Vacon 20 x Installation & Maintenance
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Vacon 20 x Installation & Maintenance

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Summary of Contents for Vacon 20 x

  • Page 1 20 x ® ac drives Installation, Technical and Maintenance Manual...

  • Page 3: Table Of Contents

    • 1 NDEX Document code (Original Instructions): DPD00992H Order code: DOC-INS06663+DLUK Rev. H Revision release date: 9.12.16 Safety........................4 Signs............................4 Units ............................4 Danger..........................5 Warnings ..........................6 Grounding and earth fault protection .................7 Insulation system........................9 Compatibility with RCDs ....................10 Extended temperature range ...................11 Declaration of conformity ....................12...
  • Page 4 7.1.2 Mains voltage 1AC 208-240V.....................64 7.1.3 Mains voltage 3AC 380-480V.....................65 7.1.4 Definitions of overloadability ....................65 Brake resistor ratings.......................66 VACON® 20 X - technical data..................67 7.3.1 Technical information on control connections..............70 Options......................72 VACON® keypad with seven-segment display..............72 8.1.1 Mounting onto the drive ....................72 8.1.2 Text Keypad - buttons .......................75...
  • Page 5 • 3 9.6.2 Checklist for commissioning ..................111 Parameters and fault tracing ..................112 Maintenance and diagnostics ..................113 10. Solar pump application ................. 114 10.1 Danger..........................114 10.2 DC Fuse selection ......................114 10.3 Manufacturers of gPV fuses ...................115 10.4 Parallel diode selection ....................115 10.5 Photovoltaic system dimensioning .................116...

  • Page 6: Safety

    Please read the warning information carefully. ® VACON 20 X is a drive designed to control asynchronous AC motors and permanent magnet mo- tors. The product is intended to be installed in a restricted access location and for a general pur- pose use.

  • Page 7: Danger

    (if no keypad is attached, see the indicators on the cover). Wait an ® additional 30 seconds before starting any work on the connections of VACON X Drive. After expiration of this time, use measuring equipment to absolutely ensure that no voltage is present.

  • Page 8: Warnings

    Before performing any measurement on the motor or the motor cable, disconnect the motor cable from the AC drive. ® Do not perform any voltage withstand test on any part of VACON 20 X. The tests shall be performed according to a specific procedure. Ignoring this procedure may damage the product.

  • Page 9: Grounding And Earth Fault Protection

    CAUTION! ® The VACON 20 X AC drive must always be grounded with a grounding conductor connected to the grounding terminal marked with Since the touch current exceeds 3.5 mA AC (for the three-phase version), according to EN61800-5- 1, the drive must have a fixed connection and provision of an additional terminal for a second pro- tective grounding conductor of the same cross-sectional area as the original protective grounding conductor.
  • Page 10 ® In VACON 20 X, the phase conductor and the corresponding protective grounding conductor can be of the same cross-sectional area, provided they are made of the same metal (because the cross- sectional area of the phase conductor is less than 16 mm...

  • Page 11: Insulation System

    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 assem- ® bly. Should you have any doubts or questions, please contact your local VACON distributor. CONTROL UNIT...

  • Page 12: Compatibility With Rcds

    • 10 Safety CONTROL UNIT R01 __ (**) DVC A or Mains R02 __ 10Vref __ Analog Inputs __ Digital Inputs__ Analog Output __ DVC A Keypad 24V __ RS485 __ POWER UNIT Mains Reinforced Figure 4. Insulation system (single-phase version).

  • Page 13: Extended Temperature Range

    ® VACON 20 X has an integrated cooling system, independent from the motor fan. Under maximum operating conditions, the ambient temperature cannot exceed 40 °C. See Table 28 for the output rated current. Higher temperatures are allowed only with derating of the output current. With de- rating the unit can operate up to 50°C.

