Danfoss P1K1, P1K5, P2K2, P3K0, P4K0 Operating Instructions Manual
...
Contents
1 Introduction
3
1.1.1 Copyright, Limitation of Liability and Revision Rights 4
2 Safety
9
2.1.2 High Voltage Warning 9
2.1.4 Before Commencing Repair Work 10
2.1.5 Special Conditions 10
2.1.7 Avoid Unintended Start 11
2.1.8 Safe Stop of the Frequency Converter 11
2.1.9 IT Mains 13
3 Mechanical Installation
14
3.1 Before Starting
14
3.2.2 Mechanical Dimensions 16
4 Electrical Installation
20
4.1 How to Connect
20
4.1.2 Electrical Installation and Control Cables 21
4.1.5 Mains Wiring Overview 26
4.1.12 Motor Wiring Overview 32
4.1.20 DC Bus Connection 36
4.1.21 Brake Connection Option 37
4.1.22 Relay Connection 38
4.1.26 How to Test Motor and Direction of Rotation 41
5 Commissioning and Application Examples
47
5.1 Commissioning
47
5.1.1 Quick Menu Mode 47
5.1.5 Tips and Tricks 50
5.2 Application Examples
52
5.2.1 Start/Stop 52
5.2.2 Pulse Start/Stop 52
5.2.3 Automatic Motor Adaptation (AMA) 53
6 How to Operate the Frequency Converter
54
6.1.2 How to Operate Graphical LCP (GLCP) 54
6.1.3 How to Operate Numeric LCP (NLCP) 58
7 How to Programme the Frequency Converter
60
7.1 How to Programme
60
7.1.1 Function Set-ups 60
Contents
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 1
7.2 Commonly Used Parameters - Explanations
65
7.3.2 0-** Operation and Display 97
7.3.3 1-** Load / Motor 99
7.3.4 2-** Brakes 100
7.3.5 3-** Reference / Ramps 100
7.3.6 4-** Limits / Warnings 101
7.3.7 5-** Digital In / Out 102
7.3.8 6-** Analog In / Out 103
7.3.9 8-** Communication and Options 104
7.3.10 9-** Profibus 105
7.3.11 10-** CAN Fieldbus 106
7.3.12 11-** LonWorks 106
7.3.13 13-** Smart Logic Controller 107
7.3.14 14-** Special Functions 108
7.3.15 15-** Drive Information 109
7.3.16 16-** Data Readouts 111
7.3.17 18-** Info & Readouts 113
7.3.18 20-** FC Closed Loop 114
7.3.19 21-** Ext. Closed Loop 115
7.3.20 22-** Application Functions 117
7.3.21 23-** Time Based Funtions 119
7.3.22 24-** Application Functions 2 120
7.3.23 25-** Cascade Pack Controller 121
7.3.24 26-** Analog I / O Option MCB 109 122
8 Troubleshooting
123
8.1 Alarms and Warnings
123
8.1.1 Fault Messages 127
8.2 Acoustic Noise or Vibration
133
9 Specifications
134
9.1 General Specifications
134
9.2 Special Conditions
145
Index
147
Contents
VLT
®
HVAC Drive Operating Instructions
2 MG.11.AD.02 - VLT® is a registered Danfoss trademark
1 Introduction
VLT HVAC Drive
FC 100 Series
Software version: 3.4.x
This guide can be used with all VLT
HVAC Drive frequency converters
with software version 3.4.x.
The actual software version number
can be read from
par. 15-43 Software Version.
Introduction
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 3
1 1
1.1.1 Copyright, Limitation of Liability and
Revision Rights
This publication contains information proprietary to Danfoss.
By accepting and using this manual the user agrees that the
information contained herein will be used solely for operating
equipment from Danfoss or equipment from other vendors
provided that such equipment is intended for communication
with Danfoss equipment over a serial communication link. This
publication is protected under the Copyright laws of Denmark
and most other countries.
Danfoss does not warrant that a software program produced
according to the guidelines provided in this manual will
function properly in every physical, hardware or software
environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or
representation, neither expressed nor implied, with respect to
this documentation, including its quality, performance, or
fitness for a particular purpose.
In no event shall Danfoss be liable for direct, indirect, special,
incidental, or consequential damages arising out of the use, or
the inability to use information contained in this manual, even
if advised of the possibility of such damages. In particular,
Danfoss is not responsible for any costs, including but not
limited to those incurred as a result of lost profits or revenue,
loss or damage of equipment, loss of computer programs, loss
of data, the costs to substitute these, or any claims by third
parties.
Danfoss reserves the right to revise this publication at any
time and to make changes to its contents without prior notice
or any obligation to notify former or present users of such
revisions or changes.
1.1.2 Available Literature for VLT HVAC Drive
- Operating Instructions MG.11.Ax.yy provide the
necessary information for getting the frequency
converter up and running.
- Operating Instructions VLT HVAC Drive High Power,
MG.11.Fx.yy
- Design Guide MG.11.Bx.yy entails all technical
information about the frequency converter and
customer design and applications.
- Programming Guide MG.11.Cx.yy provides information on how to programme and includes complete
parameter descriptions.
- Mounting Instruction, Analog I/O Option MCB109,
MI.38.Bx.yy
- Application Note, Temperature Derating Guide,
MN.11.Ax.yy
- PC-based Configuration Tool MCT 10, MG.10.Ax.yy
enables the user to configure the frequency converter from a Windows
™
based PC environment.
-
Danfoss VLT
®
Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions then
choose PC Software Download
- VLT HVAC Drive Drive Applications, MG.11.Tx.yy
- Operating Instructions VLT HVAC Drive Profibus,
MG.33.Cx.yy
- Operating Instructions VLT HVAC Drive Device Net,
MG.33.Dx.yy
- Operating Instructions VLT HVAC Drive BACnet,
MG.11.Dx.yy
- Operating Instructions VLT HVAC Drive LonWorks,
MG.11.Ex.yy
- Operating Instructions VLT HVAC Drive Metasys,
MG.11.Gx.yy
- Operating Instructions VLT HVAC Drive FLN,
MG.11.Zx.yy
- Output Filter Design Guide, MG.90.Nx.yy
- Brake Resistor Design Guide, MG.90.Ox.yy
x = Revision number
yy = Language code
Danfoss technical literature is available in print from your local
Danfoss Sales Office or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm
Introduction
VLT
®
HVAC Drive Operating Instructions
4 MG.11.AD.02 - VLT® is a registered Danfoss trademark
1
1.1.3 Abbreviations and Standards
Abbreviations: Terms: SI-units: I-P units:
a Acceleration
m/s
2
ft/s
2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°C
Celsius
ICurrent AAmp
I
LIM
Current limit
IT mains
Mains supply with star point in transformer floating to
ground.
Joule Energy J = N m ft-lb, Btu
°F
Fahrenheit
FC Frequency Converter
f Frequency Hz Hz
kHz Kilohertz kHz kHz
LCP Local Control Panel
mA Milliampere
ms Millisecond
min Minute
MCT Motion Control Tool
M-TYPE Motor Type Dependent
Nm Newton Metres in-lbs
I
M,N
Nominal motor current
f
M,N
Nominal motor frequency
P
M,N
Nominal motor power
U
M,N
Nominal motor voltage
par. Parameter
PELV Protective Extra Low Voltage
Watt Power W Btu/hr, hp
Pascal Pressure Pa = N/m psi, psf, ft of water
I
INV
Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
T Temperature C F
tTime ss,hr
T
LIM
Torque limit
UVoltage VV
Table 1.1: Abbreviation and standards table
Introduction
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 5
1 1
1.1.4 Frequency Converter Identification
Below is an example of an identification label. This label is
situated on the frequency converter and shows the type and
options fitted to the unit. See below for details of how to read
the Type code string (T/C).
Illustration 1.1: This example shows an identification label.
NOTE
Please have T/C (type code) number and serial number
ready before contacting Danfoss.
Introduction
VLT
®
HVAC Drive Operating Instructions
6 MG.11.AD.02 - VLT® is a registered Danfoss trademark
1
1.1.5 Type Code String low and medium
power
Description Pos Possible choice
Product group & FC Series 1-6 FC 102
Power rating 8-10 1.1- 90 kW (P1K1 - P90K)
Number of phases 11 Three phases (T)
Mains voltage 11-12
T 2: 200-240 VAC
T 4: 380-480 VAC
T 6: 525-600 VAC
Enclosure 13-15
E20: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E66: IP66
P21: IP21/NEMA Type 1 w/backplate
P55: IP55/NEMA Type 12 w/backplate
RFI filter 16-17
H1: RFI filter class A1/B
H2: RFI filter class A2
H3: RFI filter class A1/B (reduced cable length)
Hx: No RFI filter
Brake 18
X: No brake chopper included
B: Brake chopper included
T: Safe Stop
U: Safe + brake
Display 19
G: Graphical Local Control Panel (GLCP)
N: Numeric Local Control Panel (NLCP)
X: No Local Control Panel
Coating PCB 20
X. No coated PCB
C: Coated PCB
Mains option 21
X: No Mains disconnect switch and Load Sharing
1: With Mains disconnect switch (IP55 only)
8: Mains disconnect and Load Sharing
D: Load Sharing
See Chapter 8 for max. cable sizes.
Adaptation 22
X: Standard
0: European metric thread in cable entries.
Adaptation 23 Reserved
Software release 24-27 Actual software
Software language 28
A options 29-30
AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
AG: MCA 108 Lonworks
AJ: MCA 109 BACnet gateway
B options 31-32
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO: MCB 109 Analog I/O option
C0 options MCO 33-34 CX: No options
Introduction
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 7
1 1
Description Pos Possible choice
C1 options 35 X: No options
C option software 36-37 XX: Standard software
D options 38-39
DX: No option
D0: DC back-up
Table 1.2: Type code description.
The various Options and Accessories are described further in the VLT HVAC Drive Design Guide, MG.11.BX.YY.
Introduction
VLT
®
HVAC Drive Operating Instructions
8 MG.11.AD.02 - VLT® is a registered Danfoss trademark
1
2Safety
2.1.1 Symbols
Symbols used in this manual:
NOTE
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
✮
Indicates default setting
2.1.2 High Voltage Warning
The voltage of the frequency converter and the MCO
101 option card is dangerous whenever it is connected
to mains. Incorrect installation of the motor or frequency converter may causedeath, serious injury or damage
to the equipment. Consequently, it is essential to
comply with the instructions in this manual as well as
local and national rules and safety regulations.
2.1.3 Safety Note
The voltage of the frequency converter is dangerous
whenever connected to mains. Incorrect installation of
the motor, frequency converter or fieldbus may cause
death, serious personal injury or damage to the
equipment. Consequently, the instructions in this
manual, as well as national and local rules and safety
regulations, must be complied with.
Safety Regulations
1. The frequency converter must be disconnected from
mains if repair work is to be carried out. Check that
the mains supply has been disconnected and that
the necessary time has passed before removing
motor and mains plugs.
2. The [STOP/RESET] key on the LCP of the frequency
converter does not disconnect the equipment from
mains and is thus not to be used as a safety switch.
3. Correct protective earthing of the equipment must
be established, the user must be protected against
supply voltage, and the motor must be protected
against overload in accordance with applicable
national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is set by
par. 1-90 Motor Thermal Protection. If this function is
desired, set par. 1-90 Motor Thermal Protection to
data value [ETR trip] (default value) or data value
[ETR warning]. Note: The function is initialized at 1.16
x rated motor current and rated motor frequency.
For the North American market: The ETR functions
provide class 20 motor overload protection in
accordance with NEC.
6. Do not remove the plugs for the motor and mains
supply while the frequency converter is connected
to mains. Check that the mains supply has been
disconnected and that the necessary time has
passed before removing motor and mains plugs.
7. Please note that the frequency converter has more
voltage inputs than L1, L2 and L3, when load sharing
(linking of DC intermediate circuit) and external 24 V
DC have been installed. Check that all voltage inputs
have been disconnected and that the necessary time
has passed before commencing repair work.
Safety
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 9
2
2
Installation at high altitudes
380 - 500 V, enclosure A, B and C: At altitudes above 2
km, please contact Danfoss regarding PELV.
380 - 500 V, enclosure D, E and F: At altitudes above 3
km, please contact Danfoss regarding PELV.
525 - 690 V: At altitudes above 2 km, please contact
Danfoss regarding PELV.
Warning against Unintended Start
1. The motor can be brought to a stop by means
of digital commands, bus commands, references or a local stop, while the frequency
converter is connected to mains. If personal
safety considerations make it necessary to
ensure that no unintended start occurs, these
stop functions are not sufficient.
2. While parameters are being changed, the
motor may start. Consequently, the stop key
[STOP/RESET] must always be activated;
following which data can be modified.
3. A motor that has been stopped may start if
faults occur in the electronics of the frequency
converter, or if a temporary overload or a fault
in the supply mains or the motor connection
ceases.
Touching the electrical parts may be fatal - even after
the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC
intermediate circuit), as well as the motor connection for
kinetic back up. Refer to the Operating Instructions for further
safety guidelines.
The frequency converter DC link capacitors remain
charged after power has been disconnected. To avoid
an electrical shock hazard, disconnect the frequency
converter from the mains before carrying out maintenance. Wait at least as follows before doing service on
the frequency converter:
Voltage
(V)
Min. Waiting Time (Minutes)
415203040
200 240
1.1 - 3.7kW5.5 - 45
kW
380 480
1.1 - 7.5kW11 - 90 kW 110 - 250
kW
315 - 1000
kW
525 600
1.1 - 7.5kW11 - 90 kW
525 690
11 - 90 kW 45 - 400kW450 - 1400
kW
Be aware that there may be high voltage on the DC link even when
the LEDs are turned off.
2.1.4 Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned in section General
Warning above
4. Remove motor cable
2.1.5 Special Conditions
Electrical ratings:
The rating indicated on the nameplate of the frequency
converter is based on a typical 3-phase mains power supply,
within the specified voltage, current and temperature range,
which is expected to be used in most applications.
The frequency converters also support other special applications, which affect the electrical ratings of the frequency
converter.
Special conditions which affect the electrical ratings might be:
•
Single phase applications
•
High temperature applications which require derating of the electrical ratings
•
Marine applications with more severe environmental
conditions.
Other applications might also affect the electrical ratings.
Consult the relevant sections in this manual and in the VLT
HVAC Drive Design Guide, MG.11.BX.YY for information about
the electrical ratings.
Safety
VLT
®
HVAC Drive Operating Instructions
10 MG.11.AD.02 - VLT® is a registered Danfoss trademark
2
Installation requirements:
The overall electrical safety of the frequency converter
requires special installation considerations regarding:
•
Fuses and circuit breakers for over-current and shortcircuit protection
•
Selection of power cables (mains, motor, brake,
loadsharing and relay)
•
Grid configuration (grounded delta transformer leg,
IT,TN, etc.)
•
Safety of low-voltage ports (PELV conditions).
Consult the relevant clauses in these instructions and in the
VLT HVAC Drive Design Guide for information about the installation requirements.
2.1.6 Installation at High Altitudes (PELV)
Hazardous Voltage!
By altitudes above 2 km, please contact Danfoss regarding PELV.
Avoid un-intended start
While the frequency converter is connected to mains,
the motor can be started/stopped using digital
commands, bus commands, references or via the LCP.
•
Disconnect the frequency converter from
mains whenever personal safety considerations make it necessary to avoid unintended
start.
•
To avoid unintended start, always activate the
[OFF] key before changing parameters.
•
Unless terminal 37 is turned off, an electronic
fault, temporary overload, a fault in the mains
supply, or lost motor connection may cause a
stopped motor to start.
