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
2
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
Supplied with the unit ........................................................................................... 152
Index .................................................................................................................... 160
MG.28.E9.02 - VLT is a registered Danfoss trademark
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.
4
MG.28.E9.02 - VLT is a registered Danfoss trademark
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
MG.28.E9.02 - VLT is a registered Danfoss trademark
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
6
MG.28.E9.02 - VLT is a registered Danfoss trademark
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 converter’s 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.
MG.28.E9.02 - VLT is a registered Danfoss trademark
7
■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 manufacturer’sdeclaration.
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.
8
MG.28.E9.02 - VLT is a registered Danfoss trademark
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 converter’s 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]
28030.370.52.20.9
28050.550.753.21.3
28070.751.04.21.7
28111.11.56.02.4
28151.52.06.82.7
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]
28030.370.52.20.9
28050.550.753.21.3
28070.751.04.21.7
28111.11.56.02.4
28151.52.06.82.7
28222.23.09.63.8
28403.75.016.06.4
2800
Introduction to VLT
INV.
INV.
MG.28.E9.02 - VLT is a registered Danfoss trademark
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]
28050.550.751.71.1
28070.751.02.11.7
28111.11.53.02.0
28151.52.03.72.6
28222.23.05.23.6
28303.04.07.04.8
28404.05.09.16.3
28555.57.512.08.3
28757.510.016.011.1
288011152416.6
288115203222.2
288218.52537.526.0
■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 Brakeresistors 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
10
MG.28.E9.02 - VLT is a registered Danfoss trademark
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.
MG.28.E9.02 - VLT is a registered Danfoss trademark
11
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 filterfor 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
EnclosureIP 20
Max. rated c urre nt
Max. voltage
1)
1)
16 A
480 V AC
Min. distance between VLT and motor coilSide-by-side
Min. distance above and below motor coil100 mm
Dimensions H x W x D (mm)
2)
200 x 90 x 152
Weight3.8 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.
12
MG.28.E9.02 - VLT is a registered Danfoss trademark
■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 V100 m (At 1A: 100 m)
Max. cable length ( screened/armoured) 380-480 V25 m (At 1A: 50 m)
EnclosureIP 20
Max. rated current16 A
Max. Voltage480 V AC
Max. voltage to earth300 V AC
Min. distance between VLT and RFI 1B filterSide-by-Side
Min. distance above and below RFI 1B filter100 mm
Dimensions H x W x D (mm)
1)
200 x 60 x 87
Weight0.9 kg
1)
For mechanical dimensions see under
Mechanical dimensions.
MG.28.E9.02 - VLT is a registered Danfoss trademark
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 converter’s 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 voltage’s du/dt, the peak voltage
and ripple currentItothemotor,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 Thermistorwarning [1] or Thermistor trip [2] are selected.
The thermistor is connected as follows:
14
MG.28.E9.02 - VLT is a registered Danfoss trademark
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 V25 m (At 1A: 50 m)
EnclosureIP 20
Max. rated current4.0 (Order no.: 195N3100); 9.1 (Order no.:
195N3101)
Max. voltage480 V AC
Max. voltage to earth300 V AC
Min. distance between VLT and RFI 1B/LC filterSide-by-Side
Min. distance abo ve and below RFI 1B/LC filter100 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 A2.4 kg
Weight 195N3101 9.1 A4.0 kg
MG.28.E9.02 - VLT is a registered Danfoss trademark
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 filterfor 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
EnclosureIP 20
Max. rated current192H4719: 3.2 A, 192H4720: 9.0 A, 192H4893: 16 A
Input voltage range3 x 380-480 V ± 10%
Mains frequency50-60 Hz
InputTerminals 2,5 mm2(192H4893 4 mm2)
OutputFlexible cords with sleeves
DesignMetal housing (suited for foot print and side mounting to VLT
2800)
Min. distance above and below filter100 mm
Ambient temperatureTa= 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 converter’s parameter
Setups can be changed immediately via the LCP
2 control panel. See also the section entitled TheLCP 2 control unit in the Design Guide.
