ________ s
link timeout: ≤60 s)
Discharge time:
________ s

Confirm that the INU control unit is giving the "Online and
ready" signal.

Check that the motor parameters have been set in the INU
control unit.

Perform the Motor ID Run (P3.1.2.8.1) with or without rota-

tion.
For details, see the VACON® 3000 Application Guide.

If applicable, make sure that the encoder is connected and

configured properly.
See 8.3.7 Encoder Setup.

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Item Comments Date completed Employee

(mm/dd/yy)

To verify correct rotation, operate the motor (with the load

uncoupled).

Operate the motor (with the load uncoupled) and incre-

mentally increase the output up to the maximum rated fre-
quency.

Operate the motor under load.

Verify the operation up to full load.

Tune the control parameters as necessary to achieve the

required operational specifications of the application.

8.3 Commissioning Procedures

8.3.1 Filling the Liquid Cooling System

Before operating a drive, the cooling system must be filled, pressurized, and purged of air. For this procedure, it is assumed that the
system is empty of coolant and must be filled. Under normal situations, the system has already been tested before shipping out and
typically has some fluid.
Note:
• Accessibility to certain components of the cooling system can be an issue depending on the layout of the drive and/or the heat
exchanger unit.
• This guide is not intended to be used as a reference for commissioning cooling systems which are not installed in a VACON®
3000 drive.

1. To access the inlet and outlet cooling manifolds, locate the cabinet in which the cooling system is installed.

The location of the manifolds varies depending on the internal layout of the cabinet. Sometimes there might not be ac-
cess to install quick disconnects to the manifolds. In these cases, it is necessary to connect straight to one of the hoses on
the power module instead of the manifold.

2. Connect the cooling fluid pump assembly to the inlet and outlet manifolds with quick connects (if available). Open the
valves.
3. Before filling the system with glycol, verify that all cooling hoses throughout the system are firmly connected and/or tor-
qued. Make certain that any hoses with valves connected to a module have their valves in the open position.
4. Make sure that the automatic air purger on the main heat exchanger is uncapped and its valve is open.

The location of the air purger varies depending on the cabinet and heat exchanger design.

5. Begin running the standalone pump and fill the system. Water should be flowing into the inlet while a combination of wa-
ter and air pockets/bubbles are flowing out from the outlet. If any leak is detected, immediately shut off the pump.

The power of the pump and size of the cooling system dictates the flow rate and how quickly the air can be purged from
the system. Use an appropriately sized pump. A pump of at least 0.5 hp or greater is ideal.

6. When air bubbles/pockets flowing out of the outlet hose are no longer visible, stop the pump.
7. Close the inlet and outlet valves.
8. Slowly open the air bleeders on the pumps. Air bubbles out. When the bubbling starts becoming only fluid seeping out,
close off the bolts to seal the pumps.
9. Open the inlet and outlet valves and start to run the standalone pump from the glycol tank again.
- a. Run the pump for at least 5 minutes before shutting off.
- b. Close the inlet and outlet valves.
- c. Repeat step 8. There should be fewer air bubbles this time around.
- d. Move to step 10.
10. Pressurize the system.
- a. Open the inlet valve.
-

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b. Activate the standalone glycol pump.

- c. Wait for the pressure to build up to approximately 1.2 bar.
- d. Close the inlet valve and turn off the pump.
11. Run the heat exchanger.
- a. Verify that the HX is in ready state.
- b. Run the pump for about 5 minutes.
12. Wait ~2 minutes after stopping. Briefly open and close the outlet valve. More air bubbles should come out. Repeat this
several times until the pressure is no longer enough to force out any more air pockets.

e30bi803.10

Illustration 100: Removing the Air

13. Run the standalone pump again.

- a. Open the inlet valve.
- b. Start to operate the standalone pump and open the outlet valve.
- c. Repeat steps 10–12.
- d. After the 2nd cycle, the number of air pockets that are purged should be reduced.
- e. Repeat the cycle until there are only few small air bubbles remaining. It is not possible to eliminate all the air bub-
bles.
14. When the air has been purged, pressurize the system to 1.2 bar with the standalone pump again.
15. Check the fluid level gauge.
- If the fluid level is above the nominal line: To release excess fluid back into the glycol tank, open the outlet valve. The
pressure drops from the 1.2 bar. If the fluid level is still above the “nominal” line after the pressure drops to 0, add air to
the “air filling” tank until the fluid level drops to the “nominal” marker.
- If the fluid level is below the nominal line: Bleed air out of the tank by pressing the pin on the nozzle. The fluid level on
the gauge climbs while the pressure decreases from 1.2 bar. Operate the standalone pump and repressurize. The goal is
to be at or slightly above the nominal marker while having 1.2 bar of pressure.

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8.3.2 Grid Voltage Feedback Configuration

Grid voltage feedback is a critical component of AFE drives. It must be correctly connected and configured for an AFE drive to be
able to properly synchronize with the MV input supply voltage of the drive.
Grid voltage feedback is also necessary to perform the commissioning test. For the commissioning test to be done safely, it must be
able to detect whether there is mains power applied to the drive (that it is not powered).

1. Locate the grid voltage feedback connector on the AFE control unit. It is located next to the FO1–FO6 fiber optic slots.

e30bi770.10

Illustration 101: Grid Voltage Feedback Connector on the AFE Control Unit

2. Identify the type of potential transformer that is connected from the MV supply to the drive. The feedback configuration is
either Wye or Delta.
3. Connect the grid voltage feedback to the AFE control unit based on the PT type.
- If the PT is WYE configured:
Connect phase A to CH1.
Connect phase B to CH2.
Connect phase C to CH3.
Connect the reference to CHR.
Go to the 2.1.1 Line Configuration menu and do these parameter settings:
Grid Voltage FBK Ch A: AN phase voltage
Grid Voltage FBK Ch B: BN phase voltage
Grid Voltage FBK Ch C: CN phase voltage
- If the PT is Delta configured:
Connect phase A to CH1.
Connect phase B to CHR.
Connect phase C to CH3.
Leave CH2 empty.
Go to the 3.1.1 Line Configuration menu and do these parameter settings:
Grid Voltage FBK Ch A: AB line voltage
Grid Voltage FBK Ch B: Ground/reference
Grid Voltage FBK Ch C: CB line voltage
4. Set the other parameters in the 3.1.1 Line Configuration menu.
- a. Nominal Grid Voltage/Frequency: Set to the rated input voltage/frequency of the drive.
- b. Grid Voltage FBK Mode: Set to "Source Voltage".
-

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c. Grid Voltage FBK Scale: Set based on the expected voltage on the PT secondary. For example, a 35:1 PT ratio at
4160 V equals ≈ 118.8 V secondary voltage.
- d. Filter Topology: Set to "LCL".
- e. Regen Filter Select: Select based on the type of phase modules used in the drive.

For example, L20.4, where L20 is the phase module size (L20 or L30) and 4 stands for the input voltage (3=3300 V
and 4=4160 V).

- f. Special Filter Index: Set to 21000.

8.3.3 Installing Software on the Control Unit

To install the software, each control unit must be connected to separately. After finishing one software installation, disconnect the
cable and move it to the next control unit. Make sure that the correct control unit (AFE/INU/BCU) is connected to the PC.

Items required for the software installation:

• RS485 to USB cable.
• PC or laptop.
• The VACON® Live PC tool.
Download VACON® Live from .
1. Verify that the control unit is powered (the screen on the control panel is on).
2. Verify that the indicator light on the control unit is green (there are no faults).
- If the indicator light is green, skip to step #3.
- If the indicator light is red, check the number of the fault. If the fault code is 59 (communication fault), one or more of
the power modules is likely disconnected.
Before opening the cover of the power module section to check the connections, verify that medium voltage is
locked out.
Check the modules and verify that the fiber optic cables and the 24 V DC supply are properly connected.
Verify that all the indicator lights are lit on each of the modules.
When the communication fault is cleared, continue to the next step.
If there are still issues with the fault, refer to *INU and AFE phasing* procedure for troubleshooting.
3. To access the RS485 port, remove the control panel from the control unit.
4. Connect the RS485 end of the cable to the port on the control unit and the USB end to a PC.
5. Open the VACON® Live PC tool. When prompted for startup mode, select Online.
6. After VACON® Live completes searching for connected drives, select the drive, and click Connect to Selected.
e30bi772.10

Illustration 102: Connecting to the Drive with VACON® Live

7. After VACON® Live opens, save the current parameter settings.

- a. Open the File menu and select Save file as….
- b. Select an appropriate file name (for example, customer name_drive identity_date).
- c. Save the file into a folder/location that coincides with the contents of the file.

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8. Obtain an up-to-date software build directly from the Danfoss server or request one from the Danfoss software team.

The software build is a file with a ".vcx" extension.

9. Click this file, and VACON® Loader opens automatically. If VACON® Live is still open, you are prompted to close it.
10. Click Next to begin.
11. The same procedure as in VACON® Live for connecting to the drive occurs (step 6). After searching for connected drives is
completed, select the drive, and click Connect to Selected.
12. Select the appropriate modules to be installed. The modules selected vary depending on the control unit and the drive
type.

e30bi773.11

Illustration 103: Selecting the Modules to Install in VACON® Loader

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- Modules to install for AFE control unit in AFE drive

Control firmware
Control firmware (part2)
Select appropriate language
AFE AVUS1253AFE application
M-star firmware
Network configuration
Filter parameters
Belt 1 A phase firmware
Belt 1 B phase firmware
Belt 1 C phase firmware
If the AFE drive has a parallel module configuration, also select the following modules:
Belt 2 A phase firmware
Belt 2 B phase firmware
Belt 2 C phase firmware
If the AFE drive has an Auxiliary I/O board, select the following modules:
Channel 5 Index 1 AUX firmware
No position 2 firmware
No position 3 firmware
If the AFE drive has no Auxiliary I/O board, select the following modules:
No position 1 firmware
No position 2 firmware
No position 3 firmware
- Modules to install for INU control unit in AFE drive
Control firmware
Control firmware (part2)
Select appropriate language
INU AVUS1252INU application
M-star firmware
Network configuration
Filter parameters
Belt 1 A phase firmware
Belt 1 B phase firmware
Belt 1 C phase firmware
If the drive has a parallel module configuration, select the following modules:
Belt 2 A phase firmware
Belt 2 B phase firmware
Belt 2 C phase firmware
For the INU control unit of an AFE drive, there are no Auxiliary I/O board settings since the Auxiliary I/O board is already
connected to the AFE control unit. Select the modules:
No position 1 firmware
No position 2 firmware
No position 3 firmware
- Modules to install for INU control unit in 12-pulse drive
Control firmware

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Control firmware (part2)

Select appropriate language
INU AVUS1252INU application
M-star firmware
Network configuration
Filter parameters
Belt 1 A phase firmware
Belt 1 B phase firmware
Belt 1 C phase firmware
If the drive has a parallel module configuration, select the following modules:
Belt 2 A phase firmware
Belt 2 B phase firmware
Belt 2 C phase firmware
If the 12-pulse drive has an Auxiliary I/O board, select the following modules:
Channel 5 Index 1 AUX firmware
No position 2 firmware
No position 3 firmware
Also select the following modules:
Channel 5 Index 1 CBL firmware
No position 2 firmware
No position 3 firmware
- Modules to install for CBU control unit in 12-pulse drive (optional)
Control firmware
Control firmware (part2)
Select appropriate language
BCU AVUS1260BCU application
Single unit network configuration
Belt 1 A phase firmware
13. When the appropriate modules are selected, click Next to begin the installation.

The loading time takes upwards of 30 minutes to complete depending on how many modules are loaded.

14. After the loading is completed, click Yes to close VACON® Loader.
15. If the loading fails to reach 100% completion and stops, try again starting from step 8. Before attempting to reinstall:
- a. Check that the core board is fully seated on the auxiliary I/O board.
- b. Check that the fiber cable from the auxiliary I/O board to the appropriate control unit is connected in the correct
ports at both ends.
16. After the software loading is completed, perform a parameter compare between the new parameter set and the parameter
settings saved in step 7.

See the instructions for comparing the parameters in the VACON® 3000 Application Guides.

8.3.4 Verifying the Phase Module Connections

Before running the drive for the first time, verify the phasing of the INU and/or AFE modules. The verification is done both physically
(cabling, busbars) and electrically (identified with 24 V DC control power and fiber optic communication cables).

1. Obtain a copy of the mechanical drawings of the drive and identify the locations of the phase modules.
2. Perform a continuity check of the phase module terminal connections.
-

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a. For INU modules, check the continuity of the connections from the output on the phase module to its correspond-
ing output busbar terminal.
- b. For AFE modules, check the continuity of the connections from the output to the L1, L2, L3 busbars where the
main input supply voltage cables are mounted.
- c. For dual-belt drives, do the same for the other belt.
3. Verify, that the fiber optic cables are connected properly between the control units and phase modules.

The fiber from the FO1 slot on the control unit connects to the fiber connector A on either the INU U-phase module or the
AFE L1-phase module. The control unit automatically designates the phase module connected to FO1 as a U-phase mod-
ule (if INU control unit) or L1-phase module (if AFE control unit).
See 7.8 Optical Fiber Connections.

4. For the remaining module-to-module connections, connect the optical fiber from connector B of the U-phase module to
connector A of the next module (which is then designated as V-phase). Then connect the optical fiber from connector B of
the V-phase module to connector A of the next module (W-phase). Leave connector B of the last module (W-phase) empty.

The AFE connections are the same, except the designations for the modules are L1, L2, and L3.

5. If the connections are correct and control power is applied, then the phase modules show the correct belt and phase infor-
mation on the 4-character LED displays.

In the operation mode, the LED display view changes at an interval of 3 s. The display changes between the belt informa-
tion indicator and the module information indicator. See 6.2.7 LED Display on the Phase Module.

- INU, belt 1
Module 1: __B1 and _2_U
Module 2: __B1 and _3_V
Module 3: __B1 and _4_W
INU, belt 2 (if applicable)
Module 4: __B2 and _5_U
Module 5: __B2 and _6_V
Module 6: __B2 and _7_W
- AFE, belt 1
Module 1: __B1 and _2L1
Module 2: __B1 and _3L2
Module 3: __B1 and _4L3
AFE, belt 2 (if applicable)
Module 4: __B2 and _5L1
Module 5: __B2 and _6L2
Module 6: __B2 and _7L3
6. Confirm that the identification on the LED displays matches the correct input or output terminal that the phase module is
connected to.

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8.3.5 Commissioning Test

The commissioning test verifies that the drive can be successfully operated without applying medium voltage to the main power
terminals (L1, L2, L3). The purpose of the test is to verify operation of the system interlocks and that the pre-charge circuit can close
the contactor that supplies medium voltage to the drive.
• This test does not power up the drive.
• This test does not run if:
- Medium voltage is detected on the input to the mains contactor.
- The pre-charge unit has 480 V AC supply power and is connected to the circuit.
• If either of these two conditions is present, the control unit generates a fault.
The following procedures must be completed before performing the commissioning test:
• INU/AFE module installation.
• INU/AFE phasing (see 8.3.4 Verifying the Phase Module Connections).
• Software download (see 8.3.3 Installing Software on the Control Unit).
• Cooling fluid addition (see 8.3.1 Filling the Liquid Cooling System).
• Insulation test of the MV input and output cables.
• Grid voltage feedback configuration (see 8.3.2 Grid Voltage Feedback Configuration).

Remove power from the input to the main supply power contactor or main circuit breaker (MCB).
The drive controls switchgear external to the drive to supply utility voltage to the drive. There is no main circuit breaker internal to
the drive that opens/closes the voltage on the supply terminals (L1, L2, L3). The lockout/tagout procedure must be properly per-
formed.
1. To prevent accidental charging of the DC link, open the circuit breaker that supplies 480 V AC to the pre-charge unit.
2. Verify that there was no mistake in the control power wiring and that there is no shock hazard.
- a. On the INU phase modules, disconnect the 24 V DC connector.

See 6.2.1 Phase Module L20/L30 Terminals.

- b. Use a DMM in V AC mode and measure from the +24 V and 0 V terminals to GND.
3. Verify that the "breaker enable" DIP switches are in the correct position.

The DIP switches (S1) are on the INU/AFE control unit between fiber optic connectors FR1 and FR2. These two fiber optic
inputs are used for the "breaker enable" function. If the DIP switches are in the correct position, a green LED next to the
switches is on.
e30bi775.10

LED
S1
BYPASS

ON
FR1 FR2
Illustration 104: "Breaker Enable" Connectors, DIP Switches, and LED

- If the "breaker enable" function is not used, the fiber optic connectors are plugged. Check that both DIP switches are in
the "bypass" position.

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- If one or both of the "breaker enable" inputs are used, then the corresponding DIP switches must be in the "on" posi-
tion.
4. In VACON® Live, make sure that “PCC Gating Enabled” is checkmarked in the Precharge Status Word. If the breaker enable
is not properly set, then the commissioning test fails due to failure to receive MX close feedback.

Location of PreCharge Status Word in the menu:

- INU application: V2.12.4
- AFE application: V2.10.4

5. Set the Commissioning test mode parameter to Enable.

Parameter location in the menu:

- AFE drives: P3.3.5.3
- 12-pulse drives (INU application): P3.17.5.3

6. Perform the commissioning test with the VACON® Live PC tool. See 8.3.5.1 Commissioning Test with VACON® Live.

8.3.5.1 Commissioning Test with VACON® Live

1. In VACON® Live, go to the Precharge monitoring menu. To see if the drive is ready to attempt a commissioning test, check
the monitoring values Precharge State and PowerOn State.

AFE application:
- Precharge monitoring menu: M2.10
- Precharge State monitoring value: V2.10.1
- PowerOn State monitoring value: V2.10.5.1
INU application (12-pulse):
- Precharge monitoring menu: M2.12
- Precharge State monitoring value: V2.12.1
- PowerOn State monitoring value: V2.12.5.1

 If either of the two values is not in "ready" state, then an interlock is active and must be resolved before the com-
missioning test can be attempted. Determine what is missing (which unchecked box must be checked), and check
the hardware and/or I/O settings of the device which is failing to give the required feedback.
2. Right-click the PowerOn State parameter, select To Monitoring, and then New Monitor. This value is then used to determine
whether the commissioning test is completed successfully.

 If Precharge State and PowerOn State are both "ready", then PowerOn State has a value of "3" when viewed with
the monitoring function.
3. Give the system a "power on" command.
- a. Go to the Internal Control menu.
- b. Change the value of parameter Power Off to "DigIN Slot0.2".
- c. Change the value of parameter Power On to "DigIN Slot0.2".

AFE application:
- Internal Control menu: M3.3.2.2
- Power Off parameter: P3.3.2.2.2
- Power On parameter: P3.3.2.2.1
INU application (12-pulse):
- Internal Control menu: M3.17.2.2
- Power Off parameter: P3.17.2.2.2
- Power On parameter: P3.17.2.2.1

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4. Check that the cooling system starts.

- a. Check that the drive of the heat exchanger runs and the HX circulates the coolant.
- b. Check that the PowerOn State changes to "4" when the HX starts.
5. Keep monitoring PowerOn State. After a while, the system starts to pre-charge the DC link. In reality, there is no voltage
being generated in the DC link. The value set in parameter DC Precharge Timeout starts to count down. PowerOn State
shows a value of "5" during the countdown.

The location of the DC Precharge Timeout parameter:

- AFE application: P3.3.4.9
- INU application (12-pulse): P3.17.4.9

6. Keep monitoring PowerOn State. After the time programmed into DC Precharge Timeout elapses, the mains contactor
closes, and PowerOn State changes states to 6, 7, and 8 in succession.

- State 6 indicates completion of precharge and closing of the mains contactor.

