Danfoss VLT 5000 User Manual Download

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Contents

1. General Information

2. Preinstallation

Planning the Installation Site

Receiving the Frequency Converter

Transportation and Unpacking

Lifting

Shipping Weights and Dimensions

3. Installation

Mechanical Installation

Tools Needed

General Considerations

Installation in Enclosures - IP00 / Chassis units

Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units

Floor Mounting - Pedestal Installation IP21 (NEMA1) and IP54 (NEMA12)

Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)

IP21 Drip shield installation (D1 and D2 enclosure)

Electrical Installation

Control Wires

Power Connections

Mains connection

4. Duct Work Cooling Kit for IP00 Units

5. Installation on Pedestal - IP 21 / IP 54 Units

6. Start-Up Check

Connection Examples

Electrical Installation Procedures

Programming Procedures - VLT 5000

Programming Procedures - VLT 6000 HVAC, VLT 8000 AQUA and VLT 4000

Motor Start

7. Service During Use

8. Drawings

Index

VLT

5000/6000/8000

High Power Installation Guide

Contents

MI.90.J2.02 - VLT

is a registered Danfoss trademark

Summary of Contents for VLT 5000

Page 1: ...P54 NEMA12 20 Gland Conduit Entry IP21 NEMA 1 and IP54 NEMA12 21 IP21 Drip shield installation D1 and D2 enclosure 22 Electrical Installation 23 Control Wires 23 Power Connections 25 Mains connection 34 4 Duct Work Cooling Kit for IP00 Units 35 5 Installation on Pedestal IP 21 IP 54 Units 43 6 Start Up Check 47 Connection Examples 47 Electrical Installation Procedures 47 Programming Procedures VLT...

Page 2: ...1 General Information VLT 5000 6000 8000 High Power Installation Guide 2 MI 90 J2 02 VLT is a registered Danfoss trademark 1 ...

Page 3: ...ion is desired set parameter 128 to data value ETR trip or data value ETR warning For VLT 6000 VLT 8000 and VLT 4000 set parameter 117 to data value ETR trip or data value ETR warning Note The function is initialised at 1 16 x rated motor current and rated motor frequency see the Operating Instructions The ETR functions provide class 20 motor overload protection in accordance with NEC North Americ...

Page 4: ...nt parameters for brake control have been defined Select output in parameters 319 321 323 or 326 and cut in current and frequency in parameters 223 and 225 1 1 5 Use on Isolated Mains See section RFI Switch in the Operating Instructions regarding use on isolated mains It is im portant to follow the recommendations regarding installation on IT mains including isolated delta systems since sufficient...

Page 5: ...tion examples Electrical installation procedures short form Motor start As the units are available in different enclosure sizes depending on the rated output power the structure of the instruction is based on these enclosure variants 380 460 480 500 V variants Type Voltage Enclosure D1 Enclosure D2 Enclosure E1 VLT 5000 380 500 V AC VLT 5122 5152 VLT 5202 5302 VLT 5352 5552 VLT 5000 FLUX 380 500 V...

Page 6: ...2 Preinstallation VLT 5000 6000 8000 High Power Installation Guide 6 MI 90 J2 02 VLT is a registered Danfoss trademark 2 ...

Page 7: ...the frequency converter is without built in fuses ensure that the external fuses are rated correctly 2 1 2 Receiving the Frequency Converter When receiving the frequency converter please make sure that the packaging is intact and be aware of any damage that might have occurred to the unit during transport In case damage has occurred contact immediately the shipping company to claim the damage 2 1 ...

Page 8: ...Enclosure D1 1220 650 570 48 25 6 22 4 1730 650 570 53 9 25 6 22 4 Enclosure D2 1490 650 570 58 7 25 6 22 4 1730 650 570 68 1 25 6 22 4 Enclosure E1 1705 831 736 67 1 32 8 29 0 2197 840 736 86 5 33 1 29 0 Table 2 2 Card board box size Shipping dimensions width hight depth in mm in The units are shipped laying down and the above dimensions are according to this The dimen sions include the skid wher...

Page 9: ...uits or cable glands in IP 21 and IP 54 units Lifting bar to lift the unit rod or tube Ø 20 mm 0 75 inch able to lift minimum 400 kg 880 lbs Crane or other lifting aid to place the frequency converter in position A Torx T50 tool is needed to install the E1 enclosure in IP21 and IP54 enclosure variants 3 1 2 General Considerations Space Ensure proper space above and below the frequency converter to...

Page 10: ...ft Enclosure IP21 54 D1 and D2 Right Enclosure IP00 D1 D2 and E1 Illustration 3 4 Airflow direction and necessary space for cooling Enclosure IP21 54 E1 3 Installation VLT 5000 6000 8000 High Power Installation Guide 10 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 11: ...losures Take the following position of the terminals into consideration when you design for cables access Illustration 3 5 Position of power connections Illustration 3 6 Position of power connections Disconnect Be aware that the power cables are heavy and hard to bend Consider the optimum position of the frequency converter for ensuring easy installation of the cables VLT 5000 6000 8000 High Power...

Page 12: ... 361 14 2 K 277 10 9 270 10 6 284 11 2 277 10 9 L 326 12 8 326 12 8 334 13 1 334 13 1 M 243 9 6 243 9 6 250 9 8 250 9 8 N 159 6 3 159 6 3 167 6 6 167 6 6 O 261 10 3 261 10 3 261 10 3 260 10 3 P 170 6 7 170 6 7 170 6 7 169 6 7 Q 120 4 7 120 4 7 120 4 7 120 4 7 R 98 3 8 93 3 7 256 10 1 350 13 8 S 301 11 8 324 12 8 308 12 1 332 13 0 T 245 9 6 255 10 0 252 9 9 262 10 3 U 189 7 4 185 7 3 196 7 7 192 7 ...

Page 13: ... consideration when designing the cable access Illustration 3 7 IP00 enclosure power connection positions Illustration 3 8 IP00 enclosure power connection positions VLT 5000 6000 8000 High Power Installation Guide 3 Installation MI 90 J2 02 VLT is a registered Danfoss trademark 13 3 ...

Page 14: ...ons positions of disconnect switch Illustration 3 10 IP21 NEMA Type 1 and IP54 NEMA Type 12 enclosure power connection positions 3 Installation VLT 5000 6000 8000 High Power Installation Guide 14 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 15: ...power connection positions detail B Illustration 3 12 IP21 NEMA type 1 and IP54 NEMA type 12 enclosure power connection position of disconnect switch VLT 5000 6000 8000 High Power Installation Guide 3 Installation MI 90 J2 02 VLT is a registered Danfoss trademark 15 3 ...

Page 16: ...les Each terminal allows use of up to 4 cables with cable lugs or use of standard box lug Earth is connected to relevant termination point in the drive Illustration 3 13 Terminal in details Illustration 3 14 Position of earth terminals IP00 3 Installation VLT 5000 6000 8000 High Power Installation Guide 16 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 17: ...ow The necessary airflow over the heat sink must be secured The flow rate is shown below Enclosure Door fan Top fan air flow Airflow over heatsink IP00 Chassis D1 and D2 255 m3 h 150 cfm 765 m3 h 450 cfm E1 255 m3 h 150 cfm 1444 m3 h 850 cfm IP21 NEMA 1 IP54 NEMA 12 D1 and D2 170 m3 h 100 cfm 765 m3 h 450 cfm E1 340 m3 h 200 cfm 1444 m3 h 850 cfm Table 3 2 Heat Sink Air Flow VLT 5000 6000 8000 Hig...

Page 18: ...e 2000 mm 176F1826 176F1825 176F1850 Table 3 3 Duct Kit Ordering Numbers Back cooling Using the channel from the back allows easy installation in for example control rooms The unit mounted to the backside of the enclosure allows a similar easy cooling of the units as the duct cooling principle The hot air is ventilated out of the back of the enclosure This offers a solution where the hot cooling a...

Page 19: ... 1 and IP54 NEMA 12 Units This only applies for D1 and D2 enclosures It must be considered where to install the unit Take the relevant points into consideration before you select the final installation site Free space for cooling Access to open the door Cable entry from the bottom Mark the mounting holes carefully using the mounting template on the wall and drill the holes as indicated Ensure prop...

Page 20: ...frequency converters can also be installed on a pedestral Details can be found later in a later section of this Installation Guide and in the information included in the Pedestal kit D1 and D2 enclosures Ordering No 176F1827 Illustration 3 19 Drive on Pedestal 3 Installation VLT 5000 6000 8000 High Power Installation Guide 20 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 21: ...54 NEMA12 Cables are connected through the gland plate from the bottom Remove the plate and plan where to place the entry for the glands or conduits Prepare holes in the marked area on the drawing The gland plate must be fitted to the frequen cy converter to ensure the specified protection degree as well as ensuring proper cooling of the unit If the gland plate is not mounted it may trip the unit ...

Page 22: ...equency converter is placed on the pedestal Illustration 3 24 Mounting of bottom plate E1 enclosure 3 1 7 IP21 Drip shield installation D1 and D2 enclosure To comply with the IP21 rating a separate drip shield is to be installed as explained be low Remove the two front screws Insert the drip shield and replace screws Torque the screws to 5 6 Nm 50 in lbs Illustration 3 25 Drip shield installation ...

Page 23: ... fieldbus from the top of the unit as shown on the pic ture below On the IP 21 NEMA 1 unit a cover plate must be removed Illustration 3 27 Top connection for fieldbus Installation of 24 Volt external DC Supply Torque 0 5 0 6 Nm 5 in lbs Screw size M3 No Function 35 36 24 V external DC supply 24 V external DC supply can be used as low voltage supply to the control card and any option cards installe...

Page 24: ...ure correct galvanic isolation type PELV on the control terminals of the frequency converter Relay output Torque 0 5 0 6 Nm 5 in lbs Screw size M3 No Function 1 3 Relay output 1 3 break 1 2 make See the Operating In structions 4 5 Relay output 4 5 make See the Operating Instructions 3 Installation VLT 5000 6000 8000 High Power Installation Guide 24 MI 90 J2 02 VLT is a registered Danfoss trademark...

Page 25: ...tions for details For protection of the frequency converter the recommended fuses must be used or the unit must be with built in fuses Recommended fuses can be seen in the Operating Instructions Always ensure that proper fusing is made according to local regulation Illustration 3 28 Compact IP 00 Chassis enclosure D1 VLT 5000 6000 8000 High Power Installation Guide 3 Installation MI 90 J2 02 VLT i...

Page 26: ... enclosure D1 with disconnect fuse and RFI filter Illustration 3 30 Compact IP 00 Chassis with disconnect fuse and RFI filter enclosure D2 3 Installation VLT 5000 6000 8000 High Power Installation Guide 26 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 27: ... and IP 54 NEMA 12 with disconnect fuse and RFI filter enclo sure D2 Illustration 3 32 Compact IP 00 Chassis enclosure E1 VLT 5000 6000 8000 High Power Installation Guide 3 Installation MI 90 J2 02 VLT is a registered Danfoss trademark 27 3 ...

Page 28: ... 00 Chassis with disconnect fuse and RFI filter enclosure E1 Illustration 3 34 Position of earth terminals IP00 3 Installation VLT 5000 6000 8000 High Power Installation Guide 28 MI 90 J2 02 VLT is a registered Danfoss trademark 3 ...

Page 29: ... 1 and IP 54 NEMA 12 enclosure E1 Illustration 3 36 Position of earth terminals IP21 NEMA type 1 and IP54 NEMA type 12 VLT 5000 6000 8000 High Power Installation Guide 3 Installation MI 90 J2 02 VLT is a registered Danfoss trademark 29 3 ...

Page 30: ...ith In the case of an earth fault a DC content may develop in the faulty current If ELCB relays are used local regulations must be observed Relays must be suitable for protection of 3 phase equipment with a bridge rectifier and for a brief discharge on power up See also the section Special Conditions in the relevant Design Guide 3 2 5 RFI Switch Mains supply isolated from earth If the frequency co...

Page 31: ... M10 Brake 9 5 84 in lbs M8 Table 3 4 Torque for terminals 3 2 7 Shielded Cables It is important that shielded and armoured cables are connected in a proper way to ensure high EMC immunity and low emissions Connection can be made with either cable glands or clamps EMC cable glands Generally available cable glands can be used to ensure an optimum EMC connection EMC cable clamp Clamps allowing easy ...

Page 32: ... the brake resistor Size the brake cable cross section to match the brake torque See also Brake instructions MI 90 FX YY and MI 50 SX YY for further information regarding safe installation Please note that voltages up to 1099 V DC depending on the supply voltage may occur on the terminals 3 2 10 Brake Resistor Temperature Switch Torque 0 5 0 6 Nm 5 in lbs Screw size M3 This input can be used to mo...

Page 33: ...o the DC bar is 25 metres 82 feet Load sharing enables linking of the DC intermediate circuits of several frequency converters Please note that voltages up to 1099 V DC may occur on the terminals Load sharing calls for extra equipment For further information please consult Load sharing Instructions MI 50 NX XX Illustration 3 38 Load sharing connection 3 2 12 Shielding against Electrical Noise Befo...

Page 34: ... the correct current rating 3 2 14 External Fan Supply In case DC supplies the frequency converter or the fan must run independently of the power supply an external power supply can be applied The connection is done to the power card Terminal No Function 100 101 102 103 Auxiliary supply S T Internal supply S T The connector located on the power card provides the connection of line voltage for the ...

Page 35: ... suitable for use only with IP 00 Chassis frequency converters in Rittal TS8 IP 20 and UL and NEMA 1 and IP 54 and UL and NEMA 12 enclosures The duct work shown is for D1 and d2 enclosures The duct work for E1 enclosures has a different look but is installed in the same way For the E1 enclosures it is important to mount the plate at the absolute rear of the Rittal enclosure due to the weight of th...

Page 36: ...he Rittal enclosure The template is referenced to the top left corner of the back panel Therefore the template may be used with any size back panel and both the 1800 mm and 2000 mm high enclosures Illustration 4 2 Openings on rear not used in this application Before installing the back panel in the enclo sure assemble the gasket on both sides of the bottom duct adapter as shown below and in stall ...

Page 37: ...e Rittal TS8 enclosure remove and discard the rearmost 5 screws see illustration below located on the top cov er of the frequency converter The holes will be used to fasten the top ductwork with longer screws provided with the kit Illustration 4 7 Top of IP 00 Chassis frequency converter Install the back panel in the enclosure see illustration below Use Rittal PS4593 000 brackets minimum one per s...

Page 38: ... partially as sembled with frequency converter bracket Temporarily install the top duct section as shown above Use the top duct cover piece to mark the enclosure top for the opening Alternatively the mounting template supplied drawing can be used to make the enclosure cut out Illustration 4 12 Rittal enclosure top with cutout Standard Rittal enclosures top is cut Gasket is not used on the cutout G...

Page 39: ... on the frequency converter The top duct work is attached to the frequency converter using existing holes on the top cover of the frequency converter Use the longer T25 screws provided with the kit in the existing frequency converter top cover holes The duct work will fit over the frequency converter mounting bolts Once the ductwork is attached to the frequency converter the duct closing plate can...

Page 40: ...m duct collar is bolted to the duct using 3 T25 screws in the outermost holes of the brackets Tighten the screws to compress the gasket Illustration 4 23 Bottom ductwork pieces Illustration 4 24 Bottom ductwork partially as sembled Illustration 4 25 Completely assembled bottom duct work The duct assembly is used to mark the bottom cutout Temporarily install the bottom duct work as shown to the rig...

Page 41: ...on 4 28 Bottom ductwork installed Illustration 4 29 Installation of bottom duct After the bottom ductwork has been posi tioned in place remove the three T25 screws from the outer holes in the mounting brackets on the sides and front of ductwork and move them to the inner holes of the same brackets Tighten the three screws to the specified tor que The bottom duct work is not fastened to Rittal encl...

Page 42: ...Illustration 4 31 Bottom duct installed 4 Duct Work Cooling Kit for IP00 Units VLT 5000 6000 8000 High Power Installation Guide 42 MI 90 J2 02 VLT is a registered Danfoss trademark 4 ...

Page 43: ...o the power components The frequency converter gland plate must be installed to provide adequate cooling air to the control components of the frequency converter via the door fan and to maintain the IP21 NEMA 1 or IP54 NEMA 12 degrees of enclosure protections There is one pedestal that fits both frames D1 and D2 Required Tools Required Tools Socket wrench with 7 17 mm sockets T30 Torx Driver Torqu...

Page 44: ...partially assembled The completely assembled pedestal with ven ted front cover and two side covers installed Multiple frequency converters may be moun ted side by side The interior side closing plates are left off NOTE The front and side cover mounting screws are now recessed M6 Torx socket flat head screws Illustration 5 4 Final assambled pedestal Install the frequency converter by lowering on to...

Page 45: ...de Illustration 5 7 Three front screws Illustration 5 8 Frame D2 with pedestal installed VLT 5000 6000 8000 High Power Installation Guide 5 Installation on Pedestal IP 21 IP 54 Units MI 90 J2 02 VLT is a registered Danfoss trademark 45 5 ...

Page 46: ...6 Start Up Check VLT 5000 6000 8000 High Power Installation Guide 46 MI 90 J2 02 VLT is a registered Danfoss trademark 6 ...

Page 47: ...your VLT fre quency converter Before you start please read the safety instructions on the first page of this instruction Note that the user is responsible that the VLT frequency converter motor and other units are installed according to recognized local regulations Pay special attention to cable dimensioning pre fuses earthing and over current protection 1 Mechanical installation check Check the f...

Page 48: ... and mains supply connections NOTE Only supplied on drives with an RFI filter 6 Mains connection 1 Check that the mains voltage matches the VLT frequency converter nominal input volt age 2 Ensure that the power supply can supply the necessary current to the VLT frequency converter see Technical data in the relevant Operating Instructions 3 Install earth from the power supply to the earthing point ...

Page 49: ... Choose parameters by means of and Press CHANGE DATA to change parameter value Data values are changed using and Press or to move the cursor Press OK to save parameter setting Set the desired language in parameter 001 Set motor parameters according to the motor plate Motor power Parameter 102 Motor voltage Parameter 103 Motor frequency Parameter 104 Motor current Parameter 105 Rated motor speed Pa...

Page 50: ...LT 8000 Press HAND START to start the motor Set motor speed in parameter 003 by VLT 5000 Set motor speed with the keys on LCP of VLT 6000 VLT 8000 and VLT 4000 Check if the direction of rotation is as shown in the display It can be changed by swapping two phases of the motor cable VLT 5000 Press STOP to stop the motor VLT 4000 VLT 6000 VLT 8000 Press OFF STOP to stop the motor Select total or redu...

Page 51: ...erter Remember to switch off the frequency converter before cleaning Checking connections Measuring the temperature on power connections with a thermal camera or infrared meter is recommended as a preventive maintenance activity Early detection of changes in the power con nections to the frequency converter allows relevant action to avoid overheating connections and in worst case stops Checking te...

Page 52: ...8 Drawings VLT 5000 6000 8000 High Power Installation Guide 52 MI 90 J2 02 VLT is a registered Danfoss trademark 8 ...

Page 53: ...8 Drawings Mechanical detailed drawing VLT 5000 6000 8000 High Power Installation Guide 8 Drawings MI 90 J2 02 VLT is a registered Danfoss trademark 53 8 ...

Page 54: ...8 Drawings VLT 5000 6000 8000 High Power Installation Guide 54 MI 90 J2 02 VLT is a registered Danfoss trademark 8 ...

Page 55: ...VLT 5000 6000 8000 High Power Installation Guide 8 Drawings MI 90 J2 02 VLT is a registered Danfoss trademark 55 8 ...

Page 56: ...8 Drawings VLT 5000 6000 8000 High Power Installation Guide 56 MI 90 J2 02 VLT is a registered Danfoss trademark 8 ...

Page 57: ...VLT 5000 6000 8000 High Power Installation Guide 8 Drawings MI 90 J2 02 VLT is a registered Danfoss trademark 57 8 ...

Page 58: ...s Connection 23 Floor Mounting 20 Fusing 25 I Installation Of 24 Volt External Dc Supply 23 Installation On Pedestal 43 Isolated Mains 4 It Mains 30 L Lifting 8 Load Sharing 33 M Mains Connection 34 Mechanical Brake 4 Mechanical Installation 9 Motor Cable 31 Motor Start 50 O Ordering 35 P Pedestal Installation 20 Power Connections 11 Programming Procedures 49 R Rfi Switch 30 Index VLT 5000 6000 80...

Page 59: ...lded Cables 31 T Terminal Locations 11 Torque 31 U Unintended Start 4 Unpacking 7 W Weight And Dimensions 8 Wire Access 11 VLT 5000 6000 8000 High Power Installation Guide Index MI 90 J2 02 VLT is a registered Danfoss trademark 59 ...

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