Danfoss VACON 100 industrial User manual

Operating Guide
VACON® 100 Wall-mounted Drives
VACON® 100 INDUSTRIAL, VACON® 100 FLOW,
VACON® 100 HVAC

Contents
1 Introduction 7
1.1 Additional Resources 7
1.2 Disposal 7
1.3 Type Approvals and Certifications 7
2 Safety 9
2.1 Safety Symbols 9
2.2 Danger and Warnings 9
2.3 Cautions and Notices 11
3 Product Overview 13
3.1 Manual Version 13
3.2 Package Label 13
3.3 Description of the Type Code 14
3.4 Enclosure Sizes 15
4 Receiving the Delivery 19
4.1 Checking the Delivery 19
4.2 Accessories 19
4.2.1 Accessories Bag, MR4 19
4.2.2 Accessories Bag, MR5 19
4.2.3 Accessories Bag, MR6 20
4.2.4 Accessories Bag, MR7 20
4.2.5 Accessories Bag, MR8 21
4.2.6 Accessories Bag, MR9 21
4.3 Storing the Product 22
4.4 Lifting the Enclosure Sizes MR8 and MR9 22
4.5 Using the Product Modified Label 23
5 Mounting 25
5.1 Wall-mounting Requirements 25
5.2 Flange-mounting Requirements 25
5.3 Cooling Requirements 27
5.3.1 General Cooling Requirements 27
5.3.2 Cooling 27
5.3.3 Necessary Quantity of Cooling Air 30
6 Electrical Installation 31
6.1 Cable Connections 31
6.1.1 General Cable Requirements 31
Contents
Operating Guide | VACON® 100 Wall-mounted Drives
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6.1.2 UL Standards on Cabling 32
6.1.3 Cable Selection and Dimensioning 32
6.1.4 Cable Selection and Dimensioning, North America 32
6.1.5 Fuse Selection 33
6.1.6 Fuse Selection, North America 33
6.1.7 Brake Resistor Cables 33
6.2 EMC-compliant Installation 34
6.2.1 Installation in a Corner-grounded Network 35
6.3 Grounding 35
6.4 Get Access and Locate the Terminals 36
6.4.1 Get Access and Locate the Terminals for MR4-MR7 36
6.4.2 Get Access and Locate the Terminals for MR8 38
6.4.3 Get Access and Locate the Terminals for MR9 40
6.5 Installation of Cables 43
6.5.1 Additional Instructions for Cable Installation 43
6.5.2 Installing the Cables, MR4-MR7 44
6.5.3 Installing the Cables, MR8-MR9 48
6.6 Installation in an IT System 53
6.6.1 Installing the AC drive in an IT System, MR4-MR6 53
6.6.2 Installing the AC drive in an IT System, MR7 55
6.6.3 Installing the AC drive in an IT System, MR8 58
6.6.4 Installing the AC drive in an IT System, MR9 60
6.7 Installation in a Marine Environment 63
7 Control Unit 64
7.1 Control Unit Components 64
7.2 Control Unit Cabling 65
7.2.1 Selection of the Control Cables 65
7.2.2 Control Unit Terminals 65
7.3 DIP Switches on the Control Unit 67
7.3.1 Selection of Terminal Functions with DIP Switches 67
7.3.2 Isolation of the Digital Inputs from Ground 69
7.4 Fieldbus Connection 69
7.4.1 Fieldbus Terminals 69
7.4.2 Internal Fieldbuses in VACON® 100 Products 70
7.4.3 General Cabling Instructions for Fieldbus 71
7.4.3.1 Cable Routing 71
7.4.3.2 Strain Relief 73
7.4.4 Ethernet Commissioning and Cabling 73
7.4.4.1 General Cabling Instructions for Ethernet 73
7.4.4.2 Grounding the Cable Shield 73
7.4.4.3 Using Fieldbus through an Ethernet Cable 75
Contents
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7.4.5 RS485 Commissioning and Cabling 78
7.4.5.1 General Cabling Instructions for RS485 78
7.4.5.2 Grounding the Cable Shield 79
7.4.5.3 The RS485 Bus Biasing 80
7.4.5.4 Using Fieldbus through an RS485 Cable 80
7.5 Available Option Boards 84
7.6 Option Board Installation 85
7.7 Battery for the Real-Time Clock (RTC) 87
7.8 Galvanic Isolation Barriers 87
7.9 Description of the Control Panel 88
7.9.1 Control Panel and the Keypad 88
7.9.2 Displays of the Control Panel 89
8 Commissioning 91
8.1 Safety Checks before Starting the Commissioning 91
8.2 Commissioning the AC Drive 92
8.3 Measuring the Cable and Motor Insulation 92
8.3.1 Insulation Checks of the Motor Cable 93
8.3.2 Insulation Checks of the Mains Cable 93
8.3.3 Insulation Checks of the Motor 93
8.4 Checking the AC Drive after Commissioning 94
9 Maintenance 95
9.1 Maintenance Schedule 95
10 Specifications 96
10.1 Weight of the Drive 96
10.2 Dimensions 96
10.2.1 Dimensions for Wall-mounting 96
10.2.1.1 Dimensions for Wall-mounting for MR4 96
10.2.1.2 Dimensions for Wall-mounting for MR5 97
10.2.1.3 Dimensions for Wall-mounting for MR6 98
10.2.1.4 Dimensions for Wall-mounting for MR7 99
10.2.1.5 Dimensions for Wall-mounting for MR8 100
10.2.1.6 Dimensions for Wall-mounting for MR9 101
10.2.2 Dimensions for Flange-mounting 102
10.2.2.1 Dimensions for Flange-mounting for MR4 102
10.2.2.2 Dimensions for Flange-mounting for MR5 103
10.2.2.3 Dimensions for Flange-mounting for MR6 104
10.2.2.4 Dimensions for Flange-mounting for MR7 105
10.3 Cable and Fuse Sizes 105
10.3.1 List of Cable and Fuse Size Information 105
10.3.2 Cable and Fuse Sizes, Mains Voltage 208–240 V and 380–500 V 106
Contents
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10.3.3 Cable and Fuse Sizes, Mains Voltage 525–690 V 107
10.3.4 Cable and Fuse Sizes, Mains Voltage 208–240 V and 380–500 V, North America 109
10.3.5 Cable and Fuse Sizes, Mains Voltage 525–690 V, North America 111
10.4 Cable Stripping Lengths 112
10.5 Tightening Torques of the Terminals 113
10.6 Power Ratings 114
10.6.1 Power Ratings of VACON® 100 INDUSTRIAL, 208–240 V 114
10.6.2 Power Ratings of VACON® 100 INDUSTRIAL, 380–500 V 116
10.6.3 Power Ratings of VACON® 100 INDUSTRIAL, 525–600 V 117
10.6.4 Power Ratings of VACON® 100 INDUSTRIAL, 525–690 V 118
10.6.5 Power Ratings of VACON® 100 FLOW, 208–240 V 119
10.6.6 Power Ratings of VACON® 100 FLOW, 380–500 V 120
10.6.7 Power Ratings of VACON® 100 FLOW, 525–600 V 121
10.6.8 Power Ratings of VACON® 100 FLOW, 525–690 V 122
10.6.9 Power Ratings of VACON® 100 HVAC, 208–240 V 123
10.6.10 Power Ratings of VACON® 100 HVAC, 380–500 V 124
10.7 Overload Capability 124
10.8 Brake Resistor Ratings 126
10.8.1 Brake Resistor Ratings 126
10.8.2 Brake Resistance in Light duty and Heavy Duty 126
10.8.3 Brake Resistor Types, Mains Voltage 208–240 V and 380–500 V 127
10.8.4 Brake Resistor Types, Mains Voltage 525–690 V 127
10.8.5 Brake Resistance and Brake Power, Mains Voltage 208–240 V 128
10.8.6 Brake Resistance and Brake Power, Mains Voltage 380–500 V 129
10.8.7 Brake Resistance and Brake Power, Mains Voltage 525–600 V 129
10.8.8 Brake Resistance and Brake Power, Mains Voltage 525–690 V 129
10.9 Control Connections 130
10.10 Technical Data, VACON® 100 INDUSTRIAL 133
10.11 Technical Data, VACON® 100 FLOW 138
10.12 Technical Data, VACON® 100 HVAC 142
Contents
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1 Introduction
1.1 Additional Resources
Other resources are available to understand advanced AC drive functions and operation.
• VACON® 100 INDUSTRIAL Application Guide
• VACON® 100 FLOW Application Guide
• VACON® 100 HVAC Application Guide
• VACON® 100 Enclosed Drives Installation Manual
• VACON® 100 IP00 Drive Modules Installation Manual
• VACON® 100 X Installation Manual
• Instructions for operation with option boards and other optional equipment.
Supplementary publications and manuals are available from Danfoss.
For US and Canada market:
NOTE! Download the English and French product manuals with applicable safety, warning and caution information from https://
www.danfoss.com/en/service-and-support/.
REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l'ensemble des informations
de sécurité, avertissements et mises en garde applicables sur le site https://www.danfoss.com/en/service-and-support/.
1.2 Disposal
Context:
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with
local and currently valid legislation.
1.3 Type Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
Introduction
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089
NOTICE
The specific approvals and certification for the drive are on the nameplate of the drive. For more information, contact the local
Danfoss office or partner.
Introduction
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2 Safety
2.1 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.2 Danger and Warnings
DANGER
SHOCK HAZARD FROM POWER UNIT COMPONENTS
The power unit components are live when the drive is connected to mains. A contact with this voltage can lead to death or
serious injury.
-Do not touch the components of the power unit when the drive is connected to mains. Before connecting the drive to
mains, make sure that the covers of the drive are closed.
DANGER
SHOCK HAZARD FROM TERMINALS
The motor terminals U, V, W, the brake resistor terminals, or the DC terminals are live when the drive is connected to mains, also
when the motor does not operate. A contact with this voltage can lead to death or serious injury.
-Do not touch the motor terminals U, V, W, the brake resistor terminals, or the DC terminals when the drive is connected to
mains. Before connecting the drive to mains, make sure that the covers of the drive are closed.
Safety
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DANGER
SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE
The terminal connections and the components of the drive can be live 5 minutes after the drive is disconnected from the mains
and the motor has stopped. Also the load side of the drive can generate voltage. A contact with this voltage can lead to death
or serious injury.
-Before doing electrical work on the drive:
• Disconnect the drive from the mains and make sure that the motor has stopped.
• Lock out and tag out the power source to the drive.
• Make sure that no external source generates unintended voltage during work.
• Wait 5 minutes before opening the cabinet door or the cover of the AC drive.
• Use a measuring device to make sure that there is no voltage.
WARNING
SHOCK HAZARD FROM CONTROL TERMINALS
The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this
voltage can lead to injury.
-Make sure that there is no voltage in the control terminals before touching the control terminals.
WARNING
ACCIDENTAL MOTOR START
When there is a power-up, a power break, or a fault reset, the motor starts immediately if the start signal is active, unless the
pulse control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions
(including the start inputs) can change. If you activate the auto reset function, the motor starts automatically after an automatic
fault reset. See the Application Guide. Failure to ensure that the motor, system, and any attached equipment are ready for start
can result in personal injury or equipment damage.
-Disconnect the motor from the drive if an accidental start can be dangerous. Make sure that the equipment is safe to
operate under any condition.
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.
-Ensure the correct grounding of the equipment by a certified electrical installer.
WARNING
SHOCK HAZARD FROM PE CONDUCTOR
The drive can cause a DC current in the PE conductor. Failure to use a residual current-operated protective (RCD) device Type B
or a residual current-operated monitoring (RCM) device can lead to the RCD not providing the intended protection and
therefore can result in death or serious injury.
-Use a type B RCD or RCM device on the mains side of the drive.
Safety
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2.3 Cautions and Notices
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT MEASUREMENTS
Doing measurements on the AC drive when it is connected to mains can damage the drive.
-Do not do measurements when the AC drive is connected to mains.
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS
Using spare parts that are not from the manufacturer can damage the drive.
-Do not use spare parts that are not from the manufacturer.
CAUTION
DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING
Not using a grounding conductor can damage the drive.
-Make sure that the AC drive is always grounded with a grounding conductor that is connected to the grounding terminal
that is identified with the PE symbol.
CAUTION
CUT HAZARD FROM SHARP EDGES
There can be sharp edges in the AC drive that can cause cuts.
-Wear protective gloves when mounting, cabling, or doing maintenance operations.
CAUTION
BURN HAZARD FROM HOT SURFACES
Touching surfaces, which are marked with the 'hot surface' sticker, can result in injury.
-Do not touch surfaces which are marked with the 'hot surface' sticker.
NOTICE
DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE
Some of the electronic components inside the AC drive are sensitive to ESD. Static voltage can damage the components.
-Remember to use ESD protection always when working with electronic components of the AC drive. Do not touch the
components on the circuit boards without proper ESD protection.
Safety
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NOTICE
DAMAGE TO THE AC DRIVE FROM MOVEMENT
Movement after installation can damage the drive.
-Do not move the AC drive during operation. Use a fixed installation to prevent damage to the drive.
NOTICE
DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL
The EMC level requirements for the AC drive depend on the installation environment. An incorrect EMC level can damage the
drive.
-Before connecting the AC drive to the mains, make sure that the EMC level of the AC drive is correct for the mains.
NOTICE
RADIO INTERFERENCE
In a residential environment, this product can cause radio interference.
-Take supplementary mitigation measures.
NOTICE
MAINS DISCONNECTION DEVICE
If the AC drive is used as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN
60204-1).
NOTICE
MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES
Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not
operate correctly.
NOTICE
VOLTAGE WITHSTAND TESTS
Doing voltage withstand tests can damage the drive.
-Do not do voltage withstand tests on the AC drive. The manufacturer has already done the tests.
Safety
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3 Product Overview
3.1 Manual Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is English.
Table 1: Manual and Software Version
Edition Remarks
DPD01711H Information about the new enclosure size MR9B and internal fieldbuses was added.
Information about option boards was updated.
EC declaration was removed.
Information about VACON® 100 IP00 drive modules was removed.
Hyperlink to company web page was updated.
Structure of the manual was changed.
Minor changes throughout the manual.
3.2 Package Label
The package label gives detailed information about the delivery.
Product Overview
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1003350719
V00002373919
70-AB3L00045W04B220BM2H-00055783
135U1814
Danfoss A/S, 6430 Nordborg, Denmark
1.5kW:400V / 2HP:480V
IP21/Type1
3~AC,0-Uin, 0-320Hz,
Uin:3~AC,380-500V, 50/60Hz,4.6A
Made in Finland
POWER:
4.8A
OUTPUT:
INPUT:
Danfoss S.A.
DLES
VACON0100-3L-0004-5-FLOW+FL03+DPAP+
190304
0021396473
FW0159V021
Marks:
Cust. Ord. No:
Application:
Firmware:
B.ID:
V00002373919
S/N:
70-AB3L00045W04B220BM2H-00055783
Code:
Type:
AC DRIVE
A
C
B
D
F
E
G
H
I
e30bh338.10
AThe batch ID
CThe type code
EThe mains voltage
GThe protection rating
IThe order number of the customer
BThe VACON® order number
DThe serial number
FThe nominal output current
HThe application code
Illustration 1: Package Label of VACON® 100 Wall-mounted Drives
3.3 Description of the Type Code
The type code of VACON® is made of standard codes and optional codes. Each part of the type code agrees to the data in the order.
Product Overview
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Example:
The code can have this format, for example:
• VACON0100-3L-0061-5+IP54
• VACON0100-3L-0061-5-FLOW
Table 2: Description of the Type Code
Code Description
VACON0100 The product family: VACON0100 = the VACON® 100 product family
3L Input/Function: 3L = A 3-phase input
0061 The drive rating in amperes. For example, 0061 = 61 A
5 The mains voltage:
2 = 208–240 V
5 = 380–500 V
6 = 525–600 V
7 = 525–690 V
FLOW The product:
(empty) = The VACON® 100 INDUSTRIAL AC drive
FLOW = The VACON® 100 FLOW AC drive
HVAC = The VACON® 100 HVAC AC drive
+IP54 The optional codes. There are many options, for example +IP54 (an AC drive with the protection rating IP54).
3.4 Enclosure Sizes
The codes for nominal current and nominal mains voltage are part of the type code (see 3.3 Description of the Type Code) on the
package label (see 3.2 Package Label). Use these values to find out the enclosure size of the AC drive from the table.
In the example "VACON0100-3L-0061-5+IP54", the code for nominal current is 0003 and the code for nominal mains voltage is 5.
Product Overview
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Table 3: Enclosure Sizes
Nominal mains voltage Nominal current Enclosure size
2 (208–240 V) 0003 MR4
0004
0007
0008
0011
0012
0018 MR5
0024
0031
0048 MR6
0062
0075 MR7
0088
0105
0140 MR8
0170
0205
0261 MR9A
0310
Product Overview
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Nominal mains voltage Nominal current Enclosure size
5 (380–500 V) 0003 MR4
0004
0005
0008
0009
0012
0016 MR5
0023
0031
0038 MR6
0046
0061
0072 MR7
0087
0105
0140 MR8
0170
0205
0261 MR9A
0310
0386 MR9B
Product Overview
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Nominal mains voltage Nominal current Enclosure size
6 (525–600 V) 0004 MR5
0006
0009
0011
0018 MR6
0022
0027
0034
0041 MR7
0052
0062
0080 MR8
0100
0125
0144 MR9A
0208
0262 MR9B
7 (525–690 V) 0007 MR6
0010
0013
0018
0022
0027
0034
0041 MR7
0052
0062
0080 MR8
0100
0125
0144 MR9A
0170
0208
0262 MR9B
Product Overview
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4 Receiving the Delivery
4.1 Checking the Delivery
Context:
Procedure
1. After you remove the packaging, examine the drive for transport damages.
AIf the drive was damaged during the shipping, speak to the cargo insurance company or the carrier.
2. To make sure that the delivery is correct, compare your order data to the data on the package label.
AIf the delivery does not agree with your order, speak to the vendor immediately.
3. To make sure that the contents of the delivery is correct and complete, compare the type designation of the product to the type
code.
4.2 Accessories
4.2.1 Accessories Bag, MR4
Table 4: The Content of the Accessories Bag
Item Quantity Description
M4x16 screw 11 Screws for the grounding clamps for cable shield (6), the grounding
clamps for control cable (3), and the grounding clamps for grounding
conductor (2)
M4x8 screw 1 Screw for the optional grounding
M5x12 screw 1 Screw for the external grounding of the drive
Grounding clamp for control cable 3 Control cable grounding
Grounding clamp for cable shield, size M25 3 Clamping the power cables
Grounding clamp for grounding conductor 2 Power cable grounding
"Product modified" label 1 Data about changes
IP21: Cable grommet 3 Sealing for the cables
IP54: Cable grommet 6 Sealing for the cables
4.2.2 Accessories Bag, MR5
Table 5: The Content of the Accessories Bag
Item Quantity Description
M4x16 screw 13 Screws for the grounding clamps for cable shield (6), the grounding
clamps for control cable (3), and the grounding clamps for grounding
conductor (4)
M4x8 screw 1 Screw for the optional grounding
Receiving the Delivery
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Item Quantity Description
M5x12 screw 1 Screw for the external grounding of the drive
Grounding clamp for control cable 3 Control cable grounding
Grounding clamp for cable shield, size M25 1 Clamping the brake cable
Grounding clamp for cable shield, size M32 2 Clamping the power cables
Grounding clamp for grounding conductor 2 Power cable grounding
"Product modified" label 1 Data about changes
IP21: Cable grommet, hole diameter 25.3 mm 1 Sealing for the cables
IP54: Cable grommet, hole diameter 25.3 mm 4 Sealing for the cables
Cable grommet, hole diameter 33.0 mm 2 Sealing for the cables
4.2.3 Accessories Bag, MR6
Table 6: The Content of the Accessories Bag
Item Quantity Description
M4x20 screw 10 Screws for the grounding clamps for cable shield (6), and the ground-
ing clamps for grounding conductor (4)
M4x16 screw 3 Screws for the control cable clamps
M4x8 screw 1 Screw for the optional grounding
M5x12 screw 1 Screw for the external grounding of the drive
Grounding clamp for control cable 3 Control cable grounding
Grounding clamp for cable shield, size M32 1 Clamping the brake resistor cable
Grounding clamp for cable shield, size M40 2 Clamping the power cables
Grounding clamp for grounding conductor 2 Power cable grounding
"Product modified" label 1 Data about changes
Cable grommet, hole diameter 33.0 mm 1 Sealing for the cables
Cable grommet, hole diameter 40.3 mm 2 Sealing for the cables
IP54: Cable grommet, hole diameter 25.3 mm 3 Sealing for the cables
4.2.4 Accessories Bag, MR7
Table 7: The Content of the Accessories Bag
Item Quantity Description
M6x30 slotted nut 6 Nuts for the grounding clamps for cable shield
M4x16 screw 3 Screws for the grounding clamps for control cable
M6x12 screw 1 Screw for the external grounding of the drive
Grounding clamp for control cable 3 Control cable grounding
Receiving the Delivery
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