Danfoss VT2800 Series Design Manual

Contents
VLT®2800 Series
Introduction to VLT 2800
Software version ...................................................................................................... 4
High voltage warning ............................................................................................... 5
Warning against unintended start ............................................................................. 5
Technology .............................................................................................................. 6
CE labelling ............................................................................................................. 8
Modbus RTU ......................................................................................................... 11
Motor coils ............................................................................................................. 12
EMC filter for long motor cables ............................................................................ 16
Ordering numbers for VLT 2800 200-240 V .................................................. ........ 17
Ordering numbers for VLT 2800 380-480V ............................................................ 19
Order form ............................................................................................................. 21
PC software ........................................................................................................... 22
PC Software tools .................................................................................................. 22
Accessories for the VLT 2800 ........................................................................ ........ 23
Control unit ............................................................................................................ 30
Manual initialisation ................................................................................................. 30
Hand Auto ............................................................................................................. 31
Automatic motor tuning ......................................................................................... 32
The LCP 2 Control unit, option .............................................................................. 33
Parameter selection ............................................................................................... 36
............................................................................... 4
Installation ......................................................................................................... 38
Mechanical dimensions .......................................................................................... 38
Mechanical installation ........................................................................................... 42
General information about electrical installation ...................................................... 43
EMC-correct electrical installation .......................................................................... 44
Earthing of screened/armoured control cables ....................................................... 46
Diagram ................................................................................................................. 47
Electrical installation ............................................................................................... 48
Safety clamp .......................................................................................................... 50
Pre-fuses ....................................................................................................... ......... 50
Mains connection ................................................................................................... 50
Motor connection ................................................................................................... 50
RFI switch .............................................................................................................. 51
Direction of motor rotation ..................................................................................... 51
Parallel connection of motors ................................................................................. 51
Motor cables ................................................................................................. ......... 52
Motor thermal protection ....................................................................................... 52
Brake connection ................................................................................................... 52
Earth connection .................................................................................................... 52
Load sharing .......................................................................................................... 53
Tightening Torque, Power Terminals ...................................................................... 53
Control of mechanical brake .................................................................................. 53
Access to control terminals .................................................................................... 53
Electrical installation, control cables ....................................................................... 54
Tightening torques, control cables .......................................................................... 55
Electrical installation, control terminals ................................................................... 55
Relay connection ................................................................................................... 55
VLT Software Dialog .............................................................................................. 55
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1
VLT®2800 Series
Connection examples ............................................................................................ 56
Use of internal PID-controller - closed loop process control .................................. 58
Programming .............................. ...................................................................... 60
Operation & Display ............................................................................................... 60
Setup configuration ................................................................................................ 60
Load and Motor ..................................................................................................... 68
DC Braking ............................................................................................................ 73
References & Limits ............................................................................................... 78
Handling of references ........................................................................................... 78
Reference function ................................................................................................. 82
Inputs and outputs ................................................................................................. 87
Special functions .................................................................................................... 97
PID functions ....................................................................................................... 100
Handling of feedback ........................................................................................... 101
Serial communication for VLT 2800 ..................................................................... 108
Control Word according to FC protocol ............................................................... 112
Status Word according to FC Profile .................................................................... 114
Control word according to Fieldbus Profile .......................................................... 115
Status word according to Profidrive protocol ....................................................... 116
Serial communication ........................ ................................................................... 119
Technical functions .............................................................................................. 127
All about VLT 2800 ....................................................................................... 131
Special conditions ................................................................................................ 131
Galvanic Isolation (PELV) ...................................................................................... 131
Earth leakage current and RCD relays ................................................................. 131
Extreme operating conditions ............................................................................... 131
dU/dt on motor .................................................................................................... 132
Switching on the input ......................................................................................... 132
Acoustic noise ...................................................................................................... 132
Temperature-dependent switch frequency ........................................................... 133
Derating for air pressure ...................................................................................... 133
Derating for running at low speed ........................................................................ 133
Derating for long motor cables ............................................................................. 133
Derating for high switching frequency - VLT 2800 ................................................ 133
Vibration and shock ............................................................................................. 134
Air humidity .......................................................................................................... 134
UL Standard ........................................................................................................ 134
Efficiency .............................................................................................................. 134
Mains supply interference/harmonics .............................................................. ..... 134
Power factor ........................................................................................................ 135
Generic EMC standards/product standards ......................................................... 136
EMC emission .................................. .................................................................... 136
EMC Immunity ...................................................................................................... 138
Harmonic Current Emission .................................................................................. 139
Aggressive environments ...................................................................................... 139
Display readout .................................................................................................... 140
Warnings/alarm messages ................................................................................... 140
Warning words, extended status words and Alarmwords ................................... 145
General technical data ......................................................................................... 146
Technical data, mains supply 1 x 220 - 240 V/3 x 200-240V .............................. 150
Technical data, mains supply 3 x 380 - 480 V ..................................................... 151
Available literature ................................................................................................. 152
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VLT®2800 Series
Supplied with the unit ........................................................................................... 152
Index .................................................................................................................... 160
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3
VLT®2800 Series
VLT 2800 Series
Design Guide
Software version: 2.8x
This design guide can be used for all VLT 2800 Series fre­quency converters with software version 2.8x. The software version number can be seen from parameter 640; Software version no.
195NA021.19
NB!:
This symbol indicates something that should be noted by the reader.
Indicates a general warning.
This symbol indicates a warning of high voltage.
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VLT®2800 Series
High voltage warning
The voltage of the frequency converter is dangerous whenever the converter
is connected to mains. Incorrect fitting of the motor or frequency converter may cause damage to the equipment, serious injury or death. Consequently, it is essential to com ply with the instructions in this manual as well as local and national rules and safety regulations.
These rules concern your safety
1. The frequency converter must be disconnected
from the mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the prescribed time has passed before removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of
the frequency converter the equipment from mains and is thus n to be used as a safety switch.
3. The unit must be properly connected to the
earth, the user must be protected against the supply voltage and the motor must be protected against overloading pursuant to prevailing national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is not included
in the factory setting. If this function is required, set parameter 128 Motor thermal protection to data value ETR trip or data value ETR warning.For the North American market: The ETR functions provide overload protection of the motor, class 20, in accordance with N EC.
6. Do n
7. Note that the frequency converter has more voltage
ot remove the plugs for the motor - and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the prescribed time has passed before removing motor and mains plugs.
inputs than L1, L2 and L3 when the DC bus terminals are used. Check that all voltage inputs are disconnected and that the prescribed time has passed before repair work is commenced.
does not disconnect
ot
ensure that no unintended start occurs, stop functions are not sufficient.
2. While parameters are being changed, the motor may start. Consequently, t [STOP/RESET] must always be activated, 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 f ault in the supply mains or the motor connection ceases.
Use on isolated mains
See section RFI Switch regarding use on isolated mains.
It is important to follow the recommendations regarding installation on IT-mains, since sufficient protection of the complete installation must be observed. Not taking care using relevant monitoring devices for IT-mains may result in damage.
he stop key
these
2800
Introduction to VLT
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 frequency converter is connected to mains. If personal safety considerations make it necessary to
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5
Technology
Control principle
A frequency converter rectifies AC voltage from the mains supply into DC voltage, following which it changes this v oltage to an AC voltage with variable amplitude and frequency. The motor thus receives a variable voltage and frequency, which enables infinitely variable speed control of three-phase, standard AC motors.
1. Mains voltage
1 x 220 - 240 V AC, 50 / 60 Hz 3 x 200 - 240 V AC, 50 / 60 Hz 3 x 380 - 480 V AC, 50 / 60 Hz
. Rectifier
2 Three-phase rectifier bridge which rectifies AC voltage into DC voltage.
VLT®2800 Series
VLT 2800 control principle
A frequency converter is an electronic unit which is able to infinitely vari ab ly control the rpm of an AC motor. The frequency converter governs the motor speed by converting the regular voltage and frequency from mains, e.g. 400 V / 50 Hz, into variable magnitudes. Today the frequency converter controlled AC motor is a natural part of all types of automated plan ts. The frequency converter has an inverter control system called VVC (Voltage Vector Control). VVC controls an induction motor by energizing with a variable frequency and a voltage suitable for it. If the motor load changes, so do its energizing and speed. That is why the motor current is measured on an ongoing basis, and a motor model is used to calculate the actual voltage requirement and slip o f the motor.
Programmable inputs and outputs in four Setups
In the frequency converter is possible to program the different control inputs and signal outputs and to select four different user-defined Setups for most parameters. It is easy for the user to p rogram the required functions on the control panel or via serial c ommunication.
3
. Intermediate circuit
DC voltage 2 x mains voltage [V].
4
. Intermediate circuit coils Evens out the intermediate circuit current and limits the load on mains and components (mains transformer, cables, fuses and contactors).
. Intermediate circuit condenser
5 Evens out the intermediate circuit voltage.
6
. Inverter Converts DC voltage into a variable AC voltage withavariablefrequency.
. Motor voltage
7 Variable AC voltage d e pe nding on supply voltage. Variable frequency: 0.2 - 132 / 1 - 1000 Hz.
8
. Control card Here is the computer that controls the inverter which generates the pulse pattern by which the DC voltage is converted into variable AC voltage with a variable frequency.
Mains protector
The frequency converter is protected against the transients that occur on the mains sometimes, e.g. if coupling with a phase compensation system, or if fuses blow when lightning strikes.
Rated motor voltage and full torque can be maintained down to approx. 10% undervoltage in the mains supply.
As all 400 V units in the VLT 2800 Series have intermediate circuit coils, there is only a low amount of harmonic mains supply interference. This gives a good power factor (lower peak current), which reduces the load on the mains installation.
Frequency converter protections
The current measurement in the intermediate circuit constitutes perfect protection of the frequency in case there is a short-circuit or an earth fault on the motor connection. Constant monitoring of the intermediate circuit current enables switching on the motor output, e.g. by means of a contactor. Efficient monitoring of the mains supply means that the unit will stop in the c ase of a phase drop-out. In this way, the inverter and the condensers in the intermediate
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circuit are not overloaded, which would dramatically reduce the service life of the frequency converter. The frequency converter offers temperature protection as standard. If there is a thermal overload, this function cuts out the inverter.
Reliable galvanic isolation
In the frequency converter all digital inputs/outputs, analogue inputs/outputs and the terminals for serial communication are supplied from or in connection with circuits that comply with PELV requirements. PELV is also complied with in relation to relay terminals, so that they can be connected to the mains potential. For further information see the section entitled Galvanic Isolation (PELV).
Advanced motor protection
The frequency converter has integral electronic motor protection. The frequency converter calculates the motor temperature on the basis of current, frequency and time. As opposed to traditional, bimetallic protection, electronic protection takes account of reduced cooling at low frequencies because of reduced fan speed (motors with internal fan). This function cannot protect the individual motors when motors are connected in parallel. Thermal motor protection can be compared to a protective motor switch, CTI. To give the motor maximum protection against overheating when it is covered or blocked, or if the fan should fail, you can install a thermistor and connect it
to the frequency converters thermistor input (Digital
input), see parameter 128 Thermal motor protection.
VLT®2800 Series
2800
Introduction to VLT
See also the section entitled Galvanic Isolation (PELV) for further information.
NB!:
This function cannot protect the individual motors in the case of motors linked in parallel.
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CE labelling
What is CE labelling?
The p urp ose of CE labelling is to avoid technical obstacles to trade 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 direct ive, which came into force on 1 January 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 manufacturersdeclaration.
The low-voltage directive (73/23/EEC)
Frequency converters must be CE labe lled in accordance with the low-voltage directive, which came into force on 1 January 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 Volt AC and the 75 ­1500 Volt 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 compat ibility means that the mutual i nterference between different components/appliances is so small that the functioning of the appliances is not affected. The EMC directive came into force on 1 January 1996. Danfoss CE labels in accordance with the directive and issues a declaration of conformity upon request. In order that EMC-correct installation can be carried out, this manual gives detailed instructions for installation. In addition, we specify the standards w hich our different products comply with. We offe r the filters that can be seen from the specifications and provide other types of assistance to ensure the optimum EMC result.
VLT®2800 Series
In the great majority of cases, the frequency converter is 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 EM C properties of the appliance, system or installation rests with the installer.
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This section makes it easier for you to specify and order a VLT 2800.
Choice of frequency converter
The frequency converter must be chosen on the basis of the present motor current at maximum
loading of the unit. The frequency converters rated
output current I
must be equal to or greater than
INV.
the required motor current.
VLT®2800 Series
Mains voltage
VLT2800is ranges: 200-240 V and 380-480 V.
Select whether the frequency converter is connected to a mains voltage of:
1 x 220 - 240 Volt mains voltage
available for two mains voltage
Typical sh a ft output
P
INV.
Max. constant ou tput
- 1 x 220 - 240 V single-phase AC voltage
- 3 x 200 - 240
- 3 x 380 - 480 V three-phase AC voltage
V three-phase A C voltage
Max. constant output power
current I
INV.
at 230 V S Type [kW] [HP] [A] [kVA] 2803 0.37 0.5 2.2 0.9 2805 0.55 0.75 3.2 1.3 2807 0.75 1.0 4.2 1.7 2811 1.1 1.5 6.0 2.4 2815 1.5 2.0 6.8 2.7
3 x 200 - 240 Volt mains voltage
Typical sh a ft output
P
INV.
Max. constant ou tput
current I
INV.
Max. constant output power
at 230 V S Type [kW] [HP] [A] [kVA] 2803 0.37 0.5 2.2 0.9 2805 0.55 0.75 3.2 1.3 2807 0.75 1.0 4.2 1.7 2811 1.1 1.5 6.0 2.4 2815 1.5 2.0 6.8 2.7 2822 2.2 3.0 9.6 3.8 2840 3.7 5.0 16.0 6.4
2800
Introduction to VLT
INV.
INV.
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9
3 x 380 - 480 Volt mains voltage
VLT®2800 Series
Typical sh a ft output
P
INV.
Max. constant ou tput
current I
INV.
Max. constant output power
at 400 V S Type [kW] [HP] [A] [kVA] 2805 0.55 0.75 1.7 1.1 2807 0.75 1.0 2.1 1.7 2811 1.1 1.5 3.0 2.0 2815 1.5 2.0 3.7 2.6 2822 2.2 3.0 5.2 3.6 2830 3.0 4.0 7.0 4.8 2840 4.0 5.0 9.1 6.3 2855 5.5 7.5 12.0 8.3 2875 7.5 10.0 16.0 11.1 2880 11 15 24 16.6 2881 15 20 32 22.2 2882 18.5 25 37.5 26.0
Enclosure
All VLT 2800 units are supplied with IP 20 enclosure as standard. This enclosure level is idea l for panel mounting in areas where a h igh degree of protection is required; at the same time IP 20 enclosures allow side-by-side installation with for extra cooling equipment. IP 20 units can be upgraded with IP 21 / top coverand/orNEMA1byfittingatermin See ordering number for terminal cover under Accessories for VLT 2800 .
out any need
al cover.
RFI filter
VLT 2800 is available with or without an integral 1A RFI-filter. The integral 1A RFI filter complies with EMC standards EN 55011-1A.
With an integral RFI filter there is compliance with EN 55011-1B with a max. 15-metre screened/armoured motor cable on VLT 2803-2815 1 x 220-240 Volt. VLT 2880-82 with integral 1B filter comply with EMC standard EN 50011 - 1B
INV.
In a ddition, VLT 2880-82 units are supplied with Nema 1 enclosure as standard.
Brake
VLT 2800 is available with or without an integral brake module. See also the section entitled Brake resistors for ordering a
Wobble function
The wobble function is used for winding applications in the textile industries. All VLT 2800 frequency converters are suppl standard feature. The frequency converter is able to operate a motor, which turns a grooved drum. During winding, the gro correct position on the bobbin, in a diamond pattern. For further informat ion, see VLT 2800 Wobble Instruction MI
oved drum places the thread in the
50JXYY.
Brake resistor.
ied with a wobble function as a
Harmonic filter
The harmonic currents do not affect power consumption directly, but they increase the heat losses in the installation (transformer, cables). That is why, in a system with a relatively high percentage of rectifier load, it is important to keep the harmonic currents at a low level so as to avoid a transformer overload and high cable temperature. For the purpose of ensuring low harmonic currents, VLT 2822-2840 3 x 200-240 V and VLT 2805-2882 380-480 V are fitted with coils in their intermediate circuit as standard. This reduces the input current I Please note that 1 x 220-240 V units are not supplied with coils in their intermediate circuit.
FC protocol
Danfoss frequency converters are able to fulfill many different functions in a monitoring system. The frequency converter can be integrated directly in an overall surveillance system, which will allow detailed process data to be transferred via serial communication.
by typically 40 %.
RMS
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VLT®2800 Series
The protocol standard is based on an RS 485 bus system with a maximum transmission speed of 9600 baud. The following Drive profiles are supported as standard:
- FC Drive, which is a profile adapted to Danfoss.
- Profidrive, which supports the profidrive profile.
See Serial communicat ion for further details of telegram structure and Drive profile.
Fieldbus option
The increasing information requirements in industry make it nece ssary to collect or visualize many different process data. Important process data help the system technician with the daily monitoring of the system. The large amounts of data involved in m ajor systems make a higher transmission speed than 9600 baud desirable.
Fieldbus option
Profibus
Profibus is a fieldbus system, which can be used for linking automation devices such as sensors and actuators with the controls by means of a two-conductor cable. Profibus DP is a very fast communication protocol, made specially for communication between the automation system and various types of equipment. Profibus is a registered trade mark.
MODBUS is often applied in Gas and Oil appl ications, but also in building, infrastructure, transportation and energy, applicat ions are m aking use of its benefits.
2800
Introduction to VLT
DeviceNet
DeviceNet fieldbus systems can be used for linking automation devices such as sensors and actuators with the controls by means of a four-wire conductor cable. DeviceNet is a medium speed communication protocol, made specially for communication between the automation system and various types of equipment. Units with DeviceN et protocol cannot be controlled by FC protocol and Profidrive protocol.
VLT Software Dialog can be used on the Sub D plug.
Modbus RTU
MODBUS RTU (Remote Terminal Unit) Protocol is a m essaging structure developed by Modicon in 1979, used to establish master-slave/client-server communication between intelligent devices. MODBUS is used to monitor and program devices; to communicate intelligent devices with sensors and instruments; to monitor field devicesusingPCsandHMIs.
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VLT®2800 Series
Motor coils
By fitting the motor coil module between the frequency converter and the motor it is possible to use up to 200 metres of unscreened/unarmoured motor cable or 100 metres of screened/armoured motor cable. The motor c oil module has an enclosure of IP 20 and can be installed side-by-side.
NB!:
To have long motor cables and still comply with EN55011-1A, motor coil and EMC filter for long motor cables are needed.
NB!:
To comply with EN55011-1A the EMC filter for long motor cables can only be fitted to a VLT
2800 with integral 1A filter (R1 option).
See also the section EMC Emission.
Technical data for VLT 2803-2875 Motor coils Max. cable length (un screened/unarmoured) Max. cable length (screened/armoured)
1)
1)
200 m
100 m Enclosure IP 20 Max. rated c urre nt Max. voltage
1)
1)
16 A
480 V AC Min. distance between VLT and motor coil Side-by-side Min. distance above and below motor coil 100 mm Dimensions H x W x D (mm)
2)
200 x 90 x 152 Weight 3.8 kg
1)
Parameter 411 Switching frequency =4500Hz.
2)
For mechanical dimensions see under
See ordering number for motor coil module under Accessories for VLT 2800.
Mechanical dimensions.
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RFI 1B filter
All frequency converters will cause electromagnetic noise in the mains supply w hen they are operating. An RFI (Radio Frequency Interference) filter will reduce theelectromagneticnoiseinthemainssupply. Without an RFI filter there is a risk that a frequency converter will disrupt other electrical components
VLT®2800 Series
that are connected to the mains and might thus cause operating disruption. By fitting an RFI 1B filter m od ule between the mains supply and the VLT 2800, the VLT 2800 complies with the EMC norm EN 55011-1B.
NB!:
To comply with EN 55011-1B the RFI 1B filter module must be fitted together with a VLT 2800 with integral 1A RFI filter.
2800
Introduction to VLT
Technical data for VLT 2803-2875 RFI 1B filter Max. cable length ( screened/armoured) 200-240 V 100 m (At 1A: 100 m) Max. cable length ( screened/armoured) 380-480 V 25 m (At 1A: 50 m) Enclosure IP 20 Max. rated current 16 A Max. Voltage 480 V AC Max. voltage to earth 300 V AC Min. distance between VLT and RFI 1B filter Side-by-Side Min. distance above and below RFI 1B filter 100 mm Dimensions H x W x D (mm)
1)
200 x 60 x 87
Weight 0.9 kg
1)
For mechanical dimensions see under
Mechanical dimensions.
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See ordering number for RFI 1B filter module under Accessories for VLT 2800.
13
RFI 1B/LC filter
The RFI 1B/LC filter contains both an RFI module that complies with EN 55011-1B and an LC filter that reduces the acoustic noise.
LC filter
When a motor is controlled by a frequency converter, at times you will be able to hear the acoustic noise from the motor. The noise, which is caused by the design of the motor, is generated e very time one of the inverter contacts in the frequency converter is activated. The frequency of the acoustic noise therefore corresponds
to the frequency converters connection frequency.
VLT®2800 Series
Installation of thermistor (PTC)
The RFI 1B/LC filter has an i ntegral thermistor (PTC), which is activated if an overtemperature arises. The frequency converter can be programmed to stop the motor and activatee an alarm via a relay output or a digital output if the the rmistor is activated.
The filter reduces the voltages du/dt, the peak voltage
and ripple current Itothemotor,sothatthe
U
peak
current and voltage are almost sine-shaped. The acoustic motor noise is thus reduced to a minimum.
Becauseoftheripplecurrentinthecoilssome noisewillbeemittedbythecoils. Thisproblem can be solved completely by fitting the filter inside a cabinet or equivalent.
Danfoss can supply an LC filter for the frequency converter, which muffles the acoustic motor noise. Beforethefiltersareputintouseyoumustensurethat:
- rated current is observed
- mains voltage is 200-480 V
- parameter 412 Variable switching frequency
is set to LC filter attached [3]
- output frequency is max. 120 Hz
See drawing on the next page.
The thermistor must be connected between terminal 50 (+10V) and one of the digital inputs 18 , 19, 27 and 29. In parameter 128 Motor thermal protection Thermistor warning [1] or Thermistor trip [2] are selected. The thermistor is connected as follows:
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VLT®2800 Series
RFI 1B/LC filter
NB!:
To comply with EN 55011-1B the RFI 1B filter module must be fitted to a VLT 2800 with integral 1A RFI filter.
NB!:
The 1B/LC filter is not suitable for 200 V devices due to the high 1Ø input current.
2800
Introduction to VLT
Technical d ata for VLT 280 3-2840 RFI 1B/LC filter Max. cable length (screened/armoured) 380-480 V 25 m (At 1A: 50 m) Enclosure IP 20 Max. rated current 4.0 (Order no.: 195N3100); 9.1 (Order no.:
195N3101) Max. voltage 480 V AC Max. voltage to earth 300 V AC Min. distance between VLT and RFI 1B/LC filter Side-by-Side Min. distance abo ve and below RFI 1B/LC filter 100 mm Dimensions 195N3100 4.0 A H x W x D (mm) 200 x 75 x 168 Dimensions 195N3101 9.1 A H x W x D (mm) 267.5 x 90 x 168 Weight 195N3100 4.0 A 2.4 kg Weight 195N3101 9.1 A 4.0 kg
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15
VLT®2800 Series
EMC filter for long motor cables
NB!:
Set switching frequency, parameter 411, to 4500 Hz
NB!:
Fitting position of frequency converter: Vertical only.
NB!:
To have long motor cables and still comply with EN55011-1A, motor coil and EMC filter for long motor cables are needed.
NB!:
NB: To comply with EN55011-1A the EMC filter for long motor cables can only be fitted to a
VLT 2800 with integral 1A filter (R1 opt ion).
See also the section EMC Emission.
Technical data for VLT 2805-2875 380-480 V EMC filter for long motor cables Max. cable length (screened/armoured) VLT 2805-2875 380-480 V: 100 m Enclosure IP 20 Max. rated current 192H4719: 3.2 A, 192H4720: 9.0 A, 192H4893: 16 A Input voltage range 3 x 380-480 V ± 10% Mains frequency 50-60 Hz Input Terminals 2,5 mm2(192H4893 4 mm2) Output Flexible cords with sleeves Design Metal housing (suited for foot print and side mounting to VLT
2800) Min. distance above and below filter 100 mm Ambient temperature Ta= 50 °C Dimensions 192H4719 H x W x D (mm)1244 x 75 x 45 Dimensions 192H4720 H x W x D (mm)1313 x 90 x 50 Dimensions 192H4893 H x W x D (mm)1313 x 140 x 50
See ordering numbers for EMC filter for long motor cables in Accessories for V L T 2800
1
For drawin g and more detailed dimensions, see in Mechanical dimensions
Control unit
The frequency converter is always supplied with an integral control unit. All displays are in the form of a six-digit LED display capable of showing one item of operating data continuously during normal operation. As a supplement to the display, there are three indicator lamps for voltage (ON), warning (WARNING) and
alarm (ALARM). Most of the frequency converter’s
parameter Setups can be changed immediately via the integral control panel.
An LCP 2 control panel to be connected via a plug to the front of the frequency converter is available as an option. The LCP 2 control panel can be installed up to 3 metres away from the frequency converter, e.g. on a front panel, by means of the accompanying mount ing kit. All displays of data are via a 4-line alpha-numerical display, which in normal operation is able to show 4 operating data items and 3 operation modes continuously. During programming, all the i nformat ion required for quick, efficient parameter Setup of the frequency converter is displayed. As a supplement
to the display, there are three indicator lamps for voltage (ON), warning (WARNING) and alarm
(ALARM). Most of the frequency converters parameter
Setups can be changed immediately via the LCP 2 control panel. See also the section entitled The LCP 2 control unit in the Design Guide.
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VLT®2800 Series
Ordering numbers for VLT 2800 200-240 V
0,37 kW VLT 2803 1 x 220-240 V / 3 x 200-240 V
RFI Unit Profibus
1)
DP
3MBits/s
- ST - - 195N0001
- SB - - 195N0002
R1 ST - - 195N0003
R1 SB - - 195N0004
-ST - 195N0005
-SB - 195N0006
R1 ST - 195N0007
R1 SB - 195N0008
-ST - 195N0009
-SB - 195N0010
R1 ST - 195N0011
R1 SB - 195N0012
0,55 kW VLT 2805 1 x 220-240 V / 3 x 200-240 V
RFI Unit Profibus
1)
DP
3MBits/s
- ST - - 195N0013
- SB - - 195N0014
R1 ST - - 195N0015
R1 SB - - 195N0016
-ST - 195N0017
-SB - 195N0018
R1 ST - 195N0019
R1 SB - 195N0020
-ST - 195N0021
-SB - 195N0022
R1 ST - 195N0023
R1 SB - 195N0024
0,75 kW VLT 2807 1 x 220-240 V / 3 x 200-240 V
RFI Unit Profibus
1)
DP
3MBits/s
- ST - - 195N0025
- SB - - 195N0026
R1 ST - - 195N0027
R1 SB - - 195N0028
-ST - 195N0029
-SB - 195N0030
R1 ST - 195N0031
R1 SB - 195N0032
-ST - 195N0033
-SB - 195N0034
R1 ST - 195N0035
R1 SB - 195N0036
DeviceNet Ordering no.
DeviceNet Ordering no.
DeviceNet Ordering no.
1,1 kW VLT 2811 1 x 220-240 V / 3 x 200-240 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBits/s
- ST - - 195N0037
- SB - - 195N0038
R1 ST - - 195N0039
R1 SB - - 195N0040
-ST - 195N0041
-SB - 195N0042
R1 ST - 195N0043
R1 SB - 195N0044
-ST - 195N0045
-SB - 195N0046
R1 ST - 195N0047
R1 SB - 195N0048
1,5 kW VLT 2815 1 x 220-240 V / 3 x 200-240 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBits/s
- ST - - 195N0049
- SB - - 195N0050
R1 ST - - 195N0051
R1 SB - - 195N0052
-ST - 195N0053
-SB - 195N0054
R1 ST - 195N0055
R1 SB - 195N0056
-ST - 195N0057
-SB - 195N0058
R1 ST - 195N0059
R1 SB - 195N0060
2,2 kW V LT 2822 3 x 200-240 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBits/s
- ST - - 195N0061
- SB - - 195N0062
R1 ST - - 195N0063
R1 SB - - 195N0064
-ST - 195N0065
-SB - 195N0066
R1 ST - 195N0067
R1 SB - 195N0068
-ST - 195N0069
-SB - 195N0070
R1 ST - 195N0071
R1 SB - 195N0072
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
17
3,7 kW VLT 2840 3 x 200-240 V
RFI Unit Profibus
1)
DP
3MBits/s
- ST - - 195N0073
- SB - - 195N0074
R1 ST - - 195N0075
R1 SB - - 195N0076
-ST - 195N0077
-SB - 195N0078
R1 ST - 195N0079
R1 SB - 195N0080
-ST - 195N0081
-SB - 195N0082
R1 ST - 195N0083
R1 SB - 195N0084
DeviceNet Ordering no.
ST: Standard unit. SB: Standard unit with integral brake. R1: With RFI filter that complies w
ith EN 55011-1A.
VLT®2800 Series
NB!:
For VLT 2803-2815 with an R1 filter it is only possible to c o nnect single-phase mains voltage 1 x 220 - 240 Volt.
1) Also available in 12 MBi
t/s version.
18
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
Ordering numbers for VLT 2800 380-480V
0,55kW VLT28053x380-480V
RFI Unit Profibus
1)
DP
3MBit/s
- ST - - 195N1001
- SB - - 195N1002
R1 ST - - 195N1003
R1 SB - - 195N1004
-ST - 195N1005
-SB - 195N1006
R1 ST - 195N1007
R1 SB - 195N1008
-ST - 195N1009
-SB - 195N1010
R1 ST - 195N1011
R1 SB - 195N1012
0,75 kW VLT 2807 3 x 380-480 V
RFI Unit Profibus
1)
DP
3MBit/s
- ST - - 195N1013
- SB - - 195N1014
R1 ST - - 195N1015
R1 SB - - 195N1016
-ST - 195N1017
-SB - 195N1018
R1 ST - 195N1019
R1 SB - 195N1020
-ST - 195N1021
-SB - 195N1022
R1 ST - 195N1023
R1 SB - 195N1024
1,1 kW VLT 2811 3 x 380-480 V
RFI Unit Profibus
1)
DP
3MBit/s
- ST - - 195N1025
- SB - - 195N1026
R1 ST - - 195N1027
R1 SB - - 195N1028
-ST - 195N1029
-SB - 195N1030
R1 ST - 195N1031
R1 SB - 195N1032
-ST - 195N1033
-SB - 195N1034
R1 ST - 195N1035
R1 SB - 195N1036
DeviceNet Ordering no.
DeviceNet Ordering no.
DeviceNet Ordering no.
1,5 kW V LT 2815 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1037
- SB - - 195N1038
R1 ST - - 195N1039
R1 SB - - 195N1040
-ST - 195N1041
-SB - 195N1042
R1 ST - 195N1043
R1 SB - 195N1044
-ST - 195N1045
-SB - 195N1046
R1 ST - 195N1047
R1 SB - 195N1048
2,2 kW V LT 2822 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1049
- SB - - 195N1050
R1 ST - - 195N1051
R1 SB - - 195N1052
-ST - 195N1053
-SB - 195N1054
R1 ST - 195N1055
R1 SB - 195N1056
-ST - 195N1057
-SB - 195N1058
R1 ST - 195N1059
R1 SB - 195N1060
3,0 kW V LT 2830 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1061
- SB - - 195N1062
R1 ST - - 195N1063
R1 SB - - 195N1064
-ST - 195N1065
-SB - 195N1066
R1 ST - 195N1067
R1 SB - 195N1068
-ST - 195N1069
-SB - 195N1070
R1 ST - 195N1071
R1 SB - 195N1072
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
19
VLT®2800 Series
4,0 kW VLT 2840 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1073
- SB - - 195N1074
R1 ST - - 195N1075
R1 SB - - 195N1076
-ST - 195N1077
-SB - 195N1078
R1 ST - 195N1079
R1 SB - 195N1080
-ST - 195N1081
-SB - 195N1082
R1 ST - 195N1083
R1 SB - 195N1084
5,5 kW VLT 2855 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1085
- SB - - 195N1086
R1 ST - - 195N1087
R1 SB - - 195N1088
-ST - 195N1089
-SB - 195N1090
R1 ST - 195N1091
R1 SB - 195N1092
-ST - 195N1093
-SB - 195N1094
R1 ST - 195N1095
R1 SB - 195N1096
11 kW VLT 2880 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1109
- SB - - 195N1110
R3 ST - - 195N1111
R3 SB - - 195N1112
-ST - 195N1113
-SB - 195N1114
R3 ST - 195N1115
R3 SB - 195N1116
-ST - 195N1117
-SB - 195N1118
R3 ST - 195N1119
R3 SB - 195N1120
15 kW VLT 2881 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1121
- SB - - 195N1122
R3 ST - - 195N1123
R3 SB - - 195N1124
-ST - 195N1125
-SB - 195N1126
R3 ST - 195N1127
R3 SB - 195N1128
-ST - 195N1129
-SB - 195N1130
R3 ST - 195N1131
R3 SB - 195N1132
7,5 kW VLT 2875 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1097
- SB - - 195N1098
R1 ST - - 195N1099
R1 SB - - 195N1100
-ST - 195N1101
-SB - 195N1102
R1 ST - 195N1103
R1 SB - 195N1104
-ST - 195N1105
-SB - 195N1106
R1 ST - 195N1107
R1 SB - 195N1108
ST: Standard unit.
SB: Standard unit with integral brake.
R1: With RFI filter that complies with EN 55011-1A.
R3: With RFI filter that complies with EN 55011-1
B.
18.5 k W VLT 2882 3 x 380-480 V
RFI Unit Profibus
1)
DP
DeviceNet Ordering no.
3MBit/s
- ST - - 195N1133
- SB - - 195N1134
R3 ST - - 195N1135
R3 SB - - 195N1136
-ST - 195N1137
-SB - 195N1138
R3 ST - 195N1139
R3 SB - 195N1140
-ST - 195N1141
-SB - 195N1142
R3 ST - 195N1143
R3 SB - 195N1144
1) Also available in 12 MBit/s.
20
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
21
VLT®2800 Series
PC Software tools
PC Software - MCT 10
All drives are equipped with a serial communication port. We provide a PC tool for communication between PC and frequency converter, VLT Motio n Control Tool MCT 10 Set-up Software.
MCT 10 Set-up Software
MCT 10 has been designed as an easy to use interactive tool for setting parame ters in our frequency converters. The MCT 10 Set-up Software will be useful for:
Planning a communic ation network off-line. MCT 10
contains a complete frequency converter database
Commissioning frequency converters on line
Saving settings for all frequency converters
Replacing a drive in a network
Expandinganexistingnetwork
Future developed drives will be supported
MCT10Set-upSoftwaresupportProfibusDP-V1via a Master class 2 connection. It makes it possible to
on line read/write parameters in a frequency converter via the Profibus network. This will eliminate the need for an extra communication network.
The MCT 10 Set-up Software Modules
The following modules are included in the software package:
MCT 10 Set-up Software
Setting parameters Copy to and from frequency converters Documentation and print out of parameter settings incl. diagrams
SyncPos
Creating SyncPos programme
Ordering number:
Please order your CD containing MC Software using code number 130B1000.
T10Set-up
MCT 31
The MCT 31 harmonic calculation PC tool enables easy estimation of the harmonic distortion in a given application. Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with different additional harmonic reduction measurements, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated.
Ordering number:
Please order your CD containing the MCT 31 PC tool using code number 130B1031.
22
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
Accessories for the VLT 2800
Type Description Ordering no. Motor coil The motor coil module can be used for VLT 2803-2875 195N3110 RFI 1B filter The RFI 1B filter module can be used for VLT 2803-2875 195N3103 RFI 1B/LC filter 4 A The RFI 1B/LC filter 4 A can be used for VLT 2803-2805
200-240 V and VLT 2805-2815 380-400 V
RFI 1B/LC filter 9.1 A RFI 1B/LC filter 9.1 A can be used for VLT 2807-2815
200-240 V and VLT 2822-2840 380-400 V
EMC filter EMC filter for long motor cables can be used for VLT
2805-2815 380-480 V
EMC filter EMC filter for long motor cables can be used for VLT
2822-2840 380-480 V
EMC filter EMC filter for long motor cables can be used for VLT
2855-2875 380-480 V NEMA 1 terminal cover VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V 195N1900 NEMA 1 terminal cover VLT 2822 200-240 V, VLT 2822-2840 380-480 V 195N1901 NEMA 1 terminal cover VLT 2840 200-240 V, VLT 2855-2875 380-480 V 195N1902 IP 21 top cover VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V 195N2179 IP 21 top cover VLT 2822 200-240 V, VLT 2822-2840 380-480 V 195N2180 IP 21 top cover VLT 2840 200-240 V, VLT 2855-2875 380-480 V 195N2181 IP 21 top cover VLT 2880-2882 380-480 V 195N2182 LCP 2 control unit LCP 2 for programming the frequency converter 175N0131 Cable for LCP 2 control unit Cable from LCP 2 to frequency converter 175Z0929 DeviceNet cable Cable for DeviceNet connection 195N3113 LCP2remote-mountingkit Kitforremote-mountingofLCP2(incl. 3mcable,
excl. LCP 2) LOP (Loca l Operation Pad) LOP can be used fo r setting the reference
andstart/stopviathecontrolterminals. VLT Software Dialog CD-ROM version
1
MCT 10 Set-up Software 130B1000 External heat sink, small External heat sink, large
1)
Incl. the modules Basis, Logging, Template,
2
2
W x H x D = 222 x 450 x 65mm
W x H x D = 288 x 450 x 71mm
3
3
Guided Tour in 6 languages (Danish, English, German, Italian, Spanish and French).
2)
For further information see VLT 2800 Cold
Plate Instruction MI.28.DX.02.
195N3100
195N3101
192H4719
192H4720
192H4893
175Z0850
175N0128
175Z0967
195N3111 195N3112
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
23
Dynamic braking
With the VLT 2800 the dynamic braking quality in an application can be improved in two ways, either with the aid of brake resistors or AC braking.
Danfoss offers a complete range of brake resistors for all VLT 2800 frequency converters. It is the job of the brake resistor to apply a load to the intermediate circuit during braking, thereby ensuring that the brake power can be absorbed by the brake resistor. Without a brake resistor, the intermediate circuit voltage of the frequency converter would go on rising, until cutting out for protection. The advantage of using a brake resistor is that you can brake quickly with large loads, e.g. on a conveyor belt.
Danfoss has chosen a solution in which the brake resistor is not integrated into the frequency converter. This gives the user the following advantages:
-Theresistor’s cycle time can be selected as required.
- The heat generated during braking can be
diverted outside the panel cabinet, where the energy can possibly be utilised.
- No overhea ting of the e lectronic components,
even if the brake resistor is overloaded.
VLT®2800 Series
Calculation of brake resistance
The following example and formula only apply to VLT 2800 Series. To ensure that the frequency converter does not cut out for safety reasons when the motor brakes, the resistance value is selected on the basis of the peak braking effec t and the intermediate circuit voltage:
AC braking is an integrated function that is used for applications in which there is a need for limited dynamic braking. The AC braking function makes it possible to reduce the brake power in the motor instead of in a brake resistor. The function is intended for applicati ons where the required braking torque is less than 50% of rated torque. AC braking is selected in par. 400 Brake function.
NB!:
The AC brake cannot be used if the required braking torque is more than 50% of rated braking torque. In such instances
a brake resistor must be used.
Brake Setup
ThefigureshowsabrakeSetupwitha frequency converter. In the following paragraphs, expressions and acronyms are used about brake Setups that can be seen from the figure.
It can be seen that the brake resistance depends on the intermediate circuit voltage (UDC). With frequency converters that have a mains voltage of 3 x 380 - 480 Volt, the brake will be active at 770 Volt (UDC); if the frequency converter has a mains voltage of 3 x 200 - 240 Volt, the brake will be active at 385 Volt (UDC). You can also choose to use the brake resistance recommended by Danfoss (R guarantee that the frequency converter brakeatthehighestbrakingtorque(M
). This is a
REC
is able to
). The
BR
recommended brake resistance can be seen from the ordering table for brake resi
calculated as:
R
REC
stors.
NB!:
Remember to check that the brake resistance can manage a voltage of 850 Volt or 430 Volt, if Danfoss brake resistors are not being used.
24
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
η
is typically 0.90 and η
motor
is typically 0.98. For 400
INV
Volt and 200 Volt frequency converters, respectively,
at 160% braking torque can be written as:
R
REC
NB!:
The brake resistance selected should have an ohmic value no more than 10% lower
than that recommended by Danfoss. I lower brake resistance is selected there is a risk of overcurrent, which can destroy the unit.
Calculation of braking power
When calculating the braking pow er, it must be ensured that the mean and pe ak powers can be dissipated to the brake resistor. The mean power is determined by the period time of the process, i.e. for how long the brake is applied in relation to the period time of the process. The peak power is determined by the braking torque, which means that during braking the brake resistor must be able to dissipate the energy input. The figure shows the relation between mean power and peak power.
f a
of the motor and the frequency converter. The peak effect is calculated as follows:
If you select Danfossrecommended braking resistor
), you are certain that the braking resistance can
(R
REC
generate a braking torque of 160% on the m otor shaft.
Calculation of mean power on brake resistor
The mean power is determined by the period of the process, i.e. how long you brake in relation to the period of the process. Duty-cycle for braking is calculated as follows:
Tp= The process time in seconds.
= The braking time in seconds.
T
b
Danfoss sells brake resistors with variable duty-cycles up to 40%. For example, with a 10% duty-cycle, brake resistors can take up P
in 10% of the
peak
process period. The remaining 90% of the period time is spent on redirecting surplus heat. The mean power at 10% duty cycle can be calculated as follows:
2800
Introduction to VLT
Calculation of peak power of brake resistor
P
PEAK, MEC
is the peak power at which the motor
brakes on the motor shaft. It is calculated as follows:
P
is the term describing the braking power that
peak
is applied to the brake resistor when the motor applies the brakes. P
, as the power is reduced by the efficiency
MEC
MG.28.E9.02 - VLT is a registered Danfoss trademark
is smaller than P
PEAK
PEAK,
The mean power at 40% duty cycle can be calculated as follows:
These calculations apply to intermittent braking with period times of up to 120 seconds.
NB!:
Period times longer than 120 sec. may lead to overheating of the resistor.
Continuous braking
For continuous braking, a brake resistor should be selected in which the constant braking power does not exceed the mean power P
of the brake resistor.
AVG
25
VLT®2800 Series
Please contact your D anfoss supplier for further information.
D.C. injection braking
If the three-phase winding of the stator is fed with direct current, a stationary magnetic field will be set up in the stator bore causing a voltage to be induced in the bars of the cage rotor as long as the rotor is in motion. Since the electrical resistance of the rotor cage is very low, even small induced voltages can create a high rotor current. This current will produce a strong braking effect on the bars and hence on the rotor. As the speed falls, the frequency of the induced voltage falls and with it the inductive impedance. The ohmic resistance of the rotor gradually becomes dominant and so increases the braking effect as the speed comes down. The braking torque generated falls away steeply just before standstill and finally ceases when there is no further movement. Direct current injection braking is therefore not suitable for actually holding a load at rest.
AC-braking
When the motor acts as a brake the DC-link voltage will increase because energy is fed back to the DC-link. The principle in AC-brake is to increase the magnetisation during the braking and thereby increase the thermal losses of the motor. Using par. 144 in VLT 2800 it is possible to adjust the size of the generator torque that can be applied to the motor without the intermediate circuit voltage exceeding the warning level.
The braking torque depends on the speed. With the AC-brake function enabled and parameter 144 = 1,3 (factory setting) it is possible to brake with about 50 % of rated torque below 2/3 of rated speed and with about 25 % at rated speed. The function is not working at low speed (below 1/3 of nominal motor speed). It is only possible to run for about 30 seconds with pa rameter 144 greater than 1.2.
NB!:
If the value in parameter 144 is increased,
the motor current will simultaneously increase
significantly when generator loads are applied. The parameter should therefore only be changed if it is guaranteed during measurement that the motor current in all operating situations will never exceed the maximum permitted current in the motor. Please note: The current can not be read out from the display.
DC braking is to be applied a s required. The most efficient way of doing this is by using a combinat ion of dynamic and DC braking. See the illustration.
NB!:
When changing from dynamic to DC braking, there will be a short period (2-6 milliseconds) with very low braking torque.
How to calculate optimum DC-brake cut in frequency:
Slip S=
Synchronous speed [1/min]
f = frequency p=no. ofpolepairs
= speed of the rotor
n
n
DC-brake cut in frequency =
Hz
Brake cable
Max. length [m]: 20 m The connection cable to the brake resistor must be screened/armoured. Connect the screen totheconductivebackplateatthefrequency converter and to the brake resistor metal cabinet by means of cable clamps.
NB!:
If D anfoss brake resistors are not used, it must be ensured that the brake resistor is induction-free.
Optimal braking using resistor
Dynamic braking is useful from maximum speed down to a certain frequency. Below this frequency
26
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
Protective functions during installation
When a brake resistor is installed, the best possible endeavors should be made to avoid overloads, as the heat generating from a brake resistor may involve a fire risk.
NB!:
The brake resistor should be fitted to a
nonflammable material.
For p rotection of the installation, a thermal relay should be fitted that cuts off the frequency converter if the brake current becomes too high. Flat pack resistors are self-protecting.
Calculate the brake current setting of the thermal relay as follows:
Itherm relay =
Rbris the current brake resistor value calculated in the section on "Calc ulation of brake resistance". The figure shows an installation with a thermal relay.
The brake current setting of thermal relay for Danfoss 40% brakeresistors can be found in the table further on.
2800
Introduction to VLT
Some of the Danfoss Brakeresistors contain a thermal switch (see table further on). This switch is NC (normally closed) and can be used e.g. coasting stop reverse between terminal 12 and 27. The drive will then coast, if the thermal switch is opened.
NB!:
The thermal switch is not a protective
device. For protection, use a thermal
switch as shown in the figure.
MG.28.E9.02 - VLT is a registered Danfoss trademark
27
Brake resistors
Flatpack brake resistors IP 65
VLT®2800 Series
Type P
motor
[kW]
R
MIN
[ ]
Size [ ]/[W]
per item
Duty cycle % Order no.
175Uxxxx 2803 (200 V) 0.37 297 330 /100W 30 1003 2805 (200 V) 0.55 198 220 /100W 20 1004 2807 (200 V) 0.75 135 150 /100W 14 1005 2811 (200 V) 1.10 99 100 /100W 8 1006 2815 (200 V) 1.50 69 72 / 200 W 16 0992 2822 (200 V) 2.20 43 50 / 200 W 9 0993 2840 (200 V) 3.70 21 50 / 200 W 11 2x0993 2805 (400 V) 0.55 747 830 /100W 20 1000 2807 (400 V) 0.75 558 620 /100W 14 1001 2811 (400 V) 1.10 387 430 /100W 8 1002 2815 (400 V) 1.50 297 310 /200W 16 0984 2822 (400 V) 2.20 198 210 /200W 9 0987 2830 (400 V) 3.00 135 150 /200W 5.5 0989 2830 (400 V) 3.00 135 300 /200W 11 2x0985 2840 (400 V) 4.00 99 240 /200W 11 2x0986
1
These two resistors must be connected in parallel. Order two
pieces. See dimensions of Flatpack brake resistors on the next page.
Brake resistor for VLT 2803-2882 duty-cycle 40% data and codenumber
VLT type Intermit-
tent brak-
ing period
time
[seconds]
2803 (200 V) 120 0,37 297 330 0,16 0,7 1900* 1,5** 2805 (200 V) 120 0,55 198 220 0,25 1,1 1901* 1,5** 2807 (200 V) 120 0,75 135 150 0,32 1,5 1902* 1,5** 2811 (200 V) 120 1,1 99 110 0,45 2,0 1975* 1,5** 2815 (200 V) 120 1,5 74 82 0,85 3,2 1903* 1,5** 2822 (200 V) 120 2,2 50 56 1,00 4,2 1904* 1,5** 2840 (200 V) 120 3,7 22 25 3,00 11,0 1925 1,5**
P
motor
[kW]
R
[ ]
min
R
[ ]
rec
P
b, max
[kW]
Therm.re-
lay
[Amp]
Code
number
175Uxxxx
1
1
1
Cable cross
section
[mm
2
]
2805 (400 V) 120 0,55 747 830 0,45 0,7 1976* 1,5** 2807 (400 V) 120 0,75 558 620 0,32 0,7 1910* 1,5** 2811 (400 V) 120 1,1 387 430 0,85 1,4 1911* 1,5** 2815 (400 V) 120 1,5 297 330 0,85 1,6 1912* 1,5** 2822 (400 V) 120 2,2 198 220 1,00 2,1 1913* 1,5** 2830 (400 V) 120 3,0 135 150 1,35 3,0 1914* 1,5** 2840 (400 V) 120 4,0 99 110 1,60 3,8 1979* 1,5** 2855 (400 V) 120 5,5 80 80 2,00 5,0 1977* 1,5** 2875 (400 V) 120 7,5 56 56 3,00 6,8 1978* 1,5** 2880 (400 V) 120 11 40 40 5,00 11,2 1997* 1,5** 2881 (400 V) 120 15 30 30 10,0 18,3 1998 2,5** 2882 (400 V) 120 18,5 25 25 13,0 22,8 1999 4**
*With KLIXON switch **Always observe national and local regulations
P
motor
R
min
R
rec
P
b, max
Therm. relay : Brake current setting of thermal relay
:RatedmotorsizeforVLTtype : Minimum permissible brake resistor : Recommended brake resistor (Danfoss) : Brake resistor rated power as stated by supp
lier
Code number : Order numbers for Danfoss brake resistors Cable cross section : Recommended m
inimum value based upon PVC insul
ated copper cable, 30 degree C elsius
ambient temperature with normal heat dissipation
28
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
See dimensions of brake resistor for VLT 2803-2882 duty cycle 40% in instruction MI.90.FX.YY.
Dimensions of Flatpack brake resistors
100 W 200 W
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
29
VLT®2800 Series
Control unit
On the front of the frequency converter there is a control panel.
The control panel is divided into four function groups:
1. Six-digit LED display.
2. Keys for changing parameters and shifting
display function.
3. Indicator lamps.
4. Keys for local operation.
All displays of data are in the form of a six-digit LED display capable of showing one item of operating data continuously during normal operation. As a supplement to the display, there are three indicator lamps for indicat ion of mains connection (ON), warning (WARNING) and alarm (ALARM). Most of
the frequency converters parameter Setups can be
changed immediately via the control panel, unless this function has been programmed as Locked [1] via parameter 018 Lock for data changes.
These keys are also used in Display mode for selecting the display of an operating value.
The [QUICK MENU] + [+] keys must be
pressed at the same time to give access to all parameters. See Menu mode.
[STOP/RESET] is used for stopping the
connected motor or for resetting the frequency converter after a trip. Can be selected as Active [1] or Not active [0] via parameter 014 Local stop/reset. In Display mode, the display will flash if the stop function is ac tivated.
NB!:
If the [STOP/RESET] key is set at Not active [0] in parameter 014 Loca l stop/reset,and
there is no stop command via the digital inputs or serial communication, the motor can only be stopped by disconnecting the mains voltage to the frequency converter.
[START] is used for starting the frequency
converter. It is always active, but the [START] key cannot override a stop command.
Manual initialisation
Disconnect mains voltage. Hold the [QUICK MENU] + [+] + [CHANGE DATA] keys down while simultaneously reconnecting the mains voltage. Release the keys; the frequency converter has now been programmed for the factory setting.
Control keys
[QUICK MENU] allows access to the parameters
used for the Quick menu. The[QUICK MENU] key is also used if a change to a parameter value is not to be implemented. See also [QUICK MENU] + [+].
[CHANGE DATA] is used for changing a setting.
The [CHANGE DATA] key is also used for confirming a change of parameter settings.
[+] / [-] are used for selecting parameters and
for changing parameter values.
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MG.28.E9.02 - VLT is a registered Danfoss trademark
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