  • Page 14: Declaration Of Conformity

    Danfoss A/S Vacon Ltd declares under our sole responsibility that the Product(s) Vacon 20 CP and Vacon 20 X AC drives Type(s) Vacon 0020 1L 0004 2…0007 2 CP Vacon 0020 1L 0004 2…0007 2 X Vacon 0020 3L 0004 2…0017 2 CP Vacon 0020 3L 0004 2…0017 2 X...
  • Page 15 Safety vacon • 13 Figure 7. STO certificate. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 16 • 14 Safety NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from http://drives.danfoss.com/knowledge-center/technical-documentation/. REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site http://drives.danfoss.com/knowledge-center/technical-documentation/...

  • Page 17: Receipt Of Delivery

    Receipt of delivery vacon • 15 ECEIPT 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 your supplier immedi- ately.

  • Page 18: Type Designation Code

    VACON +xxxx +yyyy This segment is common for all products. Additional codes. 0020 Examples of additional codes: Product range: +HMTX 0020 = Vacon 20 Text keypad IP66 +QDSS Input/Function: Integrated disconnect switch = Three-phase input +QDSH = Single-phase input Simple operator panel 0009 Drive rating in ampere;...

  • Page 19: Order Codes

    Receipt of delivery vacon • 17 Order codes ® The order codes for VACON 20 X drive family are shown in the following table: ® Table 3. Order codes of VACON 20 X. Enclosure size Order code Description Supply voltage 3AC 208-240V VACON0020-3L-0004-2-X 0.75 kW - 1.0 HP drive...

  • Page 20: Unpacking And Lifting The Ac Drive

    ® VACON 20 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 trans- port damage are to be found on the product and that the delivery is complete.

  • Page 21: Product Modified' Sticker

    Receipt of delivery vacon • 19 2.4.1 ‘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 staff about the modifications made in the AC drive. At- tach the sticker on the side of the AC drive to avoid losing it.

  • Page 22: Mounting

    Both enclosure sizes can be mounted in any position. Fix the drive with four screws (or bolts, depending on the unit size). Dimensions 3.1.1 Enclosure MU2 and MU3 ® Figure 11. 20 X, MU2. VACON Dimensions W x H x D Enclosure size [mm] [in] 169.2 x 294.7 x153.8 6.66 x 11.60 x 6.06...
  • Page 23 Mounting vacon • 21 ® Figure 12. 20 X, MU3. VACON Dimensions W x H x D Enclosure size [mm] [in] 205.2 x 375.2 x 180.5 8.08 x 14.77 x 7.11 MU3 +HMTX 205.2 x 375.2 x 202.1 8.08 x 14.77 x 7.96 MU3 +QDSS 205.2 x 375.2 x 200.0...

  • Page 24: Cooling

    • 22 Mounting Cooling The AC drive produces heat in operation and is cooled down by air circulated by a fan. Enough free space must be left around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance may also require certain amount of free space.
  • Page 25 Mounting vacon • 23 Figure 14. Installation space when drives are mounted on top of each other. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 26: Power Cabling

    • 24 Power cabling OWER CABLING The mains cables are connected to terminals L1, L2 and L3 (or L and N) and the motor cables to terminals marked with U, V and W. See principal connection diagrams in Figure 15 and Figure 16.
  • Page 27 Power cabling vacon • 25 Use cables with heat resistance in accordance with the application requirements. The cables and the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can find on the rating plate.

  • Page 28: Circuit Breaker

    • 26 Power cabling Circuit breaker Disconnect the drive via an external circuit breaker. You have to provide a switching device between the supply and main connection terminals. When connecting the input terminals to the power supply using a circuit breaker, observe that this is of type B or type C and ensure it has a capacity of 1.5 to 2 times of the inverter’s rated current...

  • Page 29: Description Of The Terminals

    Power cabling vacon • 27 Description of the terminals ® The following pictures describe the power terminals and the typical connections in VACON drives. 4.3.1 MU2 three-phase version power connections AC power supply Single or Three phases Motor Figure 18. Power connections, MU2 three-phase version.

