• 1 TABLE OF CONTENTS Document: DPD00926G Order code: DOC-INS02234+DLUK Rev. G Version release date: 16.11.12 Safety ....................... 4 Danger ..........................4 Warnings ..........................5 Earthing and earth fault protection ................... 6 Electro-magnetic compatibility (EMC)................7 Compability with RCDs....................... 7 Receipt of delivery....................
Page 4
7.1.1 Mains voltage 208-240 V ....................75 7.1.2 Mains voltage 380-480 V ....................76 7.1.3 Definitions of overloadability ................... 77 Vacon 100 - technical data ....................78 7.2.1 Technical information on control connections ..............81 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.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)
• 4 Safety AFETY This manual contains clearly marked cautions and warnings which are intended for your per- sonal safety and to avoid any unintentional damage to the product or connected appliances. Please read the information included in cautions and warnings carefully.
(EN 60204-1). 13006.emf Only spare parts delivered by Vacon can be used. 13006.emf At power-up, power brake or fault reset the motor will start immediately if the start signal is active, unless the pulse control for Start/Stop logic has been selected.
• 6 Safety Earthing and earth fault protection CAUTION! 13006.emf The AC drive must always be earthed with an earthing conductor connected to the earthing ter- minal marked with The touch current of the drive exceeds 3.5 mA AC. According to EN 61800-5-1, one or more of...
Safety vacon • 7 Do not perform any voltage withstand tests on any part of the AC drive. There is a certain procedure according to which the tests shall be performed. Ignoring this 13006.emf procedure may result in damaged product.
• 9 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:...
9012.emf 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.
Receipt of delivery vacon • 11 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...
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 9080.emf Figure 4. Vacon AC drive dimensions, MR4, wall mount Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
Mounting vacon • 19 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 Figure 10. Note the IP classes of different sections in figure below.
Page 22
• 20 Mounting 3.1.2.1 Flange mount - Frames MR4 to MR9 Figure 17. presents the dimensions of the mounting opening and Figure 11. - 16. the dimen- sions of the drives with the flange mount option. 152,0 122,0 15,0...
Mounting vacon • 27 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 30
• 28 Mounting Note that if several units are mounted above each other the required free space equals C + D (see Figure 19.). Moreover, the outlet air used for coo- ling by the lower unit must be directed away from the air intake of the upper unit by means of e.g.
U, V and W. See principal connection diagram in Figure 20. See also Table 13 for the cable recommmendations for different EMC levels. NOTE! R+ and R- terminals are not used in Vacon 100 HVAC drive and no external components can be connected to them.
Page 32
• 30 Power cabling 2 = Symmetrical power cable equipped with concentric protection wire and intended for the specific mains voltage. (MCMK or similar recommended). See Figure 21. 3 = Symmetrical power cable equipped with compact low-impedance shield and intended for the specific mains voltage.
To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with a minium 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, 600 V maximum.
Page 34
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 35
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 36
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 37
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.
• 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).
Power cabling vacon • 37 4.2.1 Frames MR4 to MR7 Strip the motor and mains cables as advised below. Earth conductor Earth conductor MAINS MOTOR Figure 22. Stripping of cables Table 19. Cables stripping lengths [mm] Frame Leave as short...
Page 41
Power cabling vacon • 39 Remove the screws of the cable protection plate. Do not open the cover of the power unit! M4x8 9022.emf Figure 24. Insert the cable grommets (included in the delivery) in the openings of the cable entry plate (included) as shown in the picture (Picture EU version).
Page 42
• 40 Power cabling • Insert the cables - supply cable and motor cable - in the openings of the cable entry plate. • Then cut the rubber grommets open to slide the cables through. Should the grommets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up.
Page 43
Power cabling vacon • 41 Detach the cable clamps and the grounding clamps (Figure 27) and place the cable entry plate with the cables in the groove on the AC drive frame (Figure 28). M4x16 (2.2 Nm) 9024.emf Figure 27.
