vacon 100 installation manual
Contents
1. 126 0 3x42 120 11130 emf Figure 16 MR9 flange mount dimensions 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 26 MOUNTING 11136 emf Figure 17 Flange mount cutout dimensions for MR4 to MR9 Table 10 Flange mount cutout dimensions for MR4 to MR9 Frame A B C D E MR4 315 137 357 152 24 MR5 408 152 454 169 23 MR6 541 203 580 220 23 MR7 655 240 680 286 13 MR8 859 298 898 359 18 MR9 975 485 1060 550 54 Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 27 3 2 COOLING The AC drives produce heat in operation and are cooled down by air circulated by a fan Enough free space shall therefore be left around the AC drive to ensure sufficient air circulation and cooling Different acts of maintenance also require certain amount of free space Make sure that the temperature of the cooling air does not exceed the maximum ambient tem perature of the converter Table 11 Min clearances around AC drive Min clearance mm vee Ac MR4 20 20 100 50 MR5 20 20 120 60 MR6 20 20 160 80 MR7 20 20 250 100 MR8 20 20 300 150 MR9 20 20 350 200 Min clearances A and B for drives with IP542. XD E 1 Ethernet 9107 emf cable Figure 52 Protection class IP21 Cut free the opening on the AC drive cover for the Ether net cable Protection class IP54 Cut the rubber grommets open to slide the cables through Should the grommets fold in while inserting the cable just draw the cable back a bit to straighten the grommets up Do not cut the grommet open 2 ings wider than what is necessary for the cables you are using IMPORTANT To meet the requirements of the enclosure class IP54 the connec tion between the grommet and the cable must be tight Therefore lead the first bit of the cable out of the grommet straight before letting it bend If this is not possible the tightness of the connection must be ensured with insulation tape ora cable tie 9068 emf Figure 53 Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 61 Remount the AC drive cover NOTE When planning the cable runs remember to 3 keep the distance between the Ethernet cable and the motor cable at a minimum of 30 cm Ethernet cable 9265 emf Figure 54 For more detailed information see the user s manual of the fieldbus you are using 5 2 2 PREPARE FOR USE THROUGH RS485 5 2 2 1 RS485 CABLE DA
3. 9048 emf Figure 36 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 47 5 Remove the EMC shield plate loi e 8 9 Wing nut nl a 9026 emf Figure 37 6 Locate the terminals OBSERVE the exceptional placement of motor cable termi nals in MR8 9221 emf Figure 38 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 48 POWER CABLING Cut the rubber grommets open to slide the cables through Should the grom 7 mets fold in while inserting the cable just draw the cable back a bit to straighten the grommets up Do not cut the grommet openings wider than what is neces sary for the cables you are using 9030 emf Figure 39 Place the grommet with the cable so that the frame end plate fits in the groove on the grommet see Figure 40 To meet the requirements of the enclosure class IP54 the connection between 8 the grommet and the cable must be tight Therefore lead the first bit of the cable out of the gro
4. 9217 emf Figure 26 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 41 6 Detach the cable clamps and the grounding clamps Figure 27 and place the cable entry plate with the cables in the groove on the AC drive frame Figure 28 9024 emf Figure 27 9218 emf Figure 28 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 42 POWER CABLING Connect the stripped cables see Figure 22 and Table as shown in Figure 29 e Expose the shield of all three cables in order to make a 360 degree con nection with the cable clamp 1 e Connect the phase conductors of the supply and motor cables into their 7 respective terminals 2 e Form the rest of the cable shield of all three cables into pigtails and make a grounding connection with a clamp as shown in Figure 29 3 Make the pigtails just long enough to reach and be fixed to the terminal not longer L1L2L3 E E 9148 soon 9049 emf Figure 29 Tightening torgues of cable terminals Table 20 Tightening torg
5. 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 52 POWER CABLING 9224 emf Figure 46 Check the connection of the earth cable to the motor and the AC drive terminals marked with 1 5 NOTE Two protective conductors are required according to standard EN61800 5 1 See chapter Earthing and earth fault protection on page 6 Connect the protective conductor using a cable shoe and an M8 screw included in the Accessories bag on either of the screw connectors as advised in Figure 47 9225 emf Figure 47 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 53 4 3 INSTALLATION IN CORNER GROUNDED NETWORK Corner grounding is allowed for the drive types rating from 72 A to 310 A at 380 480 V supply and from 75 A to 310 A at 208 240 V supply In these circumstances the EMC protection class must be changed to level C4 following the in structions in Chapter 6 3 of this manual Corner grounding is not allowed for the drive types with rating from 3 4 A to 61 A at 380 480 V supply and 3 7 A to 62 A with 208 240 V supply 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 54 CONTROL UNIT 5 CONTROL UNIT The control unit of the AC drive consists of the control board and additional boards option boards connected to the slot connectors of the
6. COCOC OCUCIC 2 OC 02CoCOQOCOCOCOCS STi SST 88 o OOM DODAM OC Y ODODOOOOS f DI 28 Der 9065 emf Figure 61 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 72 COMMISSIONING 3 Additionally for MR7 locate the DC grounding busbar between connectors R and U and detach the busbar from the frame by undoing the M4 screw 9062 emf Figure 62 MR7 Detaching the DC grounding busbar from frame 6 3 3 FRAME MR9 Follow the procedure described below to modify the EMC protection of the AC drive of frame MR9 to EMC level C4 Find the Molex connector in the accessories bag Remove the main cover of the 1 AC drive and locate the place for the connector next to the fan Push the Molex connector in its place See Figure 63 Connector 9063 emf Figure 63 Tel 358 0 201 2121 e Fax 358 0 201 212 205 COMMISSIONING VACON 73 Further remove the extension box cover the touch shield and the 1
7. 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 59 5 2 I 0 CABLING AND FIELDBUS CONNECTION The AC drive can be connected to fieldbus either through RS485 or Ethernet The connection for RS485 is on the basic 1 0 board terminals A and B and the connection for Ethernet is under the drive cover left to the control keypad See Figure 51 RS485 terminals DIP A Data B Data switches po 212223 242526 3233 connector 12 13 14 15 16 17 18 19 X sii l 000000000 conduit 1238486078410 1 OD OOOO aa 1 0 terminal see larger picture Grounding bar 9106 emf Figure 51 5 2 1 PREPARE FOR USE THROUGH ETHERNET 5 2 1 1 ETHERNET CABLE DATA Table 27 Ethernet cable data connector NOTE length of the connector 40mm Cable type CATbe STP Cable length Max 100m Connector Connect the Ethernet cable see specification on page 59 to its terminal and run 1 the cable through the conduit as shown in Figure 52 NOTE Pay attention that the length of the connector does not exceed 40 mm See Figure 52 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 60 CONTROL UNIT max 40 mm
8. All signal descriptions are gi ven in Tables to 23 25 21 22 23 24 25 26 32 33 PRESTAN OOO OOO OOO O WAI OM OOO CANO O Basic control terminals AU Z GO Figure 49 5 1 1 CONTROL CABLE SIZING The control cables shall be at least 0 5 mm screened multicore cables see Table 13 The max imum terminal wire size is 2 5 mm for the relay and other terminals Find the tightening torques of the control and relay board terminals in Table 23 below Table 23 Control cable tightening torques Tightening torque Terminal screw All 1 0 and relay terminals screw M3 0 5 4 5 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 56 CONTROL UNIT 5 1 2 CONTROL TERMINALS AND DIP SWITCHES The terminals of the Basic I O board and the Relay boards are described below For more in formation on the connections see Chapter 7 2 1 The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches See more information in Chapter 5 1 2 1 on page 58 Table 24 Control I O terminal signals on basic I O board and connection example Basic 1 0 board A 4 10 Vref ME output Reference Analogue input potentiometer 1 10 kQ i ees 2 A voltage or current I E 1 3 AM Analogue input com bi Sa zh le mon current um 4 Al2 Analogue input Remote reference voltage or current 4 20 mA 0 10 V Analogue input com NOT SCR EM 5 AI2 mon
9. 01054 105 0 150 AWG1 0 AWG9 AWG2 0 AWG9 AWC2 0 0140 2 0140 4 140 0 200 AWG3 0 AWG1 350 kcmil AWG1 350 kcmil 0170 2 i MR8 0170 4 170 0 225 250 kcmil AWG1 350 kcmil AWG1 350 kcmil 0205 2 1 0205 4 205 0 250 350 kcmil AWG1 350 kcmil AWG1 350 kcmil 02612 A l 0261 4 261 0 350 2 250 kcmil AWG1 350 kcmil AWG1 350 kcmil nx 0310 2 0310 4 310 0 400 2 350 kcmil AWG1 350 kcmil AWG1 350 kcmil The cable dimensioning is based on the criteria of the Underwriters Laboratories UL508C Cables must be PVC isolated Max ambient temperature 30 C max temperature of cable surface 70 C Use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the requirements of the earthing conductor see standard Underwriters Laboratories UL508C For the correction factors for each temperature see the instructions of standard Underwriters Labo ratories UL508C 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 36 POWER CABLING 4 2 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 o
10. The insula tion resistance must be gt 1 MQ at ambient temperature of 20 C Mains cable insulation checks Disconnect the mains cable from terminals L1 L2 and L3 of the AC drive and from the mains Measure the insulation resistance of the mains cable between each phase conduc tor as well as between each phase conductor and the protective ground conductor The insulation resistance must be gt 1MQ at ambient temperature of 20 C 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 1 MQ at ambient temperature of 20 C Always fol low the instructions of the motor manufacturer VACON 70 COMMISSIONING 6 3 INSTALLATION IN IT SYSTEM If your supply network is an IT impedance grounded system but your AC drive is EMC pro tected according to class C2 you need to modify the EMC protection of the AC drive to EMC level C4 This is done by removing the built in EMC jumpers with a simple procedure described below A Warning Do not perform any modifications on the AC drive when it is con nected to mains 6 3 1 FRAMES MR4 TO MR6 1 Remove the main cover of the AC drive see page 37 and locate the jumpers con necting the built in RFl filters
11. current IL EE 6 24Vout 24V aux voltage I I 7 GND I O ground I 1 EPIT EE E EE 8 DI1 Digital input 1 d ETHER 9 D2 Digital input 2 NP A pe 10 pi3 Digital input 3 I I E 11 CM Common for DI1 DI6 I I 12 24Vout 24V aux voltage I I ERES 13 GND I O ground E Me 1 14 DI4 Digital input 4 I wg ee ERES 15 DI5 Digital input 5 I A SR 16 DI6 Digital input 6 I i ee 17 cM Common for DI1 DI6 I i z i Analogue signal I TT 18 SONE output I 3 stes 19 AO GND Analogue output com i mon i i ra l i 30 24 Vin MuR input i 6 voltage hue A RS485 Serial bus negative v yv B RS485 Serial bus positive Digital inputs can be isolated from ground see Chapter 5 1 2 1 Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 57 Table 25 Control I O terminal signals on relay board 1 and connection example From Basic I O board From term 6 or 12 From term 13 y RUN L E Relay board 1 Terminal 21 RO1 1 NC Relay output 1 22 RO1 2 CM A 23 RO1 3 NO 24 RO2 1 NC Relay output 2 25 RO2 2 CM m 26 RO2 3 NO a gt j 32 R03 1 CM ET Relay output 3 33 R03 2N0 Table 26 Control I O terminal signals on relay board 2 and connection example From Basic 1 0 board From term 12 From term 13 24 hour support 358 0 201 212 575 e E
12. lt 100 mVrms max 250 mA 6 24 V aux voltage Dimensioning max 1000 mA control unit Short circuit protected Ground for reference and controls connected internally to frame earth N aa through 1MO 8 Digital input 1 Positive or negative logic 9 Digitalinput2 Ri min 5 kQ F 0 3V 0 10 Digital input 3 15 30 V 1 11 Common A for DIN1 DIN6 Digital inputs can be disconnected from ground see Chapter 5 1 2 1 24 V 10 max volt ripple lt 100 mVrms max 250 mA 12 24 V aux voltage Dimensioning max 1000 mA control unit Short circuit protected Ground for reference and controls connected internally to frame earth through 1 MQ 14 Digital input 4 Positive or negative logic 13 1 0 ground 15 Digital input 5 Ri min 5 kQ 0 5V 0 16 Digital input 6 15 30 V 1 17 Common A for DIN1 DIN6 Digital inputs can be isolated from ground see Chapter 5 1 2 1 18 Analogue signal output Analogue output channel 1 selection 0 20 mA load lt 500 2 Default 0 20 mA 0 10 V 19 Analogue output common Resolution 0 1 96 accuracy 2 Selection V mA with dip switches see page 58 Short circuited protected 30 24V auxiliary input voltage Can be used as external power backup for the control unit 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 82 TECHNICAL DATA Table 32 Technical in
13. 0 plate with 2 O grommet plate Locate the EMC jumper on the EMC board see magnification below and remove it 9067 emf Figure 64 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 delivery see below and note the date Unless already done attach the sticker close to the name plate of the AC drive Product modified 9005 emf 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 74 COMMISSIONING 6 4 MAINTENANCE In normal conditions the AC drive is maintenance free However regular maintenance is re commended to ensure atrouble free operation and a long lifetime ofthe 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 filters e Check input and output terminals and control 1 0 terminals e Check operation of cooling fan e Check for corrosion on terminals busbars and other surfaces e Check door filters in case of cabinet installation 6 24 months depending on environmen
14. Frames MRS and MRI o eitis eo ER Propter rela otedl ista Installation in corner grounded network nns Control Ud acc ies Control nttcablifig te retraite be e te aliante Control cable SIzing ii Control terminals and DIP switches oscene la Mae prt oen ie e dina I O cabling and Fieldbus cofiti amp cios tadas Prepare for use through ethernet eene nnne Prepare for use through RS485 e Battery installation for Real Time Clock REG istaec lle lil cia Ent Galvanic Isolation barriers suos ated ae ale n uode eat a ea Laud COMMISSIONING sii ira Commissioning of the drive eene ener nennen nnne nnne R nning the motore in EFRON RERO GL Ne ld Cable and motor insulation checks MES oe sese indt dedii eine AE TR qu SE Oko Ci ni Frames MRA to MR iei eig O Aa e Que der rt ti VACON 2 6 3 2 Frames MR7 and MR dias 71 63 9 Frame MRO 3 ad etu ett toa EH A E I a 72 6 4 E 74 Ta Technical dala sica 75 4 AGCdrpvepowerrattnmgs e aee ia eie i E de eie PEE te ds 75 7 1 1 Mains voltage 208 240 Vi 75 7 1 2 Mains voltage 380 480 V KKK enne 76 7 1 3 Definitions of overloadability ener nnn 77 tio Macon 100 technical data ide c a 78 7 2 1 Technical information on control connections 81 Tel 358 0 201 2121 e Fax 358 0 201 212 205 VACON 3 VACON DRIVEN BY DRIVES EC DECLARATION OF CONFORMI
15. Using the cable clamp included in the delivery of the drive ground the shield of the RS485 cable to the frame of the AC drive Cable clamp 9200 emf If the AC drive is the last device on the bus the bus termination must be set Locate the DIP switches to the right of the control keypad of the drive and turn the switch for the RS485 bus termination resistor to position ON Biasing is built in the termination resistor See also step 7 on page 64 O Z o Z J gt ip A 25485 c E DGND leeeeceooeo eeeecdoeee TI T o mn mn Nasi E Bus termination resistor o 9205 emf 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 64 CONTROL UNIT Unless already done for the other control cables cut free the opening on the AC drive cover for the RS485 cable protection class IP21 E 9201 emf Remount the AC drive cover and run the RS485 cables as shown in picture NOTE When planning the cable runs remember to keep the distance between the fieldbus cable and the m
16. Voltage for relay outputs Up to 3 000 m Allowed up to 240 V 3 000 m 4 000 m Allowed up to 120 V Corner grounding up to 2 000 m only Vibration EN61800 5 1 EN60068 2 6 5 150 Hz Displacement amplitude 1 mm peak at 5 15 8 Hz MR4 MR9 Max acceleration amplitude 1 G at 15 8 150 Hz MR4 MR9 Shock EN61800 5 1 EN60068 2 27 UPS Drop Test for applicable UPS weights Storage and shipping max 15 G 11 ms in package Enclosure class IP21 Type 1 standard in entire kW HP range IP54 Type 12 option Note Keypad required for IP54 Type 12 Fulfils EN61800 3 2004 first and second Immunity environment EMC2 EN61800 3 2004 Category C2 Emissions The drive can be modified for IT networks See Chapter 6 3 on page 70 Average noise level cooling fan sound power level in dB A MR4 65 MR7 77 MR5 70 MR8 86 MR6 77 MR9 87 EN 61800 5 1 2007 CE cUL see unit nameplate for more detailed approvals 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 80 TECHNICAL DATA Table 31 Vacon 100 technical data 240 volt drives 456 VDC Overvoltage trip limit o volt drives 911 VDC Depends on supply voltage 0 8775 supply voltage Undervoltage trip limit Supply voltage 240 V Trip limit 211 VDC Supply voltage 400 V Trip limit 351 VDC Supply voltage 480 V Trip limit 421 VDC Earth fault prot
17. below Earth conductor Earth conductor l u Figure 32 Stripping of cables 9019 emf Table 21 Cables stripping lengths mm MR8 40 180 25 300 25 300 Leave as short as MR9 40 180 25 300 25 300 possible Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 45 2 MR9 only Remove the main cover of the AC drive M4 x 10 9046 emf Figure 33 3 Remove the cable cover 1 and the cable fitting plate 2 M4x8 O O 2 9028 emf Figure 34 Removing cable cover and cable fitting plate MR8 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 46 POWER CABLING APD O CD C 2 25 M5x 10 8 e 8 9041 emf Figure 35 Removing cable cover and cable fitting plate MR9 4 MR only Loosen the screws and remove the sealing plate
18. cable grounding lamella 3 Control cable grounding EMC cable clamps size M40 2 Clamping power cables Grounding clamp 2 Power cable grounding Product modified label 1 Information about modifications Cable grommet hole diameter 33 0 mm 1 Cable run through sealing Cable grommet hole diameter 40 3 mm 2 Cable run through sealing IP54 Cable grommet hole diameter 25 3 mm 3 Cable run through sealing 2 3 4 SIZE MR7 Table 7 Contents of accessories bag MR7 Item Quantity Purpose M6x30 slotted nut 6 Nuts for power cable clamps M4x16 screw Screws for control cable clamps M6x12 screw Screw for drive external grounding Control cable grounding lamella EMC cable clamps size M50 Grounding clamp Product modified label Cable grommet hole diameter 50 3 mm Control cable grounding Clamping power cables Power cable grounding Information about modifications Cable run through sealing CO CW INI O W YY IP54 Cable grommet hole diameter 25 3 mm Cable run through sealing 2 3 5 SIZE MR8 Table 8 Contents of accessories bag MR8 Item Quantity Purpose M4x16 screw 3 Screws for control cable clamps Control cable grounding lamella 3 Control cable grounding Cable lugs KP40 3 Clamping power cables Cable insulator 11 Avoiding contact between cables Cable grommet hole diameter 25 3 mm 4 Control cable run through sealing Tel 358 0 201 2121 e Fax 358 0 201 212 205 RECEIPT O
19. control board Locations of essential control unit components 1 Control terminals of the control board 2 Terminals of relay board NOTE There are two different compilations of relay boards available See section Chapter 5 1 3 Optional boards L a A 9058 emf Figure 48 Location of control unit components 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 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 24 VDC 100 mA 10 by connecting the ex ternal power source to terminal 30 see page 56 This voltage is sufficient for parameter set ting 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 connect ed Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 55 5 1 CONTROL UNIT CABLING The basic control unit connections are presented in Figure 49 below The control board is equipped with 22 fixed control I O terminals and the relay board with 8 or 9 The relay board is available in two different configurations see Table 24 and 25
20. e Fax 358 0 201 212 205 MOUNTING VACON 19 3 1 2 FLANGE MOUNT The AC drive can also be recessed into the cabinet wall or similar surface A special flange mount option is available for this purpose For an example of a flange mounted drive see Figure 10 Note the IP classes of different sections in figure below Cabinet wall or similar Cabinet wall P Y or similar 9070 emf Figure 10 Example of flange mount frame MR9 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 20 MOUNTING 3 1 2 1 FLANGE MOUNT FRAMES MR4 TO MR9 Figure 17 presents the dimensions of the mounting opening and Figure 11 16 the dimen sions of the drives with the flange mount option 11134 emf Figure 11 MR4 flange mount dimensions Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 21 11132 emf Figure 12 MR5 flange mount dimensions 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 22 MOUNT
21. enclosure is 0 mm 9013 emf Figure 18 Installation space A clearance around the freq converter see also B B distance from one AC drive to another or distance to cabinet wall C free space above the AC drive D free space underneath the AC drive Table 12 Reguired cooling air Cooling air reguired Type m h MR4 45 MR5 75 MR6 190 MR7 185 MR8 335 MR9 621 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 28 MOUNTING Note that if several units are mounted above each other the required free space equals C D see Figure 19 Moreover the outlet air used for coo ling by the lower unit must be directed away from the air intake of the upper unit by means of e g a piece of metal plate fixed to cabinet wall between the drives as shown in Figure 19 In addition when planning the air circulation inside cabinets recir culation of the air has to be avoided J0328 Jap sly 9014 emf Figure 19 Installation space when drives are mounted on top of each other Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 29 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 20 See also Table 13 for the cable recommmendations
22. of the AC drive corresponds to the requirements of your supply network See Chapter 6 3 In a domestic environment this product may cause radio interference in which case supplementary mitigation measures may be required PPP PPP P P P eRe 24 hour support 358 0 40 837 1150 e Email vacon vacon com VACON 6 SAFETY 1 3 EARTHING AND EARTH FAULT PROTECTION N CAUTION The AC drive must always be earthed with an earthing conductor connected to the earthing ter minal marked with CD The touch current of the drive exceeds 3 5 mA AC According to EN 61800 5 1 one or more of the following conditions for the associated protective circuit shall be satisfied A fixed connection and a theprotective earthing conductor shall have a cross sectional area of at least 10 mm Cu or 16 mm Al or b anautomatic disconnection of the supply in case of discontinuity of the protective earthing conductor See Chapter 4 or c provision of an additional terminal for a second protective earthing conductor of the same cross sectional area as the original protective earthing conductor Table 2 Protective earthing conductor cross section Minimum cross sectional area of the cor Cross sectional area of phase conductors S responding protective earthing conductor mm 2 mm S lt 16 5 16 lt S lt 35 16 25x45 S 2 The values above are valid only if the protective earthing conductor is made of the same met
23. to ground See Figure 58 9064 emf Figure 58 Locations of the EMC jumpers in frames MR4 to MR6 2 Disconnect the RFI filters from ground by removing the EMC jumpers using long nose pliers or similar See Figure 59 Sy 9060 emf n I US 9 WR E amp OOA aloo Figure 59 Removing the jumper MR5 as example Tel 358 0 201 2121 e Fax 358 0 201 212 205 COMMISSIONING VACON 71 6 3 2 FRAMES MR7 AND MRa Follow the procedure described below to modify the EMC protection of the AC drive of frames MR7 and MR8 to EMC level C4 1 Remove the main cover of the AC drive and locate the jumper MR8 only Push down the grounding arm See Figure 60 p80960896688580 9066 emf Figure 60 2 MR and MR8 Locate the EMC box under the cover Remove the screws of the box cover to expose the EMC jumper Detach the jumper and re fix the box cover
24. 40 0 160 o a Bolt size M8 Bolt size M8 MR8 o 170 0 200 a Bolt size M8 Bolt size M8 i o i 205 0 250 sl di Bolt size M8 Bolt size M8 vi Ha 261 0 315 i Bolt size M8 Bolt size M8 a 310 0 350 m Bolt size M8 Bolt size M8 The cable dimensioning is based on the criteria of the International Standard IEC60364 5 52 Cables must be PVC isolated Max ambient temperature 30 C max temperature of cable surface 70 C Use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the reguirements of the earthing conductor see chapter Earthing and earth fault protection on page 6 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 vacon vacon com VACON 34 POWER CABLING 4 1 1 3 CABLE AND FUSE SIZES FRAMES MR4 TO MR6 NORTH AMERICA The recommended fuse types are gG gL IEC 60269 1 or class T UL amp CSA The fuse voltage rating should be selected according to the supply network The final selection should be made according to local regulations cable installation conditions and cable specification Bigger fus es than what is recommended below shall not be used Check that the fuse operating time is less than 0 4 seconds Ope
25. F DELIVERY VACON 13 Table 8 Contents of accessories bag MR8 Item Quantity Purpose IP00 Touch protection shield 1 Avoiding contact with live parts IP00 M4x8 screw 2 Fixing the touch protection shield 2 3 6 SIZE MR9 Table 9 Contents of accessories bag MR9 Item Quantity Purpose M4x16 screw 3 Screws for control cable clamps Control cable grounding lamella 3 Control cable grounding Cable lugs KP40 5 Clamping power cables Cable insulator 10 Avoiding contact between cables Cable grommet hole diameter 25 3 mm Control cable run through sealing 4 IP00 Touch protection shield 1 Avoiding contact with live parts 2 IP00 MAx8 screw Fixing the touch protection shield 2 4 PRODUCT MODIFIED STICKER In the Accessories 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 9004 emf Figure 3 Product modified sticker 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 14 MOUNTING 3 MOUNTING The AC drive must be mounted in vertical position on the wall or on the back plane of a cubicle Ensure that the mounting plane is relatively even The AC drive shall be fixe
26. ING 286 3 20 Figure 13 MR6 flange mount dimensions Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 23 11135 emf Figure 14 MR7 flange mount dimensions 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 24 MOUNTING 00685 amii i 000000 000000 H 11131 emf Figure 15 MR8 flange mount dimensions Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 25
27. N 9 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 uniquely corresponds to the product and options you have ordered The code is of the following format VACON0100 3L 0061 4 HVAC xxxx yyyy VACON XXXX YYYY This segment is common for all products Additional codes 0100 Examples of additional codes Product range 1P54 0100 Vacon 100 AC drive with IP protection class IP54 3L SBF2 Input Function Two relays and a PTC input instead of three relays 3L Three phase input 0061 Drive rating in ampere e g 0061 61A 4 Supply voltage 2 208 240V 4 380 480 V HVAC 1P21 Type 1 EMC level C2 HVAC Application software standard HVAC documentation standard Graphical display panel Three relay outputs 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 10 RECEIPT OF DELIVERY 2 2 UNPACKING AND LIFTING THE AC DRIVE The weights of the AC drives vary greatly according to the size You may need to use a piece of special lifting eguipment to move the converter from its package Note the weights of each in dividual frame size in Table 3 below Table 3 Frame weights Frame Weight kg MR4 6 0 MR5 10 0 MR6 20 0 MR7 37 5 MR8 66 0 MR9 108 0 If you decide to use a piece of lifting equipment see picture below for recommendations to Lift the dri
28. TA Table 28 RS485 cable data 2 9 mm STP Shielded Twisted Pair type Belden 9841 or similar Depends on the used fieldbus See respective bus manual Cable length 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 62 CONTROL UNIT Strip about 15 mm of the RS485 cable see specification on page 61 and cut off the grey cable shield Remember to do this for both bus cables 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 10 9189 emf 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 ay 9188 emf Then connect the cable to its appropriate terminals on Vacon 100 AC drive stan dard terminal block terminals A and B A negative B positive See Figure 55 RS485 terminals A and B ec 21 22 23 242526 ELE DOG DEI 12131 15167778 eoi E ij INT OU 88 9198 emf Figure 55 Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 63
29. TY We Manufacturer s name Vacon Oyj Manufacturer s address P 0 Box 25 Runsorintie 7 FIN 65381 VAASA Finland hereby declare that the product Product name Vacon 100 AC drive Model designation Vacon 100 3L 0003 2 3L 0310 2 Vacon 100 3L 0003 4 3L 0310 4 has been designed and manufactured in accordance with the following standards Safety EN 61800 5 1 2007 EN 60204 1 2009 as relevant EMC EN 61800 3 2004 EN 61000 3 12 and conforms to the provisions of the Low Voltage Directive 2006 95 EC and the EMC Di rective 2004 108 EC It is ensured through internal measures and quality control that the product conforms at all times to the requirements of the current Directive and the relevant standards In Vaasa 7th of February 2012 Vesa Laisi President The year the CE marking was affixed 2009 24 hour support 358 0 40 837 1150 e Email vacon vacon com VACON 4 1 SAFETY 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 The cautions and warnings are marked as follows Table 1 Warning signs DANGER Dangerous voltage WARNING or CAUTION gt gt gt Caution Hot surface P P DANGER The components of the power unit are
30. VACON 100 HVAC DRIVES INSTALLATION MANUAL VACO DRIVEN BY DRIVES 3 1 3 1 1 3 1 2 3 2 4 4 1 4 1 1 4 2 4 2 1 4 2 2 4 3 5 5 1 5 1 1 5 1 2 5 2 5 2 1 5 2 2 5 3 5 4 6 6 1 6 2 6 2 1 6 3 6 3 1 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 1 TABLE OF CONTENTS Document DPD00926G Order code DOC INS02234 DLUK Rev G Version release date 16 11 12 Earthing and earth fault protection 2 44 ceereereeeaceareerenaaacareeraeaaneea 6 Electro magnetic compatibility EMC zi iaa sada a pako id e de di 7 Comipability with RGDS esee eet b ai 7 hien M 8 Type designation code 9 Unpacking and lifting the AC drive nene 10 Lifting frames MRB and MRI sit e er P be e aaa 10 AGCBSSOLIBS aida Badio edet Dualo acd inest vac la 11 Size MR Ie uii io e ipeo E AI UN P euro ru dud maie E ac rs 13 Product modified sticker 13 Jp Mee DIMENSIONS RENTUR CREER E Wa IE FO ET EO ite OT cec ommo nO A ao a e ar D Os Flange mount di si be Reid m bes sus ii baute bri eie eni ie dents Coolinges lla etti thee mt ehm eun Power cable i Ul st ndards on cabllmng 4 a eR ad E eei a Oe e deae Cable dimensioning and selection ate tErannn areren nnee C bleinstallati om od eec bts tue eid eA n Se oo e tad M od ELO Frames MR4 to MU tt lio sei e elio z l dou ooo eny
31. al as the phase conductors If this is not so the cross sectionalarea of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table 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 5mm if mechanical protection is provided or e 4mm if mechanical protection is not provided For cord connected equipment provi sions shall be made so that the protective earthing conductor in the cord shall in the case of failure of the strain relief mechanism be the last conductor to be interrupted However always follow the Local regulations for the minimum size of the protective earthing conductor NOTE Due to the high capacitive currents present in the AC drive fault current protective switches may not function properly Tel 358 0 201 2121 e Fax 358 0 201 212 205 SAFETY VACON 7 Do not perform any voltage withstand tests on any part of the AC drive There is A a certain procedure according to which the tests shall be performed Ignoring this procedure may result in damaged product 1 4 ELECTRO MAGNETIC COMPATIBILITY EMC This equipment complies with IEC 61000 3 12 provided that the short circuit power Scc is greater than or equal to 120 at the interface point between the user s supply and th
32. allel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the requirements of the earthing conductor see standard Underwriters Laboratories UL508C For the correction factors for each temperature see the instructions of standard Underwriters Laboratories UL508C Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 35 4 1 1 4 CABLE AND FUSE SIZES FRAMES MR7 TO MR9 NORTH AMERICA The recommended fuse types are gG gL IEC 60269 1 or class T UL amp CSA The fuse voltage rating should be selected according to the supply network The final selection should be made according to local regulations cable installation conditions and cable specification Bigger fus es than what is recommended below shall not be used Check that the fuse operating time is less than 0 4 seconds Operating time depends on used fuse type and impedance of the supply circuit Consult the factory about faster fuses Vacon of fers recommendations also for high speed J UL amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges Table 17 Cable and fuse sizes for Vacon 100 MR7 to MR9 Mains motor Terminal cable size class T and gog E e Main terminal Earth terminal u 00752 75 0 00724 1720 100 AWG2 AWG9 AWG2 0 AWG9 AWG2 0 00882 88 0 MR7 00874 1870 110 AWG1 AWG9 AWG2 0 AWG9 AWG2 0 0105 2
33. amella EMC cable clamps size M25 Grounding clamp Product modified label IP21 Cable grommet Control cable grounding Clamping power cables Power cable grounding Information about modifications Cable run through sealing Or Wi a N GW GW IP54 Cable grommet Cable run through sealing 2 3 2 SIZE MR5 Table 5 Contents of accessories bag MR5 Item Quantity Purpose Screws for power cable clamps M4x16 screw 13 6 control cable clamps 3 grounding clamps 4 M4x8 screw Screw for optional grounding M5x12 screw Screw for drive external grounding Control cable grounding lamella EMC cable clamps size M32 Grounding clamp Product modified label IP21 Cable grommet hole diameter 25 3 mm IP54 Cable grommet hole diameter 25 3 mm Cable grommet hole diameter 33 0 mm Control cable grounding Clamping power cables Power cable grounding Information about modifications Cable run through sealing Cable run through sealing NI DS NINI O Cable run through sealing 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 12 RECEIPT OF DELIVERY 2 3 3 SIZE MR6 Table 6 Contents of accessories bag MR6 Item Quantity Purpose ibd We M4x16 screw 3 Screws for control cable clamps M4x8 screw 1 Screw for optional grounding M5x12 screw 1 Screw for drive external grounding Control
34. ated currents in given ambient temperatures in Table 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 vacon vacon com VACON 9 76 TECHNICAL DATA 7 1 2 MAINS VOLTAGE 380 480 V Table 30 Power ratings of Vacon 100 supply voltage 380 480 V Mains voltage 380 480V 50 60 Hz 3 Loadability Motor shaft power Converter Low 400 V supply 480V supply type Rated continuous Input 10 overload 10 overload 1096 overload current current lin current 40 C 40 C A A A kW HP 0003 3 4 3 4 3 7 1 1 1 5 0004 4 8 4 6 5 3 1 5 2 0 a 0005 5 6 5 4 6 2 2 2 3 0 0008 8 0 8 1 8 8 3 0 5 0 0009 9 6 9 3 10 6 4 0 5 0 0012 12 0 11 3 13 2 5 5 7 5 LO 0016 16 0 15 4 17 6 7 5 10 QC 0023 23 0 21 3 25 3 11 0 15 0 0031 31 0 28 4 34 1 15 0 20 0 0038 380 367 418 185 250 OZ 0046 46 0 43 6 50 6 22 0 30 0 0061 61 0 58 2 67 1 30 0 40 0 n 072 720 675 72 30 500 Q 0087 87 0 85 3 95 7 45 0 60 0 2 0105 105 0 100 6 115 5 55 0 75 0 oo 040 1400 1394 1540 750 100 0 QC 0170 170 0 166 5 187 0 90 0 125 0 0205 205 0 199 6 225 5 110 0 150 0 e 0261 2610 2580 2871 1320 2000 0310 310 0 303 0 341 0 160 0 250 0 See Chapter 7 1 3 NOTE Th
35. cover of the AC drive 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 38 POWER CABLING 9051 emf Figure 23 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 39 3 Remove the screws of the cable protection plate Do not open the cover of the power unit 9022 emf Figure 24 4 Insert the cable grommets included in the delivery in the openings of the cable entry plate included as shown in the picture Picture EU version 9017 emf Figure 25 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 40 POWER CABLING e Insert the cables supply cable and motor cable in the openings of the cable entry plate e Then cut the rubber grommets open to slide the cables through Should the grommets fold in while inserting the cable just draw the cable back a bit to straighten the grommets up e Do not cut the grommet openings wider than what is necessary for the cables 5 you are using IMPORTANT NOTE FOR IP54 INSTALLATION To meet the requirements of the enclosure class IP54 the connection between the grommet and the cable must be tight Therefore lead the first bit of the cable out of the grommet straight before letting it bend If this is not possible the tight ness of the connection must be ensured with insulation tape or a cable tie
36. cted to the mains The touch current of the AC drives exceeds 3 5 mA AC According to standard EN 61800 5 1 a reinforced protective ground connection must be ensured See Chapter 1 3 Corner grounding is allowed for the drive types with the ratings from 72 A to 310 A at 380 480 V supply and from 75 A to 310 A at 208 240 V supply Remember to change the EMC level by removing the jumpers See Chapter 6 3 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 Only spare parts delivered by Vacon can be used At power up power brake or fault reset the motor will start immediately if the start signal is active unless the pulse control for Start Stop logic has been selected Futhermore the I O functionalities including start inputs may change if para meters applications or software are changed Disconnect therefore the motor if an unexpected start can cause danger R and R terminals are not used in this product The motor starts automatically after automatic fault reset if the autoreset func tion is activated See the Application Manual for more detailed information Prior to measurements on the motor or the motor cable disconnect the motor cable from the AC drive Do not touch the components on the circuit boards Static voltage discharge may damage the components Check that the EMC level
37. d with four screws or bolts depending on the unit size 3 1 DIMENSIONS 3 1 1 WALL MOUNT a j r D RH 9080 emf Figure 4 Vacon AC drive dimensions MR4 wall mount Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 15 1P21 033 025 033 ATTE SIT 9081 emf 1P21 040 033 040 9082 emf Figure 6 Vacon AC drive dimensions MR6 wall mount 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 16 MOUNTING 9083 emf Figure 7 Vacon AC drive dimensions MR7 wall mount Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 17 9084 emf Figure 8 Vacon AC drive dimensions MR8 IP21 and IP54 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 18 MOUNTING 326 4x81 5 9085 emf Figure 9 Vacon AC drive dimensions MR9 IP21 and IP54 Tel 358 0 201 2121
38. e 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 toa supply with a short circuit power Ssc greater than or equal to 120 1 5 COMPABILITY WITH RCDS If a fault protection relay is used it must be of at least type B preferably B according to EN 50178 with a trip level of 300 mA This is for protection not for touch protection in grounded systems 24 hour support 358 0 40 837 1150 e Email vacon vacon com VACON 8 RECEIPT OF DELIVERY 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 1 AC DRIVE 0022345628 e Vacon order V number acon type code amp Type VACONO100 3L 0031 4 HVAC f e Batch ID Serial number O S N VO789012245 B ID 122245 Doo Code 70 AB3L00315A02B5H1MB1C 12345678 TUNE OD OR AA AAN 1 S l Rated voltage Rated current 31 A Li 330 480 v IP class X IP21 Type1 m EMC level EMC level C2 O Application code Firmware FW0065V008 cust 5 Application lo as e os No 3234500378 CE CUSTOMER NAME VACON DRIVEN BY DRIVES 11118 emf Figure 1 Vacon package label Tel 358 0 201 2121 e Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACO
39. e rated currents in given ambient temperatures in Table are achieved only when the switching frequency is equal to or less than the factory default Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA VACON 0 77 7 1 3 DEFINITIONS OF OVERLOADABILITY Low overload Following continuous operation at rated output current the converter is fed with 110 for 1 min followed by a period of Example If the duty cycle requires 110 rated current for 1 min in every 10 min the remaining 9 min must be at rated current or less Current 1 110 l 110 9011 emf Figure 65 Low overload 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 78 7 2 Mains connection Motor connection Control characteristics VACON 100 TECHNICAL DATA TECHNICAL DATA Table 31 Vacon 100 technical data Input voltage Uin 208 240 V 380 480 V 1096 1096 Input frequency 50 60 Hz 5 10 Connection to mains Once per minute or less Starting delay 6 s MR4 to MR6J 8 s MR7 to MR Output voltage 0 U Continuous output cur rent I Ambient temperature max 40 C up to 50 C with derating overload 1 1 x 1 1 min 10 min Output frequency 0 320 Hz standard Frequency resolution 0 01 Hz Switching frequency see parameter P3 1 2 1 MR4 6 1 5 10 kHz D
40. ection Yes Mains supervision Yes Motor phase supervision Yes Protections Overcurrent protection Yes Unit overtemperature protection s Motor overload protection Yes Motor stall protection Yes Motor underload pro tection Yes Short circuit protection of 24 V and 10V re Yes ference voltages Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA VACON 81 7 2 1 TECHNICAL INFORMATION ON CONTROL CONNECTIONS Table 32 Technical information on standard I O board Standard 1 0 board Terminal Signal Technical information 1 Reference output 10 V 3 Maximum current 10 mA Analogue input channel 1 0 10 V Ri 200 KQ 2 Analogue input 4 20 mA Ri 250 2 voltage or current Resolution 0 1 accuracy 1 Selection V mA with dip switches see page 58 Short circuited protected 3 Analogue input common Differential input if not connected to ground current Allows 20 V differential mode voltage to GND Analogue input channel 2 Defauit 4 20 mA Ri 250 4 Analogue input 0 10 V Ri 200 kQ voltage or current Resolution 0 1 96 accuracy 1 96 Selection V mA with dip switches see page 58 Short circuited protected 5 Analogue input common Differential input if not connected to ground current Allows 20V differential mode voltage to GND 24 V 10 max volt ripple
41. efaults MR4 6 6 kHz except 0012 2 0031 2 0062 2 0012 4 0031 4 and 0061 4 4 kHz MR7 9 1 5 6 kHz Defaults MR7 4 kHz MR8 3 kHz MR9 2 kHz Automatic switching frequency derating in case of overload Frequency reference Analogue input Panel reference Resolution 0 1 10 bit accuracy 1 Resolution 0 01 Hz Field weakening point 8 320 Hz Acceleration time 0 1 3000 sec Deceleration time 0 1 3000 sec Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA Ambient conditions Ambient conditions cont EMC at default set tings Noise level Safety VACON 79 Table 31 Vacon 100 technical data Ambient operating tem perature IL 10 C no frost 40 C up to 50 C with derating Storage temperature 40 C 70 C Relative humidity 0 95 Ry non condensing non corrosive Air quality e chemical vapours e mechanical particles Tested according to IEC 60068 2 60 Test Ke Flowing mixed gas corrosion test Method 1 H5S hydrogen sulfide and SO sulfur dioxide Designed according to IEC 60721 3 3 unit in operation class 3C2 IEC 60721 3 3 unit in operation class 352 Altitude 100 load capacity no derating up to 1 000m 1 derating for each 100m above 1 000m Max altitudes 208 240 V 4 000 m TN and IT systems 380 500 V 4 000 m TN and IT systems
42. for different EMC levels NOTE R and R terminals are not used in Vacon 100 HVAC drive and no external A components can be connected to them Control Power unit 9216 emf Figure 20 Principal connection diagram Use cables with heat resistance of at least 70 C The cables and the fuses must be dimen sioned according to the AC drive nominal OUTPUT current which you can find on the rating plate Table 13 Cable types required to meet standards EMC levels 2nd environment Cable type Category C2 Category C3 Level C4 1 1 2 Mains cable 1 Motor cable 3 2 Control cable 4 1 Power cable intended for fixed installation and the specific mains voltage Shielded cable not required MCMK or similar recommended 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 30 POWER CABLING 2 Symmetrical power cable equipped with concentric protection wire and intended for the specific mains voltage MCMK or similar recommended See Figure 21 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 100mohm m See Figure 21 360 earthing of the shield with cable glands in motor end needed for EMC level C2 4 Screened cable equipped with compact lo
43. formation on standard I O board Standard 1 0 board Terminal Signal Technical information A RS485 Differential receiver transmitter B RS485 Set bus termination with dip switches see page 58 Table 33 Technical information on Relay board 1 Relay board with two change over contact SPDT relays and one Relay relay with normally open NO or SPST contact board 1 5 5 mm isolation between channels Terminal Signal Technical information 21 Switching capacity 24 VDC 8 A 22 Rel 1 250 VAC 8 A ere output 125 VDC 0 4 A 23 Min switching load 5 V 10 mA 24 Switching capacity 24 VDC 8 A 250 VAC 8 A 25 Relay output 2 125 VDC O 4 A 26 Min switching load 5 V 10 mA 32 Switching capacity 24 VDC 8 A 250 VAC 8 A ago Pe Sy outputs 125 VDC 0 4 A Min switching load 5 V 10 mA If 230 VAC is used as control voltage from the output relays the control cir cuitry 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 34 Technical information on Relay board 2 Relay board with two change over contact SPDT relays and a PTC ipic 2 thermistor input 5 5 mm isolation between channels Terminal Signal Technical information 21 Switchi
44. is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the requirements of the earthing conductor see chapter Earthing and earth fault protection on page 6 of the standard For the correction factors for each temperature see International Standard IEC60364 5 52 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 33 4 1 1 2 CABLE AND FUSE SIZES FRAMES MR7 TO MR9 The recommended fuse types are gG gL IEC 60269 1 or class T UL amp CSA The fuse voltage rating should be selected according to the supply network The final selection should be made according to local regulations cable installation conditions and cable specification Bigger fu ses 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 amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges Table 15 Cable and fuse sizes for Vacon 100 Mains and Terminal cable size js CN Main terminal EBEN pamm terminal in 22 8 80 o n 6 70 mm Cu Al 6 70 mm MR 00874 e 100 n s m 6 70 mm Cu Al 6 70 mm dio 1090 125 i di 6 70 mm Cu Al 6 70 mm M i 1
45. 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 and the brake resistor terminals are live when the AC drive is connected to mains even if the motor is not running After disconnecting the AC drive from the mains wait 5 minutes before doing any work on the connections of the drive Do not open the cover before this time has expired After expiration of this time use a measuring eguipment to absolutely ensure that no voltage is present Always ensure absence of voltage before star ting any electrical work The control O terminals are isolated from the mains potential However the relay outputs and other I O terminals may have a dangerous control voltage present even when the AC drive is disconnected from mains Before connecting the AC drive to mains make sure that the front and cable co vers of the drive are closed gt gt gt gt BP During a coast stop see 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 Wait 5 minutes before starting any work on the drive Tel 358 0 201 2121 e Fax 358 0 201 212 205 SAFETY VACON 5 2 WARNINGS P The AC drive is meant for fixed installations only Do not perform any measurements when the AC drive is conne
46. mail vacon vacon com Relay board 2 Terminal Signal 21 RO1 1 Relay output 1 22 RO1 2 a 23 RO1 3 y 24 RO2 1 Relay output 2 25 RO2 2 m 26 RO2 3 28 T 29 E Thermistor input VACON 58 CONTROL UNIT 5 1 2 1 SELECTION OF TERMINAL FUNCTIONS AND ISOLATING DIGITAL INPUTS FROM GROUND WITH DIP SWITCHES Current Voltage selection The shadowed terminals in Table allow for three functional selections current voltage refe rence signal each with the so called dip switches The switches have two positions left cur rent signal and right voltage signal Bus termination If necessary the bus termination can be set with the respective dip switch Locate the switch under the control cover of the drive and turn the switch for the RS485 bus termination resistor to position ON Isolating digital inputs from ground The digital inputs terminals 8 10 and 14 16 on the standard 1 0 board can also be isolated from ground by setting the dip switch on the control board to position OFF See Figure 50 to locate the switches and make appropriate selections for your requirements o z 4 3 e O Y o TI TU 9054 emf Figure 50 Dip switches and their default positions Bus terminator resistor Tel
47. mmet straight before letting it bend If this is not possible the tight ness of the connection must be ensured with insulation tape or a cable tie As an example see Figure 26 9040 emf Figure 40 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 49 9 If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables Figure 41 Connect the cables stripped as shown in Figure 32 e Connect the phase conductors of the supply and motor cables into their respective terminals a 1 0 e Form the rest of the cable shield of all cables into pigtails and make a grounding connection as shown in Figure 42 b using the clamp from the Accessories bag e NOTE If you use several cables on one connector observe the position of cable lugs on top of each other See Figure 43 below A CH 9222 emf Figure 42 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 50 POWER CABLING Connector 9015 emf Figure 43 Placing two cable lugs on top of each other Tigh
48. n conditions and cable specification Bigger fu ses 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 amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges Table 14 Cable and fuse sizes for Vacon 100 MR4 to MR6 Terminal cable size Mains and 3 motor cable Main Earth Cu mm terminal terminal mm mm 0003 2 0004 2 3 7 4 8 n 1 6 solid 0003 4 0004 413 448 LL 1 4 stranded 0006 2 0008 2 6 6 8 0 f 1 6 solid MR 005400084 5 66 0 PIRLO 1 4 stranded 00112 00122 11 0 12 5 1 6 solid 0009 4 0012 4 9 6 12 0 FARI 1 4 stranded 17 i s 20 3 6 6 1 10Cu 1 10 MRS 00257 a 25 3 6 6 i 10Cu 1 10 i si 32 3 10 10 1 10Cu 1 10 0038 4 38 0 20 3 10410 25 50 Cu Al 2 5 35 0048 2 48 0 3 16 16 Cul MR6 0046 4 46 0 Pe A JA oe en ee 00622 620 325416 Cul 00614 61 0 OB V foe ico The cable dimensioning is based on the criteria of the International Standard IEC60364 5 52 Cables must be PVC isolated Max ambient temperature 30 C max temperature of cable surface 70 C Use only cables with concentric copper shield Max number of parallel cables
49. ng capacity 24 VDC 8 A 22 Re 1 250 VAC 8 A Abi 125 VDC 0 4 A 23 Min switching load 5 V 10 mA 24 Switching capacity 24 VDC 8 A 250 VAC 8 A 25 Relay output 2 125 VDC O 4 A 26 Min switching load 5 V 10 mA 28 i 3 Thermistor input Rtrip 4 7 kQ PTC Measuring voltage 3 5 V If 230 VAC is used as control voltage from the output relays the control cir cuitry must be powered with a separate isolation transformer to limit short circuit current and ovrvoltage spikes This is to prevent welding on the relay contacts Refer to standard EN 60204 1 section 7 2 9 Tel 358 0 201 2121 e Fax 358 0 201 212 205 VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW Vacon com Document ID Manual authoring M D PDO 0 documentation dvacon com 9 2 6 G Vacon Plc Order code Runsorintie 7 65380 Vaasa Finland DOC NS 02 2 3 4 DLU K Subject to change without prior notice 2012 Vacon Plc Rev G
50. onnected to 24 V or ground of the I O terminal or the external supply Check the quality and quantity of cooling air Chapter and Table 12 Check the inside of the AC drive for condensation Check that all Start Stop switches connected to the 1 0 terminals are in Stop posi tion Before connecting the AC drive to mains Check mounting and condition of all fuses and other protective devices Run the Startup Wizard see the Application Manual 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 A A A A A Make sure that the motor terminals are not connected to mains potential Tel 358 0 201 2121 e Fax 358 0 201 212 205 COMMISSIONING VACON 69 6 2 1 CABLE AND MOTOR INSULATION CHECKS 1 24 hour support 358 0 201 212 575 e Email vacon vacon com 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
51. otor cable at a minimum of 30 cm TR y Fieldbus fW cables 9202 emf The bus termination must be set for the first and the last device of the fieldbus line See picture below See also step 4 on page 63 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 1 A ze A Ex zn X Termination activated VA NX z Fieldbus Termination activated with uz inati DIP switch 5 Bus termination Teu deactivated Resistance 120 ohm 9042 emf Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 65 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 HVAC drive The place for the battery can be found in all frames left to the control keypad see Figure 56 Detailed information on the functions of the Real Time Clock RTC can be found in the Vacon 100 HVAC Application Manual 9059 emf Figure 56 Optional battery 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 66 CONTROL UNIT 5 4 GALVANIC ISOLATION BARRIERS The control connections are isolated from the mains potential and the GND terminals are per manently connected to ground See Figure 57 The digital inputs are galvanically isolated from the I O ground The relay outpu
52. rating 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 amp CSA aR UL recognized IEC 60269 4 and gS IEC 60269 4 fuse ranges Table 16 Cable and fuse sizes for Vacon 100 MR4 to MR6 Mains motor and Terminal cable size class T ground cable J 00032 13 7 00034 134 6 AWG14 AWG24 AWG10 AWG17 AWG10 0004 2 0004 4 4 8 6 AWG14 AWG24 AWG10 AWG17 AWG10 00062 16 6 00054 56 10 AWG14 AWG24 AWG10 AWG17 AWG10 MRA 0008 2 0008 4 8 0 10 AWG14 AWG24 AWG10 AWG17 AWG10 00112 11 0 00094 19 6 15 AWG14 AWG24 AWG10 AWG17 AWG10 00122 12 5 00124 1120 20 AWG14 AWG24 AWG10 AWG17 AWG10 00182 118 0 00164 1160 25 AWG10 AWG20 AWG5 AWG17 AWG8 00242 24 0 MR5 00234 1230 30 AWG10 AWG20 AWG5 AWG17 AWG8 0031 2 0031 4 31 0 40 AWG8 AWG20 AWG5 AWG17 AWG8 00384 38 0 50 AWG4 AWG13 AWG0 AWG13 AWG2 00482 48 0 mre 100464 460 60 AWG4 AWG13 AWG0 AWG13 AWG2 00622 62 0 80 AWG4 AWG13 AWGO AWG13 AWG2 00614 161 0 The 460 V models require 90 degree wire to meet UL regulations The cable dimensioning is based on the criteria of the Underwriters Laboratories UL508C Cables must be PVC isolated Max ambient temperature 30 C max temperature of cable surface 70 C Use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in par
53. t 24 months e Clean heatsink and cooling tunnel 3 6 years e Change internal IP54 fan 6 10 years e Change main fan Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA VACON 75 7 TECHNICAL DATA 7 1 AC DRIVE POWER RATINGS 7 1 1 MAINS VOLTAGE 208 240 V Table 29 Power ratings of Vacon 100 supply voltage 208 240 V Mains voltage 208 240V 50 60 Hz 3 Loadability Motor shaft power Converter Low 230 supply o type Rated continuous Input 10 overload 10 overload 10 overload current current lin current 40 C 40 C A A A kw hp 0003 3 7 3 2 4 1 0 55 0 75 0004 4 8 4 2 5 3 0 75 1 0 gt 0006 6 6 6 0 7 3 1 1 1 5 0008 8 0 7 2 8 8 1 5 2 0 001 11 0 97 121 22 30 012 125 109 138 30 40 LO 0018 18 0 16 1 19 8 4 0 5 0 QC 0024 242 217 264 55 75 0031 31 0 27 7 34 1 7 5 10 0 gt 0048 48 0 43 8 52 8 11 0 15 0 0062 62 0 57 0 68 2 15 0 20 0 N 0075 75 0 69 0 82 5 18 5 25 0 Q 0088 88 0 82 1 96 8 22 0 30 0 uo 1050 990 1155 300 400 co 0140 143 0 135 1 154 0 37 0 50 0 QC 0170 170 0 162 0 187 0 45 0 60 0 uo 2080 2000 2255 50 750 c 0261 261 0 253 0 287 1 75 0 100 0 0310 310 0 301 0 341 0 90 0 125 0 See Chapter 7 1 3 NOTE The r
54. tening torques of cable terminals Table 22 Tightening torques of terminals Tightening torque Tightening torque Nm lb in Nm lb in Power and motor EMC grounding terminals clamps SAMOA 0140 2 0205 2 MR8 0440 4 0205 4 20 40 177 354 1 5 13 3 20 177 02612 03102 MRI 361 40310 4 20 40 177 354 1 5 13 3 20 177 Tightening torque Nm lb in Grounding terminals Cable clamping e g Ouneva Pressure Terminal Connector 1 1 Expose the shield of all three cables in order to make a 360 degree connection with the cable clamp Figure 44 Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 51 1 2 Remount now first the EMC shield plate see Figure 37 and then the sealing plate for MR9 see Figure 36 1 3 Re attach then the cable fitting plate and then the cable cover 9223 emf Figure 45 14 MR9 only Now re mount the main cover unless you want to make the control connections first
55. ther 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 Table 18 Distance between Shielded cables m cable m 0 3 lt 50 1 0 lt 200 e The given distances also apply between the motor cables and signal cables of other sys tems e The maximum lengths of motor cables shielded are 100 m MR4 150 m MR5 and MR6 and 200 m MR7 to MR9 e The motor cables should cross other cables at an angle of 90 degrees e If cable insulation checks are needed see chapter Cable and motor insulation checks on page 69 NOTE R and R terminals are not used in Vacon 100 HVAC drive and no external N components can be connected to them Start the cable installation according to the instructions below Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 37 4 2 1 FRAMES MR4 TO MR7 1 Strip the motor and mains cables as advised below Earth conductor Earth conductor l u Figure 22 Stripping of cables 9019 emf Table 19 Cables stripping lengths mm Frame A1 B1 C1 D1 C2 D2 E MR4 15 35 10 20 7 35 Leave MR5 20 40 10 30 10 40 asehori MR6 120 90 15 60 15 60 a9 pass sible MR7 120 80 20 80 20 80 2 Open the
56. ts are addition ally double isolated from each other at 300 VAC EN 50178 10Vref GND CONTROL UNIT POWER UNIT DC DC R R 9097 emf Figure 57 Galvanic isolation barriers Tel 358 0 201 2121 e Fax 358 0 201 212 205 COMMISSIONING VACON 67 6 COMMISSIONING Before commissioning note the following directions and warnings Internal components and circuit boards of Vacon 100 except for the galvanically isolated I O 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 are live when Vacon 100 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 I O terminals may have a dangerous control voltage present even when Vacon 100 is disconnected from mains Do not make any connections to or from the AC drive when it is connected to the mains After disconnecting the frequency converter from the mains wait until the fan stops and the indicators on the keypad go out if no keypad is attached see the indicators on the cover Wait 5 more minutes before doing any work on the con nections of Vacon100 Do not open the cover before this time has expired After expiration of this time use a meas
57. ues of terminals Tightening torgue Tightening torgue Nm lb in Nm lb in Power and motor EMC grounding Tightening torgue Nm lb in Grounding terminals terminals clamps MR4 0 5 0 6 4 5 5 3 1 5 13 3 20 17 7 0003 2 0012 2 0003 4 0012 4 0018 2 0031 2 MR5 0016 4 0031 4 1 2 1 5 10 6 13 3 1 5 13 3 2 0 17 7 0048 2 0062 2 0038 4 0061 4 0075 2 0105 2 P i MR7 0072 40105 418 15 170 8 132 8 1 5 13 3 8 15 70 8 132 8 MR6 0 88 5 1 5 13 3 2 0 17 7 Cable clamping e g Ouneva Pressure Terminal Connector Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 43 Check the connection of the earth cable to the motor and the AC drive terminals marked with 8 NOTE Two protective conductors are required according to standard EN 61800 5 1 See Figure 30 and chapter Earthing and earth fault protection on page 6 Use an M5 size screw and tighten it to 2 0 Nm 17 7 lb in 9219 emf Figure 30 Additional protective earthing connector 9 Re mount the cable protection plate Figure 31 and the cover of the AC drive 9220 emf Figure 31 Re mounting of cover components 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 44 POWER CABLING 4 2 2 FRAMES MR8 AND MR9 1 Strip the motor and mains cables as advised
58. uring equipment to absolutely ensure that no voltage is present Always ensure abscence of voltage before electrical work Before connecting the AC drive to mains make sure that the front and cable co vers of Vacon 100 are closed Corner grounding is allowed for the drive types with ratings from 72 A to 310 A at 380 480 V supply and from 75 A to 310 A at 208 240 V supply Remember to change the EMC level by removing the jumpers See Chapter 6 3 NOTE R and R terminals are not used in Vacon 100 HVAC drive and no external components can be connected to them gt gt gt P PPR gt 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 68 COMMISSIONING 6 1 COMMISSIONING OF THE DRIVE Read carefully the safety instructions in Chapter 1 and above and follow them After the installation 6 2 Check that both the AC drive and the motor are grounded Check that the mains and motor cables comply with the requirements given in Chapter 4 1 1 Check that the control cables are located as far as possible from the power cables see Chapter 4 2 Check that the shields of the shielded cables are connected to protective earth marked with Check the tightening torques of all terminals Check that the wires do not touch the electrical components of the drive Check that the common inputs of digital input groups are c
59. ve 2 2 1 LIFTING FRAMES MR8 AND MR9 NOTE First detach the drive from the pallet it has been bolted to NOTE Place the lifting hooks symmetrically in at least two holes The lifting device must be able to carry weight of the drive NOTE The maximum allowed lifting angle is 45 degrees 9012 emf Figure 2 Lifting bigger frames Vacon 100 AC 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 Tel 358 0 201 2121 e Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 11 2 3 ACCESSORIES After having opened the transport package and lifted the converter out check immediately that these various accessories were included in the delivery The contents of the accessories bag differ by drive size and IP protections class 2 3 1 SIZE MR4 Table 4 Contents of accessories bag MR4 Item Quantity Purpose Screws for power cable clamps M4x16 screw 11 6 control cable clamps 3 grounding clamps 2 M4x8 screw Screw for optional grounding M5x12 screw Screw for drive external grounding Control cable grounding l
60. w impedance shield JAMAK SAB 0ZCuY 0 or similar PE conductor PE conductors and shield 1 ZA Shield 9007 emf Figure 21 NOTE The EMC reguirements are fulfilled at factory defaults of switching freguencies all frames NOTE If safety switch is connected the EMC protection shall be continuous over the whole cab le installation Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 31 4 1 UL STANDARDS ON CABLING To meet the UL Underwriters Laboratories regulations use a UL approved copper cable with a minium heat resistance of 60 75 C Use Class 1 wire only The units are suitable for use ona circuit capable of delivering not more than 100 000 rms sym metrical amperes 600 V maximum 4 1 1 CABLE DIMENSIONING AND SELECTION Table shows the minimum dimensions of the Cu Al cables and the corresponding fuse sizes Recommended fuse types are gG gL 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 24 hour support 358 0 201 212 575 e Email vacon vacon com VACON 32 POWER CABLING 4 1 1 1 CABLE AND FUSE SIZES FRAMES MR4 TO MR6 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 installatio
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