Danfoss VLT 6002-6011, VLT 6006-6032, VLT 6002-6005, VLT 6042-6062, VLT 6075-6125 Installation, Operation And Maintenance Manual

...

Installation, Operation and

Maintenance Manual

VLT® 6000 Series

Adjustable Frequency Drive

03/00 23-6108-00 Revision G

DANGER

Rotating shafts and electrical equipment can be hazardous. Therefore, it is strongly recommended that all electrical work conform to National Electrical Code (NEC) and all local regulations. Installation, start-up and maintenance should be performed only by qualified personnel.

Factory recommended procedures, included in this manual, should be followed. Always disconnect electrical power before working on the unit.

Although shaft couplings or belt drives are generally not furnished by the manufacturer, rotating shafts, couplings and belts must be protected with securely mounted metal guards that are of sufficient thickness to provide protection against flying particles such as keys, bolts and coupling parts. Even when the motor is stopped, it should be considered “alive” as long as its controller is energized. Automatic circuits may start the motor at any time. Keep hands away from the output shaft until the motor has completely stopped and power is disconnected from the controller.

Motor control equipment and electronic controls are connected to hazardous line voltages. When servicing drives and electronic controls, there will be exposed components at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case of an emergency. Disconnect power whenever possible to check controls or to perform maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electric control or rotating equipment.

Safety Guidelines

1. The drive must be disconnected from the AC line before any service work is done.

2. The “Stop/Off” key on the local control panel of the drive does not disconnect the equipment from the AC line and is not to be used as a safety switch.

3. Correct protective grounding 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. Ground currents are higher than 3 mA.

Warnings Against Unintended Start

1. While the drive is connected to the AC line, the motor can be brought to a stop by means of external switch closures, serial bus commands or references. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stops are not sufficient.

2. During programming of parameters, the motor may start. Be certain that no one is in the area of the motor or driven equipment when changing parameters.

3. A motor that has been stopped may start unexpectedly if faults occur in the electronics of the drive, or if an overload, a fault in the supply AC line or a fault in the motor connection or other fault clears.

4. If the “Local/Hand” key is activated, the motor can only be brought to a stop by means of the “Stop/Off” key or an external safety interlock.

NOTE It is responsibility of user or person installing drive to provide proper grounding and branch circuit protection for incoming power and motor overload according to National Electrical Code (NEC) and local codes.

Touching electrical parts may be fatal – even after equipment has

been disconnected from AC line. To be sure that capacitors have

fully discharged, wait 14 minutes after power has been removed

before touching any internal component.

The Electronic Thermal Relay (ETR) in UL listed VLTs provides Class 20 motor overload protection in accordance with NEC in single motor applications, when parameter 117 is set for “ETR TRIP 1”, “ETR TRIP 2”, “ETR TRIP 3”, or “ETR TRIP 4”, and parameter 105 is set for rated motor (nameplate) current.

DANGER

Table of Contents

Safet y Gui deli nes .................................................................................................................................................................................................... 2

Warnings Against Unintended Start.......................................................................................................................................................................... 2

General ...............................................................................................................................................................................................................5

Clearances ............................................................................................................................................................................................. 5

Plenum Mounting..................................................................................................................................................................................... 5

Grounding Plate ...................................................................................................................................................................................... 5

Shielded Wires ........................................................................................................................................................................................ 5

Cross Reference – Model Number to VLT T ype......................................................................................................................................................6

Input Fuses............................................................................................................................................................................................................. 7

Locations of Conduit Entry , T erminal Blocks and Switches ....................................................................................................................................... 8

Location of Input Power and Output Power........................................................................................................................................................... 11

Power Connections............................................................................................................................................................................................... 14

Input Power Connection ........................................................................................................................................................................ 14

Motor Wiring Connection........................................................................................................................................................................ 14

Grounding............................................................................................................................................................................................. 14

Electrical Thermal Protection.................................................................................................................................................................. 14

T erminal Tightening Torque................................................................................................................................................................... 15

Auxiliary Control Panel Tightening T orques........................................................................................................................................... 15

Multiple Motors ...................................................................................................................................................................................... 16

External DC Bus Connection................................................................................................................................................................. 16

High Voltage Form C Relay...................................................................................................................................................................16

Control Connections.............................................................................................................................................................................................. 17

Electrical Installations, Control T erminals ................................................................................................................................................17

Typical Control Connections.................................................................................................................................................................. 18

Electrical Installation, Control Wiring ....................................................................................................................................................... 19

DIP Switches 1 through 4 ...................................................................................................................................................................... 19

Ground Leakage Current ...................................................................................................................................................................... 19

Galvanic Isolation .................................................................................................................................................................................. 20

Electrical Noise ......................................................................................................................................................................................20

Application Control Connection Examples.............................................................................................................................................................. 21

Control Panel........................................................................................................................................................................................................22

Keys for Parameter Changes ................................................................................................................................................................22

Indicator Lamps .....................................................................................................................................................................................23

Local Control......................................................................................................................................................................................... 23

Display Mode........................................................................................................................................................................................23

Display Mode I................................................................................................................. .....................................................................24

Display Mode II................................................................................................................ .....................................................................24

Display mode III .................................................................................................................................................................................... 25

Display Mode IV.................................................................................................................................................................................... 25

Navigation Between Display Modes ...................................................................................................................................................... 25

Quick Menu ..........................................................................................................................................................................................................26

T o Enter or Change Quick Menu Parameter Data ................................................................................................................................. 26

Example of Changing Parameter Data................................................................................................................................................... 26

Extended Menu..................................................................................................................................................................................... 27

Changing Data......................................................................................................................................................................................27

Step Change of Numeric Values............................................................................................................................................................27

Manual Initialization of Parameters ......................................................................................................................................................... 27

Uploading Parameters........................................................................................................................................................................... 27

VL T 6000 Start-up................................................................................................................................................................................................. 28

Pre-installation Checks........................................................................................................................................................................... 28

Installation Checks ................................................................................................................................................................................. 28

Setting Up Drive for Motor Start ............................................................................................................................................................. 28

Operational T ests – HAND..................................................................................................................................................................... 28

Operational T ests – AUTO..................................................................................................................................................................... 28

Final Adjustments................................................................................................................................................................................... 28

General Troubleshooting.......................................................................................................................................................................28

Programming ........................................................................................................................................................................................................ 29

Description of Parameters...................................................................................................................................................................... 29

Setup Configuration ............................................................................................................................................................................... 29

Operation and Display – Parameters 000 through 017...................................................................................................................................29 - 34

Connection Examples............................................................................................................................................................................ 30

Load and Motor – Parameters 100 through 117............................................................................................................................................. 34 - 39

DC Braking ........................................................................................................................................................................................... 38

Motor Thermal Protection....................................................................................................................................................................... 39

References and Limits – Parameters 200 through 228.................................................................................................................................... 40 - 47

Reference Handling .............................................................................................................................................................................. 41

Reference Type .................................................................................................................................................................................... 44

Warning Functions................................................................................................................................................................................. 46

Input and Outputs – Parameters 300 through 328 ..........................................................................................................................................48 - 58

Analog Inputs ........................................................................................................................................................................................ 51

Analog/Digital Outputs............................................................................................................................................................................ 54

Relay Outputs........................................................................................................................................................................................ 57

Application Functions – Parameters 400 through 427 ..................................................................................................................................... 59 - 69

Sleep Mode .......................................................................................................................................................................................... 59

Feedback Signals in Open Loop............................................................................................................................................................ 63

PID for Process Regulation ...................................................................................................................................................................................64

Feedback .............................................................................................................................................................................................. 64

Reference (Set Point) ............................................................................................................................................................................ 64

Inverse Regulation ................................................................................................................................................................................ 64

Anti-Windup...........................................................................................................................................................................................64

Start-up Conditions ................................................................................................................................................................................ 64

Differentiator Gain Limit .......................................................................................................................................................................... 65

Lowpass Filter.......................................................................................................................................................................................65

Optimization of the Process Regulator .................................................................................................................................................... 65

PID Overview....................................................................................................................................................................................................... 65

Feedback Handling ............................................................................................................................................................................... 65

Serial Communication for FC Protocol ...................................................................................................................................................................70

