Danfoss VLT 6000 HVAC Design guide

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Design Guide

VLT® 6000 HVAC

Contents

VLT

6000 HVAC Series

Introduction to HVAC

Software version 4 Safety regulations 5 Warning against unintended start 5 Introduction to the Design Guide 7 Available literature 8 Fire mode 11 Star/delta starter or soft-starter not required 15 Control principle 17 CE labelling 18 The new standard 19 The new standard 20 The new standard 21 Choice of frequency converter 25 Unpacking and ordering a VLT frequency converter 28 Type code ordering number string 28 Ordering form 32 PC software and serial communication 33 PC Software tools 33 Fieldbus options 33 Profibus 34 LON - Local Operating Network 34 DeviceNet 34 Modbus RTU 34

Installation

Mains supply (L1, L2, L3) 41 Max. imbalance of supply voltage 41 Technical data, mains supply 3 x 200-240V 46 Technical data, mains supply 3 x 380-460V 47 Technical data, mains supply 3 x 525-600 V 52 Fuses 57 Mechanical dimensions 60 Mechanical installation 64 General information about electrical installation 67 High voltage warning 67 Earthing 67 Cables 67 Screened/armoured cables 68 Extra protection with regard to indirect contact 68 RFI switch 69 High voltage test 72 Heat emission from VLT 6000 HVAC 72 Ventilation of integrated VLT 6000 HVAC 72 EMC correct electrical installation 72 Use of EMC-correct cables 74 Electrical installation - earthing of control cables 75

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Electrical installation, enclosures 76 Tightening-up torque and screw sizes 83 Mains connection 83 Motor connection 83 Direction of motor rotation 84 Motor cables 84 Motor thermal protection 85 Earth connection 85 Installation of 24 Volt external DC supply 85 DC bus connection 85 High-voltage relay 85 Control card 85 Electrical installation, control cables 86 Switches 1-4 87 Bus connection 87 Connection examples, VLT 6000 HVAC 88

6000 HVAC Series

Programming

Control unit LCP 90 Control keysfor parameter setup 90 Indicator lamps 91 Local control 91 Display mode 92 Navigation between display modes 94 Changing data 95 Manual initialisation 95 Quick Menu 96 Operation and Display 001-017 98 The Setup configuration 98 Setup of user-defined readout 99 Load and Motor 100-117 105 Configuration 105 Motor power factor (Cos ø) 111 Reference handling 113 Reference type 116 Inputs and outputs 300-365 121 Analogue inputs 125 Analog/digital outputs 128 Relay outputs 132 Application functions 400-427 135 Sleep mode 136 PID for process control 141 PID overview 143 Feedback handling 143 Serial communication for FC protocol 150 Protocols 150 Telegram communication 150 Telegram build-up under FC protocol 151 Data character (byte) 152

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Process word 156 Control word according to FC protocol 157 Status word as per FC protocol 158 Serial communication reference 159 Present output frequency 160 Serial communication 500 - 556 161 Extended status word, warning word, and alarm word 168 Service functions 600-631 171 Electrical installation of the relay card 176 Description of Real Time Clock 177

6000 HVAC Series

All about VLT 6000 HVAC

Status messages 180 List of warnings and alarms 182 Aggressive environments 189 Calculation of resulting reference 189 Galvanic isolation (PELV) 190 Earth leakage current 190 Extreme running conditions 191 Peak voltage on motor 192 Switching on the input 192 Acoustic noise 193 Derating for ambient temperature 193 Derating for air pressure 194 Derating for running at low speed 194 Derating for long motor cables or cables with larger cross-section 194 Derating for high switching frequency 194 Vibration and shock 195 Air humidity 195 Efficiency 196 Mains supply interference/harmonics 197 Power factor 197 (Emission) 197 EMC Immunity 199 Definitions 201 Parameter overview and factory settings 203

180

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VLT

6000 HVAC Series

Software version

VLT 6000 HVAC

Design Guide

Software version: 3.2x

This Design Guide can be used with all VLT 6000 HVAC frequency converters with software version 3.2x. The software version number can be seen from parameter 624.

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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.

The Protective Extra Low Voltage (PELV) requirements stated in IEC 61800-5-1 are not fulfilled at altitudes above 2000 m (6562 ft.). For 200V frequency converters the requirements are not fulfilled at altitudes above 5000 m (16 404 ft.). Please contact Danfoss Drives for further information.

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 [OFF/STOP] key on the control panel of the frequency converter does the equipment from mains and is thus 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.

not disconnect

not to

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Warning against unintended start

6000 HVAC Series

Note: The function is initialised at 1.0 x rated motor current and rated motor frequency (see parameter 117, Motor thermal protec- tion).

6. Do

7. Reliable galvanic isolation (PELV) is not

8. Please note that the frequency converter has

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

not 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.

complied with if the RFI switch is placed in OFF position. This means that all control in and outputs can only be considered low-voltage terminals with basic galvanic isolation.

more voltage inputs than L1, L2 and L3, when the DC-bus terminals are used. Check that connected 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, cient.

motor may start. Consequently, [OFF/STOP] must always be activated, following which data can be modified.

faults 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.

all voltage inputs have been dis-

these stop functions are not suffi-

the stop key

Introduction to HVAC

5. Protection against motor overload is included in the factory setting. Parameter 117, Motor thermal protection default value is ETR trip 1.

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6000 HVAC Series

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. VLT 6002 - 6005, 200-240 V: wait at least 4 minutes VLT 6006 - 6062, 200-240 V : wait at least 15 minutes VLT 6002 - 6005, 380-460 V: wait at least 4 minutes VLT 6006 - 6072, 380-460 V: wait at least 15 minutes VLT 6102 - 6352, 380-460 V: wait at least 20 minutes VLT 6402 - 6602, 380-460 V: wait at least 40 minutes VLT 6002 - 6006, 525-600 V: wait at least 4 minutes VLT 6008 - 6027, 525-600 V: wait at least 15 minutes VLT 6032 - 6072, 525-600 V: wait at least 30 minutes VLT 6102 - 6402, 525-600 V: wait at least 20 minutes VLT 6502 - 6652, 525-600 V: wait at least 30 minutes

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Introduction to the Design Guide

This Design Guide is a tool intended to facilitate the sizing of systems in which VLT 6000 HVAC frequency converters are used. HVAC stands for Heating Ventilation Air-Conditioning.

This Design Guide progresses step-by-step through the different procedures required for selecting, installing and programming a VLT 6000 HVAC.

The Design Guide forms part of the literature concept supplied with VLT 6000 HVAC. However, the Design Guide is the most comprehensive document available. When a VLT 6000 HVAC is supplied, it is accompanied by Operating Instructions and a Quick Setup Guide. See the section Other Literature.

Operating Instructions:

Quick Setup Guide:

Design Guide:

This Design Guide is split in four sections that have information about VLT 6000 HVAC.

Introduction to HVAC:

There are also examples of applications and information is given about Danfoss

The specification section deals with the requirements relating to being allowed to

The section ends with an Ordering Guide that makes it easier for you to specify

Describe how to ensure optimum mechanical and electrical installation, and also deal with commissioning and service. The Operating Instructions furthermore provide a description of the software parameters, thereby ensuring that you can easily fit the VLT 6000 HVAC into your application.

Helps you get your VLT 6000 HVAC installed and commissioned quickly.

Used when designing systems with VLT 6000 HVAC. The Design Guide gives all useful information about the VLT 6000 HVAC and HVAC systems. There is a selection tool for you to choose the right VLT 6000 HVAC with the relevant options and modules. The Design Guide has examples of the most common types of HVAC applications. In addition, the Design Guide has all information relating to Serial Communication.

This section tells you the advantages that can be obtained by using frequency converters in HVAC systems. Furthermore, you can read about the way a frequency converter operates and about the advantages of the VLT 6000 HVAC, such as AEO - Automatic Energy Optimisation, RFI filter and other HVAC-relevant functions.

and CE-labelling.

supply and install frequency converters. This section can be used in contract documents, whereby the total list of requirements relating to frequency converters is determined.

and order a VLT 6000 HVAC.

6000 HVAC Series

Introduction to HVAC

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Introduction to the Design Guide

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6000 HVAC Series

Installation:

This section shows you how to carry out correct mechanical installation of a VLT 6000 HVAC. In addition, the section has a description of how you ensure that the installation of the VLT 6000 HVAC is EMC-correct. Furthermore, the section includes a list of mains and motor connections, as well as a description of control card terminals.

Programming:

This section describes the control unit and the software parameters for the VLT 6000 HVAC. There is also a guide to the Quick Setup menu, which means that you will be able to start using your application very quickly.

All about VLT 6000:

This section has information about status, warning and fault indications from the VLT 6000 HVAC. In addition, the section has technical data, service information, factory settings and information on special conditions.

NB!

This symbol indicates something to be noted by the reader.

This symbol indicates a general warning.

This symbol indicates a high-voltage warning.

Available literature

Below is a list of the literature available for VLT 6000 HVAC. It must be noted that there may be deviations from one country to the next.

Please also refer to our web site http://drives.danfoss.com for information about new literature.

Supplied with the unit:

Operating instructions MG.61.AX.YY Quick Setup MG.60.CX.YY High Power Introduction Guide MI.90.JX.YY

Communication with VLT 6000 HVAC:

Profibus Manual MG.90.DX.YY Metasys N2 Manual MG.60.FX.YY LonWorks Manual MG.60.EX.YY Landis/Staefa Apogee FLN Manual MG.60.GX.YY Modbus RTU Manual MG.10.SX.YY DeviceNet Manual MG.50.HX.YY

Instructions for VLT 6000 HVAC:

LCP Remote Kit IP20 MI.56.AX.51 LCP Remote Kit IP54 MI.56.GX.52 Sine wave-filter MI.56.DX.51 IP20 terminal cover MI.56.CX.51

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Various literature for VLT 6000 HVAC:

Operating Instructions MG.60.AX.YY Design Guide MG.61.BX.YY Data sheet MD.60.AX.YY VLT 6000 HVAC Cascade Controller MG.60.IX.YY X = version number YY = language version

Why use a frequency converter for controlling fans and pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further information see the text The Laws of Proportionality.

The clear advantage - energy savings

The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the electricity savings. When comparing with alternative control systems and technologies, a frequency converter is the optimum energy control system for controlling fan and pump systems.

6000 HVAC Series

Introduction to HVAC

The graph is showing fan curves (A, B and C) for

reduced fan volumes.

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When using a frequency converter to reduce fan

capacity to 60% - more than 50% energy savings

may be obtained in typical applications.

VLT

Example of energy savings

As can be seen from the figure (the laws of proportionality), the flow is controlled by changing the rpm. By reducing the speed only 20% from the rated speed, the flow is also reduced by 20%. This is because the flow is directly proportional to the rpm. The consumption of electricity, however, is reduced by 50%. If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the rated flow for the remainder of the year, the amount of energy saved is even more than 50%.

The laws of proportionality

The figure below describes the dependence of flow, pressure and power consumption on rpm.

Q = Flow P = Power

= Rated flow P1 = Rated power

= Reduced flow P2 = Reduced power

H = Pressure n = Speed regulation

= Rated pressure n1 = Rated speed

= Reduced pressure n2 = Reduced speed

6000 HVAC Series

The example below is calculated on the basis of pump characteristics obtained from a pump datasheet. The result obtained shows energy savings in excess of 50% at the given flow distribution over a year. The pay back period depends on the price per kwh and price of frequency converter. In this example it is less than a year when compared with valves and constant speed.

Flow

Pressure

Power

Example with varying flow over 1 year

Energy savings

shaft=Pshaft output

Flow distribution over 1 year

(

)

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6000 HVAC Series

Introduction to HVAC

m3/h

350 5 438 42,5 18.615 42,5 18.615 300 15 1314 38,5 50.589 29,0 38.106 250 20 1752 35,0 61.320 18,5 32.412 200 20 1752 31,5 55.188 11,5 20.148 150 20 1752 28,0 49.056 6,5 11.388 100 20 1752 23,0 40.296 3,5 6.132

Distribution Valve regulation Frequency converter control % Hours Power Consumption Power Consumption

A1 - B

Σ 100 8760 275.064 26.801

kWh A1 - C

Fire mode

over pressure and result in damage to

NB!

Please note the frequency converter is only one component of the HVAC system. Correct function of Fire Mode depends on the correct design and selection of system components. Ventilation systems working in life safety applications have to be approved by the local fire Authorities. Non-

interruption of the frequency converter due to Fire Mode operation may cause

HVAC system and components, including dampers and air ducts. The frequency converter itself may be damaged and it may cause damage or fire. Danfoss A/S accepts no responsibility for errors, malfunctions personal injury or any damage to the frequency converter itself or components herein, HVAC systems and components herein or other property when the frequen-

kWh

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cy converter has been programmed for Fire Mode. In no event shall Danfoss be liable to the end user or any other party for any direct or indirect, special or consequential damage or loss suffered by such party, which has occurred due to the frequency converter being programmed and operated in Fire Mode

The Fire Mode function is made to ensure the VLT 6000 can run without interruption. This means most alarms and warnings will not cause a trip and trip lock is disabled. This is useful in case of fire or other emergencies. Until the motor wires or the frequency converter itself are destroyed every attempt is made to keep running. A warning will flash when these limits have been exceeded. If the warning still flashes after a power cycle please contact your local Danfoss supplier. In the following is a table to show the alarms and when the frequency converter changes state depend-

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6000 HVAC Series

ing on selection in parameter 430. Trip and lock ([0] in parameter 430) are valid in normal operation mode. Fire Mode trip and reset ([1] or [2] in parameter 430) means that a reset is automatically performed without the need of manual resetting. Go to Fire Mode bypass ([3] in parameter 430) is valid in case one of the mentioned alarms causes a trip. After the in parameter 432 selected time delay has passed an output is set. This output is programmed in parameter 319, 321, 323 or

326. If a relay option is fitted it can also be selected in parameter 700, 703, 706 or 709. In parameter 300 and 301 it can be selected if the logic, for the Fire Mode activation, shall be active high or low. Please note parameter 430 must be different to [0] for the Fire Mode to be enabled. To be able to use Fire Mode please also note that input 27 must be “high” and no coast bit present via fieldbus. To ensure that no coast can interrupt Fire Mode via fieldbus please select Digital Input [0] in par. 503. Then coasting via fieldbus disabled.

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No. Description TRIP

[0]

2 Live zero fault

(LIVE ZERO ERROR)

4 Mains imbalance

(MAINS IMBALANCE)

7 Overvoltage

(DC LINK OVERVOLT)

8 Undervoltage

(DC LINK UNDERVOLT)

9 Inverter overloaded

(INVERTER TIME)

10 Motor overloaded

(MOTOR TIME)

11 Motor thermistor(MOTOR

THERMISTOR)

12 Current limit

(CURRENT LIMIT)

13 Overcurrent

(OVERCURRENT)

14 Earth fault

(EARTH FAULT)

15 Switch mode fault

(SWITCH MODE FAULT)

16 Short-circuit

(CURR.SHORT CIRCUIT)

17 Serial communication timeout

(STD BUSTIMEOUT)

18 HPFB bus timeout

(HPFB TIMEOUT)

22 Auto-optimation fault

(AMA FAULT)

29 Heat-sink temperature too high

(HEAT SINK OVERTEMP.)

30 Motor phase U missing

(MISSING MOT.PHASE U)

31 Motor phase V missing

(MISSING MOT.PHASE V)

32 Motor phase W missing

(MISSING MOT.PHASE W)

34 HPFB communication fault

(HPFB TIMEOUT)

37 Inverter fault (GATE DRIVE

FAULT)

60 Safety stop

(EXTERNAL FAULT)

63 Output current low

(I MOTOR < I LOW)

80 Fire mode was active

(FIRE MODE WAS ACTIVE)

99 Unknown fault

(UNKNOWN FAULT)

x x x

x x x x

x x x

x x x x

x x

LOCK

[0]

FIRE MODE Trip & reset

[1], [2]

Go to FIRE MODE BYPASS [3]

Introduction to HVAC

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6000 HVAC Series

Better control

If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained. A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure. Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.

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6000 HVAC Series

Simpler installation when using a frequency converter

A frequency converter can replace a traditional control system, in which mechanical dampers and valves are used for controlling flow or pressure. The great advantage involved in using a frequency converter is that the system becomes simpler, since a lot of the mechanical and electrical equipment is no longer required.

V-belts no longer required

In mechanical control systems, where the fan is driven by V-belts, it is necessary to change belt pulleys in order to adjust the fan speed to match the necessary maximum load. Using a frequency converter, the Vbelts can be replaced by directly driven motors, whose speed is changed simply by means of the frequency converter. The efficiency of the system improves and the entire installation takes up less space. There is no dust from the V-belt and less maintenance.

Regulating dampers and valves no longer required

Since the flow or pressure can be controlled by means of the frequency converter, no regulating dampers and valves are required in the system.

Cos φ compensation

Introduction to HVAC

Generally speaking, a frequency converter with a cos φ of 1 provides power factor correction for the cos φ of the motor, which means that there is no need to make allowance for the cos φ of the motor when sizing the power factor correction unit.

Star/delta starter or soft-starter not required

When larger motors are started, it is necessary in many countries to use equipment that limits the startup current. In more traditional systems, a star/delta starter or soft-starter is widely used. Such motor starters are not required if a frequency converter is used.

As illustrated in the figure below, a frequency converter does not consume more than rated current.

1 = VLT 6000 HVAC 2 = Star/delta starter 3 = Soft-starter 4 = Start directly on mains

Using a frequency converter saves money

The example on the following page shows that a lot of equipment is not required when a frequency converter is used. It is possible to calculate the cost of installing the two different systems. In the example on the following

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6000 HVAC Series

page, the two systems can be established at roughly the same price.

Without a frequency converter

The figure shows a fan system made in the traditional way. D.D.C. = Direct Digital Control E.M.S. = Energy Management system

V.A.V. = Variable Air Volume

Sensor P = Pressure Sensor T = Temperature

With a frequency converter

The figure shows a fan system controlled by VLT 6000 HVAC frequency converters.

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6000 HVAC Series

Control principle

A frequency converter rectifies AC voltage from mains into DC voltage, after which this DC voltage is converted into a AC current with a variable amplitude and frequency.

1. Mains voltage 3 x 200 - 240 V AC, 50 / 60 Hz. 3 x 380 - 460 V AC, 50 / 60 Hz. 3 x 525 - 600 V AC, 50 / 60 Hz.

2. Rectifier A three-phase rectifier bridge that rectifies AC current into DC current.

3. Intermediate circuit DC voltage = 1.35 x mains voltage [V].

4. Intermediate circuit coils Even out the intermediate circuit voltage and reduce the harmonic current feedback to the mains supply.

The motor is thus supplied with variable voltage and frequency, which enables infinitely variable speed control of three-phased, standard AC motors.

Introduction to HVAC

5. Intermediate circuit capacitors Even out the intermediate circuit voltage.

6. Inverter Converts DC voltage into variable AC voltage with a variable frequency.

7. Motor voltage Variable AC voltage, 0-100% of mains supply voltage.

8. Control card This is where to find the computer that controls the inverter which generates the pulse pattern by which the DC voltage is converted into variable AC voltage with a variable frequency.

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6000 HVAC Series

CE labelling

What is CE labelling?

The purpose of CE labelling is to avoid technical obstacles to trade within EFTA and the EU. The EU has introduced the CE label as a simple way of showing whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency converters are regulated by three EU directives:

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by the machinery directive, which came into force on 1 January 1995. Since a frequency converter is largely electrical, it does not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, we provide information on safety aspects relating to the frequency converter. We do this by means of a manufacturer's declaration.

The low-voltage directive (73/23/EEC)

Frequency converters must be CE labelled in accordance with the low-voltage directive, which came into force on 1 January 1997. The directive applies to all electrical equipment and appliances used in the 50 1000 Volt AC and the 75 - 1500 Volt DC voltage ranges. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request.

