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Danfoss D9h, Operating Manual

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8 Wiring Configuration Examples

8.1 Application Examples

The examples in this section are intended as a quick reference for common applications.

Parameter settings are the regional default values selected in 

parameter 0-03 Regional Settings

, unless otherwise indicated.

Parameters associated with the terminals and their settings are shown next to the drawings.
Required switch settings for analog terminals A53 or A54 are also shown.

8.1.1 Programming a Closed-loop Drive System

A closed-loop drive system usually consists of:

Motor.
Drive.
Encoder (as feedback system).
Mechanical brake.
Brake resistor (for dynamic braking).
Transmission.
Gear box.
Load.

Applications demanding mechanical brake control typically need a brake resistor.

e

3

0

b

t8

6

5

.1

0

Encoder

Mechanical brake

Motor

Gearbox

Load

Transmission

Brake resistor

Illustration 66: Basic Setup for Closed-loop Speed Control

AQ262139143212en-000301 / 130R0879

122 | Danfoss A/S © 2021.10

Wiring Configuration Examples

VLT® AutomationDrive FC 302

Operating Guide

Summary of Contents for D9h

Page 1: ...Operating Guide VLT AutomationDrive FC 302 90 710 kW D9h D10h and E5h E6h Enclosed Drives drives danfoss com...

Page 2: ......

Page 3: ...at is an Enclosed Drive 17 Location of Options within an Enclosed Drive 20 Drive Identification 22 Identifying the Drive and Its Options 22 Enclosure Size Identification 23 Type Code Identification 24...

Page 4: ...6h Enclosed Drives 54 Control Terminal Wiring Diagram Cross reference 55 Split Shipment Wiring Harnesses 56 Connecting Wiring Harnesses 56 Cable Routing 57 D10h Wiring Harness 65 E5h Wiring Harness 69...

Page 5: ...r an Open loop Application 117 Entering System Information 118 Configuring Automatic Energy Optimization 119 Configuring Automatic Motor Adaptation 119 Testing Before System Start up 119 Testing Motor...

Page 6: ...aintenance Diagnostics and Troubleshooting 137 Maintenance and Service 137 Disposal 137 Status Messages 137 Warnings and Alarms 140 Troubleshooting 158 Specifications 161 Electrical Data 161 Electrica...

Page 7: ...ase Circuit Breakers 184 Enclosure Dimensions 185 Pedestal Dimensions 185 D9h Enclosed Drive Exterior Dimensions 186 D10h Enclosed Drive Exterior Dimensions 186 E5h Enclosed Drive Exterior Dimensions...

Page 8: ...ting Guide provides detailed specifications requirements and installation instructions for the Safe Torque Off function Supplementary publications and manuals are available from Danfoss see www danfos...

Page 9: ...or more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In land Waterways ADN refer to section ADN compliant Installation in the product s...

Page 10: ...1 6 Declaration of Conformity Certificate AQ262139143212en 000301 130R0879 10 Danfoss A S 2021 10 Introduction VLT AutomationDrive FC 302 Operating Guide...

Page 11: ...AQ262139143212en 000301 130R0879 11 Danfoss A S 2021 10 Introduction VLT AutomationDrive FC 302 Operating Guide...

Page 12: ...AQ262139143212en 000301 130R0879 12 Danfoss A S 2021 10 Introduction VLT AutomationDrive FC 302 Operating Guide...

Page 13: ...AQ262139143212en 000301 130R0879 13 Danfoss A S 2021 10 Introduction VLT AutomationDrive FC 302 Operating Guide...

Page 14: ...proven skills are allowed to transport store as semble install program commission maintain and decommission this equipment Persons with proven skills Are qualified electrical engineers or persons who...

Page 15: ...ore performing any service or repair work use an appropriate voltage measuring device to make sure that the capacitors are fully discharged Table 2 Discharge Time Drive model Minimum waiting time D9h...

Page 16: ...jury Ensure that only trained and qualified personnel perform installation start up and maintenance Ensure that electrical work conforms to national and local electrical codes Follow the procedures in...

Page 17: ...or cables with the optional dU dt filter Provide sinusoidal output with optional sine wave filter The enclosed drive is designed for residential industrial and commercial environments in accordance wi...

Page 18: ...67 10 1 2 4 5 3 Illustration 2 Possible Configurations for a D10h Enclosed Drive 1 Input filter cabinet passive harmonic filter or line re actor 2 Input power options cabinet 1 3 Drive cabinet 4 Sine...

Page 19: ...1 Input filter cabinet passive harmonic filter or line re actor 2 Input power options cabinet 3 Drive cabinet 4 Sine wave filter cabinet 5 Control compartment 6 dU dt filter cabinet AQ262139143212en 0...

Page 20: ...ble Options 1 Passive harmonic filter PHF 2 Line reactor 3 Non fusible disconnect 4 Fusible disconnect 5 Molded case circuit breaker MCCB 6 Mains contactor 7 dU dt filter 8 Common mode filter 9 Sine w...

Page 21: ...rmonic filter PHF 2 Line reactor 3 Non fusible disconnect 4 Fusible disconnect 5 Molded case circuit breaker MCCB 6 Mains contactor 7 dU dt filter 8 Common mode filter 9 Sine wave filter 10 Drive modu...

Page 22: ...ut this guide whenever procedures or components differ based on the drive and its options Use the following steps to identify the enclosed drive Procedure Locate the type code T C on the nameplate The...

Page 23: ...lter option if any 5 Mains voltage 4 380 480 V 5 380 500 V 7 525 690 V 6 Model power rating 7 Build date wwy where ww the week and y the last digit of the year 8 Option codes 3 4 2 Enclosure Size Iden...

Page 24: ...rive FC 202 302 VLT AutomationDrive FC 302 Table 6 Low harmonic Filter Codes Character position Code Description 7 T None P Passive filter THDi 5 50 Hz H Passive filter THDi 8 50 Hz L Passive filter T...

