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Vacon 20 CP Installation, Technical And Maintenance Manual

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Summary of Contents for Vacon 20 CP

  • Page 1 20 cp ® ac drives Installation, Technical and Maintenance Manual...

  • Page 3: Table Of Contents

    • 1 NDEX Document code (Original Instructions): DPD00489J Order code: DOC-INS03976+DLUK Rev. J Revision release date: 26.5.17 Safety........................4 Signs............................4 Units ............................4 Danger..........................5 Hot surface warning......................5 Warnings ..........................6 Grounding and earth fault protection .................7 Insulation system........................9 Compatibility with RCDs ....................10 Cooling System .........................11...
  • Page 4 7.1.2 Mains voltage 1AC 208-240V.....................65 7.1.3 Mains voltage 3AC 380-480V.....................66 7.1.4 Definitions of overloadability ....................66 Brake resistors .........................67 VACON® 20 CP - technical data ..................68 7.3.1 Technical information on control connections..............71 Options......................73 VACON® keypad with seven-segment display..............73 Text keypad ........................74 Menu structure .........................74...
  • Page 5 • 3 Maintenance and diagnostics ..................103 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 6: Safety

    CP is a Cold Plate 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. Only VACON® authorized, trained and qualified personnel are allowed to install, operate and maintain the drive. Signs...

  • Page 7: Danger

    (if no keypad is attached, see the indicators on the cover). Wait an ® additional 30 seconds before starting any work on the connections of VACON Cold Plate Drive. After expiration of this time, use measuring equipment to abso- lutely ensure that no voltage is present.

  • Page 8: Warnings

    Before performing any measurement on the motor or the motor cable, disconnect the motor cable from the AC drive. ® Do not perform any voltage withstand test on any part of VACON 20 CP. The tests shall be performed according to a specific procedure. Ignoring this procedure may damage the product.

  • Page 9: Grounding And Earth Fault Protection

    CAUTION! ® The VACON 20 CP AC drive must always be earthed with an grounding conductor connected to the grounding terminal marked with Since the touch current exceeds 3.5 mA AC (for the three-phase version), according to EN61800-5- 1, the drive shall have a fixed connection and provision of an additional terminal for a second protective grounding conductor of the same cross-sectional area as the original protective grounding conductor.
  • Page 10 • 8 Safety Figure 2. Protective grounding connections MS2, single-phase version. The cross-sectional area of every protective grounding conductor which does not form a part of the supply cable or cable enclosure shall, in any case, be not less than: •...

  • Page 11: Insulation System

    ® The control unit of VACON 20 CP fulfils the insulation requirements of the stan- dard IEC 61800-5-1 regarding DVC A circuits and also the strongest insulation requirements of IEC 60950-1 regarding SELV circuits.

  • Page 12: Compatibility With Rcds

    • 10 Safety CONTROL UNIT R01 __ (**) DVC A or Mains R02 __ 10Vref __ Analog Inputs __ Digital Inputs__ Analog Output __ DVC A Keypad 24V __ RS485 __ POWER UNIT Mains Reinforced Figure 4. Insulation system (single-phase version).

  • Page 13: Cooling System

    Cooling System ® VACON 20 CP is available as a cold-plate solution. Customers have to enclose it in their own housing and provide a suitable heatsink. However under maximum operating conditions the unit should not exceed the following temperatures: ®...

  • Page 14: Declaration Of Conformity

    • 12 Safety 1.10 Declaration of conformity Figure 5. Declaration of conformity. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 15 Safety vacon • 13 Figure 6. STO certificate. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 16 • 14 Safety 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/. REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site 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 your supplier immedi- ately.

  • Page 18: Type Designation Code

    This segment is common for all products. Additional codes. 0020 Examples of additional codes: Product range: +DBIR 0020 = Vacon 20 Dynamic Brake Internal Resistance (optional) Input/Function: = Three-phase input = Single-phase input 0009 Drive rating in ampere; e.g. 0009 = 9 A...

  • Page 19: Order Codes

    4.0 kW - 5.0 HP drive VACON0020-3L-0012-4-CP 5.5 kW - 7.5 HP drive VACON0020-3L-0016-4-CP 7.5 kW - 10.0 HP drive ® Table 3. Order codes of VACON 20 Cold Plate. For all technical details, see chapter 7. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 20: Unpacking And Lifting The Ac Drive

    • 18 Receipt of delivery Unpacking and lifting the AC drive The weights of the AC drives vary according to enclosure size. Note the weights of each individual enclosure size in Table 4 below. Enclosure Weight [kg] Weight [lb] Table 4.

