VSC 2000 Installation Manual
Contents
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3. 5 x 29 5 x 17 3 inches IM02000H conductive material to enter the enclosure or damage may result Installation Manual 5 VSC Large Chassis Mechanical Installation Diagrams Air vents on both sides 05196 01 e Mounting holes are 12mm 0 48 diameter Through panel mounting position e Dimension tolerance is 1 0mm 0 04 A kit is available for through panel mounting the chassis e Eyebolt inside diameter is 25mm 1 0 VSC 2000 Chassis 4 Power Terminal Locations For a Bus Bar Connected Installation SK SUBTRACT THIS DIMENSION FOR THROUGH PANEL MOUNTING 16586 01 IM02000H in 1000 1050 mm A 1000 NI SUN E Hi 940 Ha 1050 Di 458 D2 491 W 620 500 from top Dim H2 310 from right oim W 160 from back Dim D1 Centre of Gravity IMPORTANT 1 The VSC 2000 must be mounted in a vibration free location 2 Allow 100mm above below and either side of each enclosure for ventillation 3 Mount the VSC 2000 vertically away from heat radiating sources 4 Do not mount the VSC 2000 in direct sunlight or on hot surfaces 5 If the VSC 2000 is mounted inside another enclos
4. It is default enabled and set to drive rated current To adjust the Pt value press and enter the desired value as a percentage of motor nameplate current as entered in MOTOH menu Check each value again and make any corrections Installation Manual 17 Monitoring Drive Output Important parameters can be individually displayed on the Run screen in an area of the display set aside to display these quantities By touching the screen on the rotation symbol in the top right corner as shown in figure 5 the drive s output current will be displayed The rotating symbol is otherwise displayed Figure 5 Touch the rotation symbol to display output quantities By touching again the quantity will change to DC bus voltage Further pressing will scroll through output power load and then back to the rotating symbol Alternatively all these quantities can be displayed simultaneously on the METER READOUTS screen To get this display to come up press SETUP scroll down once W then press METER READOUTS To return to the Run Screen press SETUP and then RUN The quantites displayed are in the following units Output frequency Output Current Amps DC Bus Voltage Vdc Output power kW Output load of full load Restoring Factory Settings This feature can be used to restore the drive back to a known group of settings after having made changes to the Setup via the CCS Touch Screen Stop the drive before restoring
5. and The VSC 2000 flexibility that delivers Common Customer interface from 7 through to 160kw for simplified operation IGBT s for silent operation compact size as well as high reliability and performance Solid State electronics for high reliability compact size and vibration resistance Touch sensitive programmable easy to read back lit LCD screen Comprehensive Control Station IP55 NEMA12 enclosure Metal construction for harsh industrial environments The Comprehensive control station may be removed and remote mounted up to 100m from controller Comprehensive display to provide indication of a range of variables simultaneously UL listing for Selected Chassis and undergoing tests for CE amp CSA Keypad pushbuttons for motor control and potentiometer for ease of manual speed control High speed digital microprocessor with in built PWM output waveform synthesis Mounting Points provided for through panel mounting of heat producing section to the outside of cabinets RS 485 serial communications port for control and computer link 2 Programmable analog inputs Up to 12 programmable digital inputs A DC bus choke for reduced harmonics improved power factor and improved immunity to mains transients Up to 4 programmable digital outputs with optional Extended Features Board Quick disconnect terminal strip isolated from ground and power 2 programmabl
6. and exit press MOTOR VOLTAGE The CANCEL is to exit without changing the original value After pressing MOTOR VOLTAGE or CANCEL press the EXIT button to return to the MOTOR menu Now enter rated current by pressing NAMEPLATE CURRENT and keying in 11 Save the value by pressing NAMEPLATE CURRENT Select MOTOH FHEQUENCY and press 50Hz Press the MOTOR FREQUENCY button in the top left or EXIT to return back to the MOTOR menu Next press the NAMEPLATE SPEED RPM button and key in 1440 Return to the MOTOR menu and then press MOTOR or EXIT and then EXIT again to get to the Run Screen That completes the entry of motor parameters In a similar manner all other parameters are programmed into the drive Using the EXIT key returns to the top of the menu system figure 2 Pressing Run will cause a jump back to the Run screen but the complete setup menu will not be exited completely Installation Manual 14 Adjustment Procedure Cont The VSC 2000 can be configured to suit different applications Industrial Terminals is the general purpose configuration and Enhanced Terminals is an extension of this offering additional input outputs and features HVAC Terminals offers special purpose Control inputs and operating features Refer to the three different terminal assignment tables on pages 8 to 9 and the Control Wiring Diagrams on pages 10 to 12 to see how the configurations differ in use WARNING Terminal Configuration shoul
