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Vacon 100 X Installation Manual

1. Figure 12 VACON 100 X drive dimensions MM5 Dimensions WxHxD mm in MM5 232 6 x 367 4 x 213 5 9 16 x 14 46 x 8 41 MM5 HMGR 232 6 x 367 4 x 230 8 9 16 x 14 46 x 9 08 MOUNTING VACON 24 l RE i L
2. brake resistor AC power supply Sx Three phases S PE Figure 21 Power connections MM6 POWER CABLING VACON 36 4 4 CABLE DIMENSIONING AND SELECTION Table 12 shows the minimum dimensions of the Cu cables and the corresponding fuse sizes These instructions apply only to cases with one motor and one cable connection from the AC drive to the motor In any other case ask the factory for more information 4 4 1 CABLE AND FUSE SIZES FRAMES MM4 TO MM6 The recommended fuse types are gG gL IEC 60269 1 or class T UL amp CSA The fuse voltage rating should be selected according to the supply network The final selection should be made according to local regulations cable installation conditions and cable specification Bigger fus es than what is recommended below shall not be used Check that the fuse operating time is less than 0 4 seconds Operating time depends on used fuse type and impedance of the supply circuit Consult the factory about faster fuses VACON offers recommendations also for high speed J UL amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4
3. Figure 13 VACON 100 X drive dimensions MM6 Dimensions WxHxD mm in MM6 349 5 x 499 8 x 235 4 13 76 x 19 68 x 9 27 MM6 HMGR 349 5 x 499 8 x 254 2 13 76 x 19 68 x 10 00 Service support find your nearest Vacon service center at www vacon com VACON 25 MOUNTING 3 2 INTRODUCTION OF MODULES The mechanical concept of VACON 100 X drive is based on two segregated parts power and control connected to each other by pluggable terminals The power unit called powerhead in cludes all the power electronics such as the EMC filter IGBTs capacitors choke or power boards while the control board and the control terminals are located in the terminal box Powerhead Terminal box Figure 14 VACON 100 X drive modules MOUNTING VACON 26 3 3 MOUNTING The drive consists of two main elements 1 The terminal box that includes the power terminals and control board with the control ter minals and 2 The powerhead containing all the power electronics To install the drive both parts need to be separated The terminal box must be fixed first and all cabling done After this the powerhead will be plugged on the terminal box and fixed with 4 MM4 and MM or 6 MM5 dedicated screws located on top side of the powerhead see Fig ure 15 In order to guarantee specified IP protection recommended fastening
4. Figure 55 Mounting of the keypad Figure 56 Keypad mounted onto the drive Tighten the fixing screws of the cable connector to the enclosure of the drive This is to keep the high IP66 protection degree of the drive Service support find your nearest Vacon service center at www vacon com VACON 81 OPTIONS 8 2 3 WALL MOUNTING The keypad can be mounted on the wall in a convenient location by using the same keypad holder and three screws provided with the keypad option kit 1 e Fix the keypad holder with three screws to the wall Figure 57 Fix the keypad holder with three screws to the wall OPTIONS VACON 82 2 e Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall Figure 58 Keypad connected to the drive Service support find your nearest Vacon service center at www vacon com VACON 83 OPTIONS 8 2 4 GRAPHICAL AND TEXT KEYPAD There are two keypad types you can choose for your user interface keypad with graphical display and keypad with text segment display text keypad The button section of the keypad is identical for both keypad types Move backward in menu Scroll menu up Exit edit mode Increase value Reset faults with long press eval dec onbrel pace Move cursor left Move cursor right
5. b Terminal Signal 10 Vref Reference output TE eee 2 Ae E ee 3 Ale Analogue input com mon o MIS ee ae SOUS 5 N Analogue input com mon ES A a E 6 24Vout 24V aux voltage 7 GND 1 0 ground 1 Sas 8 DI Digital input 1 ey ate Oe teh oat 8s 9 D2 Digital input 2 DE Pret 10 D Digital input 3 i 11 cM Common for DI1 DI6 12 24Vout 24V aux voltage I Sa date Nae 13 GND 1 0 ground I wae j Sry She ae a 14 DI4 Digital input 4 Sa REE EES 15 Di5 Digital input 5 I f f DRE UM ARE 16 DI Digital input 6 17 CM Common for DI1 DI6 Analogue output 18 AO1 or aa voltage or current See te 19 AO GND Analogue output com mon 24V auxiliary input 30 24 Vin voltage A RS485 Serial bus negative l j I I I I I I I I I I I I I I I I I I I v v B RS485 Serial bus positive Can be isolated from ground see chap ter chapter 5 1 6 Service support find your nearest Vacon service center at www vacon com VACON 49 CONTROL UNIT 5 1 3 RELAY AND THERMISTOR INPUT TERMINALS Table 20 I O terminal signals for relay and thermistor terminals and connection example From p siemdardiy Relays and thermistor From term From term 6 13 21 RO1 1 Relay output 1 RUN LL pel 22 R012 y Q 23 R013 24 R02 1 Relay output 2 25 RO2 2 26 RO2 3 J 02 1238 i Thermistor input
6. Figure 74 Heater option for MM4 Figure 75 Heating element and terminals Service support find your nearest Vacon service center at www vacon com VACON 101 OPTIONS DC Figure 76 Remove the cable entry plate right side example ig ut ZO SOL EEE 2 Figure 77 Remove the powerhead from the terminal box OPTIONS VACON 102 D QE TO H COCECECEC Figure 78 Connect the supply voltage black cable and the output relay red cable to the op tional heater through the bottom cable entry plate Color of the cables is only as example Figure 79 Mount the optional heater on the terminal box and then close the powerhead Service support find your nearest Vacon service center at www vacon com VACON 103 OPTIONS 8 4 OPTION BOARDS VACON 100 X drive family embodies a wide selection of expander boards with which the available 1 0 of VACON 100 X frequency converter can be increased and its versatility improved There are two board slots labelled D and E on the VACON 100 X control board To locate the slot see chapter 5 Usually when the AC drive is delivered from the factory the control unit doesn t in
7. Can be used with an external power supply with a current 24V auxiliary input limiter or fuse protected to supply the control unit and 30 voltage fieldbus for backup purposes Dimensioning max 1000mA control unit A RS485 Differential receiver transmitter Set bus termination with dip switches see page 50 B RS485 Default but termination disconnected Table 30 Technical information on standard I O terminals Relays with two change over contact SPDT and a PTC thermistor input Relays 5 5 mm isolation between channels Terminal Signal Technical information 21 Switching capacity 24VDC 8A 22 Rel 1 250VAC 8A elay output 125VDC 0 4A 23 Min switching load 5V 10mA 24 Switching capacity 24VDC 8A 250VAC 8A x 25 Relay output 2 125VDC 0 4A 26 Min switching load 5V 10mA 28 Thermistor input Rtrip 4 7 kQ PTC Measuring voltage 3 5V 29 If 230VAC is used as control voltage from the output relays the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes This is to prevent welding on the relay contacts Refer to standard EN 60204 1 section 7 2 9 Table 31 Technical information on Relay and thermistor terminals Service support find your nearest Vacon service center at www vacon com VACON 73 TECHNICAL DATA OPTIONS VACON
8. VACON 29 MOUNTING POWER CABLING VACON 30 4 POWER CABLING The mains cables are connected to terminals L1 L2 and L3 and the motor cables to terminals marked with U V and W See principal connection diagram in Figure 17 See also Table 11 for the cable recommendations for different EMC levels Control Power unit Figure 17 Principal connection diagram Use cables with heat resistance in accordance with the application requirements The cables and the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can find on the rating plate Service support find your nearest Vacon service center at www vacon com VACON 31 POWER CABLING EMC levels Cable type Category C2 Category C3 Category C4 Mains cable 1 1 1 Motor cable 3 2 2 Control cable 4 4 4 Table 11 Cable types required to meet standards 1 Power cable intended for fixed installation and the specific mains voltage Shielded cable not required MCMK or similar recommended 2 Symmetrical power cable equipped with concentric protection wire and intended for the specific mains voltage MCMK or similar recommended See Figure 18 3 Symmetrical power cable equipped with compact low impedance shield and intended for the specific mains voltage MCCMK EMCMK or similar recommended Recom mended cable transfer impedance 1 30MHz max 100 mOhm m See Figure 18 360 earthing of t
9. Physical SI value US value Conversion factor US designation dimension length 1 mm 0 0394 inch 25 4 inch Weight 1kg 2 205 lb 0 4536 pound 1 revolution per Speed 1 min 1 rpm 1 miriute Temperature 1 C T1 33 8 F T2 T2 T1x9 5 32 Fahrenheit pound force inches Power 1 kW 1 341 HP 0 7457 horsepower Torque 1 Nm 8 851 lbf in 0 113 Table 2 Unit conversion table Service support find your nearest Vacon service center at www vacon com VACON 5 SAFETY 1 DANGER The components of the power unit of VACON 100 X drives are live when the drive is con nected to mains potential Coming into contact with this voltage is extremely dangerous and may cause death or severe injury The motor terminals U V W the brake resistor terminals and the DC terminals are live when VACON 100 X Drive is connected to mains even if the motor is not running After disconnecting the AC drive from the mains wait until the indicators on the keypad go out if no keypad is connected see the indicators on the cover Wait 30 more seconds before doing any work on the connections of VACON 100 X Drive Do not open the unit before this time has expired After expiration of this time use a measuring equipment to absolutely ensure that no voltage is present Always ensure absence of voltage before starting any electrical work The control O terminals are isolated from the mains potential However t
10. Stop button S rollmenu down Start button Decrease value Enter active level item Confirm selection Figure 59 Keypad buttons OPTIONS VACON 84 8 2 5 VACON KEYPAD WITH GRAPHICAL DISPLAY The graphical keypad features an LCD display and 9 buttons 8 2 5 1 Keypad display The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions On the display the user sees information about his present location in the menu structure and the item displayed 8 2 5 2 Main menu The data on the control keypad are arranged in menus and submenus Use the Up and Down arrows to move between the menus Enter the group item by pressing the OK button and return to the for mer level by pressing the Back Reset button The Location field indicates your current location The Status field gives information about the present status of the drive See Figure 60 Status field Status field STOP RUN READY NOT READY FAULT Direction ALARM Control place STOP READY 1 0 ci Aes PC I0 KEYPAD FIELDBUS m e field Parameter ID number k Set i are S uP and current menu location Activated group item Press OK to enter 3 Monito Re 5 Parameters a 12 Number of items in the group Figure 60 Main menu 8 2 5 3 Using the graphical keypad Editing values Change value of a parameter following the procedure below 1 Locate the parameter Enter the Edit
11. long time super vision 200 Motor control Start angle identification has failed Reset the fault and restart 25 fault Should the fault re occur con 241 Generic motor control fault tact the distributor near to you Emergency stop button has been con S 30 530 STO fault nected or some other STO operation men tne AIU tunete Haml vated the drive is in safe state has been activated 32 312 Fan cooling Fan life time is up Change Tan Andrese ame time counter 33 320 Fire mode Fire mode of the drive is enabled The Check the parametersettings enabled drive s protections are not in use Device changed Option board changed for one previ Device is ready for use Old 37 360 g ously inserted in the same slot The parameter settings will be same type board s parameter settings are saved used Table 32 Fault codes and descriptions Service support find your nearest Vacon service center at www vacon com VACON 97 OPTIONS Fault code Fault ID Fault name Possible cause Remedy Option board added The option board oo Device is ready for use Old Device changed was previously inserted in the same 38 370 A parameter settings will be same type slot The board s parameter settings used are saved 39 380 Device removed Option board removed from slot Device no longer available 40 390 Device unknown Uni nom
12. Short circuit current Max short circuit current has to be lt 100kA Output voltage SAC Ons Un Rated output current IN Ambient temperature max 40 C See Table 24 and Table 25 Overload output current 1 5 x IN 1 min 10 min Starting output current Is for 2 s every 20 s ls 2 0 IN Output frequency 0 320 Hz standard Frequency resolution 0 01 Hz Protection class Motor characteristics AC squirrel cage motors Permanent magnet motors Cable type Screened motor cable Cable maximum length full EMC compliance C2 15m Switching frequency Programmable 1 5 16 kHz Default 6 kHz Automatic switching frequency derating in case of overheating Frequency reference Analogue input Panel reference Resolution 0 1 10 bit accuracy 1 Resolution 0 01 Hz Field weakening point 8 320 Hz Acceleration time 0 1 3000 sec Deceleration time 0 1 3000 sec Braking Brake chopper standard in all frames External brake resistor optional See chapter 5 Service support find your nearest Vacon service center at www vacon com VACON 69 TECHNICAL DATA Communication interface Ambient conditions Directives Standards Approvals Declaration of Conformity CE Fieldbus Standard Serial communication RS485 Mod bus Ethernet O
13. STO terminals Dip switches I oO O1 BY BM Ethernet terminal see chapter chapter 5 2 1 8 Option boards Table 17 Locations of components in control unit SiG e2 Gi amp F _ ACS Figure 30 Locations of components in control unit When delivered from the factory the control unit of the AC drive contains the standard control ling interface the control and relay terminals of the control unit unless otherwise specifi Service support find your nearest Vacon service center at www vacon com VACON 47 CONTROL UNIT cally ordered On the next pages you will find the arrangement of the control 1 0 and the relay terminals the general wiring diagram and the control signal descriptions The control board can be powered externally 24VDC max 1000mA 10 by connecting the external power source to terminal 30 see chapter 5 1 2 This voltage is sufficient for param eter setting and for keeping the control unit active Note however that the measurements of the main circuit e g DC link voltage unit temperature are not available when the mains is not connected 5 1 CONTROL UNIT CABLING The principal terminal block placement is presented in Figure 31 below The control board is equipped with 22 fixed control 1
14. falling of suspended loads are present additional measures e g mechanical brakes may be necessary to prevent any hazard STO shall not be used as a control for starting or stopping the drive PPP PRP PIP BP o Service support find your nearest Vacon service center at www vacon com VACON 105 SAFE TORQUE OFF 9 3 STANDARDS The STO function has been designed for being used in accordance with the following standards Standards IEC 61508 Parts 1 7 EN 61800 5 2 EN 62061 ISO 13849 1 EN 954 1 IEC 60204 1 Table 36 Safety Standards The STO function has to be applied correctly to achieve the desired level of operational safety Four different levels are allowed depending on the use of the STO signals see the following table STO inputs STO feedback Cat PL SIL Both dynamically used Used 4 e 3 Both statically used Used 3 e 3 Connected in parallel Used 2 d 2 Connected in parallel Not used 1 c 1 Table 37 Four different STO levels see 9 5 1 The same values are calculated for SIL and SIL CL According to EN 60204 1 the emergency stop category is 0 The SIL value for Safety related system operating in high demand continuous mode is related to the probability of dangerous failure per hour PFH reported in the following table STO inputs STO feedback PFH PFDav Dea DCavg Both dynamically used Used 1 2 E 09 1 h 1 0
15. fuse ranges Terminal cable size l Fuse Mains and INPUT gG gL motor cable Main Earth A A Cu mm terminal terminal mm mm2 0 5 10 solid M4ringterminal a Ls 0003 4 00044 3 4 4 6 6 3 1 5 1 5 en or 1 6 0007 2 0008 2 6 0 7 2 J 0 5 10 solid M4 ring termina Mma 0005 4 0008 4 5 4 38 1 1 Satta 0 5 6 stranded or 1 6 0011 2 0012 2 9 7 10 9 0 5 10 solid M4 ring termina 0009 4 0012 4 9 3 11 3 l Dre 0 5 6 stranded or 1 6 0018 2 16 1 0 5 16 solid M5 ring termina 0016 4 15 4 Es Re 0 0024 2 21 7 x 0 5 16 solid M5 ring termina MMS 0023 4 21 3 a SR re 0031 2 27 7 A 0 5 16 solid or M5 ring termina 0031 4 28 4 j ie or 1 10 0038 4 36 7 40 3 10 10 M6 ring terminal M6 ring terminal a a 50 3 16 16 M6 ring terminal M6 ring terminal sinks 0062 2 57 0 0061 4 58 2 63 3 25 16 M6 ring terminal M6 ring terminal 0072 4 67 5 80 3 35 16 M6 ring terminal M6 ring terminal Table 12 Cable and fuse sizes for VACON 100 X The terminal sizes are intended for 1 conductor For MM6 the max diameter of the ring terminal is 14 mm The cable dimensioning is based on the criteria of the International Standard IEC60364 5 52 Ca bles must be PVC isolated Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observ
16. 5 CONNECTIONS To make the STO function available and ready to be used both the STO jumpers have to be removed They are located in front of the STO inputs to mechanically prevent the insertion of the STO connec tor For the correct configuration see the following table and the Figure 81 Signal Terminal Technical information Data STO S1 Insulated digital input 1 24V 20 G1 interchangeable polarity 10 15 MA zm S2 Insulated digital input 2 24V 20 G2 interchangeable polarity 10 15 MA Insulated digital output for STO 24V 20 STO feed F feedback 15 mA max back CAUTION Polarity must be F respected GND Table 41 STO connector and data signals Figure 81 Removing the STO jumpers Make sure that the frequency converter is switched off before cabling When the STO function is used the IP class of the drive may not be reduced below IP54 The P class of drive is IP66 It can be reduced by the wrong use of the cable entry plates or the cable glands A Disconnect both the STO jumpers to allow the cabling of the terminals The following examples show the basic principles for wiring the STO inputs and the STO output feedback Local standards and regulations should be always followed in the final design Service support find your nearest Vacon service center at www vacon com VACON 109 SAFE TORQUE OFF 9 5 1 SAFETY CAPABILITY CAT 4
17. AC drive to EMC level T C4 This is done by removing the EMC screws as described below Warning Do not perform any modifications on the AC drive when it is connected to mains Separate the powerhead and the terminal box Turn the powerhead upside down 1 and remove the two screws marked in Figure 39 for MM4 Figure 40 for MM5 and in Figure 42 for MM4 Figure 40 Locations of EMC screws in MM5 Service support find your nearest Vacon service center at www vacon com VACON 61 COMMISSIONING Figure 42 Locations of EMC screws in MM6 CAUTION Before connecting the AC drive to mains make sure that the EMC pro tection class settings of the drive are appropriately made NOTE After having performed the change write EMC level modified on the sticker included in the VACON 100 X delivery see below and note the date Un less already done attach the sticker close to the name plate of the AC drive Product modified COMMISSIONING VACON 62 6 3 RUNNING THE MOTOR MOTOR RUN CHECK LIST Before starting the motor check that the motor is mounted properly and ensure that the machine connected to the m
18. Keypad and Remote control places Control places The control place is the source of control where the drive can be started and stopped Every control place has its own parameter for selecting the frequency reference source In the drive the Local control place is always the keypad The Remote control place is determined by parameter P1 15 I O or Fieldbus The selected control place can be seen on the status bar of the keypad Remote control place 1 0 A 1 0 B and Fieldbus can be used as remote control places 1 0 A and Fieldbus have the lowest priority and can be chosen with parameter P3 2 1 Rem Control Place 1 0 B again can bypass the remote control place selected with parameter P3 2 1 using a digital input The digital input is se lected with parameter I O B Ctrl Force Local control Keypad is always used as control place while in local control Local control has higher priority than remote control Therefore if for example bypassed by parameter I O B Ctrl Force through dig ital input while in Remote the control place will still switch to Keypad if Local is selected Switching between Local and Remote Control can be done by pressing the Loc Rem button on the keypad or by using the Local Remote ID211 parameter Changing control places Change of control place from Remote to Local keypad 1 Anywhere in the menu structure push the Loc Rem button 2 Push the Arrow up or the Arrow down button to select Local R
19. LR tete 112 COMMISSIONINQ arii a E ea est A EAER 113 General wiring instructions sus 113 Checklist for the COMMISSIONING ss 113 VACON 2 9 7 Parameters and fault tracing ss 114 9 8 Maintenance and diagnostics iii 115 Service support find your nearest Vacon service center at www vacon com VACON 3 SAFETY VACON 4 1 SAFETY This manual contains clearly marked cautions and warnings which are intended for your per sonal safety and to avoid any unintentional damage to the product or connected appliances Please read the information included in cautions and warnings carefully VACON 100 X is a drive conceived for controlling asynchronous AC motors and permanent magnet motors The product is intended to be installed in a restricted access location and for a general purpose use Only VACON authorized trained and qualified personnel are allowed to install operate and maintain the drive 1 1 SIGNS The cautions and warnings are marked as follows AN DANGEROUS VOLTAGE HOT SURFACE A WARNING or CAUTION Table 1 Warning signs 1 2 UNITS Every physical dimension included in this manual uses International Metric System units oth erwise known as SI Syst me International d Unit s units For the purpose of the equipment s UL certification some of these dimensions are accompanied by their equivalents in imperial units
20. PAS RATIO As E E et E On ANT 74 Control K ypadsisrme nee Rhea oo ie eh ee oe TE SR 78 Mounting 6nto th driIVe ernas nn DR NAN ees date de eee eee tee 78 mstatlati m aerie i ie e ha Nha aera eames ate o E a CaN eas atacand 79 Ma OO O ett atte eM a cece Gente Gb ete MAT Re tlt wee von meer a 81 Graphical and Text kKeypad see 83 VACON keypad with graphical display 84 VACON keypad with text segment display 89 Fault l acide fe este tee antenne late Tate SR ete NE rer ede 92 H dter Ug on otc 5 0a eRe ea E an re tn 99 SEL PR PR EE PE OI 99 Dangers RE TT RTE RO tant ee ie eA esse 99 Technical data aia ssrin nies nef Sn RS A M EE cael EE fe 99 Mounting instructions MM4 Example ss 100 Option board Soit TRE QUE LA E SO E E A E Ea E a NN ek 103 Safe Torgue Off Sr ren nn Seta oat adden twas tend auai inidan ed 6 Rias es ab ATE 104 General description sienne 104 Warning ass etre fonte Mrs lentes ged cesagaet Pons freres et deaa a Seu a aa o ATERATEN 104 Standard CRT RG A 105 Th principl OF ST Ox sede i note lire te anim ne AR tee man a 106 Technical details donema tn nn A eaten emanate ured aman AN S 107 CONNECTION Saet RTS AR nen at e e en TR ae nt 108 Safety Capability Cat wel SIL RER RSS eas a Gia eee Saeed acess 109 Safety Capability Cat 3 PL e SIL en en ren ne drame tante 111 Safety Capability Cat 2 PL D S Rs A cia he nd eds ates 111 Safety Capability Cat 1 PL c ZSIL TES ee
21. PLe SIL 3 For this safety capability an external safety device must be installed This must be used to dynam ically activate the STO inputs and to monitor the STO output feedback The STO inputs are dynamically used when they do not commute together static use but according to the following picture where the inputs are released with delay in turn The dynamic use of the STO inputs allows detecting faults that may otherwise accumulate 24V STOT input JOODOOSOSNS STO2 input STO feedback Figure 82 An emergency push button connected to the STO inputs does not assure the same quality because no fault detection is performed at a sufficient frequency once a day is recommended The external safety device which forces the STO inputs and evaluates the STO output feedback has to be a safe device and it has to fulfil the requirements of the specific application A simple switch cannot be used in this case gt EE SAFE TORQUE OFF VACON 110 The picture below shows an example of connection for the STO function The external device has to be connected with 6 wires to the drive EXTERNAL DEVICE DC R R DC Reinforced Figure 83 STO example with automatic monitoring of the feedback and both STO inputs used The external device has to monitor the STO function in accordance with theTable 39 The device has to periodically de ener
22. VACON 116 Service support find your nearest Vacon service center at www vacon com VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW vacon com Manual authoring documentation dvacon com Vacon Plc Runsorintie 7 65380 Vaasa Finland Subject to change without prior notice 2013 Vacon Plc Document ID D P D 0 DOC NS 0 3 9 8 5 0 5 3 4 Order code D L U K Rev F
23. at a maximum length of 15 mm Do not strip the aluminum cable shield Then connect the cable to its appropriate terminals on VACON 100 X AC drive 2 standard terminal block terminals A and B A negative B positive See Figure 35 Using the cable clamp included in the delivery of the drive ground the shield of 3 the RS485 cable to the frame of the AC drive If VACON 100 X AC drive is the last device on the bus the bus termination must be set Locate the DIP switches to the top of the control unit see Figure 32 and turn the right most switch to position 1 Biasing is built in the termination resistor See also step 6 CONTROL UNIT VACON 54 5 NOTE When planning the cable runs remember to keep the distance between the fieldbus cable and the motor cable at a minimum of 30 cm The bus termination must be set for the first and the last device of the fieldbus line See picture below and step 4 We recommend that the first device on the bus and thus terminated was the Master device Vacon 100X Vacon 100X Vacon 100X Vacon 100X Vacon 100X Termination s 8 activated NC EE Fieldbus Termination activated with DIP switch wet Termination Bus termination deactivated Resistor 220 ohm 5 2 3 RS485 CABLE DATA 2 5 mm STP Shielded Twisted Pair type Be
24. be OV on Power removed from STO demand The feedback must disabled motor both inputs be 24V de energized The STO inputs have Pae demand The feedback must disabled motor or due to internal different values fault be OV de energized Table 39 Values of the STO output feedback and torque on the motor Only one channel is preventing the motor from moving The diagram below is a conceptual schematic diagram and is presented to illustrate the safety function with relevant safety components only shown F G1 F S2 G2 L1 U L2 V L3 W DC R R DC Re Reinforced Figure 80 STO function principle Service support find your nearest Vacon service center at www vacon com VACON 107 SAFE TORQUE OFF 9 4 1 TECHNICAL DETAILS The STO inputs are digital inputs intended for a nominal 24V d c input positive logic e g enabled when high Technical information Technical values Absolute maximum voltage range 24V 20 Typical input current at 24V 10 15 mA Logic threshold according to IEC 61131 2 15V 30V 1 OV 15V 0 Response time at nominal voltage Reaction time lt 20ms Table 40 Electrical data The reaction time of the STO function is the amount of time which passes from the moment in which the STO is demanded till the system is in the Safe State For VACON 100 X the reaction time is 20 ms minimum SAFE TORQUE OFF VACON 108 9
25. discharge may damage the components Check that the EMC level of the AC drive corresponds to the requirements of your supply network See paragraph 6 2 for more details In a domestic environment this product may cause radio interference in which case supplementary mitigation measures may be required EEE gt oeeo RP D Service support find your nearest Vacon service center at www vacon com VACON 7 SAFETY 1 5 EARTHING AND EARTH FAULT PROTECTION A CAUTION The VACON 100 X AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with Cl See Table 12 and Table 13 for the required cross section of phase conductor and protective earthing conductor both made of copper Since the touch current exceeds 3 5 mA AC according to EN61800 5 1 the MM4 and MM5 shall have a fixed connection and provision of an additional terminal for a second protective earth ing conductor of the same cross sectional area as the original protective earthing conductor MM6 shall have a fixed installation and a cross section of the protective earthing conductor of at least 10 mm Cu On the terminal box three screws for MM4 and MM5 and two screws for MM6 are provided for the ORIGINAL protective earthing conductor the SECOND protective conductor and the MOTOR protective conductor the customer can choose the screw for each one The cross sectional area of every protective earthing con
26. is used as a part of a machine the machine manufacturer is responsible for providing the machine with a supply disconnecting device EN 60204 1 See paragraph 4 1 for more details Only spare parts delivered by VACON can be used At power up or fault reset the motor will start immediately if the start signal is active unless the pulse control for Start Stop logic has been selected and the STO inputs are ready to be used normal operation The 1 0 functionalities including start inputs may change if parameters applications or software are changed Disconnect therefore the motor if an unexpected start can cause danger This is valid only if STO inputs are energized For prevention on unexpected restart use appropriate safety relay connected to the STO inputs The motor starts automatically after automatic fault reset if the autoreset func tion is activated See the Application Manual for more detailed information This is valid only if STO inputs are energized For prevention on unexpected restart use appropriate safety relay connected to the STO inputs Before performing any measurement on the motor or on the motor cable dis connect the motor cable from the AC drive Do not perform any voltage withstand test on any part of VACON 100 X The tests shall be performed according to a specific procedure Ignoring this procedure may damage the product Do not touch the components on the circuit boards Static voltage
27. mode 3 Set new value with the arrow buttons up down You can also move from digit to digit with the arrow buttons left right if the value is numerical and change then the value with the arrow but tons up down 4 Confirm change with OK button or ignore change by returning to previous level with Back Reset button Service support find your nearest Vacon service center at www vacon com VACON 85 OPTIONS STOP IG READY 1 0 STOP Gl READY 1 0 STOP C READY 1 0 Start Stop Setup aT Rem Control Place aT Rem Control Place 1D 172 8 2 1 2 D M 2 1 z 1 2 1 SF Rem Control Place fok fok 2 1 0 Control 7 F9 Contre FieldbusCTRL Gr KeypadStopButton 3 Help I O Control A Yes 1 0 Control v B ACK Start Function RESET Ramping Q Add to favorites STOP C READY 1 0 STOP C READY 1 0 Start Stop Setup oT Rem Control Place 1D 172 M 2 1 2 1 2 1 0 R lal 5 Rem Control Place n I O Control FieldbusCTRL KeypadStopButton Yes I O Control a Start Function Ramping Figure 61 Editing values on graphical keypad Resetting fault Instructions for how to reset a fault can be found in the Application Manual Local Remote control button The LOC REM button is used for two functions to quickly access the Control page and to easily change between the Local
28. or ignore change by returning to previous level with Back Reset button FWD REV Vo KEYPAD BUS Figure 67 Editing values Resetting fault Instructions for how to reset a fault can be found in paragraph chapter 8 2 7 Local Remote control button The LOC REM button is used for two functions to quickly access the Control page and to easily change between the Local Keypad and Remote control places Control places The control place is the source of control where the drive can be started and stopped Every control place has its own parameter for selecting the frequency reference source In the HVAC drive the Local control place is always the keypad The Remote control place is determined by parameter P1 15 I O or Fieldbus The selected control place can be seen on the status bar of the keypad Remote control place 1 0 A 1 0 B and Fieldbus can be used as remote control places 1 0 A and Fieldbus have the lowest priority and can be chosen with parameter P3 2 1 Rem Control Place 0 B again can bypass the remote control place selected with parameter P3 2 1 using a digital input The digital input is se lected with parameter I O B Ctrl Force Local control Keypad is always used as control place while in local control Local control has higher priority than remote control Therefore if for example bypassed by parameter I O B Ctrl Force through dig ital input while in Remote the control place will still switch to Keypad
29. 0 0024 21 7 24 2 36 3 48 4 5 5 7 5 0031 27 7 31 0 46 5 62 0 7 5 10 0 0048 43 8 48 0 72 0 96 0 11 0 15 0 0062 57 0 62 0 93 0 124 0 15 0 20 0 Table 24 Power ratings of VACON 100 X supply voltage 3AC 208 240V NOTE The rated currents in given ambient temperatures in Table 24 are achieved only when the switching frequency is equal to or less than the factory default Service support find your nearest Vacon service center at www vacon com VACON 65 TECHNICAL DATA 7 1 2 MAINS VOLTAGE 3AC 380 480V Mains voltage 3AC 380 480V 50 60 Hz Motor shaft power Loadability Converter Input 400V 480V current type A Rated continuous 50 overload M t current IN current a P kw HP A A 0003 3 4 3 4 5 1 6 8 1 1 1 5 0004 4 6 4 8 7 2 9 6 1 5 2 0 0005 5 4 5 6 8 4 11 2 2 2 3 0 0008 8 1 8 0 12 0 16 0 3 0 5 0 0009 9 3 9 6 14 4 19 2 4 0 5 0 0012 11 3 12 0 18 0 24 0 5 5 7 5 LO 0016 15 4 16 0 24 0 32 0 7 5 10 0 0023 21 3 23 0 34 5 46 0 11 0 15 0 2 0031 28 4 31 0 46 5 62 0 15 0 20 0 0038 36 7 38 0 57 0 76 0 18 5 25 0 0046 43 6 46 0 69 0 92 0 22 0 30 0 2 0061 58 2 61 0 91 5 122 0 30 0 40 0 Table 25 Power ratings of VACON 100 X supply voltage 3AC 380 480V high overload Mains voltage 3AC 380 480V 50 60 Hz Motor shaft power Load
30. 0 board can be isolated from ground by setting the dip switch to position 0 The switch in the position 1 means that the common of digital input has been connected to 24 V negative logic The switch in the position 2 means that the common of digital inputs has been connected to ground positive logic See Figure 33 Locate the switch and set it in desired position Factory default is 2 Figure 33 Digital inputs dip switch Service support find your nearest Vacon service center at www vacon com VACON 51 CONTROL UNIT 5 1 7 BUS TERMINATION OF THE RS485 CONNECTION This dip switch is related to the RS485 connection It s used for bus termination The bus ter mination must be set to the first and to the last device on the network This switch in position 0 means that a termination resistor of 120 ohm is connected and the termination of the bus has been set This switch in the position 1 means that a pull up and a pull down resistors of 10 kOhm have been connected for biasing purpose The switch in the position 2 means no ter mination and no biasing resistors have been connected Factory default is 2 See Figure 34 Figure 34 RS485 dip switch CONTROL UNIT VACON 52 5 2 I 0 CABLING AND FIELDBUS CONNECTION The AC drive can be connected to fieldbus either through RS485 or Ethernet The connection for RS485 is on the standard 1 0 terminals A
31. 0 terminals and the relay board with 6 2 Additionally the ter minals for the Safe Torque Off STO function see chapter chapter 9 can be seen in the picture below All signal descriptions are given in Table 19 err be A ae S1Gi 2 G2 F F er HEHN A 22 23 1213141516171819 80 A HH T a F 24 25 26 1234567 8 91011 Figure 31 Control terminals 5 1 1 CONTROL CABLE SIZING The control cables shall be at least 0 5 mm screened multicore cables see Table 18 The max imum terminal wire size is 2 5 mm for the relay terminals and 1 5 mm for other terminals Find the tightening torques of the control and relay board terminals in Table below Tightening torque Terminal screw 1 0 terminals and STO terminals 0 5 45 screw M2 Relay terminals screw M3 0 5 4 5 Table 18 Control cable tightening torques CONTROL UNIT VACON 48 5 1 2 STANDARD I 0 TERMINALS The terminals of the Standard I Os and the Relays are described below For more information on the connections see chapter 7 The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches See more information in chapter 5 1 5 and in chapter 5 1 6 Table 19 Control I O terminal signals and connection example Standard 1 0
32. 124 11 3 20 ANOTE PANCZA ANGO T o erain 0018 2 16 1 AWG17 AWGE 0016 4 15 4 29 AOI AE TR ESS erna 0024 2 21 7 AWG17 AWG8 MMS 0023 4 21 3 20 ANGIO AWCE AOSS Ramin 0031 2 27 7 AWG17 AWG8 0031 4 28 4 40 ANGES ANGAU AWAS RSS terminal 0038 4 36 7 50 AWGE EN GISAWDUO AWG TASAWG M6 ring terminal M6 ring terminal 0048 2 13 8 i Ange AWG13 AWGO AWG13 AWG2 MM 0046 4 43 6 M6 ring terminal M6 ring terminal 00622 57 0 AWG13 AWGO AWG13 AWG2 0061 4 58 2 80 ANGS M6 ring terminal M6 ring terminal 0072 4 67 5 100 awe2 AWG AWG2 0_ AWG9 AWG2 0 M6 ring terminal M ring terminal Table 13 Cable and fuse sizes for VACON 100 X The cable dimensioning is based on the criteria of the Underwriters Laboratories UL508C Cables must be PVC isolated Max ambient temperature 40 C 104 F max temperature of cable surface 70 75 C 158 167 F Use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the requirements of the earthing conductor see standard Underwriters Laboratories UL508C For the correction factors for each temperature see the instructions of standard Underwriters Labo ratories UL508C POWER CABLING VACON 38 4 4 3 BRAKE RESISTOR CABLES VACON 100 X AC drives are equipped with termina
33. 2010 These products are intended for installation in machines Operation is prohibited until it has been determined that the machines in which these products are to be installed conforms to the above mentioned EC Directive s Signature Andrea Perin Postal 07 05 2012 Figure 6 Declaration of conformity Service support find your nearest Vacon service center at www vacon com VACON 13 SAFETY A TUVRheinland ZERTIFIKAT EC Type Examination Certificate CERTIFICATE Reg No 01 205 5219 12 Product tested Safety function Safe Torque Certificate Vacon S R L Off STO within Adjustable holder Via Roma 2 Frequency AC Drive 1 39014 Postal BZ Italy Type designation Vacon 100 X AC Drive Manufacturer see certificate holder VACON0100 3L a b c d e a 0003 0012 Frame Size 4 a 0016 0031 Frame Size 5 b 4 5 Voltage Rating c X Enclosure Option d e Additional Codes Codes and standards EN 61800 5 2 2007 EN 62061 2005 AC 2010 forming the basis of EN 61800 5 1 2007 IEC 61508 Parts 1 7 2010 testing EN 61800 3 2004 EN 60204 1 2006 A1 2009 EN ISO 13849 1 2008 AC 2009 AC 2010 in extracts Intended application The safety function Safe Torque Off complies with the requirements of the relevant standards PL e acc to EN ISO 13849 1 SIL CL 3 acc to EN 61800 5 2 EN 62061 IEC 61508 and can be used in applications up to PL e acc to EN ISO 13849 1 and SIL 3 acc to E
34. 6 e Remove the powerhead from the terminal box by loosing the screws on the top cof HN i me Figure 48 Powerhead separated from the terminal box OPTIONS VACON 76 e Connect the supply cable to the Mains switch passing through the cable entry plate of the bottom side use the cable gland for sealing the cable to the gland plate and then through the terminal box as shown in the figure below ma l lsl lsis ls ele Figure 49 Connection of the supply cable to the Mains switch right hand side example 8 e Connect the cables from the Mains switch to the terminal box The cables have to be connected to the terminals L1 L2 and L3 9 e Place the Mains switch plate with the cables in the groove and f
35. 74 8 OPTIONS The options available for VACON 100 X are described below 8 1 MAINS SWITCH The purpose of the Mains switch is to disconnect the VACON 100 X from the mains when for ex ample service actions are needed The mains switch is available as option and it can be integrated in the drive The switch can be mounted on either side of the drive See Figure 45 Figure 45 The mains switch mounted on either side of the drive 8 1 1 INSTALLATION e Remove the cable entry plate from the drive on the left hand side if the mains 4 switch must be mounted on this side Otherwise remove the cable entry plate from the right hand side See the Figure 46 Figure 46 Disconnect the cable entry plate example for MM5 Service support find your nearest Vacon service center at www vacon com VACON 75 OPTIONS 5 e Remove the cable entry plate from the bottom side of the terminal box by loos ing the six screws Cables pass through this inlet hole All I Figure 47 Cable entry plate from the bottom side of the drive side of the drive
36. CON 113 SAFE TORQUE OFF 9 6 COMMISSIONING 9 6 1 GENERAL WIRING INSTRUCTIONS The wiring should be done according to the general wiring instructions for the specific product A shielded cable is required In addition the voltage drop from the supply point to the load shall not exceed 5 EN 60204 1 part 12 5 The following table indicates examples of cables to be used STO feedback Cable size STO feedback automatically monitored by an external safety 3 x 2 1 x 0 5 mm2 device Protect the STO cabling with a shielding or an enclosure to exclude external fault Wires ferrules are highly recommended for all STO signals inputs and feedback STO feedback ignored simply 2 safety device switch used 2x 2 1 x 0 5 mm Table 42 Cable types required to meet the standards Additional wires are needed for restarting the drive after each STO demand 9 6 2 CHECKLIST FOR THE COMMISSIONING Follow the checklist of the table below with the steps required to use the STO function Carry out a risk assessment of the system to ensure that the use of the STO function is safe and according to the local regulations Include in the assessment an examination of whether the use of external devices such as a mechanical brake is required Check if the switch if used has been chosen according to the required safety perfor L mance target SIL PL Category s
37. D control ler has timed out The wanted process 100 1100 Soft fill time out value was not achieved within time It s Reason might be a pipe burst a characteristic fault of the HVAC Application PID controller Feedback value outside Process supervi of supervision limits and the delay if IRS es sion fault PID1 set It s a characteristic fault of the CPEE SSNINOE HVAC Application PID controller Feedback value outside 105 1105 Process supervi of supervision limits and the delay if Check settings sion fault PID2 set It s a characteristic fault of the HVAC Application Table 32 Fault codes and descriptions Service support find your nearest Vacon service center at www vacon com VACON 99 OPTIONS 8 3 HEATER ARCTIC OPTION 8 3 1 SAFETY This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances Please read the information included in dangers carefully The optional heater allows the drive to operate in low temperature conditions down to 40 C This option is intended to be installed inside the drive Only VACON authorized trained and qualified personnel are allowed to install and maintain this component 8 3 2 DANGERS The components of the optional heater are live when the element is connected to mains potential Coming into contact with this voltage is ext
38. E 04 gt 4274y HIGH Both statically used Used 1 2E 09 t h 1 1 E 04 gt 4274y MEDIUM Connected in parallel Used 1 2E 09 1 h 1 1 E 04 gt 4274y MEDIUM Connected in parallel Not used 1 5 E 09 1 h 1 3 E 04 gt 4274y NONE Table 38 SIL values see 9 5 1 The power supply of the safety device may be external or taken from the drive as The STO inputs must always be supplied by a safety device A long as this is compliant with the rating specified for terminal 6 SAFE TORQUE OFF VACON 106 9 4 THE PRINCIPLE OF STO The STO functionality such as the technical principles and data wiring examples and commission ing will be described in this chapter In VACON 100 X the STO function is realized by preventing the propagation of the control signals to the inverter circuit The inverter power stage is disabled through redundant disabling paths which start from the two separated and galvanically isolated STO inputs S1 G1 S2 G2 in Figure 80 In addition an isolated output feedback is generated to improve the diagnostics of the STO function and to achieve a better safety capability F F terminals The values assumed by the STO output feedback are indicated in the following table 3 Operating STO feedback Torque at the STO inputs conditions output motor shaft Both inputs energized Normal oserston The feedback must present motor with 24V DC P
39. ISSIONING 6 1 COMMISSIONING OF THE DRIVE Read carefully the safety instructions in Chapter 1 and above and follow them After the installation Check that both the frequency converter and the motor are grounded Check that the mains and motor cables comply with the requirements given in chapter 5 Check that the control cables are located as far as possible from the power cables Check that the shields of the shielded cables are connected to protective earth marked with Check the tightening torques of all terminals Check that the wires do not touch the electrical components of the drive Check that the common inputs of digital input groups are connected to 24V or ground of the 1 0 terminal Check the quality and quantity of cooling air Check the inside of the frequency converter for condensation Check that all Start Stop switches connected to the 1 0 terminals are in Stop po sition Before connecting the frequency converter to mains Check mounting and condi tion of all fuses and other protective devices Run the Startup Wizard see the Application Manual COMMISSIONING VACON 60 6 2 CHANGING EMC PROTECTION CLASS If your supply network is an IT impedance grounded system but your AC drive is EMC pro tected according to class C1 or C2 you need to modify the EMC protection of the
40. L 29 T 5 1 4 SAFE TORQUE OFF STO TERMINALS For more information on the functionalities of the Safe Torque Off STO see chapter 9 Table 21 I O terminal signals for the STO functions Safe Torque Off terminals RS RE EE s1 Isolated digital input 1 inter changeable polarity G1 24V 20 10 15mA S2 Isolated digital input 2 inter changeable polarity G2 24V 20 10 15mA Isolated feedback CAUTION F Polarity to be respected 24V 20 Isolated feedback CAUTION F Polarity to be respected GND CONTROL UNIT VACON 50 5 1 5 SELECTION OF TERMINAL FUNCTIONS WITH DIP SWITCHES The VACON 100 X drive embodies five so called dip switches that allow for three functional selections each The shadowed terminals in Table 19 can be functionally modified with the dip switches The switches have three positions C 0 and V The switch in the position C means that the input or the output has been set in current mode The switch in the position V means voltage mode The middle position 0 is for Test mode See Figure 32 to locate the switches and make appropriate selections for your requirements Factory defaults are All V Al2 C AO C Figure 32 Dip switches for analogue inputs and analogue output 5 1 6 ISOLATING DIGITAL INPUTS FROM GROUND The digital inputs terminals 8 10 and 14 16 on the standard 1
41. N 62061 IEC 61508 Specific requirements The instructions of the associated Installation and Operating Manual shall be considered It is confirmed that the product under test complies with the requirements for machines defined in Annex of the EC Directive 2006 42 EC This certificate is valid until 2017 05 31 The test report no 968 M 351 00 12 dated 2012 05 31 is an integral part of this certificate This certificate is valid only for products which are identical with the product tes wie at any change of the codes and standards forming gt tended application E Berlin 2012 05 31 TUV Rheinland Industrie Service GmbH Alboinstr 56 12103 Berlin Germany Tel 49 30 7562 1557 Fax 49 30 7562 1370 E Mail tuvat de tuv com Certification Body for Machinery NB 0035 Dipl Ing Eberhard Frejno Figure 7 STO certificate SAFETY VACON 14 NOTE You can download the English and French product manuals with applicable safety warning and caution information from www vacon com downloads REMARQUE Vous pouvez t l charger les versions anglaise et francaise des manuels produit contenant l ensemble des informations de s curit avertissements et mises en garde appli cables sur Le site www vacon com downloads Service support find your nearest Vacon service center at www vacon com VACON 15 SAFETY RECEIPT OF DELIVERY VACON 16 2 RECEIPT OF DELIVERY Check the correctness of deliver
42. O Salted specs RE tr odds ceases lasts a ne den antennes lite ee 20 de Mounting aaaea nn an lt inst est mate as lentes 22 3 10 1DIMENSIONS Hs vez sree e etoudevess e Reociuedey re be dupevwertocencere toute test AE EENE 22 3 2 Introduction of modules sise 25 3 93 MOUntind sn isa ie E ee aed in ead eed elected 26 3 3 1 WalEmountingissst ssansst mans A T enr nee tt ne ne ete nt et T 27 3 9 2 MOt r MOUNTN QE M nee nr nn A re an ra AE AAEE e E 27 3 3 3 sSegregated modules ren mins eee An M te nl a 27 34 Cooling sis atend ants Lect Ge dat acd hve theca rite enter ARR En M Oral et us 28 k Power CAN nn ne nn er de Ne trie a Enine aaaea 30 4 1 Circuit breaker sise 31 42 UkLst ndardson cabling se aa eesti lan nt der tiss 32 4 3 Description of the terminals sise 33 4 4 Cable dimensioning and selection 36 4 4 1 Cable and fuse sizes frames MM4 to MM6 une rreeeeceneneeceneeee 36 4 4 2 Cable and fuse sizes frames MM4 to MM6 North America 37 4 4 3 Brake resistor cables sise 38 AAA Control cables ne Meese Ma Nan he Soe tle ent eds 38 4 59 Gable installation ass a REA Mie ARE LA MR A NS 39 22 CORIFOL CUTE ses or nn dansent ef an oser e een le dense ane Nic hsserse 46 Bile Control unit CABLING sis SR AP ae athe At 47 5 lel Control cabl SiZINg SR TR TA AT EST AN at sca asta eat daa aea aaas 47 5 1 2 Standard OREN Mia Ss mures ser diner rende teat coud marae 48 5 1 3 Relay and thermistor input terminals sis 49 5 1 4 Sa
43. PAD BUS Figure 69 Accessing Control page OPTIONS VACON 92 8 2 7 FAULT TRACING When an unusual operating condition is detected by the AC drive control diagnostics the drive ini tiates a notification visible for example on the keypad The keypad will show the code the name and a short description of the fault or alarm The notifications vary in consequence and required action Faults make the drive stop and require reset of the drive Alarms inform of unusual operating conditions but the drive will continue run ning Info may require resetting but do not affect the functioning of the drive For some faults you can program different responses in the application See parameter group Pro tections The fault can be reset with the Reset button on the control keypad or via the I O terminal The faults are stored in the Fault history menu which can be browsed The different fault codes you will find in the table below NOTE When contacting distributor or factory because of a fault condition always write down all texts and codes on the keypad display Fault appears When a fault appears and the drive stops examine the cause of fault perform the actions advised here and reset the fault as instructed below 1 With a long 1s press on the Reset button on the keypad or 2 By entering the Diagnostics Menu M4 entering Reset faults M4 2 and selecting Reset faults parameter 3 For keypad with LCD display only By selecti
44. RM FAULT READY RUN STOP ALARM FAULT FWD REV Vo KEYPAD BUS FWD REV Vo KEYPAD BUS Figure 73 Fault history menu with text keypad OPTIONS VACON 94 8 2 7 2 Fault codes Fault code Fault ID Fault name Possible cause Remedy e brake resistor short circuit or overload 1 Overcurrent AC drive has detected too high a cur Check loading hardware fault rent gt 4 l in the motor cable Check motor 1 0 e sudden heavy load increase Check cables and connections 2 aie tt e short circuit in motor cables Make identification run PAPE e unsuitable motor Check ramp times 10 Overvoltage The DC link voltage has exceeded the Make develeration time longer hardware fault limits defined ue Use brake chopper or brake e too short a deceleration time l 2 bre chobper is disabled resistor available as options q1 Overvoltage soft PP ae Activate overvoltage controller ware fault e high overvoltage spikes in supply Check input voltage e Start Stop sequence too fast 20 Earth fault hard Current measurement has detected ware fault that the sum of motor phase current is 3 not zero Check motor cables and motor 21 Earth fault soft e insulation failure in cables or ware fault motor e Ee eee tani the Reset the fault and restart 5 40 Charging switch g i Should the fault re occur con e faulty operation ee tact the distributor near to you e compone
45. Screws for control cable clamps screw M1 3 Cable clamp 5 Clamping control cables M4 x 25 DIN6900 3 Combi Delta Tx 6 Screws for power cable clamps screw M40 Cable clamp 3 Clamping power cables Product modified sticker 1 Information about modifications HMI cap 1 Closing cap for the HMI connector Table 6 Content of accessory bag MM6 Provided only if the drive is delivered with the keypad mounted RECEIPT OF DELIVERY VACON 20 2 3 4 STO TERMINAL CONNECTOR Figure 9 STO connector 2 3 5 PRODUCT MODIFIED STICKER In the small plastic bag included in the delivery you will find a silver Product modified sticker The purpose of the sticker is to notify the service personnel about the modifications made in the AC drive Attach the sticker on the side of the AC drive to avoid losing it Should the AC drive be later modified mark the change on the sticker Product modified Figure 10 Product modified sticker 2 3 6 DISPOSAL When the device reaches the end of its operating life do not dispose of it as a part of standard household garbage Main components of the product can be recycled but some need to be fragmented to separate different types of materials and components that need to be treated as special waste from electrical and electronic components To ensure environmentally sound and safe recycling treatment the product can be taken to appro
46. TA 7 2 BRAKE RESISTOR RATINGS Make sure that the resistance is higher than the minimum resistance defined The power han dling capacity must be sufficient for the application Recommended minimum brake resistor values for VACON 100 X AC drives Mains Voltage 3AC 208 240V 50 60 Hz Minimum Resistance Frame Type recommended ohm 0007 25 0008 25 MM4 0011 25 0012 20 0018 15 MM5 0024 15 0031 10 0048 8 MM6 0062 8 Table 27 Brake resistor ratings 208 240V Mains Voltage 3AC 380 480V 50 60 Hz Minimum Resistance recommended o 003 50 0004 50 MM 0005 50 0008 50 0009 50 0012 50 0016 30 MM5 0023 30 0031 20 0038 15 MM6 0046 15 0061 15 Table 28 Brake resistor ratings 380 480V TECHNICAL DATA 7 3 VACON 68 VACON 100 X TECHNICAL DATA Mains connection Motor connection Control characteristics Control connections Input voltage Uin 3AC 208 240V SAC 380 480V Input voltage 15 10 continuously tolerance Input frequency 50 60 Hz Protection class Input frequency 47 5 66 Hz tolerance Connection to mains Once per minute or less Starting delay lt 75s Supply network TN and IT network cannot be used with cor ner earthed network
47. VACON 100 X AC DRIVES INSTALLATION TECHNICAL AND MAINTENANCE MANUAL VACON DRIVEN BY DRIVES VACON O INDEX Document code Original Instructions DPD00534F Order code DOC INS03985 DLUK Rev F Revision release date 21 11 13 Mie SAR rs nent nmen deniers unten ntislenanmspenine 4 EST A ailncavadl anand leave tel acer edits 4 Wie 2e MINES eee eles stein easter TS gt ate cae tea take tee 4 153 J DING I ie PAT hea she oh ee se I vd PD eg PAG Oe ore 5 TAN ARNINQS 5 shee et aoe Pee e gD Rete e E T Te a a a 6 1 5 Earthing and earth fault protection cccecccceccececseeceececeeeeeeeeeseeeaeeeeeesesneeeeeessneeeeeeeeseas 7 1 67 INSULATIOM syste ene ia a a lin a AU 10 1 7 Compatibility with RCDs iii 11 1 8 Extended temperature range sise 11 1 9 Electro magnetic compatibility EMC inieturilenenteiinn eatssanenederasens 11 1 10 Declaration of conformity sise 12 2 Receipt OF AELIVG Venere sis ture de ni a nc ardt sait aua raaa ananasai 16 2 1 Type desigmation cod s icnc nantais ane annee lanterne ii AE 17 2 2 Unpacking and lifting the AC drive sise 18 2 37 ACCOSSONIES MS rem rm na he ten nr ere ln en een eee 18 23 1 Frame MME hein tin nn ne cab ockbesa tee beanveg ete EE ASA 18 2 3 2 Frame MMS nn tients a a 19 2 3 3 Frame MM leu et ete tee Mer aline rare he terra ee 19 2 3 4 STO terminal Connector siennes 20 21325 ProduelinodifiedisSti Re rte nn ne en tal TE lahat tae es 20 2370 DIS P
48. a dewe conned pewer Device no longer available unit option board IGBT tempera IGBT temperature unit temperature Check loading 41 400 hire LT is too high Check motor size 2 Make identification run Set the option board parame Option board changed or Power unit ters again if option board was Device changed i 44 430 changed No parameter settings are changed Set converter param different type saved eters again if power unit was changed Device changed Option hoard added The option beaks Set the option board parame 45 440 was not previously present in the same different type ters again slot No parameter settings are saved Check the digital input or the 51 1051 External Fault Fault activated by digital input device connected to it Check the parameter settings 52 1052 Keypad commu TEn a ne ene Check keypad connection and 1352 nication fault md q y possible keypad cable The data connection between the field f 53 1053 Fieldbus commu bus master nd fieldbus board is bro Check installation and fieldbus nication fault master ken 1654 Slot D fault 54 Defective option board or slot Check board and slot 1754 Slot E fault PC communica The data connection between the PC 65 1065 tion fault and frequency converter is broken Check motor cooling and load b6 1066 Thermistor fault The thermistor input has detected an Check thermistor connection increase of motor temperature If thermistor input is no
49. ability current type A Rated continuous 10 overload M t current IN current a oe kW HP A A 3 O 0072 67 5 72 0 80 0 80 0 37 0 50 0 Table 26 Power ratings of VACON 100 X supply voltage 3AC 380 480V low overload NOTE The rated currents in given ambient temperatures in Table 25 are achieved only when the switching frequency is equal to or less than the factory default TECHNICAL DATA VACON 66 7 1 3 DEFINITIONS OF OVERLOADABILITY High overload Following continuous operation at rated output current Iy the converter supplies 150 IN for 1 min followed by a period of at least 9 min at IN or below Example If the duty cycle requires 150 rated current for 1 minin every 10 min the remaining 9 min must be at rated current IN or less Current IN 150 IN 150 Figure 43 High overload Low overload Following continuous operation at rated output current Iy the converter supplies 110 IN for 1 min followed by a period of at least 9 min at IN or below Example If the duty cycle requires 110 rated current for 1 minin every 10 min the remaining 9 min must be at rated current IN or less IL 110 1L 110 Figure 44 Low overload NOTE For more information please refer to IEC61800 2 IEC 1998 Standard Service support find your nearest Vacon service center at www vacon com VACON 67 TECHNICAL DA
50. age 2 208 240V 4 380 480 V X IP66 Type 4X EMC level C2 Two relay outputs One thermistor input XXXX YYYY Additional codes Several options possible Examples of additional codes HMGR Graphical keypad IP66 F0065 HVAC Application installed F0159 FLOW application installed SRBT Integrated battery for real time clock FBIE Onboard fieldbus protocols activated RECEIPT OF DELIVERY VACON 18 2 2 UNPACKING AND LIFTING THE AC DRIVE The weights of the AC drives vary according to frame size You may need to use a piece of spe cial lifting equipment to move the converter from its package Note the weights of each indi vidual frame size in Table 3 below MM4 8 8 19 4 MM5 14 9 32 8 MM6 31 5 69 4 Table 3 Frame weights VACON 100 X drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer However after unpacking the product check that no signs of transport damages are to be found on the product and that the delivery is complete Should the drive have been damaged during the shipping please contact primarily the cargo insurance company or the carrier 2 3 ACCESSORIES After having opened the transport package and lifted the drive out check immediately that these various accessories were included in the delivery The contents of the accessories bag differ by drive size 2 3 1 FRAME MM4 Item Quant
51. and B and the connection for Ethernet is left to the control terminals See Figure 35 RS485 terminals eee OD0OOO0OO0OOOOR amp 12 US a a ea 0000000000 connection the cable through the conduit plate Figure 35 5 2 1 PREPARE FOR USE THROUGH ETHERNET 1 Connect the Ethernet cable see specification on page 52 to its terminal and run Remount the powerhead NOTE When planning the cable runs remember to 2 keep the distance between the Ethernet cable and the motor cable at a minimum of 30 cm For more detailed information see the user s manual of the fieldbus you are using 5 2 1 1 Ethernet cable data connector Note max length of the connector 40 mm Cable type CAT5e STP Cable length Max 100m Table 22 Ethernet cable data Connector Service support find your nearest Vacon service center at www vacon com VACON 53 CONTROL UNIT 5 2 2 PREPARE FOR USE THROUGH RS485 Strip about 15 mm of the RS485 cable see specification on page 54 and cut off the grey cable shield Remember to do this for both bus cables except for the last device Leave no more than 10 mm of the cable outside the terminal block and strip the cables at about 5 mm to fit in the terminals See picture below 5 Also strip the cable now at such a distance from the terminal that you can fix it to the frame with the grounding clamp Strip the cable
52. bient temperature of 20 C Service support find your nearest Vacon service center at www vacon com VACON 63 COMMISSIONING 6 4 MAINTENANCE In normal conditions the AC drive is maintenance free However regular maintenance is rec ommended to ensure a trouble free operation and a long lifetime of the drive We recommend to follow the table below for maintenance intervals NOTE Because of capacitor type thin film capacitors reforming of capacitors is not neces sary Maintenance interval Maintenance action Regularly and according to Check tightening torques of terminals general maintenance interval e Check input and output terminals and control 1 0 terminals e Check operation of cooling fan e Check the heatsink for dust and clean if necessary 6 24 months depending on environment 6 10 years e Change main fan TECHNICAL DATA Zs TECHNICAL DATA 7 1 AC DRIVE POWER RATINGS 7 1 1 MAINS VOLTAGE 3AC 208 240V VACON 64 Mains voltage 3AC 208 240V 50 60 Hz Motor shaft power Loadability Converter Put 230V supply current type A Rated continuous 50 overload M t current IN current a eae kW HP A A gt 0007 6 0 6 6 9 9 13 2 1 1 1 5 0008 7 2 8 0 12 0 16 0 1 5 2 0 0011 9 7 11 0 16 5 22 0 2 2 3 0 0012 10 9 12 5 18 8 25 0 3 0 4 0 LO 0018 16 1 18 0 27 0 36 0 4 0 5
53. ble for ensuring that the end system is safe and in compliance with relevant regulations When a permanent magnet motor is used and in case of a multiple IGBT power semi conductor failure when the STO option energizes the drive outputs to the off state the drive system may still provide an alignment torque which maximally rotates the motor shaft by 180 p where p is the number of poles of the motor before the torque production ceases Electronic means and contactors are not adequate for protection against electric shock The Safe Torque Off function does not disconnect the voltage or the mains from the drive Therefore hazardous voltages may still be present on the motor If electrical or maintenance work has to be carried out on electrical parts of the drive or the motor the drive has to be completely isolated from the main supply e g using an external supply disconnecting switch see EN60204 1 This safety function corresponds to an uncontrolled stop in accordance with stop cat egory 0 of IEC 60204 1 The STO function does not comply with Emergency Switching Off according to IEC 60204 1 no galvanic insulation from the Mains in case the motor is stopped The STO function is not a prevention of unexpected start up To fulfil those require ments additional external components are required according to appropriate stan dards and application requirements In circumstances where external influences e g
54. clude any option board in the board slots The following option boards are supported Code Description Note Option board with six bidirec ARR jun peT ns ne possible ug OPTB1 use each terminal as digital input or tional terminals Has as digital output I O expander board with a OPTB2 thermistor input and two relay outputs I O expander board with one galvanically isolated analogue OPTB4 input and two galvanically isolated analogue outputs standard signals 0 4 20mA OPTBS I O expander board with three relay outputs 1 0 expander board with five OPTB9 42 240 VAC digital inputs and one relay output 1 0 expander board with ana On the OPTBF board there is one OPTBF logue output digital output and jumper block for selecting the ana relay output logue output mode mA V Temperature measurement Supported sensors PT100 PT1000 OPTBH board with three individual N11000 KTY84 130 KTY84 150 channels KTY84 131 OPTC4 ei Pluggable connector with screw ter minals OPTE3 Profibls UP option board Pluggable connector with screw ter minals OPTES Profibus DP option board 9 pin Sub D terminal OPTE6 CANopen option board OPTE7 DeviceNet option board Table 35 Option boards supported in VACON 100 X See the Option boards User s Manual to use and install the option boards SAFE TORQUE OFF VACON 104 9 SAFE TORQUE OFF This chapter describes the Safe Torque Off STO func
55. cted 11 100 put P that there is no current in one motor Check motor cable and motor supervision phase Brake chopper Check brake resistor and 110 supervision No brake resistor installed cabling 12 hardware fault Brake resistor is broken If these are ok the chopper is aa Brake chopper _ Brake chopper failure faulty Contact the distributor saturation alarm near to you AC drive under Too low temperature measured in d entemnoes 13 120 temperature power unit s heatsink or board Heat fie P fault sink temperature is under 10 C AC drive over 130 temperature fault heatsink Check the correct amount and AC drive over flow of cooling air 131 temperature Check the heatsink for dust alarm heatsink Too high temperature measured in Check the ambient tempera 14 i power unit s heatsink or board Heat ture AC drive over cink temperature is over 100 C Make sure that the switching 132 temperature frequency is not too high in fault board relation to ambient tempera AC drive over ture and motor load 133 temperature alarm board 15 140 Motor stalled Motor is stalled Check motor and load Decrease motor load 16 150 Motor overtem Motoris overloaded If no motor overload exists perature check the temperature model parameters 17 160 Motor underload Motor is underloaded Check load Power overload 180 short time supervision 19 Drive power is too high Decrease load Power overload 181
56. d situation The source of fault has been suspended Memory access has failed For exam Reset the fault and restart 609 ple retain variables could not be Should the fault re occur con restored tact the distributor near to you Necessary device properties cannot be 610 read 614 Configuration error 647 Software error Invalid function block used in applica 648 tion System software and application are not compatible Update software Should the fault re occur contact the dis Resource overload tribut Error when loading parameter initial dot Le yon 649 values Error when restoring parameters Error when saving parameters Undervoltage DC link voltage is under the voltage 80 wee i fault limits defined In case of temporary supply e most probable cause too lowa voltage break reset the fault supply voltage and restart the AC drive Check 9 e AC drive internal fault the supply voltage If it is ade Undervoltage e defect input fuse quate an internal failure has 81 alarm e external charge switch not occurred closed Contact the distributor near to NOTE This fault is activated only if the you drive is in Run state 10 91 Input phase Input line phase is missing i ee Table 32 Fault codes and descriptions OPTIONS VACON 96 Fault code Fault ID Fault name Possible cause Remedy re dise Current measurement has dete
57. ductor which does not form a part of the supply cable or cable enclosure shall in any case be not less than e 2 5mm if mechanical protection is provided or e 4mm if mechanical protection is not provided For cord connected equipment provi sions shall be made so that the protective earthing conductor in the cord shall in the case of failure of the strain relief mechanism be the last conductor to be interrupted The power head is earthed through metal aglets located on the terminal box which fit into spring baskets on the powerhead See Figure 1 Figure 2 and Figure 3 for the location of the screws three for MM4 and MM5 two for MM64 and the metal aglets two for each frame size Please pay attention not to damage or remove these aglets SAFETY VACON 8 Earth connection Earth connection Metal aglet O Earth connection Figure 1 Earth connections and metal aglet in MM4 Earth connections Earth connection Figure 2 Earth connections and metal aglet in MM5 Service support find your nearest Vacon service center at www vacon com VACON 9 SAFETY Earth connection Earth connection O O Metal aglet Oja Metal aglet Figure 3 Earth connections and metal aglet in MM6 However always follow the local regulations for the minimum size of the protective earthing conductor NOTE Due to the high capacitive currents present in the AC drive fault current protective switches may not functio
58. e keypad holder to an enclosure cabinet or any special housing for the drive in which you want to have a remote keypad control available 8 2 1 MOUNTING ONTO THE DRIVE BD Figure 52 Drive and the optional keypad kit Service support find your nearest Vacon service center at www vacon com VACON 79 OPTIONS 8 2 2 INSTALLATION 1 e Remove the HMI cap from the drive as shown in the Figure 53 Figure 53 Disconnection of the HMI cap from the drive e Install the keypad holder with a screw as shown in the Figure 54 The metal 2 sheets of the keypad holder have to be mounted under the fan holder as shown in the following figures Figure 54 Installation of the keypad holder on the powerhead OPTIONS VACON 80 3 e Connect the keypad to the drive and plug the cable on the HMI connector as shown in the Figure 55 and in the Figure 56
59. ective earthing conductor Where a residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product 1 8 EXTENDED TEMPERATURE RANGE VACON 100 X has an integrated cooling system independent from the motor fan Under maximum operating conditions the ambient temperature cannot exceed 40 C See Table 24 and Table 25 for the output rated current Higher temperatures are allowed only with derating of the output current With derating the unit can operate up to 60 C See the Figure 5 Temperature Output Current Derating Curve 150 Zz 100 5 T 2 5 75 O 5 Q 5 50 wo p 25 D a 10 0 10 20 30 40 50 60 Ambient temperature C Figure 5 Temperature output current derating curve NOTE the maximum allowed switching frequency above 50 C is 1 5 kHz The AC drive is cooled down by air ventilation Therefore make sure that enough free space is left around the AC drive to ensure sufficient air circulation see for more details the mounting instructions on chapter 3 1 9 ELECTRO MAGNETIC COMPATIBILITY EMC The VACON 100 X complies with IEC 61000 3 12 provided that the short circuit power SSC is greater than or equal to 120 at the interface point between the user s supply and the public system It is the responsibility of t
60. ed For important information on the requirements of the earthing conductor see chapter Earthing and earth fault protection of the standard For the correction factors for each temperature see International Standard IEC60364 5 52 Service support find your nearest Vacon service center at www vacon com VACON 37 POWER CABLING 4 4 2 CABLE AND FUSE SIZES FRAMES MM4 TO MM6 NORTH AMERICA The recommended fuse types are gG gL IEC 60269 1 or class T UL amp CSA The fuse voltage rating should be selected according to the supply network The final selection should be made according to local regulations cable installation conditions and cable specification Bigger fus es than what is recommended below shall not be used Check that the fuse operating time is less than 0 4 seconds Operating time depends on used fuse type and impedance of the supply circuit Consult the factory about faster fuses VACON offers recommendations also for high speed J UL amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges l Fuse Mains and Terminal cable size TA class T motor cable A Cu Main terminal Earth terminal AWG17 AWG10 0003 4 00044 3 4 4 6 6 awc14 lawG24 aw610 AWC M4 ring terminal 00072 00082 6 0 7 2 AWG17 AWG10 vane 00084 00084 5 4 8 1 9 AWG14 J AWG24 AWG10 M4 ring terminal 00112 9 7 AWG17 AWG10 0009 4 9 3 19 OT ENG ZENG a na 00122 10 9 AWG17 AWG10 00
61. emote and confirm with the OK button 3 On the next display select Loca or Remote and again confirm with the OK button 4 The display will return to the same location as it was when the Loc Rem button was pushed However if the Remote control place was changed to Local Keypad you will be prompted for keypad reference OPTIONS VACON 86 STOP CI w Keypad stop C5 Ready Keypad STOP IS READY Keypad Main Menu Choose action Local Remote Ci Local Remote A Vv ID M1 1D 1805 1D 211 oy Change direction REM Parameters Control page EN 15 Local Remote S J Diagnostics 6 STOP C READY 1 0 Main Menu ID M1 Monitor 7 Parameters Er 15 Diagnostics 6 6 Figure 62 Changing control places Accessing the control page The Control page is meant for easy operation and monitoring of the most essential values 1 Anywhere in the menu structure push the Loc Rem button 2 Push the Arrow up or the Arrow down button to select Control page and confirm with the OK button 3 The control page appears If keypad control place and keypad reference are selected to be used you can set the Keypad reference after having pressed the OK button If other control places or reference values are used the display will show Frequency reference which is not editable The other values on the page are M
62. et during the risk evaluation Check if the external device for automatic monitoring of the STO output feedback if LJ used has been chosen in accordance with the specific application Check if the reset function with the STO function if used is edge sensitive The shaft of a permanent magnet motor might in an IGBT fault situation still provide energy before the torque production ceases This may result in a jerk of max 180 elec trically Ensured that the system is designed in such a way that this can be accepted m Check if the degree of protection of the enclosure is at least IP54 See paragraph 9 5 Check if the recommendations on EMC for cables have been followed Check if the system has been designed in such a way that enabling of the drive through Lt ISTO inputs will not lead to an unexpected start of the drive m Check if only approved units and parts have been used Set up a routine to ensure that the functionality of the STO function is being checked at regular intervals Table 43 Checklist for the commissioning of STO SAFE TORQUE OFF VACON 114 9 7 PARAMETERS AND FAULT TRACING There are no parameters for the STO function itself Before testing the STO function make sure that the checklist Table 43 is inspected and completed When STO function awakes the drive always generates a fault F30 and the motor stops by c
63. fe Torque off STO terminals ne aan nas el a Ean Bik ad 49 5 1 5 Selection of terminal functions with dip switches 50 Service support find your nearest Vacon service center at www vacon com VACON 1 9 1 6 Isolating digital inputs from ground 50 Bus termination of the RS485 connections sens ennuis nine dsl 51 I O cabling and Fieldbus COMME CTION un Sa et tn te 52 Prepare for use through Ethernet ss 52 Prepare for use through RS485 iii 53 RS489 Cape data isn AURA ee aa T nd tte db te 54 Battery installation for Real Time Clock RTC 55 COMMISSION cnrs rca ner etai annees nni ei asveneteereuchnnss 58 COMMISSIONING OF th dre esinin add ie nine 59 Changing EMC protection class sis 60 Running the motors nn hee nn ee ae eee 62 Cable and motor insulation CRSCRES She ins ne ie ni Gala 62 MAILE MANOS st nee thug te de lt ts nt n ee nt en eds 63 Technical date nn nn a nr ln me nest Lea ee et oc sente 64 AC drive power ratings sienne 64 Mains voltage SAC 208 240 Vin ennemi entente at E 64 Mains voltage 3AC 380 480V 0 ie 65 Definitions of overloadability ss 66 Brake r sistor ratings seeds oes See AA ak Rev ce Re MAR este 67 VACON 100 X technical dates nn ct Riise db auleu oe wads nach Sn Pants Me 68 Technical information on controliconnettions s ss tastes ed teed tente 71 ODEONS issues T E danse era E en sverebee restaure 74 MANS SN IEC Sale nn en a ne ne sn tale ne ete 74
64. gize the STO inputs andit has to verify that the STO output feedback assumes the expected value Any difference between the expected and the real value has to be considered as a failure and has to drive the system into a Safe State In case of failure check the wiring If the fault recognized by the external safety device persists the drive will have to be replaced repaired Service support find your nearest Vacon service center at www vacon com VACON 111 SAFE TORQUE OFF 9 5 2 SAFETY CAPABILITY CAT 3 PLe SIL 3 The safety capability is reduced to Cat 3 PL e SIL 3 if the STO inputs are statically used which means they are forced to commute together Both STO inputs and the STO feedback have to be used The same warnings and cabling instruction of 9 5 1 apply 9 5 3 SAFETY CAPABILITY CAT 2 PLd SIL 2 The safety capability is even more reduced to Cat 2 PL d SIL 2 if the STO inputs are connected in parallel no redundancy of the STO inputs The STO feedback has to be used The same warnings of 9 5 1 apply The picture below shows an example of connection for the STO function The external device has to be connected with 4 wires to the drive EXTERNAL DEVICE DC R R DC Re Reinforced Figure 84 STO Example with automatic monitoring of the feedback and STO inputs connected in parallel SAFE TORQUE OFF VACON 112 9 5 4 SAFETY CAPABILITY CAT 1 PLc SIL1 Without any automatic monitoring
65. he installer or user of the equipment to ensure by consulta tion with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power SSC greater than or equal to 120 SAFETY VACON 12 1 10 DECLARATION OF CONFORMITY VACON EC DECLARATION OF CONFORMITY Manufacturer s name Vacon Srl Via Roma 2 1 39014 Postal BZ Italy Manufacturer s address We hereby declare that the following product Product name Vacon 100 AC drive VACONO100 3L a b c d e a 0003 0012 Frame Size 4 a 0016 0031 Frame Size 5 b 4 5 Voltage Rating c X Enclosure option d e Additional Codes Product Identification Product Safety Functions Safe Torque Off EN 61800 5 2 2007 and Emergency stop EN 60204 1 2006 A1 2009 AC 2010 in extracts Complies with the following EU legislation Low Voltage Directive LVD 2006 95 EC Electromagnetic Compatibility EMC 2004 108 EC EC Machinery Directive 2006 42 EC Notified body that carried out the EC type examination TUV Rheinland Industrie Service GmbH Alboinstr 56 12103 Berlin Germany Certification Body for Machinery NB 0035 Certificate No 01 205 5219 12 The following standards and or technical specifications referenced below were used EN 61800 5 2 2007 EN 61800 5 1 2007 LV Directive compliance EN 61800 3 2004 EMC Directive compliance EN ISO 13849 1 2008 AC 2009 EN 62061 2005 AC
66. he relay out puts and other 1 0 terminals may have a dangerous control voltage present even when VACON 100 X drive is disconnected from mains Before connecting the AC drive to mains make sure that the powerhead of VACON 100 X Drive is mounted firmly on the terminal box During a coast stop see the Application Manual the motor is still generating voltage to the drive Therefore do not touch the components of the AC drive before the motor has completely stopped and wait until the indicators on the keypad go out if no keypad is con nected see the indicators on the cover Wait additional 30 seconds before starting any work on the drive gt PP PPR SAFETY VACON 6 1 WARNINGS VACON 100 X AC drive is meant for fixed installations on the motor or on the wall only Only DVC A circuits Decisive Voltage Class A according to IEC 61800 5 1 are allowed to be connected to the control unit This hint aims to protect both the drive and the client application VACON is not responsible for direct or conse quential damages resulting from unsafe connections of external circuits to the drive See paragraph 1 6 for more details Do not perform any measurements when the AC drive is connected to the mains The touch current of VACON 100 X AC drives exceeds 3 5mA AC According to standard EN61800 5 1 a reinforced protective ground connection must be ensured See paragraph 1 5 for more details If the AC drive
67. he shield with cable glands in motor end needed for EMC level C2 4 Screened cable equipped with compact low impedance shield JAMAK SAB OZCuY 0 or similar PE conductors J A Shield PE conductor Shield Figure 18 NOTE The EMC requirements are fulfilled at factory defaults of switching frequencies all frames NOTE If safety switch is connected the EMC protection shall be continuous over the whole ca ble installation 4 1 CIRCUIT BREAKER Please disconnect the drive via an external circuit breaker You have to provide a switching de vice between supply and main connection terminals When connecting the input terminals to the power supply using a circuit breaker observe that this is of type B or type C and chose it with a capacity of 1 5 to 2 times of the inverter s rated current see Table 24 and Table 25 NOTE circuit breaker is not allowed in installations where C UL is required Only fuses are recommended POWER CABLING VACON 32 4 2 UL STANDARDS ON CABLING To meet the UL Underwriters Laboratories regulations use a UL approved copper cable with a minimum heat resistance of 70 75 C Use Class 1 wire only The units are suitable for use ona circuit capable of delivering not more than 100 000 rms sym metrical amperes 600V AC maximum when protected by T or J class fuses Integral solid state short circuit protection does not provide branch circuit pro A tection Branch circuit protec
68. if Local is selected Switching between Local and Remote Control can be done by pressing the Loc Rem button on the keypad or by using the Local Remote ID211 parameter Changing control places Change of control place from Remote to Local keypad 1 Anywhere in the menu structure push the Loc Rem button Service support find your nearest Vacon service center at www vacon com VACON 91 OPTIONS Using the arrow buttons select Local Remote and confirm with the OK button On the next display select Local or Remote and again confirm with the OK button The display will return to the same location as it was when the Loc Rem button was pushed However if the Remote control place was changed to Local Keypad you will be prompted for keypad reference Figure 68 Changing control places Accessing the control page The Control page is meant for easy operation and monitoring of the most essential values 7 Anywhere in the menu structure push the Loc Rem button 8 Push the Arrow up or the Arrow down button to select Control page and confirm with the OK button 9 The control page appears If keypad control place and keypad reference are selected to be used you can set the Keypad reference after having pressed the OK button If other control places or reference values are used the display will show Frequency reference which is not editable READY RUN STOP ALARM FAULT READY RUN STOP ALARM FAULT FWD REV vo KEY
69. igure 22 Stripping of cables POWER CABLING VACON 40 MM4 15 70 10 30 7 30 MM5 20 70 10 40 10 40 as short as possible MM6 20 90 15 60 15 60 Table 14 Cables stripping lengths mm IEC installation e Remove the cable entry plate The cable entry system is a combination of a cable entry plate see the figure below and cable glands In the cable 2 entry plate there are several openings available for the cables with ISO metric thread e Open only the inlet holes where you need to run the cables 3 e Choose the correct cable glands according to drive and cable size as shown in the following pictures M25x1 5 Figure 24 Cable entry plate MM5 Service support find your nearest Vacon service center at www vacon com VACON 41 POWER CABLING 7A Figure 25 Cable entry plate MM6 e Cable glands must be made of plastic materials They are used for sealing 4 cables passing through cable entries to ensure the characteristics of the enclosure Figure 26 Cable gland Plastic cable glands are recommend If metal cable glands are needed all insulation system requirements and all protective earthing requirements have to be fulfilled in accordance with the na
70. ith text segment display Text keypad for your user interface It has mainly the same functionalities as the keypad with graphical display although some of these are somewhat limited 8 2 6 1 Keypad display The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions On the display the user sees information about his present location in the menu structure and the item displayed If the text on the text line is too long to fit in the display the text will scroll from left to right to reveal the whole text string 8 2 6 2 Main menu The data on the control keypad are arranged in menus and submenus Use the Up and Down arrows to move between the menus Enter the group item by pressing the OK button and return to the for mer level by pressing the Back Reset button Indicators Indicators Status Alarm Fault READY RUN STOP ALARM FAULT Group or parameter name Menu location FWD REV yo KEYPAD BUS Indicators Indicators Direction Control place OPTIONS VACON 90 8 2 6 3 Using the keypad Editing values Change value of a parameter following the procedure below 1 Locate the parameter Enter the Edit mode by pressing OK Set new value with the arrow buttons up down You can also move from digit to digit with the arrow buttons left right if the value is numerical and change then the value with the arrow but tons up down 4 Confirm change with OK button
71. ity Purpose Six pin black connector see STO terminal connector 1 Figure 9 to use STO function Beadle a a ix 10 Screws for control cable clamps screw M1 3 Cable clamp 5 Clamping control cables M4 x 12 DIN6900 3 Combi Delta Tx 6 Screws for power cable clamps screw M25 Cable clamp 3 Clamping power cables Product modified sticker 1 Information about modifications HMI cap 1 Closing cap for the HMI connector Table 4 Content of accessory bag MM4 Provided only if the drive is delivered with the keypad Service support find your nearest Vacon service center at www vacon com VACON 19 2 3 2 FRAME MM5 Item STO terminal connector Quantity 1 RECEIPT OF DELIVERY Purpose Six pin black connector see Figure 9 to use STO function M4 x 12 DIN6900 3 Combi Delta Tx 10 Screws for control cable clamps screw M1 3 Cable clamp 5 Clamping control cables M4 x 12 DIN6900 3 Combi Delta Tx 6 Screws for power cable clamps screw M32 Cable clamp 3 Clamping power cables Product modified sticker 1 Information about modifications HMI cap 1 Closing cap for the HMI connector Table 5 Content of accessory bag MM5 Provided only if the drive is delivered with the keypad 2 3 3 FRAME MM6 Item STO terminal connector Quantity 1 Purpose Six pin black connector see Figure 9 to use STO function M4 x 12 DIN6900 3 Combi Delta Tx 10
72. ix it with its Screws 10 e Place the cable entry plate with the other cables motor cable brake cable 1 0 cables in the groove on the bottom side of the drive and fix it with its screws Service support find your nearest Vacon service center at www vacon com VACON 77 OPTIONS SQSOGGOe S S818181818 181818 O Figure 50 Mains switch cable entry and cables connected 11 Mount the powerhead on the terminal box with its screws the installation pro cess has been completed See Figure 51 Figure 51 Mount the powerhead on the terminal box OPTIONS VACON 78 8 2 CONTROL KEYPAD The control keypad is the interface between the VACON 100 X frequency converter and the user With the control keypad it is possible to control the speed of a motor to supervise the state of the equipment and to set the frequency converter s parameters The keypad is an option and can be delivered separately The option includes the keypad the keypad holder and three screws You can use one screw to fix the keypad holder to the drive or three screws to fix th
73. lden 9841 or similar Depends on the used fieldbus See respective bus manual Table 23 RS485 cable data Cable length Service support find your nearest Vacon service center at www vacon com VACON 55 CONTROL UNIT 5 3 BATTERY INSTALLATION FOR REAL TIME CLOCK RTC Enabling the functions of the Rea Time Clock RTC requires that an optional battery is in stalled in the VACON 100 X drive Detailed information on the functions of the Real Time Clock RTC can be found in the Appli cation Manual See the following figures to install the battery on the control box of Vacon 100X frequency converter 1 Remove the three screws on the control box as shown in Figure 36 Figure 36 Remove the three screws on the contro box 2 Rotate and open the cover of the control box as shown in Figure 37 CONTROL UNIT VACON 56 Figure 37 Open the cover of control box 3 Install the battery in the correct place and connect it to the control box See Figure 38 for battery location and connector Service support find your nearest Vacon service center at www vacon com VACON 57 CONTROL UNIT Connector for __ gt re battery Location for battery Figure 38 Location and connector for the battery on the control box COMMISSIONING VACON 58 6 COMMISSIONING Before commissioning note the f
74. ls for an optional external brake resistor These terminals are marked with DC R and R See Table 27 and Table 28 for the resistor ratings 4 4 4 CONTROL CABLES For information on control cables see chapter Control unit Service support find your nearest Vacon service center at www vacon com VACON 39 POWER CABLING 4 5 CABLE INSTALLATION e Before starting check that none of the components of the AC drive is live Read care fully the warnings in chapter 1 e Place the motor cables sufficiently far from other cables e Avoid placing the motor cables in long parallel lines with other cables e lf the motor cables run in parallel with other cables note the minimum distances between the motor cables and other cables given in table below Distance between Shielded cables m cable m 0 3 lt 50 1 0 lt 200 e The given distances also apply between the motor cables and signal cables of other sys tems e The maximum lengths of motor cables shielded are 100 m MM4 and 150 m MM5 and MM e The motor cables should cross other cables at an angle of 90 degrees e If cable insulation checks are needed see chapter Cable and motor insulation checks Start the cable installation according to the instructions below 1 Strip the motor and mains cables as advised below Earth conductor Earth conductor Shield F
75. n properly SAFETY VACON 10 1 6 INSULATION SYSTEM Please consider carefully the insulation system depicted in Figure 4 before con necting any circuit to the unit A distinction has to be made for the following three groups of terminals according the insula tion system of VACON 100 X e Mains and motor connections L1 L2 L3 U V W Relays R01 RO2 Thermistor input Control terminals I Os RS485 Ethernet STO The Control terminals I Os RS485 Ethernet STO are isolated from the Mains the insulation is reinforced according to IEC 61800 5 1 and the GND terminals are referred to PE This is important when you need to connect other circuits to the drive and test the complete assembly Should you have any doubt or question please contact your local VACON distribu tor CONTROL UNIT RO1 _ DVC A or Mains Thermistor RO2_ Mainsl 10Vref _ Analog Inputs __ Digital Inputs__ Digital Outputs__ 24V __ DVCA Keypad Ethernet __ RS485 STO L1 U L2 POWER UNIT V L3 Mains W Reinforced DC DC R R Figure 4 Insulation system The relays may be used also with DVC A circuits This is possible only if both re A lays are used with DVC A circuit to mix Mains and DVC A is not allowed Service support find your nearest Vacon service center at www vacon com VACON 11 SAFETY 1 7 COMPATIBILITY WITH RCDS This product can cause a d c current in the prot
76. nalogue input 4 voltage or current 5 Analogue input com Differential input if not connected to ground mon Allows 20V differential mode voltage to GND 24V 10 max volt ripple lt 100mVrms max 250mA 6 24V aux voltage Short circuit protected Ground for reference and controls connected internally to 4 orgrouna frame earth through 1MQ 8 Digital input 1 Positive or negative logic ae Ri min 5kQ 9 Digital input 2 18 30V 1 10 Digital input 3 0 5V 0 11 Common A for DIN1 Digital inputs can be isolated from ground see chapter 5 DIN6 Default connected to ground 12 24V aux voltage Same as terminal 6 Ground for reference and controls connected internally to 13 1 0 ground frame earth through 1MQ 14 Digital input 4 Positive or negative logic Ri min 5kQ 15 Digital input 5 Re 16 Digital input 6 0 5V 0 17 Common A for DIN1 Digital inputs can be isolated from ground see chapter 5 DIN6 Default connected to ground 18 Analogue output Analogue output channel 1 voltage or current 0 20 mA R lt 500 Q 0 10 V R gt 1kQ Resolution 0 1 accuracy 2 Selection V mA with dip switches see chapter 5 Default 0 20mA Short circuited protected 19 Analogue output com mon TECHNICAL DATA VACON 72 Standard 1 0 Terminal Technical information
77. ng value Yes for the parameter and clicking OK STOP C READY 1 0 STOP C READY 1 0 STOP READY 1 0 QG Main Menu Diagnostics Reset faults ID M4 D M 1 oT D M4 2 7 Monitor Active faults A 5 fok 0 Reset faults Parameters 5 12 2f Reset faults Help Diagnostics G Fault history 6 39 Figure 70 Diagnostic menu with graphical keypad FWD REV vo KEYPAD BUS FWD REV vo KEYPAD BUS Figure 71 Diagnostic menu with text keypad Service support find your nearest Vacon service center at www vacon com VACON 93 OPTIONS 8 2 7 1 Fault History In menu M4 3 Fault history you find the maximum number of 40 occurred faults On each fault in the memory you will also find additional information see below STOP GC READY 1 0 STOP GC READY 1 0 STOP Diagnostics Fault history IQ D M4 1 D Device removed M4 3 3 2 Active faults External Fault 51 0 IQ Fault old 891384s 380 lt gt External Fault 51 State Info old ST Reset faults Kv Z Fault old 871061s Date 7 12 2009 Fault history Device removed 39 Time 04 46 33 39 Info old 862537s Operating time 862537s READY RUN STOP ALARM FAULT READY RUN STOP ALARM FAULT READY RUN STOP ALARM FAULT FWD REV Vo KEYPAD BUS FWD REV vo KEYPAD BUS FWD REV vo KEYPAD BUS READY RUN STOP ALA
78. nt failure Cannot be reset from keypad Va Switch off power defective cot aheri DO NOT RE CONNECT POWER 7 60 Saturation P Contact factory If this fault appears simultane ously with F1 check motor cables and motor Table 32 Fault codes and descriptions Service support find your nearest Vacon service center at www vacon com VACON 95 OPTIONS Fault code Fault ID Fault name Possible cause Communication between control board 600 a and power unit has failed Communication between control board 601 and power unit has interference but it is still working 602 Watchdog has reset the CPU Reset the fault and restart Should the fault re occur con 603 Voltage of auxiliary power in power unit tact the distributor near to you is too low Phase fault Voltage of an output phase 604 does not follow the reference 605 CPLD has faulted but there is no detailed information about the fault Update software Should the Control and power unit software are 606 fault re occur contact the dis incompatible tributor near to you Software version cannot be read There Update Pawar tint SONWANE 607 ee Een Should the fault re occur con p tact the distributor near to you 8 System fault CPU overload Some part of the soft sae ware for example application has caused an overloa
79. oasting In the application the STO state can be indicated using a digital output gt EE To re enable the motor operation after the STO state it is necessary to perform the following steps e Release the switch or the external device F30 is displayed even after this has been released e Reset the fault through a digital input or from the keypad e It is possible that a new start command is required for the restart depending on the applica tion and your further setting Service support find your nearest Vacon service center at www vacon com VACON 115 SAFE TORQUE OFF 9 8 MAINTENANCE AND DIAGNOSTICS If any service or repair is to be conducted on the drive installed please inspect the checklist given in Table 43 STO function is available and fully functional by testing it During maintenance breaks or in case of service repair ALWAYS make sure that the The STO function or the STO input output terminals do not need any maintenance The following table shows faults that may be generated by the software that monitors the hardware related to the STO safety function If you detect any failure in safety functions including STO contact your local VACON supplier Fault Code Correction STO inputs in a differ 30 STO fault ent state or both de Check cabling energized Table 44 Fault related to the STO function SAFE TORQUE OFF
80. of STO output feedback the safety capability is reduced to Cat 1 PLc SIL1 The STO inputs which can be connected in parallel must be supplied by a safety push button or a safety relay The choice of using the STO inputs without the automatic monitoring of the output feedback does not permit to achieve the other safety capabilities The standards for functional safety require that functional proof tests are performed on the equipment at user defined intervals Therefore this safety capability can be achieved as long as the STO function is manually monitored at the frequency deter mined by the specific application once a month can be acceptable This safety capability can be achieved by connecting in parallel the STO inputs exter nally and by ignoring the use of the STO output feedback gt PP The picture below shows an example of connection for the STO function A switch a safety push but ton or a safety relay may be connected with 2 wires to the drive When the contacts of the switch are opened the STO is demanded the drive indicates F30 Safe Torque Off and the motor stops by coasting SWITCH S1 F G1 F S2 G2 L1 U L2 V L3 W DC R R DC RO Reinforced Figure 85 STO example without automatic monitoring of the feedback and STO inputs connect ed in parallel Service support find your nearest Vacon service center at www vacon com VA
81. of the cable shield of all two cables into pigtails and make a grounding connection with the clamp Make the pigtails just long enough to reach and be fixed to the terminal no longer Tightening torques of cable terminals Tightening torque Tightening torque Tightening torque Nm lb in Nm lb in Type Power and motor EMC grounding Nm lb in Grounding terminals terminals clamps Nm lb in Nm lb in Nm lb in 0007 2 0012 2 MM4 0003 4 00124 1 2 1 5 10 6 13 3 1 5 13 3 2 0 17 7 0018 2 0031 2 MM5 0016 4 0031 4 1 2 1 5 10 6 13 3 1 5 13 3 2 0 17 7 0048 2 0062 2 MM6 0038 4 0072 4 4 5 35 4 44 3 1 5 13 3 2 0 17 7 Table 16 Tightening torques of terminals ES Check the connection of the earth cable to the motor and the AC drive ter minals marked with aa CONTROL UNIT VACON 46 5 CONTROL UNIT Remove the powerhead of the drive to reveal the terminal box with the control terminals The control unit of the AC drive consists of the control board and additional boards option boards connected to the slot connectors of the control board The locations of boards termi nals and switches are presented in Figure 30 below Number Meaning Control terminals 1 11 see chapter 5 1 2 Control terminals 12 30 A B see chapter 5 1 2 Relay terminals see chapter 5 1 2 Thermistor input see chapter 5 1 2
82. ollowing directions and warnings Internal components and circuit boards of VACON 100 X drive except for the galvanically isolated 1 0 terminals are live when it is connected to mains poten tial Coming into contact with this voltage is extremely dangerous and may cause death or severe injury The motor terminals U V W and the brake resistor terminals R R are live when VACON 100 X drive is connected to mains even if the motor is not run ning The control O terminals are isolated from the mains potential However the relay outputs and other 1 0 terminals may have a dangerous control voltage present even when VACON 100 X drive is disconnected from mains Do not make any connections to or from the frequency converter when it is con nected to the mains After disconnecting the AC drive from the mains wait until the fan stops and the indicators on the powerhead go out Wait 30 more seconds before doing any work on the connections of VACON 100 X Drive Do not open the unit before this time has expired After expiration of this time use a measuring equipment to abso lutely ensure that no voltage is present Always ensure absence of voltage before starting any electrical work gt gt PPP Before connecting the AC drive to mains make sure that the powerhead VACON 100 X Drive is mounted firmly on the terminal box Service support find your nearest Vacon service center at www vacon com VACON 59 COMM
83. otection class the recommended fastening torque is 2 3 Nm Frame Screw number Screw size MM4 4 M5 MM5 6 M5 MM6 4 M6 Table 8 Screws for fixing the powerhead to the terminal box MOUNTING VACON 28 3 4 COOLING The AC drive produces heat in operation and is cooled down by air circulated by a fan The cool ing concept is independent of the motor fan Enough free space shall therefore be left around the AC drive to ensure sufficient air circula tion and cooling Different acts of maintenance may also require certain amount of free space The minimum clearances given in Table 9 must not be exceeded It is also important to ensure that the temperature of the cooling air does not exceed the maximum ambient temperature of the converter Contact local VACON distributor for more information on required clearances in different in stallations Min clearance mm All types 80 160 60 Table 9 Min clearances around AC drive Clearance left and right from the drive B Clearance above the drive C Clearance underneath the AC drive Figure 16 Installation space Cooling air required Type m h MM4 140 MM5 140 MM6 280 Table 10 Required cooling air Should you need further details on the cooling system of the VACON 100 X please contact your local VACON distributor Service support find your nearest Vacon service center at www vacon com
84. otor allows the motor to be started Set the maximum motor speed frequency according to the motor and the machine connected to it Before reversing the motor make sure that this can be done safely Make sure that no power correction capacitors are connected to the motor cable Make sure that the motor terminals are not connected to mains potential PPP RE 6 3 1 CABLE AND MOTOR INSULATION CHECKS 1 Motor cable insulation checks Disconnect the motor cable from terminals U V and W of the AC drive and from the motor Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor The insula tion resistance must be gt 1MQ at ambient temperature of 20 C 2 Mains cable insulation checks Disconnect the mains cable from terminals L1 L2 and L3 of the AC drive and from the mains Measure the insulation resistance of the mains cable between each phase conduc tor as well as between each phase conductor and the protective ground conductor The insulation resistance must be gt 1MQ at ambient temperature of 20 C 3 Motor insulation checks Disconnect the motor cable from the motor and open the bridging connections in the motor connection box Measure the insulation resistance of each motor winding The measurement voltage must equal at least the motor nominal voltage but not exceed 1000 V The insulation resistance must be gt 1MQ at am
85. p limit 211 V Overvoltage fault pro tection tes Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature protection Yes Motor overload protec tion Yes These devices provide motor overeload protection at 105 of full load amperes Motor stall protection Yes Motor underload pro Yes tection Short circuit protec tion of 24V and 10V Yes reference voltages Thermal motor protec Yes by PTC tion Service support find your nearest Vacon service center at www vacon com Table 29 VACON 100 X technical data VACON 71 TECHNICAL DATA 7 3 1 TECHNICAL INFORMATION ON CONTROL CONNECTIONS Standard 1 0 Terminal Technical information 1 Reference output 10V 3 Maximum current 10 mA Analogue input channel 1 0 20 mA Ri 250 Q 0 10 V Ri 200kQ Resolution 0 1 accuracy 1 Selection V mA with dip switches see chapter 5 Default 0 10V Short circuited protected Analogue input 2 voltage or current 3 Analogue input com Differential input if not connected to ground mon Allows 20V differential mode voltage to GND Analogue input channel 2 0 20 mA Ri 250 Q 0 10 V Ri 200kQ Resolution 0 1 accuracy 1 Selection V mA with dip switches see chapter 5 Default 0 20mA Short circuited protected A
86. priate recycling center or returned to the manufacturer Observe local and other applicable laws as they may mandate special treatment for specific components or special treatment may be ecologically sensible Service support find your nearest Vacon service center at www vacon com VACON 21 RECEIPT OF DELIVERY MOUNTING VACON 22 3 MOUNTING VACON 100 X is the ideal solution for a decentralised installation It is conceived to be mount ed ona wall or directly on the motor saving space and reducing the cabling complexity In both of the cases it must be ensured that the mounting plane is even 3 1 DIMENSIONS Figure 11 VACON 100 X drive dimensions MM4 Dimensions WxHxD mm in 190 7 x 315 3 x 196 4 7 51 x 12 41 x 7 73 MM4 HMGR 190 7 x 315 3 x 213 8 7 51 x 12 41 x 8 42 Service support find your nearest Vacon service center at www vacon com VACON 23 MOUNTING
87. ptional CanOpen Profibus DP DeviceNet Status indicators Drive status indicators LED on top side POWER RUN FAULT READY Ambient operating temperature 10 C 40 C Extended temperature range up to 60 C with current derating see chapter 1 8 Storage temperature 40 C 70 C Relative humidity 0 to 100 Ry PD2 Pollution degree These devices were evaluated for installation in a pollution degree 2 environment Altitude 100 load capacity no derating up to 1 000m derating 1 100m at 1 000 3 000m Stationary vibration sinusoidal 3 Hz lt f lt 8 72 Hz 10 mm 8 72 Hz lt f lt 200 Hz 3g 3M7 acc to IEC 60721 3 3 Shock Bump 25g 6 ms 3M7 acc to IEC 60721 3 3 Degree of protection IP66 Type 4X EMC 2004 108 EC Low Voltage 2006 95 EC Immunity EN61800 3 2004 15t and 2 4 environment Eee EN61800 3 2004 Category C2 The drive can be modified for IT networks THD EN61000 3 12 see chapter 1 9 Safety EN 61800 5 1 Safety TUV Mark USA Canada VACON Compliance testing EMC TUV Tested EC Conformation Declaration TECHNICAL DATA VACON 70 Protections Undervoltage trip limit Depends on supply voltage 0 8775 supply voltage Supply voltage 400 V Trip limit 351 V Supply voltage 480 V Trip limit 421 V Supply voltage 240 V Tri
88. remely dangerous A and may cause death or severe injury The heater can be used only inside the drive and in combination with only the VACON 100X Before connecting the heater to mains make sure that the VACON 100X drive is closed firmly Table 33 Dangers 8 3 3 TECHNICAL DATA The optional heater has to be supplied with single phase 230V The thermal element is always sup plied and if the drive is connected at 40 C the drive will be heated up until the temperature of 10 C is exceeded The heating is temperature controlled and an internal fan ensures that the air is equal ly distributed inside the enclosure The integrated relay output switching capacity 24VDC 3A 250VAC 3A can be used to control the power up of the drive The contact is closed when the internal temperature is higher than the min imum allowed value for the power up 10 C This can be included and manage in the logic of the entire system A bi color LED on the enclosure of this option shows the status of the drive ready or not ready Heater connections Terminal Signal Technical information Supply voltage input terminals 1AC 230V 50Hz N Neutral 500 mA Switching capacity X1 Feedback relay output 24VDC 3A 250VAC 3A Table 34 Technical information on input and relay terminals OPTIONS VACON 100 8 3 4 MOUNTING INSTRUCTIONS MM4 EXAMPLE E P Ready NOT Ready
89. rmation is also available for faults alarms and the startup wizard STOP C READY 1 0 STOP IG READY 1 0 STOP READY 1 0 Digital Inputs D Ctrl signal 1A GD Ctrl signal 1A 1D 403 M 5 1 1 1D 403 1 5 1 1 1D 403 M3 5 1 1 s Ctrl Signal 1A 5 Start Signal 1 for control Place of Edit I O A Start Signal 1 o functionality chosen with I O A Logic in Start Stop Setup Menu Ctrl Signal 2A oF F Q Help Ctrl Signal 1B 4 Add to favorites Figure 65 Help text example Adding item to favourites You might need to refer to certain parameter values or other items often Instead of locating them one by one in the menu structure you may want to add them to a folder called Favorites where they can easily be reached To add an item to the Favorites STOP Gl READY 170 STOP IG READY 1 0 stop C REA 1 0 Basic Settings 5 Motor Nom Freq Motor Nom Freq a D Motor Nom Voltg o 2 Edit was added to 230 00 v fok gt fok favorites Press OK to continue Motor Nom Freq Help 50 00 Hz Motor Nom Speed 8 Add to favorites 0 s Figure 66 Adding item to Favorites Service support find your nearest Vacon service center at www vacon com VACON 89 OPTIONS 8 2 6 VACON KEYPAD WITH TEXT SEGMENT DISPLAY You can also choose a Keypad w
90. ssible functions to be selected e Restore factory defaults will re establish the parameter settings originally made at the fac tory e By selecting Save to keypad you can copy all parameters to the keypad e Restore from keypad will copy all parameters from keypad to a drive stop READY Keypad stop READY Keypad stop READY Keypad EJ Main Menu 4 User settings Sa Parameter backup 2 ID M6 2 ID M6 5 ID M6 5 1 ri 1 0 d Hard e Appli ti lecti of f bc Re eee Fe Restore factory defaults User settings Pa 4 Er Save to keypad F it Dri CA ei Poe p eT Restore from keypad 0 Drive O Figure 64 Parameter copy NOTE If the keypad is changed between drives of different sizes the copied values of these param eters will not be used Motor nominal current P3 1 1 4 Motor nominal voltage P3 1 1 1 Motor nominal speed P3 1 1 3 Motor nominal power P3 1 1 6 Motor nominal frequency P3 1 1 2 Motor cosphi P3 1 1 5 Switching frequency P3 1 2 1 Motor current limit P3 1 1 7 Stall current limit P3 9 12 Stall time limit P3 9 13 Stall frequency P3 9 14 Maximum frequency P3 3 2 OPTIONS VACON 88 Help texts The graphical keypad features instant help and information displays for various items All parameters offer an instant help display Select Help and press the OK button Text info
91. t in use it has to be short circuited Maintenance Maintenance CORRE as RARE ule Carry out the needed mainte 1301 counter 1 Slaven alarm limit It s a characteristic fault of nance and RESEE core the HVAC Application i Maintenance Maintenance counter has reached the Carry out the needed mainte 1302 alarm limit It s a characteristic fault of counter 2 alarm ee nance and reset counter i the HVAC Application Maintenance Maintenance counter has yeached the Carry out the needed mainte 1303 counter 3 alarm alarm limit It s a characteristic fault of neue and ieser oes the HVAC Application Maintenance Mainienance tonne has reached tie Carry out the needed mainte 1304 canter alari alarm limit It s a characteristic fault of nance and reset counter the HVAC Application i Table 32 Fault codes and descriptions OPTIONS VACON 98 Fault code Fault ID Fault name Possible cause Remedy Non existing ID number is used for Check parameters in Fieldbus 1310 mapping values to Fieldbus Process Data Mapbina menu Data Out pPINng i The value being mapped may 69 1311 Fieldbus map Not possible to convert one or more be of undefined type Check ping error values for Fieldbus Process Data Out parameters in Fieldbus Data Mapping menu Overflow when mapping and converting 1312 values for Fieldbus Process Data Out 16 bit The Soft fill function in the PI
92. tion must be provided in accordance with the National Electrical Code and any additional local codes Service support find your nearest Vacon service center at www vacon com VACON 33 POWER CABLING 4 3 DESCRIPTION OF THE TERMINALS The following pictures describe the power terminals and the typical connections in Vacon 100X drives FT ca an cd TE NN un LT ds Fy UD ou brake resistor Sx AC power supply Three phases K TYNT i PE Ji TT Figure 19 Power connections MM4 POWER CABLING VACON 34 M __ CZ ESS Ne MA T ET Ann nl r NN il e Ni EGA Uo UI gt ll ifi Eii Hh brake resistor i D e AC power supply S5 Three phases a Teh Py Figure 20 Power connections MM5 Service support find your nearest Vacon service center at www vacon com VACON 35 POWER CABLING
93. tion which is a functional safety feature pres ent into VACON 100 X drive products as standard 9 1 GENERAL DESCRIPTION The STO function brings the motor in no torque state as defined by 4 2 2 2 of the IEC 61800 5 2 Power that can cause rotation or motion in the case of a linear motor is not applied to the motor The Power Drive System Safety Related will not provide energy to the motor which can generate torque or force in the case of a linear motor Therefore the STO function is suitable for applications that rely on the immediate removal of power to the actuator resulting in an uncontrolled coast to stop activated by an STO demand Additional protective measures need to be applied when an application requires a different stopping action 9 2 WARNINGS Designing of safety related systems require specialist knowledge and skills Only qualified people are permitted to install and set up the STO function The use of STO does not itself ensure safety An overall risk evaluation is required for ensuring that the commissioned system is safe Safety devices must be correctly incorporated into the entire system which must be designed in compliance with all relevant standards within the field of industry The information in this manual provides guidance on the use of the STO function This information is in compliance with accepted practice and regulations at the time of writing However the end product system designer is responsi
94. tional electrical regulations and IEC 61800 5 1 5 e Screw the cable glands on the cable entry holes using the proper tighten ing torque as shown in Table 15 POWER CABLING Tightening torques of cable glands VACON 42 Frame Gland screw Tightening torque Nm lb in type metric Nm lb in M16 1 0 8 9 MM4 M25 4 0 35 5 M16 1 0 8 9 MM5 M25 4 0 35 5 M32 7 0 62 1 M16 1 0 8 9 MM6 M25 4 0 35 5 M40 10 0 88 7 Table 15 Tightening torque and dimension of cable glands Service support find your nearest Vacon service center at www vacon com VACON 43 POWER CABLING UL installation e To connect NPT pipes to Vacon 100X use the optional metal cable entry plate included in R02 option to meet UL installation rules 6 e One metal conduit plate with accessories screws and gasket is delivered in a separate bag together with the drive See the following figures for more details O O O gn OO 0 O O O Figure 27 Cable entry plate MM4 UL installation O O O O O O Figure 28 Cable entry plate MM5 UL installation POWER CABLING VACON 44 O O O O O O O O Figure 29 Cable entry plate MM6 UL installation All the 3 terminal box openings are closed with the standard plastic plates with the metric threads The metal cable en
95. torque is 2 3 Nm The screws should be tightened crosswise Figure 15 Separation of modules MM5 example Service support find your nearest Vacon service center at www vacon com VACON 27 MOUNTING 3 3 1 WALL MOUNTING The drive can be mounted in vertical or horizontal position on the wall or any other relatively even mounting plane or machine frame and fixed with the screws recommended in Table 7 Recommended screw or bolt size for MM4 is M5 for MM5 M6 and MM6 is M8 Frame Screw number Screw size MM4 4 M5 MM5 4 M6 MM6 4 M8 Table 7 Screws for wall mounting 3 3 2 MOTOR MOUNTING The drive can also be mounted on a motor on top or on any side of the motor The drive is equipped with a cooling system independent of the motor Motor mounting requires special adapting components Contact your local VACON distributor for additional information 3 3 3 SEGREGATED MODULES In order to ease replacements in case of failure the power and the control sub systems are enclosed in two segregated parts connected together through pluggable terminals e Power head heat sink enclosing all power electronics e Terminal box block containing unit control and power terminals Firstly the terminal box has to be fixed and the cabling has to be done Secondly the power head has to be plugged and fixed to the terminal box with dedicated screws see Table 8 In order to preserve the specified IP pr
96. try plate for UL installation has to be installed in place of one of standard plastic cable entries provided with the default package The metal cable entry plate has three not threaded openings input line motor and I Os and can be mounted only on left or right hand side of the drive Flexible or rigid cable conduit can be used Use proper fittings to join and terminate rigid conduit tubing and protect it from damage too The proper selection of electrical conduit materials fittings and installa tion are important for safe electrical wiring Setscrew fittings are commonly used with conduit they provide weather 10 tight joints that are firm to keep the IP degree of the drive Service support find your nearest Vacon service center at www vacon com VACON 45 Cable installation POWER CABLING 11 Pass the cables supply cable motor cable brake cable and 1 0 cables through the conduits UL connections or through the cable glands IEC connections and cable entries 12 Detach the cable clamps and the grounding clamps 13 Connect the stripped cables Expose the shield of all two cables in order to make a 360 degree connec tion with the cable clamp reverse the shield over the plastic cover of the cable and fix all together Connect the phase conductors of the supply and motor cables into their respective terminals Form the rest
97. ultimonitoring values You can choose which values appear here for monitoring stop READY 1 0 STOP IG Ready Keypad STOP READY Keypad Main Menu Choose action I Keypad Reference ID 1805 ID M1 Monit A vex Change direction V4 yv 0K00 Hz Parameters REM Control page Output Frequency Motor Torque CF cas Local Remote A Q 0 00Hz 0 00 Diagnostics Motor Current Motor Power 6 ID 184 0 00A 0 00 STOP READY Keypad Keypad Reference fe G A N 0 00Hz Output Frequency Motor Torque fok 0 00Hz 0 00 Motor Current Motor Power 0 00A 0 00 Figure 63 Accessing Control page Service support find your nearest Vacon service center at www vacon com VACON 87 OPTIONS Copying parameters NOTE This feature is available with graphical keypad only The parameter copy function can be used to copy parameters from one drive to another The parameters are first saved to the keypad then the keypad is detached and connected to another drive Finally the parameters are downloaded to the new drive restoring them from the keypad Before any parameters can successfully be copied from one drive to another the drive has to be stopped when the parameters are downloaded e First go into User settings menu and locate the Parameter backup submenu In the Param eter backup submenu there are three po
98. y by comparing your order data to the drive information found on the package label If the delivery does not correspond to your order contact the supplier immediately See chapter 2 3 Vacon type code AC DRIVE 0022345628e Vacon order number Type VACONO100 3L 0031 4 X Batch ID Serial number S N Vo789012245 B ID 122245 LL IE Code 20 AB3L00315A02B5H1MB1C 12345678 MOE ONI OANIEN DO DO OON AN T 1 D EE Rated Rated current 31 A current 380 480 v Supply IP class IP66 Type 4x O voltage EMC level EMC level C2 oO Application sr code Firmware FW0065V008 eus Application Cust Ord No 3234500378 Marks Customer s order number CUSTOMER NAME VACON DRIVEN BY DRIVES Figure 8 VACON package label Service support find your nearest Vacon service center at www vacon com VACON 17 2 1 TYPE DESIGNATION CODE RECEIPT OF DELIVERY VACON type designation code is formed of a nine segment code and optional codes Each segment of the type designation code uniquely corresponds to the product and options you have ordered The code is of the following format VACONO100 3L 0061 4 X xxxx yyyy VACON This segment is common for all products 0100 Product range 0100 VACON 100 3L Input Function 3L Three phase input 0061 Drive rating in ampere e g 0061 61 A See Table 24 and Table 25 for all the drive rat ings 4 Supply volt

Vacon 100 X Installation Manual

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