vacon 100 installation manual

vacon 100

ac drives

installation manual

vacon • 0

INDEX

Document: DPD00873C

Order code: DOC-INS04123+DLUK

Rev. C

Version release date: 3.5.12

1.

Approvals ......................................................................................................... 2

1.1

EC Declaration of conformity ............................................................................................. 2

1.2

UL approval ........................................................................................................................ 2

1.3

C-tick approval ................................................................................................................... 2

2.

Safety ............................................................................................................... 4

2.1

Danger ................................................................................................................................ 4

2.2

Warnings ............................................................................................................................ 5

2.3

Earthing and earth fault protection ................................................................................... 6

2.4

Electro-magnetic compatibility (EMC)............................................................................... 7

3.

Receipt of delivery............................................................................................ 8

3.1

Type designation code........................................................................................................ 9

3.2

Unpacking and lifting the AC drive .................................................................................. 10

3.2.1 Lifting frames MR8 and MR9 ........................................................................................... 10

3.3

Accessories ...................................................................................................................... 12

3.3.1 Frame MR4 ....................................................................................................................... 12

3.3.2 Frame MR5 ....................................................................................................................... 12

3.3.3 Frame MR6 ....................................................................................................................... 13

3.3.4 Frame MR7 ....................................................................................................................... 13

3.3.5 Frame MR8 ....................................................................................................................... 13

3.3.6 Frame MR9 ....................................................................................................................... 14

3.4

‘Product modified’ sticker................................................................................................ 15

3.5

Disposal ............................................................................................................................ 15

4.

Mounting......................................................................................................... 16

4.1

Dimensions....................................................................................................................... 16

4.1.1 Wall mount ....................................................................................................................... 16

4.1.2 Flange mount ................................................................................................................... 23

4.2

Cooling.............................................................................................................................. 27

5.

Power cabling................................................................................................. 29

5.1

UL standards on cabling .................................................................................................. 31

5.1.1 Cable dimensioning and selection................................................................................... 31

5.2

Brake resistor cables....................................................................................................... 36

5.3

Cable installation ............................................................................................................. 36

5.3.1 Frames MR4 to MR7......................................................................................................... 37

5.3.2 Frames MR8 and MR9...................................................................................................... 43

5.4

Installation in corner-grounded network ........................................................................ 53

6.

Control unit .................................................................................................... 54

6.1

Control unit cabling.......................................................................................................... 55

6.1.1 Control cable sizing.......................................................................................................... 55

6.1.2 Control terminals and DIP switches ................................................................................ 56

6.2

Fieldbus connection ......................................................................................................... 58

6.2.1 Prepare for use through ethernet ................................................................................... 59

6.2.2 Prepare for use through RS485 ....................................................................................... 60

6.3

Option board installation.................................................................................................. 64

6.4

Battery installation for Real Time Clock (RTC)................................................................ 67

6.5

Galvanic isolation barriers ............................................................................................... 68

24-hour support +358 (0)201 212 575 • Email: [email protected]

vacon • 1

7.

Commissioning ............................................................................................... 69

7.1

Commissioning of the drive ............................................................................................. 70

7.2

Running the motor ........................................................................................................... 70

7.2.1 Cable and motor insulation checks ................................................................................. 71

7.3

Installation in it system.................................................................................................... 72

7.3.1 Frames MR4 to MR6......................................................................................................... 72

7.3.2 Frames MR7 and MR8...................................................................................................... 73

7.3.3 Frame MR9 ....................................................................................................................... 74

7.4

Maintenance ..................................................................................................................... 76

8.

Technical data ................................................................................................ 77

8.1

AC drive power ratings..................................................................................................... 77

8.1.1 Mains voltage 208-240 V .................................................................................................. 77

8.1.2 Mains voltage 380-500 V .................................................................................................. 78

8.1.3 Definitions of overloadability ........................................................................................... 79

8.1.4 Brake resistor ratings...................................................................................................... 80

8.2

Vacon 100 - technical data ............................................................................................... 82

8.2.1 Technical information on control connections ................................................................ 85

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Approvals

1.

A

PPROVALS

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.

vacon • 2


1

vacon • 3 Approvals

1

EC DECLARATION OF CONFORMITY

We

Manufacturer's name: Vacon Oyj

Manufacturer's address: P.O.Box 25

R u n s o r i n t i e 7

F I N 6 5 3 8 1 V a a s a

F i n l a n d hereby declare that the product

Product name: Vacon 100 AC drive

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

Vacon 0100-3L-0003-2...0310-2 has been designed and manufactured in accordance with the following standards:

Safety: EN 61800-5-1 (2007)

E N 6 0 2 0 4 1 ( 2 0 0 9 ) ( a s r e l e v a n t )

EMC: EN61800-3 (2004)

E N 6 1 0 0 0 3 1 2 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

The year the CE marking was affixed:

Vesa Laisi

P r e s i d e n t

2012

9226.emf

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Safety vacon • 4

2.

S

AFETY

This manual contains clearly marked cautions and warnings which are intended for your personal 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:

= DANGEROUS VOLTAGE!

9000.emf

9000.emf

9000.emf

9000.emf

9000.emf

9000.emf

9000.emf

= WARNING or CAUTION

13006.emf

Table 1. Warning signs

2.1

Danger

The components of the power unit of Vacon 100 are live when the AC 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

Vacon 100 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 Vacon100. 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 Vacon 100 is disconnected from mains.

Before connecting the AC drive to mains make sure that the front and cable covers of Vacon 100 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.


2

2 vacon • 5

2.2

Warnings

Safety

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

Vacon 100 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 Vacon 100 AC drives exceeds 3.5mA AC. According to standard EN61800-5-1, 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 parameters, 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 function 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, 600V maximum.

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Safety

2.3

Earthing and earth fault protection

vacon • 6

CAUTION!

13006.emf

The Vacon 100 AC drive must always be earthed with an earthing conductor connected to the earthing terminal marked with .

The touch current of Vacon 100 exceeds 3.5mA AC. According to EN61800-5-1, 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 protective

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.

Cross-sectional area of phase conductors (

[mm 2 ]

S  16

16  S 35

35 < S

S )

Minimum cross-sectional area of the corresponding protective earthing conductor

[mm 2 ]

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.

Table 2. Protective earthing conductor cross-section

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, provisions 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.


2

vacon • 7 Safety

13006.emf

Do not perform any voltage withstand tests on any part of Vacon 100. There is a certain procedure according to which the tests shall be performed. Ignoring this procedure may result in damaged product.

2.4

Electro-magnetic compatibility (EMC)

Vacon 100 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 system. 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

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Receipt of delivery vacon • 8

3.

R

ECEIPT 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.

Vacon type designation code

Vacon order number

Batch ID

Serial number

Supply voltage

Rated output current

IP class

Application code

Customer’s order number

9112.emf

Figure 1. Vacon package label


3

vacon • 9 Receipt of delivery

3.1

Type designation code

Vacon type designation code is formed of a nine-segment code and optional +codes. Each segment of the type designation code uniquely corresponds to the product and options you have ordered. The code is of the following format:

VACON

This segment is common for all products.

0100

Product range:

0100 = Vacon 100

3L

Input/Function:

3L = Three-phase input

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

+xxxx +yyyy

Additional codes. (Several options possible)

Examples of additional codes:

+IP54

AC drive with IP protection class IP54

0061

Drive rating in ampere; e.g. 0061 = 61 A

5

Supply voltage:

2 = 208-240 V

5 = 380-500 V

3

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3.2

Unpacking and lifting the AC drive

MR4

MR5

MR6

MR7

MR8

MR9

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 individual frame size in Table 3 below.

Frame

Weight, IP21/IP54

[kg]

6.0

10.0

20.0

37.5

66.0

108.0

Weight, IP00

[kg]

62.0

97.0

Weight, IP21/IP54

[lb.]

13.2

22.0

44.1

82.7

145.5

238.1

Table 3. Frame weights

Weight, IP00

[lb.]

136.7

213.8

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

Max. 45°

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.

9012.emf

Figure 2. Lifting bigger frames


3


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.