  • Page 21: Disposal

    Receipt of delivery vacon • 19 2.4.1 Disposal When the device reaches the end of its operating life do not dispose of it as a part of standard household garbage. Main components of the product can be recycled, but some need to...

  • Page 22: Mounting

    • 20 Mounting OUNTING The AC drive can be mounted on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. Both enclosure sizes can be mounted in any position (IP20 rating is preserved only if mounted as in the following pictures).

  • Page 23: Enclosure Ms2 Single-Phase Version

    Mounting vacon • 21 3.1.2 Enclosure MS2 single-phase version ® Figure 10. VACON 20 Cold Plate, MS2 single-phase version. Table 6. Dimensions W x H x D Enclosure [mm] [in] 133.0 x 163.5 x 73.5 5.23 x 6.43 x 2.89 MS2 with plate 133.0 x 163.5 x 79.5...

  • Page 24: Enclosure Ms3

    • 22 Mounting 3.1.3 Enclosure MS3 ® Figure 11. VACON 20 Cold Plate, MS3. Table 7. Dimensions W x H x D Enclosure [mm] [in] 161.0 x 246.0 x 73.5 6.34 x 9.69 x 2.89 MS3 with plate 161.0 x 246.0 x 83.0 6.34 x 9.69 x 3.27...

  • Page 25: Cooling

    ® The VACON 20 CP AC drives are designed for installation on surfaces which comply with the specifications listed in this paragraph. The heatsink surface that is in contact with the AC drive cold plate must be free from dirt and particles.
  • Page 26 • 24 Mounting ® Place the VACON 20 CP on the appropriate heatsink area and tighten the screws as listed in the following table: Tightening torque N•m Enclosure size Screw size (lb•in) M5 (according to DIN 2.0 to 2.5 Nm 7985 - 8.8...
  • Page 27 Mounting vacon • 25 Figure 13. Heatsink plate for MS3 (upper view).The thickness of the plate is 9.5 mm (0.37 in). Table 11. Dimensions W x H x D Enclosure [mm] [in] 100.0 x 148.0 x 9.5 3.94 x 5.83 x 0.37...

  • Page 28: Installation Spacing

    • 26 Mounting Installation spacing Enough free must be left space around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance may also require a certain amount of free space. The minimum clearances given in Table 13 must be respected. It is also important to ensure that the temperature of the cooling air does not exceed the maximum environment temperature of the AC drive.

  • Page 29: Power Loss Thermal Characteristics

    Power loss thermal characteristics ® In the table below are the thermal characteristics of VACON 20 CP AC drive at nominal output current. The power loss in stand-by conditions is 12 W for all sizes (supply voltage 24 V, 100 mA).

  • Page 30: Dimensioning An External Heatsink

    Mounting Dimensioning an external heatsink ® This paragraph describes a useful procedure to select a suitable heatsink for VACON 20 CP drives. The heatsinks are devices that enhance heat dissipation from a hot surface, usually the case of a heat generating component, to a cooler ambient, usually air. For the following discussion, air is assumed to be the cooling fluid.
  • Page 31 Mounting vacon • 29 – CPmax ------------------------------------ - R – HSmax loss For a given ambient temperature T the cold plate temperature T must not exceed the CPmax maximum allowable value (85°C). As the R is essentially fixed, this condition must be satisfied ®...
  • Page 32 • 30 Mounting • Heatsink attachment/orientation: heatsink attachment/orientation plays a significant role under natural convection. It is recommended that the heatsink be installed to orient the fins in a direction that will not block air movement under natural convection. Based practical experi- ence, if the heatsink is oriented in a wrong way, the thermal performance will be approximately 25% worse under natural convection condition.

  • Page 33: Power Cabling

    Power cabling vacon • 31 OWER CABLING The mains cables are connected to terminals L1, L2 and L3 (three-phase versions) and the motor cables to terminals marked with U, V and W. See principal connection diagram in Figure 16. See also Table 19 for the cable recommendations for different EMC levels.
  • Page 34 • 32 Power cabling Use cables with heat resistance in accordance with the application requirements. The cables and the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can find on the rating plate.

  • Page 35: Circuit Breaker

    Power cabling vacon • 33 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 is has a capacity of 1.5 to 2 times the inverter’s rated current (see...

