Danfoss VLT 28 User manual

VLT® 2800 Series
■Hig voltage warning
The voltage of the adjusta le frequency
drive is dangerous whenever the drive is
connected to electrical current. Incorrect
fitting of the motor or adjusta le frequency drive may
cause damage to the equipment, serious injury or
death. Consequently, it is essential to comply with
the instructions in this manual as well as local and
national rules and safety regulations.
■T ese rules concern your safety:
1. Disconnect the adjusta le frequency drive from
the AC line if repair work is to e carried out. Wait
4 minutes to allow for electrical discharge efore
removing motor and AC line connectors.
2. The [STOP/RESET] key on the control panel
of the adjusta le frequency drive does not
disconnect the equipment from the AC line.
Do not use it as a safety switch.
3. The unit must e grounded correctly. The user
must e protected against supply voltage and the
motor protected against overload in accordance
with applica le national and local regulations.
4. The ground leakage currents are higher than 3.5 mA.
5. Protection against motor overload is not included in
the factory setting. If this function is required, set
parameter 128 Motor thermal protection to ETR
trip or ETR warning. For North America: The ETR
functions provide class 20 overload protection for
the motor, in accordance with NEC requirements.
6. Do not remove the terminal plugs for the motor
and AC line supply while the adjusta le frequency
drive is connected to the AC line. Ensure that
the AC line supply has een disconnected and
that 4 minutes has passed efore removing
motor and AC line plugs.
7. The DC us terminals are another high voltage
input that must e disconnected efore servicing
thedrive. Ensurethatallvoltageinputshave
een disconnected and that 4 minutes has
passed efore repair work egins.
■Warnings against unintended start:
1. The motor can e started y means of digital
commands, us commands, references or
a local start command whenever the drive
is connected to the AC line. Therefore, an
unintended start may occur anytime power is
applied. Never service the drive or equipment
when power is applied to the drive.
2. The motor may start while parameters are
eing changed. Always activate the stop key
[STOP/RESET] y pressing it efore data is modified.
3. A motor that has een stopped may start if
faults occur in the electronics of the drive, or
if a temporary overload or fault clears in the
AC line or motor connection.
■Motor overload protection
The electronic thermal relay (ETR) in UL listed
VLTs provides Class 20 motor overload protection
in accordance with the NEC in single motor
applications when parameter 128 is set for "ETR
TRIP" and parameter 105 Motor current is set
for the rated motor current.
195NA139.10
Warning:
It can e extremely dangerous to touch the electrical parts
even when the mains supply has een disconnected.
Also ensure that other voltage inputs are disconnected
from load sharing through the DC us.
Wait at least 4 minutes after the input power has een
removed efore servicing the drive.
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VLT® 2800 Series
Installation
■Mec anical dimensions
The drawings elow give the mechanical dimensions.
All dimensions are in mm.
VLT 2803-2815 200-240 Volt
VLT 2805-2815 380-480 Volt
The drawing elow gives the mechanical dimensions of
VLT 2822 (3 HP) 200-240 Volts and VLT 2822-2840 (3
- 5 HP) 380-480 Volts. All dimensions are in inches.
VLT 2822 200-240 Volt
VLT 2822-2840 380-480 Volt
The drawing elow gives the mechanical dimensions of
VLT 2840 (5 HP) 200-240 Volt and VLT 2855-2875 (7 -
10HP) 380-480 Volt. All dimensions are in inches.
VLT 2840 200-240 Volt
VLT 2855-2875 380-480 Volt
VLT 2880-82 380-480V
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VLT® 2800 Series
■Motor coils (195N3110)
■RFI 1B filter (195N3103)
■Terminal cover
The drawing elow gives the dimensions for NEMA
1 terminal covers for VLT 2803-2875.
Dimension ’a’depends on the unit type.
■IP 21 solution
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VLT® 2800 Series
Installation
Dimensions
Typ e Code num er A B C
VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V 195N2118 47 80 170
VLT 2822 200-240 V, VLT 2822-2840 380-480 V 195N2119 47 95 170
VLT 2840 200-240 V, VLT 2855-2875 380-480 V 195N2120 47 145 170
VLT 2880-2882 380-480 V 195N2126 47 205 245
■EMC filter for long motor cables
192H4719
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VLT® 2800 Series
192H4720
192H4893
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VLT® 2800 Series
Installation
■Mec anical installation
The adjusta le frequency drive is cooled y air
circulation. For proper cooling, allow a minimum
of 4 inches (100 mm) of open space a ove and
elow the unit. To protect the unit from overheating,
ensure that oth the am ient temperature and the
24-hour average temperature are not exceeded.
The maximum temperature and 24-hour average
are listed in General technical data in this manual. If
the am ient temperature is in the range of 113°F -
131°F (45°C - 55°C), derating of the drive must e
carried out. See Derating for ambient temperature
in this manual. The service life of the unit will e
reduced without applica le derating.
The requirements that apply to enclosures
and remote mounting must e complied
with to avoid serious injury or equipment
damage, especially when installing large units.
■Enclosures
In the USA and some other countries, a NEMA 1
terminal cover enclosing terminal connectors is required
if the drive is not installed within another enclosure.
■Spacing for mec anical installation
All units require a minimum of 4 in of air from other
components a ove and elow the enclosure.
■Side-by-side
All VLT 2800 units can e installed side- y-side
and in any position, as the units do not require
ventilation on the side.
NOTE
With the IP 21 solution all units require a
minimum of 4 in air on each side. This means
that side- y-side mounting is not allowed.
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VLT® 2800 Series
■General information about electrical installation
■Hig voltage warning
The voltage of the adjusta le frequency
drive is dangerous whenever the drive
is connected to the AC line. Incorrect
installation of the motor or drive may cause damage
to the equipment, serious injury or death. Comply
with the safety instructions in this manual as well
as local and national rules and safety regulations.
Touching electrical parts may e fatal - even after the
equipment has een disconnected from the AC line.
Wait at least 4 minutes for current to dissipate.
NOTE
It is the responsi ility of the user or installer
to ensure correct grounding and protection in
accordance with national and local standards.
■Grounding
Comply with the following at installation:
•Safety grounding: The drive has a high leakage
current and must e grounded properly for safety.
Follow all local safety regulations.
•High frequency grounding: Keep grounding
ca les as short as possi le.
Connect all grounds to ensure the lowest possi le
conductor impedance. The lowest possi le conductor
impedance is achieved y keeping the conductor as
short as possi le and y grounding with the greatest
possi le surface area. If multiple drives are installed
in a ca inet, the ca inet ackplate, which must e
made of metal, should e used as a joint ground
referenceplate. Thedrivesmust efittedtothe
ackplate at the lowest possi le impedance.
To achieve low impedance, connect the drive to the
ackplate with the drive fastening olts. Remove
all paint from the contact points.
■Hig voltage test
A high voltage test can e performed y short-circuiting
terminalsU,V,W,L1,L2andL3,andapplying
max. 2160 V DC in 1 sec. etween this
short-circuit and terminal 95.
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VLT® 2800 Series
Installation
■EMC-correct electrical installation
General points to e o served to ensure
EMC-correct electrical installation.
- Use only shielded/armoured motor ca les and
shielded/armoured control ca les.
- Connect the screen to ground at oth ends.
- Avoid installation with twisted shield ends (pigtails),
since this ruins the shielding effect at high
frequencies. Use ca le clamps instead.
- It is important to ensure good electrical contact from
the installation plate through the installation screws
to the metal ca inet of the varia le frequency drive.
- Use starwashers and galvanically conductive
installation plates.
- Do not use unshielded/unarmoured motor
ca les in the installation ca inets.
The illustration elow shows EMC-correct electrical
installation, in which the varia le frequency
drive has een fitted in an installation ca inet
and connected to a PLC.
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VLT® 2800 Series
■Grounding of s ielded/armoured control cables
In general control ca les must e shielded/armoured,
and the shield must e connected to the unit’s metal
ca inet with a ca le clamp at each end.
The drawing elow shows the correct way to perform
the grounding, and what to do when in dou t.
1. Correct grounding
Control ca les and ca les for serial
communication must e attached with ca le
clamps at oth ends to ensure maximum
possi le electrical contact.
2. Incorrect grounding
Do not use twisted shield ends that are
plaited together (pigtails), as these increase shield
impedance at higher frequencies.
3. Protection wit respect to ground
potential between PLC and VLT
f the ground potential etween the VLT
varia le frequency drive and the PLC (etc.)
is different, electric noise may occur that will
distur the whole system. This pro lem can
e solved y fitting an equalising ca le, to e
placed next to the control ca le. Minimum ca le
cross-section: 6 AWG (16 mm2).
4. n t e event of a 50/60 Hz ground loop
If very long control ca les are used, 50/60 Hz
ground loops can arise, and these can interfere
with the whole system. This pro lem is resolved
y attaching one end of the shield to the ground
via a 100 nF capacitor (short pin length).
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VLT® 2800 Series
Installation
■Diagram
* Integrated 1A RFI filter and rake is an option.
** VLT 2803-2815 200-240 V is not supplied
with intermediate circuit coils.
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VLT® 2800 Series
■Electrical installation
VLT 2803-2815 200-240 V, 2805-2815 380-480 V
VLT 2822 200-240 V, 2822-2840 380-480 V
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VLT® 2800 Series
Installation
VLT 2840 200-240 V, 2855-2875 380-480 V
VLT 2880-2882 380-480V
Please note, that the units will e supplied
with two ottom plates; one for metric glands
and one for conduits.
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VLT® 2800 Series
■Safety clamp
To maintain the galvanic isolation (PELV) etween
the control terminals and high-voltage terminals, the
accompanying safety clamp must e attached to
VLT 2803-2815, 200-240 V, and VLT 2805-2815,
380-480 V. Attach the safety clamp to the strain
relief plate with the two screws provided.
■Input fuses
For all unit types, external fuses must e fitted in the
AC line supply to the drive. For UL/cUL applications
with an AC voltage of 200-240 Volts, use fuses type
Bussmann KTN-R (200-240 Volts) or Ferraz Shawmut
type ATMR (max. 30A). For UL/ cUL applications
with an AC voltage of 380-480 Volts, use fuses type
Bussmann KTS-R (380-480 Volts). See Technical data
in this manual for correct dimensioning of fuses.
It is the responsi ility of the installer or
user to insure proper external AC power
input fusing to the drive.
■AC line connection
All drives that are equipped with an RFI
filter cannot e connected to a grounded
DELTA or IT mains/AC line system.
NOTE
Check that the AC voltage matches the voltage
rating of the drive. The drive rating is on the
drive nameplate. See Technical data in this
manual for correct dimensioning of ca le cross-section.
For single phase 220-240 Volts input, attach the
neutral wire to terminal N (L2) and connect the
phase wire to terminal L1 (L1).
No. N(L2) L1(L1) (L3) AC line voltage 1 x 220-240 V
NL1
No. 95 Ground connection
No. N(L2) L1(L1) (L3) AC line voltage 3 x 220-240 V
L2 L1 L3
No. 95 Ground connection
No. 91 92 93 AC line voltage 3 x 380-480 V
L1 L2 L3
No. 95 Ground connection
380-460 Volt units with RFI-filters may not
e connected to AC line supplies in which
the voltage etween phase and ground is
more than 300 Volts. Please note that for the AC line
for IT and the delta ground the AC line voltage can
exceed 300 Volts etween phase and ground. Units
with type code R5 can e connected to mains supplies
with up to 400 V etween phase and ground.
See Technical data for correct dimensioning
of ca le cross-section.
■Motor connection
NOTE
It is recommended that an LC filter e
connected to the output of the drive for motors
without phase insulation paper.
See Technical data in this manual for correct
dimensioning for ca le cross-section. All types
of three-phase asynchronous standard motors
can e connected to a drive.
Connect the motor to terminals 96, 97, 98.
Connect ground to terminal 99.
N0. 96 97 98 Motor voltage 0-100%
UVW of AC line voltage.
N0. 99 Ground connection
See Technical data for correct dimensioning
of ca le cross-section.
Ensure that the motor is wired for the line voltage
efore connecting to the drive.
■Direction of motor rotation
To change the direction of motor rotation, switch any
two phases at the drive output or at motor terminals.
■Motor t ermal protection
The electronic thermal relay in UL approved varia le
frequency drives has received the UL approval for single
motor protection, when parameter 128 Motor thermal
protection has een set for ETR Trip and parameter
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VLT® 2800 Series
Installation
105 Motor current, IM, N has een programmed to
the rated motor current (see motor nameplate).
■Parallel connection of motors
The adjusta le frequency drive is a le to control
several motors connected in parallel. The com ined
total current consumption of the motors is not to
exceed the maximum rated output current (IINV)for
the adjusta le frequency drive. If the motors are to
have different rpm values, use motors with different
rated rpm values. Motor frequency is changed
simultaneously, which means that the ratio etween
the rated rpm values is maintained.
Pro lems may arise at start-up and when operating
at low rpm if the motor sizes are widely different.
This is ecause the small motors’relatively high
resistance in the stator calls for a higher voltage
at the start-up and at low rpm.
In systems with motors connected in
parallel, the electronic thermal relay (ETR)
of the adjusta le frequency drive cannot
e used as motor protection for the individual motor.
Protection must e provided individually for each motor.
■Motor cables
See Technical data for correct sizing of motor ca le
cross-section and length. Always comply with national
and local regulations on ca le cross-section.
NOTE
If an unshielded/unarmoured ca le is used,
some EMC requirements are not complied with,
see EMC test results in the Design Guide.
If the EMC specifications regarding emission are
to e complied with, the motor ca le must e
shielded/armoured, unless otherwise stated for the
RFI filter in question. It is important to keep the
motor ca le as short as possi le so as to reduce the
noise level and leakage currents to a minimum. The
motor ca le shield must e connected to the metal
ca inet of the varia le frequency drive and to the metal
ca inet of the motor. The shield connections are to
e made with the iggest possi le surface area (ca le
clamp). This is ena led y different installation devices
in different varia le frequency drives. Mounting with
twisted shield ends (pigtails) is to e avoided, since
these spoil the shielding effect at high frequencies. If
it is necessary to reak the shield to install a motor
isolator or motor relay, the shield must e continued
at the lowest possi le HF impedance.
■Brake connection
NOTE
Voltages up to 850 VDC occur on the terminals.
No. 81 82 Brake resistor
R- R+ terminals
Connect the rake resistor wiring to drive terminals 81
and 82. The connection ca le to the rake resistor
must e shielded/armored. Connect the shield to
oth the ground of the drive and the rake resistor y
means of ca le clamps. Dimension the cross-section
of the rake ca le to match the rake torque.
■Ground connection
Since the leakage currents to ground may e higher
than 3.5 mA, the adjusta le frequency drive must
always e connected to ground in accordance with
applica le national and local regulations. To ensure
that the ground ca le has good mechanical connection
to terminal 95, the ca le cross section must e a
minimum 7 AWG (10 mm2). To improve protection
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VLT® 2800 Series
even further, a Recidual Current Device (RCD) can e
fitted to ensure that the adjusta le frequency drive
cuts out when the leakage currents get too high. Also
see RCD Application note MN.90.GX.02.
■Load s aring
Load sharing provides the facility to connect several
frequency converters’DC intermediate circuits.
This requires that the installation is extended using
extra fuses and AC coils (see drawing elow).
For load sharing parameter 400 Brake function
must e set to oad sharing [5].
Use 6.3 mm Faston Plugs for DC (Load Sharing).
Contact Danfoss or see instructions no. MI.50.NX.02
for further information.
No. 88 89 Loadsharing
-+
Note that voltage levels of up to 850 V DC
may occur etween terminals 88 and 89.
■Tig tening Torque, Power Terminals
Power and ground terminals must e tightened
with the following torques:
VLT Terminals To r q u e [ N m ]
Power line rake 0.5-0.62803-
{new-
line/}2875
Ground 2-3
Power line rake 1.2-1.52880-
{new-
line/}2882
Ground 2-3
■Calculation of brake resistance
In lifting/lowering applications you need to e a le
to control an electromagnetic rake. The rake is
controlled using a relay output or digital output (terminal
46). The output must e kept closed (voltage-free)
for the period of time during which the varia le
frequency drive is not a le to ’support’the motor,
for example due to the load eing too great. Select
Mechanical brake control in parameter 323 or 341 for
applications with an electromagnetic rake.
When the output frequency exceeds the rake cut
out value set in par. 138, the rake is released if the
motor current exceeds the preset value in parameter
140. When stopping the rake is engaged when the
output frequency is less than the rake engaging
frequency, which is set in par. 139.
If the varia le frequency drive is placed at alarm
status or in an overvoltage situation the mechanical
rake is cut in immediately.
NOTE
This application is only for lifting/lowering
without a counter alance.
■Access to control terminals
All control terminals are located underneath the
protective plate on the front of the adjusta le
frequency drive. Remove the protective plate y
sliding it downwards (see drawing).
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VLT® 2800 Series
Installation
■Electrical installation, control circuitry
NOTE
Using unshielded/unarmored ca le may not
comply with some EMI/RFI requirements.
Control wires must e shielded/armored. Connect the
shield to the drive chassis with a clamp. Normally,
the shield must also e connected to the chassis of
the controlling device. (See the instructions for the
specific device.) In analog signals or connections using
very long wires, 50/60 Hz ground loops may occur
ecause of noise transmitted from the AC line. It may
e necessary to reak the shield and insert a 100 µF
capacitor etween the shield and the chassis.
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VLT® 2800 Series
■Tig tening torques, control cables
Control wires must e connected with a tightening
torque of 0.22–0.25 Nm.
■Electrical installation, control terminals
NOTE
Using unshielded/unarmored ca le may not
comply with some EMC/RFI requirements.
Refer to the following ta le for VLT 2800 terminal
designations and their functional descriptions.
No. Function
01-03 Relay outputs 01-03 can e used for
indicating status and alarms/warnings.
12 24 VDC voltage supply.
18-33 Digital inputs.
20, 55 Common frame for input
and output terminals.
42 Analog output for displaying frequency,
reference, current or torque.
461Digital output for displaying status,
warnings or alarms, as well as
frequency output.
50 +10 VDC supply
voltage for potentiometer or thermistor.
53 Analog voltage input 0 - 10 V DC.
60 Analog current input 0/4 - 20 mA.
671+ 5 VDC supply voltage
to Profi us.
68,
691
RS-485, Serial communication.
701Frame for terminals 67, 68 and 69.
Normally this terminal is not to e used.
1. The terminals are not valid for DeviceNet. See the
DeviceNet manual, MG.90.BX.YY for further details.
NOTE
To supply internal 24 VDC voltage to the
digital input terminals, jumper terminal
12 to terminal 27.
■Relay connection
See parameter 323, Relay output for programming
of relay output.
No. 01 - 02 1 - 2 make (normally open)
01 - 03 1 - 3 reak (normally closed)
NOTE
The ca le jacket for the relay must cover
the first row of control card terminals -
otherwise the galvanic isolation (PELV)
cannot e maintained. Maximum ca le diameter:
0-160 in (4 mm). See drawing.
■Profibus DIP switc es setting
The dip switch is only on the control card with Profi us
DP communication. The switch position shown is the
factory setting. Switches 1 and 2 are used as ca le
termination for the RS-485 interface. If the adjusta le
frequency drive is located as the first or last (or only)
unit in the us system, switches 1 and 2 must e ON.
On the remaining adjusta le frequency drives, switches
1 and 2 must e OFF. Switches 3 and 4 are not applied.
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VLT® 2800 Series
Installation
■VLT Software Dialog
Connection to terminals 68-70 or
Su D:
-PIN3GND
- PIN 8 P-RS 485
- PIN 9 N-RS 485
■Sub D plug
An LCP 2 control unit can e connected to the Su D
plug on the control card. Ordering num er: 175N0131.
LCP control units with ordering num er 175Z0401
are not to e connected.
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VLT® 2800 Series
■Connection examples
■Start/stop
Start/stop using terminal 18 and coasting
stop using terminal 27.
Par. 302 Digital input =Start [7]
Par. 304 Digital input =Coasting stop inverted [2]
For Precise start/stop the following settings are made:
Par. 302 Digital input =Precise start/stop [27]
Par. 304 Digital input =Coasting stop inverted [2]
■Pulse start/stop
Pulse start using terminal 18 and pulse stop
using terminal 19. In addition, the jog frequency
is activated via terminal 29.
Par. 302 Digital input =Pulse start [8]
Par. 303 Digital input =Stop inverted [6]
Par. 304 Digital input =Coasting stop inverted [2]
Par. 305 Digital input =Jog [13]
■Speed up/slow down
Speed up/slow down using terminals 29/33.
Par. 302 Digital input =Start [7]
Par. 303 Digital input =Freeze reference [14]
Par. 305 Digital input =Speed up [16]
Par. 307 Digital input =Slow down [17]
■Potentiometer reference
Voltage reference via a potentiometer.
Par. 308 Analog input =Reference [1]
Par. 309 Terminal 53, min. scaling =0Volt
Par. 310 Terminal 53, max. scaling =10Volt
■Connection of a 2-wire transmitter
Connection of a 2-wire transmitter as feed ack
to terminal 60.
Par. 314 Analog input =Feedback [2]
Par. 315 Terminal 60, min. scaling =4mA
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VLT® 2800 Series
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Par. 316 Terminal 60, max. scaling =20mA
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