Danfoss VLT Parallel Drive Modules Installation guide

ENGINEERING TOMORROW

Installation Guide

VLT® Parallel Drive Modules

250–1200 kW

vlt-drives.danfoss.com

Contents Installation Guide

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Document and Software Version

1.4 Approvals and Certications

1.5 Disposal

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Product Overview

3.1 Intended Use

3.2 Drive Modules

3.3 Control Shelf

3.4 Wire Harness

3.5 DC Fuses

4 Mechanical Installation

4.1 Receiving and Unpacking the Unit

4.1.1 Items Supplied 11

4.1.2 Lifting the Unit 12

4.1.3 Storage 12

4.2 Requirements

4.2.1 Environmental 14

4.3 Installing the Drive Modules

4.4 Installing the Control Shelf

5 Electrical Installation

5.1 Safety Instructions

5.2 Electrical Requirements for Certications and Approvals

5.3 Wiring Diagram

5.4 Fuses

5.5 Electrical Kit Installation

5.6 DC Bus Fuse Installation

5.7 Motor Connections

5.7.3 Motor Terminal Connections 26

5.7.3.1 Motor Cable 26

5.7.3.2 Motor Terminal Connections in 2-Drive Module Systems 27

Contents

VLT® Parallel Drive Modules

5.7.3.3 Motor Terminal Connections in 4-Drive Module Systems 27

5.8 Mains Connections

5.8.1 AC Mains Terminal Connections 28

5.8.1.1 Mains Terminal Connections in 2-Drive Module Systems 28

5.8.1.2 Mains Terminal Connections in 4-Drive Module Systems 29

5.8.2 12-Pulse Disconnector Conguration 29

5.8.3 Discharge Resistors 30

5.9 Control Shelf Installation

5.10 Control Wiring Connections

5.10.1 Control Cable Routing 32

5.10.2 Control Wiring 33

5.10.2.1 Control Terminal Types 33

5.10.2.2 Wiring to Control Terminals 35

5.10.2.3 Enabling Motor Operation (Terminal 27) 35

5.10.2.4 Voltage/Current Input Selection (Switches) 35

5.10.2.5 RS485 Serial Communication 36

5.10.3 Safe Torque O (STO) 36

5.11 Relay Output

5.12 EMC Recommendations

6 Initial Start-up

6.1 Pre-start Check List

6.2 Safety Instructions

6.3 Applying Power

6.4 Conguring the Drive System

6.5 Testing the Motor Operation

7 Specications

7.1 Power-dependent Specications

7.2 Mains Supply to Drive Module

7.3 Motor Output and Motor Data

7.4 12-Pulse Transformer Specications

7.5 Ambient Conditions for Drive Modules

7.6 Cable Specications

7.7 Control Input/Output and Control Data

7.8 Kit Dimensions

7.9 Fastener Tightening Torques

7.9.1 Tightening Torques for Terminals 66

8 Appendix

8.1 Disclaimer

Contents Installation Guide

8.2 Symbols, Abbreviations, and Conventions

8.3 Block Diagrams

Index

Introduction

VLT® Parallel Drive Modules

1 Introduction

1.1 Purpose of the Manual

This manual provides requirements for mechanical and

electrical installation of the VLT® Parallel Drive Modules basic kit. Separate installation instructions for optional components - bus bars and back-channel cooling - are provided with those kits.

This guide includes information on:

Wiring of mains and motor connections.

•

Wiring of control and serial communications.

•

Control terminal functions.

•

Detailed tests that must be performed before

•

start-up.

Initial programming to verify proper functioning

•

of the drive system.

The installation guide is intended for use by personnel.

To install the drive modules and paralleling kit safely and professionally, read and follow the installation guide. Pay particular attention to the safety instructions and general warnings. Always keep this installation guide with the

panel containing the VLT® Parallel Drive Modules components.

VLT® is a registered trademark.

Additional Resources

1.2

Other resources are available to understand functions and

programming of the VLT® Parallel Drive Modules.

qualied

The VLT® FC Series, D-frame Service Manual

•

contains detailed service information, including

information applicable to the VLT® Parallel Drive Modules.

The VLT® Parallel Drive Modules DC Fuses Instal-

•

lation Instructions contain detailed information about installing the DC fuses.

The VLT

•

lation Instructions contain detailed information about installing the bus bar kit.

The VLT® Parallel Drive Modules Duct Kit Instal-

•

lation Instructions contain detailed information about installing the duct kit.

Refer to other supplemental publications and manuals, available from Danfoss. See drives.danfoss.com/knowledge-

center/technical-documentation/ for listings.

Parallel Drive Modules Bus Bar Kit Instal-

1.3 Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the document version and the corresponding software version.

