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Illustration 2.16 Installation to Achieve a Stopping Category 0 (EN 60204-1) with Safety Cat. 3 (EN 954-1) / PL “d” (ISO 13849-1).

Safety device Cat. 3 (circuit interrupt device, possibly with

release input)

Inverter

Door contact

Motor

Contactor (Coast)

5V DC

Frequency converter

Safe channel

Mains

Short-circuit protected cable (if not inside installation cabinet)

Control board

Safe Stop Commissioning Test
After installation and before first operation, perform a commissioning test of the installation making use of safe stop. Moreover,
perform the test after each modification of the installation.

Installation

VLT

AutomationDrive Operating

Instructions

MG.33.AJ.02 - VLT

is a registered Danfoss trademark

Содержание VLT AutomationDrive

Страница 1: ...start WARNING DISCHARGE TIME Frequency converters contain DC link capacitors that can remain charged even when AC mains is disconnected To avoid electrical hazards remove AC mains from the frequency c...

Страница 2: ...Safety VLT AutomationDrive Operating Instructions MG 33 AJ 02 VLT is a registered Danfoss trademark...

Страница 3: ...Grounding Using Shielded Cable 13 2 4 3 Motor Connection 13 2 4 4 AC Mains Connection 14 2 4 5 Control Wiring 14 2 4 5 1 Access 14 2 4 5 2 Control Terminal Types 15 2 4 5 3 Wiring to Control Terminal...

Страница 4: ...30 5 About Frequency Converter Programming 31 5 1 Introduction 31 5 2 Programming Example 31 5 3 Control Terminal Programming Examples 32 5 4 International North American Default Parameter Settings 3...

Страница 5: ...Specifications 62 10 1 Power dependent Specifications 62 10 2 General Technical Data 71 10 3 Fuse Tables 76 10 3 2 CE Compliance 77 10 4 Connection Tightening Torques 84 Index 85 Contents VLT Automat...

Страница 6: ...d sharing 88 89 terminals 5 Analog switches A53 A54 14 Mains input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Serial bus terminal switch 8 Groun...

Страница 7: ...equirements for mechanical and electrical installation including input motor control and serial communications wiring and control terminal functions Chapter 3 Start Up and Functional Testing provides...

Страница 8: ...e as status indications to an outside control system or serial communication network 1 4 Internal Frequency Converter Controller Functions Below is a block diagram of the frequency converter s interna...

Страница 9: ...0 37 1 5 0 37 4 0 5 5 7 5 0 37 4 0 0 37 7 5 11 15 18 5 22 11 15 18 5 30 30 45 55 75 37 45 55 75 525 600 N A N A 0 75 7 5 N A 0 75 7 5 11 15 18 5 22 11 15 18 5 30 30 45 55 90 37 45 55 90 525 690 N A N...

Страница 10: ...verify the proper equipment Ensure each of the following are rated for same voltage Mains power Frequency converter Motor Ensure that frequency converter output current rating is equal to or greater t...

Страница 11: ...urface or to the optional back plate to provide cooling airflow see Illustration 2 2 and Illustration 2 3 Improper mounting can result in over heating and reduced performance Use the slotted mounting...

Страница 12: ...has been applied checking input and motor power programming control terminals for their intended functions Illustration 2 4 Basic Wiring Schematic Drawing A Analog D Digital Terminal 37 is used for Sa...

Страница 13: ...verter 7 Motor 3 phase and PE 3 Output contactor Generally not recommended 8 Mains 3 phase and reinforced PE 4 Earth grounding rail PE 9 Control wiring 5 Cable insulation stripped 10 Equalising min 16...

Страница 14: ...parately Use metallic conduit or separated shielded wire Failure to isolate power motor and control wiring could result in less than optimum equipment performance All frequency converters must be prov...

Страница 15: ...e RCDs of type B only which are capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu r...

Страница 16: ...hen supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded leg grounded delta set 14 50 RFI Filter to OFF When off the internal RFI filter capacitors betwee...

Страница 17: ...equency converter configuration and size Some options available for ordering with the unit may provide additional terminals See the manual provided with the equipment option See 10 2 General Technical...

Страница 18: ...pical control wiring connections Illustration 2 13 Connecting Control Wiring 2 4 5 4 Using Screened Control Cables Correct screening The preferred method in most cases is to secure control and serial...

Страница 19: ...ome option cards available for the unit may cover these switches and must be removed to change switch settings Always remove power to the unit before removing option cards Terminal 53 default is for a...

Страница 20: ...age supply from the unit and waiting the time specified could result in death or serious injury It is not recommended to stop the frequency converter by using the Safe Torque Off function If a running...

Страница 21: ...requency converter 10 Safe channel 5 Mains 11 Short circuit protected cable if not inside installation cabinet 6 Control board Safe Stop Commissioning Test After installation and before first operatio...

Страница 22: ...order to be able to stop the load in case of emergency or malfunction of the system according to relevant national crane lift regulations Illustration 2 17 Connecting the Mechanical Brake to the Freq...

Страница 23: ...ter disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on out...

Страница 24: ...dequate to ensure proper air flow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental considerations See equipment label for the maximum...

Страница 25: ...m of the LCP reads AUTO REMOTE COAST this indicates that the unit is ready to operate but is missing an input signal on terminal 27 See Illustration 2 15 for details 3 3 Basic Operational Programming...

Страница 26: ...characteristics of the motor to optimize compatibility between the frequency converter and the motor The frequency converter builds a mathematical model of the motor for regulating output motor curre...

Страница 27: ...he responsibility of the user to ensure safe operation under any operational condition Failure to ensure that the motor system and any attached equipment is ready for start could result in personal in...

Страница 28: ...application set up by the user is completed CAUTION MOTOR START Ensure that the motor system and any attached equipment is ready for start It is the responsibility of the user to ensure safe operation...

Страница 29: ...operates in a manner similar to the LCP See the Programming Guide for details on use of the NLCP NOTE The display contrast can be adjusted by pressing STATUS and the up down key 4 1 1 LCP Layout The L...

Страница 30: ...lays Press repeatedly to scroll through each status display Press and hold Status plus or to adjust the display brightness The symbol in the upper right corner of the display shows the direction of mo...

Страница 31: ...signal by control input or serial communication overrides the local hand on Off Stops the motor but does not remove power to the frequency converter Auto On Puts the system in remote operational mode...

Страница 32: ...rating hours serial communication selections personal menu settings fault log alarm log and other monitoring functions Using 14 22 Operation Mode is generally recommended Manual initialisation erases...

Страница 33: ...o receive a 0 10V DC analog control signal on input terminal 53 The frequency converter will respond by providing 6 60Hz output to the motor proportional to the input signal 0 10V DC 6 60Hz Select the...

Страница 34: ...cedure is complete Illustration 5 1 shows the wiring connections used to enable this set up Illustration 5 1 Wiring Example for External Device Providing 0 10V Control Signal frequency converter left...

Страница 35: ...Note 4 50Hz 60Hz 4 19 Max Output Frequency 132Hz 120Hz 4 53 Warning Speed High 1500RPM 1800RPM 5 12 Terminal 27 Digital Input Coast inverse External interlock 5 40 Function Relay No operation No alarm...

Страница 36: ...Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent About Frequency Converter P VLT AutomationDrive Operating Instructions 34 MG 33 AJ 02 VLT is a registered Da...

Страница 37: ...terminals minimum and maximum signal ranges custom displays automatic restart and other features See the LCP display to view detailed parameter programming and setting options Press Info in any menu l...

Страница 38: ...Reference Limits 3 00 Reference Range 3 01 Reference Feedback Unit 3 02 Minimum Reference 3 03 Maximum Reference 3 04 Reference Function 3 1 References 3 10 Preset Reference 3 11 Jog Speed Hz 3 12 Cat...

Страница 39: ...rd Timeout Function 8 05 End of Timeout Function 8 06 Reset Control Word Timeout 8 07 Diagnosis Trigger 8 08 Readout Filtering 8 1 Ctrl Word Settings 8 10 Control Word Profile 8 13 Configurable Status...

Страница 40: ...ake Energy s 16 33 Brake Energy 2 min 16 34 Heatsink Temp 16 35 Inverter Thermal 16 36 Inv Nom Current 16 37 Inv Max Current 16 38 SL Controller State 16 39 Control Card Temp 16 40 Logging Buffer Full...

Страница 41: ...1 and X59 2 Mode 33 61 Terminal X59 1 Digital Input 33 62 Terminal X59 2 Digital Input 33 63 Terminal X59 1 Digital Output 33 64 Terminal X59 2 Digital Output 33 65 Terminal X59 3 Digital Output 33 6...

Страница 42: ...ne and simply downloaded into frequency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal are available...

Страница 43: ...ters Function Setting 1 29 Automatic Motor Adaptation AMA 1 Enable complete AMA 5 12 Terminal 27 Digital Input 2 Coast inverse Default Value Notes comments Parameter group 1 2 must be set according to...

Страница 44: ...afe Stop Alarm Default Value Notes comments If 5 12 Terminal 27 Digital Input is set to 0 No operation a jumper wire to terminal 27 is not needed Table 6 5 Start Stop Command with Safe Stop Parameters...

Страница 45: ...alue Notes comments Table 6 8 External Alarm Reset Parameters Function Setting 6 10 Terminal 53 Low Voltage 0 07V 6 11 Terminal 53 High Voltage 10V 6 14 Terminal 53 Low Ref Feedb Value 0RPM 6 15 Termi...

Страница 46: ...AUTION Thermistors must use reinforced or double insulation to meet PELV insulation requirements Parameters Function Setting 1 90 Motor Thermal Protection 2 Thermistor trip 1 93 Thermistor Source 1 An...

Страница 47: ...C monitors Warning 90 and in the case that Warning 90 becomes TRUE then Relay 1 is triggered External equipment may then indicate that service may be required If the feedback error goes below the limi...

Страница 48: ...signals applied to the control terminals can override local control Reference site Remote The speed reference is given from external signals serial communication or internal preset references Local Th...

Страница 49: ...is running as programmed in 3 19 Jog Speed RPM Jog was selected as function for a digital input parameter group 5 1 The corresponding terminal e g Terminal 29 is active The Jog function is activated...

Страница 50: ...me expires Start fwd rev Start forward and start reverse were selected as functions for two different digital inputs parameter group 5 1 The motor will start in forward or reverse depending on which c...

Страница 51: ...p The frequency converter logic will continue to operate and monitor the frequency converter status After the fault condition is remedied the frequency converter can be reset It will then be ready to...

Страница 52: ...X X 17 Control word time out X X 8 04 Control Word Timeout Function 20 Temp Input Error 21 Param Error 22 Hoist Mech Brake X X Parameter group 2 2 23 Internal Fans X 24 External Fans X 25 Brake resis...

Страница 53: ...Low X 2 20 Release Brake Current 64 Voltage Limit X 65 Control Board Over temperature X X X 66 Heat sink Temperature Low X 67 Option Configuration has Changed X 68 Safe Stop X X 1 5 19 Terminal 37 Sa...

Страница 54: ...zero error This warning or alarm will only appear if programmed by the user in 6 01 Live Zero Timeout Function The signal on one of the analog inputs is less than 50 of the minimum value programmed fo...

Страница 55: ...100 in 1 90 Motor Thermal Protection The fault occurs when the motor is overloaded by more than 100 for too long Troubleshooting Check for motor overheating Check if the motor is mechanically overloa...

Страница 56: ...id value WARNING ALARM 22 Hoist mechanical brake Report value will show what kind it is 0 The torque ref was not reached before timeout 1 There was no brake feedback before timeout WARNING 23 Internal...

Страница 57: ...n an internal fault occurs a code number defined in the table below is displayed Troubleshooting Cycle power to the frequency converter Check that the option is properly installed Check for loose or m...

Страница 58: ...ecified range in 4 11 Motor Speed Low Limit RPM and 4 13 Motor Speed High Limit RPM the frequency converter will show a warning When the speed is below the specified limit in 1 86 Trip Speed Low RPM e...

Страница 59: ...2 is deactivated When that happens a reset signal must be is be sent via Bus Digital I O or by pressing RESET ALARM 72 Dangerous failure Safe Stop with Trip Lock The Dangerous Failure Alarm is issued...

