Vacon 100 INDUSTRIAL User manual

vacon 100
vacon 100 flow
vacon 100 hvac
ac drives
installation manual
wall-mounted drives
®
®
®

PREFACE
Document ID: DPD01711G
Date: 15.12.2015
ABOUT THIS MANUAL
This manual is copyright of Vacon Plc. All Rights Reserved.
PREFACE VACON · 3
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TABLE OF CONTENTS
Preface
About this manual 3
1 Approvals 8
2 Safety 10
2.1 The safety symbols used in the manual 10
2.2 Warning 10
2.3 Caution 11
2.4 Grounding and earth fault protection 12
2.5 Electro-magnetic compatibility (EMC) 13
2.6 Using an RCD or an RCM device 13
3 Receiving the delivery 15
3.1 Package label 15
3.2 Type designation code 16
3.3 Contents of the delivery 16
3.4 Removing the packaging and lifting the AC drive 16
3.4.1 Weight of the AC drive 16
3.4.2 Lifting the frames MR8 and MR9 17
3.5 Accessories 18
3.5.1 Frame MR4 19
3.5.2 Frame MR5 19
3.5.3 Frame MR6 20
3.5.4 Frame MR7 21
3.5.5 Frame MR8 21
3.5.6 Frame MR9 22
3.6 "Product modified" label 22
3.7 Disposal 22
4 Mounting 23
4.1 General information about mounting 23
4.2 Dimensions for wall mounting 23
4.2.1 Wall mounting of MR4 23
4.2.2 Wall mounting of MR5 24
4.2.3 Wall mounting of MR6 25
4.2.4 Wall mounting of MR7 26
4.2.5 Wall mounting of MR8, IP21 and IP54 27
4.2.6 Wall mounting of MR8, IP00 28
4.2.7 Wall mounting of MR9, IP21 and IP54 29
4.2.8 Wall mounting of MR9, IP00 30
TABLE OF CONTENTS VACON · 5
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4.3 Dimensions for wall mounting, North America 31
4.3.1 Wall mounting of MR4, North America 31
4.3.2 Wall mounting of MR5, North America 32
4.3.3 Wall mounting of MR6, North America 33
4.3.4 Wall mounting of MR7, North America 34
4.3.5 Wall mounting of MR8, North America 35
4.3.6 Wall mounting of MR8, UL Open Type, North America 36
4.3.7 Wall mounting of MR9, North America 37
4.3.8 Wall mounting of MR9, UL Open Type, North America 38
4.4 Dimensions for flange mounting 38
4.4.1 Flange mounting of MR4 42
4.4.2 Flange mounting of MR5 43
4.4.3 Flange mounting of MR6 44
4.4.4 Flange mounting of MR7 45
4.4.5 Flange mounting of MR8 46
4.4.6 Flange mounting of MR9 47
4.5 Dimensions for flange mounting, North America 48
4.5.1 Flange mounting of MR4, North America 48
4.5.2 Flange mounting of MR5, North America 49
4.5.3 Flange mounting of MR6, North America 50
4.5.4 Flange mounting of MR7, North America 51
4.5.5 Flange mounting of MR8, North America 52
4.5.6 Flange mounting of MR9, North America 53
4.6 Cooling 54
5 Power cabling 57
5.1 Cable connections 57
5.2 UL standards on cabling 58
5.3 Cable dimensioning and selection 58
5.3.1 Cable and fuse sizes 58
5.3.2 Cable and fuse sizes, North America 63
5.4 Brake resistor cables 68
5.5 Preparing for the cable installation 69
5.6 Cable installation 69
5.6.1 Frames MR4 to MR7 69
5.6.2 Frames MR8 to MR9 76
5.7 Installation in a corner-grounded network 88
6 Control unit 89
6.1 Control unit components 89
6.2 Control unit cabling 90
6.2.1 Selection of the control cables 90
6.2.2 Control terminals and DIP switches 91
6.3 Fieldbus connection 95
6.3.1 Using fieldbus through an Ethernet cable 96
6.3.2 Using fieldbus through an RS485 cable 99
6.4 Installation of option boards 103
6.4.1 The installation procedure 104
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6.5 Installation of a battery for the Real Time Clock (RTC) 105
6.6 Galvanic isolation barriers 105
7 Commissioning and additional instructions 107
7.1 Commissioning safety 107
7.2 Commissioning of the drive 107
7.3 Operation of the motor 108
7.3.1 Checks before starting the motor 108
7.4 Measuring the cable and motor insulation 108
7.5 Installation in a marine environment 109
7.6 Installation in an IT system 109
7.6.1 The EMC jumper in MR4, MR5 and MR6 109
7.6.2 The EMC jumper in MR7 112
7.6.3 The EMC jumper in MR8 114
7.6.4 The EMC jumper in MR9 115
7.7 Maintenance 116
8 Technical data, Vacon®100 118
8.1 AC drive power ratings 118
8.1.1 Mains voltage 208-240 V 118
8.1.2 Mains voltage 380-500 V 120
8.1.3 Mains voltage 525-600 V 121
8.1.4 Mains voltage 525-690 V 122
8.1.5 Overload capability 122
8.1.6 Brake resistor ratings 123
8.2 Vacon®100 - technical data 128
9 Technical data, Vacon®100 FLOW 133
9.1 AC drive power ratings 133
9.1.1 Mains voltage 208-240 V 133
9.1.2 Mains voltage 380-500 V 135
9.1.3 Mains voltage 525-600 V 136
9.1.4 Mains voltage 525-690 V 137
9.1.5 Overload capability 137
9.2 Vacon®100 FLOW - technical data 139
10 Technical data, Vacon® 100 HVAC 144
10.1 AC drive power ratings 144
10.1.1 Mains voltage 208-240 V 144
10.1.2 Mains voltage 380-500 V 145
10.1.3 Overload capability 146
10.2 Vacon®100 HVAC - technical data 147
11 Technical data on control connections 152
11.1 Technical data on control connections 152
TABLE OF CONTENTS VACON · 7
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1 APPROVALS
Here are the approvals that have been granted to this Vacon product.
1.EC Declaration of conformity
•Find the EC Declaration of Conformity on the next page.
2.UL approval
•cULus approval file number E171278.
3.RCM approval
•RCM approval number E2204.
VACON · 8 APPROVALS
1 TEL. [phone] · FAX [phone]

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 2...0310 2
Vacon 0100 3L 0003 4...0310 4
Vacon 0100 3L 0003 5...0310 5
Vacon 0100 3L 0004 6...0208 6
Vacon 0100 3L 0007 7...0208 7
IP00 Drives:
Vacon 0100 3L 0140 2...0310 2
Vacon 0100 3L 0140 5...1180 5
Vacon 0100 3L 0080 6...0820 6
Vacon 0100 3L 0080 7...0820 7
Enclosed Drives:
Vacon 0100 3L 0140 5...0590 5
Vacon 0100 3L 0080 7...0820 7
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, 31st of March, 2015
Vesa Laisi
President
The year the CE marking was affixed: 2009
APPROVALS VACON · 9
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2 SAFETY
2.1 THE SAFETY SYMBOLS USED IN THE MANUAL
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!
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.
WARNING!
Do not touch the motor cable terminals U, V, W, the brake resistor terminals or the
DC 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 control terminals. They can have a dangerous voltage also when
the drive is disconnected from mains.
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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 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 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.
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.
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 Grounding 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.
SAFETY VACON · 11
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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
7.6 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 GROUNDING AND EARTH FAULT PROTECTION
CAUTION!
The AC drive must always be grounded with a grounding conductor that is
connected to the grounding terminal that is identified with the symbol . Not using
a grounding 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 grounding 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 grounding
conductor breaks. See chapter 5 Power cabling. OR
c)There must be a terminal for a second protective grounding conductor in the same
cross-sectional area as the first protective grounding conductor.
VACON · 12 SAFETY
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Table 2: Protective grounding conductor cross-section
Cross-sectional area of the phase conductors (S)
[mm2]The minimum cross-sectional area of the protective grounding 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 grounding conductor is made of the
same metal as the phase conductors. If this is not so, the cross-sectional area of the
protective grounding 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 grounding 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 grounding 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 grounding 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 ELECTRO-MAGNETIC COMPATIBILITY (EMC)
The drive must obey the standard IEC 61000-3-12. To obey it, the short-circuit power SSC
must be a minimum of 120 RSCE at the interface point between your mains and the public
mains. Make sure that you connect the drive and the motor to mains with a short-circuit
power SSC that is a minimum of 120 RSCE. If necessary, contact your mains operator.
2.6 USING AN RCD OR AN RCM DEVICE
The drive can cause a current in the protective grounding 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.
SAFETY VACON · 13
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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 · 14 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
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 nominal output current
G. The IP class
H. The application code
I. The order number of the customer
RECEIVING THE DELIVERY VACON · 15
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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-0061-5+IP54
VACON0100-3L-0061-5-FLOW
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
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 Vacon 100 FLOW AC drive
+IP54 The optional codes. There are many options, for example +IP54 (an AC drive with
the IP protection class IP54)
3.3 CONTENTS OF THE DELIVERY
The contents of the delivery, MR4-MR9
•The wall-mounted drive with an integrated control unit
•An accessories bag
•Quick Guide, Safety Instructions, and the manuals for the options that you ordered
•Installation Manual and Application Manual if you ordered them
3.4 REMOVING THE PACKAGING AND LIFTING THE AC DRIVE
3.4.1 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.
VACON · 16 RECEIVING THE DELIVERY
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Table 4: The weights of the different frames
Frame Weight, IP21/IP54
[kg] Weight, IP00 [kg] Weight, UL Type 1 / Type 12 [lb.] Weight, UL Open Type [lb.]
MR4 6.0 13.2
MR5 10.0 22.0
MR6 20.0 44.1
MR7 37.5 82.7
MR8 66.0 62.0 145.5 136.7
MR9 119.5 103.5 263.5 228.2
3.4.2 LIFTING THE FRAMES MR8 AND MR9
1 Remove the drive from the pallet where it was
bolted to.
2 Use a lifting device that is sufficiently strong for the
weight of the drive.
3 Put the lifting hooks symmetrically in a minimum of
2 holes.
RECEIVING THE DELIVERY VACON · 17
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4 The maximum lifting angle is 45 degrees.
≤45°
3.5 ACCESSORIES
After you open the package and lift the drive out, make sure that you received all the
accessories. The content of the accessories bag is different for the different frames and
protection classes.
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3.5.1 FRAME MR4
Table 5: 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
3.5.2 FRAME MR5
Table 6: 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
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
RECEIVING THE DELIVERY VACON · 19
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3.5.3 FRAME MR6
Table 7: The content of the accessories bag
Item Quantity Description
M4x20 screw 10 Screws for the grounding clamps for cable
shield (6), and the grounding 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
NOTE!
The Vacon®100 FLOW and HVAC software do not have the dynamic braking or the
brake resistor functions.
VACON · 20 RECEIVING THE DELIVERY
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