Danfoss VLT Ea4 User manual

Operating Guide
VLT Ea4 Parallel Drive Modules

1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.4
4.4.1
4.4.2
4.4.3
4.5
4.6
4.7
Contents
Introduction and Safety 6
Purpose of this Manual 6
Disclaimer 6
Safety and Installation Awareness 6
Qualified Personnel 6
Safety Symbols 6
Safety Precautions 7
Disposal 9
Receiving the Drive 10
Verifying the Shipment and the Contents 10
Lifting the Drive Module 11
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 Ratings 15
Required Tools 16
Operating Environment 17
Gases 17
Dust 17
Potentially Explosive Atmospheres 17
Installation Requirements 18
Thermal Considerations 18
Cooling Requirements 18
Busbars 18
Exploded View of Parallel Drive System 19
Installing the Drive Modules 19
Installing the Control Shelf 20
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Contents
VLT Ea4 Parallel Drive Modules
Operating Guide

5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.11.1
5.11.2
5.11.3
5.11.4
5.11.5
5.12
5.13
5.14
6
6.1
6.2
6.3
6.4
6.5
6.6
6.6.1
6.7
6.8
6.9
6.10
6.11
7
7.1
7.2
7.3
Electrical Installation 22
Safety Precautions 22
Electrical Requirements 22
Wiring Diagram 23
Block Diagram 24
Control Shelf Connections 25
Ground Connections 26
Installing DC Bus Fuses 27
Connecting to the Motor 27
Connecting to the AC Mains 28
Example of the Ground, Motor, and Mains Wiring 29
Installing Control Wiring 29
Control Terminals 29
Relay Terminals 31
Routing Control Cables 31
Connecting 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 Input Signal 34
Operating the Drive 36
Pre-start Check List 36
Applying Power to the Drive 37
Local Control Panel (LCP) 38
LCP Menu 40
Entering System Information 41
Testing Before System Start Up 42
Testing Motor Rotation 42
Starting Up the Drive for the First Time 42
Status Messages 42
Warnings and Alarms 46
Troubleshooting 64
Maintenance and Service 66
Specifications 67
Electrical Data, 380–500 V AC 67
Mains Supply to Drive Modules 68
Motor Output 68
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Contents
VLT Ea4 Parallel Drive Modules
Operating Guide

7.4
7.5
7.6
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
7.7.6
7.7.7
7.7.8
7.7.9
7.7.10
7.7.11
7.7.12
7.7.13
7.8
Torque Characteristics 68
Ambient Conditions for Drive Modules 68
Cable Specifications 69
Control Input/Output and Control Data 69
Digital Inputs 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
Control Card, +10 V DC Output 72
Control Characteristics 72
Control Card Performance 73
Control Card, USB Serial Communication 73
Fuses 73
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Contents
VLT Ea4 Parallel Drive Modules
Operating Guide

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1 Introduction and Safety
1.1 Purpose of this Manual
This manual provides requirements for mechanical and electrical installation of the VLT® Ea4 Parallel Drive Modules basic kit.
This guide includes information on:
Wiring of mains and motor connections.
Wiring of control and serial communications.
Control terminal functions.
Detailed tests that must be performed before start-up.
Initial programming to verify proper functioning of the drive system.
This operating guide is intended for use by qualified personnel. To install the drive modules and paralleling kit safely and professio-
nally, read and follow the operating guide. Pay particular attention to the safety instructions and general warnings. Always keep this
guide with the panel containing the VLT® Parallel Drive Modules components.
VLT® is a registered trademark of Danfoss A/S.
1.2 Disclaimer
Danfoss shall have no obligation regarding any product that
is not installed according to the standard configuration as specified in the installation guide.
is improperly repaired or altered.
is subjected to misuse, negligence, and improper installation where the guidelines were not followed.
is used in a contradictory manner to the instructions provided.
is a result of normal wear and tear.
NOTICE
OUTPUT FREQUENCY LIMIT
The output frequency of the drive is limited to 590 Hz due to export control regulations.
1.3 Safety and Installation Awareness
Before starting installation, read all safety guidelines and precautions in this operating guide. PC tools and MyDrive®ecoSmart™can
be downloaded at www.danfoss.com.
1.4 Qualified Personnel
Only qualified personnel are allowed to install, commission, and maintain Danfoss drives. Qualified personnel are trained individuals
who are familiar with and authorized to mount and wire the drive in accordance with pertinent laws and regulations. Also, qualified
personnel must be familiar with the instructions and safety measures described in this installation guide.
1.5 Safety Symbols
The following symbols are used in this guide:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
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Introduction and Safety
VLT Ea4 Parallel Drive Modules
Operating Guide

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NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
1.6 Safety Precautions
WARNING
LACK OF SAFETY AWARENESS
This guide gives important information on preventing injury and damage to the equipment or the system. Ignoring this informa-
tion can lead to death, serious injury, or severe damage to the equipment.
Make sure to fully understand the dangers and safety measures present in the application.
Before performing any electrical work on the drive, lock out and tag out all power sources to the drive.
WARNING
LIFTING HEAVY LOAD
The drive is heavy. Lifting heavy objects incorrectly can result in death, injury, or property damage.
Follow local safety regulations on lifting.
Check the weight of the drive. The weight is provided on the outside of the shipping box.
If lifting equipment is used, ensure that it is in proper working condition and can safely lift the weight of the drive.
Test lift the drive to verify the proper center of gravity lift point. Reposition if not level.
WARNING
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 can result in death or serious injury.
Only qualified personnel must perform installation, start-up, and maintenance.
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be
present even when the warning indicator lights are off. Failure to wait the specified time after power has been removed before
performing service or repair work can result in death or serious injury.
Stop the motor.
Disconnect all power sources, including permanent magnet type motors.
Wait for capacitors to discharge fully. The discharge time is shown on the nameplate. See Illustration 1 and Illustration 2.
Verify full discharge by measuring the voltage level.
CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the drive can result in serious injury when the drive is not properly closed.
Ensure that all safety covers are in place and securely fastened before applying power.
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Introduction and Safety
VLT Ea4 Parallel Drive Modules
Operating Guide

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WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
The drive can cause a DC current in the ground conductor. Failure to use a Type B residual current-operated protective device
(RCD) can lead to the RCD not providing the intended protection which can result in death, fire, or other serious hazard.
Use an RCD device.
When an RCD is used for protection against electrical shock or fire, use only a Type B device on the supply side.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned
off and locked out/tagged out. Failure to run output motor cables separately, or to use shielded cables, could result in death or
serious injury.
Run output motor cables separately or use shielded cables.
Simultaneously lock out/tag out all the drives.
WARNING
ELECTRICAL SHOCK HAZARD
Due to the stray capacitance of the shielded motor cable, the leakage currents exceed 3.5 mA. Failure to properly ground the
drive can result in death or serious injury.
Ensure that minimum size of the ground conductor complies with the local safety regulations for high touch current equip-
ment.
Use a reinforced ground conductor according to IEC 60364-5-54 cl. 543.7 or local safety regulations for equipment with leak-
age current >3.5 mA.
For reinforced grounding:
Use a ground 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 60364-5-54, with a minimum
cross-sectional area of 2.5 mm2(14 AWG) mechanically protected or 4 mm2(12 AWG) not mechanically protected.
Use a ground conductor inside an enclosure or otherwise protected throughout its length against mechanical damage.
Use a ground conductor that is part of a multi-conductor power cable with a minimum PE conductor cross-section of
2.5 mm2(14 AWG) that is permanently connected or plugged in by an industrial connector. The multi-conductor power ca-
ble must be installed with an appropriate strain relief.
CAUTION
THERMISTOR INSULATION
Risk of personal injury or equipment damage.
To meet PELV insulation requirements, use only thermistors with reinforced or double insulation.
NOTICE
EXCESSIVE HEAT AND PROPERTY DAMAGE
Overcurrent can generate excessive heat within the drive. Failure to provide overcurrent protection can result in risk of fire and
property damage.
Use additional protective devices such as short-circuit protection or motor thermal protection between the drive and the
motor for applications with multiple motors.
Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer
must provide them.
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Introduction and Safety
VLT Ea4 Parallel Drive Modules
Operating Guide

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NOTICE
PROPERTY DAMAGE
Protection against motor overload is not active by default. The ETR function provides class 20 motor overload protection. Failure
to set the ETR function means that motor overload protection is not provided 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 components together with domestic waste. Collect it separately in accordance
with applicable local regulations.
AQ434333248451en-000101 / 130R1286 | 9Danfoss A/S © 2023.01
Introduction and Safety
VLT Ea4 Parallel Drive Modules
Operating Guide

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2 Receiving the Drive
2.1 Verifying the Shipment and the Contents
Items supplied can vary according to product configuration.
Make sure that the items supplied and the information on the nameplates correspond to the order confirmation.
Visually check the packaging and the drive modules for damage caused by inappropriate handling during shipment. File any
claim for damage with the carrier. Retain damaged parts for clarification.
NOTICE
Removing the nameplates can result in loss of warranty.
Max. Tamb. 55˚
C/131˚
F w/ Output Current Derating
OUT: 3x0-Vin 0-590Hz 1260/1160 A
IN: 3x380-500V 50/60Hz 1227/1129 A
710 kW / 1000 HP, High Overload
OUT: 3x0-Vin 0-590Hz 1460/1380 A
IN: 3x380-500V 50/60Hz 1422/1344 A
800 kW /1200 HP, Normal Overload
VLT
T/C: FC-302N710T5E00P2BGC7XXSXXXXAXBXCXXXXDX
P/N: 134X4109
RAutomationDrive
www.danfoss.com
e30bb139.10
ASSEMBLED IN USA
Tamb. 45˚
C/113˚
F at Full Output Current
CHASSIS (OPEN TYPE) / IP00
CAUTION - ATTENTION:
Stored charge, wait 40 min.
Charge residuelle, attendez 40 min.
See 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 Found on Drive Module Exterior
1
Typecode
2
Part number and serial number
3
Power rating
4
Input voltage, frequency, and current
5
Output voltage, frequency, and current
6
Discharge time
Module system only. Specific electrical
Modules are intended for use in Parallel Drive
Intended use - The Individual Base Drive
be referred for actual drive ratings.
Parallel Drive Module system should
ratings are not applicable. Name plate of
VLT
T/C: FC-BDMN250T5E00H2SXC7XXSXXXXAXBXCXXXXDX
P/N: 178N0025
RAutomationDrive
www.danfoss.com
e30bb140.10
ASSEMBLED IN USA
CHASSIS (OPEN TYPE) / IP00
CAUTION - ATTENTION:
Stored charge, wait 40 min.
Charge residuelle, attendez 40 min.
See manual for special condition / prefuses
Voir manuel de conditions speciales / fusibles
WARNING - AVERTISSEMENT:
`
`
SN: 123456H123
1
2
3
4
Illustration 2: Example of the Drive Module Nameplate in the Interior Beneath the Local Control Panel
AQ434333248451en-000101 / 130R128610 | Danfoss A/S © 2023.01
Receiving the Drive
VLT Ea4 Parallel Drive Modules
Operating Guide