Danfoss vacon 20 cp Installation guide

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vacon®20 cp

ac drives

Installation, Technical and Maintenance

Manual

vacon • 3

INDEX

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

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

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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:

•2.5 mm

•4 mm

if mechanical protection is provided or

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

R01 __

R02 __

10Vref __

Analog Inputs __

Digital Inputs__

AnalogOutput__

24V __

RS485 __

STO __

Keypad

CONTROL UNIT

Reinforced

Mains

DVCA

DVCAorMains

(**)

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.

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Figure 3. Insulation system (three-phase version).

vacon • 12 Safety

POWER UNIT

L N

U V

R01 __

R02 __

10Vref __

Analog Inputs __

Digital Inputs__

AnalogOutput__

24V __

RS485 __

Keypad

CONTROL UNIT

Reinforced

Mains

DVCA

DVCAorMains

(**)

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

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

Supply voltage: 2 = 208-240 V 4 = 380-480 V

- 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

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 50m (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

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

loss

amb

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

amb

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

HSmax

CPmaxTamb

–

loss

-------------------------------------

–=

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

must not exceed the

CPmax

with a proper heatsink selection. The table below shows the typical values for R CP:

Enclosure R

MS2 MS3

=0.091 K/W

= 0,055 K/W

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

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

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

DC+/R+

R-

DC-

(*)

Keypad

Control

Power unit

U/T1

V/T2

W/T3

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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Power cabling vacon • 31

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 is has a capacity of 1.5 to 2 times the inverter’s rated current (see Chapter 7.1).

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 no more than 50,000 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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vacon • 32 Power cabling

PES

3AC

Motor

AC power supply

Single or

Three phases

4.3 Description of the terminals

The following pictures describe the power terminals and the typical connections in VACON® 20 CP drives.

4.3.1 MS2 three-phase version power connections

Figure 17. Power connections, MS2 three-phase version.

Terminal Description

L1 L2 L3

U/T1 V/T2 W/T3

Table 20. Description of VACON

These terminals are the input connections for the power supply. 230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derating of 50%).

These terminals are for motor connections.

20CP MS2 power terminals.

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Power cabling vacon • 33

PES

AC power supply single phase

3AC

Motor

4.3.2 MS2 single-phase version power connections

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Figure 18. Power connections, MS2 single-phase version.

Terminal Description

L N

U V W

Table 21. Description of VACON

These terminals are the input connections for the power supply. Single-phase 230 VAC voltage has to be connected to L and N terminals.

These terminals are for motor connections.

20CP MS2 power terminals (single-phase version).

vacon • 34 Power cabling

PES

AC power supply

Single or

Three phases

3AC

Motor

4.3.3 MS3 power connections

Figure 19. Power connections, MS3.

Terminal Description

L1 L2 L3

U/T1 V/T2 W/T3

Table 22. Description of VACON

These terminals are the input connections for the power supply. 230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derating of 50%).

These terminals are for motor connections.

20CP MS3 power terminals.

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Power cabling vacon • 35

4.4 Cable dimensioning and selection

Table 23 shows 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 MS2 to MS3

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage rating should be selected according to the supply network. The final selection should be made according to local regulations, cable installation conditions and cable specifications. 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. We also recommend high speed J (UL & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.

Enclosure Type

0004 2 0003 4 - 0004 4

MS2

0005 2 - 0007 2 0005 4 - 0006 4

0008 4 9.6 16

0004 2 8.3 20

MS2

1-phase

0005 2 11.2 20

0007 2 14.1 25

0011 2 0009 4

MS3

0012 2 0012 4

Table 23. Cable and fuse sizes for VACON

INPUT

[A]

4.3

3.2 - 4.0

6.8 - 8.4

5.6 - 7.3

13.4

11.5

14.2

14.9

Fuse

(gG/gL)

[A]

Mains and

motor cable

Cu [mm

3*1.5+1.5

3*2.5+2.5

(Mains) 2*1.5+1.5 (Motor) 3*1.5+1.5

(Mains) 2*2.5+2.5 (Motor) 3*2.5+2.5

3*2.5+2.5

]

20 CP.

Terminal cable size

Main terminal

]

[mm

0.2 — 2.5

0.2 — 2.5 stranded

0.5 — 16.0

Earth

terminal

M4 ring

terminal

M4 ring

terminal

M4 ring

terminal

M4 ring

terminal

M4 ring

terminal

M4 ring

terminal

M5 ring

terminal

M5 ring

terminal

0017 2 0016 4

The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be PVC-isolated; use only cables with concentric copper shield; 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.

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20.6

20.0

3*6+6

0.5 — 16.0

M5 ring

terminal

NOTE HOWEVER that the requirements of both the cross-sectional area and

vacon • 36 Power cabling

4.4.2 Cable and fuse sizes, enclosures MS2 to MS3, North America

Table 24. Cable and fuse sizes for VACON

Enclosure Type

0004 2 0003 4 - 0004 4

MS2

0005 2 - 0007 2 0005 4 - 0006 4

0008 4 9.6 15 0004 2 8.3 20

MS2

1-phase

0005 2 11.2 20 0007 2 14.1 25 0011 2

0009 4

MS3

0012 2 0012 4

0017 2 0016 4

INPUT

[A]

4.3

3.2 - 4.0

6.8 - 8.4

5.6 - 7.3

13.4

11.5

14.2

14.9

20.6

20.0

Fuse

(class T)

[A]

20 CP, North America.

Mains and

motor cable

AWG14 AWG24-AWG12 AWG17-AWG10

AWG14 AWG24-AWG12 AWG17-AWG10 AWG14 AWG24-AWG12 AWG17-AWG10 AWG14 AWG24-AWG12 AWG17-AWG10 AWG14 AWG24-AWG12 AWG17-AWG10

AWG14 AWG20-AWG6 AWG17-AWG10

AWG12 AWG20-AWG6 AWG17-AWG10

AWG10 AWG20-AWG6 AWG17-AWG10

Terminal cable size

Main terminal

Earth

terminal

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be PVC-isolated; Max ambient temperature +30 °C, max temperature of cable surface +70 °C; Use only cables with concentric copper shield; Max number of parallel cables is 9.

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.

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Power cabling vacon • 37

4.5 Brake resistor cables

VACON® 20 CP AC drives (three-phase version) are equipped with terminals for an optional external brake resistor. These terminals are 6.3 mm Faston for MS2 and spring-type terminals for MS3. See Figure 21 and Figure 23 for the location of these terminals.

See Table 43 and Table 44 for the resistor ratings.

4.6 Control cables

For information on control cables see chapter Control unit cabling.

4.7 Cable installation

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

in chapter 1 carefully

• Place the motor cables sufficiently far from other cables

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

Table 25.

Distance between cables, [m] Shielded cable, [m]

0.3  50

1.0  200

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

•The maximum length for motor cables is 30m

• 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.

Earth conductor Earth conductor Earth conductor

A A

MAINS (1-phase)

MAINS MOTOR

Figure 20. Stripping of cables.

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11746A_uk

vacon • 38 Power cabling

Table 26. Cables stripping lengths [mm].

Enclosure A1 B1 C1 D1 C2 D2 E

MS2 8 8 8203620

MS2

1-phase

MS3 8 8 8203620

7 8 8203620

Connect the stripped cables:

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

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

respective terminals.

• Form the rest of the cable shield of both cables into “pigtails” and make a grounding connection with the clamp. Make the pigtails just long enough to reach and be fixed to the terminal - no longer.

Tightening torques of cable terminals:

Table 27. Tightening torques of terminals

Tightening torque

Enclosure Type

Power and motor

terminals

Tightening torque

EMC grounding

clamps

Leave as short

as possible

Tightening torque,

Grounding terminals

MS2

MS3

0003 4—0008 4 0004 2—0007 2

0009 4—0016 4 0011 2—0017 2

[Nm] lbs-in. [Nm] lbs-in. [Nm] lbs-in.

0.5—0.6 4.5—5.3 1.5 13.3 2.0 17.7

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

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Control unit vacon • 39

5. CONTROL UNIT

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 21, Figure 22 and Figure 23.

Number Meaning

1 Control terminals A-20 2 STO terminals (only in three-phase version) 3 Relay terminals 4 Option board terminals 5 STO Jumpers (only in three-phase version) 6DIP switches 7 Status LEDs 8 HMI connector (RJ45 keypad connector)*

9 Optional brake resistor terminals 10 Supply voltage connector for main cooling fan 11 Control terminals A-20 echo connector 12 HMI echo connector (keypad connector) 13 DC-bus terminals

Table 28. Locations of components in control unit

The HMI connector is only to connect the keypad and not for Ethernet comunica-

tion.

Figure 21. Locations of the components in control unit of MS2 (three-phase version).

