Vacon 100 Flow Installation Manual
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Vacon 100 Flow Installation Manual

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Maclean Gadri
April 2, 2025

please I'm having a problem with my AC drive at my factory. there is a current overload on the display anytime I switch on the lift fan.

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1 comments:
Mr. Anderson
April 2, 2025

A current overload on the display of a Vacon 100 Flow AC drive when switching on the lift fan could be caused by the capacitive currents generated in the AC drive. These currents may affect the operation of fault current protective switches, potentially leading to incorrect detection and overload indication.

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Summary of Contents for Vacon 100 Flow

  • Page 1 100 industrial ® vacon 100 flow ® ac drives installation manual ip00 drive modules...

  • Page 3: About This Manual

    Date: 6.11.2017 ABOUT THIS MANUAL This manual is copyright of VACON Ltd. All Rights Reserved. The manual is subject to change without prior notice. The language of the original instructions is English. ABOUT THE PRODUCT This manual describes the VACON 100 IP00 Drive Module.
  • Page 4 VACON · 4 LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS VACON · 5 TABLE OF CONTENTS Preface Document details About this manual About the product 1 Approvals 2 Safety The safety symbols used in the manual Warning Caution Grounding and earth fault protection Using an RCD or an RCM device...

  • Page 6: Vacon

    10 Technical data, VACON 100 FLOW ® 10.1 AC drive power ratings 10.1.1 Mains voltage 208-240 V 10.1.2 Mains voltage 380-500 V 10.1.3 Mains voltage 525-690 V 10.1.4 Overload capability 10.2 VACON 100 FLOW - technical data ® LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 7: Table Of Contents Vacon

    TABLE OF CONTENTS VACON · 7 11 Technical data on control connections 11.1 Technical data on control connections LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 8: Approvals

    VACON · 8 APPROVALS APPROVALS Here are the approvals that have been granted to this VACON product. ® 1. EC Declaration of conformity Find the EC Declaration of Conformity on the next page. • 2. UL approval * cULus approval file number E171278.
  • Page 9 Product(s) VACON® 100 AC drive IP00 Drives: Type(s) Wall-Mounted Drives: VACON® 0100 3L 0140 2...0310 2 VACON® 0100 3L 0003 2...0310 2 VACON® 0100 3L 0003 4...0310 4 VACON® 0100 3L 0140 5...1180 5 VACON® 0100 3L 0080 6...0820 6 VACON®...

  • Page 10: Safety

    VACON · 10 SAFETY SAFETY THE SAFETY SYMBOLS USED IN THE MANUAL This manual contains warnings and cautions, which are identified with safety symbols. The warnings and cautions give important information on how to prevent injury and damage to the equipment or your system.

  • Page 11: Caution

    SAFETY VACON · 11 WARNING! Before you do electrical work on the drive, disconnect the drive from the mains and make sure that the motor has stopped. Lock out and tag out the power source to the drive. Make sure that no external source generates unintended voltage during work.

  • Page 12: Grounding And Earth Fault Protection

    VACON · 12 SAFETY CAUTION! Make sure that the EMC level of the AC drive is correct for your mains. See chapter 8.5 Installation in an IT system. An incorrect EMC level can cause damage to the drive. If you use Corner-grounding, change the EMC level to C4, see chapter 8.5 Installation in an IT system.

  • Page 13: Using An Rcd Or An Rcm Device

    SAFETY VACON · 13 Table 2: Protective grounding conductor cross-section Cross-sectional area of the phase conductors (S) The minimum cross-sectional area of the protective grounding conductor in question [mm S ≤ 16 16 < S ≤ 35 35 < S The values of the table are valid only if the protective grounding conductor is made of the same metal as the phase conductors.

  • Page 14: Receiving The Delivery

    Cust. Ord. No: 16695624 Marks: MSIP-REM-V93-VC100 Danfoss Industries Pte. Ltd. Made in Finland Danfoss A/S, 6430 Nordborg, Denmark Fig. 2: The package label of VACON AC drives ® A. The batch ID F. The nominal output current B. The VACON order number G.

  • Page 15: Type Designation Code

    VACON0100-3L-0385-5-FLOW+IP00 Table 3: The description of the parts in the type designation code Code Description VACON0100 The product family: VACON0100 = the VACON 100 product family ® Input/Function: 3L = A 3-phase input 0385 The drive rating in amperes. For example, 0385 = 385 A...

  • Page 16: Removing The Packaging And Lifting The Ac Drive

    VACON · 16 RECEIVING THE DELIVERY REMOVING THE PACKAGING AND LIFTING THE AC DRIVE 3.4.1 WEIGHT OF THE AC DRIVE The weights of AC drives of different enclosure sizes are very different. It can be necessary for you to use a lifting device to move the drive from its package.
  • Page 17 RECEIVING THE DELIVERY VACON · 17 The maximum lifting angle is 45 degrees. ≤45º ≤45º LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...
  • Page 18 VACON · 18 RECEIVING THE DELIVERY LIFTING THE IP00 DRIVE MODULE, MR10 OR MR12 WITHOUT THE OPTIONS MODULE Make sure that the support is attached to the bottom of the drive. It gives the terminals protection when you lift the drive or put it vertically on the floor.