Edition Remarks Software

version

MG37K3xx Added 230 V external

power supply content

Table 1.1 Document and Software Version

Approvals and Certications

1.4

FC 102 (5.0x),

FC 202 (3.0x),

FC 302 (7.6x)

The VLT® Parallel Drive Modules Design Guide

•

contains detailed information about the capabilities and functionality of motor control systems using these drive modules, and provides guidance for designing this type of system.

The VLT® Parallel Drive Modules User Guide

•

contains detailed procedures for start-up, basic operational programming, and functional testing. Additional information describes the user interface, application examples, troubleshooting, and specications.

Refer to the Programming Guide applicable to the

•

particular series of VLT® Parallel Drive Modules used in creating the drive system. The programming guide describes in greater detail how to work with parameters and provides application examples.

Table 1.2 Approvals and Certications

Disposal

1.5

Do not dispose of equipment containing

electrical components together with

domestic waste.

Collect it separately in accordance with

local and currently valid legislation.

Safety Installation Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

WARNING

UNINTENDED START

When the drive system is connected to AC mains, the motor can start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start via an external switch, a eldbus command, an input reference signal from the LCP, a cleared fault condition, or remote operation using MCT 10 Set-up Software.

To prevent unintended motor start:

Disconnect the drive system from AC mains.

•

Press [O/Reset] on the LCP, before

•

programming parameters.

The drive system, motor, and any driven

•

equipment must be fully wired and assembled when the drive is connected to AC mains.

2 2

2.2 Qualied Personnel

Correct and reliable transport, storage, and installation are required for the trouble-free and safe operation of the

VLT® Parallel Drive Modules. Only qualied personnel are allowed to install this equipment.

Qualied personnel are dened as trained sta, who are authorized to install equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

Safety Precautions

2.3

WARNING

HIGH VOLTAGE

The drive system contains high voltage when connected to AC mains input. Failure to ensure that only qualied personnel install the drive system can result in death or serious injury.

Only qualied personnel are allowed to install the

•

drive system.

CAUTION

POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE

There is a risk of personal injury when the drive modules are not properly closed.

Before applying power, ensure that all safety

•

covers are in place and securely fastened.

WARNING

DISCHARGE TIME

The drive module contains DC-link capacitors. Once mains power has been applied to the drive, these capacitors can remain charged even after the power has been removed. High voltage can be present even when the warning indicator lights are o. Failure to wait 20 minutes after power has been removed before performing service or repair work can result in death or serious injury.

1. Stop the motor.

2. Disconnect AC mains and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

3. Disconnect or lock the PM motor.

4. Wait 20 minutes for the capacitors to discharge fully before performing any service or repair work.

WARNING

UNINTENDED MOTOR ROTATION WINDMILLING

Unintended rotation of permanent magnet motors creates voltage and can charge the capacitors in the drive system, resulting in death, serious injury, or equipment damage.

Ensure that permanent magnet motors are

•

blocked to prevent unintended rotation.

Safety

VLT® Parallel Drive Modules

WARNING

LEAKAGE CURRENT HAZARD (>3.5 mA)

Leakage currents exceed 3.5 mA. Failure to ground the drive system properly can result in death or serious injury. Follow national and local codes regarding protective earthing of equipment with a leakage current >3.5 mA. Frequency converter technology implies high frequency switching at high power. This switching generates a leakage current in the ground connection. A fault current in the drive system at the output power terminals sometimes contain a DC component, which can charge the lter capacitors and cause a transient ground current. The ground leakage current depends on various system congurations including RFI ltering, shielded motor cables, and drive system power. If the leakage current exceeds 3.5 mA, EN/IEC 61800-5-1 (Power Drive System Product Standard) requires special care.

Grounding must be reinforced in 1 of the following ways:

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

Ground wire of at least 10 mm2 (6 AWG).

•

Two separate ground wires, both complying

•

with the dimensioning rules.

See EN 60364-5-54 § 543.7 for further information.

WARNING

HEAVY LOAD

Unbalanced loads can fall and loads can tip over. Failure to take proper lifting precautions increases risk of death, serious injury, or equipment damage.

Never walk under suspended loads.

•

To guard against injury, wear personal

•

protective equipment such as gloves, safety glasses, and safety shoes.

Be sure to use lifting devices with the

•

appropriate weight rating. The lifting bar must be able to handle the weight of the load.

The load’s center of gravity may be in an

•

unexpected location. Failure to locate the center of gravity correctly, and position the load accordingly before lifting the load, can cause the unit to fall over or tilt unexpectedly during lifting and transport.

The angle from the top of the drive module to

•

the lifting cables has an impact on the maximum load force on the cable. This angle must be 65° or greater. Attach and dimension the lifting cables properly.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualied personnel

•

perform the installation.

Ensure that electrical work conforms to national

•

and local electrical codes.

Follow the procedures in this document.

•

WARNING

DISCONNECT POWER BEFORE SERVICING

Sometimes during installation, AC mains power is applied but then must be disconnected to change the line connections. Failure to follow these steps can result in death or serious injury.

