Page 1 ENGINEERING TOMORROW Design Guide ® Parallel Drive Modules 250–1200 kW vlt-drives.danfoss.com...
Page 3: Table Of Contents
6.7 Motor Output and Motor Data 6.8 12-Pulse Transformer Specifications 6.9 Ambient Conditions for Drive Modules 6.10 Cable Specifications 6.11 Control Input/Output and Control Data 6.12 Derating Specifications 7 Ordering Information 7.1 Ordering Form 7.2 Drive Configurator MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 4 10.7 dU/dt Conditions 10.8 Parallel Connection of Motors 11 Mains 11.1 Mains Configurations 11.2 Mains Terminal Connections 11.3 12-pulse Disconnector Configuration 12 Control Wiring 12.1 Control Cable Routing 12.2 Control Terminals 12.3 Relay Output Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 5 17.7 RS485 Network Connection 17.8 Motor Thermistor 17.9 Relay Set-up with Smart Logic Control 17.10 Mechanical Brake Control 17.11 Encoder Connection 17.12 Encoder Direction 17.13 Closed-loop Drive System 17.14 Programming of Torque Limit and Stop MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 7: Introduction
• ® The VLT FC Series, D-frame Service Manual contains detailed service information, including ® information applicable to the VLT Parallel Drive Modules. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 8: Safety
• Ground wire of at least 10 mm (6 AWG). • Two separate ground wires, both complying with the dimensioning rules. See EN 60364-5-54 § 543.7 for further information. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 9: Approvals And Certifications
8.3 Electrical Requirements long as the equipment is properly installed, maintained, for Certifications and Approvals. and used as intended. Danfoss CE-labels comply with the Low Voltage Directive and provide a declaration of 3.6 RCM Mark Compliance conformity on request.
Page 10 The ECCN number is provided in the documents accompanying the frequency converter. In case of re-export, it is the responsibility of the exporter to ensure compliance with the relevant export control regulations. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 11: Product Overview
HO: 160–250 kW (200–350 hp). IP 00. NEMA Type 00. (1.6) 1122 (44.2) 1048 (41.3) 346 (13.6) 376 (14.8) Illustration 4.1 Drive Module Dimensions Available Danfoss options • 2-drive module system • 4-drive module system MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 12: Datasheet For 2-Drive System
Illustration 4.2 2-drive System with Minimum Cabinet Dimensions Available Danfoss options • 6-pulse busbar kit • 12-pulse busbar kit • In-back/out-back cooling kit • In-back/out-top cooling kit • In-bottom/out-back cooling kit • In-bottom/out-top cooling kit Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 13: Datasheet For 4-Drive System
Illustration 4.3 4-drive System with Minimum Cabinet Dimensions Available Danfoss options • 6-pulse busbar kit • 12-pulse busbar kit • In-back/out-back cooling kit • In-back/out-top cooling kit • In-bottom/out-back cooling kit • In-bottom/out-top cooling kit MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 14: Internal Components
NOTICE The installer is responsible for the details of the drive system construction, including connections. Also, if the installer does not use the Danfoss recommended design, the installer must obtain separate regulatory approvals. Danfoss A/S © 6/2016 All rights reserved.
Page 15 Used to house the drive modules and other drive system components. (installer- provided) DC busbars Used to connect the DC terminals of the drive modules in parallel. The kit can be ordered from Danfoss or (part of fabricated by the panel builder. busbar kit...
Page 16: Back-Channel Cooling Examples
Parallel Drive Modules 4.5 Back-channel Cooling Examples Illustration 4.5 Cooling Kit Airflow (from Left to Right), In-back/Out-back, In-back/Out-top, In-bottom/Out-top, In-bottom/Out-back Illustration 4.6 2-drive Cabinet with In-back/Out-back Cooling Kit (Left) and In-bottom/Out-top Cooling Kit (Right) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 17: Product Features
560 (750) 2000 1500 6000 2000 630 (900) 2000 1500 6000 2000 710 (1000) 2000 1500 6000 2000 800 (1200) 2000 1500 6000 2000 Table 5.1 Carrier Frequency Operational Ranges for 380–500 V MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 19 The frequency converter is designed to comply with the EMC product standard for IEC/EN 61800-3. For more information regarding EMC performance, see chapter 9.2 EMC Test Results. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 20: Programmable Functions
The frequency converter accommodates 2 feedback signals from 2 different devices. This feature allows regulating a system with different feedback requirements. The Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 21: Safe Torque Off (Sto)
(number of poles). The application using synchronous or maintenance or emergency bypass. permanent magnet motors must take this possibility into consideration and ensure that this scenario is not a critical MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 22 Selections [6] through [9] in parameter 5-19 Terminal 37 Safe Stop must be selected for the combination of external safety device and MCB 112. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 23: System Monitoring
