Vacon 20 CP Installation, Technical And Maintenance Manual Download Page 51 | Manualshive

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background image

Control unit

vacon • 48

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

5

When delivered from the factory, the control unit of the AC drive contains the standard control-
ling interface - the control terminals of the control board - unless otherwise specifically or-
dered. In the following pages you will find the arrangement of the control I/O and the relay
terminals, the general wiring diagram and the control signal descriptions.

The control board can be powered externally by connecting an external power source (about
130-150mA at 24VDC are needed to supply the control board without keypad, option board or
other loads) between terminal #6 and GND, see chapter 5.1.2. To ensure that the external sup-
ply works with any configurations we recommend to use an external supply of +24VDC ±10%,
1000mA overcurrent protected.

This voltage is sufficient for parameter setting and for keeping the control unit active. Note
however that the values of the measurements of the main circuit (e.g. DC-link voltage, unit
temperature) are not available when the mains is not connected.

In addition to the internal fan, VACON

®

20 CP frequency converters include an auxiliary fan

power supply connector (see 10 in the Figure 23, Figure 24 and Figure 25) for improved air flow
and system cooling. The power supply also has automatic thermal switching on/off control: it
automatically switches on/off depending on internal cold plate temperature. The electric spec-
ifications for the auxiliary fan power supply are shown in the following table:

The connector for the auxiliary fan supply is a Micro-Fit 3.0

TM

Header, Surface Mount Compat-

ible, Single Row, Vertical with PCB Polarizing Peg by Molex (part number 43650-0215). This
connection is echoed in the HMI echo connector. See Figure 23, Figure 24 and Figure 25 for the
location of the connectors and Table 28 for the description of the HMI echo terminal.

To connect the auxiliary fan to VACON

®

20 CP drives you will need a Micro-Fit 3.0™ Receptacle

Crimp Housing, Single Row by Molex

®

(part number 43645-0200). See the picture below for

more details.

Figure 26. Micro-Fit 3.0™ Housing.

Terminals

SIgnals

MS2

MS3

FAN+

24VDC ±10%
maximum output
current 200mA

24VDC ±10%
maximum output cur-
rent 700mA

FAN-

GND

GND

Table 22. Electric specifications for the auxiliary fan power supply.

FAN+

FAN-

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Summary of Contents for 20 CP

Page 1: ...vacon 20 cp ac drives installation Technical and Maintenance manual ...

Page 2: ......

Page 3: ... 22 3 1 2 Frame MS2 single phase version 23 3 1 3 Frame MS3 24 3 2 Cooling 25 3 3 Environment temperature 25 3 4 Heatsink assembly instructions 25 3 5 Installation spacing 28 3 6 Power loss thermal characteristics 29 3 7 Dimensioning an external heatsink 30 4 Power cabling 34 4 1 Circuit breaker 36 4 2 UL standards on cabling 36 4 3 Description of the terminals 37 4 3 1 MS2 three phase version pow...

Page 4: ...08 240V 70 7 1 3 Mains voltage 3AC 380 480V 71 7 1 4 Definitions of overloadability 71 7 2 Brake resistors 72 7 3 VACON 20 CP technical data 73 7 3 1 Technical information on control connections 76 8 Options 78 8 1 Vacon keypad with seven segment display 78 8 2 Text keypad 79 8 3 Menu structure 79 8 4 Using the keypad 80 8 4 1 Main menu 80 8 4 2 Resetting fault 81 8 4 3 Local Remote control button...

Page 5: ...ce support find your nearest Vacon service center at www vacon com 9 6 1 General wiring instructions 105 9 6 2 Checklist for commissioning 105 9 7 Parameters and fault tracing 106 9 8 Maintenance and diagnostics 107 ...

Page 6: ...vacon 3 ...

Page 7: ...install operate and maintain the drive 1 1 Signs The cautions and warnings are marked as follows Table 1 Warning signs 1 2 Units The dimensions used in this manual conform to International Metric System units otherwise known as SI Système International d Unités units For the purpose of the equipment s UL cer tification some of these dimensions are accompanied by their imperial equivalents DANGEROU...

Page 8: ...ation of this time use measuring equipment to abso lutely ensure that no voltage is present Always ensure absence of voltage before starting any electrical work The control I O terminals are isolated from the mains potential However the relay outputs and other I O terminals may have a dangerous control voltage present even when VACON 20 CP Drive is disconnected from the mains During a coast stop s...

Page 9: ...e control for Start Stop logic has been selected Furthermore the I O functionalities including start inputs may change if param eters applications or software are changed Disconnect therefore the motor if an unexpected start can cause danger This is valid only if STO inputs are ener gized For prevention on unexpected restart use appropriate safety relay con nected to the STO inputs The motor start...

Page 10: ...ctive earthing conductor Three screws for the three phase version are provided for the ORIGINAL protective earthing conductor the SECOND protective conductor and the MOTOR protective conductor the cus tomer can choose the screw for each one See Figure 1 for the location of the three screws in the two possible options available Figure 1 Protective earthing connections MS2 and MS3 three phase versio...