Disconnect the frequency converters from the

•

AC mains, 230 V supply, and motor lines.

After the lines have been disconnected, wait 20

•

minutes for the capacitors to discharge.

Product Overview Installation Guide

3 Product Overview

3.1 Intended Use

A frequency converter is an electronic motor controller that uses 1 or more drive modules to convert AC mains input into a variable AC waveform output. The frequency and voltage of the output are regulated to control the motor speed or torque. The frequency converter varies the motor speed based on system feedback, such as position sensors on a conveyor belt. The frequency converter also regulates the motor in response to remote commands from external controllers.

The VLT® Parallel Drive Modules basic kit described in this guide is UL 508 C compliant. The kit is used to create drive systems of 2 or 4 drive modules. These drive modules are based on the D4h frequency converter and can provide a greater power range in a smaller enclosure. The basic kit is designed to allow the exibility to either order components through Danfoss or fabricate custom components.

The basic kit contains the following components:

Drive modules

•

Control shelf

•

Wire harnesses

•

- Ribbon cable with 44-pin connector (on both ends of the cable)

- Relay cable with 16-pin connector (on 1 end of the cable)

- DC fuse microswitch cable with 2-pin connectors (on 1 end of the cable)

DC fuses

•

Microswitches

•

Other components, such as bus bar kits and back-channel cooling duct kits, are available as options to customize the drive system.

3 3

NOTICE

EXTERNAL 230 V SUPPLY

An external 230 V supply is needed to power the SMPS (switch mode power supply) and any cabinet fans.

130BE561.11

Product Overview

VLT® Parallel Drive Modules

3.2 Drive Modules

Each drive module has an IP00 protection rating. Either 2 or 4 drive modules can be connected in parallel to create a drive system, based on power requirements.

1 DC-link terminal and DC fuse 8 Ground terminals

2 MDCIC plug 9 Top fan

3 Microswitch to DC fuse 10 Drive module label. See Illustration 4.2.

4 Relays 1 and 2 11 Motor output terminals (inside the unit)

5 Brake fault jumper and connector 12 Heat sink and heat sink fan

6 Mains input terminals (inside the unit) 13 Ground plate

7 Terminal cover – –

Illustration 3.1 Drive Module Overview

130BE597.11

Product Overview Installation Guide

3.3 Control Shelf

The control shelf contains the LCP, MDCIC, and control card. The LCP provides access to the system parameters. The MDCIC is connected to each of the drive modules via a ribbon cable and communicates to the control card. The control card controls the operation of the drive modules.

3 3

1 LCP cradle 7 MDCIC card

2 Control card (underneath cover) 8 Control shelf

3 Control terminal blocks 9 Switch mode power supply (SMPS). Note that an external 230 V

supply is needed to power the SMPS.

4 Top-level drive system label. See Illustration 4.1. 10 Pilz relay

5 44-pin cables from MDCIC board to drive modules 11 DIN rail

6 Ferrite core 12 Terminal block mounted on DIN rail

Illustration 3.2 Control Shelf

130BE750.10

Product Overview

VLT® Parallel Drive Modules

3.4 Wire Harness

The VLT® Parallel Drive Modules basic kit contains the following wire harnesses:

Ribbon cable with 44-pin connector (on both ends of the cable)

•

Relay cable with 16-pin connector (on 1 end of the cable)

•

DC fuse microswitch cable with 2-pin connectors (on 1 end of the cable)

•

3.5 DC Fuses

The VLT® Parallel Drive Modules kit contains 2 DC fuses per drive module. These fuses on the supply side ensure that any damage is contained to inside the drive modules.

NOTICE

Use of fuses on the supply side is mandatory for IEC 60364 (CE) compliant installations.

1 DC fuse 2 Microswitch connector

Illustration 3.3 DC Fuse and Microswitch Connector

130BE710.12

OUT: 3x0-Vin 0-590Hz 1260/1160 A

IN: 3x380-500V 50/60Hz 1227/1129 A

710 kW / 1000 HP, High Overload

OUT: 3x0-Vin 0-590Hz 1460/1380 A

IN: 3x380-500V 50/60Hz 1422/1344 A

800 kW / 1200 HP, Normal Overload

VLT

T/C: FC-302N710T5E00P2BGC7XXSXXXXAXBXCXXXXDX P/N: 134X4109 S/N:

AutomationDrive www.danfoss.com

1 2

3 4 5

ASSEMBLED IN USA

CAUTION - ATTENTION:

Stored charge, wait 20 min. Charge residuelle, attendez 20

See manual for special condition / prefuses Voir manuel de conditions speciales / fusibles

WARNING - AVERTISSEMENT:

Tamb. 45

C/113

F at Full Output Current

CHASSIS (OPEN TYPE) / IP00

SCCR 100 kA at UL Voltage range 380-500 V

Listed 36U0 E70524 IND. CONT. EQ. UL Voltage range 380-500 V

Max. Tamb. 55

C/131

F w/ Output Current Derating

123456H123

130BE711.14

Intended use - The Individual Base Drive Modules are intended for use in Parallel Drive Module system only. Specic electrical ratings are not applicable. Name plate of Parallel Drive Module system should be referred for actual drive ratings.

