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  4. 100 INDUSTRIAL
  5. Installation Manual

Vacon 100 INDUSTRIAL Installation Manual

Summary of 100 INDUSTRIAL

  • Page 1

    Vacon 100 ac drives installation manual.

  • Page 2

    Vacon • 0 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com index document: dpd00390d version release date: 27.1.11 1. Safety ............................................................................................................... 4 1.1 danger .........................................

  • Page 3

    Vacon • 1 tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 6.3.3 frame mr9 ....................................................................................................................... 67 6.4 maintenance .........................................................................................

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    Vacon • 2 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com.

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    Vacon • 3 tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 ec declaration of conformity we manufacturer’s name: vacon oyj manufacturer’s address: p.O.Box 25 runsorintie 7 fin-65381 vaasa finland hereby declare that the product product name: vacon 100 ac drive model designation: vacon 100 3l 0003 2.....

  • Page 6

    Safety vacon • 4 24-hour support +358 (0)40 837 1150 • email: vacon@vacon.Com 1 1. S afety this manual contains clearly marked cautions and warnings which are intended for your per- sonal safety and to avoid any unintentional damage to the product or connected appliances. Please read the information...

  • Page 7

    1 vacon • 5 safety tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 1.2 warnings vacon 100 ac drive is meant for fixed installations only. Do not perform any measurements when the ac drive is connected to the mains. The touch current of vacon 100 ac drives exceeds 3.5ma ac. According to stan- dard e...

  • Page 8

    Safety vacon • 6 24-hour support +358 (0)40 837 1150 • email: vacon@vacon.Com 1 1.3 earthing and earth fault protection the vacon 100 ac drive must always be earthed with an earthing conductor connected to the earthing terminal marked with . The touch current of vacon 100 exceeds 3.5ma ac. According...

  • Page 9

    1 vacon • 7 safety tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 1.4 electro-magnetic compatibility (emc) this equipment complies with iec 61000-3-12 provided that the short-circuit power s sc is greater than or equal to 120 at the interface point between the user’s supply and the public sys- tem...

  • Page 10

    Receipt of delivery vacon • 8 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 2 2. R eceipt of delivery check the correctness of delivery by comparing your order data to the drive information found on the package label. If the delivery does not correspond to your order, contact the supp...

  • Page 11

    2 vacon • 9 receipt of delivery tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 2.1 type designation code vacon type designation code is formed of a nine-segment code and optional +codes. Each seg- ment of the type designation code uniquely corresponds to the product and options you have ordered. T...

  • Page 12

    Receipt of delivery vacon • 10 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 2 2.2 unpacking and lifting the ac drive the weights of the ac drives vary greatly according to the size. You may need to use a piece of special lifting equipment to move the converter from its package. Note ...

  • Page 13

    2 vacon • 11 receipt of delivery tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 2.3 accessories after having opened the transport package and lifted the converter out, check immediately that these various accessories were included in the delivery. The contents of the accessories bag differ by driv...

  • Page 14

    Receipt of delivery vacon • 12 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 2 2.3.3 size mr6 table 6. Contents of accessories bag, mr6 2.3.4 size mr7 table 7. Contents of accessories bag, mr7 2.3.5 size mr8 table 8. Contents of accessories bag, mr8 item quantity purpose m4x20 screw 1...

  • Page 15

    2 vacon • 13 receipt of delivery tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 2.3.6 size mr9 table 9. Contents of accessories bag, mr9 2.4 ‘product modified’ sticker in the accessories bag included in the delivery you will find a silver product modified sticker. The purpose of the sticker is to ...

  • Page 16

    Mounting vacon • 14 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 3 3. M ounting the ac drive must be mounted in vertical position on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. The ac drive shall be fixed with four screws (or bolts, ...

  • Page 17

    3 vacon • 15 mounting tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 5. Vacon ac drive dimensions, mr5, wall mount figure 6. Vacon ac drive dimensions, mr6, wall mount *optional mounting holes (for nx replacement) 214 144 115 Ø7 Ø14 Ø7 100* 115 Ø7 100* ip21 Ø33 Ø33 Ø25 ip54 Ø25 195 148 Ø 15...