16
MG.28.E9.02 - VLT is a registered Danfoss trademark
VLT®2800 Series
■Ordering numbers for VLT 2800 200-240 V
0,37 kWVLT 2803 1 x 220-240 V / 3 x 200-240 V
RFIUnitProfibus
1)
DP
3MBits/s
-ST--195N0001
-SB--195N0002
R1ST--195N0003
R1SB--195N0004
-ST-195N0005
-SB-195N0006
R1ST-195N0007
R1SB-195N0008
-ST-195N0009
-SB-195N0010
R1ST-195N0011
R1SB-195N0012
0,55 kWVLT 2805 1 x 220-240 V / 3 x 200-240 V
RFIUnitProfibus
1)
DP
3MBits/s
-ST--195N0013
-SB--195N0014
R1ST--195N0015
R1SB--195N0016
-ST-195N0017
-SB-195N0018
R1ST-195N0019
R1SB-195N0020
-ST-195N0021
-SB-195N0022
R1ST-195N0023
R1SB-195N0024
0,75 kWVLT 2807 1 x 220-240 V / 3 x 200-240 V
RFIUnitProfibus
1)
DP
3MBits/s
-ST--195N0025
-SB--195N0026
R1ST--195N0027
R1SB--195N0028
-ST-195N0029
-SB-195N0030
R1ST-195N0031
R1SB-195N0032
-ST-195N0033
-SB-195N0034
R1ST-195N0035
R1SB-195N0036
DeviceNetOrdering no.
DeviceNetOrdering no.
DeviceNetOrdering no.
1,1 kWVLT 2811 1 x 220-240 V / 3 x 200-240 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBits/s
-ST--195N0037
-SB--195N0038
R1ST--195N0039
R1SB--195N0040
-ST-195N0041
-SB-195N0042
R1ST-195N0043
R1SB-195N0044
-ST-195N0045
-SB-195N0046
R1ST-195N0047
R1SB-195N0048
1,5 kWVLT 2815 1 x 220-240 V / 3 x 200-240 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBits/s
-ST--195N0049
-SB--195N0050
R1ST--195N0051
R1SB--195N0052
-ST-195N0053
-SB-195N0054
R1ST-195N0055
R1SB-195N0056
-ST-195N0057
-SB-195N0058
R1ST-195N0059
R1SB-195N0060
2,2 kWV LT 2822 3 x 200-240 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBits/s
-ST--195N0061
-SB--195N0062
R1ST--195N0063
R1SB--195N0064
-ST-195N0065
-SB-195N0066
R1ST-195N0067
R1SB-195N0068
-ST-195N0069
-SB-195N0070
R1ST-195N0071
R1SB-195N0072
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
17
3,7 kWVLT 2840 3 x 200-240 V
RFIUnitProfibus
1)
DP
3MBits/s
-ST--195N0073
-SB--195N0074
R1ST--195N0075
R1SB--195N0076
-ST-195N0077
-SB-195N0078
R1ST-195N0079
R1SB-195N0080
-ST-195N0081
-SB-195N0082
R1ST-195N0083
R1SB-195N0084
DeviceNetOrdering 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
0,55kWVLT28053x380-480V
RFIUnitProfibus
1)
DP
3MBit/s
-ST--195N1001
-SB--195N1002
R1ST--195N1003
R1SB--195N1004
-ST-195N1005
-SB-195N1006
R1ST-195N1007
R1SB-195N1008
-ST-195N1009
-SB-195N1010
R1ST-195N1011
R1SB-195N1012
0,75 kWVLT 2807 3 x 380-480 V
RFIUnitProfibus
1)
DP
3MBit/s
-ST--195N1013
-SB--195N1014
R1ST--195N1015
R1SB--195N1016
-ST-195N1017
-SB-195N1018
R1ST-195N1019
R1SB-195N1020
-ST-195N1021
-SB-195N1022
R1ST-195N1023
R1SB-195N1024
1,1 kWVLT 2811 3 x 380-480 V
RFIUnitProfibus
1)
DP
3MBit/s
-ST--195N1025
-SB--195N1026
R1ST--195N1027
R1SB--195N1028
-ST-195N1029
-SB-195N1030
R1ST-195N1031
R1SB-195N1032
-ST-195N1033
-SB-195N1034
R1ST-195N1035
R1SB-195N1036
DeviceNetOrdering no.
DeviceNetOrdering no.
DeviceNetOrdering no.
1,5 kWV LT 2815 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1037
-SB--195N1038
R1ST--195N1039
R1SB--195N1040
-ST-195N1041
-SB-195N1042
R1ST-195N1043
R1SB-195N1044
-ST-195N1045
-SB-195N1046
R1ST-195N1047
R1SB-195N1048
2,2 kWV LT 2822 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1049
-SB--195N1050
R1ST--195N1051
R1SB--195N1052
-ST-195N1053
-SB-195N1054
R1ST-195N1055
R1SB-195N1056
-ST-195N1057
-SB-195N1058
R1ST-195N1059
R1SB-195N1060
3,0 kWV LT 2830 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1061
-SB--195N1062
R1ST--195N1063
R1SB--195N1064
-ST-195N1065
-SB-195N1066
R1ST-195N1067
R1SB-195N1068
-ST-195N1069
-SB-195N1070
R1ST-195N1071
R1SB-195N1072
2800
Introduction to VLT
MG.28.E9.02 - VLT is a registered Danfoss trademark
19
VLT®2800 Series
4,0 kWVLT 2840 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1073
-SB--195N1074
R1ST--195N1075
R1SB--195N1076
-ST-195N1077
-SB-195N1078
R1ST-195N1079
R1SB-195N1080
-ST-195N1081
-SB-195N1082
R1ST-195N1083
R1SB-195N1084
5,5 kWVLT 2855 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1085
-SB--195N1086
R1ST--195N1087
R1SB--195N1088
-ST-195N1089
-SB-195N1090
R1ST-195N1091
R1SB-195N1092
-ST-195N1093
-SB-195N1094
R1ST-195N1095
R1SB-195N1096
11 kWVLT 2880 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1109
-SB--195N1110
R3ST--195N1111
R3SB--195N1112
-ST-195N1113
-SB-195N1114
R3ST-195N1115
R3SB-195N1116
-ST-195N1117
-SB-195N1118
R3ST-195N1119
R3SB-195N1120
15 kWVLT 2881 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1121
-SB--195N1122
R3ST--195N1123
R3SB--195N1124
-ST-195N1125
-SB-195N1126
R3ST-195N1127
R3SB-195N1128
-ST-195N1129
-SB-195N1130
R3ST-195N1131
R3SB-195N1132
7,5 kWVLT 2875 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1097
-SB--195N1098
R1ST--195N1099
R1SB--195N1100
-ST-195N1101
-SB-195N1102
R1ST-195N1103
R1SB-195N1104
-ST-195N1105
-SB-195N1106
R1ST-195N1107
R1SB-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 WVLT 2882 3 x 380-480 V
RFIUnitProfibus
1)
DP
DeviceNetOrdering no.
3MBit/s
-ST--195N1133
-SB--195N1134
R3ST--195N1135
R3SB--195N1136
-ST-195N1137
-SB-195N1138
R3ST-195N1139
R3SB-195N1140
-ST-195N1141
-SB-195N1142
R3ST-195N1143
R3SB-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
TypeDescriptionOrdering no.
Motor coilThe motor coil module can be used for VLT 2803-2875195N3110
RFI 1B filterThe RFI 1B filter module can be used for VLT 2803-2875195N3103
RFI 1B/LC filter 4 AThe 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 ARFI 1B/LC filter 9.1 A can be used for VLT 2807-2815
200-240 V and VLT 2822-2840 380-400 V
EMC filterEMC filter for long motor cables can be used for VLT
2805-2815 380-480 V
EMC filterEMC filter for long motor cables can be used for VLT
2822-2840 380-480 V
EMC filterEMC filter for long motor cables can be used for VLT
2855-2875 380-480 V
NEMA 1 terminal coverVLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V195N1900
NEMA 1 terminal coverVLT 2822 200-240 V, VLT 2822-2840 380-480 V195N1901
NEMA 1 terminal coverVLT 2840 200-240 V, VLT 2855-2875 380-480 V195N1902
IP 21 top coverVLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V195N2179
IP 21 top coverVLT 2822 200-240 V, VLT 2822-2840 380-480 V195N2180
IP 21 top coverVLT 2840 200-240 V, VLT 2855-2875 380-480 V195N2181
IP 21 top coverVLT 2880-2882 380-480 V195N2182
LCP 2 control unitLCP 2 for programming the frequency converter175N0131
Cable for LCP 2 control unitCable from LCP 2 to frequency converter175Z0929
DeviceNet cableCable for DeviceNet connection195N3113
LCP2remote-mountingkitKitforremote-mountingofLCP2(incl. 3mcable,
excl. LCP 2)
LOP (Loca l Operation Pad)LOP can be used fo r setting the reference
andstart/stopviathecontrolterminals.
VLT Software DialogCD-ROM version
1
MCT 10Set-up Software130B1000
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 Danfoss’ recommended 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
*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 converter’s 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.
30
MG.28.E9.02 - VLT is a registered Danfoss trademark
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