Danfoss Turbocor Operating guide
MAKING MODERN LIVING POSSIBLE
Installation Guide
Danfoss Turbocor
www.danfoss.com/drives
Contents Installation Guide
Contents
1 Introduction
1.1 Product Overview
1.2 Purpose of the Manual
1.3 Product Overview
1.4 Internal Controller Functions
2 Safety
2.1 Safety Symbols
3 Installation
3.1 Planning the Installation Site
3.2 Pre-Installation Check List
3.3 Mechanical Installation
3.3.1 Cooling 6
3.3.1.1 Refrigerant Cooling 6
3.3.2 Lifting 7
3.3.3 Wall Mounting - IP21 (NEMA 1) Units 7
3.4 Electrical Installation
3
3
4
4
4
5
5
6
6
6
6
7
3.4.1 General Requirements 7
3.4.2 Grounding Requirements 10
3.4.2.1 Leakage Current (>3.5 mA) 10
3.4.2.2 Grounding IP21 Enclosures 11
3.4.3 Motor Connection 11
3.4.3.1 Terminal Locations 12
3.4.4 Motor Cable 13
3.4.5 Motor Rotation Check 13
3.4.6 AC Mains Connection 13
3.4.7 DC-Link Connection 13
3.5 Control Wiring Connection
3.5.1 Access 14
3.5.2 Using Screened Control Cables 14
3.5.3 Grounding of Screened Control Cables 14
3.5.4 Control Terminal Types 15
3.5.5 Wiring to Control Terminals 16
3.6 Serial Communication
14
16
4 Start Up and Commissioning
4.1 Pre-start
4.2 Applying Power
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17
18
Contents Danfoss Turbocor
5 Specifications
5.1 Power-dependent Specifications
5.2 General Technical Data
5.3 Fuse Tables
5.3.1 Protection 22
5.3.2 Fuse Selection 22
5.3.3 Short Circuit Current Rating (SCCR) 23
5.3.4 Connection Tightening Torques 23
Index
19
19
20
22
24
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1
15
14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
130BC252.11
130BC301.11
1
2
3
4
5
6
7
8
9
10
11
Introduction
1 Introduction
1.1 Product Overview
1.1.1 Interior Views
Installation Guide
1
1
Illustration 1.1 D1 Interior Components
LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
1
2 RS-485 serial bus connector 10 Lifting ring
3 Digital I/O and 24 V power supply 11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Earth (ground)
6 Serial bus terminal switch 14 Motor output terminals 96 (U), 97 (V), 98 (W)
7 Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03) 16 TB5 (IP21 only). Terminal block for anti-condensation heater
Table 1.1 Legend to Illustration 1.1 and Illustration 1.2
Illustration 1.2 Close-up View: LCP and Control Functions
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Introduction Danfoss Turbocor
1
1.2 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 communications wiring
•
Control terminal functions
•
VLT® is a registered trademark.
1.3 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
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.
1.4
Internal Controller Functions
Illustration 1.3 is a block diagram of the frequency
converter's internal components.
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
Table 1.2 Legend to Illustration 1.3
•
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.
Illustration 1.3 Frequency Converter Block Diagram
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Safety
Installation Guide
2 Safety
2.1 Safety Symbols
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.
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.
2 2
Table 2.2 Approvals
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product specific design guide.
NOTICE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72 onwards, the output
frequency of the frequency converter is limited to 590
Hz. Software versions 6x.xx also limit the maximum
output frequency to 590 Hz, but these versions cannot
be flashed, that is, neither downgraded nor upgraded.
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] Power range [kW] Minimum waiting time
(minutes)
3x400 110-315 20
3x460 110-315 20
3x575 110-315 20
Table 2.1 Discharge Time
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Installation
Danfoss Turbocor
3 Installation
3.1 Planning the Installation Site
Ensure that frequency converter output current
33
NOTICE
Before performing the installation it is important to plan
the installation of the frequency converter. 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 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
Voltage [V] Altitude restrictions
380-500 At altitudes above 3,000 m, contact Danfoss
regarding PELV
525-690 At altitudes above 2,000 m, contact Danfoss
regarding PELV
Table 3.1 Installation in High Altitudes
3.2
Pre-Installation Check List
Before unpacking the frequency converter, ensure
•
the packaging is intact. If any damage has
occurred, immediately contact the shipping
company to claim the damage.
Before unpacking the frequency converter, locate
•
it as close as possible to the final installation site
Compare the model number on the nameplate to
•
what was ordered to verify the proper equipment
Ensure each of the following are rated for the
•
same voltage:
Mains (power)
•
Frequency converter
•
Motor
•
•
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
3.3 Mechanical Installation
3.3.1 Cooling
Top and bottom clearance for air cooling must be
•
provided. Generally, 225 mm (9 in) is required.
Improper mounting can result in over heating
•
and reduced performance
NOTICE
A door fan(s) is required on the enclosure to remove the
heat not contained in the backchannel of the frequency
converters and any additional losses generated by other
components inside the enclosure. The total required air
flow must be calculated so that the appropriate fans can
be selected.
Airflow
The necessary airflow over the heat sink must be secured.
The flow rate is shown in Table 3.2.
Frame Door fan/top fan Heat sink fan
D1h
D2h
Table 3.2 Airflow
3.3.1.1
The Danfoss Turbocor frequency converters are equipped
with refrigerant cooling.
The refrigerant inlet is on the top of the frequency
converter to the left.
The refrigerant outlet is on the top of the frequency
converters to the right.
Dimensions
Material COPPER ALLOY 122, ASTM B-75, annealed
Nominal operating
pressure
Maximum working
pressure
Table 3.3 Tubing Specifications
102 m3/hr (60 CFM) 420 m3/hr (250 CFM)
204 m3/hr (120 CFM) 840 m3/hr (500 CFM)
Refrigerant Cooling
3/8 inch OD X 0.049 inch wall thk
10 bar/145 psi
12 bar/174 psi
6 Danfoss A/S © 01/2015 All rights reserved. MG35Q202
Installation
Installation Guide
WARNING
CONDENSATION
Condensation must not be allowed to form on the inside
of the frequency converter. The flow of refrigerant must
be controlled in a way that ensures that the temperature
of the internal heatsink stays above the dew point.
Failure to control condensation will result in damage to
the frequency converter.
3.3.2 Lifting
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 chapter 5.1 Power-dependent Specifications
•
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.
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 be
performed only by trained and qualified personnel.
Failure to follow these guidelines could result in death or
serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in
three 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 frequency converter and associated
equipment performance.
3 3
Wall Mounting - IP21 (NEMA 1) Units
3.3.3
Consider the following before selecting the final installation site:
Free space for cooling
•
Access to open the door
•
Cable entry from the bottom
•
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
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