  • Page 18

    Mounting vacon • 16 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 3 figure 7. Vacon ac drive dimensions, mr7, wall mount figure 8.Vacon ac drive dimensions, mr8 ip21 and ip54 259 Ø20 237 190 Ø9 Ø16 Ø51 ip21 ip54 Ø25 Ø50 Ø25 3 x 38 Ø60 62,5 164 290 Ø22 343 Ø11 Ø9 216 672 694 956 235 21...

  • Page 19

    3 vacon • 17 mounting tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 9. Vacon ac drive dimensions, mr9 ip21 and ip54 3.1.2 flange mount the ac drive can also be recessed into the cabinet wall or similar surface. A special flange mount option is available for this purpose. For an example of ...

  • Page 20

    Mounting vacon • 18 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 3 3.1.2.1 flange mount - frames mr4 to mr6 figure 11. Presents the dimensions of the mounting opening and figure 12. The depth dimen- sions of the drives with the flange mount option. Figure 11. Flange mount cutout dime...

  • Page 21

    3 vacon • 19 mounting tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 12. Mr4 to mr6, flange mount, depth dimensions mr4 mr5 mr6.

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    Mounting vacon • 20 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 3 3.1.2.2 flange mount mr7 to mr9 figure 13. Presents the dimensions of the mounting opening and figure 14. The dimensions of the drives with the flange mount option. Figure 13. Flange mount cutout dimensions for mr7 to...

  • Page 23

    3 vacon • 21 mounting tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 3.2 cooling the ac drives produce heat in operation and are cooled down by air circulated by a fan. Enough free space shall therefore be left around the ac drive to ensure sufficient air circulation and cooling. Different acts of...

  • Page 24

    Mounting vacon • 22 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 3 note that if several units are mounted above each other the required free space equals c + d (see figure 16.). Moreover, the outlet air used for cool- ing by the lower unit must be directed away from the air intake of...

  • Page 25

    3 vacon • 23 mounting tel. +358 (0) 201 2121 • fax +358 (0)201 212 205.

  • Page 26

    Power cabling vacon • 24 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 4. P ower cabling the mains cables are connected to terminals l1, l2 and l3 and the motor cables to terminals marked with u, v and w. See principal connection diagram in figure 17. See also table 14 for the cable...

  • Page 27

    4 vacon • 25 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 3 = symmetrical power cable equipped with compact low-impedance shield and intended for the specific mains voltage. [mccmk, emcmk or similar recommended; recom- mended cable transfer impedance (1...30mhz) max. 100mohm/m]. Se...

  • Page 28

    Power cabling vacon • 26 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 4.1 ul standards on cabling to meet the ul (underwriters laboratories) regulations, use a ul-approved copper cable with a minimum heat-resistance of +60/75°c. Use class 1 wire only. The units are suitable for use...

  • Page 29

    4 vacon • 27 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 4.1.1.1 cable and fuse sizes, frames mr4 to mr6 the recommended fuse types are gg/gl (iec 60269-1) or class t (ul & csa). The fuse voltage rating should be selected according to the supply network. The final selection should...

  • Page 30

    Power cabling vacon • 28 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 4.1.1.2 cable and fuse sizes, frames mr7 to mr9 the recommended fuse types are gg/gl (iec 60269-1) or class t (ul & csa). The fuse voltage rating should be selected according to the supply network. The final sele...

  • Page 31

    4 vacon • 29 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 4.1.1.3 cable and fuse sizes, frames mr4 to mr6, north america the recommended fuse types are gg/gl (iec 60269-1) or class t (ul & csa). The fuse voltage rating should be selected according to the supply network. The final s...

  • Page 32

    Power cabling vacon • 30 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 4.1.1.4 cable and fuse sizes, frames mr7 to mr9, north america the recommended fuse types are gg/gl (iec 60269-1) or class t (ul & csa). The fuse voltage rating should be selected according to the supply network....

  • Page 33

    4 vacon • 31 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 4.3 cable installation • before starting, check that none of the components of the ac drive is live. Read care- fully the warnings in chapter 1. • place the motor cables sufficiently far from other cables • avoid placing the...

  • Page 34

    Power cabling vacon • 32 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 table 19. Cables stripping lengths [mm] figure 20. Frame a1 b1 c1 d1 c2 d2 e mr4 15 35 10 20 7 35 leave as short as pos- sible mr5 20 40 10 30 10 40 mr6 20 90 15 60 15 60 mr7 20 80 20 80 20 80 2 open the cover of...

  • Page 35

    4 vacon • 33 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 21. Figure 22. 3 remove the screws of the cable protection plate. Do not open the cover of the power unit! 4 insert the cable grommets (included in the delivery) in the openings of the cable entry plate (included) as ...

  • Page 36

    Power cabling vacon • 34 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 23. 5 • insert the cables - supply cable, motor cable and optional brake cable - in the openings of the cable entry plate. • then cut the rubber grommets open to slide the cables through. Should the gromme...

  • Page 37

    4 vacon • 35 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 24. Figure 25. 6 detach the cable clamps and the grounding clamps (figure 24) and place the cable entry plate with the cables in the groove on the ac drive frame (figure 25). M4x16 (2.2 nm).

  • Page 38

    Power cabling vacon • 36 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 26. Tightening torques of cable terminals: table 20. Tightening torques of terminals 7 connect the stripped cables (see figure 19 and table 19) as shown in figure 26. • expose the shield of all three cable...

  • Page 39

    4 vacon • 37 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 27. Additional protective earthing connector figure 28. Re-mounting of cover components 8 check the connection of the earth cable to the motor and the ac drive terminals marked with . Note: two protective conductors a...

  • Page 40

    Power cabling vacon • 38 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 4.3.2 frames mr8 and mr9 figure 29.Stripping of cables table 21. Cables stripping lengths [mm] 1 strip the motor and mains cables as advised below. Frame a1 b1 c1 d1 c2 d2 e mr8 40 180 25 300 25 300 leave as shor...

  • Page 41

    4 vacon • 39 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 30. Figure 31. Removing cable cover and cable fitting plate (mr8). 2 mr9 only: remove the main cover of the ac drive. 3 remove the cable cover (1) and the cable fitting plate (2). M4 x 10 m4x8 1 m4 x 8 2.

  • Page 42

    Power cabling vacon • 40 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 32. Removing cable cover and cable fitting plate (mr9). Figure 33. 4 mr9 only: loosen the screws and remove the sealing plate. M4 x 8 1 2 m5 x 10

  • Page 43: Mr9

    4 vacon • 41 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 34. Figure 35. 5 remove the emc shield plate. 6 locate the terminals. Observe the exceptional placement of motor cable termi- nals in mr8! Mr9 mr8 m5 m4x8.

  • Page 44

    Power cabling vacon • 42 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 36. Figure 37. 7 cut the rubber grommets open to slide the cables through. Should the grom- mets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up. Do not cut ...

  • Page 45: Mr8

    4 vacon • 43 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 38. Figure 39. 9 if you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables. 10 connect the cables stripped as shown in figure 29. • connect the (phase) c...

  • Page 46

    Power cabling vacon • 44 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 40. Placing two cable lugs on top of each other tightening torques of cable terminals: table 22. Tightening torques of terminals figure 41. Frame type tightening torque [nm]/[lb-in.] power and motor termin...

  • Page 47

    4 vacon • 45 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 42. 12 remount now first the emc shield plate (see figure 34) and then the sealing plate for mr9 (see figure 33). 13 re-attach then the cable fitting plate and then the cable cover. 14 mr9 only: now re-mount the main ...

  • Page 48

    Power cabling vacon • 46 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 4 figure 43. Figure 44. 15 check the connection of the earth cable to the motor and the ac drive terminals marked with . Note: two protective conductors are required according to standard en61800- 5-1. See chapter ...

  • Page 49

    4 vacon • 47 power cabling tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 4.4 installation in corner-grounded network corner grounding is allowed for the drive types rating from 72 a to 310 a at 380…480 v supply and from 75 a to 310 a at 208…240 v supply. In these circumstances the emc protection ...

  • Page 50

    Control unit vacon • 48 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 5. C 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. Figure 45. Location of control unit comp...

  • Page 51

    5 vacon • 49 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 5.1 control unit cabling the basic control unit connections are presented in figure 46 below. The control board is equipped with 22 fixed control i/o terminals and the relay board with 8 or 9. The relay board is available in ...

  • Page 52

    Control unit vacon • 50 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 5.1.2 control terminals and dip switches the terminals of the basic i/o board and the relay boards are described below. For more in- formation on the connections, see chapter 7.2.1. The terminals shown on shadowed...

  • Page 53

    5 vacon • 51 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 table 25. Control i/o terminal signals on relay board 1 and connection example table 26. Control i/o terminal signals on relay board 2 and connection example relay board 1 terminal signal 21 ro1/1 nc relay output 1 22 ro1/2 c...

  • Page 54

    Control unit vacon • 52 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 5.1.2.1 selection of terminal functions with dip switches the shadowed terminals in table 24 allow for three functional selections each with the so- called dip switches . The switches have three positions, left, m...

  • Page 55

    5 vacon • 53 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 5.2 i/o cabling and fieldbus connection the ac drive can be connected to fieldbus either through rs485 or ethernet. The connection for rs485 is on the basic i/o board (terminals a and b) and the connection for ethernet is und...

  • Page 56

    Control unit vacon • 54 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 figure 50. Figure 51. 2 protection class ip21: cut free the opening on the ac drive cover for the ether- net cable. Protection class ip54: cut the rubber grommets open to slide the cables through. Should the gromm...

  • Page 57

    5 vacon • 55 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 52. For more detailed information, see the user’s manual of the fieldbus you are using. 5.2.2 prepare for use through rs485 5.2.2.1 rs485 cable data table 28. Rs485 cable data 3 remount the ac drive cover. Note: when p...

  • Page 58

    Control unit vacon • 56 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 figure 53. 1 strip about 15 mm of the rs485 cable (see specification on page 55) and cut off the grey cable shield. Remember to do this for both bus cables. Leave no more than 10 mm of the cable outside the termin...

  • Page 59

    5 vacon • 57 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 3 using the cable clamp included in the delivery of the drive, ground the shield of the rs485 cable to the frame of the ac drive. 4 if the ac drive is the last device on the bus, the bus termination must be set. Locate the di...

  • Page 60

    Control unit vacon • 58 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 5 unless already done for the other control cables, cut free the opening on the ac drive cover for the rs485 cable (protection class ip21). 6 remount the ac drive cover and run the rs485 cables as shown in picture...

  • Page 61

    5 vacon • 59 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 5.3 battery installation for real time clock (rtc) enabling the functions of the real time clock (rtc) requires that an optional battery is in- stalled in the vacon 100 hvac drive. The place for the battery can be found in al...

  • Page 62

    Control unit vacon • 60 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 5 5.4 galvanic isolation barriers the control connections are isolated from the mains potential and the gnd terminals are per- manently connected to ground. See figure 55. The digital inputs are galvanically isolate...

  • Page 63

    5 vacon • 61 control unit tel. +358 (0) 201 2121 • fax +358 (0)201 212 205.

  • Page 64

    Commissioning vacon • 62 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 6 6. C ommissioning before commissioning, note the following directions and warnings: internal components and circuit boards of vacon 100 (except for the galvanically isolated i/o terminals) are live when it is con...

  • Page 65

    6 vacon • 63 commissioning tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 6.1 commissioning of the drive read carefully the safety instructions in chapter 1 and above and follow them. After the installation:  check that both the ac drive and the motor are grounded.  check that the mains and moto...

  • Page 66

    Commissioning vacon • 64 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 6 6.2.1 cable and motor insulation checks 1. Motor cable insulation checks disconnect the motor cable from terminals u, v and w of the ac drive and from the motor. Measure the insulation resistance of the motor cab...

  • Page 67

    6 vacon • 65 commissioning tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 6.3 installation in it system if your supply network is an it (impedance-grounded) system but your ac drive is emc-pro- tected according to class c2 you need to modify the emc protection of the ac drive to emc- level c4. Thi...

  • Page 68

    Commissioning vacon • 66 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 6 6.3.2 frames mr7 and mr8 follow the procedure described below to modify the emc protection of the ac drive of frames mr7 and mr8 to emc-level c4. Figure 58. Figure 59. 1 remove the main cover of the ac drive and ...

  • Page 69

    6 vacon • 67 commissioning tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 figure 60. Mr7: detaching the dc grounding busbar from frame 6.3.3 frame mr9 follow the procedure described below to modify the emc protection of the ac drive of frame mr9 to emc-level c4. Figure 61. 3 additionally for mr7, ...

  • Page 70

    Commissioning vacon • 68 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 6 figure 62. 2 further remove the extension box cover, the touch shield and the i/o plate with i/ o grommet plate. Locate the emc jumper on the emc board (see magnification below) and remove it. Caution! Before con...

  • Page 71

    6 vacon • 69 commissioning tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 6.4 maintenance in normal conditions, the ac drive is maintenance-free. However, regular maintenance is rec- ommended to ensure a trouble-free operation and a long lifetime of the drive. We recommend to follow the table belo...

  • Page 72

    Commissioning vacon • 70 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 6.

  • Page 73: Mr4

    7 vacon • 71 technical data tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 7. T echnical data 7.1 ac drive power ratings 7.1.1 mains voltage 208-240 v table 29. Power ratings of vacon 100, supply voltage 208-240v. Note: the rated currents in given ambient temperatures (in table 31) are achieved on...

  • Page 74: Mr4

    Technical data vacon • 72 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 7 7.1.2 mains voltage 380-480 v table 30. Power ratings of vacon 100, supply voltage 380-480v. Note: the rated currents in given ambient temperatures (in table 31) are achieved only when the switching frequency is...

  • Page 75

    7 vacon • 73 technical data tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 7.1.3 definitions of overloadability low overload = following continuous operation at rated output current i l , the converter is fed with 110% * i l for 1 min, followed by a period of i l . Example: if the duty cycle requi...

  • Page 76

    Technical data vacon • 74 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 7 7.2 vacon 100 - technical data mains connection input voltage u in 208...240v; 380…480v; -10%…+10% input frequency 50...60 hz -5...+10% connection to mains once per minute or less starting delay 4 s (mr4 to mr6)...

  • Page 77

    7 vacon • 75 technical data tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 table 31. Vacon 100 technical data ambient conditions (cont.) vibration en61800-5-1/ en60068-2-6 5…150 hz displacement amplitude 1 mm (peak) at 5…15.8 hz (mr4…mr9) max acceleration amplitude 1 g at 15.8…150 hz (mr4…mr9) sho...

  • Page 78

    Technical data vacon • 76 24-hour support +358 (0)201 212 575 • email: vacon@vacon.Com 7 7.2.1 technical information on control connections table 32. Technical information on standard i/o board standard i/o board terminal signal technical information 1 reference output +10v, +3%; maximum current 10 ...

  • Page 79

    7 vacon • 77 technical data tel. +358 (0) 201 2121 • fax +358 (0)201 212 205 table 33. Technical information on relay board 1 table 34. Technical information on relay board 2 relay board 1 relay board with two change-over contact (spdt) relays and one relay with normally-open (no or spst) contact. 5...

  • Page 80

    Document id: order code: rev. D manual authoring: documentation@vacon.Com vacon plc. Runsorintie 7 65380 vaasa finland subject to change without prior notice © 2011 vacon plc. Find your nearest vacon office on the internet at: www.Vacon.Com.