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vacon • 40 Control unit

Figure 22. Locations of the components in control unit of MS2 (single-phase version).

Figure 23. Location of the components in the control unit of MS3.

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Control unit vacon • 41

FAN+

FAN-

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

The control board can be powered externally by connecting an external power source (about 130150mA at 24VDC are needed to supply the control board without keypad, option board or other loads) between terminal #6 and GND, see chapter 5.1.2. To ensure that the external supply works with any configurations we recommend to use an external supply of +24VDC ±10%, 1000mA overcurrent protected.

This voltage is sufficient for parameter setting and for keeping the control unit active. Note however that the values of the measurements of the main circuit (e.g. DC-link voltage, unit temperature) are not available when the mains is not connected.

In addition to the internal fan, VACON connector (see 10 in the Figure 21, Figure 22 and Figure 23) for improved air flow and system cooling. The power supply also has automatic thermal switching on/off control: it automatically switches on/off depending on internal cold plate temperature. The electric specifications for the auxiliary fan power supply are shown in the following table:

Ter mi na ls

20 CP AC drives include an auxiliary fan power supply

SIgnals

MS2 MS3

24VDC ±10%

FAN+

FAN- GND GND

Table 29. Electric specifications for the auxiliary fan power supply.

The connector for the auxiliary fan supply is a Micro-Fit 3.0 Single Row, Vertical with PCB Polarizing Peg by Molex (part number 43650-0215). This connection is echoed in the HMI echo connector. See Figure 21, Figure 22 and Figure 23 for the location of the connectors and Table 35 for the description of the HMI echo terminal.

To connect the auxiliary fan to VACON Crimp Housing, Single Row by Molex details.

maximum output current 200mA

20 CP drives you will need a Micro-Fit 3.0™ Receptacle

(part number 43645-0200). See the picture below for more

24VDC ±10% maximum output current 700mA

Header, Surface Mount Compatible,

Figure 24. Micro-Fit 3.0™ Housing.

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vacon • 42 Control unit

5.1 Control unit cabling

The principal terminal block placement is shown in Figure 25 below. The control board is equipped with 23 fixed control I/O terminals. 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 31.

Figure 25. Control terminals.

5.1.1 Control cable sizing

The I/O (control and relays) and STO cables must be screened multi core cables with following cable sizes:

• 0.14...1.5 mm

• 0.25...1.5 mm

without ferrules

with ferrules (no plastic neck)

with ferrules (with plastic neck)

Find the tightening torques of the I/O (control and relays) and STO terminals in the Table below.

Tightening torque

Term ina l sc re w

Nm lbs-in.

I/O terminals and STO terminals (screw M2)

0.22 min

0.25 max

1.95 min

2.21 max

Table 30. Control cable tightening torques.

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Control unit vacon • 43

Remote reference

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

5.1.2 Standard I/O terminals

The terminals of the

Standard I/O are described below. For more information on connections, see

chapter 7.3.1. The terminals shown on shadowed background are assigned for signals with optional functions

selectable with DIP switches. For more information, see chapter 5.1.7.

Table 31. Control I/O terminal signals and connection example.

Standard I/O terminals

Ter mi na l Signal

A RS485_A Serial bus, negative

Reference potentiometer

1...10k

B RS485_B Serial bus, positive 1 +10 Vref Reference output

3 6

8 9

14 15 16

20 DO1+ Digital output 1

AI1+

GND I/O signal ground

24Vout 24V aux. voltage

DIN COM

DI1 Digital input 1

DI2 Digital input 2

DI3 Digital input 3

AI2+

GND I/O signal ground

DO1-

DI4 Digital input 4

DI5 Digital input 5

DI6 Digital input 6

AO1+

Analogue input, voltage or current

Digital inputs common

Analogue input, voltage or current

Digital output 1 common

Analogue signal (+output)

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vacon • 44 Control unit

From

standard I/O board

From term.

RUN

5.1.3 Relay terminals

Table 32. I/O terminal signals for relays and connection example.

Relays terminals

Ter mi na l Signal

24 25

RO1/2

RO1/3

RO2/1

RO2/2

RO2/3

Relay output 1

Relay output 2

5.1.4 Safe Torque off (STO) terminals

For more information on the functionalities of the Safe Torque Off (STO), see chapter 9. This function is available only in the three-phase version.

Table 33. I/O terminal signals for the STO functions.

Safe Torque Off terminals

Ter mi na l Signal

Isolated digital input 1 (interchangeable polarity);

+24V ±20% 10...15mA

F+

F-

Isolated digital input 2 (interchangeable polarity); +24V ±20% 10...15mA

Isolated feedback (CAUTION! Polarity to be respected); +24V ±20%

Isolated feedback (CAUTION! Polarity to be respected); GND

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Control unit vacon • 45

5.1.5 Description of additional echo connectors

In this paragraph you will find the description of the additional echo connectors for the I/O terminals and for the HMI.

Figure 26. The I/O remote echo connector mounted on the control board.

In Figure 26 the view of Molex

connector for the I/O terminals is shown. In the control unit the position of this connector is numbered with 11 as shown in Figure 21 and Figure 23. The type of this connector is Pico-Clasp™ Wire-to Board PCB Header, Dual Row, RIght Angle. The code by Molex is: 501571-2007.

It mates with Pico-Clasp™ Wire-to Board Receptacle Housing (crimp housing), Dual Row, 20 Circuits. The code by Molex

is: 501189-2010. See Figure 27.

Figure 27. Receptacle housing for I/O remote echo connector.

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vacon • 46 Control unit

To connect I/Os to the control unit through echo terminals this connector has to be used. In the

following table, the correspondence between the pins of this connector and the VACON

20 CP

terminals is shown.

Pin number Signal Description

1 RS485_B Serial bus, positive

2 DI2 Digital input 2

3 RS485_A Serial bus, negative

4 DI3 Digital input 3

5 NC not connected

6AI2+

7 NC not connected

8GND

9 +10Vref

10 DO1- common for digital output 1

11 AI1+

12 DI4 Digital input 4

13 GND

14 DI5 Digital input 5

15 24Vout

16 DI6 Digital input 6

17 DIN COM

18 AO1+ Analogue output 1

19 DI1 Digital input 1

20 DO1+ Digital output 1

Table 34. I/O remote connector description.

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Control unit vacon • 47

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Figure 28. HMI remote connector.

In Figure 28 the view of Molex

connector for the HMI terminals is shown. In the control box the position of this connector is numbered with 8, as shown in Figure 21 and Figure 23. The type of connector is Pico-Clasp™ Wire-to-Board Header, Surface Mount, Single Row, Vertical, with Positive Lock. The code by Molex

is: 501331-1507.

It mates with Pico-Clasp™ Wire-to Board Female Housing (crimp housing), Single Row, with Positive lock, 15 Circuits. The code by Molex

is: 501330-1500.

To connect HMI to the control unit through echo terminals this connector has to be used. In the

following table, the correspondence between the pins of this connector and the VACON

20 CP HMI

terminals is shown.

Pin number in RJ45

connector

2 15 +24V Panel supply

6 14 +3.3V Panel supply

5 13 GND ground

Pin number of echo

connector

Signal Description

Table 35. HMI remote connector description with RJ45 correspondences.

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vacon • 48 Control unit

Pin number in RJ45

connector

1 12 Keyp_TX+

411Keyp_TX-

3 10 Keyp_RX+

79Keyp_RX-

8 8 Led_CTRL1 Control signal for LED1

- 7 Led_CTRL2 Control signal for LED2

- 6 Led_CTRL3 Control signal for LED3

- 5 FAN+ External FAN+(+24V)

- 4 FAN- GND for external FAN

- 3 nc not connected

- 2 nc not connected

- 1 nc not connected

Table 35. HMI remote connector description with RJ45 correspondences.

Pin number of echo

connector

Signal Description

RS422 (connection for panel

communication)

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Control unit vacon • 49

5.1.6 Led handling

As VACON

20 Cold plate is often without the keypad, on the plastic cover of the drive there are 4

status LEDs. See the picture below.

Figure 29. LED position on the MS2 cover.

Led “PWR” (orange led) means the drive is supplied by mains. Led “RUN” (green led) means the drive is running. Led “FLT” (red led) means the drive is experiencing a fault. Led “RDY” (orange led) means the drive is ready and no fault is present. When a Warning is active,

the led starts blinking.

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vacon • 50 Control unit

5.1.7 Selection of terminal functions with dip switches

VACON

20 Cold Plate drive embodies four so-called switches that allow for two functional selections each. The shadowed terminals in Table 31 can be functionally modified with the dip switches.

The switches have two positions: 0 and 1. See Figure 30 to locate the switches and make appropriate selections for your requirements.