7. material to enter the enclosure or damage may result VSC Cont Max Fuse or Enclosure Model Current C B Rating kg ib Rating Weights Shown include packaging For drive net weight subtract 45 kg 99 Ib of packing material Crate dimensions W x H x D 760 x 1150 x 640 mm 29 2 x 45 3 x 25 2 in Dimension W1 applies only to IP54 drives All other parameters are as per the VSC 2000 General Specifications IM02000H 28 February 2001 Installation Manual VSC 2000 Electrical Installation Diagram Three Phase Input VSC 2A VSC 2G and VSC 2J Power Wiring Diagram Mi M2 M3 For compliance with EMC standards the motor wiring and ground conductor must be enclosed together in a continuous metallic sheath or conduit which has good contact to both the motor and the inverter chassis The sheath shall contain only the wiring from one inverter and its associated motor cables No other conductors may be included VSC 2A 208 220 230 240 Vac Motor VSC 2G 346 380 415 440 460 480 Vac Voltage VSC 2J 440 460 480 575 600 Vac Output voltage cannot exceed input voltage IMPORTANT 1 Either fuses or a circuit breaker should be connected as shown Fast semiconductor fuses are not required Three phase induction motor Three Phase Supply 208Vac to 240Vac 45 to 10 Three Phase Supply 346Vac to 480Vac 15 to 10 Cable sizes should be selected according to local codes or stand
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10. 03 12 Installation Manual IM02000H Start Up Procedure Warning Ensure that input power supply has been removed and the filter capacitors are fully discharged before attempting any work inside the VSC 2000 For safety wear a face shield when working inside VSC 2000 enclosure if power is applied or close covers Connect the input wiring and the motor wiring to the VSC 2000 as shown in the Electrical Installation Diagram At this point the VSC 2000 is ready to run a motor Before applying power it is recommended that the Adjustment Procedure below be read and understood to ensure safe operation of the drive motor configuration Before running a motor ensure that the direction of rotation will not damage machinery or harm personnel On application of power to the VSC 2000 the LEDs on the Comprehensive Control Station CCS will flash momentarily The Zener logo will appear on the LCD touch screen for three seconds then the Run Screen fig 1 will be displayed If a message appears at the bottom of this display it could mean that a trip has occured Refer to Messages and Trouble Shooting Guide for details on possible faults and remedies The CCS front panel will have an amber LED indicating MANual mode and a red LED indicating STOP To run the motor it is now only a matter of setting the CCS SPEED pot to minimum anti clockwise and pushing the FWD button Slowly rotate the speed pot clockwise and check mot
11. 3k3 nominal rated temperature Mioroihierminermal switch thermal overload Tacho Feedback Ft Protection PE M ER Em KANA AA AA Automatic Boost SEVICE MEA Drive Config Fan Controll Select Terminalaren a agiia n te ccs Phase Failure Trip Analog Inputs Power Failure Trip WAU i uum PEERS Imbalance Trip ies p Thermal Display Analog Outputs Run Log orte Output RS 485 Setup Output 2 Drive ID Number Outputs J K L M ORT aaa e OTERO TT Ai paige cos eee Power On Contig Data Formalt Power on Mode ts psa trie gie pergens VAI Power on SCreen iii Factory Controls CCS in Auto Display Units Display Scale Slip Compensation Start Delay Auto Restart Number of restarts Reset AA Power Fail Trip Reset Preset Speeds 6 programmable preset speeds Skip Speeds 4 programmable skip speeds Jog Speed Source Essential Services Speed Override Essential Services Audible Frequency Drive Stopping Modes Coast to Stop Ramp to Stop DG Brake eines DC Braking Brake Strength
12. Brake Duration Dynamic Braking Motorized Pot PID Controller IM02000H Photcopy this page or complete in pencil PID Controller Settings Installation Manual 21 Australian ZENER ELECTRIC PTY LIMITED Manufacturers A DELIVERY ADDRESS POSTAL ADDRESS 366 Horsley Road P O Box 4462 Tel 61 2 9795 3600 MILPERRA MILPERRA DC Fax 61 2 9795 3611 NSW 2214 NSW 1891 Email zenergzener net ZENER AUSTRALIA AUSTRALIA http www zener net Zener Electric Pty Limited 2001 IM02000F 23 November 2001
13. IF ANY OBVIOUS DAMAGE EXISTS After the initial inspection the VSC 2000 can be re packed and stored in a clean dry location until it is ready to be used again DO NOT store this equipment in any area where the ambient temperature will rise above 70 C 158 F or drop below 20 4 F DO NOT store this equipment in areas of high condensation or corrosive atmosphere Proper storage is necessary to ensure satisfactory controller start up and performance IM02000H Installation Maunual Page 1 of 21 VSC 2000 General Specifications VSC 2000 A 208Vac 15 to 240Vac 10 User Serial Port Series EIA Standard RS 485 VSC 2000 G Series 346Vac 15 to 480Vac 10 Analog Inputs Two analog inputs IN 1 IN 1 and IN 2 IN 2 VSC 2000 J 440Vac 15 to 600Vac 10 Both inputs are independently configurable as either Series 0 to 5Vdc Rin gt 100 kOhms 1 to 5Vdc Rin gt 100 kOhms 48Hz to 62Hz 0 to 10Vdc Rin gt 100 kOhms 4 to 20mAdc Rin 250 Ohms 0 to 20mAde Rin 250 Ohms VSC 2000 A Series 0 to 240Vac Input signals may be differential or ground referenced Common mode range for IN 1 IN 1 IN 2 and IN 2 is 26 V with respect to ANA COM or ground 5V terminal 10 max current rating is 33mA sourced VSC 2000 G Series 0 to 480Vac VSC 2000 J Series 0 to 600Vac Output voltage cannot exceed input voltage Two differential outputs OUT 1 and OUT 2 independently configurable as either 1 1 x Continuous Output Curre
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15. NHANCED TERMINALS this is 42 If Reverse is to be the chosen direction then ensure that REVERSE DIRECTION is enabled from the CCS Check wiring for terminals 11 8 12 if IN 1 is used as a speed reference input or terminals 14 amp 15 if IN 2 is used See Control Wiring Diagram Choose the appropriate speed signal type from the INPUT SELECTION menu and ensure that the DIP switch settings are correct This is a normal operating mode for the VSC 2000 If the extended acceleration time can be tolerated then there is no need to make further adjustments When the load is being accelerated too fast the VSC 2000 limits current drawn by the motor by extending the acceleration ramp time Increase ACCEL ramp time Increase current limit value so that the VSC 2000 is not prematurely limiting current Check that motor current rating is not exceeded Check the actual load is within the motor s capacity at the required speed Check the mechanical drive system Check that motor is wired correctly Enter correct motor voltage from the MOTOR menu Enter correct motor frequency from the MOTOR menu Reduce AUTOMATIC BOOST setting Check that ramp times for RAMP 1 and RAMP 2 are set correctly and that the appropriate ramp has been selected from the terminals strip See Terminal Strip Configurations and Ramps in the manual Installation Manual 19 Motor does not decelerate in the time set by the DECEL ramp and VOLTAGE LIMIT message appea
