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
AQ298036140958en-000101 / | 3Danfoss A/S © 2019.05

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
Operating Guide | VACON® 100 Wall-mounted Drives
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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
Operating Guide | VACON® 100 Wall-mounted Drives
AQ298036140958en-000101 / | 5Danfoss A/S © 2019.05

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
Operating Guide | VACON® 100 Wall-mounted Drives
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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
Operating Guide | VACON® 100 Wall-mounted Drives
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Danfoss A/S © 2019.05

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
Operating Guide | VACON® 100 Wall-mounted Drives
AQ298036140958en-000101 / DPD01711
8 | Danfoss A/S © 2019.05

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
Operating Guide | VACON® 100 Wall-mounted Drives
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Danfoss A/S © 2019.05

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
Operating Guide | VACON® 100 Wall-mounted Drives
AQ298036140958en-000101 / DPD01711
10 | Danfoss A/S © 2019.05