Danfoss vacon 20 cp Installation guide

vacon®20 cp
ac drives
Installation, Technical and Maintenance
Manual
vacon • 3
Document code (Original Instructions): DPD00489L
Order code: DOC-INS03976+DLUK
Revision release date: 8.12.21
1. Safety................................................................................................................6
1.1 Signs....................................................................................................................................6
1.2 Units ....................................................................................................................................6
1.3 Danger.................................................................................................................................7
1.4 Hot surface warning............................................................................................................7
1.5 Warnings .............................................................................................................................8
1.6 Grounding and earth fault protection.................................................................................9
1.7 Insulation system..............................................................................................................10
1.8 Compatibility with RCDs ...................................................................................................12
1.9 Cooling System .................................................................................................................13
2. Receipt of delivery ..........................................................................................14
2.1 Type designation code.......................................................................................................15
2.2 Order codes.......................................................................................................................16
2.3 Unpacking and lifting the AC drive ...................................................................................16
2.4 Accessories .......................................................................................................................17
2.4.1 Disposal.............................................................................................................................17
3. Mounting......................................................................................................... 18
3.1 Dimensions .......................................................................................................................18
3.1.1 Enclosure MS2 three-phase version ................................................................................18
3.1.2 Enclosure MS2 single-phase version...............................................................................19
3.1.3 Enclosure MS3 ..................................................................................................................20
3.2 Cooling ..............................................................................................................................21
3.3 Environment temperature ................................................................................................21
3.4 Heatsink assembly instructions .......................................................................................21
3.5 Installation spacing...........................................................................................................24
3.6 Power loss thermal characteristics .................................................................................25
3.7 Dimensioning an external heatsink..................................................................................26
4. Power cabling ................................................................................................. 29
4.1 Circuit breaker ..................................................................................................................31
4.2 UL standards on cabling...................................................................................................31
4.3 Description of the terminals .............................................................................................32
4.3.1 MS2 three-phase version power connections..................................................................32
4.3.2 MS2 single-phase version power connections.................................................................33
4.3.3 MS3 power connections....................................................................................................34
4.4 Cable dimensioning and selection....................................................................................35
4.4.1 Cable and fuse sizes, enclosures MS2 to MS3.................................................................35
4.4.2 Cable and fuse sizes, enclosures MS2 to MS3, North America.......................................36
4.5 Brake resistor cables........................................................................................................37
4.6 Control cables ...................................................................................................................37
4.7 Cable installation ..............................................................................................................37
5. Control unit.....................................................................................................39
5.1 Control unit cabling...........................................................................................................42
5.1.1 Control cable sizing ..........................................................................................................42
5.1.2 Standard I/O terminals .....................................................................................................43
5.1.3 Relay terminals .................................................................................................................44
5.1.4 Safe Torque off (STO) terminals .......................................................................................44
5.1.5 Description of additional echo connectors .......................................................................45
5.1.6 Led handling......................................................................................................................49
Rev. L
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vacon • 4
5.1.7 Selection of terminal functions with dip switches ...........................................................50
5.2 Fieldbus connection..........................................................................................................51
5.2.1 Modbus RTU protocol .......................................................................................................52
5.2.2 Preparation for use through RS485..................................................................................53
6. Commissioning ...............................................................................................54
6.1 Commissioning of the drive ..............................................................................................55
6.2 Changing EMC protection class........................................................................................56
6.2.1 Changing EMC protection class - MS2 three-phase version ...........................................56
6.2.2 Changing EMC protection class - MS2 single-phase version..........................................58
6.2.3 Changing EMC protection class - MS3 .............................................................................59
6.3 Running the motor ............................................................................................................60
6.3.1 Cable and motor insulation checks ..................................................................................60
6.4 Maintenance......................................................................................................................61
6.4.1 Recharging capacitors in stored units..............................................................................61
7. Technical data.................................................................................................62
7.1 AC drive power ratings......................................................................................................62
7.1.1 Mains voltage 3AC 208-240V.............................................................................................62
7.1.2 Mains voltage 1AC 208-240V.............................................................................................62
7.1.3 Mains voltage 3AC 380-480V.............................................................................................63
7.1.4 Definitions of overloadability ............................................................................................63
7.2 Brake resistors .................................................................................................................64
7.2.1 Internal brake resistor......................................................................................................64
7.2.2 External brake resistor.....................................................................................................64
7.3 VACON® 20 CP - technical data .......................................................................................65
7.3.1 Technical information on control connections.................................................................68
8. Options............................................................................................................ 70
8.1 VACON® keypad with seven-segment display.................................................................70
8.2 Text keypad .......................................................................................................................71
8.3 Menu structure .................................................................................................................72
8.4 Using the keypad...............................................................................................................73
8.4.1 Main menu.........................................................................................................................73
8.4.2 Resetting fault...................................................................................................................74
8.4.3 Local/Remote control button............................................................................................74
8.4.4 Reference menu................................................................................................................75
8.4.5 Monitoring menu...............................................................................................................76
8.4.6 Parameter menu...............................................................................................................77
8.4.7 System/Fault menu...........................................................................................................78
8.5 Fault tracing......................................................................................................................80
8.6 Option boards....................................................................................................................84
8.6.1 Option board installation ..................................................................................................85
9. Safe Torque Off ...............................................................................................88
9.1 General description...........................................................................................................88
9.2 Warnings ...........................................................................................................................89
9.3 Standards ..........................................................................................................................90
9.4 The principle of STO..........................................................................................................91
9.4.1 Technical details ...............................................................................................................92
9.5 Connections.......................................................................................................................93
9.5.1 Safety Capability Cat. 4 / PL e / SIL 3 ...............................................................................94
9.5.2 Safety Capability Cat. 3 / PL e / SIL 3 ...............................................................................96
9.5.3 Safety Capability Cat. 2 / PL d / SIL 2 ...............................................................................96
9.5.4 Safety Capability Cat. 1 / PL c / SIL 1................................................................................97
9.6 Commissioning .................................................................................................................98
9.6.1 General wiring instructions ..............................................................................................98
9.6.2 Checklist for commissioning ............................................................................................98
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vacon • 5
9.7 Parameters and fault tracing ...........................................................................................99
9.8 Maintenance and diagnostics ...........................................................................................99
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vacon • 6 Safety

