Danfoss ADAP-COOL Operating guide

Contents

ADAP-KOOL

Drive Operating Instructions

1 Introduction

1.1.2 Copyright, Limitation of Liability and Revision Rights 4

1.1.6 Type Code String 6

2 Safety

2.1.2 High Voltage Warning 7

2.1.5 Before Commencing Repair Work 8

2.1.6 Special Conditions 9

2.1.7 Safe Stop of the Frequency Converter 9

2.1.8 IT Mains 11

3 Application Guide

3.1.1 ADAP-KOOL® Drive Application Guide 12

3.1.2 Application Descriptions

4 Mechanical Installation

4.1 Before starting

4.1.2 Mechanical Dimensions 20

4.2 How to Install

5 Electrical Installation

5.1 How to Connect

5.1.2 Electrical Installation and Control Cables 26

5.1.5 Mains Wiring Overview 30

5.1.11 Motor Wiring Overview 36

5.1.19 How to Test Motor and Direction of Rotation 41

6 How to Operate the Frequency Converter

6.1.2 How to Operate the Graphical LCP (GLCP) 45

6.1.6 Tips and Tricks 52

7 How to Programme the Frequency Converter

7.1 How to Programme

7.2 Parameter list

7.2.1 0-** Operation and Display 81

7.2.2 1-** Load / Motor 83

7.2.3 2-** Brakes 84

7.2.4 3-** Reference / Ramps 85

7.2.5 4-** Limits / Warnings 86

7.2.6 5-** Digital In / Out 87

7.2.7 6-** Analog In / Out 89

MG.11.L4.02 - ADAP-KOOL® Drive 1

Contents

ADAP-KOOL

7.2.8 8-** Communication and Options 91

7.2.9 11-** ADAP-KOOL LON 92

7.2.10 13-** Smart Logic Controller 93

7.2.11 14-** Special Functions 94

7.2.12 15-** FC Information 95

7.2.13 16-** Data Readouts 97

7.2.14 18-** Info & Readouts 99

7.2.15 20-** FC Closed Loop 100

7.2.16 21-** Ext. Closed Loop 101

7.2.17 22-** Application Functions 103

7.2.18 23-** Time Based Funtions 105

7.2.19 25-** Pack Controller 106

7.2.20 26-** Analog I / O Option MCB 109 107

7.2.21 28-** Compressor Functions 108

Drive Operating Instructions

8 Troubleshooting

8.1.1 Warning/Alarm list 112

9 Specifications

9.1 General Specifications

9.2 Special Conditions

Index

109

116

124

128

2 MG.11.L4.02 - ADAP-KOOL® Drive

Introduction

ADAP-KOOL

Drive Operating Instructions

1Introduction

1.1 Introduction

The AKD 102 ADAP-KOOL Drive from Danfoss Food Retail has been designed with our refrigeration customers clearly in mind. The drive is designed to make commissioning and installation a simple and easy task. The built in “wizard” set up menu guides the installer through the set up of the drive in a clear and structured manner, and has been constructed with reference to the industries refrigeration engineers, to ensure that the text and language used makes complete sense to the installer.

The AKD 102 drive comes with a common user interface which covers all power ratings between 1.1- 250 kW. Thus ensuring that once you have learnt how to commission one drive you understand how to commission them all. Included on this local control panel is an “info” button which is essentially a built in drive instruction manual which help the user to both gain information and also suggests other parameters which may need to be changed. The AKD 102 also features a built in “pack controller” controlled via the drives own standard software. This allows the drive to control the lead compressor via variable speed and the bringing on line of another 2 compressors in fixed speed mode. This leads to extremely efficient pack design which also adds the energy efficiency of variable speed control. Using the drive in this way eliminates the need for an external pack controller thus giving financial savings to the customer.

The drive can be supplied in either of two protection classes IP21(IP20 up to 7,5kW) or IP55 (IP66 on request); this insures that our customers benefit from having the most robust of designs supplied directly from the factory, without the need for additional cabinets in which to house the drive. The AKD also benefits from the inclusion of having built in RFI filters as standard which means that the problems associated with radio interference and long cable runs are no problem for our customers.

The modular construction of the AKD means that you only have to pay for what you need. Each AKD is manufactured only when we receive a customer order and so is built exactly to customer specification with any chosen options added at this stage. But by using this manufacturing and design philosophy it means that should options such as ADAP-KOOL Lon be required at some future date they are a simple retrofit inside of the drive which can be done by anyone with extreme ease. Warranty: Each AKD comes with 18 months warranty from date of manufacture or 12 months from date of documented installation, whichever comes first thus ensuring that our Food Retail customers have complete peace of mind when choosing AKD as their drive of choice.

1.1.1

Software Version and Approvals: ADAP-KOOL

ADAP-KOOL® Drive

Operating Instructions

Software version: 2.xx

Drive

This Operating Instructions can be used for all ADAP-KOOL® Drive frequency converters with software version 2.xx. The software version number can be seen from parameter 15-43.

MG.11.L4.02 - ADAP-KOOL® Drive 3

Introduction

ADAP-KOOL

Drive Operating Instructions

1.1.2 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware or software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third parties.

Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.

1.1.3 Available Literature

- Operating Instructions MG.11.Lx.yy provide the neccessary information for getting the drive up and running.

- Design Guide MG.11.Mx.yy entails all technical information about the drive and customer design and applications.

- Programming Guide MG.11.Nx.yy provides information on how to programme and includes complete parameter descriptions.

- Operating Instructions AKD102 High Power, MG.11.Ox.yy

- Operating InstructionsAKD LonWorks, MG.11.Px.yy

x = Revision number yy = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/ Technical+Documentation.htm.

4 MG.11.L4.02 - ADAP-KOOL® Drive

Introduction

ADAP-KOOL

1.1.4 Abbreviations and Standards

Drive Operating Instructions

Abbreviations: Terms: SI-units: I-P units:

a Acceleration

AWG American wire gauge

Auto Tune Automatic Motor Tuning

°C

I Current A Amp

LIM

Joule Energy J = Nm ft-lb, Btu

°F

FC Frequency Converter

f Frequency Hz Hz kHz Kilohertz kHz kHz LCP Local Control Panel mA Milliampere

ms Millisecond

min Minute

MCT Motion Control Tool

M-TYPE Motor Type Dependent

Nm Newton Metres in-lbs I

M,N

par. Parameter

PELV Protective Extra Low Voltage

Watt Power W Btu/hr, hp

Pascal Pressure Pa = N/m psi, psf, ft of water

INV

RPM Revolutions Per Minute

SR Size Related

TTemperature CF

t Time s s,hr T

LIM

U Voltage V V

Celsius

Current limit

Fahrenheit

Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage

Rated Inverter Output Current

Torque limit

m/s

ft/s

Table 1.1 Abbreviation and standards table.

1.1.5 Frequency Converter Identification

Below is an example of an identification label. This label is situated on the frequency converter and shows the type and options fitted to the unit. See table 2.1 for details of how to read theType code string (T/C).

Illustration 1.1 This example shows an identification label.

NOTE

Please have T/C (type code) number and serial number ready before contacting Danfoss.

MG.11.L4.02 - ADAP-KOOL® Drive 5



Introduction

ADAP-KOOL

Drive Operating Instructions

1.1.6 Type Code String

Description Pos Possible choice Product group & VLT Series 1-6 AKD102 Power rating 8-10 1.1 - 250 kW (P1K1 - P250) Number of phases 11 Three phases (T)

Mains voltage 11-12

Enclosure 13-15

RFI filter 16-17

Display 19

Coating PCB 20 C: Coated PCB

Mains option 21

Adaptation 22 Reserved Adaptation 23 Reserved Software release 24-27 Actual software Software language 28

A options 29-30

B options 31-32

C0 options MCO 33-34 CX: No options C1 options 35 X: No options C option software 36-37 XX: Standard software

D options 38-39

T 2: 200-240 VAC T 4: 380-480 VAC E20: IP20 E21: IP 21/NEMA Type 1 E55: IP 55/NEMA Type 12 E66: IP66 P21: IP21/NEMA Type 1 w/backplate P55: IP55/NEMA Type 12 w/backplate H1: RFI filter class A1/B H2: RFI filter class A2 H4: RFI filter class A2/A1 G: Graphical Local Control Panel (GLCP) X: No Local Control Panel

X: No Mains disconnect switch 1: With Mains disconnect switch (IP55 only)

AX: No options AZ: MCA 107AKD LonWorks BX: No option BK: MCB 101 General purpose I/O option BP: MCB 105 Relay option BO:MCB 109 Analog I/O option

DX: No option D0: DC back-up MCB107

Table 1.2 Type code description.

The various options are described further in the ADAP-KOOL® Drive AKD102 Design Guide, MG.11.Mx.yy.

6 MG.11.L4.02 - ADAP-KOOL® Drive

Safety

2Safety

ADAP-KOOL

Drive Operating Instructions

2.1.1 Symbols

Symbols used in this manual:

NOTE

Indicates something to be noted by the reader.

CAUTION

Indicates a general warning.

WARNING

Indicates a high-voltage warning.