16. Start Up Procedure and Adjustment Procedure have been read and understood To operate the drive from local Comprehensive Control Station CCS controls the Enable control input must be high ie terminals 40 and 48 are connected The MAN ual button when pressed sets the CCS to Manual mode then the FWD REV STOP buttons and SPEED potentiometer are available The STOP MAN ual buttons and SPEED pot can also be available in Auto mode if enabled via the touch screen in the COMPLETE SETUP menu The default setting is Stop enabled in Auto see CCS IN AUTO in the VSC 2000 User s Manual From the examples in the Control Wiring Diagrams it is important to note the following All of the Control inputs are high when connected to 24V dc and ow when open circuit or connected to Digital Common Trip Reset inputs are edge triggered by either positive or negative going edges Forward and Reverse Control inputs are internally latched so do not need to be held high once set All other Control inputs are level dependent and must be held high or low to be valid All wiring examples show that the Enable Run Stop must be held high and a direction Forward or Reverse set for the drive to run at the speed set by the selected speed reference When Enable goes low the drive will immediately stop operating ie no output and the motor will coast to a stop Enable therefore can also be an Emergency Stop input When Run Stop goes low the drive will eith
17. TE Additional Digital Outputs are available if an Extended Features Board is used A These Control Inputs active in AUTO mode only RL 2 dr 64 65 66 Power on ESO not Open Closed selected Power on ESO selected ESO Relay RL 2 Proof Relay RL 1 Enhanced Terminal Configuration FA Number 24V SES 9 2V __ 80 ControlinputJ Increase Speed Motorized Pot 284 2 C I RL 1 are 60 61 62 Power on drive stopped Closed Power on Closed Open drive enabled and direction selected Run Relay RL 1 IM02000H Reference Input F Input G Input H IN 1 11 12 ow IN 2 Motorized Pot o Preset Speed 1 ig Preset Speed 2 ig Preset Speed 3 Preset Speed 4 Low Preset Speed 5 High Preset Speed 6 High All of the control inputs are high when connected to 24Vdc and low when open circuit or connected to Digital Common NOTE Motorized Pot requires the Extended Features EF Board Control Inputs J and K 80 amp 81 replace IN 2 as speed reference when MOTORIZED POT function is enabled from the COMPLETE SETUP menu These Control Inputs active in AUTO mode only re 64 65 66 No input power Power on no trip Power on trip detected Trip Relay RL 2 Installation Manual 9 andino yy eanoe NO U8UM Apz 0 dn ind sindino jey6id dldl dW31l H3AO dlHl tzl did TYWYJHL
18. VSC 2000 Installation Manual ZENER TECHNOLOGY AND QUALITY ASSURANCE Since 1978 Zener Electric has supplied many thousands of AC drives to Australian Industries These drives have been installed into numerous applications resulting in a wealth of in house experience The Zener VSC 2000 AC motor variable speed controller is the culmination of this expertise modern technology and industrial application requirements The Zener Quality Assurance program ensures that every VSC 2000 manufactured has proven to operate correctly in the production test bay before dispatch VSC 2000 PRODUCT WARRANTY Zener Electric warranty the VSC 2000 against defective workmanship and materials for a period of 24 months from the date of dispatch Such defects will be rectified free of charge for both labour and material at Zener Electric s premises subject to 1 Zener Electric s customer raising an order upon Zener for service and or repairs subject to a warranty claim The order is to state particulars of the model and serial number the date of original purchase and invoice delivery docket number 2 All damage resulting from incorrect installation or use other than in accordance with the instruction manuals issued by Zener Electric is excluded from this warranty 3 The Warranty being rendered invalid if the product is misused or if any unauthorised alteration modification or substitution of any part of the product be made or the serial number of the p
19. ailable as well as the custom entry The range of acceptable values is 5Hz to 200Hz Make a selection and then EXIT back to the Run Screen Reverse Direction If reverse direction is required it must be enabled first EXIT from the QUICK SETUP menu Enter the COMPLETE SETUP menu to find REVERSE DIRECTION as the bottom item on the IM02000H first page Press REVERSE DIRECTION and then ENABLE Now press EXIT Current Limit To ensure that the motor does not draw more than its rated current current limit should be set to a value near rated motor current The value is a percentage of drive rated current eg a VSC 2G41 is a 41A unit So a 10096 current limit point will limit output to the motor to 414A Press CURRENT LIMIT and enter a value Then EXIT Thermal Protection From the COMPLETE SETUP menu press the button until THERMAL PROTECTION appears on the menu Select it If a microtherm thermal overload or thermistor is fitted to the motor and it is wired up to terminals 20 and 21 then press THERMAL DEVICE to choose THERMISTOR or MICROTHERM use MICROTHERM for thermal overloads Then EXIT and press THERMAL TRIP then ENABLE and EXIT When external motor thermal protection is fitted Pt protection which is enabled by default can be disabled by pressing 4t PROTECTION and then DISABLE l t is not suitable if multiple motors are being driven but can be an alternative to external motor thermal protection with single motors
