Danfoss VLT AutomationVTDrive FC322 Design Manual

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Rev. 2010-05-26

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130R0204 MG20X122

*MG20X122*

MG20X122

VLT

Automation VT Drive FC 322 Design Guide

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT® Automation VT Drive FC 322

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Contents

1 How to Read this Design Guide

Symbols 6

Abbreviations 7

Definitions 7

2 Introduction to VLT Automation VT Drive

CE labelling 17

Vibration and shock 19

Control Structures 24

General aspects of EMC 34

Immunity Requirements 38

Galvanic isolation (PELV) 39

PELV - Protective Extra Low Voltage 39

Earth leakage current 40

Control with Brake Function 41

Control with Brake Function 42

Mechanical Brake Control 42

Extreme Running Conditions 42

Safe Stop Operation (Optional) 47

3 VLT Automation VT Drive Selection

General Specifications 49

Efficiency 65

Special Conditions 72

Options and Accessories 77

General Description 89

High Power Options 95

Installation of Duct Cooling Kit in Rittal Enclosures 95

Outside Installation/ NEMA 3R Kit for Rittal Enclosures 98

Installation on Pedestal 99

Input Plate Option 102

Installation of Mains Shield for Frequency Converters 103

Frame size F Panel Options 104

4 How to Order

107

Ordering Form 107

Type Code String 108

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Ordering Numbers 111

5 How to Install

125

Mechanical Installation 125

Pre-installation 131

Planning the Installation Site 131

Receiving the Frequency Converter

131

Transportation and Unpacking 131

Lifting 132

Cooling and Airflow 136

Electrical Installation 140

Connections - Frame sizes D, E and F 156

Power Connections 156

Disconnectors, Circuit Breakers and Contactors 170

Final Set-Up and Test 171

Safe Stop Installation 173

Safe Stop Commissioning Test 174

Additional Connections 176

Installation of Misc. Connections 179

Safety 181

EMC-correct Installation 182

Residual Current Device 186

6 Application Examples

187

Potentiometer Reference 188

Automatic Motor Adaptation (AMA) 188

SLC Application Example 189

System Status and Operation 192

Cascade Controller Wiring Diagram

193

Fixed Variable Speed Pump Wiring Diagram 194

Lead Pump Alternation Wiring Diagram 194

7 RS-485 Installation and Set-up

197

RS-485 Installation and Set-up 197

FC Protocol Overview 199

Network Configuration 201

FC Protocol Message Framing Structure 201

Examples 209

Modbus RTU Overview 210

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VLT Automation VT Drive with Modbus RTU 210

Modbus RTU Message Framing Structure 211

How to Access Parameters 216

Examples 217

Danfoss FC Control Profile 222

8 Troubleshooting

231

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1 How to Read this Design Guide Automation VT Drive FC322 Design Guide

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1 How to Read this Design Guide

1.1.1 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein

will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication

with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual wil l function properly in every physical,

hardware or software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor

implied, with respect to this documentation, including its quality, per formance, or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use informat ion

contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not

limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute

these, or any claims by third parties.

Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former

or present users of such revisions or changes.

1.1.2

Available Literature for VLT

Automation VT Drive FC322

VLT

Automation VT Drive FC322 Instruction Manual MG.20.Ux.yy provide the neccessary information for getting the drive up and running.

VLT

Automation VT Drive FC322 High Power Instruction Manual MG.20.Vx.yy provide the neccessary information for getting the HP drive up

and running.

VLT

Automation VT Drive FC322 Design Guide MG.20.Xx.yy entails all technica l information about the drive and customer design and appli-

cations.

VLT

Automation VT Drive FC322 Programming Guide MN.20.Wx.yy provides information on how to programme and includes complet e pa-

rameter descriptions.

VLT

Automation VT Drive FC322 Profibus MG.33.Cx.yy

VLT

Automation VT Drive FC322 DeviceNet MG.33.Dx.yy

- Output Filters Design Guide MG.90.Nx.yy

VLT

Automation VT Drive FC322 Cascade Controller MI.38.Cx.yy

- Application Note MN20A102: Submersible Pump Application

- Application Note MN20B102: Master/Follower Operation Application

- Application Note MN20F102: Drive Closed Loop and Sleep Mode

- Instruction MI.38.Bx.yy: Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66

- Instruction MI.90.Lx.yy: Analog I/O Option MCB109

- Instruction MI.33.Hx.yy: Panel through mount kit

x = Revision number

yy = Language code

Danfoss technical literature is also available online at

www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm

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1.1.3 Symbols

Symbols used in this guide.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

* Indicates default setting

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1.1.4 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit I

LIM

Degrees Celsius °C

Direct current DC

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

Drive FC

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Motion Control Tool MCT

Nanofarad nF

Newton Meters Nm

Nominal motor current I

M,N

Nominal motor frequency f

M,N

Nominal motor power P

M,N

Nominal motor voltage U

M,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current I

INV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second s

Synchronous Motor Speed n

Torque limit T

LIM

Volts V

VLT,MAX

The maximum output current

VLT,N

The rated output current supplied by the frequency converter

1.1.5 Definitions

Drive:

VLT,MAX

The maximum output current.

VLT,N

The rated output current supplied by the frequency converter.

VLT, MAX

The maximum output voltage.

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Input:

Control command You can start and stop the connected motor by means of LCP and the digital inputs. Functions are divided into two groups. Functions in group 1 have higher priority than functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-

stop, DC braking, Stop and the "Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing, Jog and

Freeze output

Motor:

JOG

The motor frequency when the jog function is activated (via digital terminals).

The motor frequency.

MAX

The maximum motor frequency.

MIN

The minimum motor frequency.

M,N

The rated motor frequency (nameplate data).

The motor current.

M,N

The rated motor current (nameplate data).

M,N

The rated motor speed (nameplate data).

M,N

The rated motor power (nameplate data).

M,N

The rated torque (motor).

The instantaneous motor voltage.

M,N

The rated motor voltage (nameplate data).

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VLT

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands - see this grou p.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54, can be voltage or current.

Bus Reference

A signal transmitted to the serial communication port (FC port).

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

Ref

MAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum

reference value set in par. 3-03.

Ref

MIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting referen ce. The minimum reference value

set in par. 3-02.

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC.

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative brakin g. This regenerative braking power increases the

intermediate circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for positive displacement pumps and blowers.

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Digital Inputs

The digital inputs can be used for controlling various functions of the frequency converter.

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Digital Outputs

The drive features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Relay Outputs:

The frequency converter drive features two programmable Relay Outputs.

ETR

Electronic Thermal Relay is a thermal load calculat ion based on present load and time. Its purpose is to estimate the motor temperature.

GLCP:

Graphical Local Control Panel (LCP102)

Initialising

If initialising is carried out (par. 14-22), the programmable parameters of the frequency converter return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either

periodic duty or none-periodic duty.

LCP

The Local Control Panel (LCP) makes up a complete interface for control and programming of the frequency converter. The control panel is detachable

and can be installed up to 3 metres from the frequency converter, i.e. in a front panel by means of t he installation kit option.

The Local Control Panel is available in two versions:

- Numerical LCP101 (NLCP)

- Graphical LCP102 (GLCP)

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡ 0.5067 mm

msb

Most significant bit.

NLCP

Numerical Local Control Panel LCP101

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter

[OK] on the LCP.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting th e output frequency to match the varying load.

RCD

Residual Current Device.

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Set-up

You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.

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SFAVM

Switching pattern called

S tator F lux oriented A synchronous V ector M odulation (par. 14-00).

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keep ing the motor

speed almost constant..

Smart Logic Control (SLC)

The SLC is a sequence of user defined actions executed when the associated user defined events are evalua ted as true by the SLC.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency convert er is protecting the

motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in

some cases, by being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is

subject to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the

frequency converter. Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically.

Trip locked may not be used for personal safety.

VT Characteristics

Variable torque characteristics used for pumps and fans.

VVC

plus

If compared with standard voltage/frequency ratio control, Voltage Vector Control (VVC

plus

) improves the dynamics and the stability, both when the speed

reference is changed and in relation to the load torque.

60° AVM

Switching pattern called 60°

A synchronous V ector M odulation (par. 14-00).

1.1.6 Power Factor

The power factor is the relation between I1 and I

RMS

Power factor

3 × U ×

1 ×

COS

3 × U ×

RMS

The power factor for 3-phase control:

cos

ϕ1

RMS

since cos

ϕ1=1

The power factor indicates to which extent the frequency converter im-

poses a load on the mains supply.

The lower the power factor, the higher the I

RMS

for the same kW per-

formance.

RMS

+ . . +

In addition, a high power factor indicates that the different harmonic currents are low.

The frequency converters' built-in DC coils produce a high power factor, which minimi zes the imposed load on the mains supply.

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2 Introduction to VLT Automation VT Drive

2.1 Safety

2.1.1 Safety Note

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect inst allation of the motor, frequency

converter or fieldbus 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 r egulations, 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 su pply has been disconnected and

that the necessary time has passed before removing motor and mains plugs.

2. The [STOP/RESET] key on the control panel of the frequency converter does not disconnect the equipment from mains and is thus not to be used as

a safety switch.

3. Correct protective earthing of the equipment must be established, the user must be prot ected against supply voltage, and the motor must be protected

against overload in accordance with applicable national and local regulat ions.

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

5. Protection against motor overload is set by par. 1-90

Motor Thermal Protection

. If this function is desired, set par. 1-90 to data value [ETR trip] (default

value) or data value [ETR warning]. Note: The function is initialised at 1.16 x rated motor current and rated motor frequency. For the North American

market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been

disconnected and that the necessary time has passed before removing motor and mains plugs.

7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, whe n load sharing (linking of DC intermediate circuit) and external

24 V DC have been installed. Check that all voltage inputs have been disconnected and t hat the necessary time has passed before commencing repair

work.

Installation at High Altitudes

By altitudes above 2 km, please contact Danfoss regarding PELV.

Warning against Unintended Start

1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the frequen cy converter is

connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.

2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] mus t always be a ctivated; following which data

can be modified. 3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or

a fault in the supply mains or the motor connection ceases.

Warning:

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

Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as

the motor connection for kinetic back up.

Refer to

VLT® Automation VT Drive FC322 Instruction Manual MG.20.UX.YY

for further safety guidelines.

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2.1.2 Caution

The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,

disconnect the frequency converter from the mains before carrying out mainten ance. Wait at least as follows before doing service on

the frequency converter:

Voltage (V) Min. Waiting Time (Minutes)

4 15 20 30 40

200 - 240 0.25 - 3.7 kW 5.5 - 45 kW

380 - 480 0.37 - 7.5 kW 11 - 90 kW 110 - 250 kW 315 - 1000 kW

525-600 0.75 kW - 7.5 kW 11 - 90 kW 315 - 1200 kW

525-690 11 - 90 kW 45 - 400 kW 450 - 1200 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned of f.

2.1.3 Disposal Instruction

Equipment containing electrical components may not be disposed of together with domestic

waste.

It must be separately collected with electrical and electronic waste according to local and cur-

rently valid legislation.

2.2 Software Version

2.2.1 Software Version and Approvals

VLT Automation VT Drive FC322

Software version: 1.7x

This manual can be used with all VLT Automation VT Drive FC322 frequency converters with software version 1.7x.

The software version number can be found in parameter 15-43.

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2.3 CE labelling

2.3.1 CE Conformity and Labelling

What is CE Conformity and Labelling?

The purpose of CE labelling is to avoid technical trade obstacles within EFTA and the EU. The EU has introduced the CE label as a simple way of showing

whether a product complies with the relevant EU directives. The CE label says nothing about the specifications or quality of the product. Frequency

converters are regulated by three EU directives:

The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by the machinery directive of January 1, 1995. Since a frequency converter is largely electrical, it does

not fall under the machinery directive. However, if a frequency converter is supplied for use in a machine, we provide information on safety aspects

relating to the frequency converter. We do this by means of a manufacturer's declaration.

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

Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment

and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. Danfoss CE-labels in accordance with the directive and issues a

declaration of conformity upon request.

The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibility means that the mutual interference between different

components/appliances does not affect the way the appliances work.

The EMC directive came into effect January 1, 1996. Danfoss CE-labels in accordance with the directive and issues a declaration of conformity upon

request. To carry out EMC-correct installation, see the instructions in this Design Guide. In addition, we specify which standards our products comply

with. We offer the filters presented in the specifications and provide other types of assistance to ensure the optimum EMC result.

The frequency converter is most often used by professionals of the trade as a complex component forming part of a larger appliance, system or in stallation.

It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer.

2.3.2 What Is Covered

The EU "

Guidelines on the Application of Council Directive 89/336/EEC

" outline three typical situations of using a frequency converter. See below for EMC

coverage and CE labelling.

1. The frequency converter is sold directly to the end-consumer. The frequency converter is for example sold to a DIY market. The end-consumer

is a layman. He installs the frequency converter himself for use with a hobby machine, a kitchen appliance, etc. For such applications, the

frequency converter must be CE labelled in accordance with the EMC directive.

2. The frequency converter is sold for installation in a plant. The plant is built up by professionals of the trade. It could be a production plant or a

heating/ventilation plant designed and installed by professionals of the trade. Neither the frequency converter nor the finished plant has to be

CE labelled under the EMC directive. However, the unit must comply with the basic EMC requirements of the directive. This is ensured by using

components, appliances, and systems that are CE labelled under the EMC dir ective.

3. The frequency converter is sold as part of a complete system. The system is being marketed as complete and could e.g. be an air-condi tioning

system. The complete system must be CE labelled in accordance with the EMC directive. The manufacturer can ensure CE labelling under the

EMC directive either by using CE labelled components or by testing the EMC of the system. If he chooses to us e only CE labelled components,

he does not have to test the entire system.

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2.3.3 Danfoss Frequency Converter and CE Labelling

CE labelling is a positive feature when used for its original purpose, i.e. to facilitate t rade within the EU and EFTA.

However, CE labelling may cover many different specificat ions. Thus, you have to check what a given CE label specifically covers.

The covered specifications can be very different and a CE label may therefore give the installer a false feeling of security when using a frequency converter

as a component in a system or an appliance.

Danfoss CE labels the frequency converters in accordance with the low-voltage directive. This means that if the frequen cy converter is installed correctly,

we guarantee compliance with the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CE labelling in accordance with the

low-voltage directive.

The CE label also applies to the EMC directive provided that the instructions for EMC-correct installation and filtering are followed. On this basis, a

declaration of conformity in accordance with the EMC directive is issued.

The Design Guide offers detailed instructions for installation to ensure EMC-correct installation. Furthermore, Danfoss specifies which our different prod-

ucts comply with.

Danfoss gladly provides other types of assistance that can help you obtain the best EMC result.

2.3.4 Compliance with EMC Directive 89/336/EEC

As mentioned, the frequency converter is mostly used by professionals of the trade as a complex component forming part of a larger appliance, system,

or installation. It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an

aid to the installer, Danfoss has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive

systems are complied with, provided that the EMC-correct instructions for installation are followed, see the section

EMC Immunity

The frequency converter has been designed to meet the IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 50°C.

A frequency converter contains a large number of mechanical and electronic components. All are to some extent vulnerable to environmental effects.

The frequency converter should not be installed in environments with airborne liq uids, particles, or gases capable of affecting and

damaging the electronic components. Failure to take the necessary protective measures increases the risk of stoppages, thus reducing

the life of the frequency converter.

Liquids can be carried through the air and condense in the frequency converter and may cause corrosion of components and metal parts. Steam, o il, and

salt water may cause corrosion of components and metal parts. In such environments, use equipment with enclosure rating IP 54/55. As an extra

protection, coated printed circuit boards can be ordered as an option.

Airborne

Particles such as dust may cause mechanical, electrical, or thermal failure in the frequency converter. A typical indicator of excessive levels of

airborne particles is dust particles around the frequency converter fan. In very dusty environments, use equipment with enclosure rating IP 54/55 or a

cabinet for IP 00/IP 20/TYPE 1 equipment.

In environments with high temperatures and humidity,

corrosive gases such as sulphur, nitrogen, and chlorine compounds will cause chemical processes

on the frequency converter components.

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Such chemical reactions will rapidly affect and damage the electronic components. In such environments, mount the equipment in a cabinet with fresh

air ventilation, keeping aggressive gases away from the frequency converter.

An extra protection in such areas is a coating of the printed circuit boards, wh ich can be ordered as an option.

NB!

Mounting frequency converters in aggressive environments increases the risk of stoppages and considerably reduces the life of the

converter.

Before installing the frequency converter, check the ambien t air for liquids, particles, and gases. This is done by observing existing installations in this

environment. Typical indicators of harmful airborne liquids are water or oil on metal parts, or corrosion of metal parts.

Excessive dust particle levels are often found on installation cabi nets and existing electrical installations. One indicator of aggressive airborne gases is

blackening of copper rails and cable ends on existing installations.

NB!

D and E enclosures have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still

required for the internal components of the drive. Contact Danfoss for additional information.

2.4 Vibration and shock

The frequency converter has been tested according to the procedure based on the shown st andards:

The frequency converter complies with requirements that exist for units mounted on the walls and fl oors of production premises, as well as in panels

bolted to walls or floors.

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970

IEC/EN 60068-2-64: Vibration, broad-band random

2.5 Advantages

2.7.1 Why use a Frequency Converter for Controlling Fans and Pumps?

A frequency converter takes advantage of the fact that centrifugal fans and pumps follow the laws of proportionality for such fans and pumps. For further

information see the text

The Laws of Proportionality

2.7.2 The Clear Advantage - Energy Savings

The very clear advantage of using a frequency converter for controlling the speed of fans or pumps lies in the el ectricity savings.

When comparing with alternative control systems and technologies, a frequency converter is the optimu m energy control system for controlling fan and

pump systems.

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Illustration 2.1: The graph is showing fan curves (A, B and

C) for reduced fan volumes.

Illustration 2.2: When using a frequency converter to reduce

fan capacity to 60% - more than 50% energy savings may

be obtained in typical applications.

2.7.3 Example of Energy Savings

As can be se en from the figur e (the laws of prop ortionality), the flow is contr olled by changing the RPM. By redu cing the speed only 20% from the rated

speed, the flow is also reduced by 20%. This is because the flow is directly propor tional to the RPM . The consumptio n of electricity, however, is reduced

by 50%.

If the system in question only needs to be able to supply a flow that corresponds to 100% a few days in a year, while the average is below 80% of the

rated flow for the remainder of the year, the amount of energy saved is even more than 50%.

The laws of proportionality

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

Q = Flow P = Power

Q1 = Rated flow P1 = Rated power

= Reduced flow P2 = Reduced power

H = Pressure n = Speed regulation

H1 = Rated pressure n1 = Rated speed

= Reduced pressure n2 = Reduced speed

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Flow

Pressure

(

)

Power

(

)

2.7.4 Example with Varying Flow over 1 Year

The example below is calculated on the basis of pump characteristics ob-

tained from a pump datasheet.

The result obtained shows energy savings in excess of 50% at the given

flow distribution over a year. The pay back period depends on the price

per kwh and price of frequency converter. In this example it is less than

a year when compared with valves and constant speed.

Energy savings

shaft=Pshaft output

Flow distribution over 1 year

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Distribution Valve regulation Frequency converter control

% Hours Power Consumption Power Consumption

- B

kWh A1 - C

kWh

350 5 438 42,5 18.615 42,5 18.615

300 15 1314 38,5 50.589 29,0 38.106

250 20 1752 35,0 61.320 18,5 32.412

200 20 1752 31,5 55.188 11,5 20.148

150 20 1752 28,0 49.056 6,5 11.388

100 20 1752 23,0 40.296 3,5 6.132

Σ 100 8760 275.064 26.801

2.7.5 Better Control

If a frequency converter is used for controlling the flow or pressure of a system, improved control is obtained.

A frequency converter can vary the speed of the fan or pump, thereby obtaining variable control of flow and pressure.

Furthermore, a frequency converter can quickly adapt the speed of the fan or pump to new flow or pressure conditions in the system.

Simple control of process (Flow, Level or Pressure) utilizing the built in PID control.

2.7.6 Cos φ Compensation

Generally speaking, a frequency converter with a cos φ of 1 provides power factor correction for the cos φ of the motor, which means that there is no

need to make allowance for the cos φ of the motor when sizing the power factor correction unit.

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2.7.7 Star/delta Starter or Soft-starter not required

When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional syste ms, a star/

delta starter or soft-starter is widely used. Such motor starters are not required if a frequency converter is used.

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

1 = VLT Automation VT Drive

2 = Star/delta starter

3 = Soft-starter

4 = Start directly on mains

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2.6 Control Structures

2.8.1 Control Principle

Illustration 2.3: Control structures.

The frequency converter is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special

motor mode and VVC plus and can handle normal squirrel cage asynchronous motors.

Short circuit behavior on this FC depends on the 3 current transducers in the motor phases.

par. 1-00 Configuration Mode

it can be se lected if open or closed loop

is to be used

2.8.2 Control Structure Open Loop

Illustration 2.4: Open Loop structure.

In the configuration shown in the illustration above,

par. 1-00 Configuration Mode

is set to Open loop [0]. The resulting reference from the reference

handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control.

The output from the motor control is then limited by the maximum frequency limit.

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2.8.3 Local (Hand On) and Remote (Auto On) Control

The frequency converter can be operated manually via the local control panel (LCP) or remotely via analog/digital inputs or serial bus.

If allowed in par. 0-40

[Hand on] Key on LCP

, par. 0-41

[Off] Key on LCP

, par. 0-42

[Auto on] Key on LCP

, and par. 0-43

[Reset] Key on LCP

, it is possible

to start and stop the frequency converter byLCP using the [Hand ON] and [Off] keys. Alarms can be reset via the [RESET] key. After pressing the [Hand

On] key, the frequency converter goes into Hand Mode and follows (as default) the Local reference set by using the LCP arrow keys up [▲] and down

[▼].

After pressing the [Auto On] key, the frequency converter goes into Auto

mode and follows (as default) the Remote reference. In this mode, it is

possible to control the frequency converter via the digital inputs and var-

ious serial interfaces (RS-485, USB, or an optional fieldbus). See more

about starting, stopping, changing ramps and parameter set-ups etc. in

par. group 5-1* (digital inputs) or par. group 8-5* (serial communica-

tion).

130BP046.1

Hand Off

Auto

LCP Keys

Reference Site

par. 3-13

Reference Site

Active Reference

Hand Linked to Hand / Auto Local

Hand -> Off Linked to Hand / Auto Local

Auto Linked to Hand / Auto Remote

Auto -> Off Linked to Hand / Auto Remote

All keys Local Local

All keys Remote Remote

The table shows under which conditions either the Local Reference or the Remote Reference is active. One of them is always active, but both can not be

active at the same time.

NB!

Local Reference will be restored at power-down.

par. 1-00

Configuration Mode

determines what kind of application control principle (i.e. Open Loop or Closed loop) is used when the Remote reference

is active (see table above for the conditions).

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2.8.4 Control Structure Closed Loop

The closed loop controller allows the drive to become an integral part of the controlled system. Th e drive receives a feedback signal from a sensor in the

system. It then compares this feedback to a set-point reference value and determines the error, if any, between these two signals. It then adju sts the

speed of the motor to correct this error.

For example, consider a pump application where the speed of a pump is to be controlled so that the static pressure in a pipe is constant. The desired

static pressure value is supplied to the drive as the set-point reference. A static pressure sensor measures the actual static pressure in the pipe and

supplies this to the drive as a feedback signal. If the feedback signal is gre ater than the set-point reference, the drive will slow down to reduce the

pressure. In a similar way, if the pipe pressure is lower than the set-point reference, the drive will automatically speed up to increase the pressure provided

by the pump.

NB!

While the default values for the drive’s Closed Loop controller will often provide satisfa ctory performance, the control of the system

can often be optimized by adjusting some of the Closed Loop controller’s parameters. It is also possible to autotune the PI constants.

The figure is a block diagram of the drive’s Closed Loop controller. The details of the Reference Handling block and Feedback Handling block are described

in their respective sections below.

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2.8.5 Feedback Handling

A block diagram of how the drive processes the feedback signal is shown below.

Feedback handling can be configured to work with applications requiring advanced control, such as multiple setpoints and multiple feedbacks. Three

types of control are common.

Single Zone, Single Setpoint

Single Zone Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference (if any, see Reference Handling) and the feedback signa l

is selected using par. 20-20.

Multi Zone, Single Setpoint

Multi Zone Single Setpoint uses two or three feedback sensors but only one setpoint. The feedbacks can be added, subtracted (only feedback 1 and 2)

or averaged. In addition, the maximum or minimum value may be used. Setpoint 1 is used exclusively in this configuration.

Multi Setpoint Min

[13] is selected, the setpoint/feedback pair with the largest difference controls the speed of the drive.

Multi Setpoint Maximum

[14]

attempts to keep all zones at or below their respective setpoints, while

Multi Setpoint Min

[13] attempts to keep all zones at or above their respective

setpoints.

Example:

A two zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar and the feedback is 4.6 bar. If

Multi

Setpoint Max

[14] is selected, Zone 1’s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedback is high er tha n

setpoint, resulting in a negative difference). If

Multi Setpoint Min

[13] is selected, Zone 2’s setpoint and feedback is sent to the PID controller, since this

has the larger difference (feedback is lower than setpoint, resulting in a positive di fference).

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2.8.6 Feedback Conversion

In some applications it may be useful to convert the feedback signal . One example of this is using a pressure signal to provide flow feedback. Since the

square root of pressure is proportional to flow, the square root of the pressure signal yields a value proportional to the flow. This is shown below.

2.8.7 Reference Handling

Details for Open Loop and Closed Loop operation.

A block diagram of how the drive produces the Remote Reference is shown below:.

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The Remote Reference is comprised of:

• Preset references.

• External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bu s references).

• The Preset relative reference.

• Feedback controlled setpoint.

Up to 8 preset references can be programmed in the drive. The active preset reference can be selected using digital inputs or the serial communications

bus. The reference can also be supplied externally, most commonly from an analog input. This external source is selected by one of the 3 Reference

Source parameters (par. 3-15

Reference 1 Source

, par. 3-16

Reference 2 Source

and par. 3-17

Reference 3 Source

). Digipot is a digital potentiometer.

This is also commonly called a Speed Up/Speed Down Control or a Floating Point Control. To set it up, one digital input is programmed to increase the

reference while another digital input is programmed to decrease the reference. A third digital input can be used to reset the Digipot reference. All reference

resources and the bus reference are added to produce the total External Reference. The External Reference, the Preset Reference or the sum of the two

can be selected to be the active reference. Finally, this reference can by be scaled using par. 3-14

Preset Relative Reference

The scaled reference is calculated as follows:

Reference

= X + X ×

(

100

)

Where X is the external reference, the preset reference or the sum of these and Y is par. 3-14

Preset Relative Reference

in [%].

NB!

If Y, par. 3-14

Preset Relative Reference

is set to 0%, the reference will not be affected by the scaling

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2.8.8 Example of Closed Loop PID Control

The following is an example of a Closed Loop Control for a booster pump application:

In a water distribution system, the pressure is to be maintained at a constant value. The desired pressure (setpoint) is set between 0 and 10 Bar using

a 0-10 volt potentiometer or can be set by a parameter. The pressure sensor has a range of 0 to 10 Bar and uses a two-wire transmitter to provide a

4-20 mA signal. The output frequency range of the drive is 10 to 50 Hz.

1. Start/Stop via switch connected between terminals 12 (+24 V) and 18.

2. Pressure reference via a potentiometer (0-10 Bar, 0-10 V) connected

to terminals 50 (+10 V), 53 (input) and 55 (common).

3. Pressure feedback via transmitter (0-10 Bar, 4-20 mA) connected to

terminal 54. Switch S202 behind the Local Control Panel set to ON

(current input).

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2.8.9 Programming Order

Function Par. no. Setting

1) Make sure the motor runs properly. Do the following:

Set the drive to control the motor based on drive output fre-

quency.

0-02

[1]

Set the motor parameters using nameplate data. 1-2* As specified by motor name plate

Run Automatic Motor Adaptation. 1-29

Enable complete AMA

[1] and then run the AMA function.

2) Check that the motor is running in the right direction.

Press the “Hand On” LCP key and the ^ key to make the

motor turn slowly. Check that the motor runs in the correct

direction.

If the motor runs in the wrong direction, remove power

temporarily and reverse two of the motor phases.

3) Make sure the frequency converter limits are set to safe values

Check that the ramp settings are within capabilities of the

drive and allowed application operating specifications.

3-41

3-42

60 sec.

Depends on motor/load size!

Also active in Hand mode.

Prohibit the motor from reversing (if necessary) 4-10

Clockwise

[0]

Set acceptable limits for the motor speed. 4-12

4-14

4-19

10 Hz,

Motor min speed

50 Hz,

Motor max speed

50 Hz,

Drive max output frequency

Switch from open loop to closed loop. 1-00

Closed Loop

[3]

4) Configure the feedback to the PID controller.

Set up Analog Input 54 as a feedback input. 20-00

Analog input 54

[2] (default)

Select the appropriate reference/feedback unit. 20-12

Bar

[71]

5) Configure the setpoint reference for the PID controller.

Set acceptable limits for the setpoint reference. 3-02

3-03

0 Bar

10 Bar

Set up Analog Input 53 as Reference 1 Source. 3-15

Analog input 53

[1] (default)

6) Scale the analog inputs used for setpoint reference and feedback.

Scale Analog Input 53 for the pressure range of the potenti-

ometer (0 - 10 Bar, 0 - 10 V).

6-10

6-11

6-14

6-15

0 V

10 V (default)

0 Bar

10 Bar

Scale Analog Input 54 for pressure sensor (0 - 10 Bar, 4 - 20

mA)

6-22

6-23

6-24

6-25

4 mA

20 mA (default)

0 Bar

10 Bar

7) Tune the PID controller parameters.

Adjust the drive’s Closed Loop Controller, if needed. 20-93

20-94

See Optimization of the PID Controller, below.

8) Finished!

Save the parameter setting to the LCP for safe keeping 0-50

All to LCP

[1]

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2.8.10 Tuning the Drive Closed Loop Controller

Once the drive’s Closed Loop Controller has been set up, the performance of the controller should be tested. In many cases, its performance may be

acceptable using the default values of PID Proportional Gain (par. 20-93) and PID Integral Time (par. 20-94). However, in some cases it may be helpful

to optimize these parameter values to provide faster system response while still controlling speed overshoot.

2.8.11 Manual PID Adjustment

1. Start the motor

2. Set par. 20-93 (PID Proportional Gain) to 0.3 and increase it until the feedback signal begins to oscillate. If necessary, start and stop the drive

or make step changes in the set-point reference to attempt to cause oscillation. Next reduce the PID Proportion al Gain until the feedback signal

stabilizes. Then reduce the proportional gain by 40-60%.

3. Set par. 20-94 (PID Integral Time) to 20 sec. and reduce it until the feedback signal begins to oscillate. If necessary, start and stop the drive

or make step changes in the set-point reference to attempt to cause oscillation. Next, increase the PID I ntegral Time until the feedback signal

stabilizes. Then increase of the Integral Time by 15-50%.

4. Par. 20-95 (PID Differential Time) should only be used for very fast-acting systems. The typical value is 25% of the PID Integral Time (par.

20-94). The differential function should only be used when the setting of the proportional gain and the integral time has been fully optimized.

Make sure that oscillations of the feedback signal are sufficiently damp ened by the low-pass filter for the feedback signal (par 6 16, 6 26, 5 54

or 5 59, as required).

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2.7 General aspects of EMC

2.9.1 General Aspects of EMC Emissions

Electrical interference is usually conducted at frequences in the range 150 kHz to 30 MHz. Airborne interference from the drive system in the range 30

MHz to 1 GHz is generated from the inverter, motor cable, and the motor.

As shown in the illustration below, capacitive currents in the motor cable coupled with a high dV/dt from the motor voltage generate leakage currents.

The use of a screened motor cable increases the leakage current (see illustration below) because screened cables have higher capacitance to earth than

unscreened cables. If the leakage current is not filtered, it will cause greater interference on the mains in the radio frequency range below approx. 5

MHz. Since the leakage current (I

) is carried back to the unit through the screen (I 3), there will in principle only be a small electro-magnetic field (I4)

from the screened motor cable according to the below figure.

The screen reduces the radiated interference but increases the low-frequency interference on t he mains. The motor cable screen must be connected to

the frequency converter enclosure as well as on the motor enclosure. This is best done by using integrated screen clamps so as to avoid twisted screen

ends (pigtails). These increase the screen impedance at higher frequencies, which reduces the screen effect and increases the l eakage current (I

If a screened cable is used for Fieldbus, relay, control cable, signal interface and brake, the screen must be mounted on the enclosure a t both ends. In

some situations, however, it will be necessary to break the screen to avoid current loops.

If the screen is to be placed on a mounting plate for the frequency converter, the mounting plate must be made of metal, because the screen currents

have to be conveyed back to the unit. Moreover, ensure good electrical contact from the mounting plate through the mounting screws to the frequency

converter chassis.

NB!

When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are ob-

served.

In order to reduce the interference level from the entire system (unit + installation), make motor and brake cabl es as short as possible. Avoid placing

cables with a sensitive signal level alongside motor and brake cables. Radio in terference higher than 50 MHz (airborne) is especially generated by the

control electronics.

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2.9.2 Emission Requirements

According to the EMC product standard for adjustable speed frequency converters EN/IEC61800-3:2004 the EMC requirements depend on the intended

use of the frequency converter. Four categories are defined in the EMC product standard. The definitions of the four categories together with the

requirements for mains supply voltage conducted emissions are given in the table below:

Category Definition

Conducted emission requirement

according to the limits given in

EN55011

C1 frequency converters installed in the first environment (home and office) with a supply

voltage less than 1000 V.

Class B

C2 frequency converters installed in the first environment (home and office) with a supply

voltage less than 1000 V, which are neither plug-in nor movable and are intended to be

installed and commissioned by a professional.

Class A Group 1

C3 frequency converters installed in the second environment (industrial) with a supply volt-

age lower than 1000 V.

Class A Group 2

C4 frequency converters installed in the second environment with a supply voltage above

1000 V and rated current above 400 A or intended for use in complex systems.

No limit line.

An EMC plan should be made.

When the generic emission standards are used the frequency converters are required to c omply with the following limits:

Environment Generic standard

Conducted emission requirement ac-

cording to the limits given in

EN55011

First environment

(home and office)

EN/IEC61000-6-3 Emission standard for residential, commercial and

light industrial environments.

Class B

Second environment

(industrial environment)

EN/IEC61000-6-4 Emission standard for industrial environments. Class A Group 1

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2.9.3 EMC Test Results (Emission)

The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a

control box with potentiometer, as well as a motor and motor screened cable.

RFI filter type

Phas

type

Conducted emission.

Maximum shielded cable length.

Radiated emission

Industrial environment

Housing, trades

and light indus-

tries

Industrial environ-

ment

Housing, trades and

light industries

Setup: S / T

EN 55011 ClassA2EN 55011

Class A1

EN 55011 Class

EN 55011 Class A1 EN 55011 Class B

H1 meter meter meter

1.1-22 kW 220-240 V S2 150 150 50 Yes No

0.25-45 kW 200-240 V T2 150 150 50 Yes No

7.5-37 kW 380-480 V S4 150 150 50 Yes No

0.37-90 kW 380-480 V T4 150 150 50 Yes No

1.1-22 kW 220-240 V S2 25 No No No No

0.25-3.7 kW 200-240 V T2 5NoNo No No

5.5-45 kW 200-240 V T2 25 No No No No

0.37-7.5 kW 380-480 V T4 5NoNo No No

7.5-37 kW 380-480 V S4 25 No No No No

11-90 kW 380-480 V T4 25 No No No No

110-1000 kW 380-480 V T4 50 No No No No

0.75-90 kW 525-600 V T6 150 No No No No

11-90 kW 525-690 V T7 Yes No No No No

45-1200 kW 525-690 V T7 150 No No No No

0.25-45 kW 200-240 V T2 75 50 10 Yes No

0.37-90 kW 380-480 V T4 75 50 10 Yes No

110-1000 kW 380-480 V T4 150 150 No Yes No

11-90 kW 525-690 V T7 No Yes No Yes No

45-400 kW 525-690 V T7 150 30 No No No

0.75-90 kW 525-600 V T6 -- - - -

Table 2.1: EMC Test Results (Emission)

2.9.4 General Aspects of Harmonics Emission

A frequency converter takes up a non-sinusoidal current from mains,

which increases the input current I

RMS

. A non-sinusoidal current is trans-

formed by means of a Fourier analysis and split up into sine-wave cur-

rents with different frequencies, i.e. different harmonic currents I

with

50 Hz as the basic frequency:

Harmonic currents I1I5I

Hz 50 Hz 250 Hz 350 Hz

The harmonics do not affect the power consumption directly but increase

the heat losses in the installation (transformer, cables). Consequently, in

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plants with a high percentage of rectifier load, maintain harmonic cur-

rents at a low level to avoid overload of the transformer and high tem-

perature in the cables.

NB!

Some of the harmonic currents might disturb communication equipment connected to the same transformer or cause resonance in

connection with power-factor correction batteries.

NB!

To ensure low harmonic currents, the frequency converter is equipped with intermediate circuit coils as standard. This normally reduces

the input current I

RMS

by 40%.

The voltage distortion on the mains supply voltage depends on the size of the harmonic curre nts multiplied by the mains impedance for the frequency

in question. The total voltage distortion THD is calculated on the basis of the individual voltage harmonics using this formula:

THD%=U

2 5

2 7

+ ... +

(UN% of U)

2.9.5 Harmonics Emission Requirements

Equipment connected to the public supply network:

Options: Definition:

1 IEC/EN 61000-3-2 Class A for 3-phase balanced equip-

ment (for professional equipment only up to 1 kW total

power).

2 IEC/EN 61000-3-12 Equipment 16A-75A and professio-

nal equipment as from 1 kW up to 16A phase current.

2.9.6 Harmonics Test Results (Emission)

Power sizes up to PK75 in T2 and T4 complies with IEC/EN 61000-3-2 Class A. Power sizes from P1K1 and up to P18K in T2 and up to P90K in T4 complies

with IEC/EN 61000-3-12. Power sizes P110 - P450 in T4 also complies with IEC/EN 61000-3-12 even though not required because currents are above 75

Table 4, R

sce

>= 120, THD <= 48% and PWHD >=46% provided that the short-circuit power of the supply Ssc is greater than or equal to:

= 3 ×

SCE

mains

equ

= 3 × 120 × 400 ×

equ

at the interface point between the user’s supply and the public system.

It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the

equipment is connected only to a supply with a short-circuit power S

greater than or equal to specified above.

Other power sizes can be connected to the public supply network by consultation with the distribution network operator.

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2.8 Immunity Requirements

The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment

are higher than the requirements for the home and office environment. All Danfoss frequency converters comply with the requirements for the industrial

environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

In order to document immunity against electrical interference from electrical phenomena, the following immunity tests have been made on a system

consisting of a frequency converter (with options if relevant), a screened control cable and a control box with potentiometer, motor cable and motor.

The tests were performed in accordance with the following basic standards:

• EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD): Simulation of electrostatic discharges from human beings.

• EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation, amplitude modulated simulation of the effects of radar and radio

communication equipment as well as mobile communications equipment.

• EN 61000-4-4 (IEC 61000-4-4): Burst transients: Simulation of interference brought about by switching a contactor, relay or similar devices.

• EN 61000-4-5 (IEC 61000-4-5): Surge transients: Simulation of transients brought about e.g. by lightning that strikes near installations.

• EN 61000-4-6 (IEC 61000-4-6): RF Common mode: Simulation of the effect from radio-transmission equipment joined by connection cables.

See following EMC immunity form.

Voltage range: 200-240 V, 380-480 V

Basic standard Burst

IEC 61000-4-4

Surge

IEC 61000-4-5

ESD

IEC

61000-4-2

Radiated electromagnetic field

IEC 61000-4-3

RF common

mode voltage

IEC 61000-4-6

Acceptance criterion B B B A A

Line

4 kV CM

2 kV/2 Ω DM

4 kV/12 Ω CM

— —

10 V

RMS

Motor

4 kV CM

4 kV/2 Ω

——

10 V

RMS

Brake 4 kV CM

4 kV/2 Ω

— —

10 V

RMS

Load sharing 4 kV CM

4 kV/2 Ω

——

10 V

RMS

Control wires

2 kV CM

2 kV/2 Ω

— —

10 V

RMS

Standard bus 2 kV CM

2 kV/2 Ω

——

10 V

RMS

Relay wires 2 kV CM

2 kV/2 Ω

— —

10 V

RMS

Application and Fieldbus op-

tions

2 kV CM

2 kV/2 Ω

——

10 V

RMS

LCP cable

2 kV CM

2 kV/2 Ω

— —

10 V

RMS

External 24 V DC

2 kV CM

0.5 kV/2 Ω DM

1 kV/12 Ω CM

——

10 V

RMS

Enclosure

— —

8 kV AD

6 kV CD

10 V/m —

AD: Air Discharge

CD: Contact Discharge

CM: Common mode

DM: Differential mode

1. Injection on cable shield.

Table 2.2: Immunity

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2.9 Galvanic isolation (PELV)

2.11.1 PELV - Protective Extra Low Voltage

PELV offers protection by way of extra low voltage. Protection against electric shock is e nsured when the electrical supply is of the PELV type and the

installation is made as described in local/national regulations on PELV supplies.

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra Low Voltage) (Does not apply to grounded Delta leg above 400

V).

Galvanic (ensured) isolation is obtained by fulfilli ng requirements for higher isolation and by providing the relevant creapage/clearance distances. These

requirements are described in the EN 61800-5-1 standard.

The components that make up the electrical isolation, as described below, also comply with the requirements for higher isol ation and the relevant test

as described in EN 61800-5-1.

The PELV galvanic isolation can be shown in six locations (see illustration):

In order to maintain PELV all connections made to the control terminals must be PELV, e.g. thermistor must be reinforced/double insulated.

1. Power supply (SMPS) incl. signal isolation of U

, indicating the

intermediate current voltage.

2. Gate drive that runs the IGBTs (trigger transformers/opto-cou-

plers).

3. Current transducers.

4. Opto-coupler, brake module.

5. Internal inrush, RFI, and temperature measurement circuits.

6. Custom relays.

Illustration 2.5: Galvanic isolation

The functional galvanic isolation (a and b on drawing) is for the 24 V bac k-up option and for the RS 485 standard bus interface.

Installation at high altitude:

380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV.

380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV.

525 - 690 V: At altitudes above 2 km, please contact Danfoss regarding PELV.

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2.10 Earth leakage current

Warning:

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

Also make su re that other vo ltage inputs hav e been disconnec ted, such as load sharing (linkag e of DC intermedia te circuit), as well a s

the motor connection for kinetic back-up.

Before touching any electrical parts, wait at least the amount of time indicated in the

Safety Precautions

section.

Shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage Current

The earth leakage current from the frequency converter exceeds 3.5 mA. To ensure that the earth cable has a good mechanical

connection to the earth connection (terminal 95), the cable cross section must be at least 10 mm

or 2 rated earth wires terminated

seately.

Residual Current Device

This product can cause a d.c. current in the protective conductor. Where a residual current device (RCD) is used for protection in case

of d irec t or i ndir ect c onta ct, only an RC D of T ype B is al lowe d on t he s uppl y sid e of t his p rodu ct. O ther wis e, an othe r pro tect ive measure

shall be applied, such as separation from the environment by double or reinforced insulation, or isolation from the supply system by a

transformer. See also RCD Application Note MN.90.GX.02.

Protective earthing of the frequency converter and the use of RCD's must always follow nationa l and local regulations.

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2.11 Control with Brake Function

2.13.1 Selection of Brake Resistor

In certain applications, for instance centrifuges, it is desirable to bring the motor to a stop more rapidly than can be achieved through controlling via

ramp down or by free-wheeling. In such applications, dynamic braking with a braking resistor may be utilized. Using a braking resistor ensures that the

energy is absorbed in the resistor and not in the frequency converter.

If the amount of kinetic energy transferred to the resistor in each braking period is not known, the average power can be calculated on the basis of the

cycle time and braking time also called intermitted duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at which the resistor

is active. The below figure shows a typical braking cycle.

The intermittent duty cycle for the resistor is calculated as follows:

Duty Cycle = tb/T

T = cycle time in seconds

is the braking time in seconds (as part of the total cycle time)

Danfoss offers brake resistors with duty cycle of 5%, 10% and 40% suitable for use with the Automation VT Drive FC322 series. If a 10% duty cycle

resistor is applied, this is able of absorbing braking power upto 10% of the cycle time with the remaining 90% being used to dissipate heat from the

resistor.

For further selection advice, please contact Danfoss.

NB!

If a short circuit in the brake transistor occurs, power dissipation in the brake resistor is only prevented by using a mains switch or

contactor to disconnect the mains for the frequency converter. (The contactor can be controlled by the frequency converter).

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2.13.2 Control with Brake Function

The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the tra nsistor

is detected. A relay/digital output can be used for protecting the brake resistor against overloading in connection with a fault in the frequency converter.

In addition, the brake makes it possible to read out the momentary power and the mean power for the latest 120 seconds. The brake can also monitor

the power energizing and make sure it does not exceed a limit selected in par. 2-12

Brake Power Limit (kW)

. In par. 2-13

Brake Power Monitoring

, select

the function to carry out when the power transmitted to the brake resistor exceeds the limit set in par. 2-12

Brake Power Limit (kW)

NB!

Monitoring the brake power is not a safety function; a thermal switch is required for that purpose. The brake resistor circuit is not earth

leakage protected.

Over voltage control (OVC)

(exclusive brake resistor) can be selected as an alternative brake function in par. 2-17

Over-voltage Control

. This function is

active for all units. The function ensures that a trip can b e avoided if the DC link voltage increases. This is done by increasing the output frequency to

limit the voltage from the DC link. It is a very useful function, e.g. if the ramp-down time is too short since tripping of the frequency converter is avoided.

In this situation the ramp-down time is extended.

2.12 Mechanical Brake Control

2.14.1 Brake Resistor Cabling

EMC (twisted cables/shielding)

To reduce the electrical noise from the wires between the brake resistor and the frequency convert er, the wires must be twisted.

For enhanced EMC performance a metal screen can be used.

2.13 Extreme Running Conditions

Short Circuit (Motor Phase – Phase)

The frequency converter is protected against short circuits by means of current measurement in each of the three motor phases or in the DC link. A short

circuit between two output phases will cause an overcurrent in the inverter. The inverter will be turned off individually when the short circuit current

exceeds the permitted value (Alarm 16 Trip Lock.

To protect the drive against a short circuit at the load sharing and brake outputs please see the design guidelines.

Switching on the Output

Switching on the output between the motor and the frequency converter is fully permitted. You cannot damage the frequency converter in any way by

switching on the output. However, fault messages may appear.

Motor-generated Overvoltage

The voltage in the intermediate circuit is increased when the motor acts as a generator.

This occurs in following cases:

1. The load drives the motor, ie. the load generates energy.

2. During deceleration ("ramp-down") if the moment of inertia is high, the friction is low and the ramp-down time is too short for the energy to be

dissipated as a loss in the frequency converter, the motor and the installation.

3. In-correct slip compensation setting may cause higher DC link voltage.

The control unit may attempt to correct the ramp if possible (par. 2-17

Over-voltage Control

The inverter turns off to protect the transistors and the intermediate circuit capacitors when a certain voltage level is reached.

See par. 2-10 and par. 2-17 to select the method used for controlling the intermediate circuit voltage level.

High Temperature

High ambient temperature may overheat the frequency converter.

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Mains Drop-out

During a mains drop-out, the frequency converter keeps running until the intermediate circuit voltage drops below the minimum stop level, which is

typically 15% below the frequency converter's lowest rated su pply voltage.

The mains voltage before the drop-out and the motor load determines how long it takes for the inverter to coast.

Static Overload in VVC

plus

mode

When the frequency converter is overloaded (the torque limit in par. 4-16/4-17 is reached), the controls reduces the output frequency to reduce the load.

If the overload is excessive, a current may occur that makes the frequency converter cut out after approx. 5-10 s.

Operation within the torque limit is limited in time (0-60 s) in par. 14-25.

2.15.1 Motor Thermal Protection

This is the way Danfoss is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal

measurements. The characteristic is shown in the following figure:

Illustration 2.6: The X-axis is showing the ratio between I

motor

and I

motor

nominal. The Y- axis is showing the time in seconds before the ETR

cuts off and trips the drive. The curves are showing the characteristic nominal spee d at twice the nominal speed and at 0,2x the nominal

speed.

It is clear that at lower speed the ETR cuts of at lower heat due to less cooling of the motor. In that way the motor are protected from being over heated

even at low speed. The ETR feature is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a

read out parameter in par. 16-18

Motor Thermal

in the frequency converter.

The thermistor cut-out value is > 3 kΩ.

Integrate a thermistor (PTC sensor) in the motor for winding protection.

Motor protection can be implemented using a range of techniques: PTC

sensor in motor windings; mechanical thermal switch (Klixon type); or

Electronic Thermal Relay (ETR).

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Using a digital input and 24 V as power supply:

Example: The frequency converter trips when the motor temperature is

too high.

Parameter set-up:

Set par. 1-90

Motor Thermal Protection

Thermistor Trip

[2]

Set par. 1-93

Thermistor Source

Digital Input 33

[6]

Using a digital input and 10 V as power supply:

Example: The frequency converter trips when the motor temperature is

too high.

Parameter set-up:

Set par. 1-90

Motor Thermal Protection

Thermistor Trip

[2]

Set par. 1-93

Thermistor Source

Digital Input 33

[6]

Using an analog input and 10 V as power supply:

Example: The frequency converter trips when the motor temperature is

too high.

Parameter set-up:

Set par. 1-90

Motor Thermal Protection

Thermistor Trip

[2]

Set par. 1-93

Thermistor Source

Analog Input 54

[2]

Do not select a reference source.

Input

Digital/analog

Supply Voltage

Volt

Threshold

Cut-out Values

Digital 24 V < 6.6 kΩ - > 10.8 kΩ

Digital 10 V < 800Ω - > 2.7 kΩ

Analog 10 V < 3.0 kΩ - > 3.0 kΩ

NB!

Check that the chosen supply voltage follows the specification of the used thermistor element.

Summary

With the Torque limit feature the motor is protected for being overloaded independent of the speed. With the ETR the motor is protected for being over

heated and there is no need for any further motor protection. That means when the motor is heated up the ETR timer controls for how long time the

motor can be running at the high temperature before it is stopped in order to prevent over heating. If the motor is overloaded without reaching the

temperature where the ETR shuts of the motor, the torque limit is protecting the motor and applicat ion for being overloaded.

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NB!

ETR is a ctivate d in par. and is co ntrolled in par. 4 -16

Torque Limit Motor Mode

. The time before the torque limit warning trips the frequency converter

is set in par. 14-25

Trip Delay at Torque Limit

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2.15.2 Safe Stop Operation (Optional)

The FC322 can perform the Safety Function “Uncontrolled Stopping by removal of power” (as defined by draft IEC 61800-5-2) or Stop Category 0 (as

defined in EN 60204-1).

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop.

Prior to integration and use of FC322 Safe Stop in an inst allation, a thorough risk analysis on the installation must be carried out in order to determine

whether the FC322 Safe Stop functionality and safety category are appropriate and sufficient.

The Safe Stop function is activated by removing the voltage at Terminal 37 of the Safe Inverter. By connecting the Safe Inverter to external safety devices

providing a safe relay, an installation for a safe Stop Category 1 can be obtained. The Safe Stop function of FC322 can be used for asynchronous and

synchronous motors.

Safe Stop activation (i.e. removal of 24 V DC voltage supply t o terminal 37) does not provide electrical safety.

NB!

The Safe Stop function of FC322 can be used for asynchronous and synchronous motors. It may happen that two faults occur in the

frequency converter's power semiconductor. When using synchronous motors this may cause a residual rotation. The rotation can be

calculated to Angle=360/(Number of Poles). The application using synchronous motors must take this into consideration and ensure

that this is not a safety critical issue. This situation is not relevant for asynchronous motors.

NB!

In order to use the Safe Stop functionality in conformance with the requirements of EN-954-1 Category 3, a number of conditions must

be fulfilled by the installation of Safe Stop. Please see section

Safe Stop Installation

for further information.

NB!

The frequency converter does not provide a safety-related protection against unintended or malicious volta ge supply to terminal 37

and subsequent reset. Provide this protection via the interrupt device, at the application level, or organisational level.

For more information - see section

Safe Stop Installation

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3 VLT Automation VT Drive Selection

3.1 General Specifications

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Mains Supply 1 x 200 - 240 VAC - Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW]

P1K1

1.1

P1K5

1.5

P2K2

2.2

P3K0

3.0

P3K7

3.7

P5K5

5.5

P7K5

7.5

P15K0

P22K0

Typical Shaft Output [HP] at 240 V 1.5 2.0 2.9 4.0 4.9 7.5 10 20 30

IP 20 / Chassis A3 - - - - - - - -

IP 21 / NEMA 1 - B1B1B1B1B1B2 C1C2

IP 55 / NEMA 12 A5 B1 B1 B1 B1 B1 B2 C1 C2

IP 66 A5 B1 B1 B1 B1 B1 B2 C1 C2

Output current

Continuous

(3 x 200-240 V) [A]

6.6 7.5 10.6 12.5 16.7 24.2 30.8 59.4 88

Intermittent

(3 x 200-240 V) [A]

7.3 8.3 11.7 13.8 18.4 26.6 33.4 65.3 96.8

Continuous kVA

(208 V AC) [kVA]

5.00 6.40 12.27 18.30

Max. cable size:

(mains, motor, brake)

[[mm

/ AWG]

0.2-4 / 4-10 10/7 35/2 50/1/0 95/4/0

Max. input current

Continuous

(1 x 200-240 V ) [A]

12.5 15 20.5 24 32 46 59 111 172

Intermittent

(1 x 200-240 V ) [A]

13.8 16.5 22.6 26.4 35.2 50.6 64.9 122.1 189.2

Max. pre-fuses

[A]

20 30 40 40 60 80 100 150 200

Environment

Estimated power loss

at rated max. load [W]

44 30 44 60 74 110 150 300 440

Weight enclosure IP 20 [kg] 4.9 - - - - - - - -

Weight enclosure IP 21 [kg] - 23 23 23 23 23 27 45 65

Weight enclosure IP 55 [kg] - 23 23 23 23 23 27 45 65

Weight enclosure IP 66 [kg] - 23 23 23 23 23 27 45 65

Efficiency

0.968 0.98 0.98 0. 98 0.98 0.98 0.98 0.98 0.98

3.1.1 Mains Supply 1 x 200 - 240 VAC

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Normal overload 110% for 1 minute

IP 20 / NEMA Chassis A2 A2 A2 A2 A2 A2 A2 A3 A3

IP 21 / NEMA 1 A2 A2 A2 A2 A2 A2 A2 A3 A3

IP 55 / NEMA 12 A5 A5 A5 A5 A5 A5 A5 A5 A5

IP 66 A5 A5 A5 A5 A5 A5 A5 A5 A5

Mains supply 200 - 240 VAC

Frequency converter

Typical Shaft Output [kW]

PK25

0.25

PK37

0.37

PK55

0.55

PK75

0.75

P1K1

1.1

P1K5

1.5

P2K2

2.2

P3K0

P3K7

3.7

Typical Shaft Output [HP] at 208 V 0.25 0.37 0.55 0.75 1.5 2.0 2.9 4.0 4.9

Output current

Continuous

(3 x 200-240 V ) [A]

1.8 2.4 3.5 4.6 6.6 7.5 10.6 12.5 16.7

Intermittent

(3 x 200-240 V ) [A]

1.98 2.64 3.85 5.06 7.26 8.3 11.7 13.8 18.4

Continuous

kVA (208 V AC) [kVA]

0.65 0.86 1.26 1.66 2.38 2.70 3.82 4.50 6.00

Max. cable size:

(mains, motor, brake)

[mm

/AWG]

0.2 - 4 mm

/ 4 - 10 AWG

Max. input current

Continuous

(3 x 200-240 V ) [A]

1.6 2.2 3.2 4.1 5.9 6.8 9.5 11.3 15.0

Intermittent

(3 x 200-240 V ) [A]

1.7 2.42 3.52 4.51 6.5 7. 5 10.5 12.4 16.5

Max. pre-fuses

[A]

10 10 10 10 20 20 20 32 32

Environment

Estimated power loss

at rated max. load [W]

21 29 42 54 63 82 116 155 185

Weight enclosure IP20 [kg] 4.9 4.9 4.9 4.9 4.9 4. 9 4.9 6.6 6.6

Weight enclosure IP21 [kg] 5.5 5.5 5.5 5.5 5.5 5.5 5.5 7.5 7.5

Weight enclosure IP55 [kg] 13.5 13.5 13. 5 13.5 13.5 13.5 13.5 13.5 13.5

Weight enclosure IP 66 [kg] 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5

Efficiency

0.94 0.94 0.95 0.95 0.96 0.96 0.96 0.96 0.96

3.1.2 Mains Supply 3 x 200 - 240 VAC

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Mains supply 3 x 200 - 240 VAC - Normal overload 110% for 1 minute

IP 20 / NEMA Chassis

(B3+4 and C3+4 may be converted to IP21 using a conversion kit (Please contact Danfoss)

B3 B3 B3 B4 B4 C3 C3 C4 C4

IP 21 / NEMA 1 B1 B1 B1 B2 C1 C1 C1 C2 C2

IP 55 / NEMA 12 B1 B1 B1 B2 C1 C1 C1 C2 C2

IP 66 B1 B1 B1 B2 C1 C1 C1 C2 C2

Frequency converter

Typical Shaft Output [kW]

P5K5

5.5

P7K5

7.5

P11K

P15K

P18K

18.5

P22K

P30K

P37K

P45K

Typical Shaft Output [HP] at 208 V 7.5101520253040 50 60

Output current

Continuous

(3 x 200-240 V ) [A]

24.2 30.8 46.2 59.4 74.8 88.0 115 143 170

Intermittent

(3 x 200-240 V ) [A]

26.6 33.9 50.8 65.3 82.3 96.8 127 157 187

Continuous

kVA (208 V AC) [kVA]

8.7 11.1 16.6 21.4 26.9 31.7 41.4 51.5 61.2

Max. cable size:

(mains, motor, brake)

[mm

/AWG]

10/7 35/2 50/1/0 95/4/0

120/250

MCM

Max. input current

Continuous

(3 x 200-240 V ) [A]

22.0 28.0 42.0 54.0 68.0 80.0 104.0 130.0 154.0

Intermittent

(3 x 200-240 V ) [A]

24.2 30.8 46.2 59.4 74.8 88.0 114.0 143.0 169.0

Max. pre-fuses

[A]

63 63 63 80 125 125 160 200 250

Environment:

Estimated power loss

at rated max. load [W]

269 310 447 602 737 845 1140 1353 1636

Weight enclosure IP20 [kg] 12 12 12 23.5 23.5 35 35 50 50

Weight enclosure IP21 [kg] 23 23 23 27 45 45 65 65 65

Weight enclosure IP55 [kg] 23 23 23 27 45 45 65 65 65

Weight enclosure IP 66 [kg] 23 23 23 27 45 45 65 65 65

Efficiency

0.96 0.96 0.96 0.96 0.96 0.97 0.97 0.97 0.97

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Mains Supply 1x 380 VAC - Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW]

P7K5

7.5

P11K

P18K

18.5

P37K

Typical Shaft Output [HP] at 460 V 10 15 25 50

IP 21 / NEMA 1 B1 B2 C1 C2

IP 55 / NEMA 12 B1 B2 C1 C2

IP 66 B1 B2 C1 C2

Output current

Continuous

(3 x 380-440 V) [A]

16 24 37.5 73

Intermittent

(3 x 380-440 V) [A]

17.6 26.4 41.2 80.3

Continuous

(3 x 441-480 V) [A]

14.5 21 34 65

Intermittent

(3 x 441-480 V) [A]

15.4 23.1 37.4 71.5

Continuous kVA

(400 V AC) [kVA]

11.0 16.6 26 50.6

Continuous kVA

(460 V AC) [kVA]

11.6 16.7 27.1 51.8

Max. cable size:

(mains, motor, brake)

[[mm

/ AWG]

10/7 35 /2 50/1/0 120/4/0

Max. input current

Continuous

(1 x 380-440 V ) [A]

33 48 78 151

Intermittent

(1 x 380-440 V ) [A]

36 53 85.8 166

Continuous

(1 x 441-480 V) [A]

30 41 72 135

Intermittent

(1 x 441-480 V) [A]

33 46 79.2 148

Max. pre-fuses

[A]

63 80 160 250

Environment

Estimated power loss

at rated max. load [W]

300 440 740 1480

Weight enclosure IP 21 [kg] 23 27 45 65

Weight enclosure IP 55 [kg] 23 27 45 65

Weight enclosure IP 66 [kg] 23 27 45 65

Efficiency

0.96 0.96 0.96 0.96

3.1.3 Mains Supply 1 x 380 - 480 VAC

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Mains Supply 3 x 380 - 480 VAC - Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW]

PK37

0.37

PK55

0.55

PK75

0.75

P1K1

1.1

P1K5

1.5

P2K2

2.2

P3K0

P4K0

P5K5

5.5

P7K5

7.5

Typical Shaft Output [HP] at 460 V 0.5 0.75 1.0 1.5 2.0 2.9 4.0 5.3 7.5 10

IP 20 / NEMA Chassis A2 A2 A2 A2 A2 A2 A2 A2 A3 A3

IP 21 / NEMA 1

IP 55 / NEMA 12 A5 A5 A5 A5 A5 A5 A5 A5 A5 A5

IP 66 A5 A5 A5 A5 A5 A5 A5 A5 AA A5

Output current

Continuous

(3 x 380-440 V) [A]

1.3 1.8 2.4 3 4.1 5.6 7.2 10 13 16

Intermittent

(3 x 380-440 V) [A]

1.43 1.98 2.64 3.3 4.5 6.2 7.9 11 14.3 17.6

Continuous

(3 x 441-480 V) [A]

1.2 1.6 2.1 2.7 3.4 4.8 6.3 8.2 11 14.5

Intermittent

(3 x 441-480 V) [A]

1.32 1.76 2.31 3.0 3.7 5.3 6.9 9.0 12.1 15.4

Continuous kVA

(400 V AC) [kVA]

0.9 1.3 1.7 2.1 2.8 3.9 5.0 6.9 9.0 11.0

Continuous kVA

(460 V AC) [kVA]

0.9 1.3 1.7 2.4 2.7 3.8 5.0 6.5 8.8 11.6

Max. cable size:

(mains, motor, brake)

[[mm

/ AWG]

4/10

Max. input current

Continuous

(3 x 380-440 V ) [A]

1.2 1.6 2.2 2.7 3.7 5.0 6.5 9.0 11.7 14.4

Intermittent

(3 x 380-440 V ) [A]

1.32 1.76 2.42 3.0 4.1 5.5 7.2 9.9 12.9 15.8

Continuous

(3 x 441-480 V) [A]

1.0 1.4 1.9 2.7 3.1 4.3 5.7 7.4 9.9 13.0

Intermittent

(3 x 441-480 V) [A]

1.1 1.54 2.09 3.0 3.4 4.7 6.3 8.1 10.9 14.3

Max. pre-fuses

[A]

10 10 10 10 10 20 20 20 30 30

Environment

Estimated power loss

at rated max. load [W]

35 42 46 58 62 88 116 124 187 25 5

Weight enclosure IP20 [kg] 4.7 4.7 4.8 4.8 4.9 4.9 4.9 4.9 6.6 6.6

Weight enclosure IP 21 [kg]

Weight enclosure IP 55 [kg] 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 14.2 14.2

Weight enclosure IP 66 [kg] 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 14.2 14.2

Efficiency

0.93 0.95 0.96 0.96 0.97 0.97 0.97 0.97 0.97 0.97

3.1.4 Mains Supply 3 x 380 - 480 VAC

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Mains Supply 3 x 380 - 480 VAC - Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW]

P11K

P15K

P18K

18.5

P22K

P30K

P37K

P45K

P55K

P75K

P90K

Typical Shaft Output [HP] at 460 V 15 20 25 30 40 50 60 75 100 125

IP 20 / NEMA Chassis

(B3+4 and C3+4 may be converted to IP21 using a conversion kit (Please

contact Danfoss)

B3 B3 B3 B4 B4 B4 C3 C3 C4 C4

IP 21 / NEMA 1 B1 B1 B1 B2 B2 C1 C1 C1 C2 C2

IP 55 / NEMA 12 B1 B1 B1 B2 B2 C1 C1 C1 C2 C2

IP 66 B1 B1 B1 B2 B2 C1 C1 C1 C2 C2

Output current

Continuous

(3 x 380-440 V) [A]

24 32 37.5 44 61 73 90 106 147 177

Intermittent

(3 x 380-440 V) [A]

26.4 35.2 41.3 48.4 67.1 80.3 99 117 162 195

Continuous

(3 x 441-480 V) [A]

21 27 34 40 52 65 80 105 130 160

Intermittent

(3 x 441-480 V) [A]

23.1 29.7 37.4 44 61.6 71.5 88 116 143 176

Continuous kVA

(400 V AC) [kVA]

16.6 22.2 26 30.5 42.3 50.6 62.4 73.4 102 123

Continuous kVA

(460 V AC) [kVA]

16.7 21.5 27.1 31.9 41.4 51.8 63.7 83.7 104 128

Max. cable size:

(mains, motor, brake)

[[mm

/ AWG]

10/7 35/2 50/1/0 120/4/0 120/4/0

Max. input current

Continuous

(3 x 380-440 V ) [A]

22 29 34 40 55 66 82 96 133 161

Intermittent

(3 x 380-440 V ) [A]

24.2 31.9 37.4 44 60.5 72.6 90.2 106 146 177

Continuous

(3 x 441-480 V) [A]

19 25 31 36 47 59 73 95 118 145

Intermittent

(3 x 441-480 V) [A]

20.9 27.5 34.1 39.6 51.7 64.9 80.3 105 130 160

Max. pre-fuses

[A]

63 63 63 63 80 100 125 160 250 250

Environment

Estimated power loss

at rated max. load [W]

278 392 465 525 698 739 843 1083 1384 1474

Weight enclosure IP20 [kg] 12 12 12 23.5 23.5 23.5 35 35 50 50

Weight enclosure IP 21 [kg] 23 23 23 27 27 45 45 45 65 65

Weight enclosure IP 55 [kg] 23 23 23 27 27 45 45 45 65 65

Weight enclosure IP 66 [kg] 23 23 23 27 27 45 45 45 65 65

Efficiency

0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.99

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Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW] at 400V

P110

110

P132

132

P160

160

P200

200

P250

250

315

P400

400

P450

450

P500

500

P560

560

P630

630

P710

710

P800

800

P1M0

1000

Typical Shaft Output [HP] at 460V 150 200 250 300 350 450 550 600 650 750 900 1000 1200 1350

IP 00 D3 D3 D4 D4 D4 E2 E2 E2 F1/F3 F1/F3 F1/F3 F1/F3 F2/F4 F2/F4

IP 21 / Nema 1 D1 D1 D2 D2 D2 E1 E1 E1 F1/F3 F1/F3 F1/F3 F1/F3 F2/F4 F2/F4

IP 54 / Nema 12 D1 D1 D2 D2 D2 E1 E1 E1 F1/F3 F1/F3 F1/F3 F1/F3 F2/F4 F2/F4

Output current

Continuous (3 x 380-440 V) [A] 212 260 315 395 480 600 745 800 880 990 1120 1260 1460 1720

Intermittent (3 x 380-440 V) [A] 233 286 347 435 528 660 820 880 968 1089 1232 1386 1606 1892

Continuous (3 x 441-480V) [A] 190 240 302 361 443 540 678 730 780 890 1050 1160 1380 1530

Intermittent (3 x 441-480V) [A] 209 264 332 397 487 594 746 803 858 979 1155 1276 1518 1683

Continuous kVA (400 VAC) [kVA] 147 180 218 274 333 416 516 554 610 686 776 873 1012 1192

Continuous kVA (460 VAC) [kVA] 151 191 241 288 353 430 540 582 621 709 837 924 1100 1219

Max. cable size:

( motor,) [mm

/ AWG

]

2x70

2x2/0

2x185

2x300 mcm

4x240

4x500 mcm

8x150

8x300 mcm

12x150

12x300 mcm

(mains, ) [mm

/ AWG

]

2x70

2x2/0

2x185

2x300 mcm

4x240

4x500 mcm

8x240

8x500 mcm

(loadsharing) [mm

/ AWG

]

2x70

2x2/0

2x185

2x300 mcm

4x240

4x500 mcm

4x120

4x250 mcm

( brake) [mm

/ AWG

]

2x70

2x2/0

2x185

2x300 mcm

2x185

2x350 mcm

4x185

4x350 mcm

6x185

6x350 mcm

Max. input current

Continuous (3 x 380-440 V) [A] 204 251 304 381 463 590 733 787 857 964 1090 1227 1422 1675

Continuous (3 x 441-480V) [A] 183 231 291 348 427 531 667 718 759 867 1022 1129 1344 1490

Max. pre-fuses

[A]

300 350 400 500 630 700 900 900 1600 1600 20 00 2000 2500 2500

Environment:

Estimated power loss at 400 VAC

at rated max. load [W]

3234 3782 4213 5119 5893 6790 8879 9670 10647 12338 13201 15436 18084 20358

Estimated power loss at 460 VAC

at rated max. load [W]

2947 3665 4063 4652 5634 6082 8089 8803 9414 11006 12353 14041 17137 17752

Weight enclosure IP00 [kg] 82 91 112 123 138 221 236 277 - - - - - -

Weight enclosure IP 21 [kg] 96 104 125 136 151 263 272 313 1004 1004 1004 1004 1246 1246

Weight enclosure IP 54 [kg] 96 104 125 136 151 263 272 313 1299 1299 1299 1299 1541 1541

Efficiency

0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98

For type of fuse see section

Fuses

American Wire Gauge3) Measured using 5 m screened motor cables at rated load and rated frequency4) The typical power loss is at normal load conditions and expected to be within +/- 15% (tolerance relates to variety in voltage and cable conditions).

Values are based on a typical motor efficiency (eff2/eff3 border line). L ower efficiency motors will also add to the power loss in the frequency converter and vice versa.

If the switching frequency is raised from nominal the power losses may rise significantly.

LCP and typical control card power consumptions are included. Further options and customer load may add up to 30 Watts to the losses. (Though typically only 4 Watts extra for a fully loaded control card or options

for slot A or slot B, each).

Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5 %).

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Normal overload 110% for 1 minute

Size: PK75 P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Typical Shaft Output [kW] 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90

IP 20 / NEMA Chassis A2 A2 A2 A2 A2 A2 A3 A3 B3 B3 B3 B4 B4 B4 C3 C3 C4 C4

IP 21 / NEMA 1 A2A2A2A2A2A2A3A3B1 B1B1B2 B2B2 C1 C1C2C2

IP 55 / NEMA 12 A5 A5 A5 A5 A5 A5 A5 A5 B1 B1 B1 B2 B2 B2 C1 C1 C2 C2

IP 66 A5 A5 A5 A5 A5 A5 A5 A5 B1 B1 B1 B2 B2 B2 C1 C1 C2 C2

Output current

Continuous

(3 x 525-550 V ) [A]

1.8 2.6 2.9 4.1 5.2 6.4 9.5 11.5 19 23 28 36 43 54 65 87 105 137

Intermittent

(3 x 525-550 V ) [A]

2.9 3.2 4.5 5.7 7.0 10.5 12.7 21 25 31 40 47 59 72 96 116 151

Continuous

(3 x 525-600 V ) [A]

1.7 2.4 2.7 3.9 4.9 6.1 9.0 11.0 18 22 27 34 41 52 62 83 100 131

Intermittent

(3 x 525-600 V ) [A]

2.6 3.0 4.3 5.4 6.7 9.9 12.1 20 24 30 37 45 57 68 91 110 144

Continuous kVA (525 V AC)

[kVA]

1.7 2.5 2.8 3.9 5.0 6.1 9.0 11.0 18.1 21.9 26.7 34.3 41 51.4 61.9 82.9 100 130.5

Continuous kVA (575 V AC)

[kVA]

1.7 2.4 2.7 3.9 4.9 6.1 9.0 11.0 17.9 21.9 26.9 33.9 40.8 51.8 61.7 82.7 99.6 130.5

Max. cable size

(mains, motor, brake)

[AWG]

[mm

]

24 - 10 AWG

0.2 - 4

3/0

Max. input current

Continuous

(3 x 525-600 V ) [A]

1.7 2.4 2.7 4.1 5.2 5.8 8.6 10.4 17.2 20.9 25.4 32.7 39 49 59 78.9 95.3 124.3

Intermittent

(3 x 525-600 V ) [A]

2.7 3.0 4.5 5.7 6.4 9.5 11.5 19 23 28 36 43 54 65 87 105 137

Max. pre-fuses

[A]

10 10 10 20 20 20 32 32 40 40 50 60 80 100 150 160 225 250

Environment:

Estimated power loss

at rated max. load [W]

35 50 65 92 122 145 195 261 225 285 329 460 560 740 860 890 1020 1130

Weight [kg]:

Enclosure IP20 6.5 6.5 6.5 6.5 6.5 6.5 6.6 6.6 12 12 12 23.5 23.5 23.5 35 35 50 50

Efficiency

0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98

Table 3.1:

Motor and mains cable: 300MCM/150mm

3.1.5 Mains Supply 3 x 525 - 600 VAC

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Normal overload 110% for 1 minute

Size: P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K

Typical Shaft Output [kW] 11 15 18.5 22 30 3 7 45 55 75 9 0

Typical Shaft Output [HP] at 575 V 10 16.4 20.1 24 33 40 50 60 75 100

IP 21 / NEMA 1 B2 B2 B2 B2 B2 C2 C2 C2 C2 C2

IP 55 / NEMA 12 B2 B2 B2 B2 B2 C2 C2 C2 C2 C2

Output current

Continuous

(3 x 525-550 V ) [A]

14 19 23 28 36 43 54 65 87 105

Intermittent

(3 x 525-550 V ) [A]

15.4 20.9 25.3 30.8 39.6 47.3 59.4 71.5 95.7 115.5

Continuous

(3 x 551-690 V ) [A]

13 18 22 27 34 41 52 62 83 100

Intermittent

(3 x 551-690 V ) [A]

14.3 19.8 24.2 29.7 37.4 45.1 57.2 68.2 91.3 110

Continuous kVA (550 V AC) [kVA] 13.3 18.1 21.9 26.7 34.3 41 51.4 61.9 82.9 100

Continuous kVA (575 V AC) [kVA] 12.9 17.9 21.9 26.9 33.8 40.8 51.8 61.7 82.7 99.6

Continuous kVA (690 V AC) [kVA]

15.5

21.5 26.3 32.3

40.6 49

62.1 74.1 99.2 119.5

Max. cable size

(mains, motor, brake)

[mm

]/[AWG]

1/0

4/0

Max. input current

Continuous

(3 x 525-690 V ) [A]

15 19.5 24 29 36 49 59 71 87 99

Intermittent

(3 x 525-690 V ) [A]

16.5 21.5 26.4 31.9 39.6 53.9 64.9 78.1 95.7 108.9

Max. pre-fuses

[A]

60 60 60 60 60 150 150 150 150 150

Environment:

Estimated power loss

at rated max. load [W]

201 285 335 375 430 592 720 880 1200 1440

Weight:

IP21 [kg] 27 27 27 27 27 65 65 65 65 65

IP55 [kg] 27 27 27 27 27 65 65 65 65 65

Efficiency

0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98

Table 3.2:

Motor and mains cable: 300MCM/150mm

3.1.6 Mains Supply 3 x 525 - 690 VAC

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Normal overload 110% for 1 minute

Frequency converter

Typical Shaft Output [kW]

P45K

P55K

P75K

P90K

P110

110

P132

132

P160

160

P200

200

P250

250

P315

315

P400

400

P450

450

P500

500

P560

560

P630

630

P710

710

P800

800

P900

900

P1M0

1000

P1M2

1200

Typical Shaft Output [HP] at 575 V 50 60 75 100 125 150 200 250 300 350 400 450 500 600 650 750 950 1050 1150 1350

IP 00 D3 D3 D3 D3 D3 D3 D3 D4 D4 D4 D4 E2 E2 E2 E2 - - - - -

IP 21 / Nema 1 D1 D1 D1 D1 D1 D1 D1 D2 D2 D2 D2 E1 E1 E1 E1

F1/

F2/

IP 54 / Nema 12 D1 D1 D1 D1 D1 D1 D1 D2 D2 D2 D2 E1 E1 E1 E1

F1/

Output current

Continuous (3 x 550 V) [A] 56 76 90 113 137 162 201 253 303 360 41 8 470 523 596 630 763 889 988 1108 1317

Intermittent (3 x 550 V) [A] 62 84 99 124 151 178 221 278 333 396 460 517 575 656 693 839 978 1087 1219 1449

Continuous (3 x 690V) [A] 54 73 86 108 131 155 192 242 290 344 400 450 500 570 630 730 850 945 1060 1260

Intermittent (3 x 690 V) [A] 59 80 95 119 144 171 211 266 319 378 440 495 550 627 693 803 935 1040 1166 1386

Continuous kVA (550 VAC) [kVA] 53 72 86 108 131 154 191 241 289 343 398 448 498 568 600 727 847 941 1056 1255

Continuous kVA (575 VAC) [kVA] 54 73 86 108 130 154 191 241 289 343 398 448 498 568 627 727 847 941 1056 1255

Continuous kVA (690 VACr) [kVA] 65 87 103 129 157 185 229 289 347 411 478 538 598 681 753 872 1016 1129 1267 1506

Max. cable size:

(Mains) [mm

/ AWG]

2x70

2x2/0

2x185

2x300 mcm

4x240

4x500 mcm

8x240

8x500 mcm

8x240

8x500 mcm

(Motor) [mm

/ AWG]

2x70

2x2/0

2x185

2x300 mcm

4x240

4x500 mcm

8x150

8x300 mcm

12x150

12x300 mcm

(Brake) [mm

/ AWG]

2x70

2x2/0

2x185

2x300 mcm

2x185

2x350 mcm

4x185

4x350 mcm

6x185

6x350 mcm

Max. input current

Continuous (3 x 550 V) [A] 60 77 89 110 130 158 198 245 299 355 40 8 453 504 574 607 743 866 962 1079 1282

Continuous (3 x 575 V) [A] 58 74 85 106 124 151 189 224 286 339 390 434 482 549 607 711 828 920 1032 1227

Continuous (3 x 690 V) [A] 58 77 87 109 128 155 197 240 296 352 40 0 434 482 549 607 711 828 920 1032 1227

Max. mains pre-fuses

[A]

125 160 200 200 250 315 350 350 400 500 550 700 700 900 900 2000 2000 2000 2000 2000

Environment:

Estimated power loss at 690 VAC

at rated max. load [W]

1458 1717 1913 2262 2662 3430 3612 4292 5156 5821 6149 6440 7249 8727 9673 11315

1290

14533

1637

19207

Estimated power loss at 575 VAC

at rated max. load [W]

1398 1645 1827 2157 2533 2963 3430 4051 4867 5493 5852 6132 6903 8343 9244 10771

1227

13835

1559

18281

Weight enclosure IP00 [kg] 82 82 82 82 82 82 91 112 123 138 151 221 221 236 277 - - - - -

Weight enclosure IP 21 [kg]

96 96 96 96 96 96 104 125 136 151 165 263 263 272 313 1004 1004 1004 1246 1246

Weight enclosure IP 54 [kg]

96 96 96 96 96 96 104 125 136 151 165 263 263 272 313 1004 1004 1004 1246 1246

Efficiency

0.97 0.97 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98

For type of fuse see section

Fuses

American Wire Gauge3) Measured using 5 m screened motor cables at rated load and rated frequency4) The typical power loss is at normal load conditions and expected to be within +/- 15% (tolera nce relates to variety in voltage and cable conditions). Values are based on a typical motor efficien cy (eff2/eff3 border

line). Lower efficiency motors will also add to the power loss in the frequency converter and vice versa.

If the switching frequency is raised from nominal the power losses may rise significantly. LCP and typical control card power consumptions are included. Further option s and customer load may add up to 30 [W]

to the losses. (Though typically only 4 [W] extra for a fully loaded control card, or option s for slot A or slot B, each).

Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/- 5 %).

Adding the F-enclosure option cabinet (resulting in the F3 and F4 enclosure sizes) adds 295 kg to the estimated weight.

3.1.7 Mains Supply 3 x 525 - 690 VAC

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Protection and Features:

• Electronic thermal motor protection against overload.

• Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches 95 °C ± 5°C. An overload tem-

perature cannot be reset until the temperature of the heatsink is below 70 °C ± 5°C (Guideline - these temperatures may vary for different

power sizes, enclosures etc.). VLT Automation VT Drive Drive has an auto derating function to avoid it's heatsink reaching 95 °C.

• The frequency converter is protected against short-circuits on motor terminals U, V, W.

• If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

• Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high.

• The frequency converter is protected against earth faults on motor terminals U, V, W.

Mains supply (L1, L2, L3):

Supply voltage 200-240 V ±10%

Supply voltage 380-480 V ±10%

Supply voltage 525-600 V ±10%

Supply voltage 525-690 V ±10%

Mains voltage low / mains drop-out:

During low mains voltage or a mains drop-out, the FC continues until the intermediate circuit voltage drops below the minimum stop level, which

corresponds typically to 15% below the FC's lowest rated supply voltage. Power-up and full torque cannot be expected a t mains voltage lower than

10% below the FC's lowest rated supply voltage.

Supply frequency 50/60 Hz +4/-6%

The frequency converter power supply is tested in accordance with IEC61000-4-28, 50 Hz +4/-6%.

Max. imbalance temporary between mains phases 3.0 % of rated supply voltage

True Power Factor (λ) ≥ 0.9 nominal at rated load

Displacement Power Factor (cosφ) near unity (> 0.98)

Switching on input supply L1, L2, L3 (power-ups) ≤ enclosure type A maximum 2 times/min.

Switching on input supply L1, L2, L3 (power-ups) ≥ enclosure type B, C maximum 1 time/min.

Switching on input supply L1, L2, L3 (power-ups) ≥ enclosure type D, E, F ma ximum 1 time/2 min.

Environment according to EN60664-1 overvoltage category III/pollution degree 2

The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 240/480 V maximum.

Motor output (U, V, W):

Output voltage 0 - 100% of supply voltage

Output frequency 0 - 1000 Hz

Switching on output Unlimited

Ramp times 1 - 3600 sec.

Dependent on power size.

Torque characteristics:

Starting torque (Constant torque) maximum 110% for 1 min.

Starting torque maximum 135% up to 0.5 sec.

Overload torque (Constant torque) maximum 110% for 1 min.

*Percentage relates to VLT Automation VT Drive's nominal torque.

Cable lengths and cross sections:

Max. motor cable length, screened/armoured VLT Automation VT Drive: 150 m

Max. motor cable length, unscreened/unarmoured VLT Automation VT Drive: 300 m

Max. cross section to motor, mains, load sharing and brake *

Maximum cross section to control terminals, rigid wire 1.5 mm2/16 AWG (2 x 0.75 mm2)

Maximum cross section to control terminals, flexible cable 1 mm2/18 AWG

Maximum cross section to control terminals, cable with enclosed core 0.5 mm2/20 AWG

Minimum cross section to control terminals 0.25 mm

* See Mains Supply tables for more information!

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Control card, RS-485 serial communication:

Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-)

Terminal number 61 Common for terminals 68 and 69

The RS-485 serial communication circuit is functionally separated from othe r central circuits and galvanically isolated from the supply voltage (PELV).

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Analog inputs:

Number of analog inputs 2

Terminal number 53, 54

Modes Voltage or current

Mode select Switch S201 and switch S202

Voltage mode Switch S201/switch S202 = OFF (U)

Voltage level : 0 to + 10 V (scaleable)

Input resistance, R

approx. 10 kΩ

Max. voltage ± 20 V

Current mode Switch S201/switch S202 = ON (I)

Current level 0/4 to 20 mA (scaleable)

Input resistance, R

approx. 200 Ω

Max. current 30 mA

Resolution for analog inputs 10 bit (+ sign)

Accuracy of analog inputs Max. error 0.5% of full scale

Bandwidth : 200 Hz

The analog inputs are galvanically isolated from the su pply voltage (PELV) and other high-voltage terminals.

Analog output:

Number of programmable analog outputs 1

Terminal number 42

Current range at analog output 0/4 - 20 mA

Max. resistor load to common at analog output 500 Ω

Accuracy on analog output Max. error: 0.8 % of full scale

Resolution on analog output 8 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Digital inputs:

Programmable digital inputs 4 (6)

Terminal number 18, 19, 27

, 29

, 32, 33,

Logic PNP or NPN

Voltage level 0 - 24 V DC

Voltage level, logic'0' PNP < 5 V DC

Voltage level, logic'1' PNP > 10 V DC

Voltage level, logic '0' NPN > 19 V DC

Voltage level, logic '1' NPN < 14 V DC

Maximum voltage on input 28 V DC

Input resistance, R

approx. 4 k

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as output.

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Digital output:

Programmable digital/pulse outputs 2

Terminal number 27, 29

Voltage level at digital/frequency output 0 - 24 V

Max. output current (sink or source) 40 mA

Max. load at frequency output 1 kΩ

Max. capacitive load at frequency output 10 nF

Minimum output frequency at frequency output 0 Hz

Maximum output frequency at frequency output 32 kHz

Accuracy of frequency output Max. error: 0.1 % of full scale

Resolution of frequency outputs 12 bit

1) Terminal 27 and 29 can also be programmed as input.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Pulse inputs:

Programmable pulse inputs 2

Terminal number pulse 29, 33

Max. frequency at terminal, 29, 33 110 kHz (Push-pull driven)

Max. frequency at terminal, 29, 33 5 kHz (open collector)

Min. frequency at terminal 29, 33 4 Hz

Voltage level see section on Digital input

Maximum voltage on input 28 V DC

Input resistance, R

approx. 4 kΩ

Pulse input accuracy (0.1 - 1 kHz) Max. error: 0.1% of full scale

Control card, 24 V DC output:

Terminal number 12, 13

Max. load : 200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital input s and outputs.

Relay outputs:

Programmable relay outputs 2

Relay 01 Terminal number 1-3 (break), 1-2 (make)

Max. terminal load (AC-1)1) on 1-3 (NC), 1-2 (NO) (Resistive load) 240 V AC, 2 A

Max. terminal load (AC-15)1) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Max. terminal load (DC-1)1) on 1-2 (NO), 1-3 (NC) (Resistive load) 60 V DC, 1A

Max. terminal load (DC-13)1) (Inductive load) 24 V DC, 0.1A

Relay 02 Terminal number 4-6 (break), 4-5 (make)

Max. terminal load (AC-1)1) on 4-5 (NO) (Resistive load)

2)3)

400 V AC, 2 A

Max. terminal load (AC-15)1) on 4-5 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Max. terminal load (DC-1)1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A

Max. terminal load (DC-13)1) on 4-5 (NO) (Inductive load) 24 V DC, 0.1A

Max. terminal load (AC-1)1) on 4-6 (NC) (Resistive load) 240 V AC, 2 A

Max. terminal load (AC-15)1) on 4-6 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2A

Max. terminal load (DC-1)1) on 4-6 (NC) (Resistive load) 50 V DC, 2 A

Max. terminal load (DC-13)1) on 4-6 (NC) (Inductive load) 24 V DC, 0.1 A

Min. terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO) 24 V DC 10 mA, 24 V AC 20 mA

Environment according to EN 60664-1 overvoltage category III/pollution degree 2

1) IEC 60947 part 4 and 5

The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

2) Overvoltage Category II

3) UL applications 300 V AC 2A

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Control card, 10 V DC output:

Terminal number 50

Output voltage 10.5 V ±0.5 V

Max. load 25 mA

The 10 V DC supply is galvanically isolated from the supply vol tage (PELV) and other high-voltage terminals.

Control characteristics:

Resolution of output frequency at 0 - 1000 Hz : +/- 0.003 Hz

System response time (terminals 18, 19, 27, 29, 32, 33) : ≤ 2 ms

Speed control range (open loop) 1:100 of synchronous speed

Speed accuracy (open loop) 30 - 4000 rpm: Maximum error of ±8 rpm

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

Surroundings:

Enclosure type A IP 20/Chassis, IP 21kit/Type 1, IP55/Type12, IP 66

Enclosure type B1/B2 IP 21/Type 1, IP55/Type12, IP 66

Enclosure type B3/B4 IP20/Chassis

Enclosure type C1/C2 IP 21/Type 1, IP55/Type 12, IP66

Enclosure type C3/C4 IP20/Chassis

Enclosure type D1/D2/E1 IP21/Type 1, IP54/Type12

Enclosure type D3/D4/E2 IP00/Chassis

Enclosure kit available ≤ enclosure type A IP21/TYPE 1/IP 4X top

Vibration test enclosure A/B/C 1.0 g

Vibration test enclosure D/E/F 0.7 g

Max. relative humidity 5% - 95%(IEC 721-3-3; Class 3K3 (non-condensing) during ope ration

Aggressive environment (IEC 721-3-3), uncoated class 3C2

Aggressive environment (IEC 721-3-3), coated class 3C3

Test method according to IEC 60068-2-43 H2S (10 days)

Ambient temperature Max. 50 °C

Derating for high ambient temperature, see section on special conditions

Minimum ambient temperature during full-scale operation 0 °C

Minimum ambient temperature at reduced performance - 10 °C

Temperature during storage/transport -25 - +65/70 °C

Maximum altitude above sea level without derating 1000 m

Maximum altitude above sea level with derating 3000 m

Derating for high altitude, see section on special conditions

EMC standards, Emission EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3

EMC standards, Immunity

EN 61800-3, EN 61000-6-1/2,

EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

See section on special conditions

Control card performance:

Scan interval : 5 ms

Control card, USB serial communication:

USB standard 1.1 (Full speed)

USB plug USB type B “device” plug

Connection to PC is carried out via a standard host/device USB cable.

The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

The USB connection is

not galvanically isolated from protection earth. Use only isolated laptop/PC as connection to the USB connector

on VLT Automation VT Drive or an isolated USB cable/converter.

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3.2 Efficiency

Efficiency of VLT Automation VT Drive (η

VLT

)

The load on the frequency converter has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f

M,N

, even if the

motor supplies 100% of the rated shaft torque or only 75%, i.e. in case of part loads.

This also means that the efficiency of the frequency converter does not change even if other U /f characteristics are chosen.

However, the U/f characteristics influence the efficiency of the motor.

The efficiency declines a little when the switching frequency is set to a value of above 5 kHz. The efficiency will also be slightly re duced if the mains

voltage is 480 V, or if the motor cable is longer than 30 m.

Efficiency of the motor (η)

MOTOR

The efficiency of a motor connected to the frequency converter depends on magnetising level. In general, the efficiency is just as good as with mains

operation. The efficiency of the motor depends on the type of motor.

In the range of 75-100% of the rated torque, the efficiency of the motor is practically constant, both when it is controlled by the frequency converter

and when it runs directly on mains.

In small motors, the influence from the U/f characteristic on efficie ncy i s ma rgin al. H owev er, i n mot ors f rom 1 1 kW a nd up , the advantages are significant.

In general, the switching frequency does not affect the efficiency of sm all mot ors. Mo tors f rom 11 k W and up have t heir ef ficiency improve d (1-2%). This

is because the sine shape of the motor current is almost perfect at high switching frequency.

Efficiency of the system (η

SYSTEM

To calculate the system efficiency, the efficiency of VLT Automation VT Drive (η

VLT

) is multiplied by the efficiency of the motor (η

MOTOR

SYSTEM

) = η

VLT

x η

MOTOR

Calculate the efficiency of the system at different loads based on the graph above.

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3.3 Acoustic Noise

The acoustic noise from the frequency converter comes from three sources:

1. DC intermediate circuit coils.

2. Integral fan.

3. RFI filter choke.

The typical values measured at a distance of 1 m from the unit:

Enclosure At reduced fan speed (50%) [dBA] *** Full fan speed [dBA]

A2 51 60

A3 51 60

A5 54 63

B1 61 67

B2 58 70

B3 59.4 70.5

B4 53 62.8

C1 52 62

C2 55 65

C3 56.4 67.3

C4 --

D1+D3 74 76

D2+D4 73 74

E1/E2 * 73 74

E1/E2 ** 82 83

F1/F2/F3/F4 78 80

* 315 kW, 380-480 VAC and 450/500 kW, 525-690 VAC only!

** Remaining E1+E2 power sizes.

*** For D, E and F sizes, reduced fan speed is at 87%, measured at 200 V.

3.4 Peak Voltage on Motor

When a transistor in the inverter bridge switches, the voltage across the motor increases by a du/dt ratio depending on:

- the motor cable (type, cross-section, length screened or unscreened)

- inductance

The natural induction causes an overshoot U

PEAK

in the motor voltage before it stabilizes itself at a level depending on the voltage in the intermediate

circuit. The rise time and the peak voltage U

PEAK

affect the service life of the motor. If the peak voltage is too high, especially motors without phase coil

insulation are affected. If the motor cable is short (a few metres), the rise time and peak voltage are low er.

If the motor cable is long (100 m), the rise time and peak voltage increa ses.

In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter),

fit a sine-wave filter on the output of the frequency converter.

To obtain approximate values for cable lengths and voltages not mentioned below, use the following rules of thumb:

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1. Rise time increases/decreases proportionally with cable length.

2. U

PEAK

= DC link voltage x 1.9

(DC link voltage = Mains voltage x 1.35).

dU/dt

0.8 ×

PEAK

Risetime

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Data are measured according to IEC 60034-17.

Cable lengths are in metres.

FC322, P7K5T2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 230 0.13 0.510 3.090

50 230 0.23 2.034

100 230 0.54 0.580 0.865

150 230 0.66 0.560 0.674

FC322, P11KT2

Cable

length [m]

Mains

voltage [V]

Rise time [μsec]

Vpeak

[kV]

dU/dt [kV/μsec]

36 240 0.264 0.624 1.890

136 240 0.536 0.596 0.889

150 240 0.568 0.568 0.800

FC322, P15KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 240 0.556 0.650 0.935

100 240 0.592 0.594 0.802

150 240 0.708 0.587 0.663

FC322, P18KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

36 240 0.244 0.608 1.993

136 240 0.568 0.580 0.816

150 240 0.720 0.574 0.637

FC322, P22KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

36 240 0.244 0.608 1.993

136 240 0.568 0.580 0.816

150 240 0.720 0.574 0.637

FC322, P30KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

15 240 0.194 0.626 2.581

50 240 0.252 0.574 1.822

150 240 0.488 0.538 0.882

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FC322, P37KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 240 0.300 0.598 1.594

100 240 0.536 0.566 0.844

150 240 0.776 0.546 0.562

FC322, P45KT2

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 240 0.300 0.598 1.594

100 240 0.536 0.566 0.844

150 240 0.776 0.546 0.562

FC322, P1K5T4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 690 0.640 0.690 0.862

50 985 0.470 0.985

150 1045 0.760 1.045 0.947

FC322, P4K0T4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 400 0.172 0.890 4.156

50 400 0.310 2.564

150 400 0.370 1.190 1.770

FC322, P7K5T4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 500 0.04755 0.739 8.035

50 500 0.207 4.548

150 500 0.6742 1.030 2.828

FC322, P11KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

15 480 0.192 1.300 5.416

100 480 0.612 1.300 1.699

150 480 0.512 1.290 2.015

FC322, P15KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

36 480 0.396 1.210 2.444

100 480 0.844 1.230 1.165

150 480 0.696 1.160 1.333

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FC322, P18KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

36 480 0.396 1.210 2.444

100 480 0.844 1.230 1.165

150 480 0.696 1.160 1.333

FC322, P22KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

36 480 0.312 2.846

100 480 0.556 1.250 1.798

150 480 0.608 1.230 1.618

FC322, P30KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

15 480 0.288 3.083

100 480 0.492 1.230 2.000

150 480 0.468 1.190 2.034

FC322, P37KT4

Cable

length [m]

Mains

voltage

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 480 0.368 1.270 2.853

50 480 0.536 1.260 1.978

100 480 0.680 1.240 1.426

150 480 0.712 1.200 1.334

FC322, P45KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 480 0.368 1.270 2.853

50 480 0.536 1.260 1.978

100 480 0.680 1.240 1.426

150 480 0.712 1.200 1.334

FC322, P55KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

15 480 0.256 1.230 3.847

50 480 0.328 1.200 2.957

100 480 0.456 1.200 2.127

150 480 0.960 1.150 1.052

FC322, P75KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 480 0.371 1.170 2.523

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FC322, P90KT4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

5 480 0.371 1.170 2.523

High Power Range:

FC322, P110 - P250, T4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 400 0.34 1.040 2.447

FC322, P315 - P1M0, T4

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 500 0.71 1.165 1.389

30 400 0.61 0.942 1.233

FC322, P110 - P400, T7

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 690 0.38 1.513 3.304

30 575 0.23 1.313 2.750

690

1.72 1.329 0.640

1) With Danfoss dU/dt filter.

FC322, P450 - P1M2, T7

Cable

length [m]

Mains

voltage [V]

Rise time

[μsec]

Vpeak

[kV]

dU/dt

[kV/μsec]

30 690 0.57 1.611 2.261

30 575 0.25 2.510

690

1.13 1.629 1.150

1) With Danfoss dU/dt filter.

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3.5 Special Conditions

3.5.1 Purpose of Derating

Derating must be taken into account when using the frequency converter at low air pressure (heights), at low speeds, with long motor cables, cables

with a large cross section or at high ambient temperatur e. The required action is described in this section.

3.5.2 Derating for Ambient Temperature

The average temperature (T

AMB, AVG

) measured over 24 hours must be at least 5 °C lower than the maximum allowed ambient temperature (T

AMB,MAX

If the frequency converter is operated at high ambient temperatures, the continuous output current should be decreased.

The derating depends on the switching pattern, which can be set to 60 AVM or SFAVM in parameter 14-00.

A enclosures

60 AVM - Pulse Width Modulation

Illustration 3.1: Derating of I

out

for different T

AMB, MAX

for

enclosure A, using 60 AVM

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.2: Derating of I

out

for different T

AMB, MAX

for

enclosure A, using SFAVM

In enclosure A, the length of the motor cable has a relatively high impact on the recommended derating. Therefore, the recommended derating for an

application with max. 10 m motor cable is also shown.

Illustration 3.3: Derating of I

out

for different T

AMB, MAX

for

enclosure A, using 60 AVM and maximum 10 m motor cable

Illustration 3.4: Derating of I

out

for different T

AMB, MAX

for

enclosure A, using SFAVM and maximum 10 m motor cable

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B enclosures

60 AVM - Pulse Width Modulation

Illustration 3.5: Derating of I

out

for different T

AMB, MAX

for

enclosure B, using 60 AVM in Normal torque mode (110%

over torque)

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.6: Derating of I

out

for different T

AMB, MAX

for

enclosure B, using SFAVM in Normal torque mode (110%

over torque)

C enclosures

Please note: For 90 kW in IP55 and IP66 the max. ambient temperature is 5° C lower.

60 AVM - Pulse Width Modulation

Illustration 3.7: Derating of I

out

for different T

AMB, MAX

for

enclosure C, using 60 AVM in Normal torque mode (110%

over torque)

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.8: Derating of I

out

for different T

AMB, MAX

for

enclosure C, using SFAVM in Normal torque mode (110%

over torque)

D enclosures

60 AVM - Pulse Width Modulation, 380 - 480 V

Illustration 3.9: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 480 V, using 60 AVM in Normal torque mode

(110% over torque)

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.10: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 480 V, using SFAVM in Normal torque mode

(110% over torque)

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60 AVM - Pulse Width Modulation, 525 - 690 V (except P400)

Illustration 3.11: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 690 V, using 60 AVM in Normal torque mode

(110% over torque). Note:

not

valid for P400.

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.12: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 690 V, using SFAVM in Normal torque mode

(110% over torque). Note:

not

valid for P400.

60 AVM - Pulse Width Modulation, 525 - 690 V, P400

Illustration 3.13: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 690 V, using 60 AVM in Normal torque mode

(110% over torque). Note: P400

only

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.14: Derating of I

out

for different T

AMB, MAX

for

enclosure D at 690 V, using SFAVM in Normal torque mode

(110% over torque). Note: P400

only

E and F enclosures

60 AVM - Pulse Width Modulation, 380 - 480 V

Illustration 3.15: Derating of I

out

for different T

AMB, MAX

for

enclosure E at 480 V, using 60 AVM in Normal torque mode

(110% over torque)

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.16: Derating of I

out

for different T

AMB, MAX

for

enclosure E and F at 480 V, using SFAVM in Normal torque

mode (110% over torque)

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60 AVM - Pulse Width Modulation, 525 - 690 V

Illustration 3.17: Derating of I

out

for different T

AMB, MAX

for

enclosure E and F at 690 V, using 60 AVM in Normal torque

mode (110% over torque).

SFAVM - Stator Frequency Asyncron Vector Modulation

Illustration 3.18: Derating of I

out

for different T

AMB, MAX

for

enclosure E and F at 690 V, using SFAVM in Normal torque

mode (110% over torque).

3.5.3 Derating for Low Air Pressure

The cooling capability of air is decreased at lower air pressure.

Below 1000 m altitude no derating is necessary but above 1000 m the ambient temperature (T

AMB

) or max. output current (I

out

) should be derated in

accordance with the shown diagram.

Illustration 3.19: Derating of output current versus altitude at T

AMB, MAX

for frame sizes A, B and C. At altitudes above 2 km, please contact

Danfoss Drives regarding PELV.

An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to

read the graph, the situation at 2 km is elaborated. At a temperature of 45° C (T

AMB, MAX

- 3.3 K), 91% of the rated output current is available. At a

temperature of 41.7° C, 100% of the rated output current is available.

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Derating of output current versus altitude at T

AMB, MAX

for frame sizes D, E and F.

3.5.4 Derating for Running at Low Speed

When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate.

The level of heating depends on the load on the motor, as well as the operating speed and time.

Constant torque applications (CT mode)

A problem may occur at low RPM values in constant torque applications. In a constant torque application s a motor may over-heat at low speeds due to

less cooling air from the motor integral fan.

Therefore, if the motor is to be run continuously at an RPM value lower than half of the rated value, the motor must be supplied with ad ditional air-cooling

(or a motor designed for this type of operation may be used).

An alternative is to reduce the load level of the motor by choosing a larger motor. However, the design of the frequency converter puts a limit to the

motor size.

Variable (Quadratic) torque applications (VT)

In VT applications such as centrifugal pumps and fans, where th e torque is proportional to the square of the speed and the power is proportional to the

cube of the speed, there is no need for additional cooling or de-rating of the motor.

In the graphs shown below, the typical VT curve is below the maximum torque with de-rating and maximum torque with forced cooling at all speeds.

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Maximum Load for a Standard Motor at 40 °C driven by a frequency converter type VLT FCxxx

Legend: ─ ─ ─ ─Typical torque at VT load ─•─•─•─Max torque with forced cooling ‒‒‒‒‒Max torque

Note 1) Over-syncronous speed operation will result in the available motor torque decreasing inversely proportional with the increase in speed. This

must be considered during the design phase to avoid over-loading of the motor.

3.5.5 Derating for Installing Long Motor Cables or Cables with Larger Cross-Section

NB!

Applicable for drives up to 90 kW only.

The maximum cable length for this frequency converter is 300 m unscreened and 150 m screened cable.

The frequency converter has been designed to work using a motor cable with a rated cross-section. If a cable with a larger cross-section is used, reduce

the output current by 5% for every step the cross-section is increased.

(Increased cable cross-section leads to increased capacity to earth, and thus an increased earth leakage current).

3.5.6 Automatic Adaptations to Ensure Performance

The frequency converter constantly checks for critical levels of internal temperature, load current, high voltage on the intermediate circuit and low motor

speeds. As a response to a critical level, the frequency converter can adjust the switching frequency and / or change the switching pattern in order to

ensure the performance of the frequency converter. The capability to automatically reduce the output current extends the acceptable operating conditions

even further.

3.6 Options and Accessories

Danfoss offers a wide range of options and accessories for the frequency converters.

3.6.1 Mounting of Option Modules in Slot B

The power to the frequency converter must be disconnected.

For A2 and A3 enclosures:

• Remove the LCP (Local Control Panel), the terminal cover, and the LCP frame from the frequency converter.

• Fit the MCB10x option card into slot B.

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• Connect the control cables and relieve the cable by the enclosed cable strips.

Remove the knock out in the extended LCP frame delivered in the option set, so that the option will fit under the extended LCP frame.

• Fit the extended LCP frame and terminal cover.

• Fit the LCP or blind cover in the extended LCP frame.

• Connect power to the frequency converter.

• Set up the input/output functions in the corresponding parameters, as mentioned in the section

General Technical Data

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For B1, B2, C1 and C2 enclosures:

• Remove the LCP and the LCP cradle

• Fit the MCB 10x option card into slot B

• Connect the control cables and relieve the cable by the enclosed cable strips

• Fit the cradle

•Fit the LCP

A2, A3 and B3 enclosures A5, B1, B2, B4, C1, C2, C3 and C4 enclosures

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3.6.2 General Purpose Input Output Module MCB 101

MCB 101 is used for extension of the number of digital and analog inputs

and outputs of the VLT Automation VT Drive.

Contents: MCB 101 must be fitted into slot B in the VLT Auto-

mation VT Drive.

• MCB 101 option module

•Extended LCP frame

• Terminal cover

Galvanic Isolation in the MCB 101

Digital/analog inputs are galvanically isolated from other inputs/outputs on the MCB 101 and in the control card of the drive. Digital/analog outputs in

the MCB 101 are galvanically isolated from other inputs/outputs on the MCB 101, but not from these on the control card of the drive.

If the digital inputs 7, 8 or 9 are to be switched by use of the internal 24 V power supply (terminal 9) the connection be tween terminal 1 and 5 which is

illustrated in the drawing has to be established.

Illustration 3.20: Principle Diagram

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3.6.3 Digital inputs - Terminal X30/1-4

Parameters for set-up: 5-16, 5-17 and 5-18

Number of digital

inputs

Voltage level Voltage levels Tolerance Max. Input impedance

3 0-24 V DC PNP type:

Common = 0 V

Logic “0”: Input < 5 V DC

Logic “0”: Input > 10 V DC

NPN type:

Common = 24 V

Logic “0”: Input > 19 V DC

Logic “0”: Input < 14 V DC

± 28 V continuous

± 37 V in minimum 10 sec.

Approx. 5 k ohm

3.6.4 Analog Voltage inputs - Terminal X30/10-12

Parameters for set-up: 6-3*, 6-4* and 16-76

Number of analog voltage inputs Standardize d input signal Tolerance Resolution Max. Input impedance

2 0-10 V DC ± 20 V continuously 10 bits Approx. 5 K ohm

3.6.5 Digital Outputs - Terminal X30/5-7

Parameters for set-up: 5-32 and 5-33

Number of digital outputs Output level Tolerance Max.impedance

2 0 or 24 V DC ± 4 V ≥ 600 ohm

3.6.6 Analog Outputs - Terminal X30/5+8

Parameters for set-up: 6-6* and 16-77

Number of analog outputs Output signal level Tolerance Max.impedance

1 0/4 - 20 mA ± 0.1 mA < 500 ohm

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3.6.7 Relay Option MCB 105

The MCB 105 option includes 3 pieces of SPDT contacts and must be fitted int o option slot B.

Electrical Data:

Max terminal load (AC-1)

(Resistive load) 240 V AC 2A

Max terminal load (AC-15 )

(Inductive load @ cosφ 0.4) 240 V AC 0.2 A

Max terminal load (DC-1)

(Resistive load) 24 V DC 1 A

Max terminal load (DC-13)

(Inductive load) 24 V DC 0.1 A

Min terminal load (DC) 5 V 10 mA

Max switching rate at rated load/min load 6 min-1/20 sec

-1

1) IEC 947 part 4 and 5

When the relay option kit is ordered separately the kit includes:

• Relay Module MCB 105

• Extended LCP frame and enlarged terminal cover

• Label for covering access to switches S201, S202 and S801

• Cable strips for fastening cables to relay module

A2-A3-B3 A5-B1-B2-B4-C1-C2-C3-C4

IMPORTANT! The label MUST be placed on the LCP frame as shown (UL approved).

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Warning Dual supply

How to add the MCB 105 option:

• See mounting instructions in the beginning of section

Options and Accessories

• The power to the live part connections on relay terminals must be disconnected.

• Do not mix live parts (high voltage) with control signals (PELV).

• Select the relay functions in par. 5-40

Function Relay

[6-8], par. 5-41

On Delay, Relay

[6-8] and par. 5-42

Off Delay, Relay

[6-8].

NB! (Index [6] is relay 7, index [7] is relay 8, and index [8] is relay 9)

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Do not combine low voltage parts and PELV systems.

3.6.8 24 V Back-Up Option MCB 107 (Option D)

External 24 V DC Supply

An external 24 V DC supply can be installed for low-voltage supply to the control card and any option card installed. This enables full operation of the

LCP (including the parameter setting) and field busses without mains supplied to the power section.

External 24 V DC supply specification:

Input voltage range 24 V DC ±15 % (max. 37 V in 10 s)

Max. input current 2.2 A

Average input current for the frequency converter 0.9 A

Max cable length 75 m

Input capacitance load < 10 uF

Power-up delay < 0.6 s

The inputs are protected.

Terminal numbers:

Terminal 35: - external 24 V DC supply.

Terminal 36: + external 24 V DC supply.

Follow these steps:

1. Remove the LCP or Blind Cover

2. Remove the Terminal Cover

3. Remove the Cable De-coupling Plate and the plastic cover un-

derneath

4. Insert the 24 V DC Backup External Supply Option in the Option

Slot

5. Mount the Cable De-coupling Plate

6. Attach the Terminal Cover and the LCP or Blind Cover.

When MCB 107, 24 V backup option is supplying the control circuit, the

internal 24 V supply is automatically disconnected.

Illustration 3.21: Connection to 24 V backup supplier (A2-

A3).

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Illustration 3.22: Connection to 24 V backup supplier (A5-

C2).

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3.6.9 Analog I/O Option MCB 109

The Analog I/O card is supposed to be used in e.g. the following cases:

• Providing battery back-up of clock function on control card

• As general extension of analog I/O selection available on control card, e.g. for multi-zone control with three pressure transmitters

• Turning frequency converter into de-central I/O block supporting Building Management System with inputs for sensors and outputs for operating

dampers and valve actuators

• Support Extended PID controllers with I/Os for set point inputs, transmitter/sensor inputs and outputs for actuators.

Illustration 3.23: Principle diagram for Analog I/O mounted in frequency converter.

Analog I/O configuration

3 x Analog Inputs, capable of handling following:

• 0 - 10 VDC

• 0-20 mA (voltage input 0-10V) by mounting a 510Ω resistor across terminals (see NB!)

• 4-20 mA (voltage input 2-10V) by mounting a 510Ω resistor across terminals (see NB)

•

Ni1000 temperature sensor of 1000 Ω at 0° C. Specifications according to DIN43760

• Pt1000 temperature sensor of 1000 Ω at 0° C. Specifications according to IEC 60751

3 x Analog Outputs supplying 0-10 VDC.

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NB!

Please note the values available within the different standard groups of resistors:

E12: Closest standard value is 470Ω, creating an input of 449.9Ω and 8.997V.

E24: Closest standard value is 510Ω, creating an input of 486.4Ω and 9.728V.

E48: Closest standard value is 511Ω, creating an input of 487.3Ω and 9.746V.

E96: Closest standard value is 523Ω, creating an input of 498.2Ω and 9.964V.

Analog inputs - terminal X42/1-6

Parameter group for read out: 18-3*. See also

Programming Guide.

Parameter groups for set-up: 26-0*, 26-1*, 26-2* and 26-3*. See also

Programming Guide.

3 x Analog inputs Operating range Resolution Accuracy Sampling Max load Impedance

Used as

temperature

sensor input

-50 to +150 °C 11 bits -50 °C

±1 Kelvin

+150 °C

±2 Kelvin

3 Hz - -

Used as

voltage input

0 - 10 VDC 10 bit s

0.2% of full

scale at cal.

temperature

2.4 Hz

+/- 20 V

continuously

Approximately

5 kΩ

When used for voltage, analog inputs are scalable by parameters for each input.

When used for temperature sensor, analog inputs scaling is preset to necessary signal level for specified temperature span.

When analog inputs are used for temperature sensors, it is possible to read out feedback value in both °C and °F.

When operating with temperature sensors, maximum cable length to connect sensors is 80 m non-screened / non-twisted wires.

Analog outputs - terminal X42/7-1 2

Parameter group for read out and write: 18-3*. See also

Programming Guide

Parameter groups for set-up: 26-4*, 26-5* and 26-6*. See also

Programming Guide

3 x Analog outputs Output signal level Resolution Linearity Max load

Volt 0-10 VDC 11 bits 1% of full scale 1 mA

Analog outputs are scalable by parameters for each output.

The function assigned is selectable via a parameter and have same options as for analog outputs on control card.

For a more detailed description of parameters, please refer to the

Programming Guide

Real-time clock (RTC) with back-up

The data format of RTC includes year, month, date, hour, minutes and weekday.

Accuracy of clock is better than ± 20 ppm at 25 °C.

The built-in lithium back-up battery lasts on average for minimum 0 years, when frequency converter is operating at 40 °C ambient temperature. If batte ry

pack back-up fails, analog I/O option must be exchanged.

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3.6.10 Extended Cascade Controller MCO 101 and Advanced Cascade Controller, MCO 102

Cascade control is a common control system used to control parallel pumps or fans in an energy efficient way.

The Cascade Controller option provides the capability to control multiple pumps configured in parallel in a way that makes them appear as a single larger

pump.

When using Cascade Controllers, the individual pumps are automatically turned on (staged) and turned off (de-staged) as needed in order to satisfy the

required system output for flow or pressure. The speed of pumps connected to VLT Automation VT Drive is also controlled to provide a continuous range

of system output.

Illustration 3.24: Cascade control of multiple pumps

The Cascade Controllers are optional hardware and software components that can be added to the VLT Automation VT Drive. It cons ists of an option

board containing 3 relays that is installed in the B option location on the Drive. Once options are installed the parameters needed to support the Cascade

Controller functions will be available through the control panel in the 27-** parameter group. The Extended Cascade Controller offers more functionality

than the Basic Cascade Controller. It can be used to extend the Basic Cascade with 3 relays and even to 8 relays with the Advanced Cascade Control card

installed.

While the Cascade controller is designed for pumping applications and this document describes the cascade controller fo r this application, it is also possible

to use the Cascade Controllers for any application requiring multiple motors configured in parallel.

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3.6.11 General Description

The Cascade Controller software runs from a single VLT Automation VT Drive with the Cascade Controller option card installed. This frequency converter

is referred to as the Master Drive. It controls a set of pumps each controlled by a frequency converter or connected directly to mains through a contactor

or through a soft starter.

Each additional frequency converter in the system is referred to as a Follower Drive. These frequency converters do not need the Cascade Controller

option card installed. They are operated in open loop mode and receive their speed reference from the Master Drive. The pump s connected to these

frequency converters are referred to as Variable Speed Pumps.

Each additional pump connected to mains through a contactor or through a soft starter is referred to as a Fixed Speed Pump.

Each pump, variable speed or fixed speed, is controlled by a relay in the Master Drive. The frequency convert er with the Cascade Controller option card

installed has five relays available for controlling pumps. Two (2) relays are standard in the FC and additional 3 relays are found on the option card MCO

101 or 8 relays and 7 digital inputs on option card MCO 102.

The Cascade Controller is capable of controlling a mix of variable speed and fixed speed pumps. Possible co nfigurations are described in more detail in

the next section. For simplicity of description within this manual, Pressure and Flow will be used to describe the variable o utput of the set of pumps

controlled by the cascade controller.

3.6.12 Extended Cascade Control MCO 101

The MCO 101 option includes 3 pieces of change-over contacts and can be fitted into option slot B.

Electrical Data:

Max terminal load (AC) 240 V AC 2A

Max terminal load (DC) 24 V DC 1 A

Min terminal load (DC) 5 V 10 mA

Max switching rate at rated load/min load 6 min-1/20 sec

-1

Illustration 3.25: Mounting of B-options

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Warning Dual supply

NB!

The label MUST be placed on the LCP frame as shown (UL approved).

How to add the MCO 101 option:

• The power to the frequency converter must be disconnected.

• The power to the live part connections on relay terminals must be disconnected.

• Remove the LCP, the terminal cover and the cradle from the FC322.

• Fit the MCO 101 option in slot B.

• Connect the control cables and relief the cables by the enclosed cable strips.

• Various systems must not be mixed.

• Fit the extended cradle and terminal cover.

•Replace the LCP

• Connect power to the frequency converter.

Wiring the Terminals

Do not combine low voltage parts and PELV systems.

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3.6.13 Brake Resistors

In applications where the motor is used as a brake, energy is generated in the motor and send back into the frequency converter. If the energy can not

be transported back to the motor it will increase the voltage in the converter DC-line. In applications with frequent braking and/or high inertia loads this

increase may lead to an over voltage trip in the converter and finally a shut down. Brake resistors are used to dissipate the excess energy resulting from

the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety

of different resistors that are specially designed to our frequency converters. See the section

Control with brake function

for the dimensioning of brake

resistors. Code numbers can be found in the section

How to order

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3.6.14 Remote Mounting Kit for LCP

The Local Control Panel can be moved to the front of a cabinet by using

the remote build in kit. The enclosure is the IP65. The fastening screws

must be tightened with a torque of max. 1 Nm.

Technical data

Enclosure: IP 65 front

Max. cable length between and unit: 3 m

Communication std: RS 485

Ordering no. 130B1113 Orderi ng no. 130B1114

Illustration 3.26: LCP Kit with graphical LCP, fasteners, 3 m cable and

gasket.

Illustration 3.27: LCP Kit with numerical LCP, fasternes and gasket.

LCP Kit without LCP is also available. Ordering number: 130B1117

For IP55 units the ordering number is 130B1129.

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3.6.15 IP 21/IP 4X/ TYPE 1 Enclosure Kit

IP 20/IP 4X top/ TYPE 1 is an optional enclosure element available for IP 20 Compact units, enclosure size A2-A3 up to 7.5 kW.

If the enclosure kit is used, an IP 20 unit is upgraded to comply with enclosure IP 21/ 4X top/TYPE 1.

The IP 4X top can be applied to all standard IP 20 VLT Automation VT Drive variants.

A – Top cover

B – Brim

C – Base part

D – Base cover

E – Screw(s)

Place the top cover as

shown. If an A or B option

is used the brim must be fit-

ted to cover the top inlet.

Place the base part C at the

bottom of the drive and use

the clamps from the acces-

sory bag to correctly fasten

the cables. Holes for cable

glands:

Size A2: 2x M25 and 3xM32

Size A3: 3xM25 and 3xM32

A2 Enclosure A3 Enclosure

A2, A3, B3 B4, C3, C4

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3.6.16 Input Filters

Harmonic current distortion is caused by the 6-pulse diode rectifier of the variable speed drive. The harmonic currents are affecting the insta lled serial

equipment identical to reactive currents. Consequently harmonic current distortion can result in overheating of the supply transformer, cables etc. De-

pending on the impedance of the power grid, harmonic current distortion can lead to volta ge distortion also affecting other equipment powered by the

same transformer. Voltage distortion is increasing losses, causes premature aging and worst of all erratic operation. The majority of harmonics are reduced

by the built-in DC coil but if additional reduction is needed, Danfoss offers two types of passive filters.

The Danfoss AHF 005 and AHF 010 are advanced harmonic filters, not to be compared with traditional harmonic trap filters. The Danfoss harmonic filters

have been specially designed to match the Danfoss frequency converters.

AHF 010 is reducing the harmonic currents to less than 10% and the AHF 005 is reducing harmonic currents to less than 5% at 2% background distortion

and 2% imbalance.

3.6.17 Output Filters

The high speed switching of the frequency converter produces some secondary effects, which influence the motor and the enclosed environment. These

side effects are addressed by two different filter types, -the du/d t and the Sine-wave filter.

du/dt filters

Motor insulation stresses are often caused by the combination of rapid voltage and current inc rease. The rapid energy changes can also be reflected back

to the DC-line in the inverter and cause shut down. The du /dt filter is designed to reduce the voltage rise time/the rapid energy change in the motor and

by that intervention avoid premature aging and flashover in the motor insulation. du/dt filters have a positive influence on the radiation of magnetic noise

in the cable that connects the drive to the motor. The voltage wave form is still pulse shaped but the du/dt ratio is reduced in comparison with the

installation without filter.

Sine-wave filters

Sine-wave filters are designed to let only low frequencies pass. High frequencies are consequently shunted away which results in a sinusoidal phase to

phase voltage waveform and sinusoidal current waveforms.

With the sinusoidal waveforms the use of special frequency converter motors with reinforced insulation is no longer needed. The acoustic noise from the

motor is also damped as a consequence of the wave condition.

Besides the features of the du/dt filter, the sine-wave filter also reduces insulation stress and bearing currents in the motor thus leading to prolonged

motor lifetime and longer periods between services. Sine-wave filters enable use of longer motor cables in applications where the motor is in stalled far

from the drive. The length is unfortunately limited because the filter does not reduce leakage currents in the cables.

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3.7 High Power Options

3.7.1 Installation of Duct Cooling Kit in Rittal Enclosures

This section deals with the installation of IP00 / chassis enclosed frequency converters with duct work cooling kits in Rittal enclosures. In addition to the

enclosure a 200 mm base/plinth is required.

Illustration 3.28: Installation of IP00 in Rittal TS8 enclosure.

The minimum enclosure dimension is:

• D3 and D4 frame: Depth 500 mm and width 600 mm.

• E2 frame: Depth 600 mm and width 800 mm.

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The maximum depth and width are as required by the installation. When using multiple frequency converters in one enclosure it is recommended that

each drive is mounted on its own back panel and supported along the mid-section of the panel. These duct work kits do not support the “in frame”

mounting of the panel (see Rittal TS8 catalogue for details). The duct work cooling kits listed in the table bel ow are suitable for use only with IP 00 /

Chassis frequency converters in Rittal TS8 IP 20 and UL and NEMA 1 and IP 54 and UL and NEMA 12 enclosures.

For the E2 frames it is important to mount the plate at the absolute rear of the Rittal enclosure due to the weight of the frequency

converter.

NB!

A door-fan(s) is required on the Rittal cabinet to remove the loses not contained in the back-channel of the drive. The minimum door-

fan(s) airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door-fan(s) airflow

required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm). If the ambient is below maximum or if additional compo-

nents, heat loses, are added within the enclosure a calculation must be mad e to en sure th e prope r airf low is p rovide d to coo l the inside

of the Rittal enclosure.

Ordering Information

Rittal TS-8 Enclosure Frame D3 Kit Part No. Frame D4Kit Part No. Frame E2 Part No.

1800 mm 176F1824 176F1823 Not possible

2000 mm 176F1826 176F1825 176F1850

2200 mm 176F0299

Kit Contents

• Ductwork components

• Mounting hardware

•Gasket material

• Delivered with D3 and D4 frame kits:

• 175R5639 - Mounting templates and top/bottom cut out for Rittal enclosure.

• Delivered with E2 frame kits:

• 175R1036 - Mounting templates and top/bottom cut out for Rittal enclosure.

All fasteners are either:

• 10 mm, M5 Nuts torque to 2.3 Nm (20 in-lbs)

• T25 Torx screws torque to 2.3 Nm (20 in-lbs)

NB!

Please see the

Duct Kit Instruction Manual, 175R5640,

for further information

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

frequency converter according to the pressure drop.

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Illustration 3.29: D Frame Derating vs. Pressure Change

Drive air flow: 450 cfm (765 m3/h)

Illustration 3.30: E Frame Derating vs. Pressure Change (Small Fan), P250T5 and P355T7-P400T7

Drive air flow: 650 cfm (1105 m3/h)

Illustration 3.31: E Frame Derating vs. Pressure Change (Large Fan), P315T5-P400T5 and P500T7-P560T7

Drive air flow: 850 cfm (1445 m3/h)

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3.7.2 Outside Installation/ NEMA 3R Kit for Rittal Enclosures

This section is for the installation of NEMA 3R kits available for the frequ ency converter frames D3, D4 and E2. These kits are designed and tested to be

used with IP00/ Chassis versions of these frames in Rittal TS8 NEMA 3R or NEMA 4 enclosures. The NEMA-3R enclosure is an outdoor enclosure that

provides a degree of protection against rain and ice. The NEMA-4 enclosure is an outdoor enclosure that provides a great er degree of protection against

weather and hosed water.

The minimum enclosure depth is 500 mm (600 mm for E2 frame) and the kit is designed for a 600 mm (800 mm for E2 frame) wide enclosure. Other

enclosure widths are possible, however additional Rittal hardware is required. The maximum depth and width ar e as required by the installation.

NB!

The current rating of drives in D3 and D4 frames are de-rated by 3%, when adding the NEMA 3R kit. Drives in E2 frames require no

derating

NB!

A door-fan(s) is required on the Rittal cabinet to remove the loses not contained in the back-channel of the drive. The minimum door-

fan(s) airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door-fan(s) airflow

required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm). If the ambient is below maximum or if additional compo-

nents, heat loses, are added within the enclosure a calculation must be mad e to en sure th e prope r airf low is p rovide d to coo l the inside

of the Rittal enclosure.

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Ordering information

Frame size D3: 176F4600

Frame size D4: 176F4601

Frame size E2: 176F1852

Kit contents:

• Ductwork components

• Mounting hardware

• 16 mm, M5 torx screws for top vent cover

• 10 mm, M5 for attaching drive mounting plate to enclosure

• M10 nuts to attach drive to mounting plate

• Gasket material

NB!

Please see the instructions

175R5922

for further information

3.7.3 Installation on Pedestal

This section describes the installation of a pedestal unit available for the

frequency converters frames D1 and D2. This is a 200 mm high pedestal

that allows these frames to be floor mounted. The front of the pedestal

has openings for input air to the power components.

The frequency converter gland plate must be installed to provide ade-

quate cooling air to the control components of the frequency converter

via the door fan and to maintain the IP21/NEMA 1 or IP54/NEMA 12 de-

grees of enclosure protections.

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Danfoss VLT AutomationVTDrive FC322 Design Manual

Specifications and Main Features

Frequently Asked Questions

User Manual