1. DL manuals
  2. Vacon
  3. Controller
  4. 20 x
  5. Installation, Technical And Maintenance Manual

Vacon 20 x Installation, Technical And Maintenance Manual

Summary of 20 x

  • Page 1

    Vacon 20 x ac drives installation, technical and maintenance manual ® phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 2

    Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 3

    Vacon • 0 i ndex document code(original instructions): dpd00992b order code: doc-ins06663+dluk rev. B revision release date: 1.8.12 1. Safety ............................................................................................................... 2 1.1 danger ....................................

  • Page 4

    Vacon • 1 6.4 maintenance ..................................................................................................................... 50 7. Technical data ................................................................................................ 52 7.1 ac drive power ratings............

  • Page 5

    Safety vacon • 2 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 included in cautions and warnings carefully. Vacon ® 20 x is...

  • Page 6

    1 vacon • 3 safety 1.2 warnings vacon ® 20 x ac drive is meant for fixed installations only. Only dvc a circuits (decisive voltage class a, according to iec 61800-5-1) are allowed to be connected to the control unit. This hint aims to protect both the drive and the client-application. Vacon is not r...

  • Page 7

    Safety vacon • 4 1 1.3 earthing and earth fault protection the vacon ® 20 x ac drive must always be earthed with an earthing conductor connected to the earthing terminal marked with . Since the touch current exceeds 3.5 ma ac, according to en61800-5-1, the drive shall have a fixed connection and pro...

  • Page 8

    1 vacon • 5 safety in vacon ® 20 x, the phase conductor and the corresponding protective earthing conductor can be of the same cross-sectional area, provided they are made of the same metal (because the cross-sectional area of the phase conductor is less than 16 mm 2 ). The cross-sectional area of e...

  • Page 9

    Safety vacon • 6 1 1.4 insulation system a distinction has to be made for the following three groups of terminals, according to the insu- lation system of vacon ® 20 x: • mains and motor connections (l1, l2, l3, u, v, w) • relays (r01, r02) (**) • control terminals (i/os, rs485, sto) the control ter...

  • Page 10

    1 vacon • 7 safety by performing the cabling, a suitable clearance has to be guaranteed between dvc a circuits and mains (reinforced insulation is required, according to iec 61800-5-1). Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 11

    Safety vacon • 8 1 1.5 compatibility with rcds this product can cause a d.C. Current in the protective earthing conductor. Where a residual current-operated protective (rcd) or monitoring (rcm) device is used for protection in case of direct or indirect contact, only an rcd or rcm of type b is allow...

  • Page 12

    1 vacon • 9 safety 1.6 extended temperature range vacon ® 20 x has an integrated cooling system, independent from the motor fan. Under max- imum operating conditions, the ambient temperature cannot exceed 40 °c. See table 19 for the output rated current. Higher temperatures are allowed only with der...

  • Page 13

    Safety vacon • 10 1 1.7 declaration of conformity figure 4. Declaration of conformity. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 14

    1 vacon • 11 safety figure 5. Sto certificate. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 15

    Receipt of delivery vacon • 12 2 2. R eceipt of delivery check 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 im- mediately. See paragraph 2.3. Figure 6. Vacon package ...

  • Page 16

    Vacon • 13 receipt of delivery 2 2.1 type designation code vacon ® type designation code is formed of a nine-segment code and optional +codes. Each segment of the type designation code uniquely corresponds to the product and options you have ordered. The format of the code is as follows: vacon0020-3...

  • Page 17

    Receipt of delivery vacon • 14 2 2.2 unpacking and lifting the ac drive the weights of the ac drives vary according to frame size. Note the weights of each individual frame size in table 2 below. Table 2. Frame weights vacon ® 20 x drives have undergone scrupulous tests and quality checks at the fac...

  • Page 18

    Vacon • 15 receipt of delivery 2 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 19

    Mounting vacon • 16 3 3. M ounting the ac drive has to be mounted on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. Both frame sizes can be mounted in any position. The drive shall be fixed with four screws (or bolts, depending on the unit size). 3.1 d...

  • Page 20

    3 vacon • 17 mounting figure 10. Vacon ® 20 x, mu3. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 21

    Mounting vacon • 18 3 3.2 wall-mounting the drive can be mounted in vertical or horizontal position on the wall or any other relatively even mounting plane or machine frame and fixed with the screws recommended in table 3. Recommended screw or bolt size for mu2 and mu3 is m5. Frame screw number scre...

  • Page 22

    3 vacon • 19 mounting 3.3 cooling the ac drive produces heat in operation and is 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 maintenance may also require certain amount of fr...

