This manual provides detailed information for the installation and start-up of the frequency converter.
Chapter 3 Installation provides requirements for mechanical
and electrical installation, including:
Input
•
Motor
•
Control wiring
•
Serial communication wiring
•
Control terminal functions
•
Chapter 4 Start-up and Functional Testing provides detailed
procedures for:
Start-up
•
Basic operational programming
•
Functional testing
•
The remaining chapters provide supplementary details.
These details include:
User interface
•
Detailed programming
•
Application examples
•
Start-up
•
Troubleshooting
•
Specifications.
•
VLT® is a registered trademark.
1.2
Additional Resources
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website:
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/VLT+Technical+Documentation.htm, for downloads or additional
information.
1.3 Approvals and Certifications
More approvals and certifications are available. Contact the
local Danfoss partner.
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the DesignGuide.
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
Design Guide.
1.4
Disposal Instruction
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Other resources are available to understand advanced
frequency converter functions and programming.
The VLT® Refrigeration Drive FC 103 Programming
•
Guide provides greater detail on working with
parameters and many application examples.
The VLT® Refrigeration Drive FC 103 Design Guide
•
provides detailed capabilities and functionality to
design motor control systems.
Supplemental publications and manuals are
•
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical
+Documentation.htm for listings.
A frequency converter is an electronic motor controller
that converts DC 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.
The frequency converter offers many control, monitoring
and efficiency functions such as:
Monitoring the system and motor status
•
Issuing warnings or alarms for fault conditions
•
Starting and stopping the motor
•
Optimising energy efficiency
•
Operation and monitoring functions are available as status
indications to an outside control system or serial communication network.
1
1
Interior Views
1.5.1
LCP (Local Control Panel) 9Relay 2 (04, 05, 06)
1
2 RS-485 fieldbus
connector
3 Digital I/O and 24 V
supply
4 Analog I/O connector12Cable clamp (PE)
5 USB connector13Ground
6 Fieldbus terminal switch 14Motor output terminals 96
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE
Indicates important information, including situations that
can result in damage to equipment or property.
2.1 Qualified Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the troublefree and safe operation of the frequency converter. Only
qualified personnel are allowed to install or operate this
equipment.
Qualified personnel are defined as trained staff, who are
authorised to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Additionally, the personnel must be familiar
with the instructions and safety measures described in this
document.
2.2
Safety Precautions
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input, DC power supply, or load
sharing. Failure to perform installation, start-up, and
maintenance by qualified personnel can result in death
or serious injury.
Installation, start-up, and maintenance must be
•
performed by qualified personnel only.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
or DC power supply, the motor may start at any time.
Unintended start during programming, service or repair
work can result in death, serious injury, or property
damage. The motor can start by means of an external
switch, a serial bus command, an input reference signal
from the LCP, or after a cleared fault condition.
To prevent unintended motor start:
Disconnect the frequency converter from mains.
•
Press [Off/Reset] on the LCP, before
•
programming parameters.
The frequency converter, motor, and any driven
•
equipment must be fully wired and assembled
when the frequency converter is connected to
AC mains, or DC power supply.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. Failure to wait the specified
time after power has been removed before performing
service or repair work, could result in death or serious
injury.
Stop the motor.
•
Disconnect the AC mains, permanent magnet
•
type motors, and remote DC-link power
supplies, including battery back-ups, UPS, and
DC-link connections to other frequency
converters.
Wait for the capacitors to discharge fully before
•
performing any service or repair work. The
duration of waiting time is specified in
Table 2.1.
Voltage [V]Minimum waiting time (minutes)
2040
380-480110-315 kW355-450 kW
525-69055-400 kW450-630 kW
High voltage may be present even when the warning LED
indicator lights are off.
Plan the installation site of the frequency converter
before commencing the installation. Neglecting this may
result in extra work during and after installation.
Select the best possible operation site by considering
the following (see details on the following pages and
the respective Design Guides):
Ambient operating temperature
•
Installation method
•
How to cool the unit
•
Position of the frequency converter
•
Cable routing
•
Ensure that the power source supplies the correct
•
voltage and necessary current.
Ensure that the motor current rating is within the
•
maximum current from the frequency converter.
If the frequency converter is without built-in
•
fuses, ensure that the external fuses are rated
correctly.
33
Illustration 3.1 Front Clearance of IP21/IP54 Rated Enclosure
Types D1h, D5h, and D6h
Voltage [V] Altitude restrictions
380-690At altitudes above 2000 m, contact Danfoss
regarding PELV
Table 3.1 Installation at High Altitudes
General Considerations
3.1.2
Wire access
Ensure that proper cable access is present including
necessary bending allowance. As the IP00/IP20 enclosure is
open to the bottom, cables must be fixed to the back
panel of the enclosure where the frequency converter is
mounted, i.e. by using cable clamps.
CAUTION
All cable lugs/shoes must mount within the width of the
terminal bus bar.
Space
Ensure proper space above and below the frequency
converter to allow airflow and cable access. In addition
space in front of the unit must be considered to enable
opening of the panel door, see Illustration 3.1 to
Illustration 3.3.
Illustration 3.2 Front Clearance of IP21/IP54 Rated Enclosure
Types D2h, D7h, and D8h
Illustration 3.3 Front Clearance of IP21/IP54 Rated Enclosure
Type E1
in IP21/Nema 1 and IP54 units
Lifting bar to lift the unit (rod or tube max. Ø 5
•
mm (1 inch), able to lift minimum 400 kg (880
lbs).
Crane or other lifting aid to place the frequency
•
converter in position
A Torx T50 tool is needed to install the E1 in IP21
•
and IP54 enclosure types.
3.2 Pre-installation Checklist
Before unpacking the frequency converter, ensure
•
that the packaging is intact. If any damage has
occurred, immediately contact the shipping
company to claim the damage.
Unpack the frequency converter as close as
•
possible to the final installation site.
Ensure the model number number on the
•
nameplate corresponds to the model number on
the order.
Ensure that each of the following are rated for
•
the same voltage:
Mains (power)
•
Frequency converter
•
Motor
•
Ensure that the frequency converter output
•
current rating is equal to or greater than the
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.
3.3
Mechanical Installation
3.3.1 Cooling
Provide top and bottom clearance for air cooling.
•
Generally, 225 mm (9 in) is required.
Improper mounting can result in overheating and
•
reduced performance.
Consider derating for temperatures starting
•
between 45 °C (113 °F) and 50 °C (122 °F) and
elevation 1000 m (3300 ft) above sea level. See
VLT® Refrigeration Drive FC 103 Design Guide for
detailed information.
The high-power frequency converters utilise a backchannel cooling concept that removes heat sink cooling
air. Approximately 90% of the heat is lead out of the back
channel of the frequency converters. The back-channel air
can be redirected from the panel or room using one of the
kits below.
Duct cooling
A back-channel cooling kit is available to direct the heat
sink cooling air out of the panel when an IP20/chassis
frequency converter is installed in a Rittal enclosure. Use of
this kit reduces the heat in the panel and smaller door fans
can be specified on the enclosure.
Cooling out the back (top and bottom covers)
The back-channel cooling air can be ventilated out of the
room so that the heat from the back channel is not
dissipated into the control room.
NOTICE
A door fan(s) is required on the enclosure to remove the
heat not contained in the back channel of the frequency
converters and any additional losses generated by other
components inside the enclosure. Calculate the total
required air flow so that the appropriate fans can be
selected. A cooling clearance of 225 mm is required
above the frequency converter.
Airflow
Secure the necessary airflow over the heat sink. The flow
rate is shown in Table 3.2.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
3Air space inlet minimum 225 mm [8.9 in]
4Floor
Illustration 3.5 Mechanical Dimensions, D1h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
3Air space inlet minimum 225 mm [8.9 in]
4Floor
Illustration 3.7 Mechanical Dimensions, D2h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
3Air space inlet minimum 225 mm [8.9 in]
4Floor
Illustration 3.9 Mechanical Dimensions, D3h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
3Air space inlet minimum 225 mm [8.9 in]
4Floor
Illustration 3.11 Mechanical Dimensions, D4h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
Illustration 3.13 Mechanical Dimensions, D5h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
3Air space intlet minimum 225 mm [8.9 in]
4Floor
Illustration 3.15 Mechanical Dimensions, D6h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
Illustration 3.17 Mechanical Dimensions, D7h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
Illustration 3.18 Top Mounting Hole Dimension Detail, D7h
1Ceiling
2Air space outlet minimum 225 mm [8.9 in]
Illustration 3.19 Mechanical Dimensions, D8h
NOTICE
If using a kit to direct the airflow from the heat sink to
the outside vent on the back of the frequency converter,
the required ceiling clearance is 100 mm.
Illustration 3.20 Top Mounting Hole Dimension Detail, D8h
This section contains detailed instructions for wiring the
frequency converter. The following tasks are described:
Wiring the motor to the frequency converter
•
output terminals.
Wiring the AC mains to the frequency converter
•
input terminals.
Connecting control and serial communication
•
wiring.
After power has been applied, checking input
•
and motor power; programming control terminals
for their intended functions.
WARNING
EQUIPMENT HAZARD
Rotating shafts and electrical equipment can be
hazardous. All electrical work must conform to national
and local electrical codes. It is strongly recommended
that installation, start up, and maintenance are
performed only by trained and qualified personnel.
Failure to follow these guidelines could result in death or
serious injury.
33
CAUTION
WIRING ISOLATION
Run input power, motor wiring, and control wiring in 3
separate metallic conduits, or use separated shielded
cable for high frequency noise isolation. Failure to isolate
power, motor, and control wiring could result in less
than optimum performance of the frequency converter
and associated equipment.
For safety, comply with the following requirements:
Electronic controls equipment is connected to
•
hazardous mains voltage. Take extreme to protect
against electrical hazards when applying power
to the unit.
Run motor cables from multiple frequency
•
converters separately. Induced voltage from
output motor cables run together can charge
equipment capacitors, even with the equipment
turned off and locked out.
Field wiring terminals are not intended to receive
•
a conductor one size larger.
Overload and equipment protection
An electronically activated function within the
•
frequency converter provides overload protection
for the motor. The overload calculates the level of
increase to activate timing for the trip (controller
output stop) function. The higher the current
draw, the quicker the trip response. The overload
provides Class 20 motor protection. See
chapter 9 Warnings and Alarms for details on the
trip function.
Because the motor wiring carries high frequency
•
current, it is important that wiring for mains,
motor power, and control are run separately. Use
metallic conduit or separated shielded wire. See
Illustration 3.24. Failure to isolate power, motor,
and control wiring could result in less than
optimum equipment performance.
All frequency converters must be provided with
•
short-circuit and overcurrent protection. Input
fusing is required to provide this protection, see
Illustration 3.25. If not factory supplied, fuses must
be provided by the installer as part of installation.
See maximum fuse ratings in
chapter 11.3.1 Protection.
33
Illustration 3.24 Example of Proper Electrical Installation using
Conduit
power, motor power, and control wiring.
Use the clamps provided with the equipment for
•
33
1Fuses
2Ground
Illustration 3.25 Frequency Converter Fuses
Wire Type and Ratings
All wiring must comply with local and national
•
regulations regarding cross-section and ambient
temperature requirements.
Danfoss recommends that all power connections
•
are made with a minimum 75 °C rated copper
wire.
Grounding Requirements
3.4.2
WARNING
GROUNDING HAZARD
For operator safety, it is important to ground
•
the frequency converter properly in accordance
with national and local electrical codes as well
as instructions contained within this document.
Do not use conduit connected to the frequency
•
converter as a replacement for proper
grounding.
Ground currents are higher than 3.5 mA.
•
Failure to ground the frequency converter properly could
result in death or serious injury.
3.4.2.1
Follow national and local codes regarding protective
earthing of equipment with a leakage current >3.5 mA.
Frequency converter technology implies high frequency
switching at high power. This generates a leakage current
in the ground connection. A fault current in the frequency
converter at the output power terminals might contain a
DC component, which can charge the filter capacitors and
cause a transient ground current. The ground leakage
current depends on various system configurations
including RFI filtering, screened motor cables, and
frequency converter power.
EN/IEC61800-5-1 (Power Drive System Product Standard)
requires special care if the leakage current exceeds 3.5 mA.
Grounding must be reinforced in one of the following
ways:
See EN 60364-5-54 § 543.7 for further information.
proper ground connections.
Do not ground one frequency converter to
•
another in a daisy-chain fashion.
Keep the ground wire connections as short as
•
possible.
Use high-strand wire to reduce electrical noise.
•
Follow motor manufacturer wiring requirements.
•
Leakage Current (>3.5 mA)
Ground wire of at least 10 mm
•
2 separate ground wires both complying with the
•
dimensioning rules
chapter 3.4.2.1 Leakage Current
2
NOTICE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding of the equipment in
accordance with national and local electrical codes and
standards.
Follow all local and national electrical codes to
•
ground electrical equipment properly.
Proper protective earthing for equipment with