Vacon 100 x Installation And Maintenance Manual

vacon®100 x

ac drives

Installation, Technical and Maintenance

Manual

vacon • 0

Service support: find your nearest Vacon service center at www.vacon.com

INDEX

Document code (Original Instructions): DPD00534G

Order code: DOC-INS03985+DLUK

Rev. G

Revision release date: 11.7.14

1. Safety................................................................................................................2

1.1 Signs....................................................................................................................................2

1.2 Units ....................................................................................................................................2

1.3 Danger.................................................................................................................................3

1.4 Warnings .............................................................................................................................4

1.5 Earthing and earth fault protection ....................................................................................5

1.6 Insulation system................................................................................................................8

1.7 Compatibility with RCDs .....................................................................................................9

1.8 Extended temperature range .............................................................................................9

1.9 Electro-magnetic compatibility (EMC)................................................................................9

1.10 Declaration of conformity .................................................................................................10

2. Receipt of delivery ..........................................................................................14

2.1 Type designation code.......................................................................................................15

2.2 Unpacking and lifting the AC drive ...................................................................................16

2.3 Accessories .......................................................................................................................16

2.3.1 Frame MM4 .......................................................................................................................16

2.3.2 Frame MM5 .......................................................................................................................17

2.3.3 Frame MM6 .......................................................................................................................17

2.3.4 STO terminal connector....................................................................................................18

2.3.5 ‘Product modified’ sticker.................................................................................................18

2.3.6 Disposal.............................................................................................................................18

3. Mounting.........................................................................................................20

3.1 Dimensions .......................................................................................................................20

3.2 Introduction of modules....................................................................................................23

3.3 Mounting ...........................................................................................................................24

3.3.1 Wall-mounting ..................................................................................................................25

3.3.2 Motor-mounting................................................................................................................25

3.3.3 Segregated modules.........................................................................................................25

3.4 Cooling ..............................................................................................................................26

4. Power cabling .................................................................................................28

4.1 Circuit breaker ..................................................................................................................29

4.2 UL standards on cabling ...................................................................................................30

4.3 Description of the terminals .............................................................................................31

4.4 Cable dimensioning and selection....................................................................................34

4.4.1 Cable and fuse sizes, frames MM4 to MM6......................................................................34

4.4.2 Cable and fuse sizes, frames MM4 to MM6, North America............................................35

4.4.3 Brake resistor cables........................................................................................................36

4.4.4 Control cables ...................................................................................................................36

4.5 Cable installation ..............................................................................................................37

5. Control unit.....................................................................................................44

5.1 Control unit cabling...........................................................................................................45

5.1.1 Control cable sizing ..........................................................................................................45

5.1.2 Standard I/O terminals .....................................................................................................46

5.1.3 Relay and thermistor input terminals ..............................................................................47

5.1.4 Safe Torque off (STO) terminals .......................................................................................47

5.1.5 Selection of terminal functions with dip switches ...........................................................48

5.1.6 Isolating digital inputs from ground .................................................................................48

5.1.7 Bus termination of the RS485 connection........................................................................49

vacon • 1

5.2 I/O cabling and Fieldbus connection ................................................................................50

5.2.1 Prepare for use through Ethernet....................................................................................50

5.2.2 Prepare for use through RS485........................................................................................51

5.2.3 RS485 cable data...............................................................................................................52

5.3 Battery installation for Real Time Clock (RTC) ................................................................53

6. Commissioning ...............................................................................................56

6.1 Commissioning of the drive ..............................................................................................57

6.2 Changing EMC protection class........................................................................................58

6.3 Running the motor ............................................................................................................60

6.3.1 Cable and motor insulation checks ..................................................................................60

6.4 Maintenance......................................................................................................................61

7. Technical data.................................................................................................62

7.1 AC drive power ratings......................................................................................................62

7.1.1 Mains voltage 3AC 208-240V.............................................................................................62

7.1.2 Mains voltage 3AC 380-480V.............................................................................................63

7.1.3 Definitions of overloadability ............................................................................................64

7.2 Brake resistor ratings.......................................................................................................65

7.3 VACON® 100 X - technical data........................................................................................66

7.3.1 Technical information on control connections.................................................................69

8. Options............................................................................................................72

8.1 Mains switch......................................................................................................................72

8.1.1 Installation ........................................................................................................................72

8.2 Control Keypad..................................................................................................................76

8.2.1 Mounting onto the drive ....................................................................................................76

8.2.2 Installation ........................................................................................................................77

8.2.3 Wall-mounting ..................................................................................................................79

8.2.4 Graphical and Text keypad................................................................................................81

8.2.5 VACON® keypad with graphical display...........................................................................82

8.2.6 VACON® keypad with text segment display.....................................................................89

8.2.7 Fault Tracing .....................................................................................................................93

8.3 Heater (arctic option) ......................................................................................................101

8.3.1 Safety...............................................................................................................................101

8.3.2 Dangers ...........................................................................................................................101

8.3.3 Technical data .................................................................................................................101

8.3.4 Mounting instructions: MM4 Example............................................................................102

8.4 Option boards..................................................................................................................105

8.5 Flange adapter ................................................................................................................106

8.5.1 Mounting instructions: MM4 Example............................................................................109

9. Safe Torque Off .............................................................................................112

9.1 General description.........................................................................................................112

9.2 Warnings .........................................................................................................................112

9.3 Standards ........................................................................................................................113

9.4 The principle of STO........................................................................................................114

9.4.1 Technical details .............................................................................................................115

9.5 Connections.....................................................................................................................116

9.5.1 Safety Capability Cat. 4 / PL e / SIL 3 .............................................................................117

9.5.2 Safety Capability Cat. 3 / PL e / SIL 3 .............................................................................119

9.5.3 Safety Capability Cat. 2 / PL d / SIL 2 .............................................................................119

9.5.4 Safety Capability Cat. 1 / PL c / SIL 1..............................................................................120

9.6 Commissioning ...............................................................................................................121

9.6.1 General wiring instructions ............................................................................................121

9.6.2 Checklist for commissioning ..........................................................................................121

9.7 Parameters and fault tracing .........................................................................................122

9.8 Maintenance and diagnostics .........................................................................................123

Safety vacon • 2

Service support: find your nearest Vacon service center at www.vacon.com

1

1. SAFETY

This manual contains clearly marked warning information which is intended for your personal safe­ty and to avoid any unintentional damage to the product or connected appliances.

Please read the warning information carefully.

VACON

®

100 X is a drive designed to control asynchronous AC motors and permanent magnet
motors. The product is intended to be installed in a restricted access location and for a general
purpose use.

Only VACON

®

authorized, trained and qualified personnel are allowed to install, operate and

maintain the drive.

1.1 Signs

The cautions and warnings are marked as follows:

Table 1. Warning signs.

1.2 Units

The dimensions used in this manual conform to International Metric System units, otherwise known
as SI (Système International d’Unités) units. For the purpose of the equipment's UL certification,
some of these dimensions are accompanied by their imperial equivalents.

= DANGEROUS VOLTAGE!

= HOT SURFACE

= WARNING or CAUTION

Physical

dimension

SI value US value Conversion factor US designation

length 1 mm 0.0394 inch 25.4 inch

Weight 1 kg 2.205 lb 0.4536 pound

Speed

1 min

-1

1 rpm 1

revolution per
minute

Temperature 1 °C (T1) 33.8 °F (T2) T2 = T1 x 9/5 + 32 Fahrenheit

Torque 1 Nm 8.851 lbf in 0.113

pound-force
inches

Power 1 kW 1.341 HP 0.7457 horsepower

Table 2. Unit conversion table.

1

vacon • 3 Safety

1.3 Danger

The components of the power unit of VACON® 100 X drives are live when the drive is con­nected to mains potential. Coming into contact with this voltage is extremely dangerous and
may cause death or severe injury.

The motor terminals (U, V, W), the brake resistor terminals and the DC-terminals are live
when VACON® 100 X Drive is connected to the mains, even if the motor is not running.

After disconnecting the AC drive from the mains, wait until the indicators on the keypad go out
(if no keypad is connected, see the indicators on the cover). Wait an additional 30 seconds

before doing any work on the connections of VACON

®

100 X Drive. Do not open the unit before
this time has expired. After expiration of this time, use measuring equipment to absolutely
ensure that no

voltage is present.

Always ensure absence of voltage before starting any elec-

trical work!
The control I/O-terminals are isolated from the mains potential. However, the relay outputs

and other I/O-terminals may have a dangerous control voltage present even when VACON

®

100 X drive is disconnected from the mains.

Before connecting the AC drive to mains make sure that the powerhead of VACON

®

100 X

Drive is mounted firmly on the terminal box.

During a coast stop (see the Application Manual), the motor is still generating voltage to the
drive. Therefore, do not touch the components of the AC drive before the motor has completely
stopped and wait until the indicators on the keypad go out (if no keypad is connected, see the
indicators on the cover). Wait an additional 30 seconds before starting any work on the drive.

Safety vacon • 4

Service support: find your nearest Vacon service center at www.vacon.com

1

1.4 Warnings

VACON® 100 X AC drive is meant for fixed installations (on the motor or on the wall)
only.

Only DVC A circuits (Decisive Voltage Class A, according to IEC 61800-5-1) are
allowed to be connected to the control unit. This advice aims to protect both the drive

and the client-application. VACON

®

is not responsible for direct or consequential
damages resulting from unsafe connections of external circuits to the drive. See para­graph 1.6 for more details.

Do not perform any measurements when the AC drive is connected to the mains.

The touch current of VACON

®

100 X AC drives exceeds 3.5mA AC. According to stan­dard EN61800-5-1, a reinforced protective ground connection must be ensured. See
paragraph 1.5 for more details.

If the AC drive is used as a part of a machine, the machine manufacturer is responsi-
ble for providing the machine with a supply disconnecting device (EN 60204-1). See
paragraph 4.1 for more details.

Only spare parts delivered by VACON

®

can be used.

At power-up or fault reset, the motor will start immediately if the start signal is
active, unless the pulse control for

Start/Stop logic has been selected

) and the STO inputs
are ready to be used (normal operation). The I/O functionalities (including start inputs)
may change if parameters, applications or software are changed. Disconnect, there­fore, the motor if an unexpected start can cause danger. This is valid only if STO inputs
are energized. For prevention on unexpected restart, use appropriate safety relay con­nected to the STO inputs.

The motor starts automatically after automatic fault reset if the autoreset function is
activated. See the Application Manual for more detailed information. This is valid only
if STO inputs are energized. For prevention on unexpected restart, use appropriate
safety relay connected to the STO inputs.

Before performing any measurement on the motor or on the motor cable, discon­nect the motor cable from the AC drive.

Do not perform any voltage withstand test on any part of VACON

®

100 X. The tests
shall be performed according to a specific procedure. Ignoring this procedure may
damage the product.

Do not touch the components on the circuit boards. Static voltage discharge may
damage the components.

Check that the EMC level of the AC drive corresponds to the requirements of your
supply network. See paragraph 6.2 for more details.

In a domestic environment, this product may cause radio interference in which case
supplementary mitigation measures may be required.

1

vacon • 5 Safety

1.5 Earthing and earth fault protection

The VACON® 100 X AC drive must always be earthed with an earthing conductor connected to the
earthing terminal marked with .

See Table 12 and Table 13 for the required cross-section of phase conductor and protective earth­ing conductor (both made of copper).

Since the touch current exceeds 3.5 mA AC, according to EN61800-5-1, the MM4 and MM5 shall
have a fixed connection and provision of an additional terminal for a second protective earthing
conductor of the same cross-sectional area as the original protective earthing conductor. MM6
shall have a fixed installation and a cross-section of the protective earthing conductor of at least 10
mm

2

Cu.

On the terminal-box, three screws (for MM4 and MM5) and two screws (for MM6)are provided for
ORIGINAL and MOTOR protective earthing conductors: the customer can choose the screw for each
one.

The cross-sectional area of every protective earthing conductor which does not form a part of the
supply cable or cable enclosure shall, in any case, be not less than:

•2.5 mm

2

if mechanical protection is provided or

•4 mm

2

if mechanical protection is not provided. For cord-connected equipment, provisions
shall be made so that the protective earthing conductor in the cord shall, in the case of fail­ure of the strain-relief mechanism, be the last conductor to be interrupted.