  • Page 23

    Mounting vacon • 20 3 figure 12. Installation space when drives are mounted on top of each other. B+c air def lec tor phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 24

    3 vacon • 21 mounting phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 25

    Power cabling vacon • 22 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 13. See also table for the cable recommendations for different emc levels. Figure 13. Principal ...

  • Page 26

    4 vacon • 23 power cabling figure 14. Note: the emc requirements are fulfilled at factory defaults of switching frequencies (all frames). Note: if safety switch is connected the emc protection shall be continuous over the whole ca- ble installation. 4.1 circuit breaker please, disconnect the drive v...

  • Page 27

    Power cabling vacon • 24 4 4.2.1.1 cable and fuse sizes, frames mu3 to mu3 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 be made according to local regulations, cable in...

  • Page 28

    4 vacon • 25 power cabling 4.3 brake resistor cables vacon ® 20 x ac drives are equipped with terminals for an optional external brake resistor. For mu2, break resitor wires with faston 6.3 mm have to be used. For mu3, a pcb terminal block with push-in spring-cage connector is provided. Stranded wir...

  • Page 29

    Power cabling vacon • 26 4 4.5 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 cabl...

  • Page 30

    4 vacon • 27 power cabling figure 16. Mu2 example: open cover. Figure 17. Cable gland. 2 • remove the plastic cover of the drive as shown in figure 16. The cable entries consists of several openings available for the cables with iso met- ric thread. • open only the inlet holes where you need to run ...

  • Page 31

    Power cabling vacon • 28 4 tightening torques of cable terminals: table 10. Tightening torques of terminals. 5 • screw the cable glands on the cable entry holes. 6 • pass the cables (supply cable, motor cable, brake cable and i/o cables) through the cable glands. 7 • detach the cable clamps and the ...

  • Page 32

    4 vacon • 29 power cabling phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 33

    Control unit vacon • 30 5 5. C ontrol unit 5.1 opening the drives figure 18. Open front cover of the drive: control unit mu2. Figure 19. Open front cover of the drive: control unit mu3. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 34

    5 vacon • 31 control unit 5.2 control units mu2 and mu3 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, termi- nals and switches are presented in figure 20 and figure ...

  • Page 35

    Control unit vacon • 32 5 figure 21. Location of the components in the control unit of mu3. When delivered from the factory, the control unit of the ac drive contains the standard control- ling interface - the control terminals of the control board and the relay board - unless other- wise specifical...

  • Page 36

    5 vacon • 33 control unit 5.3 control unit cabling the principal terminal block placement is shown in figure 22 below. The control board is equipped with 18 fixed control i/o terminals and the relay board with 5. Additionally, the termi- nals for the safe torque off (sto) function (see chapter 9) ca...

  • Page 37

    Control unit vacon • 34 5 5.3.2 standard i/o terminals the terminals of the standard i/o and the relays 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 switche...

  • Page 38

    5 vacon • 35 control unit 5.3.3 relay terminals 5.3.4 safe torque off (sto) terminals for more information on the functionalities of the safe torque off (sto), see chapter chapter 9.. Table 14. I/o terminal signals for relays and connection example. Relays terminals terminal signal 22 ro1/2 relay ou...

  • Page 39

    Control unit vacon • 36 5 5.3.5 description of additional echo connectors in this paragraph you will find the description of the additional echo connector for the i/o ter- minals. Figure 23. The i/o remote echo connector mounted on the control board. In figure 23 the view of molex ® connector for th...

  • Page 40

    5 vacon • 37 control unit 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 x terminals is shown. Pin number signal description 1 rs485_b serial bus, negative 2 di...

  • Page 41

    Control unit vacon • 38 5 5.3.6 led handling as vacon ® 20 x is often without the panel, on the plastic cover of the drive there are 4 status leds. See the picture below. Figure 25. Led position on the mu2 cover. Led “pwr” (orange led) means the drive is supplied by mains. Led “run” (green led) mean...

  • Page 42

    5 vacon • 39 control unit 5.3.7 selection of terminal functions with dip switches the vacon ® 20 x drive embodies four so-called switches that allow for two functional selec- tions each. The shadowed terminals in table 13 can be functionally modified with the dip switches. The switches have two posi...

  • Page 43

    Control unit vacon • 40 5 5.4 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 ar...

  • Page 44

    5 vacon • 41 control unit 5.4.1 modbus rtu protocol vacon ® 20 x drive is equipped with modbus support as standard. The ac drive can be connect- ed to fieldbus through rs485. The connection for rs485 is on the standard i/o (terminals a and b). See figure 28. Figure 28. Position of the rs485 terminal...

  • Page 45

    Control unit vacon • 42 5 5.4.2 preparation for use through rs485 1 strip about 15 mm of the rs485 cable (see specification on table 17) and cut off the grey cable shield. Remember to do this for both bus cables (except for the last device). Leave no more than 10 mm of the cable outside the terminal...

  • Page 46

    5 vacon • 43 control unit phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 47

    Commissioning vacon • 44 6 6. C ommissioning before commissioning, note the following directions and warnings: internal components and circuit boards of vacon ® 20 x drive (except for the gal- vanically isolated i/o terminals) are live when it is connected to mains potential. Coming into contact wit...

  • Page 48

    6 vacon • 45 commissioning 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 frequency converter and the motor are grounded. Check that the mains and motor cables comply with the requirements give...

  • Page 49

    Commissioning vacon • 46 6 6.2 changing emc protection class the emc protection class of vacon 20 x can be changed from class c2 to class c4. This is done as described below: 6.2.1 changing emc protection class - mu2 figure 29.Changing of the emc class in mu2 control unit. Warning! Do not perform an...

  • Page 50

    6 vacon • 47 commissioning figure 30. Changing of the emc class in mu2 control unit. 2 remove the emc plate from the control unit. Then turn up the thin plate with pli- ers to disconnect the emc plate from the ground. See figure 30. Then reconnect the emc plate to the unit. Phone: 800.894.0412 - fax...

  • Page 51

    Commissioning vacon • 48 6 6.2.2 changing emc protection class - mu3 figure 31. Changing the emc class in the mu3 control unit. 1 remove the emc screw as shown in the figure 31. Caution! Before connecting the ac drive to mains make sure that the emc pro- tection class settings of the drive are appro...

  • Page 52

    6 vacon • 49 commissioning 6.3 running the motor motor run check list 6.3.1 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 cable between each ph...

  • Page 53

    Commissioning vacon • 50 6 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 below for maintenance intervals. Maintenance interval...

  • Page 54

    6 vacon • 51 commissioning phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 55: Mu2

    Technical data vacon • 52 7 7. T echnical data 7.1 ac drive power ratings 7.1.1 mains voltage 3ac 208-240 v note: the rated currents in given ambient temperatures (in table 19) are achieved only when the switching frequency is equal to or less than the factory default. Mains voltage 3ac 208-240v, 50...

  • Page 56: Mu2

    7 vacon • 53 technical data 7.1.2 mains voltage 3ac 380-480v note: the rated currents in given ambient temperatures (in table 20) are achieved only when the switching frequency is equal to or less than the factory default. 7.1.3 definitions of overloadability overloadability =following continuous op...

  • Page 57

    Technical data vacon • 54 7 7.2 brake resistors mains voltage 3ac 208-240 v, 50/60 hz frame type minimum resistance recommended [ohm] mu2 0004 50 0005 50 0007 50 mu3 0011 25 0012 25 0017 25 table 21. Brake resistor ratings, 208-240v. Mains voltage 3ac 380-480 v, 50/60 hz frame type minimum resistanc...

  • Page 58

    7 vacon • 55 technical data 7.3 vacon ® 20 x - technical data mains connection input voltage u in 3ac 208…240v 3ac 380...480v input voltage tolerance -15%…+10% continuously input frequency 50/60 hz input frequency tolerance 45…66 hz protection class i connection to mains once per minute or less star...

  • Page 59

    Technical data vacon • 56 7 communication interface fieldbus standard: serial communication (rs485/ modbus); optional: canopen; profibus dp, devicenet status indicators drive status indicators (led) on top side (power, run, fault, ready) ambient conditions ambient operating tem- perature -10°c…+40°c...

  • Page 60

    7 vacon • 57 technical data table 23. Vacon 20 x technical data. Protections undervoltage trip limit depends on supply voltage (0,8775*supply voltage): supply voltage 400 v: trip limit 351 v supply voltage 480 v: trip limit 421 v supply voltage 240 v: trip limit 211 v earth fault protection yes main...

  • Page 61

    Technical data vacon • 58 7 7.3.1 technical information on control connections table 24. Technical information on standard i/o terminals. Standard i/o terminal signal technical information a rs485 differential receiver/transmitter set bus termination with dip switches (see chapter 5) b rs485 1 refer...

  • Page 62

    7 vacon • 59 technical data table 25. Technical information on relays. Relays terminal signal technical information 22 relay output 1 * * 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 cu...

  • Page 63

    Options vacon • 60 8 8. O ptions 8.1 vacon keypad with seven-segment display the text keypad is an option available for vacon ® 20 x. The control keypad is the interface between the vacon ® 20 x frequency converter and the user. Figure 33. Text keypad. With the keypad it’s possible to control the sp...

  • Page 64

    8 vacon • 61 options 8.2 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. Figure 35. Keypad disp...

  • Page 65

    Options vacon • 62 8 8.4 using the keypad 8.4.1 editing values change value of a parameter following the procedure below: 1. Locate the parameter. 2. Enter the edit mode by pressing ok. 3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the arrow buttons left...

  • Page 66

    8 vacon • 63 options 8.4.4 parameters through this submenu, you can reach the application parameter groups and parameters. More in- formation on parameters in the vacon ® 20 x application manual. 8.4.5 faults under this menu, you can find active faults , reset faults , fault history , counters and s...

  • Page 67

    Options vacon • 64 8 8.5 fault tracing fault code fault name possible cause remedy 1 overcurrent ac drive has detected too high a current (>4*i h ) in the motor cable: • sudden heavy load increase • short circuit in motor cables • unsuitable motor check loading. Check motor. Check cables and connect...

  • Page 68

    8 vacon • 65 options 25 watchdog error in the microprocessor monitoring malfunction component fault reset the fault and restart. If the fault occurs again, please contact your closest vacon repre- sentative. 27 back emf protection of unit when starting with rotat- ing motor reset the fault and resta...

  • Page 69

    Options vacon • 66 8 8.6 option boards vacon ® 20 x drive family embodies a wide selection of expander boards with which the available i/o of vacon ® 20 x frequency converter can be increased and its versatility improved. There is one board slot (labelled d) on the vacon ® 20 x control board. To loc...

  • Page 70

    8 vacon • 67 options phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 71

    Safe torque off vacon • 68 9 9. S afe t orque o ff this chapter describes the safe torque off (sto) function which is a functional safety feature pres- ent into vacon ® 20 x drive products as standard. 9.1 general description the sto function brings the motor in no-torque-state as defined by 4.2.2.2...

  • Page 72

    9 vacon • 69 safe torque off 9.3 standards the sto function has been designed for being used in accordance with the following standards: the sto function has to be abblied correctly to achieve the desired level of operational safety. Four different levels are allowed, depending on the use of the sto...

  • Page 73

    Safe torque off vacon • 70 9 9.4 the principle of sto the sto functionality, such as the technical principles and data (wiring examples and commission- ing) will be described in this chapter. In vacon ® 20 x, the sto function is realized by preventing the propagation of the control signals to the in...

  • Page 74

    9 vacon • 71 safe torque off 9.4.1 technical details the sto inputs are digital inputs intended for a nominal 24v d.C. Input, positive logic (e.G. Enabled when high). The reaction time of the sto function is the amount of time which passes from the moment in which the sto is demanded till the system...

  • Page 75

    Safe torque off vacon • 72 9 9.5 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. For the correct configuration, see the following...

  • Page 76

    9 vacon • 73 safe torque off 9.5.1 safety capability cat.4 / pl e / sil 3 for this safety capability, an external safety device must be installed. This must be used to dinami- cally activate the sto inputs and to monitor the sto output feedback. The sto inputs are dynamically used when they do not c...

  • Page 77

    Safe torque off vacon • 74 9 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. Figure 39. Sto example with automatic monitoring of the feedback and both sto inputs used. (*) only for mu3. The external device has ...

  • Page 78

    9 vacon • 75 safe torque off 9.5.2 safety capability cat. 3 / pl e / sil 3 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). Both sto inputs and the sto feedback have to be used. The same warnings and cab...

  • Page 79

    Safe torque off vacon • 76 9 9.5.4 safety capability cat.1 / pl c / sil 1 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 80

    9 vacon • 77 safe torque off 9.6 commissioning 9.6.1 general wiring instructions the wiring should be done according to the general wiring instructions for the specific product. A shielded cable is required. In addition, the voltage drop from the supply point to the load shall not exceed 5% [en 6020...

  • Page 81

    Safe torque off vacon • 78 9 9.7 parameters and fault tracing there are no parameters for the sto function itself. To re-enable the motor operation, after the sto state, it is necessary to perform the following steps: • release the switch or the external device (“f30” is displayed even after this ha...

  • Page 82

    9 vacon • 79 safe torque off 9.8 maintenance and diagnostics the sto function or the sto input/output terminals do not need any maintenance. The following table shows faults that may be generated by the software that monitors the hardware related to the sto safety function. If you detect any failure...

  • Page 83

    Document id: order code: rev. B subject to change without prior notice © 2012 vacon plc. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.