In open-loop operation, the reference signal directly determines the speed of the frequency converter. The display shows a flashing reference high or low warning when the programmed maximum or minimum is reached. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 24 When the delay is exceeded, available options can: • Maintain the last speed. • Go to maximum speed. • Go to a preset speed. • Stop and issue a warning. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 25: Specifications
Module weight [kg (lb)] Length x width x depth [mm (in)] Drive module 125 (275) 1121.7 x 346.2 x 375 (44.2 x 13.6 x 14.8) Table 6.1 Drive Module Weight and Dimensions MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 26 Illustration 6.2 Drive Module Terminal Dimensions (Front View) Section A-A Section B-B Mains Terminals Motor and Brake Terminals Brake terminal Mains terminal Motor terminal Illustration 6.3 Drive Module Terminal Dimensions (Side Views) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 28: Control Shelf Dimensions
® Specifications Parallel Drive Modules 6.2 Control Shelf Dimensions (13.1) (27.8) Illustration 6.5 Control Shelf Dimensions Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 29: 2-Drive System Dimensions
Specifications Design Guide 6.3 2-drive System Dimensions (15.9) (13.3) 2201 2261 (86.7) (89.0) 1959 (77.1) 808 (31.8) (25.0) (31.3) (25.0) Illustration 6.6 2-drive System Exterior Dimensions (Front, Side, and Door Opening Views) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 30 ® Specifications Parallel Drive Modules (76.0) (21.9) Mains jumper busbars (module 1) Mains jumper busbars (module 2) Brake terminals Mains terminals Illustration 6.7 2-drive System Mains Terminals (Side and Front Views) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 31 465 (18.3) 465 (18.3) Motor jumper busbars (module 1) Motor jumper busbars (module 2) Motor terminals Brake terminals Ground terminals Illustration 6.8 2-drive System Motor and Ground Terminals (Front and Side Views) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 32 ® Specifications Parallel Drive Modules 188 (7.4) 89 (3.5) (3.8) 165 (6.5) 323 (12.8) 344 (13.5) Illustration 6.9 2-drive System DC Bus and Relays (Side and Front Views) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 33: 4-Drive System Dimensions
Design Guide 6.4 4-drive System Dimensions 1600 (24.8) (63.0) (31.5) 2200 (86.6) 1970 2254 (77.6) (88.7) (24.8) (31.3) 1800 (71.0) Illustration 6.10 4-drive System Exterior Dimensions (Front, Side, and Door Opening Views) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 35 Brake terminals (modules 1 and 2) Ground terminals (modules 3 and 4) Ground terminals (modules 1 and 2) Connecting ground terminal (see Illustration 6.13) Illustration 6.12 4-drive System Mains and Ground Terminals (Front View) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 36 ® Specifications Parallel Drive Modules (1.4) Illustration 6.13 4-drive System Mains and Ground Terminals (Side View, Left, and Connecting Ground Terminal View, Right) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 37 Motor terminals (modules 1 and 2) Motor terminals (modules 3 and 4) Motor jumper busbars (module 3 and 4) Motor terminal detail (see Illustration 6.15) Illustration 6.14 4-drive System Motor and Brake Terminals (Front View) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 38 ® Specifications Parallel Drive Modules 3x 25 (1.0) (0.7) (1.4) Illustration 6.15 4-drive System Motor and Brake Terminals (Side View, Left, Motor Terminals, Top Right, and Brake Terminals, Bottom Right) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 39 175 (6.9) 4x 88 (3.5) 135 (5.3) 166 (6.5) 323 (12.7) 344 (13.6) Ground jumper busbars (module 1) Grounding shield (module 1) Illustration 6.16 4-drive System DC Bus/Relays and Grounding Shield (Front View) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 41: Power-Dependent Specifications
700 A, 600 V – Table 6.2 FC 102, 380–480 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 42 1500 A Table 6.3 FC 102, 380–480 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 43 700 V, 630 A Table 6.4 FC 102, 525–690 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 44 700 V, 1500 A Table 6.5 FC 102, 525–690 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 45 600 V, 900 A Table 6.6 FC 202, 380–480 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 46 600 V, 1500 A Table 6.7 FC 202, 380–480 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 47 700 V, 550 A Table 6.8 FC 202, 525–690 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 48 700 V, 630 A Table 6.9 FC 202, 525–690 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 49 700 V, 900 A Table 6.10 FC 202, 525–690 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 50 600 V, 900 A Table 6.11 FC 302, 380–500 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 51 600 V, 1500 A Table 6.12 FC 302, 380–500 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 52 700 V, 550 A Table 6.13 FC 302, 525–690 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 53 700 V, 630 A Table 6.14 FC 302, 525–690 V AC Mains Supply (2-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 54 700 V, 1500 A Table 6.15 FC 302, 525–690 V AC Mains Supply (4-Drive System) 1) For 12-pulse units, the cables between the star and delta terminals must be equal in number and length. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 55: Mains Supply To Drive Module