The power-head is earthed through metal aglets, located on the terminal-box, which fit into spring
baskets on the powerhead. See Figure 1, Figure 2 and Figure 3 for the location of the screws (three
for MM4 and MM5, two for MM6) and the metal aglets (one for MM4 and MM5, two for MM6). Please,
pay attention not to damage or remove these aglets.

CAUTION!

Safety vacon • 6

Service support: find your nearest Vacon service center at www.vacon.com

1

Figure 1. Earth connections and metal aglet in MM4.

Figure 2. Earth connections and metal aglet in MM5.

Earth connection

Metal aglet

Earth connection

Earth connection

Earth connections

Metal aglet

Earth connection

1

vacon • 7 Safety

Figure 3. Earth connections and metal aglet in MM6.

However, always follow the local regulations for the minimum size of the protective earthing
conductor.

NOTE: Due to the high capacitive currents present in the AC drive, fault current protective switches

may not function properly.

Earth connection Earth connection

Metal aglet

Metal aglet

Safety vacon • 8

Service support: find your nearest Vacon service center at www.vacon.com

1

1.6 Insulation system

A distinction has to be made for the following three groups of terminals, according the insulation
system of VACON

®

100 X:

• Mains and motor connections (L1, L2, L3, U, V, W)

• Relays (R01, R02)

(*)

• Thermistor-input

• Control terminals (I/Os, RS485, Ethernet, STO)

The Control terminals (I/Os, RS485, Ethernet, STO) are isolated from the Mains (the insulation is re­inforced, according to IEC 61800-5-1) and the GND terminals are referred to PE.

This is important when you need to connect other circuits to the drive and test the complete assem­bly. Should you have any doubt or question, please contact your local VACON

®

distributor.

Figure 4. Insulation system.

Please, consider carefully the insulation system depicted in Figure 4 before connect­ing any circuit to the unit.

(*)

The relays may be used also with DVC A circuits. This is possible only if both relays

are used with DVC A circuit: to mix Mains and DVC A is not allowed.

POWER UNIT

L1
L2
L3

U
V

W

R01 __

R02 __

DC- DC+/R+ R-

10Vref __

Analog Inputs __

Digital Inputs__

Digital Outputs__

24V __

Ethernet __

RS485 _ _

STO __

___Thermistor

Keypad

CONTROL UNIT

Reinforced

Mains

Mains

DVC A

DVC A or
Mains

(*)

1

vacon • 9 Safety

1.7 Compatibility with RCDs

1.8 Extended temperature range

VACON® 100 X has an integrated cooling system, independent from the motor fan. Under maxi­mum operating conditions, the ambient temperature cannot exceed 40 °C. See Table 24 and
Table 25 for the output rated current. Higher temperatures are allowed only with derating of the
output current. With derating the unit can operate up to 60°C. See the Figure 5.

Figure 5. Temperature-output current derating curve.

NOTE: the maximum allowed switching frequency above 50°C is 1.5 kHz.
The AC drive is cooled down by air-ventilation. Therefore, make sure that enough free space is left

around the AC drive to ensure sufficient air circulation (see for more details the mounting instruc­tions on chapter 3).

1.9 Electro-magnetic compatibility (EMC)

The VACON® 100 X complies with IEC 61000-3-12, provided that the short circuit power (SSC) is
greater than or equal to 120 at the interface point between the user's supply and the public system.
It is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment is connected only to a supply with a
short-circuit power SSC greater than or equal to 120.

This product can cause a d.c. current in the protective earthing conductor. Where a re­sidual current-operated protective (RCD) or monitoring (RCM) device is used for pro­tection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed
on the supply side of this product.

Ambient temperature (°C)

Percent rated output current (% I

N

)

10 20 30 40 50

100

75

50

25

0-10

150

60

Temperature - Output Current Derating Curve

Safety vacon • 10

Service support: find your nearest Vacon service center at www.vacon.com

1

1.10 Declaration of conformity

Figure 6. Declaration of conformity.

1

vacon • 11 Safety

Figure 7. STO certificate.

Safety vacon • 12

Service support: find your nearest Vacon service center at www.vacon.com

1

NOTE! You can download the English and French product manuals with applicable safety, warn­ing and caution information from www.vacon.com/downloads.

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.

1

vacon • 13 Safety

Receipt of delivery vacon • 14

Service support: find your nearest Vacon service center at www.vacon.com

2

2. RECEIPT OF DELIVERY

Check the correctness of delivery by comparing your order data to the drive information found on
the package label. If the delivery does not correspond to your order, contact the supplier immedi­ately. See chapter 2.3.

Figure 8. VACON® package label.

Marks:

3234500378

Cust. Ord. No:

Application:

FW0065V008

Firmware:

EMC level C2

380-480 V
IP66 / Type 4X

31 A

Rated current:

122245

B.ID:

V0789012245

S/N:

223456789012345678901234567 29012345

20-AB3L00315A02B5H1MB1C-12345678

Code:

VACON0100-3L-0031-4-X

Type:

0022345628AC DRIVE

223456789012245

Vacon type code

Rated
current

Supply
voltage

Application
code

IP class
EMC level

Serial number

CUSTOMER NAME

Customer’s
order number

Vacon order
number

Batch ID

2

vacon • 15 Receipt of delivery

2.1 Type designation code

VACON® type designation code is formed of a nine-segment code and optional +codes. Each seg­ment of the type designation code uniquely corresponds to the product and options you have or­dered. The code is of the following format:

VACON0100-3L-0061-4-X +xxxx +yyyy

VACON

This segment is common for all products.

0100

Product range:
0100 = VACON

®

100

3L

Input/Function:
3L = Three-phase input

0061

Drive rating in ampere; e.g. 0061 = 61 A
See Table 24 and Table 25 for all the drive rat-

ings.

4

Supply voltage:
2 = 208-240 V

4 = 380-480 V

X

-IP66/ Type 4X

-EMC-level C2

-Two relay outputs

-One thermistor input

+xxxx +yyyy

Additional codes (Several options possible).
Examples of additional codes:
+HMGR
Graphical keypad IP66
+F0065
HVAC Application installed
+F0159
FLOW application installed
+SRBT
Integrated battery for real time clock
+FBIE
Onboard fieldbus protocols activated

Receipt of delivery vacon • 16

Service support: find your nearest Vacon service center at www.vacon.com

2

2.2 Unpacking and lifting the AC drive

The weights of the AC drives vary according to frame size. You may need to use a piece of special
lifting equipment to move the converter from its package. Note the weights of each individual frame
size in Table 3 below.

Table 3. Frame weights.

VACON® 100 X drives have undergone scrupulous tests and quality checks at the factory before they
are delivered to the customer. However, after unpacking the product, check that no signs of trans­port damage are to be found on the product and that the delivery is complete.

Should the drive have been damaged during shipping, please contact the cargo insurance company
or the carrier in the first instance.

2.3 Accessories

After having opened the transport package and lifted the drive out, check immediately that these
various accessories were included in the delivery. The contents of the accessories bag differ by
drive size:

2.3.1 Frame MM4

Frame

Weight

[kg] [lb]

MM4 8.8 19.4
MM5 14.9 32.8
MM6 31.5 69.4

Item Quantity Purpose

STO terminal connector 1

Six pin black connector (see
Figure 9) to use STO function

M4 x 12 DIN6900-3-Combi-Delta-Tx
screw

10 Screws for control cable clamps

M1-3 Cable clamp 5 Clamping control cables

M4 x 12 DIN6900-3-Combi-Delta-Tx
screw

6 Screws for power cable clamps

M25 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*

*. Provided only if the drive is delivered with the keypad.

1 Closing cap for the HMI connector

Table 4. Content of accessory bag, MM4.

2

vacon • 17 Receipt of delivery

2.3.2 Frame MM5

2.3.3 Frame MM6

Item Quantity Purpose

STO terminal connector 1

Six pin black connector (see
Figure 9) to use STO function

M4 x 12 DIN6900-3-Combi-Delta-Tx
screw

10 Screws for control cable clamps

M1-3 Cable clamp 5 Clamping control cables

M4 x 12 DIN6900-3-Combi-Delta-Tx
screw

6 Screws for power cable clamps

M32 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*

*. Provided only if the drive is delivered with the keypad.

1 Closing cap for the HMI connector

Table 5. Content of accessory bag, MM5.

Item Quantity Purpose

STO terminal connector 1

Six pin black connector (see
Figure 9) to use STO function

M4 x 12 DIN6900-3-Combi-Delta-Tx
screw

10 Screws for control cable clamps

M1-3 Cable clamp 5 Clamping control cables

M4 x 25 DIN6900-3-Combi-Delta-Tx
screw

6 Screws for power cable clamps

M40 Cable clamp 3 Clamping power cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

*

*. Provided only if the drive is delivered with the keypad mounted.

1 Closing cap for the HMI connector

Table 6. Content of accessory bag, MM6.

Receipt of delivery vacon • 18

Service support: find your nearest Vacon service center at www.vacon.com

2

2.3.4 STO terminal connector

Figure 9. STO connector.

2.3.5 ‘Product modified’ sticker

In the small plastic bag included in the delivery you will find a silver

Product modified sticker. The

purpose of the sticker is to notify the service personnel about the modifications made in the AC
drive. Attach the sticker on the side of the AC drive to avoid losing it. Should the AC drive be later
modified mark the change on the sticker.

Figure 10. ‘Product modified’ sticker.

2.3.6 Disposal

When the device reaches the end of its operating life do not dispose
of it as a part of standard household garbage. Main components of
the product can be recycled, but some need to be fragmented to
separate different types of materials and components that need to
be treated as special waste from electrical and electronic
components. To ensure environmentally sound and safe recycling
treatment, the product can be taken to appropriate recycling center
or returned to the manufacturer.
Observe local and other applicable laws as they may mandate
special treatment for specific components or special treatment may
be ecologically sensible.

Product modified

Date:

Date:

Date:

13064.emf

2

vacon • 19 Receipt of delivery

Mounting vacon • 20

Service support: find your nearest Vacon service center at www.vacon.com

3

3. MOUNTING

VACON® 100 X is the ideal solution for a decentralised installation. It is conceived to be mounted on
a wall or directly on the motor, saving space and reducing the cabling complexity. In both of the cas­es, it must be ensured that the mounting plane is even.

3.1 Dimensions

Figure 11. VACON® 100 X drive dimensions, MM4.

Frame

Dimensions W x H x D

[mm] [in]

MM4 190.7 x 315.3 x 196.4 7.51 x 12.41 x 7.73

MM4 +HMGR 190.7 x 315.3 x 213.8 7.51 x 12.41 x 8.42

315,3

190,7

187,8

213,8

293,0

296,5

5

,

9

143,5

196,4

3

vacon • 21 Mounting

Figure 12. VACON® 100 X drive dimensions, MM5.

Frame

Dimensions W x H x D

[mm] [in]

MM5 232.6 x 367.4 x 213.5 9.16 x 14.46 x 8.41

MM5 +HMGR 232.6 x 367.4 x 230.8 9.16 x 14.46 x 9.08

367,4

203,7

230,8

180,0

345,2

349,2

6

,

1

232,6

213,5

Mounting vacon • 22

Service support: find your nearest Vacon service center at www.vacon.com

3

Figure 13. VACON® 100 X drive dimensions, MM6.

Frame

Dimensions W x H x D

[mm] [in]

MM6 349.5 x 499.8 x 235.4 13.76 x 19.68 x 9.27

MM6 +HMGR 349.5 x 499.8 x 254.2 13.76 x 19.68 x 10.00

229,6

254,2

322,0

349,5

382,8

385,3

499,8

8

,

2

235,4

3

vacon • 23 Mounting

3.2 Introduction of modules

The mechanical concept of VACON® 100 X drive is based on two segregated parts, power and con­trol, connected to each other by pluggable terminals. The power unit, called powerhead, includes
all the power electronics such as the EMC-filter, IGBTs, capacitors, choke or power boards while
the control board and the control terminals are located in the terminal box.

Figure 14. VACON® 100 X drive modules.

Powerhead

Terminal box

Mounting vacon • 24

Service support: find your nearest Vacon service center at www.vacon.com

3

3.3 Mounting

The drive consists of two main elements:

1. The terminal box that includes the power terminals and control board with the control terminals
and

2. The powerhead containing all the power electronics.

To install the drive, both parts need to be separated. The terminal box must be fixed first and all
cabling done. After this, the powerhead will be plugged on the terminal box and fixed with 4 (MM4
and MM6) or 6 (MM5) dedicated screws located on top side of the powerhead (see Figure 15.). In or­der to guarantee specified IP protection, recommended fastening torque is 2-3 Nm. The screws
should be tightened crosswise.

Figure 15. Separation of modules(MM5 example).

3

vacon • 25 Mounting

3.3.1 Wall-mounting

The drive can be mounted in vertical or horizontal position on the wall or any other relatively even
mounting plane or machine frame and fixed with the screws recommended in Table 7.

Recommended screw or bolt size for MM4 is M5, for MM5 M6 and MM6 is M8.

3.3.2 Motor-mounting

The drive can also be mounted on a motor (on top or on any side of the motor). The drive is equipped
with a cooling system independent of the motor. Motor-mounting requires special adapting com­ponents. Contact your local VACON

®

distributor for additional information.

3.3.3 Segregated modules

In order to ease replacements in case of failure, the power and the control sub-systems are en­closed in two segregated parts, connected together through pluggable terminals:

• Power-head: heat-sink enclosing all power electronics

• Terminal-box: block containing unit control and power terminals

Firstly, the terminal-box has to be fixed and the cabling has to be done. Secondly, the power-head
has to be plugged and fixed to the terminal-box with dedicated screws (see Table 8). In order to pre­serve the specified IP protection class, the recommended fastening torque is 2-3 Nm.

Frame Screw number Screw size

MM4 4 M5
MM5 4 M6
MM6 4 M8

Table 7. Screws for wall mounting.

Frame Screw number Screw size

MM4 4 M5
MM5 6 M5
MM6 4 M6

Table 8. Screws for fixing the powerhead to the terminal box.

Mounting vacon • 26

Service support: find your nearest Vacon service center at www.vacon.com

3

3.4 Cooling

The AC drive produces heat in operation and is cooled down by air circulated by a fan. The cooling
concept is independent of the motor fan.

Enough free space shall be left around the AC drive to ensure sufficient air circulation and cooling.
Different acts of maintenance may also require a certain amount of free space.

The minimum clearances given in Table 9 must not be exceeded. It is also important to ensure that
the temperature of the cooling air does not exceed the maximum ambient temperature of the con­verter.

Contact local VACON

®

distributor for more information on required clearances in different instal-

lations.

Table 9. Min. clearances around AC drive.

A = Clearance left and right from the drive
B = Clearance above the drive
C = Clearance underneath the AC drive

Figure 16. Installation space.

Table 10. Required cooling air.

Should you need further details on the cooling system of the VACON® 100 X, please contact your
local VACON

®

distributor.

Min clearance [mm]

Type A B C

All types 80 160 60

Type

Cooling air required

[m

3

/h]

MM4 140
MM5 140
MM6 280

B

C

AAA

3

vacon • 27 Mounting

Power cabling vacon • 28

Service support: find your nearest Vacon service center at www.vacon.com

4

4. POWER CABLING

The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals
marked with U, V and W. See principal connection diagram in Figure 17. See also Table 11 for the
cable recommendations for different EMC levels.

Figure 17. Principal connection diagram.

Use cables with heat resistance in accordance with the application requirements. The cables and
the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can
find on the rating plate.

Keypad

Control

U/T1

V/T2

W/T3

M

L1

L2

L3

Power unit

4

vacon • 29 Power cabling

Table 11. Cable types required to meet standards.

1 = Power cable intended for fixed installation and the specific mains voltage. Shielded cable not

required. (MCMK or similar recommended).

2 = Symmetrical power cable equipped with concentric protection wire and intended for the spe-

cific mains voltage. (MCMK or similar recommended). See Figure 18.

3 = Symmetrical power cable equipped with compact low-impedance shield and intended for

the specific mains voltage. [MCCMK, EMCMK or similar recommended; Recommended
cable transfer impedance (1...30MHz) max. 100 mOhm/m]. See Figure 18.
*360º earthing of the shield with cable glands in motor end needed for EMC level C2.

4 = Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-O or

similar).

Figure 18.

NOTE: The EMC requirements are fulfilled at factory defaults of switching frequencies (all frames).
NOTE: If safety switch is connected the EMC protection shall be continuous over the whole cable

installation.

4.1 Circuit breaker

Please disconnect the drive via an external circuit breaker. You have to provide a switching device
between supply and main connection terminals.

When connecting the input terminals to the power supply using a circuit breaker, observe that this
is of type B or type C and ensure it has a capacity of 1.5 to 2 times of the inverter’s rated current
(see Table 24 and Table 25).

NOTE: circuit breaker is not allowed in installations where C-UL is required. Only fuses are recom­mended.

EMC levels

Cable type

1st environment 2nd environment

Category C2 Category C3 Category C4

Mains cable 1 1 1
Motor cable 3* 2 2
Control cable 4 4 4

Shield

PE conductors

Shield

PE conductor

Power cabling vacon • 30

Service support: find your nearest Vacon service center at www.vacon.com

4

4.2 UL standards on cabling

To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with a
minimum heat-resistance of +70/75°C. Use Class 1 wire only.

The units are suitable for use on a circuit capable of delivering not more than 100,000 rms symmet­rical amperes, 600V AC maximum, when protected by T or J class fuses.

Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protection must be provided in accordance with the National Electrical
Code and any additional local codes.

4

vacon • 31 Power cabling

4.3 Description of the terminals

The following pictures describe the power terminals and the typical connections in Vacon® 100X
drives.

Figure 19. Power connections, MM4.

PES

AC power supply

Three phases

PE

3AC

Motor

PE

brake

resistor

Power cabling vacon • 32

Service support: find your nearest Vacon service center at www.vacon.com

4

Figure 20. Power connections, MM5.

PES

AC power supply

Three phases

PE

3AC

Motor

PE

brake

resistor

4

vacon • 33 Power cabling

Figure 21. Power connections, MM6.

PES

AC power supply

Three phases

PE

3AC

Motor

PE

brake

resistor

Power cabling vacon • 34

Service support: find your nearest Vacon service center at www.vacon.com

4

4.4 Cable dimensioning and selection

Table 12 shows the minimum dimensions of the Cu-cables and the corresponding fuse sizes.
These instructions apply only to cases with one motor and one cable connection from the AC drive

to the motor. In any other case, ask the factory for more information.

4.4.1 Cable and fuse sizes, frames MM4 to MM6

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage rating
should be selected according to the supply network. The final selection should be made according
to local regulations, cable installation conditions and cable specification. Bigger fuses than those
recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used fuse
type and impedance of the supply circuit. Consult the factory about faster fuses. VACON

®

also rec­ommends high speed J (UL & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse
ranges.

Table 12. Cable and fuse sizes for VACON® 100 X.

The terminal sizes are intended for 1 conductor. For MM6, the max. diameter of the ring terminal is 14 mm.
The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be
PVC-isolated; Max number of parallel cables is 9.

When using cables in parallel,

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

the max number of cables must be observed.
For important information on the requirements of the earthing conductor, see chapter Earthing and earth
fault protection of the standard.
For the correction factors for each temperature, see International Standard IEC60364-5-52.

Frame Type

I

INPUT

[A]

Fuse

(gG/gL)

[A]

Mains and

motor cable

Cu [mm

2

]

Ter minal ca ble size

Main terminal

[mm

2

]

Earth terminal

[mm

2

]

MM4

0003 4 - 0004 4 3.4 - 4.6 6 3*1.5+1.5

0.5—10

solid

0.5—6 stranded

M4 ring terminal

or 1—6

0007 2 - 0008 2
0005 4 - 0008 4

6.0 - 7.2

5.4 - 8.1

10 3*1.5+1.5

0.5—10

solid

0.5—6 stranded

M4 ring terminal

or

1—6

0011 2 - 0012 2
0009 4 - 0012 4

9.7 - 10.9

9.3 - 11.3

16 3*2.5+2.5

0.5—10

solid

0.5—6 stranded

M4 ring terminal or
1—6

MM5

0018 2
0016 4

16.1

15.4

20 3*6+6

0.5—16

solid

or stranded

M5 ring terminal or
1—10

0024 2
0023 4

21.7

21.3

25 3*6+6

0.5—16

solid

or stranded

M5 ring terminal or
1—10

0031 2
0031 4

27.7

28.4

32 3*10+10

0.5—16

solid or

stranded

M5 ring terminal or
1—10

MM6

0038 4 36.7 40 3*10+10 M6

ring terminal M6 ring terminal

0048 2
0046 4

43.8

43.6

50 3*16+16 M6

ring terminal M6 ring terminal

0062 2
0061 4

57.0
58,2

63 3*25+16 M6

ring terminal M6 ring terminal

0072 4 67.5 80 3*35+16 M6 ring terminal M6 ring terminal

4

vacon • 35 Power cabling

4.4.2 Cable and fuse sizes, frames MM4 to MM6, North America

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage rating
should be selected according to the supply network. The final selection should be made according
to local regulations, cable installation conditions and cable specification. Bigger fuses than those
recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used fuse
type and impedance of the supply circuit. Consult the factory about faster fuses. VACON

®

also rec­ommends high speed J (UL & CSA), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse
ranges.

Table 13. Cable and fuse sizes for VACON® 100 X.

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be
PVC-isolated; Max ambient temperature +40 °C (104 °F), max temperature of cable surface +70/+75 °C (158/
167 °F); Use only cables with concentric copper shield; Max number of parallel cables is 9.

When using cables in parallel, NOTE HOWEVER that the requirements of both the cross-sectional area and
the max number of cables must be observed.
For important information on the requirements of the earthing conductor, see standard Underwriters’ Labo­ratories UL508C.

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

Frame Type

I

INPUT

[A]

Fuse

(class T)

[A]

Mains and

motor cable

Cu

Terminal cable size

Main terminal Earth terminal

MM4

0003 4 - 0004 4 3.4 - 4.6 6

AWG14 AWG24-AWG10

AWG17-AWG10
M4

ring terminal

0007 2 - 0008 2
0005 4 - 0008 4

6.0 - 7.2

5.4 - 8.1

10

AWG14 AWG24-AWG10

AWG17-AWG10
M4

ring terminal

0011 2
0009 4

9.7

9.3

15

AWG14 AWG24-AWG10

AWG17-AWG10
M4

ring terminal

0012 2
0012 4

10.9

11.3

20

AWG14 AWG24-AWG10

AWG17-AWG10
M4

ring terminal

MM5

0018 2
0016 4

16.1

15.4

25

AWG10 AWG20-AWG5

AWG17-AWG8
M5

ring terminal

0024 2
0023 4

21.7

21.3

30

AWG10 AWG20-AWG5

AWG17-AWG8
M5

ring terminal

0031 2
0031 4

27.7

28.4

40

AWG8 AWG20-AWG5

AWG17-AWG8
M5

ring terminal

MM6

0038 4 36.7 50

AWG4

AWG13-AWG0

M6 ring terminal

AWG13-AWG2
M6

ring terminal

0048 2
0046 4

43.8

43.6

60

AWG4

AWG13-AWG0
M6

ring terminal

AWG13-AWG2
M6 ring terminal

0062 2
0061 4

57.0
58,2

80

AWG4

AWG13-AWG0
M6

ring terminal

AWG13-AWG2
M6 ring terminal

0072 4 67.5 100

AWG2

AWG9-AWG2/0
M6

ring terminal

AWG9-AWG2/0
M6 ring terminal

Power cabling vacon • 36

Service support: find your nearest Vacon service center at www.vacon.com

4

4.4.3 Brake resistor cables

VACON

®

100 X AC drives are equipped with terminals for an optional external brake resistor. These

terminals are marked with DC+/R+ and R-. See Table 27 and Table 28 for the resistor ratings.

4.4.4 Control cables

For information on control cables see chapter Control unit.

4

vacon • 37 Power cabling

4.5 Cable installation

• Before starting, check that none of the components of the AC drive is live. Read carefully the
warnings in chapter 1.

• Place the motor cables sufficiently far from other cables

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

• If the motor cables run in parallel with other cables note the minimum distances between
the motor cables and other cables given in table below.

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

•The maximum lengths of motor cables (shielded) are 100 m (MM4) and 150 m (MM5 and
MM6).

• The motor cables should cross other cables at an angle of 90 degrees.

• If cable insulation checks are needed, see chapter Cable and motor insulation checks.

Start the cable installation according to the instructions below:

Figure 22. Stripping of cables.

Distance between

cables, [m]

Shielded

cable, [m]

0.3 ≤ 50

1.0 ≤ 200

1

Strip the motor and mains cables as recommended below.

D1

B1

C1

A1

D2

C2

Earth conductor

MAINS MOTOR

Shield

E

Earth conductor

Power cabling vacon • 38

Service support: find your nearest Vacon service center at www.vacon.com

4

Table 14. Cables stripping lengths [mm].

IEC installation:

Figure 23. Cable entry plate, MM4.

Figure 24.Cable entry plate, MM5.

Frame A1 B1 C1 D1 C2 D2 E

MM4 15 70 10 30 7 30

as short as possibleMM5 20 70 10 40 10 40

MM6 20 90 15 60 15 60

2

• Remove the cable entry plate. The cable entry system is a combination of a
cable entry plate (see the figure below) and cable glands. In the cable entry
plate there are several openings available for the cables with ISO metric
thread.

• Open only the inlet holes where you need to run the cables.

3

• Choose the correct cable glands according to drive and cable size as shown in
the following pictures.

4

vacon • 39 Power cabling

Figure 25.Cable entry plate, MM6.

Figure 26.Cable gland.

4

• Cable glands must be made of plastic materials. They are used for sealing
cables passing through cable entries to ensure the characteristics of the
enclosure.

Plastic cable glands are recommend. If metal cable glands are needed, all insula­tion system requirements and all protective earthing requirements have to be ful­filled in accordance with the national electrical regulations and IEC 61800-5-1.

5

• Screw the cable glands on the cable entry holes using the proper tightening
torque as shown in Table 15.

Power cabling vacon • 40

Service support: find your nearest Vacon service center at www.vacon.com

4

Tightening torques of cable glands:

UL installation:

Figure 27.Cable entry plate, MM4 UL installation.

Frame

Gland screw

type [metric]

Tightening torque [Nm]/[lb-in.]

[Nm] lb-in.

MM4

M16 1.0 8.9
M25 4.0 35.5

MM5

M16 1.0 8.9
M25 4.0 35.5
M32 7.0 62.1

MM6

M16 1.0 8.9
M25 4.0 35.5
M40 10.0 88.7

Table 15. Tightening torque and dimension of cable glands.

6

• To connect NPT pipes to Vacon®100X, use the optional metal cable entry plate
(included in -R02 option) to meet UL installation rules.

• One metal conduit plate with accessories (screws and gasket) is delivered in a
separate bag together with the drive. See the following figures for more
details.

4

vacon • 41 Power cabling

Figure 28.Cable entry plate, MM5 UL installation.

Figure 29.Cable entry plate, MM6 UL installation.

Power cabling vacon • 42

Service support: find your nearest Vacon service center at www.vacon.com

4

Cable installation:

Tightening torques of cable terminals:

Table 16. Tightening torques of terminals.

7

• All the (3) terminal box openings are closed with the standard plastic plates
with the metric threads.

8

• The metal cable entry plate for UL installation has to be installed in place of
one of standard plastic cable entries provided with the default package. The
metal cable entry plate has three not-threaded openings: input line, motor and
I/Os and can be mounted only on left or right-hand side of the drive.

9

• Flexible or rigid cable conduit can be used.

• Use proper fittings to join and terminate rigid conduit tubing, and protect it
from damage too.

• The proper selection of electrical conduit materials, fittings, and installation
are important for safe electrical wiring.

10

• Setscrew fittings are commonly used with conduit; they provide weather tight
joints that are firm to keep the IP degree of the drive.

11

• Pass the cables (supply cable, motor cable, brake cable and I/O cables) through
the conduits (UL connections) or through the cable glands (IEC connections)
and cable entries.

12

• Detach the cable clamps and the grounding clamps.

13

Connect the stripped cables:

• Expose the shield of both cables in order to make a 360-degree connection with
the cable clamp (reverse the shield over the plastic cover of the cable and fix all
together).

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

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

Frame Type

Tightening torque

[Nm]/[lb-in.]

Power and motor

terminals

Tightening torque

[Nm]/[lb-in.]

EMC grounding

clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding terminals

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

MM4

0007 2 - 0012 2
0003 4 - 0012 4

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

MM5

0018 2 - 0031 2
0016 4 - 0031 4

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

MM6

0048 2 - 0062 2
0038 4 - 0072 4

4—5 35.4—44.3 1.5 13.3 2.0 17.7

14

• Check the connection of the earth cable to the motor and the AC drive termi­nals marked with .

4

vacon • 43 Power cabling

Control unit vacon • 44

Service support: find your nearest Vacon service center at www.vacon.com

5

5. CONTROL UNIT

Remove the powerhead of the drive to reveal the terminal box with the control terminals.
The control unit of the AC drive consists of the control board and additional boards (option boards)

connected to the slot connectors of the control board. The locations of boards, terminals and
switches are presented in Figure 30 below.

Figure 30. Locations of components in control unit.

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

Number Meaning

1 Control terminals 1-11 (see chapter 5.1.2)
2 Control terminals 12-30, A-B (see chapter 5.1.2)
3 Relay terminals (see chapter 5.1.2)
4 Thermistor input (see chapter 5.1.2)
5STO terminals
6Dip switches
7 Ethernet terminal (see chapter chapter 5.2.1)
8 Option boards

Table 17. Locations of components in control unit.

8

8

4

7

5

3

1 2

6

5

vacon • 45 Control unit

The control board can be powered externally (+24VDC, max. 1000mA, ±10%) by connecting the ex­ternal power source to terminal #30, see chapter 5.1.2. This voltage is sufficient for parameter set­ting and for keeping the control unit active. Note however that the measurements of the main circuit
(e.g. DC-link voltage, unit temperature) are not available when the mains is not connected.

5.1 Control unit cabling

The principal terminal block placement is presented in Figure 31 below. The control board is
equipped with 22 fixed control I/O terminals and the relay board with 6+2. Additionally, the termi­nals for the Safe Torque Off (STO) function (see chapter chapter 9.) can be seen in the picture below.
All signal descriptions are also given in Table 19.

Figure 31. Control terminals.

5.1.1 Control cable sizing

The control cables shall be at least 0.5 mm

2

screened multicore cables, see Table 18. The maxi-

mum terminal wire size is 2.5 mm

2

for the relay terminals and 1.5 mm2 for other terminals.

Find the tightening torques of the control and relay board terminals in Table 18.

Terminal screw

Tightening torque

Nm lb-in.

I/O terminals and STO terminals
(screw M2)

0.5 4.5

Relay terminals (screw M3) 0.5 4.5

Table 18. Control cable tightening torques.

Control unit vacon • 46

Service support: find your nearest Vacon service center at www.vacon.com

5

5.1.2 Standard I/O terminals

The terminals of the

Standard I/Os and the Relays are described below. For more information on

the connections, see chapter 7.
The terminals shown on shadowed background are assigned for signals with optional functions se-

lectable with DIP switches. See more information in chapter 5.1.5 and in chapter 5.1.6.

Table 19. Control I/O terminal signals and connection example.

Standard I/O

Term inal Signal

1 +10 Vref Reference output

2

AI1+

Analogue input,
voltage or current

3

AI1-

Analogue input com­mon

4

AI2+

Analogue input,
voltage or current

5

AI2-

Analogue input com­mon

6

24Vout 24V aux. voltage

7

GND I/O ground

8

DI1 Digital input 1

9

DI2 Digital input 2

10

DI3 Digital input 3

11

CM

Common for DI1-DI6

*

*. Can be isolated from ground, see chap-

ter chapter 5.1.6.

12

24Vout 24V aux. voltage

13

GND I/O ground

14

DI4 Digital input 4

15

DI5 Digital input 5

16

DI6 Digital input 6

17

CM Common for DI1-DI6*

18

AO1+

Analogue output,
voltage or current

19

AO-/GND

Analogue output com­mon

30 +24 Vin

24V auxiliary input
voltage

A RS485 Serial bus, negative
B RS485 Serial bus, positive

Reference

potentiometer 1...10 kΩ

Remote reference

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

mA

5

vacon • 47 Control unit

5.1.3 Relay and thermistor input terminals

5.1.4 Safe Torque off (STO) terminals

For more information on the functionalities of the Safe Torque Off (STO), see chapter 9.

Table 20. I/O terminal signals for relay and thermistor terminals and connection example.

Relays and thermistor

Term inal Signal

21

RO1/1

Relay output 1

22

RO1/2

23

RO1/3

24

RO2/1

Relay output 2

25

RO2/2

26

RO2/3

28

TI1+

Thermistor input

29

TI1-

Table 21. I/O terminal signals for the STO functions.

Safe Torque Off terminals

Ter mina l Signal

S1

Isolated digital input 1 (inter­changeable polarity);
+24V ±20% 10...15mA

G1

S2

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

G2

F+

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

F-

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

From

standard I/O

From term.

#13

From term.

#6

RUN

Control unit vacon • 48

Service support: find your nearest Vacon service center at www.vacon.com

5

5.1.5 Selection of terminal functions with dip switches

The VACON

®

100 X drive embodies five so-called dip switches that allow for three functional selec­tions each. The shadowed terminals in Table 19 can be functionally modified with the dip switches.
The switches have three positions: C, 0 and V. The switch in the position “C” means that the input
or the output has been set in current mode. The switch in the position “V” means voltage mode.The
middle position ”0” is for

Test mode. See Figure 32 to locate the switches and make appropriate

selections for your requirements. Factory defaults are: AI1 = V; AI2 = C, AO = C.

Figure 32. Dip switches for analogue inputs and analogue output.

5.1.6 Isolating digital inputs from ground

The digital inputs (terminals 8-10 and 14-16) on the standard I/O board can be isolated from ground
by setting the

dip switch to position ‘0’. The switch in the position “1” means that the common of

digital input has been connected to 24 V (negative logic). The switch in the position “2” means that
the common of digital inputs has been connected to ground (positive logic). See Figure 33. Locate
the switch and set it in desired position. Factory default is 2.

Figure 33. Digital inputs dip switch.

5

vacon • 49 Control unit

5.1.7 Bus termination of the RS485 connection

This dip switch is related to the RS485 connection. It’s used for bus termination. The bus termina­tion must be set to the first and to the last device on the network. This switch in position “0” means
that a termination resistor of 120 ohm is connected and the termination of the bus has been set.
This switch in the position “1” means that a pull-up and a pull-down resistors of 10 kOhm have been
connected for biasing purpose. The switch in the position “2” means no termination and no biasing
resistors have been connected. Factory default is 2. See Figure 34.

Figure 34. RS485 dip switch.

Control unit vacon • 50

Service support: find your nearest Vacon service center at www.vacon.com

5

5.2 I/O cabling and Fieldbus connection

The AC drive can be connected to fieldbus either through RS485 or Ethernet. The connection for
RS485 is on the standard I/O terminals (A and B) and the connection for Ethernet is left to the con­trol terminals. See Figure 35.

Figure 35.

5.2.1 Prepare for use through Ethernet

For more detailed information, see the user’s manual of the fieldbus you are using.

5.2.1.1 Ethernet cable data

Table 22. Ethernet cable data.

1

Connect the Ethernet cable (see specification on page 50) to its terminal and run the
cable through the conduit plate.

2

Remount the powerhead. NOTE: When planning the cable runs, remember to keep
the distance between the Ethernet cable and the motor cable at a minimum of 30 cm.

Connector

Shielded RJ45 connector. Note: max

length of the connector 40 mm.
Cable type CAT5e STP
Cable length Max. 100m

1234567891011

12 13 14 15 16 17 18 19 30

BA

RS485

terminals

Ethernet
connection

5

vacon • 51 Control unit

5.2.2 Prepare for use through RS485

1

Strip about 15 mm of the RS485 cable (see specification on page 52) and cut off the
grey cable shield. Remember to do this for both bus cables (except for the last
device).
Leave no more than 10 mm of the cable outside the terminal block and strip the
cables at about 5 mm to fit in the terminals. See picture below.

Also strip the cable now at such a distance from the terminal that you can fix it to the
frame with the grounding clamp. Strip the cable at a maximum length of 15 mm. Do

not strip the aluminum cable shield!

2

Then connect the cable to its appropriate terminals on VACON® 100 X AC drive stan­dard terminal block, terminals A and B (A = negative, B = positive). See Figure 35.

3

Using the cable clamp included in the delivery of the drive, ground the shield of the
RS485 cable to the frame of the AC drive.

4

If VACON® 100 X AC drive is the last device on the bus, the

bus termination must be set. Locate the DIP switches to the
top of the control unit (see Figure 32) and turn the right most
switch to position “1”. Biasing is built in the termination
resistor. See also step 6.

5

NOTE: When planning the cable runs, remember to keep the distance between the

fieldbus cable and the motor cable at a minimum of 30 cm.

10

5

Control unit vacon • 52

Service support: find your nearest Vacon service center at www.vacon.com

5

5.2.3 RS485 cable data

Table 23. RS485 cable data.

6

The bus termination must be set for the first and the last device of the fieldbus line.
See picture below and step 4. We recommend that the first device on the bus and,
thus, terminated, was the Master device.

Connector

2.5 mm

2

Cable type

STP (Shielded Twisted Pair), type Belden

9841 or similar

Cable length

Depends on the used fieldbus. See

respective bus manual.

Fieldbus

= Bus termination

Resistor = 220 ohm

Ter mi nat io n

activated

Ter mi na ti on

activated with

DIP switch

Termination

deactivated

Vacon 100X Vacon 100X Vacon 100X Vacon 100X Vacon 100X

5

vacon • 53 Control unit

5.3 Battery installation for Real Time Clock (RTC)

Enabling the functions of the Real Time Clock (RTC) requires that an optional battery is installed
in the VACON

®

100 X drive.

Detailed information on the functions of the

Real Time Clock (RTC) can be found in the Application

Manual. See the following figures to install the battery on the control box of Vacon

®

100X frequency

converter.

Figure 36. Remove the three screws on the control box.

1

Remove the three screws on the control box as shown in Figure 36.

2

Rotate and open the cover of the control box as shown in Figure 37.

Control unit vacon • 54

Service support: find your nearest Vacon service center at www.vacon.com

5

Figure 37. Open the cover of control box.

3

Install the battery in the correct place and connect it to the control box. See Figure 38
for battery location and connector.

5

vacon • 55 Control unit

Figure 38. Location and connector for the battery on the control box.

Location for battery

Connector for
battery

Commissioning vacon • 56

Service support: find your nearest Vacon service center at www.vacon.com

6

6. COMMISSIONING

Before commissioning, note the following directions and warnings:

Internal components and circuit boards of VACON® 100 X drive (except for the galvan­ically isolated I/O terminals) are live when it is connected to the mains potential.

Coming into contact with this voltage is extremely dangerous and may cause death
or severe injury.

The motor terminals U, V, W and the brake resistor terminals R-/R+ are live when
VACON

®

100 X drive is connected to the mains, even if the motor is not running.

The control I/O-terminals are isolated from the mains potential. However, the relay
outputs and other I/O-terminals may have a dangerous control voltage present

even when VACON

®

100 X drive is disconnected from the mains.

Do not make any connections to or from the frequency converter when it is connected
to the mains.

After disconnecting the AC drive from the mains, wait until the fan stops and the
indicators on the powerhead go out. Wait an additional 30 seconds before doing any

work on the connections of VACON

®

100 X Drive. Do not open the unit before this time
has expired. After expiration of this time, use a measuring equipment to absolutely
ensure that no

voltage is present.

Always ensure absence of voltage before starting

any electrical work!

Before connecting the AC drive to mains make sure that the powerhead VACON

®

100

X Drive is mounted firmly on the terminal box.

6

vacon • 57 Commissioning

6.1 Commissioning of the drive

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

Check that both the frequency converter and the motor are grounded.

Check that the mains and motor cables comply with the requirements given in
chapter 5.

Check that the control cables are located as far as possible from the power cables.

Check that the shields of the shielded cables are connected to protective earth
marked with .

Check the tightening torques of all terminals.

Check that the wires do not touch the electrical components of the drive.

Check that the common inputs of digital input groups are connected to +24V or
ground of the I/O terminal.

Check the quality and quantity of cooling air.

Check the inside of the frequency converter for condensation.

Check that all Start/Stop switches connected to the I/O terminals are in the Stop­position.

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

Run the Startup Wizard (see the Application Manual).

Commissioning vacon • 58

Service support: find your nearest Vacon service center at www.vacon.com

6

6.2 Changing EMC protection class

If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected
according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC-level T
(C4). This is done by removing the EMC screws as described below:

Figure 39. Locations of EMC screws in MM4.

Figure 40. Locations of EMC screws in MM5.

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

1

Separate the powerhead and the terminal box. Turn the powerhead upside down and
remove the two screws marked in Figure 39 (for MM4), Figure 40 (for MM5) and in
Figure 42(for MM6).

6

vacon • 59 Commissioning

Figure 41. Powerhead separated from the terminal box in MM6.

Figure 42.Locations of EMC screws in MM6.

2

CAUTION! Before connecting the AC drive to mains make sure that the EMC protec-

tion class settings of the drive are appropriately made.

3

NOTE! After having performed the change write ‘EMC level modified’ on the sticker

included in the VACON

®

100 X delivery (see below) and note the date. Unless already

done, attach the sticker close to the name plate of the AC drive.

Product modified

Date:

Date:

Date:

EMC-level modified C1->C4

DDMMYY

Commissioning vacon • 60

Service support: find your nearest Vacon service center at www.vacon.com

6

6.3 Running the motor

MOTOR RUN CHECK LIST

6.3.1 Cable and motor insulation checks

1. Motor cable insulation checks
Disconnect the motor cable from terminals U, V and W of the AC drive and from the motor.
Measure the insulation resistance of the motor cable between each phase conductor as well as
between each phase conductor and the protective ground conductor. The insulation resistance
must be >1MΩ at ambient temperature of 20°C.

2. Mains cable insulation checks
Disconnect the mains cable from terminals L1, L2 and L3 of the AC drive and from the mains.
Measure the insulation resistance of the mains cable between each phase conductor as well as
between each phase conductor and the protective ground conductor. The insulation resistance
must be >1MΩ at ambient temperature of 20°C.

3. Motor insulation checks
Disconnect the motor cable from the motor and open the bridging connections in the motor
connection box. Measure the insulation resistance of each motor winding. The measurement
voltage must equal at least the motor nominal voltage but not exceed 1000 V. The insulation
resistance must be >1MΩ at ambient temperature of 20°C.

Before starting the motor, check that the motor is mounted properly and ensure
that the machine connected to the motor allows the motor to be started.

Set the maximum motor speed (frequency) according to the motor and the machine
connected to it.

Before reversing the motor make sure that this can be done safely.

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

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

6

vacon • 61 Commissioning

6.4 Maintenance

In normal conditions, the AC drive is maintenance-free. However, regular maintenance is recom­mended to ensure trouble-free operation and longevity of the drive. We recommend the table below
is followed for maintenance intervals.

NOTE: Because of capacitor type (thin film capacitors), reforming of capacitors is not necessary.

Maintenance interval Maintenance action

Regularly and according to
general maintenance interval

• Check tightening torques of terminals

6...24 months (depending on
environment)

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

• Check operation of cooling fan

• Check the heatsink for dust and clean
if necessary

6...10 years • Change main fan
10 years • Replace the battery of the RTC.

Technical data vacon •

Service support: find your nearest Vacon service center at www.vacon.com

7

7. TECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

Table 24. Power ratings of VACON® 100 X, supply voltage 3AC 208-240V.

NOTE: The rated currents in given ambient temperatures (in Table 24) are achieved only when the
switching frequency is equal to or less than the factory default.

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

Converter

type

Input

current

[A]

Loadability

Motor shaft power

230V supply

Rated continuous

current I

N

[A]

50% overload

current

[A]

Max current

I

S

[kW] [HP]

MM4

0007 6.0 6.6 9.9 13.2 1.1 1.5
0008 7.2 8.0 12.0 16.0 1.5 2.0
0011 9.7 11.0 16.5 22.0 2.2 3.0
0012 10.9 12.5 18.8 25.0 3.0 4.0

MM5

0018 16.1 18.0 27.0 36.0 4.0 5.0
0024 21.7 24.2 36.3 48.4 5.5 7.5
0031 27.7 31.0 46.5 62.0 7.5 10.0

MM6

0048 43.8 48.0 72.0 96.0 11.0 15.0

0062 57.0 62.0 93.0 124.0 15.0 20.0

7

vacon • 63 Technical data

7.1.2 Mains voltage 3AC 380-480V

NOTE: The rated currents in given ambient temperatures (in Table 25) are achieved only when the
switching frequency is equal to or less than the factory default.

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

Converter

type

Input

current

[A]

Loadability

Motor shaft power

400V 480V

Rated continuous

current I

N

[A]

50% overload

current

[A]

Max current

I

S

[kW] [HP]

MM4

0003 3.4 3.4 5.1 6.8 1.1 1.5
0004 4.6 4.8 7.2 9.6 1.5 2.0
0005 5.4 5.6 8.4 11.2 2.2 3.0
0008 8.1 8.0 12.0 16.0 3.0 5.0
0009 9.3 9.6 14.4 19.2 4.0 5.0
0012 11.3 12.0 18.0 24.0 5.5 7.5

MM5

0016 15.4 16.0 24.0 32.0 7.5 10.0
0023 21.3 23.0 34.5 46.0 11.0 15.0
0031 28.4 31.0 46.5 62.0 15.0 20.0

MM6

0038 36.7 38.0 57.0 76.0 18.5 25.0
0046 43.6 46.0 69.0 92.0 22.0 30.0
0061 58,2 61.0 91.5 122.0 30.0 40.0

Table 25. Power ratings of VACON® 100 X, supply voltage 3AC 380-480V, high overload.

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

Converter

type

Input

current

[A]

Loadability

Motor shaft power

400V 480V

Rated continuous

current I

N

[A]

10% overload

current

[A]

Max current

I

S

[kW] [HP]

MM6

0072 67.5 72.0 80.0 108.0 37.0 50.0

Table 26. Power ratings of VACON® 100 X, supply voltage 3AC 380-480V, low overload.

Technical data vacon •

Service support: find your nearest Vacon service center at www.vacon.com

7

7.1.3 Definitions of overloadability

High overload= Following continuous operation at rated output current IN, the converter supplies 150% * IN

for 1 min, followed by a period of at least 9 min at I

N

or below.

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

must be at rated current I

N

or less.

Figure 43. High overload.

Low overload= Following continuous operation at rated output current I

N

, the converter supplies 110% * IN

for 1 min, followed by a period of at least 9 min at I

N

or below.

Example: If the duty cycle requires 110% rated current for 1 min in every 10 min, the remaining 9 min

must be at rated current I

N

or less.

Figure 44. Low overload.

NOTE! For more information, please refer to IEC61800-2 (IEC:1998) Standard.

I

N

I

N*150%

1 min 9 min

I

N*150%

Current

Time

I

N

I

N*110%

1 min 9 min

I

N*110%

Current

Time

7

vacon • 65 Technical data

7.2 Brake resistor ratings

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

Recommended minimum brake resistor values for VACON

®

100 X AC drives:

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

Frame Type

Minimum Resistance

recommended

[ohm]

Brake power @405

VDC

[kW]

MM4

0007 25 6.6
0008 25 6.6
0011 25 6.6
0012 25 6.6

MM5

0018 15 10.9
0024 15 10.9
0031 10 16.4

MM6

0048 8 20.5
0062 8 20.5

Table 27. Brake resistor ratings, 208-240V.

