Danfoss FC 103 Operating guide

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® Refrigeration Drive FC 103
75-630 kW
www.danfoss.com/drives
Contents Operating Instructions
Contents
1.1 Purpose of the Manual
1.2 Additional Resources
1.3 Approvals and Certifications
1.4 Disposal Instruction
1.5 Product Overview
1.5.1 Interior Views 5
1.6 Internal Controller Functions
1.7 Enclosure Types and Power Ratings
2 Safety
2.1 Qualified Personnel
2.2 Safety Precautions
3 Installation
3.1 Pre-Installation
3.1.1 Planning the Installation Site 11
3.1.2 General Considerations 11
4 4 4 4 4 5
7 8
9 9 9
11 11
3.1.3 Tools Required for Installation 12
3.2 Pre-installation Checklist
3.3 Mechanical Installation
3.3.1 Cooling 12
3.3.2 Lifting 13
3.3.3 Mechanical Dimensions 14
3.4 Electrical Installation
3.4.1 General Requirements 25
3.4.2 Grounding Requirements 28
3.4.2.1 Leakage Current (>3.5 mA) 28
3.4.2.2 Grounding 29
3.4.3 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA 12) 31
3.4.4 Motor Connection 32
3.4.4.1 Terminal Locations: D1h-D4h 33
3.4.4.2 Terminal Locations: D5h-D8h 35
3.4.4.3 Terminal Locations: E1-E2 43
3.4.5 Motor Cable 47
12 12
25
3.4.6 Motor Rotation Check 48
3.4.7 AC Mains Connection 48
3.4.8 Shielding against Electrical Noise 49
3.5 Control Wiring Connection
3.5.1 Access 49
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49
Contents Operating Instructions
3.5.2 Using Screened Control Cables 49
3.5.3 Grounding of Screened Control Cables 50
3.5.4 Control Terminal Types 51
3.5.5 Wiring to Control Terminals 51
3.5.6 Safe Torque Off (STO) 52
3.5.7 Control Terminal Functions 52
3.6 Serial Communication
3.7 Optional Equipment
3.7.1 Anti-condensation Heater 53
3.7.2 Mains Shield 53
4 Start-up and Functional Testing
4.1 Pre-start
4.1.1 Safety Inspection 54
4.2 Applying Power
4.3 Basic Operational Programming
4.3.1 Set-up Wizard 56
4.4 Automatic Motor Adaptation
4.5 Check Motor Rotation
4.6 Local-control Test
4.7 System Start-up
5 User Interface
5.1 Local Control Panel
53 53
54 54
56 56
61 61 61 62
63 63
5.1.1 LCP Layout 63
5.1.2 Setting LCP Display Values 65
5.1.3 Display Menu Keys 65
5.1.4 Navigation Keys 66
5.1.5 Operation Keys 66
5.2 Back-up and Copying Parameter Settings
5.2.1 Uploading Data to the LCP 67
5.2.2 Downloading Data from the LCP 67
5.3 Restoring Default Settings
5.3.1 Recommended Initialisation 67
5.3.2 Manual Initialisation 67
6 Programming
6.1 Introduction
6.2 Programming Example
6.3 Control Terminal Programming Examples
6.4 International/North American Default Parameter Settings
66
67
68 68 68 69 70
2 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
Contents Operating Instructions
6.5 Parameter Menu Structure
6.5.1 Main Menu Structure 72
6.6 Remote Programming with MCT 10 Set-up Software
7 Application Examples
7.1 Introduction
7.2 Application Examples
8 Status Messages
8.1 Status Display
8.2 Status Message Definitions
9 Warnings and Alarms
9.1 System Monitoring
9.2 Warning and Alarm Types
9.2.1 Warnings 83
9.2.2 Alarm Trip 83
9.2.3 Alarm Trip-lock 83
71
76
77 77 77
81 81 81
83 83 83
9.3 Warning and Alarm Displays
9.4 Warning and Alarm Definitions
9.5 Fault Messages
10 Basic Troubleshooting
10.1 Start-up and Operation
11 Specifications
11.1 Power-dependent Specifications
11.2 General Technical Data
11.3 Fuse Tables
11.3.1 Protection 102
11.3.2 Fuse Selection 102
11.3.3 Short Circuit Current Rating (SCCR) 104
11.3.4 Connection Tightening Torques 104
Index
83 84 85
92 92
95 95 98
102
105
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 3
Introduction Operating Instructions
1
1 Introduction
1.1 Purpose of the Manual
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 Design Guide.