  • Page 36: Description Of The Terminals

    • 34 Power cabling Description of the terminals ® The following pictures describe the power terminals and the typical connections in VACON 20 CP drives. 4.3.1 MS2 three-phase version power connections AC power supply Single or Three phases Motor Figure 19.

  • Page 37: Ms2 Single-Phase Version Power Connections

    These terminals are the input connections for the power supply. Single-phase 230 VAC voltage has to be connected to L and N terminals. These terminals are for motor connections. ® Table 21. Description of VACON 20CP MS2 power terminals (single-phase version). Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 38: Ms3 Power Connections

    230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derat- ing of 50%). U/T1 V/T2 These terminals are for motor connections. W/T3 ® Table 22. Description of VACON 20CP MS3 power terminals. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 39: Cable Dimensioning And Selection

    20.0 terminal ® Table 24. Cable and fuse sizes for VACON 20 CP. The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be PVC-isolated; use only cables with concentric copper shield; Max number of parallel cables is 9.

  • Page 40: Cable And Fuse Sizes, Enclosures Ms2 To Ms3, North America

    0016 4 20.0 ® Table 26. Cable and fuse sizes for VACON 20 CP, North America. The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be PVC-isolated; Max ambient temperature +30 °C, max temperature of cable surface +70 °C; Use only cables with concentric copper shield;...

  • Page 41: Brake Resistor Cables

    ® VACON 20 CP AC drives (three-phase version) are equipped with terminals for an optional external brake resistor. These terminals are 6.3 mm Faston for MS2 and spring-type terminals for MS3. See Figure 23 and Figure 25 for the location of these terminals.

  • Page 42: Cable Installation

    • 40 Power cabling Cable installation • Before starting, check that none of the components of the AC drive is live. Read the warnings in chapter 1 carefully • Place the motor cables sufficiently far from other cables • Avoid placing the motor cables in long parallel lines with other cables.
  • Page 43 Power cabling vacon • 41 Table 28. Enclosure Leave as short 1-phase as possible Table 29. Cables stripping lengths [mm]. Connect the stripped cables: • Expose the shield of both cables in order to make a 360-degree connection with the cable clamp.

  • Page 44: Control Unit

    • 42 Control unit ONTROL UNIT 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 23, Figure 24 and Figure 25.
  • Page 45 Control unit vacon • 43 Figure 24. Locations of the components in control unit of MS2 (single-phase version). Figure 25. Location of the components in the control unit of MS3. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...
  • Page 46 ® In addition to the internal fan, VACON 20 CP AC drives include an auxiliary fan power supply connector (see 10 in the Figure 23, Figure 24 and Figure 25) for improved air flow and system cooling. The power supply also has automatic thermal switching on/off control: it automatically switches on/off depending on internal cold plate temperature.

  • Page 47: Control Unit Cabling

    Control unit vacon • 45 Control unit cabling The principal terminal block placement is shown in Figure 27 below. The control board is equipped with 23 fixed control I/O terminals. Additionally, the terminals for the Safe Torque Off (STO) function (see chapter 9) can be seen in the picture below.

  • Page 48: Standard I/O Terminals

    • 46 Control unit 5.1.2 Standard I/O terminals Standard I/O The terminals of the are described below. For more information on connections, see chapter 7.3.1. The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches. For more information, see chapter 5.1.7.

  • Page 49: Relay Terminals

    Control unit vacon • 47 5.1.3 Relay terminals Table 36. I/O terminal signals for relays and connection example. Relays terminals From Terminal Signal standard I/O board Relay output 1 RO1/2 From term. From term. RO1/3 Relay output 2 RO2/1 RO2/2 RO2/3 5.1.4...

  • Page 50: Description Of Additional Echo Connectors

    • 48 Control unit 5.1.5 Description of additional echo connectors In this paragraph you will find the description of the additional echo connectors for the I/O terminals and for the HMI. Figure 28. The I/O remote echo connector mounted on the control board.
  • Page 51 • 49 To connect I/Os to the control unit through echo terminals this connector has to be used. In the ® following table, the correspondence between the pins of this connector and the VACON 20 CP terminals is shown.
  • Page 52 501330-1500. To connect HMI to the control unit through echo terminals this connector has to be used. In the ® following table, the correspondence between the pins of this connector and the VACON 20 CP HMI terminals is shown.
  • Page 53 Control unit vacon • 51 Pin number in RJ45 Pin number of echo Signal Description connector connector Keyp_TX+ Keyp_TX- RS422 (connection for panel communication) Keyp_RX+ Keyp_RX- Led_CTRL1 Control signal for LED1 Led_CTRL2 Control signal for LED2 Led_CTRL3 Control signal for LED3...

