Danfoss VLT 5042, VLT 5052, VLT 5072, VLT 5062, VLT 5152 Operating Instructions Manual
...
Operating Instructions
VLT® 5000 Crane
■ Contents
VLT® 5000 Crane
Introduction
Safety ....................................................................................................................... 4
General Instructions ................................................................................................. 5
Abbreviations and Definitions .................................................................................... 6
Brief Product Description .......................................................................................... 9
Function and System Description ............................................................................. 9
Key Diagram for VLT 5000 Crane 5042, 5102 400-500 V ....................................... 14
Key Diagram for VLT 5000 Crane 5122-5202 400-500 V ....................................... 15
......................................................................................................... 3
Technical Data .................................................................................................. 16
General Technical Data ........................................................................................... 16
Mains Supply 400 - 500 V ...................................................................................... 20
Mains supply 3 x 400 - 500 V ................................................................................. 20
Fuses ..................................................................................................................... 22
Mechanical Dimensions .......................................................................................... 23
Installation ......................................................................................................... 24
General Warning before Installation ........................................................................ 24
Mechanical Installation ........................................................................................... 24
Installation of VLT 5042–5062 400-500 V Compact IP20/IP00 ............................... 24
Installation of VLT 5072-5202 400-500 V Compact IP20/IP00 ................................ 25
Electrical Installation ............................................................................................... 26
RFI switch .............................................................................................................. 33
LCP - Local Control Panel .......................................................................... 36
Control Panel ......................................................................................................... 36
Display ................................................................................................................... 37
Parameter programming ........................................................................................ 39
Programming .................................................................................................... 42
General Advice on Programming ............................................................................ 42
Operation & Display ................................................................................................ 50
Load and Motor ..................................................................................................... 54
References & Limits ................................................................................................ 58
Inputs & Outputs .................................................................................................... 61
Application Functions ............................................................................................. 68
Service Functions ................................................................................................... 70
Crane Functions ..................................................................................................... 74
Serial communication .................................................................................. 80
Factory Settings ..................................................................................................... 81
Defined Parameters ................................................................................................ 85
All About VLT 5000 Crane .......................................................................... 86
Status Messages .................................................................................................... 86
List of Warnings and Alarms ................................................................................... 87
Warnings ................................................................................................................ 87
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1
VLT® 5000 Crane
Appendix ............................................................................................................. 92
Trouble-shooting .................................................................................................... 92
Derating for air pressure ......................................................................................... 94
Efficiency .............................................................................................................. 113
General aspects of EMC emissions ...................................................................... 114
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MG.50.N4.02 - VLT is a registered Danfoss trademark
VLT® 5000 Crane
VLT 5000 Crane
175ZA522.12
Operating instructions
Software version: 20.3x
These operating instructions can be used for VLT 5000
Crane frequency converters with software version 20.3x.
See software version number in parameter 624.
Introduction
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3
VLT® 5000 Crane
■Safety
The voltage of the frequency converter
is dangerous whenever the equipment is
connected to mains. Incorrect installation
of the motor or the frequency converter may cause
damage to the equipment, serious personal injury
or death. Consequently, the instructions in this
manual, as well as national and local rules and safety
regulations, must be complied with
■Safety Regulations
1. The frequency converter must be disconnected
from mains if repair work is to be carried out. Check
that the mains supply has been disconnected
and that the necessary time has passed before
removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of
the frequency converter does n
the equipment from mains and is thus n
be used as a safety switch.
3. Correct protective earthing of the equipment
must be established, the user must be protected
against supply voltage, and the motor must be
protected against overload in accordance with
applicable national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is n
in the factory setting. If this function is desired,
set parameter 128 to data value ETR trip or
data value ETR warning.
N
ote: The function is initialised at 1.16 x rated
motor current and rated motor frequency. For
the North American market: The ETR function
ot disconnect
ot to
ot included
provide class 20 motor overload protection
in accordance with NEC.
6. Do n
7. Please note that the frequency converter has more
■Warning Against Unintended Start
1. The motor can be brought to a stop by means
2. While parameters are being changed, the
3. A motor that has been stopped may start if faults
4. Immediate stop. Direct stop input (term. 37). When
s
ot remove the plugs for the motor and mains
supply while the frequency converter is connected
to mains. Check that the mains supply has been
disconnected and that the necessary time has
passed before removing motor and mains plugs.
voltage inputs than L1, L2 and L3, when loadsharing
terminals (linking of DC intermediate circuit) and
external 24 V DC have been installed. Check
that all voltage inputs have been disconnected
and that the necessary time has passed before
repair work is commenced.
of digital commands, bus commands, references
or a local stop, while the frequency converter
is connected to mains. If personal safety
considerations make it necessary to ensure
that no unintended start occurs, these stop
functions are not sufficient.
motor may start. Consequently, the stop key
[STOP/RESET] must always be activated, following
which data can be modified.
occur in the electronics of the frequency converter,
or if a temporary overload or a fault in the supply
mains or the motor connection ceases.
contact is open, the drive will stop (coast).
Warning:
Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains.
Also make sure that other voltage inputs have been
disconnected, such as external 24 V DC, load-sharing (linkage of
DC intermediate circuit), as well as the motor connection for
kinetic back-up.
Using VLT 5042-5062: wait at least 15 minutes.
Using VLT 5072-5202: wait at least 20 minutes.
175ZA523.11
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VLT® 5000 Crane
■General Instructions
These Operating Instructions are intended for
persons who are to install, operate and program
the VLT 5000 Crane.
They comprise the specific technical publications on
the VLT 5000 Crane and are delivered with the product.
When reading these Operating Instructions you come across different symbols that require special attention:
The symbols used are the following:
Indicates a general warning
Indicates a high-voltage warning
NB!:
Indicates something to be noted by the reader
Introduction
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5
■Abbreviations and Definitions
■Frequency converter
Abbreviation/Definition Description
I
VLT,MAX
I
VLT,N
U
VLT,MAX
■Output
Abbreviation/Definition Description
I
M
U
M
f
M
Break-away torque
VLT® 5000 Crane
The maximum output current
The rated output current supplied by the frequency converter
The maximum output voltage
The current transmitted to the motor
The voltage transmitted to the motor
The frequency transmitted to the motor
η
VLT
The efficiency of the frequency converter is defined as the ratio between the
power output and power input
■NO/NC
Abbreviation/Definition Description
NO Normally open
NC Normally closed
■Input
Abbreviation/Definition Description
Control command
Immediate stop
Stop command
By means of LCP and the digital inputs, it is possible to start and stop the
connected motor.
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■Motor
I
M,N
f
M,N
U
M,N
P
M,N
n
M,N
T
M,N
■References
VLT® 5000 Crane
Abbreviation/Definition Description
The rated motor current (nameplate data)
The rated motor frequency (nameplate data)
The rated motor voltage (nameplate data)
The rated power delivered by the motor (nameplate data)
The rated motor speed (nameplate data)
The rated torque (motor)
Abbreviation/Definition Description
Analogue ref. A signal transmitted to input 53, 54 or 60. Can be voltage or current
Binary ref. A signal transmitted to the serial communication port
Ref
MAX
The maximum value which the reference signal may have. Set in parameter 205
■Miscellaneous
Abbreviation/Definition Description
ELCB Earth Leakage Circuit Breaker
Trip A state which occurs in different situations, eg. if the frequency converter is subject to a live zero warning.
A trip can be cancelled by pressing Reset
Trip locked A state which occurs in different situations, eg. if the frequency converter is subject to an overtemperature.
A locked trip can be cancelled by cutting off mains and restarting the frequency converter and pressing
Reset
Initializing If initializing is carried out (see parameter 620), the frequency converter returns to the factory setting
LCP The Local Control Panel, which makes up a complete interface for control and programming of VLT 5000
Crane. The control panel is detachable and may, as an alternative, be installed up to 3 metres away from
the frequency converter, ie. in a front panel, by means of the installation kit option
Flux Vector If compared with standard voltage/frequency ratio control, Flux Vector improves the dynamics and the
stability, both when the speed reference is changed and in relation to the load torque
Thermistor A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter
or motor)
Analogue inputs The analogue inputs can be used for controlling various functions of the frequency converter. There are
two types of analogue inputs:
Current input and voltage input
Analogue outputs There are two analogue current outputs
Digital inputs The digital inputs can be used for controlling various functions of the frequency converter
Digital outputs There are four digital outputs, two of which activate relay switches.
Brake resistor The brake resistor is a module capable of absorbing the brake power that is generated in regenerative
braking. This regenerative braking power increases the intermediate circuit voltage and a brake chopper
ensures that the power is transmitted to the brake resistor
Incremental encoder An external, digital pulse transmitter used for feeding back information on motor speed. The encoder is
used in applications where high accuracy in speed control is required
AWG Means American Wire Gauge, ie. the American measuring unit for cable cross-section
Introduction
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7
VLT® 5000 Crane
■Miscellaneous- continued
Abbreviations/Definitions Description
Manual initialisation Press the [CHANGE DATA] + [MENU] + [OK] keys at the same time to carry out
manual initialisation. See also Parameter 620.
Note that manual initialisation is only to be used if the reset function does not work!
SFAVM Switching pattern called Stator Flux oriented Asynchronous Vector Modulation
On-line/off-line parameters On-line parameters are activated immediately after the data value is changed.
Off-line parameters are not activated until OK has been entered on the control unit
CT characteristics Constant torque characteristics, used for all applications, such as conveyor belt
and cranes.
MCM Stands for Mille Circular Mil, an American measuring unit for cable cross-section
1 MCM=0.5067mm
ETR Electronic thermal relay is a thermal load calculation based on present load and
time. Its purpose is to estimate the motor temperature
CP Constant power
2
s
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■Brief Product Description
The VLT 5000 Crane frequency converter supplies
a motor with variable voltage and frequency and
thereby enables infinitely variable speed control of
three-phased standard AC-motors.
The VLT 5000 Crane features the Flux Vector
control system.
The VLT 5000 Crane uses a digital technique
making it possible to program the different control
inputs and signal outputs.
The user can easily program the desired functions
by means of the VLT 5000 Crane control panel or
the user interfaces RS485 and RS232.
The VLT 5000 Crane is protected against the transients
occurring in the mains supply. Furthermore, a
good power factor and low peak current, reducing
the load on the mains installation, are ensured
through intermediate circuit coils.
Current measurement on all three motor phases
perfectly protects VLT 5000 Crane against earthing and
short-circuiting faults on the motor connenction.
VLT® 5000 Crane
Introduction
VLT 5000 Crane offers:
• Full utilisation of control range
• 130% torque for acceleration
• Fine adjustment at standstill + full load possible
without activating the system brake
■System Description
The sketch on next page shows how a tower crane
works together with VLT Crane Control.
The system consists of the following:
Efficient monitoring of the mains supply phases
ensures that the unit stops in case of phase failure.
This eliminates the risk of overloading the inverter an
the capacitors in the intermediate circuit and thereby
prolongs the service life of the frequency converter.
As standard, VLT 5000 Crane features integral
thermal protection. If a situation of thermal overload
occurs, this function cuts out the inverter.
The VLT 5000 Crane features reliable galvanic isolation
on all control terminals and integrated electronic
thermal protection on the motor.
■Function and System Description
With VLT 5000 Crane the speed is infinitely varied in the
whole speed range from standstill (0 RPM) until rated
speed (750 RPM for VLT 5052-5072, 1125 RPM for
VLT 5102) according to the CT characteristic and rated
power up to max. speed (3000 or 4500 RPM).
There is full torque in the whole speed range.
1. VLT 5000 Flux Vector Control
2. Brake resistor
d
3. Motor
4. Cable drum
5. Angular gear box
6. NC system brake
7. Electric 2-step-gears: Normal load and heavy load
8. Optical encoder: Motor speed information for
flux vector control with closed loop
9. Load signals: VLT 5000 Crane checks on the basis of
load signals that the working range is not exceeded
10. Control signal: Analogue reference as well as
hoist, lowering and position operation
11. Quick stop with brake
12. Digital outputs: For combination of warning
and alarm at your operation
13. Crane ready signal
14. Gear step selection signal
15. VLT ready signal
16. RS 485 bus
17. RS 232 bus
18. Local control panel
MG.50.N4.02 - VLT is a registered Danfoss trademark
Installation and mains connection of brake resistor
and motor are described in Electrical installation
9
VLT® 5000 Crane
■Description of Functions
With Danfoss VLT 5000 Crane the hoist/lower function
can be infinitely varied in the whole speed range.
Up to 750 RPM for VLT 5052-5072, 1125 RPM for
VLT 5102, 1500 RPM for VLT 5152-5202, respectively
themax. torquecurveappliesandabove750
RPM for VLT 5052-5072, 1125 RPM for VLT 5102,
1500 RPM for VLT 5152-5202, respectively the
max. power curve. There is up to 130% torque for
acceleration in the whole speed range.
Working curve, motor:
1: Speed limit at heavy load (parameter 702)
2: Speed limit at normal load (parameter 701)
The 2-step gear box (see System description )
increases the working range, as it is possible to switch
between normal load and heavy load.
VLT 5000 will optimise the motor control to the selected
gear stage on the basis of the signal on terminal
29, see System Description, position 14.
ignal definition
S
24 V signal: Normal load
0 V signal: Heavy load
■Operating Status at Remote Control
Control ready
Voltage on VLT 5000 Crane. The frequency
converter is ready for use and the control card
receives supply voltage.
No faults were found during initialisation.
Inverter section disabled.
10
Normal operation
The reference signal is higher than minimum. Up to
750 RPM the working range is limited by max. torque.
Above 750 RPM it is working in field weakening range.
Here the working range is limited by constant power.
MG.50.N4.02 - VLT is a registered Danfoss trademark
VLT 5000 Crane controls the mechanical brake
of the crane. It holds the load when speed is
below the set minimum value.
VLT 5000 Crane monitors that the system brake
holds and releases the load as required. In case
of faults, Brake fault 2 is displayed.
Load determination and speed measuring will ensure
that the working range is not exceeded. For each
load contact the max. allowed motor speed is set
(parameters 701 and 702). VLT 5000 Crane cuts off
automatically when motor speed for the activated
load contact exceeds the value recorded
Positioning
The reference signal is higher than minimum. The
condition for VLT ready is fulfilled. 24V is applied
to terminal 17 (parameter 301).
During positioning the speed is limited to 750 RPM
for VLT 5052-5072, 1125 RPM for VLT 5102, 1500
RPM for VLT 5152-5202, respectively, and system
brake is not activated at 0 RPM.
Quick stop with brake
If control signal to terminal 27(parameter 304)
is removed, the motor ramps down according
to the alternative ramp (parameter 212) and the
brake is activated momentarily.
■Operating Status at Local Operation
It is only possible to change to local operation from
Control Ready. Besides, parameter 003 must be
set for Local and parameter 010 for Enable.VLT
5000 Crane can be operated over the control panel
or over parameters 004 - 009. This state acts
as Normal operating state, however there are no
load functions and monitoring of system brake.
This means that the whole working range from 0
- 3000 RPM can be used and the crane system
brake is controlled at approx. 0 RPM.
VLT® 5000 Crane
Brake fault 2
VLT 5000 Crane monitors in the state normal operation,
that the system brake releases the load as required.
If that is not the case Brake fault 2 applies. The unit
will cut in the system brake again. This means that the
system brake signal is deactivated. This ensures that
the load is held. Then the inverter section is disabled.
Brake fault 2 may also occur during commissioning
if the encoder connection is not correct.
Atreference0theunitgoesbacktothestateVLTready.
Function fault
VLT 5000 Crane monitors several functions. Should
severe faults occur, the unit will trip automatically.
For fault types, see Trouble-shooting
To reset the fault switch off/switch on the mains
supply and press the stop/reset button.
■System Components
Motor
Select the motor type for the rated output in question
in parameters 102-106, 150-155..
Incremental Encoder
The encoder must meet the following requirements:
• Pulses pr. revolution, see parameter 329
• Out puts: A (0º ), inv. A, B ( 9 0 º), inv. B, Z, i nv. Z
• Supply: +5 V ±5%
• Max. current (5V supply): 200mA
Note that outputs must be compatible with RS 422!
Brake resistor
See data for calculation in Control with brake function.
Introduction
■Fault Status at Remote and Local Control
Brake fault 1
VLT 5000 Crane monitors in the state VLT ready that
the system brake holds the load as required. If that is
not the case, Brake fault 1 appliesandtheloadisslowly
lowered according to the speed set in parameter 704.
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11
VLT® 5000 Crane
■Control Principle
A frequency converter rectifies AC voltage from mains
into DC voltage. This DC voltage is then converted into
aACvoltagewithavariableamplitudeandfrequency.
1. Mains voltage
3 x 400 - 500 V AC, 50 / 60 Hz.
2
. Rectifier
A three-phase rectifier bridge that rectifies AC
voltage into DC voltage.
3
. Intermediate circuit
The motor is thus supplied with variable voltage and
frequency, which enables infinitely variable speed
control of three-phased, standard AC motors.
5
. Intermediate circuit capacitors
Smooth the intermediate circuit voltage.
. Inverter
6
Converts DC voltage into variable AC voltage
with a variable frequency.
. Motor voltage
7
Variable AC voltage, 0-100% of mains supply voltage.
Variable frequency: 0 - 300 Hz.
4. Intermediate circuit coils
Smooth the intermediate circuitcurrent and limit the
load on mains and components (mains transformer,
wires, fuses and contactors).
■Flux Vector Control Principle
TheaimofdevelopingtheFluxVectorcontrol
principle has been to obtain a robust motor control
that is tolerant to different motor characteristics
without motor derating being required.
The current is split into magnetising and
torque-generating parts and provides for much
better and quicker estimation of the actual motor
loads. It is now possible to compensate for rapid
load changes. Full torque as well as extremely
accurate speed control can now be obtained even
at low speeds or even at standstill.
Good torque control properties and smooth transitions
to and from current limit operation are ensured.
Advantages of the Flux Vector control system:
- Accurate speed control down to 0 speed
- Quick response from received signal to
full motor shaft torque
- Good compensation for step loads
- Controlled transition from normal operation to
current limit operation (and vice versa)
. Control circuit
8
On basis of parameters, reference settings and input
signals, pulse patterns are generated for forming
thevariablemotorvoltageandfrequency.
- Torque control, comprising control of both
the torque-generating and the magnetising
component of the current
- Full holding torque
P
rogrammable signal outputs
VLT 5000 Crane uses a digital technique which makes
it possible to program the signal outputs.
For the user, it is easy to program the desired functions
by means of the control panel on VLT 5000 Crane
or the RS 485/RS 232 user interfaces.
rotection against mains interference
P
VLT 5000 Crane is protected against the transients
that occur in the mains supply, eg. when switching
power factor correction or when fuses blow.
The rated motor voltage and full torque can be
maintained all the way down to 10% undervoltage
in the mains supply.
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VLT® 5000 Crane
Minor interference on mains
Since as standard the VLT 5000 Crane features
intermediate circuit coils, there is only a small amount
of harmonic mains supply interference. This ensures
a good power factor and lower peak current, which
reduces the load on the mains installation.
A
dvanced VLT protection
Current measurement on all three motor phases
provides perfect protection of VLT 5000 Crane
against earthing and short-circuiting faults on
the motor connection.
Efficient monitoring of the three mains supply phases
ensures that the unit stops in the case of phase failure.
This avoids overloading the inverter and the capacitors
in the intermediate circuit, which would dramatically
reduce the service life of the frequency converter.
As standard, VLT 5000 Crane features integral
thermal protection. If a situation of thermal overload
occurs, this function cuts out the inverter.
ncoder supervisory circuit
E
The signals from the incremental encoder and hence
the cabling are continuously supervised.
The encoder signals are made up of three channels,
each of which are supervised, and status is given
on LEDs placed near the encoder terminals for each
channel as well as for the supply voltage for the encoder.
Green LED turned on means channel or voltage OK.
fan fails, a thermistor can be integrated and connected
to the thermistor input of the frequency converter
(terminals 53), see parameters 128 and 308.
Introduction
R
eliable galvanic isolation
In the VLT 5000 Crane all of the control circuits are
separated from mains potential through isolation
meeting the PELV requirements.
One set of relay contacts, terminals 01 - 03, is
separated from the remaining control circuits through
isolation also complying with PELV.
Furthermore, the control circuits are placed in blocks
individually separated through functional isolation
(< 100 V), see General Technical Data.
A
dvanced motor protection
VLT 5000 Crane features integrated
thermal motor protection.
The frequency converter calculates the motor
temperature on the basis of current, frequency and time.
As opposed to the traditional bimetallic protection,
electronic protection takes ac
cooling at low frequencies that comes from reduced
fan speed (motors with internal ventilation).
To obtain maximum protection against overheating of
the motor if the motor is covered or blocked, or if the
count of the reduction in
electronic,
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13
■Key Diagram for VLT 5000 Crane 5042,
5102 400-500 V
VLT® 5000 Crane
14
MG.50.N4.02 - VLT is a registered Danfoss trademark
■Key Diagram for VLT 5000 Crane 5122-
5202 400-500 V
VLT® 5000 Crane
Introduction
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15
VLT® 5000 Crane
■General Technical Data
Mains Supply (L1, L2, L3)
Supply voltage 400 - 500 V units 3 x 400/415/440/460/500 V ± 10%
Supply frequency 50/60 Hz ± 1%
Max. imbalance of supply voltage
VLT 5052 - 5062/400 - 500 V
VLT 5072 - 5202/400 - 500 V
Power factor/cos ϕ
No. of switches on supply input L1, L2, L3 Appr. 1 time/minute
Max. short-circuit rating 100.000 A
Output voltage 0-100% of supply voltage
Output frequency 0-160 Hz
Rated motor voltage 400 - 500 V units 315 V
Rated motor frequency 25/37 Hz
Ramp times 0.05 - 3600 Seconds
Starting torque, VLT 5042–5202, 400 - 500 V 160%
Acceleration torque, VLT 5042–5302, 400 - 500 V 160%
Overload torque, VLT 5042-5302, 400 - 500 V 160%
Holding torque at 0 rpm (closed loop), VLT 5042–5302, 400 - 500 V 160%
1
VLT Data Output (U, V, W)
Torque Characteristics
of rated supply voltage
1.5%
3%
0.90/1 at rated load
for 1 minute
for 1 minute
for 1 minute
for 1 minute
Digital Inputs
Number of digital inputs 9
Voltage level 0-24 V DC (PNP positive logics)
Voltage level, logical ’0’ <5 V DC
Voltage level, logical ’1’ >10 V DC
Max. voltage on input 28 V DC
Input resistance, Ri(terminal 29) Appr. 4 K /2 K (2 K )
Scanning time per input 3msec
NOTE: All digital inputs are galvanic isolated from the mains voltage (PELV). In addition, the digital inputs can be isolated from the other
terminals on the control card by connecting an external 24 V DC supply and opening switch 4, see Electrical installation.
Analogue Inputs
Number of programmable analogue voltage inputs/thermistor inputs 1
Voltage level 0- ± 10 V DC (Scalable)
Input resistance, R
Number of programmable analogue current inputs 2
Current range 0/4- 20 mA (Scalable)
Input resistance, R
Resolution 10 + sign bit
Accuracy on input Max. error: 1% of full scale
Scanning time per input 3msec
NOTE: Analogue inputs are galvanic isolated from the mains voltage (PELV) and functionally isolated from all other inputs
i
i
Appr. 10 K
200
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VLT® 5000 Crane
Incremental/Encoder Input
Number of encoder input terminals 6
Max. frequency 205 kHz
Voltage level 0-5 V (RS422)
Voltage level, logical ’0’ <0.5V
Voltage level, logical ’1’ >2.5V
Max. voltage on input 7VDC
Input resistance, R
Supply voltage 5V+/-5%
Supply current 200 mA
NOTE: Encoder input terminals are galvanic isolated from the supply voltage (PELV) and functionally isolated from all other inputs
and outputs.
Number of programmable digital outputs 2
Number of programmable analogue outputs 2
Voltage level at digital/pulse output 0-24 V DC
Min. load to ground (terminal 39) at digital/pulse output 600
Frequency ranges (digital output used as pulse output) 0-50 kHz
Resolution
<5kHz
<50 kHz
Current ranges at analogue output 0/4-20 mA
Max. load to ground (terminal 39) at analogue output 500
Accuracy of analogue output Max error: 1.5% of full scale
Resolution on analogue output 8bit
NOTE: All digital and analogue outputs are galvcanic isolated from the supply voltage (PELV) and functionally isolated from all other inputs
NB: Digital and analogue outputs have one common ground terminal (39)
i
Digital/Pulse and Analogue Outputs
Appr. 120
0.1%
1%
Data
Technical
24 V DC Output
Max. load (short-circuit protection) 200 mA
Terminal numbers, ground (with switch 4 closed) 39 (20)
NOTE: The 24 V DC supply is galvanic isolated from the supply volta
outputs
RS 485 Serial Communication
Terminal numbers 68 (TX+, RX+), 69 (TX-,RX-)
NOTE: The signal input is galvanic isolated from the mains volta
RS 232 Serial Communication (Peer to Peer)
Connection RJ 11
NOTE: The signal input is galvanic isolated from mains supply (PELV) but not from RS 485
ge (PELV), but has the same potential as analogue and digital
ge (PELV) but not from RS 232
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17
VLT® 5000 Crane
Relay Outputs
Number of programmable relay outputs 2
Terminal numbers, control cards 4-5 NO
Max. terminal load (AC) on 4-5 control card 50 V AC, 1A, 60 VA
Max. terminal load (DC) on 4-5, control card 75 V DC, 1A, 30W
Max. terminal load (DC) on 4-5, control card
UL applications
cUL applications
Terminal numbers, power card 1-3 NC, 1-2 NO
Max. terminal load (AC) on 1-3, 1-2, power card 240 V AC, 2A, 60 VA
Max. terminal load on 1-3, 1-2, power card 50 V DC, 2 A
Min. terminal load on 1-3, 1-2, power card 24 V AC/24 V DC, 10/100mA
Brake Resistor Terminal
Terminal numbers 81, 82
Cable Lenghts and Cross-Sections
Max. motor cable length, screened cable 25m
Max. brake cable length, screened cable 5m
Max. cable cross-section for control cables 0.75mm2/AWG
Max. cross-section for serial communication 0.75mm2/AWG
NOTE: Max. cable cross-section for motor and brake, see Installation
30 V AC, 1A
1A, 42.5 V DC
Accuracy of Display Readout (Parameters 009 - 012)
Motor Current [6] 0 - 140% load Max error: 2% of rated output current
Torque % [7] -100 - 140% load Max error: 5% of rated motor size
Output [8], power HP [9] 0 - 90% load Max error: 5% of rated output
Control Caracteristics
Frequency range 0-160 Hz
Resolution on output frequency ± 0.003 Hz
System response time* <5msec
Speed, control range 1:1000 of synchro speed
Speed, accuracy
<1500 rpm
>1500 rpm
Torque control accuracy (Speed feedback) Max error: ± 5% of rated torque
NOTE: All control caracteristics are based on 4-pole asynchronous motors
Max error:
±1.5rpm
0.1% of actual speed
*The system response time is the time passing
from the input receives a signal to a reaction
occurs on the VLT output.
18
MG.50.N4.02 - VLT is a registered Danfoss trademark
VLT® 5000 Crane
Externals
Enclosure Ty pe IP 20 /I P 0 0
Vibration Test: 0.7 g RMS 18 - 100 Hz random, 3
directions for 2 hrs (IEC 68-2-34/35/36)
Max. relative humidity for storage/transport 93% (IEC 68-2-3)
Max. relative humidity non-condensing for operation 95% (IEC 721-3-3; Class 3K3)
Ambient temperature 55°C
Ambient temperature, 24-hour average Max 50°C
Min. ambient temperature in full operation 0°C
Min. ambient temperature at reduced performance -10°C
Temperature during storage/transport -25 - +65/70°C
Max. altitude above sea level, without derating* 1000m
NOTE: EMC standards used:
Emission: EN50081-1/2, EN61800-3, EN55011,
Immunity: EN50082-2, EN61000-4-2,, EN61000-4-4,ENV50204, EN61000–4–3, EN61000–4–5, EN61000–4–6, VDE0160/1990.12
Derating for high ambient temperature, see Special Conditions in Appendix
*For more information on derating, see Special
Conditions in Appendix.
■VLT 5000 Crane Protection
• Electronic motor thermal protection against overload
• Electronic thermal protection against overload
• Temperature monitoring of heat-sink ensures that the frequency converter cuts out if the temperature reaches
90°C. An overtemperature fault can only be reset when the temperature of the heat-sink has fallen below 60°C
• The frequency converter is protected against short-circuiting on motor terminals U, V, W
• The frequency converter is protected against earth fault on motor terminals U, V, W
• Monitoring of the intermediate circuit voltage ensures that the frequency converter cuts out if
the intermediate circuit voltage gets too high or too low
• If a motor phase is missing, the frequency converter cuts out, see parameter 234 Motor Phase Monitor
• If a mains phase is missing, the frequency converter will cut out when a load is applied to the motor
Data
Technical
MG.50.N4.02 - VLT is a registered Danfoss trademark
19
VLT® 5000 Crane
■Mains Supply 400 - 500 V
According to international requirements VLT type 5042 5052 5062
I
(S3 60%) [A]
Output current
Output
Typical shaft output P
Typical shaft output P
Max. cable cross-section to motor and
brake [mm
2
Rated input current I
Max. cable cross-section
power[mm2]/[AWG]
Max. pre-fuses [-]/UL1)[A] 100/100 125/125 150/50
Efficiency 0.96 0,96 0.96
Weight IP 20 SB [kg] 41 42 43
Power loss at max. load. 1004 1210 1500
Enclosure IP20 IP20 IP20
1. For type of fuse see section Fuses.
2. American wire gauge.
3. Connection stud 1 x M8/2 x M8.
]/[AWG]
I
VLT, MAX
2)3)
2)3)
VLT,N
(400-500 V)
58 69 85
(60 s) [A] (400-500 V) 97.6 116.8 135
S
(S3 60%) [kVA]
VLT,N
(400-500 V)
VLT,N
VLT,N
39.2
46.6 57.4
[kW] 22 30 37
[HP] 30 41 50
IP20 50/0 50/0
(S3 60%) [A] (400 V) 51 62 76
L,N
35/2 50/0 50/0
20
MG.50.N4.02 - VLT is a registered Danfoss trademark
VLT® 5000 Crane
■Mains supply 3 x 400-500 V
According to international
requirements VLT type 5072 5102 5152 5202
Output
current
Output
Typical shaft output P
Typical shaft output P
Max. cable cross-section to motor
(400-500 V) [mm
Max. cable cross-section to brake
(400-500 V) [mm2]
Max. cable cross-section to motor
(400-500 V) AWG]
Max. cable cross-section to brake
(400-500 V) AWG]
Max input current I
Max. cable cross-section to power
(400-500 V) [mm
Max. cable cross-section to power
(400-500V) [AWG]
Efficiency
Weight IP 20 EB/IP 00 [kg] 109 109 89 134
Power loss at max. load [W] 1860 2250 2828 3231
Enclosure IP20 IP20 IP00 IP00
1. For type of fuse see section Fuses.
2. American wire gauge.
3. Connection Dual M10 screws.
4. Connection Dual M8 screws.
I
[A] (S3 60%) (400-500 V) 100 139 201 246
VLT,N
I
VLT, MAX
(60 s) [A] (400-500 V) 159 221 301 369
S
(S3 60%) [kVA]
VLT,N
(400-500 V) 67.5 93.9 135.8 166.2
[kW] 45 65 90 110
VLT,N
[HP] 61 89 125 150
VLT,N
2]3)
2) 3)
2) 4)
2]3)
4)
2) 3)
(S3 60%) [A] (400 V) 89 124 186 224
L,MAX
95 120 2x70 2x185
95 120 2x35 2x70
3/0 4/0 2x2/0
3/0 4/0 2x3 2x2/0
95 120 2x70 2x185
3/0 4/0 2x2/0
0.96-
0.97
0.96-
0.97
0.97-
0.98
2x350
MCM
Data
Technical
2x350
MCM
0.97-
0.98
MG.50.N4.02 - VLT is a registered Danfoss trademark
21
VLT® 5000 Crane
■Fuses
UL compliance
Bussmann SIBA Littel fuse Ferraz-Shawmut
5042 KTS-R100 2028220-125 KLS-R100 A6K-100R
5052 KTS-R125 2028220-125 KLS-R125 A6K-125R
5062 KTS-R150 2028220-160 KLS-R150 A6K-150R
5072 FWH-220 2028220-200 L50S-225 A50-P225
5102 FWH-250 2028220-250 L50S-250 A50-P250
5122 FWH-300 2028220-315 L50S-300 A50-P300
5152 FWH-350 2028220-315 L50S-350 A50-P350
5202 FWH-400 206xx32-400 L50S-400 A50-P400
KTS-fuses from Bussmann may substitute KTN for 240 V drives.
FWH-fuses from Bussmann may substitute FWX for 240 V drives.
KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V drives.
L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V drives.
A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V drive
A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V drives.
Non UL
compliance
380-500 V
s.
If UL/cUL is not to be complied with, we recommend the above mentioned fuses or:
VLT 5001-5027 200-240 V type gG
VLT 5001-5062 380-500 V type gG
VLT 5032-5052 200-240 V type gR
VLT 5072-5500 380-500 V type gR
Not following the recommendation may result
in unnecessary damage of the drive in case of
malfunction. Fuses must be designed for protection in
a circuit capable of supplying a maximum of 100000
A
(symmetrical), 500/600 V maximum.
rms
22
MG.50.N4.02 - VLT is a registered Danfoss trademark
VLT® 5000 Crane
■Mechanical Dimensions
■Compact IP 00 and IP 20
IP 00 enclosure 400-500 V
VLT type A (mm) B (mm) C (mm) a (mm) b (mm) ab/be (mm) l/r (mm)
5152 - 5202 1400 420 400 1380 350 225 0
IP 20 enclosure 400-500 V
VLT type A (mm) B (mm) C (mm) a (mm) b (mm) ab/be (mm) l/r (mm)
5042 - 5062 800 308 296 780 270 200 0
5072 - 5102 800 370 335 780 330 225 0
ab: Min. space above enclosure.
be: Min. space below enclosure.
l/r: Min. distance between frequency converter and
other plant components, left and right sides.
VLT 5042-5102/400-500 V
Data
Technical
VLT 5152-5202/400-500 V
MG.50.N4.02 - VLT is a registered Danfoss trademark
23
VLT® 5000 Crane
■General Warning before Installation
Before starting the installation, please
be aware of heavy weight and sharp
edges. Furthermore, make sure that
no mains are connected
■Mechanical Installation
The frequency converter must be installed vertically.
The frequency converter is cooled by means of air
circulation. For the unit to be able to release its cooling
air, the minimum distance over and below the unit
must be as shown in the illustration below. To protect
■Installation of VLT 5042–5062 400-500 V
Compact IP20/IP00
Cooling
the unit from overheating, it must be ensured that the
ambient temperature does not rise above the max.
temperature stated for the frequency converter and
that the 24-hour average temperature is not exceeded.
The max. temperature and 24-hour average can be
seen from the General Technical Data.
■Enclosure Protection
Compact
VLT 5042 - 5102 400-500 V IP 20
VLT 5152 - 5202 400-500 V IP 00
Side-by-side
All Compact units in the above-mentioned series
require a minimum space of 200 mm above and
below the enclosure and must be installed on a
plane, vertical surface (no spacers).
Compact IP 00/IP20
All units in the above-mentioned series can be installed
side by side without any space between them, since
these units do not require cooling on the sides.
24
MG.50.N4.02 - VLT is a registered Danfoss trademark
■Installation of VLT 5072-5202 400-500 V
Compact IP20/IP00
Cooling
All Compact units in the above-mentioned series
require a minimum space of 225 mm above and
below the enclosure and must be installed on a
plane, vertical surface (no spacers).
VLT® 5000 Crane
Side-by-side
Compact IP 00/IP20
All units in the above-mentioned series can be installed
side by side without any space between them.
■Ventilation when Panelmounted
The quantity of air needed to cool VLT 5000 Crane
can be calculated as follows:
1. Add up the values of P
to be installed at the same panel (
2. Determine the air inlet temperature (t
air outlet temperature (t
for all VLT 5000 Crane
P )[W]
)andthe
IN
)[ºCorK]
OUT
3. Calculate the necessary air quantity in m
Insert t
OUT-tIN
in Kelvin
• The output from the fan must be located above
the highest mounted frequency converter
• Remember to take pressure drops over filters
into account and that the pressure decreases
as the filters are choked
• The max. cooling air temperature (t
)must
IN
be lower than 55ºC. The average of day/night
temperature may be 5ºC lower than that stated
in VDE 160. The cooling outlet temperature
(t
) may not exceed 60ºC
OUT
3
/h:
Installation
MG.50.N4.02 - VLT is a registered Danfoss trademark
25
■Electrical Installation
The voltage on the frequency converter is
dangerous when the unit is connected to
mains. Incorrect installation of the motor
or frequency converter may lead to material damage
or serious injury or it may be fatal. Consequently, the
instructions in this manual as well as national and
local rules and safety regulations must be complied
with. Touching the electrical parts may be fatal, even
after the mains supply has been disconnected. Wait
at least 15 minutes if using VLT 5052-5102.
NB!:
It is the user’s or certified electrician’s
responsibility to ensure correct earthing and
protection in accordance with applicable
national and local norms and standards.
All terminals for the control cables are located under
the protective cover of the frequency converter. The
protective cover (see drawing) can be removed by
means of a pointed object - a screwdriver or similar.
VLT® 5000 Crane
Once the protective cover has been removed, the
actual EMC-correct installation can start.
26
Wiring diagram VLT 5000 Crane
A: Encoder
B: Brake resistor
12: +24 V
16 Crane ready (NO)
17: Positioning (NO)
18: Lower (NO)
19: Hoist (NO)
20: Ground for digital inputs
26: Digital output
27: Quick stop (NC)
29: Gear ratio select (NO)
32: Load low (NO)
MG.50.N4.02 - VLT is a registered Danfoss trademark
33: Load high (NO)
37: Hardware coast (NC)
39: Ground for analogue/digital outputs
42: Analogue output warning/alarm
45: Analogue output warning/alarm
46: Digital output
50: 10 V supply
53: Reference voltage
55: Common for anal. ref.
60: Reference current
68, 69: RS 485
01, 02: System brake signal
04, 05: Ready signal
73: Pulse signal A from encoder (0°)
74: Inverted pulse signal from encoder (0°)
75: Pulse signal B from encoder (90°)
76: Inverted pulse signal B from encoder (90°)
77: Zero pulse signal from encoder
78: Inverted zero pulse signal from encoder
49: 5 V supply to encoder
47: Common for encoder supply
VLT® 5000 Crane
■Electrical Installation, Power Cables
Compact IP 20 VLT Type 5042–5062
Compact IP 00 VLT 5125-5250 400-500 V
■Connection of Mains
Connect the three mains phases to terminals L
■Connection of Motor
All types of 3-phased asynchronous standard motors
can be used with the VLT 5000 Crane.
1,L2,L3
.
Installation
Compact IP 20/IP 00 VLT Types 5072-5102
MG.50.N4.02 - VLT is a registered Danfoss trademark
27
Normally, small motors are star-connected.
Large motors are delta-connected.
Note the voltage value at the type plate.
■Installation of Motor Cables
NB!:
If an unscreened cable is used, some EMC
requirements are not complied with, see
Special conditions in Appendix.IftheEMC
specifications regarding emission are to be complied
with, the motor cable must be screened, unless
otherwise stated for the RFI filter in question. It is
important to keep the motor cable as short as possible
to reduce the noise level and leakage currents to a
minimum. The motor cable screen must be connected
to the metal cabinet of the frequency converter and to
the metal housing of the motor. The screen connections
are to be made with the biggest possible surface
(cable clamp). This is enabled by different installation
devices in the different frequency converters.
Mounting with twisted screen ends (pigtails) is to
be avoided, since these spoil the screening effect
at higher frequencies. If it is necessary to break
the screen to install a motor isolator or motor
contactor, the screen must be continued at the
lowest possible HF impedance.
VLT® 5000 Crane
LEDs on encoder board:
When all LEDs are on the connection to encoder
and encoder condition are OK.
LED 403 OFF: 5 V supply missing
LED 400 OFF: Channel A or inv. A missing
or shortcircuited
LED 401 OFF: Channel B or inv. B missing
or shortcircuited
LED 402 OFF: Channel Z or inv. Z missing
or shortcircuited.
The frequency converter has been tested with a given
length of cable and a given cross-section of that cable.
If the cross-section is increased, the cable capacitance
- and thus the leakage current - increases, and the
cable length must be reduced correspondingly.
■Installation of Control Cables
Tightening-up torque: 0.22 - 0.25 Nm
Screw size: M2
Screw driver type: 0.4 x 2.5 x 80 mm
See Earthing of Braided Screened/Armoured
Control Cables for correct earthing.
28
MG.50.N4.02 - VLT is a registered Danfoss trademark
Connection of shield:
VLT® 5000 Crane
The connection cable to the brake resistor must
be screened/armoured. Connect the screen to the
metal cabinet of the frequency converter and to
the metal cabinet of the brake resistor by means of
cable clamps. Dimension the cross-section of the
brake cable to match the brake torque.
NB!:
Please note that voltages up to 850 V DC
occur on the terminals.
No. Function
12, 13 Voltage supply to digital inputs.
Forthe24VDCtobeusable
for the digital inputs, switch 4 on
the control card must be closed
position "ON".
Max. current 350 mA
16-33 Digital inputs
37 Digital inputs. Hardware coast
20 Ground for digital inputs
39 Ground for analogue/digital
outputs
26, 46 Digital outputs for output
functions (messages)
42, 45 Analogue outputs for indicating
frequency, reference, current and
torque
47, 49 Supply 5 V, 200 mA for
incremental encoder
50 Supply voltage to potentiometer
and thermistor 10 V DC.
Max. current 12 mA
53 Analogue reference input, voltage
0-±10V
55 Ground for analogue reference
inputs
58, 60 Analogue reference input, current
0/4-20 mA
68, 69 RS 485 interface, serial
communication.
73, 78 Encoder input
■Installation of Relay Terminals
Tightening-up torque: 0.22 - 0.25 Nm
Screw size: M3/M2
No. Function
1-3 Relay output, 1+3 NC, 1+2 NO See
parameter 323. See also General
technical data.
4, 5 Relay output, 4+5 NO See parameter
326. See also General technical
data.
■Installation of Brake Resistor Temperature Switch
Torque: 0.5-0.6 Nm
Screw size: M3
No. Function
106, 104,
Brake resistor temperature switch.
105
NB!:
This function is only available on VLT
5072-5202 400-500 V.
If the temperature of the brake resistor gets too high and
the terminal switch drops out, the frequency converter
will stop braking. The motor will start coasting.
A terminal switch must be installed that can either be
‘normally closed’ or ‘normally open’. If this function is
not used, 106 and 104 must be short-circuited together.
Installation
■Brake Connection
No. 81 82 Brake resistor
R- R+ terminals
MG.50.N4.02 - VLT is a registered Danfoss trademark
29
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