Vacon X4 AC Drive Users Manual

X4 AC Drive

user's manual

Need Help?

This manual answers most installation and startup questions

that may arise. However, if you have any problems,

please let your first call be to us.

Vacon, Inc.

Chambersburg, PA 17202

Normal business hours:

(North America)

8:00 AM to 5:00 PM, Eastern time

+1 877-Vacon06

(+1 877-822-6606)

After-hours support is also available

and Vacon, Inc. are trademarks of Vacon Plc, a member of Vacon Group.

All other product names are trademarks of their respective companies.

Summary of X4 Parameters

No. Parameter Name Options Default User Setting See Page

001 Model Number Model Dependent Read-only 60

002 Software Rev 0.00-99.99 Read-only 60

003 Rated Current 0.0-200.0 A Read-only 60

005 Serial No. 1 0-65535 Read-only 60

006 Serial No. 2 0-65535 Read-only 60

010 Last Fault text string Read-only 60

025 4th Fault text string Read-only 60

040 3rd Fault text string Read-only 60

055 2nd Fault text string Read-only 60

070 1st Fault text string Read-only 60

102 Output Freq 0.0-400.0 Hz Read-only 61 103 Output Voltage 0-600 V Read-only 61 104 Output Current 0.0-200.0 A Read-only 61 105 Drive Load -200.0-200.0% Read-only 61 106 Load Torque -200.0-200.0% Read-only 61 107 Drive Temp -20.0-200.0 °C Read-only 61

108 Total Run Time 0.0-6553.5 h Read-only 61

109 Power On Hours 0-65535 h Read-only 61

110 Stator Freq 0.0-400.0 Hz Read-only 61

111 DC Bus Voltage 0 - 1000 Vdc Read-only 61

115 Drive Power Out 0.0-200.0% Read-only 61

201 Input Mode text string Local Only 62 202 Rev Enable text string Forward 62

203 Stop Key Re mot e text string Coast 62

204 Ref Select text string Vin1 63

205 Vin1 Config text string 0-10V 63

206 Vin1 Offset 0.0% to 100.0 % 0.00% 63

207 Vin1 Span 10.0% to 200.0% 100.00% 64

208 Cin Config text string 0-20mA 50 64

209 Cin Offset 0.0% to 100.0% 0.0% 64

210 Cin Span 10.0% to 200.0% 100.0% 64

211 Vin2 Config text string 0-10V 64

212 Vin2 Offset 0.0% to 100.0 % 0.00% 64

213 Vin2 Span 10.0% to 200.0% 100.00% 64

214 Vin1 Filter Time 0 to 1000 ms 20 ms 64

215 Cin Filter Time 0 to 1000 ms 20 ms 64

216 Vin2 Filter Time 0 to 1000 ms 20 ms 65

217 Trim Ref Enable text string Disabled 65

218 Trim % Factor -100.0 - 100.0% 0.0% 65

222 Ref Loss Config text string No Fault 65

301 Min Frequency 0.0 - Max Freq. 0.0 Hz 65 302 Max Frequency 0.0 - 400.0 Hz 60.0 Hz 65 303 Preset Freq 1 Min Freq-Max Freq 5.0 Hz 65

304 Preset Freq 2 Min Freq-Max Freq 10.0 Hz 65

305 Preset Freq 3 Min Freq-Max Freq 20.0 Hz 65

306 Preset Freq 4 Min Freq-Max Freq 30.0 Hz 65

307 Preset Freq 5 Min Freq-Max Freq 40.0 Hz 65

308 Preset Freq 6 Min Freq-Max Freq 50.0 Hz 65

Bold type = Level 1 parameter

= cannot change in Run

(cont’d)

Note that all parameters can be addressed by adding 40000 to the parameter number. For example, parameter 201 (Input Mode) can be addressed by Modbus address 40201.

X4 AC Drive User’s Manual Summary of X4 Parameters

Bold type = Level 1 parameter

No. Parameter Name Options Default User Setting See Page

309 Cut-Off Freq 0.0-5.0 Hz 0.0 Hz 66

401 Ramp Select text string ART-DI 66

402 Accel Time 1 0.1-3200.0 sec 5.0 sec 66 403 Decel Time 1 0.1-3200.0 sec 5.0 sec 66

404 Accel Time 2 0.1-3200.0 sec 3.0 sec 67

405 Decel Time 2 0.1-3200.0 sec 3.0 sec 67

406 DC Inject Config text string DC at Stop 67

407 DC Inject Time 0.0-5.0 sec 0.2 sec 67

408 DC Inject Level 0.0% to 100.0% 50.0% 67

409 DC Inj Freq 0.0 to 20.0 Hz 0.0 Hz 68

410 DB Config text string Internal 68

414 S Ramp Rounding 1 - 100% 25% 68

490 App Macro text string Factory 50 491 Seq Appl text string Disabled 50 492 SIO Visible text string No 50

501 V/Hz Select text string Linear Fixed 69 502 Voltage Boost 0.0-50% 1.0% 69

503 V/Hz Knee Freq 25.0-400.0 Hz 60.0 Hz 69

504 Skip Freq Band 0.2-20.0 Hz 0.2 Hz 70

505 Skip Freq 1 Min Freq-Max Freq 0.0 Hz 70

506 Skip Freq 2 Min Freq-Max Freq 0.0 Hz 70

507 Skip Freq 3 Min Freq-Max Freq 0.0 Hz 70

508 Skip Freq 4 Min Freq-Max Freq 0.0 Hz 70

509 Rated Mtr Volt 100V-690V Model Dependent 70

510 Rated Mtr FLA 50% - 200% of ND Rating ND Rating 70

511 Rated Mtr RPM 0-24000 rpm 1750 rpm 70

512 Midpoint Freq 0.0 Hz-V/Hz Knee Freq 60.0 Hz 70

513 Midpoint Volt 0.0-100.0% 100.0% 70

514 Motor RS 0.0-655.35 Ohms Model Dependent 70

515 Power Factor 0.50-1.00 0.80 70

516 Slip Comp Enable text string No 71

517 Single Phase text string No 71

519 Find Mtr Data Not active / Motor RS Not active 71

520 Filter FStator 1 - 100 ms 8 ms 71

521 Start Field En Ye s / N o No 71

522 Filter Time Slip 10 - 1000 ms 100 ms 71

523 Id Percent 0 - 200% Read-only 72

524 Iq Percent 0 - 200% Read-only 72

525 Power Fail Config text string CTS No Msg 72

526 UV Ride-Thru En text string w/ LVT 72

600 Current Lim Sel text string Fixed Lvls 73

601 Cur Lim Mtr Fwd 5%-150% 120% 73

602 Cur Lim Mtr Rev 5%-150% 120% 73

603 Cur Lim Reg Fwd 5%-150% 80% 73

604 Cur Lim Reg Rev 5%-150% 80% 73

605 Cur Lim Freq 0-400 Hz 3.0 Hz 73

606 Ramp Time CL 0.1-3200.0 sec 1.0 sec 73

607 Cur Limit Minimum 0 - 50% 10% 73

608 Restart Number text string 0 74

609 Restart Delay 0-60 sec 60 sec 74

= cannot change in Run

(cont’d)

Note that all parameters can be addressed by adding 40000 to the parameter number. For example, parameter 201 (Input Mode) can be addressed by Modbus address 40201.

X4 AC Drive User’s Manual Summary of X4 Parameters

Bold type = Level 1 parameter

No. Parameter Name Options Default User Setting See Page

610 Timed OL Select text string Std Ind 60s 74

613 Max Regen Ramp 100 - 1000% 300% 74

614 Stability Gain 0 - 10 Model Dependent 75

615 Stability Rate 0 - 1000 Model Dependent 75 700 Vmet Config text string Freq Out 75

701 Vmet Span 0.0-200.0% 100.0% 75

702 Imet Config text string Drive Load 75

703 Imet Span 0.0-200.0% 100.0% 75

704 Imet Offset 0.0-90.0-% 0.0% 75

705 Relay 1 Select text string Drv Fault 76 706 Relay 2 Select text string Drive Run 76

707 DO1 Select text string Drv Ready 76

708 DO2 Select text string At Speed 76

720 Active Logic text string Active High 76

721 D1 Configure text string Preset 1 77

722 D2 Configure text string Preset 2 77

723 D3 Configure text string Preset 3 77

724 D4 Configure text string Alt Ramp 77

725 D5 Configure text string Fault Reset 77

726 MOL Polarity text string NO Operate 77

727 MOL Configure text string MOL 77

801 Program Number 0-9999 0 77

802 Start Options text string LS Lockout 78

803 PWM Frequency 0.6-16.0 kHz 3.0 kHz 78

804 Display Mode text string Std Disply 78

805 Display Units alphanumeric RPM:1 79

809 Display Scale 1-65535 1 79

810 Language text string English 79

811 Access Code 0-9999 0 79

812 Freq Ref Output text string 6FS 79

813 Speed Ratio 0.0-200.0% 100.0% 79

814 Display Status text string Drive load 80

816 Fly Catch Mode Sweep FWD / REV / F/R Sweep FWD 80

850 PI Configure text string No PI 80

851 PI Feedback text string Vin1 80

852 PI Prop Gain 0-2000 0 80

853 PI Int Gain 0-10000 0 81

854 PI Feed Gain 0-2000 1000 81

855 PI Error 1 0.00-100.00% Read-only 81

856 PI Error 2 0.00-100.00% Read-only 81

857 PI High Corr 0.00-100.00% 100.00% 81

858 PI Low Corr 0.00-100.00% 0.00% 81

900 SIO Protocol text string RTU N81 81

901 SIO Baud Rate text string 9600 81

902 Comm Drop # 1-247 1 81

903 SIO Timer 0.0-60.0 sec 1.0 sec 81

904 SIO Cntl Word text string 0x0000 82

905 Ext Ref Freq1 Min-Max Freq 0.0 Hz 82

906 Ext Ref Freq2 Min-Max Freq 0.0 Hz 82

= cannot change in Run

(cont’d)

Note that all parameters can be addressed by adding 40000 to the parameter number. For example, parameter 201 (Input Mode) can be addressed by Modbus address 40201.

X4 AC Drive User’s Manual Summary of X4 Parameters

Bold type = Level 1 parameter

No. Parameter Name Options Default User Setting See Page

908 Status Word text string Read-only 82

909 DI Status text string Read-only 82

910 Vin1 Status 0.00-100.00% Read-only 83

911 Cin Status 0.00-100.00% Read-only 83

912 Vin2 Status 0.00-100.00% Read-only 83

913 Output Status text string Read-only 83

914 Vmet Status 0.00-100.00% Read-only 83

915 Imet Status 0.00-100.00% Read-only 83

916 Infrared Baud n/a 9600 83

931 Seq Cntl 1 n/a 00000000000 83

932 Seq Cntl 2 n/a 00000000000 83

933 Seq Cntl 3 n/a 00000000000 83

934 Seq Cntl 4 n/a 00000000000 83

935 Seq Cntl 5 n/a 00000000000 83

936 Seq Cntl 6 n/a 00000000000 83

937 Seq Cntl 7 n/a 00000000000 83

938 Seq Cntl 8 n/a 00000000000 83

939 Seq Cntl 9 n/a 00000000000 83

951 Seq Count 1 0-65535 0 84

952 Seq Count 2 0-65535 0 84

953 Seq Count 3 0-65535 0 84

954 Seq Count 4 0-65535 0 84

955 Seq Count 5 0-65535 0 84

956 Seq Count 6 0-65535 0 84

957 Seq Count 7 0-65535 0 84

958 Seq Count 8 0-65535 0 84

959 Seq Count 9 0-65535 0 84

= cannot change in Run

Note that all parameters can be addressed by adding 40000 to the parameter number. For example, parameter 201 (Input Mode) can be addressed by Modbus address 40201.

X4 AC Drive User’s Manual Table of Contents

CONTENTS

Summary of X4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2 Overview of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 User’s Manual Publication History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 2: Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Interpreting Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Power and Current Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.4 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5 Control Features Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.6 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 3: Receiving and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1 Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.3 Dissipation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4 Cover Assembly and Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.5 Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.6 Conduit Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 4: Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 General Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2.1 Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.2.2 Considerations for Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4.2.3 Considerations for Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.3 Input Line Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.3.2 Line Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.3.3 Phase Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.3.4 Single-phase Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.3.5 Ground Fault Circuit Interrupters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.3.6 Motor Lead Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.3.7 Using Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.4 Terminals Found on the X4 Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4.1 Description of the Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.4.2 Typical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.5 Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6 Terminals Found on the X4 Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.6.1 Description of the Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.6.2 Typical Connection Diagrams for Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . .37

X4 AC Drive User’s Manual Table of Contents

4.6.3 Typical Connection Diagrams for Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . .38

4.6.4 Typical Connection Diagrams for Analog Outputs . . . . . . . . . . . . . . . . . . . . . . .38

4.6.5 Modbus Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.7 Reducing Current Surges and Voltage Transients . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chapter 5: Keypad Operation and Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.2 Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.3 LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3.1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.3.2 X4 Keypad Status and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.3.3 Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.3.4 Other Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.4 Keypad Display Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.5 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.5.1 Accessing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

5.5.2 Changing the Display Scroll Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

5.5.3 Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

5.5.4 Restoring Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

5.5.5 Viewing Parameters That Have Changed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.5.6 Using Macro Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

5.6 Measuring Stator Resistance (RS Measurement) . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.6.1 Activating Automatic RS Measurement Using the Keypad . . . . . . . . . . . . . . . .47

5.6.2 Activating Automatic RS Measurement via Serial Link (Modbus) . . . . . . . . . .48

Chapter 6: Using Macro Mode and Getting a Quick Start . . . . . . . . . . . . . . . . . . . . . . . . 49

6.1 Entering Macro Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.2 Description of Parameters Used in Macro Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.3 Macro Mode Applications and Included Parameters . . . . . . . . . . . . . . . . . . . . . . . . 52

6.4 Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 7: X4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.2 Level 1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.3 Description of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.4 Using the X4 Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7.4.1 Enabling the X4 Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

7.4.2 Controlling the X4 Program Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

7.4.3 Sequencer State Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

7.4.4 Sequencer Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

7.4.5 Sample Sequencer Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Blank Worksheet to Remove and Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Chapter 8: Troubleshooting and Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Chapter 9: X4 AC Drive Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Appendix A: Parameter 201 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Chapter 1: Introduction

1.1 Product Overview

Although the X4 AC drive is small in size, it is big on performance. It is an economical yet powerful solution for many industrial applications. It features remote communications capability (using Modbus / IP55 enclosures that eliminate the need for mounting in a separate enclosure.

The X4 product family includes a wide variety of models to suit almost any input voltage requirement. An ‘x’ in the following table indicates what models are currently available. Refer to

“Chapter 2: Technical Characteristics” on page 11 for help in interpreting model numbers.

protocol), a keypad for easy configuration, and standard NEMA 4X / IP66 and NEMA 12

Input Voltage

Horsepower

1xxx x

2xxx

3xxx

5xxx

7.5 x x x

10 x x x

15 x x x

20 x x x

25 x x x

30 x x x

40 x x

50 x x

60 x x

75 x x

100 x x

125 x x

150 x x

200 x x

115 Vac

1 Phase

230 Vac 3 Phase

460 Vac 3 Phase

575 Vac 3 Phase

1.2 Overview of This Manual

This manual contains specifications, receiving and installation instructions, configuration, description of operation, and troubleshooting procedures for X4 AC drive devices.

For experienced users, a Quick Start section begins on page 58. A summary of parameters begins on page iii of this manual.

X4 AC Drive User’s Manual Chapter 1: Introduction

1.3 User’s Manual Publication History

Date Form Number Nature of Change

June 2005 1428 First release

Minor corrections throughout manual. Clarification of technical information and specifications.

March 2006 1428B

August 2006 1428C

June 2007 1428D

March 2008 1428E

May 2008 1428F

June 2008 1428G Changed corporate information for Vacon Incorporated

DPD00088

November 2008

April 2009 DPD00088A Revised EU Declaration of Conformity

(1st release under this

number)

Added X4 models for Frame Size 2. Reformatted to larger page-size document; separated appendices from manual to be available on the web site (www.vacon.com).

Minor corrections and enhancements throughout manual. Added 40 and 50 HP models.

Added 60-200 HP models, new parameters. Minor corrections and reformatting throughout manual.

Minor changes to format, copyright information, and logo Minor corrections throughout manual

Minor corrections throughout manual; added new EU Declaration of Conformity

Changed installation diagrams to reflect changes in product; changed photographs of product; added information to Chapter 2 on current surges and voltage transients; deleted mention of Model X4C20300C; other minor changes and corrections.

Chapter 2: Technical Characteristics

2.1 Interpreting Model Numbers

The model number of the X4 AC drive appears on the shipping carton label and on the technical data label affixed to the model. The information provided by the model number is shown below:

X4 C 20 030 C

X4 Series

Torque:

C = Constant - Normal duty

Input Voltage:

1S = 115 Vac, Single-phase

20 = 230 Vac, Three-phase 40 = 460 Vac, Three-phase 50 = 575 Vac, Three-phase

Horsepower: For example, 010 = 1.0 HP and 075 = 7.5 HP

Enclosure:

C = NEMA 4X / IP66, with keypad D = NEMA 12 / IP55

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

2.2 Power and Current Ratings

115 Vac Ratings

Model

number

X4C1S010C

230 Vac Ratings

Model

number

X4C20010C

X4C20020C

X4C20030C

X4C20050C

X4C20075C

X4C20100C

X4C20150C

X4C20200C

X4C20250C

460 Vac Ratings

Model

number

X4C40010C

X4C40020C

X4C40030C

X4C40050C

X4C40075C

X4C40100C

X4C40150C

X4C40200C

X4C40250C

X4C40300C

X4C40400C

X4C40500C

X4C40600C

X4C40750C

X4C41000C

X4C41250D

X4C41500D

X4C42000D

Normal Duty Input current (A) Output current (A) Heavy Duty Input current (A) Output current (A)

HP kW - 115 Vac - 230 Vac HP kW - 115 Vac - 230 Vac

1 0.75 - 15 - 4.2 0.5 0.37 - 11 0 2.2

Normal Duty Input current (A) Output current (A) Heavy Duty Input current (A) Output current (A)

HP kW 200 Vac 230 Vac 200 Vac 230 Vac HP kW 200 Vac 230 Vac 200 Vac 230 Vac

1 0.75 5.6 4.8 4.8 4.2 0.5 0.37 2.9 2.5 2.5 2.2

2 1.5 9 7.8 7.8 6.8 1 0.75 5.6 4.8 4.8 4.2

3 2.2 12.7 11 11 9.6 2 1.5 9 7.8 7.8 6.8

5 4 20.2 17.5 17.5 15.2 3 2.2 12.7 11 11 9.6

7.5 5.5 29.2 25.3 25.3 22 5 4 20.2 17.5 17.5 15.2

10 7.5 37.2 32.2 37.2 28 7.5 5.5 29.2 25.3 25.3 22

15 11 52.1 46.4 48.3 42 10 7.5 37.2 32.2 37.2 28

20 15 68.3 57.4 62.1 54 15 11 52.1 46.4 48.3 42

25 18.5 82.3 73.8 78.2 68 20 15 68.3 57.4 62.1 54

NOTE: All 230 Vac models can be operated at single-phase, with 50% derating

Normal Duty Input current (A) Output current (A) Heavy Duty Input current (A) Output current (A)

HP kW 380 Vac 460 Vac 380 Vac 460 Vac HP kW 380 Vac 460 Vac 380 Vac 460 Vac

1 0.75 3 2.4 2.4 2.1 0.5 0.37 1.6 1.3 1.3 1.1

2 1.5 5.2 3.9 3.8 3.4 1 0.75 3 2.4 2.4 2.1

3 2.2 7.2 5.6 5.1 4.8 2 1.5 5.2 3.9 3.8 3.4

5 412 8.88.97.63 2.2 7.2 5.6 5.1 4.8

7.5 5.5 15 12.8 12 11 5 412 8.8 8.9 7.6

10 7.5 19.7 16.3 15.6 14 7.5 5.5 15 12.8 12 11

15 11 30.9 25.8 23 21 10 7.5 19.7 16.3 15.6 14

20 15 40 33.3 31 27 15 11 30.9 25.8 23 21

25 18 46.3 40 37 34 20 15 40 33.3 31 27

30 22 57.5 47.8 43 40 25 18 46.3 40 37 34

40 30 73.2 62.4 61 52 30 22 57.5 47.8 43 40

50 37 82 78 71 65 40 30 73.2 62.4 61 52

60 45 94 80 86 77 50 37 82 78 71 65

75 55 114 99 105 96 60 45 94 80 86 77

100 75 149 129 140 124 75 55 114 99 105 96

125 90 168 156 168 156 100 75 140 124 140 124

150 110 205 180 205 180 125 90 168 156 168 156

200 132 240 240 240 240 150 110 205 180 205 180

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

575 Vac Ratings

Model

number

X4C50010C

X4C50020C

X4C50030C

X4C50050C

X4C50075C

X4C50100C

X4C50150C

X4C50200C

X4C50250C

X4C50300C

X4C50400C

X4C50500C

X4C50600C

X4C50750C

X4C51000C

X4C51250D

X4C51500D

X4C52000D

Normal Duty Input current (A) Output current (A) Heavy Duty Input current (A) Output current (A)

HP kW - 575 Vac - 575 Vac HP kW - 575 Vac - 575 Vac

1 0.75 - 2.0 - 1.7 0.5 0.37 - 1.2 - 0.9

2 1.5 - 3.6 - 2.7 1 0.75 - 2.0 - 1.7

3 2.2 - 5.0 - 3.9 2 1.5 - 3.6 - 2.7

5 4- 7.6-6.13 2.2 - 5.0 - 3.9

7.5 5.5 - 10.4 - 9.0 5 4- 7.6 - 6.1

10 7.5 - 14.1 - 11.0 7.5 5.5 - 10.4 - 9.0

15 11 - 23 - 17 10 7.5 - 14.1 - 11

20 15 - 31 - 22 15 11 - 2 3 - 17

25 18 - 37 - 27 20 15 - 31 - 22

30 22 - 39.5 - 32 25 18 - 37 - 27

40 30 - 49 - 41 30 22 - 39.5 - 32

50 37 - 58 - 52 40 30 - 49 - 41

60 45 - 68 - 62 50 37 - 58 - 52

75 55 - 82 - 77 60 45 - 68 - 62

100 75 - 107 - 99 75 55 - 82 - 77

125 90 - 125 - 125 100 75 - 99 - 99

150 110 - 144 - 144 125 90 - 125 - 125

200 132 - 192 - 192 150 110 - 144 - 144

2.3 Environmental Specifications

For 2003, 2005, 5005, 2030, 4030, and 5030 models:

Operating temperature

Storage temperature –20 °C to +65 °C (-4 °F to 149 °F)

Humidity 0% to 95% non-condensing

Altitude 1000 m (3300 ft) without derating

Maximum vibration per EN50178 (1g @ 57-150 Hz)

Acoustic noise 80 dba sound power at 1 m (3 ft), maximum

Cooling

–10 °C to +35 °C (14 °F to 95 °F)

For all other models:

–10 °C to +40 °C (14 °F to 104 °F)

1 to 5 HP models: Natural convection

7.5 to 200.0 HP models: Forced air Note: 575Vac 5 HP model has a fan.

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

2.4 Electrical Specifications

X4C1Sx models: 115 Vac 1 phase, +/- 10%

Input voltage

Line frequency 50 / 60 Hz ±2 Hz

Source kVA (maximum) 10 times the unit rated kVA (see note below)

DC bus voltage for:

Overvoltage trip Dynamic brake activation Nominal undervoltage (UV) trip

Control system

Output voltage 3-phase: 0 to 100% of incoming line (0-230 Vac for 115 Vac models)

Overload capacity

Frequency range 0.1 to 400 Hz

Frequency stability 0.1 Hz (digital), 0.1% (analog) over 24 hours +/- 10 °C

Frequency setting

X4C2x models: 200-230 Vac, 3 phase, +/- 15% X4C4x models: 380-460 Vac, 3 phase, +/- 15% X4C5x models: 575Vac, 3 phase, +/-15%

115 Vac models

406 Vdc 388 Vdc 199 Vdc

V/Hz or SVC Carrier frequency = 1 - 16 kHz, programmable; 8 kHz max. for 125-200 HP models

120% of rated normal duty rms current for 60 seconds 150% of rated heavy duty rms current for 60 seconds

By keypad or by external signal (Speed Pot 0 to 5 Vdc; 0 to 10 Vdc; 0 to 20 mA, or 4 to 20 mA) OR by pulse train up to 100 kHz

230 Vac models

406 Vdc 388 Vdc 199 Vdc

460 Vac models

814 Vdc 776 Vdc 397 Vdc

575 Vac models

1017 Vdc

970 Vdc 497 Vdc

Note: Unit Rated kVA = rated Voltage x rated Current x 1.732

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

2.5 Control Features Specifications

0-5/10 Vdc, 0/4-20 mAdc (250 Ω load)

Vin1 reference input

Vin2 reference input

Cin reference input

Reference voltage 10 Vdc (10 mAdc maximum)

Digital inputs - 10

Digital supply voltage 24 Vdc (150 mAdc maximum)

Preset frequencies 3 inputs for seven preset frequencies (selectable)

Digital outputs

Digital pulse train output Open collector output pulse train proportional to output frequency

Vmet analog output 0 to 10 Vdc (5 mAdc maximum)

Imet analog output 0-20 mAdc output into a 500 Ω load (maximum)

DC holding / injection braking

Current limit Four quadrant adjustable from 5 to 150%

Speed ramps Primary and alternate adjustable from 0.1 to 3200.0 seconds

Voltage boost Fixed boost adjustable from 0 to 50%, or auto boost in Vector mode

Voltage characteristic (V/Hz) Linear, pump, fan or 2-piece linear

Timed overload

Protective features

Program Sequence Logic Controller (PSLC)

Serial communications Modbus Standard: RTU or ASCII

6FS pulse train input, 0-1/10/100 kHz pulse input, inverted function, 0-5-10 bipolar input, broken wire detection. Span and offset adjustment.

0-5/10 Vdc, 0-5-10 bipolar input, inverted function, broken wire detection, span and offset adjustment. Programmable for frequency reference or current limit input.

0/4-20 mAdc (50 Ω load), inverted function, span and offset adjustment. Programmable for frequency reference or current limit input.

Off=0 to 3 Vdc; On=10 to 32 Vdc (pullup logic), selectable between pullup and pulldown logic

2 SPDT relay output - 130 Vac, 1 A/250 Vac, 0.5 A 2 open collector outputs 50 mA per device

At start, stop, by frequency with adjustable current level and time or continuous DC injection by digital input.

Adjustable inverse time trip (shear pin, 30 sec, 60 sec, 5 min), standard or inverterduty motors

Overcurrent, overvoltage fault, ground fault, short circuit, dynamic brake overload, drive temperature, power wiring fault, drive timed overload, input voltage quality, overvoltage ridethrough

9-step PLC type functionality that can control speed, direction, and ramps based on time, analog input, digital input, or pulse input.

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

2.6 Dimensions and Weights

Table 2-1 lists dimensions and weights for the X4 frame size 0, 1, 2, and 3 models. Dimensions and weights for the X4 frame size 4 and 5 models are shown in Table 2-2 on page 18.

See Figures 2-1, 2-2, 2-3, 2-4, 2-5, and 2-6 on pages 16 - 19 for locations of dimensions. Dimensions A through Q are in inches / millimeters (in/mm). Weight is in pounds / kilograms (lb/kg).

Table 2-1: Dimensions and Weights for Frame Sizes 0 - 2

Frame 0 1 2

Vol tag e

Horsepower 1 1-3 5-7.5 5-10 1-10 10-15 15-30 15-30

Dimensions

inches (mm)

(See the

corresponding X4 diagrams on following pages

Weight

lb (kg)

115

Vac

A 9.47 (241) 12.01 (306) 17.38 (442)

B 6.50 (165) 8.72 (221) 10.75 (273)

C 6.08 (155) 6.51 (166) 7.91 (201)

D 8.45 (215) 11.03 (280) 16.50 (419)

E 5.69 (145) 7.88 (200) 9.76 (248)

F 0.28 (7.11) 0.28 (7.11) 0.41 (10)

G 3.84 (98) 4.05 (103) 4.72 (120)

H 2.77 (70) N/A N/A

J 1.93 (49) 2.31 (59) 2.88 (73)

K 2.85 (72) 3.94 (100) 4.84 (123)

L 3.75 (95) 5.56 (1.41) 6.88 (175)

M 0.88 (22) 0.88 (22) 1.38 (35)

N N/A N/A 1.13 (29)

P N/A N/A N/A

Q N/A N/A N/A

230 Vac

8.5 (3.85) 14.0 (6.35) 29.5 (13.38)

460

230 Vac 460 Vac 575 Vac

Vac

230 Vac

460 Vac

575 Vac

Figure 2-1: X4 Frame Size 0 Models

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

)

FF((44ppllaacceess)

MM((33ppllaacceess)

Figure 2-2: X4 Frame Size 1 Models

F(4PLACES)

Figure 2-3: X4 Frame Size 2 Models

M(2PLACES)

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

Table 2-2: Dimensions and Weights for Frame Sizes 3-5

Frame 3 4 5

Voltage 230 Vac 460 Vac 575 Vac 460 Vac 575 Vac 460 Vac 575 Vac

Horsepower 20-30 40-50 40-50 60-100 60-100 125-200 125-200

A 20.19 (513) 29.35 (745) 50.77 (1290) 51.02 (1296)

B 11.25 (286) 12.84 (326) 16.31 (414)

C 11.73 (314) 13.80 (351) 16.88 (429)

D 19.25 (489) 28.00 (711) 45.77 (1163)

E 7.88 (200) 7.88 (200) 7.65 (194)

F 0.28 (7.11) 0.42 (11) 0.42 (11)

Dimensions

inches (mm)

(See the

corresponding

X4 diagrams

on following

pages

Weight

lb (kg)

G 7.78 (198) 8.63 (219) 12.57 (319)

H N/A 8.26 (210) 11.10 (282)

J 0.65 (13) 0.53 (14) 0.20 (5)

K 2.29 (58) 2.69 (68) 2.32 (59)

L 3.95 (100) 3.94 (100) 3.82 (97)

M 1.69 (44) 2.44 (62) 2.94 (75)

N 0.88 (22) 0.88 (22) 0.88 (22)

P 5.60 (142) 5.19 (132) 5.32 (135)

Q 7.24 (184) 7.35 (187) 7.45 (189)

R N/A 10.23 (260) N/A

S N/A 1.94 (49) 1.86 (47)

50.0 (22.68) 95.0 (43.10)) 305.0 (138.35)

F(8PLACES)

N (2 PLACES)

M(2PLACES)

Figure 2-4: X4 Frame Size 3 Models

X4 AC Drive User’s Manual Chapter 2: Technical Characteristics

F(8PLACES)

(2 PLACES)

Figure 2-5: X4 Frame Size 4 Models

F(8PLACES)

(2 PLACES)

Figure 2-6: X4 Frame Size 5 Models

Chapter 3: Receiving and Installation

3.1 Preliminary Inspection

Before storing or installing the X4 AC drive, thoroughly inspect the device for possible shipping damage. Upon receipt:

1. Remove the drive from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent and your sales representative.

2. Remove the cover and inspect the drive for any apparent damage or foreign objects. (See Figure 3-1 on

page 22 for locations of cover screws.) Ensure that all mounting hardware and terminal connection

hardware is properly seated, securely fastened, and undamaged.

3. Read the technical data label affixed to the drive and ensure that the correct horsepower and input voltage for the application has been purchased.

4. If you will be storing the drive after receipt, place it in its original packaging and store it in a clean, dry place free from direct sunlight or corrosive fumes, where the ambient temperature is not less than -20 °C (-4 °F) or greater than +65 °C (+149 °F).

CAUTION

EQUIPMENT DAMAGE HAZARD

Do not operate or install any drive that appears damaged.

Failure to follow this instruction can result in injury or equipment damage.

ATTENTION

RISQUE DE DOMMAGES MATÉRIELS

Ne faites pas fonctionner et n’installez pas tout variateur de vitesse qui semble être endommagé.

Si cette directive n’est pas respectée, cela peut entraîner des blessures corporelles ou des dommages matériels.

3.2 Installation Precautions

Improper installation of the X4 AC drive will greatly reduce its life. Be sure to observe the following precautions when selecting a mounting location. Failure to observe these precautions may void the warranty! See the inside front cover of this manual for more information about the warranty.

• Do not install the drive in a place subjected to high temperature, high humidity, excessive vibration, corrosive gases or liquids, or airborne dust or metallic particles. See Chapter 2 for temperature, humidity, and maximum vibration limits.

• Do not mount the drive near heat-radiating elements or in direct sunlight.

• Mount the drive vertically and do not restrict the air flow to the heat sink fins.

• The drive generates heat. Allow sufficient space around the unit for heat dissipation. See “Dissipation

Requirements” on page 21.

X4 AC Drive User’s Manual Chapter 3: Receiving and Installation

3.3 Dissipation Requirements

Table 3-1: Dissipation Requirement for X4 Models (Page 1 of 2)

Required Dissipation for Models

Model

Entirely Inside an Enclosure at Rated

Current, 3KHz Carrier Frequency (Watts)

X4C1S010C 47 13

X4C20010C 48 14

X4C20020C 71 17

X4C20030C 92 16

X4C20050C 132 20

X4C20075C 177 23

X4C20100C 263 67

X4C20150C 362 68

X4C20200C 550 97

X4C20250C 653 96

X4C40010C 34 13

X4C40020C 46 16

X4C40030C 71 20

X4C40050C 91 21

X4C40075C 114 28

X4C40100C 155 30

X4C40150C 304 77

X4C40200C 393 76

X4C40250C 459 78

X4C40300C 458 77

X4C40400C 695 95

X4C40500C 834 100

X4C40600C 776 130

X4C40750C 988 135

X4C41000C 1638 155

X4C41250D 1656 353

X4C41500D 1891 372

X4C42000D 2302 382

Required Dissipation When Fins are

External to the Enclosure (Watts)

X4 AC Drive User’s Manual Chapter 3: Receiving and Installation

Table 3-1: Dissipation Requirement for X4 Models (Page 2 of 2)

Required Dissipation for Models

Model

Entirely Inside an Enclosure at Rated

Current, 3KHz Carrier Frequency (Watts)

X4C50010C 32 15

X4C50020C 50 22

X4C50030C 66 21

X4C50050C 112 33

X4C50075C 159 37

X4C50100C 187 54

X4C50150C 334 124

X4C50200C 431 143

X4C50250C 528 154

X4C50300C 597 155

X4C50400C 742 160

X4C50500C 877 170

X4C50600C 766 200

X4C50750C 913 200

X4C51000C 1542 275

X4C51250D 1988 337

X4C51500D 2282 349

X4C52000D 3043 355

Required Dissipation When Fins are

External to the Enclosure (Watts)

3.4 Cover Assembly and Torque Specifications

Figure 3-1 shows the locations of the X4 cover screws. The torque range for the X4 covers is 18-26 in/lbs.

Cover screw locations

Figure 3-1: X4 Cover Assembly and Screw Locations

Torque specifications for control terminals and power terminals are listed in “General Wiring

Information” on pages 25 and 26.

Cover screw locations

X4 AC Drive User’s Manual Chapter 3: Receiving and Installation

3.5 Serial Number Label

All X4 AC drives are warranted for three years from date of manufacture, or two years from the date of installation, whichever comes first. For a more detailed description of the warranty policy, visit our web site at http://www.vacon.com. To determine if your drive is within the warranty time frame, find the bar code label or look in the lower left of the technical nameplate. The serial number can be broken down as follows:

yywwxxxx = yy...year of manufacture

ww...week of manufacture

xxxx...sequential number drive during that week

3.6 Conduit Usage

The X4 drive in the NEMA 4X / IP66 enclosure is rated for 1000 psi washdown from 6 inches. To keep this rating, the use of a sealed conduit is required. The use of a Romex-type conduit will not prevent water entry into the enclosure. If the approved conduit is not used, all warranty claims against water damage will be void.

3.7 Condensation

The washdown process of an X4 drive may create a temperature and humidity change in and around the drive. If the unit is mounted in a cool environment and washed down with higher-temperature water, as the drive cools to room temperature, condensation can form inside the drive, especially around the display. To prevent this from happening, avoid using sealed connectors around rubbercoated cables to seal the drive. These do not allow any air transfer and hence create a level of condensation and humidity that exceeds the drive’s rating.

Chapter 4: Connections

HAZARDOUS VOLTAGE

• Read and understand this manual in its entirety before installing or operating the X4 AC drive. Installation, adjustment, repair, and maintenance of these drives must be performed by qualified personnel.

• Disconnect all power before servicing the drive. WAIT 5 MINUTES until the DC bus capacitors discharge.

• DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present.

• Install all covers before applying power or starting and stopping the drive.

• The user is responsible for conforming to all applicable code require-ments with respect to grounding all equipment.

• Many parts in this drive, including printed circuit boards, operate at line voltage. DO NOT TOUCH. Use only electrically-insulated tools.

Before servicing the drive:

• Disconnect all power.

• Place a “DO NOT TURN ON” label on the drive disconnect.

• Lock the disconnect in the open position.

Failure to observe these precautions will cause shock or burn, resulting in severe personal injury or death.

DANGER

TENSION DANGEREUSE

• Lisez et comprenez ces directives dans leurs intégralité avant d’installer ou de faire fonctionner le variateur de vitesse X4. L’installation, le réglage, les réparations et l’entretien des ces variateurs de vitesse doivent être effectuées par du personnel qualifié.

• Coupez toutes les alimentations avant de travailler sur le variateur de vitesse. ATTENDEZ CINQ MINUTES pour que la décharge des condensateurs du bus cc s’effectue.

• NE court-cuitez PAS les condensateurs du bus cc ou ne touchez pas aux composantes non blindées ou aux connexions des vis du bornier si l’appareil est sous tension.

• Installez tous les couvercles avant de mettre le variateur de vitesse sous tension, de le mettre en marche ou de l’arrêter.

• L’utilisateur est responsable de la conformité avec tous les codes électriques en vigueur concernant la mise à la terre de tous les appareils.

• De nombreuses pièces de ce variateur de vitesse, y compris les cartes de circuits imprimés, fonctionnent à la tension du secteur. N’Y TOUCHEZ PAS. N’utilisez que des outils dotés d’une isolation électrique.

Avant tout entretien ou réparation sur le variateur de vitesse:

• Coupez toutes les alimentations.

• Placez une étiquette «NE PAS METTRE SOUS TENSION» sur le sectionneur du variateur de vitesse.

• Verrouillez le sectionneur en position ouverte.

Si ces précautions ne sont pas respectées, cela causera une électrocution ou des brûlures, ce qui entraînera des blessures graves ou la mort.

X4 AC Drive User’s Manual Chapter 4: Connections

4.1 Introduction

This chapter provides information on connecting power and control wiring to the X4 AC drive.

4.2 General Wiring Information

4.2.1 Wiring Practices

When making power and control connections, observe these precautions:

• Never connect input AC power to the motor output terminals T1/U, T2/V, or T3/W. Damage to the drive will result.

• Power wiring to the motor must have the maximum possible separation from all other power wiring. Do not run in the same conduit; this separation reduces the possibility of coupling electrical noise between circuits.

• Cross conduits at right angles whenever power and control wiring cross.

• Good wiring practice also requires separation of control circuit wiring from all power wiring. Since power delivered from the drive contains high frequencies which may cause interference with other equipment, do not run control wires in the same conduit or raceway with power or motor wiring.

4.2.2 Considerations for Power Wiring

Power wiring refers to the line and load connections made to terminals L1/R, L2/S, L3/T, and T1/U, T2/V, T3/W respectively. Select power wiring using these guidelines:

• Use only UL-recognized wire.

• Wire voltage rating must be a minimum of 300 V for 230 Vac systems and 600 V (Class 1 wire) for 460 or 575 Vac systems.

• Wire gauge must be selected based on 125% of the continuous input current rating of the drive. Wire gauge must be selected from wire tables for 75 °C insulation rating, and must be of copper construction. The 230 V 7.5 and 15 HP models, and the 460 V 30 HP models require 90 °C wire to meet UL requirements. See Chapter 2 for the continuous output ratings for the drive.

• Grounding must be in accordance with NEC and CEC. If multiple X4 drives are installed near each other, each must be connected to ground. Take care not to form a ground loop.

See Table 4-1 on page 26 and Table 4-2 on page 26 for information on power terminal wiring specifications.

X4 AC Drive User’s Manual Chapter 4: Connections

Table 4-1: X4 Power Terminal Wiring Specifications

Frame Size

Specifications

Torque Nom. Torque Max. Max. Wire Size Strip Length

Size 0 12 in-lbs 13 in-lbs 12-24 AWG 5/16” (0.3125”)

Size 1 16 in-lbs 18 in-lbs 8-18 AWG 5/16” (0.3125”)

Size 2 30 in-lbs 6-8 AWG 3/8” (0.38”)

Size 3 35 in-lbs 3 AWG

Size 4 65 in-lbs 3/0 AWG

Size 5 132 in-lbs 400 MCM

Note: Wire type not specified by the manufacturer. Some types of wire may not fit within the constraints of the conduit entry and bend radius inside the drive..

Table 4-2: User-Supplied Terminal Cross-Reference

Wire Size Manufacturer Manufacturer’s P/N Manufacturer Manufacturer’s P/N

3 AWG T&B 54107

2 AWG T&B 54107

1 AWG T&B 54108

1/0 AWG T&B 54152-TB Burndy YA25-L6BOX

2/0 AWG T&B 54157 Burndy YA26-L5BOX

3/0 AWG T&B 54162-TB Burndy YA27-LBOX

4/0 AWG Burndy YA28-LBOX

250 MCM Burndy YA29-LBOX

300 MCM Burndy YA30-L

350 MCM Burndy YA31-L

400 MCM Burndy YA32-L1

4.2.3 Considerations for Control Wiring

Control wiring refers to the wires connected to the control terminal strip. Select control wiring as follows:

• Shielded wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping.

• Use only UL recognized wire.

• Wire voltage rating must be at least 300 V for 230 Vac systems. It must be at least 600 V for 460 or 575 Vac systems.

See Table 4-3 below for a summary of control terminal wiring specifications.

Table 4-3: X4 Control Wiring Specifications

X4 Size / Models Specifications

4.4 in-lbs maximum torque

All Sizes / Models

12-24 awg wire

9/32” strip length

X4 AC Drive User’s Manual Chapter 4: Connections

4.3 Input Line Requirements

4.3.1 Line Voltage

See “Power and Current Ratings” on page 12 for the allowable fluctuation of AC line voltage for your particular X4 model. A supply voltage above or below the limits given in the table will cause the drive to trip with either an overvoltage or undervoltage fault.

Exercise caution when applying the X4 AC drive on low-line conditions.

For example, an X4 2000 series unit will operate properly on a 208 Vac line, but the maximum output voltage will be limited to 208 Vac. If a motor rated for 230 Vac line voltage is controlled by this drive, higher motor currents and increased heating will result.

Therefore, ensure that the voltage rating of the motor matches the applied line voltage.

4.3.2 Line Capacity

If the source of AC power to the X4 AC drive is greater than 10 times the kVA rating shown in Ta ble

4-4 below, an isolation transformer or line reactor is recommended. Consult the factory for

assistance in sizing the reactor.

Table 4-4: X4 Line Capacity (kVA)

Drive HP 12357.51015202530405060 75 100125150200

Transformer kVA

Note: X4 AC drive devices are suitable for use on a circuit capable of delivering not more than 65,000 rms symmetrical amperes at 10% above the maximum rated voltage.

2459131823283642577090112150180220250

4.3.3 Phase Imbalance

Phase voltage imbalance of the input AC source can cause unbalanced currents and excessive heat in the drive’s input rectifier diodes and DC bus capacitors. Phase imbalance can also damage motors running directly across the line. The phase imbalance should not exceed 2% of the voltage rating.

CAUTION

EQUIPMENT DAMAGE HAZARD

Never use power-factor correction capacitors on motor terminals T1/U, T2/V, or T3/W of the X4 AC drive. Doing so will damage the semiconductors.

Failure to follow this instruction can result in injury or equipment damage.

ATTENTION

RISQUE DE DOMMAGES MATÉRIELS

Ne raccordez jamais de condensateurs de correction du facteur de puissance aux bornes T1/U, T2/V, ou T3/W du moteur du variateur de vitesse X4. Car cela endommagera les semiconducteurs.

Si cette directive n’est pas respectée, cela peut entraîner des blessures corporelles ou des dommages matériels.

X4 AC Drive User’s Manual Chapter 4: Connections

4.3.4 Single-phase Operation

X4 AC drive 230 Vac models ranging from 1 to 5 HP are designed for both three-phase and singlephase input power. If one of these models is operated with single-phase power, use any two line input terminals. The output of the device will always be three-phase.

The safe derating of the X4 series of drives is 50% of the nominal current (HP) rating. Consult the factory with the particular application details for exact derating by model.

4.3.5 Ground Fault Circuit Interrupters

X4 drives rated for 115 Vac are not designed to operate with ground fault circuit interrupters (GFCI). The GFCI breakers are designed for residential use to protect personnel from stray currents to ground. Most GFCI breakers will shut off at 5 mA of leakage. It is not uncommon for an AC drive to have 30 to 60 mA of leakage.

4.3.6 Motor Lead Length

Vacon, Inc. recommends that the total lead length should not exceed the motor manufacturer’s guidelines. Line disturbance and noise can be present in motor wiring of any distance. As a rule of thumb, any non-inverter duty motor should have a reactor or filter added when the motor lead length exceeds 150 feet. The carrier frequency for the drive should also be reduced using parameter 803

(PWM Frequency).

Nuisance trips can occur due to capacitive current flow to ground. These currents can cause shock to personnel and can create problems within the motor. Care should be taken when working in these areas.

Some applications can have a restricted lead length because of type of wire, motor type, or wiring placement. Consult the factory and the motor manufacturer for additional information.

4.3.7 Using Output Contactors

Contactors in the output wiring of an AC drive may be needed as part of the approved safety circuit. Problems can arise if these contactors are opened for the safety circuit and the drive is left in run mode of operation. When the contactor is open, the drive is in a no-load, no-resistance state, but is still trying to supply current to the motor. However, when the contactor closes, the drive sees the motor resistance and instantly demands current. This inrush of current when the contactor closes can fault or cause failure to the drive.

To prevent problems, interlock an auxiliary contact to the drive’s Run or Enable circuit to stop the drive when the contactor opens. In this way, the drive will be disabled and no inrush will occur when the contactor is closed again.

X4 AC Drive User’s Manual Chapter 4: Connections

4.4 Terminals Found on the X4 Power Board

4.4.1 Description of the Terminals

Table 4-5 describes the X4 power terminals.

Table 4-5: Description of X4 Power Terminals

Terminal Description

L1/R

L2/S L3/T

T1/U T2/V T3/W

Note that earth ground is on the terminal strip (see Figure 4-1 below). Dynamic brake (DB) connections are not on the terminal strip, but on “fast on” (spade) connectors for models up to 30 HP, and on the terminal strip for models 40 HP and larger. See page 32 for specific information about dynamic braking.

These terminals are the line connections for input power. (Single-phase 115 and 230 Vac, 1 to 5 HP models connect to any two of these terminals.)

These terminals are for motor connections.

Figure 4-1: X4 Power Terminals

X4 AC Drive User’s Manual Chapter 4: Connections

Figure 4-2: Power Terminals on Higher-HP Models

4.4.2 Typical Power Connections

See Section 4.3 starting on page 27 for input line requirements.

Note that when testing for a ground fault, do not short any motor lead (T1/U, T2/V, or T3/W) back to an input phase (L1/R, L2/S, or L3/T).

It is necessary to provide fuses and a disconnect switch for the input AC line in accordance with all applicable electrical codes. The X4 AC drive is able to withstand a 150% overload for 60 seconds for heavy duty rating, and 120% overload for normal duty rating.

The fusing and input protection of the drive must always meet UL, NEC (National Electric Code), and CEC (Canadian Electric Code) requirements. All fuse ratings included in Table 4 -6 below are for reference only and do not supersede code requirements. The recommended supplier is Bussman.

Table 4-6: Fuse Ratings (Page 1 of 2)

Fuse Size

115 Vac

Model Number

X4C1S010C 20 — — — — —

X4C20010C — 10 6 — — —

X4C20020C — 15 10 — — —

X4C20030C — 20 15 — — —

X4C20050C — 30 25 — — —

X4C20075C — 40 35 — — —

X4C20100C — 50 40 — — —

X4C20150C — 70 60 — — —

X4C20200C — 90 80 — — —

X4C20250C — 100 90 — — —

JJS/JJN

Fuse Size

208 Vac

JJS/JJN

Fuse Size

230 Vac

JJS/JJN

Fuse Size

380 Vac

JJS

Fuse Size

460 Vac

JJS

Fuse Size

575 Vac

JJS

+ 72 hidden pages

Vacon X4 AC Drive Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of X4 Parameters

Chapter 1: Introduction

1.1 Product Overview

1.2 Overview of This Manual

1.3 User’s Manual Publication History

Chapter 2: Technical Characteristics

2.1 Interpreting Model Numbers

2.2 Power and Current Ratings

2.3 Environmental Specifications

2.4 Electrical Specifications

2.5 Control Features Specifications

2.6 Dimensions and Weights

Chapter 3: Receiving and Installation

3.1 Preliminary Inspection

3.2 Installation Precautions

3.3 Dissipation Requirements

3.4 Cover Assembly and Torque Specifications

3.5 Serial Number Label

3.6 Conduit Usage

3.7 Condensation

Chapter 4: Connections

4.1 Introduction

4.2 General Wiring Information

4.2.1 Wiring Practices

4.2.2 Considerations for Power Wiring

4.2.3 Considerations for Control Wiring

4.3 Input Line Requirements

4.3.1 Line Voltage

4.3.2 Line Capacity

4.3.3 Phase Imbalance

4.3.4 Single-phase Operation

4.3.5 Ground Fault Circuit Interrupters

4.3.6 Motor Lead Length

4.3.7 Using Output Contactors

4.4 Terminals Found on the X4 Power Board

4.4.1 Description of the Terminals

4.4.2 Typical Power Connections