Danfoss vacon 500x User guide

vacon 500x

ac drives

users manual

1 z vacon summary of vacon 500x

SUMMARY OF VACON 500X PARAMETERS

No. Parameter Name Options Default

001 Model Number Model dependent Read-only 61
002 Software Rev 0.00-99.99 Read-only 61
003 Rated Current 0.0-200.0 A Read-only 62
005 Serial No. 1 0-65535 Read-only 62
006 Serial No. 2 0-65535 Read-only 62
007 USB Soft. Rev 0.00 - 99.99 Read-only 62
008 Option Installed text string Read-only 62
009 Fbus Soft. Rev 0.00 - 99.99 Read-only 62
030 Pwr Down Date dd/mm/yy Read-only 62
031 Pwr Down Time Dd/hh/mm (Dd = Tu, Th, etc.) Read-only 62
102 Output Freq 0.0-400.0 Hz Read-only 62
103 Output Voltage 0-600 V Read-only 62
104 Output Current 0.0-200.0 A Read-only 62
105 Drive Load -200.0-200.0% Read-only 63
106 Load Torque -200.0-200.0% Read-only 63
107 Drive Temp -20.0-200.0 °C Read-only 63
108 Total Run Time 0.0-6553.5 h Read-only 63
109 Power On Hours 0-65535 h Read-only 63
110 Stator Freq 0.0-400.0 Hz Read-only 63
111 DC Bus Voltage 0 - 1000 Vdc Read-only 63
115 Drive Power Out 0.0-200.0% Read-only 63
116 Out Power (kW) 0.0 - 327.67 Read-only 63
117 MWh Meter 0 - 32767 Read-only 63
118 kWh Meter 0.0 - 999.9 Read-only 63
120 Today’s Date MM/dd/YY Read-only 63
121 Today’s Time hh:mm Read-only 63

Show Clock
Parameters

150

(Parameters 151-

179)
151 Tiime Zone Setup text string 12 (-5 East. US) 64
152 TOD Run Enable 0-23 hours, 0-59 min 12:00 64
154 TOD Run Disable 0-23 hours, 0-59 min 12:00 64
156 TOD Run En 2 0-23 hours, 0-59 min 12:00 64
158 TOD Run Dis 2 0-23 hours, 0-59 min 12:00 64
160 Weekend TOD En 0-23 hours, 0-59 min 12:00 64
162 Weekend TOD Dis 0-23 hours, 0-59 min 12:00 64
171 Reminder 1 Conf. text string 0 (disabled) 65
172 Reminder 1 Time 1-32000 hours 1 65
173 Reminder 1 ETA +/- 32000 hours Read-only 65
174 Reminder 2 Conf. text string 0 (disabled) 65
175 Reminder 2 Time 1-32000 hours 1 65
176 Reminder 2 ETA +/- 32000 hours Read-only 65
177 Reminder 3 Conf. text string 0 (disabled) 65

text string 0 (No) 64

User

Setting See Page

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summary of vacon 500x parameters vacon z 2

No. Parameter Name Options Default

178 Reminder 3 Time 1-32000 hours 1 65
179 Reminder 3 ETA +/- 32000 hours Read-only 65
201 Input Mode text string Local On ly 66
202 Rev Enable text string Forward 66
203 Stop Key Remote text string Coast 66
204 Ref Select text string Vin1 67
205 Vin1 Config text string 0-10V 67
206 Vin1 Offset 0.0% to 100.0% 0.00% 67
207 Vin1 Span 10.0% to 200.0% 100.00% 67
208 Cin Config text string 0-20mA 50 67
209 Cin Offset 0.0% to 100.0% 0.0% 68
210 Cin Span 10.0% to 200.0% 100.0% 68
211 Vin2 Config text string 0-10V 68
212 Vin2 Offset 0.0% to 100.0 % 0.00% 68
213 Vin2 Span 10.0% to 200.0% 100.00% 68
214 Vin1 Filter Time 0 to 1000 ms 20 ms 68
215 Cin Filter Time 0 to 1000 ms 20 ms 68
216 Vin2 Filter Time 0 to 1000 ms 20 ms 68

Trim Ref E nabl e

217

(Set k-Factor)
218 Trim % Factor -100.0 - 100.0% 0.0% 69
301 Min Frequency 0.0 - Max Freq. 0.0 Hz 69
302 Max Frequency 20.0 - 400.0 Hz 60.0 Hz 69
303 Preset Freq 1 Min Freq-Max Freq 5.0 Hz 69
304 Preset Freq 2 Min Freq-Max Freq 10.0 Hz 69
305 Preset Freq 3 Min Freq-Max Freq 20.0 Hz 69
306 Preset Freq 4 Min Freq-Max Freq 30.0 Hz 69
307 Preset Freq 5 Min Freq-Max Freq 40.0 Hz 69
308 Preset Freq 6 Min Freq-Max Freq 50.0 Hz 69
309 Cut-off Freq 0.0 - 5.0 Hz 0.0 Hz 70
310 Preset Freq 7 Min Freq-Max Freq 60.0 Hz 69
311 Preset Freq 8 Min Freq-Max Freq 0.0 Hz 69
312 Preset Freq 9 Min Freq-Max Freq 2.5 Hz 69
313 Preset Freq 10 Min Freq-Max Freq 7.5 Hz 69
314 Preset Freq 11 Min Freq-Max Freq 15.0 Hz 69
315 Preset Freq 12 Min Freq-Max Freq 25.0 Hz 69
316 Preset Freq 13 Min Freq-Max Freq 35.0 Hz 69
317 Preset Freq 14 Min Freq-Max Freq 45.0 Hz 69
318 Preset Freq 15 Min Freq-Max Freq 55.0 Hz 69
380 Keeper Input Cfg text string 4 (disabled) 70
381 Keeper Max Scale 0-32000 1000 70
382 Keeper Save Time 00:00 - 23:59 0:00 70
384 Keeper Save Rate text string 0 (24 hour) 70

Keeper Input
385

Valu e

text string 0 69

0-32000 Read-only 70

User

Setting See Page

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3 z vacon summary of vacon 500x

No. Parameter Name Options Default

386 Keeper Time Rate text string 1 (minute) 70
387 Keeper Rec. Num 0-255 Read-only 70
388 Active Kpr. Record 0-255 Read-only 71
389 Keeper Units text string 1 (GPM) 71
401 Ramp Select text string ART-DI 71
402 Accel Time 1 0.1-3200.0 sec 5.0 sec 71
403 Decel Time 1 0.1-3200.0 sec 5.0 sec 72
404 Accel Time 2 0.1-3200.0 sec 3.0 sec 72
405 Decel Time 2 0.1-3200.0 sec 3.0 sec 72
406 DC Inject Config text string DC at Stop 72
407 DC Inject Time 0.0-5.0 sec 0.2 sec 72
408 DC Inject Level 0.0% to 100.0% 50.0% 72
409 DC Inj Freq 0.0 to 20.0 Hz 0.0 Hz 72
410 DB Config text string Internal 73
414 S Ramp Rounding 1 - 100% 25% 73
415 Accel Time 3 0.1-3200.0 sec 10.0 sec 73
416 Decel Time 3 0.1-3200.0 sec 10.0 sec 74
417 Accel Time 4 0.1-3200.0 sec 15.0 sec 74
418 Decel Time 4 0.1-3200.0 sec 15.0 sec 74
490 App Macro text string Fac tory 74
491 Seq Appl text string Disabled 74
492 SIO Visible text string No 74
501 V/Hz Select text string Linear Fixed 75
502 Voltage Boost 0.0-50% 1.0% 75
503 V/Hz Knee Freq 25.0-400.0 Hz 60.0 Hz 75
504 Skip Freq Band 0.2-20.0 Hz 0.2 Hz 76
505 Skip Freq 1 Min Freq-Max Freq 0.0 Hz 76
506 Skip Freq 2 Min Freq-Max Freq 0.0 Hz 76
507 Skip Freq 3 Min Freq-Max Freq 0.0 Hz 76
508 Skip Freq 4 Min Freq-Max Freq 0.0 Hz 76

509 Rated Mtr Volt 100V-690V

510 Rated Mtr FLA 50% - 200% of ND Rating ND Rating 76
511 Rated Mtr RPM 0-24000 rpm 1750 rpm 76
512 Midpoint Freq 0.0 Hz-V/Hz Knee Freq 60.0 Hz 76
513 Midpoint Volt 0.0-100.0% 100.0% 76

514 Motor RS 0.0-655.35 Ohms

515 Power Factor 0.50-1.00 0.80 76
516 Slip Comp Enable text string No 77
517 Single Phase text string No 77
519 Find Mtr Data Not active / Motor RS Not active 77
520 Filter FStator 1 - 100 ms 8 ms 77
521 Start Field En text string No 77
522 Filter Time Slip 10 - 1000 ms 100 ms 77

Model

dependent

Model

dependent

User

Setting See Page

76

76

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summary of vacon 500x parameters vacon z 4

No. Parameter Name Options Default

523 Id Percent 0 - 200% Read-only 78
524 Iq Percent 0 - 200% Read-only 78
525 Power Fail Config text string CTS No Msg 78
526 UV Ride-Thru En text string w/ LVT 78
600 Current Lim Sel text string 0 79
601 Cur Lim Mtr Fwd 5%-150% 120% 79
602 Cur Lim Mtr Rev 5%-150% 120% 79
603 Cur Lim Reg Fwd 5%-150% 80% 79
604 Cur Lim Reg Rev 5%-150% 80% 79
605 Cur Lim Freq 0.0 - 400.0 Hz 3.0 Hz 79
606 Ramp Time CL 0.1-3200.0 sec 1.0 sec 79

Cur Limit
607

Minimum
608 Restart Number text string 0 80
609 Restart Delay 0-60 sec 60 sec 80
610 Timed OL Select text string 0 (Std Ind 60s) 80
613 Max Regen Ramp 100 - 1000% 300% 81
700 Vmet Config text string Freq Out 81
701 Vmet Span 0.0-200.0% 100.0% 81
702 Imet Config text string Drive Load 82
703 Imet Span 0.0-200.0% 100.0% 82
704 Imet Offset 0.0-90.0-% 0.0% 82
705 Relay 1 Select text string 1 (Drv Fault) 83
706 Relay 2 Select text string 2 (Drive Run) 83
707 DO1 Select text string 0 (Drv Ready) 83
708 DO2 Select text string 6 (At Speed) 83
720 Active Logic text string 1 (Active High) 83
721 DI1 Configure text string 0 (Preset 1) 84
722 DI2 Configure text string 1 (Preset 2) 84
723 DI3 Configure text string 2 (Preset 3) 84
724 DI4 Configure text string 6 (Alt Ramp) 84
725 DI5 Configure text string 7 (Fault Reset) 84
726 MOL Polarity text string 1 (NO Operate) 85
727 MOL Configure text string 21 (MOL) 84
740 Thres 1 Select text string 9 (Load High) 85
741 Thres 1 High -300.00 to 300.00% 100.00% 85
742 Thres 1 Low -300.00 to 300.00% 0.00% 85

743 Thres 2 Select text string

744 Thres 2 High -300.00 to 300.00% 100.00% 86
745 Thres 2 Low -300.00 to 300.00% 0.00% 86
746 Timer 1 Type text string 0 (On Delay) 86
747 Timer 1 Signal text string 1 (Drv Fault) 86
748 Timer 1 Time 0.0 - 320.0 sec 1.0 sec 86
749 Timer 2 Type text string 0 (On Delay) 86

0 - 50% 10% 79

15 (Current

High)

User

Setting See Page

85

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5 z vacon summary of vacon 500x