- State 7 indicates opening of the precharge contactor.
- State 8 indicates that the drive is now ready to be issued a start command to operate the motor and that the commis-
sioning test was successful.

e30bi778.10

Illustration 105: Monitoring the PowerOn State Parameter

7. After the mains contact has been closed, give the system a "power off" command by changing Power On and Power Off in
the Internal Control menu back to "DigIN Slot0.1".
8. Test that the interlocks function correctly and the circuit breaker opens as expected.
- a. Check that the main circuit breaker cannot be closed manually.
- b. Give the system a Power On command.
- c. Turn off the cooling, and check that the breaker opens.
- d. Check that PCC interlock opens the breaker.
-

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e. Check that other customer interlocks open the breaker.

D A N G E R
INTERLOCK BYPASS
Bypassed interlocks can lead to safety functions not working properly. This causes a risk of electric shock and damage to
the equipment.
- If any interlock is bypassed at some point during installation or commissioning, make sure that it is reconnected
afterwards.

9. Set the Commissioning Test Mode parameter to Disabled.

8.3.6 AFE Synchronization Test

D A N G E R
SHOCK HAZARD DURING TEST
It is necessary to keep the cabinet doors open for this test. Measuring instruments are attached on cabling or busbars which have
live medium voltage during the test. Contact with this voltage can lead to death or serious injury.
- Perform proper lock-out and tag-out procedure before the test setup. Stay away from the drive while the test is being per-
formed.

The purpose of this test is to verify that the AFE can properly synchronize to the voltage and phase of the main voltage supply. This
test does not apply to 12-pulse (DFE) drives.
Important notes about this test:
• The mains contactor does not close during this test.
• The control unit pre-charges the DC link during this test.
• The performing of this test can conflict with safety regulations. Special allowances to perform this procedure must be discussed
before the beginning of commissioning.

Perform the commissioning test before this test. See 8.3.5 Commissioning Test.
An oscilloscope is required to record the voltage waveforms on each side of the mains contactor.
1. The main contactor is not housed inside the drive cabinet. Instrumentation must be done in the switchgear cabinet of the
end user, which can conflict with the electrical safety regulations of the facility, and access may not be permitted.
- If it is possible to make the instrumentation in the switchgear cabinet, connect the oscilloscope on each side of the
mains contactor.
MV supply voltage L1-L2: Connect red probe to L1 and black probe to L2 on the input side of the contactor.
MV supply voltage L2-L3: Connect red probe to L2 and black probe to L3 on the input side of the contactor.
AFE voltage L1-L2: Connect red probe to L1 and black probe to L2 on the output side of the contactor.
AFE voltage L2-L3: Connect red probe to L2 and black probe to L3 on the output side of the contactor.
e30bi786.10

Oscilloscope
+- +- +- +-

Contactor
L1
L2
L3

Illustration 106: Oscilloscope Connections for the Voltage Measurements

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- If access to the switchgear cabinet is not permitted, the 120 V AC signal from the grid voltage feedback must be com-
pared with the voltage captured on L1/L2/L3. Thus, all scope testing points are local to the drive.
Instrument the scope to L1/L2, L2/L3, and the corresponding phases coming from the stepped down LV side of the PT.
The stepped down voltages connect to the grid voltage feedback connector on the AFE control unit.

e30bi787.10
Switchgear cabinet Drive cabinet Oscilloscope
L1
+- +- +- +-
L2

L3

3
PT CNU-AFE

GND/PE GND/PE

Illustration 107: Alternative Oscilloscope Connections for the Voltage Measurements

2. Configure the oscilloscope.

- a. Set 5 kV per division (Y-axis) on the channels measuring L1/L2 and L2/L3 voltages (output side of MV feeder cabi-
net).
- b. Set 200 V per division on the channels measuring the MV supply voltage through PT secondaries (corresponding
to input side of contactor in MV feeder cabinet).
- c. Set the time base to 10 ms per division (X-axis).
- d. Set the trigger to the rising edge on either channel of the output (AFE side). 1500 V is enough.
3. Open the grounding switch.
4. To prevent the drive from closing the main contactor that links the AFE output to the MV supply, set the parameter P3.3.5.4
Synchronization Test Mode on the AFE control unit to "Enable".
5. Apply power to the auxiliary voltage input of the drive. Verify that the necessary circuit breaker to activate the pre-charge
unit is closed. If applicable, do the same for the cooling system (HX).

Auxiliary voltage required for the pre-charge:

- 3300 V drives: 380–440 V ±10%
- 4160 V drives: 460–480 V ±10%
In the example diagram, the circuit breakers FC11 and FC12 must be closed.
L1 L2 L3 PE AUXILARY VOLTAGE INPUT
e30bi789.10

400VAC, 50/60Hz
FC11

PE
PE

HXL-L1
HXL-L2
HXL-L3
FC12

Pre-Charge
L1 L2
Assembly
S1 A1+

S2 A2-
DC+DCMID DC-

DC+
DCN
DC-

Illustration 108: Circuit Breakers for the Auxiliary Supply

6. Apply MV supply power to the input of the contactor.

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7. Verify that this voltage is visible in VACON® Live. Go to the M2.3 AFE Monitor menu and M2.3.2 Line PLL.

 The line voltage and line frequency must correspond to the rated input of the drive. If it does not, the grid voltage
feedback is not properly set up and the power on command does not become available.
The MV supply voltages are the yellow and pink waveforms in the screen capture. The AFE outputs are flat, since
the drive is not operating. When operating properly, the AFE waveforms almost perfectly superimpose on top of
the mains waveforms.

e30bi790.10
Illustration 109: MV Supply Voltage Waveforms

8. Start any other auxiliary systems needed for operation.

9. Make sure that there are no interlocks preventing the drive from being able to start.

The drive does not actually start in synchronization test mode.

10. Give the system a "Power Up" command.

 After the "Power Up" command is received:

-
If all the interlocks are made, the power-up sequence starts.
The cooling system starts.
The pre-charge circuit charges the DC-link.
The AFE activates to generate voltage on the downstream side of the mains contactor.
After approximately a second of operating the AFE, the system trips on "pre-charge supervision" because
the pre-charge sequence was interrupted (no contactor feedback).

11. Compare the mains voltage to the AFE generated voltage. The AFE generated voltage must complete the synchronization
by its 4th cycle from start up.
e30bi791.10

Illustration 110: Synchronization Test Screen Capture

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12. Use the zoom function of the scope and look at the 0 V crossing. Measure the approximate time delay using the cursor
function.

 The waveforms must match with a delay of less than 100 μs. In the example, the delay is ~52 μs on the L2-L3 phase
and even less on L1-L2 phase. This result is good and no further tuning is required.

e30bi792.10
Illustration 111: Acceptable Time Delay

If the delay is more than 100 μs, adjust the Ref Frame Adapt Angle parameter P3.2.5.5 on the AFE control unit.
Perform the test again until an acceptable result is reached. The typical adjustment range is between -5 and +5.

e30bi793.10

Illustration 112: Unacceptable Time Delay

13. After successfully matching the waveforms, set parameter P3.3.5.4 Synchronization Test Mode on the AFE control unit to
"Disable".
14. The AFE now requires tuning to optimize the power factor of the drive. The same parameter that was adjusted in the syn-
chronization test is used for this procedure.
- a. Confirm that the drive is ready to be fully energized.
- b. Close the mains contactor.
- c. Energize the drive, but the drive does not need to output voltage to the motor.
15. In VACON® Live, monitor the V2.3.3.3 Grid Active Current while adjusting the Ref Frame Adapt Angle parameter P3.2.5.5.

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16. While adjusting the Ref Frame Adapt Angle, take note of which direction the current goes. Adjust the angle so that the
Grid Active Current is close to zero.

e30bi794.10
0 0

Illustration 113: Monitoring Grid Active Current while adjusting Ref Frame Adapt Angle

17. To measure the synchronization delay again, reperform the synchronization test.

 If the delay is over 100 μs, it is acceptable as long as the drive does not trip at energization. For operation purposes,
the tuning to minimize Grid Active Current takes higher priority because it affects power factor.

8.3.7 Encoder Setup

Closed loop Vector Control requires an encoder installed on the motor. The encoder wiring is connected to channel A on the INU
control unit. The objective of this procedure is to verify that the encoder wiring is connected to the proper terminals and to set the
encoder parameters in the INU control unit.

1. Locate the encoder terminal blocks on the INU control unit. The encoder wiring is connected to channel A (unless a 2nd
control unit is set up as a follower).

See 7.10 Encoder Interface.

2. Obtain the pinout diagram for the encoder connector.

3. Connect the encoder wiring to the corresponding position on the control unit terminal block.

See 7.10.1 Encoder Terminals and Signals.

4. Set the encoder jumpers on the control unit according to the specifications.

See 7.10.2 Encoder Jumper Configurations.

5. Use the VACON® Live PC tool to connect to the INU control unit.
6. Open menu M3.15 Encoders and set the encoder parameters.
- a. Set parameter P3.15.4.9 Encoder Resolution.
- b. Set parameter P3.15.4.10 Motor Pole Pairs.
- c. Set parameter P3.15.4.13 Filter Time Constant.
- d. The rest of the parameters can most likely remain at default settings.
7. Test the encoder in open loop configuration.
- a. Open the menu M3.1.2 Motor Control and set the parameter P3.1.2.1 Control Mode to "OL Speed Ctrl".
- b. Open the menu M3.1.5 Flux Vector Control and set the parameter P3.1.5.1 Sensorless Ctrl to "Disabled".
8. Use the VACON® Live monitoring to verify that the encoder feedback (V2.10.3.6 Encoder Elec. Freq.) matches the output
frequency of the drive (V2.3.1 Output Frequency) while the drive is in operation. Confirm the matching values up to 100%
speed through monitoring.
9. When the encoder operation is confirmed, stop operation of the drive.
10. Set the drive to closed-loop operation.
- a. Open the menu M3.1.5 Flux Vector Control and set the parameter P3.1.5.1 Sensorless Ctrl to "Enabled".
-

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b. Set the Sensorless Ctrl Options with parameter P3.1.5.3.

Make sure that these options are selected:

- "Ena Flux Controller"
- "Use Curr Ref. in Model"
- "Ena Ramp AntiWindup"
- "Ena CL Control"
- "CL Flying Start"

8.4 Insulation Resistance Measurements

8.4.1 Measuring the Switchgear Insulation Resistance

The measurement of the switchgear insulation resistance is a standard procedure.
Measure the insulation resistance and refer to the test voltages in Table 53. Use Megger test equipment or an equivalent instrument
for the measurement. Make sure that the test device can supply a 1 mA current at the measurement voltages.
Before the measurement:
• Disconnect the N/PE (PEN) connection (TN-C-S systems only).
• Open the grounding switch (GSW).
• If the circuit contains AC drives, only do the measurement from L1-L2-L3-(N) to frame.
• Measure the insulation resistance between all connected phases (also N) and the frame.
During measurement, make sure that the switches are in the off position and that there are fuses installed. Make sure that the
switchgear is in normal operation condition but with all operated equipment (for example, motors) disconnected.

Table 53: Insulation Resistance Measurement Voltages and the Minimum Permitted Insulation

Circuit Un Test voltage Insulation resistance(1)

≤ 500 V 500 V DC ≥ 0.5 MΩ

> 500 V 1000 V DC ≥ 1.0 MΩ

1 The number of devices connected can lower the values. If the results are much lower than the values in the table, speak to the manufacturer.

8.4.2 Measuring the Cable and Motor Insulation

Do these checks if necessary.
NOTE! AC drive is already measured at the factory.
• The insulation checks of the motor cable, see 8.4.2.1 Insulation Checks of the Motor Cable
• The insulation checks of the mains cable, see 8.4.2.2 Insulation Checks of the Mains Cable
• The insulation checks of the motor, see 8.4.2.3 Insulation Checks of the Motor

8.4.2.1 Insulation Checks of the Motor Cable

Use these instructions to check the insulation of the motor cable.

Procedure
1. Disconnect the motor cable from the terminals U, V, and W and from the motor.
2. Measure the insulation resistance of the motor cable between phase conductors 1 and 2, between phase conductors 1 and
3, and between phase conductors 2 and 3.
3. Measure the insulation resistance between each phase conductor and the grounding conductor.
4. The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

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8.4.2.2 Insulation Checks of the Mains Cable

Use these instructions to check the insulation of the mains cable.

Procedure
1. Disconnect the mains cable from the terminals L1, L2, and L3 and from mains.
2. Measure the insulation resistance of the mains cable between phase conductors 1 and 2, between phase conductors 1 and
3, and between phase conductors 2 and 3.
3. Measure the insulation resistance between each phase conductor and the grounding conductor.
4. The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

8.4.2.3 Insulation Checks of the Motor

Use these instructions to check the insulation of the motor.

N O T I C E
Obey the instructions of the motor manufacturer.

Procedure
1. Disconnect the motor cable from the motor.
2. Open the bridging connections in the motor connection box.
3. Measure the insulation resistance of each motor winding. The voltage must be the same or higher than the motor nominal
voltage, but at least 1000 V.
4. The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).
5. Connect the motor cables to the motor.
6. Do the final insulation check on the drive side. Put all phases together and measure to the ground.
7. Connect the motor cables to the drive.

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9 Maintenance
9.1 Preventive Maintenance Recommendations
Generally, all technical equipment, including Danfoss AC Drives, need a minimum level of preventive maintenance. Regular mainte-
nance is recommended to ensure trouble-free operation and long life of the drive. It is also recommended, as a good service prac-
tice, to record a maintenance log with counter values, date, and time describing the maintenance and service actions.
Danfoss recommends the following inspections and service intervals for liquid-cooled drive/system.
NOTE: The service schedule for part replacements can vary depending on operation conditions. Under specific conditions, the com-
bination of stressful operating and environment conditions work together to significantly reduce the lifetime of the components.
These conditions can include, for example, extreme temperature, dust, high humidity, hours of use, corrosive environment, and
loading.
For operation in stressful conditions, Danfoss offers the DrivePro® Preventive Maintenance service. DrivePro® services extend the
lifetime and increase the performance of the product with scheduled maintenance including customized part replacements. Drive-
Pro® services are tailored to your application and operating conditions.

Table 54: Maintenance Schedule for Liquid-cooled Drives

Component Inspec- Service Preventive maintenance actions

tion in- schedule(2)
terval(1)

Installation

Visual drive in- 1 year – Check for the unusual, for example, for signs of overheating, aging, corrosion, and
spection for dusty and damaged components.

Auxiliary equip- 1 year According Inspect equipment, switchgear, relays, disconnects, or fuses/circuit breakers. Exam-
ment to manufac- ine the operation and condition for possible causes of operational faults or defects.
turer recom- The continuity check on fuses is performed by trained service personnel.
mendations

EMC considera- 1 year – Inspect the installation wiring regarding the electromagnetic capability and the
tion separation distance between control wiring and power cables.

Cable routing 1 year According Check for parallel routing of motor cables, mains wiring, and signal wiring. Parallel
to manufac- routing must be avoided. Avoid routing cables through free air without support.
turer recom- Check for aging and wearing of the cable insulation.
mendations

Control wiring 1 year – Check for tightness, damaged or crimped wires or ribbon wires. The connections
should be terminated correctly with solid crimped ends. The use of shielded cables
and grounded EMC plate, or a twisted pair is recommended.

Proper clearan- 1 year – Check that the required external clearances for proper airflow for cooling are fol-
ces lowed according to the frame designation and drive type of the drive. For clearan-
ces, refer to the local design regulations.

Seals condition 1 year – Check that the seals of the enclosure, the covers, and the cabinet doors are in good
condition.

Corrosive envi- 1 year – Aggressive gases, such as sulphide, chloride, and salt mist can damage the electri-
ronments cal and mechanical components. Air filters do not remove airborne corrosive
chemicals. Act based on findings.

Drive

Programming 1 year – Check that the AC drive parameter settings are correct according to the motor,
drive application, and I/O configuration. Only trained service personnel may per-
form this action.

Control panel 1 year – Check that the display pixels are intact. Check the event log for warnings, alarms,
and faults. Repetitive events are a sign of potential issues. Contact your local serv-
ice center.

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Component Inspec- Service Preventive maintenance actions

tion in- schedule(2)
terval(1)

Drive cooling 1 year – Check for blockages or constrictions in the air passages of the cooling channel. The
capacity channels must be free of dust and condensation.

Cleaning and 1 year – The interior of the enclosure must be cleaned annually, and more frequently if nec-
filters essary. The level of dust in the filter, inside the enclosure, or in the internal fans
between cabinets is an indicator for when the next cleaning or filter replacement is
required.

Fans 1 year 5 years Inspect the condition and operational status of all cooling fans. With the power off,
the fan axis should feel tight, and spinning the fan with a finger, the rotation
should be smooth and almost silent. When in RUN mode, fan vibration, excessive
or strange noise is a sign of the bearings wearing, and the fan must be replaced.

Grounding 1 year – The drive system requires a dedicated ground wire connecting the drive, the out-
put filter, and the motor to the building ground. Check that the ground connec-
tions are tight and free of paint or oxidation. Daisy-chain connections are not al-
lowed. Braided straps are recommended if applicable.

PCB 1 year 10–12 years Visually inspect the PCBs for signs of damage or degrading due to aging, corrosive
environments, or environments with high temperatures. Only trained service per-
sonnel may perform the inspection and service action.

Power cables 1 year According Check for loose connections, aging, insulation condition, and proper torque to the
and wiring to manufac- drive connections. Check for proper rating of fuses and continuity check. Observe
turer recom- if there are any signs of operation in a demanding environment. For example, dis-
mendations coloration of the fuse housing can be a sign of condensation or high temperatures.

Vibration 1 year – Check for abnormal vibration or noise coming from the drive to ensure that the
environment is stable for electronic components.

Insulator gas- 1 year 10–15 years Inspect the insulators for signs of degradation due to high temperature and aging.
kets Replacement is based on findings. Only trained service personnel may perform this
action.

Batteries 1 year 7–10 years Replace the batteries according to manufacturer recommendations. Replace the
RTC battery in the control unit every 7–10 years.

Spare Parts

Spare parts 1 year 2 years Stock spares in their original boxes in a dry and clean environment. Avoid hot stor-
age areas.

Exchange units 1 year 2 years Visually inspect for signs of damage, water, high humidity, corrosion, and dust
within the visual field of view without disassembly. The exchange units with
mounted electrolytic capacitors require reforming as stated in the service sched-
ule. The reforming is performed by trained service personnel.

Coolant

Log Commis- – Record the water quality specification values to create a baseline for future refer-
sioning/ ence before and after adding inhibitor and glycol. Also record the system pressure,
start-up, coolant flow rate, temperature range, and create a baseline for future reference.
or at time
of replac-
ing liquid
coolant

Glycols 1 year Based on Measure and record the level of glycol in the cooling system. The minimum con-
findings centration level is always 75/25% demineralized water/glycol.

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Component Inspec- Service Preventive maintenance actions

tion in- schedule(2)
terval(1)

Corrosive in- 1 year Based on Measure and record the level of Danfoss recommended corrosive inhibitor (Cortec-
hibitors findings VpCI-649) in the liquid coolant (see specification). The level of inhibitor must be
measured every year. If inhibitor is below the 1% recommended level, practice
caution before adding more inhibitor to not exceed the level of electrical conduc-
tivity.

Pre-mixed gly- 1 year Based on The pre-mixed coolants contain specific percentages of glycol and inhibitor for an-
col and inhibi- findings tifreeze and corrosion protection. The advantage of using a pre-mixed coolant is
tor coolant that the chemical composition is within Danfoss specifications, and there is no
need for analyzing the coolant.

Demineralized 1 year Based on Only use demineralized or deionized water in the coolant solution. Record and
water findings compare the chemical composition values when replacing or adding coolant.

Liquid Cooling System

Pipes, hoses, 1 year 1 year Check for external signs of moisture, corrosion, and coolant leaks. Check the tight-
and connec- ness of the cooling pipe connections. Check the heat sinks and host pipes in the
tions cooling system.

Leak detector 1 year 10 years Test the functioning of the leak detector.

