Vacon 20CP Installation, Technical And Maintenance Manual

Download

Page 1

vacon®20 cp

ac drives

installation, Technical and Maintenance

manual

Page 2

Page 3

vacon • 0

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

INDEX

Document code (Original Instructions): DPD00489I

Order code: DOC-INS03976+DLUK

Rev. I

Revision release date: 27.1.15

1. Safety ............................................................................................................... 4

1.1 Signs ................................................................................................................................... 4

1.2 Units ................................................................................................................................... 4

1.3 Danger ................................................................................................................................ 5

1.4 Hot surface warning........................................................................................................... 5

1.5 Warnings ............................................................................................................................ 6

1.6 Earthing and earth fault protection ................................................................................... 7

1.7 Insulation system ............................................................................................................... 9

1.8 Compatibility with RCDs................................................................................................... 10

1.9 Cooling System................................................................................................................. 11

1.10 Declaration of conformity ................................................................................................ 12

2. Receipt of delivery.......................................................................................... 16

2.1 Type designation code...................................................................................................... 17

2.2 Order codes ...................................................................................................................... 18

2.3 Unpacking and lifting the AC drive .................................................................................. 19

2.4 Accessories ...................................................................................................................... 19

2.4.1 Disposal............................................................................................................................ 20

3. Mounting......................................................................................................... 22

3.1 Dimensions....................................................................................................................... 22

3.1.1 Frame MS2 three-phase version ..................................................................................... 22

3.1.2 Frame MS2 single-phase version.................................................................................... 23

3.1.3 Frame MS3 ....................................................................................................................... 24

3.2 Cooling.............................................................................................................................. 25

3.3 Environment temperature ............................................................................................... 25

3.4 Heatsink assembly instructions ...................................................................................... 25

3.5 Installation spacing .......................................................................................................... 28

3.6 Power loss thermal characteristics ................................................................................ 29

3.7 Dimensioning an external heatsink ................................................................................. 30

4. Power cabling................................................................................................. 34

4.1 Circuit breaker ................................................................................................................. 36

4.2 UL standards on cabling .................................................................................................. 36

4.3 Description of the terminals ............................................................................................ 37

4.3.1 MS2 three-phase version power connections ................................................................. 37

4.3.2 MS2 single-phase version power connections................................................................ 38

4.3.3 MS3 power connections ................................................................................................... 39

4.4 Cable dimensioning and selection................................................................................... 40

4.4.1 Cable and fuse sizes, frames MS2 to MS3....................................................................... 40

4.4.2 Cable and fuse sizes, frames MS2 to MS3, North America............................................. 41

4.5 Brake resistor cables....................................................................................................... 42

4.6 Control cables .................................................................................................................. 42

4.7 Cable installation ............................................................................................................. 43

5. Control unit .................................................................................................... 46

5.1 Control unit cabling.......................................................................................................... 49

5.1.1 Control cable sizing.......................................................................................................... 49

5.1.2 Standard I/O terminals.....................................................................................................50

5.1.3 Relay terminals ................................................................................................................ 51

Page 4

vacon • 1

5.1.4 Safe Torque off (STO) terminals ...................................................................................... 51

5.1.5 Description of additional echo connectors ...................................................................... 52

5.1.6 Led handling..................................................................................................................... 56

5.1.7 Selection of terminal functions with dip switches........................................................... 57

5.2 Fieldbus connection ......................................................................................................... 58

5.2.1 Modbus RTU protocol....................................................................................................... 59

5.2.2 Preparation for use through RS485................................................................................. 60

6. Commissioning ............................................................................................... 62

6.1 Commissioning of the drive ............................................................................................. 63

6.2 Changing EMC protection class....................................................................................... 64

6.2.1 Changing EMC protection class - MS2 three-phase version .......................................... 64

6.2.2 Changing EMC protection class - MS2 single-phase version ......................................... 66

6.2.3 Changing EMC protection class - MS3 ............................................................................ 67

6.3 Running the motor ........................................................................................................... 68

6.3.1 Cable and motor insulation checks ................................................................................. 68

6.4 Maintenance ..................................................................................................................... 69

7. Technical data ................................................................................................ 70

7.1 AC drive power ratings..................................................................................................... 70

7.1.1 Mains voltage 3AC 208-240V............................................................................................ 70

7.1.2 Mains voltage 1AC 208-240V............................................................................................ 70

7.1.3 Mains voltage 3AC 380-480V............................................................................................ 71

7.1.4 Definitions of overloadability ........................................................................................... 71

7.2 Brake resistors ................................................................................................................ 72

7.3 VACON® 20 CP - technical data ...................................................................................... 73

7.3.1 Technical information on control connections ................................................................ 76

8. Options ........................................................................................................... 78

8.1 Vacon keypad with seven-segment display ..................................................................... 78

8.2 Text keypad....................................................................................................................... 79

8.3 Menu structure................................................................................................................. 79

8.4 Using the keypad.............................................................................................................. 80

8.4.1 Main menu........................................................................................................................ 80

8.4.2 Resetting fault.................................................................................................................. 81

8.4.3 Local/Remote control button........................................................................................... 81

8.4.4 Reference menu............................................................................................................... 82

8.4.5 Monitoring menu .............................................................................................................. 83

8.4.6 Parameter menu .............................................................................................................. 84

8.4.7 System/Fault menu..........................................................................................................85

8.5 Fault tracing ..................................................................................................................... 87

8.6 Option boards ................................................................................................................... 91

8.6.1 Option board installation..................................................................................................92

9. Safe Torque Off............................................................................................... 96

9.1 General description..........................................................................................................96

9.2 Warnings .......................................................................................................................... 96

9.3 Standards ......................................................................................................................... 97

9.4 The principle of STO .........................................................................................................98

9.4.1 Technical details .............................................................................................................. 99

9.5 Connections.................................................................................................................... 100

9.5.1 Safety Capability Cat. 4 / PL e / SIL 3............................................................................. 101

9.5.2 Safety Capability Cat. 3 / PL e / SIL 3............................................................................. 103

9.5.3 Safety Capability Cat. 2 / PL d / SIL 2............................................................................. 103

9.5.4 Safety Capability Cat. 1 / PL c / SIL 1............................................................................. 104

9.6 Commissioning............................................................................................................... 105

Page 5

vacon • 2

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

9.6.1 General wiring instructions ........................................................................................... 105

9.6.2 Checklist for commissioning ......................................................................................... 105

9.7 Parameters and fault tracing......................................................................................... 106

9.8 Maintenance and diagnostics ........................................................................................ 107

Page 6

vacon • 3

Page 7

Safety vacon • 4

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

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

CP is a Cold Plate 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.

Page 8

vacon • 5 Safety

1.3 Danger

1.4 Hot surface warning

The components of the power unit of VACON® 20 CP 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) are live when VACON

20 CP 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 attached, see the indicators on the cover). Wait an additional 30 seconds before starting any work on the connections of Vacon20 Cold Plate Drive. After expiration of this time, use measuring equipment to absolutely ensure that no

voltage is present.

Always ensure absence of voltage before

starting any electrical 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

20 CP Drive is disconnected from the mains.

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. Wait until the indicators on the keypad go out (if no keypad is attached, see the indicators on the cover). Wait an additional 30 seconds before starting any work on the drive.

The metal parts of the enclosure may exceed 70°C (158 °F). Do not touch them to

a high risk of being burn.

Page 9

Safety vacon • 6

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

1.5 Warnings

VACON® 20 CP AC drive is meant for fixed installations 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 1.7 for more details.

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

The touch current of VACON

20 CP drives exceeds 3.5mA AC. According to standard EN61800-5-1, a reinforced protective ground connection must be ensured. See paragraph 1.6.

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

Only spare parts supplied by Vacon can be used.

At power-up, power brake 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

. Furthermore, 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 the motor cable, disconnect the motor cable from the AC drive.

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

20 CP. 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.

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

Page 10

vacon • 7 Safety

1.6 Earthing and earth fault protection

The VACON® 20 CP AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with .

Since the touch current exceeds 3.5 mA AC (for the three-phase version), according to EN61800-5-1, the drive 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.

Three screws (for the three-phase version) are provided for: the ORIGINAL protective earthing conductor, the SECOND protective conductor and the MOTOR protective conductor (the customer can choose the screw for each one). See Figure 1 for the location of the three screws in the two possible options available.

Figure 1. Protective earthing connections MS2 and MS3, three-phase version.

In VACON® 20 CP, the phase conductor and the corresponding protective earthing conductor can be of the same cross-sectional area, provided they are made of the same metal (because the cross-sectional area of the phase conductor is less than 16 mm

CAUTION!

Page 11

Safety vacon • 8

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

Figure 2.Protective earthing connections MS2, single-phase version.

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

if mechanical protection is provided or

•4 mm

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.

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.

Page 12

vacon • 9 Safety

1.7 Insulation system

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

20 CP:

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

• Relays (R01, R02)

(**)

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

The Control terminals (I/Os, RS485, 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 doubts or questions, please contact your local Vacon distributor.

Figure 3. Insulation system (three-phase version).

Please, consider carefully the insulation system depicted in Figure 2, before connecting any circuit to the unit.

The control unit of VACON

20 CP fulfils the insulation requirements of the standard IEC 61800-5-1 regarding DVC A circuits and also the strongest insulation requirements of IEC 60950-1 regarding SELV circuits.

POWER UNIT

L1 L2 L3

U V

R01 __

R02 __

10Vref __

Analog Inputs __

Digital Inputs__

Analog Output __

24V __

RS485 __

STO __

Keypad

CONTROL UNIT

Reinforced

Mains

DVC A

DVC A or Mains

(**)

DC-

(*)

DC+/R+ R-

Page 13

Safety vacon • 10

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

Figure 4. Insulation system (single-phase version).

1.8 Compatibility with RCDs

(*)

Only for MS3.

