9.6.1 General wiring instructions ............................................................................................121
9.6.2 Checklist for commissioning ..........................................................................................121
9.7Parameters and fault tracing .........................................................................................122
9.8Maintenance and diagnostics .........................................................................................123
Safety vacon • 2
1.S
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
motors. The product is intended to be installed in a restricted access location and for a general
purpose use.
Only VACON
maintain the drive.
®
AFETY
100 X is a drive designed to control asynchronous AC motors and permanent magnet
®
authorized, trained and qualified personnel are allowed to install, operate and
1.1Signs
The cautions and warnings are marked as follows:
= DANGEROUS VOLTAGE!
= HOT SURFACE
= WARNING or CAUTION
Table 1. Warning signs.
1.2Units
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.
Physical
dimension
length1 mm0.0394 inch25.4inch
Weight1 kg2.205 lb0.4536pound
Speed
Temperature1 °C (T1)33.8 °F (T2)T2 = T1 x 9/5 + 32Fahrenheit
Torque1 Nm8.851 lbf in0.113
Power1 kW1.341 HP0.7457horsepower
SI valueUS valueConversion factorUS designation
1 min
-1
1 rpm1
revolution per
minute
pound-force
inches
Table 2. Unit conversion table.
1
vacon • 3 Safety
1.3Danger
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
this time has expired. After expiration of this time, use measuring equipment to absolutely
ensure that no
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.
voltage is present.
Always ensure absence of voltage before starting any elec-
100 X Drive. Do not open the unit before
®
Before connecting the AC drive to mains make sure that the powerhead of VACON
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.
®
100 X
1
Safety vacon • 4
1.4Warnings
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
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
dard 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.
100 X AC drives exceeds 3.5mA AC. According to stan-
is not responsible for direct or consequential
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
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.
Start/Stop logic has been selected
) and the STO inputs
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
1.5Earthing and earth fault protection
CAUTION!
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 earthingconductor 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
2
mm
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
•4 mm
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.
2
if mechanical protection is provided or
2
if mechanical protection is not provided. For cord-connected equipment, provisions
1
Safety vacon • 6
Earth connection
Metal aglet
Earth connection
Earth connection
Earth connections
Metal aglet
Earth connection
Figure 1. Earth connections and metal aglet in MM4.
Figure 2. Earth connections and metal aglet in MM5.
1
vacon • 7 Safety
Earth connectionEarth connection
Metal aglet
Metal aglet
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.
1
Safety vacon • 8
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
(*)
1.6Insulation system
Please, consider carefully the insulation system depicted in Figure 4 before connecting any circuit to the unit.
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 assem-
®
bly. Should you have any doubt or question, please contact your local VACON
distributor.
(*)
The relays may be used also with DVC A circuits. This is possible only if both relays
Figure 4. Insulation system.
are used with DVC A circuit: to mix Mains and DVC A is not allowed.
1
vacon • 9 Safety
Ambient temperature (°C)
Percent rated output current (% I
N
)
1020304050
100
75
50
25
0-10
150
60
Temperature - Output Current Derating Curve
1.7Compatibility with RCDs
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.
1.8Extended 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).
1.9Electro-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.
1
Safety vacon • 10
1.10Declaration of conformity
Figure 6. Declaration of conformity.
1
vacon • 11 Safety
1
Figure 7. STO certificate.
1
vacon • 13 Safety
1
Receipt of delivery vacon • 14
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.R
ECEIPT 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.
2
vacon • 15 Receipt of delivery
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
2.1Type 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
2
Receipt of delivery vacon • 16
2.2Unpacking 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.
Weight
Frame
[kg][lb]
MM48.819.4
MM514.932.8
MM631.569.4
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.
2.3Accessories
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:
2.3.1Frame MM4
ItemQuantityPurpose
STO terminal connector 1
M4 x 12 DIN6900-3-Combi-Delta-Tx
screw
M1-3 Cable clamp5Clamping control cables
M4 x 12 DIN6900-3-Combi-Delta-Tx
screw
M25 Cable clamp3Clamping power cables
‘Product modified’ sticker1Information about modifications
10Screws for control cable clamps
6Screws for power cable clamps
Six pin black connector (see
Figure 9) to use STO function
HMI cap
*. Provided only if the drive is delivered with the keypad.
*
Table 4. Content of accessory bag, MM4.
1Closing cap for the HMI connector
2
vacon • 17 Receipt of delivery
2.3.2Frame MM5
ItemQuantityPurpose
STO terminal connector 1
M4 x 12 DIN6900-3-Combi-Delta-Tx
screw
M1-3 Cable clamp5Clamping control cables
M4 x 12 DIN6900-3-Combi-Delta-Tx
screw
M32 Cable clamp3Clamping power cables
‘Product modified’ sticker1Information about modifications
HMI cap
*. Provided only if the drive is delivered with the keypad.
2.3.3Frame MM6
*
Table 5. Content of accessory bag, MM5.
ItemQuantityPurpose
10Screws for control cable clamps
6Screws for power cable clamps
1Closing cap for the HMI connector
Six pin black connector (see
Figure 9) to use STO function
STO terminal connector 1
M4 x 12 DIN6900-3-Combi-Delta-Tx
screw
M1-3 Cable clamp5Clamping control cables
M4 x 25 DIN6900-3-Combi-Delta-Tx
screw
M40 Cable clamp3Clamping power cables
‘Product modified’ sticker1Information about modifications
HMI cap
*. Provided only if the drive is delivered with the keypad mounted.
*
Table 6. Content of accessory bag, MM6.
10Screws for control cable clamps
6Screws for power cable clamps
1Closing cap for the HMI connector
Six pin black connector (see
Figure 9) to use STO function
2
Receipt of delivery vacon • 18
Product modified
Date:
Date:
Date:
13064.emf
2.3.4STO 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.
2.3.6Disposal
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.
2
vacon • 19 Receipt of delivery
2
Mounting vacon • 20
315,3
190,7
187,8
213,8
293,0
296,5
5
,
9
143,5
196,4
3.M
OUNTING
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.
3.1Dimensions
Figure 11. VACON® 100 X drive dimensions, MM4.
Dimensions W x H x D
Frame
[mm][in]
MM4190.7 x 315.3 x 196.47.51 x 12.41 x 7.73
MM4 +HMGR190.7 x 315.3 x 213.87.51 x 12.41 x 8.42
3
vacon • 21 Mounting
367,4
203,7
230,8
180,0
345,2
349,2
6
,
1
232,6
213,5
Figure 12. VACON® 100 X drive dimensions, MM5.
Dimensions W x H x D
Frame
[mm][in]
MM5232.6 x 367.4 x 213.59.16 x 14.46 x 8.41
MM5 +HMGR232.6 x 367.4 x 230.89.16 x 14.46 x 9.08
3
Mounting vacon • 22
229,6
254,2
322,0
349,5
382,8
385,3
499,8
8
,
2
235,4
Figure 13. VACON® 100 X drive dimensions, MM6.
Dimensions W x H x D
Frame
[mm][in]
MM6349.5 x 499.8 x 235.413.76 x 19.68 x 9.27
MM6 +HMGR349.5 x 499.8 x 254.213.76 x 19.68 x 10.00
3
vacon • 23 Mounting
Powerhead
Terminal box
3.2Introduction 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.
3
Mounting vacon • 24
3.3Mounting
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
3.3.1Wall-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.
FrameScrew numberScrew size
MM44M5
MM54M6
MM64M8
Table 7. Screws for wall mounting.
3.3.2Motor-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.
3.3.3Segregated 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.
FrameScrew numberScrew size
MM44M5
MM56M5
MM64M6
Table 8. Screws for fixing the powerhead to the terminal box.
3
Mounting vacon • 26
B
C
AAA
3.4Cooling
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
lations.
®
distributor for more information on required clearances in different instal-
Min clearance [mm]
TypeABC
All types8016060
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.
Type
Cooling air required
[m3/h]
MM4140
MM5140
MM6280
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.
3
vacon • 27 Mounting
3
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