Figure 30. Dip switches

5.1.7.1

Switch SW1

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 SW1 to position ‘1’. See Figure 30. Locate the switch and set it in the

desired position. The switch in the position “0” means that the common of digital input have been connected to the ground.The default position is “0”.

5.1.7.2

Switches SW2 and SW3

Analogue inputs can be used as either current inputs or voltage inputs. The signal type is selected with two switches on the control board.

The switch SW2 is related to analogue input AI1. In position “1” the analogue input AI1 works in voltage mode. In position “0” the analogue input works in current mode. The default position for SW2 is “1”.

The voltage range is 0...10V and the current is 0/4.....20 mA.

The switch SW3 is related to analogue input AI2. In the position “1” the analogue input AI2 works in voltage mode. In the position “0” the analogue input works in current mode. The default position for SW3 is “0”.

The voltage range is 0...10V and the current is 0/4.....20 mA.

5.1.7.3

Switch SW4

The switch SW4 is related to the RS485 connection. It’s used for bus termination. The bus termination must be set to the first and to the last device on the network. The switch SW4 in position “0” means that termination resistance is connected and the termination of the bus has been set. If the VACON

20 CP is the last device on the net, this switch must be set to “0” position. The default

position for SW4 is “0”.

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Control unit vacon • 51

5.2 Fieldbus connection

Modbus is a communication protocol developed by Modicon systems. In other words, it is a way of sending information between electronic devices. The device requesting the information is called the Modbus Master and the devices supplying information are Modbus Slaves. In a standard Modbus network, there is one Master and up to 247 Slaves, each with a unique Slave Address from 1 to 247. The Master can also write information to the Slaves. Modbus is typically used to transmit signals from instrumentation and control devices back to a main controller or data gathering system.

The Modbus communication interface is built around messages. The format of these Modbus messages is independent of the type of physical interface used. The same protocol can be used regardless of the connection type. Thanks to this, Modbus allows for the easy upgrade of the hardware structure of an industrial network, without the need for significant changes in the software. A device can also communicate with several Modbus nodes at once, although they are connected with different interface types, without the need to use a different protocol for every connection.

Figure 31. Basic structure of Modbus frame.

On simple interfaces such as RS485, the Modbus messages are sent in plain form over the network. In this case the network is dedicated to Modbus.

Each Modbus message has the same structure. Four basic elements are present in each message. The sequence of these elements is the same for all messages, to make it easy to parse the content of the Modbus message. A conversation is always started by a master in the Modbus network. A Modbus master sends a message and — depending on the contents of the message — a slave takes action and responds to it. There can be more masters in a Modbus network. The address in the message header is used to define which device should respond to a message. All other nodes on the Modbus network ignore the message if the address field doesn't match their own address.

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vacon • 52 Control unit

5.2.1 Modbus RTU protocol

Interface RS-485

Data transfer method RS-485 MS/TP, half-duplex

Transfer cable

Connector

STP (shielded twisted pair), type

Belden 9841 or similar

2.5 mm

Connections and communications

Electrical isolation Functional

Modbus RTU

Baud rate

As described in “Modicon Modbus

Protocol Reference Guide”

300, 600, 1200, 2400, 4800, 9600,

19200, 38400 and 57600 baud

Addresses 1 to 247

Table 36.

VACON

20 CP drive is equipped with Modbus support as standard. The AC drive can be connected to fieldbus through RS485. The connection for RS485 is on the standard I/O (terminals A and B). See Figure 32.

Figure 32. Position of the RS485 terminals on the I/O standard terminal connector.

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Control unit vacon • 53

5.2.2 Preparation for use through RS485

Strip about 15 mm of the RS485 cable (see specification on Table 36) 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.

2 3

Also strip the cable now at such a distance from the terminal that you can fix it to the enclosure with the grounding clamp. Strip the cable at a maximum length of 15 mm. Do not strip the aluminium cable shield!

Then connect the cable to its appropriate terminals on VACON® 20 CP AC drive standard terminal block, terminals A and B (A = negative, B = positive).

Using the cable clamp included in the supply of the drive, ground the shield of the RS485 cable to the enclosure of the AC drive.

If VACON® 20 Cold Plate drive is the last device on the bus, the bus termination must be set. Locate the

switches to the right of the control terminals (see Figure 30) and turn the SW4 switch to position “0”. Biasing is built in the termination resistor.

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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.

The bus termination must be set for the first and the last device of the fieldbus line. We recommend that the first device terminated is the Master device.

vacon • 54 Commissioning

6. COMMISSIONING

Before commissioning, note the following directions and warnings:

Internal components and circuit boards of VACON® 20 CP drive (except for the galvanically isolated I/O terminals) are live when it 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 and the brake resistor terminals are live when VACON

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

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

20 CP drive is connected to mains, even if the motor is not running.

20 CP drive is disconnected from mains.

After disconnecting the AC drive from the mains, wait until the indicators on the cover go out. Wait additional 30 seconds before doing any work on the connec-

tions of VACON

20 CP 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

voltage is present.

Always ensure absence of voltage before starting any

electrical work!

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Commissioning vacon • 55

6.1 Commissioning of the drive

Read carefully the safety instructions in Chapter 1 and above and follow them. After the installation:

Table 37.

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 4.

Check that the control cables are located as far as possible from the power cables, see chapter 4.4.

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 the in Stopposition.

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

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vacon • 56 Commissioning

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 as described below:

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

6.2.1 Changing EMC protection class - MS2 three-phase version

Remove the three screws on the EMC plate from the unit.

Figure 33. Changing of the EMC class in MS2 (three-phase version).

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Commissioning vacon • 57

Remove the EMC plate from the unit. Then lift the plate with pliers to disconnect

the EMC plate from the ground. See Figure 34. Then reconnect the EMC plate to the unit.

Figure 34. Changing of the EMC class in MS2 (three-phase version).

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vacon • 58 Commissioning

6.2.2 Changing EMC protection class - MS2 single-phase version

Remove the EMC screw as shown in the Figure 35.

Figure 35. Changing the EMC class in the MS2 (single-phase version).

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Commissioning vacon • 59

6.2.3 Changing EMC protection class - MS3

Remove the EMC screw as shown in the Figure 36.

Figure 36. Changing the EMC class in the MS3.

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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vacon • 60 Commissioning

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.

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 >1M at ambient temperature of 20°C.

2. Mains cable insulation checks Disconnect the mains cable from terminals L1 (L), L2 (N) 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 >1M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 >1M at ambient temperature of 20°C.

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Commissioning vacon • 61

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.

Table 38.

Maintenance interval Maintenance action

Regularly and according to

• Check tightening torques of terminals

general maintenance interval

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

6...24 months (depending on environment)

• Check for corrosion on terminals and other surfaces

• Check door filter in case of cabinet installation

24 months • Clean heatsink

• Charge capacitors, only after long

12...24 months

storage times or long down times without supply: contact your nearest Danfoss service center

6.4.1 Recharging capacitors in stored units

When complete AC Drive units are stored without any voltage being applied to them, the recharging of the capacitors should be done at least every 12 months, by connecting the power supply to the unit and then keeping the unit powered up for a minimum of one hour.

If the storing time is much longer than one year, the recharging of the capacitors has to be done in a way that possible high leakage current through the capacitors is limited. The best alternative is to use a DC-power supply with an adjustable current limit. The current limit has to be set, for example, to 50...200mA and the DC-power supply has to be connected to the DC+/DC- terminals of the DC link.

Power up instruction for MS02 (three-phase) unit without DC+/DC- terminals:

• The DC supply is connected between the two input phases L1 and L2.

• The DC voltage has to be adjusted up to the nominal DC voltage level of the unit (1.35xUn AC) and has to be supplied for at least one hour.

If a DC voltage is not available and the unit has been stored much longer than one year deenergized, consult the manufacturer before connecting the power.

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vacon • 62 Technical data

7. TECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

Table 39. Power ratings of VACON® 20 CP, supply voltage 3AC 208-240V.

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

Motor shaft power

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

0004 4.3 3.7 5.6 7.4 0.75 1.0 0005 6.8 4.8 7.2 9.6 1.1 1.5

MS2

0007 8.4 7.0 10.5 14.0 1.5 2.0

Loadability

50% overload

current

[A]

Max current

230V 230V

[kW] [HP]

0011 13.4 11.0 16.5 22.0 2.2 3.0 0012 14.2 12.5 18.8 25.0 3.0 4.0

MS3

0017 20.6 17.5 26.3 35.0 4.0 5.0

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

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

7.1.2 Mains voltage 1AC 208-240V

Table 40. Power ratings of VACON® 20 CP, supply voltage 1AC 208-240V.