The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different components/appliances is so small that the functioning of the appliances is not affected. The EMC directive came into force on 1 January 1996. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request. In order that EMC-correct installation can be carried out, this manual gives detailed instructions for installation. In addition, we specify the standards which our different products comply with. We offer the filters that can be seen from the specifications and provide other types of assistance to ensure the optimum EMC result.

In the great majority of cases, the frequency converter is used by professionals of the trade as a complex component forming part of a larger appliance, system or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

NOTE: VLT 6001-6072, 525-600 V are not CE labelled.

Application examples

The next few pages give typical examples of applications within HVAC. If you would like to receive further information about a given application, please ask your Danfoss supplier for an information sheet that gives a full description of the application.

Variable Air Volume

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improving Variable Air Volume Ventilation Systems MN.60.A1.02

Constant Air Volume

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improving Constant Air Volume Ventilation Systems MN.60.B1.02

Cooling Tower Fan

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improving fan control on cooling towers MN.60.C1.02

Condenser pumps

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improving condenser water pumping systems MN.60.F1.02

Primary pumps

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improve your primary pumping in primay/secondary pumping systems MN.60.D1.02

Secondary pumps

3 x 200/208/220/230/240 V ±10%

Ask for The Drive to...Improve your secondary pumping in primay/secondary pumping systems MN.60.E1.02

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Variable Air Volume

VAV or Variable Air Volume systems, are used to control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained. The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements.

The new standard

While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and reduces the complexity of the installation. Instead of creating an artificial pressure drop or causing a decrease in fan efficiency, the frequency converter decreases the speed of the fan to provide the flow and pressure required by the system. Centrifugal devices such as fans behave according to the centrifugal laws. This means the fans decrease the

Cooling coil

Heating coil

Filter

pressure and flow they produce as their speed is reduced. Their power consumption is thereby significantly reduced. The return fan is frequently controlled to maintain a fixed difference in airflow between the supply and return. The advanced PID controller of the VLT 6000 HVAC can be used to eliminate the need for additional controllers.

Pressure signal

VAV boxes

Supply fan

Pressure transmitter

Flow

Introduction to HVAC

Return fan

Flow

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6000 HVAC Series

Constant Air Volume

CAV, or Constant Air Volume systems are central ventilation systems usually used to supply large common zones with the minimum amounts of fresh tempered air. They preceded VAV systems and therefore are found in older multi-zoned commercial buildings as well. These systems preheat amounts of fresh air utilizing Air Handling Units (AHUs) with a heating coil, and many are also used to air condition buildings and have a cooling coil. Fan coil units are frequently used to assist in the heating and cooling requirements in the individual zones.

The new standard

With a frequency converter, significant energy savings can be obtained while maintaining decent control of the building. Temperature sensors or CO2 sensors can be used as feedback signals to frequency converters. Whether controlling temperature, air quality, or both, a CAV system can be controlled to operate based on actual building conditions. As the number of people in the controlled area decreases, the need for fresh air decreases. The CO2 sensor detects lower levels and decreases the supply fans speed. The return fan modulates to maintain a static pressure setpoint or fixed difference between the supply and return air flows.

With temperature control, especially used in air conditioning systems, as the outside temperature varies as well as the number of people in the controlled zone changes, different cooling requirements exist. As the temperature decreases below the set-point, the supply fan can decrease its speed. The return fan modulates to maintain a static pressure set-point. By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of Danfoss HVAC dedicated frequency converter, the VLT 6000 HVAC can be utilized to improve the performance of your CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal. The frequency converter also includes a two zone, 2 setpoint PID controller which allows monitoring both temperature and air quality. Even if the temperature requirement is satisfied, the drive will maintain enough supply air to satisfy the air quality sensor. The controller is capable of monitoring and comparing two feedback signals to control the return fan by maintaining a fixed differential air flow between the supply and return ducts as well.

Cooling coil

Heating coil

Temperature signal

Filter

Supply fan

Temperature transmitter

Pressure signal

Return fan

Pressure transmitter

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6000 HVAC Series

Cooling Tower Fan

Cooling Tower Fans are used to cool condenser water in water cooled chiller systems. Water cooled chillers provide the most efficient means of creating chilled water. They are as much as 20% more efficient than air cooled chillers. Depending on climate, cooling towers are often the most energy efficient method of cooling the condenser water from chillers. They cool the condenser water by evaporation. The condenser water is sprayed into the cooling tower onto the cooling towers “fill” to increase its surface area. The tower fan blows air through the fill and sprayed water to aid in the evaporation. Evaporation removes energy from the water dropping its temperature. The cooled water collects in the cooling towers basin where it is pumped back into the chillers condenser and the cycle is repeated.

The new standard

With a frequency converter, the cooling towers fans can be controlled to the required speed to maintain the condenser water temperature.T frequency converters can also be used to turn the fan on and off as needed.

Several features of Danfoss HVAC dedicated drive, the VLT 6000 HVAC can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gear-box to frequency converter the tower fan, a minimum speed of 40-50% may be required.

Water Inlet

The customer programmable minimum frequency setting of the is available to maintain this minimum frequency even as the feedback or speed reference calls for lower speeds.

Also as a standard feature, you can program the frequency converter to enter a “sleep” mode and stop the fan until a higher speed is required. Additionally, some cooling tower fans have undesireable frequencies that may cause vibrations. These frequencies can easily be avoided by programming the bypass frequency ranges in the frequency converter.

Introduction to HVAC

BASIN

Water Outlet

Temperature Sensor

Conderser Water pump

CHILLER

Supply

MG.61.B6.02 - VLT

is a registered Danfoss trademark 21

VLT

6000 HVAC Series

Condenser pumps

Condenser Water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower. These systems are used to provide the most efficient means of creating chilled water, they are as much as 20% more efficient than air cooled chillers.

The VLT solution

Frequency converters can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller.

Using a frequency converter instead of a throttling valve simply saves the energy that would have been absorbed by the valve. This can amount to savings of 15-20% or more. Trimming the pump impeller is irreversible, thus if the conditions change and higher flow is required the impeller must be replaced.

22 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Primary pumps

Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/ secondary pumping technique decouples the “primary” production loop from the “secondary” distribution loop. This allows devices such as chillers to obtain constant design flow and operate properly while allowing the rest of the system to vary in flow.

As the evaporator flow rate decreases in a chiller, the chilled water begins to become over-chilled. As this happens, the chiller attempts to decrease its cooling capacity. If the flow rate drops far enough, or too quickly, the chiller cannot shed its load sufficiently and the chiller’s low evaporator temperature safety trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed if primary/ secondary pumping is not utilized.

The VLT solution

Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial. A frequency converter can be added to the primary system, to replace the throttling valve and/or trimming of the impellers, leading to reduced operating expenses. Two control methods are common:

The first method uses a flow meter. Because the desired flow rate is known and is constant, a flow meter installed at the discharge of each chiller, can be used to control the pump directly. Using the built-in PID controller, the frequency converter will always maintain the appropriate flow rate, even compensating for the changing resistance in the primary piping loop as chillers and their pumps are staged on and off.

Introduction to HVAC

The other method is local speed determination. The operator simply decreases the output frequency until the design flow rate is achieved. Using a frequency converter to decrease the pump speed is very similar to trimming the pump impeller, except it doesn’t require any labor and the pump efficiency remains higher. The balancing contractor simply decreases the speed of the pump until the proper flow rate is achieved and leaves the speed fixed. The pump will operate at this speed any time the chiller is staged on. Because the primary loop doesn’t have control valves or other devices that can cause the system curve to change and the variance due to staging pumps and chillers on and off is usually small, this fixed speed will remain appropriate. In the event the flow rate needs to be increased later in the systems life, the frequency converter can simply increase the pump speed instead of requiring a new pump impeller.

Flowmeter

CHILLER

Flowmeter

CHILLER

MG.61.B6.02 - VLT

is a registered Danfoss trademark 23

VLT

6000 HVAC Series

Secondary pumps

Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically decouple one piping loop from another. In this case. The primary pump is used to maintain a constant flow through the chillers while allowing the secondary pumps to vary in flow, increase control and save energy. If the primary/secondary design concept is not used and a variable volume system is designed, when the flow rate drops far enough or too quickly, the chiller cannot shed its load properly. The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed.

The VLT solution

While the primary-secondary system with two-way valves improves energy savings and eases system control problems, the true energy savings and control potential is realized by adding frequency converters. With the proper sensor location, the addition of frequency converters allows the pumps to vary their speed to follow the system curve instead of the pump curve. This results in the elimination of wasted energy and eliminates most of the over-pressurization, two-way valves can be subjected too. As the monitored loads are reached, the two-way valves close down. This increases the differential pressure measured across the load and two-way valve. As this differential pressure starts to rise, the pump is slowed to maintain the control head also called setpoint value. This set-point value is calculated by summing the pressure drop of the load and two way valve together under design conditions.

NB!

Please note that when running multiple pumps in parallel, they must run at the same speed to maximize energy savings, either with individual dedicated drives or one frequency converter running multiple pumps in parallel.

24 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Choice of frequency converter

The frequency converter should be chosen on the basis of the given motor current at maximum load on the system. The rated output current I

must be equal

VLT,N

Choose mains voltage for 50/60 Hz:

- 200-240 V three-phase AC voltage

- 380-460 V three-phase AC voltage

- 525-600 V three-phase AC voltage

to or higher than the required motor current.

VLT 6000 HVAC is available for three mains voltage ranges: 200-240 V, 380-460 V, and 525-600 V.

Mains voltage 200 - 240 V

Typical shaft output

VLT type [kW] [HP] [A] [kVA] 6002 6003 1.5 2.0 7.5 3.1 6004 2.2 3.0 10.6 4.4 6005 3.0 4.0 12.5 5.2 6006 4.0 5.0 16.7 6.9 6008 5.5 7.5 24.2 10.1 6011 7.5 10 30.8 12.8 6016 11 15 46.2 19.1 6022 15 20 59.4 24.7 6027 18.5 25 74.8 31.1 6032 22 30 88.0 36.6 6042 30 40 115/104* 43.2 6052 37 50 143/130* 54.0 6062 45 60 170/154* 64.0

*The first figure is for a motor voltage of 200-230 V. The next figure is for a motor voltage of 231-240 V.

VLT,N

1.1 1.5 6.6 2.7

Max continuous output current Max continuous output power

VLT,N

at 240 V S

VLT,N

Introduction to HVAC

Mains voltage 380 - 415 V

VLT type [kW] [A] [kVA] 6002 6003 1.5 4.1 2.9 6004 2.2 5.6 4.0 6005 3.0 7.2 5.2 6006 4.0 10.0 7.2 6008 5.5 13.0 9.3 6011 7.5 16.0 11.5 6016 11 24.0 17.3 6022 15 32.0 23.0 6027 18.5 37.5 27.0 6032 22 44.0 31.6 6042 30 61.0 43.8 6052 37 73.0 52.5 6062 45 90.0 64.7 6072 55 106 73.4 6102 75 147 102 6122 90 177 123 6152 110 212 147 6172 132 260 180 6222 160 315 218 6272 200 395 274 6352 250 480 333 6402 315 600 416 6502 355 658 456 6552 400 745 516 6602 450 800 554

Typical shaft output Max continuous output current Max continuous output power

VLT.N

1.1 3.0 2.2

VLT.N

at 400 V S

VLT.N

MG.61.B6.02 - VLT

is a registered Danfoss trademark 25

VLT

6000 HVAC Series

Mains voltage 440-460 V

Typical shaft output Max continuous output current Max continuous output power

VLT.N

at 460 V S

VLT type [HP] [ A] [kVA] 6002

1.5 3.0 2.4 6003 2.0 3.4 2.7 6004 3.0 4.8 3.8 6005 - 6.3 5.0 6006 5.0 8.2 6.5 6008 7.5 11.0 8.8 6011 10 14.0 11.2 6016 15 21.0 16.7 6022 20 27.0 21.5 6027 25 34.0 27.1 6032 30 40.0 31.9 6042 40 52.0 41.4 6052 50 65.0 51.8 6062 60 77.0 61.3 6072 75 106 84.5 6102 100 130 104 6122 125 160 127 6152 150 190 151 6172 200 240 191 6222 250 302 241 6272 300 361 288 6352 350 443 353 6402 450 540 430 6502 500 590 470 6552 600 678 540 6602 600 730 582

VLT.N

Mains voltage 525 V

Typical shaft output Max. constant output current, 525 V Max. constant output power

VLT.N

at 525 V S

VLT type [kW] [ A] [kVA] 6002

1.1 2.6 2.3 6003 1.5 2.9 2.5 6004 2.2 4.1 3.6 6005 3.0 5.2 4.5 6006 4.0 6.4 5.5 6008 5.5 9.5 8.2 6011 7.5 11.5 10.0 6016 11 18 15.6 6022 15 23 20 6027 18.5 28 24 6032 22 34 29 6042 30 43 37 6052 37 54 47 6062 45 65 56 6072 55 81 70 6102 75 113 98 6122 90 137 119 6152 110 162 140 6172 132 201 174 6222 160 253 219 6272 200 303 262 6352 250 360 312 6402 315 418 362 6502 400 523 498 6602 450 596 568 6652 500 630 600

VLT.N

26 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

Mains voltage 575 - 600 V

VLT type [kW] [ A] [kVA] 6002 6003 1.5 2.7 2.7 6004 2.2 3.9 3.9 6005 3.0 4.9 4.9 6006 4.0 6.1 6.1 6008 5.5 9 9.0 6011 7.5 11 11.0 6016 11 17 16.9 6022 15 22 22 6027 18.5 27 27 6032 22 32 32 6042 30 41 41 6052 37 52 52 6062 45 62 62 6072 55 77 77 6102 75 108 108 6122 90 131 130 6152 110 155 154 6172 132 192 289 6222 160 242 241 6272 200 290 288 6352 250 344 343 6402 315 400 398 6502 400 500 498 6602 450 570 568 6652 500 630 627

Typical shaft output Max. constant output current, 575 V Max. constant output kVA,

VLT.N

1.1 2.4 2.4

VLT.N

6000 HVAC Series

575

VLT.N

Introduction to HVAC

MG.61.B6.02 - VLT

is a registered Danfoss trademark 27

VLT

6000 HVAC Series

Unpacking and ordering a VLT frequency converter

If you are in doubt as to which frequency converter you have received and which options it contains, use the following to find out.

Type code ordering number string

On the basis of your order, the frequency converter is given an ordering number that can be seen from the nameplate on the unit. The number may look as follows:

VLT-6008-H-T4-B20-R3-DL-F10-A00-C0

This means that the frequency converter ordered is a VLT 6008 for three-phase mains voltage of 380-460 V (T4) in Bookstyle enclosure IP 20 (B20). The hardware variant is with integral RFI filter, classes A & B (R3). The frequency converter features a control unit (DL) with a PROFIBUS option card (F10). No option card (A00) and no conformal coating (C0) Character no. 8 ( H) indicates the application range of the unit: H = HVAC.

IP 00: This enclosure is only available for the larger power sizes of the VLT 6000 HVAC series. It is recommended for installation in standard cabinets. IP 20 Bookstyle: This enclosure is designed for cabinet installation. It takes up a minimum of space and can be fitted side-by-side without installation of extra cooling equipment. IP 20/NEMA 1: This enclosure is used as standard enclosure for VLT 6000 HVAC. It is ideal for cabinet installation in areas where a high degree of protection is required. This enclose also permits side-by-side installation. IP 54: This enclosure can be fitted direct to the wall. Cabinets are not required. IP 54 units can also be installed side-by-side.

Hardware variant The units in the programme are available in the following hardware variants: ST: Standard unit with or without control unit. With-

out DC terminals, except for VLT 6042-6062, 200-240 V

VLT 6016-6072, 525-600 V SL: Standard unit with DC terminals. EX: Extended unit with control unit, DC terminals,

connection of external 24 V DC supply for back-

up of control PCB. DX: Extended unit with control unit, DC terminals,

built-in mains fuses and disconnector, connec-

tion of external 24 V DC supply for back-up of

control PCB. PF: Standard unit with 24 V DC supply for back-up

of control PCB and built-in main fuses. No DC

terminals. PS: Standard unit with 24 V DC supply for back-up

of control PCB. No DC terminals. PD: Standard unit with 24 V DC supply for back-up

of control PCB, built-in main fuses and discon-

nect. No DC terminals.

RFI filter Bookstyle units always come with an integral RFI filter that complies with EN 55011-B with 20 m screened/armoured motor cable and EN 55011-A1 with 150 m screened/armoured motor cable. Units for mains voltage of 240 V and a motor power of up to and including 3.0 kW (VLT 6005) and units for a mains voltage of 380-460 V and a motor power of up to 7.5 kW (VLT 6011) are always supplied with an integral class A1 & B filter. Units for higher motor power than these (3.0 and 7.5 kW, respectively) can be ordered either with or without an RFI filter.

Control unit (keypad and display) All types of units in the programme, except for IP21 VLT 6402-6602, 380-460 V, VLT 6502-6652, 525-600 V and IP 54 units, can be ordered either with or without the control unit. IP 54 units always come with a control unit. All types of units in the programme are available with built-in application options including a relay card with four relays or a cascade controller card.

Conformal Coating All types of units in the programme are available with or without conformal coating of the PCB. VLT 6402-6602, 380-460 V and VLT 6102-6652, 525-600 V are only available coated.

28 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

200-240 V

Typecode

Position in string

1.1 kW/1.5 HP 6002 X X X X X

1.5 kW/2.0 HP 6003 X X X X X

2.2 kW/3.0 HP 6004 X X X X X

3.0 kW/4.0 HP 6005 X X X X X

4.0 kW/5.0 HP 6006 X X X X X X

5.5 kW/7.5 HP 6008 X X X X X X

7.5 kW/10 HP 6011 X X X X X X 11 kW/15 HP 6016 X X X X X X 15 kW/20 HP 6022 X X X X X X

18.5 kW/25 HP 6027 X X X X X X 22 kW/30 HP 6032 X X X X X X 30 kW/40 HP 6042 X X X X X X 37 kW/50 HP 6052 X X X X X X 45 kW/60 HP 6062 X XXX XX

9-10

C00

11-13

B20

11-13

C20

11-13

CN1

11-13

C54

11-13ST14-15SL14-15R016-17R116-17R316-17

380-460 V

Typecode

Position in string

9-10

1.1 kW/1.5 HP 6002 X X X X X

1.5 kW/2.0 HP 6003 X X X X X

2.2 kW/3.0 HP 6004 X X X X X

3.0 kW/4.0 HP 6005 X X X X X

4.0 kW/5.0 HP 6006 X X X X X

5.5 kW/7.5 HP 6008 X X X X X

7.5 kW/10 HP 6011 X X X X X 11 kW/15 HP 6016 X X X X X X 15 kW/20 HP 6022 X X X X X X

18.5 kW/25 HP 6027 X X X X X X 22 kW/30 HP 6032 X X X X X X 30 kW/40 HP 6042 X X X X X X 37 kW/50 HP 6052 X X X X X X 45 kW/60 HP 6062 X X X X X X 55 kW/75 HP 6072 X X X X X X 75 kW/100 HP 6102 X X X X X X 90 kW/125 HP 6122 X X X X X X 110 kW/150 HP 6152 X X X X X X X X X X X 132 kW/200 HP 6172 X X X X X X X X X X X 160 kW/250 HP 6222 X X X X X X X X X X X 200 kW/300 HP 6272 X X X X X X X X X X X 250 kW/350 HP 6352 X X X X X X X X X X X 315 kW/450 HP 6402 X X X X X X X X X X X 355 kW/500 HP 6502 X X X X X X X X X X X 400 kW/550 HP 6552 X X X X X X X X X X X 450 kW/600 HP 6602 X XXX XXXXXXX

C00

11-13

B20

11-1

C20

11-1

CN1

11-1

C54

11-13

14-1

14-15

14-1

14-15

14-1

16-1

16-17

16-1

Introduction to HVAC

Voltage

T2: 200-240 VAC T4: 380-460 VAC

Enclosure

C00: Compact IP 00 B20: Bookstyle IP 20

NB!

