Vacon 20 X ac drives Users Manual

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vacon®20 x

ac drives

installation, Technical and Maintenance

manual

vacon • 0

INDEX

Document code (Original Instructions): DPD00992E

Order code: DOC-INS06663+DLUK

Rev. E

Revision release date: 19.6.14

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

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

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

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

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

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

1.6 Insulation system ............................................................................................................... 7

1.7 Compatibility with RCDs..................................................................................................... 8

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

1.9 Declaration of conformity ................................................................................................ 10

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

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

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

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

2.3.1 ‘Product modified’ sticker................................................................................................ 17

2.3.2 Disposal............................................................................................................................ 17

3. Mounting......................................................................................................... 18

3.1 Dimensions....................................................................................................................... 18

3.1.1 Frame MU2 and MU3 ....................................................................................................... 18

3.2 Cooling.............................................................................................................................. 20

4. Power cabling................................................................................................. 22

4.1 Circuit breaker ................................................................................................................. 24

4.2 UL standards on cabling .................................................................................................. 24

4.3 Description of the terminals ............................................................................................ 25

4.4 Cable dimensioning and selection................................................................................... 27

4.5 Brake resistor cables....................................................................................................... 29

4.6 Control cables .................................................................................................................. 29

4.7 Cable installation ............................................................................................................. 30

4.8 Wiring way ........................................................................................................................ 36

5. Control unit .................................................................................................... 38

5.1 Opening the drives ...........................................................................................................38

5.2 Control units MU2 and MU3............................................................................................. 39

5.3 Control unit cabling.......................................................................................................... 41

5.3.1 Control cable sizing.......................................................................................................... 41

5.3.2 Standard I/O terminals.....................................................................................................42

5.3.3 Relay terminals ................................................................................................................ 43

5.3.4 Safe Torque off (STO) terminals ...................................................................................... 43

5.3.5 Description of additional echo connectors ...................................................................... 44

5.3.6 Led handling..................................................................................................................... 46

5.3.7 Selection of terminal functions with dip switches........................................................... 47

5.4 Fieldbus connection ......................................................................................................... 48

5.4.1 Modbus RTU protocol....................................................................................................... 49

5.4.2 Preparation for use through RS485................................................................................. 50

6. Commissioning ............................................................................................... 52

6.1 Commissioning of the drive ............................................................................................. 53

6.2 Changing EMC protection class....................................................................................... 54

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

vacon • 1

6.2.1 Changing EMC protection class - MU2............................................................................ 54

6.2.2 Changing EMC protection class - MU3............................................................................ 56

6.3 Running the motor ........................................................................................................... 57

6.3.1 Cable and motor insulation checks ................................................................................. 57

6.4 Maintenance ..................................................................................................................... 58

7. Technical data ................................................................................................ 60

7.1 AC drive power ratings..................................................................................................... 60

7.1.1 Mains voltage 3AC 208-240 V........................................................................................... 60

7.1.2 Mains voltage 3AC 380-480V............................................................................................ 61

7.1.3 Definitions of overloadability ........................................................................................... 61

7.2 Brake resistor ratings...................................................................................................... 62

7.3 VACON® 20 X - technical data......................................................................................... 63

7.3.1 Technical information on control connections ................................................................ 66

8. Options ........................................................................................................... 68

8.1 Vacon keypad with seven-segment display ..................................................................... 68

8.1.1 Mounting onto the drive ................................................................................................... 68

8.1.2 Text Keypad - buttons ......................................................................................................71

8.2 Text keypad....................................................................................................................... 72

8.3 Menu structure................................................................................................................. 72

8.4 Using the keypad.............................................................................................................. 73

8.4.1 Main menu........................................................................................................................ 73

8.4.2 Resetting fault.................................................................................................................. 74

8.4.3 Local/Remote control button........................................................................................... 74

8.4.4 Reference menu............................................................................................................... 75

8.4.5 Monitoring menu .............................................................................................................. 76

8.4.6 Parameter menu .............................................................................................................. 77

8.4.7 System/Fault menu..........................................................................................................78

8.4.8 Fault tracing ..................................................................................................................... 80

8.5 Option boards ................................................................................................................... 83

8.5.1 Option board installation..................................................................................................84

8.6 Mains switch..................................................................................................................... 88

8.6.1 Installation........................................................................................................................ 89

8.7 Simple operator panel ..................................................................................................... 92

8.7.1 Installation........................................................................................................................ 93

9. Safe Torque Off............................................................................................... 98

9.1 General description..........................................................................................................98

9.2 Warnings .......................................................................................................................... 98

9.3 Standards ......................................................................................................................... 99

9.4 The principle of STO ....................................................................................................... 100

9.4.1 Technical details ............................................................................................................ 101

9.5 Connections.................................................................................................................... 102

9.5.1 Safety Capability Cat.4 / PL e / SIL 3.............................................................................. 103

9.5.2 Safety Capability Cat. 3 / PL e / SIL 3............................................................................. 105

9.5.3 Safety Capability Cat. 2 / PL d / SIL 2............................................................................. 105

9.5.4 Safety Capability Cat.1 / PL c / SIL 1.............................................................................. 106

9.6 Commissioning............................................................................................................... 107

9.6.1 General wiring instructions ........................................................................................... 107

9.6.2 Checklist for commissioning ......................................................................................... 107

9.7 Parameters and fault tracing......................................................................................... 108

9.8 Maintenance and diagnostics ........................................................................................ 109

Safety vacon • 2

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 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:

20 X is a drive designed to control asynchronous AC motors and permanent magnet

= DANGEROUS VOLTAGE!

= HOT SURFACE!

= WARNING or CAUTION

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.

Physical

dimension

length 1 mm 0.0394 inch 25.4 inch

Weight 1 kg 2.205 lb 0.4536 pound

Speed

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

Torque 1 Nm 8.851 lbf in 0.113

Power 1 kW 1.341 HP 0.7457 horsepower

SI value US value Conversion factor US designation

1 min

-1

1 rpm 1

revolution per minute

pound-force inches

Table 2. Unit conversion table.

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

vacon • 3 Safety

1.3 Danger

The components of the power unit of VACON® 20 X drives are live when the drive is connected to the mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury.