VLT

ASSEMBLED IN USA

T/C: FC-BDMN250T5E00H2SXC7XXSXXXXAXBXCXXXXDX P/N: 178N0025 S/N: 123456H123

CAUTION - ATTENTION:

Stored charge, wait 20 min. Charge residuelle, attendez 20

See manual for special condition / prefuses Voir manuel de conditions speciales / fusibles

WARNING - AVERTISSEMENT:

AutomationDrive www.danfoss.com

CHASSIS (OPEN TYPE) / IP00

SCCR 100 kA at UL Voltage range 380-500 V

Listed 36U0 E70524 IND. CONT. EQ.

1 2

UL Voltage range 380-500 V

Mechanical Installation Installation Guide

4 Mechanical Installation

4.1 Receiving and Unpacking the Unit

4.1.1 Items Supplied

Make sure that the items supplied and the

•

information on the labels correspond to the order.

- Top-level drive system. This label is found on the control shelf, lower right side of the LCP. See Illustration 3.2.

- Drive module. This label is found inside the drive module enclosure, on the right side panel. See Illustration 3.1.

Visually check the packaging and the VLT

•

Parallel Drive Modules components for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts, in case is needed.

clarication

4 4

1 Type code

2 Code number

3 Intended use disclaimer

4 Discharge time

5 Serial number

Illustration 4.2 Drive Module Label (Example)

NOTICE

LOSS OF WARRANTY

Removing the labels from the VLT® Parallel Drive Modules can result in loss of warranty.

1 Type code

2 Code number

3 Power rating

4 Input voltage, frequency, and current

5 Output voltage, frequency, and current

6 Discharge time

Illustration 4.1 Top-level Drive System Label (Example)

Mechanical Installation

Receiving and unloading

I-beam and hooks rated to lift a drive module having a weight of 125 kg (275 lb), with the necessary safety

•

margins.

Crane or other lifting aid rated to lift the minimum weight specied in the documentation package supplied with

•

the drive module.

Crowbar to disassemble the wooden shipping container.

•

Installation

Drill with 10 mm or 12 mm drill bits.

•

Tape measurer.

•

Screwdriver.

•

Wrench with relevant metric sockets (7–17 mm).

•

Wrench extensions.

•

Torx T50 tool.

•

Cabinet construction

Acquire the tools necessary for assembly of the panel - according to the design plans and established practices.

VLT® Parallel Drive Modules

4.1.2 Lifting the Unit

For measurements and center of gravity, see chapter 7.8 Kit Dimensions.

Ensure that the lifting device is suitable for the task.

•

Move the unit using a hoist, crane, or forklift with the appropriate rating.

•

Always use the dedicated lifting eye bolts. See Illustration 4.3.

•

CAUTION

HEAVY LOAD

Unbalanced loads can fall and loads can tip over. Failure to take proper lifting precautions increases risk of death, serious injury, or equipment damage.

Never walk under suspended loads.

•

To guard against injury, wear personal protective equipment such as gloves, safety glasses, and safety shoes.

•

Be sure to use lifting devices with the appropriate weight rating. The lifting bar must be able to handle the

•

weight of the load.

The load’s center of gravity may be in an unexpected location. Failure to locate the center of gravity correctly

•

and position the load accordingly before lifting the load can cause the unit to fall over or tilt unexpectedly during lifting and transport.

The angle from the top of the drive module to the lifting cables has an impact on the maximum load force on

•

the cable. This angle must be 65° or greater. Refer to Illustration 4.3. Attach and dimension the lifting cables properly.

4.1.3 Storage

Store the kit in a dry location. Keep the equipment sealed in its packaging until installation. Refer to chapter 7.5 Ambient Conditions for Drive Modules for recommended ambient conditions.

130BE566.10

65° min

Mechanical Installation Installation Guide

4 4

Illustration 4.3 Lifting the Drive Module

Mechanical Installation

VLT® Parallel Drive Modules

4.2 Requirements

This section describes the minimum recommended requirements for mechanical installation. For UL and CE requirements, see chapter 5.2 Electrical Requirements for Certications and Approvals.

4.2.3 Busbars

If the Danfoss busbar kit is not used, see Table 4.2 for the cross-section measurements that are required when creating customized busbars. For terminal dimensions, refer to chapter 7.8.2 Terminal Dimensions and chapter 7.8.3 DC Bus Dimensions.

4.2.1 Environmental

Refer to for information on required operating temperature, humidity, and other environmental conditions.

