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vacon 100 x - Synchro Dan

1. Figure 23 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 terminals of the control board and the relay board unless other 24 hour support 358 0 201 212 575 e Email vaconfavacon com VRCON 33 CONTROL UNIT wise specifically 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 24 below The control board is equipped with 22 fixed control 1 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 13 ZB od be gBuduwew S
2. Standard 1 0 Terminal Technical information 1 Reference output 10V 3 Maximum current 10 mA Analogue input channel 1 0 20 mA Ri 2250 2 Analogue input dp y Ri 200k0 voltage or current Resolution 0 196 accuracy 196 Selection V mA with dip switches see chapter 5 Default 0 10V Short circuited protected 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 2250 Q Analogue input 0 10 V Ri 200kC2 4 voltage or current Resolution 0 1 accuracy 1 Selection V mA with dip switches see chapter 5 Default 0 20mA Short circuited protected 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 aue voltage Short circuit protected 7 o d Ground for reference and controls connected internally to nd frame earth through 1MQ 8 Digital input 1 Positive or negative logic 9 Digital input 2 i eos 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 13 0 d Ground for reference and controls connected internally to Z frame earth through 1MQ 14 Digital input 4 Positive or negative logic 15 Digital input 5 rer
3. Ethernet connection Figure 28 5 2 1 PREPARE FOR USE THROUGH ETHERNET 1 Connect the Ethernet cable see specification on page 38 to its terminal and run the cable through the conduit plate 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 CATbe STP Cable length Max 100m Table 16 Ethernet cable data Connector 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 39 CONTROL UNIT 5 2 2 PREPARE FOR USE THROUGH RS485 Strip about 15 mm of the RS485 cable see specification on page 40 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 at a maximum length of 15 mm Do not strip the aluminum cable shield
4. Figure 33 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 Unless already done attach the sticker close to the name plate of the AC drive Product modified COMMISSIONING VACON 46 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 motor 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 gt gt eee 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 temperatu
5. 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 28 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 25 and turn the rightmost switch to position 1 Biasing is built in the termination resistor See also step 6 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 CONTROL UNIT VACON 40 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 100 Vacon 100 Vacon 100 Vacon 100 Vacon 100 Motor mounted Motor mounted Motor mounted Motor mounted Motor mounted Termination activated BACnet MS TP Termination activated with eye ae Termination DIP switch 8 Bus termination deactivated 5 2 3 RS485 CABLE DATA 2 5 mm STP Shielded Twisted Pair type Belden 9841 or similar Depends on t
6. l lsl lsis ls ele Figure 39 Connection of the supply cable to the Mains switch right hand side example 5 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 6 e Place the Mains switch plate with the cables in the groove and fix it with its Screws 7 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 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 9 59 OPTIONS OS Oe 8 SO OU OO OON Figure 40 Mains switch cable entry and cables connected Mount the powerhead on the terminal box with its screws the installation pro cess has been completed See Figure 41 Figure 41 Mount the powerhead on the terminal box OPTIONS VACON 60 8 2 CONTROL KEYPAD The control keypad is the inter
7. 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 Multimonitoring values You can choose which values appear here for monitoring STOP READY 1 0 STOP Ic Ready Keypad STOP READY Keypad Main Menu Choose action I Keypad Reference ID 1805 ID M1 Monit A UT Change direction Ny v 0010 Hz Parameters REM Control page Output Frequency Motor Torque CY cas Local Remote o 0 00Hz 0 00 Diagnostics Motor Current Motor Power 6 ID 184 0 00A 0 00 STOP G READY Keypad Keypad Reference G ZO 0 00Hz Output Frequency Motor Torque o 0 00Hz 0 00 Motor Current Motor Power 0 00A 0 00 Figure 53 Accessing Control page 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 69 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
8. po 57 Hz lt f lt 150 Hz 1g Degree of protection IP66 E EMC 2004 108 EC Directives Low Voltage 2006 95 EC Immunity EN61800 3 2004 1Stand 2 environment e EN61800 3 2004 Category C2 Standards The drive can be modified for IT networks THD EN61000 3 12 see chapter 1 7 Safety EN 61800 5 1 Approvals Safety TUV Mark Declaration of USA Canada Vacon Compliance testing Conformity EMC TUV Tested EC Conformation Declaration 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 53 TECHNICAL DATA 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 Trip limit 211 V Overvoltage fault pro tection Mes Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature Yes protection Motor overload protec Yes tion 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 Table 22 Vacon 100 X technical data TECHNICAL DATA 7 3 1 VACON 54 TECHNICAL INFORMATION ON CONTROL CONNECTIONS
9. VACON 5 SAFETY The cross sectional area of every protective earthing conductor which does not form a part of the supply cable or cable enclosure shall in any case be not less than e 2 5 mm if mechanical protection is provided or e 4 mm 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 Earth connections Metal aglet Figure 2 Earth connections and metal aglet in MM5 However always follow the local regulations for the minimum size of the protective earth ing conductor NOTE Due to the high capacitive currents present in the AC drive fault current protective switches may not function properly SarETY VACON O 6 1 4 INSULATION SYSTEM Please consider carefully the insulation system depicted in Figure 3 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 R02 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 a
10. 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 500 Q 0 10 V Rj gt 1kQ Resolution 0 1 accuracy 2 Anal tput 19 RAGE output COM Selection V mA with dip switches see chapter 5 Default 0 20mA Short circuited protected 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 55 TECHNICAL DATA Standard 1 0 Terminal Technical information 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 36 B RS485 Default but termination disconnected Table 23 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 i 250VAC 8A elay output 125VDC 0 4A 23 Min switching load 5V 10mA 24 Switching capacity 24VDC 8A 250VAC 8A 25 Relay output 2 125VDC 0 4A 26 Min switching load 5V 10mA 28
11. Figure 12 Vacon 100 X drive dimensions MM6 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 19 MOUNTING 3 2 INTRODUCTION OF MODULES The mechanical concept of Vacon 100 X drive is based on two segregated parts power and con trol 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 boards and the control unit are located in the terminal box Powerhead Terminal box Figure 13 Vacon 100 X drive modules MOUNTING VACON e 20 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 he 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 MM6 or 6 MM5 dedicated screws located on top side of the powerhead see Fig ure 14 In order to guarantee specified IP protection recommended fastening torque is 2 3 Nm The screws should be tightened crosswise Figure 14 Separation of modules MM5 example 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 21 MOUNTING 3 3 1 WALL MOUNTING The drive
12. Remote reference voltage or current 4 20mA 0 10V 5 Al2 Analogue input com EE Ss mon r 6 24Vout 24V aux voltage I I 7 GND 1 0 ground o E SENE 8 DI1 Digital input 1 d TIE PORE 9 Di2 Digital input 2 up PENNE ME 10 pi3 Digital input 3 I i 11 CM Common for DI1 DI I i 12 24Vout 24V aux voltage I I Pate 13 GND 1 0 ground I m See She do ae 14 DI4 Digital input 4 Sa em 15 Di5 Digital input 5 I 4 EA obl 16 DI6 Digital input 6 17 CM Common for DI1 DI6 Analogue output 18 AO1 rar voltage or current I A Ime 19 AO GND Analogue output com mon e i l X1 30 424 Vin E input e cas A RS485 Serial bus negative v B RS485 Serial bus positive Can be isolated from ground see chap ter chapter 5 1 6 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 9 35 CONTROL UNIT 5 1 3 RELAY AND THERMISTOR INPUT TERMINALS Table 14 I O terminal signals for relay and thermistor terminals and connection example From ES TEGTIE Relays and thermistor From term From term 12 13 21 RO1 1 Relay output 1 RUN voc 22 R012 A H gt 23 Ro1 3 I 24 RO2 1 Relay output 2 25 RO2 2 EP 26 RO2 3 c DZe 28 qne Thermistor input L 29 T 5 1 4 SAFE TORQUE OFF STO TERMINALS For more information on the functionalities of the
13. 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 24 Technical information on Relay and thermistor terminals OPTIONS VACON O 56 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 example 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 35 Figure 35 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 1 switch must be mounted on this side Otherwise remove the cable entry plate from the right hand side See the Figure 36 Figure 36 Disconnect the cable entry plate example for MM5 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 9 57 OPTIONS 2 e Remove the cable entry plate from the bottom side of the terminal box by
14. eer Use brake chopper or brake too short a deceleration time 2 s brake chobper is disabled resistor available as options 11 Overvoltage soft PP ae Activate overvoltage controller ware fault 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 insulation failure in cables or ware fault motor ao the Reset the fault and restart 5 40 Charging switch 9 Should the fault re occur con faulty operation Mns tact the distributor near to you component failure Cannot be reset from keypad T Switch off power defective a 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 25 Fault codes and descriptions 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 77 OPTIONS Fault code Fault ID Fault name Possible cause Communication between control board 600 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 Sho
15. S161 92 G2 F F Soos HEHN 21 22 23 121314151617181930 A wm KaK l F 24 25 26 1234567 8 91011 Figure 24 Control terminals 5 1 1 CONTROL CABLE SIZING The control cables shall be at least 0 5 mm screened multicore cables see Table 12 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 termi 0 5 4 5 nals screw M2 Relay terminals screw M3 0 5 4 5 Table 12 Control cable tightening torques CONTROL UNIT VACON 34 5 1 2 STANDARD I O 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 13 Control I O terminal signals and connection example Standard 1 0 ENTRE E Terminal Signal MEA 10 Vref Reference output Reference Analogue i i gue input potentiometer 1 10 kQ i m 2 AN voltage or current 3 A1 Analogue input com vie mon Se NRA SO En Analogue input 4 Al2
16. and the motor stops by coasting In the application the STO state can be indicated using a digital output PPP 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 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 93 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 33 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 34 Fault related to the STO function SAFE TORQUE
17. ground of the 1 0 terminal Check the guality and guantity of cooling air Check the inside of the freguency 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 44 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 AC drive to EMC level T 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 30 for MM4 Figure 31 for MM5 and in Figure 33 for MM4 Figure 31 Locations of EMC screws in MM5 24 hour support 358 0 201 212 575 e Email vaconfavacon com VRCON 45 COMMISSIONING
18. Hi 17 and current menu location Activated group item Press OK to enter Ex Quick Setup T Monito Q A 5 Parameters o M Ga 12 Number of items in the group Figure 50 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 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 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 67 OPTIONS STOP IG READY 1 0 STOP Cl READY 1 0 STOP G READY 1 0 Start Stop Setup Bi Rem Control Place Bi Rem Control Place 10 172 8 2 1 2 D 13 2 1 M3 2 1 m Rem Control Place o o o E I O Control F9 Contre FieldbusCTRL 85 KeypadStopButton 8 Help 1 0 Control A o Yes I O Control v B ACK Start Function RESET Ramping qp Add to favorites STOP Cl READY 1 0 STOP c READY 1 0 Start Stop Setup B Rem Control Place 15 172 M3 2 1 2 1 2 1 O R n o Rem Control Place I O Control FieldbusCTRL KeypadStopBu
19. SAFE TORQUE OFF 9 5 1 SAFETY CAPABILITY CAT 4 PLe SIL3 For this safety capability an external safety device must be installed This must be used to dinami cally 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 24 V STOT input Se STO2 input STO feedback Figure 62 An emergency push button connected to the STO inputs does not assure the same quality because no fault detection is performed at a sufficient proof test interval 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 88 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 63 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 th
20. Safe Torque Off STO see chapter 9 Table 15 I O terminal signals for the STO functions Safe Torque Off terminals RS ME 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 F4 Isolated feedback CAUTION Polarity to be respected F 24V 20 CONTROL UNIT VACON 36 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 se lections each The shadowed terminals in Table 13 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 25 to locate the switches and make appropriate selections for your requirements Factory defaults are All V Al2 C AO C Figure 25 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 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 negati
