Vacon 100 flow, 0100 3L 0007 7...0208 7, 0100 3L 0003 2...0310 2, 0100 3L 0004 6...0208 6, 0100 3L 0140 2...0310 2 Installation Manual

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vacon 100 industrial

vacon 100 flow

ac drives

installation manual

enclosed drives

PREFACE

DOCUMENT DETAILS

Document ID: DPD01666D Date: 11.11.2016

ABOUT THIS MANUAL

ABOUT THE PRODUCT

This manual describes the VACON® 100 Enclosed Drive. The power range of the drive is between 75-800 kW, and its voltage range is 380-500 V or 525-690 V. The drive comes installed in a cabinet, and is available in 4 different enclosure sizes: MR8, MR9, MR10 and MR12. The drive can include 1 or more cabinets.

The drive is available in 2 regional versions: IEC (qualified to the IEC criteria) or NAM (qualified to the UL criteria).

Fig. 1: An example of the VACON® 100 Enclosed Drive

PREFACE VACON · 3

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VACON · 4

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TABLE OF CONTENTS

Preface

Document details 3 About this manual 3 About the product 3

1 Approvals 7 2 Safety 9

2.1 The safety symbols used in the manual and the drive 9

2.2 Warning 9

2.3 Caution 10

2.4 Grounding and earth fault protection 11

2.5 Using an RCD or an RCM device 12

3 Receiving the delivery 14

3.1 Package label 14

3.2 Type designation code 15

3.3 The contents of the delivery 15

3.4 Storage 15

3.5 Removing the packaging and lifting the AC drive 16

3.5.1 Weight of the AC drive 16

3.5.2 Lifting the AC drive 16

3.6 "Product modified" label 18

3.7 Disposal 19

4 Mounting 20

4.1 Dimensions of the cabinet, IEC 20

4.2 Dimensions of the cabinet with additional cabinet sections, IEC 22

4.3 Dimensions of the cabinet, NAM 27

4.4 Dimensions of the cabinet, with additional cabinet sections, NAM 30

4.5 The options 35

4.6 Installation of the cabinet 43

4.7 Cooling and free space around the AC drive 44

4.8 The optional back channel cooling 46

4.8.1 Using the back channel for cooling 46

5 Power cabling 49

5.1 Cable dimensioning and selection 49

5.1.1 Main circuit diagrams of the cabinet 49

5.1.2 Cable and fuse sizes, IEC 51

5.1.3 Cable and fuse sizes, NAM 58

5.2 Brake resistor cables 64

5.3 Preparing for the cable installation 66

5.4 Cable installation in MR8-MR12 67

5.4.1 Installing the cables 70

TABLE OF CONTENTS VACON · 5

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6 Control compartment 76

6.1 The control compartment of the enclosed drive 76

6.2 Fieldbus connection 80

6.2.1 Using fieldbus through an Ethernet cable 80

6.2.2 Using fieldbus through an RS485 cable 81

7 Commissioning and additional instructions 85

7.1 Commissioning safety 85

7.2 Operation of the motor 86

7.2.1 Checks before starting the motor 86

7.3 Measuring the cable and motor insulation 86

7.4 Installation in a marine environment 86

7.5 Installation in a corner-grounded network 87

7.6 Installation in an IT system 87

7.6.1 The EMC jumper in MR8 87

7.6.2 The EMC jumper in MR9 88

7.6.3 The EMC jumper in MR10 and MR12 90

7.7 Maintenance 91

7.7.1 Maintenance intervals 91

7.7.2 Replacing the air filters of the AC drive 92

7.7.3 Replacing the fans of the AC drive 93

7.7.4 Replacing the power unit of the AC drive 99

7.7.5 Downloading the software 108

8 Technical data, VACON® 100 INDUSTRIAL 112

8.1 AC drive power ratings 112

8.1.1 Mains voltage 380-500 V 112

8.1.2 Mains voltage 525-690 V 113

8.1.3 Brake resistor ratings 113

8.2 VACON® 100 INDUSTRIAL - technical data 117

9 Technical data, VACON® 100 FLOW 122

9.1 AC drive power ratings 122

9.1.1 Mains voltage 380-500 V 122

9.1.2 Mains voltage 525-690 V 123

9.2 VACON® 100 FLOW - technical data 124

10 Technical data on control connections 129

10.1 Technical data on control connections 129

VACON · 6 TABLE OF CONTENTS

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1 APPROVALS

Here are the approvals that have been granted to this VACON® product.

EC Declaration of conformity

•

Find the EC Declaration of Conformity on the next page.

UL approval *

•

cULus approval file number E171278.

* The UL approval is valid for input voltage up to 600 V.

APPROVALS VACON · 7

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Antti Vuola Head of Standard Drives

Timo Kasi VP, Design Center Finland and Italy

Danfoss A/S

DK-6430 Nordborg Denmark CVR nr.: 20 16 57 15

Telephone: +45 7488 2222 Fax: +45 7449 0949

15-04-2016 15-04-2016

Date Issued by Date Approved by

Signature Name Title

Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated into any other language, the translator concerned shall be liable for the correctness of the translation.

EU DECLARATION OF CONFORMITY

Danfoss A/S

Vacon Ltd

declares under our sole responsibility that the

Product(s) VACON® 100 AC drive

Type(s)

Wall-Mounted Drives:

VACON® 0100 3L 0003 2...0310 2 VACON® 0100 3L 0003 4...0310 4 VACON® 0100 3L 0003 5...0310 5 VACON® 0100 3L 0004 6...0208 6 VACON® 0100 3L 0007 7...0208 7

Covered by this declaration is in conformity with the following directive(s), standard(s) or other normative document(s), provided that the product is used in accordance with our instructions.

Safety: EN 61800-5-1: 2007 EN 60204-1: 2006+A1:2009 (as relevant) EMC: EN 61800-3: 2004 + A1: 2012

and conforms to the relevant safety provisions of Low Voltage Directive 2006/95/EC (until April 19th, 2016), 2014/35/EU (from April 20th, 2016) and EMC Directive 2004/108/EC (until April 19th, 2016), 2014/30/EU (from April 20th, 2016).

The year the CE marking was affixed: 2009

IP00 Drives:

VACON® 0100 3L 0140 2...0310 2 VACON® 0100 3L 0140 5...1180 5 VACON® 0100 3L 0080 6...0820 6 VACON® 0100 3L 0080 7...0820 7

Enclosed Drives:

VACON® 0100 3L 0140 5...1180 5 VACON® 0100 3L 0080 7...0820 7

VACON · 8 APPROVALS

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2 SAFETY

2.1 THE SAFETY SYMBOLS USED IN THE MANUAL AND THE DRIVE

This manual contains warnings and cautions, which are identified with safety symbols. The warnings and cautions give important information on how to prevent injury and damage to the equipment or your system.

Read the warnings and cautions carefully and obey their instructions.

Table 1: The safety symbols

The safety symbol The safety word Description

WARNING!

If you do not obey the instructions, injury or death is possible.

CAUTION!

If you do not obey the instructions, damage to the equipment is possible.

HOT SURFACE!

If you do not obey the instructions, burns are possible.

READ THE MANUAL!

You must read the manual.

WAIT 5 MINUTES! You must wait 5 minutes.

2.2 WARNING

WARNING!

Do not touch the components of the power unit when the drive is connected to mains. The components are live when the drive is connected to mains. A contact with this voltage is very dangerous.

SAFETY VACON · 9

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WARNING!

Do not touch the motor cable terminals U, V, W, the brake resistor terminals or the DC terminals when the drive is connected to mains. These terminals are live when the drive is connected to mains, also when the motor does not operate.

WARNING!

Do not touch the control terminals. They can have a dangerous voltage also when the drive is disconnected from mains.

WARNING!

Before you do electrical work on the drive, disconnect the drive from the mains and make sure that the motor has stopped. Lock out and tag out the power source to the drive. Make sure that no external source generates unintended voltage during work. Note that also the load side of the drive can generate voltage. Wait 5 minutes before you open the cabinet door or the cover of the AC drive. Use a measuring device to make sure that there is no voltage. The terminal connections and the components of the drive can be live 5 minutes after it is disconnected from the mains and the motor has stopped.

WARNING!

Before you connect the drive to mains, make sure that the front cover and the cable cover of the drive are closed. The connections of the AC drive are live when the drive is connected to mains.

WARNING!

Disconnect the motor from the drive if an accidental start can be dangerous. When there is a power-up, a power break or a fault reset, the motor starts immediately if the start signal is active, unless the pulse control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions (including the start inputs) can change.

WARNING!

Wear protective gloves when you do mounting, cabling or maintenance operations. There can be sharp edges in the AC drive that can cause cuts.

2.3 CAUTION

CAUTION!

Do not move the AC drive. Use a fixed installation to prevent damage to the drive.

CAUTION!

Do not make measurements when the AC drive is connected to mains. It can cause damage to the drive.

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CAUTION!

Make sure that there is reinforced protective ground connection. It is mandatory, because the touch current of the AC drives is more than 3.5 mA AC (refer to EN 61800-5-1). See chapter 2.4 Grounding and earth fault protection.

CAUTION!

Do not use spare parts that are not from the manufacturer. Using other spare parts can cause damage to the drive.

CAUTION!

Do not touch the components on the circuit boards. Static voltage can cause damage to these components.

CAUTION!

Make sure that the EMC level of the AC drive is correct for your mains. See chapter

7.6 Installation in an IT system. An incorrect EMC level can cause damage to the drive. If you use Corner-grounding, change the EMC level to C4, see chapter 7.6 Installation in an IT system. For information on permitted drive types for Corner-grounding, see chapter 7.5 Installation in a corner-grounded network.

CAUTION!

Prevent radio interference. The AC drive can cause radio interference in a domestic environment.

NOTE!

If you activate the autoreset function, the motor starts automatically after an automatic fault reset. See the Application Manual.

NOTE!

If you use the AC drive as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN 60204-1).

2.4 GROUNDING AND EARTH FAULT PROTECTION

CAUTION!

The AC drive must always be grounded with a grounding conductor that is connected to the grounding terminal that is identified with the symbol . Not using

a grounding conductor can cause damage to the drive.

The touch current of the drive is more than 3.5 mA AC. The standard EN 61800-5-1 tells that 1 or more of these conditions for the protective circuit must be true.

SAFETY VACON · 11

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The connection must be fixed.

The protective grounding conductor must have a cross-sectional area of minimum 10 mm2 Cu or 16 mm2 Al. OR

There must be an automatic disconnection of the mains, if the protective grounding conductor breaks. See chapter 5 Power cabling. OR

There must be a terminal for a second protective grounding conductor in the same cross-sectional area as the first protective grounding conductor.