  • Page 19: Product Modified" Label

    RECEIVING THE DELIVERY VACON · 19 Lift the drive into a vertical position. The maximum lifting angle is 60 degrees. ≤60º "PRODUCT MODIFIED" LABEL In the accessories bag, there is also a "product modified" label. The function of the label is to tell the service personnel about the changes that are made in the AC drive.

  • Page 20: Disposal

    VACON · 20 RECEIVING THE DELIVERY DISPOSAL When the drive is at the end of its operation life, do not discard it as a part of municipal waste. You can recycle the primary components of the drive. You must disassemble some components before you can remove the different materials.

  • Page 21: Mounting Dimensions

    MOUNTING DIMENSIONS VACON · 21 MOUNTING DIMENSIONS DIMENSIONS OF MR8, IP00 663 (26.10) (0.37) Ø9 (0.35) Ø11 (0.43) Ø9 (0.43) (0.35) Ø22 (0.87) 683 (26.89) (0.71) (0.59) 794 (31.26) Fig. 3: The dimensions of the AC drive, MR8, [mm (in)]...

  • Page 22: Dimensions Of Mr9, Ip00

    VACON · 22 MOUNTING DIMENSIONS A. An optional main connector cover for the cabinet installation DIMENSIONS OF MR9, IP00 50 (1.97) Ø9 (0.35) Ø9 (0.35) 17 (0.65) 810 (31.89) 14 (0.55) 841 (33.09) 130 (5.12) Ø22 (0.87) Fig. 4: The dimensions of the AC drive, MR9 [mm (in)] A.

  • Page 23: Dimensions Of Mr10 And Mr12, Ip00

    MOUNTING DIMENSIONS VACON · 23 DIMENSIONS OF MR10 AND MR12, IP00 432 (17.01) 418 (16.46) 980 (38.58) 412 (16.22) 870 (34.25) 383 (15.08) 53 (2.09) 348 (13.70) Ø12 (0.47) 483 (19.02) Ø25 (0.98) 930 (36.61) Ø30 (1.18) 876 (34.49) Ø9 (0.35) Ø25 (0.98)
  • Page 24 VACON · 24 MOUNTING DIMENSIONS NOTE! The MR12 drive includes 2 power units, and 1 of them includes a control unit. 1425 (56.10) (1.61 (0.71) (2.09) 900 (35.43) Ø25 (0.98) Ø10 (0.39) Ø30 (1.18) (1.18) 1538 (60.55) 338 (13.31) 506 (19.92) 471 (18.54)

  • Page 25: Dimensions For Flange Mounting Of Mr8

    MOUNTING DIMENSIONS VACON · 25 DIMENSIONS FOR FLANGE MOUNTING OF MR8 19.4 (1.02) (0.76) 89.6 82.5 (3.53) (3.25) 852.6 (33.57) 890.8 (35.07) 831.5 (32.74) 573.5 (22.58) 315.5 (12.42) (0.27) 102 (4.02) 424.7 (16.72) 898 (35.35) (0.07) GND M8 109.5 (4.31) Fig.

  • Page 26: Dimensions For Flange Mounting Of Mr9

    VACON · 26 MOUNTING DIMENSIONS DIMENSIONS FOR FLANGE MOUNTING OF MR9 56 (2.20) (6.42) 1039 (40.90) (3.35) 75 (2.95) 300 (11.81) 300 (11.81) 10.5 10.5 (0.41) (0.41) 102 (4.02) 397.5 (15.65) 1060 (41.73) 210 (8.27) 108.5 (4.27) Fig. 8: The dimensions of the AC drive, flange mounting, MR9 [mm (in)]...

  • Page 27: Dimensions For Flange Mounting Of Mr10

    MOUNTING DIMENSIONS VACON · 27 DIMENSIONS FOR FLANGE MOUNTING OF MR10 1070 (42.13) Ø22 (0.87) 103 (4.06) (2.95) 1080 (42.52) (0.6) Ø12 (0.47) Ø11 1110 (43.70) (0.43) M8 GND (2.48) Fig. 9: The dimensions of the AC drive, flange mounting, MR10 [mm (in)]...

  • Page 28: Dimensions Of Options For Mr10 And Mr12

    VACON · 28 MOUNTING DIMENSIONS DIMENSIONS OF OPTIONS FOR MR10 AND MR12 174 (6.85) 155 (6.10) 160 (6.31) 53 (2.09) 40 (1.57) (3.26) Ø13 (0.49) (2.27) (0.20) Ø7 (0.28) Ø13 (0.49) 169 (6.66) Ø7 (0.26) 53 (2.09) (6.10) 148 (5.83) Fig.
  • Page 29 MOUNTING DIMENSIONS VACON · 29 128 (5.04) 120 (4.72) 106 (4.17) (2.20) (1.54) (3.70) (3.94) Fig. 11: Dimensions of the installation kit for a detached control unit (ENC-QCDU) [mm (in)] LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 30: Installation Into Cabinet

    VACON · 30 INSTALLATION INTO CABINET INSTALLATION INTO CABINET GENERAL INFORMATION The AC drives that are described in this manual have the enclosure class IP00. You must install them in a cabinet or other enclosure that has a correct level of protection against the ambient conditions in the installation area.

  • Page 31: General Information About The Installation, Mr10

    INSTALLATION INTO CABINET VACON · 31 Table 5: The options for MR8 and MR9 Option Order code Location Description The brake chopper The options module Enables dynamic braking with an exter- +DBIN nal brake resistor. Flange mounting Enables mounting the drive through the...
  • Page 32 VACON · 32 INSTALLATION INTO CABINET NOTE! The optional external power connection block is not necessary if you have an options module. L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 Fig. 14: The main circuit diagram, MR10 with the options module and options A.
  • Page 33 INSTALLATION INTO CABINET VACON · 33 Table 6: The options for MR10 Option Order code Location Description The brake chopper The options module Enables dynamic braking with an exter- +DBIN nal brake resistor. The common mode filter +POCM The options module Decreases motor bearing currents.

  • Page 34: General Information About The Installation, Mr12

    VACON · 34 INSTALLATION INTO CABINET 5.1.3 GENERAL INFORMATION ABOUT THE INSTALLATION, MR12 2L1 2L22L3 1L1 1L2 1L3 L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 Fig. 15: The main circuit diagram, MR12 without the options module and options A.
  • Page 35 INSTALLATION INTO CABINET VACON · 35 NOTE! The optional external power connection block is not necessary if you have an options module. 2L1 2L22L3 1L1 1L2 1L3 L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 DC+/ DC+/ Fig.

  • Page 36: Mechanical Installation

    VACON · 36 INSTALLATION INTO CABINET Table 7: The options for MR12 Option Order code Location Description The brake chopper The options module Enables dynamic braking with an exter- +DBIN nal brake resistor. The common mode filter +POCM The options module Decreases motor bearing currents.

  • Page 37: Installing The Ip00 Drive Module Into The Cabinet

    INSTALLATION INTO CABINET VACON · 37 5.2.1 INSTALLING THE IP00 DRIVE MODULE INTO THE CABINET INSTALLING THE IP00 DRIVE MODULE WITHOUT THE OPTIONS MODULE We recommend that you install the IP00 drive module on rails inside the cabinet. A. The rails inside the cabinet Use fixing points to attach the IP00 drive module into the cabinet.
  • Page 38 VACON · 38 INSTALLATION INTO CABINET Use the fixing points at the front of the drive. A. The front fixing points B. The fixing points of the options module. These are important for a safe maintenance if the IP00 drive module is removed.

  • Page 39: Flange Mounting Of The Ip00 Drive Module

    INSTALLATION INTO CABINET VACON · 39 5.2.2 FLANGE MOUNTING OF THE IP00 DRIVE MODULE You can also install the IP00 drive module into the cabinet wall with a flange mounting option. NOTE! The protection classes are different in different sections of the drive module.
  • Page 40 VACON · 40 INSTALLATION INTO CABINET Fig. 19: The dimensions of the opening and drive module outline with flange A. The height of the opening for the flange F. The outline of the opening mounting G. The outline of the drive module B.

  • Page 41: Installing A Detached Control Unit

    INSTALLATION INTO CABINET VACON · 41 Table 9: The dimensions of the opening for the flange mounting Enclosure A [mm] B [mm] E [mm] A [in] B [in] E [in] size 33.8 11.7 38.4 19.1 MR10 37.8 20.1 Fig. 20: Sealing of the opening for MR8, MR9, and MR10 A.

  • Page 42: Cooling And Free Space Around The Ac Drive

    VACON · 42 INSTALLATION INTO CABINET Attach the side plate to the assembly plate. You can attach it on the left or on the right. Dismount the control unit and the control cable grounding bar from the MR10 power unit.
  • Page 43 INSTALLATION INTO CABINET VACON · 43 Fig. 21: The correct circulation of cooling air inside the cabinet A. Cool air going in D. Minimum 200 mm (7.87 in) B. Hot air coming out C. Install shields to prevent recirculation of hot air inside the cabinet.
  • Page 44 VACON · 44 INSTALLATION INTO CABINET Table 10: The necessary quantity of cooling air Enclosure The quantity of The quantity of The surface area of The surface area of size cooling air [m cooling air [CFM] the air intake holes the air intake holes 23.25...

