Danfoss VLT FC 322 User manual

MAKING MODERN LIVING POSSIBLE
IInstruction Manual
VLTpAutomation VT Drive FC 322
www.danfoss.com/drives
*MG21E122*
130R0411 MG21E122 Rev. 2012-05-03
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Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start up,
and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Frequency converters are connected to hazardous mains
voltages. Extreme care should be taken to protect against
shock. Only trained personnel familiar with electronic
equipment should install, start, or maintain this equipment.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency converter,
motor, and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
frequency converter is connected to AC mains could result
in death, serious injury, equipment, or property damage.
Unintended Start
When the frequency converter is connected to the AC
mains, the motor may be started by means of an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate cautions to
guard against an unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is not
powered. To avoid electrical hazards, disconnect AC mains,
any permanent magnet type motors, and any remote DC-
link power supplies, including battery backups, UPS and
DC-link connections to other frequency converters. Wait for
the capacitors to fully discharge before performing any
service or repair work. The amount of wait time is listed in
the Discharge Time table. Failure to wait the specified time
after power has been removed before doing service or
repair could result in death or serious injury.
Voltage [V] Power range [kW] Minimum waiting time
[min]
3x400 90-250 20
3x400 110-315 20
3x500 110-315 20
3x500 132-355 20
3x525 75-250 20
3x525 90-315 20
3x690 90-250 20
3x690 110-315 20
Discharge Time
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Safety VLT® Automation VT Drive FC 322 D-Frame Instruction Manual
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Contents
1 Introduction
2-1
1.1 Exploded Views 2-1
1.2 Purpose of the Manual 2-2
1.3 Additional Resources 2-2
1.4 Product Overview 2-2
1.5 Internal Controller Functions 2-2
1.6 Frame Sizes and Power Ratings 2-3
2 Installation
3-1
2.1 Planning the Installation Site 3-1
2.2 Pre-Installation Check List 3-1
2.3 Mechanical Installation 3-1
2.3.1 Cooling 3-1
2.3.2 Lifting 3-2
2.3.3 Wall Mounting - IP21 (NEMA 1) and IP54 (NEMA 12) Units 3-2
2.4 Electrical Installation 3-3
2.4.1 General Requirements 3-3
2.4.2 Earth (Grounding) Requirements 3-5
2.4.2.1 Leakage Current (>3.5 mA) 3-5
2.4.2.2 Earthing (Grounding) IP20 Enclosures 3-6
2.4.2.3 Earthing (Grounding) IP21/54 Enclosures 3-6
2.4.3 Motor Connection 3-7
2.4.4 Motor Cable 3-10
2.4.5 Motor Rotation Check 3-10
2.4.6 AC Mains Connection 3-10
2.5 Control Wiring Connection 3-11
2.5.1 Access 3-11
2.5.2 Using Screened Control Cables 3-11
2.5.3 Earthing (Grounding) of Screened Control Cables 3-12
2.5.4 Control Terminal Types 3-13
2.5.5 Wiring to Control Terminals 3-13
2.5.6 Control Terminal Functions 3-13
2.6 Serial Communication 3-13
3 Start Up and Commissioning
4-1
3.1 Pre-start 4-1
3.2 Applying Power to the Frequency Converter 4-2
3.3 Basic Operational Programming 4-2
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3.4 Local-control Test 4-4
3.5 System Start Up 4-4
4 User Interface
5-1
4.1 Local Control Panel 5-1
4.1.1 LCP Layout 5-1
4.1.2 Setting LCP Display Values 5-2
4.1.3 Display 5-2
4.1.4 Navigation Keys 5-3
4.1.5 Operation Keys 5-3
4.2 Back Up and Copying Parameter Settings 5-3
4.2.1 Uploading Data to the LCP 5-4
4.2.2 Downloading Data from the LCP 5-4
4.3 Restoring Default Settings 5-4
4.3.1 Recommended Initialisation 5-4
4.3.2 Manual Initialisation 5-4
5 Programming
6-1
5.1 Introduction 6-1
5.2 Programming Example 6-1
5.3 Control Terminal Programming Examples 6-3
5.4 International/North American Default Parameter Settings 6-3
5.5 Parameter Menu Structure 6-4
5.5.1 Main Menu Structure 6-5
5.6 Remote Programming with MCT 10 Set-up Software 6-9
6 Application Examples
7-1
6.1 Introduction 7-1
6.2 Application Examples 7-1
7 Status Messages
8-1
7.1 Status Display 8-1
7.2 Status Message Definitions Table 8-1
8 Warnings and Alarms
9-1
8.1 System Monitoring 9-1
8.2 Warning and Alarm Types 9-1
8.2.1 Warnings 9-1
8.2.2 Alarm Trip 9-1
8.2.3 Alarm Trip-lock 9-1
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8.3 Warning and Alarm Displays 9-1
8.4 Warning and Alarm Definitions 9-2
8.5 Fault Messages 9-5
9 Basic Troubleshooting
10-1
9.1 Start Up and Operation 10-1
10 Specifications
11-1
10.1 Power-dependent Specifications 11-1
10.2 General Technical Data 11-2
10.3 Fuse Tables 11-7
10.3.1 Protection 11-7
10.3.2 Non UL Compliance 11-7
10.3.3 UL Compliance 11-8
10.3.4 Connection Tightening Torques 11-8
12 Index
12-1
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1Introduction
1.1 Exploded Views
Figure 1.1 D1 Interior Components
Figure 1.2 Close-up View: LCP and Control Functions
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1 LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Earth (ground)
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03)
Table 1.1
1.2 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
2 Installation provides requirements for mechanical and
electrical installation, including input, motor, control and
serial communications wiring, and control terminal
functions. 3 Start Up and Commissioning provides detailed
procedures for start up, basic operational programming,
and functional testing. The remaining chapters provide
supplementary details. These details include user interface,
detailed programming, application examples, start-up
troubleshooting, and specifications.
1.3 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•
The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•
The VLT
®
Design Guide is intended to provide
detailed capabilities and functionality to design
motor control systems.
•
Optional equipment is available that may change
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website for
downloads or additional information.
1.4 Product Overview
A frequency converter is an electronic motor controller
that converts AC mains input into a variable AC waveform
output. The frequency and voltage of the output are
regulated to control the motor speed or torque. The
frequency converter can vary the speed of the motor in
response to system feedback, such as position sensors on a
conveyor belt. The frequency converter can also regulate
the motor by responding to remote commands from
external controllers.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, and offers many more control, monitoring, and
efficiency functions. Operation and monitoring functions
are available as status indications to an outside control
system or serial communication network.
1.5 Internal Controller Functions
Figure 1.3 is a block diagram of the frequency converter's
internal components. See Table 1.2 for their functions.
Figure 1.3 Frequency Converter Block Diagram
Area Title Functions
1Mainsinput
•
Three-phase AC mains power
supply to the frequency
converter
2Rectifier
•
The rectifier bridge converts
the AC input to DC current to
supply inverter power
3DCbus
•
Intermediate DC-bus circuit
handles the DC current
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Area Title Functions
4 DC reactors
•
Filter the intermediate DC
circuit voltage
•
Prove line transient protection
•
Reduce RMS current
•
Raise the power factor
reflected back to the line
•
Reduce harmonics on the AC
input
5 Capacitor bank
•
Stores the DC power
•
Provides ride-through
protection for short power
losses
6Inverter
•
Converts the DC into a
controlled PWM AC waveform
for a controlled variable
output to the motor
Area Title Functions
7 Output to motor
•
Regulated three-phase output
power to the motor
8 Control circuitry
•
Input power, internal
processing, output, and motor
current are monitored to
provide efficient operation
and control
•
User interface and external
commands are monitored and
performed
•
Status output and control can
be provided
Table 1.2 Frequency Converter Internal Components
1.6 Frame Sizes and Power Ratings
kW rated frequency converters
kW High Overload 75 90 110 132 160 200 250 315 315
kW Normal Overload 90 110 132 160 200 250 315 355 400
400 V D3h D3h D3h D4h D4h D4h
500 V D3h D3h D3h D4h D4h D4h
525 V D4h D3h D3h D4h D4h D4h D4h
690 V D3h D3h D3h D4h D4h D4h
Table 1.3
Horsepower rated frequency converters
HP High
Overload
100 125 150 200 250 300 350 350
HP Normal
Overload
125 150 200 250 300 350 400 450
460 V D3h D3h D3h D4h D4h D4h
575 V D3h D3h D3h D4h D4h D4h D4h
Table 1.4
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2 Installation
2.1 Planning the Installation Site
CAUTION
Before performing the installation it is important to plan
the installation of the frequency converter. Neglecting this
may result in extra work during and after installation.
Select the best possible operation site by considering the
following (see details on the following pages, and the
respective Design Guides):
•
Ambient operating temperature
•
Installation method
•
How to cool the unit
•
Position of the frequency converter
•
Cable routing
•
Ensure the power source supplies the correct
voltage and necessary current
•
Ensure that the motor current rating is within the
maximum current from the frequency converter
•
If the frequency converter is without built-in
fuses, ensure that the external fuses are rated
correctly.
Installation in High Altitudes
Voltage Altitude Restrictions
380-500 V At altitudes above 3 km, contact Danfoss regarding
PELV
525-690 V At altitudes above 2 km, contact Danfoss regarding
PELV.
Table 2.1
2.2 Pre-Installation Check List
•
Before unpacking the frequency converter, ensure
the packaging is intact. If any damage has
occurred, immediately contact the shipping
company to claim the damage.
•
Before unpacking the frequency converter, locate
it as close as possible to the final installation site.
•
Compare the model number on the nameplate to
what was ordered to verify the proper
equipment.
•
Ensure each of the following are rated for the
same voltage:
•
Mains (power)
•
Frequency converter
•
Motor
•
Ensure that frequency converter output current
rating is equal to or greater than motor full load
current for peak motor performance.
•
Motor size and frequency converter
power must match for proper overload
protection.
•
If frequency converter rating is less than
motor, full motor output cannot be
achieved.
2.3 Mechanical Installation
2.3.1 Cooling
•
Top and bottom clearance for air cooling must be
provided. Generally, 225 mm (9 in) is required.
•
Improper mounting can result in over heating
and reduced performance
•
Derating for temperatures starting between 45°C
(113°F) and 50°C (122°F) and elevation 1000 m
(3300 ft) above sea level must be considered. See
VLT
® Design Guide for detailed information.
The high power Danfoss VLT frequency converters utilize a
back-channel cooling concept that removes heatsink
cooling air, which carries approximately 90% of the heat
out of the back channel of the frequency converters. The
back-channel air can be redirected from the panel or room
using one of the kits below.
Duct cooling
A back-channel cooling kit is available to direct the
heatsink cooling air out of the panel when an IP20/chassis
frequency converters is installed in a Rittal enclosure. Use
of this kit reduces the heat in the panel and smaller door
fans can be specified on the enclosure.
Cooling out the back (top and bottom covers)
The back channel cooling air can be ventilated out of the
room so that the heat from the back channel is not
dissipated into the control room.
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A door fan(s) is required on the enclosure to remove the
heat not contained in the backchannel of the frequency
converters and any additional losses generated by other
components inside the enclosure. The total required air
flow must be calculated so that the appropriate fans can
be selected.
Airflow
The necessary airflow over the heat sink must be secured.
The flow rate is shown in Table 2.2.
The fan runs for the following reasons:
•
AMA
•
DC Hold
•
Pre-Mag
•
DC Brake
•
60% of nominal current is exceeded
•
Specific heatsink temperature exceeded (power
size dependent).
•
Specific Power Card ambient temperature
exceeded (power size dependent)
•
Specific Control Card ambient temperature
exceeded
Frame Door fan/top fan Heatsink fan
D1h/D3h 102 m
3
/hr (60 CFM) 420 m
3
/hr (250 CFM)
D2h/D4h 204 m
3
/hr (120 CFM) 840 m
3
/hr (500 CFM)
Table 2.2 Airflow
2.3.2 Lifting
Always lift the frequency converter using the dedicated
lifting eyes. Use a bar to avoid bending the lifting holes.
Figure 2.1 Position Lifting Straps where Indicated
CAUTION
The angle from the top of the frequency converter to the
lifting cables should be 60 °or greater.
2.3.3 Wall Mounting - IP21 (NEMA 1) and
IP54 (NEMA 12) Units
Consider the following before selecting the final instal-
lation site:
•
Free space for cooling
•
Access to open the door
•
Cable entry from the bottom
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2.4 Electrical Installation
2.4.1 General Requirements
This section contains detailed instructions for wiring the
frequency converter. The following tasks are described:
•
Wiring the motor to the frequency converter
output terminals
•
Wiring the AC mains to the frequency converter
input terminals
•
Connecting control and serial communication
wiring
•
After power has been applied, checking input
and motor power; programming control terminals
for their intended functions
Figure 2.2
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WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be hazardous.
All electrical work must conform to national and local
electrical codes. It is strongly recommended that instal-
lation, start up, and maintenance be performed only by
trained and qualified personnel. Failure to follow these
guidelines could result in death or serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in three
separate metallic conduits or use separated shielded cable
for high frequency noise isolation. Failure to isolate power,
motor and control wiring could result in less than
optimum frequency converter and associated equipment
performance.
For your safety, comply with the following requirements
•
Electronic controls equipment is connected to
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
•
Run motor cables from multiple frequency
converters separately. Induced voltage from
output motor cables run together can charge
equipment capacitors even with the equipment
turned off and locked out.
•
Field wiring terminals are not intended to receive
a conductor one size larger.
Overload and Equipment Protection
•
An electronically activated function within the
frequency converter provides overload protection
for the motor. The overload calculates the level of
increase to activate timing for the trip (controller
output stop) function. The higher the current
draw, the quicker the trip response. The overload
provides Class 20 motor protection. See
8 Warnings and Alarms for details on the trip
function.
•
Because the motor wiring carries high frequency
current, it is important that wiring for mains,
motor power, and control are run separately. Use
metallic conduit or separated shielded wire. See
Figure 2.3. Failure to isolate power, motor, and
control wiring could result in less than optimum
equipment performance.
•
All frequency converters must be provided with
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Figure 2.4. If not factory supplied, fuses must be
provided by the installer as part of installation.
See maximum fuse ratings in 10.3.1 Protection.
Figure 2.3 Example of Proper Electrical Installation Using Conduit
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•
All frequency converters must be provided with
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Figure 2.4. If not factory supplied, fuses must be
provided by the installer as part of installation.
See maximum fuse ratings in 10.3.1 Protection.
Figure 2.4 Frequency Converter Fuses
Wire Type and Ratings
•
All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•
Danfoss recommends that all power connections
be made with a minimum 75°C rated copper
wire.
2.4.2 Earth (Grounding) Requirements
WARNING
EARTHING (GROUNDING) HAZARD!
For operator safety, it is important to earth (ground) the
frequency converter properly in accordance with national
and local electrical codes as well as instructions contained
within this document. Do not use conduit connected to
the frequency converter as a replacement for proper
grounding. Earth (ground) currents are higher than 3.5 mA.
Failure to earth (ground) the frequency converter properly
could result in death or serious injury.Earthing (grounding)
hazard
NOTE!
It is the responsibility of the user or certified electrical
installer to ensure correct earthing (grounding) of the
equipment in accordance with national and local electrical
codes and standards.
•
Follow all local and national electrical codes to
earth (ground) electrical equipment properly.
•
Proper protective earthing (grounding) for
equipment with earth (ground) currents higher
than 3.5 mA must be established, see
2.4.2.1 Leakage Current (>3.5 mA).
•
A dedicated earth wire (ground wire) is required
for input power, motor power and control wiring.
•
Use the clamps provided with the equipment for
proper earth connections (ground connections).
•
Do not earth (ground) one frequency converter to
another in a “daisy chain” fashion.
•
Keep the earth (ground) wire connections as
short as possible.
•
Using high-strand wire to reduce electrical noise
is recommended.
•
Follow motor manufacturer wiring requirements.
2.4.2.1 Leakage Current (>3.5 mA)
Follow national and local codes regarding protective
earthing of equipment with a leakage current > 3.5 mA.
Frequency converter technology implies high frequency
switching at high power. This will generate a leakage
current in the earth connection. A fault current in the
frequency converter at the output power terminals might
contain a DC component, which can charge the filter
capacitors and cause a transient earth current. The earth
leakage current depends on various system configurations
including RFI filtering, screened motor cables, and
frequency converter power.
EN/IEC61800-5-1 (Power Drive System Product Standard)
requires special care if the leakage current exceeds 3.5 mA.
Earthing (grounding) must be reinforced in one of the
following ways:
•
Earth (ground) wire of at least 10 mm
2
•
Two separate earth (ground) wires both
complying with the dimensioning rules.
See EN 60364-5-54 § 543.7 for further information.
Using RCDs
Where residual current devices (RCDs)–also known as earth
leakage circuit breakers (ELCBs)–are used, comply with the
following: residual current devices (RCDs)
•
Use 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-
ration and environmental considerations.
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2.4.2.2 Earthing (Grounding) IP20
Enclosures
The frequency converter can be earthed (grounded) using
conduit or shielded cable. For earthing (grounding) of the
power connections, use the dedicated earthing
(grounding) points as shown in Figure 2.6.
Figure 2.5 Earthing (Grounding) Points for IP20 (Chassis)
Enclosures
2.4.2.3 Earthing (Grounding) IP21/54
Enclosures
The frequency converter can be earthed (grounded) using
conduit or shielded cable. For earthing (grounding) of the
power connections, use the dedicated earthing
(grounding) points as shown in Figure 2.6.
Figure 2.6 Earthing (Grounding) for IP21/54 Enclosures.
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2.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple frequency
converters separately. Induced voltage from output motor
cables run together can charge equipment capacitors even
with the equipment turned off and locked out. Failure to
run output motor cables separately could result in death
or serious injury.
•
For maximum cable sizes, see 10.1 Power-
dependent Specifications..
•
Comply with local and national electrical codes
for cable sizes.
•
Gland plates are provided at the base of IP21/54
and higher (NEMA1/12) units.
•
Do not install power factor correction capacitors
between the frequency converter and the motor.
•
Do not wire a starting or pole-changing device
between the frequency converter and the motor.
•
Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W).
•
Earth (ground) the cable in accordance with the
instructions provided.
•
Torque terminals in accordance with the
information provided in 10.3.4 Connection
Tightening Torques
•
Follow motor manufacturer wiring requirements.
Figure 2.7 Terminal Locations D1h
Installation VLT® Automation VT Drive FC 322 D-Frame Instruction Manual
MG21E122 - VLT® is a registered Danfoss trademark 2-7
2
2
Remote Site Products - 1-888-532-2706 - www.remotesiteproducts.com
http://www.remotesiteproducts.com/p-20776-Danfoss-131X8139-VLT-Automation-VT-Drive-VFD-FC322-230V-20-HP.aspx

Figure 2.8 Terminal Locations D3h
Figure 2.9 Terminal Locations D2h
Installation VLT® Automation VT Drive FC 322 D-Frame Instruction Manual
2-8 MG21E122 - VLT® is a registered Danfoss trademark
2
2
Remote Site Products - 1-888-532-2706 - www.remotesiteproducts.com
http://www.remotesiteproducts.com/p-20776-Danfoss-131X8139-VLT-Automation-VT-Drive-VFD-FC322-230V-20-HP.aspx

Figure 2.10 Terminal Locations D4h
Installation VLT® Automation VT Drive FC 322 D-Frame Instruction Manual
MG21E122 - VLT® is a registered Danfoss trademark 2-9
2
2
Remote Site Products - 1-888-532-2706 - www.remotesiteproducts.com
http://www.remotesiteproducts.com/p-20776-Danfoss-131X8139-VLT-Automation-VT-Drive-VFD-FC322-230V-20-HP.aspx