Vacon 100 INDUSTRIAL User manual

vacon 100
ac drives
installation manual
enclosed drives
®

PREFACE
Document ID: DPD01666A
Date: 9.1.2015
ABOUT THIS MANUAL
This manual is copyright of Vacon Plc. All Rights Reserved.
PREFACE VACON · 3
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VACON · 4
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TABLE OF CONTENTS
Preface
About this manual 3
1 Approvals 7
2 Safety 9
2.1 The safety symbols used in the manual and the drive 9
2.2 Warning 9
2.3 Caution 10
2.4 Earthing and earth fault protection 11
2.5 Using an RCD or an RCM device 12
3 Receiving the delivery 13
3.1 Package label 13
3.2 Type designation code 14
3.3 The contents of the delivery 14
3.4 Storage 14
3.5 Removing the packaging and lifting the AC drive 15
3.5.1 Weight of the AC drive 15
3.5.2 Lifting the AC drive 15
3.6 "Product modified" label 17
3.7 Disposal 17
4 Mounting 18
4.1 Dimensions of the cabinet 18
4.2 Installation of the cabinet 19
4.3 Cooling and free space around the AC drive 20
4.4 The optional back channel cooling 21
4.4.1 Using the back channel for cooling 22
5 Power cabling 23
5.1 Cable and fuse sizes 23
5.2 Brake resistor cables 27
5.3 Preparing for the cable installation 28
5.4 Cable installation 29
5.4.1 Frames MR8 to MR9 29
5.4.2 Frame MR10 34
6 Control compartment 38
6.1 The control compartment of the enclosed drive 38
6.2 Fieldbus connection 39
6.2.1 Using fieldbus through an Ethernet cable 40
6.2.2 Using fieldbus through an RS485 cable 41
7 Commissioning and additional instructions 45
7.1 Commissioning safety 45
7.2 Operation of the motor 46
7.2.1 Checks before starting the motor 46
7.3 Measuring the cable and motor insulation 46
TABLE OF CONTENTS VACON · 5
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7.4 Installation in an IT system 46
7.4.1 The EMC jumper in MR8 47
7.4.2 The EMC jumper in MR9 48
7.4.3 The EMC jumper in MR10 50
7.5 Maintenance 51
7.5.1 Maintenance intervals 51
7.5.2 Replacing the filters of the AC drive 52
7.5.3 Replacing the fans of the AC drive 53
7.5.4 Replacing the power unit of the AC drive 58
8 Technical data, Vacon®100 68
8.1 Mains voltage 380-500 V 68
8.2 Brake resistor ratings 68
8.3 Vacon®100 - technical data 71
9 Technical data, Vacon®100 FLOW 74
9.1 Mains voltage 380-500 V 74
9.2 Vacon®100 FLOW - technical data 75
10 Technical data on control connections 78
10.1 Technical data on control connections 78
11 Options 82
11.1 The codes of the options 82
VACON · 6 TABLE OF CONTENTS
TEL. [phone] · FAX [phone]

1 APPROVALS
Here are the approvals that have been granted to this Vacon product.
Find the EC Declaration of Conformity on the next page.
APPROVALS VACON · 7
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EC DECLARATION OF CONFORMITY
We
Manufacturer’s name: Vacon Oyj
Manufacturer’s address: P.O. Box 25
Runsorintie 7
FIN-65381 Vaasa
Finland
hereby declare that the product
Product name: Vacon 100 AC drive
Model Designation: Wall-Mounted Drives:
Vacon 0100 3L 0003 5...0310 5
Vacon 0100 3L 0003 4...0310 4
Vacon 0100 3L 0003 2...0310 2
Vacon 0100 3L 0004 6...0208 6
Vacon 0100 3L 0007 7...0208 7
IP00 Drives:
Vacon 0100 3L 0140 5...0590 5
Vacon 0100 3L 0140 2...0310 2
Enclosed Drives:
Vacon 0100 3L 0140 5...0590 5
has been designed and manufactured in accordance with the following
standards:
Safety: EN 61800-5-1: 2007
EN 60204-1: 2009 (as relevant)
EMC: EN 61800-3: 2004 + A1: 2012
EN 61000-3-12
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, 7th of January, 2015
Vesa Laisi
President
The year the CE marking was affixed: 2009
VACON · 8 APPROVALS
1 TEL. [phone] · FAX [phone]

2 SAFETY
2.1 THE SAFETY SYMBOLS USED IN THE MANUAL AND THE DRIVE
This manual contains warnings and cautions, which are identified with safety symbols. The
warnings and cautions give important information on how to prevent injury and damage to
the equipment or your system.
Read the warnings and cautions carefully and obey their instructions.
Table 1: The safety symbols
The safety symbol Description
WARNING!
CAUTION!
HOT SURFACE!
READ THE MANUAL!
WAIT 5 MINUTES!
2.2 WARNING
WARNING!
Do not touch the components of the power unit when the drive is connected to
mains. The components are live when the drive is connected to mains. A contact
with this voltage is very dangerous.
SAFETY VACON · 9
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WARNING!
Do not touch the motor terminals U, V, W or the brake resistor terminals when the
drive is connected to mains. These terminals are live when the drive is connected to
mains, also when the motor does not operate.
WARNING!
Do not touch the relay outputs or the I/O terminals. They can have a dangerous
voltage also when the drive is disconnected from mains.
WARNING!
Before you do electrical work, make sure that there is no voltage in the
components of the drive.
WARNING!
To do work on the terminal connections of the drive, disconnect the drive from
mains and make sure that the motor has stopped. Wait 5 minutes before you open
the cabinet door or the cover of the drive. Then use a measuring device to make
sure that there is no voltage. The terminal connections and the components of the
drive are live 5 minutes after it is disconnected from mains and the motor has
stopped.
WARNING!
Before you connect the drive to mains, make sure that the front cover and the cable
cover of the drive are closed. The connections of the AC drive are live when the
drive is connected to mains.
WARNING!
Disconnect the motor from the drive if an accidental start can be dangerous. When
there is a power-up, a power brake 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.
WARNING!
Wear protective gloves when you do mounting, cabling or maintenance operations.
There can be sharp edges in the AC drive that can cause cuts.
2.3 CAUTION
CAUTION!
Do not move the AC drive. Use a fixed installation to prevent damage to the drive.
CAUTION!
Do not make measurements when the AC drive is connected to mains. It can cause
damage to the drive.
VACON · 10 SAFETY
2 TEL. [phone] · FAX [phone]

CAUTION!
Make sure that there is reinforced protective ground connection. It is mandatory,
because the touch current of the AC drives is more than 3.5 mA AC (refer to EN
61800-5-1). See chapter 2.4 Earthing and earth fault protection.
CAUTION!
Do not use spare parts that are not from the manufacturer. Using other spare parts
can cause damage to the drive.
CAUTION!
Do not touch the components on the circuit boards. Static voltage can cause
damage to these components.
CAUTION!
Make sure that the EMC level of the AC drive is correct for your mains. See chapter
7.4 Installation in an IT system. An incorrect EMC level can cause damage to the
drive.
CAUTION!
Prevent radio interference. The AC drive can cause radio interference in a domestic
environment.
NOTE!
If you activate the autoreset function, the motor starts automatically after an
automatic fault reset. See the Application Manual.
NOTE!
If you use the AC drive as a part of a machine, the machine manufacturer must
supply a mains disconnection device (refer to EN 60204-1).
2.4 EARTHING AND EARTH FAULT PROTECTION
CAUTION!
The AC drive must always be earthed with an earth conductor that is connected to
the earth terminal that is identified with the symbol . Not using an earth
conductor can cause damage to the drive.
The touch current of the drive is more than 3.5 mA AC. The standard EN 61800-5-1 tells that
1 or more of these conditions for the protective circuit must be true.
The connection must be fixed.
a)The protective earth conductor must have a cross-sectional area of minimum 10 mm2Cu
or 16 mm2Al. OR
b)There must be an automatic disconnection of the mains, if the protective earth conductor
breaks. See chapter 5 Power cabling. OR
c)There must be a terminal for a second protective earth conductor in the same cross-
sectional area as the first protective earth conductor.
SAFETY VACON · 11
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Table 2: Protective earthing conductor cross-section
Cross-sectional area of the phase conductors (S)
[mm2]The minimum cross-sectional area of the protective earthing conductor in question [mm2]
S ≤ 16 S
16 < S ≤ 35 16
35 < S S/2
The values of the table 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 must be determined in a manner that produces a conductance equivalent
to that which results from the application of this table.
The cross-sectional area of each protective earthing conductor that is not a part of the mains
cable or the cable enclosure, must be a minimum of:
•2.5 mm2if there is mechanical protection, and
•4 mm2if there is not mechanical protection. If you have cord-connected equipment,
make sure that the protective earthing conductor in the cord is the last conductor to be
interrupted, if the strain-relief mechanism breaks.
Obey the local regulations on the minimum size of the protective earthing conductor.
NOTE!
Because there are high capacitive currents in the AC drive, it is possible that the
fault current protective switches do not operate correctly.
CAUTION!
Do not do voltage withstand tests on the AC drive. The manufacturer has already
done the tests. Doing voltage withstand tests can cause damage to the drive.
2.5 USING AN RCD OR AN RCM DEVICE
The drive can cause a current in the protective earthing conductor. You can use a residual
current-operated protective (RCD) device, or a residual current-operated monitoring (RCM)
device to give protection against a direct or an indirect contact. Use a type B RCD or RCM
device on the mains side of the drive.
NOTE! You can download the English and French product manuals with applicable safety, warning and caution
information from www.vacon.com/downloads.
REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit contenant l'en-
semble des informations de sécurité, avertissements et mises en garde applicables sur le site www.vacon.com/
downloads.
VACON · 12 SAFETY
2 TEL. [phone] · FAX [phone]

3 RECEIVING THE DELIVERY
Before a Vacon®AC drive is sent to the customer, the manufacturer makes many tests on
the drive. However, after you remove the packaging, examine the drive for transport
damages.
If the drive was damaged during the shipping, speak to the cargo insurance company or the
carrier.
To make sure that the contents of the delivery is correct and complete, compare the type
designation of the product to the type designation code. See Chapter 3.2 Type designation
code.
3.1 PACKAGE LABEL
AC DRIVE B.ID: 121001
Type: VACON0100-3L-0205-5-ED
S/N: V00000245581
Code: 70-AB3L02055W08B220BM26-00009499
Firmware: FW0072V004
Application:
Marks:
Cust. Ord. No: 20528906
Made by Vacon
Vacon Pasific
INPUT: Uin:3~AC,380-500V, 50/60Hz
200A 40˚C / 205A 50˚C
OUTPUT: 3~AC,0-Uin, 0-320Hz
205A 40˚C / 170A 50˚C
POWER: 110kW:400V / 150HP:480V
IP21
70-AB3L02055W08b220BM26-00009499
V00000245581
0020528906
A B
C
H
I
D
F
G
E
Fig. 1: The package label of Vacon AC drives
A. The batch ID
B. The order number of Vacon
C. The type designation code
D. The serial number
E. The mains voltage
F. The rated output current
G. The IP class
H. The application code
I. The order number of the customer
RECEIVING THE DELIVERY VACON · 13
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3.2 TYPE DESIGNATION CODE
The type designation code of Vacon is made of standard codes and optional codes. Each part
of the type designation code agrees to the data in your order. The code can have this format,
for example:
VACON0100-3L-0385-5-ED
Table 3: The description of the parts in the type designation code
Code Description
VACON This part is same for all the products.
0100 The product range: 0100 = Vacon 100
3L Input/Function: 3L = A 3-phase input
0385 The drive rating in amperes. For example, 0385 = 385 A
5 The mains voltage:
5 = 380-500 V
ED The AC drive is enclosed in a cabinet
In chapter 11 Options you will find descriptions of the option codes.
3.3 THE CONTENTS OF THE DELIVERY
The contents of the delivery, MR8-MR10
•The enclosed drive
•An accessories bag
•Installation Manual, Application Manual and manuals for the options that you ordered
•Order-specific documents
3.4 STORAGE
The storage conditions
•Temperature: -40 °C...+70 °C
•Humidity: < 95%, no condensation
If you keep the package in storage for more than 2 months, keep it in controlled conditions.
Make sure that the temperature variation is small and that the humidity is less than 50%.
VACON · 14 RECEIVING THE DELIVERY
3 TEL. [phone] · FAX [phone]

3.5 REMOVING THE PACKAGING AND LIFTING THE AC DRIVE
3.5.1 WEIGHT OF THE AC DRIVE
The weights of AC drives of different frames are very different. It can be necessary for you to
use a lifting device to move the drive from its package.
Table 4: The default weight of the enclosed drive and some options
Frame IP21/IP54 [kg] Common mode filter +
du/dt filter [kg] Top cabling cabinet sections [kg]
MR8 200 30 65
MR9 270 40 65
MR10 420 40 65
3.5.2 LIFTING THE AC DRIVE
The AC drive is delivered horizontally on a wooden pallet.
MOVING THE ENCLOSED DRIVE
1 Do not remove the package material before you
install the AC drive.
2 Put the drive onto a level base.
3 Move the drive in the vertical position.
4 Use a hoist to move the drive.
RECEIVING THE DELIVERY VACON · 15
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5 If you move more than 1 drive at a time, use rollers.
LIFTING THE ENCLOSED DRIVE
1 Remove the drive from the package.
>60°
2 Use a lifting device that is sufficiently strong for the
weight of the drive.
3 Put the lifting hooks in the holes on the top of the
cabinet.
4 The minimum angle between the drive and the
chain is 60 degrees.
VACON · 16 RECEIVING THE DELIVERY
3 TEL. [phone] · FAX [phone]

5 Lift the drive into a vertical position.
>60° >60°
3.6 "PRODUCT MODIFIED" LABEL
In the accessories bag, there is also a "product modified" label. The function of the label is to
tell the service personnel about the changes that are made in the AC drive. Attach the label
on the side of the AC drive to know where to find it. If you make changes in the AC drive, write
the change on the label.
Product modified
Date:
Date:
Date:
3.7 DISPOSAL
When the drive is at the end of its operation life, do not discard it as a part of municipal
waste. You can recycle the primary components of the drive. You must disassemble
some components before you can remove the different materials. Recycle the electrical
and electronic components as waste.
To make sure that the waste is recycled correctly, send the waste to a recycling centre.
You can also send the waste back to the manufacturer.
Obey the local and other applicable regulations.
RECEIVING THE DELIVERY VACON · 17
24-HOUR SUPPORT [phone] · EMAIL: [email protected] 3

4 MOUNTING
4.1 DIMENSIONS OF THE CABINET
Install the AC drive in a vertical position. Attach the drive with screws to the wall and/or the
floor.
406
Ø13 Ø13
Ø13
335
663 399
354
602 605
2100.5
2135.5
2155.5
120.5
100
200
Fig. 2: The dimensions of the cabinet (without options), MR8
VACON · 18 MOUNTING
4 TEL. [phone] · FAX [phone]

606
Ø13 Ø13
Ø13
535
663 599
555
600
604
2100.5
2135.5
2155.5
120.5
100
200
Fig. 3: The dimensions of the cabinet (without options), MR9 and MR10
4.2 INSTALLATION OF THE CABINET
To attach the cabinet to the floor, there are 3 alternatives.
•Use the 4 fixing points at the bottom of the cabinet.
•Use the 2 fixing points at the front bottom and the 2 fixing points at the rear top of the
cabinet.
•Use the 2 fixing points in the fixing bracket and the 2 fixing points at the front bottom of
the cabinet. To use the fixing bracket, first attach it to the floor. Slide the edge of the
cabinet plinth under the fixing bracket. Then attach the 2 fixing points at the front
bottom.
MOUNTING VACON · 19
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A
B
D
E
C
Fig. 4: The fixing points of the cabinet, MR8-MR10
A. The 4 fixing points at the bottom
B. The 2 fixing points at the front bottom
C. The 2 fixing points at the rear top
D. The 2 fixing points in the fixing bracket
E. The 2 fixing points at the front bottom
4.3 COOLING AND FREE SPACE AROUND THE AC DRIVE
The AC drive produces heat in operation. The fan circulates air and decreases the
temperature of the drive. Make sure that there is sufficiently free space around the drive.
Some free space in front of the drive is also necessary for maintenance. You must also have
80 cm of free space in front of the cabinet to be able to open the cabinet door. When you have
2 or more drives, you can install them side by side.
Make sure that the temperature of the cooling air does not become higher than the
maximum ambient operating temperature or lower than the minimum ambient operating
temperature of the drive.
The air must move freely and efficiently through the cabinet and the drive. There must be a
minimum of 30 cm of space above the cabinet without obstacles that can stop the airflow.
Make sure that the hot air goes out of the cabinet and does not come back into the cabinet.
VACON · 20 MOUNTING
4 TEL. [phone] · FAX [phone]