Danfoss vacon 100 x Installation guide

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

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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.

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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

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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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