Protocols ............................................................................................................................................................................................... 70

Packet Communication ...........................................................................................................................................................................70

Serial Communication – Parameters 500 through 566 .................................................................................................................................... 80 - 85

Warning Word, Extended Status Word and Alarm Word......................................................................................................................... 86

Service Functions – Parameters 600 through 631.......................................................................................................................................... 88 - 92

Relay Card Functions – Parameters 700 through 711........................................................................................................................................... 93

Electrical Installation of the Relay Card ..................................................................................................................................................93

Status Messages ...................................................................................................................................................................................................94

Warnings and Alarms ............................................................................................................................................................................................ 96

Calculation of Resulting Reference ...................................................................................................................................................................... 101

Factory Settings .........................................................................................................................................................................................102 - 107

Index ........................................................................................................................................................................................................ 108 - 115

SOFTWARE VERSION NOTICE: These Operating Instructions are used for all VLT 6000 Series Drives with software version 2.X and all prior versions. The software version number

can be determined from parameter 624,

Software Version

General

(

)

The specific installation instructions may vary depending upon the model of VLT 6000 Series being installed. When this occurs, the model can be identified by a “VLT T ype 6XXX” number . This number can be found on the red nameplate on the outside of the left side of the drive enclosure, or the outside of the right side of a drive with an auxiliary enclosure. A cross reference from the VLT T ype to the Danfoss Graham model number can be found on the next page.

The drive must always be installed vertically. To ensure that no injury or damage occurs, the drive must always be firmly attached to the wall or the floor before further installation work is carried out.

Clearances

The drive is cooled by means of air circulation. For proper cooling, the minimum distances above and below the unit must be maintained as shown in the table below. For units with an auxiliary enclosure mounted with the drive on a back panel, the required clearances are measured from the top and bottom of the drive, not the back panel.

Drive Type

VLT 6002-6005, 200-240V VLT 6002-6011, 380-460V VLT 6006-6032, 200-240V VLT 6016-6062, 380-460V VLT 6042-6062, 200-240V VLT 6075-6125, 380-460V VLT 6150-6275, 380-460V VLT 6350-6550, 380-460V 16" (400mm) floor mount

Top

Clearance

4" (100mm) 4" (100mm) No

8" (200mm) 8" (200mm) Yes

9" (225mm) 9" (225mm) Yes

300mm) 12" (300mm

12"

Bottom

Clearance

All drives can be mounted with no side clearance. VLT 6350-6550 drives require 25 inches (605 mm) front space for access.

All drives except VLT 6002-6005, 200 to 240 V and VLT 6002-6011, 380 to 460 V must be mounted directly to the wall with no spacers. This is to ensure that air flow is in contact with the heatsink all the way from the bottom of the drive. If this is not possible, a metal plate at least as large as the back of the drive must be firmly mounted to the back of the drive. See the Cross Reference T able on the next page to convert model numbers to drive type.

Must be mounted

flush to wall

Yes Yes

Sufficient space must be left in front of the drive to provide for door swing on units with a hinged door. In addition, sufficient room must be available for installation and service access. On units with an auxiliary enclosure, the auxiliary enclosure door will have a greater door swing than the drive. See the dimensional drawings of the auxiliary enclosure which are included with the drive.

Plenum Mounting

The drive is UL rated for plenum mounting. If the drive is to be mounted in the plenum, allow sufficient access for servicing. All normal clearance, temperature and humidity limitations apply.

Grounding Plate

VLT Type 6002-6005, 200 to 240 V and VLT 6002-6001, 380 to 460 V drives with a NEMA 1 enclosure have a plastic bottom cover with provision for conduit entry . T o meet UL requirements, the metal grounding plate must be in place above the plastic bottom cover. It must be grounded to the chassis, and the conduit grounded to it. If the grounding plate is not factory installed, it must be installed in the drives that have a plastic bottom panel to ensure proper grounding of the conduit to the enclosure. Connect the ground wire from the grounding plate to the ground tab marked with the ground symbol.

This tab is located near the AC line terminal strip. Mount the bottom cover on the control unit.

Shielded Wires

Wires to control signals should be shielded to reduce radio frequency noise interference.

When RFI is a concern, shielded cable should be used between the drive and the motor.

If unshielded control wires are used, control inputs are subject to signal disturbances. Such disturbances may affect drive operation. Extreme noise levels may disturb the microprocessor of the control card.

The shield of the control wires must be grounded at the cable clamp at the bottom of the drive, but the shield must continue with the cable all the way up to the control card. The shield is not to be connected to any of the terminals on the control card. For safety reasons, the insulation around the shield should only be removed where it is connected to the cable clamp. The insulation should be left on the shield between the clamp and the terminals.

All drives except VL T 6002-6005, 200 to 240 V

and VL T 6002-6011, 380 to 460 V must be

mounted directly to a solid wall with no spacers

between the drive and the wall.

Generally speaking, all conductors coming from a shielded control cable must be as short as possible. Long conductor ends attract noise. The shield must be connected to the chassis by means of the cable clamp. Long pigtails on the shield reduce the effectiveness of the shield.

Cross Reference — Model Number to VLT Type

208 V Input

Model Number VLT Type Max. Nominal

Output HP

VLT6000C4.6 6002 1 4.6 VLT6000C6.6 6002 1½ 6.6 VLT6000C7.5 6003 2 7.5

VLT6000C11

6004

310.6 VLT6000C17 6006 5 16.7 VLT6000C24 6008 7½ 24.2 VLT6000C31 6011 10 30.8 VLT6000C46 6016 15 46.2 VLT6000C59 6022 20 59.4 VLT6000C75 6027 25 74.8 VLT6000C88 6032 30 88

VLT6000C114 6042 40 114 VLT6000C143 6052 50 143 VLT6000C169 6062 60 169

460 V Input

Model Number VLT Type Max. Nominal

Output HP

VLT6000H2.1 6002 1 2.1 VLT6000H3.0 6002 1½ 3.0 VLT6000H3.4 6003 2 3.4 VLT6000H4.8 6004 3 4.8 VLT6000H8.2 6006 5 8.2

VLT6000H11 6008 7½ 11.0 VLT6000H14 6011 10 14 VLT6000H21 6016 15 21 VLT6000H27 6022 20 27 VLT6000H34 6027 25 34 VLT6000H40 6032 30 40 VLT6000H52 6042 40 52 VLT6000H65 6052 50 65 VLT6000H77 6062 60 77

VLT6000H106 6075 75 106 VLT6000H130 6100 100 130 VLT6000H160 6125 125 160 VLT6000H190 6150 150 190 VLT6000H240 6175 200 240 VLT6000H302 6225 250 302 VLT6000H361 6275 300 361 VLT6000H443 6350 350 443 VLT6000H540 6400 450 540 VLT6000H590 6500 500 590 VLT6000H678 6550 600 678

Max. Drive

Output Current

Max. Drive

Output Current

230 V Input

Model Number VLT Type Max. Nominal

Output HP

VLT6000E4.2 6002 1 4.2 VLT6000E6.6 6002 1½ 6.6 VLT6000E7.5 6003 2 7.5

VLT6000R11 6004 3 10.6 VLT6000E17 6006 5 16.7 VLT6000E24 6008 7½ 24.2 VLT6000E31 6011 10 30.8 VLT6000E46 6016 15 46.2 VLT6000E59 6022 20 59.4 VLT6000E75 6027 25 74.8

VLT6000E88 6032 30 88 VLT6000E104 6042 40 104 VLT6000E130 6052 50 130 VLT6000E154 6062 60 154

380 V Input

Model Number VLT Type Max. Nominal

Output kW

VLT6000F3.0 6002 1.1 3.0 VLT6000F4.1 6003 1.5 4.1 VLT6000F5.6 6004 2.2 5.6 VLT6000F7.2 6005 3 7.2

VLT6000F10 6006 4 10

VLT6000F13 6008 5.5 13

VLT6000F16 6011 7.5 16

VLT6000F24 6016 11 24

VLT6000F32 6022 15 32

VLT6000F38 6027 18.5 37.5

VLT6000F44 6032 22 44

VLT6000F61 6042 30 61

VLT6000F73 6052 37 73

VLT6000F90 6062 45 90

VLT6000F106 6075 55 106 VLT6000F147 6100 75 147 VLT6000F177 6125 90 177 VLT6000F212 6150 110 212 VLT6000F260 6175 132 260 VLT6000F315 6225 160 315 VLT6000F368 6275 200 368

