Danfoss vacon 10 Operating guide

VACON®10

AC DRIVES

COMPLETE USER MANUAL

		INDEX
	Document: DPD00717F1
	Version release date: Apr. 2014
	Software package: FW0135V010
1. Safety		1
1.1	Warnings	1
1.2	Safety instructions	3
1.3	Earthing and earth fault protection	3
1.4	Before running the motor	4
2. Receipt of delivery		5
2.1	Type designation code	5
2.2	Storage	6
2.3	Maintenance	6
2.4	Warranty	6
2.5	Manufacturer’s declaration of conformity	7
3. Installation		9
3.1	Mechanical installation	9
3.1.1 Vacon 10 dimensions		10
3.1.2 Cooling		12
3.1.3 Power losses		13
3.1.4 EMC levels		18
3.1.5 Changing the EMC protection class from C2 to C4		19
3.2	Cabling and connections	20
3.2.1 Power cabling		20
3.2.2 Control cabling		21
3.2.3 Screw of cables		23
3.2.4 Cable and fuse specifications		25
3.2.5 General cabling rules		28
3.2.6 Stripping lengths of motor and mains cables		29
3.2.7 Cable installation and the UL standards		29
3.2.8 Cable and motor insulation checks		29
4. Commissioning		31
4.1 Commissioning steps of Vacon 10		31
5. Fault tracing		33
6. Vacon 10 Application Interface		37
6.1	Introduction	37
6.2	Control I/O	39
7. Control panel		41
7.1	General	41
7.2	Display	41
7.3 Keypad		42
7.4	Navigation on the Vacon 10 control panel	44
7.4.1 Main menu		44
7.4.2 Reference menu		45
7.4.3 Monitoring menu		46
7.4.4 Parameter menu		48
7.4.5 System menu		50

8. STANDARD application parameters			53
8.1	Quick setup parameters
	Virtual menu, shows when par. 17.2 = 1)		54
8.2	Motor settings (Control panel: Menu PAR -> P1)		56
8.3	Start / stop setup (Control panel: Menu PAR -> P2)		58
8.4	Frequency references (Control panel: Menu PAR -> P3)		58
8.5 Ramps and brakes setup (Control panel: Menu PAR -> P4)			59
8.6	Digital inputs (Control panel: Menu PAR -> P5)		60
8.7	Analogue inputs (Control panel: Menu PAR -> P6)		60
8.8	Digital outputs (Control panel: Menu PAR -> P8)		61
8.9	Analogue outputs (Control panel: Menu PAR -> P9)		61
8.10		Protections (Control panel: Menu PAR -> P13)	62
8.11		Fault autoreset parameters (Control panel: Menu PAR -> P14)	62
8.12		PI control parameters (Control panel: Menu PAR -> P15)	63
8.13		Application Setting (Control panel: Menu PAR -> P17)	63
8.14 System parameters			64
9. Parameter descriptions			67
9.1	Motor settings (Control panel: Menu PAR -> P1)		67
9.2	Start / stop setup (Control panel: Menu PAR -> P2)		72
9.3	Frequency references (Control panel: Menu PAR -> P3)		79
9.4 Ramps & brakes setup (Control panel: Menu PAR -> P4)			80
9.5	Digital inputs (Control panel: Menu PAR -> P5)		84
9.6	Analogue inputs (Control panel: Menu PAR -> P6)		85
9.7	Digital outputs (Control panel: Menu PAR -> P8)		86
9.8	Analogue outputs (Control panel: Menu PAR -> P9)		87
9.9	Protections (Control panel:Menu Par->P13)		88
9.10		Automatic reset (Control panel: Menu PAR -> P14)	92
9.11		PI control parameters (Control panel: Menu PAR -> P15)	93
9.12		Application setting (Control panel: Menu PAR->P17)	94
9.13 Modbus RTU			96
9.13.1 Termination resistor			96
9.13.2 Modbus address area			96
9.13.3 Modbus process data			97
10. Technical data			99
10.1		Vacon 10 technical data	99
10.2		Power ratings	101
10.2.1 Vacon 10 – Mains voltage 208-240 V			101
10.2.2 Vacon 10 – Mains voltage 115 V			102
10.2.3 Vacon 10 – Mains voltage 380-480 V			102
10.2.4 Vacon 10 – Mains voltage 600 V			103
10.3		Brake resistors	103

safety

vacon • 1

1. SAFETY

ONLY A COMPETENT ELECTRICIAN IS ALLOWED TO CARRY OUT THE ELECTRICAL INSTALLATION!

This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances.

Please read the information included in cautions and warnings carefully:

=Dangerous voltage

Risk of death or severe injury

=General warning

Risk of damage to the product or connected appliances

1.1 Warnings

The components of the power unit of the frequency converter are live when Vacon 10 is connected to mains. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury. The control unit is isolated from the mains potential.

The motor terminals U, V, W (T1, T2, T3) and the possible brake resistor terminals - / + are live when Vacon 10 is connected to mains, even if the motor is not running.

The control I / O-terminals are isolated from the mains potential. However, the relay output terminals may have a dangerous control voltage present even when Vacon 10 is disconnected from mains.

The earth leakage current of Vacon 10 frequency converters exceeds 3.5 mA AC. According to standard EN61800-5-1, a reinforced protective ground connection must be ensured.

If the frequency converter is used as a part of a machine, the machine manufacturer is responsible for providing the machine with a main switch (EN 60204-1).

If Vacon 10 is disconnected from mains while running the motor, it remains live if the motor is energized by the process. In this case the motor functions as a generator feeding energy to the frequency converter.

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safety

After disconnecting the frequency converter from the mains, wait until the fan stops and the indicators on the display go out. Wait 5 more minutes before doing any work on Vacon 10 connections.

The motor can start automatically after a fault situation, if the autoreset function has been activated.

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safety

vacon • 3

1.2 Safety instructions

The Vacon 10 frequency converter has been designed for fixed installations only.

Do not perform any measurements when the frequency converter is connected to the mains.

Do not perform any voltage withstand tests on any part of

Vacon 10. The product safety is fully tested at factory.

Prior to measurements on 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 fingers may damage the components. Opening the cover may also damage the device. If the cover of Vacon 10 is opened, warranty becomes void.

1.3 Earthing and earth fault protection

The Vacon 10 frequency converter must always be earthed with an earthing conductor connected to the earthing terminal. See figure below:

MI1 - MI3

•The earth fault protection inside the frequency converter protects only the converter itself against earth faults.

•If fault current protective switches are used they must be tested with the drive with earth fault currents that are possible to arise in fault situations.

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safety

1.4 Before running the motor

Checklist:

Before starting the motor, check that the motor is mounted properly and ensure that the machine connected to the motor allows the motor to be started.

Set the maximum motor speed (frequency) according to the motor and the machine connected to it.

Before reversing the motor shaft rotation direction make sure that this can be done safely.

Make sure that no power correction capacitors are connected to the motor cable.

NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from www.vacon.com/downloads.

REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l’ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site www.vacon.com/downloads.

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receipt of delivery

vacon • 5

2. RECEIPT OF DELIVERY

After unpacking the product, check that no signs of transport damages are to be found on the product and that the delivery is complete (compare the type designation of the product to the code below).

Should the drive have been damaged during the shipping, please contact primarily the cargo insurance company or the carrier.

If the delivery does not correspond to your order, contact the supplier immediately.

2.1 Type designation code

VACON00101L- 0001-

1

+OPTIONS

Vacon 10

Input phase

1L = Single phase

3L = Three phases

Output Current

Input Voltage

1=115V

2= 208 - 230V

4= 380 - 480V

7 = 600V

+Options

EMC2

QPES

	Language of the documentation
		+DLNL = Dutch
	+DLCN = Chinese
	+DLCZ = Czech	+DLNO = Norwegian
	+DLDE = German	+DLPT = Portuguese
	+DLDK = Danish	+DLRU = Russian
	+DLES = Spanish	+DLSE = Swedish
	+DLFI = Finnish	+DLTR = Turkish
	+DLFR = French	+DLUS = US English
	+DLIT = Italian	empty = English

Figure 2.1: Vacon 10 type designation code

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receipt of delivery

2.2 Storage

If the frequency converter is to be kept in store before use make sure that the ambient conditions are acceptable:

Storing temperature -40…+70°C

Relative humidity < 95%, no condensation

2.3 Maintenance

In normal operating conditions, Vacon 10 frequency converters are maintenancefree.

2.4 Warranty

Only manufacturing defects are covered by the warranty. The manufacturer assumes no responsibility for damages caused during or resulting from transport, receipt of the delivery, installation, commissioning or use.

The manufacturer shall in no event and under no circumstances be held responsible for damages and failures resulting from misuse, wrong installation, unacceptable ambient temperature, dust, corrosive substances or operation outside the rated specifications. Neither can the manufacturer be held responsible for consequential damages.

The Manufacturer's time of warranty is 18 months from the delivery or 12 months from the commissioning whichever expires first (Vacon Warranty Terms).

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

In all matters concerning the warranty, please contact first your distributor.

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receipt of delivery	vacon • 7
2.5 Manufacturer’s declaration of conformity

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 10 Freq uency Converter
Model designation:	Vacon 10 1L 0001 2…to	0009 2
	Vacon 10 3L 0001 2…to	0011 2
	Vacon 10 3L 0001 4…to	0012 4

has been designed and manufactured in accordance with the following standards:

Safety:	EN 60204 -1:2009 (as re levant),
	EN 61800-5-1:2007
EMC:	EN 61800-3:2004+A1:2012

and conforms to t he relevant safety provisions of the Low Voltage Directive 2006/95/EC and EMC Directive 2004/108/EC.

It is ensured through internal measures and quality control t hat the product conforms at all times to the req uirements of the current Directive and the relevant standards.

In Vaasa, 16th of April, 2014

Vesa Laisi

President

The year the CE marking was affixed:

2011

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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.

MI1

=M4

OK

MI2

=M5

OK

MI3

=M5

OK

Figure 3.1: Screw mounting, MI1 - MI3

1 2

Figure 3.2: DIN-rail mounting, MI1 - MI3

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installation		vacon •9

3.1.1 Vacon 10 dimensions

Figure 3.3: Vacon 10 dimensions, MI1 - MI3

Frame	H1	H2	H3	W1	W2	W3	D1	D2
MI1	160.1	147	137.3	65.5	37.8	4.5	98.5	7
MI2	195	183	170	90	62.5	5.5	101.5	7
MI3	254.3	244	229.3	100	75	5.5	108.5	7

Table 3.1: Vacon 10 dimensions in millimetres

Frame	Dimensions(mm)			Weight*
	W	H	D	(kg.)
MI1	66	160	98	0.5
MI2	90	195	102	0.7
MI3	100	254.3	109	1

*without shipping package

Table 3.2: Vacon 10 frame dimensions (mm) and weights (kg)

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	Frame	Dimensions(Inches)			Weight*
		W	H	D	(Ibs.)
	MI1	2.6	6.2	3.9	1.2
	MI2	3.5	9.9	4	1.5
	MI3	3.9	10.3	4.3	2.2
					*without shipping package

Table 3.3: Vacon 10 frame dimensions (Inch) and weights (Ibs)

Figure 3.4: Vacon10 dimensions, MI2 - 3 Display Location

Dimensions(mm)		Frame
	MI2		MI3
A	17		22.3
B	44		102

Table 3.4: Vacon 10 frame dimensions (mm)

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installation		vacon •11

3.1.2 Cooling

Enough free space shall be left above and below the frequency converter to ensure sufficient air circulation and cooling. You will find the required dimensions for free space in the table below.

If several units are mounted above each other the required free space equals C + D (see Installation space). Moreover, the outlet air used for cooling by the lower unit must be directed away from the air intake of the upper unit.

The amount of cooling air required is indicated below. Also make sure that the temperature of the cooling air does not exceed the maximum ambient temperature of the converter.

Min clearance (mm)

Frame	A*	B*	C	D
MI1	20	20	100	50
MI2	20	20	100	50
MI3	20	20	100	50

Table 3.5: Min. clearances around AC drive

*. Min clearance A and B for drives for MI1 ~ MI3 can be 0 mm if the ambient temperature is below 40 degrees.

	C
A	B
	B
	A
	D

Figure 3.5: Installation space

A = clearance around the freq. converter (see also B)

B = distance from one frequency converter to another or distance to cabinet wall C = free space above the frequency converter

D = free space underneath the frequency converter

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 ambient temperature is below 40 °C.

Frame	Cooling air required (m³/h)
MI1	10
MI2	10
MI3	30

Table 3.6: Required cooling air

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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 select the switching frequency according to the graphs below.

MI1 - MI3 3P 400 V POWER LOSS

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installation		vacon •13

MI1 - MI3 3P 230 V POWER LOSS

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installation		vacon •15
		MI1 - MI3 1P 230 V POWER LOSS

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installation		vacon •17

3.1.4 EMC levels

EN61800-3 defines the division of frequency converters into four classes according to the level of electromagnetic disturbances emitted, the requirements of a power system network and the installation environment (see below). The EMC class of each product is defined in the type designation code.

