Danfoss VLT Micro Drive FC 51 Series User manual

Contents
1. Safety
3
Safety Instructions 3
Approvals 3
General Warning 3
Avoid unintended Start 4
Before Commencing Repair Work 5
2. Mechanical Installation 7
Before Starting 7
Mechanical Dimensions 8
3. Electrical Installation 9
How to Connect 9
Electrical Installation in General 9
EMC-Correct Installation 10
Mains Connection 11
Motor Connection 11
Control Terminals 12
Connecting to Control Terminals 12
Switches 13
Power Circuit - Overview 14
Load sharing/Brake 14
4. Programming 15
How to Programme 15
Programming with MCT-10 15
Programming with LCP 11 or LCP 12 15
Status Menu 17
Quick Menu 17
Quick Menu Parameters 18
Main Menu 22
5. Parameter Overview 23
6. Troubleshooting 27
7. Specifications 29
Mains Supply 29
Other Specifications 31
Special Conditions 33
The Purpose of Derating 33
VLT Micro Drive FC 51 Operating Instructions Contents
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Derating for Ambient Temperature 33
Derating for Low Air Pressure 33
Derating for Running at Low Speeds 34
Options for VLT Micro Drive FC 51 35
Index
36
Contents VLT Micro Drive FC 51 Operating Instructions
2 MG.02.A2.02 - VLT®is a registered Danfoss trademark

1. Safety
1.1.1. High Voltage Warning
The voltage of the frequency converter is dangerous whenever it is connected to
mains. Incorrect installation of the motor or frequency converter 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.
1.1.2. Safety Instructions
• Make sure the frequency converter is properly connected to earth.
• Do not remove mains connections, motor connections or other power connections while
the frequency converter is connected to power.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
• The earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from
mains.
1.1.3. Approvals
1.1.4. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
Also make sure that other voltage inputs have been disconnected, (linkage of DC
intermediate circuit).
Be aware that there may be high voltage on the DC link even when the LEDs are
turned off.
Before touching any potentially live parts of the VLT Micro Drive, wait at least 4
minutes for all sizes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
VLT Micro Drive FC 51 Operating Instructions 1. Safety
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Leakage Current
The earth leakage current from the VLT Micro Drive FC 51 exceeds 3.5 mA. According
to IEC 61800-5-1 a reinforced Protective Earth connection must be ensured by
means of a min. 10mm² Cu or an addtional PE wire - with the same cable cross
section as the Mains wiring - must be terminated separately.
Residual Current Device
This product can cause a D.C. current in the protective conductor. Where a residual
current device (RCD) is used for extra protection, only an RCD of Type B (time de-
layed) shall be used on the supply side of this product. See also Danfoss Application
Note on RCD, MN.90.GX.YY.
Protective earthing of the VLT Micro Drive and the use of RCDs must always follow
national and local regulations.
Motor overload protection is possible by setting Parameter 1-90 Motor thermal pro-
tection to the value ETR trip. For the North American market: ETR functions provide
class 20 motor overload protection, in accordance with NEC.
Installation in high altitudes:
By altitudes above 2km, please contact Danfoss Drives regarding PELV.
1.1.5. IT Mains
IT Mains
Installation on isolated mains source, i.e. IT mains.
Max. supply voltage allowed when connected to mains: 440 V.
As an option, Danfoss offers line filters for improved harmonics performance.
1.1.6. Avoid unintended Start
While the frequency converter is connected to mains, the motor can be started/stopped using
digital commands, bus commands, references or via the Local Control Panel.
• Disconnect the frequency converter from mains whenever personal safety considerations
make it necessary to avoid unintended start of any motors.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
1.1.7. Disposal Instruction
Equipment containing electrical components must not be disposed of
together with domestic waste.
It must be separately collected with electrical and electronic waste
according to local and currently valid legislation.
1. Safety VLT Micro Drive FC 51 Operating Instructions
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1.1.8. Before Commencing Repair Work
1. Disconnect FC 51 from mains (and external DC supply, if present.)
2. Wait for 4 minutes for discharge of the DC-link.
3. Disconnect DC bus terminals and brake terminals (if present)
4. Remove motor cable
VLT Micro Drive FC 51 Operating Instructions 1. Safety
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2. Mechanical Installation VLT Micro Drive FC 51 Operating Instructions
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2. Mechanical Installation
2.1. Before Starting
2.1.1. Checklist
When unpacking the frequency converter,
make sure that the unit is undamaged and
complete. Check that the packaging contains
the following:
• VLT Micro Drive FC 51
•QuickGuide
Optional: LCP and/or de-coupling plate.
Illustration 2.1: Content of box.
2.2. Side-by-Side Installation
The Danfoss VLT Micro Drive can be mounted side-by-side for IP 20 rating units and requires 100
mm clearance above and below for cooling. Regarding surroundings in general, please see chapter
7. Specifications .
Illustration 2.2: Side-by-side installation.
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2.3.1. Mechanical Dimensions
Illustration 2.3: Mechanical dimensions.
NB!
A template for drilling can be found on the flap of the packaging.
Power (kW) Height (mm) Width (mm) Depth 1)
(mm)
Max.
Weight
Frame 1 X
200-240 V
3 X
200 -240 V
3 X
380-480 V A
A (incl. de-
coupling
plate)
a B b C Kg
M1 0.18 - 0.75 0.25 - 0.75 0.37 - 0.75 150 205 140.4 70 55 148 1.1
M2 1.5 1.5 1.5 - 2.2 176 230 166.4 75 59 168 1.6
M3 2.2 2.2 -3.7 3.0 - 7.5 2) 2) 2) 2) 2) 2) 2)
Table 2.1: Mechanical Dimensions
1)
For LCP with potentiometer, please add 7.6 mm.
2
These dimensions will be announced at a later point.
NB!
DIN rail mounting kit is available for M1. Please use ordering number 132B0111
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3. Electrical Installation
3.1. How to Connect
3.1.1. Electrical Installation in General
NB!
All cabling must comply with national and local regulations on cable cross-sections
and ambient temperature. Copper conductors required, (60-75° C) recommended.
Details of terminal tightening torques.
Power (kW) Torque (Nm)
Frame 1 x
200-240 V
3 x
200-240 V
3 x
380-480 V Line Motor
DC con-
nection/
Brake1)
Control
Terminals Earth Relay
M1 0.18 - 0.75 0.25 - 0.75 0.37 - 0.75 1.4 0.7 -0.15 30.5
M2 1.5 1.5 1.5 - 2.2 1.4 0.7 -0.15 30.5
M3 2.2 2.2 - 3.7 3.0 - 7.5 1.4 0.7 -0.15 30.5
1) Spade connectors
Table 3.1: Tightening of terminals.
3.1.2. Fuses
Branch circuit protection:
In order to protect the installation against electrical and fire hazard, all branch circuits in an in-
stallation, switch gear, machines etc., must be short-circuited and overcurrent protected according
to national/international regulations.
Short circuit protection:
Danfoss recommends using the fuses mentioned in the following tables to protect service per-
sonnel or other equipment in case of an internal failure in the unit or short-circuit on DC-link. The
frequency converter provides full short circuit protection in case of a short-circuit on the motor or
brake output.
Overcurrent protection:
Provide overload protection to avoid overheating of the cables in the installation. Overcurrent
protection must always be carried out according to national regulations. Fuses must be designed
for protection in a circuit capable of supplying a maximum of 100,000 A
rms
(symmetrical), 480 V
maximum.
NonUL compliance:
If UL/cUL is not to be complied with, Danfoss recommends using the fuses mentioned in table
1.3, which will ensure compliance with EN50178:
In case of malfunction, not following the fuse recommendation may result in damage to the fre-
quency converter.
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FC 51 Bussmann Bussmann Bussmann Littel fuse Ferraz-
Shawmut
Ferraz-
Shawmut
Max. fuses non
UL
1 X 200-240 V
kW Type RK1 Type J Type T Type RK1 Type CC Type RK1 Type gG
0K18 -
0K37
KTN-R15 JKS-15 JJN-15 KLN-R15 ATM-R15 A2K-15R 15A
0K75 KTN-R25 JKS-25 JJN-25 KLN-R25 ATM-R25 A2K-25R 25A
1K5 KTN-R35 JKS-35 JJN-35 KLN-R35 -A2K-35R 35A
2K2 KTN-R45 JKS-45 JJN-45 KLN-R45 -A2K-45R 45A
3 x 200-240 V
0K25 KTN-R10 JKS-10 JJN-10 KLN-R10 ATM-R10 A2K-10R 10A
0K37 KTN-R15 JKS-15 JJN-15 KLN-R15 ATM-R15 A2K-15R 15A
0K75 KTN-R20 JKS-20 JJN-20 KLN-R20 ATM-R20 A2K-20R 20A
1K5 KTN-R25 JKS-25 JJN-25 KLN-R25 ATM-R25 A2K-25R 25A
2K2 KTN-R30 JKS-30 JJN-30 KLN-R30 ATM-R30 A2K-30R 30A
3K7 KTN-R45 JKS-45 JJN-45 KLN-R45 -A2K-45R 45A
3 x 380-480 V
0K37 -
0K75
KTS-R10 JKS-10 JJS-10 KLS-R10 ATM-R10 A6K-10R 10A
1K5 KTS-R15 JKS-15 JJS-15 KLS-R15 ATM-R15 A2K-15R 15A
2K2 KTS-R20 JKS-20 JJS-20 KLS-R20 ATM-R20 A6K-20R 20A
3K0 KTS-R25 JKS-25 JJS-25 KLS-R25 ATM-R25 A6K-25R 25A
4K0 KTS-R30 JKS-30 JJS-30 KLS-R30 ATM-R30 A6K-30R 30A
5K5 KTS-R35 JKS-35 JJS-35 KLS-R35 - A6K-35R 35A
7K5 KTS-R45 JKS-45 JJS-45 KLS-R45 -A6K-45R 45A
Table 3.2: Fuses
3.1.3. EMC-Correct Installation
Following these guidelines is advised, where compliance with EN 61000-6-3/4, EN 55011 or EN
61800-3
First environment is required. If the installation is in EN 61800-3 Second environment ,
then it is acceptable to deviate from these guidelines. It is however not recommended.
Good engineering practice to ensure EMC-correct electrical installation:
• Use only braided screened/armoured motor cables and control cables.
The screen should provide a minimum coverage of 80%.The screen material must be
metal, not limited to but typically copper, aluminium, steel or lead. There are no special
requirements for the mains cable.
• Installations using rigid metal conduits are not required to use screened cable, but the
motor cable must be installed in conduit separate from the control and mains cables. Full
connection of the conduit from the drive to the motor is required. The EMC performance
of flexible conduits varies a lot and information from the manufacturer must be obtained.
• Connect the screen/armour/conduit to earth at both ends for motor cables and control
cables.
• Avoid terminating the screen/armour with twisted ends (pigtails). Such a termination
increases the high frequency impedance of the screen, which reduces its effectiveness
at high frequencies. Use low impedance cable clamps or glands instead.
• Ensure good electrical contact between the de-coupling plate and the metal chassis of
the frequency converter, see Instruction MI.02.BX.YY
• Avoid using unscreened/unarmoured motor or control cables inside cabinets housing the
drive(s), where possible.
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3.2. Mains Connection
3.2.1. Connecting to Mains
Step 1: First mount earth cable.
Step 2: Mount wires in terminals L1/L, L2 and
L3/N and tighten.
Illustration 3.1: Mounting of earth cable and mains
wires.
For 3-phase connection, connect wires to all
three terminals.
For single-phase connection, connect wires to
terminals L1/L and L3/N.
Illustration 3.2: Three-phase and single-phase
wire connections.
3.3. Motor Connection
3.3.1. How to Connect the Motor
See the chapter Specifications for correct dimensioning of motor cable cross-section and length.
• Use a shielded/armored motor cable to comply with EMC emission specifications, and
connect this cable to both the decoupling plate and the motor metal.
• Keep motor cable as short as possible to reduce the noise level and leakage currents.
For further details on mounting of the decoupling plate, please see instruction MI.02.BX.YY.
All types of three-phased asynchronous
standard motors can be connected to the fre-
quency converter. Normally, small motors are
star-connected (230/400 V, Δ/Y). Large mo-
tors are delta-connected (400/690 V, Δ/Y).
Refer to motor nameplate for correct connec-
tion and voltage.
Illustration 3.3: Star and delta connections.
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Step 1: First, mount the earth cable.
Step 2: Connect wires to terminals either in
star or delta-connection. See motor name-
plate for further information.
Illustration 3.4: Mounting of earth cable and motor
wires.
For EMC correct installation, use optional de-
coupling plate, see chapter
Options for VLT
Micro Drive FC 51
.
Illustration 3.5: VLT Micro Drive with de-coupling
plate
3.4. Control Terminals
3.4.1. Access to Control Terminals
All control cable terminals are located under-
neath the terminal cover in front of the fre-
quency converter. Remove the terminal cover
using a screwdriver.
Illustration 3.6: Removing terminal cover.
NB!
See back of terminal cover for outlines of control terminals and switches.
3.4.2. Connecting to Control Terminals
This illustration shows all control terminals of the VLT Micro Drive. Applying Start (term. 18) and
an analog reference (term. 53 or 60) make the frequency converter run.
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Illustration 3.7: Overview of control terminals in PNP-configuration and factory setting.
3.5. Switches
NB!
Do not operate switches with power on the frequency converter.
Bus termination:
Switch
BUS TER pos. ON terminates the
RS485 port, terminals 68, 69. See power cir-
cuit drawing.
Default setting = Off.
Illustration 3.8: S640 Bus termination.
S200 Switches 1-4:
Switch 1: *OFF = PNP terminals 29
ON = NPN terminals 29
Switch 2: *OFF = PNP terminal 18, 19, 27
and 33
ON = NPN terminal 18, 19, 27
and 33
Switch 3: No function
Switch 4: *OFF = Terminal 53 0 - 10 V
ON = Terminal 53 0/4 - 20 mA
* = default setting
Table 3.3: Settings for S200 Switches 1-4 Illustration 3.9: S200 Switches 1-4.
NB!
Parameter 6-19 must be set ac-
cording to Switch 4 position.
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3.6. Power Circuit - Overview
3.6.1. Power Circuit - Overview
Illustration 3.10: Diagram showing all electrical terminals.
Brake not applicable for frame M1.
Brake resistors are available from Danfoss.
Improved power factor and EMC performance can be achieved by installing optional Danfoss line
filters.
Danfoss power filters can also be used for load sharing.
3.6.2. Load sharing/Brake
Use 6.3 mm insulated Faston Plugs designed for high voltage for DC (Load Sharing and brake).
Contact Danfoss or see instruction no. MI.50.Nx.02 for load sharing and instruction no. MI.90.Fx.
02 for brake.
Load sharing: Connect terminals UDC- and UDC/BR+.
Brake: Connect terminals BR- and UDC/BR+.
Note that voltage levels of up to 850 V DC may occur between terminals
UDC+/BR+ and UDC-. Not short circuit protected.
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4. Programming
4.1. How to Programme
4.1.1. Programming with MCT-10
The frequency converter can be programmed from a PC via RS485 com-port by installing the
MCT-10 Set-up Software.
This software can either be ordered using code number 130B1000 or downloaded from the Dan-
foss Web site: www.danfoss.com, Business Area: Motion Controls.
Please refer to manual MG.10.RX.YY.
4.1.2. Programming with LCP 11 or LCP 12
The LCP is divided into four functional groups:
1. Numeric display.
2. Menu key.
3. Navigation keys.
4. Operation keys and indicator lights (LEDs).
Illustration 4.1: LCP 12 with potentiometer Illustration 4.2: LCP 11 without potentiometer
The display:
A number of information can be read from the display.
Set-up number shows the active set-up and
the edit set-up. If the same set-up acts as
both active and edit set-up, only that set-up
number is shown (factory setting).
When active and edit set-up differ, both num-
bers are shown in the display (Setup 12). The
number flashing, indicates the edit set-up.
Illustration 4.3: Indicating Set-up
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The small digits to the left are the selected
parameter number .
Illustration 4.4: Indicating selected par. no.
The large digits in the middle of the display
show the value of the selected parameter.
Illustration 4.5: Indicating value of selected par.
The right side of the display shows the unit
of the selected parameter. This can be either
Hz, A, V, kW, HP, %, s or RPM.
Illustration 4.6: Indicating unit of selected par.
Motor direction is shown to the bottom left
of the display - indicated by a small arrow
pointing either clockwise or counterclockwise.
Illustration 4.7: Indicating motor direction
Use the [MENU] key to select one of the following menus:
Status Menu:
The Status Menu is either in
Readout Mode or Hand on Mode . In Readout Mode the value of the
currently selected readout parameter is shown in the display.
In
Hand on Mode the local LCP reference is displayed.
Quick Menu:
Displays Quick Menu parameters and their settings. Parameters in the Quick Menu can be accessed
and edited from here. Most applications can be run by setting the parameters in the Quick Menus.
Main Menu:
Displays Main Menu parameters and their settings. All parameters can be accessed and edited
here. A parameter overview is found later in this chapter. For detailed information on program-
ming, please see
Programming Guide , MG02CXYY.
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Indicator lights:
• Green LED: Power is on the frequency converter.
• Yellow LED: Indicates a warning.
• Flashing red LED: Indicates an alarm.
Navigation Keys:
[Back]: For moving to the previous step or layer in the navigation structure.
Arrows [▲] [▼]: For manoeuvring between parameter groups, parameters and within parame-
ters.
[OK]: For selecting a parameter and for accepting changes to parameter settings.
Operation Keys:
A yellow light above the operation keys indicates the active key.
[Hand on]: Starts the motor and enables control of the frequency converter via the LCP.
[Off/Reset]: The motor stops except in alarm mode. In that case the motor will be reset.
[Auto on]: The frequency converter is controlled either via control terminals or serial communi-
cation.
[Potentiometer] (LCP12): The potentiometer works in two ways depending on the mode in
which the frequency converter is running.
In
Auto Mode the potentiometer acts as an extra programmable analog input.
In
Hand on Mode the potentiometer controls local reference.
4.2. Status Menu
After power up the Status Menu is active. Use
the [MENU] key to toggle between Status,
Quick Menu and Main Menu.
Arrows [▲] and [▼] toggles between the
choices in each menu.
The display indicates the status mode with a
small arrow above “Status”.
Illustration 4.8: Indicating Status mode
4.3. Quick Menu
The Quick Menu gives easy access to the most frequently used parameters.
1. To enter the Quick Menu, press
[MENU] key until indicator in display
is placed above
Quick Menu , then
press [OK].
2. Use [▲] [▼] to browse through the
parameters in the Quick Menu.
3. Press [OK] to select a parameter.
4. Use [▲] [▼] to change the value of a
parameter setting.
5. Press [OK] to accept the change.
6. To exit, press either [Back] twice to
enter
Status , or press [Menu] once
to enter
Main Menu .
Illustration 4.9: Indicating Quick Menu mode
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4.4. Quick Menu Parameters
4.4.1. Quick Menu Parameters - Basic Settings QM1
Below are descriptions of all parameters found in the Quick Menu.
＊= Factory setting.
1-20 Motor Power [kW]/[HP] (P
m.n
)
Range: Function:
Enter motor power from nameplate data.
[0.09 kW/0.12 HP -
11 kW/15 HP]
Two sizes down, one size up from nominal VLT rating.
NB!
Changing this parameter affects par. 1-22 to 1-25,
1-30, 1-33 and 1-35.
1-22 Motor Voltage (U
m.n
)
Range: Function:
230/400
V
[50 - 999 V] Enter motor voltage from nameplate data.
1-23 Motor Frequency (f
m.n
)
Range: Function:
50 Hz
*
[20-400 Hz] Enter motor frequency from nameplate data.
1-24 Motor Current (I
m.n
)
Range: Function:
M-type
depend-
ent
*
[0.01 - 26.00 A] Enter motor current from nameplate data.
1-25 Motor Nominal Speed (n
m.n
)
Range: Function:
M-type
Depend-
ent
*
[100 - 9999 RPM] Enter motor nominal speed from nameplate data.
1-29 Automatic Motor Tuning (AMT)
Option: Function:
Use AMT to optimize motor performance.
NB!
This parameter cannot be changed while motor
runs.
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1. Stop VLT – make sure motor is at standstill
2. Choose [2] Enable AMT
3. Apply start signal
– Via LCP: Press Hand On
- Or in Remote On mode: Apply start signal on terminal
18
[0]
*
Off AMT function is disabled.
[2] Enable AMT AMT function starts running.
NB!
To gain optimum tuning of frequency converter,
run AMT on a cold motor.
3-02 Minimum Reference
Range: Function:
0.00
*
[-4999 - 4999] Enter value for minimum reference.
The sum of all internal and external references are clamped
(limited) to the minimum reference value, par. 3-02.
3-03 Maximum Reference
Range: Function:
Maximum Reference is adjustable in the range Minimum Refer-
ence - 4999.
50.00
*
[-4999 - 4999] Enter value for Maximum Reference.
The sum of all internal and external references are clamped
(limited) to the maximum reference value, par. 3-03.
3-41 Ramp1 Ramp-up Time
Range: Function:
3.00 s
*
[0.05 - 3600 s ] Enter ramp-up time from 0 Hz to rated motor frequency (f
M,N
)
set in par. 1-23.
Choose a ramp-up time ensuring that torque limit is not excee-
ded, see par. 4-16.
3-42 Ramp1 Ramp-down Time
Range: Function:
3.00
*
[0.05 - 3600 s] Enter ramp down time from rated motor frequency (f
M,N
) in par.
1-23 to 0 Hz.
Choose a ramp down time that does not cause over-voltage in
inverter due to regenerative operation of motor. Furthermore,
regenerative torque must not exceed limit set in par. 4-17.
4.4.2. Quick Menu Parameters - PI Basic Settings QM2
The following is a brief description of the parameters for the PI Basic Settings. For a more detailed
description, please see
VLT Micro Drive Programming Guide , MG.02.CX.YY.
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1-00 Configuration Mode
Range: Function:
[] Choose [3] Process Closed Loop
3-02 Min. Reference
Range: Function:
[-4999 - 4999] Sets limits for set-point and feedback.
3-03 Max. Reference
Range: Function:
[-4999 - 4999] Sets limits for set-point and feedback.
3-10 Preset Reference
Range: Function:
[-100.00 - 100.00] Preset [0] works as set-point.
4-12 Motor Speed Low Limit
Range: Function:
[0.0 - 400 Hz] Lowest possible output frequency.
4-14 Motor Speed High Limit
Range: Function:
[0.0 - 400.00 Hz] Highest possible output frequency.
NB!
Default 65 Hz should normally be reduced to 50 - 55 Hz.
6-22 Terminal 60 Low Current
Range: Function:
[0.00 - 19.99 mA] Normally set to 0 or 4 mA.
6-23 Terminal 60 High Current
Range: Function:
[0.01 - 20.00 mA] Normally (default) set to 20 mA.
6-24 Terminal 60 Low Feedback Value
Range: Function:
[-4999 - 4999] Value corresponding to P. 6-22 setting.
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