20. anically overloaded Motor shaft jammed Fault in motor or motor wiring Incorrect motor voltage selected Incorrect motor frequency selected AUTOMATIC BOOST is set too high Motor does not accelerate in the time set by the ACCEL ramp Wrong ramp has been selected IM02000H Check that terminal 40 is connected to 24V terminals 48 or 49 and that the green LED behind this terminal is illuminated Press the MAN button on the CCS to enable local controls Increase speed pot clockwise Press the AUTO button on the CCS to enable remote controls Check control wiring to terminals 10 through 50 Refer to Control Wiring Diagram and Terminal Configurations From DRIVE CONFIG menu press TERMINAL SELECTION and choose the appropriate terminal strip configuration See Industrial HVAC Enhanced Terminal Configurations for terminal definitions Check that terminal 40 is connected to 24V terminals 48 or 49 and that the green LED behind this terminal is illuminated For INDUSTRIAL TERMINALS and HVAC TERMINALS terminal 42 should be connected to 24V terminals 48 or 49 and that the green LED behind this terminal is illuminated For ENHANCED TERMINALS terminal 41 should be connected to 24V terminals 48 or 49 and that the green LED behind this terminal is illuminated Check that the Forward terminal is at 24V with respect to digital common DIG COM This is terminal 43 on INDUSTRIAL TERMINALS and HVAC TERMINALS On E
21. ards For complete motor thermal protection microtherms or thermistors should be installed in the motor winding Three Phase Supply 440Vac to 600Vac 15 to 10 04696 01 Maximum Fuse and Circuit Breaker Ratings Model Numbers sung uy vscedt4 vscas4 140 154 83 VsC2A6 J 1 wo 17 3 VSC 2427 vsc 2 27 VSCaJ27 270 297 40 VSC2A4 VSC2G41 VSC2JMM so 451 63 VSC 2455 VSC 2G55 vsc 2455 550 605 8 VSC 2A82 VSC 2682 vsc ae 820 02 150 VSC2A109 vsc 2G109 vVSC2J100 1090 1199 150 VSC2A143 vsc 2G143 VSC2J143 1430 1573 20 VSC 2A190 VSC 2G190 VSC 2J190 1900 2090 20 VSC 2A203 VSC 2G208 VSC 2J208 2080 2233 250 VSC 2A271 VSC G27 mo 2981 3 IM02000H Installation Manual 7 Terminal Configurations The VSC 2000 Control Wiring Diagrams show examples of suitable field wiring The Control terminal strip terminals 40 to 47 can be configured via the CCS Touch Screen as either Industrial HVAC or Enhanced Terminals These Configurations are described in the Terminal Configuration tables below Note that some Control input terminal assignments vary slightly between configurations The VSC 2000 is factory set for Industrial Terminals See Drive Configuration for how to select HVAC or Enhanced Terminals from CCS Touch Screen It is recommended you do not power up the drive until the VSC 2000
22. d not be changed in an already installed drive system unless the Control Wiring is set up for the Terminals selected Terminals assignments terminals 40 to 47 differ slightly between configurations Unexpected drive system operation may result otherwise Drive Configuration Two examples of simple setup procedures are now described For most industrial applications a ramp time and minimum and maximum speeds might be the only settings required Follow the Industrial Setup for this If the VSC 2000 is in an HVAC installation follow instructions for the HVAC Setup and then proceed to the Industrial Setup To configure the drive firstly set the Terminals assignment to match the Control Wiring installed Go to the COMPLETE SETUP menu press the Y button until DRIVE CONFIG appears and press it Now press SELECT TERMINALS A warning will appear Read this press OK then choose either INDUSTRIAL HVAC or ENHANCED TERMINALS A new screen appears asking for confirmation press OK Press EXIT then SET CUSTOM DEFAULTS and then OK Press EXIT three times to exitthe COMPLETE SETUP menu Motor Parameters Enter the motor nameplate information after the drive configuration has been set see Entering Motor Nameplate Information IM02000H HVAC Setup Drive CONFIG HVAC terminals Firstly ensure HVAC TERMINALS are selected from the DRIVE CONFIG menu and SET CUSTOM DEFAULTS is pressed This will make essential services
23. down the menus to adjust drive or user parameters To return back up a level in the menu hierarchy use the Exit button When the Hun button is available it can be used to jump to the Run Screen from any level in the menu hierarchy Entering Motor Nameplate Information The following steps serve as an example of how to use the Touch Screen and are beneficial in commissioning the VSC 2000 The four motor parameters of interest for setting up the drive are voltage current frequency and nameplate speed not synchronous speed As an example say a motor has the following parameters Voltage 460V Rated Current 11A Frequency 50Hz Nameplate Speed 1440RPM To enter this information into the drive go into the VSC 2000s menu system by pressing the Setup button From there a selection on the right hand column will contain QUICK SETUP Select this by pressing over the words Now the items on the right hand column are MOTOR RAMP MINIMUM FREQUENCY and MAXIMUM FREQUENCY Press MOTOR to enter the Motor menu Figure 3 MOTOR Menu Now select MOTOR VOLTAGE and examine the values listed in the right hand column IM02000H Press the Y button to see more values Press CUSTOM to type in a value manually Figure 4 CUSTOM screen for MOTOR VOLTAGE For example to manually enter 460 as the motor voltage just start pressing the numbers on the keypad Use the key to backspace the to move forward To save the value