  • Page 54: Led Handling

    • 52 Control unit 5.1.6 Led handling ® As VACON 20 Cold plate is often without the keypad, on the plastic cover of the drive there are 4 status LEDs. See the picture below. Figure 31. LED position on the MS2 cover.

  • Page 55: Selection Of Terminal Functions With Dip Switches

    “0” means that termination resistance is connected and the termination of the bus has been set. If ® the VACON 20 CP is the last device on the net, this switch must be set to “0” position. The default position for SW4 is “0”. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 56: Fieldbus Connection

    • 54 Control unit Fieldbus connection Modbus is a communication protocol developed by Modicon systems. In other words, it is a way of sending information between electronic devices. The device requesting the information is called the Modbus Master and the devices supplying information are Modbus Slaves. In a standard Modbus network, there is one Master and up to 247 Slaves, each with a unique Slave Address from 1 to 247.

  • Page 57: Modbus Rtu Protocol

    Table 40. ® VACON 20 CP drive is equipped with Modbus support as standard. The AC drive can be connected to fieldbus through RS485. The connection for RS485 is on the standard I/O (terminals A and B). See Figure 34.

  • Page 58: Preparation For Use Through Rs485

    Strip the cable at a maximum length of 15 mm. Do not strip the aluminium cable shield! ® Then connect the cable to its appropriate terminals on VACON 20 CP AC drive standard terminal block, terminals A and B (A = negative, B = positive).

  • Page 59: Commissioning

    The motor terminals U, V, W and the brake resistor terminals are live when ® VACON 20 CP drive is connected to mains, even if the motor is not running. The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage ®...

  • 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: Table 41. 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.

  • 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 Remove the EMC plate from the unit. Then lift the plate with pliers to disconnect the EMC plate from the ground. See Figure 36. Then reconnect the EMC plate to the unit. Figure 36. Changing of the EMC class in MS2 (three-phase version).

  • Page 63: Changing Emc Protection Class - Ms2 Single-Phase Version

    Commissioning vacon • 61 6.2.2 Changing EMC protection class - MS2 single-phase version Remove the EMC screw as shown in the Figure 37. Figure 37. Changing the EMC class in the MS2 (single-phase version). Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 64: Changing Emc Protection Class - Ms3

    • 62 Commissioning 6.2.3 Changing EMC protection class - MS3 Remove the EMC screw as shown in the Figure 38. Figure 38. Changing the EMC class in the MS3. CAUTION! Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made.

  • Page 65: Running The Motor

    Commissioning vacon • 63 Running the motor MOTOR RUN CHECK LIST Before starting the motor, check that the motor is mounted properly and ensure that the machine connected to the motor allows the motor to be started. Set the maximum motor speed (frequency) according to the motor and the machine connected to it.

  • Page 66: Maintenance

    • 64 Commissioning Maintenance In normal conditions, the AC drive is maintenance-free. However, regular maintenance is recommended to ensure trouble-free operation and longevity of the drive. We recommend the table below is followed for maintenance intervals. Table 42. Maintenance interval...

  • Page 67: Technical Data

    ® Table 44. Power ratings of VACON 20 CP, supply voltage 3AC 208-240V. NOTE: The rated currents in given ambient temperatures (in Table 44) are achieved only when the switching frequency is equal to or less than the factory default.

  • Page 68: Mains Voltage 3Ac 380-480V

    ® Table 47. Power ratings of VACON 20 CP, supply voltage 3AC 380-480V. NOTE: The rated currents in given ambient temperatures (in Table 47) are achieved only when the switching frequency is equal to or less than the factory default.

  • Page 69: Brake Resistors

    Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application. Brake chopper is available only in three-phase version. ® Recommended brake resistor values for VACON 20 CP AC drives: Mains Voltage 3AC 208-240 V, 50/60 Hz Minimum Resistance...