The motor terminals (U, V, W) are live when VACON 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 VACON X Drive. After expiration of this time, use measuring equipment to absolutely ensure that no

ing 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 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.

voltage is present.

Always ensure absence of voltage before start-

20 X Drive is disconnected from the mains.

20 X Drive is connected to

Safety vacon • 4

1.4 Warnings

VACON® 20 X 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 1.6 for more details.

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

The touch current of VACON dard EN61800-5-1, a reinforced protective ground connection must be ensured. See paragraph 1.5.

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 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.

20 X drives exceeds 3.5mA AC. According to stan-

Start/Stop logic has been selected

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

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

20 X. The tests

vacon • 5 Safety

1.5 Earthing and earth fault protection

CAUTION!

The VACON® 20 X 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, 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 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.

Safety vacon • 6

In VACON® 20 X, 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

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

•2.5 mm

•4 mm sions 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.

if mechanical protection is provided or

if mechanical protection is not provided. For cord-connected equipment, provi-

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

vacon • 7 Safety

POWER UNIT

L1 L2 L3

U V

R01 __

R02 __

DC-

(*)

DC+/R+ R-

10Vref __

Analog Inputs __

Digital Inputs__

Analog Output __

24V __

RS485 __

STO __

Keypad

CONTROL UNIT

Reinforced

Mains

DVC A

DVC A or Mains

(**)

1.6 Insulation system

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

The control unit of VACON dard IEC 61800-5-1 regarding DVC A circuits and also the strongest insulation requirements of IEC 60950-1 regarding SELV circuits.

20 X fulfils the insulation requirements of the stan-

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

20 X:

• Mains and motor connections (L1, L2, L3, 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.

(**)

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.

Figure 2. Insulation system(* only for MU3).

Safety vacon • 8

By performing the cabling, a suitable clearance has to be guaranteed between DVC A circuits and Mains (reinforced insulation is required, according to IEC 61800-5-1).

1.7 Compatibility with RCDs

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

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

vacon • 9 Safety

Ambient temperature (°C)

Percent rated output current (% I

)

10 20 30 40 50

100

0-10

150

Temperature - Output Current Derating Curve

1.8 Extended temperature range

VACON® 20 X has an integrated cooling system, independent from the motor fan. Under maximum operating conditions, the ambient temperature cannot exceed 40 °C. See Table 24 for the output rated current. Higher temperatures are allowed only with derating of the output current. With derating the unit can operate up to 50°C.

Figure 3.Temperature-output current derating curve.

The AC drive is cooled down by air-ventilation. Therefore, make sure that enough free space is left around the AC drive to ensure sufficient air circulation (see for more details the mounting instructions on chapter 3).

NOTE: Up to 1.5 kW (Voltage range 380-480V) and 1.1 kW (Voltage range 208-240V) the drive is not equipped with external cooling fan.

Safety vacon • 10

1.9 Declaration of conformity

Figure 4. Declaration of conformity.

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

vacon • 11 Safety

Figure 5. STO certificate.

Safety vacon • 12

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.

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

vacon • 13 Safety

Receipt of delivery vacon • 14

Marks:

3234500378

Cust. Ord. No:

Application:

FW0065V008

Firmware:

EMC level:

380-480 V

IP66/ 4X

6 A

Rated current:

122245

B.ID:

M100112345

S/N:

70SCO000293-BM1X

Code:

VACON0020-3L-0006-4-X

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

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 2.3.

Figure 6. Vacon package label.

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

vacon • 15 Receipt of delivery

+xxxx +yyyy

Additional codes. Examples of additional codes: +HMTX Text keypad IP66 +QDSS Integrated disconnect switch

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-X +xxxx +yyyy

Receipt of delivery vacon • 16

2.2 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 3 below.

Weight

Frame

[kg] [lb]

MU2 3.4 7.5 MU3 6.0 13.2

Table 3. Frame weights.

VACON® 20 X drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transport damage are to be found on the product and that the delivery is complete.

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

2.3 Accessories

After lifting the converter out, check that the delivery is complete and the following accessories ar included:

Item Quantity Purpose

STO terminal connector 1

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

M1-3 Cable clamp 2 Clamping control cables

‘Product modified’ sticker 1 Information about modifications

HMI cap

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

Table 4. Content of accessory bag.

Six pin black connector (see Figure 7) to use STO function

Closing cap for the HMI connector

Figure 7. STO connector.

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

vacon • 17 Receipt of delivery

Product modified

Date:

13064.emf

2.3.1 ‘Product modified’ sticker

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

Product modified sticker.

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

Figure 8. ‘Product modified’ sticker.

2.3.2 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.

Mounting vacon • 18

3. MOUNTING

The AC drive has to 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. The drive shall be fixed with four screws (or bolts, depending on the unit size).

3.1 Dimensions

3.1.1 Frame MU2 and MU3

Figure 9. VACON® 20 X, MU2.

Dimensions W x H x D

Frame

[mm] [in]

MU2 169.2 x 294.7 x153.8 6.66 x 11.60 x 6.06 MU2 +HMTX 169.2 x 294.7 x175.7 6.66 x 11.60 x 6.92 MU2 +QDSS 169.2 x 294.7 x176 6.66 x 11.60 x 6.93

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

vacon • 19 Mounting

Figure 10. VACON® 20 X, MU3.

Dimensions W x H x D

Frame

[mm] [in]

MU3 205.2 x 375.2 x 180.5 8.08 x 14.77 x 7.11 MU3 +HMTX 205.2 x 375.2 x 202.1 8.08 x 14.77 x 7.96 MU3 +QDSS 205.2 x 375.2 x 200.0 8.08 x 14.77 x 7.87

The drive can be mounted in vertical or horizontal position on the wall or any other relatively even mounting plane or machine frame and fixed with the screws recommended in Table 5. Recommended screw or bolt size for MU2 and MU3 is M5.

Frame Screw number Screw size

MU2 4 M5

MU3 4 M5

Table 5. Screws for wall mounting.

Mounting vacon • 20

AA A

3.2 Cooling

The AC drive produces heat in operation and is cooled down by air circulated by a fan. Enough free space shall be left around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance may also require certain amount of free space.

The minimum clearances given in Table 6 should 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.

