Danfoss VLT Setup guide

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VLT Installation
Rev.02 1
North America
Motion Controls
Confidential / Property of Danfoss Drives A/S
Danfoss Drives
VLT®Installation
General Installation
Danfoss Drives, VLT - Installation Startup Check List
General Installation
This presentation deals with the start-up of a Danfoss Drive, also known as a VLT. It
is designed to help handle the start-up of the drive for general installation in normal
applications. Because of the flexibility of these drives, there may be some specialized
applications that are not covered by these instructions. In that case, refer to the
Instruction Manual that came with the drive for specific information.

VLT Installation
Rev.02 2
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VLT®Installation
General Installation
Introduction & Objectives
1. Warning
2. Reference material
3. Pre-Installation Checks
4. Installation Checks
5. Wiring
General Installation
This training module covers the checks and installation for any VLT. This section
starts with warnings, reference material, pre-installation checks, installation checks
and then covers general information about wiring. Control Wiring, Programming and
Startup of the VLT are covered in greater detail in following module designed for a
specific drive and application.

VLT Installation
Rev.02 3
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Confidential / Property of Danfoss Drives A/S
Student is able to…
• State the main danger and precaution to be taken
when working with a VLT.
• Identify the Reference Material needed for an
installation and where that material may be found.
• Locate and explain each of the 9 steps needed during
the pre-installation checks.
• Identify the 4 installation checks for proper operation.
• Identify the correct terminals and general instructions
concerning the wiring of the power input, motor
output, control, external 24Vdc, brake and load-
sharing.
Objectives
Objectives
These objectives are listed as a goal for this training module. A review at the end of
this module tests the student concerning these objectives.

VLT Installation
Rev.02 4
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Confidential / Property of Danfoss Drives A/S
Touching the electrical parts of the VLT may be fatal.
The largest models can require a significant amount of
time to discharge it’s internal circuitry to a safe level after
being disconnected from the incoming AC line power.
Check Instruction Manual for further warnings.
Warning
Warning
Touching the electrical parts of the VLT may be fatal — even after it has been
disconnected from the AC line. Even after power has been removed, the DC Link
Capacitors may take up to 50 minutes to fully discharge. The larger the drive the
larger the electrolytic capacitors in its power circuitry, which can maintain a
dangerous voltage level for up to 50 minutes on the largest power models, even
after power has been removed. Always be sure that power has been removed from
the drive for at least 50 minutes before working with the power circuitry of the drive.
Smaller drives can discharge sooner, refer to the instruction manual for more
details.
It is always wise to use a voltmeter to measure any potentially dangerous electrical
circuit before working on it.
It is important that the installer review additional warnings found in the instruction
manual for each Danfoss Drive.

VLT Installation
Rev.02 5
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a. Instruction Manual
with each Drive
Other Useful Information
b. Connection Diagram
c. Schematic Diagram
2) Reference Material
2) Reference Material
These three pieces of reference material may be available to you when you are
starting up a drive.
a) The VLT Instruction Manual provides general information on topics like mounting
clearances, fuses, terminal tightening torques, and drive parameters. An instruction
Manual is shipped with each drive.
From the Customer, a Connection Diagram may be available which provides a sketch
indicating the layout and use of the equipment in the system.
c) A Schematic Diagram from the customer could also provide details of the wiring
between the drive, any options, and the control system.

VLT Installation
Rev.02 6
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Confidential / Property of Danfoss Drives A/S
a. Visual Inspection
b. Proper Handling
c. Remove IM and kits from box
d. Check that VLT matches what was ordered
e. Check Incoming Power, Drive and Motor that they are
the same voltage range.
f. Insure that all hand tools, auxiliary equipment and kits
are available.
g. Insure Drive can handle maximum current of motor
h. Record Motor Data
i. Check Motor Wiring
3) Pre-Installation Checks
3) Pre-Installation Checks
This next section covers the 9 steps necessary in the pre-installation check.

VLT Installation
Rev.02 7
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Confidential / Property of Danfoss Drives A/S
• Make a visual inspection for damage to the drive.
• Take into account the weight and size of the drive
and have proper equipment to lift the drive from its
container and to mount it safely.
a. Inspection and b. Handling
3) Pre-Installation Checks
3) Pre-Installation Checks
a. Once you have opened the box, check the VLT for any visual damage. If there is
major damage, please contact the organization that sold you the drive.
b. Some of the VLTs are very large, which require special equipment to remove it
from its container and mount it safely. It is important that a qualified material
handler removes the VLT from its packaging. It might also be necessary to
investigate the pathway the VLT takes to its mounting to insure it can fit around
each turn and under doorways.

VLT Installation
Rev.02 8
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• Remove the Instruction Manual (IM) from
the box; and the Accessory Kit if present.
3) Pre-Installation Checks
c. Remove IM and kits
3) Pre-Installation Checks
c. It is important that all extra material, such as the Instruction Manual and
accessory kit be removed from the drive’s container. These are used later. If you
can not find the Instruction Manual, contact the person who originally opened the
container.

VLT Installation
Rev.02 9
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Compare VLT model number with what was ordered.
Sales Number
Catalog Number Serial Number
Output Ratings of Drive
3) Pre-Installation Checks
d. Compare drive
3) Pre-Installation Checks
d. Compare the VLT model number with what was ordered.
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.

VLT Installation
Rev.02 10
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Confidential / Property of Danfoss Drives A/S
Compare VLT number with what was ordered.
Look for the RED label, typically on the Top or Left Side
Catalog Order Number System
Example: - XXXX–P-T5-B20–ST-R0–DL-F00-A00-C0
Series: VLT, FC, FCM, FCD
Model Number ---------------------|
Application --------------------------------|
P – Process; F - Flux; A - AQUA; G – Graham; H - HVAC
AC Line Voltage -----------------------------|
T2: 3 phase 200 – 240 Vac
T4: 3 phase 380 – 480 Vac
T5: 3 phase 380 – 500 Vac
T6: 3 phase 550 – 600 Vac
Enclosure (index mechanical dimensions)--|
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)
3) Pre-Installation Checks
d. Compare drive
Hardware – ST
DE= Fuse/Disc, 24V, Loadshare, DBrake; DX= Fuse/Disc, 24V, Loadshare;
EB= 24V, Loadshare, DBrake; EX= 24V, Loadshare; PB= Fuse/Disc, 24V, DBrake;
PD= Fuse/Disc, 24V; PF= 24V, Fuse; PS= 24V; SL= 24V, Loadshare; ST= No
options;
SB= DBrake
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 FTP; F41= LonWorks 78 kbps; F42= LonWorks 1.25mbps
Application Option – A00
A00= none; A10= Programmable Sync/Pos Card; A11= Synchronizing card;
A12= Positioning Card; A30= 1 Relay Card; A31= 4 Relay Card;
A32= Cascade Controller Card
Conformal Coating – C0
C0 means no coating
C1 has coating

VLT Installation
Rev.02 11
North America
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Confidential / Property of Danfoss Drives A/S
3) Pre-Installation Checks
d. Compare VLT drive & APU Panel
Drive with Panel – Label inside the panel
Material Number Serial Number
Schematic
Number
Input Ratings Output Ratings
A drive with an APU Panel has a nameplate with complete rating information inside
the panel enclosure. This includes the following useful elements:
The Material Number, which uniquely identifies the drive and all of its options.
The Serial Number, which describes the manufacturing date.
The Schematic Number, which shows the control and power wiring for the drive and
its options.
The input ratings, the most important of which is the input voltage rating. This
should be checked and compared to the available AC power line voltage prior to
applying power to the drive.
The output ratings, the most important of which is the output current rating. This
must be greater than or equal to the motor’s full load current rating in order to
operate the motor at full load.

VLT Installation
Rev.02 12
North America
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Confidential / Property of Danfoss Drives A/S
3) Pre-Installation Checks
d. Compare VLT drive & APU Panel
Drive with Panel – Label inside the panel
On the
right or
left side
of the
drive
On the
panel or
the right
side of
the option
box
Material Number Serial Number
These are the other two nameplates that are present on drives with an APU panel
option enclosure. While they don’t provide drive rating information, the Material
Number completely describes the drive and all of the included options. This number
should be checked against the order confirmation. The Material Number and Serial
Number should be provided if the factory service is required.

VLT Installation
Rev.02 13
North America
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Confidential / Property of Danfoss Drives A/S
Be sure the Incoming Power, VLT and Motor have
the same voltage range
3) Pre-Installation Checks
e. Match power, drive and motor
3) Pre-Installation Checks
e. Before installing the drive, check to be sure that the power line, the drive, and the
motor are all rated for the same voltage range. It may be necessary to check the
wiring inside the motor's conduit box to confirm its voltage rating.

VLT Installation
Rev.02 14
North America
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Confidential / Property of Danfoss Drives A/S
Insure that all hand tools, auxiliary equipment,
and kits are available.
3) Pre-Installation Checks
f. Hand Tools available
3) Pre-Installation Checks
f. Insure that all hand tools, auxiliary equipment and kits are available.
Options and kits: Part numbers for a dynamic brake resistor, additional RFI Filters,
an LCP remote mounting kit, serial communication card, application card, additional
relay card, LC filters and terminal lug kits are covered in the catalog.
Hand tools: It is important that all hand tools be present before starting to mount
the VLT.

VLT Installation
Rev.02 15
North America
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Confidential / Property of Danfoss Drives A/S
Always insure that VLT can handle maximum
current of the motor.
Example above – Red label shows 32.0A, motor
nameplate needs 27.0 for 230Vac, so its OK
3) Pre-Installation Checks
g. Check Max current
3) Pre-Installation Checks
g. Always insure that VLT can handle maximum current of the motor.
It is important to check the technical data of the instruction manual for the drive you
are installing to certify that the VLT is able to handle the maximum FLA of the
motor.
Example: a 100Hp (75kW) motor has a FLA of 125amps at 460Vac. 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.

VLT Installation
Rev.02 16
North America
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Confidential / Property of Danfoss Drives A/S
Record motor data information
– Motor Power
– Motor Voltage
– Motor Frequency
– Motor Current (FLA)
– Motor Speed (RPM)
3) Pre-Installation Checks
h. Record Motor Info
3) Pre-Installation Checks
h. Record motor data information
Write down the motor nameplate information. This is 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

VLT Installation
Rev.02 17
North America
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Confidential / Property of Danfoss Drives A/S
• Record motor HP in kW; 1 Hp = 0.75kW
• Hp has been rounded off in table; Only kW appears in
the VLT & some kW setting are unique to certain drives.
• Using Parameter 102, each VLT can be under sized by 4
and over sized by 1, but always check current limits.
3) Pre-Installation Checks
Hp to kW Chart
3) Pre-Installation Checks
The VLT 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. A 100Hp drive must be programmed for 75kW in the drive.
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.
A 75kW (100Hp) drive can be used to properly operate a 30kW (40Hp) motor. This
same 75kW drive might also be used on a 90kW (125Hp) if the current rating is
within limits.
The chart above shows all the settings that may be encountered at the Motor size
parameter, number 102. This parameter is discussed in more detail in the next
module. For more information see your Instruction Manual.

VLT Installation
Rev.02 18
North America
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Confidential / Property of Danfoss Drives A/S
Check Motor Wiring
• Remove all power correction capacitors between drive and
motor
• 2-speed motors (Star-Delta) must be wired for full speed
• Part-winding start motors, must be wired for run.
• Check motor wiring to see if it is the same voltage as VLT.
3) Pre-Installation Checks
i. Motor Wiring
3) Pre-Installation Checks
i. Check Motor Wiring
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.