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.
Optional equipment is available that may change
some of the procedures described. Refer to the
4 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
130BC252.11
1
15
14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
130BC301.11
1
2
3
4
5
6
7
8
9
10
11
Introduction
Operating Instructions
1.5 Product Overview
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) 9 Relay 2 (04, 05, 06)
1 2 RS-485 fieldbus
connector
3 Digital I/O and 24 V
supply 4 Analog I/O connector 12 Cable clamp (PE) 5 USB connector 13 Ground 6 Fieldbus terminal switch 14 Motor output terminals 96
7 Analog switches (A53),
(A54) 8 Relay 1 (01, 02, 03) 16 TB5 (IP21/54 only). Terminal
Illustration 1.2 Close-up View: LCP and Control Functions
10 Lifting ring
11 Mounting slot
(U), 97 (V), 98 (W)
15 Mains input terminals 91
(L1), 92 (L2), 93 (L3)
block for anti-condensation heater
Illustration 1.1 Interior Components - Enclosure Type D
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130BB019.10
1
2
3
4
5
6
7
8
9
10
130BB020.10
1
2
3
4
5
6
7
8
10
1
Introduction Operating Instructions
Illustration 1.3 Compact IP21 (NEMA 1) and IP54 (NEMA 12) Enclosure Type E1
Illustration 1.4 Compact IP00 (Chassis) with Disconnect, Fuse and RFI Filter, Enclosure Type E2
AUX relay 5) Load sharing
1) 01 02 03 -DC +DC 04 05 06 88 89
2) Temp switch 6) SMPS fuse 106 104 105 7) Fan fuse
3) Mains 8) AUX fan R S T 100 101 102 103 91 92 93 L1 L2 L1 L2 L1 L2 L3 9) Mains ground
4) Brake 10) Motor
-R +R U V W 81 82 96 97 98 T1 T2 T3
Table 1.1 Legend to Illustration 1.3 and Illustration 1.4
6 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
Introduction Operating Instructions
1.6 Internal Controller Functions
Illustration 1.5 is a block diagram of the frequency converter's internal components.
Illustration 1.5 Frequency Converter Block Diagram
Area Title Functions
3-phase AC mains supply to the
1 Mains input
2 Rectifier
3 DC-bus
4 DC reactors
5 Capacitor bank
6 Inverter
7 Output to motor
8 Control circuitry
frequency converter
The rectifier bridge converts the
AC input to DC current to supply inverter power.
Intermediate DC-bus circuit
handles the DC current.
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.
Stores the DC power.
Provides ride-through protection
for short power losses.
Converts the DC into a
controlled PWM AC waveform for a controlled variable output to the motor.
Regulated 3-phase output
power to the motor
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.
1
1
Table 1.2 Legend to Illustration 1.5
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Introduction Operating Instructions
1
1.7 Enclosure Types and Power Ratings
Normal Over­load [kW]
400 V D1h/
525 V D1h/
690 V D1h/
Table 1.3 kW Rated Frequency Converters
Normal Overload [hp]
55 75 90 110 132 160 200 250 315 355 400 450 500 560 630
D1h/
D1h/D3h/
D3h/
D3h/
D5h/D6h
D5h/
D5h/
D6h
D6h
D1h/
D1h/
D3h/
D3h/
D3h/
D5h/
D5h/
D5h/
D6h
D6h
D1h/
D3h/
D3h/
D5h/
D5h/
D6h
75 100 125 150 200 250 300 350 400 450 500 550/
D6h
D6h
D1h/ D3h/ D5h/
D6h D1h/ D3h/ D5h/
D6h
D1h/ D3h/ D5h/
D6h D1h/ D3h/ D5h/
D6h
D2h/D4h/
D7h/D8h
D1h/D3h/
D5h/D6h
D2h/D4h/
D7h/D8h
D2h/D4h/
D7h/D8h
D2h/D4h/
D7h/D8h
D2h/ D4h/ D7h/
D8h D2h/ D4h/ D7h/
D8h D2h/ D4h/ D7h/
D8h
D2h/D4h/
D7h/D8h
D2h/D4h/
D7h/D8h
D2h/D4h/
D7h/D8h
E1/E2 E1/E2 E1/E2
E1/E2 E1/E2 E1/E2 E1/E2
E1/E2 E1/E2E1/E2 E1/E2
600 650
600
460 V D1h/D3h/
D5h/D6h
575 V D1h/D3h/
D5h/D6h
Table 1.4 Hp Rated Frequency Converters
D1h/ D3h/ D5h/ D6h
D1h/D3h/
D5h/D6h
D1h/D3h/
D5h/D6h
D1h/ D3h/ D5h/
D6h D1h/ D3h/ D5h/
D6h
D1h/ D3h/ D5h/
D6h D2h/ D4h/ D7h/
D8h
D2h/ D4h/ D7h/
D8h D2h/ D4h/ D7h/
D8h
D2h/ D4h/ D7h/
D8h D2h/ D4h/ D7h/
D8h
D2h/
D2h/ D4h/ D7h/
D8h
E1/E2 E1/E2E1/E2 D4h/ D7h/
D8h
E1/E2 E1/E2 E1/E2 E1/E2
8 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
Safety
2 Safety
Operating Instructions
The following symbols are used in this document:
WARNING
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)
20 40
380-480 110-315 kW 355-450 kW 525-690 55-400 kW 450-630 kW High voltage may be present even when the warning LED indicator lights are off.
2 2
Table 2.1 Discharge Time
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 9
Safety Operating Instructions
WARNING
LEAKAGE CURRENT HAZARD
22
Leakage currents exceed 3.5 mA. Failure to ground the frequency converter properly can result in death or serious injury.
Ensure correct grounding of the equipment by
a certified electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment can result in death or serious injury.
Ensure that only trained and qualified
personnel perform installation, start up, and maintenance.
Ensure that electrical work conforms to national
and local electrical codes. Follow the procedures in this manual.
CAUTION
UNINTENDED MOTOR ROTATION WINDMILLING
Unintended rotation of permanent magnet motors can result in serious injury or equipment damage.
Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the frequency converter can result in serious injury, when the frequency converter is not properly closed.
Ensure that all safety covers are in place and
securely fastened, before applying power.
10 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
105
298
[11.7]
404
[15.9]
130BC519.10
130BC520.10
105
523
[20.6]
395
[15.6]
748
(29.5)
579
(22.8)
176FA276.12
≤105,0°
Installation Operating Instructions
3 Installation
3.1 Pre-Installation
3.1.1 Planning the Installation Site
NOTICE
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.
3 3
Illustration 3.1 Front Clearance of IP21/IP54 Rated Enclosure Types D1h, D5h, and D6h
Voltage [V] Altitude restrictions
380-690 At 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
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 11
Installation
Operating Instructions
3.1.3 Tools Required for Installation
Drill with 10 or 12 mm drill
Tape measure
Wrench with relevant metric sockets (7-17 mm)
33
Extensions to wrench
Sheet metal punch for conduits or cable glands
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.
12 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
176FA245.10
Installation Operating Instructions
NOTICE
The fan runs for the following reasons:
AMA
DC hold
Pre-mag
DC brake
60% of nominal current is exceeded
Specific heat sink temperature exceeded (power
size dependent) Specific power card ambient temperature
exceeded (power size dependent) Specific control card ambient temperature
exceeded
Enclosure type Door fan/top fan Heat sink fan
D1h/D3h/D5h/D6h D2h/D4h/D7h/D8h E1 P450T7, P500T7
E1 P355-P450T4, P560-P630T7
E2 P450T7, P500T7
E2 P355-P450T4, P560-P630T7
Table 3.2 Airflow
102 m3/hr (60 CFM) 420 m3/hr (250 CFM) 204 m3/hr (120 CFM) 840 m3/hr (500 CFM) 340 m3/hr (200 CFM) 1105 m3/hr (650
CFM)
340 m3/hr (200 CFM) 1445 m3/hr (850
CFM)
255 m3/hr (150 CFM) 1105 m3/hr (650
CFM)
255 m3/hr (150 CFM) 1445 m3/hr (850
CFM)
Lifting
3.3.2
Always lift the frequency converter using the dedicated lifting eyes. Use a bar to avoid bending the lifting holes.
Illustration 3.4 Recommended Lifting Method
WARNING
RISK OF INJURY OR DEATH
The lifting bar must be able to handle the weight of the frequency converter to ensure that it will not break during lifting.
See Mechanical Dimensions for the weight of the
different enclosure types. Maximum diameter for bar is 2.5 cm (1 inch).
The angle from the top of the frequency
converter to the lifting cable should be 60° or greater.
Failure to follow recommendations could result in death or serious injury.
3 3
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 13
Installation Operating Instructions
3.3.3 Mechanical Dimensions
Enclosure type D1h D2h D3h D4h
110-160 kW
(380-480 V)
75-160 kW
33
IP NEMA Shipping dimensions [mm]
Drive dimensions [mm]
Max weight [kg] 98 164 98 164
Table 3.3 Mechanical Dimensions, Enclosure Types D1h-D4h
Enclosure type D5h D6h D7h D8h E1 E2
IP NEMA Shipping dimensions [mm]
Drive dimensions [mm]
Max weight [kg] 116 129 200 225 313 277
Height 587 587 587 587 Width 997 1170 997 1170 Depth 460 535 460 535 Height 901 1107 909 1122 Width 325 420 250 350 Depth 378 378 375 375
110-160 kW
(380-480 V)
75-160 kW
(525-690 V)
21/54
Type 1/12 Height 660 660 660 660 840 831 Width 1820 1820 2470 2470 2197 1705 Depth 510 510 590 590 736 736 Height 1324 1663 1978 2284 2000 1547 Width 325 325 420 420 600 585 Depth 381 381 386 406 494 498
(525-690 V)
21/54
Type 1/12
110-160 kW
(380-480 V)
75-160 kW
(525-690 V)
21/54
Type 1/12
200-315 kW
(380-480 V)
200-400 kW
(525-690 V)
21/54
Type 1/12
200-315 kW
(380-480 V)
200-400 kW
(525-690 V)
21/54
Type 1/12
110-160 kW
(380-480 V)
75-160 kW
(525-690 V)
Chassis
200-315 kW
(380-480 V)
200-400 kW
(525-690 V)
21/54
Type 1/12
20
355-450 kW
(380-480 V)
450-630 kW
(525-690 V)
21, 54
Type 12
200-315 kW
(380-480 V)
200-400 kW
(525-690 V)
20
Chassis
355-450 kW
(380-480 V)
450-630 kW
(525-690 V)
00
Chassis
Table 3.4 Mechanical Dimensions, Enclosure Types D5h-D8h, E1-E2
14 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
130
[5.1]
656
[25.8]
844
[33.2]
901
[35.5]
148 [5.8]
18 [0.7]
82
[3.2]
20
[0.8]
378
[14.9]
507
[20.0]
164
[6.5]
674
[26.5]
99
[3.9]
200
[7.9]
200
[7.9]
180
[7.1]
246
[9.7]
325
[12.8]
78
[3.1]
123
[4.8]
844
[33.2]
561
[22.1]
130BC515.11
1
4
2
3
1
33 [1.3]
63 [2.5]
24 [0.9]
22 [0.9]
25 [1.0]
11 [0.4]
10 [0.4]
11 [0.4]
2
130BD514.10
Installation Operating Instructions
All dimensions are in mm [in]
3 3
1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor
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.
1 Bottom mounting slot detail
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 15
2 Top mounting hole detail
Illustration 3.6 Detail Dimensions, D1h
211 [8.3]
623
[24.5]
148
[5.8]
280
[11.0]
346
[13.6]
420
[16.5]
1051
[41.4]
1107 [43.6]
857
[33.7]
130
[5.1]
320
[12.6]
271
[10.7]
20
[0.8]
18
[0.7]
379
[14.9]
96
[3.8]
879
[34.6]
142
[5.6]
107
[4.2]
213
[8.4]
1050
[41.3]
718
[28.3]
130BC516.11
1
4
2
3
1
2
33 [1.3]
25 [1.0]
24 [0.9]
20 [0.8]
75 [2.9]
11 [0.4]
9 [0.3]
11 [0.4]
12 [0.5]
130BD515.10
Installation Operating Instructions
33
1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor
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.
1 Top mounting hole detail 2 Bottom mounting slot detail
Illustration 3.8 Detail Dimensions, D2h
16 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
130BC517.11
250
[9.8]
844
[33.2]
889
[35.0]
909
[35.8]
130
[5.1]
656
[25.8]
200 [7.9]
180
[7.1]
495
[19.5]
660
[26.0]
61
[2.4]
148 [5.8]
82
[3.2]
18
[0.7]
375
[14.8]
20
[0.8]
200
[7.9]
77.5
[3.1]
122.5 [4.8]
26
[1.0]
844
[33.2]
128
[5.0]
1
4
2
3
1 2
33 [1.3]
25 [1.0]
24 [0.9]
20 [0.8]
40 [1.6]
11 [0.4]
9 [0.3]
11 [0.4]
130BD517.10
Installation Operating Instructions
3 3
1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor
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.
1 Top mounting hole detail 2 Bottom mounting slot detail
Illustration 3.10 Detail Dimensions, D3h
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 17
130BC518.11
280
[11.0]
857
[33.7]
130
[5.1]
320
[12.6]
1051
[41.4]
1096
[43.1]
1122
[44.2]
148 [5.8]
18 [0.7]
142 [5.6]
375
[14.8]
611
[24.1]
176 [6.9]
868
[34.2]
59
[2.3]
271
[10.7]
350
[13.8]
107
[4.2]
213
[8.4]
39
[1.5]
1050
[41.3]
20
[0.8]
1
4
2
3
64 [2.5]
63 [2.5]
24 [0.9]
9 [0.3]
25 [1.0]
11 [0.4]
20 [0.8]
15 [0.6]
11 [0.4]
4X
1 2
130BD518.10
Installation Operating Instructions
33
1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space inlet minimum 225 mm [8.9 in] 4 Floor
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.
1 Top mounting hole detail 2 Bottom mounting slot detail
Illustration 3.12 Detail Dimensions, D4h
18 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
130BD463.10
149 [5.9]
731 [28.8]
1107 [43.6]
381 [15]
115 [4.5]
23 [0.9]
16.1 [6.3]
1277 [50.3]
123 [4.8]
1324 [52.1]
1276 [50.2]
200 [7.9]
78 [3.1]
123 [4.8]
78 [3.1]
200 [7.9]
220 [8.7]
130 [5.1]
200 [7.9]
1111 [43.7]
130 [5.1]
325
[12.8] 306 [12.1]
276 [10.9]
180 [7.1]
2
1
64 [2.5]
63 [2.5]
24 [0.9]
9 [0.3]
25 [1.0]
11 [0.4]
20 [0.8]
15 [0.6]
11 [0.4]
4X
1 2
130BD518.10
Installation Operating Instructions
3 3
1 Ceiling 2 Air 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.
1 Top mounting hole detail 2 Bottom mounting slot detail
Illustration 3.14 Detail Dimensions, D5h
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 19
130BD464.10
1447 [57.0]
909 [35.8]
159 [6.3]
381 [15.0]
115 [4.5]
23 [0.9]
1663 [65.5]
1615 [63.6]
1452 [57.2]
559 [22.0]
130 [5.1]
200 [7.9]
123 [4.8]
78 [3.1]
200 [7.9]
325 [12.8]
306 [12.1]
276 [10.9]
180 [7.1]
130 [5.1]
1617 [63.7]
181 [7.1]
200 [7.9]
78 [3.1]
123 [4.8]
1
2
3
4
63.5 [3]
63 [2.5]
24 [0.9]
9 [0.3]
25 [1.0]
11 [0.4]
20 [0.8]
15 [0.6]
1 2
11 [0.4]
4X
130BD519.10
Installation Operating Instructions
33
1 Ceiling 2 Air space outlet minimum 225 mm [8.9 in] 3 Air space intlet minimum 225 mm [8.9 in] 4 Floor
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.
1 Top mounting hole detail 2 Bottom mounting slot detail
Illustration 3.16 Detail Dimensions, D6h
20 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
1754 [69.1]
209 [8.2]
1282 [50.5]
386 [15.2]
156 [6.2]
23 [0.9]
25 [1]
161 [6.3]
1931 [76]
170 [4.2] 213 [8.4] 320 [12.6]
1978 [77.9]
1953 [76.9]
107 [4.2]
213 [8.4]
320 [12.6]
1
280 [11]
374 [14.7]
411 [16.2]
420 [16.5]
130 [5.1]
1760 [69.3]
130 [5.1]
668 [26.3]
130BD465.10
2
70 [2.8]
25 [1.0]
23 [0.9]
11 [0.4]
4X
130BD520.10
Installation Operating Instructions
3 3
1 Ceiling 2 Air 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
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 21
1699 [66.9]
1400 [55.1]
215 [8.5]
2236 [88]
406 [16]
156 [6.2]
23 [0.9]
25 [1]
162 [6.4]
2284 [89.9]
2259 [88.9]
107 [4.2] 213 [8.4]
320 [12.6]
107 [4.2] 213 [8.4]
320 [12.6]
420 [16.5]
411 [16.2]
374 [14.7]
280 [11]
130 [5.1]
130 [5.1]
2065 [81.3]
973 [38.3]
1
130BD466.10
2
70
[2.8] 25 [1.0]
23 [0.9]
11 [0.4]
4X
130BD521.10
Installation Operating Instructions
33
1 Ceiling 2 Air 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
22 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
E1
225
8.86( )
1551
61.1( )
2000
(78.74)
727
28.6( )
72
2.8( )
164
600
(23.62)
198
7.8( )
145
5.7( )
494
19.4( )
392
15.4( )
538
21.2( )
160
6.3( )
1043
41.1( )
160
6.3( )
72
2.8( )
27
1.1( )
23
0.9( )
185
7.3( )
185
7.3( )
58
2.3( )
484
19.1()
2X13
0.5
( )
25
1.0
(
)
56
2.2( )
6.5( )
185
7.3( )
1.0( )
F
F
130BA444.10
SIDE CABLE ENTRY KNOCK-OFF PLATE
CABLE BASE
BOTTOM CABLE ENTRY
IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
Ø 25
Installation Operating Instructions
3 3
F Lifting eye detail
Illustration 3.21 Mechanical Dimensions, E1
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 23
130BA445.10
225
64
1320
585
269
156
23
25
498
539
1547
1502
160
1043
14
184
184
184
139
304
2X13
(2.5)
(23.0)
(52.0)
(6.2)
(19.5)
(10.6)
(21.2)
(60.9)
(5.5)
(12.0)
(7.3) (7.3)
(0.5)
(1.5)
120 (4.7)
25
(1.0)
(59.1)
(41.1)
(6.3)
(8.9)
225 (8.9)
(1.0)
25
(1.0)
(0.9)
27
(1.0)
13
(0.5)
E2
D
E
D
E
IP00 / CHASSIS
Installation Operating Instructions
33
D Lifting eye detail E Rear mounting slots
Illustration 3.22 Mechanical Dimensions, E2
24 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
Installation
Operating Instructions
3.4 Electrical Installation
3.4.1 General Requirements
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.
3 3
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.
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 25
130BD599.11
3-phase power
input
DC bus
Switch Mode Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated OFF=Open
Brake resistor
91 (L1) 92 (L2) 93 (L3)
PE
88 (-) 89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
13 (+24 V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC 15 mA 130/200 mA
+ - + -
(U) 96 (V) 97 (W) 98 (PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0 V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/-10 V DC -
+10 V DC
+10 V DC 0/4-20 mA
0/-10 V DC-
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON=0/4-20 mA OFF=0/-10 V DC ­ +10 V DC
95
P 5-00
21
ON
S801
(R+) 82
(R-) 81
: Chassis
**
240 V AC, 2 A
400 V AC, 2 A
*
*
*
: Ground
: Ground 1
: Ground 2
: PE
Installation
Operating Instructions
33
Illustration 3.23 Interconnect Diagram
A=Analog, D=Digital *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT® Frequency
Converters - Safe Torque Off Operating Instructions. **Do not connect cable screen.
26 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
Motor
Line Power
Stop
Start
Speed
Control
130BX370.10
Installation Operating Instructions
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.
3 3
Illustration 3.24 Example of Proper Electrical Installation using Conduit
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 27
L1
L1L2L2L3L3
2
91 92 93
1
130BB460.11
Installation Operating Instructions
established, see (>3.5 mA).
A dedicated ground wire is required for input
power, motor power, and control wiring. Use the clamps provided with the equipment for
33
1 Fuses 2 Ground
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
ground currents higher than 3.5 mA must be
28 Danfoss A/S © Rev. 05/2014 All rights reserved. MG16J202
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