1. SAFETY

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 magnet motors. The product is intended to be installed in a restricted access location and for a general purpose use.
Only VACON maintain the drive.

1.1 Signs

The cautions and warnings are marked as follows:
®
20 CP is a Cold Plate drive designed to control asynchronous AC motors and permanent
®
authorized, trained and qualified personnel are allowed to install, operate and
= DANGEROUS VOLTAGE!
= HOT SURFACE!
= WARNING or CAUTION
Table 1. Warning signs.

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.
Physical
dimension
Length 1 mm 0.0394 inch 25.4 inch Weight 1 kg 2.205 lb 0.4536 pound
Speed
SI value US value Conversion factor US designation
1 min
-1
1 rpm 1
revolution per minute
Temperature 1 °C (T1) 33.8 °F (T2) T2 = T1 x 9/5 + 32 Fahrenheit
Torque 1 Nm 8.851 lbf in 0.113
pound-force inches
Power 1 kW 1.341 HP 0.7457 horsepower
Table 2. Unit conversion table.
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Safety vacon • 7

1.3 Danger

The components of the power unit of VACON® 20 CP 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) are live when VACON 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 attached, see the indicators on the cover). Wait an
additional 30 seconds before starting any work on the connections of VACON Cold Plate Drive. After expiration of this time, use measuring equipment to abso­lutely ensure that no
voltage is present.
Always ensure absence of voltage before
starting any electrical 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
20 CP Drive is disconnected from the mains.
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. Wait until the indicators on the keypad go out (if no keypad is attached, see the indicators on the cover). Wait an addi­tional 30 seconds before starting any work on the drive.
20 CP Drive is connected to
®
20

1.4 Hot surface warning

The metal parts of the enclosure may exceed 70°C (158 °F). Do not touch them due a high risk of being burn.
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vacon • 8 Safety

1.5 Warnings

VACON® 20 CP AC drive is meant for fixed installations only.
Only DVC A circuits (Decisive Voltage Class A, according to IEC 61800-5-1) are allowed to be connected to the control unit. This advice aims to protect both the drive and the
client-application. VACON resulting from unsafe connections of external circuits to the drive. See 1.7 for more details.
Do not perform any measurements when the AC drive is connected to the mains.
®
is not responsible for direct or consequential damages
The touch current of VACON
®
20 CP drives exceeds 3.5mA AC. According to standard
EN61800-5-1, a reinforced protective ground connection must be ensured. See 1.6.
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 4.1
®
Only spare parts supplied by VACON
can be used.
At power-up, power brake 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
. Furthermore, 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 the motor cable, disconnect the motor cable from the AC drive.
Do not perform any voltage withstand test on any part of VACON
®
20 CP. The tests shall 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.
In a domestic environment, this product may cause radio interference, in which case supplementary mitigation measures may be required.
Do not use the internal Brake Resistor in installations above 2000 m altitude.
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Safety vacon • 9

1.6 Grounding and earth fault protection

CAUTION!
The VACON® 20 CP AC drive must always be earthed with an grounding conductor connected to the grounding terminal marked with .
Since the touch current exceeds 3.5 mA AC (for the three-phase version), according to EN61800-5­1, the drive shall 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.
Three screws (for the three-phase version) are provided for: the ORIGINAL protective grounding conductor, the SECOND protective conductor and the MOTOR protective conductor (the customer can choose the screw for each one). See Figure 1 for the location of the three screws in the two possible options available.
Figure 1. Protective grounding connections MS2 and MS3, three-phase version.
®
In VACON
20 CP, the phase conductor and the corresponding protective grounding conductor can
be of the same cross-sectional area, provided they are made of the same metal (because the cross­sectional area of the phase conductor is less than 16 mm
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
2
).
vacon • 10 Safety
Figure 2. Protective grounding connections MS2, single-phase version.
The cross-sectional area of every protective grounding conductor which does not form a part of the supply cable or cable enclosure shall, in any case, be not less than:
2
•2.5 mm
•4 mm
if mechanical protection is provided or
2
if mechanical protection is not provided. For cord-connected equipment, provisions shall be made so that the protective grounding conductor in the cord shall, in the case of failure of the strain-relief mechanism, be the last conductor to be interrupted.
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.

1.7 Insulation system

Please, consider carefully the insulation system depicted in Figure 2, before con­necting any circuit to the unit.
®
The control unit of VACON dard IEC 61800-5-1 regarding DVC A circuits and also the strongest insulation requirements of IEC 60950-1 regarding SELV circuits.
20 CP fulfils the insulation requirements of the stan-
A distinction has to be made for the following three groups of terminals, according to the insulation system of VACON
®
20 CP:
Mains and motor connections (L1, L2, L3, U, V, W) or (L, N, U, V, W)
(**)
Relays (R01, R02)
Control terminals (I/Os, RS485, STO)
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Safety vacon • 11
POWER UNIT
L1 L2 L3
U V
W
R01 __
R02 __
10Vref __
Analog Inputs __
Digital Inputs__
AnalogOutput__
24V __
RS485 __
STO __
Keypad
CONTROL UNIT
Reinforced
Mains
DVCA
DVCAorMains
(**)
DC
(*)
DC+/R+ R
The Control terminals (I/Os, RS485, 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 doubts or questions, please contact your local distributor.
Local contacts: https://www.danfoss.com/en/contact-us/contacts-list/
Figure 3. Insulation system (three-phase version).
vacon • 12 Safety
POWER UNIT
L N
U V
W
R01 __
R02 __
10Vref __
Analog Inputs __
Digital Inputs__
AnalogOutput__
24V __
RS485 __
Keypad
CONTROL UNIT
Reinforced
Mains
DVCA
DVCAorMains
(**)
DC DC+

1.8 Compatibility with RCDs

Figure 4. Insulation system (single-phase version).
(*)
Only for MS3.
(**)
The relays may be used also with DVC A circuits. This is possible only if both
relays are used for DVC A circuitry: to mix Mains and DVC A is not allowed.
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.
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Safety vacon • 13

1.9 Cooling System

VACON® 20 CP is available as a cold-plate solution. Customers have to enclose it in their own housing and provide a suitable heatsink. However under maximum operating conditions the unit should not exceed the following temperatures:
Temperature around the polymeric enclosure (of VACON
Temperature at the cooling-plate (of VACON
®
20 CP): max. 85 °C (185 °F)
®
20 CP): max. 70 °C (158 °F)
Please, contact your local distributor if you need further details or support to dimension the cooling system in your final application.
NOTE: Up to 1.5 kW (Voltage range 380-480V) and 0.75 kW (Voltage range 208-240V) the drive is not equipped with main cooling fan.
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/.
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vacon • 14 Receipt of delivery
44025325
M171600182
70SCO00343
Danfoss A/S, 6430 Nordborg, Denmark
P2:2.2kW: 400 V / 3 hp: 480 V IP66
U2: 3AC 0-Input V 0-320 Hz, I2: 5.6 A
U1: 3AC 380-480 V 50/60 Hz, I1: 7.3 A
Made in Italy
POWER:
OUTPUT:
INPUT:
S.A.
VACON0020-3L-0006-4-X
170426
FW0117V012
Marks:
Cust. Ord. No:
Application:
Firmware:
B.ID:
S/N:
Code:
Type:
AC DRIVE
M171600182
70SC O00343
DANFOSS
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. RECEIPT OF DELIVERY

Check the correctness of delivery by comparing your order data to the drive information found on the package label. If the delivery does not correspond to your order, contact your supplier immedi­ately. See paragraph 2.4.
Figure 5. VACON® package label.
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Receipt of delivery vacon • 15
VACON
This segment is common for all products.
0020
Product range: 0020 = Vacon 20
3L
Input/Function: 3L = Three-phase input 1L = Single-phase input
0009
Drive rating in ampere; e.g. 0009 = 9 A See Table , Table and Table 41 for all the drive
ratings
4
Supply voltage: 2 = 208-240 V 4 = 380-480 V
CP
- Cold Plate
+xxxx +yyyy
Additional codes. Examples of additional codes: +DBIR Dynamic Brake Internal Resistance (optional)

2.1 Type designation code

VACON® type designation code is formed of a nine-segment code and optional +codes. Each segment of the type designation code uniquely corresponds to the product and options you have ordered. The format of the code is as follows:
VACON0020-3L-0009-4-CP +xxxx +yyyy
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vacon • 16 Receipt of delivery

2.2 Order codes

The order codes for VACON® 20 Cold Plate drive family are shown in the following table:
Enclosure size Order code Description
Supply voltage 3AC 208-240V
VACON0020-3L-0004-2-CP 0.75 kW - 1.0 HP drive
MS2
MS3
Supply voltage 1AC 208-240V
MS2
Supply voltage 3AC 380-480V
VACON0020-3L-0005-2-CP 1.1 kW - 1.5 HP drive VACON0020-3L-0007-2-CP 1.5 kW - 2.0 HP drive VACON0020-3L-0011-2-CP 2.2 kW - 3.0 HP drive VACON0020-3L-0012-2-CP 3.0 kW - 4.0 HP drive VACON0020-3L-0017-2-CP 4.0 kW - 5.0 HP drive
VACON0020-1L-0004-2-CP 0.75 kW - 1.0 HP drive VACON0020-1L-0005-2-CP 1.1 kW - 1.5 HP drive VACON0020-1L-0007-2-CP 1.5 kW - 2.0 HP drive
VACON0020-3L-0003-4-CP 0.75 kW - 1.0 HP drive VACON0020-3L-0004-4-CP 1.1 kW - 1.5 HP drive
MS2
VACON0020-3L-0005-4-CP 1.5 kW - 2.0 HP drive VACON0020-3L-0006-4-CP 2.2 kW - 3.0 HP drive VACON0020-3L-0008-4-CP 3.0 kW - 4.0 HP drive VACON0020-3L-0009-4-CP 4.0 kW - 5.0 HP drive
MS3
VACON0020-3L-0012-4-CP 5.5 kW - 7.5 HP drive VACON0020-3L-0016-4-CP 7.5 kW - 10.0 HP drive
Table 3. Order codes of VACON
®
20 Cold Plate.
For all technical details, see chapter 7.

2.3 Unpacking and lifting the AC drive

The weights of the AC drives vary according to enclosure size. Note the weights of each individual enclosure size in Table 4 below.
Enclosure Weight [kg] Weight [lb]
MS2 2 4.4 MS3 3 6.6
Table 4. Enclosure weights.
VACON
®
20 Cold Plate 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.
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Receipt of delivery vacon • 17

2.4 Accessories

After lifting the AC drive out, check that the delivery is complete and the following accessories are included in the plastic bag:
Item Quantity Purpose
STO terminal connector
*
1
Six pin black connector (see Figure 6) to use STO function
M3.5 x 8 TapTite screw 4 Screws for control cable clamps
M1-3 Cable clamp 2 Clamping control cables
*. Included only in the MS2 three-phase version and MS3.

2.4.1 Disposal

Figure 6. STO connector.
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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vacon • 18 Mounting

3. MOUNTING

The AC drive can be mounted on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. Both enclosure sizes can be mounted in any position (IP20 rating is preserved only if mounted as in the following pictures). The drive shall be fixed with two screws (or bolts, depending on the unit size).

3.1 Dimensions

3.1.1 Enclosure MS2 three-phase version

Figure 7. VACON
Enclosure
MS2 133.0 x 164.5 x 73.5 5.24 x 6.48 x 2.89
MS2 with plate 133.0 x 164.5 x 79.5 5.24 x 6.48 x 3.13
®
20 Cold Plate, MS2 three-phase version.
Table 5.
Dimensions W x H x D
[mm] [in]
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Mounting vacon • 19

3.1.2 Enclosure MS2 single-phase version

®
Figure 8. VACON
20 Cold Plate, MS2 single-phase version.
Table 6.
Dimensions W x H x D
Enclosure
[mm] [in]
MS2 133.0 x 163.5 x 73.5 5.23 x 6.43 x 2.89
MS2 with plate 133.0 x 163.5 x 79.5 5.23 x 6.43 x 3.13
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vacon • 20 Mounting

3.1.3 Enclosure MS3

Figure 9. VACON
®
20 Cold Plate, MS3.
Table 7.
Dimensions W x H x D
Enclosure
[mm] [in]
MS3 161.0 x 246.0 x 73.5 6.34 x 9.69 x 2.89
MS3 with plate 161.0 x 246.0 x 83.0 6.34 x 9.69 x 3.27
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Mounting vacon • 21

3.2 Cooling

The AC drive produces heat in operation due to the energy dissipation of the electronic components (rectifier and IGBT) and is cooled by a heatsink via the cold plate of the AC drive. The capacity to dissipate this heat mainly depends on the size of the heatsink surface, the environment temperature and the heat transmission resistance. An increase of the heat transmission rate can only be realized to a certain extent by increasing the surface of the heatsink. An additional increase of the heat dissipation by increasing the heatsink is not possible. The AC drive should be mounted with the cold plate on a heatsink with lowest thermal resistance possible.

3.3 Environment temperature

The drive environment temperature must not exceed 70 °C (158 °F) for the drive installed location. The aluminium panel of the back of the drive is called “cold plate”. The cold plate should never exceed 85 °C (185 °F).
The drive may be damaged if the temperature of the cooling plate exceeds speci­fied tolerance level. Excessive heat can also shorten the performance life of the various AC drive components.

3.4 Heatsink assembly instructions

The VACON® 20 CP AC drives are designed for installation on surfaces which comply with the specifications listed in this paragraph.
The heatsink surface that is in contact with the AC drive cold plate must be free from dirt and particles. The mating surface flatness must not exceed 50m (DIN EN ISO 1101) across the entire mating surface, and the roughness less than 6.3 m(DIN EN ISO 4287). The maximum peak-valley height of the surface shall not exceed 10 m (DIN EN ISO 4287).
Apply a thermal compound between the heatsink and the AC drive cooling mating surface. The thermal paste assists the drive heat dissipation. We recommend the thermal compounds listed in the following table:
Manufacturer Type Model
Wacker Chemie
Fischer Elektronik WLPF
Silicon paste for heat
dissipation
Silicon paste for heat
dissipation
P 12
WLPF
Recommended spread amount
100 m Apply the coating evenly across the
surface
Table 8. Recommended cold plate thermal compound.
We recommend screen printing for applying the thermal paste. In certain cases an application by hard rubber roller might be applicable. After mounting the AC drive to the heatsink panel, wipe away any excess compound from around the plate.
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vacon • 22 Mounting
Place the VACON® 20 CP on the appropriate heatsink area and tighten the screws as listed in the following table:
Enclosure size Screw size
M5 (according to DIN
MS2
7985 - 8.8
(with washer))
M5 (according to DIN
MS3
7985 - 8.8
(with washer))
Tightening torque N•m
(lb•in)
2.0 to 2.5 Nm
(17.70 to 22.13 lbf•in)
2.0 to 2.5 Nm
(17.70 to 22.13 lbf•in)
Table 9. Screw size and tightening torque.
Tighten all screws according to specified torques. Failure to do so, may inhibit drive cooling and cause possible damage to the drive.
Figure 10. Heatsink plate for MS2 (upper view).The thickness of the plate is 6.0 mm (0.24 in).
Table 10.
Dimensions W x H x D
Enclosure
[mm] [in]
MS2 64.0 x 110.0 x 6.0 2.52 x 4.33 x 0.24
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Mounting vacon • 23
Figure 11. Heatsink plate for MS3 (upper view).The thickness of the plate is 9.5 mm (0.37 in).
Table 11.
Dimensions W x H x D
Enclosure
[mm] [in]
MS3 100.0 x 148.0 x 9.5 3.94 x 5.83 x 0.37
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vacon • 24 Mounting
B
AACA

3.5 Installation spacing

Enough free must be left space 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 13 must be respected. It is also important to ensure that the temperature of the cooling air does not exceed the maximum environment temperature of the AC drive.
Contact our factory for more information on required clearances in different installations.
Table 12.
Min clearance mm
Type A B C
All types 30 30 30
Table 13. Min. clearances around AC drive.
Figure 12. Installation space.
A = Clearance left and right from the drive B = Clearance above the drive C = Clearance underneath the AC drive
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Mounting vacon • 25

3.6 Power loss thermal characteristics

In the table below are the thermal characteristics of VACON® 20 CP AC drive at nominal output current. The power loss in stand-by conditions is 12 W for all sizes (supply voltage 24 V, 100 mA).
Mains voltage 3AC 208-240V, 50/60 Hz
Enclosure
AC drive
Type
Rated output
current [A]
Cold plate
loss [W]
Internal loss
[W]
0004 3.7 27 18 45
MS2
0005 4.8 37 21 58 0007 7.0 58 30 88 0011 11.0 85 28 113
MS3
0012 12.5 101 37 138 0017 17.5 146 50 196
Table 14. Drive power loss at rated conditions, voltage range 3AC 208-240V.
Mains voltage 1AC 208-240V, 50/60 Hz
Enclosure
AC drive
Type
Rated output
current [A]
Cold plate
loss [W]
Internal loss
[W]
0004 3.7 31 22 53
MS2
0005 4.8 37 24 61 0007 7.0 59 31 90
Total loss
[W]
Total loss
[W]
Table 15. Drive power loss at rated conditions, voltage range 1AC 208-240V.
Mains voltage 3AC 380-480V, 50/60 Hz
Enclosure
AC drive
Type
Rated output
current [A]
Cold plate
loss [W]
Internal loss
[W]
0003 2.4 23 16 39 0004 3.3 31 18 49
MS2
0005 4.3 43 21 64 0006 5.6 58 25 83 0008 7.6 84 33 117 0009 9.0 86 31 117
MS3
0012 12.0 120 37 157 0016 16.0 171 48 219
Table 16. Drive power loss at rated conditions, voltage range 3AC 380-480V.
Total loss
[W]
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vacon • 26 Mounting
CP
loss
T
amb
R
CP
R
HS
T
CP
T
CP
T
amb
T
Enclosure

3.7 Dimensioning an external heatsink

This paragraph describes a useful procedure to select a suitable heatsink for VACON® 20 CP drives. The heatsinks are devices that enhance heat dissipation from a hot surface, usually the case of a
heat generating component, to a cooler ambient, usually air. For the following discussion, air is assumed to be the cooling fluid. The primary purpose of a heatsink is to maintain the device temperature below the maximum allowable specified by the device manufacturers. Before discussing the heatsink selection process, it is necessary to define common terms, notations and definitions and establish the concept of a thermal circuit.
Notations and definitions of the terms are as follows:
Symbol Description
CP T
CPmax
T
amb
R
CP
R
HSmax
loss
Cold plate loss: see Table 14, Table 15 or Table 16 expressed in W Maximum cold plate temperature expressed in °K (358 °K = 85°C) heatsink ambient temperature expressed in °K(°K = °C + 273) Equivalent thermal resistance [K/W] of the cold plate. Thermal resistance of the heatsink [K/W]
Table 17. Terms and definitions for the thermal model.
The purpose of this paragraph is to select an external heatsink by calculating its thermal resistance. The heat transfer principle from the cold plate to the heatsink ambient air is shown in Figure 13.
Figure 13. Thermal equivalent circuit.
The formula to calculate the maximum thermal resistance of the heatsink is as follows:
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Mounting vacon • 27
R
HSmax
T
CPmaxTamb
CP
loss
-------------------------------------
R
CP
=
For a given ambient temperature T maximum allowable value (85°C). As the R
the cold plate temperature T
amb
is essentially fixed, this condition must be satisfied
CP
must not exceed the
CPmax
with a proper heatsink selection. The table below shows the typical values for R CP:
Enclosure R
MS2 MS3
R
R
CP
=0.091 K/W
CP
= 0,055 K/W
CP
Table 18. Typical values for the equivalent thermal resistances of the cold plate.
Select a heatsink with a smaller thermal resistance than R
. The heatsink dimensions should
HSmax
be closed to the cold plate dimensions.
If the heatsink height and width are much larger than the drive cold plate dimen­sions, or if multiple drives are installed on one heatsink, it may be necessary to apply correction factors to the thermal resistance value given in the heatsink specification. Contact the heatsink manufacturer.
for VACON® 20
CP
Note: remember that the heatsink cooling capacity can be reduced over time due to dirt.
In order to choose an heatsink from a catalogue please consider that usually the reported heat resistances are measured under free convection conditions. In this case the heatsink has to be oversized with respect to the cold plate dimensions, otherwise an additional fan must be used to reduce the heatsink resistance and its dimensions. Most heatsink manufacturers give correction factors according to various air flow speeds.
The designing factors which influence the thermal performances of an heatsink are as follows:
Spreading resistance: Spreading resistance occurs when thermal energy is transferred from a small area to a larger area in a substance with finite thermal conductivity. In a heatsink, this means that heat does not distribute uniformly through the heatsink base. The spreading resis­tance phenomenon is shown by how the heat travels from the heat source location and causes a large temperature gradient between the heat source and the edges of the heatsink. This means that some fins are at a lower temperature than if the heat source were uniform across the base of the heatsink. This non uniformity increases the heatsink's effective thermal resistance.
Heatsink manufacturer dimensioning data: the heatsink thermal resistance given in a cata- logue is measured on a temperature sink to ambient differential (T) and since Rhs under free
convection depends on T with the power law Rth ~ T
-0.25
(with laminar flow), a correction fac­tor must be considered when the operating T is different from what used by the heatsink man­ufacturer in the measurement.
Surface finishing: the heatsink dissipation depends on the type of surface finishing of heat­sink itself (anodized/black surfaces dissipate differently from polished surfaces).
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vacon • 28 Mounting
Heatsink attachment/orientation: heatsink attachment/orientation plays a significant role under natural convection. It is recommended that the heatsink be installed to orient the fins in a direction that will not block air movement under natural convection. Based practical experi­ence, if the heatsink is oriented in a wrong way, the thermal performance will be approximately 25% worse under natural convection condition.
Taking account of the above, we recommend that the calculated R
is multiplied
HS
by 0.7 to obtain a resistance value with a reasonable safety margin in order to ensure tripless drive operation.
Note: to study the heat transfer in other cooling media of different geometry (e.g. cooling plate without fins), please contact your local distributor to receive support in dimensioning method.
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Power cabling vacon • 29
U/T1
V/T2
W/T3
M
L1
L2
L3
DC+/R+
R-
DC-
(*)
Keypad
Control
Power unit
U/T1
V/T2
W/T3
M
L
N
Keypad
Control
Power unit

4. POWER CABLING

The mains cables are connected to terminals L1, L2 and L3 (three-phase versions) and the motor cables to terminals marked with U, V and W. See principal connection diagram in Figure 14. See also Table 19 for the cable recommendations for different EMC levels.
* only MS3.
Figure 14. Principal connection diagram (three-phase version).
Figure 15. Principal connection diagram (single-phase version)
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vacon • 30 Power cabling
Shield
PE conductors
Shield
PE conductor
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.
EMC levels
1st environment 2nd environment
Cable type
Category C1 and C2 Category C3 Category C4
Mains cable 1 1 1 Motor cable 3* 2 2 Control cable 4 4 4
Table 19: Cable types required to meet standards.
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
specific 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; Recommended cable transfer impedance (1...30MHz) max. 100mohm/m]. See Figure 16.
*360º grounding of the shield with cable glands in motor end needed for EMC category C1 and C2.
4 = Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-O or
similar).
Figure 16. Example with three-phase cable.
NOTE: The EMC requirements are fulfilled at factory defaults of switching frequencies (all enclosures).
NOTE: If safety switch is connected the EMC protection shall be continuous over the whole cable installation.
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