VACON® 100: Versatile AC Drives for Energy Savings and Process Control

Product Family Highlights

The VACON® 100 is more than just a single type of AC drive; it's a comprehensive product family offering significant flexibility in both hardware and software. Danfoss provides innovative and reliable AC drive solutions tailored for key applications in numerous industries, resulting in enhanced energy efficiency and productivity.

Key Features Across the VACON® 100 Family:

• Extensive Voltage/Power Range: Suitable for use in any location where a drive is needed.
• Freedom in Motor Choice: Allows selection of the motor that best fits the application.
• Reliable and Built to Last: Designed for demanding environments.
• Inbuilt Safety: Provides protection for both personnel and machinery.
• Full Customization: Enables the creation of individual drive features, from simple to complex.
• Free to Connect: Facilitates quick and easy system integration with common protocols like Modbus RTU, BACnet MSTP, Metasys N2, Modbus TCP, Profinet, and EtherNet/IP.
• Design for Environment: Contributes to high energy savings with reduced emissions and pollution.
• Easy to Set-up, Easy to Operate: Features an intuitive user interface and smart tools.
• Easy Installation with Various Enclosure Types: Offers suitable solutions for any installation requirement.

VACON® 100 INDUSTRIAL

The VACON® 100 INDUSTRIAL is a robust workhorse designed for a wide array of industrial applications. It integrates seamlessly into major control systems and is easily adaptable to diverse needs. Key features include:

• Integrated RS485 and Ethernet interfaces supporting major industrial protocols, reducing the need for additional option cards.
• VACON® Programming enables built-in PLC functionality (IEC61131-3) for OEM customization.
• VACON® Customizer facilitates minor logic adaptations for specific requirements or retrofit situations.
• Suitable for industries such as Wood, Metal, Chemical, Mining & Mineral, Oil & Gas, Material Handling, Pulp & Paper, Plastics & Rubber, Marine & Offshore, Water & Wastewater, Refrigeration, and HVAC.
• Offers constant torque handling with capacity for high overload and advanced control functions.
• Features advanced motor control, including open-loop control with frequency, speed, and torque reference, and advanced sensorless control modes.
• Supports numerous advanced functions for motor control setting, such as load drooping.
• Includes a highly advanced MPPT control algorithm for solar pump applications to maximize output power.
• Provides mechanical brake control and supports open, fully customized application software packages.

VACON® 100 FLOW

The VACON® 100 FLOW is specifically designed to enhance flow control and energy savings in commercial pumping and ventilation systems. It builds upon the core VACON® 100 functionality with dedicated features for pump and fan applications:

• Multi-pump control: Enhances pump performance and protects pipes and equipment.
• Intelligent PID controller: Controls pump speed using a sensor for quick reaction to demand fluctuations, ensuring accurate process control and optimal energy savings.
• 2 x PID controller: Allows control of pressure, flow, temperature, etc., based on measurement signals.
• 2-Zone PID controller: Enables parallel control of two process values, such as temperature and flow.
• Start boost: Increases starting torque for reliable pump starts in all conditions.
• Dry pump / Broken belt protection: Stops the pump or fan if motor shaft torque is insufficient.
• Auto-cleaning / Anti-ragging: Detects abnormal torque increase when a pump is blocked and initiates a cleaning sequence.
• Frost protection: Automatically restarts the pump in sleep mode to prevent freezing.
• Soft filling of pipes: Runs the pump at a lower speed until the pipe is full, indicated by a pressure increase.
• Sleep mode: Automatically stops the pump/drive during periods of low demand, restarting when pressure drops below a set threshold.
• Sleep boosting: Temporarily increases system pressure before entering sleep mode to maximize restart time.
• No-demand detection: Prevents the pump from running at unnecessarily high speeds when there is no demand.
• Pressure loss compensation: Adjusts the pressure reference to account for pressure drops in piping or ducting.

Multipump Control Solutions:

The VACON® 100 offers intelligent multipump control solutions:

• Multipump – Single drive system: Controls up to 8 pumps with one drive, increasing system efficiency and redundancy. Allows for fixed control or alternation of auxiliary pumps.
• Multipump – Multi drive system: Connects up to 8 pumps without additional controllers or PLCs, offering a fully redundant system. Features include drive-to-drive communication via RS485, integrated pump control functionality, and automatic pump alternation.
• Multi Master Mode: Multiple pumps operate to meet demand, with one pump in speed control and others operating at maximum frequency.
• Multi Follower Mode: Multiple pumps operate to meet load demand, with all pumps running in speed control mode for increased efficiency and reduced noise.

VACON® 100 X Decentral Drive

The VACON® 100 X is a benchmark in decentral drives, offering a power range from 1.1 kW to 37 kW. It features an IP66/Type 4X outdoor protection rating and advanced control capabilities for precise process execution. Key attributes include:

• Robust, die-cast metal enclosure designed to withstand 3g vibrations.
• Excellent cooling capabilities with a powder-coated enclosure for corrosion protection, suitable for outdoor environments.
• Built-in harmonic filtering chokes, making it ideal for public networks.
• Pressure equalizer vent: Allows the enclosure to breathe while preventing dust and dirt ingress, equalizing internal pressure.
• Large cooling ribs: Designed to not collect dust and allow easy cleaning with pressurized water, ensuring reliable operation.
• Terminal box: Consolidates wiring and the control unit in a single, accessible box.
• Power head: Contains all power components in a compact, robust unit with removable connectors for easy maintenance.
• Expansion slots: Provide connectivity for additional option boards and fieldbus communication.
• Mains switch (optional): Allows for disconnection and locking of the drive's main supply during maintenance.
• Mountable in four orientations: Offers flexibility in mounting the drive and keypad.
• Motor mountable: Can be mounted onto any flat surface using additional adaptable parts.

VACON® 100 Drive Modules for System Integration

The IP00 Drive Modules are designed for easy installation into any enclosure, featuring a compact design. They are available for enclosure sizes MR8 up to MR12 and include essential components like DC chokes and optional brake choppers. Options modules for MR10 and MR12 house optional output filters and brake choppers, integrated into the main cooling channel.

• Features: Wide power range, integrated DC chokes, optional brake chopper and output filters, remotely mountable control box, and IP54 main cooling channel.
• Benefits: Reduced installation space and costs, easier integration, and improved reliability due to separated cooling air flow.

VACON® 100 Enclosed Drive

The VACON® 100 Enclosed Drive is engineered to meet demanding requirements for flexibility, robustness, and service-friendliness. It serves as a smart, ready-made 'plug and play' solution with numerous customization options.

• Features: Accessible door-mounted control compartment, separate cooling air channel, integrated filters, fast-acting fuses, and configurable options.
• Benefits: IP54/UL rating without derating, reduced installation space, higher reliability in demanding environments, and a safe, integrated solution for faster commissioning and serviceability.

Technical Data Summary

The VACON® 100 series offers a wide range of technical specifications, including:

• Mains Connection: Input voltages from 208-240 V to 525-690 V, input frequency 50-60 Hz, displacement power factor > 0.98.
• Motor Connection: Output voltage 0-Input voltage, continuous output current and overloadability from 1.1x to 1.5x IL, output frequency 0-320 Hz.
• Control Performance: Open loop vector control, speed control accuracy of 0.5%, dynamic response of 0.3%/sec, and torque linearity <2%.
• Ambient Conditions: Operating temperatures range from -10°C to 50°C for wall-mounted/modules/enclosed drives and -40°C to 60°C for VACON® 100 X (IP66).
• EMC: Immunity and emissions compliant with IEC 61800-3, with Category C2 for wall-mounted drives (240V/500V) and Category C3 for IP00 modules, enclosed drives, and 690V drives.
• Functional Safety: Features Safe Torque Off (STO) and Safe Stop 1 (SS1) options, with SIL 3 rating available.
• Control Connection: Includes multiple I/O options, Ethernet connectivity (Modbus TCP/IP, BACnet IP, PROFINET, EtherNet/IP), and RS485 communication.
• Approvals: UL 508C, CE, UL, CUL, EAC, RCM, and various marine certifications (DNV-GL, BV, LR, ABS, RINA).

DrivePro® Life Cycle Services

Danfoss offers DrivePro® Life Cycle Services to provide a customized service experience throughout the AC drive's lifecycle. These services include:

• DrivePro® Retrofit: Minimizes impact and maximizes benefits during the replacement of legacy drives.
• DrivePro® Spare Parts: Ensures availability of critical parts for optimal uptime and performance.
• DrivePro® Extended Warranty: Provides long-term peace of mind with coverage up to six years.
• DrivePro® Exchange: Offers a fast and cost-efficient alternative to repair for quick replacement and increased uptime.
• DrivePro® Upgrade: Maximizes AC drive investment by keeping drives up-to-date with on-site evaluations and upgrade plans.
• DrivePro® Start-up: Fine-tunes drives for optimal performance, safety, and availability.
• DrivePro® Preventive Maintenance: Provides a maintenance plan and budget based on audits, with expert execution of tasks.
• DrivePro® Remote Expert Support: Offers speedy resolution of on-site issues through remote access to information.
• DrivePro® Remote Monitoring: Provides real-time online information for proactive issue resolution.

For more information on available products and services in your region, contact your local Danfoss Drives sales office or visit the Danfoss website.

Case Studies

• Quintex chooses VACON® AC drives - 3,500 times! (Berkshire, UK)
• VACON® 100 FLOW improves water pumping (Kristinestad, Finland)
• VACON® 100 X to control RUBBLE MASTER's Compact crushers (Linz, Austria)

Discover more case studies at: https://www.danfoss.com/en/service-and-support/case-studies/

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