21. Without any automatic monitoring of STO output feedback the safety capability is reduced to Cat 1 PLc SIL 1 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 proof test interval determined 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 PPP 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 51 F 61 F S2 G2 L1 U L2 V L3 W DC R R DC 5 Reinforced Figure 65 STO example without automatic monitoring of the feedback and STO inputs connect ed in parallel 24 hour support 358 0 201 212 575 e Ema
22. and application requirements In circumstances where external influences e g 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 P PPP 24 hour support 358 0 201 212 575 e Email vacon dvacon com VRCON 83 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 26 Safety Standards The STO function has to be abblied 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 27 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
23. 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 of fers recommendations also for high speed J UL 8 CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges Terminal cable size l Fuse Mains and INPUT gG gL motor cable Main Earth A A Cu mm terminal terminal mm mm 1 6 solid 1 6 or 0003 4 00044 3 4 4 6 6 3 1 5 1 5 1h stranded ring terminal 0007 2 00082 6 0 7 2 7 1 6 solid 1 6 or MM4 0005 4 00084 5 4 8 1 19 Qu 1 4 stranded ring terminal 0011 2 0012 2 9 7 10 9 1 6 solid 1 6 or 0009 4 0012 4 9 3 11 3 te PTS 1 4 stranded ring terminal a un 20 3 646 1 10 Cu 1 10 MM5 eu 2 25 3 6 6 1 10 Cu 1 10 st 2 32 3 10 10 1 10 Cu 1 10 0038 4 36 7 40 3 10 10 2955060 Tec mor ring terminal 0048 2 43 8 3 2 5 35 or MMS 0046 4 43 6 30 dime Assn eu ring terminal 0062 2 57 0 2 5 35 or 0061 4 58 2 po i EPELE ASR EN a t rmin l Table 8 Cable and fuse sizes for Vacon 100 X The cable dimensioning is based on the criteria of the International Standard IEC60364 5 52 Cables must be PVC isolated Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements
24. 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 3 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 M MM6 4 M8 Table 3 Screws for wall mounting 3 3 2 MOTOR MOUNTING The drive can also be mounted in horizontal position 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 factory 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 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 4 In order to preserve the specified IP protection class the recommended fastening torque is 2 3 Nm Frame Screw number Screw size MM4 4 M5 MM5 6 M5 MM6 4 M6 Table 4 Screws for fixing the powerhead to the terminal box MOUNTING VACON 22 3 4 COOLING The AC drive
25. energized Nan DE The feedback must present motor with 24V DC P be OV on Power removed from STO demand The feedback must disabled motor both inputs be 24V de energized The STO inputs have Failure i denang The feedback must disabled motor or due to internal different values fault be OV de energized Table 29 Values of the STO output feedback and torgue on the motor Only one channel is preventing the drive from moving The diagram below is a conceptual schematic diagram and is presented to illustrate the safety func tion with relevant safety components only shown S1 F G1 F S2 G2 L1 U L2 V L3 W DC R R DC BA Reinforced Figure 60 STO function principle 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 85 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 20ms Table 30 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 re
26. loos ing the six screws Cables pass through this inlet hole Wi Figure 37 Cable entry plate from the bottom side of the drive side of the drive 3 e Remove the powerhead from the terminal box by loosing the screws on the top e cof AMI E e Figure 38 Powerhead separated from the terminal box OPTIONS VACON 58 e Connect the supply cable to the Mains switch passing through the cable entry 4 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 mm E
27. 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 0 196 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 TECHNICAL DATA VACON 9 52 Communication interface Ambient conditions Fieldbus Standard Serial communication RS485 Mod bus Ethernet Optional CanOpen Profibus DP Status indicators Drive status indicators LED on top side POWER RUN FAULT READY Ambient operating temperature 10 C no frost 40 C Extended temperature range up to 50 C with current derating see chapter 1 6 Storage temperature 40 C 70 C Relative humidity 0 to 95 Ry non condensing non corrosive Pollution degree PD2 Altitude 100 load capacity no derating up to 1 000m derating 1 100m at 1 000 3 000m Stationary vibration 10 Hz lt f lt 57 Hz 0 075 mm CE
28. must be constructed from plastic materials They are used 4 for sealing cables passing through gland plates to ensure the characteris tics of the enclosure which the cable enters can be maintained adequately Figure 22 Cable gland A ONLY PLASTIC GLANDS ARE ALLOWED METAL GLANDS ARE FORBIDDEN 5 e Screw the cable glands on the cable entry plate 6 e Pass the cables supply cable motor cable brake cable and 1 0 cables through the cable glands 7 e Pull the cables into the terminal box and detach the cable clamps and the grounding clamps 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 31 POWER CABLING 8 e Place the cable entry plate with the cables in the groove on the AC drive frame Connect the stripped cables e 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 9 e Connect the phase conductors of the supply and motor cables into their respective terminals e Form the rest 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
29. 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 5 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 instal lations Min clearance mm All types 80 160 60 Table 5 Min clearances around AC drive A Clearance left and right from the drive B Clearance above the drive C Clearance underneath the AC drive Figure 15 Installation space Cooling air required Type m3 h MM4 140 MM5 140 MM6 280 Table 6 Required cooling air Should you need further details on the cooling system of the Vacon 100 X please contact your local Vacon distributor 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 23 MOUNTING POWER CABLING VACON 24 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 16 See also Table 7 for the cable recomm
30. torque a Nm tb in Nm ib in bi i YP Power and motor EMC grounding Grounding terminals terminals clamps Nm lb in Nm lb in Nm lb in 0007 2 00122 MM4 0003 4 0012 4 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 0061 4 4 5 35 4 44 3 1 5 13 3 2 0 17 7 Table 10 Tightening torques of terminals e Check the connection of the earth cable to the motor and the AC drive ter 1 0 minals marked with d CONTROL UNIT VACON 32 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 23 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 STO terminals Dip switches I O OTF E O BM Ethernet terminal see chapter chapter 5 2 1 8 Option boards Table 11 Locations of components in control unit SXGTES GI amp F
31. 201 212 575 e Email vaconfavacon com VACON 17 MOUNTING Figure 11 Vacon 100 X drive dimensions MM5 MOUNTING VACON 18
32. 96 overload M t current IN current id RE kW HP A A 5 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 93 9 6 14 4 19 2 4 0 5 0 0012 113 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 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 0061 58 2 61 0 91 5 122 0 30 0 40 0 Table 19 Power ratings of Vacon 100 X supply voltage 3AC 380 480V NOTE The rated currents in given ambient temperatures in Table 19 are achieved only when the switching frequency is equal to or less than the factory default 7 1 3 DEFINITIONS OF OVERLOADABILITY Overloadability Following continuous operation at rated output current IN 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 min in every 10 min the remaining 9 min must be at rated current IN or less IN 150 IN 150 Figure 34 High overload TECHNICAL DATA 7 2 BRAKE RESISTOR 0004 25 0006 25 MM4 0008 29 0011 25 0012 25 0018 15 MM5 0024 15 0031 10 MM 0048 8 0062 8 Table 20 Brake resistor ratings 208 240V Mains Voltag
33. 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 or ignore change by returning to previous level with Back Reset button FWD REV Vo KEYPAD BUS Figure 57 Editing values Resetting fault Instructions for how to reset a fault can be found in paragraph 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 O 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 1 0 B Ctrl Force Local control Keyp
34. M 2 73 Monitor Active faults 1 AI 5 o 0 A Reset faults Parameters S 12 Reset faults Diagnostics Fault history 6 E 39 24 hour support 358 0 201 212 575 e Email vacon dvacon com Vo KEYPAD BUS VACON 9 75 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 G STOP IG READY 1 0 Diagnostics Fault history IX D M4 1 ID Active faults om External Fault 51 0 o 19 Fault old 891384s er HabatctauTts External Fault 51 E Fault old 871061s Fault history Device removed 39 EN 39 Info old 862537s Operating time 862537s OPTIONS VACON 9 76 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 4 ljj in the motor cable Check motor 1 0 e sudden heavy load increase Check cables and connections 2 aie tt short circuit in motor cables Make identification run Soya Tau e unsuitable motor Check ramp times 10 Overvoltage The DC link voltage has exceeded the Make deceleration time longer hardware fault limits defined
35. OFF VACON 94 24 hour support 358 0 201 212 575 Email vacon dvacon 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 O 2012 Vacon Plc Document ID D P D 9 DOC NS 03 9 8 5 0 5 3 4 Order code D L UK Rev D
36. QUE Orr VACON 82 9 SAFE TORQUE OFF This chapter describes the Safe Torque Off STO function 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
37. SIONING TEILT SE M VACON O 1 8 2 4 8 2 5 8 2 6 8 2 7 Commissioning of the drive sise 43 Changing EMC protection Class gens c e He ite deseada 44 R nningsth MOTORS ARS a oe Se UG iter rene serene oa rts 46 Cable and motor insulation Hee Sct facets situ tot e oet did emet 46 MAR tea e sack anat atra erede deseada teneo andes t dead RE do donde TR RE deus 47 Technical data suite ana b d ep Ebo CC IR cv ERE ada FE era daa Fav io rd 48 AC drive power Fatlnigs teet e o te rie e ee e e aha 48 Mains voltage 3AC 208 240 V eene eene nennen een nnne nnns 48 Mains voltage 3AC 380 480 Vie 49 Definitions of overloadability ss 49 sip uui eed TT M Em 50 Vacon 10D teehnieab data oo onec eet ee esed ate eei e d teet RE EH da es 51 Technical information on control Connections sis ssa dardo apela peace nude 54 oc Lee NL NoD 56 MAS SWIECh as theca tan etapas lect um qa A tel T Ut A etse 56 Stat Io itu esM srt Dado PE AE PR ER RER Re 56 Control Keypad cte e t eet eo pedi ERI e fco TON TEES 60 Mounting ontoxle drIVe eo ettet a ed ee aree nee de Uo n e 60 Makes tat IG pi sisse ecce aiebat RR URU RR fe SR dd ede s dot ony 61 Wall MOU Gas Lasers et rete tesi te e NONE o nan ot dese ua E ER enh 63 Graphical and Text kKeypad see 65 Vacon keypad with graphical display 66 Vacon keypad with text segment display 71 Fault T EaCIDng usn ree eit EE ae c ER OBERE C ERES 74 Safe Torque Off ii nada near c
38. STO feedback PFH PFDav MTTFd DCavg Both dynamically used Used 1 2 E 09 1 h 1 0 E 04 gt 4274a HIGH Both statically used Used 1 2E 091 h 1 1 E 04 4274a MEDIUM Connected in parallel Used 1 2 E 09 1 h 1 1 E 04 gt 4274a MEDIUM Connected in parallel Not used 1 5 E 09 1 h 1 3 E 04 gt 4274a NONE Table 28 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 AN long as this is compliant with the rating specified for terminal 6 SAFE TORQUE OFF VACON 84 9 4 THE PRINCIPLE OF STO The STO functionality such as the technical principles and data wiring examples and commission ing willbe 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 sep arated and galvanically isolated STO inputs S1 G1 S2 G2 in Figure 60 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 Operating STO feedback Torgue at the STO inputs conditions output motor shaft Both inputs
39. VACON 100X AC DRIVES INSTALLATION TECHNICAL AND MAINTENANCE MANUAL VACON DRIVEN BY DRIVES NO O O O O O A OJOG NON ZA at Fa e N c ooo ODD w ND m 24 hour support 358 0 201 212 575 e E mail vacon dvacon com VACON O INDEX Document code Original Instructions DPD00534D Order code DOC INS03985 DLUK Rev D Revision release date 4 6 12 cul dekou oak ha aaa beda Vadu dea r M M ka a 2 Danger cime eot eva Hutt d ivt o z TA Lt MR RT ad 2 EDI T E 3 Earthing and earth fault protection ss 4 InSulationSYstem sa e emit dt Mined o rt ann 6 Compatibility withiiRGDS iio verterit el e te lett lu Aid ev t t PR 7 Extended temperature range sien 8 Electromagnetic compatibility EMO xxn usuais potare rte Ea de DE ette a e teg 8 Declaration OF conformity iet EP E ER E EPI ER RUE RD a 9 Receipt of delivery iuis ies iua cedens edu Ce rex UR enr P NU VER ES aqua Sd a RCRUM E UES 12 Type designation Code i ee erret ee ee eee ee Tre ad c dea de Da 13 Unpacking and lifting the AC drive sise 14 RECESSO at ops Iced atico RT og ha estote i Meets ut eut ent me dieta 14 STO termin l Consec Ipse koz da oda n ducet Mat o 14 Froduct Modified SUCK 2 aaa rc p petat Ive ec dad pria etta balia Fu s nens 15 Ignem ane 16 DIMENSIONS si Mie ee Ra TR 16 Introduction of rmodules 34333 i DS P oa 19 MOLDE OR teen denn eec Toa M AUS peu A S o o orae 20 Wal
40. Via Roma 2 Frequency AC Drive 1 39014 Postal BZ Italy Type designation Vacon 100 X AC Drive Manufacturer see certificate holder 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 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 EN 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 ee at any change of the codes and standards forming gt tended application E Berlin 2012 05 31 T V Rheinland Ind
41. XT 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 Dano S PoM EDATE Move cursor left Move cursor right Stop button Cerati mend own Start button Decrease value Enter active level item Confirm selection Figure 49 Keypad buttons OPTIONS VACON O 66 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 50 Status field Status field STOP RUN READY NOT READY FAULT Direction ALARM Control place PC IO KEYPAD FIELDBUS Location field Parameter ID number
42. 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 T V 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 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 ountry Manager Figure 5 Declaration of conformity SarETY VACON 10 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
43. a 14 E power unit s heatsink or board Heat ture AC drive over sink 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 long time super vision 240 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 290 Safe OFF signal A does not allow AC drive to be set to READY state Reset the fault and restart 30 STO fault Should the fault re occur con 291 Safe OFF signal B does not allow AC tact the distributor near to you drive to be set to READY state 32 312 Fan cooling Fan life time is up change te Wand ee time counter Fire mode of the drive is enabled The Fire mode drive s protections are notin use It s a m n enabled characteristic fault of the HVAC Appli VISITOR parameter sens cation Table 25 Fault codes and descriptions 24 hour sup
44. action time is 20 ms minimum SAFE TORQUE Orr VACON 86 9 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 61 Signal Terminal Technical information Data DiglN 1 51 Insulated digital input 1 24V 20 G1 interchangeable polarity 10 15 mA DialN 2 S2 Insulated digital input 2 24V 20 g G2 interchangeable polarity 10 15 MA F Insulated digital output for STO 24V 420 DigOut 1 feedback 15 mA max F CAUTION Polarity must be i respected Table 31 STO connector and data signals Figure 61 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 IP 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 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 87
45. ad 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 24 hour support 358 0 201 212 575 Email vacon dvacon com VRCON 73 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 Fit READY RUN STOP ALARM FAULT READY RUN STOP ALARM FAULT ad re FWD REV Vo KEYPAD BUS FWD REV Vo KEYPAD BUS CORTE icm REM Purine cn RER M 1 I 11121 N L B Vv Q lt FWD REV Vo KEYPAD BUS FWD REV Vo KEYPAD BUS Figure 59 Accessing Control page OPTIONS VACON 74 8 2 7 FAULT TRACING When an unusual operating condition is detected by the AC drive control diagnostics the driv
46. ance target SIL PL Category set 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 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 r 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 r4 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 33 Checklist for the commissioning of STO SAFE TORQUE Orr VACON 92 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 33 is inspected and completed When STO function awakes the drive always generates a fault F30
47. and regulations at the time of writing However the end product system designer is responsible 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
48. break reset the fault supply voltage and restart the AC drive Check 9 AC drive internal fault the supply voltage If it is ade Undervoltage defect input fuse quate an internal failure has 81 alarm 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 en ee Table 25 Fault codes and descriptions OPTIONS VACON 78 Fault code Fault ID Fault name Possible cause Remedy m Current measurement has detected 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 m Brake chopper Brake chopper failure faulty Contact the distributor saturation alarm near to you AC drive under Too low temperature measured in Ghedcthioamblenttemprde 13 120 temperature power unit s heatsink or board Heat Mire 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 temper
49. ct and options you have ordered The code is of the following format VACON0100 3L 0061 4 X xxxx yyyy VACON XXXX Vyyy This segment is common for all products Additional codes 0100 Examples of additional codes Product range HMGR 0100 Vacon 100 Graphical keypad IP66 3L Input Function JL Three phase input 0061 Drive rating in ampere e g 0061 61 A See Table 18 for all the drive ratings 4 Supply voltage 2 208 240V 4 380 480 V X P66 EMC level C2 Two relay outputs One thermistor input RECEIPT OF DELIVERY VACON 14 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 2 below Frame Weight kg MM4 8 8 MM5 14 9 MM6 31 5 Table 2 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 lifting the converter out check that the delivery is complete and the following accessories are inclu
50. d holder with a screw as shown in the Figure 44 The metal 2 sheets of the keypad holder have to be mounted under the fan holder as shown in the following figures Figure 44 Installation of the keypad holder on the powerhead OPTIONS VACON 62 3 e Connect the keypad to the drive and plug the cable on the HMI connector as shown in the Figure 45 and in the Figure 46 Figure 45 Mounting of the keypad Figure 46 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 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 63 OPTIONS 8 2 3 WALL MOUNTING The keypad can be mounted on the wall in a convinient 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 47 Fix the keypad holder with three screws to the wall OPTIONS VACON 64 2 e Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall Figure 48 Keypad connected to the drive 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON O 65 OPTIONS 8 2 4 GRAPHICAL AND TE
51. d to install operate and maintain the drive The cautions and warnings are marked as follows z DANGEROUS VOLTAGE z HOT SURFACE z WARNING or CAUTION PPP Table 1 Warning signs 1 1 DANGER The components of the power unit of Vacon 100 X Drives are live when the drive is connected 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 termi nals 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 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 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 se
52. ded e STO terminal connector six pins black connector see Figure 8 e Product modified sticker 2 3 1 STO TERMINAL CONNECTOR Figure 8 STO connector 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 15 RECEIPT OF DELIVERY 2 3 2 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 9 Product modified sticker MOUNTING VACON 16 3 MOUNTING Vacon 100 X is the ideal solution for a decentralised installation It is conceived to be mounted on a 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 10 Vacon 100 X drive dimensions MM4 24 hour support 358 0
53. e 3AC 380 480 V 50 60 Hz Minimum Resistance Frame Type recommended ohm 0003 50 0004 50 Mid 0005 50 0008 50 0009 50 0012 50 0016 30 MM5 0023 30 0031 20 0038 15 MM6 0046 15 0061 15 Table 21 Brake resistor ratings 380 480V 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 50 VACON 9 51 7 3 TECHNICAL DATA VACON 100 TECHNICAL DATA Mains connection Motor connection Control characteristics Control connections Input voltage Ui 3AC 208 240V 3AC 380 480V Input voltage 15 10 continuously tolerance Input frequency 50 60 Hz Protection class Input frequency 45 66 Hz tolerance Connection to mains Once per minute or less Starting delay 4s Supply network TN and IT network cannot be used with cor ner earthed network Short circuit current Max short circuit current has to be lt 50kA Output voltage 0 Un Rated output current IN Ambient temperature max 40 C See Table 18 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
54. e 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 1 0 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 1 s 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 selecting value Yes for the parameter and clicking OK STOP Ic READY 1 0 STOP G READY 1 0 Main Menu Diagnostics Reset faults ID M4 ID M4 1 D
55. e 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 key pad go out if no keypad is connected see the indicators on the cover Wait addi tional 30 seconds before starting any work on the drive gt PP EEE 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON e 3 SAFETY 1 WARNINGS Vacon 100 X AC drive is meant for fixed installations on the motor or on the wall only Only Safety Extra Low Voltage SELV circuits 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 consequential damages resulting from unsafe connections of external circuits to the drive See paragraph 1 4 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 stan dard EN61800 5 1 a reinforced protective ground connection must be ensured See paragraph 1 3 for more details If the AC drive 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 mot
56. eTable 29 The device has to periodically de energize 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 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 89 SAFE TORQUE OFF 9 5 2 SAFETY CAPABILITY CAT 3 PLe SIL3 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 SIL2 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 5 Reinforced Figure 64 STO Example with automatic monitoring of the feedback and STO inputs connected in parallel SAFE TORQUE Orr VRCON 90 9 5 4 SAFETY CAPABILITY CAT 1 PLc SIL1
57. endations for different EMC levels Figure 16 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 EMC levels Cable type Category C2 Category C3 Category C4 Mains cable 1 1 1 Motor cable oF 2 2 Control cable 4 4 4 Table 7 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 17 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 ml See Figure 17 360 earthing of the shield with cable glands in motor end needed for EMC level C2 4 Screened cable equipped with compact low impedance shield JAMAK SAB OZCuY O or similar 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 25 POWER CABLING PE conductors S Shield PE conductor Shield Figure 17 NOTE The EMC requirements are fulfilled at factory defaults of switching fre
58. er surfaces 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 VACON 48 7 TECHNICAL DATA 7 1 RC DRIVE POWER RATINGS 7 1 1 MAINS VOLTAGE 3AC 208 240 V Mains voltage 3AC 208 240V 50 60 Hz Motor shaft power Loadability current type A Rated continuous 50 overload M t current IN current an ba kW HP A A 5 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 0 0024 21 7 24 2 36 3 48 4 5 5 7 5 z 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 18 Power ratings of Vacon 100 X supply voltage 3AC 208 240V NOTE The rated currents in given ambient temperatures in Table 18 are achieved only when the switching frequency is equal to or less than the factory default 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 49 TECHNICAL DATA 7 1 2 MAINS VOLTAGE 3AC 380 480 V Mains voltage 3AC 380 480V 50 60 Hz Motor shaft power Loadability Converter nput 400V 480V current type A Rated continuous 50
59. face 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 equip ment 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 the 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 Figure 42 Drive and the optional keypad kit 24 hour support 358 0 201 212 575 Email vacon dvacon com VACON 61 OPTIONS 8 2 2 INSTALLATION 1 e Remove the HMI cap from the drive as shown in the Figure 43 Figure 43 Disconnection of the HMI cap from the drive e Install the keypa
60. he used fieldbus See respective bus manual Table 17 RS485 cable data Cable length 24 hour support 358 0 201 212 575 e Email vaconfavacon com VRCON 41 CONTROL UNIT 5 3 BATTERY INSTALLATION FOR REAL TIME CLOCK RTC Enabling the functions of the Real Time Clock RTC requires that an optional battery is in stalled in the Vacon 100 X drive The place for the battery can be found under the control box cover as shown in Figure 29 Detailed information on the functions of the Real Time Clock RTC can be found in the Appli cation Manual Og BBBBBEBDDBB Battery Figure 29 Optional battery COMMISSIONING VACON 42 6 COMMISSIONING Before commissioning note the following directions and warnings Internal components and circuit boards of Vacon 100 X drive except for the gal vanically isolated 1 0 terminals are live when it is connected 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 and the brake resistor terminals R R are live when Vacon 100 X drive is connected to mains even if the motor is not running 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 freq
61. il vacon dvacon com VACON 91 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 596 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 mm 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 2 x 2 1 x 0 5 mm Table 32 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 LI m
62. istic fault of o eand occi counter the HVAC Application Maintenance Maintenance Counter das T Uie Carry out the needed mainte 1304 counter 4 alari alarm limit It s a characteristic fault of nance and reset co nter the HVAC Application Noncexisung ID number Isusedtor Check parameters in Fieldbus 1310 mapping values to Fieldbus Process D ta sodn renu Data Out pping 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 PID control ler has timed out The wanted process 100 1100 Soft fill timeout 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 m ud sion fault PID1 set It s a characteristic fault of the Ghee setings 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 25 Fault codes and descriptions 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 81 OPTIONS SAFE TOR
63. limit P3 9 13 Stall frequency P3 9 14 Maximum frequency P3 3 2 OPTIONS VACON 70 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 information is also available for faults alarms and the startup wizard STOP G READY 1 0 sro Cz READY 1 0 STOP C READY 1 0 Digital Inputs Ctrl signal 1 A GD Ctrl signal 1A sr 1D 403 M3 5 1 1 1D 403 M3 5 1 1 ID 403 M3 5 1 1 Start Signal 1 for control Place crel Simar IA E Edit I O A Start Signal 1 o o functionality chosen with I O A Logic in Start Stop Setup Menu Ctrl Signal 2 A Help ST Stem Signal 13 i Add to favorites Figure 55 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 Cl READY 1 0 STOP IG READY yo stop C READY 1 0 Basic Settings S Motor Nom Freg Motor Nom Freg C1 21 Motor Nom Voltg o Edit was added to 230 00 V o T o favorites Press OK to continue Motor Nom Freq D Help 50 00 Hz M
64. lzmoUuntrig t5 elo tet t scere e d tud ett tel AR ono gb d t ale eile ts 21 Motor moubtihg zs e eq uenia a Tee aie s 21 Segregated modules sise 21 eere aaa dade axeudebebes shldis optus ict aa aaae aa eee 22 Power cabling iris assi canais sescsuanaadedanaaednasiaaneceuvs sutdetiwasvaqsedescasdcusasdadeduseccesasats 24 Circuit TES REP tutoris SS AO ED URN 25 Ul st ndards omcabllng eet etes eed te E eese GE EET ie te 25 Cable dimensioning and selection 26 Cable and fuse sizes frames MM4 to MM6 Hmmm rennen 26 Brake resistor Cables s utc te ane Om ti za uns AE A 27 ControtcableS e ETT 27 Cable mstellallobi a cose dux E Re a ER ria nen Neer chr ME meee E 28 Control UNI e 32 Controb urnieeablimguss tmm teo debeo tas 33 Controlicable SIZING ee ee yet P RR LAE I Aided tee 33 Standard O tenminalo so da ceste eva k mee fee er E tc LM dc RS 34 Relay and thermistor input terminals iii 35 Safe Torque off STO terminals caso goias eniro ri dr eu fe beate bala b t 35 Selection of terminal functions with dip switches 36 Isolating digital inputs from ground Bus termination of the RS485 connection I O cabling and Fieldbus connection e en acera eer te e e utis eco Prepare for use through Ethernet eene Prepare for use through RS485 iii RS485 cable dala akad ssi damen a ste es eus d alas m Ela A nd son Battery installation for Real Time Clock RTC COMMIS
65. mitigation measures may be required EEE EEE RE SarETY VACON 4 1 3 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 Since the touch current exceeds 3 5 mA AC according to EN61800 5 1 the drive shall have a fixed connection and provision of an additional terminal for a second protective earthing con ductor of the same cross sectional area as the original protective earthing conductor Three screws are provided on the terminal box for the ORIGINAL protective earthing conduc tor the SECOND protective conductor and the MOTOR protective conductor the customer can choose the screw for each one The power head is earthed through a metal aglet located on the terminal box which fits into a spring basket on the powerhead See Figure 1 and Figure 2 for the location of the three screws and the metal aglet Please pay attention not to damage or remove this aglet Earth connections Metal aglet Figure 1 Earth connections and metal aglet in MM4 In Vacon 100 X the phase conductor and the corresponding protective earthing conductor can be of the same cross sectional area provided they are made of the same metal because the cross sectional area of the phase conductor is less than 16 mm 24 hour support 358 0 201 212 575 e Email vaconfavacon com
66. oa PASEO E e Conn acu oux CE M Res on sen dieu ses 82 G n ral describes A a dehet died dto e eoe rasa 82 WARNINGS ecce cnt Let e Le t OS NV ia eno tw etre rre E 82 Stand al US uode coi ctum mit Libcr IR RAR ER AR ctp eet fec aat dat dioe 83 The principle of S TO sir eR RENTEN tn DEREN rm dE e SEEN mx is 84 Technical details nimes eoe ra Iob etre bine hber tatit ode tee fer d erant 85 CONNECTION RU T E cu team M TEE 86 Safety Capability Cat 4 PL e SIL Len a a ne A betta dise 87 Safety Capability Cat 3 PL e SIL ds tes tua tis ede n dicus 89 Safety Capability Cat 2 Pd SIE 2 decedit Ett estt e o E son 89 Satety Capability Cat T4 PE eJ SIE Tog aii aire fn een NE RT 90 COMMISSIONING ede 91 General wiring instructions sise 91 Checklist for the commissioning sis 91 Parameters and fault tracing enne ener nennen nnne 92 Maintenance and diagnostics iii 93 SarETY VACON 92 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 100X is a drive conceived for controlling asynchronous AC motors and permanent magnet motors The product is inteded to be installed in a restricted access location and for a general purpose use Only by Vacon authorized trained and qualified personnelare allowe
67. 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 chapter Earthing and earth fault protection of the standard For the correction factors for each temperature see International Standard IEC60364 5 52 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 27 POWER CABLING 4 3 2 BRAKE RESISTOR CABLES Vacon 100 X AC drives are eguipped with terminals for an optional external brake resistor These terminals are marked with DC R and R See Table 20 and Table 21 for the resistor ratings 4 3 3 CONTROL CABLES For information on control cables see chapter Control unit POWER CABLING VACON e 28 4 4 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 If 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 50 1 0 200 The given distances also apply between the motor cables and signal cables of other sys tems e The maximum length with full EMC compliance for motor cables 15m C2 e The motor cables should cro
68. or 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 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
69. otor Nom Speed H Add to favorites o em Figure 56 Adding item to Favorites 24 hour support 358 0 201 212 575 e Email vacon dvacon com VACON 71 OPTIONS 8 2 6 VACON KEYPAD WITH TEXT SEGMENT DISPLAY You can also choose a Keypad with 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 vo KEYPAD BUS Indicators Indicators Direction Control place OPTIONS VACON 72 8 2 6 3 Using the keypad Editing values Change value of a parameter following the procedure below 1 Locate the parameter
70. port 358 0 201 212 575 Email vacon dvacon com VRCON 79 OPTIONS Fault code Fault ID Fault name Possible cause Remedy He Option board changed for one previ Device is ready for use Old 37 360 9 ously inserted in the same slot The parameter settings will be same type board s parameter settings are saved used Option board added The option board Device is ready for use Old Device changed was previously inserted in the same 38 370 parameter settings will be same type slot The board s parameter settings ised are saved 39 380 Device removed Option board removed from slot Device no longer available 40 390 Device unknown nona connected power Device no longer available unit option board Check loading IGBT tempera IGBT temperature unit temperature 41 400 ana LT is too high Check motor size Make identification run Set the option board parame Option board changed or Power unit ters again if option board was Device changed 44 430 changed No parameter settings are changed Set converter param different type n saved eters again if power unit was changed Device changed Option board agded Thesoption Bose 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 Faul
71. quencies 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 18 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 60 75 C Use Class 1 wire only The units are suitable for use on a circuit capable of delivering not more than 100 000 rms sym metrical amperes 600V AC maximum POWER CABLING VACON 26 4 3 CABLE DIMENSIONING AND SELECTION Table 8 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 3 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
72. re 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 1MO 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 ambient temperature of 20 C 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 47 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 for corrosion on terminals and oth
73. re 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 distributor CONTROL UNIT Sor MU M Thermistor RO2 10Vref Analog Inputs Digital Inputs Digital Outputs 24V __ 3 Keypad Ethernet RS485 STO L1 U L2 POWER UNIT V S SELV L3 M W M Mains Reinforced DC DC R R Figure 3 Insulation system I The relays may be used also with Safety Extra Low Voltage SELV circuits This A is possible only if both relays are used with Safety Extra Low Voltage SELV cir cuit to mix Mains and SELV is not allowed 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 7 SAFETY 1 5 COMPATIBILITY WITH RCDs This product can cause a d c current in the protective 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 SarETY VACON e 8 1 6 EXTENDED TEMPERATURE RANGE Vacon 100 X has an integrated cooling system independent from the motor fan Under maxi mum operating conditions the ambient temperature cannot exceed 40 C See Table 18 forthe output rated current Higher temperatures are allowed only with derating of the output cur ren
74. 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 possible 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 7 READY Keypad STOP READY Keypad STOP READY Keypad EJ Main Menu a User settings Ea Parameter backup E ID M6 2 ID M6 5 ID M6 5 1 a 1 0 d Hard e Appli ti lecti o ST bc s T o Restore factory defaults User settings Pa 4 Em Save to keypad F it Dri CA ms Poe E eT Restore from keypad 0 o Drive o Figure 54 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
75. ss 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 EB C2 4 Shield N Figure 18 Stripping of cables 24 hour support 358 0 201 212 575 e Email vaconfavacon com VRCON 29 POWER CABLING 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 9 Cables stripping lengths mm 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 M16x1 5 M25x1 5 Figure 20 Cable entry plate MM5 POWER CABLING VACON 30 M25x1 5 M16x1 5 M40x1 5 Figure 21 Cable entry plate MM6 e Cable glands
76. t With derating the unit can operate up to 50 C See the Figure 4 Temperature Output Current Derating Curve 150 100 c L 5 75 o 5 o 5 e 50 ob o 25 A 10 0 10 20 30 40 50 60 Ambient temperature C Figure 4 Temperature output current derating curve 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 7 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 sys tem It is the responsibility of the installer or user of the equipment to ensure by consultation 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 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 9 1 8 DECLARATION OF CONFORMITY SAFETY 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
77. t Fault activated by digital input device connected to it Check the parameter settings 52 1052 Keypad commu ea ipo 8 Check keypad connection and 1352 nication fault iid q y possible keypad cable The data connection between the field 53 1053 Fieldbus commu bus masterand fieldbus board bene 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 66 1066 Theriistor fault The thermistor input has detected an Check thermistor connection increase of motor temperature If thermistor input is not in use it has to be short circuited Table 25 Fault codes and descriptions OPTIONS VACON 80 Fault code Fault ID Fault name Possible cause Remedy Maintenance counter has reached the i Maintenance ER P Carry out the needed mainte 1301 ince i alarm alarm limit It s a characteristic fault of ee le the HVAC Application Maintenance Meinl Nance E A E Carry out the needed mainte 1302 alarm limit It s a characteristic fault of counter 2 alarm mo nance and reset counter f the HVAC Application Maintenance Maintenanes counter has reached the Carry out the needed mainte 1303 outer as alarm limit It s a character
78. tton Yes I O Control Start Function Ramping Figure 51 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 guickly 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 freguency 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 O 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 S
79. uency 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 Vacon100 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 start ing any electrical work Before connecting the AC drive to mains make sure that the powerhead Vacon 100 X Drive is mounted firmly on the terminal box gt gt PEPE 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 43 COMMISSIONING 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 freguency converter and the motor are grounded Check that the mains and motor cables comply with the reguirements 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 torgues 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
80. uld 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 pawerunibsen sre 607 cus en Should the fault re occur con p tact the distributor near to you 8 System fault CPU overload Some part of the soft End ware for example application has caused an overload 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 t Error when loading parameter initial dot Le URS 649 values Error when restoring parameters Error when saving parameters Undervoltage DC link voltage is under the voltage 80 c fault limits defined In case of temporary supply e most probable cause too low a voltage
81. ustrie 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 6 STO certificate 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 11 SAFETY RECEIPT OF DELIVERY VACON 12 2 RECEIPT OF DELIVERY Check the correctness of delivery 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 00223456286 Vacon order number Type VACONO100 3L 0031 4 X Batch ID Serial number S N Vo789012245 B ID 122245 TR OLEI Code 20 AB3L00315A02B5H1MB1C 12345678 dE RO CELL O LILI MEE Rated Rated current 31 A9 current 380 480 v Supply IP class __ IP66 Type4X Elos voltage EMC level EMC level C2 a Application nd code Firmware FW0065V008 um Application Cust Ord No 3234500378 C Marks Customer s order number CUSTOMER NAE VACON DRIVEN BY DRIVES Figure 7 Vacon package label 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 13 RECEIPT OF DELIVERY 2 1 TYPE DESIGNATION CODE Vacon type designation code is formed of a nine segment code and optional codes Each seg ment of the type designation code uniguely corresponds to the produ
82. ve logic The switch in the position 2 means that the common of digital inputs has been connected to ground positive logic See Figure 26 Locate the switch and set it in desired position Factory default is 2 Figure 26 Digital inputs dip switch 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 37 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 noter mination and no biasing resistors have been connected Factory default is 2 See Figure 27 Figure 27 RS485 dip switch CONTROL UNIT VACON 38 5 2 1 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 I O terminals terminals A and B and the connection for Ethernet is left to the control terminals See Figure 28 RS485 terminals eee 0000000040 12 3 4A 5 Orsa e OOOOOOOOOOO
83. witching 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 Remote and confirm with the OK button 3 On the next display select Local 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 VACON 68 OPTIONS STOP READY Keypad stop C Read Keypad STOP IS READY Keypad Main Menu Choose action Local Remote E ni EE IN ID 211 rapis Change direction Ny o REM Local Parameters Control page 15 Local Remote A Remote v V A Diagnostics 6 STOP G READY 1 0 Main Menu ID M1 Monitor 7 Parameters Bi 15 Diagnostics 6 Figure 52 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

vacon 100 x - Synchro Dan

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