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

Frame Type

Minimum Resistance

recommended

[ohm]

Brake power @845

VDC

[kW]

MM4

0003 50 14.3
0004 50 14.3
0005 50 14.3
0008 50 14.3
0009 50 14.3
0012 50 14.3

MM5

0016 30 23.8
0023 30 23.8
0031 20 35.7

MM6

0038 15 47.6
0046 15 47.6
0061 15 47.6
0072 15 47.6

Table 28. Brake resistor ratings, 380-480V.

Technical data vacon •

Service support: find your nearest Vacon service center at www.vacon.com

7

7.3 VACON® 100 X - technical data

Mains connection

Input voltage U

in

3AC 208…240V
3AC 380...480V

Input voltage
tolerance

-15%...+10% continuously

Input frequency 50/60 Hz
Protection class I
Input frequency

tolerance

47.5...66 Hz

Connection to mains Once per minute or less
Starting delay <7 s

Supply network

TN- and IT-network (cannot be used with corner
earthed network)

Short-circuit current Max. short-circuit current has to be < 100kA

Motor connection

Output voltage

3AC 0... U

in

Rated output current

IN: Ambient temperature max. +40°C. See
Table 24 and Table 25.

Overload output
current

1.5 x IN (1 min/10 min);

1.1 x I

N

(1 min/10 min) only for MM6 0072.

See Table 24 and Table 25.

Starting output current

IS for 2 s every 20 s. See Table 24 and Table 25.

Output frequency 0…320 Hz (standard)
Frequency resolution 0.01 Hz
Protection class I

Motor characteristics

AC squirrel cage motors

Permanent magnet motors
Cable type Screened motor cable
Cable maximum length

(full EMC compliance)

C2: 15m

Control
characteristics

Switching frequency

Programmable 1.5…16 kHz;

Default: 6 kHz (MM4 and MM5); 4 kHz (MM6)

Automatic switching frequency derating in case of

overheating
Frequency reference

Analogue input
Panel reference

Resolution 0.1% (10-bit), accuracy ±1%

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

Braking

Brake chopper standard in all frames

External brake resistor optional

Control
connections

See chapter 5.

7

vacon • 67 Technical data

Communication
interface

Fieldbus

Standard: Serial communication (RS485/Mod-

bus); Ethernet IP, Profinet IO, Modbus TCP, Bac-

net IP

Optional: CanOpen; Profibus DP, DeviceNet, Lon-

works

Status indicators

Drive status indicators (LED) on top side (POWER,

RUN, FAULT, READY)

Ambient
conditions

Ambient operating tem­perature

-10°C …+40°C

Extended temperature
range

up to 60°C with current derating (see chapter 1.8)

Storage temperature -40°C…+70°C
Relative humidity

0 to 100% R

H

Pollution degree

PD2 used for PCB design.

However the drives are suitable for outdoor use

because of dust-tight enclosure to numeral 6

[acc. to IEC 60529].

Altitude

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

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

Stationary vibration:
sinusoidal

3 Hz ≤ f ≤ 8,72 Hz: 10 mm

8,72 Hz

≤ f ≤ 200 Hz: 3g

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

Shock/Bump

25g / 6 ms

[3M7 acc. to IEC 60721-3-3]
Degree of protection IP66/Type 4X

Noise Level

Average noise level (min­max) in dB (A)

The sound pressure depends on the cooling fan

speed, which is controlled in accordance with the

drive temperature.

MM4: 45-56

MM5: 57-65

MM6: 63-72

Directives

EMC 2004/108/EC
Low Voltage Directive 2006/95/EC
RoHS 2002/95/EC
WEEE 2012/19/EC

Standards

Immunity

EN61800-3 (2004), 1st and 2nd environment

Emissions

EN61800-3 (2004), Category C2

The drive can be modified for IT-networks.
THD EN61000-3-12 (see chapter 1.9)
Safety EN 61800-5-1

Production quality ISO 9001

Approvals

Functional Safety TÜV (Rheinland) - Tested
Electrical Safety TÜV (SÜD) - Tested
EMC TÜV - Tested
USA, Canada cULus approval, file number E171278

Technical data vacon •

Service support: find your nearest Vacon service center at www.vacon.com

7

Table 29. VACON® 100 X technical data.

Declaration of Con­formity

Korea KC mark
Australia C-tick Declaration of Conformity
Europe EC Declaration of Conformity

Protections

Undervoltage trip limit

Depends on supply voltage (0,8775*supply volt-

age):

Supply voltage 400 V: Trip limit

351 V

Supply voltage 480 V: Trip limit 421 V

Supply voltage 240 V: Trip limit 211 V
Overvoltage fault protec-

tion

Yes

Earth fault protection Ye s
Mains supervision Yes

Motor phase supervision Yes

Overcurrent protection Ye s
Unit overtemperature

protection

Yes

Motor overload protec­tion

Yes. These devices provide motor overeload pro-

tection at 105% of full load amperes.
Motor stall protection Yes
Motor underload protec-

tion

Yes

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

Yes

Thermal motor protec­tion

Yes (by PTC)

7

vacon • 69 Technical data

7.3.1 Technical information on control connections

Standard I/O

Terminal Signal Technical information

1 Reference output +10V, +3%; Maximum current 10 mA

2

Analogue input,
voltage or current

Analogue input channel 1
0-20 mA (Ri =250

Ω)

0-10 V (Ri=200k

Ω)

Resolution 0.1%, accuracy ±1%
Selection V/mA with dip-switches (see chapter 5).
Default 0-10V
Short-circuited protected.

3

Analogue input common

Differential input if not connected to ground;
Allows ±20V differential mode voltage to GND

4

Analogue input,
voltage or current

Analogue input channel 2
0-20 mA (Ri =250

Ω)

0-10 V (Ri=200k

Ω)

Resolution 0.1%, accuracy ±1%
Selection V/mA with dip-switches (see chapter 5).
Default 0-20mA
Short-circuited protected.

5

Analogue input common

Differential input if not connected to ground;
Allows 20V differential mode voltage to GND

6

24V aux. voltage

+24V, ±10%, max volt. ripple < 100mVrms; max. 250mA
Short-circuit protected

7

I/O ground

Ground for reference and controls (connected internally to frame earth
through 1M

Ω)

8

Digital input 1

Positive or negative logic
Ri = min. 5k

Ω

18…30V = "1"

0...5V = “0”

9

Digital input 2

10

Digital input 3

11

Common A for DIN1-DIN6.

Digital inputs can be isolated from ground, see chapter 5.
Default: connected to ground.

12

24V aux. voltage Same as terminal 6.

13

I/O ground

Ground for reference and controls (connected internally to frame earth
through 1M

Ω)

14

Digital input 4

Positive or negative logic
Ri = min. 5k

Ω

18…30V = "1"

0...5V = “0”

15

Digital input 5

16

Digital input 6

17

Common A for DIN1-DIN6.

Digital inputs can be isolated from ground, see chapter 5.
Default: connected to ground.

18

Analogue output,
voltage or current

Analogue output channel 1
0-20 mA (R

L

<500 Ω)

0-10 V (R

L

>1kΩ)

Resolution 0.1%, accuracy ±2%
Selection V/mA with dip-switches (see chapter 5).
Default 0-20mA
Short-circuited protected.

19

Analogue output common

30 24V auxiliary input voltage

Can be used with an external power supply (with a current limiter or fuse
protected) to supply the control unit and fieldbus for backup purposes.
Dimensioning: max. 1000mA/control unit.

Table 30. Technical information on standard I/O terminals.

Technical data vacon •

Service support: find your nearest Vacon service center at www.vacon.com

7

A RS485 Differential receiver/transmitter

Set bus termination with dip switches (see page 48).
Default: but termination disconnected.

B RS485

Relays

Relays with two change-over contact (SPDT) and a PTC thermistor input.
5,5 mm isolation between channels.

Terminal Signal Technical information

21

Relay output 1

*

*

If 230VAC is used as control voltage from the output relays, the control circuitry must be powered with a
separate isolation transformer to limit short circuit current and overvoltage spikes. This is to prevent
welding on the relay contacts. Refer to standard EN 60204-1, section 7.2.9

Switching capacity 24VDC/8A

250VAC/8A
125VDC/0.4A

Min.switching load 5V/10mA

22
23
24

Relay output 2*

Switching capacity 24VDC/8A

250VAC/8A
125VDC/0.4A

Min.switching load 5V/10mA

25
26
28

Thermistor input

Rtrip = 4.7 kΩ (PTC); Measuring voltage 3.5V

29

Table 31. Technical information on Relay and thermistor terminals.

Standard I/O

Terminal Signal Technical information

Table 30. Technical information on standard I/O terminals.

7

vacon • 71 Technical data

Options vacon • 72

Service support: find your nearest Vacon service center at www.vacon.com

8

8. OPTIONS

The options available for VACON® 100 X are described below.

8.1 Mains switch

The purpose of the Mains switch is to disconnect the VACON® 100 X from the mains when, for ex­ample, service actions are needed. The mains switch is available as option and it can be integrated
in the drive. The switch can be mounted on either side of the drive. See Figure 45.

Figure 45. The mains switch mounted on either side of the drive, MM4 example.

8.1.1 Installation

Figure 46. Disconnect the cable entry plate: example for MM5.

1

• Remove the cable entry plate from the drive on the left-hand-side if the mains
switch must be mounted on this side. Otherwise remove the cable entry plate
from the right-hand-side. See the Figure 46.

8

vacon • 73 Options

Figure 47. Cable entry plate from the bottom side of the drive.

Figure 48. Powerhead separated from the terminal box.

2

• Remove the cable entry plate from the bottom side of the terminal box by loos­ing the six screws. Cables pass through this inlet hole.

3

• Remove the powerhead from the terminal box by loosing the screws on the top
side of the drive.

Options vacon • 74

Service support: find your nearest Vacon service center at www.vacon.com

8

Figure 49. Connection of the supply cable to the Mains switch (right-hand-side example).

4

• Connect the supply cable to the Mains switch passing through the cable entry
plate of the bottom side (use the cable gland for sealing the cable to the gland
plate) and then through the terminal box as shown in the figure below.

5

• Connect the cables from the Mains switch to the terminal box. The cables have
to be connected to the terminals L1, L2 and L3.

6

• Place the Mains switch plate with the cables in the groove and fix it with its
screws.

7

• Place the cable entry plate with the other cables (motor cable, brake cable, I/O
cables) in the groove on the bottom side of the drive and fix it with its screws.

8

vacon • 75 Options

Figure 50. Mains switch, cable entry and cables connected.

Figure 51. Mount the powerhead on the terminal box.

8

• Mount the powerhead on the terminal box with its screws: the installation pro­cess has been completed. See Figure 51.

Options vacon • 76

Service support: find your nearest Vacon service center at www.vacon.com

8

8.2 Control Keypad

The control keypad is the interface between the VACON® 100 X frequency converter and the user.
With the control keypad it is possible to control the speed of a motor, to supervise the state of the
equipment and to set the frequency converter's parameters.

The keypad is an option and can be delivered separately. The option includes the keypad, the keypad
holder and three screws. You can use one screw to fix the keypad holder to the drive or three screws
to fix the keypad holder to an enclosure/cabinet or any special housing for the drive in which you
want to have a remote keypad control available.

8.2.1 Mounting onto the drive

Figure 52. Drive and the optional keypad kit.

8

vacon • 77 Options

8.2.2 Installation

Figure 53. Disconnection of the HMI cap from the drive.

Figure 54. Installation of the keypad holder on the powerhead.

1

• Remove the HMI cap from the drive as shown in the Figure 53.

2

• Install the keypad holder with a screw as shown in the Figure 54. The metal
sheets of the keypad holder have to be mounted under the fan holder as
shown in the following figures.

Options vacon • 78

Service support: find your nearest Vacon service center at www.vacon.com

8

Figure 55. Mounting of the keypad.

Figure 56. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector to

the enclosure of the drive. This is to keep the high IP66 protection degree of the drive.

3

• Connect the keypad to the drive and plug the cable on the HMI connector as
shown in the Figure 55 and in the Figure 56.

8

vacon • 79 Options

8.2.3 Wall-mounting

The keypad can be mounted on the wall in a convenient location by using the same keypad holder
and three screws provided with the keypad option kit.

Figure 57. Fix the keypad holder with three screws to the wall.

1

• Fix the keypad holder with three screws to the wall.

Options vacon • 80

Service support: find your nearest Vacon service center at www.vacon.com

8

Figure 58. Keypad connected to the drive.

2

• Connect and fix the cable to the enclosure of the drive and hold the keypad
to the wall.

8

vacon • 81 Options

8.2.4 Graphical and Text keypad

There are two keypad types you can choose for your user interface: keypad with graphical display
and keypad with text segment display (text keypad).

The button section of the keypad is identical for both keypad types.

Figure 59. Keypad buttons.

9086.emf

FUNCT

Scroll menu up
Increase value

Scroll menu down
Decrease value

Move cursor left Move cursor right

Move backward in menu
Exit edit mode
Reset faults with long press

Change control place

Access control page
Change direction

Stop button Start button

Enter active level/item
Confirm selection

Options vacon • 82

Service support: find your nearest Vacon service center at www.vacon.com

8

8.2.5 VACON® keypad with graphical display

The graphical keypad features an LCD display and 9 buttons.

8.2.5.1 Keypad display

The keypad display indicates the status of the motor and the drive and any irregularities in motor or
drive functions. On the display, the user sees information about

his present

location in the menu

structure and the item displayed.

8.2.5.2

Main menu

The data on the control keypad are arranged in menus and submenus. Use the Up and Down arrows
to move between the menus. Enter the group/item by pressing the OK button and

return

to the for-

mer level by pressing the Back/Reset button.
The

Location field indicates your current location. The Status field gives information about the

present status of the drive. See Figure 60.

Figure 60. Main menu.

8.2.5.3

Using the graphical keypad

Editing values

The selectable values can be accessed and edited in two different ways on the graphical keypad.

Parameters with one valid value

Typically, one parameter is set one value. The value is selected either from a list of values (see ex­ample below) or the parameter is given a numerical value from a defined range (e.g. 0.00...50.00
Hz).

Change value of a parameter following the procedure below:

1. Locate the parameter.

2. Enter the

Edit mode.

3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the
arrow buttons left/right if the value is numerical and then change the value with the arrow but­tons up/down.

4. Confirm change with OK button or ignore change by returning to previous level with Back/
Reset button.

Location field

Status field

(Parameter ID number

Main Menu

Quick Setup

( 17 )

Parameters

( 12 )



STOP READY I/O

ID: M1

( 5 )

Monitor



Activated group/item. Press OK to enter.

Number of items in the group

STOP/RUN

Status field
READY/NOT READY/FAULT

Control place:
PC/IO/KEYPAD/FIELDBUS

ALARM

and current menu location)

Direction

8

vacon • 83 Options

Figure 61. Typical editing of values on graphical keypad (text value).

Figure 62. Typical editing of values on graphical keypad (numerical value).

Parameters with checkbox selection

Some parameters allow selecting several values. Make a checkbox selection at each value you wish
to activate as instructed below.

Figure 63. Applying the checkbox value selection on graphical keypad



Start/St op Setup

Rem Control Place

I/O Control

KeypadStopB utton

Yes

Start Funct ion

Ramping

STOP READY I/O

ID:172 M3.2.1



Edit

Help

Add to favo rites

Rem Cont rol Place

STOP READY I/O

ID: M3.2.1



Rem Cont rol Place

STOP READY I/O

M3. 2. 1

I/O Con trol

Fieldbu sCTRL



Start/St op Setup

Rem Control Place

I/O Control

KeypadStopB utton

Yes

Start Funct ion

Ramping

STOP READY I/O

ID:172 M3.2.1



Rem Cont rol Place

STOP READY I/O

M3.2.1

I/O Con trol

Fieldbu sCTRL

OR:

OKOKOK

BACK

RESET

9257.emf

OK

9256.emf

...

OK

Symbol for checkbox selection

Options vacon • 84

Service support: find your nearest Vacon service center at www.vacon.com

8

Resetting fault

Instructions for how to reset a fault can be found in chapter 8.2.7.

Function button

The FUNCT button is used for four functions:

1. to quickly access the Control page,

2. to easily change between the Local (Keypad) and Remote control places,

3. to change the rotation direction and

4. to quickly edit a parameter value.

Control places

The control place is the source of control where the drive can be started and stopped. Every control
place has its own parameter for selecting the frequency reference source. The Local control place
is always the keypad. The

Remote control place is determined by parameter P3.2.1 (I/O or Field-

bus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O A, I/O B and Fieldbus can be used as remote control places. I/O A and Fieldbus have the lowest
priority and can be chosen with parameter P3.2.1

(Rem Control Place). I/O B, again, can bypass the

remote control place selected with parameter P3.2.1 using a digital input. The digital input is se­lected with parameter P3.5.1.7

(I/O B Ctrl Force).

Local control

Keypad is always used as control place while in local control. Local control has higher priority than
remote control. Therefore, if, for example, bypassed by parameter P3.5.1.7 through digital input
while in

Remote, the control place will still switch to Keypad if Local is selected. Switching between

Local and Remote Control can be done by pressing the FUNCT-button on the keypad or by using the
"Local/Remote" (ID211) parameter.

Changing control places

Change of control place from Remote to Local (keypad).

1. Anywhere in the menu structure, push the

FUNCT button.

2. Push the

Arrow up or the Arrow down button to select Local/Remote and confirm with the OK

button.

3. On the next display, select

Local or Remote and again confirm with the OK button.

4. The display will return to the same location as it was when the

FUNCT button was pushed. How-

ever, if the Remote control place was changed to Local (Keypad) you will be prompted for key­pad reference.

8

vacon • 85 Options

Figure 64. Changing control places.

Accessing the control page

The Control page is meant for easy operation and monitoring of the most essential values.

1. Anywhere in the menu structure, push the

FUNCT button.

2. Push the

Arrow up or the Arrow down button to select Control page and confirm with the OK

button.

3. The control page appears

If keypad control place and keypad reference are selected to be used you can set the

Keypad

Reference

after having pressed the OK button. If other control places or reference values are
used the display will show Frequency reference which is not editable. The other values on the
page are Multimonitoring values. You can choose which values appear here for monitoring.

Figure 65. Accessing Control page.

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY Keypad

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

STOP Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

?

Remote

ID:

Local/Remote

STOP READY Keypad

ID:211

Remote

Local

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

FUNCT

OK

OK

9161.emf

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

STOP Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

STOP READY Keypad

( 6 )

Keypad Reference

0.00 Hz

Output Frequency

0.00Hz

Motor Current

0.00A

Motor Torque

0.00%

0.00%

Motor Power

ID:184

Keypad

0.00 Hz

Output Frequency

0.00Hz

Motor Current

0.00A

Motor Torque

0.00%

0.00%

Motor Power

STOP READY Keypad

( 6 )

ID:168

Keypad Reference

0.00 Hz

Output Frequency

0.00Hz

Motor Current

0.00A

Motor Torque

0.00%

0.00%

Motor Power

FUNCT

OK

OK

OK

9162.emf

Options vacon • 86

Service support: find your nearest Vacon service center at www.vacon.com

8

Changing direction

Rotation direction of the motor can quickly be changed by applying the FUNCT button. NOTE! Chang-

ing direction

command is not visible in the menu unless the selected control place is Local.

1. Anywhere in the menu structure, push the Funct button.

2. Push the Arrow up or the Arrow down button to select Change direction and confirm with the OK
button.

3. Then choose the direction you wish to run the motor to. The actual rotation direction is blinking.
Confirm with the OK button.

4. The rotation direction changes immediately and the arrow indication in the status field changes.

Quick edit

Through the Quick edit functionality you can quickly access the desired parameter by entering the
parameter’s ID number.

1. Anywhere in the menu structure, push the FUNCT button.

2. Push the Arrow up or the Arrow down buttons to select Quick Edit and confirm with the OK but­ton.

3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK but­ton to confirm.

4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.)

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

ID:

Choose action

RUN Ready Keypad

ID:1805

Local/Remote

Control page

Change direction

ID:

Choose action

RUN Ready Keypad

ID:1805

Forward

Reverse

Main Menu

Parameters

( 15 )



Diagnostics



STOP READY I/O

ID: M1

( 7 )

Monitor



( 6 )

FUNCT

OK OK

9163.ai

8

vacon • 87 Options

Copying parameters

NOTE:

This feature is available with graphical keypad only.
The parameter copy function can be used to copy parameters from one drive to another.
The parameters are first saved to the keypad, then the keypad is detached and connected to another

drive. Finally the parameters are downloaded to the new drive restoring them from the keypad.
Before any parameters can successfully be copied from one drive to another the drive has to be

stopped when the parameters are downloaded.

• First go into

User settings menu and locate the Parameter backup submenu. In the Param-

eter backup

submenu, there are three possible functions to be selected:

•

Restore factory defaults will re-establish the parameter settings originally made at the fac-

tory.

• By selecting

Save to keypad you can copy all parameters to the keypad.

•

Restore from keypad will copy all parameters from keypad to a drive.

Figure 66. Parameter copy.

NOTE: If the keypad is changed between drives of different sizes, the copied values of these param-

eters will not be used:

Motor nominal current (P3.1.1.4)
Motor nominal voltage (P3.1.1.1)
Motor nominal speed (P3.1.1.3)
Motor nominal power (P3.1.1.6)
Motor nominal frequency (P3.1.1.2)
Motor cos phi (P3.1.1.5)
Switching frequency (P3.1.2.3)
Motor current limit (P3.1.3.1)
Stall current limit (P3.9.3.2)
Stall time limit (P3.9.3.3)
Stall frequency (P3.9.3.4)
Maximum frequency (P3.3.1.2)

STOP READY Keypad






Application selection

HVAC

User settings

Drive name

Drive

Parameter backup

( 3 )

ID: M6.5

STOP READY Keypad



Restore factory defaults

Parameter backup

Restore from keypad

Save to keypad

ID: M6.5.1

STOP READY Keypad










I/O and Hardware

( 8 )

Main Menu

Favourites

( 0 )

User settings

( 4 )

ID: M6

OK OK

Options vacon • 88

Service support: find your nearest Vacon service center at www.vacon.com

8

Help texts

The graphical keypad features instant help and information displays for various items.
All parameters offer an instant help display. Select Help and press the OK button.
Text information is also available for faults, alarms and the startup wizard.

Figure 67. Help text example.

Adding item to favourites

You might need to refer to certain parameter values or other items often. Instead of locating them
one by one in the menu structure, you may want to add them to a folder called

Favorites where they

can easily be reached.
To add an item to the Favorites.

Figure 68. Adding item to Favorites.

( 6 )



Digital Inp uts

Ctrl Signal 1 A

Ctrl Signal 1 B

STOP READY I/O

ID:403 M3.5.1.1

Ctrl Signal 2 A

( 6 )



Add to favo rites

STOP READY I/O

ID:403 M3.5.1.1

Ctrl signal 1 A

Edit

Help

Start Sign al 1 for cont rol P lace
I/O A . Sta rt Si gnal 1
funct ional ity chos en wi th I/ O A
Logic in S tart/Sto p Set up Me nu.

STOP READY I/O

Ctrl si gnal 1 A

ID:403 M3.5.1.1

OK

OK



Basic Setti ngs

Motor Nom V oltg

230.00 V

Motor Nom S peed

1430 rpm

STOP READY I/O

Motor Nom F req

50.00 Hz

Edit

Help

Motor N om Freq

STOP READY I/O

Add to favor ites

Motor N om Freq

was added to
favorites. Press OK
to continue.

STOP READY I/O

OK

OK

8

vacon • 89 Options

8.2.6 VACON® keypad with text segment display

You can also choose a Keypad with text segment display (Text keypad) for your user interface. It
has mainly the same functionalities as the keypad with graphical display although some of these
are somewhat limited.

8.2.6.1 Keypad display

The keypad display indicates the status of the motor and the drive and any irregularities in motor or
drive functions. On the display, the user sees information about

his present

location in the menu
structure and the item displayed. If the text on the text line is too long to fit in the display, the text
will scroll from left to right to reveal the whole text string.

8.2.6.2

Main menu

The data on the control keypad are arranged in menus and submenus. Use the Up and Down arrows
to move between the menus. Enter the group/item by pressing the OK button and

return

to the for-

mer level by pressing the Back/Reset button.

Indicators:
Status

Indicators:
Alarm, Fault

Indicators:
Direction

Indicators:
Control place

Group or parameter
name

Menu location

Options vacon • 90

Service support: find your nearest Vacon service center at www.vacon.com

8

8.2.6.3 Using the keypad

Editing values

Change value of a parameter following the procedure below:

1. Locate the parameter.

2. Enter the Edit mode by pressing OK.

3. Set new value with the arrow buttons up/down. You can also move from digit to digit with the

arrow buttons left/right if the value is numerical and change then the value with the arrow but­tons up/down.

4. Confirm change with OK button or ignore change by returning to previous level with Back/

Reset button.

Figure 69. Editing values.

Resetting fault

Instructions for how to reset a fault can be found in chapter 8.2.7.

Function button

The FUNCT button is used for four functions:

1. to quickly access the Control page,

2. to easily change between the Local (Keypad) and Remote control places,

3. to change the rotation direction and

4. to quickly edit a parameter value.

Control places

The control place is the source of control where the drive can be started and stopped. Every control
place has its own parameter for selecting the frequency reference source. The

Local control place

is always the keypad. The

Remote control place is determined by parameter P3.2.1 (I/O or Field-

bus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O A, I/O B and Fieldbus can be used as remote control places. I/O A and Fieldbus have the lowest
priority and can be chosen with parameter P3.2.1

(Rem Control Place). I/O B, again, can bypass the

remote control place selected with parameter P3.2.1 using a digital input. The digital input is se­lected with parameter P3.5.1.7

(I/O B Ctrl Force).

Local control

Keypad is always used as control place while in local control. Local control has higher priority than
remote control. Therefore, if, for example, bypassed by parameter P3.5.1.7 through digital input
while in

Remote, the control place will still switch to Keypad if Local is selected. Switching between

Local and Remote Control can be done by pressing the FUNCT-button on the keypad or by using the
"Local/Remote" (ID211) parameter.

BACK

RESET

OKOKOK

8

vacon • 91 Options

Changing control places

Change of control place from Remote to Local (keypad).

1. Anywhere in the menu structure, push the FUNCT button.

2. Using the arrow buttons, select Local/Remote and confirm with the OK button.

3. On the next display, select Local or Remote and again confirm with the OK button.

4. The display will return to the same location as it was when the

FUNCT button was pushed.

However, if the Remote control place was changed to Local (Keypad) you will be prompted for
keypad reference.

Figure 70. Changing control places.

Accessing the control page

The Control page is meant for easy operation and monitoring of the most essential values.

1. Anywhere in the menu structure, push the

FUNCT button.

2. Push the

Arrow up or the Arrow down button to select Control page and confirm with the OK

button.

3. The control page appears

If keypad control place and keypad reference are selected to be used you can set the

Keypad

Reference

after having pressed the OK button. If other control places or reference values are

used the display will show Frequency reference which is not editable.

Figure 71. Accessing Control page.

FUNCT

OK OK

9169.emf

9170.emf

FUNCT

OK

OK

Options vacon • 92

Service support: find your nearest Vacon service center at www.vacon.com

8

Changing direction

Rotation direction of the motor can quickly be changed by applying the FUNCT button.NOTE! Chang-

ing direction

command is not visible in the menu unless the selected control place is Local.

1. Anywhere in the menu structure, push the Funct button.

2. Push the Arrow up or the Arrow down button to select Change direction and confirm with the OK

button.

3. Then choose the direction you wish to run the motor to. The actual rotation direction is blinking.

Confirm with the OK button.

4. The rotation direction changes immediately and the arrow indication in the status field changes.

Quick edit

Through the Quick edit functionality you can quickly access the desired parameter by entering the
parameter’s ID number.

1. Anywhere in the menu structure, push the FUNCT button.

2. Push the Arrow up or the Arrow down buttons to select Quick Edit and confirm with the OK but-

ton.

3. Then enter the ID number of parameter or monitoring value you wish to access. Press OK but-

ton to confirm.

4. Requested Parameter/Monitoring value appears on the display (in editing/monitoring mode.)

8

vacon • 93 Options

8.2.7 Fault Tracing

When an unusual operating condition is detected by the AC drive control diagnostics, the drive ini­tiates a notification visible, for example, on the keypad. The keypad will show the code, the name
and a short description of the fault or alarm.

The notifications vary in consequence and required action.

Faults make the drive stop and require

reset of the drive.

Alarms inform of unusual operating conditions but the drive will continue run-

ning.

Info may require resetting but do not affect the functioning of the drive.

For some faults you can program different responses in the application. See parameter group Pro­tections.

The fault can be reset with the

Reset button on the control keypad or via the I/O terminal. The faults

are stored in the Fault history menu which can be browsed. The different fault codes you will find
in the table below.

NOTE: When contacting distributor or factory because of a fault condition, always write down all

texts and codes on the keypad display.

Fault appears

When a fault appears and the drive stops examine the cause of fault, perform the actions advised
here and reset the fault as instructed below.

1. With a long (1 s) press on the

Reset button on the keypad or

2. By entering the

Diagnostics Menu (M4), entering Reset faults (M4.2) and selecting Reset faults

parameter.

3.

For keypad with LCD display only: By selecting value Yes for the parameter and clicking OK.

Figure 72. Diagnostic menu with graphical keypad.

Figure 73. Diagnostic menu with text keypad.

Main Menu

( 5 )

Monito r



Parame ters

( 12 )



Diagno stics

( 6 )



ID: M4

STOP READY I/O





Diagnostics

Active faul ts

( 0 )

Fault histo ry

( 39 )

ID: M4.1

STOP READY I/O

Reset fa ults



Reset faults

Reset fault s

Help

ID: M4 .2

STOP READY I/O

OK

OK

OK

OK

Options vacon • 94

Service support: find your nearest Vacon service center at www.vacon.com

8

8.2.7.1 Fault History

In menu M4.3 Fault history you find the maximum number of 40 occurred faults. On each fault in the
memory you will also find additional information, see below.

Figure 74. Fault history menu with graphical keypad.

Figure 75. Fault history menu with text keypad.







Diagnostics

Active faul ts

( 0 )

Reset faults

Fault history

( 39 )

ID: M4.1

STOP READY I/O






!



!

!

Fault history

External Fault

Fault old

51

891384s

External Fault

Fault old

51

871061s

Device removed

Info old

39

862537s

ID:

STOP READY I/O



!

Device remo ved

ID: M4.3.3.2

Code 39

ID 380

State Info old

Date 7.12.2009

Time 04:46:33

Operating time 862537s

STOP READY I/O

OKOKOK

8

vacon • 95 Options

8.2.7.2 Fault codes

Fault

code

Fault

ID

Fault name Possible cause Remedy

1

1

Overcurrent
(hardware fault)

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

H

) in the motor cable:

• sudden heavy load increase

• short circuit in motor cables

• unsuitable motor

Check loading.
Check motor.
Check cables and connections.
Make identification run.
Check ramp times.

2

Overcurrent
(software fault)

2

10

Overvoltage
(hardware fault)

The DC-link voltage has exceeded the
limits defined.

• too short a deceleration time

• brake chopper is disabled

• high overvoltage spikes in supply

• Start/Stop sequence too fast

Make deceleration time longer.
Use brake chopper or brake
resistor (available as options).
Activate overvoltage controller.
Check input voltage.

11

Overvoltage (soft­ware fault)

3

20

Earth fault (hard­ware fault)

Current measurement has detected
that the sum of motor phase current is
not zero.

• insulation failure in cables or
motor

Check motor cables and motor.

21

Earth fault (soft­ware fault)

540

Charging switch

The charging switch is open, when the
START command has been given.

• faulty operation

• component failure

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

760

Saturation

Various causes:

• defective component

• brake resistor short-circuit or
overload

Cannot be reset from keypad.
Switch off power.
DO NOT RE-CONNECT POWER!
Contact factory.
If this fault appears simultane­ously with F1, check motor
cables and motor.

Table 32. Fault codes and descriptions.

Options vacon • 96

Service support: find your nearest Vacon service center at www.vacon.com

8

8

600

System fault

Communication between control board
and power unit has failed.

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

601

Communication between control board
and power unit has interference, but it
is still working.

602

Watchdog has reset the CPU

603

Voltage of auxiliary power in power unit
is too low.

604

Phase fault: Voltage of an output phase
does not follow the reference

605

CPLD has faulted but there is no
detailed information about the fault

606

Control and power unit software are
incompatible

Update software. Should the
fault re-occur, contact the dis­tributor near to you.

607

Software version cannot be read. There
is no software in power unit.

Update power unit software.
Should the fault re-occur, con­tact the distributor near to you.

608

CPU overload. Some part of the soft­ware (for example application) has
caused an overload situation. The
source of fault has been suspended

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

609

Memory access has failed. For exam­ple, retain variables could not be
restored.

610

Necessary device properties cannot be
read.

614

Configuration error.

647

Software error

Update software. Should the
fault re-occur, contact the dis­tributor near to you.

648

Invalid function block used in applica­tion. System software and application
are not compatible.

649

Resource overload.
Error when loading parameter initial
values.
Error when restoring parameters.
Error when saving parameters.

9

80

Undervoltage
(fault)

DC-link voltage is under the voltage
limits defined.

• most probable cause: too low a
supply voltage

• AC drive internal fault

• defect input fuse

• external charge switch not
closed

NOTE! This fault is activated only if the

drive is in Run state.

In case of temporary supply
voltage break reset the fault
and restart the AC drive. Check
the supply voltage. If it is ade­quate, an internal failure has
occurred.
Contact the distributor near to
you.

81

Undervoltage
(alarm)

10 91

Input phase Input line phase is missing.

Check supply voltage, fuses and
cable.

Fault

code

Fault

ID

Fault name Possible cause Remedy

Table 32. Fault codes and descriptions.

8

vacon • 97 Options

11 100

Output phase
supervision

Current measurement has detected
that there is no current in one motor
phase.

Check motor cable and motor.

12

110

Brake chopper
supervision
(hardware fault)

No brake resistor installed.
Brake resistor is broken.
Brake chopper failure.

Check brake resistor and
cabling.
If these are ok, the chopper is
faulty. Contact the distributor
near to you.

111

Brake chopper
saturation alarm

13 120

AC drive under­temperature
(fault)

Too low temperature measured in
power unit’s heatsink or board. Heat­sink temperature is under -10°C.

Check the ambient tempera­ture

14

130

AC drive over­temperature
(fault, heatsink)

Too high temperature measured in
power unit’s heatsink or board. Heat­sink temperature is over 100°C.

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

131

AC drive over­temperature
(alarm, heatsink)

132

AC drive over­temperature
(fault, board)

133

AC drive over­temperature
(alarm, board)

15 140

Motor stalled Motor is stalled. Check motor and load.

16 150

Motor overtem­perature

Motor is overloaded.

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

17 160

Motor underload Motor is underloaded. Check load.

19

180

Power overload
(short-time
supervision)

Drive power is too high. Decrease load.

181

Power overload
(long-time super­vision)

25

240

Motor control
fault

Start angle identification has failed.

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

241

Generic motor control fault.

26 250

Start-up pre­vented

Start-up of the drive has been pre­vented. Run request is ON when a new
software (firmware or application),
parameter setting or any other file,
which has affects the operation of the
drive, has been loaded to drive.

Reset the fault and stop the AC
drive.
Load the software and start the
AC drive.

30 530

STO fault

Emergency stop button has been con­nected or some other STO operation
has been activated.

When the STO function is acti­vated, the drive is in safe state.

32 312

Fan cooling Fan life time is up.

Change fan and reset fan life
time counter.

Fault

code

Fault

ID

Fault name Possible cause Remedy

Table 32. Fault codes and descriptions.