Vacon 100 Installation Manual
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Vacon 100 Installation Manual

Vacon 100 Installation Manual

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Summary of Contents for Vacon 100

  • Page 1 100 ac drives installation manual...

  • Page 2: Table Of Contents

    Commissioning of the drive ..................... 63 Running the motor ......................63 6.2.1 Cable and motor insulation checks ................. 64 Installation in it system....................65 6.3.1 Frames MR4 to MR6......................65 6.3.2 Frames MR7 and MR8...................... 66 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 3 7.1.1 Mains voltage 208-240 V ....................71 7.1.2 Mains voltage 380-480 V ....................72 7.1.3 Definitions of overloadability ................... 73 Vacon 100 - technical data ....................74 7.2.1 Technical information on control connections ..............76 Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
  • Page 4 • 2 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 5 Product name: Vacon 100 AC drive Model designation: Vacon 100 3L 0003 2...3L 0310 2 Vacon 100 3L 0003 4...3L 0310 4 has been designed and manufactured in accordance with the following standards: Safety: EN 61800-5-1 (2007)

  • Page 6: Safety

    Table 1. Warning signs Danger The components of the power unit of Vacon 100 are live when the AC drive is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.

  • Page 7: Warnings

    Vacon 100 AC drive is meant for fixed installations only. Do not perform any measurements when the AC drive is connected to the mains. The touch current of Vacon 100 AC drives exceeds 3.5mA AC. According to stan- dard EN61800-5-1, a reinforced protective ground connection must be ensured.

  • Page 8: Earthing And Earth Fault Protection

    Earthing and earth fault protection CAUTION! The Vacon 100 AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with The touch current of Vacon 100 exceeds 3.5mA AC. According to EN61800-5-1, one or more of...

  • Page 9: Electro-Magnetic Compatibility (Emc)

    • 7 Safety Do not perform any voltage withstand tests on any part of Vacon 100. There is a certain procedure according to which the tests shall be performed. Ignoring this procedure may result in damaged product. Electro-magnetic compatibility (EMC) This equipment complies with IEC 61000-3-12 provided that the short-circuit power S greater than or equal to 120 at the interface point between the user’s supply and the public sys-...

  • Page 10: Receipt Of Delivery

    IP21 / Type 1 voltage IP class EMC level Application EMC level C2 code Firmware: FW0065V008 Application: Cust. Ord. No: 3234500378 Marks: Customer’s order number CUSTOME R NAME Figure 1. Vacon package label 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 11: Type Designation Code

    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:...

  • Page 12: Unpacking And Lifting The Ac Drive

    NOTE: The maximum allowed lifting angle is 45 degrees. Figure 2. Lifting bigger frames Vacon 100 AC drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transport damages are to be found on the product and that the delivery is complete.

  • Page 13: Accessories

    • 11 Receipt of delivery Accessories After having opened the transport package and lifted the converter out, check immediately that accessories bag these various accessories were included in the delivery. The contents of the differ by drive size and IP protections class: 2.3.1...

  • Page 14: Size Mr6

    Control cable grounding Cable lugs KP34 Clamping power cables Cable insulator Avoiding contact between cables Cable grommet, hole diameter 25.3 mm Control cable run-through sealing Table 8. Contents of accessories bag, MR8 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 15: Size Mr9

    • 13 Receipt of delivery 2.3.6 Size MR9 Item Quantity Purpose M4x16 screw Screws for control cable clamps Control cable grounding lamella Control cable grounding Cable lugs KP40 Clamping power cables Cable insulator Avoiding contact between cables Cable grommet, hole diameter 25.3 mm Control cable run-through sealing Table 9.

  • Page 16: Mounting

    The AC drive shall be fixed with four screws (or bolts, depending on the unit size). Dimensions 3.1.1 Wall mount IP21 Ø7 Ø13 Ø25 IP54 Ø25 Figure 4. Vacon AC drive dimensions, MR4, wall mount 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 17 IP21 IP54 Ø33 Ø25 Ø33 Ø25 Ø7 100* *Optional mounting holes (for NX replacement) Figure 5. Vacon AC drive dimensions, MR5, wall mount IP21 Ø40 Ø33 Ø40 Ø9 Ø 15,5 Ø25 Ø25 IP54 Ø9 Figure 6. Vacon AC drive dimensions, MR6, wall mount...
  • Page 18 Mounting vacon • 16 Ø9 IP21 Ø20 Ø16 Ø51 IP54 Ø25 Ø50 Figure 7. Vacon AC drive dimensions, MR7, wall mount Ø9 Ø22 3 x 38 Ø25 Ø60 62,5 Ø11 Ø9 Figure 8.Vacon AC drive dimensions, MR8 IP21 and IP54...

  • Page 19: Flange Mount

    • 17 Mounting Figure 9. Vacon AC drive dimensions, MR9 IP21 and IP54 3.1.2 Flange mount flange The AC drive can also be recessed into the cabinet wall or similar surface. A special mount option is available for this purpose. For an example of a flange-mounted drive, see Fig- ure 10.
  • Page 20 Drive outline Opening outline Figure 11. Flange mount cutout dimensions for MR4 to MR6 Frame Table 10. Flange mount cutout dimensions for MR4 to MR6 [mm] 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 21 • 19 Mounting Figure 12. MR4 to MR6, flange mount, depth dimensions Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
  • Page 22 Figure 13. Flange mount cutout dimensions for MR7 to MR9 Frame 13.5 1050 Table 11. Flange mount cutout dimensions for MR7 to MR9 Ø22 Figure 14. MR7 to MR9, flange mount, depth dimensions 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 23: Cooling

    • 21 Mounting Cooling The AC drives produce heat in operation and are cooled down by air circulated by a fan. Enough free space shall therefore be left around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance also require certain amount of free space.
  • Page 24 Figure 16. FRONT SIDE Figure 16. Installation space when drives are mounted on top of each other 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 25 • 23 Mounting Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 26: Power Cabling

    (MCMK or similar recommended). 2 = Symmetrical power cable equipped with concentric protection wire and intended for the specific mains voltage. (MCMK or similar recommended). See Figure 18. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 27 • 25 Power cabling 3 = Symmetrical power cable equipped with compact low-impedance shield and intended for the specific mains voltage. [MCCMK, EMCMK or similar recommended; Recom- mended cable transfer impedance (1...30MHz) max. 100mohm/m]. See Figure 18. *360º earthing of the shield with cable glands in motor end needed for EMC level C2.

  • Page 28: Ul Standards On Cabling

    To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with a minimum heat-resistance of +60/75°C. Use Class 1 wire only. The units are suitable for use on a circuit capable of delivering not more than 100,000 rms sym- metrical amperes, 600V maximum.
  • Page 29 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.
  • Page 30 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.
  • Page 31 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.

  • Page 32: Brake Resistor Cables

    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.

  • Page 33: Cable Installation

    • The given distances also apply between the motor cables and signal cables of other sys- tems. • The maximum lengths of motor cables (shielded) are 100 m (MR4), 150 m (MR5 and MR6) and 200 m (MR7 to MR9).
  • Page 34 Power cabling vacon • 32 Frame Leave as short as pos- sible Table 19. Cables stripping lengths [mm] Open the cover of the AC drive. M4x55 Figure 20. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 35 • 33 Power cabling Remove the screws of the cable protection plate. Do not open the cover of the power unit! M4x8 Figure 21. Insert the cable grommets (included in the delivery) in the openings of the cable entry plate (included) as shown in the picture (upper pictures EU version, lower pictures US version).
  • Page 36 If this is not possible, the tight- ness of the connection must be ensured with insulation tape or a cable tie. Figure 23. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 37 • 35 Power cabling Detach the cable clamps and the grounding clamps (Figure 24) and place the cable entry plate with the cables in the groove on the AC drive frame (Figure 25). M4x16 (2.2 Nm) Figure 24. Figure 25.
  • Page 38 13.3 17.7 0038 4—0061 4 0075 2—0105 2 70.8/132.8* 1.5 13.3 8/15* 70.8/132.8* 0072 4—0105 4 8/15 *. Cable clamping (e.g. Ouneva Pressure Terminal Connector) Table 20. Tightening torques of terminals 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 39 • 37 Power cabling Check the connection of the earth cable to the motor and the AC drive terminals marked with NOTE: Two protective conductors are required according to standard EN61800- 5-1. See Figure 27 and chapter Earthing and earth fault protection. Use an M5 size screw and tighten it to 2.0 Nm (17.7 lb-in.).

  • Page 40: Frames Mr8 And Mr9

    Strip the motor and mains cables as advised below. Earth conductor Earth conductor MAINS MOTOR Figure 29.Stripping of cables Frame Leave as short as possible Table 21. Cables stripping lengths [mm] 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 41 • 39 Power cabling MR9 only: Remove the main cover of the AC drive. M4 x 10 Figure 30. Remove the cable cover (1) and the cable fitting plate (2). M4x8 M4 x 8 Figure 31. Removing cable cover and cable fitting plate (MR8).
  • Page 42 • 40 M4 x 8 M5 x 10 Figure 32. Removing cable cover and cable fitting plate (MR9). MR9 only: Loosen the screws and remove the sealing plate. Figure 33. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 43 • 41 Power cabling Remove the EMC shield plate. M4x8 Figure 34. Locate the terminals. OBSERVE the exceptional placement of motor cable termi- nals in MR8! Figure 35. Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...
  • Page 44 If this is not possible, the tight- ness of the connection must be ensured with insulation tape or a cable tie. As an example,see Figure 23. Figure 37. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 45 • 43 Power cabling If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables. Figure 38. Connect the cables stripped as shown in Figure 29. • Connect the (phase) conductors of the supply, brake and motor cables into their respective terminals (a).
  • Page 46 *. Cable clamping (e.g. Ouneva Pressure Terminal Connector) Table 22. Tightening torques of terminals Expose the shield of all three cables in order to make a 360-degree connection with the cable clamp. Figure 41. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 47 • 45 Power cabling Remount now first the EMC shield plate (see Figure 34) and then the sealing plate for MR9 (see Figure 33). Re-attach then the cable fitting plate and then the cable cover. M4x8 M4x8 Figure 42.
  • Page 48 Connect the protective conductor using a cable shoe and an M8 screw (included Accessories bag in the ) on either of the screw connectors as advised in Figure 44. Figure 44. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 49: Installation In Corner-Grounded Network

    • 47 Power cabling Installation in corner-grounded network Corner grounding is allowed for the drive types rating from 72 A to 310 A at 380…480 V supply and from 75 A to 310 A at 208…240 V supply. In these circumstances the EMC protection class must be changed to level C4 following the in- structions in chapter 6.3 of this manual.

  • Page 50: Control Unit

    Note however that the measurements of the main cir- cuit (e.g. DC-link voltage, unit temperature) are not available when the mains is not connected. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 51: Control Unit Cabling

    • 49 Control unit Control unit cabling The basic control unit connections are presented in Figure 46 below. The control board is equipped with 22 fixed control I/O terminals and the relay board with 8 or 9. The relay board is available in two different configurations (see Table 25 and 26 ).

  • Page 52: Control Terminals And Dip Switches

    Serial bus, negative RS485 Serial bus, positive *. Digital inputs can be isolated from ground, see chapter 5.1.2.2. Table 24. Control I/O terminal signals on basic I/O board and connection example 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 53 • 51 Control unit From Relay board 1 Basic I/O board Terminal Signal From term. From term. #6 or 12 Relay output 1 RO1/1 NC RO1/2 CM RO1/3 NO Relay output 2 RO2/1 NC RO2/2 CM RO2/3 NO Relay output 3...
  • Page 54 See Figure 48. Lift the plastic lid to expose the jumper and apply long-nose pliers or similar to remove it. Figure 48. Remove this jumper to isolate the digital inputs from ground. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 55: I/O Cabling And Fieldbus Connection

    • 53 Control unit 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 basic I/O board (terminals A and B) and the connection for Ethernet is under the drive cover, left to the control keypad.
  • Page 56 If this is not possible, the tightness of the connection must be ensured with insulation tape or a cable tie. IP54 IP21 Figure 51. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 57: Prepare For Use Through Rs485

    • 55 Control unit Remount the AC drive cover. NOTE: When planning the cable runs, remember to keep the distance between the Ethernet cable and the motor cable at a minimum of 30 cm. Ethernet cable IP54 IP21 Figure 52.
  • Page 58 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 AC drive stan- dard terminal block, terminals A and B (A = negative, B = positive). See Figure 53.
  • Page 59 • 57 Control unit Using the cable clamp included in the delivery of the drive, ground the shield of the RS485 cable to the frame of the AC drive. Cable clamp If the AC drive is the last device on the bus, the bus termination must be set.
  • Page 60 The bus termination must be set for the first and the last device of the fieldbus line. See picture below. See also step 4 on page 57. We recommend that the first device on the bus and, thus, terminated was the Master device. Vacon 100 Vacon 100 Vacon 100 Vacon 100 Vacon 100 Termination...

  • Page 61: Battery Installation For Real Time Clock (Rtc)

    Enabling the functions of the requires that an optional battery is in- stalled in the Vacon 100 HVAC drive. The place for the battery can be found in all frames left to the control keypad (see Figure 54). Real Time Clock (RTC)

  • Page 62: Galvanic Isolation Barriers

    300VAC (EN-50178). 10Vref +24V CONTROL UNIT AI1+ AI1- AI2+ AI2- DI1... AO1+ AO1- +24Vin RS485 RO1/1 RO1/2 RO1/3 RO2/1 RO2/2 RO2/3 TI1+ TI1- POWER UNIT DC+/R+ Figure 55. Galvanic isolation barriers 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 63 • 61 Control unit Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 64: Commissioning

    The motor terminals U, V, W and the brake resistor terminals (R+/R- (MR4-MR6) or DC+/R+ and R- (MR7 and bigger)) are live when Vacon 100 is connected to mains, even if the motor is not running. The control 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 is disconnected from mains.

  • Page 65: Commissioning Of The Drive

    • 63 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 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 66: Cable And Motor Insulation Checks

    1000 V. The insulation resistance must be >1M at ambient temperature of 20°C. Always follow the instructions of the motor manufacturer. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 67: Installation In It System

    • 65 Commissioning Installation in it system If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-pro- tected according to class C2 you need to modify the EMC protection of the AC drive to EMC- level C4.

  • Page 68: Frames Mr7 And Mr8

    MR7 and MR8: Locate the EMC box under the cover. Remove the screws of the box cover to expose the EMC-jumper. Detach the jumper and re-fix the box cover. Figure 59. 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 69: Frame Mr9

    • 67 Commissioning Additionally for MR7, locate the DC grounding busbar between connectors R- and U and detach the busbar from the frame by undoing the M4 screw. Figure 60. MR7: Detaching the DC grounding busbar from frame 6.3.3...
  • Page 70 ‘EMC level modified’ NOTE! After having performed the change write on the sticker included in the Vacon 100 delivery (see below) and note the date. Unless already done, attach the sticker close to the name plate of the AC drive. Product modified...

  • Page 71: Maintenance

    • 69 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.
  • Page 72 Commissioning vacon • 70 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...

  • Page 73: Technical Data

    125.0 See chapter 7.1.3. Table 29. Power ratings of Vacon 100, supply voltage 208-240V. NOTE: The rated currents in given ambient temperatures (in Table 31) are achieved only when the switching frequency is equal to or less than the factory default.

  • Page 74: Mains Voltage 380-480 V

    250.0 See chapter 7.1.3 Table 30. Power ratings of Vacon 100, supply voltage 380-480V. NOTE: The rated currents in given ambient temperatures (in Table 31) are achieved only when the switching frequency is equal to or less than the factory default.

  • Page 75: Definitions Of Overloadability

    • 73 Technical data 7.1.3 Definitions of overloadability Low overload = Following continuous operation at rated output current I , the converter is fed with 110% * I for 1 min, followed by a period of I Example: If the duty cycle requires 110% rated current I for 1 min in every 10 min, the remaining 9 min must be at rated current or less.

  • Page 76: Vacon 100 - Technical Data

    Designed according to: Ambient conditions IEC 60721-3-3, unit in operation, class 3C2 IEC 60721-3-3, unit in operation, class 3S2 100% load capacity (no derating) up to 1,000m 1-% derating for each 100m above 1,000m Max. altitudes: 208...240V: 4,500m (TN and IT systems) Altitude 380...480V: 4,500m (TN and IT systems)
  • Page 77 Unit overtemperature protection Motor overload protection Yes Motor stall protection Motor underload pro- tection Short-circuit protec- tion of +24V and +10V reference voltages Table 31. Vacon 100 technical data Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205...

  • Page 78: Technical Information On Control Connections

    24V auxiliary input voltage Can be used as external power backup for the control unit. RS485 Differential receiver/transmitter Set bus termination with dip switches (see page 52) RS485 Table 32. Technical information on standard I/O board 24-hour support +358 (0)201 212 575 • Email: vacon@vacon.com...
  • Page 79 • 77 Technical data Relay board with two change-over contact (SPDT) relays and one Relay relay with normally-open (NO or SPST) contact. board 1 5,5 mm isolation between channels. Terminal Signal Technical information Switching capacity 24VDC/8A 250VAC/8A Relay output 1 125VDC/0.4A...
  • Page 80 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 © 2011 Vacon Plc. Rev. D...

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