  • Page 30: Mu2 Single-Phase Version Power Connections

    11747_uk Figure 19. Power connections, MU2 single-phase version. ® Table 11. Description of VACON 20 X MU2 power terminals (single-phase version). Terminal Description These terminals are the input connections for the power supply. Single-phase 230 VAC voltage has to be connected to L and N terminals.

  • Page 31: Mu3 Power Connections

    Single or Three phases Motor Figure 20. Power connections, MU3. ® Table 12. Description of VACON 20 X power terminals. Terminal Description These terminals are the input connections for the power supply. 230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derat- ing of 50%).

  • Page 32: Cable Dimensioning And Selection

    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 also rec- ommends for high speed gS (IEC 60269-4) fuse ranges.

  • Page 33: Cable And Fuse Sizes, Enclosures Mu2 And Mu3, North America

    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 also rec- ommends for high speed J (UL & CSA) fuse ranges.

  • Page 34: Recommended Fuse Sizes For Group Installation

    ® VACON 20 X is approved for group installation by UL provided the fuse in the main branch circuit is a 60 A class T or J fuse (300V or 600V AC maximum according to the drive rating). It is possible to choose any combination of AC drives, but you have to pay attention that the total cur- rent does not open the fuses in normal operation.

  • Page 35: Brake Resistor Cables

    Brake resistor cables ® VACON 20 X AC drives (three-phase version) are equipped with terminals for an optional external brake resistor. For MU2, brake resistor wires with faston 6.3 mm have to be used. For MU3, a PCB terminal block with push-in spring-cage connector is provided. Stranded wires (max.

  • Page 36: Cable Installation

    • 34 Power cabling Cable installation • Before starting, check that none of the components of the AC drive is live. Read the warnings in chapter 1 carefully • Place the motor cables sufficiently far from other cables • Avoid placing the motor cables in long parallel lines with other cables.
  • Page 37 Power cabling vacon • 35 • Remove the plastic cover of the drive as shown in Figure 22. Figure 22. MU2 example: open cover. IEC installations: • The cable entries consists of several openings available for the cables with ISO metric thread.
  • Page 38 • 36 Power cabling Figure 23.Cable entries, MU2. Figure 24. Cable entries, MU3. • Cable glands must be made of plastic materials. They are used for sealing cables passing through cable entries to ensure the characteristics of the enclosure.
  • Page 39 Power cabling vacon • 37 Figure 25. Cable gland. Plastic cable glands are recommended. If metal cable glands are needed, all insulation system and protective grounding requirements have to be fulfilled in accordance with the national electrical regulations and IEC 61800-5-1.
  • Page 40 35.5 ® The VACON 20 X drive is IP66/Type 4X rated. To keep this rating, the use of a sealed conduit is required: if the approved conduit is not used, all warranty claims against wa- ter will be void. NPT adapter order information: M20 ->...
  • Page 41 Power cabling vacon • 39 Cables installation: • Pass the cables (supply cable, motor cable, brake cable and I/O cables) through the pipes and adapters (UL installations) or through the cable glands (IEC installations) and cable entries. • Detach the cable clamps and the grounding clamps.

  • Page 42: Wiring Way

    • 40 Power cabling Wiring way In the following picture an example of wire cabling is given: Input Line Motor output I/O terminals STO terminals Option board terminals Relays Figure 27. Wiring example with three-phase versions. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 43: Control Unit

    Control unit vacon • 41 ONTROL UNIT Opening the drives Figure 28. Open front cover of the drive: control unit MU2 (three-phase version). Figure 29. Open front cover of the drive: control unit MU2 (single-phase version). Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 44 • 42 Control unit Figure 30. Open front cover of the drive: control unit MU3. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 45: Control Units Mu2 And Mu3

    Control unit vacon • 43 Control units MU2 and MU3 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, terminals and switches are presented in Figure 31, Figure 32 and Figure 33.
  • Page 46 • 44 Control unit Figure 32. Locations of the components in control unit of MU2 (single-phase version). Figure 33. Location of the components in the control unit of MU3. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 47 Control unit vacon • 45 When delivered from the factory, the control unit of the AC drive contains the standard controlling interface - the control terminals of the control board and the relay board - unless otherwise spe- cifically ordered. In the following pages you will find the arrangement of the control I/O and the relay terminals, the general wiring diagram and the control signal descriptions.

  • Page 48: Control Unit Cabling

    • 46 Control unit Control unit cabling The principal terminal block placement is shown in Figure 34 below. The control board is equipped with 18 fixed control I/O terminals and the relay board with 5. Additionally, the terminals for the Safe Torque Off (STO) function (see chapter 9) can be seen in the picture below.

  • Page 49: Standard I/O Terminals

    Control unit vacon • 47 5.3.2 Standard I/O terminals The terminals of the Standard I/O and the Relays are described below. For more information on con- nections, see chapter 7.3.1. The terminals shown on shadowed background are assigned for signals with optional functions se- lectable with DIP switches.

  • Page 50: Relay Terminals

    • 48 Control unit 5.3.3 Relay terminals Table 22. I/O terminal signals for relays and connection example. Relays terminals Terminal Signal From Relay output 1 RO1/2 standard I/O board RO1/3 From term. From term. Relay output 2 RO2/1 RO2/2 RO2/3 5.3.4...

  • Page 51: Description Of Additional Echo Connectors

    Control unit vacon • 49 5.3.5 Description of additional echo connectors In this paragraph you will find the description of the additional echo connector for the I/O terminals. Figure 35. The I/O remote echo connector mounted on the control board.
  • Page 52 Control unit To connect I/Os to the control unit through echo terminals this connector has to be used. In the fol- ® lowing table, the correspondence between the pins of this connector and the VACON 20 X termi- nals is shown.

  • Page 53: Led Handling

    Led handling ® As VACON 20 X is often without the keypad, on the plastic cover of the drive there are 4 status LEDs. See the picture below. Figure 37. LED position on the MU2 cover. Led “PWR” (orange led) means the drive is supplied by mains.

  • Page 54: Selection Of Terminal Functions With Dip Switches

    If the ® VACON 20 X is the last device on the net, this switch must be set to “0” position. The default posi- tion for SW4 is “0”. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 55: Fieldbus Connection

    Control unit vacon • 53 Fieldbus connection Modbus is a communication protocol developed by Modicon systems. In other words, it is a way of sending information between electronic devices. The device requesting the information is called the Modbus Master and the devices supplying information are Modbus Slaves. In a standard Modbus network, there is one Master and up to 247 Slaves, each with a unique Slave Address from 1 to 247.

  • Page 56: Modbus Rtu Protocol

    1 to 247 ® VACON 20 X drive is equipped with Modbus support as standard. The AC drive can be connected to fieldbus through RS485. The connection for RS485 is on the standard I/O (terminals A and B). See Figure 40.

  • Page 57: Preparation For Use Through Rs485

    RS485 cable to the enclosure of the AC drive. ® If VACON 20 X drive is the last device on the bus, the bus termination must be set. Locate the switches to the right of the control terminals (see Figure 38) and turn the SW4 switch to position “0”.

  • Page 58: Commissioning

    The motor terminals U, V, W and the brake resistor terminals are live when ® VACON 20 X drive is connected to the mains, even if the motor is not running. The control I/O-terminals are isolated from the mains potential. However, the relay outputs may have a dangerous control voltage present even when ®...

  • Page 59: Commissioning Of The Drive

    Commissioning vacon • 57 Commissioning of the drive Read carefully the safety instructions in Chapter 1 and above and follow them. After the installation: Check that both the AC drive and the motor are grounded. Check that the mains and motor cables comply with the requirements given in chapter 4.1.1.