Min clearance [mm]

Type A B C

MU2 153060 MU3 153080

Table 6. 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 11. Installation space.

Type Cooling air required [m3/h]

MU2 50 MU3 110

Table 7. Required cooling air.

Note that if several units are mounted above each other the required free space equals B+C (see the Figure 12.). Moreover, the outlet air used for cooling by lower unit must be directed away from the air intake of the upper unit by means of e.g. a piece of metal plate fixed to the wall between the drives as shown in Figure 12..

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

vacon • 21 Mounting

B+C

Air deflector

Figure 12. Installation space when drives are mounted on top of each other.

Power cabling vacon • 22

U/T1

V/T2

W/T3

DC+

R-

DC-

(*)

Keypad

Control

Power unit

4. POWER CABLING

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

Figure 13. Principal connection diagram(* only MU3).

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.

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

vacon • 23 Power cabling

Shield

PE conduc tors

Shield

PE conductor

EMC levels

1st environment 2nd environment

Cable type

Category C2 Category C3 Category C4

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

Table 8: Cable types required to meet standards.

1 = Power cable intended for fixed installation and the specific mains voltage. Shielded

cable not required. (MCMK or similar recommended).

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

specific mains voltage. (MCMK or similar recommended). See Figure 14.

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 14. *360º earthing of the shield with cable glands in motor end needed for EMC category C2.

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

or similar).

Figure 14.

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.

Power cabling vacon • 24

4.1 Circuit breaker

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

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

current (see Table 24 and Table 25). NOTE: circuit breaker is not allowed in installations where C-UL is required. Only fuses are

recommended.

4.2 UL standards on cabling

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

The units are suitable for use on a circuit capable of delivering 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.

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

vacon • 25 Power cabling

PES

3AC

Motor

AC power supply

Single or

Three phases

4.3 Description of the terminals

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

Figure 15. Power connections, MU2.

Power cabling vacon • 26

PES

AC power supply

Single or

Three phases

3AC

Motor

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

Figure 16. Power connections, MU3.

Termin al Description

L1 L2 L3

U/T1 V/T2 W/T3

These terminals are the input connections for the power supply. Single-phase 230 VAC models connect to L1 and L2 terminals.

These terminals are for motor connections.

Table 9. Description of Vacon 20X power terminals.

vacon • 27 Power cabling

4.4 Cable dimensioning and selection

Table 10 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.

4.4.0.1 Cable and fuse sizes, frames MU2 and MU3

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

Terminal cable size

Frame Type

INPUT

[A]

Fuse

(gG/gL)

[A]

Mains and

motor cable

Cu [mm

]

Main

terminal

[mm

]

Earth terminal

0004 2 0003 4 - 0004 4

MU2

MU3

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, 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.

0005 2 - 0007 2 0005 4 - 0006 4

0008 4 9.6 10 3*2.5+2.5 0.2 — 2.5 M4 ring terminal 0011 2

0009 4 0012 2

0012 4 0017 2

0016 4

4.3

3.2 - 4.0

6.8 - 8.4

5.6 - 7.3

13.4

11.5

14.2

14.9

20.6

20.0

Table 10. Cable and fuse sizes for VACON® 20 X.

6 3*1.5+1.5 0.2 — 2.5 M4 ring terminal

10 3*1.5+1.5 0.2 — 2.5 M4 ring terminal

16 3*2.5+2.5 0.5 — 16.0 M5 ring terminal

20 3*2.5+2.5 0.5 — 16.0 M5 ring terminal

25 3*6+6 0.5 — 16.0 M5 ring terminal

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

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

Power cabling vacon • 28

4.4.0.2 Cable and fuse sizes, frames MU2 and MU3, North America

Frame Type

0004 2 0003 4 - 0004 4

MU2

MU3

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

0005 2 - 0007 2 0005 4 - 0006 4

0008 4 9.6 10 AWG14 AWG24-AWG10

0011 2 0009 4

0012 2 0012 4

0017 2 0016 4

Table 11. Cable and fuse sizes for VACON® 20 X, North America.

INPUT

[A]

4.3

3.2 - 4.0

6.8 - 8.4

5.6 - 7.3

13.4

11.5

14.2

14.9

20.6

20.0

Fuse

(class T)

[A]

6 AWG14 AWG24-AWG10

10 AWG14 AWG24-AWG10

15 AWG14 AWG24-AWG10

20 AWG14 AWG24-AWG10

25 AWG10 AWG20-AWG5

Mains and

motor cable

Terminal cable size

Main terminal Earth terminal

AWG17-AWG10

M4 ring terminal

AWG17-AWG10

M4 ring terminal

AWG17-AWG10

M4 ring terminal

AWG17-AWG10

M5 ring terminal

AWG17-AWG10

M5 ring terminal

AWG17-AWG8

M5 ring terminal

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.

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vacon • 29 Power cabling

4.5 Brake resistor cables

VACON® 20 X AC drives are equipped with terminals for an optional external brake resistor. For MU2, brake resistor wires with faston 6.3 mm have to be used. For MU3, a PCB terminal block with push-in spring-cage connector is provided. Stranded wires

(max. 4 mm See Table 26 and Table 27 for the resistor ratings.

) with ferrules should be used.

4.6 Control cables

For information on control cables see chapter Control unit cabling.

Power cabling vacon • 30

Earth conductor

MAINS MOTOR

Shield

Earth conductor

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.

Distance between

cables, [m]

Shielded

cable, [m]

0.3 ≤ 50

1.0 ≤ 200

• 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:

Strip the motor and mains cables as recommended below.

Figure 17. Stripping of cables.

Frame A1 B1 C1 D1 C2 D2 E

MU2 888203620

MU3 888203620

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Table 12. Cables stripping lengths [mm].

Leave as short

as possible

vacon • 31 Power cabling

• Remove the plastic cover of the drive as shown in Figure 18.

IEC installations:

• The cable entries consists of several openings available for the cables with

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

• Choose the correct cable glands (in compliance with CE rules) according

Figure 18. MU2 example: open cover.

ISO metric thread.

to drive and cable size as shown in the following pictures.

Power cabling vacon • 32

Figure 19.Cable entries, MU2.

Figure 20. Cable entries, MU3.

