VLT ® 2800 Series Contents Introduction to VLT 2800 Software version High voltage warning These rules concern your safety Warning against unintended start Technology CE labelling Motor coils Ordering numbers for VLT 2800 200-240 V Ordering numbers for VLT 2800 380-480V PC Software tools Accessories for the VLT 2800 Control unit Manual initialisation Hand Auto Automatic motor tuning The LCP 2 Control unit, option Parameter selection 4 4 5 5 5 6 8 12 16 17 21 22 29 29 30 31 32 35 37 37 41 42 44 46 47 48 50 50 50 51 51 51 52 52 53 53 53 54 54 54 54 55 56 56 56 56 Installation Mechanical dimensions Mechanical installation General information about electrical installation EMC-correct electrical installation Earthing of screened/armoured control cables Diagram Electrical installation Safety clamp Pre-fuses Mains connection Motor connection RFI switch Direction of motor rotation Parallel connection of motors Motor cables Motor thermal protection Brake connection Earth connection Load sharing Tightening Torque, Power Terminals Control of mechanical brake Access to control terminals Electrical installation, control cables Tightening torques, control cables Electrical installation, control terminals Relay connection VLT Software Dialog MG.27.E3.02 - VLT ® is a registered Danfoss trademark 1 VLT ® 2800 Series Connection examples Use of internal PID-controller - closed loop process control 57 59 61 61 62 69 74 80 81 84 88 98 101 102 110 115 119 121 122 123 126 134 139 139 139 139 139 140 140 140 141 142 142 142 142 142 143 143 143 143 144 144 145 145 146 147 147 Programming Operation & Display Setup configuration Load and Motor DC Braking References & Limits Handling of references Reference function Inputs and outputs Special functions PID functions Handling of feedback Enhanced Sleep Mode Serial communication for VLT 2800 Control Word according to FC protocol Status Word according to FC Profile Control word according to Fieldbus Profile Status word according to Profidrive protocol Serial communication Technical functions All about VLT 2800 Special conditions Galvanic Isolation (PELV) Earth leakage currentand RCD relays Extreme operating conditions dU/dt on motor Switching on the input Peak voltage on motor Acoustic noise Temperature-dependent switch frequency Derating for air pressure Derating for running at low speed Derating for long motor cables Derating for high switching frequency - VLT 2800 Vibration and shock Air humidity UL Standard Efficiency Mains supply interference/harmonics Power factor Generic EMC standards/product standards EMC emission EMC Immunity Harmonic Current Emission Aggressive environments 2 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Display readout Warnings/alarm messages Warning words, extended status words and Alarmwords General technical data Technical data, mains supply 1 x 220 - 240 V/3 x 200-240V Technical data, mains supply 3 x 380 - 480 V Available literature Supplied with the unit 149 149 153 154 159 160 161 161 169 Index MG.27.E3.02 - VLT ® is a registered Danfoss trademark 3 VLT ® 2800 Series VLT 2800 Design Guide Software version: 3.1x This Design Guide can be used for all VLT 2800 Series frequency converters with software version 3.1x. The software version number can be seen from parameter 640. 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.27.E3.02 - 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 comply with the instructions in this manual as well as local and national rules and safety regulations. The Protective Extra Low Voltage (PELV) requirements stated in IEC 61800-5-1 are not fulfilled at altitudes above 2000 m (6562 ft.). For 200V frequency converters the requirements are not fulfilled at altitudes above 5000 m (16 404 ft.). Please contact Danfoss Drives for further information. 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. 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 ensure that no unintended start occurs, these stop functions are not sufficient. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated, following which data can be modified. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases. 2. 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. The [STOP/RESET] key on the control panel of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch. 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. The earth leakage currents are higher than 3.5 mA. 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 NEC. Do not remove the plugs for the motor - and mains supply while the frequency converter 3. 2. 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 ITmains may result in damage. 3. 4. 5. 6. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 5 Introduction to VLT 2800 7. Note that the frequency converter has more voltage 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. VLT ® 2800 Series Technology Control principle A frequency converter rectifies AC voltage from the mains supply into DC voltage, following which it changes this voltage 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. VLT 2800 control principle A frequency converter is an electronic unit which is able to infinitely variably 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 plants. 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 of the motor. 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 2. Rectifier Three-phase rectifier bridge which rectifies AC voltage into DC voltage. 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). 5. Intermediate circuit condenser Evens out the intermediate circuit voltage. 6. Inverter Converts DC voltage into a variable AC voltage with a variable frequency. 7. Motor voltage Variable AC voltage depending 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. 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 program the required functions on the control panel or via serial communication. 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 case of a phase drop-out. In this 6 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series way, the inverter and the condensers in the intermediate 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. 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.27.E3.02 - VLT ® is a registered Danfoss trademark 7 Introduction to VLT 2800 VLT ® 2800 Series CE labelling What is CE labelling? The purpose 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 directive, 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's declaration. •The low-voltage directive (73/23/EEC) Frequency converters must be CE labelled 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 compatibility means that the mutual interference 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 which our different products comply with. We offer the filters that can be seen from the specifications and provide other types of assistance to ensure the optimum EMC result. 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 EMC properties of the appliance, system or installation rests with the installer. 8 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Order form 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 IINV. must be equal to or greater than the required motor current. Mains voltage VLT 2800 is available for two mains voltage ranges: 200-240 V and 380-480 V. Select whether the frequency converter is connected to a mains voltage of: - 1 x 220 - 240 V single-phase AC voltage 3 x 200 - 240 V three-phase AC voltage 3 x 380 - 480 V three-phase AC voltage 1 x 220 - 240 Volt mains voltage Typical shaft output PINV. [kW] 0.37 0.55 0.75 1.1 1.5 2.2 3.7 Max. constant output current IINV. Max. constant output power at 230 V SINV. [A] [kVA] 2.2 0.9 3.2 1.3 4.2 1.7 6.0 2.4 6.8 2.7 9.6 3.8 16 6.4 Type 2803 2805 2807 2811 2815 2822 2840 [HP] 0.5 0.75 1.0 1.5 2.0 3.0 5.0 3 x 200 - 240 Volt mains voltage Typical shaft output PINV. [kW] 0.37 0.55 0.75 1.1 1.5 2.2 3.7 Max. constant output current IINV. Max. constant output power at 230 V SINV. [A] [kVA] 2.2 0.9 3.2 1.3 4.2 1.7 6.0 2.4 6.8 2.7 9.6 3.8 16.0 6.4 Type 2803 2805 2807 2811 2815 2822 2840 [HP] 0.5 0.75 1.0 1.5 2.0 3.0 5.0 MG.27.E3.02 - VLT ® is a registered Danfoss trademark 9 Introduction to VLT 2800 VLT ® 2800 Series 3 x 380 - 480 Volt mains voltage Typical shaft output PINV. [kW] 0.55 0.75 1.1 1.5 2.2 3.0 4.0 5.5 7.5 11 15 18.5 Max. constant output current IINV. Max. constant output power at 400 V SINV. [A] [kVA] 1.7 1.1 2.1 1.7 3.0 2.0 3.7 2.6 5.2 3.6 7.0 4.8 9.1 6.3 12.0 8.3 16.0 11.1 24 16.6 32 22.2 37.5 26.0 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 IRMS by typically 40 %. Please note that 1 x 220-240 V units up to 1.5 kW are not supplied with coils in their intermediate circuit. Type 2805 2807 2811 2815 2822 2830 2840 2855 2875 2880 2881 2882 Enclosure [HP] 0.75 1.0 1.5 2.0 3.0 4.0 5.0 7.5 10.0 15 20 25 All VLT 2800 units are supplied with IP 20 enclosure as standard. This enclosure level is ideal for panel mounting in areas where a high degree of protection is required; at the same time IP 20 enclosures allow side-by-side installation without any need for extra cooling equipment. IP 20 units can be upgraded with IP 21 / top cover and/ or NEMA 1 by fitting a terminal cover. See ordering number for terminal cover under Accessories for VLT 2800 . In addition, VLT 2880-82 and 2840 PD2 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 Brake resistor. 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 10 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series 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 mounting 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 information 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 The LCP 2 control unit in the Design Guide. 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. 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. technician with the daily monitoring of the system. The large amounts of data involved in major 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. 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 DeviceNet protocol cannot be controlled by FC protocol and Profidrive protocol. VLT Software Dialog can be used on the Sub D plug. See Serial communication for further details of telegram structure and Drive profile. Fieldbus option The increasing information requirements in industry make it necessary to collect or visualize many different process data. Important process data help the system MG.27.E3.02 - VLT ® is a registered Danfoss trademark 11 Introduction to VLT 2800 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 coil 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 (unscreened/unarmoured) 1) Max. cable length (screened/armoured) 1) Enclosure Max. rated current 1) Max. voltage1) Min. distance between VLT and motor coil Min. distance above and below motor coil Mounting Dimensions H x W x D (mm)2) Weight 1) Parameter 411 Switching frequency = 4500 Hz. 2) For 200 m 100 m IP 20 16 A 480 V AC Side-by-side 100 mm Vertical mounting only 200 x 90 x 152 3.8 kg mechanical dimensions see under Mechanical dimensions. See ordering number for motor coil module under Accessories for VLT 2800. 12 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series RFI 1B filter All frequency converters will cause electromagnetic noise in the mains supply when they are operating. An RFI (Radio Frequency Interference) filter will reduce the electromagnetic noise in the mains supply. Without an RFI filter there is a risk that a frequency converter will disrupt other electrical components that are connected to the mains and might thus cause operating disruption. By fitting an RFI 1B filter module between the mains supply and the VLT 2800, the VLT 2800 complies with the EMC norm EN 55011-1B. Technical data for VLT 2803–2875 RFI 1B filter Max. cable length (screened/armoured) 200-240 V Max. cable length (screened/armoured) 380-480 V Enclosure Max. rated current Max. Voltage Max. voltage to earth Min. distance between VLT and RFI 1B filter Min. distance above and below RFI 1B filter Mounting Dimensions H x W x D (mm) Weight See ordering number for RFI 1B filter module under Accessories for VLT 2800. 100 m (At 1A: 100 m) 25 m (At 1A: 50 m) IP 20 16 A 480 V AC 300 V AC Side-by-Side 100 mm Vertical mounting only 200 x 60 x 87 0.9 kg MG.27.E3.02 - VLT ® is a registered Danfoss trademark 13 Introduction to VLT 2800 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. VLT ® 2800 Series 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 Installation of thermistor (PTC) The RFI 1B/LC filter has an integral 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 thermistor is activated. 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 every 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. The filter reduces the voltage's du/dt, the peak voltage Upeak and ripple current ΔI to the motor, so that the current and voltage are almost sine-shaped. The acoustic motor noise is thus reduced to a minimum. Because of the ripple current in the coils some noise will be emitted by the coils. This problem can be solved completely by fitting the filter inside a cabinet or equivalent. Danfoss can supply an LC filter for the VLT series 2800, which muffles the acoustic motor noise . Before the filters are put into use you must ensure that: 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 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: See drawing on the next page. 14 MG.27.E3.02 - 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. Technical data for VLT 2803–2875 RFI 1B/LC filter Max. cable length (screened/armoured) 380-480 V Enclosure Max. rated current Max. voltage Max. voltage to earth Min. distance between VLT and RFI 1B/LC filter Min. distance above and below RFI 1B/LC filter Mounting Dimensions 195N3100 4.0 A H x W x D (mm) Dimensions 195N3101 9.1 A H x W x D (mm) Weight 195N3100 4.0 A Weight 195N3101 9.1 A 25 m (At 1A: 50 m) IP 20 4.0 (Order no.: 195N3100); 9.1 (Order no.: 195N3101) 480 V AC 300 V AC Side-by-Side 100 mm Vertical mounting only 200 x 75 x 168 267.5 x 90 x 168 2.4 kg 4.0 kg MG.27.E3.02 - VLT ® is a registered Danfoss trademark 15 Introduction to VLT 2800 VLT ® 2800 Series Ordering numbers for VLT 2800 200-240 V 0,37 kW Unit RFI VLT 2803 1 x 220-240 V / 3 x 200-240 V Profibus DeviceNet Ordering no. DP1) 3 MBits/s 195N0001 195N0002 195N0003 195N0004 195N0005 ✓ 195N0006 ✓ 195N0007 ✓ 195N0008 ✓ 195N0009 ✓ 195N0010 ✓ 195N0011 ✓ 195N0012 ✓ VLT 2805 1 x 220-240 V / 3 x 200-240 V Profibus DeviceNet Ordering no. DP1) 3 MBits/s 195N0013 195N0014 195N0015 195N0016 195N0017 ✓ 195N0018 ✓ 195N0019 ✓ 195N0020 ✓ 195N0021 ✓ 195N0022 ✓ 195N0023 ✓ 195N0024 ✓ VLT 2807 1 x 220-240 V / 3 x 200-240 V Ordering no. Profibus DP1) DeviceNet 3 MBits/s 195N0025 195N0026 195N0027 195N0028 195N0029 ✓ 195N0030 ✓ 195N0031 ✓ 195N0032 ✓ 195N0033 ✓ 195N0034 ✓ 195N0035 ✓ 195N0036 ✓ 1,1 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB VLT 2811 1 x 220-240 V / 3 x 200-240 V Ordering no. Profibus DP1) DeviceNet 3 MBits/s 195N0037 195N0038 195N0039 195N0040 195N0041 ✓ 195N0042 ✓ 195N0043 ✓ 195N0044 ✓ 195N0045 ✓ 195N0046 ✓ 195N0047 ✓ 195N0048 ✓ VLT 2815 1 x 220-240 V / 3 x 200-240 V Ordering no. Profibus DP1) DeviceNet 3 MBits/s 195N0049 195N0050 195N0051 195N0052 195N0053 ✓ 195N0054 ✓ 195N0055 ✓ 195N0056 ✓ 195N0057 ✓ 195N0058 ✓ 195N0059 ✓ 195N0060 ✓ VLT 2822 PD2 1 x 220-240 V / 3 x 200-240 V Ordering no. Profibus DP1) DeviceNet 3 MBits/s 178F5167 178F5168 ✓ 178F5169 ✓ VLT 2822 3 x 200-240 V Profibus DP1) DeviceNet 3 MBits/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB 1,5 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB 0,55 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB 2,2 kW Unit RFI ST ST ST 0,75 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB 2,2 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N0061 195N0062 195N0063 195N0064 195N0065 195N0066 195N0067 195N0068 195N0069 195N0070 195N0071 195N0072 16 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series 3,7 kW Unit RFI ST ST ST VLT 2840 PD2 1 x 220-240 V / 3 x 200-240 V Ordering no. Profibus DP1) DeviceNet 3 MBits/s 178F5170 178F5171 ✓ 178F5172 ✓ VLT 2840 3 x 200-240 V Profibus DP1) DeviceNet 3 MBits/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Ordering no. 195N0073 195N0074 195N0075 195N0076 195N0077 195N0078 195N0079 195N0080 195N0081 195N0082 195N0083 195N0084 1,1 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB VLT 2811 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2815 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2822 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2830 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Ordering no. 195N1025 195N1026 195N1027 195N1028 195N1029 195N1030 195N1031 195N1032 195N1033 195N1034 195N1035 195N1036 3,7 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB 1,5 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1037 195N1038 195N1039 195N1040 195N1041 195N1042 195N1043 195N1044 195N1045 195N1046 195N1047 195N1048 ST: Standard unit. SB: Standard unit with integral brake. R1: With RFI filter that complies with EN 55011-1A. NB! For VLT 2803-2815 with an R1 filter it is only possible to connect single-phase mains voltage 1 x 220 - 240 Volt. 1) Also available in 12 MBit/s version. 2,2 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1049 195N1050 195N1051 195N1052 195N1053 195N1054 195N1055 195N1056 195N1057 195N1058 195N1059 195N1060 Ordering numbers for VLT 2800 380-480V 0,55 kW VLT 2805 3 x 380-480 V Unit Profibus DP1) DeviceNet RFI 3 MBit/s ST SB R1 ST R1 SB ST ✓ SB ✓ R1 ST ✓ R1 SB ✓ ST ✓ SB ✓ R1 ST ✓ R1 SB ✓ 0,75 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB VLT 2807 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Ordering no. 195N1001 195N1002 195N1003 195N1004 195N1005 195N1006 195N1007 195N1008 195N1009 195N1010 195N1011 195N1012 3,0 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1061 195N1062 195N1063 195N1064 195N1065 195N1066 195N1067 195N1068 195N1069 195N1070 195N1071 195N1072 Ordering no. 195N1013 195N1014 195N1015 195N1016 195N1017 195N1018 195N1019 195N1020 195N1021 195N1022 195N1023 195N1024 MG.27.E3.02 - VLT ® is a registered Danfoss trademark 17 Introduction to VLT 2800 VLT ® 2800 Series 4,0 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB VLT 2840 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2855 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2875 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2880 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Ordering no. 195N1073 195N1074 195N1075 195N1076 195N1077 195N1078 195N1079 195N1080 195N1081 195N1082 195N1083 195N1084 15 kW Unit RFI R3 R3 R3 R3 R3 R3 ST SB ST SB ST SB ST SB ST SB ST SB VLT 2881 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ VLT 2882 3 x 380-480 V Profibus DP1) DeviceNet 3 MBit/s ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Ordering no. 195N1121 195N1122 195N1123 195N1124 195N1125 195N1126 195N1127 195N1128 195N1129 195N1130 195N1131 195N1132 5,5 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1085 195N1086 195N1087 195N1088 195N1089 195N1090 195N1091 195N1092 195N1093 195N1094 195N1095 195N1096 18.5 kW Unit RFI R3 R3 R3 R3 R3 R3 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1133 195N1134 195N1135 195N1136 195N1137 195N1138 195N1139 195N1140 195N1141 195N1142 195N1143 195N1144 7,5 kW Unit RFI R1 R1 R1 R1 R1 R1 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1097 195N1098 195N1099 195N1100 195N1101 195N1102 195N1103 195N1104 195N1105 195N1106 195N1107 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 55011-1B. 1) Also available in 12 MBit/s. 11 kW Unit RFI R3 R3 R3 R3 R3 R3 ST SB ST SB ST SB ST SB ST SB ST SB Ordering no. 195N1109 195N1110 195N1111 195N1112 195N1113 195N1114 195N1115 195N1116 195N1117 195N1118 195N1119 195N1120 18 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series MG.27.E3.02 - VLT ® is a registered Danfoss trademark 19 Introduction to VLT 2800 VLT ® 2800 Series 20 MG.27.E3.02 - VLT ® is a registered Danfoss trademark 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 Motion 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 parameters in our frequency converters. The MCT 10 Set-up Software will be useful for: • Planning a communication 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 Expanding an existing network • Future developed drives will be supported 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 MCT 10 Set-up Software using code number 130B1000. 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 reduc- tion 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. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 21 Introduction to VLT 2800 MCT 10 Set-up Software support Profibus DP-V1 via 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. VLT ® 2800 Series Accessories for the VLT 2800 Type Motor coil RFI 1B filter RFI 1B/LC filter 4 A RFI 1B/LC filter 9.1 A EMC filter EMC filter EMC filter NEMA 1 terminal cover NEMA 1 terminal cover NEMA 1 terminal cover IP 21 top cover IP 21 top cover IP 21 top cover IP 21 top cover LCP 2 control unit Cable for LCP 2 control unit DeviceNet cable LCP 2 remote-mounting kit LOP (Local Operation Pad) VLT Software Dialog MCT 10 External heat sink, small2 External heat sink, large2 1) Description The motor coil module can be used for VLT 2803-2875 The RFI 1B filter module can be used for VLT 2803-2875 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 can be used for VLT 2807-2815 200-240 V and VLT 2822-2840 380-400 V EMC filter for long motor cables can be used for VLT 2805-2815 380-480 V EMC filter for long motor cables can be used for VLT 2822-2840 380-480 V EMC filter for long motor cables can be used for VLT 2855-2875 380-480 V VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V VLT 2822 200-240 V, VLT 2822-2840 380-480 V VLT 2840, VLT 2840 PD2 200-240 V, VLT 2855-2875 380-480 V VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V VLT 2822 200-240 V, VLT 2822-2840 380-480 V VLT 2840 200-240 V, VLT 2822 PD2, VLT 2855-2875 380-480 V VLT 2880-2882 380-480 V, VLT 2840 PD2 LCP 2 for programming the frequency converter Cable from LCP 2 to frequency converter Cable for DeviceNet connection Kit for remote-mounting of LCP 2 (incl. 3 m cable, excl. LCP 2) LOP can be used for setting the reference and start/stop via the control terminals. CD-ROM version1 Set-up Software W x H x D = 222 x 450 x 65mm3 W x H x D = 288 x 450 x 71mm3 Ordering no. 195N3110 195N3103 195N3100 195N3101 192H4719 192H4720 192H4893 195N1900 195N1901 195N1902 195N2179 195N2180 195N2181 195N2182 175N0131 175Z0929 195N3113 175Z0850 175N0128 175Z0967 130B1000 195N3111 195N3112 Incl. the modules Basis, Logging, Template, 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. 22 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series 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: The resistor'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 overheating of the electronic components, even if the brake resistor is overloaded. 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 effect and the intermediate circuit voltage: - Rbr = U DC ² P PEAK Ω 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 applications 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. 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 (RREC). This is a guarantee that the frequency converter is able to brake at the highest braking torque (MBR). The recommended brake resistance can be seen from the ordering table for brake resistors. RREC calculated as: R REC = U DC ² × 100 Pmotor × M br ( % ) × η motor × η inv 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. Introduction to VLT 2800 Ω •motor is typically 0.90 and •INV is typically 0.98. For 400 Volt and 200 Volt frequency converters, respectively, R REC at 160% braking torque can be written as: 23 Brake Setup The figure shows a brake Setup with a frequency converter. In the following paragraphs, expressions and acronyms are used about brake Setups that can be seen from the figure. MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series 400 volt R REC = 200 volt R REC = 420139 105035 Pmotor Pmotor Ω Ω If you select Danfoss' recommended braking resistor (RREC), you are certain that the braking resistance can generate a braking torque of 160% on the motor shaft. NB! The brake resistance selected should have an ohmic value no more than 10% lower than that recommended by Danfoss. If a lower brake resistance is selected there is a risk of overcurrent, which can destroy the unit. 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: Duty − cycle = Tb × 100 Tp % Calculation of braking power When calculating the braking power, it must be ensured that the mean and peak 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. Tp = The process time in seconds. T b = The braking time in seconds. Danfoss sells brake resistors with variable duty-cycles up to 40%. For example, with a 10% duty-cycle, brake resistors can take up Ppeak in 10% of the 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: Pavg = P peak × 10 % W The mean power at 40% duty cycle can be calculated as follows: Pavg = P peak × 40 % W 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. Calculation of peak power of brake resistor PPEAK, MEC is the peak power at which the motor brakes on the motor shaft. It is calculated as follows: 100 Ppeak is the term describing the braking power that is applied to the brake resistor when the motor applies the brakes. PPEAK is smaller than PPEAK, MEC, as the power is reduced by the efficiency of the motor and the frequency converter. The peak effect is calculated as follows: P PEAK , MEC = P MOTOR × MBR (%) W P PEAK = P MOTOR × MBR ( % ) × η INV 100 × η MOTOR W 24 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Continuous braking For continuous braking, a brake resistor should be selected in which the constant braking power does not exceed the mean power PAVG of the brake resistor. Please contact your Danfoss supplier for further information. the motor. Please note: The current can not be read out from the display. Optimal braking using resistor Dynamic braking is useful from maximum speed down to a certain frequency. Below this frequency DC braking is to be applied as required. The most efficient way of doing this is by using a combination of dynamic and DC braking. See the illustration. 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 DClink. 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 parameter 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 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 = n0 − nn × 100 n0 % 1 / min S ynchronous speed n0 = f = frequency p = no. of pole pairs nn = speed of the rotor f × 60 p DC − brake cut in frequency = 2 × s × f 100 MG.27.E3.02 - VLT ® is a registered Danfoss trademark 25 Introduction to VLT 2800 Hz VLT ® 2800 Series Brake cable Max. length [m]: 20 m The connection cable to the brake resistor must be screened/armoured. Connect the screen to the conductive backplate at the frequency converter and to the brake resistor metal cabinet by means of cable clamps. NB! If Danfoss brake resistors are not used, it must be ensured that the brake resistor is induction-free. 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 protection 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: I therm relay = Rbrakeresistor Pavg Rbris the current brake resistor value calculated in the section on “Calculation 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. 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. 26 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Brake resistors Flatpack brake resistors IP 65 Type 2803 (200 V) 2805 (200 V) 2807 (200 V) 2811 (200 V) 2815 (200 V) 2822 (200 V) 2840 (200 V) 2805 (400 V) 2807 (400 V) 2811 (400 V) 2815 (400 V) 2822 (400 V) 2830 (400 V) 2830 (400 V) 2840 (400 V) 1These Pmotor [kW] 0.37 0.55 0.75 1.10 1.50 2.20 3.70 0.55 0.75 1.10 1.50 2.20 3.00 3.00 4.00 RMIN [Ω] 297 198 135 99 69 43 21 747 558 387 297 198 135 135 99 Size [Ω] / [W] per item 330 Ω / 100 W 220 Ω / 100 W 150 Ω / 100 W 100 Ω / 100 W 72 Ω / 200 W 50 Ω / 200 W 50 Ω / 200 W 830 Ω / 100 W 620 Ω / 100 W 430 Ω / 100 W 310 Ω / 200 W 210 Ω / 200 W 150 Ω / 200 W 300 Ω / 200 W 240 Ω / 200 W Duty cycle % 30 20 14 8 16 9 11 20 14 8 16 9 5.5 11 11 Order no. 175Uxxxx 1003 1004 1005 1006 0992 0993 2x09931 1000 1001 1002 0984 0987 0989 2x09851 2x09861 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 Intermittent braking period time [seconds] 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 Pmotor [kW] Rmin [Ω] Rrec [Ω] Pb, max [kW] Therm.relay [Amp] Code number 175Uxxxx 1900* 1901* 1902* 1975* 1903* 1904* 1925 1976* 1910* 1911* 1912* 1913* 1914* 1979* 1977* 1978* 1997* 1998 1999 Cable cross section [mm 2] 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 1,5** 2,5** 4** 2803 (200 V) 2805 (200 V) 2807 (200 V) 2811 (200 V) 2815 (200 V) 2822 (200 V) 2840 (200 V) 2805 (400 V) 2807 (400 V) 2811 (400 V) 2815 (400 V) 2822 (400 V) 2830 (400 V) 2840 (400 V) 2855 (400 V) 2875 (400 V) 2880 (400 V) 2881 (400 V) 2882 (400 V) 0,37 0,55 0,75 1,1 1,5 2,2 3,7 0,55 0,75 1,1 1,5 2,2 3,0 4,0 5,5 7,5 11 15 18,5 297 198 135 99 74 50 22 747 558 387 297 198 135 99 80 56 40 30 25 330 220 150 110 82 56 25 830 620 430 330 220 150 110 80 56 40 30 25 0,16 0,25 0,32 0,45 0,85 1,00 3,00 0,45 0,32 0,85 0,85 1,00 1,35 1,60 2,00 3,00 5,00 10,0 13,0 0,7 1,1 1,5 2,0 3,2 4,2 11,0 0,7 0,7 1,4 1,6 2,1 3,0 3,8 5,0 6,8 11,2 18,3 22,8 *With KLIXON switch **Always observe national and local regulations Pmotor Rmin Rrec Pb, max Therm. relay Code number Cable cross section : Rated motor size for VLT type : Minimum permissible brake resistor : Recommended brake resistor (Danfoss) : Brake resistor rated power as stated by supplier : Brake current setting of thermal relay : Order numbers for Danfoss brake resistors : Recommended minimum value based upon PVC insulated copper cable, 30 degree Celsius ambient temperature with normal heat dissipation See dimensions of brake resistor for VLT 2803-2882 duty cycle 40% in instruction MI.90.FX.YY. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 27 Introduction to VLT 2800 VLT ® 2800 Series Dimensions of Flatpack brake resistors 100 W 200 W 28 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Control unit On the front of the frequency converter there is a control panel. [+] / [-] are used for selecting parameters and for changing parameter values. These keys are also used in Display mode for selecting the display of an operating value. [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 activated. NB! If the [STOP/RESET] key is set at Not active [0] in parameter 014 Local 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. The control panel is divided into four function groups: 1. 2. 3. 4. Six-digit LED display. Keys for changing parameters and shifting display function. Indicator lamps. Keys for local operation. 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. 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 indication 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. 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. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 29 Introduction to VLT 2800 The [QUICK MENU] + [+] keys must be pressed at the same time to give access to all parameters. See Menu mode. VLT ® 2800 Series Display readout states Display mode Using the [QUICK MENU] key, it is possible to access the 12 most important parameters of the frequency converter. After programming, the frequency converter is in most cases ready for operation. When the [QUICK MENU] key is activated in Display mode, the Quick menu starts. Scroll through the quick menu using the [+/-] keys and change the data values by first pressing [CHANGE DATA] and then changing the parameter value with the [+/-] keys. TheQuick menu parameters are: • • • • • In order to enter the Menu mode [QUICK MENU] + [+] must be activated at the same time. In Menu mode, most of the frequency converter parameters can be changed. Scroll through the parameters using the [+/-] keys. While scrolling in the Menu mode proceeds, the parameter number will flash. • • • • • • • • The display shows that the setting in parameter 102 Motor power PM,N is 0.75. In order to change the value of 0.75, [CHANGE DATA] must first be activated; the parameter value can then be changed using the [+/-] keys. • • • Par. 100 Configuration Par. 101 Torque characteristic Par. 102 Motor power PM,N Par. 103 Motor voltage UM,N Par. 104 Motor frequency fM,N Par. 105 Motor current IM,N Par. 106 Rated motor speed nM,N Par. 107 Automatic motor adaptation Par. 202 Output frequency high limit fMAX Par. 203 Reference range Par. 204 Minimum reference RefMIN Par. 205 Maximum reference RefMAX Par. 207 Ramp-up time Par. 208 Ramp-down time Par. 002 Local/remote operation Par. 003 Local reference Quick menu In normal operation, one item of operating data can be displayed continuously at the operator's own choice. By means of the [+/-] keys the following options can be selected in Display mode: Output frequency [Hz] Output current [A] Output voltage [V] Intermediate circuit voltage [V] Output power [kW] Scaled output frequency fout x p008 Menu mode Parameter 102 - 106 can be read out from the motor's nameplate. Hand Auto If for a given parameter the display shows three dots at the right, it means that the parameter value has more than three digits. In order to see the value, activate [CHANGE DATA]. During normal operation the frequency converter is in Auto mode, where the reference signal is given externally, analog or digital via the control terminals. However, in Hand mode, it is possible to give the reference signal locally via the control panel. On the control terminals, the following control signals will remain active when Hand mode is activated: • • The display shows that in parameter 128 Motor thermal protection the selection made is Thermistor trip [2]. • Hand Start (LCP2) Off Stop (LCP2) Auto Start (LCP2) 30 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series • • • • • • • • • • • • • • Reset Coasting Stop Inverse Reset and Coasting Stop Inverse Quick Stop Inverse Stop Inverse Reversing DC Braking Inverse Setup Select LSB Setup Select MSB Thermistor Precise Stop Inverse Precise Stop/Start Jog Stop Command Via Serial Comm. 4. 3. 2. Automatic motor tuning Automatic motor tuning (AMT) is performed as follows: 1. In parameter 107 Automatic motor tuning select data value [2]. “107” will now flash, and “2” will not flash. AMT is activated by pressing start. “107” will now flash and dashes will move from left to right in the data value field. When “107” appears once more with the data value [0], AMT is complete. Press [STOP/ RESET] to save the motor data. “107” will then continue to flash with the data value [0]. You can now proceed. NB! VLT 2880-2882 do not have AMT function. Switching between Auto- and Hand mode: By activating the [Change Data] key in [Display Mode], the display will indicate the mode of the frequency converter. Scroll up/down in order to switch to Hand mode: When the frequency converter is in Hand mode the readout will be like: and the reference can be changed by using the following keys: NB! Please note, that parameter 020 may block the choice of mode. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 31 Introduction to VLT 2800 VLT ® 2800 Series The LCP 2 Control unit, option frequency converter parameter Setups can be changed immediately from the control panel, unless this function has been programmed as Locked [1] via parameter 018 Lock for data changes. Control keys for parameter Setup The control keys are divided into functions, in such a way that the keys between the display and the indicator lamps are used for parameter Setup, including selection of the display's view mode during normal operation. [DISPLAY/STATUS] is used to select the display's view mode or to change back to Display mode from either Quick Menu or Menu mode. The frequency converter can be combined with an LCP control unit (Local Control Panel - LCP 2) which makes up a complete interface for operation and programming of the frequency converter. The LCP 2 control unit can be attached up to three metres from the frequency converter, e.g. on a front panel, using an accessory kit. The control panel is divided into five functional groups: 1. 2. 3. 4. 5. Display. Keys used to change the display function. Keys used to change the programme parameters. Indicator lamps. Local control keys. [QUICK MENU] provides access to the parameters used in the Quick Menu. It is possible to switch between Quick Menu and Menu mode. [MENU] gives access to all parameters. It is possible to switch between Menu mode and Quick Menu. [CHANGE DATA] is used to change a parameter that has been selected either in Menu mode or Quick Menu. [CANCEL] is used if a change to the selected parameter is not to be implemented. [OK] is used to confirm a change to a selected parameter. [+ / -] are used for selecting parameters and for changing parameter values. These keys are also used in Display mode to switch between the readouts of operating variables. [< >] are used for selecting parameter group and to move the cursor when changing a numerical value. All data is displayed via a 4-line alphanumeric display, which during normal operation will be able to continuously display 4 items of operating data and 3 operating modes. During programming all information needed for quick, effective parameter setup of the frequency converter will be displayed. As a supplement to the display, there are three indicator lamps for voltage (ON), warning (WARNING) and alarm (ALARM). All 32 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Indicator lamps At the bottom of the control panel are a red alarm lamp, a yellow warning lamp and a green voltage indicator lamp. frequency converter is set to Local control and Remote control via parameter 002 Local/remote operation, with the exception of [FWD/REV], which is only active in Local control. Display mode 195NA113.10 If certain threshold values are exceeded, the alarm and/or warning lamp are activated, while a status or alarm text is shown on the display. NB! The voltage indicator lamp is activated when voltage is connected to the frequency converter. VAR 1.1 VAR 1.2 VAR 1.3 VAR 2 STATUS SETUP 1 Local control [STOP/RESET] is used for stopping the motor connected or for resetting the frequency converter after a drop-out (trip). Can be set to active or inactive via parameter 014 Local stop. If stop is activated Display line 2 will flash. NB! If an external stop function is not selected and the [STOP/RESET] key is set to inactive, the motor can only be stopped by disconnecting the voltage to the motor or the frequency converter. [JOG] changes the output frequency to a preset frequency while the key is held down. Can be set to active or inactive via parameter 015 Local jog. [FWD / REV] changes the direction of rotation of the motor, which is indicated by means of the arrow on the display. Can be set to active or inactive via parameter 016 Local reversing. The [FWD/REV] key is only active when parameter 002 Local/remote operation is set to Local control. [START] is used to start the frequency converter. Is always active, but cannot override a stop command. NB! If the local control keys are set to inactive, these will both become active when the In normal operation, up to 4 different display data items can optionally be shown continuously: 1,1, 1,2, 1,3 and 2. The present operation status or alarms and warnings that have been generated are displayed in line 2 in the form of a number. In the event of alarms this is displayed in lines 3 and 4 with explanatory text. A warning will appear flashing in line 2 with explanatory text in line 1. The active Setup will also appear on the display. The arrow indicates the selected direction of rotation. Here the frequency converter shows that it has an active reversing signal. The body of the arrow will disappear if a stop command is given, or if the output frequency drops below 0.1 Hz. The bottom line displays the frequency transformer's status. The scrollbar shows which operating values can be displayed in lines 1 and 2 in Display mode. Changes are made using the [+ / -] keys. Operating data Resulting reference Resulting reference Feedback Output frequency Output frequency x scaling Motor current Torque Power Power Motor voltage DC link voltage Thermal load motor Thermal load Hours run Digital input Pulse reference External reference Status word Heatsink temperature Alarm word Control word Warning word Extended status word Analogue input 53 Analogue input 60 Unit [%] [unit] [unit] [Hz] [-] [A] [%] [kW] [HP] [V] [V] [%] [%] [hours] [binary] [Hz] [%] [hex] [°C] [hex] [hex] [hex] [hex] [V] [mA] MG.27.E3.02 - VLT ® is a registered Danfoss trademark 33 Introduction to VLT 2800 VLT ® 2800 Series Three operating data items can be shown in the first display line, and one operating variable can be shown in the second display line. Is programmed via parameters 009, 010, 011 and 012 Display readout . Display mode III: This display mode is called up as long as the [DISPLAY / STATUS] key is held down. When the key is released it switches back to Display mode II, unless the key is held down for less than approx. 1 sec., in which case the system always reverts to Display mode I. REF% TORQUE CURR A Display modes The LCP control unit has different display modes, which depend on the mode selected for the frequency converter. Display mode I: This display mode is standard after startup or initialisation. FREQUENCY 50.0 Hz SETUP 1 MOTOR IS RUNNING 50.0 Hz MOTOR IS RUNNING Here you can read out the parameter names and units for operating data in the first and second lines. Line 2 in the display remains unchanged. Display mode IV: This display mode can be called up during operation if a change has to be made in another Setup without stopping the frequency converter. This function is activated in parameter 005 Programming Setup. REF% TORQUE CURR A Line 2 shows the data value of an operating data item with unit, and line 1 contains a text that explains line 2. In the example, Frequency has been selected as readout via parameter 009 Large display readout. In normal operation, another variable can be entered immediately using the [+ / -] keys. Display mode II: Switch between Display modes I and II is performed by briefly pressing the [DISPLAY / STATUS] key. 24.3% 30.2% 13.8A 50.0 Hz SETUP 1 MOTOR IS RUNNING Here the programming Setup number 2 will flash to the right of the active Setup. 50.0 Hz MOTOR IS RUNNING Parameter Setup A frequency converter's comprehensive work area can be accessed via a large number of parameters, making it possible to adapt its functionality for a specific application. To provide a better overview of the many parameters, there is a choice of two programming modes - Menu mode and Quick Menu mode. The former provides access to all parameters. The latter takes the user through the parameters, which make it possible to start operating the frequency converter in most cases, in accordance with the Setup made. Regardless of the mode of programming, a change of a parameter will take effect and be visible both in the Menu mode and in the Quick menu mode. Structure for Quick menu mode v Menu mode In addition to having a name, each parameter is linked up with a number which is the same regardless of the programming mode. In Menu mode, parameters will be split into groups, with the first digit (left) of the parameter number indicating the group number of the parameter in question. In this mode, all data values for four operating data items with any pertaining units are shown, see table. In the example, the following have been selected: Frequency, Reference, Torque and Current as readout in the first and second line. 34 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series • Using the [QUICK MENU] key, it is possible to get access to the most important parameters of the frequency converter. After programming, the frequency converter is in most cases ready for operation. Scroll through the Quick menu using the [+ / -] keys and change the data values by pressing [CHANGE DATA] + [OK]. The Menu mode allows choosing and changing all parameters as required. However, some parameters will be "shaded off", depending on the choice in parameter 100 Configuration . Line 3 on the display shows the parameter group number and name. In Menu mode, the parameters are divided into groups. Selection of parameter group is effected using the [< >] keys. The following parameter groups will be accessible: Group no. 0 1 2 3 4 5 6 Parameter group Operation & Display Load & Motor References & Limits Inputs & Outputs Special functions Serial communication Technical functions • Quick menu with LCP 2 control unit Start Quick Setup by pressing the [QUICK MENU] key, which will bring out the following display values: QUICK MENU X OF Y When the required parameter group has been selected, each parameter can be chosen by means of the [+ / -] keys: FREQUENCY 50.0 Hz 001 LANGUAGE ENGLISH 50.0 Hz 001 LANGUAGE ENGLISH SETUP 1 At the bottom of the display, the parameter number and name are given together with the status/value of the first parameter under the Quick menu. The first time the [QUICK MENU] key is pressed after the unit has been switched on, the readouts always start in pos. 1 - see table below. Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 Parameter no. 001 Language 102 Motor power 103 Motor voltage 104 Motor frequency 105 Motor current 106 Rated motor speed 107 AMT 204 Minimum reference 205 Maximum reference 207 Ramp-up time 208 Ramp-down time 002 Local/remote operation 003 Local reference Unit [kW] [V] [Hz] [A] [rpm] [Hz] [Hz] [sec] [sec] [Hz] The 3rd line of the display shows the parameter number and name, while the status/value of the selected parameter is shown in line 4. Changing data Regardless of whether a parameter has been selected under the Quick menu or the Menu mode, the procedure for changing data will be the same. Pressing the [CHANGE DATA] key gives access to changing the selected parameter, following which the underlining in line 4 will flash on the display. The procedure for changing data depends on whether the selected parameter represents a numerical data value or a text value. Changing a data value If the selected parameter is a text value, the text value is changed by means of the [+ / -] keys. FREQUENCY 50.0 Hz 001 LANGUAGE ENGLISH Parameter selection Menu mode is started by pressing the [MENU] key, which produces the following readout on the display: FREQUENCY The bottom display line will show the value that will be entered (saved) when acknowledgment is given [OK]. Change of numeric data value If the selected parameter is represented by a numerical data value, a digit is first chosen using the [< >] keys. 50.0 Hz 0 KEYB.&DISPLAY MG.27.E3.02 - VLT ® is a registered Danfoss trademark 35 Introduction to VLT 2800 VLT ® 2800 Series FREQUENCY 130 START FREQUENCY 09.0 HZ 50.0 Hz SETUP 1 The selected digit can then be changed infinitely variably using the [+ / -] keys: FREQUENCY 130 START FREQUENCY 10.0 HZ 50.0 Hz SETUP 1 The chosen digit is indicated by the digit flashing. The bottom display line shows the data value that will be entered (saved) when signing off with [OK]. Manual initialisation NB! Manual initialisation is not possible on the LCP 2 175N0131 control unit. It is, however, possible to perform an initialisation via par. 620 Operation mode: The following parameters are not set to zero when initialising via par. 620 Operation mode. par. 500 Address par. 501 Baud rate par. 600 Operating hours par. 601 Hours run par. 602 kWh counter par. 603 Number of power-ups par. 604 Number of overtemperatures par. 605 Number of overvoltages par. 615-617 Fault log 36 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Mechanical dimensions The drawings below describe the mechanical dimensions. All dimensions are in mm. NB! Please note that all filter options must be vertically mounted. VLT 2803-2815 200-240 Volt VLT 2805-2815 380-480 Volt VLT 2822 220 - 240 V, PD2 VLT 2840 200-240 Volt VLT 2855-2875 380-480 Volt VLT 2822 200-240 Volt VLT 2822-2840 380-480 Volt VLT 2840 220-240 V, PD2 VLT 2880-82 380-480V MG.27.E3.02 - VLT ® is a registered Danfoss trademark 37 Installation VLT ® 2800 Series Motor coils (195N3110) Terminal cover The drawing below gives the dimensions for NEMA 1 terminal covers for VLT 2803-2875. Dimension 'a' depends on the unit type. RFI 1B filter (195N3103) IP 21 solution 38 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Dimensions Type VLT 2803-2815 200-240 V, VLT 2805-2815 380-480 V VLT 2822 200-240 V, VLT 2822-2840 380-480 V VLT 2840 200-240 V, VLT 2822 PD2, TR1 2855-2875 380-480 V TR1 2880-2882 380-480 V, VLT 2840 PD2 EMC filter for long motor cables Code number 195N2118 195N2119 195N2120 195N2126 A 47 47 47 47 80 95 145 205 B 170 170 170 245 C 192H4719 192H4720 MG.27.E3.02 - VLT ® is a registered Danfoss trademark 39 Installation VLT ® 2800 Series 192H4893 40 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Mechanical installation Please pay attention to the requirements that apply to installation. Side-by-side All VLT 2800 units can be installed side-by-side and in any position, as the units do not require ventilation on the side. The frequency converter is cooled by means of air circulation. For the unit to be able to release its cooling air, the minimum free distance above and below the unit must be minimum 100 mm . To protect the unit from overheating, it must be ensured that the ambient temperature does not rise above the max. temperature stated for the frequency converter and that the 24-hour average temperature is not exceeded. The max. temperature and 24-hour average can be seen in General technical data. If the ambient temperature is in the range of 45 °C - 55 °C, derating of the frequency converter is to be carried out. See Derating for ambient temperature. Please note that the service life of the frequency converter will be reduced if no allowance is made for the derating for ambient temperature. Integration All units with enclosure IP 20 must be integrated in cabinets and panels. IP 20 is not suitable for remote mounting. In some countries, e.g. in the USA, units with enclosure NEMA 1 are approved for remote mounting. Spacing for mechanical installation All units require a minimum of 100 mm air between other components and vents of the enclosure. NB! With the IP 21 solution all units require a minimum of 100 mm air on each side. This means that side-by-side mounting is not allowed. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 41 Installation VLT ® 2800 Series High voltage warning The voltage of the frequency converter is dangerous whenever the equipment is connected to mains. Incorrect installation of the motor or frequency converter may cause damage to the equipment, serious injury or death. Comply with the instructions in this manual, as well as national and local rules and safety regulations. Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains: Wait at least 4 minutes for current dissipate. NB! It is the responsibility of the user or installer to ensure correct earthing and protection in accordance with national and local standards. For sensitive signal cables such as telephone or data cables the greatest possible distance is recommended. Please note that the required distance depends on the installation and the sensitivity of the signal cables, and that for this reason exact values cannot be given. When being placed in cable trays, sensitive cables may not be placed in the same cable tray as the motor cable. If signal cables run across power cables, this is done at an angle of 90 degrees. Remember that all noise-filled inlet and outlet cables to a cabinet must be screened/armoured. See also EMC-correct electrical installation. Screened/armoured cables The screen must have low HF impedance, which is achieved by a braided screen of copper, aluminium or iron. Screen reinforcement intended for mechanical protection, for example, is not suitable for EMC-correct installation. See also Use of EMC-correct cables. Extra protection RCD relays, multiple protective earthing or earthing can be used as extra protection, provided that local safety regulations are complied with. In the case of an earth fault, a DC content may develop in the faulty current. Never use an RCD (ELCB relay), type A, as it is not suitable for DC faulty currents. If RCD relays are used, local regulations must be complied with.If RCD relays are used, they must be: Suitable for protecting equipment with a DC content in the faulty current (3-phase bridge rectifier). Suitable for a pulse-shaped, brief discharge on power-up. Suitable for a high leakage current. Earthing Comply with the following at installation: • Safety earthing: The drive has a high leakage current and must be earthed properly for safety. Follow all local safety regulations. High frequency earthing: Keep earthing connections as short as possible. • Connect all earthing SYSTEMs to ensure the lowest possible conductor impedance. The lowest possible conductor impedance is achieved by keeping the conductor as short as possible and by grounding with the greatest possible surface area. If multiple drives are installed in a cabinet, the cabinet backplate, which must be made of metal, should be used as a joint earth reference plate. The drives must be fitted to the backplate at the lowest possible impedance. To achieve low impedance, connect the drive to the backplate with the drive fastening bolts. Remove all paint from the contact points. - N must be connected before L1 for single phase 200 V reduced leakage current units (type code R4). High voltage test Cables The control cable and the mains cable should be installed separately from motor cables to prevent noise transfer. As a rule a distance of 20 cm is sufficient, but it is recommended that the distance is as great as possible, particularly when cables are installed in parallel over large distances. A high voltage test can be performed by short-circuiting terminals U, V, W, L1, L2 and L3, and applying max. 2160 V DC in 1 sec. between this short-circuit and terminal 95. Do not perform a high voltage test between the control terminals and the chassis, because the voltage potential of the 42 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series control card cannot exceed approx. 100 volt with respect to chassis due to a voltage limiting circuitry. The terminals are protected against direct hazardous access through barriers. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 43 Installation VLT ® 2800 Series EMC-correct electrical installation General points to be observed to ensure EMC-correct electrical installation. Use only screened/armoured motor cables and screened/armoured control cables. Connect the screen to earth at both ends. Avoid installation with twisted screen ends (pigtails), since this ruins the screening effect at high frequencies. Use cable clamps instead. It is important to ensure good electrical contact from the installation plate through the installation screws to the metal cabinet of the frequency converter. Use starwashers and galvanically conductive installation plates. Do not use unscreened/unarmoured motor cables in the installation cabinets. The illustration below shows EMC-correct electrical installation, in which the frequency converter has been fitted in an installation cabinet and connected to a PLC. 44 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Use of EMC compliant cables In order to comply with requirements for EMC immunity of the control cables and EMC emissions from the motor cables screened/armoured cables must be used. The ability of a cable to reduce the amount of ingoing and outgoing radiation of electric noise depends on the transfer impedance (Z T). The screen of a cable is normally designed to reduce the transfer of electric noise, and a screen with a lower ZT is more effective than a screen with a higher ZT. ZT is rarely stated by cable manufacturers, but it is often possible to estimate Z T by looking at and assessing the physical design of the cable. ZT can be assessed on the basis of the following factors: the contact resistance between the individual screen conductors. Screen coverage, i.e. the physical area of the cable covered by the screen. Is often stated as a percentage and should be no less than 85%. The screen type, i.e. braided or twisted pattern. A braided pattern or closed pipe is recommended. - MG.27.E3.02 - VLT ® is a registered Danfoss trademark 45 Installation VLT ® 2800 Series Earthing of screened/armoured control cables In general control cables must be screened/armoured, and the screen must be connected to the unit's metal cabinet with a cable clamp at each end. The drawing below shows the correct way to perform the earthing, and what to do when in doubt. 1. Correct earthing Control cables and cables for serial communication must be attached with cable clamps at both ends to ensure maximum possible electrical contact. Incorrect earthing Do not use twisted screen ends that are plaited together (pigtails), as these increase screen impedance at higher frequencies. Protection with respect to earth potential between PLC and VLT If the earth potential between the VLT frequency converter and the PLC (etc.) is different, electric noise may occur that will disturb the whole system. This problem can be solved by fitting an equalising cable, to be placed next to the control cable. Minimum cable cross-section: 16 mm2. In the event of a 50/60 Hz earth loop If very long control cables are used, 50/60 Hz earth loops can arise, and these can interfere with the whole system. This problem is resolved by attaching one end of the screen to the earth via a 100 nF capacitor (short pin length). 2. 3. 4. 46 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Diagram * Integrated 1A RFI filter and brake is an option. ** VLT 2803-2815 200-240 V is not supplied with intermediate circuit coils. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 47 Installation VLT ® 2800 Series Electrical installation See also the section Brake Connection. VLT 2822 200-240 V, 2822-2840 380-480 V VLT 2803-2815 200-240 V, 2805-2815 380-480 V 48 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series VLT 2840 200-240 V, VLT 2822 PD2, 2855-2875 380-480 V VLT 2880-2882 380-480 V, VLT 2840 PD2 Please note that the units will be supplied with two bottom plates; one for metric glands and one for conduits. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 49 Installation VLT ® 2800 Series Safety clamp 2803-2815, 200-240 2805-2815, 380-480 V. V, and VLT Pre-fuses For all unit types, external pre-fuses must be fitted in the mains supply to the frequency converter. For UL/ cUL applications with a mains voltage of 200-240 Volt, use pre-fuses type Bussmann KTN-R (200-240 Volt) or Ferraz Shawmut type ATMR (max. 30A). For UL/ cUL applications with a mains voltage of 380-480 Volt, use pre-fuses type Bussmann KTS-R (380-480 Volt). Prefuses for UL application /cUL If the galvanic isolation (PELV) between control terminals and high-voltage terminals is to be maintained, the accompanying safety clamp must be fitted to VLT Alternative fuses 380-500 V drives Bussmann Bussmann VLT 2800 E52273 E4273 Bussmann Bussmann Bussmann E4273 E4273 E4273 Bussmann SIBA E4273 E180276 Little Fuse E81895 28052820 28552875 28802882 RK1/JDDZ KTS-R20 KTS-R25 KTS-R50 J/JDDZ JKS-20 JKS-25 JKS-50 T/JDDZ JJS-20 JJS-25 JJS-50 CC/JDDZ FNQ-R-20 CC/JDDZ KTK-R-20 CC/JDDZ LP-CC-20 RK1/JDDZ 5017906-02 0 5017906-02 5 5014006-05 0 FerrazShawmut E163267/ E2137 RK1/JDDZ CC/JDDZ KLS-R20 ATM-R25 KLS-R25 KLS-R50 ATM-R20 - FerrazShawmut E163267/ E2137 RK1/JDDZ A6K-20R A6K-25R A6K-50R Alternative Fuses 200-240 V drives VLT 2800 Bussmann Bussmann E52273 E4273 Bussmann E4273 SIBA E180276 Little Fuse E81895 2803-2822 2840 RK1/JDDZ KTN-R20 KTN-R25 J/JDDZ JKS-20 JKS-25 T/JDDZ JJN-20 JJN-25 RK1/JDDZ 5017906-02 0 5017906-02 5 FerrazShawmut E163267/ E2137 RK1/JDDZ CC/JDDZ KLS-R20 ATM-R25 KLS-R25 ATM-R20 FerrazShawmut E163267/ E2137 RK1/JDDZ A6K-20R A6K-25R Mains connection Please note that at 1 x 220-240 Volt the neutral wire must be attached to terminal N (L2) and the phase wire must be connected to terminal L1 (L1). No. N(L2) L1(L1) N L1 No. 95 (L3) verter, which can be seen from the nameplate. 400-Volt units with RFI-filters may not be connected to mains supplies in which the voltage between phase and earth is more than 300 Volts. Please note that for the IT mains and the delta earth the mains voltage can exceed 300 Volts between phase and earth. Units with type code R5 can be connected to mains supplies with up to 400 V between phase and earth. See Technical data for correct dimensioning of cable cross-section. See also the section entitled Galvanic isolation for further details. Mains voltage 1 x 220-240 V Earth connection No. N(L2) L1(L1) (L3) Mains voltage 3 x 220-240 V L2 L1 L3 No. 95 Earth connection No. 91 92 93 Mains voltage 3 x 380-480 V L1 L2 L3 No. 95 Earth connection NB! Please check that the mains voltage fits the mains voltage of the frequency con- 50 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Motor connection Connect the motor to terminals 96, 97, 98. Connect earth to terminal 99. No. 96 97 98 U V W Motor voltage 0-100% of mains voltage. 3 wires of motor 6 wires out of motor, Delta connected 6 wires out of motor, Star connected U2, V2, W2 to be interconnected separely (optional terminal block) above 25 m, it is recommended to set the switch in ON position. In OFF position, the internal RFI capacities (filter capacitors) between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate circuit and to reduce the earth capacity currents (according to IEC 61800-3). Please also refer to the application note VLT on IT mains, MN.90.CX.02. It is important to use isolation monitors that are capable for use together with power electronics (IEC 61557-8). NB! The RFI switch is not to be operated with mains connected to the unit. Check that the mains supply has been disconnected before operating the RFI switch. NB! The RFI switch disconnects the capacitors galvanically from ground. The switch Mk9, placed next to terminal 96, should be removed to disconnect the RFI-filter. The RFI switch is only available on VLT 2880-2882. U1 V1 W1 W2 U2 V2 U1 V1 W1 No. PE Earth connection See Technical data for correct dimensioning of cable cross-section. All types of three-phase asynchronous standard motors can be connected to a frequency converter. Normally, small motors are star-connected (230/400 V, Δ/ Y). Large motors are delta-connected (400/690 V, Δ/ Y). The correct connection mode and voltage can be read from the motor nameplate. NB! In motors without phase insulation paper, an LC filter should be fitted on the output of the frequency converter. Direction of motor rotation The factory setting is for clockwise rotation with the frequency converter transformer output connected as follows: RFI switch Mains supply isolated from earth: If the frequency converter is supplied from an isolated mains source (IT mains) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off (OFF). For further reference, see IEC 364-3. In case optimum EMC performance is needed, parallel motors are connected or the motor cable length is Terminal 96 connected to U-phase. Terminal 97 connected to V-phase. Terminal 98 connected to W-phase. The direction of rotation can be changed by switching two phases on the motor terminals. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 51 Installation VLT ® 2800 Series Parallel connection of motors NB! If an unscreened/unarmoured cable is used, some EMC requirements are not complied with, see EMC test results in the Design Guide. If the EMC specifications regarding emission are to be complied with, the motor cable must be screened/armoured, unless otherwise stated for the RFI filter in question. It is important to keep the motor cable as short as possible so as to reduce the noise level and leakage currents to a minimum. The motor cable screen must be connected to the metal cabinet of the frequency converter and to the metal cabinet of the motor. The screen connections are to be made with the biggest possible surface area (cable clamp). This is enabled by different installation devices in different frequency converters. Mounting with twisted screen ends (pigtails) is to be avoided, since these spoil the screening effect at high frequencies. If it is necessary to break the screen to install a motor isolator or motor relay, the screen must be continued at the lowest possible HF impedance. The frequency converter is able to control several motors connected in parallel. If the motors are to have different rpm values, use motors with different rated rpm values. Motor rpm is changed simultaneously, which means that the ratio between the rated rpm values is maintained across the range. The total current consumption of the motors is not to exceed the maximum rated output current IINV for the frequency converter. Problems may arise at the start and at low rpm values if the motor sizes are widely different. This is because the small motors' relatively high ohmic resistance in the stator calls for a higher voltage at the start and at low rpm values. In systems with motors connected in parallel, the electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor. For this reason further motor protection must be used, e.g. thermistors in each motor or an individual thermal relay. (Circuit breakers are not suitable as protection). NB! Parameter 107 Automatic motor adaption, AMT cannot be used when motors are connected in parallel. Parameter 101 Torque characteristic must be set to Special motor characteristics [8] when motors are connected in parallel. Motor cables See Technical data for correct dimensioning of motor cable cross-section and length. Always comply with national and local regulations on cable cross-section. 52 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Motor thermal protection The electronic thermal relay in UL-approved frequency converters has received the UL-approval for single motor protection, when parameter 128 Motor thermal protection has been set for ETR Trip and parameter 105 Motor current, IM, N has been programmed to the rated motor current (see motor nameplate). Brake connection No. 81 82 Brake resistor R- R+ terminals The connection cable to the brake resistor must be screened/armoured. Connect the screen to the metal cabinet of the frequency converter and to the metal cabinet of the brake resistor by means of cable clamps. Dimension the cross-section of the brake cable to match the brake torque. See the Design Guide for dimensioning of brake resistors. NB! Please note that voltages up to 850 V DC occur on the terminals. Earth connection As leak current to the earth is higher than 3.5 mA, the frequency converter must always be earthed according to prevailing national and local regulations. To guarantee that the earth cable has a good mechanical connection to terminal 95, the cable cross section must be at least 10 mm2 or 2 rated earth wires that are terminated separately. To increase safety you can install an RCD (Residual Current Device), which guarantees that the frequency converter trips when leak current becomes too high. See also RCD Application Note MN.90.GX.02. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 53 Installation VLT ® 2800 Series Load sharing Load sharing provides the facility to connect several frequency converters' DC intermediate circuits. This requires that the installation is extended using extra fuses and AC coils (see drawing below). For load sharing parameter 400 Brake function must be set to Load sharing [5]. Use 6.3 mm Faston Plugs for DC (Load Sharing). Contact Danfoss or see instructions no. MI.50.NX.02 for further information. No. 88 89 + Loadsharing Note that voltage levels of up to 850 V DC may occur between terminals 88 and 89. Tightening Torque, Power Terminals Power and earth terminals must be tightened with the following torques: Terminals Torque [Nm] VLT 2803Power mains brake 0.5-0.6 2875 Earth 2-3 2880Power mains brake 1.2-1.5 2882, 2840 Earth 2-3 PD2 NB! This application is only for lifting/lowering without a counterbalance. Access to control terminals All terminals to the control cables are located underneath the protective plate on the front of the frequency converter. Remove the protective plate by pulling it downwards (see drawing). Control of mechanical brake In lifting/lowering applications you need to be able to control an electromagnetic brake. The brake is controlled using a relay output or digital output (terminal 46). The output must be kept closed (voltage-free) for the period of time during which the frequency converter is not able to 'support' the motor, for example due to the load being too great. Select Mechanical brake control in parameter 323 or 341 for applications with an electromagnetic brake. When the output frequency exceeds the brake cut out value set in par. 138, the brake is released if the motor current exceeds the preset value in parameter 140. The brake is engaged when the output frequency is less than the brake engaging frequency, which is set in par. 139. If the frequency converter is placed at alarm status or in an overvoltage situation the mechanical brake is cut in immediately. 54 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Electrical installation, control cables chassis by means of a clamp. Normally, the screen must also be connected to the chassis of the controlling unit (use the instructions for the unit in question). In connection with very long control cables and analogue signals, in rare cases depending on the installation, 50/60 Hz earth loops may occur because of noise transmitted from mains supply cables. In this connection, it may be necessary to break the screen and possibly insert a 100 nF capacitor between the screen and the chassis. Control cables must be screened/armoured. The screen must be connected to the frequency converter MG.27.E3.02 - VLT ® is a registered Danfoss trademark 55 Installation VLT ® 2800 Series Tightening torques, control cables Control wires must be connected with a tightening torque of 0.22-0.25 Nm. NB! Please note that the cable jacket for the relay must cover the first row of control card terminals - otherwise the galvanic isolation (PELV) cannot be maintained. Max. cable diameter: 4 mm. See drawing. Electrical installation, control terminals See section entitled Earthing of screened/armoured control cables in the VLT 2800 Design Guide for the correct termination of control cables. No. 01-03 12 18-33 20, 55 42 461 50 53 60 671 68, 691 701 Function Relay outputs 01-03 can be used for indicating status and alarms/warnings. 24 V DC voltage supply. Digital inputs. Common frame for input and output terminals. Analog output for displaying frequency, reference, current or torque. Digital output for displaying status, warnings or alarms, as well as frequency output. +10 V DC supply voltage for potentiometer or thermistor. Analogue voltage input 0 - 10 V DC. Analogue current input 0/4 - 20 mA. + 5 V DC supply voltage to Profibus. RS 485, Serial communication. Frame for terminals 67, 68 and 69. Normally this terminal is not to be used. Switches 1-4 The dip switch is only on the control card with Profibus DP communication. The switch position shown is the factory setting. Switches 1 and 2 are used as cable termination for the RS 485 interface. If the frequency converter is located as the first or last unit in the bus SYSTEM, switches 1 and 2 must be ON. On the remaining frequency converters, switches 1 and 2 must be OFF. Switches 3 and 4 are not applied. VLT Software Dialog Connection to terminals 68-70 or Sub D: PIN 3 GND PIN 8 P-RS 485 PIN 9 N-RS 485 1. The terminals are not valid for DeviceNet/CANopen. See also the DeviceNet manual, MG.90.BX.YY for further details. Sub D plug Relay connection See parameter 323 Relay output for programming of relay output. Nr. 01 - 02 01 - 03 1 - 2 make (normally open) 1 - 3 break (normally closed) An LCP 2 control unit can be connected to the Sub D plug on the control card. Ordering number: 175N0131. LCP control unit with ordering number 175Z0401 is not to be connected. 56 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Connection examples Start/stop Start/stop using terminal 18 and coasting stop using terminal 27. Speed up/down Speed up/down using terminals 29/33. Par. 302 Digital input = Start [7] Par. 303 Digital input = Freeze reference [14] Par. 302 Digital input = Start [7] Par. 304 Digital input = Coasting stop inverted [2] For Precise start/stop the following settings are made: Par. 302 Digital input = Precise start/stop [27] Par. 304 Digital input = Coasting stop inverted [2] Potentiometer reference Voltage reference via a potentiometer. Par. 305 Digital input = Speed up [16] Pulse start/stop Pulse start using terminal 18 and pulse stop using terminal 19. In addition, the jog frequency is activated via terminal 29. Par. 308 Analog input = Reference [1] Par. 309 Terminal 53, min. scaling = 0 Volt Par. 310 Terminal 53, max. scaling = 10 Volt Connection of a 2-wire transmitter Connection of a 2-wire transmitter as feedback to terminal 60. Par. 302 Digital input = Pulse start [8] Par. 303 Digital input = Stop inverted [6] Par. 304 Digital input = Coasting stop inverted [2] Par. 305 Digital input = Jog [13] Par. 314 Analog input = Feedback [2] Par. 315 Terminal 60, min. scaling = 4 mA Par. 316 Terminal 60, max. scaling = 20 mA MG.27.E3.02 - VLT ® is a registered Danfoss trademark 57 Installation Par. 307 Digital input = Speed down [17] VLT ® 2800 Series 4-20 mA reference 4-20 mA reference on terminal 60 and speed feedback signal on terminal 53. Par. 203 Reference range = Min. ref. - Max. ref. [0] Par. 204 Min. reference = - 50 Hz Par. 205 Max. reference = 50 Hz Par. 302 Digital input = Start [7] Par. 304 Digital input = Coasting stop inverted [2] Par. 308 Analogue input = Reference [1] Par. 309 Terminal 53, min. scaling = 0 Volt Par. 100 Configuration = Speed closed loop [1] Par. 308 Analog input = Feedback [2] Par. 309 Terminal 53, min. scaling = 0 Volt Par. 310 Terminal 53, max. scaling = 10 Volt Par. 314 Analog input = Reference [1] Par. 309 Terminal 60, min. scaling = 4 mA Par. 310 Teminal 60, max. scaling = 20 mA Preset references Switch between 8 preset references via two digital inputs and Setup 1 and Setup 2. Par. 310 Terminal 53, max. scaling = 10 Volt 50 Hz counter-clockwise to 50 Hz clockwise Par. 004 Active Setup = Multisetup 1 [5] Par. 204 Min. reference = 0 Hz Par. 205 Max. reference = 50 Hz Par. 302 Digital input = Start [7] Par. 303 Digital input = Choice of Setup, lsb [31] Par. 304 Digital input = Coasting stop inverted [2] Par. 305 Digital input = Preset ref., lsb [22] Par. 307 Digital input = Preset ref., msb [23] Setup 1 contains the following preset references: Par. 215 Preset reference 1 = 5.00% Par. 216 Preset reference 2 = 10.00% Par. 217 Preset reference 3 = 25.00% Par. 218 Preset reference 4 = 35.00% Par. 100 Configuration = Speed regulation open loop [0] Par. 200 Output frequency range = Both directions, 0-132 Hz [1] 58 MG.27.E3.02 - VLT ® is a registered Danfoss trademark VLT ® 2800 Series Setup 2 contains the following preset references: Par. 215 Preset reference 1 = 40.00% Par. 216 Preset reference 2 = 50.00% Par. 217 Preset reference 3 = 70.00% Par. 218 Preset reference 4 = 100.00% This table shows what the output frequency is: Preset ref., msb 0 0 1 1 0 0 1 1 Preset ref., lsb 0 1 0 1 0 1 0 1 Selection of Setup 0 0 0 0 1 1 1 1 Output frequency [Hz] 2.5 5 10 17.5 20 25 35 50 Connection of mechanical brake Use of the relay for 230V AC brake Par. 307 Digital input = Pulse input [30] Par. 343 Precise stop function = Counter stop with reset [1] Par. 344 Counter value = 100000 Par. 302 Digital input = Start [7] Par. 304 Digital input = Coasting stop inverted [2] Par. 323 Relay output = Mechanical brake control [25] Mechanical brake control [25] = '0' => Brake is closed. Mechanical brake control [25] = '1' => The brake is open. See more detailed parameter settings under Control of mechanical brake . NB! Do not use the internal relay for DC brakes or brake voltages > 250 V. Use of internal PID-controller - closed loop process control 1. 2. Connect the frequency converter to mains and motor cables as usual. Connect transmitter (feedback signal) to + terminal 12 and - terminal 60 (applies to 2wire transmitters 4-20 mA). (Connect transmitters with 0-10 V DC to + terminal 53 and terminal 55). NB! Connect terminal 55 as - and terminal 60 as + for current signal (0/4-20 mA) and terminal 53-55 for voltage signal (0-10 V DC) if transmitters with separate voltage supply are used. 3. Connect the start signal between terminal 12 and 18, 12-27 must be connected or set to no function (parameter 304 = 0). Set all parameters in the Quick Menu and enter the Main Menu (to enter the Main Menu: Press Quick Menu and + simultaneously). Set the following parameters: 100 = Process controller closed loop [3] Counter stop via terminal 33 The start signal (terminal 18) must be active, i.e. logical '1', until the output frequency is equal to the reference. The start signal (terminal 18 = logical '0') must then be removed before the counter value in parameter 344 has managed to stop the VLT frequency converter. 4. 5. MG.27.E3.02 - VLT ® is a registered Danfoss trademark 59 Installation VLT ® 2800 Series 101 = Variable torque medium [3] If used with centrifugal pumps and fans.
VLT 2800 Design Guide Software version: 3.1x This Design Guide can be used for all VLT 2800 Series frequency converters with software version 3.1x.
VLT® 2800 Instruction Manual. VLT. This Instruction Manual can be used for all VLT 2800. f the ground potential between the VLT variable frequency drive and.
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Introduction to VLT 2800
. VLT is a registered Danfoss trademark 195R0033. VLT 2800 Quick Reference Guide. 302 Digital input See manual [7].