✮

Indicates default setting

2.1.2 High Voltage Warning

WARNING

The voltage of the frequency converter and the MCO 101 option card is dangerous whenever it is connected to mains. Incorrect installation of the motor or frequency converter may causedeath, serious injury or damage to the equipment. Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations.

2.1.3 Safety Note

WARNING

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter or fieldbus may cause death, serious personal injury or damage to the equipment. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

2. The [STOP/RESET] key on the LCP of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch.

3. Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.

4. The earth leakage currents are higher than 3.5 mA.

5. Protection against motor overload is set by 1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

MG.11.L4.02 - ADAP-KOOL® Drive 7

Safety

7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair work.

Installation at high altitudes

ADAP-KOOL

Drive Operating Instructions

WARNING

Installation at high altitude: 380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV. 380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV.

WARNING

Warning against Unintended Start

1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated; following which data can be modified.

3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

WARNING

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.

Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back up. Refer to the Operating Instructions for further safety guidelines.

2.1.4 Caution

Caution

The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter:

Voltage

200 - 240 V 1.1 - 3.7 kW 5.5 - 45 kW 380 - 480 V 1.1 - 7.5 kW 11 - 90 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

4 min. 15 min.

2.1.5 Before Commencing Repair Work

Minimum Waiting Time

1. Disconnect the frequency converter from mains

2. Disconnect DC bus terminals 88 and 89

3. Wait at least the time mentioned in section General Warning above

4. Remove motor cable

8 MG.11.L4.02 - ADAP-KOOL® Drive

Safety

2.1.6 Special Conditions

ADAP-KOOL

Drive Operating Instructions

Electrical ratings: The rating indicated on the nameplate (Illustration 2.1) of the frequency converter is based on a typical 3-phase mains power supply, within the specified voltage, current and temperature range, which is expected to be used in most applications.

The frequency converters also support other special applications, which affect the electrical ratings of the frequency converter. Special conditions which affect the electrical ratings might be:

□ Single phase applications □ High temperature applications which require de-rating of the electrical ratings □ Marine applications with more severe environmental conditions.

Other applications might also affect the electrical ratings.

Consult the relevant clauses in these instructions and in the AKD102 Design Guide, MG.11.Mx.yy for information about the electrical ratings.

Installation requirements: The overall electrical safety of the frequency converter requires special installation considerations regarding:

□ Fuses and circuit breakers for over-current and short-circuit protection □ Selection of power cables (mains, motor, brake, loadsharing and relay) □ Grid configuration (IT,TN, grounded leg, etc.) □ Safety of low-voltage ports (PELV conditions).

Consult the relevant clauses in these instructions and in the AKD102 Design Guide for information about the installation requirements.

2.1.7 Safe Stop of the Frequency Converter

For versions fitted with a Safe Stop terminal 37 input, the frequency converter can perform the safety function Safe Torque Off (As defined by draft CD IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality and safety category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1, the related information and instructions of the AKD102 Design Guide MG.11.MX.YY must be followed! The information and instructions of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!

MG.11.L4.02 - ADAP-KOOL® Drive 9

Safety

ADAP-KOOL

Drive Operating Instructions

Illustration 2.1 This certificate also covers AKD102

10 MG.11.L4.02 - ADAP-KOOL® Drive

130BA491

Safety

2.1.8 IT Mains

ADAP-KOOL

Drive Operating Instructions

WARNING

IT mains Do not connect frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V for 400 V converters and 760 V for 690 V converters. For 400 V IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth. For 690 V IT mains and delta earth (grounded leg), mains voltage may exceed 760 V between phase and earth.

14-50 RFI Filter can be used to disconnect the internal RFI capacitors from the RFI filter to ground.

2.1.9 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.

MG.11.L4.02 - ADAP-KOOL® Drive 11

Application Guide

3Application Guide

ADAP-KOOL

Drive Operating Instructions

3.1.1

ADAP-KOOL

The built in “wizard” menu guides the installer through the set up of the drive in a clear and structured manner, and has been constructed with reference to the industries refrigeration engineers, to ensure that the text and language used makes complete sense to the installer. The ADAP-KOOL Drive AKD 102 will initially start up with the Application guide (each time until it has been run), thereafter in the event of power failure the application guide is accessed through the Quick menu screen. If “Cancel” is pressed, the AKD 102 will return to the status screen. An automatic timer will cancel the wizard after 5 min. of inactivity (no buttons pressed). The wizard must be re-entered through the Quick Menu when it has been run once. Answering the questions on the screens will take the user though a complete setup for the ADAP-KOOL Drive. Most standard refrigeration applications can be setup by using this Application Guide. Advanced features must be accessed though the menu structure (Quick Menu or Main Menu) in the drive.

The Application guide covers all standard settings for:

- Compressors

- Single fan and pump

- Condenser fans

After completing setup, choose to re-run wizard or start application

The Application Guide can be cancelled at any time by pressing “Back”. The Application Guide can be re-entered through the Quick Menu. When re-entering the Application Guide, the user will be asked to keep previous changes to the factory setup or to restore default values.

Drive Application Guide

The ADAP-KOOL Drive AKD 102 will start up initially with the Application guide thereafter in the event of power failure the application guide is accessed through the Quick menu screen. The following screen will be presented:

If “Cancel” is pressed, the AKD 102 will return to the status screen. An automatic timer will cancel the wizard after 5 min. of inactivity (no buttons pressed). The wizard must be re-entered through the Quick Menu as described below. If “OK” is pressed, the Application Guide will start with the following screen:

This screen will automatically change to the first input screen of the Application Guide:

12 MG.11.L4.02 - ADAP-KOOL® Drive

Application Guide

ADAP-KOOL

Drive Operating Instructions

Answering the questions on the screens will take the user though a complete setup for the ADAP-KOOL Drive. Most standard refrigeration applications can be setup by using this Application Guide. Advanced features must be accessed though the menu structure (Quick Menu, Main Menu etc.) in the drive.

The Application guide covers all standard settings for:

- Compressors

- Single fan and pump

- Condenser fans

Current and nominal speed setup

Min. and max. frequency setup

Compressor pack setup

As an example, please see screens below for a compressor pack setup:

Voltage and frequency setup

Min. time between two starts

MG.11.L4.02 - ADAP-KOOL® Drive 13

Application Guide

ADAP-KOOL

Drive Operating Instructions

Choose with/ without bypass valve

Select open or closed loop

Settings for sensor

Info: 4-20 mA feedback chosen - please connect accordingly

NOTE

Internal / Closed loop : The AKD 102 will control the application directly using the internal PID control within the drive and needs an input from an external input such as a temperature or other sensor which is wired directly into the drive and controls from the sensor signal. External / Open loop: The AKD 102 takes its control signal from another controller (such as a pack controller) which gives the drive e.g. 0-10v, 4-20 mA or ADAP-KOOL Lon. The drive will change its speed depending upon this reference signal.

Select sensor type

Info: Set switch accordingly

14 MG.11.L4.02 - ADAP-KOOL® Drive

Application Guide

Select unit and conversion from pressure

Select fixed or floating setpoint

ADAP-KOOL

Drive Operating Instructions

Set cut out/ in value

Set setpoint

Set high/ low limit for setpoint

Choose pack control setup

Set number of compressors in pack

MG.11.L4.02 - ADAP-KOOL® Drive 15

Application Guide

Info: Connect accordingly

Info: Setup completed

ADAP-KOOL

Drive Operating Instructions

The Application Guide can be cancelled at any time by pressing “Back”. The Application Guide can be re-entered through the Quick Menu:

After completing setup, choose to re-run wizard or start application. Here we can select the following options:

Re-run wizard

•

Go to main menu

•

Go to status

•

Run AMA - Note this is a reduced AMA if

•

compressor application is selected and full AMA if single fan and pump is selected.

If condenser fan is selected in application NO

•

AMA can be run.

Run application- this mode starts the drive in

•

either hand / local mode or via an external control signal if open loop is selected in an earlier screen

When re-entering the Application Guide, the user will be asked to keep previous changes to the factory setup or to restore default values.

NOTE

If the system requirement is to have the internal pack controller for 3 compressors plus by-pass valve connected, there is the need to specify AKD 102 with the extra relay card (MCB105) mounted inside the drive. The bypass valve must be programmed to operate from one of the extra relay outputs on the MCB105 board. This is needed because the standard relay outputs in the AKD 102 are used to control the compressors in the pack.

16 MG.11.L4.02 - ADAP-KOOL® Drive

Application Guide

ADAP-KOOL

Drive Operating Instructions

3.1.2 Application Descriptions

The AKD Wizard is structured into three basic applications:

Compressor

•

Multi condenser fan

•

Single fan and pump

•

These applications are then further expanded to allow control of the drive to be controlled via the drives own internal PID controllers or from an external control signal.

Compressor The wizard guides the user through the set up of a refrigeration compressor by asking him to input data about the compressor and the refrigeration system on which the drive will be running. All terminology and units used within the wizard are common refrigeration type and set up is thus completed in 10-15 easy steps using just two buttons of the drives local control panel.

Illustration 3.1 Standard drawing of “Compressor with internal control”

Single or multiple fans or pumps The wizard guides the user through the set up of a refrigeration condenser fan or pump by asking him to input data about the condenser or pump and the refrigeration system on which the drive will be running. All terminology and units used within the wizard are common refrigeration type and set up is thus completed in 10-15 easy steps using just two buttons of the drives local control panel.

Illustration 3.2 Speed control using analogue reference (open loop) – single fan or pump / multiple fans or pumps in parallel

MG.11.L4.02 - ADAP-KOOL® Drive 17

Application Guide

Illustration 3.3 Pressure control in closed loop – stand alone system. single fan or pump / multiple fans or pumps in parallel

Compressor pack

ADAP-KOOL

Drive Operating Instructions

Illustration 3.4 P0 pressure transmitter

Illustration 3.5 How to connect the AKD102 and AKS33 for closed loop applications

18 MG.11.L4.02 - ADAP-KOOL® Drive

Mechanical Installation

4 Mechanical Installation

4.1 Before starting

4.1.1 Checklist

ADAP-KOOL

Drive Operating Instructions

When unpacking the frequency converter, ensure that the unit is undamaged and complete. Use the following table to identify the packaging:

Enclosure type:

Unit size (kW):

200-240 V 1.1-3.0 3.7 1.1-3.7

380-480 V 1.1-4.0 5.5-7.5 1.1-7.5

Table 4.1 Unpacking table

(IP 20-21)

A4/A5

(IP 55-66)

B1 (IP 21-55-66) B2 (IP 21-55-66)

5.5-11/

5.5-11

11-18.5/

11-18.5

15/

15-18.5

22-30/

22-37

(IP 21-55-66)

18.5-30/ 22-30

37-55/

45-55

(IP 21-55-66)

37-45/

37-45

75-90/

75-90

Please note that a selection of screwdrivers (phillips or cross-thread screwdriver and torx), a side-cutter, drill and knife is also recommended to have handy for unpacking and mounting the frequency converter. The packaging for these enclosures contains, as shown: Accessories bag(s), documentation and the unit. Depending on options fitted there may be one or two bags and one or more booklets.

MG.11.L4.02 - ADAP-KOOL® Drive 19

Mechanical Installation

4.1.2 Mechanical Dimensions

ADAP-KOOL

Drive Operating Instructions

* A5 in IP55/66 only

All measurements in mm.

A2 A3 A4 A5 B1 B2 C1 C2

IP20/21 IP20/21 IP55/66 IP55/66 IP21/55/66 IP21/55/66 IP21/55/66 IP21/55/66

20 MG.11.L4.02 - ADAP-KOOL® Drive

Mechanical Installation

37-45

75-90

21/55/66

Type 1/12

37-55

18.5-30

21/55/66

Type 1/12

22-30

21/55/66

Type 1/12

5.5-11

11-18.5

21/ 55/66

Type 1/12

ADAP-KOOL

Drive Operating Instructions

Mechanical dimensions

1.1-3.7

1.1-7.5

1.1-2.2

1.1-4.0

3.7

5.5-7.5

1.1-3.0

1.1-4.0

55/66

Type 12

55/66

Type 1

Chassis

Type 1

Chassis

a 257 350 257 350 401 402 454 624 648 739

b 70 70 110 110 171 215 210 210 272 334

4.9 5.3 6.6 7.0 9.7 14 23 27 45 65

f 9 9 9 9 6 9 9 9 9.8 9.8

c 8.0 8.0 8.0 8.0 8.2 8.2 12 12 12 12

Frame size (kW): A2 A3 A4 A5 B1 B2 C1 C2

NEMA

Enclosure A** 246 372 246 372 390 420 480 650 680 770

Back plate A1 268 375 268 375 390 420 480 650 680 770

Width (mm)

Enclosure B 90 90 130 130 200 242 242 242 308 370

With one C option B 130 130 170 170 242 242 242 308 370

Distance between mount.

holes

Without option A/B C 205 205 205 205 175 200 260 260 310 335

Screw holes (mm)

200-240 V

380-480 V

..with de-coupling plate A2 374 - 374 - - - - - - -

Distance between mount.

Height (mm)

holes

Back plate B 90 90 130 130 200 242 242 242 308 370

Depth (mm)

With option A/B C* 220 220 220 220 175 200 260 260 310 335

Diameter ø d 11 11 11 11 12 12 19 19 19 19

Diameter ø e 5.5 5.5 5.5 5.5 6.5 6.5 9 9 9.0 9.0

Max weight

(kg)

* Depth of enclosure will vary with different options installed.

** The free space requirements are above and below the bare enclosure height measurement A. See section 3.2.3 for further information.

MG.11.L4.02 - ADAP-KOOL® Drive 21

Mechanical Installation

ADAP-KOOL

Drive Operating Instructions

4.1.3 Accessory Bags

Accessory Bags: Find the following parts included in the frequency converter accessory bags

Frame sizes A2 and A3 Frame size A4/A5

Frame sizes B1 and B2 Frame sizes C1 and C2

1 + 2 only available in units with brake chopper. For DC link connection (Load sharing) the connector 1 can be ordered separately. An eight pole connector is included in accessory bag for AKD 102 without Safe Stop.

22 MG.11.L4.02 - ADAP-KOOL® Drive

Mechanical Installation

ADAP-KOOL

Drive Operating Instructions

4.2 How to Install

4.2.1 Mechanical Mounting

All IP20 enclosure sizes as well as IP21/ IP55 enclosure sizes except A2 and A3 allow side-by-side installation.

If the IP 21 Enclosure kit (130B1122 or 130B1123) is used on enclosure A2 or A3, there must be a clearance between the drives of min. 50 mm.

For optimal cooling conditions allow a free air passage above and below the frequency converter. See table below.

Air passage for different enclosures

Enclosure: A2 A3 A4 A5 B1 B2 C1 C2

a (mm): 100 100 100 100 200 200 200 225

b (mm): 100 100 100 100 200 200 200 225

1. Drill holes in accordance with the measurements given.

2. You must provide screws suitable for the surface on which you want to mount the frequency converter. Re-tighten all four screws.

Table 4.2 Mounting frame sizes A5, B1, B2, C1 and C2 on a non-solid back wall, the drive must be provided with a back plate A due to insufficient cooling air over the heat sink.

MG.11.L4.02 - ADAP-KOOL® Drive 23

Mechanical Installation

ADAP-KOOL

Drive Operating Instructions

4.2.2 Safety Requirements of Mechanical Installation

WARNING

Pay attention to the requirements that apply to integration and field mounting kit. Observe the information in the list to avoid serious injury or equipment damage, especially when installing large units.

NOTE

The frequency converter is cooled by means of air circulation. To protect the unit from overheating, it must be ensured that the ambient temperature does not exceed the maximum temperature stated for the frequency converter and that the 24-hour average temperature is not exceeded. Locate the maximum temperature and 24-hour average in the paragraph Derating for Ambient Temperature. If the ambient temperature is in the range of 45 °C - 55 ° C, derating of the frequency converter will become relevant, see Derating for Ambient Temperature. The service life of the frequency converter is reduced if derating for ambient temperature is not taken into account.

4.2.3 Field Mounting

For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55 units are recommended.

4.2.4 Panel Through Mounting

A Panel Through Mount Kit is available for frequency converter series ADAP-KOOL Drive.

In order to increase heatsink cooling and reduce panel depth, the frequency converter may be mounted in a through panel. Furthermore the in-built fan can then be removed.

The kit is available for enclosures A5 through C2.

NOTE

This kit cannot be used with cast front covers. No cover or IP21 plastic cover must be used instead.

Information on ordering numbers is found in the Design Guide, section Ordering Numbers. More detailed information is available in the Panel Through Mount Kit instruction, MI.33.H1.YY, where yy=language code.

24 MG.11.L4.02 - ADAP-KOOL® Drive

Electrical Installation

ADAP-KOOL

Drive Operating Instructions

5 Electrical Installation

5.1 How to Connect

5.1.1 Cables General

NOTE

For the AKDHigh Power series mains and motor connections, please see the ADAP-KOOL® Drive AKD102High Power Operating Instructions, MG.11.Ox.yy.

NOTE

Cables General Always comply with national and local regulations on cable cross-sections.

Details of terminal tightening torques.

Power (kW) Torque (Nm)

Enclo-

sure

A2 1.1 - 3.0 1.1 - 4.0 1.8 1.8 1.8 1.8 3 0.6 A3 3.7 5.5 - 7.5 1.8 1.8 1.8 1.8 3 0.6 A4 1.1 - 2.2 1.4 - 4 1.8 1.8 1.8 1.8 3 0.6 A5 1.1 - 3.7 1.1 - 7.5 1.8 1.8 1.8 1.8 3 0.6 B1 5.5 - 11 11 - 18.5 1.8 1.8 1.5 1.5 3 0.6

C1 18.5 - 30 37 - 55 10 10 10 10 3 0.6

200-240

37 45

380-480

22 30

75 90

Line Motor

2.5

4.5

14 24

2.5

4.5

14 24

connection

3.7

14 14

Brake Earth Relay

3.7

14 14

3 3

0.6

Table 5.1 Tightening of terminals

MG.11.L4.02 - ADAP-KOOL® Drive 25

Electrical Installation

ADAP-KOOL

Drive Operating Instructions

5.1.2 Electrical Installation and Control Cables

Illustration 5.1 Diagram showing all electrical terminals. (Terminal 37 present for units with Safe Stop Function only.)

26 MG.11.L4.02 - ADAP-KOOL® Drive

Electrical Installation

Terminal number Terminal description Parameter number Factory default 1+2+3 Terminal 1+2+3-Relay1 5-40 Alarm Running 4+5+6 Terminal 4+5+6-Relay2 5-40 Alarm Running 12 Terminal 12 Supply - +24 V DC 13 Terminal 13 Supply - +24 V DC 18 Terminal 18 Digital Input 5-10 Start 19 Terminal 19 Digital Input 5-11 Reversing 20 Terminal 20 - Common 27 Terminal 27 Digital Input/Output 5-12/5-30 Coast inverse 29 Terminal 29 Digital Input/Output 5-13/5-31 Jog 32 Terminal 32 Digital Input 5-14 No operation 33 Terminal 33 Digital Input 5-15 No operation 37 Terminal 37 Digital Input - Safe Stop 42 Terminal 42 Analog Output 6-50 Speed 0-HighLim 53 Terminal 53 Analog Input 3-15/6-1*/20-0* Reference 54 Terminal 54 Analog Input 3-15/6-2*/20-0* Feedback

Table 5.2 Terminal connections

Very long control cables and analog signals may, in rare cases and depending on installation, result in 50/60 Hz earth loops due to noise from mains supply cables.

ADAP-KOOL

Drive Operating Instructions

If this occurs, break the screen or insert a 100 nF capacitor between screen and chassis.

NOTE

The common of digital / analog inputs and outputs should be connected to separate common terminals 20, 39, and 55. This will avoid ground current interference among groups. For example, it avoids switching on digital inputs disturbing analog inputs.

NOTE

Control cables must be screened/armoured.

MG.11.L4.02 - ADAP-KOOL® Drive 27

Electrical Installation

ADAP-KOOL

Drive Operating Instructions

5.1.3 Fuses

Branch circuit protection In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be shortcircuit and overcurrent protected according to the national/international regulations.

Short circuit protection The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned in tables 4.3 and 4.4 to protect service personnel or other equipment in case of an internal failure in the unit. The frequency converter provides full short circuit protection in case of a short-circuit on the motor output.

Over-current protection Provide overload protection to avoid fire hazard due to overheating of the cables in the installation. Over current protection must always be carried out according to national regulations. The frequency converter is equipped with an internal over

current protection that can be used for upstream overload protection (UL-applications excluded). See ADAP-KOOL

Drive

AKD102 Programming Guide, par. 4-18. Fuses must be designed for protection in a circuit capable of supplying a maximum

of 100,000 A

(symmetrical), 500 V/600 V maximum.

rms

Non UL compliance If UL/cUL is not to be complied with, Danfoss recommends using the fuses mentioned in table 4.2, which will ensure compliance with EN50178: In case of malfunction, not following the recommendation may result in unnecessary damage to the frequency converter.

Frequency converter 200-240 V K25-K75 1K1-1K5 2K2 3K0 3K7 5K5 7K5

11K 15K 18K5 22K 30K 37K 45K 380-480 V K37-1K5 2K2-3K0 4K0-5K5 7K5 11K-15K 18K 22K 30K 37K 45K 55K 75K 90K

Max. fuse size

10A

16A

25A

35A

50A

63A

80A

125A

160A

200A

250A

10A

16A

25A

35A

63A

80A

100A

125A

160A

250A

Voltage Type

200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type gG 200-240 V type aR 200-240 V type aR

380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type gG 380-500 V type aR 380-500 V type aR

Table 5.3 Non UL fuses 200 V to 480 V

1) Max. fuses - see national/international regulations for selecting an applicable fuse size. *170M fuses from Bussmann shown use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use.

28 MG.11.L4.02 - ADAP-KOOL® Drive

Electrical Installation

ADAP-KOOL

Drive Operating Instructions

Frequency

converter

UL Compliance - 200-240 V

kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 K25-K37 KTN-R05 JKS-05 JJN-05 5017906-005 KLN-R005 ATM-R05 A2K-05R K55-1K1 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10 ATM-R10 A2K-10R

1K5 KTN-R15 JKS-15 JJN-15 5017906-015 KLN-R15 ATM-R15 A2K-15R 2K2 KTN-R20 JKS-20 JJN-20 5012406-020 KLN-R20 ATM-R20 A2K-20R 3K0 KTN-R25 JKS-25 JJN-25 5012406-025 KLN-R25 ATM-R25 A2K-25R 3K7 KTN-R30 JKS-30 JJN-30 5012406-030 KLN-R30 ATM-R30 A2K-30R 5K5 KTN-R50 JKS-50 JJN-50 5012406-050 KLN-R50 - A2K-50R 7K5 KTN-R50 JKS-60 JJN-60 5012406-050 KLN-R60 - A2K-50R 11K KTN-R60 JKS-60 JJN-60 5014006-063 KLN-R60 A2K-60R A2K-60R 15K KTN-R80 JKS-80 JJN-80 5014006-080 KLN-R80 A2K-80R A2K-80R

18K5 KTN-R125 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R A2K-125R

22K KTN-R125 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R A2K-125R 30K FWX-150 - - 2028220-150 L25S-150 A25X-150 A25X-150 37K FWX-200 - - 2028220-200 L25S-200 A25X-200 A25X-200 45K FWX-250 - - 2028220-250 L25S-250 A25X-250 A25X-250

Bussmann Bussmann Bussmann SIBA Littel fuse

Ferraz-

Shawmut

Table 5.4 UL fuses 200 - 240 V

Frequency

converter

UL Compliance - 380-480 V, 525-600

kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 K37-1K1 KTS-R6 JKS-6 JJS-6 5017906-006 KLS-R6 ATM-R6 A6K-6R 1K5-2K2 KTS-R10 JKS-10 JJS-10 5017906-010 KLS-R10 ATM-R10 A6K-10R

3K0 KTS-R15 JKS-15 JJS-15 5017906-016 KLS-R16 ATM-R16 A6K-16R 4K0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R 5K5 KTS-R25 JKS-25 JJS-25 5017906-025 KLS-R25 ATM-R25 A6K-25R 7K5 KTS-R30 JKS-30 JJS-30 5012406-032 KLS-R30 ATM-R30 A6K-30R 11K KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 - A6K-40R 15K KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 - A6K-40R 18K KTS-R50 JKS-50 JJS-50 5014006-050 KLS-R50 - A6K-50R 22K KTS-R60 JKS-60 JJS-60 5014006-063 KLS-R60 - A6K-60R 30K KTS-R80 JKS-80 JJS-80 2028220-100 KLS-R80 - A6K-80R 37K KTS-R100 JKS-100 JJS-100 2028220-125 KLS-R100 A6K-100R 45K KTS-R125 JKS-150 JJS-150 2028220-125 KLS-R125 A6K-125R 55K KTS-R150 JKS-150 JJS-150 2028220-160 KLS-R150 A6K-150R 75K FWH-220 - - 2028220-200 L50S-225 A50-P225 90K FWH-250 - - 2028220-250 L50S-250 A50-P250

Bussmann Bussmann Bussmann SIBA Littel fuse

Ferraz-

Shawmut

Ferraz-

Table 5.5 UL fuses 380 - 600 V

KTS-fuses from Bussmann may substitute KTN for 240 V frequency converters.

FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters.

KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V frequency converters.

L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters.

A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters.

A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters.

MG.11.L4.02 - ADAP-KOOL® Drive 29

Electrical Installation

ADAP-KOOL

Drive Operating Instructions

5.1.4 Earthing and IT mains

WARNING

The earth connection cable cross section must be at least 10 mm2 or 2 rated mains wires terminated separately according to EN 50178 or IEC 61800-5-1 unless national regulations specify differently. Always comply with national and local regulations. on cable cross-sections.

The mains is connected to the main disconnect switch if this is included.

NOTE

Check that mains voltage corresponds to the mains voltage of the frequency converter name plate.

Illustration 5.2 Terminals for mains and earthing.

WARNING

IT Mains Do not connect 400 V frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V. For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth.

5.1.5 Mains Wiring Overview

Enclosure:

Motor size:

200-240 V

380-480 V

Goto: 5.1.6 5.1.7 5.1.8 5.1.9

(IP 20/IP 21)A3(IP 20/IP 21)A5(IP 55/IP 66)

1.1-3.0 kW

1.1-4.0 kW

3.7

5.5-7.5 kW

1.1-3.7 kW

1.1-7.5 kW

(IP 21/IP 55/IP

66)

5.5-11 kW

11-18.5

(IP 21/IP 55/IP

66)

22-30

(IP 21/IP 55/66)C2(IP 21/IP 55/66)

18.5-30 kW

37-55

37-45

75-90

Table 5.6 Mains wiring table.

30 MG.11.L4.02 - ADAP-KOOL® Drive

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