Vacon 10 PFC User Manual
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Vacon 10 PFC User Manual

Vacon 10 PFC User Manual

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  • Page 1 ® ac drives vacon 10 pfc user manual...

  • Page 3: Table Of Contents

    6. PFC system interface 6.1 I/O Control 7. Control panel 7.1 General 7.2 Display 7.3 Keypad 7.4 Navigation on the Vacon 10 control panel 7.4.1 Main menu 7.4.2 Reference menu 7.4.3 Monitoring menu 7.4.4 Parameter menu 7.4.5 System menu 8. START-UP 8.1 Quick start-up wizard...
  • Page 4 11. Technical data 11.1 Vacon 10 technical data 11.2 Power ratings 11.2.1 Vacon 10 - Mains voltage 115 V 11.2.2 Vacon 10 – Mains voltage 208-240 V 11.2.3 Vacon 10 – Mains voltage 208-240 V 11.2.4 Vacon 10 – Mains voltage 380-480 V...

  • Page 5: Safety

    The motor terminals U, V, W (T1, T2, T3) and the possible brake resistor terminals -/+ are live when Vacon 10 is connected to the mains, even if the motor is not running. The control unit I/O-terminals are isolated from the mains. However, the relay output terminals may have a dangerous control voltage present even when Vacon 10 is disconnected from the mains.

  • Page 6: Safety Instructions

    Prior to measuring the motor or the motor cable, disconnect the motor cable from the frequency converter. Do not open the cover of Vacon 10. Static voltage discharge from your fin- gers may damage the components. Opening the cover may also damage the device.

  • Page 7: Before Running The Motor

    REMARQUE Vous pouvez télécharger les versions anglaise et française des ma- nuels produit contenant l’ensemble des informations de sécurité, avertisse- ments et mises en garde applicables sur le site www.vacon.com/downloads. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 8: Receipt Of Delivery

    +DLUS = US English +DLIT = Italian empty = English Figure 2.1: Vacon 10 type designation code 2.2 Storage If the frequency converter is to be kept in store before use make sure that the ambi- ent conditions are acceptable: Storing temperature -40…+70°C...

  • Page 9: Maintenance

    The local distributor may grant a warranty time different from the above. This war- ranty time shall be specified in the distributor's sales and warranty terms. Vacon as- sumes no responsibility for any other warranties than that granted by Vacon itself.

  • Page 10: Installation

    3. INSTALLATION 3.1 Mechanical installation There are two possible ways to mount Vacon 10 in the wall. For MI1-MI3, either screw or DIN-rail mounting. The mounting dimensions are given on the back of the drive and on the following page.

  • Page 11: Vacon 10 Dimensions

    37.8 98.5 62.5 101.5 254.3 229.3 108.5 Table 3.1: Vacon 10 dimensions in millimetres Frame Dimensions(mm) Weight* (kg.) 254.3 *without shipping package Table 3.2: Vacon 10 frame dimensions (mm) and weights (kg) 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 12 Frame Dimensions(Inches) Weight* (Ibs.) 10.3 *without shipping package Table 3.3: Vacon 10 frame dimensions (Inch) and weights (Ibs) Figure 3.4: Vacon10 dimensions, MI2 - 3 Display Location Frame Dimensions(mm) 22.3 Table 3.4: Vacon 10 frame dimensions (mm) Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...

  • Page 13: Cooling

    NOTE! See the mounting dimensions on the back of the drive. Leave free space for cooling above (100 mm), below (50 mm), and on the sides (20 mm) of Vacon 10! For MI1 - MI3, side-to-side installation allowed only if the am- bient temperature is below 40 °C Frame Cooling air required (m³/h)

  • Page 14: Power Losses

    • VACON NSTALLATION 3.1.3 Power losses If the operator wants to raise the switching frequency of the drive for some reason (typically e.g. in order to reduce the motor noise), this inevitably affects the power losses and cooling requirements, for different motor shaft power, operator can se- lect the switching frequency according to the graphs below.
  • Page 15 • NSTALLATION VACON MI1 - MI3 3P 230 V POWER LOSS 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 16 • VACON NSTALLATION Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...
  • Page 17 • NSTALLATION VACON MI1 - MI3 1P 230 V POWER LOSS 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 18 • VACON NSTALLATION Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...

  • Page 19: Emc Levels

    NOTE: industrial areas, technical areas of any building fed from a dedicated trans- former are examples of second environment locations. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 20: Changing The Emc Protection Class From C2 To C4

    • VACON NSTALLATION 3.1.5 Changing the EMC protection class from C2 to C4 The EMC protection class of MI1-3 frequency converters can be changed from class C2 to class C4 (except 115V and 600V drives) by removing the EMC-capacitor discon- necting screw, see figure below.

  • Page 21: Cabling And Connections

    Mot or out L1 L2/N L3 R+ R- U/T1 V/T2 W/T3 Strip the plastic cable coating for 360° earthing BRAKE MOTOR MAINS RESISTOR Figure 3.8: Vacon 10 power connections, MI2 - MI3 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 22: Control Cabling

    • VACON NSTALLATION 3.2.2 Control cabling Attach the support AFTER installing the power cables Attach this plate BEFORE installing the power cables Figure 3.9: Mount the PE-plate and API cable support, MI1 - MI3 Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...
  • Page 23 Figure 3.10: Open the lid, MI1 - MI3 Control cable tightening torque: 0.4 Nm Strip the plastic cable coating for 360°earthing Figure 3.11: Install the control cables. MI1 - MI3. See Chapter 6.1 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 24: Screw Of Cables

    • VACON NSTALLATION 3.2.3 Screw of cables Figure 3.12: MI1 screws Figure 3.13: MI2 screws Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...
  • Page 25 • NSTALLATION VACON Figure 3.14: MI3 screws 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 26: Cable And Fuse Specifications

    • VACON NSTALLATION 3.2.4 Cable and fuse specifications Use cables with heat resistance of at least +70°C. The cables and the fuses must be dimensioned according to the tables below. Installation of cables according to UL regulations is presented in Chapter 3.2.7.
  • Page 27 2*2.5+2.5 3*1.5+1.5 1.5-4 1.5-4 0.5-1.5 0.5-1.5 0009 2*6+6 3*1.5+1.5 1.5-6 1.5-6 0.5-1.5 0.5-1.5 Table 3.10: Cable and fuse sizes for Vacon 10, 208 - 240 V, 1~ Terminal cable size (min/max) Mains Motor cable cable Fuse Main Earth Control Relay Frame...
  • Page 28 0.5-1.5 0.5-1.5 Table 3.13: Cable and fuse sizes for Vacon 10, 600 V,3~ Note! To fulfil standard EN61800-5-1, the protective conductor should be at least 10 mm2 Cu or 16 mm2 Al. Another possibility is to use an additional protective conduc- tor of at least the same size as the original one.

  • Page 29: General Cabling Rules

    • Check the connection of the earth cable to the motor and the frequency con- verter terminals marked with. • Connect the separate shield of the motor cable to the earth plate of the fre- quency converter, motor and the supply centre. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 30: Stripping Lengths Of Motor And Mains Cables

    • VACON NSTALLATION 3.2.6 Stripping lengths of motor and mains cables Earth con ductor 8 mm 8 mm 20 mm 35 mm Figure 3.15: Stripping of cables Note! Strip also the plastic cover of the cables for 360 degree earthing. See Figures 3.7- 3.8 and 3.11.
  • Page 31 Measure the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed 1000 V. The insulation resistance must be >1 MOhm. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 32: Commissioning

    OMMISSIONING 4. COMMISSIONING Before commissioning, read the warnings and instructions listed in Chapter 1! 4.1 Commissioning steps of Vacon 10 Read carefully the safety instructions in Chapter 1 and follow them. After the installation, make sure that: • both the frequency converter and the motor are grounded.
  • Page 33 Connect the motor to the process (if the no-load test was run without the motor being connected). • Before running the tests, make sure that this can be done safely. • Inform your co-workers of the tests. • Repeat test 7A. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 34: Fault Tracing

    • VACON AULT TRACING 5. FAULT TRACING Note: The fault codes listed in this chapter are visible if the Application Interface has a display, like e.g. in API FULL or API LIMITED or if a personal computer has been connected to the drive.
  • Page 35 • faulty operation tributor. • component failure Reset the fault and restart. Microcontroller • faulty operation watchdog fault • component failure If the fault recurs, contact the nearest distributor. Table 5.1: Fault codes 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 36 Check installation. The data connection between the If installation is correct Fieldbus fault fieldbus Master and the fieldbus contact the nearest Vacon of the drive has broken. distributor. Use the monitoring menu (M1.14) to check the state An autochange with interlocks...

