Danfoss LD 302 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Lift Drive LD 302

www.danfoss.com/drives

Contents

VLT® Lift Drive LD 302

Contents

1 Introduction	4
1.1 Purpose of the Manual	4
1.2 Additional Resources	4
1.3 Document and Software Version	4
1.4 Intended Use	4
1.5 Certifications	4
1.6 Disposal Instruction	4
2 Safety	5
2.1 Qualified Personnel	5
2.2 Safety Precautions	5
3 Mechanical Installation	6
3.1 Equipment Pre-installation Check List	6
3.2 Unpacking	6
3.3 Installation Environment	6
3.3.1 Installation Site Check List	6
3.4 Mounting	6
3.4.1 Cooling	6
3.4.2 Lifting	7
3.4.3 Mounting	7
4 Electrical Installation	8
4.1 Safety instructions	8
4.1.1 Requirements	8
4.1.2 Cable Entries	8
4.2 EMC Compliant Installation	11
4.2.1 General Aspects of EMC Emissions	11
4.2.2 EMC Immunity	12
4.3 Harmonics	14
4.4 Grounding	15
4.4.1 Grounding Requirements	15
4.4.1.1 Ground Leakage Current	15
4.4.1.2 Grounding Using Screened Cable	16
4.5 PELV - Protective Extra Low Voltage	16
4.6 Wiring Schematic	18
4.6.1 Operation with Motor Contactors	18
4.6.2 Operation without Motor Contactors	19
4.7 Motor Connection	20
4.8 AC Mains Connection	20

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Contents

VLT® Lift Drive LD 302

4.9 Control Wiring	20
4.9.1.1 Removing the Cover	20
4.9.1.2 Control Terminal Types	21
4.9.1.3 Relay Connection	22
4.9.1.4 Wiring to Control Terminals	23
4.9.1.5 Lift Controller MCO 361 Control Terminals	23
4.9.1.6 Using Screened Control Cables	24
4.9.1.7 Terminal 37, Safe Torque Off	25
4.9.1.8 Lift Control without Motor Contactors	26
4.10 Installation Check List	27

5 Commissioning	28
5.1 Safety Instructions	28
5.1.1 Safety Inspection	28
5.2 Applying Power to the Frequency Converter	28
5.2.1 Applying Power Procedure	28
5.3 Local Control Panel	28
5.3.1 LCP Layout	29
5.3.2 Setting LCP Display Values	29
5.3.3 Display Menu Keys	30
5.3.4 Navigation Keys	30
5.3.5 Operation Keys	31
5.3.6 Back-up and Copying Parameter Settings	31
5.3.7 Recommended Initialisation	31
5.3.8 Manual Initialisation	32
6 Programming	33
6.1 Basic Operational Programming	33
6.2 Automatic Motor Adaptation	33
6.3 Programming the Lift Application	33
6.3.1 Start and Stop Sequences	35
7 Functions	37
7.1 Brake Functions	37
7.1.1 Introduction	37
7.1.1.1 Mechanical Holding Brake	37
7.1.1.2 Dynamic Brake	37
7.1.2 Brake Resistor Requirements	37
7.1.2.1 Mechanical Brake Control	38
7.1.3 Brake Resistor Cabling	39
7.2 DCP Communication	39

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Contents

VLT® Lift Drive LD 302

8 Diagnostics and Troubleshooting	40
8.1 Status Messages	40
8.2 Warnings and Alarms	40
8.3 Basic Troubleshooting	47
9 Application Examples	48
9.1 Main Contactors	48
9.2 Operation with Absolute Encoder (SSI/EnDat)	48
9.3 Check Encoder Rotation	48
9.4 Emergency Operation UPS	49
10 Special Conditions	50
10.1 Special Conditions	50
10.1.1 Extreme Running Conditions	50
10.1.2 Motor Thermal Protection	50
10.1.3 Derating	51
11 Parameter Overview	52
11.1 xx-** Active Parameters	52
11.2 Parameters 0-** Operation and Display	53
11.3 Parameters 1-** Load and Motor	54
11.4 Parameters 4-** Limits/Warnings	55
11.5 Parameters 14-** Special Functions	56
11.6 Parameters 19-** Application Parameters	56
11.7 Parameters 32-** Encoder	66
12 Specifications	67
12.1 Electrical Data	67
12.2 Ambient Conditions	70
12.3 Power Ratings, Weight and Dimensions	70
12.4 Connection Tightening Torques	73
12.5 Lift Controller MCO 361 Specifications	74
12.6 Motor Type and Associated Motor Number	76
12.6.1 Motor Type and Associated Motor Number Stored in Motor Database	76
12.6.2 Motor Type and Associated Motor Number not Stored in Motor Database	78
Index	80

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Introduction VLT® Lift Drive LD 302

1	1	1 Introduction
		1.1 Purpose of the Manual	1.4 Intended Use
		This manual targets	The frequency converter is an electronic motor controller
			intended for

•system designers

•installers

•service technicians

It provides detailed information for the installation and start-up of the frequency converter. Chapter 3 Mechanical Installation provides requirements for mechanical and electrical installation, including

•input

•motor

•control and serial communications wiring

•control terminal functions

chapter 5 Commissioning provides detailed procedures for

•start-up

•basic operational programming

•functional testing

The remaining chapters provide information about

•user interface

•programming

•applications

•start-up troubleshooting

•specifications

1.2Additional Resources

Supplemental publications and manuals are available from Danfoss.

See www.danfoss.com/BusinessAreas/DrivesSolutions/ Documentations/Technical+Documentation.htm for listings.

1.3 Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the document version and the corresponding software version.

Edition	Remarks	Software
		version
MG34X1	This is the first edition of this manual	6.72

Table 1.1 Document and Software Versions

•regulation of motor speed in response to system feedback or to remote commands from external controllers. A power drive system consists of the frequency converter, the motor and equipment driven by the motor.

•system and motor status surveillance.

The frequency converter can also be used for motor protection.

Depending on configuration, the frequency converter can be used in standalone applications or form part of a larger appliance or installation.

The frequency converter is allowed for use in residential, industrial and commercial environments in accordance with local laws and standards.

NOTICE

In a residential environment this product can cause radio interference, in which case supplementary mitigation measures can be required.

Foreseeable misuse

Do not use the frequency converter in applications which are non-compliant with specified operating conditions and environments. Ensure compliance with the conditions specified in chapter 12 Specifications.

1.5Certifications

1.6Disposal Instruction

Do not dispose of equipment containing electrical components together with domestic waste.

Collect it separately in accordance with local and currently valid legislation.

Table 1.2 Disposal Instruction

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Safety

VLT® Lift Drive LD 302

2 Safety

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 may also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that may 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 is allowed to install or operate this equipment.

Qualified personnel is 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 power. Qualified personnel only should perform installation, start up, and maintenance. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury.

2 2

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death, serious injury, equipment, or property damage.

WARNING

DISCHARGE TIME

Frequency converters contain DC-link capacitors that can remain charged even when the frequency converter is not powered. To avoid electrical hazards, disconnect AC mains, any permanent magnet type motors, and any remote DC-link power supplies, including battery backups, UPS, and DC-link connections to other frequency converters. Wait for the capacitors to fully discharge before performing any service or repair work. The amount of wait time is listed in the Discharge Time table. Failure to wait the specified time after power has been removed before doing service or repair could result in death or serious injury.

Voltage [V]	Minimum waiting time (minutes)
	4	15
380-400	0.25-7.5 kW	11-75 kW
	[0.34-10 hp]	[15-100 hp]

High voltage may be present even when the warning LEDs are off!

Table 2.1 Discharge Time

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Mechanical Installation

VLT® Lift Drive LD 302

3 Mechanical Installation

3.1 Equipment Pre-installation Check List

3 3 • Compare the model number of the unit on the nameplate to what was ordered to verify the proper equipment

•Ensure each of the following are rated for same voltage:

3.3 Installation Environment

3.3.1 Installation Site Check List

•The frequency converter relies on the ambient air for cooling. Observe the limitations on ambient temperature for optimal operation.

Mains (power)

Frequency converter

Motor

•Ensure that the frequency converter output current rating is equal to or greater than motor full load current for peak motor performance

Motor size and frequency converter power must match for proper overload protection

If frequency converter rating is less than motor, full motor output cannot be achieved

3.2 Unpacking

3.2.1 Items Supplied

Items supplied may vary according to product configuration.

•Make sure the items supplied and the information on the nameplate correspond to the order confirmation.

•Check the packaging and the frequency converter visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification.

NOTICE

Do not remove the nameplate from the frequency converter (loss of warranty).

3.2.2 Storage

Ensure that requirements for storage are fulfilled. Refer to chapter 12.2 Ambient Conditions for further details.

•Before mounting the frequency converter, ensure that the installation location has sufficient support strength

•Keep the frequency converter interior free from dust and dirt. Ensure that the components stay as clean as possible. In construction areas, provide a protective covering. Optional IP54 (NEMA 12) or IP66 (NEMA 4) enclosures may be necessary.

•Keep the manual, drawings, and diagrams accessible for detailed installation and operating instructions. It is important that the manual is available for equipment operators.

•Locate equipment as near to the motor as possible. Keep motor cables as short as possible. Check the motor characteristics for actual tolerances. Do not exceed

•300 m [1,000 ft] for unshielded motor cables

•150 m [500 ft] for screened cable.

•Consider derating for temperatures between 40 °C [104 °F] and 50 °C [122 °F] and elevation 1,000 m [3,300 ft] above sea level. See the equipment Design Guide for detailed information.

3.4Mounting

3.4.1 Cooling

Ensure that top and bottom clearance for air cooling is provided. See Illustration 3.1 for clearance requirements.

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a	<![if ! IE]> <![endif]>130BA419.10

b

Illustration 3.1 Top and Bottom Cooling Clearance

Enclosure type	A1-A5	B1-B4	C1, C3	C2, C4
a/b [mm]	100	200	200	225

Table 3.1 Minimum Airflow Clearance Requirements

3.4.2 Lifting

•To determine a safe lifting method, check the weight of the unit

•Ensure that the lifting device is suitable for the task

•If necessary, plan for a hoist, crane, or forklift with the appropriate rating to move the unit

•For lifting, use hoist rings on the unit, when provided

3.4.3 Mounting

1.Ensure that the strength of the mounting location supports the unit weight. The frequency converter allows side-by-side installation.

2.Mount the unit vertically to a solid flat surface or to the optional back plate (see Illustration 3.2 and

Illustration 3.3).

3.Use the slotted mounting holes on the unit for wall mount, when provided.

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<![endif]>130BA219.11

3 3

1

Item Description

1 Back plate

Illustration 3.2 Proper Mounting with Back Plate

Install the back plate properly for required airflow to cool the unit.

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<![endif]>130BA228.11

1

Item Description

1 Back plate

Illustration 3.3 Proper Mounting with Railings

NOTICE

Back plate is needed when mounted on railings.

NOTICE

Improper mounting can result in overheating and reduced performance.

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Electrical Installation

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4 Electrical Installation

4.1 Safety instructions 4.1.1 Requirements

4 4	WARNING
	EQUIPMENT HAZARD!

Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. Only trained and qualified personnel should install, start up, and maintain the equipment. Failure to follow these guidelines could result in death or serious injury.

NOTICE

WIRING ISOLATION!

Run input power, motor wiring and control wiring in 3 separate metallic conduits or use separated screened cable for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum frequency converter and associated equipment performance.

For safety, comply with the following requirements.

•Electronic controls equipment is connected to hazardous mains voltage. Take extreme care 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 that are run together can charge equipment capacitors even with the equipment turned off and locked out.

Overload and equipment protection

•The frequency converter provides overload protection for the motor (Class 20 motor protection). See chapter 10 Special Conditions for details.

•All frequency converters must be provided with short circuit and overcurrent protection. Input fusing is required to provide this protection, see Illustration 4.1. If not factory supplied, the installer must provide fuses as part of installation.

L1	L2	L3	<![if ! IE]> <![endif]>130BB460.11
91	92	93

1

L1

L2

L3

2

Item Description

1Fuses

2Ground

Illustration 4.1 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 [167 °F] rated copper wire.

•See chapter 12.3 Power Ratings, Weight and Dimensions for recommended wire sizes.

4.1.2 Cable Entries

NOTICE

Other solutions are possible. Unused cable entries can be sealed with rubber grommets (for IP21).

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				[3]	<![if ! IE]> <![endif]>130BB664.10
				[4]
				[5]
				[6]
				[2]
				[1]
Item	Recommended	Dimensions1)		Nearest
	use	UL [in]	[mm]	metric
1	Mains	3/4	28.4	M25
2	Motor	3/4	28.4	M25
3	Brake/load	3/4	28.4	M25
	sharing
4	Control cable	3/4	28.4	M25
5	Control cable2)	3/4	28.4	M25
6	Control cable 2)	3/4	28.4	M25
1) Tolerance ±0.2 mm
2) Knockout hole
Illustration 4.2 A5 (IP55)
				[4]	<![if ! IE]> <![endif]>130BB666.10
				[5]
				[3]
				[6]
				[2]
				[1]
Item	Recommended use		Dimensions
1	Mains		M25
2	Motor		M25
3	Brake/load sharing		28.4 mm1)
4	Control cable		M25
5	Control cable		M25
6	Control cable		M25

1) Knock-out hole

Illustration 4.3 A5 (IP55) Threaded Gland Holes

[1]	<![if ! IE]> <![endif]>130BB659.10
[4]
[5]
[3]
[2]

4

4

Item

Recommended

Dimensions1)

Nearest

use

UL [in]

[mm]

metric

1

Mains

1

34.7

M32

2

Motor

1

34.7

M32

3

Brake/load

1

34.7

M32

sharing

4

Control cable

1

34.7

M32

5

Control cable

1/2

22.5

M20

1) Tolerance ±0.2 mm

Illustration 4.4 B1 (IP21)

[5]

<![if ! IE]> <![endif]>130BB667.10

[4]

[3]

[6]

[2]

[1]

Item

Recommended use

Dimensions1)

Nearest metric

UL [in]

[mm]

1

Mains

1

34.7

M32

2

Motor

1

34.7

M32

3

Brake/load sharing

1

34.7

M32

4

Control cable

3/4

28.4

M25

5

Control cable

1/2

22.5

M20

6

Control cable2)

1/2

22.5

M20

1) Tolerance ±0.2 mm

2) Knockout hole

Illustration 4.5 B1 (IP55)

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Electrical Installation

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					[6]	<![if ! IE]> <![endif]>130BB669.10
					[5]
					[3]
					[2]
					[4]
					[1]
Item		Recommended use	Dimensions
1		Mains	M32
4 4 2		Motor	M32
3		Brake/load sharing	M32
4		Control cable	M25
5		Control cable	M25
6		Control cable	22.5 mm 1)
1)	Knockout
Illustration 4.6 B1 (IP55) Threaded Gland Holes
					[3]	<![if ! IE]> <![endif]>130BB668.10
					[4]
					[5]
					[2]
					[1]
Item		Recommended	Dimensions1)		Nearest
		use	UL [in]	[mm]	metric
1		Mains	1 1/4	44.2	M40
2		Motor	1 1/4	44.2	M40
3		Brake/load sharing	1	34.7	M32
4		Control cable	3/4	28.4	M25
5		Control cable2)	1/2	22.5	M20
1) Tolerance ±0.2 mm
2)	Knockout hole

Illustration 4.7 B2 (IP55)

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[4]

[3]

[5]

[1]

Item	Recommended use	Dimensions
1	Mains	M40
2	Motor	M40
3	Brake/Load Sharing	M32
4	Control cable	M25
5	Control cable	M20

Illustration 4.8 B2 (IP55) Threaded Gland Holes

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4.2 EMC Compliant Installation

4.2.1 General Aspects of EMC Emissions

The frequency converter, motor cable and the motor generate airborne interference in the range 30 MHz to 1 GHz. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents.

	Use screened motor cable to reduce radiated interference. Connect the motor cable screen to the frequency converter	4	4
	enclosure as well as to the motor enclosure. Use integrated screen clamps to avoid twisted screen ends (pigtails).

To reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Especially control electronics generate radio interference higher than 50 MHz (airborne).

z	L1	CS	U			CS	<![if ! IE]> <![endif]>175ZA062.12
z	L2		V	I1
z	L3		W
z PE	PE		I2	CS	1
			I3		2
		CS			CS	CS
			I4		I4
3		4			5		6

1Ground wire

2Screen

3AC mains supply

4Frequency converter

5Screened motor cable

6Motor

Table 4.1

Illustration 4.9 Situation that Generates Leakage Currents

Ensure that screen currents can be conveyed back to the frequency converter. Also, ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis.

NOTICE

When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are observed.

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4.2.2 EMC Immunity

All Danfoss frequency converters comply with the requirements for the industrial environment as well as home and office environments.

Immunity tests were performed in accordance with the following standards:

				•	EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD): Simulation of electrostatic discharges from human
4		4
					beings.
				•	EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated simulation of the
					effects of radar and radio communication equipment as well as mobile communications equipment.
				•	EN 61000-4-4 (IEC 61000-4-4): Burst transients: Simulation of interference brought about by switching a contactor,
					relay, or similar devices.
				•	EN 61000-4-5 (IEC 61000-4-5): Surge transients: Simulation of transients brought about for example, by lightning
					that strikes near installations.
				•	EN 61000-4-6 (IEC 61000-4-6): RF common mode: Simulation of the effect from radio-transmission equipment
					joined by connection cables.
				Voltage range: 380-400 V
				Basic standard		Burst	Surge	ESD	Radiated electromagnetic	RF common
						IEC 61000-4-4	IEC 61000-4-5	IEC	field	mode voltage
								61000-4-2	IEC 61000-4-3	IEC 61000-4-6
				Acceptance criterion		B	B	B	A	A
				Line		4 kV CM	2 kV/2 Ω DM	—	—	10 VRMS
							4 kV/12 Ω CM
				Motor		4 kV CM	4 kV/2 Ω 1)	—	—	10 VRMS
				Brake		4 kV CM	4 kV/2 Ω1)	—	—	10 VRMS
				Load sharing		4 kV CM	4 kV/2 Ω 1)	—	—	10 VRMS
				Control wires		2 kV CM	2 kV/2 Ω1)	—	—	10 VRMS
				Standard bus		2 kV CM	2 kV/2 Ω1)	—	—	10 VRMS
				Relay wires		2 kV CM	2 kV/2 Ω 1)	—	—	10 VRMS
				Application and fieldbus		2 kV CM	2 kV/2 Ω 1)	—	—	10 VRMS
				options
				LCP cable		2 kV CM	2 kV/2 Ω 1)	—	—	10 VRMS
				External 24 V DC		2 V CM	0.5 kV/2 Ω DM	—	—	10 VRMS
							1 kV/12 Ω CM
				Enclosure		—	—	8 kV AD	10 V/m	—
								6 kV CD

Table 4.2 EMC Immunity

1) Injection on cable screen AD: Air discharge

CD: Contact discharge CM: Common mode DM: Differential mode

EMC Test Results

The following test results have been obtained using a system with

•

•

•

•

a frequency converter a screened cable

a control box with potentiometer a motor

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VLT® Lift Drive LD 302

•a screened motor cable

RFI filter type

Conducted emission

Radiated emission

Standards

EN 55011

Class B

Class A

Class A

Class B

Class A

and

Housing,

Group 1

Group 2

Housing,

Group 1

requirements

trades and

Industrial

Industrial

trades and

Industrial

light

environment

environment

light

environment

industries

industries

4

4

EN/IEC 61800-3

Category C1

Category C2

Category C3

Category C1

Category C2

First

First

Second

First

First

environment,

environment,

environment,

environment,

environment,

home and

home and

industrial

home and

home and

office

office

office

office

H1: RFI Class A1/B, Category 1/2

LD 302

0-75 kW

IP20

50 m [164 ft]

150 m [492 ft]

150 m [492 ft]

No

Yes

[0-100 hp]

380-480 V

0-7.5 kW

IP55

50 m [164 ft]

150 m [492 ft]

150 m [492 ft]

No

Yes

[0-10 hp]

380-480 V

H2: RFI Class A2, Category 3

LD 302

0-7.5 kW

IP20

No

No

5 m [16 ft]

No

No

[0-10 hp]

380-480 V

11-75 kW

IP20

No

No

25 m [82 ft]

No

No

[15-100 hp]

380-480 V

0-7.5 kW

IP55

No

No

5 m [16 ft]

No

No

[0-10 hp]

380-480 V

H3: RFI Class A1/B, Category 1/2

LD 302

11-55 kW

IP55

50 m [164 ft]

150 m [492 ft]

150 m [492 ft]

No

Yes

[15-75 hp]

380-480 V

Table 4.3 EMC Test Results (Emission, Immunity)

H1, H2 or H3 is defined in the type code position 16-17 for EMC filters

H1 - Integrated EMC filter. Fulfils EN 55011 Class A1/B and EN/IEN 61800-3 Category 1/2

H2 - No additional EMC filter. Fulfils EN 55011 Class A2 and EN/IEC 61800-2 Category 3

H3 - Integrated EMC filter. Fulfils EN 55011 Class A1/B and EN/IEC 61800-3 Category 1/2.

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4.3 Harmonics

4.3.1General Aspects of Harmonics Emission

A frequency converter takes up a non-sinusoidal current from mains, which increases the input current IRMS. A nonsinusoidal current is transformed with a Fourier analysis and split into sine-wave currents with different frequencies,

4 4 that is, different harmonic currents In with 50 Hz basic frequency:

	I1	I5	I7
Hz	50	250	350

Table 4.4 Harmonic Currents

4.3.2 Harmonics Emission Requirements

Equipment connected to the public supply network

Options Definition

1IEC/EN 61000-3-2 Class A for 3-phase balanced equipment (for professional equipment only up to 1 kW total power).

2IEC/EN 61000-3-12 Equipment 16-75 A and professional equipment as from 1 kW up to 16 A phase current.

Table 4.5 Connected Equipment

4.3.3 Harmonics Test Results (Emission)

The harmonics do not affect the power consumption directly, but increase the heat losses in the installation (transformer, cables). So, in plants with a high percentage of rectifier load, maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables.

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Illustration 4.10 Harmonic Currents

NOTICE

Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance with power-factor correction batteries.

To ensure low harmonic currents, the frequency converter is equipped with intermediate circuit coils as standard. This normally reduces the input current IRMS by 40%.

The voltage distortion on the mains supply voltage depends on the size of the harmonic currents multiplied by the mains impedance for the frequency in question. The total voltage distortion THD is calculated based on the individual voltage harmonics using this formula:

	2		2	2
THD % = U	5	+ U	7	+ ... + U	N

(UN% of U)

Power sizes up to PK75 in T2 and T4 comply with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 comply with IEC/EN 61000-3-12, Table 4. Power sizes P110 - P450 in T4 also comply with IEC/EN 61000-3-12 even though not required because currents are above 75 A.

		Individual harmonic current In/I1 (%)
	I5		I7	I11		I13
Actual	40		20	10		8
(typical)
Limit for	40		25	15		10
Rsce≥120
		Harmonic current distortion factor (%)
		THD			PWHD
Actual		46			45
(typical)
Limit for		48			46
Rsce≥120
Table 4.6 Harmonics Test Results (Emission)

If the short-circuit power of the supply Ssc is greater than or equal to:

SSC = 3 × RSCE × Umains × Iequ = 3 × 120 × 400 × Iequ

at the interface point between the user’s supply and the public system (Rsce).

It is the responsibility of the installer or user of the equipment to ensure that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to what is specified above. If necessary, consult the distribution network operator.

Other power sizes can be connected to the public supply network by consultation with the distribution network operator.

Compliance with various system level guidelines: The harmonic current data in Table 4.6 are given in

accordance with IEC/EN61000-3-12 with reference to the

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Power Drive Systems product standard. The data may be used to calculate the harmonic currents' influence on the power supply system and to document compliance with relevant regional guidelines: IEEE 519 -1992; G5/4.

4.4 Grounding

4.4.1 Grounding Requirements

WARNING

GROUNDING HAZARD!

Ground the frequency converter in accordance with national and local electrical codes as well as instructions contained within these instructions. Ground currents are higher than 3.5 mA. Failure to ground frequency converter properly could result in death or serious injury.

•To ground electrical equipment properly, follow all local and national electrical codes

•Proper protective earthing for equipment with ground currents higher than 3.5 mA must be established, see chapter 4.4.1.1 Ground Leakage Current

•A dedicated ground wire is required for input power, motor power and control wiring

•Use the clamps provided with the equipment for 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 of high-strand wire to reduce electrical noise is recommended

•Follow motor manufacturer wiring requirements

4.4.1.1 Ground Leakage Current

Follow national and local codes regarding protective earthing of equipment with a leakage current > 3.5 mA. Frequency converters generate a leakage current in the ground connection. A fault current in the frequency converter at the output power terminals might 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.

Leakage current

a

<![if ! IE]>

<![endif]>130BB955.12

4 4

b

Motor cable length

Illustration 4.11 Cable Length and Power Size Influence on

Leakage Current. Pa > Pb.

Leakage current	<![if ! IE]> <![endif]>130BB956.12

THVD=0%

THVD=5%

Illustration 4.12 Line Distortion Influences Leakage Current

According to EN/IEC 61800 5 1, ground wire must be reinforced, if the leakage current exceeds 3.5 mA:

•Ground wire (terminal 95) of at least 10 mm2 [8 AWG]

•2 separate ground wires both complying with the dimensioning rules

See EN/IEC61800-5-1 and EN50178 for further information.

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Using RCDs

Where residual current devices (RCDs), also known as earth leakage circuit breakers (ELCBs), are used, comply with the following:

Only use RCDs of type B, capable of detecting AC and DC currents

To prevent faults due to transient ground currents, use RCDs with an inrush delay

4 4 Dimension RCDs according to the system configuration and environmental considerations

Leakage current	RCD with low fcut-	<![if ! IE]> <![endif]>130BB958.12
	RCD with high fcut-

		50 Hz		150 Hz					fsw	Frequency
	Mains		3rd harmonics						Cable
Illustration 4.13 Main Contributions to Leakage Current
Leakage current [mA]											<![if ! IE]> <![endif]>130BB957.11
									100 Hz
									2 kHz
									100 kHz

4.4.1.2 Grounding Using Screened Cable

Grounding clamps are provided for motor wiring (see

Illustration 4.15).

		L1			M	A			<![if ! IE]> <![endif]>2	<![if ! IE]> <![endif]>130BA266.10
							I	N
			L2
	91	92			L3				S
			93
									<![if ! IE]> <![endif]>RELAY
									<![if ! IE]> <![endif]>RELAY 1
		+DC	BR-
					B
99		U		MOTOR
				V		W
										- LC -

Illustration 4.15 Grounding with Screened Cable

4.5 PELV - Protective Extra Low Voltage

WARNING

ELECTRICAL SHOCK HAZARD!

Protect against electrical shock by using electrical supply of the PELV type and the setting up the installation as described in local/national regulations on PELV supplies. Failure to protect against electrical shock can cause personal injury or death.

All control terminals and relay terminals 01-03/04-06 comply with PELV, except for grounded Delta leg above 400 V.

The electrical isolation complies with the requirements for higher isolation according to EN 61800-5-1.

To maintain PELV all connections made to the control terminals must be PELV, e.g. thermistor must be reinforced/double insulated.

Illustration 4.14 Influence of the Cut-off Frequency of the RCD

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				3	<![if ! IE]> <![endif]>130BC968.11
					M
7	5	4	1	2
6

										4	4
	8				9
Item	Description
1	Power supply (SMPS) incl. signal isolation of UDC,
	indicating the voltage of intermediate DC link circuit
2	Gate drive that runs the IGBTs (trigger transformers/opto-
	couplers)
3	Current transducers
4	Opto-coupler, brake module
5	Internal inrush, RFI, and temperature measurement
	circuits
6	Custom relays
7	Mechanical brake
8	Functional galvanic isolation for 24 V back-up option
9	Functional galvanic isolation for RS-485 standard bus
	interface

Illustration 4.16 Galvanic Isolation

WARNING

Installation at high altitude:

380-400 V, enclosure types A, B and C: At altitudes above 2,000 m [6,600 ft], contact Danfoss regarding PELV.

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4.6 Wiring Schematic

4.6.1 Operation with Motor Contactors

Illustration 4.17 is valid when 19-86 Enable SC is set to [1] Simple control.

					Motor						Direction		Drive																				<![if ! IE]> <![endif]>130BD154.10
		L1		Thermistor							up	down	enable
4	4																	Speed
		L2
																		select
		L3
		PE											K1
																	Parameter										Encoder
																											Interface
																		19 - 50
													K2
		91 92 93 95			50 53 55			20	37	12	32	33	13	27	1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8	9	10 1112
					Frequency Converter												X57 - Input									X55 - Encoder
																						MCO 361
		81 82 PE		96	97	98	99	20		29				18											X59 - Output							X58
																							1	2	3	4	5	6	7	8		1	2
																														Safety
			K1										K1																	Chain
											K10.1		K2
			K2																													K12
													K10
		Brake	U		V	W PE			K10.1		K10													K12						K1			K2
					M
		Resistor																															N
					3~				Brake Relay			Brake		Brake
				Motor				(max. 29 mA)				Contractor		Motor

Illustration 4.17 Wiring Schematic with Contactors

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4.6.2 Operation without Motor Contactors

Illustration 4.18 is valid when 19-86 Enable SC is set to [1] Simple control.

		Motor					Direction		Drive																				<![if ! IE]> <![endif]>130BD155.10
L1	Thermistor						up	down	enable
														Speed
L2
														select
L3
																													4	4
PE					K1				K1
													Parameter										Encoder
														19 - 50									Interface
					K2
									K2
91 92 93 95		50 53 55		20	37	12	32	33	13	27	1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8	9	10 1112
		Frequency Converter											X57 - Input									X55 - Encoder
																		MCO 361
81 82 PE	96	97	98 99	20		29				18											X59 - Output							X58
																			1	2	3	4	5	6	7	8		1	2
																										Safety
									K1																	Chain
	U	V	W PE				K10.1		K2
																												K12
		M
									K10
		3~
					K10.1		K10													K12						K1			K2
Brake	Motor
Resistor																													N
					Brake Relay			Brake		Brake
					(max. 29 mA)			Contractor		Motor

Illustration 4.18 Wiring Schematic without Contactors

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4.7 Motor Connection

WARNING

INDUCED VOLTAGE!

Run output motor cables from multiple frequency converters separately. Induced voltage from output motor cables that are run together can charge equipment capacitors even with the equipment turned

4 4 off and locked out. Failure to run output motor cables separately could result in death or serious injury.

•For maximum cable sizes and length, see

chapter 12.3 Power Ratings, Weight and Dimensions

•Comply with local and national electrical codes for cable sizes

•Do not install power factor correction capacitors between the frequency converter and the motor

•Do not wire a starting or pole-changing device between the frequency converter and the motor

1.Connect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W).

2.Ground the cable in accordance with grounding instructions provided.

3.Torque terminals in accordance with the information provided in chapter 12.4 Connection Tightening Torques.

4.Follow motor manufacturer wiring requirements.

Illustration 4.15 represents mains input, motor, and grounding for basic frequency converters. Actual configurations vary with unit types and optional equipment.

4.8AC Mains Connection

•Size wiring based on the input current of the frequency converter. For maximum wire sizes, see chapter 12.3 Power Ratings, Weight and Dimensions.

•Comply with local and national electrical codes for cable sizes.

•Connect 3-phase AC input power wiring to terminals L1, L2, and L3 (see Illustration 4.15).

•Depending on the configuration of the equipment, input power is connected to the mains input terminals or the input disconnect.

•Ground the cable in accordance with grounding instructions provided in chapter 4.4.1 Grounding Requirements

•All frequency converters may be used with an isolated input source as well as with ground reference power lines. When supplied from an isolated mains source (IT mains or floating delta)

or TT/TN-S mains with a grounded leg (grounded delta), set 14-50 RFI Filter to OFF. When off, the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated. This isolation prevents damage to the intermediate circuit and reduces ground capacity currents in accordance with IEC 61800-3.

4.9Control Wiring

•Isolate control wiring from high-power components in the frequency converter.

•If the frequency converter is connected to a thermistor, for PELV isolation, optional thermistor control wiring must be reinforced/double insulated. A 24 V DC supply voltage is recommended.

4.9.1.1 Removing the Cover

•Remove cover plate with a screw driver. See

Illustration 4.19.

•Or remove front cover by loosening attaching screws. See Illustration 4.20.

<![if ! IE]>

<![endif]>130BT248.10

Illustration 4.19 Control Wiring Access for Enclosure Types A2, A3, B3, B4, C3 and C4

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<![if ! IE]>

<![endif]>130BT334.10

Illustration 4.20 Control Wiring Access for Enclosure Types A4, A5, B1, B2, C1 and C2

Enclosure types A2 and A3

Encoder and I/O terminal are located behind the C option terminal cover, see Illustration 4.21.

The lift controller bus terminals and debug terminals (RS-485) are on the top of the C-option cover. If these connections are used, cut out the plastic parts above the connectors and mount the cable relief.

<![if ! IE]>

<![endif]>11.130BA248

Illustration 4.21 Location of Encoder and I/O Terminals

Enclosure types A5, B1 and B2

All MCO 361 terminals are located next to the control card. To get access, remove the front cover, see Illustration 4.20.

See Table 4.7 before tightening the covers.

Enclosure type	IP20	IP55
A4/A5	-	2/1.5
B1	-	2.2/1.6
B2	-	2.2/1.6
C1	-	2.2/1.6
C2	-	2.2/1.6
- Does not exist			4	4

Table 4.7 Tightening Torques for Covers [Nm]/[lb-ft]

4.9.1.2 Control Terminal Types

Illustration 4.22 shows the removable frequency converter connectors.

<![if ! IE]>

<![endif]>130BB921.11

2

3

4

1

Illustration 4.22 Control Terminal Locations

	1				<![if ! IE]> <![endif]>130BB931.10
	12 13	18	19 27 29 32 33 20 37
	2		3
	61 68	69	39 42	50 53 54 55

Illustration 4.23 Terminal Numbers

•Connector 1, terminals 12-37

•Connector 2, terminals 61, 68, 69

•Connector 3, terminals 39-55

•Connector 4, USB port for use with the MCT 10 Set-up Software

•Also provided are 2 Form C relay outputs. Location depends upon the frequency converter configuration and size.

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4.9.1.3 Relay Connection

To set relay output, see parameter group 5-4* Relays.

No.	01-02	make (normally open)
	01-03	break (normally closed)
	04-05	make (normally open)
	04-06	break (normally closed)

4	4	Table 4.8 Relay Connections
		Location of relays
		Relay2	<![if ! IE]> <![endif]>130BA029.12
			Relay1

36 35

Illustration 4.24 Terminals for Relay Connection (Enclosure Types A1, A2 and A3).

			RELAY		1		<![if ! IE]> <![endif]>130BA215.10
		10	02			RELAY	2
				03
						40
							50
						90
9	6
		9

311

Illustration 4.25 Terminals for Relay Connection (Enclosure Types A5, B1 and B2).

	<![if ! IE]> <![endif]>RELAY 2	<![if ! IE]> <![endif]>04 05 06	<![if ! IE]> <![endif]>130BA391.12
DC+	<![if ! IE]> <![endif]>RELAY1	<![if ! IE]> <![endif]>0102 03

Illustration 4.26 Terminals for Relay Connection (Enclosure Types C1 and C2).

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4.9.1.4 Wiring to Control Terminals

Control terminal connectors can be unplugged from the frequency converter for ease of installation, as shown in

Illustration 4.22.

1.Open the contact by inserting a small screwdriver into the slot above or below the contact, as shown in Illustration 4.27.

2.Insert the bared control wire into the contact.

3.To fasten the control wire into the contact, remove the screwdriver.

4.Ensure that the contact is not loose. Loose control wiring can cause equipment faults or less than optimal operation.

12	1	18					<![if ! IE]> <![endif]>130BA310.10
	3			19	27 29	32
							33
	1
			10	mm	2

Illustration 4.27 Connecting Control Wiring

See chapter 12.3 Power Ratings, Weight and Dimensions for control terminal wiring sizes.

See chapter 4.7 Motor Connection for typical control wiring connections.

4.9.1.5 Lift Controller MCO 361 Control

Terminals

2	X62	X60	<![if ! IE]> <![endif]>130BB794.10

1

X55	4	4

X56

X57

X58

X59

Item	Description	Item	Description
1	Terminal block 1	X58	24 V DC supply
2	Terminal block 2	X59	Digital outputs
X55	Encoder 2	X62	Not used
X56	Not used	X60	DCP connector
X57	Digital inputs

Illustration 4.28 Location of Terminal Blocks on MCO 361

MCO control terminals are plug connectors with screw terminals.

X55 = Encoder

X56 = Not used

X57 = Digital inputs

X58 = 24 V DC supply

X59 = Digital outputs

X62 = Not used

X60 = DCP connector

Terminal block 1 is used with bookstyle and terminal block 2 with compact enclosure types.

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