  • Page 45: Power Cabling

    POWER CABLING VACON · 45 POWER CABLING CABLE DIMENSIONING AND SELECTION 6.1.1 CABLE AND FUSE SIZES We recommend the fuse type gG/gL (IEC 60269-1) for mains fuses (-F1). Use only fuses that have a sufficient voltage rating according to the mains voltage. Do not use larger fuses than what is recommended in Table 11.
  • Page 46 VACON · 46 POWER CABLING Table 11: The recommended mains cables and fuses in 208-240 V and 380-500 V Enclosure Type IL [A] Mains fuses per Mains and motor Mains cable Grounding size phase (gG/gL) [A] cable (Cu/AI) [mm2] terminal,...
  • Page 47 POWER CABLING VACON · 47 Table 12: The recommended mains cables and fuses in 525-690 V Enclosure Type IL [A] Mains fuses per Mains and motor Mains cable Grounding size phase (gG/gL) [A] cable (Cu/AI) [mm2] terminal, terminal, bolt size...
  • Page 48 VACON · 48 POWER CABLING Table 13: Drive fuses, 208-240 V and 380-500 V, Mersen Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0140 2 NH1UD69V250PV 1400...
  • Page 49 POWER CABLING VACON · 49 Table 14: Drive fuses, 525-690 V, Mersen Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0080 6 NH1UD69V125PV 0080 7 0100 6...
  • Page 50 VACON · 50 POWER CABLING Table 15: Drive fuses, 208-240 V and 380-500 V, Bussmann Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0140 2 170M3817D 1700...
  • Page 51 POWER CABLING VACON · 51 Table 16: Drive fuses, 525-690 V, Bussmann Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0080 6 170M3814D 0080 7 0100 6...

  • Page 52: Cable And Fuse Sizes, North America

    Do not use other devices than fuses to supply branch circuit protection. NOTE! The VACON 100 FLOW software does not have the dynamic braking or the brake ® resistor functions. The dimensions of the cables must agree with the requirements of the Underwriters Laboratories UL 61800-5-1.
  • Page 53 POWER CABLING VACON · 53 Table 17: The cable and fuse sizes for VACON 100 INDUSTRIAL and FLOW in North America, ® mains voltage 208-240 V and 380-500 V Enclosure Type IL [A] Fuse Mains and Terminal cable size size...
  • Page 54 VACON · 54 POWER CABLING Table 18: The cable and fuse sizes for VACON 100 INDUSTRIAL and FLOW in North America, ® mains voltage 525-690 V Enclosure Type IL [A] Fuse Mains and Terminal cable size size (Class T/J) motor cable...
  • Page 55 POWER CABLING VACON · 55 Table 19: Drive fuses in North America, 208-240 V and 380-500 V, Mersen Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0140 2...
  • Page 56 VACON · 56 POWER CABLING Table 20: Drive fuses in North America, 525-690 V, Mersen Enclosure Type Catalogue number of the Fuse Number Fuse Minimum size fuse rating of fuses size prospective needed short circuit current 0080 7 PC30UD69V160TF 0100 7...

  • Page 57: Brake Resistor Cables

    One of the cable conductors stays unconnected. Use a symmetrically shielded cable, same type as the mains and motor cables. NOTE! The different VACON 100 applications have different functions. For example, the ® VACON 100 FLOW does not have the dynamic braking or the brake resistor ® functions. LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...
  • Page 58 VACON · 58 POWER CABLING Table 22: Brake resistor cables, 525-690 V Enclosure size Type * IL [A] Brake resistor Brake resistor cable cable (Cu) [mm (Cu) [AWG] 0080 6 3x35+16 0080 7 0100 6 3x50+25 0100 7 0125 6...

  • Page 59: Preparing For The Cable Installation

    The different VACON 100 applications have different functions. For example, the ® VACON 100 FLOW does not have the dynamic braking or the brake resistor ® functions. PREPARING FOR THE CABLE INSTALLATION Before you start, make sure that none of the components of the AC drive is live. Read •...

  • Page 60: Cable Installation

    VACON · 60 POWER CABLING Table 23: The minimum distances between cables in long parallel lines The distance between The length of the The distance between The length of the cables [m] shielded cable [m] cables [ft] shielded cable [ft] ≤...
  • Page 61 POWER CABLING VACON · 61 Find the motor cable terminals. L2 L3 DC- DC+ U/T1 V/T2 W/T3 L2 L3 DC- DC+ V/T2 U/T1 W/T3 LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...
  • Page 62 VACON · 62 POWER CABLING Connect the cables. The picture shows an example of good cabling. a) Connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals.
  • Page 63 POWER CABLING VACON · 63 If you use many cables on one connector, put the cable lugs on top of each other. A. The first cable lug B. The second cable lug C. The connector If you use thick cables, put the cable insulators in between the terminals to prevent contact between the cables.

  • Page 64: Enclosure Sizes Mr10 And Mr12

    VACON · 64 POWER CABLING Table 24: Tightening torques of the terminals, MR8 and MR9 Tightening torque: the Tightening torque: the Tightening torque: the mains and motor cable grounding clamps for grounding terminals Enclosu Type terminals cable shield re size [Nm] lb-in.
  • Page 65 POWER CABLING VACON · 65 CABLE INSTALLATION WITHOUT THE OPTIONS MODULE Find the motor cable terminals. L1 L2 L3 V/T2 U/T1 W/T3 In MR12, connect the DC terminals of the 2 power DC+ DC- DC+ DC- units with the DC link cable. Connect the DC+ terminals together, and the DC- terminals together.
  • Page 66 VACON · 66 POWER CABLING Connect the cables. The picture shows an example of good cabling. a) Connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals.
  • Page 67 POWER CABLING VACON · 67 If you use many cables on one connector, put the cable lugs on top of each other. The pictures show the connection in MR10 and • MR12. The bolt holder of the connector keeps the bolt •...
  • Page 68 VACON · 68 POWER CABLING Make sure that the grounding conductor is connected to the motor and also to the terminals that are identified with a) To obey the requirements of the standard EN61800-5-1, obey the instructions in chapter 2.4 Grounding and earth fault protection.
  • Page 69 POWER CABLING VACON · 69 Table 25: Tightening torques of the terminals, MR10 or MR12 without options module Tightening torque: the mains and Tightening torque: the grounding Enclosu motor cable terminals terminals Type re size [Nm] lb-in. [Nm] lb-in. 0385 5-0590 5...
  • Page 70 VACON · 70 POWER CABLING Connect the cables. The picture shows an example of good cabling. a) Connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals.
  • Page 71 POWER CABLING VACON · 71 If you use many cables on one connector, put the cable lugs on top of each other. The pictures show the connection in MR10 and • MR12. The bolt holder of the connector keeps the bolt •...
  • Page 72 VACON · 72 POWER CABLING Make sure that the grounding conductor is connected to the motor and also to the terminals that are identified with a) To obey the requirements of the standard EN61800-5-1, obey the instructions in chapter 2.4 Grounding and earth fault protection.

  • Page 73: Control Unit

    CONTROL UNIT VACON · 73 CONTROL UNIT CONTROL UNIT COMPONENTS The control unit of the AC drive contains the standard boards and the option boards. The option boards are connected to the slots of the control board (see 7.4 Installation of option boards).
  • Page 74 VACON · 74 CONTROL UNIT STO JMP Fig. 25: The components of the control unit A. The control terminals for the standard H. A DIP switch for the signal selection of I/O connections Analogue Input 2 B. The Ethernet connection A DIP switch for the signal selection of C.

  • Page 75: Control Unit Cabling

    CONTROL UNIT VACON · 75 It is possible to use the drive with an external power source with these properties: +24 VDC ±10%, minimum 1000 mA. Connect the external power source to terminal 30. This voltage is sufficient to keep the control unit on and for you to set the parameters. The measurements of the main circuit (for example, the DC link voltage, and the unit temperature) are not available when the drive is not connected to mains.
  • Page 76 VACON · 76 CONTROL UNIT Standard I/O board Signal Terminal Description +10 Vref Reference output Reference potentiometer 1...10kΩ Analogue input, AI1+ voltage or current Frequency reference Analogue input AI1- 2-wire transmitter common, (current) Actual value Analogue input, AI2+ voltage or current...
  • Page 77 CONTROL UNIT VACON · 77 * = You can isolate digital inputs from ground with a DIP switch. See 7.2.2.2 Isolation of digital inputs from ground. There are 2 different relay boards available. From Standard I/O board Relay board 1 Default From term.
  • Page 78 VACON · 78 CONTROL UNIT RS-485 Fig. 29: The selections of the DIP switches A. The voltage signal (U), 0-10 V input D. ON B. The current signal (I), 0-20 mA input E. The RS-485 bus termination C. OFF Table 29: The default positions of the DIP switches...

  • Page 79: Fieldbus Connection

    CONTROL UNIT VACON · 79 7.2.2.2 Isolation of digital inputs from ground It is possible to isolate from ground the digital inputs (terminals 8-10 and 14-16) on the standard I/O board. To do this, change the position of a DIP switch on the control board.

  • Page 80: Using Fieldbus Through An Ethernet Cable

    VACON · 80 CONTROL UNIT Fig. 31: The Ethernet and RS485 connections A. RS485 terminal A = Data - C. The Ethernet terminal B. RS485 terminal B = Data + D. The control terminals 7.3.1 USING FIELDBUS THROUGH AN ETHERNET CABLE...

  • Page 81: Using Fieldbus Through An Rs485 Cable

    CONTROL UNIT VACON · 81 7.3.2 USING FIELDBUS THROUGH AN RS485 CABLE Table 31: RS485 cable data Item Description The plug type 2.5 mm The cable type STP (shielded twisted pair), Belden 9841 or almost the same The cable length So that it agrees with the fieldbus.
  • Page 82 VACON · 82 CONTROL UNIT Connect the cable to the standard I/O board of the drive, in terminals A and B. A = negative • B = positive • Attach the shield of the cable to the frame of the drive with a grounding clamp for control cable to make a grounding connection.
  • Page 83 CONTROL UNIT VACON · 83 If the drive is the last device on the fieldbus line, set the bus termination. a) Find the DIP switches on the left side of the control unit of the drive. b) Set the DIP switch of the RS485 bus termination to the ON position.

  • Page 84: Installation Of Option Boards

    VACON · 84 CONTROL UNIT NOTE! If you do power-down to the last device, there is no bus termination. INSTALLATION OF OPTION BOARDS CAUTION! Do not install, remove, or replace option boards on the drive when the power is on.

  • Page 85: The Installation Procedure

    CONTROL UNIT VACON · 85 THE INSTALLATION PROCEDURE Open the cover of the AC drive. WARNING! Do not touch the control terminals. They can have a dangerous voltage also when the drive is disconnected from mains. If you have an OPTB or an OPTC option board, make sure that the label on it says "dv"...

  • Page 86: Installation Of A Battery For The Real Time Clock (Rtc)

    VACON · 86 CONTROL UNIT Install the option board into the correct slot: C, D or E. See Table 32. a) The option board has a slot coding, because of which it is not possible to install the option board in an incorrect slot.
  • Page 87 CONTROL UNIT VACON · 87 10Vref +24V AI1+ AI1- AI2+ AI2- DI1... AO1+ AO1- +24Vin RS485 RO1/1 RO1/2 RO1/3 RO2/1 RO2/2 RO2/3 TI1+ TI1- DC+/R+ Fig. 32: The galvanic isolation barriers A. The control unit B. The power unit LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 88: Commissioning And Additional Instructions

    VACON · 88 COMMISSIONING AND ADDITIONAL INSTRUCTIONS COMMISSIONING AND ADDITIONAL INSTRUCTIONS COMMISSIONING SAFETY Before you start the commissioning, read these warnings. WARNING! Do not touch the internal components or the circuit boards of the drive when the drive is connected to mains. These components are live. A contact with this voltage is very dangerous.

  • Page 89: Operation Of The Motor

    COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 89 OPERATION OF THE MOTOR 8.2.1 CHECKS BEFORE STARTING THE MOTOR Before you start the motor, do these checks. Make sure that all the START and STOP switches that are connected to the control •...

  • Page 90: Installation In An It System

    VACON · 90 COMMISSIONING AND ADDITIONAL INSTRUCTIONS INSTALLATION IN AN IT SYSTEM If your mains is impedance-grounded (IT), the AC drive must have the EMC protection level C4. If your drive has the EMC protection level C3, it is necessary to change it to C4. To do this, remove the EMC jumper.

  • Page 91: The Emc Jumper In Mr9

    COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 91 Find the grounding arm and push it down. A. The grounding arm is up (level B. The grounding arm is down (level C4) After the change, write "The EMC level was changed" and the date on the "product modified"...

  • Page 92: The Emc Jumper In Mr10 And Mr12

    VACON · 92 COMMISSIONING AND ADDITIONAL INSTRUCTIONS Remove the EMC jumper. If you change the EMC level, write "The EMC level was changed" and the date on the "product Product modified changed" label. If the label is not attached at this...
  • Page 93 COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 93 FINDING THE EMC JUMPER, WITHOUT THE OPTIONS MODULE Find the EMC jumper between the terminals L2 and Remove the EMC jumper. If you change the EMC level, write "The EMC level was changed" and the date on the "product Product modified modified"...
  • Page 94 VACON · 94 COMMISSIONING AND ADDITIONAL INSTRUCTIONS FINDING THE EMC JUMPER, WITH AN OPTIONS MODULE Remove the covers of the options module. Find the EMC jumper between the terminals L2 and LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 95: Maintenance

    COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 95 Remove the EMC jumper. If you change the EMC level, write "The EMC level was changed" and the date on the "product Product modified modified" label. If the label is not attached at this...

  • Page 96: Replacing The Fans Of The Ac Drive

    VACON · 96 COMMISSIONING AND ADDITIONAL INSTRUCTIONS This table is valid for VACON components. To do maintenance on components that are ® made by other manufacturers, obey the manual of the component in question. 8.6.2 REPLACING THE FANS OF THE AC DRIVE 8.6.2.1...
  • Page 97 COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 97 To release the fan from the cover plate, remove the 4 screws. A. The fan cable Release the grommet on the fan cable from the cover plate and pull out the cable. Replace the main fan. Attach the screws.
  • Page 98 VACON · 98 COMMISSIONING AND ADDITIONAL INSTRUCTIONS Disconnect the cables from the fan power supply. Remove the 12 screws from the fan cover plate. Use the handle to lift off the main fan unit. To release the fan from the cover plate, remove the 4 screws.
  • Page 99 COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 99 REPLACING THE MAIN FAN ASSEMBLY, MR10 AND MR12 Loosen the 8 screws and lift off the service lid. Disconnect the cables from each fan power supply. X61 X8 X61 X8 a) Disconnect the fan driver cable from connector X61.

  • Page 100: Downloading The Software

    VACON · 100 COMMISSIONING AND ADDITIONAL INSTRUCTIONS REPLACING THE FAN POWER SUPPLIES, MR10 AND MR12 You can replace only 1 or both the fan power supplies. Remove the main fan assembly. See the previous instructions. a) Disconnect the fan supply cable from connector X81.
  • Page 101 COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 101 DOWNLOADING WITH MAINS, MR8-MR12 When the drive is supplied from mains, you can download a new software with the VACON ® Loader PC tool and a CAB-USB/RS485 cable. To download a new software, connect the PC into the control panel connector with the CAB-USB/ RS485 cable.
  • Page 102 VACON · 102 COMMISSIONING AND ADDITIONAL INSTRUCTIONS In MR10 and MR12, connect an external 24 VDC into the connector X50 on the measurement board. The connector pins are X50-22 (+) and X50-23 (-). In MR12, connect the external 24 VDC to the •...

  • Page 103: Technical Data, Vacon ® 100 Industrial

    VACON · 103 TECHNICAL DATA, VACON 100 INDUSTRIAL ® AC DRIVE POWER RATINGS 9.1.1 MAINS VOLTAGE 208-240 V Table 34: The power ratings of VACON 100 INDUSTRIAL in mains voltage 208-240 V, 50-60 Hz, ® Enclos Drive Loadability Motor shaft power...

  • Page 104: Mains Voltage 380-500 V

    VACON · 104 TECHNICAL DATA, VACON® 100 INDUSTRIAL 9.1.2 MAINS VOLTAGE 380-500 V Table 35: The power ratings of VACON 100 INDUSTRIAL in mains voltage 380-500V, 50-60 Hz, ® Enclos Drive Loadability Motor shaft power type size High 400 V mains...

  • Page 105: Mains Voltage 525-690 V

    TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON · 105 9.1.3 MAINS VOLTAGE 525-690 V Table 36: The power ratings of VACON 100 INDUSTRIAL in mains voltage 525-690 V, 50-60 Hz, ® Enclos Drive Loadability Motor shaft power type size High 600 V mains...

  • Page 106: Brake Resistor Ratings

    VACON · 106 TECHNICAL DATA, VACON® 100 INDUSTRIAL I L*110% I L*110% 1 min 9 min Fig. 33: Low overload The high overload means that if 150% of the continuous current (I ) is required for 1 minute every 10 minutes, the remaining 9 minutes must be approximately 92% of I or less.
  • Page 107 TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON · 107 Table 37: The recommended brake resistor types and the calculated resistance of the drive, 208-240 V Enclosure size Duty cycle Type of brake resistor Resistance [Ω] Light duty BRR 0105 LD 5...
  • Page 108 VACON · 108 TECHNICAL DATA, VACON® 100 INDUSTRIAL Table 39: The recommended brake resistor types and the calculated resistance of the drive, 525-690 V Enclosure size Drive type Duty cycle Type of brake Resistance [Ω] resistor Light duty BRR 0052 LD 6...
  • Page 109 TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON · 109 P [%] t [s] 3 5 10 123 125 130 Fig. 36: The duty cycles of the LD and HD pulses Table 40: The minimum resistance and the brake power, mains voltage...

  • Page 110: Vacon ® 100 Industrial - Technical Data

    VACON · 110 TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON 100 INDUSTRIAL - TECHNICAL DATA ® Table 43: The technical data of the VACON 100 INDUSTRIAL AC drive ® Technical item or function Technical data Input voltage U 208-240 V, 380-500 V, 525-690 V, -10%...+10%...
  • Page 111 TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON · 111 Table 43: The technical data of the VACON 100 INDUSTRIAL AC drive ® Technical item or function Technical data Switching frequency (see 200-500 V parameter P3.1.2.3) MR8-MR12: • 1.5-6 kHz • Default: MR8: 3 kHz, MR9: 2 kHz, MR10: 2 •...
  • Page 112 VACON · 112 TECHNICAL DATA, VACON® 100 INDUSTRIAL Table 43: The technical data of the VACON 100 INDUSTRIAL AC drive ® Technical item or function Technical data Ambient operating tem- current: -10°C (no frost)...+40 °C perature current: -10°C (no frost)...+40 °C Maximum operating temperature: +50 °C with derating...
  • Page 113 TECHNICAL DATA, VACON® 100 INDUSTRIAL VACON · 113 Table 43: The technical data of the VACON 100 INDUSTRIAL AC drive ® Technical item or function Technical data Immunity Fulfils EN61800-3, 1 and 2 environment Emissions 200-690 V: EN 61800-3 (2004), category C3, if the drive is correctly installed.
  • Page 114 VACON · 114 TECHNICAL DATA, VACON® 100 INDUSTRIAL Table 43: The technical data of the VACON 100 INDUSTRIAL AC drive ® Technical item or function Technical data Overvoltage trip limit Mains voltage 240 V: 456 VDC Mains voltage 500 V: 911 VDC...

  • Page 115: Technical Data, Vacon® 100 Flow

    100 FLOW ® 10.1 AC DRIVE POWER RATINGS 10.1.1 MAINS VOLTAGE 208-240 V Table 44: The power ratings of VACON 100 FLOW in mains voltage 208-240 V, 50-60 Hz, 3~ ® Enclosure Drive type Loadability Motor shaft power size Continuous...

  • Page 116: Mains Voltage 380-500 V

    VACON · 116 TECHNICAL DATA, VACON® 100 FLOW 10.1.2 MAINS VOLTAGE 380-500 V Table 45: The power ratings of VACON 100 FLOW in mains voltage 380-500 V, 50-60 Hz, 3~ ® Enclosure Drive type Loadability Motor shaft power size Continuous...

  • Page 117: Mains Voltage 525-690 V

    TECHNICAL DATA, VACON® 100 FLOW VACON · 117 10.1.3 MAINS VOLTAGE 525-690 V Table 46: The power ratings of VACON 100 FLOW in mains voltage 525-690 V, 50-60 Hz, 3~ ® Enclosure Drive type Loadability Motor shaft power size Continuous...
  • Page 118 VACON · 118 TECHNICAL DATA, VACON® 100 FLOW I L*110% I L*110% 1 min 9 min Fig. 37: Low overload in VACON 100 FLOW ® For more information, refer to the standard IEC61800-2 (IEC:1998). LOCAL CONTACTS: HTTP://DRIVES.DANFOSS.COM/DANFOSS-DRIVES/LOCAL-CONTACTS/...

  • Page 119: Vacon ® 100 Flow - Technical Data

    TECHNICAL DATA, VACON® 100 FLOW VACON · 119 10.2 VACON 100 FLOW - TECHNICAL DATA ® Table 47: The technical data of the VACON 100 FLOW AC drive ® Technical item or function Technical data Input voltage U 208-240 V, 380-500 V, 525-690 V, -10%...+10%...
  • Page 120 VACON · 120 TECHNICAL DATA, VACON® 100 FLOW Table 47: The technical data of the VACON 100 FLOW AC drive ® Technical item or function Technical data Switching frequency (see 200-500 V parameter P3.1.2.3) MR8-MR12: • 1.5-6 kHz • Default: MR8: 3 kHz, MR9: 2 kHz, MR10: 2 •...
  • Page 121 TECHNICAL DATA, VACON® 100 FLOW VACON · 121 Table 47: The technical data of the VACON 100 FLOW AC drive ® Technical item or function Technical data Ambient operating tem- current: -10°C (no frost)…+40 °C perature Maximum operating temperature: +50 °C with derating (1.5%/1°C)
  • Page 122 VACON · 122 TECHNICAL DATA, VACON® 100 FLOW Table 47: The technical data of the VACON 100 FLOW AC drive ® Technical item or function Technical data Immunity Fulfils EN61800-3, 1 and 2 environment Emissions 200-690 V: EN 61800-3 (2004), category C3, if the drive is correctly installed.
  • Page 123 TECHNICAL DATA, VACON® 100 FLOW VACON · 123 Table 47: The technical data of the VACON 100 FLOW AC drive ® Technical item or function Technical data Overvoltage trip limit Mains voltage 240 V: 456 VDC Mains voltage 500 V: 911 VDC...
  • Page 124 VACON · 124 TECHNICAL DATA ON CONTROL CONNECTIONS TECHNICAL DATA ON CONTROL CONNECTIONS 11.1 TECHNICAL DATA ON CONTROL CONNECTIONS Table 48: The standard I/O board Standard I/O board Terminal Signal Technical information Reference output +10 V, 0%...+3%, maximum current: 10 mA Analogue input channel 1 0...+10 V (Ri = 200 kΩ)
  • Page 125 TECHNICAL DATA ON CONTROL CONNECTIONS VACON · 125 Table 48: The standard I/O board Standard I/O board Terminal Signal Technical information Digital input 4 Positive or negative logic Ri = min. 5 kΩ Digital input 5 0-5 V = 0...
  • Page 126 VACON · 126 TECHNICAL DATA ON CONTROL CONNECTIONS Table 49: The standard relay board (+SBF3) Terminal Signal Technical information Change-over contact (SPDT) relay. 5.5 mm isolation between channels. Switching capacity 24 VDC/8 A Relay output 1 * • 250 VAC/8 A •...
  • Page 127 TECHNICAL DATA ON CONTROL CONNECTIONS VACON · 127 Table 50: The optional relay board (+SBF4) Terminal Signal Technical information Change-over contact (SPDT) relay. 5.5 mm isolation between channels. Switching capacity 24 VDC/8 A Relay output 1 * • 250 VAC/8 A •...
  • Page 128 Document ID: Vacon Ltd DPD01665D Member of the Danfoss Group Rev. D Runsorintie 7 65380 Vaasa Sales code: DOC-INS100IP00+DLUK Finland...

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