Страница 60: ...onverter after the fault has been cleared ALARM 95 Broken belt Torque is below the torque level set for no load indicating a broken belt 22 60 Broken Belt Function is set for alarm Troubleshoot the sy...

Страница 61: ...right inverter module in F2 or F4 frequency converter 5 rectifier module ALARM 248 Illegal power section configuration This alarm is only for F Frame frequency converters It is equivalent to Alarm 79...

Страница 62: ...lem is in the control wiring Check the wiring for shorts or incorrect connections If the display continues to cut out follow the procedure for display dark Motor not running Service switch open or mis...

Страница 63: ...settings Check parameter group2 0 DC brake and 3 0 Reference limits Open power fuses or circuit breaker trip Phase to phase short Motor or panel has a short phase to phase Check motor and panel phase...

Страница 64: ...4 9 4 9 4 9 6 6 6 6 A1 IP20 2 7 2 7 2 7 2 7 2 7 2 7 A5 IP55 66 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 Efficiency 4 0 94 0 94 0 95 0 95 0 96 0 96 0 96 0 96 0 96 0 25 3 7kW only available as 160 h...

Страница 65: ...P21 A2 A2 A2 A2 A2 A2 A2 A2 A3 A3 Enclosure IP20 FC 301 only A1 A1 A1 A1 A1 Enclosure IP55 66 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A4 A5 A5 A5 Output current High overload 160 for 1 min Shaft out...

Страница 66: ...16 6 22 2 22 2 26 26 30 5 30 5 42 3 Continuous kVA 460V AC kVA 21 5 27 1 31 9 41 4 Max input current Continuous 3 x 380 440V A 22 29 29 34 34 40 40 55 Intermittent 60 sec overload 3 x 380 440V A 35 2...

Страница 67: ...Max input current Continuous 3 x 380 440V A 55 66 66 82 82 96 96 133 133 161 Intermittent 60 sec overload 3 x 380 440V A 82 5 72 6 99 90 2 123 106 144 146 200 177 Continuous 3 x 441 500V A 47 59 59 73...

Страница 68: ...VA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Max input current Continuous 3 x 525 600V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 3 x 525 600V A...

Страница 69: ...9 33 9 40 8 40 8 51 8 Max input current Continuous at 550V A 17 2 20 9 20 9 25 4 25 4 32 7 32 7 39 39 49 Intermittent at 550V A 28 23 33 28 41 36 52 43 59 54 Continuous at 575V A 16 20 20 24 24 31 31...

Страница 70: ...current Continuous at 550V A 49 59 59 78 9 78 9 95 3 95 3 124 3 Intermittent at 550V A 74 65 89 87 118 105 143 137 Continuous at 575V A 47 56 56 75 75 91 91 119 Intermittent at 575V A 70 62 85 83 113...

Страница 71: ...551 690V A 20 8 19 8 28 8 24 2 35 2 29 7 43 2 37 4 Continuous KVA at 550V KVA 13 3 18 1 18 1 21 9 21 9 26 7 26 7 34 3 Continuous KVA at 575V KVA 12 9 17 9 17 9 21 9 21 9 26 9 26 9 33 9 Continuous KVA...

Страница 72: ...share and brake mm2 AWG 95 4 0 Estimated power loss at rated max load W 4 480 592 720 880 1200 Weight enclosure IP21 IP55 kg 65 Efficiency4 0 98 0 98 0 98 0 98 0 98 For fuse ratings see 10 3 1 Fuses 1...

Страница 73: ...690 V maximum Motor output U V W Output voltage 0 100 of supply voltage Output frequency 0 25 75kW FC 301 0 2 1000Hz FC 302 0 1000Hz Output frequency 90 1000kW 0 8001 Hz Output frequency in Flux Mode...

Страница 74: ...t is important to make a return way for the current from the coil when turning it off This can be done by using a freewheel diode or alternatively a 30 or 50 V MOV for quicker response time across the...

Страница 75: ...tput 500 Accuracy on analog output Max error 0 5 of full scale Resolution on analog output 12 bit The analogue output is galvanically isolated from the supply voltage PELV and other high voltage termi...

Страница 76: ...1 Max motor cable length screened FC 301 50m FC 301 A1 25m FC 302 150m Max motor cable length unscreened FC 301 75m FC 301 A1 50 m FC 302 300m Maximum cross section to control terminals flexible rigid...

Страница 77: ...ture cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages Guideline these temperatures may vary for different power sizes frame sizes e...

Страница 78: ...es in the instal lation The frequency converter is equipped with an internal over current protection 4 18 Current Limit that can be used for upstream overload protection UL applications excluded Moreo...

Страница 79: ...G 16 2 2 gG 25 PKZM0 25 25 A3 3 0 3 7 gG 16 3 gG 20 3 7 gG 32 PKZM0 25 25 B3 5 5 gG 25 gG 63 PKZM4 50 50 B4 7 5 15 gG 32 7 5 gG 50 11 gG 63 15 gG 125 NZMB1 A100 100 C3 18 5 22 gG 80 18 5 aR 125 22 gG...

Страница 80: ...25 A5 0 37 7 5 gG 10 0 37 3 gG 16 4 7 5 gG 32 PKZM0 25 25 B1 11 15 gG 40 gG 80 PKZM4 63 63 B2 18 5 22 gG 50 18 5 gG 63 22 gG 100 NZMB1 A100 100 C1 30 45 gG 80 30 gG 100 37 gG 160 45 gG 160 NZMB2 A200...

Страница 81: ...A250 250 Table 10 3 525 600V Frame Sizes A B and C Enclosure FC 300 Power Recommended fuse size Recommended Max fuse Recommended circuit breaker Max trip level Size kW Moeller A B2 11 15 18 22 gG 25...

Страница 82: ...30 LP CC 30 5 5 KTN R 50 KS 50 JJN 50 7 5 KTN R 60 JKS 60 JJN 60 11 KTN R 80 JKS 80 JJN 80 15 18 5 KTN R 125 JKS 125 JJN 125 22 KTN R 150 JKS 150 JJN 150 30 KTN R 200 JKS 200 JJN 200 37 KTN R 250 JKS...

Страница 83: ...WMUT may substitute A25X for 240V frequency converters Recommended max fuse FC 300 Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann kW Type RK1 Type J Type T Type CC Type CC Type CC 0 37 1 1 KTS...

Страница 84: ...2028220 160 KLS R 150 A6K 150 R 55 2028220 200 KLS R 200 A6K 200 R 75 2028220 250 KLS R 250 A6K 250 R Table 10 9 380 500V Frame Sizes A B and C Recommended max fuse FC 302 Bussmann Ferraz Shawmut Ferr...

Страница 85: ...t Ferraz Shawmut kW Type RK1 Type RK1 Type RK1 J 0 75 1 1 5017906 005 KLS R 005 A6K 5 R HSJ 6 1 5 2 2 5017906 010 KLS R 010 A6K 10 R HSJ 10 3 5017906 016 KLS R 015 A6K 15 R HSJ 15 4 5017906 020 KLS R...

Страница 86: ...compliance only 525 600 V Table 10 13 525 690V Frame Sizes B and C 10 4 Connection Tightening Torques Power kW Torque Nm Enclo sure 200 240V 380 480 500V 525 600V 525 690V Mains Motor DC connection B...

Страница 87: ...Characteristics 74 Signal 31 32 46 System 5 6 Terminals 10 24 29 46 48 32 16 Wire 16 Wiring 12 16 22 14 Cooling Cooling 8 Clearance 22 Copying Parameter Settings 29 Current Limit 25 53 Rating 8 53 D...

Страница 88: ...8 12 13 Current 6 24 53 56 28 Data 24 25 30 54 53 56 24 Leads 54 Output 71 Power 10 12 56 Protection 12 75 Rotation 25 28 Speeds 23 Status 6 Wiring 12 13 Wiring And 22 Mounting 9 22 Multiple Frequenc...

Страница 89: ...es 46 Mode 46 Stop Command 47 Supply Voltage 14 15 21 52 53 55 Surroundings 74 Switching Frequency 47 53 Symbols 1 System Feedback 6 Monitoring 49 Start Up 26 T Technical Data 71 Temperature Limits 22...

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