Vacon 100 x Installation, Technical And Maintenance Manual
  1. Manuals
  2. Brands
  3. Vacon Manuals
  4. Controller
  5. 100X series
  6. Installation, technical and maintenance manual

Vacon 100 x Installation, Technical And Maintenance Manual

Designed to control asynchronous ac motors and permanent magnet motors
Hide thumbs Also See for 100 x:
Table of Contents

Advertisement

Quick Links

See also: Technical Manual , User Manual
vacon
100 x
®
ac drives
Installation, Technical and Maintenance
Manual

Advertisement

Table of Contents
loading

Related Manuals for Vacon 100 x

Summary of Contents for Vacon 100 x

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

  • Page 3: Table Of Contents

    • 1 NDEX Document code (Original Instructions): DPD00534J Order code: DOC-INS03985+DLUK Rev. J Revision release date: 13.2.17 Safety........................4 Signs............................4 Units ............................4 Danger..........................5 Warnings ..........................5 Grounding and earth fault protection .................7 Insulation system......................10 Compatibility with RCDs ....................11 Extended temperature range ...................11 Electro-magnetic compatibility (EMC)................11...
  • Page 4 AC drive power ratings......................63 7.1.1 Mains voltage 3AC 208-240V.....................63 7.1.2 Mains voltage 3AC 380-480/500V..................64 7.1.3 Definitions of overloadability ....................65 Brake resistor ratings.......................66 VACON® 100 X - technical data..................67 7.3.1 Technical information on control connections..............70 Options......................72 Mains switch........................72 8.1.1 Installation ........................72 Control Keypad........................76...
  • Page 5 • 3 Commissioning .......................121 9.6.1 General wiring instructions ....................121 9.6.2 Checklist for commissioning ..................121 Parameters and fault tracing ..................122 Maintenance and diagnostics ..................122 10. Solar pump application ................. 123 10.1 Danger..........................123 10.2 Warning ...........................123 10.3 DC Fuse selection ......................123 10.4 Manufacturers of gPV fuses ...................124...

  • Page 6: 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 7: Danger

    ® 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 and the client- ®...
  • Page 8 Before performing any measurement on the motor or on the motor cable, disconnect the motor cable from the AC drive. ® Do not perform any voltage withstand test on any part of VACON 100 X. The tests must be performed according to a specific procedure. Ignoring this procedure may damage the product.

  • Page 9: Grounding And Earth Fault Protection

    CAUTION! ® The VACON 100 X AC drive must always be earthed with a grounding conductor connected to the grounding terminal marked with See Table 16 and Table 17 for the required cross-section of phase conductor and protective ground- ing conductor (both made of copper).
  • Page 10 • 8 Safety Earth connection 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. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 11 Safety vacon • 9 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 grounding conductor. NOTE: Due to the high capacitive currents present in the AC drive, fault current protective switches may not function properly.

  • Page 12: 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 13: 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 and Table 29 for the output rated current. Higher temperatures are allowed only with derating of the output cur- rent.

  • Page 14: Declaration Of Conformity

    Product(s) Vacon 100 X AC drive Type(s) Vacon 0100 3L 0007 2…0062 2 X Vacon 0100 3L 0003 4…0072 4 X Vacon 0100 3L 0003 5…0072 5 X Product Safety Functions: Safe Torque Off (EN 61800-5-2:2007) and Emergency stop (EN-60204-1:2006+A1:2009+...
  • Page 15 Safety vacon • 13 Figure 7. STO certificate. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 16: Marine Environment

    • 14 Safety 1.11 Marine environment For installation, safety and EMC requirements in a marine environment download and read the Ma- rine Installation Guide. NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from http://drives.danfoss.com/knowledge-center/technical-documentation/.

  • Page 17: Receipt Of Delivery

    Receipt of delivery vacon • 15 ECEIPT OF DELIVERY Check the correctness of delivery by comparing your order data to the drive information found on the package label. If the delivery does not correspond to your order, contact the supplier immedi- ately.

  • Page 18: Type Designation Code

    • 16 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: Order Codes

    Receipt of delivery vacon • 17 order codes ® The order codes for VACON 100 X drive family are shown in the following table: ® Table 3. Order codes of VACON 100 X. See chapter 7 for more details. Enclosure size...

  • Page 20: 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 21: Frame Mm5

    Receipt of delivery vacon • 19 2.4.2 Frame MM5 Table 6. Content of accessory bag, 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...

  • Page 22: Sto Terminal Connector

    • 20 Receipt of delivery 2.4.4 STO terminal connector Figure 9. STO connector. 2.4.5 ‘Product modified’ sticker Product modified In the small plastic bag included in the delivery you will find a silver sticker. The purpose of the sticker is to notify the service personnel about the modifications made in the AC drive.

  • 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 cases, it must be ensured that the mounting plane is even.

  • Page 24: Dimensions Mm5

    • 22 Mounting Dimensions mm5 345,2 349,2 367,4 ® Figure 12. VACON 100 X drive dimensions, MM5. Dimensions W x H x D Enclosure size [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 Mm6

    Mounting vacon • 23 Dimensions mm6 382,8 385,3 499,8 ® Figure 13. VACON 100 X drive dimensions, MM6. Dimensions W x H x D Enclosure size [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...

  • 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

    Mounting vacon • 25 Mounting The drive consists of two main elements: 1. The terminal box that includes the power terminals and control board with the control terminals 2. The powerhead containing all the power electronics. To install the drive, both parts need to be separated. The terminal box must be fixed first and all cabling done.

  • 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. 3.5.3...

  • Page 29: Cooling

    C = Clearance underneath the AC drive Figure 16. Installation space. Table 11. Required cooling air. Cooling air required Type ® Should you need further details on the cooling system of the VACON 100 X, please contact your ® local VACON distributor. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 30: Power Cabling

    • 28 Power cabling OWER CABLING The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals marked with U, V and W. See principal connection diagram in Figure 17. See also Table 12 for the cable recommendations for different EMC levels.
  • Page 31 Power cabling vacon • 29 Table 12. Cable types required to meet standards. EMC levels environment environment Cable type Category C2 Category C3 Category C4 Mains cable Motor cable Control cable 1 = Power cable intended for fixed installation and the specific mains voltage. Shielded cable not required.

  • Page 32: Circuit Breaker

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

  • Page 33: Description Of The Terminals

    Power cabling vacon • 31 Description of the terminals ® VACON The following pictures describe the power terminals and the typical connections in 100 X drives. brake resistor AC power supply Three phases Motor Figure 19. Power connections, MM4. Table 13. Terminal description.
  • Page 34 • 32 Power cabling brake resistor AC power supply Three phases Motor Figure 20. Power connections, MM5. Table 14. Terminal description. Terminal Description These terminals are the input connections for the power supply. DC bus terminals (DC- DC+) DC+/R+...
  • Page 35 Power cabling vacon • 33 brake resistor AC power supply Three phases Motor Figure 21. Power connections, MM6. Table 15. Terminal description. Terminal Description These terminals are the input connections for the power supply. DC bus terminals (DC- DC+) DC+/R+...

  • Page 36: 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 gS (IEC 60269-4) fuse ranges.
  • Page 37 Power cabling vacon • 35 The terminal sizes are intended for 1 conductor. For MM6, the max. diameter of the ring terminal is 14 mm. The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be PVC-isolated;...

  • 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) 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 31 and Table 32 for the resistor ratings. 4.4.4 Control cables For information on control cables see chapter Control unit.

  • Page 40: Cable Installation

    • 38 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 Power cabling vacon • 39 Table 18. Cables stripping lengths [mm]. Enclosure size as short as possible IEC installation: • Remove the cable entry plate. The cable entry system is a combination of a cable entry plate (see the figure below) and cable glands. In the cable entry plate there are several openings available for the cables with ISO metric thread.
  • Page 42 • 40 Power cabling Figure 24.Cable entry plate, MM5. 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.
  • Page 43 ® • To connect NPT pipes to VACON 100 X, use the optional metal cable entry plate (included in -R02 option) to meet UL installation rules. • One metal conduit plate with accessories (screws and gasket) is delivered in a separate bag together with the drive.
  • Page 44 • 42 Power cabling Figure 28.Cable entry plate, MM5 UL installation. Figure 29.Cable entry plate, MM6 UL installation. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 45 Power cabling vacon • 43 • All the (3) terminal box openings are closed with the standard plastic plates with the metric threads. • The metal cable entry plate for UL installation has to be installed in place of one of standard plastic cable entries provided with the default package. The tightening torque of cable entry plate screws: 1.5 -2.0 Nm (13.2-17.7 lb-in).
  • Page 46 • 44 Power cabling Tightening torques of cable terminals: Table 20. Tightening torques of terminals. Tightening torque Tightening torque Tightening torque, Enclosure [Nm]/[lb-in.] [Nm]/[lb-in.] [Nm]/[lb-in.] Type size Power and motor EMC grounding Grounding terminals clamps terminals [Nm] lb-in. [Nm] lb-in.

  • Page 47: Control Unit

    Control unit vacon • 45 ONTROL UNIT Remove the powerhead of the drive to reveal the terminal box with the control terminals. The control unit of the AC drive consists of the control board and additional boards (option boards) connected to the slot connectors of the control board. The locations of boards, terminals and switches are presented in Figure 30 below.

  • Page 48: Control Unit Cabling

    • 46 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

    Control unit vacon • 47 5.1.2 Standard I/O terminals Standard I/Os Relays The terminals of the and the are described below. For more information on the connections, see chapter 7. The terminals shown on shadowed background are assigned for signals with optional functions se- lectable with DIP switches.

  • Page 50: Relay And Thermistor Input Terminals

    • 48 Control unit 5.1.3 Relay and thermistor input terminals Table 24. 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: Local Contacts: Http://Drives.danfoss.com/Danfoss-Drives/Local-Contacts

    ® dip switches The VACON 100 X drive embodies five so-called that allow for three functional selec- tions each. The shadowed terminals in Table 23 can be functionally modified with the dip switches. The switches have three positions: C, 0 and V. The switch in the position “C” means that the input or the output has been set in current mode.

  • Page 52: Bus Termination Of The Rs485 Connection

    • 50 Control unit 5.1.7 Bus termination of the RS485 connection This dip switch is related to the RS485 connection. It is 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

    Control unit vacon • 51 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 standard I/O terminals (A and B) and the connection for Ethernet is left to the con- trol terminals.

  • 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

    The bus termination must be set for the first and the last device of the fieldbus line. See picture below and step 4. We recommend that the first device on the bus and, thus, terminated, was the Master device. Vacon 100X Vacon 100X Vacon 100X Vacon 100X Vacon 100X Termination...

  • 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 100 X AC drive. Remove the three screws on the control box as shown in Figure 36.
  • Page 57 Control unit vacon • 55 Rotate and open the cover of the control box as shown in Figure 37. Figure 37. Open the cover of control box. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 58 • 56 Control unit Install the battery in the correct place and connect it to the control box. See Figure 38 for battery location and connector. 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

    • 58 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 5.

  • Page 61: Changing Emc Protection Class

    Commissioning vacon • 59 Changing EMC protection class If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC-level T (C4).
  • Page 62 • 60 Commissioning Figure 41. Powerhead separated from the terminal box in MM6. Figure 42.Locations of EMC screws in MM6. CAUTION! Before connecting the AC drive to mains make sure that the EMC protec- tion class settings of the drive are appropriately made.

  • Page 63: Running The Motor

    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 64: Maintenance

    • 62 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

    • 63 ECHNICAL DATA AC drive power ratings 7.1.1 Mains voltage 3AC 208-240V ® Table 28. Power ratings of VACON 100 X, supply voltage 3AC 208-240V. Mains voltage 3AC 208-240V, 50/60 Hz Motor shaft power Loadability Input 230V supply AC drive...

  • Page 66: Mains Voltage 3Ac 380-480/500V

    • 64 Technical data 7.1.2 Mains voltage 3AC 380-480/500V ® Table 29. Power ratings of VACON 100 X, supply voltage 3AC 380-480/500V, high overload. Mains voltage 3AC 380-480/500V, 50/60 Hz Motor shaft power Loadability Input 400V 480V AC drive...

  • Page 67: Definitions Of Overloadability

    Technical data vacon • 65 7.1.3 Definitions of overloadability High overload= Following continuous operation at rated output current I , the drive supplies 150% * I 1 min, followed by a period of at least 9 min at I or below.

  • 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: Table 31. Brake resistor ratings, 208-240V.

  • Page 69: Vacon 100 X - Technical Data

    Technical data vacon • 67 ® VACON 100 X - technical data ® Table 33. VACON 100 X technical data. 3AC 208…240V Input voltage U 3AC 380...480V 3AC 380...500V Input voltage -15%...+10% continuously tolerance Input frequency 50/60 Hz Protection class...
  • Page 70 • 68 Technical data ® Table 33. VACON 100 X technical data. Programmable 1.5…16 kHz; Switching frequency Default: 6 kHz (MM4 and MM5); 4 kHz (MM6) Automatic switching frequency derating in case of overheating Frequency reference Analogue input Resolution 0.1% (10-bit), accuracy ±1%...
  • Page 71 Technical data vacon • 69 ® Table 33. VACON 100 X technical data. 2004/108/EC Low Voltage Directive 2006/95/EC Directives RoHS 2002/95/EC WEEE 2012/19/EC Immunity EN61800-3 (2004), 1 and 2 environment EN61800-3 (2004), Category C2 Emissions The drive can be modified for IT-networks.

  • Page 72: Technical Information On Control Connections

    • 70 Technical data 7.3.1 Technical information on control connections Table 34. Technical information on standard I/O terminals. 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...
  • Page 73 Technical data vacon • 71 Table 34. Technical information on standard I/O terminals. Standard I/O Terminal Signal Technical information RS485 Differential receiver/transmitter Set bus termination with dip switches (see page 49). RS485 Default: but termination disconnected. Table 35. Technical information on Relay and thermistor terminals.

  • Page 74: Options

    The purpose of the is to disconnect the VACON 100 X from the mains when, for ex- ample, service actions are needed. The mains switch is available as option and it can be integrated in the drive. The switch can be mounted on either side of the drive. See Figure 45.
  • Page 75 Options vacon • 73 • 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 76 • 74 Options • Connect the supply cable to the Mains switch passing through the cable entry plate of the bottom side (use the cable gland for sealing the cable to the gland plate) and then through the terminal box as shown in the figure below.
  • Page 77 Options vacon • 75 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 78: Control Keypad

    ® The control keypad is the interface between the VACON 100 X AC drive and the user. With the con- trol keypad it is possible to control the speed of a motor, to supervise the state of the equipment and to set the AC drive's parameters.

  • Page 79: Installation

    Options vacon • 77 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 80 • 78 Options • Connect the keypad to the drive and plug the cable on the HMI connector as shown in the Figure 55 and in the Figure 56. Figure 55. Mounting of the keypad. Figure 56. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector (to 0.5 Nm or 4.5 lb-in) to the enclosure of the drive.

  • Page 81: Wall-Mounting

    Options vacon • 79 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 82 • 80 Options • 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. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 83: Graphical And Text Keypad

    Options vacon • 81 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 84: Vacon Keypad With Graphical Display

    • 82 Options ® 8.2.5 VACON keypad with graphical display The graphical keypad features an LCD display and 9 buttons. 8.2.5.1 Keypad display The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions.
  • Page 85 Options vacon • 83 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 86 • 84 Options Resetting fault Instructions for how to reset a fault can be found in chapter 8.2.7. Function button The FUNCT button is used for four functions: 1. to quickly access the Control page, 2. to easily change between the Local (Keypad) and Remote control places, 3.
  • Page 87 Options vacon • 85 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 88 • 86 Options Changing direction Chang- Rotation direction of the motor can quickly be changed by applying the FUNCT button. NOTE! ing direction Local command is not visible in the menu unless the selected control place is 1. Anywhere in the menu structure, push the Funct button.
  • Page 89 Options vacon • 87 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 90 • 88 Options Help texts The graphical keypad features instant help and information displays for various items. All parameters offer an instant help display. Select Help and press the OK button. Text information is also available for faults, alarms and the startup wizard.

  • Page 91: Vacon Keypad With Text Segment Display

    Options vacon • 89 ® 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 92 • 90 Options 8.2.6.3 Using the keypad Editing values Change value of a parameter following the procedure below: 1. Locate the parameter. 2. Enter the Edit mode by pressing OK. 3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the arrow buttons left/right if the value is numerical and change then the value with the arrow but- tons up/down.
  • Page 93 Options vacon • 91 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 94 • 92 Options Changing direction Chang- Rotation direction of the motor can quickly be changed by applying the FUNCT button. NOTE! ing direction Local command is not visible in the menu unless the selected control place is 1. Anywhere in the menu structure, push the Funct button.

  • Page 95: Fault Tracing

    Options vacon • 93 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 96 • 94 Options 8.2.7.1 Fault History In menu M4.3 Fault history you find the maximum number of 40 occurred faults. On each fault in the memory you will also find additional information, see below. STOP READY STOP READY STOP READY ...
  • Page 97 Options vacon • 95 8.2.7.2 Fault codes Table 36. Fault codes and descriptions. 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.
  • Page 98 • 96 Options Table 36. Fault codes and descriptions. Fault Fault Fault name Possible cause Remedy code Communication between control board and power unit has failed. Communication between control board and power unit has interference, but it is still working.
  • Page 99 Options vacon • 97 Table 36. Fault codes and descriptions. 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...
  • Page 100 • 98 Options Table 36. Fault codes and descriptions. Fault Fault Fault name Possible cause Remedy code Check the Safety switch and cabling. Unstable STO input A Safe off Reset the fault and restart. (spurious pulses detected). Should the fault re-occur, con- tact the distributor near to you.
  • Page 101 Options vacon • 99 Table 36. Fault codes and descriptions. Fault Fault Fault name Possible cause Remedy code At least one of the available analogue Change the failed parts. input signals has gone below 50% of Check the analog input circuit.
  • Page 102 • 100 Options Table 36. Fault codes and descriptions. Fault Fault Fault name Possible cause Remedy code Non-existing ID number is used for Check parameters in Fieldbus 1310 mapping values to Fieldbus Process Data Mapping menu. Data Out. The value being mapped may...
  • Page 103 Options vacon • 101 Table 36. Fault codes and descriptions. Fault Fault Fault name Possible cause Remedy code The application is not compatible (it is Replace the application. unsupported). Unsupported The option board or the slot is not com- Remove the option board.

  • Page 104: Heater (Arctic Option)

    The heater can be used only inside the drive and in combination with only the ® VACON 100 X. Before connecting the heater to mains, make sure that the ® VACON 100 X drive is closed firmly.

  • Page 105: Fuses

    Options vacon • 103 8.3.4 Fuses The recommended fuse types for the heater supply voltage are shown in the table below. Table 39. Fuses ratings. Fuses for heater supply voltage input - 230VAC gG/gL (IEC 60269-1) class T ( UL& CSA) class J ( UL&...
  • Page 106 • 104 Options Figure 78. Remove the cable entry plate (right side example). Figure 79. Remove the powerhead from the terminal box. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 107 Options vacon • 105 Figure 80. Connect the supply voltage (black cable) and the output relay (red cable) to the op- tional heater through the bottom cable entry plate. Color of the cables is only an example. Figure 81. Mount the optional heater on the terminal box and then close the powerhead.

  • Page 108: Option Boards

    • 106 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 AC drive 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.
  • Page 110 • 108 Options Table 41 shows the corresponding flange adapters for different motor sizes. See also the relations with the inverter enclosure sizes. Table 41. Correspondences between flange adapters, motors and inverter sizes. Rated Power at Inverter Flange adapter type...
  • Page 111 Options vacon • 109 Figure 84. MM5 flange adapter dimensions. Figure 85. MM6 flange adapter dimensions. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 112: Mounting Instructions: Mm4 Example

    • 110 Options 8.5.1 Mounting instructions: MM4 Example Figure 86. Flange adapter for MM4. Figure 87. Mount the flange adapter on the motor. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 113 Options vacon • 111 Figure 88. Mount the drive on the flange adapter using 4 screws. NOTE: Recommended screw type: countersunk head. Figure 89. Drive mounted onto the motor. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 114: Safe Torque Off

    This chapter describes the Safe Torque Off (STO) function which is a functional safety feature pres- ® ent into VACON 100 X drive products as standard. General description The STO function brings the motor in no-torque-state as defined by 4.2.2.2 of the IEC 61800-5-2: “Power that can cause rotation (or motion in the case of a linear motor) is not applied to the...

  • Page 115: Standards

    Safe Torque Off vacon • 113 Standards The STO function has been designed for use in accordance with the following standards: Table 42. Safety Standards. Standards IEC 61508, Parts 1-7 EN 61800-5-2 EN 62061 ISO 13849-1 EN 954-1 IEC 60204-1 The STO function has to be applied correctly to achieve the desired level of operational safety.