Power unit 1 year 6 years Under normal conditions, the heat sinks must be cleaned or acid-washed every 6
heat sinks years with Danfoss recommended cleaning products. Refill the coolant system and
log the new coolant specification values.

Auxiliary equip- 1 year According Check that the sensors, gauges, and indicators are functioning correctly. Act based
ment to manufac- on findings.
turer recom-
mendations

System cooling 1 year Based on Test the cooling capacity and the thermal transfer of the system. Record the cool-
capacity findings ant system flow, pressure, and input and output temperature, and compare to the
previous measurements. Act based on findings.

1 Defined as the time after the commissioning/start-up or the time from the previous inspection.
2 Defined as the time after the commissioning/start-up or the time from the previous service schedule actions.

9.1.1 Maintenance Log for Cooling System

During the commissioning phase of the product and during each inspection refer to the maintenance schedule. Record values such
as the ambient air temperature, system pressure, flow, and input/output cooling liquid temperature during run condition. Record
the water chemical analysis values and the type and percentages of glycol and inhibitor or pre-mixed solutions of the liquid coolant.
The initial values create a base-line value to compare versus future values measured during preventive maintenance intervals. Re-
cord the chemical analysis values each time the liquid coolant is replaced. Record all the maintenance tasks and service tasks with
counter values, date, and time.

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Operating Guide Fault Tracing

10 Fault Tracing
10.1 Fault Types
When the control diagnostics of the AC drive find an unusual condition in the operation of the drive, the drive shows a notification
about it. The notification can be seen on the display of the control panel. The display shows the code, the name, and a short descrip-
tion of the fault or alarm.
The source info tells the source of the fault, what caused it, where it occurred, and other data.
There are 3 different types of notification.
• An info does not affect the operation of the drive. The info must be reset.
• An alarm informs of unusual operation on the drive. It does not stop the drive. The alarm must be reset.
• A fault stops the drive. The drive must be reset and find a solution to the problem.
It is possible to program different responses for some faults in the application.
Reset the fault with the [BACK/RESET] button on the keypad, or through the I/O terminal, fieldbus, or PC tool. The faults stay in the
Fault history where they can be examined. See the different fault codes in 10.2 Faults and Alarms.
Before contacting the distributor or the factory because of unusual operation, prepare some data. Write down all the texts on the
display, the fault code, the fault ID, the source info, the Active Faults list, and the Fault History.

10.2 Faults and Alarms

10.2.1 Fault Code 1 - Overcurrent

10.2.1.1 Fault Code 1, ID 1 - Overcurrent (Hardware Fault)

Cause
There is too high a current (> 4 × IH) in the motor cable.
• a sudden heavy load increase
• a short circuit in the motor cables
• the motor is not the correct type
• the parameter settings are not properly made
Troubleshooting
• Check the loading.
• Check the motor.
• Check the cables and connections.
• Make an identification run.
• Set the acceleration time longer (P3.4.1.2 and P3.4.2.2).

10.2.1.2 Fault Code 1, ID 2 - Overcurrent (Software Fault)

Cause
If the current limit controller draws the output frequency down to zero and the current is still over the current limit, this fault is
generated after 1 s.
Troubleshooting
• Check the loading.
• Check the motor.
• Check the cables and connections.
• Make an identification run.
• Set the acceleration time longer (P3.4.1.2 and P3.4.2.2).

10.2.1.3 Fault Code 1, ID 4 - Phase Overcurrent

Cause
The phase current is too high.

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Operating Guide Fault Tracing

Troubleshooting
• Check the loading.
• Check the motor.
• Check the cables and connections.
• Make an identification run.
• Set the acceleration time longer (P3.4.1.2 and P3.4.2.2).

10.2.2 Fault Code 2 - Overvoltage

10.2.2.1 Fault Code 2, ID 10 - Overvoltage (Hardware Fault)

Cause
The DC link voltage is higher than the limits.
• too short a deceleration time
• high overvoltage spikes in the supply
Troubleshooting
• Set the deceleration time longer (P3.4.1.3 and P3.4.2.3).
• Use a brake chopper. It is available as an option.
• Activate the overvoltage controller.
• Check the input voltage.

10.2.2.2 Fault Code 2, ID 11 - Overvoltage (Software Fault)

Cause
The DC link voltage is higher than the limits.
• too short a deceleration time
• high overvoltage spikes in the supply
Troubleshooting
• Set the deceleration time longer (P3.4.1.3 and P3.4.2.3).
• Use a brake chopper. It is available as an option.
• Activate the overvoltage controller.
• Check the input voltage.

10.2.2.3 Fault Code 2, ID 13 - DC+ Overvoltage

Cause
The positive DC-link voltage is higher than the limits.
• too short a deceleration time
• high overvoltage spikes in the supply
Troubleshooting
• Set the deceleration time longer (P3.4.1.3 and P3.4.2.3).
• Use a brake chopper. It is available as an option.
• Activate the overvoltage controller.
• Check the input voltage.

10.2.2.4 Fault Code 2, ID 14 - DC- Overvoltage

Cause
The negative DC-link voltage is higher than the limits.
• too short a deceleration time
• high overvoltage spikes in the supply

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Operating Guide Fault Tracing

Troubleshooting
• Set the deceleration time longer (P3.4.1.3 and P3.4.2.3).
• Use a brake chopper. It is available as an option.
• Activate the overvoltage controller.
• Check the input voltage.

10.2.2.5 Fault Code 2, ID 16 - DC-Link Overvoltage

Cause
The DC-link voltage is too high for the motor.
Troubleshooting
• Set the deceleration time longer (P3.4.1.3 and P3.4.2.3).
• Use a brake chopper. It is available as an option.
• Activate the overvoltage controller.
• Check the input voltage.

10.2.3 Fault Code 3 - Earth Fault

10.2.3.1 Fault Code 3, ID 20 - Earth Fault (Hardware Fault)

Cause
The ground current sensor has detected a too high current flowing to the ground or the current measurement has detected that
the sum of output phase currents is not zero (0 A).
• an insulation malfunction in the cables or the motor
• a filter (dU/dt, sine) malfunction
Troubleshooting
• Check the motor cables and the motor.
• Check the filters.

10.2.3.2 Fault Code 3, ID 21 - Earth fault (Software Fault)

Cause
The ground current sensor has detected a too high current flowing to the ground or the current measurement has detected that
the sum of output phase currents is not zero (0 A).
• an insulation malfunction in the cables or the motor
• a filter (dU/dt, sine) malfunction
Troubleshooting
• Check the motor cables and the motor.
• Check the filters.

10.2.3.3 Fault Code 3, ID 22 - Ground Fault

Cause
The DC link neutral to ground voltage is higher than the fault level.
Troubleshooting
• Check the motor cables and the motor.
• Check the filters.

10.2.4 Fault Code 5 - Charging Switch

10.2.4.1 Fault Code 5, ID 40 - Charging Switch

Cause
The charging switch is closed and the feedback information is OPEN.

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Operating Guide Fault Tracing

The fault is hardware triggered. The feedback signal is compared to the control signal.
• operation malfunction
• defective component
Troubleshooting
• Reset the fault and restart the drive.
• Check the feedback signal and the cable connection between the control unit and the power unit.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.5 Fault Code 7 - Saturation

10.2.5.1 Fault Code 7, ID 60 - Saturation

Cause
The fault is hardware triggered. The fault is detected by measuring the collector to emitter voltage on the IGBT module. Excessive
voltage when the IGBT is on indicates excess current flow.
• Defective IGBT.
• An IGBT does not execute its operation.
• De-saturation short circuit in the IGBT.
• A short circuit or an overload in the brake resistor.
• Noise issues can cause saturation faults.
• Extreme temperatures can cause saturation faults
Troubleshooting
• Check the source information for the fault. It indicates which module to check.
• This fault cannot be reset from the control panel.
• Switch off the power.
• After switching off the power from the drive, including the control supply, switch on the control supply and try to reset the fault.
- If the fault cannot be reset, there is probably an issue on a circuit board inside the phase module. The entire phase module
must be replaced.
• If the fault is on an INU module, check the motor cables and the motor for short circuits with a Megger tester.
• Do not connect the main power to the phase modules until all the tests are done to the modules!
• Ask for instructions from the factory.

10.2.6 Fault Code 8 - System Fault

10.2.6.1 Fault Code 8, ID 600 - System Fault

Cause
• Communication between the control unit and power unit has failed when the drive is in RUN state.
• Component failure.
• Faulty operation.
Troubleshooting
• Reset the fault and restart the drive.
• Check the fiber optic connections between the control unit and phase modules.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

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Operating Guide Fault Tracing

10.2.6.2 Fault Code 8, ID 601 - System Fault

Cause
• There is no communication between the control board and the power.
• Failure in communication between the control unit and power unit when the control updated the initial values to the power
unit.
• Component failure.
• Faulty operation.
Troubleshooting
• Reset the fault and restart the drive.
• Check the fiber optic connections between the control unit and phase modules.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.3 Fault Code 8, ID 602 - System Fault

Cause
• The watchdog has reset the CPU.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.4 Fault Code 8, ID 603 - System Fault

Cause
The fault is hardware triggered.
• Defective component.
• Operation malfunction.
• The voltage of auxiliary power in the power unit is too low.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.5 Fault Code 8, ID 604 - System Fault

Cause
The fault is hardware triggered.
• Phase fault.
• Defective component.
• Operation malfunction.
• Output phase voltage does not agree to the reference.
• Feedback fault.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

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Operating Guide Fault Tracing

10.2.6.6 Fault Code 8, ID 605 - System Fault

Cause
Unknown fault in the power unit.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.7 Fault Code 8, ID 606 - System Fault

Cause
• The software of the control unit is not compatible with the software of the power unit.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.8 Fault Code 8, ID 607 - System Fault

Cause
• The software version cannot be read. There is no software in the power unit.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.9 Fault Code 8, ID 608 - System Fault

Cause
• A CPU overload. Software or application causes the overload.
• Too heavy application.
• Faulty operation.
Troubleshooting
• Reset the fault and restart the drive.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.10 Fault Code 8, ID 609 - System Fault

Cause
• Access to the memory has failed.
• SPI EEPROM failure. Cannot be restored.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and make a power down of the drive twice.
• Download the latest software from the Danfoss Drives website. Update the drive with it.

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Operating Guide Fault Tracing

10.2.6.11 Fault Code 8, ID 610 - System Fault

Cause
• Device Properties is not readable.
• Unreadable memory on the control board.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.12 Fault Code 8, ID 614 - System Fault

Cause
• Configuration error.
• Software error.
• Defective component (a defective control board).
• Operation malfunction.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.13 Fault Code 8, ID 615 - System Fault

Cause
• Powerbus high-speed process data failure.
• Error in the communication between two power units.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.14 Fault Code 8, ID 616 - System Fault

Cause
• Powerbus high-speed socket communication failure.
• Error in the communication between two power units.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.15 Fault Code 8, ID 618 - System Fault

Cause
• Powerbus high-speed link error.
• Error in the communication between two power units.

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Operating Guide Fault Tracing

Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.16 Fault Code 8, ID 620 - System Fault

Cause
• Gate driver board error A.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.17 Fault Code 8, ID 621 - System Fault

Cause
• Gate driver board error B.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.18 Fault Code 8, ID 622 - System Fault

Cause
• The connection between the gate driver board and the measurement board is broken.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.19 Fault Code 8, ID 623 - System Fault

Cause
• The negative voltage of the 24 V supply is below the limit.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.20 Fault Code 8, ID 624 - System Fault

Cause
• The positive voltage of the 24 V supply is below the limit.
Troubleshooting
• Check the 24 V power supply.

10.2.6.21 Fault Code 8, ID 625 - System Fault

Cause
• The positive voltage of the 24 V supply is below the limit in a follower unit.
Troubleshooting
• Check the 24 V power supply.

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Operating Guide Fault Tracing

10.2.6.22 Fault Code 8, ID 647 - System Fault

Cause
• Cannot start the software/application, or software/application error.
• Defective component.
• Operation malfunction.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.23 Fault Code 8, ID 648 - System Fault

Cause
• Invalid function block used in the application.
• Operation malfunction.
• The system software is not compatible with the application.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.24 Fault Code 8, ID 649 - System Fault

Check the Source 1, Source 2, and Source 3 information of the fault.
Source 1 = Control; Source 2 = 12; Source 3 = 0
Cause
• A resource overload.
• Component failure.
• Faulty operation.
• Internal resources of the software have run out.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.
Source 1 = Control; Source 2 = 12; Source 3 = 1000
Cause
• Parameter initial value loading error.
• Parameter problem.
Troubleshooting
• Load factory default settings.
• Update the latest software.
Source 1 = Control; Source 2 = 12; Source 3 = 2000
Cause
• Parameter initial value loading error.
• Parameter restoring error.
Troubleshooting

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Operating Guide Fault Tracing

• Load factory default settings.

• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.
Source 1 = Control; Source 2 = 12; Source 3 = 3001–3007, 10000–15000
Cause
• Parameter saving error.
• Parameter restoring error.
Troubleshooting
• Load factory default settings.
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.
Source 1 = Control; Source 2 = Number (module); Source 3 = Number (depends on module)
Cause
• A resource overload.
• Internal resources of the software have run out.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.
Source 1 = Control; Source 2 = Motor control; Source 3 =
Cause
• A resource overload.
• More than 10% of the motor control cycles consume more time than budgeted during a 10 s supervision period.
• Internal software resources have run out.
Troubleshooting
• Reset the fault and restart.
• Download the latest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask instructions from your nearest distributor.

10.2.6.25 Fault Code 8, ID 667 - System Fault

Cause
• Ethernet configuration problem.
• Problem on the physical interface transceiver.
• Ethernet PHY is not recognized or it is in the wrong state.
Troubleshooting
• Reset the fault and restart the AC drive.
• Download the newest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.26 Fault Code 8, ID 670 - System Fault

Cause
• The current of the 24 V auxiliary output is higher than the maximum limit (>250 mA).

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Operating Guide Fault Tracing

Troubleshooting
• Check the loading of the auxiliary output.
• Reset the fault and restart the AC drive.
• Download the newest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.27 Fault Code 8, ID 681 - System Fault

Cause
• The maximum amount of datatables has been reserved.
Troubleshooting
• Reset faults and alarms that are waiting to be reset. Active faults cannot be reset.
• Return to previous working software version.
• If the fault occurs again, ask instructions from your nearest service center or distributor.

10.2.6.28 Fault Code 8, ID 827 - System Fault

Cause
• Invalid/incorrect license key provided (via keypad or VCX).
• The license key check fails, either by hash not matching with the drive, or a crc-check failure.
• The license key is incorrect or not for this drive.
Troubleshooting
• Reset the fault and restart the AC drive.
• Make sure that the license key is correct and enter the license key to the AC drive again.
• Download the newest software from the Danfoss Drives website. Update the drive with it.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.6.29 Fault Code 8, ID 828 - System Fault

Cause
• The entered license key was accepted and stored to the drive.
Troubleshooting
• No actions required. Notification only.

10.2.6.30 Fault Code 8, ID 829 - System Fault

Cause
• A license vcx-file has been loaded to the drive.
• New licenses have been taken into use since the previous start-up.
Troubleshooting
• No actions required. Notification only.

10.2.6.31 Fault Code 8, ID 830 - System Fault

Cause
• Licenses have been removed from the drive.
Troubleshooting
• No actions required. Notification only.

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Operating Guide Fault Tracing

10.2.7 Fault Code 9 - Undervoltage

10.2.7.1 Fault Code 9, ID 80 - Undervoltage (Fault)

Cause
The DC link voltage is lower than the limits.
• too low a supply voltage
• defective component
• a defective input fuse
• the external charge switch is not closed
NOTE! This fault becomes active only if the drive is in Run state.
Troubleshooting
• If there is a temporary supply voltage break, reset the fault and restart the drive.
• Do a check of the supply voltage. If the supply voltage is sufficient, there is an internal fault.
• Examine the electrical network for fault.
• Ask for instructions from your nearest distributor.

10.2.8 Fault Code 10 - Input Phase

10.2.8.1 Fault Code 10, ID 91 - Input Phase

Cause
• supply voltage malfunction
• a defective fuse or malfunction in the supply cables
The load must be a minimum of 10–20% for the supervision to work.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.
• Check the rectifying bridge.

10.2.8.2 Fault Code 10, ID 92 - Input Phase

Cause
• Software-based input phase supervision.
• Bridge 0 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.8.3 Fault Code 10, ID 93 - Input Phase

Cause
• Software based input phase supervision
• Bridge 1 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

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Operating Guide Fault Tracing

10.2.8.4 Fault Code 10, ID 94 - Input Phase

Cause
• Software-based input phase supervision.
• An input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.
• Check the rectifying bridge.

10.2.8.5 Fault Code 10, ID 95 - Input Phase

Cause
• Software based input phase supervision.
• Bridge 2 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.8.6 Fault Code 10, ID 96 - Input Phase

Cause
• Software based input phase supervision
• Bridge 3 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.8.7 Fault Code 10, ID 192 - Input Phase (Alarm)

Cause
• Software based input phase supervision
• Bridge 0 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.8.8 Fault Code 10, ID 193 - Input Phase (Alarm)

Cause
• Software based input phase supervision
• Bridge 1 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

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10.2.8.9 Fault Code 10, ID 195 - Input Phase (Alarm)

Cause
• Software based input phase supervision
• Bridge 2 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.8.10 Fault Code 10, ID 196 - Input Phase (Alarm)

Cause
• Software based input phase supervision
• Bridge 3 input phase is detected missing based on phase voltage measurements.
Troubleshooting
• Check the supply voltage.
• Check the fuses.
• Check the supply cable.

10.2.9 Fault Code 11 - Output Phase Supervision

10.2.9.1 Fault Code 11, ID 100 - Output Phase Supervision

Cause
The current measurement tells that there is no current in 1 motor phase.
• A motor or motor cables malfunction.
• Filter (dU/dt, sine wave) malfunction.
Troubleshooting
• Check the motor cable and the motor.
• Check the dU/dt or sine wave filter.

10.2.9.2 Fault Code 11, ID 101 - Output Phase Supervision

Cause
• Output phase current di/dt is above the threshold level.
Troubleshooting
• Check the motor cable and the motor.

10.2.10 Fault Code 12 - Brake Chopper Supervision

10.2.10.1 Fault Code 12, ID 110 - Brake Chopper Supervision (Hardware Fault)
Cause
• The fault is hardware triggered.
• There is no brake resistor.
• The brake resistor is broken.
• A defective brake chopper.
Troubleshooting
• Check the brake resistor and the cabling. If they are in good condition, there is a fault in the resistor or the brake chopper. Ask
instructions from your nearest distributor.

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10.2.10.2 Fault Code 12, ID 111 - Brake Chopper Saturation Alarm

Cause
• The fault is hardware triggered.
• There is no brake resistor.
• The brake resistor is broken.
• A defective brake chopper.
Troubleshooting
• Check the brake resistor and the cabling. If they are in good condition, there is a fault in the resistor or the brake chopper. Ask
instructions from your nearest distributor.

10.2.11 Fault Code 13 - AC Drive Undertemperature

10.2.11.1 Fault Code 13, ID 120 - AC Drive Undertemperature (Fault)

Cause
• Too low a temperature in the heat sink of the power unit or in the power board.
Troubleshooting
• The ambient temperature is too low for the drive. Move the drive in a warmer position.

10.2.11.2 Fault Code 13, ID 121 - AC Drive Undertemperature (Alarm)

Cause
• Too low a temperature in the heat sink of the power unit or in the power board.
Troubleshooting
• The ambient temperature is too low for the drive. Move the drive in a warmer position.

10.2.12 Fault Code 14 - AC Drive Overtemperature

10.2.12.1 Fault Code 14, ID 130 - AC Drive Overtemperature (Fault, Heat Sink)
Cause
• Too high a temperature in the heat sink of the power unit or in the power board.
Troubleshooting
• Check the actual amount and flow of cooling air.
• Examine the heat sink for dust.
• Check the ambient temperature.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.

10.2.12.2 Fault Code 14, ID 131 - AC Drive Overtemperature (Alarm, Heat Sink)
Cause
• Too high a temperature in the heat sink of the power unit or in the power board.
Troubleshooting
• Check the actual amount and flow of cooling air.
• Examine the heat sink for dust.
• Check the ambient temperature.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.

10.2.12.3 Fault Code 14, ID 132 - AC Drive Overtemperature (Fault, Board)

Cause
• Too high a temperature in the heat sink of the power unit or in the power board.

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Troubleshooting
• Check the actual amount and flow of cooling air.
• Examine the heat sink for dust.
• Check the ambient temperature.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.

10.2.12.4 Fault Code 14, ID 133 - AC Drive Overtemperature (Alarm, Board)

Cause
• Too high a temperature in the heat sink of the power unit or in the power board.
Troubleshooting
• Check the actual amount and flow of cooling air.
• Examine the heat sink for dust.
• Check the ambient temperature.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.

10.2.12.5 Fault Code 14, ID 134 - AC Drive Overtemperature (Fault)

Cause
• Power unit auxiliary temperature is too high.
Troubleshooting
• Check the actual amount and flow of cooling air.
• Examine the heat sink for dust.
• Check the ambient temperature.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.

10.2.12.6 Fault Code 14, ID 136 - Overvoltage Protection Circuit Temperature (Alarm)
Cause
• An internal circuit overtemperature caused by a ground fault in the output.
• Too high an output capacitance or a ground fault in the floating network.
Troubleshooting
• Check the cables and the motor.

10.2.12.7 Fault Code 14, ID 137 - Overvoltage Protection Circuit Temperature (Fault)
Cause
• Too high an output capacitance or a ground fault in the floating network.
Troubleshooting
• Check the cables and the motor.

10.2.12.8 Fault Code 14, ID 138 - AC Drive Overtemperature (Fault)

Cause
• Output filter temperature is too high.
Troubleshooting
• Check the motor cables and the motor.
• Check the correct amount and flow of cooling air.
• Check the ambient temperature.

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10.2.12.9 Fault Code 14, ID 139 - AC Drive Overtemperature (Fault)

Cause
• Brake chopper temperature is too high.
Troubleshooting
• Check the correct amount and flow of cooling air.
• Check the heat sink of the brake chopper for dust.
• Check the ambient temperature.

10.2.13 Fault Code 15 - Motor Stall

10.2.13.1 Fault Code 15, ID 140 - Motor Stall

Cause
• The motor stalled.
• Motor stall protection has tripped. The motor is stuck for some reason.
Troubleshooting
• Check the motor and the load.
• Check the parameters.

10.2.14 Fault Code 16 - Motor Overtemperature

10.2.14.1 Fault Code 16, ID 150 - Motor Overtemperature

Cause
• Motor over heating has been detected by the AC drive motor temperature model.
• There is too heavy a load on the motor.
Troubleshooting
• Decrease the motor load. If there is no motor overload, check the motor thermal protection parameters (parameter group 3.8
Protections).
• Check the motor.

10.2.15 Fault Code 17 - Motor Underload

10.2.15.1 Fault Code 17, ID 160 - Motor Underload

Cause
• There is not a sufficient load on the motor.
Troubleshooting
• Check the load.
• Check the parameters.
• Check the dU/dt and sine wave filters.

10.2.16 Fault Code 19 - Power Overload

10.2.16.1 Fault Code 19, ID 180 - Power Overload (Short-time Supervision)

Cause
• The motor overload protection has tripped.
• The power of the drive is too high.
Troubleshooting
• Decrease the load.
• Examine the dimensions of drive. Examine if it is too small for the load.

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10.2.16.2 Fault Code 19, ID 181 - Power Overload (Long-time Supervision)

Cause
• The motor overload protection has tripped.
• The power of the drive is too high.
Troubleshooting
• Decrease the load.
• Examine the dimensions of drive. Examine if it is too small for the load.

10.2.17 Fault Code 25 - Motor Control Fault

10.2.17.1 Fault Code 25, ID 240 - Motor Control Fault

Cause
This fault is available only if you use a customer-specific application. A malfunction in the start angle identification.
• The rotor moves during identification.
• The new angle does not agree with the old value.
Troubleshooting
• Reset the fault and restart the drive.
• Increase the identification current.
• See the fault history source for more information.

10.2.17.2 Fault Code 25, ID 241 - Motor Control Fault

Cause
This fault is available only if you use a customer-specific application. A malfunction in the start angle identification.
• The rotor moves during identification.
• The new angle does not agree with the old value.
Troubleshooting
• Reset the fault and restart the drive.
• Increase the identification current.
• See the fault history source for more information.

10.2.18 Fault Code 26 - Start-up Prevented

10.2.18.1 Fault Code 26, ID 250 - Start-up Prevented

Cause
• It is not possible to do a start-up of the drive. When the Run request is ON, a new software (a firmware or an application), a
parameter setting, or other file that affects the operation of the drive, is loaded to drive.
Troubleshooting
• Proceed with caution! Acknowledge the prevention of unexpected start-up by removing the Run request.
• Reset the fault and stop the drive.
• Load the software and start the drive.

10.2.19 Fault Code 29 - ATEX Thermistor

10.2.19.1 Fault Code 29, ID 280 - ATEX Thermistor

Cause
• The ATEX thermistor tells that there is an overtemperature.
Troubleshooting
• Reset the fault. Check the thermistor and its connections.

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10.2.20 Fault Code 30 - Safety

10.2.20.1 Fault Code 30, ID 290 - Safe Off

Cause
• The safe Off signal A does not let you set the drive to the READY state.
Troubleshooting
• Reset the fault and restart the drive.
• Check the signals from the control board to the power unit and the D connector.

10.2.20.2 Fault Code 30, ID 291 - Safe Off

Cause
• The safe Off signal B does not let you set the drive to the READY state.
Troubleshooting
• Reset the fault and restart the drive.
• Check the signals from the control board to the power unit and the D connector.

10.2.20.3 Fault Code 30, ID 500 - Safety Configuration

Cause
• The safety configuration switch was installed.
Troubleshooting
• Remove the safety configuration switch from the control board.

10.2.20.4 Fault Code 30, ID 501 - Safety Configuration

Cause
• There are too many STO option boards. It is possible to have only 1.
Troubleshooting
• Keep 1 of the STO option boards. Remove the others. See the safety manual.

10.2.20.5 Fault Code 30, ID 502 - Safety Configuration

Cause
• The STO option board was installed in an incorrect slot.
Troubleshooting
• Put the STO option board into the correct slot. See the OPTBJ STO Safety manual.

10.2.20.6 Fault Code 30, ID 503 - Safety configuration

Cause
• There is no safety configuration switch on the control board.
Troubleshooting
• Install the safety configuration switch on the control board. See the safety manual.

10.2.20.7 Fault Code 30, ID 504 - Safety configuration

Cause
• The safety configuration switch was installed incorrectly on the control board.
Troubleshooting
• Install the safety configuration switch into the correct position on the control board. See the safety manual.

10.2.20.8 Fault Code 30, ID 505 - Safety configuration

Cause
• The safety configuration switch was installed incorrectly on the STO option board.

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Troubleshooting
• Check the installation of the safety configuration switch on the STO option board. See the safety manual.

10.2.20.9 Fault Code 30, ID 506 - Safety configuration

Cause
• There is no communication with the STO option board.
• Communication has failed between the control board and STO option board.
Troubleshooting
• Check the installation of the STO option board. See the safety manual.

10.2.20.10 Fault Code 30, ID 507 - Safety configuration

Cause
• The STO option board is not compatible with the hardware.
Troubleshooting
• Reset the drive and restart it. If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.11 Fault Code 30, ID 520 - Safety diagnostics

Cause
• The STO inputs have a different status.
Troubleshooting
• Check the external safety switch. Check the input connection and cable of the safety switch.
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.12 Fault Code 30, ID 521 - Safety diagnostics

Cause
• A malfunction in the ATEX thermistor diagnostic. There is no connection in the ATEX thermistor input.
Troubleshooting
• Reset the drive and restart.
• If the fault occurs again, change the option board.

10.2.20.13 Fault Code 30, ID 522 - Safety diagnostics

Cause
• A short circuit in the connection of the ATEX thermistor input.
Troubleshooting
• Check the ATEX thermistor input connection.
• Check the external ATEX connection.
• Check the external ATEX thermistor.

10.2.20.14 Fault Code 30, ID 523 - Safety diagnostics

Cause
• A problem occurred in the internal safety circuit.
Troubleshooting
• Check the test pulses from the safety lines.
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

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Operating Guide Fault Tracing

10.2.20.15 Fault Code 30, ID 524 - Safety diagnostics

Cause
• An overvoltage in the safety option board.
Troubleshooting
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.16 Fault Code 30, ID 525 - Safety Diagnostics

Cause
• An undervoltage in the safety option board.
Troubleshooting
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.17 Fault Code 30, ID 526 - Safety Diagnostics

Cause
• An internal malfunction in the safety option board CPU or in the memory handling.
Troubleshooting
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.18 Fault Code 30, ID 527 - Safety Diagnostics

Cause
• An internal malfunction in the safety function.
• More than one STO board installed.
• Communication to the STO board does not work.
• Old hardware does not support the STO board.
Troubleshooting
• Check that the STO board is installed correctly.
• Reset the drive and restart.
• If the fault occurs again, ask for instructions from your nearest distributor.

10.2.20.19 Fault Code 30, ID 530 - Safe Torque Off

Cause
• An emergency stop was connected or some other STO operation was activated.
Troubleshooting
• When the STO function is activated, the drive is in safe state.

10.2.21 Fault Code 32 - Fan Cooling

10.2.21.1 Fault Code 32, ID 311 - Fan Cooling

Cause
• The fan speed does not agree to the speed reference accurately, but the drive operates correctly.
Troubleshooting
• Reset the fault and restart the drive.
• Clean or replace the fan.

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Operating Guide Fault Tracing

10.2.21.2 Fault Code 32, ID 312 - Fan Cooling

Cause
• The fan life time (that is, 50 000 h) is complete.
Troubleshooting
• Replace the fan and reset the life time counter of the fan.

10.2.22 Fault Code 33 - Fire Mode Enabled

10.2.22.1 Fault Code 33, ID 320 - Fire Mode Enabled

Cause
• The fire mode of the drive is enabled. The protections of the drive are disabled or autoreset.
Troubleshooting
• Check the parameter settings and the signals.
• This alarm is reset automatically when fire mode is disabled.

10.2.23 Fault Code 37 - Device Changed (Same Type)

10.2.23.1 Fault Code 37, ID 361 - Device Changed (Same Type)

Cause
• The power unit was replaced by a new one that has the same size. The device is ready to be used. The parameters are available
in the drive.
Troubleshooting
• Reset the fault. The drive reboots after you reset the fault.

10.2.23.2 Fault Code 37, ID 362 - Device Changed (Same Type)

Cause
• The option board in slot B was replaced by a new one that you have used before in the same slot. The device is ready to be used.
Troubleshooting
• Reset the fault. The drive starts to use the old parameter settings.

10.2.23.3 Fault Code 37, ID 363 - Device Changed (Same Type)

Cause
• The option board in slot C was replaced by a new one that you have used before in the same slot. The device is ready to be
used.
Troubleshooting
• Reset the fault. The drive starts to use the old parameter settings.

10.2.23.4 Fault Code 37, ID 364 - Device Changed (Same Type)

Cause
• The option board in slot D was replaced by a new one that you have used before in the same slot. The device is ready to be
used.
Troubleshooting
• Reset the fault. The drive starts to use the old parameter settings.

10.2.23.5 Fault Code 37, ID 365 - Device Changed (Same Type)

Cause
• The option board in slot E was replaced by a new one that you have used before in the same slot. The device is ready to be used.
Troubleshooting
• Reset the fault. The drive starts to use the old parameter settings.

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Operating Guide Fault Tracing

10.2.24 Fault Code 38 - Device Added (Same Type)

10.2.24.1 Fault Code 38, ID 372 - Device Added (Same Type)

Cause
• An option board was put into slot B. You have used the option board before in the same slot.
Troubleshooting
• The device is ready for use. The drive starts to use the old parameter settings.

10.2.24.2 Fault Code 38, ID 373 - Device Added (Same Type)

Cause
• An option board was put into slot C. You have used the option board before in the same slot.
Troubleshooting
• The device is ready for use. The drive starts to use the old parameter settings.

10.2.24.3 Fault Code 38, ID 374 - Device Added (Same Type)

Cause
• An option board was put into slot D. You have used the option board before in the same slot.
Troubleshooting
• The device is ready for use. The drive starts to use the old parameter settings.

10.2.24.4 Fault Code 38, ID 375 - Device Added (Same Type)

Cause
• An option board was put into slot E. You have used the option board before in the same slot.
Troubleshooting
• The device is ready for use. The drive starts to use the old parameter settings.

10.2.25 Fault Code 39 - Device Removed

10.2.25.1 Fault Code 39, ID 382 - Device Removed

Cause
• An option board was removed from slot A or B.
Troubleshooting
• The device is not available. Reset the fault.

10.2.25.2 Fault Code 39, ID 383 - Device Removed

Cause
• An option board was removed from slot C.
Troubleshooting
• The device is not available. Reset the fault.

10.2.25.3 Fault Code 39, ID 384 - Device Removed

Cause
• An option board was removed from slot D.
Troubleshooting
• The device is not available. Reset the fault.

10.2.25.4 Fault Code 39, ID 385 - Device Removed

Cause
• An option board was removed from slot E.

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Troubleshooting
• The device is not available. Reset the fault.

10.2.26 Fault Code 40 - Device Unknown

10.2.26.1 Fault Code 40, ID 390 - Device Unknown

Cause
• An unknown device was connected (the power unit/option board).
• The device can be unknown because of, for example, missing configuration values.
Troubleshooting
• The device is not available. If the fault occurs again, ask for instructions from your nearest distributor.

10.2.27 Fault Code 41 - IGBT Temperature

10.2.27.1 Fault Code 41, ID 400 - IGBT Temperature

Cause
The calculated IGBT temperature is too high.
• too high a motor load
• too high an ambient temperature
• hardware malfunction
Troubleshooting
• Check the parameter settings.
• Examine the actual amount and flow of cooling air.
• Check the ambient temperature.
• Examine the heatsink for dust.
• Make sure that the switching frequency is not too high in relation to the ambient temperature and the motor load.
• Check the cooling fan.
• Make an identification run.

10.2.28 Fault Code 43 - Encoder Fault

10.2.28.1 Fault Code 43, ID 420 - Encoder Fault

Cause
• Problem detected in the encoder signals.
• Encoder 1 channel A is missing.
Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.

10.2.28.2 Fault Code 43, ID 421 - Encoder Fault

Cause
• Problem detected in the encoder signals.
• Encoder 1 channel B is missing.

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Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.

10.2.28.3 Fault Code 43, ID 422 - Encoder Fault

Cause
• Problem detected in the encoder signals.
• Encoder 1 channels A and B are both missing.
Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.

10.2.28.4 Fault Code 43, ID 423 - Encoder Fault

Cause
The encoder is reversed.
Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.

10.2.28.5 Fault Code 43, ID 424 - Encoder Fault

Cause
The encoder board is missing.
Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.

10.2.28.6 Fault Code 43, ID 425 - Encoder Fault

Cause
Encoder speed deviation supervision.
Troubleshooting
• Check the encoder connections.
• Check the encoder and the encoder cable.
• Check the encoder board.
• Check the encoder frequency in open-loop mode.
• Check the basic motor parameters.

10.2.28.7 Fault Code 43, ID 426 - Encoder Fault

Cause
• Encoder pulse count supervision.
• The estimated encoder pulse count/revolution is different from the value set by the parameter.

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Troubleshooting
• Check the encoder pulse count/revolution value.
• Check the encoder coupling (gear ratio, friction wheel).
• Check the basic motor parameters.

10.2.28.8 Fault Code 43, ID 427 - Encoder Fault

Cause
• The maximum acceleration rate is exceeded.
• The motor acceleration calculated from the encoder speed is higher than the actual maximum of the application.
Troubleshooting
• Check the encoder channel connections.
• Check the encoder board.
• Check the encoder and the encoder cable.
• Check the mechanical mounting of the encoder.
• Check the encoder frequency in open-loop mode.

10.2.29 Fault Code 44 - Device Changed (Different Type)

10.2.29.1 Fault Code 44, ID 431 - Device Changed (Different Type)

Cause
• There is a new power unit of a different type. Parameters are not available in the settings.
Troubleshooting
• Reset the fault. The drive reboots after you reset the fault.
• Set the power unit parameters again.

10.2.29.2 Fault Code 44, ID 432 - Device Changed (Different Type)

Cause
• The option board in slot B was replaced by a new one that you have not used before in the same slot. No parameter settings are
saved.
Troubleshooting
• Reset the fault. Set the option board parameters again.

10.2.29.3 Fault Code 44, ID 433 - Device Changed (Different Type)

Cause
• The option board in slot C was replaced by a new one that you have not used before in the same slot. No parameter settings are
saved.
Troubleshooting
• Reset the fault. Set the option board parameters again.

10.2.29.4 Fault Code 44, ID 434 - Device Changed (Different Type)

Cause
• The option board in slot D was replaced by a new one that you have not used before in the same slot. No parameter settings are
saved.
Troubleshooting
• Reset the fault. Set the option board parameters again.

10.2.29.5 Fault Code 44, ID 435 - Device Changed (Different Type)

Cause
• The option board in slot E was replaced by a new one that you have not used before in the same slot. No parameter settings are
saved.

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Troubleshooting
• Reset the fault. Set the option board parameters again.

10.2.29.6 Fault Code 44, ID 436 - Device Changed (Different Type)

Cause
• The power configuration has changed. The power unit resets and initializes to a different configuration.
Troubleshooting
• Wait until the power unit is reset.

10.2.30 Fault Code 45 - Device Added (Different Type)

10.2.30.1 Fault Code 45, ID 441 - Device Added (Different Type)

Cause
• The control unit has connected to a power unit for the first time.
• There is a new power unit of a different type. Parameters are not available in the settings.
Troubleshooting
• Reset the fault. The drive reboots after you reset the fault.
• Set the power unit parameters again.

10.2.30.2 Fault Code 45, ID 442 - Device Added (Different Type)

Cause
• A new option board, that you have not used before in the same slot, was put in slot B. No parameter settings are saved.
Troubleshooting
• Set the option board parameters again.

10.2.30.3 Fault Code 45, ID 443 - Device Added (Different Type)

Cause
• A new option board, that you have not used before in the same slot, was put in slot C. No parameter settings are saved.
Troubleshooting
• Set the option board parameters again.

10.2.30.4 Fault Code 45, ID 444 - Device Added (Different Type)

Cause
• A new option board, that you have not used before in the same slot, was put in slot D. No parameter settings are saved.
Troubleshooting
• Set the option board parameters again.

10.2.30.5 Fault Code 45, ID 445 - Device Added (Different Type)

Cause
• A new option board, that you have not used before in the same slot, was put in slot E. No parameter settings are saved.
Troubleshooting
• Set the option board parameters again.

10.2.31 Fault Code 46 - Real Time Clock

10.2.31.1 Fault Code 46, ID 662 - Real Time Clock

Cause
• The voltage of the RTC battery is low.

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Troubleshooting
• Replace the battery.

10.2.32 Fault Code 47 - Software Update

10.2.32.1 Fault Code 47, ID 661 - Software Update

Cause
• A software update is in progress.
• The software is updating from the control unit to the power unit.
Troubleshooting
• No steps are necessary.

10.2.32.2 Fault Code 47, ID 663 - Software Updated

Cause
• The software of the drive was updated, the full software package or an application.
Troubleshooting
• No steps are necessary.

10.2.33 Fault Code 49 - Precharge

10.2.33.1 Fault Code 49, ID 901 - Pre-charge

Cause
• Main contactor pilot relay open timeout.
Troubleshooting
• Check the main contactor pilot relay wires.

10.2.33.2 Fault Code 49, ID 902 - Pre-charge

Cause
• Main contactor open timeout.
Troubleshooting
• Check the main contactor auxiliary contact wires.

10.2.33.3 Fault Code 49, ID 903 - Pre-charge

Cause
• Pre-charge transformer contactor open timeout.
Troubleshooting
• Check the pre-charge contactor auxiliary contact wires.

10.2.33.4 Fault Code 49, ID 904 - Pre-charge

Cause
• DC link discharge timeout.
• DC link discharge time exceeded the expected discharge time.
Troubleshooting
• Check the mains contactor state and pre-charge wires.

10.2.33.5 Fault Code 49, ID 905 - Pre-charge

Cause
• Front-end fault clear timeout.

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Operating Guide Fault Tracing

Troubleshooting
• If the INU controls the pre-charge, make sure that the AFE does not have a fault. If there is a fault, the pre-charge cannot contin-
ue.

10.2.33.6 Fault Code 49, ID 906 - Pre-charge

Cause
• DC-link overvoltage. The pre-charge control sensed an overvoltage.
Troubleshooting
• Check the AFE control signal wires and that the fieldbus connection is active.

10.2.33.7 Fault Code 49, ID 907 - Pre-charge

Cause
• Front-end PLL phase lock lost. The PLL lost the synchronization during the operation.
Troubleshooting
• Make sure that there is no input phase or voltage missing during operation.

10.2.33.8 Fault Code 49, ID 908 - Pre-charge

Cause
• The front end had a fault after it reached the ready state. This fault applies only when the INU controls the pre-charge.
Troubleshooting
• –

10.2.33.9 Fault Code 49, ID 909 - Pre-charge

Cause
• The main contactor closes before the pre-charge control command.
Troubleshooting
• Check the main contactor actuation circuit wires and the feedback wires.

10.2.33.10 Fault Code 49, ID 910 - Pre-charge

Cause
• The main contactor pilot relay closes before the pre-charge control command.
Troubleshooting
• Check the main contactor pilot relay wires.

10.2.33.11 Fault Code 49, ID 911 - Pre-charge

Cause
• The pre-charge sequence was stopped before it was completed.
• The circuit breaker on the pre-charge circuit opened due to:
- Overheating of the pre-charge unit transformer.
- A short circuit in the DC link.
Troubleshooting
• If the sequence was not stopped manually, check the pre-charge circuit and protections (pre-charge transformer overcurrent or
overtemperature).

10.2.33.12 Fault Code 49, ID 912 - Pre-charge

Cause
• The DC-link charge rate is above the maximum value.
• The DC-link voltage time rate of change exceeded the expected maximum for the given power stage configuration.

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Operating Guide Fault Tracing

Troubleshooting
• Check the pre-charge transformer primary voltage.
• Check the cabling of the phase modules.
• Make sure that the drive configuration has not changed.

10.2.33.13 Fault Code 49, ID 913 - Pre-charge

Cause
• The DC link charge rate is below the minimum value during the pre-charge.
• The DC-link voltage time rate of change is below the expected minimum for the given drive configuration.
Troubleshooting
• Check the pre-charge transformer primary voltage.
• If the system has parallel power circuits, and therefore two pre-charge units, make sure that both pre-charge circuits have input
power.
• Make sure that the drive configuration has not changed.

10.2.33.14 Fault Code 49, ID 914 - Pre-charge

Cause
• Pre-charge timeout during DC-link charging. The DC-link voltage rise time to the target voltage was too long.
Troubleshooting
• Check the pre-charge transformer primary voltage and the tap configuration.
• If the system has parallel power circuits, and therefore two pre-charge units, make sure that both pre-charge circuits have input
power.

10.2.33.15 Fault Code 49, ID 915 - Pre-charge

Cause
• The DC-link voltage is too low to complete the synchronization.
Troubleshooting
• Make sure that the synchronization threshold voltage is sufficient.
• Make sure that the LC filter capacitance is not too large.

10.2.33.16 Fault Code 49, ID 916 - Pre-charge

Cause
• AFE cannot synchronize with the grid voltage in the approved time limit.
Troubleshooting
• Make sure that the grid voltage is stable or that the imbalance is not too high.

10.2.33.17 Fault Code 49, ID 917 - Pre-charge

Cause
• Main contactor pilot relay close timeout.
• The main contactor pilot relay did not close within the expected time.
Troubleshooting
• Check the relay wiring.

10.2.33.18 Fault Code 49, ID 918 - Pre-charge

Cause
• The AFE lost synchronization with the grid while it waited for the mains contactor to close.
Troubleshooting
• –

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Operating Guide Fault Tracing

10.2.33.19 Fault Code 49, ID 919 - Pre-charge

Cause
• Main contactor close timeout.
• The main contactor did not close within the expected time.
Troubleshooting
• Check the main contactor wiring and main contactor pilot wiring.

10.2.33.20 Fault Code 49, ID 920 - Pre-charge

Cause
• The main contactor opened during the DC stabilization phase.
Troubleshooting
• Check the main contactor wiring and main contactor pilot wiring.

10.2.33.21 Fault Code 49, ID 921 - Pre-charge

Cause
• The front end could not make the DC-link voltage stable in the necessary time.
• The AFE was unable to commit to DC voltage control mode within the allotted time.
Troubleshooting
• Make sure that the grid voltage feedback configuration is correct (line or phase voltage measurement).
• Make sure that the feedback agrees with the AFE phase order.
• Make sure that the phase shift of the potential transformer is accounted for in the PLL adaptation angle parameter.

10.2.33.22 Fault Code 49, ID 922 - Pre-charge

Cause
• The AFE was stopped while the INU was in operation.
Troubleshooting
• Always stop the INU before shutting down the AFE.

10.2.33.23 Fault Code 49, ID 923 - Pre-charge

Cause
• The front end could not keep up the DC-link voltage stabilization.
• AFE or DFE voltage regulation could not be maintained.
Troubleshooting
• Check the DC voltage control parameters and the synchronous current controller parameters.

10.2.33.24 Fault Code 49, ID 924 - Pre-charge

Cause
• Parameter settings changed after the pre-charge sequence was activated.
Troubleshooting
• Do not change the pre-charge configuration after starting the pre-charge sequence.

10.2.33.25 Fault Code 49, ID 925 - Pre-charge

Cause
• The parameter settings are not valid.
Troubleshooting
• Do not select the test modes "disable mains contactor" and "dry run" at the same time.

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Operating Guide Fault Tracing

10.2.33.26 Fault Code 49, ID 926 - Pre-charge

Cause
• Test mode activated while grid voltage is connected.
Troubleshooting
• Do not select the "dry run" test mode while grid voltage is connected.

10.2.33.27 Fault Code 49, ID 927 - Pre-charge

Cause
• The INU had a fault during the pre-charge sequence.
Troubleshooting
• Check the INU status.

10.2.33.28 Fault Code 49, ID 928 - Pre-charge

Cause
• The pre-charge transformer contactor closed unexpectedly after the pre-charge sequence was completed.
Troubleshooting
• Check the pre-charge contactor wiring.

10.2.33.29 Fault Code 49, ID 930 - Pre-charge

Cause
• Breaker enable was lost while the precharge output was active.
Troubleshooting
• –

10.2.34 Fault Code 50 - AI Low Fault

10.2.34.1 Fault Code 50, ID 1050 - AI Low Fault

Cause
• The used analog input signal has gone below 50% of the minimum signal range.
• A control cable is broken or loose.
• A signal source has failed.
Troubleshooting
• Check the control cable connection.
• Check the analog input circuit and signals.
• Replace the defective parts.
• Make sure that parameter AI1 Signal Range is set correctly.

10.2.35 Fault Code 51 - Device External Fault

10.2.35.1 Fault Code 51, ID 1051 - Device External Fault

Cause
• Digital input fault.
• The digital input signal that is set with parameter Ext Fault Close (ID 405) or Ext Fault Open (ID 406) was activated.
Troubleshooting
• This is a user-defined fault.
• Check the digital inputs and schematics.
• Remove the fault situation on external device.

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Operating Guide Fault Tracing

10.2.36 Fault Code 52 - Keypad Communication Fault

10.2.36.1 Fault Code 52, ID 1052 - Keypad Communication Fault

Cause
• The connection between the control panel and the drive is defective.
Troubleshooting
• Check the control panel connection and the control panel cable if you have it.

10.2.36.2 Fault Code 52, ID 1352 - Keypad Communication Fault

Cause
• The connection between the control panel and the drive is defective.
Troubleshooting
• Check the control panel connection and the control panel cable if you have it.

10.2.37 Fault Code 53 - Fieldbus Communication Fault

10.2.37.1 Fault Code 53, ID 1053 - Fieldbus Communication Fault

Cause
• The data connection between the fieldbus master and the fieldbus board is defective.
Troubleshooting
• Check the installation and fieldbus master.

10.2.37.2 Fault Code 53, ID 1054 - Redundant Switchover

Cause
• The data connection between controlling fieldbus and the drive has timed out. Redundant control has changed the controlling
fieldbus connection.
Troubleshooting
• Check the installation and the communication cables.

10.2.37.3 Fault Code 53, ID 1055 - Redundant Timeout

Cause
• The data connection between controlling fieldbus protocols and the drive has timed out.
Troubleshooting
• Check the installation and the communication cables.

10.2.38 Fault Code 54 - Slot Fault

10.2.38.1 Fault Code 54, ID 1354 - Slot A fault

Cause
• A defective option board or slot.
Troubleshooting
• Check the board and the slot.
• Ask for instructions from your nearest distributor.

10.2.38.2 Fault Code 54, ID 1454 - Slot B fault

Cause
• A defective option board or slot.

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Operating Guide Fault Tracing

Troubleshooting
• Check the board and the slot.
• Ask for instructions from your nearest distributor.

10.2.38.3 Fault Code 54, ID 1554 - Slot C fault

Cause
• A defective option board or slot.
Troubleshooting
• Check the board and the slot.
• Ask for instructions from your nearest distributor.

10.2.38.4 Fault Code 54, ID 1654 - Slot D fault

Cause
• A defective option board or slot.
Troubleshooting
• Check the board and the slot.
• Ask for instructions from your nearest distributor.

10.2.38.5 Fault Code 54, ID 1754 - Slot E fault

Cause
• A defective option board or slot.
Troubleshooting
• Check the board and the slot.
• Ask for instructions from your nearest distributor.

10.2.39 Fault Code 57 - Identification

10.2.39.1 Fault Code 57, ID 1057 - Identification

Cause
• There was a failure in the identification run.
Troubleshooting
• Make sure that the motor is connected to the drive.
• Make sure that there is no load on the motor shaft.
• Make sure that the start command is not removed before the identification run is complete.

10.2.39.2 Fault Code 57, ID 1157 - Identification

Cause
• During the identification run, drive was not able to reach required frequency reference.
Troubleshooting
• Make sure that minimum and maximum frequency references are set correctly. Too low maximum frequency can prevent drive
from reaching required frequency.

10.2.39.3 Fault Code 57, ID 1257 - Identification

Cause
• During the identification run, drive was not able to reach required frequency reference.
Troubleshooting
• Make sure that acceleration time is set correctly. Too long acceleration time can prevent drive from reaching required frequency
in 40 seconds.

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Operating Guide Fault Tracing

10.2.39.4 Fault Code 57, ID 1357 - Identification

Cause
• During the identification run, drive was not able to reach required frequency reference.
Troubleshooting
• Make sure that current, torque, and power limits of the drive are set correctly. Too low limit settings can prevent drive from
reaching required frequency.

10.2.40 Fault Code 58 - Mechanical Brake

10.2.40.1 Fault Code 58, ID 1058 - Mechanical Brake

Cause
• The actual status of the mechanical brake is different from the control signal for longer than the value of Brake Fault Delay (ID
352).
Troubleshooting
• Check the status and connections of the mechanical brake.
• See parameter Mech. Brake Feedback (ID1210) and Mechanical brake parameter group.

10.2.41 Fault Code 59 - Communication

10.2.41.1 Fault Code 59, ID 590 - Communication

Cause
• The Source2 unit cannot connect to the Source3 unit.
Troubleshooting
• Check the power unit connections.

10.2.42 Fault Code 61 - Speed Error Fault

10.2.42.1 Fault Code 61, ID 1061 - Speed Error Fault

Cause
• The difference between encoder frequency and output frequency exceeds the fault limit.
Troubleshooting
• Check the encoder and encoder connections.

10.2.43 Fault Code 63 - Quick Stop

10.2.43.1 Fault Code 63, ID 1063 - Quick Stop Fault

Cause
• The quick stop function is activated by digital input signal or from fieldbus.
Troubleshooting
• Find the cause for the quick stop activation. After you find it, correct it. Reset the fault and restart the drive.
• See parameter Quick Stop Activation (ID 1213) and the quick stop parameters.

10.2.43.2 Fault Code 63, ID 1363 - Quick Stop Alarm

Cause
• The quick stop function is activated by digital input signal or from fieldbus.
Troubleshooting
• Find the cause for the quick stop activation. After you find it, correct it. Reset the fault and restart the drive.
• See parameter Quick Stop Activation (ID 1213) and the quick stop parameters.

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Operating Guide Fault Tracing

10.2.44 Fault Code 65 - PC Communication Fault

10.2.44.1 Fault Code 65, ID 1065 - PC Communication Fault

Cause
• The data connection between the PC and the drive is defective.
Troubleshooting
• Check the installation, cable, and terminals between the PC and the drive.

10.2.45 Fault Code 66 - Thermistor Input Fault

10.2.45.1 Fault Code 66, ID 1366 - Thermistor Input 1 Fault

Cause
• The motor temperature increased.
Troubleshooting
• Check the motor cooling and the load.
• Check the thermistor connection.
• If the thermistor input is not used, you have to short-circuit it.
• Ask for instructions from your nearest distributor.

10.2.45.2 Fault Code 66, ID 1466 - Thermistor Input 2 Fault

Cause
• The motor temperature increased.
Troubleshooting
• Check the motor cooling and the load.
• Check the thermistor connection.
• If the thermistor input is not used, you have to short-circuit it.
• Ask for instructions from your nearest distributor.

10.2.45.3 Fault Code 66, ID 1566 - Thermistor Input 3 Fault

Cause
• The motor temperature increased.
Troubleshooting
• Check the motor cooling and the load.
• Check the thermistor connection.
• If the thermistor input is not used, you have to short-circuit it.
• Ask for instructions from your nearest distributor.

10.2.46 Fault Code 67 - Module Test Stand

10.2.46.1 Fault Code 67, ID 672 - Module Test Stand

Cause
• Fault ID and code reservation for internal production module test stand. Specific fault information is passed in Source2 and is
readable via MtsErrorWord_fi.
• Not for external/customer use!
Troubleshooting
•

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Operating Guide Fault Tracing

10.2.47 Fault Code 68 - Maintenance Counter

10.2.47.1 Fault Code 68, ID 1301 - Maintenance Counter 1 Alarm

Cause
• The value of the maintenance counter is higher than the alarm limit.
Troubleshooting
• Do the necessary maintenance.
• Reset the counter. See parameter Maintenance Counter 1 Reset (ID 490).

10.2.47.2 Fault Code 68, ID 1302 - Maintenance Counter 1 Fault

Cause
• The value of the maintenance counter is higher than the fault limit.
Troubleshooting
• Do the necessary maintenance.
• Reset the counter. See parameter Maintenance Counter 1 Reset (ID 490).

10.2.48 Fault Code 69 - Fieldbus Mapping Error

10.2.48.1 Fault Code 69, ID 1310 - Fieldbus Mapping Error

Cause
• The ID number that is used to map the values to Fieldbus Process Data Out is not valid.
Troubleshooting
• Check the parameters in the Fieldbus Data menu.

10.2.48.2 Fault Code 69, ID 1311 - Fieldbus Mapping Error

Cause
• It is not possible to convert 1 or more values for Fieldbus Process Data Out.
• The type of the value is undefined.
Troubleshooting
• Check the parameters in the Fieldbus Data menu.

10.2.48.3 Fault Code 69, ID 1312 - Fieldbus Mapping Error

Cause
• There is an overflow when the values for Fieldbus Process Data Out (16-bit) are mapped and converted.
Troubleshooting
• Check the parameters in the Fieldbus Data menu.

10.2.49 Fault Code 76 - Start Prevented

10.2.49.1 Fault Code 76, ID 1076 - Start Prevented

Cause
• The start command is blocked to prevent the accidental rotation of the motor during the first power-up.
Troubleshooting
• Reset the drive to start the correct operation. The parameter settings tell if it is necessary to restart the drive.

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Operating Guide Fault Tracing

10.2.50 Fault Code 77 - >5 Connections

10.2.50.1 Fault Code 77, ID 1077 - > 5 Connections

Cause
• There are more than 5 active fieldbus or PC tool connections. You can use only 5 connections at the same time.
Troubleshooting
• Leave 5 active connections. Remove the other connections.

10.2.51 Fault Code 78 - Identification Ongoing

10.2.51.1 Fault Code 78, ID 1078 - Identification Ongoing

Cause
• The drive is running the identification for the motor.
Troubleshooting
• You can stop the identification run at any time by removing the start command. When the identification run is completed, a
new start command is needed to start the drive.

10.2.52 Fault Code 80 - Fieldbus Watchdog Fault

10.2.52.1 Fault Code 80, ID 1080 - FB Watchdog Fault

Cause
• There is no communication between the fieldbus master and the fieldbus follower.
Troubleshooting
• Check the installation and the fieldbus master.

10.2.53 Fault Code 84 - Overspeed Error

10.2.53.1 Fault Code 84, ID 1084 - Overspeed Error

Cause
• The motor speed is over the speed limit.
Troubleshooting
• –

10.2.54 Fault Code 111 - Temperature Input Fault 1

10.2.54.1 Fault Code 111, ID 1315 - Temperature Fault 1

Cause
• 1 or more of the temperature input signals (set in parameter ID 739) is higher than the alarm limit (parameter ID 741).
Troubleshooting
• Find the cause of the temperature rise.
• Check the parameters in the Temperature Input Fault 1 menu.
• Check the temperature sensor and connections.
• If no sensor is connected, make sure that the temperature input is hardwired.
• See the option board manual for more data.

10.2.54.2 Fault Code 111, ID 1316 - Temperature Fault 1

Cause
• 1 or more of the temperature input signals (set in parameter ID 739) is higher than the fault limit (parameter ID 742).

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Operating Guide Fault Tracing

Troubleshooting
• Find the cause of the temperature rise.
• Check the parameters in the Temperature Input Fault 1 menu.
• Check the temperature sensor and connections.
• If no sensor is connected, make sure that the temperature input is hardwired.
• See the option board manual for more data.

10.2.55 Fault Code 112 - Temperature Input Fault 2

10.2.55.1 Fault Code 112, ID 1317 - Temperature Fault 2

Cause
• 1 or more of the temperature input signals (set in parameter ID 763) is higher than the alarm limit (parameter ID 764).
Troubleshooting
• Find the cause of the temperature rise.
• Check the parameters in the Temperature Input Fault 2 menu.
• Check the temperature sensor and connections.
• If no sensor is connected, make sure that the temperature input is hardwired.
• See the option board manual for more data.

10.2.55.2 Fault Code 112, ID 1318 - Temperature Fault 2

Cause
• 1 or more of the temperature input signals (set in parameter ID 763) is higher than the fault limit (parameter ID 765).
Troubleshooting
• Find the cause of the temperature rise.
• Check the parameters in the Temperature Input Fault 2 menu.
• Check the temperature sensor and connections.
• If no sensor is connected, make sure that the temperature input is hardwired.
• See the option board manual for more data.