NEMA 1 exceeds IP 20

MG.61.B6.02 - VLT

C20: Compact IP 20 CN1: Compact NEMA 1 C54: Compact IP 54

Hardware variant

ST: Standard SL: Standard with DC terminals EX: Extended with 24 V supply and DC terminals DX: Extended with 24 V supply, DC terminals, disconnect and fuse

is a registered Danfoss trademark 29

PS: Standard with 24 V supply PD: Standard with 24 V supply, fuse and disconnect PF: Standard with 24 V supply and fuse

RFI filter

R0: Without filter R1: Class A1 filter R3: Class A1 and B filter

VLT

6000 HVAC Series

525-600 V

Typecode

Position in string

1.1 kW/1.5 HP 6002 X X X X

1.5 kW/2.0 HP 6003 X X X X

2.2 kW/3.0 HP 6004 X X X X

3.0 kW/4.0 HP 6005 X X X X

4.0 kW/5.0 HP 6006 X X X X

5.5 kW/7.5 HP 6008 X X X X

7.5 kW/10 HP 6011 X X X X 11 kW/15 HP 6016 X X X 15 kW/20 HP 6022 X X X

18.5 kW/25 HP 6027 X X X 22 kW/30 HP 6032 X X X 30 kW/40 HP 6042 X X X 37 kW/50 HP 6052 X X X 45 kW/60 HP 6062 X X X 55 kW/75 HP 6072 XX X

9-10

C00

11-13

C20

11-13

CN1

11-13

14-15

16-17

VLT 6102-6652, 525-600 V

Typecode

Position in stringT69-10 75 kW / 100 HP 6102 X X X X X X X X X X 90 kW / 125 HP 6122 X X X X X X X X X X 110 kW / 150 HP 6152 X X X X X X X X X X 132 kW / 200 HP 6172 X X X X X X X X X X 160 kW / 250 HP 6222 X X X X X X X X X X 200 kW / 300 HP 6272 X X X X X X X X X X 250 kW / 350 HP 6352 X X X X X X X X X X 315 kW / 400 HP 6402 X X X X X X X X X X 400 kW / 500 HP 6502 X X X X X X X X X X X 450 kW / 600 HP 6602 X X X X X X X X X X X 500 kW / 650 HP 6652 XXXXXXX X XXX

C00

11-13

CN1

11-13

C54

11-13ST14-15EX14-15DX14-15PS14-15PD14-15PF14-15R016-17R116-17

1) R1 is not available with DX, PF, PD options.

NB!

NEMA 1 exceeds IP 20

Voltage

T6: 525-600 VAC

Enclosure

C00: Compact IP 00 C20: Compact IP 20 CN1: Compact NEMA 1 C54: Compact IP 54

Hardware variant

ST: Standard EX: Extended with 24 V supply and DC terminals DX: Extended with 24 V supply, DC terminals, disconnect and fuse PS: Standard with 24 V supply

PD: Standard with 24 V supply, fuse and disconnect PF: Standard with 24 V supply and fuse

RFI filter

R0: Without filter R1: Class A1 filter

30 MG.61.B6.02 - VLT

is a registered Danfoss trademark

Optional selections, 200-600 V

VLT

6000 HVAC Series

Display

Without LCP

D0 DL With LCP

Fieldbus option

F00 No options F10 Profibus DP V1 F13 Profibus FMS F30 DeviceNet F40 LonWorks free topology F41 LonWorks 78 kBps F42 LonWorks 1.25 MBps

Application option

A00 No options

Relay card 4 relays

A31 A32 Cascade Controller A40 Real Time Clock

Coating

No coating

C0 C1 With coating

1) Not available with enclosure compact IP 54

2) Not available with fieldbus options (Fxx)

3) Not available for power sizes from 6402 to 6602, 380-460 V and 6102-6652, 525-600 V

Position: 18-19

Position: 20-22

Position: 23-25

Position: 26-27

Introduction to HVAC

MG.61.B6.02 - VLT

is a registered Danfoss trademark 31

Ordering form

VLT

6000 HVAC Series

32 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

PC software and serial communication

Danfoss offers various options for serial communication. Using serial communication, it is possible to monitor, program and control one or several frequency converters from a centrally located computer. All VLT 6000 HVAC units have a RS 485 port as standard with a choice of three protocols. The three protocols selectable in parameter 500 Protocols are:

• FC protocol

• Johnson Controls Metasys N2

• Landis/Staefa Apogee FLN

• Modbus RTU

A bus option card allows higher transmission speed than RS 485. In addition, a higher number of units can be linked to the bus and alternative transmission media can be used. Danfoss offers the following option cards for communication:

• Profibus

• LonWorks

• DeviceNet

MCT 10 has been designed as an easy to use interactive tool for setting parameters in our frequency converters. The MCT 10 Set-up Software will be useful for:

• Planning a communication network off-line. MCT 10 contains a complete frequency converter database

• Commissioning frequency converters on line

• Saving settings for all frequency converters

• Replacing a drive in a network

• Expanding an existing network

• Future developed drives will be supported

MCT 10 Set-up Software support Profibus DP-V1 via a Master class 2 connection. It makes it possible to on line read/write parameters in a frequency converter via the Profibus network. This will eliminate the need for an extra communication network.

The MCT 10 Set-up Software Modules

The following modules are included in the software package:

Introduction to HVAC

Information on the installation of various options is not included in this Design Guide.

PC Software tools

PC Software - MCT 10

All drives are equipped with a serial communication port. We provide a PC tool for communication between PC and frequency converter, VLT Motion Control Tool MCT 10 Set-up Software.

MCT 10 Set-up Software

MCT 31

The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduc-

MCT 10 Set-up Software

Setting parameters Copy to and from frequency converters Documentation and print out of parameter settings incl. diagrams

SyncPos

Creating SyncPos programme

Ordering number:

Please order your CD containing MCT 10 Set-up Software using code number 130B1000.

tion measurements, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated.

Ordering number:

Please order your CD containing the MCT 31 PC tool using code number 130B1031.

Fieldbus options

The increasing need for information in building management systems makes it necessary to collect or visualise many different types of process data. Important process data can help the system technician in the day to day monitoring of the system, which

MG.61.B6.02 - VLT

is a registered Danfoss trademark 33

means that a negative development, e. g. an increase in energy consumption, can be rectified in time.

The substantial amount of data in large buildings may generate a need for a higher transmission speed than 9600 baud.

VLT

6000 HVAC Series

Profibus

Profibus is a fieldbus system with FMS and DP, which can be used for linking automation units, such as sensors and actuators, to the controls by means of a twoconductor cable.

Profibus FMS is used if major communication tasks are to be solved at cell and system level by means of large volumes of data.

Profibus DP is an extremely fast communication protocol, made specially for communication between the automation system and various units.

LON - Local Operating Network

LonWorks is an intelligent fieldbus system which improves the possibility of decentralising control, as communication is enabled between individual units in the same system (Peer-to-Peer). This means that there is no need for a big main station for handling all the signals of the system (MasterSlave). Signals are sent direct to the unit that needs them via a common network medium. This makes communication much more flexible and the central building state control and monitoring system can be changed into a dedicated building state monitoring system whose task is to ensure that everything is running as planned. If the potential of LonWorks is fully utilised, sensors will also be connected to the bus, which means that a sensor signal can quickly be moved to another controller. If room dividers are mobile, this is a particularly useful feature.

used to establish master-slave/client-server communication between intelligent devices. MODBUS is used to monitor and program devices; to communicate intelligent devices with sensors and instruments; to monitor field devices using PCs and HMIs. MODBUS is often applied in Gas and Oil applications, but also in building, infrastructure, transportation and energy, applications are making use of its benefits.

Accessories for VLT 6000 HVAC

IP 20 bottom cover

DeviceNet

DeviceNet is a digital, multi-drop network, based on the CAN protocol, that connects and serves as a communication network between industrial controllers and I/O devices. Each device and/or controller is a node on the network. DeviceNet is a producer-consumer network that supports multiple communication hierarchies and message prioritization. DeviceNet systems can be configured to operate in a master-slave or a distributed control architecture using peer-to-peer communication. This system offers a single point of connection for configuration and control by supporting both I/O and explicit messaging. DeviceNet also has the feature of having power on the network. This allows devices with limited power requirements to be powered directly from the network via the 5-conductor cable.

Modbus RTU

MODBUS RTU (Remote Terminal Unit) Protocol is a messaging structure developed by Modicon in 1979,

Application option

34 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Ordering numbers, misc.

Type Description Order no. IP 4x top cover IP 4x top cover IP IP 4 x top cover NEMA 12 bonding plate NEMA 12 bonding plate IP 20 terminal cover Option, VLT type 6006-6022 200-240 V 175Z4622 IP 20 terminal cover Option, VLT type 6027-6032 200-240 V 175Z4623 IP 20 terminal cover Option, VLT type 6016-6042 380-460 V 175Z4622 IP 20 terminal cover Option, VLT type 6016-6042 525-600 V 175Z4622 IP 20 terminal cover Option, VLT type 6052-6072 380-460 V 175Z4623 IP 20 terminal cover Option, VLT type 6102-6122 380-460 V 175Z4280 IP 20 terminal cover Option, VLT type 6052-6072 525-600 V 175Z4623 IP 20 bottom cover Option, VLT type 6042-6062 200-240 V 176F1800 Terminal adaptor kit VLT type 6042-6062 200-240 V, IP 54 176F1808 Terminal adaptor kit VLT type 6042-6062 200-240 V, IP 20/NEMA 1 176F1805 Control panel LCP Separate LCP 175Z7804 LCP remote-mounting kit IP 00 & 20 LCP remote-mounting kit IP 54 LCP blind cover for all IP00/IP20 drives 175Z7806 Cable for LCP Separate cable, 3 m 175Z0929 Relay card Application card with four relay outputs 175Z7803 Cascade controller card With conformal coating 175Z3100 Real Time Clock Option Without/with conformal coating 175Z4852/175Z4853 Profibus option Without/with conformal coating 175Z7800/175Z2905 LonWorks option, Free topology Without/with conformal coating 176F1515/176F1521 LonWorks option, 78 KBPS Without/with conformal coating 176F1516/176F1522 LonWorks option, 1.25 MBPS Without/with conformal coating 176F1517/176F1523 Modbus RTU option Without conformal coating 175Z3362 DeviceNet option Without/with conformal coating 176F1586/176F1587 MCT 10 Set-up software CD-Rom 130B1000 MCT 31 Harmonic calculation CD-Rom 130B1031

Option, VLT type 6002-6005 200-240 V compact 175Z0928 Option, VLT type 6002-6011 380-460 V compact 175Z0928 Option, VLT type 6002-6011 525-600 V compact 175Z0928 Option, VLT type 6002-6005 200-240 V 175H4195 Option, VLT type 6002-6011 380-460 V 175H4195

Remote-mounting kit, incl. 3 m cable Remote-mounting kit, incl. 3 m cable 175Z7802

175Z0850

Rittal Installation Kit

Introduction to HVAC

Type Rittal TS8 enclosure for IP00

Description Order No.

Installation kit for 1800mm high enclosure, VLT6152-6172,

176F1824

380-460V, VLT 6102-6172, 525-600 V

Rittal TS8 enclosure for IP00

Installation kit for 2000mm high enclosure, VLT6152-6172,

176F1826

380-460V, VLT 6102-6172, 525-600 V

Rittal TS8 enclosure for IP00

Installation kit for 1800mm high enclosure, VLT6222-6352,

176F1823

380-460V, VLT 6222-6402, 525-600 V

Rittal TS8 enclosure for IP00

Installation kit for 2000mm high enclosure, VLT6222-6352,

176F1825

380-460V, VLT 6222-6402, 525-600 V

Rittal TS8 enclosure for IP00

Installation kit for 2000mm high enclosure, VLT6402-6602,

176F1850

380-460V and VLT 6502-6652, 525-600 V Floor stand for IP21 and IP54 enclosure

Mains shield kit Protection kit: for VLT 6152-6352, 380-460V, VLT

Option, VLT6152-6352, 380-460V, VLT 6102-6402,

525-600 V

176F1827

176F0799

6102-6402, 525-600V Mains shield kit Protection kit for VLT 6402-6602, 380-460V; VLT

176F1851

6502-6652, 525-600 V

1) IP 4x/NEMA 1 top cover is for IP 20 units only and only horizontal surfaces comply with IP 4x. The kit also contains a bonding plate (UL).

2) NEMA 12 bonding plate (UL) is only for IP 54 units.

3) The remote-mounting kit is only for IP 00 and IP 20 units. Enclosure of the remote-mounting kit is IP 65.

4) The remote-mounting kit is only for IP 54 units. Enclosure of the remote-mounting kit is IP 65.

5) For details: See High Power Installation Guide, MI.90.JX.YY.

VLT 6000 HVAC is available with an integral fieldbus option or application option. Ordering numbers for the individual VLT types with integrated options can be

MG.61.B6.02 - VLT

is a registered Danfoss trademark 35

seen from the relevant manuals or instructions. In addition, the ordering number system can be used for ordering a frequency converter with an option.

Output Filters

The high speed switching of the frequency converter produces some secondary effects, which influence the motor and the enclosed environment. These side effects are addressed by two different filter types, -the du/dt and the Sine-wave filter.

dU/dt filters

Motor insulation stresses are often caused by the combination of rapid voltage and current increase. The rapid energy changes can also be reflected back to the DC-line in the inverter and cause shut down. The du/ dt filter is designed to reduce the voltage rise time/the rapid energy change in the motor and by that intervention avoid premature aging and flashover in the motor insulation. du/dt filters have a positive influence on the radiation of magnetic noise in the cable that connects the drive to the motor. The voltage wave form is still pulse shaped but the du/dt ratio is reduced in comparison with the installation without filter.

VLT

6000 HVAC Series

Sine-wave filters

Sine-wave filters are designed to let only low frequencies pass. High frequencies are consequently shunted away which results in a sinusoidal phase to phase voltage waveform and sinusoidal current waveforms. With the sinusoidal waveforms the use of special frequency converter motors with reinforced insulation is no longer needed. The acoustic noise from the motor is also damped as a consequence of the wave condition. Besides the features of the du/dt filter, the sine-wave filter also reduces insulation stress and bearing currents in the motor thus leading to prolonged motor lifetime and longer periods between services. Sinewave filters enable use of longer motor cables in applications where the motor is installed far from the drive. The length is unfortunately limited because the filter does not reduce leakage currents in the cables.

Ordering Numbers: Sine Wave Filter Modules, 200-500 VAC

Mains supply 3 x 200 to 500 V

Minimum switching frequency

5 kHz 120 Hz 130B2439 130B2404 2.5 A 5 kHz 120 Hz 130B2441 130B2406 4.5 A 5 kHz 120 Hz 130B2443 130B2408 8 A 5 kHz 120 Hz 130B2444 130B2409 10 A 5 kHz 120 Hz 130B2446 130B2411 17 A 4 kHz 60 Hz 130B2447 130B2412 24 A 4 kHz 60 Hz 130B2448 130B2413 38 A 4 kHz 60 Hz 130B2307 130B2281 48 A 3 kHz 60 Hz 130B2308 130B2282 62 A 3 kHz 60 Hz 130B2309 130B2283 75 A 3 kHz 60 Hz 130B2310 130B2284 115 A 3 kHz 60 Hz 130B2311 130B2285 180 A 3 kHz 60 Hz 130B2312 130B2286 260 A 3 kHz 60 Hz 130B2313 130B2287 410 A 3 kHz 60 Hz 130B2314 130B2288 480 A 2 kHz 60 Hz 130B2315 130B2289 660 A 2 kHz 60 Hz 130B2316 130B2290 750 A 2 kHz 60 Hz 130B2317 130B2291 880 A 2 kHz 60 Hz 130B2318 130B2292 1200 A

Maximum output fre-

quency

NB!

When using Sine-wave filters, the switching frequency should comply with filter specifications in par. 411 Switching Frequency.

Part No. IP20 Part No. IP00 Rated filter current at 50Hz

36 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

Ordering Numbers: Sine-Wave Filter Modules, 525-600 VAC

Mains supply 3 x 525 to 690 V

Minimum switching frequency

2 kHz 60 Hz 130B2341 130B2321 13 A 2 kHz 60 Hz 130B2342 130B2322 28 A 2 kHz 60 Hz 130B2343 130B2323 45 A 2 kHz 60 Hz 130B2344 130B2324 76 A 2 kHz 60 Hz 130B2345 130B2325 115 A 2 kHz 60 Hz 130B2346 130B2326 165 A 2 kHz 60 Hz 130B2347 130B2327 260 A 2 kHz 60 Hz 130B2348 130B2329 303 A

1.5 kHz 60 Hz 130B2270 130B2241 430 A

1.5 kHz 60 Hz 130B2271 130B2242 530 A

1.5 kHz 60 Hz 130B2381 130B2337 660 A

1.5 kHz 60 Hz 130B2382 130B2338 765 A

1.5 kHz 60 Hz 130B2383 130B2339 940 A

1.5 kHz 60 Hz 130B2384 130B2340 1320 A

NB!

When using Sine-wave filters, the switching frequency should comply with filter specifications in par. 14-01 Switching Frequency.

Maximum output frequen-

Part No. IP20 Part No. IP00

6000 HVAC Series

Rated filter current at

50Hz

Introduction to HVAC

Ordering Numbers: du/dt Filters, 380-480 VAC Mains supply 3x380 to 3x480 V

Minimum switching frequen-cyMaximum output frequen-

Part No. IP20 Part No. IP00

Rated filter current at 50

4 kHz 60 Hz 130B2396 130B2385 24 A 4 kHz 60 Hz 130B2397 130B2386 45 A 3 kHz 60 Hz 130B2398 130B2387 75 A 3 kHz 60 Hz 130B2399 130B2388 110 A 3 kHz 60 Hz 130B2400 130B2389 182 A 3 kHz 60 Hz 130B2401 130B2390 280 A 3 kHz 60 Hz 130B2402 130B2391 400 A 3 kHz 60 Hz 130B2277 130B2275 500 A 2 kHz 60 Hz 130B2278 130B2276 750 A 2 kHz 60 Hz 130B2405 130B2393 910 A 2 kHz 60 Hz 130B2407 130B2394 1500 A 2 kHz 60 Hz 130B2410 130B2395 2300 A

Ordering Numbers: du/dt Filters, 525-600 VAC

Mains supply 3x525 to 3x600 V

Minimum switching frequen-cyMaximum output frequen-

Part No. IP20 Part No. IP00

Rated filter current at 50

4 kHz 60 Hz 130B2423 130B2414 28 A 4 kHz 60 Hz 130B2424 130B2415 45 A 3 kHz 60 Hz 130B2425 130B2416 75 A 3 kHz 60 Hz 130B2426 130B2417 115 A 3 kHz 60 Hz 130B2427 130B2418 165 A 3 kHz 60 Hz 130B2428 130B2419 260 A 3 kHz 60 Hz 130B2429 130B2420 310 A 3 kHz 60 Hz 130B2278 130B2235 430 A 2 kHz 60 Hz 130B2239 130B2236 530 A 2 kHz 60 Hz 130B2274 130B2280 630 A 2 kHz 60 Hz 130B2430 130B2421 765 A 2 kHz 60 Hz 130B2431 130B2422 1350 A

MG.61.B6.02 - VLT

is a registered Danfoss trademark 37

Harmonic filter

Harmonic currents do not directly affect the electricity consumption but has an impact on following conditions:

Higher total current to be handled by the installations

Increases load on transformer (sometimes it

will require a larger transformer, particular at retrofit)

Increases heat losses in transformer and in-

stallation

In some cases demands larger cables,

switches and fuses

Higher voltage distortion due to higher current

Increase risk for disturbing electronic equip-

ment connected to same grid

A high percentage of rectifier load from eg frequency converters, will increase the harmonic current, which must be reduced to avoid the above consequences. Therefore the frequency converter has as standard, built in DC coils reducing the total current with about 40% (compared to devices without any arrangement for harmonic suppression), down to 40-45% ThiD.

VLT

6000 HVAC Series

In some cases there is a need for further suppression (eg retrofit with frequency converters). For this purpose Danfoss can offer two advanced harmonic filters AHF05 and AHF10, bringing the harmonic current down to around 5% and 10% respectively. For further details see instruction MG.80.BX.YY.

38 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Ordering numbers, Harmonic filters

Harmonic filters are used to reduce mains harmonics

380-415V, 50Hz

AHF,N

10 A 4, 5.5 175G6600 175G6622 6006, 6008 19 A 7.5 175G6601 175G6623 6011, 6016 26 A 11 175G6602 175G6624 6022 35 A 15, 18.5 175G6603 175G6625 6027 43 A 22 175G6604 175G6626 6032

72 A 30, 37 175G6605 175G6627 6042, 6052 101 A 45. 55 175G6606 175G6628 6062, 6072 144 A 75 175G6607 175G6629 6102 180 A 90 175G6608 175G6630 6122 217 A 110 175G6609 175G6631 6152 289 A 132, 160 175G6610 175G6632 6172, 6222 324 A 175G6611 175G6633

Higher ratings can be achieved by paralleling the filter units

370 A 200 175G6688 175G6691 6272

434 A 578 A 315 Two 289 A units 6402 613 A 355 289 A and 324 A units 6502 648 A 400 Two 324 A units 6552 740 A 450 Two 324 A units 6602

Typical Motor Used [kW]

250 Two 217 A units 6352

Danfoss ordering number VLT 6000 AHF 005 AHF 010

• AHF 010: 10% current distortion

• AHF 005: 5% current distortion

Introduction to HVAC

MG.61.B6.02 - VLT

is a registered Danfoss trademark 39

440-480V, 60Hz

AHF,N

19 A 10, 15 175G6612 175G6634 6011, 6016

26 A 20 175G6613 175G6635 6022

35 A 25, 30 175G6614 175G6636 6027, 6032

43 A 40 175G6615 175G6637 6042

72 A 50, 60 175G6616 175G6638 6052, 6062 101 A 75 175G6617 175G6639 6072 144 A 100, 125 175G6618 175G6640 6102, 6122 180 A 150 175G6619 175G6641 6152 217 A 200 175G6620 175G6642 6172 289 A 250 175G6621 175G6643 6222 324 A 300 175F6689 175G6692 6272

Higher ratings can be achieved by paralleling the filter units

397 A 350 175G6690 175G6693 6352

506 A 578 A 500 Two 289 A units 6502 578 A 550 Two 289 A units 6552 648 A 600 Two 324 A units 6602

Typical Motor Used [HP]

450 217 A and 289 A units 6402

Danfoss ordering number VLT 6000 AHF 005 AHF 010

Please note that the matching of the Danfoss frequency converter and filter is pre-calculated based on 400V/480V and assuming typical motor load (4 pole) and 110 % torque. Regarding harmonic filters for 500-525V, please contact Danfoss or consult MG.

80.BX.YY.

For other combinations, please consult MG.80.BX.YY.

VLT

6000 HVAC Series

application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduction devices, such as Danfoss AHF filters and 12-18pulse rectifiers, can be calculated.

Ordering number:

Please order your CD containing the MCT 31 PC tool using code number 130B1031.

MCT 31

The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given

MCT 31 can also be downloaded from the Danfoss Internet: WWW.DANFOSS.COM, Business Area: Motion Controls.

40 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

Mains supply (L1, L2, L3)

Mains supply (L1, L2, L3): Supply voltage 200-240 V units 3 x 200/208/220/230/240 V ±10% Supply voltage 380-460 V units 3 x 380/400/415/440/460 V ±10% Supply voltage 525-600 V units 3 x 525/550/575/600 V ±10% Supply frequency 48-62 Hz ± 1%

Max. imbalance of supply voltage: VLT 6002-6011, 380-460 V and 525-600 V and VLT 6002-6005, 200-240 V ±2.0% of rated supply voltage VLT 6016-6072, 380-460 V and 525-600 V and VLT 6006-6032, 200-240 V ±1.5% of rated supply voltage VLT 6102-6602, 380-460 V and VLT 6042-6062, 200-240 V ±3.0% of rated supply voltage VLT 6102-6652, 525-600 V ±3% of rated supply voltage True Power factor (λ) Displacement Power Factor (cos. ) No. of switches on supply input L1, L2, L3 approx. 1 time/2 min. Max. short-circuit current 100.000 A

VLT output data (U, V, W): Output voltage 0-100% of supply voltage Output frequency: Output frequency 6002-6032, 200-240V Output frequency 6042-6062, 200-240V 0-120 Hz, 0-450 Hz Output frequency 6002-6062, 380-460V 0-120 Hz, 0-1000 Hz Output frequency 6072-6602, 380-460V 0-120 Hz, 0-450 Hz Output frequency 6002-6016, 525-600V 0-120 Hz, 0-1000 Hz Output frequency 6022-6062, 525-600V 0-120 Hz, 0-450 Hz Output frequency 6072, 525-600V 0-120 Hz, 0-450 Hz Output frequency 6102-6352, 525-600V 0-132 Hz, 0-200 Hz Output frequency 6402-6652, 525-600V 0-132 Hz, 0-150 Hz Rated motor voltage, 200-240 V units 200/208/220/230/240 V Rated motor voltage, 380-460 V units 380/400/415/440/460 V Rated motor voltage, 525-600 V units 525/550/575 V Rated motor frequency 50/60 Hz Switching on output Unlimited Ramp times 1 - 3600 sec.

6000 HVAC Series

0.90 nominal at rated load near unity (>0.98)

0-120 Hz, 0-1000 Hz

Installation

Torque characteristics: Starting torque 110% for 1 min. Starting torque (parameter 110 High break-away torque) Max. torque: 160% for 0.5 sec. Acceleration torque 100% Overload torque 110%

MG.61.B6.02 - VLT

is a registered Danfoss trademark 41

VLT

6000 HVAC Series

Control card, digital inputs: Number of programmable digital inputs 8 Terminal nos. 16, 17, 18, 19, 27, 29, 32, 33 Voltage level 0-24 V DC (PNP positive logics) Voltage level, logical '0' < 5 V DC Voltage level, logical '1' >10 V DC Maximum voltage on input 28 V DC Input resistance, R

2 kΩ

Scanning time per input 3 msec.

Reliable galvanic isolation: All digital inputs are galvanically isolated from the supply 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 Switches 1-4.

Control card, analogue inputs No. of programmable analogue voltage inputs/thermistor inputs 2 Terminal nos. 53, 54 Voltage level 0 - 10 V DC (scalable) Input resistance, R

approx. 10 kΩ No. of programmable analogue current inputs 1 Terminal no ground. 55 Current range 0/4 - 20 mA (scalable) Input resistance, R

200 Ω Resolution 10 bit + sign Accuracy on input Max. error 1% of full scale Scanning time per input 3 msec.

Reliable galvanic isolation: All analogue inputs are galvanically isolated from the supply voltage (PELV) and other highvoltage terminals.

Control card, pulse input: No. of programmable pulse inputs 3 Terminal nos. 17, 29, 33 Max. frequency on terminal 17 5 kHz Max. frequency on terminals 29, 33 20 kHz (PNP open collector) Max. frequency on terminals 29, 33 65 kHz (Push-pull) Voltage level 0-24 V DC (PNP positive logics) Voltage level, logical '0' < 5 V DC Voltage level, logical '1' >10 V DC Maximum voltage on input 28 V DC Input resistance, R

2 kΩ Scanning time per input 3 msec. Resolution 10 bit + sign Accuracy (100-1 kHz), terminals 17, 29, 33 Max. error: 0.5% of full scale Accuracy (1-5 kHz), terminal 17 Max. error: 0.1% of full scale Accuracy (1-65 kHz), terminals 29, 33 Max. error: 0.1% of full scale

Reliable galvanic isolation: All pulse inputs are galvanically isolated from the supply voltage (PELV). In addition, pulse 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 Switches 1-4.

Control card, digital/pulse and analogue outputs: No. of programmable digital and analogue outputs 2 Terminal nos. 42, 45 Voltage level at digital/pulse output 0 - 24 V DC Minimum load to ground (terminal 39) at digital/pulse output

42 MG.61.B6.02 - VLT

is a registered Danfoss trademark

600 Ω

VLT

6000 HVAC Series

Frequency ranges (digital output used as pulse output) 0-32 kHz Current range at analogue output 0/4 - 20 mA Maximum load to ground (terminal 39) at analogue output

500 Ω Accuracy of analogue output Max. error: 1.5% of full scale Resolution on analogue output. 8 bit

Reliable galvanic isolation: All digital and analogue outputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, 24 V DC supply: Terminal nos. 12, 13 Max. load 200 mA Terminal nos. ground 20, 39

Reliable galvanic isolation: The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analogue outputs.

Control card, RS 485 serial communication: Terminal nos. 68 (TX+, RX+), 69 (TX-, RX-)

Reliable galvanic isolation: Full galvanic isolation (PELV).

Relay outputs:

No. of programmable relay outputs 2 Terminal nos., control card (resistive load only) 4-5 (make) Max. terminal load (AC1) on 4-5, control card 50 V AC, 1 A, 50 VA Max. terminal load (DC1 (IEC 947)) on 4-5, control card 25 V DC, 2 A / 50 V DC, 1 A, 50 W Max. terminal load (DC1) on 4-5, control card for UL/cUL applications 30 V AC, 1 A / 42.5 V DC, 1A Terminal nos., power card (resistive and inductive load) 1-3 (break), 1-2 (make) Max. terminal load (AC1) on 1-3, 1-2, power card 250 V AC, 2 A, 500 VA Max. terminal load (DC1 (IEC 947)) on 1-3, 1-2, power card 25 V DC, 2 A / 50 V DC, 1A, 50 W Min. terminal load (AC/DC) on 1-3, 1-2, power card 24 V DC, 10 mA / 24 V AC, 100 mA

1) Rated values for up to 300,000 operations. At inductive loads the number of operations are reduced by 50%, alternatively the current can be reduced by 50%, thus the 300,000 operations are maintained.

Installation

External 24 Volt DC supply(only available with VLT 6152-6602, 380-460 V): Terminal nos. 35, 36 Voltage range 24 V DC ±15% (max. 37 V DC for 10 sec.) Max. voltage ripple 2 V DC Power consumption 15 W - 50 W (50 W for start-up, 20 msec.) Min. pre-fuse 6 Amp

Reliable galvanic isolation: Full galvanic isolation if the external 24 V DC supply is also of the PELV type.

Cable lengths and cross-sections: Max. motor cable length, screened cable 150 m Max. motor cable length, unscreened cable 300 m Max. motor cable length, screened cable VLT 6011 380-460 V 100 m Max. motor cable length, screened cable VLT 6011 525-600 V 50 m Max. DC-bus cable length, screened cable 25 m from frequency converter to DC bar.

Max. cable cross-section to motor, see next section

Max. cross-section for 24 V external DC supply

2.5 mm2 /12 AWG Max. cross-section for control cables 1.5 mm 2 /16 AWG Max. cross-section for serial communication 1.5 mm2 /16 AWG

If UL/cUL is to be complied with, copper cable with temperature class 60/75°C must be used

MG.61.B6.02 - VLT

is a registered Danfoss trademark 43

VLT

6000 HVAC Series

(VLT 6002 - 6072 380 - 460 V, 525-600 V and VLT 6002 - 6032 200 - 240 V). If UL/cUL is to be complied with, copper cable with temperature class 75°C must be used (VLT 6042 - 6062 200 - 240 V, VLT 6102 - 6602 380 - 460 V, VLT 6102 - 6652 525 - 600 V). Connectors are for use of both copper and aluminium cables, unless other is specified.

Control characteristics: Frequency range 0 - 1000 Hz Resolution on output frequency ±0.003 Hz System response time 3 msec. Speed, control range (open loop) 1:100 of synchro. speed

< 1500 rpm: max. error ± 7.5 rpm

Speed, accuracy (open loop)

>1500 rpm: max. error of 0.5% of actual speed

< 1500 rpm: max. error ± 1.5 rpm

Process, accuracy (closed loop)

>1500 rpm: max. error of 0.1% of actual speed

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

Accuracy of display readout (parameters 009-012, Display readout): Motor current [5] 0-140% load Max. error: ±2.0% of rated output current Power kW [6], Power HP [7], 0-90% load Max. error: ±5% of rated output power

Externals: Enclosure IP 00, IP 20, IP 21/NEMA 1, IP 54 Vibration test 0.7 g RMS 18-1000 Hz random. 3 directions for 2 hours (IEC 68-2-34/35/36) Max. relative humidity 93 % + 2 %, -3 % (IEC 68-2-3) for storage/transport Max. relative humidity 95 % non condensing (IEC 721-3-3; class 3K3) for operation Aggressive environment (IEC 721-3-3) Uncoated class 3C2 Aggressive environment (IEC 721-3-3) Coated class 3C3 Ambient temperature, VLT 6002-6005 200-240 V, 6002-6011 380-460 V, 6002-6011 525-600 V Bookstyle, IP 20

Max. 45°C (24-hour average max. 40°C) Ambient temperature, VLT 6006-6062 200-240 V, 6016-6602 380-460 V, 6016-6652 525-600 V IP 00, IP 20

Max. 40°C (24-hour average max. 35°C) Ambient temperature, VLT 6002-6062 200-240 V, 6002-6602 380-460 V, VLT 6102-6652, 525-600 V, IP 54

Max. 40°C (24-hour average max. 35°C) See Derating for high ambient temperature 0°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 1000 m See Derating for high air pressure EN 61000-6-3/4, EN 61800-3, EN 55011, EN 55014 EMC standards applied, Emission EN 61000-6-3/4, EN 61800-3, EN 55011, EN 55014

EN 50082-2, EN 61000-4-2, IEC 1000-4-3, EN 61000-4-4, EN 61000-4-5,

EMC standards applied, Immunity

ENV 50204, EN 61000-4-6, VDE 0160/1990.12

IP54 units are not intended for direct outdoor installation. The IP54 rating does not relate to other exposures as sun, icing, wind blown driving rain. Under such circumstances Danfoss recommends to install the units in an enclosure designed for these environmental conditions. Alternatively, an installation at minimum 0.5 m above surface and covered by a shed is recommended.

44 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

NB!

VLT 6002-6072, 525-600 V units do not comply with EMC, Low Voltage or PELV directives.

VLT 6000 HVAC protection

• Electronic motor thermal protection against overload.

• Temperature monitoring of heat-sink ensures that the frequency converter cuts out if the temperature reaches 90°C for IP00, IP20 and NEMA 1. For IP54, the cut-out temperature is 80°C. An overtemperature can only be reset when the temperature of the heat-sink has fallen below 60°C.

For the units mentioned below, the limits are as follows:

- VLT 6152, 380-460 V, cuts out at 75° C and can be reset if the temperature is below 60 °C.

- VLT 6172, 380-460 V, cuts out at 80° C and can be reset if the temperature has fallen below 60° C.

- VLT 6222, 380-460 V, cuts out at 95° C and can be reset if the temperature has fallen below 65° C.

- VLT 6272, 380-460 V, cuts out at 95° C and can be reset if the temperature has fallen below 65° C.

- VLT 6352, 380-460 V, cuts out at 105° C and can be reset if the temperature has fallen below 75° C.

- VLT 6402-6602, 380-460 V cuts out at 85° C and can be reset if the temperature has fallen below 60° C

- VLT 6102-6152, 525-600 V, cuts out at 75° C and can be reset if the temperature has fallen below 60° C. VLT 6172, 525-600 V, cuts out at 80° C and can be reset if the temperature has fallen below 60° C. VLT 6222-6402, 525-600 V, cuts out at 100° C and can be reset if the temperature has fallen below 70° C. VLT 6502-6652, 525-600 V, cuts out at 75° C and can be reset if the temperature has fallen below 60° C.

6000 HVAC Series

Installation

• 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.

• If there is a mains fault, the frequency converter is able to carry out a controlled decelleration.

• If a mains phase is missing, the frequency converter will cut out or autoderate when a load is placed on the motor.

MG.61.B6.02 - VLT

is a registered Danfoss trademark 45

VLT

6000 HVAC Series

Technical data, mains supply 3 x 200-240V

According to international requirements VLT type 6002 6003 6004 6005 6006 6008 6011

Output current

Output power (240 V) S Typical shaft output Typical shaft output

Max. cable cross-section to motor and DC-bus

VLT, MAX VLT,N

VLT,N

(60 s) [A]

[kVA]

VLT,N

[A] 6.6 7.5 10.6 12.5 16.7 24.2 30.8

7.3 8.3 11.7 13.8 18.4 26.6 33.9

2.7 3.1 4.4 5.2 6.9 10.1 12.8

[kW]

1.1 1.5 2.2 3.0 4.0 5.5 7.5

[HP]

1.5 2 3 4 5 7.5 10

[mm2 ]/[AWG]

4/10 4/10 4/10 4/10 10/8 16/6 16/6

Max. input current Max. cable

cross-section power Max. pre-fuses Efficiency

(200 V) (RMS)I

[mm2 ]/[AWG]

L,N

[A]

2 )

[-]/UL1) [A]

6.0 7.0 10.0 12.0 16.0 23.0 30.0

4/10 4/10 4/10 4/10 4/10 16/6 16/6

16/10 16/15 25/20 25/25 35/30 50 60

0.95

0.95 0.95 0.95 0.95 0.95 0.95 Weight IP 20 [kg] 7 7 9 9 23 23 23 Weight IP 54 [kg] 11.5 11.5 13.5 13.5 35 35 38 Power loss at max. load. [W]

Total 76 95 126 172 194 426 545

Enclosure VLT type IP 20 / IP 54

1. For type of fuse, see section Fuses.

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Current ratings fulfill UL requirements for 208-240 V.

Technical data, mains supply 3x200-240V

According to international requirements VLT type 6016 6022 6027 6032 6042 6052 6062

Output current

Output power Typical shaft out-

put Typical shaft output Max. cable crosssection to motor and DC-bus

]/[AWG]

[mm Min. cable cross-section to motor and DC-bus [mm

2) 5)

]/[AWG]

Max. input current (200 V) (RMS)

[A]

L,N

Max. cable crosssection power [mm

]/[AWG]

2) 5)

Max. pre-fuses Efficiency

Weight IP 00 [kg] - - - - 90 90 90 Weight IP 20/ NEMA 1 Weight IP 54 [kg] 38 49 50 55 104 104 104 Power loss at max. load. Enclosure IP 00/IP 20/NEMA 1/IP 54

1. For type of fuse, see section Fuses.

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Current ratings fulfill UL requirements for 208-240 V.

5. Connection stud 1 x M8 / 2 x M8.

6. Aluminium cables with cross section above 35 mm

VLT,N

(200-230 V)

(60 s)

VLT, MAX

[A] (200-230 V)

[A] (240 V)

VLT,N

(60 s)

VLT, MAX

[A] (240 V)

[kVA]

VLT,N

(240 V)

[kW]

VLT,N

[HP]

VLT,N

Copper Aluminium

[-]/UL1) [A]

[kg] 23 30 30 48 101 101 101

[A]

46.2 59.4 74.8 88.0 115 143 170

50.6 65.3 82.3 96.8 127 158 187

46.0 59.4 74.8 88.0 104 130 154

50.6 65.3 82.3 96.8 115 143 170

19.1 24.7 31.1 36.6 43.2 54 64

11 15 18.5 22 30 37 45

15 20 25 30 40 50 60

16/6 16/6

35/2 35/2

50/0 50/0

70/1/0

95/3/0

90/250

mcm

120/4/0

120/300

mcm

10/8 10/8 10/8 16/6 10/8 10/8 10/8

46.0

16/6 16/6

59.2 74.8 88.0 101.3 126.6 149.9

35/2 35/2

50/0 50/0

70/1/0

95/3/0

90/250

mcm

120/4/0

120/300

mcm

60 80 125 125 150 200 250

0.95

0.95 0.95 0.95 0.95 0.95 0.95

[W] 545 783 1042 1243 1089 1361 1613

must be connected by use of an Al-Cu connector.

