Vacon 100 INDUSTRIAL User manual

vacon 100 industrial
vacon 100 flow
ac drives
installation manual
enclosed drives
®
®

PREFACE
DOCUMENT DETAILS
Document ID: DPD01666D
Date: 11.11.2016
ABOUT THIS MANUAL
This manual is copyright of Vacon Ltd. All Rights Reserved. The manual is subject to change
without prior notice. The original language of these instructions is English.
ABOUT THE PRODUCT
This manual describes the VACON®100 Enclosed Drive. The power range of the drive is
between 75-800 kW, and its voltage range is 380-500 V or 525-690 V. The drive comes
installed in a cabinet, and is available in 4 different enclosure sizes: MR8, MR9, MR10 and
MR12. The drive can include 1 or more cabinets.
The drive is available in 2 regional versions: IEC (qualified to the IEC criteria) or NAM
(qualified to the UL criteria).
Fig. 1: An example of the VACON®100 Enclosed Drive
PREFACE VACON · 3
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VACON · 4
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TABLE OF CONTENTS
Preface
Document details 3
About this manual 3
About the product 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 Grounding and earth fault protection 11
2.5 Using an RCD or an RCM device 12
3 Receiving the delivery 14
3.1 Package label 14
3.2 Type designation code 15
3.3 The contents of the delivery 15
3.4 Storage 15
3.5 Removing the packaging and lifting the AC drive 16
3.5.1 Weight of the AC drive 16
3.5.2 Lifting the AC drive 16
3.6 "Product modified" label 18
3.7 Disposal 19
4 Mounting 20
4.1 Dimensions of the cabinet, IEC 20
4.2 Dimensions of the cabinet with additional cabinet sections, IEC 22
4.3 Dimensions of the cabinet, NAM 27
4.4 Dimensions of the cabinet, with additional cabinet sections, NAM 30
4.5 The options 35
4.6 Installation of the cabinet 43
4.7 Cooling and free space around the AC drive 44
4.8 The optional back channel cooling 46
4.8.1 Using the back channel for cooling 46
5 Power cabling 49
5.1 Cable dimensioning and selection 49
5.1.1 Main circuit diagrams of the cabinet 49
5.1.2 Cable and fuse sizes, IEC 51
5.1.3 Cable and fuse sizes, NAM 58
5.2 Brake resistor cables 64
5.3 Preparing for the cable installation 66
5.4 Cable installation in MR8-MR12 67
5.4.1 Installing the cables 70
TABLE OF CONTENTS VACON · 5
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6 Control compartment 76
6.1 The control compartment of the enclosed drive 76
6.2 Fieldbus connection 80
6.2.1 Using fieldbus through an Ethernet cable 80
6.2.2 Using fieldbus through an RS485 cable 81
7 Commissioning and additional instructions 85
7.1 Commissioning safety 85
7.2 Operation of the motor 86
7.2.1 Checks before starting the motor 86
7.3 Measuring the cable and motor insulation 86
7.4 Installation in a marine environment 86
7.5 Installation in a corner-grounded network 87
7.6 Installation in an IT system 87
7.6.1 The EMC jumper in MR8 87
7.6.2 The EMC jumper in MR9 88
7.6.3 The EMC jumper in MR10 and MR12 90
7.7 Maintenance 91
7.7.1 Maintenance intervals 91
7.7.2 Replacing the air filters of the AC drive 92
7.7.3 Replacing the fans of the AC drive 93
7.7.4 Replacing the power unit of the AC drive 99
7.7.5 Downloading the software 108
8 Technical data, VACON®100 INDUSTRIAL 112
8.1 AC drive power ratings 112
8.1.1 Mains voltage 380-500 V 112
8.1.2 Mains voltage 525-690 V 113
8.1.3 Brake resistor ratings 113
8.2 VACON®100 INDUSTRIAL - technical data 117
9 Technical data, VACON®100 FLOW 122
9.1 AC drive power ratings 122
9.1.1 Mains voltage 380-500 V 122
9.1.2 Mains voltage 525-690 V 123
9.2 VACON®100 FLOW - technical data 124
10 Technical data on control connections 129
10.1 Technical data on control connections 129
VACON · 6 TABLE OF CONTENTS
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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.
* The UL approval is valid for input voltage up to 600 V.
APPROVALS VACON · 7
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Antti Vuola
Head of Standard Drives
Timo Kasi
VP, Design Center Finland and Italy
Danfoss A/S
DK-6430 Nordborg
Denmark
CVR nr.: 20 16 57 15
Telephone: [phone]
Fax: [phone]
15-04-2016 15-04-2016
Date Issued by Date Approved by
Signature
Name
Title
Signature
Name
Title
Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated
into any other language, the translator concerned shall be liable for the correctness of the translation.
EU DECLARATION OF CONFORMITY
Danfoss A/S
Vacon Ltd
declares under our sole responsibility that the
Product(s) VACON® 100 AC drive
Type(s) 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
Covered by this declaration is in conformity with the following directive(s), standard(s) or other normative document(s),
provided that the product is used in accordance with our instructions.
Safety: EN 61800-5-1: 2007
EN 60204-1: 2006+A1:2009 (as relevant)
EMC: EN 61800-3: 2004 + A1: 2012
and conforms to the relevant safety provisions of Low Voltage Directive 2006/95/EC (until April 19th, 2016), 2014/35/EU
(from April 20th, 2016) and EMC Directive 2004/108/EC (until April 19th, 2016), 2014/30/EU (from April 20th, 2016).
The year the CE marking was affixed: 2009
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...1180 5
VACON® 0100 3L 0080 7...0820 7
VACON · 8 APPROVALS
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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 The safety word Description
WARNING! If you do not obey the instructions, injury or
death is possible.
CAUTION! If you do not obey the instructions, damage to
the equipment is possible.
HOT SURFACE! If you do not obey the instructions, burns are
possible.
READ THE MANUAL! You must read the man-
ual.
WAIT 5 MINUTES! You must 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 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.
WARNING!
Before you do 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. Note that also the load side of the drive can generate voltage.
Wait 5 minutes before you open the cabinet door or the cover of the AC drive. Use a
measuring device to make sure that there is no voltage. The terminal connections
and the components of the drive can be live 5 minutes after it is disconnected from
the 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.
VACON · 10 SAFETY
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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.
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.
If you use Corner-grounding, change the EMC level to C4, see chapter 7.6
Installation in an IT system.
For information on permitted drive types for Corner-grounding, see chapter 7.5
Installation in a corner-grounded network.
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.
SAFETY VACON · 11
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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.
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 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.
VACON · 12 SAFETY
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NOTE! You can download the English and French product manuals with applicable safety, warning and caution
information from http://drives.danfoss.com/knowledge-center/technical-documentation/.
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 http://
drives.danfoss.com/knowledge-center/technical-documentation/.
SAFETY VACON · 13
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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
H
G
F
E
D
C
I
VACON AB
MSIP-REM-V93-VC100
1000631129
V00001246377
70-AB3L05205C10B240BM26-00096461
Danfoss A/S, 6430 Nordborg, Denmark
3~AC,0-Uin, 0-320Hz
Uin:3~AC,380-500V, 50/60Hz
520A 40°C / 460A 50°C
520 A 40°C / 459A 50°C
250kW:400V / 450HP:480V
IP21/Type1
Made in Finland
POWER:
OUTPUT:
INPUT:
CM+GNUL
BT+EMC4+FBIE+CAPU+CAPD+CICO+CIFD+PO
VACON0100-3L-0520-5- ED+SCB4+SEBJ+SR
160928
2610011001
FW0072V024
Marks:
Cust. Ord. No:
Application:
Firmware:
B.ID:
V00001246377
S/N:
70-AB3L05205C10B240BM26-00096461
Code:
Type:
AC DRIVE
Fig. 2: The package label of VACON®AC drives
A. The batch ID
B. The order number
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
VACON · 14 RECEIVING THE DELIVERY
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3.2 TYPE DESIGNATION CODE
The type designation code is made of standard codes and option 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-FLOW-ED-R02+IP54
In chapter 4.5 The options you will find descriptions of the option codes.
Table 3: The description of the parts in the type designation code
Code Description
VACON0100 The product family: VACON0100 = the VACON®100 product family
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
7 = 525-690 V
FLOW The product:
(empty) = The VACON®100 INDUSTRIAL AC drive
FLOW = The VACON®100 FLOW AC drive
ED The AC drive is enclosed in a cabinet
R02 The regional code: R02 = North American Market version (the product is quali-
fied to the UL criteria)
+IP54 The option codes. There are many options, for example, +IP54 = an AC drive with
the IP class IP54
You can find the type designation code on a label in the lower right corner of the control
compartment door.
3.3 THE CONTENTS OF THE DELIVERY
The contents of the delivery, MR8-MR12
•The enclosed drive
•An accessories bag
•Installation Manual, Application Manual and manuals for the options that you ordered
•Order-specific documents (on the inside of the control compartment door)
3.4 STORAGE
The storage conditions
•Temperature: -40 °C...+70 °C
•Humidity: < 95%, no condensation
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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%.
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 enclosure sizes 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
Enclosure size The enclosed drive,
IP21/IP54, without
options [kg]
Common mode filter
+ du/dt filter [kg] The sine filter [kg] Any of the 3 cabling from top options [kg]
MR8 200 30 270 65
MR9 270 40 270 65
MR10 420 40 350 80
MR12 825 80 700 95
3.5.2 LIFTING THE AC DRIVE
The AC drive is delivered horizontally or vertically on a wooden pallet. Most enclosure sizes
of the AC drive include additional cabinet sections when you order any of the 3 cabling from
top options (+CHIT, +CHOT, or +CHCT), the input contactor (+CICO), or the sine filter (+COSI).
The products are delivered with all the cabinets attached together, except for the MR12 if you
order it with the +COSI option and/or the +CICO option.
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.
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4 Use a hoist to move the drive.
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.
RECEIVING THE DELIVERY VACON · 17
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CAUTION!
To divide the weight of the AC drive
equally, and to prevent damage to the
equipment, always use 4 lifting holes.
4 The minimum angle between the drive and the
chain is 60 degrees.
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:
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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.
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4 MOUNTING
4.1 DIMENSIONS OF THE CABINET, IEC
IEC = The product is qualified to the IEC criteria.
NAM = The product is qualified to the UL criteria.
The information on dimensions that you will need in cabling can be found in the order-
specific documents.
NOTE!
The height of the standard base plinth is 100 mm, but the height of the base plinth
option (+CHPH) is 200 mm.
406
Ø13 Ø13
Ø13
335
639 399
354
602 605
2100.5
2135.5
2155.5
120.5
100
200
Fig. 3: The dimensions of the default cabinet, MR8, [mm], IEC
VACON · 20 MOUNTING
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