10.2.56 Fault Code 114 - User Defined Fault 1

10.2.56.1 Fault Code 114, ID 1114 - User Defined Fault 1

Cause
• This user-defined fault was activated either from a digital input, fieldbus, the drive customizer, or a time channel.
Troubleshooting
• See parameter menu User Defined Fault 1 to find out the source of the fault activation.

10.2.57 Fault Code 115 - User Defined Fault 2

10.2.57.1 Fault Code 115, ID 1115 - User Defined Fault 2

Cause
• This user-defined fault was activated either from a digital input, fieldbus, the drive customizer, or a time channel.
Troubleshooting
• See parameter menu User Defined Fault 2 to find out the source of the fault activation.

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Operating Guide Fault Tracing

10.2.58 Fault Code 200 - Precharge

10.2.58.1 Fault Code 200, ID 1721 - MCB/Interlock Fault

Cause
• MCB is lost or interlock is required for power-on.
Troubleshooting
• –

10.2.58.2 Fault Code 200, ID 1722 - Leak Detector Fault

Cause
• Leak detection issue.
Troubleshooting
• –

10.2.58.3 Fault Code 200, ID 1723 - Overtemp in LCL

Cause
• Overtemperature detected in LCL component.
Troubleshooting
• –

10.2.58.4 Fault Code 200, ID 1724 - Cooling Fault

Cause
• Loss of "Cooling OK" from heat exchanger, or loss of cabinet cooling.
Troubleshooting
• –

10.2.58.5 Fault Code 200, ID 1725 - Cooling Ok Timeout

Cause
• The cooling system did not reach OK status in time.
Troubleshooting
• –

10.2.58.6 Fault Code 200, ID 1726 - Precharge Contactor Close Timeout

Cause
• Precharge contactor did not close within the timeout period after the close command.
Troubleshooting
• –

10.2.58.7 Fault Code 200, ID 1727 - Loss of Precharge Permissive

Cause
• Unexpected loss of "Precharge permissive".
Troubleshooting
• –

10.2.58.8 Fault Code 200, ID 1728 - Loss of MX Permissive

Cause
• Loss of breaker (MX) permissive.
Troubleshooting
• –

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Operating Guide Fault Tracing

10.2.58.9 Fault Code 200, ID 1729 - GSW/UFES Fault

Cause
• GSW or UFES is in the wrong position.
Troubleshooting
• –

10.2.58.10 Fault Code 200, ID 1731 - DC Cap Overpressure

Cause
• Overpressure detected in the DC-link capacitors.
Troubleshooting
• –

10.2.59 Fault Code 201 - High Humidity/Temperature

10.2.59.1 Fault Code 201, ID 1730 - High Humidity/Temperature

Cause
• The humidity or temperature switches indicate a high condition.
Troubleshooting
• –

10.2.60 Fault Code 202 - Encoder

10.2.60.1 Fault Code 202, ID 1740 - Encoder Difference

Cause
• Encoder measurement difference exceeds 2x limit during operation.
Troubleshooting
• –

10.2.60.2 Fault Code 202, ID 1741 - Encoder Difference

Cause
• Encoder measurement difference exceeds the limit at overcurrent/overvoltage fault.
Troubleshooting
• –

10.2.60.3 Fault Code 202, ID 1742 - Fall Back to OL

Cause
• Overcurrent or overvoltage fault occurred during transition from closed loop to open loop.
Troubleshooting
• –

10.2.61 Fault Code 203 - STO Fault

10.2.61.1 Fault Code 203, ID 1735 - STO Fault

Cause
• The STO input is active.
Troubleshooting
• –

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Operating Guide Fault Tracing

10.2.62 Fault Code 204 - Output Filter

10.2.62.1 Fault Code 204, ID 1744 - Output Filter

Cause
• A component in the output filter has overtemperature or overpressure.
Troubleshooting
• –

10.2.63 Fault Code 205 - Coolant Temperature

10.2.63.1 Fault Code 205, ID 1745 - Coolant Temperature

Cause
• Coolant temperature ≥ 70.0 °C (158 °F).
Troubleshooting
• –

10.2.63.2 Fault Code 205, ID 1745 - Coolant Temperature

Cause
• Coolant temperature ≤ -10.0 °C (14 °F).
Troubleshooting
• –

10.2.64 Fault Code 300 - Unsupported

10.2.64.1 Fault Code 300, ID 700 - Unsupported

Cause
• The application is not compatible (it is unsupported).
Troubleshooting
• Replace the application.

10.2.64.2 Fault Code 300, ID 701 - Unsupported

Cause
• The option board or the slot is not compatible (it is unsupported).
Troubleshooting
• Remove the option board.

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Operating Guide Specifications

11 Specifications
11.1 Dimensions
The main dimensions of the VACON® 3000 Drive Kit components are given in this chapter. For more dimensions, see the 3D-models
of the components, which are available for members of the Danfoss MVP Program®.

11.1.1 Dimensions, Phase Module (L20/L30)

e30bg620.10
398.5
(15.69)

103.1
(4.06)

755.3
(29.74) Ø13.0
(0.51)

160.0
(6.30)

162.7
(6.41)

404.8
(15.94)
Ø9.0
(0.35)

83.0 238.0
(3.27) (9.37)

436.6
(17.19)

Illustration 114: VACON® 3000 Phase Module L20 Dimensions in mm (in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg621.10
594.0
(23.39)

103.1
(4.06)

Ø13.0
(0.51)

160.0
(6.30)

163.2
(6.42)

600.3
(23.63)
Ø9.0
(0.35)

83.0 238.0
(3.27) (9.37)

632.1 761.1
(24.89) (29.97)

Illustration 115: VACON® 3000 Phase Module L30 Dimensions in mm (in)

11.1.2 Dimensions, DFE Power Module

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bi549.10
404.8
(15.94)

Ø12.0
(0.47)

463.4 463.4
(18.24) (18.24)

96.0
48.0 (3.78)
(1.89)

436.6 803.2
(17.19) (31.62)
103.1 74.5 96.5 74.5
(4.06) (2.93) (3.80) (2.93)
163.2 160.0
(6.42) (6.30)

Ø13.0
(0.51)

398.5
(15.69)

Illustration 116: VACON® 3000 DFE power module dimensions in mm (in)

11.1.3 Dimensions, Brake Chopper Unit

See the L20/L30 phase module dimensions in 11.1.1 Dimensions, Phase Module (L20/L30).

11.1.4 Dimensions, Control Unit

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg632.10
216.9 106.1
(8.54) (4.18)

Ø 7.0 148.5
(0.28) (5.85)

Ø 11.0
(0.43)

360.0 392.0
(14.17) (15.43)

Illustration 117: VACON® 3000 Control Unit Dimensions in mm (in)

11.1.5 Dimensions, Auxiliary I/O Board

323.5
(12.74) e30bi923.10

142.3
(5.60)

67.2
(2.65)

150.5 158.7
(5.93) (6.25)

Illustration 118: VACON® 3000 Auxiliary I/O Board Dimensions in mm (in)

11.1.6 Dimensions, HCM Board

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VACON® 3000 Drive Kit

Operating Guide Specifications

85.5

e30bj476.10
(3.37)

142.3
(5.60)

323.5
(12.74)

Illustration 119: VACON® 3000 HCM Board Dimensions in mm (in)

11.1.7 Dimensions, Pre-Charge Unit

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg637.10
243.6
(9.59)

162.2
(6.39)

239.4 210.5
(9.43) (8.29)

Ø 7.14
(0.28)

185
(7.28)

88.65 111.6
(3.49) (4.39)

12.7
(0.5)
221.5
(8.72)

Illustration 120: VACON® 3000 Pre-Charge Unit Dimensions in mm (in)

11.1.8 Dimensions, LC Filter

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg639.11
8
Ø 11
(0.43)

1 3

230 230
(9.06) (9.06)
4
2
9

Ø 14
(0.55)

5 6

580
(22.84)
620
(24.41)

Illustration 121: VACON® 3000 AFE Side Input Inductor (LCV) Dimensions in mm (in)

1–7 Dimensions, see Table 55 9 Fan grille (09418-2-4039, ebm papst)

8 Terminal block for thermal switch

Table 55: VACON® 3000 AFE Side Input Inductor Dimensions 1–7

Type Code Dim. 1 Dim. 2 Dim. 3 Dim. 4 Dim. 5 Dim. 6 Dim. 7

FLU-LCV-SSI- 425-3-HAF0 642 mm 700 mm 679 mm 503 mm 260 mm 290 mm 214 mm

(25.3 in) (27.6 in) (26.7 in) (19.8 in) (10.2 in) (11.4 in) (8.4 in)

FLU-LCV-SSI- 425-3-HAF1 838 mm

FLU-LCV-SSI- 425-3-HAF2 (33.0 in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Type Code Dim. 1 Dim. 2 Dim. 3 Dim. 4 Dim. 5 Dim. 6 Dim. 7

FLU-LCV-HSI- 425-3-HAF0 658 mm 700 mm 697 mm 503 mm 260 mm 290 mm 230 mm

(25.9 in) (27.6 in) (27.4 in) (19.8 in) (10.2 in) (11.4 in) (9.1 in)

FLU-LCV-HSI- 425-3-HAF1 854 mm

FLU-LCV-HSI- 425-3-HAF2 (33.6 in)

FLU-LCV-SSI- 640-3- HAF0 594 mm 701 mm 829 mm 499 mm 300 mm 330 mm 169 mm
(23.4 in) (27.6 in) (32.6 in) (19.6 in) (11.8 in) (13.0 in) (6.7 in)

FLU-LCV-SSI- 640-3- HAF1 960 mm

FLU-LCV-SSI- 640-3- HAF2 (37.8 in)

FLU-LCV-HSI- 640-3- HAF0

FLU-LCV-HSI- 640-3- HAF1

FLU-LCV-HSI- 640-3- HAF2

FLU-LCV-340-4- HAF0 388 mm 701 mm 614 mm 505 mm 300 mm 330 mm 167 mm

(15.3 in) (27.6 in) (24.2 in) (19.9 in) (11.8 in) (13.0 in) (6.6 in)

FLU-LCV-340-4- HAF1 754 mm

FLU-LCV-340-4- HAF2 (29.7 in)

FLU-LCV-SSI- 510-4- HAF0 559 mm 689 mm 616 mm 513 mm 298 mm 328 mm 235 mm
(22.0 in) (27.1 in) (24.3 in) (20.2 in) (11.7 in) (12.9 in) (9.3 in)

FLU-LCV-SSI- 510-4- HAF1 775 mm

FLU-LCV-SSI- 510-4- HAF2 (30.5 in)

FLU-LCV-HSI- 510-4- HAF0

FLU-LCV-HSI- 510-4- HAF1

FLU-LCV-HSI- 510-4- HAF2

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg640.11
114.3 114.3 114.3
(4.50) (4.50) (4.50)

N X1 X2 X3 Ø12.7
(0.50)

616.0
(24.25)

74.4
(2.93)

25.4
(1.00)

Ø12.7
(0.50)

489.0 772.9
(19.25) (30.43)

698.5
(27.50)

82.6
(3.25)

558.8
(22.00) 1
615.9
(24.25) 2
647.7
(25.50)

Illustration 122: VACON® 3000 Shunt Capacitor Dimensions in mm (in)

1, 2 See Table 56

Table 56: VACON® 3000 Shunt Capacitor Dimensions A and B

Type Code Dimension 1 Dimension 2

FLU-CSH-43-4-HANA 92.2 mm (3.63 in) 104.9 mm (4.13 in)

FLU-CSH-100-4-HANA 152.4 mm (6.00 in) 165.1 mm (6.50 in)

FLU-CSH-125-4-HANA 174.8 mm (6.88 in) 187.5 mm (7.38 in)

11.1.9 Dimensions, Input Common-mode Filter

See the common-mode capacitor (CCM) dimensions in 11.1.10 Dimensions, Common-Mode Capacitor.
The inductors FLU-LCV-SSI-425-3-HAFX and FLU-LCV-SSI-510-4-HAFX are used as grid side input inductors in HSI type drives. See
their dimensions in 11.1.8 Dimensions, LC Filter.

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg642.12
8
Ø 11
(0.43)

1 2

230 230
(9.06) (9.06)
620
3
(24.41)

9
Ø 14
(0.55)

6 7

580
(22.84)

4
Illustration 123: VACON® 3000 Grid Side Input Inductor (LGI) Dimensions in mm (in)

1–7 Dimensions, see Table 57 9 Fan grille (09418-2-4039, ebm papst)

8 Terminal block for thermal switch

Table 57: VACON® 3000 Grid Side Input Inductor Dimensions 1–7

Type Code Dim. 1 Dim. 2 Dim. 3 Dim. 4 Dim. 5 Dim. 6 Dim. 7

FLU-LGI-SSI-425-3-HAF0 561 mm 596 mm 420 mm 650 mm 214 mm 230 mm 260 mm

(22.1 in) (23.5 in) (16.5 in) (25.6 in) (8.4 in) (9.1 in) (10.2 in)

FLU-LGI-SSI-425-3-HAF1 757 mm 470 mm 700 mm

FLU-LGI-SSI-425-3-HAF2 (29.8 in) (18.5 in) (27.6 in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Type Code Dim. 1 Dim. 2 Dim. 3 Dim. 4 Dim. 5 Dim. 6 Dim. 7

FLU-LCV-SSI-425-3-HAFX See 11.1.8 Dimensions, LC Filter.

FLU-LGI-SSI- 640-3- HAF0 410 mm 636 mm 518 mm 700 mm 169 mm 300 mm 330 mm
(16.1 in) (25.0 in) (20.4 in) (27.6 in) (6.7 in) (11.8 in) (13.0 in)

FLU-LGI-SSI- 640-3- HAF1 860 mm

FLU-LGI-SSI- 640-3- HAF2 (33.9 in)

FLU-LGI-HSI- 640-3- HAF0

FLU-LGI-HSI- 640-3- HAF1

FLU-LGI-HSI- 640-3- HAF2

FLU-LGI-340-4-HAF0 363 mm 589 mm 388 mm 718 mm 167 mm 229 mm 257 mm

(14.3 in) (23.2 in) (15.3 in) (28.3 in) (6.6 in) (9.0 in) (10.1 in)

FLU-LGI-340-4-HAF1 699 mm
FLU-LGI-340-4-HAF2 (27.5 in)

FLU-LGI-SSI- 510-4- HAF0

FLU-LGI-SSI- 510-4- HAF1

FLU-LGI-SSI- 510-4- HAF2

FLU-LCV-SSI- 510-4- HAF2 See 11.1.8 Dimensions, LC Filter.

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg643.12
5

1
Ø11
(0.43)

120 120
(4.72) (4.72)

257
215 (10.12)
(8.47)

500
(19.69)
2

6
400
(15.75)

Ø14
(0.55)

3 4

Illustration 124: VACON® 3000 Common-mode Inductor (LCM) Dimensions in mm (in)

1–4 Dimension, see Table 58 6 Fan grille (09418-2-4039, ebm papst)

5 Terminal block for thermal switch

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VACON® 3000 Drive Kit

Operating Guide Specifications

Table 58: VACON® 3000 Common-mode Inductor Dimensions 1–4

Type Code Dim. 1 Dim. 2 Dim. 3 Dim. 4

FLU-LCM-425-3-HAF0 812 mm 568 mm 512 mm 344 mm

(32.0 in) (22.4 in) (20.2 in) (13.5 in)

FLU-LCM-425-3-HAF1 978 mm
FLU-LCM-425-3-HAF2 (38.5 in)

FLU-LCM-640-3-HAF0 822 mm 608 mm 552 mm 384 mm

(32.4 in) (23.9 in) (21.7 in) (15.1 in)

FLU-LCM-640-3-HAF1 1040 mm
FLU-LCM-640-3-HAF2 (40.9 in)

FLU-LCM-340-4-HAF0 745 mm 568 mm 512 mm 344 mm

(29.3 in) (22.4 in) (20.2 in) (13.5 in)

FLU-LCM-340-4-HAF1 868 mm
FLU-LCM-340-4-HAF2 (34.2 in)

FLU-LCM-510-4-HAF0 765 mm 536 mm 512 mm 344 mm

(30.1 in) (21.1 in) (20.2 in) (13.5 in)

FLU-LCM-510-4-HAF1 928 mm
FLU-LCM-510-4-HAF2 (36.5 in)

11.1.10 Dimensions, Common-Mode Capacitor

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VACON® 3000 Drive Kit

Operating Guide Specifications

396.8

e30bg645.11
(15.62)
Ø 12.7
(0.50)

203.2
(8.00)
342.9
(13.50)
431.8
(17.00)
143.0
(5.63)

79.5
(3.13)

Ø 12.7
(0.50)

120.6 330.2
(4.75) (13.00)

104.8
(4.13)

396.8 155.7
(15.62) (6.13)

Illustration 125: VACON® 3000 Common-Mode Capacitor Dimensions in mm (in)

11.1.11 Dimensions, DC Capacitor for DFE

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bj839.10
673.0±0.8
(26.50±0.03)

160
(6.30)
Ø13.0 (Ø0.51)
1
89.9 12.7
(3.54) (0.5)

<80.0 (<3.15) 81.6±0.3

(3.22±0.01)

398.5 (15.69)

436.6±0.8 (17.19±0.03)
Ø10.0 404.8 (15.94)
(Ø0.39) 65±0.3 (2.56±0.01)
M12

1 3 5

238.0±0.5 83.0 153.0

(9.37±0.02) 189.7 (3.27) (6.02)
(7.47) 119.0±0.5
106.7 2 4 6
77.5
(4.20) (4.69±0.02)
(3.05)

42.5 2 3 29±0.5
(1.67) (1.14±0.02)

Illustration 126: 6-terminal DC Capacitor for DFE Dimensions in mm (in), Enclosure Size L20

1 Overpressure switch 3 Grounding terminal, size M6

2 Oil fill hole, Ø = 11 mm (0.43 in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg648.12
673.0±0.8
(26.50±0.03)

160
(6.30)
Ø13.0 (Ø0.51)
1
89.9 12.7
(3.54) (0.5)

<80.0 (<3.15) 83±0.3

(3.27±0.01)

594.0 (23.39)

632.8±0.8 (24.91±0.03)

Ø10.0 600.3 (23.63)

(Ø0.39) 81.8±0.3 (3.22±0.01)
M12

1 3 5

238.0±0.5 83.0 153.0

(9.37±0.02) 187.8 (3.27) (6.02)
(7.39) 109.0±0.5
104.8 2 4 6
77.5
(4.13) (4.29±0.02)
(3.05)

42.5 2 3 28.9±0.5
(1.67) (1.14±0.02)

Illustration 127: 6-terminal DC Capacitor for DFE Dimensions in mm (in), Enclosure Size L30

1 Overpressure switch 3 Grounding terminal, size M6

2 Oil fill hole, Ø = 11 mm (0.43 in)

192 | Danfoss A/S © 2022.11 AQ286660482920en-000201 / DPD01895

VACON® 3000 Drive Kit

Operating Guide Specifications

e30bk185.10
673.0±0.8
(26.50±0.03)

160
(6.30)
Ø13.0 (Ø0.51)
2
1
89.9 12.7
(3.54) (0.5)

<56.5 (<2.22) 94.4

(3.72)
73.7 (2.90)
594.0 (23.39)

632.1±0.8 (24.89±0.03)
600.3 (23.63)
Ø10.0 81.8±0.3 (3.22±0.01)
(Ø0.39)

1 M12
3
268.0±0.5 6
83.0 210.5 239.7
(10.55±0.02) 215.8 2
(8.50) (3.27) (8.29) 4 (9.44)
77.5 7
52.2
(3.05)
(2.06) 5
57.5 3 4 58.5
(2.26) (2.30)

Illustration 128: 7-terminal DC Capacitor for DFE Dimensions in mm (in), Enclosure Size L30

1 2 coolant connectors 1/2 in BSPP 3 Oil fill hole, Ø = 11 mm (0.43 in)

2 Capacitor health monitoring sensor 4 Grounding terminal, size M6

Ø34
e30bj311.10

(1.34) 8.2
Ø32 (0.32)
(1.26)
12
(0.47)
32.8
(1.29)
12 14 11
61.8 25
(2.43) Ø28 (0.98)
19 (1.10)
(0.75) 5
(0.20) HEX 28

10
(0.39) G1/4 - 19-A

Illustration 129: Overpressure Switch Dimensions in mm (in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

11.1.12 Dimensions, Potential Transformer

Ø 12.7 55.7 55.7

e30bg650.10
(0.50) (2.19) (2.19)

241.3
(9.50)

215.9 227.1
(8.50) (8.94)

Ø 8.6
(0.34) 190.5
(7.50)

193.8
(7.63)

15.8
(0.62)

Illustration 130: VACON® 3000 Potential Transformer Dimensions in mm (in)

11.1.13 Dimensions, Isolation Transformer

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg652.11
 6.7 (0.266)
6 (0.25)
165 (6.50)

6 (0.25)

6 8

5 7 19 (0.75)

12.7 (0.50)

79 (3.13)
19 (0.75)

3 (0.13)

2
4

1
19 (0.75)
GND
19 (0.75)
5 (0.19)
3 4
178 (7.00)
12.7 (0.50)

Illustration 131: VACON 3000 Isolation Transformer Dimensions in mm (in)

®

1–4 See the dimensions in table

Table 59: Dimensions 1–4

Transformer type Dim. 1 Dim. 2 Dim. 3 Dim. 4

AXU-ITR-05 92 (3.63) 191 (7.50) 146 (5.75) 203 (8.00)

AXU-ITR-10 98 (3.88) 216 (8.50) 143 (5.63) 216 (8.50)

11.1.14 Dimensions, Grounding Switch

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg654.11
240 28
(9.45) (1.10)
60
° B
C
Ø 16.5
77
(0.65)
(3.03)

354.5 337
(13.96) (13.27)
245
(9.65)

20
(0.79)
54.1
(2.13)
Ø 12
(0.47)
6.0 32
(0.24) 82.5 105 105 105 105
190 (3.25) (4.13) (4.13) (4.13) (4.13) (1.26)
D
(7.48) 45 66
(1.77) (2.60)
F
52
(2.05)
G

44.5
(1.75) 72
(2.84)
E
24.5
(0.97)

149
(5.87) M6

56
(2.21)

Illustration 132: Grounding Switch Dimensions in mm (in)

A Hole on the switch for a lock (not provided), posi- D Ground connection, size M12
tions “0” and “ground”
E Magnetic lock
B Magnetic lock in ground and open position, 24 V DC
F, G Dimensions, see Table 60
C SW11-auxiliary switches CA11 and CA12 (1NO+1NC)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Table 60: Dimensions F and G

Grounding switch Dimension F Dimension G

GSW-5 585 mm (23.03 in) 789.5 mm (31.08 in)

GSW-2 270 mm (10.63 in) 474.5 mm (18.68 in)

11.1.15 Dimensions, Surge Protection Device

e30bg656.10
257.0
(10.12)

100.0 80.0 100.0

(3.94) (3.15) (3.94) Ø9.0
(0.35)

257.0
(10.12)

310.0 370.0
(12.21) (14.57)
323.0
(12.72)

Illustration 133: Surge Protection Device for VACON® 3000, Dimensions in mm (in).

11.1.16 Dimensions, Mounting Rack

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg657.11
1

83.0
(3.27)

3
672.3
2 (26.47)
101.0 101.0
(3.98) (3.98)
4

Ø12
(0.47)

610.8
(24.05)

Illustration 134: Mounting Rack L20/L30 Dimensions in mm (in)

1–4 Dimensions, see Table 61

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bj425.11
1

83.0
(3.27)

200
(7.87)

404.8
(15.94)
674.2
3 (26.54)

101.0 101.0
(3.98) (3.98)
4

Ø12
(0.47)

610.8
(24.05)

Illustration 135: Mounting Rack D20/D30 Dimensions in mm (in)

1–4 Dimensions, see Table 61

Table 61: Mounting Rack Dimensions 1–4

Type code Dim. 1 Dim. 2 Dim. 3 Dim. 4

MEC-RCK-L20HL-3 809.0 mm (31.85 in) 499.0 mm (19.65 in) 404.8 mm (15.94 in) 297.0 mm (11.69 in)

MEC-RCK-L20HL-6 1571.0 mm (61.85 in) 499.0 mm (19.65 in) 404.8 mm (15.94 in) 297.0 mm (11.69 in)

MEC-RCK-L30HL-3 809.0 mm (31.85 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Type code Dim. 1 Dim. 2 Dim. 3 Dim. 4

MEC-RCK-L30HL-6 1571.0 mm (61.85 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

MEC-RCK-D20HL-1 555 mm (21.85 in) 499.0 mm (19.65 in) – 297.0 mm (11.69 in)

MEC-RCK-D30HL-1 555 mm (21.85 in) 694.5 mm (27.34 in) – 492.5 mm (19.39 in)

MEC-RCK-D20HL-5 1571.0 mm (61.85 in) 499.0 mm (19.65 in) 404.8 mm (15.94 in) 297.0 mm (11.69 in)

MEC-RCK-D30HL-5 1571.0 mm (61.85 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

MEC-RCK-D30HS-5(1) 1602 mm (63.07 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

MEC-RCK-D20HL-6 1826 mm (71.89 in) 499.0 mm (19.65 in) 404.8 mm (15.94 in) 297.0 mm (11.69 in)

MEC-RCK-D30HL-6 1826 mm (71.89 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

MEC-RCK-D30HS-6(1) 1856 mm (73.07 in) 694.5 mm (27.34 in) 600.3 mm (23.63 in) 492.5 mm (19.39 in)

1 Has a slot for 7-terminal DC capacitor.

11.2 Power Ratings

11.2.1 Power Ratings for Mains Voltage 3300 V

Table 62: Power Ratings for the VACON® 3000 AFE and 12-Pulse Drives, 3300 V Supply

Drive type code(1) Continuous rating (varia- Low overload rating 110% High overload rating 150% Output
ble torque) (constant torque) (constant torque) phase mod-
ules
Continuous Continuous Continuous Continuous Continuous Continuous
power current Ith power [kVA] current Ith power [kVA] current Ith
[kVA] [A] [A] [A]

VACON3000- 2430 425 2209 386 1620 283 3 x L20

XX-0425-03

VACON3000- 3660 640 3327 582 2440 427 3 x L30

XX-0640-03

VACON3000- 4690 820 4264 745 3127 547 6 x L20

XX-0820-03

VACON3000- 7030 1230 6391 1118 4680 820 6 x L30

XX-1230-03

1
XX = 4Q or 12

11.2.2 Power Ratings for Mains Voltage 4160 V

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VACON® 3000 Drive Kit

Operating Guide Specifications

Table 63: Power Ratings for the VACON® 3000 AFE and 12-Pulse Drives, 4160 V Supply

Drive type(1) Continuous rating (varia- Low overload rating 110% High overload rating 150% Output
ble torque) (constant torque) (constant torque) phase mod-
ules
Continuous Continuous Continuous Continuous Continuous Continuous
power current Ith power [kVA] current Ith power [kVA] current Ith
[kVA] [A] [A] [A]

VACON3000- 2450 340 2227 309 1633 227 3 x L20

XX-0340-04

VACON3000- 3670 510 3336 464 2450 340 3 x L30

XX-0510-04

VACON3000- 4680 650 4255 591 3120 433 6 x L20

XX-0650-04

VACON3000- 7060 980 6418 891 4680 650 6 x L30

XX-0980-04

1 XX = 4Q or 12

11.2.3 Overload Capability

The low overload means that if 110% of the continuous current (IL) is required for 1 minute every 10 minutes, the remaining 9
minutes must be approximately 98% of IL or less. This is to make sure that the output RMS current is not more than IL during the
duty cycle.
e30bg038.10

IL*110% IL*110%

IL

1 min 9 min

t
Illustration 136: Low Overload

The high overload means that if 150% of the continuous current (IH) is required for 1 minute every 10 minutes, the remaining 9
minutes must be approximately 92% of IH or less. This is to make sure that the output RMS current is not more than IH during the
duty cycle.

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VACON® 3000 Drive Kit

Operating Guide Specifications

e30bg039.10
I

I I
H*150% H*150%

I
H

1 min 9 min

t
Illustration 137: High Overload

For more information, refer to the standard IEC61800-2.

11.3 Technical Data

11.3.1 Mains Supply

Table 64: Mains Supply Specifications

Item or function Specification

Input voltage Uin AFE

(Supply trans- 3300 V AC ±10%
former secondary 4160 V AC ±10%
voltage) 12-pulse
1850 V AC ±10%
2360 V AC ±10%
For operation outside these voltage ranges, contact Danfoss.

Input frequency 3300 V AC: 50 Hz ± 5%

4160 V AC: 60 Hz ± 5%

Supply transform- AFE

er requirements Nominal power: Motor power +10%
Recommended short circuit impedance: See 11.3.7 Source Impedance Specifications
Vector group: Dy11
Primary winding configuration: Delta
Secondary winding terminal voltage at full Load: 3300/4160 V

N O T I C E
INPUT COMMON-MODE FILTER
In VACON® 3000 AFE installations, which are not supplied by a dedicated transformer, always install an
input common-mode filter (available as option +PICM).

12-pulse
Nominal apparent power: ~ Motor shaft power +20%
Short-circuit current: Maximum 11 kA
Vector group example: Dy5Dd0

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VACON® 3000 Drive Kit

Operating Guide Specifications

Item or function Specification

Primary winding configuration: Delta
Secondary winding configuration: 30° phase shifted. The secondary windings must be decoupled.
Secondary winding A terminal voltage at no Load: ~ 1850/2360 V
Secondary winding B terminal voltage at no Load: ~ 1850/2360 V
Recommended BIL (secondary side): Minimum 30 kV
A shield is recommended between primary and secondary.
Inter-phase balance: < 1%
Inter-winding balance: < ±0.5%

11.3.2 Motor Output

Table 65: Motor output specifications

Item or function Specification

Output voltage 0 - Uin

Output current ratings (RMS) 3300 V AC: 425 A, 640 A, 820 A, 1230 A
4160 V AC: 340 A, 510 A, 650 A, 980 A

Output frequency 0–120 Hz

Output dU/dt 5 kV/μs

Motor type Induction motor

For operation of synchronous or PM motors, contact Danfoss.

11.3.3 Control Properties

Table 66: Control Properties

Item or function Specification

Control method U/f control

Open loop control (sensorless vector control)
Indirect closed loop control (augmented sensorless vector control)
Closed loop control (field-oriented)

Switching frequency AFE: 1050 Hz (50 Hz input) / 1260 Hz (60 Hz input)

INU: 900 Hz (synchronous PWM with SoftSync)

Acceleration time 0.1 - 3600 s

Deceleration time 0.1 - 3600 s

Control power 3 A, 24 V DC (±10%) per power module (customer supplied)

(power module) Pluggable Mini Terminal Blocks, Phoenix Contact, female part 1829358 in power module (male part
delivered with power module)
An isolation (safety) transformer is necessary for the control power for the power modules

Control power 3 A, 24 V DC (±5%) per control unit (customer supplied)

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Item or function Specification

(control unit)

Communication AI/O, DI/O, fieldbuses (e.g. Profibus DPV1, CANopen, DeviceNet), industrial ethernet protocols (Profi-
net IO & Ethernet/IP), VACON® PC tool

Main protective functions Torque and power limit, current limit, overcurrent, overvoltage, undervoltage, loss of auxiliary pow-
er, loss of communication, ground fault detection

11.3.4 Drive Properties

Table 67: Drive Properties

Item or function Specification

Power module topology 3-level neutral point clamped (NPC)

Rectifier types Active front end (AFE)

12-pulse DFE (requires a dedicated transformer with 2 secondary windings)

Number of power conversion Input

units AFE: 3 or 6
DFE: 1

Output
INU: 3 or 6

Grounding Resistance grounded neutral point, high resistance grounding system of electricity supply, if
no dedicated transformer is installed.
For operation in an IT network without a dedicated transformer, consult Danfoss.

Power device HV IGBT

Rating 100% continuous load (>12 Hz output frequency)

Efficiency (at full load and nomi- AFE: ≥ 97.8%

nal conditions, approximate typi- AFE +PICM: ≥ 97.4%
cal losses, without output filters)
12-pulse: ≥ 98.8%

DC-link voltage AFE 3300 V AC: 5.2 kV DC

AFE 4160 V AC: 6.6 kV DC
12-pulse 1850 V AC: 5.2 kV DC (no load)
12-pulse 2360 V AC: 6.6 kV DC (no load)

DC-link discharge time AFE: < 7 minutes

12-pulse: < 21 minutes

D A N G E R
SHOCK HAZARD FROM THE DC LINK
A contact with the DC-link voltage can lead to death or serious injury.
- Wait after the AC drive is disconnected from the mains for the DC link to discharge.
Use a measuring device to make sure that there is no voltage.

Input current THDi AFE: < 5% (at rated load)

12-pulse: < 15% (at rated load)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Item or function Specification

Power factor > 0.95 (at rated load)

Basic impulse level (BIL)/Impulse IEC61800-5-1, all drives: 23.1 kV

voltage level UL347A, AFE +QSPD: ≤60 kV
UL347A, 12-pulse: ≤60 kV
If higher BIL is required, contact Danfoss.

Approximate power module los- L20: 4.5–5.5 kW (340–425 A)

ses to liquid at nominal load for L30: 8–9 kW (510–640 A)
each module(2)
D22: 2–8 kW (340–640 A)

Creepage distance between ter- L20/L30: 87 mm (3.42 in)

minals D22:
• Front (DC) terminals: 67 mm (2.63 in)
• Back (AC) terminals: 130 mm (5.11 in)

Clearance distance between ter- L20/L30: 46 mm (1.81 in)

minals D22:
• Front (DC) terminals: 46 mm (1.81 in)
• Back (AC) terminals: 99 mm (3.89 in)

2 The losses to air are much smaller than losses to liquid.

11.3.5 Ambient Conditions

Table 68: Ambient Condition Specifications

Item or function Specification

Ambient operating 0°C … +45°C (+32°F ... +113°F)

temperature If operation in below 0°C temperature is required, contact Danfoss for instructions.

Storage temperature -40°C … +70°C (-40°F ... +158°F)

No liquid in the heat sink under 0ºC (+32°F)

Relative humidity (op- < 95% RH, non-condensating, non-corrosive

eration/storage)

Altitude VACON® 3000 is rated for operation at up to 2000 m without thermal or electrical derating.
VACON® 3000 with nominal voltage 3300 V is rated electrically for operation at up to 4000 m, if certified
per IEC 61800-5-1 (not UL347A, option +GAUL). For thermal derating above 2000 m, contact Danfoss.
The thermal derating above 2000 m depends only on the inductors of the input and output filters.

11.3.6 Cooling
Table 69: Cooling Specifications

Item or function Specification

Cooling type Liquid cooling, closed loop with constant flow of cooling liquid

Required cooling liquid flow L20: 25 l/min ± 4 l/min (6.6 gal/min ± 1.1 gal/min)
rate(1) L30: 37 l/min ± 6 l/min (9.8 gal/min ± 1.6 gal/min)
D22: 25–80 l/min (6.6–21.1 gal/min)

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Operating Guide Specifications

Item or function Specification

Inductor HX: 25 l/min ± 4 l/min (6.6 gal/min ± 1.1 gal/min)

Cooling liquid pressure drop L20 with connectors: 1.13 bar (16.4 psi)
inside component (heat L20 without connectors: 0.83 bar (12 psi)
sink/HX)(2)
L30 with connectors: 1.08 bar (16 psi)
L30 without connectors: 0.69 bar (10 psi)
D22: 0.07–0.41 bar (1–6 psi)
LCV: 3 bar (43.5 psi)
LGI: 3 bar (43.5 psi)
LCM: 3.2 bar (46.4 psi)
LSI: 3 bar (43.5 psi)

Maximum static pressure of 10 bar (145 psi)

cooling liquid (heat sink/HX)

Test pressure for cooling liquid 16 bar (232 psi)

in power module heat sink

The cooling liquid volume of L20: 500 ml (16.9 fl oz)

the components (heat L30: 700 ml (23.7 fl oz)
sink/HX)
D22: 2000 ml (67.6 fl oz)
LCV: 750 ml (25.4 fl oz)
LGI: 750 ml (25.4 fl oz)
LCM: 650 ml (22.0 fl oz)
LSI: 750 ml (25.4 fl oz)

Recommended cooling liquid 80% water with 20% glycol (% mixture based on the required freezing temperature require-
type ment), type DOWTHERM SR-1

Cooling liquid temperature 0°C ... +43°C (+32°F ... +109°F)

The cooling liquid temperature must be kept 2°C (3.6°F) above dew point

Cooling liquid temperature Typical temperature difference between inlet and outlet is below 4°C (7.2°F).
rise in power module (3)

Cooling connection L20/L30: G 0.5 in holes with threads (BSPP: ISO/DIN 1179-1) in heat sink with removable ship-
ping plugs.
D22: G 0.75 in holes with threads.
No connectors included.

Hose Non-conductive (customer supplied)

Recommended: Parker Parflex 83FR-8 (inner diameter: 12.7 mm, 0.5 in)

N O T I C E
HOSE SIZE
A 19 mm (0.75 in) hose can be necessary if the hoses are long or if the capacity of the heat
exchanger is low.

Recommended connectors or Heat sink connector: G 12.7 mm (0.5 in) male stud straight adapter thread BSP parallel (World
adapters wide metric #310408)
Hose connection: Stainless steel BSP Swivel female, ball nose type (Parker 19255-8-8C), or BSP
female Swivel 90° elbow, ball nose type (Parker 1B255-8-8C)

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VACON® 3000 Drive Kit

Operating Guide Specifications

Item or function Specification

Sealing kit: G 12.7 mm (0.5 in) O-ring and retaining ring set (from Stäubli)

Recommended flow restrictors L20 = 30 l/min (7.9 gal/min), Kobold REG-3230D

(stainless steel)(4) L30 = 40 l/min (10.6 gal/min), Kobold REG-3240D
Inductor HX = 25 l/min (6.6 gal/min), Kobold REG-1225D

Cooling of passive compo- Forced air cooling. External fans are necessary.
nents (external inductors)

1 Values defined with a 70/30% water/glycol mix. If a higher concentration of glycol is required, contact Danfoss for more information.
2Values measured with a 70/30% water/glycol mix, the required flow rates, and the recommended connectors (from CEJN). The pressure drop is
quadratically related to the cooling liquid flow rate.
3 With a 70/30% water/glycol mix and flow rate 25 l/min.
4 Install the flow restrictors on the outlet side of the components, not on the inlet side.

11.3.7 Source Impedance Specifications

This section describes the source impedance specifications for VACON® 3000 AFE drives. Two tables are provided to help with the
selection of the drive type.
For VACON® 3000 AFE drives without a dedicated transformer, Table 70 gives example combinations of the apparent power (Sb) and
relative impedance (XS) values and the corresponding source inductance (LS). The short circuit power (Ssc) of the feeding grid is also
given in the table.
For VACON® 3000 AFE drives with a dedicated transformer, Ltotal values are given in Table 71.
Ltotal is the sum of the grid inductance and the stray inductance of the transformer: Ltotal = LS + Lxf.
The tables give values for two types of installation locations:
• SSI: Grid with a small source impedance
• HSI: Grid with a high source impedance
Make sure that the cabinet is designed for the resulting short-circuit currents, especially if there is a lower grid impedance. The
output voltage of the transformer is 3300 V or 4160 V (see the drive type code).
If the grid frequency (fgrid) is different to the one in the table, contact Danfoss for instructions.
If more than one drive is connected to the grid, contact Danfoss for instructions.

Table 70: Source Impedance Specifications for VACON® 3000 AFE Drives without a Dedicated Transformer

Drive Type Code Type fgrid (Hz) Example Ssc (MVA) Ls (µH)

Sb (MVA) Xs (%)

VACON3000-4Q-0340-04+PICM SSI 60 ≥8.3 15 ≥55.0 ≤835

≤25.0 15 ≤166.7 ≥275

VACON3000-4Q-0340-04+PICM+PHSI HSI 60 ≥3.3 15 ≥22.0 ≤2087

≤10.0 15 ≤66.7 ≥689

VACON3000-4Q-0425-03+PICM SSI 50 ≥8.3 15 ≥55.0 ≤630

≤25.0 15 ≤166.7 ≥208

VACON3000-4Q-0425-03+PICM+PHSI HSI 50 ≥3.3 15 ≥22.0 ≤1576

≤10.0 15 ≤66.7 ≥520

VACON3000-4Q-0510-04+PICM SSI 60 ≥8.3 15 ≥55.0 ≤835

≤25.0 15 ≤166.7 ≥275

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Operating Guide Specifications

Drive Type Code Type fgrid (Hz) Example Ssc (MVA) Ls (µH)

Sb (MVA) Xs (%)

VACON3000-4Q-0510-04+PICM+PHSI HSI 60 ≥3.5 15 ≥23.6 ≤1947

≤10.0 15 ≤66.7 ≥689

VACON3000-4Q-0640-03+PICM SSI 50 ≥8.3 15 ≥55.0 ≤630

≤25.0 15 ≤166.7 ≥208

VACON3000-4Q-0640-03+PICM+PHSI HSI 50 ≥3.5 15 ≥23.6 ≤1471

≤10.0 15 ≤66.7 ≥520

VACON3000-4Q-0650-04+PICM SSI 60 ≥16.5 15 ≥110.0 ≤417

≤50.0 15 ≤333.3 ≥138

VACON3000-4Q-0650-04+PICM+PHSI HSI 60 ≥6.6 15 ≥44.0 ≤1043

≤20.0 15 ≤133.3 ≥344

VACON3000-4Q-0820-03+PICM SSI 50 ≥16.5 15 ≥110.0 ≤315

≤50.0 15 ≤333.3 ≥104

VACON3000-4Q-0820-03+PICM+PHSI HSI 50 ≥6.6 15 ≥44.0 ≤788

≤20.0 15 ≤133.3 ≥260

VACON3000-4Q-0980-04+PICM SSI 60 ≥16.5 15 ≥110.0 ≤417

≤50.0 15 ≤333.3 ≥138

VACON3000-4Q-0980-04+PICM+PHSI HSI 60 ≥7.1 15 ≥47.1 ≤974

≤20.0 15 ≤133.3 ≥344

VACON3000-4Q-1230-03+PICM SSI 50 ≥16.5 15 ≥110.0 ≤315

≤50.0 15 ≤333.3 ≥104

VACON3000-4Q-1230-03+PICM+PHSI HSI 50 ≥7.1 15 ≥47.1 ≤735

≤20.0 15 ≤133.3 ≥260

Example
A VACON® 3000 AFE without a dedicated transformer with nominal motor current of 340 A is to be installed in a marine 4160 V grid.
• Uin = 4160 V
• f = 60 Hz
The lumped generator apparent power Sb = 6 MVA, with a subtransient reactance Xd” = XS = 15%. Thus, the grid source inductance
is:
2
Uin Xs 4160 V 2 0 . 15
Ls = × = × ≈ 1 . 15 mH
Sb 2πf 6 MVA 2π × 60 Hz

Since LS is between 689 µH and 2.087 mH, the +PHSI option is required in addition to +PICM. Therefore, VACON3000-4Q-0340-04
+PICM+PHSI must be selected.

Example
A VACON® 3000 AFE without a dedicated transformer with nominal motor current of 640 A is to be installed in a 3300 V grid.

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VACON® 3000 Drive Kit

Operating Guide Specifications

• Uin = 3300 V
• f = 50 Hz
The short circuit power (Ssc) of the feeding grid is 100 MVA. Thus, the grid source inductance is:
2
Uin 3300 V 2
Ls = = ≈347 μH
2πf × Ssc 2π ×50 Hz × 100 MVA

Since LS is between 208–630 µH, drive type VACON3000-4Q-0640-03+PICM must be selected.

Table 71: Source Impedance Specifications for VACON® 3000 AFE Drives with a Dedicated Transformer

Drive Type Code Type fgrid (Hz) Ltotal (µH)

VACON3000-4Q-0340-04 SSI 60 ≤2035

≥1475

VACON3000-4Q-0340-04+PHSI HSI 60 ≤3287

≥1889

VACON3000-4Q-0425-03 SSI 50 ≤1630

≥1208

VACON3000-4Q-0425-03+PHSI HSI 50 ≤2826

≥1770

VACON3000-4Q-0510-04 SSI 60 ≤1685

≥1125

VACON3000-4Q-0510-04+PHSI HSI 60 ≤3297

≥2039

VACON3000-4Q-0640-03 SSI 50 ≤1380

≥958

VACON3000-4Q-0640-03+PHSI HSI 50 ≤1971

≥1020

VACON3000-4Q-0650-04 SSI 60 ≤1017

≥738

VACON3000-4Q-0650-04+PHSI HSI 60 ≤1643

≥944

VACON3000-4Q-0820-03 SSI 50 ≤815

≥604

VACON3000-4Q-0820-03+PHSI HSI 50 ≤1413

≥885

VACON3000-4Q-0980-04 SSI 60 ≤842

≥563

VACON3000-4Q-0980-04+PHSI HSI 60 ≤1649

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VACON® 3000 Drive Kit

Operating Guide Specifications

Drive Type Code Type fgrid (Hz) Ltotal (µH)

≥1019

VACON3000-4Q-1230-03 SSI 50 ≤690

≥479

VACON3000-4Q-1230-03+PHSI HSI 50 ≤985

≥510

Example
A VACON® 3000 AFE with a nominal motor current of 1230 A and nominal motor voltage of 3300 V is to be installed in a land-based
grid.
• Uin = 3300 V
• f = 50 Hz
The VACON® 3000 is supplied by a dedicated transformer with:
• Base power of transformer, Sxf = 6.6 MVA
• Xs = 6%
The feeding grid voltage can be, for example, 11 kV, but is not relevant for this calculation. The transformer secondary voltage must
be selected the same as the motor voltage (Uin = 3300 V).
The short circuit power (Ssc) of the feeding grid is 200 MVA. Thus, the lumped input inductance to the drive is the sum of the grid
inductance and transformer stray inductance, both referred to the secondary side:
2 2 2
Uin Uin × Xs Uin 1 Xs 3300 V 2 1 0 . 06
Ltotal = Ls + Lxf = + = × + = × + = 173 μH + 315 μH = 488 μH
2π ×f ×Ssc 2π ×f × Sxf 2π ×f Ssc Sxf 2π ×50 Hz 200 MVA 6 . 6 MVA

Since the Ltotal is between 479–690 µH, drive type VACON3000-4Q-1230-03 must be selected. The total inductance could be up to
690 µH. Therefore, for this VACON® 3000 variant, a transformer with a slightly higher stray inductance could be selected.

11.4 Main Circuit Diagrams

Only main level circuit diagrams of the drive are shown in this chapter. For complete main circuit diagrams, see the project-specific
documentation provided in the VACON® 3000 delivery.

11.4.1 VACON® 3000 AFE Main Circuit Diagrams

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VACON® 3000 Drive Kit

Operating Guide Specifications

+QGSW

e30bg695.11
+QPTR
CNU-AFE CNU-INU
+QAIT
AXU-IOB

LV~
CCM CCM
(+PICM)
PRC
2 x CSH
+PODU
AFE INU
+POSI
+ +
3300/ o o Motor
4160 V - -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM)
+DBCU
+QSPD
PCU

CNU-BCU

Illustration 138: Main Circuit Diagram for VACON® 3000 AFE, 3.3 kV 425/640 A, 3.3 kV 640 A with Option +PHSI and 4.16 kV 340/510 A with
Option + PHSI

+QGSW

e30bg696.11
+QPTR
CNU-AFE CNU-INU
+QAIT
AXU-IOB

LV~
CCM CCM
(+PICM)
PRC
CSH
+PODU
AFE INU
+POSI
+ +
3300/ o o Motor
4160 V - -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM)
+DBCU
+QSPD
PCU

CNU-BCU

Illustration 139: Main Circuit Diagram for VACON® 3000 AFE, 4.16 kV 340/510 A, and 3.3 kV 425 A with Option +PHSI

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VACON® 3000 Drive Kit

Operating Guide Specifications

+QGSW

e30bg697.11
+QPTR
CNU-AFE CNU-INU
+QAIT
AXU-IOB

CCM CCM
(+PICM) LV~

2 x CSH
PRC
+PODU
AFE INU +POSI
+ +
o o
- -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM)
+DBCU
PCU

3300/
Motor
4160 V

2 x CSH
+QSPD PRC
+PODU
AFE INU +POSI
+ +
o o
- -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM) +DBCU
PCU

CNU-BCU

Illustration 140: Main Circuit Diagram for VACON® 3000 AFE, 3.3 kV 820/1230 A, 3.3 kV 1230 A with Option +PHSI and 4.16 kV 650/980 A with
Option +PHSI

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VACON® 3000 Drive Kit

Operating Guide Specifications

+QGSW

e30bg698.11
+QPTR
CNU-AFE CNU-INU
+QAIT
AXU-IOB

CCM CCM
(+PICM) LV~

CSH
PRC
+PODU
AFE INU +POSI
+ +
o o
- -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM)
+DBCU
PCU

3300/
Motor
4160 V

CSH
+QSPD PRC
+PODU
AFE INU +POSI
+ +
o o
- -

LGI LCM LCV 3 x PCU 3 x PCU

(+PICM) (+PICM) +DBCU
PCU

CNU-BCU

Illustration 141: Main Circuit Diagram for VACON® 3000 AFE, 4.16 V 650/980 A, and 3.3 kV 820 A with Option +PHSI

11.4.2 VACON® 3000 12-Pulse Main Circuit Diagrams e30bi547.10

AXU-IOB CNU-INU
+QGSW
+QAIT

LV~
CCM

PRC
PCU
+PODU
CDC INU +POSI
~1840/
2300 V + + + +
o o o o Motor
- - - -
~1840/
2300 V
3 x PCU
+DBCU
PCU

CNU-BCU

Illustration 142: Main Circuit Diagram for VACON® 3000 12-Pulse, 3.3 kV 425/640 A, and 4.16 kV 340/510 A

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VACON® 3000 Drive Kit

Operating Guide Specifications

AXU-IOB CNU-INU

e30bi548.10
+QAIT
+QGSW

LV~

CCM PRC
+PODU
CDC INU
+POSI
+ + +
o o o
- - -

3 x PCU
+DBCU
PCU
PCU
~1840/
2300 V
+
o Motor
-
~1840/
2300 V
PRC
+PODU
INU
CDC +POSI
+ + +
o o o
- - -

3 x PCU
+DBCU
PCU

CNU-BCU

Illustration 143: Main Circuit Diagram for VACON® 3000 12-Pulse, 3.3 kV 820/1230 A, and 4.16 kV 650/980 A

11.5 Abbreviations
12P 12-pulse

4Q 4-quadrant, or regenerative operation

AF Forced air cooling

AFE Active front end

AI Analog input

AIT Auxiliary isolation transformer

AN Natural air cooling

AO Analog output

BCU Brake chopper unit

BIL Basic impulse level

CCA Crowbar control assembly

CCM Common-mode capacitor

CDC DC capacitor for DFE

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VACON® 3000 Drive Kit

Operating Guide Specifications

CLB Crowbar logic board

CM Common mode (voltage)

CNU Control unit

CSH Shunt capacitor

DFE Diode front end, a passive rectifier which uses diodes

DI Digital input

DO Digital output

EMC Electromagnetic compatibility

EMI Electromagnetic interference

ESD Electrostatic discharge

FLC LC filter

FLU Filter unit

GND Ground

GSW Grounding switch

HCM Heat sink capacitor monitor

HMI Human machine interface

HSI High source impedance

HX Heat exchanger

INU Inverter unit

IOB I/O board

IP Ingress protection, for example, IP00, IP21, or IP54

ITR Isolation transformer

KMX Pilot relay of the pre-charge unit

KPC Pre-charge contactor

LCM Common-mode inductor (included in the common-mode filter, option +PICM)

LCV AFE converter side input inductor

LED Light emitting diode

LGI Grid side AFE input inductor (included in the common-mode filter, option +PICM)

LV Low voltage (< 1000 V AC)

MCB Main circuit breaker

MEC Mechanical component

MOV Metal oxide varistor

MV Medium voltage (> 1000 V AC)

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Operating Guide Specifications

MX Main contactor of the pre-charge unit

OPT Option board

PBHS High-speed PowerBus

PCU Power conversion unit

PE Protective earth

PLC Programmable logic controller

PPE Personal protective equipment

PRC Pre-charge unit

PTR Potential transformer

RH Relative humidity

RMS Root mean square

RO Relay output

RTC Real-time clock

SI Source impedance

SIL Safety integrity level

SPD Surge protection device

SS1 Safe Stop 1

SSI Small source impedance

THD Total harmonic distortion

UFES Ultra fast earthing switch

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Operating Guide Index

Index
1 Supply voltage feedback connections........................................ 88
Encoder interface................................................................................ 89
12-pulse........................................................................................................... 19
Real-time clock.....................................................................................94
Software..................................................................................................94
A Signals..................................................................................................... 94
Abbreviations..............................................................................................214 Dimensions......................................................................................... 179
Additional resources................................................................................... 11 Cooling.......................................................................................................... 205
AFE.....................................................................................................................18 Cooling liquid
AFE synchronization test.........................................................................125 Temperature......................................................................................... 34
Air cooling.......................................................................................................39 Cooling system piping................................................................................37
Ambient conditions........................................................................... 25, 205
Antifreeze........................................................................................................33 D
Arc flash detector......................................................................................... 64
DC capacitor for DFE
Auxiliary I/O board
Installation....................................................................................... 31,59
Connector locations........................................................................... 96
Dimensions......................................................................................... 190
Connector specifications..................................................................97
DC-link connections.................................................................................... 51
LED display..........................................................................................101
Dew point........................................................................................................35
Dimensions......................................................................................... 180
DFE power module
Auxiliary power supply...............................................................................63
Installation............................................................................................. 31
Cooling connections.......................................................................... 38
B Terminals..........................................................................................49,53
Brake chopper unit Control terminals.................................................................................49
Installation....................................................................................... 31,53 Grounding..............................................................................................50
Dimensions......................................................................................... 179 LED display............................................................................................ 55
Breaker enable Dimensions......................................................................................... 178
Signals...................................................................................................102 Disposal............................................................................................................11
Flowchart.............................................................................................102 Drive properties..........................................................................................204
Logic...................................................................................................... 102
Mapping examples...........................................................................103 E
EMC....................................................................................................................25
C Encoder...................................................................................................89, 129
Cabinet.............................................................................................................25 Environment......................................................................................... 25, 205
Cabinet heater...............................................................................................64
Cable selection F
Power cables......................................................................................... 42
Mains and motor cables....................................................................44 Fault tracing.................................................................................................135
Control cables.......................................................................................75
Optical fiber cables............................................................................. 86 G
Cabling Galvanic isolation barriers.........................................................................94
Cable inlets............................................................................................ 43 Grid voltage feedback configuration..................................................116
Mains and motor cables....................................................................44 Grounding.......................................................................................................46
Additional instructions......................................................................48 Grounding configurations........................................................................ 46
Fieldbus.................................................................................................. 78 Grounding switch
Commissioning Installation............................................................................................. 59
Safety.....................................................................................................108 Operation............................................................................................... 60
Commissioning test.................................................................................. 122 Dimensions......................................................................................... 195
Common-mode capacitor
Installation............................................................................................. 61 H
Dimensions......................................................................................... 189
Condensation................................................................................................ 34 HCM board
Connector locations.........................................................................106
Control properties..................................................................................... 203
Installation...........................................................................................106
Control unit
Dimensions......................................................................................... 180
Components......................................................................................... 73
Heat exchanger.............................................................................................37
Installation............................................................................................. 74
High overload..............................................................................................201
Interface..................................................................................................74
Cabling....................................................................................................75
Terminals................................................................................................75 I
DIP switches.......................................................................................... 76 Input common-mode filter
Fieldbus terminals...............................................................................78 Installation............................................................................................. 58
Optical fiber connections................................................................. 83 Dimensions......................................................................................... 185
Pre-charge connections....................................................................88 Insulation checks

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Operating Guide Index

Switchgear.......................................................................................... 130 Installation............................................................................................. 56

Intended use.................................................................................................. 18 Dimensions......................................................................................... 194
Isolation transformer Power cabling................................................................................................41
Installation............................................................................................. 62 Power ratings
Dimensions......................................................................................... 194 3300 V................................................................................................... 200
IT grid................................................................................................................47 4160 V................................................................................................... 200
Pre-charge unit
L Installation............................................................................................. 62
Dimensions......................................................................................... 181
LC filter
Precharge unit
Installation............................................................................................. 57
Safety....................................................................................................... 61
Dimensions......................................................................................... 182
Purified water..........................................................................................33, 33
Leak detector................................................................................................. 64
Leakage current............................................................................................ 14
Lifting instructions.......................................................................................24 Q
Liquid cooling Qualified personnel.............................................................................. 11, 12
General information...........................................................................32
Materials................................................................................................. 36 R
Cooling system installation............................................................. 37
Real-time clock.............................................................................................. 94
Connections.......................................................................................... 38
Commissioning..................................................................................114
Low overload...............................................................................................201 S
Low-voltage section....................................................................................41 Safe Stop 1
Operating principle............................................................................ 66
M Response time......................................................................................69
Fault reaction time..............................................................................69
Main circuit breaker..............................................................................16, 56
Safety relay wiring...............................................................................69
Main circuit diagrams
Safety-related data............................................................................. 70
AFE......................................................................................................... 210
Safe torque off
12-pulse................................................................................................213
Safety considerations........................................................................ 65
Mains supply................................................................................................202
Diagnostic test..................................................................................... 65
Maintenance................................................................................................132
Operating principle............................................................................ 65
Maintenance log........................................................................................ 134
Installation guidelines....................................................................... 66
Mechanical interlocking system............................................................. 71
Components......................................................................................... 67
Medium-voltage section............................................................................41
Delay time..............................................................................................68
Motor output...............................................................................................203
Response time......................................................................................68
Mounting rack
Fault reaction time..............................................................................68
Installation............................................................................................. 30
Safety relay wiring...............................................................................69
Grounding..............................................................................................30
Safety-related data............................................................................. 70
Cabling....................................................................................................30
Safety......................................................................................................... 12, 14
Dimensions......................................................................................... 197
Single-belt operation..................................................................................56
Software installation.................................................................................117
O Source impedance.....................................................................................207
Option boards.........................................................................................22, 82 SS1..................................................................................................................... 64
Options.............................................................................................................20 STO.....................................................................................................................64
Overload capability................................................................................... 201 Storage.............................................................................................................23
Overtemperature indicator.......................................................................64 Surge protection device
Installation............................................................................................. 56
P Dimensions......................................................................................... 197
Symbols........................................................................................................... 12
Phase module (L20/L30)
Installation............................................................................................. 31
Cooling connections.......................................................................... 38 T
Terminals..........................................................................................48,53 Type code........................................................................................................20
Grounding..............................................................................................50
LED display............................................................................................ 53 V
Dimensions......................................................................................... 177
Version history...............................................................................................11
Phasing.......................................................................................................... 120
Potential transformer

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VACON® 3000 Drive Kit

Operating Guide Index

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