IP rating IP00 Acoustic noise 84 dB (running at full load) Vibration test 1.0 g Vibration and shock (IEC 60721-33-3) Class 3M3 Maximum relative humidity 5–95% (IEC 721–3–3; Class 3K3 (non-condensing)) during operation MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 56: Cable Specifications
Safe Torque Off (STO) Terminal 37 1), 2) (Terminal 37 is fixed PNP logic) Voltage level 0–24 V DC Voltage level, logic 0 PNP <4 V DC Voltage level, logic 1 PNP >20 V DC Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 57 Maximum error: 0.05% of full scale The pulse and encoder inputs (terminals 29, 32, 33) are galvanically isolated from the supply voltage (PELV) and other high- voltage terminals. 1) Pulse inputs are 29 and 33. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 58 Minimum terminal load on 1–3 (NC), 1–2 (NO), 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 20 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2 1) IEC 60947 part 4 and 5. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 59 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB ground connection is NOT galvanically isolated from protective earth. Use only an isolated laptop as PC connection to the USB connector on the frequency converter. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 60: Derating Specifications
Long motor cables • Cables with a large cross-section If these conditions are present, Danfoss recommends stepping up 1 power size. 6.12.1 Derating for Altitude Below 1000 m 1000 m (3281 ft), derating is not necessary. Above 1000 m 1000 m (3281 ft), the ambient temperature (T...
Page 64: Ordering Information
Mains Voltage Order standard frequency converters and frequency converters with integral options by sending a type code Enclosure 13–15 string describing the product to the local Danfoss sales Enclosure type Enclosure class office, for example: Control supply voltage Hardware configuration 16–23...
Page 65 English, German, Slovenian, Bulgarian, Serbian, Romanian, Hungarian, Czech, and Russian. Language Package 4 English, German, Spanish, English US, Greek, Brazilian Portuguese, Turkish, and Polish. To order frequency converters with a different language package, contact the local Danfoss sales office. Description Possible choice Product group 1–6...
Page 66 ® 11: VLT Position Controller MCO 351 ® 12: VLT Center Winder MCO 352 D options DX: No option ® D0: VLT 24 V DC Supply MCB 107 Table 7.4 Ordering Options Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 67 130B3187 1120 1050 1050 2x130B3191 2x130B3192 130B3186 130B3187 1260 1000 1160 1160 3x130B3188 2x130B3189 130B3188 130B3189 1460 1200 1380 1000 1380 3x130B3188 2x130B3189 130B3188 130B3189 Table 7.7 Available Sine-wave Filters, 380–500 V MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 68 130B4129 130B4151 Table 7.8 Available Sine-wave Filters, 525–690 V U V W U V W U V W U V W Drive module Filter Illustration 7.1 Filter Configuration Without Common Busbars (Individual) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 69 Design Guide U V W U V W U V W U V W Drive module Cabinet 2 Cabinet 1 Cables Filter – – Illustration 7.2 Filter Configuration With Common Busbars (Common) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 70: Options And Accessories
7.3.1 Galvanic Isolation in the VLT ® 7.3 Options and Accessories General Purpose I/O MCB 101 Danfoss offers a wide range of options and accessories for ® the VLT AutomationDrive FC 302. The following options Digital/analog inputs are galvanically isolated from other...
Page 71 Terminal number Current range at analog output 0–20 mA 500 Ω Maximum load GND - analog output Accuracy on analog output Maximum error: 0.5% of full scale Resolution on analog output 12 bit MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 72 Data in inv. Data in inv. Future use Max. 5 V on X31.5-12 Table 7.10 Encoder Option MCB 102 Terminal Descriptions for Supported Encoder Types 1) Supply for encoder: see data on encoder. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 73 Ordering Information Design Guide 5 V GND 24 V Illustration 7.6 Incremental Encoder Maximum cable length 150 m (492 ft). Illustration 7.7 SinCos Encoder HIPERFACE Illustration 7.8 Rotation Direction MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 74 LED 1 is on when the reference signal is OK to resolver. LED 2 is on when Cosinus signal is OK from resolver. LED 3 is on when Sinus signal is OK from resolver. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 75 Resolver datasheet Parameter 17-51 Input Voltage Resolver datasheet Parameter 17-52 Input Frequency Resolver datasheet Parameter 17-53 Transformation Ratio Resolver datasheet Parameter 17-59 Resolver Interface [1] Enabled Table 7.12 Parameters to be Adjusted MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 76 Warning Dual supply. Do not combine 24/48 V systems with high-voltage systems. Relay 7 Relay 8 Relay 9 Illustration 7.11 Disconnect Relay Terminals Illustration 7.13 Correct Method to Install Live Parts and Illustration 7.12 Proper Length of Stripped Wire Control Signals Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 78 Motor protection MCB 112 PTC Thermistor Card Option B Code No.130B1137 Reference for 10, 12 20-28 VDC 10 mA 20-28 VDC 60 mA Control Terminals of FC302 Illustration 7.15 Installation of MCB 112 Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 79 2 for maintenance cycle of 2 years 1 for maintenance cycle of 3 years PFD (for yearly functional test) 4.10 x 10 λ +λ 8494 FIT λ 934 FIT Ordering number 130B1137 MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 80 German NAMUR NE37 recommendations. NOTICE ® The MCB 113 is a standard C1-option for the Danfoss VLT AutomationDrive FC 302 and is detected automatically It is acceptable to combine 24 V signals with high- after mounting.
