This manual is copyright of Vacon Plc. All Rights Reserved.
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VACON · 4
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TABLE OF CONTENTS VACON · 5
TABLE OF CONTENTS
Preface
About this manual 3
1Approvals 8
2Safety 10
2.1The safety symbols used in the manual 10
2.2Warning 10
2.3Caution 11
2.4Earthing and earth fault protection 12
2.5Electro-magnetic compatibility (EMC) 13
2.6Using an RCD or an RCM device 13
3Receiving the delivery 14
3.1Package label 14
3.2Type designation code 14
3.3Unpacking and lifting the AC drive 15
3.3.1Weight of the AC drive 15
3.3.2Lifting the frames MR8 and MR9 15
3.4Accessories 16
3.4.1Frame MR4 17
3.4.2Frame MR5 17
3.4.3Frame MR6 18
3.4.4Frame MR7 19
3.4.5Frame MR8 19
3.4.6Frame MR9 20
3.5"Product modified" label 20
3.6Disposal 20
4Mounting 21
4.1General information about mounting 21
4.2Dimensions for wall mounting 21
4.2.1Wall mounting of MR4 21
4.2.2Wall mounting of MR5 22
4.2.3Wall mounting of MR6 23
4.2.4Wall mounting of MR7 24
4.2.5Wall mounting of MR8, IP21 and IP54 25
4.2.6Wall mounting of MR8, IP00 26
4.2.7Wall mounting of MR9, IP21 and IP54 27
4.2.8Wall mounting of MR9, IP00 28
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VACON · 6TABLE OF CONTENTS
4.3Dimensions for flange mounting 28
4.3.1Flange mounting of MR4 32
4.3.2Flange mounting of MR5 33
4.3.3Flange mounting of MR6 34
4.3.4Flange mounting of MR7 35
4.3.5Flange mounting of MR8 36
4.3.6Flange mounting of MR9 37
4.4Cooling 38
5Power cabling 41
5.1Cable connections 41
5.2UL standards on cabling 42
5.3Cable dimensioning and selection 42
5.3.1Cable and fuse sizes 43
5.3.2Cable and fuse sizes, North America 45
5.4Brake resistor cables 49
5.5Preparing for the cable installation 49
5.6Cable installation 50
5.6.1Frames MR4 to MR7 50
5.6.2Frames MR8 to MR9 56
5.7Installation in a corner-grounded network 68
6Control unit 69
6.1Control unit components 69
6.2Control unit cabling 70
6.2.1Selection of the control cables 70
6.2.2Control terminals and DIP switches 70
6.3Fieldbus connection 74
6.3.1Using fieldbus through an Ethernet cable 75
6.3.2Using fieldbus through an RS485 cable 78
6.4Installation of option boards 82
6.4.1The installation procedure 83
6.5Installation of a battery for the Real Time Clock (RTC) 85
6.6Galvanic isolation barriers 85
7Commissioning and additional instructions 87
7.1Commissioning safety 87
7.2Commissioning of the drive 87
7.3Operation of the motor 88
7.3.1Checks before starting the motor 88
7.4Measuring the cable and motor insulation 88
7.5Installation in an IT system 89
7.5.1Frames MR4, MR5, and MR6 89
7.5.2Frames MR7 and MR8 91
7.5.3Frame MR9 94
7.6Maintenance 95
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TABLE OF CONTENTS VACON · 7
8Technical data, Vacon® 100 96
8.1AC drive power ratings 96
8.1.1Mains voltage 208-240 V 96
8.1.2Mains voltage 380-500 V 98
8.1.3Overload capability 99
8.1.4Brake resistor ratings 100
8.2Vacon® 100 - technical data 103
9Technical data, Vacon® 100 FLOW 107
9.1AC drive power ratings 107
9.1.1Mains voltage 208-240 V 107
9.1.2Mains voltage 380-500 V 108
9.1.3Overload capability 109
9.2Vacon® 100 FLOW - technical data 110
10 Technical data on control connections 114
10.1Technical data on control connections 114
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VACON · 8APPROVALS
1APPROVALS
Here are the approvals that have been granted to this Vacon product.
EC Declaration of conformity
1.
Find the EC Declaration of Conformity on the next page.
•
UL approval
2.
cULus approval file number E171278.
•
C-tick approval
3.
C-tick approval file number N16307.
•
1
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EC DECLARATION OF CONFORMITY
We
Manufacturer’s name: Vacon Oyj
Manufacturer’s address: P.O. Box 25
Runsorintie 7
FIN-65381 Vaasa
Finland
hereby declare that the product
Product name: Vacon 100 AC drive
Model designation: Vacon 0100-3L-0003-5...0310-5
Vacon 0100-3L-0003-2...0310-2
has been designed and manufactured in accordance with the following standards:
Safety:EN 61800-5-1: 2007
EN 60204-1: 2009 (as relevant)
EMC:EN 61800-3: 2004 + A1: 2012
EN 61000-3-12
and conforms to the relevant safety provisions of the Low Voltage Directive
(2006/95/EC) and EMC Directive 2004/108/EC.
It is ensured through internal measures and quality control that the product
conforms at all times to the requirements of the current Directive and the relevant
standards.
In Vaasa, 26th of February, 2014
Vesa Laisi
President
The year the CE marking was affixed: 2012
APPROVALS VACON · 9
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1
VACON · 10SAFETY
2SAFETY
2.1THE SAFETY SYMBOLS USED IN THE MANUAL
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 symbolDescription
WARNING!
2.2WARNING
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.
WARNING!
Do not touch the motor terminals U, V, W or the brake resistor 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!
CAUTION!
HOT SURFACE!
2
Do not touch the relay outputs or the I/O terminals. They can have a dangerous
voltage also when the drive is disconnected from mains.
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SAFETY VACON · 11
WARNING!
Before you do electrical work, make sure that there is no voltage in the
components of the drive.
WARNING!
To do work on the terminal connections of the drive, disconnect the drive from
mains and make sure that the motor has stopped. Wait 5 minutes before you open
the cover of the drive. Then use a measuring device to make sure that there is no
voltage. The terminal connections and the components of the drive are live 5
minutes after it is disconnected from 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 brake 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.
2.3CAUTION
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.
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 Earthing 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.
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2
VACON · 12SAFETY
CAUTION!
Make sure that the EMC level of the AC drive is correct for your mains. See chapter
7.5 Installation in an IT system. An incorrect EMC level can cause damage to the
drive.
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).
2.4EARTHING AND EARTH FAULT PROTECTION
CAUTION!
The AC drive must always be earthed with an earth conductor that is connected to
the earth terminal that is identified with the symbol . Not using an earth
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.
The connection must be fixed.
The protective earth conductor must have a cross-sectional area of minimum 10 mm2 Cu
a)
or 16 mm2 Al. OR
There must be an automatic disconnection of the mains, if the protective earth conductor
b)
breaks. See chapter 5 Power cabling. OR
There must be a terminal for a second protective earth conductor in the same cross-
c)
sectional area as the first protective earth conductor.
Cross-sectional area of the phase conductors (S)
[mm2]
S ≤ 16S
The minimum cross-sectional area of the protective
earthing conductor in question [mm2]
16 < S ≤ 3516
35 < SS/2
The values of the table are valid only if the protective earthing conductor is made of the same
metal as the phase conductors. If this is not so, the cross-sectional area of the protective
2
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SAFETY VACON · 13
earthing 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 earthing 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 earthing 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 earthing 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.
2.5ELECTRO-MAGNETIC COMPATIBILITY (EMC)
The drive must obey the standard IEC 61000-3-12. To obey it, the short-circuit power SSC
must be a minimum of 120 RSCE at the interface point between your mains and the public
mains. Make sure that you connect the drive and the motor to mains with a short-circuit
power SSC that is a minimum of 120 RSCE. If necessary, contact your mains operator.
2.6USING AN RCD OR AN RCM DEVICE
The drive can cause a current in the protective earthing 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.
NOTE! You can download the English and French product manuals with applicable safety, warning and caution
information from
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 www.vacon.com/
downloads.
www.vacon.com/downloads.
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2
AB
C
H
I
D
F
G
E
VACON · 14RECEIVING THE DELIVERY
3RECEIVING THE DELIVERY
3.1PACKAGE LABEL
To make sure that the delivery is correct, compare your order data to the data on the
package label. If the delivery does not agree with your order, speak to the vendor
immediately.
Fig. 1: The package label of Vacon AC drives
A.The batch ID
B.The order number of Vacon
C.The type designation code
D. The serial number
E.The mains voltage
F.The rated output current
G. The IP class
H. The application code
I.The order number of the customer
3.2TYPE DESIGNATION CODE
The type designation code of Vacon is made of standard codes and optional 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-0061-5+IP54
VACON0100-3L-0061-5-FLOW
3
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RECEIVING THE DELIVERY VACON · 15
Table 3: The description of the parts in the type designation code
CodeDescription
VACONThis part is same for all the products.
0100The product range: 0100 = Vacon 100
3LInput/Function: 3L = A 3-phase input
0061The drive rating in amperes. For example, 0061 = 61 A
5The mains voltage:
2 = 208-240 V
5 = 380-500 V
FLOWThe Vacon 100 FLOW AC drive
+IP54The optional codes. There are many options, for example +IP54 (an AC drive with
the IP protection class IP54)
3.3UNPACKING AND LIFTING THE AC DRIVE
3.3.1WEIGHT OF THE AC DRIVE
The weights of AC drives of different frames are very different. It can be necessary for you to
use a lifting device to move the drive from its package.
Table 4: The weights of the different frames
FrameWeight, IP21/IP54
[kg]
MR46.013.2
MR510.022.0
MR620.044.1
MR737.582.7
MR866.062.0145.5136.7
MR9119.5103.5263.5228.2
Weight, IP00 [kg]Weight, UL Type 1 /
Type 12 [lb.]
Weight, UL Open
Type [lb.]
3.3.2LIFTING THE FRAMES MR8 AND MR9
1Remove the drive from the pallet where it was
bolted to.
2Use a lifting device that is sufficiently strong for the
weight of the drive.
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3
≤45°
VACON · 16RECEIVING THE DELIVERY
3Put the lifting hooks symmetrically in a minimum of
2 holes.
4The maximum lifting angle is 45 degrees.
Before a Vacon® AC drive is sent to the customer, the manufacturer makes many tests on
the drive. After you lift the drive, do a check for signs of damage on the drive. Make sure that
the contents of the package are correct.
If the drive was damaged during the shipping, speak to the cargo insurance company or the
carrier.
3.4ACCESSORIES
After you open the package and lift the drive out, make sure that you received all the
accessories. The content of the accessories bag is different for the different frames and
protection classes.
3
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RECEIVING THE DELIVERY VACON · 17
3.4.1FRAME MR4
Table 5: The content of accessories bag
ItemQuantityDescription
M4x16 screw11Screws for the power cable clamps (6), the
control cable clamps (3), and the grounding
clamps (2)
M4x8 screw1Screw for the optional grounding
M5x12 screw1Screw for the external grounding of the drive
Control cable grounding lamella3Control cable grounding
EMC cable clamp, size M253Clamping the power cables
Grounding clamp2Power cable grounding
"Product modified" label1Data about changes
IP21: Cable grommet3Sealing for the cables
IP54: Cable grommet6Sealing for the cables
3.4.2FRAME MR5
Table 6: The content of the accessories bag
ItemQuantityDescription
M4x16 screw13Screws for the power cable clamps (6), the
control cable clamps (3), and the grounding
clamps (4)
M4x8 screw1Screw for the optional grounding
M5x12 screw1Screw for the external grounding of the drive
Control cable grounding lamella3Control cable grounding
EMC cable clamps, size M251Clamping brake cable
EMC cable clamps, size M322Clamping power cables
Grounding clamp2Power cable grounding
"Product modified" label1Data about changes
IP21: Cable grommet, hole diameter 25.3 mm1Sealing for the cables
IP54: Cable grommet, hole diameter 25.3 mm4Sealing for the cables
Cable grommet, hole diameter 33.0 mm2Sealing for the cables
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3
VACON · 18RECEIVING THE DELIVERY
3.4.3FRAME MR6
Table 7: The content of the accessories bag
ItemQuantityDescription
M4x20 screw10Screws for the power cable clamps (6), and
the grounding clamps (4)
M4x16 screw3Screws for the control cable clamps
M4x8 screw1Screw for the optional grounding
M5x12 screw1Screw for the external grounding of the drive
Control cable grounding lamella3Control cable grounding
EMC cable clamps, size M321Clamping the brake resistor cable
EMC cable clamps, size M402Clamping the power cables
Grounding clamp2Power cable grounding
"Product modified" label1Data about changes
Cable grommet, hole diameter 33.0 mm1Sealing for the cables
Cable grommet, hole diameter 40.3 mm2Sealing for the cables
IP54: Cable grommet, hole diameter 25.3 mm3Sealing for the cables
NOTE!
The Vacon® 100 FLOW software does not have the dynamic braking or the brake
resistor functions.
3
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RECEIVING THE DELIVERY VACON · 19
3.4.4FRAME MR7
Table 8: The content of the accessories bag
ItemQuantityDescription
M6x30 slotted nut6Nuts for the power cable clamps
M4x16 screw3Screws for the control cable clamps
M6x12 screw1Screw for the external grounding of the drive
Control cable grounding lamella3Control cable grounding
EMC cable clamps, size M253Clamping the power cables
Grounding clamp2Power cable grounding
‘Product modified’ label1Data about changes
IP21: Cable grommet3Sealing for the cables
IP54: Cable grommet3Sealing for the cables
3.4.5FRAME MR8
Table 9: The content of accessories bag
ItemQuantityDescription
M4x16 screw3Screws for the control cable clamps
Control cable grounding lamella3Control cable grounding
Cable lugs KP403Clamping power cables
Cable insulator11To prevent contact between cables
Cable grommet, hole diameter 25.3 mm4Sealing for the cables
IP00: Touch shield1To prevent contact with live parts
IP00: M4x8 screw2To attach the touch protection shield
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3
Product modified
Date:
Date:
Date:
VACON · 20RECEIVING THE DELIVERY
3.4.6FRAME MR9
Table 10: The content of the accessories bag
ItemQuantityDescription
M4x16 screw3Screws for the control cable clamps
Control cable grounding lamella3Control cable grounding
Cable lugs KP405Clamping power cables
Cable insulator10To prevent contact between cables
Cable grommet, hole diameter 25.3 mm4Sealing for the cables
IP00: Touch shield1To prevent contact with live parts
IP00: M4x8 screw2To attach the touch protection shield
3.5"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.
3.6DISPOSAL
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.
3
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Ø25
Ø25
Ø7
Ø13
IP21
IP54
112
147
128
100
313
100
328
190
151
112
MOUNTING VACON · 21
4MOUNTING
4.1GENERAL INFORMATION ABOUT MOUNTING
Install the AC drive in a vertical position on the wall. If you install the drive in a horizontal
position, it is possible that some functions with the nominal values that are found in chapter
8 Technical data, Vacon® 100 or 9 Technical data, Vacon® 100 FLOW are not available.
Attach the AC drive with the screws and other components that you received in the delivery.
4.2DIMENSIONS FOR WALL MOUNTING
4.2.1WALL MOUNTING OF MR4
Fig. 2: The dimensions of the AC drive, MR4
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4
Ø7
Ø33 Ø25
Ø25
Ø33
A
A
214
144
115
Ø7
Ø14
Ø7
100*
419
406
115
100*
IP21
39
37.5
130
134
130
134
IP54
VACON · 22MOUNTING
4.2.2WALL MOUNTING OF MR5
Fig. 3: The dimensions of the AC drive, MR5
A.Use these mounting holes when you
replace your Vacon® NX AC drive with a
Vacon® 100 or Vacon® 100 FLOW AC
drive.
4
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195
148
Ø15.5
Ø9
557
541
Ø9
148
229
148
151
IP21
IP54
4243.7
148
151
Ø40 Ø33Ø40
Ø25
MOUNTING VACON · 23
4.2.3WALL MOUNTING OF MR6
Fig. 4: The dimensions of the AC drive, MR6
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4
259
Ø20
660
645
237
190
IP21
IP54
160
211
160
217
Ø9
Ø16
Ø51
Ø25
Ø50
VACON · 24MOUNTING
4.2.4WALL MOUNTING OF MR7
Fig. 5: The dimensions of the AC drive, MR7
4
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9
3 x 38
114
117
188
62.5
164
290
343
216
663
996
22
262
235
217
Ø25
Ø60
Ø11
Ø22
Ø9
Ø9
MOUNTING VACON · 25
4.2.5WALL MOUNTING OF MR8, IP21 AND IP54
Fig. 6: The dimensions of the AC drive, MR8, IP21 and IP54
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4
9.3
290
186.5
255
217
794
683
663
18
171.5
343
215.7
10.8
15.1
Ø9
Ø9
Ø22
Ø11
VACON · 26MOUNTING
4.2.6WALL MOUNTING OF MR8, IP00
4
Fig. 7: The dimensions of the AC drive, MR8, IP00
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Ø25
Ø59
Ø22
84
3 x 42
126
318
166
77
4 x 81.5
326
1122
1150
Ø9
14
480
400
355
365
292
284
27,5
360
810
360
M8 GND
Ø9
Ø9Ø9
MOUNTING VACON · 27
4.2.7WALL MOUNTING OF MR9, IP21 AND IP54
Fig. 8: The dimensions of the AC drive, MR9, IP21 and IP54
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4
130
810
840.5
16.5
65
50
360
8 x 42
72
M8
GND
318
3 X 42
84.5
14
Ø9
Ø22
400
480
355
365
Ø9
M8
A
Ø25
126
336
VACON · 28MOUNTING
4.2.8WALL MOUNTING OF MR9, IP00
Fig. 9: The dimensions of the AC drive, MR9, IP00
A.An optional main connector cover for the
cabinet installation
4.3DIMENSIONS FOR FLANGE MOUNTING
You can also install the AC drive into the cabinet wall with a flange mounting option.
4
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A
B
D
A
C
E
MOUNTING VACON · 29
NOTE!
The protection classes are different in different sections of the drive.
Fig. 10: Example of flange mounting (frame MR9)
A.The cabinet wall or other surface
B. The front
C. The rear
D. IP00 / UL Open Type
E.IP54 / UL Type 12
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4
G
F
AE
B
D
C
H
VACON · 30MOUNTING
Fig. 11: The dimensions of the opening and drive outline with flange
A.The height of the opening for the flange
mounting
B. The width of the opening
C. The height of the drive
D. The width of the drive
E.The distance between the bottom of the
drive and the bottom of the opening
F.The outline of the opening
G. The outline of the drive
H. The top of the drive
Table 11: The dimensions of the drive, frames MR4 to MR9
FrameC [mm]D [mm]C [in]D [in]
MR435715214.16.0
MR545416917.96.7
MR658022022.88.7
MR768028626.811.3
MR889835935.414.1
MR9106055041.721.7
4
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