Table 2: Protective grounding conductor cross-section

Cross-sectional area of the phase conductors (S) [mm2]

The minimum cross-sectional area of the protective grounding conductor in question [mm2]

S ≤ 16 S

16 < S ≤ 35 16

35 < S S/2

The values of the table are valid only if the protective grounding conductor is made of the same metal as the phase conductors. If this is not so, the cross-sectional area of the protective grounding conductor must be determined in a manner that produces a conductance equivalent to that which results from the application of this table.

The cross-sectional area of each protective grounding conductor that is not a part of the mains cable or the cable enclosure, must be a minimum of:

•

2.5 mm2 if there is mechanical protection, and

•

4 mm2 if there is not mechanical protection. If you have cord-connected equipment, make sure that the protective grounding conductor in the cord is the last conductor to be interrupted, if the strain-relief mechanism breaks.

Obey the local regulations on the minimum size of the protective grounding conductor.

NOTE!

Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not operate correctly.

CAUTION!

Do not do voltage withstand tests on the AC drive. The manufacturer has already done the tests. Doing voltage withstand tests can cause damage to the drive.

2.5 USING AN RCD OR AN RCM DEVICE

The drive can cause a current in the protective grounding conductor. You can use a residual current-operated protective (RCD) device, or a residual current-operated monitoring (RCM) device to give protection against a direct or an indirect contact. Use a type B RCD or RCM device on the mains side of the drive.

VACON · 12 SAFETY

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NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from http://drives.danfoss.com/knowledge-center/technical-documentation/.

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 http:// drives.danfoss.com/knowledge-center/technical-documentation/.

SAFETY VACON · 13

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3 RECEIVING THE DELIVERY

Before a VACON® AC drive is sent to the customer, the manufacturer makes many tests on the drive. However, after you remove the packaging, examine the drive for transport damages.

If the drive was damaged during the shipping, speak to the cargo insurance company or the carrier.

To make sure that the contents of the delivery is correct and complete, compare the type designation of the product to the type designation code. See Chapter 3.2 Type designation code.

3.1 PACKAGE LABEL

A B

VACON AB

MSIP-REM-V93-VC100

1000631129

V00001246377

70-AB3L05205C10B240BM26-00096461

Danfoss A/S, 6430 Nordborg, Denmark

3~AC,0-Uin, 0-320Hz

Uin:3~AC,380-500V, 50/60Hz

520A 40°C / 460A 50°C

520 A 40°C / 459A 50°C

250kW:400V / 450HP:480V IP21/Type1

Made in Finland

POWER:

OUTPUT:

INPUT:

CM+GNUL

BT+EMC4+FBIE+CAPU+CAPD+CICO+CIFD+PO

VACON0100-3L-0520-5-ED+SCB4+SEBJ+SR

160928

2610011001

FW0072V024

Marks:

Cust. Ord. No:

Application:

Firmware:

B.ID:

V00001246377

S/N:

70-AB3L05205C10B240BM26-00096461

Code:

Type:

AC DRIVE

Fig. 2: The package label of VACON® AC drives

A. The batch ID B. The order number C. The type designation code D. The serial number E. The mains voltage

F. The nominal output current G. The IP class H. The application code I. The order number of the customer

VACON · 14 RECEIVING THE DELIVERY

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3.2 TYPE DESIGNATION CODE

The type designation code is made of standard codes and option codes. Each part of the type designation code agrees to the data in your order. The code can have this format, for example:

VACON0100-3L-0385-5-FLOW-ED-R02+IP54 In chapter 4.5 The options you will find descriptions of the option codes.

Table 3: The description of the parts in the type designation code

Code Description

VACON0100 The product family: VACON0100 = the VACON® 100 product family

3L Input/Function: 3L = A 3-phase input

0385 The drive rating in amperes. For example, 0385 = 385 A

5 The mains voltage:

5 = 380-500 V 7 = 525-690 V

FLOW The product:

(empty) = The VACON® 100 INDUSTRIAL AC drive FLOW = The VACON® 100 FLOW AC drive

ED The AC drive is enclosed in a cabinet

R02 The regional code: R02 = North American Market version (the product is quali-

fied to the UL criteria)

+IP54 The option codes. There are many options, for example, +IP54 = an AC drive with

the IP class IP54

You can find the type designation code on a label in the lower right corner of the control compartment door.

3.3 THE CONTENTS OF THE DELIVERY

The contents of the delivery, MR8-MR12

•

The enclosed drive

•

An accessories bag

•

Installation Manual, Application Manual and manuals for the options that you ordered

•

Order-specific documents (on the inside of the control compartment door)

3.4 STORAGE

The storage conditions

•

Temperature: -40 °C...+70 °C

•

Humidity: < 95%, no condensation

RECEIVING THE DELIVERY VACON · 15

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If you keep the package in storage for more than 2 months, keep it in controlled conditions. Make sure that the temperature variation is small and that the humidity is less than 50%.

3.5 REMOVING THE PACKAGING AND LIFTING THE AC DRIVE

3.5.1 WEIGHT OF THE AC DRIVE

The weights of AC drives of different enclosure sizes are very different. It can be necessary for you to use a lifting device to move the drive from its package.

Table 4: The default weight of the enclosed drive and some options

Enclosure size The enclosed drive,

IP21/IP54, without options [kg]

Common mode filter + du/dt filter [kg]

The sine filter [kg] Any of the 3 cabling

from top options [kg]

MR8 200 30 270 65

MR9 270 40 270 65

MR10 420 40 350 80

MR12 825 80 700 95

3.5.2 LIFTING THE AC DRIVE

The AC drive is delivered horizontally or vertically on a wooden pallet. Most enclosure sizes of the AC drive include additional cabinet sections when you order any of the 3 cabling from top options (+CHIT, +CHOT, or +CHCT), the input contactor (+CICO), or the sine filter (+COSI). The products are delivered with all the cabinets attached together, except for the MR12 if you order it with the +COSI option and/or the +CICO option.

MOVING THE ENCLOSED DRIVE

1 Do not remove the package material before you

install the AC drive.

2 Put the drive onto a level base. 3 Move the drive in the vertical position.

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4 Use a hoist to move the drive.

5 If you move more than 1 drive at a time, use rollers.

LIFTING THE ENCLOSED DRIVE

1 Remove the drive from the package.

>60°

2 Use a lifting device that is sufficiently strong for the

weight of the drive.

3 Put the lifting hooks in the holes on the top of the

cabinet.

RECEIVING THE DELIVERY VACON · 17

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CAUTION!

To divide the weight of the AC drive equally, and to prevent damage to the equipment, always use 4 lifting holes.

4 The minimum angle between the drive and the

chain is 60 degrees.

5 Lift the drive into a vertical position.

>60°

3.6 "PRODUCT MODIFIED" LABEL

In the accessories bag, there is also a "product modified" label. The function of the label is to tell the service personnel about the changes that are made in the AC drive. Attach the label on the side of the AC drive to know where to find it. If you make changes in the AC drive, write the change on the label.

Product modified

Date:

VACON · 18 RECEIVING THE DELIVERY

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3.7 DISPOSAL

When the drive is at the end of its operation life, do not discard it as a part of municipal waste. You can recycle the primary components of the drive. You must disassemble some components before you can remove the different materials. Recycle the electrical and electronic components as waste. To make sure that the waste is recycled correctly, send the waste to a recycling centre. You can also send the waste back to the manufacturer. Obey the local and other applicable regulations.

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4 MOUNTING

4.1 DIMENSIONS OF THE CABINET, IEC

IEC = The product is qualified to the IEC criteria. NAM = The product is qualified to the UL criteria.

The information on dimensions that you will need in cabling can be found in the orderspecific documents.

NOTE!

The height of the standard base plinth is 100 mm, but the height of the base plinth option (+CHPH) is 200 mm.

406

Ø13

335

639

399

354

602

605

2100.5

2135.5

2155.5

120.5

100

200

Fig. 3: The dimensions of the default cabinet, MR8, [mm], IEC

VACON · 20 MOUNTING

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606

Ø13 Ø13

Ø13

535

639

599

555

600

604

2100.5

2135.5

2155.5

120.5

100

200

Fig. 4: The dimensions of the default cabinet, MR9 and MR10, [mm], IEC

MOUNTING VACON · 21

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100

120.5

2100.5

1135

1199 1206

555

200 200

555

639

Ø 13

2135.5

2155.5

600

604

Ø 13

Fig. 5: The dimensions of the default cabinet, MR12, [mm], IEC

4.2 DIMENSIONS OF THE CABINET WITH ADDITIONAL CABINET SECTIONS, IEC

IEC = The product is qualified to the IEC criteria. NAM = The product is qualified to the UL criteria.

The information on dimensions that you will need in cabling can be found in the orderspecific documents.

Table 5: The width of the additional cabinet section [mm]

Enclosure size With the input

contactor (+CICO)

With +CHIT, +CHOT, or +CHCT *

With +CICO and +CHIT, +CHOT, or +CHCT *

With the sine filter (+COSI)

MR8 - 400 400 600

MR9 - 400 400 600

MR10, max 385 A - 400 400 600

MR10, min 416 A 600 400 600 600

MR12 600 600 600 2 x 600

* = Input cabling from top (+CHIT), output cabling from top (+CHOT), or cabling from top (+CHCT)

VACON · 22 MOUNTING

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NOTE!

The height of the standard base plinth is 100 mm, but the height of the base plinth option (+CHPH) is 200 mm.

MOUNTING VACON · 23

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639 651

200 200 354

754

354

602

100

120.5

2100.5

2135.5

2155.5

605

799 806

735

335

Ø13

335

Fig. 6: The dimensions of the cabinet with the optional cabling from top, MR8, [mm], IEC

VACON · 24 MOUNTING

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639

200 200

555

1155

555

600

100

120.5

2100.5

2135.5

2155.5

604

1199

206

1135

535

Ø13

535

Fig. 7: The dimensions of the cabinet with the optional cabling from top and the input contactor, MR10 with min 416 A, [mm], IEC. See Table 5.

MOUNTING VACON · 25

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1735

535 535 535

Ø13

2100.5

2135.5

2155.5

100

120.5

1799 1806

200 555 555

1755

555

45 45200 200

604

600

Fig. 8: The dimensions of the cabinet with the optional cabling from top and/or the input contactor, MR12, [mm], IEC

VACON · 26 MOUNTING

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535

Ø13

535

639

100

120.5

2100.5

1135

Ø13

200

555

1155

555

600

604

2135.5

2155.5

Fig. 9: The dimensions of the cabinet with the optional sine filter, MR10, [mm], IEC

4.3 DIMENSIONS OF THE CABINET, NAM

IEC = The product is qualified to the IEC criteria. NAM = The product is qualified to the UL criteria.

The information on dimensions that you will need in cabling can be found in the orderspecific documents.

MOUNTING VACON · 27

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406

Ø13

335

639.5

399

354

602

605

2200.5

2235.5

2255.5

220.5

200

Fig. 10: The dimensions of the default cabinet, MR8, [mm], NAM

VACON · 28 MOUNTING

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606

Ø13 Ø13

Ø13

535

638.5

599

555

600

604

2200.5

2235.5

2255.5

220.5

200

Fig. 11: The dimensions of the default cabinet, MR9 and MR10, [mm], NAM

MOUNTING VACON · 29

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200

220.5

2200.5

1135

1199 1206

555

200 200

555

639

Ø13

2235.5

2255.5

600

604

Ø13

Fig. 12: The dimensions of the default cabinet, MR12, [mm], NAM

4.4 DIMENSIONS OF THE CABINET, WITH ADDITIONAL CABINET SECTIONS, NAM

IEC = The product is qualified to the IEC criteria. NAM = The product is qualified to the UL criteria.

The information on dimensions that you will need in cabling can be found in the orderspecific documents.

VACON · 30 MOUNTING

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639

259 448

354

745

354

200

779 806

735

335 335

200

602

605

443100

76.2

38.1

117.9

220.5

2200.5

2235.5

2255.5

662.3 Ø13

Ø13

Fig. 13: The dimensions of the cabinet with the optional cabling from top, MR8, [mm], NAM

A. 3 x conduit hole Ø 22 mm

MOUNTING VACON · 31

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639

200

354

200

555

1000 1007

935.9

335

535

200

600

605

76.2

38.1

443

220.5

2200.5

2235.5

2255.5

259 648.9

Ø13

Fig. 14: The dimensions of the cabinet with the optional cabling from top, MR10 with min 416 A, [mm], NAM

A. 3 x conduit hole Ø 22 mm

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639

676.5

1799

1735

1807

1755

555 555 555

200

64.75

459

600

1248

200

535 535 535

2200.5

200

200.5

2235.5

2255.5

605

76.2

38.1

149.65

600

Ø13

443

Fig. 15: The dimensions of the cabinet with the optional cabling from top and/or the input contactor, MR12, [mm], NAM. The image shows the AC drive with the optional cabling from top.

A. 6 x conduit hole Ø 22 mm

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535

Ø13

535

639

200

220.5

2200.5

1135

Ø13

200

555

1155

360.1

133.4

555

600

431.8

149.7

38.1

76.2

104.6

604

2235.5

2255.5

Fig. 16: The dimensions of the cabinet with the optional sine filter, MR10, [mm], NAM

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4.5 THE OPTIONS

Table 6: The options and their codes

Group Name Code

Auxiliary equipment Motor heater control +CAMH

Cabinet heater +CACH

Cabinet light +CACL

Cabinet power supply for accessories

Auxiliary voltage transformer +CAPT

Auxiliary AC supply terminals +CAPU

24 VDC power supply +CAPD

AC customer socket +CAPS

Door-mounted options Signal lights and reset button +CDLP

Control terminals Extended I/O terminals +CTID

Protection devices STO with emergency stop push button on door +CPS0

SS1 with emergency stop push button on door +CPS1

Emergency switch off +CPSB

Insulation monitoring +CPIF

Input devices AC fuses and fuse switch +CIFD

Input contactor +CICO *

Dynamic braking Brake chopper +DBIN

Output filters Common mode filter +POCM

du/dt filter +PODU

Sine filter +COSI

Cabling options Input cabling from top +CHIT

Output cabling from top +CHOT

Cabling from top +CHCT

Base plinth options Base plinth 200 mm +CHPH

Cooling options Back channel cooling +CHCB

Enclosure IP 54 +IP54

Special construction Marine construction +EMAR *

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Table 6: The options and their codes

Group Name Code

Approvals UL listed +GAUL

Not UL listed +GNUL

* = These options are not available for the NAM variation.

+ CAMH: MOTOR HEATER CONTROL

With this option, you can control the supply for the motor anti-condensation heater. The external supply is connected to terminals -XD1.1 that are located in the lower part of the cabinet. When the drive is not in Run state, the control relay +QAM changes the external supply to the output terminals (-XDN). When the drive is in Run state, the control relay disconnects the external supply to the motor heater. To disable the function, open the MCB – FCN.

The control relay +QAM uses the GND (-XD2:13) and relay RO1 (-XD2:21) terminals. The requirements: +CAPU Auxiliary AC supply terminals and +CAPD 24 VDC power supply

-XDN

-XD1

-FCN

6 A

-QAM

-XDN

Fig. 17: The motor heater control

A. The heater element, not included in the

delivery

+CACH: CABINET HEATER

This option increases the inside temperature of the cabinet above the ambient temperature, and thus prevents condensation in the cabinet. Each cabinet has 1 cabinet heater.

The external supply is connected to terminals -XD1.1. The heater element is of a selfregulating type. When the drive is not in Run state, the control relay +QAM changes the supply to the output terminals (-XD4). When the drive is in Run state, the control relay disconnects the supply to the cabinet heater. To disable the function, open the MCB –FCE.

The control relay +QAM uses the GND (-XD2:13) and relay RO1 (-XD2:21) terminals. The requirements: +CAPU Auxiliary AC supply terminals and +CAPD 24 VDC power supply

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-XD1

-FCE

6 A

-EB1.1

-XD4

-EB1.2

-EB1.3

-EB1.4

-QAM

-XD4

Fig. 18: The cabinet heater

+CACL: CABINET LIGHT

With this option the control compartment will have a light as default by an internal auxiliary transformer or as an option by an external auxiliary voltage supply connected to –XD1.1.

The requirements: +CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

-XD1

-FCC

2 A

-EA1

Fig. 19: The cabinet light

+CAPT: AUXILIARY VOLTAGE TRANSFORMER

This option provides the supply of auxiliary voltage for other options. The supply for the auxiliary transformer is taken from mains. If you use the option AC fuses and fuse switch (+CIFD), the supply for the auxiliary voltage transformer is taken from between the drive and the fuse switch. This means that the control voltage is disconnected with the main switch.

The requirements: Not +CAPU Auxiliary AC supply terminals

4 A

-TA4

L1-L2

-FC6

-FC4

-XD1

Fig. 20: The auxiliary voltage transformer

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+CAPU: AUXILIARY AC SUPPLY TERMINALS

This option provides terminals –XD1.1 for an external voltage supply. The external supply must be short-circuit protected. The power of this supply depends on other selected cabinet options.

The requirements: Not +CAPT Auxiliary voltage transformer.

WARNING!

The main switch does not disconnect the external voltage supply. Before you touch the components of the control compartment, disconnect the external voltage supply. The voltage can be very dangerous.

-FC6

-XD1.1 -XD1

10 A

Fig. 21: The auxiliary AC supply terminals

+CAPD: 24 VDC POWER SUPPLY

This option provides a backup supply for the control unit of the drive. Use it also for other auxiliary options for which a 24 VDC supply is necessary.

The +24 VDC voltage is supplied to the GND (-XD2:20) and +24 Vin (-XD2:30) terminals. The requirements: +CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage

transformer. The backup supply for the control unit requires +CAPU Auxiliary AC supply terminals, because for +CAPU, the power is not switched off with the main switch.

ACAC

- +

-XD1

-FC7

2 A

-TB7

24 V

60 W

-XD1

-XD3

Fig. 22: The 24 VDC power supply

+CAPS: AC CUSTOMER SOCKET

The socket provides a power supply for your measurement equipment, tools or computer. The type of the socket is CEE 7/3 ("Schuko", Type F) or NEMA 5-15 grounded (Type B).

The default voltage is 230 VAC, and 115 VAC in the North American regional variant. The maximum output power with 230 VAC is 450 VA and with 115 VAC it is 230 VA when an external supply (+CAPU) is used, and 180 VA when a transformer supply (+CAPT) is used.

The requirements: +CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

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-XD1-XD1

-FCC

2 A

-XD10

-PE

Fig. 23: The AC customer socket

+CDLP: SIGNAL LIGHTS AND RESET BUTTON

This option includes signal lights on the control compartment door for Ready, Run and Fault states of the AC drive. The door also has a button for the reset function of the AC drive. The Ready signal light is not available if you use the optional relay board OPTF4.

If you use the relay board OPTF3, this option uses the digital input 6 (-XD2:16) and the relays RO1 (-XD2:23), RO2 (-XD2:26) and RO3 (-XD2:33).

The requirements:

•

+CAPD 24 VDC power supply

•

+CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

+CTID: EXTENDED I/O TERMINALS

The option includes 20 control terminals (-XDW) in the control compartment for your own free use.

No requirements.

+CPS0: STO WITH EMERGENCY STOP PUSH BUTTON ON DOOR

This option provides the STO (Safe Torque Off) function with the OPT-BJ option board and an emergency stop push button on the door of the control compartment. The STO Channel 1 and STO Channel 2 are wired to the emergency stop push button. The STO function corresponds to an emergency stop category 0. See the user manual of the OPT-BJ option board for the regulations and the certified safety functions.

The requirements:

•

The option board OPT-BJ

•

+CAPD 24 VDC power supply

•

+CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

+CPS1: SS1 WITH EMERGENCY STOP PUSH BUTTON ON DOOR

This option provides the SS1 (Safe Stop 1) function with the OPTBJ option board, a safety relay and an emergency stop push button on the control compartment door. Pushing the emergency stop push button activates the motor deceleration and makes the motor stop in the set deceleration ramp time. The STO Channel 1 and STO Channel 2 are wired to the safety relay that activates the STO function after the set delay. See the user manual of the OPTBJ option board and the safety relay for the regulations and the certified safety functions.

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This option uses the digital input 5 (-XD2:15). The requirements:

•

The option board OPTBJ

•

+CAPD 24 VDC power supply

•

+CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

CAUTION!

The delay of the safety relay is process/machine-dependent. The designer and the user of your system are responsible for understanding and setting the delay of the safety relay. An incorrect delay can cause damage to the equipment.

+CPSB: EMERGENCY SWITCH OFF

The Emergency switch off function uses an input contactor to disconnect the drive from mains. Pushing the emergency stop push button on the control compartment door opens the control circuit of the input contactor.

The requirements:

•

+CICO Input contactor

•

+CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

+CPIF: INSULATION MONITORING

With this option it is possible to monitor the insulation level in an IT supply network with an insulation monitor in the control compartment. The insulation monitor supervises the supply and the insulation faults in the output network.

The requirements:

•

+CAPD 24 VDC power supply

•

+CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage transformer

+CIFD: AC FUSES AND FUSE SWITCH

When you have this option, you can isolate the drive safely from the mains with a fuse switch that is located directly below the power unit.

With the enclosure size MR12 and the input contactor +CICO, the fuse switches are located in the additional cabinet section. The fuse switches have overtemperature protection by means of a thermostat. When the temperature limit of the thermostat is reached, a safety circuit opens and an external fault occurs. The function uses the terminals +24 Vout (-XD2:12) and digital input 4 (-XD2:14).

The wiring of the option can be seen in chapter 5.1.1 Main circuit diagrams of the cabinet.

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+CICO: INPUT CONTACTOR

This option makes it possible for you to connect or disconnect the drive from mains. To do it, use a control switch on the control compartment door, or connect an external switch to terminals –XD0. To connect the external switch, refer to the electrical drawings.

The option includes the fuse switch (+CIFD) for safety reasons. When your product is MR10 with minimum 416 A, the option includes additional cabinet

sections. The wiring of the option can be seen in chapter 5.1.1 Main circuit diagrams of the cabinet. The requirements: +CAPU Auxiliary AC supply terminals or +CAPT Auxiliary voltage

transformer

+DBIN: BRAKE CHOPPER

The power unit has a dynamic brake chopper. The external brake resistor is connected directly to the brake resistor terminals of the power unit, see chapter 5.4.1 Installing the cables. The brake resistor is not included in the option.

+POCM: COMMON MODE FILTER

The option includes an output filter that decreases the common mode voltage. The filter is connected between the motor cable terminals of the power unit and the motor cable terminals of the drive. The filter does not have an effect on the connection of the external motor cables.

The wiring of the option can be seen in chapter 5.1.1 Main circuit diagrams of the cabinet.

+PODU: DU/DT FILTER

The option includes an output filter that increases the rise time of the voltage pulse, and thus decreases the voltage stress on the motor winding insulation.

The filter is connected between the motor cable terminals of the power unit and the motor cable terminals of the drive. The filter does not have an effect on the connection of the external motor cables. With this option, the maximum length of motor cables is 150 m. If the cables are longer than 150 m, use a sine filter option.

The wiring of the option can be seen in chapter 5.1.1 Main circuit diagrams of the cabinet. The requirements: Not +COSI Sine filter.

+COSI: SINE FILTER

The option includes an output filter that removes the switching frequency. The output filter leaves only the output frequency and thus eliminates all voltage stress on the motor. The filter is connected after the motor cable terminals of the AC drive. The filter is located in an additional cabinet section. The option is necessary if the motor requires filtering, and if longer than 150 meter cables are used. The option can also be used with shorter cables if necessary. If you use long cables, we recommend you to use the common mode filter option (+POCM) also.

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The wiring of the option can be seen in chapter 5.1.1 Main circuit diagrams of the cabinet. When you use the sine filter option, make sure that the parameter Sine Filter is in use. The

sine filter option is designed for a minimum of 2 kHz switching frequency. Parameter Sine Filter disables switching frequencies below 2 kHz when automatic derating becomes active.

This option has an overtemperature protection function. The coils of the sine filter have thermal relays that are connected to the control terminals of the AC drive. The function uses the terminals +24 Vout (-XD2:12) and digital input 4 (-XD2:14). When the overtemperature limit is reached, a safety circuit opens and an external fault appears. Find the cause of the fault. The cause of the fault can be, for example, a fan failure, a clogged air channel, or high ambient temperature. You can reset the fault after the sine filter has cooled down.

The requirements: Not +PODU du/dt filter.

+CHIT: INPUT CABLING FROM TOP

With this option you can make the input cables, that is, the mains cables enter the cabinet from the top. The option includes an additional cabinet section.

+CHOT: OUTPUT CABLING FROM TOP

With this option you can make the output cables, that is, the motor cables enter the cabinet from the top. The option includes an additional cabinet section.

+CHCT: CABLING FROM TOP

With this option you can make the cables enter the cabinet from the top. The option includes an additional cabinet section.

+CHPH: BASE PLINTH 200 MM

This option includes a 200 mm base plinth that you can use instead of the standard 100 mm base plinth.

+CHCB: BACK CHANNEL COOLING

See more in chapter 4.8 The optional back channel cooling. The requirements:

•

+CACH Cabinet heater

•

+CAPU Auxiliary AC supply terminals

•

+IP54 IP54

+IP54: IP54

This option provides the enclosure class IP54 for your product.

+EMAR: MARINE CONSTRUCTION

See more information in the Marine Installation Guide.

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The requirements:

•

+IP54 IP54

•

+CACH Cabinet heater

•

Not +CHCB Back channel cooling

+GAUL: UL LISTED

The product is qualified to the UL criteria.

+GNUL: NOT UL LISTED

The product is not qualified to the UL criteria.

4.6 INSTALLATION OF THE CABINET

Install the AC drive in a vertical position on level ground. Attach the drive with screws to the wall and/or the floor.

To attach the cabinet to the floor, there are 3 alternatives.

•

Use the 4 fixing points at the bottom of the cabinet.

•

Use the 2 fixing points at the front bottom and the 2 fixing points at the rear top of the cabinet.

•

Use the 2 fixing points in the fixing bracket and the 2 fixing points at the front bottom of the cabinet. To use the fixing bracket, first attach it to the floor. Slide the edge of the cabinet plinth under the fixing bracket. Then attach the 2 fixing points at the front bottom.

NOTE!

If you have multiple additional cabinet sections (for example with MR12 or the optional cabling from top), these steps must be done for each section.

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Fig. 24: The fixing points of the cabinet

A. The 4 fixing points at the bottom B. The 2 fixing points at the front bottom

C. The 2 fixing points at the rear top D. The 2 fixing points in the fixing bracket

4.7 COOLING AND FREE SPACE AROUND THE AC DRIVE

The AC drive produces heat in operation. The fan circulates air and decreases the temperature of the drive. Make sure that there is sufficiently free space around the drive.

Some free space in front of the drive is also necessary for maintenance. You must also have 80 cm of free space in front of the cabinet to be able to open the cabinet door. When you have 2 or more drives, you can install them side by side.

Make sure that the temperature of the cooling air does not become higher than the maximum ambient operating temperature or lower than the minimum ambient operating temperature of the drive.

The air must move freely and efficiently through the cabinet and the drive. There must be a minimum of 30 cm of space above the cabinet without obstacles that can stop the airflow. Make sure that the hot air goes out of the cabinet and does not come back into the cabinet.

The power loss of the AC drive can change significantly, when the load, the output frequency or the switching frequency changes. It is useful to know the power loss, when you plan the

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cooling equipment in an electrical room. Use this formula to calculate the approximate power loss of the drive in nominal conditions.

loss

[kW] = P

mot

[kW] x 0.025

It is possible that there will be an increase of 0-0.5% in the power loss when you have options in the cabinet. Some options, for example output filters and input devices, cause more power losses.

To calculate the power loss, use the ecoSmart tool. See www.danfoss.com.

Fig. 25: The circulation of cooling air

Table 7: The necessary quantity of cooling air

Enclosure size The quantity of cooling

air [m3/h]

MR8 330

MR9 620

MR10 1400

MR12 2 x 1400

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4.8 THE OPTIONAL BACK CHANNEL COOLING

You can also use the back channel cooling option (+CHCB) for the cooling of the AC drive. With this option, the intake air to the main cooling channel of the AC drive can be taken from and exhausted to the outside of the electrical room. Because the heat losses of the drive are directed outside, the cooling load of the electrical room is reduced.

USING THE BACK CHANNEL FOR COOLING

1 Make an opening in the wall behind the cabinet. 2 To prevent condensation in the cabinet, connect the

supply cable of the cabinet heater (+CACH, delivered as default with this option) to the correct terminals in the control compartment.

3 Attach the duct adapter flanges to the cabinet with

screws.

4 Do not install the cabinet in an airtight space.

Approximately 5-10% of the intake air must come from the front.

•

The estimated amount of intake air is for MR8: 0 m3, MR9: 10m3, for MR10: 20m3, for MR12: 40m3.

NOTE!

MR8 does not take in air from the front.

5 Make sure that there are no particles in the air that

can block the heat sink.

6 Move the cabinet adjacent to the wall, or attach the

duct adapter flanges to the air duct.

•

Do not make attachments to other parts of the drive except the white flange that you can see in the picture.

7 Make sure that you seal the openings correctly.

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CAUTION!

If you use long air ducts in addition to the duct adapter flanges, use a duct fan or equivalent to prevent back pressure. Back pressure must be prevented because it decreases the performance of the drive.

NOTE!

The height of the standard base plinth is 100 mm, but the height of the base plinth option (+CHPH) is 200 mm.

258

252

202

252

202

1939

Fig. 26: Dimensions for the back channel cooling, MR8

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402

258

202

402

202

1935

Fig. 27: Dimensions for the back channel cooling, MR9 and MR10

The additional cabinet sections do not need back channels. The exception is the additional cabinet section of the sine filter option, which has back channel cooling.

In MR12, there are two back channels.

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5 POWER CABLING

5.1 CABLE DIMENSIONING AND SELECTION

5.1.1 MAIN CIRCUIT DIAGRAMS OF THE CABINET

+POCM

+PODU

+DBIN

+CICO

W1V1U1PE

L1 L2 L3

U V WPE

DC+/R +

DC-

R-

TX STO

+COSI

U V W

+CIFD

/+CIFU

U V W

PE L1 L2 L3

Fig. 28: Main circuit diagram of the cabinet, MR8-MR10

A. Main cabinet

B. Sine filter cabinet C. PE bus

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D. Brake resistor (not included in delivery)

A A

B B

+POCM

+PODU

+POCM

+PODU

+DBIN

+CICO

W1V1U1PE

L1 L2 L3

U V WPE

PU1

DC+/R +

DC-

R-

TX STO

+COSI

1V 1W

+CIFD

/+CIFU

1U 1V 1W

+CICO

U V WPE

PU2

DC+/R+

DC-

R-

TX STO

+COSI

2V 2W

+CIFD

/+CIFU

2U 2V 2W

1DC+ 1DC-

2DC+

2DC-

1R-

2R-

PE 1L1 1L2 1L3 2L1 2L2 2L3

Fig. 29: Main circuit diagram of the cabinet, MR12

A. Main cabinet B. Sine filter cabinet C. PE bus D. Brake resistor (not included in delivery)

E. Symmetrical motor cabling. The cables

must have the same length from the power unit to a common point of coupling.

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The minimum length of motor cables from the power unit to a common point of coupling is 10 m. When a du/dt filter is used, the cables can be less than 10 m long.

Fig. 30: The 12-pulse operation of MR12

A. The MR12 drive With MR12 you can also use a 12-pulse connection to reduce the harmonics level in the

supply side of the drive. In the 12-pulse connection, the parallel drives are cabled to the transformer's secondary windings that have a 30-degree phase shift.

5.1.2 CABLE AND FUSE SIZES, IEC

We recommend the fuse type gG/gL (IEC 60269-1) for mains fuses (-F1). Use only fuses that have a sufficient voltage rating according to the mains voltage. Do not use larger fuses than what is recommended in Table 8. The fuses are selected for short circuit protection only.

NOTE!

The overcurrent protection of parallel cables must be done with separate fuses.

Make sure that the operation time of the fuse is less than 0.4 seconds. The operation time agrees with the fuse type and the impedance of the supply circuit.

The table also shows the typical symmetrically shielded copper and aluminum types of the cables that can be used with the AC drive.

NOTE!

The mains cable and fuse sizes are valid up to a cable length of 100 m, with mains IK = 20 kA.

33 3

-F1 3

-FC1 -TA1-T1

Fig. 31: The location of the fuses, MR8-MR10

A. The mains fuses B. The cabinet

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3 3

-F1 3

-FC1.1 -TA1.1

-F1 3

-FC1.2 -TA1.2

-T

Fig. 32: The location of the fuses, MR12

A. The mains fuses B. The cabinet The drive must be protected with fast acting aR-type fuses (-FC1) (see Table 10, Table 11,

Table 12 and Table 13). Do not use other fuses than these. These fuses are included in the delivery.

The dimensions of the cables agree with the requirements of the standards EN 60204-1 and IEC 60364-5-52: 2001.

•

The cables are PVC-isolated.

•

The maximum ambient temperature is +30 °C.

•

The maximum temperature of the cable surface is +70 °C.

•

The maximum number of parallel cables on a ladder type tray is 9 side by side.

In other conditions, when you select the dimensions of the cables, refer to local safety regulations, the input voltage and the load current of the drive.

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Table 8: The recommended cables and fuses in 380-500 V (IEC)

Enclosure

size

Type IL [A] Mains fuse

(gG/gL) [A]

Mains and motor

cable (Cu/AI) [mm2]

Mains and

motor cable

terminals,

bolt size

Grounding

terminal,

bolt size

MR8

0140 5 140 160

(3x70+35) (Cu)

(3x95+29) (Al)

M8 M8

0170 5 170 200

(3x95+50) (Cu) (3x150+41) (Al)

M8 M8

0205 5 205 250

(3x120+70) (Cu)

(3x185+57) (Al)

M8 M8

MR9

0261 5 261 315

(3x185+95) (Cu)

2x(3x120+41) (Al)

M10 M8

0310 5 310 355

2x(3x95+50) (Cu)

2x(3x120+41) (Al)

M10 M8

MR10

0385 5 385 400

2x(3x120+70) (Cu)

2x(3x185+57) (Al)

M12 M8

0460 5 460 500

2x(3x150+70) (Cu)

2x(3x240+72) (Al)

M12 M8

0520 5 520 630

2x(3x185+95) (Cu)

3x(3x150+41) (Al)

M12 M8

0590 5 590 630

2x(3x240+120) (Cu)

3x(3x185+57) (Al)

M12 M8

MR12

0650 5 650 2 x 355

4x(3x95+50) (Cu)

4x(3x120+41) (Al)

M12 M8

0730 5 730 2 x 400

4x(3x95+50) (Cu)

4x(3x150+41) (Al)

M12 M8

0820 5 820 2 x 500

4x(3x120+70) (Cu)

4x(3x185+57) (Al)

M12 M8

0920 5 920 2 x 500

4x(3x150+70) (Cu)

4x(3x240+72) (Al)

M12 M8

1040 5 1040 2 x 630

4x(3x185+95) (Cu)

6x(3x150+41) (Al)

M12 M8

1180 5 1180 2 x 630

4x(3x240+120) (Cu)

6x(3x185+57) (Al)

M12 M8

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Table 9: The recommended cables and fuses in 525-690 V (IEC)

Enclosure

size

Type IL [A] Mains fuse

(gG/gL) [A]

Mains and motor

cable (Cu/AI) [mm2]

Mains and

motor cable

terminals,

bolt size

Grounding

terminal,

bolt size

MR8

0080 7 80 100

3x35+16 (Cu)

3x50+21 (Al)

M8 M8

0100 7 100 125

3x50+25 (Cu)

3x70+21 (Al)

M8 M8

0125 7 125 160

3x70+35 (Cu)

3x95+29 (Al)

M8 M8

MR9

0144 7 144 160

3x70+35 (Cu)

3x120+41 (Al)

M10 M8

0170 7 170 200

3x95+50 (Cu)

3x150+41 (Al)

M10 M8

0208 7 208 250

3x120+70 (Cu)

3x185+57 (Al)

M10 M8

MR10

0261 7 261 315

3x185+95 (Cu)

2x(3x95+29) (Al)

M12 M8

0325 7 325 355

3x240+120 (Cu)

2x(3x120+41) (Al)

M12 M8

0385 7 385 400

2x(3x120+70) (Cu)

2x(3x185+57) (Al)

M12 M8

0416 7 416 450

2x(3x120+70) (Cu)

2x(3x185+57) (Al)

M12 M8

MR12

0460 7 460 2 x 315

2x(3x150+70) (Cu)

2x(3x240+72) (Al)

M12 M8

0520 7 520 2 x 315

2x(3x185+95) (Cu)

4x(3x95+29) (Al)

M12 M8

0590 7 590 2 x 315

4x(3x70+35) (Cu)

4x(3x120+41) (Al)

M12 M8

0650 7 650 2 x 355

4x(3x95+50) (Cu)

4x(3x150+41) (Al)

M12 M8

0730 7 730 2 x 400

4x(3x120+70) (Cu)

4x(3x150+41) (Al)

M12 M8

0820 7 820 2 x 425

4x(3x120+70) (Cu)

4x(3x185+57) (Al)

M12 M8

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Table 10: Drive fuses, 380-500 V, Mersen (IEC)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0140 5 140 NH1UD69V250PV 250 3 1 1400

0170 5 170 NH1UD69V350PV 350 3 1 2400

0205 5 205 NH1UD69V400PV 400 3 1 2800

MR9

0261 5 261 NH2UD69V500PV 500 3 2 3300

0310 5 310 NH2UD69V630PV 630 3 2 5000

MR10

0385 5 385 NH2UD69V700PV 700 3 2 5700

0460 5 460 NH3UD69V900PV 900 3 3 7000

0520 5 520 NH3UD69V1000PV 1000 3 3 8600

0590 5 590 PC73UD90V10CPA 1000 3 3 13000

MR12

0650 5 650 NH2UD69V630PV 630 6 2 5000

0730 5 730 NH2UD69V700PV 700 6 2 5700

0820 5 820 NH3UD69V900PV 900 6 3 7000

0920 5 920 NH3UD69V1000PV 1000 6 3 8600

1040 5 1040 NH3UD69V1000PV 1000 6 3 8600

1180 5 1180 PC73UD90V10CPA 1000 6 3 13000

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Table 11: Drive fuses, 525-690 V, Mersen (IEC)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0080 7 80 NH1UD69V125PV 125 3 1 500

0100 7 100 NH1UD69V160PV 160 3 1 700

0125 7 125 NH1UD69V200PV 200 3 1 1000

MR9

0144 7 144 NH1UD69V315PV 315 3 1 2000

0170 7 170 NH1UD69V350PV 350 3 1 2400

0208 7 208 NH1UD69V400PV 400 3 1 2800

MR10

0261 7 261 NH2UD69V400PV 400 3 2 2800

0325 7 325 NH2UD69V500PV 500 3 2 3300

0385 7 385 NH2UD69V630PV 630 3 2 5000

0416 7 416 NH3UD69V900PV 900 3 3 7100

MR12

0460 7 460 NH2UD69V400PV 400 6 2 2400

0520 7 520 NH2UD69V450PV 450 6 2 2800

0590 7 590 NH2UD69V500PV 500 6 2 3300

0650 7 650 NH2UD69V550PV 550 6 2 4000

0750 7 750 NH2UD69V630PV 630 6 2 5000

0820 7 820 NH3UD69V900PV 900 6 3 7100

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Table 12: Drive fuses, 380-500 V, Bussmann (IEC)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0140 5 140 170M3817D 315 3 1 1700

0170 5 170 170M3818D 350 3 1 1950

0205 5 205 170M3819D 400 3 1 2400

MR9

0261 5 261 170M5810D 500 3 2 2800

0310 5 310 170M5812D 630 3 2 4000

MR10

0385 5 385 170M5814D 800 3 2 5750

0460 5 460 170M6814D 1000 3 3 7500

0520 5 520 170M6892D 1100 3 3 8500

0590 5 590 170M8554D 1250 3 3 10500

MR12

0650 5 650 170M5814D 800 6 2 5750

0730 5 730 170M5814D 800 6 2 5750

0820 5 820 170M6813D 900 6 3 6000

0920 5 920 170M6814D 1000 6 3 7500

1040 5 1040 170M6892D 1100 6 3 8500

1180 5 1180 170M8554D 1250 6 3 10500

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Table 13: Drive fuses, 525-690 V, Bussmann (IEC)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0080 7 80 170M3814D 160 3 1 650

0100 7 100 170M3815D 200 3 1 950

0125 7 125 170M3816D 250 3 1 1300

MR9

0144 7 144 170M3817D 315 3 1 1700

0170 7 170 170M3819D 400 3 1 2400

0208 7 208 170M4863D 450 3 1 2800

MR10

0261 7 261 170M5811D 550 3 2 3400

0325 7 325 170M5813D 700 3 2 4800

0385 7 385 170M5814D 800 3 2 5750

0416 7 416 170M6814D 1000 3 3 7500

MR12

0460 7 460 170M5811D 550 6 2 3400

0520 7 520 170M5812D 630 6 2 4000

0590 7 590 170M5813D 700 6 2 4800

0650 7 650 170M5813D 700 6 2 4800

0750 7 750 170M5814D 800 6 2 5750

0820 7 820 170M6813D 900 6 3 6000

5.1.3 CABLE AND FUSE SIZES, NAM

Fuses that are contained in the product (-FC1) are suitable for both short circuit and branch circuit protection (see Table 16 and Table 17). Do not use other fuses than these.

NOTE!

The overcurrent protection of parallel cables must be done with separate fuses.

Make sure that the operation time of the fuse is less than 0.4 seconds. The operation time agrees with the fuse type and the impedance of the supply circuit.

The table also shows the typical symmetrically shielded copper and aluminum types of the cables that can be used with the AC drive.

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NOTE!

The mains cable and fuse sizes are valid up to a cable length of 100 m, with mains IK = 20 kA.

33 3

-F1 3

-FC1 -TA1-T1

Fig. 33: The location of the fuses, MR8-MR10

A. The mains fuses B. The cabinet

3 3

-F1 3

-FC1.1 -TA1.1

-F1 3

-FC1.2 -TA1.2

-T

Fig. 34: The location of the fuses, MR12

A. The mains fuses B. The cabinet The cable dimensioning in Table 14 and Table 15 is in accordance with UL61800-5-1 and the

National Electric Code per table 310.15(B)(16). The values of the tables were calculated using correction factors for a 40°C ambient operating temperature, and using AC drive cables with a minimum insulation rating of 90°C. Refer to local or municipal regulations for more sizing requirements.

The UL approval is valid for input voltage up to 600 V.

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Table 14: The recommended cables and terminal lugs in 380-500 V (NAM)

Enclosure size Type IL (A) Mains and motor

cable (Cu) [AWG/

kcmil]

Mains and motor

cable

termination,

Panduit terminal

part number

Grounding

terminal, bolt and

lug size

MR8

0140 5 140 (3x2/0+3x10) LCAX2/0-38-X P10-56R-L

0170 5 170 (3x4/0+3x8) LCAX4/0-38-X LCAX8-56-L

0205 5 205 (3x262+3x6) LCAX250-38-X LCAX6-56-L

MR9

0261 5 261 2x(3x2/0+3x10) LCAX2/0-38-X P10-56R-L

0310 5 310 2x(3x4/0+3x8) LCAX4/0-38-X LCAX8-56-L

MR10

0385 5 385 2x(3x262+3x6) LCAX250-12-X LCAX6-56-L

0460 5 460 2x(3x313+3x6) LCAX300-12-6 LCAX6-56-L

0520 5 520 2x(3x373+3x6) LCAX350-12-6 LCAX6-56-L

0590 5 590 3x(3x262+3x6) LCAX250-12-X LCAX6-56-L

MR12

0650 5 650 4x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0730 5 730 4x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0820 5 820 4x(3x262+3x6) LCAX250-12-X LCAX6-56-L

0920 5 920 4x(3x313+3x6) LCAX300-12-6 LCAX6-56-L

1040 5 1040 4x(3x373+3x6) LCAX350-12-6 LCAX6-56-L

1180 5 1180 6x(3x262+3x6) LCAX250-12-X LCAX6-56-L

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Table 15: The recommended cables and terminal lugs in 525-690 V (NAM)

Enclosure size Type IL (A) Mains and motor

cable (Cu) [AWG/

kcmil]

Mains and motor

cable

termination,

Panduit terminal

part number

Grounding

terminal, bolt and

lug size

MR8

0080 7 80 (3x2+3x10) LCAX2-38-E P10-56R-L

0100 7 100 (3x1+3x10) LCAX1-38-X P10-56R-L

0125 7 125 (3x2/0+3x10) LCAX2/0-38-X P10-56R-L

MR9

0144 7 144 (3x4/0+3x8) LCAX4/0-38-X LCAX8-56-L

0170 7 170 (3x4/0+3x8) LCAX4/0-38-X LCAX8-56-L

0208 7 208 2x(3x1+3x10) LCAX1-38-X P10-56R-L

MR10

0261 7 261 2x(3x2/0+3x10) LCA2/0-12-X P10-56R-L

0325 7 325 2x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0385 7 385 2x(3x262+3x6) LCAX250-12-X LCAX6-56-L

0416 7 416 2x(3x262+3x6) LCAX250-12-X LCAX6-56-L

MR12

0460 7 460 4x(3x1/0+3x10) LCAX1/0-12-X P10-56R-L

0520 7 520 4x(3x2/0+3x10) LCAX2/0-12-X P10-56R-L

0590 7 590 4x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0650 7 650 4x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0730 7 730 4x(3x4/0+3x8) LCAX4/0-12-X LCAX8-56-L

0820 7 820 4x(3x262+3x6) LCAX250-12-X LCAX6-56-L

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Table 16: Drive fuses, 380-500 V, Mersen (NAM)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0140 5 140 PC30UD69V250TF 250 3 PSC30 1550

0170 5 170 PC30UD69V315TF 315 3 PSC30 2250

0205 5 205 PC30UD69V350TF 350 3 PSC30 2550

MR9

0261 5 261 PC30UD69V400TF 400 3 PSC30 3100

0310 5 310 PC30UD69V550TF 550 3 PSC30 4700

MR10

0385 5 385 PC32UD69V630TF 630 3 PSC32 4700

0460 5 460 PC32UD69V700TF 700 3 PSC32 5700

0520 5 520 PC32UD69V900TF 900 3 PSC32 8200

0590 5 590 PC32UD69V1000TF 1000 3 PSC32 9600

MR12

0650 5 650 PC32UD69V630TF 630 6 PSC32 4700

0730 5 730 PC32UD69V630TF 630 6 PSC32 4700

0820 5 820 PC32UD69V700TF 700 6 PSC32 5700

0920 5 920 PC32UD69V800TF 800 6 PSC32 6800

1040 5 1040 PC32UD69V900TF 900 6 PSC32 8200

1180 5 1180 PC32UD69V1000TF 1000 6 PSC32 9600

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Table 17: Drive fuses, 525-690 V, Mersen (NAM)

Enclosure

size

Type IL [A] Catalogue number of the

fuse

Fuse

rating

[A]

Number

of fuses

needed

Fuse

size

Minimum

prospective

short

circuit

current [A]

MR8

0080 7 80 PC30UD69V160TF 160 3 PSC30 800

0100 7 100 PC30UD69V200TF 200 3 PSC30 1200

0125 7 125 PC30UD69V250TF 250 3 PSC30 1550

MR9

0144 7 144 PC30UD69V315TF 315 3 PSC30 2250

0170 7 170 PC30UD69V315TF 315 3 PSC30 2250

0208 7 208 PC30UD69V350TF 350 3 PSC30 2550

MR10

0261 7 261 PC32UD69V450TF 450 3 PSC32 3000

0325 7 325 PC32UD69V500TF 500 3 PSC32 3400

0385 7 385 PC32UD69V630TF 630 3 PSC32 4700

0416 7 416 PC32UD69V700TF 700 3 PSC32 5700

MR12

0460 7 460 PC32UD69V450TF 450 6 PSC32 3000

0520 7 520 PC32UD69V450TF 450 6 PSC32 3000

0590 7 590 PC32UD69V500TF 500 6 PSC32 3400

0650 7 650 PC32UD69V550TF 550 6 PSC32 3900

0750 7 750 PC32UD69V630TF 630 6 PSC32 4700

0820 7 820 PC32UD69V700TF 700 6 PSC32 5700

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5.2 BRAKE RESISTOR CABLES

Table 18: Brake resistor cables, 380-500 V

Enclosure size Type IL [A] Brake resistor cable (Cu)

[mm2]

MR8

0140 5 140 3x70+35

0170 5 170 3x95+50

0205 5 205 3x120+70

MR9

0261 5 261 2x(3x70+35)

0310 5 310 2x(3x95+50)

MR10

0385 5 385

2x(3x95+50)

0460 5 460

0520 5 520

2x(3x120+70)

0590 5 590

MR12

0650 5 650

4x(3x95+50)

0730 5 730

0820 5 820

0920 5 920

1040 5 1040

4x(3x120+70)

1180 5 1180

One of the cable conductors remains unconnected. Use a symmetrically shielded cable, the same type as with the mains and motor cables.

NOTE!

The different VACON® 100 applications have different functions. For example, the VACON® 100 FLOW does not have the dynamic braking or the brake resistor functions.

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Table 19: Brake resistor cables, 525-690 V

Enclosure size Type IL [A] Brake resistor cable (Cu)

[mm2]

MR8

0080 7 80 3x35+16

0100 7 100 3x50+25

0125 7 125 3x70+35

MR9

0144 7 144 3x70+35

0170 7 170 3x95+50

0208 7 208 3x120+70

MR10

0261 7 261

2x(3x70+35)

0325 7 325

0385 7 385

2x(3x95+50)

0416 7 416

MR12

0460 7 460

4x(3x70+35)

0520 7 520

0590 7 590

0650 7 650

0750 7 750

4x(3x95+50)

0820 7 820

One of the cable conductors remains unconnected. Use a symmetrically shielded cable, the same type as with the mains and motor cables.

NOTE!

The different VACON® 100 applications have different functions. For example, the VACON® 100 FLOW does not have the dynamic braking or the brake resistor functions.

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5.3 PREPARING FOR THE CABLE INSTALLATION

•

Before you start, make sure that none of the components of the AC drive is live. Read carefully the warnings in chapter 2 Safety.

•

Make sure that the motor cables are sufficiently far from other cables.

•

The motor cables must cross other cables at an angle of 90°.

•

If it is possible, do not put the motor cables in long parallel lines with other cables.

L1 L2 L3 U V W

A. The mains cables B. The motor cables C. The grounding conductor D. Pull relief

E. The grounding clamp for cable shield,

360° grounding F. The control cable G. The grounding bar of the control cable

•

Only use

symmetrically EMC shielded motor cables.

•

The maximum length of shielded motor cables is 200 m without sine filter (MR8-MR12).

•

If the cable insulation checks are necessary, see chapter 7.3 for instructions.

•

If the motor cables are in long parallel lines with other cables, obey the minimum distances.

•

The minimum distances are also valid between the motor cables and the signal cables of other systems.

Table 20: The minimum distances between cables in long parallel lines

The distance between cables [m] The length of the shielded cable [m]

0.3 ≤ 50

1.0 ≤ 200

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5.4 CABLE INSTALLATION IN MR8-MR12

Fig. 35: The inside layout of MR8, without protective covers

A. The output air grill B. The control connector of the power unit C. The EMC jumpers D. The contactor option E. The main switch option and the fuses F. The mains cable terminals G. The 360-degree grounding H. The PE bar I. Input air grill J. The terminals for the option +CAPU

K. The motor cable terminals with the

common mode and/or the du/dt filter

options L. The options CAPT and CPIF M. The motor cable terminals, without the

common mode and/or the du/dt filter

options N. The internal fan for IP54 O. The main fan P. The cable entry plate for control cables

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Fig. 36: The inside layout of MR9, without protective covers

K. The motor cable terminals with the

common mode and/or the du/dt filter

options L. The options CAPT and CPIF M. The motor cable terminals, without the

common mode and/or the du/dt filter

options N. The internal fan for IP54 O. The main fan P. The cable entry plate for control cables

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G H

Fig. 37: The inside layout of MR10, without protective covers

A. The output air grill B. The control connector of the power unit C. The EMC jumper (behind the covers) D. The main switch option and the fuses E. The mains cable terminals F. The 360-degree grounding

G. The PE bar H. Input air grill I. The terminals for the option +CAPU J. The motor cable terminals K. The service lid, and the main fan under it L. The cable entry plate for control cables

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Fig. 38: The inside layout of MR12, without protective covers

A. Power unit 1 B. Power unit 2 C. Optical fibre cables D. The connector for control unit cable (in

power unit 1)

E. The fuse switch linkage for the fuse

switch option. F. The DC link connection G. The auxiliary voltage transformer

INSTALLING THE CABLES

1 Open the cabinet door.

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2 In MR12, if you have the fuse switch option, remove

the the fuse switch linkage.

3 Remove the covers of the AC drive. 4 In IP54, cut the grommets open to move the cables

through them.

Do not cut the grommet openings wider than what is necessary for the cables that you use.

IP54 only

5 Put the cables into their places. 6 Strip the motor cable and the mains cable.

Keep the grounding conductor as short as possible, but so that it reaches the grounding bar.

7 Strip the brake resistor cable.

Keep the grounding conductor as short as possible, but so that it reaches the grounding bar.

8 Connect the stripped cables.

Connect the phase conductors of the mains cable and of the motor cable into the correct terminals. If you use a brake resistor cable, connect its conductors into the correct terminals.

Attach the grounding conductor of each cable to a grounding terminal with a grounding clamp for grounding conductor.

Make sure that the external grounding conductor is connected to the grounding bar. See chapter 2.4 Grounding and earth fault protection.

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9 If you use many cables on one connector, put the

cable lugs on top of each other.

•

The picture shows the connection in MR8 and MR9.

A. The first cable lug B. The second cable lug C. The connector

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10 If you use many cables on one connector, put the

cable lugs on top of each other.

•

The pictures show the connection in MR10 and MR12.

•

The bolt holder of the connector keeps the bolt still when you turn the nut.

1. 2.

A. The bolt holder of the

connector B. The first cable lug C. The connector D. The second cable lug

A. The bolt holder of the

connector B. The first cable lug C. The connector D. The second cable lug E. The connection bush F. The third cable lug

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11 Expose the shield of all 3 cables to make a 360-

degree connection with the metallic grounding clamps for cable shield.

IP21

IP54

A. The grounding clamp for cable

shield B. The shield of the cable

12 Attach the terminal cover, and then the extension

box cover.

13 Close the cabinet door.

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14 Make sure that the grounding conductor is

connected to the motor and also to the terminals that are identified with .

To obey the requirements of the standard EN61800-5-1, obey the instructions in chapter

2.4 Grounding and earth fault protection.

Table 21: Tightening torques of the terminals, MR8-MR12

Enclosu

re size

Type

Tightening torque: the mains and motor cable terminals

Tightening torque: the grounding terminals

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

MR8

0140 5-0205 5 0080 7-0125 7

30-44 * 266-389 * 20 177

MR9

0261 5-0310 5 0144 7-0208 7

30-44 * 266-389 * 20 177

MR10

0385 5-0590 5 0261 7-0416 7

55-70 490-620 20 177

MR12

0650 5-1180 5 0460 7-0820 7

55-70 490-620 20 177

* = Counter torque is required for the mains cable terminals.

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6 CONTROL COMPARTMENT

6.1 THE CONTROL COMPARTMENT OF THE ENCLOSED DRIVE

The enclosed drive has a door-mounted control compartment, separated from the cabinet section, for the mains and motor cable terminals. You can have an access to the control compartment through a separate door located on the cabinet door.

On the inside of the control compartment door, you can find the order-specific documents. Make sure that the control cables are long enough to prevent tight bends in the cables

between the control compartment and the frame of the drive.

The control compartment contains these items:

•

the control unit

•

the control panel

•

the option boards

•

the optional auxiliary components and the related wires

•

the terminals for internal connections

•

the terminals for control cabling

•

the order-specific documentation (on the inside of the door)

•

the optional buttons and signal lights (on the door)

Connect the cables of the option boards OPTB2, OPTB4, OPTB5, OPTF3 and OPTF4 (depending on the configuration of the drive) as default to the terminals for control cabling – XD2 on the control compartment.

Do not connect the cables of the fieldbus boards to the -XD2 terminals, but directly to the control terminals or the Ethernet terminal on the control unit. Connect the analogue signals (for example reference signals and temperature signals) and the fieldbus cables directly to the correct option board.

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RUN

FAULT

READY

Reference output

+10 Vref

Terminal

Standard I/O board

Signal

24V auxiliary voltage

24Vout6

Analogue input, voltage or current

Reference

potentiometer

1...10kΩ

Actual value

2-wire transmitter

I = (0)4...20mA

AI1+2

Analogue input common, (current)

AI1-3

Analogue input, voltage or current

AI2+4

Analogue input common, (current)

AI2-5

Analogue signal (+output)

AO1+

RUN

Analogue output common / I/O ground

AO1-/GND19

24V auxiliary input voltage

+24Vin

24V auxiliary voltage

24Vout

I/O ground

GND7

I/O ground

GND13

Digital input 1

DI18

Digital input 2

DI29

Digital input 3

DI310

Digital input 4

DI414

Digital input 5

DI515

Digital input 6

DI616

Relay output 1

RO1 NC21

RO1 CM

RO1 NO23

Common for DI1-DI6

CM11

Common for DI1-DI6

Serial bus, negative

RS485A

Serial bus, positive

RS485

Relay output 2

Relay output 3

RO2 NC24

RO2 CM

RO2 NO26

RO3 CM

RO3 NO33

Description

Frequency reference

Start forward

Start reverse

External fault

DI4

DI5

Freq. ref. Open Closed Open Closed

Open Open Closed Closed

Analog input 1 Preset Freq. 1 Preset Freq. 2 Preset Freq. 3

Fault reset

Output frequency

Modbus RTU BACnet, N2

Fig. 39: The signals of the control terminals on the standard I/O board, and a connection example. If you include the option code +SBF4 in your order, the relay output 3 is replaced with a thermistor input.

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* = You can isolate digital inputs from ground with a DIP switch.

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

40 41 42 43 44 45 46 47 48 49

-XD2

50 51 52

Fig. 40: The markings of the extended I/O terminals

Fig. 41: Control cabling of the enclosed drive

A. I/O cabling from top B. I/O cabling from bottom C. The cable routing plate with places for

cable ties

D. The cable carrier E. The cable ducts F. The extended I/O terminals (+CTID) to be

used freely

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G. The control grounding plate H. The customer grounding plate I. The terminals for control cabling

(default)

J. Grounding clamps for cable shield

CBA

G H

Fig. 42: The control compartment components of the cabinet

A. The insulation fault sensor (+CPIF) B. The 24 VDC power supply (+CAPD) C. The emergency stop Cat 1 (+CPS1) D. The MCBs for auxiliary devices E. The control unit F. The 230 VAC socket (+CAPS) G. The extended I/O terminals (+CTID) to be

used freely

H. The terminals for control cabling

(default)

I. The control panel

J. The emergency stop push button

(+CPS0, +CPS1, +CPSB)

K. The emergency stop reset button

(+CPS1) L. The Fault signal light (+CDLP) M. The Run signal light (+CDLP) N. The Ready signal light (+CDLP) O. The Reset button (+CDLP) P. The 0 - 1 - start switch (+CICO) Q. The insulation fault (+CPIF) R. The rating plate of the drive, the option

codes and the serial number

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6.2 FIELDBUS CONNECTION

You can connect the drive to fieldbus with an RS485 or an Ethernet cable. If you use an RS485 cable, connect it to terminal A and B of the standard I/O board. If you use an Ethernet cable, connect it to the Ethernet terminal below the cover of the drive.

Fig. 43: The Ethernet and RS485 connections

A. RS485 terminal A = Data B. RS485 terminal B = Data +

C. The Ethernet terminal D. The control terminals

6.2.1 USING FIELDBUS THROUGH AN ETHERNET CABLE

Table 22: Ethernet cable data

Item Description

The plug type A shielded RJ45 plug, maximum length 40 mm (1.57 in)

The cable type CAT5e STP

The cable length Maximum 100 m (328 ft)

ETHERNET CABLING

1 Connect the Ethernet cable to its terminal. 2 Put the cover of the drive back. Keep the distance

between the Ethernet cable and the motor cable at a minimum of 30 cm (11.81 in).

See more in the Installation Manual of the fieldbus that you have.

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6.2.2 USING FIELDBUS THROUGH AN RS485 CABLE

Table 23: RS485 cable data

Item Description

The plug type 2.5 mm

The cable type STP (shielded twisted pair), Belden 9841 or almost the same

The cable length So that it agrees with the fieldbus. See the fieldbus manual.

RS485 CABLING

1 Remove approximately 15 mm (0.59 in) of the grey

shield of the RS485 cable. Do this for the 2 fieldbus cables.

Strip the cables for approximately 5 mm (0.20 in) to put them in the terminals. Do not keep more than 10 mm (0.39 in) of the cable outside the terminals.

Strip the cable at such a distance from the terminal that you can attach it to the frame with the grounding clamp for control cable. Strip the cable at a maximum length of 15 mm (0.59 in). Do not remove the aluminium shield of the cable.

15 mm

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2 Connect the cable to the standard I/O board of the

drive, in terminals A and B.

•

A = negative

•

B = positive

3 Attach the shield of the cable to the frame of the

drive with a grounding clamp for control cable to make a grounding connection.

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4 If the drive is the last device on the fieldbus line,

set the bus termination.

Find the DIP switches on the left side of the control unit of the drive.

Set the DIP switch of the RS485 bus termination to the ON position.

Biasing is built in the bus termination resistor. The termination resistance is 220 Ω.

5 Set the bus termination for the first and the last

device of the fieldbus line. We recommend that the first device on the fieldbus is the master device.

A. The termination is activated B. The termination is deactivated C. The termination is activated with a DIP

switch

D. The bus termination. The resistance is

220 Ω. E. The fieldbus

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NOTE!

If you do power-down to the last device, there is no bus termination.

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7 COMMISSIONING AND ADDITIONAL

INSTRUCTIONS

7.1 COMMISSIONING SAFETY

Before you start the commissioning, read these warnings.

WARNING!

Do not touch the internal components or the circuit boards of the drive when the drive is connected to mains. These components are live. A contact with this voltage is very dangerous. The galvanically isolated control terminals are not live.

WARNING!

Do not make connections to or from the AC drive when it is connected to mains. There is a dangerous voltage.

WARNING!

To do work on the connections of the drive, disconnect the drive from mains. Wait 5 minutes before you open the cabinet door or the cover of the drive. Then use a measuring device to make sure that there is no voltage. The connections of the drive are live 5 minutes after it is disconnected from mains.

WARNING!

Before you do electrical work, make sure that there is no voltage.

WARNING!

Do not touch the control terminals. They can have a dangerous voltage also when the drive is disconnected from mains.

WARNING!

Before you connect the drive to mains, make sure that the front cover and the cable cover of the drive are closed. The connections of the AC drive are live when the drive is connected to mains.

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7.2 OPERATION OF THE MOTOR

7.2.1 CHECKS BEFORE STARTING THE MOTOR

Before you start the motor, do these checks.

•

Make sure that all the START and STOP switches that are connected to the control terminals are in the STOP position.

•

Make sure that you can start the motor safely.

•

Activate the Start-up wizard. See the Application Manual for the AC drive that you have.

•

Set the maximum frequency reference (that is, the maximum speed of the motor), so that it agrees with the motor and the device that is connected to the motor.

7.3 MEASURING THE CABLE AND MOTOR INSULATION

Do these checks if necessary.

The insulation checks of the motor cable

Disconnect the motor cable from the terminals U, V, and W and from the motor.

Measure the insulation resistance of the motor cable between phase conductors 1 and 2, between phase conductors 1 and 3, and between phase conductors 2 and 3.

Measure the insulation resistance between each phase conductor and the grounding conductor.

The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

The insulation checks of the mains cable

Disconnect the mains cable from the terminals L1, L2, and L3 and from mains.

Measure the insulation resistance of the mains cable between phase conductors 1 and 2, between phase conductors 1 and 3, and between phase conductors 2 and 3.

Measure the insulation resistance between each phase conductor and the grounding conductor.

The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

The insulation checks of the motor

Disconnect the motor cable from the motor.

Open the bridging connections in the motor connection box.

Measure the insulation resistance of each motor winding. The voltage must be the same or higher than the motor nominal voltage, but not higher than 1000 V.

The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

Obey the instructions of the motor manufacturer.

7.4 INSTALLATION IN A MARINE ENVIRONMENT

When you install the AC drive in a marine environment, use the marine construction option (+EMAR). See the Marine Installation Guide.

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7.5 INSTALLATION IN A CORNER-GROUNDED NETWORK

You can use corner grounding with the enclosed drive sizes MR8-MR12 with a 380-480 V mains and with a 208-240 V mains. In these conditions, you must change the EMC protection level to C4. See the instructions in chapter 7.6 Installation in an IT system.

7.6 INSTALLATION IN AN IT SYSTEM

If your mains is impedance-grounded (IT), the AC drive must have the EMC protection level C4. If your drive has the EMC protection level C3, it is necessary to change it to C4. To do this, remove the EMC jumper.

WARNING!

Do not make changes in the AC drive when it is connected to mains. The components of the drive are live when the drive is connected to mains.

CAUTION!

Before you connect the AC drive to mains, make sure that the EMC level of the drive is correct. An incorrect EMC level can cause damage to the drive.

7.6.1 THE EMC JUMPER IN MR8

Change the EMC protection of the AC drive from level C3 to level C4. 1 Open the cover of the AC drive.

2 Find the EMC box. To get access to the EMC

jumper, remove the cover of the EMC box.

A. The EMC jumper

3 Remove the EMC jumper. Attach the cover of the

EMC box again.

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4 Find the grounding arm and push it down.

A. The grounding arm is up B. The grounding arm is down

(level C3)

5 After the change, write "The EMC level was

changed" and the date on the "product changed" label. If the label is not attached at this time, attach it on the drive near the name plate.

Product modified

Date:

7.6.2 THE EMC JUMPER IN MR9

Change the EMC protection of the AC drive from level C3 to level C4.

THE EMC JUMPER 1

1 Open the covers of the AC drive.

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2 Loosen the screws of the cover plate and remove it.

3 Remove the EMC jumper.

4 If you change the EMC level, write "The EMC level

was changed" and the date on the "product changed" label. If the label is not attached at this time, attach it on the drive near the name plate.

Product modified

Date:

THE EMC JUMPERS 2 AND 3

1 Remove the cover of the extension box, the touch

shield, and the I/O plate with the I/O grommet plate.

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2 Find the 2 EMC jumpers on the EMC board. They

are not adjacent to each other. Remove the EMC jumpers.

A. The EMC jumpers

3 If you change the EMC level, write "The EMC level

was changed" and the date on the "product changed" label. If the label is not attached at this time, attach it on the drive near the name plate.

Product modified

Date:

7.6.3 THE EMC JUMPER IN MR10 AND MR12

Change the EMC protection of the AC drive from level C3 to level C4.

FINDING THE EMC JUMPER

1 Remove the covers of the AC drive.

•

In MR12, do these steps for each power unit. Also remove the fuse switch linkage.

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2 Find the EMC jumper between the terminals L2 and

L3.

3 Remove the EMC jumper.

4 If you change the EMC level, write "The EMC level

was changed" and the date on the "product modified" label. If the label is not attached at this time, attach it on the drive near the name plate.

Product modified

Date:

7.7 MAINTENANCE

7.7.1 MAINTENANCE INTERVALS

To make sure that the drive operates correctly and has a long life, we recommend that you do regular maintenance. Refer to Table 24.

It is not necessary to replace the main capacitors of the drive, because they are a thin film type capacitors.

WARNING!

Do not make changes in the AC drive when it is connected to mains. The components of the drive are live when the drive is connected to mains.

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Table 24: The maintenance intervals and tasks

Maintenance interval Maintenance task

Regularly Do a check of the tightening torques of the terminals.

Do a check of the filters.

6-24 months (The interval is different in different envi-

ronments.)

Do a check of the mains and motor cable terminals and the control terminals. Make sure that the cooling fan operates correctly. Make sure that there is no corrosion on the terminals, the busbars or other surfaces. Do a check of the door filters of the cabinet. Do a check of the internal filter of the power unit.

24 months (The interval is different in different envi-

ronments.)

Clean the heatsink and the cooling tunnel.

6-10 years Replace the main fan.

Replace the internal fans if the drive has them. Replace the fan power supply.

10 years Replace the battery of the RTC. The battery is optional.

This table is valid for VACON® components. To do maintenance on components that are made by other manufacturers, obey the manual of the component in question.

7.7.2 REPLACING THE AIR FILTERS OF THE AC DRIVE

Clean or replace the filters of the cabinet regularly.

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REPLACING THE FILTER ON THE CABINET DOOR

1 To remove the cover of the filter, pull it out and up.

2 Clean or replace the filter. 3 Put the cover of the filter back.

7.7.3 REPLACING THE FANS OF THE AC DRIVE

7.7.3.1 Replacing the fans in MR8 Here are the instructions on how to replace the fans of the drive.

REPLACING THE FAN POWER SUPPLY, MR8

1 Remove the cover of the AC drive.

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2 Disconnect the cables from the fan power supply.

Disconnect the fan supply cable from connector X81.

Disconnect the fan driver cable from connector X61.

Disconnect the DC supply cable from connector X8.

Remove the 4 screws that hold the fan power supply.

X81 X61

A. The 4 screws

3 Lift off the fan power supply. 4 Replace the fan power supply. Attach it with the

screws.

5 Connect the cables and put the cover of the drive

back.

REPLACING THE MAIN FAN, MR8

1 Remove the cover of the AC drive. 2 Remove the fan power supply. See the previous

instructions.

3 Remove the 4 screws that hold the main fan unit.

Lift off the main fan unit.

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4 To release the fan from the cover plate, remove the

4 screws.

A. The fan cable

5 Release the grommet on the fan cable from the

cover plate and pull out the cable.

6 Replace the main fan. Attach the screws. 7 Re-assemble the drive and connect the cables.

7.7.3.2 Replacing the fans in MR9 Here are the instructions on how to replace the fans of the drive.

REPLACING THE FAN POWER SUPPLY, MR9

1 Remove the cover of the AC drive. 2 Disconnect the cables from the fan power supply.

Disconnect the fan supply cable from connector X81.

Disconnect the fan driver cable from connector X61.

Disconnect the DC supply cable from connector X8.

Remove the 4 screws that hold the fan power supply.

X81 X61

A. The 4 screws

3 Lift off the fan power supply. 4 Replace the fan power supply. Attach it with the

screws.

5 Connect the cables and put the cover of the drive

back.

REPLACING THE MAIN FAN, MR9

1 Remove the cover of the AC drive.

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2 Disconnect the cables from the fan power supply. 3 Remove the 12 screws from the fan cover plate.

Use the handle to lift off the main fan unit.

1 2

4 To release the fan from the cover plate, remove the

4 screws.

A. The fan cable

5 Release the grommet on the fan cable from the

cover plate and pull out the cable.

6 Replace the main fan.

When you re-attach the main fan unit, make sure that the sealing tape under the fan plate is in good condition.

Attach the screws in the tightening order that is marked in the figure of the main fan unit (1 > 2 > 3).

7 Re-assemble the drive and connect the cables.

7.7.3.3 Replacing the fans in MR10 and MR12 Here are the instructions on how to replace the fans of the drive.

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REPLACING THE MAIN FAN ASSEMBLY, MR10 AND MR12

1 Loosen the 8 screws and lift off the service lid.

2 Disconnect the cables from each fan power supply.

Disconnect the fan driver cable from connector X61.

Disconnect the DC supply cable from connector X8.

Remove the 5 screws.

X61 X8 X61 X8

A A

A. The 5 screws

3 Pull out the whole fan assembly. The assembly

weighs approximately 11 kg.

4 Replace the main fan assembly. Attach it with the

screws.

5 Connect the cables and attach the service lid.

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REPLACING THE FAN POWER SUPPLIES, MR10 AND MR12

You can replace only 1 or both the fan power supplies. 1 Remove the main fan assembly. See the previous

instructions.

Disconnect the fan supply cable from connector X81.

Disconnect the fan driver cable from connector X61.

Disconnect the DC supply cable from connector X8.

Remove the 4 screws from each supply.

X81 X61

A. The 4 screws

3 Replace the fan power supplies. 4 Attach the screws, connect the cables, and re-

assemble the drive.

7.7.3.4 Replacing the fan of the additional cabinet section of the sine filter The sine filter option (+COSI) comes installed in an additional cabinet section that has a fan.

REPLACING THE FAN, SINE FILTER OPTION

1 Remove the touch shield. 2 Disconnect the cables of the fan unit. Remove the 4

screws that hold the fan unit.

A. The cables of the fan B. The 4 screws

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3 Lift off the fan unit.

4 To release the fan from the fan unit, remove 8

screws.

A. 4 screws B. 4 screws

5 Replace the fan. 6 Re-assemble the drive and connect the cables. 7 Put the touch shield back.

7.7.4 REPLACING THE POWER UNIT OF THE AC DRIVE

7.7.4.1 Replacing the power unit, MR8

WARNING!

Before you start replacing the power unit, make sure that there is no input voltage coming into the cabinet. Switch off the voltage at the power source. Replacing the

power unit when there is voltage in the cabinet can cause injury or death. 1 Remove the protective covers of the drive. 2 Disconnect all the power cables from the bottom of

the power unit.

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3 Remove the 2 screws from the top of the power

unit.

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Vacon 100 flow, 0100 3L 0007 7...0208 7, 0100 3L 0003 2...0310 2, 0100 3L 0004 6...0208 6, 0100 3L 0140 2...0310 2 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual