Danfoss vacon 100 x Installation guide

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vacon® 100 x

ac drives

installation manual

vacon • 3

NDEX

Document code (Original Instructions): DPD00534L

Revision release date: 5.2.2021

1. Safety................................................................................................................6

1.1 Signs....................................................................................................................................6

1.2 Units ....................................................................................................................................6

1.3 Danger.................................................................................................................................7

1.4 Warnings .............................................................................................................................7

1.5 Grounding and earth fault protection .................................................................................9

1.6 Insulation system ..............................................................................................................12

1.7 Compatibility with RCDs ...................................................................................................13

1.8 Extended temperature range ...........................................................................................13

1.9 Electro-magnetic compatibility (EMC)..............................................................................13

1.10 Marine environment..........................................................................................................14

2. Receiving the delivery.....................................................................................15

2.1 Type designation code.......................................................................................................16

2.2 order codes .......................................................................................................................17

2.3 Unpacking and lifting the AC drive ...................................................................................18

2.4 Accessories .......................................................................................................................18

2.4.1 Enclosure MM4 .................................................................................................................18

2.4.2 Enclosure MM5 .................................................................................................................19

2.4.3 Enclosure MM6 .................................................................................................................19

2.4.4 STO terminal connector....................................................................................................20

2.4.5 ‘Product modified’ sticker.................................................................................................20

2.4.6 Disposal.............................................................................................................................20

3. Mounting......................................................................................................... 21

3.1 Dimensions MM4...............................................................................................................21

3.2 Dimensions MM5...............................................................................................................22

3.3 Dimensions MM6...............................................................................................................23

3.4 Introduction of modules....................................................................................................24

3.5 Mounting ...........................................................................................................................25

3.5.1 Wall-mounting ..................................................................................................................26

3.5.2 Motor-mounting ................................................................................................................26

3.5.3 Segregated modules.........................................................................................................26

3.6 Cooling ..............................................................................................................................27

4. Power cabling .................................................................................................28

4.1 Circuit breaker ..................................................................................................................30

4.2 UL standards on cabling ...................................................................................................30

4.3 Description of the terminals .............................................................................................31

4.4 Cable dimensioning and selection....................................................................................34

4.4.1 Cable and fuse sizes, enclosures MM4 to MM6 ...............................................................34

4.4.2 Cable and fuse sizes, enclosures MM4 to MM6, North America .....................................35

4.4.3 Brake resistor cables........................................................................................................36

4.4.4 Control cables ...................................................................................................................36

4.5 Cable installation ..............................................................................................................37

5. Control unit.....................................................................................................45

5.1 Control unit cabling...........................................................................................................46

5.1.1 Control cable sizing ..........................................................................................................46

5.1.2 Standard I/O terminals .....................................................................................................47

5.1.3 Relay and thermistor input terminals ..............................................................................48

5.1.4 Safe Torque off (STO) terminals .......................................................................................48

5.1.5 Selection of terminal functions with DIP switches...........................................................49

5.1.6 Isolating digital inputs from ground .................................................................................49

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 4

5.1.7 Bus termination of the RS485 connection ........................................................................50

5.2 I/O cabling and fieldbus connection .................................................................................51

5.2.1 Prepare for use through Ethernet ....................................................................................51

5.2.2 Prepare for use through RS485........................................................................................52

5.2.3 RS485 cable data...............................................................................................................53

5.3 Battery installation for Real Time Clock (RTC) ................................................................54

6. Commissioning ...............................................................................................57

6.1 Commissioning of the drive ..............................................................................................58

6.2 Changing EMC protection class........................................................................................59

6.3 Running the motor ............................................................................................................61

6.3.1 Cable and motor insulation checks ..................................................................................61

6.3.2 Motor overload protection ................................................................................................61

6.4 Maintenance......................................................................................................................64

7. Technical data.................................................................................................65

7.1 AC drive power ratings......................................................................................................65

7.1.1 Mains voltage 3AC 208-240V.............................................................................................65

7.1.2 Mains voltage 3AC 380-480/500V......................................................................................66

7.1.3 Definitions of overloadability ............................................................................................67

7.2 Brake resistor ratings.......................................................................................................68

7.3 VACON® 100 X - technical data........................................................................................69

7.3.1 Technical information on control connections.................................................................72

8. Options............................................................................................................74

8.1 Mains switch......................................................................................................................74

8.1.1 Installation ........................................................................................................................75

8.2 Control Keypad..................................................................................................................79

8.2.1 Mounting onto the drive ....................................................................................................79

8.2.2 Installation ........................................................................................................................80

8.2.3 Wall-mounting ..................................................................................................................82

8.2.4 Graphical and Text keypad................................................................................................85

8.2.5 VACON® keypad with graphical display...........................................................................86

8.2.6 VACON® keypad with text segment display.....................................................................93

8.2.7 Fault Tracing .....................................................................................................................97

8.3 Heater (arctic option) ......................................................................................................106

8.3.1 Safety...............................................................................................................................106

8.3.2 Dangers ...........................................................................................................................106

8.3.3 Technical data .................................................................................................................106

8.3.4 Fuses ...............................................................................................................................107

8.3.5 Mounting instructions: MM4 Example............................................................................107

8.4 Option boards ..................................................................................................................110

8.5 Flange adapter ................................................................................................................111

8.5.1 Mounting instructions: MM4 Example............................................................................114

9. Safe Torque Off .............................................................................................116

9.1 General description.........................................................................................................116

9.2 Warnings .........................................................................................................................116

9.3 Standards ........................................................................................................................117

9.4 The principle of STO ........................................................................................................118

9.4.1 Technical details .............................................................................................................119

9.5 Connections.....................................................................................................................119

9.5.1 Safety Capability Cat. 4 / PL e / SIL 3 .............................................................................120

9.5.2 Safety Capability Cat. 3 / PL e / SIL 3 .............................................................................122

9.5.3 Safety Capability Cat. 2 / PL d / SIL 2 .............................................................................123

9.5.4 Safety Capability Cat. 1 / PL c / SIL 1..............................................................................124

9.6 Commissioning ...............................................................................................................125

9.6.1 General wiring instructions ............................................................................................125

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 5

9.6.2 Checklist for commissioning ..........................................................................................126

9.7 Parameters and fault tracing .........................................................................................127

9.8 Maintenance and diagnostics .........................................................................................127

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vacon • 6 Safety

1. S

This manual contains clearly marked warning information which is intended for your personal safety and to avoid any unintentional damage to the product or connected appliances.

Please read the warning information carefully.

VACON® 100 X is a drive designed to control asynchronous AC motors and permanent magnet motors. The product is intended to be installed in a restricted access location and for a general purpose use.

Only trained and qualified personnel authorized by the manufacturer are allowed to install, operate and maintain the drive.

AFETY

1.1 Signs

The cautions and warnings are marked as follows:

Table 1. Warning signs.

= DANGEROUS VOLTAGE!

= HOT SURFACE

= WARNING or CAUTION

1.2 Units

The dimensions used in this manual conform to International Metric System units, otherwise known as SI (Système International d’Unités) units. For the purpose of the equipment's UL certification, some of these dimensions are accompanied by their imperial equivalents.

Table 2. Unit conversion table.

Physical

dimension

length 1 mm 0.0394 inch 25.4 inch

Weight 1 kg 2.205 lb 0.4536 pound

Speed

Temperature 1 °C (T1) 33.8 °F (T2) T2 = T1 x 9/5 + 32 Fahrenheit

SI value US value Conversion factor US designation

1 min

-1

1 rpm 1

revolution per minute

Torque 1 Nm 8.851 lbf in 0.113

Power 1 kW 1.341 HP 0.7457 horsepower

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

pound-force inches

Safety vacon • 7

1.3 Danger

The components of the power unit of VACON® 100 X drives are live when the drive is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.

The motor terminals (U, V, W), the brake resistor terminals and the DC-terminals are live when VACON® 100 X Drive is connected to the mains, even if the motor is not running.

After disconnecting the AC drive from the mains, wait until the indicators on the keypad go out (if no keypad is connected, see the indicators on the cover). Wait an additional 30 seconds

before doing any work on the connections of VACON® 100 X Drive. Do not open the unit before this time has expired. After expiration of this time, use measuring equipment to absolutely ensure that no

trical work! The control I/O-terminals are isolated from the mains potential. However, the relay outputs

and other I/O-terminals may have a dangerous control voltage present even when VACON

100 X drive is disconnected from the mains.

Before connecting the AC drive to mains make sure that the powerhead of VACON® 100 X Drive is mounted firmly on the terminal box.

voltage is present.

Always ensure absence of voltage before starting any elec-

During a coast stop (see the Application Manual), the motor is still generating voltage to the drive. Therefore, do not touch the components of the AC drive before the motor has completely stopped and wait until the indicators on the keypad go out (if no keypad is connected, see the indicators on the cover). Wait an additional 30 seconds before starting any work on the drive.

The terminals are live when the VACON®100X Drive is connected to a photovoltaic system. Photovoltaic cells generate DC voltage even at low intensity of sunlight.

1.4 Warnings

VACON® 100 X AC drive is meant for fixed installations (on the motor or on the wall) 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 advice aims to protect both the drive and the client-

application. The manufacturer is not responsible for direct or consequential damages resulting from unsafe connections of external circuits to the drive. See paragraph 1.6 for more details.

Do not perform any measurements when the AC drive is connected to the mains.

The touch current of VACON® 100 X AC drives exceeds 3.5mA AC. According to standard EN61800-5-1, a reinforced protective ground connection must be ensured. See paragraph 1.5 for more details.

If the AC drive is used as a part of a machine, the machine manufacturer is responsible for providing the machine with a supply disconnecting device (EN 60204-1). See paragraph 4.1 for more details.

Only spare parts delivered by the manufacturer can be used.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 8 Safety

At power-up or fault reset, the motor will start immediately if the start signal is active, (unless the pulse control for

Start/Stop logic has been selected

) and the STO inputs are ready to be used (normal operation). The I/O functionalities (including start inputs) may change if parameters, applications or software are changed. Disconnect, therefore, the motor if an unexpected start can cause danger. This is valid only if STO inputs are energized. For prevention on unexpected restart, use appropriate safety relay connected to the STO inputs.

The motor starts automatically after automatic fault reset if the autoreset function is activated. See the Application Manual for more detailed information. This is valid only if STO inputs are energized. For prevention on unexpected restart, use appropriate safety relay connected to the STO inputs.

Before performing any measurement on the motor or on the motor cable, disconnect the motor cable from the AC drive.

Do not perform any voltage withstand test on any part of VACON® 100 X. The tests must be performed according to a specific procedure. Ignoring this procedure may damage the product.

Do not touch the components on the circuit boards. Static voltage discharge may damage the components.

Check that the EMC level of the AC drive corresponds to the requirements of your supply network. See paragraph 6.2 for more details.

In a domestic environment, this product may cause radio interference in which case supplementary mitigation measures may be required.

Optional keypad is IP66/Type 4X outdoor rated. Strong exposure to direct sunlight or to heavy temperatures might cause the degradation of display LCD.

Do not remove the EMC screws in the solar pump application. IT (impedance-grounded) AC supply network is not allowed in the solar pump application.

If a service switch is used on the motor output, parameter P3.1.2.6 Motor Switch must be enabled. Otherwise turning the service switch on while the drive is modulating can cause damage to the equipment. Notice also that the parameter Motor Switch is designed for a service switch or similar, not for repeated daily use.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Safety vacon • 9

1.5 Grounding and earth fault protection

CAUTION!

The VACON® 100 X AC drive must always be earthed with a grounding conductor connected to the grounding terminal marked with .

See Table 16 and Table 17 for the required cross-section of phase conductor and protective grounding conductor (both made of copper).

Since the touch current exceeds 3.5 mA AC, according to EN61800-5-1, the MM4 and MM5 must have a fixed connection and provision of an additional terminal for a second protective grounding conductor of the same cross-sectional area as the original protective grounding conductor. MM6 must have a fixed installation and a cross-section of the protective grounding conductor of at least 10 mm2 Cu.

On the terminal-box, three screws (for MM4 and MM5) and two screws (for MM6)are provided for ORIGINAL and MOTOR protective grounding conductors: the customer can choose the screw for each one.

The cross-sectional area of every protective grounding conductor which does not form a part of the supply cable or cable enclosure must, in any case, be not less than:

• 2.5 mm2 if mechanical protection is provided or

• 4 mm2 if mechanical protection is not provided. For cord-connected equipment, provisions must be made so that the protective grounding conductor in the cord is, in the case of failure of the strain-relief mechanism, the last conductor to be interrupted.

The power-head is earthed through metal aglets, located on the terminal-box, which fit into spring baskets on the powerhead. See Figure 1, Figure 2 and Figure 3 for the location of the screws (three for MM4 and MM5, two for MM6) and the metal aglets (one for MM4 and MM5, two for MM6). Please, pay attention not to damage or remove these aglets.

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vacon • 10 Safety

Earth connection

Metal aglet

Earth connection

Earth connections

Metal aglet

Earth connection

Figure 1. Earth connections and metal aglet in MM4

Figure 2. Earth connections and metal aglet in MM5

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Safety vacon • 11

Earth connection Earth connection

Metal aglet

Figure 3. Earth connections and metal aglet in MM6

However, always follow the local regulations for the minimum size of the protective grounding conductor.

NOTE: Due to the high capacitive currents present in the AC drive, fault current protective switches

may not function properly.

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vacon • 12 Safety

POWER UNIT

L1 L2 L3

U V

R01 __

R02 __

DC- DC+/R+ R-

10Vref __

Analog Inputs __

Digital Inputs__

Digital Outputs__

24V __

Ethernet __

RS485 __

STO __

___Thermistor

Keypad

CONTROL UNIT

Reinforced

Mains

DVC A

DVC A or Mains

(*)

1.6 Insulation system

Please, consider carefully the insulation system depicted in Figure 4 before connecting any circuit to the unit.

A distinction has to be made for the following three groups of terminals, according the insulation system of VACON® 100 X:

• Mains and motor connections (L1, L2, L3, U, V, W)

• Relays (R01, R02)

• Thermistor-input

• Control terminals (I/Os, RS485, Ethernet, STO)

The Control terminals (I/Os, RS485, Ethernet, STO) are isolated from the Mains (the insulation is reinforced, according to IEC 61800-5-1) and the GND terminals are referred to PE.

This is important when you need to connect other circuits to the drive and test the complete assembly. Should you have any doubt or question, please contact your local distributor.

(*)

The relays may be used also with DVC A circuits. This is possible only if both relays

are used with DVC A circuit: to mix Mains and DVC A is not allowed.

Figure 4. Insulation system

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Safety vacon • 13

Ambient temperature (°C)

Percent rated output current (% I

)

10 20 30 40 50

100

0-10

150

Temperature - Output Current Derating Curve

1.7 Compatibility with RCDs

This product can cause a d.c. current in the protective grounding 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 allowed on the supply side of this product.

1.8 Extended temperature range

VACON® 100 X has an integrated cooling system, independent from the motor fan. Under maximum operating conditions, the ambient temperature cannot exceed 40 °C. See Table and Table 31 for the output rated current. Higher temperatures are allowed only with derating of the output current. With derating the unit can operate up to 60°C. See the Figure 5.

Figure 5. Temperature-output current derating curve

NOTE: the maximum allowed switching frequency above 50°C is 1.5 kHz. The AC drive is cooled down by air-ventilation. Therefore, make sure that enough free space is left

around the AC drive to ensure sufficient air circulation (see for more details the mounting instructions on chapter 3).

1.9 Electro-magnetic compatibility (EMC)

The VACON® 100 X complies with IEC 61000-3-12, provided that the short circuit ratio (R greater than or equal to 120 at the interface point between the user's supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit ratio R

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

greater than or equal to 120.

SCE

) is

vacon • 14 Safety

1.10 Marine environment

For installation, safety and EMC requirements in a marine environment download and read the Marine Installation Guide.

NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from https://www.danfoss.com/en/service-and-support/.

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 https://www.danfoss.com/en/service-and-support/.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Receiving the delivery vacon • 15

44023949

M163500721

70SCO00387

Danfoss A/S, 6430 Nordborg, Denmark

P2: 18.5 kW: 400 V / 25 hp: 480 V IP66

U2: 3AC 0-Input V 0-320 Hz, I2: 38 A

U1: 3AC 380-480 V 50/60 Hz, I1: 36.7 A

Made in Italy

POWER:

OUTPUT:

INPUT:

VACON DRIVES A/S

VACON0100-3L-0038-4-X+HMGR

160907

FW0072V021

Marks:

Cust. Ord. No:

Application:

Firmware:

B.ID:

M163500721

S/N:

70SCO00387

Code:

Type:

AC DRIVE

Vacon type code

Rated current

Supply voltage

Application code

EMC level

IP class

Serial number

Customer’s

order number

Vacon order number

Batch ID

2. R

ECEIVING THE 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 supplier immediately. See chapter 2.4.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Figure 6. VACON® package label

vacon • 16 Receiving the delivery

VACON

This segment is common for all products.

0100

Product range: 0100 = VACON® 100 Product family

Input/Function: 3L = Three-phase input

0061

Drive rating in ampere; e.g. 0061 = 61 A See Table 30, Table 31 and Table 32 for all the drive ratings.

Supply voltage: 2 = 208-240 V

4 = 380-480 V 5 = 380-500 V

-IP66/ Type 4X

-EMC-level C2

-Two relay outputs

-One thermistor input

-STO function

-GP software package installed

R02

+EMC4 +LS60 +LSUS +QGLC

+xxxx +yyyy

Additional codes (Several options possible). Examples of additional codes: +HMGR Graphical keypad IP66 +SRBT Integrated battery for real time clock +FBIE Onboard fieldbus protocols activated

(EtherNet/IP and PROFINET IO) +A1181 Solar pump application

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 code is of the following format:

VACON0100-3L-0061-4-X +xxxx +yyyy

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Receiving the delivery vacon • 17

2.2 order codes

The order codes for VACON® 100 X drive family are shown in the following table:

Table 3. Order codes of VACON® 100 X. See chapter 7 for more details.

Enclosure size Order code Description

Supply voltage 3AC 208-240V

VACON0100-3L-0006-2-X 1.1 kW - 1.5 HP drive

MM4

MM5

MM6

Supply voltage 3AC 380-480V

MM4

MM5

VACON0100-3L-0008-2-X 1.5 kW - 2.0 HP drive VACON0100-3L-0011-2-X 2.2 kW - 3.0 HP drive VACON0100-3L-0012-2-X 3.0 kW - 4.0 HP drive VACON0100-3L-0018-2-X 4.0 kW - 5.0 HP drive VACON0100-3L-0024-2-X 5.5 kW - 7.5 HP drive VACON0100-3L-0031-2-X 7.5 kW - 10.0 HP drive VACON0100-3L-0048-2-X 11.0 kW - 15.0 HP drive VACON0100-3L-0062-2-X 15.0 kW - 20.0 HP drive

VACON0100-3L-0003-4-X 1.1 kW - 1.5 HP drive VACON0100-3L-0004-4-X 1.5 kW - 2.0 HP drive VACON0100-3L-0005-4-X 2.2 kW - 3.0 HP drive VACON0100-3L-0008-4-X 3.0 kW - 4.0 HP drive VACON0100-3L-0009-4-X 4.0 kW - 5.0 HP drive VACON0100-3L-0012-4-X 5.5 kW - 7.5 HP drive VACON0100-3L-0016-4-X 7.5 kW - 10.0 HP drive VACON0100-3L-0023-4-X 11.0 kW - 15.0 HP drive VACON0100-3L-0031-4-X 15.0 kW - 20.0 HP drive

MM6

Supply voltage 3AC 380-500V

MM4

MM5

MM6

VACON0100-3L-0038-4-X 18.5 kW - 25.0 HP drive VACON0100-3L-0046-4-X 22.0 kW - 30.0 HP drive VACON0100-3L-0061-4-X 30.0 kW - 40.0 HP drive VACON0100-3L-0072-4-X 37.0 kW - 50.0 HP drive

VACON0100-3L-0003-5-X 1.1 kW - 1.5 HP drive VACON0100-3L-0004-5-X 1.5 kW - 2.0 HP drive VACON0100-3L-0005-5-X 2.2 kW - 3.0 HP drive VACON0100-3L-0008-5-X 3.0 kW - 4.0 HP drive VACON0100-3L-0009-5-X 4.0 kW - 5.0 HP drive VACON0100-3L-0012-5-X 5.5 kW - 7.5 HP drive VACON0100-3L-0016-5-X 7.5 kW - 10.0 HP drive VACON0100-3L-0023-5-X 11.0 kW - 15.0 HP drive VACON0100-3L-0031-5-X 15.0 kW - 20.0 HP drive VACON0100-3L-0038-5-X 18.5 kW - 25.0 HP drive VACON0100-3L-0046-5-X 22.0 kW - 30.0 HP drive VACON0100-3L-0061-5-X 30.0 kW - 40.0 HP drive VACON0100-3L-0072-5-X 37.0 kW - 50.0 HP drive

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vacon • 18 Receiving the delivery

2.3 Unpacking and lifting the AC drive

The weights of the AC drives vary according to enclosure size. You may need to use a piece of special lifting equipment to move the drive from its package. Note the weights of each individual enclosure size in Table below.

Table 4. Enclosure weights.

Enclosure

size

[kg] [lb]

Weight

MM4 8.8 19.4 MM5 14.9 32.8 MM6 31.5 69.4

VACON® 100 X drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transport damage are to be found on the product and that the delivery is complete.

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

2.4 Accessories

After having opened the transport package and lifted the drive out, check immediately that these various accessories were included in the delivery. The contents of the accessories bag differ by drive size:

2.4.1 Enclosure MM4

Table 5. Content of accessory bag, MM4.

Item Quantity Purpose

STO terminal connector 1

M4 x 12 DIN6900-3-Combi-Delta-Tx screw

10 Screws for control cable clamps

Six pin black connector (see Figure 7) to use STO function

M1-3 Cable clamp 5 Clamping control cables

M4 x 12 DIN6900-3-Combi-Delta-Tx screw

6 Screws for power cable clamps

M25 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*. Provided only if the drive is delivered with the keypad.

1 Closing cap for the HMI connector

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Receiving the delivery vacon • 19

2.4.2 Enclosure MM5

Table 6. Content of accessory bag, MM5.

Item Quantity Purpose

STO terminal connector 1

M4 x 12 DIN6900-3-Combi-Delta-Tx screw

10 Screws for control cable clamps

Six pin black connector (see Figure 7) to use STO function

M1-3 Cable clamp 5 Clamping control cables

M4 x 12 DIN6900-3-Combi-Delta-Tx screw

6 Screws for power cable clamps

M32 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*. Provided only if the drive is delivered with the keypad.

1 Closing cap for the HMI connector

2.4.3 Enclosure MM6

Table 7. Content of accessory bag, MM6.

Item Quantity Purpose

STO terminal connector 1

M4 x 12 DIN6900-3-Combi-Delta-Tx screw

10 Screws for control cable clamps

Six pin black connector (see Figure 7) to use STO function

M1-3 Cable clamp 5 Clamping control cables

M4 x 25 DIN6900-3-Combi-Delta-Tx screw

6 Screws for power cable clamps

M40 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*. Provided only if the drive is delivered with the keypad mounted.

1 Closing cap for the HMI connector

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 20 Receiving the delivery

Product modified

Date:

2.4.4 STO terminal connector

Figure 7. STO connector

2.4.5 ‘Product modified’ sticker

In the small plastic bag included in the delivery you will find a silver

Product modified

sticker. The purpose of the sticker is to notify the service personnel about the modifications made in the AC drive. Attach the sticker on the side of the AC drive to avoid losing it. Should the AC drive be later modified, mark the change on the sticker.

Figure 8. ‘Product modified’ sticker

2.4.6 Disposal

When the device reaches the end of its operating life do not dispose of it as a part of standard household garbage. Main components of the product can be recycled, but some need to be fragmented to separate different types of materials and components that need to be treated as special waste from electrical and electronic components. To ensure environmentally sound and safe recycling treatment, the product can be taken to appropriate recycling center or returned to the manufacturer. Observe local and other applicable laws as they may mandate special treatment for specific components or special treatment may be ecologically sensible.

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Mounting vacon • 21

315,3

190,7

187,8

213,8

293,0

296,5

143,5

196,4

3. M

OUNTING

VACON® 100 X is the ideal solution for a decentralised installation. It is conceived to be mounted on a wall or directly on the motor, saving space and reducing the cabling complexity. In both cases, it must be ensured that the mounting plane is even.