Page 81 DC-line in the its physical size. Danfoss offers a wide variety of different inverter, which can cause a shutdown. The dU/dt filter is...
Page 82 Illustration 7.19 Ordering Number 130B1113, LCP Kit with Graphical LCP, Fasteners, Cable, and Gasket Panel cut out Illustration 7.18 Dimensions Illustration 7.20 Ordering Number 130B1114, LCP Kit with Numerical LCP, Fasteners, and Gasket Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 83: System Design Checklist
Type Length Fuses Type Size Rating Options Connectors Contacts Filters Output Cables Type Length Fuses Type Size Rating Options Filters Control Wiring Type Length Terminal connections Communication Protocol Connection Wiring Options Connectors MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 84 Ordering Information Parallel Drive Modules ☑ Category Details Notes Contacts Filters Motor Type Rating Voltage Options Special tools and equipment Moving and storage Mounting Connection of mains Table 7.14 System Design Checklist Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 85: Considerations During Installation
Safe Torque Off (STO) function must be installed and operated in an IP54 or higher rated control cabinet (or equivalent environment). MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 86: Minimum System Requirements
8.2.2 Busbars environments, use equipment with enclosure rating IP54/ IP55. If the Danfoss busbar kit is not used, see Table 8.2 for the In environments with high temperatures and humidity, cross-section measurements that are required when corrosive gases such as sulphur, nitrogen, and chlorine creating customized busbars.
Page 87 Each drive module contains a heat sink fan and a mixing fan. Typical enclosure designs utilize door fans along with the drive module fans to remove waste heat from the enclosure. Danfoss provides several back-channel cooling kits as options. These kits remove 85% of the waste heat from the enclosure, reducing the need for large door fans.
Page 88: Electrical Requirements For Certifications And Approvals
(NEC) and any applicable local codes. To fulfill this requirement, use UL-classified fuses. • For installation in Canada, branch circuit protection must be provided according to the Canadian Electrical Code and any applicable provincial codes. To fulfill this requirement, use the UL-classified fuses. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 89: Fuses And Circuit Breakers
8.4.1.2 Short-circuit Protection Danfoss recommends the fuses listed in chapter 8.4.1.3 Recommended Fuses for CE Compliance and chapter 8.4.1.4 Recommended Fuses for UL Compliance to achieve CE or UL Compliance in the protection of service personnel and property against the consequences of component breakdown in the drive modules.
Page 90 Any minimum 500 V UL-listed fuse can be used for the 380–500 V AC Any minimum 700 V UL-listed fuse can be used for the 525–690 V AC drive systems. drive systems. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 91: Emc And Harmonics
AC mains supply Frequency converter Shielded motor cable Motor Illustration 9.1 Leakage Currents Illustration 9.1 shows an example of a 6-pulse frequency converter, but could be applicable to a 12-pulse as well. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 92: Emc Test Results
Illustration 9.2 shows the electrical diagram of the RFI filter that was used to qualify the frequency converter. In this scenario, the RFI filter is isolated from the ground, and the RFI relay is disabled using parameter 14-50 RFI Filter. The attenuation factor for the RFI filter is provided in Illustration 9.3. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 93 EMC and Harmonics Design Guide Line Load Table 9.2 Illustration 9.2 Electrical Diagram of RFI Filter -100 -120 Illustration 9.3 Attenuation Requirement for an External Filter MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 94 60 dBµV 50 dBµV 40 dBµV 30 dBµV 20 dBµV 10 dBµV Start 150.0 kHz Stop 30.0 MHz Illustration 9.4 Conducted Emission on the Mains in P4/P8 Configuration Without an External RFI Filter Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 95 60 dBµV 50 dBµV 40 dBµV 30 dBµV 20 dBµV 10 dBµV Start 150.0 kHz Stop 30.0 MHz Illustration 9.5 Conducted Emission on the Mains in P4/P8 Configuration Without an External RFI Filter MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 96 60 dBµV 50 dBµV 40 dBµV 30 dBµV 20 dBµV 10 dBµV Start 150.0 kHz Stop 30.0 MHz Illustration 9.6 Conducted Emission on the Mains in P4/P8 Configuration Without an External RFI Filter Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 97: Emission Requirements
EN/IEC 61000-6-3 Emission standard for residential, commercial, Class B (home and office) and light industrial environments. Second environment EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1 (industrial environment) Table 9.4 Generic Emission Standard Limits MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 98: Immunity Requirements
All Danfoss frequency converters comply with the requirements for both the industrial and the home/office environment. To document immunity against electrical interference, the following immunity tests have been performed on a frequency converter (with options if relevant), a shielded control cable and a control box with potentiometer, motor cable, and motor.
Page 99: Emc Recommendations
If the installation is not carried out according to the guideline, and if unshielded cables and control wires are used, some emission requirements are not in compliance, although the immunity requirements are fulfilled. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 100 Illustration 9.7 EMC-correct Electrical Installation of a Frequency Converter in Cabinet 9.5.1 Using Shielded Control Cables Danfoss recommends braided shielded/armored cables to optimize EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the incoming and outgoing radiation of electric noise depends on the transfer impedance ).
Page 101 100 MHz Aluminum-clad with copper wire. Twisted copper wire or armored steel wire cable. Single-layer braided copper wire with varying percentage shield coverage (this type of cable is the typical Danfoss reference cable). Double-layer braided copper wire. Twin layer of braided copper wire with a magnetic, shielded/armored intermediate layer.
Page 102: General Aspects Of Harmonics
Illustration 9.11 Recommended Method for Avoiding EMC Table 9.6 Harmonics-related Abbreviations Noise Basic Harmonic current (I current (I Alternatively, the connection to terminal 61 can be Current omitted: Frequency [Hz] Table 9.7 Basic Currents and Harmonic Currents Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 103: Effect Of Harmonics In A Power Distribution System
Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 104: Iec Harmonics Standards
Harmonic order (h) Class 1 (V Class 2 (V Class 3 (V 17˂h≤49 2.27 x (17/h) – 0.27 2.27 x (17/h) – 0.27 4.5 x (17/h) – 0.5 Table 9.10 Compatibility Levels for Harmonics Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 105: Ieee Harmonics Standards
Table 9.14 Allowable Harmonic Currents at the PCC 9.11 VLT ® Parallel Drive Modules Harmonics Compliance ® The VLT Parallel Drive Modules comply with the following standards: • IEC 61000-2-4 • IEC 61000-3-4 • IEEE 519 • G5/4 MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 106: Galvanic Isolation
NOTICE INSTALLATION AT HIGH ALTITUDE When installing 380–500 V units above 3000 m (9843 ft), contact Danfoss regarding PELV. When installing 525–690 V units above 2000 m (6562 ft), contact Danfoss regarding PELV. Protection against electric shock is ensured when the electrical supply is of the PELV type, and the installation complies with local/national regulations on PELV supplies.
Page 107: Motor
Consult the cable manufacturer specifi- Table 10.1. If a motor has lower insulation rating, Danfoss cations regarding the length and expected voltage drop recommends using a dU/dt or sine-wave filter.
Page 108: Motor Thermal Protection
Input digital/ Supply Trip resistance Reset analog voltage [V] kΩ resistance <800 Ω Digital >2.7 Analog >3.0 <3.0 kΩ Digital >10.8 <6.6 kΩ Table 10.2 PTC Thermistor Resistance Parameters Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 109 Use 1 mm (18 AWG), reinforced and 1000 double insulated wire for the connection. NOTICE Danfoss is not responsible for the failure of any Klixon thermal switch. Temperature [°C] KTY type 1 KTY type 2 KTY type 3 Illustration 10.5 KTY Type Selection...
Page 110: Motor Terminal Connections
For example, do not use 1 cable on one motor terminal and 2 cables on another motor terminal. • Terminal V/T2/97 connected to V-phase • Terminal W/T3/98 connected to W-phase Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 111 1 set of motor terminals. DC fuses DC-link busbars Drive modules DC terminals Mains input busbars Brake terminals Mains input terminals Motor output busbars Illustration 10.8 Connections in 6-Pulse 2-Drive Module System MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 112 Motor Parallel Drive Modules 130BE743.10 DC fuses DC-link busbars Drive modules DC terminals Motor output busbars Brake terminals Mains input terminals Motor output terminals Illustration 10.9 Connections in 12-Pulse 2-Drive Module System Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 113 DC fuses DC terminals Drive module Brake terminals Mains input busbars Motor output busbars Mains input terminals Motor output terminals DC-link busbars – – Illustration 10.10 Connections in 4-Drive Module System MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 114: Extreme Running Conditions
Minimum speed limit If it is possible that the motor may overspeed, Parameter 4-11 Motor Speed Low Limit [RPM] or Danfoss recommends that a brake resistor be parameter 4-12 Motor Speed Low Limit [Hz] limit the equipped to the frequency converter.
Page 115: Du/Dt Conditions
PEAK In particular, motors without phase coil insulation are affected if the peak voltage is too high. Motor cable length affects the rise time and peak voltage. For example, if the MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 116 The total motor cable length specified in chapter 6.10 Cable Specifications is valid as long as the parallel cables are kept less than 10 m (32 ft) each. See example 2. Illustration 10.12 Different Parallel Connections of Motors Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 117: Mains
If connecting more than 1 set of mains terminals, use the same number, size, and length of cables for each set of terminals. For example, do not use 1 cable on one mains terminal and 2 cables on another mains terminal. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 118 Parallel Drive Modules Drive module 1 Disconnector 1 Drive module 2 Brake fault Supplementary fuses Drive module 3 Mains input busbars Drive module 4 Brake fault Disconnector 2 Illustration 11.1 Connection of 12-Pulse Disconnector/Interlock Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 119 Illustration 11.2 BRF Connection with 12-Pulse Disconnector/Interlock NOTICE If the brake option is not selected, the Klixon switch can be bypassed. NOTICE Danfoss is not responsible for any failure or malfunction in the disconnector/contactor switch. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 120: Control Wiring
44-pin ribbon cable from MDCIC to drive modules 1 and 2 Relay cable (shown connected to relay terminal on control shelf ) Ferrite core – – Illustration 12.1 Control Cable Routing for a 4-Drive System Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 121: Control Terminals
4 programmable digital inputs terminals, 2 extra digital terminals programmable as either input or output, a 24 V DC terminal supply voltage, and a common for optional customer-supplied 24 V DC voltage. Illustration 12.2 Control Terminal Locations MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 122 Table 12.1 Terminal Description Extra terminals: • Two form C relay outputs. Location of the outputs depends on frequency converter configuration. • Terminals on built-in optional equipment. See the manual provided with the equipment option. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 123 (+)68 and (-)69. • Terminate each segment at both ends, using either the termination switch (bus term on/off, see Illustration 12.4) on the drive module, or a biased network termination resistor. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 124: Relay Output
Relay 1 and relay 2 are programmed in parameter 5-40 Function Relay, parameter 5-41 On Delay, Relay, and parameter 5-42 Off Delay, Relay. ® Use VLT Relay Card MCB 105 option module for extra relay outputs. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 125: Braking
If the frequency converter is brought into an alarm condition, such as an overvoltage situation, the mechanical brake immediately cuts in. The mechanical brake also cuts in during Safe Torque Off. Time Illustration 13.1 Typical Braking Cycle MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 126 NOTICE 355–1000 Check that the brake resistor can handle a voltage of 410 (500–1350) V, 820 V, 850 V, 975 V, or 1130 V - unless Danfoss brake ® ® HVAC Drive FC 102 and VLT AQUA Drive FC 202 resistors are used.
Page 127 Overvoltage control (OVC) can be selected as an alternative brake function. This function is active for all units and ensures that if the DC-link voltage increases, the output frequency also increases to limit the voltage from the DC link, thereby avoiding a trip. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 128 ® Braking Parallel Drive Modules 13.2.3 Brake Resistor Connection Drive module Individual brake resistors Brake terminals – – Illustration 13.2 Connection of Individual Brake Resistor to Each Drive Module Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 129 Braking Design Guide 130BE737.10 Drive module Common brake resistor Brake terminals – – Illustration 13.3 Connection of Common Brake Resistor to Each Drive Module MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 130: Controls
[2] Flux control closed loop with motor speed feedback. Torque setting is done by setting an analog, digital, or bus controlled reference. The maximum speed limit factor is set in parameter 4-21 Speed Limit Factor Source. When running torque control, Danfoss recommends to make a full AMA procedure since the correct motor data is essential for optimal performance.
Page 131 Used for reference or feedback signals. A thermistor can be connected here. Common for terminals 53 and 54. RS485 common. 68, 69 RS485 interface and serial communication. Table 14.1 Terminal Control Functions (without Optional Equipment) MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 132 (N RS-485) 69 0 V (PNP) 24 V (NPN) (COM RS-485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 14.1 Wiring Diagram Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 133: Control Structure In Vvc + Advanced Vector Control
To use the process PID control for closed-loop control of speed or pressure in the controlled application, for example, select [3] Process in parameter 1-00 Configuration Mode. The process PID parameters are located in parameter group 7-2* Process Ctrl. Feedback and parameter group 7-3* Process PID Ctrl. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 134: Control Structure In Flux Sensorless
(RPM) P 7-22 Process feedback P 4-12 Motor speed 2 source low limit (Hz) ® Illustration 14.4 Control Structure in Flux with Motor Feedback Configuration (only Available in VLT AutomationDrive FC 302) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 135: Internal Current Control In Vvc
LCP. After pressing [Auto On], the frequency converter goes into auto-on mode and follows (as default) the remote reference. In this mode, it is possible to control the MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 136: Smart Logic Controller
Stop operand becomes true. This condition leads to an event P13-02 associated action as shown in Illustration 14.8. Illustration 14.9 Internal Current Control Example Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 137 If the feedback error goes below the limit again within 5 s, the frequency converter continues and the warning disappears. Press [Reset] on the LCP to reset relay 1. Table 14.3 Using SLC to Set a Relay MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 138: Handling Of References
Speed up/ speed down No function P 16-02 Analog ref. 200% Ref. in % Pulse ref. -200% Local bus ref. DigiPot No function Analog ref. Pulse ref. Local bus ref. DigiPot Illustration 15.1 Remote Reference Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 140: Scaling Of Preset References
The only difference is that a reference above or below the specified minimum and maximum endpoints (P1 and P2 in Illustration 15.5) are clamped, whereas feedback above or below is not. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 141: Dead Band Around Zero
Thus a reference endpoint of P1=(0 V, 0 RPM) does not result in any dead band, but a reference endpoint of P1=(1 V, 0 RPM), results in a -1 V to +1 V dead band if the P2 endpoint is placed in either Quadrant 1 or Quadrant 4. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 142 High Reversing Limits Speed Setpoint according to min max speed Motor PID Range: Motor Motor -200 RPM control +200 RPM Illustration 15.9 Positive Reference with Dead Band, Digital Input to Trigger Reverse Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 143 Limits Speed Setpoint according to min max speed Motor PID Range: Motor Motor -200 RPM control +200 RPM Illustration 15.10 Positive Reference with Dead Band, Digital Input to Trigger Reverse. Clamping Rules MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 144 Limits speed to min max motor speed -500 No Dead Motor PID Band Motor Motor control Illustration 15.11 Negative to Positive Reference with Dead Band, Sign Determines the Direction, -Maximum to +Maximum Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 145: Pid Controls
The required motor speed is set via a potentiometer connected to terminal 53. The speed range is 0–1500 RPM corresponding to 0–10 V over the potentiometer. A switch connected to terminal 18 controls the starting and stopping. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 146 3) Make sure that the frequency converter limits are set to safe values. Set acceptable limits for the references. Parameter 3-02 Minimum 0 RPM (default) Reference Parameter 3-03 Maximum 1500 RPM (default) Reference Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 147 7-0* Speed PID Ctrl See chapter 16.1.4 Tuning Speed PID Control manually. 8) Finished. Save the parameter setting to the LCP. Parameter 0-50 LCP Copy [1] All to LCP Table 16.3 Programming Order MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 148: Process Pid Controls
Integral Time could be set to approximately 2.5 s. Time varies with the application. Set the parameter 7-04 Speed PID Differentiation Time to 0 until everything else is tuned. If necessary, finish the tuning by adjusting this setting in small increments. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 149 In applications where there is a good and approximately linear correlation between the process reference Feed Forward Factor and the motor speed necessary for obtaining that reference, the feed forward factor can be used to achieve better dynamic performance of the process PID control. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 150 °C (23 to 95 °F), 0–10 V DC) connected to terminal 53. Temperature feedback via transmitter (-10 to 40 °C (14 to 104 °F), 4–20 mA) connected to terminal 54. Switch S202 set to ON (current input). Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 151 Set S201 or S202 to desired analog input function (Voltage (V) or milliamps (I)): NOTICE Turn off the frequency converter before moving the switches from one setting to another. Use finger to gently move the switches. 5) Scale analog inputs used for reference and feedback MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 152: Optimization Of Pid Controls
Only use the differentiator when the setting of the proportional gain and the integration time are fully optimized. Make sure that the low-pass filter sufficiently dampens the oscillations on the feedback signal. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 153 K , is reached. To obtain the critical time constant, measure the period of oscillation: P To calculate the necessary PID control parameters, use Table 16.7. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 154: Application Examples
