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MAKING MODERN LIVING POSSIBLE Operating Instructions VLT® AQUA Drive FC 202 Low Harmonic Drive www.danfoss.com/drives Contents Operating Instructions Contents 1 Introduction 4 1.1 Purpose of the Manual 4 1.2 Additional Resources 4 1.3 Product Overview 4 1.3.1 Intended Use 4 1.3.2 Working Principle 5 1.3.3 Exploded View Drawings 6 1.4 Enclosure Types and Power Ratings 14 1.5 Approvals and Certifications 14 1.5.1 Approvals 14 1.5.2 Compliance with ADN 14 2 Safety 15 2.1 Safety Symbols 15 2.2 Qualified Personnel 15 2.3 Safety Precautions 15 3 Mechanical Installation 3.1 Equipment Pre-Installation Checklist 16 3.2 Unpacking 16 3.2.1 Items Supplied 3.3 Installation Environment 3.3.1 Planning the Installation Site 3.4 Mounting MG21B202 16 16 17 17 17 3.4.1 Cooling and Airflow 17 3.4.2 Lifting 19 3.4.3 Cable Entry and Anchoring 20 3.4.4 Terminal Locations for Frame Size D13 22 3.4.5 Terminal Locations for Frame Size E9 23 3.4.6 Terminal Locations for Frame Size F18 24 3.4.7 Torque 27 4 Electrical Installation 28 4.1 Safety Instructions 28 4.2 EMC Compliant Installation 28 4.3 Power Connections 28 4.4 Grounding 29 4.5 Input Options 29 4.5.1 Extra Protection (RCD) 29 4.5.2 RFI Switch 29 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 1 Contents Operating Instructions 4.5.3 Shielded Cables 4.6 Motor Connection 30 4.6.1 Motor Cable 30 4.6.2 Brake Cable 30 4.6.3 Brake Resistor Temperature Switch 31 4.6.4 Motor Insulation 31 4.6.5 Motor Bearing Currents 31 4.6.6 Motor Thermal Protection 32 4.7 AC Mains Connection 32 4.7.1 Mains Connection 32 4.7.2 External Fan Supply 32 4.7.3 Power and Control Wiring for Unscreened Cables 32 4.7.4 Mains Disconnects 34 4.7.5 F-Frame Circuit Breakers 34 4.7.6 F-Frame Mains Contactors 34 4.8 Control Wiring 35 4.8.1 Control Cable Routing 35 4.8.2 Access to Control Terminals 36 4.8.3 Electrical Installation, Control Terminals 36 4.8.4 Electrical Installation, Control Cables 38 4.9 Additional Connections 39 4.9.1 Mechanical Brake Control 39 4.9.2 Parallel Connection of Motors 40 4.9.3 Motor Thermal Protection 40 4.9.4 Safe Torque Off (STO) 41 4.9.5 Switches S201, S202, and S801 41 4.9.6 Serial Communication 41 4.9.7 F-frame Options 41 4.10 Final Set-up and Test 5 Commissioning 43 45 5.1 Safety Instructions 45 5.2 Applying Power 47 5.3 Local Control Panel Operation 47 5.3.1 Local Control Panel 47 5.3.2 LCP Layout 47 5.3.3 Parameter Settings 48 5.3.4 Uploading/Downloading Data to/from the LCP 49 5.4 Basic Programming 2 30 50 5.4.1 Commissioning with SmartStart 50 5.4.2 Commissioning via [Main Menu] 50 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Contents Operating Instructions 5.4.3 Asynchronous Motor Set-up 51 5.4.4 Permanent Magnet Motor Set-up 51 5.4.5 Automatic Energy Optimisation (AEO) 52 5.4.6 Automatic Motor Adaptation (AMA) 52 5.5 Checking Motor Rotation 52 5.6 Local-control Test 53 5.7 System Start-up 53 6 Application Examples 54 6.1 Introduction 54 6.2 Application Examples 54 6.2.1 Speed 54 6.2.2 Start/Stop 55 6.2.3 External Alarm Reset 56 6.2.4 RS-485 57 6.2.5 Motor Thermistor 57 7 Diagnostics and Troubleshooting 7.1 Status Messages 58 7.2 Warning and Alarm Types 60 7.2.1 Warnings 60 7.2.2 Alarm Trip 60 7.2.3 Alarm Trip-lock 60 7.3 Warnings and Alarm Definitions - Frequency Converter 61 7.4 Warning and Alarm Definitions - Filter (Left LCP) 69 7.5 Troubleshooting 74 8 Specifications 76 8.1 Power-Dependent Specifications 76 8.1.1 Mains Supply 3x380-480 V AC 76 8.1.2 Derating for Temperature 79 8.2 Mechanical Dimensions 79 8.3 General Technical Data - Frequency Converter 81 8.4 General Technical Data - Filter 86 8.5 Fuses 89 8.5.1 Fuse Specifications 9 Appendix 90 92 9.1 Abbreviations and Conventions Index MG21B202 58 92 93 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 3 1 1 Introduction Operating Instructions 1 Introduction 1.1 Purpose of the Manual 1.3 Product Overview The purpose of this manual is to provide information for the installation and operation of a VLT® Low Harmonic Drive. The manual includes relevant safety information for installation and operation. Chapter 1 Introduction and chapter 2 Safety introduce the unit function and cover proper mechanical and electrical installation procedures. There are chapters on start-up and commissioning, applications and basic troubleshooting. Chapter 8 Specifications provides a quick reference for ratings and dimensions, as well as other operating specifications. This manual provides a basic knowledge of the unit and explains setup and basic operation. VLT® is a registered trademark. 1.3.1 Intended Use 1.2 Additional Resources Other resources are available to understand advanced functions and programming. 4 • The VLT® AQUA Drive FC 202 Operating Instructions provide details on installation and operation of the frequency converter. • The VLT® AQUA Drive FC 202 Programming Guide provides greater detail on working with parameters and many application examples. • The VLT® AQUA Drive FC 202 Design Guide provides detailed capabilities and functionality to design motor control systems. • Supplemental publications and manuals are available from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical +Documentation.htm for listings. • Optional equipment may change some of the procedures described. Reference the instructions supplied with those options for specific requirements. Contact the local Danfoss supplier or visit the Danfoss website: www.danfoss.com/ BusinessAreas/DrivesSolutions/Documentations/ Technical+Documentation.htm, for downloads or additional information. • The VLT® Active Filter AAF00x Operating Instructions provide additional information about the filter portion of the Low Harmonic Drive. A frequency converter (also called a drive) is an electronic motor controller that converts DC into a variable AC waveform output. The frequency and voltage of the output are regulated to control the motor speed or torque. The frequency converter can vary the speed of the motor in response to system feedback, such as with position sensors on a conveyor belt. The frequency converter can also regulate the motor by responding to remote commands from external controllers. The frequency converter • • • • monitors the system and motor status issues warnings or alarms for fault conditions starts and stops the motor optimises energy efficiency Operation and monitoring functions are available as status indications to an outside control system or serial communication network. A Low Harmonic Drive (LHD) is a single unit that combines the frequency converter with an advanced active filter (AAF) for harmonic mitigation. The frequency converter and filter are 2 separate pieces packaged together in an integrated system, but each functions independently. In this manual, there are separate specifications for the frequency converter and the filter. Since the frequency converter and filter are together in the same enclosure, the unit is transported, installed, and operated as a single entity. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Introduction Operating Instructions 1 1 1.3.2 Working Principle The VLT Low Harmonic Drive is a high-power frequency converter with an integrated active filter. An active filter is a device that actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the harmonics. 130bb406.10 Relay 12 Control & AUX Feedback Soft-Charge NC Relay HI Reactor Lm Mains 380 to 500 VAC Optional RFI Optional Manual Disconnect Optional Fuses Converter Side Filter Lc AC Contactor Lac Lm Lac Lm Lac Power Stage Ir Lc Is Lc It 3 Relay 12 Control & AUX Cef Feedback Ref Cef Ref 3 Capacitor Current Sensors Cef AF Current Sensors Ref Frequency converter 3 Main’s CTs Illustration 1.1 Basic Layout for the Low Harmonic Drive Low Harmonic Drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of 1. Where traditional non-linear load draws pulse-shaped currents, the Low Harmonic Drive compensates that via the parallel filter path, lowering the stress on the supply grid. The Low Harmonic Drive meets the highest harmonic standards with a THiD less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 5 Operating Instructions 1.3.3 Exploded View Drawings 3 130BX167.10 1 1 Introduction 4 2 1 5 6 7 25 24 8 9 10 11 23 22 21 12 20 13 19 18 14 15 17 16 1 Control card 14 SCR/diode module 2 Control input terminals 15 IGBT output bus bar 3 Local control panel (LCP) 16 Output motor terminals 4 Control card C option 17 Current sensor 5 Mounting bracket 18 Fan assembly 6 Power card mounting plate 19 Fan transformer 7 Power card 20 AC input terminals 8 Capacitor bank assembly 21 AC input bus bar 9 Soft charge fuses 22 Input terminal mounting plate assembly 10 Soft charge card 23 Fan fuse 11 DC inductor 24 Capacitor bank cover plate 12 Soft charge module 25 IGBT gate drive card 13 IGBT module Illustration 1.2 Frame Size D13 Drive Enclosure 6 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BD571.11 Introduction 1 2 3 22 21 4 20 6 7 5 19 17 18 8 9 16 10 15 11 12 13 14 1 Local control panel (LCP) 13 Mains fuses 2 Active filter card (AFC) 14 Mains disconnect 3 Metal oxide varistor (MOV) 15 Mains terminals 4 Soft charge resistors 16 Heat sink fan 5 AC capacitors discharge board 17 DC capacitor bank 6 Mains contactor 18 Current transformer 7 LC inductor 19 RFI differential mode filter 8 AC capacitors 20 RFI common mode filter 9 Mains bus bars to drive input 21 HI inductor 10 IGBT fuses 22 Power card 11 RFI Illustration 1.3 Frame Size D13 Filter Enclosure MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 7 1 1 Introduction Operating Instructions 1 1 1 130BX168.10 3 2 4 5 6 7 25 8 9 24 23 22 21 11 10 12 20 13 14 15 16 17 18 19 1 Control card 14 SCR and diode 2 Control input terminals 15 Fan inductor (not on all units) 3 Local control panel (LCP) 16 Soft charge resistor assembly 4 Control card C option 17 IGBT output bus bar 5 Mounting bracket 18 Fan assembly 6 Power card mounting plate 19 Output motor terminals 7 Power card 20 Current sensor 8 IGBT gate drive card 21 Main AC power input terminals 9 Upper capacitor bank assembly 22 Input terminal mounting plate 10 Soft charge fuses 23 AC input bus bar 11 DC inductor 24 Soft charge card 12 Fan transformer 25 Lower capacitor bank assembly 13 IGBT module Illustration 1.4 Frame Size E9 Drive Enclosure 8 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BD572.11 Introduction 1 2 21 3 20 19 4 5 6 7 18 17 16 8 15 9 13 10 14 12 11 1 Local control panel (LCP) 12 AC capacitor current transducers 2 Active filter card (AFC) 13 Heat sink fan 3 Mains contactors 14 Mains terminals 4 Soft charge resistors 15 Mains disconnect 5 RFI differential mode filter 16 Mains fuses 6 RFI common mode filter 17 LC inductor 7 Current transformer (CT) 18 HI inductor 8 Mains bus bars to drive output 19 Power card 9 AC capacitors 20 Control card 10 RFI 21 LCP cradle 11 Lower DC capacitor bank Illustration 1.5 Frame Size E9 Filter Enclosure MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 9 1 1 Introduction Operating Instructions 130BX334.11 1 1 1 5 4 2 3 1 Contactor 4 Circuit breaker or disconnect (if purchased) 2 RFI filter 5 AC mains/line fuses (if purchased) 3 Mains AC power input terminals Illustration 1.6 Frame Size F18 Options Cabinet* *The options cabinet is not optional for the LHD. The ancillary equipment is stored in the cabinet. 10 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Introduction Operating Instructions 130BD573.10 1 2 3 4 18 17 5 16 15 14 6 13 7 8 9 10 12 11 1 Local control panel (LCP) 10 Mains bus bars to drive input 2 Active filter card (AFC) 11 Heat sink fans 3 Soft charge resistors 12 Mains terminals (R/L1, S/L2, T/L3) from options cabinet 4 Metal oxide varistor (MOV) 13 RFI differential mode filter 5 AC capacitors discharge board 14 RFI common mode filter 6 LC inductor 15 Mains contactor 7 HI inductor 16 Power card 8 Mixing fan 17 Control card 9 IGBT fuses 18 LCP cradle Illustration 1.7 Frame Size F18 Filter Cabinet MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 11 1 1 Operating Instructions 1 1 130BX331.11 Introduction 1 2 3 12 4 11 5 10 6 9 8 7 1 Rectifier module 7 Module lifting eye bolts (mounted on a vertical strut) 2 DC bus bar 8 Module heat sink fan 3 SMPS fuse 9 Fan door cover 4 (Optional) back AC fuse mounting bracket 10 SMPS fuse 5 (Optional) middle AC fuse mounting bracket 11 Power card 6 (Optional) front AC fuse mounting bracket 12 Panel connectors Illustration 1.8 Frame Size F18 Rectifier Cabinet 12 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Introduction Operating Instructions 130BX330.10 2 1 16 15 3 14 13 12 11 5 10 4 6 7 8 9 1 Fan transformer 9 Fan door cover 2 DC link inductor 10 Module heat sink fan 3 Top cover plate 11 Inverter module 4 MDCIC board 12 Panel connectors 5 Control card 13 DC fuse 6 SMPS fuse and fan fuse 14 Mounting bracket 7 Motor output bus bar 15 (+) DC bus bar 8 Brake output bus bar 16 (-) DC bus bar Illustration 1.9 Frame Size F18 Inverter Cabinet MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 13 1 1 1 1 Introduction Operating Instructions 1.4 Enclosure Types and Power Ratings Frame size D13 E9 F18 IP 21/54 21/54* 21/54 Type 1/Type 12 Type 1/Type 12 Type 1/Type 12 160-250 kW at 400 V (380-480 V) 315-450 kW at 400 V (380-480 V) 500-710 kW at 400 V (380-480 V) Enclosure protection NEMA High overload rated power - 160% overload torque Height Drive dimensions Width [mm/inch] Depth 1780.570.1 2000.7/78.77 2278.4/89.70 1021.9 mm/40.23 1200/47.24 2792/109.92 377.8/14.87 493.5/19.43 605.8/23.85 390/860 676/1490 1900/4189 454/1001 840/1851 2345/5171 Max Weight Drive dimensions Shipping [kg/lbs] Weight Table 1.1 Mechanical Dimensions and Rated Power, D, E and F Frames 1.5 Approvals and Certifications 1.5.1 Approvals Table 1.2 Compliance Marks: CE, UL, and C-Tick 1.5.2 Compliance with ADN For compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to ADN-compliant Installation in the Design Guide. 14 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Safety Operating Instructions 2 Safety 2 2 2.3 Safety Precautions 2.1 Safety Symbols The following symbols are used in this document: WARNING HIGH VOLTAGE WARNING Indicates a potentially hazardous situation which could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices. Frequency converters contain high voltage when connected to AC mains input power. Qualified personnel only should perform installation, start up, and maintenance. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury. WARNING UNINTENDED START NOTICE Indicates important information, including situations that may result in damage to equipment or property. 2.2 Qualified Personnel Correct and reliable transport, storage, installation, operation and maintenance are required for the safe operation of the frequency converter. Only qualified personnel are allowed to install or operate this equipment. Qualified personnel is defined as trained staff, who are authorised to install, commission, and maintain equipment, systems and circuits in accordance with pertinent laws and regulations. Additionally, qualified personnel are familiar with the instructions and safety measures described in this document. When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness when the frequency converter is connected to AC mains could result in death, serious injury, equipment, or property damage. WARNING DISCHARGE TIME Frequency converters contain DC-link capacitors that can remain charged even when the frequency converter is not powered. To avoid electrical hazards, disconnect AC mains, any permanent magnet type motors, and any remote DC-link power supplies, including battery backups, UPS, and DC-link connections to other frequency converters. Wait for the capacitors to fully discharge before performing any service or repair work. The amount of wait time is listed in the Discharge Time table. Failure to wait the specified time after power has been removed before doing service or repair could result in death or serious injury. Voltage [V] Power range [kW] 380-500 Minimum waiting time (minutes) 132-250 kW* 20 315-630 kW 40 Table 2.1 Discharge Times *Power ranges are for normal overload operation. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 15 Mechanical Installation Operating Instructions 3.1 Equipment Pre-Installation Checklist 3 3 • Before unpacking the frequency converter, examine the packaging for signs of damage. If the unit is damaged, refuse delivery and immediately contact the shipping company to claim the damage. 1 2 • Before unpacking the frequency converter, locate it as close as possible to the final installation site 7 • Compare the model number on the nameplate to what was ordered to verify the proper equipment • Ensure each of the following are rated for the same voltage: • - Mains (power) - Frequency converter - Motor Ensure the output current rating is equal to or greater than the motor full load current for peak motor performance. - - Motor size and frequency converter power must match for proper overload protection. If frequency converter rating is less than that of the motor, full motor output is impossible. 4 5 6 VLT R Automation Drive www.danfoss.com T/C: FC-302PK37T2E20H1BGXXXXSXXXXA6BKC4XXXD0 P/N: 131X3537 0.37kW/ 0.50HP 9 IN: 3x200-240V 50/60Hz 2.2A OUT: 3x0-Vin 0-1000Hz 2.4A o *1 3 1 X 3 5 3 7 0 1 0 1 2 2 G 4 3 0 * CAUTION: See manual for special condition/mains fuse ` voir manual de conditions speclales/fusibles 10 WARNING: Stored charge, wait 4 min. ` attendez 4 min. Charge residuelle, 1 Type code 2 Order number 3 Serial number 4 Power rating 5 Input voltage, frequency and current (at low/high voltages) 6 Output voltage, frequency and current (at low/high voltages) 7 Enclosure type and IP rating 8 Maximum ambient temperature 9 Certifications Discharge time (Warning) 3.2.1 Items Supplied Illustration 3.1 Product Nameplate (Example) 16 Make sure the items supplied and the information on the nameplate correspond to the order confirmation. • Check the packaging and the frequency converter visually for damage caused by inappropriate handling during shipment. File any claim for damage with the carrier. Retain damaged parts for clarification. MADE IN DENMARK Listed 76X1 E134261 Ind. Contr. Eq. 10 • 8 o CHASSIS/ IP20 Tamb.50 C/122 F 3.2 Unpacking Items supplied may vary according to product configuration. 3 S/N: 010122G430 130BD600.10 3 Mechanical Installation NOTICE Do not remove the nameplate from the frequency converter (loss of warranty). Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Mechanical Installation Operating Instructions 3.3 Installation Environment 3.3.1 Planning the Installation Site Select the best possible operation site by considering the following (see details on the following pages, and in the Design Guide): • Ambient operating temperature • • • • • • • Installation method Cooling Position of the unit Cable routing Voltage and current supply from power source Current rating within range Fuse ratings if not using built-in fuses 3.4 Mounting 3.4.1 Cooling and Airflow Back cooling The backchannel air can also be ventilated in and out the back of a Rittal TS8 enclosure for frame size F18 LHD. This offers a solution where the backchannel could take air from outside the facility and return the heat loses outside the facility thus reducing air-conditioning requirements. NOTICE A door fan(s) is required on the enclosure to remove the heat losses not contained in the backchannel of the drive and any additional losses generated from other components installed inside the enclosure. The total required air flow must be calculated so that the appropriate fans can be selected. Some enclosure manufacturers offer software for performing the calculations (i.e. Rittal Therm software). Airflow The necessary airflow over the heat sink must be secured. The flow rate is shown in Table 3.1. Cooling Cooling can be obtained in different ways, by using the cooling ducts in the bottom and the top of the unit, by taking air in and out the back of the unit or by combining the cooling possibilities. Enclosure protection IP21/NEMA 1 IP54/NEMA 12 Frame size Door fan/top fan airflow Total airflow of multiple fans Heat sink fan Total airflow for multiple fans D13 (LHD120) 3 door fans, 510 m3/h (300 cfm) (2+1, 3x170=510) 2 heat sink fans, 1530 m3/h (900 cfm) (1+1, 2x765=1530) E9 P315-P400 (LHD210) 4 door fans, 680 m3/h (400 cfm) (2+2, 4x170=680) 2 heat sink fans, 2675 m3/h (1574 cfm) (1+1, 1230+1445=2675) F18 (LHD330) 6 door fans, 3150 m3/h (1854 cfm) (6x525=3150) 5 heat sink fans, 4485 m3/h (2639 cfm) 2+1+2, ((2x765)+(3x985)=4485) Table 3.1 Heat Sink Air Flow MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 17 3 3 Operating Instructions NOTICE (%) 90 For the drive section, the fan runs for the following reasons: 70 DC Hold Pre-Mag 60 50 40 30 DC Brake 20 60% of nominal current is exceeded 10 • Specific power card ambient temperature exceeded (power size dependent) • Specific control card ambient temperature exceeded 0 70 Specific heat sink temperature exceeded (power size dependent) • Specific power card ambient temperature exceeded (power size dependent) • 27.3 45.9 66 Pressure Increase 89.3 115.7 147 (Pa) Drive Derating 80 60 50 40 30 20 Active filter not running, but mains current exceeding limit (power size dependent) • 13 (%) NOTICE Active filter running 4.9 Drive Air Flow: 450 cfm (765 m3/h) 90 • • 0.5 Illustration 3.2 D-Frame Derating vs. Pressure Change Once the fan is started, it runs for minimum 10 minutes. For the active filter, the fan runs for the following reasons: 0 130BB010.10 Specific heat sink temperature exceeded (power size dependent) 10 0 0 0 0.1 3.6 9.8 21.5 43.4 Pressure Change 76 147.1 237.5 278.9 (Pa) Illustration 3.3 E-Frame Derating vs. Pressure Change (Small Fan), P315 Drive Air Flow: 650 cfm (1105 m3/h) Specific control card ambient temperature exceeded (%) 90 Once the fan is started, it runs for minimum 10 minutes. 80 70 Drive Derating External ducts If additional duct work is added externally to the Rittal cabinet, the pressure drop in the ducting must be calculated. Use the charts below to derate the frequency converter according to the pressure drop. 130BB011.10 3 3 AMA 80 Drive Derating • • • • • • 130BB007.10 Mechanical Installation 60 50 40 30 20 10 0 0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 Pressure Change 69.5 152.8 210.8 (Pa) Illustration 3.4 E-Frame Derating vs. Pressure Change (Large Fan) P355-P450 Drive Air Flow: 850 cfm (1445 m3/h) 18 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BB190.10 (%) 90 80 Drive Derating 70 130BD574.10 Mechanical Installation 1 2 60 50 3 3 40 30 20 10 0 0 25 50 75 100 125 150 175 200 225 Pressure Change Illustration 3.5 F-Frame Derating vs. Pressure Change Drive Air Flow: 580 cfm (985 m3/h) 3.4.2 Lifting Lift the frequency converter using the dedicated lifting eyes. For all D-frames, use a bar to avoid bending the lifting holes of the frequency converter. 1 Lifting holes for the filter 2 Lifting holes for the frequency converter Illustration 3.8 Recommended Lifting Method, Frame Size F18 130BC166.10 Lifting Holes NOTICE A spreader bar is also an acceptable way to lift the Fframe. NOTICE Illustration 3.6 Recommended Lifting Method, Frame Size D13 The F18 pedestal is packaged separately and included in the shipment. Mount the frequency converter on the pedestal in its final location. The pedestal allows proper airflow and cooling. 130BC170.10 Lifting Holes Illustration 3.7 Recommended Lifting Method, Frame Size E9 WARNING The lifting bar must be able to handle the weight of the frequency converter. See chapter 8.2 Mechanical Dimensions for the weight of the different frame sizes. Maximum diameter for bar is 2.5 cm (1 inch). The angle from the top of the frequency converter to the lifting cable should be 60° or greater. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 19 Operating Instructions 3.4.3 Cable Entry and Anchoring Cables enter the unit through gland plate openings in the bottom. The illustrations in this section show gland entry locations and detailed views of anchoring hole dimensions. 130BC585.10 Bottom View, D13 1 1 Cable entry locations Illustration 3.9 Cable Entry Diagram, D13 Bottom View, E9 130BC586.10 3 3 Mechanical Installation 1 1 Cable entry locations Illustration 3.10 Cable Entry Diagram, E9 20 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Mechanical Installation Operating Instructions 130BC587.10 Bottom View, F18 1 3 3 2 3 4 5 6 1 Mains cable entry 4 Motor cable entry 2 Option enclosure 5 Inverter enclosure 3 Filter enclosure 6 Rectifier enclosure Illustration 3.11 Cable Entry Diagram, F18 MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 21 Mechanical Installation Operating Instructions 130BC603.10 3.4.4 Terminal Locations for Frame Size D13 3 3 29.0 [1.1] .8 [.0] 476.0 [18.7] 267.4 [10.5] MAINS INPUT TERMINALS 88.0 [3.5] 120.2 [4.7] 83.5 [3.3] 268.1 [10.6] 204.0 [8.0] 259.7 [10.2] 167.0 [6.6] MOTOR OUTPUT TERMINALS 796.3 [31.3] Illustration 3.12 Frame Size D13 Terminal Locations Allow for bend radius of heavy power cables. NOTICE All D-frames are available with standard input terminals, fuse, or disconnect switch. 22 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Mechanical Installation Operating Instructions 130BC604.10 3.4.5 Terminal Locations for Frame Size E9 3 3 90.0 [3.5] 517.5 [20.4] 518.0 [20.4] MAINS INPUT TERMINAL 383 [15.1] 168.7 [6.6] 90.0 [3.5] 180.0 [7.1] 153.8 [6.1] 112.5 [4] 323.3 [12.7] 368.3 [14.5] MOTOR OUTPUT TERMINAL 225.0 [8.9] 900.0 [35.4] Illustration 3.13 Frame Size E9 Terminal Locations Allow for bend radius of heavy power cables. NOTICE 176FA271.10 All E-frames are available with standard input terminals, fuse, or disconnect switch. 