3

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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

Item Quantity Purpose

M4x16 screw

M4x8 screw

M5x12 screw

Control cable grounding lamella

EMC cable clamps, size M25

Grounding clamp

‘Product modified’ label

IP21: Cable grommet

IP54: Cable grommet

11

1

1

3

3

2

1

3

6

Screws for power cable clamps

(6), control cable clamps (3), grounding clamps (2)

Screw for optional grounding

Screw for drive external grounding

Control cable grounding

Clamping power cables

Power cable grounding

Information about modifications

Cable run-through sealing


Table 4. Contents of accessories bag, MR4

3.3.2

Frame MR5


M4x16 screw 13

M4x8 screw

M5x12 screw




Grounding clamp


IP21: Cable grommet, hole diameter 25.3 mm


Cable grommet, hole diameter 33.0 mm

1

1

3

1

2

2

1

1

4

2


Screws for power cable clamps

(6), control cable clamps (3), grounding clamps (4)




Clamping brake resistor cable








3

3 vacon • 13

3.3.3

Frame MR6

Receipt of delivery


M4x20 screw

M4x16 screw

M4x8 screw

M5x12 screw




Grounding clamp





10

3

1

1

3

1

2

2

1

1

2

3

Screws for power cable clamps (6) and grounding clamps (4)

Screws for control cable clamps




Clamping brake resistor cable








3.3.4

Frame MR7


M5x30 slotted nut

M4x16 screw

M6x12 screw



Grounding clamp




6

3

1

3

3

2

1

3

3

Nuts for power cable clamps










3.3.5

Frame MR8


M4x16 screw


Cable lugs KP34

Cable insulator


IP00: Touch protection shield

IP00: M4x8 screw

3

3

3

11

4

1

2




Avoiding contact between cables

Control cable run-through sealing

Avoiding contact with live parts

Fixing the touch protection shield


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Receipt of delivery

3.3.6

Frame MR9 vacon • 14


M4x16 screw


Cable lugs KP40

Cable insulator


IP00: Touch protection shield

IP00: M4x8 screw

3

3

5

10

4

1

2




Avoiding contact between cables

Control cable run-through sealing

Avoiding contact with live parts

Fixing the touch protection shield



3


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.

Product modified

Date:

Date:

Date:

9004.emf

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 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 for specific components or special treatment may be ecologically sensible.

3

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Mounting vacon • 16

4.

M

OUNTING

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

ed in chapter 8 cannot be guaranteed.

The AC drive shall be fixed with the screws and other possible components included in the delivery.

4.1

Dimensions

4.1.1

Wall mount

IP21

Ø7

Ø13

128

100

190

Ø25

100

9080.emf

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

IP54

Ø25


4

vacon • 17

Ø7

Ø14

144

115

100*

Ø7

214

Mounting

IP21

Ø33 Ø25 Ø33

IP54

Ø25

Ø7

100*

115

*Optional mounting holes (for NX replacement)


Ø9

195

148

Ø 15,5

229

IP21

Ø40 Ø33 Ø40

9081.emf

Ø25

IP54

Ø25

4

Ø9

148

9082.emf


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Mounting

259

Ø20

237

190 Ø9

Ø16

Ø51

IP21 vacon • 18

Ø25

Ø50

IP54

9083.emf



4

vacon • 19

117 188

663 22 262

Mounting

4

966

Figure 8.Vacon AC drive dimensions, MR8 IP21 and IP54

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vacon • 20 Mounting

9.3

663

10.8

18

683

15.1

794

Figure 9. Vacon AC drive dimensions, MR8 IP00


4


318

166

4

Figure 10. Vacon AC drive dimensions, MR9 IP21 and IP54

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Figure 11. Vacon AC drive dimensions, MR9 IP00


4


4.1.2

Flange mount

The AC drive can also be recessed into the cabinet wall or similar surface. A special flange mount option

is available for this purpose. For an example of a flange-mounted drive, see Figure 12. Note the IP classes of different sections in figure below.

Cabinet wall

(or similar)

Cabinet wall or similar

Front

Rear

IP54

4

IP00

9070.emf

Figure 12. Example of flange mount (frame MR9)

4.1.2.1

Flange mount - Frames MR4 to MR6

Figure 13. presents the dimensions of the mounting opening and Figure 14. the depth dimen-

sions of the drives with the flange mount option.

F

A

C

Figure 13. Flange mount cutout dimensions for MR4 to MR6

9069.emf

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Frame

MR4

MR5

MR6

A B C D E

310

408

534

137

152

203

337

434

560

144

160

211

110

132

184

Table 10. Flange mount cutout dimensions for MR4 to MR6 [mm]

F

316

414

541

MR4 MR5 MR6

9074.ai

Figure 14. MR4 to MR6, flange mount, depth dimensions


4

4 vacon • 25 Mounting

4.1.2.2

Flange mount MR7 to MR9

Figure 15. presents the dimensions of the mounting opening and Figure 17. the dimensions of

the drives with the flange mount option.

Remember to seal the contact surface between the flange and the cutout with the gasket tape provided. If the parts or the drive delivered are already equipped with a sealing no action is

required. See Figure 16.

Drive outline

9075.emf

Opening outline

A E

C

Figure 15. Flange mount cutout dimensions for MR7 to MR9

Frame

MR7

MR8

MR9

A

655

859

975

B

240

298

485

C

682

888

1050

D

268

359

530

Table 11. Flange mount cutout dimensions for MR7 to MR9

E

13.5

17

54

Drive

Opening outline ( ) Gasket tape ( )

9254.emf

Figure 16. Sealing the cutout

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Mounting

110

MR7

149

MR8

233

MR9

Ø22 vacon • 26

9076.emf

108

Figure 17. MR7 to MR9, flange mount, depth dimensions

247

257


4

4 vacon • 27 Mounting

4.2

Cooling

The AC drives produce heat in operation and are cooled down by air circulated by a fan. Enough free space shall therefore be left around the AC drive to ensure sufficient air circulation and cooling. Different acts of maintenance also require certain amount of free space.

Make sure that the temperature of the cooling air does not exceed the maximum ambient temperature of the drive.

A

C

A

B B

Type

MR4

MR5

MR6

MR7

MR8

MR9

Min clearance [mm]

A

*

B * C D

20 20 100 50

20 20 120 60

20 20 160 80

20 20 250 100

20 20 300 150

20 20 350 200

*. Min clearances A and B for drives with IP54 enclosure is 0

mm.

Table 12. Min. clearances around AC drive

D

9013.emf

Figure 18. Installation space

A = clearance around the AC drive (see also B)

B = distance from one AC drive to another or distance to cabinet wall

C = free space above the AC drive

D = free space underneath the AC drive

MR4

MR5

MR6

MR7

MR8

MR9

Table 13. Required cooling air

Type

Cooling air required

[m 3 /h]

45

75

190

185

335

621

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Mounting

Note that if several units are mounted above each other the required free space equals C + D (see

Figure 19.). Moreover, the outlet air used for cool-

ing by the lower unit must be directed away from the air intake of the upper unit by means of e.g. a piece of metal plate fixed to cabinet wall between

the drives as shown in Figure 19.

C+D vacon • 28

FRONT

9014.emf

SIDE

Figure 19. Installation space when drives are mounted on top of each other


4

vacon • 29 Power cabling

5.

P

OWER CABLING

The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals

marked with U, V and W. See principal connection diagram in Figure 20. See also Table 14 for

the cable recommmendations for different EMC levels.

Keypad

Control

L1

L2

L3

Power unit

U/T1

V/T2

W/T3

M

9050.emf

Figure 20. Principal connection diagram

Use cables with heat resistance of at least +70°C. The cables and the fuses must be dimensioned according to the AC drive nominal OUTPUT current which you can find on the rating plate.

5

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Power cabling vacon • 30

EMC levels

Cable type 1 st

environment 2nd environment

Category C2 Category C3 Level C4

Mains cable

Motor cable

1

3*

1

2

Control cable 4 4 4

Table 14. Cable types required to meet standards

1

2

1 = Power cable intended for fixed installation and the specific mains voltage. Shielded cable 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 21.

3 = Symmetrical power cable equipped with compact low-impedance shield and intended for the specific mains voltage. [MCCMK, EMCMK or similar recommended; Recom-

mended cable transfer impedance (1...30MHz) max. 100mohm/m]. See Figure 21.

*360º earthing of the shield with cable glands in motor end needed for EMC level C2.

4 = Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-O or similar).

PE conductor and shield

PE conductors

9007.emf

Figure 21.

Shield

NOTE: The EMC requirements are fulfilled at factory defaults of switching frequencies (all frames).

NOTE: If safety switch is connected the EMC protection shall be continuous over the whole cable installation.


5


5.1

UL standards on cabling

To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with a minimum heat-resistance of +60/75°C. Use Class 1 wire only.

The units are suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes, 600V maximum.

5.1.1

Cable dimensioning and selection

Table shows the minimum dimensions of the Cu/Al-cables and the corresponding fuse sizes.

Recommended fuse types are gG/gL.

These instructions apply only to cases with one motor and one cable connection from the AC drive to the motor. In any other case, ask the factory for more information.