  • Page 37: Pfc System Interface

    RO 14 RO 22 Relay output Max. switching load: Programmable RO 21 Pump 2 Control 250Vac/2A or 250Vdc/0,4A in P5.1 RO 24 Table 6.1: PFC System preset I/O connections and settings for Vacon 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 38 • VACON SYSTEM INTERFACE Figure 6.1: 2-pump autochange systems, sample control diagram Figure 6.2: 3-pump autochange system, sample control diagram Tel. +358 (0)201 2121 • Fax +358 (0)201 212 205...
  • Page 39 • SYSTEM INTERFACE VACON Figure 6.3: Example of 2-pump autochange, power diagram Figure 6.4: Example of 3-pump autochange, power diagram 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 40: Control Panel

    • VACON ONTROL PANEL 7. CONTROL PANEL 7.1 General The panel is an irremovable part of the drive consisting of corresponding control board; The overlay with display status on the cover and the button are in clarifica- tions in the user language.

  • Page 41: Keypad

    Table 7.1. The drive stops by pressing the keypad STOP button. The drive starts by pressing the keypad START button when the selected control place is KEYPAD. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 42 • VACON ONTROL PANEL Symbol Button Name Function Description Start Motor START from the panel STOP Motor STOP from the panel Used for confirmation. Enter edit mode for parameter Alternate in display between the parameter value and parameter code. Reference frequency value adjusting no...

  • Page 43: Navigation On The Vacon 10 Control Panel

    This chapter provides you with information on navigating the menus on Vacon 10 and editing the values of the parameters. 7.4.1 Main menu The menu structure of Vacon 10 control software consists of a main menu and sev- eral submenus. Navigation in the main menu is shown below: R E A D Y...

  • Page 44: Reference Menu

    • VACON ONTROL PANEL 7.4.2 Reference menu RE ADY R UN S TOP ALAR M FAULT RE F M O N PA R F WD KEY PAD B US Press to enter Change edit mode value Figure 7.3: Reference menu display Move to the reference menu with the UP / DOWN button (see Figure 7.2).

  • Page 45: Monitoring Menu

    Figure 7.4: Monitoring menu display Monitoring values are actual values of measured signals as well as status of some control settings. It is visible in Vacon 10 display, but it can not be edited. The moni- toring values are listed in Table 7.2.

  • Page 46: Parameter Menu

    • VACON ONTROL PANEL NOTE! Vacon 10 PFC only have one monitor group! Code Monitoring signal Unit Description V1.1 Output frequency Output frequency to motor V1.2 Frequency reference V1.3 Motor speed Rated motor speed V1.4 Motor current Measured motor current V1.5...
  • Page 47 Up increases / Down decreases parameter value. In edit mode, the value of Px.x is displayed blinkingly in the panel. After about 10 s, Px.x is displayed in the panel again if you don't press any button. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 48: System Menu

