MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT® AutomationDrive FC 302 Low Harmonic Drive
132–630 kW
www.danfoss.com/drives
Contents Instruction Manual
Contents
1 Safety
1.1 Safety
2 Introduction
2.1 Exploded View Drawings
2.2 Purpose of the Manual
2.3 Approvals
2.4 Additional Resources
2.5 Product Overview
2.6 Internal Equipment Functions
2.6.1 Working Principle 15
2.6.2 IEEE519 Compliance 15
3 Installation
3.1 Installation Site Checklist
3.1.1 Planning the Installation Site 16
3.2 Equipment Pre-Installation Checklist
3.3 Mechanical Installation
5
5
6
6
14
14
14
14
15
16
16
16
16
3.3.1 Cooling and Airflow 16
3.3.2 Lifting 18
3.3.3 Terminal Locations - Frame Size D13 20
3.3.4 Terminal Locations - Frame Size E9 21
3.3.5 Terminal Locations - Frame Size F18 22
3.3.6 Torque 25
3.4 Electrical Installation
3.4.1 Power Connections 25
3.4.2 Grounding 26
3.4.3 Extra Protection (RCD) 26
3.4.4 RFI Switch 27
3.4.5 Shielded Cables 27
3.4.6 Motor Cable 27
3.4.7 Brake Cable 28
3.4.8 Brake Resistor Temperature Switch 28
3.4.9 AC line input connections 28
3.4.10 External Fan Supply 28
25
3.4.11 Power and Control Wiring for Non-shielded Cables 29
3.4.12 Line Power Disconnects 30
3.4.13 F-Frame Circuit Breakers 30
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved.
Contents Instruction Manual
3.4.14 F-Frame Line Power Contactors 30
3.4.15 Motor Insulation 30
3.4.16 Motor Bearing Currents 31
3.4.17 Control Cable Routing 31
3.4.18 Access to Control Terminals 32
3.4.19 Electrical Installation, Control Terminals 33
3.4.20 Electrical Installation, Control Cables 34
3.4.21 Safe Torque Off (STO) 35
3.4.22 Switches S201, S202, and S801 36
3.4.23 Serial Communication 36
3.5 Final Set-up and Test
3.6 Additional Connections
3.6.1 Mechanical Brake Control 38
3.6.2 Parallel Connection of Motors 38
3.6.3 Motor Thermal Protection 39
4 Start-up and Functional Testing
4.1 Pre-start
4.2 Applying Power to the Equipment
4.3 Basic Operational Programming
4.4 Local Control Test
4.5 System Start-up
5 User Interface
5.1 How to Operate
5.1.1 Modes of Operation 44
5.1.2 How to Operate the Graphical LCP (GLCP) 44
5.1.3 Changing Data 48
36
38
40
40
41
41
42
43
44
44
5.1.4 Changing a Text Value 48
5.1.5 Changing a Group of Numeric Data Values 48
5.1.6 Changing Data Values, Step-by-Step 49
5.1.7 Readout and Programming of Indexed Parameters 49
5.1.8 Quick Transfer of Parameter Settings when Using GLCP 49
5.1.9 Initialization to Default Settings 49
5.1.10 RS-485 Bus Connection 50
5.1.11 How to Connect a PC to the Adjustable Frequency Drive 50
5.1.12 PC Software Tools 51
6 Programming
52
Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
Contents Instruction Manual
6.1 How to Program the Adjustable Frequency Drive
6.1.1 Quick Set-up Parameters 52
6.1.2 Basic Set-up Parameters 55
6.2 How to Program the Active Filter
6.2.1 Using the Low Harmonic Drive in NPN Mode 77
6.3 Parameter Lists - Adjustable Frequency Drive
6.3.1 Parameter Selection 78
6.4 Parameter Lists - Active Filter
7 Application Examples
7.1 Introduction
7.2 Application Examples
7.3 Connection Examples for Control of Motor with External Signal Provider
7.3.1 Start/Stop 124
7.3.2 Pulse Start/Stop 124
7.3.3 Speed Up/Down 125
7.3.4 Potentiometer Reference 125
52
77
78
110
119
119
119
124
8 Status Messages
8.1 Status Display
8.2 Status Message Definitions
9 Warnings and Alarms
9.1 System Monitoring
9.2 Warning and Alarm Types
9.2.1 Warnings 129
9.2.2 Alarm Trip 129
9.2.3 Alarm Trip Lock 129
9.3 Warning and Alarm Displays
9.4 Warnings and Alarm Definitions - Adjustable Frequency Drive
9.5 Warning and Alarm Definitions - Filter (Left LCP)
10 Basic Start-up Troubleshooting
11 Specifications
11.1 Power-Dependent Specifications
126
126
126
129
129
129
129
130
139
146
149
149
11.1.1 Line Power Supply 3x380–480 V AC 149
11.1.2 Derating for Temperature 152
11.2 Mechanical Dimensions
11.3 General Technical Data - Adjustable Frequency Drive
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved.
153
156
Contents Instruction Manual
11.4 General Technical Data - Filter
11.4.1 Power Rating 161
11.4.2 Derating for Altitude 164
11.5 Fuses
11.5.1 Non- UL compliance 164
11.5.2 Fuse Tables 165
11.5.3 Supplementary Fuses - High Power 166
11.6 General Torque Tightening Values
Index
160
164
167
168
Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
Safety Instruction Manual
1 Safety
1
1
1.1 Safety
WARNING
HIGH VOLTAGE
Adjustable frequency drives contain high voltage when
connected to AC line input power. Qualified personnel
only should perform installation, start-up, and
maintenance. Failure to have qualified personnel
perform installation, start-up, and maintenance could
result in death or serious injury.
WARNING
UNINTENDED START
When the adjustable frequency drive is connected to AC
line power, the motor may start at any time. The
adjustable frequency drive, motor, and any driven
equipment must be in operational readiness. Failure to
be in operational readiness when the adjustable
frequency drive is connected to AC line power could
result in death, serious injury, equipment, or property
damage.
WARNING
DISCHARGE TIME
Adjustable frequency drives contain DC link capacitors
that can remain charged even when the adjustable
frequency drive is not powered. To avoid electrical
hazards, disconnect AC line power, any permanent
magnet type motors, and any remote DC link power
supplies, including battery backups, UPS and DC link
connections to other adjustable frequency drives. Wait
for the capacitors to fully discharge before performing
any service or repair work. The wait time required is
listed in the Discharge Time table. Failure to wait the
specified time after power has been removed before
doing service or repair could result in death or serious
injury.
Voltage
[V]
380–500
Table 1.1 Discharge Times
*Power ranges are for normal overload operation.
Power range
(hp [kW])
175–350 [132–250 kW]* 20
425–850 [315–630 kW] 40
Minimum waiting time
(min)
Table 1.2 Approvals
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 5
130BX167.10
1
19
13
12
25
5
4
22
21
20
18
17
3
16
15
14
11
24
2
10
9
8
7
6
23
Introduction
Instruction Manual
22
2 Introduction
2.1 Exploded View Drawings
1 Control card 14 SCR/diode module
2 Control input terminals 15 IGBT output bus bar
3 Local control panel (LCP) 16 Output motor terminals
4 Control card C option 17 Current sensor
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Fan transformer
7 Power card 20 AC input terminals
8 Capacitor bank assembly 21 AC input bus bar
9 Soft-charge fuses 22 Input terminal mounting plate assembly
10 Soft-charge card 23 Fan fuse
11 DC inductor 24 Capacitor bank cover plate
12 Soft charge module 25 IGBT gate drive card
13 IGBT module
Figure 2.1 Frame Size D13 Drive Enclosure
6 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
130BD571.11
1
6
7
8
9
11
13
15
16
20
21
22
2
3
4
5
10
12
14
18
19
17
Introduction
Instruction Manual
2 2
1 Local control panel (LCP) 13 Electrical fuses
2 Active filter card (AFC) 14 Line power disconnect
3 Metal oxide varistor (MOV) 15 Line Power Terminals
4 Soft-charge resistors 16 Heatsink fan
5 AC capacitors discharge board 17 DC capacitor bank
6 Line power contactor 18 Current transformer
7 LC inductor 19 RFI differential mode filter
8 AC capacitors 20 RFI common mode filter
9 Line power bus bars to drive input 21 HI inductor
10 IGBT fuses 22 Power card
11 RFI
Figure 2.2 Frame Size D13 Filter Enclosure
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 7
1
3
2
7
5
4
10
9
8
25
24
6
130BX168.10
20
19
18
17
16
15
14
13
12
11
23
22
21
Introduction
Instruction Manual
22
1 Control card 14 SCR and diode
2 Control input terminals 15 Fan inductor (not on all units)
3 Local control panel (LCP) 16 Soft-charge resistor assembly
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly
6 Power card mounting plate 19 Output motor terminals
7 Power card 20 Current sensor
8 IGBT gate drive card 21 Main AC power input terminals
9 Upper capacitor bank assembly 22 Input terminal mounting plate
10 Soft-charge fuses 23 AC input bus bar
11 DC inductor 24 Soft-charge card
12 Fan transformer 25 Lower capacitor bank assembly
13 IGBT module
Figure 2.3 Frame Size E9 Drive Enclosure
8 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
130BD572.11
1
5
6
7
9
10
11
12
14
16
17
18
19
20
21
2
3
4
8
13
15
Introduction
Instruction Manual
2 2
1 Local control panel (LCP) 12 AC capacitor current transducers
2 Active filter card (AFC) 13 Heatsink fan
3 Line power contactors 14 Line power terminals
4 Soft-charge resistors 15 Line power disconnect
5 RFI differential mode filter 16 Electrical fuses
6 RFI common mode filter 17 LC inductor
7 Current transformer (CT) 18 HI inductor
8 Line power bus bars to drive output 19 Power card
9 AC capacitors 20 Control card
10 RFI 21 LCP cradle
11 Lower DC capacitor bank
Figure 2.4 Frame Size E9 Filter Enclosure
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 9
1
2
3
4
5
130BX334.11
Introduction Instruction Manual
22
1 Contactor 4 Circuit breaker or disconnect (if purchased)
2 RFI filter 5 AC line power/line fuses (if purchased)
3 Line power AC power input terminals
Figure 2.5 Frame Size F18 Options Cabinet
*The options cabinet is not optional for the LHD. The ancillary equipment is stored in the cabinet.