Category C1: Frequency converters of this class comply with the requirements of category C1 of the product standard EN 61800-3 (2004). Category C1 ensures the best EMC characteristics and it includes converters the rated voltage of which is less than 1000 V and which are intended for use in the 1st environment.

NOTE: The requirements of class C are fulfilled only as far as the conducted emissions are concerned.

Category C2: Frequency converters of this class comply with the requirements of category C2 of the product standard EN 61800-3 (2004). Category C2 includes converters in fixed installations and the rated voltage of which is less than 1000 V. The class C2 frequency converters can be used both in the 1st and the 2nd environment.

Category C4: The drives of this class do not provide EMC emission protection. These kinds of drives are mounted in enclosures.

Environments in product standard EN 61800-3 (2004)

First environment: Environment that includes domestic premises. It also includes establishments directly connected without intermediate transformers to a low-volt- age power supply network which supplies buildings used for domestic purposes.

NOTE: houses, apartments, commercial premises or offices in a residential building are examples of first environment locations.

Second environment: Environment that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for domestic purposes.

NOTE: industrial areas, technical areas of any building fed from a dedicated transformer are examples of second environment locations.

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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 removingthe EMC-capacitordiscon- necting screw, see figure below.

Note! Do not attempt to change the EMC level back to class C2. Even if the procedure above is reversed, the frequency converter will no longer fulfil the EMC requirements of class C2!

Figure 3.6: EMC protection class, MI1 - MI3

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installation		vacon •19

3.2 Cabling and connections

3.2.1 Power cabling

Note! Tightening torque for power cables is 0.5 - 0.6 Nm

3~ (230V, 400V)

1~ (230V)			Motor out

		Strip the
		plastic cable
		coating for
	MAINS	360° earthing	MOTOR
	Figure 3.7:
	3~(230V, 400V,600V) External brake resistor
		3~(230V, 400V,600V)
	1~ (230V) 1~ (115V)		Motor out
	L1 L2/N	L3 R+ R- U/T1 V/T2 W/T3
	Strip the
	plastic
	cable
	coating
	for 360°
	earthing
	MAINS	BRAKE	MOTOR
		RESISTOR

Figure 3.8: Vacon 10 power connections, MI2 - MI3

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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

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installation		vacon •21

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 6.2

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3.2.3 Screw of cables

Figure 3.12: MI1 screws

Figure 3.13: MI2 screws

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installation		vacon •23

Figure 3.14: MI3 screws

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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 Cable installation and the UL standards.

The fuses function also as cable overload protection.

These instructions apply only to cases with one motor and one cable connection from the frequency converter to the motor. In any other case, ask the factory for more information.

EMC category	cat. C2	cat. C4
Mains cable types	1	1
Motor cable types	3	1
Control cable types	4	4
Table 3.7: Cable	types required	to meet standards. EMC
categories are described in Chapter EMC levels

	Cable type	Description
	1	Power cable intended for fixed installation and the specific mains voltage.
		Shielded cable not required.
		(NKCABLES / MCMK or similar recommended)
		Power cable equipped with concentric protection wire and intended for
	2	the specific mains voltage.
		(NKCABLES / MCMK or similar recommended).
		Power cable equipped with compact low-impedance shield and intended
	3	for the specific mains voltage.
		(NKCABLES / MCCMK, SAB / ÖZCUY-J or similar recommended).
		*360º earthing of both motor and FC connection required to meet the standard
	4	Screened cable equipped with compact low-impedance shield (NKCA-
		BLES /Jamak, SAB / ÖZCuY-O or similar).
	Table 3.8: Cable	type descriptions

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	installation							vacon •25
				Mains	Motor	Terminal cable size (min/max)
	Frame	Type	Fuse	cable	cable	Main	Earth	Control	Relay
			[A]
				Cu [mm2]	Cu [mm2]	terminal	terminal	terminal	terminal
						[mm2]	[mm2]	[mm2]	[mm2]
	MI2	0001-0004	20	2*2.5+2.5	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5	0.5-1.5
	MI3	0005	32	2*6+6	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5	0.5-1.5
	Table 3.9: Cable and fuse sizes for Vacon 10, 115 V, 1~
				Mains	Motor	Terminal cable size (min/max)
	Frame	Type	Fuse	cable	cable	Main	Earth	Control	Relay
			[A]
				Cu [mm2]	Cu [mm2]	terminal	terminal	terminal	terminal
						[mm2]	[mm2]	[mm2]	[mm2]
	MI1	0001-0003	10	2*1.5+1.5	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5	0.5-1.5
	MI2	0004-0007	20	2*2.5+2.5	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5	0.5-1.5
	MI3	0009	32	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~
				Mains	Motor	Terminal cable size (min/max)
	Frame	Type	Fuse
			[A]	cable	cable	Main	Earth	Control	Relay
				Cu [mm2] Cu [mm2]		terminal	terminal	terminal	terminal
						[mm2]	[mm2]	[mm2] [mm2]
	MI1	0001-0003	6	3*1.5+1.5	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5 0.5-1.5
	MI2	0004-0007	10	3*1.5+1.5	3*1.5+1.5	1.5-4	1.5-4	0.5-1.5 0.5-1.5
	MI3	0011	20	3*2.5+2.5	3*2.5+2.5	1.5-6	1.5-6	0.5-1.5	0.5-1.5

Table 3.11: Cable and fuse sizes for Vacon 10, 208 - 240 V, 3~

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			Mains	Motor			Terminal cable size (min/max)
Frame	Type	Fuse	cable	cable			Main	Earth	Control	Relay
		[A]	Cu
					2		terminal	terminal	terminal	terminal
			[mm2]	Cu [mm		]	[mm2]	[mm2]	[mm2]	[mm2]
MI1	0001-0003	6	3*1.5+1.5	3*1.5+1.5			1.5-4	1.5-4	0.5-1.5	0.5-1.5
MI2	0004-0006	10	3*1.5+1.5	3*1.5+1.5			1.5-4	1.5-4	0.5-1.5	0.5-1.5
MI3	0008-0012	20	3*2.5+2.5	3*2.5+2.5			1.5-6	1.5-6	0.5-1.5	0.5-1.5
Table	3.12: Cable	and fuse sizes for Vacon 10, 380 - 480 V, 3~
			Mains	Motor			Terminal cable size (min/max)
Frame	Type	Fuse	cable	cable			Main	Earth	Control	Relay
		[A]	Cu
				Cu [mm	2	]	terminal	terminal	terminal	terminal
			[mm2]
							[mm2]	[mm2]	[mm2] [mm2]
MI3	0002-0004	6	3*1.5+1.5	3*1.5+1.5			1.5-4	1.5-4	0.5-1.5 0.5-1.5
MI3	0005-0006	10	3*1.5+1.5	3*1.5+1.5			1.5-4	1.5-4	0.5-1.5 0.5-1.5
MI3	0009	20	3*2.5+2.5	3*2.5+2.5			1.5-6	1.5-6	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 Cuor16 mm2 Al. Another possibility is to use an additional protective conductor of at least the same size as the original one.

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installation			vacon •27
3.2.5		General cabling rules
1		Before starting the installation, check that none of the components of the fre-
		quency converter is live.
		Place the motor cables sufficiently far from other cables:
		• Avoid placing the motor cables in long parallel lines with other cables.
		• If the motor cable runs in parallel with other cables, the minimum distance
2		between the motor cable and other cables is 0.3 m.
		• The given distance also applies between the motor cables and signal cables
		of other systems.
		• The maximum length of the motor cables for MI1-3 is 30 m. If use longer
		cable, current accuracy will be decreased.
		• The motor cables should cross other cables at an angle of 90 degrees.

3Ifchecks.cable insulation checks are needed, see Chapter Cable and motor insulation Connecting the cables:

•Strip the motor and mains cables as advised in Figure Stripping of cables.

•Connect the mains, motor and control cables into their respective terminals, see Figures Vacon 10 power connections, MI1 - Install the control cables.

•Note the tightening torques of chapter3.2.1 power cables and chapter 3.2.2 control cables given in Vacon 10 power connections, MI1 and Install the control cables. MI1 - MI3. See Chapter6.2.

•For information on cable installation according to UL regulations see Chap-

4ter Cable installation and the UL standards.

•Make sure that the control cable wires do not come in contact with the electronic components of the unit.

•If an external brake resistor (option) is used, connect its cable to the appropriate terminal.

•Check the connection of the earth cable to the motor and the frequency converter terminals marked with.

•Connect the separate shield of the motor cable to the earth plate of the frequency converter, motor and the supply centre.

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