Vacon 100 INDUSTRIAL Instructions for use

vacon 100
ac drives
application manual
®

PREFACE
Document ID: DPD00927F
Date: 30.1.2014
Software version: FW0072V012
ABOUT THIS MANUAL
This manual is copyright of Vacon Plc. All Rights Reserved.
In this manual, you can read about the functions of the Vacon®AC drive and how to use the
drive. The manual has the same structure than the menu of the drive (chapters 1 and 4-8).
Chapter 1, Quick Startup Guide
•How to start the work with the control panel.
Chapter 2, Wizards
•Making a selection of the application configuration.
•Setting up an application quickly.
•The different applications with examples.
Chapter 3, User Interfaces
•The display types and how to use the control panel.
•The PC tool Vacon Live.
•The functions of the fieldbus.
Chapter 4, Monitoring menu
•Data on the monitoring values.
Chapter 5, Parameter menu
•A list of all the parameters of the drive.
Chapter 6, Diagnostics menu
Chapter 7, I/O and Hardware menu
Chapter 8, User settings, favourites and user level menus
Chapter 9, Parameter descriptions
•How to use the parameters.
•Digital and analogue input programming.
•Application-specific functions.
PREFACE VACON · 3
24-HOUR SUPPORT [phone] · EMAIL: [email protected]

Chapter 10, Fault tracing
•The faults and their causes.
•Resetting the faults.
Chapter 11, Appendix
•Data on the different default values of the applications.
This manual includes a large quantity of parameter tables. These instructions tell you how to
read the tables.
Index Min Max Unit Default ID DescriptionParameter
A
I
B C D E F G H
A. The location of the parameter in the
menu, that is, the parameter number.
B. The name of the parameter.
C. The minimum value of the parameter.
D. The maximum value of the parameter.
E. The unit of the value of the parameter.
The unit shows if it is available.
F. The value that was set in the factory.
G. The ID number of the parameter.
H. A short description of the values of the
parameter and/or its function.
I. When the symbol shows, you can find
more data about the parameter in
Chapter Parameter descriptions.
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'ensemble des informations de sécurité, avertissements et mises en garde applicables sur le site
www.vacon.com/downloads.
VACON · 4 PREFACE
TEL. [phone] · FAX [phone]

FUNCTIONS OF THE VACON®AC DRIVE
•Wizards for startup, PID control, multipump and fire mode to make the commissioning
easy.
•The FUNCT button for an easy change between the local and the remote control place.
The remote control place can be I/O or fieldbus. You can make a selection of the remote
control place with a parameter.
•8 preset frequencies.
•Motor pontentiometer functions.
•A joystick control.
•A jogging function.
•2 programmable ramp times, 2 supervisions and 3 ranges of prohibited frequencies.
•A forced stop.
•A control page to operate and monitor of the most important values quickly.
•A fieldbus data mapping.
•An automatic reset.
•Different pre-heat modes to prevent condensation problems.
•A maximum output frequency of 320 Hz.
•A Real time clock and timer functions (an optional battery is necessary). It is possible to
program 3 time channels to get different functions on the drive.
•An external PID controller is available. You can use it, for example, to control a valve with
the I/O of the AC drive.
•A sleep mode function that automatically enables and disables the operation of the drive
to save energy.
•A 2-zone PID controller with 2 different feedback signals: minimum and maximum
control.
•2 setpoint sources for the PID control. You can make the selection with a digital input.
•A function for PID setpoint boost.
•A feedforward function to make the response to the process changes better.
•A process value supervision.
•A multipump control.
•A maintenance counter.
•Pump control functions: priming pump control, jockey pump control, pump impeller
auto-cleaning, pump input pressure supervision and frost protection function.
PREFACE VACON · 5
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VACON · 6
TEL. [phone] · FAX [phone]

TABLE OF CONTENTS
Preface
About this manual 3
Functions of the Vacon®AC drive 5
1 Quick Startup Guide 11
1.1 Control panel and keypad 11
1.2 The displays 11
1.3 First start-up 12
1.4 Description of the applications 14
1.4.1 Standard application 14
1.4.2 Local/Remote application 21
1.4.3 Multi-step speed application 28
1.4.4 PID control application 35
1.4.5 Multi-purpose application 45
1.4.6 Motor potentiometer application 55
2 Wizards 63
2.1 Standard application wizard 63
2.2 Local/Remote application wizard 64
2.3 Multi-step speed application wizard 65
2.4 PID control application wizard 66
2.5 Multi-purpose application wizard 68
2.6 Motor potentiometer application wizard 69
2.7 Multipump wizard 70
2.8 Fire mode wizard 72
3 User interfaces 74
3.1 Navigation on the keypad 74
3.2 Using the graphical display 76
3.2.1 Editing the values 76
3.2.2 Resetting a fault 79
3.2.3 The FUNCT button 79
3.2.4 Copying the parameters 83
3.2.5 Comparing the parameters 85
3.2.6 Help texts 86
3.2.7 Using the Favourites menu 87
3.3 Using the text display 87
3.3.1 Editing the values 88
3.3.2 Resetting a fault 89
3.3.3 The FUNCT button 89
3.4 Menu structure 93
3.4.1 Quick setup 94
3.4.2 Monitor 94
3.5 Vacon Live 96
TABLE OF CONTENTS VACON · 7
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4 Monitoring menu 97
4.1 Monitor group 97
4.1.1 Multimonitor 97
4.1.2 Trend curve 98
4.1.3 Basic 101
4.1.4 I/O 103
4.1.5 Temperature inputs 103
4.1.6 Extras and advanced 105
4.1.7 Timer functions monitoring 107
4.1.8 PID controller monitoring 108
4.1.9 External PID controller monitoring 109
4.1.10 Multipump monitoring 109
4.1.11 Maintenance counters 110
4.1.12 Fieldbus data monitoring 111
5 Parameters menu 113
5.1 Group 3.1: Motor settings 113
5.2 Group 3.2: Start/stop setup 121
5.3 Group 3.3: References 124
5.4 Group 3.4: Ramps and brakes setup 134
5.5 Group 3.5: I/O configuration 137
5.6 Group 3.6: Fieldbus data mapping 151
5.7 Group 3.7: Prohibit frequencies 153
5.8 Group 3.8: Supervisions 154
5.9 Group 3.9: Protections 155
5.10 Group 3.10: Automatic reset 166
5.11 Group 3.11: Application settings 168
5.12 Group 3.12: Timer functions 169
5.13 Group 3.13: PID controller 172
5.14 Group 3.14: External PID controller 188
5.15 Group 3.15: Multipump 193
5.16 Group 3.16: Maintenance counters 195
5.17 Group 3.17: Fire mode 196
5.18 Group 3.18: Motor preheat parameters 198
5.19 Group 3.20: Mechanical brake 200
5.20 Group 3.21: Pump control 201
6 Diagnostics menu 204
6.1 Active faults 204
6.2 Reset faults 204
6.3 Fault history 204
6.4 Total counters 204
6.5 Trip counters 206
6.6 Software info 207
7 I/O and hardware menu 208
7.1 Basic I/O 208
7.2 Option board slots 210
7.3 Real time clock 211
VACON · 8 TABLE OF CONTENTS
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7.4 Power unit settings 211
7.5 Keypad 213
7.6 Fieldbus 213
8 User settings, favourites and user level menus 218
8.1 User settings 218
8.1.1 Parameter backup 219
8.2 Favourites 219
8.2.1 Adding an item to the Favourites 220
8.2.2 Removing an item from the Favourites 220
8.3 User levels 221
8.3.1 Changing the access code of the user levels 222
9 Parameter descriptions 224
9.1 Motor settings 224
9.1.1 I/f start function 232
9.1.2 Torque stabilator function 233
9.2 Start/Stop setup 234
9.3 References 241
9.3.1 Frequency reference 241
9.3.2 Torque reference 241
9.3.3 Preset frequencies 243
9.3.4 Motor potentiometer parameters 246
9.4 Joystick parameters 248
9.5 Jogging parameters 249
9.6 Ramps and brakes setup 251
9.7 I/O configuration 252
9.7.1 Programming of digital and analogue inputs 252
9.7.2 Default functions of programmable inputs 263
9.7.3 Digital inputs 263
9.7.4 Analogue inputs 264
9.7.5 Digital outputs 269
9.7.6 Analogue outputs 271
9.8 Prohibit frequencies 274
9.9 Supervisions 275
9.9.1 Motor thermal protections 276
9.9.2 Motor stall protection 279
9.9.3 Underload protection 280
9.10 Automatic reset 285
9.11 Timer functions 286
9.12 PID controller 290
9.12.1 Feedforward 291
9.12.2 Sleep function 291
9.12.3 Feedback supervision 293
9.12.4 Pressure loss compensation 294
9.12.5 Soft fill 296
9.12.6 Input pressure supervision 297
9.12.7 Frost protection 298
TABLE OF CONTENTS VACON · 9
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9.13 Multipump function 299
9.14 Maintenance counters 305
9.15 Fire mode 305
9.16 Motor preheat function 307
9.17 Mechanical brake 308
9.18 Pump control 311
9.18.1 Auto-cleaning 311
9.18.2 Jockey pump 312
9.18.3 Priming pump 313
9.19 Total and trip counters 314
9.19.1 Operating time counter 314
9.19.2 Operating time trip counter 315
9.19.3 Run time counter 315
9.19.4 Power on time counter 316
9.19.5 Energy counter 316
9.19.6 Energy trip counter 317
10 Fault tracing 319
10.1 A fault comes into view 319
10.1.1 Resetting with the Reset button 319
10.1.2 Resetting with a parameter in the graphical display 319
10.1.3 Resetting with a parameter in the text display 320
10.2 Fault history 321
10.2.1 Examining the Fault history in the graphical display 321
10.2.2 Examining the Fault history in the text display 322
10.3 Fault codes 324
11 Appendix 1 337
11.1 The default values of parameters in the different applications 337
VACON · 10 TABLE OF CONTENTS
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1 QUICK STARTUP GUIDE
1.1 CONTROL PANEL AND KEYPAD
The control panel is the interface between the AC drive and the user. With the control panel,
you can control the speed of a motor and monitor the status of the AC drive. You can also set
the parameters of the AC drive.
A B C
I
H D
G F E
Fig. 1: The buttons of the keypad
A. The BACK/RESET button. Use it to move
back in the menu, exit the Edit mode,
reset a fault.
B. The arrow button UP. Use it to scroll the
menu up and to increase a value.
C. The FUNCT button. Use it to change the
rotation direction of the motor, access
the control page, and change the control
place. See more in Table 38 Frequency
reference parameters.
D. The arrow button RIGHT.
E. The START button.
F. The arrow button DOWN. Use it to scroll
the menu down and to decrease a value.
G. The STOP button.
H. The arrow button LEFT. Use it to move
the cursor left.
I. The OK button. Go into an active level or
item, accept a selection.
1.2 THE DISPLAYS
There are 2 display types: the graphical display and the text display. The control panel always
has the same keypad and buttons.
The display shows this data.
•The status of the motor and the drive.
•Faults in the motor and in the drive.
•Your location in the menu structure.
QUICK STARTUP GUIDE VACON · 11
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STOP READY I/O
Main Menu
A B C D E
F
H
G
Quick Setup
( 17 )
Monitor
( 5 )
Parameters
( 12 )
M1ID:
Fig. 2: The graphical display
A. The first status field: STOP/RUN
B. The rotation direction of the motor
C. The second status field: READY/NOT
READY/FAULT
D. The alarm field: ALARM/-
E. The control place field: PC/IO/KEYPAD/
FIELDBUS
F. The location field: the ID number of the
parameter and the current location in
the menu
G. An activated group or item
H. The number of items in the group in
question
A B
F
C
D
E
Fig. 3: The text display. If the text is too long to show, the text scrolls automatically on the display.
A. The indicators of status
B. The indicators of alarm and fault
C. The name of the group or item of the
current location
D. The current location in the menu
E. The indicators of the control place
F. The indicators of the rotation direction
1.3 FIRST START-UP
The Start-up wizard tells you to give necessary data for the drive to control your procedure.
VACON · 12 QUICK STARTUP GUIDE
1 TEL. [phone] · FAX [phone]

1Language selection (P6.1) The selection is different in all the language
packages
2
Daylight saving* (P5.5.5) Russia
US
EU
OFF
3Time* (P5.5.2) hh:mm:ss
4Year* (P5.5.4) yyyy
5Date* (P5.5.3) dd.mm.
* If a battery is installed, you see these questions.
6Run Startup wizard? Yes
No
To set the parameter values manually, make the selection No and push the OK button.
7
Make a selection of an application (P1.2 Application,
ID212) Standard
Local/Remote
Multi-step speed
PID control
Multi-purpose
Motor potentiometer
8Set a value for P3.1.2.2 Motor Type (so that it agrees
with the nameplate) PM motor
Induction motor
9Set a value for P3.1.1.1 Motor Nominal Voltage (so
that it agrees with the nameplate) Range: Varies
10 Set a value for P3.1.1.2 Motor Nominal Frequency
(so that it agrees with the nameplate) Range: 8.00...320.00 Hz
11 Set a value for P3.1.1.3 Motor Nominal Speed (so
that it agrees with the nameplate) Range: 24...19200
12 Set a value for P3.1.1.4 Motor Nominal Current Range: Varies
13 Set a value for P3.1.1.5 Motor Cos Phi Range: 0.30-1.00
If you set Motor Type to Induction Motor, you see the next question. If your selection is PM
Motor, the value of parameter P3.1.1.5 Motor Cos Phi is set to 1.00 and the wizard goes
directly to question 14.
QUICK STARTUP GUIDE VACON · 13
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14 Set a value for P3.3.1.1 Minimum Frequency
Reference Range: 0.00...P3.3.1.2 Hz
15 Set a value for P3.3.1.2 Maximum Frequency
Reference Range: P3.3.1.1...320.00 Hz
16 Set a value for P3.4.1.2 Acceleration Time 1 Range: 0.1...300.0 s
17 Set a value for P3.4.1.3 Deceleration Time 1 Range: 0.1...300.0 s
18 Run the Application wizard? Yes
No
To continue to the application wizard, set the selection to Yes and push the OK button. See
the description of the different application wizards in Chapter 2 Wizards.
After these selections, the Start-up wizard is completed. To start the Start-up wizard again,
you have 2 alternatives. Go to the parameter P6.5.1 Restore Factory Defaults or to the
parameter B1.1.2 Start-up Wizard. Then set the value to Activate.
1.4 DESCRIPTION OF THE APPLICATIONS
Use the parameter P1.2 (Application) to make a selection of an application for the drive.
Immediately when the parameter P1.2 changes, a group of parameters get their preset
values.
1.4.1 STANDARD APPLICATION
You can use the Standard application in speed-controlled processes where no special
functions are necessary, for example pumps, fans, or conveyors.
It is possible to control the drive from the keypad, Fieldbus or I/O terminal.
When you control the drive with the I/O terminal, the frequency reference signal is connected
to AI1 (0…10V) or AI2 (4…20mA). The connection depends the type of the signal. There are
also 3 preset frequency references available. You can activate the preset frequency
references with DI4 and DI5. The start/stop signals of the drive are connected to DI1 (start
forward) and DI2 (start reverse).
It is possible to configure all the drive outputs freely in all the applications. There are 1
analogue output (Output Frequency) and 3 relay outputs (Run, Fault, Ready) available on the
basic I/O board.
VACON · 14 QUICK STARTUP GUIDE
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RUN
FAULT
READY
Reference output+10 Vref
Terminal
Standard I/O board
Signal
1
24V auxiliary voltage24Vout6
Analogue input 1 +AI1+2
AI1-3
Analogue input 2 +
AI2+4
AI2-5
Analogue output 1 +
AO1+
RUN
18 Analogue output 1 -
AO1-19
+24Vin
30
24V auxiliary voltage24Vout
12
I/O groundGND7
I/O groundGND13
Digital input 1DI18
Digital input 2DI29
Digital input 3DI310
Digital input 4DI414
Digital input 5DI515
Digital input 6DI616
Relay output 1
RO1/1 NC21
22 RO1/2 CM
RO1/3 NO23
Common for DI1-DI6CM11
Common for DI1-DI6CM
17
Serial bus, negativeRS485A
Serial bus, positiveRS485
B
Relay output 2
Relay output 3
RO2/1 NC24
25 RO2/2 CM
RO2/3 NO26
32 RO3/2 CM
RO3/3 NO33
Description
Frequency reference
(default 0...10V)
Frequency reference
(Default 4...20mA)
Start forward
Start reverse
External fault
DI4 DI5 Freq. ref.
Open
Closed
Open
Closed
Open
Open
Closed
Closed
Analog input 1
Preset Freq. 1
Preset Freq. 2
Preset Freq. 3
Fault reset
Output frequency
(default: 0...20mA)
Modbus RTU
N2, BACnet
Analogue input 1 -
FAULT
Analogue input 2 -
Reference
potentiom-
eter
1...10kΩ
mA
*)
*)
**)
24V auxiliary
input voltage
Fig. 4: The default control connections of the Standard application
* = You can isolate the digital inputs from the ground with a DIP switch.
QUICK STARTUP GUIDE VACON · 15
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Digital inputs
Floating
Connected to GND
(Default!)
Fig. 5: The DIP switch
Table 2: M1.1 Wizards
Index Parameter Min Max Unit Default ID Description
1.1.1 Startup wizard 0 1 0 1170
0 = Do not activate
1 = Activate
The selection Activate
starts the Start-up
wizard (see Chapter
Table 1 The Start-up
wizard.
1.1.3 Multi-pump Wizard 0 1 0 1671
The selection Activate
starts the Multipump
wizard (see Chapter
2.7 Multipump wizard).
1.1.4 Fire mode Wizard 0 1 0 1672
The selection Activate
starts the Fire mode
wizard (see Chapter
2.8 Fire mode wizard).
VACON · 16 QUICK STARTUP GUIDE
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.2
Application 0 5 0 212
0 = Standard
1 = Local/Remote
2 = Multi-Step Speed
3 = PID Control
4 = Multi-Purpose
5 = Motor
Potentiometer
1.3 Minimum Frequency
Reference 0.00 P1.4 Hz 0.0 101 The minimum
frequency reference
that is acceptable.
1.4 Maximum Frequency
Reference P1.3 320.0 Hz 50.0 / 60.0 102 The maximum
frequency reference
that is acceptable.
1.5 Acceleration Time 1 0.1 300.0 s 5.0 103
Gives the quantity of
time that is necessary
for the output
frequency to increase
from zero frequency to
the maximum
frequency.
1.6 Deceleration Time 1 0.1 300.0 s 5.0 104
Gives the quantity of
time that is necessary
for the output
frequency to decrease
from the maximum
frequency to zero
frequency.
1.7 Motor Current Limit IH*0.1 ISA Varies 107 The maximum motor current from the AC
drive.
1.8 Motor Type 0 1 0 650 0 = Induction Motor
1 = Permanent Magnet
Motor
1.9 Motor Nominal
Voltage Varies Varies V Varies 110
Find this value Unon
the rating plate of the
motor.
NOTE!
Find out if the motor
connection is Delta or
Star.
QUICK STARTUP GUIDE VACON · 17
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.10 Motor Nominal
Frequency 8.0 320.0 Hz 50 / 60 111 Find this value fnon
the rating plate of the
motor.
1.11 Motor Nominal
Speed 24 19200 Rpm Varies 112 Find this value nnon
the rating plate of the
motor.
1.12 Motor Nominal
Current IH* 0.1 IH* 2 A Varies 113 Find this value Inon
the rating plate of the
motor.
1.13 Motor Cos Phi
(Power Factor) 0.30 1.00 Varies 120 Find this value on the
rating plate of the
motor.
1.14 Energy Optimization 0 1 0 666
The drive searches for
the minimum motor
current to save energy
and to lower the motor
noise. Use this function
with, for example, fan
and pump processes.
0 = Disabled
1 = Enabled
1.15 Identification 0 2 0 631
The identification run
calculates or measures
the motor parameters
that are necessary for
a good control of the
motor and speed.
0 = No action
1 = At standstill
2 = With rotation
Before you do the
identification run, you
must set the motor
nameplate parameters.
1.16 Start Function 0 1 0 505 0 = Ramping
1 = Flying Start
1.17 Stop Function 0 1 0 506 0 = Coasting
1 = Ramping
VACON · 18 QUICK STARTUP GUIDE
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.18 Automatic Reset 0 1 0 731 0 = Disabled
1 = Enabled
1.19 Response to External
Fault 0 3 2 701
0 = No action
1 = Alarm
2 = Fault (Stop
according to stop
mode)
3 = Fault (Stop by
coasting)
1.20 Response to AI Low
Fault 0 5 0 700
0 = No action
1 = Alarm
2 = Alarm+preset fault
frequency (P3.9.1.13)
3 = Alarm + previous
frequency
4 = Fault (Stop
according to stop
mode)
5 = Fault (Stop by
coasting)
1.21 Remote Control
Place 0 1 0 172
The selection of the
remote control place
(start/stop).
0 = I/O control
1 = Fieldbus control
QUICK STARTUP GUIDE VACON · 19
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Table 3: M1 Quick Setup
Index Parameter Min Max Unit Default ID Description
1.22 I/O Control Reference A
Selection 0 9 5 117
The selection of the
frequency reference
source when the
control place is I/O A.
0 = Preset Frequency 0
1 = Keypad Reference
2 = Fieldbus
3 = AI1
4 = AI2
5 = AI1+AI2
6 = PID Reference
7 = Motor
Potentiometer
8 = Joystick Reference
9 = Jogging Reference
10 = Block Out.1
11 = Block Out.2
12 = Block Out.3
13 = Block Out.4
14 = Block Out.5
15 = Block Out.6
16 = Block Out.7
17 = Block Out.8
18 = Block Out.9
19 = Block Out.10
The application that
you set with parameter
1.2 gives the default
value.
1.23 Keypad Control
Reference Selection 0 9 1 121
The selection of the
frequency reference
source when the
control place is keypad.
See P1.22.
1.24 Fieldbus Control
Reference Selection 0 9 2 122
The selection of the
frequency reference
source when the
control place is
fieldbus. See P1.22.
1.25 AI1 Signal Range 0 1 0 379 0= 0..10V / 0..20mA
1= 2..10V / 4..20mA
1.26 AI2 Signal Range 0 1 1 390 0= 0..10V / 0..20mA
1= 2..10V / 4..20mA
1.27 RO1 Function 0 51 2 1101 See P3.5.3.2.1
VACON · 20 QUICK STARTUP GUIDE
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