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vacon 100 installation manual

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1. gt Frames MR8 and MRI e i etait Ae Installation in corner grounded network sssssssssssseeneeenee eene oai od Enc Dona i ciao iu d vua dun DO ad os a on Control unit a Mediae cack Ab eet ee Control cable sizIng e ERR I O cabling and Prepare for use Prepare for use through 485 eene nennen Battery installation for Real Time Clock RIG Galvanic isolation COMMISSIONING Commissioning Cable and motor insulation checks eene Installation in it SYStOIM eene ener enne nnne ense ener nne Frames MR4 to 7 Frames MRZ and epe Pe VACON 9 1 6 3 3 Frame MRO iit e edet eate e ect te deze te deeds 67 6 5 MaintenatCes iicet cin doeet eee lr ado b fut bd dade edd 69 7 E 71 7 1 AC drive power 65 2020 0200000 000000000000 71 7 1 1 Mains voltage 208 240 41 12 0 000000060 000000000 000 71 7 1 2 Mains voltage 380 480
2. Figure 28 Re mounting of cover components Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 38 4 3 2 FRAMES MR8 AND MR9 1 Strip the motor and mains cables as advised below Earth conductor Earth conductor i Figure 29 Stripping of cables MR8 40 180 25 300 25 300 Leave as short as MR9 40 180 25 300 25 300 possible Table 21 Cables stripping lengths 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 39 POWER CABLING 2 MR only Remove the main cover of the AC drive Figure 30 3 Remove the cable cover 1 and the cable fitting plate 2 Figure 31 Removing cable cover and cable fitting plate MR8 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 40 B c M4 x8 o7 ESO Figure 32 Removing cable cover and cable fitting plate MR9 M5 x 10 4 MR only Loosen the screws and remove the sealing plate Figure 33 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 41 POWER CABLING 5 Remove the EMC shield plate Figure 34 6 Locate the terminals OBSERVE the exceptional placement of motor cable termi nals in MR8 MR8 DC 11 12 13 0 R fe
3. Table 11 Flange mount cutout dimensions for MR7 to MR9 Figure 14 MR7 to MR9 flange mount depth dimensions 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 21 MOUNTING 3 2 COOLING 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 Min clearance mm 20 20 100 50 5 20 20 120 60 MR6 20 20 160 80 MR7 20 20 250 100 8 20 20 300 150 MR9 20 20 350 200 Min clearances A and for drives with IP54 enclosure is 0 mm Table 12 Min clearances around AC drive Figure 15 Installation space clearance around the freq converter see also 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 13 Required cooling air Cooling air required Type m h MR4 45 MR5 75 MR6 190 MR7 185 MR8 335 MR9 621 Tel 358 0 201 2121 e Fax 358 0 201
4. 11 110 11 110 Figure 63 Low overload Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA 7 2 VACON 74 VACON 100 TECHNICAL DATA Mains connection Motor connection Control characteris tics Ambient conditions Input voltage Uin 208 240V 380 480V 10 10 Input frequency 50 60 Hz 5 10 Connection to mains Once per minute or less Starting delay 4 s to 6 MR7 to MR Output voltage 0 Ui Continuous output current Ambient temperature max 40 C up to 50 C with derating overload 1 1 x lj 1 min 10 min Output frequency 0 320 Hz standard Frequency resolution 0 01 Hz Switching frequency see parameter 1 2 1 1 5 10 kHz Defaults MR4 6 6 kHz except 0012 2 0031 2 0062 2 0012 4 0031 and 0061 4 4 kHz MR7 4 kHz MR8 9 3 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 Ambient operating l 10 C no frost 40 C up to 50 C with temperature derating Storage temperature 40 70 Relative humidity 0 95 Ry non condensing non corrosive
5. 6 8 8 8 8 U Q j R LTL2 L30C DCrR died a ia TR jd D Figure 35 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 42 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 Figure 36 Place the grommet with the cable so that the frame end plate fits in the groove on the grommet see Figure 37 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 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 As an example see Figure 23 Figure 37 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 43 POWER CABLING 9 If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables Figure 38 Connect the cables stripped as shown in Figure 29 e Connect the phase conductors of the supply brake and motor cables into their respec
6. Rated continuous Input 10 overload 10 overload 1096 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 a 0006 6 6 6 0 7 3 1 1 1 5 gt 0008 8 0 7 2 8 8 1 5 2 0 0011 11 0 9 7 12 1 2 2 3 0 0012 12 5 10 9 13 8 3 0 4 0 LO 0018 18 0 16 1 19 8 4 0 5 0 QC 0024 24 2 21 7 26 4 5 5 7 5 0031 31 0 27 7 34 1 7 5 10 0 e 0048 48 0 43 8 52 8 11 0 15 0 gt 0062 62 0 57 0 68 2 15 0 20 0 0075 75 0 69 0 82 5 18 5 25 0 02 0088 880 821 968 220 300 gt 0105 105 0 99 0 115 5 30 0 40 0 0140 153 0 135 1 154 0 37 0 50 0 QC 0170 170 0 162 0 187 0 45 0 60 0 0205 208 0 200 0 225 5 55 0 75 0 ES 0261 261 0 253 0 287 1 75 0 100 0 gt 0310 310 0 301 0 341 0 90 0 125 0 See chapter 7 1 3 Table 29 Power ratings of Vacon 100 supply voltage 208 240V NOTE The rated currents in given ambient temperatures in Table 31 are achieved only when the switching frequency is equal to or less than the factory default Tel 358 0 201 2121 Fax 358 0 201 212 205 TECHNICAL DATA VACON 72 7 1 2 MAINS VOLTAGE 380 480 V Mains voltage 380 480V 50 60 Hz 3 Loadability Motor shaft power Converter Low 400V supply 480V supply type Rated continuous Input 10 overload 10 overload 1096 overload current IL
7. 212 205 CONTROL UNIT VACON 56 Strip about 15 mm of the RS485 cable see specification on page 55 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 J 1 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 2 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 53 RS485 terminals A and B 1021 2223 53 24 hour support 358 0201 212 575 e Email vaconfavacon com VACON 57 CONTROL UNIT 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 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 58 4
