Vacon 20 x Installation, Technical And Maintenance Manual Download Page 1

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vacon 20 x

ac drives

installation, technical and

maintenance manual

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

Summary of Contents for 20 x

Page 1: ...vacon 20 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: ...election 23 4 3 Brake resistor cables 25 4 4 Control cables 25 4 5 Cable installation 26 5 Control unit 30 5 1 Opening the drives 30 5 2 Control units MU2 and MU3 31 5 3 Control unit cabling 33 5 3 1...

Page 4: ...al Remote control button 62 8 4 4 Parameters 63 8 4 5 Faults 63 8 5 Fault tracing 64 8 6 Option boards 66 9 Safe Torque Off 68 9 1 General description 68 9 2 Warnings 68 9 3 Standards 69 9 4 The princ...

Page 5: ...are live when VACON 20 X Drive is connected to mains even if the 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 att...

Page 6: ...nalities 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 a...

Page 7: ...for a second protective earthing con ductor of the same cross sectional area as the original protective earthing conductor Three screws are provided for the ORIGINAL protective earthing conductor the...

Page 8: ...ess than 2 5 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...

Page 9: ...stribu tor Figure 2 Insulation system only for MU3 Please consider carefully the insulation system depicted in Figure 2 before con necting any circuit to the unit The control unit of VACON 20 X fulfil...

Page 10: ...ng the cabling a suitable clearance has to be guaranteed between DVC A circuits and Mains reinforced insulation is required according to IEC 61800 5 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwt...

Page 11: ...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 12: ...derating the unit can operate up to 50 C Figure 3 Temperature output current derating curve The AC drive is cooled down by air ventilation Therefore make sure that enough free space is left around th...

Page 13: ...Safety vacon 10 1 1 7 Declaration of conformity Figure 4 Declaration of conformity Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 14: ...1 vacon 11 Safety Figure 5 STO certificate Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 15: ...Figure 6 Vacon package label Marks 3234500378 Cust Ord No Application FW0065V008 Firmware EMC level 380 480 V IP66 4X 6 A Rated current 122245 B ID M100112345 S N 70SCO000293 BM1X Code VACON0020 3L 00...

Page 16: ...0 3L 0009 4 X xxxx yyyy VACON This segment is common for all products 0020 Product range 0020 Vacon 20 3L Input Function 3L Three phase input 0009 Drive rating in ampere e g 0009 9 A See Table 19 and...

Page 17: ...r the carrier 2 3 Accessories After lifting the converter out check that the delivery is complete and the following accessories are included STO terminal connector six pins black connector see Figure...

Page 18: ...vacon 15 Receipt of delivery 2 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 19: ...re that the mounting plane is relatively even Both frame sizes can be mounted in any position The drive shall be fixed with four screws or bolts depending on the unit size 3 1 Dimensions 3 1 1 Frame M...

Page 20: ...3 vacon 17 Mounting Figure 10 VACON 20 X MU3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 21: ...y other relatively even mounting plane or machine frame and fixed with the screws recommended in Table 3 Recommended screw or bolt size for MU2 and MU3 is M5 Frame Screw number Screw size MU2 4 M5 MU3...

Page 22: ...ired clearances in different installations Table 4 Min clearances around AC drive A Clearance left and right from the drive B Clearance above the drive C Clearance underneath the AC drive Figure 11 In...

Page 23: ...Mounting vacon 20 3 Figure 12 Installation space when drives are mounted on top of each other B C Air deflector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 24: ...3 vacon 21 Mounting Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 25: ...trical power cable equipped with concentric protection wire and intended for the specific mains voltage MCMK or similar recommended See Figure 14 3 Symmetrical power cable equipped with compact low im...

Page 26: ...ity of 1 5 to 2 times of the inverter s rated current see Table 19 and Table 20 4 2 UL standards on cabling To meet the UL Underwriters Laboratories regulations use a UL approved copper cable Use Clas...

Page 27: ...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 chapter Earthing and earth fault...

Page 28: ...faston 6 3 mm have to be used For MU3 a PCB terminal block with push in spring cage connector is provided Stranded wires max 4 mm2 with ferrules should be used See Table 21 and Table 22 for the resist...

Page 29: ...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 mot...

Page 30: ...to run the cables 3 Choose the correct cable glands according to drive and cable size as shown in the following pictures 4 Cable glands must be constructed from plastic materials They are used for se...

Page 31: ...upply and motor cables into their respective terminals Form the rest of the cable shield of all two cables into pigtails and make a grounding connection with the clamp Make the pigtails just long enou...

Page 32: ...4 vacon 29 Power cabling Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 33: ...CONTROL UNIT 5 1 Opening the drives Figure 18 Open front cover of the drive control unit MU2 Figure 19 Open front cover of the drive control unit MU3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr...

Page 34: ...ons of the components in control unit of MU2 Number Meaning 1 Control terminals A 20 2 STO terminals 3 Relay terminals 4 Option board terminals 5 STO Jumpers 6 DIP switches 7 Status LEDs 8 HMI connect...

Page 35: ...trol I O and the relay terminals the general wiring diagram and the control signal descriptions The control board can be powered externally 24VDC 10 1000mA by connecting the exter nal power source bet...

Page 36: ...in Table 13 too Figure 22 Control terminals 5 3 1 Control cable sizing The control cables shall be at least 0 14 mm2 screened multi core cables see Table The max imum terminal wire size for the I O t...

Page 37: ...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...

Page 38: ...elay output 2 25 RO2 2 26 RO2 3 Table 15 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...

Page 39: ...shown In the control unit the position of this connector is numbered with 11 as shown in Figure 20 and Figure 21 The type of this connector is Pico Clasp Wire to Board PCB Header Dual Row RIght Angle...

Page 40: ...bus negative 2 DI2 Digital input 2 3 RS485_A Serial bus positive 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 Digit...

Page 41: ...5 LED position on the MU2 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 in fault Led RDY orange led mean...

Page 42: ...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...

Page 43: ...without the need for large changes in the software A device can also communicate with several Modbus nodes at once although they are connected with different interface types with no need to use a diff...

Page 44: ...tandard terminal connector MU2 control unit example Connections and communications Interface RS 485 Data transfer method RS 485 MS TP half duplex Transfer cable STP shielded twisted pair type Belden 9...

Page 45: ...con20 X AC drive stan dard 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 A...

Page 46: ...5 vacon 43 Control unit Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 47: ...lated from the mains potential However the relay outputs may have a dangerous control voltage present even when VACON 20 X drive is disconnected from mains Do not make any connections to or from the f...

Page 48: ...e 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 digit...

Page 49: ...is done as described below 6 2 1 Changing EMC protection class MU2 Figure 29 Changing of the EMC class in MU2 control unit Warning Do not perform any modifications on the AC drive when it is connected...

Page 50: ...trol unit 2 Remove the EMC plate from the control unit Then turn up the thin plate with pli ers to disconnect the EMC plate from the ground See Figure 30 Then reconnect the EMC plate to the unit Phone...

Page 51: ...the EMC pro tection class settings of the drive are appropriately made NOTE After having performed the change write EMC level modified on the sticker included in the VACON 20 X delivery see below and...

Page 52: ...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 53: ...ce intervals Maintenance interval Maintenance action Regularly and according to general maintenance interval Check tightening torques of terminals 6 24 months depending on environment Check input and...

Page 54: ...6 vacon 51 Commissioning Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 55: ...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 MU2 0004 4 3 3 7 5 6 7 4 0 75 1 0 0005 6 8 4 8...

Page 56: ...in the remaining 9 min must be at rated current IN or less Figure 32 High overload Mains Voltage 3AC 380 480V 50 60 Hz Converter type Input current A Loadability Motor shaft power 400V 480V Rated cont...

Page 57: ...7 50 MU3 0011 25 0012 25 0017 25 Table 21 Brake resistor ratings 208 240V Mains Voltage 3AC 380 480 V 50 60 Hz Frame Type Minimum Resistance recommended Ohm MU2 0003 100 0004 100 0005 100 0006 100 000...

Page 58: ...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...

Page 59: ...ude 100 load capacity no derating up to 1 000m derating 1 100m at 1 000 3 000m Degree of protection IP66 Type 4X Stationary vibration Sinusoidal IEC 60068 2 MU2 3 Hz f 9Hz 10mm 9 Hz f 200Hz 3g MU3 10...

Page 60: ...Trip limit 211 V Earth fault protection Yes Mains supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature pro tection Yes Motor overload protection Yes Motor stall...

Page 61: ...ply 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 Posi...

Page 62: ...red 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 ca...

Page 63: ...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 34 Keypad buttons Scroll menu up Increa...

Page 64: ...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 35 the REF menu is active The table below s...

Page 65: ...OC REM button is used for two functions to quickly access the Control page and to easily change between the Local Keypad and Remote control places Control places The control place is the source of con...

Page 66: ...o return to the Diagnostics menu The Active faults submenu shows the number of faults Select the fault and push OK to see the fault time data The fault remains active until it is cleared with the RESE...

Page 67: ...ive internal fault defect input fuse external charge switch not closed NOTE This fault is activated only if the drive is in Run state In case of temporary supply volt age break reset the fault and res...

Page 68: ...nalog input Selected signal range 4 20 mA see Application Manual Current less than 4 mA Signal line broken detached The signal source is faulty Check the analog input s current source and circuit 51 E...

Page 69: ...cally isolated analogue input and two galvanically isolated analogue outputs standard signals 0 4 20mA OPTB5 I O expander board with three relay outputs OPTB9 I O expander board with five 42 240 VAC d...

Page 70: ...8 vacon 67 Options Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com...

Page 71: ...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 f...

Page 72: ...9 1 EN 954 1 IEC 60204 1 Table 29 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 par...

Page 73: ...ed 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 36 STO function princ...

Page 74: ...t in which the STO is demanded till the system is in the Safe State For VACON 20 X the reaction time is 20 ms minimum Technical information Technical values Absolute maximum voltage range 24V 20 Typic...

Page 75: ...ignal Terminal Technical information Data STO1 S1 Insulated digital input 1 interchangeable polarity 24V 10 15 mA G1 STO 2 S2 Insulated digital input 2 interchangeable polarity 24V 10 15 mA G2 STO fee...

Page 76: ...elay in turn The dynamic use of the STO inputs allows detecting faults that may otherwise accumulate Figure 38 An emergency push button connected to the STO inputs does not assure the same quality bec...

Page 77: ...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...

Page 78: ...ore 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 shows an...

Page 79: ...g of the feedback and STO inputs connect ed in parallel Only for MU3 The choice of using the STO inputs without the automatic monitoring of the output feedback does not permit to achieve the other saf...

Page 80: ...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 81: ...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 82: ...TO 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 36 During maintenance breaks or in case of service...

Page 83: ...Document ID Order code Rev B 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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