• Cable glands must be made of plastic materials. They are used for sealing

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cables passing through cable entries to ensure the characteristics of the enclosure.

vacon • 33 Power cabling

Figure 21. Cable gland.

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

Tightening torque and dimensions of cable glands:

UL installations:

• Screw the cable glands (in compliance with CE rules) on the cable entry holes using the proper tightening torque as shown in Table 13.

Gland screw

Frame

MU2

MU3

Table 13. Tightening torque and dimension of cable glands.

type

[metric]

M16 1.0 8.9 M20 2.0 17.7 M25 4.0 35.5 M16 1.0 8.9 M25 4.0 35.5

[Nm] lbs-in.

Tightening torque

• Flexible conduit (plastic or metallic) are used as raceway for wires and cables in accordance with the National Electrical Code.

• To connect NPT conduits to the metric threads of cable entries, adapters must be used. These adapters must first be connected to the cable entries plate, using the proper tightening torque as shown in the Table 13, and then to the pipes according to UL regulations.

• For MU2 three NPT-to-Metric adapters must be used: number two 1/2” M20 adapters and number one 3/4” - M25 adapter. See Table 14 for further details.

Power cabling vacon • 34

• For MU3 three NPT-to-Metric adapters must be used: 3/4” - M25 adapters. See Table 14 for further details.

Figure 22. NPT-to-metric threads adapter.

• Teflon tape has to be used to ensure that you get a water tight seal on pipe joints.

• Start by cleaning the male threads at the end of the pipe with a clean rag.

• Place the end of the Teflon tape on the second thread in and hold it in place with one hand.

• Wrap the tape in the same direction of the threads.

• Keep tension on the tape and wrap it several times working away from the end of the NPT pipe.

• When you have finished wrapping the Teflon smooth the loose end down into the threads.

• Screw the NPT-to-metric adapter on the cable entry plate using the proper tightening torque. See Table 14 for more details.

• Screw the NPT pipes on the adapters.

Tightening torque of NPT adapters to metric threads cable entries:

Frame

MU2

MU3 M25 3/4” 4.0 35.5

Table 14. Tightening torque of NPT adapters to metric threads cable entries.

Thread male

metric

M20 1/2” 2.0 17.7 M25 3/4” 4.0 35.5

The Vacon 20X drive is IP66/Type 4X rated. To keep this rating, the use of a sealed conduit is required: if the approved conduit is not used, all warranty claims against water will be void.

Thread female

NPT

Tightening torque

[Nm] lbs-in.

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vacon • 35 Power cabling

Cables installation:

• Pass the cables (supply cable, motor cable, brake cable and I/O cables)

Connect the stripped cables:

Tightening torques of cable terminals:

through the pipes and adapters (UL installations) or through the cable glands (IEC installations) and cable entries.

• Detach the cable clamps and the grounding clamps.

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

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

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

Frame Type

MU2

MU3

0003 4—0008 4 0004 2—0007 2

0009 4—0016 4 0011 2—0017 2

• Check the connection of the earth cable to the motor and the AC drive ter-

Tightening torque

Power and motor

terminals

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

0.5—0.6 4.5—5.3 1.5 13.3 2.0 17.7

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

Table 15. Tightening torques of terminals.

minals marked with .

Tightening torque

EMC grounding

clamps

Tightening torque,

Grounding terminals

Power cabling vacon • 36

Input Line Motor output

Relays

I/O terminals STO terminals Option board terminals

4.8 Wiring way

In the following picture an example of wire cabling is given:

Figure 23.

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vacon • 37 Power cabling

Control unit vacon • 38

5. CONTROL UNIT

5.1 Opening the drives

Figure 24. Open front cover of the drive: control unit MU2.

Figure 25. Open front cover of the drive: control unit MU3.

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vacon • 39 Control unit

5.2 Control units MU2 and MU3

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 26 and Figure 27.

Number Meaning

1 Control terminals A-20 2STO terminals 3 Relay terminals 4 Option board terminals 5 STO Jumpers 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)

Table 16. Locations of components in control unit

Figure 26. Locations of the components in control unit of MU2.

Control unit vacon • 40

Figure 27. Location of the components in the control unit of MU3.

When delivered from the factory, the control unit of the AC drive contains the standard controlling interface - the control terminals of the control board and the relay 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 (+24VDC ±10%, 1000mA) by connecting the external power source between terminal #6 and GND, see chapter 5.3.2. 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.

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vacon • 41 Control unit

5.3 Control unit cabling

The principal terminal block placement is shown in Figure 28 below. The control board is equipped with 18 fixed control I/O terminals and the relay board with 5. 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 18.

Figure 28. Control terminals.

5.3.1 Control cable sizing

The control cables shall be at least 0.14 mm Table 11. 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 17 below.

Terminal screw

I/O terminals and STO terminals (screw M2)

Table 17. Control cable tightening torques.

screened multi core cables, see Table 10 and

Tightening torque

Nm lb-in.

0.22 min

0.25 max

1.94 min

2.21 max

Control unit vacon • 42

Remote reference

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

5.3.2 Standard I/O terminals

The terminals of the

Standard I/O and the Relays 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 5.3.7.

Table 18. 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

Reference potentiometer

1...10kΩ

1 +10 Vref Reference output

3 6

8 9

14 15 16

20 DO1+ Digital output 1

AI1+

GND I/O signal ground

24Vout 24V aux. voltage

DIN COM

DI1 Digital input 1

DI2 Digital input 2

DI3 Digital input 3

AI2+

GND I/O signal ground

DO1-

DI4 Digital input 4

DI5 Digital input 5

DI6 Digital input 6

AO1+

Analogue input, voltage or current

Digital inputs common

Analogue input, voltage or current

Digital output 1 common

Analogue signal (+output)

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vacon • 43 Control unit

From

standard I/O board

From term.

RUN

5.3.3 Relay terminals

Table 19. I/O terminal signals for relays and connection example.

Relays terminals

Terminal Signal

22 23

24 25 26

RO1/2

RO1/3

RO2/1

RO2/2

RO2/3

Relay output 1

Relay output 2

5.3.4 Safe Torque off (STO) terminals

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

Table 20. I/O terminal signals for the STO functions.

Safe Torque Off terminals

Term inal Signal

Isolated digital input 1 (interchangeable polarity);

+24V ±20% 10...15mA Isolated digital input 2 (inter-

changeable polarity);

+24V ±20% 10...15mA Isolated feedback (CAUTION!

F+

Polarity to be respected); +24V ±20%

F-

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

Control unit vacon • 44

5.3.5 Description of additional echo connectors

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

Figure 29. The I/O remote echo connector mounted on the control board.

In Figure 29 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 26 and Figure 27. The type of this connector is Pico-Clasp™ Wire-to Board PCB Header, Dual Row, RIght Angle. The code by Molex

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

is: 501571-2007.

is: 501189-2010. See Figure 30.

Figure 30.Receptacle housing for I/O remote echo connector.

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vacon • 45 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 X

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 21. I/O remote connector description.

Control unit vacon • 46

5.3.6 Led handling

As VACON LEDs. See the picture below.

20 X is often without the keypad, on the plastic cover of the drive there are 4 status

Figure 31. LED position on the MU2 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.

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vacon • 47 Control unit

5.3.7 Selection of terminal functions with dip switches

The VACON tions each. The shadowed terminals in Table 18 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.

20 X drive embodies four so-called switches that allow for two functional selec-

Figure 32. Dip switches on the control unit.

5.3.7.1

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

5.3.7.2 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.

5.3.7.3 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 X is the last device on the net, this switch must be set to “0” position. The default position for SW4 is “0”.

Switch SW1

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

Control unit vacon • 48

5.4 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.

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vacon • 49 Control unit

5.4.1 Modbus RTU protocol

Interface RS-485

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

Transfer cable

Connector

Connections and communications

VACON ed to fieldbus through RS485. The connection for RS485 is on the standard I/O (terminals A and B). See Figure 34.

20 X drive is equipped with Modbus support as standard. The AC drive can be connect-

Electrical isolation Functional

Modbus RTU

Baud rate

Addresses 1 to 247

Table 22.

STP (shielded twisted pair), type

Belden 9841 or similar

2.5 mm

As described in “Modicon Modbus

Protocol Reference Guide”

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

19200, 38400 and 57600 baud

Figure 34. Position of the RS485 terminals on the I/O standard terminal connector(MU2

control unit example).

Control unit vacon • 50

5.4.2 Preparation for use through RS485

Strip about 15 mm of the RS485 cable (see specification on Table 22) 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.

2 3

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 Vacon20 X 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 X 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.

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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.

vacon • 51 Control unit

Commissioning vacon • 52

6. COMMISSIONING

Before commissioning, note the following directions and warnings:

Internal components and circuit boards of VACON® 20 X drive (except for the galvanically isolated I/O terminals) are live when it is connected to the mains potential. Coming into contact with this voltage is extremely dangerous and may

cause death or severe injury.

The motor terminals U, V, W and the brake resistor terminals are live when VACON

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

VACON

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

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

20 X drive is disconnected from the mains.

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

connections of VACON expired. After expiration of this time, use a measuring equipment to absolutely ensure that no

ing any electrical work!

voltage is present.

20 X Drive. Do not open the unit before this time has

Always ensure absence of voltage before start-

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vacon • 53 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 4.1.1.

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 in the Stopposition.

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

Commissioning vacon • 54

6.2 Changing EMC protection class

The EMC protection class of Vacon® 20 X can be changed from class C2 to class C4 (T). This is done as described below:

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

6.2.1 Changing EMC protection class - MU2

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

Figure 35.Changing of the EMC class in MU2 control unit.

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vacon • 55 Commissioning

Remove the EMC plate from the control unit. Then lift the plate with pliers to dis-

connect the EMC plate from the ground. See Figure 36. Then reconnect the EMC plate to the unit.

Figure 36. Changing of the EMC class in MU2 control unit.

Commissioning vacon • 56

Product modified

Date:

EMC-level modified C1->C4

DDMMYY

6.2.2 Changing EMC protection class - MU3

Remove the EMC screw as shown in the Figure 37.

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Figure 37. Changing the EMC class in the MU3 control unit.

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

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

20 X delivery (see below) and note the date. Un-

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

vacon • 57 Commissioning

6.3 Running the motor

MOTOR RUN CHECK LIST

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

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

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

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

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

6.3.1 Cable and motor insulation checks

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

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

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

Commissioning vacon • 58

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

6...24 months (depending on environment)

6...10 years • Change main fan

12...24 months

• Check tightening torques of terminals

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

• Check for corrosion on terminals and other surfaces

• Check the heatsink for dust and clean if necessary

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

Table 23.

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vacon • 59 Commissioning

Technical data vacon • 60

7. TECHNICAL DATA

7.1 AC drive power ratings

7.1.1 Mains voltage 3AC 208-240 V

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

Motor shaft power

Converter

type

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

MU2

0007 8.4 7.0 10.5 14.0 1.5 2.0 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

MU3

0017 20.6 17.5 26.3 35.0 4.0 5.0

Input

current

[A]

Rated continuous

current I

[A]

Loadability

50% overload

current

[A]

Max current

230V 240V

[kW] [HP]

Table 24. Power ratings of VACON® 20 X, supply voltage 208-240V.

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

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vacon • 61 Technical data

N*150%

1 min 9 min

N*150%

Current

Time

7.1.2 Mains voltage 3AC 380-480V

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

Motor shaft power

Loadability

50% overload

current

[A]

Max current

400V 480V

[kW] [HP]

Converter

type

Input

current

[A]

Rated continuous

current I

[A]

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

MU2

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 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

MU3

0016 20 16.0 24.0 32.0 7.5 10.0

Table 25. Power ratings of VACON® 20 X, supply voltage 380-480V.

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

7.1.3 Definitions of overloadability

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

150% * I

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

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

or less.

Figure 38. High overload.

Technical data vacon • 62

7.2 Brake resistor ratings

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

Recommended minimum brake resistor values for Vacon 20 X AC drives:

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

Frame Type

0004 50

MU2

MU3

Table 26. Brake resistor ratings, 208-240V.

