Danfoss VLT AutomationDrive User manual

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 converts 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 AC mains is disconnected. To
avoid electrical hazards, remove AC mains from the
frequency converter before doing any service or repair and
wait the amount of time specified in Table 1.1. Failure to wait
the specified time after power has been removed prior to
doing service or repair on the unit could result in death or
serious injury.
Voltage (V) Minimum waiting time (minutes)
415
200 - 240 0.25 - 3.7 kW 5.5 - 37 kW
380 - 480 0.25 - 7.5 kW 11 - 75 kW
525 - 600 0.75 - 7.5 kW 11 - 75 kW
525 - 690 n/a 11 - 75 kW
High voltage may be present even when the warning LEDs are off!
Table 1.1 Discharge Time
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also
be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
Approvals
Safety VLT
®
AutomationDrive Operating
Instructions
MG.33.AJ.02 - VLT
®
is a registered Danfoss trademark

Safety VLT
®
AutomationDrive Operating
Instructions
MG.33.AJ.02 - VLT
®
is a registered Danfoss trademark

Contents
1 Introduction
4
1.1 Purpose of the Manual 5
1.2 Additional Resources 5
1.3 Product Overview 6
1.4 Internal Frequency Converter Controller Functions 6
1.5 Frame Sizes and Power Ratings 7
2 Installation
8
2.1 Installation Site Check List 8
2.2 Frequency Converter and Motor Pre-installation Check List 8
2.3 Mechanical Installation 8
2.3.1 Cooling 8
2.3.2 Lifting 9
2.3.3 Mounting 9
2.3.4 Tightening Torques 9
2.4 Electrical Installation 10
2.4.1 Requirements 12
2.4.2 Earth (Grounding) Requirements 12
2.4.2.1 Leakage Current (>3,5mA) 13
2.4.2.2 Grounding Using Shielded Cable 13
2.4.3 Motor Connection 13
2.4.4 AC Mains Connection 14
2.4.5 Control Wiring 14
2.4.5.1 Access 14
2.4.5.2 Control Terminal Types 15
2.4.5.3 Wiring to Control Terminals 16
2.4.5.4 Using Screened Control Cables 16
2.4.5.5 Control Terminal Functions 16
2.4.5.6 Jumper Terminals 12 and 27 17
2.4.5.7 Terminal 53 and 54 Switches 17
2.4.5.8 Terminal 37 17
2.4.5.9 Mechanical Brake Control 20
2.4.6 Serial Communication 20
3 Start Up and Functional Testing
21
3.1 Pre-start 21
3.1.1 Safety Inspection 21
3.1.2 Start Up Check List 22
3.2 Applying Power to the Frequency Converter 23
3.3 Basic Operational Programming 23
Contents VLT
®
AutomationDrive Operating
Instructions
MG.33.AJ.02 - VLT
®
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3.4 Automatic Motor Adaptation 24
3.5 Check Motor Rotation 25
3.6 Check Encoder Rotation 25
3.7 Local-control Test 25
3.8 System Start Up 26
4 User Interface
27
4.1 Local Control Panel 27
4.1.1 LCP Layout 27
4.1.2 Setting LCP Display Values 28
4.1.3 Display Menu Keys 28
4.1.4 Navigation Keys 29
4.1.5 Operation Keys 29
4.2 Back Up and Copying Parameter Settings 29
4.2.1 Uploading Data to the LCP 30
4.2.2 Downloading Data from the LCP 30
4.3 Restoring Default Settings 30
4.3.1 Recommended Initialisation 30
4.3.2 Manual Initialisation 30
5 About Frequency Converter Programming
31
5.1 Introduction 31
5.2 Programming Example 31
5.3 Control Terminal Programming Examples 32
5.4 International/North American Default Parameter Settings 33
5.5 Parameter Menu Structure 35
5.5.1 Main Menu Structure 36
5.6 Remote Programming with MCT 10 Set-up Software 40
6 Application Set-Up Examples
41
6.1 Introduction 41
6.2 Application Examples 41
7 Status Messages
46
7.1 Status Display 46
7.2 Status Message Definitions Table 46
8 Warnings and Alarms
49
8.1 System Monitoring 49
8.2 Warning and Alarm Types 49
8.3 Warning and Alarm Displays 49
8.4 Warning and Alarm Definitions 50
Contents VLT
®
AutomationDrive Operating
Instructions
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8.4.1 Fault Messages 52
9 Basic Troubleshooting
60
9.1 Start Up and Operation 60
10 Specifications
62
10.1 Power-dependent Specifications 62
10.2 General Technical Data 71
10.3 Fuse Tables 76
10.3.2 CE Compliance 77
10.4 Connection Tightening Torques 84
Index
85
Contents VLT
®
AutomationDrive Operating
Instructions
MG.33.AJ.02 - VLT
®
is a registered Danfoss trademark 3

1 Introduction
Illustration 1.1 Exploded View A1-A3, IP20
1 LCP 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 1 (01, 02, 03)
3 Analog I/O connector 12 Relay 2 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief / PE ground 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate
Introduction VLT
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AutomationDrive Operating
Instructions
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1

Illustration 1.2 Exploded View B and C Sizes, IP55/66
1 LCP 11 Relay 2 (04, 05, 06)
2Cover 12Liftingring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable strain relief / PE ground
6 Cable strain relief / PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
Chapter 2 Installation provides requirements for mechanical
and electrical installation, including input, motor, control and
serial communications wiring, and control terminal
functions. Chapter 3 Start Up and Functional Testing provides
detailed procedures for start up, basic operational
programming, and functional testing. The remaining
chapters provide supplementary details. These include user
interface, detailed programming, application examples, start-
up troubleshooting, and specifications.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•
The Programming Guide provides greater detail in
how to work with parameters and many
application examples.
•
The Design Guide is intended to provide detailed
capabilities and functionality to design motor
control systems.
Introduction VLT
®
AutomationDrive Operating
Instructions
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®
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11

•
Supplemental publications and manuals are
available from Danfoss.
See http://www.danfoss.com/Products/Literature/
Technical+Documentation.htm for listings.
•
Optional equipment is available that may change
some of the procedures described. Be sure to see
the instructions supplied with those options for
specific requirements.
Contact the local Danfoss supplier or go to
http://www.danfoss.com/Products/Literature/Technical
+Documentation.htm for downloads or additional
information.
1.3 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.
1.4 Internal Frequency Converter Controller
Functions
Below is a block diagram of the frequency converter's
internal components. See Table 1.1 for their functions.
Illustration 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
•
The frequency converter's
intermediate DC-bus circuit
handles the DC current
4DCreactors
•
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
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 1.1 Frequency Converter Internal Components
Introduction VLT
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AutomationDrive Operating
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1.5 Frame Sizes and Power Ratings
Frame size (kW)
VoltsA1A2A3A4A5B1B2B3B4C1C2C3C4
200-240 0.25-1.5 0.25-2.2 3.0-3.7 0.25-2.2 0.25-3.7 5.5-7.5 11 5.5-7.5 11-15 15-22 30-37 18.5-22 30-37
380-480 0.37-1.5 0.37-4.0 5.5-7.5 0.37-4.0 0.37-7.5 11-15 18.5-22 11-15 18.5-30 30-45 55-75 37-45 55-75
525-600 N/A N/A 0.75-7.5 N/A 0.75-7.5 11-15 18.5-22 11-15 18.5-30 30-45 55-90 37-45 55-90
525-690 N/A N/A N/A N/A N/A N/A 11-22 N/A N/A N/A 30-75 N/A N/A
Table 1.2 Frames Sizes and Power Ratings
Introduction VLT
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11

2Installation
2.1 Installation Site Check List
•
The frequency converter relies on the ambient air
for cooling. Observe the limitations on ambient air
temperature for optimal operation
•
Ensure that the installation location has sufficient
support strength to mount the frequency converter
•
Keep the frequency converter interior free from
dust and dirt. Ensure that the components stay as
clean as possible. In construction areas, provide a
protective covering. Optional IP55 (NEMA 12) or
IP66 (NEMA 4) enclosures may be necessary.
•
Keep the manual, drawings, and diagrams
accessible for detailed installation and operation
instructions. It is important that the manual is
available for equipment operators.
•
Locate equipment as near to the motor as possible.
Keep motor cables as short as possible. Check the
motor characteristics for actual tolerances. Do not
exceed
•
300m (1000ft) for unshielded motor leads
•
150m (500ft) for shielded cable.
2.2 Frequency Converter and Motor Pre-
installation Check List
•
Compare the model number of unit on the
nameplate to what was ordered to verify the
proper equipment
•
Ensure each of the following are rated for 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
•
To provide cooling airflow, mount the unit to a
solid flat surface or to the optional back plate (see
2.3.3 Mounting)
•
Top and bottom clearance for air cooling must be
provided. Generally, 100-225mm (4-10in) is
required. See Illustration 2.1 for clearance
requirements
•
Improper mounting can result in over heating and
reduced performance
•
Derating for temperatures starting between 40°C
(104°F) and 50°C (122°F) and elevation 1000m
(3300ft) above sea level must be considered. See
the equipment Design Guide for detailed
information.
Illustration 2.1 Top and Bottom Cooling Clearance
Enclosure A1-A5 B1-B4 C1, C3 C2, C4
a/b (mm) 100 200 200 225
Table 2.1 Minimum Airflow Clearance Requirements
Installation VLT
®
AutomationDrive Operating
Instructions
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