Parameter 6-15 T 1500 RPM erminal 53 High +10 V Ref./Feedb. Value A IN *=Default value A IN Notes/comments: A OUT -10 - +10V U - I Table 17.3 Analog Speed Reference (Voltage) Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 155: Start/Stop
A IN operation, a jumper wire to Latched Start (18) terminal 27 is not needed. Stop Inverse (27) A OUT Illustration 17.2 Latched Start/Stop Inverse Table 17.5 Start/Stop Command with Safe Torque Off MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 156: External Alarm Reset
Digital Input D IN *=Default value D IN Notes/comments: D IN D IN D IN D IN D IN +10 V A IN A IN A OUT Table 17.8 External Alarm Reset Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 157: Speed Up/Down
Table 17.10 Speed Up/Down Table 17.11 RS485 Network Connection Speed Reference Start ( 18) Freeze ref ( 27) Speed up ( 29 ) Speed down ( 32 ) Illustration 17.3 Speed Up/Down MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 158: Motor Thermistor
5 s, then the frequency converter continues and the warning disappears. Reset Relay 1 by pressing [Reset] on the LCP. Table 17.13 Using SLC to Set a Relay Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 159: Mechanical Brake Control
• Clockwise (CW) direction means channel A is 90 electrical degrees before channel B. • Counterclockwise (CCW) direction means channel B is 90 electrical degrees before A. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 160: Closed-Loop Drive System
27 changes from logic 1 to logic 0 and the motor starts to coast, ensuring that the hoist stops even if the frequency converter itself cannot handle the required torque, for example due to excessive overload. Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 161: Appendix
Appendix Design Guide 18 Appendix 18.1 Disclaimer 18.2 Conventions • Danfoss shall have no obligation with respect to any Numbered lists indicate procedures. product that • Bullet lists indicate other information and • is not installed according to the standard configu- description of illustrations.
Page 162: Glossary
DC-link voltage and a brake chopper ensures that the power is transmitted to the brake resistor. Bus reference A signal transmitted to the serial communication port (FC port). Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 163 Numerical LCP 101 (NLCP) if there is an imbalance between an energized conductor • Graphical LCP 102 (GLCP) and ground. Also known as a ground fault circuit interrupter (GFCI). Least significant bit. MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 164 For example, if the frequency converter is subject to a short circuit on the output, it enters trip lock. A locked trip can only be canceled by cutting off mains, Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 165: Index
Conventions..................159 Limits....................124 Mechanical holding..............123 Cooling....................17, 83 OVC..................... 125 CT characteristics................161 Power levels..................124 Resistor................79, 123, 160 Resistor switch................107 Breakaway torque............... 19, 160 Broken belt....................22 MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 166 Encoder direction................157 Humidity................... 81, 83 Energy efficiency................... 53 Energy efficiency class................ 53 IEE standards..................103 ETR......................161 Imbalance....................21 Export control regulations..............8 Industrial environment............... 95 External 24 V DC supply..............75 Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 167 Overload....................19 MCB 101....................68 Overtemperature................16, 21 MCB 102................70, 146, 161 Overvoltage................112, 125 MCB 103....................72 MCB 105....................74 MCB 107....................75 PELV....................104, 152 MCB 112.................... 20, 76 MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 168 Relay................... 56, 74, 78, 120 Switching pattern................160 Relay setting up using smart logic controller......156 System design checklist..............81 Remote start................... 18 Requirements Emission (EMC)................. 95 Temperature................... 59 Residential environment..............95 Danfoss A/S © 6/2016 All rights reserved. MG37N102...
Page 169 VVC+..................131, 133, 162 VVC+ static overload................. 112 Warning....................21 Weight..................23, 81, 84 Wire sizes....................108 Wiring Control terminal................121 Wiring....................81 Wiring..................... 100 Wiring diagram................... 130 Ziegler Nichols tuning method............. 150 MG37N102 Danfoss A/S © 6/2016 All rights reserved.
Page 170 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.

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Vlt 525-690 v

Danfoss VLT 380-500 V Design Manual

1 Introduction

2 Safety

3 Approvals and Certifications

4 Product Overview

5 Product Features

6 Specifications

7 Ordering Information

8 Considerations During Installation

9 EMC and Harmonics

10 Motor

11 Mains

12 Control Wiring

13 Braking

14 Controls

15 Handling of References

16 PID Controls

17 Application Examples

18 Appendix

Index

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