Vacon 100 INDUSTRIAL Installation Manual Download Page 68

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COMMISSIONING AND ADDITIONAL

INSTRUCTIONS

7.1

COMMISSIONING SAFETY

Before you start the commissioning, read these warnings.

WARNING!

Do not touch the internal components or the circuit boards of the drive when the

drive is connected to mains. These components are live. A contact with this voltage

is very dangerous. The galvanically isolated control terminals are not live.
WARNING!

Do not touch the motor cable terminals U, V, W, the brake resistor terminals or the

DC terminals when the drive is connected to mains. These terminals are live when

the drive is connected to mains, also when the motor does not operate.
WARNING!

Do not make connections to or from the AC drive when it is connected to mains.

There is a dangerous voltage.
WARNING!

To do work on the connections of the drive, disconnect the drive from mains. Wait 5

minutes before you open the cabinet door or the cover of the drive. Then use a

measuring device to make sure that there is no voltage. The connections of the

drive are live 5 minutes after it is disconnected from mains.
WARNING!

Before you do electrical work, make sure that there is no voltage.
WARNING!

Do not touch the control terminals. They can have a dangerous voltage also when

the drive is disconnected from mains.
WARNING!

Before you connect the drive to mains, make sure that the front cover and the cable

cover of the drive are closed. The connections of the AC drive are live when the

drive is connected to mains.

VACON · 68

COMMISSIONING AND ADDITIONAL INSTRUCTIONS

TEL. +358 (0)201 2121 · FAX +358 (0)201 212 205

Summary of Contents for 100 INDUSTRIAL

Page 1: ...vacon 100 ac drives installation manual enclosed drives ...

Page 2: ......

Page 3: ...d its voltage range is 380 500 V or 525 690 V The drive comes installed in a cabinet and is available in 4 different frame sizes MR8 MR9 MR10 and MR12 The drive can include 1 or more cabinets The drive is available in 2 regional variations IEC qualified to the IEC criteria or NAM North America qualified to the UL criteria Fig 1 An example of the Vacon 100 Enclosed Drive PREFACE VACON 3 24 HOUR SUP...

Page 4: ...VACON 4 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 5: ...binet IEC 18 4 2 Dimensions of the cabinet NAM 20 4 3 The options 24 4 4 Installation of the cabinet 29 4 5 Cooling and free space around the AC drive 30 4 6 The optional back channel cooling 32 4 6 1 Using the back channel for cooling 32 5 Power cabling 35 5 1 Cable dimensioning and selection 35 5 1 1 Cable and fuse sizes IEC 35 5 1 2 Cable and fuse sizes NAM 42 5 2 Brake resistor cables 48 5 3 P...

Page 6: ...the AC drive 75 7 6 3 Replacing the fans of the AC drive 76 7 6 4 Replacing the power unit of the AC drive 81 7 6 5 Downloading the software 90 8 Technical data Vacon 100 94 8 1 AC drive power ratings 94 8 1 1 Mains voltage 380 500 V 94 8 1 2 Mains voltage 525 690 V 95 8 1 3 Brake resistor ratings 95 8 2 Vacon 100 technical data 99 9 Technical data Vacon 100 FLOW 104 9 1 AC drive power ratings 104...

Page 7: ...product 1 EC Declaration of conformity Find the EC Declaration of Conformity on the next page 2 UL approval cULus approval file number E171278 The UL approval is valid for input voltage up to 600 V APPROVALS VACON 7 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 1 ...

Page 8: ...7 0820 7 Enclosed Drives Vacon 0100 3L 0140 5 0590 5 Vacon 0100 3L 0080 7 0820 7 has been designed and manufactured in accordance with the following standards Safety EN 61800 5 1 2007 EN 60204 1 2009 as relevant EMC EN 61800 3 2004 A1 2012 EN 61000 3 12 and conforms to the relevant safety provisions of the Low Voltage Directive 2006 95 EC and EMC Directive 2004 108 EC It is ensured through interna...

Page 9: ...m Read the warnings and cautions carefully and obey their instructions Table 1 The safety symbols The safety symbol Description WARNING CAUTION HOT SURFACE READ THE MANUAL WAIT 5 MINUTES 2 2 WARNING WARNING Do not touch the components of the power unit when the drive is connected to mains The components are live when the drive is connected to mains A contact with this voltage is very dangerous SAF...

Page 10: ...sconnected from mains and the motor has stopped WARNING Before you connect the drive to mains make sure that the front cover and the cable cover of the drive are closed The connections of the AC drive are live when the drive is connected to mains WARNING Disconnect the motor from the drive if an accidental start can be dangerous When there is a power up a power break or a fault reset the motor sta...

Page 11: ...lication Manual NOTE If you use the AC drive as a part of a machine the machine manufacturer must supply a mains disconnection device refer to EN 60204 1 2 4 GROUNDING AND EARTH FAULT PROTECTION CAUTION The AC drive must always be grounded with a grounding conductor that is connected to the grounding terminal that is identified with the symbol Not using a grounding conductor can cause damage to th...

Page 12: ...reaks Obey the local regulations on the minimum size of the protective grounding conductor NOTE Because there are high capacitive currents in the AC drive it is possible that the fault current protective switches do not operate correctly CAUTION Do not do voltage withstand tests on the AC drive The manufacturer has already done the tests Doing voltage withstand tests can cause damage to the drive ...

Page 13: ...ype VACON0100 3L 0205 5 ED S N V00000245581 Code 70 AB3L02055W08B220BM26 00009499 Firmware FW0072V004 Application Marks Cust Ord No 20528906 Made by Vacon Vacon Pasific INPUT Uin 3 AC 380 500V 50 60Hz 200A 40 C 205A 50 C OUTPUT 3 AC 0 Uin 0 320Hz 205A 40 C 170A 50 C POWER 110kW 400V 150HP 480V IP21 70 AB3L02055W08b220BM26 00009499 V00000245581 0020528906 A B C H I D F G E Fig 2 The package label o...

Page 14: ...The mains voltage 5 380 500 V 7 525 690 V FLOW The Vacon 100 FLOW AC drive ED The AC drive is enclosed in a cabinet You can find the type designation code on a lable in the lower right corner of the control compartment door 3 3 THE CONTENTS OF THE DELIVERY The contents of the delivery MR8 MR12 The enclosed drive An accessories bag Installation Manual Application Manual and manuals for the options ...

Page 15: ...P21 IP54 kg Common mode filter du dt filter kg Top cabling sections kg MR8 200 30 65 MR9 270 40 65 MR10 420 40 80 MR12 825 80 95 3 5 2 LIFTING THE AC DRIVE The AC drive is delivered horizontally on a wooden pallet MOVING THE ENCLOSED DRIVE 1 Do not remove the package material before you install the AC drive 2 Put the drive onto a level base 3 Move the drive in the vertical position 4 Use a hoist t...

Page 16: ...from the package 60 2 Use a lifting device that is sufficiently strong for the weight of the drive 3 Put the lifting hooks in the holes on the top of the cabinet 4 The minimum angle between the drive and the chain is 60 degrees VACON 16 RECEIVING THE DELIVERY 3 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 17: ... Date Date Date 3 7 DISPOSAL When the drive is at the end of its operation life do not discard it as a part of municipal waste You can recycle the primary components of the drive You must disassemble some components before you can remove the different materials Recycle the electrical and electronic components as waste To make sure that the waste is recycled correctly send the waste to a recycling ...

Page 18: ...tical position on level ground Attach the drive with screws to the wall and or the floor 406 Ø13 Ø13 Ø13 335 639 399 354 602 605 2100 5 2135 5 2155 5 120 5 100 200 Fig 3 The dimensions of the default cabinet MR8 mm VACON 18 MOUNTING 4 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 19: ...Ø13 Ø13 Ø13 535 639 599 555 600 604 2100 5 2135 5 2155 5 120 5 100 200 Fig 4 The dimensions of the default cabinet MR9 and MR10 mm MOUNTING VACON 19 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 4 ...

Page 20: ... 604 Ø 13 Ø 13 Fig 5 The dimensions of the default cabinet MR12 mm 4 2 DIMENSIONS OF THE CABINET NAM Install the AC drive in a vertical position on level ground Attach the drive with screws to the wall and or the floor VACON 20 MOUNTING 4 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 21: ...06 Ø13 Ø13 Ø13 335 639 5 399 354 602 605 2200 5 2235 5 2255 5 220 5 200 200 Fig 6 The dimensions of the default cabinet MR8 mm MOUNTING VACON 21 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 4 ...

Page 22: ...606 Ø13 Ø13 Ø13 535 638 5 599 555 600 604 2200 5 2235 5 2255 5 220 5 200 200 Fig 7 The dimensions of the default cabinet MR9 and MR10 mm VACON 22 MOUNTING 4 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 23: ... 5 2200 5 1135 1199 1206 555 200 200 555 45 639 Ø13 2235 5 2255 5 600 604 Ø13 Ø13 Fig 8 The dimensions of the default cabinet MR12 mm MOUNTING VACON 23 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 4 ...

Page 24: ...tton on door CPS0 SS1 with emergency stop push button on door CPS1 Emergency switch off CPSB Insulation monitoring CPIF Input devices AC fuses and fuse switch CIFD Input contactor CICO Dynamic braking Brake chopper DBIN Output filters Common mode filter POCM du dt filter PODU Cabling options Input cabling from top CHIT Output cabling from top CHOT Cabling from top CHCT Base plinth options Base pli...

Page 25: ...he inside temperature of the cabinet above the ambient temperature and thus prevents condensation in the cabinet The external supply is connected to terminals XD1 1 The heater element is of a self regulating type When the drive is not in Run state the control relay QAM changes the supply to the output terminals XD4 When the drive is in Run state the control relay disconnects the supply to the cabi...

Page 26: ...age transformer CAPD 24 VDC POWER SUPPLY This option provides a backup supply for the control unit of the drive Use it also for other auxiliary options for which a 24 VDC supply is necessary The requirements CAPU Auxiliary AC supply terminals or CAPT Auxiliary voltage transformer The backup supply for the control unit requires CAPU Auxiliary AC supply terminals L 1 AC AC N XD1 FC7 2 A TB7 24 V 60 ...

Page 27: ...wn free use No requirements CAPU AUXILIARY AC SUPPLY TERMINALS This option provides terminals XD1 1 for an external voltage supply The external supply must be short circuit protected The power of this supply depends on other selected cabinet options The requirements Not CAPT Auxiliary voltage transformer WARNING The main switch does not disconnect the external voltage supply Before you touch the c...

Page 28: ...ons and the certified safety functions The requirements The option board OPT BJ CAPD 24 VDC power supply CAPU Auxiliary AC supply terminals or CAPT Auxiliary voltage transformer CAUTION The delay of the safety relay is process machine dependent The designer and the user of your system are responsible for understanding and setting the delay of the safety relay An incorrect delay can cause damage to...

Page 29: ...n mode voltage The filter is connected between the motor cable terminals of the power unit and the motor cable terminals of the drive The filter does not have an effect on the connection of the external motor cables PODU DU DT FILTER The option includes an output filter that increases the rise time of the voltage pulse and thus decreases the voltage stress on the motor winding insulation The filte...

Page 30: ...ration The fan circulates air and decreases the temperature of the drive Make sure that there is sufficiently free space around the drive Some free space in front of the drive is also necessary for maintenance You must also have 80 cm of free space in front of the cabinet to be able to open the cabinet door When you have 2 or more drives you can install them side by side Make sure that the tempera...

Page 31: ...gnificantly when the load the output frequency or the switching frequency changes It is useful to know the power loss when you plan the cooling equipment in an electrical room Use this formula to calculate the approximate power loss of the drive in nominal conditions Ploss kW Pmot kW x 0 025 It is possible that there will be an increase of 0 0 5 in the power loss when you have options in the cabin...

Page 32: ...ning in the wall behind the cabinet 2 To prevent condensation in the cabinet connect the supply cable of the cabinet heater to the correct terminals in the control compartment 3 Attach the duct adapter flanges to the cabinet with screws 4 Do not install the cabinet in an airtight space Approximately 5 10 of the intake air must come from the front 5 Move the cabinet adjacent to the wall 6 Make sure...

Page 33: ...t fan or equivalent to prevent back pressure Back pressure must be prevented because it decreases the performance of the drive 50 50 258 252 202 252 202 1939 Fig 18 Dimensions for the back channel cooling MR8 MOUNTING VACON 33 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 4 ...

Page 34: ...50 402 50 258 202 402 202 1935 Fig 19 Dimensions for the back channel cooling MR9 and MR12 VACON 34 MOUNTING 4 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 35: ...he impedance of the supply circuit The table also shows the typical symmetrically shielded copper and aluminum types of the cables that can be used with the AC drive NOTE The mains cable and fuse sizes are valid up to a cable length of 100 m with mains IK 20 kA B A 3 3 3 3 3 F1 3 FC1 TA1 T1 Fig 20 The location of the fuses MR8 MR10 A The mains fuses B The cabinet B A 3 3 3 3 3 F1 3 FC1 1 TA1 1 3 3...

Page 36: ...erature is 30 C The maximum temperature of the cable surface is 70 C The maximum number of parallel cables on a ladder type tray is 9 side by side In other conditions when you select the dimensions of the cables refer to local safety regulations the input voltage and the load current of the drive VACON 36 POWER CABLING 5 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 37: ... MR10 0385 5 385 400 2x 3x120 70 Cu 2x 3x185 57 Al M12 M8 0460 5 460 500 2x 3x150 70 Cu 2x 3x240 72 Al M12 M8 0520 5 520 630 2x 3x185 95 Cu 3x 3x150 41 Al M12 M8 0590 5 590 630 2x 3x240 120 Cu 3x 3x185 57 Al M12 M8 MR12 0650 5 650 2 x 355 4x 3x95 50 Cu 4x 3x120 41 Al M12 M8 0730 5 730 2 x 400 4x 3x95 50 Cu 4x 3x150 41 Al M12 M8 0820 5 820 2 x 500 4x 3x120 70 Cu 4x 3x185 57 Al M12 M8 0920 5 920 2 x...

Page 38: ...x120 70 Cu 3x185 57 Al M10 M8 MR10 0261 7 261 315 3x185 95 Cu 2x 3x95 29 Al M12 M8 0325 7 325 355 3x240 120 Cu 2x 3x120 41 Al M12 M8 0385 7 385 400 2x 3x120 70 Cu 2x 3x185 57 Al M12 M8 0416 7 416 450 2x 3x120 70 Cu 2x 3x185 57 Al M12 M8 MR12 0460 7 460 2 x 315 2x 3x150 70 Cu 2x 3x240 72 Al M12 M8 0520 7 520 2 x 315 2x 3x185 95 Cu 4x 3x95 29 Al M12 M8 0590 7 590 2 x 315 4x 3x70 35 Cu 4x 3x120 41 Al...

Page 39: ... 2 3300 0310 5 310 NH2UD69V630PV 630 3 2 5000 MR10 0385 5 385 NH2UD69V700PV 700 3 2 5700 0460 5 460 NH3UD69V900PV 900 3 3 7000 0520 5 520 NH3UD69V1000PV 1000 3 3 8600 0590 5 590 PC73UD90V10CPA 1000 3 3 13000 MR12 0650 5 650 NH2UD69V630PV 630 6 2 5000 0730 5 730 NH2UD69V700PV 700 6 2 5700 0820 5 820 NH3UD69V900PV 900 6 3 7000 0920 5 920 NH3UD69V1000PV 1000 6 3 8600 1040 5 1040 NH3UD69V1000PV 1000 6...

Page 40: ...00 0170 7 170 NH1UD69V350PV 350 3 1 2400 0208 7 208 NH1UD69V400PV 400 3 1 2800 MR10 0261 7 261 NH2UD69V400PV 400 3 2 2800 0325 7 325 NH2UD69V500PV 500 3 2 3300 0385 7 385 NH2UD69V630PV 630 3 2 5000 0416 7 416 NH3UD69V900PV 900 3 3 7100 MR12 0460 7 460 NH2UD69V400PV 400 6 2 2400 0520 7 520 NH2UD69V450PV 450 6 2 2800 0590 7 590 NH2UD69V500PV 500 6 2 3300 0650 7 650 NH2UD69V550PV 550 6 2 4000 0750 7 ...

Page 41: ...61 170M5810D 500 3 2 2800 0310 5 310 170M5812D 630 3 2 4000 MR10 0385 5 385 170M5814D 800 3 2 5750 0460 5 460 170M6814D 1000 3 3 7500 0520 5 520 170M6892D 1100 3 3 8500 0590 5 590 170M8554D 1250 3 3 10500 MR12 0650 5 650 170M5814D 800 6 2 5750 0730 5 730 170M5814D 800 6 2 5750 0820 5 820 170M6813D 900 6 3 6000 0920 5 920 170M6814D 1000 6 3 7500 1040 5 1040 170M6892D 1100 6 3 8500 1180 5 1180 170M8...

Page 42: ...2D 630 6 2 4000 0590 7 590 170M5813D 700 6 2 4800 0650 7 650 170M5813D 700 6 2 4800 0750 7 750 170M5814D 800 6 2 5750 0820 7 820 170M6813D 900 6 3 6000 5 1 2 CABLE AND FUSE SIZES NAM Fuses that are contained in the product FC1 are suitable for both short circuit and branch circuit protection see Table 15 and Table 16 Do not use other fuses than these NOTE The overcurrent protection of parallel cab...

Page 43: ...abinet The cable dimensioning in Table 13 and Table 14 is in accordance with UL61800 5 1 and the National Electric Code per table 310 15 B 16 The values of the tables were calculated using correction factors for a 40 C ambient operating temperature and using AC drive cables with a minimum insulation rating of 90 C Refer to local or municipal regulations for more sizing requirements The UL approval...

Page 44: ... L 0310 5 310 2x 3x4 0 3x8 LCAX4 0 38 X LCAX8 56 L MR10 0385 5 385 2x 3x262 3x6 LCAX250 12 X LCAX6 56 L 0460 5 460 2x 3x313 3x6 LCAX300 12 6 LCAX6 56 L 0520 5 520 2x 3x373 3x6 LCAX350 12 6 LCAX6 56 L 0590 5 590 3x 3x262 3x6 LCAX250 12 X LCAX6 56 L MR12 0650 5 650 4x 3x4 0 3x8 LCAX4 0 12 X LCAX8 56 L 0730 5 730 4x 3x4 0 3x8 LCAX4 0 12 X LCAX8 56 L 0820 5 820 4x 3x262 3x6 LCAX250 12 X LCAX6 56 L 092...

Page 45: ...8 X LCAX8 56 L 0208 7 208 2x 3x1 3x10 LCAX1 38 X P10 56R L MR10 0261 7 261 2x 3x2 0 3x10 LCA2 0 12 X P10 56R L 0325 7 325 2x 3x4 0 3x8 LCAX4 0 12 X LCAX8 56 L 0385 7 385 2x 3x262 3x6 LCAX250 12 X LCAX6 56 L 0416 7 416 2x 3x262 3x6 LCAX250 12 X LCAX6 56 L MR12 0460 7 460 4x 3x1 0 3x10 LCAX1 0 12 X P10 56R L 0520 7 520 4x 3x2 0 3x10 LCAX2 0 12 X P10 56R L 0590 7 590 4x 3x4 0 3x8 LCAX4 0 12 X LCAX8 5...

Page 46: ...00 0310 5 310 PC30UD69V550TF 550 3 PSC30 4700 MR10 0385 5 385 PC32UD69V630TF 630 3 PSC32 4700 0460 5 460 PC32UD69V700TF 700 3 PSC32 5700 0520 5 520 PC32UD69V900TF 900 3 PSC32 8200 0590 5 590 PC32UD69V1000TF 1000 3 PSC32 9600 MR12 0650 5 650 PC32UD69V630TF 630 6 PSC32 4700 0730 5 730 PC32UD69V630TF 630 6 PSC32 4700 0820 5 820 PC32UD69V700TF 700 6 PSC32 5700 0920 5 920 PC32UD69V800TF 800 6 PSC32 680...

Page 47: ...F 315 3 PSC30 2250 0208 7 208 PC30UD69V350TF 350 3 PSC30 2550 MR10 0261 7 261 PC32UD69V450TF 450 3 PSC32 3000 0325 7 325 PC32UD69V500TF 500 3 PSC32 3400 0385 7 385 PC32UD69V630TF 630 3 PSC32 4700 0416 7 416 PC32UD69V700TF 700 3 PSC32 5700 MR12 0460 7 460 PC32UD69V450TF 450 6 PSC32 3000 0520 7 520 PC32UD69V450TF 450 6 PSC32 3000 0590 7 590 PC32UD69V500TF 500 6 PSC32 3400 0650 7 650 PC32UD69V550TF 5...

Page 48: ...x120 70 0590 5 590 MR12 0650 5 650 4x 3x95 50 0730 5 730 0820 5 820 0920 5 920 1040 5 1040 4x 3x120 70 1180 5 1180 One of the cable conductors remains unconnected Use a symmetrically shielded cable the same type as with the mains and motor cables NOTE The different Vacon 100 applications have different functions For example the Vacon 100 FLOW does not have the dynamic braking or the brake resistor...

Page 49: ... 416 MR12 0460 7 460 4x 3x70 35 0520 7 520 0590 7 590 0650 7 650 0750 7 750 4x 3x95 50 0820 7 820 One of the cable conductors remains unconnected Use a symmetrically shielded cable the same type as with the mains and motor cables NOTE The different Vacon 100 applications have different functions For example the Vacon 100 FLOW does not have the dynamic braking or the brake resistor functions POWER ...

Page 50: ...ng clamp for cable shield 360 grounding F The control cable G The grounding bar of the control cable Only use symmetrically EMC shielded mains and motor cables The maximum length of shielded motor cables is 200 m MR8 MR12 If the cable insulation checks are necessary see chapter 7 3 Measuring the cable and motor insulation for instructions If the motor cables are in parallel with other cables obey ...

Page 51: ... mains cable terminals G The 360 degree grounding H The PE bar I Input air grill J The terminals for the option CAPU K The motor cable terminals with the common mode and or the du dt filter options L The options CAPT and CPIF M The motor cable terminals without the common mode and or the du dt filter options N The internal fan for IP54 O The main fan P The cable entry plate for control cables POWE...

Page 52: ...le terminals G The 360 degree grounding H The PE bar I Input air grill J The terminals for the option CAPU K The motor cable terminals with the common mode and or the du dt filter options L The options CAPT and CPIF M The motor cable terminals without the common mode and or the du dt filter options N The internal fan for IP54 O The main fan P The cable entry plate for control cables VACON 52 POWER...

Page 53: ...nd the covers D The main switch option and the fuses E The mains cable terminals F The 360 degree grounding G The PE bar H Input air grill I The terminals for the option CAPU J The motor cable terminals K The service lid and the main fan under it L The cable entry plate for control cables POWER CABLING VACON 53 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 5 ...

Page 54: ...tive covers A Power unit 1 B Power unit 2 C Optical fibre cables D The connector for control unit cable in power unit 1 E The fuse switch linkage for the fuse switch option F The DC link connection VACON 54 POWER CABLING 5 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 55: ... reaches the grounding bar 7 Strip the brake resistor cable a Keep the grounding conductor as short as possible but so that it reaches the grounding bar 8 Connect the stripped cables a Connect the phase conductors of the mains cable and of the motor cable into the correct terminals If you use a brake resistor cable connect its conductors into the correct terminals b Attach the grounding conductor ...

Page 56: ...e connector put the cable lugs on top of each other The picture shows the connection in MR8 and MR9 A C B A The first cable lug B The second cable lug C The connector VACON 56 POWER CABLING 5 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 57: ...bolt still when you turn the nut A B C 1 2 3 4 D A The bolt holder of the connector B The first cable lug C The connector D The second cable lug E A C B D F A The bolt holder of the connector B The first cable lug C The connector D The second cable lug E The connection bush F The third cable lug POWER CABLING VACON 57 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 5 ...

Page 58: ...he extension box cover 13 Close the cabinet door 14 Make sure that the grounding conductor is connected to the motor and also to the terminals that are identified with a To obey the requirements of the standard EN61800 5 1 obey the instructions in chapter 2 4 Grounding and earth fault protection VACON 58 POWER CABLING 5 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 59: ...lb in Nm lb in MR8 0140 5 0205 5 0080 7 0125 7 30 44 266 389 20 177 MR9 0261 5 0310 5 0144 7 0208 7 30 44 266 389 20 177 MR10 0385 5 0590 5 0261 7 0416 7 55 70 490 620 20 177 MR12 0650 5 1180 5 0460 7 0820 7 55 70 490 620 20 177 Counter torque is required for the mains cable terminals POWER CABLING VACON 59 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 5 ...

Page 60: ...d the frame of the drive The control compartment contains these items the control unit the control panel the option boards the optional auxiliary components and the related wires the terminals for internal connections the terminals for control cabling the order specific documentation on the inside of the door the optional buttons and signal lights on the door Connect the cables of the option board...

Page 61: ...ith places for cable ties D The cable carrier E The cable ducts F The extended I O terminals CTID to be used freely G The control grounding plate H The customer grounding plate I The terminals for control cabling default J Grounding clamps for cable shield CONTROL COMPARTMENT VACON 61 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 6 ...

Page 62: ...rminals CTID to be used freely H The terminals for control cabling default I The control panel J The emergency stop push button CPS0 CPS1 CPSB K The emergency stop reset button CPS1 L The Fault signal light CDLP M The Run signal light CDLP N The Ready signal light CDLP O The Reset button CDLP P The 0 1 start switch CICO Q The insulation fault CPIF R The rating plate of the drive the option codes a...

Page 63: ...net terminal D The control terminals 6 2 1 USING FIELDBUS THROUGH AN ETHERNET CABLE Table 21 Ethernet cable data Item Description The plug type A shielded RJ45 plug maximum length 40 mm The cable type CAT5e STP The cable length Maximum 100 m 328 ft ETHERNET CABLING 1 Connect the Ethernet cable to its terminal 2 Put the cover of the drive back Keep the distance between the Ethernet cable and the mo...

Page 64: ...ield of the RS485 cable Do this for the 2 fieldbus cables a Strip the cables for approximately 5 mm 0 20 in to put them in the terminals Do not keep more than 10 mm 0 39 in of the cable outside the terminals b Strip the cable at such a distance from the terminal that you can attach it to the frame with the grounding clamp for control cable Strip the cable at a maximum length of 15 mm 0 59 in Do no...

Page 65: ...in terminals A and B A negative B positive 3 Attach the shield of the cable to the frame of the drive with a grounding clamp for control cable to make a grounding connection CONTROL COMPARTMENT VACON 65 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 6 ...

Page 66: ...tion resistor The termination resistance is 220 Ω 5 Set the bus termination for the first and the last device of the fieldbus line We recommend that the first device on the fieldbus is the master device D D E A C B A The termination is activated B The termination is deactivated C The termination is activated with a DIP switch D The bus termination The resistance is 220 Ω E The fieldbus VACON 66 CO...

Page 67: ...NOTE If you do power down to the last device there is no bus termination CONTROL COMPARTMENT VACON 67 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 6 ...

Page 68: ...rive when it is connected to mains There is a dangerous voltage WARNING To do work on the connections of the drive disconnect the drive from mains Wait 5 minutes before you open the cabinet door or the cover of the drive Then use a measuring device to make sure that there is no voltage The connections of the drive are live 5 minutes after it is disconnected from mains WARNING Before you do electri...

Page 69: ...he mains cable from the terminals L1 L2 and L3 and from mains 2 Measure the insulation resistance of the mains cable between phase conductors 1 and 2 between phase conductors 1 and 3 and between phase conductors 2 and 3 3 Measure the insulation resistance between each phase conductor and the grounding conductor 4 The insulation resistance must be 1 MΩ at the ambient temperature of 20 C 68 F The in...

Page 70: ...rrect An incorrect EMC level can cause damage to the drive 7 5 1 THE EMC JUMPER IN MR8 Change the EMC protection of the AC drive from level C3 to level C4 1 Open the cover of the AC drive 2 Find the EMC box To get access to the EMC jumper remove the cover of the EMC box A A The EMC jumper 3 Remove the EMC jumper Attach the cover of the EMC box again VACON 70 COMMISSIONING AND ADDITIONAL INSTRUCTIO...

Page 71: ...t changed label If the label is not attached at this time attach it on the drive near the name plate Product modified Date Date Date 7 5 2 THE EMC JUMPER IN MR9 Change the EMC protection of the AC drive from level C3 to level C4 THE EMC JUMPER 1 1 Open the covers of the AC drive COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 71 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 7 ...

Page 72: ... product changed label If the label is not attached at this time attach it on the drive near the name plate Product modified Date Date Date THE EMC JUMPERS 2 AND 3 1 Remove the cover of the extension box the touch shield and the I O plate with the I O grommet plate VACON 72 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 73: ...this time attach it on the drive near the name plate Product modified Date Date Date 7 5 3 THE EMC JUMPER IN MR10 AND MR12 Change the EMC protection of the AC drive from level C3 to level C4 FINDING THE EMC JUMPER WITH AN EXTENSION BOX 1 Remove the covers of the AC drive In MR12 do these steps for each power unit Also remove the fuse switch linkage COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 7...

Page 74: ...ANCE 7 6 1 MAINTENANCE INTERVALS To make sure that the drive operates correctly and has a long life we recommend that you do regular maintenance Refer to Table 23 It is not necessary to replace the main capacitors of the drive because they are a thin film type capacitors WARNING Do not make changes in the AC drive when it is connected to mains The components of the drive are live when the drive is...

Page 75: ...Do a check of the internal filter of the power unit 24 months The interval is different in different envi ronments Clean the heatsink and the cooling tunnel 6 10 years Replace the main fan Replace the internal fans if the drive has them Replace the fan power supply 10 years Replace the battery of the RTC The battery is optional This table is valid for Vacon components To do maintenance on componen...

Page 76: ...the cover of the filter back 7 6 3 REPLACING THE FANS OF THE AC DRIVE 7 6 3 1 Replacing the fans in MR8 Here are the instructions on how to replace the fans of the drive REPLACING THE FAN POWER SUPPLY MR8 1 Remove the cover of the AC drive VACON 76 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 77: ... A A The 4 screws 3 Lift off the fan power supply 4 Replace the fan power supply Attach it with the screws 5 Connect the cables and put the cover of the drive back REPLACING THE MAIN FAN MR8 1 Remove the cover of the AC drive 2 Remove the fan power supply See the previous instructions 3 Remove the 4 screws that hold the main fan unit Lift off the main fan unit COMMISSIONING AND ADDITIONAL INSTRUCT...

Page 78: ... of the AC drive 2 Disconnect the cables from the fan power supply a Disconnect the fan supply cable from connector X81 b Disconnect the fan driver cable from connector X61 c Disconnect the DC supply cable from connector X8 Remove the 4 screws that hold the fan power supply X81 X61 X8 A A A The 4 screws 3 Lift off the fan power supply 4 Replace the fan power supply Attach it with the screws 5 Conn...

Page 79: ...he cable 6 Replace the main fan a When you re attach the main fan unit make sure that the sealing tape under the fan plate is in good condition b Attach the screws in the tightening order that is marked in the figure of the main fan unit 1 2 3 7 Re assemble the drive and connect the cables 7 6 3 3 Replacing the fans in MR10 and MR12 Here are the instructions on how to replace the fans of the drive...

Page 80: ...nnector X61 b Disconnect the DC supply cable from connector X8 Remove the 5 screws X61 X8 X61 X8 A A A A The 5 screws 3 Pull out the whole fan assembly The assembly weighs approximately 11 kg 4 Replace the main fan assembly Attach it with the screws 5 Connect the cables and attach the service lid VACON 80 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 81: ...ly cable from connector X8 Remove the 4 screws from each supply X81 X61 X8 A A A The 4 screws 3 Replace the fan power supplies 4 Attach the screws connect the cables and re assemble the drive 7 6 4 REPLACING THE POWER UNIT OF THE AC DRIVE 7 6 4 1 Replacing the power unit MR8 1 Remove the protective covers of the drive 2 Disconnect all the power cables from the bottom of the power unit COMMISSIONIN...

Page 82: ...3 Remove the 2 screws from the top of the power unit VACON 82 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 83: ...m the bottom of the power unit 5 Pull the power unit out carefully until it is possible to use the front lifting holes COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 83 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 7 ...

Page 84: ...wer unit out of the cabinet 7 6 4 2 Replacing the power unit MR9 1 Remove the protective covers of the drive 2 Disconnect all the power cables from the bottom of the power unit VACON 84 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 85: ...the 2 screws from the top of the power unit Also remove the lifting lugs You will re attach them later COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 85 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 7 ...

Page 86: ...rews from the bottom of the power unit 5 Pull the power unit out carefully until it is possible to re attach the lifting lugs VACON 86 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 87: ...lugs You can use the extra nut that is on the screw Remove the nut and attach it to the other side of the lifting lug COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 87 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 7 ...

Page 88: ...the power unit out of the cabinet 7 6 4 3 Replacing the power unit MR10 and MR12 1 Remove the protective covers of the drive In MR12 do these steps for each cabinet VACON 88 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 89: ...unit and remove the cover 3 Disconnect all the power cables from the bottom of the power unit 4 Remove the 2 screws from the top of the power unit COMMISSIONING AND ADDITIONAL INSTRUCTIONS VACON 89 24 HOUR SUPPORT 358 0 201 212 575 EMAIL VACON VACON COM 7 ...

Page 90: ... the power unit out of the cabinet 7 6 5 DOWNLOADING THE SOFTWARE When it is necessary to get a new version of the software of the drive obey these instructions For more information speak to the manufacturer Before you start to download the software read these warnings and the warnings in Chapter 2 Safety VACON 90 COMMISSIONING AND ADDITIONAL INSTRUCTIONS 7 TEL 358 0 201 2121 FAX 358 0 201 212 205...

Page 91: ...B USB RS485 cable The downloading time MR8 and MR9 approximately 6 minutes MR10 approximately 12 minutes MR12 approximately 25 minutes When the drive is not supplied from mains there are 2 alternatives to download the software 1 The first is to use the Software Service Kit The kit enables the power up of the control board without the power up of the drive and enables you to download the software R...

Page 92: ... and X50 23 In MR12 connect the external 24 VDC to the two X50 connectors NOTE The size of the power supply wire for the external 24 VDC must be a minimum of 1 mm2 The lenght of the wire from the 24 VDC power supply to the X50 connectors and to the control unit connectors must be a maximum of 3 m X50 4 In all the frame sizes do power up to the external 24 VDC power supply 5 Remove the control pane...

Page 93: ...50 connectors 12 In MR10 and MR12 attach the service lid In MR12 there are two service lids 13 After the downloading procedure is complete start the Startup wizard see the Application Manual WARNING Before you connect the drive to mains make sure that the front cover and the cable cover of the drive are closed The connections of the AC drive are live when the drive is connected to mains COMMISSION...

Page 94: ...02 0 160 0 132 0 250 0 200 0 MR10 0385 385 0 385 0 423 5 310 0 311 0 465 0 620 0 200 0 160 0 300 0 250 0 0460 460 0 460 0 506 0 385 0 391 0 577 5 770 0 250 0 200 0 350 0 300 0 0520 520 0 520 0 572 0 460 0 459 0 690 0 920 0 250 0 250 0 450 0 350 0 0590 590 0 590 0 649 0 520 0 515 0 780 0 1040 0 315 0 250 0 500 0 450 0 MR12 0650 650 0 648 0 715 0 590 0 587 0 885 0 1180 0 355 0 315 0 500 0 500 0 0730...

Page 95: ... 200 0 250 0 200 0 0325 325 0 330 0 357 5 261 0 269 0 391 5 522 0 300 0 250 0 315 0 250 0 0385 385 0 386 0 423 5 325 0 327 0 487 5 650 0 400 0 300 0 355 0 315 0 0416 416 0 415 0 457 6 385 0 382 0 577 5 770 0 450 0 300 0 400 0 355 0 MR12 0460 460 0 477 0 506 0 416 0 433 0 624 0 832 0 450 0 400 0 450 0 400 0 0520 520 0 532 0 572 0 460 0 472 0 690 0 920 0 500 0 450 0 500 0 450 0 0590 590 0 597 0 649 ...

Page 96: ...e Duty cycle Type of brake resistor Resistance Ω MR8 0080 Light duty BRR 0052 LD 6 18 Heavy duty BRR 0052 HD 6 18 0100 0125 Light duty BRR 0100 LD 6 9 Heavy duty BRR 0100 HD 6 9 MR9 0144 Light duty BRR 0100 LD 6 9 Heavy duty BRR 0100 HD 6 9 0170 0208 Light duty BRR 0208 LD 6 7 Heavy duty BRR 0208 HD 6 7 MR10 0261 0416 Light duty BRR 0416 LD 6 2 5 Heavy duty BRR 0416 HD 6 2 5 MR12 0460 0820 Light d...

Page 97: ...aking with a 7 second ramp to 0 A B P 120 100 80 60 40 20 0 0 1 2 3 4 5 6 7 8 9 t s 10 Fig 31 The LD and HD pulses A Light duty B Heavy duty 0 0 3 5 10 100 P t s 120 240 123 125 130 Fig 32 The duty cycles of the LD and HD pulses Table 28 The minimum resistance and the brake power mains voltage 380 500 V Frame The minimum brake resistance Ω Brake power 845 VDC kW MR8 6 5 109 9 MR9 3 3 216 4 MR10 1 ...

Page 98: ... 690 V Frame The minimum brake resistance Ω Brake power 1166 VDC kW MR8 9 110 MR9 7 193 MR10 2 5 400 MR12 2 x 2 5 800 When you use recommended resistor types The MR12 must have 2 brake resistors VACON 98 TECHNICAL DATA VACON 100 8 TEL 358 0 201 2121 FAX 358 0 201 212 205 ...

Page 99: ...ypes TN TT and IT Short circuit current the maximum short circuit current must be Icc 65 kA Motor connection Output voltage 0 Uin Continuous output current IL Ambient temperature max 40 C overload 1 1 x IL 1 min 10 min IH Ambient temperature max 40 C overload 1 5 x IH 1 min 10 min IH in 690 V drives Ambient temperature max 40 C overload 1 5 x IH 1 min 10 min Output frequency 0 320 Hz standard Freq...

Page 100: ... Default 2 kHz For a product that is configured for a C4 installation on IT network the maximum switching frequency is limited to default 2kHz Automatic switching frequency derating in case of overload Frequency reference Analogue input Panel reference Resolution 0 1 10 bit accuracy 1 Resolution 0 01 Hz Field weakening point 8 320 Hz Acceleration time 0 1 3000 s Deceleration time 0 1 3000 s VACON ...

Page 101: ...and SO2 sulfur dioxide Designed according to Chemical vapours IEC 60721 3 3 unit in opera tion class 3C2 Mechanical particles IEC 60721 3 3 unit in oper ation class 3S2 Altitude 100 load capacity no derating up to 1000 m 1 derating for each 100m above 1000 m Maximum altitudes 380 500 V 4000 m TN and IT systems 380 500 V 2000 m corner grounded network 525 690 V 2000 m TN and IT systems no corner gr...

Page 102: ...00 3 1st and 2nd environment Emissions 380 500 V EN 61800 3 2004 category C3 if the drive is correctly installed 525 690 V EN 61800 3 2004 category C3 if the drive is correctly installed All The drive can be changed to C4 for IT type mains See chapter 7 5 Installation in an IT system Noise level Average noise level min max sound pressure level in dB A The sound pressure depends on the cooling fan ...

Page 103: ...C Mains voltage 525 V trip limit 461 VDC Mains voltage 690 V trip limit 606 VDC Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature protection Yes Motor overload protection Yes The motor overload protection activates at 110 of the full load current Motor stall protection Yes Motor underload protec tion Yes Short circuit prote...

Page 104: ...0 0310 310 0 303 0 341 0 502 0 160 0 250 0 MR10 0385 385 0 385 0 423 5 620 0 200 0 300 0 0460 460 0 460 0 506 0 770 0 250 0 350 0 0520 520 0 520 0 572 0 920 0 250 0 450 0 0590 590 0 590 0 649 0 1040 0 315 0 500 0 MR12 0650 650 0 648 0 715 0 1180 0 355 0 500 0 0730 730 0 724 0 803 0 1300 0 400 0 600 0 0820 820 0 822 0 902 0 1460 0 450 0 700 0 0920 920 0 916 0 1012 0 1640 0 500 0 800 0 1040 1040 0 1...

Page 105: ... 0 228 8 340 0 200 0 160 0 MR10 0261 261 0 272 0 287 1 416 0 250 0 200 0 0325 325 0 330 0 357 5 522 0 300 0 250 0 0385 385 0 386 0 423 5 650 0 400 0 315 0 0416 416 0 415 0 457 6 770 0 450 0 355 0 MR12 0460 460 0 477 0 506 0 832 0 450 0 400 0 0520 520 0 532 0 572 0 920 0 500 0 450 0 0590 590 0 597 0 649 0 1040 0 600 0 500 0 0650 650 0 653 0 715 0 1180 0 650 0 560 0 0750 750 0 747 0 825 0 1300 0 700...

Page 106: ...s Once per minute or less frequently Starting delay 8 s MR8 to MR12 Mains Mains types TN TT and IT Short circuit current the maximum short circuit current must be Icc 65 kA Motor connection Output voltage 0 Uin Continuous output current IL Ambient temperature max 40 C overload 1 1 x IL 1 min 10 min Output frequency 0 320 Hz standard Frequency resolution 0 01 Hz VACON 106 TECHNICAL DATA VACON 100 F...

Page 107: ... kHz For a product that is configured for a C4 installation on IT network the maximum switching frequency is limited to default 2kHz Automatic switching frequency derating in case of overload Frequency reference Analogue input Panel reference Resolution 0 1 10 bit accuracy 1 Resolution 0 01 Hz Field weakening point 8 320 Hz Acceleration time 0 1 3000 s Deceleration time 0 1 3000 s TECHNICAL DATA V...

Page 108: ...sulfur dioxide Designed according to Chemical vapours IEC 60721 3 3 unit in opera tion class 3C2 Mechanical particles IEC 60721 3 3 unit in oper ation class 3S2 Altitude 100 load capacity no derating up to 1000 m 1 derating for each 100m above 1000 m Maximum altitudes 380 500 V 4000 m TN and IT systems 380 500 V 2000 m corner grounded network 525 690 V 2000 m TN and IT systems no corner grounding ...

Page 109: ... and 2nd environment Emissions 380 500 V EN 61800 3 2004 category C3 if the drive is correctly installed 525 690 V EN 61800 3 2004 category C3 if the drive is correctly installed All The drive can be changed to C4 for IT type mains See chapter 7 5 Installation in an IT system Noise level Average noise level min max sound pressure level in dB A The sound pressure depends on the cooling fan speed wh...

Page 110: ... 438 VDC Mains voltage 525 V trip limit 461 VDC Mains voltage 690 V trip limit 606 VDC Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature protection Yes Motor overload protection Yes The motor overload protection activates at 110 of the full load current Motor stall protection Yes Motor underload protec tion Yes Short circui...

Page 111: ...o GND 4 Analogue input voltage or cur rent Analogue input channel 2 Default 4 20 mA Ri 250 Ω 0 10 V Ri 200 kΩ Resolution 0 1 accuracy 1 Selection V mA with DIP switches see chapter Selection of terminal functions with DIP switches in the Installation Man ual 5 Analogue input common cur rent Differential input if not connected to ground Allows 20 V common mode voltage to GND 6 24 V aux voltage 24 V...

Page 112: ... isolated from ground see chapter Isola tion of digital inputs from ground in the Installation Manual 18 Analogue signal output Analogue output channel 1 selection 0 20 mA load 500 Ω Default 0 20 mA 0 10 V Resolution 0 1 accuracy 2 Selection V mA with DIP switches see chapter Selection of terminal functions with DIP switches in the Installation Man ual Short circuit protected 19 Analogue output co...

Page 113: ...ching load 5 V 10 mA 25 26 32 Relay output 3 Normally open NO or SPST contact relay 5 5 mm isolation between channels Switching capacity 24 VDC 8 A 250 VAC 8 A 125 VDC 0 4 A Minimum switching load 5 V 10 mA 33 If you use 230 VAC as control voltage from the output relays the control circuitry must be powered with a separate isolation transformer to limit the short circuit current and the overvoltag...

Page 114: ...ching capacity 24 VDC 8 A 250 VAC 8 A 125 VDC 0 4 A Minimum switching load 5 V 10 mA 25 26 28 TI1 TI1 Thermistor input Rtrip 4 7 kΩ PTC Measuring voltage 3 5V 29 If you use 230 VAC as control voltage from the output relays the control circuitry must be powered with a separate isolation transformer to limit the short circuit current and the overvoltage spikes This is to prevent welding on the relay...

Page 115: ......

Page 116: ...Document ID Rev B Sales code DOC INS100ED DLUK Vacon Ltd Member of the Danfoss Group Runsorintie 7 65380 Vaasa Finland www danfoss com ...

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