  • Page 70: Vacon® 20 Cp - Technical Data

    • 68 Technical data ® VACON 20 CP - technical data Table 50. 3AC 208…240V Input voltage U 1AC 208…240V 3AC 380…480V Input voltage tolerance -15%…+10% continuously Input frequency 50/60 Hz Input frequency 45…66 Hz tolerance Protection class Mains connection...
  • Page 71 Technical data vacon • 69 Table 50. Standard: Serial communication (RS485/Mod- bus); Fieldbus Optional: CANopen; Profibus DP, Lonworks, Communication DeviceNet, Profinet IO, Ethernet IP, Modbus interface TCP, EtherCAT, AS-interface Drive status indicators (LED) on front side Status indicators (POWER, RUN, FAULT, READY) Enclosure operating -10°C (no frost)…+70°C...
  • Page 72 • 70 Technical data Table 50. EN61800-3: 2004 + A1: 2011, 1 and 2 envi- Immunity ronment EN61800-3: 2004 + A1: 2011, Category C2 as standard for 3-phase version conducted and radiated emissions Category C1 as standard for Standards...

  • Page 73: Technical Information On Control Connections

    Technical data vacon • 71 7.3.1 Technical information on control connections Table 52. Standard I/O terminals Terminal Signal Technical information RS485 Differential receiver/transmitter Set bus termination with dip switches (see Chapter 5) RS485 Reference output +10V, ±5%; Maximum current 10 mA Analogue input channel 1 Ω...
  • Page 74 • 72 Technical data Table 54. Relay terminals Terminal Signal Technical information Switching capacity 250VAC/3A Relay output 1 (only earthed network allowed) Switching capacity NO 250VAC/5A Relay output 2* NC 250VAC/3A (only earthed network allowed) If 230VAC is used as control voltage from the output relays, the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes.

  • Page 75: Options

    ® VACON keypad with seven-segment display ® The text keypad is an option available for VACON 20 CP. The control keypad is the interface between ® the VACON 20 CP AC drive and the user. Figure 40. Text keypad. Order code...

  • Page 76: Text Keypad

    • 74 Options Text keypad The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions. On the display, the user can see the information about his present location in the menu structure and the item displayed.

  • Page 77: Using The Keypad

    Options vacon • 75 Using the keypad ® This chapter provides you with information on navigating the menus on VACON 20 CP and editing the values of the parameters. 8.4.1 Main menu ® The menu structure of VACON 20 CP control software consists of a main menu and several submenus.

  • Page 78: Resetting Fault

    Every ® control place has its own parameter for selecting the frequency reference source. In the VACON Local control place Remote control place 20 CP drive, the is always the keypad.

  • Page 79: Reference Menu

    Options vacon • 77 8.4.4 Reference menu RE ADY R U N S T OP ALAR M FAULT RE F M O N PA R SYS / F WD KEY PA D B US Press to enter Change edit mode value Figure 44.

  • Page 80: Monitoring Menu

    Monitoring values are actual values of measured signals as well as status of some control settings. ® It is visible in VACON 20 CP display, but it can not be edited. The monitoring values are listed in the Application Manual. READY RU N...

  • Page 81: Parameter Menu

    Options vacon • 79 8.4.6 Parameter menu In Parameter menu only the Quick setup parameter list is shown as default. To view the other advanced parameter groups, see the Application Manual. The following figure shows the parameter menu view: R E A D Y...

  • Page 82: System/Fault Menu

    • 80 Options 8.4.7 System/Fault menu SYS/FLT menu including fault submenu, field bus submenu and system parameter submenu. In system parameter submenu, there are some editable parameter (P) and some not editable parameters (V). The Fault submenu of SYS/FLT menu includes active fault submenu and fault history submenu.
  • Page 83 Options vacon • 81 Active faults Menu Function Note Active faults When a fault/faults appear(s), the The fault remains active until it is display with the name of the fault cleared with the RESET button or starts to blink. Press OK to return with a reset signal from the I/O to the Diagnostics menu.

  • Page 84: Fault Tracing

    • 82 Options Fault tracing Fault Fault name Subcode Possible cause Remedy code AC drive has detected too high a Check loading. current (>4*I ) in the motor cable: Check motor. Overcurrent Check cables and connections. • sudden heavy load increase Make identification run.
  • Page 85 Try to reduce ambient noise. flow Should the fault re-occur, contact the distributor near to you. ® Do not close VACON Live when PC control is active. PC control time out fault Check PC-Drive cable. Try to reduce ambient noise.
  • Page 86 • 84 Options Fault Fault name Subcode Possible cause Remedy code DC-link voltage is under the volt- age limits defined. • most probable cause: too In case of temporary supply voltage low a supply voltage break reset the fault and restart the •...
  • Page 87 Options vacon • 85 Fault Fault name Subcode Possible cause Remedy code Firmware Interface version Load a compatible application. between Application and Control Please contact your nearest distribu- not matching tor. Application Application software flash error Reload Application error Load a compatible application.

  • Page 88: Option Boards

    • 86 Options Option boards ® VACON 20 CP drive family embodies a wide selection of expander boards with which the available ® I/O resources of VACON 20 CP AC drive can be increased and its versatility improved. ®...

  • Page 89: Option Board Installation

    Options vacon • 87 8.6.1 Option board installation NOTE! Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards. • Remove the option slot cover. Figure 48. Opening the main cover, MS2 three-phase version example.
  • Page 90 • 88 Options • Make sure that the sticker on the connector of the board says “dv” (dual ® voltage). This indicates that the board is compatible with VACON 20 CP. See below: 9116.emf Slot coding ® • NOTE: Incompatible boards cannot be installed on VACON 20 CP.
  • Page 91 Options vacon • 89 • Mount the option slot cover. Figure 50. Mounting of the option slot cover: remove the plastic opening for the option board terminals. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/...

  • Page 92: Safe Torque Off

    This chapter describes the Safe Torque Off (STO) function which is a functional safety feature ® present in VACON 20 CP drive products as standard. This function is available only in the three- phase version. 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 93: Warnings

    Safe Torque Off vacon • 91 Warnings Designing of safety-related systems requires specialist knowledge and skills. Only qualified people are permitted to install and set up the STO function. The use of STO does not itself ensure safety. An overall risk evaluation is required for ensuring that the commissioned system is safe.

  • Page 94: Standards

    • 92 Safe Torque Off Standards The STO function has been designed for use in accordance with the following standards: Standards IEC 61508, Parts 1-7 IEC 61800-5-2 IEC 62061 ISO 13849-1 IEC 60204-1 Table 59. Safety Standards. The STO function has to be applied correctly to achieve the desired level of operational safety. Four different levels are allowed, depending on the use of the STO signals (see the following table).

  • Page 95: The Principle Of Sto

    ® In VACON 20 CP, 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 51).

  • Page 96: Technical Details

    The reaction time of the STO function is the amount of time which passes from the moment in which ® the STO is demanded until the system is in the Safe State. For VACON 20 CP, the reaction time is 20 ms maximum.

  • Page 97: Connections

    Safe Torque Off vacon • 95 Connections To make the STO function available and ready to be used, both the STO jumpers have to be removed. They have been located in front of the STO terminal to mechanically prevent the insertion of the STO inputs.

  • Page 98: Safety Capability Cat. 4 / Pl E / Sil 3

    • 96 Safe Torque Off 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 dynamically activate the STO inputs and to monitor the STO output feedback.
  • Page 99 Safe Torque Off vacon • 97 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+ DC-* Reinforced Figure 54. STO example with automatic monitoring of the feedback and both STO inputs used. (*) Only for MS3.

  • Page 100: Safety Capability Cat. 3 / Pl E / Sil 3

    • 98 Safe Torque Off 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 101: Safety Capability Cat. 1 / Pl C / Sil 1

    Safe Torque Off vacon • 99 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 102: Commissioning

    • 100 Safe Torque Off Commissioning 9.6.1 General wiring instructions Protect the STO cabling with shielding or an enclosure to exclude external damage. Wire ferrules are highly recommended for all STO signals (inputs and feedback). The wiring should be done according to the general wiring instructions for the specific product. A shielded cable is required.
  • Page 103 Safe Torque Off vacon • 101 Check if only approved units and parts have been used. Set up a routine to ensure that the functionality of the STO function is being checked at regular intervals. Table 66. Checklist for commissioning of STO.

  • Page 104: Parameters And Fault Tracing

    • 102 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 66) is inspected and completed. When STO function is demanded, the drive always generates a fault (“F30”) and the motor stops by coasting.
  • Page 105 Safe Torque Off vacon • 103 Maintenance and diagnostics If any service or repair has to be conducted on the drive installed, please inspect the checklist given in Table 66. During maintenance breaks, or in case of service/repair, ALWAYS make sure that the STO function is available and fully functional by testing it.
  • Page 106 Document ID: Vacon Ltd DPD00489J Member of the Danfoss Group Rev. J Runsorintie 7 65380 Vaasa Finland...

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