The motor terminals (U, V, W), the brake resistor terminals and the DC-termi- nals are live when Vacon 100 X Drive is connected to mains, even if the motor is not running.
• 3 Safety Warnings Vacon 100 X AC drive is meant for fixed installations (on the motor or on the wall) only. Only Safety Extra Low Voltage (SELV) circuits are allowed to be connected to the control unit. This hint aims to protect both the drive and the client-application.
Earthing and earth fault protection CAUTION! The Vacon 100 X AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with Since the touch current exceeds 3.5 mA AC, according to EN61800-5-1, the drive shall have a fixed connection and provision of an additional terminal for a second protective earthing con- ductor of the same cross-sectional area as the original protective earthing conductor.
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• 5 Safety The cross-sectional area of every protective earthing conductor which does not form a part of the supply cable or cable enclosure shall, in any case, be not less than • 2.5 mm if mechanical protection is provided or •...
IEC 61800-5-1) and the GND terminals are referred to PE. This is important when you need to connect other circuits to the drive and test the complete assembly. Should you have any doubt or question, please contact your local Vacon distributor. CONTROL UNIT R01 __ S or M...
• 7 Safety Compatibility with RCDs This product can cause a d.c. current in the protective earthing conductor. Where a residual current-operated protective (RCD) or monitoring (RCM) device is used for protection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed on the supply side of this product.
3). Electro-magnetic compatibility (EMC) The Vacon 100 X complies with IEC 61000-3-12, provided that the short circuit power (SSC) is greater than or equal to 120 at the interface point between the user's supply and the public sys- tem.
Receipt of delivery 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:...
31.5 Table 2. Frame weights. Vacon 100 X drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transport damages are to be found on the product and that the delivery is complete.
• 15 Receipt of delivery 2.3.2 ‘Product modified’ sticker Product modified In the small plastic bag included in the delivery you will find a silver sticker. The purpose of the sticker is to notify the service personnel about the modifications made in the AC drive.
• 16 OUNTING Vacon 100 X is the ideal solution for a decentralised installation. It is conceived to be mounted on a wall or directly on the motor, saving space and reducing the cabling complexity. In both of the cases, it must be ensured that the mounting plane is even.
Mounting Introduction of modules The mechanical concept of Vacon 100 X drive is based on two segregated parts, power and con- trol, connected to each other by pluggable terminals. The power unit, called powerhead, in- cludes all the power electronics such as the EMC-filter, IGBTs, capacitors, choke or power boards while the control board and the control terminals are located in the terminal box.
Mounting vacon • 20 Mounting The drive consists of two main elements: 1. The terminal box that includes the power terminals and control board with the control ter- minals and 2. The powerhead containing all the power electronics. To install the drive, both parts need to be separated. The terminal box must be fixed first and all cabling done.
The drive can also be mounted on a motor (on top or on any side of the motor). The drive is equipped with a cooling system independent of the motor. Motor-mounting requires special adapting components. Contact your local Vacon distributor for additional information. 3.3.3...
Cooling air required Type Table 6. Required cooling air. Should you need further details on the cooling system of the Vacon 100 X, please contact your local Vacon distributor. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
Power cabling vacon • 24 OWER CABLING The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals marked with U, V and W. See principal connection diagram in Figure 16. See also Table 7 for the cable recommendations for different EMC levels.
• 25 Power cabling PE conductors Shield Shield PE conductor Figure 17. 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.
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 & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.
Power cabling 4.3.2 Brake resistor cables Vacon 100 X AC drives are equipped with terminals for an optional external brake resistor. These terminals are marked with DC+/R+ and R-. See Table 20 and Table 21 for the resistor ratings. 4.3.3 Control cables For information on control cables see chapter Control unit.
Power cabling vacon • 28 Cable installation • Before starting, check that none of the components of the AC drive is live. Read care- fully the warnings in chapter 1. • Place the motor cables sufficiently far from other cables •...
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• 29 Power cabling Frame as short as possible Table 9. Cables stripping lengths [mm]. • Remove the cable entry plate. The cable entry system is a combination of a cable entry plate (see the figure below) and cable glands. In the cable entry plate there are several openings available for the cables with ISO metric thread.
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Power cabling vacon • 30 Figure 21.Cable entry plate, MM6. • Cable glands must be constructed from plastic materials. They are used for sealing cables passing through gland plates to ensure the characteris- tics of the enclosure which the cable enters can be maintained adequately.
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• 31 Power cabling • Place the cable entry plate with the cables in the groove on the AC drive frame. Connect the stripped cables: • Expose the shield of all two cables in order to make a 360-degree connec- tion with the cable clamp (reverse the shield over the plastic cover of the cable and fix all together).
Control unit vacon • 32 ONTROL UNIT Remove the powerhead of the drive to reveal the terminal box with the control terminals. The control unit of the AC drive consists of the control board and additional boards (option boards) connected to the slot connectors of the control board. The locations of boards, termi- nals and switches are presented in Figure 23 below.
• 33 Control unit cally ordered. On the next pages you will find the arrangement of the control I/O and the relay terminals, the general wiring diagram and the control signal descriptions. The control board can be powered externally (+24VDC, max. 1000mA, ±10%) by connecting the external power source to terminal #30, see chapter 5.1.2.
Control unit vacon • 34 5.1.2 Standard I/O terminals Standard I/Os Relays The terminals of the and the are described below. For more information on the connections, see chapter 7. The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches.
• 35 Control unit 5.1.3 Relay and thermistor input terminals Table 14. I/O terminal signals for relay and thermistor terminals and connection example. From Relays and thermistor standard I/O From term. From term. Terminal Signal Relay output 1 RO1/1...
5.1.5 Selection of terminal functions with dip switches dip switches The Vacon 100 X drive embodies five so-called that allow for three functional se- lections each. The shadowed terminals in Table 13 can be functionally modified with the dip switches. The switches have three positions: C, 0 and V. The switch in the position “C” means that the input or the output has been set in current mode.
• 37 Control unit 5.1.7 Bus termination of the RS485 connection This dip switch is related to the RS485 connection. It’s used for bus termination. The bus ter- mination must be set to the first and to the last device on the network. This switch in position “0”...
Control unit vacon • 38 I/O cabling and Fieldbus connection The AC drive can be connected to fieldbus either through RS485 or Ethernet. The connection for RS485 is on the standard I/O terminals (terminals A and B) and the connection for Ethernet is left to the control terminals.
Strip the cable at a maximum length of 15 mm. Do not strip the aluminum cable shield! Then connect the cable to its appropriate terminals on Vacon 100 X AC drive standard terminal block, terminals A and B (A = negative, B = positive). See Figure 28.
Control unit vacon • 40 The bus termination must be set for the first and the last device of the fieldbus line. See picture below and step 4. We recommend that the first device on the bus and, thus, terminated, was the Master device.
Enabling the functions of the requires that an optional battery is in- stalled in the Vacon 100 X drive. The place for the battery can be found under the control box cover as shown in Figure 29. Real Time Clock (RTC)
The motor terminals U, V, W and the brake resistor terminals R-/R+ are live when Vacon 100 X drive is connected to mains, even if the motor is not running. The control I/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 X drive is disconnected from mains.
• 43 Commissioning Commissioning of the drive Read carefully the safety instructions in Chapter 1 and above and follow them. After the installation: Check that both the frequency converter and the motor are grounded. Check that the mains and motor cables comply with the requirements given in chapter 5.
Commissioning vacon • 44 Changing EMC protection class If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-pro- tected according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC-level T.
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NOTE! After having performed the change write on the sticker included in the Vacon 100 X delivery (see below) and note the date. Unless already done, attach the sticker close to the name plate of the AC drive. Product modified...
Commissioning vacon • 46 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.
• 47 Commissioning 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.
15.0 20.0 Table 18. Power ratings of Vacon 100 X, supply voltage 3AC 208-240V. NOTE: The rated currents in given ambient temperatures (in Table 18) are achieved only when the switching frequency is equal to or less than the factory default.
30.0 40.0 Table 19. Power ratings of Vacon 100 X, supply voltage 3AC 380-480V. NOTE: The rated currents in given ambient temperatures (in Table 19) are achieved only when the switching frequency is equal to or less than the factory default.
Technical data vacon • 50 7.1.3 Definitions of overloadability Overloadability= Following continuous operation at rated output current I , the converter supplies 150% * I for 1 min, followed by a period of at least 9 min at I or below.
Technical data vacon • 52 Vacon 100 X - technical data 3AC 208…240V Input voltage U 3AC 380...480V Input voltage -15%...+10% continuously tolerance Input frequency 50/60 Hz Protection class Mains connection Input frequency 45...66 Hz tolerance Connection to mains Once per minute or less...
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• 53 Technical data Standard: Serial communication (RS485/Mod- Fieldbus bus); Ethernet Communication Optional: CanOpen; Profibus DP, DeviceNet interface Drive status indicators (LED) on top side Status indicators (POWER, RUN, FAULT, READY) Ambient operating -10°C …+40°C temperature Extended temperature up to 50°C with current derating (see chapter range 1.6)
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Motor stall protection Motor underload pro- tection Short-circuit protec- tion of +24V and +10V reference voltages Thermal motor protec- Yes (by PTC) tion Table 22. Vacon 100 X technical data. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
• 55 Technical data 7.3.1 Technical information on control connections Standard I/O Terminal Signal Technical information Reference output +10V, +3%; Maximum current 10 mA Analogue input channel 1 0-20 mA (Ri =250 0-10 V (Ri=200k Analogue input, Resolution 0.1%, accuracy ±1%...
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Technical data vacon • 56 Standard I/O Terminal Signal Technical information Can be used with an external power supply (with a current 24V auxiliary input limiter or fuse protected) to supply the control unit and voltage fieldbus for backup purposes.
Mains switch The purpose of the is to disconnect the Vacon 100 X from the mains when, for example, service actions are needed. The mains switch is available as option and it can be integrated in the drive. The switch can be mounted on either side of the drive. See Figure 35.
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• 59 Options • Remove the cable entry plate from the bottom side of the terminal box by loos- ing the six screws. Cables pass through this inlet hole. Figure 37. Cable entry plate from the bottom side of the drive.
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Options vacon • 60 • Connect the supply cable to the Mains switch passing through the cable entry plate of the bottom side (use the cable gland for sealing the cable to the gland plate) and then through the terminal box as shown in the figure below.
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• 61 Options Figure 40. Mains switch, cable entry and cables connected. • Mount the powerhead on the terminal box with its screws: the installation pro- cess has been completed. See Figure 41. Figure 41. Mount the powerhead on the terminal box.
• 62 Control Keypad The control keypad is the interface between the Vacon 100 X frequency converter and the user. With the control keypad it is possible to control the speed of a motor, to supervise the state of the equip- ment and to set the frequency converter's parameters.
• 63 Options 8.2.2 Installation • Remove the HMI cap from the drive as shown in the Figure 43. Figure 43. Disconnection of the HMI cap from the drive. • Install the keypad holder with a screw as shown in the Figure 44. The metal sheets of the keypad holder have to be mounted under the fan holder as shown in the following figures.
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Options vacon • 64 • Connect the keypad to the drive and plug the cable on the HMI connector as shown in the Figure 45 and in the Figure 46. Figure 45. Mounting of the keypad. Figure 46. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector to the enclosure of the drive.
• 65 Options 8.2.3 Wall-mounting The keypad can be mounted on the wall in a convinient location by using the same keypad holder and three screws provided with the keypad option kit. Fix the keypad holder with three screws to the wall.
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Options vacon • 66 • Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall. Figure 48. Keypad connected to the drive. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
• 67 Options 8.2.4 Graphical and Text keypad There are two keypad types you can choose for your user interface: keypad with graphical display and keypad with text segment display (text keypad). The button section of the keypad is identical for both keypad types.
Options vacon • 68 8.2.5 Vacon keypad with graphical display The graphical keypad features an LCD display and 9 buttons. 8.2.5.1 Keypad display The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions.
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• 69 Options STOP READY STOP READY STOP READY Start/Stop Setup Rem Control Place Rem Control Place ID:172 M3.2.1 M3.2.1 M3.2.1 Rem Control Place Edit I/O Control FieldbusCTRL KeypadStopButton Help I/O Control BACK RESET Start Function...
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Options vacon • 70 STOP READY Keypad STOP Ready Keypad STOP READY Keypad Choose action Local/Remote Main Menu ID:1805 ID:211 Monitor Change direction ( 7 ) Local Control page Parameters Local/Remote Remote Remote ( 15 ) Diagnostics...
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• 71 Options Copying parameters NOTE: This feature is available with graphical keypad only. The parameter copy function can be used to copy parameters from one drive to another. The parameters are first saved to the keypad, then the keypad is detached and connected to another drive.
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Options vacon • 72 Help texts The graphical keypad features instant help and information displays for various items. All parameters offer an instant help display. Select Help and press the OK button. Text information is also available for faults, alarms and the startup wizard.
• 73 Options 8.2.6 Vacon keypad with text segment display Keypad with text segment display You can also choose a (Text keypad) for your user interface. It has mainly the same functionalities as the keypad with graphical display although some of these are somewhat limited.
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Options vacon • 74 8.2.6.3 Using the keypad Editing values Change value of a parameter following the procedure below: 1. Locate the parameter. 2. Enter the Edit mode by pressing OK. 3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the arrow buttons left/right if the value is numerical and change then the value with the arrow but- tons up/down.
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• 75 Options 2. Using the arrow buttons, select Local/Remote and confirm with the OK button. 3. On the next display, select Local or Remote and again confirm with the OK button. Loc/Rem 4. The display will return to the same location as it was when the button was pushed.
Options vacon • 76 8.2.7 Fault Tracing When an unusual operating condition is detected by the AC drive control diagnostics, the drive ini- tiates a notification visible, for example, on the keypad. The keypad will show the code, the name and a short description of the fault or alarm.
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• 77 Options 8.2.7.1 Fault History In menu M4.3 Fault history you find the maximum number of 40 occurred faults. On each fault in the memory you will also find additional information, see below. STOP READY STOP READY STOP READY ...
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Options vacon • 78 8.2.7.2 Fault codes Fault Fault Fault name Possible cause Remedy code Overcurrent AC drive has detected too high a cur- Check loading. (hardware fault) rent (>4*I ) in the motor cable: Check motor. Check cables and connections.
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• 79 Options Fault Fault Fault name Possible cause Remedy code Communication between control board and power unit has failed. Communication between control board and power unit has interference, but it is still working. Reset the fault and restart.
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Options vacon • 80 Fault Fault Fault name Possible cause Remedy code Current measurement has detected Output phase that there is no current in one motor Check motor cable and motor. supervision phase. Brake chopper Check brake resistor and supervision No brake resistor installed.
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• 81 Options Fault Fault Fault name Possible cause Remedy code Option board added. The option board Device is ready for use. Old Device changed was previously inserted in the same parameter settings will be (same type) slot. The board’s parameter settings used.
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Options vacon • 82 Fault Fault Fault name Possible cause Remedy code Non-existing ID number is used for Check parameters in Fieldbus mapping values to Fieldbus Process 1310 Data Mapping menu. Data Out. The value being mapped may Fieldbus map- Not possible to convert one or more be of undefined type.
ORQUE This chapter describes the Safe Torque Off (STO) function which is a functional safety feature pres- ent into Vacon 100 X drive products as standard. General description The STO function brings the motor in no-torque-state as defined by 4.2.2.2 of the IEC 61800-5-2: “Power that can cause rotation (or motion in the case of a linear motor) is not applied to the...
• 85 Safe Torque Off Standards The STO function has been designed for being used in accordance with the following standards: Standards IEC 61508, Parts 1-7 EN 61800-5-2 EN 62061 ISO 13849-1 EN 954-1 IEC 60204-1 Table 26. Safety Standards.
The STO functionality, such as the technical principles and data (wiring examples and commission- ing) will be described in this chapter. In Vacon 100 X, the STO function is realized by preventing the propagation of the control signals to the inverter circuit.
The reaction time of the STO function is the amount of time which passes from the moment in which the STO is demanded till the system is in the Safe State. For Vacon 100 X, the reaction time is 20 ms minimum.
Safe Torque Off vacon • 88 Connections To make the STO function available and ready to be used, both the STO jumpers have to be removed. They are located in front of the STO inputs to mechanically prevent the insertion of the STO connec- tor.
• 89 Safe Torque Off Safety Capability Cat. 4 / PL e / SIL 3 9.5.1 For this safety capability, an external safety device must be installed. This must be used to dinami- cally activate the STO inputs and to monitor the STO output feedback.
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Safe Torque Off vacon • 90 The picture below shows an example of connection for the STO function. The external device has to be connected with 6 wires to the drive. EXTERNAL DEVICE POWER UNIT DC+/R+ Reinforced Figure 67. STO example with automatic monitoring of the feedback and both STO inputs used.
• 91 Safe Torque Off Safety Capability Cat. 3 / PL e / SIL 3 9.5.2 The safety capability is reduced to Cat. 3 / PL e / SIL 3 if the STO inputs are statically used(which means they are forced to commute together).
Safe Torque Off vacon • 92 Safety Capability Cat. 1 / PL c / SIL 1 9.5.4 Without any automatic monitoring of STO output feedback, the safety capability is reduced to Cat. 1 / PL c / SIL 1. The STO inputs (which can be connected in parallel) must be supplied by a safety push button or a safety relay.
• 93 Safe Torque Off Commissioning 9.6.1 General wiring instructions Protect the STO cabling with a shielding or an enclosure to exclude external fault. Wires ferrules are highly recommended for all STO signals (inputs and feedback). The wiring should be done according to the general wiring instructions for the specific product. A shielded cable is required.
Safe Torque Off vacon • 94 Parameters and fault tracing There are no parameters for the STO function itself. Before testing the STO function, make sure that the checklist (Table 33) is inspected and completed. When STO function awakes, the drive always generates a fault (“F30”) and the motor stops by coasting.
The following table shows faults that may be generated by the software that monitors the hardware related to the STO safety function. If you detect any failure in safety functions, including STO, contact your local Vacon supplier. Fault Code Fault...
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