  • Page 116: 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 117: 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 ms maximum.

  • Page 118: Connections

    • 116 Safe Torque Off Connections To make the STO function available and ready to be used, both the STO jumpers have to be removed. They are located in front of the STO inputs to mechanically prevent the insertion of the STO connec- tor.

  • Page 119: Safety Capability Cat. 4 / Pl E / Sil 3

    Safe Torque Off vacon • 117 Safety Capability Cat. 4 / PL e / SIL 3 9.5.1 For this safety capability, an external safety device must be installed. This must be used to dynam- ically activate the STO inputs and to monitor the STO output feedback.
  • Page 120 • 118 Safe Torque Off The picture below shows an example of connection for the STO function. The external device has to be connected with 6 wires to the drive. EXTERNAL DEVICE POWER UNIT DC+/R+ Reinforced Figure 93. STO example with automatic monitoring of the feedback and both STO inputs used.

  • Page 121: Safety Capability Cat. 3 / Pl E / Sil 3

    Safe Torque Off vacon • 119 Safety Capability Cat. 3 / PL e / SIL 3 9.5.2 The safety capability is reduced to Cat. 3 / PL e / SIL 3 if the STO inputs are statically used (which means they are forced to commute together).

  • Page 122: Safety Capability Cat. 1 / Pl C / Sil 1

    • 120 Safe Torque Off Safety Capability Cat. 1 / PL c / SIL 1 9.5.4 Without any automatic monitoring of STO output feedback, the safety capability is reduced to Cat. 1 / PL c / SIL 1. The STO inputs (which can be connected in parallel) must be supplied by a safety push button or a safety relay.

  • Page 123: Commissioning

    Safe Torque Off vacon • 121 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 must be done according to the general wiring instructions for the specific product. A shielded cable is required.

  • Page 124: Parameters And Fault Tracing

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

  • Page 125: Solar Pump Application

    Solar pump application vacon • 123 OLAR PUMP APPLICATION ® The installation instructions in this chapter are intended only for VACON 100 X Drives with addi- tional solar pump application. 10.1 Danger ® The terminals are live when the VACON 100 X Drive is connected to a photovoltaic system.

  • Page 126: Manufacturers Of Gpv Fuses

    • 124 Solar pump application See table below for recommended fuse sizes: Table 52. Recommended fuse sizes, Mains voltage 3AC 208-240V, 50/60 Hz, up to 400V in Enclosure Rated continuous IEC60269-6 Fuse UL-2579 Fuse size AC drive type size...

  • Page 127: Parallel Diode Selection

    Parallel diode selection ® When VACON 100 X is used in the Solar Pump application, a diode must be connected between DC+ and DC- to protect the inverter against reverse voltage. See tables below for diode specifica- tion. Table 54. Diode specification, Mains voltage 3AC 208-240V, 50/60 Hz, up to 400V in VDC...

  • Page 128: Photovoltaic System Dimensioning

    The photovoltaic system has to be dimensioned in order to not exceed the values specified in the tables below. ® Table 56. VACON 100 X (208…240V 3AC 50/60Hz, up to 400V in VDC) DC-link input ratings Enclosure Max. Recommended PV Array Power AC drive type...

  • Page 129: Grounding

    Solar pump application vacon • 127 10.7 Grounding 10.7.1 Pole Grounding It is prohibited to connect any pole, DC+ or DC-, of the photovoltaic system directly to PE. 10.7.2 Drive Grounding All non-current-carrying metal parts (module frames, enclosures) and also the midpoint of the cur- rent carrying conductors of the photovoltaic system must be connected to the PE of the drive.

  • Page 130: Dc Power Connection

    • 128 Solar pump application 10.10 DC power connection power fuses supply switch protection diode 11742_uk Figure 96. Example of the power connections: MM4/MM5 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 131 Solar pump application vacon • 129 power supply fuses switch protection diode 11743_uk Figure 97. Example of the power connections: MM6 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 132 Document ID: Vacon Ltd DPD00534J Member of the Danfoss Group Rev. J Runsorintie 7 65380 Vaasa Finland...

Table of Contents