Vacon 100 FLOW Installation guide

®

vacon 100

vacon 100 flow

ac drives

installation manual

®

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

vacon • 1

TABLE OF CONTENTS

Document: DPD00873D

Order code: DOC-INS04123+DLUK

Rev. D

Version release date: 7.11.12

1. Approvals ......................................................................................................... 3

1.1 EC Declaration of conformity............................................................................................. 3

1.2 UL approval ........................................................................................................................ 3

1.3 C-tick approval ................................................................................................................... 3

2. Safety ............................................................................................................... 5

2.1 Danger ................................................................................................................................ 5

2.2 Warnings ............................................................................................................................ 6

2.3 Earthing and earth fault protection ................................................................................... 7

2.4 Electro-magnetic compatibility (EMC)............................................................................... 8

2.5 Compability with RCDs....................................................................................................... 8

3. Receipt of delivery............................................................................................ 9

3.1 Type designation code...................................................................................................... 10

3.2 Unpacking and lifting the AC drive .................................................................................. 11

3.2.1 Lifting frames MR8 and MR9 ........................................................................................... 11

3.3 Accessories ...................................................................................................................... 13

3.3.1 Frame MR4....................................................................................................................... 13

3.3.2 Frame MR5....................................................................................................................... 13

3.3.3 Frame MR6....................................................................................................................... 14

3.3.4 Frame MR7....................................................................................................................... 14

3.3.5 Frame MR8....................................................................................................................... 14

3.3.6 Frame MR9....................................................................................................................... 15

3.4 ‘Product modified’ sticker................................................................................................ 16

3.5 Disposal............................................................................................................................ 16

4. Mounting......................................................................................................... 17

4.1 Dimensions....................................................................................................................... 17

4.1.1 Wall mount ....................................................................................................................... 17

4.1.2 Flange mount ................................................................................................................... 24

4.2 Cooling.............................................................................................................................. 33

5. Power cabling................................................................................................. 35

5.1 UL standards on cabling .................................................................................................. 37

5.1.1 Cable dimensioning and selection................................................................................... 37

5.2 Brake resistor cables....................................................................................................... 42

5.3 Cable installation ............................................................................................................. 42

5.3.1 Frames MR4 to MR7......................................................................................................... 43

5.3.2 Frames MR8 and MR9...................................................................................................... 49

5.4 Installation in corner-grounded network ........................................................................ 59

6. Control unit .................................................................................................... 60

6.1 Control unit cabling.......................................................................................................... 61

6.1.1 Control cable sizing.......................................................................................................... 61

6.1.2 Control terminals and DIP switches................................................................................ 62

6.2 Fieldbus connection ......................................................................................................... 64

6.2.1 Prepare for use through ethernet ................................................................................... 65

6.2.2 Prepare for use through RS485 ....................................................................................... 66

6.3 Option board installation.................................................................................................. 70

6.4 Battery installation for Real Time Clock (RTC)................................................................ 73

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vacon • 2

6.5 Galvanic isolation barriers............................................................................................... 74

7. Commissioning ............................................................................................... 75

7.1 Commissioning of the drive ............................................................................................. 76

7.2 Running the motor ........................................................................................................... 76

7.2.1 Cable and motor insulation checks ................................................................................. 77

7.3 Installation in it system....................................................................................................78

7.3.1 Frames MR4 to MR6......................................................................................................... 78

7.3.2 Frames MR7 and MR8...................................................................................................... 79

7.3.3 Frame MR9....................................................................................................................... 80

7.4 Maintenance..................................................................................................................... 82

8. Technical data, Vacon 100............................................................................... 83

8.1 AC drive power ratings..................................................................................................... 83

8.1.1 Mains voltage 208-240 V .................................................................................................. 83

8.1.2 Mains voltage 380-500 V .................................................................................................. 84

8.1.3 Definitions of overloadability ........................................................................................... 85

8.1.4 Brake resistor ratings...................................................................................................... 86

8.2 Vacon 100 - technical data ............................................................................................... 88

8.2.1 Technical information on control connections................................................................ 91

9. Technical data, Vacon 100 FLOW .................................................................... 93

9.1 AC drive power ratings..................................................................................................... 93

9.1.1 Mains voltage 208-240 V .................................................................................................. 93

9.1.2 Mains voltage 380-500 V .................................................................................................. 94

9.1.3 Definitions of overloadability ........................................................................................... 95

9.2 Vacon 100 FLOW - technical data .................................................................................... 96

9.2.1 Technical information on control connections................................................................ 99

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Approvals vacon • 3

1

1. APPROVALS

Approvals granted to this Vacon product are listed on the following pages.

1.1 EC Declaration of conformity

Find the EC Declaration of Conformity on the next page.

1.2 UL approval

cULus approval file number E171278.

1.3 C-tick approval

C-tick approval file number N16307.

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1

vacon • 4 Approvals

EC DECLARATION OF CONFORMITY

We

M

anufacturer's name: Vacon Oyj

M

anufacturer's address: P.O.Box 25

7eitnirosnuR

asaaV18356-NIF

dnalniF

hereby declare that the product

P

roduct name: Vacon 100 AC drive

M

odel designation: Vacon 0100-3L-0003-5...0310-5

has been designed and manufactured in accordance with the following standards:

S

afety: EN 61800-5-1 (2007)

)tnavelersa()9002(1-40206NE

E

MC: EN61800-3 (2004)

21-3-00016NE

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 internal measures and quality control that the product

conforms at all times to the requirements of the current Directive and the relevant

standards.

In Vaasa, 29th of February, 2012

Vesa Laisi

tnediserP

The year the CE marking was affixed: 2012

9226.emf

Vacon 0100-3L-0003-2...0310-2

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Safety vacon • 5

2

2. SAFETY

This manual contains clearly marked cautions and warnings which are intended for your per-

sonal safety and to avoid any unintentional damage to the product or connected appliances.

Please read the information included in cautions and warnings carefully.

The cautions and warnings are marked as follows:

2.1 Danger

Table 1. Warning signs

= DANGER! Dangerous voltage

= WARNING or CAUTION

= Caution! Hot surface

The components of the power unit are live when the drive is connected to mains

potential. Coming into contact with this voltage is extremely dangerous and may

cause death or severe injury.

The motor terminals U, V, W and the brake resistor terminals are live when the

AC drive is connected to mains, even if the motor is not running.

After disconnecting the AC drive from the mains, wait 5 minutes before doing any

work on the connections of the drive. Do not open the cover before this time has

expired. After expiration of this time, use a measuring equipment to absolutely

ensure that no

voltage is present.

Always ensure absence of voltage before start-

ing 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 the AC drive is disconnected from mains.

Before connecting the AC drive to mains make sure that the front and cable co-

vers of the drive are closed.

During a coast stop (see Application Manual), the motor is still generating voltage

to the drive. Therefore, do not touch the components of the AC drive before the

motor has completely stopped. Wait 5 minutes before starting any work on the

drive.

9000.emf

13006.emf

9001.emf

9000.emf

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2

vacon • 6 Safety

2.2 Warnings

The AC drive is meant for fixed installations only.

Do not perform any measurements when the AC drive is connected to the mains.

The touch current of the AC drives exceeds 3.5 mA AC. According to standard EN

61800-5-1, a reinforced protective ground connection must be ensured. See

Chapter 2.3.

If the AC drive is used as a part of a machine, the machine manufacturer is

responsible for providing the machine with a supply disconnecting device (EN

60204-1).

Only spare parts delivered by Vacon can be used.

At power-up, power brake or fault reset the motor will start immediately if the

start signal is active, unless the pulse control for

Start/Stop logic

has been

selected

.

Futhermore, the I/O functionalities (including start inputs) may change if para-

meters, applications or software are changed. Disconnect, therefore, the motor if

an unexpected start can cause danger.

The motor starts automatically after automatic fault reset if the autoreset func-

tion is activated. See the Application Manual for more detailed information.

Prior to measurements on the motor or the motor cable, disconnect the motor

cable from the AC drive.

Do not touch the components on the circuit boards. Static voltage discharge may

damage the components.

Check that the EMC level of the AC drive corresponds to the requirements of your

supply network. See Chapter 7.3.

In a domestic environment, this product may cause radio interference in which

case supplementary mitigation measures may be required.

The AC drives are suitable for use on a circuit capable of delivering not more than

100,000 rms symmetrical amperes, 600 V maximum.

13006.emf

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Safety vacon • 7

2

2.3 Earthing and earth fault protection

The AC drive must always be earthed with an earthing conductor connected to the earthing ter-

minal marked with .

The touch current of the drive exceeds 3.5 mA AC. According to EN 61800-5-1, one or more of

the following conditions for the associated protective circuit shall be satisfied:

A fixed connection and

a) the protective earthing conductor shall have a cross-sectional area of at least 10 mm

2

Cu or 16 mm

2

Al.

or

b) an automatic disconnection of the supply in case of discontinuity of the protecti

ve

earthing conductor. See Chapter 5.

or

c) provision of an additional terminal for a second protective earthing conductor

of the

same cross-sectional area as the original protective earthing conductor.

The cross-sectional area of every protective earthing conductor which does not form a part of

the supply cable or cable enclosure shall, in any case, be not less than

•2.5 mm

2

if mechanical protection is provided or

•4 mm

2

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

conductor.

NOTE: Due to the high capacitive currents present in the AC drive, fault current protective

switches may not function properly.

CAUTION!

Table 2. Protective earthing conductor cross-section

Cross-sectional area of phase conductors (S)

[mm

2

]

Minimum cross-sectional area of the cor-

responding protective earthing conductor

[mm

2

]

S ≤ 16

16 <

S ≤ 35

35 <

S

16

S/2

The values above are valid only if the protective earthing conductor is made of the same metal as

the phase conductors. If this is not so, the cross-sectional area of the protective earthing conductor

shall be determined in a manner which produces a conductance equivalent to that which results

from the application of this table.

13006.emf

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2

vacon • 8 Safety

2.4 Electro-magnetic compatibility (EMC)

The AC drives comply with IEC 61000-3-12 provided that the short-circuit power S

SC

is greater

than or equal to 120 R

SCE

at the interface point between the user’s supply and the public sys-

tem. It is the responsibility of the installer or user of the equipment to ensure, by consultation

with the distribution network operator if necessary, that the equipment is connected only to a

supply with a short-circuit power S

SC

greater than or equal to 120 R

SCE

.

2.5 Compability with RCDs

Do not perform any voltage withstand tests on any part of the AC drive. There is

a certain procedure according to which the tests shall be performed. Ignoring this

procedure may result in damaged product.

If a fault protection relay is used, it must be of at least type B, preferably B+

(according to EN 50178), with a trip level of 300 mA. This is for protection, not for

touch protection in grounded systems.

13006.emf

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Receipt of delivery vacon • 9

3

3. RECEIPT OF DELIVERY

Check the correctness of delivery by comparing your order data to the drive information found

on the package label. If the delivery does not correspond to your order, contact the supplier

immediately. See Chapter 3.1.

Figure 1. Vacon package label

9112.emf

Vacon type

designation code

Rated output

current

Application

code

IP class

Serial number

Customer’s

order number

Vacon order

number

Batch ID

Supply voltage

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3

vacon • 10 Receipt of delivery

3.1 Type designation code

Vacon type designation code is formed of a nine-segment code and optional +codes. Each seg-

ment of the type designation code uniquely corresponds to the product and options you have

ordered. The code is of the following format:

VACON0100-3L-0061-5 +xxxx +yyyy

VACON0100-3L-0061-FLOW +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

5

Supply voltage:

2 = 208-240 V

5 = 380-500 V

FLOW

Only for Vacon 100 FLOW drives

+xxxx +yyyy

Additional codes. (Several options possible)

Examples of additional codes:

+IP54

AC drive with IP protection class IP54

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Receipt of delivery vacon • 11

3

3.2 Unpacking and lifting the AC drive

The weights of the AC drives vary greatly according to the size. You may need to use a piece of

special lifting equipment to move the drive from its package. Note the weights of each individ-

ual frame size in Table below.

If you decide to use a piece of lifting equipment see picture below for recommendations to lift

the drive.

3.2.1 Lifting frames MR8 and MR9

Figure 2. Lifting bigger frames

Table 3. Frame weights

Frame

Weight, IP21/IP54

[kg]

Weight, IP00

[kg]

Weight, IP21/IP54

[lb.]

Weight, IP00

[lb.]

MR4 6.0

13.2

MR5 10.0 22.0

MR6 20.0 44.1

MR7 37.5 82.7

MR8 66.0 62.0 145.5 136.7

MR9 108.0 97.0 238.1 213.8

Max. 45°

9012.emf

NOTE: First detach the drive from the pallet it has been

bolted to.

NOTE: Place the lifting hooks symmetrically in at least two

holes.The lifting device must be able to carry weight of the

drive.

NOTE: The maximum allowed lifting angle is 45 degrees.

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3

vacon • 12 Receipt of delivery

Vacon 100 AC drives have undergone scrupulous tests and quality checks at the factory before

they are delivered to the customer. However, 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 contact primarily the cargo

insurance company or the carrier.

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Receipt of delivery vacon • 13

3

3.3 Accessories

After having opened the transport package and lifted the drive out, check immediately that

these various accessories were included in the delivery. The contents of the

accessories bag

differ by drive size and IP protections class:

3.3.1 Frame MR4

3.3.2 Frame MR5

Table 4. Contents of accessories bag, MR4

Item Quantity Purpose

M4x16 screw 11

Screws for power cable clamps

(6), control cable clamps (3),

grounding clamps (2)

M4x8 screw 1 Screw for optional grounding

M5x12 screw 1 Screw for drive external grounding

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M25 3 Clamping power cables

Grounding clamp 2 Power cable grounding

‘Product modified’ label 1 Information about modifications

IP21: Cable grommet 3 Cable run-through sealing

IP54: Cable grommet 6 Cable run-through sealing

Table 5. Contents of accessories bag, MR5

Item Quantity Purpose

M4x16 screw 13

Screws for power cable clamps

(6), control cable clamps (3),

grounding clamps (4)

M4x8 screw 1 Screw for optional grounding

M5x12 screw 1 Screw for drive external grounding

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M25 1 Clamping brake cable

EMC cable clamps, size M32 2 Clamping power cables

Grounding clamp 2 Power cable grounding

‘Product modified’ label 1 Information about modifications

IP21: Cable grommet, hole diameter 25.3 mm 1 Cable run-through sealing

IP54: Cable grommet, hole diameter 25.3 mm 4 Cable run-through sealing

Cable grommet, hole diameter 33.0 mm 2 Cable run-through sealing

NOTE! Dynamic braking and brake resistor is not supported in Vacon 100 FLOW.

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3

vacon • 14 Receipt of delivery

3.3.3 Frame MR6

3.3.4 Frame MR7

3.3.5 Frame MR8

Table 6. Contents of accessories bag, MR6

Item Quantity Purpose

M4x20 screw 10

Screws for power cable clamps (6)

and grounding clamps (4)

M4x16 screw 3 Screws for control cable clamps

M4x8 screw 1 Screw for optional grounding

M5x12 screw 1 Screw for drive external grounding

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M32 1 Clamping brake resistor cable

EMC cable clamps, size M40 2 Clamping power cables

Grounding clamp 2 Power cable grounding

‘Product modified’ label 1 Information about modifications

Cable grommet, hole diameter 33.0 mm 1 Cable run-through sealing

Cable grommet, hole diameter 40.3 mm 2 Cable run-through sealing

IP54: Cable grommet, hole diameter 25.3 mm 3 Cable run-through sealing

NOTE! Dynamic braking and brake resistor is not supported in Vacon 100 FLOW.

Table 7. Contents of accessories bag, MR7

Item Quantity Purpose

M6x30 slotted nut 6 Nuts for power cable clamps

M4x16 screw 3 Screws for control cable clamps

M6x12 screw 1 Screw for drive external grounding

Control cable grounding lamella 3 Control cable grounding

EMC cable clamps, size M50 3 Clamping power cables

Grounding clamp 2 Power cable grounding

‘Product modified’ label 1 Information about modifications

Cable grommet, hole diameter 50.3 mm 3 Cable run-through sealing

IP54: Cable grommet, hole diameter 25.3 mm 3 Cable run-through sealing

Table 8. Contents of accessories bag, MR8

Item Quantity Purpose

M4x16 screw 3 Screws for control cable clamps

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Receipt of delivery vacon • 15

3

3.3.6 Frame MR9

Control cable grounding lamella 3 Control cable grounding

Cable lugs KP40 3 Clamping power cables

Cable insulator 11 Avoiding contact between cables

Cable grommet, hole diameter 25.3 mm 4 Control cable run-through sealing

IP00: Touch protection shield 1 Avoiding contact with live parts

IP00: M4x8 screw 2 Fixing the touch protection shield

Table 9. Contents of accessories bag, MR9

Item Quantity Purpose

M4x16 screw 3 Screws for control cable clamps

Control cable grounding lamella 3 Control cable grounding

Cable lugs KP40 5 Clamping power cables

Cable insulator 10 Avoiding contact between cables

Cable grommet, hole diameter 25.3 mm 4 Control cable run-through sealing

IP00: Touch protection shield 1 Avoiding contact with live parts

IP00: M4x8 screw 2 Fixing the touch protection shield

Table 8. Contents of accessories bag, MR8

Item Quantity Purpose

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3

vacon • 16 Receipt of delivery

3.4 ‘Product modified’ sticker

In the Accessories bag included in the delivery you will find a silver Product modified sticker.

The purpose 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 mark the change on the sticker.

Figure 3. ‘Product modified’ sticker

3.5 Disposal

When the device reaches the end of its operating life do not dispose of it as a part

of standard household garbage. Main components of the product can be recycled,

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 elec-

tronic components. To ensure environmentally sound and safe recycling treat-

ment, 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

for specific components or special treatment may be ecologically sensible.

Product modified

Date:

9004.emf

13064.emf

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Mounting vacon • 17

4

4. MOUNTING

The AC drive must be mounted in vertical position on the wall or on the back plane of a cubicle.

Ensure that the flatness variation shall not exceed 3 mm. Should the conditions of the moun-

ting place require horizontal mounting, the functionalities within the given nominal values sta-

ted in Chapter 8 cannot be guaranteed.

The AC drive shall be fixed with the screws and other possible components included in the de-

livery.

4.1 Dimensions

4.1.1 Wall mount

Figure 4. Vacon AC drive dimensions, MR4, wall mount

128

100

Ø7

Ø13

313

100

328

190

IP21

Ø25

151

112

IP54

Ø25

112

147

9080.emf

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4

vacon • 18 Mounting

Figure 5. Vacon AC drive dimensions, MR5, wall mount

Figure 6. Vacon AC drive dimensions, MR6, wall mount

*Optional mounting holes (for NX replacement)

214

144

115

Ø7

Ø14

Ø7

100*

419

406

115

Ø7

100*

IP21

39

130

134

Ø33 Ø33Ø25

IP54

37,5

130

134

Ø25

9081.emf

195

148

Ø 15,5

Ø9

557

541

Ø9

148

229

43,7

148

151

IP21

Ø40 Ø33 Ø40

42

148

151

IP54

Ø25Ø25

9082.emf

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