575 V Input

Model Number VLT Type Max. Nominal

Output HP

VLT6000J2.7 6016 2 2.7 VLT6000J3.9 6016 3 3.9 VLT6000J6.1 6016 5 6.1 VLT6000J9.0 6016 7½ 9

VLT6000J11 6016 10 11

VLT6000J17 6016 15 17

VLT6000J22 6022 20 22

VLT6000J27 6027 25 27

VLT6000J32 6032 30 32

VLT6000J41 6042 40 41

VLT6000J52 6052 50 52

VLT6000J62 6062 60 62

Max. Drive

Output Current

Max. Drive

Output Current

Max. Drive

Output Current

Input Fuses

All drives must have input fuses installed in the power supply to the drive. These fuses may be specified as an option to the drive and supplied by Danfoss Graham. If specified, they will be installed by Danfoss Graham in an enclosure external to the drive which may include other optional features. If not supplied by Danfoss Graham, they must be supplied by the installer of the drive at the time of installation.

The required type of fuse for each drive size is shown in the table below. The fuse rating shown is both the maximum and the recommended fuse rating.

The drives are suitable for use on circuits capable of delivering not more than 100,000 RMS symmetrical amps, 500 volts maximum (600 volts maximum for 575 volt drives), when used with the recommended fuses.

208 Volt Input

Maximum Fuse

Model Number VLT Type

VLT6000C4.6 6002 10 KTN-R or JJN VLT6000C6.6 6003 15 KTN-R or JJN VLT6000C7.5 6003 20 KTN-R or JJN

VLT6000C11 6004 25 KTN-R or JJN VLT6000C17 6006 50 KTN-R or JJN VLT6000C24 6008 50 KTN-R or JJN VLT6000C31 6011 50 KTN-R or JJN VLT6000C46 6016 60 KTN-R or JJN VLT6000C59 6022 80 KTN-R or JJN VLT6000C75 6027 125 K TN-R or JJN

VLT6000C88 6032 125 K TN-R or JJN VLT6000C114 6042 150 FWX or FWH VLT6000C143 6052 200 FWX or FWH VLT6000C169 6062 250 FWX or FWH

Rating Bussman Type

460 Volt Input

Maximum Fuse

Model Number VLT Type

VLT6000H2.1 6002 6 KTS -R or JJS VLT6000H3.0 6002 6 KTS -R or JJS VLT6000H3.4 6003 10 KTS-R or JJS VLT6000H4.8 6004 10 KTS-R or JJS VLT6000H8.2 6006 20 KTS-R or JJS

VLT6000H11 6008 25 KTS-R or JJS

VLT6000H14 6011 30 KTS-R or JJS

VLT6000H21 6016 40 KTS-R or JJS

VLT6000H27 6022 40 KTS-R or JJS

VLT6000H34 6027 50 KTS-R or JJS

VLT6000H40 6032 60 KTS-R or JJS

VLT6000H52 6042 80 KTS-R or JJS

VLT6000H65 6052 100 KTS-R or JJS

VLT6000H77 6062 125 KTS-R or JJS VLT6000H106 6075 150 FWH VLT6000H130 6100 200 FWH VLT6000H160 6125 250 FWH VLT6000H190 6150 300 FWH VLT6000H240 6175 350 FWH VLT6000H302 6225 400 FWH VLT6000H361 6275 500 FWH VLT6000H443 6350 600 FWH VLT6000H540 6400 700 FWH VLT6000H590 6500 800 FWH VLT6000H678 6550 800 FWH

Rati ng Bussma n Type

575 Volt Input

Model Numbe r VLT Type

VLT6000J2.7 6016 6 KTS-R or similar VLT6000J3.9 6016 6 KTS-R or similar VLT6000J6.1 6016 10 KTS-R or similar

VLT6000J9 6016 20 KTS-R or similar VLT6000J11 6016 25 KTS-R or sim ilar VLT6000J17 6016 40 KTS-R or sim ilar VLT6000J22 6022 40 KTS-R or sim ilar VLT6000J27 6027 50 KTS-R or sim ilar VLT6000J32 6032 60 KTS-R or sim ilar VLT6000J41 6042 80 KTS-R or sim ilar VLT6000J52 6052 100 KTS-R or similar VLT6000J62 6062 125 KTS-R or similar

Maximum Fuse

Rating Bussman Type

All fuse ratings are in amps

Locations of Conduit Entry, Terminal Blocks and Switches

NEMA 1

VLT 6002-6032, 200 to 240 V VLT 6002-6062, 380 to 575 V

VLT 6042-6062, 200 to 240 V, VLT 6075-6125, 380 to 460 V VLT 6150-6275, 380 to 460 V

Locations of Conduit Entry, Terminal Blocks and Switches (continued)

NEMA 12

VLT 6002-6005, 200 to 240 V, VLT 6002-6011, 380 to 460 V VLT 6006-6032, 200 to 240 V ; VLT 6016-6032, 380 to 460 V

VLT 6042-6062, 200 to 240 V ; VLT 6075-6125, 380 to 460 V VLT 6150-6275, 380 to 460 V

Locations of Conduit Entry, Terminal Blocks and Switches (continued)

NEMA 1 and NEMA 12

VLT 6350-6550, 380 to 460 V

Location of Input Power (Mains) and Output

WARNING

Power (Motor Terminal Blocks)

Connect input power to the terminals identified as L1, L2 and L3. Connect the motor leads to the terminals identified as U, V and W.

Connecting input power to motor terminals will result in drive failure when the power is applied.

NEMA 1 and NEMA 12 VLT 6002-6005, 200-240 V VLT 6002-6011, 380-460 V

NEMA 1 VLT 6006-6032, 200-240 V VLT 6016-6062, 380-575 V

NEMA 1 VLT 6042-6062, 200-240 V VLT 6075-6125, 380-460 V

NEMA 1

VLT 6150-6275, 380-460 V

Location of Input Power (Mains) and Output Power (Motor Terminal Blocks), continued

Connect input power to the terminals identified as L1, L2 and L3.

NEMA 12 VLT 6006-6032, 200-240 V VLT 6016-6062, 380-460 V

NEMA 12 VLT 6042-6062, 200-240 V VLT 6075-6125, 380-460 V

NEMA 12

VLT 6150-6275, 380-460 V

Location of Input Power (Mains) and Output Power (Motor Terminal Blocks), continued

Connect input power to the terminals identified as L1, L2 and L3.

NEMA 1 and NEMA 12, VLT 6350-6550, 380-460 V

without disconnector and mains fuses

NEMA 1 and NEMA 12, VLT 6350-6550, 380-460 V

with disconnector and mains fuses

Power Connections

Make all power connections with 75

C rated copper wiring.

Conduit entry must be from the bottom on all drives. Conduit entries are provided on smaller drives. For drives with auxiliary enclosures, refer to the dimensional drawings provided for conduit entry locations.

T o meet UL requirements, install the metal grounding plate in all drives that have a plastic bottom. Install the grounding plate just above the plastic bottom. Ground the metal plate to the chassis and ground the conduit to the metal plate.

The conduit entries provide strain relief for the wires in drives mounted in NEMA 1 or NEMA 12 enclosures. With chassis mounted drives, the power and control wires must have strain relief supplied by the installer.

O NOT rely on the terminal blocks to provide strain relief.

Input Power Connection

For drives with no auxiliary enclosure, connect input power to drive terminals L1, L2, and L3, (terminal numbers 91, 92, and 93). If an auxiliary enclosure is provided, input power connections are made in the auxiliary enclosure. Refer to the connection diagrams shipped with the drive.

Size wiring to the input current of the drive as shown in the tables below. Maximum AWG wire size is also provided.

WARNING

Connecting input power to motor terminals will result in drive failure when power is applied.

Motor Wiring Connection

For drives with no auxiliary enclosure, connect the motor to drive terminals U, V , and W (terminal numbers 96, 97, and 98). T erminal 99 is earth ground. If an auxiliary enclosure is provided, refer to the connection diagrams shipped with the drive. Ground the shield on the motor wire, if used, at both the drive and the motor.

DANGER

For operator safety, it is important to ground drive properly.

Grounding

Ground the drive properly. Use a ground wire at least 7 AWG (10mm2). Connect the ground wire directly to a reliable earth ground. Do not use the conduit connecting to the drive as a replacement for a ground wire. Do not ground one drive to another in a “daisy chain” fashion.

Electronic Thermal Protection

The electronic thermal relay is UL approved for single motor thermal protection as long as the following is complied with:

CAUTION

Enclosures for larger drives and auxiliary enclosures are made of metal. To avoid getting metal chips into electronics, do not drill any holes after unit has been installed in a vertical position.

575 VAC Input Current/Wire Gage

208 VAC Input Current/Wire Gage

Drive Input

Current

5.0 10

6.0 10

7.0 10

10.0 10

16.0 10

23.0 6

30.0 6

46.0 6

59.2 2

74.8 2

88.0 0

101.3 1/0

126.6

149.9 4/0 C169

Maximum

AWG

3/0

Model

C4.6 C6.6 C7.5

C11 C17 C24 C31 C46 C59 C75

C88 C114 C143

All current ratings are in amps.

1. Parameter 1 17, Thermal Protection, is set to ETR TRIP .

2. Parameter 105, Motor Current, is set for the full-load nameplate

Drive Input

Current

2.5 6 J2.7

3.0 6 J3.9

6.0 6 J6.1

9.0 6 J9.0

10.0 6 J11

16.7 6 J17

21.6 6 J22

26.6 6 J27

31.5 6 J32

40.3 2 J41

51.2 2 J52

61.0 0 J62

Maximum

AWG

motor current.

Model

460 VAC Input Current/Wire Gage

Drive Input

Current

2.5 10 H2.1

2.5 10 H3.0

3.4 10 H3.4

4.8 10 H4.8

8.3 10 H8.2

10.6 10 H11

27.6 6 H27

103 1/0 H106 145 2/0 H130 174 3/0 H160 206 2x1/0 H190 256 2x1/0 H240 317 2x3/0 H302 366 2x4/0 H361 443 3x1/0 H443 540 3x3/0 H540 590 3x3/0 H590 678 3x4/0 H678

Maximum

AWG

14 10 H14 21 6 H21

34 6 H34 41 6 H40 53 2 H52 64 2 H65 77 2 H77

Model

Terminal Tightening Torque

Tighten terminals connecting the drive input power, output to the motor(s) and ground to the values shown in the tables below. Drives with 200 to 240 volts of 88 amps and less, and drives with 380 to 575 volts of 90 amps and less, have removable terminal blocks with screws. Larger drives have fixed bolts. (See the drive nameplate for maximum drive output current.)

200 to 240 VAC Terminal Tightening Torque

NOTE Tighten terminals of 575 volt drives of 32 amps and below to 17 in-lbs (1.8 Nm), and above 32 amps to 28 in-lbs (3.0 Nm).

380 to 460 VAC Terminal Tightening Torque

Max. Drive

Output Current

6.6 5 (0.6)

7.5 5 (0.6)

10.6 5 (0.6)

16.7 5 (0.6)

24.2 17 (1.8)

30.8 17 (1.8)

46.2 28 (3.0)

59.4 28 (3.0)

74.8 28 (3.0) 88 35 (4.0)

114 100 (11.3) 143 100 (11.3) 169 100 (11.3)

Torque

in-lbs (Nm )

Max. Drive

Output Current

All current ratings are in amps.

200 to 240 VAC Auxiliary Control Panel Tightening Torques

Max. Drive

Output Current

to 6.6 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 20 (2.3) 35 (4.0) 45 (5.1)

7.5 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 25 (2.8) 35 (4.0) 45 (5.1)

10.6 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 25 (2.8) 35 (4.0) 45 (5.1)

16.7 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 25 (2.8) 35 (4.0) 45 (5.1)

24.2 15 (1.7) 50 (5.7) 22 (2.5) 7 (0.8) 45 (5.1) 45 (5.1) 45 (5.1)

30.8 15 (1.7) 50 (5.7) 22 (2.5) 7 (0.8) 120 (13.6) 45 (5.1) 45 (5.1) 46 75 (8.5) 50 (5.7) 44 (5.0) 18 (2.0) 120 (13.6) 120 (13.6) 45 (5.1)

61.2 75 (8.5) 275 (31.1) 44 (5.0) 18 (2.0) 120 (13.6) 275 (31.1) 50 (5.6)

74.8 120 (13.6) 275 (31.1) 44 (5.0) 18 (2.0) 120 (13.6) 275 (31.1) 50 (5.6) 88 120 (13.6) 275 (31.1) 44 (5.0) 70 (8.0) 120 (13.6) 275 (31.1) 50 (5.6)

115 120 (13.6) 275 (31.1) 44 (5.0) 375 (42.4) 275 (31.1) 150 (16.9) 50 (5.6) 143 250 (28.3) 275 (31.1) 50 (5.6) 375 (42.4) 275 (31.1) 150 (16.9) 120 (13.6) 169 275 (31.4) 275 (31.1) 50 (5.6) 375 (42.4) 275 (31.1) 150 (16.9) 150 (16.9)

Overload

Rela

Power Terminal

Blocks

Circ uit

Breaker

Disconnect or

Transfer Switch

Torque

in-lbs (Nm)

to 10 5 (0.6) 147 100 (11.3)

16 5 (0.6) 177 100 (11.3) 24 17 (1.8) 212 100 (11.3) 32 17 (1.8) 260 100 (11.3)

37.5 17 (1.8) 315 100 (11.3) 44 28 (3.0) 368 100 (11.3) 61 28 (3.0) 487 372 (42.0) 73 28 (3.0) 594 372 (42.0) 90 28 (3.0) 649 372 (42.0)

106 100 (11.3) 746 372 (42.0)

Main or pass Fuse

Block

Drive Fuse

Block

Max. Drive

Output Current

Ground

Term inal

Torque

in-lbs (Nm)

380 to 575 VAC Auxiliary Control Panel Tightening Torques

Max. Drive

Output Current

10 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 20 (2.3) 25 (2.8) 45 (5.1) 16 15 (1.7) 15 (1.7) 22 (2.5) 7 (0.8) 25 (2.8) 25 (2.8) 45 (5.1) 24 75 (8.5) 15 (1.7) 22 (2.5) 7 (0.8) 25 (2.8) 45 (5.1) 45 (5.1) 32 75 (8.5) 35 (4.0) 22 (2.5) 7 (0.8) 45 (5.1) 45 (5.1) 45 (5.1)

37.5 75 (8.5) 35 (4.0) 22 (2.5) 18 (2.0) 45 (5.1) 45 (5.1) 45 (5.1) 44 75 (8.5) 50 (5.6) 44 (5.0) 18 (2.0) 45 (5.1) 120 (13.6) 45 (5.1) 61 75 (8.5) 110 (12.5) 44 (5.0) 18 (2.0) 120 (13.6) 120 (13.6) 50 (5.6) 73 75 (8.5) 110 (12.5) 44 (5.0) 55 (6.2) 120 (13.6) 275 (31.1) 50 (5.6) 90 75 (8.5) 110 (12.5) 44 (5.0) 70 (8.0) 120 (13.6) 275 (31.1) 50 (5.6)

106 120 (13.6) 110 (12.5) 50 (5.6) 375 (42.4) 275 (31.1) 150 (16.9) 50 (5.6) 147 250 (28.3) 275 (31.1) 50 (5.6) 375 (42.4) 275 (31.1) 150 (16.9) 120 (13.6) 177 275 (31.1) 275 (31.1) 50 (5.6) 375 (42.4) 275 (31.1) 150 (16.9) 150 (16.9) 212 275 (31.1) 275 (31.1) 50 (5.6) 375 (42.4) 450 (50.8) 275 (31. 1) 150 (16.9) 260 275 (31.1) 275 (31.1) 375 (42.4) 500 (56.5) 450 (50.8) 275 (31.1) 150 (16.9) 315 375 (42.4) 375 (42.4) 375 (42.4) 500 (56.5) 450 (50.8) 275 (31.1) 150 (16.9) 368 375 (42.4) 375 (42.4) 375 (42.4) 375 (42.4) 375 (42.4) 275 (31.1) 150 (16.9)

All current ratings are in amps. All torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

Overload

Relay

Power Terminal

Blocks

Circuit

Breaker

Disc onnect or

Transfer Switch

Main or

Bypass Fuse

Block

Drive Fuse

Block

Ground

Terminal

Multiple Motors

The VLT 6000 can control several motors at once, all changing speed together. The sum of the nameplate currents of all the motors must not exceed the current rating of the drive.

WARNING

When multiple motors are used, VLT 6000 electronic thermal relay cannot be used to provide individual motor protection. A separate motor overload must be supplied for each motor.

If the multiple motors are of significantly different sizes, starting problems may occur. This is because the higher electrical resistance of smaller motors will require more start voltage than larger motors.

CAUTION

Automatic Motor Adaptation and Automatic Energy Optimization cannot be used for multiple motor installations.

External DC Bus Connection

T erminals 88 and 89 access the DC bus of the drive. They can provide DC backup power for the drive or to connect to a 12-pulse input rectifier.

DANGER

Terminals 88 and 89 will be at approximately 150% of line voltage and remain at high voltage for up to 14 minutes after power has been removed from the drive.

WARNING

Do not connect anything to terminals 88 and 89 without first consulting with Danfoss Graham.

High Voltage Form C Relay

The connections for the high-voltage relay are terminals 01, 02, 03. The high-voltage relay is programmed in parameter 323, Relay

Output 1.

1+3 normally closed, 1+2 normally open

Max. 240 VAC, 2 Amp Min. 24 VDC, 10 mA or

24 VAC, 100 mA Max. wire gage: 10 AWG (4 mm2) T erminal Torque: 5 in-lbs ( 0.5 - 0.6 Nm)

Electronic Control T erminals

Control Connections

All terminals for the low voltage control wires are located under the protective cover below the keypad. Remove the cover with a screwdriver or other pointed object as shown below.

The following is a description of the functions of the control terminals. Many of these terminals have multiple functions determined by parameter settings.

No. Function

01, 02, 03 Form C relay output. Maximum 240 V AC, 2 A.

Minimum 24 VDC, 10 mA or 24 VAC, 100 mA. (Location of Form C relay output varies with unit type. See connection diagram with unit for location.)

04, 05 30 VAC, 42.5 VDC, 1 A relay output can be used

for indicating status and warnings.

12, 13 Voltage supply to digital inputs and external

transducers. For the 24 VDC to be used for digital inputs, switch 4 on the control card must be closed, position “on.” The maximum output current is 200 mA.

16 - 33 Digital inputs. R = 2 kohm. <5 V = logical “0”,

>10 V = logical “1”. See parameters 300 through 307, Digital Inputs.

Electrical Installation, Control Terminals

T orque the control terminals to 5 in-lbs (0.5-0.6 N-m) The diagram below shows the location of the control terminals. The

programming section of the manual covers the programmable terminals in greater depth.

20 Common for digital inputs. 39 Common for analog and digital outputs. 42, 45 Analog and digital outputs for indicating frequency,

reference, current and torque. The analog signal is 0 to 20 mA, or 4 to 20 mA at a maximum of 500€Ω. The digital signal is 24 VDC at a minimum of 600 Ω . See parameters 319-322, Analog/ digital Outputs.

50 10 VDC, 17 mA maximum analog supply voltage

to potentiometer and thermistor.

53, 54 0 to 10 VDC voltage input, R = 10 kΩ. 55 Common for analog inputs. This common is

isolated from the common of all other power supplies. If, for example, the drive’s 24 VDC power supply is used to power an external transducer which provides an analog input signal, terminal 55 must be wired to terminal 39.

60 0 to 20 mA or 4 to 20 mA, analog current input, R

= 188 Ω . See parameters 314 through 316.

61 Shield for serial communication. 68, 69 RS-485 interface and serial communication. When

the drive is connected to an RS-485 serial communication bus, DIP switch settings on the control card may have to be reset. See Dip Switches 1 through 4 in this manual.

Typical Control Connections

Shown below are typical interfaces between the VLT 6000 and other components in an HVAC system. The terminal numbers and the functions of the terminals are identical on all VLT 6000s. An optional relay card, not shown, can provide four additional Form C output relays. The RS-485 connections allow direct communication through

Typical* VLT 6000 Wiring

the drive’s built-in serial communication protocols: Johnson Controls

Metasys

N2, Siemens System 600 FLN®, or VLT Software Dialog®. LonWorks® and Profibus® are available through option cards that fit into the relay output card location.

3 Phase

Power

Input

External

DC Bus

Connection

+10 V DC

0 - 10 V DC

Ref. Input*

0 - 10 V DC

Ref. Input*

4 - 20 mA

Ref. Input*

Reset*

Lockout*

Run/Stop*

Reverse*

Interlock*

Preset Speed*

91 (L1)

92 (L2)

93 (L3)

99 (PE)

88 (-)

89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

60 (A IN)

12 (+24 V OUT)

13 (+24 V OUT)

16 (D IN)

17 (D IN)

18 (D IN)

19 (D IN)

20 (COM D IN)

27 (D IN)

29 (D IN)

SW4

Switch Mode

Power Supply

10 V DC

17 mA

RS-485

Interface

5 V

SW2 SW3

24 V DC

200 mA

(U) 96

(V) 97

(W) 98

(PE) 95

(AUX RELAY) 01

( AUX RELAY) 02

(AUX RELAY) 03

(RELAY) 04

(RELAY) 05

(COM A OUT) 39

(A OUT) 42

0 V

(A OUT) 45

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

Motor

Fault Indication* 240 V AC, 2 A

Run Indication* 30 V AC, 1 A

Output Current Indication* 4 - 20 mA

Output Speed Indication* 4 - 20 mA

RS-485

Setup Select*

32 (D IN)

33 (D IN)

* The operation of all control inputs and outputs is programmable.

* Typical terminal functions are shown.

CAUTION

Incoming power, motor wiring and control wiring should be run in three separate conduits or raceways.

Electrical Installation, Control Wiring

Torque: 5 - 6 in-lbs Screw size: M3

Shield control wires, when necessary, to reduce interference from electrical noise by means of a cable clamp at both ends to the metal enclosure of the unit. Connect the shield to earth ground. Very long control wires may create 60 Hz interference. This problem can be solved by connecting one end of the shield to earth with a 0.1 µF capacitor, keeping the leads as short as possible. If this doesn’t solve the problem, disconnect the shield’s connection to earth ground at the end opposite to the drive.

DIP Switches 1 through 4

DIP switches are located on the control card. They are used for serial communication and the common of digital

inputs 16 through 33. The switch positions shown are the factory settings.

Switch 1 is not used. Switches 2 and 3 are used for terminating serial communication. On the

first and last drive in a multiple device network, or on the only drive of a single drive network, switches 2 and 3 must be ON (the default setting). On all other drives in a multiple device network, set switches 2 and 3 to OFF.

Switch 4 separates the common for the internal 24 VDC supply from the common of the external 24 VDC supply. Normally this switch is ON and the power supply is present at terminals 12 and 13. Set Switch 4 to the OFF position when an external 24 VDC supply is used.

Ground Leakage Current

It is normal for there to be some leakage current from the drive to earth ground. Paths of current leakage are shown on the drawing below. The leakage current will exceed 3.5 mA.

Paths of Normal Current Leakage to Ground

Galvanic Isolation

Galvanic isolation offers protection from electric shock. All control terminals of all VLT 6000 drives, and terminals 1 through 3 of the relay output, offer galvanic isolation as long as the RFI switch (if provided) is in the ON position. The galvanic isolation in the VLT 6000 conforms to the European standard EN 50178. (See figure below.)

The components that make up the galvanic isolation are:

1. Power supply, including signal isolation.

2. Gate drive for the IGBT s, the trigger transformers and optocouplers.

3. The output current Hall effect transducers.

Galvanic Isolation

Electrical Noise

In general, electrical noise can be divided into two forms: wire-borne electromagnetic interference (EMI), and radiating radio frequency interference (RFI).

Using shielded motor cables reduces RFI but increases EMI. This is because shielded wires have a greater capacitance than unshielded wires. Unshielded input power connections to the drive generate more noise in the radio frequency range on the AC line. The shield reduces the radiated noise, but increases the low-frequency electromagnetic noise on the AC line. But, since the noise current is taken back to the unit through the shield, only a small electromagnetic field is generated from shielded motor wires.

With an EMI filter, the noise level on the AC line will be reduced to about the same level for shielded and unshielded wires alike.

Connect the motor wiring shield, if used, in the enclosure of the drive as well as at the motor. Use shield brackets to avoid “pigtail” shield ends. Even short “pigtails” increase the shield’s impedance at higher frequencies, which reduces the shield’s effect and increases the noise produced.

It is generally easier and less complicated to use unshielded motor wires than shielded cables. If unshielded wires are used, the RFI will be greater. But, since the strength of the radiated signal decreases with distance from the signal source, radiated noise is generally not a problem.

T o reduce the noise level from the total system (drive + installation) make the motor wiring as short as possible.

Provide separate conduits, or raceways, for power, motor and control wiring to provide the greatest immunity from distortion.

Application Control Connection Examples Two-wire Start/Stop

In Auto mode, closing the contact to terminal 18 will make the drive run. In any mode, opening the safety interlock contact to terminal 27 will stop the drive.

Set Parameter 302 to Start. Set Parameter 304 to External Fault.

Digital Speed Up/down

Closing the switch to terminal 32 will make the drive accelerate. Closing the switch to terminal 33 will make the drive decelerate.

Run Permissive

After receiving a run command, the drive will apply power to the damper motor and wait until it receives “permission” via the switch that is connected to terminal 16.

Set Parameter 300 to Run Permissive. Set Parameter 302 to Start. Set Parameter 304 to External Fault. Set Parameter 323 to Start Signal Applied.

Two Feedback Signals

The drive processes two independent feedback signals during closed loop operation. It can respond to the sum, difference, average, minimum or maximum of these signals.

Set Parameter 306 to Speed up. Set Parameter 307 to Speed down. Set Parameter 305 to Freeze reference.

Potentiometer Reference

A manual potentiometer is used as a input reference for the drive.

Set Parameter 308, T erminal 53, Analog Input V oltage, to Reference. Set Parameter 309, T erminal 53, Min. Scaling, to 0 V. Set Parameter 310, T erminal 53, Max. Scaling, to 10 V.

Set Parameter 308 to FEEDBACK. Set Parameter 311 to FEEDBACK Set Parameter 417 for the desired operation.

Transmitter Connection

The drive’s internal 24 VDC power supply is used to power an external 4 to 20 mA transducer.

Set Parameter 314, T erminal 60, Analog Input Curent, to correspond to the purpose of the 4 to 20 mA signal. Set Parameter 315, T erminal 60, Min. Scaling, to 4 mA Set Parameter 316, T erminal 60, Max. Scaling, to 20 mA.

Because the commons of the +24 VDC power supply and the input reference follower have separate circuit commons, it is necessary to connect a jumper between terminals 39 and 55.

Control Panel

The Local Control Panel (LCP), normally mounted on the front of the drive, is a complete interface for programming and operating the drive. The control panel can be removed from the drive and installed up to 10 feet (3 meters) from the drive by using a remote mounting kit.

The control panel has five functions:

1. Display

2. Keys for changing the display

3. Keys for changing programming parameters

4. Keys for controlling drive operation

5. Indicator lamps

The LCP uses a four-line, alpha-numeric, back-lit, LCD display. The display can show four operating data values and three operating condition values continuously. During programming, all the information required for quick, effective parameter setup of the drive will be displayed. As a supplement to the display, there are three indicator lamps for power on (ON), warning (WARNING) and alarm (ALARM).

All drive parameters can be changed from the control panel, unless this ability has been locked out by setting parameter 016, Lock for Data Change, to Locked, or by a digital input to terminals 16 through 33. See the related parameters for more information.

Keys for Parameter Changes

The keys are divided into groups by function. The keys between the display and indicator lamps are used for parameter setup, selecting the display indication during normal operation and controlling the drive speed during local speed control operation. The keys below the indicator lamps are used for Start/Stop control and selection of the operating site.

The DISPLAY MODE key is used to select the mode of the display or to return to the Display Mode from either the Quick Menu or the Extend Menu mode.

The QUICK MENU key gives access to the parameters available for the Quick Menu setup. Parameters in this menu are the 12 most important setup parameters for the drive.

The EXTEND MENU key gives access to all parameters. The CHANGE DATA key is used for changing the value

of a parameter selected either in the Extend Menu or the Quick Menu mode. The desired parameter is first selected. Then the CHANGE DAT A key is pressed to enable the editing of the parameter. The underline in the display will move under the parameter’s value to show that it is being edited.

The CANCEL key is used if a change of the selected parameter is not to be carried out.

The OK key is used for confirming a change of the parameter selected.

The + and - keys are used to scroll through parameters and to change the value of a chosen parameter. These keys are also used to change the local reference. In Display Mode, these keys are used to switch between readouts.

The L and M keys are used to select a parameter group and also to move the cursor to the desired digit when changing numerical values.

Indicator Lamps

At the bottom of the control panel is a red alarm LED, a yellow warning LED, and a green power on LED.

red yellow green

The OFF/STOP key is used for stopping the connected motor in either the Hand or Auto mode. Enable or Disable via parameter 013. If this stop function is activated, the second line in the LCD display will flash.

AUTO ST ART is used if the drive is to be started via the control terminals and/or serial communication. When a remote start signal is active, the drive will start if the AUTO ST ART key has been pressed.

DANGER

A start signal via digital inputs may cause drive to start at any time. Remove power to drive before working on output wiring, motor or any driven equipment.

If certain threshold values are exceeded, the alarm and/or warning lamps will flash and text describing the alarm or warning condition will be displayed.

Local Control

Below the indicator lamps are keys which are used to determine the point of control. Each of these keys can be individually enabled or disabled using parameter 012 through 015. The Hand Start and Auto Start keys will also be disabled if any of the control terminals are programmed for either Remote Hand or Remote Auto.

The HAND STAR T key is used if the drive is to be started from the control panel. Pressing HAND STAR T will give a start command to the drive.

WARNING

If a minimum speed is set in parameter 201,

Output Frequency Low Limit

and ramp up to this frequency when HAND START is pressed. If drive is already running in Auto Mode when the HAND START key is pressed, it will switch to run in Hand Mode at same speed.

, motor will start

The RESET key is used for manually resetting the drive after a fault trip (alarm). In this case, the top line of the display will show TRIP (RESET). If the top line of the display shows TRIP (AUTO START), the drive will automatically restart. If the top line of the display shows TRIPLOCK (DISC. MAINS), input power to the drive must be removed before the trip can be reset.

Display Mode

Information is displayed on the LCD by selecting one of three programmable display modes. Pressing the Display Mode key toggles among the displays. When in Mode II, pressing and holding down the Display Mode key accesses an additional mode used to identify the data units the display is showing. (See Navigation Between Display Modes.)

In normal operation, any four meters can be shown continuously on the first and second lines of the display. Parameters 008, 009 and 010 select the three readouts displayed on the top line. Parameter 007, Large Display Readout, selects the meter displayed on line 2. In Display Mode, the + and - keys choose any meter on the LCD.

A list on the next page gives the operating data that can be shown on the three meter readouts for line 1 and the large display (line 2).

The right side of line 2 shows the active setup number and an arrow indicateing the direction of motor rotation. Clockwise indicates forward and counterclockwise indicates reverse. The arrow body disappears if a stop command is given or if the output frequency falls below 0.01 Hz.

Warnings and alarms (fault trips) will also be displayed. For an alarm, “ALARM” and the alarm number is shown in line 2 with an explanation in line 3 or in lines 3 and 4. For a warning, “WARN.” and the warning number is shown in line 2 and an explanation in 3 and/or 4. Both alarms and warnings cause the display to flash.

The line 4 automatically displays the operating status of the drive.

The table below gives the operating data options for the first and second lines of the display .

Data Item: Unit:

Resulting reference, % % Resulting reference unit chosen in par. 415 Frequency Hz % of maximum output frequency % Motor current A Power kW Power HP Output energy kW h Hours run hours User defined readout unit chosen in par. 006 Setpoint 1 unit chosen in par. 415 Setpoint 2 unit chosen in par. 415 Feedback 1 unit chosen in par. 415 Feedback 2 unit chosen in par. 415 Feedback unit chosen in par. 415 Motor voltage V DC link voltage V Thermal load on motor % Thermal load on VLT % Input status, digital input binary code Input status, analog terminal 53 V Input status, analog terminal 54 V Input status, analog terminal 60 mA Pulse reference Hz External reference % Heat sink temperature

Line 4 is the status line and the information is automatically generated for display by the drive in response to its operation. It shows that the drive is in auto mode, with remote reference, and that the motor is running. Some possible displays of the status line are shown below.

80.0% 5.08A

2.15kW

40.0Hz

SETUP

AUTO REMOTE RUN

HAND

OFF

LOCAL

STOP

RAMPING JOGGING

. . . .

STAND BY

The left part of the status line indicates where the drive Run/Stop command is from, and whether it is on or off. AUTO means that Run/ Stop control is via the control terminals and/or serial interface; HAND indicates that the drive started locally by the Hand Start key . OFF means that the drive ignores all control commands and the motor will not run.

The center part of the status line indicates the reference source that is active. REMOTE means that the reference is from the control terminals. LOCAL indicates that the reference is determined by the + and - keys on the control panel.

Display Mode I:

Below is an example of Display Mode I, in which the drive is running in setup 1, in Auto mode, with remote reference, at an output frequency of 40 Hz.

FREQUENCY

SETUP

40.0Hz

AUTO REMOTE RUN

The text in line 1, FREQUENCY , describes the meter shown in line 2. Line 2 shows the current output frequency (40.0Hz), direction of rotation (reverse), and active setup (1).

The right part of the status line indicates the drive’s operational status.

Display Mode II:

This display mode makes it possible to have three meters displayed at the same time on line 1. The meters displayed are selected through parameters 008, 009 and 010.

100% 7.8A 5.9kW

SETUP

50.0Hz

AUTO REMOTE RUN

Display Mode III:

This display mode is shown when the drive is in Display Mode II and the Display Mode key is pressed and held. In the first line, a description of the three top meters in Display Mode II is shown. The other lines are unchanged. When the key is released, Display Mode II is again shown.

REF% CURR.A POW. kW

Display Mode IV:

This display mode is available when local reference is selected. In this display mode, the speed reference is increased or decreased via +/- keys.

The first line shows the present speed reference. The second line shows the present drive output frequency. The third line show a bar graph of the relative value of the present drive output frequency in relation to the maximum frequency.

50.0Hz

AUTO REMOTE RUN

Navigation Between Display Modes

With local reference

SETUP

FREQUENCY

40.0Hz

AUTO REMOTE RUNNING

Display Mode I

USE +/- 56Hz

40Hz

0 -----60

HAND LOCAL RAMPING

SETUP

With remote controlled reference

SETUP

With local/remote reference

USE +/- 56Hz

SETUP

40.0Hz

0 ----60

HAND LOCAL RAMPING

Display Mode IV

With local reference

▲▲

▲

Keep DISPLAY MODE key down

80% 7.8A 5.9kW

SETUP

40.0Hz

AUTO REMOTE RUN

Display Mode II

▲▲

▲

▲▲

REF% CURR.A POW. kW

40.0Hz

AUTO REMOTE RUN

Display Mode III

▼▼

▼

▼▼

Release DISPLAY MODE key

SETUP

Quick Menu

The QUICK MENU key gives access to 12 of the most important setup parameters of the drive. After programming, 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 (HP) of motor. See

chart in parameter 102, Motor Power, to convert HP to kW. 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 frequency of

motor. This is typically equal to line frequency . 5 105 Motor Current Sets output characteristics of drive based on full load current in amps

(FLA) of motor. This sets overload protection for 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 frequency set in

Quick Menu Item 4 to 0 Hz.

1 1 323 Relay 1 Function Sets function of high voltage Form C relay.

12 326 Relay 2 Function Sets function of low voltage Form A relay.

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

To Enter or Change Quick Menu Parameter Data

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

1. Press Quick Menu key.

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

3. Press Change Data key.

4. Use ‘+’ and ‘-’ keys to select correct parameter setting. T o move to a different digit within parameter , use J and K arrows. Flashing

cursor 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.

1. Press Quick Menu key.

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

3. Press Change Data key.

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

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

6. Press K 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.

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

Extended Menu

CAUTION

In some applications, the Quick Menu items will not set up all the desired characteristics of the drive. T o access all the parameters, including the Quick Menu parameters, press the Extend Menu key. The Programming section of this manual will describe in detail all the parameters available through the Extended Menu.

Step Change of Numeric Values

The values of certain numeric items can also be selected from a list. These parameters are Motor Power, parameter 102; Motor Voltage, parameter 103; and Motor Frequency, parameter 104. T o select a value not on the list, use the L and M keys to select the digit to be changed, as described above.

Changing Data

T o change any parameter in either the Quick Menu mode or the Extended Menu mode, press the CHANGE DAT A key. When the CHANGE DAT A key is pressed, the data in line four will be underlined, and a cursor will be shown if the parameter controls numeric data.

The procedure for changing data depends on whether the value of the parameter is a number or a item from a list.

FREQUENCY

SETUP

24.2 Hz

205 MAX. REFERENCE

000060.000 Hz

Parameter is a Number

T o change a number , move the cursor to the digit to be changed by using the LM keys. Then change the digit by using the + and - keys.

MOTOR CURRENT

SETUP

3.90 A

210 REFERENCE TYPE SUM

Parameter is a Value Chosen from a List

Manual Initialization of Parameters

It is possible to reset nearly all parameters back to their original default values at once. T o reset the drive parameters to their read only memory default values, remove power from the drive. Press and hold the Display Mode, Change Data and OK keys down while reapplying power. Shortly after power is reapplied, the bottom line of the display will read “Initialized”. After the display stops changing, release the keys. If “Initialized” did not appear, repeat the procedure.

These parameters are not reset by manual initialization:

Parameter 600 Operating hours Parameter 601 Hours run Parameter 602 kWh counter Parameter 603 Number of power-ups Parameter 604 Number of overtemperatures Parameter 605 Number of overvoltages

Initialization can also be done using Parameter 620.

Manual initialization using either this procedure or parameter 620 will reset drive to standard default parameters. Any special programming for application that was performed at factory, during start-up or subsequently, will be lost. If desired parameters have been previously stored in drive’s local control panel (LCP), it may be better to download those parameters from LCP using parameter download functions of parameter 004.

Uploading Parameters

At any time the present parameters may be copied to the local control panel (LCP). This may be useful when setting up multiple drives. It is also useful when it is desired to return to a previous set of parameters. See parameter 004, LCP Copy, for more information.

If the selected parameter’s value is selected from a list, its value can be changed by using the + and - keys.

When the desired value is displayed, press the OK key to accept the new value. If you wish to cancel the change and return to the previously accepted value, press the CANCEL key . If neither OK nor CANCEL is pressed, the new value will be accepted after 20 seconds.

Manually initializing the drive using either the procedure described above or parameter 620, Operating Mode, does not change the values uploaded to the local control panel.

VLT 6000 Start-Up

Pre-installation Checks

1. Compare drive model number to what was ordered.

2. Ensure each of following are rated for same voltage:

• Drive

• Power line

• Motor

3. Record following motor data:

• Voltage

• Frequency

• Full load current

• Full load speed

• Power — convert HP to kW (See conversion table in parameter

102, Motor Power, in this manual.)

4. Ensure that rated drive current is equal to or greater than total full load current.

• For multiple motor operations, add up full load current ratings of

all motors.

• Drive can be at most one size smaller than motor.

• If drive rating is less than motor, full motor output cannot be achieved.

5. Check motor wiring:

• Any disconnect between drive and motor should be interlocked

to drive safety interlock circuit to avoid unwanted drive trips.

• No power factor correction capacitors can be connected between

drive and motor.

• Two speed motors must be wired permanently for full speed.

• Y-start, H-run motors must be wired permanently for run.

Installation Checks

1. Input fusing in power supply for all drives must be provided (see Input Fuses section in this manual).

2. Environmental concerns — for standard NEMA 1 drive:

• Clean air supply

• Dry air (max 95% relative humidity , non-condensing)

• 14

F to 104oF ambient temperature operating range, or as rated

• 3,300 foot maximum elevation with no derating

3. Mounting

• Vertical

• Drives with heat sink fins exposed in back of unit must be

mounted against a solid surface (see Clearances section in this manual).

• Keep any construction dirt out of drive.

4. Wiring

• Wire drive in accordance with instructions and diagrams received

with drive.

• Separate conduits must be provided to drive for input power,

output power, and control wiring.

• Note that safety interlock and remote run/stop circuitry is 115 V AC

for drives with bypasses.

• Use knockouts or conduit entry plates. Avoid metal shavings in cabinet.

• Protect signal wires from noise.

• Ground each drive individually.

• Double check input and output power wiring for correct location.

Setting Up Drive for Motor Start

Enter motor nameplate data into drive through Quick Menu.

1. Parameter 101:

• If one motor is connected to drive, set to AEO FUNCTION.

• If more than one motor connected to drive, set to MULTIPLE

MOTORS. (Parameter 108, MUL TIPLE MOTOR ST ARTING VOLT AGE should be adjusted later to provide reliable starts and minimum starting current.)

2. Parameter 102, MOTOR POWER (in kW) (See conversion table in parameter 102, Motor Power, in this manual.)

3. Parameter 103, MOTOR VOLT AGE

4. Parameter 104, MOTOR FREQUENCY

5. Parameter 105, MOTOR CURRENT

6. Parameter 106, MOTOR SPEED

7. Parameter 107, (optional) select AUTOMATIC MOTOR ADAPT ATION and run AMA in accordance with procedure in parameter 107, Automatic Motor Adaptation, in this manual.

8. Press HAND STAR T key to initiate operation in local control.

Operational Tests — HAND

1. Check motor rotation from drive. If incorrect, disconnect input power from drive and reverse two leads between drive and motor.

2. If a bypass is provided, check motor rotation in bypass mode. If incorrect, disconnect input power from drive and reverse two input power leads.

3. Accelerate motor quickly to full speed and verify operation.

4. Decelerate motor quickly to stop and verify operation.

5. Operate motor over entire speed range while closely checking for resonance.

Operational Tests — AUTO

1. Ensure that drive follows run/stop and safety interlock commands from system.

2. Ensure drive follows speed reference, or feedback, from system.

Final Adjustments

1. Use parameters 216 through 220 to reject any resonant points.

2. Lock out keypad functions, as required.

General Troubleshooting

1. Display Messages:

• AUTO ST ART—Drive has tripped off and is in process of

automatically restarting.

• TRIP—Drive has tripped off. Press RESET to start.

• TRIP LOCKED—Drive has tripped off. Remove and apply

power before restarting with RESET .

2. Refer to Warnings and Alarms section in this manual.

3. Check tightness of all connections and wires for proper location.

4. Measure input signals.

5. Check drive input and output for balanced voltage and current.

Programming

Using the Extend Menu key, it is possible to access to all the parameters for the drive.

Operation and Display Parameters 000 through 017

This parameter group deals with the display, control keys and other general functions.

Description of Parameters

Parameters are grouped by function. The groups are:

Operation and Display Parameters 001 through 017 Load and Motor Parameters 100 through 117 References and Limits Parameters 200 through 228 Input and Outputs Parameters 300 through 328 Appli cat ion Func tio ns Parameters 400 through 427 Serial Communication Parameters 500 through 566 Service Functions Parameters 600 through 631 Relay Card Functions Parameters 700 through 711

The numbers shown in the square brackets ([ ]) after the parameter values are used in serial communications to choose the parameter value from the list. They are not shown on the local control panel when programming the drive locally.

Setup Configuration

The drive has four setups that can be programmed independently. The active setup can be selected in parameter 002, Active Setup. The active setup number is shown on the right of line two in the display under the word “Setup.”

It is also possible to set the drive to Multi-Setup to allow switching setups through digital inputs or serial communication.

More than one setup can be used. An example would be a changing setups for day/night or summer/winter operation.

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

By means of parameter 004, LCP Copy, any setup can be transferred from one drive to another using the removable local control panel (LCP). First, upload all parameter values to the control panel installed in the drive. Insert this panel into the next drive. Download all parameter values from the control unit to the second drive. Repeat this procedure to program additional drives.

001 Language (Language) Value:

✭ English (ENGLISH) [0]

German (DEUTSCH) [1] French (FRANCAIS) [2] Danish (DANSK) [3] Spanish (ESP A¥OL) [4] Italian (ITALIANO) [5] Swedish (SVENSKA) [6] Dutch (NEDERLANDS) [7] Portuguese (PORTUGUESA) [8]

Function:

This parameter determines the language to be used on the display .

Description of choice:

There is a choice of the languages indicated.

002 Active Setup (ACTIVE SETUP) Value:

Factory Setup (FACTOR Y SETUP) [0]

✭ Setup 1 (SETUP 1) [1]

Setup 2 (SETUP 2) [2] Setup 3 (SETUP 3) [3] Setup 4 (SETUP 4) [4] Multi-Setup (MULTI SETUP) [5]

Function:

This parameter defines the setup number that controls the drive. All parameters can be programmed in four individual parameter setups,

Setup 1, Setup 2, Setup 3 and Setup 4. In addition, a pre-programmed read-only setup, called the Factory

Setup, exists.

Description of choice:

Factory Setup contains the parameter values preset at the factory. This setup can be used as a data source if the other setups are to be returned to a known state.

Setups 1 through 4 are four individual setups that can be selected as required.

✭ Indicates default parameter. Depending upon the application, the drive may be delivered with other parameters selected.

Multi-Setup is used if remote switching between different setups is required. T erminals 16, 17, 29, 32, 33 and the serial communication port can be used for switching between setups.

Connection Examples:

Setup Change

Selection of setup using terminals 32 and 33. See the descriptions of parameters 300 through 307. Parameter 306 = Selection of Setup, lsb Parameter 307 = Selection of Setup, msb Parameter 002 = Multi Setup

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 parameters (DOWNLOAD SIZE INDEP .) [3]

Function:

Parameter 004, LCP Copy, is used to copy all parameter setups to or from the Local Control Panel (LCP). This can be used to store a backup copy of all parameters in the LCP or to copy all setups from one drive to another.

Description of choice:

Select Upload all parameters if all parameter values are to be copied from the drive to the LCP .

Select Download all parameters if all parameter values are to be copied from the LCP to the drive on which the control panel has been mounted.

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 SETUP 4) [4] Copy active Setup to all (COPY TO ALL) [5]

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.

NOTE

Copying is only possible when drive is stopped.

Description of choice:

The copying starts when the required copying function has been selected and the OK key has been pressed.

Select Download power-independent parameters if only the powerindependent parameters are to be downloaded. This allows the parameters from one drive to be easily copied to another drive of a different size.

NOTE

Copying is only possible when drive is stopped.

Setup of User-Defined Readout

Parameter 005, Maximum Value of User-Defined Readout, and Parameter 006, Unit for User-Defined Readout, allow users to design their own readout which can be seen if the User-Defined Readout has been selected as one of the displayed meters. The range is set in parameter 005, Maximum Value of User-Defined Readout and the unit is determined in parameter 006, Unit for User-Defined Readout. The choice of unit determines whether the relationship between the output frequency and the readout is a linear, square or cubed. Units representing rates (RPM, CFM, GPM, etc.) are linear. Units representing pressure (PSI, in. wg., etc.) are square. Units representing power (HP , kW , etc.) are cubed.

The display indicates when copying is in progress.

✭ Indicates default parameter. Depending upon the application, the drive may be delivered with other parameters selected.

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Danfoss VLT 6002-6011, VLT 6006-6032, VLT 6002-6005, VLT 6042-6062, VLT 6075-6125 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual