Danfoss VLT 5000 Series User manual

1
VLT 5000 Installation
Startup Check List
• Reference material
• Pre-Installation
• Installation Checks
•Wiring
– Incoming Power
– Motor
–Brake
– Control
– Serial Communications
This presentation deals with the start-up of VLT 5000 drives. It is designed to help you
handle the start-up of the drive in normal applications. Because of the flexibility of these
drives, there may be some specialized applications that are not specifically covered by these
instructions. In that case, refer to the documentation that came with the drive for more
specific information.
This training module covers the installation and wiring of the VLT 5000. This section starts
with reference material, installation checks and then covers a number of wiring options.
Programming of the VLT 5000 is covers in another module.

2
Touching the electrical parts may be fatal — even after
the equipment has been disconnected from the AC line.
To be sure that the capacitors have fully discharged,
wait 15 minutes after power has been removed before
touching any internal component
DANGE
R
!
Because the drive uses large electrolytic capacitors in its power circuitry, it can maintain a
dangerous voltage level for up to 15 minutes after power has been removed. Therefore,
always be sure that power has been removed from the drive for at least 15 minutes before
working with the power circuitry of the drive.
It is always wise to use a voltmeter to measure any potentially dangerous electrical circuit
before working on it.

3
Reference Material
• Instruction Manuals
• Connection Diagram
• Schematic Diagram
These three pieces of reference material might be available to you when you are starting up
a drive.
The VLT 5000 Instruction Manual provides general information on topics like mounting
clearances, drive fuses, terminal tightening torques, and drive parameters.
From the Customer, a Connection Diagram might be available which provides a sketch
indicating the layout and use the equipment in the system. A Schematic Diagram from the
customer could also provide details of the wiring between the drive, any options, and the
control system.

4
Hp to kW Chart
• 1 Hp = 0.746kW
• Each VLT 5000 can be under sized by 4 and over
sized by 1 – but watch current limits.
• This chart shows most of the Parameter 102 settings
Model Hp kW Model Hp kW
0.25 0.18 5032 30.0 22.0
0.33 0.25 5042 40.0 30.0
0.50 0.37 5052 50.0 37.0
0.75 0.55 5062 60.0 45.0
5001 1.0 0.75 5075 75.0 55.0
5002 1.5 1.1 5100 100.0 75.0
5003 2.0 1.5 5125 125.0 90.0
5004 3.0 2.2 5150 150.0 110.0
5005 4.0 3.0 5200 200.0 132.0
5006 5.0 4.0 5250 250.0 160.0
5008 7.5 5.5 5300 300.0 200.0
5011 10.0 7.5 5350 350.0 250.0
5016 15.0 11.0 5450 450.0 315.0
5022 20.0 15.0 5500 500.0 355.0
5027 25.0 18.5
The drive takes all size information in kilowatts (kW), so horsepower (Hp) must be converted
to kW. The formula is 1 Hp = ¾ of a kW. The chart above shows the equivalent.
Each drive size can be programmed to accommodate 4 sizes smaller and one size larger.
On the larger size – do not exceed the maximum current rating of the drive.
Parameter 102 in the Instruction Manual shows all the kW sizes.

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The Nameplates
All Drives – On the Top or Left Side of the Drive
Output Ratings of Drive
Catalog Number
Sales Number
Serial Number
The drive has two identifying numbers, the catalog number and the sales number.
A Catalog Number, which is explained on the next slide, is the long number. In the example
above the catalog number is VLT 5011-P-T2-CN1-ST-R0-DL-F00-A00.
When ordered, the Catalog Number is converted into a Sales Number which is much less
cumbersome. In the example above 178B3372 is the Sales Number.
The Serial Number, 805016H332 indicates the series, revision, place and date of
manufacturing, and is very important concerning warranty work. The last 3 numbers
indicate the week followed by the year. In this example 332, means week 33 of 2002.
Input and Output ratings are also placed on the label for an additional check.

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Pre-Installation Check
• Compare AFD model number with what was ordered.
Catalog Order Number System (Found on page D 62 of the catalog)
Example: VLT- 5008–P-T5-B20–EB-R0–DL-F00-A00-C0
VLT: Series
5XXX: Model Number -------------|
P: Process Application -----------------|
AC Line Voltage -----------------------------|
T2: 3 phase 200 – 240 Vac
T5: 3 phase 380 – 500 Vac
T6: 3 phase 550 – 600 Vac
Enclosure (dimensions -page 39)-------------|
B20: Bookstyle Chassis (IP20)
C00: Compact Chassis (IP 00)
C20: Compact Protected Chassis (IP 20)
CN1: Compact NEMA 1 (IP 20)
C54: Compact NEMA 12 (IP 54)
Hardware – EB ST means Standard
SB means Standard with Brake
EB means Extended with brake (load-sharing) the 300-
500Hp have EX and DX which has a fuse disconnect
RFI Filter – R0 R0 means no extra filter
R1 adds 1A filter
R3 adds both 1A and 1B filter
Display – DL DL means with LCP display
D0 is without the LCP
Fieldbus Option – F00
F00 = none; F10 = Profibus DP/FMS; F20 = Modbus +; F30 =
DeviceNet; F40 = LonWorks
Application Option – A00
A00 = none; A10 = Programmable Sync/Pos Card; A11 =
Synchronizing card; A12 = Positioning Card
Conformal Coating – C0
C0 means no coating
C1 has coating

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Pre-Installation Check
• Be sure the Line Power, AFD and Motor have the same voltage
range
• Insure that all hand tools and kits are available.
Before installing the drive, check to be sure that the power line, the drive, and the motor are
all rated for the same voltage. It may be necessary to check the wiring inside the motor's
conduit box to confirm its voltage rating.
Options and kits:
Part numbers for Dynamic Brake Resistors, additional RFI Filters, LCP Remote mounting kit,
serial communication cards, application cards, additional relay cards, LC Filters and
Terminal Lug Kits are covered in the catalog.

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Pre-Installation Check
• Record motor data information
– Motor Power
– Motor Voltage
– Motor Frequency
– Motor Current (FLA)
– Motor Speed (RPM)
Write down the motor nameplate information. This will be important later during
programming. A conversion between HP and kW must be calculated 1Hp = 0.75kW.
In the example 20Hp = 15kW.
Motor Power = ___________________ kW
Motor Voltage = __________________ Vac
Motor Frequency = 50Hz 60Hz
Motor Current = __________________ Amps
Motor Speed = ___________________RPM

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Pre-Installation Check
• Always ensure that Drive can handle maximum current
of the motor.
• Example page 20 – VLT 5100 – CT, HO
It is always important to check the technical data of the instruction manual for the drive you
are installing to certify that the drive is able to handle the maximum current of the motor. In
the example above a 100Hp (75kW) motor uses 125amps maximum current. The technical
data using the High Overload (150%) section and 460 V and VLT,N rating equals 130amp,
which means that it can handle this motor.

10
Pre-Installation Check
• Check Motor Wiring
– No power correction capacitors between drive and motor
– 2-speed motors must be wired for full speed
– Part-winding start motors, must be wired for run.
Insure that there are no power correction capacitors between the drive and the motor.
These types of capacitors must always be located on the incoming power to the drive, never
the output of the drive.
If you are using the drive on a 2-speed motor, always use the “run” wiring configuration,
never use the “start” wiring.

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Installation Checks
• Fuses must be installed
– Sized using Pages 34-35 in Instruction Manual
To comply with UL / cUL, fuses must be wired on the incoming power side of the drive. The
types of fuses are shown in the technical data section of the instruction manual. In the
example above fuses and a disconnect switch are diagramed. To comply with UL never wire
the drive to circuit breakers because they do not trip as fast as fuses.

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Installation Checks
• Environmental Concerns
– Clean and Dry
– 24-Hour temperature limit – page 214
– Altitude Limits – page 214
The VLT 5000 can be supplied with a NEMA 1(IP 20) or NEMA 12(IP 54) enclosure. These
enclosures provides some degree of protection from falling dust. Therefore, drives with a
NEMA 1(IP 20) and 12(IP 54) enclosures should be mounted indoors in a relatively clean
and dry location.
Because the drive relies on the ambient air for cooling, it is important to observe the
limitations on ambient air temperature and elevation. Contact the Service Department if you
think that the mounting location of the drive compromises its ability to provide long term,
reliable operation. Charts for temperature and elevation are found near the back of the
instruction manual in the “List of Functions” section.
Temperature equivalents Heights equivalents
30°C = 86°F 1kM = 3300 feet
35°C = 95°F 2kM = 6600 feet
40°C = 104°F 3kM = 10,000 feet
45°C = 113°F Enclosure equivalents
50°C = 122°F IP 00 = chassis
55°C = 131°F IP 20, 21 = NEMA 1
60°C = 140°F IP 54 = NEMA 12
65°C = 149°F IP 65 = NEMA 4

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Installation Checks
• Mounting
– Vertical
– Flush Mounted Only
In order to provide proper cooling, the drive must always be mounted vertically.
It is also important to establish a "chimney" around the drive's heat sink to ensure that all
cooling air passes along the entire length of the heat sink. If a drive with no option panel is
not mounted directly to a vertical flat surface, it is important to see if this leaves any heat sink
fins exposed in the back. If it does, a flat plate must be mounted to the back of the drive to
ensure proper cooling.
Drives that include a bypass or other option enclosure are generally factory-mounted to a
back plate. Therefore, this is not a concern with such drives.

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Installation Checks
• Mounting
– Side by Side is acceptable
– Needs space above and below drive
The VLT 5000 cools itself by drawing cooling air through the bottom of its enclosure and
exhausting it out the top. It is therefore important to provide enough space above and below
the drive to ensure proper flow of cooling air. To determine the necessary clearances, see
the “installation” section of the Instruction Manual, pages 43-44. The smallest drive requires
4” (10cm) on the top and bottom, nothing on the sides. This top and bottom space goes
from 4”, to 9” (10-22.5cm) on smaller units, then 16” (40cm) on the largest drive which is on
the top only. All drives can be mounted side by side.

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Mounting the Drive
• Keep the drive clean
– Use dust covers to keep construction dust from
getting into it
– Remove the dust covers before applying power
If construction work continues after the drive is mounted, it is important to keep the drive as
free as possible from concrete dust and similar dirt. If the drive does not have power applied
to it, it should be kept covered. If the drive must be powered up and run, this cover must be
removed. It is still important to ensure that the drive stays as clean as possible. It may be
necessary to clean the interior of the drive once construction is completed.

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Wiring the Drive
• General Wiring
• Power Input
•Brake
• Motor Output
•Control
• Serial Comms
This next section covers the wiring of the drive. The first area to be covered is general
wiring practices. The other sections cover power or line wiring from the drive to incoming
power, brake wiring. The motor wiring covers the connections between the drive and the
motor. Control wiring for Digital Inputs/Outputs and Analog Input/Outputs are also covered.
The last section covers the wiring for serial communications.

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Wiring the Drive
• Conduit entry
– All wiring enters the bottom of drive
– Knock-outs are provided on many drives
– Larger drives have a removable conduit entry or
gland plate
General Practices
Most smaller drives have knock-outs for conduit entry. Larger drives provide a removable
conduit entry plate. It is important to remove this plate before drilling or punching it.
When a drive is supplied with an auxiliary enclosure, it generally is necessary to drill or
punch conduit entry holes in the auxiliary enclosure. It is important to ensure that metal chips
or filings don't get into any of the devices which are housed in the auxiliary enclosure.

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Wiring the Drive
• At least three separate METALLIC conduits must be connected
to the drive
– Power into the drive [L1, L2, L3 and a ground back to the
distribution panel]
– Power from the drive to the motor [U, V, W, and PE (power
earth ground)]
– Control wiring
• A dedicated ground wire is needed
At least three separate conduits must be connected to the drive. One is for the incoming
power wiring, one is for the power wiring between the drive and the controlled motor, and the
third is for the control wiring.
Because the wiring from the drive to the motor carries high frequency electrical pulses, it is
important to be sure that no other wires are run in this conduit. If the incoming power wiring
is run in the same conduit as the motor wiring, these pulses can couple electrical noise back
onto the building's power grid.
Control wiring should always be isolated from the high voltage input power wiring to the
drive or the high voltage output power wiring from the drive to the motor.

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Wiring the Drive
• Input fuses
– All drives must have input fuses installed in the
power supply to the drive
– Refer to the Instruction Manual for fuse sizing
In order to fulfill the requirements of Underwriters Laboratory (UL) as was stated on page 11,
all drives must be provided with fast-acting input power line fuses. The proper style and
rating for these fuses is specified in the Instruction Manual on page 24.

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Wiring
• General Information
– Maximum voltage to control card is 24Vdc
– Do NOT connect 120/240/460/575 to Control
terminals
– Use Relay 01, 02, 03 for 120 or 240Vac
The maximum voltage for the control circuit must not exceed 24Vdc. A separate relay
terminal 01, 02, 03 is used for higher voltages, 120/240 Vac.