Mains Voltage 1AC 208-240V, 50/60 Hz

Motor shaft power

Loadability

50% overload

current

[A]

Max current

230V 230V

[kW] [HP]

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

0004 8.3 3.7 5.6 7.4 0.75 1.0 0005 11.2 4.8 7.2 9.6 1.1 1.5

MS2

0007 14.1 7.0 10.5 14.0 1.5 2.0

NOTE: The rated currents in given ambient temperatures (in Table ) are achieved only when the switching frequency is equal to or less than the factory default.

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Technical data vacon • 63

N*150%

1 min 9 min

N*150%

Current

Time

7.1.3 Mains voltage 3AC 380-480V

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

Motor shaft power

Loadability

50% overload

current

[A]

Max current

400V 480V

[kW] [HP]

AC drive

type

Input

current

[A]

Rated continuous

current I

[A]

0003 3.2 2.4 3.6 4.8 0.75 1.0 0004 4.0 3.3 5.0 6.6 1.1 1.5 0005 5.6 4.3 6.5 8.6 1.5 2.0

MS2

0006 7.3 5.6 8.4 11.2 2.2 3.0 0008 9.6 7.6 11.4 15.2 3.0 4.0 0009 11.5 9.0 13.5 18.0 4.0 5.0 0012 14.9 12.0 18.0 24.0 5.5 7.5

MS3

0016 20 16.0 24.0 32.0 7.5 10.0

Table 41. Power ratings of VACON

20 CP, supply voltage 3AC 380-480V.

NOTE: The rated currents in given ambient temperatures (in Table 41) are achieved only when the switching frequency is equal to or less than the factory default.

7.1.4 Definitions of overloadability

Overloadability =Following continuous operation at rated output current IN, the AC drive supplies

150% * I

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

must be at rated current I

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

or less.

Figure 37. High overload.

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vacon • 64 Technical data

7.2 Brake resistors

7.2.1 Internal brake resistor

Internal brake resistor is available with following plus code: +DBIR (Dynamic Brake Internal Resistance)

Table 42. Internal brake resistor rating, 3AC 380-480V

Internal Brake Resisotr Technical data

MS2

1500 Ohm

460 W

MS3 not available

7.2.2 External brake resistor

Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application. Brake chopper is available only in three-phase version.

Recommended brake resistor values for VACON

20 CP AC drives:

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

Enclosure Type

Minimum Resistance

recommended [Ohm]

0004 50

MS2

0005 50 0007 50 0011 25

MS3

0012 25 0017 25

Table 43. Extrenal brake resistor ratings, 3AC 208-240V.

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

Enclosure Type

Minimum Resistance

recommended [Ohm]

0003 100 0004 100

MS2

0005 100 0006 100 0008 100 0009 50

MS3

0012 50 0016 50

Table 44. External brake resistor ratings, 3AC 380-480V.

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Technical data vacon • 65

7.3 VACON® 20 CP - technical data

Mains connection

Motor connection

Table 45. VACON

20 Cold Plate technical data.

3AC 208…240V

Input voltage U

1AC 208…240V

3AC 380…480V Input voltage tolerance -15%…+10% continuously Input frequency 50/60 Hz Input frequency

tolerance

45…66 Hz

Protection class I Connection to mains Once per minute or less Starting delay 4 s

Supply network

IT and TN-networks (cannot be used with cor-

ner earthed networks) Short-circuit current Maximum short-circuit current has to be <50kA

DC connection

Output voltage

Rated output current

Overload output current

Starting current

Available as standard in MS2 single-phase

enclosures and MS3

0…U

IN: Enclosure temperature max. +70°C.

See Chapter 7.1.

1.5 x IN (1 min/10 min)

IS for 2 s every 20 s (IS = 2.0 * IN) Output frequency 0…320 Hz

Control characteristics

Control connections

Frequency resolution 0.01 Hz Protection class I

Motor characteristics

AC squirrel cage motors

Permanent magnet motors Cable type Screened motor cable Cable maximum length 30 m

Programmable 2…16 kHz; Switching frequency

Default 6 kHz.

Automatic switching frequency derating in case

of overheating Frequency reference:

Analogue input Panel reference

Resolution ±0.05% (11-bit), accuracy ±1%

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

Braking

Brake chopper standard in all three-phase

enclosures. External brake resistor optional.

See Chapter 5.

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vacon • 66 Technical data

Communication interface

Ambient conditions

Table 45. VACON

20 Cold Plate technical data.

Standard: Serial communication (RS485/Mod-

bus); Fieldbus

Optional: CANopen; Profibus DP, Lonworks,

DeviceNet, Profinet IO, Ethernet IP, Modbus

TCP, EtherCAT, AS-interface

Status indicators

Enclosure operating

Drive status indicators (LED) on front side

(POWER, RUN, FAULT, READY)

-10°C (no frost)…+70°C

temperature Storage temperature -40°C…+85°C

Relative humidity

0 to 95% RH, non-condensing, non-corrosive,

no dripping water Pollution degree PD2

Altitude

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

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

MS2 (three-phase version): IP00 Degree of protection

MS2 (single-phase version): IP20

MS3: IP20

MS2 (three-phase version):

3 Hz f9Hz: 10mm

9 Hz f200Hz: 3g Stationary vibration:

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

MS2 (single-phase version) and MS3:

3 Hz  f  8.43 Hz: 7.5 mm

8.43 Hz f  200 Hz: 2g

[3M6 acc. to IEC 60721-3-3]

MS2 (three-phase version):

25g / 6 ms Shock/Bump:

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

MS2 (single-phase version) and MS3:

25g / 6 ms

[3M6 acc. to IEC 60721-3-3] EMC 2004/108/EC

Directives

Low Voltage 2006/95/EC RoHS 2002/95/EC WEEE 2012/19/EC

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Technical data vacon • 67

Table 45. VACON

Immunity

Standards

Emissions

Safety EN 61800-5-1

Production quality ISO 9001

Functional Safety TÜV - Tested Electrical Safety TÜV - Tested

Approvals

EMC TÜV - Tested USA, Canada cURus approval, file number E171278

20 Cold Plate technical data.

EN61800-3: 2004 + A1: 2011, 1st and 2nd envi-

ronment

EN61800-3: 2004 + A1: 2011,

Category C2 as standard for

3-phase version

conducted and radiated emissions

Category C1 as standard for conducted emissions

1-phase version

Category C2 as standard for radiated emissions. It can be C1 with a suitable enclosure and cabling.

The drive can be modified to category C4.

Declaration of Conformity

Protections

Korea KC mark Australia RCM Declaration of Conformity Europe EC Declaration of Conformity

Depends on supply voltage (0.8775*supply volt-

age): Undervoltage trip limit

Supply voltage 400 V: Trip limit 351 V

Supply voltage 480 V: Trip limit 421 V

Supply voltage 240 V: Trip limit 211 V Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes (not available in 1-phase version) Overcurrent protection Yes Unit overtemperature

protection Motor overload protec-

tion

Yes

Motor stall protection Yes Motor underload

protection

Yes

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

Yes reference voltages

Thermal motor protection

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Yes (by PTC with option card)

vacon • 68 Technical data

7.3.1 Technical information on control connections

Table 46. Technical information on standard I/O terminals.

Standard I/O terminals

Terminal Signal Technical information

A RS485 B RS485 1 Reference output +10V, ±5%; Maximum current 10 mA

8 9

14 15 16

Analogue input, voltage or current

I/O ground

24V aux. voltage

DIN COM

Digital input 1

Digital input 2

Digital input 3

Analogue input, voltage or current

I/O ground

Digital output common

Digital input 4

Digital input 5

Digital input 6

Analogue signal (+output)

Digital Output 1 Open Collector max 35V / 50mA (DO1+)

Differential receiver/transmitter Set bus termination with dip switches (see Chapter 5)

Analogue input channel 1 0- +10V (Ri = 200 k 0/4-20 mA (Ri =250 Resolution 0.05 %, accuracy ±1 %

Selection V/mA with dip-switches (see Chapter 5). Default 0- +10V

Ground for reference and controls (connected internally to enclosure earth through 2M

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

Common for digital inputs. Connected to GND with dipswitch SW1. See Chapter 5

Positive or negative logic Ri = min. 4k 15…30V = "1"

0...5V = “0” Analogue input channel 2

0- +10V (Ri = 200 k 0/4-20 mA (Ri =250

Resolution 0.05%, accuracy ±1 % Selection V/mA with dip-switches (see Chapter 5). Default 0/4-20 mA

Ground for reference and controls (connected internally to enclosure earth through 2M

Common for digital output 1 (DO1-)

Positive or negative logic Ri = min. 4k 15…30V = "1"

0...5V = “0” Analogue output channel 1,

0-10V (30mA max) Resolution 0.1%, accuracy ±2.5 % Short-circuited protected.

)



)

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Technical data vacon • 69

Table 47. Technical information on relays.

Relay terminals

Terminal Signal Technical information

22 23

Relay output 1

24 25

Relay output 2*

If 230VAC is used as control voltage from the output relays, the control circuitry

Switching capacity 250VAC/3A (only earthed network allowed)

Switching capacity NO 250VAC/5A NC 250VAC/3A (only earthed network allowed)

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 • 70 Options

11863_00

8. OPTIONS

8.1 VACON® keypad with seven-segment display

The text keypad is an option available for VACON® 20 CP. The control keypad is the interface between the VACON

20 CP AC drive and the user.

Main Switch only for AC voltage. Do not use for DC voltage.

Figure 38. Text keypad.

Order code Description Type of option

VACON-PAN-HMTX-MC06-CP

Handheld/Magnetic fixing IP66 text

keypad w/ cable, l=1m/39.37 inches

Loose option

Figure 39. Display holder dimensions for wall-mounting

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Options vacon • 71

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

Stop button Start button

Enter active level/item Confirm selection

Indicators:

Status

Indicators:

Alarm, Fault

Indicators:

Menus

Indicators:

Direction

Indicators:

Control place

READY RUN STOP ALARM FAULT

FWD REV I/O KEYPAD BUS

REF

MON

PAR

SYS/FLT

.

With the keypad it is possible to control the speed of the motor, to supervise the state of the drive and to set the AC drive’s parameters. The button section of the text keypad is shown in the following picture.

8.2 Text keypad

The keypad display indicates the status of the motor and the drive and any irregularities in motor or drive functions. On the display, the user can see the information about menu structure and the item displayed.

Figure 40. Keypad buttons.

his present

location in the

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Figure 41. Keypad display.

vacon • 72 Options

8.3 Menu structure

The data on the control keypad are arranged in menus. Use the Up and Down arrows to move between the menus. Enter the group/item by pressing the OK button and by pressing the Back/Reset button. The arrows on the left of the display show the active menu. In Figure 41 the REF menu is active. The table below shows the structure of the main menu:

Reference (REF) Reference from Keypad Monitor (MON) Monitoring values Parameters (PAR) Application parameters

System Menu

System/Fault (SYS/FLT)

Active fault History fault

Table 48. Keypad menus.

return

to the former level

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Options vacon • 73

FWD REV I/O K EY PAD BUS

REF

MON

PA R

FA ULTALARMSTOPREADY RU N

FWD REV I/O KEYPAD BU S

REF

PA R

FA U LTALARMSTOPREADY RUN

MON

FW D REV I/O KEYPAD BUS

REF

PAR

FAU L TALARMSTO PREADY RUN

MON

FWD REV I/O KEYPAD BUS

PAR

FAULTALARMSTOPREADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAULTALARMSTOPRE ADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAULTALAR MSTOPRE ADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAU LTALARMST O PREADY RUN

MON

PRESS

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTAL ARMSTOPRE ADY RU N

PRESS

In th is me nu you can browse the monitoring values.

In th is me nu you can browse and edit the parameters.

Dispalys the keypad reference value regardless of the selected contron place.

Here you will be able to browse system paramete and fault submenu.

FLTSYS /

SYSTEM/FAULT MENU

PA R A METE R MENU

MONITOR MENU

REFERENCE MENU

8.4 Using the keypad

This chapter provides you with information on navigating the menus on VACON® 20 CP and editing the values of the parameters.

8.4.1 Main menu

The menu structure of VACON

20 CP control software consists of a main menu and several

submenus. Navigation in the main menu is shown below:

Figure 42. The Main menu of VACON

20 CP.

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vacon • 74 Options

8.4.2 Resetting fault

When a fault appears and the drive stops examine the cause of the fault, perform the action advised in the Fault Tracing paragraph and reset the fault by pressing the RESET button.

8.4.3 Local/Remote control button

The LOC/REM button is used for two functions: to quickly access the Control page and to easily change between the Local (Keypad) and Remote control places.

Control places

The

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

control place has its own parameter for selecting the frequency reference source. In the VACON 20 CP drive, the Local control place is always the keypad. The Remote control place is determined by parameter (I/O or Fieldbus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O and Fieldbus can be used as remote control places.

Local control

Keypad is always used as control place while in local control. Local control has higher priority than remote control. Switching between Local and Remote Control can be done by pressing the LOC/ REM-button on the keypad.

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Options vacon • 75

Press to enter edit mode

Change value

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTALARMSTOPREADY R UN

FLTSYS /

8.4.4 Reference menu

Figure 43. Reference menu.

Move to the reference menu with the UP / DOWN button (see Figure 42). The reference value can be changed with UP / DOWN button as shown in Figure 43. If the value has big change, first press Left and Right buttons to select the digit which has to be

changed, then press Up button to increase and Down button to decreases the value in the selected digit. The changing reference frequency will been taken into use immediately without pressing OK.

NOTE! LEFT and RIGHT buttons can be used to change the direction in Ref menu in local control mode.

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vacon • 76 Options

FAULTALARMSTOPREADY RU N

REF

MON

PA R

REF

MON

PA R

FAULTALARMSTOPRE ADY RU N

FWD R EV I/O K EYPAD BUS FWD R EV I/O K EYPAD BUS

REF

MON

PA R

FAULTALARMSTOPREADY RU N

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAU LTALARMSTOPRE ADY RU N

FWD R EV I/O K EYPAD BUS

FAULTALARMSTOPREADY RU N

REF

MON

PA R

FWD R EV I/O K EYPAD BUS

FLTSYS /

Press OK to enter Monitoring menu

Press Left/Right to browse other Monitoring groups

Press Down to browse V4.5

Press OK to select V4.5

Press OK to display the value

8.4.5 Monitoring menu

Monitoring values are actual values of measured signals as well as status of some control settings. It is visible in VACON

20 CP display, but it can not be edited. The monitoring values are listed in the

Application Manual.

Pressing Left/Right button to change the actual parameter to the first parameter of the next group, to browse monitor menu from V1.x to V2.1 to V3.1 to V4.1. After entering the desired group, the monitoring values can be browsed by pressing UP/DOWN button, as shown in Figure 44. In MON menu the selected signal and its value are alternating in the display by pressing OK button.

Note! Turn on drive power, arrowhead of main menu is at MON, V x.x or monitor parameter value of Vx.x is displayed in Panel. Display Vx.x or monitor parameter value of Vx.x is determined by the last show status before power shut down.

Figure 44. Monitoring menu.

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Options vacon • 77

Press Right to browse other Par. group

Press OK button to enter edit mode

Press down button to browse P3.4

Press Up / Down to change value

Press OK to confirm

FA ULTALARMSTOPRE ADY R U N FA ULTALAR MSTOPRE ADY RU N

FA U LTALARMSTOPREADY R U N

FWD R EV I/O KEYPAD BUS FWD R EV I/O K EYPAD BUS

FWD R EV I/O K EY PAD B US

Press OK to enter Pa r. menu

FAU LTALARMSTOPRE AD Y RU N

FWD R EV I/O K EYPAD BUS

FA U LTALARMSTOPRE ADY RU N

FWD R EV I/O K EYPAD BUS

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

8.4.6 Parameter menu

In Parameter menu only the Quick setup parameter list is shown as default. To view the other advanced parameter groups, see the Application Manual. The following figure shows the parameter menu view:

Figure 45. Parameter menu

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.

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vacon • 78 Options

Press OK to enter V1.1

Press Left/Right button

to browse other groups

Pressdowntobrowse other active faults

FAU LTALA RMSTOP

FWD R EV I/O KEYPAD BUS

READY RU N

Press OK to select one fault to browse its time

FAU LTAL ARMSTOPREADY RU N

FWD R EV I/O KEYPAD BUS

Browse for fault code(C xx), subcode(Id xx), days(d xx), hours(H xx), minutes(M xx)

FAU LTALARMSTOPRE ADY RU N

FWD R EV I/O KEYPAD BUS

FAU LTALA RMSTOPRE ADY RU N

FWD R EV I/O KEYPAD BUS

FAU LTAL ARMSTOPREADY RU N

FWD R EV I/O KEYPAD BUS

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

8.4.7 System/Fault menu

SYS/FLT menu including fault submenu, field bus submenu and system parameter submenu. In system parameter submenu, there are some editable parameter (P) and some not editable parameters (V). The Fault submenu of SYS/FLT menu includes active fault submenu and fault history submenu.

8.4.7.1

Faults

Under this menu, you can find Active faults, Reset faults, Fault history, Counters and Software info. In active fault situation, FAULT arrow is blinking and the display is blinking active fault menu item

with fault code. If there are several active faults, you can check it by entering the active fault

Figure 46. System and Fault menu.

submenu F5.x. F5.1 is always the latest active fault code. The active faults can be reset by pressing BACK / RESET button with long time (>2 s), when the API is in active fault submenu level (F5.x). If the fault cannot be reset, the blinking continues. It is possible to select other display menus during active fault, but in this case the display returns automatically to the fault menu if no button is pressed in 10 seconds. The fault code, subcode and the operating day, hour and minute values at the fault instant are shown in the value menu (operating hours = displayed reading).