46 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Technical data, mains supply 3 x 380-460V

According to international requirements VLT type 6002 6003 6004 6005 6006 6008 6011

Output current

Output power S Typical shaft output Typical shaft output Max. cable crosssection to motor Max. input current (RMS) I Max. cable cross-section power Max. pre-fuses Efficiency

Weight IP 20 [kg] 8 8 8.5 8.5 10.5 10.5 10.5 Weight IP 54 [kg] 11.5 11.5 12 12 14 14 14 Power loss at max. load. [W] Enclosure VLT type IP 20/IP 54

For type of fuse, see section Fuses.

[A] (380-415

VLT,N

(60 s) [A]

VLT, MAX

(380-415 V)

[A] (440-460

VLT, N

(60 s) [A]

VLT, MAX

(440-460 V)

[kVA] (400 V)

VLT,N

[kVA] (460 V)

VLT,N

[mm2 ]/[AWG]

[A] (380 V)

L,N

[A] (460 V)

L,N

[mm2 ]/[AWG]

[-]/UL1)[A]

3.0 4.1 5.6 7.2 10.0 13.0 16.0

3.3 4.5 6.2 7.9 11.0 14.3 17.6

3.0 3.4 4.8 6.3 8.2 11.0 14.0

3.3 3.7 5.3 6.9 9.0 12.1 15.4

2.2 2.9 4.0 5.2 7.2 9.3 11.5

2.4 2.7 3.8 5.0 6.5 8.8 11.2

[kW]

[HP]

2) 4)

1.1 1.5 2.2 3.0 4.0 5.5 7.5

1.5 2 3 - 5 7.5 10

4/10 4/10 4/10 4/10 4/10 4/10 4/10

2.8 3.8 5.3 7.0 9.1 12.2 15.0

2) 4)

2.5 3.4 4.8 6.0 8.3 10.6 14.0

4/10 4/10 4/10 4/10 4/10 4/10 4/10

16/6 16/10 16/10 16/15 25/20 25/25 35/30

0.96

0.96 0.96 0.96 0.96 0.96 0.96

Total 67 92 110 139 198 250 295

Installation

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Max. cable cross section is the maximum possible cable cross section that can be fitted on the terminals. Always comply with national and local regulations on min. cable cross-section.

MG.61.B6.02 - VLT

is a registered Danfoss trademark 47

VLT

6000 HVAC Series

Technical data, mains supply 3x380-460V

According to international requirements VLT type 6016 6022 6027 6032 6042

Output current

Output power S Typical shaft output Typical shaft output Max. cable cross-section to motor and DC-bus, IP 20 Max. cable cross-section to motor and DC-bus, IP 54 Min. cable cross-section to motor and DC-bus Max. input current (RMS) Max. cable cross-section power, IP 20 Max. cable cross-section power, IP 54 Max. pre-fuses Efficiency at rated frequency 0.96 0.96 0.96 0.96 0.96 Weight IP 20 [kg] 21 21 22 27 28 Weight IP 54 [kg] 41 41 42 42 54 Power loss at max. load. [W] 419 559 655 768 1065 Enclosure IP 20/ IP 54

For type of fuse, see section Fuses.

2. American Wire Gauge.

[A] (380-415 V)

VLT,N

VLT, MAX

(380-415 V)

[A] (440-460 V)

VLT,N

VLT, MAX

(60 s) [A]

(441-460 V)

[kVA] (400 V)

VLT,N

[kVA] (460 V)

VLT,N

[mm2]/[AWG]

[A] (460 V)

L,N

[mm2]/[AWG]

(60 s) [A]

[kW]

VLT,N

[HP]

VLT,N

2) 4)

[A] (380 V)

2) 4)

[-]/UL1) [A]

24.0 32.0 37.5 44.0 61.0

26.4 35.2 41.3 48.4 67.1

21.0 27.0 34.0 40.0 52.0

23.1 29.7 37.4 44.0 57.2

17.3 23.0 27.0 31.6 43.8

16.7 21.5 27.1 31.9 41.4 11 15 18.5 22 30 15 20 25 30 40

16/6 16/6 16/6 35/2 35/2

16/6 16/6 16/6 16/6 35/2

10/8 10/8 10/8 10/8 10/8

24.0 32.0 37.5 44.0 60.0

21.0 27.6 34.0 41.0 53.0

16/6 16/6 16/6 35/2 35/2

16/6 16/6 16/6 16/6 35/2

63/40 63/40 63/50 63/60 80/80

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Min. cable cross-section is the smallest cable cross-section allowed to be fitted on the terminals. Max. cable cross section is the maximum possible cable cross section that can be fitted on the terminals. Always comply with national and local regulations on min. cable cross-section.

48 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Technical data, mains supply 3x380-460V

According to international requirements VLT type 6052 6062 6072 6102 6122

Output current

Output power S Typical shaft output Typical shaft output Max. cable cross-section to motor and DC-bus, IP 20 Max. cable cross-section to motor and DC-bus, IP 54 Min. cable cross-section to motor and DC-bus Max. input current (RMS) Max. cable cross-section power, IP 20 Max. cable cross-section power, IP 54 Max. pre-fuses Efficiency at rated frequency 0.96 0.96 0.96 0.98 0.98 Weight IP 20 [kg] 41 42 43 54 54 Weight IP 54 [kg] 56 56 60 77 77 Power loss at max. load. [W] 1275 1571 1322 1467 1766 Enclosure IP 20/IP 54

For type of fuse, see section Fuses.

2. American Wire Gauge.

[A] (380-415 V)

VLT,N

VLT, MAX

[A] (440-460 V)

VLT,N

VLT, MAX

(60 s) [A]

(440-460 V)

[kVA] (400 V)

VLT,N

[kVA] (460 V)

VLT,N

[mm2]/[AWG]

[A] (460 V)

L,N

[mm2]/[AWG]

(60 s) [A]

(380-415 V)

VLT,N

2) 4) 6)

2) 4)

[A] (380 V)

L,N

2) 4) 6)

[-]/UL1) [A]

73.0 90.0 106 147 177

80.3 99.0 117 162 195

65.0 77.0 106 130 160

71.5 84.7 117 143 176

52.5 64.7 73.4 102 123

51.8 61.3 84.5 104 127

[kW]

[HP]

37 45 55 75 90 50 60 75 100 125

35/2 50/0 50/0

120 / 250

150 / 300

10/8 16/6 16/6 25/4 25/4

72.0 89.0 104 145 174

64.0 77.0 104 128 158 35/2 50/0 50/0

35/2 50/0 50/0

120 / 250

150 / 300

100/100 125/125 150/150 225/225 250/250

mcm

120 / 250

mcm

150 / 300

mcm

120 / 250

mcm

150 / 300

mcm

Installation

3. Measured using 30 m screened motor cables at rated load and rated frequency.

DC connection 95 mm

Aluminium cables with cross-section above 35 mm

/AWG 3/0.

must be connected by use of an Al-Cu con-

nector.

MG.61.B6.02 - VLT

is a registered Danfoss trademark 49

VLT

6000 HVAC Series

Technical data, mains supply 3x380-460V

According to international requirements VLT type 6152 6172 6222 6272 6352

For type of fuse, see section Fuses.

2. American Wire Gauge.

Output current

Output power Typical shaft output (380-415 V) P

Typical shaft output (440-460 V) P Max. cable cross-section to motor and DC-bus

2]2) 4) 5)

[mm Max. cable cross-section to motor and DC-bus

2) 4) 5)

[AWG]

Min. cable cross-section to motor and DC-bus

/AWG]

2) 4) 5)

[mm

Max. input current (RMS) Max. cable cross-section to power [mm2]

Max. cable cross-section to power [AWG] Max. pre-fuses

Weight IP 00 [kg] 82 91 112 123 138 Weight IP 20 [kg] 96 104 125 136 151 Weight IP 54 [kg] 96 104 125 136 151 Efficiency at rated frequency 0.98 Power loss at max. load. Enclosure IP 00/IP 21/NEMA 1/IP 54

VLT,N

(60 s) [A] (380-415

VLT, MAX

VLT,N

(60 s) [A] (440-460

VLT, MAX

VLT,N

[A] (380-415 V)

[A] (440-460 V)

[kVA] (400 V) [kVA] (460 V)

[kW]

VLT,N

[HP]

VLT,N

212 260 315 395 480 233 286 347 435 528

190 240 302 361 443 209 264 332 397 487

147 180 218 274 333 151 191 241 288 353 110 132 160 200 250 150 200 250 300 350

2x70 2x70 2x185 2x185 2x185

2x2/0

mcm

2x2/0

mcm

2x350

mcm

2x350

mcm

2x350

mcm

35/2 35/2 35/2 35/2 35/2

[A] (380 V)

L,N

[A] (460 V)

L,N

[-]/UL1) [A]

2) 4) 5)

208 256 317 385 467 185 236 304 356 431

2x70 2x70 2x185 2x185 2x185

2x2/0

mcm

2x2/0

mcm

2x350

mcm

2x350

mcm

2x350

mcm

300/300 350/350 450/400 500/500 630/600

[W] 2619 3309 4163 4977 6107

3. Measured using 30 m screened motor cables at rated load and rated frequency.

5. Connection bolt 1 x M10 / 2 x M10 (mains and motor), connection bolt 1 x M8 / 2 x M8 (DC-bus).

50 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Technical data, mains supply 3 x 380-460 V

According to international requirements VLT type 6402 6502 6552 6602

Output current

VLT, MAX

Output power S

Typical shaft output (380-415 V) P Typical shaft output (440-460 V) P Max. cable cross-section to motor and DC-bus

2] 4) 5)

[mm Max. cable cross-section to motor and DC-bus

2) 4) 5)

[AWG] Max. input current (RMS) Max. cable cross-section to power [mm2] Max. cable cross-section to power [AWG] Max. pre-fuses (mains) Efficiency

Weight IP 00 [kg] 221 234 236 277 Weight IP 20 [kg] 263 270 272 313 Weight IP 54 [kg] 263 270 272 313 Power loss at max. load Enclosure IP 00 / IP 21/NEMA 1 / IP 54

For type of fuse, see section Fuses.

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

[A] (380-415 V) 600 658 745 800

VLT,N

(60 s) [A] (380-415 V)

[A] (440-460 V) 540 590 678 730

VLT,N

(60 s) [A] (440-460 V)

[kVA] (400 V) 416 456 516 554

VLT,N

[kVA] (460 V)

VLT,N

[kW]

VLT,N

[HP]

VLT,N

660 724 820 880

594 649 746 803

430 470 540 582 315 355 400 450 450 500 550/600 600

4 x 240 4 x 240 4 x 240 4 x 240

4 x 500 mcm 4 x 500 mcm 4 x 500 mcm 4 x 500 mcm

L,MAX

[A] (380 V) [A] (460 V)

4) 5)

2) 4) 5)

[-]/UL [A]

584 648 734 787 526 581 668 718

4 x 240 4 x 240 4 x 240 4 x 240

4 x 500 mcm 4 x 500 mcm 4 x 500 mcm 4 x 500 mcm

1 )

700/700 900/900 900/900 900/900

0.98 0.98 0.98 0.98

[W] 7630 7701 8879 9428

Installation

4. Always comply with national and local regulations on min. cable cross-section. Max. cable cross section is the maximum possible cable cross section that can be fitted on the terminals.

5. Connection bolt power supply, motor and load sharing: M10 compression (lug), 2 x M8 (box lug)

MG.61.B6.02 - VLT

is a registered Danfoss trademark 51

VLT

6000 HVAC Series

Technical data, mains supply 3 x 525-600 V

According to international requirements VLT type 6002 6003 6004 6005 6006 6008 6011

Output current I

Output S

VLT,N

Typical shaft output P Typical shaft output P

[A] (550 V) 2.6 2.9 4.1 5.2 6.4 9.5 11.5

VLT,N

(60 s) [A] (550V)

VLT, MAX

(60 s) [A] (575 V)

VLT, MAX

VLT,N

[A] (575 V)

[kVA] (550 V)

[kVA] (575 V)

VLT,N

[kW]

VLT,N

[HP] 1.5 2 3 4 5 7.5 10

VLT,N

Max. copper cable cross-section to motor and loadsharing

[mm

2.9

3.2 4.5 5.7 7.0 10.5 12.7

2.4

2.7 3.9 4.9 6.1 9.0 11.0

2.6 3.0 4.3 5.4 6.7 9.9 12.1

2.5 2.8 3.9 5.0 6.1 9.0 11.0

2.4 2.7 3.9 4.9 6.1 9.0 11.0

1.1 1.5 2.2 3 4 5.5 7.5

]

4 4 4 4 4 4

Rated Input Current

VLT,N

[A] (550 V) [A] (600 V)

Max.copper cable cross-section, power

Max. prefuses (mains)

[ - ]/UL [A]

[AWG]

[mm

[AWG]

10 10 10 10 10 10 10

2.5

2.8

4.0

5.1

2.2

2.5

3.6

]

4 4 4 4 4 4

10 10 10 10 10 10 10

4 5 6 8 10 15

4.6

6.2

5.7

9.2

8.4

Efficiency 0.96 Weight IP20 / NEMA 1

[kg]

10.52310.52310.52310.52310.52310.52310.5

[Ibs] Estimated power loss at max. load (550 V) [W] 65 73 103 131 161 238 288 Estimated power loss at max. load (600V) [W]

63 71 102 129 160 236 288

Enclosure IP 20/NEMA 1

For type of fuse, see section Fuses.

2. American Wire Gauge (AWG).

3. Min. cable cross-section is the smallest cable cross-section allowed to be fitted into the terminals to comply with IP20. Always comply with national and local regulations on min. cable cross-section.

11.2

10.3

52 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Technical data, mains supply 3 x 525-600 V

According to international requirements 6016 6022 6027 Output current I

(60 s) [A] (550V)

VLT, MAX

[A] (575 V)

VLT,N

(60 s) [A] (575 V)

VLT, MAX

Output

Typical shaft output P Typical shaft output P

VLT,N

[A] (550 V)

[kW]

VLT,N

[HP]

VLT,N

S S

VLT,N VLT,N

[kVA] (550 V) [kVA] (575 V)

18 23 28 34 43 54 65 81 20 25 31 37 47 59 72 89 17 22 27 32 41 52 62 77 19

24 30 35 45 57 68 85 17 22 27 32 41 51 62 77 17 22 27 32 41 52 62 77 11 15 18.5 22 30 37 45 55 15

20 25 30 40 50 60 75

Max. copper cable cross-section to motor and loadsharing

[mm2]

[AWG]

16 16 16 35 35 50 50 50

6 6 6 2 2 1/0 1/0 1/0 Min. cable cross-section to motor and loadshar-

ing

[mm2]

[AWG]

0.5 0.5 10 10 16 16 16

0.5

20 20 20 8 8 6 6 6

Rated Input Current

[A] (550 V) 18 22 27 33 42 53 63 79

VLT.N

[A] (600 V)

VLT.N

Max copper cable cross section, power

Max. prefuses (mains)

[mm2] [AWG]

[-]/UL [A]

21 25 30 38 49 38 72

16 16 16 35 35 50 50 50

6 6 6 2 2 1/0 1/0 1/0

30 35 45 60 75 90 100

Efficiency 0.96 Weight IP20 / NEMA 1

[kg]

[Ibs]23512351235130663066481064810648106 Estimated power loss at max. load (550 V) [W] 451 576 702 852 1077 1353 1628 2029 Estimated power loss at max. load (600 V) [W]

446 576 707 838 1074 1362 1624 2016

603

6042 6052 6062 6072

Installation

Enclosure

NEMA 1

For type of fuse, see section Fuses.

2. American Wire Gauge (AWG).

Aluminium cables with cross-section above 35 mm

must be connected by use of an Al-Cu connector.

MG.61.B6.02 - VLT

is a registered Danfoss trademark 53

VLT

6000 HVAC Series

Mains supply 3 x 525-600 V

According to international requirements VLT type 6102 6122

Output current

Output

Typical shaft output [kW] (550 V) 75 90 [HP] (575 V) 100 125

Max. cable cross-section to motor

Max. cable cross-section to loadsharing and brake Rated input current

I Max. cable cross-section power supply Min. cable cross-section to motor and power supply Min. cable cross-section to brake and loadsharing Max. pre-fuses (mains) [-]/UL

Efficiency Power loss [W]

Weight Weight IP 21/Nema1 [kg] 96 Weight

Enclosure IP 00, IP 21/Nema 1 and IP 54/Nema12

VLT,N

(60 s) [A] (525-550 V)

VLT, MAX

VLT,N

(60 s) [A] (551-600 V)

VLT, MAX

VLT,N

IP 54/Nema12 [kg] 96

[A] (525-550 V)

[A] (551-600 V)

[kVA] (550 V) [kVA] (575 V)

[mm2]

2,4,5

[AWG]

[mm2]

2,4,5

[AWG]

[A] (550 V)

L,N

[A] (575 V)

L,N

[A] (690 V)

L,N

[mm2]

2,4,5

[AWG]

[mm2]

2,4,5

[AWG]

[mm2]

2,4,5

[AWG]

[A]

2156

IP 00 [kg]

113 137 124 151 108 131 119 144 108 131 108 130

4,5

110 130 106 124 109 128

4,5

200 250

0.98

2 x 70

2 x 2/0

2 x 70

2 x 2/0

2 x 70

2 x 2/0

2532

For type of fuse see section Fuses

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Max. cable cross-section is the maximum possible cable cross-section allowed to be fitted on the terminals. Min. cable cross-section is the minimum

allowed cross-section. Always comply with national and local regulations on min. cable cross-section.

5. Connection bolt 1 x M10 / 2 x M10 (mains and motor), connection bolt 1 x M8 / 2 x M8 (DC-bus).

54 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Mains supply 3 x 525-600 V

According to international requirements VLT type 6152 6172 6222 6272 6352 6402

Output current

Output

Typical shaft output [kW] (550 V) 110 132 160 200 250 315 [HP] (575 V) 150 200 250 300 350 400 Max. cable cross-section to motor

Max. cable cross-section to loadsharing and brake Rated input current

I Max. cable cross-section power supply Min. cable cross-section to motor and power supply Min. cable cross-section to brake and loadsharing Max. pre-fuses (mains) [-]/ UL

Efficiency

Power loss [W]

Weight Weight IP 21/Nema1 [kg] 96 104 125 136 151 165 Weight

Enclosure I

VLT,N

(60 s) [A] (525-550

VLT, MAX

VLT,N

(60 s) [A] (551-600

VLT, MAX

VLT,N

[A] (525-550 V)

[A] (551-600 V)

[kVA] (550 V) [kVA] (575 V)

[mm2]

[AWG]

[mm2]

[AWG]

[A] (550 V)

L,N

[A] (575 V)

L,N

[A] (690 V)

L,N

[mm2]

[AWG]

[mm2]

[AWG]

[mm2]

[AWG]

162 201 253 303 360 418 178 221 278 333 396 460

155 192 242 290 344 400 171 211 266 319 378 440

154 191 241 289 343 398 154 191 241 289 343 398

4,5

2,4,5

2 x 70

2 x 2/0

4,5

2 x 70

2 x 2/0

2 x 185

2 x 350 mcm

2 x 185

2 x 350 mcm 158 198 245 299 355 408 151 189 234 286 339 390 155 197 240 296 352 400

4,5

2,4,5

[A]

2 x 70

2 x 2/0

4,5

315 350 350 400 500 550

2 x 185

2 x 350 mcm

0,98

2963 3430 4051 4867 5493 5852

IP 00 [kg]

82 91 112 123 138 151

IP 54/Nema12 [kg] 96 104 125 136 151 165

P 00, IP 21/Nema 1 and IP 54/

Nema12

Installation

For type of fuse see section Fuses

2. American Wire Gauge.

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Max. cable cross-section is the maximum possible cable cross-section allowed to be fitted on the terminals. Min. cable cross-section is the minimum allowed cross-section. Always comply with national and local regulations on min. cable cross-section.

5. Connection bolt 1 x M10 / 2 x M10 (mains and motor), connection bolt 1 x M8 / 2 x M8 (DC-bus).

MG.61.B6.02 - VLT

is a registered Danfoss trademark 55

VLT

6000 HVAC Series

Technical data, mains supply 3 x 525-600 V

According to international requirements VLT type 6502 6602 6652

Output current

VLT, MAX

Output power S

Typical shaft output (525-550 V) P Typical shaft output (551-600 V) P Max. cable cross-section to motor and DC-bus [mm2] Max. cable cross-section to motor and DC-bus [AWG]

4) 5)

Max. input current (RMS) Max. cable cross-section to power [mm2] Max. cable cross-section to power [AWG] Max. pre-fuses (mains) Efficiency

Weight IP 00 [kg] 221 236 277 Weight IP 20 [kg] 263 272 313 Weight IP 54 [kg] 263 272 313 Power loss at max. load Enclosure IP 00 / IP 21/NEMA 1 / IP 54

For type of fuse, see section Fuses.

2. American Wire Gauge.

[A] (525-550 V) 523 596 630

VLT,N

(60 s) [A] (525-550 V)

[A] (551-600 V) 500 570 630

VLT,N

(60 s) [A] (551-600 V)

[kVA] (550 V) 498 568 600

VLT,N

[kVA] (575 V)

VLT,N

[kW]

VLT,N

[HP]

VLT,N

L,MAX

4) 5)

2) 4) 5)

4) 5)

[A] (550 V) [A] (575 V)

[-]/UL [A]

1 )

757 656 693

550 627 693

498 568 627 400 450 500 500 600 650

4 x 240 4 x 240 4 x 240

4 x 500 mcm 4 x 500 mcm 4 x 500 mcm

504 574 607 482 549 607

4 x 240 4 x 240 4 x 240

4 x 500 mcm 4 x 500 mcm 4 x 500 mcm

700/700 900/900 900/900

0.98 0.98 0.98

[W] 7630 7701 8879

3. Measured using 30 m screened motor cables at rated load and rated frequency.

4. Always comply with national and local regulations on min. cable cross-section. Max. cable cross section is the maximum possible

cable cross section that can be fitted on the terminals.

5. Connection bolt power supply, motor and load sharing: M10 compression (lug), 2 x M8 (box lug)

56 MG.61.B6.02 - VLT

is a registered Danfoss trademark

VLT

6000 HVAC Series

Fuses

UL compliance

To comply with UL/cUL approvals, pre-fuses according to the table below must be used.

200-240 V

VLT Bussmann SIBA Littel fuse Ferraz-Shawmut 6002 KTN-R10 5017906-010 KLN-R10 ATM-R10 or A2K-10R 6003 KTN-R15 5017906-016 KLN-R15 ATM-R15 or A2K-15R 6004 KTN-R20 5017906-020 KLN-R20 ATM-R20 or A2K-20R 6005 KTN-R25 5017906-025 KLN-R25 ATM-R25 or A2K-25R 6006 KTN-R30 5017906-032 KLN-R30 ATM-R30 or A2K-30R 6008 KTN-R50 5012406-050 KLN-R50 A2K-50R 6011, 6016 KTN-R60 5014006-063 KLN-R60 A2K-60R 6022 KTN-R80 5014006-080 KLN-R80 A2K-80R 6027, 6032 KTN-R125 2028220-125 KLN-R125 A2K-125R 6042 FWX-150 2028220-150 L25S-150 A25X-150 6052 FWX-200 2028220-200 L25S-200 A25X-200 6062 FWX-250 2028220-250 L25S-250 A25X-250

380-460 V

Bussmann SIBA Littel fuse Ferraz-Shawmut 6002 KTS-R6 5017906-006 KLS-R6 ATM-R6 or A6K-6R 6003, 6004 KTS-R10 5017906-010 KLS-R10 ATM-R10 or A6K-10R 6005 KTS-R15 5017906-016 KLS-R15 ATM-R15 or A6K-15R 6006 KTS-R20 5017906-020 KLS-R20 ATM-R20 or A6K-20R 6008 KTS-R25 5017906-025 KLS-R25 ATM-R25 or A6K-25R 6011 KTS-R30 5012406-032 KLS-R30 ATM-R30 or A6K-30R 6016, 6022 KTS-R40 5014006-040 KLS-R40 A6K-40R 6027 KTS-R50 5014006-050 KLS-R50 A6K-50R 6032 KTS-R60 5014006-063 KLS-R60 A6K-60R 6042 KTS-R80 2028220-100 KLS-R80 A6K-80R 6052 KTS-R100 2028220-125 KLS-R100 A6K-100R 6062 KTS-R125 2028220-125 KLS-R125 A6K-125R 6072 KTS-R150 2028220-160 KLS-R150 A6K-150R 6102 FWH-220 2028220-200 L50S-225 A50-P225 6122 FWH-250 2028220-250 L50S-250 A50-P250 6152* FWH-300/170M3017 2028220-315 L50S-300 A50-P300 6172* FWH-350/170M3018 2028220-315 L50S-350 A50-P350 6222* FWH-400/170M4012 206xx32-400 L50S-400 A50-P400 6272* FWH-500/170M4014 206xx32-500 L50S-500 A50-P500 6352* FWH-600/170M4016 206xx32-600 L50S-600 A50-P600 6402 170M4017 6502 170M6013 6552 170M6013 6602 170M6013

Installation

* Circuit Breakers manufactured by General Electric, Cat .No. SKHA36AT0800, with the rating plugs listed below can be used to meet UL requirement.

6152 rating plug No. SRPK800 A 300 6172 rating plug No. SRPK800 A 400 6222 rating plug No. SRPK800 A 400 6272 rating plug No. SRPK800 A 500 6352 rating plug No. SRPK800 A 600

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VLT

6000 HVAC Series

525-600 V

Bussmann SIBA Littel fuse Ferraz-Shawmut 6002 KTS-R3 5017906-004 KLS-R003 A6K-3R 6003 KTS-R4 5017906-004 KLS-R004 A6K-4R 6004 KTS-R5 5017906-005 KLS-R005 A6K-5R 6005 KTS-R6 5017906-006 KLS-R006 A6K-6R 6006 KTS-R8 5017906-008 KLS-R008 A6K-8R 6008 KTS-R10 5017906-010 KLS-R010 A6K-10R 6011 KTS-R15 5017906-016 KLS-R015 A6K-15R 6016 KTS-R20 5017906-020 KLS-R020 A6K-20R 6022 KTS-R30 5017906-030 KLS-R030 A6K-30R 6027 KTS-R35 5014006-040 KLS-R035 A6K-35R 6032 KTS-R45 5014006-050 KLS-R045 A6K-45R 6042 KTS-R60 5014006-063 KLS-R060 A6K-60R 6052 KTS-R75 5014006-080 KLS-R075 A6K-80R 6062 KTS-R90 5014006-100 KLS-R090 A6K-90R 6072 KTS-R100 5014006-100 KLS-R100 A6K-100R

525-600 V

Bussmann SIBA FERRAZ-SHAWMUT 6102 170M3015 2061032,2 6.6URD30D08A0200 6122 170M3016 2061032,25 6.6URD30D08A0250 6152 170M3017 2061032,315 6.6URD30D08A0315 6172 170M3018 2061032,35 6.6URD30D08A0350 6222 170M4011 2061032,35 6.6URD30D08A0350 6272 170M4012 2061032,4 6.6URD30D08A0400 6352 170M4014 2061032,5 6.6URD30D08A0500 6402 170M5011 2062032,55 6.6URD32D08A550 6502 170M4017 6602 170M6013 6652 170M6013

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 L25S fuses for 240 V drives.

A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V drives. A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V drives.

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VLT

6000 HVAC Series

Non UL compliance

If UL/cUL is not to be complied with, we recommend the above mentioned fuses or:

VLT 6002-6032 200-240 V type gG VLT 6042-6062 200-240 V type gR VLT 6002-6072 380-460 V type gG VLT 6102-6122 380-460 V type gR VLT 6152-6352 380-460 V type gG VLT 6402-6602 380-460 V type gR VLT 6002-6072 525-600 V type gG

Not following the recommendation may result in 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 V / 600 V

rms

maximum.

Installation

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VLT

6000 HVAC Series

Mechanical dimensions

All the below listed measurements are in mm.

VLT type Bookstyle IP 20 200 - 240 V

6002 - 6003

A B C

395 90 260 384 70 100 A

6004 - 6005 395 130 260 384 70 100 A

Bookstyle IP 20 380 - 460 V

6002 - 6005

395 90 260 384 70 100 A

6006 - 6011 395 130 260 384 70 100 A

IP 00 200 - 240 V

6042 - 6062

IP 00 380 - 460 V

6152 - 6172 6222 - 6352 1327 408 6402 - 6602 1547 585

IP 20 200 - 240 V

6002 - 6003

800 370 335 780 270 225 B

1046 408

373 373

494

395 220 160 384 200 100 C 6004 - 6005 395 220 200 384 200 100 C 6006 - 6011 560 242 260 540 200 200 D 6016 - 6022 700 242 260 680 200 200 D 6027 - 6032 800 308 296 780 270 200 D 6042 - 6062 954 370 335 780 270 225 E

IP 20 380 - 460 V

6002 - 6005

395 220 160 384 200 100 C 6006 - 6011 395 220 200 384 200 100 C 6016 - 6027 560 242 260 540 200 200 D 6032 - 6042 700 242 260 680 200 200 D 6052 - 6072 800 308 296 780 270 200 D 6102 - 6122 800 370 335 780 330 225 D

IP 21/NEMA 1 380-460 V

6152 - 6172 6222 - 6352 1588 420 6402 - 6602 2000 600

1208 420

373 373

494

IP 54 200 - 240 V

A B C D a b aa/bb Type

6002 - 6003 460 282 195 85 260 258 100 F 6004 - 6005 530 282 195 85 330 258 100 F 6006 - 6011 810 350 280 70 560 326 200 F 6016 - 6032 940 400 280 70 690 375 200 F 6042 - 6062 937 495 421 - 830 374 225 G

IP 54 380 - 460 V

6002 - 6005

460 282 195 85 260 258 100 F 6006 - 6011 530 282 195 85 330 258 100 F 6016 - 6032 810 350 280 70 560 326 200 F 6042 - 6072 940 400 280 70 690 375 200 F 6102 - 6122 940 400 360 70 690 375 225 F 6152 - 6172 1208 420 6222 - 6352 1588 420 6402 - 6602 2000 600

373 373

494

1. With disconnect add 44 mm.

aa: Minimum space above enclosure

1001 304 225 J

1282 304 225 J

1502 304 225 J

1154 304 225 J

1535 304 225 J

- - 225 H

- 1154 304 225 J

- 1535 304 225 J

- - - 225 H

a b aa/bb Type

bb: Minimum space below enclosure

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VLT

6000 HVAC Series

Mechanical dimensions

All the below listed measurements are in mm. VLT Type

IP 00 525 - 600 V

6102 - 6172 1046 408 6222 - 6402 1327 408 6502 - 6652 1547 585

IP 20/NEMA 1 525 - 600 V

A B C a b aa/bb Type

373 373 494

1001 304 225 J 1282 304 225 J 1502 304 225 J

6002 - 6011 395 220 200 384 200 100 C 6016 - 6027 560 242 260 540 200 200 D 6032 - 6042 700 242 260 680 200 200 D 6052 - 6072 800 308 296 780 270 200 D 6102 - 6172 1208 420 6222 - 6402 1588 420 6502 - 6652 2000 600

IP 54 525 - 600 V

6102 - 6172

1208 420 6222 - 6402 1588 420 6502 - 6652 2000 600

373 373

494

373 373

494

1154 304 225 J 1535 304 225 J

- - 225 H

1154 304 225 J 1535 304 225 J

- - 225 H

aa: Minimum space above enclosure bb: Minimum space below enclosure

1) With disconnect add 44 mm.

Installation

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Mechanical dimensions

VLT

6000 HVAC Series

62 MG.61.B6.02 - VLT

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Mechanical dimensions (cont.)

VLT

Type H, IP 20, IP 54

6000 HVAC Series

Installation

Type I, IP 00

Type J, IP 00, IP 21, IP 54

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VLT

6000 HVAC Series

Mechanical installation

Please pay attention to the requirements that apply to integration and field mounting kit, see the below list. The information given in the list must be observed to avoid serious damage or injury, especially when installing large units.

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 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. If the ambient temperature is in the range of 45°C -55° C, derating of the frequency converter will become relevant, see Derating for ambient temperature. The service life of the frequency converter will be reduced if derating for ambient temperature is not taken into account.

Side by side/flange by flange

All frequency converters can be mounted side by side/ flange by flange.

Installation of VLT 6002-6652

All frequency converters must be installed in a way that ensures proper cooling.

Cooling

All Bookstyle and Compact units require a minimum space above and below the enclosure.

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d [mm] Comments Bookstyle VLT 6002-6005, 200-240 V 100 VLT 6002-6011, 380-460 V 100

Compact (all enclosure types) VLT 6002-6005, 200-240 V 100

VLT 6002-6011, 525-600 V 100

VLT 6006-6032, 200-240 V 200 VLT 6016-6072, 380-460 V 200 VLT 6102-6122, 380-460 V 225 VLT 6016-6072, 525-600 V 200

VLT 6042-6062, 200-240 V 225 VLT 6102-6402, 525-600 V 225 VLT 6152-6352, 380-460 V 225 VLT 6402-6602, 380-460 V VLT 6502-6652, 525-600 V

225 IP 00 above and below enclosure.

Installation on a plane, vertical surface (no spacers)

Installation on a plane, vertical surface (no spacers)VLT 6002-6011, 380-460 V 100

Installation on a plane, vertical surface (no spacers)

Installation on a plane, vertical surface (no spacers) IP 54 filter mats must be changed when they are dirty.

IP 21/IP 54 only above enclosure.

VLT

6000 HVAC Series

Installation

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Installation of VLT 6402-6602 380-460 V and VLT 6502-6652, 525-600 V Compact IP 21 and IP 54

Cooling

VLT

6000 HVAC Series

Side-by-side

All units in the above-mentioned series require a minimum space of 225 mm above the enclosure and must be installed on a flat level surface. This applies to both IP 21 and IP 54 units. Gaining access requires a minimum space of 579 mm in front of the frequency converter.

NB!

All IP 21 and IP 54 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.

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6000 HVAC Series

General information about electrical installation

High voltage warning

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 Design Guide, as well as national and local safety regulations, must be complied with. Touching the electrical parts may be fatal

- even after disconnection from mains: Using VLT 6002-6005, 200-240 V wait at least 4 minutes Using VLT 6006-6062, 200-240 V wait at least 15 minutes Using VLT 6002-6005, 380-460 V wait at least 4 minutes Using VLT 6006-6072, 380-460 V wait at least 15 minutes Using VLT 6102-6352, 380-460 V wait at least 20 minutes Using VLT 6402-6602, 380-460 V wait at least 40 minutes Using VLT 6002-6006, 525-600 V wait at least 4 minutes Using VLT 6008-6027, 525-600 V wait at least 15 minutes Using VLT 6032-6072, 525-600 V wait at least 30 minutes Using VLT 6102-6402, 525-600 V wait at least 20 minutes Using VLT 6502-6652, 525-600 V wait at least 30 minutes

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.

Earthing

The following basic issues need to be considered when installing a frequency converter, so as to obtain electromagnetic compatibility (EMC).

• Safety earthing: Please note that the frequency converter has a high leakage current and must be earthed appropriately for safety reasons. Apply local safety regulations.

• High-frequency earthing: Keep the earth wire connections as short as possible.

Connect the different earth systems at the lowest possible conductor impedance. The lowest possible conductor impedance is obtained by keeping the conductor as short as possible and by using the greatest possible surface area. A flat conductor, for example, has a lower HF impedance than a round conductor for the same conductor cross-section C

. If more than

VESS

one device is installed in cabinets, the cabinet rear plate, which must be made of metal, should be used as a common earth reference plate. The metal cabinets of the different devices are mounted on the cabinet rear plate using the lowest possible HF impedance. This avoids having different HF voltages for the individual devices and avoids the risk of radio interference currents running in connection cables that may be used between the devices. The radio interference will have been reduced. In order to obtain a low HF impedance, use the fastening bolts of the devices as HF connection to the rear plate. It is necessary to remove insulating paint or similar from the fastening points.

Cables

Control cables and the filtered mains cable should be installed separate from the motor cables so as to avoid interference overcoupling. Normally, a distance of 20 cm will be sufficient, but it is recommended to keep the greatest possible distance wherever possible, especially where cables are installed in parallel over a substantial distance. With respect to sensitive signal cables, such as telephone cables and data cables, the greatest possible distance is recommended with a minimum of 1 m per 5 m of power cable (mains and motor cable). It must be pointed out that the necessary distance depends on the sensitivity of the installation and the signal cables, and that therefore no precise values can be stated. If cable jaws are used, sensitive signal cables are not to be placed in the same cable jaws as the motor cable or brake cable. If signal cables are to cross power cables, this should be done at an angle of 90 degrees. Remember that all interference-filled in- or outgoing cables to/from a cabinet should be screened/armoured or filtered. See also EMC-correct electrical installation.

Installation

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Screened/armoured cables

The screen must be a low HF-impedance screen. This is ensured by using a braided screen of copper, aluminium or iron. Screen armour intended for mechanical protection, for example, is not suitable for an EMCcorrect installation. See also Use of EMC-correct cables.

Extra protection with regard to indirect contact

ELCB relays, multiple protective earthing or earthing can be used as extra protection, provided that local safety regulations are complied with. In the case of an earth fault, a DC content may develop in the faulty current. Never use ELCB relays, type A, since such relays are not suitable for DC fault currents. If ELCB relays are used, this must be:

• Suitable for protecting equipment with a direct current content (DC) in the faulty current (3-phase bridge rectifier)

VLT

6000 HVAC Series

• Suitable for power-up with short charging current to earth

• Suitable for a high leakage current

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6000 HVAC Series

RFI switch

Mains supply isolated from earth: If the frequency converter is supplied from an isolated mains source (IT mains) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off (OFF)

. For further reference, see IEC 364-3. In case optimum EMC performance is needed, parallel motors are connected or the motor cable length is above 25 m, it is recommended to set the switch in ON position. In OFF position, the internal RFI capacities (filter capacitors) between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate circuit and to reduce the earth capacity currents (according to IEC 61800-3). Please also refer to the application note VLT on IT mains, MN.90.CX.02. It is important to use isolation monitors that are capable for use together with power electronics (IEC 61557-8).

NB!

The RFI switch is not to be operated with mains connected to the unit. Check that the mains supply has been disconnected before operating the RFI switch.

Position of RFI switches

Bookstyle IP 20 VLT 6002 - 6011 380 - 460 V VLT 6002 - 6005 200 - 240 V

Installation

NB!

Open RFI switch is only allowed at factory set switching frequencies.

NB!

The RFI switch connects the capacitors galvanically to earth.

The red switches are operated by means of e.g. a screwdriver. They are set in the OFF position when they are pulled out and in ON position when they are pushed in. Factory setting is ON.

Mains supply connected to earth: The RFI switch

must be in ON position in order for the

frequency converter to comply with the EMC standard.

1) Not possible with 6102-6652, 525-600 V units.

Compact IP 20 and NEMA 1 VLT 6002 - 6011 380 - 460 V VLT 6002 - 6005 200 - 240 V VLT 6002 - 6011 525 - 600 V

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VLT

6000 HVAC Series

Compact IP 20 and NEMA 1 VLT 6016 - 6027 380 - 460 V VLT 6006 - 6011 200 - 240 V VLT 6016 - 6027 525 - 600 V

Compact IP 20 and NEMA 1 VLT 6032 - 6042 380 - 460 V VLT 6016 - 6022 200 - 240 V VLT 6032 - 6042 525 - 600 V

Compact IP 20 and NEMA 1 VLT 6052 - 6122 380 - 460 V VLT 6027 - 6032 200 - 240 V VLT 6052 - 6072 525 - 600 V

Compact IP 54 VLT 6102 - 6122 380 - 460 V

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Compact IP 54 VLT 6002 - 6011 380 - 460 V VLT 6002 - 6005 200 - 240 V

VLT

Compact IP 54 VLT 6042 - 6072 380 - 460 V VLT 6016 - 6032 200 - 240 V

6000 HVAC Series

Installation

Compact IP 54 VLT 6016 - 6032 380 - 460 V VLT 6006 - 6011 200 - 240 V

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All enclosure types VLT 6152 - 6602, 380 - 460 V

VLT

6000 HVAC Series

High voltage test

A high voltage test can be carried out by short-circuiting terminals U, V, W, L1, L2 and L3 and energizing by max. 2.5 kV DC for one second between this shortcircuit and the chassis.

NB!

The RFI switch must be closed (position ON) when high voltage tests are carried out. The mains and motor connection must be interrupted in the case of high voltage tests of the total installation if the leakage currents are too high.

Heat emission from VLT 6000 HVAC

The tables in General technical data show the power loss P cooling air temperature t

(W) from VLT 6000 HVAC. The maximum

, is 40° at 100% load (of

IN MAX

rated value).

Ventilation of integrated VLT 6000 HVAC

The quantity of air required for cooling frequency converters can be calculated as follows:

1. Add up the values of P

for all the frequency

converters to be integrated in the same panel. The highest cooling air temperature (t present must be lower than t

IN, MAX

(40°C). The day/night average must be 5°C lower (VDE 160). The outlet temperature of the cooling air must not exceed: t

OUT, MAX

(45° C).

2. Calculate the permissible difference between the temperature of the cooling air (t outlet temperature (t Δt = 45° C-t

OUT

) and its

3. Calculate the required

quantity of air =

ϕ ×3.1

∑

insert Δt in Kelvin

The outlet from the ventilation must be placed above the highest-mounted frequency converter. Allowance must be made for the pressure loss across the filters and for the fact that the pressure is going to drop as the filters are choked.

EMC correct electrical installation

Following these guidelines is recommended in cases where compliance with EN 61000-6-3/4, EN 55011 or

EN 61800-3 First environment is required. If the installation is in EN 61800-3 Second environment, then it is acceptable to deviate from these guidelines. It is however not recommended. See also CE labelling, Emis- sion and EMC test results under special conditions in the Design Guide for further details.

Good engineering practice to ensure EMC correct electrical installation:

• Use only braided screened/armoured motor cables and control cables. The screen should provide a minimum coverage of 80%. The screen material must be metal, not limited to but typically copper, aluminium, steel or lead. There are no special requirements for the mains cable.

• Installations using rigid metal conduits are not required to use screened cable, but the motor cable must be installed in conduit separate from the control and mains cables. Full connection of the conduit from the drive to the motor is required. The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained.

• Connect the screen/armour/conduit to earth at both ends for motor cables and control cables. See also Earthing of braided screened/

)

armoured control cables.

• Avoid terminating the screen/armour with twisted ends (pigtails). Such a termination increases the high frequency impedance of the screen, which reduces its effectiveness at high frequencies. Use low impedance cable clamps or glands instead.

• Ensure good electrical contact between the mounting plate and the metal chassis of the frequency converter. This does not apply to IP54 units as they are designed for wall mounting and VLT 6152-6602, 380-480 V, VLT 6102-6652, 525-600 V, VLT 6042-6062, 200-240 VAC in IP20/NEMA1 enclosure.

• Use starwashers and galvanically conductive installation plates to secure good electrical connections for IP00, IP20, IP21 and NEMA 1 installations.

• Avoid using unscreened/unarmoured motor or control cables inside cabinets housing the drive(s), where possible.

• An uninterrupted high frequency connection between the frequency converter and the motor units is required for IP54 units.

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6000 HVAC Series

The illustration shows an example of an EMC correct electrical installation of an IP20 or NEMA 1 frequency converter. The frequency converter has been fitted in an installation cabinet with an output contactor and connected to a PLC, which in this example is installed in a separate cabinet. Other ways of making the installation may have as good an EMC performance,

provided the above guide- lines to engineering practice are followed. Please note that when unscreened cables and control wires are used, some emission requirements are not complied with, although the immunity requirements are fulfilled. See the section EMC test results for further details.

Installation

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VLT

6000 HVAC Series

Use of EMC-correct cables

Braided screened/armoured cables are recommended to optimise EMC immunity of the control cables and the EMC emission from the motor cables.

The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the switching impedance (Z

). The screen of a cable is normally de-

signed to reduce the transfer of electric noise; however, a screen with a lower Z a screen with a higher Z

is rarely stated by cable manufacturers, but it is of-

ten possible to estimate Z

value is more effective than

by assessing the physical

design.

ZT can be assessed on the basis of the following factors:

The contact resistance between the individ-

ual screen conductors.

The screen coverage, i.e. the physical area

of the cable covered by the screen - often stated as a percentage value. Should be min. 85%.

Screen type, i.e. braided or twisted pattern.

Aluminium-clad with copper wire.

Twisted copper wire or armoured steel wire cable.

Single-layer braided copper wire with varying percentage screen coverage.

Double-layer braided copper wire.

Twin layer of braided copper wire with a magnetic, screened/armoured intermediate layer.

Cable that runs in copper tube or steel tube.

Lead cable with 1.1 mm wall thickness with full coverage.

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6000 HVAC Series

Electrical installation - earthing of control cables

Generally speaking, control cables must be braided screened/armoured and the screen must be connected by means of a cable clampat both ends to the metal cabinet of the unit.

The drawing below indicates how correct earthing is carried out and what to be done if in doubt.

Correct earthing

Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical contact

Wrong earthing Do not use twisted cable ends (pigtails), since these increase the screen impedance at high frequencies.

Protection with respect to earth potential between PLC and VLT

If the earth potential between the frequency converter and the PLC (etc.) is different, electric noise may occur that will disturb the whole system. This problem can be solved by fitting an equalising cable, to be placed next to the control cable. Minimum cable cross-section: 16

For 50/60 Hz earth loops

If very long control cables are used, 50/60 Hz earth loops may occur. This problem can be solved by connecting one end of the screen to earth via a 100nF capacitor (keeping leads short).

Cables for serial communication Low-frequency noise currents between two frequency converters can be eliminated by connecting one end of the screen to terminal 61. This terminal is connected to earth via an internal RC link. It is recommended to use twisted-pair cables to reduce the differential mode interference between the conductors.

Installation

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Electrical installation, enclosures

Bookstyle IP 20 VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V

VLT

6000 HVAC Series

Compact IP 20 and NEMA 1 (IP 20) VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V VLT 6002-6011, 525-600 V

Compact IP 54 VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V

Compact IP 20 and NEMA 1 VLT 6006-6032, 200-240 V VLT 6016-6072, 380-460 V VLT 6016-6072, 525-600 V

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VLT

Compact IP 00 VLT 6042-6062, 200-240 V

6000 HVAC Series

Installation

Compact IP 54 VLT 6006-6032, 200-240 V VLT 6016-6072, 380-460 V

Compact IP 54 VLT 6042-6062, 200-240 V

Compact NEMA 1 (IP 20) VLT 6042-6062, 200-240 V

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Compact IP 20 VLT 6102-6122, 380-460 V

VLT

6000 HVAC Series

IP 54, IP 21/NEMA 1 VLT 6152-6172, 380-460 V VLT 6102-6172, 525-600 V

Compact IP 54 VLT 6102-6122, 380-460 V

VLT 6152-6172, 380-460 V VLT 6102-6172, 525-600 V

Note: The RFI switch has no function in the 525-600 V drives.

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VLT

6000 HVAC Series

IP 54, IP 21/NEMA 1 with disconnect and main fuse VLT 6222-6352, 380-460 V VLT 6222-6402, 525-600 V

IP 00 with disconnect and fuse VLT 6222-6352, 380-460 V VLT 6222-6402, 525-600 V

Note: The RFI switch has no function in the 525-600 V drives.

Installation

Compact IP 00 with disconnect and fuse

VLT 6402-6602 380-460 V and VLT 6502-6652

525-600 V

Compact IP 00 without disconnect and fuse

VLT 6402-6602 380-460 V and VLT 6502-6652

525-600 V

MG.61.B6.02 - VLT

Note: The RFI switch has no function in the 525-600 V drives.

is a registered Danfoss trademark 79

Position of earth terminals, IP 00

VLT

6000 HVAC Series

Position of earth terminals, IP 21 / IP 54

Compact IP 21 / IP 54 without disconnect and

fuse

VLT 6402-6602 380-460 V and VLT 6502-6652

525-600 V

Note: The RFI switch has no function in the 525-600 V drives.

80 MG.61.B6.02 - VLT

is a registered Danfoss trademark

Bookstyle IP 20 VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V

VLT

Compact IP 20, NEMA 1, and IP 54 VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V VLT 6002-6011, 525-600 V

6000 HVAC Series

Installation

IP 20 and NEMA 1 VLT 6006-6032, 200-240 V VLT 6016-6122, 380-460 V VLT 6016-6072, 525-600 V

IP 54 VLT 6006-6032, 200-240 V VLT 6016-6072, 380-460 V

MG.61.B6.02 - VLT

is a registered Danfoss trademark 81

IP 00 and NEMA 1 (IP 20) VLT 6042-6062, 200-240 V

VLT

6000 HVAC Series

IP 54 VLT 6042-6062, 200-240 V

Compact IP 54 VLT 6102-6122, 380-460 V

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VLT

6000 HVAC Series

Tightening-up torque and screw sizes

The table shows the torque required when fitting terminals to the frequency converter. For VLT 6002-6032, 200-240 V, VLT 6002-6122, 380-460 and VLT 6002-6072 525-600 V the cables must be fastened with screws. For VLT 6042-6062, 200-240 V and for VLT 6152-6550, 380-460 V and VLT 6102-6652, 525-600 V the cables must be fastened with bolts.

See Technical data for correct sizing of cable crosssections.

NB!

Check that the mains voltage fits the mains voltage of the frequency converter, which can be seen from the nameplate.

These figures apply to the following terminals:

Mains terminals (Nos.) L1, L2, L3

Motor terminals (Nos.) U, V, W

Earth terminal (Nos.) 94, 95, 99 VLT type

3 x 200 - 240 V VLT 6002-6005 0.5-0.6 Nm M3 VLT 6006-6011 1.8 Nm (IP 20) M4 VLT 6006-6016 1.8 Nm (IP 54) M4 VLT 6016-6027 3.0 Nm (IP 20) VLT 6022-6027 VLT 6032 6.0 Nm VLT 6042-6062 11.3 Nm M8 (bolt)

VLT type 3 x 380-460 V VLT 6002-6011 0.5-0.6 Nm M3 VLT 6016-6027 1.8 Nm (IP 20) M4 VLT 6016-6032 1.8 Nm (IP 54) M4 VLT 6032-6052 3.0 Nm (IP 20) VLT 6042-6052 VLT 6062-6072 6.0 Nm VLT 6102-6122 15 Nm (IP 20)

VLT 6152-6352 VLT 6402-6602 19 Nm M10 (com-

9.5 Nm

VLT type 3 x 525-600 V VLT 6002-6011 0.5-0.6 Nm M3 VLT 6016-6027 1.8 Nm M4 VLT 6032-6042 VLT 6052-6072 6.0 Nm VLT 6102-6402 VLT 6502-6652 19 Nm M10 (com-

9.5 Nm

1. Loadsharing terminals 14 Nm/M6, 5 mm Allen key

2. IP 54 units with RFI filter line terminals 6 Nm

3. Allen screws (hexagon)

4. Loadsharing terminals 9.5 Nm/M8 (bolt)

5. Wrench

91, 92, 93

96, 97, 98

Tightening-up

torque

3.0 Nm (IP 54)

Tightening-up

torque

3.0 Nm (IP 54)

24 Nm (IP 54)

Tightening-up

19 Nm

torque

3.0 Nm

19 Nm

Screw/bolt

size

M5 M6

Screw/bolt

size

M5 M6 M8

1) 3)

M10 (bolt)

pression lug)

M8 (box lug)

Screw/bolt

size

M5 M6

M10 (bolt)

pression lug)

M8 (box lug)

Tool

4 mm

5 mm

Tool

4 mm

5 mm

6 mm 8 mm

16 mm 16 mm

13 mm

Tool

4 mm

5 mm

16 mm 16 mm

13 mm

Motor connection

The motor must be connected to terminals 96, 97, 98. Earth to terminal 94/95/99.

Nos.

96. 97. 98 U, V, W No. 94/95/99 Earth connection

See Technical data for correct sizing of cable crosssections.

All types of three-phase asynchronous standard motors can be used with a VLT 6000 HVAC unit.

Small-size motors are normally star-connected. (220/380 V, Δ/Y). Large-size motors are delta-connected (380/660 V, Δ/Y). The correct connection and voltage can be read from the motor nameplate.

NB!

In older motors without phase coil insulation, a sine wave filter should be fitted to the frequency converter output. For further information, please contact Danfoss.

Mains connection

Motor voltage 0-100 % of mains voltage

Installation

Mains must be connected to terminals 91, 92, 93. Mains voltage 3 x 200-240 V 91, 92, 93 Mains voltage 3 x 380-460 V L1, L2, L3 Mains voltage 3 x 525-600 V

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VLT

6000 HVAC Series

Direction of motor rotation

The factory setting is for clockwise rotation with the frequency transformer output connected as follows.

Terminal 96 connected to U-phase Terminal 97 connected to V-phase Terminal 98 connected to W-phase

The direction of motor rotation can be changed by switching two phases in the motor cable.

Parallel coupling of motors

Problems may arise at the start and at low rpm values if the motor sizes are widely different. This is because the relatively high ohmic resistance in small motors calls for a higher voltage at the start and at low rpm values. In systems with motors connected in parallel, the electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor. Consequently, additional motor protection is required, such as thermistors in each motor (or individual thermal relays).

NB!

Parameter 107 Automatic Motor Adaptation, AMA and Automatic Energy Optimization, AEO in parameter 101 Torque characteristics cannot be used if motors

are connected in parallel.

Motor cables

See Technical data for correct sizing of motor cable cross-section and length. Always comply with national and local regulations on cable cross-sections.

NB!

If an unscreened cable is used, some EMC requirements are not complied with, see EMC test results.

VLT 6000 HVAC is able to control several motors connected in parallel. If the motors are to have different rpm values, the motors must have different rated rpm values. Motor rpm is changed simultaneously, which means that the ratio between the rated rpm values is maintained across the range. The total current consumption of the motors is not to exceed the maximum rated output current I

for the frequency converter.

VLT,N

If the EMC 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 so as 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 cabinet 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 differentT 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.

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VLT

6000 HVAC Series

Motor thermal protection

The electronic thermal relay in UL-approved frequency converters has received UL-approval for single motor protection, as long as parameter 117 Motor thermal protection has been set to ETR Trip and parameter 105 Motor current I

, has been programmed for the

VLT,N

rated motor current (can be read from the motor nameplate).

Earth connection

Since the leakage currents to earth may be higher than

3.5 mA, the frequency converter must always be earthed in accordance with applicable na-tional and local regulations. In order to ensure good mechanical connection of the earth cable, its cable cross-section must

be at least 10 mm

. For added security, an RCD (Residual Current Device) may be installed. This ensures that the frequency converter will cut out if the leakage currents get too high. See RCD instructions MI.66.AX.

02.

DC bus connection

The DC bus terminal is used for DC back-up, with the intermediate circuit being supplied from an external DC source.

Terminal nos. 88, 89

Contact Danfoss if you require further information.

High-voltage relay

The cable for the high-voltage relay must be connected to terminals 01, 02, 03. The high-voltage relay is programmed in parameter 323, Relay 1, out-put.

No. 1 Relay ouput 1 1+3 break, 1+2 make Max 240 V AC, 2 Amp Min. 24 V DC 10 mA or 24 V AC, 100 mA

Max Cross-section: Torque: 0.5-0.6 Nm Screw size: M3

4 mm

/10 AWG

Installation

Installation of 24 Volt external DC supply

Torque: 0.5 - 0.6 Nm Screw size: M3 No. 35(-), 36 (+) 24 V External DC supply (Available with VLT 6152-6602 380-460 V and VLT 6102-6652, 525-600 V only)

Function

24 V external DC supply can be used as low-voltage supply to the control card and any option cards installed. This enables full operation of the LCP (incl. parameter setting) without connection to mains. Please note that a warning of low voltage will be given when 24 V DC has been connected; however, there will be no tripping. If 24 V external DC supply is connected or switched on at the same time as the mains supply, a time of min. 200 msec. must be set in parameter 111, Start delay . A pre-fuse of min. 6 Amp, slow-blow, can be fitted to protect the external 24 V DC supply. The power consumption is 15-50 W, depending on the load on the control card.

NB!

Use 24 V DC supply of type PELV to ensure correct galvanic isolation (type PELV) on the control terminals of the frequency converter.

Control card

All terminals for the control cables are located under the protective cover of the frequency converter. The protective cover (see drawing below) can be removed by means of a pointed object - a screwdriver or similar.

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VLT

6000 HVAC Series

Electrical installation, control cables

Torque: 0.5-0.6 Nm Screw size: M3

Generally speaking, control cables must be screened/ armoured and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the unit (see Earthing of screened/ armoured control cables). Normally, the screen must also be connected to the body of the controlling unit (follow the instructions for installation given for the unit in question). If very long control cables are used, 50/60 Hz earth loops may occur that will disturb the whole system. This problem can be solved by connecting one end of the screen to earth via a 100nF condenser (keeping leads short).

No. Function

04, 05 Relay output 2 can be used for indicating sta-

12, 13 Voltage supply to digital inputs. For the 24 V

16-33

20 Ground for digital inputs.

39 Ground for analogue/digital outputs. Must be

42, 45 Analogue/digital outputs for indicating frequen-

50 Supply voltage to potentiometer and thermis-

53, 54 Analogue voltage input, 0 - 10 V DC.

55 Ground for analogue voltage inputs.

60 Analogue current input 0/4-20 mA. See pa-

68, 69 RS 485 interface, serial communication.

tus and warnings.

DC to be used for digital inputs, switch 4 on the control card must be closed, position "on". Digital inputs. See parameters 300-307 Digital

inputs.

connnected to terminal 55 by means of a threewire transmitter. See Examples of connection.

cy, reference, current and torque. See parameters 319-322 Analogue/digital outputs.

tor 10 V DC.

rameters 314-316 Terminal 60.

Termination of serial communication. See

Earthing of screened/armoured control cables.

This terminal is not normally to be used.

Where the frequency converter is connected to a bus, switches 2 and 3 (switches 1- 4 - see next page) must be closed on the first and the last frequency converter. On the remaining frequency converters, switches 2 and 3 must be open. The factory setting is closed (position on).

Electrical installation, control cables

Max. control cable cross section: 1.5 mm

/16 AWG Torque: 0.5-0.6 Nm Screw size: M3 See Earthing of screened/armoured control cables for correct termination of control cables.

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VLT

6000 HVAC Series

Installation

Switches 1-4

The dipswitch is located on the control card. It is used for serial communication and external DC supply. The switching position shown is the factory setting.

Switch 1 has no function.

Switches 2 and 3 are used for terminating an RS-485 interface to the serial communication bus

NB!

When the frequency converter is the or

last device on the serial communication bus, switches 2 and 3 must be ON in that designated VLT. serial communication bus must have switches 2 and 3 set to OFF.

NB!

Please note that when Switch 4 is in position "OFF," the external 24 V DC supply is galvanically isolated from the frequency converter.

Any other VLTs on the

first

Signal P is the positive potential (TX+,RX+), while signal N is the negative potential (TX-,RX-).

If more than one frequency converter is to be connected to a given master, use parallel connections.

In order to avoid potential equalizing currents in the screen, the cable screen can be earthed via terminal 61, which is connected to the frame via an RC-link.

Bus connection

The serial bus connection in accordance with the RS 485 (2-conductor) norm is connected to terminals 68/69 of the frequency converter (signals P and N).

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VLT

6000 HVAC Series

Connection examples, VLT 6000 HVAC

The diagram below gives an example of a typical VLT 6000 HVAC installation. The mains supply is connected to terminals 91 (L1), 92 (L2) and 93 (L3), while the motor is connected to 96 (U), 97 (V) and 98 (W). These numbers can also be seen from the terminals of the frequency converter. An external DC supply or a 12-pulse option can be connected to terminals 88 and 89. Please ask Danfoss for a Design Guide to learn more. Analogue inputs can be connected to terminals 53 [V], 54 [V] and 60 [mA]. These inputs can be programmed for either reference, feedback or thermistor. See An- alogue inputs in parameter group 300.

There are 8 digital inputs, which can be connected to terminals 16-19, 27, 29, 32, 33. These inputs can be programmed in accordance with the table in Inputs and outputs 300-328. There are two analogue/digital outputs (terminals 42 and 45), which can be programmed to show the present status or a process value, such as 0-f

MAX

. Relay outputs 1 and 2 can be used for giving the present status or a warning. On terminals 68 (P+) and 69 (N-) RS 485 interface, the frequency converter can be controlled and monitored via serial communication.

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VLT

6000 HVAC Series

Single-pole start/stop

Start/stop using terminal 18.

Parameter 302 = Start [1]

Quick-stop using terminal 27.

Parameter 304 = Coasting stop, inverse [0]

Digital speed up/down

Run permissive

Start permitted with terminal 16.

Parameter 300 = Run permissive [8]

Start/stop with terminal 18.

Parameter 302 = Start [1]

Quickstop with terminal 27.

Parameter 304 = Coasting stop, inverse [0].

Activated damper (motor)

Parameter 323 = Start command active [13].

Installation

Speed up and down using terminals 32 and

33. Parameter 306 = Speed up [7] Parameter 307 = Speed down [7] Parameter 305 = Freeze reference [2]

Potentiometer reference

-Parameter 308 = Reference [1] Parameter 309 = Terminal 53, min. scaling Parameter 310 = Terminal 53, max. scaling

2-zone regulation

Parameter 308 = Feedback [2].

- Parameter 311 = Feedback [2].

Transmitter connection

MG.61.B6.02 - VLT

Parameter 314 = Reference [1]

- Parameter 315 = Terminal 60, min. scaling

Parameter 316 = Terminal 60, max. scaling

is a registered Danfoss trademark 89

Control unit LCP

The front of the frequency converter features a control panel - LCP(Local Control Panel). This is a complete interface for operation and programming of the frequency converter. The control panel is detachable and can - as an alternative - be installed up to 3 metres away from the frequency converter, e.g. on the front panel, by means of a mounting kit option. The functions of the control panel can be divided into five groups:

1. Display

2. Keys for changing display mode

3. Keys for changing program parameters

4. Indicator lamps

5. Keys for local operation

All data are indicated by means of a 4-line alphanumeric display, which, in normal operation, is able to show 4 operating data values and 3 operating condition values continuously. During programming, all the information required for quick, effective parameter Setup of the frequency converter will be displayed. As a supplement to the display, there are three indicator lamps for voltage (ON), warning (WARNING) and alarm (ALARM), respectively. All frequency converter parameter Setups can be changed immediately via the control panel, unless this function has been programmed to be Locked [1] via parameter 016 Lock for data change or via a digital input, parameters 300-307 Data change lock.

VLT

6000 HVAC Series

Control keysfor parameter setup

The control keys are divided into functions. This means that the keys between display and indicator lamps are used for parameter Setup, including selecting the display indication during normal operation.

[DISPLAY MODE] is used for selecting the indication mode of the display or when returning to the Display mode from either the Quick menu or the Extend menu mode.

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[QUICK MENU] gives access to the parameters used for the Quick menu. It is possible to switch between the Quick menu and the Extend menu modes.

[EXTEND MENU] gives access to all parameters. It is possible to switch between the Extend menu and the Quick menu modes.

[CHANGE DATA] is used for changing a setting selected either in the Extend menu or the Quick menu mode.

[CANCEL] is used if a change of the selec-ted parameter is not to be carried out.

[OK] is used for confirming a change of the parameter selected.

VLT

6000 HVAC Series

[HAND START] is used if the frequency converter is to be controlled via the control unit. The frequency converter will start the motor, since a start command is given by means of [HAND START]. On the control terminals, the following control signals will still be active when [HAND START] is activated:

• Hand start - Off stop - Auto start

• Safety Interlock

• Reset

• Coasting stop inverse

• Reversing

• Setup select lsb - Setup select msb

[+/-] is used for selecting parameters and for changing a chosen parameter. These keys are also used to change the local reference. In addition, the keys are used in Display mode to switch between operation variable readouts.

[<>] is used when selecting a parameter group and for moving the cursor when changing numerical values.

Indicator lamps

At the bottom of the control panel is a red alarm lamp and a yellow warning lamp, as well as a green voltage LED.

If certain threshold values are exceeded, the alarm and/ or warning lamp is activated, and a status or alarm text is displayed.

•Jog

• Run permissive

• Lock for data change

• Stop command from serial communication

NB!

If parameter 201 Output frequency low limit f

is set to an output frequency greater

MIN

than 0 Hz, the motor will start and ramp up to this frequency when [HAND START] is activated.

[OFF/STOP] is used for stopping the connected motor. Can be selected as Enable [1] or Disable [0] via parameter 013. If the stop function is activated, line 2 will flash. [AUTO START] is used if the frequency converter is to be controlled via the control terminals and/or serial communication. When a start signal is active on the control terminals and/or the bus, the frequency converter will start.

Programming

NB!

The voltage indicator lamp is activated when the frequency converter receives voltage.

Local control

Underneath the indicator lamps are keys for local control.

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NB!

An active HAND-OFF-AUTO signal via the digital inputs will have higher priority than the control keys [HAND START][AUTO START].

[RESET] is used for resetting the frequency converter after an alarm (trip). Can be selected as Enable [1] or Disable [0] via parameter 015 Reset on LCP. See also List of warnings and alarms.

Display mode

In normal operation, any 4 different operating variables can be indicated continuously: 1.1 and 1.2 and 1.3 and

2. The present operating status or alarms and warnings that have arisen are shown in line 2 in the form of a number. In the case of alarms, the alarm in question will be shown in lines 3 and 4, accompanied by an explanatory note. Warnings will flash in line 2, with an explanatory note in line 1. In addition, the display shows the active Setup. The arrow indicates the direction of rotation; here the frequency converter has an active reversing signal. The arrow body disappears if a stop command is given or if the output frequency falls below 0.01 Hz. The bottom line gives the status of the frequency converter. The scroll list on the next page gives the operating data that can be shown for variable 2 in display mode. Changes are made via the [+/-] keys.

195NA113.10

1st line

2nd line

3rd line

VAR 1.1 VAR 1.2 VAR 1.3

SETUP

VAR 2

STATUS

4th line

Display mode, cont.

Three operating data values can be shown in the first display line, while one operating variable can be shown in the second display line. To be programmed via parameters 007, 008, 009 and 010 Display read- out.

• Status line (4th line):

VLT

The left part of the status line indicates the control element of the frequency converter that is active. AUTO means that control is via the control terminals, while HAND indicates that control is via the local keys on the control unit. OFF means that the frequency converter ignores all control commands and stops the motor. The centre part of the status line indicates the reference element that is active. REMOTE means that the reference from the control terminals is active, while LOCAL indicates that the reference is determined via the [+/-] keys on the control panel.

The last part of the status line indicates the current status, for example "Running", "Stop" or "Alarm".

Display mode I:

VLT 6000 HVAC offers different display modes depending on the mode selected for the frequency converter. The figure on the next page shows the way to navigate between different display modes. Below is a display mode, in which the frequency converter is in Auto mode with remote reference at an output frequency of 40 Hz. In this display mode, reference and control are determined via the control terminals. The text in line 1 gives the operating variable shown in line 2.

6000 HVAC Series

80.0% 5.08A 2.15kW

40.0Hz

AUTO REMOTE RUNNING

HAND LOCAL STOP

OFF

LOCAL STOP HAND JOGGING

. . .

FREQUENCY

40.0Hz

RAMPING

STAND BY

SETUP

175ZA701.10

175ZA683.10

AUTO REMOTE RUNNING

Line 2 gives the current output frequency and the active Setup. Line 4 says that the frequency converter is in Auto mode with remote reference, and that the mo tor is running.

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Display mode II:

This display mode makes it possible to have three operating data values displayed at the same time in line

1. The operating data values are determined in parameters 007-010 Display readout.

100% 7.8A 5.9kW

SETUP

50.0Hz

AUTO REMOTE RUNNING

Display mode III:

This display mode is active as long as the [DISPLAY MODE] key is kept depressed. In the first line, operating data names and units of operating data are displayed. In the second line, operating data 2 remains unchanged. When the key is released, the different operating data values are shown.

175ZA685.10

VLT

6000 HVAC Series

REF% CURR.A.POW.,KW

SETUP

50.0Hz

AUTO REMOTE RUNNING

Display mode IV:

This display mode is only active in connection with local reference, see also Reference handling. In this display mode, the reference is determined via the [+/-] keys and control is carried out by means of the keys underneath the indicator lamps. The first line indicates the required reference. The third line gives the relative value of the present output frequency at any given time in relation to the maximum frequency. The display is in the form of a bar graph.

USE +/- 40Hz

40.0Hz

----60

HAND LOCAL RUNNING

SETUP

175ZA695.10

176FA156.10

Programming

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is a registered Danfoss trademark 93

Navigation between display modes

Press briefly

HAND LOCAL RUNNING

USE +/- 40Hz

40.0Hz

VLT

FREQUENCY

40.0Hz

AUTO REMOTE RUNNING

▲▲

▲

▲▲

SETUP

Display mode I

With remote reference

6000 HVAC Series

▲▲

▲

▲▲

▲

▲▲

80% 7,8A 5,9 KW

40.0 Hz

0 ---- 60

HAND LOCAL RUNNING

Display mode IV

175ZA697.10

▲▲

▲

With local reference

Keep the [DISPLAY MODE] key down

AUTO REMOTE RUNNING

Display mode II

▲▲

▲

▲▲

REF% CURR.A POW.,KW

40.0 Hz

AUTO REMOTE RUNNING

Display mode III

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Changing data

Regardless of whether a parameter has been selected under the Quick menu or the Extended menu, the procedure for changing data is the same. Pressing the [CHANGE DATA] key allows change of the selected parameter, and the underlining in line 4 will flash on the display. The procedure for changing data depends on whether the selected parameter represents a numerical data value or a functional value. If the chosen parameter represents a numeric data value, the first digit can be changed by means of the [+/-] keys. If the second digit is to be changed, first move the cursor by using the [<>] keys, then change the data value using the [+/-] keys.

FREQUENCY

24.2 Hz

205 MAX. REFERENCE

60,000 Hz

0000

SETUP

175ZA698.10

The selected digit is indicated by a flashing cursor. The bottom display line gives the data value that will be entered (saved) when signing off by pressing the [OK] button. Use [CANCEL] to cancel the change.

If the selected parameter is a functional value, the selected text value can be changed by means of the [+/-] keys.

MOTOR CURRENT

3.90 A

210 REFERENCE TYPE

SUM

SETUP

175ZA689.10

The functional value flashes until signing off by pressing the [OK] button. The functional value has now been selected. Use [CANCEL] to cancel the change.

VLT

6000 HVAC Series

FREQUENCY

50.0

209 JOG FREQUENCY

0.0 Hz

SETUP

175ZA700.10

The chosen digit flashes. The bottom display line shows the data value that will be entered (saved) when signing off with [OK].

Changing of data value, step-by-step

Certain parameters can be changed both step by step and infinitely variably. This applies to Motor power (parameter 102), Motor voltage (parameter 103) and Motor frequency (parameter 104). This means that the parameters are changed both as a group of numeric data values and as numeric data values infinitely variably.

Manual initialisation

Disconnect from mains and hold the [DISPLAY MODE] + [CHANGE DATA] + [OK] keys down while at the same time reconnecting the mains supply. Release the keys; the frequency converter has now been programmed for the factory setting.

The following parameters are not zeroed by means of manual initialisation: Parameter

500, Protocol 600, Operating hours 601, hours run 602, kWh counter 603, Number of power-ups 604, Number of overtemperatures 605, Number of overvoltages

It is also possible to carry out initialisation via parameter 620 Operating mode.

Programming

Infinitely variable change of numeric data value

If the chosen parameter represents a numeric data value, a digit is first selected by means of the [<>] keys.

FREQUENCY

SETUP

50.0 Hz

209 JOG FREQUENCY

9 .0 Hz

SETUP

175ZA699.10

Then the chosen digit is changed infinitely by means of the [+/-] keys:

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VLT

6000 HVAC Series

Quick Menu

The QUICK MENU key gives access to 12 of the most important setup parameters of the drive. After pro-

shown in the table below. A complete description of the function is given in the parameter sections of this manual.

gramming, the drive will, in many cases, be ready for operation. The 12 Quick Menu parameters are

Quick Menu

Parameter Description Item Number Name 1 001 Language Selects language used for all displays. 2 102 Motor Power Sets output characteristics of drive based on kW size of

motor.

3 103 Motor Voltage Sets output characteristics of drive based on voltage of-

motor.

4 104 Motor Frequency Sets output characteristics of drive based on nominal fre-

quency of motor. This is typically equal to line frequency.

5 105 Motor Current Sets output characteristics of drive based on nominal cur-

rent in amps of motor.

6 106 Motor Nominal Speed Sets output characteristics of drive based on nominal full

load speed of motor.

7 201 Minimum Frequency Sets minimum controlled frequency at which motor will

run.

8 202 Maximum Frequency Sets maximum controlled frequency at which motor will

run.

9 206 Ramp Up Time Sets time to accelerate motor from 0 Hz to nominal motor

frequency set in Quick Menu Item 4.

10 207 Ramp Down Time Sets time to decelerate motor from nominal motor fre-

quency set in Quick Menu Item 4 to 0 Hz. 11 323 Relay1 Function Sets function of high voltage Form C relay. 12 326 Relay 2 Function Sets function of low voltage Form A relay.

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Parameter Data

Enter or change parameter dataor settings in accordance with the following procedure.

1. Press Quick Menu key.

2. Use ‘+’ and ‘-’ keys to find parameter you choose to edit.

3. Press Change Data key.

4. Use ‘+’ and ‘-’ keys to select correct parameter setting. To move to a different digit within parameter, use < and > arrows. Flashing cur-

sor indicates digit selected to change.

5. Press Cancel key to disregard change, or press OK key to accept change and enter new setting.

Example of Changing Parameter Data

Assume parameter 206, Ramp Up Time, is set at 60 seconds. Change the ramp up time to 100 seconds in accordance with the following procedure.

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6000 HVAC Series

NB!

Programming of extended parameters functions available through EXTENDED MENU key is done in accordance with same procedure as described for Quick Menu functions.

1. Press Quick Menu key.

2. Press ‘+’ key until you reach Parameter 206,

Ramp Up Time.

3. Press Change Data key.

4. Press < key twice – hundreds digit will flash.

5. Press ‘+’ key once to change hundreds digit to ‘1.’

6. Press > key to change to tens digit.

7. Press ‘-’ key until ‘6’ counts down to ‘0’ and setting for Ramp Up Time reads ‘100 s.’

8. Press OK key to enter new value into drive controller.

Programming

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VLT

6000 HVAC Series

Programming

Using the [EXTEND MENU] key, it is possible to have access to all the parameters for the frequency converter.

Operation and Display 001-017

This parameter group allows to set up parameters such as language, display readout and the possibility of making the function keys on the control unit inactive.

001 Language

(LANGUAGE)

Value:

English (ENGLISH) [0] German (DEUTSCH) [1] French (FRANCAIS) [2] Danish (DANSK) [3] Spanish (ESPAÑOL) [4] Italian (ITALIANO) [5] Swedish (SVENSKA) [6] Dutch (NEDERLANDS) [7] Portuguese (PORTUGUESA) [8] Finnish (SUOMI) [9]

State when delivered may vary from factory setting.

Function:

The choice in this parameter defines the language to be used on the display.

Description of choice:

There is a choice of the languages indicated.

The Setup configuration

The frequency converter has four Setups (parameter Setups) that can be programmed independently of each other. The active Setup can be selected in parameter 002 Active Setup. The active Setup number will be shown in the display under "Setup". It is also possible to set the frequency converter to Multi-Setup to allow switching of Setups with the digital inputs or serial communication. Setup shifts can be used in systems where, one Setup is used during the day and another at night.

By means of parameter 004 LCP copy, all Setups can be transferred from one frequency converter to another by moving the control panel. First all parameter values are copied to the control panel. This can then be moved to another frequency converter, where all parameter values can be copied from the control unit to the frequency converter.

002 Active Setup

(ACTIVE SETUP)

Value:

Factory Setup (FACTORY SETUP) [0] Setup 1 (SETUP 1) [1] Setup 2 (SETUP 2) [2] Setup 3 (SETUP 3) [3] Setup 4 (SETUP 4) [4] MultiSetup (MULTI SETUP) [5]

Function:

The choice in this parameter defines the Setup number you want to control the functions of the frequency converter. All parameters can be programmed in four individual parameter Setups, Setup 1 - Setup 4. In addition, a pre-programmed Setup called the Factory Setup exists. This only allows specific parameters to be changed.

Description of choice:

Factory Setup [0] contains the parameter values preset at the factory. Can be used as a data source if the other Setups are to be returned to a common state. In this case Factory Setup is selected as the active Setup. Setups 1-4 [1]-[4] are four individual Setups that can be selected as required. MultiSetup [5] is used if remote switching between different Setups is required. Terminals 16/17/29/32/33 and the serial communication port can be used for switching between Setups.

Parameter 003 Copying of Setups enables copying from one Setup to another.

= factory setting, () = display text, [] = value for use in communication via serial communication port

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Connection examples Setup change

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6000 HVAC Series

004 LCP copy

(LCP COPY)

Value:

No copying (NO COPY) [0] Upload all parameters

(UPLOAD ALL PARAMET.) [1] Download all parameters

(DOWNLOAD ALL PARAM.) [2] Download power-independent par.

(DOWNLOAD SIZE INDEP.) [3]

Selection of Setup using terminals 32 and 33.

Parameter 306 = Selection of Setup, lsb [4] Parameter 307 = Selection of Setup, msb [4] Parameter 002 =MultiSetup [5].

003 Copying of Setups

(SETUP COPY)

Value:

No copying (NO COPY) [0] Copy active Setup to Setup 1

(COPY TO SETUP 1) [1] Copy active Setup to Setup 2

(COPY TO SETUP 2) [2] Copy active Setup to Setup 3

(COPY TO SETUP 3) [3] Copy active Setup to Setup 4 (COPY TO SET-

UP 4) [4] Copy active Setup to all

(COPY TO ALL) [5]

Function:

Parameter 004 LCP copy is used if the integrated copying function of the control panel is to be used. This function is used if all parameter Setups are to be copied from one frequency converter to another by moving the control panel.

Description of choice:

Select Upload all parameters [1] if all parameter values are to be transmitted to the control panel. Select Download all parameters [2] if all transmitted parameter values are to be copied to the frequency converter on which the control panel has been mounted. Select Download power-independent par. [3] if only the power-independent parameters are to be downloaded. This is used if downloading to a frequency converter that has a different rated power than the one from where the parameter Setup originates.

NB!

Uploading/Downloading can only be carried out in the Stop mode.

Programming

Function:

A copy is made from the active Setup selected in parameter 002 Active Setup to the Setup or Setups selected in parameter 003 Copying of Setups.

Setup of user-defined readout

Parameter 005 Max. value of user-defined readout and 006 Unit for user-defined readout allow users to design their own readout which can be seen if user-defined

NB!

Copying is only possible in Stop mode (motor stopped on a Stop command).

readout has been selected under display readout. The range is set in parameter 005 Max. value of user-de- fined readout and the unit is determined in parameter 006 Unit for user-defined readout. The choice of unit decides whether the ratio between the output frequen-

Description of choice:

cy and the readout is a linear, square or cubed ratio.

The copying starts when the required copying function has been selected and the [OK] key has been pressed. The display indicates when copying is in progress.

= factory setting, () = display text, [] = value for use in communication via serial communication port

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Danfoss VLT 6000 HVAC Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual