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Vacon 100 flow Installation Manual

Summary of 100 flow

  • Page 1

    Vacon 100 industrial vacon 100 flow ac drives installation manual ip00 drive modules ® ®.

  • Page 3: Preface

    Preface document details document id: dpd01665d date: 6.11.2017 about this manual this manual is copyright of vacon ltd. All rights reserved. The manual is subject to change without prior notice. The language of the original instructions is english. About the product this manual describes the vacon ...

  • Page 4

    Vacon · 4 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/.

  • Page 5: Table of Contents

    Table of contents preface document details 3 about this manual 3 about the product 3 1 approvals 8 2 safety 10 2.1 the safety symbols used in the manual 10 2.2 warning 10 2.3 caution 11 2.4 grounding and earth fault protection 12 2.5 using an rcd or an rcm device 13 3 receiving the delivery 14 3.1 p...

  • Page 6

    6.3 preparing for the cable installation 59 6.4 cable installation 60 6.4.1 enclosure sizes mr8 and mr9 60 6.4.2 enclosure sizes mr10 and mr12 64 7 control unit 73 7.1 control unit components 73 7.2 control unit cabling 75 7.2.1 selection of the control cables 75 7.2.2 control terminals and dip swit...

  • Page 7

    11 technical data on control connections 124 11.1 technical data on control connections 124 table of contents vacon · 7 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/.

  • Page 8: Approvals

    1 approvals here are the approvals that have been granted to this vacon ® product. 1 . Ec declaration of conformity • find the ec declaration of conformity on the next page. 2 . Ul approval * • culus approval file number e171278. 3 . Kc approval • registration number msip-rem-v93-vc100. * the ul app...

  • Page 9

    Antti vuola head of standard drives timo kasi vp, design center finland and italy danfoss a/s dk-6430 nordborg denmark cvr nr.: 20 16 57 15 telephone: +45 7488 2222 fax: +45 7449 0949 15-04-2016 15-04-2016 date issued by date approved by signature name title signature name title danfoss only vouches...

  • Page 10: Safety

    2 safety 2.1 the safety symbols used in the manual this manual contains warnings and cautions, which are identified with safety symbols. The warnings and cautions give important information on how to prevent injury and damage to the equipment or your system. Read the warnings and cautions carefully ...

  • Page 11

    Warning! Before you do electrical work on the drive, disconnect the drive from the mains and make sure that the motor has stopped. Lock out and tag out the power source to the drive. Make sure that no external source generates unintended voltage during work. Note that also the load side of the drive...

  • Page 12

    Caution! Make sure that the emc level of the ac drive is correct for your mains. See chapter 8.5 installation in an it system. An incorrect emc level can cause damage to the drive. If you use corner-grounding, change the emc level to c4, see chapter 8.5 installation in an it system. For information ...

  • Page 13

    Table 2: protective grounding conductor cross-section cross-sectional area of the phase conductors (s) [mm 2 ] the minimum cross-sectional area of the protective grounding conductor in question [mm 2 ] s ≤ 16 s 16 16 35 s/2 the values of the table are valid only if the protective grounding conductor...

  • Page 14: Receiving The Delivery

    3 receiving the delivery before a vacon ® ac drive is sent to the customer, the manufacturer makes many tests on the drive to ensure its quality. When you receive the delivery, examine the packaging carefully. After you remove the packaging, examine the drive for transport damages. If the drive was ...

  • Page 15

    3.2 type designation code the type designation code is made of standard codes and option codes. Each part of the type designation code agrees to the data in your order. The code can have this format, for example: vacon0100-3l-0385-5-flow+ip00 table 3: the description of the parts in the type designa...

  • Page 16

    3.4 removing the packaging and lifting the ac drive 3.4.1 weight of the ac drive the weights of ac drives of different enclosure sizes are very different. It can be necessary for you to use a lifting device to move the drive from its package. Table 4: the weight of the ac drive, mr8-mr12 enclosure s...

  • Page 17

    4 the maximum lifting angle is 45 degrees. ≤45º ≤45º receiving the delivery vacon · 17 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/ 3.

  • Page 18

    Lifting the ip00 drive module, mr10 or mr12 without the options module 1 make sure that the support is attached to the bottom of the drive. It gives the terminals protection when you lift the drive or put it vertically on the floor. A a a. The support / fixing bracket 2 lift the drive with a lifting...

  • Page 19

    4 lift the drive into a vertical position. 5 the maximum lifting angle is 60 degrees. ≤60º 3.5 "product modified" label in the accessories bag, there is also a "product modified" label. The function of the label is to tell the service personnel about the changes that are made in the ac drive. Attach...

  • Page 20

    3.6 disposal when the drive is at the end of its operation life, do not discard it as a part of municipal waste. You can recycle the primary components of the drive. You must disassemble some components before you can remove the different materials. Recycle the electrical and electronic components a...

  • Page 21: Mounting Dimensions

    4 mounting dimensions 4.1 dimensions of mr8, ip00 10 (0.37) 290 (11.42) 187 (7.34) 255 (10.04) 217 (8.54) 794 (31.26) 683 (26.89) 663 (26.10) 18 (0.71) 172 (6.75) 343 (13.50) 216 (8.49) 11 (0.43) 15 (0.59) Ø9 (0.35) Ø9 (0.35) Ø22 (0.87) Ø11 (0.43) a fig. 3: the dimensions of the ac drive, mr8, [mm (...

  • Page 22

    A. An optional main connector cover for the cabinet installation 4.2 dimensions of mr9, ip00 130 (5.12) 810 (31.89) 841 (33.09) 17 (0.65) 50 (1.97) 360 (14.17) 14 (0.55) Ø9 (0.35) Ø22 (0.87) 400 (15.75) 480 (18.90) 355 (13.98) 365 (14.37) Ø9 (0.35) a fig. 4: the dimensions of the ac drive, mr9 [mm (...

  • Page 23

    4.3 dimensions of mr10 and mr12, ip00 a b c 24 (0.94) 37 (1.46) 930 (36.61) 432 (17.01) 483 (19.02) 418 (16.46) 412 (16.22) 383 (15.08) 348 (13.70) 876 (34.49) 43 (1.69) 76 (2.99) 476 (18.74) 268 (10.55) 461 (18.15) 418 (16.46) 525 (20.67) 506 (19.92) 370 (14.57) 20 (0.79) 396 (15.59) 133 (5.24) 223...

  • Page 24

    Note! The mr12 drive includes 2 power units, and 1 of them includes a control unit. A b 92 (3.62) 506 (19.92) 471 (18.54) 418 (16.46) 365 (14.37) 308 (12.13) 225 (8.86) 202 (7.95) 145 (5.71) 92 (3.62) 39 (1.54) m12 1538 (60.55) 30 (1.18) 900 (35.43) 41 (1.61 1425 (56.10) 506 (19.92) 476 (18.74) 396 ...

  • Page 25

    4.4 dimensions for flange mounting of mr8 359 (14.13) 326 (12.83) 6.8 (0.27) 424.7 (16.72) 89.6 (3.53) 890.8 (35.07) 233 (9.17) 831.5 (32.74) 315.5 (12.42) 19.4 (0.76) 852.6 (33.57) 573.5 (22.58) 82.5 (3.25) 26 (1.02) 182.5 (7.18) 334 (13.15) 72 (2.83) 898 (35.35) 102 (4.02) gnd m8 293 (11.53) 109.5...

  • Page 26

    4.5 dimensions for flange mounting of mr9 1060 (41.73) 397.5 (15.65) 550 (21.65) 525 (20.67) 108 (4.25) 255.8 (10.07) 247 (9.72) m8 gnd 72 (2.83) 102 (4.02) 73 (2.87) 175 (6.89) 175 (6.89) 85 (3.35) 10.5 (0.41) 163 (6.42) 300 (11.81) 300 (11.81) 1039 (40.90) 10.5 (0.41) 56 (2.20) 75 (2.95) Ø22 (0.87...

  • Page 27

    4.6 dimensions for flange mounting of mr10 1070 (42.13) 1080 (42.52) 103 (4.06) 243 (9.57) 525 (20.67) 222 (8.74) 576 (22.68) 544 (21.42) 200 (7.87) 45 (1.77) 75 (2.95) 15 (0.6) m8 gnd Ø22 (0.87) Ø11 (0.43) Ø12 (0.47) 215 (8.46) 63 (2.48) 1110 (43.70) fig. 9: the dimensions of the ac drive, flange m...

  • Page 28

    4.7 dimensions of options for mr10 and mr12 18 (0.71) 70 (2.76) 9 (0.35) 31 288 (11.33) 286 (11.25) 305 (12.01) 315 (12.38) 181 (7.13) 107 Ø13 (0.49) Ø13 (0.49) Ø7 (0.26) Ø7 (0.28) 174 (6.85) 160 (6.31) 155 (6.10) 83 (3.26) 155 (6.10) 148 (5.83) 169 (6.66) 53 (2.09) 58 (2.27) 5 (0.20) 53 (2.09) 40 (...

  • Page 29

    Ø12 (0.72) Ø6 (0.24) Ø6 (0.24) 8 (0.31) 100 (3.94) 94 (3.70) 56 (2.20) 39 (1.54) 31 (1.22) 27.5 (1.08) 36 (1.42) 125 (4.92) 266 (10.47) 260 (10.24) 128 (5.04) 120 (4.72) 106 (4.17) 135 (5.31) fig. 11: dimensions of the installation kit for a detached control unit (enc-qcdu) [mm (in)] mounting dimens...

  • Page 30: Installation Into Cabinet

    5 installation into cabinet 5.1 general information the ac drives that are described in this manual have the enclosure class ip00. You must install them in a cabinet or other enclosure that has a correct level of protection against the ambient conditions in the installation area. Make sure that the ...

  • Page 31

    Table 5: the options for mr8 and mr9 option order code location description the brake chopper +dbin the options module enables dynamic braking with an exter- nal brake resistor. Flange mounting +qflg - enables mounting the drive through the cabinet wall so that the control unit stays inside the cabi...

  • Page 32

    Note! The optional external power connection block is not necessary if you have an options module. E b c d f a l1 l2 l3 pe w/t3 v/t2 u/t1 w1 v1 u1 pe m pe l1 l2 l3 com sto pe dc- dc+ pe w/ t3 v/ t2 u/ t1 dc- dc+ r- dc- dc+ r- r+ fig. 14: the main circuit diagram, mr10 with the options module and opt...

  • Page 33

    Table 6: the options for mr10 option order code location description the brake chopper +dbin the options module enables dynamic braking with an exter- nal brake resistor. The common mode filter +pocm the options module decreases motor bearing currents. The du/dt filter +podu the options module decre...

  • Page 34

    5.1.3 general information about the installation, mr12 b c c e a d 2l1 2l22l3 pe pe pe w/t3 v/t2 u/t1 w/ t3 v/ t2 u/ t1 w/ t3 v/ t2 u/ t1 pe l1 l2 l3 pe 1l11l2 1l3 pe l1 l2 l3 pe dc- dc+ pe w/t3 v/t2 u/t1 dc- dc+ com sto com sto m w1 v1 u1 pe fig. 15: the main circuit diagram, mr12 without the optio...

  • Page 35

    Note! The optional external power connection block is not necessary if you have an options module. B c d e c d e g a f 2l1 2l22l3 pe w/t3 v/t2 u/t1 pe l1 l2 l3 pe 1l11l2 1l3 pe l1 l2 l3 pe dc- dc+ com sto com sto ok 3 m dc- dc+ r- dc- dc+ r- pe w/t3 v/t2 u/t1 dc- dc+ pe w/ t3 v/ t2 u/ t1 dc- dc+/ r-...

  • Page 36

    Table 7: the options for mr12 option order code location description the brake chopper +dbin the options module enables dynamic braking with an exter- nal brake resistor. The common mode filter +pocm the options module decreases motor bearing currents. The du/dt filter +podu the options module decre...

  • Page 37

    5.2.1 installing the ip00 drive module into the cabinet installing the ip00 drive module without the options module 1 we recommend that you install the ip00 drive module on rails inside the cabinet. A a. The rails inside the cabinet 2 use fixing points to attach the ip00 drive module into the cabine...

  • Page 38

    1 use the fixing points at the front of the drive. B a a. The front fixing points b. The fixing points of the options module. These are important for a safe maintenance if the ip00 drive module is removed. 2 use the fixing points at the rear of the drive. A a. The rear fixing points vacon · 38 insta...

  • Page 39

    5.2.2 flange mounting of the ip00 drive module you can also install the ip00 drive module into the cabinet wall with a flange mounting option. Note! The protection classes are different in different sections of the drive module. A b d a c e fig. 18: example of flange mounting (enclosure size mr9) a....

  • Page 40

    G f a e b d c h fig. 19: the dimensions of the opening and drive module outline with flange a. The height of the opening for the flange mounting b. The width of the opening c. The height of the drive module d. The width of the drive module e. The distance between the bottom of the drive module and t...

  • Page 41

    Table 9: the dimensions of the opening for the flange mounting enclosure size a [mm] b [mm] e [mm] a [in] b [in] e [in] mr8 859 298 18 33.8 11.7 0.7 mr9 975 485 54 38.4 19.1 2.1 mr10 960 510 122 37.8 20.1 4.8 d a fig. 20: sealing of the opening for mr8, mr9, and mr10 a. The ac drive b. The outline o...

  • Page 42

    2 attach the side plate to the assembly plate. You can attach it on the left or on the right. 3 dismount the control unit and the control cable grounding bar from the mr10 power unit. 4 mount the control unit and the control cable grounding bar to the assembly plate. 5 mount the installation kit to ...

  • Page 43

    A b c d fig. 21: the correct circulation of cooling air inside the cabinet a. Cool air going in b. Hot air coming out c. Install shields to prevent recirculation of hot air inside the cabinet. D. Minimum 200 mm (7.87 in) a b fig. 22: the cooling air must move freely inside the cabinet a. Cool air go...

  • Page 44

    Table 10: the necessary quantity of cooling air enclosure size the quantity of cooling air [m 3 /h] the quantity of cooling air [cfm] the surface area of the air intake holes [cm 2 ] * the surface area of the air intake holes [in 2 ] * mr8 335 197 150 23.25 mr9 620 365 300 46.50 mr10 1400 824 600 93...

  • Page 45: Power Cabling

    6 power cabling 6.1 cable dimensioning and selection 6.1.1 cable and fuse sizes we recommend the fuse type gg/gl (iec 60269-1) for mains fuses (-f1). Use only fuses that have a sufficient voltage rating according to the mains voltage. Do not use larger fuses than what is recommended in table 11. The...

  • Page 46

    Table 11: the recommended mains cables and fuses in 208-240 v and 380-500 v enclosure size type il [a] mains fuses per phase (gg/gl) [a] mains and motor cable (cu/ai) [mm2] mains cable terminal, bolt size [mm 2 ] grounding terminal, bolt size [mm 2 ] mr8 0140 2 0140 5 140 160 (3x70+35) (cu) (3x95+29...

  • Page 47

    Table 12: the recommended mains cables and fuses in 525-690 v enclosure size type il [a] mains fuses per phase (gg/gl) [a] mains and motor cable (cu/ai) [mm2] mains cable terminal, bolt size [mm 2 ] grounding terminal, bolt size [mm 2 ] mr8 0080 6 0080 7 80 100 3x35+16 (cu) 3x50+21 (al) m8 m8 0100 6...

  • Page 48

    Table 13: drive fuses, 208-240 v and 380-500 v, mersen enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0140 2 0140 5 140 nh1ud69v250pv 250 3 1 1400 0170 2 0170 5 170 nh1ud69v350pv 350 3 1 2400 020...

  • Page 49

    Table 14: drive fuses, 525-690 v, mersen enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0080 6 0080 7 80 nh1ud69v125pv 125 3 1 500 0100 6 0100 7 100 nh1ud69v160pv 160 3 1 700 0125 6 0125 7 125 nh...

  • Page 50

    Table 15: drive fuses, 208-240 v and 380-500 v, bussmann enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0140 2 0140 5 140 170m3817d 315 3 1 1700 0170 2 0170 5 170 170m3818d 350 3 1 1950 0205 2 02...

  • Page 51

    Table 16: drive fuses, 525-690 v, bussmann enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0080 6 0080 7 80 170m3814d 160 3 1 650 0100 6 0100 7 100 170m3815d 200 3 1 950 0125 6 0125 7 125 170m3816...

  • Page 52

    6.1.2 cable and fuse sizes, north america we recommend the fuse class t (ul & csa). To make a selection of the fuse voltage rating, refer to the mains. Refer also to local regulations, cable installation conditions and cable specification. Do not use larger fuses than what is recommended in table 17...

  • Page 53

    Table 17: the cable and fuse sizes for vacon ® 100 industrial and flow in north america, mains voltage 208-240 v and 380-500 v enclosure size type il [a] fuse (class t/j) [a] mains and motor cable (cu) [awg/ kcmil] terminal cable size mains cable terminal [awg/ kcmil] grounding terminal [awg/ kcmil]...

  • Page 54

    Table 18: the cable and fuse sizes for vacon ® 100 industrial and flow in north america, mains voltage 525-690 v enclosure size type il [a] fuse (class t/j) [a] mains and motor cable (cu) [awg/ kcmil] terminal cable size mains cable terminal [awg/ kcmil] grounding terminal [awg/ kcmil] mr8 0080 7 80...

  • Page 55

    Table 19: drive fuses in north america, 208-240 v and 380-500 v, mersen enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0140 2 0140 5 140 pc30ud69v250tf 250 3 30 1550 0170 2 0170 5 170 pc30ud69v31...

  • Page 56

    Table 20: drive fuses in north america, 525-690 v, mersen enclosure size type i l [a] catalogue number of the fuse fuse rating [a] number of fuses needed fuse size minimum prospective short circuit current mr8 0080 7 80 pc30ud69v160tf 160 3 30 800 0100 7 100 pc30ud69v200tf 200 3 30 1200 0125 7 125 p...

  • Page 57

    6.2 brake resistor cables table 21: brake resistor cables, 208-240 v and 380-500 v enclosure size type il [a] brake resistor cable (cu) [mm 2 ] brake resistor cable (cu) [awg/ kcmil] mr8 0140 2 0140 5 140 3x70+35 4/0 0170 2 0170 5 170 3x95+50 300 0205 2 0205 5 205 3x120+70 350 mr9 0261 2 0261 5 261 ...

  • Page 58

    Table 22: brake resistor cables, 525-690 v enclosure size type * il [a] brake resistor cable (cu) [mm 2 ] brake resistor cable (cu) [awg] mr8 0080 6 0080 7 80 3x35+16 2 0100 6 0100 7 100 3x50+25 1/0 0125 6 0125 7 125 3x70+35 3/0 mr9 0144 6 0144 7 144 3x70+35 4/0 0170 6 0170 7 170 3x95+50 250 0208 6 ...

  • Page 59

    Note! The different vacon ® 100 applications have different functions. For example, the vacon ® 100 flow does not have the dynamic braking or the brake resistor functions. 6.3 preparing for the cable installation • before you start, make sure that none of the components of the ac drive is live. Read...

  • Page 60

    Table 23: the minimum distances between cables in long parallel lines the distance between cables [m] the length of the shielded cable [m] the distance between cables [ft] the length of the shielded cable [ft] 0.3 ≤ 50 1.0 ≤ 164.0 1.0 ≤ 200 3.3 ≤ 656.1 6.4 cable installation 6.4.1 enclosure sizes mr...

  • Page 61

    3 find the motor cable terminals. L2 l3 dc- dc+ r+ r- l1 u/t1 v/t2 w/t3 mr8 l2 l3 dc- dc+ r+ r- l1 u/t1 v/t2 w/t3 mr9 power cabling vacon · 61 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/ 6.

  • Page 62

    4 connect the cables. The picture shows an example of good cabling. A ) connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals. B ) attach the grounding conductor of each ...

  • Page 63

    5 if you use many cables on one connector, put the cable lugs on top of each other. A c b a. The first cable lug b. The second cable lug c. The connector 6 if you use thick cables, put the cable insulators in between the terminals to prevent contact between the cables. 7 for mr9, attach the cover of...

  • Page 64

    Table 24: tightening torques of the terminals, mr8 and mr9 enclosu re size type tightening torque: the mains and motor cable terminals tightening torque: the grounding clamps for cable shield tightening torque: the grounding terminals [nm] lb-in. [nm] lb-in. [nm] lb-in. Mr8 0140 2-0205 2 0140 5-0205...

  • Page 65

    Cable installation without the options module 1 find the motor cable terminals. Dc+ l1 l2 l3 u/t1 v/t2 w/t3 dc- 2 in mr12, connect the dc terminals of the 2 power units with the dc link cable. Connect the dc+ terminals together, and the dc- terminals together. The dc link cable is included in the de...

  • Page 66

    4 connect the cables. The picture shows an example of good cabling. A ) connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals. B ) attach the grounding conductor of each ...

  • Page 67

    5 if you use many cables on one connector, put the cable lugs on top of each other. • the pictures show the connection in mr10 and mr12. • the bolt holder of the connector keeps the bolt still when you turn the nut. A b c 1. 2. 3. 4. D a. The bolt holder of the connector b. The first cable lug c. Th...

  • Page 68

    8 make sure that the grounding conductor is connected to the motor and also to the terminals that are identified with . A ) to obey the requirements of the standard en61800-5-1, obey the instructions in chapter 2.4 grounding and earth fault protection. A c d b max. 70 nm (620 lb-in) 20° +/-5° fig. 2...

  • Page 69

    Table 25: tightening torques of the terminals, mr10 or mr12 without options module enclosu re size type tightening torque: the mains and motor cable terminals tightening torque: the grounding terminals [nm] lb-in. [nm] lb-in. Mr10 0385 5-0590 5 0261 6-0416 6 0261 7-0461 7 55-70 * 490-620 * 20 177 mr...

  • Page 70

    4 connect the cables. The picture shows an example of good cabling. A ) connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals. B ) attach the grounding conductor of each ...

  • Page 71

    5 if you use many cables on one connector, put the cable lugs on top of each other. • the pictures show the connection in mr10 and mr12. • the bolt holder of the connector keeps the bolt still when you turn the nut. A b c 1. 2. 3. 4. D a. The bolt holder of the connector b. The first cable lug c. Th...

  • Page 72

    8 make sure that the grounding conductor is connected to the motor and also to the terminals that are identified with . A ) to obey the requirements of the standard en61800-5-1, obey the instructions in chapter 2.4 grounding and earth fault protection. Table 26: tightening torques of the terminals, ...

  • Page 73: Control Unit

    7 control unit 7.1 control unit components the control unit of the ac drive contains the standard boards and the option boards. The option boards are connected to the slots of the control board (see 7.4 installation of option boards). Control unit vacon · 73 local contacts: http://drives.Danfoss.Com...

  • Page 74

    Sto jmp l i m k h g f j e d a b c fig. 25: the components of the control unit a. The control terminals for the standard i/o connections b. The ethernet connection c. The relay board terminals for 3 relay outputs or 2 relay outputs and a thermistor d. The option boards e. A dip switch for the rs485 b...

  • Page 75

    It is possible to use the drive with an external power source with these properties: +24 vdc ±10%, minimum 1000 ma. Connect the external power source to terminal 30. This voltage is sufficient to keep the control unit on and for you to set the parameters. The measurements of the main circuit (for ex...

  • Page 76

    Run fault ready *) *) reference output +10 vref terminal standard i/o board signal 1 24v auxiliary voltage 24vout 6 analogue input, voltage or current reference potentiometer 1...10kΩ actual value 2-wire transmitter i = (0)4...20ma ai1+ 2 analogue input common, (current) ai1- 3 analogue input, volta...

  • Page 77

    * = you can isolate digital inputs from ground with a dip switch. See 7.2.2.2 isolation of digital inputs from ground. There are 2 different relay boards available. Ro1 nc ro1 cm ro1 no ro2 nc ro2 cm ro2 no ro3 cm ro3 no 21 22 23 24 25 26 32 33 run run fault ready relay output 1 relay output 2 relay...

  • Page 78

    A b a b c d e ai2 u i ai1 u i rs-485 off on ao1 u i fig. 29: the selections of the dip switches a. The voltage signal (u), 0-10 v input b. The current signal (i), 0-20 ma input c. Off d. On e. The rs-485 bus termination table 29: the default positions of the dip switches the dip switch the default p...

  • Page 79

    7.2.2.2 isolation of digital inputs from ground it is possible to isolate from ground the digital inputs (terminals 8-10 and 14-16) on the standard i/o board. To do this, change the position of a dip switch on the control board. A b c fig. 30: change the position of this switch to isolate the digita...

  • Page 80

    C d b a fig. 31: the ethernet and rs485 connections a. Rs485 terminal a = data - b. Rs485 terminal b = data + c. The ethernet terminal d. The control terminals 7.3.1 using fieldbus through an ethernet cable table 30: ethernet cable data item description the plug type a shielded rj45 plug, maximum le...

  • Page 81

    7.3.2 using fieldbus through an rs485 cable table 31: rs485 cable data item description the plug type 2.5 mm 2 the cable type stp (shielded twisted pair), belden 9841 or almost the same the cable length so that it agrees with the fieldbus. See the fieldbus manual. Rs485 cabling 1 remove approximatel...

  • Page 82

    2 connect the cable to the standard i/o board of the drive, in terminals a and b. • a = negative • b = positive 3 attach the shield of the cable to the frame of the drive with a grounding clamp for control cable to make a grounding connection. Vacon · 82 control unit 7 local contacts: http://drives....

  • Page 83

    4 if the drive is the last device on the fieldbus line, set the bus termination. A ) find the dip switches on the left side of the control unit of the drive. B ) set the dip switch of the rs485 bus termination to the on position. C ) biasing is built in the bus termination resistor. The termination ...

  • Page 84

    Note! If you do power-down to the last device, there is no bus termination. 7.4 installation of option boards caution! Do not install, remove, or replace option boards on the drive when the power is on. Doing this can cause damage to the boards. Install the option boards into the option board slots ...

  • Page 85

    The installation procedure 1 open the cover of the ac drive. Warning! Do not touch the control terminals. They can have a dangerous voltage also when the drive is disconnected from mains. 2 if you have an optb or an optc option board, make sure that the label on it says "dv" (dual voltage). This sho...

  • Page 86

    4 install the option board into the correct slot: c, d or e. See table 32. A ) the option board has a slot coding, because of which it is not possible to install the option board in an incorrect slot. B a a. The slot coding b. The option board slots 5 close the cover of the control unit. Put the cov...

  • Page 87

    A b 10vref gnd +24v gnd ai1+ ai1- ai2+ ai2- di1... Di6 cm ao1+ ao1- +24vin rs485 ro1/1 ro1/2 ro1/3 ro2/1 ro2/2 ro2/3 ti1+ ti1- l1 l2 l3 dc- dc+/r+ r- u v w fig. 32: the galvanic isolation barriers a. The control unit b. The power unit control unit vacon · 87 local contacts: http://drives.Danfoss.Com...

  • Page 88: Commissioning and Additional

    8 commissioning and additional instructions 8.1 commissioning safety before you start the commissioning, read these warnings. Warning! Do not touch the internal components or the circuit boards of the drive when the drive is connected to mains. These components are live. A contact with this voltage ...

  • Page 89

    8.2 operation of the motor 8.2.1 checks before starting the motor before you start the motor, do these checks. • make sure that all the start and stop switches that are connected to the control terminals are in the stop position. • make sure that you can start the motor safely. • activate the start-...

  • Page 90

    8.5 installation in an it system if your mains is impedance-grounded (it), the ac drive must have the emc protection level c4. If your drive has the emc protection level c3, it is necessary to change it to c4. To do this, remove the emc jumper. Warning! Do not make changes in the ac drive when it is...

  • Page 91

    4 find the grounding arm and push it down. A b a. The grounding arm is up (level c3) b. The grounding arm is down (level c4) 5 after the change, write "the emc level was changed" and the date on the "product modified" label. If the label is not attached at this time, attach it on the drive near the ...

  • Page 92

    3 remove the emc jumper. 4 if you change the emc level, write "the emc level was changed" and the date on the "product changed" label. If the label is not attached at this time, attach it on the drive near the name plate. Product modified date: date: date: the emc jumpers 2 and 3 1 remove the cover ...

  • Page 93

    Finding the emc jumper, without the options module 1 find the emc jumper between the terminals l2 and l3. 2 remove the emc jumper. 3 if you change the emc level, write "the emc level was changed" and the date on the "product modified" label. If the label is not attached at this time, attach it on th...

  • Page 94

    Finding the emc jumper, with an options module 1 remove the covers of the options module. 2 find the emc jumper between the terminals l2 and l3. Vacon · 94 commissioning and additional instructions 8 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/.

  • Page 95

    3 remove the emc jumper. 4 if you change the emc level, write "the emc level was changed" and the date on the "product modified" label. If the label is not attached at this time, attach it on the drive near the name plate. Product modified date: date: date: 8.6 maintenance 8.6.1 maintenance interval...

  • Page 96

    This table is valid for vacon ® components. To do maintenance on components that are made by other manufacturers, obey the manual of the component in question. 8.6.2 replacing the fans of the ac drive 8.6.2.1 replacing the fans in mr8 here are the instructions on how to replace the fans of the drive...

  • Page 97

    4 to release the fan from the cover plate, remove the 4 screws. A a. The fan cable 5 release the grommet on the fan cable from the cover plate and pull out the cable. 6 replace the main fan. Attach the screws. 7 re-assemble the drive and connect the cables. 8.6.2.2 replacing the fans in mr9 here are...

  • Page 98

    2 disconnect the cables from the fan power supply. 3 remove the 12 screws from the fan cover plate. Use the handle to lift off the main fan unit. 1 2 2 3 3 4 to release the fan from the cover plate, remove the 4 screws. A a. The fan cable 5 release the grommet on the fan cable from the cover plate a...

  • Page 99

    Replacing the main fan assembly, mr10 and mr12 1 loosen the 8 screws and lift off the service lid. 2 disconnect the cables from each fan power supply. A ) disconnect the fan driver cable from connector x61. B ) disconnect the dc supply cable from connector x8. Remove the 5 screws. X61 x8 x61 x8 a a ...

  • Page 100

    Replacing the fan power supplies, mr10 and mr12 you can replace only 1 or both the fan power supplies. 1 remove the main fan assembly. See the previous instructions. 2 a ) disconnect the fan supply cable from connector x81. B ) disconnect the fan driver cable from connector x61. C ) disconnect the d...

  • Page 101

    Downloading with mains, mr8-mr12 when the drive is supplied from mains, you can download a new software with the vacon ® loader pc tool and a cab-usb/rs485 cable. 1 to download a new software, connect the pc into the control panel connector with the cab-usb/ rs485 cable. • the downloading time: • mr...

  • Page 102

    3 in mr10 and mr12, connect an external 24 vdc into the connector x50 on the measurement board. The connector pins are x50-22 (+) and x50-23 (-). • in mr12, connect the external 24 vdc to the two x50 connectors. Note! The size of the power supply wire for the external 24 vdc must be a minimum of 1 m...

  • Page 103: Technical Data, Vacon

    9 technical data, vacon ® 100 industrial 9.1 ac drive power ratings 9.1.1 mains voltage 208-240 v table 34: the power ratings of vacon ® 100 industrial in mains voltage 208-240 v, 50-60 hz, 3~ enclos ure size drive type loadability motor shaft power low high max curre nt i s 2s 230 v mains 230 v mai...

  • Page 104

    9.1.2 mains voltage 380-500 v table 35: the power ratings of vacon ® 100 industrial in mains voltage 380-500v, 50-60 hz, 3~ enclos ure size drive type loadability motor shaft power low high max curre nt i s 2s 400 v mains 480 v mains contin uous curre nt i lout [a] input curre nt i lin [a] 10% over-...

  • Page 105

    9.1.3 mains voltage 525-690 v table 36: the power ratings of vacon ® 100 industrial in mains voltage 525-690 v, 50-60 hz, 3~ enclos ure size drive type loadability motor shaft power low high max curre nt i s 2s 600 v mains 690 v mains contin uous curre nt i lout [a] input curre nt i lin [a] 10% over...

  • Page 106

    Il il*110% 1 min 9 min i t il*110% fig. 33: low overload the high overload means that if 150% of the continuous current (i h ) is required for 1 minute every 10 minutes, the remaining 9 minutes must be approximately 92% of i h or less. This is to make sure that the output current is not more than i ...

  • Page 107

    Table 37: the recommended brake resistor types and the calculated resistance of the drive, 208-240 v enclosure size duty cycle type of brake resistor resistance [Ω] mr8 light duty brr 0105 ld 5 6.5 heavy duty brr 0105 hd 5 6.5 mr9 light duty brr 0300 ld 5 3.3 heavy duty brr 0300 hd 5 3.3 table 38: t...

  • Page 108

    Table 39: the recommended brake resistor types and the calculated resistance of the drive, 525-690 v enclosure size drive type duty cycle type of brake resistor resistance [Ω] mr8 0080 light duty brr 0052 ld 6 18 heavy duty brr 0052 hd 6 18 0100-0125 light duty brr 0100 ld 6 9 heavy duty brr 0100 hd...

  • Page 109

    0 0 3 5 10 100 p [%] t [s] 120 240 123 125 130 fig. 36: the duty cycles of the ld and hd pulses table 40: the minimum resistance and the brake power, mains voltage 208-240 v enclosure size the minimum brake resistance [Ω] brake power* @845 vdc [kw] mr8 3.0 25.2 mr9 1.4 49.7 table 41: the minimum res...

  • Page 110

    9.2 vacon ® 100 industrial - technical data table 43: the technical data of the vacon ® 100 industrial ac drive technical item or function technical data mains connection input voltage u in 208-240 v, 380-500 v, 525-690 v, -10%...+10% input frequency 50-60 hz, -5...+10% connection to mains once per ...

  • Page 111

    Table 43: the technical data of the vacon ® 100 industrial ac drive technical item or function technical data control characteristics switching frequency (see parameter p3.1.2.3) 200-500 v • mr8-mr12: • 1.5-6 khz • default: mr8: 3 khz, mr9: 2 khz, mr10: 2 khz, mr12: 2 khz 690 v • mr8-mr12: • 1.5-6 k...

  • Page 112

    Table 43: the technical data of the vacon ® 100 industrial ac drive technical item or function technical data ambient conditions ambient operating tem- perature i l current: -10°c (no frost)...+40 °c i h current: -10°c (no frost)...+40 °c maximum operating temperature: +50 °c with derating (1.5%/1°c...

  • Page 113

    Table 43: the technical data of the vacon ® 100 industrial ac drive technical item or function technical data emc (at default settings) immunity fulfils en61800-3, 1 st and 2 nd environment emissions 200-690 v: en 61800-3 (2004), category c3, if the drive is correctly installed. The drive can be cha...

  • Page 114

    Table 43: the technical data of the vacon ® 100 industrial ac drive technical item or function technical data protections overvoltage trip limit mains voltage 240 v: 456 vdc mains voltage 500 v: 911 vdc mains voltage 690 v: 1258 vdc undervoltage trip limit depends on mains voltage (0.8775 x mains vo...

  • Page 115: Technical Data, Vacon

    10 technical data, vacon ® 100 flow 10.1 ac drive power ratings 10.1.1 mains voltage 208-240 v table 44: the power ratings of vacon ® 100 flow in mains voltage 208-240 v, 50-60 hz, 3~ enclosure size drive type loadability motor shaft power continuous current i lout [a] input current i lin [a] 10% ov...

  • Page 116

    10.1.2 mains voltage 380-500 v table 45: the power ratings of vacon ® 100 flow in mains voltage 380-500 v, 50-60 hz, 3~ enclosure size drive type loadability motor shaft power continuous current i lout [a] input current i lin [a] 10% overload current [a] max current i s 2s 400 v mains 480 v mains 10...

  • Page 117

    10.1.3 mains voltage 525-690 v table 46: the power ratings of vacon ® 100 flow in mains voltage 525-690 v, 50-60 hz, 3~ enclosure size drive type loadability motor shaft power continuous current i lout [a] input current i lin [a] 10% overload current [a] max current i s 2s 600 v mains 690 v mains 10...

  • Page 118

    Il il*110% 1 min 9 min i t il*110% fig. 37: low overload in vacon ® 100 flow for more information, refer to the standard iec61800-2 (iec:1998). Vacon · 118 technical data, vacon® 100 flow 10 local contacts: http://drives.Danfoss.Com/danfoss-drives/local-contacts/.

  • Page 119

    10.2 vacon ® 100 flow - technical data table 47: the technical data of the vacon ® 100 flow ac drive technical item or function technical data mains connection input voltage u in 208-240 v, 380-500 v, 525-690 v, -10%...+10% input frequency 50-60 hz, -5...+10% connection to mains once per minute or l...

  • Page 120

    Table 47: the technical data of the vacon ® 100 flow ac drive technical item or function technical data control characteristics switching frequency (see parameter p3.1.2.3) 200-500 v • mr8-mr12: • 1.5-6 khz • default: mr8: 3 khz, mr9: 2 khz, mr10: 2 khz, mr12: 2 khz 690 v • mr8-mr12: • 1.5-6 khz • d...

  • Page 121

    Table 47: the technical data of the vacon ® 100 flow ac drive technical item or function technical data ambient conditions ambient operating tem- perature i l current: -10°c (no frost)…+40 °c maximum operating temperature: +50 °c with derating (1.5%/1°c) storage temperature -40 °c…+70 °c relative hu...

  • Page 122

    Table 47: the technical data of the vacon ® 100 flow ac drive technical item or function technical data emc (at default settings) immunity fulfils en61800-3, 1 st and 2 nd environment emissions 200-690 v: en 61800-3 (2004), category c3, if the drive is correctly installed. The drive can be changed t...

  • Page 123

    Table 47: the technical data of the vacon ® 100 flow ac drive technical item or function technical data protections overvoltage trip limit mains voltage 240 v: 456 vdc mains voltage 500 v: 911 vdc mains voltage 690 v: 1258 vdc undervoltage trip limit depends on mains voltage (0.8775 x mains voltage)...

  • Page 124

    11 technical data on control connections 11.1 technical data on control connections table 48: the standard i/o board standard i/o board terminal signal technical information 1 reference output +10 v, 0%...+3%, maximum current: 10 ma 2 analogue input, voltage or cur- rent analogue input channel 1 0.....

  • Page 125

    Table 48: the standard i/o board standard i/o board terminal signal technical information 14 digital input 4 positive or negative logic ri = min. 5 kΩ 0-5 v = 0 15-30 v = 1 15 digital input 5 16 digital input 6 17 common a for din1-din6 digital inputs can be isolated from ground, see chapter 7.2.2.2...

  • Page 126

    Table 49: the standard relay board (+sbf3) terminal signal technical information 21 relay output 1 * change-over contact (spdt) relay. 5.5 mm isolation between channels. Switching capacity • 24 vdc/8 a • 250 vac/8 a • 125 vdc/0.4 a minimum switching load • 5 v/10 ma 22 23 24 relay output 2 * change-...

  • Page 127

    Table 50: the optional relay board (+sbf4) terminal signal technical information 21 relay output 1 * change-over contact (spdt) relay. 5.5 mm isolation between channels. Switching capacity • 24 vdc/8 a • 250 vac/8 a • 125 vdc/0.4 a minimum switching load • 5 v/10 ma 22 23 24 relay output 2 * change-...

  • Page 128

    Document id: dpd01665d rev. D sales code: doc-ins100ip00+dluk vacon ltd member of the danfoss group runsorintie 7 65380 vaasa finland www.Danfoss.Com.