5

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5.1.1.1

Cable and fuse sizes

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage rating should be selected according to the supply network. The final selection should be made according to local regulations, cable installation conditions and cable specification. Bigger fuses than what is recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used fuse type and impedance of the supply circuit. Consult the factory about faster fuses. The manufacturer offers recommendations also for high speed J (UL & CSA ), aR (UL recognized, IEC

60269-4) and gS (IEC 60269-4) fuse ranges.

Table 15. Cable and fuse sizes for Vacon 100

Frame

MR4

MR5

MR6

MR7

MR8

Type

I

L

[A]

0075 2

0072 4

0088 2

0087 4

0105 2

0105 4

0140 2

0140 4

0003 2—0004 2

0003 4—0004 4

3.7—4.8

3.4—4.8

0006 2—0008 2

0005 4—0008 4

6.6—8.0

5.6—8.0

0011 2—0012 2

0009 4—0012 4

11.0—12.5

9.6—12.0

16

0018 2

0016 4

0024 2

0023 4

18.0

16.0

24.0

23.0

20

25

0031 2

0031 4

0038 4

31.0

31.0

38.0

6

10

32

40

0048 2

0046 4

0062 2

0061 4

48.0

46.0

62.0

61.0

50

63

75,0

72,0

88,0

87,0

80

100

105,0

140,0

125

160

0170 2

0170 4

0205 2

0205 4

170,0

205,0

200

250

Fuse

(gG/gL)

[A]

Mains, motor and brake resistor

*

cable

Cu [mm

2

]

Terminal cable size

Main terminal

[mm

2

]

Earth terminal

[mm

2

]

3*1.5+1.5

3*1.5+1.5

3*2.5+2.5

1—6 solid

1—4 stranded

1—6 solid

1—4 stranded

1—6 solid

1—4 stranded

1—6

1—6

1—6

3*6+6

3*6+6

3*10+10

3*10+10

3*16+16 (Cu)

3*25+16 (Al)

3*25+16 (Cu)

3*35+10 (Al)

3*35+16 (Cu)

3*50+16 (Al)

3*35+16 (Cu)

3*70+21 (Al)

3*50+25 (Cu)

3*70+21 (Al)

3*70+35 (Cu)

3*95+29 (Al)

3*95+50 (Cu)

3*150+41 (Al)

3*120+70 (Cu)

3*185+57 (Al)

1—10 Cu

1—10 Cu

1—10 Cu

2.5—50 Cu/Al

2.5—50 Cu/Al

2.5—50 Cu/Al

6-70 mm 2

6-70 mm 2

6-70 mm 2

1—10

1—10

1—10

2.5—35

2.5—35

2.5—35

Cu/Al 6-70 mm

Cu/Al 6-70 mm

Cu/Al 6-70 mm

Bolt size M8

Bolt size M8

Bolt size M8

2

2

2

Bolt size M8

Bolt size M8

Bolt size M8


5



Frame Type

I

L

[A]

Fuse

(gG/gL)

[A]

Mains, motor and brake resistor

*

cable

Cu [mm

2

]


Main terminal

[mm

2

]

Earth terminal

[mm

2

]

MR9

0261 2

0261 4

0310 2

0310 4

261,0

310,0

315

350

3*185+95 (Cu)

2*3*120+41 (Al)

2*3*95+50 (Cu)

2*3*120+41 (Al)

Bolt size M8

Bolt size M8

Bolt size M8

Bolt size M8

*. If you use a multi-conductor cable, NOTE that one of the conductors of the brake resistor cable remains unconnected. Use of single cable is also allowed provided that the minimum cable cross-sectional area given in this table is observed.

The cable dimensioning is based on the criteria of the International Standard IEC60364-5-52:Cables must be PVC-isolated; Max ambient temperature +30°C, max temperature 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 chapter Earthing and earth fault protection of the standard.

For the correction factors for each temperature, see International Standard IEC60364-5-52.

5

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5.1.1.2

Cable and fuse sizes, North America

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse voltage rating should be selected according to the supply network. The final selection should be made according to local regulations, cable installation conditions and cable specification. Bigger fuses than what is recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used fuse type and impedance of the supply circuit. Consult the factory about faster fuses. Vacon offers recommendations also for high speed J (UL & CSA ), aR (UL recognized, IEC 60269-4) and gS (IEC 60269-4) fuse ranges.

Frame

MR4

MR5

MR6

MR7

Type

0011 2

0009 4

0012 2

0012 4

0018 2

0016 4

0024 2

0023 4

0003 2

0003 4

0004 2

0004 4

0006 2

0005 4

0008 2

0008 4

3,7

3.4

4.8

6.6

5.6

8.0

0031 2

0031 4

31.0

0038 4 38.0

11.0

9.6

12.5

12.0

18.0

16.0

24.0

23.0

0048 2

0046 4

0062 2

0061 4

**

48.0

46.0

62.0

61.0

0075 2

0072 4

0088 2

0087 4

0105 2

0105 4

75,0

72,0

88,0

87,0

105,0


I

L

[A]

Fuse

(class T)

[A]

Mains, motor, brake resistor

* and ground cable,

Cu


Main terminal Earth terminal

6

6

10

10

15

20

25

30

40

50

60

80

100

110

150

AWG14

AWG14

AWG14

AWG14

AWG14

AWG14

AWG10

AWG10

AWG8

AWG4

AWG4

AWG4

AWG2

AWG1

AWG1/0

AWG24-AWG10 AWG17-AWG10






AWG20-AWG5

AWG20-AWG5

AWG20-AWG5

AWG13-AWG0

AWG13-AWG0

AWG13-AWG0

AWG17-AWG8

AWG17-AWG8

AWG17-AWG8

AWG13-AWG2

AWG13-AWG2

AWG13-AWG2

AWG9-AWG2/0 AWG9-AWG2/0




5



Frame Type

I

L

[A]

Fuse

(class T)

[A]

Mains, motor, brake resistor

* and ground cable,

Cu


Main terminal Earth terminal

MR8

MR9

0140 2

0140 4

0170 2

0170 4

0205 2

0205 4

0261 2

0261 4

0310 2

0310 4

140,0

170,0

205,0

261,0

310,0

200

225

250

350

400

AWG3/0

250 kcmil

350 kcmil

2*250 kcmil

2*350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

AWG1-350 kcmil

*. If you use a multi-conductor cable, NOTE that one of the conductors of the brake resistor cable remains unconnected. Use of single cable is also allowed provided that the minimum cable cross-sectional area given in this table is observed.

**. The 460V models require 90-degree wire to meet UL regulations

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must be PVC-isolated; Max ambient temperature +30°C, max temperature 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 for each temperature, see the instructions of standard Underwriters’ Laboratories UL508C.

5

Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205


5.2

Brake resistor cables

Vacon 100 AC drives are equipped with terminals for an optional external brake resistor. These terminals are marked with R+ and R- (MR4-MR6) or DC+/R+ and R- (MR7 and bigger). The recommended sizes for the brake resistor cables are listed in tables on pages 32 to 34.

9000.emf

If you use a multi-conductor cable, NOTE that one of the conductors of the brake resistor cable remains unconnected! Cut off the remaining conductor in order to avoid contact with a conducting component.

See brake resistor ratings on page 80.

5.3

Cable installation

• Before starting, check that none of the components of the AC drive is live. Read care-

fully the warnings in chapter 2.

• Place the motor cables sufficiently far from other cables

• Avoid placing the motor cables in long parallel lines with other cables.

• If the motor cables run in parallel with other cables note the minimum distances between the motor cables and other cables given in table below.

Distance between cables, [m]

0.3

1.0

Shielded cable, [m]

 50

 200

• The given distances also apply between the motor cables and signal cables of other systems.

• The maximum lengths of motor cables (shielded) are 100 m (MR4), 150 m (MR5 and

MR6) and 200 m (MR7 to MR9).

• 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:


5

5


5.3.1

Frames MR4 to MR7

1

Strip the motor, mains and brake resistor cables as advised below.

Earth conductor Earth conductor

C1

A1 C2

D1

B1 D2

E

MAINS MOTOR

Figure 22. Stripping of cables

Frame

MR4 15

MR5 20

MR6 20

MR7 20

A1 B1 C1 D1 C2

35

40

90

80

10

10

15

20

20

30

60

80

7

10

15

20

35

40

60

80

Table 17. Cables stripping lengths [mm]

D2 E

Leave as short as possible

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2

Open the cover of the AC drive.

M4x55

3

9174.emf

Figure 23. Opening cover

Remove the screws of the cable protection plate. Do not open the cover of the power unit!

M4x8

9228.emf

Figure 24. Removing screws


5


4

Insert the cable grommets (included in the delivery) in the openings of the cable entry plate (included) as shown in the picture (upper pictures EU version, lower pictures US version).

5

5

9017.emf

Figure 25. Examples of cable entry plates with grommets, IP21

• Insert the cables - supply cable, motor cable and optional brake cable - in the openings of the cable entry plate.

• Then cut the rubber grommets open to slide the cables through. Should the grommets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up.

• Do not cut the grommet openings wider than what is necessary for the cables you are using.

IMPORTANT NOTE FOR IP54 INSTALLATION:

To meet the requirements of the enclosure class IP54, the connection between the grommet and the cable must be tight. Therefore, lead the first bit of the cable out of the grommet straight before letting it bend. If this is not possible, the tightness of the connection must be ensured with insulation tape or a cable tie.

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6

9071.emf

Figure 26. Grommet cutting and sealing

Detach the cable clamps and the grounding clamps (Figure 27) and place the

cable entry plate with the cables in the groove on the AC drive frame (Figure 28).

M4x16

(2.2 Nm)

9229.emf

Figure 27. Detaching cable clamps


5


R+ RU V W

5

7

9232.emf

Figure 28. Cable entry plate and cables

Connect the stripped cables (see Figure 22 and Table 17) as shown in Figure 29.

• Expose the shield of all three cables in order to make a 360-degree connection with the cable clamp (1).

• Connect the (phase) conductors of the supply, brake and motor cables into their respective terminals (2).

• Form the rest of the cable shield of all three cables into “pigtails” and

make a grounding connection with a clamp as shown in Figure 29 (3).

Make the pigtails just long enough to reach and be fixed to the terminal - not longer.

L1L2L3 R+ R- U V W

3

3

1

2

9230.emf

Figure 29. Cable connection

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Tightening torques of cable terminals:

Frame Type

Tightening torque

[Nm]/[lb-in.]

Power and motor terminals


[Nm]/[lb-in.]

EMC grounding clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding terminals

MR4

MR5

MR6

MR7

[Nm] lb-in.

0003 2—0012 2

0003 4—0012 4

0.5—0.6 4.5—5.3

1.5

0018 2—0031 2

0016 4—0031 4

1.2—1.5 10.6—13.3 1.5

0048 2—0062 2

0038 4—0061 4

10

0075 2—0105 2

0072 4—0105 4 8/15

*

88.5

1.5

70.8/132.8* 1.5

[Nm] lb-in.

13.3

13.3

13.3

13.3

*. Cable clamping (Ouneva Pressure Terminal Connector)

Table 18. Tightening torques of terminals

2.0

2.0

2.0

[Nm]

8/15* lb-in.

17.7

17.7

17.7

70.8/132.8*

8

Check the connection of the earth cable to the motor and the AC drive terminals marked with .

NOTE: Two protective conductors are required according to standard EN61800-

5-1. See Figure 30 and chapter Earthing and earth fault protection. Use an M5

size screw and tighten it to 2.0 Nm (17.7 lb-in.).

9233.emf

= M5; 2 Nm

Figure 30. Additional protective earthing connector


5


9 Re-mount the cable protection plate (Figure 31) and the cover of the AC drive.

5

1,5Nm

5.3.2

Figure 31. Re-mounting of cover components

Frames MR8 and MR9

1

Strip the motor, mains and brake resistor cables as advised below.

9234.emf

A1

Earth conductor

C1

B1

D1

Earth conductor

C2

D2

E

MAINS MOTOR

Figure 32.Stripping of cables

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Frame

MR8

MR9

A1

40

40

B1

180

180

C1

25

25

D1

300

300

C2

25

25

Table 19. Cables stripping lengths [mm]

D2 E

300 Leave as short as

300 possible

2

MR9 only: Remove the main cover of the AC drive.

M4 x 10

9046.emf

Figure 33. Removing main cover (MR9)


5

5 vacon • 45

3

Remove the cable cover (1) and the cable fitting plate (2).

Power cabling

M4x8

M4 x 8

1

2

9029.emf

9039.emf

Figure 34. Removing cable cover and cable fitting plate (MR8).

1

M4 x 8

2

9041.emf

Figure 35. Removing cable cover and cable fitting plate (MR9).

M5 x 10

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Power cabling

4

MR9 only: Loosen the screws and remove the sealing plate.

vacon • 46

MR9

Figure 36.Removing sealing plate (MR9)

5

Remove the EMC shield plate.

9048.emf

M4x8

M5

Wing nut

M4x8

9026.emf

Figure 37. Removing EMC shield plate, left: MR8, right: MR9


5


6 Locate the terminals. OBSERVE the exceptional placement of motor cable terminals especially in frame MR8!

L1 L2 L3 DC-

DC+

R+ R-

U V W

R+

L1 L2 L3 DC- DC+ RU V W

7

9027.emf

Figure 38.Power terminals, left: MR8, right: MR9

Cut the rubber grommets open to slide the cables through. Should the grommets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up. Do not cut the grommet openings wider than what is necessary for the cables you are using.

5

9030.emf

Figure 39.Cutting the cable grommets

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8

Place the grommet with the cable so that the frame end plate fits in the groove on the grommet, see Figure 40.

To meet the requirements of the enclosure class IP54, the connection between the grommet and the cable must be tight. Therefore, lead the first bit of the cable out of the grommet straight before letting it bend. If this is not possible, the tightness of the connection must be ensured with insulation tape or a cable tie. As an

example,see Figure 26.

9

Figure 40. Placing the grommet

9040.emf

If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables.

9032.emf

Figure 41.Inserting the cable insulators


5

5 vacon • 49 Power cabling

10

Connect the cables stripped as shown in Figure 32.

• Connect the (phase) conductors of the supply, brake and motor cables into their respective terminals (a).

• Form the rest of the cable shield of all cables into “pigtails” and make a grounding connection as shown in Figure 42 (b) using the clamp from the

Accessories bag

.

• NOTE: If you use several cables on one connector observe the position of cable lugs on top of each other. See Figure 43 below.

L1 L2 L3

DC-

DC+

R+ R-

R+

L1 L2 L3 DC-DC+ RU V W a

U V W b a a b b

9025.emf

Figure 42. Connecting power cables, left: MR8, right: MR9

Connector

Cable lug Cable lug

9015.emf

Figure 43. Placing two cable lugs on top of each other

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Tightening torques of cable terminals:

Frame

MR8

MR9

Type


[Nm]/[lb-in.]

Power and motor terminals


[Nm]/[lb-in.]

EMC grounding clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding terminals

0140 2—0205 2

0140 4—0205 4

20

0261 2—0310 2

0261 4—0310 4

20

[Nm]

177

177 lb-in.

1.5

1.5

[Nm] lb-in.

13.3

13.3

Table 20. Tightening torques of terminals

20

20

[Nm]

177

177 lb-in.

11 Expose the shield of all three cables in order to make a 360-degree connection with the cable clamp.

9035.emf

Figure 44. Exposing cable shields

12

Remount now first the EMC shield plate (see Figure 37) and then the sealing plate for MR9 (see Figure 36).


5

vacon • 51

13 Re-attach then the cable fitting plate and then the cable cover.

Power cabling

M4x8

M4x8

9034.emf

Figure 45. Reattaching cable fitting plate and cover

14 MR9 only: Now re-mount the main cover (unless you want to make the control connections first).

5

M4x10

9047.emf

Figure 46. Re-mounting the main cover (MR9)

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15

Check the connection of the earth cable to the motor and the AC drive terminals marked with .

NOTE: Two protective conductors are required according to standard EN61800-

5-1. See chapter Earthing and earth fault protection.

Connect the protective conductor using a cable shoe and an M8 screw (included in the Accessories bag ) on either of the screw connectors as advised in Figure 47.

9045.emf

Figure 47. Connecting the protective conductor


5


5.4

Installation in corner-grounded network

Corner grounding is allowed for the drive types rating from 72 A to 310 A at 380…480 V supply and from 75 A to 310 A at 208…240 V supply.

In these circumstances the EMC protection class must be changed to level C4 following the in-

structions in chapter 7.3 of this manual.

Corner grounding is not allowed for the drive types with rating from 3.4 A to 61 A at 380…480 V supply and 3.7 A to 62 A with 208…240 V supply.

5

Tel. +358 (0) 201 2121 • Fax +358 (0)201 212 205

Control unit vacon • 54

6.

C

ONTROL UNIT

The control unit of the AC drive consists of the standard boards and additional boards (option

boards, see chapter 6.3) connected to the slot connectors of the control board.

10

1

12

2

3

9

11

8

7

6

5

4

9117.emf

Figure 48. Location of control unit components

Locations of essential control unit components:

1 = Terminals for standard I/O connections; See chapter 6.1.

2 = Ethernet connection

3 = Terminals for three relays connections (or optionally two relays and a termistor); See

chapter 6.1.

4 = Optional boards; See chapter 6.3

5 = DIP switch for RS485 bus termination; See chapter 6.2.2

6 = DIP switch for Analogue output signal selection; See chapter 8.2.1

7 = DIP switch for isolating digital inputs from ground, see chapter 6.1.2.2

8 = DIP switch for Analogue input 2 signal selection; See chapter 8.2.1

9 = DIP switch for Analogue input 1 signal selection; See chapter 8.2.1

10 = RTC Battery

11 = Fan (in frames MR4 and MR5 and protection class IP54 only)

12 = Ethernet led status

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


6

vacon • 55 Control unit

The control board can be powered externally (+24VDC, 1000mA, ±10%) by connecting the ex-

ternal power source to terminal #30, see page 56. This voltage is sufficient for parameter set-

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

6.1

Control unit cabling

The standard control unit connections are presented in Figure 49 below. The control board is

equipped with 22 fixed control I/O terminals and the relay board with 8. All signal descriptions

are given in Figure 49.

6.1.1

Control cable sizing

The control cables shall be at least 0.5 mm 2

screened multicore cables, see Table 14. The max-

imum terminal wire size is 2.5 mm 2 for the relay and other terminals.

Find the tightening torques of the control and relay board terminals in Table below.

Table 21. Control cable tightening torques

Terminal screw

Nm

Tightening torque lb-in.

All I/O and relay terminals

(screw M3)

0.5

4.5

6

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6.1.2

Control terminals and DIP switches

The terminals of the

Basic I/O board

and the

Relay boards

are described below. For more in-

formation on the connections, see chapter 8.2.1.

The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches. See more information in chapter 6.1.2.1 on page 57.

Reference potentiometer 1...10kΩ

2-wire transmitter

Actual value

I = (0)4...20mA

mA

1

2

3

4

5

15

16

17

12

13

14

8

9

6

7

10

11

18

19

30

+10 Vref

AI1+

AI1-

AI2+

AI2-

GND

DI4

DI5

DI6

CM

24Vout

GND

DI1

DI2

DI3

CM

24Vout

AO1+

AO1-/GND

+24Vin

Reference output

Analogue input, voltage or current

Analogue input common, (current)


Analogue input common, (current)

24V auxiliary voltage

I/O ground

Digital input 1

Digital input 2

Digital input 3

Common for DI1-DI6

24V auxiliary voltage

I/O ground

Digital input 4

Digital input 5

Digital input 6

Common for DI1-DI6

Analogue signal

(+output)

Analogue output common

24V auxiliary input voltage

Serial bus, negative

Serial bus, positive

Relay output 1

Frequency reference

Frequency reference

Start forward

Start reverse

External fault

DI4

Open

Closed

Open

Closed

DI5

Open

Open

Closed

Closed

Freq. ref.

Analog input 1

Preset Freq. 1

Preset Freq. 2

Preset Freq. 3

Fault reset

Output frequency

Modbus RTU

*)

*)

RUN

RUN

24

25

26

21

22

23

32

33

A

B

RS485

RS485

RO1/1 NC

RO1/2 CM

RO1/3 NO

RO2/1 NC

RO2/2 CM

RO2/3 NO

RO3/2 CM

RO3/3 NO

Relay output 2

Relay output 3

FAULT

READY

9111.emf

Figure 49. Control I/O terminal signals on basic I/O board and connection example

*Digital inputs can be isolated from ground with a DIP switch, see chapter 6.1.2.2.


6


6.1.2.1

Selection of terminal functions with dip switches

The shadowed terminals in Figure 49 allow for three functional selections each with the so-

called dip switches

. The switches have two positions, up and down. See figure to locate the switches and make appropriate selections for your requirements.

AI1

U = Voltage signal (Default!)

I = Current signal

AI2

U = Voltage signal

I = Current signal (Default!)

AO1

U = Voltage signal

I = Current signal (Default!)

RS-485 bus termination

OFF (Default!)

ON

9108.emf

Figure 50. Dip switches

6.1.2.2

Isolating digital inputs from ground

The digital inputs (terminals 8-10 and 14-16) on the basic I/O board can be isolated from

ground by changing the position of a dip switch on the control board. See Figure 51.

6

Digital inputs

Floating

Connected to GND (Default!)

9109.emf

Figure 51. Change position of this jumper to isolate the digital inputs from ground.

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6.2

Fieldbus connection

The AC drive can be connected to fieldbus either through RS485 or Ethernet. The connection for RS485 is on the basic I/O board (terminals A and B) and the connection for Ethernet is under the drive cover, left to the control keypad. See Figure 52.

DIP switches

Ethernet connector

RS485 terminals

A = Data- B = Data+

17 18 19 30

I/O terminals

Grounding bar

9113.emf

Figure 52. Ethernet and RS485 connections


6


6.2.1

Prepare for use through ethernet

6.2.1.1

Ethernet cable data

1

Connector

Cable type

Cable length

Shielded RJ45 connector; NOTE: Max length of the connector 40mm.

CAT5e STP

Max .100m

Table 22. Ethernet cable data

Connect the Ethernet cable (see specification on page 59) to its terminal and run the cable through the rubber grommets as other I/O cables.

2

Protection class IP21: Cut free the opening on the AC drive cover for the Ethernet cable.

Protection class IP54: Cut the rubber grommets open to slide the cables through. Should the grommets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up. Do not cut the grommet openings wider than what is necessary for the cables you are using.

IMPORTANT: To meet the requirements of the enclosure class IP54, the connection between the grommet and the cable must be tight. Therefore, lead the first bit of the cable out of the grommet straight before letting it bend. If this is not possible, the tightness of the connection must be ensured with insulation tape or a cable tie.

6

9068.emf

Figure 53.Leading the cables, left: IP21, right: IP54

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3

Remount the AC drive cover. NOTE: When planning the cable runs, remember to keep the distance between the Ethernet cable and the motor cable at a minimum

of 30 cm.

Ethernet cable

9056.emf

Figure 54. Distance between cables, left: IP21, right: IP54

For more detailed information, see the user’s manual of the fieldbus you are using.

6.2.2

Prepare for use through RS485

6.2.2.1

RS485 cable data

Connector

Cable type

Cable length

2.5 mm 2

STP (Shielded Twisted Pair), type Belden

9841 or similar

Depends on the used fieldbus. See respective bus manual.

Table 23. RS485 cable data


6


Strip about 15 mm of the RS485 cable (see specification on page 60) and cut off

the grey cable shield. Remember to do this for both bus cables.

Leave no more than 10 mm of the cable outside the terminal block and strip the cables at about 5 mm to fit in the terminals. See picture below.

10

1

9189.emf

5

Also strip the cable now at such a distance from the terminal that you can fix it to the frame with the grounding clamp. Strip the cable at a maximum length of 15 mm. Do not strip the aluminum cable shield!

15

m m

9188.emf

2 Then connect the cable to its appropriate terminals on Vacon 100 AC drive standard terminal block, terminals A and B (A = negative, B = positive). See Figure 55.

6

Figure 55. Connecting the RS485 cable

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Using the cable clamp included in the delivery of the drive, ground the shield of the RS485 cable to the frame of the AC drive.

Cable clamp

3

9200.emf

If the AC drive is the last device on the bus, the bus termination must be set.

Locate the DIP switches to the right of the control keypad of the drive and turn the switch for the RS485 bus termination resistor to position ON. Biasing is built in the termination resistor (resistance = 120 ohm). See also step 7 on page 63.

4

9110.emf

RS-485 bus termination

OFF

ON


6

vacon • 63

Unless already done for the other control cables, cut free the opening on the AC drive cover for the

RS485 cable (protection class IP21).

5

Control unit

9201.emf

6

6

Remount the AC drive cover and run the RS485 cables as shown in picture.

NOTE: When planning the cable runs, remember to keep the distance between the Ethernet, I/O and Fieldbus cables and the motor cable at a

minimum of 30 cm. It is recommended to route the fieldbus cables away from the power cables as shown in the picture.

7

Fieldbus cables

9202.emf

The bus termination must be set for the first and the last device of the fieldbus line. See picture below. See also step 4 on page 62. We recommend that the first device on the bus and, thus, terminated was the Master device.

Vacon 100 Vacon 100 Vacon 100 Vacon 100

Termination activated

Fieldbus

= Bus termination

Resistance = 120 ohm

Termination deactivated

Vacon 100

9042.emf

Termination

activated with

DIP switch

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Control unit

6.3

Option board installation

vacon • 64

13006.emf

NOTE! It is not allowed to add or replace option boards or fieldbus boards on an AC drive with the power switched on. This may damage the boards.

The option boards are placed in the board slots on the drive.

The table below gives information about which option board can be placed in which board slot on the drive.

Table 24. Option board compatibilities for board slots

Option board type

OPTB1

OPTB2

OPTB4

OPTB5

OPTB9

OPTBF

OPTBH

OPTBJ

OPTC4

OPTCP

OPTE3

OPTE5

OPTE6

OPTE7

Board description

I/O expander board

Thermistor relay board

I/O expander board

Relay board

I/O expander board

I/O expander board

Temperature measurement board

Safe Torque-Off board

LonWorks fieldbus board

Ethernet, Profinet I/O option board

Profibus DPV1 fieldbus board

Profibus DPV1 fieldbus board

(D type connector)

CanOpen fieldbus board

DeviceNet fieldbus board

Insertable in slots

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

E

D, E

D, E

D, E

E

D, E

D, E


6


1

Open the cover of the AC drive.

DANGER

The relay outputs and other I/O-terminals may have a dangerous control voltage present even when the drive is disconnected from mains.

M4x55

6

9174.emf

Figure 56.Opening the main cover

Make sure that the sticker on the connector of the board says “dv” (dual voltage).

This indicates that the board is compatible with Vacon 100. See below:

2

Slot coding

9116.emf

NOTE: Incompatible boards cannot be installed on Vacon 100. Compatible boards have a slot coding that enable the placing of the board (see above)

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To reveal the option board slots, open the control unit cover as shown in picture below.

3

4

9235.emf

Install the option board into the appropriate slot C, D or E (see Table 24 on page 64 and Figure below).

Close the cover of the control unit and remount the keypad.

D E

3024.emf


6


6.4

Battery installation for Real Time Clock (RTC)

Enabling the functions of the

Real Time Clock (RTC)

requires that an optional battery is installed in the Vacon 100 drive.

Use ½ AA battery with voltage of 3.6V and capacity of 1000...1200 mAh (e.g. Panasonic BR-1/2

AA or Vitzrocell SB-AA02). The battery will last approximately ten years .

The place for the battery can be found in all frames left to the control keypad (see Figure 48).

Detailed information on the functions of the Real Time Clock (RTC) can be found in the Vacon

100 Application Manual.

6

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6.5

Galvanic isolation barriers

The control connections are isolated from the mains potential and the GND terminals are permanently connected to ground. See Figure 57.

The digital inputs are galvanically isolated from the I/O ground. The relay outputs are additionally double-isolated from each other at 300VAC (EN-50178).

10Vref

GND

+24V

GND

AI1+

AI1-

AI2+

AI2-

DI1...

DI6

CM

AO1+

AO1-

+24Vin

RS485

RO1/1

RO1/2

RO1/3

RO2/1

RO2/2

RO2/3

TI1+

TI1-

CONTROL

UNIT

L1

L2

L3

POWER UNIT

U

V

W

9057.emf

DCDC+/R+ R-

Figure 57. Galvanic isolation barriers


6

vacon • 69 Commissioning

7.

C

OMMISSIONING

Before commissioning, note the following directions and warnings:

13006.emf

13006.emf

13006.emf

13006.emf

13006.emf

Internal components and circuit boards of Vacon 100 (except for the galvanically isolated I/O terminals) are live when it 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 (R+/R- (MR4-MR6) or DC+/R+ and R- (MR7 and bigger)) are live when Vacon 100 is connected to mains, 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 100 is disconnected from mains.

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

After disconnecting the AC drive from the mains, wait 5 minutes before doing any work on the connections of Vacon100. 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 abscence of voltage before electrical work!

Before connecting the AC drive to mains make sure that the front and cable covers of Vacon 100 are closed.

9000.emf

7

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Commissioning vacon • 70

7.1

Commissioning of the drive

Read carefully the safety instructions in Chapter 1 and above and follow them.

After the installation:

 Check that both the AC drive and the motor are grounded.

 Check that the mains, brake and motor cables comply with the requirements given in

chapter 5.1.1.

 Check that the control cables are located as far as possible from the power cables, see

chapter 5.3.

 Check that the 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 or the external supply.

 Check the quality and quantity of cooling air (chapter 4.2 and Table 13).

 Check the inside of the AC drive for condensation.

 Check the installation space for foreign objects.

 Check that all Start/Stop switches connected to the I/O terminals are in Stop-posi- tion.

 Before connecting the AC drive to mains: Check mounting and condition of all fuses and other protective devices.

 Run the Startup Wizard (see the Application Manual).

7.2

Running the motor

MOTOR RUN CHECK LIST

13006.emf

13006.emf

Before starting the motor, check that the motor is mounted properly and ensure that the machine connected to the motor allows the motor to be started.

Set the maximum motor speed (frequency) according to the motor and the machine connected to it.

Before reversing the motor make sure that this can be done safely.

13006.emf

Make sure that no power correction capacitors are connected to the motor cable.

13006.emf

Make sure that the motor terminals are not connected to mains potential.

13006.emf


7


7.2.1

Cable and motor insulation checks

1.

Motor cable insulation checks

Disconnect the motor cable from terminals U, V and W of the AC drive and from the motor.

Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1M at ambient temperature of 20°C.

2.

Mains cable insulation checks

Disconnect the mains cable from terminals L1, L2 and L3 of the AC drive and from the mains. Measure the insulation resistance of the mains cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation 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 the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed 1000

V. The insulation resistance must be >1M at ambient temperature of 20°C. Always follow the instructions of the motor manufacturer.

7

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7.3

Installation in it system

If your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected according to class C2 you need to modify the EMC protection of the AC drive to EMClevel C4. This is done by removing the built-in EMC jumpers with a simple procedure described below:

Warning! Do not perform any modifications on the AC drive when it is connected to mains.

13006.emf

7.3.1

Frames MR4 to MR6

1

Remove the main cover of the AC drive (see page 38) and locate the jumpers con-

necting the built-in RFI-filters to ground. See Figure 58.

2

9236.emf

9237.emf

MR4 MR5

MR6

Figure 58. Locations of the EMC-jumpers in frames MR4 to MR6

9238.emf

Disconnect the RFI-filters from ground by removing the EMC-jumpers. NOTE!

The cable cover must be removed in MR4 and MR5 before the jumper(s) can be reached. See Figure 59.

Figure 59. Removing the jumper, MR6 as example


9060.emf

7


7.3.2

Frames MR7 and MR8

Follow the procedure described below to modify the EMC protection of the AC drive of frames

MR7 and MR8 to EMC-level C4.

1 Remove the main cover of the AC drive and locate the jumper. MR8 only: Push

down the grounding arm. See Figure 60.

2

9066.emf

Figure 60.Grounding arm, MR8

MR7 and MR8: Locate the EMC box under the cover. Remove the screws of the box cover to expose the EMC-jumper. Detach the jumper and re-fix the box cover.

7

Figure 61. Detaching the EMC jumper, MR7-8

9065 emf

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3 Additionally for MR7, locate the DC grounding busbar between connectors R- and U and detach the busbar from the frame by undoing the M4 screw.

9062.emf

Figure 62. MR7: Detaching the DC grounding busbar from frame

7.3.3

Frame MR9

Follow the procedure described below to modify the EMC protection of the AC drive of frame

MR9 to EMC-level C4.

1

Find the connector in the accessories bag. Remove the main cover of the AC drive and locate the place for the connector next to the fan. Push the connector in its place. See Figure 63.

Connector

Figure 63. Placing the connector


9063.emf

7

7 vacon • 75 Commissioning

2

Further remove the extension box cover, the touch shield and the I/O plate with I/

O grommet plate. Locate the EMC jumper on the EMC board (see magnification below) and remove it.

9067.emf

Figure 64. Removing the EMC jumper

CAUTION! Before connecting the AC drive to mains make sure that the EMC protection 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 100 delivery (see below) and note the date. Unless already done, attach the sticker close to the name plate of the AC drive.

Product modified

Date:

EMC-level modified C2->T

Date:

Date: DDMMYY

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7.4

Maintenance

In normal conditions, the AC drive is maintenance-free. However, regular maintenance is recommended to ensure a trouble-free operation and a long lifetime of the drive. We recommend to follow the table below for maintenance intervals.

NOTE: Because of capacitor type (thin film capacitors), reforming of capacitors is not necessary.

Maintenance interval

Regularly and according to general maintenance interval

6...24 months (depending on environment)

24 months (depending on the environment)

3...6 years

6...10 years

10 years

Maintenance action

• Check tightening torques of terminals

• Check filters

• Check input and output terminals and control I/O terminals.

• Check operation of cooling fan

• Check for corrosion on terminals, busbars and other surfaces

• Check door filters in case of cabinet installation

• Clean heatsink and cooling tunnel

• Change internal IP54 fan

• Change main fan

• Replace the RTC battery

NOTE! See the service manual for information on cleaning tools.


7

8 vacon • 77 Technical data

8.

T

ECHNICAL DATA

8.1

8.1.1

AC drive power ratings

Mains voltage 208-240 V

Table 25. Power ratings of Vacon 100, supply voltage 208-240V.

Mains voltage 208-240V, 50-60 Hz, 3~

0075

0088

0105

0140

0170

0205

0261

0310

0003

0004

0007

0008

0011

0012

0018

0024

0031

0048

0062

Drive type

Low

*

Continuous current I

L

[A]

11.0

12.5

18.0

24.0

3.7

4.8

6.6

8.0

31.0

48.0

10% overload current

[A]

12.1

13.8

19.8

26.4

4.1

5.3

7.3

8.8

34.1

52.8

Loadability Motor shaft power


H

[A]

High*


[A]

Max current I

S

2s

8.0

11.0

12.5

18.0

2.6

3.7

4.8

6.6

25.0

31.0

12.0

16.5

18.8

27.0

3.9

5.6

7.2

9.9

37.5

46.5

16.0

19.6

25.0

36.0

5.2

7.4

9.6

13.2

46.0

62.0

230V supply

10% overload 40°C

[kW]

2.2

3.0

4.0

5.5

0.55

0.75

1.1

1.5

7.5

11.0

50% overload 50°C

[kW]

10% overload 40°C

[hp]

1.5

2.2

3.0

4.0

0.37

0.55

0.75

1.1

5.5

7.5

230V supply

3.0

4.0

5.0

7.5

0.75

1.0

1.5

2.0

10.0

15.0

50% overload 50°C

[hp]

2.0

3.0

4.0

5.0

0.5

0.75

1.0

1.5

7.5

10.0

62.0

75.0

88.0

105.0

143.0

170.0

208.0

261.0

310.0

68.2

82.5

96.8

115.5

154.0

187.0

225.5

287.1

341.0

48.0

62.0

75.0

88.0

114.0

140.0

170.0

211.0

251.0

72.0

93.0

112.5

132.0

171.0

210.0

255.0

316.5

376.5

96.0

124.0

150.0

176.0

210.0

280.0

340.0

410.0

502.0

15.0

18.5

22.0

30.0

37.0

45.0

55.0

75.0

90.0

11.0

15.0

18.5

22.0

30.0

37.0

45.0

55.0

75.0

20.0

25.0

30.0

40.0

50.0

60.0

75.0

100.0

125.0

15.0

20.0

25.0

30.0

40.0

50.0

60.0

75.0

100.0

*

See chapter 8.1.3.

NOTE! The rated currents in given ambient temperatures (in Table 29) are achieved only when

the switching frequency is equal to or less than the factory default.

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Technical data vacon • 78

8.1.2

Mains voltage 380-500 V

Table 26. Power ratings of Vacon 100, supply voltage 380-500V.

Mains voltage 380-500V, 50-60 Hz, 3~

0031

0038

0046

0061

0072

0087

0105

0140

0003

0004

0005

0008

0009

0012

0016

0023

0170

0205

0261

0310

Drive type

Low

*


L

[A]

31.0

38.0

46.0

61.0

72.0

87.0

105.0

140.0

9.6

12.0

16.0

23.0

3.4

4.8

5.6

8.0

170.0

205.0

261.0


[A]

34.1

41.8

50.6

67.1

79.2

95.7

115.5

154.0

10.6

13.2

17.6

25.3

3.7

5.3

6.2

8.8

187.0

225.5

287.1

Loadability Motor shaft power


H

[A]

High*


[A]

Max current I

S

2s

23.0

31.0

38.0

46.0

61.0

72.0

87.0

105.0

8.0

9.6

12.0

16.0

2.6

3.4

4.3

5.6

140.0

170.0

205.0

34.5

46.5

57.0

69.0

91.5

108.0

130.5

157.5

12.0

14.4

18.0

24.0

3.9

5.1

6.5

8.4

210.0

255.0

307.5

46.0

62.0

76.0

92.0

122.0

144.0

174.0

210.0

16.0

19.2

24.0

32.0

5.2

6.8

8.6

11.2

280.0

340.0

410.0

400 V supply

10% overload 40°C

[kW]

37.0

45.0

55.0

75.0

15.0

18.5

22.0

30.0

4.0

5.5

7.5

11.0

1.1

1.5

2.2

3.0

90.0

110.0

132.0

30.0

37.0

45.0

55.0

11.0

15.0

18.5

22.0

3.0

4.0

5.5

7.5

0.75

1.1

1.5

2.2

75.0

90.0

110.0

480 V supply

50% overload 50°C

[kW]

10% overload 40°C

[hp]

50% overload 50°C

[hp]

20.0

25.0

30.0

40.0

50.0

60.0

75.0

100.0

5.0

7.5

10.0

15.0

1.5

2.0

3.0

4.0

125.0

150.0

200.0

40.0

50.0

60.0

75.0

15.0

20.0

25.0

30.0

4.0

5.0

7.5

10.0

1.0

1.5

2.0

3.0

100.0

125.0

150.0

310.0

341.0

251.0

376.5

502.0

160.0

132.0

250.0

200.0

*

See chapter 8.1.3.

NOTE! The rated currents in given ambient temperatures (in Table 29) are achieved only when

the switching frequency is equal to or less than the factory default.


8


8.1.3

Definitions of overloadability

Low overload = Following continuous operation at rated output current, 110% rated output current (I

L

) for 1 min, followed by a period of load current less than rated current, and of such duration that the r.m.s output current, over the duty cycle, does not exceed rated output

Example: current (I

L

).

If the duty cycle requires 110% rated current for 1 min in every 10min, the remaining 9 min must be at approximately 98% rated current or less to maintain an r.m.s value

>=100%.

Current

I

L*110%

I

L*110%

I

L

1 min 9 min

Time

9011.emf

Figure 65. Low overload

High overload = Following continuous operation at rated output current, 150 % rated output current (I

H

) for 1 min, followed by a period of load current less than rated current, and of such duration that the r.m.s output current, over the duty cycle, does not exceed rated

Example: output current (I

H

).

If the duty cycle requires 150% rated current for 1 min in every 10min, the remaining 9 min must be at approximately 92% rated current or less to maintain an r.m.s value

>=100%.

Current

I

H*150%

I

H*150%

I

H

1 min 9 min

Time

9009.emf

Figure 66. High overload

NOTE! For more information, please refer to standard IEC61800-2, chapter 5.2.2 (IEC: 1998)

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8.1.4

Brake resistor ratings

Make sure that the resistance is higher than the minimum resistance defined. The power handling capacity must be sufficient for the application.

Recommended brake resistor types and calculated resistances for Vacon 100 AC drives:

Frame Duty cycle Type of brake resistor

Resistance

[ohm]

63.0

MR4

MR5

MR6

MR7

MR8

MR9

Light duty

*

Heavy duty*

Light duty

Heavy duty

Light duty

Heavy duty

Light duty

Heavy duty

Light duty

Heavy duty

Light duty

Heavy duty

BRR 0022 LD 5

BRR 0022 HD 5

BRR 0031 LD 5

BRR 0031 HD 5

BRR 0045 LD 5

BRR 0045 HD 5

BRR 0061 LD 5

BRR 0061 HD 5

BRR 0105 LD 5

BRR 0105 HD 5

BRR 0300 LD 5

BRR 0300 HD 5

63.0

41.0

41.0

21.0

21.0

14.0

14.0

6.5

6.5

3.3

3.3

*

Light duty cycle for brake resistor cyclic use (one LD pulse within 120-second period). The light duty resistor is rated for a 5-second ramp from full power to zero;

Heavy duty cycle for brake resistor cyclic use (one HD pulse within 120-second period). The heavy duty resistor is rated for a 3-second full power braking with a 7second ramp to zero

Predefined power pulses

Heavy duty

Light duty

9252.emf

Time

Figure 67. LD and HD pulse shapes


8


100

Brake power [%]

0

0 3 5 10 120

123 125 130

Time [s]

Figure 68. Duty cycles of LD and HD pulses

240

9253.emf

Table 27. Minimum resistance value and braking power with recommended resistor types, mains voltage 208-240V

Frame

MR4

MR5

MR6

MR7

MR8

MR9

Mains voltage 208-240 V, 50/60 Hz, 3~

Brake min. resistance

[ohm]

Brake power

*

@405 Vdc

[kW]

30.0

20.0

10.0

5.5

3.0

1.4

*

With recommended resistor types

2.6

3.9

7.8

11.7

25.2

49.7

Table 28. Minimum resistance value and braking power with recommended resistor types, mains voltage 380-500V

Type

MR4

MR5

MR6

MR7

MR8

MR9

Mains voltage 380-500 V, 50/60 Hz, 3~

Brake min. resistance

[ohm]

Brake power

*

@845 Vdc

[kW]

63.0

41.0

21.0

14.0

6.5

3.3

*

With recommended resistor types

11.3

17.0

34.0

51.0

109.9

216.4

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8.2

Vacon 100 - technical data

Table 29. Vacon 100 technical data

Mains connection

Motor connection

Control characteristics

Input voltage U in

Starting delay

Output voltage

208...240V; 380…500V; -10%…+10%

Input frequency 50...60 Hz -5...+10%

Connection to mains Once per minute or less

4 s (MR4 to MR6); 6 s (MR7 to MR9)

0-U in

Continuous output current

Switching frequency

(see parameter

P3.1.2.3)

I

L

: Ambient temperature max. +40°C overload 1.1 x I

L

(1 min./10 min)

I

H

: Ambient temperature max. +50°C overload 1.5 x I

H

(1 min./10 min)

Output frequency 0…320 Hz (standard)

Frequency resolution 0.01 Hz

1.5…10 kHz;

Defaults:

MR4-6: 6 kHz (except 0012 2, 0031 2, 0062 2,

0012 4, 0031 4 and 0061 4: 4 kHz)

MR7: 4 kHz

MR8-9: 3 kHz

Automatic switching frequency derating in case of overload.

Frequency reference

Analogue input

Panel reference

Resolution 0.1% (10-bit), accuracy ±1%

Resolution 0.01 Hz

Field weakening point 8…320 Hz

Acceleration time

Deceleration time

0.1…3000 sec

0.1…3000 sec


8


Ambient conditions

Ambient conditions

(cont.)

EMC (at default settings)

Noise level

Safety


Ambient operating temperature

I

L

current: -10°C (no frost)…+40°C

I

H

current: -10°C (no frost)…+50°C

Max. operating temperature: +50°C

Storage temperature -40°C…+70°C

Relative humidity 0...95% R

H

, non-condensing, non-corrosive

Air quality:

• chemical vapours

• mechanical particles

Altitude

Vibration

EN61800-5-1/

EN60068-2-6

Tested according to IEC 60068-2-60 Test Ke:

Flowing mixed gas corrosion test, Method 1

(H

2

S [hydrogen sulfide] and SO

2

[sulfur dioxide])

Designed according to:

IEC 60721-3-3, unit in operation, class 3C2

IEC 60721-3-3, unit in operation, class 3S2

100% load capacity (no derating) up to 1,000m

1-% derating for each 100m above 1,000m

Max. altitudes:

208...240V: 4,000m (TN and IT systems)

380...500V: 4,000m (TN and IT systems)

Voltage for relay outputs:

Up to 3,000m : Allowed up to 240V

3,000m...4,000m: Allowed up to 120V

Corner-grounding: up to 2,000m only (see

chapter 5.4.)

5…150 Hz

Displacement amplitude 1 mm (peak) at

5…15.8 Hz (MR4…MR9)

Max acceleration amplitude 1 G at

15.8…150 Hz (MR4…MR9)

Shock

EN61800-5-1

EN60068-2-27

Enclosure class

Immunity

Emissions

Average noise level

(min...max) sound pressure level in dB(A)

UPS Drop Test (for applicable UPS weights)

Storage and shipping: max 15 G, 11 ms (in package)

IP21/Type 1 standard in entire kW/HP range

IP54/Type 12 option

NOTE! Keypad or panel adapter required for

IP54/Type 12

Fulfils EN61800-3 (2004), first and second environment

+EMC2: EN61800-3 (2004), Category C2

The drive can be modified for IT-networks.

See chapter 7.3 on page 72.

MR4: 45...56

MR5: 57...65

MR7: 43...73

MR8: 58...73

MR6: 63...72

MR9: 54...75

Sound pressure depends on the cooling fan speed which is controlled in accordance with the drive temperature.

EN 61800-5-1 (2007), CE; (see unit nameplate for more detailed approvals)

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Technical data

Protections vacon • 84


Overvoltage trip limit

Undervoltage trip limit

240-volt drives: 456 V

500-volt drives: 911 V

Depends on supply voltage (0,8775*supply voltage):

Supply voltage 240 V: Trip limit 211 V

Supply voltage 400 V: Trip limit 351 V

Supply voltage 500 V: Trip limit 421 V

Earth fault protection Yes

Mains supervision Yes

Motor phase supervision Yes

Overcurrent protection Yes

Unit overtemperature protection

Yes

Motor overload protection Yes

Motor stall protection Yes

Motor underload protection

Short-circuit protection of +24V and +10V reference voltages

Yes

Yes


8


8.2.1

Technical information on control connections

Table 30. Technical information on standard I/O board

Standard I/O board

Terminal Signal Technical information

1

2

3

4

5

6

7

Reference output


Analogue input common

(current)


Analogue input common

(current)

24V aux. voltage

I/O ground

+10V, +3%; Maximum current 10 mA

Analogue input channel 1

0- +10V (Ri = 200 k



)

4-20 mA (Ri =250



)

Resolution 0.1 %, accuracy ±1 %

Selection V/mA with dip-switches (see page 57)

Short-circuited protected.

Differential input if not connected to ground;

Allows ±20V differential mode voltage to GND

Analogue input channel 2

Defauit: 4-20 mA (Ri =250



)

0-10 V (Ri=200k



)




Differential input if not connected to ground;

Allows 20V differential mode voltage to GND

+24V, ±10%, max volt. ripple < 100mVrms; max. 250mA

Short-circuit protected.

Ground for reference and controls (connected internally to frame earth through 1M



)

8

9

10

Digital input 1

Digital input 2

Digital input 3

Positive or negative logic

Ri = min. 5k



0...5V = “0”

15…30V = "1"

11 Common A for DIN1-DIN6

Digital inputs can be disconnected from ground, see chapter 6.1.2.2.

12

13

24V aux. voltage

I/O ground

+24V, ±10%, max volt. ripple < 100mVrms; max. 250mA

Short-circuit protected

Ground for reference and controls (connected internally to frame earth through 1M



)

14

15

16

30

A

B

Digital input 4

Digital input 5

Digital input 6

Positive or negative logic

Ri = min. 5k



0...5V = “0”

15…30V = "1"

17 Common A for DIN1-DIN6

Digital inputs can be isolated from ground, see chapter 6.1.2.2.

18 Analogue signal (+output) Analogue output channel 1, selection 0 -20mA, load <500



19 Analogue output common

Default: 0-20 mA

0-10V




24V auxiliary input voltage Can be used as external power backup for the control unit.

RS485

RS485

Differential receiver/transmitter

Set bus termination with dip switches (see page 57). Termination resis-

tance = 220 ohm.

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Standard relay board (+SBF3)

Terminal Signal Technical information

21

22

23

24

25

26

32

33

Relay output

1

*

Change-over contact (SPDT) relay. 5,5 mm isolation between channels.

Switching capacity 24VDC/8A

Min.switching load

250VAC/8A

125VDC/0.4A

5V/10mA

Relay output

2*



250VAC/8A

Min.switching load

125VDC/0.4A

5V/10mA

Relay output 3*

Normally-open (NO or SPST) contact relay. 5,5 mm isolation between channels.


250VAC/8A

Min.switching load

125VDC/0.4A

5V/10mA

*

If 230VAC is used as control voltage from the output 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

Optional relay board (+SBF4)

Terminal

21

22

23

24

25

26

Signal Technical information

Relay output 1

*



250VAC/8A

Min.switching load

125VDC/0.4A

5V/10mA

Relay output 2*



250VAC/8A

Min.switching load

125VDC/0.4A

5V/10mA

28

29

TI1+

TI1-

Thermistor input. Rtrip = 4.7 k



(PTC); Measuring voltage 3.5V

*

If 230VAC is used as control voltage from the output 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


8

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Manual authoring: [email protected]

Vacon Plc.

Runsorintie 7

65380 Vaasa

Finland

Subject to change without prior notice

© 2012 Vacon Plc.

Document ID:

Order code:

Rev. C

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