  • Page 60: Changing Emc Protection Class

    • 58 Commissioning Changing EMC protection class If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC-level T (C4).
  • Page 61 Commissioning vacon • 59 Remove the EMC plate from the control unit. Then lift the plate with pliers to dis- connect the EMC plate from the ground. See Figure 42. Then reconnect the EMC plate to the unit. Figure 42. Changing of the EMC class in MU2 control unit.

  • Page 62: Changing Emc Protection Class - Mu2 Single-Phase Version

    • 60 Commissioning 6.2.2 Changing EMC protection class - MU2 single-phase version Remove the EMC screw as shown in the Figure 43. Figure 43. Changing the EMC class in the MU2 (single-phase version). Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 63: Changing Emc Protection Class - Mu3

    NOTE! After having performed the change write ‘EMC level modified’ on the sticker ® included in the VACON 20 X delivery (see below) and note the date. Unless al- ready done, attach the sticker close to the name plate of the AC drive. Product modified...

  • Page 64: Running The Motor

    • 62 Commissioning 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.

  • Page 65: Maintenance

    Commissioning vacon • 63 Maintenance In normal conditions, the AC drive is maintenance-free. However, regular maintenance is recom- mended to ensure trouble-free operation and longevity of the drive. We recommend the table below is followed for maintenance intervals. Table 26.

  • Page 66: Technical Data

    7.1.2 Mains voltage 1AC 208-240V ® Table 28. Power ratings of 20 X, supply voltage 1AC 208-240V. VACON Mains Voltage 1AC 208-240V, 50/60 Hz Motor shaft power Loadability Input...

  • Page 67: Mains Voltage 3Ac 380-480V

    Technical data vacon • 65 7.1.3 Mains voltage 3AC 380-480V ® Table 29. Power ratings of 20 X, supply voltage 380-480V. VACON Mains Voltage 3AC 380-480V, 50/60 Hz Motor shaft power Loadability Input 400V 480V AC drive current type Rated continuous...

  • Page 68: Brake Resistor Ratings

    Brake chopper is available only in three-phase ver- sion. ® Recommended minimum brake resistor values for VACON 20 X AC drives: Table 30. Brake resistor ratings, 208-240V. Mains Voltage 3AC 208-240 V, 50/60 Hz...

  • Page 69: Vacon® 20 X - Technical Data

    Technical data vacon • 67 ® VACON 20 X - technical data ® Table 32. VACON 20 X technical data. 3AC 208…240V Input voltage U 1AC 208...240V 3AC 380...480V Input voltage tolerance -15%…+10% continuously Input frequency 50/60 Hz Input frequency toler- 45…66 Hz...
  • Page 70 • 68 Technical data ® Table 32. VACON 20 X technical data. Standard: Serial communication (RS485/ Modbus); Fieldbus Optional: CANopen; Profibus DP, Lonworks, Communication DeviceNet, Profinet IO, Ethernet IP, Modbus interface TCP, EtherCAT, AS-interface Drive status indicators (LED) on top side...
  • Page 71 Technical data vacon • 69 ® Table 32. VACON 20 X technical data. Functional Safety TÜV - Tested Electrical Safety TÜV - Tested Approvals TÜV - Tested USA, Canada cULus approval, file number E171278 Korea KC mark Declaration of RMA Declaration of Conformity...

  • Page 72: Technical Information On Control Connections

    • 70 Technical data 7.3.1 Technical information on control connections Table 33. Technical information on standard I/O terminals. Standard I/O Terminal Signal Technical information RS485 Differential receiver/transmitter Set bus termination with dip switches (see Chapter 5) RS485 Reference output +10V, ±5%;...
  • Page 73 Technical data vacon • 71 Table 34. Technical information on Relays. Relays Terminal Signal Technical information Switching capacity 250VAC/3A Relay output 1 (only earthed network allowed) Switching capacity NO 250VAC/5A Relay output 2* NC 250VAC/3A (only earthed network allowed) If 230VAC is used as control voltage from the output relays, the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes.