4.2.2 Cabinet

The kit consists of either 2 or 4 drive modules, depending on the power rating. The cabinets have to meet the following minimum requirements:

Description Width [mm (in)] Thickness [mm (in)]

AC motor 143.6 (5.7) 6.4 (0.25)

AC mains 143.6 (5.7) 6.4 (0.25)

DC bus 76.2 (3.0) 12.7 (0.50)

Table 4.2 Cross-section Measurements for Customized Busbars

NOTICE

Align busbars vertically to provide maximum airow.

4.2.4 Thermal Considerations

Width [mm (in)] 2-drive: 800 (31.5), 4-drive: 1600 (63)

Depth [mm (in)] 600 (23.6)

Height [mm (in)]

Weight capacity

[kg (lb)]

Ventilation openings See chapter 4.2.5 Cooling and Airow

Table 4.1 Cabinet Requirements

1) Required if Danfoss busbar or cooling kits are used.

2000 (78.7)

2-drive: 450 (992), 4-drive: 910 (2006)

Requirements.

NOTICE

EXTERNAL 230 V SUPPLY

An external 230 V supply is required for the SMPS (switch mode power supply). Danfoss recommends using a 6 A, 10 A, or 16 A slow-blow fuse when installing the external supply.

For heat dissipation values, refer to chapter 7.1 Powerdependent Specications. The following heat sources must

be considered when determining cooling requirements:

Ambient temperature outside enclosure.

•

Filters (for example, sine-wave and RF).

•

Fuses.

•

Control components.

•

For required cooling air, refer to chapter 4.2.5 Cooling and Airow Requirements.

130BE569.10

Mechanical Installation Installation Guide

4.2.5 Cooling and Airow Requirements

The recommendations provided in this section are necessary for eective cooling of the drive modules within the panel enclosure. Each drive module contains a heat sink fan and a mixing fan. Typical enclosure designs utilize door fans along with the drive module fans to remove waste heat from the enclosure.

Danfoss provides several back-channel cooling kits as options. These kits remove 85% of the waste heat from the enclosure, reducing the need for large door fans.

NOTICE

Make sure that the total ow of the cabinet fans meets the recommended airow.

Drive module cooling fans

The drive module is equipped with a heat sink fan, which provides the required heat sink. Also, there is a cooling fan mounted on the top of the unit, and a small 24 V DC mixing fan mounted under the input plate that operates any time the drive module is powered on.

In each drive module, the power card provides DC voltage to power the fans. The mixing fan is powered by 24 V DC from the main switch mode power supply. The heat sink fan and the top fan are powered by 48 V DC from a dedicated switch mode power supply on the power card. Each fan has a tachometer feedback to the control card to conrm that the fan is operating correctly. On/o and speed control of the fans help reduce unnecessary acoustical noise and extend the life of the fans.

Cabinet fans

When the back-channel option is not used, fans mounted in the cabinet must remove all the heat generated inside the enclosure.

For each enclosure housing 2 drive module, the cabinet fan ow recommendation is as follows:

When back-channel cooling is used, 680 m3/h (400 cfm) ow is recommended.

•

When back-channel cooling is not used, 4080 m3/h (2400 cfm) ow is recommended.

•

ow rate of 840 m3/h (500 cfm) across the

4 4

Illustration 4.4 Airow, Standard Unit (Left), Bottom/Top Cooling Kit (Middle), and Back/Back Cooling Kit (Right)

130BE571.10

Mechanical Installation

VLT® Parallel Drive Modules

4.3 Installing the Drive Modules

Install the drive modules into the cabinet frame as described in the following steps.

1. Unpack the drive modules from the packaging. See chapter 4.1 Receiving and Unpacking the Unit.

2. Install 2 eye bolts in the top of the lifting harness and an overhead hoist or crane with the necessary lifting capacity. See chapter 4.1.2 Lifting the Unit.

rst drive module. Prepare the drive module for lifting, using an appropriate

Illustration 4.5 Installation of Eye Bolts

3. Install the 2 bottom mounting screws and gaskets onto the mounting panel.

4. Using the crane or hoist, lift the drive module and then lower the unit through the top of the cabinet frame. Align the bottom mounting holes of the unit with the 2 bottom mounting screws on the mounting panel.

5. Verify that the drive module is correctly aligned on the mounting panel and then secure the bottom of the unit to the panel with the 2 hex nuts. See Illustration 4.6. Torque the hex nuts. Refer to chapter 7.9 Fastener Tightening Torques.

6. Secure the top of the unit to the mounting panel with M10x26 screws, and then torque the screws.

7. Line up the groove on the microswitch with the edges on each DC fuse and press rmly until the microswitch clicks into place.

8. Install 2 DC fuses with microswitches onto the tops of the DC-link terminals on each drive module. The microswitches should be installed on the outer side of each terminal. Refer to Illustration 3.1.

