Danfoss VLT 7000 Operating guide

■ Contents

VLT® 7000 Booster

Introduction to Booster

Software version ....................................................................................................... 4

Safety regulations ..................................................................................................... 5

Warning against unintended start ............................................................................. 5

Introduction to Operating Instructions ....................................................................... 7

Control principle ....................................................................................................... 8

AEO - Automatic Energy Optimization ...................................................................... 9

PC software and serial communication ................................................................... 10

Unpacking and ordering a VLT frequency converter ................................................ 11

Type code ordering number string ......................................................................... 11

Ordering form ......................................................................................................... 13

................................................................................. 4

Installation ......................................................................................................... 14

General technical data ............................................................................................ 14

Technical data, mains supply 3 x 380-460V ............................................................ 18

Fuses ..................................................................................................................... 20

Mechanical dimensions .......................................................................................... 21

Mechanical installation ............................................................................................ 23

General information about electrical installation ...................................................... 25

High voltage warning .............................................................................................. 25

Earthing .................................................................................................................. 25

Cables .................................................................................................................... 25

Screened/armoured cables .................................................................................... 25

Extra protection with regard to indirect contact ....................................................... 25

RFI switch .............................................................................................................. 26

High voltage test .................................................................................................... 28

Heat emission from VLT 7000 Booster ................................................................... 28

Ventilation of integrated VLT 7000 Booster ............................................................. 28

EMC-correct electrical installation ........................................................................... 29

Use of EMC-correct cables .................................................................................... 31

Electrical installation - earthing of control cables ..................................................... 32

Electrical installation, enclosures ............................................................................. 33

Tightening-up torque and screw sizes .................................................................... 35

Mains connection ................................................................................................... 35

Motor connection ................................................................................................... 35

Direction of motor rotation ...................................................................................... 36

Motor cables .......................................................................................................... 36

Motor thermal protection ........................................................................................ 37

Earth connection .................................................................................................... 37

DC bus connection ................................................................................................ 37

High-voltage relay ................................................................................................... 37

Control card ........................................................................................................... 37

Electrical installation, control cables ........................................................................ 38

Switches 1-4 .......................................................................................................... 39

Bus connection ...................................................................................................... 39

Programming .................................................................................................... 40

Control unit LCP ..................................................................................................... 40

Control keys for parameter setup ........................................................................... 40

Indicator lamps ....................................................................................................... 41

Local control .......................................................................................................... 41

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VLT® 7000 Booster

Display mode ......................................................................................................... 42

Navigation between display modes ........................................................................ 44

Changing data ........................................................................................................ 45

Manual initialisation ................................................................................................. 45

Quick Menu ............................................................................................................ 46

Operation and Display 001-017 .............................................................................. 48

The Setup configuration ......................................................................................... 48

Setup of user-defined readout ................................................................................ 49

Load and Motor 100-117 ....................................................................................... 55

Configuration .......................................................................................................... 55

Motor power factor (Cos ø) .................................................................................... 60

Inputs and outputs 300-328 ................................................................................... 68

Analogue inputs ..................................................................................................... 69

Analogue/digital outputs ......................................................................................... 72

Relay outputs ........................................................................................................ 75

Application functions 400-427 ................................................................................ 77

PID for process control ........................................................................................... 81

PID overview .......................................................................................................... 83

Feedback handling ................................................................................................. 83

Service functions 600-631 ...................................................................................... 88

Cascade Controller Settings ..................................................................... 93

Operation modes ................................................................................................... 93

Mode no ................................................................................................................ 93

Control type ........................................................................................................... 94

Fixed lead pump control (mode 1-8) ....................................................................... 94

Alternating lead pump control (Mode 9-14) ............................................................. 94

AUX pump ............................................................................................................. 94

Staging and destaging order .................................................................................. 94

FILO: First in, last out ............................................................................................. 95

LRHIMRHO: Least-running-hours-in, most running-hours out ................................ 95

Default value for digital input on terminal 18 (DI18) .................................................. 95

No. of pumps, excl. AUX pump ............................................................................. 95

Wiring diagram mode 1-8 ....................................................................................... 96

Wiring diagram modes 9-14 .................................................................................. 97

Parameter settings ......................................................................................... 98

Quick menu 17 Par. 700 Cascade Mode ................................................................ 98

Quick menu 18 Par. 701 Pump combination .......................................................... 98

