Vacon 100 ac drives, 100 flow ac drives Installation Manual

vacon 100

®

vacon 100 flow

®

ac drives

installation manual

PREFACE VACON · 3

PREFACE

Document ID: DPD00873E
Date: 3.4.2014

ABOUT THIS MANUAL

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

1 Approvals 8
2 Safety 10

2.1 The safety symbols used in the manual 10

2.2 Warning 10

2.3 Caution 11

2.4 Earthing and earth fault protection 12

2.5 Electro-magnetic compatibility (EMC) 13

2.6 Using an RCD or an RCM device 13

3 Receiving the delivery 14

3.1 Package label 14

3.2 Type designation code 14

3.3 Unpacking and lifting the AC drive 15

3.3.1 Weight of the AC drive 15

3.3.2 Lifting the frames MR8 and MR9 15

3.4 Accessories 16

3.4.1 Frame MR4 17

3.4.2 Frame MR5 17

3.4.3 Frame MR6 18

3.4.4 Frame MR7 19

3.4.5 Frame MR8 19

3.4.6 Frame MR9 20

3.5 "Product modified" label 20

3.6 Disposal 20

4 Mounting 21

4.1 General information about mounting 21

4.2 Dimensions for wall mounting 21

4.2.1 Wall mounting of MR4 21

4.2.2 Wall mounting of MR5 22

4.2.3 Wall mounting of MR6 23

4.2.4 Wall mounting of MR7 24

4.2.5 Wall mounting of MR8, IP21 and IP54 25

4.2.6 Wall mounting of MR8, IP00 26

4.2.7 Wall mounting of MR9, IP21 and IP54 27

4.2.8 Wall mounting of MR9, IP00 28

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VACON · 6 TABLE OF CONTENTS

4.3 Dimensions for flange mounting 28

4.3.1 Flange mounting of MR4 32

4.3.2 Flange mounting of MR5 33

4.3.3 Flange mounting of MR6 34

4.3.4 Flange mounting of MR7 35

4.3.5 Flange mounting of MR8 36

4.3.6 Flange mounting of MR9 37

4.4 Cooling 38

5 Power cabling 41

5.1 Cable connections 41

5.2 UL standards on cabling 42

5.3 Cable dimensioning and selection 42

5.3.1 Cable and fuse sizes 43

5.3.2 Cable and fuse sizes, North America 45

5.4 Brake resistor cables 49

5.5 Preparing for the cable installation 49

5.6 Cable installation 50

5.6.1 Frames MR4 to MR7 50

5.6.2 Frames MR8 to MR9 56

5.7 Installation in a corner-grounded network 68

6 Control unit 69

6.1 Control unit components 69

6.2 Control unit cabling 70

6.2.1 Selection of the control cables 70

6.2.2 Control terminals and DIP switches 70

6.3 Fieldbus connection 74

6.3.1 Using fieldbus through an Ethernet cable 75

6.3.2 Using fieldbus through an RS485 cable 78

6.4 Installation of option boards 82

6.4.1 The installation procedure 83

6.5 Installation of a battery for the Real Time Clock (RTC) 85

6.6 Galvanic isolation barriers 85

7 Commissioning and additional instructions 87

7.1 Commissioning safety 87

7.2 Commissioning of the drive 87

7.3 Operation of the motor 88

7.3.1 Checks before starting the motor 88

7.4 Measuring the cable and motor insulation 88

7.5 Installation in an IT system 89

7.5.1 Frames MR4, MR5, and MR6 89

7.5.2 Frames MR7 and MR8 91

7.5.3 Frame MR9 94

7.6 Maintenance 95

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TABLE OF CONTENTS VACON · 7

8 Technical data, Vacon® 100 96

8.1 AC drive power ratings 96

8.1.1 Mains voltage 208-240 V 96

8.1.2 Mains voltage 380-500 V 98

8.1.3 Overload capability 99

8.1.4 Brake resistor ratings 100

8.2 Vacon® 100 - technical data 103

9 Technical data, Vacon® 100 FLOW 107

9.1 AC drive power ratings 107

9.1.1 Mains voltage 208-240 V 107

9.1.2 Mains voltage 380-500 V 108

9.1.3 Overload capability 109

9.2 Vacon® 100 FLOW - technical data 110

10 Technical data on control connections 114

10.1 Technical data on control connections 114

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VACON · 8 APPROVALS

1 APPROVALS

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 · 10 SAFETY

2 SAFETY

2.1 THE 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 symbol Description

WARNING!

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.

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.

2.3 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.

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 · 12 SAFETY

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).

2.4 EARTHING 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.

Table 2: Protective earthing conductor cross-section

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

S ≤ 16 S

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

16 < S ≤ 35 16

35 < S S/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.

2.5 ELECTRO-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.

2.6 USING 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

A B

C

H

I

D

F

G

E

VACON · 14 RECEIVING THE DELIVERY

3 RECEIVING THE DELIVERY

3.1 PACKAGE 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

3.2 TYPE 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

Code Description

VACON This part is same for all the products.

0100 The product range: 0100 = Vacon 100

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

0061 The drive rating in amperes. For example, 0061 = 61 A

5 The mains voltage:

2 = 208-240 V
5 = 380-500 V

FLOW The Vacon 100 FLOW AC drive

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

the IP protection class IP54)

3.3 UNPACKING AND LIFTING THE AC DRIVE

3.3.1 WEIGHT 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

Frame Weight, IP21/IP54

[kg]

MR4 6.0 13.2

MR5 10.0 22.0

MR6 20.0 44.1

MR7 37.5 82.7

MR8 66.0 62.0 145.5 136.7

MR9 119.5 103.5 263.5 228.2

Weight, IP00 [kg] Weight, UL Type 1 /

Type 12 [lb.]

Weight, UL Open
Type [lb.]

3.3.2 LIFTING THE FRAMES MR8 AND MR9

1 Remove the drive from the pallet where it was

bolted to.

2 Use a lifting device that is sufficiently strong for the

weight of the drive.

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3

≤45°

VACON · 16 RECEIVING THE DELIVERY

3 Put the lifting hooks symmetrically in a minimum of

2 holes.

4 The 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.

3.4 ACCESSORIES

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

3.4.1 FRAME MR4

Table 5: The content of accessories bag

Item Quantity Description

M4x16 screw 11 Screws for the power cable clamps (6), the

control cable clamps (3), and the grounding
clamps (2)

M4x8 screw 1 Screw for the optional grounding

M5x12 screw 1 Screw for the external grounding of the drive

Control cable grounding lamella 3 Control cable grounding

EMC cable clamp, size M25 3 Clamping the power cables

Grounding clamp 2 Power cable grounding

"Product modified" label 1 Data about changes

IP21: Cable grommet 3 Sealing for the cables

IP54: Cable grommet 6 Sealing for the cables

3.4.2 FRAME MR5

Table 6: The content of the accessories bag

Item Quantity Description

M4x16 screw 13 Screws for the power cable clamps (6), the

control cable clamps (3), and the grounding
clamps (4)

M4x8 screw 1 Screw for the optional grounding

M5x12 screw 1 Screw for the external grounding of the drive

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M25 1 Clamping brake cable

EMC cable clamps, size M32 2 Clamping power cables

Grounding clamp 2 Power cable grounding

"Product modified" label 1 Data about changes

IP21: Cable grommet, hole diameter 25.3 mm 1 Sealing for the cables

IP54: Cable grommet, hole diameter 25.3 mm 4 Sealing for the cables

Cable grommet, hole diameter 33.0 mm 2 Sealing for the cables

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3

VACON · 18 RECEIVING THE DELIVERY

3.4.3 FRAME MR6

Table 7: The content of the accessories bag

Item Quantity Description

M4x20 screw 10 Screws for the power cable clamps (6), and

the grounding clamps (4)

M4x16 screw 3 Screws for the control cable clamps

M4x8 screw 1 Screw for the optional grounding

M5x12 screw 1 Screw for the external grounding of the drive

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M32 1 Clamping the brake resistor cable

EMC cable clamps, size M40 2 Clamping the power cables

Grounding clamp 2 Power cable grounding

"Product modified" label 1 Data about changes

Cable grommet, hole diameter 33.0 mm 1 Sealing for the cables

Cable grommet, hole diameter 40.3 mm 2 Sealing for the cables

IP54: Cable grommet, hole diameter 25.3 mm 3 Sealing 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

3.4.4 FRAME MR7

Table 8: The content of the accessories bag

Item Quantity Description

M6x30 slotted nut 6 Nuts for the power cable clamps

M4x16 screw 3 Screws for the control cable clamps

M6x12 screw 1 Screw for the external grounding of the drive

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M25 3 Clamping the power cables

Grounding clamp 2 Power cable grounding

‘Product modified’ label 1 Data about changes

IP21: Cable grommet 3 Sealing for the cables

IP54: Cable grommet 3 Sealing for the cables

3.4.5 FRAME MR8

Table 9: The content of accessories bag

Item Quantity Description

M4x16 screw 3 Screws for the control cable clamps

Control cable grounding lamella 3 Control cable grounding

Cable lugs KP40 3 Clamping power cables

Cable insulator 11 To prevent contact between cables

Cable grommet, hole diameter 25.3 mm 4 Sealing for the cables

IP00: Touch shield 1 To prevent contact with live parts

IP00: M4x8 screw 2 To attach the touch protection shield

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3

Product modified

Date:

Date:

Date:

VACON · 20 RECEIVING THE DELIVERY

3.4.6 FRAME MR9

Table 10: The content of the accessories bag

Item Quantity Description

M4x16 screw 3 Screws for the control cable clamps

Control cable grounding lamella 3 Control cable grounding

Cable lugs KP40 5 Clamping power cables

Cable insulator 10 To prevent contact between cables

Cable grommet, hole diameter 25.3 mm 4 Sealing for the cables

IP00: Touch shield 1 To prevent contact with live parts

IP00: M4x8 screw 2 To 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.

3.6 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.

3

TEL. [phone] · FAX [phone]

Ø25

Ø25

Ø7

Ø13

IP21

IP54

112

147

128
100

313

100

328

190

151

112

MOUNTING VACON · 21

4 MOUNTING

4.1 GENERAL 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.

4.2 DIMENSIONS FOR WALL MOUNTING

4.2.1 WALL 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 · 22 MOUNTING

4.2.2 WALL 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

42 43.7

148

151

Ø40 Ø33 Ø40

Ø25

MOUNTING VACON · 23

4.2.3 WALL 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 · 24 MOUNTING

4.2.4 WALL 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

4.2.5 WALL 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 · 26 MOUNTING

4.2.6 WALL MOUNTING OF MR8, IP00

4

Fig. 7: The dimensions of the AC drive, MR8, IP00

TEL. [phone] · FAX [phone]

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

4.2.7 WALL 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 · 28 MOUNTING

4.2.8 WALL MOUNTING OF MR9, IP00

Fig. 9: The dimensions of the AC drive, MR9, IP00

A. An optional main connector cover for the

cabinet installation

4.3 DIMENSIONS 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

A E

B

D

C

H

VACON · 30 MOUNTING

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

Frame C [mm] D [mm] C [in] D [in]

MR4 357 152 14.1 6.0

MR5 454 169 17.9 6.7

MR6 580 220 22.8 8.7

MR7 680 286 26.8 11.3

MR8 898 359 35.4 14.1

MR9 1060 550 41.7 21.7

4

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D

A

MOUNTING VACON · 31

Table 12: The dimensions of the opening for the flange mounting, frames MR4 to MR9

Frame A [mm] B [mm] E [mm] A [in] B [in] E [in]

MR4 315 137 24 12.4 5.4 0.9

MR5 408 152 23 16.1 6.0 0.9

MR6 541 203 23 21.3 8.0 0.9

MR7 655 240 13 25.8 9.4 0.5

MR8 859 298 18 33.8 11.7 0.7

MR9 975 485 54 38.4 19.1 2.1

Fig. 12: Sealing of the opening for MR8 and MR9

A. The AC drive
B. The outline of the opening

C. Gasket tape
D. The top of the drive

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4

152

15

122

285

24

113

357

341

102

72

18.5

9

32.8

39

77

190

134
128

186.9

Ø7

VACON · 32 MOUNTING

4.3.1 FLANGE MOUNTING OF MR4

Fig. 13: The dimensions of the AC drive, flange mounting, MR4

4

TEL. [phone] · FAX [phone]

Ø7

Ø7

436

454.1

262.5

145

144

150

169

9

13

382

24

39

33

27.5

100

214

114

11.5

72

145

102

12

MOUNTING VACON · 33

4.3.2 FLANGE MOUNTING OF MR5

Fig. 14: The dimensions of the AC drive, flange mounting, MR5

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4

13.9

123

16.8

514

36.4

26.2

229

106

Ø7

Ø4

115.5

196

12

18

6

184
220

195

201

Ø7

102

566

580

232

72

355.6

VACON · 34 MOUNTING

4.3.3 FLANGE MOUNTING OF MR6

Fig. 15: The dimensions of the AC drive, flange mounting, MR6

4

TEL. [phone] · FAX [phone]

230

51.2

35.2

720

192.5

197.5

660

680

192.5

102

441.6

20.3

237

271

286

7.5 72

Ø5.5

110.4 148.8

MOUNTING VACON · 35

4.3.4 FLANGE MOUNTING OF MR7

Fig. 16: The dimensions of the AC drive, flange mounting, MR7

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4

359

326

6.8

424.7

89.6

890.8

233

831.5

315.5

19.4

852.6

573.5

82.5

26

182.5

334

72

898

102

GND M8

293

109.5

1.9

Ø7

Ø6.5

Ø7

Ø7

VACON · 36 MOUNTING

4.3.5 FLANGE MOUNTING OF MR8

Fig. 17: The dimensions of the AC drive, flange mounting, MR8

4

TEL. [phone] · FAX [phone]

1060

397.5

550

525

108

255.8

247

M8

GND

72

102

73

175175

85

10.5

163

300

300

1039

10.5

56

75

Ø22

210

Ø25

3 x 42

120

449

108.5

Ø6.5

126

MOUNTING VACON · 37

4.3.6 FLANGE MOUNTING OF MR9

Fig. 18: The dimensions of the AC drive, flange mounting, MR9

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4

A

D

B

C

VACON · 38 MOUNTING

4.4 COOLING

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 is also necessary for maintenance.

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

Fig. 19: Installation space

A. the clearance around the drive
B. the distance from a drive to a second

C. the free space above the drive
D. the free space below the drive

drive, or the distance to the cabinet wall

4

TEL. [phone] · FAX [phone]

MOUNTING VACON · 39

Table 13: The minimum clearances around the AC drive

Minimum clearance [mm] Minimum clearance [in]

Frame A * B * C D A * B * C D

MR4 20 20 100 50 0.8 0.8 3.9 2.0

MR5 20 20 120 60 0.8 0.8 4.7 2.4

MR6 20 20 160 80 0.8 0.8 6.3 3.1

MR7 20 20 250 100 0.8 0.8 9.8 3.9

MR8 20 20 300 150 0.8 0.8 11.8 5.9

MR9 20 20 350 200 0.8 0.8 13.8 7.9

* = For a drive with IP54 / UL Type 12, the minimum clearances A and B are 0 mm / 0 in.

Table 14: The necessary quantity of cooling air

Frame The quantity of cooling

air [m3/h]

MR4 45 26.5

MR5 75 44.1

MR6 190 111.8

MR7 185 108.9

MR8 335 197.2

MR9 621 365.5

The quantity of cooling
air [CFM]

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4

C+D

VACON · 40 MOUNTING

Fig. 20: The installation space when drives are installed on top of each other

If you install many drives above each other

The necessary free space is C + D.

1.
Make the outlet air of the lower unit go away from the air intake of the upper unit. To do

2.
this, attach a metal plate to the cabinet wall between the drives.
When you install the drives in a cabinet, make sure that you prevent recirculation of air.

3.

4

TEL. [phone] · FAX [phone]

A

B

C

U/T1

V/T2

W/T3

L1

L2

L3

DC-

DC+/R+

R-

POWER CABLING VACON · 41

5 POWER CABLING

5.1 CABLE CONNECTIONS

The mains cables are connected to terminals L1, L2 and L3. The motor cables are connected
to terminals U, V and W.

Fig. 21: The principal connection diagram

A. The control panel

C. The power unit

B. The control unit
Use cables with a minimum heat resistance of +70 °C (158 °F). In the selection of the cables

and the fuses, refer to the nominal output current of the drive. You can find the nominal
output current on the rating plate.

Table 15: The selection of the correct cable

Cable type EMC requirements

The mains cable 1 1 1

The motor cable 3 * 2 2

The control cable 4 4 4

1st environment 2nd environment

Category C2 Category C3 Category C4

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A

C

B

VACON · 42 POWER CABLING

A power cable for a fixed installation. A cable for the specified mains voltage. A shielded

1.
cable is not necessary. We recommend an MCMK cable.
A symmetrical power cable with a concentric protection wire. A cable for the specified

2.
mains voltage. We recommend an MCMK cable. See Fig. 22.
A symmetrical power cable with a compact low-impedance shield. A cable for the

3.
specified mains voltage. We recommend an MCCMK, or an EMCMK cable. We
recommend that the cable transfer impedance (1...30MHz) is a maximum of 100 mΩ/m.
See Fig. 22. * = For the EMC level C2, it is necessary to have a 360º earthing of the shield
with cable glands in the motor end.
A screened cable with a compact low-impedance shield, for example a JAMAK, or an

4.
SAB/ÖZCuY-O cable.

Fig. 22: Cables with PE conductors

A. The PE conductor and the shield
B. The PE conductors

In all the frames, to obey the EMC requirements, use the default values of the switching
frequencies.

If you installed a safety switch, make sure that the EMC protection continues from the start
of the cables until their ends.

C. The shield

5.2 UL STANDARDS ON CABLING

To obey the UL (Underwriters Laboratories) regulations, use a UL-approved Class 1 copper
wire with a minimum heat resistance of 60 or 75 °C (140 or 167 °F).

You can use the drive on a circuit that gives a maximum of 100 000 rms symmetrical
amperes, and a maximum of 600 V, when the drive is protected by Class T and J fuses.

5.3 CABLE DIMENSIONING AND SELECTION

These instructions are valid only for processes that have 1 motor and 1 cable connection
from the AC drive to the motor. In other conditions, speak to the manufacturer to get more
information.

5

TEL. [phone] · FAX [phone]

POWER CABLING VACON · 43

5.3.1 CABLE AND FUSE SIZES

We recommend the fuse type gG/gL (IEC 60269-1). To make a selection of the fuse voltage
rating, refer to the mains. Do not use larger fuses than what is recommended Table 16.

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. For more information on
faster fuses, speak to the manufacturer. The manufacturer can also recommend some aR
(UL recognised, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.

The table also shows the typical sizes and types of cables that can be used with the AC drive.
In the selection of cables, refer to local regulations, cable installation conditions and cable
specification.

NOTE!

The Vacon® 100 FLOW software does not have the dynamic braking or the brake
resistor functions.

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5

VACON · 44 POWER CABLING

Table 16: The cable and fuse sizes for Vacon® 100

Frame Type IL [A] Fuse

(gG/gL)
[A]

6 3x1.5+1.5

MR4

MR5

0003 2—0004 2
0003 5—0004 5

0006 2—0008 2
0005 5—0008 5

0011 2—0012 2
0009 5—0012 5

0018 2
0016 5

0024 2
0023 5

3.7—4.8

3.4—4.8

10 3x1.5+1.5

6.6—8.0

5.6—8.0

16 3x2.5+2.5

11.0—12.5

9.6—12.0

20 3x6+6 1—10 Cu 1-10

18.0

16.0

25 3x6+6 1—10 Cu 1-10

24.0

23.0

Mains, motor and
brake resistor*
cable Cu [mm2]

Terminal cable size

Main terminal
[mm2]

1—6 solid
1—4 stranded

1—6 solid
1—4 stranded

1—6 solid
1—4 stranded

Earth terminal
[mm2]

1-6

1-6

1-6

MR6

MR7

32 3x10+10 1—10 Cu 1-10

0031 2
0031 5

0038 5 38.0 40 3x10+10 2.5—50 Cu/Al 2.5-35

0048 2
0046 5

0062 2
0061 5

0075 2
0072 5

0088 2
0087 5

0105 2
0105 5

31.0

31.0

50

48.0

46.0

63

62.0

61.0

80

75.0

72.0

100

88.0

87.0

105.0 125

3x16+16 (Cu)
3x25+16 (Al)

3x25+16 (Cu)
3x35+10 (Al)

3x35+16 (Cu)
3x50+16 (Al)

3x35+16 (Cu)
3x70+21 (Al)

3x50+25 (Cu)
3x70+21 (Al)

2.5—50 Cu/Al 2.5-35

2.5—50 Cu/Al 2.5-35

6-70 mm
Cu/Al

6-70 mm
Cu/Al

6-70 mm
Cu/Al

2

2

2

6-70 mm

6-70 mm

6-70 mm

2

2

2

5

TEL. [phone] · FAX [phone]

POWER CABLING VACON · 45

Table 16: The cable and fuse sizes for Vacon® 100

Frame Type IL [A] Fuse

(gG/gL)
[A]

140.0 160

0140 2
0140 5

170.0 200

MR8

MR9

0170 2
0170 5

205.0 250

0205 2
0205 5

261.0 315

0261 2
0261 5

310.0 350

0310 2
0310 5

Mains, motor and
brake resistor*
cable Cu [mm2]

3x70+35 (Cu)
3x95+29 (Al)

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

3x120+70 (Cu)
3x185+57 (Al)

3x185+95 (Cu)
2x3x120+41 (Al)

2x3x95+50 (Cu)
2x3x120+41 (Al)

Terminal cable size

Main terminal
[mm2]

Bolt size M8 Bolt size M8

Bolt size M8 Bolt size M8

Bolt size M8 Bolt size M8

Bolt size M10 Bolt size M8

Bolt size M10 Bolt size M8

Earth terminal
[mm2]

* = If you use a multi-conductor cable, 1 of the conductors of the brake resistor cable stays
unconnected. It is also possible to use a single cable if you obey the minimum cross­sectional area of the cable.

The dimensions of the cables must agree with the requirements of the standard
IEC60364-5-52.

The cables must be PVC-isolated.

•

The maximum ambient temperature is +30 °C (86 °F).

•

The maximum temperature of the cable surface is +70 °C (158 °F).

•

Use only cables with a concentric copper shield.

•

The maximum number of parallel cables is 9.

•

When you use parallel cables, make sure that you obey the requirements of the cross­sectional area and the maximum number of cables.

For important information on the requirements of the earth conductor, see chapter 2.4
Earthing and earth fault protection.

For the correction factors for each temperature, see the standard IEC60364-5-52.

5.3.2 CABLE AND FUSE SIZES, NORTH AMERICA

We recommend the fuse class T (UL & CSA). To make a selection of the fuse voltage rating,
refer to the mains. Refer also to local regulations, cable installation conditions and cable
specification. Do not use larger fuses than what is recommended Table 17.

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5

VACON · 46 POWER CABLING

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. For more information on
faster fuses, speak to the manufacturer. The manufacturer can also recommend some high
speed Class J (UL & CSA ) and aR (UL recognised) fuse ranges.

The solid state short circuit protection does not supply protection for the branch circuit of the
AC drive. To supply the branch circuit protection, refer to the National Electric Code and the
local regulations. Do not use other devices than fuses to supply branch circuit protection.

NOTE!

The Vacon® 100 FLOW software does not have the dynamic braking or the brake
resistor functions.

5

TEL. [phone] · FAX [phone]

POWER CABLING VACON · 47

Table 17: The cable and fuse sizes for Vacon® 100 in North America

Frame Type IL [A] Fuse

(Class
T/J) [A]

6 AWG14 AWG24-AWG10 AWG17-AWG10

0003 2
0003 5

0004 2
0004 5

0006 2
0005 5

MR4

0008 2
0008 5

0011 2
0009 5

3.7

3.4

4.8 6 AWG14 AWG24-AWG10 AWG17-AWG10

10 AWG14 AWG24-AWG10 AWG17-AWG10

6.6

5.6

8.0 10 AWG14 AWG24-AWG10 AWG17-AWG10

15 AWG14 AWG24-AWG10 AWG17-AWG10

11.0

9.6

Mains, motor and
brake resistor*
cable Cu [AWG]

Terminal cable size

Main terminal
[AWG]

Earth terminal
[AWG]

MR5

MR6

20 AWG14 AWG24-AWG10 AWG17-AWG10

0012 2
0012 5

0018 2
0016 5

0024 2
0023 5

0031 2
0031 5

0038 5 38.0 50 AWG4 AWG13-AWG0 AWG13-AWG2

0048 2
0046 5

0062 2
0061 5 **

12.5

12.0

25 AWG10 AWG20-AWG5 AWG17-AWG8

18.0

16.0

30 AWG10 AWG20-AWG5 AWG17-AWG8

24.0

23.0

31.0 40 AWG8 AWG20-AWG5 AWG17-AWG8

60 AWG4 AWG13-AWG0 AWG13-AWG2

48.0

46.0

80 AWG4 AWG13-AWG0 AWG13-AWG2

62.0

61.0

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VACON · 48 POWER CABLING

Table 17: The cable and fuse sizes for Vacon® 100 in North America

Frame Type IL [A] Fuse

(Class
T/J) [A]

100 AWG2 AWG9-AWG2/0 AWG9-AWG2/0

MR7

MR8

0075 2
0072 5

0088 2
0087 5

0105 2
0105 5

0140 2
0140 5

0170 2
0170 5

75.0

72.0

110 AWG1 AWG9-AWG2/0 AWG9-AWG2/0

88.0

87.0

105.0 150 AWG1/0 AWG9-AWG2/0 AWG9-AWG2/0

140.0 200 AWG3/0 AWG1-350

170.0 225 250 kcmil AWG1-350

Mains, motor and
brake resistor*
cable Cu [AWG]

Terminal cable size

Main terminal
[AWG]

kcmil

kcmil

Earth terminal
[AWG]

AWG1-350
kcmil

AWG1-350
kcmil

MR9

0205 2
0205 5

0261 2
0261 5

0310 2
0310 5

205.0 250 350 kcmil AWG1-350
kcmil

261.0 350 2x250 kcmil AWG1-350
kcmil

310.0 400 2x350 kcmil AWG1-350
kcmil

AWG1-350
kcmil

AWG1-350
kcmil

AWG1-350
kcmil

* = If you use a multi-conductor cable, 1 of the conductors of the brake resistor cable stays
unconnected. It is also possible to use a single cable if you obey the minimum crosssectional
area of the cable.

** = To obey the UL regulations with the 500 V drive, it is necessary to have cables with a +90
°C (194 °F) heat resistance.

The dimensions of the cables must agree with the requirements of the Underwriters
Laboratories UL508C.

The cables must be PVC-isolated.

•

The maximum ambient temperature is +30 °C (86 °F).

•

The maximum temperature of the cable surface is +70 °C (158 °F).

•

Use only cables with a concentric copper shield.

•

The maximum number of parallel cables is 9.

•

5

TEL. [phone] · FAX [phone]

POWER CABLING VACON · 49

When you use parallel cables, make sure that you obey the requirements of the cross­sectional area and the maximum number of cables.

For important information on the requirements of the earth conductor, see the Underwriters
Laboratories standard UL508C.

For the correction factors for each temperature, see the instructions of the Underwriters
Laboratories UL508C.

5.4 BRAKE RESISTOR CABLES

Vacon® 100 AC drives have terminals for an optional external brake resistor. These
terminals are identified with R+ and R- (in MR4, MR5, MR6) or DC+/R+ and R- (in MR7, MR8,
MR9). You can find the dimensions that we recommend for the brake resistor cables in the
tables in chapters 5.3.1 Cable and fuse sizes and 5.3.2 Cable and fuse sizes, North America.

CAUTION!

If you use a multi-conductor cable, 1 of the conductors of the brake resistor cable
stays unconnected. Cut off the remaining conductor to prevent an accidental
contact with a conducting component.

See the brake resistor ratings in chapter 8.1.4 Brake resistor ratings.

NOTE!

The frames MR7, MR8, and MR9 have the brake chopper, only if their type
designation code has the code +DBIN. The frames MR4, MR5, and MR6 have the
brake chopper as standard.

NOTE!

The Vacon® 100 FLOW software does not have the dynamic braking or the brake
resistor functions.

5.5 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.

•

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

•

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

•

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

•

systems.
The maximum lengths of shielded motor cables are 100 m (for MR4), 150 m (for MR5 and

•

MR6), and 200 m (for MR7, MR8, and MR9).
The motor cables must cross other cables at an angle of 90°.

•

If the cable insulation checks are necessary, see chapter 7.4 Measuring the cable and

•

motor insulation for instructions.

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5

VACON · 50 POWER CABLING

Table 18: The minimum distances between cables

The distance between
cables [m]

0.3 ≤ 50 1.0 ≤ 164.0

1.0 ≤ 200 3.3 ≤ 656.1

The length of the
shielded cable [m]

The distance between
cables [ft]

The length of the
shielded cable [ft]

5.6 CABLE INSTALLATION

5.6.1 FRAMES MR4 TO MR7

Table 19: The cable stripping lengths [mm]. See the figure in step 1.

Frame A B C D E F G

MR4 15 35 10 20 7 35 *

MR5 20 40 10 30 10 40 *

MR6 20 90 15 60 15 60 *

MR7 20 80 20 80 20 80 *

* = As short as possible.

Table 20: The cable stripping lengths [in]. See the figure in step 1.

Frame A B C D E F G

MR4 0.6 1.4 0.4 0.8 0.3 1.4 *

MR5 0.8 1.6 0.4 1.2 0.4 1.6 *

MR6 0.8 3.6 0.6 2.4 0.6 2.4 *

MR7 0.8 3.1 0.8 3.1 0.8 3.1 *

* = As short as possible.

5

TEL. [phone] · FAX [phone]

B

D

A

C

F

E

G

MAINS MOTOR

M4x55

M4x8

POWER CABLING VACON · 51

1 Strip the motor cable, the mains cable, and the

brake resistor cable.

NOTE!

The Vacon® 100 FLOW software does not
have the dynamic braking or the brake
resistor functions.

G. The earth

conductor

2 Open the cover of the AC drive.

3 Remove the screws of the cable cover. Remove the

cable cover. Do not open the cover of the power
unit.

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5

VACON · 52 POWER CABLING

4 Put the grommets in the openings of the cable

entry plate. These parts are included in the
package. The picture shows the grommets in IP21
in the EU version.

5

TEL. [phone] · FAX [phone]

A B C

M4x16

(2.2 Nm)

POWER CABLING VACON · 53

5 Put the cables - the mains cable, the motor cable

and the optional brake cable - in the openings of
the cable entry plate.

Cut the grommets open to move the cables

a)

through them. If the grommets fold in when
you put the cable, pull the cable back to make
the grommets straight.
Do not cut the grommet openings wider than

b)

what is necessary for the cables that you use.
With the enclosure class IP54, the connection

c)

between the grommet and the cable must be
tight. Pull the first bit of the cable out of the
grommet so that is stays straight. If this is not
possible, make the connection tight with some
insulation tape or a cable tie.

A. The mains

cable

C. The motor

cable

B. The brake

cable

6 Remove the cable clamps and the grounding

clamps.

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5

Brake cable

C

D E F

C

B

A

VACON · 54 POWER CABLING

7 Put the cable entry plate with the cables into the

groove on the frame of the drive.

8 Connect the stripped cables.

Expose the shield of all the 3 cables to make a

a)

360-degree connection with the cable clamp.
Connect the phase conductors of the mains

b)

cable and of the motor cable, and the
conductors of the the brake resistor cable into
the correct terminals.
Attach the earth conductor of each cable to an

c)

earth terminal with a clamp.
See the correct tightening torques in Table 21.

d)

A. The cable

clamp

B. The

terminals

C. The earth

E. The brake

resistor
cable

F. The motor

cable

terminal

D. The mains

cable

5

TEL. [phone] · FAX [phone]

= M5; 2 Nm

POWER CABLING VACON · 55

9 Make sure that the earth conductor is connected to

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

To obey the requirements of the standard

a)

EN61800-5-1, obey the instructions in chapter

2.4 Earthing and earth fault protection.
If a double earthing is necessary, use the earth

b)

terminal under the drive. Use an M5 screw and
tighten it to 2.0 Nm or 17.7 lb-in.

10 Attach again the cable cover and the cover of the

drive.

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VACON · 56 POWER CABLING

Table 21: The tightening torques of the terminals

Tightening torque: the
power and motor

Frame Type

MR4

MR5

MR6

MR7

0003 2-0012 2
0003 5-0012 5

0018 2-0031 2
0016 5-0031 5

0048 2-0062 2
0038 5-0061 5

0075 2-0105 2
0072 5-0105 5

terminals

Nm lb-in. Nm lb-in. Nm lb-in.

0.5-0.6 4.5-5.3 1.5 13.3 2.0 17.7

1.2-1.5 10.6-13.3 1.5 13.3 2.0 17.7

10 88.5 1.5 13.3 2.0 17.7

8 * / 5.6 ** 70.8 * /

49.6 **

* = The tightening torque for a torx screw.
** = The tightening torque for an Allen screw.

Tightening torque: the
EMC grounding clamps

1.5 13.3 8 * / 5.6 ** 70.8 * /

Tightening torque: the
earth terminals

49.6 **

Fig. 23: The tightening torque for the Allen screw in MR7 is 5.6 Nm

5.6.2 FRAMES MR8 TO MR9

Table 22: The cable stripping lengths [mm]. See the figure in step 1.

Frame A B C D E F G

MR8 40 180 25 300 25 300 *

MR9 40 180 25 300 25 300 *

* = As short as possible.

5

TEL. [phone] · FAX [phone]

B

D

A

C

F

E

G

MAINS MOTOR

M4x10

POWER CABLING VACON · 57

Table 23: The cable stripping lengths [in]. See the figure in step 1.

Frame A B C D E F G

MR8 1.6 7.1 1 11.8 1 11.8 *

MR9 1.6 7.1 1 11.8 1 11.8 *

* = As short as possible.
1 Strip the motor cable, the mains cable, and the

brake resistor cable.

NOTE!

The Vacon® 100 FLOW software does not
have the dynamic braking or the brake
resistor functions.

2 MR9 only: Open the cover of the AC drive.

G. The earth

conductor

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5

M4x8

M4x8

VACON · 58 POWER CABLING

3 Remove the cable cover.

MR8

MR9

5

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M4x8

M5x10

POWER CABLING VACON · 59

4 Remove the cable entry plate.

MR8

MR9

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5

M4x8

VACON · 60 POWER CABLING

5 MR9 only: Loosen the screws and remove the

sealing plate.

5

TEL. [phone] · FAX [phone]

M5

M4x8

A

POWER CABLING VACON · 61

6 Remove the EMC shield plate.

A. The wing

nut in MR8

MR9

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5

L1

U V W

L2 L3 DC-

DC+

R+

R-

L1

U V W

L2

L3 DC-

DC+

R+

R-

VACON · 62 POWER CABLING

7 Find the terminals of the motor cables. The

location of the terminals is unusual, especially in
MR8.

MR8

MR9

5

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POWER CABLING VACON · 63

8 Cut the grommets open to move the cables through

them.

Do not cut the grommet openings wider than

a)

what is necessary for the cables that you use.
If the grommets fold in when you put the cable,

b)

pull the cable back to make the grommets
straight.

9 Attach the grommet and the cable so that the

frame of the drive goes into the groove of the
grommet.

With the enclosure class IP54, the connection

a)

between the grommet and the cable must be
tight. Pull the first bit of the cable out of the
grommet so that it stays straight.
If this is not possible, make the connection

b)

tight with some insulation tape or a cable tie.

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5

VACON · 64 POWER CABLING

10 If you use thick cables, put the cable insulators in

between the terminals to prevent contact between
the cables.

5

TEL. [phone] · FAX [phone]

A

B

A

POWER CABLING VACON · 65

11 Connect the stripped cables.

Connect the phase conductors of the mains

a)

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 earth conductor of each cable to an

b)

earth terminal with a clamp.
See the correct tightening torques in Table 24.

c)

A. Connection

of the
cables

A. Make a

grounding
connection
in MR9

B. Make a

grounding
connection
in MR8

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5

A

C

B

VACON · 66 POWER CABLING

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

cable lugs on top of each other.

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

degree connection with the cable clamp.

14 Attach again the EMC shield plate. For MR9, attach

the sealing plate.

A. The first

cable lug

B. The second

cable lug

C. The

connector

5

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M4x10

POWER CABLING VACON · 67

15 Attach the cable entry plate, and then the cable

cover.

16 For MR9, attach the cover of the drive (unless you

want to make the control connections first).

17 Make sure that the earth conductor is connected to

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

To obey the requirements of the standard

a)

EN61800-5-1, obey the instructions in chapter

2.4 Earthing and earth fault protection.
Connect the protective conductor to 1 of the

b)

screw connectors with a cable shoe and an M8
screw.

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5

VACON · 68 POWER CABLING

Table 24: Tightening torques of the terminals

Frame Type

MR8

MR9

0140 2-0205 2
0140 5-0205 5

0261 2-0310 2
0261 5-0310 5

Tightening torque: the
power and motor
terminals

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

30 266 1.5 13.3 20 177

30 266 1.5 13.3 20 177

Tightening torque: the
EMC grounding clamps

Tightening torque: the
earth terminals

5.7 INSTALLATION IN A CORNER-GROUNDED NETWORK

You can use corner grounding with the drive types (MR7 to MR9) with a rating of 72-310 A
with a 380-480 V mains, and 75-310 A with a 208-240 V mains.

In these conditions, you must change the EMC protection level to C4. See the instructions in

7.5 Installation in an IT system.
Do not use corner grounding with the drive types (MR4 to MR6) with a rating of 3.4-61 A with

a 380-480 V mains, or 3.7-62 A with a 208-240 V mains.

5

TEL. [phone] · FAX [phone]

L

I

K

H

G

F

J

E

D

A

B

C

CONTROL UNIT VACON · 69

6 CONTROL UNIT

6.1 CONTROL UNIT COMPONENTS

The control unit of the AC drive contains the standard boards and the option boards. The
option boards are connected to the slots of the control board (see 6.4 Installation of option

boards).

Fig. 24: The components of the control unit

A. The terminals for the standard I/O

connections
B. The Ethernet connection
C. The terminals for 3 relay outputs or 2

relay outputs and a thermistor
D. The option boards
E. A DIP switch for the RS485 bus

termination

F. A DIP switch for the signal selection of

Analogue Output

G. A DIP switch for the isolation of the

digital inputs from ground

H. A DIP switch for the signal selection of

Analogue Input 2

I. A DIP switch for the signal selection of

Analogue Input 1

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VACON · 70 CONTROL UNIT

J. The status indicator of the Ethernet

connection

K. A fan (only in IP54 of MR4 and of MR5)
L. The battery for the RTC

When you receive the AC drive, the control unit contains the standard control interface. If you
included special options in your order, the AC drive will be as in your order. On the next
pages, you will find information on the terminals and general wiring examples.

It is possible to use the drive with an external power source with these properties: +24 VDC
±10%, minimum 1000 mA. Connect the external power source to terminal 30. This voltage is
sufficient to keep the control unit on and for you to set the parameters. The measurements
of the main circuit (for example, the DC link voltage, and the unit temperature) are not
available when the drive is not connected to mains.

6.2 CONTROL UNIT CABLING

The control board has 22 fixed I/O terminals, and the relay board has 8. You can see the
standard connections of the control unit and the descriptions of signals in Fig. 25.

6.2.1 SELECTION OF THE CONTROL CABLES

The control cables must be a minimum of 0.5 mm2 screened multicore cables. See more on
the cable types in Table 15 The selection of the correct cable. The terminal wires must be a
maximum of 2.5 mm2 for the terminals of the relay board and other terminals.

Table 25: The tightening torques of the control cables

The terminal The terminal screw The tightening torque

Nm lb-in.

All the terminals of
the I/O board and the
relay board

M3 0.5 4.5

6.2.2 CONTROL TERMINALS AND DIP SWITCHES

Here you see the basic description of the terminals of the I/O board and the relay board. For
more information, see 10.1 Technical data on control connections.

Some terminals are assigned for signals that have optional functions that you can use with
the DIP switches. See more in 6.2.2.1 Selection of terminal functions with DIP switches.

6

TEL. [phone] · FAX [phone]

RUN

FAULT

READY

*)

*)

Reference output

+10 Vref

Terminal

Standard I/O board

Signal

1

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

18

Analogue output
common / I/O ground

AO1-/GND19

24V auxiliary
input voltage

+24Vin

30

24V auxiliary voltage

24Vout

12

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

22

RO1 CM

RO1 NO23

Common for DI1-DI6

CM11

Common for DI1-DI6

CM

17

Serial bus, negative

RS485A

Serial bus, positive

RS485

B

Relay output 2

Relay output 3

RO2 NC24

25

RO2 CM

RO2 NO26

32

RO3 CM

RO3 NO33

Description

Frequency reference

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

mA

CONTROL UNIT VACON · 71

Fig. 25: The signals of the I/O terminals on the standard I/O board, and a connection example. If
you include the optional code +SBF4 in your order, the relay output 3 is replaced with a thermistor
input.

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6

RO1 NC
RO1 CM
RO1 NO

RO2 NC
RO2 CM
RO2 NO

RO3 CM

RO3 NO

21
22

23
24

25

26

32

33

RUN

RUN

FAULT

READY

Relay output 1

Relay output 2

Relay output 3

From Standard I/O board

Terminal Signal

Default

Relay board 1

From term.

#6 or 12

From term.

#13

RO1 NC
RO1 CM
RO1 NO

RO2 NC
RO2 CM
RO2 NO

TI1+

TI1-

21
22

23
24

25

26

28

29

RUN

RUN

FAULT

NO ACTION

Relay output 1

Relay output 2

From Standard I/O board

Terminal Signal

Default

Relay board 2

From term.

#12

From term.

#13

Thermistor input

VACON · 72 CONTROL UNIT

* = You can isolate digital inputs from ground with a DIP switch. See 6.2.2.2 Isolation of digital
inputs from ground.

There are 2 different relay boards available.

Fig. 26: The standard relay board (+SBF3)

Fig. 27: The optional relay board (+SBF4)

NOTE!

The Thermistor input function is not automatically active.

To use the Thermistor input function, you must activate the parameter Thermistor Fault in
the software. See the Application Manual.

6.2.2.1 Selection of terminal functions with DIP switches
You can make 2 selections with the DIP switches for specified terminals. The switches have 2

positions: up and down. You can see the location of the DIP switches and the possible
selections in Fig. 28.

6

TEL. [phone] · FAX [phone]

A B

A

B

C

D

AI2

U
I

AI1

U
I

RS-485
bus
termination

OFF
ON

AO1

U
I

CONTROL UNIT VACON · 73

Fig. 28: The selections of the DIP switches

A. The voltage signal, 0-10 V input
B. The current signal, 0-20 mA input

C. OFF
D. ON

Table 26: The default positions of the DIP switches

The DIP switch The default position

AI1 U

AI2 I

AO1 I

RS485 bus termination OFF

6.2.2.2 Isolation of digital inputs from ground
It is possible to isolate from ground the digital inputs (terminals 8-10 and 14-16) on the

standard I/O board. To do this, change the position of a DIP switch on the control board.

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6

A

B

C

VACON · 74 CONTROL UNIT

Fig. 29: Change the position of this switch to isolate the digital inputs from ground

A. The digital inputs

C. Connected to GND (default)

B. Floating

6.3 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 or 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.

6

TEL. [phone] · FAX [phone]

C

D

F

A

B

E

CONTROL UNIT VACON · 75

Fig. 30: The Ethernet and RS485 connections

A. RS485 terminal A = Data ­B. RS485 terminal B = Data +
C. The DIP switches

D. The Ethernet terminal
E. The I/O terminals
F. The grounding bar

6.3.1 USING FIELDBUS THROUGH AN ETHERNET CABLE

Table 27: Ethernet cable data

Item Description

The plug type A shielded RJ45 plug, maximum length 40 mm

The cable type CAT5e STP

The cable length Maximum 100 m (328 ft)

1 Connect the Ethernet cable to its terminal.

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6

VACON · 76 CONTROL UNIT

2 In IP21, cut free the opening on the cover of the AC

drive for the Ethernet cable.
In IP54, cut a hole in a grommet and move the
cable through it.

If the grommet folds in when you put the cable,

a)

pull the cable back to make the grommet
straight.
The hole in the grommet must not be wider

b)

than your cable.
Pull the first bit of the cable out of the

c)

grommet so that it stays straight. If this is not
possible, make the connection tight with some
insulation tape or a cable tie.

IP21

IP54

6

TEL. [phone] · FAX [phone]

A

A

CONTROL UNIT VACON · 77

3 Put the cover of the drive back. Keep the distance

between the Ethernet cable and the motor cable at
a minimum of 30 cm.

A. The

Ethernet
cable in
IP21

A. The

Ethernet
cable in
IP54

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

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6

10

5

15 mm

VACON · 78 CONTROL UNIT

6.3.2 USING FIELDBUS THROUGH AN RS485 CABLE

Table 28: 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.

2

1 Remove approximately 15 mm of the grey shield of

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

Strip the cables for approximately 5 mm to put

a)

them in the terminals. Do not keep more than
10 mm of the cable outside the terminals.
Strip the cable at such a distance from the

b)

terminal that you can attach it to the frame
with the cable clamp. Strip the cable at a
maximum length of 15 mm. Do not remove the
aluminium shield of the cable.

6

TEL. [phone] · FAX [phone]

CONTROL UNIT VACON · 79

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 cable clamp to make a grounding
connection.

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VACON · 80 CONTROL UNIT

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

set the bus termination.

Find the DIP switches on the right side of the

a)

control panel of the drive.
Set the DIP switch of the RS485 bus

b)

termination to the ON position.
Biasing is built in the bus termination resistor.

c)

The resistance is 220 Ω.

5 In IP21, unless you have cut the openings for other

cables, cut an opening on the cover of the drive for
the RS485 cable.

6

TEL. [phone] · FAX [phone]

A

D

D

E

A

C

B

CONTROL UNIT VACON · 81

6 Put the cover of the drive back. Pull the RS485

cables to the side.

Keep the distance of the Ethernet, I/O and

a)

Fieldbus cables from the motor cable at a
minimum of 30 cm.
Move the fieldbus cables away from the motor

b)

cable.

7 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

fieldbus
cables

A. The termination is activated

C. The termination is activated with a DIP

B. The termination is deactivated

D. The bus termination. The resistance is

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switch

220 Ω.

6

VACON · 82 CONTROL UNIT

E. The fieldbus

NOTE!

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

6.4 INSTALLATION OF OPTION BOARDS

CAUTION!

Do not install, remove, or replace option boards on the drive when the power is on.
Doing this can cause damage to the boards.

Install the option boards into the option board slots of the drive. Refer to Table 29.

6

TEL. [phone] · FAX [phone]

M4x55

CONTROL UNIT VACON · 83

Table 29: The option boards and their correct option board slots

Type of the option board Description of the option board The correct slot or slots

OPTB1 The I/O expander board C, D, E

OPTB2 The Thermistor relay board C, D, E

OPTB4 The I/O expander board C, D, E

OPTB5 The Relay board C, D, E

OPTB9 The I/O expander board C, D, E

OPTBF The I/O expander board C, D, E

OPTBH The Temperature measurement

OPTBJ The Safe Torque Off board E

OPTC4 The LonWorks fieldbus board D, E

OPTE3 The Profibus DPV1 fieldbus board D, E

OPTE5 The Profibus DPV1 fieldbus board

OPTE6 The CanOpen fieldbus board D, E

OPTE7 The DeviceNet fieldbus board D, E

THE INSTALLATION PROCEDURE

1 Open the cover of the AC drive.

WARNING!

Do not touch the relay outputs or the I/O
terminals without measuring that there is
no voltage in the terminals. They can have
a dangerous voltage also when the drive is
disconnected from mains.

C, D, E

board

D, E

(with a type D connector)

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6

OPT

dv

A

VACON · 84 CONTROL UNIT

2 If you have an OPTB or an OPTC option board, make

sure that the label on it says "dv" (dual voltage).
This shows that the option board is compatible with
the drive.

NOTE!

It is not possible to install option boards
that are not compatible with the drive.

A. The slot

coding

3 To get access to the option board slots, open the

cover of the control unit.

6

TEL. [phone] · FAX [phone]

B

A

CONTROL UNIT VACON · 85

4 Install the option board into the correct slot: C, D or

E. See Table 29.

The option board has a slot coding, because of

a)

which it is not possible to install the option
board in an incorrect slot.

A. The slot

coding

5 Close the cover of the control unit. Put the cover of

the AC drive back.

B. The option

board slots

6.5 INSTALLATION OF A BATTERY FOR THE REAL TIME CLOCK (RTC)

To use the Real Time Clock (RTC), you must install a battery in the drive.
1 Use a ½ AA battery with 3.6 V and a capacity of

1000-1200 mAh. You can use, for example, a
Panasonic BR-1/2 AA or a Vitzrocell SB-AA02.

2 Install the battery on the left side of the control

panel. See Fig. 24 The components of the control unit.

The battery will last approximately 10 years. See more about the functions of the RTC in the
Application Manual.

6.6 GALVANIC ISOLATION BARRIERS

The control connections are isolated from mains. The GND terminals are permanently
connected to I/O ground.

The digital inputs on the standard I/O board can be galvanically isolated from the I/O ground.
To isolate the digital inputs, use the DIP switch that has the positions FLOAT and GND.

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6

A

B

10Vref
GND
+24V

GND
AI1+
AI1-

AI2+
AI2­DI1...
DI6
CM
AO1+
AO1­+24Vin

RS485

RO1/1
RO1/2
RO1/3
RO2/1
RO2/2
RO2/3
TI1+

TI1-

L1

L2

L3

DC- DC+/R+ R-

U

V

W

VACON · 86 CONTROL UNIT

Fig. 31: The galvanic isolation barriers

A. The control unit

B. The power unit

6

TEL. [phone] · FAX [phone]

COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 87

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 I/O terminals are not live.

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!

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 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 relay outputs or other I/O terminals than the control I/O 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.

7.2 COMMISSIONING OF THE DRIVE

Read the safety instructions in chapters 2 Safety and 7.1 Commissioning safety and obey them.

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VACON · 88 COMMISSIONING AND ADDITIONAL INSTRUCTIONS

After the installation:

Make sure that the motor is installed correctly.

•

Make sure that the motor terminals are not connected to mains.

•

Make sure that the AC drive and the motor are grounded.

•

Make sure that you select the mains cable, the brake cable, and the motor cable

•

correctly (see chapter 5.3 Cable dimensioning and selection).
Make sure that the control cables are as far as possible from the power cables. See

•

chapter 5.6 Cable installation.
Make sure that the shields of the shielded cables are connected to an earth terminal that

•

is identified with .
Do a check of the tightening torques of all the terminals.

•

Make sure that no power correction capacitors are connected to the motor cable.

•

Make sure that the cables do not touch the electrical components of the drive.

•

Make sure that the common inputs of the digital input groups are connected to +24 V or

•

ground of the I/O terminal or the external power source.
Do a check of the quality and quantity of the cooling air. See chapter 4.4 Cooling and

•

Table 14 The necessary quantity of cooling air.
Make sure that there is no condensation on the inner surfaces of the AC drive.

•

Make sure that there are no unwanted objects in the installation space.

•

Before you connect the drive to mains, do a check of the installation and the condition of

•

all the fuses and other protective devices.

7.3 OPERATION OF THE MOTOR

7.3.1 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 I/O 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.

7.4 MEASURING THE CABLE AND MOTOR INSULATION

The insulation checks of the motor cable

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

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

2.
between phase conductors 1 and 3, and between phase conductors 2 and 3.
Measure the insulation resistance between each phase conductor and the earth

3.
conductor.
The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

4.

7

TEL. [phone] · FAX [phone]

COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 89

The insulation checks of the mains cable

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

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

2.
between phase conductors 1 and 3, and between phase conductors 2 and 3.
Measure the insulation resistance between each phase conductor and the earth

3.
conductor.
The insulation resistance must be >1 MΩ at the ambient temperature of 20 °C (68 °F).

4.

The insulation checks of the motor

Disconnect the motor cable from the motor.

1

.

Open the bridging connections in the motor connection box.

2.
Measure the insulation resistance of each motor winding. The voltage must be the same

3.
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).

4.
Obey the instructions of the motor manufacturer.

5.

7.5 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 C2, it is necessary to change it to C4. To do this,
remove the EMC jumpers.

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.

7.5.1 FRAMES MR4, MR5, AND MR6

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

2 In MR4 and MR5, to find the EMC jumpers, remove

the cable cover.

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7

MR4

MR5

VACON · 90 COMMISSIONING AND ADDITIONAL INSTRUCTIONS

3 Find the EMC jumpers that connect the RFI filters

to ground.

7

TEL. [phone] · FAX [phone]

MR6

Product modified

Date:

Date:

Date:

COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 91

4 To disconnect the RFI filters from ground, remove

the EMC jumpers.

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.

7.5.2 FRAMES MR7 AND MR8

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

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7

VACON · 92 COMMISSIONING AND ADDITIONAL INSTRUCTIONS

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

jumper, remove the cover of the EMC box.

3 Remove the EMC jumper. Attach the cover of the

EMC box again.

7

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L1

L2 L3

DC-

R-

DC+

R+

U

V

W

T1

T2 T3

Product modified

Date:

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COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 93

4 In MR7, find the DC grounding busbar between the

connectors R - and U. To remove the busbar from
the frame, remove the M4 screw.

5 In MR8, find the grounding arm and push it down.

6 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.

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Product modified

Date:

Date:

Date:

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Date:

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VACON · 94 COMMISSIONING AND ADDITIONAL INSTRUCTIONS

7.5.3 FRAME MR9

To make a change in the EMC protection of the AC drive, you must find the 3 EMC jumpers.
To change the EMC level from C2 to C4, remove the EMC jumpers. To change the EMC level
from C4 to C2, install the EMC jumpers. You can find the EMC jumpers, which are not
installed, in the accessories bag.

HOW TO FIND THE EMC JUMPER 1

1 Open the cover of the AC drive.
2 Remove the cover of the fan.
3 In IP54, also remove the fan.
4 Find the place of the jumper behind the fan.

5 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.

HOW TO FIND 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.

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

are not adjacent to each other.

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.

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COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON · 95

7.6 MAINTENANCE

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

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

Table 30: 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 input and output terminals and the
control I/O 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, if you have a cabinet
installation.

24 months (The interval is different in different envi-

ronments.)

3-6 years

6-10 years

10 years

Clean the heatsink and the cooling tunnel.

In IP54, change the internal fan.

Change the main fan.

Replace the battery of the RTC.

See the service manual for more information on the cleaning tools.

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7

VACON · 96 TECHNICAL DATA, VACON® 100

8 TECHNICAL DATA, VACON® 100

8.1 AC DRIVE POWER RATINGS

8.1.1 MAINS VOLTAGE 208-240 V

Table 31: The power ratings of Vacon® 100 in mains voltage 208-240V, 50-60 Hz, 3~

Frame Drive

type

MR4 0003 3.7 4.1 2.6 3.9 5.2 0.55 0.37 0.75 0.5

0004 4.8 5.3 3.7 5.6 7.4 0.75 0.55 1.0 0.75

0007 6.6 7.3 4.8 7.2 9.6 1.1 0.75 1.5 1.0

0008 8.0 8.8 6.6 9.9 13.2 1.5 1.1 2.0 1.5

0011 11.0 12.1 8.0 12.0 16.0 2.2 1.5 3.0 2.0

0012 12.5 13.8 9.6 16.5 19.6 3.0 2.2 4.0 3.0

MR5 0018 18.0 19.8 12.5 18.8 25.0 4.0 3.0 5.0 4.0

0024 24.0 26.4 18.0 27.0 36.0 5.5 4.0 7.5 5.0

0031 31.0 34.1 25.0 37.5 46.0 7.5 5.5 10.0 7.5

Loadability Motor shaft power

Low * High * Max

current
Continu
ous
current
IL [A]

10%
overloa
d
current
[A]

Continu
ous
current
IH [A]

50%
overloa
d
current
[A]

Is 2s

230 V mains 230 V mains

10%
overloa
d 40°C
[kW]

50%
overloa
d 50°C
[kW]

10%
overloa
d 40°C
[hp]

50%
overloa
d 50°C
[hp]

MR6 0048 48 52.8 31.0 46.5 62.0 11.0 7.5 15.0 10.0

0062 62.0 68.2 48.0 72.0 96.0 15.0 11.0 20.0 15.0

MR7 0075 75.0 82.5 62.0 93.0 124.0 18.5 15.0 25.0 20.0

0088 88.0 96.8 75.0 112.5 150.0 22.0 18.5 30.0 25.0

0105 105.0 115.5 88.0 132.0 176.0 30.0 22.0 40.0 30.0

MR8 0140 143.0 154.0 114.0 171.0 210.0 37.0 30.0 50.0 40.0

0170 170.0 187.0 140.0 210.0 280.0 45.0 37.0 60.0 50.0

0205 208.0 225.5 170.0 255.0 340.0 55.0 45.0 75.0 60.0

MR9 0261 261.0 287.1 211.0 316.5 410.0 75.0 55.0 100.0 75.0

0310 310.0 341.0 251.0 376.5 502.0 90.0 75.0 125.0 100.0

8

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TECHNICAL DATA, VACON® 100 VACON · 97

* = See chapter 8.1.3 Overload capability.

NOTE!

The rated currents in given ambient temperatures (in Table 36 The technical data of
the Vacon® 100 AC drive) are achieved only when the switching frequency ≤ the

factory default.

If your process includes a cyclical load, for example if there are lifts or winches, speak to the
manufacturer to get the dimensioning information.

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VACON · 98 TECHNICAL DATA, VACON® 100

8.1.2 MAINS VOLTAGE 380-500 V

Table 32: The power ratings of Vacon® 100 in mains voltage 380-500V, 50-60 Hz, 3~

Frame Drive

type

MR4 0003 3.4 3.7 2.6 3.9 5.2 1.1 0.75 1.5 1.0

0004 4.8 5.3 3.4 5.1 6.8 1.5 1.1 2.0 1.5

0005 5.6 6.2 4.3 6.5 8.6 2.2 1.5 3.0 2.0

0008 8.0 8.8 5.6 8.4 11.2 3.0 2.2 4.0 3.0

0009 9.6 10.6 8.0 12.0 16.0 4.0 3.0 5.0 4.0

0012 12.0 13.2 9.6 14.4 19.2 5.5 4.0 7.5 5.0

MR5 0016 16.0 17.6 12.0 18.0 24.0 7.5 5.5 10.0 7.5

0023 23.0 25.3 16.0 24.0 32.0 11.0 7.5 15.0 10.0

0031 31.0 34.1 23.0 34.5 46.0 15.0 11.0 20.0 15.0

Loadability Motor shaft power

Low * High * Max

current
Continu
ous
current
IL [A]

10%
overloa
d
current
[A]

Continu
ous
current
IH [A]

50%
overloa
d
current
[A]

Is 2s

400 V mains 480 V mains

10%
overloa
d 40°C
[kW]

50%
overloa
d 50°C
[kW]

10%
overloa
d 40°C
[hp]

50%
overloa
d 50°C
[hp]

MR6 0038 38.0 41.8 31.0 46.5 62.0 18.5 15.0 25.0 20.0

0046 46.0 50.6 38.0 57.0 76.0 22.0 18.5 30.0 25.0

0061 61.0 67.1 46.0 69.0 92.0 30.0 22.0 40.0 30.0

MR7 0072 72.0 79.2 61.0 91.5 122.0 37.0 30.0 50.0 40.0

0087 87.0 95.7 72.0 108.0 144.0 45.0 37.0 60.0 50.0

0105 105.0 115.5 87.0 130.5 174.0 55.0 45.0 75.0 60.0

MR8 0140 140.0 154.0 105.0 157.5 210.0 75.0 55.0 100.0 75.0

0170 170.0 187.0 140.0 210.0 280.0 90.0 75.0 125.0 100.0

0205 205.0 225.5 170.0 255.0 340.0 110.0 90.0 150.0 125.0

MR9 0261 261.0 287.1 205.0 307.5 410.0 132.0 110.0 200.0 150.0

0310 310.0 341.0 251.0 376.5 502.0 160.0 132.0 250.0 200.0

* = See chapter 8.1.3 Overload capability.

8

TEL. [phone] · FAX [phone]

I

L

I

L*110%

1 min 9 min

I

t

I

L*110%

TECHNICAL DATA, VACON® 100 VACON · 99

NOTE!

The rated currents in given ambient temperatures (in Table 36 The technical data of
the Vacon® 100 AC drive) are achieved only when the switching frequency ≤ the

factory default.

If your process includes a cyclical load, for example if there are lifts or winches, speak to the
manufacturer to get the dimensioning information.

8.1.3 OVERLOAD CAPABILITY

The low overload means that if 110% of the rated continuous current (IL) is required for 1
minute every 10 minutes, the remaining 9 minutes must be approximately 98% of IL or less.
This is to make sure that the output current is not more than IL during the duty cycle.

Fig. 32: Low overload in Vacon® 100

The high overload means that if 150% of the rated continuous current (IH) is required for 1
minute every 10 minutes, the remaining 9 minutes must be approximately 92% of IH or less.
This is to make sure that the output current is not more than IH during the duty cycle.

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8

I

H

I

H*150%

1 min 9 min

I

H*150%

I

t

VACON · 100 TECHNICAL DATA, VACON® 100

Fig. 33: High overload in Vacon® 100

For more information, refer to the standard IEC61800-2 (IEC:1998).

8.1.4 BRAKE RESISTOR RATINGS

Make sure that the resistance is higher than the set minimum resistance. The power
handling capacity must be sufficient for the application.

Table 33: The recommended brake resistor types and the calculated resistance of the drive

Frame Duty cycle Type of brake resistor Resistance [Ω]

MR4 Light duty BRR 0022 LD 5 63.0

Heavy duty BRR 0022 HD 5 63.0

MR5 Light duty BRR 0031 LD 5 41.0

Heavy duty BRR 0031 HD 5 41.0

MR6 Light duty BRR 0045 LD 5 21.0

Heavy duty BRR 0045 HD 5 21.0

MR7 Light duty BRR 0061 LD 5 14.0

Heavy duty BRR 0061 HD 5 14.0

MR8 Light duty BRR 0105 LD 5 6.5

Heavy duty BRR 0105 HD 5 6.5

MR9 Light duty BRR 0300 LD 5 3.3

Heavy duty BRR 0300 HD 5 3.3

8

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