Page 25: ...1000 hp 800 N800 800 kW 1200 hp Table 10 Drive Module PCB Coating Codes Character position Code Description 13 C Coated PCB R Coated PCB ruggedized Table 11 Plinth Pedestal Codes Character position Co...

Page 26: ...s contactor ME AC reactor non fusible disconnect MF AC reactor circuit breaker MCCB MG AC reactor mains contactor MH AC reactor non fusible disconnect mains contactor Table 14 Output Filter Codes Char...

Page 27: ...external 24 V DC internal Table 18 Back channel Cooling Codes Character position Code Description 22 X Bottom in top out 1 Back in back out C Back in top out D Bottom in back out N None Table 19 Auxil...

Page 28: ...ght cabinet heater insulation monitor AN AC socket cabinet light cabinet heater motor heater control insulation monitor AO AC socket cabinet light motor heater control insulation monitor AP Extended I...

Page 29: ...utton STO SS1 with emergency push button safely limited speed TTL encoder DE Indicator lights and reset button STO SS1 with emergency push button safely limited speed HTL encoder Table 23 A Option Cod...

Page 30: ...CB 102 FC 302 only U VLT Resolver Option MCB 103 FC 302 only Z VLT Safety PLC Interface MCB 108 FC 302 only 5 VLT Programmable I O MCB 115 6 VLT Safe Option TTL MCB 150 FC 302 only 7 VLT Safe Option H...

Page 31: ...X English no 2nd language G English German F English French 3 5 Power Ratings Weight and Dimensions Table 32 Power Ratings and Dimensions for D9h D10h and E5h E6h Enclosures Standard Configurations En...

Page 32: ...0 23 6 600 23 6 Weight kg lb 384 847 384 847 768 1693 768 1693 dU dt filter cabinet D9h D10h E5h E6h Height mm in 3 2100 82 7 2100 82 7 Width mm in 5 400 15 8 400 15 8 Depth mm in 600 23 6 600 23 6 We...

Page 33: ...ards Optional components Auxiliary supply terminals Auxiliary voltage transformer connections 24 V DC external supply AC customer socket Extended I O terminals Cabinet heater connections Motor heater...

Page 34: ...ith All Options 1 Local control panel LCP 2 Emergency push button 3 Fault indicator light 4 Run indicator light 5 Insulation fault indicator light 6 USB slot 7 0 1 Start switch 8 Reset button 9 Namepl...

Page 35: ...nces For details on how to use the NLCP see the product specific Programming Guide A Display area Each display readout has a parameter associated with it The information shown on the LCP can be custom...

Page 36: ...Indicator lights Indicator lights identify the drive status and provide a visual notification of warning or fault conditions Table 36 LCP Indicator Lights Callout Indicator LED Function D1 On Green A...

Page 37: ...The Info key can be used to see help information for various selections settings and messages Q5 Changes Made Select Q5 Changes Made for information about The 10 most recent changes Changes made from...

Page 38: ...Display 1 Load and Motor 2 Brakes 3 Reference Ramps 0 RPM 0 00 A Main Menu 1 1 Illustration 11 Main Menu View For more detailed information on the menus or parameters refer to the Programming Guide A...

Page 39: ...time N O T I C E WARRANTY Removing the nameplate from the drive results in loss of warranty 4 2 Split Shipment Depending on the options ordered with an enclosed drive the drive can consist of 5 cabin...

Page 40: ...0 V unless the drive is derated Refer to the Derating section in the design guide The unit can operate at temperatures down to 10 C 14 F However proper operation at rated load is only guaranteed at 0...

Page 41: ...C monitoring device like the VLT PTC Thermistor Card MCB 112 installation does not need an individual approval from an approbated organization Motors with class d e protection The motor itself has an...

Page 42: ...back channel cooling kits are available to redirect the airflow based on individual needs 4 8 Airflow Rates Table 39 Airflow Rates for D9h Enclosure Cabinet Back channel fan m3 hr cfm Drive module to...

Page 43: ...E6h Enclosure Cabinet Back channel fan m3 hr cfm Drive module top fan m3 hr cfm Cabinet door fan m3 hr cfm PHF line reactor 1285 755 Input options 510 310 Drive 1053 1206 620 710 629 370 430 255 dU d...

Page 44: ...eposition the lifting point if the unit is not level Never walk under suspended loads 60 60 e30bu146 11 Illustration 13 Recommended Lifting Method 4 10 Combining Multiple Cabinets from a Split Shipmen...

Page 45: ...rounding bars using the connector piece see the shaded piece in Illustration 16 Example e30bu125 10 1 2 Illustration 14 Bracket Mounting Points for Cabinets 1 Front brackets 2 Back brackets e30bu133 1...

Page 46: ...tion Procedure Select an area in which to install the enclosure Do not install the enclosure in an airtight space The drive receives approxi mately 5 10 of intake air from the front of the cabinet Mea...

Page 47: ...stal Use the 2 mounting points at the front base of the pedestal and the 2 mounting points at the upper back of the cabinet Use the 2 mounting points in the mounting bracket and the 2 mounting points...

Page 48: ...he pedestal B The 2 mounting points at the front base of the ped estal C The 2 mounting points at the upper back of the cab inet D The 2 mounting points in the mounting bracket AQ262139143212en 000301...

Page 49: ...gether can charge equipment capacitors even with the equipment turned off and locked out Failure to run output motor cables separately or use shielded cables could result in death or serious injury Ru...

Page 50: ...SHIELD ENDS PIGTAILS Twisted shield ends increase shield impedance at higher frequencies which increases the leakage current Use integrated shield clamps instead of twisted shield ends N O T I C E SH...

Page 51: ...12 8 7 10 9 4 11 13 4 4 6 15 90 DC BR B M AIN S L1 L2 L3 91 92 93 RELA Y 1 RELA Y 2 99 LC UV W MOTOR Illustration 19 Example of Proper EMC Installation AQ262139143212en 000301 130R0879 51 Danfoss A S...

Page 52: ...s 8 Brake cable shielded 9 Motor cable shielded 10 Mains cable unshielded 11 Output contactor and so on 12 Cable insulation stripped 13 Common ground busbar Follow local and national requirements for...

Page 53: ...2 17 XD2 16 XD2 15 XD2 14 XD2 18 XD2 13 XD2 12 XD2 11 XD2 10 XD2 9 XD2 8 XD2 7 XD2 6 cabinet V 97 W 98 240 V AC 2A 400 V AC 2A 240 V AC 2A 400 V AC 2A Brake temp RS485 PNP Source COM RS485 61 N RS485...

Page 54: ...15 XD2 14 XD2 18 XD2 13 XD2 12 XD2 11 XD2 10 XD2 9 XD2 8 XD2 7 XD2 6 cabinet V 97 W 98 240 V AC 2A 400 V AC 2A 240 V AC 2A 400 V AC 2A Brake temp RS485 PNP Source COM RS485 61 N RS485 69 P RS485 68 RS...

Page 55: ...22 Serial Communication Digital Input Output Analog Input Output and Relay Terminals Cross reference 1 User accessible terminals control compartment 2 Serial communication terminals drive module 3 Ana...

Page 56: ...s to the motor terminals inside the drive cabinet For the dU dt filter option the unattached filter cables are bundled inside the dU dt filter cabinet Connect the unat tached cable ends to the motor t...

Page 57: ...0bu858 10 U V W U T1 V T2 W T3 Illustration 23 Cable Routing for Top Exit Cabinet to Drive Cabinet AQ262139143212en 000301 130R0879 57 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive F...

Page 58: ...U T1 V T2 W T3 Illustration 24 Cable Routing for Sine wave Cabinet to D10h Drive Cabinet AQ262139143212en 000301 130R0879 58 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive FC 302 Oper...

Page 59: ...1 V T2 W T3 Illustration 25 Cable Routing for Sine wave Cabinet to E5h or E6h Drive Cabinet AQ262139143212en 000301 130R0879 59 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive FC 302 O...

Page 60: ...V T2 W T3 Illustration 26 Cable Routing for dU dt Cabinet with Top Exit to E5h or E6h Drive Cabinet AQ262139143212en 000301 130R0879 60 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive...

Page 61: ...V T2 W T3 Illustration 27 Cable Routing for 2 Sine wave Cabinets to E5h or E6h Drive Cabinet AQ262139143212en 000301 130R0879 61 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive FC 302...

Page 62: ...3 R S T R L1 S L2 T L3 R S T Illustration 28 Cable Routing for PHF Cabinet to E5h or E6h Drive Cabinet AQ262139143212en 000301 130R0879 62 Danfoss A S 2021 10 Electrical Installation VLT AutomationDri...

Page 63: ...V T2 W T3 Illustration 29 Cable Routing for dU dt Cabinet to Top Exit Cabinet for E5h or E6h AQ262139143212en 000301 130R0879 63 Danfoss A S 2021 10 Electrical Installation VLT AutomationDrive FC 302...

Page 64: ...ine Reactor Cabinet to Input Power Options Cabinet and E6h Drive Cabinet Internal Wiring Connection Be tween Inductors in the Line Reactor Cabinet Is Not Shown AQ262139143212en 000301 130R0879 64 Danf...

Page 65: ...Cabinet D10h Drive Cabinet 1 DC link harness to fan supply in output filter cabinet 2 Cabinet heater supply harness to output filter cabi net 3 Additional terminal connections 4 Thermal protection wir...

Page 66: ...al connections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor term...

Page 67: ...lit Shipment Electrical Connections Top Exit Cabinet 1 Motor cables U V W to motor terminals U V W in drive cabinet AQ262139143212en 000301 130R0879 67 Danfoss A S 2021 10 Electrical Installation VLT...

Page 68: ...onnections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor terminal...

Page 69: ...actor 2 supply harness to input power op tions cabinet only with PHF option 4 Input terminal cables R S T to mains terminals R S T in the input power options cabinet 5 Output terminal cables L1R L2S L...

Page 70: ...al connections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor term...

Page 71: ...lit Shipment Electrical Connections Top Exit Cabinet 1 Motor cables U V W to motor terminals U V W in drive cabinet AQ262139143212en 000301 130R0879 71 Danfoss A S 2021 10 Electrical Installation VLT...

Page 72: ...nal connections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor ter...

Page 73: ...W to motor terminals U V W in output filter cabinet 2 DC link harness to fan supply in output filter cabinet 3 Cabinet heater supply harness to output filter cabi net 4 Additional terminal connection...

Page 74: ...contactor 1 supply harness to input filter cabi net only with PHF option 5 Mains cables R S T to input terminals R S T in the input filter cabinet 6 Mains cables L1R L2S L3T to output terminals L1R L2...

Page 75: ...actor 2 supply harness to input power op tions cabinet only with PHF option 4 Input terminal cables R S T to mains terminals R S T in the input power options cabinet 5 Output terminal cables L1R L2S L...

Page 76: ...al connections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor term...

Page 77: ...lit Shipment Electrical Connections Top Exit Cabinet 1 Motor cables U V W to motor terminals U V W in drive cabinet AQ262139143212en 000301 130R0879 77 Danfoss A S 2021 10 Electrical Installation VLT...

Page 78: ...connections 2 Thermal protection wiring harness to drive cabinet 3 DC link harness to fan power supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables U V W to motor...

Page 79: ...the input filter cabi net 4 Cabinet heater supply harness to input filter cabinet 5 PHF contactor 1 supply harness to input filter cabi net only with PHF option 6 PHF contactor 2 supply harness to inp...

Page 80: ...arness to PHF cabinet only with PHF option 5 PHF contactor 2 supply harness to PHF cabinet only with PHF option 6 Mains cables R S T to input terminals R S T in the input filter cabinet 7 Mains cables...

Page 81: ...GH VOLTAGE The mains disconnect switch does not disconnect the external voltage supply Failure to disconnect the external voltage supply before touching any components in the control compartment can r...

Page 82: ...6 18 14 20 19 21 22 3 A 6 7 8 9 24 25 26 1 10 11 A 12 13 4 5 23 27 Illustration 48 Layout of Control Compartment Interior with All Options AQ262139143212en 000301 130R0879 82 Danfoss A S 2021 10 Elect...

Page 83: ...ck set XDY 24 Option C2 terminal block set XDF 25 Basic I O terminal block and option A B D card ter minal block set XD2 26 Door components terminal block set XDJ 27 Grounding clamp for the shield ter...

Page 84: ...alog In put 2 Feedback 9 Common for analog input 5 7 4 Relay Terminals Table 46 Relay Terminal Descriptions XD2 terminal Parameter Default setting Description 21 22 23 Parameter 5 40 Function Relay 0...

Page 85: ...compartment 67 XD2 40 66 XD2 41 63 XD2 42 62 XD2 43 CS XD2 44 Table 49 Option A Terminal Connections for VLT EtherNet IP MCA 121 VLT Modbus TCP MCA 122 VLT POWERLINK MCA 123 VLT Ether CAT MCA 124 Opt...

Page 86: ...XDW 8 X55 9 XDW 9 X55 10 XDW 10 X55 11 XDW 11 X55 12 XDW 12 X56 1 XDW 13 X56 2 XDW 14 X56 3 XDW 15 X56 4 XDW 16 X56 5 XDW 17 X56 6 XDW 18 X56 7 XDW 19 X56 8 XDW 20 X56 9 XDW 21 X56 10 XDW 22 X56 11 XD...

Page 87: ...ons for VLT Positioning Controller MCO 351 Option card terminal Corresponding terminal within the control compartment X55 1 XDW 1 X55 2 XDW 2 X55 3 XDW 3 X55 4 XDW 4 X55 5 XDW 5 X55 6 XDW 6 X55 7 XDW...

Page 88: ...DW 28 X57 3 XDW 29 X57 4 XDW 30 X57 5 XDW 31 X57 6 XDW 32 X57 7 XDW 33 X57 8 XDW 34 X57 9 XDW 35 X57 10 XDW 36 X59 1 XDW 37 X59 2 XDW 38 X59 3 XDW 39 X59 4 XDW 40 X59 5 XDW 41 X59 6 XDW 42 X59 7 XDW 4...

Page 89: ...5 1 XDF 17 X45 2 XDF 18 X45 3 XDF 19 X45 4 XDF 20 X46 1 XDF 1 X46 2 XDF 2 X46 3 XDF 3 X46 4 XDF 4 X46 5 XDF 5 X46 6 XDF 6 X46 7 XDF 7 X46 8 XDF 8 X46 9 XDF 9 X46 10 XDF 10 X46 11 XDF 11 X46 12 XDF 12...

Page 90: ...hin the control compartment X67 1 XDF 21 X67 2 XDF 22 X67 3 XDF 23 X67 4 XDF 24 X67 5 XDF 25 X67 6 XDF 26 X67 7 XDF 27 X67 8 XDF 28 X67 9 XDF 29 X67 10 XDF 30 X67 11 XDF 31 X67 12 XDF 32 X66 1 XDF 1 X...

Page 91: ...provides an external voltage supply to the XD1 1 terminal The external supply must be short circuit protected The power of the external supply depends on other selected cabinet options e30bu195 10 XD...

Page 92: ...r the FC4 terminal is set accordingly The customer can change the tapping provided the correct voltage is applied and the thermal magnetic circuit breaker is set accordingly e30bu192 10 L1 L2 FC4 TA4...

Page 93: ...AJ AC socket cabinet light extended I O terminals motor heater control insulation monitor AK AC socket cabinet light extended I O terminals cabinet heater motor heater control insula tion monitor AL A...

Page 94: ...ntrol insulation monitor AP Extended I O terminals cabinet heater AQ Extended I O terminals motor heater control AR Extended I O terminals insulation monitor AS Extended I O terminals cabinet heater m...

Page 95: ...ter motor heater control insulation monitor AW Cabinet heater motor heater control A8 Cabinet heater insulation monitor AY Cabinet heater motor heater control insulation monitor The cabinet heater opt...

Page 96: ...Extended I O terminals motor heater control insulation monitor AW Cabinet heater motor heater control AY Cabinet heater motor heater control insulation monitor AZ Motor heater control insulation monit...

Page 97: ...hin the insulation level in an IT supply network with an insulation monitor in the control compartment 5 7 6 9 Signal Lights and Reset Buttons Table 64 Door mounted Option Type Codes Character posi ti...

Page 98: ...1 function with the VLT Safety Option MCB 150 along with STO function using an emer gency stop push button on the control compartment door The emergency stop push button activates the motor decelerati...

Page 99: ...relay user manuals for the regu lations and the certified safety 5 8 Connecting Motor Mains and Ground Cables 5 8 1 Power Cabling and Grounding Considerations Motor and mains connections Size the wir...

Page 100: ...cable lug to the end of the stripped cable Create an electrical connection between the cable shield and ground by securing the stripped wire under the cable clamp Connect the ground wire to the neares...

Page 101: ...ration 56 Connection Points for Mains to Input Power Option Enclosed Drive Configured Without Power Options Cabinet 1 Lower cover 2 Input power terminals contactor option is shown 3 DC terminals 4 Gro...

Page 102: ...nals disconnect option is shown 5 Grounding bar 5 8 3 Connecting the Drive Module to the Motor Procedure Strip a section of the outer cable insulation Fasten a connector cable lug to the end of the st...

Page 103: ...rminals in accordance with the specifications shown in 10 11 Fastener Torque Ratings Example e30bu171 10 1 3 4 5 6 2 Illustration 58 Connection Points for Drive Module to Motor E6h Model Shown 1 Lower...

Page 104: ...ng to Ground Connect the 3 phase AC motor cable to the sine wave terminals U V and W If the enclosed drive has 1 sine wave filter cabinet run 1 set of motor cables to the cabinet If the enclosed drive...

Page 105: ...or Procedure Strip a section of the outer cable insulation Fasten a connector cable lug to the end of the stripped cable Create an electrical connection between the cable shield and ground by securing...

Page 106: ...Ratings Example e30bu175 10 1 2 4 5 6 3 Illustration 60 Connection Points for the dU dt Filter to Motor 1 Upper cover 2 Lower cover 3 Factory installed power cables from the drive mod ule 4 Factory in...

Page 107: ...the system components Recommended cable cross section 16 mm2 5 AWG Strip a section of the outer cable insulation Fasten a connector cable lug to the end of the stripped cable Connect the ground cable...

Page 108: ...ion Table 69 Recommended Fuse Ratings for IEC Installation 380 500 V Model Fuse P N Fuse size Rated cur rent A Minimum pro spective SC cur rent of the grid kA Maximum fuse rating F1 A Minimum voltage...

Page 109: ...y option have a 5 kA SCCR but can reach 65 kA if the recommended Class fuses are used upstream Enclosed drives with the MCCB option have a 65 kA interrupting rating for 380 480 V For 525 690 V the int...

Page 110: ...o receive a 24 V DC external interlock command that allows the drive to operate when using factory default programming values N O T I C E FACTORY INSTALLED OPTIONAL EQUIPMENT Do not remove factory ins...

Page 111: ...cific communication protocol changes various default parameter settings to match the specifications of the pro tocol making more protocol specific parameters available Option cards for the drive are a...

Page 112: ...PMENT DAMAGE Failure to use the correct settings for the D9h and D10h enclosures can result in the AC drive overheating resulting in damage to the AC drive and its surroundings E5h and E6h enclosures...

Page 113: ...h overload FLA I1 Time delay t1 is selected as 12 s for 6 times of I1 Short circuit instant trip setting I is followed Short circuit trip with time delay S is ignored with the factory settings Short c...

Page 114: ...elded or in 3 separate metallic conduits for high frequency interference isolation Control wiring Check for broken or damaged wires and loose connections Check that control wiring is isolated from hig...

Page 115: ...at the unit interior is free of dirt metal chips moisture and corrosion Verify that all installation tools have been removed from unit interior For enclosures with an IP20 Chassis protection rating en...

Page 116: ...alanced correct the input voltage imbalance before proceed ing Repeat this procedure after the voltage correction Ensure that any optional equipment wiring matches the installation requirements Ensure...

Page 117: ...lect Q3 Function Setups and press OK Select Parameter Data Set and press OK Select Q3 2 Open Loop Settings and press OK Select Q3 21 Analog Reference and press OK Select parameter 3 02 Minimum Referen...

Page 118: ...load type 3Dtools Procedure Press Main Menu on the LCP Select 0 Operation Display and press OK Select 0 0 Basic Settings and press OK Select parameter 0 03 Regional Settings and press OK Select 0 Inte...

Page 119: ...1 Load and Motor and press OK Select 1 2 Motor Data and press OK Select parameter 1 29 Automatic Motor Adaptation AMA and press OK Select 1 Enable complete AMA and press OK Press Hand On and then OK...

Page 120: ...e sound and vibration levels of the motor Remove the external run command 7 5 Parameter Settings 7 5 1 Parameter Setting Overview Parameters are operational settings accessed through the LCP that are...

Page 121: ...Start up takes slightly longer than normal After alarm 80 Drive initialized appears press Reset 7 5 4 Restoring Factory Default Settings Using Manual Initialization N O T I C E LOSS OF DATA Restoring...

Page 122: ...erminals A53 or A54 are also shown 8 1 1 Programming a Closed loop Drive System A closed loop drive system usually consists of Motor Drive Encoder as feedback system Mechanical brake Brake resistor fo...

Page 123: ...3 Wiring Configuration for Automatic Motor Adaptation AMA without T27 Table 75 Wiring Configuration for AMA without T27 Connected Parameters 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10V A IN A...

Page 124: ...Current 4 mA Parameter 6 13 Terminal 53 High Current 20 mA Parameter 6 14 Terminal 53 Low Ref Feedb value 0 Hz Parameter 6 15 Terminal 53 High Ref Feedb Value 50 Hz Default value Notes comments D IN...

Page 125: ...nts D IN 37 is an option Terminal 18 in the parameter title corresponds to terminal XD2 12 in the control compartment Terminal 27 in the parameter title corresponds to terminal XD2 14 in the control c...

Page 126: ...responds to terminal XD2 8 in the control compartment Table 81 Wiring Configuration for Analog Voltage Feedback Transducer 3 wire Parameters 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10V A IN A...

Page 127: ...onds to terminal XD2 8 in the control compartment 8 1 6 Wiring Configuration Run Stop Table 83 Wiring Configuration for Run Stop Command with External Interlock Parameters 24 V 24 V D IN D IN D IN COM...

Page 128: ...arameters 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10V A IN A IN COM A OUT COM R1 R2 e30bu083 10 XD2 10 XD2 11 XD2 12 XD2 13 XD2 18 XD2 14 XD2 15 XD2 16 XD2 17 XD2 19 XD2 6 XD2 7 XD2 8 XD2 9 X...

Page 129: ...in the parameter title corresponds to terminal XD2 19 in the control compartment e30bu101 10 Speed Start Stop XD2 12 Illustration 68 Wiring Configuration for Start Stop Command with Safe Torque Off Ta...

Page 130: ...Digital Input 17 Preset ref bit 1 Parameter 3 10 Preset Reference Preset ref 0 25 Preset ref 1 50 Preset ref 2 75 Preset ref 3 100 Default value Notes comments D IN 37 is an option Terminal 18 in the...

Page 131: ...n the parameter title corresponds to terminal XD2 16 in the control compartment 8 1 9 Wiring Configuration RS485 Table 90 Wiring Configuration for RS485 Network Connection Parameters e30bu089 10 XD2 1...

Page 132: ...rmistor warn ing D IN 37 is an option Input 53 in the parameter corresponds to terminal XD2 7 in the control compartment 8 1 11 Wiring for Regeneration Table 92 Wiring Configuration for Regeneration P...

Page 133: ...ameter 13 10 Comparator Operand 21 Warning no Parameter 13 11 Comparator Operator 1 equal Parameter 13 12 Comparator Value 90 Parameter 13 51 SL Controller Event 22 Comparator 0 Parameter 13 52 SL Con...

Page 134: ...Parameter 1 71 Start Delay 0 2 Parameter 1 72 Start Function 5 VVC FLUX Clockwise Parameter 1 76 Start Current Im n Parameter 2 20 Release Brake Current Application dependent Parameter 2 21 Activate B...

Page 135: ...stop command and simultaneously activate the external electro mechanical brake If a stop command is activated via terminal XD2 12 and the drive is not at the torque limit the motor ramps down to 0 Hz...

Page 136: ...elay to 32 Mechanical Brake Control 24 V DC P 5 10 8 P 5 12 2 P 5 02 1 P 5 31 27 GND P 5 40 0 32 Relay 1 e30bu096 10 XD2 19 XD2 18 XD2 17 XD2 16 XD2 15 XD2 14 XD2 13 XD2 12 XD2 11 XD2 10 XD2 23 XD2 21...

Page 137: ...red fault condi tion Press Off on the LCP before programming parameters Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor start Ch...

Page 138: ...was selected in parameter 2 10 Brake Function The AC brake overmagnetizes the motor to achieve a controlled slow down AMA finish OK Automatic motor adaptation AMA was carried out successfully AMA read...

Page 139: ...he corre sponding terminal is active The drive saves the actual reference Changing the reference is now only possible via terminal functions speed up and speed down Jog request A jog command has been...

Page 140: ...he value set in parameter 4 53 Warning Speed High Speed low The motor speed is below the value set in parameter 4 52 Warning Speed Low Standby In auto on mode the drive starts the motor with a start s...

Page 141: ...tuations to protect itself The drive requires physical intervention for example when there is a short circuit on the output A trip lock can only be canceled by disconnecting mains removing the cause o...

Page 142: ...s on all analog mains terminals Control card terminals 53 and 54 for signals terminal 55 common VLT General Purpose I O MCB 101 terminals 11 and 12 for signals terminal 10 common VLT Analog I O Option...

Page 143: ...rter protection issues a warning at 98 and trips at 100 with an alarm The drive cannot be reset until the counter is below 90 Troubleshooting Compare the output current shown on the LCP with the drive...

Page 144: ...condition to a warning followed by an alarm Troubleshooting If the motor torque limit is exceeded during ramp up extend the ramp up time If the generator torque limit is exceeded during ramp down tim...

Page 145: ...49 SW ID Control Card Parameter 15 50 SW ID Power Card Parameter 15 60 Option Mounted Parameter 15 61 Option SW Version for each option slot 9 4 17 ALARM 16 Short Circuit Cause There is short circuiti...

Page 146: ...an be disabled in parameter 14 53 Fan Monitor 0 Disabled For drives with DC fans a feedback sensor is mounted in the fan If the fan is commanded to run and there is no feedback from the sensor this wa...

Page 147: ...power size Troubleshooting Check for the following conditions The ambient temperature is too high The motor cables are too long Incorrect airflow clearance above and below the drive Blocked airflow a...

Page 148: ...fault occurs a code number defined in Table 99 is shown Troubleshooting Cycle power Check that the option is properly installed Check for loose or missing wiring It may be necessary to contact the Da...

Page 149: ...board hardware 5125 Option in slot C0 Hardware incompatible with the control board hardware 5126 Option in slot C1 Hardware incompatible with the control board hardware 5376 6231 Internal fault Contac...

Page 150: ...for proper grounding and loose connections Check for proper wire size Check the motor cables for short circuits or leakage currents 9 4 44 ALARM 46 Power Card Supply Cause The supply on the power car...

Page 151: ...on Failed Cause A calibration error has occurred Troubleshooting Contact the Danfoss supplier or Danfoss service department 9 4 49 ALARM 51 AMA Check Unom and Inom Cause The settings for motor voltage...

Page 152: ...ate safely at a higher limit 9 4 58 ALARM 60 External Interlock Cause A digital input signal indicates a fault condition external to the drive Within the control compartment the following 3 relay con...

Page 153: ...ARNING ALARM 65 Control Card Overtemperature Cause The cutout temperature of the control card has exceeded the upper limit Troubleshooting Check that the ambient operating temperature is within the li...

Page 154: ...p Auto Restart Cause STO activated Troubleshooting With automatic restart enabled the motor can start when the fault is cleared 9 4 71 ALARM 74 PTC Thermistor Cause The PTC is not working Alarm is rel...

Page 155: ...g To clear the alarm reset the unit 9 4 78 ALARM 81 CSIV Corrupt Cause The CSIV file has syntax errors 9 4 79 ALARM 82 CSIV Parameter Error Cause CSIV failed to initialize a parameter 9 4 80 ALARM 83...

Page 156: ...ubleshooting Cycle power to the drive to determine if the warning alarm returns 9 4 89 WARNING ALARM 122 Mot Rotat Unexp Cause The drive performs a function that requires the motor to be at standstill...

Page 157: ...423 FPC Updating Cause The alarm is generated when the fan power card reports it has an invalid PUD The control card attempts to update the PUD A subsequent alarm can result depending on the update Se...

Page 158: ...e the faulty LCP or connection cable Internal voltage supply fault or SMPS is defective Contact supplier Intermittent dis play Overloaded supply SMPS due to improper control wir ing or a fault within...

Page 159: ...gs Check the settings of all motor pa rameters including all motor com pensation settings For closed loop operation check PID settings Check settings in parameter group 1 6 Load Depen Setting For clos...

Page 160: ...tput motor cables 1 posi tion U to V V to W W to U If the imbalanced leg stays on same output terminal it is a problem with the unit Contact the supplier AC drive accel eration prob lems Motor data ar...

Page 161: ...ous kVA at 460 V kVA 127 151 151 191 191 241 Continuous kVA at 500 V kVA 139 165 165 208 208 262 Maximum input current Continuous at 400 V A 171 204 204 251 251 304 Continuous at 460 500 V A 154 183 1...

Page 162: ...ent Conditions section For part load losses see drives danfoss com knowledge center energy efficiency directive 3 See also Input Power Option Losses section 4 If using an output filter the output freq...

Page 163: ...osses can increase LCP and typical control card power consumptions are included For power loss data according to EN 50598 2 refer to drives danfoss com knowledge center energy efficiency direc tive Op...

Page 164: ...150 302 150 302 150 302 Sine wave filter overtemperature trip C F 150 302 150 302 150 302 1 Typical power loss is at normal conditions and expected to be within 15 tolerance relates to variety in vol...

Page 165: ...rrent Continuous at 400 V A 771 848 848 954 Continuous at 460 500 V A 704 752 752 858 Maximum number and size of cables per phase Mains mm2 AWG 4x185 4x350 mcm 4x185 4x350 mcm Mains with disconnect mm...

Page 166: ...section 4 If using an output filter the output frequency is limited further See 10 3 1 Motor Output U V W 10 1 2 Electrical Data 525 690 V AC Table 105 Electrical Data Mains Supply 3x525 690 V AC FC...

Page 167: ...switching frequency is higher than the default setting the power losses can increase LCP and typical control card power consumptions are included For power loss data according to EN 50598 2 refer to...

Page 168: ...02 150 302 150 302 Sine wave filter overtemperature trip C F 150 302 150 302 150 302 1 Typical power loss is at normal conditions and expected to be within 15 tolerance relates to variety in voltage a...

Page 169: ...3 413 504 504 574 Continuous at 575 690 V A 366 434 395 482 482 549 Maximum number and size of cables per phase Mains mm2 AWG 4x127 4x250 mcm 4x127 4x250 mcm 4x127 4x250 mcm Mains with disconnect mm2...

Page 170: ...ion Losses section 4 If using an output filter the output frequency is limited further See 10 3 1 Motor Output U V W Table 108 Electrical Data Mains Supply 3x525 690 V AC FC 302 N560 N630 N710 High no...

Page 171: ...slots A and B each add only 4 W 2 Measured using 5 m 16 4 ft shielded motor cables at rated load and rated frequency Efficiency measured at nominal current For energy efficien cy class see the Ambient...

Page 172: ...perature Maximum 50 C 122 F 24 hour average maximum 45 C 113 F 1 Minimum ambient temperature during full scale operation 0 C 32 F 1 Minimum ambient temperature at reduced speed performance 10 C 14 F 1...

Page 173: ...ms Input capacitance 400 nF 1 For more information about Terminal XD2 19 Terminal 37 on the drive module and Safe Torque Off see the VLT FC Series Safe Torque Off Operating Guide 2 When using a contac...

Page 174: ...2 19 V DC Voltage level logic 1 NPN 2 14 V DC Maximum voltage on input 28 V DC Pulse frequency range 0 110 kHz Duty cycle minimum pulse width 4 5 ms Input resistance Ri Approximately 4 k 1 Terminals...

Page 175: ...rminal load AC 15 inductive load cos 0 4 240 V AC 0 2 A Maximum terminal load DC 1 on 21 22 NO 21 23 NC resis tive load 60 V DC 1 A Maximum terminal load DC 13 inductive load 24 V DC 0 1 A Relay 02 te...

Page 176: ...2 ON I Current level 0 4 to 20 mA scaleable Input resistance Ri Approximately 200 Maximum current 30 mA Resolution for analog inputs 10 bit sign Accuracy of analog inputs Maximum error 0 5 of full sca...

Page 177: ...0 0 980 0 910 1 Positive numbers indicate lagging reactive currents Negative numbers indicate leading currents 2 The capacitor connecting contactor switches at 20 load 10 7 2 Line Reactor Specificatio...

Page 178: ...e Filter Specifications Voltage rating 3x380 500 V and 525 690 V AC Nominal current 50 Hz 212 A and 315 A for 380 500 V 137 A and 222 A for 525 690 V 1 Motor frequency with derating 1 Up to 150 Hz Mot...

Page 179: ...55 131 60 140 C F Iout 80 75 65 60 Illustration 79 Derating for Ambient Temperature While Using a Sine wave Filter 10 8 Fuses Circuit Breakers and Switches Fuses and circuit breakers ensure that poss...

Page 180: ...500 V 1000 A 500 V 1000 A 500 V 1250 A 500 V Mersen P N NH4GG50V800 NH4GG50V1000 NH4GG50V1000 NH4GG50V1000 NH4GG50V1250 UL Class J L T 800 A 600 V 1000 A 600 V 1000 A 600 V 1100 A 600 V 1200 A 600 V...

Page 181: ...e system Rated operation current 230 V 6 A Rated operation current 380 V 4 A Rated operation current 500 V 1 5 A Conventional thermal current Ith 10 A Rated voltage 500 V AC Rated impulse withstand vo...

Page 182: ...r switch is an option that safely isolates the drive from the mains with a fuse switch mounted below the drive module All units ordered and supplied with a factory installed fusible disconnect switch...

Page 183: ...00 A 600 V ABB P N OS1200L30 OS1200L30 10 8 4 Non fusible Disconnect Switches The non fusible disconnector switch is an option All units ordered and supplied with a factory installed non fusible disco...

Page 184: ...600 V ABB P N OT1200U30 OT1200U30 10 8 5 Molded case Circuit Breakers The molded case circuit breaker MCCB is an option that combines a temperature sensitive device with a current sensitive electro m...

Page 185: ...BB P N T6L630T T7L1000LSPR23 1 DS LS T7L1000LSPR23 1 DS LS T7L1000LSPR23 1 DS LS T7L1000LSPR23 1 DS LS UL 600 A 600 V 1000 A 600 V 1000 A 600 V 1200 A 600 V 1200 A 600 V ABB P N T6LQ600TW T7L1000PR231...

Page 186: ...c filter line reactor cabinet 2 D9h drive cabinet 3 Sine wave cabinet 4 Standard pedestal 10 9 3 D10h Enclosed Drive Exterior Dimensions e30bu143 10 400 15 8 2000 55 78 7 100 3 9 600 23 6 600 23 6 2 2...

Page 187: ...23 6 800 31 5 2000 78 7 1200 82 7 1 6 600 23 6 2 4 5 600 23 6 3 55 2 2 100 3 9 400 15 8 600 23 6 600 23 6 600 23 6 Illustration 82 Dimensions for E5h Enclosure with Standard Pedestal 1 Passive harmoni...

Page 188: ...600 23 6 600 23 6 600 23 6 Illustration 83 Dimensions for E6h Enclosure with Standard Pedestal 1 Passive harmonic filter line reactor cabinet 2 Options cabinet 3 E6h drive cabinet 4 Sine wave cabinet...

Page 189: ...onnection results in a bad electrical connection To ensure correct torque use a torque wrench Table 137 Fastener Torque Ratings Location Bolt size Torque Nm in lb Mains terminals M10 M12 19 168 37 335...

Page 190: ...nt AEO Automatic energy optimization ACP Application control processor AMA Automatic motor adaptation AWG American wire gauge CPU Central processing unit CSIV Customer specific initialization values C...

Page 191: ...tance Lq Motor q axis inductance LC Inductor capacitor LCP Local control panel LED Light emitting diode LOP Local operation pad mA Milliamp MCB Miniature circuit breakers MCCB Molded case circuit brea...

Page 192: ...mode power supply S N Serial number STO Safe Torque Off TLIM Torque limit UM N Nominal motor voltage V Volt VVC Voltage vector control Xh Motor main reactance 11 3 International North American Default...

Page 193: ...meter 5 10 Terminal 18 Digital Input 51 External Interlock Parameter 5 31 Terminal 29 Digital Output 188 AHF Capacitor Connect Parameter 14 51 DC link Compensation 0 Off Table 141 Parameter Settings f...

Page 194: ...3 RF3 1L1 3 1L1 3 QB1 3 3 3 PE PE CA5 1 CA5 2 TA1 1 B CA3 1 PU1 PE U V W MA1 3 3 PE M QB8 3 QB7 I I 3 L1 3 PE e30bu196 10 Illustration 85 Electrical Power Flow for D9h D10h Enclosures AQ262139143212en...

Page 195: ...ins contactor QB2 Mains fused disconnect QB8 Mains disconnect MA7 dU dt and sine wave filter fans MA8 PHF fans RF2 Sine wave filter inductor CA4 Sine wave filter capacitor RF1 dU dt filter inductor CA...

Page 196: ...MA1 3 3 PE M QB8 3 QB7 I I 3 QA2 1 CA5 1 CA5 2 QA2 2 CA5 3 CA5 4 RF4 1 RF4 2 RF4 3 RF4 4 R1 1 R1 2 R1 3 R1 4 L1 3 PE PE PE e30bu197 10 Illustration 86 Electrical Power Flow for E5h E6h Enclosures AQ2...

Page 197: ...relates to differences in voltage and cable conditions These values are based on a typi cal motor efficiency IE IE3 border line Lower efficiency motors increase power loss in the drive and filters whi...

Page 198: ...6 57 N710 76 56 69 51 11 6 2 Fusible Disconnect Losses Table 146 Power Losses for Fusible Disconnect Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO N90K 71 49 57 40 N110 89 59 76 48 N132 1...

Page 199: ...0 173 154 173 141 N630 208 155 190 142 N710 282 208 258 190 11 6 3 Non fusible Disconnect Losses Table 148 Power Losses for Non fusible Disconnect Option 380 500 V Model 380 440 V W 441 500 V W NO HO...

Page 200: ...3 19 N630 32 24 30 22 N710 44 32 40 30 11 6 4 Molded case Circuit Breaker MCCB Losses Table 150 Power Losses for MCCB Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO N90K 25 18 20 14 N110 3...

Page 201: ...ive Harmonic Filter PHF Losses Table 152 Power Losses for Passive Harmonic Filter Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO N90K 1083 841 1083 841 N110 1284 1083 1284 1083 N132 1511 1...

Page 202: ...N560 4242 3720 4242 3720 N630 4600 4242 4600 4242 N710 5700 4600 5700 4600 11 6 6 Line Reactor Losses Table 154 Power Losses for Line Reactor Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO...

Page 203: ...91 2786 2279 N630 2472 1845 2268 1686 N710 3361 2472 3069 2268 11 6 7 dU dt Filter Losses Table 156 Power Losses for dU dt Filter Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO N90K 350 24...

Page 204: ...5 878 654 N710 1430 1054 1308 964 11 6 8 Sine wave Filter Losses Table 158 Power Losses for Sine wave Filter Option 380 500 V Model 380 440 V W 441 500 V W NO HO NO HO N90K 1050 732 843 598 N110 770 5...

Page 205: ...32 673 N160 2063 1302 1888 1188 N200 1285 896 1177 820 N250 1814 1285 1657 1177 N315 2446 1814 2240 1657 N355 3560 2515 3264 2327 N400 4408 2966 4029 2709 N500 2487 1913 2274 1750 N560 2778 2486 2778...

Page 206: ...rinted material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes...

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