3.1 Dimensions MM4

Figure 9. VACON® 100 X drive dimensions, MM4

Dimensions W x H x D

Enclosure size

[mm] [in]

MM4 190.7 x 315.3 x 196.4 7.51 x 12.41 x 7.73

MM4 +HMGR 190.7 x 315.3 x 213.8 7.51 x 12.41 x 8.42

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vacon • 22 Mounting

367,4

203,7

230,8

180,0

345,2

349,2

232,6

213,5

3.2 Dimensions MM5

Figure 10. VACON® 100 X drive dimensions, MM5

Dimensions W x H x D

Enclosure size

[mm] [in]

MM5 232.6 x 367.4 x 213.5 9.16 x 14.46 x 8.41

MM5 +HMGR 232.6 x 367.4 x 230.8 9.16 x 14.46 x 9.08

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Mounting vacon • 23

229,6

254,2

322,0

349,5

382,8

385,3

499,8

235,4

3.3 Dimensions MM6

Figure 11. VACON® 100 X drive dimensions, MM6

Dimensions W x H x D

Enclosure size

[mm] [in]

MM6 349.5 x 499.8 x 235.4 13.76 x 19.68 x 9.27

MM6 +HMGR 349.5 x 499.8 x 254.2 13.76 x 19.68 x 10.00

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vacon • 24 Mounting

Powerhead

Terminal box

3.4 Introduction of modules

The mechanical concept of VACON® 100 X drive is based on two segregated parts, power and control, connected to each other by pluggable terminals. The power unit, called powerhead, includes all the power electronics such as the EMC-filter, IGBTs, capacitors, choke or power boards while the control board and the control terminals are located in the terminal box.

Figure 12. VACON® 100 X drive modules

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Mounting vacon • 25

3.5 Mounting

The drive consists of two main elements:

1. The terminal box that includes the power terminals and control board with the control terminals

and

2. The powerhead containing all the power electronics.

To install the drive, both parts need to be separated. The terminal box must be fixed first and all cabling done. After this, the powerhead will be plugged on the terminal box and fixed with 4 (MM4 and MM6) or 6 (MM5) dedicated screws located on top side of the powerhead (see Figure 13.). In order to guarantee specified IP protection, recommended fastening torque is 2-3 Nm. The screws must be tightened crosswise.

Figure 13. Separation of modules (MM5 example)

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vacon • 26 Mounting

3.5.1 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 8.

Recommended screw or bolt size for MM4 is M5, for MM5 M6 and MM6 is M8.

Table 8. Screws for wall mounting.

Enclosure

size

Screw number Screw size

MM4 4 M5 MM5 4 M6 MM6 4 M8

3.5.2 Motor-mounting

The drive can also be mounted on a motor (on top or on any side of the motor). The drive is equipped with a cooling system independent of the motor. Motor-mounting requires special adapting components. Contact your local distributor for additional information.

3.5.3 Segregated modules

In order to ease replacements in case of failure, the power and the control sub-systems are enclosed in two segregated parts, connected together through pluggable terminals:

• Power-head: heat-sink enclosing all power electronics

• Terminal-box: block containing unit control and power terminals

Firstly, the terminal-box has to be fixed and the cabling has to be done. Secondly, the power-head has to be plugged and fixed to the terminal-box with dedicated screws (see Table 9). In order to preserve the specified IP protection class, the recommended fastening torque is 2-3 Nm.

Table 9. Screws for fixing the powerhead to the terminal box.

Enclosure

size

Screw number Screw size

MM4 4 M5 MM5 6 M5 MM6 4 M6

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Mounting vacon • 27

AAA

3.6 Cooling

The AC drive produces heat in operation and is cooled down by air circulated by a fan. The cooling concept is independent of the motor fan.

Enough free space must be left around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance may also require a certain amount of free space.

The minimum clearances given in Table 10 must not be exceeded. It is also important to ensure that the temperature of the cooling air does not exceed the maximum ambient temperature of the drive.

Contact local distributor for more information on required clearances in different installations.

Min clearance [mm]

Type A B C

All types 80 160 60

Table 10. Min. clearances around AC drive.

A = Clearance left and right from the drive B = Clearance above the drive C = Clearance underneath the AC drive

Figure 14. Installation space

Table 11. Required cooling air.

Type

Cooling air required

[m3/h]

MM4 140 MM5 140 MM6 280

Should you need further details on the cooling system of the VACON® 100 X, please contact your local distributor.

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vacon • 28 Power cabling

U/T1

V/T2

W/T3

DC+

R-

DC-

Keypad

Control unit

Power unit

4. P

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 15. See also Table 12 for the cable recommendations for different EMC levels.

OWER CABLING

Figure 15. Principal connection diagram

Use cables with heat resistance in accordance with the application requirements. The cables and the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can find on the rating plate.

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Power cabling vacon • 29

Shield

PE conductors

Shield

PE conductor

Table 12. Cable types required to meet standards.

EMC levels

1st environment 2nd environment

Cable type

Category C2 Category C3 Category C4

Mains cable 1 1 1 Motor cable 3* 2 2 Control cable 4 4 4

1 = Power cable intended for fixed installation and the specific mains voltage. Shielded cable not

required. (MCMK or similar recommended).

2 = Symmetrical power cable equipped with concentric protection wire and intended for the spe-

cific mains voltage. (MCMK or similar recommended). See Figure 16.

3 = Symmetrical power cable equipped with compact low-impedance shield and intended for

the specific mains voltage. [MCCMK, EMCMK or similar recommended. See Figure 16. *360º grounding of the shield with cable glands in motor end needed for EMC level C2.

4 = Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-O or

similar).

Figure 16.

NOTE: The EMC requirements are fulfilled at factory defaults of switching frequencies (all frames). NOTE: If safety switch is connected, the EMC protection must be continuous over the whole cable

installation.

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vacon • 30 Power cabling

4.1 Circuit breaker

Please disconnect the drive via an external circuit breaker. You have to provide a switching device between supply and main connection terminals.

When connecting the input terminals to the power supply using a circuit breaker, observe that this is of type B or type C and ensure it has a capacity of 1.5 to 2 times of the inverter’s rated current (see Table and Table 31).

NOTE: circuit breaker is not allowed in installations where C-UL is required. Only fuses are recommended.

4.2 UL standards on cabling

To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with a minimum heat-resistance of +75°C. Use Class 1 wire only.

The units are suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes, 500V AC maximum, when protected by T or J class fuses.

Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes.

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Power cabling vacon • 31

PES

AC power supply

Three phases

3AC

Motor

brake

resistor

4.3 Description of the terminals

The following pictures describe the power terminals and the typical connections in drives.

VACON

100 X

Figure 17. Power connections, MM4

Table 13. Terminal description.

Terminal Description

L1 L2 L3

DCDC+/R+ R-

U/T1 V/T2

These terminals are the input connections for the power supply.

DC bus terminals (DC- DC+) and Brake resistor terminals (R+ R-)

These terminals are for motor connections.

W/T3

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vacon • 32 Power cabling

PES

AC power supply

Three phases

3AC

Motor

brake

resistor

Figure 18. Power connections, MM5

Table 14. Terminal description.

Terminal Description

L1 L2 L3

DCDC+/R+ R-

These terminals are the input connections for the power supply.

DC bus terminals (DC- DC+) and Brake resistor terminals (R+ R-)

U/T1 V/T2

These terminals are for motor connections.

W/T3

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Power cabling vacon • 33

PES

AC power supply

Three phases

3AC

Motor

brake

resistor

Figure 19. Power connections, MM6

Table 15. Terminal description.

Terminal Description

L1 L2 L3

DCDC+/R+ R-

These terminals are the input connections for the power supply.

DC bus terminals (DC- DC+) and Brake resistor terminals (R+ R-)

U/T1 V/T2

These terminals are for motor connections.

W/T3

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vacon • 34 Power cabling

4.4 Cable dimensioning and selection

Table 16 and Table 17 show the minimum dimensions of the Cu-cables and the corresponding fuse sizes.

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

4.4.1 Cable and fuse sizes, enclosures MM4 to MM6

The recommended fuse type is gG/gL (IEC 60269-1). The fuse voltage rating must be selected according to the supply network. The final selection must be made according to local regulations, cable installation conditions and cable specification. Bigger fuses than those recommended below must not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used fuse type and impedance of the supply circuit. Consult the factory about faster fuses. The manufacturer also recommends high speed gS (IEC 60269-4) fuse ranges.

Table 16. Cable and fuse sizes for VACON® 100 X.

Enclosure

size

MM4

MM5

Type

0003 4 - 0004 4 0003 5 - 0004 5

0006 2 - 0008 2 0005 4 - 0008 4 0005 5 - 0008 5

0011 2 - 0012 2 0009 4 - 0012 4 0009 5 - 0012 5

0018 2 0016 4 0016 5

0024 2 0023 4 0023 5

0031 2 0031 4 0031 5

Mains, motor

INPUT

[A]

Fuse

(gG/gL)

[A]

and brake

resistor*

cable

Cu [mm2]

3.4 - 4.6 6 3*1.5+1.5

6.0 - 7.2

5.4 - 8.1

9.7 - 10.9

9.3 - 11.3

16.1

15.4

21.7

21.3

27.7

28.4

10 3*1.5+1.5

16 3*2.5+2.5

20 3*6+6

25 3*6+6

32 3*10+10

Terminal cable size

Main terminal

[mm2]

0.5—10

0.5—6

0.5—10

0.5—6

0.5—10

0.5—6

0.5—16

or stranded

0.5—16

or stranded

0.5—16

stranded

solid

stranded

solid

stranded

solid

stranded

solid

solid or

Earth terminal

[mm2]

ring terminal

1—6

ring terminal

1—6

ring terminal or

1—6

ring terminal or

1—10

ring terminal or

1—10

ring terminal or

1—10

MM6

0038 4 0038 5

0048 2 0046 4 0046 5

0062 2 0061 4 0061 5

0072 4 0072 5

36.7 40 3*10+10 M6

43.8

43.6

57.0

58.2

50 3*16+16 M6

63 3*25+16 M6

67.5 80 3*35+16 M6

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ring terminal

Power cabling vacon • 35

The terminal sizes are intended for 1 conductor. For MM6, the max. diameter of the ring terminal is 14 mm. The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be PVC-isolated; Max number of parallel cables is 9.

When using cables in parallel, the max number of cables must be observed. For important information on the requirements of the grounding conductor, see chapter Grounding and earth fault protection of the standard. For the correction factors for each temperature, see International Standard IEC60364-5-52.

NOTE HOWEVER

that the requirements of both the cross-sectional area and

4.4.2 Cable and fuse sizes, enclosures MM4 to MM6, North America

The recommended fuse type is class T (UL & CSA). The fuse voltage rating must be selected according to the supply network. The final selection must be made according to local regulations, cable installation conditions and cable specification. Bigger fuses than those recommended below must not be used.

Table 17. Cable and fuse sizes for VACON® 100 X.

Enclosure

size

MM4

MM5

Type

0003 4 - 0004 4 0003 5 - 0004 5

0006 2 - 0008 2 0005 4 - 0008 4 0005 5 - 0008 5

0011 2 0009 4 0009 5

0012 2 0012 4 0012 5

0018 2 0016 4 0016 5

0024 2 0023 4 0023 5

0031 2 0031 4 0031 5

INPUT

[A]

Fuse

(class T)

[A]

3.4 - 4.6 6

6.0 - 7.2

5.4 - 8.1

9.7

9.3

10.9

11.3

16.1

15.4

21.7

21.3

27.7

28.4

Mains and

Terminal cable size

motor cable

AWG14 AWG24-AWG10

AWG10 AWG20-AWG5

AWG8 AWG20-AWG5

Main terminal Earth terminal

AWG17-AWG10 M4

ring

terminal

AWG17-AWG10 M4

ring

terminal

AWG17-AWG10 M4

ring

terminal

AWG17-AWG10 M4

ring

terminal

AWG17-AWG8 M5

ring

terminal

AWG17-AWG8 M5

ring

terminal

AWG17-AWG8 M5

ring

terminal

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vacon • 36 Power cabling

Table 17. Cable and fuse sizes for VACON® 100 X.

Enclosure

size

Type

0038 4* 0038 5*

0048 2* 0046 4* 0046 5*

INPUT

[A]

Fuse

(class T)

36.7 50

43.8

43.6

[A]

Mains and

motor cable

AWG4

Terminal cable size

Main terminal Earth terminal

AWG13-AWG0

ring terminal

AWG13-AWG0 M6

ring

terminal

AWG13-AWG2 M6

ring

terminal

AWG13-AWG2 M6

ring

terminal

MM6

0062 2** 0061 4** 0061 5**

0072 4** 0072 5**

* With the optional mains switch, the mains cable must be rated AWG6 (minimum 75ºC, Cu). The motor cable

must be rated AWG4 (minimum 75ºC, Cu).

** The optional mains switch cannot be used with these models, unless current derating is applied. The input

current cannot exceed 52 A at 30°C ambient temperature and 45 A at 40°C ambient temperature. With the optional main switch, use a maximum 60 A fuse.

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be PVC-isolated; Max ambient temperature +40 °C (104 °F), max temperature of cable surface +75 °C (167 °F); Use only cables with concentric copper shield; Max number of parallel cables is 9.

57.0

58.2

67.5 100

AWG4

AWG2

AWG13-AWG0 M6

ring

terminal

AWG9-AWG2/0 M6

ring

terminal

AWG13-AWG2 M6

ring

terminal

AWG9-AWG2/0 M6

ring

terminal

When using cables in parallel, NOTE HOWEVER that the requirements of both the cross-sectional area and the max number of cables must be observed. For important information on the requirements of the grounding conductor, see standard Underwriters’ Laboratories UL508C.

For the correction factors for each temperature, see the instructions of standard Underwriters’ Laboratories UL508C.

4.4.3 Brake resistor cables

VACON® 100 X AC drives are equipped with terminals for an optional external brake resistor. These terminals are marked with DC+/R+ and R-. See Table 33 and Table 34 for the resistor ratings and Table 16 for cable sizing.

4.4.4 Control cables

For information on control cables see chapter Control unit.

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Power cabling vacon • 37

Earth conductor

MAINS MOTOR

Shield

Earth conductor

4.5 Cable installation

• Before starting, check that none of the components of the AC drive is live. Read carefully the warnings in chapter 1.

• Place the motor cables sufficiently far from other cables.

• Avoid placing the motor cables in long parallel lines with other cables.

• If the motor cables run in parallel with other cables note the minimum distances between the motor cables and other cables given in table below.

Distance between

cables, [m]

0.3 ≤ 50

1.0 ≤ 200

• The given distances also apply between the motor cables and signal cables of other systems.

• The maximum lengths of motor cables (shielded) are 100 m (MM4) and 150 m (MM5 and MM6).

• The motor cables should cross other cables at an angle of 90 degrees.

• If cable insulation checks are needed, see chapter Cable and motor insulation checks.

Start the cable installation according to the instructions below:

Strip the motor and mains cables as recommended below.

Shielded

cable, [m]

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Figure 20. Stripping of cables

vacon • 38 Power cabling

Table 18. Cables stripping lengths [mm].

Enclosure

size

MM4 15 70 10 30 7 30

MM6 20 90 15 60 15 60

IEC installation:

A1 B1 C1 D1 C2 D2 E

as short as possibleMM5 20 70 10 40 10 40

• Remove the cable entry plate. The cable entry system is a combination of a cable entry plate (see the figure below) and cable glands. In the cable entry plate there are several openings available for the cables with ISO metric thread.

• Open only the inlet holes where you need to run the cables.

• Choose the correct cable glands according to drive and cable size as shown in the following pictures.

Figure 21. Cable entry plate, MM4

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Power cabling vacon • 39

Figure 22.Cable entry plate, MM5

Figure 23.Cable entry plate, MM6

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vacon • 40 Power cabling

• Cable glands must be made of plastic materials. They are used for sealing

cables passing through cable entries to ensure the characteristics of the enclosure.

Figure 24.Cable gland

Plastic cable glands are recommend. If metal cable glands are needed, all insulation system requirements and all protective grounding requirements have to be fulfilled in accordance with the national electrical regulations and IEC 61800-5-1.

Tightening torques of cable glands:

• Screw the cable glands on the cable entry holes using the proper tightening torque as shown in Table 19.

Table 19. Tightening torque and dimension of cable glands.

Enclosure

size

MM4

MM5

Gland screw

type [metric]

M16 1.0 8.9 M25 4.0 35.5 M16 1.0 8.9 M25 4.0 35.5 M32 7.0 62.1

Tightening torque [Nm]/[lb-in.]

[Nm] lb-in.

MM6

M16 1.0 8.9 M25 4.0 35.5 M40 10.0 88.7

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Power cabling vacon • 41

UL installation:

• To connect NPT pipes to VACON® 100 X, use the optional metal cable entry plate (included in -R02 option) to meet UL installation rules.

• One metal conduit plate with accessories (screws and gasket) is delivered in a separate bag together with the drive. See the following figures for more details.

Figure 25.Cable entry plate, MM4 UL installation

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vacon • 42 Power cabling

Figure 26.Cable entry plate, MM5 UL installation

Figure 27.Cable entry plate, MM6 UL installation

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Power cabling vacon • 43

• All the (3) terminal box openings are closed with the standard plastic plates

• The metal cable entry plate for UL installation has to be installed in place of

• Flexible or rigid cable conduit can be used.

• Use proper fittings to join and terminate rigid conduit tubing, and protect it

• The proper selection of electrical conduit materials, fittings, and installation

• Setscrew fittings are commonly used with conduit; they provide weather tight

Cable installation:

• Pass the cables (supply cable, motor cable, brake cable and I/O cables) through

• Detach the cable clamps and the grounding clamps.

Connect the stripped cables:

• Expose the shield of both cables in order to make a 360-degree connection with

• Connect the phase conductors of the supply and motor cables into their

• Form the rest of the cable shield of both cables into “pigtails” and make a

with the metric threads.

one of standard plastic cable entries provided with the default package. The tightening torque of cable entry plate screws: 1.5 -2.0 Nm (13.2-17.7 lb-in). The metal cable entry plate has three not-threaded openings: input line, motor and I/Os and can be mounted only on left or right-hand side of the drive.

from damage too.

are important for safe electrical wiring.

joints that are firm to keep the IP degree of the drive.

the conduits (UL connections) or through the cable glands (IEC connections) and cable entries.

the cable clamp (reverse the shield over the plastic cover of the cable and fix all together).

respective terminals.

grounding connection with the clamp. Make the pigtails just long enough to reach and be fixed to the terminal - no longer.

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vacon • 44 Power cabling

Tightening torques of cable terminals:

Table 20. Tightening torques of terminals.

Enclosure

size

MM4

MM5

MM6

Tightening torque

Type

0006 2 - 0012 2 0003 4 - 0012 4 0003 5 - 0012 5

0018 2 - 0031 2 0016 4 - 0031 4 0016 5 - 0031 5

0048 2 - 0062 2 0038 4 - 0072 4 0038 5 - 0072 5

• Check the connection of the earth cable to the motor and the AC drive terminals marked with .

[Nm]/[lb-in.]

Power and motor

terminals

[Nm] lb-in. [Nm] lb-in. [Nm] lb-in.

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

4—5 35.4—44.3 1.5 13.3 2.0 17.7

Tightening torque

[Nm]/[lb-in.]

EMC grounding

clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding

terminals

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Control unit vacon • 45

1 2

5. C

Remove the powerhead of the drive to reveal the terminal box with the control terminals. 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, terminals and switches are presented in Figure 28 below.

ONTROL UNIT

Table 21. Locations of components in control unit.

Number Meaning

1 Control terminals 1-11 (see chapter 5.1.2) 2 Control terminals 12-30, A-B (see chapter 5.1.2) 3 Relay terminals (see chapter 5.1.2) 4 Thermistor input (see chapter 5.1.2) 5 STO terminals 6 DIP switches 7 Ethernet terminal (see chapter 5.2.1) 8 Option boards

Figure 28. Locations of components in control unit

When delivered from the factory, the control unit of the AC drive contains the standard controlling interface - the control and relay terminals of the control unit - unless otherwise specifically ordered. On the next pages you will find the arrangement of the control I/O and the relay terminals, the general wiring diagram and the control signal descriptions.

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vacon • 46 Control unit

The control board can be powered externally (+24VDC, max. 1000mA, ±10%) by connecting the external power source to terminal #30, see chapter 5.1.2. This voltage is sufficient for parameter setting and for keeping the control unit active. Note however that the measurements of the main circuit (e.g. DC-link voltage, unit temperature) are not available when the mains is not connected.

5.1 Control unit cabling

The principal terminal block placement is presented in Figure 29 below. The control board is equipped with 22 fixed control I/O terminals and the relay board with 6+2. Additionally, the terminals for the Safe Torque Off (STO) function (see chapter 9.) can be seen in the picture below. All signal descriptions are also given in Table 23.

Figure 29. Control terminals

5.1.1 Control cable sizing

The control cables shall be at least 0.5 mm2 screened multicore cables, see Table 22. The maximum terminal wire size is 2.5 mm2 for the relay terminals and 1.5 mm2 for other terminals.

Find the tightening torques of the control and relay board terminals in Table 22.

Table 22. Control cable tightening torques.

Tightening torque

Terminal screw

Nm lb-in.

I/O terminals and STO terminals (screw M2)

0.22-0.25 2.0-2.2

Relay terminals (screw M3) 0.22-0.25 2.0-2.2

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Control unit vacon • 47

Reference

potentiometer 1...10 k

Ω

Remote reference

4...20mA/0...10V

5.1.2 Standard I/O terminals

The terminals of the the connections, see chapter 7.

The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches. See more information in chapter 5.1.5 and in chapter 5.1.6.

Standard I/Os

Table 23. Control I/O terminal signals and connection example.

and the

Relays

are described below. For more information on

Standard I/O

Terminal Signal

1 +10 Vref Reference output

AI1+

AI1-

AI2+

AI2-

24Vout 24V aux. voltage

GND I/O ground

DI1 Digital input 1

DI2 Digital input 2

9 10 11 12 13 14 15 16 17

30 +24 Vin

DI3 Digital input 3

24Vout 24V aux. voltage

GND I/O ground

DI4 Digital input 4

DI5 Digital input 5

DI6 Digital input 6

CM Common for DI1-DI6*

AO1+

AO-/GND

A RS485 Serial bus, negative

B RS485 Serial bus, positive

Analogue input, voltage or current

Analogue input common

Analogue input, voltage or current

Analogue input common

Common for DI1-DI6

Analogue output, voltage or current

Analogue output common

24V auxiliary input voltage

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*. Can be isolated from ground, see

chapter 5.1.6.

vacon • 48 Control unit

From

standard I/O

From term.

#13

From term.

RUN

5.1.3 Relay and thermistor input terminals

Table 24. I/O terminal signals for relay and thermistor terminals and connection example.

Relays and thermistor

Terminal Signal

21 22 23 24 25 26 28 29

RO1/1

RO1/2

RO1/3

RO2/1

RO2/2

RO2/3

TI1+

Thermistor input

TI1-

5.1.4 Safe Torque off (STO) terminals

For more information on the functionalities of the Safe Torque Off (STO), see chapter 9.

Table 25. I/O terminal signals for the STO functions.

Safe Torque Off terminals

Terminal Signal

Isolated digital input 1 (interchangeable polarity);

+24V ±20% 10...15mA Isolated digital input 2 (inter-

changeable polarity);

+24V ±20% 10...15mA

Relay output 1

Relay output 2

Isolated feedback (CAUTION!

F+

Polarity to be respected); +24V ±20%

Isolated feedback (CAUTION!

F-

Polarity to be respected); GND

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Control unit vacon • 49

5.1.5 Selection of terminal functions with DIP switches

The VACON® 100 X drive embodies five so-called

DIP switches

that allow for three functional selections each. The shadowed terminals in Table 23 can be functionally modified with the DIP switches. The switches have three positions: C, 0 and V. The switch in the position “C” means that the input or the output has been set in current mode. The switch in the position “V” means voltage mode.The middle position “0” is for

Test mode

. See Figure 30 to locate the switches and make appropriate

selections for your requirements. Factory defaults are: AI1 = V; AI2 = C, AO = C.

Figure 30. DIP switches for analogue inputs and analogue output

5.1.6 Isolating digital inputs from ground

The digital inputs (terminals 8-10 and 14-16) on the standard I/O board can be isolated from ground by setting the

DIP switch

to position ‘0’. The switch in the position “1” means that the common of digital input has been connected to 24 V (negative logic). The switch in the position “2” means that the common of digital inputs has been connected to ground (positive logic). See Figure 31. Locate the switch and set it in desired position. Factory default is 2.

Figure 31. Digital inputs DIP switch

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vacon • 50 Control unit

1 2 3 4

5.1.7 Bus termination of the RS485 connection

This DIP switch is related to the RS485 connection. It is used for bus termination. The bus termination must be set to the first and to the last device on the network. This switch in position “0” means that a termination resistor of 120 ohm is connected and the termination of the bus has been set. This switch in the position “1” means that a pull-up and a pull-down resistors of 10 kOhm have been connected for biasing purpose. The switch in the position “2” means no termination and no biasing resistors have been connected. Factory default is 2. See Figure 32.

In case other termination or biasing values are needed, use the advanced connector. Biasing resistors (for example 390 ohm) can be connected between terminals 1 (+5V) to 2 (RS485_A) and 3 (RS485_B) to 4(GND). Termination resistor (for example 220 ohm) can be connected between terminals 2 (RS485_A) to 3 (RS485_B). When the advanced connector is used, the DIP switch must be set to "2".

Figure 32. RS485 DIP switch and advanced connector

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Control unit vacon • 51

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 30

RS485

terminals

Ethernet connection

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 standard I/O terminals (A and B) and the connection for Ethernet is left to the control terminals. See Figure 33.

Figure 33.

5.2.1 Prepare for use through Ethernet

1 2

For more detailed information, see the user’s manual of the fieldbus you are using.

5.2.1.1 Ethernet cable data

Connect the Ethernet cable (see specification on page 51) to its terminal and run the cable through the conduit plate.

Remount the powerhead. NOTE: When planning the cable runs, remember to keep the distance between the Ethernet cable and the motor cable at a minimum of 30 cm.

Table 26. Ethernet cable data.

Connector

Cable type CAT5e STP Cable length Max. 100m

Shielded RJ45 connector. Note: max length of the connector 40 mm.

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vacon • 52 Control unit

5.2.2 Prepare for use through RS485

Strip about 15 mm of the RS485 cable (see specification on page 53) 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 block and strip the cables at about 5 mm to fit in the terminals. See picture below.

Also strip the cable now at such a distance from the terminal that you can fix it to the frame with the grounding clamp. Strip the cable at a maximum length of 15 mm. Do

not strip the aluminum cable shield!

Then connect the cable to its appropriate terminals on VACON® 100 X AC drive standard terminal block, terminals A and B (A = negative, B = positive). See Figure 33.

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.

If VACON® 100 X AC drive is the last device on the bus, the

bus termination must be set. Locate the DIP switches to the top of the control unit (see Figure 32) and turn the right most switch to position “0”. This setting creates a 120 ohm termination. In case something else is needed and/or biasing is needed, use the advanced connector to add external resistors (see Figure 32). See also step 6.

NOTE: When planning the cable runs, remember to keep the distance between the fieldbus cable and the motor cable at a minimum of 30 cm.

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Control unit vacon • 53

Fieldbus

= Bus termination

Resistor = 120 ohm

Termination

activated

Termination

activated with

DIP switch

Termination

deactivated

Vacon 100X Vacon 100X Vacon 100X Vacon 100X Vacon 100X

The bus termination must be set for the first and the last device of the fieldbus line. See picture below and step 4. We recommend that the first device on the bus and, thus, terminated, was the Master device.

5.2.3 RS485 cable data

Connector

Cable type

Cable length

Table 27. RS485 cable data.

2.5 mm

STP (Shielded Twisted Pair), type Belden 9841 or similar Depends on the used fieldbus. See respective bus manual.

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vacon • 54 Control unit

5.3 Battery installation for Real Time Clock (RTC)

Enabling the functions of the Real Time Clock (RTC) requires that an optional battery is installed in the VACON® 100 X drive.

Detailed information on the functions of the Manual. See the following figures to install the battery on the control box of VACON® 100 X AC drive.

Remove the three screws on the control box as shown in Figure 34.

Real Time Clock (RTC)

can be found in the Application

Figure 34. Remove the three screws on the control box

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Control unit vacon • 55

Rotate and open the cover of the control box as shown in Figure 35.

Figure 35. Open the cover of control box

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vacon • 56 Control unit

Location for battery

Connector for battery

Install the battery in the correct place and connect it to the control box. See Figure 36 for battery location and connector.

Figure 36. Location and connector for the battery on the control box

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Commissioning vacon • 57

6. C

Before commissioning, note the following directions and warnings:

OMMISSIONING

Internal components and circuit boards of VACON® 100 X drive (except for the galvanically isolated I/O terminals) are live when it is connected to the mains potential.

Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.

The motor terminals U, V, W and the brake resistor terminals R-/R+ are live when VACON® 100 X drive is connected to the mains, even if the motor is not running.

The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present

even when VACON® 100 X drive is disconnected from the mains.

Do not make any connections to or from the AC drive when it is connected to the mains.

After disconnecting the AC drive from the mains, wait until the fan stops and the indicators on the powerhead go out. Wait an additional 30 seconds before doing any

work on the connections of VACON® 100 X Drive. Do not open the unit before this time has expired. After expiration of this time, use a measuring equipment to absolutely ensure that no

any electrical work!

voltage is present.

Always ensure absence of voltage before starting

Before connecting the AC drive to mains make sure that the powerhead VACON® 100 X Drive is mounted firmly on the terminal box.

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vacon • 58 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 AC drive and the motor are grounded.

Check that the mains and motor cables comply with the requirements given in chapter 5.

Check that the control cables are located as far as possible from the power cables.

Check that the shields of the shielded cables are connected to protective earth marked with .

Check the tightening torques of all terminals.

Check that the wires do not touch the electrical components of the drive.

Check that the common inputs of digital input groups are connected to +24V or ground of the I/O terminal.

Check the quality and quantity of cooling air.

Check the inside of the AC drive for condensation.

Check that all Start/Stop switches connected to the I/O terminals are in the Stopposition.

Before connecting the AC drive to mains: Check mounting and condition of all fuses and other protective devices.

Run the Startup Wizard (see the Application Manual).

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Commissioning vacon • 59

6.2 Changing EMC protection class

If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC-level T (C4). This is done by removing the EMC screws as described below:

Warning! Do not perform any modifications on the AC drive when it is connected to mains.

Do not remove the EMC screws in the solar pump application. IT (impedancegrounded) AC supply network is not allowed in the solar pump application.

Separate the powerhead and the terminal box. Turn the powerhead upside down and

remove the two screws marked in Figure 37 (for MM4), Figure 38 (for MM5) and in Figure 40(for MM6).

Figure 37. Locations of EMC screws in MM4

Figure 38. Locations of EMC screws in MM5

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vacon • 60 Commissioning

Figure 39. Powerhead separated from the terminal box in MM6

Figure 40.Locations of EMC screws in MM6

CAUTION! Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made.

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Commissioning vacon • 61

Product modified

Date:

EMC-level modified C1->C4

DDMMYY

NOTE! After having performed the change write included in the VACON® 100 X delivery (see below) and note the date. Unless already done, attach the sticker close to the name plate of the AC drive.

6.3 Running the motor

MOTOR RUN CHECK LIST

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 make sure that this can be done safely.

‘EMC level modified’

on the sticker

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

Make sure that the motor terminals are not connected to mains potential.

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 phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1MΩ at ambient temperature of 20°C.

2. Mains cable insulation checks

Disconnect the mains cable from terminals L1, L2 and L3 of the AC drive and from the mains. Measure the insulation resistance of the mains cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1MΩ at ambient temperature of 20°C.

3. Motor insulation checks

Disconnect the motor cable from the motor and open the bridging connections in the motor connection box. Measure the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed 1000 V. The insulation resistance must be >1MΩ at ambient temperature of 20°C.

6.3.2 Motor overload protection

On VACON® 100 X, the motor temperature can be measured with sensors in the motor or be calculated by the electronic motor overload protection. The AC drive provides an input for an external

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vacon • 62 Commissioning

temperature sensor, which must be embedded in the motor. This is a standard feature of VACON® 100 X.

The electronic motor overload protection is based on a temperature model and algorithms to estimate the motor temperature from the operating conditions. The internal electronic motor overload protection implemented in VACON® 100 X has thermal memory retention and speed sensitivity.

According to EN 61800-5-1:2007/A1:2017, the electronic motor overload protection shall comply with

Table 28

Table 28. Multiplier values for current settings

Multiplier Maximum trip time

7.2 (trip at a lower overload could occur) 20 s

1.5 8 min

1.2 2 h

To guarantee a thermal protection in accordance with the standard, set the following parameters for VACON® 100 X.

Table 29. Parameter settings

Index Parameter Description Value

The estimated temperature rise is added to a motor ambient temperature set by the parameter

P3.9.2.6 MotorThermMemoryAdjust

P3.9.2.2 MotAmbientTemp. 0 = Disabled

100

1 = Constant 2 = Last value 3 = Real time clock

The time constant is the time

P3.9.2.4 Motor Thermal Time Const

within which the calculated thermal stage has reached 63% of its

final value

For more parameters related to the motor overload protection, see the Application Manual.

Internal motor overload protection operates at 105% of the motor full load current.

Instruct the AC drives with nominal motor current (full load current according to the motor technical label) in order to use the protection properly.

Parameters other than those previously described may not be changed. If further parameters related to the motor overload protection are changed, the protection function of the motor model can no longer be guaranteed.

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Commissioning vacon • 63

The thermal model cannot protect the motor in the event of incorrect installation or parameter assignment. Follow the instructions for installation and commissioning.

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vacon • 64 Commissioning

6.4 Maintenance

In normal conditions, the AC drive is maintenance-free. However, regular maintenance is recommended to ensure trouble-free operation and longevity of the drive. We recommend the table below is followed for maintenance intervals.

NOTE: Because of capacitor type (thin film capacitors), reforming of capacitors is not necessary.

Maintenance interval Maintenance action

Regularly and according to general maintenance interval

6...24 months (depending on environment)

6...20 years • Change the main fan. 10 years • Replace the battery of the RTC.

• Check the tightening torques of terminals.

• Check the input and output terminals and the control I/O terminals.

• Check the operation of the cooling fan.

• Clean the fan and the fan housing if necessary.

• Check the heatsink for dust, and clean it if necessary.

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Technical data vacon • 65

7. T

ECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

Table 30. Power ratings of VACON® 100 X, supply voltage 3AC 208-240V.

Mains voltage 3AC 208-240V, 50/60 Hz

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

0006 6.0 6.6 9.9 13.2 1.1 1.5 0008 7.2 8.0 12.0 16.0 1.5 2.0 0011 9.7 11.0 16.5 22.0 2.2 3.0

MM4

0012 10.9 12.5 18.8 25.0 3.0 4.0 0018 16.1 18.0 27.0 36.0 4.0 5.0

Loadability

50% overload

current

[A]

Max current

Motor shaft power

230V supply

[kW] [HP]

0024 21.7 24.2 36.3 48.4 5.5 7.5

MM5

0031 27.7 31.0 46.5 62.0 7.5 10.0 0048 43.8 48.0 72.0 96.0 11.0 15.0

0062 57.0 62.0 93.0 124.0 15.0 20.0

MM6

NOTE: The rated currents in given ambient temperatures (in Table 30) are achieved only when the

switching frequency is equal to or less than the factory default.

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vacon • 66 Technical data

7.1.2 Mains voltage 3AC 380-480/500V

Table 31. Power ratings of VACON® 100 X, supply voltage 3AC 380-480/500V, high overload.

Mains voltage 3AC 380-480/500V, 50/60 Hz

Motor shaft power

Loadability

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

50% overload

current

[A]

Max current

400V 480V

[kW] [HP]

0003 3.4 3.4 5.1 6.8 1.1 1.5 0004 4.6 4.8 7.2 9.6 1.5 2.0 0005 5.4 5.6 8.4 11.2 2.2 3.0 0008 8.1 8.0 12.0 16.0 3.0 5.0

MM4

0009 9.3 9.6 14.4 19.2 4.0 5.0 0012 11.3 12.0 18.0 24.0 5.5 7.5 0016 15.4 16.0 24.0 32.0 7.5 10.0 0023 21.3 23.0 34.5 46.0 11.0 15.0

MM5

0031 28.4 31.0 46.5 62.0 15.0 20.0 0038 36.7 38.0 57.0 76.0 18.5 25.0 0046 43.6 46.0 69.0 92.0 22.0 30.0

MM6

0061 58,2 61.0 91.5 122.0 30.0 40.0

Table 32. Power ratings of VACON® 100 X, supply voltage 3AC 380-480/500V, low overload.

Mains voltage 3AC 380-480/500V, 50/60 Hz

Motor shaft power

Loadability

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

10% overload

current

[A]

Max current

400V 480V

[kW] [HP]

0072 67.5 72.0 80.0 108.0 37.0 50.0

MM6

NOTE: The rated currents in given ambient temperatures (in Table 31 and Table 32) are achieved

only when the switching frequency is equal to or less than the factory default.

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Technical data vacon • 67

N*150%

1 min 9 min

N*150%

Current

Time

N*110%

1 min 9 min

N*110%

Current

Time

7.1.3 Definitions of overloadability

High overload

Example: If the duty cycle requires 150% rated current for 1 min in every 10 min, the remaining 9 min

= Following continuous operation at rated output current IN, the drive supplies 150% * IN for

1 min, followed by a period of at least 9 min at IN or below.

must be at rated current IN or less.

Figure 41. High overload

Low overload

Example: If the duty cycle requires 110% rated current for 1 min in every 10 min, the remaining 9 min

NOTE! For more information, refer to IEC61800-2 (IEC:1998) Standard.

= Following continuous operation at rated output current IN, the drive supplies 110% * IN for

1 min, followed by a period of at least 9 min at IN or below.

must be at rated current IN or less.

Figure 42. Low overload

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vacon • 68 Technical data

7.2 Brake resistor ratings

Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application.

Recommended minimum brake resistor values for VACON® 100 X AC drives:

Table 33. Brake resistor ratings, 208-240V.

Mains Voltage 3AC 208-240V, 50/60 Hz

Enclosure

size

MM4

MM5

MM6

Enclosure

size

Type

Minimum Resistance

recommended

[ohm]

Brake power @405

[kW]

0006 25 6.6 0008 25 6.6 0011 25 6.6 0012 25 6.6 0018 15 10.9 0024 15 10.9 0031 10 16.4 0048 8 20.5 0062 8 20.5

Table 34. Brake resistor ratings, 380-480/500V.

Mains Voltage 3AC 380-480/500V, 50/60 Hz

Type

Minimum Resistance

recommended

Brake power @845

[ohm]

VDC

[kW]

MM4

MM5

MM6

0003 50 14.3 0004 50 14.3 0005 50 14.3 0008 50 14.3 0009 50 14.3 0012 50 14.3 0016 30 23.8 0023 30 23.8 0031 20 35.7 0038 15 47.6 0046 15 47.6 0061 15 47.6 0072 15 47.6

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Technical data vacon • 69

7.3 VACON® 100 X - technical data

Table 35. VACON® 100 X technical data.

3 AC 208…240 V

Input voltage U

3 AC 380...480 V 3 AC 380...500 V

Mains connection

DC connection

Input voltage tolerance

-15%...+10%

Input frequency 50/60 Hz Protection class I Input frequency

tolerance

47.5...66 Hz

Connection to mains Once per minute or less Starting delay <7 s

Supply network

Short-circuit current

TN- and IT-network (cannot be used with corner earthed network)

Max. short-circuit current has to be < 100 kA (with optional mains switch < 5 kA)

234 … 400 VDC 436 … 800 VDC

Input Voltage UDC:

Input voltage tolerance: No tolerance permissible, 0%

Output voltage

Rated output current

3 AC 0... U

IN: Ambient temperature max. +40°C. See Table 30, Table 31 and Table 32.

Motor connection

Overload output current

1.1 x IN (1 min/10 min) only for MM6 0072. See Table 30, Table 31 and Table 32.

1.5 x IN (1 min/10 min);

Starting output current

IS for 2 s every 20 s.

See Table 30, Table 31 and Table 32. Output frequency 0…320 Hz (standard) Frequency resolution 0.01 Hz Protection class I

AC squirrel cage motors Motor characteristics

Permanent magnet motors

Synchronous Reluctance Motors Cable type Screened motor cable Cable maximum length

(full EMC compliance)

C2: 5 m

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vacon • 70 Technical data

Table 35. VACON® 100 X technical data.

Programmable 1.5…16 kHz; Switching frequency

Default: 6 kHz (MM4 and MM5); 4 kHz (MM6)

Automatic switching frequency derating in case of

overheating Frequency reference

Control characteristics

Analogue input Panel reference

Resolution 0.1% (10-bit), accuracy ±1%

Resolution 0.01 Hz Field weakening point 8…320 Hz Acceleration time 0.1…3000 s Deceleration time 0.1…3000 s

Brake chopper standard in all frames

External brake resistor optional

Control connections

Braking

See chapter 5.

Standard: Serial communication (RS485/Mod-

bus); EtherNet/IP, PROFINET IO, Modbus TCP,

Communication

Fieldbus

interface

Status indicators

Ambient operating temperature

Extended temperature range

BACnet IP

Optional: CANOpen; PROFIBUS DP, DeviceNet,

LonWorks, AS-interface

Drive status indicators (LED) on top side (POWER,

RUN, FAULT, READY)

-10°C …+40°C

up to 60°C with current derating (see chapter 1.8)

Storage temperature -40°C…+70°C

Ambient conditions

Noise Level

Relative humidity

0 to 100% R

PD2 used for PCB design.

Pollution degree

However the drives are suitable for outdoor use

because of dust-tight enclosure to numeral 6

[acc. to IEC 60529].

Altitude

Stationary vibration: sinusoidal

Shock/Bump

100% load capacity (no derating) up to 1,000m;

derating 1%/100m at 1,000...3,000m

3 Hz ≤ f ≤ 8.72 Hz: 10 mm

8.72 Hz ≤ f ≤ 200 Hz: 3g

[3M7 acc. to IEC 60721-3-3]

25g / 6 ms

[3M7 acc. to IEC 60721-3-3] Degree of protection IP66/Type 4X

The sound pressure depends on the cooling fan

Average noise level (min-max) in dB (A)

speed, which is controlled in accordance with the

drive temperature.

MM4: 45-56

MM5: 57-65

MM6: 63-72

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Technical data vacon • 71

Table 35. VACON® 100 X technical data.

EMC 2014/30/EU

Directives

Low Voltage Directive 2014/35/EU RoHS 2011/65/EU, amended 2015/863/EU WEEE 2012/19/EU

Immunity

Standards

Emissions

THD EN61000-3-12 (see chapter 1.9) Safety EN 61800-5-1

Production quality ISO 9001

Functional Safety TÜV - Tested Electrical Safety TÜV - Tested

Approvals

EMC TÜV - Tested USA, Canada cULus approval, file number E171278 Korea KC mark

Declaration of Conformity

Australia

Europe EC Declaration of Conformity

Undervoltage trip limit

EN61800-3, 1st and 2nd environment

EN61800-3, Category C2

The drive can be modified for IT-networks.

RCM Declaration of Conformity

Registration number E2204

Depends on supply voltage (0.8775*supply volt-

age):

Supply voltage 240 V: Trip limit 211 V

Supply voltage 400 V: Trip limit 351 V

Supply voltage 480 V: Trip limit 421 V

Protections

Overvoltage fault protection

Yes

Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature

protection Motor overload protec-

tion

Yes

Yes. These devices provide motor overload protec-

tion at 105% of full load amperes. Motor stall protection Yes Motor underload protec-

tion

Yes

Short-circuit protection of +24V and +10V refer-

Yes ence voltages

Thermal motor protection

DC-link absolute maximum voltage

Yes (by PTC)

Supply voltage 240 V: absolute maximum 450 VDC

Supply voltage 400 V: 900 V

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vacon • 72 Technical data

7.3.1 Technical information on control connections

Table 36. Technical information on standard I/O terminals.

Standard I/O

Terminal Signal Technical information

1 Reference output +10V, +3%; Maximum current 10 mA

Analogue input channel 1 0-20 mA (Ri =250 Ω)

Analogue input,

voltage or current

Analogue input common

Analogue input,

voltage or current

Analogue input common

24V aux. voltage

I/O ground

Digital input 1

Digital input 2

14 15 16

30 24V auxiliary input voltage

Digital input 3

Common A for DIN1-DIN6.

24V aux. voltage Same as terminal 6.

I/O ground

Digital input 4

Digital input 5

Digital input 6

Common A for DIN1-DIN6.

Analogue output, voltage or current

Analogue output common

0-10 V (Ri=200kΩ) Resolution 0.1%, accuracy ±1% Selection V/mA with DIP switches (see chapter 5). Default 0-10V Short-circuited protected.

Differential input if not connected to ground; Allows ±20V differential mode voltage to GND

Analogue input channel 2 0-20 mA (Ri =250 Ω) 0-10 V (Ri=200kΩ) Resolution 0.1%, accuracy ±1%

Selection V/mA with DIP switches (see chapter 5). Default 0-20mA Short-circuited protected.

Differential input if not connected to ground; Allows 20V differential mode voltage to GND

+24V, ±10%, max volt. ripple < 100mVrms; max. 250mA Short-circuit protected

Ground for reference and controls (connected internally to frame earth through 1MΩ)

Positive or negative logic Ri = min. 5k 18…30V = "1"

0...5V = “0” Digital inputs can be isolated from ground, see chapter 5.

Default: connected to ground.

Ground for reference and controls (connected internally to frame earth through 1MΩ)

Positive or negative logic Ri = min. 5k 18…30V = "1"

0...5V = “0” Digital inputs can be isolated from ground, see chapter 5.

Default: connected to ground. Analogue output channel 1

0-20 mA (RL<500 Ω) 0-10 V (RL>1kΩ)

Resolution 0.1%, accuracy ±2% Selection V/mA with DIP switches (see chapter 5). Default 0-20mA Short-circuited protected.

Can be used with an external power supply (with a current limiter or fuse protected) to supply the control unit and fieldbus for backup purposes. Dimensioning: max. 1000mA/control unit.

Ω

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Technical data vacon • 73

Table 36. Technical information on standard I/O terminals.

Standard I/O

Terminal Signal Technical information

A RS485 Differential receiver/transmitter

B RS485

Table 37. Technical information on Relay and thermistor terminals.

Set bus termination with DIP switches (see page 49). Default: but termination disconnected.

Relays

Terminal Signal Technical information

21 22 23 24 25 26

Relays with two change-over contact (SPDT) and a PTC thermistor input.

5.5 mm isolation between channels.

Switching capacity 24VDC/8A

Relay output 1

Relay output 2*

Min.switching load 5V/10mA

Switching capacity 24VDC/8A

Min.switching load 5V/10mA

250VAC/8A 125VDC/0.4A

Thermistor input

Rtrip = 4.7 kΩ (PTC); Measuring voltage 3.5V

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 current and overvoltage spikes. This is to prevent welding on the relay contacts. Refer to standard EN 60204-1, section 7.2.9

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vacon • 74 Options

8. O

The options available for VACON® 100 X are described below.

PTIONS

8.1 Mains switch

The mains switch can be used for service or urgency stop. The purpose of the mains switch is to disconnect the VACON® 100 X from the mains when, for example, service actions are needed. The mains switch color is red/yellow. The mains switch is available as option and it can be integrated in the drive. The mains switch can be mounted on either side of the drive. See Figure 43.

Figure 43. The mains switch mounted on either side of the drive, MM4 example

NOTE! If the cULus mark is required, the use of the optional mains switch is not allowed with the models 0062-2, 0061-4, 0061-5, 0072-4, and 0072-5, unless current derating is applied. The input current cannot exceed 52 A at 30°C ambient temperature and 45 A at 40°C ambient temperature.

NOTE! Mains switch only for AC voltage. Do not use for DC voltage. NOTE! Braided cable types recommended for mains switch cabling.

Table 38. Order codes for VACON® 100 X Mains Switch

Order code Description Option type

POW-QDSS-MM04 POW-QDSS-MM05 POW-QDSS-MM06

VACON®100 X MM4 Mains Switch Option VACON®100 X MM5 Mains Switch Option VACON®100 X MM6 Mains Switch Option

Loose Option Loose Option Loose Option

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Options vacon • 75

8.1.1 Installation

• Remove the cable entry plate from the drive on the left-hand-side if the mains

switch must be mounted on this side. Otherwise remove the cable entry plate from the right-hand-side. See the Figure 44.

Figure 44. Disconnect the cable entry plate: example for MM5

• Remove the cable entry plate from the bottom side of the terminal box by loosing the six screws. Cables pass through this inlet hole.

Figure 45. Cable entry plate from the bottom side of the drive

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vacon • 76 Options

• Remove the powerhead from the terminal box by loosing the screws on the top side of the drive.

Figure 46. Powerhead separated from the terminal box

• Connect the supply cable to the Mains switch passing through the cable entry plate of the bottom side (use the cable gland for sealing the cable to the gland plate) and then through the terminal box as shown in the figure below.

Figure 47. Connection of the supply cable to the Mains switch (right-hand-side example)

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Options vacon • 77

5 6 7

• Connect the cables from the Mains switch to the terminal box. The cables have to be connected to the terminals L1, L2 and L3.

• Place the Mains switch plate with the cables in the groove and fix it with its screws.

• Place the cable entry plate with the other cables (motor cable, brake cable, I/O cables) in the groove on the bottom side of the drive and fix it with its screws.

Figure 48. Mains switch, cable entry and cables connected

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• Mount the powerhead on the terminal box with its screws: the installation process has been completed. See Figure 49.

vacon • 78 Options

Figure 49. Mount the powerhead on the terminal box

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Options vacon • 79

8.2 Control Keypad

The control keypad is the interface between the VACON® 100 X AC drive and the user. With the control keypad it is possible to control the speed of a motor, to supervise the state of the equipment and to set the AC drive's parameters.

The keypad is an option and can be delivered separately. The option includes the keypad, the keypad holder and three screws. You can use one screw to fix the keypad holder to the drive or three screws to fix the keypad holder to an enclosure/cabinet or any special housing for the drive in which you want to have a remote keypad control available.

Table 39. Keypad order codes

Order code Description Type of option

PAN-HMWM-MK02 Keypad Wallmounting Kit Loose Option CAB-HMI2M-MC05-X MC05 HMI cable l=2m for -X keypads Option Loose Option CAB-HMI5M-MC05-X MC05 HMI cable l=5m for -X keypads Option Loose Option

8.2.1 Mounting onto the drive

Figure 50. Drive and the optional keypad kit

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vacon • 80 Options

8.2.2 Installation

• Remove the HMI cap from the drive as shown in the Figure 51.

Figure 51. Disconnection of the HMI cap from the drive

• Install the keypad holder with a screw as shown in the Figure 52. The metal sheets of the keypad holder have to be mounted under the fan holder as shown in the following figures.

Figure 52. Installation of the keypad holder on the powerhead

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Options vacon • 81

• Connect the keypad to the drive and plug the cable on the HMI connector as shown in the Figure 53 and in the Figure 54.

Figure 53. Mounting of the keypad

Figure 54. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector (to

0.5 Nm or 4.5 lb-in) to the enclosure of the drive. This is to keep the high IP66 protection degree of the drive.

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vacon • 82 Options

8.2.3 Wall-mounting

The keypad can be mounted on the wall in a convenient location by using the same keypad holder and three screws provided with the keypad option kit.

•

Fix the keypad holder with three screws to the wall.

Figure 55. Fix the keypad holder with three screws to the wall

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Options vacon • 83

11863_00

Figure 56. Display holder dimensions for wall-mounting

• Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall.

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vacon • 84 Options

Figure 57. Keypad connected to the drive

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Options vacon • 85

9086.emf

FUNCT

Scroll menu up Increase value

Scroll menu down Decrease value

Move cursor left Move cursor right

Move backward in menu Exit edit mode Reset faults with long press

Change control place

Access control page Change direction

Stop button Start button

Enter active level/item Confirm selection

8.2.4 Graphical and Text keypad

There are two keypad types you can choose for your user interface: keypad with graphical display and keypad with text segment display (text keypad).

The button section of the keypad is identical for both keypad types.

Figure 58. Keypad buttons

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vacon • 86 Options

Location field

Status field

(Parameter ID number

Main Menu

Quick Setup

( 17 )

Parameters

( 12 )



STOP READY I/O

ID: M1

( 5 )

Monitor



Activated group/item. Press OK to enter.

Number of items in the group

STOP/RUN

Status field READY/NOT READY/FAULT

Control place: PC/IO/KEYPAD/FIELDBUS

ALARM

and current menu location)

Direction

8.2.5 VACON® keypad with graphical display

The graphical keypad features an LCD display and 9 buttons.

8.2.5.1 Keypad display

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 sees information about

his present

location in the menu

structure and the item displayed.

8.2.5.2 Main menu The data on the control keypad are arranged in menus and submenus. Use the Up and Down arrows

to move between the menus. Enter the group/item by pressing the OK button and

return

to the for-

mer level by pressing the Back/Reset button. The

Location field

indicates your current location. The

Status field

gives information about the

present status of the drive. See Figure 59.

Figure 59. Main menu

8.2.5.3 Using the graphical keypad

Editing values

The selectable values can be accessed and edited in two different ways on the graphical keypad.

Parameters with one valid value

Typically, one parameter is set one value. The value is selected either from a list of values (see example below) or the parameter is given a numerical value from a defined range (e.g. 0.00...50.00 Hz).

Change value of a parameter following the procedure below:

1. Locate the parameter.

2. Enter the

3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the arrow buttons left/right if the value is numerical and then change the value with the arrow buttons up/down.

Edit

4. Confirm change with OK button or ignore change by returning to previous level with Back/ Reset button.

mode.

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Options vacon • 87



Start/Stop Setup

Rem Control Place

I/O Control

KeypadStopButton

Yes

Start Function

Ramping

STOP READY I/O

ID:172 M3.2.1



Edit

Help

Add to favorites

Rem Control Place

STOP READY I/O

ID: M3.2.1



Rem Control Place

STOP READY I/O

M3.2.1

I/O Control

FieldbusCTRL



Start/Stop Setup

Rem Control Place

I/O Control

KeypadStopButton

Yes

Start Function

Ramping

STOP REA DY I/O

ID:172 M3.2.1



Rem Control Place

STOP READY I/O

M3.2.1

I/O Control

FieldbusCTRL

OR:

OKOKOK

BACK

RESET

9257.emf

9256.emf

...

O K

Symbol for checkbox selection

Figure 60. Typical editing of values on graphical keypad (text value)

Figure 61. Typical editing of values on graphical keypad (numerical value)

Parameters with checkbox selection

Some parameters allow selecting several values. Make a checkbox selection at each value you wish to activate as instructed below.

Figure 62. Applying the checkbox value selection on graphical keypad

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vacon • 88 Options

Resetting fault

Instructions for how to reset a fault can be found in chapter 8.2.7.

Function button

The FUNCT button is used for four functions:

1. to quickly access the Control page,

2. to easily change between the Local (Keypad) and Remote control places,

3. to change the rotation direction and

4. to quickly edit a parameter value.

Control places

The

control place

place has its own parameter for selecting the frequency reference source. The is always the keypad. The

is the source of control where the drive can be started and stopped. Every control

Local control place

Remote control place

is determined by parameter P3.2.1 (I/O or Field-

bus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O A, I/O B and Fieldbus can be used as remote control places. I/O A and Fieldbus have the lowest priority and can be chosen with parameter P3.2.1

(Rem Control Place)

. I/O B, again, can bypass the remote control place selected with parameter P3.2.1 using a digital input. The digital input is selected with parameter P3.5.1.7

(I/O B Ctrl Force)

Local control

Keypad is always used as control place while in local control. Local control has higher priority than remote control. Therefore, if, for example, bypassed by parameter P3.5.1.7 through digital input while in

Remote

, the control place will still switch to Keypad if

Local

is selected. Switching between Local and Remote Control can be done by pressing the FUNCT-button on the keypad or by using the "Local/Remote" (ID211) parameter.

Changing control places

Change of control place from

1. Anywhere in the menu structure, push the

2. Push the

Arrow up

or the

Remote

Arrow down

Local

(keypad).

FUNCT

button.

button to select

Local/Remote

and confirm with the OK

button.

3. On the next display, select

4. The display will return to the same location as it was when the

Local

Remote

and again confirm with the OK button.

FUNCT

button was pushed. However, if the Remote control place was changed to Local (Keypad) you will be prompted for keypad reference.

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Options vacon • 89

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY Keypad

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

STOP Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

Remote

ID:

Local/Remote

STOP READY Keypad

ID:211

Remote

Local

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

FUNCT

O K

9161.emf

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

STOP Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

STOP READY Keypad

( 6 )

Keypad Reference

0.00 Hz

Output Frequ ency

0.00Hz

Motor Curren t

0.00A

Motor Torque

0.00%

Motor Power

ID:184

Keypad

0.00 Hz

Output Frequ ency

0.00Hz

Motor Curren t

0.00A

Motor Torque

0.00%

Motor Power

STOP READY Keypad

( 6 )

ID:168

Keypad Reference

0.00 Hz

Output Frequ ency

0.00Hz

Motor Curren t

0.00A

Motor Torque

0.00%

Motor Power

FUNCT

O K

9162.emf

Figure 63. Changing control places

Accessing the control page

The

Control page

is meant for easy operation and monitoring of the most essential values.

1. Anywhere in the menu structure, push the

2. Push the

Arrow up

or the

Arrow down

FUNCT

button.

button to select

Control page

and confirm with the OK

button.

3. The control page appears If keypad control place and keypad reference are selected to be used you can set the

Reference

after having pressed the OK button. If other control places or reference values are

Keypad

used the display will show Frequency reference which is not editable. The other values on the page are Multimonitoring values. You can choose which values appear here for monitoring.

Figure 64. Accessing Control page

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vacon • 90 Options

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

RUN Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

ID:

Choose action

RUN Ready Keypad

ID:1805

Forward

Reverse

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

FUNCT

O K O K

9163.ai

Changing direction

Rotation direction of the motor can quickly be changed by applying the FUNCT button.

ing direction

command is not visible in the menu unless the selected control place is

NOTE!

Local

Chang-

1. Anywhere in the menu structure, push the Funct button.

2. Push the Arrow up or the Arrow down button to select Change direction and confirm with the OK button.

3. Then choose the direction you wish to run the motor to. The actual rotation direction is blinking. Confirm with the OK button.

4. The rotation direction changes immediately and the arrow indication in the status field changes.

Figure 65. Changing direction

Quick edit

Through the parameter’s ID number.

1. Anywhere in the menu structure, push the FUNCT button.

2. Push the Arrow up or the Arrow down buttons to select Quick Edit and confirm with the OK button.

3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK button to confirm.

4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.)

Quick edit

functionality you can quickly access the desired parameter by entering the

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Options vacon • 91

STOP READY Keypad

 



Application selection

HVAC

User settings

Drive name

Drive

Parameter backup

( 3 )

ID: M6.5

STOP READY Keypad



Restore factory defaults

Parameter backup

Restore from keypad

Save to keypad

ID: M6.5.1

STOP READY Keypad

  

 



I/O and Hardware

( 8 )

Main Menu

Favourites

( 0 )

User settings

( 4 )

ID: M6

OK OK

Copying parameters NOTE: This feature is available with graphical keypad only.

The parameter copy function can be used to copy parameters from one drive to another. The parameters are first saved to the keypad, then the keypad is detached and connected to another

drive. Finally the parameters are downloaded to the new drive restoring them from the keypad. Before any parameters can successfully be copied from one drive to another the drive has to be

stopped when the parameters are downloaded.

• First go into

eter backup

•

Restore factory defaults

User settings

menu and locate the

Parameter backup

submenu. In the

submenu, there are three possible functions to be selected:

will re-establish the parameter settings originally made at the fac-

Param-

tory.

• By selecting

•

Restore from keypad

Figure 66. Parameter copy

Save to keypad

will copy all parameters from keypad to a drive.

you can copy all parameters to the keypad.

NOTE: If the keypad is changed between drives of different sizes, the copied values of these parameters will not be used:

Motor nominal current (P3.1.1.4) Motor nominal voltage (P3.1.1.1) Motor nominal speed (P3.1.1.3) Motor nominal power (P3.1.1.6) Motor nominal frequency (P3.1.1.2) Motor cos phi (P3.1.1.5) Switching frequency (P3.1.2.3) Motor current limit (P3.1.3.1) Stall current limit (P3.9.3.2) Stall time limit (P3.9.3.3) Stall frequency (P3.9.3.4) Maximum frequency (P3.3.1.2)

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vacon • 92 Options

( 6 )



Digital Inputs

Ctrl Signal 1 A

Ctrl Signal 1 B

STOP READY I/O

ID:403 M3.5.1.1

Ctrl Signal 2 A

( 6 )



Add to favorites

STOP READY I/O

ID:403 M3.5.1.1

Ctrl signal 1 A

Edit

Help

Start Signal 1 for control Place I/O A. Start Signal 1 functionality chosen with I/O A Logic in Start/Stop Setup Menu.

STOP READY I/O

Ctrl signal 1 A

ID:403 M3. 5.1.1



Basic Settings

Motor Nom Voltg

230.00 V

Motor Nom Speed

1430 rpm

STOP REA DY I/O

Motor Nom Freq

50.00 Hz

Edit

Help

Motor Nom Freq

STOP RE ADY I/O

Add to favorites

Motor Nom Freq

was added to favorites. Press OK to continue.

STOP RE ADY I/O

Help texts

The graphical keypad features instant help and information displays for various items. All parameters offer an instant help display. Select Help and press the OK button. Text information is also available for faults, alarms and the startup wizard.

Figure 67. Help text example

Adding item to favourites

You might need to refer to certain parameter values or other items often. Instead of locating them one by one in the menu structure, you may want to add them to a folder called

Favorites

where they

can easily be reached. To add an item to the Favorites.

Figure 68. Adding item to Favorites

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Options vacon • 93

Indicators:

Status

Indicators:

Alarm, Fault

Indicators:

Direction

Indicators:

Control place

Group or parameter name

Menu location

8.2.6 VACON® keypad with text segment display

You can also choose a

Keypad with text segment display

(Text keypad) for your user interface. It has mainly the same functionalities as the keypad with graphical display although some of these are somewhat limited.

8.2.6.1 Keypad display

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 sees information about

his present

location in the menu structure and the item displayed. If the text on the text line is too long to fit in the display, the text will scroll from left to right to reveal the whole text string.

8.2.6.2 Main menu The data on the control keypad are arranged in menus and submenus. Use the Up and Down arrows

to move between the menus. Enter the group/item by pressing the OK button and

return

to the for-

mer level by pressing the Back/Reset button.

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vacon • 94 Options

BACK

RESET

8.2.6.3 Using the keypad

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/right if the value is numerical and change then the value with the arrow buttons up/down.

4. Confirm change with OK button or ignore change by returning to previous level with Back/

Reset button.

Figure 69. Editing values

Resetting fault

Instructions for how to reset a fault can be found in chapter 8.2.7.

Function button

The FUNCT button is used for four functions:

1. to quickly access the Control page,

2. to easily change between the Local (Keypad) and Remote control places,

3. to change the rotation direction and

4. to quickly edit a parameter value.

Control places

The

control place

place has its own parameter for selecting the frequency reference source. The is always the keypad. The

is the source of control where the drive can be started and stopped. Every control

Local control place

Remote control place

is determined by parameter P3.2.1 (I/O or Field-

bus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O A, I/O B and Fieldbus can be used as remote control places. I/O A and Fieldbus have the lowest priority and can be chosen with parameter P3.2.1

(Rem Control Place)

. I/O B, again, can bypass the remote control place selected with parameter P3.2.1 using a digital input. The digital input is selected with parameter P3.5.1.7

(I/O B Ctrl Force)

Local control

Remote

, the control place will still switch to Keypad if

Local

is selected. Switching between Local and Remote Control can be done by pressing the FUNCT-button on the keypad or by using the "Local/Remote" (ID211) parameter.

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Options vacon • 95

FUNCT

OK OK

9169.emf

9170.emf

FUNCT

O K

Changing control places

Change of control place from

Remote

Local

(keypad).

1. Anywhere in the menu structure, push the FUNCT button.

2. Using the arrow buttons, select Local/Remote and confirm with the OK button.

3. On the next display, select Local or Remote and again confirm with the OK button.

4. The display will return to the same location as it was when the

FUNCT

button was pushed. However, if the Remote control place was changed to Local (Keypad) you will be prompted for keypad reference.

Figure 70. Changing control places

Accessing the control page

The

Control page

is meant for easy operation and monitoring of the most essential values.

1. Anywhere in the menu structure, push the

2. Push the

Arrow up

or the

Arrow down

FUNCT

button.

button to select

Control page

and confirm with the OK

button.

3. The control page appears If keypad control place and keypad reference are selected to be used you can set the

Reference

after having pressed the OK button. If other control places or reference values are

used the display will show Frequency reference which is not editable.

Figure 71. Accessing Control page

Keypad

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vacon • 96 Options

Changing direction

Rotation direction of the motor can quickly be changed by applying the FUNCT button.

ing direction

command is not visible in the menu unless the selected control place is

NOTE!

Local

Chang-

1. Anywhere in the menu structure, push the Funct button.

2. Push the Arrow up or the Arrow down button to select Change direction and confirm with the OK button.

3. Then choose the direction you wish to run the motor to. The actual rotation direction is blinking. Confirm with the OK button.

4. The rotation direction changes immediately and the arrow indication in the status field changes.

Quick edit

Through the

Quick edit

functionality you can quickly access the desired parameter by entering the

parameter’s ID number.

1. Anywhere in the menu structure, push the FUNCT button.

2. Push the Arrow up or the Arrow down buttons to select Quick Edit and confirm with the OK button.

3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK button to confirm.

4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.)

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Options vacon • 97

Main Menu

( 5 )

Monitor



Parameters

( 12 )



Diagnostics

( 6 )



ID: M4

STOP READY I/O



Diagnostics

Active faults

( 0 )

Fault history

( 39 )

ID: M4.1

STOP READY I/O

Reset faults



Reset faults

Help

ID: M4.2

STOP READY I/O

8.2.7 Fault Tracing

When an unusual operating condition is detected by the AC drive control diagnostics, the drive initiates a notification visible, for example, on the keypad. The keypad will show the code, the name and a short description of the fault or alarm.

The notifications vary in consequence and required action. reset of the drive. ning.

Info

may require resetting but do not affect the functioning of the drive.

Alarms

inform of unusual operating conditions but the drive will continue run-

Faults

make the drive stop and require

For some faults you can program different responses in the application. See parameter group Protections.

The fault can be reset with the

Reset button

on the control keypad or via the I/O terminal. The faults are stored in the Fault history menu which can be browsed. The different fault codes you will find in the table below.

NOTE: When contacting distributor or factory because of a fault condition, always write down all texts and codes on the keypad display.

Fault appears

When a fault appears and the drive stops, examine the cause of fault, perform the actions advised here and reset the fault as instructed below.

1. With a long (1 s) press on the

2. By entering the

Diagnostics

Reset

button on the keypad or

Menu (M4), entering

Reset faults

(M4.2) and selecting

Reset faults

parameter.

3. For keypad with LCD display only: By selecting value

Yes

for the parameter and clicking OK.

Figure 72. Diagnostic menu with graphical keypad

Figure 73. Diagnostic menu with text keypad

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 98 Options



Diagnostics

Active faults

( 0 )

Reset faults

Fault history

( 39 )

ID: M4.1

STOP READY I/O



 



Fault history

External Fault

Fault old

891384s

External Fault

Fault old

871061s

Device removed

Info old

862537s

ID:

STOP READY I/O



Device removed

ID: M4.3.3.2

Code 39

ID 380

State Info old

Date 7.12.2009

Time 04:46:33

Operating time 862537s

STOP READY I/O

8.2.7.1 Fault History

In menu M4.3 Fault history you find the maximum number of 40 occurred faults. On each fault in the memory you will also find additional information, see below.

Figure 74. Fault history menu with graphical keypad

Figure 75. Fault history menu with text keypad

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Options vacon • 99

8.2.7.2 Fault codes

Table 40. Fault codes and descriptions.

Fault

code

5 40

7 60

Fault

Fault name Possible cause Remedy

Overcurrent (hardware fault)

Overcurrent (software fault)

Overvoltage (hardware fault)

Overvoltage (software fault)

Earth fault (hardware fault)

Earth fault (software fault)

Charging switch

Saturation

AC drive has detected too high a current (>4*IH) in the motor cable:

• sudden heavy load increase

• short circuit in motor cables

• unsuitable motor

The DC-link voltage has exceeded the limits defined.

• too short a deceleration time

• brake chopper is disabled

• high overvoltage spikes in supply

• Start/Stop sequence too fast

Current measurement has detected that the sum of motor phase current is not zero.

• insulation failure in cables or motor

The charging switch is open, when the START command has been given.

• faulty operation

• component failure

Various causes:

• defective component

• brake resistor short-circuit or overload

Check loading. Check motor. Check cables and connections. Make identification run. Check ramp times.

Make deceleration time longer. Use brake chopper or brake resistor (available as options). Activate overvoltage controller. Check input voltage.

Check motor cables and motor.

Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.

Cannot be reset from keypad. Switch off power. DO NOT RE-CONNECT POWER! Contact factory. If this fault appears simultaneously with F1, check motor cables and motor.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

vacon • 100 Options

Table 40. Fault codes and descriptions.

Fault

code

Fault

600

601

602

603

604

605

606

607

608

609

610

Fault name Possible cause Remedy

Communication between control board and power unit has failed.

Communication between control board and power unit has interference, but it is still working.

Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.

Update software. Should the fault re-occur, contact the distributor near to you.

Update power unit software. Should the fault re-occur, contact the distributor near to you.

Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.

System fault

Watchdog has reset the CPU

Voltage of auxiliary power in power unit is too low.

Phase fault: Voltage of an output phase does not follow the reference

CPLD has faulted but there is no detailed information about the fault

Control and power unit software are incompatible

Software version cannot be read. There is no software in power unit.

CPU overload. Some part of the software (for example application) has caused an overload situation. The source of fault has been suspended

Memory access has failed. For example, retain variables could not be restored.

Necessary device properties cannot be read.

614

647

648

649

10 91

Configuration error.

Software error

Invalid function block used in application. System software and application are not compatible.

Resource overload. Error when loading parameter initial values. Error when restoring parameters. Error when saving parameters.

Undervoltage (fault)

DC-link voltage is under the voltage limits defined.

• most probable cause: too low a supply voltage

• AC drive internal fault

Undervoltage (alarm)

• defect input fuse

• external charge switch not closed

NOTE!

This fault is activated only if the

drive is in Run state.

Input phase Input line phase is missing.

Update software. Should the fault re-occur, contact the distributor near to you.

In case of temporary supply voltage break reset the fault and restart the AC drive. Check the supply voltage. If it is adequate, an internal failure has occurred. Contact the distributor near to you.

Check supply voltage, fuses and cable.

Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/

Danfoss vacon 100 x Installation guide

Specifications and Main Features

Frequently Asked Questions

User Manual

vacon • 6 Safety

1.1 Signs

1.2 Units

1.3 Danger

1.4 Warnings

1.5 Grounding and earth fault protection

1.6 Insulation system

1.7 Compatibility with RCDs

1.8 Extended temperature range

1.9 Electro-magnetic compatibility (EMC)

1.10 Marine environment

Receiving the delivery vacon • 15

2.1 Type designation code

2.2 order codes

2.3 Unpacking and lifting the AC drive

2.4 Accessories

2.4.1 Enclosure MM4

2.4.2 Enclosure MM5

2.4.3 Enclosure MM6

2.4.4 STO terminal connector

2.4.5 ‘Product modified’ sticker

2.4.6 Disposal

Mounting vacon • 21

3.1 Dimensions MM4

3.2 Dimensions MM5

3.3 Dimensions MM6

3.4 Introduction of modules

3.5 Mounting

3.5.1 Wall-mounting

3.5.2 Motor-mounting

3.5.3 Segregated modules

3.6 Cooling

vacon • 28 Power cabling

4.1 Circuit breaker

4.2 UL standards on cabling

4.3 Description of the terminals

4.4 Cable dimensioning and selection

4.4.1 Cable and fuse sizes, enclosures MM4 to MM6

4.4.2 Cable and fuse sizes, enclosures MM4 to MM6, North America

4.4.3 Brake resistor cables

4.4.4 Control cables

4.5 Cable installation

Control unit vacon • 45

5.1 Control unit cabling

5.1.1 Control cable sizing

5.1.2 Standard I/O terminals

5.1.3 Relay and thermistor input terminals

5.1.4 Safe Torque off (STO) terminals

5.1.5 Selection of terminal functions with DIP switches

5.1.6 Isolating digital inputs from ground

5.1.7 Bus termination of the RS485 connection

5.2 I/O cabling and fieldbus connection

5.2.1 Prepare for use through Ethernet

5.2.1.1 Ethernet cable data

5.2.2 Prepare for use through RS485

5.2.3 RS485 cable data

5.3 Battery installation for Real Time Clock (RTC)

Commissioning vacon • 57

6.1 Commissioning of the drive

6.2 Changing EMC protection class

6.3 Running the motor

6.3.1 Cable and motor insulation checks

6.3.2 Motor overload protection

6.4 Maintenance

Technical data vacon • 65

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

7.1.2 Mains voltage 3AC 380-480/500V

7.1.3 Definitions of overloadability

7.2 Brake resistor ratings

7.3 VACON® 100 X - technical data

7.3.1 Technical information on control connections

vacon • 74 Options

8.1 Mains switch

8.1.1 Installation

8.2 Control Keypad