Quick menu 19 Par. 702 Staging bandwidth % ..................................................... 99

Quick menu 20 Par. 703 SBW Destage delay ....................................................... 99

Quick menu 21 Par. 704 SBW Stage delay ......................................................... 100

Quick menu 22 Par. 705 Override bandwidth ...................................................... 100

Quick menu 23 Par. 706 Override Bandwidth timer ............................................. 101

Quick menu 24 Par. 707 Destage by timer .......................................................... 101

Staging and destaging of fixed speed pumps ............................... 102

Quick menu 25 Par. 708 Staging frequency ........................................................ 102

Quick menu 26 Par. 709 Destaging frequency ..................................................... 102

Staging and destaging og fixed speed pumps .............................. 103

Quick menu 27 Par. 710 Delay before running on mains ..................................... 103

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VLT® 7000 Booster

Auxiliary pump/sleep mode .................................................................... 104

Quick menu 28 Par. 711 Sleep/AUX timer ........................................................... 104

Quick menu 29 Par. 712 Sleep/AUX frequency .................................................... 104

Quick Menu 30 Par. 713 Wake up/disable aux - frequency ................................. 104

Quick Menu 31 Par. 714 Boost setpoint .............................................................. 105

Virtual control curve ................................................................................... 106

Example ............................................................................................................... 106

Quick Menu 32 Par. 418 setpoint 1 ...................................................................... 106

Quick Menu 33 Par. 419 setpoint 2 ...................................................................... 106

Start and stop functionality ..................................................................... 107

Quick Menu 34 Par. 719 Pump enable ................................................................. 107

Quick Menu 35 Par. 720 Pump running hours ...................................................... 108

Feedback transmitter wiring ................................................................................. 108

All about VLT 7000 Booster ..................................................................... 110

Status messages .................................................................................................. 110

List of warnings and alarms .................................................................................. 112

Aggressive environments ...................................................................................... 117

Calculation of resulting reference .......................................................................... 117

Earth leakage current ........................................................................................... 118

Extreme running conditions .................................................................................. 118

Peak voltage on motor ......................................................................................... 120

Switching on the input .......................................................................................... 120

Acoustic noise ...................................................................................................... 121

Derating for ambient temperature ......................................................................... 121

Derating for air pressure ....................................................................................... 122

Derating for running at low speed ......................................................................... 122

Derating for long motor cables or cables with larger cross-section ....................... 122

Derating for high switching frequency ................................................................... 122

Vibration and shock .............................................................................................. 123

Air humidity ......................................................................................................... 123

Efficiency ............................................................................................................. 124

Mains supply interference/harmonics .................................................................... 125

Power factor ........................................................................................................ 125

EMC test results (Emission, Immunity) .................................................................. 127

EMC Immunity ..................................................................................................... 128

Definitions ........................................................................................................... 130

Factory settings .................................................................................................... 132

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VLT® 7000 Booster

VLT 7000 Booster

Operating instructions

Software version: 30.00/0.00/1.x

These operating instructions can be used for all VLT 7000 Booster frequency converters with software version 30.00/

0.00/1.0x. The software version number can be seen from parameter

624.

176FA229.10

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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.

■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 n the equipment from mains and is thus n be used as a safety switch.

3. Correct protective earthing of the equipment

must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.

4. The earth leakage currents are higher than 3.5 mA.

5. Protection against motor overload is included in

the factory setting. Parameter 117, Motor thermal protection default value is ETR trip 1. N

ote: The function is initialised at 1.0 x rated motor current and rated motor frequency (see parameter 117, Motor thermal protection).

ot disconnect

ot to

VLT® 7000 Booster

6. Do n

7. Please note that the frequency converter has

■Warning against unintended start

1. The motor can be brought to a stop by

2. While parameters are being changed, the

3. A motor that has been stopped may start if faults

■Useonisolatedmains

See section RFI Switch regarding use on isolated mains.

ot remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

more voltage inputs than L1, L2 and L3, when theDC-busterminalsareused. Check that a disconnected and that the necessary time has passed before repair work is commenced.

means 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, t stop functions are not sufficient.

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

occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

ll voltage inputs have been

he stop key

Booster

Introduction to

hese

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VLT® 7000 Booster

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.

Using VLT 7002-7005, 380-460 V: wait at least 4 minutes Using VLT 7006-7072, 380-460 V: wait at least 15 minutes

176FA230.10

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■Introduction to Operating Instructions

These Operating Instructions are a tool intended for persons who are to install, operate and program the VLT 7000 Booster.

These Operating Instructions are divided into four sections with information about VLT 7000 Booster.

Introduction to Booster: This section tells you the advantages you can obtain by using a VLT

7000 Booster - such as AEO, Automatic Energy Optimization, RFI filters and other HVAC-relevant functions. This section also contains examples of application as well as information about Danfoss.

Installation: This section tells you how to carry out mechanically correct installation

of the VLT 7000 Booster. In addition, this section includes a description of how to ensure that the installation of your VLT 7000 Booster is EMC-correct. Furthermore, a list is given of mains and motor connections, together with a description of the control card terminals.

Programming: This section describes the control unit and the software parameters for

the VLT 7000 Booster. Also included is a guide to the Quick Setup menu, which allows you to get started on your application very quickly.

Booster

Introduction to

All about VLT 7000 Booster This section gives information about status, warning and error

messages from the VLT 7000 Booster. Additionally, information is given on technical data, service, factory settings and special conditions.

Indicates a general warning

NB!:

Indicates something to be noted by the reader

Indicates a high-voltage warning

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■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.

VLT® 7000 Booster

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

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

. Rectifier

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

. Intermediate circuit

DC voltage = 1.35 x mains voltage [V].

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

. Intermediate circuit capacitors

Even out the intermediate circuit voltage.

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

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

. 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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■AEO - Automatic Energy Optimization

Normally, the U/f characteristics have to be set on the basis of the expected load at different frequencies. However, knowing the load at a given frequency in an installation is often a problem. This problem can be solved by using a VLT 7000 Booster with its integral Automatic Energy Optimization (AEO), which ensures optimum energy utilization. All VLT 7000 Booster units feature this function as a factory setting, i.e. it is not necessary to adjust the frequency converter U/f ratio in order to obtain maximum energy savings. In other frequency converters, the given load and voltage/frequency ratio (U/f) must be assessed to carry out correct setting of the frequency converter. Using Automatic Energy Optimization (AEO), you no longer need to calculate or assess the system characteristics of the installation, since Danfoss VLT 7000 Booster units guarantee optimum, load-dependent energy consumption by the motor at all times.

VLT® 7000 Booster

Booster

Introduction to

The figure on the right illustrates the working range of the AEO function, within which energy optimization is enabled.

If the AEO function has been selected in parameter 101, Torque characteristics, this function will be constantly active. If there is a major deviation from the optimum U/f ratio, the frequency converter will quickly adjust itself.

Advantages of the AEO function

• Automatic energy optimization

• Compensation if an oversize motor is used

• AEO matches operations to daily or

seasonal fluctuations

• Energy savings in a constant air volume system

• Compensation in the oversynchronous

working range

• Reduces acoustic motor noise

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■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 7000 Booster units have a RS 485 port and the FC protocol as standard.

Using the RS 485 port enables communication, e.g. with a PC. A Windows

program, called MCT 10,is available for this purpose. It can be used to monitor, program and control one or several VLT 7000 Booster units. For further information, contact Danfoss.

500-566 Serial communication

NB!:

Information on the use of RS-485 serial interface is not included in this manual.

VLT® 7000 Booster

MG.70.A1.02 - VLT is a registered Danfoss trademark

■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-7008-B-T4-B20-R3-DL-F00-A33

This means that the frequency converter ordered is a VLT 7008 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)without an option card (F00). Character no. 8 ( B) indicates the application range of the unit: B = Booster.

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

unit. Most of the types are with DC terminals, please see DC bus connection for exceptions.

VLT® 7000 Booster

Booster

Introduction to

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 a mains voltage of 380-460 V and a motor power of up to 7.5 kW (VLT 7011) are always supplied with an integral class A1 & B filter. Units forhighermotorpowercanbeorderedeitherwith or without an RFI filter.

Control unit (keypad and display) All types of units in the programme, can be ordere either with or without the control unit.

Conformal Coating All types of units in the programme are available only with conformal coating of the PCB.

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380-460 V

VLT® 7000 Booster

Typecode

Position in string

1.1 kW/1.5 HP 7002 XXX X

1.5 kW/2.0 HP 7003 XXX X

2.2 kW/3.0 HP 7004 XXX X

3.0 kW/4.0 HP 7005 XXX X

4.0 kW/5.0 HP 7006 XXX X

5.5 kW/7.5 HP 7008 XXX X

7.5 kW/10 HP 7011 XXX X 11 kW/15 HP 7016 X X XX 15 kW/20 HP 7022 X X XX

18.5 kW/25 HP 7027 X X XX 22 kW/30 HP 7032 X X XX 30 kW/40 HP 7042 X X XX 37 kW/50 HP 7052 X X XX 45 kW/60 HP 7062 X X XX 55 kW/75 HP 7072 X X XX

Voltage

T4: 380-460 VAC

Enclosure

B20: Bookstyle IP 20 C20: Compact IP 20

9-10

B20

11-13

Hardware variant

ST: Standard

RFI filter

R0: Without filter R3: Class A1 and B filter

C20

11-13

14-15

16-17

Optional selections, 200-600 V

Display Position: 18-19

D0 Without LCP DL With LCP

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■Ordering form

VLT® 7000 Booster

Booster

Introduction to

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■General t echnical data

Mains supply (L1, L2, L3):

Supply voltage 380-460 V units ........................................................................ 3 x 380/400/415/440/460 V ±10%

Supply frequency ............................................................................................................................ 48-62 Hz ± 1%

Max. imbalance of supply voltage .................................................................................................................. ± 3%

VLT 6002-6011, 380-460 V .................................................................................... ±2.0% of rated supply voltage

VLT 6016-6072, 380-460 V .................................................................................... ±1.5% of rated supply voltage

True Power factor (λ) ...................................................................................................... 0.90 nominal at rated load

Displacement Power Factor (cos. ϕ) ............................................................................................ near unity (>0.98)

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 7002-7062, 380-460V .............................................................................. 0-120 Hz, 0-1000 Hz

Output frequency 7072, 380-460V ......................................................................................... 0-120 Hz, 0-450 Hz

Rated motor voltage, 380-460 V units .............................................................................. 380/400/415/440/460V

Rated motor frequency ............................................................................................................................ 50/60 Hz

Switching on output ................................................................................................................................. Unlimited

Ramp times ....................................................................................................................................... 1 - 3600 sec.

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%

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 k

Scanning time per input ............................................................................................................................. 3 msec.

Basic galvanic isolation: All d igital inputs are galvanically isolated from the supply voltage . In addition, the digital inp uts can be isolated from the other terminals on the control card by connecti

ng 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.10k

No. of programmable analogue current inputs ..................................................................................................... 1

Terminal no ground. ............................................................................................................................................ 55

Current range ...................................................................................................................... 0/4 - 20 mA (scalable)

Input resistance, R

...................................................................................................................................... 200

Resolution .......................................................................................................................................... 10 bit + sign

Accuracy on input .......................................................................................................... Max. error 1% of full scale

Scanning time per input ............................................................................................................................. 3 msec.

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VLT® 7000 Booster

Basic galvanic isolation: All analogue inputs are galvanically isolated from the supply v oltage and other high-voltage 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

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 fullscale

Accuracy (1-65 kHz), terminals 29, 33 ....................................................................... Max. error: 0.1% of full scale

Basic galvanic isolation: All pulse inputs are galvanically isolated from the supply voltage. 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.

........................................................................................................................................ 2 k

Installation

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 ....................................................................... 600

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

Accuracy of analogue output ..................................................................................... Max. error: 1.5% of full scale

Resolution on analogue output. ....................................................................................................................... 8 bit

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

Control card, 24 V DC supply:

Terminal nos. ................................................................................................................................................ 12, 13

Max. load .................................................................................................................................................. 200 mA

Terminal nos. ground .................................................................................................................................... 20, 39

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

Control card, RS 485 serial communication:

Terminal nos. .............................................................................................................. 68 (TX+, RX+), 69 (TX-, RX-)

Basic galvanic isolation.

Relay outputs:

No. of programmable relay outputs ...................................................................................................................... 2

Terminal nos., control card ..................................................................................................................... 4-5 (make)

Max. terminal load (AC) on 4-5, control card ........................................................................... 50 V AC, 1 A, 60 VA

Max. terminal load (DC-1 (IEC 947)) on 4-5, control card ......................................................... 75 V DC, 1 A, 30 W

Terminal nos., power card and relay card ............................................................................ 1-3 (break), 1-2 (make)

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VLT® 7000 Booster

Max. terminal load (AC) on 1-3, 1-2 power card ................................................................... 240 V AC, 2 A, 60 VA

Max. terminal load DC-1 (IEC 947) on 1-3, 1-2, power card and relay card ....................................... 50 V DC, 2 A

Min. terminal load on 1-3, 1-2, power card ...................................................... 24 V DC, 10 mA, 24 V AC, 100 mA

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 7011 380-460 V .................................................................... 100 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 control cables ....................................................................................... 1.5 mm

Max. cross-section for serial communication ............................................................................ 1.5 mm

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

Speed, accuracy (open loop) ............................................................................ < 1500 rpm: max. error ± 7.5 rpm

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

Process, accuracy (closed loop) ....................................................................... < 1500 rpm: max. error ± 1.5 rpm

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

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

/16 AWG

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 20

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) ........................................................................................ Coated class 3C3

Ambient temperature, 7002-7011 380-460 V, Bookstyle, IP 20 ............. Max. 45°C (24-hour average max. 40°C)

Ambient temperature, 7016-7072 380-460 V, IP 20 ............................... Max. 40°C (24-hour average max. 35°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

EMC standards applied, Emission ......................................... EN 61000-6-3/4, EN 61800-3, EN 55011, EN 55014

EMC standards applied, Immunity ................................................................................................ EN 50082-2, EN

61000-4-2, IEC 1000-4-3, EN 61000-4-4, EN 61000-4-5, ENV 50204, EN 61000-4-6, VDE 0160/1990.12

Relay outputs on the Cascade Card:

Relay 71-78: ......................................................................................................... Terminal 8 A-D and 71-78 make

Max. cross section: .................................................................................................................................. 1,5 mm

Torque: ............................................................................................................................................. 0,22-0,25 Nm

VLT 7000 Boosterprotection

• Electronic motor thermal protection against overload.

• Temperature monitoring of heat-sink ensures that the frequency converter cuts out if the temperature reaches

90°C. An overtemperature can only be reset when the temperature of the heat-sink has fallen below 60°C.

• The frequency converter is protected against short-circuiting on motor termi

MG.70.A1.02 - VLT is a registered Danfoss trademark

nals U, V, W.

VLT® 7000 Booster

• 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

Installation

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■Technical data, mains supply 3 x 380-460V

According to international requirements VLT type 7002 7003 7004 7005 7006 7008 7011

[A] (380-440

Output current

VLT,N

VLT, MAX

(60 s) [A]

(380-440 V)

[A] (441-460

VLT, N

(60 s) [A]

VLT, MAX

(441-460 V)

Output power S

Ty p ic a l s ha f t output Ty p ic a l s ha f t output Max. cable

[kVA] (400 V) 2.2 2.9 4.0 5.2 7.2 9.3 11.5

VLT,N

[kVA] (460 V) 2.4 2.7 3.8 5.0 6.5 8.8 11.2

VLT,N

[mm

]/[AWG] cross-section to motor Max. input current (RMS) I Max. cable

[A] (380 V) 2.8 3.8 5.3 7.0 9.1 12.2 15.0

L,N

[A] (460 V) 2.5 3.4 4.8 6.0 8.3 10.6 14.0

L,N

[mm

]/[AWG] cross-section power Max. pre-fuses [-]/UL1)[A] 16/6 16/10 16/10 16/15 25/20 25/25 35/30 Mains contactor [Danfoss type] CI 6 CI 6 CI 6 CI 6 CI 6 CI 6 CI 6 Efficiency

Weight IP 20 [kg] 8 8 8.5 8.5 10.5 10.5 10.5 Power loss at max. load. [W] Enclosure VLT type IP 20

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

[kW] 1.1 1.5 2.2 3.0 4.0 5.5 7.5

[HP] 1.5 2 3 - 5 7.5 10

2) 4)

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

2) 4)

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

0.96 0.96 0.96 0.96 0.96 0.96 0.96

Total 67 92 110 139 198 250 295

1. Fortypeoffuse,seesectionFuses.

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-sectio

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■Technical data, mains supply 3x380-460V

According to international requirements VLT type 7016 7022 7027 7032 7042

Output current I

Output power S

Ty pi ca l s ha ft o ut p ut P Ty pi ca l s ha ft o ut p ut P Max. cable cross-section to motor and DC-bus, IP 20 Min. cable cross-section to motor and DC-bus Max. input current I (RMS) I Max. cable cross-section power, IP 20 Max. pre-fuses [-]/UL1)[A] 63/40 63/40 63/50 63/60 80/80 Mains contactor [Danfoss type] CI 9 CI 16 CI 16 CI 32 CI 32 Efficiency at rated frequency 0.96 0.96 0.96 0.96 0.96 Weight IP 20 [kg] 21 21 22 27 28 Power loss at max. load. [W] 419 559 655 768 1065 Enclosure IP 20

1. Fortypeoffuse,seesectionFuses.

2. American Wire Gauge.

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-sectio

[A] (380-440 V) 24.0 32.0 37.5 44.0 61.0

VLT,N

(60 s) [A]

VLT, MAX

(380-440 V)

[A] (441-460 V) 21.0 27.0 34.0 40.0 52.0

VLT,N

(60 s) [A]

VLT, MAX

(441-460 V)

[kVA] (400 V) 17.3 23.0 27.0 31.6 43.8

VLT,N

[kVA] (460 V) 16.7 21.5 27.1 31.9 41.4

VLT,N

[mm

]/[AWG]

[mm

]/[AWG]

[A] (380 V) 24.0 32.0 37.5 44.0 60.0

L,N

[A] (460 V) 21.0 27.6 34.0 41.0 53.0

L,N

[mm

]/[AWG]

26.4 35.2 41.3 48.4 67.1

23.1 29.7 37.4 44.0 57.2

[kW] 11 15 18.5 22 30 [HP] 15 20 25 30 40

2) 4)

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

2) 4)

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

2) 4)

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

Installation

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■Technical data, mains supply 3x380-460V

According to international requirements VLT type 7052 7062 7072

Output current I

VLT, MAX

Output power S

Ty p ic a l s h af t o u tp u t P Ty p ic a l s h af t o u tp u t P Max. cable cross-section to motor and DC-bus, IP 20 Min. cable cross-section to motor and DC-bus Max. input current I (RMS) I Max. cable cross-section power, IP 20 Max. pre-fuses [-]/UL1)[A] 100/100 125/125 150/150 Mains contactor [Danfoss type] CI 37 CI 61 CI 85 Efficiency at rated frequency 0.96 0.96 0.96 Weight IP 20 [kg] 41 42 43 Power loss at max. load. [W] 1275 1571 1851 Enclosure IP 20

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.

5. Aluminium cables with cross-section above 35 mm

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

[A] (380-440 V) 73.0 90.0 106

VLT,N

(60 s) [A] (380-440 V) 80.3 99.0 117

[A] (441-460 V) 65.0 77.0 106

VLT,N

(60 s) [A] (441-460 V) 71.5 84.7 117

[kVA] (400 V) 52.5 64.7 73.4

VLT,N

[kVA] (460 V) 51.8 61.3 84.5

VLT,N

[kW] 37 45 55

VLT,N

[HP] 50 60 75

VLT,N

[mm

2) 4) 5)

]/[AWG]

[A] (380 V) 72.0 89.0 104

L,N

[A] (460 V) 64.0 77.0 104

L,N

]/[AWG]

35/2 50/0 50/0

2) 4)

10/8 16/6 16/6

2) 4) 5)

35/2 50/0 50/0

■Fuses

Non UL compliance

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

VLT 7002-7072 380-460 V type gG

Not following the recommendation may result in unnecessary damage of the drive in case of malfunction. Fuses must be designed for protection in a circuit capable of supplying a maximum of 100000 A

(symmetrical), 500 V/600 V maximum.

rms

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■Mechanical dimensions

All the below listed measurements are in mm.

VLT type A B C a b aa/bb Type Bookstyle IP 20 380 - 460 V

7002 - 7005 395 90 260 384 70 100 A 7006 - 7011 395 130 260 384 70 100 A

IP 20 380 - 460 V

7002 - 7005 395 220 160 384 200 100 C 7006 - 7011 395 220 200 384 200 100 C 7016 - 7027 560 242 260 540 200 200 D 7032 - 7042 700 242 260 680 200 200 D 7052 - 7072 800 308 296 780 270 200 D

Installation

MG.70.A1.02 - VLT is a registered Danfoss trademark

■Mechanical dimensions

VLT® 7000 Booster

MG.70.A1.02 - VLT is a registered Danfoss trademark

■Mechanical installation

VLT® 7000 Booster

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.

■Installation of VLT 7002-7072

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

Cooling

Installation

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

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

Side by side/flange by flange

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

d[mm] Comments Bookstyle VLT 7002-7011, 380-460 V 100 Installation on a plane, vertical surface (no spacers)

Compact (all enclosure types) VLT 7002-7011, 380-460 V 100 Installation on a plane, vertical surface (no spacers)

VLT 7016-7072, 380-460 V 200 Installation on a plane, vertical surface (no spacers)

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■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 7002-7005, 380-460 V wait at least 4 minutes Using VLT 7006-7072, 380-460 V wait at least 15 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).

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

• 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 one device is installed in cabinets,

VESS

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

■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 int

ended for mechanical protection, for example, is not suitable for an EMC-correct 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 curr

ents.

If ELCB relays are used, this must be:

• Suitable for protecting equipment with a direct

current content (DC) in the fault

y current

(3-phase bridge rectifier)

• Suitable for power-up with short charging

current to earth

• Suitable for a high leakage current

MG.70.A1.02 - VLT is a registered Danfoss trademark

■RFI switch

ains supply isolated from earth:

When the frequency converter is supplied from an isolated mains source (IT mains), the RFI switch must be closed (OFF). In the OFF position, the internal RFI capacitors (filter capacitors) between the chassis and the intermediate circuit are cut out so as to avoid damaging the intermediate circuit and to reduce the earth leakage currents (see IEC 1800-3). The position of the RFI switch can be seen from in VLT 7000 enclosures.

Please also refer to the application note VLT on IT mains, MN.90.CX.02.

NB!:

When the RFI switch is set to OFF parameter 407 Switching frequency max is only allowed to be set to factory setting.

NB!:

TheRFIswitchisnottobeoperatedwith mains supply connected to the unit. Check that the mains supply has been disconnected

before operating the RFI switch.

VLT® 7000 Booster

Bookstyle IP 20 VLT 7002 - 7011 380 - 460 V

NB!:

The RFI switch disconnects the capacitors galvanically; however, transients higher than approx. 1,000 V will be bypassed by a spark gap.

The VLT 7000 Booster EMC performance will be reduced if the RFI switch is placed in the OFF position.

Mains supply connected to earth: The RFI switch must be ON for all installations on earthed mains supplies.

Compact IP 20 VLT 7002 - 7011 380 - 460 V

Compact IP 20 VLT 7016 - 7027 380 - 460 V

MG.70.A1.02 - VLT is a registered Danfoss trademark

Compact IP 20 VLT 7032 - 7042 380 - 460 V

VLT® 7000 Booster

Compact IP 20 VLT 7052 - 7072 380 - 460 V

Installation

MG.70.A1.02 - VLT is a registered Danfoss trademark

■High voltage test

A high voltage test can be carried out by short-circuiting terminalsU,V,W,L1,L2andL3andenergizing by max. 2.5 kV DC for one second between this short-circuit 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 7000 Booster

ThetablesinGeneral technical data show the power loss P maximum cooling air temperature t

(W) from VLT 7000 Booster. The

, is 40°

IN MAX

at 100% load (of rated value).

VLT® 7000 Booster

■Ventilation of integrated VLT 7000 Booster

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

1. AddupthevaluesofP

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

(40°C). The day/night

IN, MAX

) present

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 its outlet temperature (t

OUT

)and

t = 45° C-tIN.

3. Calculate the required quantity of air = insert

t in Kelvin

m3/h

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.

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

■EMC-correct electrical installation

Following these guidelines is advised, 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.

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 tw ends (pigtails). Such a termination increases the high frequency impedance of the screen, which reduces its effectiveness at high frequen low impedance cable clamps or glands instead.

• Ensure good electrical contact between the mounting plate and the metal chassis of the frequency converter.

• Use starwashers and galvanically conductive installation plates to secure good elec connections for IP 20 installations.

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

ts housing the

cies. Use

trical

requirements are not complied with, although the immunity requirements are fulfilled. See the section EMC test results for further details.

Installation

isted

The illustration shows an example of an EMC-correct electrical installation of an IP 20 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

MG.70.A1.02 - VLT is a registered Danfoss trademark

VLT® 7000 Booster

MG.70.A1.02 - VLT is a registered Danfoss trademark

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