24. e before drilling cable holes Do not allow metal shavings or any other conductive material to enter the enclosure or damage may result Installation Manual 4 VSC Medium Chassis Mechanical Installation Diagrams quam pino e 330 180_ D2 DI B Centre of Gravity 375fromtop Dim H2 190 from right Dim W 100 from back Dim D1 e Mounting holes are 12mm 0 48 diameter e Dimension tolerance is 1 0mm 0 04 e A kit is available for through panel mounting the chassis v UL is pending on these models Model Input Cont E Weight Number Voltage Current kg b zada E Sm e must be mounted in a vibration VSC 2A55 240 V fee location VSC 2A82 240V Allow 100mm above below and either side of VSC 2A109 240V 109A the enclosure for each enclosure for ventillation VSC 2G55 480 V Mount the VSC 2000 vertically away from heat radiating sources Do not mount the VSC 2000 in direct sunlight or on hot surfaces If the VSC 2000 is mounted inside another enclosure the total heat dissipation must be e Eyebolt inside diameter is 12 5mm 0 57 IMPORTANT allowed for Weights shown include packaging Remove gland plate before drilling cable holes For drive net weight subtract 10 kg 22 Ib of Do not allow metal shavings or any other packing material Crate dimensions W x H x D 520 x 750 x 440 mm 20
25. e relay outputs Optional built in dynamic braking control and power switch NEW FEATURES Settable digital output conditions such as fan load warning over speed at speed etc Phase imbalance trip power fail trip phase failure trip and more With a host of high performance software features gt The VSC2000 gives you a range of standard built in features that puts you in control of a wide variety of applications gt Programmable carrier frequency from 2kHz to 16kHz optimizes energy efficiency and audible motor noise gt Choice of three control terminal configurations Industrial HVAC and Enhanced terminals HVAC terminals make for easy building management system integration gt Automatic slip compensation for maintaining motor speed under varying loads gt Thermal protection and output current limit are settable for critical motor sizing applications gt PID controller and tacho feedback input for closed loop control gt Four skip speed lockout frequency bands to avoid load and resonance during ramp up or ramp down gt DC injection braking and optional dynamic braking for rapid load stopping gt Two acceleration and deceleration ramps adjustable from 0 5 seconds to 10 minutes gt Customer selectable Auto Restart with programmable delay up to 20 minutes gt Run log and trip log which records the last 10 trips events gt X Remote interrogation and programming of features v
26. ent Output Frequency Terminal Power load Bus volts Above specifications are subject to change without notice IM02000H Installation Manual 3 VSC Small Chassis Mechanical Installation Diagrams X Centre of Gravity 210 from top Dim H2 0 100 from right Dim W 80 from back Dim D1 na i d Mounting holes are 10mm 0 4 diameter e Dimension tolerance is 1 0mm 0 04 eA kit is available for through panel mounting the chassis v UL applies or UL is pending Number Voltage Current kg lb VSC 2A16 PM v 16A 67 240V vsczam 240v ata 32 7 k saja IE Tos VSC 2G27 asov 27A 30 66 VSC 2041 asov 41A 32 7i vscana eov 14A 30 6 Weights shown include packaging For drive net weight subtract 3 kg 6 6 Ib of packing material Crate dimensions W x Hx D 380 x 610 x 400 mm 15 0 x 24 0 x 15 8 inches IM02000H IMPORTANT The VSC 2000 must be mounted in a vibration free location Allow 100mm above below and either side of each enclosure for ventillation Mount the VSC 2000 vertically away from heat radiating sources Do not mount the VSC 2000 in direct sunlight or on hot surfaces If the VSC 2000 is mounted inside another enclosure the total heat dissipation must be allowed for Remove gland plat
27. er Ramp to Stop Coast to Stop or apply DC Braking according to the DRIVE STOPPING mode selected in COMPLETE SETUP When a trip condition occurs the drive will immediately stop and the motor will coast to a stop If the trip condition has passed the trip can be cleared by the rising or falling edge of the Trip Reset input edge triggered Industrial Terminal Configuration ai Number Reference Input G Input H All of the control inputs are high when conn ectedto 24Vdc and low when open circuit or connected to Digital Common pesta NOTE Additional Digital Outputs are available if 49 2V __ an Extended Features Board is used DIG COM 24V com Digital Common for 24V suppl AThese Control Inputs active in AUTO mode only RL 1 ET 60 61 62 cA 65 B Power on drive stopped Power on no trip Closed Power on drive enabled and direction selected Run Relay RL 1 Power on trip detected Trip Relay RL 2 IM02000H Installation Manual 8 Terminal Configurations Cont HVAC Terminal Configuration E CNN ONE ILLE Number Sz 24V GM lt i DIG COM 24V Digital Common for 24V suppl 60 61 62 Power on trip detected Power on drive enabled Closed Open and no trip Speed Control Input G Control Input H Reference IN1 11 12 Low Low Low L L All of the control inputs are high when connected to 24Vdc and low when open circuit or connected to Digital Common NO
28. factory settings Ensure that the DIP switch SW1 on the back of the CCS is open or off default position If the CCS is in a menu press the EXIT button repeatedly until the Run Screen appears do not use the RUN button If the CCS is already in the Run Screen press SETUP and then use the EXIT button repeatedly to return to the Run Screen Now press SETUP to enter the menu system the screen should look like that shown in figure 2 If not repeat the above instructions Press the following buttons COMPLETE SETUP V 3 times DRIVE CONFIG RESTORE DEFAULTS OK EXIT 3 times The CCS should now display the Run Screen see figure 1 For further in depth information about the VSC 2000 Touch Screen programmable features consult the VSC 2000 User s Manual section Maintenance Procedure There is little maintenance required on the VSC 2000 as it has no moving parts other than the cooling fans Items that can be checked periodically are Check fans for quiet rotation and air vents for free air flow Remove any excess dust by vaccuming This should IM02000H be done periodically depending on dust in the location Annually inspect inside the drive for signs of excess heating ie disscolouration of any components and for any swelling or distortion of capacitors Contact your ZENER supplier it there are any concerns Installation Manual 17 Messages These messages will cause the VSC 2000 to trip and not restart unti
29. from the DC BRAKING menu Fit a dynamic braking module if controlled braking or maximum deceleration is required Check that ramp times for RAMP 1 and RAMP 2 are set correctly and that the appropriate ramp has been selected from the terminals strip See Terminal Strip Configurations and Ramps in the manual See VSC 2000 General Specifications for input voltage ratings Check wiring to motor terminals Check drive and motor current ratings See general specification and check input is within ratings If it is OK then restart the unit Check input supply for voltage transients Fix the external Source Ensure load cannot overdrive the motor If necessary fit dynamic braking Ensure operating ambient temperature is within specification Check fans are rotating freely and there is no build up of dust or debris in blades Visually examine the heatsink fins for build up of dust and debris Reduce audible carrier frequency by selecting a lower carrier in the AUDIBLE FREQUENCY menu choose 8 0kHz as a starting value and increase if HEATSINK TOO HOT trip is no longer occurring or decrease further if necessary Check that MOTOR NAMEPLATE RPM is equal to the motor rated speed Check that NAMEPLATE CURRENT is equal to the motor rated speed Reduce SLIP COMP setting Reduce AUTOMATIC BOOST setting Enter correct motor voltage from the MOTOR menu Enter correct motor frequency from the MOTOR menu Inc
30. functions available and provide a 60 second ramp and ESO and PROOF relay assignments Auto Restart WARNING AUTO RESTART can make the VSC 2000 start without warning It is very important for all personnel to be protected from any machinery driven by the VSC 2000 with AUTO RESTART enabled From the COMPLETE SETUP menu press the W button until AUTO RESTART appears as a menu item To set the number of restarts allowed within a certain period called the Reset Time press NUMBER OF RESTARTS Enter a value minimum of 2 to a maximum of 15 Then set the RESET TIME for a desired value The minimum time is 1 minute and maximum is 20 minutes Finally press ENABLE and then EXIT Essential Services Override ESO WARNING With ESO engaged the VSC 2000 can only be stopped by opening control input F and applying a stop signal Essential Services enabled and Control Input F high the ENABLE RUN STOP and the Comprehensive Control Station STOP AUTO or MAN are disabled All thermal trips are ignored and all other trips are AUTO RESTARTED indefinitely Warranty may be void if the drive gets over stressed ie if any trips are ignored during ESO The SPEED OVERRIDE menu in the COMPLETE SETUP menu contains ESO parameters Ensure that HVAC TERMINALS have been selected prior to making these adjustments When correctly setup the VSC 2000 on a high to Control Input F eg via contact closure will drive the motor at a set speed
31. ia RS485 serial communications VSC 2000 Installation Manual Section Page Scope Conventions Receiving 1 General Specifications 2 Small Chassis Mechanical Installation Diagram 4 Medium Chassis Mechanical Installation Diagram 5 Large Chassis Mechanical Installation Diagram 6 Electrical Installation Diagram 7 Terminal Configurations 8 Control Wiring Diagrams 10 Start Up Procedure 13 Adjustment Procedure 13 Setups 15 Monitoring Drive Output 17 Restoring Factory Settings 17 Messages 18 Trouble Shooting Guide 19 Your Set up Notes 21 This document is intended for use as a guide to install and safely power up the VSC 2000 It contains only essential information to complete this task This manual should be read in conjunction with the VSC 2000 Users Manual which contains information detailing programming and operation instructions All recommendations given should be followed and in case of uncertainty contact Zener Electric Sydney who can provide a writen recommendation on request Conventions Words that are capitalized and in italics such as COMPLETE SETUP refer to menu items that can be accessed via the touch screen on the Comprehensive Control Station or CCS Words in Bold refer to sections within this document Inspect the VSC 2000 for shipping damage If any damage is found report it to the carrier immediately Access the inside of the controller and visually check for any damage DO NOT ATTEMPT TO OPERATE THE VSC 2000
32. l a Trip Reset signal is activated or Auto restart is enabled Message Over Current Over Voltage Under Voltage Phase Failure INTERNAL TOO HOT HEATSINK TOO HOT Motor Overload I2t Ground Fault Motor Too hot Thermistor Shorted Charge Relay Fault Output Imbalance DTVSC DT V OC DTASC DTAOC DT BAD DT V BAD DT A BAD Meaning One of the outputs has exceeded maximum current Input voltage or bus voltage has exceeded maximum value Bus voltage has fallen below minimum threshold Input voltage has a phase missing or is low Drive is too hot Power devices inside drive are too hot An l t trip has occurred A ground fault has occurred on the output A Thermistor microtherm has indicated motor hot Thermistor connected to drive is short circuit Internal bus charge relay has not closed Output current and or voltage is out of balance Power Board Sizing Resistor is short circuit Power Board Sizing Resistor is open circuit Chassis Resistor is short circuit Chassis Resistor is open circuit Power Board and Chassis Resistor not compatible Power Board and Chassis Resistor not compatible Power Board and Chassis Resistor not compatible The following messages indicate operating modes and will not trip the VSC 2000 Message CURRENT LIMIT BUS VOLTAGE HIGH DC Braking SCREEN LOCKED Data Card missing Data Card blank Data Card corrupt IM02000H Meaning Motor is drawing maximum current Motor is regenera
33. mum frequency Speed Override Essential Services Speed Minimum to maximum frequency Speed Source Internal programmable Minimum to maximum frequency External default IN 2 terminals 14 15 Slip Compensation 0 to 150 of slip frequency Drive Stopping Modes Coast to Stop Ramp to Stop DC Brake DC Braking Brake Strength Oto 100 of driveintermitent Brake Duration 0 to 60s current rating User Parameters cont Auto Restart Number of restarts 2to 15 Reset Time 1 to 20 minutes Thermal Protection Devices Thermistor 3k3 nominal rated temperature Microtherm thermal switch thermal overload 36 to 150 of entered motor nameplate current Automatic Boost 0 to 150 Pt Protection Audible Frequency 2 0kHz to 16 0kHz Selectable in 2kHz steps Automatic Selection optimised for silent operation with high efficiency at near full speed Power On Mode Manual or Auto Language English Malay Spanish Swedish The following features can be enabled disabled Motorized Pot Phase FailureTrip Reverse Direction CCS in Auto Thermal Trip Power Failure Trip Pt Protection Imbalance Trip Reverse Acting Input Signals Bipolar Input Signals Auto Restart Power Fail trip Reset Skip Speeds 1 to 4 independently Essential Services DC Braking Dynamic Braking Display Running Screen Speed speed reference Temperature Display Internal Ambient temperature C Heatsink temperatures C Meter Readouts Motor Curr
34. nt 0 to 5Vdc see drive ratings VSC 2000 Electrical Installation 1 to 5Vdc Diagram 0 to 10Vdc Output Frequency 4 to 20mAdc 0Hz to 200Hz 0 to 20mAdc Analog Outputs Signal source can be speed load or bipolar load Frequency Resolution 0 196 of selected maximum with CCS pot See also PID Analog Outputs Galvanically isolated to 42Vdc Maximum output current rating 20mA OUT 2 is available on the Extended Features Board Digital Input and Outputs Inputs and outputs are opto isolated Common mode range is 42Vdc with respect to Frequency Linearity 0 296 of selected maximum frequency Enclosure Rating IP55 NEMA 12 ground Note IP55 does not require air filters 24V Supply terminals 48 49 amp 84 Maximum current from terminals 48 49 amp 84 combined Chassis Colour Number 400 mA APO Dulux Powder Coat Digital Inputs terminals 40 to 47 and 80 to 83 Environmental Rating Digital Inputs A to H and J to M logic levels Input Logic High 12Vdc to 30Vdc Input Logic Low 6Vdc to 2 2Vdc Storage Temperature 20 C 4 F to 70 C 158 F Operating Temperature 0 C 32 F to 50 C 122 F Average over a 24 hour period lt 45 C 113 F Relative Humidity 5 to 95 non condensing Digital Outputs terminals 80 81 82 amp 83 Maximum current per output 300mAdc Digital Outputs are active high source current Maximum current sourced from terminals 80 81 82 amp 83 combined 350mAdc Digital Out
35. or for rotation If the rotation is in the wrong direction press STOP disconnect power and wait for capacitors to fully discharge swap any two motor phase wires and then re apply power and press FWD Adjustment Procedure The Comprehensive Control Station CCS is the interface between the user and the drive It has local front panel controls as well as the Touch Screen programming interface The brief instructions below will acquaint the user with the CCS and how to use it Most user parameters can be adjusted while the drive is running a motor however safety should always be the first consideration The user is encouraged to navigate the menus without fear of damage to the drive however care must be taken to ensure any equipment connected to the motor will not be damaged nor harm personnel A simple method of resetting the drive to factory settings is described in Restoring Factory Settings Using the Touch Screen The Run Screen Fig 1 always appears a few seconds after powering up the VSC 2000 IM02000H Figure 1 Run Screen Touching the screen over the word Setup will take the CCS into the menu system Fig 2 To return back to the Run Screen press the Run button COMPLETE Help SETUP Y LANGUAGE Exit DISPLAY Figure 2 Menu System Installation Manual 13 Adjustment Procedure Cont The menu system is arranged as a hierarchal structure It is necessary to descend
36. puts J K L amp M and relays RL 1 RL 2 indications Local Controls Zero Speed ESO Run Signal Trip Function Name O Under Speed user set speed Manual Over Speed user set speed PID Saturation Forward At Speed PID Output Saturation Reverse Drive Enabled PV Over Alarm Stop Forward Direction Auto Restart Avallable Reverse Direction Fan Load Warning Remote Thermal trip Local l2t trip Over Temperature Trip Relays RL 1 and RL 2 Contact Ratings cos 1 0 cos 0 4 L R 7ms 8A 250Vac 3 5A 250Vac 8A 30Vdc 3 5A 30Vdc Speed Potentiometer Activation force 60 to 120g 2 to 402 Lifetime 10 million cycles IM02000H Installation Manual 2 VSC 2000 General Specifications User Parameters Limits on all user parameters Motor Voltages VSC 2000 A Series 208V to 240V VSC 2000 G Series 346V to 480V VSC 2000 J Series 440V to 600V Nameplate Current 0 5 to 1 5 x drive rated current Motor Frequency 40Hz to 200Hz Nameplate Speed RPM 600 to 7000 rpm Ramp 1 and Ramp 2 Accel and Decel 0 5s to 600s Accel S and Decel S 0 01 to 40 Current Limit 36 110 of drive rated current Minimum Frequency Programmable minimum motor frequency 0 to Maximum Frequency 5Hz Maximum Frequency Programmable maximum motor frequency 5Hz to 200Hz Preset Speeds 6 programmable preset speeds Minimum to maximum frequency Skip Speeds 4 programmable skip speeds Speed 0 to maximum frequency Range 0 to maxi
37. rease CURRENT LIMIT setting Do not run the motor at low speeds for long periods with AUTOMATIC BOOST set high unless the motor has been suitably de rated or is force cooled Check the motor and motor wiring for faults Enter correct motor voltage from the MOTOR menu Enter correct motor frequency from the MOTOR menu Touch Screen does not Touch Screen has been locked Check that switch 1 of DIP switch SW1 on the back of the CCS respond inside the door of the VSC 2000 is opened Touch Screen does not operate properly Wrong language is displayed on the CCS Display is too dark or it is too light IM02000H A change in temperature has occurred since the display was last adjusted Touch Screen out of calibration See the Touch Screen calibration procedure in the User s Manual See the User s Manual for menu structure diagram Use it to navigate the menus to LANGUAGE select the appropriate language Adjust the LCD contrast ratio from the DISPLAY menu Installation Manual 20 Your VSC 2000 Set up notes User Parameters Motor Voltages Nameplate Current Motor Frequency Nameplate Speed RPM Ramp 1 and Ramp 2 Accel and Decel Accel S and Decel S Minimum Frequency Maximum Frequency Reverse Direction Current Limit Thermal Protection Thermistor
38. roduct is defaced or altered 4 The cost of transportation both ways is to be met by the owner if it is necessary to return the product or any part of it to Zener Electric s premises 5 A charge being accepted by the owner for traveling time and expenses incurred in connection with warranty service at the user s site as requested by the owner 6 If the product was not purchased from Zener Electric directly then a warranty claim must be lodged with the original supplier in the first instance Repairs will not be effected by Zener Electric unless approved by the original supplier 7 Goods not of our own manufacture incorporated in our supply or merchanted by us carry their maker s warranty only 8 Goods returned for claim under warranty will be accepted on the condition that should the claim be rejected then all costs including inspection will be charged to the customer s account 9 Zener Electric is not liable for any consequential loss SAFETY Your VSC 2000 must be applied installed and operated in a safe manner It is the responsibility of the user to ensure compliance with all regulations and practices covering the installation and wiring of your VSC 2000 The Installation Manual section should be completely read and understood before attempting to connect or operate the VSC 2000 Only skilled personnel should install this equipment THE CONTENTS OF THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE A promise of performance
39. rs on CCS Motor does not decelerate in the time set by the DECEL ramp VOLTAGE LIMIT message appears on CCS OVER CURRENT message appears on CCS OVER VOLTAGE message appears on CCS INTERNAL TOO HOT or HEATSINK TOO HOT message on CCS Motor is unstable Excessive Motor Heating Voltage limit circuit is operating Wrong ramp has been selected Input voltage has exceeded maximum rating Short circuit on motor terminals Motor full load current is greater than 1 5 x drive rated current Input voltage has exceeded maximum ratings Motor is overhauling Ventilation problem Drive is constantly overloaded SLIP COMP is set too high AUTOMATIC BOOST is set too high Incorrect motor voltage selected Incorrect motor frequency selected CURRENT LIMIT is set too low AUTOMATIC BOOST is high and motor is running at low speeds for long times Motor damaged or incorrectly wired Incorrect motor voltage selected Incorrect motor frequency selected VSC 2000 Trouble Shooting Guide Cont This is a normal operating mode for the VSC 2000 If the extended deceleration time can be tolerated then there is no need to make further adjustments When the load is being decelerated too fast the VSC 2000 limits current regenerated by the motor by extending the deceleration ramp time Increase DECEL ramp time Select DC BRAKE from DRIVE STOPPING menu Adjust strength and duration of braking
40. ting Drive is applying DC braking to the motor Touch Screen will not respond to pressing Data card is not plugged in amp factory defaults are being used No serial number exists on data card Data is found to be corrupt Installation Manual 18 VSC 2000 Trouble Shooting Guide Power LED does not illuminate Input power wiring not connected properly Input voltage not within specification Check input power wiring refer to the VSC 2000 Electrical Installation Diagram Measure the input voltage at the VSC 2000 input terminals Check with specifications CCS does not illuminate No power to the CCS Check Power LED on control board is illuminated Check CCS is connected to control board Motor does not rotate when FWD button on the CCS is pressed Enable signal is not active VSC 2000 is in AUTO Speed pot is set to minimum anti clockwise Motor does not rotate VSC 2000 is in MAN when remote START signal is activated Incorrect control signal wiring Incorrect terminal strip selection Enable signal is not active Run signal is not active A direction has not been selected Speed signal is not correctly connected Incorrect speed signal selected Motor does not accelerate in the time set by the ACCEL ramp and CURRENT LIMIT message appears on CCS Current limit circuit is operating CURRENT LIMIT set to low CURRENT LIMIT message appears continuously on CCS Motor mech
41. ure the total heat dissipation must be allowed for 6 Remove gland plate before drilling cable holes 7 Do not allow metal shavings or any other conductive material to enter the enclosure or damage may result VSC Input Cont a w obo Model Voltage Current VSC2A143 240V 143A EAFA VSC2A190 240V 190A 211 465 VSC2J143 465 VSC2J190 Weights shown include packaging For drive net weight subtract 45 kg 99 Ib of packing material Crate dimensions W x H x D 760 x 1150 x 640 mm 29 9 x 45 3 x 25 2 inches Installation Manual 6 VSC 2000 Manual Supplement N Kipimo DEM 0 x Centre of Gravity both sides 500 from top Dim H2 310 from right Dim W hrough pane mounting position 160 from back Dim D1 e Mounting holes are 12mm 0 48 diameter The VSC SS dl wowkted Inca e Dimension tolerance is 1 0mm 0 04 vibration free location e A kit is available for through panel mounting the Allow 100mm above below and either chassis side of each enclosure for ventilation e Eyebolt inside diameter is 25mm 1 0 ae puo 2000 vertically away from eat radiating sources Do not mount the VSC 2000 in direct sunlight or on hot surfaces If the VSC 2000 is mounted inside another enclosure the total heat dissipation must be allowed for Remove gland plate before drilling cable holes Do not allow metal shavings or any other conductive
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