  • Page 74: Options

    ® VACON keypad with seven-segment display ® The text keypad is an option available for VACON 20 X. The control keypad is the interface between ® the VACON 20 X AC drive and the user. Figure 46. Text keypad. Order code...
  • Page 75 Options vacon • 73 Figure 48. Disconnection of the HMI cap from the drive. Figure 49. Mounting of the keypad. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 76 • 74 Options Figure 50. Tighten the two screws (maximum tightening torque 0.5 Nm) of the keypad cable to the enclosure of the drive. Keypad mounted onto the drive. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 77: Text Keypad - Buttons

    Options vacon • 75 8.1.2 Text Keypad - buttons With the keypad it is possible to control the speed of the motor, to supervise the state of the drive and to set the AC drive’s parameters. The button section of the text keypad is shown in the following picture.

  • Page 78: Text Keypad

    • 76 Options Text keypad The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions. On the display, the user can see the information about his present location in the menu structure and the item displayed.

  • Page 79: Using The Keypad

    Options vacon • 77 Using the keypad ® This chapter provides you with information on navigating the menus on VACON 20 X and editing the values of the parameters. 8.4.1 Main menu ® The menu structure of VACON 20 X control software consists of a main menu and several submenus.

  • Page 80: Resetting Fault

    Every control ® place has its own parameter for selecting the frequency reference source. In the VACON 20 X Local control place Remote control place drive, the is always the keypad.

  • Page 81: Monitoring Menu

    Monitoring values are actual values of measured signals as well as status of some control settings. ® It is visible in VACON 20 X display, but it can not be edited. The monitoring values are listed in the Application Manual. RE ADY RU N...

  • Page 82: Parameter Menu

    • 80 Options 8.4.6 Parameter menu In Parameter menu only the Quick setup parameter list is shown as default. To view the other ad- vanced parameter groups, see the Application Manual. The following figure shows the parameter menu view:...

  • Page 83: System/Fault Menu

    Options vacon • 81 8.4.7 System/Fault menu SYS/FLT menu including fault submenu, field bus submenu and system parameter submenu. In system parameter submenu, there are some editable parameter (P) and some not editable param- eters (V). The Fault submenu of SYS/FLT menu includes active fault submenu and fault history sub- menu.
  • Page 84 • 82 Options 8.4.7.1 Faults Active faults Reset faults Fault history Counters Software in- Under this menu, you can find In active fault situation, FAULT arrow is blinking and the display is blinking active fault menu item with fault code. If there are several active faults, you can check it by entering the active fault sub- menu F5.x.

  • Page 85: Fault Tracing

    Options vacon • 83 8.4.8 Fault tracing Table 36. Fault codes and descriptions. Fault Fault name Subcode Possible cause Remedy code AC drive has detected too high a Check loading. current (>4*I ) in the motor cable: Check motor. Overcurrent Check cables and connections.
  • Page 86 Try to reduce ambient noise. flow Should the fault re-occur, contact the distributor near to you. ® Do not close VACON Live when PC control is active. PC control time out fault Check PC-Drive cable. Try to reduce ambient noise.
  • Page 87 Reset the fault and restart. Error in the microprocessor moni- If the fault occurs again, please con- toring Watchdog ® Malfunction tact your closest VACON represen- Component fault tative. Reset the fault and restart. Protection of unit when starting Back EMF...
  • Page 88 Fault name Subcode Possible cause Remedy code Load a compatible application. Firmware Interface version ® between Application and Control Please contact your closest VACON not matching representative. Application Application software flash error Reload Application error Load a compatible application. ®...

  • Page 89: Option Boards

    Options vacon • 87 Option boards ® VACON 20 X drive family embodies a wide selection of expander boards with which the available ® I/O of VACON 20 X AC drive can be increased and its versatility improved. ® There is one board slot (labelled D) on the VACON 20 X control board.