104[4.1] 35[1.4] 26[1.0] 0[0.0] 26[1.0] 0[0.0] 40[1.6] 78[3.1] 10[0.4] 0[0.0] Illustration 3.14 Close-up Terminal Diagrams MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 23 Operating Instructions 3.4.6 Terminal Locations for Frame Size F18 Consider the position of the terminals when designing the cable access. F-frame units have 4 interlocked cabinets: • • • • Input options cabinet (not optional for LHD) Filter cabinet Rectifier cabinet Inverter cabinet 1 2 3 130BA851.12 See chapter 1.3.3 Exploded View Drawings for exploded views of each cabinet. Mains inputs are located in the input option cabinet, which conducts power to the rectifier via interconnecting bus bars. Output from the unit is from the inverter cabinet. No connection terminals are located in the rectifier cabinet. Interconnecting bus bars are not shown. 1031.4[40.61] 939.0[36.97] 4 134.6[5.30] 0.0[0.00] 0.0[1.75] 244.4[1.75] 1 Right side cut-away 3 Left side cut-away 2 Front view 4 Ground bar 0.0[0.00] 76.4[3.01] 128.4[5.05] 119.0[4.69] 171.0[6.73] 294.6[11.60] 344.0[13.54] 3639[14.33] 438.9[17.28] 219.6[18.65] 0.0[0.00] 244.4[9.62] 75.3[2.96] 150.3[5.92] 154.0[6.06] 3 3 Mechanical Installation Illustration 3.15 Frame Size F18 Input Option Cabinet - Fuses Only The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. 24 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BA852.11 Mechanical Installation 3 3 532.9 [20.98] 436.9 [17.20] 1 134.6 [5.30] 0.0 [0.00] 0.0 [0.00] 44.4 [1.75] 500 kW (mm [in.]) 0.0 [0.00] 104.3 [4.11] 179.3 [7.06] 154.0 [6.06] 219.6 [8.65] 294.6 [11.60] 344.0 [13.54] 334.8 [13.18] 409.8 [16.14] 0.0 [0.00] 244.4 [9.62] 3 2 5 4 560–710 kW (mm [in.]) 1 Ground Bar 2 34.9 [1.4] 46.3 [1.8] 3 86.9 [3.4] 98.3 [3.9] 4 122.2 [4.8] 119 [4.7] 5 174.2 [6.9] 171 [6.7] *Disconnect location and related dimensions vary with kilowatt rating Illustration 3.16 Frame Size F18 Input Option Cabinet with Circuit Breaker The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 25 Operating Instructions 1 3 2 3 3 130BA849.13 Mechanical Installation 4 308.3 [12.1] 253.1 [10.0] 180.3 [7.1] 5 6 .0 [.0] 44.40 [1.75] Front View 5 Motor output bus bar 2 Left Side View 6 Ground bar 3 Right Side View 7 Screen clamp 4 Brake Terminals .0 [.0] 339.4 [13.4] 287.4 [11.3] 1 4 465.6 [18.3] 465.6 [18.3] 287.4 [11.3] 339.4 [13.4] .0 [.0] [21.7] 522.3 [20.6] [23.1] [25.0] 637.3 [25.1] [26.4] 551.0 572.1 [22.5] 587.0 635.0 671.0 497.1 [19.6] 198.1[7.8] 169.4 [6.7] 234.1 [9.2] 282.1 [11.1] 284.4 [11.2] 318.1 [12.5] 407.3 [16.0] 204.1 [8.0] 129.1 [5.1] .0 [.0] 54.4[2.1] 244.40 [9.62] Illustration 3.17 Frame Size F18 Inverter Cabinet The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. 26 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Mechanical Installation Operating Instructions 3.4.7 Torque Correct torque is imperative for all electrical connections. Incorrect torque results in a bad electrical connection. Use a torque wrench to ensure correct torque. 176FA247.12 3 3 R/L1 91 S/L2 8 -DC 8 92 +DC T/L3 93 89 1 96 V/T2 97 W/T3 U/T Nm/in-lbs Illustration 3.18 Use a Torque Wrench to Tighten the Bolts Frame size D E Terminal Torque [Nm] (inlbs) Mains Motor 19–40 (168–354) M10 Load sharing Brake 8.5–20.5 (75–181) M8 Mains Motor Load sharing 19–40 (168–354) M10 Brake 8.5–20.5 (75–181) M8 Mains Motor 19–40 (168–354) M10 Load sharing F Brake Regen 19–40 (168–354) 8.5–20.5 (75–181) 8.5–20.5 (75–181) Bolt size M10 M8 M8 Table 3.2 Torque for Terminals MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 27 Operating Instructions 4 Electrical Installation 4.1 Safety Instructions 4.2 EMC Compliant Installation See chapter 2 Safety for general safety instructions. To obtain an EMC-compliant installation, follow the instructions provided in chapter 4.4 Grounding, chapter 4.5 Input Options, chapter 4.6 Motor Connection, and chapter 4.8 Control Wiring. WARNING INDUCED VOLTAGE Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately or use screened cables could result in death or serious injury. • • Run output motor cables separately, or use screened cables CAUTION SHOCK HAZARD The frequency converter can cause a DC current in the PE conductor. Failure to follow the recommendation below means the RCD may not provide the intended protection. • When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side. Overcurrent Protection • • Additional protective equipment such as short circuit protection or motor thermal protection between frequency converter and motor is required for applications with multiple motors. Input fusing is required to provide short circuit and overcurrent protection. If not factorysupplied, fuses must be provided by the installer. See maximum fuse ratings in chapter 8.5 Fuses. Wire Type and Ratings • • NOTICE Cables–General Information All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 75 °C copper conductors. For non-UL applications, 75 and 90 °C copper conductors are thermally acceptable. The power cable connections are situated as shown in Illustration 4.1. Dimension cable cross-section in accordance with the current ratings and local legislation. See chapter 8.3.1 Cable lengths and cross-sections for details. For protection of the frequency converter, use the recommended fuses if there are no built-in fuses. Fuse recommendations are provided in chapter 8.5 Fuses. Ensure that proper fusing is made according to local regulation. The mains connection is fitted to the mains switch, if included. 3 Phase power input 91 (L1) 92 (L2) 93 (L3) 95 PE Illustration 4.1 Power Cable Connections All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements. Power connection wire recommendation: Minimum 75 °C rated copper wire. See chapter 8.1 Power-Dependent Specifications and chapter 8.3 General Technical Data - Frequency Converter for recommended wire sizes and types. 28 4.3 Power Connections 130BA026.10 4 4 Electrical Installation NOTICE To comply with EMC emission specifications, screened/ armoured cables are recommended. If an unscreened/ unarmoured cable is used, see chapter 4.7.3 Power and Control Wiring for Unscreened Cables. See chapter 8 Specifications for correct dimensioning of motor cable cross-section and length. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions Screening of cables Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies. If breaking the screen is necessary to install a motor isolator or contactor, continue the screen at the lowest possible HF impedance. Connect the motor cable screen to both the de-coupling plate of the frequency converter and to the metal housing of the motor. Make the screen connections with the largest possible surface area (cable clamp). Use the installation devices within the frequency converter. Cable-length and cross-section The frequency converter has been EMC tested with a given length of cable. Keep the motor cable as short as possible to reduce the noise level and leakage currents. Switching frequency When frequency converters are used together with sinewave filters to reduce the acoustic noise from a motor, the switching frequency must be set according to 14-01 Switching Frequency. Term. 96 97 no. U V 98 W PE1) U1 V1 W1 W2 U2 99 V2 PE1) 4.4 Grounding Consider the following basic issues for electromagnetic compatibility (EMC) during installation: • Safety grounding: The frequency converter has a high leakage current and must be grounded appropriately for safety reasons. Apply local safety regulations. • High-frequency grounding: Keep the ground wire connections as short as possible. Connect the different ground systems at the lowest possible conductor impedance. Keep the conductor as short as possible and use the greatest possible surface area for the lowest possible conductor impedance. The metal cabinets of the different devices are mounted on the cabinet rear plate using the lowest possible HF impedance. Doing so avoids different HF voltages for individual devices and the risk of radio interference currents running in connection cables between the devices. The radio interference is reduced. To obtain a low HF impedance, use the fastening bolts of the devices as HF connection to the rear plate. Remove insulating paint or similar from the fastening points. 4.5 Input Options Motor voltage 0–100% of mains voltage. 3 wires out of motor 4.5.1 Extra Protection (RCD) Delta-connected 6 wires out of motor Star-connected U2, V2, W2 U1 V1 W1 PE1) U2, V2, and W2 to be interconnected separately. ELCB relays, multiple protective grounding, or standard grounding provide extra protection, if local safety regulations are followed. In the case of a ground fault, a DC component develops in the fault current. Table 4.1 Terminal Connections Motor U2 V2 W2 Motor U2 U1 V1 W1 U1 V1 W2 97 98 96 97 98 Illustration 4.2 Y and Delta Terminal Configurations MG21B202 If using ELCB relays, observe local regulations. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge on power-up. 4.5.2 RFI Switch W1 FC FC 96 V2 175ZA114.11 1) Protective Earth Connection Mains supply isolated from ground If the frequency converter is supplied from an isolated mains source or TT/TN-S mains with grounded leg, turn off the RFI switch via 14-50 RFI Filter on both frequency converter and the filter. For further reference, see IEC 364-3. When optimum EMC performance is needed, parallel motors are connected, or the motor cable length is above 25 m, set 14-50 RFI Filter to [ON]. In OFF, the internal RFI capacitors (filter capacitors) between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate circuit and reduce ground capacity currents (IEC 61800-3). Refer to the application note VLT on IT mains. It is important to use isolation monitors that work together with power electronics (IEC 61557-8). Danfoss A/S © Rev. 2014-01-22 All rights reserved. 29 4 4 4 4 Operating Instructions 4.5.3 Shielded Cables Motor U2 V2 W2 U1 V1 W1 96 97 98 Motor U2 V2 W2 U1 V1 W1 96 97 98 It is important to connect shielded cables properly to ensure high EMC immunity and low emissions. Connection can be made using either cable glands or clamps: • EMC cable glands: Generally available cable glands can be used to ensure an optimum EMC connection. • 175HA036.11 Electrical Installation FC EMC cable clamp: Clamps allowing easy connection are supplied with the unit. 4.6 Motor Connection 4.6.1 Motor Cable Connect the motor to terminals U/T1/96, V/T2/97, W/T3/98, on the far right of the unit. Ground to terminal 99. All types of 3-phase asynchronous standard motors can be used with a frequency converter. The factory setting is for clockwise rotation with the frequency converter output connected as follows: Terminal No. Function 96, 97, 98 99 Mains U/T1, V/T2, W/T3 Ground FC Illustration 4.3 Motor Rotation Check Table 4.2 Terminal Functions • • • The direction of rotation can be changed by switching 2 phases in the motor cable or by changing the setting of 4-10 Motor Speed Direction. F-frame requirements Use motor phase cables in quantities of 2, resulting in 2, 4, 6, or 8 to obtain an equal number of wires on both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals. Motor rotation check can be performed via 1-28 Motor Rotation Check and following the steps shown in the display. Output junction box requirements The length, minimum 2.5 m, and quantity of cables must be equal from each inverter module to the common terminal in the junction box. Terminal U/T1/96 connected to U-phase Terminal V/T2/97 connected to V-phase Terminal W/T3/98 connected to W-phase NOTICE If a retrofit application requires an unequal number of wires per phase, consult the factory or use the top/ bottom entry side cabinet option, instruction 177R0097. 4.6.2 Brake Cable Frequency converters with factory installed brake chopper option (Only standard with letter B in position 18 of type code). 30 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions The connection cable to the brake resistor must be screened and the max. length from frequency converter to the DC bar is limited to 25 m. Terminal No. Function 81, 82 Brake resistor terminals Table 4.3 Terminal Functions The connection cable to the brake resistor must be screened. Connect the screen with cable clamps to the conductive back plate of the frequency converter and the metal cabinet of the brake resistor. Size the brake cable cross-section to match the brake torque. See also Brake Instructions for further information regarding safe installation. WARNING Note that voltages up to 790 V DC, depending on the supply voltage, are possible on the terminals. F-frame requirements The brake resistors must be connected to the brake terminals in each inverter module. 4.6.3 Brake Resistor Temperature Switch The input for the brake resistor temperature switch can be used to monitor the temperature of an externally connected brake resistor. If the connection between 104 and 106 is removed, the frequency converter trips on warning/alarm 27, Brake IGBT. Install a Klixon switch that is 'normally closed' in series with the existing connection on either 106 or 104. Any connection to this terminal must be double insulated against high voltage to maintain PELV. Normally closed: 104–106 (factory installed jumper). Terminal No. Function 106, 104, 105 Brake resistor temperature switch. Table 4.4 Terminal Functions CAUTION 4.6.4 Motor Insulation For motor cable lengths ≤ the maximum cable length, the motor insulation ratings listed in Table 4.5 are recommended. The peak voltage can be twice the DC-link voltage or 2.8 times mains voltage, due to transmission line effects in the motor cable. If a motor has lower insulation rating, use a dU/dt or sine wave filter. Nominal Mains Voltage UN ≤ 420 V Standard ULL = 1,300 V 420 V < UN ≤ 500 V Reinforced ULL = 1,600 V Table 4.5 Recommended Motor Insulation Ratings 4.6.5 Motor Bearing Currents Motors with a rating 110 kW or higher combined with frequency converters are best with NDE (Non-Drive End) insulated bearings to eliminate circulating bearing currents caused by motor size. To minimise DE (Drive End) bearing and shaft currents, proper grounding is required for: • • • • 105 NO 175ZA877.10 104 C Illustration 4.4 Factory-installed Jumper MG21B202 Frequency converter Motor Motor-driven machine Motor to the driven machine Although failure due to bearing currents is infrequent, use the following strategies to reduce the likelihood: • • • Use an insulated bearing Apply rigorous installation procedures Ensure that the motor and load motor are aligned • • Strictly follow the EMC Installation guideline • Provide a good high frequency connection between the motor and the frequency converter • Ensure that the impedance from frequency converter to building ground is lower than the grounding impedance of the machine. Make a direct ground connection between the motor and load motor. • • Apply conductive lubrication If the temperature of the brake resistor is too high and the thermal switch drops out, the frequency converter stops braking. The motor coasts. 106 NC 4 4 Motor Insulation • Reinforce the PE so the high frequency impedance is lower in the PE than the input power leads Try to ensure that the line voltage is balanced to ground. Use an insulated bearing as recommended by the motor manufacturer (note: Motors from reputable manufacturers typically have insulated bearings as standard in motors of this size) Danfoss A/S © Rev. 2014-01-22 All rights reserved. 31 Electrical Installation Operating Instructions If found to be necessary and after consultation with Danfoss: • Lower the IGBT switching frequency 4 4 • Modify the inverter waveform, 60° AVM vs. SFAVM • Install a shaft grounding system or use an isolating coupling between motor and load • • Use minimum speed settings if possible Use a dU/dt or sinus filter 4.6.6 Motor Thermal Protection The electronic thermal relay in the frequency converter has received UL-approval for single motor protection, when 1-90 Motor Thermal Protection is set for ETR Trip and 1-24 Motor Current is set to the rated motor current (see the motor name plate). For thermal motor protection, it is also possible to use the MCB 112 PTC Thermistor Card option. This card provides ATEX certificate to protect motors in explosion hazardous areas, Zone 1/21 and Zone 2/22. When 1-90 Motor Thermal Protection, set to [20] ATEX ETR, is combined with the use of MCB 112, it is possible to control an Ex-e motor in explosion hazardous areas. Consult the Programming Guide for details on how to set up the frequency converter for safe operation of Ex-e motors. 4.7 AC Mains Connection 4.7.1 Mains Connection Mains must be connected to terminals 91, 92 and 93 on the far left of the unit. Ground is connected to the terminal on the right of terminal 93. Terminal No. Function 91, 92, 93 94 Mains R/L1, S/L2, T/L3 Ground 4.7.2 External Fan Supply If the frequency converter is supplied by DC or the fan must run independently of the power supply, use an external power supply. Make the connection on the power card. Terminal No. Function 100, 101 102, 103 Auxiliary supply S, T Internal supply S, T Table 4.7 Terminal Functions The connector on the power card provides the connection of line voltage for the cooling fans. The fans are connected from the factory to be supplied from a common AC line (jumpers between 100–102 and 101–103). If external power supply is needed, remove the jumpers and connect the supply to terminals 100 and 101. Protect with a 5 A. In UL applications, use a LittelFuse KLK-5 or equivalent. 4.7.3 Power and Control Wiring for Unscreened Cables WARNING INDUCED VOLTAGE Induced voltage from coupled output motor cables charges equipment capacitors even with the equipment turned off and locked out. Run motor cables from multiple frequency converters separately. Failure to run output cables separately could result in death or serious injury. CAUTION COMPROMISED PERFORMANCE The frequency converter runs less efficiently if wiring is not isolated properly. To isolate high frequency noise, the following in separate metallic conduits: Table 4.6 Terminal Functions Ensure that the power supply can supply the necessary current to the frequency converter. If the unit is without built-in fuses, ensure that the appropriate fuses have the correct current rating. • • • power wiring motor wiring control wiring Failure to isolate these connections could result in less than optimum controller and associated equipment performance. Because the power wiring carries high frequency electrical pulses, it is important to run input power and motor power in separate conduit. If incoming power wiring is in the same conduit as motor wiring, these pulses can couple electrical noise back onto the power grid. Isolate control wiring from high-voltage power wiring. 32 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions 130BB447.10 When screened/armoured cable is not used, at least 3 separate conduits are connected to the panel option (see Illustration 4.5). 4 4 Stop Start Line Power Speed Motor Separate Conduit Control Illustration 4.5 Proper Electrical Installation Using Conduit MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 33 4 4 Electrical Installation Operating Instructions 4.7.4 Mains Disconnects Frame size Power & Voltage Type D P132-P200 380–500 V OT400U12-9 or ABB OETL-NF400A E P250 380-500 V ABB OETL-NF600A E P315-P400 380-500 V ABB OETL-NF800A F P450 380-500 V Merlin Gerin NPJF36000S12AAYP F P500-P630 380-500 V Merlin Gerin NRK36000S20AAYP Table 4.8 Recommended Mains Disconnects 4.7.5 F-Frame Circuit Breakers Frame size Power & Voltage Type F P450 380-500 V Merlin Gerin NPJF36120U31AABSCYP F P500-P630 380-500 V Merlin Gerin NRJF36200U31AABSCYP Table 4.9 Recommended Circuit Breakers 4.7.6 F-Frame Mains Contactors Frame size Power & Voltage Type F P450-P500 380-500 V Eaton XTCE650N22A F P560-P630 380-500 V Eaton XTCEC14P22B Table 4.10 Recommended Contactors 34 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions 4.8 Control Wiring 4.8.1 Control Cable Routing Tie down all control wires to the designated control cable routing as shown in Illustration 4.6, Illustration 4.7, and Illustration 4.8. Remember to connect the shields in a proper way to ensure optimum electrical immunity. 4 4 Fieldbus connection Connections are made to the relevant options on the control card. For details, see the relevant fieldbus instruction. The cable must be placed in the provided path inside the frequency converter and tied down together with other control wires (see Illustration 4.6 and Illustration 4.7). Illustration 4.7 Control Card Wiring Path for Frame Size E9 Illustration 4.6 Control Card Wiring Path for Frame Size D13 MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 35 Operating Instructions 4.8.3 Electrical Installation, Control Terminals To connect the cable to the terminal: 1. Strip insulation by about 9–10 mm 130BA150.10 130BB187.10 Electrical Installation 4 4 1 9 - 10 mm (0.37 in) Illustration 4.9 Length to Strip the Insulation Insert a screwdriver (max. 0.4x2.5 mm) in the square hole. 3. Insert the cable in the adjacent circular hole. 130BT312.10 2. 1 Routing path for the control card wiring, inside the frequency converter enclosure. Illustration 4.8 Control Card Wiring Path for Frame Size F18 4.8.2 Access to Control Terminals All terminals to the control cables are located beneath the LCP (both filter and frequency converter LCPs). They are accessed by opening the door of the unit. Illustration 4.10 Inserting the Cable in the Terminal Block 4. 36 Remove the screwdriver. The cable is now mounted in the terminal. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BT306.10 Electrical Installation To remove the cable from the terminal: Insert a screwdriver (max. 0.4 x 2.5 mm) in the 1. square hole. Pull out the cable. 130BT311.10 2. 4 4 Illustration 4.12 Control Terminal Locations Illustration 4.11 Removing the Screwdriver after Cable Insertion MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 37 Electrical Installation Operating Instructions 130BD429.10 4.8.4 Electrical Installation, Control Cables Relay 12 Control & AUX Feedback Soft-Charge NC Relay HI Reactor 91 (L1) 92 (L2) 4 4 Lm Optional RFI Optional Manual Disconnect +10Vdc Is Lc It 3 Relay 12 Control & AUX Cef Feedback Ref Cef Cef Ref 3 Capacitor Current Sensors AF Current Sensors Ref PE Switch Mode Power Supply 24Vdc 10Vdc 15mA 130/200mA 88 (-) 89 (+) 50 (+10 V OUT) + - + (R+) 82 - ON 53 (A IN) S202 03 02 55 (COM A IN) relay2 12 (+24V OUT) 05 P 5-00 18 (D IN) 24V (NPN) 0V (PNP) 04 19 (D IN) 24V (NPN) 0V (PNP) (COM A OUT) 39 20 (COM D IN) 27 (D IN/OUT) (A OUT) 42 (D IN/OUT) 24V ON 0V * 29 S801 1 2 24V 24V (NPN) 0V (PNP) 240Vac, 2A 01 06 13 (+24V OUT) Brake resistor relay1 ON/I=0-20mA OFF/U=0-10V ON 54 (A IN) Motor (R-) 81 S201 1 2 -10Vdc +10Vdc 0/4-20 mA Lc Power Stage (U) 96 (V) 97 (W) 98 (PE) 99 1 2 -10Vdc +10Vdc 0/4-20 mA Ir Lac Lm Lac DC bus Converter Side Filter Lc Lac Lm Optional Fuses 93 (L3) 95 AC Contactor 240Vac, 2A 400Vac, 2A Analog Output 0/4-20 mA ON=Terminated OFF=Open 5V 24V (NPN) 0V (PNP) S801 0V 32 (D IN) 24V (NPN) 0V (PNP) 33 (D IN) 24V (NPN) 0V (PNP) RS-485 Interface 0V (N RS-485) 69 RS-485 (P RS-485) 68 (COM RS-485) 61 (PNP) = Source (NPN) = Sink * 37 (D IN) Illustration 4.13 Terminal Diagram 38 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions Long control cables and analog signals may result in 50/60 Hz ground loops due to noise from mains supply cables. If ground loops occur, break the screen or insert a 100 nF capacitor between screen and chassis, if needed. Connect the digital and analog inputs and outputs to the control cards of the units separately to avoid ground currents. These connections are on terminals 20, 55, and 39 for both the filter and frequency converter sections. 12 13 18 19 27 0 VDC Digital input wiring 29 32 33 20 To comply with EMC emission specifications, screened/ armoured cables are recommended. If using unscreened/ unarmoured cable, see chapter 4.7.3 Power and Control Wiring for Unscreened Cables. If using unscreened control cables, use ferrite cores to improve EMC performance. 130BT106.10 +24 VDC PNP (Source) NOTICE 130BT340.10 Electrical Installation 37 12 NPN (Sink) Digital input wiring 13 18 19 27 130BT107.11 0 VDC +24 VDC Illustration 4.14 Input Polarity of Control Terminals, PNP 29 32 33 20 37 Illustration 4.16 Connecting Shielded Cables Connect the shields in a proper way to ensure optimum electrical immunity. 4.9 Additional Connections 4.9.1 Mechanical Brake Control In hoisting/lowering applications, it is necessary to be able to control an electro-mechanical brake: • Control the brake using any relay output or digital output (terminal 27 or 29). Illustration 4.15 Input Polarity of Control Terminals, NPN MG21B202 • Keep the output closed (voltage-free) as long as the frequency converter is unable to ‘support’ the motor, due to the load being too heavy, for example. • Select [32] Mechanical brake control in parameter group 5-4* Relays for applications with an electromechanical brake. • The brake is released when the motor current exceeds the preset value in 2-20 Release Brake Current. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 39 4 4 4 4 Electrical Installation The brake engages when the output frequency is less than the frequency set in 2-21 Activate Brake Speed [RPM] or 2-22 Activate Brake Speed [Hz], only if the frequency converter completes a stop command. 130BA170.10 • Operating Instructions If the frequency converter is in alarm mode or in an overvoltage situation, the mechanical brake immediately cuts in. 4.9.2 Parallel Connection of Motors The frequency converter can control several parallelconnected motors. The total current consumption of the motors must not exceed the rated output current IM,N for the frequency converter. LC filter NOTICE Installations with cables connected in a common joint as in Illustration 4.17, is only recommended for short cable lengths. NOTICE When motors are connected in parallel, 1-29 Automatic Motor Adaptation (AMA) cannot be used. NOTICE The electronic thermal relay (ETR) of the frequency converter cannot be used as motor protection for the individual motor in systems with parallel-connected motors. Provide further motor protection with thermistors in each motor or individual thermal relays. Circuit breakers are not suitable as protection. Illustration 4.17 Installations with Cables Connected in a Common Joint Problems are possible at start and at low RPM values if motor sizes vary widely. The relatively high ohmic resistance in the stator of small motors calls for a higher voltage at start and at low RPM values. 4.9.3 Motor Thermal Protection The electronic thermal relay in the frequency converter has received UL-approval for single motor protection, when 1-90 Motor Thermal Protection is set for [4] ETR Trip 1 and 1-24 Motor Current is set to the rated motor current (see motor name plate). For thermal motor protection, it is also possible to use the VLT® PTC Thermistor Card MCB 112. This card provides ATEX certification to protect motors in explosion hazardous areas, Zone 1/21 and Zone 2/22. When 1-90 Motor Thermal Protection is set to [20] ATEX ETR and MCB 112 are combined, it is possible to control an Ex-e motor in explosion hazardous areas. Consult the Programming Guide for details on how to set up the frequency converter for safe operation of Ex-e motors. 40 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions 4.9.4 Safe Torque Off (STO) 4.9.6 Serial Communication To run Safe Torque Off, additional wiring for the frequency converter is required. Refer to VLT® Frequency Converters Safe Torque Off Operating Instructions for further information. RS-485 is a 2-wire bus interface compatible with multi-drop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line. A total of 32 nodes can be connected to one network segment. Repeaters divide networks. 4.9.5 Switches S201, S202, and S801 Use switches S201 (A53) and S202 (A54) to select a current (0-20 mA) or a voltage (-10 V to 10 V) configuration of the analog input terminals 53 and 54. Switch S801 (BUS TER.) can be used to enable termination on the RS-485 port (terminals 68 and 69). See Illustration 4.13. Default setting: S201 (A53) = OFF (voltage input) S202 (A54) = OFF (voltage input) S801 (Bus termination) = OFF NOTICE 130BT310.11 When changing the function of S201, S202 or S801 do not use force for the switch-over. Remove the LCP cradle when operating the switches. The switches must not be operated with power on the frequency converter. NOTICE Each repeater functions as a node within the segment in which it is installed. Each node connected within a given network must have a unique node address, across all segments. Terminate each segment at both ends, using either the termination switch (S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and always follow good common installation practice. Low-impedance ground connection of the screen at every node is important, including at high frequencies. Thus, connect a large surface of the screen to ground, for example with a cable clamp or a conductive cable gland. It may be necessary to apply potential-equalizing cables to maintain the same ground potential throughout the network - particularly in installations with long cables. To prevent impedance mismatch, always use the same type of cable throughout the entire network. When connecting a motor to the frequency converters, always use screened motor cable. Cable Screened twisted pair (STP) Impedance 120 Ω Cable length [m] Max. 1200 (including drop lines) Max. 500 station-to-station Table 4.11 Cable Recommendations 4.9.7 F-frame Options Illustration 4.18 Remove the LCP Cradle to Access Switches Space heaters and thermostat There are space heaters mounted on the cabinet interior of F-frame frequency converters. These heaters are controlled by an automatic thermostat and help control humidity inside the enclosure. The thermostat default settings turn on the heaters at 10 °C (50 °F) and turn them off at 15.6 °C (60 °F). Cabinet light with power outlet A light mounted on the cabinet interior of F-frame frequency converters increases visibility during servicing and maintenance. The housing includes a power outlet for temporarily powering tools or other devices, available in 2 voltages: • • MG21B202 230 V, 50 Hz, 2.5 A, CE/ENEC 120 V, 60 Hz, 5 A, UL/cUL Danfoss A/S © Rev. 2014-01-22 All rights reserved. 41 4 4 4 4 Electrical Installation Operating Instructions Transformer tap set-up If the cabinet light and outlet and/or the space heaters and thermostat are installed, transformer T1 requires its taps to be set to the proper input voltage. A 380-480/500 V frequency converter is initially set to the 525 V tap and a 525-690 V frequency converters is set to the 690 V tap to ensure no overvoltage of secondary equipment occurs if the tap is not changed before applying power. See Table 4.12 to set the proper tap at terminal T1 located in the rectifier cabinet. Input voltage range [V] Tap to select [V] 380 V-440 400 441 V-490 460 491 V-550 525 551 V-625 575 626 V-660 660 661 V-690 690 Only one insulation resistance monitor can be connected to each ungrounded (IT) system. • Integrated into the frequency converter safe torque off circuit • LCD display of the ohmic value of the insulation resistance • • Fault memory INFO, TEST, and RESET buttons IEC emergency stop with Pilz safety relay Includes a redundant 4-wire emergency-stop push button mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the frequency converter STO circuit and the mains contactor located in the options cabinet. Table 4.12 Transformer Tap Set-up NAMUR terminals NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in Germany. Selecting this option provides terminals organised and labeled to the specifications of the NAMUR standard for frequency converters input and output terminals. This requires VLT® PTC Thermistor Card MCB 112 VLT® Extended Relay Card MCB 113. RCD (Residual Current Device) Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm set-point) and a main alarm set-point. Associated with each set-point is an SPDT alarm relay for external use. Requires an external “windowtype” current transformer (supplied and installed by the customer). Manual motor starters Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the frequency converters is off. Up to 2 starters are allowed (one if a 30 A, fuse-protected circuit is ordered), and are integrated into the frequency converter STO circuit. Unit features include: • • Operation switch (on/off) • Manual reset function Short-circuit and overload protection with test function 30 A, fuse-protected terminals • 3-phase power matching incoming mains voltage for powering auxiliary customer equipment • Not available if 2 manual motor starters are selected • Integrated into the frequency converter safe torque off circuit • • Terminals are off when the incoming power to the frequency converter is off IEC 60755 Type B device monitors AC, pulsed DC, and pure DC ground fault currents • • LED bar graph indicator of the ground fault current level from 10–100% of the set-point Power for the fused protected terminals is provided from the load side of any supplied contactor, circuit breaker, or disconnect switch • • Fault memory TEST/RESET button Insulation Resistance Monitor (IRM) Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is an ohmic pre-warning and a main alarm set-point for the insulation level. An SPDT alarm relay for external use is associate with each setpoint. 42 NOTICE In applications where the motor is used as a brake, energy is generated in the motor and sent back into the frequency converter. If the energy cannot be transported back to the motor, it increases the voltage in the frequency converter DC line. In applications with frequent braking and/or high inertia loads, this increase may lead to an overvoltage trip in the frequency converter and finally a shut down. Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected based on its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Electrical Installation Operating Instructions 130BT307.10 variety of different resistors that are specifically designed for Danfoss frequency converters. Load sharing Load sharing is a feature on standard frequency converters, but is not available on the LHD unit. 4.10 Final Set-up and Test 4 4 Before operating the frequency converter, perform a final test of the installation: 1. Locate the motor name plate to find out whether the motor is star- (Y) or delta- connected (Δ). 2. Enter the motor name plate data in the parameter list. Access the list by pressing the [Quick Menu] key and selecting Q2 Quick Set-up. See Table 4.13. BAUER D-7 3734 ESLINGEN 1. Motor Power [kW] or Motor Power [HP] 1-20 Motor Power [kW] 1-21 Motor Power [HP] 3~ MOTOR NR. 1827421 2003 2. Motor Voltage 1-22 Motor Voltage S/E005A9 3. Motor Frequency 1-23 Motor Frequency 4. Motor Current 1-24 Motor Current 5. Motor Nominal Speed 1-25 Motor Nominal Speed 1,5 KW n2 31,5 /min. 400 n1 1400 /min. COS 0,80 Y V 50 Hz 3,6 A Table 4.13 Quick Set-up Parameters 1,7L B IP 65 H1/1A Illustration 4.19 Motor Name Plate 3. MG21B202 Perform an Automatic Motor Adaptation (AMA) to ensure optimum performance. 3a Connect terminal 27 to terminal 12 or set 5-12 Terminal 27 Digital Input to [0] No operation. 3b Activate the AMA 1-29 Automatic Motor Adaptation (AMA). 3c Select either complete or reduced AMA. If an LC filter is mounted, run only the reduced AMA, or remove the LC filter during the AMA procedure. 3d Press [OK]. The display shows “Press [Hand On] to start.” 3e Press [Hand On]. A progress bar indicates whether the AMA is in progress. 3f Press [Off] - the frequency converter enters into alarm mode and the display shows that the user terminated AMA. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 43 Electrical Installation Operating Instructions Stop the AMA during operation Successful AMA • • The display shows “Press [OK] to finish AMA”. Press [OK] to exit the AMA state. Unsuccessful AMA 4 4 • The frequency converter enters into alarm mode. A description of the alarm can be found in chapter 7.5 Troubleshooting. • "Report Value” in the alarm log shows the last measuring sequence carried out by the AMA, before the frequency converter entered alarm mode. This number, along with the description of the alarm, helps with troubleshooting. Mention the number and alarm description when contacting Danfoss service personnel. Unsuccessful AMA is the result of incorrectly registered motor name plate data or too large a difference between the motor power size and the frequency converter power size. Set up the desired limits for speed and ramp time Minimum Reference 3-02 Minimum Reference Maximum Reference 3-03 Maximum Reference Table 4.14 Reference Parameters Motor Speed Low Limit 4-11 Motor Speed Low Limit [RPM] or 4-12 Motor Speed Low Limit [Hz] Motor Speed High Limit 4-13 Motor Speed High Limit [RPM] or 4-14 Motor Speed High Limit [Hz] Table 4.15 Speed Limits Ramp-up Time 1 [s] 3-41 Ramp 1 Ramp Up Time Ramp-down Time 1 [s] 3-42 Ramp 1 Ramp Down Time Table 4.16 Ramp Times 44 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Commissioning Operating Instructions 5 Commissioning 5.1 Safety Instructions converter disconnect switches for input power isolation. See chapter 2 Safety for general safety instructions. 4. Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase and phase-to-ground. 5. Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-tophase and phase-to-ground. 6. Confirm continuity of the motor by measuring ohm values on U-V (96-97), V-W (97-98), and W-U (98-96). 7. Check for proper grounding of the frequency converter as well as the motor. 8. Inspect the frequency converter for loose connections on terminals. 9. Confirm that the supply voltage matches voltage of frequency converter and motor. WARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power. Failure to perform installation, start-up, and maintenance by qualified personnel could result in death or serious injury. • Installation, start-up, and maintenance must be performed by qualified personnel only. Before applying power: 1. Close cover properly. 2. Check that all cable glands are firmly tightened. 3. Ensure that input power to the unit is OFF and locked out. Do not rely on the frequency CAUTION Before applying power to the unit, inspect the entire installation as detailed in Table 5.1. Check mark those items when completed. ☑ Inspect for Description Auxiliary equipment • Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers on the input power side of the frequency converter or output side to the motor. Ensure that they are ready for full speed operation. Check function and installation of any sensors used for feedback to the frequency converter Cable routing • • • Remove power factor correction caps on motors, if present Use separate metallic conduits for each of the following: • • • Control wiring Cooling clearance EMC considerations Environmental considerations MG21B202 input power motor wiring control wiring • • • • Check for broken or damaged wires and loose connections • • • • Measure that top and bottom clearance is adequate to ensure proper air flow for cooling Check that control wiring is isolated from power and motor wiring for noise immunity Check the voltage source of the signals, if necessary The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly Check for proper installation regarding electromagnetic compatibility See equipment label for the maximum ambient operating temperature limits Humidity levels must be 5–95% non-condensing Danfoss A/S © Rev. 2014-01-22 All rights reserved. 45 5 5 5 5 Commissioning Operating Instructions Inspect for Description Fusing and circuit breakers • • Grounding • • • • • • • • • Input and output power wiring Panel interior Switches Vibration ☑ Check for proper fusing or circuit breakers Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are in the open position The unit requires a ground wire from its chassis to the building ground Check for good ground connections that are tight and free of oxidation Grounding to conduit or mounting the back panel to a metal surface is not a suitable ground Check for loose connections Check that motor and mains are in separate conduit or separated screened cables Inspect that the unit interior is free of debris and corrosion Ensure that all switch and disconnect settings are in the proper positions Check that the unit is mounted solidly or that shock mounts are used, as necessary Check for an unusual amount of vibration Table 5.1 Start-up Checklist 46 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 5.2 Applying Power An optional numeric LCP (NLCP) is also available. The NLCP operates in a manner similar to the LCP. See the Programming Guide for details on use of the NLCP. WARNING HIGH VOLTAGE! Frequency converters contain high voltage when connected to AC mains. Installation, start-up and maintenance should be performed by qualified personnel only. Failure to comply could result in death or serious injury. WARNING UNINTENDED START! When the frequency converter is connected to AC mains, the motor may start at any time. The frequency converter, motor, and any driven equipment must be in operational readiness. Failure to comply could result in death, serious injury, equipment, or property damage. 5.3.2 LCP Layout The LCP is divided into 4 functional groups (see Illustration 5.1). A. Display area B. Display menu keys Confirm that the input voltage is balanced within 3%. If not, correct input voltage imbalance before proceeding. 2. Ensure that optional equipment wiring, if present, matches the installation application. 3. Ensure that all operator devices are off. Panel doors should be closed or cover mounted. Apply power to the unit. Do not start the frequency converter at this time. For units with a disconnect switch, turn the switch on to apply power. NOTICE D. Operation keys and reset 1 2 Status 0.0 % 0.00 A 0.0Hz 2605 kWh A 4 3 1(1) 0.00 kW 5 Off Remote Stop 6 10 16 • Start, stop, and control speed when in local control • Display operational data, status, warnings and cautions • • Programming frequency converter functions Manually reset the frequency converter after a fault when auto-reset is inactive 11 C OK 12 Warn. 13 Alarm 17 D The LCP has several user functions: 9 8 Info 15 The local control panel (LCP) is the combined display and keypad on the front of the unit. Alarm Log 7 On 5.3.1 Local Control Panel Main Menu l ce 5.3 Local Control Panel Operation Quick Menu B Status n Ca If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed, this indicates that the unit is ready to operate but is missing an input signal on terminal 27. MG21B202 C. Navigation keys and indicator lights (LEDs) k 4. For commissioning via PC, install MCT 10 Set-up Software. The software is available for download (basic version) or for ordering (advanced version, order number 130B1000). For more information and downloads, see www.danfoss.com/BusinessAreas/DrivesSolutions/Software +MCT10/MCT10+Downloads.htm. Ba c 1. NOTICE 130BD512.10 Commissioning Hand on 18 Off 19 Auto on 20 Reset 14 21 Illustration 5.1 Local Control Panel (LCP) A. Display Area The display area is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 47 5 5 5 5 Commissioning Operating Instructions The information displayed on the LCP can be customised for user application. Select options in the Quick Menu Q3-13 Display Settings. Callout Display Parameter number 1 1.1 0-20 Reference % 2 1.2 0-21 Motor current 3 1.3 0-22 Power [kW] 4 2 0-23 Frequency 5 3 0-24 kWh counter B. Display Menu Keys Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data. 6 Key Status Function Shows operational information. 7 Quick Menu Allows access to programming parameters for initial set-up instructions and many detailed application instructions. 8 Main Menu Allows access to all programming parameters. 9 Alarm Log Displays a list of current warnings, the last 10 alarms, and the maintenance log. Table 5.3 Legend to Illustration 5.1, Display Menu Keys C. Navigation Keys and Indicator Lights (LEDs) Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 frequency converter status indicator lights in this area. Callout Key Function 10 Back Reverts to the previous step or list in the menu structure. 11 Cancel Cancels the last change or command as long as the display mode has not changed. 12 Indo 13 14 Press for a definition of the function being displayed. Navigation Press to move between items in the keys menu. OK Indicator Light Function 15 ON Green The ON light activates when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply. 16 WARN Yellow When warning conditions are met, the yellow WARN light comes on and text appears in the display area identifying the problem. 17 ALARM Red Default setting Table 5.2 Legend to Illustration 5.1, Display Area Callout Callout Press to access parameter groups or to enable a choice. Table 5.4 Legend to Illustration 5.1, Navigation Keys Table 5.5 Legend to Illustration 5.1, Indicator Lights (LEDs) D. Operation Keys and Reset Operation keys are located at the bottom of the LCP. Callout Key Function 18 Hand On Starts the frequency converter in local control. • An external stop signal by control input or serial communication overrides the local hand on 19 Off Stops the motor but does not remove power to the frequency converter. 20 Auto On Puts the system in remote operational mode. • Responds to an external start command by control terminals or serial communication 21 Reset Resets the frequency converter manually after a fault has been cleared. Table 5.6 Legend to Illustration 5.1, Operation Keys and Reset NOTICE The display contrast can be adjusted by pressing [Status] and [▲]/[▼] keys. 5.3.3 Parameter Settings Establishing the correct programming for applications often requires setting functions in several related parameters. Programming data are stored internally in the frequency converter. • • • 48 A fault condition causes the red alarm light to flash and an alarm text is displayed. For back-up, upload data into the LCP memory To download data to another frequency converter, connect the LCP to that unit and download the stored settings Restoring factory default settings does not change data stored in the LCP memory Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Commissioning Operating Instructions 5.3.4 Uploading/Downloading Data to/from the LCP 1. Press [Off] to stop the motor before uploading or downloading data. 2. Go to [Main Menu] 0-50 LCP Copy and press [OK]. 3. Select [1] All to LCP to upload data to LCP or select [2] All from LCP to download data from the LCP. 4. Press [OK]. A progress bar shows the uploading or downloading process. 5. Press [Hand On] or [Auto On] to return to normal operation. 5.3.5 Changing Parameter Settings Parameter settings can be accessed and changed from the [Quick Menu] or from the [Main Menu]. The [Quick Menu] only gives access to a limited number of parameters. 1. Press [Quick Menu] or [Main Menu] on the LCP. 2. Press [▲] [▼] to browse through the parameter groups, press [OK] to select a parameter group. 3. Press [▲] [▼] to browse through the parameters, press [OK] to select a parameter. 4. Press [▲] [▼] to change the value of a parameter setting. 5. Press [◄] [►] to shift digit when a decimal parameter is in the editing state. 6. Press [OK] to accept the change. 7. Press either [Back] twice to enter Status, or press [Main Menu] once to enter Main Menu. View changes Quick Menu Q5 - Changes Made lists all parameters changed from default settings. • The list shows only parameters which have been changed in the current edit-setup. • Parameters which have been reset to default values are not listed. • The message Empty indicates that no parameters have been changed. 5.3.6 Restoring Default Settings Restoring the default parameter settings is done by initialisation of the frequency converter. Initialisation is carried out through 14-22 Operation Mode (recommended) or manually. • Initialisation using 14-22 Operation Mode does not reset frequency converter settings such as operating hours, serial communication selections, personal menu settings, fault log, alarm log, and other monitoring functions. • Manual initialisation erases all motor, programming, localisation, and monitoring data and restores factory default settings. 5 5 Recommended initialisation procedure, via 14-22 Operation Mode 1. Press [Main Menu] twice to access parameters. 2. Scroll to 14-22 Operation Mode and press [OK]. 3. Scroll to Initialisation and press [OK]. 4. Remove power to the unit and wait for the display to turn off. 5. Apply power to the unit. Default parameter settings are restored during start-up. This may take slightly longer than normal. 6. Alarm 80 is displayed. 7. Press [Reset] to return to operation mode. Manual initialisation procedure 1. Remove power to the unit and wait for the display to turn off. 2. Press and hold [Status], [Main Menu], and [OK] at the same time while applying power to the unit (approximately 5 s or until audible click and fan starts). Factory default parameter settings are restored during start-up. This may take slightly longer than normal. Manual initialisation does not reset the following frequency converter information: • • • • 15-00 Operating hours 15-03 Power Up's 15-04 Over Temp's 15-05 Over Volt's NOTICE Risk of loosing programming, motor data, localisation, and monitoring records by restoration of default settings. To provide a back-up, upload data to the LCP before initialisation. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 49 5.4 Basic Programming 0.00A 0.0% Operation / Display 5.4.1 Commissioning with SmartStart 0-0* Basic Settings 0-1* Set-up Operations 0-2* LCP Display 0-3* LCP Custom Readout The SmartStart wizard enables fast configuration of basic motor and application parameters. • At first power up or after initialisation of the frequency converter, SmartStart starts automatically. • 5 5 • 1(1) 0-** 130BP087.10 Operating Instructions Illustration 5.3 Operation/Display Follow on-screen instructions to complete commissioning of the frequency converter. Always reactivate SmartStart by selecting Quick Menu Q4 - SmartStart. 4. Press navigation keys to scroll to 0-03 Regional Settings and press [OK]. For commissioning without use of the SmartStart wizard, refer to chapter 5.4.2 Commissioning via [Main Menu] or the Programming Guide. 0.0% Basic Settings 0.00A 1(1) 0-0* 0-03 Regional Settings 130BP088.10 Commissioning NOTICE Motor data are required for the SmartStart set-up. The required data are normally available on the motor nameplate. [0] International Illustration 5.4 Basic Settings 5.4.2 Commissioning via [Main Menu] 5. Press navigation keys to select [0] International or [1] North America as appropriate and press [OK]. (This changes the default settings for a number of basic parameters). 6. Press [Main Menu] on the LCP. 7. Press the navigation keys to scroll to 0-01 Language. 8. Select language and press [OK]. 9. If a jumper wire is in place between control terminals 12 and 27, leave 5-12 Terminal 27 Digital Input at factory default. Otherwise, select No Operation in 5-12 Terminal 27 Digital Input. 1 - ** Load/Motor 10. 3-02 Minimum Reference 2 - ** Brakes 11. 3-03 Maximum Reference 12. 3-41 Ramp 1 Ramp Up Time 13. 3-42 Ramp 1 Ramp Down Time 14. 3-13 Reference Site. Linked to Hand/Auto Local Remote. Recommended parameter settings are intended for startup and checkout purposes. Application settings may vary. 1. Press [Main Menu] on the LCP. 2. Press the navigation keys to scroll to parameter group 0-** Operation/Display and press [OK]. 1107 RPM 3.84 A 1 (1) Main menu 0 - ** Operation/Display 3 - ** Reference / Ramps Illustration 5.2 Main Menu 3. 50 130BP066.10 Enter data with power ON, but before operating the frequency converter. Press navigation keys to scroll to parameter group 0-0* Basic Settings and press [OK]. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Commissioning Operating Instructions 5.4.3 Asynchronous Motor Set-up the cable into account. Divide the measured value by 2 and enter the result. Enter the motor data in parameter 1-20 Motor Power [kW] or 1-21 Motor Power [HP] to 1-25 Motor Nominal Speed. The information can be found on the motor nameplate. 1. 1-20 Motor Power [kW] or 1-21 Motor Power [HP] 2. 1-22 Motor Voltage 3. 1-23 Motor Frequency 4. 1-24 Motor Current 5. 1-25 Motor Nominal Speed 7. 5.4.4 Permanent Magnet Motor Set-up NOTICE Only use permanent magnet (PM) motor with fans and pumps. Test motor operation 1. Start the motor at low speed (100 to 200 RPM). If the motor does not turn, check installation, general programming and motor data. 2. Check if start function in 1-70 PM Start Mode fits the application requirements. Initial Programming Steps 1. Activate PM motor operation 1-10 Motor Construction, select (1) PM, non salient SPM 2. Set 0-02 Motor Speed Unit to [0] RPM Programming motor data After selecting PM motor in 1-10 Motor Construction, the PM motor-related parameters in parameter groups 1-2* Motor Data, 1-3* Adv. Motor Data and 1-4* are active. The necessary data can be found on the motor nameplate and in the motor data sheet. Program the following parameters in the listed order 1. 1-24 Motor Current 2. 1-26 Motor Cont. Rated Torque 3. 1-25 Motor Nominal Speed 4. 1-39 Motor Poles 5. 1-30 Stator Resistance (Rs) Enter line to common stator winding resistance (Rs). If only line-line data are available, divide the line-line value with 2 to achieve the line to common (starpoint) value. It is also possible to measure the value with an ohmmeter, which takes the resistance of the cable into account. Divide the measured value by 2 and enter the result. 6. 1-37 d-axis Inductance (Ld) Enter line to common direct axis inductance of the PM motor. If only line-line data are available, divide the lineline value with 2 to achieve the line-common (starpoint) value. It is also possible to measure the value with an inductancemeter, which takes the inductance of MG21B202 1-40 Back EMF at 1000 RPM Enter line to line back EMF of PM Motor at 1000 RPM mechanical speed (RMS value). Back EMF is the voltage generated by a PM motor when no drive is connected and the shaft is turned externally. Back EMF is normally specified for nominal motor speed or for 1000 RPM measured between 2 lines. If the value is not available for a motor speed of 1000 RPM, calculate the correct value as follows: If back EMF is e.g. 320 V at 1800 RPM, it can be calculated at 1000 RPM as follows: Back EMF = (Voltage / RPM)*1000 = (320/1800)*1000 = 178. This is the value that must be programmed for 1-40 Back EMF at 1000 RPM. Rotor detection This function is the recommended choice for applications where the motor starts from standstill, e.g. pumps or conveyors. On some motors, an acoustic sound is heard when the impulse is sent out. This does not harm the motor. Parking This function is the recommended choice for applications where the motor is rotating at slow speed eg. windmilling in fan applications. 2-06 Parking Current and 2-07 Parking Time can be adjusted. Increase the factory setting of these parameters for applications with high inertia. Start the motor at nominal speed. If the application does not run well, check the VVC+ PM settings. Recommendations in different applications can be seen in Table 5.7. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 51 5 5 5 5 Commissioning Operating Instructions Application Settings Low inertia applications ILoad/IMotor <5 1-17 Voltage filter time const. to be increased by factor 5 to 10 1-14 Damping Gain should be reduced 1-66 Min. Current at Low Speed should be reduced (<100%) Low inertia applications 50>ILoad/IMotor >5 Keep calculated values High inertia applications ILoad/IMotor > 50 1-14 Damping Gain, 1-15 Low Speed Filter Time Const. and 1-16 High Speed Filter Time Const. should be increased High load at low speed <30% (rated speed) 1-17 Voltage filter time const. should be increased 1-66 Min. Current at Low Speed should be increased (>100% for a prolonged time can overheat the motor) Table 5.7 Recommendations in Different Applications If the motor starts oscillating at a certain speed, increase 1-14 Damping Gain. Increase the value in small steps. Depending on the motor, a good value for this parameter can be 10% or 100% higher than the default value. Starting torque can be adjusted in 1-66 Min. Current at Low Speed. 100% provides nominal torque as starting torque. 5.4.5 Automatic Energy Optimisation (AEO) AEO is not relevant for permanent magnet motors. Automatic Energy Optimisation (AEO) is a procedure that minimises voltage to the motor, reducing energy consumption, heat, and noise. To activate AEO, set parameter 1-03 Torque Characteristics to [2] Auto Energy Optim. CT or [3] Auto Energy Optim. VT. 5.4.6 Automatic Motor Adaptation (AMA) NOTICE The motor shaft does not turn and no harm is done to the motor while running the AMA. • Some motors may be unable to run the complete version of the test. In that case, select [2] Enable reduced AMA. • If an output filter is connected to the motor, select Enable reduced AMA. • If warnings or alarms occur, see chapter 7 Diagnostics and Troubleshooting. • Run this procedure on a cold motor for best results. To run AMA 1. Press [Main Menu] to access parameters. 2. Scroll to parameter group 1-** Load and Motor and press [OK]. 3. Scroll to parameter group 1-2* Motor Data and press [OK]. 4. Scroll to 1-29 Automatic Motor Adaptation (AMA) and press [OK]. 5. Select [1] Enable complete AMA and press [OK]. 6. Follow on-screen instructions. 7. The test runs automatically and indicate when it is complete. 5.5 Checking Motor Rotation Risk of damage to pumps/compressors caused by motor running in wrong direction. Before running the frequency converter, check the motor rotation. The motor runs briefly at 5 Hz or the minimum frequency set in 4-12 Motor Speed Low Limit [Hz]. 1. Press [Main Menu]. 2. Scroll to 1-28 Motor Rotation Check and press [OK]. 3. Scroll to [1] Enable. The following text appears: Note! Motor may run in wrong direction. 4. Press [OK]. AMA is not relevant for PM motors. Automatic motor adaptation (AMA) is a procedure that optimises compatibility between the frequency converter and the motor. 52 • NOTICE NOTICE • motor characteristics with the data entered in parameters 1-20 to 1-25. The frequency converter builds a mathematical model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the 5. Follow the on-screen instructions. NOTICE To change the direction of rotation, remove power to the frequency converter and wait for power to discharge. Reverse the connection of any 2 of the 3 motor wires on the motor or frequency converter side of the connection. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Commissioning Operating Instructions 5.6 Local-control Test 1. Press [Hand On] to provide a local start command to the frequency converter. 2. Accelerate the frequency converter by pressing [▲] to full speed. Moving the cursor left of the decimal point provides quicker input changes. 3. Note any acceleration problems. 4. Press [Off]. Note any deceleration problems. In the event of acceleration or deceleration problems, see chapter 7.5 Troubleshooting. See chapter 7.3 Warnings and Alarm Definitions - Frequency Converter and chapter 7.4 Warning and Alarm Definitions - Filter (Left LCP) for resetting the frequency converter after a trip. 5 5 5.7 System Start-up The procedure in this section requires user-wiring and application programming to be completed. The following procedure is recommended after application set-up is completed. 1. Press [Auto On]. 2. Apply an external run command. 3. Adjust the speed reference throughout the speed range. 4. Remove the external run command. 5. Check sound and vibration level of the motor to ensure that the system is working as intended. If warnings or alarms occur, see chapter 7.3 Warnings and Alarm Definitions - Frequency Converter. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 53 Application Examples Operating Instructions 6 Application Examples 6.1 Introduction The examples in this section are intended as a quick reference for common applications. FC +24 V 12 +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 NOTICE +10 V A IN 50 When the optional Safe Torque Off feature is used, a jumper wire may be required between terminal 12 (or 13) and terminal 37 for the frequency converter to operate when using factory default programming values. A IN 54 COM 55 A OUT 42 COM 39 Parameter settings are the regional default values unless otherwise indicated (selected in 0-03 Regional Settings). • Parameters associated with the terminals and their settings are shown next to the drawings. • 6 6 Where switch settings for analog terminals A53 or A54 are required, these are also shown. 6.2.1 Speed 130BB926.10 FC +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 +10 V A IN 50 A IN 54 COM 55 A OUT 42 COM 53 39 6-13 Terminal 53 20 mA* High Current 6-15 Terminal 53 50 Hz High Ref./Feedb. Value * = Default Value + Notes/comments: D IN 37 is an option. 4 - 20mA A53 Parameters 12 Setting U-I 6.2 Application Examples +24 V 53 Function 6-12 Terminal 53 4 mA* Low Current 6-14 Terminal 53 0 Hz Low Ref./Feedb. Value Function Setting Parameters 6-10 Terminal 53 0.07 V* Low Voltage 6-11 Terminal 53 10 V* High Voltage 6-14 Terminal 53 0 Hz Low Ref./Feedb. Value 6-15 Terminal 53 50 Hz High Ref./Feedb. Value * = Default Value + Table 6.2 Analog Speed Reference (Current) Notes/comments: D IN 37 is an option. -10 - +10V U-I FC +24 V 12 +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 +10 V A IN 50 A IN 54 COM 55 A OUT 42 COM 39 53 130BB683.10 • 130BB927.10 Parameters Function Setting 6-10 Terminal 53 0.07 V* Low Voltage 6-11 Terminal 53 10 V* High Voltage 6-14 Terminal 53 0 Hz Low Ref./Feedb. Value 6-15 Terminal 53 1500 Hz High Ref./Feedb. Value * = Default Value ≈ 5kΩ Notes/comments: D IN 37 is an option. U-I A53 Table 6.1 Analog Speed Reference (Voltage) A53 Table 6.3 Speed Reference (Using a Manual Potentiometer) 54 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 6.2.2 Start/Stop FC +24 V 12 +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 +10 V A IN 50 A IN 54 COM 55 A OUT 42 COM 39 130BB804.10 Parameters Function Setting 5-10 Terminal 18 [8] Start* Digital Input Parameters FC 5-12 Terminal 27 [19] Freeze Reference Digital Input +24 V 12 +24 V 13 5-13 Terminal 29 [21] Speed Up Digital Input D IN 18 D IN 19 5-14 Terminal 32 [22] Speed Down Digital Input COM 20 D IN 27 * = Default Value D IN 29 Notes/comments: D IN 37 is an option. D IN 32 D IN 33 D IN 37 +10 50 A IN 53 A IN 54 COM 55 A OUT 42 COM 39 53 130BB802.10 Application Examples Function Setting 5-10 Terminal 18 [8] Start* Digital Input 5-12 Terminal 27 [0] No operation Digital Input 5-19 Terminal 37 [1] Safe Stop Alarm Safe Stop * = Default Value Notes/comments: If 5-12 Terminal 27 Digital Input is set to [0] No operation, a jumper wire to terminal 27 is not needed. D IN 37 is an option. 6 6 Speed S peed 130BB840.10 Table 6.4 Speed Up/Down 130BB805.11 Table 6.5 Start/Stop Command with Safe Stop Option Start (18) R efe rence Illustration 6.2 Start/Stop Command with Safe Stop S tart ( 18 ) Freez e ref ( 2 7 ) S peed up ( 29 ) S peed down ( 32 ) Illustration 6.1 Speed Up/Down MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 55 Operating Instructions Parameters Setting FC 5-10 Terminal 18 [9] Latched Start Digital Input +24 V 12 +24 V 13 5-12 Terminal 27 [6] Stop Inverse Digital Input D IN 18 19 D IN 19 COM 20 * = Default Value COM 20 D IN 27 27 D IN 29 D IN 29 D IN 32 Notes/comments: If 5-12 Terminal 27 Digital Input D IN D IN 32 D IN 33 +24 V 12 +24 V 13 D IN 18 D IN is set to [0] No operation, a jumper wire to terminal 27 is not needed. D IN 37 is an option. D IN 33 D IN 37 50 53 +10 V A IN 54 A IN 54 COM 55 COM 55 A OUT 42 A OUT 42 COM 39 COM 39 D IN 37 +10 V 50 A IN A IN 130BB934.10 FC 130BB803.10 Parameters Function 53 Function 5-10 Terminal 18 Digital Input Setting [8] Start 5-11 Terminal 19 Digital Input [10] Reversing* 5-12 Terminal 27 Digital Input [0] No operation 5-14 Terminal 32 Digital Input [16] Preset ref bit 0 5-15 Terminal 33 Digital Input [17] Preset ref bit 1 3-10 Preset Reference Preset ref. Preset ref. Preset ref. Preset ref. 0 1 2 3 25% 50% 75% 100% * = Default Value Notes/comments: D IN 37 is an option. Table 6.6 Pulse Start/Stop 130BB806.10 Speed Table 6.7 Start/Stop with Reversing and 4 Preset Speeds 6.2.3 External Alarm Reset Parameters Latched Start (18) Stop Inverse (27) FC Illustration 6.3 Latched Start/Stop Inverse +24 V 12 +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 +10 V A IN 50 A IN 54 COM 55 A OUT 42 COM 39 130BB928.10 6 6 Application Examples Function Setting 5-11 Terminal 19 [1] Reset Digital Input * = Default Value Notes/comments: D IN 37 is an option. 53 Table 6.8 External Alarm Reset 56 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Application Examples Operating Instructions 6.2.5 Motor Thermistor 130BB685.10 Parameters FC +24 V 12 +24 V 13 D IN 18 D IN 19 COM 20 D IN 27 D IN 29 D IN 32 D IN 33 D IN 37 Function Setting 8-30 Protocol FC* 8-31 Address 1* 8-32 Baud Rate 9600* CAUTION THERMISTOR INSULATION Risk of equipment damage exists. • Use only thermistors with reinforced or double insulation to meet PELV insulation requirements. * = Default Value Notes/comments: Select protocol, address and baud rate in the above mentioned parameters. D IN 37 is an option. Parameters VLT +24 V 12 +24 V 13 130BB686.12 6.2.4 RS-485 Function [2] Thermistor trip [1] Analog input 53 +10 V A IN 50 D IN 18 53 A IN D IN 19 54 COM COM 20 55 1-93 Thermistor Source A OUT 42 D IN 27 * = Default Value COM 39 D IN 29 D IN 32 D IN 33 D IN 37 03 +10 V A IN 50 04 A IN 05 54 COM 55 A OUT 42 COM 39 R2 R1 01 02 RS-485 06 61 68 69 53 Setting 1-90 Motor Thermal Protection 6 6 Notes/comments: If only a warning is desired, 1-90 Motor Thermal Protection should be set to [1] Thermistor warning. D IN 37 is an option. + - Table 6.9 RS-485 Network Connection U-I A53 Table 6.10 Motor Thermistor MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 57 Diagnostics and Troubleshoo... Operating Instructions 7 Diagnostics and Troubleshooting AC Brake When the frequency converter is in status mode, status messages are generated automatically and appear in the bottom line of the display (see Illustration 7.1). AC Brake was selected in 2-10 Brake Function. The AC brake over-magnetises the motor to achieve a controlled slow down. AMA finish OK Automatic motor adaptation (AMA) was carried out successfully. AMA ready AMA is ready to start. Press [Hand On] to start. Status 799RPM 1(1) 36.4kW 7.83A 0.000 53.2% Auto Hand Off 7 7 Remote Local 1 2 130BB037.11 7.1 Status Messages Ramping Stop Running Jogging . . . Stand by 3 AMA running AMA process is in progress. Braking The brake chopper is in operation. The brake resistor absorbs generative energy. Braking max. The brake chopper is in operation. The power limit for the brake resistor has been reached. Coast • Coast inverse was selected as a function for a digital input (parameter group 5–1* Digital Inputs). The corresponding terminal is not connected. • Coast activated by serial communication Ctrl. Ramp-down Control Ramp-down was selected in 14-10 Mains Failure. • The mains voltage is below the value set 1 Operation mode (see Table 7.1) in 14-11 Mains Voltage at Mains Fault at mains fault 2 Reference site (see Table 7.2) 3 Operation status (see Table 7.3) • Illustration 7.1 Status Display Current High The frequency converter ramps down the motor using a controlled ramp down The frequency converter output current is above the limit set in 4-51 Warning Current Table 7.1 to Table 7.3 describe the displayed status messages. Off The frequency converter does not react to any control signal until [Auto On] or [Hand On] is High. Current Low DC Hold Hand On The frequency converter is controlled from the control terminals and/or the serial communication. DC hold is selected in 1-80 Function at Stop and a stop command is active. The motor is held by a DC current set in 2-00 DC Hold/ pressed. Auto On The frequency converter output current is below the limit set in 4-52 Warning Speed Low Preheat Current. DC Stop The motor is held with a DC current (2-01 DC Brake Current) for a specified time (2-02 DC Braking Time). Control the unit via the navigation keys on the LCP. Stop commands, reset, reversing, DC brake, and other signals applied to the control terminals can override local control. • DC brake is activated in 2-03 DC Brake Cut • DC brake (inverse) is selected as a function Table 7.1 Operation Mode Remote Local for a digital input (parameter group 5–1* Digital Inputs). The corresponding terminal is not active. The speed reference is given from external signals, serial communication, or internal preset references. The frequency converter uses [Hand On] control or reference values from the LCP. In Speed [RPM] and a stop command is active. • Feedback high The DC brake is activated via serial communication. The sum of all active feedbacks is above the feedback limit set in 4-57 Warning Feedback High. Table 7.2 Reference Site Feedback low The sum of all active feedbacks is below the feedback limit set in 4-56 Warning Feedback Low. 58 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Freeze output Operating Instructions The remote reference is active, which holds the present speed. • Freeze output was selected as a function Protection md for a digital input (parameter group 5–1* Digital Inputs). The corresponding terminal is active. Speed control is only possible via the terminal functions Speed Up and Speed Down. • Hold ramp is activated via serial communication. Freeze output request A freeze output command has been given, but the motor remains stopped until a run permissive signal is received. Freeze ref. Freeze Reference was selected as a function for QStop Protection mode is active. The unit has detected a critical status (an overcurrent or overvoltage). • To avoid tripping, the switching frequency is reduced to 4 kHz. • If possible, protection mode ends after approximately 10 s. • Protection mode can be restricted in The motor is decelerating using 3-81 Quick Stop Ramp Time. • Jog request Jogging A jog command has been given, but the motor remains stopped until a run permissive signal is received via a digital input. • Motor check OVC control Ramping Ref. high • The jog function is activated via the serial communication. • The jog function was selected as a reaction for a monitoring function. The monitoring function is active. In 1-80 Function at Stop, Motor Check was selected. A stop command is active. To ensure that a motor is connected to the frequency converter, a permanent test current is applied to the motor. Overvoltage control was activated in 2-17 Over- (Only frequency converters with an external 24 V power supply installed). Mains supply to the frequency converter is removed, but the control card is supplied by the external 24 V. The sum of all active references is above the The sum of all active references is below the reference limit set in 4-54 Warning Reference Low. Run on ref. The frequency converter is running in the reference range. The feedback value matches the setpoint value. Run request A start command has been given, but the motor is stopped until a run permissive signal is received via digital input. Running The frequency converter drives the motor. Sleep Mode The energy saving function is enabled. The motor has stopped, but restarts automatically when required. Speed high Motor speed is above the value set in 4-53 Warning Speed High. Speed low Motor speed is below the value set in 4-52 Warning Speed Low. Standby In Auto On mode, the frequency converter starts the motor with a start signal from a digital input or serial communication. Start delay In 1-71 Start Delay, a delay starting time was set. A start command is activated and the motor starts after the start delay time expires. Start fwd/rev Start forward and start reverse were selected as functions for 2 different digital inputs (parameter group 5–1* Digital Inputs). The motor starts in forward or reverse depending on which corresponding terminal is activated. Stop MG21B202 7 7 The motor is accelerating/decelerating using the active ramp up/down. The reference, a limit value, or a standstill is not yet reached. High. Jog was selected as function for a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal is active. The quick stop function was activated via serial communication. reference limit set in 4-55 Warning Reference Ref. low voltage Control, [2] Enabled. The connected motor supplies the frequency converter with generative energy. The overvoltage control adjusts the V/Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping. PowerUnit Off • The motor is running as programmed in 3-19 Jog Speed [RPM]. Quick stop inverse was selected as a function for a digital input (parameter group 5–1* Digital Inputs). The corresponding terminal is not active. a digital input (parameter group 5-1* Digital Inputs). The corresponding terminal is active. The frequency converter saves the actual reference. Changing the reference is now only possible via terminal functions speed up and speed down. 14-26 Trip Delay at Inverter Fault. The frequency converter has received a stop command from the LCP, digital input, or serial communication. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 59 An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, the frequency converter can be reset manually by pressing [Reset] or remotely by control terminals or serial communication. Trip lock An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, power must be cycled to the frequency converter. The frequency converter can then be reset manually by pressing [Reset] or remotely by control terminals or serial communication. Table 7.3 Operation Status NOTICE In auto/remote mode, the frequency converter requires external commands to execute functions. 7.2 Warning and Alarm Types A trip can be reset in any of 4 ways: • • • • Press [Reset] on the LCP Digital reset input command Serial communication reset input command Auto reset 7.2.3 Alarm Trip-lock An alarm that causes the frequency converter to trip-lock requires that input power is cycled. The motor coasts to a stop. The frequency converter logic continues to operate and monitors the frequency converter status. Remove input power to the frequency converter and correct the cause of the fault, then restore power. This action puts the frequency converter into a trip condition as described in chapter 7.2.2 Alarm Trip and may be reset in any of the 4 ways. The frequency converter monitors the condition of its input power, output, and motor factors as well as other system performance indicators. A warning or alarm does not necessarily indicate a problem internal to the frequency converter itself. In many cases, it indicates failure conditions from: • • • • • Status 0.0Hz 0.000psi 0.0Hz 1:0 - Off !1(1) 0.00A !Live zero error [W2] Off Remote Stop input voltage Illustration 7.2 Warning Display motor load motor temperature external signals other areas monitored by internal logic An alarm or trip-lock alarm flashes in the display along with the alarm number. Investigate as indicated in the alarm or warning. Status 0.0Hz 7.2.1 Warnings A warning is issued when an alarm condition is impending or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm. A warning clears by itself when the abnormal condition is removed. 7.2.2 Alarm Trip An alarm is issued when the frequency converter is tripped, that is, the frequency converter suspends operation to prevent frequency converter or system damage. The motor coasts to a stop. The frequency converter logic continues to operate and monitors the frequency converter status. After the fault condition is remedied, reset the frequency converter. It is then ready to start operation again. 60 130BP085.11 Trip Operating Instructions 0.000kW 0.0Hz 0 1(1) 0.00A 130BP086.11 7 7 Diagnostics and Troubleshoo... Earth Fault [A14] Auto Remote Trip Illustration 7.3 Alarm Display In addition to the text and alarm code in the display, there are 3 status indicator lights. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 2 Ba ck el nc Ca Info On 130BB467.11 130BD812.10 Diagnostics and Troubleshoo... OK Warn. • Check that the frequency converter programming and switch settings match the analog signal type. • Perform input terminal signal test. WARNING/ALARM 3, No motor No motor has been connected to the output of the frequency converter. WARNING/ALARM 4, Mains phase loss A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectifier on the frequency converter. Options are programmed at 14-12 Function at Mains Imbalance. Alarm Illustration 7.4 Status Indicator Lights Warning LED Alarm LED Warning On Off Alarm Off On (Flashing) Trip-Lock On On (Flashing) Table 7.4 Status Indicator Lights Explanations 7.3 Warnings and Alarm Definitions Frequency Converter The warning/alarm information below defines each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure. WARNING 1, 10 Volts low The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω. A short circuit in a connected potentiometer or improper wiring of the potentiometer can cause this condition. Troubleshooting • Remove the wiring from terminal 50. If the warning clears, the problem is with the wiring. If the warning does not clear, replace the control card. WARNING/ALARM 2, Live zero error This warning or alarm only appears if programmed in 6-01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. Broken wiring or faulty device sending the signal can cause this condition. Troubleshooting • Check connections on all the analog input terminals. Control card terminals 53 and 54 for signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals, terminal 10 common. MCB MG21B202 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common). Troubleshooting • Check the supply voltage and supply currents to the frequency converter. WARNING 5, DC link voltage high The intermediate circuit voltage (DC) is higher than the high-voltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active. WARNING 6, DC link voltage low The intermediate circuit voltage (DC) is lower than the lowvoltage warning limit. The limit is dependent on the frequency converter voltage rating. The unit is still active. WARNING/ALARM 7, DC overvoltage If the intermediate circuit voltage exceeds the limit, the frequency converter trips after a time. Troubleshooting • Connect a brake resistor • • • • • Extend the ramp time Change the ramp type Activate the functions in 2-10 Brake Function Increase 14-26 Trip Delay at Inverter Fault If the alarm/warning occurs during a power sag, use kinetic back-up (14-10 Mains Failure) WARNING/ALARM 8, DC under voltage If the DC-link voltage drops below the undervoltage limit, the frequency converter checks if a 24 V DC backup supply is connected. If no 24 V DC backup supply is connected, the frequency converter trips after a fixed time delay. The time delay varies with unit size. Troubleshooting • Check that the supply voltage matches the frequency converter voltage. • • Perform input voltage test. Perform soft charge circuit test. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 61 7 7 Diagnostics and Troubleshoo... Operating Instructions WARNING/ALARM 9, Inverter overload The frequency converter is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal inverter protection issues a warning at 98% and trips at 100%, while giving an alarm. The frequency converter cannot be reset until the counter is below 90%. The fault is that the frequency converter has run with more than 100% overload for too long. Troubleshooting • Compare the output current shown on the LCP with the frequency converter rated current. • Compare the output current shown on the LCP with measured motor current. • Display the thermal drive load on the LCP and monitor the value. When running above the frequency converter continuous current rating, the counter increases. When running below the frequency converter continuous current rating, the counter decreases. 7 7 WARNING/ALARM 10, Motor overload temperature According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter issues a warning or an alarm when the counter reaches 100% in 1-90 Motor Thermal Protection. The fault occurs when the motor runs with more than 100% overload for too long. Troubleshooting • Check for motor overheating. • • Check if the motor is mechanically overloaded Check that the motor current set in 1-24 Motor Current is correct. • Ensure that Motor data in parameters 1-20 to 1-25 are set correctly. • If an external fan is in use, check in 1-91 Motor External Fan that it is selected. • Running AMA in 1-29 Automatic Motor Adaptation (AMA) tunes the frequency converter to the motor more accurately and reduces thermal loading. WARNING/ALARM 11, Motor thermistor over temp The thermistor might be disconnected. Select whether the frequency converter issues a warning or an alarm in 1-90 Motor Thermal Protection. Troubleshooting • Check for motor overheating. • • 62 Check if the motor is mechanically overloaded. Check that the thermistor is connected correctly between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply). Also check that the terminal switch for 53 or 54 is set for voltage. Check that 1-93 Thermistor Resource selects terminal 53 or 54. • When using digital inputs 18 or 19, check that the thermistor is connected correctly between either terminal 18 or 19 (digital input PNP only) and terminal 50. • If a KTY sensor is used, check for correct connection between terminals 54 and 55 • If using a thermal switch or thermistor, check that the programming of 1-93 Thermistor Resource matches sensor wiring. • If using a KTY Sensor, check the programming of 1-95 KTY Sensor Type, 1-96 KTY Thermistor Resource and 1-97 KTY Threshold level match sensor wiring. WARNING/ALARM 12, Torque limit The torque has exceeded the value in 4-16 Torque Limit Motor Mode or the value in 4-17 Torque Limit Generator Mode. 14-25 Trip Delay at Torque Limit can change this warning from a warning-only condition to a warning followed by an alarm. Troubleshooting • If the motor torque limit is exceeded during ramp up, extend the ramp up time. • If the generator torque limit is exceeded during ramp down, extend the ramp down time. • If torque limit occurs while running, possibly increase the torque limit. Make sure that the system can operate safely at a higher torque. • Check the application for excessive current draw on the motor. WARNING/ALARM 13, Over current The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts about 1.5 s, then the frequency converter trips and issues an alarm. Shock loading or quick acceleration with high inertia loads can cause this fault. If the acceleration during ramp up is quick, the fault can also appear after kinetic back-up. If extended mechanical brake control is selected, trip can be reset externally. Troubleshooting • Remove power and check if the motor shaft can be turned. • Check that the motor size matches the frequency converter. • Check parameters 1-20 to 1-25 for correct motor data. ALARM 14, Earth (ground) fault There is current from the output phases to ground, either in the cable between the frequency converter and the motor or in the motor itself. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions Troubleshooting • Remove power to the frequency converter and repair the ground fault. • Check for ground faults in the motor by measuring the resistance to the ground of the motor cables and the motor with a megohmmeter. • Perform current sensor test. ALARM 15, Hardware mismatch A fitted option is not operational with the present control board hardware or software. Record the value of the following parameters and contact Danfoss: • • • • • • • • • Troubleshooting • Check fan resistance. • Check soft charge fuses. WARNING 24, External fan fault The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled). Troubleshooting • Check fan resistance. • 15-40 FC Type Check soft charge fuses. WARNING 25, Brake resistor short circuit The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still operational, but without the brake function. 15-41 Power Section 15-42 Voltage 15-43 Software Version 15-45 Actual Typecode String Troubleshooting • Remove power to the frequency converter and replace the brake resistor (see 2-15 Brake Check). 15-49 SW ID Control Card 15-50 SW ID Power Card 15-60 Option Mounted 15-61 Option SW Version (for each option slot) ALARM 16, Short circuit There is short-circuiting in the motor or motor wiring. Remove power to the frequency converter and repair the short circuit. WARNING/ALARM 17, Control word timeout There is no communication to the frequency converter. The warning is only active when 8-04 Control Word Timeout Function is not set to [0] Off. If 8-04 Control Word Timeout Function is set to [2] Stop and [26] Trip, a warning appears and the frequency converter ramps down until it trips and then displays an alarm. Troubleshooting: • Check connections on the serial communication cable. • • Increase 8-03 Control Word Timeout Time • Verify a proper installation based on EMC requirements. Check the operation of the communication equipment. WARNING/ALARM 22, Hoist mechanical brake Report value shows what kind it is. 0 = The torque ref. was not reached before time out (2-27 Torque Ramp Time). 1 = Expected brake feedback not received before time out (2-23 Activate Brake Delay, 2-25 Brake Release Time). MG21B202 WARNING 23, Internal fan fault The fan warning function is an extra protective function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor ([0] Disabled). WARNING/ALARM 26, Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2-16 AC brake Max. Current. The warning is active when the dissipated braking is higher than 90% of the brake resistance power. If [2] Trip is selected in 2-13 Brake Power Monitoring, the frequency converter trips when the dissipated braking power reaches 100%. WARNING If the brake transistor is short-circuited, there is a risk of substantial power being transmitted to the brake resistor. WARNING/ALARM 27, Brake chopper fault The brake transistor is monitored during operation and if a short circuit occurs, the brake function is disabled and a warning is issued. The frequency converter is still operational, but since the brake transistor has shortcircuited, substantial power is transmitted to the brake resistor, even if it is inactive. Remove power to the frequency converter and remove the brake resistor. This alarm/warning could also occur if the brake resistor overheats. Terminals 104 and 106 are available as brake resistors Klixon inputs. WARNING/ALARM 28, Brake check failed The brake resistor is not connected or not working. Check 2-15 Brake Check. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 63 7 7 7 7 Diagnostics and Troubleshoo... Operating Instructions ALARM 29, Heat Sink temp The maximum temperature of the heat sink has been exceeded. The temperature fault resets when the temperature falls below a defined heat sink temperature. The trip and reset points are different based on the frequency converter power size. Troubleshooting Check for the following conditions. • Ambient temperature too high. • • • • • Motor cables too long. Incorrect airflow clearance above and below the frequency converter Blocked airflow around the frequency converter. Damaged heat sink fan. Troubleshooting • Cycle power • • Check that the option is properly installed Check for loose or missing wiring It may be necessary to contact Danfoss service or the supplier. Note the code number for further troubleshooting directions. No. 0 256–258 Dirty heat sink. For the D, E, and F enclosures, this alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules. For the F enclosures, the thermal sensor in the rectifier module can also cause this alarm. Troubleshooting • Check fan resistance. • • ALARM 38, Internal fault When an internal fault occurs, a code number defined in Table 7.5 is displayed. Check soft charge fuses. IGBT thermal sensor. ALARM 30, Motor phase U missing Motor phase U between the frequency converter and the motor is missing. Remove power from the frequency converter and check motor phase U. Text Serial port cannot be initialised. Contact your Danfoss supplier or Danfoss Service Department. Power EEPROM data is defective or too old 512 Control board EEPROM data is defective or too old. 513 Communication time-out reading EEPROM data 514 Communication time-out reading EEPROM data 515 Application-oriented control cannot recognise the EEPROM data. 516 Cannot write to the EEPROM because a write command is on progress. 517 Write command is under time-out 518 Failure in the EEPROM 519 Missing or invalid barcode data in EEPROM 783 1024–1279 Parameter value outside of min/max limits A CAN telegram that has to be sent could not be sent. 1281 Digital signal processor flash time-out 1282 Power micro software version mismatch 1283 Power EEPROM data version mismatch 1284 Cannot read digital signal processor software version Remove power from the frequency converter and check motor phase V. 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old ALARM 32, Motor phase W missing Motor phase W between the frequency converter and the motor is missing. 1301 Option SW in slot C0 is too old 1302 Option SW in slot C1 is too old 1315 Option SW in slot A is not supported (not allowed) 1316 Option SW in slot B is not supported (not allowed) 1317 Option SW in slot C0 is not supported (not allowed) 1318 Option SW in slot C1 is not supported (not allowed) 1379 Option A did not respond when calculating platform version 1380 Option B did not respond when calculating platform version 1381 Option C0 did not respond when calculating platform version. 1382 Option C1 did not respond when calculating platform version. 1536 An exception in the application-oriented control is registered. Debug information written in LCP. ALARM 31, Motor phase V missing Motor phase V between the frequency converter and the motor is missing. Remove power from the frequency converter and check motor phase W. ALARM 33, Inrush fault Too many power-ups have occurred within a short time period. Let the unit cool to operating temperature. WARNING/ALARM 34, Fieldbus communication fault The fieldbus on the communication option card is not working. WARNING/ALARM 36, Mains failure This warning/alarm is only active if the supply voltage to the frequency converter is lost and 14-10 Mains Failure is not set to [0] No Function. Check the fuses to the frequency converter and mains supply to the unit. 64 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions No. Text 1792 DSP Watch Dog is active. Debugging of power part data, motor-oriented control data not transferred correctly. 2049 Power data restarted 2064–2072 H081x: Option in slot x has restarted 2080–2088 H082x: Option in slot x has issued a powerup-wait 2096–2104 H983x: Option in slot x has issued a legal powerup-wait 2304 Could not read any data from power EEPROM 2305 Missing SW version from power unit 2314 Missing power unit data from power unit 2315 Missing SW version from power unit 2316 Missing lo_statepage from power unit 2324 Power card configuration is determined to be incorrect at power-up 2325 A power card has stopped communicating while main power is applied 2326 Power card configuration is determined to be incorrect after the delay for power cards to register. WARNING 40, Overload of digital output terminal 27 Check the load connected to terminal 27 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-01 Terminal 27 Mode. WARNING 41, Overload of digital output terminal 29 Check the load connected to terminal 29 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-02 Terminal 29 Mode. WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7 For X30/6, check the load connected to X30/6 or remove the short-circuit connection. Check 5-32 Term X30/6 Digi Out (MCB 101). For X30/7, check the load connected to X30/7 or remove the short-circuit connection. Check 5-33 Term X30/7 Digi Out (MCB 101). 7 7 ALARM 45, Earth fault 2 Ground fault. Troubleshooting • Check for proper grounding and loose connections. 2327 Too many power card locations have been registered as present. 2330 Power size information between the power cards does not match. 2561 No communication from DSP to ATACD 2562 No communication from ATACD to DSP (state running) ALARM 46, Power card supply The supply on the power card is out of range. 2816 Stack overflow control board module 2817 Scheduler slow tasks 2818 Fast tasks 2819 Parameter thread 2820 LCP stack overflow 2821 Serial port overflow There are 3 power supplies generated by the switch mode power supply (SMPS) on the power card: 24 V, 5 V, ±18 V. When powered with 24 V DC with the MCB 107 option, only the 24 V and 5 V supplies are monitored. When powered with 3 phase mains voltage, all 3 supplies are monitored. 2822 USB port overflow 2836 cfListMempool too small 3072–5122 Parameter value is outside its limits 5123 Option in slot A: Hardware incompatible with control board hardware 5124 Option in slot B: Hardware incompatible with control board hardware. 5125 Option in slot C0: Hardware incompatible with control board hardware. 5126 Option in slot C1: Hardware incompatible with control board hardware. 5376–6231 Out of memory Table 7.5 Internal Fault, Code Numbers ALARM 39, Heat Sink sensor No feedback from the heat sink temperature sensor. The signal from the IGBT thermal sensor is not available on the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card. MG21B202 • • Check for proper wire size. Check motor cables for short-circuits or leakage currents. WARNING 47, 24 V supply low The 24 V DC is measured on the control card. This alarm arises when the detected voltage of terminal 12 is lower than 18 V. Troubleshooting • Check for a defective control card. WARNING 48, 1.8 V supply low The 1.8 V DC supply used on the control card is outside of allowable limits. The power supply is measured on the control card. Check for a defective control card. If an option card is present, check for an overvoltage condition. WARNING 49, Speed limit When the speed is not within the specified range in 4-11 Motor Speed Low Limit [RPM] and 4-13 Motor Speed High Limit [RPM], the frequency converter shows a warning. When the speed is below the specified limit in 1-86 Trip Speed Low [RPM] (except when starting or stopping), the frequency converter trips. ALARM 50, AMA calibration failed Contact Danfoss supplier or Danfoss service department. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 65 7 7 Diagnostics and Troubleshoo... Operating Instructions ALARM 51, AMA check Unom and Inom The settings for motor voltage, motor current and motor power are wrong. Check the settings in parameters 1-20 to 1-25. ALARM 52, AMA low Inom The motor current is too low. Check the settings. ALARM 53, AMA motor too big The motor is too big for the AMA to operate. ALARM 54, AMA motor too small The motor is too small for the AMA to operate. ALARM 55, AMA parameter out of range The parameter values of the motor are outside of the acceptable range. AMA cannot run. ALARM 56, AMA interrupted by user The user has interrupted the AMA. ALARM 57, AMA internal fault Try to restart AMA again a number of times, until the AMA is carried out. NOTICE Repeated runs may heat the motor to a level where the resistance Rs and Rr are increased. In most cases, however, this behaviour is not critical. ALARM 58, AMA Internal fault Contact the Danfoss supplier. WARNING 59, Current limit The current is higher than the value in 4-18 Current Limit. Ensure that motor data in parameters 1–20 to 1–25 are set correctly. Possibly increase the current limit. Be sure that the system can operate safely at a higher limit. WARNING 60, External interlock External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter (via serial communication, digital I/O, or by pressing [Reset]). WARNING/ALARM 61, Tracking error An error between calculated motor speed and speed measurement from feedback device. The function warning/ alarm/disable is set in 4-30 Motor Feedback Loss Function. Accepted error setting in 4-31 Motor Feedback Speed Error and the allowed time the error occur setting in 4-32 Motor Feedback Loss Timeout. During a commissioning procedure, the function could be effective. WARNING 62, Output frequency at maximum limit The output frequency is higher than the value set in 4-19 Max Output Frequency. ALARM 63, Mechanical brake low The actual motor current has not exceeded the release brake current within the start delay time window. ALARM 64, Voltage Limit The load and speed combination demands a motor voltage higher than the actual DC-link voltage. 66 WARNING/ALARM 65, Control card over temperature The cut-out temperature of the control card is 80 °C. Troubleshooting • Check that the ambient operating temperature is within limits • • • Check for clogged filters Check fan operation Check the control card WARNING 66, Heat sink temperature low The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module. Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the frequency converter whenever the motor is stopped by setting 2-00 DC Hold/Preheat Current at 5% and 1-80 Function at Stop Troubleshooting The heat sink temperature measured as 0 °C could indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is disconnected, this warning would result. Also, check the IGBT thermal sensor. ALARM 67, Option module configuration has changed One or more options have either been added or removed since the last power-down. Check that the configuration change is intentional and reset the unit. ALARM 68, Safe Stop activated Safe Torque Off has been activated. To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset]. ALARM 69, Power card temperature The temperature sensor on the power card is either too hot or too cold. Troubleshooting • Check the operation of the door fans. • Check that the filters for the door fans are not blocked. • Check that the gland plate is properly installed on IP21/IP 54 (NEMA 1/12) frequency converters. ALARM 70, Illegal FC configuration The control card and power card are incompatible. To check compatibility, contact the Danfoss supplier with the type code of the unit from the nameplate and the part numbers of the cards. ALARM 71, PTC 1 Safe Torque Off Safe Torque Off has been activated from the VLT® PTC Thermistor Card MCB 112 (motor too warm). Normal operation can resume when the VLT® PTC Thermistor Card MCB 112 applies 24 V DC to T-37 (when the motor temperature is acceptable ) and when the digital input Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions from the VLT® PTC Thermistor Card MCB 112 is deactivated. When that happens, a reset signal must be is be sent (via Bus, Digital I/O, or by pressing [Reset]). Note that if automatic restart is enabled, the motor could start when the fault is cleared. ALARM 72, Dangerous failure Safe Torque Off with trip lock. Unexpected signal levels on safe stop and digital input from the VLT® PTC Thermistor Card MCB 112. WARNING 73, Safe Stop auto restart Safe stopped. With automatic restart enabled, the motor could start when the fault is cleared. WARNING 76, Power unit setup The required number of power units does not match the detected number of active power units. WARNING 77, Reduced power mode The frequency converter is operating in reduced power mode (less than the allowed number of inverter sections). This warning is generated on power cycle when the frequency converter is set to run with fewer inverters, and remains on. ALARM 79, Illegal power section configuration The scaling card has an incorrect part number or is not installed. The MK102 connector on the power card could not be installed. ALARM 80, Drive initialised to default value Parameter settings are initialised to default settings after a manual reset. To clear the alarm, reset the unit. 2 = second frequency converter from the left inverter module in F14 frame size. 3 = right inverter module in F12 or F13 frame sizes. 3 = third from the left intverter module in F14 frame size. 4 = far right inverter module in F14 frame size. 5 = rectifier module. 6 = right rectifier module in F14 frame size. ALARM 244, Heat Sink temperature This alarm is only for F-frame frequency converters. It is equivalent to Alarm 29. The report value in the alarm log indicates which power module generated the alarm. 1 = left most inverter module. 2 = middle inverter module in F12 or F3 frame sizes. 2 = right inverter module in F10 or F11 frame sizes. 2 = second frequency converter from the left inverter module in F14 frame size. 3 = right inverter module in F12 or F13 frame sizes. 3 = third from the left intverter module in F14 frame size. 4 = far right inverter module in F14 frame size. 5 = rectifier module. ALARM 81, CSIV corrupt CSIV file has syntax errors. 6 = right rectifier module in F14 frame size. ALARM 82, CSIV parameter error CSIV failed to init a parameter. ALARM 245, Heat Sink sensor This alarm is only for F-frame frequency converters. It is equivalent to Alarm 39. The report value in the alarm log indicates which power module generated the alarm ALARM 85, Dang fail PB Profibus/Profisafe error. WARNING/ALARM 104, Mixing fan fault The fan is not operating. The fan monitor checks that the fan is spinning at power-up or whenever the mixing fan is turned on. The mixing-fan fault can be configured as a warning or an alarm trip by 14-53 Fan Monitor. Troubleshooting • Cycle power to the frequency converter to determine if the warning/alarm returns. ALARM 243, Brake IGBT This alarm is only for F-frame frequency converters. It is equivalent to Alarm 27. The report value in the alarm log indicates which power module generated the alarm: 1 = left most inverter module. 2 = middle inverter module in F12 or F13 frame sizes. 2 = right inverter module in F10 or F11 frame sizes. 2 = second frequency converter from the left inverter module in F14 frame size. 3 = right inverter module in F12 or F13 frame sizes. 3 = third from the left inverter module in F14 frame size. 1 = left most inverter module. 4 = far right inverter module in F14 frame size. 2 = middle inverter module in F12 or F3 frame sizes. 5 = rectifier module. 2 = right inverter module in F10 or F11 frame sizes. MG21B202 7 7 6 = right rectifier module in F14 frame size. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 67 Diagnostics and Troubleshoo... Operating Instructions ALARM 246, Power card supply This alarm is only for F-frame frequency converter. It is equivalent to Alarm 46. The report value in the alarm log indicates which power module generated the alarm 3 = third from the left inverter module in F14 frame size. 1 = left most inverter module. 4 = far right inverter module in F14 frame size. 2 = middle inverter module in F12 or F13 frame sizes. 5 = rectifier module. 2 = right inverter module in F10 or F11 frame sizes. 2 = second frequency converter from the left inverter module in F14 frame size. 3 = right inverter module in F12 or F13 frame sizes. 3 = third from the left inverter module in F14 frame size. 7 7 3 = right inverter module in F12 or F13 frame sizes. 6 = right rectifier module in F14 frame size. WARNING 250, New spare part A component in the frequency converter has been replaced. Reset the frequency converter for normal operation. WARNING 251, New typecode The power card or other components have been replaced and the typecode changed. Reset to remove the warning and resume normal operation. 4 = far right inverter module in F14 frame size. 5 = rectifier module. 6 = right rectifier module in F14 frame size. ALARM 247, Power card temperature This alarm is only for F-frame frequency converters. It is equivalent to Alarm 69. The report value in the alarm log indicates which power module generated the alarm 1 = left most inverter module. 2 = middle inverter module in F12 or F13 frame sizes. 2 = right inverter module in F10 or F11 frame sizes. 2 = second frequency converter from the left inverter module in F14 frame size. 3 = right inverter module in F12 or F13 frame sizes. 3 = third from the left inverter module in F14 frame size. 4 = far right inverter module in F14 frame size. 5 = rectifier module. 6 = right rectifier module in F14 frame size. ALARM 248, Illegal power section configuration This alarm is only for F-frame frequency converters. It is equivalent to Alarm 79. The report value in the alarm log indicates which power module generated the alarm: 1 = left most inverter module. 2 = middle inverter module in F12 or F13 frame sizes. 2 = right inverter module in F10 or F11 frame sizes. 2 = second frequency converter from the left inverter module in F14 frame size. 68 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions 7.4 Warning and Alarm Definitions - Filter (Left LCP) NOTICE This section covers warnings and alarms on the filter side LCP. For warning and alarms for the frequency converter, see chapter 7.3 Warnings and Alarm Definitions - Frequency Converter A warning or an alarm is signalled by the relevant LED on the front of the filter and indicated by a code on the display. A warning remains active until its cause is no longer present. Under certain circumstances operation of the unit may still be continued. Warning messages may be critical, but are not necessarily so. In the event of an alarm, the unit has tripped. To restart operation, reset the rectified alarms. This may be done in 4 ways: 1. By pressing [Reset]. 2. Via a digital input with the Reset function. 3. Via serial communication/optional fieldbus. 4. By resetting automatically using the [Auto Reset] function. 7 7 NOTICE After a manual reset pressing [Reset], press [Auto On] or [Hand On] to restart the unit. If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked (see also Table 7.6). Alarms that are trip-locked offer additional protection, meaning that the mains supply must be switched off before the alarm can be reset. After being switched back on, the unit is no longer blocked and may be reset as described above once the cause has been rectified. Alarms that are not trip-locked can also be reset using the automatic reset function in 14-20 Reset Mode (Warning: automatic wake-up is possible) If a warning and alarm is marked against a code in Table 7.6, either a warning occurs before an alarm, or it can be specified whether it is a warning or an alarm that is to be displayed for a given fault. No. Description Warning 1 10 Volts low X 2 Live zero error (X) 4 Mains phase loss X 5 DC link voltage high X 6 DC link voltage low X 7 DC over voltage X X 8 DC under voltage X X 13 Over current X X X 14 Earth fault X X X 15 Hardware mismatch X X 16 Short circuit X X 17 Control word timeout (X) 23 Internal fan fault X 24 External fan fault X 29 Heatsink temp X 33 Inrush fault 34 Fieldbus fault MG21B202 X Alarm/Trip Alarm/Trip Lock (X) Parameter Reference 6-01 (X) 8-04 14-53 X X X X X Danfoss A/S © Rev. 2014-01-22 All rights reserved. 69 7 7 Diagnostics and Troubleshoo... Operating Instructions No. Description Warning Alarm/Trip 35 Option fault X X 38 Internal fault 39 Heatsink sensor 40 Overload of digital output terminal 27 (X) 41 Overload of digital output terminal 29 (X) 46 Pwr. card supply 47 24 V supply low 48 1.8 V supply low 65 Control board over-temperature X 66 Heat sink temperature low X 67 Option configuration has changed X 68 Safe torque off activated X1) 69 Pwr. card temp X 70 Illegal FC configuration X 72 Dangerous Failure X1) 73 Safe torque off auto restart 76 Power unit setup 79 Illegal PS config X 80 Unit initialised to default value X 244 Heatsink temp X X 245 Heatsink sensor X X 246 Pwr.card supply X X 247 Pwr.card temp X X 248 Illegal PS config X X 250 New spare part 251 New type code 300 Mains cont. fault X 301 SC cont. fault X 302 Cap. over current X X 303 Cap. earth fault X X 304 DC over current X X 305 Mains freq. limit 308 Resistor temp X 309 Mains earth fault X 311 Switch. freq. limit X 312 CT range X 314 Auto CT interrupt X 315 Auto CT error 316 CT location error X 317 CT polarity error X 318 CT ratio error X X X Alarm/Trip Lock Parameter Reference X 5-00, 5-01 5-00, 5-02 X X X X X X X X X X X X X X X X X X X Table 7.6 Alarm/Warning Code List A trip is the action when an alarm has appeared. The trip coasts the motor and can be reset by pressing [Reset] or make a reset by a digital input (parameter group 5-1* Digital Inputs [1] Reset). The origin event that caused an alarm cannot damage the frequency converter or cause dangerous conditions. A trip lock is an action when an alarm occurs, which may cause damage to frequency converter or connected parts. A Trip Lock situation can only be reset by a power cycling. Warning yellow Alarm flashing red Trip locked yellow and red Table 7.7 LED Indicator Lights 70 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions Alarm Word and Extended Status Word Bit Hex 0 00000001 1 00000002 2 Dec Alarm Word Warning Word Extended Status Word 1 Mains cont. fault Reserved Reserved 2 Heatsink temp Heatsink temp Auto CT running 00000004 4 Ground fault Ground fault Reserved 3 00000008 8 Ctrl.card temp Ctrl.card temp Reserved 4 00000010 16 Ctrl. word TO Ctrl. word TO Reserved 5 00000020 32 Over current Over current Reserved 6 00000040 64 SC cont. fault Reserved Reserved 7 00000080 128 Cap. over current Cap. over current Reserved 8 00000100 256 Cap. earth fault Cap. earth fault Reserved 9 00000200 512 Inverter overld. Inverter overld. Reserved 10 00000400 1024 DC under volt DC under volt Reserved 11 00000800 2048 DC over volt DC over volt Reserved 12 00001000 4096 Short circuit DC voltage low Reserved 13 00002000 8192 Inrush fault DC voltage high Reserved 14 00004000 16384 Mains ph. loss Mains ph. loss Reserved 15 00008000 32768 Auto CT error Reserved Reserved 16 00010000 65536 Reserved Reserved Reserved 17 00020000 131072 Internal fault 10V low Password Time Lock 18 00040000 262144 DC over current DC over current Password Protection 19 00080000 524288 Resistor temp Resistor temp Reserved 20 00100000 1048576 Mains earth fault Mains earth fault Reserved 21 00200000 2097152 Switch. freq. limit Reserved Reserved 22 00400000 4194304 Fieldbus fault Fieldbus fault Reserved 23 00800000 8388608 24 V supply low 24V supply low Reserved 24 01000000 16777216 CT range Reserved Reserved 25 02000000 33554432 1.8V supply low Reserved Reserved 26 04000000 67108864 Reserved Low temp Reserved 27 08000000 134217728 Auto CT interrupt Reserved Reserved 28 10000000 268435456 Option change Reserved Reserved 29 20000000 536870912 Unit initialized Unit initialized Reserved 30 40000000 1073741824 Safe torque off Safe torque off Reserved 31 80000000 2147483648 Mains freq. limit Extended status word Reserved 7 7 Table 7.8 Description of Alarm Word, Warning Word and Extended Status Word The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnosis. See also 16-90 Alarm Word, 16-92 Warning Word and 16-94 Ext. Status Word. Reserved means that the bit is not guaranteed to be any particular value. Reserved bits should not be used for any purpose. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 71 7 7 Diagnostics and Troubleshoo... Operating Instructions 7.4.1 Fault Messages for Active Filter WARNING 1, 10 volts low The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω. Fault messages - active filter WARNING 24, External fan fault External fans have failed due to defect hardware or fans not mounted. ALARM 29, Heat sink temp The maximum temperature of the heat sink has been exceeded. The temperature fault is not reset until the temperature falls below a defined heat sink temperature. WARNING/ALARM 2, Live zero error The signal on terminal 53 or 54 is less than 50% of the value set in parameters 6-10, 6-12, 6-20 or 6-22. ALARM 33, Inrush fault Check whether a 24 V external DC supply has been connected. WARNING 4, Mains phase loss A phase is missing on the supply side, or the mains voltage imbalance is too high. WARNING/ALARM 34, Fieldbus communication fault The fieldbus on the communication option card is not working. WARNING 5, DC link voltage high The intermediate circuit voltage (DC) is higher than the high-voltage warning limit. The unit is still active. WARNING/ALARM 35, Option Fault: Contact Danfoss or supplier. WARNING 6, DC link voltage low The intermediate circuit voltage (DC) is below the undervoltage limit of the control system. The unit is still active. WARNING/ALARM 7, DC overvoltage If the intermediate circuit voltage exceeds the limit, the unit trips. WARNING/ALARM 8, DC under voltage If the intermediate circuit voltage (DC) drops below the under voltage limit, the filter checks if a 24 V back-up supply is connected. If not, the unit trips. Check that the mains voltage matches the nameplate specification. WARNING/ALARM 13, Over Current the unit current limit has been exceeded. ALARM 14, Earth (ground) fault The sum current of the IGBT CTs does not equal zero. Check if the resistance of any phase to ground has a low value. Check both before and after mains contactor. Ensure IGBT current transducers, connection cables, and connectors are ok. ALARM 38, Internal fault Contact Danfoss or supplier. ALARM 39, Heat sink sensor No feedback from the heat sink temperature sensor. WARNING 40, Overload of Digital Output Terminal 27 Check the load connected to terminal 27 or remove shortcircuit connection. WARNING 41, Overload of Digital Output Terminal 29 Check the load connected to terminal 29 or remove shortcircuit connection. WARNING 43, Ext. Supply (option) The external 24 V DC supply voltage on the option is not valid. ALARM 46, Power card supply The supply on the power card is out of range. WARNING 47, 24 V supply low Contact Danfoss or supplier. WARNING 48, 1.8 V supply low Contact Danfoss or supplier. ALARM 15, Incomp. Hardware A mounted option is incompatible with the present control card SW/HW. WARNING/ALARM/TRIP 65, Control card over temperature Control card over temperature: The cut-out temperature of the control card is 80 °C. ALARM 16, Short circuit There is a short-circuit in the output. Turn off the unit and correct the error. WARNING 66, Heat sink temperature low This warning is based on the temperature sensor in the IGBT module. WARNING/ALARM 17, Control word timeout There is no communication to the unit. The warning is only active when 8-04 Control Word Timeout Function is not set to off. Possible correction: Increase 8-03 Control Word Timeout Time. Change 8-04 Control Word Timeout Function Troubleshooting WARNING 23, Internal fan fault Internal fans have failed due to defect hardware or fans not mounted. 72 The heat sink temperature measured as 0 °C could indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is disconnected, this warning would results. Also, check the IGBT thermal sensor. ALARM 67, Option module configuration has changed One or more options have either been added or removed since the last power-down. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Diagnostics and Troubleshoo... Operating Instructions ALARM 68, Safe Torque Off activated Safe Torque Off has been activated. To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset]. See 5-19 Terminal 37 Safe Stop. ALARM 300, Mains Cont. Fault The feedback from the mains contactor did not match the expected value within the allowed time frame. Contact Danfoss or supplier. ALARM 69, Power card temperature The temperature sensor on the power card is either too hot or too cold. ALARM 301, SC Cont. Fault The feedback from the soft charge contactor did not match the expected value within the allowed time frame. Contact Danfoss or supplier. ALARM 70, Illegal FC Configuration Actual combination of control board and power board is illegal. ALARM 302, Cap. Over Current Excessive current was detected through the AC capacitors. Contact Danfoss or supplier. WARNING 73, Safe Torque Off auto restart Safe stopped. Note that with automatic restart enabled, the motor can start when the fault is cleared. ALARM 303, Cap. Earth Fault An earth fault was detected through the AC capacitor currents. Contact Danfoss or supplier. ALARM 79, Illegal power section configuration The scaling card is the incorrect part number or not installed. Also MK102 connector on the power card could not be installed. ALARM 304, DC Over Current Excessive current through the DC-link capacitor bank was detected. Contact Danfoss or supplier. ALARM 80, Unit initialised to default value Parameter settings are initialised to default settings after a manual reset. ALARM 244, Heat sink temperature Report value indicates source of alarm (from left): 1-4 inverter 5-8 rectifier ALARM 245, Heat sink sensor No feedback from the heat sink sensor. Report value indicates source of alarm (from left): 1-4 inverter 5-8 rectifier ALARM 246, Power card supply The supply on the power card is out of range. Report value indicates source of alarm (from left): 1-4 inverter 5-8 rectifier ALARM 247, Power card temperature Power card over temperature. Report value indicates source of alarm (from left): 1-4 inverter 5-8 rectifier ALARM 248, Illegal power section configuration Power size configuration fault on the power card. Report value indicates source of alarm (from left): 1-4 inverter 5-8 rectifier ALARM 250, New spare part The power or switch mode power supply has been exchanged. The filter type code must be restored in the EEPROM. Select the correct type code in 14-23 Typecode Setting according to the label on the unit. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New type code The filter has a new type code. MG21B202 ALARM 305, Mains Freq. Limit The mains frequency was outside the limits. Verify that the mains frequency is within product specification. ALARM 306, Compensation Limit The needed compensation current exceeds unit capability. Unit is running at full compensation. ALARM 308, Resistor temp Excessive resistor heat sink temperature detected. ALARM 309, Mains Earth Fault An earth fault was detected in the mains currents. Check the mains for shorts and leakage current. ALARM 310, RTDC Buffer Full Contact Danfoss or supplier. ALARM 311, Switch. Freq. Limit The average switching frequency of the unit exceeded the limit. Verify that 300-10 Active Filter Nominal Voltage and 300-22 CT Nominal Voltage are set correctly. If so, contact Danfoss or supplier. ALARM 312, CT Range Current transformer measurement limitation was detected. Verify that the CTs used are an appropriate ratio. ALARM 314, Auto CT Interrupt Auto CT detection has been interrupted. ALARM 315, Auto CT Error An error was detected while performing auto CT detection. Contact Danfoss or supplier. WARNING 316, CT Location Error The auto CT function could not determine the correct locations of the CTs. WARNING 317, CT Polarity Error The auto CT function could not determine the correct polarity of the CTs. WARNING 318, CT Ratio Error The auto CT function could not determine the correct primary rating of the CTs. Danfoss A/S © Rev. 2014-01-22 All rights reserved. 73 7 7 Diagnostics and Troubleshoo... Operating Instructions 7.5 Troubleshooting Symptom Possible cause Missing input power Missing or open fuses or circuit breaker tripped Display dark/No function Test Solution See Table 5.1 Check the input power source See Open fuses and Tripped circuit Follow the recommendations provided breaker in this table for possible causes Replace the faulty LCP or connection cable No power to the LCP Check the LCP cable for proper connection or damage Shortcut on control voltage (terminal 12 or 50) or at control terminals Check the 24 V control voltage Wire the terminals properly supply for terminals 12/13 to 20-39 or 10 V supply for terminals 50 to 55 Wrong LCP (LCP from VLT® 2800 or 5000/6000/8000/ FCD or FCM) Use only LCP 101 (P/N 130B1124) or LCP 102 (P/N 130B1107) Press [Status] + [▲]/[▼] to adjust Wrong contrast setting the contrast 7 7 Display (LCP) is defective Test using a different LCP Contact supplier Internal voltage supply fault or SMPS is defective Intermittent display Motor not running Replace the faulty LCP or connection cable Overloaded power supply (SMPS) due to improper control wiring or a fault within the frequency converter To rule out a problem in the control wiring, disconnect all control wiring by removing the terminal blocks. If the display stays lit, then the problem is in the control wiring. Check the wiring for shorts or incorrect connections. If the display continues to cut out, follow the procedure for display dark. Service switch open or missing motor connection Check if the motor is connected and the connection is not interrupted (by a service switch or other device). Connect the motor and check the service switch No mains power with 24 V DC option card If the display is functioning but no Apply mains power to run the unit output, check that mains power is applied to the frequency converter. LCP Stop Check if [Off] has been pressed Missing start signal (Standby) Check 5-10 Terminal 18 Digital Input Apply a valid start signal to start the motor for correct setting for terminal 18 (use default setting) Motor coast signal active (Coasting) Check 5-12 Coast inv. for correct setting for terminal 27 (use default setting). Wrong reference signal source Motor rotation limit Check reference signal: Local, remote or bus reference? Preset reference active? Terminal connection correct? Scaling of terminals correct? Reference signal available? Check that 4-10 Motor Speed Press [Auto On] or [Hand On] (depending on operation mode) to run the motor Apply 24 V on terminal 27 or program this terminal to no operation Program correct settings. Check 3-13 Reference Site. Set preset reference active in parameter group 3-1* References. Check for correct wiring. Check scaling of terminals. Check reference signal. Program correct settings Direction is programmed correctly. Motor running in wrong direction Active reversing signal Check if a reversing command is programmed for the terminal in parameter group 5-1* Digital inputs. Wrong motor phase connection 74 Deactivate reversing signal Danfoss A/S © Rev. 2014-01-22 All rights reserved. See chapter 4.6.1 Motor Cable in this manual MG21B202 Diagnostics and Troubleshoo... Symptom Operating Instructions Possible cause Frequency limits set wrong Test Check output limits in 4-13 Motor Solution Program correct limits Speed High Limit [RPM], 4-14 Motor Speed High Limit [Hz] and 4-19 Max Motor is not reaching maximum speed Output Frequency. Reference input signal not scaled correctly Check reference input signal Program correct settings scaling in 6-0* Analog I/O Mode and parameter group 3-1* References. Reference limits in parameter group 3-0* Reference Limit. Motor speed unstable Possible incorrect parameter settings Check the settings of all motor parameters, including all motor compensation settings. For closed loop operation, check PID settings. Possible overmagnetisation Check for incorrect motor settings in all motor parameters Motor runs rough Check settings in parameter group 1-6* Load Depen. Setting. For closed loop operation, check settings in parameter group 20-0* Feedback. Check motor settings in parameter groups 1-2* Motor Data, 1-3* Adv Motor Data, and 1-5* Load Indep. Setting. Motor will not brake Possible incorrect settings in the brake parameters. Possible too short ramp down times Check brake parameters. Check ramp time settings Phase-to-phase short Motor or panel has a short phase to phase. Check motor and panel 7 7 Check parameter group 2-0* DC Brake and 3-0* Reference Limits. Eliminate any shorts detected phase for shorts Motor overload Motor is overloaded for the application Loose connections Perform pre-startup check for loose Tighten loose connections connections Problem with mains power (See Rotate input power leads into the If imbalanced leg follows the wire, frequency converter one position: A it is a power problem. Check mains to B, B to C, C to A. power supply. Open power fuses or circuit breaker trip Mains current imbalance greater than 3% Motor current imbalance greater than 3% Alarm 4 Mains phase loss description) Perform startup test and verify motor current is within specifications. If motor current is exceeding nameplate full load current, motor may run only with reduced load. Review the specifications for the application. Problem with the frequency converter Rotate input power leads into the If imbalance leg stays on same frequency converter one position: A input terminal, it is a problem with to B, B to C, C to A. the unit. Contact the supplier. Problem with motor or motor wiring Rotate output motor leads one position: U to V, V to W, W to U. If imbalanced leg follows the wire, the problem is in the motor or motor wiring. Check motor and motor wiring. Problem with the frequency converters Rotate output motor leads one position: U to V, V to W, W to U. If imbalance leg stays on same output terminal, it is a problem with the unit. Contact the supplier. Bypass critical frequencies by using parameters in parameter group 4-6* Speed Bypass Acoustic noise or vibration (e.g. a fan blade is making noise or vibrations at certain frequencies) Turn off over-modulation in Resonances, e.g. in the motor/fan system 14-03 Overmodulation Change switching pattern and frequency in parameter group 14-0* Inverter Switching Check if noise and/or vibration have been reduced to an acceptable limit Increase Resonance Dampening in 1-64 Resonance Dampening Table 7.9 Troubleshooting MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 75 8 8 Specifications Operating Instructions 8 Specifications 8.1 Power-Dependent Specifications 8.1.1 Mains Supply 3x380-480 V AC P160 P200 Normal Overload =110% current for 60 s NO NO P250 NO Typical shaft output at 400 V [kW] 160 200 250 Typical shaft output at 460 V [hp] 250 300 350 Typical shaft output at 480 V [kW] 200 250 315 Enclosure IP21/54 D13 Output current Continuous (at 400 V) [A] 315 395 480 Intermittent (60 s overload) (at 400 V) [A] 347 435 528 Continuous (at 460/480 V) [A] 302 361 443 Intermittent (60 s overload) (at 460/480 V) [A] 332 397 487 Continuous kVA (at 400 V) [kVA] 218 274 333 Continuous kVA (at 460 V) [kVA] 241 288 353 Continuous kVA (at 480 V) [kVA] 262 313 384 Continuous (at 400 V) [A] 304 381 463 Continuous (at 460/480 V) [A] 291 348 427 Max. pre-fuses1) [A] 400 500 630 Max. Input current Max. cable size Motor (mm2/AWG2)) Mains (mm2/AWG2)) 2x185 (2x300 mcm) Loadsharing (mm2/AWG2)) Brake (mm2/AWG2)) Total LHD loss 400 V AC [kW] 8868 10527 11751 Total back channel loss 400 V AC [kW] 7318 8903 10033 Total filter loss 400 V AC [kW] 4954 5714 6234 Total LHD loss 460 V AC [kW] 9059 10192 11706 Total back channel loss 460 V AC [kW] 7123 8209 9635 Total filter loss 460 V AC [kW] 5279 5819 6681 Weight, enclosure IP21, IP54 [kg] 380 406 0.96 Efficiency4) Output frequency [Hz] 0-800 Heatsink overtemp. trip [°C] 105 Power card ambient trip [°C] 85 *High overload = 160% torque during 60 s; Normal overload = 110% torque during 60 s Table 8.1 Mains Supply 3x380-480 V AC 76 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Specifications Normal Overload =110% current for 60 s Operating Instructions P315 P355 P400 P450 NO NO NO NO Typical shaft output at 400 V [kW] 315 355 400 450 Typical shaft output at 460 V [hp] 450 500 600 600 Typical shaft output at 480 V [kW] 355 400 500 530 745 800 Enclosure IP21/54 E9 Output current Continuous (at 400 V) [A] 600 658 Intermittent (60 s overload) (at 400 V) [A] 660 724 820 880 Continuous (at 460/480 V) [A] 540 590 678 730 Intermittent (60 s overload) (at 460/480 V) [A] 594 649 746 803 Continuous kVA (at 400 V) [kVA] 416 456 516 554 Continuous kVA (at 460 V) [kVA] 430 470 540 582 Continuous kVA (at 480 V) [kVA] 468 511 587 632 Max. Input current Continuous (at 400 V) [A] 590 647 733 787 Continuous (at 460/480 V) [A] 531 580 667 718 Max. pre-fuses1) [A] 700 900 Max. cable size 8 8 Motor (mm2/AWG2)) Mains (mm2/AWG2)) 4x240 (4x500 mcm) Loadsharing (mm2/AWG2)) 2x185 (2x350 mcm) Brake (mm2/AWG2)) Total LHD loss 400 V AC [kW] 14051 15320 17180 18447 Total back channel loss 400 V AC [kW] 11301 11648 13396 14570 Total filter loss 400 V AC [kW] 7346 7788 8503 8974 Total LHD loss 460 V AC [kW] 12936 14083 15852 16962 Total back channel loss 460 V AC [kW] 10277 10522 12184 13214 Total filter loss 460 V AC [kW] 7066 7359 8033 Weight, enclosure IP21, IP54 [kg] 596 623 8435 646 0.96 Efficiency4) Output frequency [Hz] 0-600 Heatsink overtemp. trip [°C] 105 Power card ambient trip [°C] 85 *High overload = 160% torque during 60 s; Normal overload = 110% torque during 60 s Table 8.2 Mains Supply 3x380-480 V AC MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 77 8 8 Specifications Operating Instructions P500 P560 P630 P710 Normal Overload =110% current for 60 s NO NO NO NO Typical shaft output at 400 V [kW] 500 560 630 710 Typical shaft output at 460 V [hp] 650 750 900 1000 Typical shaft output at 480 V [kW] 560 630 710 800 Enclosure IP21/54 F18 Output current Continuous (at 400 V) [A] 880 990 1120 1260 Intermittent (60 s overload) (at 400 V) [A] 968 1089 1232 1386 Continuous (at 460/480 V) [A] 780 890 1050 1160 Intermittent (60 s overload) (at 460/480 V) [A] 858 979 1155 1276 Continuous kVA (at 400 V) [kVA] 610 686 776 873 Continuous kVA (at 460 V) [kVA] 621 709 837 924 Continuous kVA (at 480 V) [kVA] 675 771 909 1005 Continuous (at 400 V) [A] 857 964 1090 1227 Continuous (at 460/480 V) [A] 759 867 1022 Max. Input current Max. pre-fuses1) [A] 1129 2000 1600 Max. cable size Motor (mm2/AWG2)) 8 x 150 (8 x 300 mcm) Mains (mm2/AWG2)) 8 x 240 (8 x 500 mcm) (mm2/AWG2)) 4 x 185 (4 x 350 mcm) Brake Total LHD loss 400 V AC [kW] 21909 24592 26640 30519 Total back channel loss 400 V AC [kW] 17767 19984 21728 24936 Total filter loss 400 V AC [kW] 11747 12771 14128 15845 Total LHD loss 460 V AC [kW] 19896 22353 25030 27989 Total back channel loss 460 V AC [kW] 16131 18175 20428 22897 Total filter loss 460 V AC [kW] 11020 11929 13435 14776 Weight, enclosure IP21, IP54 [kg] 2009 0.96 Efficiency4) Output frequency [Hz] 0-600 Heatsink overtemp. trip [°C] 105 Power card ambient trip [°C] 85 *Normal overload = 110% torque during 60 s Table 8.3 Mains Supply 3x380-480 V AC 1) For type of fuse, see chapter 8.5.1 Fuses. 2) American wire gauge. 3) Measured using 5 m screened motor cables at rated load and rated frequency. 4) The typical power loss is at nominal load conditions and expected to be within ±15% (tolerence relates to variety in voltage and cable conditions). Values are based on a typical motor efficiency (IE2/IE3 border line). Motors with lower efficiency also add to the power loss in the frequency converter and opposite. If the switching frequency is increased to the default setting, the power losses may rise significantly. LCP and typical control card power consumptions are included. Further options and customer load may add up to 30 W to the losses. (Though typical only 4 W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state-of-the-art equipment, some measurement inaccuracy must be allowed for (±5%). 78 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Specifications Operating Instructions The frequency converter automatically derates the switching frequency, switching type, or output current under certain load or ambient conditions as described below. The derating curves in Illustration 8.1 apply to both SFAVM and 60 AVM switching modes. 130BX492.10 8.1.2 Derating for Temperature 110 100 Iout [%] 90 80 70 40o C 45o C 60 50o C 55o C 50 0.5 0.0 1.0 1.5 2.0 fsw [kHz] 2.5 3.0 3.5 4.0 Illustration 8.1 Derating Frame Sizes D, E, and F 380-500 V (T5) Normal Overload 110% 8.2 Mechanical Dimensions 304.0 [12.0] 510.0 [20.1] 304.0 [12.0] 130BC167.10 8 8 139.0 [5.5] 60.0 [6.3] 1581 [62.2] 1534.5 977.0 [60.4] [38.5] 1780.5 [70.1] 1755.5 [69.1] 160.0 [6.3] 112.5 [4.4] 411.0 251.0 [16.2] [9.9] 1021.9 [40.2] 377.8 [14.9] 184.5 369.0 [7.3] [14.5] 301.9 486.4 [11.9] 627.4[19.2] [24.7] 117.5 [4.6] Illustration 8.2 Frame Size D13 MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 79 Specifications Operating Instructions 130BC171.10 160.0 [6.3] 1043.0 [41.1] 2000.7 [78.8] 160.0 [6.3] 160.0 [6.3] 725.0 [28.5] 248.0 [9.8] 8 8 1200.0 [47.2] 493.5 [19.4] 369.0 553.5 [14.5] [21.8] 600.0 [23.6] 784.5 [30.9] 969.0 [38.2] 1153.5 [45.4] 184.5 [7.3] Illustration 8.3 Frame Size E9 80 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions 130BC174.11 Specifications 2278.4 2078.4 2792.0 [110] 8 8 605.8 [24] Illustration 8.4 Frame Size F18, Front and Side View 8.3 General Technical Data - Frequency Converter Mains supply (L1, L2, L3) Supply voltage 380–480 V +5% Mains voltage low/mains drop-out: During low mains voltage or mains drop-out, the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level, corresponding to 15% below the lowest rated supply voltage. Power up and full torque cannot be expected at mains voltage lower than 10% below the lowest rated supply voltage. Supply frequency Max. imbalance temporary between mains phases True power factor (λ) Displacement power factor (cosφ) near unity THiD Switching on input supply L1, L2, L3 (power-ups) Environment according to EN60664-1 50/60 Hz ±5% 3.0% of rated supply voltage > 0.98 nominal at rated load (> 0.98) < 5% maximum once/2 min. overvoltage category III/pollution degree 2 The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 480/690 V maximum. Motor output (U, V, W) Output voltage Output frequency Switching on output Ramp times 0-100% of supply voltage 0-590 Hz1) Unlimited 0.01-3600 s 1) Voltage and power dependent MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 81 8 8 Specifications Operating Instructions Torque characteristics Starting torque (constant torque) Starting torque Overload torque (constant torque) maximum 160% for 1 m1) maximum 180% up to 0.5 s1) maximum 160% for 1 m1) 1) Percentage relates to nominal torque of the unit. Cable lengths and cross-sections Max. motor cable length, screened/armoured Max. motor cable length, unscreened/unarmoured Max. cross-section to motor, mains, load sharing, and brake1) Maximum cross-section to control terminals, rigid wire Maximum cross-section to control terminals, flexible cable Maximum cross-section to control terminals, cable with enclosed core Minimum cross-section to control terminals 150 m 300 m 1.5 mm2/16 AWG (2 x 0.75 mm2) 1 mm2/18 AWG 0.5 mm2/20 AWG 0.25 mm2 1) See chapter 8.1.1 Mains Supply 3x380-480 V AC for more information Digital inputs Programmable digital inputs Terminal number Logic Voltage level Voltage level, logic'0' PNP Voltage level, logic'1' PNP Voltage level, logic '0' NPN Voltage level, logic '1' NPN Maximum voltage on input Input resistance, Ri 4 (6) 18, 19, 271), 291), 32, 33, PNP or NPN 0-24 V DC < 5 V DC > 10 V DC > 19 V DC < 14 V DC 28 V DC approx. 4 kΩ All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 1) Terminals 27 and 29 can also be programmed as output. Analog inputs Number of analog inputs Terminal number Modes Mode select Voltage mode Voltage level Input resistance, Ri Max. voltage Current mode Current level Input resistance, Ri Max. current Resolution for analog inputs Accuracy of analog inputs Bandwidth 2 53, 54 Voltage or current Switch S201 and switch S202 Switch S201/switch S202 = OFF (U) 0 to + 10 V (scaleable) approx. 10 kΩ ± 20 V Switch S201/switch S202 = ON (I) 0/4 to 20 mA (scaleable) approx. 200 Ω 30 mA 10 bit (+ sign) Max. error 0.5% of full scale 200 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 82 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Operating Instructions PELV isolation +24V 18 Control 37 Mains High voltage 130BA117.10 Specifications Motor Functional isolation RS485 DC-Bus Illustration 8.5 PELV Isolation of Analog Inputs Pulse inputs Programmable pulse inputs Terminal number pulse Max. frequency at terminal, 29, 33 Max. frequency at terminal, 29, 33 Min. frequency at terminal 29, 33 Voltage level Maximum voltage on input Input resistance, Ri Pulse input accuracy (0.1–1 kHz) 2 29, 33 110 kHz (Push-pull driven) 5 kHz (open collector) 4 Hz see chapter 8.3.1 Digital inputs 28 V DC approx. 4 kΩ Max. error: 0.1% of full scale Analog output Number of programmable analog outputs Terminal number Current range at analog output Max. resistor load to common at analog output Accuracy on analog output Resolution on analog output 1 42 0/4-20 mA 500 Ω Max. error: 0.8% of full scale 8 bit The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Control card, RS-485 serial communication Terminal number Terminal number 61 68 (P,TX+, RX+), 69 (N,TX-, RX-) Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage (PELV). Digital output Programmable digital/pulse outputs Terminal number Voltage level at digital/frequency output Max. output current (sink or source) Max. load at frequency output Max. capacitive load at frequency output Minimum output frequency at frequency output Maximum output frequency at frequency output Accuracy of frequency output Resolution of frequency outputs 2 27, 291) 0-24 V 40 mA 1 kΩ 10 nF 0 Hz 32 kHz Max. error: 0.1% of full scale 12 bit 1) Terminal 27 and 29 can also be programmed as input. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 83 8 8 8 8 Specifications Operating Instructions Control card, 24 V DC output Terminal number Output voltage Max. load 13 24 V (+1, -3 v) 200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. Relay outputs Programmable relay outputs Relay 01 Terminal number Max. terminal load (AC-1)1) on 1-3 (NC), 1-2 (NO) (resistive load) Max. terminal load (AC-15)1) (inductive load @ cosφ 0.4) Max. terminal load (DC-1)1) on 1-2 (NO), 1-3 (NC) (resistive load) Max. terminal load (DC-13)1) (inductive load) Relay 02 Terminal number Max. terminal load (AC-1)1) on 4-5 (NO) (resistive load)2)3) Max. terminal load (AC-15)1) on 4-5 (NO) (inductive load @ cosφ 0.4) Max. terminal load (DC-1)1) on 4-5 (NO) (resistive load) Max. terminal load (DC-13)1) on 4-5 (NO) (inductive load) Max. terminal load (AC-1)1) on 4-6 (NC) (resistive load) Max. terminal load (AC-15)1) on 4-6 (NC) (inductive load @ cosφ 0.4) Max. terminal load (DC-1)1) on 4-6 (NC) (resistive load) Max. terminal load (DC-13)1) on 4-6 (NC) (inductive load) Min. terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO) Environment according to EN 60664-1 2 1-3 (break), 1-2 (make) 240 V AC, 2A 240 V AC, 0.2 A 60 V DC, 1 A 24 V DC, 0.1 A 4-6 (break), 4-5 (make) 400 V AC, 2 A 240 V AC, 0.2 A 80 V DC, 2 A 24 V DC, 0.1 A 240 V AC, 2 A 240 V AC, 0.2 A 50 V DC, 2 A 24 V DC, 0.1 A 24 V DC 10 mA, 24 V AC 20 mA overvoltage category III/pollution degree 2 1) IEC 60947 parts 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV). 2) Overvoltage Category II 3) UL applications 300 V AC 2 A Control characteristics Resolution of output frequency at 0-1000 Hz System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open loop) Speed accuracy (open loop) ±0.003 Hz ≤ 2 ms 1:100 of synchronous speed 30-4000 RPM: Maximum error of ±8 RPM All control characteristics are based on a 4-pole asynchronous motor 84 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Specifications Operating Instructions Surroundings Enclosure, frame size D and E IP21, IP54 Enclosure, frame size F IP21, IP54 Vibration test 0.7 g Relative humidity 5-95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H2S test class kD Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at 60 AVM switching mode) - with derating max. 55 °C max. 50 °C - with full output power, typical IE2 motors (see chapter 8.1.2 Derating for Temperature - at full continuous FC output current max. 45 °C Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance - 10 °C Temperature during storage/transport -25 - +65/70 °C Maximum altitude above sea level without derating 1,000 m Maximum altitude above sea level with derating 3,000 m For more information on derating, consult the design guide EMC standards, emission EMC standards, immunity EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3 EN 61800-3, EN 61000-6-1/2, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6 Control card performance Scan interval 5 ms Control card, USB serial communication USB standard USB plug 1.1 (full speed) USB type B device plug NOTICE Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protective earth. Use only isolated laptop/PC as connection to the USB connector on the frequency converter or an isolated USB cable/converter. Protection and features: • Electronic thermal motor protection against overload. • Temperature monitoring of the heat sink ensures that the frequency converter trips if the temperature reaches a predefined level. An overload temperature cannot be reset until the temperature of the heat sink is below the allowed values. • • • The frequency converter is protected against short-circuits on motor terminals U, V, W. • If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load). Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high. The frequency converter is protected against earth faults on motor terminals U, V, W. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 85 8 8 8 8 Specifications Operating Instructions 8.4 General Technical Data - Filter Frame size D13 E9 F18 Voltage [V] 380–480 380–480 380–480 120 210 330 Current, RMS [A] Response time [ms] <0.5 Settling time - reactive current control [ms] <40 Settling time - harmonic current control (filtering) [ms] <20 Overshoot - reactive current control [%] <20 Overshoot - harmonic current control [%] <10 Table 8.4 Power Ranges (LHD with AF) 8.4.1 Power Rating Grid conditions Supply voltage 380–480 V Mains voltage low/mains drop-out: During low mains voltage or a mains drop-out, the filter continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds to 15% below the filter lowest rated supply voltage. Full compensation cannot be expected at mains voltage lower than 10% below the filter lowest rated supply voltage. If mains voltage exceed the filter highest rated voltage, the filter continues to work but harmonic mitigation performance is reduced. The filter does not cut out until main voltages exceed 580 V. Supply frequency Max. imbalance temporary between mains phases where mitigation performance is kept high. Max THDv pre-distortion 50/60 Hz ±5% 3.0% of rated supply voltage Filter mitigates at higher mains imbalance but harmonic mitigation performance is reduced 10% with kept mitigation performance Reduced performance for higher pre-distortion levels Harmonic mitigation performance THiD Individual harmonic mitigation ability: 2nd 4th 5th 7th 8th 10th 11th 13th 14th 16th 17th 19th 20th 22nd 23rd 25th Total current of harmonics Best performance <4% Depending on filter vs. distortion ratio. Current maximum RMS [% of rated RMS current] 10% 10% 70% 50% 10% 5% 32% 28% 4% 4% 20% 18% 3% 3% 16% 14% 90% The filter is performance tested to the 40th order Reactive current compensation Cos phi Reactive current, % of filter current rating 86 Danfoss A/S © Rev. 2014-01-22 All rights reserved. Controllable 1.0 to 0.5 lagging 100% MG21B202 Specifications Operating Instructions Cable lengths and cross-sections Max grid cable length (direct internal connection to drive) Maximum cross-section to control terminals, rigid wire Maximum cross-section to control terminals, flexible cable Maximum cross-section to control terminals, cable with enclosed core Minimum cross-section to control terminals Unlimited (determined by voltage drop) 1.5 mm2/16 AWG (2 x 0.75 mm2 1 mm2/18 AWG 0.5 mm2/20 AWG 0.25 mm2 CT terminals specification CT number The AAF burden equals Secondary current rating Accuracy 3 (one for each phase) 2 mΩ 1 A or 5 A (hardware set-up) Class 0.5 or better Digital inputs Programmable digital inputs Terminal number Logic Voltage level Voltage level, logic'0' PNP Voltage level, logic'1' PNP Voltage level, logic '0' NPN Voltage level, logic '1' NPN Maximum voltage on input Input resistance, Ri 2 (4) 18, 19, 291) PNP or NPN 0-24–V DC < 5 V DC > 10 V DC > 19 V DC < 14 V DC 28 V DC approx. 4 kΩ 271), All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 1) Terminals 27 and 29 can also be programmed as output. Control card, RS-485 serial communication Terminal number Terminal number 61 68 (P, TX+, RX+), 69 (N, TX-, RX-) Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV). Digital output Programmable digital/pulse outputs Terminal number Voltage level at digital/frequency output Max. output current (sink or source) 2 27, 29 1) 0–24 V 40 mA 1) Terminal 27 and 29 can also be programmed as input. Control card, 24 V DC output Terminal number Max. load 13 200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 87 8 8 8 8 Specifications Operating Instructions Surroundings Enclosure IP21, IP54 Vibration test 1.0 g Relative humidity 5% - 95% (IEC 721-3-3; class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H2S test class kD Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature - with derating max. NA °C - with full output current (short temperature overload) max. 45 °C - at full continuous output current (24 hours) max. 40 °C Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance -10 °C Temperature during storage/transport -25 to +70 °C Maximum altitude above sea level without derating 1000 m Maximum altitude above sea level with derating 3000 m EMC standards, Emission EN 61800-3, EN 61000-6-3/4, EN 55011, IEC 61800-3 EN 61800-3, EN 61000-6-1/2, EMC standards, Immunity EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6 Control card performance Scan interval 5 ms Control card, USB serial communication USB standard USB plug 1.1 (full speed) USB type B “device” plug Generic specifications Maximum parallel filters Filter efficiency Typical average switching frequency Response time (reactive and harmonic) Settling time - reactive current control Settling time - harmonic current control Overshoot – reactive current control Overshoot – Harmonic current control 4 on same CT set 97% 3.0–4.5 kHz < 0.5 ms < 20 ms < 20 ms <10% <10% Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from protective earth. Use only isolated laptop/PC as connection to the USB connector on the unit or an isolated USB cable/converter. Protection and features • Temperature monitoring of the heat sink ensures that the active filter trips if the temperature reaches a predefined level. An overload temperature cannot be reset until the temperature of the heat sink is below the acceptable values. • • • If a mains phase is missing, the active filter trips. • 88 The active filter has a short circuit protection current rate of 100 kA if properly fused Monitoring of the intermediate circuit voltage ensures that the filter trips if the intermediate circuit voltage is too low or too high. The active filter monitors the mains current as well as internal currents to reassure that current levels do not reach critical levels. If current exceeds a critical level, the filter trips. Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Specifications Operating Instructions 8.4.2 Derating for Altitude The cooling capability of air is decreased at lower air pressure. Below 1,000 m altitude no derating is necessary but above 1,000 m the ambient temperature (TAMB) or max. output current (Iout) should be derated in accordance with Illustration 8.6. An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to read the graph, the situation at 2,000 m is elaborated. At a temperature of 45 °C (TAMB, MAX - 3.3 K), 91% of the rated output current is available. At a temperature of 41.7 °C, 100% of the rated output current is available. Altitude Derating Derating of output current versus altitude at TAMB, MAX for frame sizes D, E and F. 130BB008.10 IOUT(%) 100 95 90 85 80 0 500 1000 1500 2000 2500 3000 Altitude (meters above sea level)* Illustration 8.6 Altitude Derating 8.5 Fuses It is recommended to use fuses and/or circuit breakers on the supply side as protection in case of component breakdown inside the frequency converter (first fault). NOTICE This is mandatory to ensure compliance with IEC 60364 for CE or NEC 2009 for UL. Branch circuit protection To protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be protected against short-circuit and overcurrent according to national/international regulations. NOTICE The recommendations given do not cover branch circuit protection for UL. Short-circuit protection Danfoss recommends using the fuses/circuit breakers mentioned below to protect service personnel and property in case of component break-down in the frequency converter. Overcurrent protection The frequency converter provides overload protection to limit threats to human life, property damage and to avoid fire hazard due to overheating of the cables in the installation. The frequency converter is equipped with an internal overcurrent protection (4-18 Current Limit) that can be used for upstream overload protection (UL-applications excluded). Moreover, fuses or circuit breakers can be used to provide the overcurrent protection in the installation. Overcurrent protection must always be carried out according to national regulations. The following tables list the recommended rated current. Recommended fuses are of the type gG for small to medium power sizes. For larger powers, aR fuses are recommended. Circuit breakers must be used, provided they meet the national/international regulations and they limit the energy into the frequency converter to an equal or lower level than the compliant circuit breakers. If fuses/circuit breakers according to recommendations are selected, possible damage on the frequency converter is mainly limited to damage inside the unit. Non UL compliance If UL/cUL is not to be complied with, use the following fuses, which ensure compliance with EN50178: P160-P250 380-480 V type gG P315-P450 380-480 V type gR Table 8.5 Fuse Types by Power Range WARNING Protect personnel and property against the consequence of component break-down internally in the frequency converter. MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 89 8 8 8 8 Specifications Operating Instructions 8.5.1 Fuse Specifications UL compliance 380-480 V, frame sizes D, E and F The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240 V, or 480 V, or 500 V, or 600 V depending on the frequency converter voltage rating. With the proper fusing the frequency converter Short Circuit Current Rating (SCCR) is 100,000 Arms. Bussmann E1958 Bussmann E4273 JFHR22) T/JDDZ2) P160 FWH400 P200 P250 Size/ Type FerrazShawmut E60314 Bussmann E4274 Bussmann E125085 H/JDDZ2) JFHR21) Internal Option Bussmann A50-P400 NOS400 170M4012 170M4016 L50S-500 A50-P500 NOS500 170M4014 170M4016 L50S-600 A50-P600 NOS600 170M4016 170M4016 SIBA E180276 JFHR2 LittelFuse E91611 JJS400 2061032.40 L50S-400 FWH500 JJS500 2061032.50 FWH600 JJS600 2062032.63 JFHR22) JFHR22) Table 8.6 Frame size D, Line Fuses, 380-480 V Bussmann PN1) Rating Ferraz Siba P315 170M4017 700 A, 700 V 6.9URD31D08A0700 20 610 32.700 P355 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900 P400 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900 P450 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900 Size/Type Table 8.7 Frame size E, Line Fuses, 380-480 V Bussmann PN1) Rating Siba Internal Bussmann Option P500 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 P560 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 P630 170M7082 2000 A, 700 V 20 695 32.2000 170M7082 P710 170M7082 2000 A, 700 V 20 695 32.2000 170M7082 Size/Type Table 8.8 Frame size F, Line Fuses, 380-480 V Bussmann PN1) Rating Siba P500 170M8611 1100 A, 1000 V 20 781 32.1000 P560 170M8611 1100 A, 1000 V 20 781 32.1000 P630 170M6467 1400 A, 700 V 20 681 32.1400 P710 170M6467 1400 A, 700 V 20 681 32.1400 Size/Type Table 8.9 Frame Size F, Inverter module DC Link Fuses, 380-480 V 1) 170M fuses from Bussmann shown use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use 2) Any minimum 500 V UL listed fuse with associated current rating may be used to meet UL requirements. Supplementary fuses Frame size Bussmann PN1) Rating D, E and F KTK-4 4 A, 600 V Table 8.10 SMPS Fuse 90 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Specifications Operating Instructions Bussmann PN1) Size/Type P160-P315, 380-480 V LittelFuse Rating KLK-15 15A, 600 V KTK-4 4 A, 600 V P355-P710, 380-480 V Table 8.11 Fan Fuses Size/Type Bussmann PN1) Rating Alternative Fuses P500-P710, 380-480 V 2.5-4.0 A LPJ-6 SP or SPI 6 A, 600 V Any listed Class J Dual Element, Time Delay, 6A P500-P710, 380-480 V 4.0-6.3 A LPJ-10 SP or SPI 10 A, 600 V Any listed Class J Dual Element, Time Delay, 10 A P500-P710, 380-480 V 6.3-10 A LPJ-15 SP or SPI 15 A, 600 V Any listed Class J Dual Element, Time Delay, 15 A P500-P710, 380-480 V 10-16 A LPJ-25 SP or SPI 25 A, 600 V Any listed Class J Dual Element, Time Delay, 25 A Table 8.12 Manual Motor Controller Fuses Frame size Bussmann PN1) Rating Alternative Fuses F LPJ-30 SP or SPI 30 A, 600 V Any listed Class J Dual Element, Time Delay, 30 A 8 8 Table 8.13 30 A Fuse Protected Terminal Fuse Bussmann PN1) Rating Alternative Fuses LP-CC-8/10 0.8A, 600V Any listed Class CC, 0.8A E LP-CC-1 1/2 1.5A, 600V Any listed Class CC, 1.5A F LPJ-6 SP or SPI 6 A, 600 V Any listed Class J Dual Element, Time Delay, 6 A Frame size D Table 8.14 Control Transformer Fuse Frame size F Bussmann PN1) Rating GMC-800MA 800 mA, 250 V Table 8.15 NAMUR Fuse Frame size F Bussmann PN1) Rating Alternative Fuses LP-CC-6 6 A, 600 V Any listed Class CC, 6 A Table 8.16 Safety Relay Coil Fuse with PILZ Relay 1) 170M fuses from Bussmann shown use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 91 9 9 Appendix Operating Instructions 9 Appendix 9.1 Abbreviations and Conventions AC Alternating Current AEO Automatic Energy Optimization AMA Automatic Motor Adaptation AWG American Wire Gauge °C Degrees Celsius DC Direct Current EMC Electromagnetic Compatibility ETR Electronic Thermal Relay fM,N Nominal Motor Frequency FC Frequency Converter ILIM Current Limit IINV Rated Inverter Output Current IM,N Nominal Motor Current IVLT,MAX The Maximum Output Current IVLT,N The Rated Output Current Supplied by the Frequency Converter IP Ingress Protection LCP Local Control Panel N.A. Not applicable PM,N Nominal Motor Power PCB Printed Circuit Board PE Protective earth PELV Protective Extra Low Voltage Regen Regenerative Terminals RPM Revolutions Per Minute TLIM Torque Limit UM,N Nominal Motor Voltage Table 9.1 Abbreviations Conventions Numbered lists indicate procedures. Bullet lists indicate other information and description of illustrations. Italicised text indicates • • • • 92 cross reference link footnote parameter name, parameter group name, parameter option Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Index Operating Instructions Index Conduit..................................................................................................... 45 Control cable.......................................................................................... 39 A Control card............................................................................................ 61 Abbreviation.......................................................................................... 92 Control card performance................................................................. 85 AC mains.................................................................................................. 15 Control card, 24 V DC output........................................................... 84 Active filter................................................................................................ 4 Control card, RS-485 serial communication............................... 83 Additional literature............................................................................... 4 Control card, USB serial communication.............................. 85, 88 ADN compliance................................................................................... 14 Control characteristic.......................................................................... 84 AEO............................................................................................................ 52 Control signal......................................................................................... 58 Airflow...................................................................................................... 17 Control system......................................................................................... 4 Alarm log................................................................................................. 48 Control terminal........................................................ 36, 48, 50, 58, 60 Alarm, warning...................................................................................... 69 Control terminal, access..................................................................... 36 Alarm/warning code list..................................................................... 69 Control terminal, input polarity, PNP............................................ 39 AMA............................................................................... 43, 52, 58, 62, 66 Control wiring........................................................................................ 45 AMA, successful..................................................................................... 44 Convention............................................................................................. 92 AMA, unsuccessful............................................................................... 44 Cooling..................................................................................................... 17 Analog input................................................................................... 61, 82 Cooling clearance................................................................................. 45 Analog output....................................................................................... 83 CT terminal, specification.................................................................. 87 Analog signal......................................................................................... 61 Current rating................................................................................. 16, 62 Analog speed reference..................................................................... 54 Anchoring................................................................................................ 20 D Approval.................................................................................................. 14 DC current........................................................................................ 28, 58 Auto on................................................................................ 48, 53, 58, 59 DC link................................................................................................ 61, 72 Auto remote coasting......................................................................... 47 Default setting....................................................................................... 49 Automatic Motor Adaptation (AMA)............................................. 43 Definition................................................................................................... 4 Auto-reset............................................................................................... 47 Delta.......................................................................................................... 43 Derating, altitude................................................................................. 89 B Digital input.............................................................................. 59, 62, 82 Back cooling........................................................................................... 17 Digital output......................................................................................... 83 Bottom view........................................................................................... 20 Dimension............................................................................................... 14 Brake cable.............................................................................................. 30 Dimension, mechanical...................................................................... 79 Brake chopper........................................................................................ 30 Discharge time...................................................................................... 15 Brake control.......................................................................................... 62 Disconnect switch......................................................................... 45, 47 Brake resistor.......................................................................................... 61 Distortion................................................................................................... 5 Brake resistor temperature switch................................................. 31 Download manual.................................................................................. 4 Braking.............................................................................................. 58, 63 Branch circuit protection................................................................... 89 E Earth connection.................................................................................. 45 C Earth wire................................................................................................ 45 Cable length, cross-section........................................................ 82, 87 Earthing.................................................................................................... 45 Cable size, maximum............................................................ 76, 77, 78 Earthing (grounding).......................................................................... 46 Cable-length, cross-section.............................................................. 29 ELCB relay................................................................................................ 29 Cabling..................................................................................................... 28 Electrical installation.................................................................... 36, 39 CE compliance mark............................................................................ 14 Electromechanical brake................................................................... 40 Circuit breaker....................................................................................... 46 EMC..................................................................................................... 28, 45 Communication option...................................................................... 64 Enclosure............................................................................ 14, 76, 77, 78 MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 93 Index Operating Instructions Exploded view.......................................................................................... 6 Insulation Resistance Monitor (IRM).............................................. 42 External alarm reset............................................................................. 56 Intermediate circuit............................................................................. 61 External command............................................................................... 60 IT main...................................................................................................... 29 External fan supply.............................................................................. 32 L F Lifting........................................................................................................ 19 Factory installed brake chopper option....................................... 30 Local control............................................................................. 47, 48, 58 Fan............................................................................................................. 32 Local control panel (LCP)................................................................... 47 Fault log................................................................................................... 48 Fault message, active filter................................................................ 72 M Feedback................................................................................... 45, 58, 65 Main menu.............................................................................................. 48 F-frame option....................................................................................... 41 Mains connection................................................................................. 32 Fieldbus connection............................................................................ 35 Mains input............................................................................................. 24 Filter capacitor....................................................................................... 29 Mains supply (L1, L2, L3).................................................................... 81 Final set-up and test............................................................................ 43 Mains voltage.................................................................................. 47, 58 Full load current.................................................................................... 16 Manual initialisation............................................................................ 49 Fuse............................................................................... 28, 45, 64, 74, 89 Manual motor starter.......................................................................... 42 Fuse specification................................................................................. 90 Maximum cable size.............................................................. 76, 77, 78 Fusing....................................................................................................... 45 Maximum input current....................................................... 76, 77, 78 MCT 10...................................................................................................... 47 G Mechanical brake control.................................................................. 39 Grid condition........................................................................................ 86 Mechanical dimension....................................................................... 79 Ground connection............................................................................. 45 Menu key.......................................................................................... 47, 48 Ground wire............................................................................................ 45 Menu structure...................................................................................... 48 Grounding................................................................................. 29, 45, 46 Motor cable...................................................................................... 28, 30 Motor current........................................................................... 47, 52, 66 H Motor data......................................................................... 51, 52, 62, 66 Hand.......................................................................................................... 58 Motor insulation................................................................................... 31 Hand on.................................................................................................... 58 Motor name plate................................................................................. 43 Hand On................................................................................................... 48 Motor output......................................................................................... 81 Harmonic mitigation performance................................................ 86 Motor power................................................................................... 47, 66 Harmonics.................................................................................................. 5 Motor protection.................................................................................. 85 Heat sink.................................................................................................. 65 Motor rotation....................................................................................... 52 Heater....................................................................................................... 41 Motor rotation check.......................................................................... 30 High voltage........................................................................................... 45 Motor speed........................................................................................... 50 Motor thermal protection.......................................................... 32, 40 I Motor thermistor.................................................................................. 57 IEC emergency stop, Pilz safety relay............................................ 42 Motor wiring........................................................................................... 45 Initialisation............................................................................................ 49 Mounting................................................................................................. 45 Input current, maximum...................................................... 76, 77, 78 Multiple frequency converters........................................................ 28 Input polarity, control terminal, PNP............................................. 39 Input power....................................................................... 15, 45, 60, 74 N Input terminal................................................................................. 45, 61 Nameplate............................................................................................... 16 Input voltage................................................................................... 47, 60 NAMUR..................................................................................................... 42 Installation....................................................................................... 45, 47 Navigation key.................................................................. 47, 48, 50, 58 Installation site, planning.................................................................. 17 NDE bearing........................................................................................... 31 94 Danfoss A/S © Rev. 2014-01-22 All rights reserved. MG21B202 Index Operating Instructions Noise isolation....................................................................................... 45 Non UL compliance............................................................................. 89 Normal overload..................................................................... 76, 77, 78 Run permissive...................................................................................... 59 S Safe Torque Off...................................................................................... 41 O Screened/armoured............................................................................ 33 Operation key........................................................................................ 47 Screened/armoured cable................................................................. 32 Optional equipment....................................................................... 4, 47 Screening, cable.................................................................................... 29 Output current.................................................... 16, 58, 62, 76, 77, 78 Serial communication............................................. 48, 58, 59, 60, 85 Output performance (U, V, W)......................................................... 81 Setpoint.................................................................................................... 59 Output terminal.................................................................................... 45 Set-up................................................................................................ 48, 53 Overcurrent............................................................................................ 59 Shielded cable................................................................................ 30, 45 Overcurrent protection...................................................................... 28 Shipping damage................................................................................. 16 Overload protection............................................................................ 16 Short circuit............................................................................................ 63 Overvoltage............................................................................................ 59 Sleep mode............................................................................................. 59 Speed reference...................................................................... 53, 54, 58 P Speed reference, analog.................................................................... 54 Parallel connection, motor................................................................ 40 Start/stop command........................................................................... 55 PELV........................................................................................................... 57 Start-up............................................................................................. 49, 74 Phase loss................................................................................................ 61 Status mode........................................................................................... 58 PNP............................................................................................................ 39 STO............................................................................................................. 41 Power connection................................................................................ 28 Stop command...................................................................................... 59 Power factor........................................................................................... 45 Supply voltage................................................................................ 45, 64 Power rating........................................................................................... 14 Surrounding........................................................................................... 85 Power, input........................................................................................... 60 Switches S201, S202, S801................................................................ 41 Programming........................................................................... 47, 48, 61 Switching frequency.................................................................... 29, 59 Protection, feature............................................................................... 85 Pulse input.............................................................................................. 83 T Pulse start/stop..................................................................................... 56 Temperature limit................................................................................. 45 Terminal function................................................................................. 32 Q Terminal location.................................................................................. 22 Qualified personnel............................................................................. 15 Thermal motor protection................................................................ 62 Quick menu..................................................................................... 47, 48 Thermistor........................................................................................ 57, 62 Torque............................................................................................... 27, 62 R Torque characteristic........................................................................... 82 RCD............................................................................................................ 29 Torque, terminal................................................................................... 27 RCD (Residual Current Device)........................................................ 42 Reactive current compensation...................................................... 86 V Reference............................................................................ 47, 54, 58, 59 Voltage imbalance............................................................................... 61 Relay output........................................................................................... 84 Voltage level.................................................................................... 82, 87 Remote reference................................................................................. 59 Voltage, input........................................................................................ 60 Reset................................................................ 47, 48, 49, 60, 62, 66, 67 VVC+.......................................................................................................... 51 RFI capacitor........................................................................................... 29 RFI switch................................................................................................. 29 W RS-485....................................................................................................... 41 Wire size................................................................................................... 28 RS-485 network connection............................................................. 57 Working principle................................................................................... 5 Run command....................................................................................... 53 MG21B202 Danfoss A/S © Rev. 2014-01-22 All rights reserved. 95 www.danfoss.com/drives Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved. 130R0400 MG21B202 *MG21B202* Rev. 2014-01-22
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