    • VACON ONTROL PANEL NOTE! In edit mode, if you edit the value and don't press OK button, the value isn't changed successfully. NOTE! In edit mode, if you don't edit the value, you can press Reset /Back button to display Px.x again.
  • Page 49 NOTE! Fault History can be reset by long pressing the BACK / RESET button for 5 second time,when the API is in fault history submenu level (F6.x), it will also clear all active faults. See Chapter5 for fault descriptions 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 50 • START-UP VACON 8. START-UP 8.1 Quick start-up wizard Note! You should only use the wizard when starting up the controller, since param- eters are reset to their factory default values every time it is used. If you need to change a particular value, you are recommended to go to the specific parameter (see page 54).
  • Page 51 REA DY S TOP ALARM FAULT BACK RESET Press for 5 seconds 3. Once the pump has stopped working, you can reopen the pressure unit intake and the equipment is ready to function. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 52 • SYSTEM PARAMETERS VACON 9. SYSTEM PARAMETERS On the next pages you can find the lists of parameters within the respective param- eter groups. The parameter descriptions are given in Chapter 10. NOTE: Parameters can only be changed when drive is in stop mode!
  • Page 53 3000,0 S 0 Hz to maximum fre- quency Deceleration time P2.3 Deceleration 3000,0 S from maximum fre- quency to 0 Hz P2.4 PI Gain 1000,0 % 125,0 Table 9.2: Advanced PFC settings 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 54 • SYSTEM PARAMETERS VACON Code Parameter Unit Default Note P2.5 I Time, PI 0,00 320,00 S 1,00 PI Inversion 0 = Not inverted P2.6 Error 1 = Inverted 0,0 = Test 40 s. Autochange 3000,0 H 48,0 1604 Autochange time P2.7...
  • Page 55 Voltage at field P3.8 10,00 200,00 % 100,00 weakening point 0 = Not used U/F Optimiza- P3.9 1 = Automatic torque tion boost Switching fre- P3.10 16,0 quency Table 9.3: Motor control 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 56 • SYSTEM PARAMETERS VACON 9.4 Analog inputs Code Parameter Unit Default Note P4.1 AI1 Hysteresis 0,000 9,000 0,100 1620 AI1 Sensitivity AI2 Signal 2 = 0 - 20mA P4.2 Range 3 = 4 - 20mA P4.3 AI2 filter time 10,0...
  • Page 57 150,00 % 40,0 speed Motor thermal P6.12 time constant 0,2 x 1,5 x Motor stall cur- Current threshold for P6.13 1622 rent block fault activation Nunit Nunit Table 9.6: Protection 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 58 • SYSTEM PARAMETERS VACON 9.7 Automatic restarts Code Parameter Unit Default Note Delay before auto- P7.1 Wait time 0,10 10,00 0.50 matic restart after a fault disappears Defines the time before the frequency con- verter attempts to Trial time 0,00...
  • Page 59 (MENU PAR -> S4) S4.1 Display contrast Adjusts the display contrast 1= Restores factory Restore factory S4.2 defaults for all defaults parameters Table 9.9: System parameters NOTE! Parameters in bold are hidden, see P8.1. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 60 • VACON ARAMETER DESCRIPTIONS 10. PARAMETER DESCRIPTIONS On the next pages you can find the descriptions of certain parameters. The descrip- tions have been arranged according to parameter group and number. GROUP 1. Quick setup parameters UTOCHANGE This parameter allows the user to select the autochange mode for the system.
  • Page 61 These parameters set the maximum load for autochange to take place. This level is defined as follows: • Autochange can take place if the number of auxiliary pumps running is lower than the value in parameter 2.89, autochange may take place. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 62 • VACON ARAMETER DESCRIPTIONS • Autochange can take place if the number of auxiliary pumps running is equivalent to the value in parameter 2.8 and controlled drive frequency is lower than the value in parameter 2.9. • If the value in parameter 2.9 is 0.0 Hz, autochange can only take place when on standby (Stop and Snooze) regardless of the value in parameter 2.8.
  • Page 63 PI has been disabled using DI3. 0 = Panel 1 = AI1 2.23 R EFERENCY RESSURE ELECTION Parameter that allows the user to select the source of work pressure. 0 = Panel (P1.9/P2.1) 1 = AI1 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 64: Start Mode

    ARAMETER DESCRIPTIONS GROUP 3. Motor Control TART The user can select two start modes for Vacon 10 with this parameter: 0 = Ramp start: The frequency converter starts from 0 Hz and accelerates to the set frequency reference within the set acceleration time (P4.2). (Load inertia or initial fric- tion may lengthen acceleration times).

  • Page 65: Linear

    Pa r. 1.11 Default: Nominal Field weakening voltage of the motor point Linear Squared Default: Nominal frequency of the motor f[Hz] Pa r. 1.14 Pa r. 1.10 Figure 10.1: Linear and motor voltage change 24-hour support (0)201 212 575 • Email: vacon@vacon.com...

  • Page 66: Not Used

    • VACON ARAMETER DESCRIPTIONS 2 = Programmable U/f curve: The U/f curve can be programmed with three different points. Programmable U/f curve can be used if the other settings do not satisfy the needs of the application Figure 10.2: Programmable U/f curve...
  • Page 67 3.10 S WITCHING FREQUENCY Motor noise can be minimised using a high switching frequency. Increasing the switching frequency reduces the capacity of the frequency converter unit. Switching frequency for Vacon 10: 1.5...16 Hz. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 68 • VACON ARAMETER DESCRIPTIONS GROUP 4. Analog Inputs AI1 H YSTERESIS Analog Input Sensitivity AI2 S IGNAL ANGE 2 = 0 - 20 mA 3 = 4 - 20 mA AI2 F ILTER This parameter, given a value greater than 0, activates the function that filters out disturbances from the incoming analog signal.
  • Page 69 IGITAL UTPUT 0 = Pump 3 Control 1 = Ready 2 = Run 3 = Fault (AO) IGITAL UTPUT 0 = Ready 1 = Run 2 = Fault 3 = Fault Inverted 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 70 • VACON ARAMETER DESCRIPTIONS GROUP 6. Protection NDERLOAD ROTECTION 0 = No response 1 = Warning 2 = Fault, stop mode after fault as in parameter 3.3 Pump is underloaded. Check: that pump suction is not obstructed or blocked, that the pump has enough water.
  • Page 71 Figure 10.5: Underload Timer Function MOTOR THERMAL PROTECTION (PARAMETERS 6.9 - 6.11) Motor thermal protection is to protect the motor from overheating. The Vacon drive is capable of supplying higher than nominal current to the motor. If the load requires this high current there is a risk that the motor will thermally overheat.
  • Page 72 • VACON ARAMETER DESCRIPTIONS HERMAL ROTECTION OF THE OTOR 0 = No response 1 = Warning 2 = Fault, stop mode after an error as in parameter 3.3 If tripping is selected, the drive will stop and activate the fault phase. AI Disable protection (that is, by setting the parameter to 0), the thermal model of the motor is reset to 0%.
  • Page 73 2xt6. If the drive is in stop mode, the time constant is internally increased to three times the set pa- rameter value. See also Figure 10.7. Figure 10.7: Motor temperature calculation 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 74 • VACON ARAMETER DESCRIPTIONS GROUP 7. Automatic Restarts UTOMATIC ESTART RIAL The automatic restart function restarts the frequency converter when the faults have disappeared and waiting time has elapsed. The time count starts from the first autorestart. If more than three faults oc- cur during trial time, the fault mode is activated.
  • Page 75 2. If we only want to restart the controller when Undervoltage and Overcurrent faults appear, we should set P7.4 to 5. 3. If we only want to restart the controller when Overcurrent faults apper, we should set P7.4 to 4. 24-hour support (0)201 212 575 • Email: vacon@vacon.com...
  • Page 76 600 V, -15%...+10% 3~ Input frequency 45…66 Hz Connection to mains Once per minute or less (normal case) Vacon 10 (400 V) cannot be used with networks that Networks have a phase to ground Supply network Short circuit current Maximum short circuit current has to be < 50 kA.
  • Page 77 Vacon); With an internal RFI filter 400V: Complies with EMC category C2; (level H Emissions Vacon): With an internal RFI filter Both: No EMC emission protection (Vacon level N): Without RFI filter For EMC: EN61800-3 Standards For safety: UL508C, EN61800-5...
  • Page 78 • VACON ECHNICAL DATA 11.2 Power ratings 11.2.1 Vacon 10 - Mains voltage 115 V Mains voltage 115 V, 50/60 Hz, 1~ series Motor Nominal Rated loadability shaft input Freq. power current Mechanical Weight converter size (kg) 150% over- type 100% contin.
  • Page 79 16.5 13.4 0.99 Table 11.4: Vacon 10 power ratings, 208-240 V, 3~ * The maximum ambient operating temperature of these drives is +40 °C. 11.2.4 Vacon 10 – Mains voltage 380-480 V Mains voltage 380 - 480 V, 50/60 Hz, 3~ series...
  • Page 80 • VACON ECHNICAL DATA 11.2.5 Vacon 10 – Mains voltage 600 V Mains voltage 600 V, 50/60 Hz, 3~ series Motor Nominal Rated loadability shaft input Freq. power current Mechanical Weight converter size (kg) 150% over- type 100% contin. load current...
  • Page 82 Find your nearest Vacon office on the Internet at: www.vacon.com Manual authoring: documentation@vacon.com Document ID: Vacon Plc. Runsorintie 7 65380 Vaasa Finland Subject to change without prior notice © 2013 Vacon Plc. Rev. B...

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