Page 11: ...mm2 if mechanical protection is provided or 4 mm2 if mechanical protection is not provided For cord connected equipment provi sions shall be made so that the protective earthing conductor in the cord shall in the case of failure of the strain relief mechanism be the last conductor to be interrupted However always follow the local regulations for the minimum size of the protective earthing conducto...

Page 12: ...to the drive and test the complete assembly Should you have any doubts or questions please contact your local Vacon distribu tor Figure 3 Insulation system three phase version Please consider carefully the insulation system depicted in Figure 2 before con necting any circuit to the unit The control unit of VACON 20 CP fulfils the insulation requirements of the stan dard IEC 61800 5 1 regarding DVC...

Page 13: ...o mix Mains and DVC A is not allowed This product can cause a d c current in the protective earthing conductor Where a residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product POWER UNIT L N U V W R01 __ R02 __ 10Vref __ Analog Inputs __ Digital Inputs__ ...

Page 14: ...ceed the following temperatures Temperature around the polymeric enclosure of VACON 20 CP max 70 C 158 F Temperature at the cooling plate of VACON 20 CP max 85 C 185 F Please contact your local Vacon distributor if you need further details or support to dimension the cooling system in your final application NOTE Up to 1 5 kW Voltage range 380 480V and 0 75 kW Voltage range 208 240V the drive is no...

Page 15: ...Safety vacon 12 Service support find your nearest Vacon service center at www vacon com 1 1 10 Declaration of conformity Figure 5 Declaration of conformity ...

Page 16: ...1 vacon 13 Safety Figure 6 STO certificate ...

Page 17: ...d French product manuals with applicable safety warning and caution information from www vacon com downloads REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l ensemble des informations de sécurité avertissements et mises en garde appli cables sur le site www vacon com downloads ...

Page 18: ...1 vacon 15 Safety ...

Page 19: ...rrespond to your order contact your supplier im mediately See paragraph 2 4 Figure 7 Vacon package label Marks 3234500378 Cust Ord No Application FW0065V008 Firmware EMC level 380 480 V IP00 6 A Rated current 122245 B ID M100112345 S N 70SCO000293 BM1X Code VACON0020 3L 0006 4 CP Type AC DRIVE Rated voltage Protection C2 Vacon type code Rated current Supply voltage Application code IP class EMC le...

Page 20: ...f the code is as follows VACON0020 3L 0009 4 CP xxxx yyyy VACON This segment is common for all products 0020 Product range 0020 Vacon 20 3L Input Function 3L Three phase input 1L Single phase input 0009 Drive rating in ampere e g 0009 9 A See Table 30 Table 31 and Table 32 for all the drive ratings 4 Supply voltage 2 208 240 V 4 380 480 V CP Cold Plate xxxx yyyy Additional codes Examples of additi...

Page 21: ...HP drive VACON0020 3L 0012 2 CP 3 0 kW 4 0 HP drive VACON0020 3L 0017 2 CP 4 0 kW 5 0 HP drive Supply voltage 1AC 208 240V MS2 VACON0020 1L 0004 2 CP 0 75 kW 1 0 HP drive VACON0020 1L 0005 2 CP 1 1 kW 1 5 HP drive VACON0020 1L 0007 2 CP 1 5 kW 2 0 HP drive Supply voltage 3AC 380 480V MS2 VACON0020 3L 0003 4 CP 0 75 kW 1 0 HP drive VACON0020 3L 0004 4 CP 1 1 kW 1 5 HP drive VACON0020 3L 0005 4 CP 1...

Page 22: ...e product and that the delivery is com plete Should the drive have been damaged during shipping please contact the cargo insurance com pany or the carrier in the first instance 2 4 Accessories After lifting the converter out check that the delivery is complete and the following accessories are included in the plastic bag Figure 8 STO connector Frame Weight kg Weight lb MS2 2 4 4 MS3 3 6 6 Item Qua...

Page 23: ...but some need to be fragmented to separate different types of materials and components that need to be treated as special waste from electrical and electronic components To ensure environmentally sound and safe recycling treatment the product can be taken to appropriate recycling center or returned to the manufacturer Observe local and other applicable laws as they may mandate special treatment fo...

Page 24: ...vacon 21 Receipt of delivery 2 ...

Page 25: ...oth frame sizes can be mounted in any position IP20 rating is preserved only if mounted as in the following pictures The drive shall be fixed with two screws or bolts depending on the unit size 3 1 Dimensions 3 1 1 Frame MS2 three phase version Figure 9 VACON 20 Cold Plate MS2 three phase version Frame Dimensions W x H x D mm in MS2 133 0 x 164 5 x 73 5 5 24 x 6 48 x 2 89 MS2 with plate 133 0 x 16...

Page 26: ... 1 2 Frame MS2 single phase version Figure 10 VACON 20 Cold Plate MS2 single phase version Frame Dimensions W x H x D mm in MS2 133 0 x 163 5 x 73 5 5 23 x 6 43 x 2 89 MS2 with plate 133 0 x 163 5 x 79 5 5 23 x 6 43 x 3 13 ...

Page 27: ...nd your nearest Vacon service center at www vacon com 3 3 1 3 Frame MS3 Figure 11 VACON 20 Cold Plate MS3 Frame Dimensions W x H x D mm in MS3 161 0 x 246 0 x 73 5 6 34 x 9 69 x 2 89 MS3 with plate 161 0 x 246 0 x 83 0 6 34 x 9 69 x 3 27 ...

Page 28: ...fications listed in this paragraph The heatsink surface that is in contact with the frequency converter cold plate must be free from dirt and particles The mating surface flatness shall not exceed 50μm DIN EN ISO 1101 across the entire mating surface and the roughness less than 6 3 μm DIN EN ISO 4287 The maximum peak valley height of the surface shall not exceed 10 μm DIN EN ISO 4287 Apply a therm...

Page 29: ...s 6 0 mm 0 24 in Frame size Screw size Tightening torque N m lb in MS2 M5 according to DIN 7985 8 8 with washer 2 0 to 2 5 Nm 17 70 to 22 13 lbf in MS3 M5 according to DIN 7985 8 8 with washer 2 0 to 2 5 Nm 17 70 to 22 13 lbf in Table 6 Screw size and tightening torque Tighten all screws according to specified torques Failure to do so may inhibit drive cooling and cause possible damage to the driv...

Page 30: ...3 vacon 27 Mounting Figure 13 Heatsink plate for MS3 upper view The thickness of the plate is 9 5 mm 0 37 in Frame Dimensions W x H x D mm in MS3 100 0 x 148 0 x 9 5 3 94 x 5 83 x 0 37 ...

Page 31: ... clearances given in Table 7 must be respected It is also important to ensure that the temperature of the cooling air does not exceed the maximum environment tempera ture of the converter Contact our factory for more information on required clearances in different installations Table 7 Min clearances around AC drive A Clearance left and right from the drive B Clearance above the drive C Clearance ...

Page 32: ...0 196 Table 8 Drive power loss at rated conditions voltage range 3AC 208 240V Mains voltage 1AC 208 240V 50 60 Hz Frame Converter Type Rated output current A Cold plate loss W Internal loss W Total loss W MS2 0004 3 7 31 22 53 0005 4 8 37 24 61 0007 7 0 59 31 90 Table 9 Drive power loss at rated conditions voltage range 1AC 208 240V Mains voltage 3AC 380 480V 50 60 Hz Frame Converter Type Rated ou...

Page 33: ...ction process it s necessary to define common terms notations and definitions and establish the concept of a thermal circuit Notations and definitions of the terms are as follows The purpose of this paragraph is to select an external heatsink by calculating its thermal re sistance The heat transfer principle from the cold plate to the heatsink ambient air is shown in Figure 15 Figure 15 Thermal eq...

Page 34: ...g resistance Spreading resistance occurs when thermal energy is transferred from a small area to a larger area in a substance with finite thermal conductivity In a heat sink this means that heat does not distribute uniformly through the heatsink base The spreading resistance phenomenon is shown by how the heat travels from the heat source location and causes a large temperature gradient between th...

Page 35: ...ural convection It is recommended that the heatsink be installed to orient the fins in a direction that will not block air movement under natural convection Based practical experience if the heatsink is oriented in a wrong way the thermal performance will be approximately 25 worse under natural convection condition Note to study the heat transfer in other cooling media of different geometry e g co...

Page 36: ...3 vacon 33 Mounting ...

Page 37: ...r cables to terminals marked with U V and W See principal connection diagram in Figure 16 See also Table 13 for the cable recommendations for different EMC levels Figure 16 Principal connection diagram three phase version only MS3 Figure 17 Principal connection diagram single phase version U T1 V T2 W T3 M L1 L2 L3 DC R R DC Keypad Control Power unit U T1 V T2 W T3 M L N DC DC Keypad Control Power...

Page 38: ...or the specific mains voltage MCCMK EMCMK or similar recommended Recom mended cable transfer impedance 1 30MHz max 100mohm m See Figure 18 360º earthing of the shield with cable glands in motor end needed for EMC category C1 and C2 4 Screened cable equipped with compact low impedance shield JAMAK SAB ÖZCuY O or similar Figure 18 Example with three phase cable NOTE The EMC requirements are fulfille...

Page 39: ...e Table 30 NOTE circuit breaker is not allowed in installations where C UL is required Only fuses are recommended 4 2 UL standards on cabling To meet the UL Underwriters Laboratories regulations use a UL approved copper cable with a minimum heat resistance of 75 C Use Class 1 wire only The units are suitable for use on a circuit capable of delivering no more than 50 000 rms sym metrical amperes 60...

Page 40: ...9 Power connections MS2 three phase version Terminal Description L1 L2 L3 These terminals are the input connections for the power supply 230 VAC models can be supplied by single phase voltage by connecting to L1 and L2 terminals with derat ing of 50 U T1 V T2 W T3 These terminals are for motor connections Table 14 Description of Vacon 20CP MS2 power terminals PES 3AC Motor AC power supply Single o...

Page 41: ...connections MS2 single phase version Terminal Description L N These terminals are the input connections for the power supply Single phase 230 VAC voltage has to be connected to L and N terminals U V W These terminals are for motor connections Table 15 Description of Vacon 20CP MS2 power terminals single phase version PES PE AC power supply single phase 3AC Motor ...

Page 42: ...ls are the input connections for the power supply 230 VAC models can be supplied by single phase voltage by connecting to L1 and L2 terminals with derat ing of 50 U T1 V T2 W T3 These terminals are for motor connections Table 16 Description of Vacon 20CP MS3 power terminals PES PE AC power supply Single or Three phases 3AC Motor ...

Page 43: ...based on the criteria of the International Standard IEC60364 5 52 Cables must be PVC isolated use only cables with concentric copper shield Max number of parallel cables is 9 When using cables in parallel NOTE HOWEVER that the requirements of both the cross sectional area and the max number of cables must be observed For important information on the requirements of the earthing conductor see chapt...

Page 44: ...ature of cable surface 70 C Use only cables with concentric copper shield 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 max number of cables must be observed For important information on the requirements of the earthing conductor see standard Underwriters Laboratories UL508C For the correction factors fo...

Page 45: ...se version are equipped with terminals for an optional ex ternal brake resistor These terminals are 6 3 mm Faston for MS2 and spring type terminals for MS3 See Figure 23 and Figure 25 for the location of these terminals See Table 33 and Table 34 for the resistor ratings 4 6 Control cables For information on control cables see chapter Control unit cabling ...

Page 46: ...nal cables of other sys tems The maximum length for motor cables is 30m The motor cables should cross other cables at an angle of 90 degrees If cable insulation checks are needed see chapter Cable and motor insulation checks Start the cable installation according to the instructions below Figure 22 Stripping of cables Table 19 Cables stripping lengths mm Distance between cables m Shielded cable m ...

Page 47: ...ply and motor cables into their respective terminals Form the rest of the cable shield of both cables into pigtails and make a grounding connection with the clamp Make the pigtails just long enough to reach and be fixed to the terminal no longer Frame Type Tightening torque Power and motor terminals Tightening torque EMC grounding clamps Tightening torque Grounding terminals Nm lbs in Nm lbs in Nm...

Page 48: ...4 vacon 45 Power cabling ...

Page 49: ...nents in control unit of MS2 three phase version Number Meaning 1 Control terminals A 20 2 STO terminals only in three phase version 3 Relay terminals 4 Option board terminals 5 STO Jumpers only in three phase version 6 DIP switches 7 Status LEDs 8 HMI connector RJ45 keypad connector 9 Optional brake resistor terminals 10 Supply voltage connector for external fan 11 Control terminals A 20 echo con...

Page 50: ...5 vacon 47 Control unit Figure 24 Locations of the components in control unit of MS2 single phase version Figure 25 Location of the components in the control unit of MS3 ...

Page 51: ...n the mains is not connected In addition to the internal fan VACON 20 CP frequency converters include an auxiliary fan power supply connector see 10 in the Figure 23 Figure 24 and Figure 25 for improved air flow and system cooling The power supply also has automatic thermal switching on off control it automatically switches on off depending on internal cold plate temperature The electric spec ific...

Page 52: ...l descriptions are also given in Table 24 Figure 27 Control terminals 5 1 1 Control cable sizing The control cables shall be at least 0 14 mm2 screened multi core cables see Table 23 The maximum terminal wire size for the I O terminals is 1 5 mm2 Find the tightening torques of the I O control and relays and STO terminals in the Table below Terminal screw Tightening torque Nm lbs in I O terminals a...

Page 53: ...gnals and connection example Standard I O terminals Terminal Signal A RS485_A Serial bus negative B RS485_B Serial bus positive 1 10 Vref Reference output 2 AI1 Analogue input voltage or current 3 GND I O signal ground 6 24Vout 24V aux voltage 7 DIN COM Digital inputs com mon 8 DI1 Digital input 1 9 DI2 Digital input 2 10 DI3 Digital input 3 4 AI2 Analogue input voltage or current 5 GND I O signal...

Page 54: ...inals Terminal Signal 22 RO1 2 Relay output 1 23 RO1 3 24 RO2 1 Relay output 2 25 RO2 2 26 RO2 3 Table 26 I O terminal signals for the STO functions Safe Torque Off terminals Terminal Signal S1 Isolated digital input 1 inter changeable polarity 24V 20 10 15mA G1 S2 Isolated digital input 2 inter changeable polarity 24V 20 10 15mA G2 F Isolated feedback CAUTION Polarity to be respected 24V 20 F Iso...

Page 55: ... the control board In Figure 28 the view of Molex connector for the I O terminals is shown In the control unit the position of this connector is numbered with 11 as shown in Figure 23 and Figure 25 The type of this connector is Pico Clasp Wire to Board PCB Header Dual Row RIght Angle The code by Molex is 501571 2007 It mates with Pico Clasp Wire to Board Receptacle Housing crimp housing Dual Row 2...

Page 56: ...ber Signal Description 1 RS485_B Serial bus positive 2 DI2 Digital input 2 3 RS485_A Serial bus negative 4 DI3 Digital input 3 5 NC not connected 6 AI2 7 NC not connected 8 GND 9 10Vref 10 DO1 common for digital output 1 11 AI1 12 DI4 Digital input 4 13 GND 14 DI5 Digital input 5 15 24Vout 16 DI6 Digital input 6 17 DIN COM 18 AO1 Analogue output 1 19 DI1 Digital input 1 20 DO1 Digital output 1 Tab...

Page 57: ...ode by Molex is 501331 1507 It mates with Pico Clasp Wire to Board Female Housing crimp housing Single Row with Positive lock 15 Circuits The code by Molex is 501330 1500 To connect HMI to the control unit through echo terminals this connector has to be used In the following table the correspondence between the pins of this connector and the VACON 20 CP HMI terminals is shown Pin number in RJ45 co...

Page 58: ...signal for LED1 7 Led_CTRL2 Control signal for LED2 6 Led_CTRL3 Control signal for LED3 5 FAN External FAN 24V 4 FAN GND for external FAN 3 nc not connected 2 nc not connected 1 nc not connected Pin number in RJ45 connector Pin number of echo connector Signal Description Table 28 HMI remote connector description with RJ45 correspondences ...

Page 59: ...c cover of the drive there are 4 status LEDs See the picture below Figure 31 LED position on the MS2 cover Led PWR orange led means the drive is supplied by mains Led RUN green led means the drive is running Led FLT red led means the drive is experiencing a fault Led RDY orange led means the drive is ready and no fault is present When a Warning is ac tive the led starts blinking ...

Page 60: ...either current inputs or voltage inputs The signal type is se lected with two switches on the control board The switch SW2 is related to analogue input AI1 In position 1 the analogue input AI1 works in voltage mode In position 0 the analogue input works in current mode The default position for SW2 is 1 The voltage range is 0 10V and the current is 0 4 20 mA The switch SW3 is related to analogue in...

Page 61: ... easy upgrade of the hardware structure of an industrial network without the need for significant changes in the software A device can also communicate with several Modbus nodes at once although they are connected with different interface types without the need to use a different protocol for ev ery connection Figure 33 Basic structure of Modbus frame On simple interfaces such as RS485 the Modbus ...

Page 62: ...igure 34 Position of the RS485 terminals on the I O standard terminal connector Connections and communications Interface RS 485 Data transfer method RS 485 MS TP half duplex Transfer cable STP shielded twisted pair type Belden 9841 or similar Connector 2 5 mm2 Electrical isolation Functional Modbus RTU As described in Modicon Modbus Protocol Reference Guide Baud rate 300 600 1200 2400 4800 9600 19...

Page 63: ...luminium cable shield 2 Then connect the cable to its appropriate terminals on VACON 20 CP AC drive standard terminal block terminals A and B A negative B positive 3 Using the cable clamp included in the supply of the drive ground the shield of the RS485 cable to the frame of the AC drive 4 If VACON 20 Cold Plate drive is the last device on the bus the bus termination must be set Locate the switch...

Page 64: ...5 vacon 61 Control unit ...

Page 65: ...even if the motor is not running The control I O terminals are isolated from the mains potential However the relay outputs and other I O terminals may have a dangerous control voltage present even when VACON 20 CP drive is disconnected from mains Do not make any connections to or from the frequency converter when it is con nected to the mains After disconnecting the AC drive from the mains wait un...

Page 66: ...he shields of the shielded cables are connected to protective earth marked with Check the tightening torques of all terminals Check that the wires do not touch the electrical components of the drive Check that the common inputs of digital input groups are connected to 24V or ground of the I O terminal Check the quality and quantity of cooling air Check the inside of the frequency converter for con...

Page 67: ...MC pro tected according to class C1 or C2 you need to modify the EMC protection of the AC drive to EMC level T C4 This is done as described below 6 2 1 Changing EMC protection class MS2 three phase version Figure 35 Changing of the EMC class in MS2 three phase version Warning Do not perform any modifications on the AC drive when it is connected to mains 1 Remove the three screws on the EMC plate f...

Page 68: ...gure 36 Changing of the EMC class in MS2 three phase version 2 Remove the EMC plate from the unit Then lift the plate with pliers to disconnect the EMC plate from the ground See Figure 36 Then reconnect the EMC plate to the unit ...

Page 69: ...ort find your nearest Vacon service center at www vacon com 6 6 2 2 Changing EMC protection class MS2 single phase version Figure 37 Changing the EMC class in the MS2 single phase version 1 Remove the EMC screw as shown in the Figure 37 ...

Page 70: ...rotection class MS3 Figure 38 Changing the EMC class in the MS3 1 Remove the EMC screw as shown in the Figure 38 CAUTION Before connecting the AC drive to mains make sure that the EMC pro tection class settings of the drive are appropriately made ...

Page 71: ...l as between each phase conductor and the protective ground conductor The insulation resistance must be 1MΩ at ambient temperature of 20 C 3 Motor insulation checks Disconnect the motor cable from the motor and open the bridging connections in the motor connection box Measure the insulation resistance of each motor winding The measurement voltage must equal at least the motor nominal voltage but n...

Page 72: ...interval Maintenance action Regularly and according to general maintenance interval Check tightening torques of terminals 6 24 months depending on environment Check input and output terminals and control I O terminals Check for corrosion on terminals and other surfaces Check door filter in case of cabinet installation 24 months Clean heatsink 12 24 months Charge capacitors only after long storage ...

Page 73: ...n Table 31 are achieved only when the switching frequency is equal to or less than the factory default Mains Voltage 3AC 208 240V 50 60 Hz Converter type Input current A Loadability Motor shaft power 230V 230V Rated continuous current IN A 50 overload current A Max current IS kW HP MS2 0004 4 3 3 7 5 6 7 4 0 75 1 0 0005 6 8 4 8 7 2 9 6 1 1 1 5 0007 8 4 7 0 10 5 14 0 1 5 2 0 MS3 0011 13 4 11 0 16 5...

Page 74: ...rated current for 1 min in every 10 min the remaining 9 min must be at rated current IN or less Figure 39 High overload Mains Voltage 3AC 380 480V 50 60 Hz Converter type Input current A Loadability Motor shaft power 400V 480V Rated continuous current IN A 50 overload current A Max current IS kW HP MS2 0003 3 2 2 4 3 6 4 8 0 75 1 0 0004 4 0 3 3 5 0 6 6 1 1 1 5 0005 5 6 4 3 6 5 8 6 1 5 2 0 0006 7 3...

Page 75: ...ilable only in three phase version Recommended brake resistor values for Vacon 20 CP AC drives Mains Voltage 3AC 208 240 V 50 60 Hz Frame Type Minimum Resistance recommended Ohm MS2 0004 50 0005 50 0007 50 MS3 0011 25 0012 25 0017 25 Table 33 Brake resistor ratings 3AC 208 240V Mains Voltage 3AC 380 480 V 50 60 Hz Frame Type Minimum Resistance recommended Ohm MS2 0003 100 0004 100 0005 100 0006 10...

Page 76: ...rature max 70 C See Table 30 Table 31 and Table 32 Overload output cur rent 1 5 x IN 1 min 10 min Starting current IS for 2 s every 20 s IS 2 0 IN Output frequency 0 320 Hz Frequency resolution 0 01 Hz Protection class I Motor characteristics AC squirrel cage motors Permanent magnet motors Cable type Screened motor cable Cable maximum length 30 m Control characteristics Switching frequency Program...

Page 77: ...0 to 95 RH non condensing non corrosive no dripping water Pollution degree PD2 Altitude 100 load capacity no derating up to 1 000m derating 1 100m at 1 000 3 000m Degree of protection MS2 three phase version IP00 MS2 single phase version IP20 MS3 IP20 Stationary vibration Sinusoidal MS2 three phase version 3 Hz f 9Hz 10mm 9 Hz f 200Hz 3g 3M7 acc to IEC 60721 3 3 MS2 single phase version and MS3 3 ...

Page 78: ...sted EMC TÜV Tested USA Canada cURus approval file number E171278 Declaration of Conformity Korea KC mark Australia C tick Declaration of Conformity Europe EC Declaration of Conformity Protections Undervoltage trip limit Depends on supply voltage 0 8775 supply volt age Supply voltage 400 V Trip limit 351 V Supply voltage 480 V Trip limit 421 V Supply voltage 240 V Trip limit 211 V Earth fault prot...

Page 79: ...ed with an external power supply with a current limiter or fuse protected to supply the control unit and fieldbus for backup purposes Dimensioning max 1000mA control unit 7 DIN COM Common for digital inputs Connected to GND with dip switch SW1 See Chapter 5 8 Digital input 1 Positive or negative logic Ri min 4kΩ 15 30V 1 0 5V 0 9 Digital input 2 10 Digital input 3 4 Analogue input voltage or curre...

Page 80: ...ut relays the control circuitry must be powered with a separate isolation transformer to limit short circuit current and overvoltage spikes This is to prevent welding on the relay contacts Refer to standard EN 60204 1 section 7 2 9 Switching capacity 250VAC 3A only earthed network allowed 23 24 Relay output 2 Switching capacity NO 250VAC 5A NC 250VAC 3A only earthed network allowed 25 26 ...

Page 81: ...tor to supervise the state of the drive and to set the frequency converter s parameters The button section of the text keypad is shown in the following picture Figure 41 Keypad buttons Order code Description Type of option VACON PAN HMTX MC06 CP Handheld Magnetic fixing IP66 text keypad w cable l 1m 39 37 inches Loose option Scroll menu up Increase value Scroll menu down Decrease value Move cursor...

Page 82: ...s Enter the group item by pressing the OK button and return to the former level by pressing the Back Reset button The arrows on the left of the display show the active menu In Figure 42 the REF menu is active The table below shows the structure of the main menu Reference REF Reference from Keypad Monitor MON Monitoring values Parameters PAR Application parameters System Fault SYS FLT System Menu A...

Page 83: ... STO P READ Y RUN M ON FWD RE V I O KE YP AD BUS EF PAR FAULT ALARM S TO P RE AD Y RUN MO N FWD RE V I O KE YP AD BUS REF PAR FAULT ALARM S TO P RE AD Y RUN MO N FWD RE V I O KE YP AD BU S REF PAR FAULT ALAR M S TO P RE ADY RU N MO N FW D RE V I O KE YP AD BUS R EF PAR FAU LT ALAR M STO P READ Y RU N MO N PRESS PRESS PRESS PRESS PRESS FWD REV I O KEY PAD BUS RE F M O N PAR FAULT ALAR M S TOP RE AD...

Page 84: ...of control where the drive can be started and stopped Every control place has its own parameter for selecting the frequency reference source In the VACON 20 CP drive the Local control place is always the keypad The Remote control place is determined by pa rameter I O or Fieldbus The selected control place can be seen on the status bar of the keypad Remote control place I O and Fieldbus can be used...

Page 85: ...has big change first press Left and Right buttons to select the digit which has to be changed then press Up button to increase and Down button to decreases the value in the selected digit The changing reference frequency will been taken into use immediately without pressing OK Note LEFT and RIGHT buttons can be used to change the direction in Ref menu in local control mode Press to enter edit mode...

Page 86: ...e alternating in the display by pressing OK button Note Turn on drive power arrowhead of main menu is at MON V x x or monitor parameter value of Vx x is displayed in Panel Display Vx x or monitor parameter value of Vx x is determined by the last show status before power shut down OK OK OK 1 2 3 5 4 FAULT ALARM STOP READY RUN REF MON PAR REF MON PAR FAULT ALARM STOP READY RUN FWD REV I O KEYPAD BUS...

Page 87: ... value is numerical and change then the value with the arrow but tons up down 4 Confirm change with OK button or ignore change by returning to previous level with Back Reset button OK OK 2 Press Right to browse otherPar group 4 Press OK button to enter edit mode 3 Press down button to browse P3 4 5 Press Up Down to change value OK 6 Press OK to confirm FAULT ALAR M S TO P RE ADY RU N FAULT ALAR M ...

Page 88: ...1 1 Press Left Right button to browse other groups 2 Press down to browse other active faults 3 FAULT ALARM STOP FWD REV I O KEYPAD BUS READY RUN OK Press OK to select one fault to browse its time 4 FAULT ALARM STOP READY RUN FWD REV I O KEYPAD BUS Browse for fault code C xx subcode Id xx days d xx hours H xx minutes M xx 5 FAULT ALARM STOP READY RUN FWD REV I O KEYPAD BUS FAULT ALARM STOP READY R...

Page 89: ...omatically to the fault menu if no button is pressed in 10 seconds The fault code subcode and the operating day hour and minute values at the fault instant are shown in the value menu operating hours displayed reading Active faults Fault history Menu Function Note Active faults When a fault faults appear s the display with the name of the fault starts to blink Press OK to return to the Diagnostics...

Page 90: ...the fault and restart Should the fault re occur contact the distributor near to you 89 HMI receives buffer overflow Check PC drive cable Try to reduce ambient noise 90 Modbus receives buffer overflow Check Modbus specifications for time out Check cable length Reduce ambient noise Check baudrate 8 System Fault 93 Power identification error Try to reduce ambient noise Reset the fault and restart Sho...

Page 91: ... slot Try to reduce ambient noise Should the fault re occur contact the distributor near to you 108 Option board SPI queue full Check contacts in option board slot Try to reduce ambient noise Should the fault re occur contact the distributor near to you 111 Parameter copy error Check if parameter set is compatible with drive Do not remove Keypad until copy is finished 113 Frequency detective timer...

Page 92: ...ir Check the heatsink for dust Check the ambient temperature Make sure that the switching fre quency is not too high in relation to ambient temperature and motor load 15 Motor stalled Motor is stalled Check motor and load Insufficient motor power check motor stall protection parametriza tion 16 Motor overtemperature Motor is overloaded Decrease motor load If no motor overload exists check the temp...

Page 93: ...sages The input is active Check the programming and check the device indicated by the error message Check the cabling for the respective device as well 52 Keypad Communication fault The connection between the con trol keypad and the frequency con verter is broken Check keypad connection and keypad cable 53 Fieldbus communication fault The data connection between the fieldbus master and fieldbus bo...

Page 94: ...anically isolated analogue input and two galvanically isolated analogue outputs standard signals 0 4 20mA OPT B5 V I O expander board with three relay outputs OPT B9 V I O expander board with five 42 240 VAC digital inputs and one relay output OPT BF V I O expander board with ana logue output digital output and relay output On the OPTBF board there is one jumper block for selecting the ana logue o...

Page 95: ... the main cover MS2 three phase version example NOTE Do not add or replace option boards or fieldbus boards on an AC drive with the power switched on This may damage the boards 1 Remove the option slot cover The relay outputs and other I O terminals may have a dangerous control voltage present even when the drive is disconnected from mains ...

Page 96: ...dicates that the board is compatible with Vacon 20 CP See below NOTE Incompatible boards cannot be installed on Vacon 20 CP Compati ble boards have a slot coding that enables the placing of the board see above 3 Install the option board into the slot as shown in the picture below Slot coding OPT dv 9116 emf ...

Page 97: ...Options vacon 94 Service support find your nearest Vacon service center at www vacon com 8 Figure 49 Option board installation 4 Mount the option slot cover ...

Page 98: ...8 vacon 95 Options Figure 50 Mounting of the option slot cover remove the plastic opening for the option board terminals ...

Page 99: ...ompliance with accepted practice and regulations at the time of writing However the end product 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 conductor failure when the STO option energizes the drive outputs to the off state the drive system may stil...

Page 100: ... 7 EN 61800 5 2 EN 62061 ISO 13849 1 EN 954 1 IEC 60204 1 Table 41 Safety Standards STO inputs STO feedback Cat PL SIL Both dynamically used Used 4 e 3 Both statically used Used 3 e 3 Connected in parallel Used 2 d 2 Connected in parallel Not used 1 c 1 Table 42 Four different STO levels see 9 5 1 STO inputs STO feedback PFH PFDav MTTFd years DCavg Both dynamically used Used 8 0 E 10 1 h 7 0 E 05 ...

Page 101: ...lity F F terminals The values assumed by the STO output feedback are 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 51 STO function principle Only for MS3 STO inputs Operating conditions STO feedback output Torque at the motor shaft Both inputs ener gized with ...

Page 102: ...unt of time which passes from the moment in which the STO is demanded until the system is in the Safe State For VACON 20 CP the reaction time is 20 ms maximum Technical information Technical values Absolute maximum voltage range 24V 20 Typical input current at 24V 10 15 mA Logic threshold according to IEC 61131 2 15V 30V 1 0V 5V 0 Response time at nominal voltage Reaction time 20ms Table 45 Electr...

Page 103: ...he STO output feedback Local standards and regulations should be always followed in the final design Signal Terminal Technical information Data STO1 S1 Insulated digital input 1 interchangeable polarity 24V 20 10 15 mA G1 STO 2 S2 Insulated digital input 2 interchangeable polarity 24V 20 10 15 mA G2 STO feedback F Insulated digital output for STO feedback CAUTION Polarity must be respected 24V 20 ...

Page 104: ...here the inputs are released with delay in turn The dynamic use of the STO inputs allows detecting faults that may otherwise accumulate Figure 53 An emergency push button connected to the STO inputs does not assure the same quality because no fault detection is performed at a sufficient proof test interval once a day is recommended The external safety device which forces the STO inputs and evaluat...

Page 105: ...s to monitor the STO function in accordance with theTable 44 The device has to periodically 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 failure and has to drive the system into a Safe State In case of failure check the wiring If the fault recognized by the ex...

Page 106: ... 2 PL d SIL 2 The safety capability is 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 as 9 5 1 apply The picture below shows an example of connection for the STO function The external device has to be connected with 4 wires to the drive Figure 55 STO Example with automatic monitoring of the f...

Page 107: ...or stops by coasting Figure 56 STO example without automatic monitoring of the feedback and STO inputs connect ed in parallel Only for MS3 The choice of using the STO inputs without the automatic monitoring of the output feedback does not allow the other safety capabilities to be achieved The standards for functional safety require that functional proof tests are performed on the equipment at user...

Page 108: ...ording to the local regulations Include in the assessment an examination of whether the use of external devices such as a mechanical brake are required Check if the switch if used has been chosen according to the required safety perfor mance target SIL PL Category set during the risk evaluation Check if the external device for automatic monitoring of the STO output feedback if used has been chosen...

Page 109: ...l device F30 is displayed even after this has been released Reset the 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 parameter settings Before testing the STO function make sure that the checklist Table 48 is inspected and completed When STO function is demanded the drive always generates a...

Page 110: ... failure in safety functions including STO contact your local Vacon supplier If any service or repair has to be conducted on the drive installed please inspect the checklist given in Table 48 During maintenance breaks or in case of service repair ALWAYS make sure that the STO function is available and fully functional by testing it Fault Code Fault Cause Correction 30 STO fault STO inputs in a dif...

Page 111: ...Safe Torque Off vacon 108 Service support find your nearest Vacon service center at www vacon com 9 ...

Page 112: ...er code Rev I Manual authoring documentation vacon com Vacon Plc Runsorintie 7 65380 Vaasa Finland Subject to change without prior notice 2015 Vacon Plc Find your nearest Vacon office on the Internet at www vacon com ...

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