10 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
130BD573.10
1
2
5
6
7
10
11
15
17
3
4
8
9
13
14
16
18
12
Introduction
Instruction Manual
2 2
1 Local control panel (LCP) 10 Line power bus bars to drive input
2 Active filter card (AFC) 11 Heatsink fans
3 Soft-charge resistors 12 Line power terminals (R/L1, S/L2, T/L3) from options cabinet
4 Metal oxide varistor (MOV) 13 RFI differential mode filter
5 AC capacitors discharge board 14 RFI common mode filter
6 LC inductor 15 Line power contactor
7 HI inductor 16 Power card
8 Mixing fan 17 Control card
9 IGBT fuses 18 LCP cradle
Figure 2.6 Frame Size F18 Filter Cabinet
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 11
1
2
5
6
7
8
9
10
11
12
4
3
130BX331.11
Introduction Instruction Manual
22
1 Rectifier module 7 Module lifting eye bolts (mounted on a vertical strut)
2 DC bus bar 8 Module heatsink fan
3 SMPS fuse 9 Fan door cover
4 (Optional) back AC fuse mounting bracket 10 SMPS fuse
5 (Optional) middle AC fuse mounting bracket 11 Power card
6 (Optional) front AC fuse mounting bracket 12 Panel connectors
Figure 2.7 Frame Size F18 Rectifier Cabinet
12 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
2
1
16
15
14
13
12
11
10
8
7
6
5
4
9
3
130BX330.10
Introduction
Instruction Manual
2 2
1 Fan transformer 9 Fan door cover
2 DC link inductor 10 Module heatsink fan
3 Top cover plate 11 Inverter module
4 MDCIC board 12 Panel connectors
5 Control card 13 DC fuse
6 SMPS fuse and fan fuse 14 Mounting bracket
7 Motor output bus bar 15 (+) DC bus bar
8 Brake output bus bar 16 (-) DC bus bar
Figure 2.8 Frame Size F18 Inverter Cabinet
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 13
Introduction
2.2 Purpose of the Manual
22
The purpose of this manual is to provide information for
the installation and operation of a VLT® Low Harmonic
Drive. The manual includes relevant safety information for
installation and operation. chapter 1 Safety and
chapter 2 Introduction introduce the unit function and
cover proper mechanical and electrical installation
procedures. There are chapters on start-up and commissioning, applications and basic troubleshooting.
chapter 11 Specifications provides a quick reference for
ratings and dimensions, as well as other operating specifications. This manual provides a basic knowledge of the
unit and explains set-up and basic operation.
2.3 Approvals
Table 2.1 Compliance Marks: CE, UL, and C-Tick
The adjustable frequency drive complies with UL508C
thermal memory retention requirements. For more
information, refer to chapter 3.6.3 Motor Thermal
Protection.
2.4
Additional Resources
Other resources are available to understand advanced
functions and programming.
Instruction Manual
Optional equipment may change some of the
•
procedures described. Reference the instructions
supplied with those options for specific
requirements. Contact the local Danfoss supplier
or visit the Danfoss website: www.danfoss.com/
BusinessAreas/DrivesSolutions/Documentations/
Technical+Documentation.htmfor downloads or
additional information.
The VLT® Active Filter AAF00x Instruction Manual
•
provides additional information about the filter
portion of the low harmonic drive.
2.5 Product Overview
An adjustable frequency drive (also called a drive) is an
electronic motor controller that converts DC into a variable
AC waveform output. The frequency and voltage of the
output are regulated to control the motor speed or torque.
The adjustable frequency drive can vary the speed of the
motor in response to system feedback, such as with
position sensors on a conveyor belt. The adjustable
frequency drive can also regulate the motor by responding
to remote commands from external controllers.
The adjustable frequency drive
monitors the system and motor status
•
issues warnings or alarms for fault conditions
•
starts and stops the motor
•
optimizes energy efficiency
•
Operation and monitoring functions are available as status
indications to an outside control system or serial communication network.
The VLT® AutomationDrive FC 302 Instruction
•
Manual provides details on installation and
operation of the adjustable frequency drive.
The VLT® AutomationDrive FC 302 Programming
•
Guide provides greater detail on working with
parameters and many application examples.
The VLT® AutomationDrive FC 302 Design Guide
•
provides detailed capabilities and functionality to
design motor control systems.
Supplementary publications and manuals are
•
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/Technical
+Documentation.htm for listings.
14 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
A Low Harmonic Drive (LHD) is a single unit that combines
the adjustable frequency drive with an advanced active
filter (AAF) for harmonic mitigation. The adjustable
frequency drive and filter are two separate pieces
packaged together in an integrated system, but each
functions independently. In this manual, there are separate
specifications for the adjustable frequency drive and the
filter. Since the adjustable frequency drive and filter are
together in the same enclosure, the unit is transported,
installed, and operated as a single entity.
Mains
380 to
500 VAC
Optional
RFI
Optional
Fuses
Optional
Manual
Disconnect
HI Reactor
L
m
L
m
L
m
L
ac
L
ac
L
ac
AC
Contactor
Relay 12
Control & AUX
Feedback
Relay 12
Control & AUX
Feedback
Soft-Charge
Converter
Side Filter
Power Stage
AF Current
Sensors
Capacitor
Current Sensors
Frequency converter
Main’s
3
3
3
CTs
NC
Relay
L
c
L
c
L
c
C
efCef
C
ef
R
ef
R
ef
R
ef
I
r
I
s
I
t
130bb406.10
Introduction Instruction Manual
2.6 Internal Equipment Functions
2.6.1 Working Principle
The VLT Low Harmonic Drive is a high-power adjustable frequency drive with an integrated active filter. An active filter is a
device that actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel
the harmonics.
2 2
Figure 2.9 Basic Layout for the Low Harmonic Drive
Low Harmonic Drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor
of 1. Where traditional non-linear load draws pulse-shaped currents, the Low Harmonic Drive compensates this via the
parallel filter path, lowering the stress on the supply grid. The Low Harmonic Drive meets the highest harmonic standards
with a THiD less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid.
IEEE519 Compliance
2.6.2
The Low Harmonic Drive is designed to meet IEEE519 recommendation for Isc/Il >20 for even individual harmonic levels.
The filter has a progressive switching frequency that creates a wide frequency spread, giving lower individual harmonic
levels above the 50th.
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 15
Installation
3 Installation
Instruction Manual
33
3.1 Installation Site Checklist
3.1.1 Planning the Installation Site
Select the best possible operation site by considering
the following (see details on the following pages, and in
the Design Guide):
Ambient operating temperature
•
Installation method
•
Cooling
•
Position of the unit
•
Cable routing
•
Voltage and current supply from power source
•
Current rating within range
•
Fuse ratings if not using built-in fuses
•
3.2 Equipment Pre-Installation Checklist
Before unpacking the adjustable frequency drive,
•
examine the packaging for signs of damage. If
the unit is damaged, refuse delivery and
immediately contact the shipping company to
claim the damage.
Before unpacking the adjustable frequency drive,
•
locate it as close as possible to the final installation site
Compare the model number on the nameplate to
•
what was ordered to verify the proper equipment
Ensure each of the following are rated for the
•
same voltage:
Line power
•
Adjustable frequency drive
•
Motor
•
Ensure the output current rating is equal to or
•
greater than the motor full load current for peak
motor performance.
Motor size and adjustable frequency
•
drive power must match for proper
overload protection.
If adjustable frequency drive rating is
•
less than that of the motor, full motor
output is impossible.
3.3
Mechanical Installation
3.3.1 Cooling and Airflow
Cooling
Cooling can be obtained in different ways, by using the
cooling ducts in the bottom and the top of the unit, by
taking air in and out the back of the unit or by combining
the cooling possibilities.
Back cooling
The backchannel air can also be ventilated in and out the
back of a Rittal TS8 enclosure for frame size F18 LHD. This
offers a solution where the backchannel could take air
from outside the facility and return the heat losses outside
the facility thus reducing air-conditioning requirements.
NOTICE!
A door fan is required on the enclosure to remove the
heat losses not contained in the backchannel of the
drive and any additional losses generated from other
components installed inside the enclosure. The total
required air flow must be calculated so that the
appropriate fans can be selected. Some enclosure
manufacturers offer software for performing the
calculations (i.e., Rittal Therm software).
16 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
90
80
70
60
50
40
30
20
10
0
0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147
(%)
(Pa)
Pressure Increase
Drive Derating
130BB007.10
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0 0.1 3.6 9.8 21.5 43.4 76 237.5 278.9
(Pa)
Pressure Change
130BB010.10
147.1
Installation Instruction Manual
Airflow
The necessary airflow over the heatsink must be ensured. The flow rate is shown in Table 3.1.
Enclosure protection Frame size
D13
(LHD120)
Door fan/top fan airflow
Total airflow of multiple fans
3 door fans, 510 m3/h (300 cfm)
(2+1, 3x170=510)
Heatsink fan
Total airflow for multiple fans
2 heatsink fans, 1530 m3/h
(900 cfm)
(1+1, 2x765=1530)
IP21/NEMA 1
IP54/NEMA 12
E9 P315-P400
(LHD210)
F18
(LHD330)
4 door fans, 680 m3/h (400 cfm)
(2+2, 4x170=680)
6 door fans, 3150 m3/h
(1854 cfm)
(6x525=3150)
2 heatsink fans, 2675 m3/h
(1574 cfm)
(1+1, 1230+1445=2675)
5 heatsink fans, 4485 m3/h
(2639 cfm)
2+1+2, ((2x765)+(3x985)=4485)
Table 3.1 Heatsink Air Flow
External ducts
If additional duct work is added externally to the Rittal cabinet, the pressure drop in the ducting must be calculated. Use
the charts below to derate the adjustable frequency drive according to the pressure drop.
3 3
Figure 3.1 D-Frame Derating vs. Pressure Change
Drive Air Flow: 450 cfm (765 m3/h)
Figure 3.2 E-Frame Derating vs. Pressure Change (Small Fan), P315
Drive Air Flow: 650 cfm (1105 m3/h)
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 17
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 152.8 210.8
(Pa)
Pressure Change
130BB011.10
69.5
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 25 50 75 100 125 150 175 225
130BB190.10
200
Pressure Change
Lifting Holes
130BC166.10
130BC170.10
Lifting Holes
Installation Instruction Manual
Lifting
3.3.2
Lift the adjustable frequency drive using the dedicated
lifting eyes. For all D-frames, use a bar to avoid bending
33
Figure 3.3 E-Frame Derating vs. Pressure Change (Large Fan)
P355-P450
Drive Air Flow: 850 cfm (1445 m3/h)
the lifting holes of the adjustable frequency drive.
Figure 3.5 Recommended Lifting Method, Frame Size D13
Figure 3.4 F-Frame Derating vs. Pressure Change
Drive Air Flow: 580 cfm (985 m3/h)
18 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
Figure 3.6 Recommended Lifting Method, Frame Size E9
WARNING
The lifting bar must be able to handle the weight of the
adjustable frequency drive. See chapter 11.2.1 Mechanical
Dimensions for the weight of the different frame sizes.
Maximum diameter for bar is 1 in [2.5 cm]. The angle
from the top of the adjustable frequency drive to the
lifting cable should be 60° or greater.
1
2
130BD574.10
Installation Instruction Manual
1 Lifting holes for the filter
2 Lifting holes for the adjustable frequency drive
Figure 3.7 Recommended Lifting Method, Frame Size F18
3 3
NOTICE!
A spreader bar is also an acceptable way to lift the Fframe.
NOTICE!
The F18 pedestal is packaged separately and included in
the shipment. Mount the adjustable frequency drive on
the pedestal in its final location. The pedestal allows
proper airflow and cooling.
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 19
267.4
[10.5]
476.0
[18.7]
29.0
[1.1]
MAINS INPUT TERMINALS
268.1
[10.6]
88.0
[3.5]
204.0
[8.0]
259.7
[10.2]
796.3
[31.3]
83.5
[3.3]
167.0
[6.6]
.8
[.0]
120.2
[4.7]
MOTOR
OUTPUT TERMINALS
130BC603.10
Installation Instruction Manual
3.3.3 Terminal Locations - Frame Size D13
33
Figure 3.8 Frame Size D13 Terminal Locations
Allow for bend radius of heavy power cables.
NOTICE!
All D-frames are available with standard input terminals, fuse, or disconnect switch
20 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
130BC604.10
383
[15.1]
518.0
[20.4]
90.0
[3.5]
153.8
[6.1]
517.5
[20.4]
225.0
[8.9]
112.5
[4]
900.0
[35.4]
368.3
[14.5]
323.3
[12.7]
180.0
[7.1]
90.0
[3.5]
168.7
[6.6]
MAINS
INPUT TERMINAL
MOTOR
OUTPUT TERMINAL
Installation Instruction Manual
3.3.4 Terminal Locations - Frame Size E9
3 3
Figure 3.9 Frame Size E9 Terminal Locations
Allow for bend radius of heavy power cables.
NOTICE!
All E-frames are available with standard input terminals, fuse, or disconnect switch
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 21
1 2 3
4
0.0[0.00]
76.4[3.01]
128.4[5.05]
119.0[4.69]
171.0[6.73]
294.6[11.60]
344.0[13.54]
3639[14.33]
438.9[17.28]
75.3[2.96]
150.3[5.92]
154.0[6.06]
219.6[18.65]
0.0[0.00]
244.4[9.62]
244.4[1.75]
939.0[36.97]
1031.4[40.61]
0.0[0.00]
134.6[5.30]
130BA851.12
0.0[1.75]
Installation
Instruction Manual
3.3.5 Terminal Locations - Frame Size F18
Take the position of the terminals into consideration when designing the cable access.
33
F-frame units have four interlocked cabinets:
1. Input options cabinet (not optional for LHD)
2. Filter cabinet
3. Rectifier cabinet
4. Inverter cabinet
See chapter 2.1 Exploded View Drawings for exploded views of each cabinet. Line power inputs are located in the input
option cabinet, which conducts power to the rectifier via interconnecting bus bars. Output from the unit is from the inverter
cabinet. No connection terminals are located in the rectifier cabinet. Interconnecting bus bars are not shown.
1 Right side cutaway 3 Left side cutaway
2 Front view 4 Ground bar
Figure 3.10 Frame Size F18 Input Option Cabinet - Fuses Only
The connector plate is 1.65 in [42 mm] below .0 level. Shown are the left side view, front, and right.
22 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
0.0 [0.00]
134.6 [5.30]
104.3 [4.11]
0.0 [0.00]
179.3 [7.06]
219.6 [8.65]
294.6 [11.60]
334.8 [13.18]
409.8 [16.14]
436.9 [17.20]
0.0 [0.00]
532.9 [20.98]
0.0 [0.00]
44.4 [1.75]
244.4 [9.62]
154.0 [6.06]
344.0 [13.54]
1
234
5
130BA852.11
Installation Instruction Manual
3 3
450 kW 500–630 kW
1 Ground Bar
2 34.9 [1.4] 46.3 [1.8]
3 86.9 [3.4] 98.3 [3.9]
4 122.2 [4.8] 119 [4.7]
5 174.2 [6.9] 171 [6.7]
Figure 3.11 Frame Size F18 Input Option Cabinet with Circuit Breaker
The connector plate is 1.65 in [42 mm] below .0 level. Shown are the left side view, front, and right.
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 23
130BA849.13
.0 [.0]
54.4[2.1]
169.4 [6.7]
284.4 [11.2]
407.3 [16.0]
522.3 [20.6]
637.3 [25.1]
287.4 [11.3]
253.1 [10.0]
.0 [.0]
.0 [.0]
339.4 [13.4]
287.4 [11.3]
.0 [.0]
339.4 [13.4]
308.3 [12.1]
465.6 [18.3]
465.6 [18.3]
198.1[7.8]
234.1 [9.2]
282.1 [11.1]
318.1 [12.5]
551.0 [21.7]
587.0 [23.1]
635.0 [25.0]
671.0 [26.4]
44.40 [1.75]
244.40 [9.62]
204.1 [8.0]
497.1 [19.6]
572.1 [22.5]
180.3 [7.1]
129.1 [5.1]
4
6
4
1
2
3
5
Installation Instruction Manual
33
1 Front View 4 Brake Terminals
2 Left Side View 5 Ground bar
3 Right Side View
Figure 3.12 Frame Size F18 Inverter Cabinet
The connector plate is 1.65 in [42 mm] below .0 level. Shown are the left side view, front, and right.
24 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
176FA247.12
Nm/in-lbs
-DC 88
+DC 89
R/L1 91
S/L2 92
T/L3 93
U/T1 96
V/T2 97
W/T3
Installation
Instruction Manual
3.3.6 Torque
Correct torque is imperative for all electrical connections.
Incorrect torque results in a bad electrical connection. Use
a torque wrench to ensure correct torque.
3.4
Electrical Installation
3.4.1 Power Connections
NOTICE!
Cables–General Information
All cabling must comply with national and local
regulations on cable cross-sections and ambient
temperature. UL applications require 167°F [75°C] copper
conductors. For non-UL applications, 167°F and 194°F
[75° and 90°C] copper conductors are thermally
acceptable.
The power cable connections are situated as shown in
Figure 3.14. Dimension cable cross-section in accordance
with the current ratings and local legislation. See
chapter 11.3.1 Cable lengths and cross-sections for details.
To protect the adjustable frequency drive, use the
recommended fuses if there are no built-in fuses. Fuse
recommendations are provided in chapter 11.5 Fuses.
Ensure that proper fusing is made according to local
regulation.
3 3
Figure 3.13 Use a Torque Wrench to Tighten the Bolts
Frame size Terminal Torque Bolt size
Line power
Motor
D
Load sharing
Brake
Line power
Motor
Load sharing
E
Brake
Line power
Motor
Load sharing
F
Brake
Regen
Table 3.2 Torque for terminals
19–40 Nm
(168–354 in-lbs)
8.5–20.5 Nm
(75–181 in-lbs)
19–40 Nm
(168–354 in-lbs)
8.5–20.5 Nm
(75–181 in-lbs)
19–40 Nm
(168–354 in-lbs)
19–40 Nm
(168–354 in-lbs)
8.5–20.5 Nm
(75–181 in-lbs)
8.5–20.5 Nm
(75–181 in-lbs)
M10
M8
M10
M8
M10
M10
M8
M8
The AC line input connection is fitted to the line power
switch if included.
Figure 3.14 Power Cable Connections
NOTICE!
To comply with EMC emission specifications, shielded/
armored cables are recommended. If a non-shielded/
armored cable is used, see chapter 3.4.11 Power and
Control Wiring for Non-shielded Cables.
See chapter 11 Specifications for correct dimensioning of
motor cable cross-section and length.
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 25
U
1
V
1
W
1
175ZA114.11
96 97 98
96 97 98
FC
FC
Motor
Motor
U
2
V
2
W
2
U
1
V
1
W
1
U
2
V
2
W
2
Installation Instruction Manual
Shielding of cables
3.4.2
Grounding
Avoid installation with twisted shield ends (pigtails). They
spoil the shielding effect at higher frequencies. If breaking
the shield is necessary to install a motor isolator or
33
contactor, continue the shield at the lowest possible HF
impedance.
Connect the motor cable shield to both the decoupling
plate of the adjustable frequency drive and to the metal
housing of the motor.
Make the shield connections with the largest possible
surface area (cable clamp). Use the installation devices
within the adjustable frequency drive.
Cable length and cross-section
The adjustable frequency drive has been EMC tested with
a given length of cable. Keep the motor cable as short as
possible to reduce the noise level and leakage currents.
Switching frequency
When adjustable frequency drives are used together with
sine-wave filters to reduce the acoustic noise from a
motor, the switching frequency must be set according to
14-01 Switching Frequency.
Term.
96 97 98 99
no.
Motor voltage 0–100% of AC line
U V W
U1 V1 W1
W2 U2 V2 6 wires out of motor
U1 V1 W1
1)
voltage.
PE
3 wires out of motor
Delta-connected
1)
PE
Star-connected U2, V2, W2
1)
U2, V2, and W2 to be interconnected
PE
separately.
Note the following basic issues for electromagnetic
compatibility (EMC) during installation:
Safety grounding: The adjustable frequency drive
•
has a high leakage current and must be
grounded appropriately for safety reasons. Always
follow local safety regulations.
High-frequency grounding: Keep the ground wire
•
connections as short as possible.
Connect the different ground systems at the lowest
possible conductor impedance. Keep the conductor as
short as possible and use the greatest possible surface area
for the lowest possible conductor impedance.
The metal cabinets of the different devices are mounted
on the cabinet rear plate using the lowest possible HF
impedance. Doing so avoids different HF voltages for
individual devices and the risk of radio interference
currents running in connection cables between the
devices. The radio interference is reduced.
To obtain a low HF impedance, use the fastening bolts of
the devices as HF connection to the rear plate. Remove
insulating paint or similar from the fastening points.
Extra Protection (RCD)
3.4.3
ELCB relays, multiple protective grounding, or standard
grounding provide extra protection, if local safety
regulations are followed.
In the case of a ground fault, a DC component develops in
the fault current.
1)
26 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
Table 3.3 Terminal Connections
Protected Ground Connection
Figure 3.15 Y and Delta Terminal Configurations
If using ELCB relays, observe local regulations. Relays must
be suitable for protection of 3-phase equipment with a
bridge rectifier and for a brief discharge on power-up.
175HA036.11
U
1
V
1
W
1
96 97 98
FC
Motor
U
2
V
2
W
2
U
1
V
1
W
1
96 97 98
FC
Motor
U
2
V
2
W
2
Installation
Instruction Manual
3.4.4 RFI Switch
Line power supply isolated from ground
If the adjustable frequency drive is supplied from an
isolated line power source or TT/TN-S line power with
grounded leg, turn off the RFI switch via 14-50 RFI 1 on
both adjustable frequency drive and the filter. For further
reference, see IEC 364-3. When optimum EMC performance
is needed, parallel motors are connected, or the motor
cable length is above 82 ft [25 m], set 14-50 RFI 1 to [ON].
In OFF, the internal RFI capacitors (filter capacitors)
between the chassis and the intermediate circuit are cut
off to avoid damage to the intermediate circuit and reduce
ground capacity currents (IEC 61800-3).
Refer to the application note VLT on IT line power. It is
important to use isolation monitors that work together
with power electronics (IEC 61557-8).
Shielded Cables
3.4.5
It is important to connect shielded cables properly to
ensure high EMC immunity and low emissions.
Connection can be made using either cable connectors
or clamps:
EMC cable connectors: generally available cable
•
connectors can be used to ensure an optimum
EMC connection.
EMC cable clamp: Clamps allowing easy
•
connection are supplied with the unit.
The direction of rotation can be changed by switching two
phases in the motor cable or by changing the setting of
4-10 Motor Speed Direction.
Motor rotation check can be performed via 1-28 Motor
Rotation Check and following the steps shown in the
display.
Figure 3.16 Motor Rotation Check
3 3
3.4.6
Connect the motor to terminals U/T1/96, V/T2/97, W/T3/98,
on the far right of the unit. Ground to terminal 99. All
types of 3-phase asynchronous standard motors can be
used with an adjustable frequency drive. The factory
setting is for clockwise rotation with the adjustable
frequency drive output connected as follows:
Terminal No. Function
96, 97, 98, 99 Line power U/T1, V/T2, W/T3
Motor Cable
Ground
Table 3.4 Terminal Functions
Terminal U/T1/96 connected to U-phase
•
Terminal V/T2/97 connected to V-phase
•
Terminal W/T3/98 connected to W-phase
•
F-frame requirements
Use motor phase cables in quantities of 2, resulting in 2, 4,
6, or 8 to obtain an equal number of wires on both
inverter module terminals. The cables are required to be
equal length within 10% between the inverter module
terminals and the first common point of a phase. The
recommended common point is the motor terminals.
Output junction box requirements
The length, a minimum of 8 ft [2.5 m], and quantity of
cables must be equal from each inverter module to the
common terminal in the junction box.
MG37A222 Danfoss A/S © Rev. 2014-02-07 All rights reserved. 27
175ZA877.10
106
NC
104
C
105
NO
Installation
Instruction Manual
3.4.7 Brake Cable
Adjustable frequency drives with factory installed brake
chopper option
33
(Only standard with letter B in position 18 of type code).
The connection cable to the brake resistor must be
shielded and the max. length from adjustable frequency
drive to the DC bar is limited to 82 ft [25 m].
Terminal No. Function
81, 82 Brake resistor terminals
Table 3.5 Terminal Functions
The connection cable to the brake resistor must be
shielded. Connect the shield with cable clamps to the
conductive backplate of the adjustable frequency drive and
the metal cabinet of the brake resistor.
Size the brake cable cross-section to match the brake
torque. See also Brake Instructions for further information
regarding safe installation.
CAUTION
If the temperature of the brake resistor is too high and
the thermal switch drops out, the adjustable frequency
drive stops braking. The motor coasts.
Figure 3.17 Factory-installed jumper
3.4.9 AC line input connections
Line power must be connected to terminals 91, 92 and 93
on the far left of the unit. Ground is connected to the
terminal on the right of terminal 93.
Terminal No. Function
91, 92, 93
94
Table 3.7 Terminal Functions
Line power R/L1, S/L2, T/L3
Ground
WARNING
Note that voltages up to 790 V DC, depending on the
supply voltage, are possible on the terminals.
F-frame requirements
The brake resistors must be connected to the brake
terminals in each inverter module.
Brake Resistor Temperature Switch
3.4.8
The input for the brake resistor temperature switch can be
used to monitor the temperature of an externally
connected brake resistor. If the connection between 104
and 106 is removed, the adjustable frequency drive trips
on warning/alarm 27, “Brake IGBT.”
Install a Klixon switch that is 'normally closed' in series
with the existing connection on either 106 or 104. Any
connection to this terminal must be double insulated
against high voltage to maintain PELV.
Normally closed: 104–106 (factory installed jumper).
Terminal No. Function
106, 104, 105 Brake resistor temperature switch.
Table 3.6 Terminal Functions
Ensure that the power supply can supply the necessary
current to the adjustable frequency drive.
If the unit is without built-in fuses, ensure that the
appropriate fuses have the correct current rating.
3.4.10
If the adjustable frequency drive is supplied by DC or the
fan must run independently of the power supply, use an
external power supply. Make the connection on the power
card.
Terminal No. Function
100, 101
102, 103
The connector on the power card provides the connection
of line voltage for the cooling fans. The fans are connected
from the factory to be supplied from a common AC line
(jumpers between 100–102 and 101–103). If external
power supply is needed, remove the jumpers and connect
the supply to terminals 100 and 101. Protect with a 5 A. In
UL applications, use a Littelfuse KLK-5 or equivalent.
External Fan Supply
Auxiliary supply S, T
Internal supply S, T
Table 3.8 Terminal Functions
28 Danfoss A/S © Rev. 2014-02-07 All rights reserved. MG37A222
Loading...