8. 212 205 MOUNTING VACON 22 Note that if several units are mounted above each other the required free space equals C D see Figure 16 Moreover the outlet air used for cool ing 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 16 J0 9a Jap FRONT SIDE Figure 16 Installation space when drives are mounted on top of each other 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 23 MOUNTING Tel 358 0 201 2121 e Fax 358 0 201 212 205 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 17 See also Table 14 for the cable recommmendations for different EMC levels Figure 17 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 EMC levels 2nd environment Cable type Category C2 Category C3 Level C4 1 1 Mains cable 1 Motor cable 3 2 2 Control cable 4 4 4 Table 14 Cable types required to meet standards 1 Power cable intended for fixed
9. 33 RO3 2 NO Table 25 Control I O terminal signals on relay board 1 and connection example From Basic 1 0 board Relay board 2 ee 12 13 21 RO1 1 Relay output 1 RN L 22 1 2 em gt 23 R013 I 24 R02 1 Relay output 2 25 RO2 2 26 RO2 3 4 cU 28 T Thermistor input POE 29 Table 26 Control I O terminal signals on relay board 2 and connection example Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL UNIT VACON 52 5 1 2 1 SELECTION OF TERMINAL FUNCTIONS WITH DIP SWITCHES The shadowed terminals in Table 24 allow for three functional selections each with the so called dip switches The switches have three positions left middle and right The middle po sition is for Test mode See figure to locate the switches and make appropriate selections for your requirements ON gt R5485 0 gt OFF Current 9 AO1 gt Voltage Current lt q A Voltage Current 4 gt Voltage Bus termination resistor Figure 47 Dip switches 5 1 2 2 ISOLATING DIGITAL INPUTS FROM GROUND The digital inputs terminals 8 10 and 14 16 on the basic 1 0 board can be isolated from ground by removing a jumper on the control board See Figure 48 Lift the plastic lid to expose the jumper and apply long nose pliers or similar to remove it T707773 2 2 4 1 Figu
10. Futhermore the 1 0 functionalities including start inputs may change if param eters applications or software are changed Disconnect therefore the motor if an unexpected start can cause danger 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 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 A Tel 358 0 201 2121 Fax 358 0 201 212 205 SAFETY VACON 6 6 1 3 EARTHING AND EARTH FAULT PROTECTION CAUTION The Vacon 100 AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with The touch current of Vacon 100 exceeds 3 5mA AC According to EN61800 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 di
11. com VACON 67 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 Figure 60 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 MR 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 61 Molex connector Figure 61 Tel 358 0 201 2121 Fax 358 0 201 212 205 COMMISSIONING VACON 68 2 O grommet plate Locate the EMC jumper on the EMC board see magnification Further remove the extension box cover the touch shield and the 1 0 plate with below and remove it Figure 62 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 24 hour support 358 0 201 212 575 e Email vaconfavacon
12. com VACON 69 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 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 Check door filters in case of cabinet installation 6 24 months depending on environment 24 months 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 COMMISSIONING VACON 70 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 71 TECHNICAL DATA 7 TECHNICAL DATA 7 1 AC DRIVE POWER RATINGS 7 1 1 MAINS VOLTAGE 208 240 V Loadability Motor shaft power Converter Low 230 supply type
13. differ by drive size and IP protections class 2 3 1 SIZE MR4 Item M4x16 screw Quantity 11 Purpose Screws for power cable clamps 6 control cable clamps 3 grounding clamps 2 M4x8 screw Screw for optional grounding M5x12 screw Control cable grounding lamella Screw for drive external grounding Control cable grounding EMC cable clamps size M25 Clamping power cables Grounding clamp Product modified label Power cable grounding Information about modifications IP21 Cable grommet Cable run through sealing 54 Cable grommet Or GC gt gt Cable run through sealing Table 4 Contents of accessories bag MR4 2 3 2 SIZE 5 Item Quantity Purpose Screws for power cable clamps M4x16 screw 13 6 control cable clamps 3 grounding clamps 4 M4x8 screw 1 Screw for optional grounding M5x12 screw 1 Screw for drive external grounding Control cable grounding lamella 3 Control cable grounding EMC cable clamps size M25 1 Clamping brake resistor cable EMC cable clamps size M32 2 Clamping power cables Grounding clamp 2 Power cable grounding Product modified label 1 Information about modifications IP21 Cable grommet hole diameter 25 3 mm 1 Cable run through sealing IP54 Cable grommet hole diameter 25 3 mm 4 Cable run through sealing Cable grommet hole diameter 33 0 mm 2 Cable run through sealing Table 5 Cont
14. ground see chapter 5 1 2 2 18 Analogue signal output Analogue output channel 1 selection 0 20mA load lt 500 Default 0 20 mA 0 10V 19 Analogue output common Resolution 0 1 accuracy 2 Selection V mA with dip switches see page 52 Short circuited protected 30 24V auxiliary input voltage be used as external power backup for the control unit A RS485 Differential receiver transmitter B RS485 Set bus termination with dip switches see page 52 Table 32 Technical information on standard I O board 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 77 TECHNICAL DATA Relay board with two change over contact SPDT relays and one Rela b 1 relay with normally open NO or SPST contact oar 5 5 mm isolation between channels Terminal Signal Technical information 21 Switching capacity 24VDC 8A 22 250VAC 8A Relay 1 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 32 Switching capacity 24VDC 8A 250VAC 8A TEE S ox 125VDC 0 4A Min switching load 5V 10mA If 230VAC 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 pre
15. 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 or similar recommended See Figure 18 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 25 POWER CABLING 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 18 360 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 PE conductor PE conductors and shield Shield Figure 18 NOTE The EMC requirements are fulfilled at factory defaults of switching frequencies all frames NOTE If safety switch is connected the EMC protection shall be continuous over the whole ca ble installation Tel 358 0 201 2121 e Fax 358 0 201 212 205 POWER CABLING VACON 26 4 1 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 ona circuit capable of delivering not more than 100 000 rms sym metrical amperes 600V maximum 4 1 1 C
16. of accessories bag MR7 2 3 5 SIZE 8 Item Quantity Purpose M4x16 screw 3 Screws for control cable clamps Control cable grounding lamella 3 Control cable grounding Cable lugs KP34 3 Clamping power cables Cable insulator 11 Avoiding contact between cables Cable grommet hole diameter 25 3 mm 4 Control cable run through sealing Table 8 Contents of accessories bag 8 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 13 RECEIPT OF DELIVERY 2 3 6 SIZE 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 4 Control cable run through sealing Table 9 Contents of accessories bag MR9 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 15 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 3 Product modified sticker Tel 358 0 201 2121 Fax 358 0 201 212 205 MOUNTING VACON 14 3 MOUNTING The AC drive must be mounted in vertical position on the wall o
17. 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 Warning Do not perform any modifications on the AC drive when it is con nected to mains 6 3 1 FRAMES MR4 TO 6 1 Remove the main cover of the AC drive see page 32 and locate the jumpers con necting the built in RFI filters to ground See Figure 56 Figure 56 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 57 Figure 57 Removing the jumper MR5 as example Tel 358 0 201 2121 Fax 358 0 201 212 205 COMMISSIONING VACON 66 6 3 2 FRAMES MR7 AND 8 Follow the procedure described below to modify the EMC protection of the AC drive of frames MR7 and MR8 to EMC level C4 Remove the main cover of the AC drive and locate the jumper MR8 only Push down the grounding arm See Figure 58 NM Figure 58 2 MR7 and 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 Figure 59 24 hour support 358 0 201 212 575 e Email vaconfavacon
18. 0 12 34 56 7890 1234 56729012345 Rated current Supply IP class voltage EMC level EMC level C2 Application code Firmware FWO0065V008 Application Cust Ord No 3234500378 Marks C Customer s order number CUSTOMER NAME VACON DRIVEN BY DRIVES Figure 1 Vacon package label 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 9 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 uniquely corresponds to the product and options you have ordered The code is of the following format VACONO0100 3L 0061 4 HVAC yyyy VACON This segment is common for all products Additional codes 0100 Examples of additional codes Product range 4 0100 Vacon 0 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 IP21 Type 1 EMC level C2 HVAC Application software standard HVAC documentation standard Graphical display panel Three relay outputs Tel 358 0 201 2121 e Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 10 2 2 UNPACKING AND LIFTING THE AC DRIVE The weights of the AC drives vary greatly accord
19. 12 5 7 1 6 solid 0009 4 0012 4 9 6 12 0 16 1 4 stranded 176 iir 20 3 646 1 10Cu 1 10 00222 2 25 3 646 1 10Cu 1 10 AE uA 32 3 10 10 i 10Cu 1 10 0038 4 38 0 50 3 10 10 2 5 50 Cu Al 2 5 35 00482 48 0 3 16 16 Cul 0046 4 46 0 2 S256 Al eee MR 00622 520 3 25 16 00614 61 0 fa eee Table 15 Cable and fuse sizes for Vacon 100 MR4 to MR6 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 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 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 28 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 8 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 cond
20. 2 2 1 00000000 000000006000 000002 72 7 1 3 Definitions of overloadability 1 4 4 4 00 0 080000000 000000000 000 nn 73 LA Nacor 100 75 7 2 1 Technical information on control 60 607 76 Tel 358 0 201 2121 e Fax 358 0 201 212 205 VACON 2 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON VACON DRIVEN BY DRIVES EC DECLARATION OF CONFORMITY We Manufacturer s name Vacon Oyj Manufacturer s address 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 Itis 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 December 2010 Vesa Laisi President The year the CE marking was affixed 2009 Tel 358 0 201 2121 Fax 358 0 201 212 205 SAFETY 1 VACON 9 4 SAFETY This manual contains clearly marked cautions and warnings w
21. 2 205 CONTROL UNIT VACON 48 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 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 5 1 3 Optional boards 4 Jumper for digital inputs see chapter 5 1 2 2 Figure 45 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 0 and the relay terminals the general wiring diagram and the control signal descriptions The control board be powered externally 24VDC 100 10 by connecting the nal power source to terminal 30 see page 50 This voltage 15 sufficient for parameter setting and for keeping the control unit active Note however that the measurements of the main cir cuit e g DC link voltage unit temperature are not available when the mains is not connected 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 49 CONTROL UNIT 5 1 CONTROL UNIT CABLING The basic control unit connections
22. ABLE DIMENSIONING AND SELECTION Table 15 shows the minimum dimensions of the Cu Al cables and the corresponding fuse siz es 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 vaconfavacon com VACON 27 POWER CABLING 4 1 1 1 CABLE AND FUSE SIZES FRAMES MR4 TO 6 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 Terminal cable size Mains and motor cable Main Earth Cu mm2 terminal terminal mm mm 0003 2 0004 2 3 7 4 8 1 6 solid 0003 4 0004 4 3 4 4 8 gee 1 4 stranded 176 0006 2 0008 2 6 6 8 0 1 6 solid MR4 00954 00084 5 6 8 0 10 ig 1 4 stranded 176 00112 00122 11 0
23. Air quality chemical vapours mechanical particles Tested according to IEC 60068 2 60 Test Ke Flowing mixed gas corrosion test Method 1 H5S hydrogen sulfide and 50 sulfur dioxide Designed according to IEC 60721 3 3 unit in operation class 3C2 IEC 60721 3 3 unit in operation class 3S2 Altitude 100 load capacity no derating up to 1 000m 1 96 derating for each 100m above 1 000m Max altitudes 208 240V 4 500m TN and IT systems 380 480V 4 500m TN and IT systems Voltage for 1 0 signals Up to 2 000m Allowed up to 240V 2 000m 4 500m Allowed up to 120V Corner grounding up to 2 000m only 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 75 TECHNICAL DATA 5 150 Hz Vibration Displacement amplitude 1 mm at EN61800 5 1 5 15 8 Hz MR4 MR9 EN60068 2 6 Max acceleration amplitude 1 G at 15 8 150 Hz MR4 MR9 conditions Shock UPS Drop Test for applicable UPS weights EN61800 5 1 Storage and shipping max 15 G 11 ms in EN60068 2 27 package IP21 Type 1 standard in entire kW HP range Enclosure class IP54 Type 12 option Note Keypad required for IP54 Type 12 Fulfils EN61800 3 2004 first and second environment EMC at default set tings EMC2 EN61800 3 2004 Category C2 Emissions The drive can be modified for IT networks See chapter 6 3 on page 65 Average no
24. ON 4 485 gt OFF Bus termination resistor Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL UNIT VACON 58 Unless already done for the other control cables cut free the opening on the AC drive cover for the RS485 cable protection class IP21 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 motor cable at a minimum of 30 cm Fieldbus cables 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 57 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 ON Termination activated BACnet MS TP Termination activated with Termination DIP switch 3 Bus termination deactivated 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 9 59 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 HVAC drive The place for the battery can be found in all frames left to the control keypad see Figure 54 Detailed information on the functions of the Rea
25. R5 00234 230 30 AWG10 AWG20 AWG5 AWG17 AWG8 0031 2 0021 4 31 0 40 AWG8 AWG20 AWG5 AWG17 AWG8 00384 38 0 50 AWG4 AWG13 AWGO AWG13 AWG2 00482 48 0 00464 460 60 AWG4 AWG13 AWGO AWG13 AWG2 00622 0 80 AWG4 AWG13 AWGO AWG13 AWG2 00614 0 The 460V models require 90 degree wire to meet UL regulations Table 17 Cable and fuse sizes for Vacon 100 MR4 to MR6 The cable dimensioning is based on the criteria of the Underwriters Laboratories UL508C Cables must be PVC iso lated 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 Laboratories UL508C Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 30 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 condition
26. Time Clock RTC can be found in the Vacon 100 HVAC Application Manual Figure 54 Optional battery Tel 358 0 201 2121 Fax 358 0 201 212 205 CONTROL UNIT VACON 60 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 55 The digital inputs are galvanically isolated from the 1 0 ground The relay outputs are addition ally double isolated from each other at 300VAC 50178 10Vref D CONTROL UNIT 5 N POWER UNIT DC DC R R Figure 55 Galvanic isolation barriers 24 hour support 358 0 201 212 575 Email vaconfavacon com VACON 61 CONTROL UNIT Tel 358 0 201 2121 e Fax 358 0 201 212 205 COMMISSIONING VACON 62 6 COMMISSIONING Before commissioning note the following directions and warnings Internal components and circuit boards of Vacon 100 except for the galvanically AN 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 V W and the brake resistor terminals R R MRA MR4 or DC R and R MR7 and bigger 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
27. VACON 100 AC DRIVES INSTALLATION MANUAL VACON DRIVEN BY DRIVES 4 3 1 5 1 1 5 1 2 5 2 1 5 2 2 5 4 6 1 6 2 1 6 3 6 3 1 6 3 2 24 hour support 358 0 201 212 575 Email vaconfavacon com VACON 9 0 INDEX Document DPD00390D Version release date 27 1 11 M M M 4 LANA 4 das et e bye edo ve 5 Earthing and earth fault protection ener nnne 6 Electro magnetic compatibility EMC sitter ee cero dette deett utter 7 Receipt of delivery uiua ceci exi gx ace mentiri eere in aas i iud rasa s rn Rig 8 designa tN 4 9 10 Lifting frames MR8 and MR ne nnne 10 7 11 Size 770 11 svi 11 MR 12 DE MIS 12 12 Size Tr oS 13 heh sc 13 14 14 tet et et Pad trei e bd Pet am bm te ie p d e Deeds 14 athbIraupbecle EL 17 Greiner 21 POWER cabUng iu cuire Lot otn UL standards on Cable dimensioning and 1 2 1 0 111 eene Cable Sta lla eR
28. al Tel 358 0 201 2121 Fax 358 0 201 212 205 COMMISSIONING VACON 9 64 6 2 1 CABLE AND MOTOR INSULATION CHECKS 1 24 hour support 358 0 201 212 575 e Email vaconfavacon 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 The insula tion resistance must be gt 1MQ 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 1MQ at ambient temperature of 20 C Always follow the instructions of the motor manufacturer VACON 65 COMMISSIONING 6 3 INSTALLATION IN IT SYSTEM If your supply network is an IT impedance grounded system but your AC drive is EMC
29. 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 Labo ratories UL508C 4 2 BRAKE RESISTOR CABLES Vacon AC drives are equipped with terminals for an optional external brake resistor These ter minals are marked with and R MR4 MR6 or DC R and R MR7 and bigger 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 031 POWER CABLING 4 3 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 fthe motor cables run in parallel with other cables note the minimum distances between the motor cables and other cables given in table below Distance between Shielded cables m cable m 0 3 lt 50 1 0 lt 200 The given distances also apply between the motor cables and signal cables of other sys tems The maximum lengths of motor cables shielded are 100 m 4 150 m MR5 and MR and 200 MR7 to MR9 e The motor cables should cross other cables at an angle of 90 d
30. are presented in Figure 46 below The control board is equipped with 22 fixed control 1 0 terminals and the relay board with 8 or 9 The relay board is available in two different configurations see Table 25 and 26 All signal descriptions are given in Tables 24 to 26 12 13 14 15 16 17 18 19 30 A B ae A OOO CI Basic control terminals Figure 46 5 1 1 CONTROL CABLE SIZING The control cables shall be at least 0 5 mm screened multicore cables see Table 14 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 Tightening torque Terminal screw 1 0 and relay terminals screw Table 23 Control cable tightening torques Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 50 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 52 Basic 1 0 board gt K Tu 20 1 10 Vref Reference output Reference M Analogue input potentiometer 1 10 pem 2 zie voltage or c
31. cov ers of Vacon 100 are closed gt e 24 hour support 358 0 40 837 1150 e Email vaconfavacon com During a coast stop see the Application Manual the motor is still generating voltage to the drive Therefore do not touch the components of the AC drive before the motor has completely stopped Wait until the indicators on the keypad go out if no keypad is attached see the indicators on the cover Wait additional 5 minutes before starting any work on the drive VACON 5 SAFETY 1 2 WARNINGS Vacon 100 AC drive is meant for fixed installations only Do not perform any measurements when the AC drive is connected to the mains The touch current of Vacon 100 AC drives exceeds 3 5mA AC According to stan dard EN61800 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
32. 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 Figure 51 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 55 CONTROL UNIT 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 Figure 52 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 5485 CABLE DATA onnector 2 5mm STP Shielded Twisted Pair type Belden 9841 or similar Depends on the used fieldbus See respective bus manual Table 28 RS485 cable data Cable type Cable length Tel 358 0 201 2121 Fax 358 0 201
33. current lin current 40 C 40 C 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 gt 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 T 0016 16 0 15 4 17 6 7 5 10 0023 23 0 21 3 25 3 11 0 15 0 0 310 284 9 150 200 0038 380 367 418 185 250 QC 0046 46 0 43 6 50 6 22 0 30 0 610 5652 3600 4090 0072 72 0 67 5 79 2 37 0 50 0 Q 0087 87 0 85 3 95 7 45 0 60 0 gt 0105 105 0 100 6 115 5 55 0 75 0 040 1400 1394 1540 750 100 0 QC 0170 170 0 166 5 187 0 90 0 125 0 uos 250 1996 255 moo 1500 5 0261 261 0 258 0 287 1 132 0 200 0 gt 0310 310 0 303 0 341 0 160 0 250 0 7 1 3 Table 30 Power ratings of Vacon 100 supply voltage 380 480V NOTE The rated currents in given ambient temperatures in Table 31 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 73 TECHNICAL DATA 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
34. egrees e If cable insulation checks are needed see chapter Cable and motor insulation checks Start the cable installation according to the instructions below 4 3 1 FRAMES MR4 TO MR7 1 Strip the motor and mains cables as advised below Earth conductor Earth conductor Figure 19 Stripping of cables Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 32 Frame 1 1 1 D1 C2 D2 E MR4 15 35 10 20 7 35 Leave MR5 20 40 10 30 10 40 MR6 20 0 15 60 15 60 as pos sible MR7 20 80 20 80 20 80 Table 19 Cables stripping lengths mm 2 Open the cover of the AC drive Figure 20 24 hour support 358 0 201 212 575 Email vaconfavacon com VACON 33 POWER CABLING 3 Remove the screws of the cable protection plate Do not open the cover of the power unit Figure 21 Insert the cable grommets included in the delivery in the openings of the cable 4 entry plate included as shown in the picture upper pictures EU version lower pictures US version Figure 22 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 34 e Insert the cables supply cable motor cable and optional brake cable in the openings of the cable entry plate Then cut the rubber grommets open to slide the cables
35. ents of accessories bag MR5 Tel 358 0 201 2121 Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 2 2 3 3 SIZE 6 Item Quantity Purpose bun i o M4x16 screw 3 Screws for control cable clamps M4x8 screw 1 Screw for optional grounding M5x12 screw 1 Screw for drive external grounding Control cable grounding lamella 3 Control cable grounding EMC cable clamps size M32 1 Clamping brake resistor cable 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 54 Cable grommet hole diameter 25 3 mm 3 Cable run through sealing Table 6 Contents of accessories bag MR6 2 3 4 SIZE 7 Item Quantity Purpose M5x30 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 Control cable grounding EMC cable clamps size M50 Clamping power cables Grounding clamp Product modified label Power cable grounding Information about modifications Cable grommet hole diameter 50 3 mm Cable run through sealing CO GW 54 Cable grommet hole diameter 25 3 mm Cable run through sealing Table 7 Contents
36. hich 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 DANGEROUS VOLTAGE A A WARNING or CAUTION Table 1 Warning signs DANGER The components of the power unit of Vacon 100 are live when the AC 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 Vacon 100 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 attached see the indicators on the cover Wait 5 more minutes before doing any work on the connections of Vacon100 Do not open the cover 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 I O terminals may have a dangerous control voltage present even when Vacon 100 is disconnected from mains Before connecting the AC drive to mains make sure that the front and cable
37. ing to the size You may need to use a piece of special lifting equipment to move the converter from its package Note the weights of each in dividual frame size in Table 3 below Frame Weight kg MR4 6 0 MR5 10 0 MR6 20 0 MR7 37 5 MR8 66 0 MR9 108 0 Table 3 Frame weights If you decide to use a piece of lifting equipment see picture below for recommendations to lift the drive 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 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 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 11 2 3 ACCESSORIES RECEIPT OF DELIVERY 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
38. ion is available for this purpose For an example of a flange mounted drive see Fig ure 10 Note the IP classes of different sections in figure below Cabinet wall or similar similar Figure 10 Example of flange mount frame MR9 Tel 358 0 201 2121 Fax 358 0 201 212 205 MOUNTING VACON 8 3 1 2 1 FLANGE MOUNT FRAMES MR4 6 Figure 11 presents the dimensions of the mounting opening and Figure 12 the depth dimen sions of the drives with the flange mount option Drive outline Opening outfine Figure 11 Flange mount cutout dimensions for MR4 to MR6 Frame A B C D E F MR4 310 137 337 144 110 316 MR5 408 152 434 160 132 414 MR6 534 203 560 211 184 541 Table 10 Flange mount cutout dimensions for MR4 to MR6 mm 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 19 MOUNTING Figure 12 MR4 to MR6 flange mount depth dimensions Tel 358 0 201 2121 e Fax 358 0 201 212 205 MOUNTING VACON 20 3 1 2 2 FLANGE MOUNT MR7 MR9 Figure 13 presents the dimensions of the mounting opening and Figure 14 the dimensions of the drives with the flange mount option Drive outline Figure 13 Flange mount cutout dimensions for MR7 to MR9 Frame A B 0 7 655 250 682 268 13 5 MR8 859 298 888 359 17 MR9 975 485 1050 530 54
39. ise level 65 MR7 77 Noise level cooling fan sound MR5 70 MR8 86 power level dB A MR 77 MR 87 EN 61800 5 1 2007 CE cUL see unit nameplate for more detailed approvals 240 volt drives 456 V 480 volt drives 911 V Depends on supply voltage 0 8775 supply voltage Undervoltage trip limit Supply voltage 240 V Trip limit 211 V Supply voltage 400 V Trip limit 351 V Supply voltage 480 V Trip limit 421 V Earth fault protection Yes Safety Overvoltage trip limit Mains supervision Yes Motor phase supervision Yes Protections Overcurrent protection Yes Unit overtemperature protection ise Motor overload protection Yes Motor stall protection Yes Motor underload pro tection Yes Short circuit protec tion of 24V and 10V Yes reference voltages Table 31 Vacon 100 technical data Tel 358 0 201 2121 e Fax 358 0 201 212 205 TECHNICAL DATA VACON 76 7 2 1 TECHNICAL INFORMATION ON CONTROL CONNECTIONS Standard 1 0 board Terminal Signal Technical information 1 Reference output 10V 3 Maximum current 10 mA Analogue input channel 1 0 10V Ri 200 2 Analogue input 4 20 mA Ri 250 Q voltage or current Resolution 0 1 accuracy 1 Selection V mA with dip switches see page 52 Short circuited protected 3 Analogue input c
40. itions 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 Terminal cable size pon OT Main terminal ann terminal Mains and Bd 80 De T 6 70 mm Cu Al 6 70 mm MR 00874 0 1 n 6 70 mm Cu Al 6 70 mm ds 105 0 125 n 6 70 mm Cu Al 6 70 mm ou 140 0 160 2 Tn Bolt size M8 Bolt size M8 MR8 d 170 0 200 size M8 Bolt size M8 oe 205 0 250 22 an Bolt size M8 Bolt size M8 NS n 261 0 315 a Bolt size M8 Bolt size M8 21 310 0 350 22 Bolt size 8 Bolt size M8 Table 16 Cable and fuse sizes for Vacon 100 The cable dimensioning is based on the criteria of the International Standard IEC60364 5 52 Cables must be PVC isolated Max ambient temperature 30 max temperature of cable surface 70 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 chapter Earthing a
41. nd 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 29 POWER CABLING 4 1 1 3 CABLE AND FUSE SIZES FRAMES MR4 MR 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 Terminal cable size Mains motor and ground cable Cu class T 00032 3 7 00034 34 6 AWG14 AWG24 AWG10 AWG17 AWG10 0004 2 0004 4 4 8 6 AWG14 AWG24 AWG10 AWG17 AWG10 00062 6 6 00054 56 10 AWG14 AWG24 AWG10 AWG17 AWG10 iip 0008 2 0008 4 8 0 10 AWG14 AWG24 AWG10 AWG17 AWG10 00112 0 00094 96 15 AWG14 AWG24 AWG10 AWG17 AWG10 00122 12 5 00124 120 20 AWG14 AWG24 AWG10 AWG17 AWG10 00182 0 00164 160 25 AWG10 AWG20 AWG5 AWG17 AWG8 00242 0 M
42. o change without prior notice 2011 Vacon Plc Document ID D P D 0 0 DOC 8022 3 4 3 9 0 D Order code D L UK Rev D
43. ommon Differential input if not connected to ground current Allows 20V differential mode voltage to GND Analogue input channel 2 Defauit 4 20 mA Ri 250 Q 5 Analogue input 0 10 V 200 voltage or current Resolution 0 1 96 accuracy 1 96 Selection V mA with dip switches see page 52 Short circuited protected 5 Analogue input common Differential input if not connected to ground current Allows 20V differential mode voltage to GND 24V 10 max volt ripple gt 100mVrms max 250mA 6 24V aux voltage Dimensioning max 1000mA control unit Short circuit protected Ground for reference and controls connected internally to frame earth 7 through 1 8 Digital input 1 Positive or negative logic Ri min 9 Digital input 2 Him 0 5 70 10 Digital input 3 15 30V 1 11 Common for DIN1 DIN6 Digital inputs can be disconnected from ground see chapter 5 1 2 2 24V 10 max volt ripple gt 100mVrms max 250mA 12 24V aux voltage Dimensioning max 1000mA control unit Short circuit protected Ground for reference and controls connected internally to frame earth through 1 14 Digital input 4 Positive or negative logic 13 1 0 ground UTE Ri min 15 Digital input 5 ho 0 5 0 16 Digital input 6 15 30V 1 17 Common for DIN1 DIN6 Digital inputs can be isolated from
44. other 1 0 5 a dangerous control voltage present even when Vacon 100 is disconnected from mains Do not make any connections to or from the frequency converter when it is con nected to the mains After disconnecting the 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 measuring 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 cov ers 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 gt gt gt lt 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 63 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
45. r on the back plane of a cubicle Ensure that the mounting plane is relatively even The AC drive shall be fixed with four screws or bolts depending on the unit size 3 1 DIMENSIONS 3 1 1 MOUNT 15 FP im 34 Figure 4 Vacon AC drive dimensions wall mount 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 15 MOUNTING 21 033 025 033 Optional mounting holes for NX replacement Figure 5 Vacon AC drive dimensions MR5 wall mount IP21 040 033 040 7 Figure 6 Vacon AC drive dimensions MR6 wall mount Tel 358 0 201 2121 Fax 358 0 201 212 205 MOUNTING VACON 16 9 Figure 8 Vacon AC drive dimensions MR8 1021 and IP54 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 17 MOUNTING J Figure 9 Vacon AC drive dimensions MR9 IP21 and IP54 3 1 2 FLANGE MOUNT The AC drive can also be recessed into the cabinet wall or similar surface A special flange mount opt
46. re 48 Remove this jumper to isolate the digital inputs from ground 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 53 CONTROL UNIT 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 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 49 DIP switche RS485 terminals J oe 21 22 23 24 25 26 32 3 thernet 12 13 14 15 16 17 18 19 CA conduit 123 4 5 67 8 9 10 11 O O0 1 0 terminal see larger picture Grounding bar Figure 49 5 2 1 PREPARE FOR USE THROUGH ETHERNET 5 2 1 1 ETHERNET CABLE DATA ene lelde connector Max length of the connector 40mm Cable type CAT5e STP Cable length Max 100m Table 27 Ethernet cable data Connect the Ethernet cable see specification on page 53 to its terminal and run 1 the cable through the conduit as shown in Figure 50 NOTE Pay attention that the length of the connector does not exceed 40 mm See Figure 50 Tel 358 0 201 2121 e Fax 358 0 201 212 205 CONTROL UNIT VACON 54 max 40 mm Ethernet cable Figure 50 Protection class IP21 Cut free the opening on the AC drive
47. s 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 Mains motor Terminal cable size Fuse and ground Frame Type class T Sei y Main terminal Earth terminal 00752 0 00724 720 100 AWG2 AWG9 AWG2 0 AWG9 AWG2 0 00882 188 0 MR7 00874 870 110 AWG1 AWG9 AWG2 0 AWG9 AWG2 0 0105 2 0105 4 105 0 150 AWG1 0 AWG9 AWG2 0 AWG9 AWG2 0 0140 2 0140 4 140 0 200 AWG3 0 AWG1 350 kcmil AWG1 350 kcmil 0170 2 8 01704 170 0 225 250 kcmil AWG1 350 kcmil AWG1 350 kcmil 0205 2 0205 4 205 0 250 350 kcmil AWG1 350 kcmil AWG1 350 kcmil 02612 02614 261 0 350 2 250 kcmil AWG1 350 kcmil AWG1 350 kcmil a 0310 2 0310 4 310 0 400 2 350 kcmil AWG1 350 kcmil AWG1 350 kcmil Table 18 Cable and fuse sizes for Vacon 100 MR7 to MR9 The cable dimensioning is based on the criteria of the Underwriters Laboratories UL508C Cables must be PVC isolated Max ambient temperature 30 max temperature of cable surface 70 Use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in par
48. sconnection of the supply in case of discontinuity of the protective earthing conductor See chapter 4 or provision of an additional terminal for a second protective earthing conductor of the same cross sectional area as the original protective earthing conductor Minimum cross sectional area of the cor Cross sectional area of phase conductors 6 2 responding protective earthing conductor mm 2 mm 5 lt 16 5 16 gt gt 35 16 35 lt S S 2 The values above are valid only if the protective earthing conductor is made of the same metal as the phase conductors If this is not so the cross sectional area 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 Table 2 Protective earthing conductor cross section 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 if mechanical protection is provided 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 cond
49. tails and make a grounding connection with a clamp as shown in Figure 26 3 Make the pigtails just long enough to reach and be fixed to the terminal not longer Figure 26 Tightening torques of cable terminals Tightening torque Tightening torque Nm tb in Nm tb in i Power and motor EMC grounding terminals clamps 0003 2 0012 2 MR4 0003 400124 0 5 0 6 4 5 5 3 1 5 13 3 2 0 17 7 0018 2 00312 5 0016 4 0031 4 1 2 1 5 10 6 13 3 1 5 13 3 2 0 17 7 0048 2 00622 0038 4 0061 4 0075 2 0105 2 MR7 0072 40105 4 8 19 70 8 132 8 1 5 13 3 8 15 70 8 132 8 Cable clamping e g Ouneva Pressure Terminal Connector Grounding terminals MR6 0 88 5 1 5 13 3 2 0 17 7 Table 20 Tightening torques of terminals 24 hour support 358 0 201 212 575 Email vaconfavacon com VACON 37 POWER CABLING 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 EN61800 5 1 See Figure 27 and chapter Earthing and earth fault protection Use an M5 size screw and tighten it to 2 0 Nm 17 7 lb in Figure 27 Additional protective earthing connector 9 Re mount the cable protection plate Figure 28 and the cover of the AC drive
50. 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 4 Check that the shields of the shielded cables are connected to protective earth marked with Check the tightening torques of all terminals Check that the wires do not touch the electrical components of the drive Check that the common inputs of digital input groups are connected to 24V or ground of the 1 0 terminal the external supply Check the quality and quantity of cooling air chapter 3 2 and Table 13 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 potenti
51. the sealing plate for MR see Figure 33 1 3 Re attach then the cable fitting plate and then the cable cover Figure 42 14 MR only Now re mount the main cover unless you want to make the control connections first Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 46 Figure 43 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 Connect the protective conductor using a cable shoe and 8 screw included in the Accessories bag on either of the screw connectors as advised in Figure 44 Figure 44 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 47 POWER CABLING 4 4 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 Tel 358 0 201 2121 e Fax 358 0 201 21
52. 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 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 Figure 23 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 35 POWER CABLING 6 Detach the cable clamps and the grounding clamps Figure 24 and place the cable entry plate with the cables in the groove on the AC drive frame Figure 25 A 4 16 i 2 2 Nm S Figure 24 Figure 25 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 36 Connect the stripped cables see Figure 19 and Table 19 as shown in Figure 26 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 brake and motor cables into 7 their respective terminals 2 e Form the rest of the cable shield of all three cables into pig
53. tive terminals 1 0 e Form the rest of the cable shield of all cables into pigtails and make grounding connection as shown in Figure 39 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 40 below DC R Figure 39 Tel 358 0 201 2121 Fax 358 0 201 212 205 POWER CABLING VACON 44 Connector Cable lug Cable lug Figure 40 Placing two cable lugs on top of each other Tightening torques of cable terminals Tightening torque Tightening torque Nm lb in Nm lb in Power and motor EMC grounding terminals clamps 0140 2 0205 2 7 MR8 0205 4 20 40 177 354 1 5 13 3 20 177 0261 2 03102 MRI 09614 0310 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 Table 22 Tightening torques of terminals 1 1 Expose the shield of all three cables in order to make a 360 degree connection with the cable clamp Figure 41 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 45 POWER CABLING 1 2 Remount now first the EMC shield plate see Figure 34 and then
54. uctor NOTE Due to the high capacitive currents present in the AC drive fault current protective switches may not function properly 24 hour support 358 0 40 837 1150 e Email vaconfavacon com VACON 9 7 Do not perform any voltage withstand tests any part of Vacon 100 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 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 Scc greater than or equal to 120 Tel 358 0 201 2121 e Fax 358 0 201 212 205 RECEIPT OF DELIVERY VACON 8 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 Vacon type code AC DRIVE Vacon order number Type VACON0100 3L 0031 4 HVAC Batch ID Serial number S N V0789012245 345678901245 20 100315 02 5 1 1 12345678 2234567 89
55. urrent 1 i 3 AM Analogue input com Pese EE mon current Vcl lic aud 4 12 Analogue input Remote reference voltage or current 4 20mA 0 10V Analogue input com Ce ee 5 Al2 mon current 6 24Vout 24 aux voltage 1 7 GND I O ground 1 4 Tae 8 Digital input 1 9 02 Digital input 2 10 Digital input 3 11 CM Common for 011 016 12 24Vout 24V aux voltage 1 hate 13 GND I O ground 1 15 DI4 Digital input 4 aa ae 15 DI5 Digital input 5 16 016 Digital input 6 1 17 Common for 011 016 1 l 18 1 Analogue signal output E 19 AO GND Analogue output com i mon i 30 424 Vin 24V auxiliary input i voltage X A RS485 Serial bus negative v B RS485 Serial bus positive Digital inputs can be isolated from ground see chapter 5 1 2 2 Table 24 Control I O terminal signals on basic I O board and connection example 24 hour support 358 0 201 212 575 e Email vaconfavacon com VACON 51 CONTROL UNIT From Basic 1 0 board From term From term 6 12 13 Relay board 1 21 RO1 1 NC LM Relay output 1 RUN ere ER 22 RO1 2 CM Q gt 23 RO1 3 NO 25 RO2 1 NC Relay output 2 25 RO2 2 CM 26 RO2 3 NO 32 RO3 1 CM Relay output 3
56. vent welding on the relay contacts Refer to standard EN 60204 1 section 7 2 9 Table 33 Technical information on Relay board 1 Relay board with two change over contact SPDT relays and a PTC Relay 2 thermistor input 5 5 mm isolation between channels Terminal Signal Technical information 21 Switching capacity 24VDC 8A 22 Rel 1 250VAC 8A ers put 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 29 Thermistor input Rtrip 4 7 Measuring voltage 3 5V f 230VAC 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 Table 34 Technical information on Relay board 2 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 Manual authoring documentation dvacon com Vacon Plc Runsorintie 7 65380 Vaasa Finland Subject t

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