Danfoss VLT Ea4 User manual

Operating Guide

VLT Ea4 Parallel Drive Modules

1.1

1.2

1.3

1.4

1.5

1.6

1.7

2.1

2.2

2.3

3.1

3.2

3.3

3.4

3.5

3.6

4.1

4.2

4.3

4.3.1

4.3.2

4.3.3

4.4

4.4.1

4.4.2

4.4.3

4.5

4.6

4.7

Contents

Introduction and Safety 6

Purpose of this Manual 6

Disclaimer 6

Safety and Installation Awareness 6

Qualified Personnel 6

Safety Symbols 6

Safety Precautions 7

Disposal 9

Receiving the Drive 10

Verifying the Shipment and the Contents 10

Lifting the Drive Module 11

Storage 11

Product Overview 12

VLT® Ea4 Parallel Drive Modules Basic Kit 12

Drive Modules 12

Control Shelf 13

Wire Harnesses 14

AC Fuses 14

DC Fuses 14

Mechanical Installation 15

Fastener Torque Ratings 15

Required Tools 16

Operating Environment 17

Gases 17

Dust 17

Potentially Explosive Atmospheres 17

Installation Requirements 18

Thermal Considerations 18

Cooling Requirements 18

Busbars 18

Exploded View of Parallel Drive System 19

Installing the Drive Modules 19

Installing the Control Shelf 20

Contents

VLT Ea4 Parallel Drive Modules

Operating Guide

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.11.1

5.11.2

5.11.3

5.11.4

5.11.5

5.12

5.13

5.14

6.1

6.2

6.3

6.4

6.5

6.6

6.6.1

6.7

6.8

6.9

6.10

6.11

7.1

7.2

7.3

Electrical Installation 22

Safety Precautions 22

Electrical Requirements 22

Wiring Diagram 23

Block Diagram 24

Control Shelf Connections 25

Ground Connections 26

Installing DC Bus Fuses 27

Connecting to the Motor 27

Connecting to the AC Mains 28

Example of the Ground, Motor, and Mains Wiring 29

Installing Control Wiring 29

Control Terminals 29

Relay Terminals 31

Routing Control Cables 31

Connecting the Control Cable to the Control Terminals 32

Disconnecting the Control Cable from the Control Terminals 33

Enabling Motor Operation 33

RS485 Serial Communication 33

Selecting the Voltage/Current Input Signal 34

Operating the Drive 36

Pre-start Check List 36

Applying Power to the Drive 37

Local Control Panel (LCP) 38

LCP Menu 40

Entering System Information 41

Testing Before System Start Up 42

Testing Motor Rotation 42

Starting Up the Drive for the First Time 42

Status Messages 42

Warnings and Alarms 46

Troubleshooting 64

Maintenance and Service 66

Specifications 67

Electrical Data, 380–500 V AC 67

Mains Supply to Drive Modules 68

Motor Output 68

Contents

VLT Ea4 Parallel Drive Modules

Operating Guide

7.4

7.5

7.6

7.7

7.7.1

7.7.2

7.7.3

7.7.4

7.7.5

7.7.6

7.7.7

7.7.8

7.7.9

7.7.10

7.7.11

7.7.12

7.7.13

7.8

Torque Characteristics 68

Ambient Conditions for Drive Modules 68

Cable Specifications 69

Control Input/Output and Control Data 69

Digital Inputs 69

STO Terminal 37 69

Analog Inputs 70

Pulse/encoder Inputs 70

Analog Output 71

Control Card, RS485 Serial Communication 71

Digital Outputs 71

Control Card, 24 V DC Output 71

Relay Outputs 71

Control Card, +10 V DC Output 72

Control Characteristics 72

Control Card Performance 73

Control Card, USB Serial Communication 73

Fuses 73

Contents

VLT Ea4 Parallel Drive Modules

Operating Guide

•

1 Introduction and Safety

1.1 Purpose of this Manual

This manual provides requirements for mechanical and electrical installation of the VLT® Ea4 Parallel Drive Modules basic kit.

This guide includes information on:

Wiring of mains and motor connections.

Wiring of control and serial communications.

Control terminal functions.

Detailed tests that must be performed before start-up.

Initial programming to verify proper functioning of the drive system.

This operating guide is intended for use by qualified personnel. To install the drive modules and paralleling kit safely and professio-

nally, read and follow the operating guide. Pay particular attention to the safety instructions and general warnings. Always keep this

guide with the panel containing the VLT® Parallel Drive Modules components.

VLT® is a registered trademark of Danfoss A/S.

1.2 Disclaimer

Danfoss shall have no obligation regarding any product that

is not installed according to the standard configuration as specified in the installation guide.

is improperly repaired or altered.

is subjected to misuse, negligence, and improper installation where the guidelines were not followed.

is used in a contradictory manner to the instructions provided.

is a result of normal wear and tear.

NOTICE

OUTPUT FREQUENCY LIMIT

The output frequency of the drive is limited to 590 Hz due to export control regulations.

1.3 Safety and Installation Awareness

Before starting installation, read all safety guidelines and precautions in this operating guide. PC tools and MyDrive®ecoSmart™can

be downloaded at www.danfoss.com.

1.4 Qualified Personnel

Only qualified personnel are allowed to install, commission, and maintain Danfoss drives. Qualified personnel are trained individuals

who are familiar with and authorized to mount and wire the drive in accordance with pertinent laws and regulations. Also, qualified

personnel must be familiar with the instructions and safety measures described in this installation guide.

1.5 Safety Symbols

The following symbols are used in this guide:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Introduction and Safety

VLT Ea4 Parallel Drive Modules

Operating Guide

NOTICE

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

1.6 Safety Precautions

WARNING

LACK OF SAFETY AWARENESS

This guide gives important information on preventing injury and damage to the equipment or the system. Ignoring this informa-

tion can lead to death, serious injury, or severe damage to the equipment.

Make sure to fully understand the dangers and safety measures present in the application.

Before performing any electrical work on the drive, lock out and tag out all power sources to the drive.

WARNING

LIFTING HEAVY LOAD

The drive is heavy. Lifting heavy objects incorrectly can result in death, injury, or property damage.

Follow local safety regulations on lifting.

Check the weight of the drive. The weight is provided on the outside of the shipping box.

If lifting equipment is used, ensure that it is in proper working condition and can safely lift the weight of the drive.

Test lift the drive to verify the proper center of gravity lift point. Reposition if not level.

WARNING

HAZARDOUS VOLTAGE

AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform

installation, start-up, and maintenance by qualified personnel can result in death or serious injury.

Only qualified personnel must perform installation, start-up, and maintenance.

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be

present even when the warning indicator lights are off. Failure to wait the specified time after power has been removed before

performing service or repair work can result in death or serious injury.

Stop the motor.

Disconnect all power sources, including permanent magnet type motors.

Wait for capacitors to discharge fully. The discharge time is shown on the nameplate. See Illustration 1 and Illustration 2.

Verify full discharge by measuring the voltage level.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

Introduction and Safety

VLT Ea4 Parallel Drive Modules

Operating Guide

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

The drive can cause a DC current in the ground conductor. Failure to use a Type B residual current-operated protective device

(RCD) can lead to the RCD not providing the intended protection which can result in death, fire, or other serious hazard.

Use an RCD device.

When an RCD is used for protection against electrical shock or fire, use only a Type B device on the supply side.

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/tagged out. Failure to run output motor cables separately, or to use shielded cables, could result in death or

serious injury.

Run output motor cables separately or use shielded cables.

Simultaneously lock out/tag out all the drives.

WARNING

ELECTRICAL SHOCK HAZARD

Due to the stray capacitance of the shielded motor cable, the leakage currents exceed 3.5 mA. Failure to properly ground the

drive can result in death or serious injury.

Ensure that minimum size of the ground conductor complies with the local safety regulations for high touch current equip-

ment.

Use a reinforced ground conductor according to IEC 60364-5-54 cl. 543.7 or local safety regulations for equipment with leak-

age current >3.5 mA.

For reinforced grounding:

Use a ground conductor with a cross-section of at least 10 mm2(8 AWG) Cu or 16 mm2(6 AWG) Al, or an extra ground con-

ductor of the same cross-sectional area as the original ground conductor as specified by IEC 60364-5-54, with a minimum

cross-sectional area of 2.5 mm2(14 AWG) mechanically protected or 4 mm2(12 AWG) not mechanically protected.

Use a ground conductor inside an enclosure or otherwise protected throughout its length against mechanical damage.

Use a ground conductor that is part of a multi-conductor power cable with a minimum PE conductor cross-section of

2.5 mm2(14 AWG) that is permanently connected or plugged in by an industrial connector. The multi-conductor power ca-

ble must be installed with an appropriate strain relief.

CAUTION

THERMISTOR INSULATION

Risk of personal injury or equipment damage.

To meet PELV insulation requirements, use only thermistors with reinforced or double insulation.

NOTICE

EXCESSIVE HEAT AND PROPERTY DAMAGE

Overcurrent can generate excessive heat within the drive. Failure to provide overcurrent protection can result in risk of fire and

property damage.

Use additional protective devices such as short-circuit protection or motor thermal protection between the drive and the

motor for applications with multiple motors.

Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer

must provide them.

Introduction and Safety

VLT Ea4 Parallel Drive Modules

Operating Guide

NOTICE

PROPERTY DAMAGE

Protection against motor overload is not active by default. The ETR function provides class 20 motor overload protection. Failure

to set the ETR function means that motor overload protection is not provided and property damage can occur if the motor over-

heats.

Enable the ETR function. See the application guide for more information.

1.7 Disposal

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance

with applicable local regulations.

Introduction and Safety

VLT Ea4 Parallel Drive Modules

Operating Guide

•

2 Receiving the Drive

2.1 Verifying the Shipment and the Contents

Items supplied can vary according to product configuration.

Make sure that the items supplied and the information on the nameplates correspond to the order confirmation.

Visually check the packaging and the drive modules for damage caused by inappropriate handling during shipment. File any

claim for damage with the carrier. Retain damaged parts for clarification.

NOTICE

Removing the nameplates can result in loss of warranty.

Max. Tamb. 55˚

C/131˚

F w/ Output Current Derating

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

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

710 kW / 1000 HP, High Overload

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

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

800 kW /1200 HP, Normal Overload

VLT

T/C: FC-302N710T5E00P2BGC7XXSXXXXAXBXCXXXXDX

P/N: 134X4109

RAutomationDrive

www.danfoss.com

e30bb139.10

ASSEMBLED IN USA

Tamb. 45˚

C/113˚

F at Full Output Current

CHASSIS (OPEN TYPE) / IP00

CAUTION - ATTENTION:

Stored charge, wait 40 min.

Charge residuelle, attendez 40 min.

See manual for special condition / prefuses

Voir manuel de conditions speciales / fusibles

WARNING - AVERTISSEMENT:

SN: 123456H123

Illustration 1: Example of the Top-level Drive System Nameplate Found on Drive Module Exterior

Typecode

Part number and serial number

Power rating

Input voltage, frequency, and current

Output voltage, frequency, and current

Discharge time

Module system only. Specific electrical

Modules are intended for use in Parallel Drive

Intended use - The Individual Base Drive

be referred for actual drive ratings.

Parallel Drive Module system should

ratings are not applicable. Name plate of

VLT

T/C: FC-BDMN250T5E00H2SXC7XXSXXXXAXBXCXXXXDX

P/N: 178N0025

RAutomationDrive

www.danfoss.com

e30bb140.10

ASSEMBLED IN USA

CHASSIS (OPEN TYPE) / IP00

CAUTION - ATTENTION:

Stored charge, wait 40 min.

Charge residuelle, attendez 40 min.

See manual for special condition / prefuses

Voir manuel de conditions speciales / fusibles

WARNING - AVERTISSEMENT:

SN: 123456H123

Illustration 2: Example of the Drive Module Nameplate in the Interior Beneath the Local Control Panel

Receiving the Drive

VLT Ea4 Parallel Drive Modules

Operating Guide

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