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Vacon 100 x Installation And Maintenance Manual

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Installation, Technical and Maintenance
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Summary of Contents for Vacon 100 x

  • Page 1 100 x ® ac drives Installation, Technical and Maintenance Manual...

  • Page 3: Table Of Contents

    5.1.4 Safe Torque off (STO) terminals ..................47 5.1.5 Selection of terminal functions with dip switches ............48 5.1.6 Isolating digital inputs from ground .................48 5.1.7 Bus termination of the RS485 connection ................49 Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 4 AC drive power ratings......................62 7.1.1 Mains voltage 3AC 208-240V.....................62 7.1.2 Mains voltage 3AC 380-480V.....................63 7.1.3 Definitions of overloadability ....................64 Brake resistor ratings.......................65 VACON® 100 X - technical data..................66 7.3.1 Technical information on control connections..............69 Options......................72 Mains switch........................72 8.1.1 Installation ........................72 Control Keypad........................76...

  • Page 5: Safety

    Please read the warning information carefully. ® VACON 100 X is a drive designed to control asynchronous AC motors and permanent magnet motors. The product is intended to be installed in a restricted access location and for a general purpose use.

  • Page 6: Danger

    ® when VACON 100 X Drive is connected to the mains, even if the motor is not running. After disconnecting the AC drive from the mains, wait until the indicators on the keypad go out (if no keypad is connected, see the indicators on the cover). Wait an additional 30 seconds ®...

  • Page 7: Warnings

    Warnings ® VACON 100 X AC drive is meant for fixed installations (on the motor or on the wall) only. Only DVC A circuits (Decisive Voltage Class A, according to IEC 61800-5-1) are allowed to be connected to the control unit. This advice aims to protect both the drive ®...

  • Page 8: 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 See Table 12 and Table 13 for the required cross-section of phase conductor and protective earth- ing conductor (both made of copper).
  • Page 9 Earth connection Metal aglet Earth connection Figure 1. Earth connections and metal aglet in MM4. Earth connections Earth connection Metal aglet Figure 2. Earth connections and metal aglet in MM5. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 10 • 7 Safety Earth connection Earth connection Metal aglet Metal aglet Figure 3. Earth connections and metal aglet in MM6. However, always follow the local regulations for the minimum size of the protective earthing conductor. NOTE: Due to the high capacitive currents present in the AC drive, fault current protective switches...

  • 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 doubt or question, please contact your local VACON distributor. CONTROL UNIT...

  • Page 12: Compatibility With Rcds

    ® VACON 100 X has an integrated cooling system, independent from the motor fan. Under maxi- mum operating conditions, the ambient temperature cannot exceed 40 °C. See Table 24 and Table 25 for the output rated current. Higher temperatures are allowed only with derating of the output current.

  • Page 13: Declaration Of Conformity

    Safety vacon • 10 1.10 Declaration of conformity Figure 6. Declaration of conformity. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 14 • 11 Safety Figure 7. STO certificate.
  • Page 15 REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applica- bles sur le site www.vacon.com/downloads. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 16 • 13 Safety...

  • Page 17: Receipt Of Delivery

    IP66 / Type 4X voltage IP class EMC level Application EMC level C2 code Firmware: FW0065V008 Application: Cust. Ord. No: 3234500378 Marks: Customer’s order number CUSTOMER NAME ® Figure 8. VACON package label. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 18: Type Designation Code

    • 15 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 or- dered.

  • Page 19: Unpacking And Lifting The Ac Drive

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

  • Page 20: Frame Mm5

    • 17 Receipt of delivery 2.3.2 Frame MM5 Item Quantity Purpose Six pin black connector (see STO terminal connector Figure 9) to use STO function M4 x 12 DIN6900-3-Combi-Delta-Tx Screws for control cable clamps screw M1-3 Cable clamp Clamping control cables...

  • Page 21: Sto Terminal Connector

    Observe local and other applicable laws as they may mandate special treatment for specific components or special treatment may be ecologically sensible. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 22 • 19 Receipt of delivery...

  • Page 23: Mounting

    ® VACON 100 X is the ideal solution for a decentralised installation. It is conceived to be mounted on a wall or directly on the motor, saving space and reducing the cabling complexity. In both of the cas- es, it must be ensured that the mounting plane is even.
  • Page 24 • 21 Mounting 345,2 349,2 367,4 ® Figure 12. VACON 100 X drive dimensions, MM5. Dimensions W x H x D Frame [mm] [in] 232.6 x 367.4 x 213.5 9.16 x 14.46 x 8.41 MM5 +HMGR 232.6 x 367.4 x 230.8...
  • Page 25 Dimensions W x H x D Frame [mm] [in] 349.5 x 499.8 x 235.4 13.76 x 19.68 x 9.27 MM6 +HMGR 349.5 x 499.8 x 254.2 13.76 x 19.68 x 10.00 Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 26: 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, includes 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.

  • Page 27: Mounting

    MM6) or 6 (MM5) dedicated screws located on top side of the powerhead (see Figure 15.). In or- der to guarantee specified IP protection, recommended fastening torque is 2-3 Nm. The screws should be tightened crosswise. Figure 15. Separation of modules(MM5 example). Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 28: Wall-Mounting

    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 com- ® ponents. Contact your local VACON distributor for additional information. 3.3.3...

  • Page 29: Cooling

    Figure 16. Installation space. Cooling air required Type Table 10. Required cooling air. ® Should you need further details on the cooling system of the VACON 100 X, please contact your ® local VACON distributor. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 30 • 27 Mounting...

  • Page 31: Power Cabling

    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. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 32: Circuit Breaker

    • 29 Power cabling EMC levels environment environment Cable type Category C2 Category C3 Category C4 Mains cable Motor cable Control cable Table 11. Cable types required to meet standards. 1 = Power cable intended for fixed installation and the specific mains voltage. Shielded cable not required.

  • Page 33: Ul Standards On Cabling

    Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 34: Description Of The Terminals

    • 31 Power cabling Description of the terminals ® The following pictures describe the power terminals and the typical connections in Vacon 100X drives. brake resistor AC power supply Three phases Motor Figure 19. Power connections, MM4.
  • Page 35 Power cabling vacon • 32 brake resistor AC power supply Three phases Motor Figure 20. Power connections, MM5. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 36 • 33 Power cabling brake resistor AC power supply Three phases Motor Figure 21. Power connections, MM6.

  • Page 37: 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 high speed J (UL & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.

  • Page 38: Cable And Fuse Sizes, Frames Mm4 To Mm6, 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 high speed J (UL & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.

  • Page 39: Brake Resistor Cables

    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 27 and Table 28 for the resistor ratings. 4.4.4 Control cables For information on control cables see chapter Control unit.

  • Page 40: Cable Installation

    • 37 Power cabling Cable installation • Before starting, check that none of the components of the AC drive is live. Read carefully the warnings in chapter 1. • Place the motor cables sufficiently far from other cables • Avoid placing the motor cables in long parallel lines with other cables.
  • Page 41 • Open only the inlet holes where you need to run the cables. • Choose the correct cable glands according to drive and cable size as shown in the following pictures. Figure 23. Cable entry plate, MM4. Figure 24.Cable entry plate, MM5. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 42 • 39 Power cabling Figure 25.Cable entry plate, MM6. • 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. Figure 26.Cable gland. Plastic cable glands are recommend. If metal cable glands are needed, all insula- tion system requirements and all protective earthing requirements have to be ful- filled in accordance with the national electrical regulations and IEC 61800-5-1.
  • Page 43 • One metal conduit plate with accessories (screws and gasket) is delivered in a separate bag together with the drive. See the following figures for more details. Figure 27.Cable entry plate, MM4 UL installation. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 44 • 41 Power cabling Figure 28.Cable entry plate, MM5 UL installation. Figure 29.Cable entry plate, MM6 UL installation.
  • Page 45 0038 4 - 0072 4 Table 16. Tightening torques of terminals. • Check the connection of the earth cable to the motor and the AC drive termi- nals marked with Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 46 • 43 Power cabling...

  • Page 47: Control Unit

    - the control and relay terminals of the control unit - unless otherwise specifically or- dered. 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. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 48: Control Unit Cabling

    • 45 Control unit The control board can be powered externally (+24VDC, max. 1000mA, ±10%) by connecting the ex- ternal power source to terminal #30, see chapter 5.1.2. This voltage is sufficient for parameter set- ting and for keeping the control unit active. Note however that the measurements of the main circuit (e.g.

  • Page 49: Standard I/O Terminals

    Analogue output com- AO-/GND 24V auxiliary input +24 Vin voltage RS485 Serial bus, negative RS485 Serial bus, positive *. Can be isolated from ground, see chap- ter chapter 5.1.6. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 50: Relay And Thermistor Input Terminals

    • 47 Control unit 5.1.3 Relay and thermistor input terminals Table 20. 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...

  • Page 51: Selection Of Terminal Functions With Dip Switches

    (positive logic). See Figure 33. Locate the switch and set it in desired position. Factory default is 2. Figure 33. Digital inputs dip switch. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 52: Bus Termination Of The Rs485 Connection

    • 49 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 termina- tion must be set to the first and to the last device on the network. This switch in position “0” means that a termination resistor of 120 ohm is connected and the termination of the bus has been set.

  • Page 53: I/O Cabling And Fieldbus Connection

    For more detailed information, see the user’s manual of the fieldbus you are using. 5.2.1.1 Ethernet cable data Shielded RJ45 connector. Note: max Connector length of the connector 40 mm. Cable type CAT5e STP Cable length Max. 100m Table 22. Ethernet cable data. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 54: Prepare For Use Through Rs485

    RS485 cable to the frame of the AC drive. ® If VACON 100 X AC drive is the last device on the bus, the bus termination must be set. Locate the DIP switches to the top of the control unit (see Figure 32) and turn the right most switch to position “1”.

  • Page 55: Rs485 Cable Data

    Connector 2.5 mm STP (Shielded Twisted Pair), type Belden Cable type 9841 or similar Depends on the used fieldbus. See Cable length respective bus manual. Table 23. RS485 cable data. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 56: Battery Installation For Real Time Clock (Rtc)

    Detailed information on the functions of the can be found in the Application ® Manual. See the following figures to install the battery on the control box of Vacon 100X frequency converter. Remove the three screws on the control box as shown in Figure 36.
  • Page 57 Figure 37. Open the cover of control box. Install the battery in the correct place and connect it to the control box. See Figure 38 for battery location and connector. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 58 • 55 Control unit Connector for battery Location for battery Figure 38. Location and connector for the battery on the control box.

  • Page 59: Commissioning

    ® VACON 100 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 and other I/O-terminals may have a dangerous control voltage present ®...

  • Page 60: Commissioning Of The Drive

    • 57 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.

  • Page 61: Changing Emc Protection Class

    Figure 39 (for MM4), Figure 40 (for MM5) and in Figure 42(for MM6). Figure 39. Locations of EMC screws in MM4. Figure 40. Locations of EMC screws in MM5. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 62 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 Date: Date: EMC-level modified C1->C4...

  • Page 63: Running The Motor

    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 >1MΩ at ambient temperature of 20°C. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 64: Maintenance

    • 61 Commissioning 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. NOTE: Because of capacitor type (thin film capacitors), reforming of capacitors is not necessary.

  • Page 65: Technical Data

    100 X, supply voltage 3AC 208-240V. NOTE: The rated currents in given ambient temperatures (in Table 24) are achieved only when the switching frequency is equal to or less than the factory default. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 66: Mains Voltage 3Ac 380-480V

    30.0 0061 58,2 61.0 91.5 122.0 30.0 40.0 ® Table 25. Power ratings of VACON 100 X, supply voltage 3AC 380-480V, high overload. Mains voltage 3AC 380-480V, 50/60 Hz Motor shaft power Loadability Input 400V 480V Converter current type Rated continuous...

  • Page 67: Definitions Of Overloadability

    I or less. Current I N*110% I N*110% 1 min 9 min Time Figure 44. Low overload. For more information, please refer to IEC61800-2 (IEC:1998) Standard. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 68: Brake Resistor Ratings

    Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application. ® Recommended minimum brake resistor values for VACON 100 X AC drives: Mains Voltage 3AC 208-240V, 50/60 Hz...

  • Page 69: Vacon® 100 X - Technical Data

    Field weakening point 8…320 Hz Acceleration time 0.1…3000 sec Deceleration time 0.1…3000 sec Brake chopper standard in all frames Braking External brake resistor optional Control See chapter 5. connections Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 70 • 67 Technical data Standard: Serial communication (RS485/Mod- bus); Ethernet IP, Profinet IO, Modbus TCP, Bac- Fieldbus net IP Communication Optional: CanOpen; Profibus DP, DeviceNet, Lon- interface works Drive status indicators (LED) on top side (POWER, Status indicators RUN, FAULT, READY) Ambient operating tem- -10°C …+40°C...
  • Page 71 Motor stall protection Motor underload protec- tion Short-circuit protection of +24V and +10V refer- ence voltages Thermal motor protec- Yes (by PTC) tion ® Table 29. VACON 100 X technical data. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 72: Technical Information On Control Connections

    • 69 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 Ω 0-20 mA (Ri =250 Ω 0-10 V (Ri=200k Analogue input, Resolution 0.1%, accuracy ±1%...
  • Page 73 If 230VAC is used as control voltage from the output relays, the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes. This is to prevent welding on the relay contacts. Refer to standard EN 60204-1, section 7.2.9 Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 74 • 71 Technical data...

  • Page 75: Options

    Otherwise remove the cable entry plate from the right-hand-side. See the Figure 46. Figure 46. Disconnect the cable entry plate: example for MM5. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 76 • 73 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 47. Cable entry plate from the bottom side of the drive.
  • Page 77 • Place the cable entry plate with the other cables (motor cable, brake cable, I/O cables) in the groove on the bottom side of the drive and fix it with its screws. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 78 • 75 Options Figure 50. 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 51. Figure 51. Mount the powerhead on the terminal box.

  • Page 79: Control Keypad

    8.2.1 Mounting onto the drive Figure 52. Drive and the optional keypad kit. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 80: Installation

    • 77 Options 8.2.2 Installation • Remove the HMI cap from the drive as shown in the Figure 53. Figure 53. Disconnection of the HMI cap from the drive. • Install the keypad holder with a screw as shown in the Figure 54. The metal sheets of the keypad holder have to be mounted under the fan holder as shown in the following figures.
  • Page 81 Figure 56. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector to the enclosure of the drive. This is to keep the high IP66 protection degree of the drive. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 82: Wall-Mounting

    • 79 Options 8.2.3 Wall-mounting The keypad can be mounted on the wall in a convenient 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.
  • Page 83 Options vacon • 80 • Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall. Figure 58. Keypad connected to the drive. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 84: Graphical And Text Keypad

    • 81 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.

  • Page 85: Vacon® Keypad With Graphical Display

    4. Confirm change with OK button or ignore change by returning to previous level with Back/ Reset button. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 86 • 83 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...
  • Page 87 4. The display will return to the same location as it was when the button was pushed. How- ever, if the Remote control place was changed to Local (Keypad) you will be prompted for key- pad reference. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 88 • 85 Options STOP READY Keypad STOP Ready Keypad STOP READY Keypad Main Menu Choose action Local/Remote ID:1805 ID:211  Monitor Change direction ( 7 ) FUNCT Local Control page  Parameters ( 15 ) Local/Remote Remote Remote ...
  • Page 89 3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK but- ton to confirm. 4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.) Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 90 • 87 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.
  • Page 91 Edit 230.00 V favorites. Press OK to continue. Motor Nom Freq Help 50.00 Hz Motor Nom Speed Add to favorites 1430 rpm Figure 68. Adding item to Favorites. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 92: Vacon® Keypad With Text Segment Display

    • 89 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.
  • Page 93 , the control place will still switch to Keypad if is selected. Switching between Local and Remote Control can be done by pressing the FUNCT-button on the keypad or by using the "Local/Remote" (ID211) parameter. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 94 • 91 Options Changing control places Remote Local Change of control place from (keypad). 1. Anywhere in the menu structure, push the FUNCT button. 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.
  • Page 95 3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK but- ton to confirm. 4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.) Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 96: Fault Tracing

    • 93 Options 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.
  • Page 97 Fault history Device removed Time 04:46:33 ( 39 ) Info old 862537s Operating time 862537s Figure 74. Fault history menu with graphical keypad. Figure 75. Fault history menu with text keypad. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 98 • 95 Options 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.
  • Page 99 This fault is activated only if the you. drive is in Run state. Check supply voltage, fuses and Input phase Input line phase is missing. cable. Table 32. Fault codes and descriptions. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 100 • 97 Options 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.
  • Page 101 1053 nication fault master. Slot D fault 1654 Defective option board or slot Check board and slot. 1754 Slot E fault Table 32. Fault codes and descriptions. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 102 • 99 Options Fault Fault Fault name Possible cause Remedy code Check that motor is connected to the drive. Ensure that there is no load on Identification Identification run has failed. the motor shaft. 1057 Ensure that the start command will not be removed before completion of identification run.
  • Page 103 See option board manual for fault 2 At least one of the selected tempera- further information. ture input signals has reached the fault 1318 limit. Table 32. Fault codes and descriptions. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 104: Heater (Arctic Option)

    • 101 Options Heater (arctic option) 8.3.1 Safety This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances. Please read the information included in dangers carefully.

  • Page 105: Mounting Instructions: Mm4 Example

    Options vacon • 102 8.3.4 Mounting instructions: MM4 Example Figure 76. Heater option for MM4. Figure 77. Heating element and terminals. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 106 • 103 Options Figure 78. Remove the cable entry plate (right side example). Figure 79. Remove the powerhead from the terminal box.
  • Page 107 Color of the cables is only as example. Figure 81. Mount the optional heater on the terminal box and then close the powerhead. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 108: Option Boards

    • 105 Options Option boards ® VACON 100 X drive family embodies a wide selection of expander boards with which the available ® I/O of VACON 100 X frequency converter can be increased and its versatility improved. ® There are two board slots (labelled D and E) on the VACON 100 X control board.

  • Page 109: Flange Adapter

    ® VACON 100 X is an IP66/Type 4X outdoor drive, designed to be installed as close as possible to the motor, minimizing the use of electrical rooms, integrating the drive as part of the machine, without the use of cabinets. Vacon 100X drives are products than can be mounted directly onto the motor, machine or wherever the most efficient location for the drive is.
  • Page 110 • 107 Options Table 36 shows the corresponding flange adapters for different motor sizes. See also the relations with the inverter frame sizes. Rated Power at Inverter Flange adapter type current at Motor size 1500 rpm A [mm] B [mm]...
  • Page 111 Options vacon • 108 Figure 84. MM5 flange adapter dimensions. Figure 85. MM6 flange adapter dimensions. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 112: Mounting Instructions: Mm4 Example

    • 109 Options 8.5.1 Mounting instructions: MM4 Example Figure 86. Flange adapter for MM4. Figure 87. Mount the flange adapter on the motor.
  • Page 113 Options vacon • 110 Figure 88. Mount the drive on the flange adapter using 4 screws. Figure 89. Drive mounted onto the motor. Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 114 • 111 Options...

  • Page 115: Safe Torque Off

    In circumstances where external influences (e.g. falling of suspended loads) are present additional measures (e.g. mechanical brakes) may be necessary to prevent any hazard. STO shall not be used as a control for starting or stopping the drive. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 116: Standards

    • 113 Safe Torque Off Standards The STO function has been designed for use 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 37. Safety Standards.

  • Page 117: The Principle Of Sto

    ® In VACON 100 X, the STO function is realized by preventing the propagation of the control signals to the inverter circuit. The inverter power stage is disabled through redundant disabling paths which start from the two separated and galvanically isolated STO inputs (S1-G1, S2-G2 in Figure 90).

  • Page 118: Technical Details

    The reaction time of the STO function is the amount of time which passes from the moment in which ® the STO is activated until the system is in the Safe State. For VACON 100 X, the reaction time is 20...

  • Page 119: Connections

    The following examples show the basic principles for wiring the STO inputs and the STO output feedback. Local standards and regulations should be always followed in the final design. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 120: Safety Capability Cat. 4 / Pl E / Sil 3

    • 117 Safe Torque Off 9.5.1 Safety Capability Cat. 4 / PL e / SIL 3 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 121 Safe State. In case of failure, check the wiring. If the fault recognized by the external safety device persists, the drive will have to be replaced/repaired . Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 122: Safety Capability Cat. 3 / Pl E / Sil 3

    • 119 Safe Torque Off 9.5.2 Safety Capability Cat. 3 / PL e / SIL 3 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 123: Safety Capability Cat. 1 / Pl C / Sil 1

    Torque Off") and the motor stops by coasting. SWITCH POWER UNIT DC+/R+ Reinforced Figure 95. STO example without automatic monitoring of the feedback and STO inputs connect- ed in parallel. Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 124: Commissioning

    • 121 Safe Torque Off 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 125: Parameters And Fault Tracing

    • Reset the fault (through a digital input or from the keypad). • It is possible that a new start command is required for the restart (depending on the applica- tion and your parameter settings). Service support: find your nearest Vacon service center at www.vacon.com...

  • Page 126: Maintenance And Diagnostics

    • 123 Safe Torque Off Maintenance and diagnostics If any service or repair is to be conducted on the drive installed, please inspect the checklist given in Table 44 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 127 Safe Torque Off vacon • 124 Service support: find your nearest Vacon service center at www.vacon.com...
  • Page 128 Find your nearest Vacon office on the Internet at: www.vacon.com Document ID: Manual authoring: documentation@vacon.com Order code: Vacon Plc. Runsorintie 7 65380 Vaasa Finland Subject to change without prior notice © 2014 Vacon Plc. Rev.G...

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