(**)

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

relays are used for DVC A circuitry: to mix Mains and DVC A is not allowed.

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.

POWER UNIT

L N

U V

R01 __

R02 __

10Vref __

Analog Inputs __

Digital Inputs__

Analog Output __

24V __

RS485 __

Keypad

CONTROL UNIT

Reinforced

Mains

DVC A

DVC A or Mains

(**)

DC- DC+

Page 14

vacon • 11 Safety

1.9 Cooling System

VACON® 20 CP is available as a cold-plate solution. Customers have to enclose it in their own housing and provide a suitable heatsink. However under maximum operating conditions the unit should not exceed the following temperatures:

• Temperature around the polymeric enclosure (of VACON

20 CP): max. 70 °C (158 °F)

• Temperature at the cooling-plate (of VACON

20 CP): max. 85 °C (185 °F)

Please, contact your local Vacon distributor if you need further details or support to dimension the cooling system in your final application.

NOTE: Up to 1.5 kW (Voltage range 380-480V) and 0.75 kW (Voltage range 208-240V) the drive is not equipped with external cooling fan.

Page 15

Safety vacon • 12

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

1.10 Declaration of conformity

Figure 5. Declaration of conformity.

Page 16

vacon • 13 Safety

Figure 6. STO certificate.

Page 17

Safety vacon • 14

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

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.

Page 18

vacon • 15 Safety

Page 19

Receipt of delivery vacon • 16

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

2. RECEIPT OF DELIVERY

Check 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 your supplier immediately. See paragraph 2.4.

Figure 7. Vacon package label

Marks:

3234500378

Cust. Ord. No:

Application:

FW0065V008

Firmware:

EMC level:

380-480 V

IP00

6 A

Rated current:

122245

B.ID:

M100112345

S/N:

70SCO000293-BM1X

Code:

VACON0020-3L-0006-4-CP

Type:

AC DRIVE

Rated voltage:

Protection:

Vacon type code

Rated current

Supply voltage

Application code

IP class EMC level

Serial number

CUSTOMER NAME

Customer’s order number

Batch ID

Page 20

vacon • 17 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 format of the code is as follows:

VACON0020-3L-0009-4-CP +xxxx +yyyy

+xxxx +yyyy

Additional codes. Examples of additional codes: +DBIR Dynamic Brake Internal Resistance (optional)

Page 21

Receipt of delivery vacon • 18

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

2.2 Order codes

The order codes for Vacon 20 Cold Plate drive family are shown in the following table:

For all technical details, see chapter 7.

Frame size Order code Description

Supply voltage 3AC 208-240V

MS2

VACON0020-3L-0004-2-CP 0.75 kW - 1.0 HP drive VACON0020-3L-0005-2-CP 1.1 kW - 1.5 HP drive VACON0020-3L-0007-2-CP 1.5 kW - 2.0 HP drive

MS3

VACON0020-3L-0011-2-CP 2.2 kW - 3.0 HP drive VACON0020-3L-0012-2-CP 3.0 kW - 4.0 HP drive VACON0020-3L-0017-2-CP 4.0 kW - 5.0 HP drive

Supply voltage 1AC 208-240V

MS2

VACON0020-1L-0004-2-CP 0.75 kW - 1.0 HP drive VACON0020-1L-0005-2-CP 1.1 kW - 1.5 HP drive VACON0020-1L-0007-2-CP 1.5 kW - 2.0 HP drive

Supply voltage 3AC 380-480V

MS2

VACON0020-3L-0003-4-CP 0.75 kW - 1.0 HP drive VACON0020-3L-0004-4-CP 1.1 kW - 1.5 HP drive VACON0020-3L-0005-4-CP 1.5 kW - 2.0 HP drive VACON0020-3L-0006-4-CP 2.2 kW - 3.0 HP drive VACON0020-3L-0008-4-CP 3.0 kW - 4.0 HP drive

MS3

VACON0020-3L-0009-4-CP 4.0 kW - 5.0 HP drive VACON0020-3L-0012-4-CP 5.5 kW - 7.5 HP drive VACON0020-3L-0016-4-CP 7.5 kW - 10.0 HP drive

Table 3. Order codes of Vacon 20 Cold Plate.

Page 22

vacon • 19 Receipt of delivery

2.3 Unpacking and lifting the AC drive

The weights of the AC drives vary according to frame size. Note the weights of each individual frame size in Table 4 below.

Table 4. Frame weights.

VACON® 20 Cold Plate 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.

2.4 Accessories

After lifting the converter out, check that the delivery is complete and the following accessories are included in the plastic bag:

Figure 8. STO connector.

Frame Weight [kg] Weight [lb]

MS2 2 4.4 MS3 3 6.6

Item Quantity Purpose

STO terminal connector

*. Included only in the MS2 three-phase version and MS3.

Six pin black connector (see Figure 8) to use STO function

M3.5 x 8 TapTite screw 4 Screws for control cable clamps

M1-3 Cable clamp 2 Clamping control cables

Page 23

Receipt of delivery vacon • 20

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

2.4.1 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.

13064.emf

Page 24

vacon • 21 Receipt of delivery

Page 25

Mounting vacon • 22

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

3. MOUNTING

The AC drive can be mounted on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. Both frame sizes can be mounted in any position (IP20 rating is preserved only if mounted as in the following pictures). The drive shall be fixed with two screws (or bolts, depending on the unit size).

3.1 Dimensions

3.1.1 Frame MS2 three-phase version

Figure 9. VACON® 20 Cold Plate, MS2 three-phase version.

Frame

Dimensions W x H x D

[mm] [in]

MS2 133.0 x 164.5 x 73.5 5.24 x 6.48 x 2.89

MS2 with plate 133.0 x 164.5 x 79.5 5.24 x 6.48 x 3.13

Page 26

vacon • 23 Mounting

3.1.2 Frame MS2 single-phase version

Figure 10. VACON® 20 Cold Plate, MS2 single-phase version.

Frame

Dimensions W x H x D

[mm] [in]

MS2 133.0 x 163.5 x 73.5 5.23 x 6.43 x 2.89

MS2 with plate 133.0 x 163.5 x 79.5 5.23 x 6.43 x 3.13

Page 27

Mounting vacon • 24

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

3.1.3 Frame MS3

Figure 11. VACON® 20 Cold Plate, MS3.

Frame

Dimensions W x H x D

[mm] [in]

MS3 161.0 x 246.0 x 73.5 6.34 x 9.69 x 2.89

MS3 with plate 161.0 x 246.0 x 83.0 6.34 x 9.69 x 3.27

Page 28

vacon • 25 Mounting

3.2 Cooling

The AC drive produces heat in operation due to the energy dissipation of the electronic components (rectifier and IGBT) and is cooled by a heatsink via the cold plate of the frequency converter. The capacity to dissipate this heat mainly depends on the size of the heatsink surface, the environment temperature and the heat transmission resistance. An increase of the heat transmission rate can only be realized to a certain extent by increasing the surface of the heatsink. An additional increase of the heat dissipation by increasing the heatsink is not possible. The frequency converter should be mounted with the cold plate on a heatsink with lowest thermal resistance possible.

3.3 Environment temperature

The drive environment temperature shall not exceed 70 °C (158 °F) for the drive installed location. The aluminium panel of the back of the drive is called “cold plate”. The cold plate should never exceed 85 °C (185 °F).

3.4 Heatsink assembly instructions

The VACON® 20 CP frequency converters are designed for installation on surfaces which comply with the specifications listed in this paragraph.

The heatsink surface that is in contact with the frequency converter cold plate must be free from dirt and particles. The mating surface flatness shall not exceed 50μm (DIN EN ISO 1101) across the entire mating surface, and the roughness less than 6.3 μm (DIN EN ISO 4287). The maximum peak-valley height of the surface shall not exceed 10 μm (DIN EN ISO 4287).

Apply a thermal compound between the heatsink and the AC drive cooling mating surface. The thermal paste assists the drive heat dissipation. Vacon recommends the thermal compounds listed in the following table:

Vacon recommends screen printing for applying the thermal paste. In certain cases an application by hard rubber roller might be applicable. After mounting the AC drive to the heatsink panel, wipe away any excess compound from around the plate.

The drive may be damaged if the temperature of the cooling plate exceeds specified tolerance level. Excessive heat can also shorten the performance life of the various AC drive components.

Manufacturer Type Model

Recommended spread amount

Wacker Chemie

Silicon paste for heat

dissipation

P 12

100 μm Apply the coating evenly across the

surface

Fischer Elektronik WLPF

Silicon paste for heat

dissipation

WLPF

Table 5. Recommended cold plate thermal compound.

Page 29

Mounting vacon • 26

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

Place the VACON® 20 CP on the appropriate heatsink area and tighten the screws as listed in the following table:

Figure 12. Heatsink plate for MS2 (upper view).The thickness of the plate is 6.0 mm (0.24

in).

Frame size Screw size

Tightening torque N•m

(lb•in)

MS2

M5 (according to DIN

7985 - 8.8

(with washer))

2.0 to 2.5 Nm

(17.70 to 22.13 lbf•in)

MS3

M5 (according to DIN

7985 - 8.8

(with washer))

2.0 to 2.5 Nm

(17.70 to 22.13 lbf•in)

Table 6. Screw size and tightening torque.

Tighten all screws according to specified torques. Failure to do so, may inhibit drive cooling and cause possible damage to the drive.

Frame

Dimensions W x H x D

[mm] [in]

MS2 64.0 x 110.0 x 6.0 2.52 x 4.33 x 0.24

Page 30

vacon • 27 Mounting

Figure 13. Heatsink plate for MS3 (upper view).The thickness of the plate is 9.5 mm (0.37

in).

Frame

Dimensions W x H x D

[mm] [in]

MS3 100.0 x 148.0 x 9.5 3.94 x 5.83 x 0.37

Page 31

Mounting vacon • 28

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

3.5 Installation spacing

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 7 must be respected. It is also important to ensure that the temperature of the cooling air does not exceed the maximum environment temperature of the converter.

Contact our factory for more information on required clearances in different installations.

Table 7. 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 14. Installation space.

Min clearance mm

Type A B C

All types 303030

AACA

Page 32

vacon • 29 Mounting

3.6 Power loss thermal characteristics

In the table below are the thermal characteristics of VACON® 20 CP AC drive at nominal output current. The power loss in stand-by conditions is 12 W for all sizes (supply voltage 24 V, 100 mA).

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

Frame

Converter

Type

Rated output

current [A]

Cold plate

loss [W]

Internal loss

[W]

Total loss

[W]

MS2

0004 3.7 27 18 45 0005 4.8 37 21 58 0007 7.0 58 30 88

MS3

0011 11.0 85 28 113 0012 12.5 101 37 138 0017 17.5 146 50 196

Table 8. Drive power loss at rated conditions, voltage range 3AC 208-240V.

Mains voltage 1AC 208-240V, 50/60 Hz

Frame

Converter

Type

Rated output

current [A]

Cold plate

loss [W]

Internal loss

[W]

Total loss

[W]

MS2

0004 3.7 31 22 53 0005 4.8 37 24 61 0007 7.0 59 31 90

Table 9. Drive power loss at rated conditions, voltage range 1AC 208-240V.

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

Frame

Converter

Type

Rated output

current [A]

Cold plate

loss [W]

Internal loss

[W]

Total loss

[W]

MS2

0003 2.4 23 16 39 0004 3.3 31 18 49 0005 4.3 43 21 64 0006 5.6 58 25 83 0008 7.6 84 33 117

MS3

0009 9.0 86 31 117 0012 12.0 120 37 157 0016 16.0 171 48 219

Table 10. Drive power loss at rated conditions, voltage range 3AC 380-480V.

Page 33

Mounting vacon • 30

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

3.7 Dimensioning an external heatsink

This paragraph describes a useful procedure to select a suitable heatsink for VACON® 20 CP drives.

The heatsinks are devices that enhance heat dissipation from a hot surface, usually the case of a heat generating component, to a cooler ambient, usually air. For the following discussion, air is assumed to be the cooling fluid. The primary purpose of a heatsink is to maintain the device temperature below the maximum allowable specified by the device manufacturers. Before discussing the heatsink selection process, it’s necessary to define common terms, notations and definitions and establish the concept of a thermal circuit.

Notations and definitions of the terms are as follows:

The purpose of this paragraph is to select an external heatsink by calculating its thermal resistance.

The heat transfer principle from the cold plate to the heatsink ambient air is shown in Figure

15.

Figure 15.Thermal equivalent circuit.

Symbol Description

loss

Cold plate loss: see Table 8, Table 9 or Table 10 expressed in W

CPmax

Maximum cold plate temperature expressed in °K (358 °K = 85°C)

amb

heatsink ambient temperature expressed in °K(°K = °C + 273)

Equivalent thermal resistance [K/W] of the cold plate.

HSmax

Thermal resistance of the heatsink [K/W]

Table 11. Terms and definitions for the thermal model.

loss

amb

Enclosure

Page 34

vacon • 31 Mounting

The formula to calculate the maximum thermal resistance of the heatsink is as follows:

For a given ambient temperature T

amb

the cold plate temperature T

CPmax

must not exceed the

maximum allowable value (85°C). As the R

is essentially fixed, this condition must be satis-

fied with a proper heatsink selection. The table below shows the typical values for R

for VA-

CON

20 CP:

Select a heatsink with a smaller thermal resistance than R

HSmax

. The heatsink dimensions

should be closed to the cold plate dimensions.

Note: remember that the heatsink cooling capacity can be reduced over time due to dirt.

In order to choose an heatsink from a catalogue please consider that usually the reported heat resistances are measured under free convection conditions. In this case the heatsink has to be oversized with respect to the cold plate dimensions, otherwise an additional fan must be used to reduce the heatsink resistance and its dimensions. Most heatsink manufacturers give correction factors according to various air flow speeds.

The designing factors which influence the thermal performances of an heatsink are as follows:

• Spreading resistance: Spreading resistance occurs when thermal energy is transferred from a small area to a larger area in a substance with finite thermal conductivity. In a heatsink, this means that heat does not distribute uniformly through the heatsink base. The spreading resistance phenomenon is shown by how the heat travels from the heat source location and causes a large temperature gradient between the heat source and the edges of the heatsink. This means that some fins are at a lower temperature than if the heat source were uniform across the base of the heatsink. This non uniformity increases the heatsink's effective thermal resistance.

• Heatsink manufacturer dimensioning data: the heatsink thermal resistance given in a catalogue is measured on a temperature sink to ambient differential (ΔT) and since Rhs

under free convection depends on ΔT with the power law Rth ~ ΔT

-0,25

(with laminar flow),

Frame R

MS2

=0.091 K/W

MS3

= 0,055 K/W

Table 12. Typical values for the equivalent thermal resistances of the cold plate.

If the heatsink height and width are much larger than the drive cold plate dimensions, or if multiple drives are installed on one heatsink, it may be necessary to apply correction factors to the thermal resistance value given in the heatsink specification. Contact the heatsink manufacturer.

HSmax

CPmaxTamb

–

loss

------------------------------------- RCP–=

Page 35

Mounting vacon • 32

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

a correction factor must be considered when the operating ΔT is different from what used by the heatsink manufacturer in the measurement.

• Surface finishing: the heatsink dissipation depends on the type of surface finishing of heatsink itself (anodized/black surfaces dissipate differently from polished surfaces).

• Heatsink attachment/orientation: heatsink attachment/orientation plays a significant role under natural convection. It is recommended that the heatsink be installed to orient the fins in a direction that will not block air movement under natural convection. Based practical experience, if the heatsink is oriented in a wrong way, the thermal performance will be approximately 25% worse under natural convection condition.

Note: to study the heat transfer in other cooling media of different geometry (e.g. cooling plate without fins), please contact your local Vacon supplier to receive support in dimensioning method.

Taking account of the above, we recommend that the calculated R

is multiplied by 0.7 to obtain a resistance value with a reasonable safety margin in order to ensure tripless drive operation.

Page 36

vacon • 33 Mounting

Page 37

Power cabling vacon • 34

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

4. POWER CABLING

The mains cables are connected to terminals L1, L2 and L3 (three-phase versions) and the motor cables to terminals marked with U, V and W. See principal connection diagram in Figure 16. See also Table 13 for the cable recommendations for different EMC levels.

Figure 16. Principal connection diagram (three-phase version).

* only MS3.

Figure 17. Principal connection diagram (single-phase version)

U/T1

V/T2

W/T3

DC+/R+

R-

DC-

(*)

Keypad

Control

Power unit

U/T1

V/T2

W/T3

Keypad

Control

Power unit

Page 38

vacon • 35 Power cabling

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.

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

specific 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. 100mohm/m]. See Figure 18. *360º earthing of the shield with cable glands in motor end needed for EMC category C1 and C2.

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

or similar).

Figure 18. Example with three-phase cable.

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.

EMC levels

Cable type

1st environment 2nd environment

Category C1 and C2 Category C3 Category C4

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

Table 13: Cable types required to meet standards.

Shield

PE conduc tors

Shield

PE conductor

Page 39

Power cabling vacon • 36

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

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 is has a capacity of 1.5 to 2 times the inverter’s rated

current (see Table 30). NOTE: circuit breaker is not allowed in installations where C-UL is required. Only fuses are

recommended.

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 75°C. Use Class 1 wire only.

The units are suitable for use on a circuit capable of delivering no more than 50,000 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.

Page 40

vacon • 37 Power cabling

4.3 Description of the terminals

The following pictures describe the power terminals and the typical connections in Vacon® 20 CP drives.

4.3.1 MS2 three-phase version power connections

Figure 19. Power connections, MS2 three-phase version.

Ter minal Description

L1 L2 L3

These terminals are the input connections for the power supply. 230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derating of 50%).

U/T1 V/T2 W/T3

These terminals are for motor connections.

Table 14. Description of Vacon 20CP MS2 power terminals.

PES

3AC

Motor

AC power supply

Single or

Three phases

Page 41

Power cabling vacon • 38

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

4.3.2 MS2 single-phase version power connections

Figure 20. Power connections, MS2 single-phase version.

Ter minal Description

L N

These terminals are the input connections for the power supply. Single-phase 230 VAC voltage has to be connected to L and N terminals.

U V W

These terminals are for motor connections.

Table 15. Description of Vacon 20CP MS2 power terminals (single-phase version).

PES

AC power supply single phase

3AC

Motor

Page 42

vacon • 39 Power cabling

4.3.3 MS3 power connections

Figure 21. Power connections, MS3.

Ter minal Description

L1 L2 L3

These terminals are the input connections for the power supply. 230 VAC models can be supplied by single-phase voltage by connecting to L1 and L2 terminals (with derating of 50%).

U/T1 V/T2 W/T3

These terminals are for motor connections.

Table 16. Description of Vacon 20CP MS3 power terminals.

PES

AC power supply

Single or

Three phases

3AC

Motor

Page 43

Power cabling vacon • 40

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

4.4 Cable dimensioning and selection

Table 17 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 MS2 to MS3

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 specifications. 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 17. Cable and fuse sizes for VACON® 20 CP.

The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52: Cables must be PVC-isolated; 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 chapter Earthing and earth fault protection of the standard.

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

Frame Type

INPUT

[A]

Fuse

(gG/gL)

[A]

Mains and

motor cable

Cu [mm

]

Terminal cable si z e

Main

terminal

[mm

]

Earth

terminal

MS2

0004 2 0003 4 - 0004 4

4.3

3.2 - 4.0

3*1.5+1.5

0.2 — 2.5

M4 ring

terminal

0005 2 - 0007 2 0005 4 - 0006 4

6.8 - 8.4

5.6 - 7.3

3*1.5+1.5

0.2 — 2.5

M4 ring

terminal

0008 4 9.6 10

3*2.5+2.5

0.2 — 2.5

M4 ring

terminal

MS2

1-phase

0004 2 8.3 20

(Mains) 2*1.5+1.5 (Motor) 3*1.5+1.5

0.2 — 2.5 stranded

M4 ring

terminal

0005 2 11.2 20

(Mains) 2*2.5+2.5 (Motor) 3*2.5+2.5

0.2 — 2.5 stranded

M4 ring

terminal

0007 2 14.1 25

(Mains) 2*2.5+2.5 (Motor) 3*2.5+2.5

0.2 — 2.5 stranded

M4 ring

terminal

MS3

0011 2 0009 4

13.4

11.5

3*2.5+2.5

0.5 — 16.0

M5 ring

terminal

0012 2 0012 4

14.2

14.9

3*2.5+2.5

0.5 — 16.0

M5 ring

terminal

0017 2 0016 4

20.6

20.0

3*6+6

0.5 — 16.0

M5 ring

terminal

Page 44

vacon • 41 Power cabling

4.4.2 Cable and fuse sizes, frames MS2 to MS3, North America

Table 18. Cable and fuse sizes for VACON® 20 CP, North America.

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be PVC-isolated; Max ambient temperature +30 °C, max temperature of cable surface +70 °C; 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’ Labo- ratories UL508C.

Frame Type

INPUT

[A]

Fuse

(class T)

[A]

Mains and

motor cable

Terminal cable size

Main terminal

Earth

terminal

MS2

0004 2 0003 4 - 0004 4

4.3

3.2 - 4.0

AWG14 AWG24-AWG12 AWG17-AWG10

0005 2 - 0007 2 0005 4 - 0006 4

6.8 - 8.4

5.6 - 7.3

AWG14 AWG24-AWG12 AWG17-AWG10

0008 4 9.6 10

AWG14 AWG24-AWG12 AWG17-AWG10

MS2

1-phase

0004 2 8.3 20

AWG14 AWG24-AWG12 AWG17-AWG10

0005 2 11.2 20

AWG14 AWG24-AWG12 AWG17-AWG10

0007 2 14.1 25

AWG14 AWG24-AWG12 AWG17-AWG10

MS3

0011 2 0009 4

13.4

11.5

AWG14 AWG20-AWG6 AWG17-AWG10

0012 2 0012 4

14.2

14.9

AWG12 AWG20-AWG6 AWG17-AWG10

0017 2 0016 4

20.6

20.0

AWG10 AWG20-AWG6 AWG17-AWG10

Page 45

Power cabling vacon • 42

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

4.5 Brake resistor cables

VACON® 20 CP AC drives (three-phase version) are equipped with terminals for an optional external brake resistor. These terminals are 6.3 mm Faston for MS2 and spring-type terminals for MS3. See Figure 23 and Figure 25 for the location of these terminals.

See Table 33 and Table 34 for the resistor ratings.

4.6 Control cables

For information on control cables see chapter Control unit cabling.

Page 46

vacon • 43 Power cabling

4.7 Cable installation

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

• 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 length for motor cables is 30m

• 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.

Table 19. Cables stripping lengths [mm].

Distance between cables, [m] Shielded cable, [m]

0.3 ≤ 50

1.0 ≤ 200

Strip the motor and mains cables as recommended below.

Frame A1 B1 C1 D1 C2 D2 E

MS2 888203620

Leave as short

as possible

MS2

1-phase

788203620

MS3 888203620

Earth conductor

MAINS MOTOR

Shield

Earth conductor

MAINS

(1-phase)

Page 47

Power cabling vacon • 44

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

Tightening torques of cable terminals:

Table 20. Tightening torques of terminals.

Connect the stripped cables:

• Expose the shield of both cables in order to make a 360-degree connection with the cable clamp.

• 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

Power and motor

terminals

Tightening torque

EMC grounding

clamps

Tightening torque,

Grounding terminals

[Nm] lbs-in. [Nm] lbs-in. [Nm] lbs-in.

MS2

0003 4—0008 4 0004 2—0007 2

0.5—0.6 4.5—5.3 1.5 13.3 2.0 17.7

MS3

0009 4—0016 4 0011 2—0017 2

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

Page 48

vacon • 45 Power cabling

Page 49

Control unit vacon • 46

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

5. CONTROL UNIT

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 23, Figure 24 and Figure 25.

Figure 23. Locations of the components in control unit of MS2 (three-phase version).

Number Meaning

1 Control terminals A-20 2 STO terminals (only in three-phase version) 3 Relay terminals 4 Option board terminals 5 STO Jumpers (only in three-phase version) 6DIP switches 7Status LEDs 8 HMI connector (RJ45 keypad connector)*

9 Optional brake resistor terminals 10 Supply voltage connector for external fan 11 Control terminals A-20 echo connector 12 HMI echo connector (keypad connector) 13 DC-bus terminals

Table 21. Locations of components in control unit

The HMI connector is only to connect the keypad and not for Ethernet comunica-

tion.

Page 50

vacon • 47 Control unit

Figure 24. Locations of the components in control unit of MS2 (single-phase version).

Figure 25. Location of the components in the control unit of MS3.

Page 51

Control unit vacon • 48

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

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

The control board can be powered externally by connecting an external power source (about 130-150mA at 24VDC are needed to supply the control board without keypad, option board or other loads) between terminal #6 and GND, see chapter 5.1.2. To ensure that the external supply works with any configurations we recommend to use an external supply of +24VDC ±10%, 1000mA overcurrent protected.

This voltage is sufficient for parameter setting and for keeping the control unit active. Note however that the values of the measurements of the main circuit (e.g. DC-link voltage, unit temperature) are not available when the mains is not connected.

In addition to the internal fan, VACON

20 CP frequency converters include an auxiliary fan power supply connector (see 10 in the Figure 23, Figure 24 and Figure 25) for improved air flow and system cooling. The power supply also has automatic thermal switching on/off control: it automatically switches on/off depending on internal cold plate temperature. The electric specifications for the auxiliary fan power supply are shown in the following table:

The connector for the auxiliary fan supply is a Micro-Fit 3.0

Header, Surface Mount Compatible, Single Row, Vertical with PCB Polarizing Peg by Molex (part number 43650-0215). This connection is echoed in the HMI echo connector. See Figure 23, Figure 24 and Figure 25 for the location of the connectors and Table 28 for the description of the HMI echo terminal.

To connect the auxiliary fan to VACON

20 CP drives you will need a Micro-Fit 3.0™ Receptacle

Crimp Housing, Single Row by Molex

(part number 43645-0200). See the picture below for

more details.

Figure 26. Micro-Fit 3.0™ Housing.

Terminals

SIgnals

MS2 MS3

FAN+

24VDC ±10% maximum output current 200mA

24VDC ±10% maximum output current 700mA

FAN- GND GND

Table 22. Electric specifications for the auxiliary fan power supply.

FAN+

FAN-

Page 52

vacon • 49 Control unit

5.1 Control unit cabling

The principal terminal block placement is shown in Figure 27 below. The control board is equipped with 23 fixed control I/O terminals. Additionally, the terminals for the Safe Torque Off (STO) function (see chapter 9) can be seen in the picture below. All signal descriptions are also given in Table 24.

Figure 27. Control terminals.

5.1.1 Control cable sizing

The control cables shall be at least 0.14 mm

screened multi core cables, see Table 23. The

maximum terminal wire size for the I/O terminals is 1.5 mm

Find the tightening torques of the I/O (control and relays) and STO terminals in the Table below.

Terminal screw

Tightening torque

Nm lbs-in.

I/O terminals and STO terminals (screw M2)

0.22 min

0.25 max

1.95 min

2.21 max

Table 23. Control cable tightening torques.

Page 53

Control unit vacon • 50

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

5.1.2 Standard I/O terminals

The terminals of the

Standard I/O are described below. For more information on connections,

see chapter 7.3.1. The terminals shown on shadowed background are assigned for signals with optional functions

selectable with DIP switches. For more information, see chapter 5.1.7.

Table 24. Control I/O terminal signals and connection example.

Standard I/O terminals

Terminal Signal

A RS485_A Serial bus, negative B RS485_B Serial bus, positive

1 +10 Vref Reference output

AI1+

Analogue input, voltage or current

GND I/O signal ground

24Vout 24V aux. voltage

DIN COM

Digital inputs common

DI1 Digital input 1

DI2 Digital input 2

DI3 Digital input 3

AI2+

Analogue input, voltage or current

GND I/O signal ground

DO1-

Digital output 1 common

DI4 Digital input 4

DI5 Digital input 5

DI6 Digital input 6

AO1+

Analogue signal (+output)

20 DO1+ Digital output 1

Remote reference

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

Reference potentiometer

1...10kΩ

Page 54

vacon • 51 Control unit

5.1.3 Relay terminals

5.1.4 Safe Torque off (STO) terminals

For more information on the functionalities of the Safe Torque Off (STO), see chapter 9. This function is available only in the three-phase version.

Table 25. I/O terminal signals for relays and connection example.

Relays terminals

Terminal Signal

RO1/2

Relay output 1

RO1/3

RO2/1

Relay output 2

RO2/2

RO2/3

Table 26. I/O terminal signals for the STO functions.

Safe Torque Off terminals

Ter minal Signal

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

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

F+

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

F-

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

From

standard I/O board

From term.

RUN

Page 55

Control unit vacon • 52

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

5.1.5 Description of additional echo connectors

In this paragraph you will find the description of the additional echo connectors for the I/O terminals and for the HMI.

Figure 28. The I/O remote echo connector mounted on the control board.

In Figure 28 the view of Molex® connector for the I/O terminals is shown. In the control unit the position of this connector is numbered with 11 as shown in Figure 23 and Figure 25. The type of this connector is Pico-Clasp™ Wire-to Board PCB Header, Dual Row, RIght Angle. The code by Molex

is: 501571-2007.

It mates with Pico-Clasp™ Wire-to Board Receptacle Housing (crimp housing), Dual Row, 20 Circuits. The code by Molex

is: 501189-2010. See Figure 29.

Figure 29. Receptacle housing for I/O remote echo connector.

Page 56

vacon • 53 Control unit

To connect I/Os to the control unit through echo terminals this connector has to be used. In the following table, the correspondence between the pins of this connector and the VACON

20 CP

terminals is shown.

Pin number Signal Description

1 RS485_B Serial bus, positive

2 DI2 Digital input 2

3 RS485_A Serial bus, negative

4 DI3 Digital input 3

5 NC not connected

6AI2+

7 NC not connected

8GND

9 +10Vref

10 DO1- common for digital output 1

11 AI1+

12 DI4 Digital input 4

13 GND

14 DI5 Digital input 5

15 24Vout

16 DI6 Digital input 6

17 DIN COM

18 AO1+ Analogue output 1

19 DI1 Digital input 1

20 DO1+ Digital output 1

Table 27. I/O remote connector description.

Page 57

Control unit vacon • 54

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

Figure 30. HMI remote connector.

In Figure 30 the view of Molex® connector for the HMI terminals is shown. In the control box the position of this connector is numbered with 8, as shown in Figure 23 and Figure 25. The type of connector is Pico-Clasp™ Wire-to-Board Header, Surface Mount, Single Row, Vertical, with Positive Lock. The code by Molex

is: 501331-1507.

It mates with Pico-Clasp™ Wire-to Board Female Housing (crimp housing), Single Row, with Positive lock, 15 Circuits. The code by Molex

is: 501330-1500.

To connect HMI to the control unit through echo terminals this connector has to be used. In the following table, the correspondence between the pins of this connector and the VACON

20 CP

HMI terminals is shown.

Pin number in RJ45

connector

Pin number of echo

connector

Signal Description

2 15 +24V Panel supply

6 14 +3.3V Panel supply

5 13 GND ground

Table 28. HMI remote connector description with RJ45 correspondences.

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Page 58

vacon • 55 Control unit

112Keyp_TX+

RS422 (connection for panel

communication)

4 11 Keyp_TX-

3 10 Keyp_RX+

79Keyp_RX-

8 8 Led_CTRL1 Control signal for LED1

- 7 Led_CTRL2 Control signal for LED2

- 6 Led_CTRL3 Control signal for LED3

- 5 FAN+ External FAN+(+24V)

- 4 FAN- GND for external FAN

- 3 nc not connected

- 2 nc not connected

- 1 nc not connected

Pin number in RJ45

connector

Pin number of echo

connector

Signal Description

Table 28. HMI remote connector description with RJ45 correspondences.

Page 59

Control unit vacon • 56

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

5.1.6 Led handling

As VACON

20 Cold plate is often without the keypad, on the plastic cover of the drive there are

4 status LEDs. See the picture below.

Figure 31. LED position on the MS2 cover.

Led “PWR” (orange led) means the drive is supplied by mains. Led “RUN” (green led) means the drive is running. Led “FLT” (red led) means the drive is experiencing a fault. Led “RDY” (orange led) means the drive is ready and no fault is present. When a Warning is ac-

tive, the led starts blinking.

Page 60

vacon • 57 Control unit

5.1.7 Selection of terminal functions with dip switches

VACON

20 Cold Plate drive embodies four so-called switches that allow for two functional selections each. The shadowed terminals in Table 24 can be functionally modified with the dip switches.

The switches have two positions: 0 and 1. See Figure 32 to locate the switches and make appropriate selections for your requirements.

Figure 32. Dip switches

5.1.7.1

Switch SW1

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 SW1 to position ‘1’. See Figure 32. Locate the switch and set

it in the desired position. The switch in the position “0” means that the common of digital input have been connected to the ground.The default position is “0”.

5.1.7.2 Switches SW2 and SW3

Analogue inputs can be used as either current inputs or voltage inputs. The signal type is selected with two switches on the control board.

The switch SW2 is related to analogue input AI1. In position “1” the analogue input AI1 works in voltage mode. In position “0” the analogue input works in current mode. The default position for SW2 is “1”.

The voltage range is 0...10V and the current is 0/4.....20 mA.

The switch SW3 is related to analogue input AI2. In the position “1” the analogue input AI2 works in voltage mode. In the position “0” the analogue input works in current mode. The default position for SW3 is “0”.

The voltage range is 0...10V and the current is 0/4.....20 mA.

5.1.7.3 Switch SW4

The switch SW4 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. The switch SW4 in position “0” means that termination resistance is connected and the termination of the bus has been set. If the Vacon 20 CP is the last device on the net, this switch must be set to “0” position. The default position for SW4 is “0”.

Page 61

Control unit vacon • 58

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

5.2 Fieldbus connection

Modbus is a communication protocol developed by Modicon systems. In other words, it is a way of sending information between electronic devices. The device requesting the information is called the Modbus Master and the devices supplying information are Modbus Slaves. In a standard Modbus network, there is one Master and up to 247 Slaves, each with a unique Slave Address from 1 to 247. The Master can also write information to the Slaves. Modbus is typically used to transmit signals from instrumentation and control devices back to a main controller or data gathering system.

The Modbus communication interface is built around messages. The format of these Modbus messages is independent of the type of physical interface used. The same protocol can be used regardless of the connection type. Thanks to this, Modbus allows for the easy upgrade of the hardware structure of an industrial network, without the need for significant changes in the software. A device can also communicate with several Modbus nodes at once, although they are connected with different interface types, without the need to use a different protocol for every connection.

Figure 33.Basic structure of Modbus frame.

On simple interfaces such as RS485, the Modbus messages are sent in plain form over the network. In this case the network is dedicated to Modbus.

Each Modbus message has the same structure. Four basic elements are present in each message. The sequence of these elements is the same for all messages, to make it easy to parse the content of the Modbus message. A conversation is always started by a master in the Modbus network. A Modbus master sends a message and — depending on the contents of the message — a slave takes action and responds to it. There can be more masters in a Modbus network. The address in the message header is used to define which device should respond to a message. All other nodes on the Modbus network ignore the message if the address field doesn't match their own address.

Page 62

vacon • 59 Control unit

5.2.1 Modbus RTU protocol

VACON

20 CP drive is equipped with Modbus support as standard. The AC drive can be connected to fieldbus through RS485. The connection for RS485 is on the standard I/O (terminals A and B). See Figure 34.

Figure 34. Position of the RS485 terminals on the I/O standard terminal connector.

Connections and communications

Interface RS-485

Data transfer method RS-485 MS/TP, half-duplex

Transfer cable

STP (shielded twisted pair), type

Belden 9841 or similar

Connector

2.5 mm

Electrical isolation Functional

Modbus RTU

As described in “Modicon Modbus

Protocol Reference Guide”

Baud rate

300, 600, 1200, 2400, 4800, 9600,

19200, 38400 and 57600 baud

Addresses 1 to 247

Table 29.

Page 63

Control unit vacon • 60

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

5.2.2 Preparation for use through RS485

Strip about 15 mm of the RS485 cable (see specification on Table 29) 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 aluminium cable shield!

Then connect the cable to its appropriate terminals on VACON® 20 CP AC drive standard terminal block, terminals A and B (A = negative, B = positive).

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

If VACON® 20 Cold Plate drive is the last device on the bus, the bus termination must be set. Locate the

switches to the right of the control terminals (see Figure 32) and turn the SW4 switch to position “0”. Biasing is built in the termination resistor.

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.

The bus termination must be set for the first and the last device of the fieldbus line. We recommend that the first device terminated is the Master device.

Page 64

vacon • 61 Control unit

Page 65

Commissioning vacon • 62

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

6. COMMISSIONING

Before commissioning, note the following directions and warnings:

Internal components and circuit boards of VACON® 20 CP drive (except for the galvanically isolated I/O terminals) are live when it 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 and the brake resistor terminals are live when VACON

20 CP drive is connected to 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

20 CP drive is disconnected from 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 indicators on the cover go out. Wait additional 30 seconds before doing any work on the connec-

tions of VACON

20 CP 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!

Page 66

vacon • 63 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 4.

Check that the control cables are located as far as possible from the power cables, see chapter 4.4.

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 the in Stopposition.

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

Page 67

Commissioning vacon • 64

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

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 as described below:

6.2.1 Changing EMC protection class - MS2 three-phase version

Figure 35.Changing of the EMC class in MS2 (three-phase version).

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

Remove the three screws on the EMC plate from the unit.

Page 68

vacon • 65 Commissioning

Figure 36. Changing of the EMC class in MS2 (three-phase version).

Remove the EMC plate from the unit. Then lift the plate with pliers to disconnect the EMC plate from the ground. See Figure 36.

Then reconnect the EMC plate to the unit.

Page 69

Commissioning vacon • 66

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

6.2.2 Changing EMC protection class - MS2 single-phase version

Figure 37. Changing the EMC class in the MS2 (single-phase version).

Remove the EMC screw as shown in the Figure 37.

Page 70

vacon • 67 Commissioning

6.2.3 Changing EMC protection class - MS3

Figure 38. Changing the EMC class in the MS3.

Remove the EMC screw as shown in the Figure 38.

CAUTION! Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made.

Page 71

Commissioning vacon • 68

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

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 (L), L2 (N) 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.

Page 72

vacon • 69 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.

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 for corrosion on terminals and other surfaces

• Check door filter in case of cabinet installation

24 months • Clean heatsink

12...24 months

• Charge capacitors, only after long storage times or long down times without supply: contact your nearest Vacon service center

Page 73

Technical data vacon • 70

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

7. TECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240V

Table 30. Power ratings of VACON® 20 CP, supply voltage 3AC 208-240V.

NOTE: The rated currents in given ambient temperatures (in Table 30) are achieved only when the switching frequency is equal to or less than the factory default.

7.1.2 Mains voltage 1AC 208-240V

Table 31. Power ratings of VACON® 20 CP, supply voltage 1AC 208-240V.

NOTE: The rated currents in given ambient temperatures (in Table 31) 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 230V

Rated continuous

current I

[A]

50% overload

current

[A]

Max current

[kW] [HP]

MS2

0004 4.3 3.7 5.6 7.4 0.75 1.0 0005 6.8 4.8 7.2 9.6 1.1 1.5 0007 8.4 7.0 10.5 14.0 1.5 2.0

MS3

0011 13.4 11.0 16.5 22.0 2.2 3.0 0012 14.2 12.5 18.8 25.0 3.0 4.0 0017 20.6 17.5 26.3 35.0 4.0 5.0

Mains Voltage 1AC 208-240V, 50/60 Hz

Converter

type

Input

current

[A]

Loadability

Motor shaft power

230V 230V

Rated continuous

current I

[A]

50% overload

current

[A]

Max current

[kW] [HP]

MS2

0004 8.3 3.7 5.6 7.4 0.75 1.0 0005 11.2 4.8 7.2 9.6 1.1 1.5 0007 14.1 7.0 10.5 14.0 1.5 2.0

Page 74

vacon • 71 Technical data

7.1.3 Mains voltage 3AC 380-480V

NOTE: The rated currents in given ambient temperatures (in Table 32) are achieved only when the switching frequency is equal to or less than the factory default.

7.1.4 Definitions of overloadability

Overloadability =Following continuous operation at rated output current IN, the converter supplies

150% * I

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

or less.

Figure 39. 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

[A]

50% overload

current

[A]

Max current

[kW] [HP]

MS2

0003 3.2 2.4 3.6 4.8 0.75 1.0 0004 4.0 3.3 5.0 6.6 1.1 1.5 0005 5.6 4.3 6.5 8.6 1.5 2.0 0006 7.3 5.6 8.4 11.2 2.2 3.0 0008 9.6 7.6 11.4 15.2 3.0 4.0

MS3

0009 11.5 9.0 13.5 18.0 4.0 5.0 0012 14.9 12.0 18.0 24.0 5.5 7.5 0016 20 16.0 24.0 32.0 7.5 10.0

Table 32. Power ratings of VACON® 20 CP, supply voltage 3AC 380-480V.

N*150%

1 min 9 min

N*150%

Current

Time

Page 75

Technical data vacon • 72

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

7.2 Brake resistors

Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application. Brake chopper is available only in threephase version.

Recommended brake resistor values for Vacon 20 CP AC drives:

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

Frame Type

Minimum Resistance

recommended [Ohm]

MS2

0004 50 0005 50 0007 50

MS3

0011 25 0012 25 0017 25

Table 33. Brake resistor ratings, 3AC 208-240V.

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

Frame Type

Minimum Resistance

recommended [Ohm]

MS2

0003 100 0004 100 0005 100 0006 100 0008 100

MS3

0009 50 0012 50 0016 50

Table 34. Brake resistor ratings, 3AC 380-480V.

Page 76

vacon • 73 Technical data

7.3 VACON® 20 CP - technical data

Mains connection

Input voltage U

3AC 208…240V 1AC 208…240V

3AC 380…480V Input voltage tolerance -15%…+10% continuously Input frequency 50/60 Hz Input frequency

tolerance

45…66 Hz

Protection class I Connection to mains Once per minute or less Starting delay 4 s

Supply network

IT and TN-networks (cannot be used with cor-

ner earthed networks) Short-circuit current Maximum short-circuit current has to be <50kA

DC connection

Available as standard in MS2 single-phase

frames and MS3

Motor connection

Output voltage

0…U

Rated output current

IN: Enclosure temperature max. +70°C.

See Table 30 , Table 31 and Table 32. Overload output cur-

rent

1.5 x IN (1 min/10 min)

Starting current

IS for 2 s every 20 s (IS = 2.0 * IN) Output frequency 0…320 Hz

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 30 m

Control characteristics

Switching frequency

Programmable 2…16 kHz;

Default 6 kHz.

Automatic switching frequency derating in case

of overheating Frequency reference:

Analogue input Panel reference

Resolution ±0.05% (11-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 three-phase

frames. External brake resistor optional.

Control connections

See Chapter 5.

Page 77

Technical data vacon • 74

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

Communication interface

Fieldbus

Standard: Serial communication (RS485/Mod-

bus);

Optional: CANopen; Profibus DP, Lonworks,

DeviceNet, Profinet IO, Ethernet IP, Modbus

TCP, EtherCAT, AS-interface

Status indicators

Drive status indicators (LED) on front side

(POWER, RUN, FAULT, READY)

Ambient conditions

Enclosure operating temperature

-10°C (no frost)…+70°C

Storage temperature -40°C…+85°C

Relative humidity

0 to 95% RH, non-condensing, non-corrosive,

no dripping water Pollution degree PD2

Altitude

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

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

Degree of protection

MS2 (three-phase version): IP00

MS2 (single-phase version): IP20

MS3: IP20

Stationary vibration: Sinusoidal

MS2 (three-phase version):

3 Hz ≤ f ≤ 9Hz: 10mm

9 Hz ≤ f ≤ 200Hz: 3g

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

MS2 (single-phase version) and MS3:

3 Hz ≤ f ≤ 8,43 Hz: 7,5 mm

8,43 Hz ≤ f ≤ 200 Hz: 2g

[3M6 acc. to IEC 60721-3-3]

Shock/Bump:

MS2 (three-phase version):

25g / 6 ms

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

MS2 (single-phase version) and MS3:

25g / 6 ms

[3M6 acc. to IEC 60721-3-3]

Directives

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

Page 78

vacon • 75 Technical data

Table 35. VACON® 20 Cold Plate technical data.

Standards

Immunity

EN61800-3: 2004 + A1: 2011, 1st and 2nd envi-

ronment

Emissions

EN61800-3: 2004 + A1: 2011,

3-phase version

Category C2 as standard for conducted and radiated emissions

1-phase version

Category C1 as standard for conducted emissions

Category C2 as standard for radiated emissions. It can be C1 with a suitable enclosure and cabling.

The drive can be modified to category C4. Safety EN 61800-5-1

Production quality ISO 9001

Approvals

Functional Safety TÜV - Tested Electrical Safety TÜV - Tested EMC TÜV - Tested USA, Canada cURus approval, file number E171278

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 Earth fault protection Ye s Mains supervision Yes Motor phase supervision Yes (not available in 1-phase version) Overcurrent protection Yes Unit overtemperature

protection

Yes

Motor overload protection

Yes

Motor stall protection Yes Motor underload

protection

Yes

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

Yes

Thermal motor protection

Yes (by PTC with option card)

Page 79

Technical data vacon • 76

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

7.3.1 Technical information on control connections

Table 36. Technical information on standard I/O terminals.

Standard I/O terminals

Terminal Signal Technical information

A RS485

Differential receiver/transmitter Set bus termination with dip switches (see Chapter 5)

B RS485

1 Reference output +10V, ±5%; Maximum current 10 mA

Analogue input, voltage or current

Analogue input channel 1 0- +10V (Ri = 200 k

Ω)

0/4-20 mA (Ri =250 Ω) Resolution 0.05 %, accuracy ±1 % Selection V/mA with dip-switches (see Chapter 5). Default 0- +10V

I/O ground

Ground for reference and controls (connected internally to frame earth through 2M

Ω)

24V aux. voltage

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

DIN COM

Common for digital inputs. Connected to GND with dipswitch SW1. See Chapter 5

Digital input 1

Positive or negative logic Ri = min. 4k

15…30V = "1"

0...5V = “0”

Digital input 2

Digital input 3

Analogue input, voltage or current

Analogue input channel 2 0- +10V (Ri = 200 k

Ω)

0/4-20 mA (Ri =250 Ω) Resolution 0.05%, accuracy ±1 % Selection V/mA with dip-switches (see Chapter 5). Default 0/4-20 mA

I/O ground

Ground for reference and controls (connected internally to frame earth through 2M

Ω)

Digital output common

Common for digital output 1 (DO1-)

Digital input 4

Positive or negative logic Ri = min. 4k

15…30V = "1"

0...5V = “0”

Digital input 5

Digital input 6

Analogue signal (+output)

Analogue output channel 1, 0-10V (30mA max) Resolution 0.1%, accuracy ±2,5 % Short-circuited protected.

Digital Output 1 Open Collector max 35V / 50mA (DO1+)

Page 80

vacon • 77 Technical data

Table 37. Technical information on relays.

Relay terminals

Terminal Signal Technical information

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 250VAC/3A (only earthed network allowed)

23 24

Relay output 2*

Switching capacity NO 250VAC/5A NC 250VAC/3A (only earthed network allowed)

25 26

Page 81

Options vacon • 78

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

8. OPTIONS

8.1 Vacon keypad with seven-segment display

The text keypad is an option available for VACON® 20 CP. The control keypad is the interface between the VACON

20 CP frequency converter and the user.

Figure 40. Text keypad.

With the keypad it’s possible to control the speed of the motor, to supervise the state of the drive and to set the frequency converter’s parameters. The button section of the text keypad is shown in the following picture.

Figure 41.Keypad buttons.

Order code Description Type of option

VACON-PAN-HMTX-MC06-CP

Handheld/Magnetic fixing IP66 text

keypad w/ cable, l=1m/39,37 inches

Loose option

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

Stop button Start button

Enter active level/item Confirm selection

Page 82

vacon • 79 Options

8.2 Text keypad

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 can see the information about

his present

location in the

menu structure and the item displayed.

Figure 42. Keypad display.

8.3 Menu structure

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

return

to the former level by pressing the Back/Reset button. The arrows on the left of the display show the active menu. In Figure 42 the REF menu is active. The table below shows the structure of the main menu:

Reference (REF) Reference from Keypad Monitor (MON) Monitoring values Parameters (PAR) Application parameters

System/Fault (SYS/FLT)

System Menu Active fault History fault

Table 38. Keypad menus.

Indicators:

Status

Indicators:

Alarm, Fault

Indicators:

Menus

Indicators:

Direction

Indicators:

Control place

READY RUN STOP ALARM FAULT

FWD REV I/O KEYPAD BUS

REF

MON

PAR

SYS/FLT

.

Page 83

Options vacon • 80

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

8.4 Using the keypad

This chapter provides you with information on navigating the menus on Vacon 20 CP and editing the values of the parameters.

8.4.1 Main menu

The menu structure of Vacon 20 CP control software consists of a main menu and several submenus. Navigation in the main menu is shown below:

Figure 43. The Main menu of Vacon 20 CP.

FWD R EV I/O K EYPAD BUS

REF

MON

PA R

FAU LTALARMSTOPREADY RUN

FWD REV I/O KEYPAD BU S

REF

PA R

FAU LTALARMSTOPREADY RUN

MON

FW D R EV I/O KEY PAD BU S

REF

PAR

FAU L TALARMSTO PREADY RUN

MON

FWD REV I/O KEYPAD BUS

PAR

FAULTALARMSTOPREADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAULTALARMSTOPREADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAULTALARMSTOPREADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAU LTALARMSTO PREAD Y RU N

MON

PRESS

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTALARMSTOPREAD Y R UN

PRESS

In this menu you can browse the monitoring values.

In this menu you can browse and edit the parameters.

Dispalys the keypad referen ce value regardless of the sele cted contron pla ce .

Here you will be able to browse system paramete and fault submenu.

FLTSYS /

SYSTEM/FAULT MENU

PA R A MET ER MEN U

MONI TOR MEN U

REFERENCE MEN U

Page 84

vacon • 81 Options

8.4.2 Resetting fault

When a fault appears and the drive stops examine the cause of the fault, perform the action advised in the Fault Tracing paragraph and reset the fault by pressing the RESET button.

8.4.3 Local/Remote control button

The LOC/REM button is used for two functions: to quickly access the Control page and to easily change between the Local (Keypad) and Remote control places.

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. In the VACON

20 CP

drive, the

Local control place is always the keypad. The Remote control place is determined by pa-

rameter (I/O or Fieldbus). The selected control place can be seen on the status bar of the keypad.

Remote control place

I/O and Fieldbus can be used as remote control places.

Local control

Keypad is always used as control place while in local control. Local control has higher priority than remote control. Switching between Local and Remote Control can be done by pressing the LOC/ REM-button on the keypad.

Page 85

Options vacon • 82

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

8.4.4 Reference menu

Figure 44. Reference menu.

Move to the reference menu with the UP / DOWN button (see Figure 43). The reference value can be changed with UP / DOWN button as shown in Figure 44. If the value has big change, first press Left and Right buttons to select the digit which has to be

changed, then press Up button to increase and Down button to decreases the value in the selected digit. The changing reference frequency will been taken into use immediately without pressing OK.

Note! LEFT and RIGHT buttons can be used to change the direction in Ref menu in local control mode.

Press to enter edit mode

Change value

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTALARMSTOPRE ADY R UN

FLTSYS /

Page 86

vacon • 83 Options

8.4.5 Monitoring menu

Monitoring values are actual values of measured signals as well as status of some control settings. It is visible in Vacon 20 CP display, but it can not be edited. The monitoring values are listed in the Application Manual.

Figure 45. Monitoring menu.

Pressing Left/Right button to change the actual parameter to the first parameter of the next group, to browse monitor menu from V1.x to V2.1 to V3.1 to V4.1. After entering the desired group, the monitoring values can be browsed by pressing UP/DOWN button, as shown in Figure 45. In MON menu the selected signal and its value are alternating in the display by pressing OK button.

Note! Turn on drive power, arrowhead of main menu is at MON, V x.x or monitor parameter value of Vx.x is displayed in Panel. Display Vx.x or monitor parameter value of Vx.x is determined by the last show status before power shut down.

FAULTALARMSTOPRE ADY RU N

REF

MON

PA R

REF

MON

PA R

FAULTALARMSTOPRE ADY R U N

FWD REV I/O K EYPAD BUS FWD REV I/O K EYPAD BUS

REF

MON

PA R

FAULTALARMSTOPREADY RU N

FWD R EV I/O KEYPAD BUS

REF

MON

PA R

FAU LTALARMSTOPRE ADY RU N

FWD REV I/O K EYPAD BUS

FAU LTALARMSTOPRE ADY RU N

REF

MON

PA R

FWD REV I/O K EYPAD BUS

FLTSYS /

Press OK to enter Monitoring menu

Press Left/Right to browse other Monitoring groups

Press Down to browse V4.5

Press OK to select V4.5

Press OK to display the value

Page 87

Options vacon • 84

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

8.4.6 Parameter menu

In Parameter menu only the Quick setup parameter list is shown as default. To view the other advanced parameter groups, see the Application Manual. The following figure shows the parameter menu view:

Figure 46.Parameter menu

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.

Press Right to browse other Par. group

Press OK button to enter edit mode

Press down button to browse P3.4

Press Up / Down to change value

Press OK to confirm

FA ULTALARMSTOPREADY RU N FAU LTALARMSTOPREADY RU N

FA ULTALARMSTOPRE ADY RU N

FWD REV I/OKEYPAD BUS FWD REV I/OKEYPAD BUS

FWD R EV I/O K EY PAD BUS

Press OK to enter Pa r. menu

FAU LTALARMSTOPRE ADY RU N

FWD R EV I/O K EYPAD BUS

FA ULTALARMSTOPREADY RU N

FWD REV I/O K EYPAD BUS

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

SYS / FLT

PAR

REF

MON

Page 88

vacon • 85 Options

8.4.7 System/Fault menu

SYS/FLT menu including fault submenu, field bus submenu and system parameter submenu. In system parameter submenu, there are some editable parameter (P) and some not editable parameters (V). The Fault submenu of SYS/FLT menu includes active fault submenu and fault history submenu.

Figure 47. System and Fault menu.

Press OK to enter V1.1

Press Left/Right button

to browse other groups

Pressdowntobrowse other active faults

FAU LTALARMSTOP

FWD R EV I/O K EYPAD BUS

READY RU N

Press OK to select one fault to browse its time

FAU LTALA RMSTOPREADY RUN

FWD REV I/O KEYPAD BUS

Browse for fault code(C xx), subcode(Id xx), days(d xx), hours(H xx), minutes(M xx)

FAU LTALARMSTOPREADY RUN

FWD REV I/O KEYPAD BUS

FAU LTALA RMSTOPREAD Y RU N

FWD REV I/O KEYPAD BUS

FAU LTALA RMSTOPREADY RUN

FWD REV I/O KEYPAD BUS

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

SYS / FLT

PA R

REF

MON

Page 89

Options vacon • 86

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

8.4.7.1 Faults

Under this menu, you can find Active faults, Reset faults, Fault history, Counters and Software in-

fo.

In active fault situation, FAULT arrow is blinking and the display is blinking active fault menu item with fault code. If there are several active faults, you can check it by entering the active fault submenu F5.x. F5.1 is always the latest active fault code. The active faults can be reset by pressing BACK / RESET button with long time (>2 s), when the API is in active fault submenu level (F5.x). If the fault cannot be reset, the blinking continues. It is possible to select other display menus during active fault, but in this case the display returns automatically to the fault menu if no button is pressed in 10 seconds. The fault code, subcode and the operating day, hour and minute values at the fault instant are shown in the value menu (operating hours = displayed reading).

Active faults

Fault history

Menu Function Note Active faults When a fault/faults appear(s), the

display with the name of the fault starts to blink. Press OK to return to the Diagnostics menu. The

Active faults submenu shows the

number of faults. Select the fault and push OK to see the fault-time data.

The fault remains active until it is cleared with the RESET button or with a reset signal from the I/O terminal or fieldbus or by choosing

Re-

set faults

(see below). The memory of active faults can store the maximum of 10 faults in the order of appearance.

Menu Function Note Fault history 10 latest faults are stored in the

Fault history.

Entering the Fault history and clicking OK on the selected fault shows the fault time data (details).

Page 90

vacon • 87 Options

8.5 Fault tracing

Fault

code

Fault name Subcode Possible cause Remedy

Overcurrent

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

) 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.

Overvoltage

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.

Earth 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.

84 MPI communication crc error

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

89 HMI receives buffer overflow

Check PC-drive cable. Try to reduce ambient noise

90 Modbus receives buffer overflow

Check Modbus specifications for time-out. Check cable length. Reduce ambient noise. Check baudrate.

System Fault 93 Power identification error

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

97 MPI off line error

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

98 MPI driver error

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

99 Option board driver error

Check contact in option board slot Try to reduce ambient noise; Reset the fault and restart. Should the fault re-occur, contact the distributor near to you.

100 Option board configuration error

Check contact in option board slot Try to reduce ambient noise; Should the fault re-occur, contact the distributor near to you.

Table 39. Fault codes and descriptions.

Page 91

Options vacon • 88

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

101 Modbus buffer overflow

Check Modbus specifications for time-out. Check cable length. Reduce ambient noise. Check baudrate.

104 Option board channel full

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

105

Option board memory allocation fail

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

106 Option board Object queue full

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

System Fault 107 Option board HMI queue full

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

108 Option board SPI queue full

Check contacts in option board slot. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

111 Parameter copy error

Check if parameter set is compatible with drive. Do not remove Keypad until copy is finished.

113

Frequency detective timer overflow

Check keypad contacts. Try to reduce ambient noise. Should the fault re-occur, contact the distributor near to you.

114 PC control time out fault

Do not close Vacon Live when PC control is active. Check PC-Drive cable. Try to reduce ambient noise.

115 DeviceProperty data format

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

120 Task stack overflow

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

Fault

code

Fault name Subcode Possible cause Remedy

Table 39. Fault codes and descriptions.

Page 92

vacon • 89 Options

Undervoltage

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.

Input phase Input line phase is missing.

Check supply voltage, fuses and cable.

Output phase

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

Check motor cables and motor.

AC drive undertemperature

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

Check the ambient temperature.

AC drive overtemperature

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.

Motor stalled Motor is stalled.

Check motor and load. Insufficient motor power, check motor stall protection parametrization.

Motor overtemperature

Motor is overloaded.

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

Motor underload Motor is under loaded

Check load. Check underload protection parametrization.

Power overload Supervision for drive power Drive power is to high: decrease load.

Watchdog

Error in the microprocessor monitoring Malfunction Component fault

Reset the fault and restart. If the fault occurs again, please contact your closest Vacon representative.

Back EMF

Protection of unit when starting with rotating motor

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

STO fault

Safe torque off signal does not allow drive to be set as ready

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

Fault

code

Fault name Subcode Possible cause Remedy

Table 39. Fault codes and descriptions.

Page 93

Options vacon • 90

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

Application error

Firmware Interface version between Application and Control not matching

Load a compatible application. Please contact your closest Vacon representative.

1 Application software flash error Reload Application

2 Application header error

Load a compatible application. Please contact your closest Vacon representative.

IGBT temp

IGBT temperature (UnitTemperature + I2T) too high

Check loading. Check motor size. Make identification run.

4 mA fault (Analog input)

Selected signal range: 4...20 mA (see Application Manual) Current less than 4 mA Signal line broken detached The signal source is faulty

Check the analog input’s current source and circuit.

External fault

Error message on digital input. The digital input was programmed as an input for external error messages. The input is active.

Check the programming and check the device indicated by the error message. Check the cabling for the respective device as well.

Keypad Communication fault

The connection between the control keypad and the frequency converter is broken.

Check keypad connection and keypad cable.

Fieldbus communication fault

The data connection between the fieldbus master and fieldbus board is broken

Check installation and fieldbus master.

Fieldbus Interface error Defective option board or slot Check board and slot.

Wrong run command

Wrong run alarm and stop command

Run forward and backward are activated at the same time

Temperature Temperature fault

Board OPTBH is installed and measured temperature is above (or below) the limit

Identification Identification alarm

Motor identification has not been successfully completed

Quick Stop Quick Stop activated

The drive has been stopped with Quick Stop digital input or Quick Stop command by fieldbus

Fault

code

Fault name Subcode Possible cause Remedy

Table 39. Fault codes and descriptions.

Page 94

vacon • 91 Options

8.6 Option boards

VACON® 20 CP drive family embodies a wide selection of expander boards with which the available I/O resources of VACON

20 CP frequency converter can be increased and its versatility improved.

There is one board slot (labelled D) on the VACON

20 CP control unit. To locate the slot, see Chapter 5. Usually, when the AC drive is delivered from the factory, the control unit doesn’t include any option board in the board slot.

The following option boards are supported:

See the Option boards User’s Manual to use and install the option boards.

Order Code Description Note

OPT-B1-V

Option board with six bidirec-

tional terminals.

With jumper blocks it’s possible to

use each terminal as digital input or

as digital output.

OPT-B2-V

I/O expander board with a

thermistor input and two relay

outputs.

OPT-B4-V

I/O expander board with one

galvanically isolated analogue

input and two

galvanically isolated analogue

outputs (standard signals

0(4)…20mA).

OPT-B5-V

I/O expander board with three

relay outputs

OPT-B9-V

I/O expander board with five

42…240 VAC digital inputs and

one relay output.

OPT-BF-V

I/O expander board with ana-

logue output, digital output and

relay output.

On the OPTBF board, there is one

jumper block for selecting the ana-

logue output mode (mA/V).

OPT-BH-V

Temperature measurement

board with three individual

channels.

Supported sensors: PT100, PT1000,

NI1000, KTY84-130, KTY84-150,

KTY84-131

OPT-BK-V ASi option board AS-interface option card

OPT-C4-V Lonworks option board

Pluggable connector with screw ter-

minals

OPT-C3/E3-V Profibus DP option board

Pluggable connector with screw ter-

minals OPT-C5/E5-V Profibus DP option board 9-pin Sub-D terminal OPT-C6/E6-V CANopen option board OPT-C7/E7-V DeviceNet option board

OPT-CI-V Modbus TCP option board OPT-CP-V Profinet option board OPT-CQ-V Ethernet IP option board OPT-EC-V EtherCat option board

Table 40. Option boards supported in VACON® 20 CP.

Page 95

Options vacon • 92

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

8.6.1 Option board installation

Figure 48. Opening the main cover, MS2 three-phase version example.

NOTE! Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards.

• Remove the option slot cover.

The relay outputs and other I/O-terminals may have a dangerous control voltage present even when the drive is disconnected from mains.

Page 96

vacon • 93 Options

• Make sure that the sticker on the connector of the board says “dv” (dual voltage). This indicates that the board is compatible with Vacon 20 CP. See below:

• NOTE: Incompatible boards cannot be installed on Vacon 20 CP. Compatible boards have a slot coding that enables the placing of the board (see above)

• Install the option board into the slot as shown in the picture below.

Slot coding

OPT

9116.emf

Page 97

Options vacon • 94

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

Figure 49. Option board installation.

• Mount the option slot cover.

Page 98

vacon • 95 Options

Figure 50. Mounting of the option slot cover: remove the plastic opening for the option board

terminals.

Page 99

Safe Torque Off vacon • 96

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

9. SAFE TORQUE OFF

This chapter describes the Safe Torque Off (STO) function which is a functional safety feature present in VACON

20 CP drive products as standard. This function is available only in the three-phase

version.

9.1 General description

The STO function brings the motor in no-torque-state as defined by 4.2.2.2 of the IEC 61800-5-2:

“Power that can cause rotation (or motion in the case of a linear motor) is not applied to the motor. The Power Drive System (Safety Related) will not provide energy to the motor which can generate torque (or force in the case of a linear motor).”

Therefore, the STO function is suitable for applications that rely on the immediate removal of power to the actuator, resulting in an uncontrolled coast to stop (activated by an STO demand). Additional protective measures need to be applied when an application requires a different stop method.

9.2 Warnings

Designing of safety-related systems requires specialist knowledge and skills. Only qualified people are permitted to install and set up the STO function. The use of STO does not itself ensure safety. An overall risk evaluation is required for ensuring that the commissioned system is safe. Safety devices must be correctly incorporated into the entire system which must be designed in compliance with all relevant standards within the field of industry.

The information in this manual provides guidance on the use of the STO function. This information is in compliance with accepted practice and regulations at the time of writing. However, the end product/system designer is responsible for ensuring that the end-system is safe and in compliance with relevant regulations.

When a permanent magnet motor is used and in case of a multiple IGBT power semiconductor failure, when the STO option energizes the drive outputs to the off state, the drive system may still provide an alignment torque which maximally rotates the motor shaft by 180°/p (where p is the number of poles of the motor) before the torque production ceases.

Electronic means and contactors are not adequate for protection against electric shock. The Safe Torque Off function does not disconnect the voltage or the mains from the drive. Therefore hazardous voltages may still be present on the motor. If electrical or maintenance work has to be carried out on electrical parts of the drive or the motor, the drive has to be completely isolated from the main supply, e.g. using an external supply disconnecting switch (see EN60204-1 section 5.3).

This safety function corresponds to an uncontrolled stop in accordance with stop category 0 of IEC 60204-1. The STO function does not comply with Emergency Switching Off according to IEC 60204-1 (no galvanic insulation from the Mains in case the motor is stopped).

The STO function is not a prevention of unexpected start-up. To fulfil those requirements, additional external components are required according to appropriate standards and application requirements.

In circumstances where external influences (e.g. falling of suspended loads) are present additional measures (e.g. mechanical brakes) may be necessary to prevent any hazard.

STO shall not be used as a control for starting or stopping the drive.

Page 100

vacon • 97 Safe Torque Off

9.3 Standards

The STO function has been designed for use in accordance with the following standards:

The STO function has to be applied correctly to achieve the desired level of operational safety. Four different levels are allowed, depending on the use of the STO signals (see the following table).

The same values are calculated for SIL and SIL CL. According to EN 60204-1, the emergency stop category is 0.

The SIL value for the safety related system, operating in high demand/continuous mode, is related to the probability of dangerous failure per hour (PFH), reported in the following table.

Standards

IEC 61508, Parts 1-7

EN 61800-5-2

EN 62061

ISO 13849-1

EN 954-1

IEC 60204-1

Table 41. Safety Standards.

STO inputs STO feedback Cat. PL SIL

Both dynamically used(*) Used 4 e 3

Both statically used Used 3 e 3 Connected in parallel Used 2 d 2 Connected in parallel Not used 1 c 1

Table 42. Four different STO levels. (*) see 9.5.1.

STO inputs STO feedback PFH PFDav

MTTFd (years)

DCavg

Both dynamically used(*) Used 8.0 E-10 1/h 7.0 E-05 8314 y HIGH

Both statically used Used 8.1 E-10 1/h 7.1 E-05 8314 y MEDIUM Connected in parallel Used 8.1 E-10 1/h 7.1 E-05 8314 y MEDIUM Connected in parallel Not used 9.2 E-10 1/h 8.0 E-05 8314 y NONE

Table 43. SIL values. (*) see 9.5.1.

The STO inputs must always be supplied by a safety device.

The power supply of the safety device may be external or taken from the drive (as long as this is compliant with the rating specified for terminal 6).