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Options vacon • 79

Active faults

Menu Function Note Active faults When a fault/faults appear(s), the

display with the name of the fault starts to blink. Press OK to return to the Diagnostics menu. The

Active faults submenu shows the

number of faults. Select the fault and push OK to see the fault-time data.

The fault remains active until it is cleared with the RESET button or with a reset signal from the I/O terminal or fieldbus or by choosing

Reset faults (see below).

The memory of active faults can store the maximum of 10 faults in the order of appearance.

Fault history

Menu Function Note Fault history 10 latest faults are stored in the

Fault history.

Entering the Fault history and clicking OK on the selected fault shows the fault time data (details).

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vacon • 80 Options

8.5 Fault tracing

Fault

code

Fault name Subcode Possible cause Remedy

AC drive has detected too high a current (>4*I

Overcurrent

Overvoltage

Earth fault

84 MPI communication crc error

89 HMI receives buffer overflow

90 Modbus receives buffer overflow

System Fault 93 Power identification error

97 MPI off line error

98 MPI driver error

99 Option board driver error

100 Option board configuration error

• 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

) in the motor cable:

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.

Check PC-drive cable. Try to reduce ambient noise

Check Modbus specifications for time-out. Check cable length. Reduce ambient noise. Check baudrate.

Try to reduce ambient noise. Reset the fault and restart. 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.

Check contact in option board slot Try to reduce ambient noise; Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.

Check contact in option board slot Try to reduce ambient noise; Should the fault re-occur, contact the distributor near to you.

Table 49. Fault codes and descriptions.

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Options vacon • 81

Fault

code

Fault name Subcode Possible cause Remedy

Check Modbus specifications for time-out.

101 Modbus buffer overflow

104 Option board channel full

105

106 Option board Object queue full

System Fault 107 Option board HMI queue full

108 Option board SPI queue full

111 Parameter copy error

113

114 PC control time out fault

115 DeviceProperty data format

120 Task stack overflow

Option board memory allocation fail

Frequency detective timer overflow

Check cable length. Reduce ambient noise. Check baudrate.

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

Check if parameter set is compatible with drive. Do not remove Keypad until copy is finished.

Check keypad contacts. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

Do not close VACON control is active. Check PC-Drive cable. Try to reduce ambient noise.

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

Live when PC

Table 49. Fault codes and descriptions.

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vacon • 82 Options

Fault

code

Fault name Subcode Possible cause Remedy

DC-link voltage is under the voltage limits defined.

Undervoltage

• most probable cause: too low a supply voltage

• AC drive internal fault

• defect input fuse

• external charge switch not closed

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.

NOTE! This fault is activated only

if the drive is in Run state.

Input phase Input line phase is missing.

Current measurement has

Output phase

detected that there is no current in one motor phase.

Too low temperature measured in AC drive undertemperature

power unit’s heatsink or board.

Heatsink temperature is under -

10°C.

Too high temperature measured in AC drive overtemperature

power unit’s heatsink or board.

Heatsink temperature is over

100°C.

Motor stalled Motor is stalled.

Motor overtemperature

Motor is overloaded.

Motor underload Motor is under loaded

Check supply voltage, fuses and cable.

Check motor cables and motor.

Check the ambient temperature.

Check the correct amount and flow of cooling air. Check the heatsink for dust. Check the ambient temperature. Make sure that the switching frequency is not too high in relation to ambient temperature and motor load.

Check motor and load. Insufficient motor power, check motor stall protection parametrization.

Decrease motor load. If no motor overload exists, check the temperature model parameters.

Check load. Check underload protection parametrization.

Power overload Supervision for drive power Drive power is to high: decrease load.

Watchdog

Back EMF

STO fault

Error in the microprocessor moni-

toring

Malfunction

Component fault

Protection of unit when starting

with rotating motor

Safe torque off signal does not

allow drive to be set as ready

Reset the fault and restart. If the fault occurs again, please contact your nearest distributor.

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

Table 49. Fault codes and descriptions.

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Options vacon • 83

Fault

code

Fault name Subcode Possible cause Remedy

Application error

1 Application software flash error Reload Application

2 Application header error

IGBT temp

4 mA fault (Analog input)

External fault

Keypad Communication fault

Fieldbus communication fault

Firmware Interface version

between Application and Control

not matching

IGBT temperature (UnitTempera-

ture + I2T) too high

Selected signal range: 4...20 mA

(see Application Manual)

Current less than 4 mA

Signal line broken detached

The signal source is faulty

Error message on digital input.

The digital input was programmed

as an input for external error mes-

sages. The input is active.

The connection between the con-

trol keypad and the AC drive is bro-

ken.

The data connection between the

fieldbus master and fieldbus board

is broken

Load a compatible application. Please contact your nearest distributor.

Check loading. Check motor size. Make identification run.

Check the analog input’s current source and circuit.

Check the programming and check the device indicated by the error message. Check the cabling for the respective device as well.

Check keypad connection and keypad cable.

Check installation and fieldbus master.

Fieldbus Interface error Defective option board or slot Check board and slot.

Wrong run command

Wrong run alarm and stop com-

mand

Run forward and backward are activated at the same time

Board OPTBH is installed and meas-

Temperature Temperature fault

ured temperature is above (or below) the limit

Identification Identification alarm

Motor identification has not been successfully completed

The drive has been stopped with

Quick Stop Quick Stop activated

Quick Stop digital input or Quick Stop command by fieldbus

Table 49. Fault codes and descriptions.

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vacon • 84 Options

8.6 Option boards

VACON® 20 CP drive family embodies a wide selection of expander boards with which the available I/O resources of VACON

There is one board slot (labelled D) on the VACON

20 CP AC drive can be increased and its versatility improved.

20 CP control unit. To locate the slot, see Chapter

5. Usually, when the AC drive is delivered from the factory, the control unit does not include any option board in the board slot.

The following option boards are supported:

Order Code Description Note

With jumper blocks it is possible to use

each terminal as digital input or as digi-

tal output.

OPT-B1-V

OPT-B2-V

Option board with six bidirectional

terminals.

I/O expander board with a therm-

istor input and two relay outputs. I/O expander board with one gal-

vanically isolated analogue input

OPT-B4-V

galvanically isolated analogue

and two

outputs (standard signals

0(4)…20mA).

OPT-B5-V

I/O expander board with three

relay outputs

I/O expander board with five

OPT-B9-V

42…240 VAC digital inputs and one

relay output.

OPT-BF-V

OPT-BH-V

I/O expander board with analogue

output, digital output and relay

output.

Temperature measurement board

with three individual channels.

On the OPTBF board, there is one

jumper block for selecting the analogue

output mode (mA/V).

Supported sensors: PT100, PT1000,

NI1000, KTY84-130, KTY84-150, KTY84-

131

OPT-BK-V ASi option board AS-interface option card

OPT-C4-V Lonworks option board

Pluggable connector with screw termi-

nals

OPT-E2-V Modbus RTU and N2 screw terminals

OPT-E3-V Profibus DP option board

Pluggable connector with screw termi-

nals OPT-E5-V Profibus DP option board 9-pin Sub-D terminal OPT-E6-V CANopen option board OPT-E7-V DeviceNet option board OPT-E8-V OPTE8 Modbus RTU and N2 sub-D9 connector

OPT-E9-V

OPT-EC-V

Dualport Ethernet option board

EtherCat option board

Table 50. Option boards supported in VACON

20 CP.

See the Option boards User’s Manual to use and install the option boards.

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Options vacon • 85

8.6.1 Option board installation

NOTE! Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards.

• Remove the option slot cover.

Figure 47. Opening the main cover, MS2 three-phase version example.

The relay outputs and other I/O-terminals may have a dangerous control voltage present even when the drive is disconnected from mains.

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vacon • 86 Options

Slot coding

OPT

9116.emf

• Make sure that the sticker on the connector of the board says “dv” (dual

voltage). This indicates that the board is compatible with VACON

20 CP.

See below:

• NOTE: Incompatible boards cannot be installed on VACON

20 CP. Compatible boards have a slot coding that enables the placing of the board (see above)

• Install the option board into the slot as shown in the picture below.

Figure 48. Option board installation.

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Options vacon • 87

• Mount the option slot cover.

Figure 49. Mounting of the option slot cover: remove the plastic opening for the option board terminals.

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vacon • 88 Safe Torque Off

9. SAFE TORQUE OFF

This chapter describes the Safe Torque Off (STO) function which is a functional safety feature

present in VACON

20 CP drive products as standard. This function is available only in the three-

phase version.

9.1 General description

The STO function brings the motor in no-torque-state as defined by 4.2.2.2 of the IEC 61800-5-2:

“Power that can cause rotation (or motion in the case of a linear motor) is not applied to the motor. The Power Drive System (Safety Related) will not provide energy to the motor which can generate torque (or force in the case of a linear motor).”

Therefore, the STO function is suitable for applications that rely on the immediate removal of power to the actuator, resulting in an uncontrolled coast to stop (activated by an STO demand). Additional protective measures need to be applied when an application requires a different stop method.

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Safe Torque Off vacon • 89

9.2 Warnings

Designing of safety-related systems requires specialist knowledge and skills. Only qualified people are permitted to install and set up the STO function. The use of STO does not itself ensure safety. An overall risk evaluation is required for ensuring that the commissioned system is safe. Safety devices must be correctly incorporated into the entire system which must be designed in compliance with all relevant standards within the field of industry.

The information in this manual provides guidance on the use of the STO function. This information is in compliance with accepted practice and regulations at the time of writing. However, the end product/system designer is responsible for ensuring that the end-system is safe and in compliance with relevant regulations.

When a permanent magnet motor is used and in case of a multiple IGBT power semiconductor failure, when the STO option energizes the drive outputs to the off state, the drive system may still provide an alignment torque which maximally rotates the motor shaft by 180°/p (where p is the number of poles of the motor) before the torque production ceases.

Electronic means and contactors are not adequate for protection against electric shock. The Safe Torque Off function does not disconnect the voltage or the mains from the drive. Therefore hazardous voltages may still be present on the motor. If electrical or maintenance work has to be carried out on electrical parts of the drive or the motor, the drive has to be completely isolated from the main supply, e.g. using an external supply disconnecting switch (see EN60204-1 section 5.3).

This safety function corresponds to an uncontrolled stop in accordance with stop category 0 of IEC 60204-1. The STO function does not comply with Emergency Switching Off according to IEC 60204-1 (no galvanic insulation from the Mains in case the motor is stopped).

The STO function is not a prevention of unexpected start-up. To fulfil those requirements, additional external components are required according to appropriate standards and application requirements.

In circumstances where external influences (e.g. falling of suspended loads) are present additional measures (e.g. mechanical brakes) may be necessary to prevent any hazard.

STO shall not be used as a control for starting or stopping the drive.

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vacon • 90 Safe Torque Off

9.3 Standards

The STO function has been designed for use in accordance with the following standards:

Standards

IEC 61508, Parts 1-7

IEC 61800-5-2

IEC 62061 ISO 13849-1 IEC 60204-1

Table 51. Safety Standards.

The STO function has to be applied correctly to achieve the desired level of operational safety. Four different levels are allowed, depending on the use of the STO signals (see the following table).

STO inputs STO feedback Cat. PL SIL

Both dynamically used(*) Used 4 e 3

Both statically used Used 3 e 3 Connected in parallel Used 2 d 2 Connected in parallel Not used 1 c 1

Table 52. Four different STO levels. (*) see 9.5.1.

The same values are calculated for SIL and SIL CL. According to EN 60204-1, the emergency stop category is 0.

The SIL value for the safety related system, operating in high demand/continuous mode, is related to the probability of dangerous failure per hour (PFH), reported in the following table.

STO inputs STO feedback PFH PFDav

MTTFd

(years)

DCavg

Both dynamically used(*) Used 8.0 E-10 1/h 7.0 E-05 8314 y HIGH

Both statically used Used 8.1 E-10 1/h 7.1 E-05 8314 y MEDIUM Connected in parallel Used 8.1 E-10 1/h 7.1 E-05 8314 y MEDIUM Connected in parallel Not used 9.2 E-10 1/h 8.0 E-05 8314 y NONE

Table 53. SIL values. (*) see 9.5.1.

The STO inputs must always be supplied by a safety device.

The power supply of the safety device may be external or taken from the drive (as long as this is compliant with the rating specified for terminal 6). See Chapter 5.1.2 for the standard I/O terminal description.

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Safe Torque Off vacon • 91

Reinforced

S1 G1

S2 G2

L1 L2 L3

F+ F-

U V W

DC+/R+ R-

POWER UNIT

DC-*

9.4 The principle of STO

The STO functionality, such as the technical principles and data (wiring examples and commissioning) will be described in this chapter.

In VACON to the inverter circuit.

The inverter power stage is disabled through redundant disabling paths which start from the two separated and galvanically isolated STO inputs (S1-G1, S2-G2 in Figure 50). In addition, an isolated output feedback is generated to improve the diagnostics of the STO function and to achieve a better safety capability (F+, F- terminals). The values assumed by the STO output feedback are indicated in the following table:

20 CP, the STO function is realized by preventing the propagation of the control signals

STO inputs Operating conditions

Both inputs energized with 24V DC

Power removed from

both inputs

The STO inputs have

different values

Table 54. Values of the STO output feedback (and torque on the motor). (*) Only one channel is

The diagram below is a conceptual schematic diagram and is presented to illustrate the safety function with relevant safety components only shown.

Normal operation

STO demand

Failure in demand or

due to internal fault

preventing the drive from moving.

STO feedback

output

The feedback must

be 0V

The feedback must

be 24V

The feedback must

be 0V

Torqu e at the

motor shaft

present (motor

on)

disabled (motor

de-energized)

disabled (motor

de-energized)(*)

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Figure 50. STO function principle. (*) Only for MS3.

vacon • 92 Safe Torque Off

9.4.1 Technical details

The STO inputs are digital inputs intended for a nominal 24V d.c. input, positive logic (e.g. enabled when high).

Technical information: Technical values

Maximum voltage range 30V

Typical input current at 24V 10...15 mA

according to IEC 61131-2

Logic threshold

15V....30V = “1”

0V....5V = “0”

Response time at nominal voltage:

Reaction time <20ms

Table 55. Electrical data.

The reaction time of the STO function is the amount of time which passes from the moment in which the STO is demanded until the system is in the Safe State. For VACON

20 CP, the reaction time is

20 ms maximum.

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Safe Torque Off vacon • 93

9.5 Connections

To make the STO function available and ready to be used, both the STO jumpers have to be removed. They have been located in front of the STO terminal to mechanically prevent the insertion of the STO inputs. For the correct configuration, see the following table and the Figure 51.

Signal Ter mi na l Technical information Data

STO1

STO 2

STO

feedback

S1 G1 S2 G2

F+

Insulated digital input 1 (interchangeable polarity)

Insulated digital input 2 (interchangeable polarity)

Insulated digital output for STO feedback

24V 

10...15 mA

24V 

10...15 mA 24V 

15 mA max.

(CAUTION! Polarity must be

F- GND

respected)

Table 56. STO connector and data signals.

Figure 51. Removing the STO jumpers.

Make sure that the AC drive is switched off before cabling.

When the STO function is used, the drive has to be mounted in an enclosure which fulfils the requirements for IP54.

Disconnect both the STO jumpers to allow the cabling of the terminals.

The following examples show the basic principles for wiring the STO inputs and the STO output feedback. Local standards and regulations should be always followed in the final design.

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

vacon • 94 Safe Torque Off

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

For this safety capability, an external safety device must be installed. This must be used to dynamically activate the STO inputs and to monitor the STO output feedback.

The STO inputs are dynamically used when they do not commute together (static use), but according to the following picture (where the inputs are released with delay in turn). The dynamic use of the STO inputs allows detecting faults that may otherwise accumulate.

Figure 52.

An emergency push button connected to the STO inputs does not assure the same quality, because no fault detection is performed at a sufficient proof test interval (once a day is recommended).

The external safety device, which forces the STO inputs and evaluates the STO output feedback, has to be a safe device and it has to fulfil the requirements of the specific application.

A simple switch cannot be used in this case!

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

Safe Torque Off vacon • 95

S1 G1

S2 G2

L1 L2 L3

F+ F-

U V W

DC+/R+ R- DC-*

Supply

11864_uk

Reinforced

POWER UNIT

EXTERNAL SAFETY DEVICE (**)

STO inputs

STO feedback

The picture below shows an example of connection for the STO function. The external device has to be connected with 6 wires to the drive.

Figure 53. STO example with automatic monitoring of the feedback and both STO inputs used. (*) Only

for MS3. (**) The external safety device must feed active voltage to the STO inputs.

The external device has to monitor the STO function in accordance with theTable 54. The device has to periodically de-energize the STO inputs and it has to verify that the STO output feedback assumes the expected value.

Any difference between the expected and the real value has to be considered as a failure and has to drive the system into a Safe State. In case of failure, check the wiring. If the fault recognized by the external safety device persists, the drive will have to be replaced/repaired.

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

vacon • 96 Safe Torque Off

S1 G1

S2 G2

L1 L2 L3

F+ F-

U V W

DC+/R+ R- DC-*

11866_uk

Reinforced

POWER UNIT

EXTERNAL SAFETY DEVICE (**)

Supply

STO feedback

STO inputs

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

The safety capability is reduced to Cat. 3 / PL e / SIL 3 if the STO inputs are statically used (which means they are forced to commute together).

Both STO inputs and the STO feedback have to be used. The same warnings and cabling instruction as 9.5.1 apply, except that the proof test interval has to be at least once every three months.

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

The safety capability is reduced to Cat. 2 / PL d / SIL 2 if the STO inputs are connected in parallel (no redundancy of the STO inputs).

The STO feedback has to be used. The same warnings as 9.5.1 apply, except that the proof test interval has to be at least once a year. The picture below shows an example of connection for the STO function. The external device has to be connected with 4 wires to the drive.

Figure 54. STO Example with automatic monitoring of the feedback and STO inputs connected in parallel.

(*) Only for MS3. (**) The external safety device must feed active voltage to the STO inputs.

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

Safe Torque Off vacon • 97

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

Without any automatic monitoring of STO output feedback, the safety capability is reduced to Cat. 1 / PL c / SIL 1. The STO inputs (which can be connected in parallel) must be supplied by a safety push button or a safety relay.

The choice of using the STO inputs (without the automatic monitoring of the output feedback) does not allow the other safety capabilities to be achieved.

The standards for functional safety require that functional proof tests are performed on the equipment at user-defined intervals. Therefore, this safety capability can be achieved, as long as the STO function is manually monitored at the proof test interval determined by the specific application (once a year can be acceptable).

This safety capability can be achieved by connecting in parallel the STO inputs externally and by ignoring the use of the STO output feedback.

The picture below shows an example of connection for the STO function. A switch (a safety push button or a safety relay) may be connected with 2 wires to the drive.

When the contacts of the switch are opened, the STO is demanded, the drive indicates F30 (= "Safe Torque Off") and the motor stops by coasting.

S1 G1

STO inputs

S2 G2

L1 L2 L3

SAFETY PUSH BUTTON or SAFETY RELAY (**)

R R

POWER UNIT

24V / GND

DC+/R+ R- DC-*

F+ F-

STO feedback

U V W

Reinforced

11865_uk

Figure 55. STO example without automatic monitoring of the feedback and STO inputs connected in

parallel. (*)Only for MS3. (**) The safety push button or safety relay must feed active voltage to the STO

inputs.

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

vacon • 98 Safe Torque Off

9.6 Commissioning

9.6.1 General wiring instructions

Protect the STO cabling with shielding or an enclosure to exclude external damage.

Wire ferrules are highly recommended for all STO signals (inputs and feedback).

The wiring should be done according to the general wiring instructions for the specific product. A shielded cable is required. In addition, the voltage drop from the supply point to the load shall not exceed 5% [EN 60204-1 part 12.5].

The following table indicates examples of cables to be used.

STO feedback Cable size

STO feedback automatically

monitored by an external safety

device

STO feedback ignored, simply

safety device (switch) used

3 x (2 + 1) x 0,5 mm

2 x (2 + 1) x 0,5 mm

(*)

Table 57. Cable types required to meet the standards. (*) Additional wires are needed for restarting the

drive after each STO demand.

9.6.2 Checklist for commissioning

Follow the checklist shown in the table below for the steps required to use the STO function.

Carry out a risk assessment of the system to ensure that the use of the STO function is safe and according to the local regulations

Include in the assessment an examination of whether the use of external devices, such as a mechanical brake, are required.

Check if the switch (if used) has been chosen according to the required safety performance target (SIL/PL/Category) set during the risk evaluation

Check if the external device for automatic monitoring of the STO output feedback (if used) has been chosen in accordance with the specific application

Check if the reset function with the STO function (if used) is edge sensitive.

The shaft of a permanent magnet motor might, in an IGBT fault situation, still provide energy before the torque production ceases. This may result in a jerk of max. 180° electrically. Ensure that the system is designed in such a way that this can be accepted.

Check if the degree of protection of the enclosure is at least IP54.

Check if the recommendations on EMC for cables have been followed.

Check if the system has been designed in such a way that enabling of the drive through STO inputs will not lead to an unexpected start of the drive

Table 58. Checklist for commissioning of STO.

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

Safe Torque Off vacon • 99

Check if only approved units and parts have been used.

Set up a routine to ensure that the functionality of the STO function is being checked at regular intervals.

Table 58. Checklist for commissioning of STO.

9.7 Parameters and fault tracing

There are no parameters for the STO function itself.

Before testing the STO function, make sure that the checklist (Table 58) is inspected and completed.

When STO function is demanded, the drive always generates a fault (“F30”) and the motor stops by coasting.

In the application the STO state can be indicated using a digital output.

To re-enable motor operation, after the STO state, it is necessary to perform the following steps:

• Release the switch or the external device (“F30” is displayed even after this has been released).

• Reset the fault (through a digital input or from the keypad).

• It is possible that a new start command is required for the restart (depending on the application and your parameter settings).

9.8 Maintenance and diagnostics

If any service or repair has to be conducted on the drive installed, please inspect the checklist given in Table 58.

During maintenance breaks, or in case of service/repair, ALWAYS make sure that the STO function is available and fully functional by testing it.

The STO function or the STO input/output terminals do not need any maintenance. The following table shows faults that may be generated by the software that monitors the hardware

related to the STO safety function. If you detect any failure in safety functions, including STO, contact your local distributor.

Fault Code Fault Cause Correction

STO inputs in a different

30 STO fault

state or both de-ener-

gized

Table 59. Fault related to the STO function.

NOTE! See Table 49 for detailed fault code descriptions.

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

Check cabling

www.danfoss.com

Danfoss A/S

Nordborgvej 81 6430 Nordborg Denmark

Document ID:

DPD00489L

Rev. L

Danfoss vacon 20 cp Installation guide

Specifications and Main Features

Frequently Asked Questions

User Manual

1. SAFETY

1.1 Signs

1.2 Units

1.3 Danger

1.4 Hot surface warning

1.5 Warnings

1.6 Grounding and earth fault protection

1.7 Insulation system

1.8 Compatibility with RCDs

1.9 Cooling System

2. RECEIPT OF DELIVERY

2.1 Type designation code

2.2 Order codes

2.3 Unpacking and lifting the AC drive

2.4 Accessories

2.4.1 Disposal

3. MOUNTING

3.1 Dimensions

3.1.1 Enclosure MS2 three-phase version

3.1.2 Enclosure MS2 single-phase version

3.1.3 Enclosure MS3

3.2 Cooling

3.3 Environment temperature

3.4 Heatsink assembly instructions

3.5 Installation spacing

3.6 Power loss thermal characteristics

3.7 Dimensioning an external heatsink

4. POWER CABLING

4.1 Circuit breaker

4.2 UL standards on cabling

4.3 Description of the terminals

4.3.1 MS2 three-phase version power connections

4.3.2 MS2 single-phase version power connections

4.3.3 MS3 power connections

4.4 Cable dimensioning and selection

4.4.1 Cable and fuse sizes, enclosures MS2 to MS3

4.4.2 Cable and fuse sizes, enclosures MS2 to MS3, North America

4.5 Brake resistor cables

4.6 Control cables

4.7 Cable installation

5. CONTROL UNIT

5.1 Control unit cabling

5.1.1 Control cable sizing

5.1.2 Standard I/O terminals

5.1.3 Relay terminals

5.1.4 Safe Torque off (STO) terminals

5.1.5 Description of additional echo connectors

5.1.6 Led handling

5.1.7 Selection of terminal functions with dip switches

5.2 Fieldbus connection

5.2.1 Modbus RTU protocol

5.2.2 Preparation for use through RS485

6. COMMISSIONING

6.1 Commissioning of the drive

6.2 Changing EMC protection class

6.2.1 Changing EMC protection class - MS2 three-phase version

6.2.2 Changing EMC protection class - MS2 single-phase version

6.2.3 Changing EMC protection class - MS3

6.3 Running the motor

6.3.1 Cable and motor insulation checks

6.4 Maintenance

6.4.1 Recharging capacitors in stored units

7. TECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

7.1.2 Mains voltage 1AC 208-240V

7.1.3 Mains voltage 3AC 380-480V

7.1.4 Definitions of overloadability

7.2 Brake resistors

7.2.1 Internal brake resistor

7.2.2 External brake resistor

7.3 VACON® 20 CP - technical data

7.3.1 Technical information on control connections

8. OPTIONS

8.1 VACON® keypad with seven-segment display

8.2 Text keypad