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

Frame Type

0005 50 0007 50 0011 25 0012 25 0017 25

0003 100 0004 100

Minimum Resistance

recommended [Ohm]

Minimum Resistance

recommended [Ohm]

MU2

MU3

Table 27. Brake resistor ratings, 380-480V.

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0005 100 0006 100 0008 100 0009 50 0012 50 0016 50

vacon • 63 Technical data

7.3 VACON® 20 X - technical data

Mains connection

Motor connection

Input voltage U

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

Short-circuit current

Output voltage

Rated output current

Overload output current Starting current

Output frequency 0…320 Hz Frequency resolution 0.01 Hz

3AC 208…240V 3AC 380...480V

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

Maximum short-circuit current has to be <50kA

3AC 0…U IN: Ambient temperature max. +40°C.

See Table 24 and Table 25.

1.5 x IN (1 min/10 min) IS for 2 s every 20 s (IS = 2.0 * IN)

Control characteristics

Control connections

Protection class I

Motor characteristics

Cable type Screened motor cable Cable maximum length 30 m

Switching frequency

Frequency reference: Analogue input Panel reference

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

Braking

See Chapter 5.

AC squirrel cage motors Permanent magnet motors

Programmable 2…16 kHz; Default 6 kHz. Automatic switching frequency derating in case of overheating

Resolution ±0.05% (11-bit), accuracy ±1% Resolution 0.01 Hz

Brake chopper standard in all frames. External brake resistor optional.

Technical data vacon • 64

Standard: Serial communication (RS485/ Modbus);

Communication interface

Ambient conditions

Fieldbus

Status indicators

Ambient operating temperature

Extended temperature range

Storage temperature -40°C…+70°C

Relative humidity

Pollution degree

Altitude

Optional: CANopen; Profibus DP, Lonworks, DeviceNet, Profinet IO, Ethernet IP, Modbus TCP, EtherCAT

Drive status indicators (LED) on top side (POWER, RUN, FAULT, READY)

-10°C…+40°C

up to 50°C with current derating (see chapter 1.8)

0 to 100% RH. Good resistance to most acids, alkalis and oils. Contact factory for

more details. PD2 used for PCB design.

However the drive is suitable for outdoor use because of dust-tight enclosure to numeral 6 [acc. to IEC 60529]

100% load capacity (no derating) up to 1,000m; derating 1% / 100m at 1.000...3.000m

Degree of protection IP66/Type 4X

Stationary vibration: Sinusoidal

Shock/Bump:

EMC 2004/108/EC

Directives

Standards

Production quality ISO 9001

Approvals

Declaration of Conformity

Low Voltage 2006/95/EC RoHS 2002/95/EC WEEE 2012/19/EC

Immunity

Emissions

Safety EN 61800-5-1

Functional Safety TÜV (Rheinland) - Tested Electrical Safety TÜV (SÜD) - Tested EMC TÜV - Tested USA, Canada cULus approval, file number E171278 Korea KC mark Australia C-tick Declaration of Conformity Europe EC Declaration of Conformity

3 Hz ≤ f ≤ 8.43 Hz: 7.5mm

8.43 Hz ≤ f ≤ 200 Hz: 2g (3M6 acc. to IEC 60721-3-3)

25g/6ms (3M6 acc. to IEC 60721-3-3)

EN61800-3 (2004), 1st and 2nd environment EN61800-3 (2004), Category C2 as standard.

The drive can be modified for category C4.

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

vacon • 65 Technical data

Depends on supply voltage (0,8775*supply voltage): Supply voltage 400 V: Trip limit 351 V Supply voltage 480 V: Trip limit 421 V Supply voltage 240 V: Trip limit 211 V

Yes

Yes. These devices provide motor overload protection at 105% of full load amperes.

Protections

Undervoltage trip limit

Earth fault protection Yes Mains supervision Yes Motor phase supervision Ye s Overcurrent protection Ye s Unit overtemperature pro-

tection

Motor overload protection

Motor stall protection Yes Motor underload protec-

tion Short-circuit protection of

+24V and +10V reference voltages

Thermal motor protection Yes (by PTC with option card)

Table 28. Vacon 20 X technical data.

Yes

Technical data vacon • 66

7.3.1 Technical information on control connections

Standard I/O

Terminal Signal Technical information

A RS485

B RS485

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

8 9

14 15 16

Analogue input, voltage or current

I/O ground

24V aux. voltage

DIN COM

Digital input 1

Digital input 2

Digital input 3

Analogue input, voltage or current

I/O ground

Digital output common

Digital input 4

Digital input 5

Digital input 6

Analogue signal (+output)

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

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

Analogue input channel 1 0- +10V (Ri = 200 k 0/4-20 mA (Ri =250 Ω) Resolution 0.05%, accuracy ±1 %

Selection V/mA with dip-switches (see Chapter 5). Default 0- +10V

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

+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.

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

Positive or negative logic Ri = min. 4k 15…30V = "1"

0...5V = “0” Analogue input channel 2

0- +10V (Ri = 200 k 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

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

Common for digital output 1 (DO1-)

Positive or negative logic Ri = min. 4k 15…30V = "1"

0...5V = “0” Analogue output channel 1,

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

Ω)

Table 29. Technical information on standard I/O terminals.

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vacon • 67 Technical data

Relays

Terminal Signal Technical information

22 23

Relay output 1

24 25

Relay output 2*

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

Table 30. Technical information on Relays.

Switching capacity 250VAC/3A (only earthed network allowed)

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

Options vacon • 68

8. OPTIONS

8.1 Vacon keypad with seven-segment display

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

20 X frequency converter and the user.

Figure 39. Text keypad.

8.1.1 Mounting onto the drive

Figure 40. Drive and the optional keypad kit.The optional keypad kit includes: keypad and cable.

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vacon • 69 Options

Figure 41. Disconnection of the HMI cap from the drive.

Figure 42. Mounting of the keypad.

Options vacon • 70

Figure 43. Tighten the two screws of the keypad cable to the enclosure of the drive. Keypad

mounted onto the drive.

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vacon • 71 Options

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

8.1.2 Text Keypad - buttons

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 44.Keypad buttons.

Options vacon • 72

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

.

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 menu structure and the item displayed.

his present

location in the

Figure 45. Keypad display.

8.3 Menu structure

The data on the control keypad are arranged in menus. Use the Up and Down arrows to move be-

return

tween the menus. Enter the group/item by pressing the OK button and

to the former level by pressing the Back/Reset button. The arrows on the left of the display show the active menu. In Figure 45 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 Menu

System/Fault (SYS/FLT)

Table 31. Keypad menus.

Active fault History fault

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vacon • 73 Options

FWD REV I/O K EYPAD BUS

REF

MON

PA R

FA ULTALARMSTOPREADY RU N

FWD REV I/O KEYPAD BU S

REF

PA R

FAU LTALARMSTOPREADY RUN

MON

FW D REV I/O K EY PA D 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

FAULTALARMSTOPRE ADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAULTAL ARMSTOPRE ADY RUN

MON

FWD REV I/O KEYPAD BUS

REF

PAR

FAU LTALARMSTO PREAD Y RUN

MON

PRESS

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTALARMSTOPRE ADY RUN

PRESS

In thi s menu you can browse the monitoring values.

In thi s menu you can browse and edit the parameters.

Dispalys the keypad reference value regardless of the sele cted contron place.

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

FLTSYS /

SYSTEM/FAULT MENU

PA R A METE R MEN U

MONI TOR MEN U

REFERENCE MEN U

8.4 Using the keypad

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

8.4.1 Main menu

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

Figure 46. The Main menu of Vacon 20X.

Options vacon • 74

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 drive, the 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.

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

20 CP

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vacon • 75 Options

Press to enter edit mode

Change value

FWD REV I/O KEYPAD BUS

REF

MON

PA R

FAULTALARMSTOPRE ADY RUN

FLTSYS /

8.4.4 Reference menu

Figure 47. Reference menu.

The reference value can be changed with UP / DOWN button as shown in Figure 47. 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.

Options vacon • 76

Press Left/Right to browse other Monitoring groups

Prsess Down to browse V4.5

Press OK V4.5 is display

Preess OK the value is displayed

FAU LTALARMSTOPREADY RUN

REF

MON

PA R

REF

MON

PA R

FAULTALARMSTOPREADY RUN

FWD REV I/O KEYPAD BUS FWD R EV I/O KEYPAD BUS

Press OK to enter

Monitoring menu

REF

MON

PA R

FAU LTALARMSTOPREADY RU N

FWD R EV I/O KEYPAD BUS

REF

MON

PA R

FAU LTALARMSTOPRE ADY RU N

FWD R EV I/O KEYPAD BUS

FAU LTALARMSTOPREADY RU N

REF

MON

PA R

FWD REV I/O KEYPAD BUS

FLTSYS /

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 20CP display, but it can not be edited. The monitoring values are listed in the Application Manual.

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 48. 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.

Figure 48. Monitoring menu.

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vacon • 77 Options

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 U LTALARMSTOPREADY RUN FAU LTALARMSTOPREADY RU N

FA U LTALARMSTOPRE 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 LTALARMSTOPREADY RU N

FWD R EV I/O KEYPAD BUS

FA ULTALARMSTOPREADY R U N

FWD R EV 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

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 49.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.

Options vacon • 78

Press OK to enter V1.1

Press Left/Right button

to browse other groups

Pressdowntobrowse other active faults

FAU LTALARMSTOP

FWD REV I/O K EYPAD BUS

READY RUN

Press OK to select one fault to browse its time

FAU LTALARMSTOPREADY 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 LTALARMSTOPRE ADY RUN

FWD REV I/O K EYPAD BUS

FAU LTALARMSTOPREADY RUN

FWD REV I/O KEYPAD BUS

FAU LTALARMSTOPREADY RUN

FWD REV I/O K EYPAD 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

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 50. System and Fault menu.

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vacon • 79 Options

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

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

set faults

The memory of active faults can store the maximum of 10 faults in the order of appearance.

(see below).

Re-

Fault history

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).

Options vacon • 80

8.4.8 Fault tracing

Fault

code

Fault name Possible cause Remedy

AC drive has detected too high a current

) in the motor cable:

(>4*I

Overcurrent

Overvoltage

Earth fault

System fault

Undervoltage

• sudden heavy load increase

• short circuit in motor cables

• unsuitable motor

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

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

• insulation failure in cables or motor

Component fault Malfunction

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.

Input phase Input line phase is missing.

AC drive undertemperature

AC drive overtemperature

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

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

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

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

Check motor cables and motor.

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

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.

Check supply voltage, fuses and cable.

Check the ambient temperature.

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.

Motor overtemper-

ature

Motor Underload Motor is under loaded Check load.

Power overload Supervision for drive power

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Motor is overloaded.

Table 32. Fault codes and descriptions.

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

Drive power is to high: decrease load.

vacon • 81 Options

Fault

code

Fault name Possible cause Remedy

Error in the microprocessor monitoring

Watchdog

Back EMF

STO fault

Application error The application is not working

IGBT temp

4 mA fault (Analog input)

External fault

Keypad Communication fault

Fieldbus communication fault

Fieldbus Interface error

Wrong run command

Temperature Temperature fault

Identification Identification alarm

Feedback Supervision Min

Feedback Supervision Max

Quick Stop Quick Stop activated

Malfunction Component fault

Protection of unit when starting with rotating motor

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

IGBT temperature (UnitTemperature + I2T) too high

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

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

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

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

Wrong run alarm and stop command

The variation between setpoint and feedback is lower than min value P12.16 for the time P12.17

The variation between setpoint and feedback is higher than max value P12.18 for the time P12.19

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

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

Please contact your closest Vacon representative.

Check loading. Check motor size. Make identification run.

Check the analog input’s current source and circuit.

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

Check keypad connection and keypad cable.

Check installation and fieldbus master.

Run forward and backward are activated at the same time

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

Motor identification has not been successfully completed

Check settings and parameters of this protection.

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

Table 32. Fault codes and descriptions.

Options vacon • 82

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vacon • 83 Options

8.5 Option boards

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

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

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

20 X control board. To locate the slot, see Chap-

Code Description Note

With jumper blocks it’s possible to

use each terminal as digital input or

as digital output.

OPTB1

OPTB2

OPTB4

Option board with six bidirec-

tional terminals.

I/O expander board with a

thermistor input and two relay

outputs.

I/O expander board with one

galvanically isolated analogue

input and two

galvanically isolated analogue

outputs (standard signals

0(4)…20mA).

OPTB5

OPTB9

OPTBF

OPTBH

OPTC4 Lonworks option board

OPTC3/E3 Profibus DP option board

OPTC5/E5 Profibus DP option board 9-pin Sub-D terminal OPTC6/E6 CANopen option board OPTC7/E7 DeviceNet option board

OPTCI Modbus TCP option board

OPTCP Profinet option board

I/O expander board with three

relay outputs

I/O expander board with five

42…240 VAC digital inputs and

one relay output.

I/O expander board with ana-

logue output, digital output and

relay output.

Temperature measurement

board with three individual

channels.

On the OPTBF board, there is one

jumper block for selecting the ana-

logue output mode (mA/V).

Supported sensors: PT100, PT1000,

NI1000, KTY84-130, KTY84-150,

KTY84-131

Pluggable connector with screw ter-

minals

Pluggable connector with screw ter-

minals

OPTCQ Ethernet IP option board

Table 33. Option boards supported in VACON® 20 X.

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

Options vacon • 84

8.5.1 Option board installation

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.

• Open the cover of the drive.

Figure 51. Opening the main cover, MU3 example.

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

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

• Remove the option slot cover.

vacon • 85 Options

Slot coding

OPT

9116.emf

Figure 52. Removing the option slot cover.

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

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

Options vacon • 86

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

Figure 53. Option board installation.

• Mount the option slot cover.

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

vacon • 87 Options

Figure 54. Mounting of option slot cover: remove the plastic opening for the option board ter-

minals.

Options vacon • 88

8.6 Mains switch

The purpose of the Mains switch is to disconnect the VACON® 20 X from the mains when, for example, service actions are needed. The mains switch is available as option and it can be integrated in the drive. The switch can be mounted on the front side of the drive. See Figure 58.

Frame

size

MU2

MU3

Figure 55. The mains switch option spare kit (MU2 example).

Description and type code Item Quantity

Main switch 40A NLT40 assembly 1

MU2 QDSS option spare kit

60S01128

MU3 QDSS option spare kit

60S01129

Table 34. Mains switch kit content.

MU2 cover for main switch 1

M4x14 screw 2

M5x23 screws 4

Main switch 40A NLT40 assembly 1

MU3 cover for main switch 1

M4x14 screw 2

M5x23 screws 6

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

vacon • 89 Options

8.6.1 Installation

• Remove the cover from the drive. See the Figure 56.

4 5

Figure 56. Cover open.

• Open only the inlet holes where you need to run the cables. Cables pass through this inlet hole.

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

• Place the Mains switch with the cables inside the drive and fix it with its screws.

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

• Fix the cables with cable clamp.

Options vacon • 90

Figure 57. Mains switch and cables connected.

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

• Connect the GROUND wire to the proper terminal (see the yellow-green cable on Figure 57.

vacon • 91 Options

• Mount the plastic cover onto the drive with its screws and HMI cap: the installation process has been completed. See Figure 58.

Figure 58. Mount the plastic cover.

Options vacon • 92

8.7 Simple operator panel

The purpose of the Simple operator panel is to provide a local control with Start/Stop selector and potentiometer for frequency reference together with a mains switch to disconnect the VACON X from the mains when, for example, service actions are needed. This option can be mounted on the front side of the drive. See Figure 59.

Figure 59. The Simple operator panel option spare kit (MU2 example).

Frame

size

MU2

MU3

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

Description and type code Item Quantity

Main switch 40A NLT40 and operator

panel assembly

MU2 QDSH option spare kit

60S01208

MU3 QDSH option spare kit

60S01209

Table 35. Simple operator panel kit content.

MU2 cover for main switch 1

M4x14 screw 2

M5x23 screws 4

Main switch 40A NLT40 and operator

panel assembly

MU3 cover for main switch 1

M4x14 screw 2

M5x23 screws 6

vacon • 93 Options

8.7.1 Installation

• Remove the cover from the drive. See the Figure 60.

4 5

Figure 60. Cover open.

• Open only the inlet holes where you need to run the cables. Cables pass through this inlet hole.

• Place the Simple Operator panel assembly with the cables inside the drive and fix it with its screws.

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

• Fix the cables with the cable clamp.

Options vacon • 94

Figure 61. Simple operator panel connected.

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

• Connect the GROUND wire to the proper terminal (see the yellow-green cable on Figure 57.

• Connect the cables from the potentiometer and from the selector to the I/O control terminals. The cables have to be connected to the I/O terminals as shown in the Figure 61 and in the Table 36.

• RED, BLUE and BLACK wires are signals from the potentiometer.

• YELLOW, WHITE and GREY wires are signal from the selector switch.

vacon • 95 Options

YELLOW WIRE

WHITE WIRE

GREY WIRE

RED WIRE

BLUE WIRE

BLACK WIRE

Table 36. Control I/O terminal signal connections to the simple operator panel.

Standard I/O terminals

Terminal Signal

A RS485_A Serial bus, negative B RS485_B Serial bus, positive 1 +10 Vref Reference output

AI1+

GND I/O signal ground

24Vout 24V aux. voltage

DIN COM

DI1 Digital input 1

DI2 Digital input 2

14 15 16

20 DO1+ Digital output 1

DI3 Digital input 3

AI2+

GND I/O signal ground

DO1-

DI4 Digital input 4

DI5 Digital input 5

DI6 Digital input 6

AO1+

Analogue input, voltage or current

Digital inputs common

Analogue input, voltage or current

Digital output 1 common

Analogue signal (+output)

Function Description Wire colors Terminal

10V reference output RED wire 1

Potentiometer

AI1+ BLUE wire 2 AI1- BLACK wire 3

24V auxiliary voltage YELLOW wire 6

Switch selector

digital input DI1 WHITE wire 8 digital input DI2 GREY wire 9

Table 37. Simple operator panel connection description.

Options vacon • 96

• Mount the plastic cover onto the drive with its screws and the HMI cap: the installation process has been completed. See Figure 62.

Figure 62. Mount the plastic cover.

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

vacon • 97 Options

Vacon 20 X ac drives Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual