Vacon X4 AC Drive Users Manual

X4 AC Drive

user's manual

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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

([phone]) 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.

Copyright 2009, Vacon, Incorporated. All rights reserved.

Summary of X4 Parameters

= cannot change in Run Bold type = Level 1 parameter

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 Remote	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

(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.

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual					Summary of X4 Parameters
							= cannot change in Run
						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	Yes / No	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

(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.

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual					Summary of X4 Parameters
							= cannot change in Run
						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

(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.

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Summary of X4 Parameters

= cannot change in Run 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

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.

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

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

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© 2009 Vacon Incorporated All Rights Reserved

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

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© 2009 Vacon Incorporated All Rights Reserved

Chapter 1: Introduction

1.1Product 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® protocol), a keypad for easy configuration, and standard NEMA 4X / IP66 and NEMA 12 / 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.

			Input Voltage
Horsepower	115 Vac	230 Vac		460 Vac	575 Vac
	1 Phase	3 Phase		3 Phase	3 Phase
1	x	x		x	x
2		x		x	x
3		x		x	x
5		x		x	x
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

1.2Overview 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.

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© 2009 Vacon Incorporated All Rights Reserved

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	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).
	August 2006	1428C	Minor corrections and enhancements throughout manual.
			Added 40 and 50 HP models.
	June 2007	1428D	Added 60-200 HP models, new parameters.
			Minor corrections and reformatting throughout manual.
	March 2008	1428E	Minor changes to format, copyright information, and logo
			Minor corrections throughout manual
	May 2008	1428F	Minor corrections throughout manual; added new EU Declaration
			of Conformity
	June 2008	1428G	Changed corporate information for Vacon Incorporated
		DPD00088	Changed installation diagrams to reflect changes in product;
			changed photographs of product; added information to Chapter 2
	November 2008	(1st release under this
		number)	on current surges and voltage transients; deleted mention of
			Model X4C20300C; other minor changes and corrections.
	April 2009	DPD00088A	Revised EU Declaration of Conformity

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

Chapter 2: Technical Characteristics

2.1Interpreting 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

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Chapter 2: Technical Characteristics

2.2Power and Current Ratings

115 Vac Ratings

Model	Normal Duty		Input current (A)		Output current (A)		Heavy Duty		Input current (A)		Output current (A)
number	HP	kW	-	115 Vac	-	230 Vac	HP	kW	-	115 Vac	-	230 Vac
X4C1S010C	1	0.75	-	15	-	4.2	0.5	0.37	-	11	0	2.2
230 Vac Ratings
Model	Normal Duty		Input current (A)		Output current (A)		Heavy Duty		Input current (A)		Output current (A)
number	HP	kW	200 Vac	230 Vac	200 Vac	230 Vac	HP	kW	200 Vac	230 Vac	200 Vac	230 Vac
X4C20010C	1	0.75	5.6	4.8	4.8	4.2	0.5	0.37	2.9	2.5	2.5	2.2
X4C20020C	2	1.5	9	7.8	7.8	6.8	1	0.75	5.6	4.8	4.8	4.2
X4C20030C	3	2.2	12.7	11	11	9.6	2	1.5	9	7.8	7.8	6.8
X4C20050C	5	4	20.2	17.5	17.5	15.2	3	2.2	12.7	11	11	9.6
X4C20075C	7.5	5.5	29.2	25.3	25.3	22	5	4	20.2	17.5	17.5	15.2
X4C20100C	10	7.5	37.2	32.2	37.2	28	7.5	5.5	29.2	25.3	25.3	22
X4C20150C	15	11	52.1	46.4	48.3	42	10	7.5	37.2	32.2	37.2	28
X4C20200C	20	15	68.3	57.4	62.1	54	15	11	52.1	46.4	48.3	42
X4C20250C	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
460 Vac Ratings
Model	Normal Duty		Input current (A)		Output current (A)		Heavy Duty		Input current (A)		Output current (A)
number	HP	kW	380 Vac	460 Vac	380 Vac	460 Vac	HP	kW	380 Vac	460 Vac	380 Vac	460 Vac
X4C40010C	1	0.75	3	2.4	2.4	2.1	0.5	0.37	1.6	1.3	1.3	1.1
X4C40020C	2	1.5	5.2	3.9	3.8	3.4	1	0.75	3	2.4	2.4	2.1
X4C40030C	3	2.2	7.2	5.6	5.1	4.8	2	1.5	5.2	3.9	3.8	3.4
X4C40050C	5	4	12	8.8	8.9	7.6	3	2.2	7.2	5.6	5.1	4.8
X4C40075C	7.5	5.5	15	12.8	12	11	5	4	12	8.8	8.9	7.6
X4C40100C	10	7.5	19.7	16.3	15.6	14	7.5	5.5	15	12.8	12	11
X4C40150C	15	11	30.9	25.8	23	21	10	7.5	19.7	16.3	15.6	14
X4C40200C	20	15	40	33.3	31	27	15	11	30.9	25.8	23	21
X4C40250C	25	18	46.3	40	37	34	20	15	40	33.3	31	27
X4C40300C	30	22	57.5	47.8	43	40	25	18	46.3	40	37	34
X4C40400C	40	30	73.2	62.4	61	52	30	22	57.5	47.8	43	40
X4C40500C	50	37	82	78	71	65	40	30	73.2	62.4	61	52
X4C40600C	60	45	94	80	86	77	50	37	82	78	71	65
X4C40750C	75	55	114	99	105	96	60	45	94	80	86	77
X4C41000C	100	75	149	129	140	124	75	55	114	99	105	96
X4C41250D	125	90	168	156	168	156	100	75	140	124	140	124
X4C41500D	150	110	205	180	205	180	125	90	168	156	168	156
X4C42000D	200	132	240	240	240	240	150	110	205	180	205	180

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual											Chapter 2: Technical Characteristics
	575 Vac Ratings
	Model	Normal Duty			Input current (A)		Output current (A)		Heavy Duty		Input current (A)		Output current (A)
	number	HP	kW		-	575 Vac	-	575 Vac	HP	kW	-	575 Vac	-	575 Vac
	X4C50010C	1	0.75		-	2.0	-	1.7	0.5	0.37	-	1.2	-	0.9
	X4C50020C	2	1.5		-	3.6	-	2.7	1	0.75	-	2.0	-	1.7
	X4C50030C	3	2.2		-	5.0	-	3.9	2	1.5	-	3.6	-	2.7
	X4C50050C	5	4		-	7.6	-	6.1	3	2.2	-	5.0	-	3.9
	X4C50075C	7.5	5.5		-	10.4	-	9.0	5	4	-	7.6	-	6.1
	X4C50100C	10	7.5		-	14.1	-	11.0	7.5	5.5	-	10.4	-	9.0
	X4C50150C	15	11		-	23	-	17	10	7.5	-	14.1	-	11
	X4C50200C	20	15		-	31	-	22	15	11	-	23	-	17
	X4C50250C	25	18		-	37	-	27	20	15	-	31	-	22
	X4C50300C	30	22		-	39.5	-	32	25	18	-	37	-	27
	X4C50400C	40	30		-	49	-	41	30	22	-	39.5	-	32
	X4C50500C	50	37		-	58	-	52	40	30	-	49	-	41
	X4C50600C	60	45		-	68	-	62	50	37	-	58	-	52
	X4C50750C	75	55		-	82	-	77	60	45	-	68	-	62
	X4C51000C	100	75		-	107	-	99	75	55	-	82	-	77
	X4C51250D	125	90		-	125	-	125	100	75	-	99	-	99
	X4C51500D	150	110		-	144	-	144	125	90	-	125	-	125
	X4C52000D	200	132		-	192	-	192	150	110	-	144	-	144

2.3Environmental Specifications

		For 2003, 2005, 5005, 2030, 4030, and 5030 models:
	Operating temperature	–10 °C to +35 °C (14 °F to 95 °F)
		For all other models:
		–10 °C to +40 °C (14 °F to 104 °F)
	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
		1 to 5 HP models: Natural convection
	Cooling	7.5 to 200.0 HP models: Forced air
		Note: 575Vac 5 HP model has a fan.

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X4 AC Drive User’s Manual

Chapter 2: Technical Characteristics

2.4Electrical Specifications

	X4C1Sx models: 115 Vac 1 phase, +/- 10%
Input voltage	X4C2x models: 200-230 Vac, 3 phase, +/- 15%
	X4C4x models: 380-460 Vac, 3 phase, +/- 15%
	X4C5x models: 575Vac, 3 phase, +/-15%
Line frequency	50 / 60 Hz ±2 Hz
Source kVA (maximum)	10 times the unit rated kVA (see note below)
DC bus voltage for:	115 Vac models	230 Vac models	460 Vac models		575 Vac models
Overvoltage trip	406 Vdc	406 Vdc	814	Vdc	1017 Vdc
Dynamic brake activation	388 Vdc	388 Vdc	776	Vdc	970 Vdc
Nominal undervoltage (UV) trip	199 Vdc	199 Vdc	397	Vdc	497 Vdc
	V/Hz or SVC
Control system	Carrier frequency = 1 - 16 kHz, programmable; 8 kHz max. for 125-200 HP
	models
Output voltage	3-phase: 0 to 100% of incoming line (0-230 Vac for 115 Vac models)
Overload capacity	120% of rated normal duty rms current for 60 seconds
	150% of rated heavy duty rms current for 60 seconds
Frequency range	0.1 to 400 Hz
Frequency stability	0.1 Hz (digital), 0.1% (analog) over 24 hours +/- 10 °C
	By keypad or by external signal
Frequency setting	(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

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

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Chapter 2: Technical Characteristics

2.5Control Features Specifications

		0-5/10 Vdc, 0/4-20 mAdc (250 Ω load)
	Vin1 reference input	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.
	Vin2 reference input	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.
	Cin reference input	0/4-20 mAdc (50 Ω load), inverted function, span and offset adjustment.
		Programmable for frequency reference or current limit input.
	Reference voltage	10 Vdc (10 mAdc maximum)
	Digital inputs - 10	Off=0 to 3 Vdc; On=10 to 32 Vdc (pullup logic), selectable between pullup and
		pulldown logic
	Digital supply voltage	24 Vdc (150 mAdc maximum)
	Preset frequencies	3 inputs for seven preset frequencies (selectable)
	Digital outputs	2 SPDT relay output - 130 Vac, 1 A/250 Vac, 0.5 A
		2 open collector outputs 50 mA per device
	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	At start, stop, by frequency with adjustable current level and time or continuous DC
		injection by digital input.
	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	Adjustable inverse time trip (shear pin, 30 sec, 60 sec, 5 min), standard or inverter-
		duty motors
		Overcurrent, overvoltage fault, ground fault, short circuit, dynamic brake overload,
	Protective features	drive temperature, power wiring fault, drive timed overload, input voltage quality,
		overvoltage ridethrough
	Program Sequence Logic	9-step PLC type functionality that can control speed, direction, and ramps based on
	Controller (PSLC)	time, analog input, digital input, or pulse input.
	Serial communications	Modbus Standard: RTU or ASCII

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Chapter 2: Technical Characteristics

2.6Dimensions 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
	Voltage	115	230	460	230 Vac	460 Vac	575 Vac	230	460		575
		Vac	Vac	Vac				Vac	Vac		Vac
	Horsepower	1	1-3		5-7.5	5-10	1-10	10-15	15-30 15-30
		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)
	Dimensions	F	0.28 (7.11)			0.28 (7.11)			0.41	(10)
	inches (mm)	G	3.84 (98)			4.05 (103)			4.72 (120)
	(See the	H	2.77 (70)			N/A			N/A
	corresponding
		J	1.93 (49)			2.31 (59)			2.88	(73)
	X4 diagrams on
	following pages	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
	Weight		8.5 (3.85)			14.0 (6.35)			29.5 (13.38)
	lb (kg)
	B		F
									M

A
D	C
	G
	H
	J
	K
E	L

Figure 2-1: X4 Frame Size 0 Models

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Chapter 2: Technical Characteristics

B

F (4 places)

M (3 places)

A

D

		C
		G
		J
	E	K
		L
		Figure 2-2: X4 Frame Size 1 Models
	B	F (4 PLACES)

N M (2 PLACES)

D

A

C

G

J

E

K

L

Figure 2-3: X4 Frame Size 2 Models

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

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
		G		7.78 (198)				8.63 (219)		12.57	(319)
inches (mm)
		H			N/A			8.26 (210)		11.10 (282)
(See the
		J		0.65 (13)				0.53	(14)	0.20 (5)
corresponding
X4 diagrams
		K		2.29 (58)				2.69	(68)	2.32	(59)
on following
		L		3.95 (100)				3.94 (100)		3.82	(97)
pages
		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)
Weight				50.0 (22.68)				95.0 (43.10))		305.0 (138.35)
lb (kg)

E
	F (8 PLACES)
	N (2 PLACES)
	M (2 PLACES)
	D
A	C
	G
	J
	K
	L
B	P

Figure 2-4: X4 Frame Size 3 Models

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

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

E		F (8 PLACES)

			N	M
			(2 PLACES)
		S		(2 PLACES)
A	C
	D	R
			G
			H
			J
			K
			L
				P
B				Q
	Figure 2-5: X4 Frame Size 4 Models

E	F (8 PLACES)

A D

		N
		(2 PLACES)
		M
C		(2 PLACES)
G	H	S
		J
		K
		L
		P
		Q

B

Figure 2-6: X4 Frame Size 5 Models

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

Chapter 3: Receiving and Installation

3.1Preliminary 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.

3.2Installation 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.

DPD00088A

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© 2009 Vacon Incorporated All Rights Reserved

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	Required Dissipation When Fins are
	Model	Entirely Inside an Enclosure at Rated
			External to the Enclosure (Watts)
		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

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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	Required Dissipation When Fins are
	Model		Entirely Inside an Enclosure at Rated
					External to the Enclosure (Watts)
		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

3.4Cover 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	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.

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X4 AC Drive User’s Manual

Chapter 3: Receiving and Installation

3.5Serial 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

3.6Conduit 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.

3.7Condensation

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.

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© 2009 Vacon Incorporated All Rights Reserved

Chapter 4: Connections

DANGER

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.

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© 2009 Vacon Incorporated All Rights Reserved

X4 AC Drive User’s Manual

Chapter 4: Connections

4.1Introduction

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

4.2General 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.

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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

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X4 AC Drive User’s Manual

Chapter 4: Connections

4.3Input 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 Table 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	1	2	3	5	7.5	10	15	20	25	30	40	50	60	75	100	125	150	200
	Transformer	2	4	5	9	13	18	23	28	36	42	57	70	90	112	150	180	220	250
	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.

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.

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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.

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X4 AC Drive User’s Manual

Chapter 4: Connections

4.4Terminals 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	These terminals are the line connections for input power. (Single-phase 115 and 230 Vac,
	L2/S
		1 to 5 HP models connect to any two of these terminals.)
	L3/T
	T1/U
	T2/V	These terminals are for motor connections.
	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.

Figure 4-1: X4 Power Terminals

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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	Fuse Size	Fuse Size	Fuse Size	Fuse Size	Fuse Size
	115 Vac	208 Vac	230 Vac	380 Vac	460 Vac	575 Vac
Model Number	JJS/JJN	JJS/JJN	JJS/JJN	JJS	JJS	JJS
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	—	—	—

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© 2009 Vacon Incorporated All Rights Reserved