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Vacon 100X series, Installation And Maintenance Manual

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vacon • 64

8

Figure 45. Mounting of the keypad.

Figure 46. Keypad mounted onto the drive. Tighten the fixing screws of the cable connector to 

the enclosure of the drive. This is to keep the high IP66 protection degree of the drive.

3

•

Connect the keypad to the drive and plug the cable on the HMI connector as
shown in the Figure 45 and in the Figure 46.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Summary of Contents for 100X series

Page 1: ...vacon 100 x ac drives installation technical and maintenance manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 2: ...Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 3: ...3 4 Cooling 22 4 Power cabling 24 4 1 Circuit breaker 25 4 2 UL standards on cabling 25 4 3 Cable dimensioning and selection 26 4 3 1 Cable and fuse sizes frames MM4 to MM6 26 4 3 2 Brake resistor cab...

Page 4: ...tallation 63 8 2 3 Wall mounting 65 8 2 4 Graphical and Text keypad 67 8 2 5 Vacon keypad with graphical display 68 8 2 6 Vacon keypad with text segment display 73 8 2 7 Fault Tracing 76 9 Safe Torque...

Page 5: ...he motor is not running After disconnecting the AC drive from the mains wait until the indicators on the keypad go out if no keypad is connected see the indicators on the cover Wait 30 more seconds be...

Page 6: ...on The I O functionalities including start inputs may change if parameters applications or software are changed Disconnect therefore the motor if an unexpected start can cause danger This is valid onl...

Page 7: ...conductor and the MOTOR protective conductor the customer can choose the screw for each one The power head is earthed through a metal aglet located on the terminal box which fits into a spring basket...

Page 8: ...that the protective earthing conductor in the cord shall in the case of failure of the strain relief mechanism be the last conductor to be interrupted Figure 2 Earth connections and metal aglet in MM5...

Page 9: ...omplete assembly Should you have any doubt or question please contact your local Vacon distributor Figure 3 Insulation system Please consider carefully the insulation system depicted in Figure 3 befor...

Page 10: ...thing conductor Where a residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the su...

Page 11: ...ient air circulation see for more details the mounting instructions on chapter 3 1 7 Electro magnetic compatibility EMC The Vacon 100 X complies with IEC 61000 3 12 provided that the short circuit pow...

Page 12: ...1 vacon 9 Safety 1 8 Declaration of conformity Figure 5 Declaration of conformity Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 13: ...Safety vacon 10 1 Figure 6 STO certificate Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 14: ...1 vacon 11 Safety Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 15: ...00378 Cust Ord No Application FW0065V008 Firmware EMC level C2 380 480 V IP66 Type 4X 31 A Rated current 122245 B ID V0789012245 S N 22345678901234567890123456729012345 20 AB3L00315A02B5H1MB1C 1234567...

Page 16: ...1 4 X xxxx yyyy VACON This segment is common for all products 0100 Product range 0100 Vacon 100 3L Input Function 3L Three phase input 0061 Drive rating in ampere e g 0061 61 A See Table 18 and Table...

Page 17: ...er after unpacking the product check that no signs of transport damages are to be found on the product and that the delivery is complete Should the drive have been damaged during the shipping please c...

Page 18: ...of the sticker is to notify the service personnel about the modifications made in the AC drive Attach the sticker on the side of the AC drive to avoid losing it Should the AC drive be later modified m...

Page 19: ...ll or directly on the motor saving space and reducing the cabling complexity In both of the cases it must be ensured that the mounting plane is even 3 1 Dimensions Figure 10 Vacon 100 X drive dimensio...

Page 20: ...3 vacon 17 Mounting Figure 11 Vacon 100 X drive dimensions MM5 367 4 203 7 230 8 180 0 345 2 349 2 6 1 232 6 213 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 21: ...Mounting vacon 18 3 Figure 12 Vacon 100 X drive dimensions MM6 229 6 254 2 322 0 349 5 382 8 385 3 499 8 8 2 235 4 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 22: ...y pluggable terminals The power unit called powerhead in cludes all the power electronics such as the EMC filter IGBTs capacitors choke or power boards while the control board and the control terminal...

Page 23: ...ated The terminal box must be fixed first and all cabling done After this the powerhead will be plugged on the terminal box and fixed with 4 MM4 and MM6 or 6 MM5 dedicated screws located on top side o...

Page 24: ...ments in case of failure the power and the control sub systems are enclosed in two segregated parts connected together through pluggable terminals Power head heat sink enclosing all power electronics...

Page 25: ...g air does not exceed the maximum ambient temperature of the converter Contact local Vacon distributor for more information on required clearances in different instal lations Table 5 Min clearances ar...

Page 26: ...3 vacon 23 Mounting Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 27: ...not required MCMK or similar recommended 2 Symmetrical power cable equipped with concentric protection wire and intended for the specific mains voltage MCMK or similar recommended See Figure 17 3 Sym...

Page 28: ...put terminals to the power supply using a circuit breaker observe that this is of type B or type C and chose it with a capacity of 1 5 to 2 times of the inverter s rated current see Table 18 and Table...

Page 29: ...tional Standard IEC60364 5 52 Cables must be PVC isolated Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the m...

Page 30: ...inals for an optional external brake resistor These terminals are marked with DC R and R See Table 20 and Table 21 for the resistor ratings 4 3 3 Control cables For information on control cables see c...

Page 31: ...tances also apply between the motor cables and signal cables of other sys tems The maximum length with full EMC compliance for motor cables 15m C2 The motor cables should cross other cables at an angl...

Page 32: ...e entry plate The cable entry system is a combination of a cable entry plate see the figure below and cable glands In the cable entry plate there are several openings available for the cables with ISO...

Page 33: ...enclosure which the cable enters can be maintained adequately ONLY PLASTIC GLANDS ARE ALLOWED METAL GLANDS ARE FORBIDDEN 5 Screw the cable glands on the cable entry plate 6 Pass the cables supply cab...

Page 34: ...all two cables into pigtails and make a grounding connection with the clamp Make the pigtails just long enough to reach and be fixed to the terminal no longer Frame Type Tightening torque Nm lb in Po...

Page 35: ...nit When delivered from the factory the control unit of the AC drive contains the standard control ling interface the control and relay terminals of the control unit unless otherwise specifi Number Me...

Page 36: ...igure 24 below The control board is equipped with 22 fixed control I O terminals and the relay board with 6 2 Additionally the ter minals for the Safe Torque Off STO function see chapter chapter 9 can...

Page 37: ...ue input com mon 4 AI2 Analogue input voltage or current 5 AI2 Analogue input com mon 6 24Vout 24V aux voltage 7 GND I O ground 8 DI1 Digital input 1 9 DI2 Digital input 2 10 DI3 Digital input 3 11 CM...

Page 38: ...3 24 RO2 1 Relay output 2 25 RO2 2 26 RO2 3 28 TI1 Thermistor input 29 TI1 Table 15 I O terminal signals for the STO functions Safe Torque Off terminals Terminal Signal S1 Isolated digital input 1 int...

Page 39: ...ppropriate selections for your requirements Factory defaults are AI1 V AI2 C AO C Figure 25 Dip switches for analogue inputs and analogue output 5 1 6 Isolating digital inputs from ground The digital...

Page 40: ...ans that a termination resistor of 120 ohm is connected and the termination of the bus has been set This switch in the position 1 means that a pull up and a pull down resistors of 10 kOhm have been co...

Page 41: ...sing 5 2 1 1 Ethernet cable data Table 16 Ethernet cable data 1 Connect the Ethernet cable see specification on page 38 to its terminal and run the cable through the conduit plate 2 Remount the powerh...

Page 42: ...hield 2 Then connect the cable to its appropriate terminals on Vacon 100 X AC drive standard terminal block terminals A and B A negative B positive See Figure 28 3 Using the cable clamp included in th...

Page 43: ...r device Connector 2 5 mm2 Cable type STP Shielded Twisted Pair type Belden 9841 or similar Cable length Depends on the used fieldbus See respective bus manual BACnet MS TP Bus termination Termination...

Page 44: ...ttery is in stalled in the Vacon 100 X drive The place for the battery can be found under the control box cover as shown in Figure 29 Detailed information on the functions of the Real Time Clock RTC c...

Page 45: ...ls may have a dangerous control voltage present even when Vacon 100 X drive is disconnected from mains Do not make any connections to or from the frequency converter when it is con nected to the mains...

Page 46: ...ked with Check the tightening torques of all terminals Check that the wires do not touch the electrical components of the drive Check that the common inputs of digital input groups are connected to 24...

Page 47: ...y removing the EMC screws as described below Figure 30 Locations of EMC screws in MM4 Figure 31 Locations of EMC screws in MM5 Warning Do not perform any modifications on the AC drive when it is conne...

Page 48: ...ss settings of the drive are appropriately made NOTE After having performed the change write EMC level modified on the sticker included in the Vacon 100 X delivery see below and note the date Unless a...

Page 49: ...ulation resistance must be 1M at ambient temperature of 20 C 3 Motor insulation checks Disconnect the motor cable from the motor and open the bridging connections in the motor connection box Measure t...

Page 50: ...acitor type thin film capacitors reforming of capacitors is not neces sary Maintenance interval Maintenance action Regularly and according to general maintenance interval Check tightening torques of t...

Page 51: ...08 240V 50 60 Hz Converter type Input current A Loadability Motor shaft power 230V 240V Rated continuous current IN A 50 overload current A Max current IS kW HP MM4 0007 6 0 6 6 9 9 13 2 1 1 1 5 0008...

Page 52: ...t A Max current IS kW HP MM4 0003 3 4 3 4 5 1 6 8 1 1 1 5 0004 4 6 4 8 7 2 9 6 1 5 2 0 0005 5 4 5 6 8 4 11 2 2 2 3 0 0008 8 1 8 0 12 0 16 0 3 0 5 0 0009 9 3 9 6 14 4 19 2 4 0 5 0 0012 11 3 12 0 18 0 2...

Page 53: ...lies 150 IN for 1 min followed by a period of at least 9 min at IN or below Example If the duty cycle requires 150 rated current for 1 min in every 10 min the remaining 9 min must be at rated current...

Page 54: ...0024 15 0031 10 MM6 0048 8 0062 8 Table 20 Brake resistor ratings 208 240V Mains Voltage 3AC 380 480V 50 60 Hz Frame Type Minimum Resistance recommended ohm MM4 0003 50 0004 50 0005 50 0008 50 0009 50...

Page 55: ...ng output current IS for 2 s every 20 s IS 2 0 IN Output frequency 0 320 Hz standard Frequency resolution 0 01 Hz Protection class I Motor characteristics AC squirrel cage motors Permanent magnet moto...

Page 56: ...tude 100 load capacity no derating up to 1 000m derating 1 100m at 1 000 3 000m Stationary vibration sinusoidal IEC 60068 2 10 Hz f 57 Hz 0 075 mm 57 Hz f 150 Hz 1 g Degree of protection IP66 Type 4X...

Page 57: ...it 211 V Overvoltage fault pro tection Yes Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature protection Yes Motor overload pr...

Page 58: ...0 max volt ripple 100mVrms max 250mA Short circuit protected 7 I O ground Ground for reference and controls connected internally to frame earth through 1M 8 Digital input 1 Positive or negative logic...

Page 59: ...mistor input 5 5 mm isolation between channels Terminal Signal Technical information 21 Relay output 1 If 230VAC is used as control voltage from the output relays the control circuitry must be powered...

Page 60: ...7 vacon 57 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 61: ...the drive The switch can be mounted on either side of the drive See Figure 35 Figure 35 The mains switch mounted on either side of the drive 8 1 1 Installation Figure 36 Disconnect the cable entry pl...

Page 62: ...terminal box 2 Remove the cable entry plate from the bottom side of the terminal box by loos ing the six screws Cables pass through this inlet hole 3 Remove the powerhead from the terminal box by loos...

Page 63: ...erminal box as shown in the figure below 5 Connect the cables from the Mains switch to the terminal box The cables have to be connected to the terminals L1 L2 and L3 6 Place the Mains switch plate wit...

Page 64: ...ables connected Figure 41 Mount the powerhead on the terminal box 8 Mount the powerhead on the terminal box with its screws the installation pro cess has been completed See Figure 41 Phone 800 894 041...

Page 65: ...e keypad is an option and can be delivered separately The option includes the keypad the keypad holder and three screws You can use one screw to fix the keypad holder to the drive or three screws to f...

Page 66: ...on the powerhead 1 Remove the HMI cap from the drive as shown in the Figure 43 2 Install the keypad holder with a screw as shown in the Figure 44 The metal sheets of the keypad holder have to be moun...

Page 67: ...ws of the cable connector to the enclosure of the drive This is to keep the high IP66 protection degree of the drive 3 Connect the keypad to the drive and plug the cable on the HMI connector as shown...

Page 68: ...nt location by using the same keypad holder and three screws provided with the keypad option kit Figure 47 Fix the keypad holder with three screws to the wall 1 Fix the keypad holder with three screws...

Page 69: ...66 8 Figure 48 Keypad connected to the drive 2 Connect and fix the cable to the enclosure of the drive and hold the keypad to the wall Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email inf...

Page 70: ...n Decrease value Move cursor left Move cursor right Move backward in menu Exit edit mode Reset faults with long press Change control place Stop button Start button Enter active level item Confirm sele...

Page 71: ...ut the present status of the drive See Figure 50 Figure 50 Main menu 8 2 5 3 Using the graphical keypad Editing values Change value of a parameter following the procedure below 1 Locate the parameter...

Page 72: ...than remote control Therefore if for example bypassed by parameter I O B Ctrl Force through dig ital input while in Remote the control place will still switch to Keypad if Local is selected Switching...

Page 73: ...ccessing Control page Main Menu Parameters 15 Diagnostics STOP READY Keypad ID M1 7 Monitor 6 ID Choose action STOP Ready Keypad ID 1805 Local Remote Control page Change direction Remote ID Local Remo...

Page 74: ...ave to keypad you can copy all parameters to the keypad Restore from keypad will copy all parameters from keypad to a drive Figure 54 Parameter copy NOTE If the keypad is changed between drives of dif...

Page 75: ...reached To add an item to the Favorites Figure 56 Adding item to Favorites 6 Digital Inputs Ctrl Signal 1 A Ctrl Signal 1 B STOP READY I O ID 403 M3 5 1 1 Ctrl Signal 2 A 6 Add to favorites STOP READ...

Page 76: ...bout his present location in the menu structure and the item displayed If the text on the text line is too long to fit in the display the text will scroll from left to right to reveal the whole text s...

Page 77: ...place is always the keypad The Remote control place is determined by parameter P1 15 I O or Fieldbus The selected control place can be seen on the status bar of the keypad Remote control place I O A...

Page 78: ...age is meant for easy operation and monitoring of the most essential values 7 Anywhere in the menu structure push the Loc Rem button 8 Push the Arrow up or the Arrow down button to select Control page...

Page 79: ...can be browsed The different fault codes you will find in the table below NOTE When contacting distributor or factory because of a fault condition always write down all texts and codes on the keypad d...

Page 80: ...lt history menu with text keypad Diagnostics Active faults 0 Reset faults Fault history 39 ID M4 1 STOP READY I O Fault history External Fault Fault old 51 891384s External Fault Fault old 51 871061s...

Page 81: ...s Activate overvoltage controller Check input voltage 11 Overvoltage soft ware fault 3 20 Earth fault hard ware fault Current measurement has detected that the sum of motor phase current is not zero i...

Page 82: ...ributor near to you 609 Memory access has failed For exam ple retain variables could not be restored 610 Necessary device properties cannot be read 614 Configuration error 647 Software error Update so...

Page 83: ...d load 16 150 Motor overtem perature Motor is overloaded Decrease motor load If no motor overload exists check the temperature model parameters 17 160 Motor underload Motor is underloaded Check load 1...

Page 84: ...3 1053 Fieldbus commu nication fault The data connection between the field bus master and fieldbus board is bro ken Check installation and fieldbus master 54 1654 Slot D fault Defective option board o...

Page 85: ...ol ler has timed out The wanted process value was not achieved within time It s a characteristic fault of the HVAC Application Reason might be a pipe burst 101 1101 Process supervi sion fault PID1 PID...

Page 86: ...8 vacon 83 Options Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 87: ...system designer is responsible for ensuring that the end system is safe and in compliance with relevant regulations When a permanent magnet motor is used and in case of a multiple IGBT power semi cond...

Page 88: ...08 Parts 1 7 EN 61800 5 2 EN 62061 ISO 13849 1 EN 954 1 IEC 60204 1 Table 26 Safety Standards STO inputs STO feedback Cat PL SIL Both dynamically used Used 4 e 3 Both statically used Used 3 e 3 Connec...

Page 89: ...indicated in the following table The diagram below is a conceptual schematic diagram and is presented to illustrate the safety function with relevant safety components only shown Figure 64 STO functi...

Page 90: ...in which the STO is demanded till the system is in the Safe State For Vacon 100 X the reaction time is 20 ms minimum Technical information Technical values Absolute maximum voltage range 24V 20 Typic...

Page 91: ...l Technical information Data STO1 S1 Insulated digital input 1 interchangeable polarity 24V 10 15 mA G1 STO2 S2 Insulated digital input 2 interchangeable polarity 24V 10 15 mA G2 STO feed back F Insul...

Page 92: ...in turn The dynamic use of the STO inputs allows detecting faults that may otherwise accumulate Figure 66 An emergency push button connected to the STO inputs does not assure the same quality because...

Page 93: ...odically de energize the STO inputs and it has to verify that the STO output feedback assumes the expected value Any difference between the expected and the real value has to be considered as a failur...

Page 94: ...even more reduced to Cat 2 PL d SIL 2 if the STO inputs are connected in parallel no redundancy of the STO inputs The STO feedback has to be used The same warnings of 9 5 1 apply The picture below sh...

Page 95: ...ing of the feedback and STO inputs connect ed in parallel The choice of using the STO inputs without the automatic monitoring of the output feedback does not permit to achieve the other safety capabil...

Page 96: ...essment an examination of whether the use of external devices such as a mechanical brake is required Check if the switch if used has been chosen according to the required safety perfor mance target SI...

Page 97: ...fault through a digital input or from the keypad It is possible that a new start command is required for the restart depending on the applica tion and your further setting Before testing the STO funct...

Page 98: ...TO contact your local Vacon supplier If any service or repair is to be conducted on the drive installed please inspect the checklist given in Table 33 During maintenance breaks or in case of service r...

Page 99: ...Safe Torque Off vacon 96 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 100: ...Document ID Order code Rev E Subject to change without prior notice 2012 Vacon Plc Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

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