Vacon CX User manual

F O R S M O O T H C O N T R O L
I/O-expander board
installation manual
(Vacon CXS-range)
Subject to changes without notice.
VACON
CX/CXL/CXS
FREQUENCY CONVERTERS

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I/ O-expander board installation (Vacon CXS-range)
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CON TEN TS
1 GEN ERAL.......................................... 2
1.1 Vacon CX1 0 0 O PT...................... 2
1.2 Vacon CX1 0 1 O PT...................... 2
1.3 Vacon CX1 0 2 O PT...................... 2
1.4 Vacon CX1 0 3 O PT...................... 2
1.5 Vacon CX1 0 4 O PT...................... 3
1.6 Vacon fieldbus boards............... 3
2 SPECIFICATION S ............................ 4
3 IN STALLATIO N ................................. 5
3.1 G eneral..................................... 5
3.2 Installation ................................ 6
4 CO N TRO L CO N N ECTION S ........ 1 1
4.1 Vacon CX1 0 0 O PT.................... 11
4.2 Vacon CX1 0 1 O PT.................... 12
4.3 Vacon CX1 0 2 O PT.................... 13
4.4 Vacon CX1 0 3 O PT.................... 14
4.5 Vacon CX1 0 4 O PT.................... 15

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1 GEN ERAL
Due to the compact frame size of the Vacon CXS series all I/ O -expander boards need
to be installed in a separate box (Vacon CXSO PTBKIT), except the smaller, specifically
for Vacon CXS designed boards (Vacon C X1 0 4 O PT, CX1 0 5 O PT, C X1 0 7 O PT,
CX1 0 8 O PT). If ordered together w ith the option board these will be preinstalled.
1.1 Vacon CX100OPT
The available I/ O can be increased by using the Vacon CX1 0 0 O PT I/ O -expander
board:
- 5 digital inputs (standard signals)
- 2 analogue inputs (standard signals)
- 3 relay outputs (standard signals)
- analogue output (programmable)
- thermistor input (can be directly connected to the motor
thermistors to monitor the motor temperature)
- encoder input
Typical use: Closed Loop Vector Control
1.2 Vacon CX101OPT
The available I/ O can be increased by using the Vacon CX1 0 1O PT I/ O -expander
board:
- 5 digital inputs (standard signals)
- relay output (standard signal)
- thermistor input (can be directly connected to the motor thermistors to monitor
the motor temperature)
Typical use: thermistor input required
1.3 Vacon CX102OPT
The available I/ O can be increased by using the Vacon CX1 0 2 O PT I/ O -expander
board:
- 5 digital inputs (standard signals)
- 2 analogue inputs (standard signals)
- 3 relay outputs (standard signals)
- analogue output (programmable)
- thermistor input (can be directly connected to the motor thermistors to
monitor the motor temperature)
- encoder input
Typical use: Closed Loop Vector Control
1.4 Vacon CX103OPT
The available I/ O can be increased by using the Vacon CX1 0 3O PT I/ O -expander
board:
- 5 digital inputs (standard signals)
- 3 relay outputs (standard signals)
- analogue output (programmable)
- thermistor input (can be directly connected to the motor thermistors to monitor
the motor temperature)
Typical use: thermistor input and additional analogue output required

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1.5 Vacon CX104OPT
The available I/ O can be increased by using the Vacon CX1 0 4 O PT I/ O -expander
board:
- encoder input
Typical use: Closed Loop Vector Control
1.6 Fieldbus boards
Vacon fieldbus boards can be installed in the Vacon CXS range frequency converters
as I/ O -expander boards. The needed information to install/ commission fieldbus
boards can be found in the respective Vacon fieldbus manual.
- Vacon C X 2 0 0 O PT (Interbus-S)
- Vacon C X 2 0 1 O PT (M odbus)
- Vacon C X 2 0 2 O PT (Profibus-DP)
- Vacon CX 2 0 3 O PT (LonW orks)
- Vacon C X 2 0 4 O PT (C -b us)
- Vacon C X 2 0 5 O PT (SDS-bus)

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2 SPECIFICATION S
Safety Fulfills EN 5 0 1 7 8 , C-UL and EN 6 0 2 0 4 -1 standards
Control Analogue voltage, input 0 — ± 1 0 V, R
i ≥2 0 0 kΩ
connections Analogue current, input 0 (4 )— 2 0 mA, R
i= 2 5 0 Ω
Digital input 2 4 V: "0 " ≤1 0 V, "1 " ≥1 8 V, R
i> 5 kΩ
Aux. voltage 2 4 V (± 2 0 %), max. 5 0 mA
Reference voltage 1 0 V ± 3 %, max. 1 0 mA
Analogue current, output 0 (4 )— 2 0 mA, R
L
= 5 0 0 Ω, resolution 1 0 bit, accuracy ≤± 2 %
Analogue voltage, output 0 (2 )— 1 0 V, R
L
≥1 kΩ, resolution 1 0 bit, accuracy ≤±2 %
Relay output M ax. sw itching voltage: 3 0 0 V DC, 2 5 0 V AC
M ax. sw itching load: 8A / 24 V DC
0 ,4 A / 3 0 0 V DC
2 kVA / 2 5 0 V AC
M ax. continuous load: 2 A rms
Thermistor input R
trip = 4 .7 kΩ
Encoder input 2 4 V: "0 " ≤1 0 V, "1 " ≥1 8 V, R
i= 2 .2 kΩ
5 V: "0 " ≤2 V, "1 " ≥3 V, R
i= 3 3 0 Ω
Table 2 -1 Specifications. (All the control connections are not found on every I/ O -expander board, for
specific information see C hapters 1 and 4 .)
The control connections are isolated from the mains potential and the I/ O ground is
connected to the frame of the inverter via a 1 -M Ωresistor and 4 ,7 -nF capacitor* ). The
control I/ O ground can be connected directly to the frame by changing the position of the
jumper X4 (G N D O N / O FF) to the O N -position. Digital inputs and relay outputs are also
isolated from the I/ O ground.
* ) Default value (X4 is G N D O FF- position).
N OTE!
Internal components and circuit boards (except the isolated I/ O terminals) are at
mains potential when the frequency converter is connected to the mains. This
voltage is extremely dangerous and may cause death or severe injury if you
come into contact with it.
The control I/ O terminals are isolated from the mains potential, but the relay
outputs and other I/ O 's may have a dangerous voltage connected even if the
power is disconnected from the frequency converter.

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1
3 IN STALLATIO N
3.1. General
Check that your have received all the required parts (Figure 3-1 ):
- I/ O -repeater board (1 ) and I/ O -pole shielded data cable (2 )
- check that you have also received the jumper for I/ O - repeater board
terminal X5 (3 )
- 4 -pole power cable (4 )
- protection foil below (5 ) and above (6 ) the I/ O -reapeater board
- stand sleeve (7 )
- screw for fixing I/ O -repeater board (8 )
- 12 -pole communication cable (9 )
- opition box (1 0 )
- I/ O -expander board (1 1 ) (check that the typecode is corresponds to
your order)
- I/ O -interface board (1 2 )
- 1 0 -pole data cable (1 3 )
- 4 -pole pow er cable (1 4 )
- screw s for I/ O -expander board (1 5 )
- screws for I/ O -interface board (1 6 )
Figure 3 -1 . I/ O -expander board parts.
If the delivery does not match your order, please contact the supplier immediately. O nly
a competent electrician should carry out the electrical installation.
Before doing any commissioning, carefully read the safety instructions in the "USER'S
M AN UAL, VACO N CX/ CXL/ CXS", Chapter 1 , SAFETY.
Disconnect the frequency converter from the mains. N O TE: Also the control circuits!
W ait further 5 minutes before opening the cover of the frequency converter. Verify by
measuring that the frequency converter is safe to touch.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

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Table 3 -2 . I/ O -expander board installation (continues ...).
1
2
4
Remove the control panel, control panel base (4 screws) and the jumper X4 from the
control board.
3
3.2 IN STALLATIO N
I/ O -repeater board (1 ) should be installed above the control board inside the frequency con-
verter. The I/ O -expander board (1 0 ) and I/ O -interface board (1 1 ) should be installed in the
option box. Follow the instructions below (see Table 3 -2 ).
Check that the jumper for I/ O -repeater board (1) is in the right position in terminal X5 (3).
The position of the jumper must be chosen according to the I/ O -expander board (11)
:
- If I/ O -expander board CX1 0 1 O PT or 1 0 3 O PT
is in use, jumper must be in position A.
- If I/ O -expander board CX1 0 0 O PT or 1 0 2 O PT
is in use, jumper must be in position B.
- If one of the following fielbus boards is in use:
CX2 0 0 O PT, C X2 0 1 O PT, C X2 0 2 O PT or
CX2 0 3 O PT, jumper must be in position C.
(Positon D is not in use).
X5
X4
M ake sure that the cable of the control panel
cover is connected to the control board X1 ter-
minal. Connect the 4 -pole pow er cable (4) to
the control board X5 terminal (The power cable
can also be connected to the X6 -terminal, if the
pow er cable from the power board is connected
to the X5 -terminal.)
Set the protection foil (5) above the control
board as shown in the picture. M ake sure that
the protection foil is correctly located, the hole
in the foil will must be located above the stand
sleeve.
X5
Remove the fixing screw from the control board
and replace it w ith the stand sleeve (7).
5
7

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Connect the shielded data cable for I/
O -repeater board (2 ) to the control
board terminal X1 4 .
7
5
Set the protection foil (6 ) above the I/ O -repeater board as shown in the picture. M ake sure
that the protection foil is correctly located, push the "arms" of the protection foil under the
control panel cover. Fasten the I/ O -repeater board and protection foil to the stand sleeve (7 )
with the screw.
X14
Install the control panel cover w ith 4
screws.
6
8Connect the power cable (4 ) to the I/ O -repeater terminal X1 and communication cable (9 ) to
the I/ O -repeater terminal X3. Uncover carefully the shield of the communication cable (max.
1 ,5 cm), tighten up to the metal clamp (of the cable) and earth the cable to the frequency
converter ground as shown in the picture.
Table 3 -2 . I/ O -expander board installation (continues ...).
4
9
6
7

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Check the connections and make sure that there are no foreign objects inside the frequency
converter.
Close the cover of the frequency converter.
9
1 0
Install the jumper removed from the control board X4 terminal into the I/ O -expander board
terminal X9 . N ote: the jumper can be connected in O N or O FF position,see Vacon CX/ CXL/
CXS User's manual, Chapter 6 .2 .2 .
1 3
If you have the option box with the I/ O -expander (1 1) and I/
O -interface boards (1 2 ) pre-installed, jump to section 1 7 .
M ount the I/ O -expanderboard (11) and I/ O -interface board
(12) in the option box (10) w ith the screws.
1 1
Connect data cable (13) between terminal X1 4 in
the I/ O -interface board (12) and terminal X1 4 in
the I/ O -expander board (11)). X14 X14
1 2
Connect power cable (14) between terminal X6
in the I/ O -interface board (12) and terminal
X6 in the I/ O -expander board (11).
X6 X6
Table 3 -2 . I/ O -expander board installation (continues ...).
X9

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Connect the communication cable (9) to the I/ O -expander board
X1 5 terminal (12). Earth the communication cable to the option box
ground.
X15
1 4
1 5 Connect the necessary control signals. If a fieldbus board is in use, see separate manual for
more specific information.
X8
1 6 If an encoder input (closed loop control) is to
be used and the encoder works at a 5 V level,
move three jumpers from terminal X5 to terminal
X8 . If the encoder w orks at 2 4 V, then terminal
X8 should be left free.
Check the connections and make sure that there are no foreign objects inside the option box.
Before connecting the mains make sure that the cover of the option box and frequency con-
verter are closed.
Set the parameters of I/ O -expander board according to the Vacon "Five in O ne+" -applica-
tion manual (parameter group 3 ).
1 7
1 8
Table 3 -2 . I/ O -expander board installation.

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Figure 3 -2 . Frequency converter and external I/ O -expander box installation (unit sizes M 3 and M 4 B).
I/ O -expander box can also be installed beside the frequency converter (unit sizes M 3 , M 4 B and M 5 B).

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4 CO N TRO L CO N N ECTION S
4.1 Vacon CX100OPT
Signal from
motor thermistors * )
Figure 4 -1 C ontrol connections of Vacon C X1 0 0 O PT.
Terminal Signal Description
2 0 1 + 1 0 Vref Reference output Voltage for a potentiometer, etc.
2 0 2 U in+ Analogue input, voltage N ot in use
range 0 —1 0 V DC
203 GN D I/ O ground G round for reference and controls
2 0 4 I in+ Analogue input, current N ot in use
2 0 5 I in- range 0 —2 0 mA
206 + 2 4 V Control voltage output Voltage for switches, etc. max. 50 mA
207 GN D I/ O ground G round for reference and controls
208 CM C Common for DIC1 -DIC 5 Connect to G N D or + 2 4 V
209 DIC1 External fault Contact open = no fault
(closing contact) Contact closed = fault
210 DIC2 Run disable Cont. open = start of motor enabled
Cont. closed= start of motor disabled
211 DIC 3 Acceler. / Decel. time Contact open = time 1 selected
selection Contact closed = time 2 selected
212 DIC4 Jogging speed selection Contact open = no action
Contact closed = jogging speed
213 DIC5 Fault reset Contact open = no action
Contact closed = fault reset
214 DI6 A+ Pulse input A
215 DI6 A- (differential input)
216 DI7 B+ Pulse input B 9 0 deg rees phase shift compared
217 DI7 B- (differential input) to pulse input A
218 DI8 Z+ Pulse input C one pulse per one revolution
219 DI8 Z- (differential input)
2 2 0 I out+ Analogue output Programmable
0 — 2 0 mA/ R
L
max. 5 0 0 Ω(M otor current as default value)
221 TI+ Thermistor input
2 2 2 TI -
2 2 3 RO 3 / 1 Relay output 3 READY
2 2 4 RO 3 / 2
2 2 5 RO 4 / 1 Relay output 4 RUN
2 2 6 RO 4 / 2
2 2 7 RO 5 / 1 Relay output 5 FAULT
2 2 8 RO 5 / 2
*) N OTE! Thermistor input (terminals 2 2 1 and 2 2 2 ) must be shorted if not used.
Enco-
der

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Terminal Signal Description
206 + 2 4 V Control voltage output Voltage for switches, etc. max. 50 mA
207 GN D I/ O ground G round for reference and controls
208 CM C Common for DIC1 -DIC 5 C onnect to G N D or + 2 4 V
209 DIC1 External fault Contact open = no fault
(closing contact) Contact closed = fault
210 DIC2 Run disable Cont. open = start of motor enabled
Cont. closed= start of motor disabled
211 DIC 3 Acceler. / Decel. time Contact open = time 1 selected
selection Contact closed = time 2 selected
212 DIC4 Jogging speed selection Contact open = no action
Contact closed = jogging speed
213 DIC5 Fault reset Contact open = no action
Contact closed = fault reset
2 1 4 N .C . N ot connected
2 1 5 N .C . N ot connected
221 TI+ Thermistor input
2 2 2 T I +
2 2 5 RO 4 / 1 Relay output 4 RUN
2 2 6 RO 4 / 2
4.2 Vacon CX101OPT
Signal from
motor thermistors * )
*) N OTE! Thermistor input (terminals 2 2 1 and 2 2 2 ) must be shorted if not used.
Figure 4 -2 C ontrol connections of Vacon CX1 0 1 O PT.

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Terminal Signal Description
201 + 1 0 Vref Reference output Voltage for a potentiometer, etc.
2 0 2 U in+ Analogue input, voltage N ot in use
range 0 —1 0 V DC
203 GN D I/ O ground Ground for reference and controls
2 0 4 U in+ Analogue input, voltage N ot in use
2 0 5 U in- range 0 —1 0 V DC
206 + 2 4 V Control voltage output Voltage for switches, etc. max. 50 mA
207 GN D I/ O ground Ground for reference and controls
208 CM C Common for DIC1 -DIC 5 C onnect to G N D or + 2 4 V
209 DIC1 External fault Contact open = no fault
(closing contact) Contact closed = fault
210 DIC2 Run disable Cont. open = start of motor enabled
Cont. closed= start of motor disabled
211 DIC 3 Acceler. / Decel. time Contact open = time 1 selected
selection Contact closed = time 2 selected
212 DIC4 Jogging speed selection Contact open = no action
Contact closed = jogging speed
213 DIC5 Fault reset Contact open = no action
Contact closed = fault reset
214 DI6 A+ Pulse input A
215 DI6 A- (differential input)
216 DI7 B+ Pulse input B 9 0 degrees phase shift compared
217 DI7 B- (differential input) to pulse input A
218 DO 1 Encoder direction output
219 DO 2 Encoder divider 1 / 6 4 output
2 2 0 U out+ Analogue output Programmable
0 —1 0 V DC/ R
L
≥1 kΩ(M otor voltage as default value)
221 TI+ Thermistor input
2 2 2 TI -
2 2 3 RO 3 / 1 Relay output 3 READY
2 2 4 RO 3 / 2
2 2 5 RO 4 / 1 Relay output 4 RUN
2 2 6 RO 4 / 2
2 2 7 RO 5 / 1 Relay output 5 FAULT
2 2 8 RO 5 / 2
4.3 Vacon CX102OPT
Figure 4 -3 C ontrol connections of Vacon C X1 0 2 O PT.
Signal from
motor thermistors * )
*) N OTE! Thermistor input (terminals 2 2 1 and 2 2 2 ) must be shorted if not used.
Enco-
der

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4.4 Vacon CX103OPT
*) N OTE! Thermistor input (terminals 2 2 1 and 2 2 2 ) must be shorted if not used.
Figure 4 -4 C ontrol connections of Vacon CX1 0 3 O PT.
Terminal Signal Description
206 + 2 4 V Control voltage output Voltage for switches, etc. max. 5 0 mA
207 GN D I/ O ground G round for reference and controls
208 CM C Common for DIC1 -DIC 5 C onnect to G N D or + 2 4 V
209 DIC1 External fault Contact open = no fault
(closing contact) Contact closed = fault
210 DIC2 Run disable Cont. open = start of motor enabled
Cont. closed= start of motor disabled
211 DIC 3 Acceler. / Decel. time Contact open = time 1 selected
selection Contact closed = time 2 selected
212 DIC4 Jogging speed selection Contact open = no action
Contact closed = jogging speed
213 DIC5 Fault reset Contact open = no action
Contact closed = fault reset
214 GN D I/ O ground
2 1 5 I out+ Analogue output Programble
0—2 0 mA/ R
L
max. 5 0 0 Ω(M otor current as default value)
221 TI+ Thermistor input
2 2 2 TI -
2 2 3 RO 3 / 1 Relay output 3 READY
2 2 4 RO 3 / 2
2 2 5 RO 4 / 1 Relay output 4 RUN
2 2 6 RO 4 / 2
2 2 7 RO 5 / 1 Relay output 5 FAULT
2 2 8 RO 5 / 2
Signal from
motor thermistors * )

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Terminal Signal Description
201 + 5 V Control voltage output Voltage for sw itches, max load 1 0 0 -1 5 0 mA
203 GN D I/ O ground G round for controls
206 + 2 4 V Control voltage output
207 GN D I/ O ground G round for controls
214 DI6 A+ Pulse input A
215 DI6 A- (differential input)
216 DI7 B+ Pulse input B
217 DI7 B- (differential input)
218 DIR Encoder direction
21 9 DIV Encoder divider 1 / 1 0 2 4
4.5 Vacon CX104OPT
M ore information on the Vacon C X1 0 4 O PT encoder option board you w ill find in a
separate manual (ud3 1 8 ). Ask your distributor for more information.
Figure 4 -5 C ontrol connections of Vacon CX1 0 4 O PT.
Enco-
der

VACON PLC
P.O. Box 25
Runsorintie 7
FIN-65381 VAASA
FINLAND
Phone: [phone]
Fax: [phone]
Service: [phone]
E-mail: [email protected]
http://www.vacon.com
Distributor:
UD 00244C1, 19.10.2000