Page 44
• 42 Power cabling Connect the stripped cables (see Figure 22 and Table ) as shown in Figure 29. • Expose the shield of all three cables in order to make a 360-degree con- nection with the cable clamp (1).
Page 45
Power cabling vacon • 43 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 EN 61800- 5-1. See Figure 30 and chapter “Earthing and earth fault protection” on page 6.
• 44 Power cabling 4.2.2 Frames MR8 and MR9 Strip the motor and mains cables as advised below. Earth conductor Earth conductor MAINS MOTOR Figure 32.Stripping of cables Table 21. Cables stripping lengths [mm] Frame Leave as short as possible Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
Page 47
Power cabling vacon • 45 MR9 only: Remove the main cover of the AC drive. M4 x 10 9046.emf Figure 33. Remove the cable cover (1) and the cable fitting plate (2). M4x8 M4 x 8 9028.emf Figure 34. Removing cable cover and cable fitting plate (MR8).
Page 48
• 46 Power cabling M4 x 8 M5 x 10 9041.emf Figure 35. Removing cable cover and cable fitting plate (MR9). MR9 only: Loosen the screws and remove the sealing plate. M4x8 9048.emf Figure 36. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
Page 49
Power cabling vacon • 47 Remove the EMC shield plate. M4x8 Wing nut 9026.emf Figure 37. Locate the terminals. OBSERVE the exceptional placement of motor cable termi- nals in MR8! L1 L2 L3 DC- DC+ L1 L2 L3 U V W DC- DC+ 9221.emf...
Page 50
• 48 Power cabling Cut the rubber grommets open to slide the cables through. Should the grom- mets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up. Do not cut the grommet openings wider than what is neces- sary for the cables you are using.
Page 51
Power cabling vacon • 49 If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables. 9032.emf Figure 41. Connect the cables stripped as shown in Figure 32. • Connect the (phase) conductors of the supply and motor cables into their respective terminals (a).
Page 52
• 50 Power cabling Connector Cable lug Cable lug 9015.emf Figure 43. Placing two cable lugs on top of each other Tightening torques of cable terminals: Table 22. Tightening torques of terminals Tightening torque Tightening torque Tightening torque, [Nm]/[lb-in.] [Nm]/[lb-in.]...
Page 53
Power cabling vacon • 51 Remount now first the EMC shield plate (see Figure 37) and then the sealing plate for MR9 (see Figure 36). Re-attach then the cable fitting plate and then the cable cover. M4x8 M4x8 9223.emf Figure 45.
Page 54
• 52 Power cabling M4x10 9224.emf Figure 46. 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 chapter “Earthing and earth fault protection” on page 6.
Power cabling vacon • 53 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.
The control board can be powered externally (+24 VDC, 100 mA, ±10%) by connecting the ex- ternal power source to terminal #30, see page 56. This voltage is sufficient for parameter set- ting and for keeping the control unit active.
Control unit vacon • 55 Control unit cabling The basic control unit connections are presented in Figure 49 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 24 and 25).
• 56 Control unit 5.1.2 Control terminals and DIP switches Basic I/O board Relay boards The terminals of the and the are described below. For more in- formation on the connections, see Chapter 7.2.1. The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches.
Page 59
Control unit vacon • 57 Table 25. Control I/O terminal signals on relay board 1 and connection example Relay board 1 From Terminal Signal Basic I/O board Relay output 1 RO1/1 NC From term. From term. #6 or 12 RO1/2 CM...
Page 60
• 58 Control unit 5.1.2.1 Selection of terminal functions and Isolating digital inputs from ground with dip switches Current/Voltage selection The shadowed terminals in Table allow for three functional selections (current/voltage refe- dip switches rence signal) each with the so-called .
Control unit vacon • 59 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 62
• 60 Control unit max. 40 mm Ethernet 9107.emf cable Figure 52. Protection class IP21: Cut free the opening on the AC drive cover for the Ether- net cable. Protection class IP54: Cut the rubber grommets open to slide the cables through.
Control unit vacon • 61 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 9265.emf IP21 IP54 Figure 54.
Page 64
Do not strip the aluminum cable shield! 9188.emf 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 55. RS485...
Page 65
Control unit vacon • 63 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 9200.emf If the AC drive is the last device on the bus, the bus termination must be set.
Page 66
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 63. 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...
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 56). Real Time Clock (RTC)
• 66 Control unit Galvanic isolation barriers The control connections are isolated from the mains potential and the GND terminals are per- manently connected to ground. See Figure 57. The digital inputs are galvanically isolated from the I/O ground. The relay outputs are addition- ally double-isolated from each other at 300 VAC (EN-50178).
9000.emf severe injury. The motor terminals U, V, W are live when Vacon 100 is connected to mains, even if the motor is not running. 9000.emf 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.
• 68 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.
Commissioning vacon • 69 6.2.1 Cable and motor insulation checks 1. Motor cable insulation checks Disconnect the motor cable from terminals U, V and W of the AC drive and from the motor. Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor.
• 70 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.
Commissioning vacon • 71 6.3.2 Frames MR7 and MR8 Follow the procedure described below to modify the EMC protection of the AC drive of frames MR7 and MR8 to EMC-level C4. Remove the main cover of the AC drive and locate the jumper. MR8 only: Push down the grounding arm.
• 72 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. 9062.emf Figure 62. MR7: Detaching the DC grounding busbar from frame 6.3.3...
Page 75
‘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...
• 74 Commissioning Maintenance In normal conditions, the AC drive is maintenance-free. However, regular maintenance is re- commended to ensure a trouble-free operation and a long lifetime of the drive. We recommend to follow the table below for maintenance intervals.
Technical data vacon • 75 ECHNICAL DATA AC drive power ratings 7.1.1 Mains voltage 208-240 V Table 29. Power ratings of Vacon 100, supply voltage 208-240 V Mains voltage 208-240V, 50-60 Hz, 3~ Loadability Motor shaft power 208-240 V 230 supply...
• 76 Technical data 7.1.2 Mains voltage 380-480 V Table 30. Power ratings of Vacon 100, supply voltage 380-480 V Mains voltage 380-480V, 50-60 Hz, 3~ Loadability Motor shaft power 400 V supply 480V supply Converter type Rated continuous...
Technical data vacon • 77 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.
• 78 Technical data Vacon 100 - technical data Table 31. Vacon 100 technical data Input voltage U 208...240 V; 380…480 V; -10%…+10% Input frequency 50...60 Hz -5...+10% Mains connection Connection to mains Once per minute or less Starting delay 6 s (MR4 to MR6);...
Page 81
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...240 V: 4,000 m (TN and IT systems) Altitude 380...500 V: 4,000 m (TN and IT systems)
Page 82
• 80 Technical data Table 31. Vacon 100 technical data 240-volt drives: 456 VDC Overvoltage trip limit 480-volt drives: 911 VDC Depends on supply voltage (0,8775*supply voltage): Undervoltage trip limit Supply voltage 240 V: Trip limit 211 VDC Supply voltage 400 V: Trip limit 351 VDC...
Analogue input common Differential input if not connected to ground; (current) Allows 20V differential mode voltage to GND +24 V, ±10%, max volt. ripple < 100 mVrms; max. 250 mA 24 V aux. voltage Dimensioning: max. 1000 mA/control unit. Short-circuit protected.
Page 84
• 82 Technical data Table 32. Technical information on standard I/O board Standard I/O board Terminal Signal Technical information RS485 Differential receiver/transmitter Set bus termination with dip switches (see page 58) RS485 Table 33. Technical information on Relay board 1...
Need help?
Do you have a question about the 100 and is the answer not in the manual?
Questions and answers