Danfoss VLT 2000, VLT 2015, VLT 2030, VLT 2010, VLT 2020 Series Manual
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MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
Contents
Section 1
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InstallationInstallation
InstallationInstallation
Installation
Section 2
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After installationAfter installation
After installationAfter installation
After installation
Section 3
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Facts about VLFacts about VL
Facts about VLFacts about VL
Facts about VL
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MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
Installation has been written for personnel who will unpack the VLT frequency converter and carry out mechanical and electrical installation.
Installation makes it easy and safe for you to install the VLT frequency converter, just
follow the instructions on the next pages.
After Installation has been written for personnel who are to set up the VLT
frequency converter, when it is to be commissioned. The VLT has a number of factory
settings. You can choose the settings to match your plant (application). The
initial settings are described in chapter 1.
When you start your setting the mechanical and electrical installation has been done.
If you want to check the electrical installation you can do that on the basis of the survey of terminals.
To go on with the settings you must know the values of the different parameters.
Typically it is the planning engineer or technician who determines the values on the
basis of the information given in the section
Facts about VLT.
Facts about VLT is written for users of VLT frequency converters for large plants.
In
Facts about VLT you can read how to size a plant, how to select the right VLT on
the basis of the technical data, how to carry out the electrical installation, the
mechanical installation, etc.
It will also appear what standards the VLT frequency converter complies with and
what safety measures you should take before you start.
Facts about VLT is your work of reference, so do keep it within reach.
When you read the manual please note the following symbols:
About this manual
Section 1
Section 2
Section 3
General warning
Pay special attention here.
MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
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Safety rules
Warning against improper start
1. The motor can be stopped using digital commands,
bus commands, references or local stop, while the
frequency converter is connected to the mains.
If personal safety requires elimination of any
possibility of unintended start,
these stops will not
be sufficient.
2. The motor can start during parameter operation.
Therefore
always activate the “Stop/Reset” key
before changiing data.
3.
A stopped motor can start if a fault occurs in the
electronics of the frequency converter or after a
temporary overload, mains fault or faulty motor
connection.
For the North American market
CAUTION: It is the responsibility of the user or person
installing the drive to provide proper grounding and
branch circuit protection for incoming power and motor
overload according to National Electrical Codes (NEC)
and local codes.
The Electronic Thermal Relay (ETR) in UL listed VLTs
provides class 20 motor overload protection in
accordance with NEC in single motor applications,
when parameter 315 is set to Trip [2] and parameter
107 is set to nominal motor (nameplate) current.
The frequency converter contains dangerous
voltages when connected to the mains.
Improper connection of the motor or the frequency
converter may cause equipment failure, serious injury
or death.
Therefore follow the directions in this manual, as well as
local and national safety rules.
Touching the electrical parts, even when the power
supply has been switched off, can cause serious injury
or death.
Wait at least 4 minutes after switching off before
touching any electrical parts.
These rules concern your safety
1. When repairs are undertaken the power supply to
the frequency converter must be disconnected.
2. The
“Stop/Reset” key on the keyboard of the
frequency converter does not disconnect the power
supply and may therefore not be used as a safety
switch.
3. The unit must be properly grounded, the user must
be protected against supply voltage and the motor
against overload according to national and local
codes.
4. The leakage currents to ground are higher than
3 mA.
5. The factory setting does
not incorporate protection
against motor overload. For this function parameter
315 is set to data value Trip [2] or data value
Warning [1]. Note: This function is initialised at
1.16 x rated motor current and rated motor
frequency (see page 63).
6. Do
not remove the motor and mains terminals,
when the unit is connected to the mains. Ensure
that the power supply has been switched off,
before you remove the motor and mains terminals.
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MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
Installation
Chapter 1 ■ Before you start ........................................... Page 6
■ Mechanical installation................................. Page 6
■ Electrical installation .................................... Page 6
■ EMC-correct installation .............................. Page 9
■ General.......................................................Page 9
■ Instructions for installation .......................... Page 9
■ For further information ............................... Page 11
■ Installation guide
VLT 2000 with built-in compact RFI filter ... Page 12
■ Technical data
VLT 2000 with built-in compact RFI-filter ... Page 12
MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
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Before you start
Read the safety rules on
pagepage
pagepage
page 4 before you start.
Mechanical installation
Item 1 Drilling template (enclosed in box)
For sizing and drilling of holes you can use the
enclosed Drilling Template.
Ensure min. 100 mm (10 cm) free air space
above and below the VLT frequency converter. This
also applies when a module has been mounted.
Make sure that the ambient temperature does not
exceed 40°C.
Item 2 Side by side mounting
VLT frequency converters can be mounted side by
side, without any space between them.
Item 3 Module
If you want to use a module (to be placed underneath)
you must take the physical dimensions into account.
Electrical installation
Item 1 Prefuses
Choose the right prefuses:
Mains supply 1 x 220/230/240 V
3 x 208/220/230/240 V
VLT 2010 Max. 10A
VLT 2015 Max. 16 A
VLT 2020 Max. 20 A
VLT 2030 Max. 20 A
VLT 2040 Max. 20 A
VLT 2050 Max. 25 A
See Special conditions: Cut-in current
That I have done
That I have done
Mains supply 3 x 380-460 V
VLT 2020 Max. 16 A
VLT 2025 Max. 16 A
VLT 2030 Max. 16 A
VLT 2040 Max. 16 A
VLT 2050 Max. 16 A
VLT 2060 Max. 20 A
Installation
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VLT® 2000 Series
Section 1 Section 2 Section 3
Electrical installation (continued)
Item 2 Extra protection
If you want extra protection, pay attention to the
following:
As extra protection, error voltage relays or neutral
grounding can be used. However, the installation
must comply with local health and safety standards.
An earth fault can introduce a direct current in the
discharge current. Any ELCB relay used must comply
with local regulations. The relays must be suitable to
protect three-phase equipment with bridge rectifier
and short discharge on power-up.
Item 3 Motor, mains and brake cables
To comply with the stated EMC emission
specifications, screened motor cable must
not be
used. However, a precondition is that an RFI filter
module is installed to comply with the EMC emission
specifications.
Observe the following max. cross sections for motor,
mains and brake cables:
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That I have done
Mains supply 1 x 220/230/240 V
3 x 208/220/230/240 V
VLT 2010 Max. 4 mm
2
VLT 2015 Max. 4 mm
2
VLT 2020 Max. 4 mm
2
VLT 2030 Max. 4 mm
2
VLT 2040 Max. 4 mm
2
VLT 2050 Max. 4 mm
2
Installation
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Cable relief fitting
195H6129
Option
Mains supply 3 x 380-460 V
VLT 2020 Max. 4 mm
2
VLT 2025 Max. 4 mm
2
VLT 2030 Max. 4 mm
2
VLT 2040 Max. 4 mm
2
VLT 2050 Max. 4 mm
2
VLT 2060 Max. 4 mm
2
MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
8
Electrical installation (continued)
Item 4 Control cables
The cables used for control cables must be
screened to comply with the stated EMC emission
specifications. Connect the screen from the control
cables to terminal 61 (ground).
Observe the following max. cross sections for control
cables:
That I have done
Mains supply 1 x 220/230/240 V
3 x 208/220/230/240 V
VLT 2010 Max. 1.5 mm
2
VLT 2015 Max. 1.5 mm
2
VLT 2020 Max. 1.5 mm
2
VLT 2030 Max. 1.5 mm
2
VLT 2040 Max. 1.5 mm
2
VLT 2050 Max. 1.5 mm
2
Mains supply 3 x 380-460 V
VLT 2020 Max. 1.5 mm
2
VLT 2025 Max. 1.5 mm
2
VLT 2030 Max. 1.5 mm
2
VLT 2040 Max. 1.5 mm
2
VLT 2050 Max. 1.5 mm
2
VLT 2060 Max. 1.5 mm
2
Installation
Cable relief fitting
195H6129
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MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
Installation
EMC correct installation
A number of factors must be considered in order to
achieve EMC correct installation of the VLT 2000
frequency converter.
General
The basic VLT 2000 units do not comply with any
EMC emission specifications, since no EMC filter (RFI
filter) is incorporated in the basic units.
Therefore it is necessary to install an
RFI and motor
filter module to comply with EMC emission
specifications.
VLT Series 2000 is available with built-in RFI filter that
fulfils the EMC emission requirements.
In addition to reducing the mains interference, the filters also reduce the interference radiating from the
unscreened motor cable. As far as the motor cable is
concerned, only interference above 30 MHz is
reduced (ref. EN 55011-1A).
To reduce the electromagnetic noise level from the total system as far as possible (frequency converter and
motor installation), it is important to make the motor
and brake cables as short as possible.
Cables having a sensitive noise level may not be led
together with motor and brake cables.
How to install
Units with RFI and motor filter module:
When the RFI and motor filter module is installed it is
recommended to use
unscreened motor cable, since
this gives the lowest electromagnetic noise level.
Control cable:
The control cable must be screened. The screen must
be installed under the screen clamp on the screen
termination bracket. Mounting with twisted screen
ends (Pigtails) should be avoided, as this will destroy
the screen effect at high frequencies.
Normally, the screen should also be connected to the
base of the controlling appliance (follow the
instructions for use of the appliance in question). In
connection with very long control cables and
analogue signals, 50 Hz ripple loops may occur in
rare cases, depending on the installation. This is
because of interference coupling from the mains
supply cables. In this connection it can be necessary
to break the screen or possible insert a 100nF condenser between screen and base.
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Cable for serial communication:
The cable for serial communication should be
screened. The screen should be installed using a
screen clamp on the VLT frequency converter (see the
instruction for installation, page 10, point B ).
Motor cable:
For the motor either screened or unscreened cable
can be used. In connection with installation of the RFI
and motor filter module it is recommended to use
unscreened motor cable. With screened motor cable,
the screen must be installed under the cable clamp
on the cable relief fitting. Mounting with twisted
screen ends (Pigtails) should be avoided as this will
destroy the screen effect at high frequences. In
principle the motor cable screen may not be
interrupted and it may not be earth connected. If it is
necessary to interrupt the screen to mount a motor
starter or motor relays, the screen must continue with
an impedance which is as low as possible.
The EMC emission specifications are complied with
by using up to 100 m of unscreened motor cable.
If screened cable is used the demand for conducted
noise (150 kHz - 30 MHz) cannot be observed.
Brake cable:
Screened cable must be used for the brake resistor.
The screen must be installed under the cable clamp
on the cable relief fitting. (See page 10 point E ).
Avoid using screen pigtails.
Use brake cable lengths of up to 5 m.
Sensitive signal cables:
Cables having a sensitive noise level may not be led
together with motor and brake cables.
Equalising currents:
Efforts should be made to avoid possible equalising
currents that may occur when the control cable
screen is connected to the base (earthed) at both
ends. Equalising currents occur because of voltage
differences between the VLT frequency converter
base and the base of the controlling appliance. They
can be avoided by making a tight fit with the cabinet
base rear plate, thereby ensuring that any equalising
currents will run via the base rear plates and their
joints, not via the cable screens.
MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
10
Installation
Three-phase mains connection
Single-phase mains connection
Between PC and VLT frequency converter
MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
VLT 2010-2030, 1/3 x 208-240 V and VLT 20202060* 3 x 380-460 V with RFI and motor filter
module or LC and RFI filter module:
If VLT frequency converters are mounted on an
electrically conductive, metal rear plate, good
electrical connection between the VLT and the rear
plate is to be ensured (use earth screw (item A in
the drawing)).
If the VLT frequency converter is mounted on a nonconductive rear plate, it is to be ensured that there is
good grounding to the earth screw (item A in the
drawing).
For further information
When you have finished installing the VLT frequency
converter, see the section
After installation for infor-
mation about how to operate the VLT frequency
converter. You will also get information about what
parameters to choose to ensure optimum operation.
*) VLT 2060 Max. 415 V
Installation
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MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
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Following this installation guide the VLT® 2000 units
with built-in compact RFI filter comply with the EMC
requirements according to EN 55011 group 1A.
Technical data
The technical data on this page only apply to VLT
®
2010, 0.37 kW, VLT® 2015, 0.55 kW and VLT
®
2020,0.75 kW.with built in compact RFI filter.
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Cable type: Screened
Max. length: 20 m
Mains supply: 1 x 220-240 V
Installation guide
Clamp to secure cables and cable screen type
195H6129 is delivered with the above units.
Mains supply connection:Mains supply connection:
Mains supply connection:Mains supply connection:
Mains supply connection:
Cable is secured in cable relief fitting.
Earth wire is secured in the earth screw on the
frequency converter.
Motor cable connection:Motor cable connection:
Motor cable connection:Motor cable connection:
Motor cable connection:
Motor cable and screen is secured in cable relief fitting
and the wires are connected in the motor plug.
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Installation
MG.20.B6.02 – VLT is a registered Danfoss trademark
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VLT® 2000 Series
Section 1 Section 2 Section 3
After installation
Chapter 1 ■ Quick Setup,
If you are familiar with a VLT ...................... Page 14
■ Quick Setup,
If you are not familiar with a VLT ................ Page 14
■ A simple connection example .................... Page 14
■ How to program ........................................ Page 15
■ Survey of terminals .................................... Page 16
■ Description of connection terminals............ Page 16
■ How to check connection of
control cables ............................................. Page 17
■ Prefuses .................................................... Page 17
■ Cables ....................................................... Page 17
■ Check grounding ....................................... Page 17
■ Commissioning and testing ....................... Page 18
■ Basic settings ............................................ Page 18
MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
14
Quick Setup
If you are familiar with a VLT
If you know the VLT and how to move round in the
menus and parameters, you can go directly to steps
1-9 overleaf to get started.
Quick Set
If you are not familiar with a VLT
If you have never operated a VLT frequency converter
before, you can learn it on the basis of the
instructions on page 15.
Connection example
■
A simple connection example
In the figure below you can see a simple connection
example based on the Quick Setup programming
overleaf.
After installation
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VLT® 2000 Series
Section 1 Section 2 Section 3
How to program
The Quick Setup shown is based on the assumption
that you want your VLT to operate with the following
setup:
1. External start/stop
2. Potentiometer connected for external speed control
3. Option to change rotation direction
4. Option to select a fixed speed (Jog)
If you use a brake module, you must program
one parameter more, and two more if you
want local operation via the display keys.
This will appear from the two tables at the bottom.
To store the data press the “menu” key!
When you have connected your VLT, as described on
the previous page, you must program a few parameeters.
Perform steps 1-9 for Quick Setup.
After installation
Standard motor with constant torque load without brake module on the frequency converter
Step Parameter Designation Settings Display indication
1 000 Language Choose English ENGLISH
2 103 Motor power Read motor plate
3 104 Motor voltage Read motor plate
4 105 Motor frequency Read motor plate
5 201 Min. frequency Set wanted frequency
6 202 Max. frequency Set wanted frequency
7 215 Ramp up 1 Set wanted ramping time
8 216 Ramp down 1 Set wanted ramping time
9 Start This is done by supplying terminals 18 and 27
the frequency with 24 V DC from the frequency converter’s terminal 12
converter or by using an external 24 V DC voltage
If a brake module is mounted, make the following settings
Step Parameter Designation Settings Display indication
1 300 Brake function If a brake module is used, choose Applied APPLIED
2 Start This is done by supplying terminals 18 and 27
the frequency with 24 V DC from the frequency converter’s terminal 12,
converter or by using an external 24 V DC voltage
If you want local operation and start, make the following settings
Step Parameter Designation Settings Display indication
1 003 Operation site Choose Local LOCAL
2 004 Local reference Record wanted output frequency by means
of the “+” and “−” keys
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MG.20.B6.02 – VLT is a registered Danfoss trademark
VLT® 2000 Series
16
Survey of terminals
Below you will see a survey of all the terminals of a
VLT frequency converter (3 x 380-460 V).
After installation
Description of connection terminals
Terminal 12: Internal voltage supply
24 V DC activates digital inputs such as Start/stop,
Jog or Quick stop.
Terminal 18: Start/stop (Digital input)
When 24 V DC is applied the motor starts
on condit-
ion that
− digital input 27 (Quick stop) is connected
to 24 V DC.
− you have made no local stop command
(“Stop/reset” key).
− f
Max
is > 0 Hz.
− a reference signal has been given (see para. 402).
Terminal 19: Reversing (Digital input)
When 24 V DC is applied to terminal 19, the motor
starts reversing, either at once or after a stop command. If you have chosen pulse start in para. 402
(terminal 18), the start reversing function of para.
403 is automatically a pulse-activated function.
Terminal 20: Digital common
This terminal is the reference for all digital signals,
including bus.
Terminal 27: Stop (Digital input)
When you apply 0 V you can give different stop signals. See also para. 404.
Terminal 29: Jogging (Digital input)
This terminal allows you to activate a fixed
preprogrammed speed. See para. 405.
Terminal 46: Output
Using parameter 408 you can choose between
different output signals. The output is an open collector
output, and a pull-up resistor of min. 600 ohm must
therefore be connected to terminal 12 (+24 V).
Terminal 50: Internal voltage supply
With 10 V DC voltage you can set an analogue
control signal using a 1 kohm potentiometer with terminal 55 as reference.
Terminal 53: Analogue control voltage
Using parameter 412 you can choose between 0 +10 V DC or +10 - 0 V DC analogue voltage. The terminal is used together with terminals 50 and 55. The
voltage value determines the output frequency and
thus also the speed of the motor.
Terminal 55: Analogue common
Is used together with terminals 50 and 53 or together
with terminal 60.
Terminal 60: Analogue control current
Using parameter 413 you can choose between four
different input signals:
0-20 mA, 4-20 mA, 20-0 mA or 20-4 mA.
The current value determines the output frequency.
Terminal 61: Not used
Terminals 71-72: RS 232 port
Connect the terminals to a PC, if you want to control
the VLT frequency converter via PC software. Terminal
20 acts as digital common.
Terminals 81-82: Brake resistor
By means of these terminals you can connect the
brake resistor on units with brake function.
Note the live voltage 550 V DC.
The control signals and the terminals for the brake
module are described at the bottom of this page.
Mains Motor
Br.
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VLT® 2000 Series
Section 1 Section 2 Section 3
How to check connection of control cables
The VLT frequency converter must be connected so
that it is possible to control it via the different signal
inputs at the top of the enclosure.
Terminals 01-03: Relay output Max. 250 V, max. 2 A. Relay: Not activated
Terminal 12: Supply to digital inputs 24 V DC, max. 140 mA
Terminals 18-19: Digital inputs 0-24 V, Ri=2 kohm (max. 37 V for 10 sec.)
27-29 (min. on-time 80 ms.)
Terminal 46: Digital output signal (open collector) Max. 24 V DC, max. 40 mA, min. 600 ohm
Terminal 50: Supply to 1 kohm potentiometer 10 V DC, max. 12 mA
Terminal 53 Analogue control voltage +0 - 10 V DC, Ri=10 kohm, +10 - 0 V
Terminal 60: Analogue control current 0/4-20 mA, Ri=226 ohm, 20-0/4 mA
Terminals 71/72: RS 232 standard bus 71 RXD, 72 TXD, 20 dig. ref.
Terminals 81/82: Used in connection with brake resistor
Terminal 20: Digital common Must be used as reference for all digital
signals
Terminal 55: Analogue common Must be used as reference for all analogue
signals.
Prefuses
Prefuses must be installed in the mains supply to the
frequency converter.
Cables
The cables to control signals and brake resistor must
be screened. It is recommended to use unscreened
motor cable.
Motor/mains cables (max. cable cross-section)
Mains supply 1/ 3 x 208/220/230/240 V Mains supply 3 x 380-460 V
2010 2015 2020 2030 2040 2050 2020 2025 2030 2040 2050 2060*
4 mm2 for all VLT 2000 Series types 4 mm2 for all VLT 2000 Series types
Control cables (max. cable cross-section)
Mains supply 1/ 3 x 208//220/230/240 V Mains supply 3 x 380-460 V
2010 2015 2020 2030 2040 2050 2020 2025 2030 2040 2050 2060*
1.5 mm2 for all VLT 2000 Series types 1.5 mm2 for all VLT 2000 Series types
How to check the grounding
The grounded line must be connected to terminal 94
(PE). If you use a thick cable this must be connected
to the 6 mm large screw (terminal 95) in the bottom of
the VLT frequency converter.
If you use screened cables, the screen must be connected to the screen termination bracket of the VLT
frequency converter and brake resistor.
(Max. sizes)(Max. sizes)
(Max. sizes)(Max. sizes)
(Max. sizes)
Mains supply 1/3 x 208/220/230/240 V Mains supply 3 x 380-460 V
2010 2015 2020 2030 2040 2050 2020 2025 2030 2040 2050 2060*
10 A 16 A 20 A 20 A 20 A 25 A 16 A 16 A 16 A 16 A 16 A 20 A
After installation
*) VLT 2060: Max. 415V
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VLT® 2000 Series
18
c) Make a quick stop by means of disconnecting
between terminal 27 and terminal 12.
Example of display indication:
During the simulation you can see that the VLT
frequency converter reacts by watching the
display indications.
If no external control has been
connected, you can choose to simulate
the function of the VLT frequency converter
locally via the keyboard. See description at
the bottom of page 31.
5. Press the “Stop” key to stop the VLT frequency
converter
before you connect the motor.
6. Test the whole system (repeat steps 4 and 5) with
the motor connected to check the direction of
rotation.
Commissioning and testing
When the VLT frequency converter has been connected to
control signals, you may want to test the system.
This following test is not suitable if you use the built-in
PI controller.
1. Disconnect the motor from the VLT frequency
converter.
2. Connect the VLT frequency converter to the mains.
3. Make the necessary settings such as min./max.
frequency and connect the necessary control
signals, possibly via PLC.
As a minimum you must set the parameters
and connect the control signals as described
in chapter 1, Quick Setup.
4. Make a simulation without motor:
a) Give a start signal via a contact to terminal 18.
Example of display indication:
b) The speed (frequency) can be changed by
means of the potentiometer connected.
Example of display indication:
After installation
00,0 Hz
FREQUENCY
STOP 1
23,7 Hz
FREQUENCY ➜
FUNCTION OK 1
30,0 Hz
FREQUENCY ➜
FUNCTION OK 1
Basic settings
The VLT frequency converter has been preset from
the factory so that normally it will function after a few
data values are recorded/changed.
See Quick Setup on page 15.
The factory settings of the VLT frequency
converter are listed on page
105.
.
.
.
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VLT® 2000 Series
Section 1 Section 2 Section 3
Chapter 1 ■ How the VLT works ................................... Page 21
Technology
Chapter 2 ■ How to size your VLT ................................. Page 29
Product range, sizing, technical data
Chapter 3 ■ How to install your VLT .............................. Page 41
The connection terminals, dimensions,
mechanical installation, electrical installation,
and motor connection
Chapter 4 ■ How to operate your VLT ........................... Page 45
The control panel and
the structure of the menus
Chapter 5 ■ The control possibilities of the VLT ............. Page 51
The menu groups and
the various parameters
Chapter 6Chapter 6
Chapter 6Chapter 6
Chapter 6 ■ Description of parameters ......................... Page 59
Chapter 7 ■ Display messages ..................................... Page 81
Status, alarm and warning and
reset messages
Chapter 8 ■ Special conditions ..................................... Page 85
CE-labelling
EMC, extreme operational conditions,
electrical noise, air humidity, efficiency and
du/dt measurements
Chapter 9 ■ Factory settings and service ...................... Page 97
Factory settings and fault location
Form to note down the VLT
parameter settings
Chapter 10 ■ Subject index .......................................... Page 107
Contents
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VLT® 2000 Series
Section 1 Section 2 Section 3
Chapter 1 ■ How the VLT is built up .............................. Page 22
■ The Danfoss VVC principle ........................ Page 23
■ Factory-programmed optimization............. Page 24
■ Control accuracy ....................................... Page 25
■ Protection against mains disturbance........ Page 25
■ Galvanic isolation....................................... Page 25
■ Advanced motor protection ....................... Page 25
■ Long motor cables .................................... Page 25
■ Functional diagrams .................................. Page 26
How the VLT works
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VLT® 2000 Series
22
Saved energy
Energy is saved when the motor runs at a speed
which is continually matched to the momentary
requirement. An example is a pump and ventilating
plant, where a frequency converter can reduce energy
consumption by the cube of the speed.
Improved process
Matching the speed to the production process has
several advantages: an increase in production and a
decrease in the consumption of materials and the
scrapping rate.
Improved quality
The number of starts and stops is reduced. This avoids
unnecessarily hard treatment of machine parts.
Less maintenance
The frequency converter requires no maintenance.
In water supply plants there are no pressure surges
which might damage the water pipes.
1. Mains supply
1 × 220/230/240 V AC, 50/60 Hz
3 × 208/220/230/240 V AC, 50/60 Hz
3 × 380/400/415/440/460 V AC, 50/60 Hz
2. Rectifier
Three-phase rectifier bridge rectifies AC to DC.
3. Intermediate circuit
DC voltage = √2 × supply voltage
4. Coils in the intermediate circuit
(not all VLT 2000 units)
Smoothen DC voltage and limit mains
supply interference (mains harmonics).
5. Capacitors in the intermediate circuit
Smoothen the voltage of the intermediate circuit
(energy store).
6. Inverter
Converts DC voltage to variable a.c.voltage and
variable frequency.
7. Motor coils (as module)
Advantages of motor coils:
− You can use long motor cables.
− Unlimited switching at the output of
the frequency converter (trip may occur).
8. Output
Variable a.c. voltage,10-100% of the supply voltage.
Variable frequency: 0-120/0-500 Hz.
9. Control card
The integrated computer controls the inverter, which
generates the pulse pattern by means of which DC
voltage is converted to variable a.c. voltage and
variable frequency.
How the VLT works
How the VLT is built up
A frequency converter is an electronic unit for infinite
speed control of a.c. motors. The frequency converter
controls the motor speed by converting the fixed voltage and frequency of the supply mains, e.g. 400 V/
50 Hz, to variable values. The frequency converter
does this by rectifying a.c. voltage to DCvoltage and
converting this to a.c. voltage with variable amplitude
and frequency.
The variable voltage and frequency supplying the motor
make infinite speed control of standard three-phase,
asynchronous motors possible.Today the a.c. motor
controlled by a frequency converter is a natural part of
all automised plants. Apart from utitilizing the good features of the a.c. motor, the infinite speed control gives
the user a multitude of additional advantages:
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VLT® 2000 Series
Section 1 Section 2 Section 3
The Danfoss VVC principle
VLT 2000 Series frequency converters use an inverter
control system known as the Voltage Vector Control
(VVC) developed by Danfoss.
The VVC principle is superior to the traditional PWM
(Pulse Width Modulation) principle used in most
modern frequency converters in the following ways:
− Full-rated motor voltage at rated motor frequency.
− Near perfect resemblance to the sinusoidal
mains supply.
− Extremely low switching losses, resulting in high
converter efficiency.
The features are obtained through a special switching
pattern: the switching intervals are very short, which
means high switching frequency, and the six
semiconductors of the inverter section are alternately
held inactive in pairs, throughout a 60° sine period.
The current wave form of the motor current closely
resembles that obtained on mains operation. The
switching pause in 60° of the sine period also means
that full-rated motor voltage can be obtained - and
inverter switching losses are reduced by about
one third.
The figures below show the switching pattern and
maximum motor voltage according to the VVC
principle and the traditional PWM principle
respectively.
The full-rated motor voltage and the perfect current
wave form mean that the Danfoss VLT 2000 Series
allows full motor performance without any derating just like running the motor on the mains.
Motor voltage and simplified switching pattern according to the Danfoss VVC principle
Motor voltage and simplified switching pattern according to the traditional PWM principle
0,50
0,00
1,00
-0,50
-1.00
0 60 120 180 300 360240
U-V U-W W-U
U-V V-W W-U
0,50
0,00
1,00
-0,50
-1.00
0 60 120 180 300 360240
0,866
U-V V-W W-U
Switching pattern for phase U
Single phase voltage
Phase-phase voltage
for motor
How the VLT works
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VLT® 2000 Series
24
How the VLT works
Factory-programmed optimization
VLT Series 2000 has dynamic adaptation of the
motor voltage and frequency. This ensures
correct magnetisation of the motor, thus
providing optimum dynamics, accuracy or efficiency.
VLT has been designed for operation of the most
common types of motors and loads.
Once parameters 103,104, 105, 107 and 108 have
been set according to the motor type plate, your
motor operation will be optimum in most cases.
Individual adaptation of VLT and motor is done via
parameters 109-112.
Start voltage
increases the motor voltage at a given frequency. This
increases the motor magnetization. The motor can yield
a higher torque, but the disadvantage is that the motor
losses are increased too. The result is a higher motor
temperature. Excessive start voltage can cause a trip
(cut-out).
Start compensation
changes the motor voltage as a function of the load.
The voltage will increase with higher motor current.
Over-compensation will overheat the motor and give
the risk of instability and can cause trip (cut-out). As
the name indicates, the function is most effective at
low motor speed.
U/f ratio
This describes the pre-programmed U/f characteristics
which indicate the relation between motor voltage (U)
and frequency (f).
The U/f ratio can be adjusted to ensure correct
excitation of the motor, thereby helping to
obtain optimal dynamism, accuracy or efficiency.
Slip compensation
adds both frequency and voltage and compensates for
the varying slip at varying load so that the motor speed
is kept constant at varying load. Over-compensation
may make the speed increase at increasing load. This
means motor overload and risk of unstable motor
operation.
Constant torque CT
Par. 104 = Rated motor voltage
Par. 105 = Rated motor frequency
Par. 107 = Rated motor current
Par. 108 = Motor no-load current
Par. 109 = Start voltage
Par. 110 = Start compensation
Par. 111 = U/f ratio
Par. 112 = Slip compensation
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25
VLT® 2000 Series
Section 1 Section 2 Section 3
How the VLT works
Control accuracy
Basically we distinguish between open loop and
closed loop control.When the control is an open loop
type the motor current acts as process feedback. The
final result is therefore highly dependent on the
characteristics of the motor.
Note that large motors give a better result than small
motors.
Open loop (depending on motor size) ±2.0 % 3-100 Hz (10-90% of max. torque)
PI (closed loop) ±0.5% 1.2-100 Hz (-90 - +90% of max. torque)
A closed loop control incorporates a direct process
feedback, which substantially improves the control
accuracy.
The stated maximum torque follows the power hyperbola in the frequency range across the motor’s rated
frequency.
Galvanic isolation
With the VLT 2000 Series safety isolation is standard,
as the high-voltage parts of the power section are
galvanically isolated from the low-voltage parts of the
control section according to VDE 0160/0106 (PELV).
Therefore PCs and the like will not be disturbed.
Advanced motor protection
The VLT 2000 Series has a built-in electronic thermal
motor protection. The frequency converter calculates
the motor temperature on the basis of voltage,
current, frequency and time.
The thermal motor protection is comparable with a
thermal relay in the motor cables. Therefore it is
superior to the traditional bi-metallic protection, where
the altered cooling conditions due to the speed
control are not taken into consideration.
Long motor cables
For the VLT 2000 Series motor coils in an IP 00 or IP
10 enclosure are available as modules.
This makes it possible to install a long cable between
motor and frequency converter.
Motor coils are also included in the RFI and motor
filter module in IP 20 enclosure. See page 34 for a
speciffication of maximum cable length.
Programmable control inputs and
signal outputs in 2 setups
The digital technique used in the VLT 2000 Series
makes it possible to redefine the different control
inputs and signal outputs and to program 2 different
user defined setups.
It is easy for the user to program the required
functions on the keyboard of the VLT 2000 Series or
via the RS 232 user interface.
Protection against mains disturbance
The VLT 2000 Series is protected against transients
arising on the mains, e.g. when you switch in power
factor phase-correction capacitors or when the
supply is subject to lightning strikes.
Adequate motor voltage and full torque can be maintained down to 10% under-voltage on the supply
mains.
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VLT® 2000 Series
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How the VLT works
Functional diagram VLT 2010-2030 single-phase/three-phase 208-240 V
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VLT® 2000 Series
Section 1 Section 2 Section 3
Function diagram VLT 2040-2050, 3-phase 208-240 V
How the VLT works
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VLT® 2000 Series
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How the VLT works
Functional diagram VLT 2020-2060 three-phase 380-460 V
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29
VLT® 2000 Series
Section 1 Section 2 Section 3
Chapter 2 ■ Selection of frequency converter ............... Page 30
Sizing ....................................................... Page 30
■ Product range ........................................... Page 31
■ Brake function ........................................... Page 33
■ Motor coils (module) .................................. Page 34
■ RFI and motor filter (module) ..................... Page
34
■ LC and RFI filter (module) .......................... Page 34
■ Dimensions ............................................... Page 35
■ Technical data ........................................... Page 38
How to size your VLT
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VLT® 2000 Series
30
How to size your VLT
Selection of frequency converter
Usually the size of frequency converter is chosen on
the basis of the shaft output, as this may be the only
value known. However, if the data are known for both
the application, the motor and the frequency converter,
it is recommended to make a more accurate sizing.
The values must be based on the rated motor speed.
VLT 2000 only operates according to the CT
(constant torque) characteristic
Sizing when you know the motor current
Exercise
Conveyor plant with a 1.1 kW, 3 × 380 V motor. At
continuous operation the motor current is 2.5 A
( 3 × 415 V).
Solution
From the table on the next page you can see that a
VLT type 2025 can yield 2.8 A at continuous operation. The right solution is therefore VLT 2025.
Sizing on the basis of the apparent power S
M
[kVA] consumed by the motor
Exercise
A motor must yield constant torque at continous
operation. Usually the necessary values will appear
from the motor plate or from the motor catalogue.
Solution
From the table on the next page you can see that VLT
type 2025 can yield 2.0 kVA (415 V) at continuous
operation. The solution is therefore VLT type 2025.
Read values
Motor current = 2.5 A (3 × 415 V)
s
M
=
U × I × √3
[kVA]
1000
=
415 × 2.5 × √3
[kVA]
1000
= 1.8 kVA
Sizing on the basis of the power requirement
P
VLT
[kW] of the motor
Exercise
A machine tool is driven by a 3 kW motor. The power
requirement is indicated to be 2.4 kW. The motor
efficiency η is 0.80, cos ϕ = 0.81 and the motor voltage is 3 x 415 V.
η and cos ϕ are measured at 3 kW output. We
estimate η and cos ϕ to be approximately the same
at 80 % load.
Solution
From the table on the next page you can see that VLT
type 2040 can yield 4.0 kVA (415 V) at continuous
operation. The right solution is therefore VLT type 2040.
S
VLT
=
P
m
η × cos ϕ
=
2.4 kW
0.80 × 0.81
= 3.7 kVA
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