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Danfoss P1K5 Design Manual Download Page 44

6 How to Install

6.1  Before Starting

6.1.1 Checklist

When unpacking the frequency converter, make sure that
the unit is undamaged and complete. Check that the
packaging contains the following:

•

VLT

®

 Micro Drive FC 51 FC 51

•

Quick Guide

Optional: LCP and/or de-coupling plate.

Illustration 6.1 Content of box

How to Install

VLT Micro Drive Design Guide

MG02K102 - VLT

®

 is a registered Danfoss trademark

43

6

6

Summary of Contents for P1K5

Page 1: ...MAKING MODERN LIVING POSSIBLE Design Guide VLT Micro Drive...

Page 2: ...essories 26 4 1 1 Local Control Panel LCP 26 4 1 2 FC 51 LCP Mounting Instruction 27 4 1 3 FC 51 Remote Mounting Kit Mounting Instruction 28 4 1 4 IP21 TYPE 1 Enclosure Kit 30 4 1 5 Type 1 NEMA 30 4 1...

Page 3: ...bles 52 6 12 Electrical Overview 55 6 12 1 Power Circuit Overview 55 6 13 Electrical Installation and Control Cables 56 6 14 Control Terminals 57 6 14 2 Connecting to Control Terminals 57 6 15 Switche...

Page 4: ...PCD 74 8 5 Examples 74 8 6 Modbus RTU Overview 75 8 6 1 Assumptions 75 8 6 2 What the User Should Already Know 75 8 6 3 Modbus RTU Overview 75 8 6 4 Frequency Converter with Modbus RTU 75 8 8 Modbus...

Page 5: ...8 10 Examples 80 8 11 Danfoss FC Control Profile 82 9 Specifications 86 9 1 Specifications 86 Index 92 Contents VLT Micro Drive Design Guide 4 MG02K102 VLT is a registered Danfoss trademark...

Page 6: ...anty or representation neither expressed nor implied with respect to this documentation including its quality performance or fitness for a particular purpose In no event shall Danfoss be liable for di...

Page 7: ...death or serious injury Indicates default setting 1 1 4 Abbreviations Alternating current AC American wire gauge AWG Ampere AMP A Automatic Motor Tuning AMT Current limit ILIM Degrees Celsius C Direc...

Page 8: ...data IM The motor current IM N The rated motor current nameplate data nM N The rated motor speed nameplate data PM N The rated motor power nameplate data UM The instantaneous motor voltage UM N The ra...

Page 9: ...duty rating refers to a sequence of duty cycles Each cycle consists of an on load and an off load period The operation can be either periodic duty or none periodic duty LCP The Local Control Panel LC...

Page 10: ...rsonal safety VT Characteristics Variable torque characteristics used for pumps and fans VVC plus If compared with standard voltage frequency ratio control Voltage Vector Control VVCplus improves the...

Page 11: ...mains plugs 7 Check that all voltage inputs have been discon nected and that the necessary time has passed before commencing repair work Installation at high altitudes CAUTION At altitudes above 2km...

Page 12: ...C outline three typical situations of using a frequency converter See below for EMC coverage and CE labeling 1 The frequency converter is sold directly to the end consumer The frequency converter is f...

Page 13: ...n coated printed circuit boards can be ordered as an option Standard on some power sizes Airborne Particles such as dust may cause mechanical electrical or thermal failure in the frequency converter A...

Page 14: ...SSURE SYSTEM CURVE FAN CURVE A B C 130BA781 10 ENERGY CONSUMED Illustration 2 2 When using a frequency converter to reduce fan capacity to 60 more than 50 energy savings may be obtained in typical app...

Page 15: ...with 3 well known solutions when fan volume is reduced to i e 60 As the graph shows more than 50 energy savings can be achieved in typical applications 130BA782 10 Discharge damper Less energy savings...

Page 16: ...ion Frequency converter control Hours Power Consumption Power Consumptio n A1 B1 kWh A1 C1 kWh 350 5 438 42 5 18 615 42 5 18 615 300 15 1314 38 5 50 589 29 0 38 106 250 20 1752 35 0 61 320 18 5 32 412...

Page 17: ...LT Micro Drive FC 51 2 Star delta starter 3 Soft starter 4 Start directly on mains 2 5 8 Using a Frequency Converter Saves Money The example on the following page shows that a lot of equipment is not...

Page 18: ...ignal 0 10V Control Mains Cooling section Heating section Fan section Inlet guide vane Pump Pump 2 5 10 With a Frequency Converter 175HA206 11 Pump Flow Return Supply air V A V outlets Duct Mains Pump...

Page 19: ...r serial bus If allowed in 0 40 Hand on Key on LCP 0 44 Off Reset Key on LCP and 0 42 Auto on Key on LCP it is possible to start and stop the frequency converter by LCP using the Hand On and Off Reset...

Page 20: ...static pressure in the pipe and supplies this to the frequency converter as a feedback signal If the feedback signal is greater than the set point reference the frequency converter will slow down to...

Page 21: ...3 2 Block Diagram Showing Remote Reference The Remote Reference is comprised of Preset references External references analog inputs and serial communication bus references The Preset relative referenc...

Page 22: ...he screen impedance at higher frequencies which reduces the screen effect and increases the leakage current I4 If a screened cable is used for fieldbus relay control cable signal interface and brake t...

Page 23: ...ms No limit line An EMC plan should be made Table 3 1 Emission Requirements When the generic emission standards are used the frequency converters are required to comply with the following limits Envir...

Page 24: ...s obtained by fulfilling requirements for higher isolation and by providing the relevant creapage clearance distances These requirements are described in the EN 61800 5 1 standard The components that...

Page 25: ...for protection in case of direct or indirect contact only an RCD of Type B is allowed on the supply side of this product Otherwise another protective measure shall be applied such as separation from t...

Page 26: ...the application from serious damages offers several dedicated features Torque Limit The Torque limit feature the motor is protected for being overloaded independent of the speed Torque limit is contro...

Page 27: ...mmed from a PC via RS485 com port by installing the MCT 10 Set up Software This software can either be ordered using code number 130B1000 or downloaded from the Danfoss Web site www danfoss com Busine...

Page 28: ...reset Auto on The frequency converter is controlled either via control terminals or serial communication Potentiometer LCP12 The potentiometer works in two ways depending on the mode in which the fre...

Page 29: ...ing Instruction Step 1 Fit gasket on LCP in the frequency converter Step 2 Place LCP on panel see dimensions of hole on drawing VLT Micro Drive Selection VLT Micro Drive Design Guide 28 MG02K102 VLT i...

Page 30: ...ing screws to fasten connector to LCP Tightening torque 1 3Nm Step 4 Connect cable to frequency converter NOTE Use the provided thread cutting screws to fasten connector to the frequency converter Tig...

Page 31: ...55 9 132B0103 M2 IP20 1 5kW 1 25kW 1 5 2 2kW 220 6 75 0 175 4 132B0104 M3 IP20 2 2kW 2 2 3 7kW 3 0 7 5kW 282 5 90 0 201 3 132B0105 M4 IP20 11 15kW 345 6 125 0 248 5 132B0120 M5 IP20 18 5 22kW 385 5 16...

Page 32: ...on frequency converter and tighten the screws Tightening torque 2 Nm Conduit sizes M1 4 x M2 5 x M3 2 x 3 x 3 4 Step 2 Fit bottom cover on frequency converter and tighten screw VLT Micro Drive Selecti...

Page 33: ...late on frequency converter and tighten the screws Tightening torque 2 Nm Conduit sizes M4 3 x M5 3 x 1 Step 2 Fit bottom cover on frequency converter and tighten screw VLT Micro Drive Selection VLT M...

Page 34: ...grommets 130BC014 10 Step 3 Mount metal plate on frequency converter and tighten screws Tightening torque 2Nm Step 4 Fit bottom cover on frequency converter and tighten screw NOTE IP21 is only achiev...

Page 35: ...frequency converter and fasten with two screws Tightening torque 2 Nm Step 2 Mount bracket on de coupling plate Step 3 VLT Micro frequency converter FC 51 mounted with de coupling plate VLT Micro Driv...

Page 36: ...e coupling plate on frequency converter and fasten with two screws Tightening torque 2 Nm Step 2 VLT Micro frequency converter FC 51 mounted with de coupling plate VLT Micro Drive Selection VLT Micro...

Page 37: ...frequency converter and fasten with two screws Tightening torque 2 Nm Step 2 VLT Micro frequency converter FC 51 mounted with de coupling plate Step 3 Mount bracket on de coupling plate VLT Micro Driv...

Page 38: ...ction Step 1 Mount plastic part on frequency converter Step 2 Fit frequency converter on DIN rail Din Rail kit is only for M1 and M2 VLT Micro Drive Selection VLT Micro Drive Design Guide MG02K102 VLT...

Page 39: ...tput current should be decreased The frequency converter has been designed for operation at max 50 C ambient temperature with one motor size smaller than nominal Continuous operation at full load at 5...

Page 40: ...o a critical level the frequency converter can adjust the switching frequency and or change the switching pattern in order to ensure the performance of the frequency converter The capability to automa...

Page 41: ...erate an eight digit sales number either for one product or a project list with several products to be delivered to your local sales office The Drive Configurator can be found on the global Internet s...

Page 42: ...filter A1 B reduced cable length Brake 18 B Brake chopper included from 1 5 kW and up X No brake chopper included Display 19 X No Local Control Panel N Numerical Local Control Panel LCP P Numerical Lo...

Page 43: ...or M1 frame 132B0109 IP21 for M2 frame 132B0110 IP21 for M3 frame 132B0111 DIN rail mounting kit for M1 and M2 frame 132B0120 Type 1 kit for M4 frame 132B0121 Type 1 kit for M5 frame 132B0122 De coupl...

Page 44: ...re that the unit is undamaged and complete Check that the packaging contains the following VLT Micro Drive FC 51 FC 51 Quick Guide Optional LCP and or de coupling plate Illustration 6 1 Content of box...

Page 45: ...amming Illustration 6 2 Side by side installation 6 3 Before Commencing Repair Work 1 Disconnect FC 51 from mains and external DC supply if present 2 Wait for 4 minutes M1 M2 and M3 and 15 minutes M4...

Page 46: ...00 240 V 3 X 200 240 V 3 X 380 480 V A A incl decoupling plate a B b C Kg M1 0 18 0 75 0 25 0 75 0 37 0 75 150 205 140 4 70 55 148 1 1 M2 1 5 1 5 1 5 2 2 176 230 166 4 75 59 168 1 6 M3 2 2 2 2 3 7 3 0...

Page 47: ...80 V Line Motor DC connection Brake Control Terminals Earth Relay M1 0 18 0 75 0 25 0 75 0 37 0 75 1 4 0 7 Spade1 0 15 3 0 5 M2 1 5 1 5 1 5 2 2 1 4 0 7 Spade1 0 15 3 0 5 M3 2 2 2 2 3 7 3 0 7 5 1 4 0 7...

Page 48: ...llation FC 51 Max Fuses UL Max fuses non UL Bussmann Bussmann Bussmann Littel fuse Ferraz Shawmut Ferraz Shawmut 1 X 200 240 V kW Type RK1 Type J Type T Type RK1 Type CC Type RK1 Type gG 0K18 0K37 KTN...

Page 49: ...Mounting of earth cable and mains wires For 3 phase connection connect wires to all three terminals For single phase connection connect wires to terminals L1 L and L3 N Illustration 6 5 Three phase an...

Page 50: ...and length Use a screened armoured motor cable to comply with EMC emission specifications Keep the motor cable as short as possible to reduce the noise level and leakage currents Connect the motor cab...

Page 51: ...as tight joint otherwise the aluminium surface will oxidize again 6 8 4 EMC Correct Electrical Installation General points to be observed to ensure EMC correct electrical installation Use only screene...

Page 52: ...s and PLC etc Panel Mains supply Min 200mm between control cable mains cable and between mains motor cable PLC Protective earth Reinforced protective earth 130BB965 10 Illustration 6 9 EMC correct Ele...

Page 53: ...ance ZT The screen of a cable is normally designed to reduce the transfer of electric noise however a screen with a lower transfer impedance ZT value is more effective than a screen with a higher tran...

Page 54: ...wire cable c Single layer braided copper wire with varying percentage screen coverage This is the typical Danfoss reference cable d Double layer braided copper wire e Twin layer of braided copper wire...

Page 55: ...are used 50 60 Hz earth loops may occur Solve this problem by connecting one end of the screen to earth via a 100nF capacitor keeping leads short e Cables for serial communication Eliminate low frequ...

Page 56: ...are not applicable for frame M1 Brake resistors are available from Danfoss Improved power factor and EMC performance can be achieved by installing optional Danfoss line filters Danfoss power filters c...

Page 57: ...e or Current 3 15 6 1 Reference 55 Terminal 55 Common Analog Ground Common 60 Terminal 60 Current Input 3 16 6 2 Reference Table 6 4 Terminal Connections Very long control cables and analog signals ma...

Page 58: ...ustration 6 12 Overview of control terminals in PNP configu ration and factory setting 6 15 Switches NOTE Do not operate switches with power on the frequency converter Bus termination Switch BUS TER p...

Page 59: ...min 50 Hz COS 0 80 3 6 A 1 7L B IP 65 H1 1A BAUER D 7 3734 ESLINGEN 130BT307 10 Step 3 Activate the Automatic Motor Tuning AMT Performing an AMT will ensure optimum performance The AMT measures the va...

Page 60: ...nd alarm description Unsuccessful AMT is often caused by incorrectly registered motor name plate data or too big difference between the motor power size and the frequency converter power size Step 4 S...

Page 61: ...zes are widely different because small motors relatively high ohmic resistance in the stator calls for a higher voltage at start and at low RPM values The electronic thermal relay ETR of the frequency...

Page 62: ...Communication protocol must be set to 8 30 Protocol 6 19 2 How to Connect a PC to the Frequency Converter To control or program the frequency converter from a PC install the PC based Configuration Too...

Page 63: ...U V W L1 L2 and L3 Energize maximum 2 15 kV DC for 380 500V frequency converters and 2 525 kV DC for 525 690V frequency converters for one second between this short circuit and the chassis WARNING Wh...

Page 64: ...tion 7 1 LCP 12 with Potentiometer Illustration 7 2 LCP 11 without Potentiometer The display Different information can be read from the display Set up number shows the active set up and the edit set u...

Page 65: ...ashing red LED Indicates an alarm Please see section Troubleshooting Navigation Keys Back For moving to the previous step or layer in the navigation structure Arrows For maneuvering between parameter...

Page 66: ...1 20 Motor Power kW HP Pm n Option Function Enter motor power from nameplate data Two sizes down one size up from nominal VLT rating 1 0 09 kW 0 12 HP 2 0 12 kW 0 16 HP 3 0 18kW 0 25 HP 4 0 25 kW 0 3...

Page 67: ...ed motor frequency fM N set in 1 23 Motor Frequency 3 41 Ramp1 Ramp up Time Range Function Choose a ramp up time ensuring that torque limit is not exceeded see 4 16 Torque Limit in Motor Mode 3 42 Ram...

Page 68: ...tor 7 34 Process PI Integral Time Range Function 0 10 9999 00 s Enter the I factor 7 38 Process Feed Forward Factor Range Function 0 400 Only applicable with changing set points 7 5 Main Menu 7 5 1 Ma...

Page 69: ...ack to leave the parameter 7 8 Initialise the Frequency Converter to Default Settings in two Ways 7 8 1 Initialise the Frequency Converter to Default Settings in two Ways Recommended initialisation vi...

Page 70: ...qualizing cables to maintain the same earth potential throughout the network partic ularly in installations with long cables To prevent impedance mismatch always use the same type of cable throughout...

Page 71: ...8 1 4 Frequency Converter Parameter Settings for Modbus Communication The following parameters apply to the RS485 interface FC port Parameter Function 8 30 Protocol Select the application protocol to...

Page 72: ...he 2 relays built into the frequency converter The Bus Reference is commonly used for speed control It is also possible to access the parameters read their values and where possible write values to th...

Page 73: ...e Calculated Checksum is 0 8 4 6 The Data Field The structure of data blocks depends on the type of telegram There are three telegram types and the type applies for both control telegrams master slave...

Page 74: ...ype 6 Not used 7 Not used 9 Description element not available 11 No parameter write access 15 No text available 17 Not while Running 18 Other error 100 100 130 No bus access for this parameter 131 Wri...

Page 75: ...ed Low Limit Hz has a conversion factor of 0 1 To preset the minimum frequency to 10Hz transfer the value 100 A conversion factor of 0 1 means that the value transferred is multiplied by 0 1 The value...

Page 76: ...d to it Determines which actions to take Extracts any data or other information contained in the message If a reply is required the controller constructs the reply message and sends it Controllers com...

Page 77: ...decodes it to determine which device is being addressed Modbus RTU messages addressed to zero are broadcast messages No response is permitted for broadcast messages A typical message frame is shown i...

Page 78: ...ue implemented as two 8 bit bytes When this is done the low order byte of the field is appended first followed by the high order byte The CRC high order byte is the last byte sent in the message 8 8 8...

Page 79: ...CP p12 28 and 12 29 store in Eeprom etc 6 7 40007 Last error code Read only Error code recieved from parameter database refer to WHAT 38295for details 7 8 40008 Last error register Read only Address o...

Page 80: ...e number and transfer length is invalid For a controller with 100 registers a request with offset 96 and length 4 would succeed a request with offset 96 and length 5 will generate exception 02 3 Illeg...

Page 81: ...ve device 01 Field Name Example HEX Slave Address 01 frequency converter address Function 01 read coils Starting Address HI 00 Starting Address LO 20 32 decimals Coil 33 No of Points HI 00 No of Point...

Page 82: ...egisters 03 HEX Description This function reads the contents of holding registers in the slave Query The query message specifies the starting register and quantity of registers to be read Register add...

Page 83: ...Write Data LO Register 4 1050 E2 Error Check CRC Response The normal response returns the slave address function code starting address and quantity of registers preset Field Name Example HEX Slave Add...

Page 84: ...the motor speed ramp down to stop via the selected ramp down parameter Bit 06 1 Permits the frequency converter to start the motor if the other starting conditions are met Make a selection in 8 53 Sta...

Page 85: ...it 03 1 The frequency converter trips To re establish operation enter Reset Bit 04 No error error no trip Bit 04 0 The frequency converter is not in fault mode Bit 04 1 The frequency converter shows a...

Page 86: ...itted to the frequency converter in a relative value in The value is transmitted in the form of a 16 bit word in integers 0 32767 the value 16384 4000 Hex corresponds to 100 Negative figures are forma...

Page 87: ...14 4 Max cable size mains motor mm2 AWG 4 10 Max input current Continuous 1 x 200 240 V A 3 3 6 1 11 6 18 7 26 4 Intermittent 1 x 200 240 V A 4 5 8 3 15 6 26 4 37 0 Max mains fuses A See Section Fuses...

Page 88: ...mains motor mm2 AWG 4 10 Max input current Continuous 3 x 200 240 V A 2 4 3 5 6 7 10 9 15 4 24 3 Intermittent 3 x 200 240 V A 3 2 4 6 8 3 14 4 23 4 35 3 Max mains fuses A See Section Fuses Environment...

Page 89: ...Supply 3 x 380 480 V AC 1 At rated load conditions Normal overload 150 for 1 minute Frequency converter Typical Shaft Output kW P5K5 5 5 P7K5 7 5 P11K 11 P15K 15 P18K 18 5 P22K 22 Typical Shaft Output...

Page 90: ...0 RMS symmetrical Amperes 240 480 V maximum Motor output U V W Output voltage 0 100 of supply voltage Output frequency 0 200 Hz VVC 0 400 Hz u f Switching on output Unlimited Ramp times 0 05 3600 sec...

Page 91: ...t Programmable relay output 1 Relay 01 Terminal number 01 03 break 01 02 make Max terminal load AC 1 1 on 01 02 NO Resistive load 250 V AC 2 A Max terminal load AC 15 1 on 01 02 NO Inductive load cos...

Page 92: ...ation 0 C Minimum ambient temperature at reduced performance 10 C Temperature during storage transport 25 65 70 C Maximum altitude above sea level without derating 1000 m Maximum altitude above sea le...

Page 93: ...r Pressure 39 Digital Inputs Pulse Encoder Inputs 89 Inputs 89 DISCHARGE TIME 10 Display 63 Disposal Instruction 10 Drive Configurator 40 E Earth Leakage Current 62 23 Earthing Earthing 54 Of Screened...

Page 94: ...ection 49 Current 66 Direction 64 Frequency 65 Name Plate 58 Name Plate Data 58 Nominal Speed 66 Output U V W 89 Phases 25 Power 65 Protection 60 89 Speed High Limit 66 Speed Low Limit 66 Thermal Prot...

Page 95: ...r 63 Software 63 Short Circuit Motor Phase Phase 25 Soft starter 16 Software Version 5 Star Delta Starter 16 Status Status 27 Menu 64 Word 84 Successful AMT 59 Surroundings 91 Switches 57 Switching Fr...

Page 96: ...www danfoss com drives MG02K102 132R0059 MG02K102 Rev 2011 08 16...

Page 97: ......

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