Danfoss VACON 3000 Operating guide

Operating Guide

VACON® 3000 Enclosed Drive

drives.danfoss.com

VACON® 3000 Enclosed Drive
Operating Guide	Contents

Contents

1 Introduction		9
1.1	Purpose of this Operating Guide	9
1.2	Additional Resources	9
1.3	Manual Version	9

2 Safety		10
2.1	Safety Symbols	10
2.2	Qualified Personnel	10
2.3	Danger and Warnings	10
2.4	Cautions and Notices	12
2.5	Main Circuit Breaker	14
	2.5.1 Safety and Protection Requirements	14
	2.5.2 Minimum Requirements for MCB and MCB Control	14

3 Product Overview			16
3.1	Intended Use		16
3.2	Product Description		16
	3.2.1	AFE Drive	16
	3.2.2	12-Pulse Drive	17
3.3	Type Code Description		17
3.4	Available Options		18

4 Receiving the Delivery		21
4.1	Checking the Delivery	21
4.2	Storage	21
4.3	Lifting and Moving the Enclosed Drive	21

5 Mechanical Installation			24
5.1	Operating Environment		24
5.2	Cabinet Installation		24
5.3	Dimensions of the Enclosed Drive		25
5.4	Liquid Cooling Requirements		26
	5.4.1	Safety in Liquid-cooling	26
	5.4.2 General Information on Liquid Cooling		26
	5.4.3	Cooling Liquid	27
		5.4.3.1 Quality Requirements for the Purified Water	27
		5.4.3.2 Purified Water as Coolant	27
		5.4.3.3 Antifreeze Mix as Coolant	27
Danfoss A/S © 2021.09			AQ286660579921en-000101/DPD02033 | 3

VACON® 3000 Enclosed Drive
Operating Guide				Contents
		5.4.3.4 Temperature of the Cooling Liquid		28
		5.4.3.5	Condensation	28
	5.4.4	Cooling System		30
		5.4.4.1	Materials	30
		5.4.4.2	Cooling System Overview	31
		5.4.4.3 Cooling Connections to the Enclosed Drive		31
5.5	Cooling and Free Space Around the Enclosed Drive			32
6 Electrical Installation				34
6.1	Galvanic Isolation Between the MV and LV Sections			34
6.2	Mains and Motor Cable Selection			35
6.3	Mains and Motor Cable Inlet and Termination			35
6.4	Grounding			38
	6.4.1	Standard Grounding Configurations		38
6.5	Additional Instructions for Cable Installation			39
6.6	Main Circuit Breaker Installation			40
6.7	Cabling of the Power Modules			40
	6.7.1 Phase Module L20/L30 Terminals			40
	6.7.2 DFE Power Module Terminals			40
		6.7.2.1	DFE Control Terminals	41
	6.7.3	Power Module Grounding		42
	6.7.4	DC-Link Connections		43
	6.7.5	Brake Chopper Installation		45
	6.7.6 Terminal Screw Tightening Torque Specifications			45
	6.7.7 LED Display on the Phase Module			45
	6.7.8 LED Display on the DFE Power Module			47
6.8	Low-Voltage Power Supplies			48
	6.8.1 Low-Voltage Power Supply Connections			48
	6.8.2 Safety Notes for the Precharge Unit			49
	6.8.3 Location of the Precharge Unit			49
6.9	Safety Functions			49
	6.9.1 Safe Torque Off (STO)			50
	6.9.2 Safe Stop 1 (SS1)			50
	6.9.3	Safety Considerations		50
		6.9.3.1	Diagnostic Test	50
	6.9.4	STO Operating Principle		51
	6.9.5	SS1 Operating Principle		51

4 | Danfoss A/S © 2021.09

AQ286660579921en-000101/DPD02033

VACON® 3000 Enclosed Drive
Operating Guide	Contents

7 Control Connections			52
7.1	Control Interface		52
7.2	The Control Compartment of the Enclosed Drive		52
7.3	Control Unit Components		53
7.4	Control Unit Cabling		54
	7.4.1	Selection of the Control Cables	55
	7.4.2	Control Unit Terminals	55
7.5	DIP Switches on the Control Unit		56
	7.5.1	Selection of Terminal Functions with DIP Switches	56
	7.5.2	Isolation of the Digital Inputs from Ground	57
7.6	Fieldbus Connection		58
	7.6.1	Fieldbus Terminals	58
	7.6.2	Using Fieldbus through an Ethernet Cable	59
	7.6.3	Using Fieldbus through an RS485 Cable	60
7.7	Option Board Installation		62
7.8	Optical Fiber Connections		63
	7.8.1	Selection of Optical Fiber Cables	66
	7.8.2	Making Optical Fiber Cables	67
7.9	Encoder Interface		68
	7.9.1	Encoder Terminals and Signals	69
	7.9.2	Encoder Jumper Configurations	70
	7.9.3	Encoder Connection	72
7.10	Battery for the Real-Time Clock (RTC)		73
7.11	Galvanic Isolation Barriers		73
7.12	System and Application Software		73
7.13	Technical Data on Control Connections		73
7.14	Auxiliary I/O Board		75
	7.14.1	Connector Locations	75
	7.14.2	Connector Specifications	76
	7.14.3	LED Display on the Auxiliary I/O Board	80

8 Commissioning			82
8.1	Safety Checks before Starting the Commissioning		82
8.2	Operating the Grounding Switch		82
8.3	Commissioning the Drive		83
	8.3.1	Basic Job Information	83
	8.3.2	Before Power-up Checklist	84
	8.3.3 Control and Auxiliary Power Commissioning Checklist		87
Danfoss A/S © 2021.09			AQ286660579921en-000101/DPD02033 | 5

VACON® 3000 Enclosed Drive
Operating Guide			Contents
	8.3.4	Medium-Voltage Power Commissioning Checklist	88
8.4	Commissioning Procedures		88
	8.4.1	Filling the Liquid Cooling System	88
	8.4.2	Grid Voltage Feedback Configuration	92
	8.4.3	Installing Software on the Control Unit	94
	8.4.4	Verifying the Phase Module Connections	97
	8.4.5	Commissioning Test	98
		8.4.5.1 Commissioning Test with HMI Touch Screen	99
		8.4.5.2 Commissioning Test with VACON® Live	100
	8.4.6	AFE Synchronization Test	101
	8.4.7	Encoder Setup	105
8.5	Insulation Resistance Measurements		106
	8.5.1	Measuring the Switchgear Insulation Resistance	106
	8.5.2	Measuring the Cable and Motor Insulation	107
		8.5.2.1 Insulation Checks of the Motor Cable	107
		8.5.2.2 Insulation Checks of the Mains Cable	107
		8.5.2.3 Insulation Checks of the Motor	107
9 Maintenance			108
9.1	Preventive Maintenance Recommendations		108
9.2	Maintenance of the Heat Exchanger		110
10 Fault Tracing			111
10.1	Fault Types		111
10.2	Faults and Alarms		111
	10.2.1	Fault Code 1 - Overcurrent	111
	10.2.2	Fault Code 2 - Overvoltage	112
	10.2.3	Fault Code 3 - Earth Fault	113
	10.2.4	Fault Code 5 - Charging Switch	114
	10.2.5	Fault Code 7 - Saturation	114
	10.2.6	Fault Code 8 - System Fault	114
	10.2.7	Fault Code 9 - Undervoltage	122
	10.2.8	Fault Code 10 - Input Phase	122
	10.2.9	Fault Code 11 - Output Phase Supervision	124
	10.2.10 Fault Code 12 - Brake Chopper Supervision		124
	10.2.11 Fault Code 13 - AC Drive Undertemperature		125
	10.2.12 Fault Code 14 - AC Drive Overtemperature		125
	10.2.13 Fault Code 15 - Motor Stall		127
	10.2.14 Fault Code 16 - Motor Overtemperature		127
6 | Danfoss A/S © 2021.09			AQ286660579921en-000101/DPD02033

VACON® 3000 Enclosed Drive
Operating Guide	Contents
10.2.15 Fault Code 17 - Motor Underload	127
10.2.16 Fault Code 19 - Power Overload	128
10.2.17 Fault Code 25 - Motor Control Fault	128
10.2.18 Fault Code 26 - Start-up Prevented	129
10.2.19 Fault Code 29 - ATEX Thermistor	129
10.2.20 Fault Code 30 - Safety	129
10.2.21 Fault Code 32 - Fan Cooling	132
10.2.22 Fault Code 33 - Fire Mode Enabled	132
10.2.23 Fault Code 37 - Device Changed (Same Type)	132
10.2.24 Fault Code 38 - Device Added (Same Type)	133
10.2.25 Fault Code 39 - Device Removed	134
10.2.26 Fault Code 40 - Device Unknown	134
10.2.27 Fault Code 41 - IGBT Temperature	135
10.2.28 Fault Code 43 - Encoder Fault	135
10.2.29 Fault Code 44 - Device Changed (Different Type)	137
10.2.30 Fault Code 45 - Device Added (Different Type)	138
10.2.31 Fault Code 46 - Real Time Clock	138
10.2.32 Fault Code 47 - Software Update	139
10.2.33 Fault Code 49 - Precharge	139
10.2.34 Fault Code 50 - AI Low Fault	143
10.2.35 Fault Code 51 - Device External Fault	143
10.2.36 Fault Code 52 - Keypad Communication Fault	144
10.2.37 Fault Code 53 - Fieldbus Communication Fault	144
10.2.38 Fault Code 54 - Slot Fault	144
10.2.39 Fault Code 57 - Identification	145
10.2.40 Fault Code 58 - Mechanical Brake	146
10.2.41 Fault Code 59 - Communication	146
10.2.42 Fault Code 61 - Speed Error Fault	146
10.2.43 Fault Code 63 - Quick Stop	146
10.2.44 Fault Code 65 - PC Communication Fault	147
10.2.45 Fault Code 66 - Thermistor Input Fault	147
10.2.46 Fault Code 67 - Module Test Stand	148
10.2.47 Fault Code 68 - Maintenance Counter	148
10.2.48 Fault Code 69 - Fieldbus Mapping Error	148
10.2.49 Fault Code 76 - Start Prevented	149
10.2.50 Fault Code 77 - >5 Connections	149
10.2.51 Fault Code 78 - Identification Ongoing	149
10.2.52 Fault Code 80 - Fieldbus Watchdog Fault	149
Danfoss A/S © 2021.09	AQ286660579921en-000101/DPD02033 | 7

VACON® 3000 Enclosed Drive
Operating Guide			Contents
	10.2.53 Fault Code 84 - Overspeed Error		149
	10.2.54 Fault Code 111 - Temperature Input Fault 1		149
	10.2.55 Fault Code 112 - Temperature Input Fault 2		150
	10.2.56 Fault Code 114 - User Defined Fault 1		150
	10.2.57 Fault Code 115 - User Defined Fault 2		151
	10.2.58 Fault Code 200 - Precharge		151
	10.2.59 Fault Code 201 - High Humidity/Temperature		152
	10.2.60 Fault Code 202 - Encoder		152
	10.2.61 Fault Code 203 - STO Fault		153
	10.2.62 Fault Code 204 - Output Filter		153
	10.2.63 Fault Code 205 - Coolant Temperature		153
	10.2.64 Fault Code 300 - Unsupported		153
11 Specifications			154
11.1	Power Ratings		154
	11.1.1 Power Ratings for Mains Voltage 3300 V		154
	11.1.2 Power Ratings for Mains Voltage 4160 V		154
	11.1.3	Overload Capability	155
11.2	Technical Data		155
	11.2.1	Mains Supply	155
	11.2.2	Motor Output	156
	11.2.3	Control Properties	156
	11.2.4	Drive Properties	157
	11.2.5	Ambient Conditions	158
	11.2.6	Cooling	159
	11.2.7	Source Impedance Specifications	160
11.3	Main Circuit Diagrams		164
	11.3.1 VACON® 3000 AFE Main Circuit Diagrams		164
	11.3.2 VACON® 3000 12-Pulse Main Circuit Diagrams		166
11.4	Abbreviations		167

8 | Danfoss A/S © 2021.09

AQ286660579921en-000101/DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally.

Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.

1.2 Additional Resources

Other resources are available to understand advanced AC drive functions, programming, and options.

•The VACON® 3000 application guides provide greater detail on how to work with the applications and how to set the parameters of the AC drive.

•The operating and installation guides for VACON® options give detailed information about specific drive options.

Supplementary publications and manuals are available from Danfoss. See www.danfoss.com for listings.

1.3 Manual Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.

Table 1: VACON® 3000 Enclosed Drive Operating Guide Version

Version	Release date	Remarks
A	29.09.2021	First version

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 9

VACON® 3000 Enclosed Drive

Operating Guide	Safety

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

•Are familiar with the basic regulations concerning health and safety/accident prevention.

•Have read and understood the safety guidelines given in all manuals, especially the instructions given in the operating guide of the unit.

•Have good knowledge of the generic and specialist standards applicable to the specific application.

•Are familiar with the structure and operation of medium-voltage drives and the related risks. Special training for medium-volt- age installations may be necessary.

2.3 Danger and Warnings

D A N G E R

SHOCK HAZARD FROM POWER UNIT COMPONENTS

The power unit components are live when the drive is connected to mains. Contact with this voltage can result in death or serious injury.

-Do not touch the components of the power unit when the drive is connected to mains. Do not do any work on live equipment.

Before doing any work on internal drive components, follow proper lock out and tag out procedure.

Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

10 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Safety

D A N G E R

SHOCK HAZARD FROM TERMINALS

The motor terminals U, V, W, the brake resistor terminals, and the DC-link terminals must be treated as live when the drive is connected to mains. Contact with this voltage can lead to death or serious injury.

-Do not touch the motor terminals U, V, W, the brake resistor terminals, or the DC terminals when the drive is connected to mains.

Do not do any work on live equipment.

Before doing any work on the drive, follow proper lock out and tag out procedure.

Before connecting the drive to mains, make sure that all covers are installed on the drive and the enclosure doors are closed.

D A N G E R

SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE

The terminal connections and the components of the drive can be live several minutes after the drive is disconnected from the mains and the motor has stopped. The load side of the drive can also generate voltage. A contact with this voltage can lead to death or serious injury.

-Disconnect the drive from the mains and make sure that the motor has stopped. Disconnect the motor.

Lock out and tag out the power source to the drive.

Make sure that no external source generates unintended voltage during work.

To ground the drive input and DC link, close the grounding switch. If there is no grounding switch, make sure that the drive input and DC link are grounded for work. Also ground the motor terminals for work.

Wait for the DC-link capacitors to discharge fully before opening the cabinet door or the cover of the AC drive. The discharge time is <7 minutes for AFE drives and <21 minutes for 12-pulse drives.

Use a measuring device to make sure that there is no voltage.

W A R N I N G

SHOCK HAZARD FROM CONTROL TERMINALS

The control terminals can have a dangerous voltage also when the drive is disconnected from mains. A contact with this voltage can lead to injury.

-Make sure that there is no voltage in the control terminals before touching the control terminals.

W A R N I N G

ACCIDENTAL MOTOR START

When there is a power-up, a power break, or a fault reset, the motor starts immediately if the start signal is active, unless the pulse control for Start/Stop logic is selected. If the parameters, the applications or the software change, the I/O functions (including the start inputs) can change. If you activate the auto reset function, the motor starts automatically after an automatic fault reset. See the Application Guide. Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equipment damage.

-Disconnect the motor from the drive if an accidental start can be dangerous. Make sure that the equipment is safe to operate under any condition.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 11

VACON® 3000 Enclosed Drive

Operating Guide	Safety

W A R N I N G

ELECTRICAL SHOCK HAZARD - LEAKAGE CURRENT HAZARD >3.5 MA

Leakage currents exceed 3.5 mA. Failure to connect the drive properly to protective earth (PE) can result in death or serious injury.

-Ensure reinforced protective earthing conductor according to IEC 60364-5-54 cl. 543.7 or according to local safety regulations for high touch current equipment. The reinforced protective earthing of the drive can be done with:

-a PE conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al.

-an extra PE conductor of the same cross-sectional area as the original PE conductor as specified by IEC 60364-5-54 with a minimum cross-sectional area of 2.5 mm2 (14 AWG) (mechanical protected) or 4 mm2 (12 AWG) (not mechanical protected).

-a PE conductor completely enclosed with an enclosure or otherwise protected throughout its length against mechanical damage.

-a PE conductor part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2 (14 AWG) (permanently connected or pluggable by an industrial connector. The multi-conductor power cable shall be installed with an appropriate strain relief).

-NOTE: In IEC/EN 60364-5-54 cl. 543.7 and some application standards (for example IEC/EN 60204-1), the limit for requiring reinforced protective earthing conductor is 10 mA leakage current.

2.4 Cautions and Notices

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS

Using spare parts that are not from the manufacturer can damage the drive.

-Do not use spare parts that are not from the manufacturer.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM CHANGES TO DRIVE COMPONENTS

Doing electrical or mechanical changes to the drive components can cause malfunctions and can damage the AC Drive.

-Do not make electrical or mechanical changes to the drive components.

C A U T I O N

DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING

Not using a grounding conductor can damage the drive.

-Always ground the AC drive with a grounding conductor that is connected to the grounding terminal that is identified with the PE symbol. If no dedicated transformer is installed, the AC drive is intended for high resistance grounding systems with a resistance grounded neutral point. For operation in an IT network without a dedicated transformer, consult Danfoss.

C A U T I O N

CUT HAZARD FROM SHARP EDGES

There can be sharp edges in the AC drive that can cause cuts.

-Wear protective gloves when mounting, cabling, or doing maintenance operations.

C A U T I O N

BURN HAZARD FROM HOT SURFACES

Touching surfaces, which are marked with the 'hot surface' sticker, can result in injury.

-Do not touch surfaces which are marked with the 'hot surface' sticker.

12 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Safety

N O T I C E

DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE

Some of the electronic components inside the AC drive are sensitive to ESD. Static voltage can damage the components.

-Use ESD protection when working with electronic components of the AC drive. Do not touch the components on the circuit boards without proper ESD protection.

N O T I C E

DAMAGE TO THE AC DRIVE FROM MOVEMENT

Movement after installation can damage the drive.

-Do not move the AC drive during operation. Use a fixed installation to prevent damage to the drive.

N O T I C E

DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL

The EMC level requirements for the AC drive depend on the installation environment. An incorrect EMC level can damage the drive.

-Before connecting the AC drive to the mains, make sure that the EMC level of the AC drive is correct for the mains.

N O T I C E

RADIO INTERFERENCE

In a residential environment, this product can cause radio interference.

-Take supplementary mitigation measures.

N O T I C E

MAINS DISCONNECTION DEVICE

If the AC drive is used as a part of a machine, the machine manufacturer must supply a mains disconnection device (refer to EN 60204-1).

N O T I C E

MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES

Because there are high capacitive currents in the AC drive, it is possible that the fault current protective switches do not operate correctly.

N O T I C E

VOLTAGE WITHSTAND TESTS

If done improperly, doing voltage withstand tests can damage the drive.

-Megohmmeter testing is the only recommended test type for field installations. Only a qualified field service engineer is allowed to perform this test.

Refer to the proper high potential/megohmmeter testing instructions in the service guide.

N O T I C E

WARRANTY

If the power modules are opened, the warranty is not valid.

-Do not open the power modules.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 13

VACON® 3000 Enclosed Drive

Operating Guide	Safety

N O T I C E

PERSONAL PROTECTIVE EQUIPMENT AND APPROVED TOOLS

When doing electrical work on the AC drive, always use personal protective equipment (PPE) and tools which are approved for work with medium-voltage devices.

2.5 Main Circuit Breaker

The main circuit breaker (MCB) is an important protection device for the drive. If there is a serious fault in the drive, the MCB immediately disconnects the main supply to the drive. To protect personnel and to prevent further damage to the equipment, the main supply must be disconnected immediately with an open or trip command from the drive.

If the drive is supplied through a dedicated transformer, install the MCB on the primary side of the supply transformer (see Illustration 1).

		1
	CB1	2
G	CB2	MVD
		~
		M
		~
		3
		4
		5

<![if ! IE]>

<![endif]>e30bi562.10

Illustration 1: Overview of the Drive System

1	Trip coil: RO from VACON® 3000 (reaction time:	CB1	Circuit breaker 1
	10 ms delay)	CB2	Circuit breaker 2
2	Undervoltage release (UVR): IGBT switch from arc	G	Grid or generator
	flash relay (reaction time: 2 ms delay)
3	Breaker open: RO from the breaker	M	Motor
4	Breaker closed: RO from the breaker	MVD	VACON® 3000 medium-voltage drive
5	Breaker ready (optional): RO from the breaker

2.5.1 Safety and Protection Requirements

For safety and protection, the MCB must meet the minimum requirements of the specifications of Danfoss medium-voltage drives. The minimum requirements for the MCB are stated in this manual and in the respective MCB specifications, which are available for each medium-voltage drive from Danfoss. The system integrator must make sure that the minimum requirements are met.

The safety requirements for the drive are based on the following standards:

•EN ISO 13849-1: Safety of machinery, Safety-related parts of control systems, General principles for design, section 6.2.6 Category 3

•UL347A, Edition 1: Standard for Medium Voltage Power Conversion Equipment

2.5.2 Minimum Requirements for MCB and MCB Control

Requirements

To meet the stipulated safety requirements, Danfoss requires the following:

•MCB is equipped with 2 independent opening coils.

•MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage.

•Route the MCB open and trip commands directly from the drive to the MCB.

-Do not route the trip command through any PLC or DCS (distributed control system) which is not certified to meet SIL 3- level requirements and to fulfill the given timing requirements.

-Opening of the MCB by the drive must be possible at any time. Do not interrupt the open and trip commands, for example, by a local-remote switch in the MCB.

14 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Safety

•Closing the MCB locally is not permitted. When the MCB is in the service position, the drive must have exclusive control of closing the MCB.

•The maximum opening time of the MCB must never exceed the product or project specific maximum time defined in the MCB specifications.

•Typical maximum protection and safety trip time for the drive: 60 ms

Recommendations

To meet the stipulated safety requirements, Danfoss recommends the following:

•Provide an upstream protection coordination scheme which uses the "breaker failure" (ANSI 50BF) signal to trip the upstream breaker automatically, in case the MCB does not open.

•After a failure has occurred, the upstream breaker must open within the maximum protection and safety trip time.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 15

VACON® 3000 Enclosed Drive

Operating Guide	Product Overview

3 Product Overview

3.1 Intended Use

VACON® 3000 is a liquid-cooled AC drive for stepless speed or torque control of medium-voltage induction motors. VACON® 3000 Enclosed Drive is a complete medium-voltage drive installed in a cabinet.

VACON® 3000 Enclosed Drive is available for industrial applications with motor voltages of 3300 V and 4160 V, and in a power range starting from 2 MW. Basic configurations have a power of 2 MW or 3 MW. These configurations can be paralleled for systems of 4 MW and above.

Two different drive configurations are available:

•Regenerative, with an active front-end (AFE)

•Non-regenerative, with a 12-pulse diode front-end (DFE)

<![if ! IE]>

<![endif]>e30bg963.10

Illustration 2: Example of the VACON® 3000 Enclosed Drive

3.2 Product Description

3.2.1 AFE Drive

An example diagram of the regenerative VACON® 3000 Enclosed Drive is shown in Illustration 3. The main components of the drive are:

•The active front-end (AFE) unit includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are installed in parallel to make a 3-phase converter. The AFE converts the supplied AC voltage to DC voltage. It also enables the supply of power to the supply network when the motor is braking.

•The inverter unit (INU) includes 3 or 6 of the same liquid-cooled 1-phase modules, which are used in the AFE. The INU converts the DC voltage to the AC voltage and frequency supplied to the motor.

•The LC filter (FLC) limits harmonic current on the supply network.

•The pre-charge unit (PRC) charges the DC-link capacitors.

•The AFE and INU control units (CNU-AFE/CNU-INU) are connected to the power conversion units with optical fibers.

•The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV section of the cabinet.

The basic VACON® 3000 AFE drive is intended for installations, where the system is supplied by a dedicated transformer and the source impedance is small. These installations are usually on land. The drive includes an LC filter instead of an LCL filter, because the supply side inductance is included in the dedicated transformer.

It is recommended to install a dedicated transformer for the drive. If the drive is not supplied by a dedicated transformer (that is, there are other loads than the drive on the same supply):

16 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Product Overview

•Install the drive in a high resistance grounding system with a resistance grounded neutral point.

•Install an input common-mode filter (option +PICM).

If the source impedance is high, select the +PHSI option. See 11.2.7 Source Impedance Specifications. For operation in an IT network without a dedicated transformer, contact Danfoss.

For the full main circuit diagrams, see 11.3.1 VACON® 3000 AFE Main Circuit Diagrams.

			CNU-AFE		CNU-INU
			AXU-IOB
CCM		CCM			LV~
	CSH
					PRC
			+	+
MV~			o	o	Motor
			-	-
LGI	LCM	LCV	3 x PCU		3 x PCU

				+PODU
+PICM	FLC	AFE	INU	+POSI

Illustration 3: Example Main Circuit Diagram of a VACON® 3000 AFE Drive

<![if ! IE]>

<![endif]>e30bg606.10

3.2.2 12-Pulse Drive

An example diagram of the 12-pulse non-regenerative VACON® 3000 Enclosed Drive is shown in Illustration 4. The main components of the drive are:

•The diode front-end unit (DFE) is a liquid-cooled 12-pulse power conversion unit (PCU), which changes the supplied AC voltage to DC voltage. The 12-pulse configuration is used to limit harmonics on the supply network.

•The inverter unit (INU) includes 3 or 6 liquid-cooled 1-phase power conversion units (PCU). 3 of the phase modules are installed in parallel to make a 3-phase converter. The INU converts the DC voltage to the AC voltage and frequency supplied to the motor.

•The pre-charge unit (PRC) charges the DC-link capacitors.

•The INU control unit (CNU-INU) is connected to the inverter units with optical fibers.

•The auxiliary I/O board (AXU-IOB) provides galvanic separation between I/Os in the MV section and the control unit in the LV section of the cabinet.

The 12-pulse DFE must be supplied by a dedicated transformer with two secondary windings.

For the full main circuit diagrams, see 11.3.2 VACON® 3000 12-Pulse Main Circuit Diagrams.

		AXU-IOB			CNU-INU
					PRC
	MV~	+	+		+
Y
		0	0		0
		-	-		-
	MV~	CDC			3 x PCU
				CCM
		PCU				+PODU
		12P-DFE			INU	+POSI

Illustration 4: Example Main Circuit Diagram of a VACON® 3000 12-Pulse Drive

<![if ! IE]>

<![endif]>e30bg607.10

LV~

Motor

3.3 Type Code Description

The type code for VACON® 3000 has five basic parts (1–5) and option codes (6).

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 17

VACON® 3000 Enclosed Drive

Operating Guide	Product Overview

VACON3000 - ED - 4Q - 0425 - 03 +XXXX +YYYY +ZZZZ

1

2

3

4

5

6

Illustration 5: VACON® 3000 Type Code Structure

<![if ! IE]>

<![endif]>e30bg964.10

1. Product series

VACON® 3000. This part of the code is always the same.

2. Product class

The VACON® 3000 product.

•ED: Enclosed Drive

3. Drive type

There are two different drive types available. All kits include an inverter unit (INU) as default. The front-end type is specified in the type code.

•4Q: A regenerative drive with an active front end (AFE) and an LC input filter, supplied through a dedicated transformer. If the drive is not supplied by a dedicated transformer, install a common-mode filter (available with option code +PICM).

•12: A non-regenerative drive with a 12-pulse diode front end (DFE) rectifier and external DC capacitors. A dedicated transformer with 2 secondary windings is necessary.

4. Nominal output current

See the available output currents in Table 2.

Table 2: Available Output Current Ratings

Input voltage [V]			3300		4160
Output current [A]			0425		0340
			0640		0510
			0820		0650
			1230		0980
5. Nominal input voltage
Nominal supply voltage: 03 = 3300 V or 04 = 4160 V.
6. Option codes
Optional components.
See the available codes in 3.4 Available Options.
3.4 Available Options
Table 3: Available Options for VACON® 3000 Enclosed Drive
Option Code		Option Description
+PICM		Input common-mode filter
(1)		The option is only available for AFE drives.
		Always include the input common-mode filter in VACON® 3000 AFE installations, which are not supplied by a
		dedicated transformer.
+PODU		dU/dt output filter
(1)
+POSI		Sine-wave output filter
(1)
+POCM		Output common-mode filter
(1)		Contact Danfoss to check the common-mode capacitor option selection.
18 | Danfoss A/S © 2021.09				AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive
Operating Guide		Product Overview
Option Code	Option Description
+DBCU	Brake chopper unit for dynamic braking
(1)	The option does not include a brake resistor.
	The option is for 12-pulse drives. If a brake chopper is required for an AFE drive, contact Danfoss.
+PHSI	High source impedance
	Option for installation locations with high source impedances (~10–15% SI). For example, marine applications
	usually have a high source impedance. The option affects the size of the input filters. The default installation lo-
	cation has small source impedance (SSI).
	This option is only available for AFE drives.
	Examine each application one by one. To see if this option is necessary, find out the source impedance and see
	11.2.7 Source Impedance Specifications. If necessary, consult Danfoss.
+SC__	C, D, and E slot option boards
+SD__	Default: No option boards in slots C, D, and E.
+SE__	See the available option boards in Table 4.
+QSTO	Safe torque off functionality.
	Only available for AFE drives.
	Control and fan supply voltage
+QFV1	115 V (default for 4160 V)
+QFV2	230 V (default for 3300 V)
	Grounding of the heat sink and connection of the grounding resistor in power modules
+PGDR	R: DC neutral-to-ground resistor connected (default)
+PGDN	N: DC neutral-to-ground resistor not connected
	Liquid cooling options
+PLIN	IN: Industrial water and grounded heat sink
+PLDI	DI: Deionized water and floating heat sink
+PUFE	Short-circuit current rating: 40 kA, for 100 ms.
	Available only for AFE drives.
+PGC0	Common-mode capacitor to ground removed
+PLCT	Coolant input from the top
	Heat exchanger option
+PHET	ET: Titanium liquid-to-liquid heat exchanger included
+PH00	00: Liquid-to-liquid heat exchanger not included
	Precharge input voltage
+QP24	240 V
+QP40	400 V (default for 3300 V)
+QP48	480 V (default for 4160 V)
+GAUL	cUL certificate
+GACE	EU declaration, CE approval
	Marine approval
+GADN	DN: Det Norske Veritas
Danfoss A/S © 2021.09		AQ286660579921en-000101 / DPD02033 | 19

VACON® 3000 Enclosed Drive
Operating Guide		Product Overview
Option Code	Option Description
+GALR	LR: Lloyd's Register

1 The nominal current and voltage selected in the type code of the VACON® 3000 affect this option. The correct size and number of parts is supplied automatically. If a different size or number of parts is needed, an order for separate parts is possible.

Table 4: Available Option Boards for Slots C, D, and E

Slot C	Slot D	Slot E	Option Board(1)
+SCB1	+SDB1	+SEB1	I/O board OPTB1: 6 x Digital input/digital output, programmable
+SCB2	+SDB2	+SEB2	I/O board OPTB2: 1 x relay output (NO/NC), 1 x relay output (NO), Thermistor
+SCB4	+SDB4	+SEB4	I/O board OPTB4: 1 x analog input, 2 x analog output (isolated)
+SCB5	+SDB5	+SEB5	I/O board OPTB5: 3 x relay output
+SCB9	+SDB9	+SEB9	I/O board OPTB9: 1 x relay output, 5 x digital input (42–240 V AC)
+SCBF	+SDBF	+SEBF	I/O board OPTBF: 1 x analog output, 1 x digital output, 1 x relay output
+SCBH	+SDBH	+SEBH	I/O board OPTBH: 3 x Temperature measurement (support for PT100, PT1000, NI1000, KTY84-130,
			KTY84-150, KTY84-131 sensors)
	+SDD3	+SED3	Adapter board OPTD3: RS232 adapter
	+SDE3	+SEE3	Fieldbus board OPTE3: PROFIBUS DP-V1 (Screw connector)
	+SDE5	+SEE5	Fieldbus board OPTE5: PROFIBUS DP-V1 (D9 connector)
	+SDE6	+SEE6	Fieldbus board OPTE6: CANopen
	+SDE7	+SEE7	Fieldbus board OPTE7: DeviceNet
	+SDE9	+SEE9	Fieldbus board OPTE9: 2-port Ethernet
	+SDEA	+SEEA	Fieldbus board OPTEA: Advanced 2-port Ethernet
	+SDEC	+SEEC	Fieldbus board OPTEC: EtherCAT

1 For a 12-pulse drive, the option includes one board. For an AFE drive, the option includes two boards, one for the AFE control unit and one for the INU control unit. If the drive also has the brake chopper option (+DBCU), the option includes one more board for the brake chopper control unit.

20 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Receiving the Delivery

4 Receiving the Delivery

4.1Checking the Delivery

1.After removing the packaging, examine the drive for transport damages.

-If the drive was damaged during the shipping, speak to the cargo insurance company or the carrier.

2.To make sure that the delivery is correct, compare the type code for the order to the type code on the package label. The type code specifies the drive type, nominal output current, nominal input voltage, and option codes. See 3.3 Type Code Description.

-If the delivery does not agree with the order, speak to the vendor immediately.

4.2Storage

N O T I C E

LIQUID IN THE HEAT SINK

If the cooling liquid is not removed from the heat sink before storage or shipping, the liquid can freeze and damage the drive. - Always remove the cooling liquid from the heat sink before storage or shipping.

If the AC drive is kept in storage, keep it in controlled conditions.

•Storage temperature: -40…+70°C (-40... +158°F). If the storage temperature is below 0°C (+32°F), make sure that there is no cooling liquid in the heat sink.

•Relative humidity: < 96%, no condensation

Keep the equipment sealed in its packaging until installation.

4.3 Lifting and Moving the Enclosed Drive

W A R N I N G

LIFTING HEAVY EQUIPMENT

Follow local safety regulations for lifting heavy weights. Failure to follow recommendations and local safety regulations can result in death or serious injury.

-Ensure that the lifting equipment is in proper working condition.

The cabinets must be moved vertically. Always refer to the shipping marks on the package for more information. Do not remove the package material before installing the AC drive.

To lift the cabinets, use a lifting device that can lift the weight of the cabinets. There are lifting holes on the top of the cabinets. Use these holes to lift the cabinets and to move them to the installation location. The minimum angle between the cabinets and the chain is 60°.

To divide the weight of the cabinets equally, and to prevent damage to the equipment, always use 4 lifting holes. Align the lifting locations with the horizontal center of gravity.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 21

VACON® 3000 Enclosed Drive
Operating Guide	Receiving the Delivery
	<![if ! IE]> <![endif]>e30bg965.10

>60°

>60°

Illustration 6: Lifting the Cabinets

You can use rollers, for example, to move the cabinets.

Move the cabinets carefully. Switchgear parts can easily fall because their center of gravity is high up at the back of the cabinets.

<![if ! IE]>

<![endif]>e30bg966.10

Illustration 7: Moving the Cabinets

When the cabinet is in the installation location, it can be necessary to make small adjustments to the position of the cabinet. Use a crowbar to move the cabinet from the special hooks on the cabinet base.

Remove the moving hooks from the base of the cabinet before installation.

22 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive
Operating Guide	Receiving the Delivery
	<![if ! IE]> <![endif]>e30bg967.10

Illustration 8: Hooks on the Cabinet Base for Adjusting the Position of the Cabinet

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 23

VACON® 3000 Enclosed Drive

Operating Guide	Mechanical Installation

5 Mechanical Installation

5.1 Operating Environment

N O T I C E

CONDENSATION

Moisture can condense on the electronic components and cause short circuits.

-Avoid installation in areas subject to frost.

Install space heaters to warm the air inside the cabinets.

Before powering the drive, run the cooling pumps to warm up the components, until the drive is warmer than the ambient air.

N O T I C E

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. For specifications regarding ambient conditions, see 11.2.5 Ambient Conditions.

5.2 Cabinet Installation

Installation guidelines:

•Locate the drive as near to the motor as possible.

•Ensure unit stability by mounting the enclosure on a solid surface.

•Make sure that the level of the floor is in permitted limits. The maximum deviation from the basic level can be no more than 5 mm (0.197 in) along a 3 m (9.84 ft) distance. The maximum permitted height difference between the cabinet front and rear edges is 2 mm (0.079 in).

•Ensure that the strength of the mounting location supports the unit weight.

•It is not recommended to install the cabinet directly against a wall.

•Attach the cabinet to the floor. There are holes in the base of the cabinet which can be used for the installation.

•Ensure that there is enough space around the unit for proper cooling.

•Ensure that there is enough room to open the cabinet doors and for working on the equipment.

•Remove the moving hooks from the base of the cabinet before installation.

24 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Mechanical Installation

5.3 Dimensions of the Enclosed Drive

Illustration 9 and Table 5 show the dimensions of the basic VACON® 3000 Enclosed Drive. Some options can affect the total width or height of the cabinet. Always refer to the delivery-specific information for the accurate dimensions.

<![if ! IE]>

<![endif]>e30bg968.10

B

A C

Illustration 9: Dimensions of the VACON® 3000 Enclosed Drive

A–C	See the dimensions in Table 5.
Table 5: Dimensions of the VACON® 3000 Enclosed Drive
Type code		Dimension A	Dimension B	Dimension C
VACON3000ED-4Q-0425-03		2400 mm (7 ft 10.5 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0640-03		2600 mm (8 ft 6.4 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0820-03		3800 mm (12 ft 5.6 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-1230-03		4400 mm (14 ft 5.2 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0340-04		2400 mm (7 ft 10.5 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0510-04		2600 mm (8 ft 6.4 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0650-04		3800 mm (12 ft 5.6 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-4Q-0980-04		4400 mm (14 ft 5.2 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0425-03		2400 mm (7 ft 10.5 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0640-03		2600 mm (8 ft 6.4 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0820-03		3400 mm (11 ft 1.9 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-1230-03		3800 mm (12 ft 5.6 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
Danfoss A/S © 2021.09			AQ286660579921en-000101 / DPD02033 | 25

VACON® 3000 Enclosed Drive
Operating Guide			Mechanical Installation
Type code	Dimension A	Dimension B	Dimension C
VACON3000ED-12-0340-04	2400 mm (7 ft 10.5 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0510-04	2600 mm (8 ft 6.4 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0650-04	3400 mm (11 ft 1.9 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)
VACON3000ED-12-0980-04	3800 mm (12 ft 5.6 in)	2130 mm (6 ft 11.9 in)	1000 mm (3 ft 3.4 in)

5.4 Liquid Cooling Requirements

5.4.1 Safety in Liquid-cooling

W A R N I N G

POISONOUS COOLANTS

Glycols and inhibitors are poisonous. If touched or consumed, they can cause injury.

-Prevent the coolant from getting into the eyes. Do not drink the coolant.

C A U T I O N

HOT COOLANT

Hot coolant can cause burns.

-Avoid contact with the hot coolant.

C A U T I O N

PRESSURIZED COOLING SYSTEM

Sudden release of pressure from the cooling system can cause injury.

-Be careful when operating the cooling system.

N O T I C E

INSUFFICIENT COOLING CAPACITY

Insufficient cooling can cause the product to become too hot and thus become damaged.

-To make sure that the cooling capacity of the cooling system stays sufficient, make sure that the cooling system is vented and that the coolant circulates properly.

5.4.2 General Information on Liquid Cooling

VACON® 3000 drives are liquid-cooled. The liquid circulation of the drive is connected to a heat-exchanger that cools down the liquid circulating in the cooling elements of the drive. The power modules have aluminum heat sinks, which give good and safe temperature control. Because the cooling elements are made of aluminum, the cooling liquids allowed to be used are inhibited pure water, inhibited demineralized water, or an inhibited mixture of water and glycol.

The inductors of the input and output filters use air-to-liquid heat exchanger units for forced air cooling. The heat exchangers decrease the heat losses to the air and thus decreases the number of fans necessary for cooling the cabinet.

There are two types of cooling systems: open systems and closed systems.

An open system has no pressure but the hydrostatic and pumping pressure. It allows free contact between the cooling liquid and air. Air is continuously dissolved into the cooling liquid.

In a closed system, the piping is air-tight and there is a preset pressure inside the pipes. The pipes must be made of metal, or a specific plastic or rubber that includes an oxygen barrier that limits the diffusion of oxygen. Minimizing of oxygen content in the cooling liquid decreases the risk of corrosion of the metal parts. Closed systems usually have an expansion vessel that allows for a safe change of volume of the cooling liquid due to temperature changes.

Always use a closed system with Danfoss liquid-cooled drives.

26 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive
Operating Guide	Mechanical Installation

5.4.3 Cooling Liquid

5.4.3.1 Quality Requirements for the Purified Water

N O T I C E
DAMAGE TO SYSTEM FROM THE USE OF HYDROCARBONS
Hydrocarbons damage the rubber seals of the cooling system.
- Do not use hydrocarbons (for example mineral oil) as coolant. Do not mix hydrocarbons to coolant.
Table 6: Requirements for the Purified Water
Property	Required value
pH	6...8
Chlorides	≤ 25 ppm
Sulphate ions	≤ 25 ppm
Maximum particle size	≤ 50 µm
Total dissolved solids	≤ 200 ppm
Total hardness (CaCO3)	3…4.6 dH° (53…80 ppm)
Hydrogen carbonate	≤ 50 ppm
Electrical conductivity	≤ 500 µS/cm

5.4.3.2 Purified Water as Coolant

Purified water can be used as coolant if there is no risk of freezing. Freezing water permanently damages the cooling system. Purified water is demineralized, deionized, or distilled water.

Always use an inhibitor Cortec VpCI-649 with 1.0% of volume with purified water.

C A U T I O N

CORROSION HAZARD WITH DRINKING WATER

Some components are made of aluminum, which has limited corrosion resistance against high chloride concentrations. Drinking water can have a chloride concentration of 250 ppm, which increases the aluminum corrosion rate. High chloride concentration exposes aluminum especially to pitting corrosion which can damage the system relatively quickly.

-Use purified (demineralized, deionized, or distilled) water with corrosion inhibitors.

5.4.3.3 Antifreeze Mix as Coolant

The following antifreeze products are a good general solution for liquid cooling since they provide freeze protection and corrosion protection.

The allowed antifreeze coolants are the following ethylene glycols and propylene glycols.

Ethylene glycols

•DOWCAL 100

•Clariant Antifrogen N

Propylene glycols

•DOWCAL 200

•Clariant Antifrogen L

These glycols already include corrosion inhibitors. Do not add any other inhibitor. Do not mix different glycol qualities because there can be harmful chemical interactions.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 27

VACON® 3000 Enclosed Drive

Operating Guide	Mechanical Installation

The glycol concentration of the coolant must be 25–55% by volume, according to the specified ambient temperature. Higher concentration reduces cooling capacity. Lower concentration results in biological growth and inadequate amount of corrosion inhibitors. Antifreeze must be mixed with purified water according to 5.4.3.1 Quality Requirements for the Purified Water.

5.4.3.4 Temperature of the Cooling Liquid

To gain full performance of the product, the temperature of the cooling liquid entering the drive components must be a maximum of 43°C (109°F) and above the dew point. While circulating inside the cooling element, the liquid transfers the heat produced by the power semiconductors and other components. The temperature rise of the cooling liquid during the circulation is typically less than 4°C (7.2°F). Typically, more than 95% of the power losses are dissipated in the cooling liquid. It is recommended to equip the cooling circulation with temperature supervision.

The secondary circuit maximum temperature must always be lower than the primary circuit temperature. The temperature difference must be at least 5°C (9°F) with equal flow. The temperature difference is necessary for the correct operation of the heat exchanger.

There are 3 external causes that affect the nominal temperature of the primary circuit:

•The maximum ambient temperature at the drive installation location.

•The maximum relative humidity at the drive installation location.

•The maximum secondary circuit liquid temperature.

All these causes must be examined when calculating the primary circuit temperature. The primary circuit temperature can be different for each installation.

5.4.3.5 Condensation

Condensation must be avoided. Always keep the temperature of the cooling liquid a minimum 2°C (3.6°F) above the dew point. Use the graph in Illustration 10 to see if the conditions (combination of room temperature, humidity, and cooling liquid temperature) are safe for the drive to operate.

The conditions are safe when the point is below the related (cooling liquid temperature) curve. If they are not, decrease the ambient temperature or the relative humidity. Also the cooling liquid temperature can be increased. Note, that if the cooling liquid temperature is increased above the figures in loadability charts, it decreases the nominal output current of the drive. The curves in Illustration 10 are valid at sea level altitude (1013 mbar/14.69 psi).

If the temperature of the liquid in the secondary circuit is lower than the ambient temperature and the relative humidity is high, condensation can occur on the secondary circuit pipes and the plate heat exchanger in the HX unit. The condensation is not dangerous, but it is not recommended. If there is condensation in the HX unit, it can cause the leak sensor in the cabinet to give a leak alarm. If a leak alarm occurs again and again, install insulation in the secondary circuit pipes and the plate heat exchanger. The insulation stops the condensation and thus prevents the incorrect leak alarms.

28 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033

VACON® 3000 Enclosed Drive

Operating Guide	Mechanical Installation

Tamb , °C (°F)											<![if ! IE]> <![endif]>e30bg701.10
60 (140)
50 (122)
40 (104)										Tc , °C (°F)
										45	(113)
										40	(104)
30 (86)										38	(100)
										35	(95)
20 (68)										30	(86)
										25	(77)
										20	(68)
10 (50)
0 (32)
100	90	80	70	60	50	40	30	20	10	0

RH (%)

Illustration 10: Safe Operating Conditions in Relation to Condensation

RH	Relative humidity	T c	Cooling liquid temperature
T amb	Ambient temperature

Example

Safe Operating Conditions

If the ambient temperature is +30°C (+86°F), the relative humidity is 40% and the cooling liquid temperature is +20°C (+68°F, the lowest curve in Illustration 10), then the drive operation conditions are safe.

If the ambient temperature increases to +35°C (+95°F) and the relative humidity to 60%, then the operation conditions of the drive are not safe. To get safe operation conditions, the ambient temperature must be decreased to +28°C (+82°F) or below. If it is not possible to lower the ambient temperature, then the cooling liquid temperature can be increased to +25°C (+77°F) or above.

Example

Dew Point and Primary Circuit Temperature

If the ambient temperature and the maximum relative humidity at the drive installation location is known, the dew point chart (see Illustration 11) can be used to find the correct temperature for the primary circuit.

•Ambient temperature = 35°C (95°F)

•Maximum relative humidity = 60%

According to the diagram in Illustration 11, the dew point for the given values is 26°C (78.8°F). Always keep the temperature of the cooling liquid a minimum 2°C (3.6°F) above the dew point. Thus the primary circuit minimum temperature is set to 28°C (82.4°F).

The secondary circuit maximum temperature must always be 5°C (9°F) lower than the primary circuit temperature. Thus, in this example, the secondary circuit temperature must be below 23°C (73.4°F) during operation.

Notice, that these conditions are valid for the starting of the drive. After the start, the temperature inside the cabinet starts to increase and the humidity decreases.

Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033 | 29

VACON® 3000 Enclosed Drive

Operating Guide	Mechanical Installation

												Tamb (°C/°F)															<![if ! IE]> <![endif]>e30bg702.10
					10		15			20			25		30			35		40		45			50	°C
	100				50		59			68			77		86			95		104		113			122	°F
	95
	90
	85
	80
	75
	70
<![if ! IE]> <![endif]>(%)	65
	60
<![if ! IE]> <![endif]>RH
	55
	50
	45
	40
	35
	30
	25
	20
	2	4	6	8	10	12	14	16	18	20	22	24	26	28	30	32	34	36	38	40	42	44	46	48	50	°C
	36	39	43	46	50	54	57	61	64	68	72	75	79	82	86	90	93	97	100	104	108	111	115	118	122	°F
												Tc (°C/°F)

Illustration 11: Dew Point Diagram for Ambient Temperatures between +10°C...+50°C (+50°F...+122°F) at 1013 mbar (14.69 psi)

RH	Relative humidity	T c	Primary circuit temperature
T amb	Ambient temperature

5.4.4 Cooling System

5.4.4.1 Materials

C A U T I O N

COPPER OR COPPER ALLOY PARTS DAMAGE THE SYSTEM

Using copper or copper alloy pipes or parts in contact with the cooling liquid damages the system.

-Do not use pipes made of copper or alloys that include copper. If metallic pipes are used in the cooling system, use aluminum or stainless steel pipes.

Allowed materials in the cooling system

These materials are allowed in the cooling system if they are compatible with the cooling liquid:

•Aluminum (EN-AW6060, EN-AW6063, or EN-AW6082)

•Stainless steel (AISI 304/316)

•Plastic*

•Elastomers (EPDM, NBR, FDM)*

* If plastic or elastomers are used, check material compatibility within the temperature range of the cooling liquid. See the specifications in 11.2.6 Cooling.

Do not use PVC, copper, brass, or other materials not compatible with the heat sink material or cooling liquid.

Recommended material for pipes

30 | Danfoss A/S © 2021.09

AQ286660579921en-000101 / DPD02033