  • Page 90: Option Board Installation

    • 88 Options 8.5.1 Option board installation NOTE! Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards. • Remove the HMI cap and open the cover of the drive.
  • Page 91 Options vacon • 89 Figure 59. Removing the option slot cover. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 92 • 90 Options • Make sure that the sticker on the connector of the board says “dv” (dual ® voltage). This indicates that the board is compatible with VACON 20 X. See below: 9116.emf Slot coding ® • NOTE: Incompatible boards cannot be installed on VACON 20 X.
  • Page 93 Options vacon • 91 Figure 60. Option board installation. • Mount the option slot cover. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 94 • 92 Options Figure 61. Mounting of option slot cover: remove the plastic opening for the option board ter- minals. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 95: Mains Switch

    The purpose of the is to disconnect the VACON 20 X from the mains when, for exam- ple, 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 the front side of the drive. See Figure 62.

  • Page 96: Installation

    • 94 Options 8.6.1 Installation • Remove the HMI cap and the cover from the drive. See the Figure 63. Figure 63. Cover open (MU2 3-phase example). • Open only the inlet holes where you need to run the cables. Cables pass through this inlet hole.
  • Page 97 Options vacon • 95 Figure 64. Mains switch and cables connected (MU2 3-phase example). • Connect the GROUND wire to the proper terminal (see the yellow-green cable on Figure 64. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 98 • 96 Options • Mount the plastic cover onto the drive with its screws and HMI cap: the instal- lation process has been completed. See Figure 65. Figure 65. Mount the plastic cover. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 99: Simple Operator Panel

    Start/Stop selector and ® potentiometer for frequency reference together with a mains switch to disconnect the VACON X from the mains when, for example, service actions are needed. This option can be mounted on the front side of the drive.

  • Page 100: Installation

    • 98 Options Table 39. Simple operator panel kit content. Enclosure Description and type code Item Quantity size Main switch 40A NLT40 and operator panel assembly MU3 QDSH option spare kit MU3 cover for main switch 60S01209 M4x14 screw M5x23 screws 8.7.1...
  • Page 101 Options vacon • 99 • Connect the supply cable to the Mains switch passing through the cable gland from the bottom side (use the cable gland for sealing the cable to the drive) and then through the terminal box as shown in the figure below.
  • Page 102 • 100 Options • Connect the GROUND wire to the proper terminal (see the yellow-green cable on Figure 68. • Connect the cables from the potentiometer and from the selector to the I/O control terminals. The cables have to be connected to the I/O terminals as shown in the Figure 68 and in the Table 40.
  • Page 103 Options vacon • 101 Function Description Wire colors Terminal 24V auxiliary voltage YELLOW wire Switch selector digital input DI1 WHITE wire digital input DI2 GREY wire Table 41. Simple operator panel connection description. • Mount the plastic cover onto the drive with its screws (use torque 2Nm) and the HMI cap: the installation process has been completed.

  • Page 104: Safe Torque Off

    This chapter describes the Safe Torque Off (STO) function which is a functional safety feature pres- ® ent into VACON 20 X drive products as standard. This function is available only in the three-phase version. General description The STO function brings the motor in no-torque-state as defined by 4.2.2.2 of the IEC 61800-5-2: “Power that can cause rotation (or motion in the case of a linear motor) is not applied to the motor.

  • Page 105: Standards

    Safe Torque Off vacon • 103 Standards The STO function has been designed for use in accordance with the following standards: Table 42. Safety Standards. Standards IEC 61508, Parts 1-7 EN 61800-5-2 EN 62061 ISO 13849-1 EN 954-1 IEC 60204-1 The STO function has to be applied correctly to achieve the desired level of operational safety.

  • Page 106: The Principle Of Sto

    ® In VACON 20 X, the STO function is realized by preventing the propagation of the control signals to the inverter circuit. The inverter power stage is disabled through redundant disabling paths which start from the two separated and galvanically isolated STO inputs (S1-G1, S2-G2 in Figure 70).

  • Page 107: Technical Details

    The reaction time of the STO function is the amount of time which passes from the moment in which ® the STO is demanded until the system is in the Safe State. For VACON 20 X, the reaction time is 20 ms maximum.

  • Page 108: Connections

    • 106 Safe Torque Off Connections To make the STO function available and ready to be used, both STO jumpers have to be removed. They have been located in front of the STO terminal to mechanically prevent the insertion of the STO inputs.

  • Page 109: Safety Capability Cat.4 / Pl E / Sil 3

    Safe Torque Off vacon • 107 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 dynam- ically activate the STO inputs and to monitor the STO output feedback.
  • Page 110 • 108 Safe Torque Off 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+ DC-* Reinforced Figure 73. STO example with automatic monitoring of the feedback and both STO inputs used.

  • Page 111: Safety Capability Cat. 3 / Pl E / Sil 3

    Safe Torque Off vacon • 109 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).

  • Page 112: Safety Capability Cat.1 / Pl C / Sil 1

    • 110 Safe Torque Off 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.

  • Page 113: Commissioning

    Safe Torque Off vacon • 111 Commissioning 9.6.1 General wiring instructions Protect the STO cabling with a shielding or an enclosure to exclude external damage. 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.

  • Page 114: Parameters And Fault Tracing

    • 112 Safe Torque Off Parameters and fault tracing There are no parameters for the STO function itself. Before testing the STO function, make sure that the checklist (Table 49) is inspected and completed. When STO function is demanded, the drive always generates a fault (“F30”) and the motor stops by coasting.

  • Page 115: Maintenance And Diagnostics

    Safe Torque Off vacon • 113 Maintenance and diagnostics If any service or repair has to be conducted on the drive installed, please inspect the checklist given in Table 49. During maintenance breaks, or in case of service/repair, ALWAYS make sure that the STO function is available and fully functional by testing it.

  • Page 116: Solar Pump Application

    • 114 Solar pump application OLAR PUMP APPLICATION ® The installation instructions in this chapter are intended only for VACON 20 X Drives with addition- al solar pump application. 10.1 Danger ® The terminals are live when the VACON 20 X Drive is connected to a photovoltaic system.

  • Page 117: Manufacturers Of Gpv Fuses

    ® When VACON 20 X is used in the Solar Pump application, a diode must be connected between DC+ and DC- to protect the inverter against reverse voltage. See tables below for diode specification. Table 55. Diode specification, Mains voltage 3AC 208-240V, 50/60 Hz, up to 400V in VDC...

  • Page 118: Photovoltaic System Dimensioning

    The photovoltaic system has to be dimensioned in order to not exceed the values specified in the tables below. ® Table 58. VACON 20 X (208…240V 3AC 50/60Hz) DC-link input ratings Enclosure Max. Recommended PV Array Power AC drive type...

  • Page 119: Grounding

    Solar pump application vacon • 117 10.6 Grounding 10.6.1 Pole Grounding It is prohibited to connect any pole, DC+ or DC-, of the photovoltaic system directly to PE. 10.6.2 Drive Grounding All non-current-carrying metal parts (module enclosures, enclosures) and also the midpoint of the current carrying conductors of the photovoltaic system must be connected to the PE of the drive.

  • Page 120: Dc Power Connection

    • 118 Solar pump application 10.9 DC power connection power fuses supply switch protection diode 11744_uk Figure 76. Example of the power connections: MU2 1AC Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 121 Solar pump application vacon • 119 power supply fuses switch protection diode 11744_uk Figure 77. Example of the power connections: MU3 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 122 Document ID: Vacon Ltd DPD00992H Member of the Danfoss Group Rev. H Runsorintie 7 65380 Vaasa Finland...

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