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Danfoss VLT Ea4, Operating Manual

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1

DC-link terminal and DC fuse

2

MDCIC plug

3

Microswitch connector to DC fuse

4

Relays 1 and 2

5

Brake fault jumper and connector

6

Mains input terminals (inside the unit)

7

Terminal cover

8

Ground terminals

9

Top fan

10

Drive module nameplate. See 

Illustration 2

.

11

Motor output terminals (inside the unit)

12

Back-channel cooling

13

Ground plate

–

–

3.3 Control Shelf

The control shelf contains the local control panel (LCP), MDCIC, and control card. The LCP provides access to the system parameters.
The MDCIC is connected to each of the drive modules via a ribbon cable and communicates to the control card. The control card
controls the operation of the drive modules.

e3

0b

e5

97

.1

1

1

2

3

5

7

8

4

9

11

6

10

12

Illustration 5: Control shelf components

AQ434333248451en-000101 / 130R1286 | 13

Danfoss A/S © 2023.01

Product Overview

VLT Ea4 Parallel Drive Modules

Operating Guide

Summary of Contents for VLT Ea4

Page 1: ...Operating Guide VLT Ea4 Parallel Drive Modules...

Page 2: ......

Page 3: ...Storage 11 Product Overview 12 VLT Ea4 Parallel Drive Modules Basic Kit 12 Drive Modules 12 Control Shelf 13 Wire Harnesses 14 AC Fuses 14 DC Fuses 14 Mechanical Installation 15 Fastener Torque Ratin...

Page 4: ...g the Control Cable to the Control Terminals 32 Disconnecting the Control Cable from the Control Terminals 33 Enabling Motor Operation 33 RS485 Serial Communication 33 Selecting the Voltage Current In...

Page 5: ...nputs 69 STO Terminal 37 69 Analog Inputs 70 Pulse encoder Inputs 70 Analog Output 71 Control Card RS485 Serial Communication 71 Digital Outputs 71 Control Card 24 V DC Output 71 Relay Outputs 71 Cont...

Page 6: ...lowed is used in a contradictory manner to the instructions provided is a result of normal wear and tear N O T I C E OUTPUT FREQUENCY LIMIT The output frequency of the drive is limited to 590 Hz due t...

Page 7: ...HAZARDOUS VOLTAGE AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals Failure to perform installation start up and maintenance by qualified personnel c...

Page 8: ...d conductor with a cross section of at least 10 mm2 8 AWG Cu or 16 mm2 6 AWG Al or an extra ground con ductor of the same cross sectional area as the original ground conductor as specified by IEC 6036...

Page 9: ...ided and property damage can occur if the motor over heats Enable the ETR function See the application guide for more information 1 7 Disposal Do not dispose of equipment containing electrical compone...

Page 10: ...ee manual for special condition prefuses Voir manuel de conditions speciales fusibles WARNING AVERTISSEMENT SN 123456H123 1 2 3 4 5 6 Illustration 1 Example of the Top level Drive System Nameplate Fou...

Page 11: ...ted into the lifting eyes Maximum diameter for the lifting bar 20mm 0 8 in The angle from the top of the drive to the lifting cable 60 or greater Test lift the unit approximately 610 mm 24 in to verif...

Page 12: ...ustom components for the system The basic kit contains the following components Drive modules Control shelf Wire harnesses DC fuses with microswitch connectors 3 2 Drive Modules The VLT Ea4 Parallel D...

Page 13: ...13 Ground plate 3 3 Control Shelf The control shelf contains the local control panel LCP MDCIC and control card The LCP provides access to the system parameters The MDCIC is connected to each of the d...

Page 14: ...cable with 2 pin connectors on 1 end of the cable 3 5 AC Fuses Fuses installed on the supply side ensure that if a component breaks down first fault inside the drive any potential damage is contained...

Page 15: ...Torque Ratings Location Bolt size Torque Nm in lb Mains terminal M10 M12 19 168 37 335 Motor terminal M10 M12 19 168 37 335 Ground terminal M8 M10 9 6 84 19 168 Load sharing terminal M10 M12 19 168 3...

Page 16: ...m 20 in lb 5 All M5 fasteners attaching input plates to side mounting rail 3 9 Nm 35 in lb 4 2 Required Tools Lifting equipment rated to lift the weight of the drive module Drill with a 12 mm 1 2 in d...

Page 17: ...ated circuit boards to reduce the effects of aggressive gases For conformal coating class specifications and ratings see the Ambient Conditions section 4 3 2 Dust When installing the unit in a dusty e...

Page 18: ...flow rate of 595 m3 h 350 cfm Typical enclosure designs utilize door fans along with the drive module fans to remove heat losses from the enclosure The drive module utilizes back channel cooling conc...

Page 19: ...the Drive Modules Procedure Unpack the drive modules Prepare the drive module for lifting using an appropriate lifting equipment See 2 2 Lifting the Drive Module Secure the top of the drive enclosure...

Page 20: ...ontrol shelf Remove the MDCIC cover from the control shelf assembly Connect the 44 pin ribbon cables from the MDCIC card to the top of the drive modules following the sequence numbers indicated next t...

Page 21: ...30be713 11 1 2 Illustration 9 Positioning the Control Shelf for EMC compliant Installation 1 Control shelf must stay below this point 2 Control shelf must stay above this point AQ434333248451en 000101...

Page 22: ...N G ELECTRICAL SHOCK AND FIRE HAZARD RCD COMPLIANCE The drive can cause a DC fault current in the PE conductor Failure to use a Type B residual current operated protective device RCD can lead to the R...

Page 23: ...T 0 V PNP 24 V NPN D IN OUT 0V 24V 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 4 20 mA OFF 0 to 10 V 95 400 V AC 2A P 5 00 R 82 R 81 37 D IN 1 P R...

Page 24: ...11 10 9 C NO NC C NO NC Regen Regen GND 1 2 BRF Jumper CBL114 R R R R R R U V W L1 L2 L3 L1 L2 L3 U V W FK101 2 1 1 2 43 44 1 2 43 44 1 2 43 44 1 2 43 44 TB1 TB2 TB1 TB2 Customer Relay DRIVE MODULE 3...

Page 25: ...verter 1 inverter 2 inverter 3 and then inverter 4 Scaling card position Place the corresponding current scaling card on each respective connector For systems with 2 drive modules connect inverter 1 a...

Page 26: ...rive module 3 at MK 112 7 44 pin cable to drive module 4 at MK 114 8 Ferrite cores 9 LCP cradle 10 Ribbon cable from LCP to MDCIC 11 44 pin cable to drive module 1 at MK 111 12 44 pin cable to drive m...

Page 27: ...failure Procedure Install the supplied harness between the microswitch terminals and the brake fault jumper port on the top of the drive modules Connect the wire harness between the NC and COM termina...

Page 28: ...C E MULTIPLE MAINS CABLES If connecting more than 1 set of mains terminals use the same number size and length of cables for each set of terminals For example do not use 1 cable on one mains terminal...

Page 29: ...2 50 53 54 55 e30bf145 11 1 2 4 3 Illustration 14 Control Terminal Locations 1 Terminals 68 and 69 are for serial communica tion connection 2 USB port available for use with the MCT 10 setup software...

Page 30: ...l Input 0 No operation 33 Parameter 5 15 Terminal 33 Digital Input 0 No operation 27 Parameter 5 12 Terminal 27 Digital Input 2 Coast inverse For digital input or output Default setting is input 29 Pa...

Page 31: ...on Parameter 5 40 Function Relay 1 0 No operation Form C relay output For AC or DC voltage and resistive or inductive loads 05 normally open 06 normally closed 5 11 3 Routing Control Cables Make sure...

Page 32: ...refer to the Cable Specifications section N O T I C E ELECTRICAL INTERFERENCE Minimize interference by keeping control wires as short as possible and separate from high power cables Procedure Strip 1...

Page 33: ...Digital input terminal 27 is designed to 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 OPTI...

Page 34: ...cation wiring to terminals 68 and 69 Use shielded serial communication cable recommended See the Connecting to Ground section for proper grounding Select the following parameter settings Protocol type...

Page 35: ...Illustration 20 Example e30bf146 10 BUS TER OFF ON A53 A54 U I U I 1 2 N O 1 2 N O 1 2 N O 1 2 N O Illustration 20 Location of Switches A53 and A54 AQ434333248451en 000101 130R1286 35 Danfoss A S 202...

Page 36: ...nd loose connections Check that control wiring is isolated from high power wiring for noise immunity Check the voltage source of the signals if necessary Use shielded cable or twisted pair and ensure...

Page 37: ...re in operational readiness N O T I C E MISSING SIGNAL If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or alarm 60 External interlock is shown it indicates that the unit is read...

Page 38: ...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 customized...

Page 39: ...icator lights Indicator lights identify the drive status and provide a visual notification of warning or fault conditions Table 12 LCP Indicator Lights Callout Indicator LED Function D1 On Green Activ...

Page 40: ...o 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 default...

Page 41: ...ed See https www danfoss com en service and support downloads sort title_asc filter download type 3Dtools Procedure Press Main Menu on the LCP Select 0 Operation Display and press OK Select 0 0 Basic...

Page 42: ...ocedure in this section requires user wiring and application programming to be completed The following procedure is rec ommended after application setup is completed W A R N I N G MOTOR START Starting...

Page 43: ...e and other signals applied to the control terminals override local control Off The drive does not react to any control signal until Auto On or Hand On is pressed 6 8 3 Status Messages Reference Site...

Page 44: ...as a function for a digital input parameter group 5 1 Digital Inputs The corre sponding terminal is not active The DC brake is activated via serial communication Feedback high The sum of all active fe...

Page 45: ...erial communication Ramping The motor is accelerating decelerating using the active ramp up down The reference a limit value or a standstill is not yet reached Ref high The sum of all active reference...

Page 46: ...afety Trip When tripping the drive suspends operation to prevent damage to the drive and other equipment When a trip occurs the motor coasts to a stop The drive logic continues to operate and monitor...

Page 47: ...trip state for personal safety Trip When tripping the drive suspends operation to prevent damage to the drive and other equipment When a trip occurs the motor coasts to a stop The drive logic continu...

Page 48: ...rcuit in a connected potentiometer or incorrect wiring of the potentiometer can cause this condition Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the wi...

Page 49: ...n the drive voltage rating The unit is still active 6 9 9 WARNING ALARM 7 DC Overvoltage Cause If the DC link voltage exceeds the limit the drive trips after a certain time Troubleshooting Extend the...

Page 50: ...rnal Fan Run AMA in parameter 1 29 Automatic Motor Adaptation AMA This tunes the drive to the motor more accurately and reduces thermal loading 6 9 13 WARNING ALARM 11 Motor Thermistor Overtemp Cause...

Page 51: ...detect the ground fault by measuring current going out from the drive and current going into the drive from the motor Ground fault is issued if the deviation of the 2 currents is too large The curren...

Page 52: ...re sensor is not connected 6 9 21 WARNING ALARM 21 Parameter Error Cause The parameter is out of range The parameter number is shown in the display Troubleshooting Set the affected parameter to a vali...

Page 53: ...warning is active when the dissipa ted braking power is higher than 90 of the brake resistor power If option 2 Trip is selected in parameter 2 13 Brake Power Monitor ing the drive trips when the diss...

Page 54: ...sonnel must perform installation start up and maintenance Disconnect power before proceeding Remove the power from the drive and check motor phase V 6 9 32 ALARM 32 Motor Phase W Missing Cause Motor p...

Page 55: ...ctive or too old Replace the power card 512 519 Internal fault Contact the Danfoss supplier or Danfoss service department 783 Parameter value outside of minimum maximum limits 1024 1284 Internal fault...

Page 56: ...te drive card 6 9 40 WARNING 40 Overload of Digital Output Terminal 27 Troubleshooting Check the load connected to terminal 27 or remove the short circuit connection Check parameter 5 00 Digital I O M...

Page 57: ...only 24 V and 5 V supplies are monitored When powered with 3 phase mains voltage all 3 supplies are monitored Troubleshooting Check for a defective power card Check for a defective control card Check...

Page 58: ...e settings in parameter 1 24 Motor Current 6 9 52 ALARM 53 AMA Motor Too Big Cause The motor is too big for the AMA to operate Troubleshooting Check the settings in parameter group 1 2 Motor Data 6 9...

Page 59: ...g in parameter 4 30 Motor Feedback Loss Function Set the tolerable error in parameter 4 31 Motor Feedback Speed Error Set the tolerable feedback loss time in parameter 4 32 Motor Feedback Loss Timeout...

Page 60: ...bus digital I O or by pressing Reset 6 9 68 ALARM 70 Illegal FC Configuration Cause The control card and power card are incompatible Troubleshooting To check compatibility contact the Danfoss supplier...

Page 61: ...drive is set to run with fewer inverters and remains on 6 9 76 ALARM 78 Tracking Error Cause The difference between setpoint value and actual value exceeds the value in parameter 4 35 Tracking Error...

Page 62: ...r VLT Resolv er Input MCB 103 6 9 87 ALARM 91 Analog Input 54 Wrong Settings Troubleshooting Set switch S202 in position OFF voltage input when a KTY sensor is connected to analog input terminal 54 6...

Page 63: ...ze This alarm is equivalent to Alarm 29 Heat Sink Temp Troubleshooting Check for the following Ambient temperature too high Motor cables too long Incorrect airflow clearance above or below the AC driv...

Page 64: ...reported the alarm Troubleshooting Check inrush card wiring Replace inrush card 6 10 Troubleshooting Table 21 Troubleshooting Symptom Possible cause Test Solution Display dark No function Missing inpu...

Page 65: ...or bus reference Preset reference active Terminal connection correct Scaling of terminals correct Reference signal available Program correct settings Check pa rameter 3 13 Reference Site Set preset r...

Page 66: ...ains supply Problem with the AC drive Rotate input power leads into the AC drive 1 position A to B B to C C to A If the imbalanced leg stays on same in put terminal it is a problem with the AC drive C...

Page 67: ...9 5758 Efficiency 2 0 98 Overtemperature trip ratings C F Heat sink 110 230 Control card 80 176 Power card 85 185 Fan power card 85 185 Active in rush card 85 185 1 Typical power loss is at normal con...

Page 68: ...put Unlimited Ramp times 0 01 3600 s 1 Dependent on voltage and power 7 4 Torque Characteristics The torque response time depends on application and load but as a rule the torque step from 0 to refere...

Page 69: ...erminals cable with enclosed core 0 5 mm2 20 AWG Minimum cross section to control terminals 0 25 mm2 24 AWG 7 7 Control Input Output and Control Data 7 7 1 Digital Inputs All digital inputs are galvan...

Page 70: ...ltage 20 V Current mode Switch A53 S201 A54 S202 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...

Page 71: ...mA Maximum load at frequency output 1 k Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy...

Page 72: ...cos 0 4 240 V AC 0 2 A Maximum terminal load DC 1 1 on 4 6 NC Resistive load 50 V DC 2 A Maximum terminal load DC 13 1 on 4 6 NC Inductive load 24 V DC 0 1 A Minimum terminal load on 4 6 NC 4 5 NO 24...

Page 73: ...ically isolated from ground Use only isolated laptop PC as connection to the USB connector on the drive or an isolated USB cable converter 7 8 Fuses Fuses installed on the supply side ensure that if a...

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Page 76: ...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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