No. Parameter Name Options Default

750 Timer 2 Signal text string 1 (Drv Fault) 86
751 Timer 2 Time 0.0 - 320.0 sec 1.0 sec 86
794 Drive Name text string serial number 86
799 Config USB Mode text string 0 (Disabled) 87
801 Program Number 0-9999 0 87
802 Start Options text string 0 (LS Lockout) 87
803 PWM Frequency 0.6-16.0 kHz 3.0 kHz 88
804 Display Mode text string 0 = Std Disply 88
805 Display Units alphanumeric 0 (blank) 88
809 Display Scale 1-65535 18000 88
810 Language text string 0 (English) 88
811 Access Code 0-9999 0 89
812 Freq Ref Output text string 0 (6FS) 89
813 Speed Ratio 0.0-200.0% 100.0% 89
814 Display Status text string 0 (Drive load) 89
816 Fly Catch Mode text string 0 (Sweep FWD) 89
819 Flt Text #1 text string User Flt 1 89
825 Flt Text #2 text string User Flt 2 90
850 PID Configure text string 0 (No PID) 90
851 PID FBk Config text string 0 (Vin1) 90
852 PID Prop Gain 0-2000 0 90
853 PID Int Gain 0-10000 0 90
854 PID Feed Gain 0-2000 1000 90
855 PID Error 1 0.00-100.00% Read-only 90
856 PID Error 2 0.00-100.00% Read-only 90
857 PID High Corr 0.00-100.00% 100.00% 90
858 PID Low Corr 0.00-100.00% 0.00% 90
859 PID Deriv Gain 0-200 0.00% 91
860 PID Sleep Cfg text string 0 (disabled) 91
861 PID Sleep Lvl 0.00-100.00% 0.00% 91
862 PID Wake-up Lvl 0.00-100.00% 100.00% 91
863 Sleep Delay Time 0.0-300.0 sec 0.0 sec 91
864 Wake-up Delay 0.0-300.0 sec 0.0 sec 91
865 PID Feedback 0.00-100.00% Read-only 91
866 PID Reference 0.00-100.00% Read-only 91
867 PID User Units text string 0 (No) 91
880 FBus Read 1 0-65535 103 92
881 FBus Read 2 0-65535 104 92
882 FBus Read 3 0-65535 105 92
883 FBus Read 4 0-65535 107 92
884 FBus Read 5 0-65535 909 92
890 FBus Write 1 0-65535 907 92
891 FBus Write 2 0-65535 402 92
892 FBus Write 3 0-65535 403 92

User

Setting See Page

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summary of vacon 500x parameters vacon z 6

No. Parameter Name Options Default

893 FBus Write 4 0-65535 920 92
894 FBus Write 5 0-65535 921 92
900 SIO Protocol text string 0 (RTU N81) 92
901 SIO Baud Rate text string 2 (9600) 92
902 Comm Drop # 1-247 1 92
903 SIO Timer 0.0-60.0 sec 1.0 sec 92
904 SIO Cntl Word Bit 0-15 0x0000 93
905 Ext Ref Freq1 Min-Max Freq 0.0 Hz 93
906 Ext Ref Freq2 Min-Max Freq 0.0 Hz 93
907 Cntl Word 2 Bit 0-15 0x0000 93
908 Status Word Bit 0-15 Read-only 94
909 DI Status Bit 0-14 Read-only 94
910 Vin1 Status 0.00-100.00% Read-only 94
911 Cin Status 0.00-100.00% Read-only 94
912 Vin2 Status 0.00-100.00% Read-only 94
913 Output Status Bit 0-5 Read-only 94
914 Vmet Status 0.00-100.00% Read-only 95
915 Imet Status 0.00-100.00% Read-only 95
916 Infrared Baud text string 2 (9600) 95
917 FBus Port Config text string 1 (485 w/ctl) 95
920 SIO Vmet Level 0.00-100.00% 100.00% 95
921 SIO Imet Level 0.00-100.00% 100.00% 95
926 Status Word 2 Bit 0-2 Read-only 95
930 Seq Cntl 1 Bit 0-15 (hex control) 0x0000 96
931 Seq Cntl 2 Bit 0-15 (hex control) 0x0000 96
932 Seq Cntl 3 Bit 0-15 (hex control) 0x0000 96
933 Seq Cntl 4 Bit 0-15 (hex control) 0x0000 96
934 Seq Cntl 5 Bit 0-15 (hex control) 0x0000 96
935 Seq Cntl 6 Bit 0-15 (hex control) 0x0000 96
936 Seq Cntl 7 Bit 0-15 (hex control) 0x0000 96
937 Seq Cntl 8 Bit 0-15 (hex control) 0x0000 96
938 Seq Cntl 9 Bit 0-15 (hex control) 0x0000 96
939 Seq Cntl 10 Bit 0-15 (hex control) 0x0000 96
940 Seq Cntl 11 Bit 0-15 (hex control) 0x0000 96
941 Seq Cntl 12 Bit 0-15 (hex control) 0x0000 96
942 Seq Cntl 13 Bit 0-15 (hex control) 0x0000 96
943 Seq Cntl 14 Bit 0-15 (hex control) 0x0000 96
944 Seq Cntl 15 Bit 0-15 (hex control) 0x0000 96
945 Seq Cntl 16 Bit 0-15 (hex control) 0x0000 96
946 Seq Cntl 17 Bit 0-15 (hex control) 0x0000 96
947 Seq Cntl 18 Bit 0-15 (hex control) 0x0000 96
948 Seq Cntl 19 Bit 0-15 (hex control) 0x0000 96
949 Seq Cntl 20 Bit 0-15 (hex control) 0x0000 96
950 Seq Cntl 21 Bit 0-15 (hex control) 0x0000 96

User

Setting See Page

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7 z vacon summary of vacon 500x

No. Parameter Name Options Default

951 Seq Cntl 22 Bit 0-15 (hex control) 0x0000 96
952 Seq Cntl 23 Bit 0-15 (hex control) 0x0000 96
953 Seq Cntl 24 Bit 0-15 (hex control) 0x0000 96
954 Seq Cntl 25 Bit 0-15 (hex control) 0x0000 96
955 Seq Count 1 0-65535 0 97
956 Seq Count 2 0-65535 0 97
957 Seq Count 3 0-65535 0 97
958 Seq Count 4 0-65535 0 97
959 Seq Count 5 0-65535 0 97
960 Seq Count 6 0-65535 0 97
961 Seq Count 7 0-65535 0 97
962 Seq Count 8 0-65535 0 97
963 Seq Count 9 0-65535 0 97
964 Seq Count 10 0-65535 0 97
965 Seq Count 11 0-65535 0 97
966 Seq Count 12 0-65535 0 97
967 Seq Count 13 0-65535 0 97
968 Seq Count 14 0-65535 0 97
969 Seq Count 15 0-65535 0 97
970 Seq Count 16 0-65535 0 97
971 Seq Count 17 0-65535 0 97
972 Seq Count 18 0-65535 0 97
973 Seq Count 19 0-65535 0 97
974 Seq Count 20 0-65535 0 97
975 Seq Count 21 0-65535 0 97
976 Seq Count 22 0-65535 0 97
977 Seq Count 23 0-65535 0 97
978 Seq Count 24 0-65535 0 97
979 Seq Count 25 0-65535 0 97
980 Seq Decision 1 Bit 0-15 0x0000 97
981 Seq Decision 2 Bit 0-15 0x0000 97
982 Seq Decision 3 Bit 0-15 0x0000 97
983 Seq Decision 4 Bit 0-15 0x0000 97
984 Seq Decision 5 Bit 0-15 0x0000 97

1500 Last Fault All fault options Read-only 97
1527 9th Fault All fault options Read-only 97
1554 8th Fault All fault options Read-only 97
1581 7th Fault All fault options Read-only 97
1608 6th Fault All fault options Read-only 98
1635 5th Fault All fault options Read-only 98
1662 4th Fault All fault options Read-only 98
1689 3rd Fault All fault options Read-only 98
1716 2nd Fault All fault options Read-only 98
1743 1st Fault All fault options Read-only 98

User

Setting See Page

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summary of vacon 500x parameters vacon z 8

24-hour support [phone] • Email: [e-mail]

9 z vacon

INDEX

SUMMARY OF VACON 500X PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Overview of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3 User’s Manual Publication History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Interpreting Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Power and Current Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5 Control Features Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.6 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. RECEIVING AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.3 Dissipation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.4 Cover Assembly and Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.5 Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6 Conduit Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.7 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.2 General Wiring Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.2.1 Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.2.2 Considerations for Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2.3 Considerations for Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.3 Input Line Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.3.2 Line Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3.3 Phase Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3.4 Single-phase Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3.5 Ground Fault Circuit Interrupters (GFCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3.6 Motor Lead Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.3.7 Using Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.4 Terminals Found on the Vacon 500x Power Board . . . . . . . . . . . . . . . . . . . . . . . 30

4.4.1 Description of the Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.4.2 Typical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.5 Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.6 Terminals Found on the Vacon 500x Control Board . . . . . . . . . . . . . . . . . . . . . . 34

4.6.1 Description of the Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.6.2 Typical Connection Diagrams for Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.6.3 Typical Connection Diagrams for Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . 37

4.6.4 Typical Connection Diagrams for Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . 38

5. OPERATION AND PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.2 Keypad Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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vacon z 10

5.3 LCD Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.3.1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

5.3.2 Vacon 500x Keypad Status and Warning Messages . . . . . . . . . . . . . . . . . . . . . . 42

5.3.3 Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

5.3.4 Other Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.4 Keypad Display Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.1 Accessing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.2 Changing the Display Scroll Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.3 Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.4 Restoring Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.5 Viewing Parameters That Have Changed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5.6 Using Macro Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.6 Measuring Stator Resistance (RS Measurement) . . . . . . . . . . . . . . . . . . . . . . . . 46

5.6.1 Activating Automatic RS Measurement via Keypad . . . . . . . . . . . . . . . . . . . . . . 46

5.6.2 Activating Automatic RS Measurement via Serial Link (Modbus) . . . . . . . . . . . 46

5.7 Storing Data and Reflashing Using a Flash Memory Device . . . . . . . . . . . . . . . 47

5.7.1 Storing Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.7.2 Recalling Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.7.3 Storing Keeper Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.7.4 Reflashing the Vacon 500x Using the USB Port and a Flash Memory Device . 48

5.8 Using the Keeper Data Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.8.1 Keeper Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.8.2 Setting up the Keeper Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.9 Using the Vacon 500x Real-Time Clock and Other Special Features . . . . . . . . 50

5.9.1 Enabling the Vacon 500x Based on Time of Day (TOD) . . . . . . . . . . . . . . . . . . . . 50

5.9.2 Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.9.3 Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

5.9.4 Thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6. USING MACRO MODE AND GETTING A QUICK START . . . . . . . . . . . . . . . . . . . . . . . . 53

6.1 Entering Macro Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.2 Description of Parameters Used in Macro Mode . . . . . . . . . . . . . . . . . . . . . . . . 53

6.3 Macro Mode Applications and Included Parameters . . . . . . . . . . . . . . . . . . . . . 55

6.4 Getting a Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7. VACON 500X PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.2 Level 1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.3 Description of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7.4 Using the Vacon 500x Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

7.4.1 Enabling the Vacon 500x Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . .98

7.4.2 Controlling the Vacon 500x Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . .99

7.4.3 Sequencer State Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

7.4.4 Advancement on Drive State Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

7.4.5 Sequencer Decision Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

7.4.6 Sequencer Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

7.4.7 Sample Sequencer Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8.1 Vacon 500X Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

9. VACON 500X ULTRAFLEX OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

APPENDIX: BINARY-HEXADECIMAL CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . 119

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11 z vacon introduction

1. INTRODUCTION

1.1 Product Overview

The Vacon 500X UltraFlex AC drive provides an economical, powerful solution for a large array of industrial
applications. It features remote communications capability (using Ethernet, Devicenet, Modbus®and
Modbus® TCP/IP protocols), a keypad for easy configuration, and standard NEMA 4X / IP66 and NEMA 12
/ IP55 enclosures that eliminate the need for mounting in a separate enclosure. A USB interface allows
you to copy parameters from drive to drive, and to download data logs. Like the X4 AC drive, it provides a
robust, compact solution for industrial applications, but with even more capability.

1.2 Overview of This Manual

This manual contains specifications, receiving and installation instructions, configuration, description of
operation, options, and troubleshooting procedures for Vacon 500x UltraFlex AC drive devices.
For experienced users, a Quick-Start section begins on page 60.

1.3 User’s Manual Publication History

Date Document Number Nature of Change

August 2008 DPD00081 First release

1

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13 z vacon technical characteristics

2. TECHNICAL CHARACTERISTICS

2.1 Interpreting Model Numbers

The model number of the Vacon 500X UltraFlex drive appears on the shipping carton label and on the
technical data label on the model. The information provided by the model number is shown below:

Vacon 0500 3L 0071 5 X

VACON

This segment is common for all products.

0500

Product range:
0500=Vacon 500X

3L

Input/Function:
3L=Three-phase input

0071

Drive rating in ampere; e.g. 0071 = 71 A

5

Supply voltage:
5=500 V

X

Information for factory

2

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technical characteristics vacon z 14

2.2 Power and Current Ratings

Vacon 0500 3L XXXX 5 (460 Vac Ratings)

Model number

0009 5 5 4128.88.97.6 3 2.2 7.2 5.6 5.1 4.8

0012 5

0016 5

0023 5

0031 5

0037 5

0043 5

0061 5

0071 5

0086 5

0105 5

0140 5

0168 5

0205 5

0240 5

2.3 Environmental Specifications

Operating temperature 0 °C to +40 °C (32 °F to 104 °F)

Storage temperature –20 °C to +65 °C (-4 °F to 149 °F)

Humidity 0% to 95% non-condensing

Altitude 1000 m (3300 ft) without derating

Maximum vibration per EN50178 (1g @ 57-150 Hz)

Acoustic noise 80 dba sound power at 1 m (3 ft), maximum

Cooling

2.4 Electrical Specifications

Input voltage Vacon 0500 models: 380-460 Vac, 3 phase, +/- 15%

Line frequency 50 / 60 Hz ±2 Hz

Source kVA (maximum) 10 times the unit rated kVA, 65kA maximum (see note below)

DC bus voltage for:

Overvoltage trip

Dynamic brake activation
Nominal undervoltage (UV)
trip

Control system

Output voltage 0 to 100% of line voltage, three-phase

Overload capacity

Frequency range 0.1 to 400 Hz

Frequency stability 0.1 Hz (digital), 0.1% (analog) over 24 hours +/- 10 °C

Normal Duty Input current (A) Output current (A) Heavy Duty Input current (A) Output current (A)

HP kW 380 Vac 460 Vac 380 Vac 460 Vac HP kW 380 Vac 460 Vac 380 Vac 460 Vac

7.5 5.5 15 12.8 12 11 5 4 12 8.8 8.9 7.6

10 7.5 19.7 16.3 15.6 14 7.5 5.5 15 12.8 12 11

15 11 30.9 25.8 23 21 10 7.5 19.7 16.3 15.6 14

20 15 40 33.3 31 27 15 11 30.9 25.8 23 21

25 18 46.3 40 37 34 20 15 40 33.3 31 27

30 22 57.5 47.8 43 40 25 18 46.3 40 37 34

40 30 73.2 62.4 61 52 30 22 57.5 47.8 43 40

50 37 82 78 71 65 40 30 73.2 62.4 61 52

60 45 94 80 86 77 50 37 82 78 71 65

75 55 114 99 105 96 60 45 94 80 86 77

100 75 149 129 140 124 75 55 114 99 105 96

125 90 168 156 168 156 100 75 140 124 140 124

150 110 205 180 205 180 125 90 168 156 168 156

200 132 240 240 240 240 150 110 205 180 205 180

4 kW/5 HP models: Natural convection

5.5 to 132 kW/7.5 to 200.0 HP models: Forced air (temperature-controlled
external fa n)

4-132 kW/5-200 HP

230 Vac models

406 Vdc
388 Vdc
199 Vdc

V/Hz or Sensorless Vector Control (SVC)
Carrier frequency = 1 - 16 kHz, programmable; 8 kHz max. for 90-132 kW/125­200 HP models

120% of rated RMS current for 60 seconds (normal duty rating)
150% of rated RMS current for 60 seconds (heavy duty rating)

460 Vac models

814 Vdc
776 Vdc
397 Vdc

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15 z vacon technical characteristics

Frequency setting

Note:

Unit Rated kVA = rated Voltage x rated Current x 1.732

By key pad, or b y extern al signa l (0 to 5 Vdc; 0 to 10 Vdc; 0/4 to 20 mA) or by pulse
train up to 100kHz

2.5 Control Features Specifications

Vin1 reference input

Vin2 reference input

Cin re ference i nput

Reference voltage 10 Vdc (10 mAdc maximum)

Digital inputs - 10

Digital supply voltage 24 Vdc (150 mAdc maximum)

Preset frequencies 4 inputs for 15 preset frequencies (selectable)

Digital outputs

Digital pulse train output Open collector output pulse train proportional to o utput frequency

Vmet analog output 0 to 10 Vdc (5 mAdc maximum)

Imet analog output 0/4-20 mAdc output into a 500 Ω load (maximum)

DC holding / injection braking

Current limit Four quadrant adjustable from 5 to 150%

Speed ramps Primary and alternate adjustable from 0.1 to 3200.0 seconds

Voltage boost Adjustable fixed boost or adjustable auto boost

Voltage characteristic V/Hz: Linear, pump, fan, or 2-piece linear. Also sensorless vector (SVC).

Timed overload

Protective features

Program Sequence Logic
Controller (PSLC)

PID Feedback

Serial communications Modbus, DeviceNet option, Ethernet IP option, Modbus TCP/IP option

0-5/10 Vdc, 0/4-20 mAdc (250 Ω load)
6FS pulse train input from another drive, 0-1/10/100 kHz pulse input, inverted
function, 0-5-10 bipolar input, broken wire detection. Span and offset adjustment.

0-5/10 Vdc, 0-5-10 bipolar input, inverted function, broken wire detection, span
and offset adjustment. Programmable for frequency reference, current limit
input, or feedback signal.

0/4-20 mAdc (50 Ω load), inverted function, span and offset adjustment.
Programmable for frequency reference, current limit input, or feedback signal.

Off=0 to 3 Vdc; On=10 to 32 Vdc (pull-up logic), selectable between pull-up and
pull-down logic

2 SPDT relay outputs - 130 Vac, 1 A/250 Vac, 0.5 A
2 open collector outputs 50 mA per device; 2 optional relays; optional encoder
interface

At start, stop, by frequency with adjustable current level and time or continuous
DC injection by digital input.

Adjustable inverse time trip (shear pin, 30 seconds, 60 seconds, 5 minutes), for
standard or inverter-duty motors

Overcurrent, overvoltage fault, ground fault, short circuit, dynamic brake
overload, drive temperature, power wiring fault, drive timed overload, input
voltage quality, overvoltage ridethrough

25-step (with ability to branch), PLC-type functionality that can control speed,
direction, and ramps based on time, analog input, digital input, or pulse input.
Addressable outputs and real-time operations possible. See “Using the Vacon
500x Program Sequencer” on page 98.

Process control available with the use of a customer-supplied transd ucer, either
0-10 Vdc, 4-20 mA, or optical encoder input to the drive. Includes an optional sleep
mode, activated when the loop is satisfied.

2.6 Dimensions and Weights

Table 1 lists dimensions and weights for the Vacon 500x frame size 1, 2, and 3 models. Dimensions and
weights for the Vacon 500x frame size 4 and 5 models are shown in Table 2 on page 17.

2

See Figures 1, 1, 2, 3, 4, and 5 on pages 18 - 22 for locations of dimensions. Dimensions A through Q are in
inches / millimeters (in/mm). Weight is in pounds / kilograms (lb/kg).

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technical characteristics vacon z 16

Frame 1 2 3

Voltage 230 Vac 460 Vac 230 Vac 460 Vac 230 Vac 460 Vac

Horsepower 5-7.5 5-10 10-15 15-50 20-25 40-50

A 12.01 (305) 17.38 (441) 20.19 (513)

B 8.72 (221) 10.75 (273) 11.25 (286)

C 8.49 (216) 7.91 (201) 11.73 (298)

D 11.03 (280) 16.50 (419) 19.25 (489)

E 7.88 (200) 9.76 (248) 7.88 (200)

Dimensions

in (mm)

(See Vacon

diagrams
on pages 18
through 22)

F 0.28 (7) 0.41 (10) 0.28 (7)

G 4.05 (103) 4.72 (120) 7.78 (198)

500x

HN/A N/A N/A

J 2.31 (59) 2.88 (73) 0.65 (17)

K 3.94 (100) 4.84 (123) 2.29 (58)

L 5.56 (1.41) 6.88 (175) 3.95 (100)

M 0.88 (22) 1.38 (35) 1.69 (43)

N N/A 1.13 (29) 0.88 (22)

P N/A N/A 5.60 (142)

Q N/A N/A 7.24 (184)

Weig ht

lb (kg)

Table 1: Dimensions and Weights for Frame Sizes 1 - 3

14.0 (6.35) 29.5 (13.38) 50.0 (22.68)

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17 z vacon technical characteristics

Frame 4 5

Volta ge 460 Va c 46 0 Vac

Horsepower 60-100 125-200

A 29.35 (745) 51.02 (1296)

B 12.84 (326) 16.31 (414)

C 13.80 (351) 16.88 (429)

D 28.00 (711) 45.77 (1163)

E 7.88 (200) 7.65 (194)

F 0.42 (11) 0.42 (11)

G 8.63 (219) 12.57 (319)

Dimensions

in (mm)

(See Vacon 500x

diagrams on pages 21 -

22)

Weig ht

lb (kg)

Table 2: Dimensions and Weights for Frame Sizes 4-5

H 8.26 (210) 11.10 (282)

J 0.53 (13) 0.20 (5)

K 2.69 (68) 2.32 (59)

L 3.94 (100) 3.82 (97)

M 2.44 (62) 2.94 (75)

N 0.88 (22) 0.88 (22)

P 5.19 (132) 5.32 (135)

Q 7.35 (187) 7.45 (189)

R 10.23 (260) N/A

S 1.94 (49) 1.86 (47)

95.0 (43.10)) 305.0 (138.35)

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technical characteristics vacon z 18

B

A

X

series

E

C

G

F

D

M

J

K

L

Figure 1: Vacon 500x Frame Size 1 Models

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19 z vacon technical characteristics

B

A

X

series

E

C

G

J

K

F

D

N

M

L

2

Figure 2: Vacon 500x Frame Size 2 Models

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technical characteristics vacon z 20

E

A

X

series

B

C

G

J
K

F (8) PLACES

D

M (2) PLACES

N (3) PLACES

L

P

Q

Figure 3: Vacon 500x Frame Size 3 Models

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21 z vacon technical characteristics

E F (8) PLACES

D

A

X

series

B

N (2) PLACES

M(2) PLACES

C

R

G

H

S (1) PLACES

2

J

K

L

P

Q

Figure 4: Vacon 500x Frame Size 4 Models

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technical characteristics vacon z 22

E F (8) PLACES

A

X

series

B

C

G

H

J

K

L

P

Q

Figure 5: Vacon 500x Frame Size 5 Models

D

N(2) PLACES

M (2) PLACES

S (1) PLACE

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23 z vacon receiving and installation

3. RECEIVING AND INSTALLATION

3.1 Preliminary Inspection

Before storing or installing the Vacon 500X drive, thoroughly inspect the device for possible shipping
damage. Upon receipt:

1. Remove the drive from its package and inspect exterior for shipping damage. If damage is apparent, notify
the shipping agent and your sales representative.

2. Remove the cover and inspec t the drive for any apparent damage or foreign objects. (See F igure 6 on page

24 for lo cations of cover s crews.) E nsure that all mo unting h ardware and te rminal conn ection h ardware

is properly seated, securely fastened, and undamaged.

3. Read the technical data label affixed to the dri ve and ensure that the correct horsepower and input voltage
for the application has been purchased.

4. If you will be storing the drive after receipt, place it in its original packaging and store it in a clean, dry
place free from direct sunlight or corrosive fumes, where the ambient temperature is not less than -20 °C
(-4 °F) or greater than +65 °C (+149 °F).

EQUIPMENT DAMAGE HAZARD
Do not operate or install any drive that appears damaged.
Failure to follow this instruction can result in injury or equipment damage.

CAUTION

RISQUE DE DOMMAGES MATÉRIELS
Ne faites pas fonctionner et n’installez pas tout variateur de vitesse qui semble

être endommagé.
Si cette directive n’est pas respectée, cela peut entraîner des blessures

ATTENTION

3.2 Installation Precautions

Improper installation of the Vacon 500x drive will greatly reduce its life. Be sure to observe the following
precautions when selecting a mounting location. Failure to observe these precautions may void the
warranty! See the inside front cover of this manual for more information about the warranty.

• Do not install the drive in a place subjected to high temperature, high humidity, excessive
vibration, corrosive gases or liquids, or airborne dust or metallic particles. See Chapter 2 for
temperature, humidity, and maximum vibration limits.

• Do not mount the drive near heat-radiating elements or in direct sunlight.

• Mount the drive vertically and do not restrict the air flow to the heat sink fins.

• The drive generates heat. Allow sufficient space around the unit for heat dissipation. See

“Dissipation Requirements” on page 24.

corporelles ou des dommages matériels.

3

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receiving and installation vacon z 24

3.3 Dissipation Requirements

Model

0009 5 91

0012 5

0016 5

0023 5

0031 5

0037 5

0043 5

0061 5

0071 5

0086 5

0105 5

0140 5

0168 5

0205 5

0240 5

3.4 Cover Assembly and Torque Specifications

Figure 6 shows the locations of the Vacon 500x cover screws. The torque range for the Size 1 cover is 18­26 in/lbs.

Required Dissipation for Models Entirely Inside an Enclosure at Rated

Current, 3KHz Carrier Frequency (Watts)

114

155

304

393

459

458

695

834

776

988

1638

1656

1891

2302

Cover screw locations

Torque specifications for control terminals and power terminals are listed in “General Wiring Information”
on page 27 .

Figure 6: Vacon 500x Cover Assembly and Screw Locations

Cover screw locations

3.5 Serial Number Label

VACON Plc warrants all AC drives for three years from date of manufacture, or two years from the date of
installation, whichever comes first. For a more detailed description of VACON Plc warranty policy, see the
inside front cover of this manual, or visit the web site at http://www.vacon.com. To determine if your drive
is within the warranty time frame, find the bar code label or look in the lower left of the technical
nameplate. The serial number can be broken down as follows:

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3

25 z vacon receiving and installation

yywwxxxx = yy...year of manufacture

3.6 Conduit Usage

The Vacon 500x drive in the NEMA 4x / IP66 enclosure is rated for 1000 psi washdown from 6 inches. To
keep this rating, the use of a sealed conduit is required. The use of a Romex-type conduit will not prevent
water entry into the enclosure. If the approved conduit is not used, all warranty claims against water
damage will be void.

3.7 Condensation

The washdown process of an Vacon 500x drive may create a temperature and humidity change in and
around the drive. If the unit is mounted in a cool environment and washed down with higher-temperature
water, as the drive cools to room temperature, condensation can form inside the drive, especially around
the display. To prevent this from happening, avoid using sealed connectors around rubber-coated cables
to seal the drive. These do not allow any air transfer and hence create a level of condensation and humidity
that exceeds the drive’s rating.

ww...week of manufacture
xxxx...sequential number drive during that week

3

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receiving and installation vacon z 26

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27 z vacon connections

4. CONNECTIONS

HAZARDOUS VOLTAGE

• Read and understand this manual in its entirety before installing or operating the Vacon 500x AC
drive. Installation, adjustment, repair, and maintenance of these drives must be performed by
qualified personnel.

• Disconnect all power before servicing the drive. WAIT 5 MINUTES until the DC bus capacitors
discharge.

• DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw
connections with voltage present.

• Install all covers before applying power or starting and stopping the drive.

• The user is responsible for conforming to all applicable code requirements with respect to
grounding all equipment.

• Many parts in this drive, including printed circuit boards, operate at line voltage. DO NOT TOUCH.

DANGER

DANGER

Use only electrically-insulated tools.

Before servicing the drive.

• Disconnect all power.

• Place a “DO NOT TURN ON” label on the drive disconnect.

• Lock the disconnect in the open position.

Failure to observe these precautions will cause shock or burn, resulting in severe personal
injury or death.

TENSION DANGEREUSE

• Lisez et comprenez ces directives dans leurs intégralité avant d’installer ou de faire fonctionner le
variateur de vitesse Vacon 500x. L’installation, le réglage, les réparations et l’entretien des ces
variateurs de vitesse doivent être effectuées par du personnel qualifié.

• Coupez toutes les alimentations avant de travailler sur le variat eur de vitesse. ATTENDEZ CINQ
MINUTES pour que la décharge des condensateurs du bus cc s’effectue.

• NE court-cuitez PAS les condensateurs du bus cc ou ne touchez pas aux composantes non blindées ou
aux connexions des vis du bornier si l’appareil est sous tension.

• Installez tous les couvercles avant de mettre le variateur de vitesse sous tension, de le mettre en
marche ou de l’arrêt er.

• L’utilisateur est responsable de la conformité avec tous les codes électriques en vigueur concernant la
mise à la terre de tous les appareils.

• De nombreuses pièces de ce variateur de vitesse, y compris les cartes de circuits imprimés,
fonctionnent à la tension du secteur. N’Y TOUCHEZ PAS. N’utilisez que des outils dotés d’une isolation
électrique.

Avant tout entretien ou r éparation sur le variateur de vitesse:

• Coupez toutes les ali mentations.

• Placez une étiquette «NE PAS METTRE SOUS TENSION» sur le sectionneur du variateur de vitesse.

• Verrouillez le sectionneur en position ouverte.

Si ces précautions ne sont pas respectées, cela causera une électrocution ou des brûlures, ce
qui entraînera des blessures graves ou la mort.

4

4.1 Introduction

This chapter provides information on connecting power and control wiring to the Vacon 500X AC drive.

4.2 General Wiring Information

4.2.1 Wiring Practices

When making power and control connections, observe these precautions:

• Never connect input AC power to the motor output terminals T1/U, T2/V, or T3/W. Damage to the
drive will result.

• Power wiring to the motor must have the maximum possible separation from all other power
wiring. Do not run in the same conduit; this separation reduces the possibility of coupling
electrical noise between circuits.

• Cross conduits at right angles whenever power and control wiring cross.

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connections vacon z 28

• Good wiring practice also requires separation of control circuit wiring from all power wiring.
Since power delivered from the drive contains high frequencies which may cause interference
with other equipment, do not run control wires in the same conduit or raceway with power or
motor wiring.

4.2.2 Considerations for Power Wiring

Power wiring refers to the line and load connections made to terminals L1/R, L2/S, L3/T, and T1/U, T2/V,
T3/W respectively. Select power wiring as follows:

1. Use only UL-recognized wire.

2. Wire voltage rating must be a minimum of 300 V for 230 Vac systems and 600 V (Class 1 wire) for 460 or
575 Vac systems.

3. Wire gauge must be selected based on 125% of the continuous input current rating of the drive. Wire
gauge must be selected from wire tables for 75 °C insulation rating, and must be of copper construction.
The 230 V 5.5 kW/7.5 HP and 11 kW/15 HP models, and the 460 V 22 kW/30 HP models require 90 °C wire
to meet UL requirements. See Chapter 2 for the continuous output ratings for the drive.

4. Grounding must be in accordance with NEC and CEC. If multiple Vacon 500x drives are installed near each
other, each must be connected to ground. Take care not to form a ground loop.

See Table 1 for a summary of power terminal wiring specifications.

Vacon 500x Size / Models Specifications

16 in-lbs nominal torque

Size 1

Size 2

Size 3

Size 4

Size 5

Table 1: Vacon 500x Power Terminal Wiring Specifications

Note: Wire type not specified by the manufacturer. Some types of wire may not fit within the constraints of
the conduit entry and bend radius inside the drive.

18 in-lbs maximum torque

8-18 awg wire

5/16” (0.3125”) strip length

30 in-lbs nominal torque

6-8 awg wire

3/8” (0.38”) strip length

35 in-lbs nominal torque

3 awg wire

65 in-lbs nominal torque

3/0 awg wire max

132 in-lbs nominal torque

250MCM wire max

4.2.3 Considerations for Control Wiring

Control wiring refers to the wires connected to the control terminal strip. Select control wiring as follows:

1. Shielded wire is recommended to prevent electrical noise interference from causing improper operation
or nuisance tripping.

2. Use only UL recognized wire.

3. Wire voltage rating must be at least 300 V for 230 Vac systems. It must be at least 600 V for 460 systems.

See Table 2 below for a summary of power terminal control wiring specifications.

Vacon 500x Size / Models Specifications

All Sizes / Models

Table 2: Vacon 500x Control Wiring Specifications

4.4 in-lbs maximum torque
12-24 awg wire

9/32” strip length

4.3 Input Line Requirements

4.3.1 Line Voltage

See “Power and Current Ratings” on page 14 for the allowable fluctuation of AC line voltage for your
particular Vacon 500x model. A supply voltage above or below the limits given in the table will cause the
drive to trip with either an overvoltage or undervoltage fault.

or

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4

29 z vacon connections

Exercise caution when applying the Vacon 500x AC drive on low-line conditions.
For example, an Vacon 500x 2000 series unit will operate properly on a 208 Vac line, but the maximum
output voltage will be limited to 208 Vac. If a motor rated for 230 Vac line voltage is controlled by this drive,

higher motor currents and increased heating will result.
Therefore, ensure that the voltage rating of the motor matches the applied line voltage.

4.3.2 Line Capacity

If the source of AC power to the Vacon 500x AC drive is greater than 10 times the kVA rating shown in Tabl e

3 below, an isolation transformer or line reactor is recommended. Consult the factory for assistance in

sizing the reactor.

Drive kW 4 5.5 7.5 11 15 18.5 18.5 30 37 45 55 75 90 110 132

Drive HP 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200

Tran sfor mer
kVA

Table 3: Vacon 500x Line Capacity (kVA)

Note: Vacon 500x AC drive devices are suitable for use on a circuit capable of delivering not more than
65,000 rms symmetrical amperes at 10% above the maximum rated voltage.

4.3.3 Phase Imbalance

Phase voltage imbalance of the input AC source can cause unbalanced currents and excessive heat in the
drive’s input rectifier diodes and DC bus capacitors. Phase imbalance can also damage motors running
directly across the line. The phase imbalance should not exceed 2% of the voltage rating; if it does, the
drive should be derated as a single-phase drive.

CAUTION

9 13 18 23 28 36 42 57 70 90 112 150 180 220 250

EQUIPMENT DAMAGE HAZARD
Never use power-factor correction capacitors on motor terminals T1/U, T2/V, or T3/W of the

Vacon 500x AC drive. Doing so will damage the semiconductors.
Failure to follow this instruction can result in injury or equipment damage.

4

RISQUE DE DOMMAGES MATÉRIELS
Ne raccordez jamais de condensateurs de correction du facteur de puissance aux bornes T1/

U, T2/V, ou T3/W du moteur du variateur de vitesse Vacon 500x. Car cela endommagera les
semiconducteurs.

Si cette directive n’est pas respectée, cela peut entraîner des blessures corporelles ou des

ATT ENT ION

dommages matériels.

4.3.4 Single-phase Operation

Vacon 500x AC drive 230 Vac, 4-kW/5-HP models are designed for both three-phase and single-phase input
power. If one of these models is operated with single-phase power, use any two line input terminals. The
output of the device will always be three-phase.
The safe derating of the Vacon 500x series of drives is 50% of the nominal current (kW/HP) rating. Consult
the factory with the particular application details for exact derating by model.

4.3.5 Ground Fault Circuit Interrupters (GFCI)

The GFCI breakers are designed for residential use to protect personnel from stray currents to ground.
Most GFCI breakers will shut off at 5 mA of leakage. It is not uncommon for an AC drive to have 30 to 60
mA of leakage.

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