Danfoss VLT 380-500 V, VLT 525-690 V Design Manual

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ENGINEERING TOMORROW

Design Guide

VLT® Parallel Drive Modules

250–1200 kW

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Approvals and Certications

4 Product Overview

4.1 Datasheet for Drive Module

4.2 Datasheet for 2-drive System

4.3 Datasheet for 4-drive System

4.4 Internal Components

4.5 Back-channel Cooling Examples

5 Product Features

5.1 Automated Functions

5.2 Programmable Functions

5.3 Safe Torque O (STO)

5.4 System Monitoring

6 Specications

6.1 Drive Module Dimensions

6.2 Control Shelf Dimensions

6.3 2-drive System Dimensions

6.4 4-drive System Dimensions

6.5 Power-dependent Specications

6.6 Mains Supply to Drive Module

6.7 Motor Output and Motor Data

6.8 12-Pulse Transformer Specications

6.9 Ambient Conditions for Drive Modules

6.10 Cable Specications

6.11 Control Input/Output and Control Data

6.12 Derating Specications

7 Ordering Information

7.1 Ordering Form

7.2 Drive Congurator

Contents

VLT® Parallel Drive Modules

7.3 Options and Accessories

7.4 System Design Checklist

8 Considerations During Installation

8.1 Operating Environment

8.2 Minimum System Requirements

8.3 Electrical Requirements for Certications and Approvals

8.4 Fuses and Circuit Breakers

9 EMC and Harmonics

9.1 General Aspects of EMC Emissions

9.2 EMC Test Results

9.3 Emission Requirements

9.4 Immunity Requirements

9.5 EMC Recommendations

9.6 General Aspects of Harmonics

9.7 Harmonics Analysis

9.8 Eect of Harmonics in a Power Distribution System

100

101

9.9 IEC Harmonics Standards

9.10 IEEE Harmonics Standards

9.11 VLT® Parallel Drive Modules Harmonics Compliance

9.12 Galvanic Isolation

10 Motor

10.1 Motor Cables

10.2 Motor Coil Insulation

10.3 Motor Bearing Currents

10.4 Motor Thermal Protection

10.5 Motor Terminal Connections

10.6 Extreme Running Conditions

10.7 dU/dt Conditions

10.8 Parallel Connection of Motors

11 Mains

11.1 Mains Congurations

11.2 Mains Terminal Connections

102

103

104

105

106

108

112

113

115

11.3 12-pulse Disconnector Conguration

12 Control Wiring

12.1 Control Cable Routing

12.2 Control Terminals

12.3 Relay Output

115

118

119

122

Contents Design Guide

13 Braking

13.1 Types of Braking

13.2 Brake Resistor

14 Controls

14.1 Overview of Speed and Torque Control

14.2 Control Principle

14.3 Control Structure in VVC+ Advanced Vector Control

14.4 Control Structure in Flux Sensorless

14.5 Control Structure in Flux with Motor Feedback

14.6 Internal Current Control in VVC

14.7 Local and Remote Control

14.8 Smart Logic Controller

15 Handling of References

15.1 Reference Limits

15.2 Scaling of Preset References

15.3 Scaling of Analog and Pulse References, and Feedback

123

128

131

132

133

134

136

137

138

15.4 Dead Band Around Zero

16 PID Controls

16.1 Speed PID Controls

16.2 Process PID Controls

16.3 Optimization of PID Controls

17 Application Examples

17.1 Automatic Motor Adaptation (AMA)

17.2 Analog Speed Reference

17.3 Start/Stop

17.4 External Alarm Reset

17.5 Speed Reference with Manual Potentiometer

17.6 Speed Up/Down

17.7 RS485 Network Connection

17.8 Motor Thermistor

17.9 Relay Set-up with Smart Logic Control

17.10 Mechanical Brake Control

139

143

146

150

152

153

154

155

156

157

17.11 Encoder Connection

17.12 Encoder Direction

17.13 Closed-loop Drive System

17.14 Programming of Torque Limit and Stop

157

158

Contents

VLT® Parallel Drive Modules

18 Appendix

18.1 Disclaimer

18.2 Conventions

18.3 Glossary

Index

159

160

163

Introduction Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide is intended for project and systems engineers, design consultants, and application and product specialists. Technical information is provided to understand the capabilities of the frequency converter for integration into motor control and monitoring systems. Details concerning operation, requirements, and recommendations for system integration are described. Information is provided for input power characteristics, output for motor control, and ambient operating conditions for the frequency converter.

Also included are safety features, fault condition monitoring, operational status reporting, serial communication capabilities, and programmable options. Design details such as site requirements, cables, fuses, control wiring, the size and weight of units, and other critical information necessary to plan for system integration is also provided.

Reviewing the detailed product information in the design stage enables developing a well-conceived system with optimal functionality and

eciency.

The VLT® Frequency Converters – Safe Torque O

•

Operating Guide contains safety guidelines and describes the operation and specications of the Safe Torque O function.

The VLT ® Brake Resistor MCE 101 Design Guide

•

describes how to select the proper brake resistor for any application.

The VLT ® FC-Series Output Filter Design Guide

•

describes how to select the proper output lter for any application.

The VLT® Parallel Drive Modules Busbar Kit Instal-

•

lation Instructions contain detailed information about installing the busbar option kit.

The VLT® Parallel Drive Modules Duct Kit Instal-

•

lation Instructions contain detailed information about installing the duct option kit.

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/knowledge-center/ technical-documentation/ for listings.

1 1

VLT® is a registered trademark.

Additional Resources

1.2

Resources available to understand advanced frequency converter functions and programming:

The VLT® Parallel Drive Modules 250–1200 kW

•

Installation Guide provides instructions for mechanical and electrical installation of these drive modules.

The VLT® Parallel Drive Modules 250–1200 kW User

•

Guide contains detailed procedures for start-up, basic operational programming, and functional testing. Additional information describes the user interface, application examples, troubleshooting, and specications.

Refer to the FC 102, FC 202, or FC 302 VLT ® Drive

•

Programming Guide applicable to the particular

series of VLT® Parallel Drive Modules used in creating the drive system. The programming guide describes in greater detail how to work with parameters and provides application examples.

The VLT ® FC Series, D-frame Service Manual

•

contains detailed service information, including

information applicable to the VLT® Parallel Drive Modules.

Safety

VLT® Parallel Drive Modules

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

2.2 Qualied Personnel

WARNING

DISCHARGE TIME

The drive module contains DC-link capacitors. Once mains power has been applied to the drive, these capacitors can remain charged even after the power has been removed. High voltage can be present even when the warning indicator lights are o. Failure to wait 20 minutes after power has been removed before performing service or repair work can result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

3. Disconnect or lock the PM motor.

4. Wait 20 minutes for the capacitors to discharge fully before performing any service or repair work.

Correct and reliable transport, storage, and installation are required for the trouble-free and safe operation of the

VLT® Parallel Drive Modules. Only qualied personnel are allowed to install this equipment.

Qualied personnel are dened as trained sta, who are authorized to install equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

Safety Precautions

2.3

WARNING

HIGH VOLTAGE

The drive system contains high voltage when connected to AC mains input. Failure to ensure that only qualied personnel install the drive system can result in death or serious injury.

WARNING

LEAKAGE CURRENT HAZARD (>3.5 mA)

Leakage currents exceed 3.5 mA. Failure to ground the drive system properly can result in death or serious injury. Follow national and local codes regarding protective earthing of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This switching generates a leakage current in the ground connection. A fault current in the drive system at the output power terminals sometimes contain a DC component, which can charge the lter capacitors and cause a transient ground current. The ground leakage current depends on various system congurations including RFI ltering, shielded motor cables, and drive system power. If the leakage current exceeds 3.5 mA, EN/IEC 61800-5-1 (Power Drive System Product Standard) requires special care.

Grounding must be reinforced in 1 of the following ways:

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

Ground wire of at least 10 mm2 (6 AWG).

•

Two separate ground wires, both complying

•

with the dimensioning rules.

See EN 60364-5-54 § 543.7 for further information.

Approvals and Certication... Design Guide

3 Approvals and Certications

Frequency converters are designed in compliance with the directives described in this section.

Table 3.1 Approvals

3.1 CE Mark

The CE mark (Communauté européenne) indicates that the product manufacturer conforms to all applicable EU directives. The EU directives applicable to the design and manufacture of frequency converters are the Low Voltage Directive, the EMC Directive, and (for units with an integrated safety function) the Machinery Directive.

The CE mark is intended to eliminate technical barriers to free trade between the EC and EFTA states inside the ECU. The CE mark does not regulate the quality of the product. Technical specications cannot be deduced from the CE mark.

A frequency converter can be used as standalone device or as part of a more complex installation. Devices used as standalone or as part of a system must bear the CE mark. Systems must not be CE marked but must comply with the basic protection requirements of the EMC directive.

3.4 Machinery Directive

Frequency converters are components subject to the Low Voltage Directive, however frequency converters with an integrated safety function must comply with the Machinery Directive 2006/42/EC. Frequency converters without safety function do not fall under the Machinery Directive. If a frequency converter is integrated into machinery system, Danfoss provides information on safety aspects relating to the frequency converter.

Machinery Directive 2006/42/EC covers a machine consisting of an aggregate of interconnected components or devices of which at least 1 is capable of mechanical movement. The directive mandates that the equipment design must ensure the safety and health of people and livestock are not endangered and the preservation of material worth so long as the equipment is properly installed, maintained, and used as intended.

classied as electronic

3 3

Low Voltage Directive

3.2

Frequency converters are classied as electronic components and must be CE labeled in accordance with the 2014/35/EU Low Voltage Directive. The directive applies to all electrical equipment in the 50–1000 V AC and the 75–1600 V DC voltage ranges.

The directive mandates that the equipment design must ensure the safety and health of people and livestock are not endangered and the preservation of material worth so long as the equipment is properly installed, maintained, and used as intended. Danfoss CE-labels comply with the Low Voltage Directive and provide a declaration of conformity on request.

EMC Directive

3.3

Electromagnetic compatibility (EMC) means that electromagnetic interference between apparatus does not hinder their performance. The basic protection requirement of the EMC Directive 2014/30/EU states that devices that generate electromagnetic interference (EMI) or whose operation could be aected by EMI must be designed to limit the generation of electromagnetic interference and shall have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

When frequency converters are used in machines with at least 1 moving part, the machine manufacturer must provide declaration stating compliance with all relevant statutes and safety measures. Danfoss CE-labels comply with the Machinery Directive for frequency converters with an integrated safety function and provide a declaration of conformity on request.

UL Compliance

3.5

To ensure that the frequency converter meets the UL safety requirements, see chapter 8.3 Electrical Requirements for Certications and Approvals.

RCM Mark Compliance

3.6

The RCM Mark label indicates compliance with the applicable technical standards for Electromagnetic Compatibility (EMC). An RCM Mark label is required for placing electrical and electronic devices on the market in Australia and New Zealand. The RCM Mark regulatory arrangements only deal with conducted and radiated emission. For frequency converters, the emission limits specied in EN/IEC 61800-3 apply. A declaration of conformity can be provided on request.

Approvals and Certication...

VLT® Parallel Drive Modules

3.7 Export Control Regulations

Frequency converters can be subject to regional and/or national export control regulations.

An ECCN number is used to classify all frequency

converters that are subject to export control regulations.

The ECCN number is provided in the documents accompanying the frequency converter.

In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations.

130BF015.10

(1.6)

1122 (44.2)

1048

(41.3)

346 (13.6)

376 (14.8)

Product Overview Design Guide

4 Product Overview

4.1 Datasheet for Drive Module

Power rating for 380–500 V

•

- HO: 160–250 kW (250–350 hp).

Power rating for 525–690 V

•

- HO: 160–250 kW (200–350 hp).

Weight

•

Protection rating

•

- 125 kg (275 lb).

4 4

- IP 00.

- NEMA Type 00.

Illustration 4.1 Drive Module Dimensions

Available Danfoss options

2-drive module system

•

4-drive module system

•

130BF016.10

2260

(89.0)

2201

(86.7)

808 (31.8) 636 (25.0)

(2.3)

Product Overview

4.2 Datasheet for 2-drive System

VLT® Parallel Drive Modules

Power rating for 380–500 V

•

- HO: 250–450 kW (350–600 hp).

- NO: 315–500 kW (450–600 hp).

Power rating for 525–690 V

•

- HO: 250–560 kW (300–600 hp).

- NO: 315–630 kW (350–650 hp).

Weight

•

Protection rating

•

- 450 kg (992 lb).

- IP54 (shown). IP rating determined by

customer requirement.

- NEMA Type 12 (shown).

Illustration 4.2 2-drive System with Minimum Cabinet Dimensions

Available Danfoss options

6-pulse busbar kit

•

12-pulse busbar kit

•

In-back/out-back cooling kit

•

In-back/out-top cooling kit

•

In-bottom/out-back cooling kit

•

In-bottom/out-top cooling kit

•

130BF017.10

636 (25.0)

2201

(86.7)

805 (31.7)

749 (29.5)

1608 (63.3)

(2.3)

(2.0)

2254

(88.7)

Product Overview Design Guide

4.3 Datasheet for 4-drive System

Power rating for 380–500 V

•

- HO: 500–800 kW (650–1200 hp).

- NO: 560–1000 kW (750–1350 hp).

Power rating for 525–690 V

•

- HO: 630–1000 kW (650–1150 hp).

- NO: 710–1200 kW (750–1350 hp).

Weight

•

Protection rating

•

- 910 kg (2000 lb).

- IP54 (shown). IP rating determined by

customer requirement.

- NEMA Type 12 (shown).

4 4

Illustration 4.3 4-drive System with Minimum Cabinet Dimensions

Available Danfoss options

6-pulse busbar kit

•

12-pulse busbar kit

•

In-back/out-back cooling kit

•

In-back/out-top cooling kit

•

In-bottom/out-back cooling kit

•

In-bottom/out-top cooling kit

•

Product Overview

VLT® Parallel Drive Modules

4.4 Internal Components

The drive system is designed by the installer to meet specied power requirements, using the VLT® Parallel Drive Modules basic kit and any selected options kits. The basic kit consists of connecting hardware and either 2 or 4 drive modules, which are connected in parallel.

The basic kit contains the following components:

Drive modules

•

Control shelf

•

Wire harnesses

•

- Ribbon cable with 44-pin connector (on both ends of the cable).

- Relay cable with 16-pin connector (on 1 end of the cable).

- DC fuse microswitch cable with 2-pin connectors (on 1 end of the cable).

DC fuses

•

Microswitches

•

Other components, such as busbar kits and back-channel cooling duct kits, are available as options to customize the drive system.

The drive system in Illustration 4.4 shows a system using 4 drive modules. A system using 2 drive modules is similar, except for the connecting hardware used. The illustrated drive system shows the cooling kit and the busbar option kit. However, the installer can use other connection methods, including custom manufactured busbars or electrical cables.

NOTICE

The installer is responsible for the details of the drive system construction, including connections. Also, if the installer does not use the Danfoss recommended design, the installer must obtain separate regulatory approvals.

130BE836.10

Product Overview Design Guide

4 4

Area Title Functions

1 Cabinet

(installer-

provided)

2 DC busbars

(part of

busbar kit

option)

3 Wire harness Used to link various components to the control shelf.

4 LCP The local control module, shown mounted on the cabinet door. Allows the operator to monitor and control the

5 Control shelf Consists of an MDCIC (multi-drive control interface card), a control card, an LCP, a safety relay, and an SMPS

6 Drive modules 2 or 4 drive modules can be installed in parallel to create a drive system.

7 Busbar kit

(optional)

8 In-bottom/out-

back cooling

(optional)

Illustration 4.4 Overview of 4-drive System without EMI/EMC Shields

Used to house the drive modules and other drive system components.

Used to connect the DC terminals of the drive modules in parallel. The kit can be ordered from Danfoss or

fabricated by the panel builder.

system and motor.

(switched-mode power supply). The MDCIC interfaces the LCP and control card with the power card in each drive

module.

Used to connect the motor, mains, and ground terminals of the drive modules in parallel. The kit can be either

ordered from Danfoss as an optional kit or fabricated by the panel builder.

Used to direct air in from the base of the enclosure, through the back channel of the drive module, and out

through the top of the enclosure. Reduces heat inside the enclosure by 85%. The kit can be ordered from Danfoss

as an optional kit. Refer to chapter 4.5.1 Back-channel Cooling Examples.

130BF018.10

130BF019.11

Product Overview

VLT® Parallel Drive Modules

4.5 Back-channel Cooling Examples

Illustration 4.5 Cooling Kit Airow (from Left to Right), In-back/Out-back, In-back/Out-top, In-bottom/Out-top, In-bottom/Out-back

Illustration 4.6 2-drive Cabinet with In-back/Out-back Cooling Kit (Left) and In-bottom/Out-top Cooling Kit (Right)

Product Features Design Guide

5 Product Features

5.1 Automated Functions

These automated functions fall into 3 categories:

Turned on by default, but can be disabled by

•

programming.

Turned o by default, but can be enabled by

•

programming.

Always enabled.

•

5.1.1 Automatic Energy Optimization

Automatic energy optimization (AEO) is used in HVAC applications. This feature directs the frequency converter to monitor continuously the load on the motor and adjust the output voltage to maximize eciency. Under light load, the voltage is reduced and the motor current is minimized. The motor benets from increased eciency, reduced heating, and quieter operation. There is no need to select a V/Hz curve because the frequency converter automatically adjusts motor voltage.

5.1.2 Automatic Switching Frequency Modulation

rate) causes noise in the motor, making a higher carrier frequency preferable. A high carrier frequency, however, generates heat in the frequency converter which can limit the amount of current available to the motor. The use of insulated gate bipolar transistors (IGBT) means high-speed switching.

Automatic switching frequency modulation regulates these conditions automatically to provide the highest carrier frequency without overheating the frequency converter. By providing a regulated high carrier frequency, it quiets motor operating noise at slow speeds, when audible noise control is critical, and produces full output power to the motor when the demand requires.

5.1.3 Automatic Derating for High Carrier Frequency

The frequency converter is designed for continuous and full load operation between the carrier frequencies between the minimum and maximum frequencies shown in Table 5.1. If the carrier frequency is higher than the maximum frequency, the output current of the frequency converter is derated automatically.

5 5

The frequency converter generates short electrical pulses to form an AC wave pattern. The carrier frequency is the rate of these pulses. A low carrier frequency (slow pulsing

Power

kW (hp)

250 (350) 3000 2000 8000 3000

315 (450) 2000 1500 6000 2000

355 (500) 2000 1500 6000 2000

400 (550) 2000 1500 6000 2000

450 (600) 2000 1500 6000 2000

500 (650) 2000 1500 6000 2000

560 (750) 2000 1500 6000 2000

630 (900) 2000 1500 6000 2000

710 (1000) 2000 1500 6000 2000

800 (1200) 2000 1500 6000 2000

Table 5.1 Carrier Frequency Operational Ranges for 380–500 V

Switching frequency

Minimum

Maximum

Factory Setting

Product Features

VLT® Parallel Drive Modules

Power

kW (hp)

250 (300) 3000 2000 8000 3000

315 (350) 2000 1500 6000 2000

355 (400) 2000 1500 6000 2000

400 (400) 2000 1500 6000 2000

500 (500) 2000 1500 6000 2000

560 (600) 2000 1500 6000 2000

630 (650) 2000 1500 6000 2000

710 (750) 2000 1500 6000 2000

800 (950) 2000 1500 6000 2000

900 (1050) 2000 1500 6000 2000

1000 (1150) 2000 1500 6000 2000

Table 5.2 Carrier Frequency Operational Ranges for 525–690 V

5.1.4 Automatic Derating for Overtemperature

Automatic overtemperature derating works to prevent tripping the frequency converter at high temperature. Internal temperature sensors measure conditions to protect the power components from overheating. The frequency converter can automatically reduce its carrier frequency to maintain its operating temperature within safe limits. After reducing the carrier frequency, the frequency converter can also reduce the output frequency and current by as much as 30% to avoid an overtemperature trip.

Switching frequency

Minimum

nuisance trips. A short circuit between 2 output phases can cause an overcurrent trip.

Maximum

Factory Setting

5.1.8 Ground Fault Protection

After receiving feedback from current sensors, the control circuitry sums up the 3-phase currents from each drive module. If the sum of all 3 output phase currents is not 0, it indicates a leakage current. If the deviation from 0 exceeds a predetermined amount, the frequency converter issues a ground fault alarm.

5.1.5 Auto Ramping

A motor trying to accelerate a load too quickly for the current available can cause the frequency converter to trip. The same is true for too quick of a deceleration. Auto ramping protects against this scenario by extending the motor ramping rate (acceleration or deceleration) to match the available current.

5.1.6 Current Limit Control

If a load exceeds the current capability of the frequency converter normal operation (from an undersized frequency converter or motor), current limit reduces the output frequency to slow the motor and reduce the load. An adjustable timer is available to limit operation in this condition for 60 s or less. The factory default limit is 110% of the rated motor current to minimize overcurrent stress.

5.1.7 Short-circuit Protection

The frequency converter provides inherent short-circuit protection with a fast acting fault-trip circuit. Current is measured in each of the 3 output phases. After 5–10 ms, if the current exceeds the permitted value, all transistors in the inverter turn o. This circuit provides the most rapid current sensing and the greatest protection against

5.1.9 Power Fluctuation Performance

The frequency converter withstands mains uctuations such as

Transients.

•

Momentary dropouts.

•

Short voltage drops.

•

Surges.

•

The frequency converter automatically compensates for input voltages ±10% from the nominal to provide full rated motor voltage and torque. With auto restart selected, the frequency converter automatically powers up after a voltage trip. And with ying start, the frequency converter synchronizes to motor rotation before starting.

5.1.10 Motor Soft Start

The frequency converter supplies the right amount of current to the motor to overcome load inertia and bring the motor up to speed. This action avoids full mains voltage being applied to a stationary or slow turning motor, which generates high current and heat. This inherent soft start feature reduces thermal load and mechanical stress, extends motor life, and provides quieter system operation.

Product Features Design Guide

5.1.11 Resonance Damping

High-frequency motor resonance noise can be eliminated by using resonance damping. Automatic or manually selected frequency damping is available.

5.1.12 Temperature-controlled Fans

The internal cooling fans are temperature controlled by sensors in the frequency converter. The cooling fan often is not running during low-load operation, or when in sleep mode or standby. This feature reduces noise, increases eciency, and extends the operating life of the fan.

5.1.13 EMC Compliance

Electromagnetic interference (EMI) or radio frequency interference (RFI) is disturbance that can aect an electrical circuit due to electromagnetic induction or radiation from an external source. The frequency converter is designed to comply with the EMC product standard for IEC/EN 61800-3. For more information regarding EMC performance, see chapter 9.2 EMC Test Results.

5 5

Product Features

VLT® Parallel Drive Modules

5.2 Programmable Functions

The following functions are the most common functions programmed for use in the frequency converter for enhanced system performance. They require minimum programming or set-up. Understanding that these functions are available can optimize a system design and possibly avoid introducing redundant components or functionality. See the product-specic programming guide, for instructions on activating these functions.

5.2.1 Automatic Motor Adaptation

frequency converter makes control decisions by comparing the 2 signals to optimize system performance.

5.2.4 Automatic Restart

The frequency converter can be programmed to restart the motor automatically after a minor trip, such as momentary power loss or uctuation. This feature eliminates the need for manual resetting and enhances automated operation for remotely controlled systems. The number of restart attempts and the duration between attempts can be limited.

Automatic motor adaptation (AMA) is an automated test procedure used to measure the electrical characteristics of the motor. AMA provides an accurate electronic model of the motor. It allows the frequency converter to calculate optimal performance and eciency with the motor. Running the AMA procedure also maximizes the automatic energy optimization feature of the frequency converter. AMA is performed without the motor rotating and without uncoupling the load from the motor.

5.2.2 Motor Thermal Protection

5.2.5 Flying Start

Flying start allows the frequency converter to synchronize with an operating motor rotating at up to full speed in either direction. This feature prevents trips due to overcurrent draw. It minimizes mechanical stress to the system since the motor receives no abrupt change in speed when the frequency converter starts.

5.2.6 Sleep Mode

Motor thermal protection can be provided in 2 ways.

One method uses a motor thermistor. The frequency converter monitors motor temperature as the speed and load vary to detect overheating conditions.

The other method calculates motor temperature by measuring current, frequency, and operating time. The frequency converter shows the thermal load on the motor in percentage and can issue a warning at a programmable overload setpoint. Programmable options at the overload allow the frequency converter to stop the motor, reduce output, or ignore the condition. Even at low speeds, the frequency converter meets I2t Class 20 electronic motor overload standards.

5.2.3 Built-in PID Controller

The built-in proportional, integral, derivative (PID) controller is available, eliminating the need for auxiliary control devices. The PID controller maintains constant control of closed-loop systems where regulated pressure, ow, temperature, or other system requirements must be maintained. The frequency converter can provide selfreliant control the motor speed in response to feedback signals from remote sensors.

Sleep mode automatically stops the motor when demand is at a low level for a specied time. When the system demand increases, the frequency converter restarts the motor. Sleep mode provides energy savings and reduces motor wear. Unlike a setback clock, the frequency converter is always available to run when the preset wakeup demand is reached.

5.2.7 Run Permissive

The frequency converter can wait for a remote systemready signal before starting. When this feature is active, the frequency converter remains stopped until receiving permission to start. Run permissive ensures that the system or auxiliary equipment is in the proper state before the frequency converter is allowed to start the motor.

5.2.8 Full Torque at Reduced Speed

The frequency converter follows a variable V/Hz curve to provide full motor torque even at reduced speeds. Full output torque can coincide with the maximum designed operating speed of the motor. This variable torque curve is unlike variable torque converters that provide reduced motor torque at low speed, or constant torque converters that provide excess voltage, heat, and motor noise at less than full speed.

The frequency converter accommodates 2 feedback signals from 2 dierent devices. This feature allows regulating a system with dierent feedback requirements. The

Product Features Design Guide

5.2.9 Frequency Bypass

In some applications, the system can have operational speeds that create a mechanical resonance. This mechanical resonance can generate excessive noise and possibly damage mechanical components in the system. The frequency converter has 4 programmable bypassfrequency bandwidths. These bandwidths allow the motor to step over speeds which induce system resonance.

5.2.10 Motor Preheat

To preheat a motor in a cold or damp environment, a small amount of DC current can be trickled continuously into the motor to protect it from condensation and a cold start. This function can eliminate the need for a space heater.

5.2.11 4 Programmable Set-ups

The frequency converter has 4 set-ups which can be independently programmed. Using multi-setup, it is possible to switch between independently programmed functions activated by digital inputs or a serial command. Independent set-ups are used, for example, to change references, or for day/night or summer/winter operation, or to control multiple motors. The active set-up is shown on the LCP.

Set-up data can be copied from frequency converter to frequency converter by downloading the information from the removable LCP.

5.2.15 Power Loss Ride-through

During a power loss, the frequency converter continues to rotate the motor until the DC link voltage drops below the minimum operating level, which corresponds to 15% below the lowest rated drive voltage. Frequency converters are rated for operation on 380–460 V, 550–600 V, and some at 690 V. The power loss ride-through time depends after the load on the frequency converter and the mains voltage at the time of the power loss.

5.2.16 Overload

When the torque required to maintain or accelerate to a determined frequency exceeds the current limit, the frequency converter attempts to continue operating. It automatically reduces the rate of acceleration or reduces the output frequency. If the overcurrent demand is not reduced enough, the frequency converter shuts down and shows a fault within 1.5 s. The current limit level is programmable. The overcurrent trip delay is used to specify the time that the frequency converter operates in current limit before shutting down. The limit level can be set from 0–60 s, or for frequency converter and motor thermal protection.

Safe Torque O (STO)

5.3

The VLT® AutomationDrive FC 302 comes standard with Safe Torque O functionality via control terminal 37. The

STO function is also available on VLT® HVAC Drive FC 102

and VLT® AQUA Drive FC 202.

innite operation, subject to the

5 5

5.2.12 DC Braking

Some applications can require braking a motor to slow or stop it. Applying DC current to the motor brakes the motor and can eliminate the need for a separate motor brake. The DC brake can be set to activate at a predetermined frequency or after receiving a signal. The rate of braking can also be programmed.

5.2.13 High Breakaway Torque

For high inertia or high friction loads, extra torque is available for starting. The breakaway current of 110% or 160% of maximum can be set for a limited amount of time.

5.2.14 Bypass

An automatic or manual bypass is an available option. The bypass allows the motor to operate at full speed when the frequency converter is not operating and allows for routine maintenance or emergency bypass.

STO disables the control voltage of the power semiconductors of the frequency converter output stage, which in turn prevents it from generating the voltage required to rotate the motor. When the Safe Torque O (T37) is activated, the frequency converter issues an alarm, trips the unit, and coasts the motor to a stop. Manual restart is required. The Safe Torque O function can be used for stopping the frequency converter in emergency stop situations. In the normal operating mode when Safe Torque O is not required, use the regular stop function instead. When automatic restart is used, the requirements according to ISO 12100-2 paragraph 5.3.2.5 must be

fullled.

The Safe Torque O function with VLT® AutomationDrive FC 302 can be used for asynchronous, synchronous, and permanent magnet motors. It is possible that 2 faults occur in the power semiconductors. If 2 faults in the power semiconductors occur while using synchronous or permanent magnet motors, it can cause a residual rotation in the motor. The rotation can be calculated to angle=360/ (number of poles). The application using synchronous or permanent magnet motors must take this possibility into consideration and ensure that this scenario is not a critical

130BA967.12

Digital Input

PTC Sensor

Non-Hazardous AreaHazardous

Area

X44/

PTC Thermistor Card

MCB 112

1 2 3 4 5 6 7 8 9 10 1112

Safety Device

Manual Restart

SIL 2

Safe AND Input

Safe Output

Safe Input

DI DI

Safe Stop

Par. 5-19

Terminal 37 Safe Stop

12 13 18 19 27 29 32 33 20 37

e.g. Par 5-15

Product Features

VLT® Parallel Drive Modules

safety issue. This situation does not apply to asynchronous motors.

5.3.1 Liability Conditions

The user is responsible for ensuring that personnel know how to install and operate the Safe Torque O function by:

Reading and understanding the safety regulations

•

concerning health and safety/accident prevention.

Understanding the generic and safety guidelines

•

given in this description and the extended

description in the VLT

Frequency Converters –

Safe Torque O Operating Guide.

Having a good knowledge of the generic and

•

safety standards for the specic application.

The user is dened as integrator, operator, service, and maintenance sta.

5.3.2 Additional Information

For more information regarding Safe Torque O, including

installation and commissioning, refer to the VLT® Frequency Converters – Safe Torque O Operating Guide.

5.3.3 Installation of External Safety Device

If the ex-certied thermistor module MCB 112, which uses terminal 37 as its safety-related switch-o channel, is connected, then the output X44/12 of MCB 112 must be AND-ed with a safety-related sensor (emergency stop key or safety-guard switch) that activates Safe Torque O. The output to Safe Torque O terminal 37 is high (24 V) only if both the signal from MCB 112 output X44/12 and the signal from the safety-related sensor are high. If at least 1 of the 2 signals are low, then the output to terminal 37 must be low, too. The safety device with this AND logic itself must conform to IEC 61508, SIL 2. The connection from the output of the safety device with safe AND logic to Safe Torque O terminal 37 must be short circuit protected. Illustration 5.1 shows a restart input for the external safety device. In this installation, for example, set

[7] PTC 1 & Relay W or [8] PTC 1 & Relay A/W in

parameter 5-19 Terminal 37 Safe Stop. Refer to the VLT Thermistor Card MCB 112 Operating Instructions for further

details.

in Combination with VLT® PTC Thermistor Card MCB 112

PTC

Illustration 5.1 Illustration of the Essential Aspects for

Installing a Combination of a Safe Torque O Application and

an MCB 112 Application

Parameter settings for external safety device with MCB 112

If MCB 112 is connected, then selections [4] through [9] become possible for parameter 5-19 Terminal 37 Safe Stop (Terminal 37 Safe Torque O). Selections [1]* Safe Stop Alarm and [3] Safe Stop Warning in parameter 5-19 Terminal 37 Safe Stop are still available, but are used only for installations without MCB 112 or any external safety devices. If [1]* Safe Stop Alarm or [3] Safe Stop Warning in parameter 5-19 Terminal 37 Safe Stop is selected by mistake and MCB 112 is triggered, then the frequency converter reacts with alarm 72, Dangerous Failure and coasts the frequency converter safely without an automatic restart. Selections [4] and [5] parameter 5-19 Terminal 37 Safe Stop are only selected when MCB 112 uses the Safe Torque O. If selections [4] PTC 1 Alarm or [5] PTC 1 Warning in parameter 5-19 Terminal 37 Safe Stop is selected by mistake and the external safety device triggers Safe Torque O, the frequency converter reacts with alarm 72, Dangerous Failure and coasts the frequency converter safely without an automatic restart. Selections [6] through [9] in parameter 5-19 Terminal 37 Safe Stop must be selected for the combination of external safety device and MCB 112.

Product Features Design Guide

NOTICE

[7] PTC 1 & Relay W and [8] PTC 1 & Relay A/W in parameter 5-19 Terminal 37 Safe Stop opens up for

automatic restart when the external safety device is deactivated again.

The automatic restart is only allowed in the following cases:

The unintended restart prevention is

•

implemented by other parts of the Safe Torque O installation.

A presence in the dangerous zone can be

•

physically excluded when Safe Torque O is not activated. In particular, paragraph 5.3.2.5 of ISO 12100-2 2003 must be observed.

See chapter 7.3.10 VLT® PTC Thermistor Card MCB 112 and

the VLT® PTC Thermistor Card MCB 112 Operating Guide for more information about MCB 112.

5.4 System Monitoring

The frequency converter monitors many aspects of system operation including:

Mains conditions.

•

Motor load and performance.

•

Frequency converter status.

•

An alarm or warning does not necessarily indicate a problem with the frequency converter itself. It can be a condition outside of the frequency converter that is being monitored for performance limits. The frequency converter has various preprogrammed fault, warning, and alarm responses. Extra alarm and warning functions can be selected to enhance or modify system performance.

5.4.3 High and Low Feedback Warning

In closed-loop operation, the frequency converter monitors selected high and low feedback values. The display shows a ashing high or ashing low warning when appropriate. The frequency converter can also monitor feedback signals in open-loop operation. While the signals do not aect the operation of the frequency converter in open loop, they can be useful for system status indication locally or via serial communication. The frequency converter handles 39 dierent units of measure.

5.4.4 Imbalance of Supply Voltage or Phase Loss

Excessive ripple current in the DC bus indicates either a mains imbalance of supply voltage or phase loss. When a power phase to the frequency converter is lost, the default is to issue an alarm and trip the unit to protect the DC bus capacitors. Other options are to issue a warning and to reduce output current to 30% of full current, or to issue a warning and continue normal operation. Operating a unit connected to an imbalanced line can be desirable until the imbalance is corrected.

5.4.5 High-frequency Warning

Useful in staging on extra equipment such as pumps or cooling fans, the frequency converter can warn when the motor speed is high. A specic high-frequency setting can be entered into the frequency converter. When the output of the unit exceeds the set warning frequency, the unit shows a high-frequency warning. A digital output from the frequency converter can signal external devices to turn on.

5 5

This section describes common alarm and warning functions. Understanding that these functions are available can optimize a system design and possibly avoid introducing redundant components or functionality.

5.4.1 Operation at Overtemperature

By default, the frequency converter issues an alarm and trips at overtemperature. If Autoderate and Warning are selected, the frequency converter warns of the condition but continues to run and attempts to cool itself by rst reducing its carrier frequency. Then, if necessary, it reduces the output frequency.

5.4.2 High and Low Reference Warning

In open-loop operation, the reference signal directly determines the speed of the frequency converter. The display shows a ashing reference high or low warning when the programmed maximum or minimum is reached.

5.4.6 Low-frequency Warning

Useful in staging o equipment, the frequency converter can warn when the motor speed is low. A specic lowfrequency setting can be selected for warning and to turn o external devices. The unit does not issue a lowfrequency warning when it is stopped nor after start-up until after the operating frequency has been reached.

5.4.7 High Current Warning

This function is similar to high-frequency warning (see chapter 5.4.5 High-frequency Warning), except a high current setting is used to issue a warning and turn on external equipment. The function is not active when stopped or at start-up until the set operating current has been reached.

Product Features

VLT® Parallel Drive Modules

5.4.8 Low Current Warning

This function is similar to low-frequency warning (see chapter 5.4.6 Low-frequency Warning), except a low current setting is used to issue a warning and turn o external equipment. The function is not active when stopped or at start up until the set operating current has been reached.

5.4.9 No Load/Broken Belt Warning

This feature can be used for monitoring a V-belt. After a

low current limit has been stored in the frequency converter, if loss of the load is detected, the frequency converter can be programmed to issue an alarm and trip or to continue operation and issue a warning.

5.4.10 Lost Serial Interface

The frequency converter can detect loss of serial communication. A time delay of up to 18000 s is selectable to avoid a response due to interruptions on the serial communications bus. When the delay is exceeded, available options can:

Maintain the last speed.

•

Go to maximum speed.

•

Go to a preset speed.

•

Stop and issue a warning.

•

346

(13.6)

868

[34.2]

856.6

(33.7)

1051

(41.4)

1096

(43.1)

1122

(44.2)

130

(5.1)

(1.6)

1048

(41.3)

280

(11.0)

107

(4.2)

213

(8.4)

320

(12.6)

271

(10.7)

(3.7)

130BE654.11

376

(14.8)

Specications Design Guide

6 Specications

6.1 Drive Module Dimensions

6.1.1 Exterior Dimensions

Illustration 6.1 shows the dimensions of the drive module related to its installation.

Illustration 6.1 VLT® Parallel Drive Modules Installation Dimensions

Description Module weight [kg (lb)] Length x width x depth [mm (in)]

Drive module 125 (275) 1121.7 x 346.2 x 375 (44.2 x 13.6 x 14.8)

Table 6.1 Drive Module Weight and Dimensions

130BE748.10

319 (12.6)

200 (7.9)

0 (0.0)

376 (14.8)

Brake terminals

236.8 (9.0)

293 (11.5)

0 (0.0)

33 (1.3)

91 (3.6)

149 (5.8)

211 (8.3)

319 (12.6)

265 (10.4)

130BE749.10

Section A-A Mains Terminals

Section B-B Motor and Brake Terminals

Brake terminal

Motor terminal

Mains terminal

284 (11.2)

0 (0.0)

306 (12.1)

255 (10.0)

Specications

6.1.2 Terminal Dimensions

VLT® Parallel Drive Modules

Illustration 6.2 Drive Module Terminal Dimensions (Front View)

Illustration 6.3 Drive Module Terminal Dimensions (Side Views)

130BE751.10

105.5 (4.15)

236 (9.3)

126 (4.9)

95 (3.7)

Specications Design Guide

6.1.3 DC Bus Dimensions

Illustration 6.4 DC Bus Dimensions (Front and Side Views)

130BF029.10

705

(27.8)

332

(13.1)

Specications

6.2 Control Shelf Dimensions

VLT® Parallel Drive Modules

Illustration 6.5 Control Shelf Dimensions

130BF026.10

405

(15.9)

808 (31.8)

796

(31.3)

1959

(77.1)

2261

(89.0)

636

(25.0)

338

(13.3)

636

(25.0)

105

2201

(86.7)

Specications Design Guide

6.3 2-drive System Dimensions

Illustration 6.6 2-drive System Exterior Dimensions (Front, Side, and Door Opening Views)

659

(76.0)

556

(21.9)

522

(20.6)

491

(19.3)

460

(18.1)

363

(14.3)

101

(4.0)

113

(4.5)

185

(7.3)

218

(8.6)

401

(15.8)

130BF027.10

Specications

VLT® Parallel Drive Modules

1 Mains jumper busbars (module 1) 3 Mains jumper busbars (module 2)

2 Brake terminals 4 Mains terminals

Illustration 6.7 2-drive System Mains Terminals (Side and Front Views)

130BF028.10

465 (18.3)

516 (20.3)

669 (27.5)

262 (10.3)0317 (12.5)

348 (13.7)

380 (15.0)

467 (18.4)

564 (22.2)

276 (10.9)

593 (23.4)

669 (26.3)

677 (26.7)

131 (12.3)

381 (15.0)

465 (18.3)

Specications Design Guide

1 Motor jumper busbars (module 1) 4 Motor jumper busbars (module 2)

2 Motor terminals 5 Brake terminals

3 Ground terminals

Illustration 6.8 2-drive System Motor and Ground Terminals (Front and Side Views)

130BF034.10

139 (5.5)

71.5 (2.8)

84 (3.3)

103 (4.0)

627 (24.7)

671 (26.4)

711 (28.0)

274 (10.8)

97 (3.8)

181 (7.1)

532 (21.0)

534 (21.0)

137 (5.4)

179 (7.1)

89 (3.5)

188 (7.4)

344 (13.5)

323 (12.8)

165 (6.5)

373 (14.7)0311 (12.3)

286 (11.3)

416 (16.4)

291 (11.5)

568 (22.4)

556 (21.9)

456 (18.0)

436 (17.2)

416 (16.4)

(3.8)

Specications

VLT® Parallel Drive Modules

Illustration 6.9 2-drive System DC Bus and Relays (Side and Front Views)

130BF033.10

796

(31.3)

105

800

(31.5)

1600 (63.0)

631

(24.8)

631

(24.8)

1970

(77.6)

2200

(86.6)

2254

(88.7)

1800

(71.0)

Specications Design Guide

6.4 4-drive System Dimensions

Illustration 6.10 4-drive System Exterior Dimensions (Front, Side, and Door Opening Views)

130BF030.10

485

(19.1)

445

(17.5)

456

(18.0)

416

(16.4)

331

(13.0)

291

(11.5)

222

(8.7)

2089 (82.2)

791

(31.1)

827

(32.5)

671

(26.4)

711

(28.0)

897

(35.3)

937

(36.9)

Specications

VLT® Parallel Drive Modules

Illustration 6.11 4-drive Jumper Connections (Side and Front Views)

130BF031.10

659 (26.0)

96 (3.8)

110 (4.3)

180 (7.1))

215 (8.4)

398 (15.7)

791 (31.1)

909 (35.8)

980 (38.6)

1014 (39.9)

1197 (47.1)

556 (21.9)

465 (18.3)

445 (17.5)

896 (35.3)

Specications Design Guide

1 Mains jumper busbars (modules 1 and 2) 5 Mains jumper busbars (modules 3 and 4)

2 Mains terminals (modules 1 and 2) 6 Mains terminals (modules 3 and 4)

3 Brake terminals (modules 1 and 2) 7 Ground terminals (modules 3 and 4)

4 Ground terminals (modules 1 and 2) 8 Connecting ground terminal (see Illustration 6.13)

Illustration 6.12 4-drive System Mains and Ground Terminals (Front View)

130BF067.10

(1.4)

522 (20.6)

491 (19.3)

460 (18.3)

363 (14.3)

262 (10.3)

222 (8.7)

(1.6)

Specications

VLT® Parallel Drive Modules

Illustration 6.13 4-drive System Mains and Ground Terminals (Side View, Left, and Connecting Ground Terminal View, Right)

130BF032.10

272 (10.7)

377 (14.8)

560 (22.1)

589 (23.2)

673 (26.5)

1072 (42.2)

1360 (53.5)

1389 (54.7)

1473 (58.0)

1177(46.3)

4x 697 (27.4)

6x 514 (20.2)

Specications Design Guide

1 Motor jumper busbars (modules 1 and 2) 5 Brake terminals (modules 3 and 4)

2 Brake terminals (modules 1 and 2) 6 Brake terminal detail (see Illustration 6.15)

3 Motor terminals (modules 1 and 2) 7 Motor terminals (modules 3 and 4)

4 Motor jumper busbars (module 3 and 4) 8 Motor terminal detail (see Illustration 6.15)

Illustration 6.14 4-drive System Motor and Brake Terminals (Front View)

130BF068.10

(0.7)

317 (12.5)

348 (13.7)

380 (18.3)

467(18.4)

(0.2)

3x 25

(1.0)

(1.4)

Specications

VLT® Parallel Drive Modules

Illustration 6.15 4-drive System Motor and Brake Terminals (Side View, Left, Motor Terminals, Top Right, and Brake Terminals, Bottom

Right)

130BF035.10

72 (2.8)

84 (3.3)

103 (4.0)

140 (5.5)

97 (3.8)

180 (7.1)

532 (21.0)

534 (21.0)

671 (26.4)

711 (28.0)

897 (35.3)

937 (36.9)

980 (38.6)

1074 (42.3)

1332 (52.5)

1471 (57.9)

1511 (59.5)

344 (13.6)

323 (12.7)

166 (6.5)

135 (5.3)

4x 88 (3.5)

188 (7.4)

175 (6.9)

137 (5.4)

274 (10.8)

627 (24.7)

980 (38.6)

1427 (56.2)

4x 96 (3.8)

Specications Design Guide

1 Ground jumper busbars (module 1) 2 Grounding shield (module 1)

Illustration 6.16 4-drive System DC Bus/Relays and Grounding Shield (Front View)

130BF069.10

568 (22.4)

556 (22.0)

458 (18.0)

427 (16.8)

456 (18.0)

291 (11.5)

286 (11.3)

311 (12.3)

331 (13.0)

436 (17.2)

416 (16.4)

373 (14.7)

Specications

VLT® Parallel Drive Modules

Illustration 6.17 4-drive System DC Bus and Relays (Side View)

Specications Design Guide

6.5 Power-dependent Specications

6.5.1

VLT® HVAC Drive FC 102

Power range N315 N355 N400 N450 N500

Drive modules 2 2 2 2 2

Rectier conguration 12-pulse 6-pulse/12-pulse

High/normal load NO NO NO NO NO

Typical shaft output at 400 V [kW] 315 355 400 450 500

Typical shaft output at 460 V [hp] 450 500 600 600 700/650

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 380–440 V) 588 658 745 800 880

Intermittent (60 s overload) at 400 V 647 724 820 880 968

Continuous (at 460/500 V) 535 590 678 730 780

Intermittent (60 s overload) at 460/500 V 588 649 746 803 858

Continuous (at 400 V) [kVA] 407 456 516 554 610

Continuous (at 460 V) [kVA] 426 470 540 582 621

Continuous (at 500 V) [kVA] 463 511 587 632 675

Input current [A]

Continuous (at 400 V) 567 647 733 787 875

Continuous (at 460/500 V) 516 580 667 718 759

Power losses [W]

Drive modules at 400 V 5825 6110 7069 7538 8468

Drive modules at 460 V 4998 5964 6175 6609 7140

AC busbars at 400 V 550 555 561 565 575

AC busbars at 460 V 548 551 556 560 563

DC busbars during regeneration 93 95 98 101 105

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 4x150 (300)

Brake 4x70 (2/0) 4x95 (3/0)

Regeneration terminals 4x120 (250) 4x150 (300) 6x120 (250)

Maximum external mains fuses

6-pulse conguration – – – – 600 V, 1600 A

12-pulse conguration 700 A, 600 V –

4x120 (250) 4x150 (300)

Table 6.2 FC 102, 380–480 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N560 N630 N710 N800 N1M0

Drive modules 4 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load NO NO NO NO NO

Typical shaft output at 400 V [kW] 560 630 710 800 1000

Typical shaft output at 460 V [hp] 750 900 1000 1200 1350

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 380–440 V) 990 1120 1260 1460 1720

Intermittent (60 s overload) at 400 V 1089 1232 1386 1606 1892

Continuous (at 460/500 V) 890 1050 1160 1380 1530

Intermittent (60 s overload) at 460/500 V 979 1155 1276 1518 1683

Continuous (at 400 V) [kVA] 686 776 873 1012 1192

Continuous (at 460 V) [kVA] 709 837 924 1100 1219

Continuous (at 500 V) [kVA] 771 909 1005 1195 1325

Input current [A]

Continuous (at 400 V) 964 1090 1227 1422 1675

Continuous (at 460/500 V) 867 1022 1129 1344 1490

Power losses [W]

Drive modules at 400 V 8810 10199 11632 13253 16463

Drive modules at 460 V 7628 9324 10375 12391 13958

AC busbars at 400 V 665 680 695 722 762

AC busbars at 460 V 656 671 683 710 732

DC busbars during regeneration 218 232 250 276 318

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x185 (350) 8x120 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 6x120 (250) 8x120 (250) 8x150 (300) 10x150 (300)

Maximum external mains fuses

6-pulse conguration 600 V,

12-pulse conguration 600 V, 700 A 600 V, 900 A 600 V,

VLT® Parallel Drive Modules

4x185 (350) 8x120 (250)

600 V, 2000 A 600 V, 2500 A

1600 A

1500 A

Table 6.3 FC 102, 380–480 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

Power range N315 N400 N450 N500 N560 N630

Drive modules 2 2 2 2 2 2

Rectier conguration 12-pulse

High/normal load NO NO NO NO NO NO

Typical shaft output at 525–550 V [kW] 250 315 355 400 450 500

Typical shaft output at 575 V [hp] 350 400 450 500 600 650

Typical shaft output at 690 V [kW] 315 400 450 500 560 630

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 360 418 470 523 596 630

Intermittent (60 s overload) at 550 V 396 360 517 575 656 693

Continuous (at 575/690 V) 344 400 450 500 570 630

Intermittent (60 s overload) at 575/690 V 378 440 495 550 627 693

Continuous (at 550 V) kVA 343 398 448 498 568 600

Continuous (at 575 V) kVA 343 398 448 498 568 627

Continuous (at 690 V) kVA 411 478 538 598 681 753

Input current [A]

Continuous (at 550 V) 355 408 453 504 574 607

Continuous (at 575 V) 339 490 434 482 549 607

Continuous (at 690 V) 352 400 434 482 549 607

Power losses [W]

Drive modules at 575 V 4401 4789 5457 6076 6995 7431

Drive modules at 690 V 4352 4709 5354 5951 6831 7638

AC busbars at 575 V 540 541 544 546 550 553

DC busbars during regeneration 88 88.5 90 91 186 191

Maximum cable size [mm2 (mcm)]

Mains

Motor 2x120 (250) 4x120 (250)

Brake 4x70 (2/0) 4x95 (3/0)

Regeneration terminals 4x120 (250)

Maximum external mains fuses 700 V, 550 A 700 V, 630 A

2x120 (250) 4x120 (250)

Table 6.4 FC 102, 525–690 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N710 N800 N900 N1M0 N1M2

Drive modules 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load NO NO NO NO NO

Typical shaft output at 525–550 V [kW] 560 670 750 850 1000

Typical shaft output at 575 V [hp] 750 950 1050 1150 1350

Typical shaft output at 690 V [kW] 710 800 900 1000 1200

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 763 889 988 1108 1317

Intermittent (60 s overload) at 550 V 839 978 1087 1219 1449

Continuous (at 575/690 V) 730 850 945 1060 1260

Intermittent (60 s overload) at 575/690 V 803 935 1040 1166 1590

Continuous (at 550 V) 727 847 941 1056 1056

Continuous (at 575 V) 727 847 941 1056 1056

Continuous (at 690 V) 872 1016 1129 1267 1506

Input current [A]

Continuous (at 550 V) 743 866 962 1079 1282

Continuous (at 575 V) 711 828 920 1032 1227

Continuous (at 690 V) 711 828 920 1032 1227

Power losses [W]

Drive modules at 575 V 8683 10166 11406 12852 15762

Drive modules at 690 V 8559 9996 11188 12580 15358

AC busbars at 575 V 644 653 661 672 695

DC busbars during regeneration 198 208 218 231 256

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 6x120 (250) 8x120 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 4x150 (300) 6x120 (250) 6x150 (300) 8x120 (250)

Maximum external mains fuses

6-pulse conguration 700 V, 1600 A 700 V, 2000 A

12-pulse conguration 700 V, 900 A 700 V, 1500 A

VLT® Parallel Drive Modules

4x120 (250) 6x120 (250) 8x120 (250)

Table 6.5 FC 102, 525–690 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

6.5.2

VLT® AQUA Drive FC 202

Power range N315 N355 N400 N450 N500

Drive modules 2 2 2 2 2

Rectier conguration 12-pulse 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] 250 315 315 355 355 400 400 450 450 500

Typical shaft output at 460 V [hp] 350 450 450 500 500 600 550 600 600 650

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C

(°F)]

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 400 V) 480 588 600 658 658 745 695 800 810 880

Intermittent (60 s overload) at 400 V 720 647 900 724 987 820 1043 880 1215 968

Continuous (at 460/500 V) 443 535 540 590 590 678 678 730 730 780

Intermittent (60 s overload) at

460/500 V

Continuous (at 400 V) [kVA] 333 407 416 456 456 516 482 554 554 610

Continuous (at 460 V) [kVA] 353 426 430 470 470 540 540 582 582 621

Continuous (at 500 V) [kVA] 384 463 468 511 511 587 587 632 632 675

Input current [A]

Continuous (at 400 V) 463 567 590 647 647 733 684 787 779 857

Continuous (at 460/500 V) 427 516 531 580 580 667 667 718 711 759

Power losses [W]

Drive modules at 400 V 4505 5825 5502 6110 6110 7069 6375 7538 7526 8468

Drive modules at 460 V 4063 4998 5384 5964 5271 6175 6070 6609 6604 7140

AC busbars at 400 V 545 550 551 555 555 561 557 565 566 575

AC busbars at 460 V 543 548 548 551 551 556 556 560 560 563

DC busbars during regeneration 93 93 95 95 98 98 101 101 105 105

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 4x150 (300)

Brake 4x70 (2/0) 4x95 (3/0)

Regeneration terminals 4x120 (250) 6x120 (250) 6x120 (250)

Maximum external mains fuses

6-pulse conguration – – – – 600 V, 1600 A

12-pulse conguration 600 V, 700 A 600 V, 900 A

665 588 810 649 885 746 1017 803 1095 858

4x120 (250)

110 (230)

4x150 (300)

Table 6.6 FC 202, 380–480 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N560 N630 N710 N800 N1M0

Drive modules 4 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] 500 560 560 630 630 710 710 800 800 1000

Typical shaft output at 460 V [hp] 650 750 750 900 900 1000 1000 1200 1200 1350

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C

(°F)]

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 400 V) 880 990 990 1120 1120 1260 1260 1460 1460 1720

Intermittent (60 s overload) at 400 V 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892

Continuous (at 460/500 V) 780 890 890 1050 1050 1160 1160 1380 1380 1530

Intermittent (60 s overload) at

460/500 V

Continuous (at 400 V) [kVA] 610 686 686 776 776 873 873 1012 1012 1192

Continuous (at 460 V) [kVA] 621 709 709 837 837 924 924 1100 1100 1219

Continuous (at 500 V) [kVA] 675 771 771 909 909 1005 1005 1195 1195 1325

Input current [A]

Continuous (at 400 V) 857 964 964 1090 1090 1227 1127 1422 1422 1675

Continuous (at 460 V) 759 867 867 1022 1022 1129 1129 1344 1344 1490

Power losses [W]

Drive modules at 400 V 7713 8810 8918 10199 10181 11632 11390 13253 13479 16463

Drive modules at 460 V 6641 7628 7855 9324 9316 10375 12391 12391 12376 13958

AC busbars at 400 V 655 665 665 680 680 695 695 722 722 762

AC busbars at 460 V 647 656 656 671 671 683 683 710 710 732

DC busbars during regeneration 218 218 232 232 250 250 276 276 318 318

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x185 (350) 8x125 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 6x125 (250) 8x125 (250) 8x150 (300) 10x150 (300)

Maximum external mains fuses

6-pulse conguration 600 V, 1600 A 600 V, 2000 A 600 V, 2500 A

12-pulse conguration 600 V, 900 A 600 V, 1500 A

VLT® Parallel Drive Modules

110 (230)

1170 979 1335 1155 1575 1276 1740 1518 2070 1683

4x185 (350)

8x125 (250)

Table 6.7 FC 202, 380–480 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

Power range N315 N400 N450

Drive modules 2 2 2

Rectier conguration 12-pulse

High/normal load HO NO HO NO HO NO

Typical shaft output at 525–550 V [kW] 200 250 250 315 315 355

Typical shaft output at 575 V [hp] 300 350 350 400 400 450

Typical shaft output at 690 V [kW] 250 315 315 400 355 450

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 303 360 360 418 395 470

Intermittent (60 s overload) at 550 V 455 396 560 460 593 517

Continuous (at 575/690 V) 290 344 344 400 380 450

Intermittent (60 s overload) at 575/690 V 435 378 516 440 570 495

Continuous (at 550 V) 289 343 343 398 376 448

Continuous (at 575 V) 289 343 343 398 378 448

Continuous (at 690 V) 347 411 411 478 454 538

Input current [A]

Continuous (at 550 V) 299 355 355 408 381 453

Continuous (at 575 V) 286 339 339 490 366 434

Continuous (at 690 V) 296 352 352 400 366 434

Power losses [W]

Drive modules at 575 V 3688 4401 4081 4789 4502 5457

Drive modules at 690 V 3669 4352 4020 4709 4447 5354

AC busbars at 575 V 538 540 540 541 540 544

DC busbars during regeneration 88 88 89 89 90 90

Maximum cable size [mm2 (mcm)]

Mains

Motor 2x120 (250) 4x120 (250)

Brake 4x70 (2/0)

Regeneration terminals 4x120 (250)

Maximum external mains fuses 700 V, 550 A

2x120 (250)

4x120 (250)

Table 6.8 FC 202, 525–690 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N500 N560 N630

Drive modules 2 2 2

Rectier conguration 12-pulse

High/normal load HO NO HO NO HO NO

Typical shaft output at 525–550 V [kW] 315 400 400 450 450 500

Typical shaft output at 575 V [hp] 400 500 500 600 600 650

Typical shaft output at 690 V [kW] 400 500 500 560 560 630

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 429 523 523 596 596 630

Intermittent (60 s overload) at 550 V 644 575 785 656 894 693

Continuous (at 575/690 V) 410 500 500 570 570 630

Intermittent (60 s overload) at 575/690 V 615 550 750 627 627 693

Continuous (at 550 V) [kVA] 409 498 498 568 568 600

Continuous (at 575 V) [kVA] 408 498 598 568 568 627

Continuous (at 690 V) [kVA] 490 598 598 681 681 753

Input current [A]

Continuous (at 550 V) 413 504 504 574 574 607

Continuous (at 575 V) 395 482 482 549 549 607

Continuous (at 690 V) 395 482 482 549 549 607

Power losses [W]

Drive modules at 575 V 4892 6076 6016 6995 6941 7431

Drive modules at 690 V 4797 5951 5886 6831 6766 7638

AC busbars at 575 V 542 546 546 550 550 553

DC busbars during regeneration 91 91 186 186 191 191

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250)

Brake 4x70 (2/0) 4x95 (3/0)

Regeneration terminals 4x120 (250)

Maximum external mains fuses 700 V, 630 A

VLT® Parallel Drive Modules

4x120 (250)

Table 6.9 FC 202, 525–690 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

Power range N710 N800 N900 N1M0 N1M2

Drive modules 4 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 525–550 V

[kW]

Typical shaft output at 575 V [hp] 650 750 750 950 950 1050 1050 1150 1150 1350

Typical shaft output at 690 V [kW] 630 710 710 800 800 900 900 1000 1000 1200

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C

(°F)]

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 659 763 763 889 889 988 988 1108 1108 1317

Intermittent (60 s overload) at 550 V 989 839 1145 978 1334 1087 1482 1219 1662 1449

Continuous (at 575/690 V) 630 730 730 850 850 945 945 1060 1060 1260

Intermittent (60 s overload) at

575/690 V

Continuous (at 550 V) [kVA] 628 727 727 847 847 941 941 1056 1056 1255

Continuous (at 575 V) [kVA] 627 727 727 847 847 941 941 1056 1056 1255

Continuous (at 690 V) [kVA] 753 872 872 1016 1016 1129 1129 1267 1267 1506

Input current [A]

Continuous (at 550 V) 642 743 743 866 866 962 1079 1079 1079 1282

Continuous (at 575 V) 613 711 711 828 828 920 1032 1032 1032 1227

Continuous (at 690 V) 613 711 711 828 828 920 1032 1032 1032 1227

Power losses [W]

Drive modules at 575 V 7469 8683 8668 10166 10163 11406 11292 12852 12835 15762

Drive modules at 690 V 7381 8559 8555 9996 9987 11188 11077 12580 12551 15358

AC busbars at 575 V 637 644 644 653 653 661 661 672 672 695

DC busbars during regeneration 198 198 208 208 218 218 231 231 256 256

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 6x120 (250) 8x120 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 4x150 (300) 6x120 (250) 6x150 (300) 8x120 (250)

Maximum external mains fuses

6-pulse conguration 700 V, 1600 A 700 V, 2000 A

12-pulse conguration

500 560 560 670 670 750 750 850 850 1000

110 (230)

945 803 1095 935 1275 1040 1418 1166 1590 1590

4x120 (250)

700 V, 900 A

6x120 (250) 8x120 (250)

700 V, 1500 A

Table 6.10 FC 202, 525–690 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

6.5.3

VLT® AutomationDrive FC 302

Power range N250 N315 N355 N400 N450

Drive modules 2 2 2 2 2

Rectier conguration 12-pulse 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] 250 315 315 355 355 400 400 450 450 500

Typical shaft output at 460 V [hp] 350 450 450 500 500 600 550 600 600 650

Typical shaft output at 500 V [kW] 315 355 355 400 400 500 500 530 530 560

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C

(°F)]

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 380–440 V) 480 588 600 658 658 745 695 800 810 880

Intermittent (60 s overload) at 400 V 720 647 900 724 987 820 1043 880 1215 968

Continuous (at 460/500 V) 443 535 540 590 590 678 678 730 730 780

Intermittent (60 s overload) at

460/500 V

Continuous (at 400 V) [kVA] 333 407 416 456 456 516 482 554 554 610

Continuous (at 460 V) [kVA] 353 426 430 470 470 540 540 582 582 621

Continuous (at 500 V) [kVA] 384 463 468 511 511 587 587 632 632 675

Input current [A]

Continuous (at 400 V) 463 567 590 647 647 733 684 787 779 857

Continuous (at 460/500 V) 427 516 531 580 580 667 667 718 711 759

Power losses [W]

Drive modules at 400 V 4505 5825 5502 6110 6110 7069 6375 7538 7526 8468

Drive modules at 460 V 4063 4998 5384 5964 5721 6175 6070 6609 6604 7140

AC busbars at 400 V 545 550 551 555 555 561 557 565 566 575

AC busbars at 460 V 543 548 548 551 556 556 556 560 560 563

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 4x150 (300)

Brake 4x70 (2/0) 4x95 (3/0)

Regeneration terminals 4x120 (250) 4x150 (300) 6x120 (250)

Maximum external mains fuses

6-pulse conguration – – – – 600 V, 1600 A

12-pulse conguration 600 V, 700 A 600 V, 900 A

VLT® Parallel Drive Modules

110 (230)

665 588 810 649 885 746 1017 803 1095 858

4x120 (250) 4x150 (300)

Table 6.11 FC 302, 380–500 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

Power range N500 N560 N630 N710 N800

Drive modules 4 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 400 V [kW] 500 560 560 630 630 710 710 800 800 1000

Typical shaft output at 460 V [hp] 650 750 750 900 900 1000 1000 1200 1200 1350

Typical shaft output at 500 V [kW] 560 630 630 710 710 800 800 1000 1000 1100

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 380–440 V) 880 990 990 1120 1120 1260 1260 1460 1460 1720

Intermittent (60 s overload) at 400 V 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892

Continuous (at 460/500 V) 780 890 890 1050 1050 1160 1160 1380 1380 1530

Intermittent (60 s overload) at 460/500 V 1170 979 1335 1155 1575 1276 1740 1518 2070 1683

Continuous (at 400 V) [kVA] 610 686 686 776 776 873 873 1012 1012 1192

Continuous (at 460 V) [kVA] 621 709 709 837 837 924 924 1100 1100 1219

Continuous (at 500 V) [kVA] 675 771 771 909 909 1005 1005 1195 1195 1325

Input current [A]

Continuous (at 400 V) 857 964 964 1090 1090 1227 1227 1422 1422 1675

Continuous (at 460/500 V) 759 867 867 1022 1022 1129 1129 1344 1344 1490

Power losses [W]

Drive modules at 400 V 7713 8810 8918 10199 10181 11632 11390 13253 13479 16463

Drive modules at 460 V 6641 7628 7855 9324 9316 10375 12391 12391 12376 13958

AC busbars at 400 V 655 665 665 680 680 695 695 722 722 762

AC busbars at 460 V 647 656 656 671 671 683 683 710 710 732

DC busbars during regeneration 218 218 232 232 250 276 276 276 318 318

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x185 (350) 8x120 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 6x125 (250) 8x125 (250) 8x150 (300) 10x150 (300)

Maximum external mains fuses

6-pulse conguration 600 V, 1600 A 600 V, 2000 A 600 V, 2500 A

12-pulse conguration 600 V, 900 A 600 V, 1500 A

4x185 (350) 8x120 (250)

Table 6.12 FC 302, 380–500 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N250 N315 N355 N400

Drive modules 2 2 2 2

Rectier conguration 12-pulse

High/normal load HO NO HO NO HO NO HO NO

Typical shaft output at 525–550 V [kW] 200 250 250 315 315 355 315 400

Typical shaft output at 575 V [hp] 300 350 350 400 400 450 400 500

Typical shaft output at 690 V [kW] 250 315 315 400 355 450 400 500

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 303 360 360 418 395 470 429 523

Intermittent (60 s overload) at 550 V 455 396 560 360 593 517 644 575

Continuous (at 575/690 V) 290 344 344 400 380 450 410 500

Intermittent (60 s overload) at 575/690 V 435 378 516 440 570 495 615 550

Continuous (at 550 V) [kVA] 289 343 343 398 376 448 409 498

Continuous (at 575 V) [kVA] 289 343 343 398 378 448 408 498

Continuous (at 690 V) [kVA] 347 411 411 478 454 538 490 598

Input current [A]

Continuous (at 550 V) 299 355 355 408 381 453 413 504

Continuous (at 575 V) 286 339 339 490 366 434 395 482

Continuous (at 690 V) 296 352 352 400 366 434 395 482

Power losses [W]

Drive modules at 600 V 3688 4401 4081 4789 4502 5457 4892 6076

Drive modules at 690 V 3669 4352 4020 4709 4447 5354 4797 5951

AC busbars at 575 V 538 540 540 541 540 544 542 546

DC busbars during regeneration 88 88 89 89 90 90 91 91

Maximum cable size [mm2 (mcm)]

Mains

Motor 2x120 (250) 4x120 (250)

Brake 4x70 (2/0)

Regeneration terminals 4x120 (250)

Maximum external mains fuses 700 V, 550 A

VLT® Parallel Drive Modules

2x120 (250) 4x120 (250)

Table 6.13 FC 302, 525–690 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

Power range N500 N560

Drive modules 2 2

Rectier conguration 12-pulse

High/normal load HO NO HO NO

Typical shaft output at 525–550 V [kW] 400 450 450 500

Typical shaft output at 575 V [hp] 500 600 600 650

Typical shaft output at 690 V [kW] 500 560 560 630

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 523 596 596 630

Intermittent (60 s overload) at 550 V 785 656 894 693

Continuous (at 575/690 V) 500 570 570 630

Intermittent (60 s overload) at 575/690 V 750 627 627 693

Continuous (at 550 V) [kVA] 498 568 568 600

Continuous (at 575 V) [kVA] 498 568 568 627

Continuous (at 690 V) [kVA] 598 681 681 753

Input current [A]

Continuous (at 550 V) 504 574 574 607

Continuous (at 575 V) 482 549 549 607

Continuous (at 690 V) 482 549 549 607

Power losses [W]

Drive modules at 600 V 6016 6995 6941 7431

Drive modules at 690 V 5886 6831 6766 7638

AC busbars at 575 V 546 550 550 553

DC busbars during regeneration 186 186 191 191

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250)

Brake 4x95 (3/0)

Regeneration terminals 4x120 (250)

Maximum external mains fuses 700 V, 630 A

4x120 (250)

Table 6.14 FC 302, 525–690 V AC Mains Supply (2-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications

Power range N630 N710 N800 N900 N1M0

Drive modules 4 4 4 4 4

Rectier conguration 6-pulse/12-pulse

High/normal load HO NO HO NO HO NO HO NO HO NO

Typical shaft output at 525–550 V [kW] 500 560 560 670 670 750 750 850 850 1000

Typical shaft output at 575 V [hp] 650 750 750 950 950 1050 1050 1150 1150 1350

Typical shaft output at 690 V [kW] 630 710 710 800 800 900 900 1000 1000 1200

Protection rating IP00

Eciency 0.98

Output frequency [Hz] 0–590

Heat sink overtemperature trip [°C (°F)] 110 (230)

Power card ambient trip [°C (°F)] 80 (176)

Output current [A]

Continuous (at 550 V) 659 763 763 889 889 988 988 1108 1108 1317

Intermittent (60 s overload) at 550 V 989 839 1145 978 1334 1087 1482 1219 1662 1449

Continuous (at 575/690 V) 630 730 730 850 850 945 945 1060 1060 1260

Intermittent (60 s overload) at

575/690 V

Continuous (at 550 V) [kVA] 628 727 727 847 847 941 941 1056 1056 1255

Continuous (at 575 V) [kVA] 627 727 727 847 847 941 941 1056 1056 1255

Continuous (at 690 V) [kVA] 753 872 872 1016 1016 1129 1129 1267 1267 1506

Input current [A]

Continuous (at 550 V) 642 743 743 866 866 962 1079 1079 1079 1282

Continuous (at 575 V) 613 711 711 828 828 920 1032 1032 1032 1227

Continuous (at 690 V) 613 711 711 828 828 920 1032 1032 1032 1227

Power losses [W]

Drive modules at 600 V 7469 8683 8668 10166 10163 11406 11292 12852 12835 15762

Drive modules at 690 V 7381 8559 8555 9996 9987 11188 11077 12580 12551 15358

AC busbars at 575 V 637 644 644 653 653 661 661 672 672 695

DC busbars during regeneration 198 198 208 208 218 218 231 231 256 256

Maximum cable size [mm2 (mcm)]

Mains

Motor 4x120 (250) 6x120 (250) 8x120 (250)

Brake 8x70 (2/0) 8x95 (3/0)

Regeneration terminals 4x150 (300) 6x120 (250) 6x150 (300) 8x120 (250)

Maximum external mains fuses

6-pulse conguration 700 V, 1600 A 700 V, 2000 A

12-pulse conguration 700 V, 900 A 700 V, 1500 A

VLT® Parallel Drive Modules

945 803 1095 935 1275 1040 1418 1166 1590 1590

4x120 (250) 6x120 (250) 8x120 (250)

Table 6.15 FC 302, 525–690 V AC Mains Supply (4-Drive System)

1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length.

Specications Design Guide

6.6 Mains Supply to Drive Module

Mains supply Supply terminals R/91, S/92, T/93

Supply voltage Supply frequency 50/60 Hz ±5% Maximum temporary imbalance between mains phases 3.0% of rated supply voltage True power factor (λ) ≥0.98 nominal at rated load Displacement power factor (cos Φ) (Approximately 1) Switching on input supply L1, L2, L3 Maximum 1 time per 2 minutes Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

1) The unit is suitable for use on a circuit capable of delivering not more than 85000 RMS symmetrical Amperes, 480/600 V.

2) Mains voltage low/mains voltage drop-out: During low mains voltage, the drive module continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage. The drive module trips for a detected mains drop-out.

380–480, 500 V 690 V ±10%10%, 525–690 V ±10%

6.7 Motor Output and Motor Data

Motor output Motor terminals U/96, V/97, W/98 Output voltage 0–100% of supply voltage Output frequency 0–590 Hz Switching on output Unlimited Ramp times 1–3600 s

Torque characteristics

Overload torque (constant torque) Maximum 150% for 60 s

Starting torque Maximum 180% up to 0.5 s

Overload torque (variable torque) Maximum 110% for s Starting torque (variable torque) Maximum 135% for s

1) Percentage relates to the nominal torque.

Eciency

1) Eciency measured at nominal current. For energy eciency class, see chapter 6.9 Ambient Conditions for Drive Modules. For part load losses, see www.danfoss.com/vltenergyeciency.

98%

6.8 12-Pulse Transformer Specications

Connection Dy11 d0 or Dyn 11d0 Phase shift between secondaries 30° Voltage dierence between secondaries <0.5% Short-circuit impedance of secondaries >5% Short-circuit impedance dierence between secondaries <5% of short-circuit impedance Other No grounding of the secondaries allowed. Static shield recommended

6.9 Ambient Conditions for Drive Modules

Environment IP rating IP00 Acoustic noise 84 dB (running at full load) Vibration test 1.0 g Vibration and shock (IEC 60721-33-3) Class 3M3 Maximum relative humidity 5–95% (IEC 721–3–3; Class 3K3 (non-condensing)) during operation

Specications

Aggressive environment (IEC 60068-2-43) H2S test Class Kd Aggressive gases (IEC 60721-3-3) Class 3C3

Ambient temperature Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced performance -10 °C (14 °F) Temperature during storage/transport -25 to +65 °C (-13 to 149 °F)

Maximum altitude above sea level without derating

EMC standards, Emission EN 61800-3 EMC standards, Immunity EN 61800-4-2, EN 61800-4-3, EN 61800-4-4, EN 61800-4-5, and EN 61800-4-6

Energy eciency class

1) Refer to chapter 6.12 Derating Specications for derating for high ambient temperature and derating for high altitude.

2) Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

VLT® Parallel Drive Modules

Maximum 45 °C (113 °F) (24-hour average maximum 40 °C (104 °F))

1000 m (3281 ft)

IE2

6.10 Cable Specications

Cable lengths and cross-sections for control cables Maximum motor cable length, shielded 150 m (492 ft) Maximum motor cable length, unshielded 300 m (984 ft)

Maximum cross-section to control terminals, exible or rigid wire without cable end sleeves 1.5 mm2/16 AWG

Maximum cross-section to control terminals, exible wire with cable end sleeves 1 mm2/18 AWG

Maximum cross-section to control terminals, exible wire with cable end sleeves with collar 0.5 mm2/20 AWG

Minimum cross-section to control terminals 0.25 mm2/24 AWG

Maximum cross-section to 230 V terminals 2.5 mm2/14 AWG

Minimum cross-section to 230 V terminals 0.25 mm2/24 AWG

1) For power cables, see electrical data tables in chapter 6.5 Power-dependent Specications.

6.11 Control Input/Output and Control Data

Digital inputs

Programmable digital inputs

Terminal number 18, 19, 271), 291), 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP <5 V DC Voltage level, logic 1 PNP >10 V DC

Voltage level, logic 0 NPN

Voltage level, logic 1 NPN Maximum voltage on input 28 V DC Pulse frequency range 0–110 kHz (Duty cycle) Minimum pulse width 4.5 ms Input resistance, R

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as output.

2) Except Safe Torque O input terminal 37.

Approximately 4 kΩ

4 (6)

>19 V DC

<14 V DC

Safe Torque O (STO) Terminal 37 Voltage level 0–24 V DC Voltage level, logic 0 PNP <4 V DC Voltage level, logic 1 PNP >20 V DC

1), 2)

(Terminal 37 is xed PNP logic)

Mains

Functional isolation

PELV isolation

Motor

DC-Bus

High voltage

Control

+24V

RS485

130BA117.10

Specications Design Guide

Maximum voltage on input 28 V DC Typical input current at 24 V 50 mA Typical input current at 20 V 60 mA

rms

Input capacitance 400 nF

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) See VLT® Frequency Converters – Safe Torque O Operating Guide for further information about terminal 37 and Safe Torque

O.

2) When using a contactor with a DC coil with STO, always make a return path for the current from the coil when turning it o. The return path can be made by using a freewheel diode across the coil. Alternatively, use a 30 V or 50 V MOV for quicker response time. Typical contactors can be bought with this diode.

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level -10 V to +10 V (scalable) Input resistance, R

Approximately 10 kΩ

Maximum voltage ±20 V Current mode Switch S201/switch S202 = ON (I) Current level 0/4–20 mA (scalable) Input resistance, R

Approximately 200 Ω

Maximum current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 20 Hz/100 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Illustration 6.18 PELV Isolation

Pulse input Programmable pulse 2/1

Terminal number pulse 291), 32/33 Maximum frequency at terminal 29, 33 110 kHz (Push-pull driven) Maximum frequency at terminal 29, 33 5 kHz (open collector) Minimum frequency at terminal 29, 33 4 Hz Voltage level 0–24 V DC Maximum voltage on input 28 V DC Input resistance, R

Approximately 4 kΩ

Pulse input accuracy (0.1–1 kHz) Maximum error: 0.1% of full scale Encoder input accuracy (1–11 kHz) Maximum error: 0.05% of full scale

The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other highvoltage terminals.

1) Pulse inputs are 29 and 33.

Specications

Analog output Number of programmable analog outputs 1 Terminal number 42 Current range at analog output 0/4–20 mA Maximum load GND - analog output 500 Ω Accuracy on analog output Maximum error: 0.5% of full scale Resolution on analog output 12 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, RS485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

VLT® Parallel Drive Modules

Digital output Programmable digital/pulse outputs 2

Terminal number 27, 29 Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Resolution of frequency outputs 12 bit

1) Terminals 27 and 29 can also be programmed as input. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, 24 V DC output Terminal number 12, 13 Output voltage 24 V +1, -3 V Maximum load 200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

Relay outputs Programmable relay outputs 2 Relay 01 terminal number 1–3 (break), 1–2 (make)

Maximum terminal load (AC-1)1) on 1–3 (NC), 1–2 (NO) (resistive load) 240 V AC, 2 A

Maximum terminal load (AC-15)1) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 1–2 (NO), 1–3 (NC) (resistive load) 60 V DC, 1 A

Maximum terminal load (DC-13)1) (inductive load) 24 V DC, 0.1 A

Relay 02 (VLT® AutomationDrive FC 302 only) terminal number 4–6 (break), 4–5 (make)

Maximum terminal load (AC-1)1) on 4–5 (NO) (resistive load)

Maximum terminal load (AC-15)1) on 4–5 (NO) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 4–5 (NO) (resistive load) 80 V DC, 2 A

Maximum terminal load (DC-13)1) on 4–5 (NO) (inductive load) 24 V DC, 0.1 A

Maximum terminal load (AC-1)1) on 4–6 (NC) (resistive load) 240 V AC, 2 A

Maximum terminal load (AC-15)1) on 4–6 (NC) (inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 4–6 (NC) (resistive load) 50 V DC, 2 A

Maximum terminal load (DC-13)1) on 4–6 (NC) (inductive load) 24 V DC, 0.1 A Minimum terminal load on 1–3 (NC), 1–2 (NO), 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 20 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

1) IEC 60947 part 4 and 5.

2)3)

overvoltage category II 400 V AC, 2 A

Specications Design Guide

The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

2) Overvoltage Category II.

3) UL applications 300 V AC 2A.

Control card, 10 V DC output Terminal number 50 Output voltage 10.5 V ±0.5 V Maximum load 25 mA

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control characteristics Resolution of output frequency at 0–590 Hz ±0.003 Hz Repeat accuracy of precise start/stop (terminals 18, 19) ≤±0.1 ms System response time (terminals 18, 19, 27, 29, 32, 33) ≤10 ms Speed control range (open loop) 1:100 of synchronous speed Speed control range (closed loop) 1:1000 of synchronous speed Speed accuracy (open loop) 30–4000 RPM: error ±8 RPM Speed accuracy (closed loop), depending on resolution of feedback device 0–6000 RPM: error ±0.15 RPM

All control characteristics are based on a 4-pole asynchronous motor

Control card performance

Scan interval (VLT® HVAC Drive FC 102, VLT® Refrigeration Drive FC 103, VLT® AQUA Drive FC 202) 5 ms (VLT® AutomationDrive FC 302) Scan interval (FC 302) 1 ms

Control card, USB serial communication USB standard 1.1 (full speed) USB plug USB type B device plug

Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB ground connection is NOT galvanically isolated from protective earth. Use only an isolated laptop as PC connection to the USB connector on the frequency converter.

0 500

100

1000 1500 2000 2500 3000

Altitude (metres above sea level)*

130BB008.10

OUT

(%)

Specications

VLT® Parallel Drive Modules

6.12 Derating Specications

Consider derating when any of the following conditions are present.

Low air pressure operating above 1000 m (3281 ft)

•

High ambient temperature

•

High switching frequency

•

Low-speed operation

•

Long motor cables

•

Cables with a large cross-section

•

If these conditions are present, Danfoss recommends stepping up 1 power size.

6.12.1 Derating for Altitude

Below 1000 m 1000 m (3281 ft), derating is not necessary. Above 1000 m 1000 m (3281 ft), the ambient temperature (T accordance with Illustration 6.19.

1. Derating of output current versus altitude

2. Derating of maximum T

Illustration 6.19 Derating for Altitude

versus altitude at 100% output current.

AMB

) or maximum output current (I

AMB

) must be derated in

MAX

130BX473.10

Iout [%]

fsw [kHz]

100

110

2 3 4 5 6 7 8

50 C

55 C

130BX474.10

100

110

2 3 4 5 6 7 8 90

50 C

55 C

45 C

Iout [%]

fsw

[kHz]

130BX475.10

Iout [%]

fsw

[kHz]

100

110

2 4 6

50 C

55 C

45 C

31 5

130BX476.10

Iout [%]

fsw

[kHz]

100

110

2 4

50 C

55 C

45 C

40 C

Specications Design Guide

6.12.2 Derating for Ambient Temperature

The ambient temperature (T

) is the maximum temperature allowed. The average (T

AMB,MAX

) is measured over 24 hours

AMB,AVG

and must be at least 5 °C (41 °F) lower.

At 41.7 °C (107°F) , 100% of the rated output current is available. At 45 °C (113 °C ) (T

, MAX-3.3 K), 91% of the rated

AMB

output current is available.

NOTICE

FACTORY DERATING

The VLT® Parallel Drive Modules is already derated for operational temperature (55 °C (131 °F) T (122 °F) T

AMB,AVG

6.12.3 Derating for Switching Frequency

Graphs are presented individually for 60° AVM and SFAVM. 60° AVM only switches 2/3 of the time, whereas SFAVM switches throughout the whole period. The maximum switching frequency is 16 kHz for 60° AVM and 10 kHz for SFAVM.

Voltage

range

Switching

pattern

60 AVM

High overload HO, 150% Normal overload NO, 110%

AMB,MAX

and 50 °C

380–500 V

SFAVM

Table 6.16 Derating for Switching Frequency, 250 kW at 400 V AC (350 hp at 460 V AC)

130BX477.10

100

110

2 3 4 5 6 7

50 C

55 C

Iout [%]

fsw

[kHz]

130BX478.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5 6 7

50 C

55 C

45 C

130BX479.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C

55 C

45 C

130BX480.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C 55 C

45 C

40 C

130BX481.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 54 5

50 C

55 C

6 7

130BX482.10

Iout [%]

fsw

[kHz]

100

110

2 3 54 5

50 C

55 C

6 7

45 C

130BX483.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C 55 C

45 C

130BX484.10

Iout [%]

fsw

[kHz]

100

110

2 3 4 5

50 C 55 C

45 C

40 C

Specications

VLT® Parallel Drive Modules

Voltage

range

Switching

pattern

High overload HO, 150% Normal overload NO, 110%

60 AVM

525–690 V

SFAVM

Table 6.17 Derating for Switching Frequency, 250 kW at 690 V AC (300 hp at 575 V AC)

Voltage

range

Switching

pattern

High overload HO, 150% Normal overload NO, 110%

60 AVM

380–500 V

SFAVM

Table 6.18 Derating for Switching Frequency, 315–800 kW at 400 V AC (450–1200 hp at 460 V AC)

130BX489.10

Iout [%]

fsw

[kHz]

0.5

100

110

2.0

50 C

55 C

0.0

1.0 1.5 2.5 4.03.0 3.5 5.54.5 5.0

130BX490.10

Iout [%]

fsw

[kHz]

0.5

100

110

2.0

50 C

55 C

0.0

1.0 1.5 2.5 4.03.0 3.5 5.54.5 5.0

45 C

130BX491.10

Iout [%]

fsw

[kHz]

0.5

100

110

2.0

50 C 55 C

0.0

1.0 1.5 2.5 4.03.0 3.5

45 C

130BX492.10

0.5

Iout [%]

100

110

2.0

fsw

[kHz]

50 C 55 C

0.0

1.0 1.5 2.5 4.03.0 3.5

45 C

40 C

Specications Design Guide

Voltage

range

Switching

pattern

High overload HO, 150% Normal overload NO, 110%

60 AVM

525–690 V

SFAVM

Table 6.19 Derating for Switching Frequency, 315–1000 kW at 400 V AC (350–1150 hp at 575 V AC)

F C - T

130BC530.10

X S A B CX X X X

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 302221 23 272524 26 28 29 31 373635343332 38 39

X D

Ordering Information

7 Ordering Information

7.1 Ordering Form

Table 7.1 Type Code String

VLT® Parallel Drive Modules

Product groups

Frequency converter series

Generation code

Power rating

Phases

Mains Voltage

Enclosure Enclosure type Enclosure class Control supply voltage

Hardware conguration

RFI lter/Low Harmonic Drive/12-

pulse

Brake

Display (LCP)

Coating PCB

Mains option

Adaptation A

Adaptation B

Software release

Software language

A options

B options

C0 options, MCO

C1 options

C option software

D options

1–3

4–6

8–10

13–15

16–23

16–17

24–27

29–30

31–32

33–34

36–37

38–39

Not all choices/options are available for each variant. To verify if the appropriate version is available, consult the drive congurator on the Internet.

7.2 Drive Congurator

It is possible to design a frequency converter according to the application requirements by using the ordering number system shown in Table 7.1 and Table 7.2.

Order standard frequency converters and frequency converters with integral options by sending a type code string describing the product to the local Danfoss sales oce, for example:

FC-302N800T5E00P2BGC7XXSXXXXAXBXCXXXXDX

The meaning of the characters in the string are Table 7.3 and Table 7.4.

Match the appropriate drive for the proper application using the drive congurator. The drive congurator automatically generates an 8-digit sales number to be delivered to the local sales oce. It is also possible to establish a project list with several products and send it to a Danfoss sales representative.

The drive congurator can be found on the global internet site: www.danfoss.com/drives.

Frequency converters are delivered automatically with a language package relevant to the region from which they are ordered. Four regional language packages cover the following languages:

Language Package 1

English, German, French, Danish, Dutch, Spanish, Swedish, Italian, and Finnish.

dened in

Table 7.2 Type Code Example for Ordering a Frequency

Converter

Ordering Information Design Guide

Language Package 2

English, German, Chinese, Korean, Japanese, Thai, Traditional Chinese, and Bahasa Indonesian.

Language Package 3

English, German, Slovenian, Bulgarian, Serbian, Romanian, Hungarian, Czech, and Russian.

Language Package 4

English, German, Spanish, English US, Greek, Brazilian Portuguese, Turkish, and Polish.

To order frequency converters with a dierent language package, contact the local Danfoss sales oce.

Description Pos Possible choice

Product group 1–6 102: FC 102

202: FC 202

302: FC 302

Generation Code 7 N

Power rating 8–10 250 kW

315 kW

355 kW

400 kW

450 kW

500 kW

560 kW

630 kW

710 kW

800 kW

900 kW

1M0 kW

1M2 kW

Phases 11 3-phases (T)

Mains voltage 11–12 T 4: 380–480 V AC

T 5: 380–500 V AC

T 7: 525–690 V AC

Enclosure 13–15 E00: IP00

C00: IP00 + stainless steel back channel

RFI lter, hardware 16–17 P2: Parallel drive + RFI lter, class A2 (6-pulse)

P4: Parallel drive + RFI lter, class A1 (6-pulse)

P6: Parallel drive + RFI lter, class A2 (12-pulse)

P8: Parallel drive + RFI lter, class A1 (12-pulse)

Brake 18 X: No brake IGBT

B: Brake IGBT mounted

R: Regeneration terminals

S: Brake + regeneration

T: Safe Torque O (STO)

U: Safe Torque O + brake

Display 19 G: Graphical local control panel (LCP)

Coating PCB 20 C: Coated PCB

Mains option 21 J: Circuit breaker + fuses

Adaptation 22 X: Standard cable entries

Adaptation 23 X: No adaptation

Q: Heat sink access panel

Software release 24–27 S067: Integrated motion control

Software language 28 X: Standard language pack

7 7

Table 7.3 Ordering Type Code for VLT® Parallel Drive Modules

Ordering Information

Description Pos Possible choice

A options 29-

B options 31-

C0/ E0 options 33-

C1 options/ A/B in C Option

Adapter

C option software/

E1 options

D options 38-

35 X: No option

36-

VLT® Parallel Drive Modules

AX: No A option

A0: VLT® PROFIBUS DP MCA 101

A4: VLT® DeviceNet MCA 104

A6: VLT® CANopen MCA 105

A8: VLT® EtherCAT MCA 124

AG: VLT® LonWorks MCA 108

AJ: VLT® BACnet MCA 109

AT: VLT® PROFIBUS Converter MCA 113

AU: VLT® PROFIBUS Converter MCA 114

AL: VLT® PROFINET MCA 120

AN: VLT® EtherNet/IP MCA 121

AQ: VLT® Modbus TCP MCA 122

AY: VLT® EtherNet/IP MCA 121

BX: No option

BK: VLT® General Purpose I/O MCB 101

BR: VLT® Encoder Input MCB 102

BU: VLT® Resolver Input MCB 103

BP: VLT® Relay Card MCB 105

BY: VLT® Extended Cascade Controller MCO 101

BZ: VLT® Safe PLC I/O MCB 108

B0: VLT® Analog I/O MCB 109

B2: VLT® PTC Thermistor Card MCB 112

B4: VLT® Sensor Input MCB-114

B6: VLT® Safety Option MCB 150

B7: VLT® Safety Options MCB 151

CX: No option

C4: VLT® Motion Control Option MCO 305

R: VLT® Extended Relay Card MCB 113

S: VLT® Advanced Cascade Controller MCO 102

XX: Standard controller

10: VLT® Synchronizing Controller MCO 350

11: VLT® Position Controller MCO 351

12: VLT® Center Winder MCO 352

DX: No option

D0: VLT® 24 V DC Supply MCB 107

Table 7.4 Ordering Options

Ordering Information Design Guide

7.2.1 Output Filters

The high-speed switching of the frequency converter produces some secondary eects that inuence the motor and the enclosed environment. Two dierent lter types, the dU/dt and the sine-wave lters, are available to address these side

eects. For more detail, see VLT® FC-Series Output Filter Design Guide.

380–500 V Common Individual

400 V, 50 Hz 460 V, 60 Hz 500 V, 50 Hz FsW

kW A hp A kW A kHz IP00 IP23 IP00 IP23

250 480 350 443 315 443 3 130B2849 130B2850 130B2844 130B2845

315 600 450 540 355 540 2 130B2851 130B2852 130B2844 130B2845

355 658 500 590 400 590 2 130B2851 130B2852 130B2844 130B2845

400 745 600 678 500 678 2 130B2853 130B2854 130B2844 130B2845

450 800 600 730 530 730 2 130B2853 130B2854 130B2847 130B2848

500 880 650 780 560 780 2 130B2853 130B2854 130B2847 130B2848

560 990 750 890 630 890 2 2x130B2849 2x130B2850 130B2847 130B2848

630 1120 900 1050 710 1050 2 3x130B2849 2x130B2850 130B2847 130B2848

710 1260 1000 1160 800 1160 2 3x130B2849 2x130B2850 130B2847 130B2848

800 1460 1200 1380 1000 1380 2 3x130B2851 3x130B2852 130B2849 130B2850

7 7

Table 7.5 Available dU/dt Filters, 380–500 V

525–690 V Common Individual

525 V, 50 Hz 575 V, 60 Hz 690 V, 50 Hz FsW

kW A hp A kW A kHz IP00 IP23 IP00 IP23

250 360 350 344 315 344 2 130B2851 130B2852 130B2841 130B2842

300 395 400 410 355 380 1.5 130B2851 130B2852 130B2841 130B2842

315 429 450 450 400 410 1.5 130B2851 130B2852 130B2841 130B2842

400 523 500 500 500 500 1.5 130B2853 130B2854 130B2844 130B2845

450 596 600 570 560 570 1.5 130B2853 130B2854 130B2844 130B2845

500 630 650 630 630 630 1.5 130B2853 130B2854 130B2844 130B2845

560 763 750 730 710 730 1.5 130B2853 130B2854 130B2847 130B2848

670 889 950 850 800 850 1.5 130B2853 130B2854 130B2847 130B2848

750 988 1050 945 – – – 3x130B2849 3x130B2850 130B2847 130B2848

850 1108 1150 1060 1000 1060 1.5 3x130B2849 3x130B2850 130B2847 130B2848

1000 1317 1350 1260 1200 1260 1.5 3x130B2851 3x130B2852 130B2849 130B2850

Table 7.6 Available dU/dt Filters, 525–690 V

380–500 V Common Individual

400 V, 50 Hz 460 V, 60 Hz 500 V, 50 Hz FsW

kW A hp A kW A kHz IP00 IP23 IP00 IP23

250 480 350 443 315 443 3 130B3188 130B3189 130B3186 130B3187

315 600 450 540 355 540 2 130B3191 130B3192 130B3186 130B3187

355 658 500 590 400 590 2 130B3191 130B3192 130B3186 130B3187

400 745 600 678 500 678 2 130B3193 130B3194 130B3188 130B3189

450 800 600 730 530 730 2 2x130B3188 2x130B3189 130B3188 130B3189

500 880 650 780 560 780 2 2x130B3188 2x130B3189 130B3186 130B3187

560 990 750 890 630 890 2 2x130B3191 2x130B3192 130B3186 130B3187

630 1120 900 1050 710 1050 2 2x130B3191 2x130B3192 130B3186 130B3187

710 1260 1000 1160 800 1160 2 3x130B3188 2x130B3189 130B3188 130B3189

800 1460 1200 1380 1000 1380 2 3x130B3188 2x130B3189 130B3188 130B3189

Table 7.7 Available Sine-wave Filters, 380–500 V

U V W U V W U V W U V W

130BF038.10

Ordering Information

525–690 V Common Individual

kW A hp A kW A kHz IP00 IP23 IP00 IP23

525 V, 50 Hz 575 V, 60 Hz 690 V, 50 Hz FsW

250 360 350 344 315 344 2 130B4129 130B4151 130B4125 130B4126

300 395 400 410 355 380 1.5 130B4129 130B4151 130B4125 130B4126

315 429 450 450 400 410 1.5 130B4152 130B4153 130B4125 130B4126

400 523 500 500 500 500 1.5 130B4154 130B4153 130B4129 130B4151

450 596 600 570 560 570 1.5 130B4156 130B4157 – –

500 630 650 630 630 630 1.5 130B4156 130B4157 130B4129 130B4151

560 763 750 730 710 730 1.5 2x130B4142 2x130B4143 130B4129 130B4151

670 889 950 850 800 850 1.5 2x130B4142 2x130B4143 130B4125 130B4126

750 988 1050 945 – – – 2x130B4142 2x130B4143 130B4129 130B4151

850 1108 1150 1060 1000 1060 1.5 3x130B4154 3x130B4155 130B4129 130B4151

1000 1317 1350 1260 1200 1260 1.5 3x130B4154 3x130B4155 130B4129 130B4151

Table 7.8 Available Sine-wave Filters, 525–690 V

VLT® Parallel Drive Modules

1 Drive module 2 Filter

Illustration 7.1 Filter Conguration Without Common Busbars (Individual)

U V W U V W U V W U V W

130BF039.11

2 4

Ordering Information Design Guide

7 7

1 Drive module 4 Cabinet 2

2 Cabinet 1 5 Cables

3 Filter – –

Illustration 7.2 Filter Conguration With Common Busbars (Common)

130BC528.10

General Purpose I/O

SW. ver. XX.XX

MCB 101

FC Series

Code No. 130BXXXX

B slot

X30/

AIN4

7 8654321 9 10 11 12

AIN3

GND(2)

24V

AOUT2

DOUT4

DOUT3

GND(1)

DIN7

COM

DIN

DIN8

DIN9

130BA208.10

130BC526.11

2 3

4 5

9 10

COM DIN

DIN7

DIN8

DIN9

GND(1)

DOUT3

0/24 V DC

DOUT4

0/24 V DC

AOUT2

0/4-20 mA

24 V

GND(2)

AIN3

AIN4

RIN= 5k ohm

RIN= 10k ohm

-0 to +10

VDC

-0 to +10

VDC

0 V 24 V

24 V DC0 V

0 V24 V DC

<500 ohm

>600 ohm

X30/

DIG IN

DIG & ANALOG OUT

ANALOG IN

CPU

CAN BUS

CPU

Control card (FC 100/200/300)

General Purpose I/O option MCB 101

PLC (PNP)

PLC (NPN)

Ordering Information

VLT® Parallel Drive Modules

7.3 Options and Accessories

7.3.1

Galvanic Isolation in the VLT® General Purpose I/O MCB 101

Danfoss oers a wide range of options and accessories for

the VLT® AutomationDrive FC 302. The following options are installed on the control card in either slot A, slot B, or slot C. Refer to Illustration 7.3. For further information, see

Digital/analog inputs are galvanically isolated from other inputs/outputs on the MCB 101 and in the control card of the frequency converter.

the instructions that accompany the optional equipment.

Digital/analog outputs in the MCB 101 are galvanically isolated from other inputs/outputs on the MCB 101, but not from the inputs/outputs on the control card of the frequency converter.

Connect terminals 1 and 5 if the digital inputs 7, 8, or 9 are to be switched by use of the internal 24 V supply (terminal 9). See Illustration 7.5.

1 Slot A

2 Slot B

3 Slot C

Table 7.9

Illustration 7.3 Slot Options on the Control Card

VLT® General Purpose I/O MCB 101 is used for extension of digital and analog inputs and outputs of FC 302. MCB 101

must be tted into slot B in the VLT® AutomationDrive FC

302.

Contents:

Illustration 7.4 MCB 101 Options Module

MCB 101 option module.

•

Extended xture for the LCP.

Terminal cover.

Illustration 7.5 Principle Diagram

Ordering Information Design Guide

7.3.2 Digital Inputs - Terminal X30/1-4

Digital Input Number of digital inputs 4 (6) Terminal number 18, 19, 27, 29, 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP (GND=0 V) <5 V DC Voltage level, logic 1 PNP (GND=0 V) >10 V DC Voltage level, logic 0 NPN (GND=24 V) <14 V DC Voltage level, logic 1 NPN (GND=24 V) >19 V DC Maximum voltage on input 28 V continuous Pulse frequency range 0–110 kHz Duty cycle, minimum pulse width 4.5 ms Input impedance >2 kΩ

7.3.3 Analog Inputs - Terminal X30/11, 12

Analog Input Number of analog inputs 2 Terminal number 53, 54, X30.11, X30.12 Modes Voltage Voltage level -10 V to +10 V Input impedance >10 kΩ Maximum voltage 20 V Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale

Bandwidth VLT® AutomationDrive FC 302: 100 Hz

7.3.4 Digital Outputs - Terminal X30/6, 7

Digital Output Number of digital outputs 2 Terminal number X30.6, X30.7 Voltage level at digital/frequency output 0–24 V Maximum output current 40 mA Maximum load ≥600 Ω Maximum capacitive load <10 nF Minimum output frequency 0 Hz Maximum output frequency ≤32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale

7 7

7.3.5 Analog Output - Terminal X30/8

Analog Output Number of analog outputs 1 Terminal number 42 Current range at analog output 0–20 mA Maximum load GND - analog output 500 Ω Accuracy on analog output Maximum error: 0.5% of full scale Resolution on analog output 12 bit

Ordering Information

7.3.6

VLT® Encoder Input MCB 102

The encoder module can be used as a feedback source for closed-loop ux control (parameter 1-02 Flux Motor Feedback

Source) and closed-loop speed control (parameter 7-00 Speed PID Feedback Source). Congure the encoder option in parameter group 17-** Motor Feedback Option .

The Encoder Option MCB 102 is used for:

VVC+ closed loop.

•

Flux vector speed control.

•

Flux vector torque control.

•

Permanent magnet motor.

•

Supported encoder types:

Incremental encoder: 5 V TTL type, RS422, maximum frequency: 410 kHz.

•

Incremental encoder: 1Vpp, sine-cosine.

•

HIPERFACE® Encoder: Absolute and Sine-Cosine (Stegmann/SICK).

•

EnDat encoder: Absolute and Sine-Cosine (Heidenheim) Supports version 2.1.

•

SSI encoder: Absolute.

•

VLT® Parallel Drive Modules

NOTICE

The LEDs are only visible when removing the LCP. Reaction if there is an encoder error can be selected in parameter 17-61 Feedback Signal Monitoring: [0] Disabled, [1] Warning, or [2] Trip.

When the encoder option kit is ordered separately, the kit includes:

VLT® Encoder Input MCB 102.

•

Enlarged LCP xture and enlarged terminal cover.

•

The encoder option does not support VLT® AutomationDrive FC 302 frequency converters manufactured before week 50/2004. Minimum software version: 2.03 (parameter 15-43 Software Version)

Connector

Designation

X31

1 NC

2 NC 8 VCC 8 V Output (7–12 V, I

3 5 VCC 5 VCC

4 GND GND GND GND

5 A input +COS +COS A input

6 A inv input REFCOS REFCOS A inv input

7 B input +SIN +SIN B input

8 B inv input REFSIN REFSIN B inv input

9 Z input +Data RS485 Clock out Clock out Z input OR +Data RS485

10 Z inv input -Data RS485 Clock out inv. Clock out inv. Z input OR -Data RS485

11 NC NC Data in Data in Future use

12 NC NC Data in inv. Data in inv. Future use

Max. 5 V on X31.5-12

Incremental

encoder (refer

Illustration 7.6)

SinCos encoder

HIPERFACE

(refer to

Illustration 7.7)

EnDat encoder SSI encoder Description

24 V

5 V

24 V Output (21–25 V, I

5 V Output (5 V ±5%, I

max

: 200 mA)

max

125 mA)

: 200 mA)

Table 7.10 Encoder Option MCB 102 Terminal Descriptions for Supported Encoder Types

1) Supply for encoder: see data on encoder.

2 3 12

130BA163.11

754 6 8 9 10 11

24 V

8 V 5 V GND A A B B Z Z D D

Us 7-12V (red)

GND (blue)

+COS (pink)

REFCOS (black)

+SIN (white)

REFSIN (brown)

Data +RS 485 (gray)

Data -RS 485 (green)

1 2 3 12754 6 8 9 10 11

130BA164.10

130BA119.10

Ordering Information Design Guide

Illustration 7.6 Incremental Encoder

Maximum cable length 150 m (492 ft).

7 7

Illustration 7.7 SinCos Encoder HIPERFACE

Illustration 7.8 Rotation Direction

Resolver Input SW. ver. X.XX

MCB 103

Code No.

Option B

Rotor

Resolver stator

Motor

LED 1 REF OK LED 2 COS OK LED 3 SIN OK LED NA

130BA247.11

REF+ REF-

COS-

COS+

SIN+ SIN- S4

COS-

COS+

REF+

REF-

SIN+

SIN-

A+

A-

B+

B-

Z+

Z-

X32/ 31 2 4 5 116 87 109 12

1 2 3 4

S4 S2

Ordering Information

7.3.7

VLT® Resolver Input MCB 103

VLT® Parallel Drive Modules

MCB 103 Resolver option is used for interfacing resolver

motor feedback to VLT® AutomationDrive FC 302. Resolvers are used as motor feedback devices for permanent magnet brushless synchronous motors.

When the resolver option is ordered separately, the kit includes:

Resolver input option.MCB 103.

•

Enlarged LCP

xture and enlarged terminal cover.

Selection of parameters: 17-5* Resolver Interface.

MCB 103 Resolver Option supports a various number of rotor resolver types.

Resolver poles Parameter 17-50 Poles: 2 x 2

Resolver input

voltage

Resolver input

frequency

Transformation ratio Parameter 17-53 Transformation Ratio: 0.1–

Secondary input

voltage

Secondary load

Table 7.11 Resolver Specications

Parameter 17-51 Input Voltage: 2.0–8.0

7.0

Vrms

Parameter 17-52 Input Frequency: 2–15 kHz

x 10.0 kHz

1.1 x 0.5

Maximum 4

Vrms

Illustration 7.9 Resolver Input MCB 103 used with a Permanent

Magnet Motor

Approximately 10 kΩ

NOTICE

The MCB 103 can be used with only rotor-supplied resolver types. Stator-supplied resolvers cannot be used.

LED indicators

The LEDs are active when parameter 17-61 Feedback Signal Monitoring is set to [1] Warning or [2] Trip.

LED 1 is on when the reference signal is OK to resolver. LED 2 is on when Cosinus signal is OK from resolver. LED 3 is on when Sinus signal is OK from resolver.

130BT102.10

Ordering Information Design Guide

Illustration 7.10 Permanent Magnet (PM) Motor with Resolver

as Speed Feedback

Set-up example

In Illustration 7.9, a permanent magnet (PM) Motor is used with resolver as speed feedback. A PM motor must usually operate in ux mode.

Wiring

The maximum cable length is 150 m (492 ft) when a twisted-pair type of cable is used.

NOTICE

Always use shielded motor cables and brake chopper cables. Resolver cables must be shielded and separated from the motor cables. The shield of the resolver cable must be correctly connected to the decoupling plate and connected to chassis (ground) on the motor side.

7 7

Parameter 1-00 Conguration Mode [1] Speed closed loop

Parameter 1-01 Motor Control Principle [3] Flux with feedback

Parameter 1-10 Motor Construction [1] PM, non-salient SPM

Parameter 1-24 Motor Current Nameplate

Parameter 1-25 Motor Nominal Speed Nameplate

Parameter 1-26 Motor Cont. Rated Torque Nameplate

AMA is not possible on PM motors

Parameter 1-30 Stator Resistance (Rs) Motor datasheet

Parameter 30-80 d-axis Inductance (Ld) Motor datasheet (mH)

Parameter 1-39 Motor Poles Motor datasheet

Parameter 1-40 Back EMF at 1000 RPM Motor datasheet

Parameter 1-41 Motor Angle Oset Motor datasheet (usually zero)

Parameter 17-50 Poles Resolver datasheet

Parameter 17-51 Input Voltage Resolver datasheet

Parameter 17-52 Input Frequency Resolver datasheet

Parameter 17-53 Transformation Ratio Resolver datasheet

Parameter 17-59 Resolver Interface [1] Enabled

Table 7.12 Parameters to be Adjusted

Relay 7

NC NCNC

Relay 9Relay 8

1 2 3 12

130BA162.10

754 6 8 9 10 11

130BA177.10

8-9mm

2mm

1 1 1

1 102 3 4 5 6 7 8 9 1211

2 2 3

1 1 1

1 102 3 4 5 6 7 8 9 1211

3 3 3

1 1 1

1 102 3 4 5 6 7 8 9 1211

2 2

130BA176.11

Ordering Information

7.3.8

VLT®Relay Card MCB 105

VLT® Parallel Drive Modules

The MCB 105 includes 3 pieces of SPDT contacts and must be tted into option slot B.

Electrical Data

Maximum terminal load (AC-1)

Maximum terminal load (AC-15)

Maximum terminal load (DC-1)

Maximum terminal load (DC-13)

(Resistive load) 240 V AC 2 A

(Inductive load @ cosφ 0.4) 240 V AC 0.2 A

(Resistive load) 24 V DC 1 A

(Inductive load) 24 V DC 0.1 A Minimum terminal load (DC) 5 V 10 mA

Maximum switching rate at rated load/minimum load 6 min-1/20

-1

1) IEC 947 part 4 and 5

When the relay option kit is ordered separately, the kit includes:

Relay Module MCB 105.

•

Enlarged LCP xture and enlarged terminal cover.

•

Label for covering access to switches S201 (A53), S202 (A54), and S801.

•

Cable strips for fastening cables to relay module.

•

IMPORTANT! The label MUST be placed on the LCP frame to meet UL Approval.

WARNING

Warning Dual supply. Do not combine 24/48 V systems with high-voltage systems.

Illustration 7.11 Disconnect Relay Terminals

Illustration 7.12 Proper Length of Stripped Wire

Illustration 7.13 Correct Method to Install Live Parts and

Control Signals

130BF022.10

Ordering Information Design Guide

7.3.9

VLT® 24 V DC Supply MCB 107

A 24 V DC external supply can be installed for low-voltage supply to the control card and any installed options card, enabling full operation of the LCP without connection to the mains.

24 V DC external supply specication Input voltage range 24 V DC ±15% (maximum 37 V in 10 s) Maximum input current 2.2 A Average input current for FC 302 0.9 A Maximum cable length 75 m (246 ft) Input capacitance load 10 uF Power-up delay 0.6 s The inputs are protected.

Terminal numbers:

Terminal 35: - 24 V DC external supply.

•

Terminal 36: + 24 V DC external supply.

•

When VLT® 24 V DC Supply MCB 107 is supplying the control circuit, the internal 24 V supply is automatically disconnected. For more information on installation, consult the separate instructions that accompany the optional equipment.

7 7

Illustration 7.14 24 V DC Supply Connection

MS 220 DA

11 10

20-28 VDC 10 mA

20-28 VDC

60 mA

com

ZIEHL

X44

12 13 18 19 27 29 32 33 20 37

4NC5NC6NC7NC8NC9NC10 11NC121

PTC

M3~

130BA638.10

Motor protection

MCB 112 PTC Thermistor Card

Option B

Reference for 10, 12

DO FOR SAFE

STOP T37

Code No.130B1137

Control Terminals of FC302

Ordering Information

VLT® Parallel Drive Modules

7.3.10

The MCB 112 option makes it possible to monitor the temperature of an electrical motor through a galvanically

isolated PTC thermistor input. It is a B-option for VLT AutomationDrive FC 302 with Safe Torque O (STO).

VLT® PTC Thermistor Card MCB 112

ATEX Certication with VLT® AutomationDrive FC 302

The VLT® PTC Thermistor Card MCB 112 has been certied for ATEX, which means that the FC 302 together with the MCB 112 can now be used with motors in potentially explosive atmospheres. See the thermistor card for more

For information on mounting and installing the option, see

information.

the instructions that accompany it. For dierent application possibilities, see chapter 17 Application Examples.

X44/1 and X44/2 are the thermistor inputs. X44/12 enables Safe Torque O of the FC 302 (T-37) if the thermistor values make it necessary, and X44/10 informs the FC 302 that a request for Safe Torque O has come from the MCB 112 to ensure suitable alarm handling. To use the

Illustration 7.16 ATmosphère EXplosive (ATEX) Symbol

information from X44/10, 1 of the digital inputs of the

VLT® AutomationDrive FC 302 (or a DI of a mounted option) must be set to PTC Card 1 [80]. Parameter 5-19 Terminal 37 Safe Stop must be congured to the desired Safe Torque O functionality. Default is [1] Safe Stop Alarm.

Illustration 7.15 Installation of MCB 112

Ordering Information Design Guide

Electrical data

Resistor Connection PTC compliant with DIN 44081 and DIN 44082 Number 1..6 resistors in series

Shut-o value 3.3 Ω.... 3.65 Ω ... 3.85 Ω

Reset value 1.7 Ω .... 1.8 Ω ... 1.95 Ω

Trigger tolerance ± 6 °C Collective resistance of the sensor loop <1.65 Ω Terminal voltage ≤ 2.5 V for R ≤3.65 Ω, ≤9 V for R=∞ Sensor current ≤ 1 mA Short circuit 20 Ω≤R ≤40 Ω Power consumption 60 mA

Testing Conditions EN 60 947-8 Measurement voltage surge resistance 6000 V Overvoltage category III Pollution degree 2 Measurement isolation voltage Vbis 690 V Galvanic isolation until Vi 500 V Permanent ambient temperature -20 °C (-4 °F)... +60 °C (140 °F)

EN 60068-2-1 Dry heat Moisture 5–95%, no condensation allowed EMC resistance EN 61000-6-2 EMC emissions EN 61000-6-4 Vibration resistance 10 ... 1000 Hz 1.14 g Shock resistance 50 g

7 7

Safety System Values EN 61508 for Tu=75 °C (167 °F) ongoing SIL 2 for maintenance cycle of 2 years

1 for maintenance cycle of 3 years HFT 0

PFD (for yearly functional test) 4.10 x 10 SFF 78%

λs+λ

Ordering number 130B1137

8494 FIT

934 FIT

-3

130BA965.10

121110987654321

4321 12111098765432121 13 14

+-+-+-+-+-+-+-+-+

A03

Ext. 24 VDC

DI1

DI2

DI3

DI4

DI5

DI6

DI7

X45/ X48/ X46/

X47/

Relay 3 Relay 4 Relay 5 Relay 6

Ordering Information

VLT® Parallel Drive Modules

7.3.11

VLT® Extended Relay Card MCB 113

Ensure galvanic isolation between the VLT® AutomationDrive and the option card MCB 113 by connecting to

The MCB 113 adds 7 digital inputs, 2 analog outputs, and 4 SPDT relays to the standard I/O of the frequency converter, providing increased exibility and compliance

an external 24 V on X58/. If galvanic isolation is not needed, the option card can be powered through internal 24 V from the frequency converter.

with the German NAMUR NE37 recommendations.

The MCB 113 is a standard C1-option for the Danfoss VLT AutomationDrive FC 302 and is detected automatically after mounting.

NOTICE

It is acceptable to combine 24 V signals with highvoltage signals in the relays as long as there is 1 unused relay in-between.

To set up MCB 113, use parameter groups 5-1* Digital Inputs, 6-7* Analog Output 3, 6-8* Analog Output 4, 14-8* Options, 5-4* Relays, and 16-6* Inputs and Outputs.

NOTICE

In parameter group 5-4* Relays, array [2] is relay 3, array

Illustration 7.17 Electrical Connections of MCB 113

Electrical data

[3] is relay 4, array [4] is relay 5, and array [5] is relay 6.

Relays Numbers 4 SPDT Load at 250 V AC/30 V DC 8A Load at 250 V AC/30 V DC with cosφ = 0.4 3.5 A Overvoltage category (contact-earth) III Overvoltage category (contact-contact) II Combination of 250 V and 24 V signals Possible with 1 unused relay in between Maximum thru-put delay 10 ms Isolated from ground/ chassis for use on IT mains systems

Digital Inputs Numbers 7 Range 0/24 V Mode PNP/NPN Input impedance 4 kW Low trigger level 6.4 V High trigger level 17 V Maximum through-put delay 10 ms

Analog Outputs Numbers 2 Range 0/4-20 mA Resolution 11 bit Linearity <0.2%

EMC EMC IEC 61000-6-2 and IEC 61800-3 regarding Immunity of BURST, ESD, SURGE, and Conducted Immunity

Ordering Information Design Guide

7.3.12 Brake Resistors

Brake resistors are used to dissipate the excess energy from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate, and its physical size. Danfoss oers a wide variety of dierent resistors that are specially designed to our frequency converters. For more information, see

chapter 13.2.1 Selection of Brake Resistor. Also, see the VLT Brake Resistor MCE 101 Design Guide.

7.3.13 Sine-wave Filters

When a frequency converter controls a motor, resonance noise is heard from the motor. This noise, which results from the motor design, occurs every time an inverter switch in the frequency converter is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the frequency converter.

For the frequency converter, Danfoss can supply a sine-

lter to dampen the acoustic motor noise. The lter

wave reduces the ramp-up time of the voltage, the peak load voltage U lter results in the current and voltage becoming almost sinusoidal, which reduces the acoustic motor noise.

, and the ripple current ΔI to the motor. The

PEAK

7.3.14 dU/dt Filters

The combination of rapid voltage and an increase in current stresses the motor insulation. These rapid energy uctuations can be reected back to the DC-line in the inverter, which can cause a shutdown. The dU/dt lter is designed to reduce the voltage rise time and the rapid energy change in the motor. This intervention avoids

premature aging and ashover in the motor insulation.

The dU/dt of magnetic noise in the cable that connects the frequency converter to the motor. The voltage wave form is still pulse shaped, but the dU/dt ratio is reduced in comparison to an installation without a lter.

lters have a positive inuence on the radiation

7 7

The ripple current in the sine-wave lter coils also causes some noise. This problem can be solved integrating the lter in a cabinet or similar enclosure.

For specic sine-wave lter part numbers, see chapter 7.2.1 Output Filters.

Max R2(0.08)

Panel cut out

Min 72(2.8)

130BA139.11

129,5± 0.5 mm

64,5± 0.5 mm (2.54± 0.04 in)

(5.1± 0.04 in)

130BA138.11

130BA200.10

Ordering Information

VLT® Parallel Drive Modules

7.3.15 Remote Mounting Kit for the LCP

The LCP can be moved to the front of a cabinet by using the remote built-in kit. Also available is an LCP Kit without LCP. For IP66 units, the ordering number is 130B1117. Use ordering number 130B1129 for IP55 units.

Enclosure IP54 front

Maximum cable length between the LCP and

the unit 3 m (9 ft. 10 in)

Communication standard RS485

Table 7.13 Technical Data for Mounting an LCP to the IP66

Enclosure

Illustration 7.19 Ordering Number 130B1113, LCP Kit with

Graphical LCP, Fasteners, Cable, and Gasket

Illustration 7.18 Dimensions

Illustration 7.20 Ordering Number 130B1114, LCP Kit with

Numerical LCP, Fasteners, and Gasket

Ordering Information Design Guide

7.4 System Design Checklist

Table 7.14 provides a checklist for integrating a frequency converter into a motor control system. The list is intended as a reminder of the general categories and options necessary for specifying the system requirements.

Category Details Notes

FC Model

Power

Volts

Current

Physical

Dimensions

Weight

Ambient operating conditions

Temperature

Altitude

Humidity

Air quality/dust

Derating requirements

Enclosure size

Input

Cables

Type

Length

Fuses

Type

Size

Rating

Options

Connectors

Contacts

Filters

Output

Cables

Type

Length

Fuses

Type

Size

Rating

Options

Filters

Control

Wiring

Type

Length

Terminal connections

Communication

Protocol

Connection

Wiring

Options

Connectors

☑

7 7

Ordering Information

VLT® Parallel Drive Modules

Category Details Notes

Contacts

Filters

Motor

Type

Rating

Voltage

Options

Special tools and equipment

Moving and storage

Mounting

Connection of mains

Table 7.14 System Design Checklist

☑

Considerations During Insta... Design Guide

8 Considerations During Installation

8.1 Operating Environment

For specications regarding ambient conditions, see chapter 6.9 Ambient Conditions for Drive Modules.

NOTICE

CONDENSATION

Moisture can condense on the electronic components and cause short circuits. Avoid installation in areas subject to frost. Install a cabinet heater when the unit is colder than the ambient air. Operating in stand-by mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of moisture.

Aggressive gases, such as hydrogen sulphide, chlorine, or ammonia can damage the electrical and mechanical

components. The VLT® Parallel Drive Modules uses conformal-coated circuit boards to reduce the eects of aggressive gases. For conformal-coating class specications and ratings, see chapter 6.9 Ambient Conditions for Drive Modules.

When installing the unit in dusty environments, pay attention to the following:

Periodic maintenance

When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling capacity of the components, and the components become warmer. The hotter environment decreases the life of the electronic components.

Keep the heat sink and fans free from dust build-up. For

more service and maintenance information, refer to VLT Parallel Drive Modules Service Manual.

Cooling fans

Fans provide airow to cool the unit. When fans are exposed to dusty environments, the dust can damage the fan bearings and cause premature fan failure.

Class d species that if a spark occurs, it is

•

contained in a protected area.

Class e prohibits any occurrence of a spark.

•

Motors with class d protection

Does not require approval. Special wiring and containment are required.

Motors with class e protection

When combined with an ATEX approved PTC monitoring

device like the VLT® PTC Thermistor Card MCB 112, installation does not need an individual approval from an approbated organization.

Motors with class d/e protection

The motor itself has an e ignition protection class, while the motor cabling and connection environment is in compliance with the d classication. To attenuate the high

peak voltage, use a sine-wave Drive Modules output.

When using the VLT® Parallel Drive Modules in a potentially explosive atmosphere, use the following:

Motors with ignition protection class d or e.

•

PTC temperature sensor to monitor the motor

•

temperature.

Short motor cables.

•

Sine-wave output lters when shielded motor

•

cables are not used.

lter at the VLT® Parallel

NOTICE

MOTOR THERMISTOR SENSOR MONITORING

VLT® AutomationDrive units with the MCB 112 option are PTB-certied for potentially explosive atmospheres.

A frequency converter contains many mechanical and electronic components, many of which are vulnerable to environmental eects.

8 8

WARNING

EXPLOSIVE ATMOSPHERE

Do not install the frequency converter in a potentially explosive atmosphere. Install the unit in a cabinet outside of this area. Failure to follow this guideline increases risk of death or serious injury.

Systems operated in potentially explosive atmospheres must fulll special conditions. EU Directive 94/9/EC (ATEX

95) classies the operation of electronic devices in potentially explosive atmospheres.

CAUTION

The frequency converter should not be installed in environments with airborne liquids, particles, or gases capable of aecting and damaging the electronic components. Failure to take the necessary protective measures increases the risk of stoppages, thus reducing the life of the frequency converter.

Degree of protection as per IEC 60529

To prevent cross faults and short circuits between terminals, connectors, tracks, and safety-related circuitry caused by foreign objects, the Safe Torque O (STO) function must be installed and operated in an IP54 or higher rated control cabinet (or equivalent environment).

Considerations During Insta...

VLT® Parallel Drive Modules

Liquids can be carried through the air and condense in the frequency converter and can cause corrosion of components and metal parts. Steam, oil, and salt water can cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP 54/55. As an extra protection, coated printed circuit boards can be ordered as an option.

Airborne particles such as dust can cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of airborne particles is dust particles around the frequency converter fan. In dusty environments, use equipment with enclosure rating IP54/ IP55.

In environments with high temperatures and humidity, corrosive gases such as sulphur, nitrogen, and chlorine compounds cause chemical reactions on the frequency converter components.

Such chemical reactions rapidly aect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh air ventilation, keeping

aggressive gases away from the frequency converter. Optional coated PCBs also oer protection in such environments.

Width [mm (in)] 2-drive: 800 (31.5), 4-drive: 1600 (63)

Depth [mm (in)] 600 (23.6)

Height [mm (in)]

Weight capacity

[kg (lb)]

Ventilation openings See chapter 8.2.4 Cooling and Airow

Table 8.1 Cabinet Requirements

1) Required if Danfoss busbar or cooling kits are used.

2000 (78.7)

2-drive: 450 (992), 4-drive: 910 (2006)

Requirements.

8.2.2 Busbars

If the Danfoss busbar kit is not used, see Table 8.2 for the cross-section measurements that are required when creating customized busbars. For terminal dimensions, refer to chapter 6.1.2 Terminal Dimensions and chapter 6.1.3 DC Bus Dimensions.

Description Width [mm (in)] Thickness [mm (in)]

AC motor 143.6 (5.7) 6.4 (0.25)

AC mains 143.6 (5.7) 6.4 (0.25)

DC bus 76.2 (3.0) 12.7 (0.50)

NOTICE

Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the frequency converter.

Before installing the frequency converter, check the ambient air for liquids, particles, and gases by observing existing installations in the environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabinets and existing electrical installations. One indicator of aggressive airborne gases is blackening of copper rails and cable ends.

Minimum System Requirements

8.2

8.2.1 Cabinet

The kit consists of either 2 or 4 drive modules, depending on the power rating. The cabinets have to meet the following minimum requirements:

Table 8.2 Cross-section Measurements for Customized Busbars

NOTICE

Align busbars vertically to provide maximum airow.

8.2.3 Thermal Considerations

For heat dissipation values, refer to chapter 6.5 Power- dependent Specications. The following heat sources must be considered when determining cooling requirements:

Ambient temperature outside enclosure.

•

Filters (for example, sine-wave and RF).

•

Fuses.

•

Control components.

•

For required cooling air, refer to chapter 8.2.4 Cooling and Airow Requirements.

130BE569.10

Considerations During Insta... Design Guide

8.2.4 Cooling and Airow Requirements

The recommendations provided in this section are necessary for eective cooling of the drive modules within the panel enclosure. Each drive module contains a heat sink fan and a mixing fan. Typical enclosure designs utilize door fans along with the drive module fans to remove waste heat from the enclosure.

Danfoss provides several back-channel cooling kits as options. These kits remove 85% of the waste heat from the enclosure, reducing the need for large door fans.

NOTICE

Make sure that the total ow of the cabinet fans meets the recommended airow.

Drive module cooling fans

The drive module is equipped with a heat sink fan, which provides the required heat sink. Also, there is a cooling fan mounted on the top of the unit, and a small 24 V DC mixing fan mounted under the input plate that operates any time the drive module is powered on.

In each drive module, the power card provides DC voltage to power the fans. The mixing fan is powered by 24 V DC from the main switch mode power supply. The heat sink fan and the top fan are powered by 48 V DC from a dedicated switch mode power supply on the power card. Each fan has a tachometer feedback to the control card to conrm that the fan is operating correctly. On/o and speed control of the fans help reduce unnecessary acoustical noise and extend the life of the fans.

Cabinet fans

When the back-channel option is not used, fans mounted in the cabinet must remove all the heat generated inside the enclosure.

For each enclosure housing 2 drive module, the cabinet fan ow recommendation is as follows:

When back-channel cooling is used, 680 m3/h (400 cfm) ow is recommended.

•

ow rate of 840 m3/h (500 cfm) across the

8 8

When back-channel cooling is not used, 4080 m3/h (2400 cfm) ow is recommended.

•

Illustration 8.1 Airow, Standard Unit (Left), Bottom/Top Cooling Kit (Middle), and Back/Back Cooling Kit (Right)

Considerations During Insta...

VLT® Parallel Drive Modules

8.3 Electrical Requirements for Certications and Approvals

The standard conguration provided in this guide (drive modules, control shelf, wire harnesses, fuses, and microswitches) is UL and CE certied. The following conditions must be met apart from the standard conguration to obtain UL and CE regulatory approval requirements. For a list of disclaimers, see chapter 18.1 Disclaimer.

Use the frequency converter in a heated, indoor-controlled environment. Cooling air must be clean, free from

•

corrosive materials, and electrically conductive dust. See chapter 6.9 Ambient Conditions for Drive Modules for specic limits.

Maximum ambient air temperature is 40 °C (104 °F) at rated current.

•

The drive system must be assembled in clean air, according to enclosure classication. To obtain UL or CE certi-

•

cation regulatory approvals, drive modules must be installed according to the standard conguration provided in this guide.

Maximum voltage and current must not exceed the values provided in for the specied drive conguration.

•

The drive modules are suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical

•

amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by fuses with the standard conguration. Refer to chapter 8.4.1 Fuse Selection. The ampere rating is based on tests done according to UL 508C.

The cables located within the motor circuit must be rated for at least 75 °C (167 °F) in UL-compliant installations.

•

The cable sizes have been provided in for the specied drive conguration.

The input cable must be protected with fuses. Circuit breakers must not be used without fuses in the U.S. Suitable

•

IEC (class aR) fuses and UL (class L or T ) fuses are listed in chapter 8.4.1 Fuse Selection. In addition, country-specic regulatory requirements must be adhered to.

For installation in the U.S., branch circuit protection must be provided according to the National Electrical Code

•

(NEC) and any applicable local codes. To fulll this requirement, use UL-classied fuses.

For installation in Canada, branch circuit protection must be provided according to the Canadian Electrical Code

•

and any applicable provincial codes. To fulll this requirement, use the UL-classied fuses.

Considerations During Insta... Design Guide

8.4 Fuses and Circuit Breakers

To protect the drive system in case 1 or more internal components break down within a drive module, use fuses and/or circuit breakers at the mains supply side.

8.4.1.1 Branch Circuit Protection

To protect the installation against electrical and re hazards, protect all branch circuits in an installation against short circuit and overcurrent according to national and international regulations.

8.4.1.2 Short-circuit Protection

Danfoss recommends the fuses listed in chapter 8.4.1.3 Recommended Fuses for CE Compliance and chapter 8.4.1.4 Recommended Fuses for UL Compliance to achieve CE or UL Compliance in the protection of service personnel and property against the consequences of component breakdown in the drive modules.

8.4.1.3 Recommended Fuses for CE Compliance

Number of drive

modules

2 N450 N500 aR-1600

4 N500 N560 aR-2000

4 N560 N630 aR-2000

4 N630 N710 aR-2500

4 N710 N800 aR-2500

4 N800 N1M0 aR-2500

Table 8.3 6-Pulse Drive Systems (380–500 V AC)

Number of drive

modules

2 N250 N315 aR-630

2 N315 N355 aR-630

2 N355 N400 aR-630

2 N400 N450 aR-800

2 N450 N500 aR-800

4 N500 N560 aR-900

4 N560 N630 aR-900

4 N630 N710 aR-1600

4 N710 N800 aR-1600

4 N800 N1M0 aR-1600

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Number of drive

modules

4 N630 N710 aR-1600

4 N710 N800 aR-2000

4 N800 N900 aR-2500

4 N900 N1M0 aR-2500

4 N1M0 N1M2 aR-2500

Table 8.5 6-Pulse Drive Systems (525–690 V AC)

Number of drive

modules

2 N250 N315 aR-550

2 N315 N355 aR-630

2 N355 N400 aR-630

2 N400 N500 aR-630

2 N500 N560 aR-630

2 N560 N630 aR-900

4 N630 N710 aR-900

4 N710 N800 aR-900

4 N800 N900 aR-900

4 N900 N1M0 aR-1600

4 N1M0 N1M2 aR-1600

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

8 8

(maximum)

Table 8.4 12-Pulse Drive Systems (380–500 V AC)

Table 8.6 12-Pulse Drive Systems (525–690 V AC)

Considerations During Insta...

VLT® Parallel Drive Modules

8.4.1.4 Recommended Fuses for UL Compliance

The drive modules are supplied with built-in AC fuses. The modules have been qualied for 100 kA short-circuit

•

current rating (SCCR) for the standard busbar congurations at all voltages (380–690 V AC).

If no power options or extra busbars are connected externally, the drive system is qualied for 100 kA SCCR with

•

any Class L or Class T UL-listed fuses connected at the input terminals of the drive modules.

Do not exceed the listed fuse rating in Table 8.8 to Table 8.9 with the current rating of the Class L or Class T fuses.

•

Number of drive

modules

2 N450 N500 1600 A

4 N500 N560 2000 A

4 N560 N630 2000 A

4 N630 N710 2500 A

4 N710 N800 2500 A

4 N800 N1M0 2500 A

Table 8.7 6-Pulse Drive Systems (380–500 V AC)

Number of drive

modules

2 N250 N315 630 A

2 N315 N355 630 A

2 N355 N400 630 A

2 N400 N450 800 A

2 N450 N500 800 A

4 N500 N560 900 A

4 N560 N630 900 A

4 N630 N710 1600 A

4 N710 N800 1600 A

4 N800 N1M0 1600 A

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Recommended fuse

(maximum)

Number of drive

modules

4 N630 N710 1600 A

4 N710 N800 2000 A

4 N800 N900 2500 A

4 N900 N1M0 2500 A

4 N1M0 N1M2 2500 A

Table 8.9 6-Pulse Drive Systems (525–690 V AC)

Number of drive

modules

2 N250 N315 550 A

2 N315 N355 630 A

2 N355 N400 630 A

2 N400 N500 630 A

2 N500 N560 630 A

2 N560 N630 900 A

4 N630 N710 900 A

4 N710 N800 900 A

4 N800 N900 900 A

4 N900 N1M0 1600 A

4 N1M0 N1M2 1600 A

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Table 8.8 12-Pulse Drive Systems (380–500 V AC)

Any minimum 500 V UL-listed fuse can be used for the 380–500 V AC

drive systems.

Table 8.10 12-Pulse Drive Systems (525–690 V AC)

Any minimum 700 V UL-listed fuse can be used for the 525–690 V AC

drive systems.

175ZA062.12

EMC and Harmonics Design Guide

9 EMC and Harmonics

9.1 General Aspects of EMC Emissions

Electrical interference is most commonly found at frequencies in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor. Capacitive currents in the motor cable coupled with a high dU/dt from the motor voltage generate leakage currents. Shielded motor cables increase the leakage current (see Illustration 9.1) because they have higher capacitance to ground than unshielded cables. If the leakage current is not ltered, it causes greater interference on the mains in the radio frequency range below 5 MHz. Since the leakage current (I1) is carried back to the unit through the shield (I 3), there is only a small electromagnetic eld (I4) from the shielded motor cable.

While the shield reduces the radiated interference, it increases the low-frequency interference on the mains. Connect the motor cable shield to the frequency converter enclosure and to the motor enclosure. To connect the shield, use integrated shield clamps to avoid twisted shield ends. The twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield eect and increases the leakage current (I4). If a shielded cable is used for eldbus, relay, control cable, signal interface, or brake, mount the shield on the enclosure at both ends. In some situations, however, it is necessary to break the shield to avoid current loops.

1 Ground wire

2 Shield

3 AC mains supply

4 Frequency converter

5 Shielded motor cable

6 Motor

Illustration 9.1 Leakage Currents

Illustration 9.1 shows an example of a 6-pulse frequency converter, but could be applicable to a 12-pulse as well.

9 9

EMC and Harmonics

If placing the shield on a mounting plate, use a metal plate because the shield currents must be conveyed back to the frequency converter. Ensure good electrical contact from the mounting plate through the mounting screws to the frequency converter chassis. When unshielded cables are used, some emission requirements are not complied with, although the immunity requirements are observed.

To reduce the interference level from the entire system (unit and installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) comes from the control electronics. For more information on EMC, see chapter 9.5 EMC Recommendations.

VLT® Parallel Drive Modules

9.2 EMC Test Results

The following test results have been obtained using a frequency converter (with options if relevant), a shielded control cable, a control box with potentiometer, motor shielded cables, and a motor.

RFI lter type Conducted emission Radiated Emission

Standards and

requirements

P2, P4 (FC 302) No 150 m No Yes

P6, P8 (FC 302) 150 m (492 ft) 150 m (492 ft) Yes Yes

Table 9.1 EMC Test Results (Emission and Immunity)

1) An external RFI

lter is required to meet the C2 category.

EN/IEC 61800-3 Category C2 Category C3 Category C2 Category C3

WARNING

This type of power drive system is not intended to be used on a low-voltage public network that supplies domestic premises. Radio frequency interference is expected if used on such a network, and supplementary mitigation measures may be required.

The frequency converter meets the emission requirement for C3 category with 150 m (492 ft) shielded cable. In order to meet the C2 category requirement, an external RFI lter is required.

Illustration 9.2 shows the electrical diagram of the RFI lter that was used to qualify the frequency converter. In this scenario, the RFI lter is isolated from the ground, and the RFI relay is disabled using parameter 14-50 RFI Filter.

The attenuation factor for the RFI

lter is provided in Illustration 9.3.

L1 L1

130BF078.10

101-1 30

-20

-40

-60

-80

-100

-120

dBm

130BF079.10

EMC and Harmonics Design Guide

1 Line 2 Load

Table 9.2

Illustration 9.2 Electrical Diagram of RFI Filter

9 9

Illustration 9.3 Attenuation Requirement for an External Filter

Start 150.0 kHz Stop 30.0 MHz

1 MHz

A_QP

A_AVG

130BF080.10

90 dBµV

80 dBµV

70 dBµV

60 dBµV

50 dBµV

40 dBµV

30 dBµV

20 dBµV

10 dBµV

83.9 dBµV 202 kHz

M1[1]

0.000 s

EMC and Harmonics

VLT® Parallel Drive Modules

Illustration 9.4 Conducted Emission on the Mains in P4/P8 Conguration Without an External RFI Filter

90 dBµV

80 dBµV

70 dBµV

60 dBµV

50 dBµV

40 dBµV

30 dBµV

20 dBµV

10 dBµV

Start 150.0 kHz Stop 30.0 MHz

1 MHz

87.31 dBµV 202 kHz

M1[1]

0.000 s

A_QP

A_AVG

EMC and Harmonics Design Guide

Illustration 9.5 Conducted Emission on the Mains in P4/P8 Conguration Without an External RFI Filter

9 9

90 dBµV

80 dBµV

70 dBµV

60 dBµV

50 dBµV

40 dBµV

30 dBµV

20 dBµV

10 dBµV

Start 150.0 kHz Stop 30.0 MHz

1 MHz

79.81 dBµV 202 kHz

M1[1]

0.000 s

A_QP

A_AVG

130BF065.10

EMC and Harmonics

VLT® Parallel Drive Modules

Illustration 9.6 Conducted Emission on the Mains in P4/P8 Conguration Without an External RFI Filter

EMC and Harmonics Design Guide

9.3 Emission Requirements

According to the EMC product standard for frequency converters EN/IEC 61800-3, the EMC requirements depend on the environment in which the frequency converter is installed. These environments along with the mains voltage supply requirements are dened in Table 9.3.

Category Denition

C1 Frequency converters installed in a home and oce environment with a supply

voltage less than 1000 V.

C2 Frequency converters installed in the home and oce environment with a supply

voltage less than 1000 V. These frequency converters are not plug-in and cannot be

moved and are intended to for professional installation and commissioning.

C3 Frequency converters installed in an industrial environment with a supply voltage

lower than 1000 V.

C4 Frequency converters installed in an industrial environment with a supply voltage

equal to or above 1000 V or rated current equal to or above 400 A or intended for

use in complex systems.

Table 9.3 Emission Requirements

Conducted emission requirement

according to EN 55011 limits

Class B

Class A Group 1

Class A Group 2

No limit line

Make an EMC plan

When the generic emission standards are used, the frequency converters are required to comply with Table 9.4

Environment Generic standard

First environment

(home and oce)

Second environment

(industrial environment)

Table 9.4 Generic Emission Standard Limits

EN/IEC 61000-6-3 Emission standard for residential, commercial,

and light industrial environments.

EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1

Conducted emission requirement

according to EN 55011 limits

Class B

9 9

EMC and Harmonics

VLT® Parallel Drive Modules

9.4 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and oce environment. All Danfoss frequency converters comply with the requirements for both the industrial and the home/oce environment.

To document immunity against electrical interference, the following immunity tests have been performed on a frequency converter (with options if relevant), a shielded control cable and a control box with potentiometer, motor cable, and motor.

The tests were performed in accordance with the following basic standards. For more details, see Table 9.5.

EN/IEC 61000-4-2: Electrostatic discharges (ESD): Simulation of electrostatic discharges from human beings.

•

EN/IEC 61000-4-3: Incoming electromagnetic

•

radar and radio communication equipment, as well as mobile communications equipment.

EN/IEC 61000-4-4: Burst transients: Simulation of interference brought about by switching a contactor, relay, or

•

similar devices.

EN/IEC 61000-4-5: Surge transients: Simulation of transients brought about by lightning strikes near installations.

•

EN/IEC 61000-4-6: RF common mode: Simulation of the eect from radio-transmission equipment joined by

•

connection cables.

eld radiation, amplitude modulated simulation of the eects of

Basic standard Burst

IEC 61000-4-4

Acceptance criterion B B B A A

Line

Motor

Brake 4 kV CM

Load sharing 4 kV CM

Control wires

Standard bus 2 kV CM

Relay wires 2 kV CM

Application and Fieldbus

options

LCP cable

External 24 V DC

Enclosure

Table 9.5 EMC Immunity Form, Voltage Range: 380–500 V, 525–600 V, 525–690 V

1) Injection on cable shield.

AD: Air Discharge; CD: Contact Discharge; CM: Common mode; DM:

4 kV CM

2 kV CM

2 V CM

– –

Surge

IEC 61000-4-5

2 kV/2 Ω DM

4 kV/12 Ω CM

4 kV/2 Ω

2 kV/2 Ω

0.5 kV/2 Ω DM

1 kV/12 Ω CM

Dierential mode.

ESD

IEC

61000-4-2

– – 10 V

8 kV AD

6 kV CD

Radiated

electromagnetic eld

IEC 61000-4-3

10 V/m –

RF common

mode voltage

IEC 61000-4-6

RMS

EMC and Harmonics Design Guide

9.5 EMC Recommendations

The following is a guideline to good engineering practice when installing frequency converters. Follow these guidelines in compliance with EN/IEC 61800-3 First environment. If the installation is in EN/IEC 61800-3 Second environment, industrial networks, or in an installation with its own transformer, deviation from these guidelines is allowed but not recommended.

Good engineering practice to ensure EMC-correct electrical installation:

Use only braided shielded/armored motor cables and braided shielded control cables. The shield provides a

•

minimum coverage of 80%. The shield material must be metal, not limited to but typically copper, aluminum, steel, or lead. There are no special requirements for the mains cable.

Installations using rigid metal conduits are not required to use shielded cable, but the motor cable must be

•

installed in conduit separate from the control and mains cables. Full connection of the conduit from the frequency converter to the motor is required. The EMC performance of manufacturer must be obtained.

Connect the shield conduit to ground at both ends for motor cables and for control cables. Sometimes, it is not

•

possible to connect the shield in both ends. If so, connect the shield at the frequency converter. See also chapter 9.5.2 Grounding of Shielded Control Cables.

Avoid terminating the shield with twisted ends (pigtails). It increases the high frequency impedance of the shield,

•

which reduces its eectiveness at high frequencies. Use low impedance cable clamps or EMC cable glands instead.

Avoid using unshielded motor or control cables inside cabinets housing the frequency converter, whenever

•

possible.

exible conduits varies a lot and information from the

Leave the shield as close to the connectors as possible.

Illustration 9.7 shows an example of an EMC-correct electrical installation of an IP20 frequency converter. The frequency converter is tted in an installation cabinet with an output contactor and connected to a PLC, which is installed in a separate cabinet. Other ways of doing the installation could have just as good an EMC performance, provided the guidelines to engineering practice are followed.

If the installation is not carried out according to the guideline, and if unshielded cables and control wires are used, some emission requirements are not in compliance, although the immunity requirements are fullled.

9 9

Reinforced protective ground

Mains supply

L1 L2 L3 PE

PLC

Control cables

Minimum 16 mm

equalizing cable

Minimum 200 mm between control cables, motor cable, and mains cable

Motor, 3-phases and protective ground

PLC, etc. Panel

Output contactor, etc.

Ground rail

Cable insulation stripped

All cable entries in 1 side of panel

130BA048.14

EMC and Harmonics

VLT® Parallel Drive Modules

Illustration 9.7 EMC-correct Electrical Installation of a Frequency Converter in Cabinet

9.5.1 Using Shielded Control Cables

Danfoss recommends braided shielded/armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables.

The ability of a cable to reduce the incoming and outgoing radiation of electric noise depends on the transfer impedance (ZT). The shield of a cable is normally designed to reduce the transfer of electric noise. However, a shield with a lower transfer impedance (ZT) value is more eective than a shield with a higher transfer impedance (ZT).

Danfoss VLT 380-500 V, VLT 525-690 V Design Manual

Specifications and Main Features

Frequently Asked Questions

User Manual