9. Secure each fuse with 2 M10 screws and torque the screws.

10. Install the next drive module.

130BE572.10

Mechanical Installation Installation Guide

4 4

Illustration 4.6 Installation of Bottom Mounting Bolts

130BE713.11

Mechanical Installation

VLT® Parallel Drive Modules

4.4 Installing the Control Shelf

NOTICE

To avoid RFI, do not route control wiring together with power cables or bus bars.

1. Remove the control shelf assembly from its package.

2. Remove the LCP from the control shelf.

3. Use some type of mounting bracket to install the control shelf. Danfoss does not supply the mounting brackets for

the control shelf. For EMC-correct installation, refer to Illustration 4.7.

4. Remove the MDCIC cover from the control shelf assembly.

5. Connect the 44-pin ribbon cables from the MDCIC card to the top of the drive modules, following the sequence numbers indicated next to the connectors on the MDCIC.

6. Route the 44-pin ribbon cables inside the cabinet.

7. Connect the external brake fault wiring harness between the microswitch terminals and the brake jumper connector on the top of the drive module.

8. Connect the relay wiring between relay 1 or 2 on the control shelf and the corresponding relay connector on the top of the drive module.

9. Connect the microswitch to the microswitch connector provided on the top of the drive module. Refer to Illustration 3.1 and Illustration 3.3.

1 Control shelf must stay below this point 2 Control shelf must stay above this point

Illustration 4.7 Positioning the Control Shelf for EMC-correct Installation

Electrical Installation Installation Guide

5 Electrical Installation

5.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

INDUCED VOLTAGE

When output motor cables from dierent frequency converters are run together, induced voltage can charge equipment capacitors even with the equipment turned o and locked out.

To avoid death or serious injury:

Run output motor cables separately or use

•

shielded cables.

Simultaneously lock out all the frequency

•

converters.

CAUTION

SHOCK HAZARD

The drive system can cause a DC current in the protective earth (PE) conductor.

When a residual current-operated protective

•

device (RCD) is used for protection against electrical shock, only an RCD of Type B is allowed on the supply side.

Failure to follow this recommendation could prevent the RCD from providing the intended protection.

NOTICE

MOTOR OVERLOAD PROTECTION

The drive modules are supplied with Class 20 overload protection for single motor applications.

Overcurrent protection

Extra protective equipment, such as short-circuit

•

protection or motor thermal protection between the drive modules and the motors, is required for applications with multiple motors.

The correct input fusing is required to acquire

•

approvals and meet certication requirements, and to provide short circuit and overcurrent protection. These fuses are not factory-supplied, and must be provided by the installer. See maximum fuse ratings in chapter 7.1 Power- dependent Specications.

Wire type and ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Power connection wire recommendation:

•

minimum 75 °C rated copper wire.

See chapter 7.6 Cable Specications for recommended wire sizes and types.

5 5

CAUTION

PROPERTY DAMAGE

Electronic thermal relay (ETR) protection against motor overload is not included in the default setting. To

program the LCP for this function, refer to the VLT Parallel Drive Modules User Guide.

Electrical Installation

VLT® Parallel Drive Modules

5.2 Electrical Requirements for Certications and Approvals

The standard conguration provided in this guide (drive modules, control shelf, wire harnesses, fuses, and microswitches) is UL and CE certied. The following conditions must be met apart from the standard congu- ration to obtain UL and CE regulatory approval requirements. For a list of disclaimers, see chapter 8.1 Disclaimer.

Use the frequency converter in a heated, indoor-

•

controlled environment. Cooling air must be

clean, free from corrosive materials, and electrically conductive dust. See for specic limits.

Maximum ambient air temperature is 40 °C

•

(104 °F) at rated current.

The drive system must be assembled in clean air,

•

according to enclosure classication. To obtain UL or CE certication regulatory approvals, drive modules must be installed according to the standard conguration provided in this guide.

Maximum voltage and current must not exceed

•

the values provided in chapter 7.1 Powerdependent

conguration.

The drive modules are suitable for use on a

•

circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive

Specications for the specied drive

nominal voltage (600 V maximum for 690 V units) when protected by fuses with the standard conguration. Refer to chapter 5.4.1 Fuse Selection. The ampere rating is based on tests done according to UL 508C.

The cables located within the motor circuit must

•

be rated for at least 75 °C (167 °F) in ULcompliant installations. The cable sizes have been provided in chapter 7.1 Power-dependent Speci- cations for the specied drive conguration.

The input cable must be protected with fuses.

•

Circuit breakers must not be used without fuses in the U.S. Suitable IEC (class aR) fuses and UL (class L or T) fuses are listed in chapter 5.4.1 Fuse Selection. In addition, country-specic regulatory requirements must be adhered to.

For installation in the U.S., branch circuit

•

protection must be provided according to the National Electrical Code (NEC) and any applicable local codes. To fulll this requirement, use UL- classied fuses.

For installation in Canada, branch circuit

•

protection must be provided according to the Canadian Electrical Code and any applicable provincial codes. To fulll this requirement, use the UL-classied fuses.

230 V AC 50/60 Hz

Brake Temp (NC)

91 (L1)

L N

230 V/24 V Power supply

92 (L2) 93 (L3)

88 (-) 89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

20 (COM D IN)

15 mA

200 mA

(U) 96

(V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

0/4–20 mA

+10 V DC

0 V DC - 10 V DC

0/4-20 mA

24 V DC

240 V AC, 2A

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24 V

0 V

(D IN/OUT)

0 V (PNP)

24 V (NPN)

(D IN/OUT)

0 V

24 V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

A53 U-I (S201)

A54 U-I (S202)

ON=0–20 mA OFF=0–10 V

400 V AC, 2A

P 5-00

(R+) 82

(R-) 81

+ - + -

(P RS485) 68

(N RS485) 69

(COM RS485) 61

0 V

5 V

S801

RS485

S801/Bus Term. OFF-ON

3-phase power

input

Switch mode Power supply

Motor

Analog output

Interface

Relay1

Relay2

ON=Terminated OFF=Open

Brake resistor

(NPN) = Sink

(PNP) = Source

240 V AC, 2A

400 V AC, 2A

0 V DC - 10 V DC

10 V DC

37 (D IN) - option

130BE752.10

Regen terminals

Electrical Installation Installation Guide

5.3 Wiring Diagram

5 5

Illustration 5.1 Wiring Diagram

Electrical Installation

VLT® Parallel Drive Modules

5.4 Fuses

5.4.1 Fuse Selection

To protect the drive system in case 1 or more internal components break down within a drive module, use fuses and/or circuit breakers at the mains supply side.

5.4.1.1 Branch Circuit Protection

To protect the installation against electrical and re hazards, protect all branch circuits in an installation against

short circuit and overcurrent according to national and international regulations.

5.4.1.2 Short-circuit Protection

Danfoss recommends the fuses listed in

chapter 5.4.1.3 Recommended Fuses for CE Compliance and chapter 5.4.1.4 Recommended Fuses for UL Compliance to

achieve CE or UL Compliance in the protection of service personnel and property against the consequences of component breakdown in the drive modules.

Number of drive

modules

4 N630 N710 aR-1600

4 N710 N800 aR-2000

4 N800 N900 aR-2500

4 N900 N1M0 aR-2500

4 N1M0 N1M2 aR-2500

Table 5.3 6-Pulse Drive Systems (525–690 V AC)

Number of drive

modules

2 N250 N315 aR-550

2 N315 N355 aR-630

2 N355 N400 aR-630

2 N400 N500 aR-630

2 N500 N560 aR-630

2 N560 N630 aR-900

4 N630 N710 aR-900

4 N710 N800 aR-900

4 N800 N900 aR-900

4 N900 N1M0 aR-1600

4 N1M0 N1M2 aR-1600

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Recommended fuse

(maximum)

5.4.1.3 Recommended Fuses for CE Compliance

Number of drive

modules

2 N450 N500 aR-1600

4 N500 N560 aR-2000

4 N560 N630 aR-2000

4 N630 N710 aR-2500

4 N710 N800 aR-2500

4 N800 N1M0 aR-2500

Table 5.1 6-Pulse Drive Systems (380–500 V AC)

Number of drive

modules

2 N250 N315 aR-630

2 N315 N355 aR-630

2 N355 N400 aR-630

2 N400 N450 aR-800

2 N450 N500 aR-800

4 N500 N560 aR-900

4 N560 N630 aR-900

4 N630 N710 aR-1600

4 N710 N800 aR-1600

4 N800 N1M0 aR-1600

Table 5.2 12-Pulse Drive Systems (380–500 V AC)

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Recommended fuse

(maximum)

Table 5.4 12-Pulse Drive Systems (525–690 V AC)

5.4.1.4 Recommended Fuses for UL Compliance

The drive modules are supplied with built-in AC

•

fuses. The modules have been qualied for 100 kA short-circuit current rating (SCCR) for the standard busbar congurations at all voltages (380–690 V AC).

If no power options or extra busbars are

•

connected externally, the drive system is qualied for 100 kA SCCR with any Class L or Class T ULlisted fuses connected at the input terminals of the drive modules.

Do not exceed the listed fuse rating in Table 5.6

•

to Table 5.7 with the current rating of the Class L or Class T fuses.

Number of drive

modules

2 N450 N500 1600 A

4 N500 N560 2000 A

4 N560 N630 2000 A

4 N630 N710 2500 A

4 N710 N800 2500 A

4 N800 N1M0 2500 A

Table 5.5 6-Pulse Drive Systems (380–500 V AC)

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Electrical Installation Installation Guide

Number of drive

modules

2 N250 N315 630 A

2 N315 N355 630 A

2 N355 N400 630 A

2 N400 N450 800 A

2 N450 N500 800 A

4 N500 N560 900 A

4 N560 N630 900 A

4 N630 N710 1600 A

4 N710 N800 1600 A

4 N800 N1M0 1600 A

Table 5.6 12-Pulse Drive Systems (380–500 V AC)

Any minimum 500 V UL-listed fuse can be used for the 380–500 V AC

drive systems.

Number of drive

modules

4 N630 N710 1600 A

4 N710 N800 2000 A

4 N800 N900 2500 A

4 N900 N1M0 2500 A

4 N1M0 N1M2 2500 A

FC 302 FC 102/

FC 202

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Recommended fuse

(maximum)

5 5

Table 5.7 6-Pulse Drive Systems (525–690 V AC)

Number of drive

modules

2 N250 N315 550 A

2 N315 N355 630 A

2 N355 N400 630 A

2 N400 N500 630 A

2 N500 N560 630 A

2 N560 N630 900 A

4 N630 N710 900 A

4 N710 N800 900 A

4 N800 N900 900 A

4 N900 N1M0 1600 A

4 N1M0 N1M2 1600 A

Table 5.8 12-Pulse Drive Systems (525–690 V AC)

Any minimum 700 V UL-listed fuse can be used for the 525–690 V AC

drive systems.

FC 302 FC 102/

FC 202

Recommended fuse

(maximum)

Electrical Installation

VLT® Parallel Drive Modules

5.5 Electrical Kit Installation

This section describes how the electrical kit is used to connect 2 or 4 drive modules in parallel - to provide controlled power to an AC motor. A diagram is provided for each of the 4 congurations which, if followed, meet specic agency approvals and certications. If designing and building other congurations, seek agency approvals or certications apart from Danfoss.

Read this section for guidance in making electrical connections when assembling the drive modules into a

panel.

5.6 DC Bus Fuse Installation

DC fuses are provided in the basic kit. Install the DC fuses at the available DC terminals at individual drive modules, using the recommended bolts. Each DC fuse has a xture for mounting the microswitches, which are used to detect a fuse failure. See Illustration 3.3. Install the supplied harness between the microswitch terminals and the brake fault jumper port on the top of the drive modules. If the jumper is not installed properly, the unit does not power up and the error Brake IGBT Fault is shown. The microswitch has 3 terminals: NO, NC, and COM. Connect the wire harness between the NC and COM terminals. If it is connected between any other terminals, the unit does not power up, and the error Brake IGBT Fault is shown.

NOTICE

The microswitch is a snap t onto the fuse. Ensure that the switch is properly installed on the fuses.

5.7 Motor Connections

5.7.1 Motor Cables

See chapter 7.6 Cable Specications for more information on wire type and sizes.

NOTICE

SHIELDED CABLE LENGTH

With a standard VLT® Parallel Drive Modules drive system, shielded cables up to 150 m (492 ft) long or unshielded up to 300 m (984 ft) long provide full voltage at the motor. If this cable length is exceeded, use a dU/dt lter. For information on the selection of a dU/dt

lter, refer to the VLT® Parallel Drive Modules Design Guide.

motor cable. Use motor cables with rated voltage specication of at least 0.6/1 kV. Cables in this range provide

good resistance to insulation breakdown.

5.7.1.2 Dimensions

Follow local codes for current capacity data for cables and conductors. Widely used codes include: NFPA 70, EN 60204-1, VDE 0113-1, and VDE 0298-4. Overdimensioning for harmonics is not required.

5.7.1.3 Length

Keep cables as short as possible. Voltage drop and heat dissipation depends on the frequency and is approximately proportional to cable length. Consult the cable manufacturer specications regarding the length and expected voltage drop when connected to the drive system. See chapter 7.6 Cable Specications.

5.7.1.4 Shielding

The following factors are important for eective shielding:

Make sure that the amount of cable surface

•

covered by the shield is at least 80%.

Use a single-layer braided copper shield. Ensure

•

that the shield is braided to reduce surface area for leakage currents.

Use cables with double shielding to improve the

•

attenuation of interference further. Twisted conductors reduce magnetic elds.

Use cables that are shielded at both ends

•

between the drive system and the motor.

To comply with radio frequency interference

•

limits, shield the cables between the drive system and the motor at both ends.

Ensure that the shield fully surrounds the cable.

•

Route cable glands or cable clamps directly to

•

the grounding point.

Keep connections as short as possible at each

•

end of the cable.

Bridge shield gaps such as terminals, switches, or

•

contactors by using connections with the lowest possible impedance and the largest possible surface area.

NOTICE

TWISTED SHIELD ENDS (PIGTAILS)

5.7.1.1 Voltage Rating

Peak voltages up to 2.8 times the mains voltage of the

VLT® Parallel Drive Modules drive system can occur in the motor cable. High peak voltages can severely stress the

Twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield eect and increases the leakage current. To avoid twisted shield ends, use integrated shield clamps. Refer to Illustration 5.2.

+ 58 hidden pages