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Danfoss VLT 380-500 V, Design Manual

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130BF027.10

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Mains jumper busbars (module 1)

3

Mains jumper busbars (module 2)

2

Brake terminals

4

Mains terminals

Illustration 6.7 2-drive System Mains Terminals (Side and Front Views)

Specifications

VLT

®

 Parallel Drive Modules

28

Danfoss A/S © 6/2016 All rights reserved.

MG37N102

6

6

Summary of Contents for VLT 380-500 V

Page 1: ...ENGINEERING TOMORROW Design Guide VLT Parallel Drive Modules 250 1200 kW vlt drives danfoss com...

Page 2: ......

Page 3: ...unctions 18 5 3 Safe Torque Off STO 19 5 4 System Monitoring 21 6 Specifications 23 6 1 Drive Module Dimensions 23 6 2 Control Shelf Dimensions 26 6 3 2 drive System Dimensions 27 6 4 4 drive System D...

Page 4: ...on System 101 9 9 IEC Harmonics Standards 102 9 10 IEEE Harmonics Standards 103 9 11 VLT Parallel Drive Modules Harmonics Compliance 103 9 12 Galvanic Isolation 104 10 Motor 105 10 1 Motor Cables 105...

Page 5: ...ferences and Feedback 138 15 4 Dead Band Around Zero 139 16 PID Controls 143 16 1 Speed PID Controls 143 16 2 Process PID Controls 146 16 3 Optimization of PID Controls 150 17 Application Examples 152...

Page 6: ...18 Appendix 159 18 1 Disclaimer 159 18 2 Conventions 159 18 3 Glossary 160 Index 163 Contents VLT Parallel Drive Modules 4 Danfoss A S 6 2016 All rights reserved MG37N102...

Page 7: ...el Drive Modules 250 1200 kW User Guide contains detailed procedures for start up basic operational programming and functional testing Additional information describes the user interface application e...

Page 8: ...f Failure to wait 20 minutes after power has been removed before performing service or repair work can result in death or serious injury 1 Stop the motor 2 Disconnect AC mains and remote DC link suppl...

Page 9: ...as standalone or as part of a system must bear the CE mark Systems must not be CE marked but must comply with the basic protection requirements of the EMC directive 3 4 Machinery Directive Frequency...

Page 10: ...verters that are subject to export control regulations The ECCN number is provided in the documents accompanying the frequency converter In case of re export it is the responsibility of the exporter t...

Page 11: ...160 250 kW 200 350 hp Weight 125 kg 275 lb Protection rating IP 00 NEMA Type 00 130BF015 10 41 1 6 1122 44 2 1048 41 3 346 13 6 376 14 8 Illustration 4 1 Drive Module Dimensions Available Danfoss opti...

Page 12: ...mined by customer requirement NEMA Type 12 shown 130BF016 10 2260 89 0 2201 86 7 808 31 8 636 25 0 59 2 3 Illustration 4 2 2 drive System with Minimum Cabinet Dimensions Available Danfoss options 6 pu...

Page 13: ...ned by customer requirement NEMA Type 12 shown 130BF017 10 636 25 0 2201 86 7 805 31 7 749 29 5 1608 63 3 2 3 59 2 0 52 2254 88 7 Illustration 4 3 4 drive System with Minimum Cabinet Dimensions Availa...

Page 14: ...er components such as busbar kits and back channel cooling duct kits are available as options to customize the drive system The drive system in Illustration 4 4 shows a system using 4 drive modules A...

Page 15: ...y The MDCIC interfaces the LCP and control card with the power card in each drive module 6 Drive modules 2 or 4 drive modules can be installed in parallel to create a drive system 7 Busbar kit optiona...

Page 16: ...ight In back Out back In back Out top In bottom Out top In bottom Out back 130BF019 11 Illustration 4 6 2 drive Cabinet with In back Out back Cooling Kit Left and In bottom Out top Cooling Kit Right P...

Page 17: ...nt available to the motor The use of insulated gate bipolar transistors IGBT means high speed switching Automatic switching frequency modulation regulates these conditions automatically to provide the...

Page 18: ...t is 110 of the rated motor current to minimize overcurrent stress 5 1 7 Short circuit Protection The frequency converter provides inherent short circuit protection with a fast acting fault trip circu...

Page 19: ...de or standby This feature reduces noise increases efficiency and extends the operating life of the fan 5 1 13 EMC Compliance Electromagnetic interference EMI or radio frequency interference RFI is di...

Page 20: ...nals from remote sensors The frequency converter accommodates 2 feedback signals from 2 different devices This feature allows regulating a system with different feedback requirements The frequency con...

Page 21: ...d for operation on 380 460 V 550 600 V and some at 690 V The power loss ride through time depends after the load on the frequency converter and the mains voltage at the time of the power loss 5 2 16 O...

Page 22: ...llation for example set 7 PTC 1 Relay W or 8 PTC 1 Relay A W in parameter 5 19 Terminal 37 Safe Stop Refer to the VLT PTC Thermistor Card MCB 112 Operating Instructions for further details 130BA967 12...

Page 23: ...ack Warning In closed loop operation the frequency converter monitors selected high and low feedback values The display shows a flashing high or flashing low warning when appropriate The frequency con...

Page 24: ...ored in the frequency converter if loss of the load is detected the frequency converter can be programmed to issue an alarm and trip or to continue operation and issue a warning 5 4 10 Lost Serial Int...

Page 25: ...130 5 1 41 1 6 1048 41 3 280 11 0 107 4 2 213 8 4 320 12 6 271 10 7 95 3 7 130BE654 11 376 14 8 Illustration 6 1 VLT Parallel Drive Modules Installation Dimensions Description Module weight kg lb Len...

Page 26: ...llustration 6 2 Drive Module Terminal Dimensions Front View 130BE749 10 Section A A Mains Terminals Section B B Motor and Brake Terminals Brake terminal Motor terminal Mains terminal 284 11 2 0 0 0 0...

Page 27: ...3 DC Bus Dimensions 130BE751 10 105 5 4 15 236 9 3 126 4 9 95 3 7 Illustration 6 4 DC Bus Dimensions Front and Side Views Specifications Design Guide MG37N102 Danfoss A S 6 2016 All rights reserved 25...

Page 28: ...6 2 Control Shelf Dimensions 130BF029 10 705 27 8 332 13 1 Illustration 6 5 Control Shelf Dimensions Specifications VLT Parallel Drive Modules 26 Danfoss A S 6 2016 All rights reserved MG37N102 6 6...

Page 29: ...9 808 31 8 796 31 3 1959 77 1 2261 89 0 636 25 0 338 13 3 636 25 0 105 2201 86 7 Illustration 6 6 2 drive System Exterior Dimensions Front Side and Door Opening Views Specifications Design Guide MG37N...

Page 30: ...8 6 0 401 15 8 130BF027 10 1 Mains jumper busbars module 1 3 Mains jumper busbars module 2 2 Brake terminals 4 Mains terminals Illustration 6 7 2 drive System Mains Terminals Side and Front Views Spe...

Page 31: ...7 131 12 3 381 15 0 465 18 3 465 18 3 465 18 3 465 18 3 0 M8 M8 1 Motor jumper busbars module 1 4 Motor jumper busbars module 2 2 Motor terminals 5 Brake terminals 3 Ground terminals Illustration 6 8...

Page 32: ...179 7 1 0 89 3 5 188 7 4 344 13 5 323 12 8 165 6 5 373 14 7 0 311 12 3 286 11 3 416 16 4 291 11 5 0 568 22 4 556 21 9 456 18 0 436 17 2 416 16 4 96 3 8 Illustration 6 9 2 drive System DC Bus and Rela...

Page 33: ...105 800 31 5 1600 63 0 631 24 8 631 24 8 1970 77 6 2200 86 6 2254 88 7 1800 71 0 Illustration 6 10 4 drive System Exterior Dimensions Front Side and Door Opening Views Specifications Design Guide MG37...

Page 34: ...13 0 291 11 5 222 8 7 0 2089 82 2 791 31 1 827 32 5 0 671 26 4 711 28 0 897 35 3 937 36 9 Illustration 6 11 4 drive Jumper Connections Side and Front Views Specifications VLT Parallel Drive Modules 3...

Page 35: ...s jumper busbars modules 3 and 4 2 Mains terminals modules 1 and 2 6 Mains terminals modules 3 and 4 3 Brake terminals modules 1 and 2 7 Ground terminals modules 3 and 4 4 Ground terminals modules 1 a...

Page 36: ...63 14 3 262 10 3 222 8 7 0 40 1 6 Illustration 6 13 4 drive System Mains and Ground Terminals Side View Left and Connecting Ground Terminal View Right Specifications VLT Parallel Drive Modules 34 Danf...

Page 37: ...ls modules 3 and 4 2 Brake terminals modules 1 and 2 6 Brake terminal detail see Illustration 6 15 3 Motor terminals modules 1 and 2 7 Motor terminals modules 3 and 4 4 Motor jumper busbars module 3 a...

Page 38: ...0 5 0 2 3x 25 1 0 36 1 4 Illustration 6 15 4 drive System Motor and Brake Terminals Side View Left Motor Terminals Top Right and Brake Terminals Bottom Right Specifications VLT Parallel Drive Modules...

Page 39: ...5 1471 57 9 1511 59 5 344 13 6 323 12 7 166 6 5 135 5 3 0 4x 88 3 5 188 7 4 175 6 9 137 5 4 274 10 8 627 24 7 980 38 6 1427 56 2 4x 96 3 8 1 Ground jumper busbars module 1 2 Grounding shield module 1...

Page 40: ...427 16 8 456 18 0 291 11 5 286 11 3 311 12 3 331 13 0 436 17 2 416 16 4 373 14 7 Illustration 6 17 4 drive System DC Bus and Relays Side View Specifications VLT Parallel Drive Modules 38 Danfoss A S...

Page 41: ...ntinuous at 460 V kVA 426 470 540 582 621 Continuous at 500 V kVA 463 511 587 632 675 Input current A Continuous at 400 V 567 647 733 787 875 Continuous at 460 500 V 516 580 667 718 759 Power losses W...

Page 42: ...1005 1195 1325 Input current A Continuous at 400 V 964 1090 1227 1422 1675 Continuous at 460 500 V 867 1022 1129 1344 1490 Power losses W Drive modules at 400 V 8810 10199 11632 13253 16463 Drive modu...

Page 43: ...98 448 498 568 600 Continuous at 575 V kVA 343 398 448 498 568 627 Continuous at 690 V kVA 411 478 538 598 681 753 Input current A Continuous at 550 V 355 408 453 504 574 607 Continuous at 575 V 339 4...

Page 44: ...nuous at 690 V 872 1016 1129 1267 1506 Input current A Continuous at 550 V 743 866 962 1079 1282 Continuous at 575 V 711 828 920 1032 1227 Continuous at 690 V 711 828 920 1032 1227 Power losses W Driv...

Page 45: ...540 540 582 582 621 Continuous at 500 V kVA 384 463 468 511 511 587 587 632 632 675 Input current A Continuous at 400 V 463 567 590 647 647 733 684 787 779 857 Continuous at 460 500 V 427 516 531 580...

Page 46: ...kVA 675 771 771 909 909 1005 1005 1195 1195 1325 Input current A Continuous at 400 V 857 964 964 1090 1090 1227 1127 1422 1422 1675 Continuous at 460 V 759 867 867 1022 1022 1129 1129 1344 1344 1490 P...

Page 47: ...89 343 343 398 376 448 Continuous at 575 V 289 343 343 398 378 448 Continuous at 690 V 347 411 411 478 454 538 Input current A Continuous at 550 V 299 355 355 408 381 453 Continuous at 575 V 286 339 3...

Page 48: ...8 498 568 568 600 Continuous at 575 V kVA 408 498 598 568 568 627 Continuous at 690 V kVA 490 598 598 681 681 753 Input current A Continuous at 550 V 413 504 504 574 574 607 Continuous at 575 V 395 48...

Page 49: ...1 1056 1056 1255 Continuous at 690 V kVA 753 872 872 1016 1016 1129 1129 1267 1267 1506 Input current A Continuous at 550 V 642 743 743 866 866 962 1079 1079 1079 1282 Continuous at 575 V 613 711 711...

Page 50: ...56 516 482 554 554 610 Continuous at 460 V kVA 353 426 430 470 470 540 540 582 582 621 Continuous at 500 V kVA 384 463 468 511 511 587 587 632 632 675 Input current A Continuous at 400 V 463 567 590 6...

Page 51: ...7 924 924 1100 1100 1219 Continuous at 500 V kVA 675 771 771 909 909 1005 1005 1195 1195 1325 Input current A Continuous at 400 V 857 964 964 1090 1090 1227 1227 1422 1422 1675 Continuous at 460 500 V...

Page 52: ...76 448 409 498 Continuous at 575 V kVA 289 343 343 398 378 448 408 498 Continuous at 690 V kVA 347 411 411 478 454 538 490 598 Input current A Continuous at 550 V 299 355 355 408 381 453 413 504 Conti...

Page 53: ...550 V kVA 498 568 568 600 Continuous at 575 V kVA 498 568 568 627 Continuous at 690 V kVA 598 681 681 753 Input current A Continuous at 550 V 504 574 574 607 Continuous at 575 V 482 549 549 607 Conti...

Page 54: ...1056 1255 Continuous at 690 V kVA 753 872 872 1016 1016 1129 1129 1267 1267 1506 Input current A Continuous at 550 V 642 743 743 866 866 962 1079 1079 1079 1282 Continuous at 575 V 613 711 711 828 828...

Page 55: ...voltage 0 100 of supply voltage Output frequency 0 590 Hz Switching on output Unlimited Ramp times 1 3600 s Torque characteristics Overload torque constant torque Maximum 150 for 60 s1 Starting torqu...

Page 56: ...to control terminals flexible wire with cable end sleeves 1 mm2 18 AWG Maximum cross section to control terminals flexible wire with cable end sleeves with collar 0 5 mm2 20 AWG Minimum cross section...

Page 57: ...itch S202 ON I Current level 0 4 20 mA scalable 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...

Page 58: ...ut voltage 24 V 1 3 V Maximum load 200 mA The 24 V DC supply is galvanically isolated from the supply voltage PELV but has the same potential as the analog and digital inputs and outputs Relay outputs...

Page 59: ...op 30 4000 RPM error 8 RPM Speed accuracy closed loop depending on resolution of feedback device 0 6000 RPM error 0 15 RPM All control characteristics are based on a 4 pole asynchronous motor Control...

Page 60: ...ing for Altitude Below 1000 m 1000 m 3281 ft derating is not necessary Above 1000 m 1000 m 3281 ft the ambient temperature TAMB or maximum output current IMAX must be derated in accordance with Illust...

Page 61: ...60 AVM only switches 2 3 of the time whereas SFAVM switches throughout the whole period The maximum switching frequency is 16 kHz for 60 AVM and 10 kHz for SFAVM Voltage range Switching pattern High...

Page 62: ...uency 250 kW at 690 V AC 300 hp at 575 V AC Voltage range Switching pattern High overload HO 150 Normal overload NO 110 380 500 V 60 AVM 130BX481 10 Iout fsw kHz o 70 80 90 1 60 100 110 2 3 4 5 4 5 50...

Page 63: ...0 C 55 C 0 0 o 1 0 1 5 2 5 4 0 3 0 3 5 5 5 4 5 5 0 50 o 45 C SFAVM 130BX491 10 Iout fsw kHz o 70 80 90 0 5 60 100 110 2 0 50 C 55 C 0 0 o 1 0 1 5 2 5 4 0 3 0 3 5 o 45 C 130BX492 10 o 70 80 90 0 5 Iout...

Page 64: ...according to the application requirements by using the ordering number system shown in Table 7 1 and Table 7 2 Order standard frequency converters and frequency converters with integral options by se...

Page 65: ...AC T 7 525 690 V AC Enclosure 13 15 E00 IP00 C00 IP00 stainless steel back channel RFI filter hardware 16 17 P2 Parallel drive RFI filter class A2 6 pulse P4 Parallel drive RFI filter class A1 6 pulse...

Page 66: ...scade Controller MCO 101 BZ VLT Safe PLC I O MCB 108 B0 VLT Analog I O MCB 109 B2 VLT PTC Thermistor Card MCB 112 B4 VLT Sensor Input MCB 114 B6 VLT Safety Option MCB 150 B7 VLT Safety Options MCB 151...

Page 67: ...2841 130B2842 315 429 450 450 400 410 1 5 130B2851 130B2852 130B2841 130B2842 400 523 500 500 500 500 1 5 130B2853 130B2854 130B2844 130B2845 450 596 600 570 560 570 1 5 130B2853 130B2854 130B2844 130...

Page 68: ...157 130B4129 130B4151 560 763 750 730 710 730 1 5 2x130B4142 2x130B4143 130B4129 130B4151 670 889 950 850 800 850 1 5 2x130B4142 2x130B4143 130B4125 130B4126 750 988 1050 945 2x130B4142 2x130B4143 130...

Page 69: ...F039 11 1 3 2 4 5 1 Drive module 4 Cabinet 2 2 Cabinet 1 5 Cables 3 Filter Illustration 7 2 Filter Configuration With Common Busbars Common Ordering Information Design Guide MG37N102 Danfoss A S 6 201...

Page 70: ...MCB 101 Options Module 7 3 1 Galvanic Isolation in the VLT General Purpose I O MCB 101 Digital analog inputs are galvanically isolated from other inputs outputs on the MCB 101 and in the control card...

Page 71: ...Resolution for analog inputs 10 bit sign Accuracy of analog inputs Maximum error 0 5 of full scale Bandwidth VLT AutomationDrive FC 302 100 Hz 7 3 4 Digital Outputs Terminal X30 6 7 Digital Output Nu...

Page 72: ...Encoder Input MCB 102 Enlarged LCP fixture and enlarged terminal cover The encoder option does not support VLT AutomationDrive FC 302 frequency converters manufactured before week 50 2004 Minimum sof...

Page 73: ...ft Us 7 12V red GND blue COS pink REFCOS black SIN white REFSIN brown Data RS 485 gray Data RS 485 green 1 2 3 12 7 5 4 6 8 9 10 11 130BA164 10 Illustration 7 7 SinCos Encoder HIPERFACE 130BA119 10 B...

Page 74: ...1 1 x 0 5 Secondary input voltage Maximum 4 Vrms Secondary load Approximately 10 k Table 7 11 Resolver Specifications Resolver Input SW ver X XX MCB 103 Code No Option B Rotor Resolver stator Motor L...

Page 75: ...ciple 3 Flux with feedback Parameter 1 10 Motor Construction 1 PM non salient SPM Parameter 1 24 Motor Current Nameplate Parameter 1 25 Motor Nominal Speed Nameplate Parameter 1 26 Motor Cont Rated To...

Page 76: ...nd enlarged terminal cover Label for covering access to switches S201 A53 S202 A54 and S801 Cable strips for fastening cables to relay module 1 IMPORTANT The label MUST be placed on the LCP frame to m...

Page 77: ...A Maximum cable length 75 m 246 ft Input capacitance load 10 uF Power up delay 0 6 s The inputs are protected Terminal numbers Terminal 35 24 V DC external supply Terminal 36 24 V DC external supply W...

Page 78: ...a DI of a mounted option must be set to PTC Card 1 80 Parameter 5 19 Terminal 37 Safe Stop must be configured to the desired Safe Torque Off functionality Default is 1 Safe Stop Alarm MS 220 DA 11 10...

Page 79: ...ollution degree 2 Measurement isolation voltage Vbis 690 V Galvanic isolation until Vi 500 V Permanent ambient temperature 20 C 4 F 60 C 140 F EN 60068 2 1 Dry heat Moisture 5 95 no condensation allow...

Page 80: ...ignals in the relays as long as there is 1 unused relay in between To set up MCB 113 use parameter groups 5 1 Digital Inputs 6 7 Analog Output 3 6 8 Analog Output 4 14 8 Options 5 4 Relays and 16 6 In...

Page 81: ...tage UPEAK and the ripple current I to the motor The filter results in the current and voltage becoming almost sinusoidal which reduces the acoustic motor noise The ripple current in the sine wave fil...

Page 82: ...ommunication standard RS485 Table 7 13 Technical Data for Mounting an LCP to the IP66 Enclosure Max R2 0 08 Panel cut out Min 72 2 8 130BA139 11 129 5 0 5 mm 64 5 0 5 mm 2 54 0 04 in 5 1 0 04 in Illus...

Page 83: ...urrent Physical Dimensions Weight Ambient operating conditions Temperature Altitude Humidity Air quality dust Derating requirements Enclosure size Input Cables Type Length Fuses Type Size Rating Optio...

Page 84: ...r Type Rating Voltage Options Special tools and equipment Moving and storage Mounting Connection of mains Table 7 14 System Design Checklist Ordering Information VLT Parallel Drive Modules 82 Danfoss...

Page 85: ...the operation of electronic devices in potentially explosive atmospheres Class d specifies that if a spark occurs it is contained in a protected area Class e prohibits any occurrence of a spark Motors...

Page 86: ...or corrosion of metal parts Excessive dust particle levels are often found on instal lation cabinets and existing electrical installations One indicator of aggressive airborne gases is blackening of c...

Page 87: ...ve module is powered on In each drive module the power card provides DC voltage to power the fans The mixing fan is powered by 24 V DC from the main switch mode power supply The heat sink fan and the...

Page 88: ...ircuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage 600 V maximum for 690 V units when protected by fuses with the standard configuration Refer to ch...

Page 89: ...N500 N560 aR 2000 4 N560 N630 aR 2000 4 N630 N710 aR 2500 4 N710 N800 aR 2500 4 N800 N1M0 aR 2500 Table 8 3 6 Pulse Drive Systems 380 500 V AC Number of drive modules FC 302 FC 102 FC 202 Recommended...

Page 90: ...mmended fuse maximum 2 N250 N315 630 A 2 N315 N355 630 A 2 N355 N400 630 A 2 N400 N450 800 A 2 N450 N500 800 A 4 N500 N560 900 A 4 N560 N630 900 A 4 N630 N710 1600 A 4 N710 N800 1600 A 4 N800 N1M0 160...

Page 91: ...d reduces the radiated interference it increases the low frequency interference on the mains Connect the motor cable shield to the frequency converter enclosure and to the motor enclosure To connect t...

Page 92: ...type Conducted emission Radiated Emission Standards and requirements1 EN IEC 61800 3 Category C2 Category C3 Category C2 Category C3 P2 P4 FC 302 No 150 m No Yes P6 P8 FC 302 150 m 492 ft 150 m 492 ft...

Page 93: ...9 2 Illustration 9 2 Electrical Diagram of RFI Filter 10 1 1 30 0 20 40 60 80 100 120 dBm 130BF079 10 Illustration 9 3 Attenuation Requirement for an External Filter EMC and Harmonics Design Guide MG...

Page 94: ...V 60 dB V 50 dB V 40 dB V 30 dB V 20 dB V 10 dB V 83 9 dB V 202 kHz M1 1 0 000 s Illustration 9 4 Conducted Emission on the Mains in P4 P8 Configuration Without an External RFI Filter EMC and Harmonic...

Page 95: ...Start 150 0 kHz Stop 30 0 MHz 1 MHz 87 31 dB V 202 kHz M1 1 0 000 s TF A_QP A_AVG Illustration 9 5 Conducted Emission on the Mains in P4 P8 Configuration Without an External RFI Filter EMC and Harmon...

Page 96: ...kHz Stop 30 0 MHz 1 MHz 79 81 dB V 202 kHz M1 1 0 000 s A_QP A_AVG 130BF065 10 TF Illustration 9 6 Conducted Emission on the Mains in P4 P8 Configuration Without an External RFI Filter EMC and Harmoni...

Page 97: ...ncy converters installed in an industrial environment with a supply voltage lower than 1000 V Class A Group 2 C4 Frequency converters installed in an industrial environment with a supply voltage equal...

Page 98: ...ients Simulation of interference brought about by switching a contactor relay or similar devices EN IEC 61000 4 5 Surge transients Simulation of transients brought about by lightning strikes near inst...

Page 99: ...ground at both ends for motor cables and for control cables Sometimes it is not possible to connect the shield in both ends If so connect the shield at the frequency converter See also chapter 9 5 2 G...

Page 100: ...net 9 5 1 Using Shielded Control Cables Danfoss recommends braided shielded armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables The ability of a ca...

Page 101: ...1 101 102 104 103 105 a b c d e f g The lower the Z the better the cable screening performance Transfer impedance Z t mOhm m a Aluminum clad with copper wire b Twisted copper wire or armored steel wir...

Page 102: ...9 12 Shielding without Using Terminal 61 9 6 General Aspects of Harmonics Non linear loads such as found with 6 pulse frequency converters do not draw current uniformly from the power line This non s...

Page 103: ...stribution System Harmonic currents drawn by non linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system Higher impedances result in highe...

Page 104: ...Frequency Conducted Disturbances and Signaling in Industrial Plants states the requirements for compatibility levels in industrial and private networks The standard further defines the following 3 cla...

Page 105: ...Individual Load Voltage at the PCC Allowable individual harmonic voltages Allowable THD V VLine 69 kV 3 5 Table 9 13 Allowable Voltage THD at the PCC for all Loads Harmonic currents must be limited t...

Page 106: ...equirements are described in the EN 61800 5 1 standard To maintain PELV all connections made to the control terminals must be PELV The components that make up the electrical isolation also comply with...

Page 107: ...shield ends increase the shield impedance at higher frequencies which reduces the shield effect and increases the leakage current To avoid twisted shield ends use integrated shield clamps Refer to Ill...

Page 108: ...X certificate to protect motors in explosion hazardous areas Zone 1 21 and Zone 2 22 When parameter 1 90 Motor Thermal Protection set to 20 ATEX ETR is combined with the use of MCB 112 it is possible...

Page 109: ...e module has a brake fault jumper connector on the top plate which is used to connect the Klixon thermal switch on the brake resistors See Illustration 10 6 This connector has a pre installed jumper T...

Page 110: ...ctory setting is for clockwise rotation with the drive system output connected as follows Terminal number Function 96 Mains U T1 97 V T2 98 W T3 99 Ground Table 10 3 Motor Cable Terminals Changing mot...

Page 111: ...motor terminals 130BE742 10 R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 5 6 7 8 1 2 3 4 1 DC fuses 5 DC link busbars 2 Drive modules 6 DC terminals 3 Mains input busbars 7 Brak...

Page 112: ...fuses 5 DC link busbars 2 Drive modules 6 DC terminals 3 Motor output busbars 7 Brake terminals 4 Mains input terminals 8 Motor output terminals Illustration 10 9 Connections in 12 Pulse 2 Drive Modu...

Page 113: ...R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 1 2 3 4 5 6 7 8 9 1 DC fuses 6 DC terminals 2 Drive module 7 Brake terminals 3 Mains input busbars...

Page 114: ...d parameter 2 17 Over voltage Control NOTICE OVC cannot be activated when running a PM motor when parameter 1 10 Motor Construction is set to 1 PM non salient SPM Mains dropout During a mains dropout...

Page 115: ...affected if the peak voltage is too high Motor cable length affects the rise time and peak voltage For example if the motor cable is short a few meters the rise time and peak voltage are lower If the...

Page 116: ...th cables connected in a common joint as shown in A and B are only recommended for short cable lengths B Be aware of the maximum motor cable length specified in chapter 6 10 Cable Specifications C The...

Page 117: ...and length of cables for each set of terminals For example do not use 1 cable on one mains terminal and 2 cables on another mains terminal 2 drive module systems Illustration 10 8 and Illustration 10...

Page 118: ...2 7 Brake fault 3 Supplementary fuses 8 Drive module 3 4 Mains input busbars 9 Drive module 4 5 Brake fault 10 Disconnector 2 Illustration 11 1 Connection of 12 Pulse Disconnector Interlock Mains VLT...

Page 119: ...ector 2 4 BRF connector Illustration 11 2 BRF Connection with 12 Pulse Disconnector Interlock NOTICE If the brake option is not selected the Klixon switch can be bypassed NOTICE Danfoss is not respons...

Page 120: ...ng is shielded and reinforced double insulated A 24 V DC supply voltage is recommended See Illustration 12 2 130BF044 10 1 3 6 5 2 7 4 1 Microswitch cable 5 44 pin ribbon cable from MDCIC to drive mod...

Page 121: ...munication connection 2 USB port available for use with the MCT 10 Set up Software 3 2 analog inputs 1 analog output 10 V DC supply voltage and commons for the inputs and output 4 4 programmable digit...

Page 122: ...t a maximum of 500 10 V DC analog supply voltage 15 mA maximum commonly used for potentiometer or thermistor 50 10 V DC 53 Parameter group 6 1 Analog Input 1 Reference Analog input Selectable for volt...

Page 123: ...in open loop see parameter 16 61 Terminal 53 Switch Setting Terminal 54 Feedback signal in closed loop see parameter 16 63 Terminal 54 Switch Setting NOTICE REMOVE POWER Remove power to the frequency...

Page 124: ...e module on the far left to the terminal blocks on the control shelf using an extended wiring harness NOTICE For reference drive modules are numbered from left to right Relay 1 Terminal 01 Common Term...

Page 125: ...gital output terminal 27 or 29 is required Normally this output must be closed for as long as the frequency converter is unable to hold the motor If the frequency converter is brought into an alarm co...

Page 126: ...0 V 1084 V 1109 V 1130 V Table 13 2 Brake Limits for VLT HVAC Drive FC 102 and VLT AQUA Drive FC 202 Parallel Drive Modules Voltage Brake active Warning before cut out Cut out trip 380 500 V 795 V 828...

Page 127: ...latest 120 s The brake can also monitor the power energizing and make sure that it does not exceed the programmable limit set in the LCP NOTICE Monitoring the brake power is not a safety function a th...

Page 128: ...96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 1 Drive module 3 Individual brake resistors 2 Brake terminals Illustration 13 2 Connection of Individual Brake Resi...

Page 129: ...8 R R R 91 S 92 T 93 U 96 V 97 W 98 R R R 91 S 92 T 93 U 96 V 97 W 98 R R 1 Drive module 3 Common brake resistor 2 Brake terminals Illustration 13 3 Connection of Common Brake Resistor to Each Drive M...

Page 130: ...n works only in 1 speed direction The torque is calculated from the current measurement within the frequency converter See chapter 17 Application Examples Speed torque reference The reference to these...

Page 131: ...fety stop some units 39 Common for analog and digital outputs 42 Analog and digital outputs for indicating values such as frequency reference current and torque The analog signal is 0 4 to 20 mA at a...

Page 132: ...IN OUT 0 V 24 V 29 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 1 2 ON A53 U I S201 ON 2 1 A54 U I S202 ON 0 20 mA OFF 0 10 V 95 400 VAC 2A P 5 00 R 82 R 81 P RS 485 68 N RS 485 69 COM RS 485 61...

Page 133: ...nce handling system is received and fed through the ramp limitation and speed limitation before being sent to the motor control The output of the motor control is then limited by the maximum frequency...

Page 134: ...l the output frequency The speed PID must be set with its P I and D parameters parameter group 7 0 Speed PID Ctrl To use the process PID control for control of speed or pressure in the controlled appl...

Page 135: ...imits as quickly as possible without losing control of the motor 14 7 Local and Remote Control The frequency converter can be operated manually via the LCP or remotely via analog and digital inputs an...

Page 136: ...omes true This condition leads to an associated action as shown in Illustration 14 8 Par 13 11 Comparator Operator Par 13 43 Logic Rule Operator 2 Par 13 51 SL Controller Event Par 13 52 SL Controller...

Page 137: ...ack Speed Error 100 RPM parameter 4 32 Motor Feedback Loss Timeout 5 s Parameter 7 00 S peed PID Feedback Source 2 MCB 102 Parameter 17 11 Resolution PPR 1024 Parameter 13 00 SL Controller Mode 1 On P...

Page 138: ...reeze output Speed up speed down ref Remote Ref in max ref max ref Scale to RPM or Hz Scale to Nm Scale to process unit Relative X X Y 100 DigiPot DigiPot DigiPot max ref min ref DigiPot D1 P 5 1x 15...

Page 139: ...bed in the programming guide The scaling of analog references is described in parameter groups 6 1 Analog Input 1 and 6 2 Analog Input 2 and the scaling of digital pulse references is described in par...

Page 140: ...these 2 values 15 3 Scaling of Analog and Pulse References and Feedback References and feedback are scaled from analog and pulse inputs in the same way The only difference is that a reference above or...

Page 141: ...Frequency Hz Parameter 5 56 Term 33 High Frequency Hz Table 15 1 P1 and P2 Parameters 15 4 Dead Band Around Zero Sometimes the reference and in rare instances the feedback needs a dead band around zer...

Page 142: ...according to min max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control Range 200 RPM 200 RPM Motor Digital input 19 Low No reversing High Reversing Limits Spee...

Page 143: ...Limited to 100 100 500 RPM 500 RPM Limited to 200 200 1000 RPM 1000 RPM Reference is scaled according to max reference giving a speed Scale to speed 500 RPM 500 RPM Range Speed setpoint Motor control...

Page 144: ...Motor Limits speed to min max motor speed Motor PID RPM Dead band General Reference parameters Reference Range Max Max Minimum Reference Don t care Maximum Reference 1000 RPM 100 0 General Motor para...

Page 145: ...A setting of 0 disables the differentiator Parameter 7 05 Speed PID Diff Gain Limit If there are quick changes in reference or feedback in a given application which means that the error changes swift...

Page 146: ...plete AMA 2 Check that the motor is running and that the encoder is attached properly Do the following Press Hand On Check that the motor is running and note in which direction it is turning positive...

Page 147: ...reference source Parameter 3 15 Reference Resource 1 Not necessary default Scale analog input 53 from 0 RPM 0 V to 1500 RPM 10 V 6 1 Analog Input 1 Not necessary default 6 Configure the 24 V HTL encod...

Page 148: ...30 83 Speed PID Proportional Gain but other factors in the application can limit the parameter 30 83 Speed PID Proportional Gain to a lower value To minimize the overshoot parameter 7 03 Speed PID Int...

Page 149: ...compensated with a speed change Disable this function by selecting 0 Off Parameter 7 32 Process PID Start Speed In some applications reaching the required speed setpoint can take a long time In such c...

Page 150: ...peed Temperature transmitter Heat Heat generating process Cold air 130BA218 10 100kW n C W Illustration 16 3 Example of a Process PID Control Used in a Ventilation System In this example using a venti...

Page 151: ...guration that is the range for handling of references Set scaling of analog input in parameter group 6 Analog In Out Set reference feedback units Set minimum reference 10 C 50 F Set maximum reference...

Page 152: ...and reduce the value until the feedback signal begins to vary continuously Increase the integration time until the feedback signal stabilizes followed by an increase of 15 50 4 Only use parameter 7 3...

Page 153: ...a Stability Boundary Use the control settings described below for initial tuning The process operator can then fine tune the control as necessary Step by step description 1 Select only proportional c...

Page 154: ...1 AMA with T27 Connected Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB930 10 Function Setting Parame...

Page 155: ...19 T erminal 37 Safe Stop 1 Safe Torque Off Alarm Default value Notes comments If parameter 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 17...

Page 156: ...D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB928 10 Function Setting Parameter 5 11 T erminal 19 Digital Input 1 Reset Defa...

Page 157: ...Up Down Start 18 Freeze ref 27 Speed up 29 Speed down 32 Speed Reference 130BB840 11 Illustration 17 3 Speed Up Down 17 7 RS485 Network Connection Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN...

Page 158: ...parameter 4 32 Motor Feedback Loss Timeout 5 s Parameter 7 00 S peed PID Feedback Source 2 MCB 102 Parameter 17 11 Resolution PPR 1024 Parameter 13 00 SL Controller Mode 1 On Parameter 13 01 Start Ev...

Page 159: ...Time Current 1 71 1 71 2 21 2 21 1 76 Open Closed 130BB842 10 Illustration 17 4 Mechanical Brake Control 17 11 Encoder Connection Before setting up the encoder the basic settings for a closed loop sp...

Page 160: ...t the torque limit and a stop command is activated the system activates terminal 29 Output programmed to 27 Torque limit stop The signal to terminal 27 changes from logic 1 to logic 0 and the motor st...

Page 161: ...e the guidelines were not followed is used in a contradictory manner to the instructions provided is a result of normal wear and tear 18 2 Conventions Numbered lists indicate procedures Bullet lists i...

Page 162: ...vanced Vector Control If compared with standard voltage frequency ratio control Advanced Vector Control improves the dynamics and the stability both when the speed reference is changed and in relation...

Page 163: ...102 GLCP lsb Least significant bit MCM Short for mille circular mil an American measuring unit for cable cross section 1 MCM 0 5067 mm2 msb Most significant bit NLCP Numerical local control panel LCP...

Page 164: ...commands parameter group Thermistor A temperature dependent resistor placed where the temperature is monitored frequency converter or motor THD Total harmonic distortion A state of full harmonic disto...

Page 165: ...23 160 Resistor switch 107 Breakaway torque 19 160 Broken belt 22 Bus termination switch 121 Busbars 84 C Cabinet heater 83 Cable Clamp 97 Control 97 98 100 Equalizing 100 Motor 97 108 Shielded 98 100...

Page 166: ...iciency 53 Energy efficiency class 53 ETR 161 Export control regulations 8 External 24 V DC supply 75 External alarm reset 154 External safety device 20 Extreme running conditions 112 F Fans 17 85 Fee...

Page 167: ...ke control 157 Mechanical holding brake 123 Moment of inertia 112 Motor Bypass 19 Cable 97 108 Calculation variables 160 Feedback 132 Full torque function 18 Insulation 105 Low high current 21 Low hig...

Page 168: ...C 95 Residential environment 95 Residual current device 161 Resolver 72 Resonance bypass 19 Resonance damping 17 Restart 18 Rise time 113 RS485 Network connection 155 Serial communication 121 S Safe T...

Page 169: ...ip 162 Type code 62 U UL compliance 88 User defined event 134 V Variables defined in 160 VLT Extended I O 68 VLT Extended Input 70 VLT Extended Relay Card 78 VLT PTC Thermistor Card 76 VLT Relay Card...

Page 170: ...ducts already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the res...

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