Failure to follow recommendations could result in death
or serious injury.
2.1.7 Avoid Unintended Start
While the frequency converter is connected to mains,
the motor can be started/stopped using digital
commands, bus commands, references or via the Local
Control Panel.
•
Disconnect the frequency converter from
mains whenever personal safety considerations make it necessary to avoid unintended
start.
•
To avoid unintended start, always activate the
[OFF] key before changing parameters.
•
Unless terminal 37 is turned off, an electronic
fault, temporary overload, a fault in the mains
supply, or lost motor connection may cause a
stopped motor to start.
2.1.8 Safe Stop of the Frequency Converter
For versions fitted with a Safe Stop terminal 37 input, the
frequency converter can perform the safety function Safe
Torque Off (As defined by draft CD IEC 61800-5-2) or Stop
Category 0 (as defined in EN 60204-1).
It is designed and approved suitable for the requirements of
Safety Category 3 in EN 954-1. This functionality is called Safe
Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be
carried out in order to determine whether the Safe Stop
functionality and safety category are appropriate and
sufficient. In order to install and use the Safe Stop function in
accordance with the requirements of Safety Category 3 in EN
954-1, the related information and instructions of the VLT
HVAC Drive Design Guide must be followed! The information
and instructions of the Operating Instructions are not
sufficient for a correct and safe use of the Safe Stop functionality!
Safety
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 11
2
2
130BA491
Illustration 2.1: This certificate also covers FC 102 and FC 202.
Safety
VLT
®
HVAC Drive Operating Instructions
12 MG.11.AD.02 - VLT® is a registered Danfoss trademark
2
2.1.9 IT Mains
IT mains
Do not connect frequency converters with RFI-filters to
mains supplies with a voltage between phase and earth
of more than 440 V for 400 V converters and 760 V for
690 V converters.
For 400 V IT mains and delta earth (grounded leg), mains
voltage may exceed 440 V between phase and earth.
For 690 V IT mains and delta earth (grounded leg), mains
voltage may exceed 760 V between phase and earth.
Failure to follow recommendations could result in death
or serious injury.
Par. 14-50 RFI Filter can be used to disconnect the internal RFI
capacitors from the RFI filter to ground.
2.1.10 Disposal Instruction
Equipment containing electrical components must
not be disposed of together with domestic waste.
It must be separately collected with electrical and
electronic waste according to local and currently
valid legislation.
Safety
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 13
2
2
3 Mechanical Installation
3.1 Before Starting
3.1.1 Checklist
When unpacking the frequency converter, ensure that the unit is undamaged and complete. Use the following table to identify
the packaging:
Enclosure
type:
A2
(IP 20-21)
A3
(IP 20-21)
A4
(IP 55-66)A5(IP 55-66)
B1/B3
(IP
20-21-55-66)
B2/B4
(IP
20-21-55-66)
C1/C3
(IP
20-21-55-66)
C2*/C4
(IP
20-21-55-66)
Unit size (kW):
200-240 V 1.1-2.2 3.0-3.7 1.1-2.2 1.1-3.7
5.5-11/
5.5-11
15/
15-18.5
18.5-30/
22-30
37-45/
37-45
380-480 V 1.1-4.0 5.5-7.5 1.1-4.0 1.1-7.5
11-18.5/
11-18.5
22-30/
22-37
37-55/
45-55
75-90/
75-90
525-600 V 1.1-7.5 1.1-7.5
11-18.5/
11-18.5
22-30/
22-37
37-55/
45-55
75-90/
75-90
Table 3.1: Unpacking table
Please note that a selection of screwdrivers (phillips or cross-thread screwdriver and torx), a side-cutter, drill and knife is also
recommended to have handy for unpacking and mounting the frequency converter. The packaging for these enclosures
contains, as shown: Accessories bag(s), documentation and the unit. Depending on options fitted there may be one or two bags
and one or more booklets.
Mechanical Installation
VLT
®
HVAC Drive Operating Instructions
14 MG.11.AD.02 - VLT® is a registered Danfoss trademark
3
3.2.1 Mechanical Front Views
A2 A3 A4 A5 B1 B2
IP20/21* IP20/21* IP55/66 IP55/66 IP21/55/66 IP21/55/66
Top and bottom mounting holes.
B3 B4 C1 C2 C3 C4
IP20/21* IP20/21* IP21/55/66 IP21/55/66 IP20/21* IP20/21*
Top and bottom mounting holes. (B4+C3+C4 only)
Accessory bags containing necessary brackets, screws and connectors are included with the drives upon delivery.
* IP21 can be established with a kit as described in the section: IP 21/ IP 4X/ TYPE 1 Enclosure Kit in the Design Guide.
Mechanical Installation
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 15
3
3
3.2.2 Mechanical Dimensions
Mechanical Dimensions
Frame size (kW): A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4
200-240 V
380-480 V
525-600 V
1.1-2.2
1.1-4.0
3.0-3.7
5.5-7.5
1.1-7.5
1.1-2.2
1.1-4.0
1.1-3.7
1.1-7.5
1.1-7.5
5.5-11
11-18.5
11-18.5
15
22-30
22-30
5.5-11
11-18.5
11-18.5
15-18.5
22-37
22-37
18.5-30
37-55
37-55
37-45
75-90
75-90
22-30
45-55
45-55
37-45
75-90
75-90
IP
NEMA
20
Chassis
21
Type 1
20
Chassis
21
Type 1
55/66 55/66
Type 12
21/ 55/66
Type 1/12
21/ 55/66
Type 1/12
20
Chassis
20
Chassis
21/ 55/66
Type 1/12
21/ 55/66
Type 1/12
20
Chassis
20
Chassis
Height (mm)
Enclosure A** 246 372 246 372 390 420 480 650 350 460 680 770 490 600
..with de-coupling plate A2 374 - 374 - - - - - 419 595 - - 630 800
Back plate A1 268 375 268 375 390 420 480 650 399 520 680 770 550 660
Distance between mount. holes a 257 350 257 350 401 402 454 624 380 495 648 739 521 631
Width (mm)
Enclosure B 90 90 130 130 200 242 242 242 165 231 308 370 308 370
With one C option B 130 130 170 170 242 242 242 205 231 308 370 308 370
Back plate B 90 90 130 130 200 242 242 242 165 231 308 370 308 370
Distance between mount. holes b 70 70 110 110 171 215 210 210 140 200 272 334 270 330
Depth (mm)
Without option A/B C 205 205 205 205 175 200 260 260 248 242 310 335 333 333
With option A/B C* 220 220 220 220 175 200 260 260 262 242 310 335 333 333
Screw holes (mm)
c 8.0 8.0 8.0 8.0 8.2 8.2 12 12 8 - 12 12 - -
Diameter ø d 11 11 11 11 12 12 19 19 12 - 19 19 - -
Diameter ø e 5.5 5.5 5.5 5.5 6.5 6.5 9 9 6.8 8.5 9.0 9.0 8.5 8.5
f 9 9 9 9 6 9 9 9 7.9 15 9.8 9.8 17 17
Max weight
(kg)
4.95.36.67.09.7 14 23 27 1223.5 45 65 35 50
* Depth of enclosure will vary with different options installed.
** The free space requirements are above and below the bare enclosure height measurement A. See section Mechanical Mounting for further information.
Mechanical Installation
VLT
®
HVAC Drive Operating Instructions
16 MG.11.AD.02 - VLT® is a registered Danfoss trademark
3
3.2.3 Accessory Bags
Accessory Bags: Find the following parts included in the frequency converter accessory bags
Frame sizes A1, A2 and A3 Frame size A5 Frame sizes B1 and B2 Frame sizes C1 and C2
Frame size B3 Frame size B4 Frame size C3 Frame size C4
1 + 2 only available in units with brake chopper. For DC link connection (Load sharing) the connector 1 can be ordered separately (Code no. 130B1064)
An eight pole connector is included in accessory bag for FC 102 without Safe Stop.
Mechanical Installation
VLT
®
HVAC Drive Operating Instructions
MG.11.AD.02 - VLT® is a registered Danfoss trademark 17
3
3
3.2.4 Mechanical Mounting
All IP20 enclosure sizes as well as IP21/ IP55 enclosure sizes
except A2 and A3 allow side-by-side installation.
If the IP 21 Enclosure kit (130B1122 or 130B1123) is used on
enclosure A2 or A3, there must be a clearance between the
drives of min. 50 mm.
For optimal cooling conditions allow a free air passage above
and below the frequency converter. See table below.
Air passage for different enclosures
Enclo
sure:
A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4
a
(mm):
100 100 100 100 200 200 200 200 200 225 200 225
b
(mm):
100 100 100 100 200 200 200 200 200 225 200 225
1. Drill holes in accordance with the measurements
given.
2. You must provide screws suitable for the surface on
which you want to mount the frequency converter.
Re-tighten all four screws.
Mounting frame sizes A4, A5, B1, B2, B3, B4, C1, C2, C3 and C4
on a non-solid back wall, the frequency converter must be
provided with a
backplate A due to insufficient cooling air over the heat sink.
With heavier drives (B4, C3, C4) use a lift. First wall-mount the
2 lower bolts - then lift the drive onto the lower bolts - finally
fasten the drive against the wall with the 2 top bolts.
Mechanical Installation
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3.2.5 Safety Requirements of Mechanical
Installation
Pay attention to the requirements that apply to integration and field mounting kit. Observe the information in
the list to avoid serious injury or equipment damage,
especially when installing large units.
CAUTION!
The frequency converter is cooled by means of air
circulation.
To protect the unit from overheating, it must be ensured
that the ambient temperature does not exceed the
maximum temperature stated for the frequency converter
and that the 24-hour average temperature is not
exceeded. Locate the maximum temperature and 24-
hour average in the paragraph Derating for Ambient
Temperature.
If the ambient temperature is in the range of 45 °C - 55 °
C, derating of the frequency converter will become
relevant, see Derating for Ambient Temperature.
The service life of the frequency converter is reduced if
derating for ambient temperature is not taken into
account.
3.2.6 Field Mounting
For field mounting the IP 21/IP 4X top/TYPE 1 kits or IP 54/55
units are recommended.
3.2.7 Panel Through Mounting
A Panel Through Mount Kit is available for frequency converter series VLT HVAC Drive, VLT Aqua Drive and VLT
AutomationDrive.
In order to increase heatsink cooling and reduce panel depth,
the frequency converter may be mounted in a through panel.
Furthermore the in-built fan can then be removed.
The kit is available for enclosures A5 through C2.
NOTE
This kit cannot be used with cast front covers. IP21
plastic cover must be used instead.
Information on ordering numbers is found in the Design Guide,
section Ordering Numbers.
More detailed information is available in the Panel Through
Mount Kit instruction, MI.33.HX.YY, where yy=language code.
Mechanical Installation
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®
HVAC Drive Operating Instructions
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3
4 Electrical Installation
4.1 How to Connect
4.1.1 Cables General
NOTE
For the VLT HVAC Drive High Power series mains and
motor connections, please see VLT HVAC Drive High
Power Operating Instructions MG.11.FX.YY.
NOTE
Cables General
All cabling must comply with national and local regulations on cable cross-sections and ambient temperature.
Copper (60/75 °C) conductors are recommended.
Details of terminal tightening torques.
Power (kW) Torque (Nm)
Enclo-
sure
200-240V 380-480V
525-600
V
Mains Motor
DC
connection
Brake Earth Relay
A2 1.1 - 3.0 1.1 - 4.0 1.1 - 4.0 1.8 1.8 1.8 1.8 3 0.6
A3 3.7 5.5 - 7.5 5.5 - 7.5 1.8 1.8 1.8 1.8 3 0.6
A4 1.1-2.2 1.1-4 1.8 1.8 1.8 1.8 3 0.6
A5 1.1 - 3.7 1.1 - 7.5 1.1 - 7.5 1.8 1.8 1.8 1.8 3 0.6
B1 5.5 - 11 11 - 18.5 11 - 18.5 1.8 1.8 1.5 1.5 3 0.6
B2
-
15
22
30
22
30
4.5
4.5
2)
4.5
4.5
2)
3.7
3.7
3.7
3.7
3
3
0.6
0.6
B3 5.5 - 11 11 - 18.5 11 - 18.5 1.8 1.8 1.8 1.8 3 0.6
B4 15 - 18.5 22 - 37 22 - 37 4.5 4.5 4.5 4.5 3 0.6
C1 18.5 - 30 37 - 55 37 - 55 10 10 10 10 3 0.6
C2 37 - 45 75 - 90 75 - 90
14/24
1)
14/24
1)
14 14 3 0.6
C3 22 - 30 45 - 55 45 - 55 10 10 10 10 3 0.6
C4 37 - 45 75 - 90 75 - 90
14/24
1)
14/24
1)
14 14 3 0.6
High Power
Enclo-
sure
380-480 V Mains Motor DC connection Brake Earth Relay
D1/D3 110-132 19 19 9.6 9.6 19 0.6
D2/D4 160-250 19 19 9.6 9.6 19 0.6
E1/E2 315-450 19 19 19 9.6 19 0.6
F1-F3
3)
500-710 710-900 19 19 19 9.6 19 0.6
F2-F4
3)
800-1000 1000-1400 19 19 19 9.6 19 0.6
Table 4.1: Tightening of terminals
1) For different cable dimensions x/y, where x ≤ 95 mm2 and y
≥ 95 mm
2
.
2) Cable dimensions above 18.5 kW ≥ 35 mm
2
and below 22
kW ≤ 10 mm
2
.
3) For data on the F frame sizes consult FC 100 High Power
Operating Instructions.
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®
HVAC Drive Operating Instructions
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4.1.2 Electrical Installation and Control Cables
Illustration 4.1: Diagram showing all electrical terminals. (Terminal 37 present for units with Safe Stop Function only.)
Electrical Installation
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®
HVAC Drive Operating Instructions
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4
Terminal number Terminal description Parameter number Factory default
1+2+3 Terminal 1+2+3-Relay1 5-40 No operation
4+5+6 Terminal 4+5+6-Relay2 5-40 No operation
12 Terminal 12 Supply - +24 V DC
13 Terminal 13 Supply - +24 V DC
18 Terminal 18 Digital Input 5-10 Start
19 Terminal 19 Digital Input 5-11 No operation
20 Terminal 20 - Common
27 Terminal 27 Digital Input/Output 5-12/5-30 Coast inverse
29 Terminal 29 Digital Input/Output 5-13/5-31 Jog
32 Terminal 32 Digital Input 5-14 No operation
33 Terminal 33 Digital Input 5-15 No operation
37 Terminal 37 Digital Input - Safe Stop
42 Terminal 42 Analog Output 6-50 Speed 0-HighLim
53 Terminal 53 Analog Input 3-15/6-1*/20-0* Reference
54 Terminal 54 Analog Input 3-15/6-2*/20-0* Feedback
Table 4.2: Terminal connections
Very long control cables and analog signals may, in rare cases
and depending on installation, result in 50/60 Hz earth loops
due to noise from mains supply cables.
If this occurs, break the screen or insert a 100 nF capacitor
between screen and chassis.
NOTE
The common of digital / analog inputs and outputs
should be connected to separate common terminals 20,
39, and 55. This will avoid ground current interference
among groups. For example, it avoids switching on
digital inputs disturbing analog inputs.
NOTE
Control cables must be screened/armoured.
4.1.3 Fuses
Branch Circuit Protection
In order to protect the installation against electrical and fire
hazard, all branch circuits in an installation, switch gear,
machines etc., must be short-circuit and over-current protected according to the national/international regulations.
Short-circuit protection:
The frequency converter must be protected against
short-circuit to avoid electrical or fire hazard. Danfoss
recommends using the fuses mentioned below to
protect service personnel and equipment in case of an
internal failure in the drive. The frequency converter
provides full short-circuit protection in case of a shortcircuit on the motor output.
Over-current protection
Provide overload protection to avoid fire hazard due to
overheating of the cables in the installation. Over
current protection must always be carried out according
to national regulations. The frequency converter is
equipped with an internal over current protection that
can be used for upstream overload protection (ULapplications excluded). See par. 4-18 Current Limit in the
VLT HVAC Drive Programming Guide . Fuses must be
designed for protection in a circuit capable of supplying
a maximum of 100,000 A
rms
(symmetrical), 500 V/600 V
maximum.
Over-current protection
If UL/cUL is not to be complied with, Danfoss recommends
using the fuses mentioned in the table below, which will
ensure compliance with EN50178.
In case of malfunction, not following the recommendation
may result in unnecessary damage to the frequency converter.
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Non-UL compliance fuses
Frequency
converter
Max. fuse size Voltage Type
200-240 V - T2
1K1-1K5
16A
1
200-240 V type gG
2K2
25A
1
200-240 V type gG
3K0
25A
1
200-240 V type gG
3K7
35A
1
200-240 V type gG
5K5
50A
1
200-240 V type gG
7K5
63A
1
200-240 V type gG
11K
63A
1
200-240 V type gG
15K
80A
1
200-240 V type gG
18K5
125A
1
200-240 V type gG
22K
125A
1
200-240 V type gG
30K
160A
1
200-240 V type gG
37K
200A
1
200-240 V type aR
45K
250A
1
200-240 V type aR
380-480 V - T4
1K1-1K5
10A
1
380-500 V type gG
2K2-3K0
16A
1
380-500 V type gG
4K0-5K5
25A
1
380-500 V type gG
7K5
35A
1
380-500 V type gG
11K-15K
63A
1
380-500 V type gG
18K
63A
1
380-500 V type gG
22K
63A
1
380-500 V type gG
30K
80A
1
380-500 V type gG
37K
100A
1
380-500 V type gG
45K
125A
1
380-500 V type gG
55K
160A
1
380-500 V type gG
75K
250A
1
380-500 V type aR
90K
250A
1
380-500 V type aR
1) Max. fuses - see national/international regulations for selecting an applicable fuse size.
Table 4.3: Non-UL fuses 200 V to 480 V
If UL/cUL is not to b e co mpli ed w ith, we recomme nd u sing the
following fuses, which will ensure compliance with EN50178:
Frequency Converter Voltage Type
P110 - P250 380 - 480 V type gG
P315 - P450 380 - 480 V type gR
Table 4.4: Compliance with EN50178
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4
UL compliance fuses
Frequency
converter
Bussmann Bussmann Bussmann SIBA Littel fuse
Ferraz-
Shawmut
Ferraz-
Shawmut
200-240 V
kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K25-K37 KTN-R05 JKS-05 JJN-05 5017906-005 KLN-R005 ATM-R05 A2K-05R
K55-1K1 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10 ATM-R10 A2K-10R
1K5 KTN-R15 JKS-15 JJN-15 5017906-015 KLN-R15 ATM-R15 A2K-15R
2K2 KTN-R20 JKS-20 JJN-20 5012406-020 KLN-R20 ATM-R20 A2K-20R
3K0 KTN-R25 JKS-25 JJN-25 5012406-025 KLN-R25 ATM-R25 A2K-25R
3K7 KTN-R30 JKS-30 JJN-30 5012406-030 KLN-R30 ATM-R30 A2K-30R
5K5 KTN-R50 JKS-50 JJN-50 5012406-050 KLN-R50 - A2K-50R
7K5 KTN-R50 JKS-60 JJN-60 5012406-050 KLN-R60 - A2K-50R
11K KTN-R60 JKS-60 JJN-60 5014006-063 KLN-R60 A2K-60R A2K-60R
15K KTN-R80 JKS-80 JJN-80 5014006-080 KLN-R80 A2K-80R A2K-80R
18K5 KTN-R125 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R A2K-125R
22K KTN-R125 JKS-150 JJN-125 2028220-125 KLN-R125 A2K-125R A2K-125R
30K FWX-150 - - 2028220-150 L25S-150 A25X-150 A25X-150
37K FWX-200 - - 2028220-200 L25S-200 A25X-200 A25X-200
45K FWX-250 - - 2028220-250 L25S-250 A25X-250 A25X-250
Table 4.5: UL fuses, 200 - 240 V
Frequency
converter
Bussmann Bussmann Bussmann SIBA Littel fuse
Ferraz-
Shawmut
Ferraz-
Shawmut
380-480 V, 525-600 V
kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1
K37-1K1 KTS-R6 JKS-6 JJS-6 5017906-006 KLS-R6 ATM-R6 A6K-6R
1K5-2K2 KTS-R10 JKS-10 JJS-10 5017906-010 KLS-R10 ATM-R10 A6K-10R
3K0 KTS-R15 JKS-15 JJS-15 5017906-016 KLS-R16 ATM-R16 A6K-16R
4K0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R
5K5 KTS-R25 JKS-25 JJS-25 5017906-025 KLS-R25 ATM-R25 A6K-25R
7K5 KTS-R30 JKS-30 JJS-30 5012406-032 KLS-R30 ATM-R30 A6K-30R
11K KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 - A6K-40R
15K KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 - A6K-40R
18K KTS-R50 JKS-50 JJS-50 5014006-050 KLS-R50 - A6K-50R
22K KTS-R60 JKS-60 JJS-60 5014006-063 KLS-R60 - A6K-60R
30K KTS-R80 JKS-80 JJS-80 2028220-100 KLS-R80 - A6K-80R
37K KTS-R100 JKS-100 JJS-100 2028220-125 KLS-R100 A6K-100R
45K KTS-R125 JKS-150 JJS-150 2028220-125 KLS-R125 A6K-125R
55K KTS-R150 JKS-150 JJS-150 2028220-160 KLS-R150 A6K-150R
75K FWH-220 - - 2028220-200 L50S-225 A50-P225
90K FWH-250 - - 2028220-250 L50S-250 A50-P250
Table 4.6: UL fuses, 380 - 600 V
KTS-fuses from Bussmann may substitute KTN for
240 V frequency converters.
FWH-fuses from Bussmann may substitute FWX for
240 V frequency converters.
KLSR fuses from LITTEL FUSE may substitute KLNR
fuses for 240 V frequency converters.
L50S fuses from LITTEL FUSE may substitute L50S
fuses for 240 V frequency converters.
A6KR fuses from FERRAZ SHAWMUT may substitute
A2KR for 240 V frequency converters.
A50X fuses from FERRAZ SHAWMUT may substitute
A25X for 240 V frequency converters.
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24 MG.11.AD.02 - VLT® is a registered Danfoss trademark
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4.1.4 Earthing and IT Mains
The earth connection cable cross section must be at
least 10 mm
2
or 2 rated mains wires terminated
separately according to EN 50178 or IEC 61800-5-1 unless
national regulations specify differently. Always comply
with national and local regulations. on cable crosssections.
The mains is connected to the main disconnect switch if this is
included.
Check that mains voltage corresponds to the mains
voltage of the frequency converter name plate.
Illustration 4.2: Terminals for mains and earthing.
IT Mains
Do not connect 400 V frequency converters with RFIfilters to mains supplies with a voltage between phase
and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains
voltage may exceed 440 V between phase and earth.
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4.1.5 Mains Wiring Overview
Enclosure: A2
(IP 20/IP 21)
A3
(IP 20/IP 21)
A4
(IP 55/IP 66)
A5
(IP 55/IP 66)B1(IP 21/IP 55/IP 66)B2(IP 21/IP 55/IP 66)
Motor size:
200-240 V
1.1-3.0
kW
3.7
kW
1.1-2.2 kW
1.1-3.7
kW
5.5-11
kW
15
kW
380-480 V
1.1-4.0
kW
5.5-7.5
kW
1.1-.4 kW
1.1-7.5
kW
11-18.5
kW
22-30
kW
525-600 V
1.1-7.5
kW
1.1-7.5
kW
11-18.5
kW
22-30
kW
Enclosure: B3
(IP 20)
B4
(IP 20)
C1
(IP 21/IP 55/66)C2(IP 21/IP 55/66)
C3
(IP 20)
C4
(IP20)
Goto: 4.1.5 4.1.6 4.1.6 4.1.7
Motor size:
200-240 V
5.5-11
kW
15-18.5
kW
18.5-30
kW
37-45
kW
22-30
kW
37-45
kW
380-480 V
11-18.5
kW
22-37
kW
37-55
kW
75-90
kW
45-55
kW
75-90
kW
525-600 V
11-18.5
kW
22-37
kW
37-55
kW
75-90
kW
45-55
kW
75-90
kW
Goto: 4.1.8 4.1.9
Table 4.7: Mains wiring table.
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4.1.6 Mains Connection for A2 and A3
Illustration 4.3: First mount the two screws on the
mounting plate, slide it into place and tighten fully.
Illustration 4.4: When mounting cables, first mount and
tighten earth cable.
The earth connection cable cross section must be at
least 10 mm
2
or 2 rated mains wires terminated
separately according to EN 50178/IEC 61800-5-1.
Illustration 4.5: Then mount mains plug and tighten wires.
Illustration 4.6: Finally tighten support bracket on mains
wires.
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4
NOTE
With single phase A3 use L1 and L2 terminals.
4.1.7 Mains Connection for A4/A5
Illustration 4.7: How to connect to mains and earthing
without mains disconnect switch. Note that a cable clamp
is used.
Illustration 4.8: How to connect to mains and earthing
with mains disconnect switch.
NOTE
With single phase A5 use L1 and L2 terminals.
4.1.8 Mains Connection for B1, B2 and B3
Illustration 4.9: How to connect to mains and earthing for
B1 and B2
Illustration 4.10: How to connect to mains and earthing
for B3 without RFI.
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Illustration 4.11: How to connect to mains and earthing
for B3 with RFI.
NOTE
With single phase B1 use L1 and L2 terminals.
NOTE
For correct cable dimensions please see the section
General Specifications at the back of this manual.
4.1.9 Mains Connection for B4, C1 and C2
Illustration 4.12: How to connect to mains and earthing
for B4.
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Illustration 4.13: How to connect to mains and earthing
for C1 and C2.
4.1.10 Mains Connection for C3 and C4
Illustration 4.14: How to connect C3 to mains and
earthing.
Illustration 4.15: How to connect C4 to mains and
earthing.
Electrical Installation
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