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Danfoss VLT Ea4 Operating Manual

Parallel drive modules
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Operating Guide
VLT Ea4 Parallel Drive Modules

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  • Page 1 Operating Guide VLT Ea4 Parallel Drive Modules...

  • Page 3: Table Of Contents

    VLT Ea4 Parallel Drive Modules Operating Guide Contents Contents Introduction and Safety Purpose of this Manual Disclaimer Safety and Installation Awareness Qualified Personnel Safety Symbols Safety Precautions Disposal Receiving the Drive Verifying the Shipment and the Contents Lifting the Drive Module...
  • Page 4 VLT Ea4 Parallel Drive Modules Operating Guide Contents Electrical Installation Safety Precautions Electrical Requirements Wiring Diagram Block Diagram Control Shelf Connections Ground Connections Installing DC Bus Fuses Connecting to the Motor Connecting to the AC Mains 5.10 Example of the Ground, Motor, and Mains Wiring 5.11...
  • Page 5 VLT Ea4 Parallel Drive Modules Operating Guide Contents Torque Characteristics Ambient Conditions for Drive Modules Cable Specifications Control Input/Output and Control Data 7.7.1 Digital Inputs 7.7.2 STO Terminal 37 7.7.3 Analog Inputs 7.7.4 Pulse/encoder Inputs 7.7.5 Analog Output 7.7.6 Control Card, RS485 Serial Communication 7.7.7...

  • Page 6: Introduction And Safety

    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.

  • Page 7: Safety Precautions

    VLT Ea4 Parallel Drive Modules Operating Guide Introduction and Safety N O T I C E Indicates information considered important, but not hazard-related (for example, messages relating to property damage). 1.6 Safety Precautions W A R N I N G LACK OF SAFETY AWARENESS This guide gives important information on preventing injury and damage to the equipment or the system.
  • Page 8 VLT Ea4 Parallel Drive Modules Operating Guide Introduction and Safety W A R N I N G 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.

  • Page 9: Disposal

    VLT Ea4 Parallel Drive Modules Operating Guide Introduction and Safety N O T I C E 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.

  • Page 10: Receiving The Drive

    VLT Ea4 Parallel Drive Modules Operating Guide Receiving the Drive 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.

  • Page 11: Lifting The Drive Module

    VLT Ea4 Parallel Drive Modules Operating Guide Receiving the Drive Typecode Intended use disclaimer Part number and serial number Discharge time 2.2 Lifting the Drive Module W A R N I N G The drive modules are heavy and failure to follow local safety regulations for lifting heavy weights may cause death, personal injury, or property damage.

  • Page 12: Product Overview

    VLT Ea4 Parallel Drive Modules Operating Guide Product Overview 3 Product Overview 3.1 VLT® Ea4 Parallel Drive Modules Basic Kit The VLT® Ea4 Parallel Drive Modules basic kit is used to create a drive system consisting of 4 drive modules. This kit provides a great- er power range in a smaller enclosure, while allowing system integrators design flexibility and the potential to fabricate custom components for the system.

  • Page 13: Control Shelf

    VLT Ea4 Parallel Drive Modules Operating Guide Product Overview DC-link terminal and DC fuse Ground terminals MDCIC plug Top fan Microswitch connector to DC fuse Drive module nameplate. See Illustration Relays 1 and 2 Motor output terminals (inside the unit)

  • Page 14: Wire Harnesses

    VLT Ea4 Parallel Drive Modules Operating Guide Product Overview LCP cradle MDCIC card Control card (underneath cover) Control shelf Control terminal blocks Switch mode power supply (SMPS). An external 230 V supply is needed to power the SMPS. Top-level drive system nameplate. See...

  • Page 15: Mechanical Installation

    VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation 4 Mechanical Installation 4.1 Fastener Torque Ratings N O T I C E Apply the specified torque when tightening fasteners. Too low or too high torque when fastening an electrical connection results in a bad electrical connection.

  • Page 16: Required Tools

    VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation Illustration 7: Unique Torque Values All M4 fasteners [2.3 Nm (20 in-lb)] 6 M5 fasteners attaching gate drive card [2.3 Nm (20 in-lb)] 3 M5 fasteners [3.9 Nm (35 in-lb)] All M5 fasteners attaching input plates to side All gasketed M5 fasteners except door screws [3.9...

  • Page 17: Operating Environment

    VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation • T25 and T50 Torx drives • Sheet metal punch and/or pliers for cable entry plate • Any additional tools for assembling the cabinet panels according to design plans and established practices 4.3 Operating Environment...

  • Page 18: Installation Requirements

    VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation As required by the EU Directive 2014/34/EU, any electrical or electronic device intended for use in an environment with a potentially explosive mixture of air, flammable gas, or dust must be ATEX-certified. Systems operated in this environment must fulfill the fol- lowing special conditions to comply with the ATEX protection class: •...

  • Page 19: Exploded View Of Parallel Drive System

    VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation 4.5 Exploded View of Parallel Drive System This example of a 4-module system is composed of a control shelf and 4 VLT® Ea4 Parallel Drive Modules in 2 side-by-side enclo- sures. The control shelf attaches to the enclosure and holds the LCP and control card, as well as the MDCIC and control terminals.

  • Page 20: Installing The Control Shelf

    Remove the control shelf assembly from its package. Remove the LCP from the control shelf. Use some type of mounting bracket to install the control shelf. Danfoss does not supply the mounting brackets for the control shelf. Remove the MDCIC cover from the control shelf assembly.
  • Page 21 VLT Ea4 Parallel Drive Modules Operating Guide Mechanical Installation Connect the microswitch to the microswitch connector provided on the top of the drive module. Example Illustration 9: Positioning the Control Shelf for EMC-compliant Installation Control shelf must stay below this point Control shelf must stay above this point Danfoss A/S ©...

  • Page 22: Electrical Installation

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation 5 Electrical Installation 5.1 Safety Precautions N O T I C E 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.

  • Page 23: Wiring Diagram

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation 5.3 Wiring Diagram 230 V AC Space heater (optional) 50/60 Hz 91 (L1) (U) 96 3-phase (V) 97 92 (L2) power 93 (L3) (W) 98 input (PE) 99 Motor Switch mode...

  • Page 24: Block Diagram

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation 5.4 Block Diagram Illustration 11: Eah Block Diagram 24 | Danfoss A/S © 2023.01 AQ434333248451en-000101 / 130R1286...

  • Page 25: Control Shelf Connections

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation 5.5 Control Shelf Connections The control shelf is preassembled. However, verify its various connections against the connection diagram. Illustration 12 shows the various control shelf connections. N O T I C E CONNECTION SEQUENCE If the connections are not made in the correct order, the drive modules do not function.

  • Page 26: Ground Connections

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Example FK100 FK101 MK110 INV1 MK107 INV2 MK108 INV3 MK109 INV4 MK110 MK111 MK106 1 2 3 4 5 6 7 8 9 10 Illustration 12: Control Shelf Connections STO relay...

  • Page 27: Installing Dc Bus Fuses

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation W A R N I N G LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury. Ensure the correct grounding of the equipment by a certified electrical installer.

  • Page 28: Connecting To The Ac Mains

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions. See 5.6 Ground Connections. Connect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W).

  • Page 29: Example Of The Ground, Motor, And Mains Wiring

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation 5.10 Example of the Ground, Motor, and Mains Wiring L1, L2, L3 M10 [19 Nm (168 in-lb)] M12 [35 Nm (310 in-lb)] M10 [19 Nm (168 in-lb)] U/T1, V/T2, W/T3 M12 [35 Nm (310 in-lb)]...
  • Page 30 VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Table 3: Serial Communication Terminals Terminal Parameter Default Description Setting – – Integrated RC-filter for cable shield. ONLY for connecting the shield if EMC problems exist. Parameter group 8-3* FC –...

  • Page 31: Relay Terminals

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Terminal Parameter Default setting Description Parameter group 6-1* Analog In- Reference Analog input. For voltage (V) or current (mA). put 1 Parameter group 6-2* Analog In- Feedback put 2 – –...

  • Page 32: Connecting The Control Cable To The Control Terminals

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Example Illustration 16: Control Cable Routing for a 4-drive System Microswitch cable Control terminals Ferrite core 44-pin ribbon cable from MDCIC to drive module 4 44-pin ribbon cable from MDCIC to drive modules 1...

  • Page 33: Disconnecting The Control Cable From The Control Terminals

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Example 12 13 18 19 27 29 32 33 Illustration 17: Connecting a Solid Control Cable to the Terminal Box 12 13 18 19 27 29 32 33 Illustration 18: Connecting a Flexible Control Cable to the Terminal Box 5.11.5 Disconnecting the Control Cable from the Control Terminals...

  • Page 34: Selecting The Voltage/Current Input Signal

    VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation • Ability to select from the following communication protocols: FC, FC MC, FC option Modbus RTU Metasys N2 BACnet • Functions can be programmed remotely using the protocol software and RS485 connection or in parameter group 8-** Commu- nications and Options.
  • Page 35 VLT Ea4 Parallel Drive Modules Operating Guide Electrical Installation Set switches A53 and A54 to select the signal type (U = voltage, I = current). See Illustration Example Illustration 20: Location of Switches A53 and A54 Danfoss A/S © 2023.01...

  • Page 36: Operating The Drive

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6 Operating the Drive 6.1 Pre-start Check List Table 8: Pre-start Check List Inspect Check for ✓ Motor Confirm continuity of the motor by measuring ohm values on U–V (96–97), V–W (97–98), and W–U (98–96).

  • Page 37: Applying Power To The Drive

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Inspect Check for ✓ For IP20/Type 1 enclosures, ensure that the unit is mounted on an unpainted, metal surface. Vibration Check that the unit is mounted solidly, or that shock mounts are used, if necessary.

  • Page 38: Local Control Panel (Lcp)

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.3 Local Control Panel (LCP) Status 1(1) A1.1 A1.3 0.00 A 0 RPM 0.00 kW A1.2 0.0 Hz 0.0 % Remote Stop Quick Main Alarm Status Menu Menu Warn. Alarm...
  • Page 39 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Table 10: LCP Menu Keys Callout Function Status Shows operational information. Quick Menu Allows access to parameters for initial set-up instructions. Also provides detailed application steps. Refer to Quick Menu mode in the LCP Menu section.

  • Page 40: Lcp Menu

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.4 LCP Menu Quick Menus The Quick Menus mode provides a list of menus used to configure and operate the drive. Select the Quick Menus mode by pressing the [Quick Menu] key. The resulting readout appears on the LCP display.

  • Page 41: Entering System Information

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive • List the parameter groups available to the drive and drive options. • Change parameter values. 0 RPM 0.00 A 1(1) Main Menu O-** Operation / Display 1-** Load and Motor...

  • Page 42: Testing Before System Start Up

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.6 Testing Before System Start Up W A R N I N G MOTOR START Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equip- ment damage.
  • Page 43 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Status 1(1) 799RPM 7.83A 36.4kW 0.000 53.2% Auto Remote Ramping Hand Local Stop Off Running Jogging Standby Illustration 24: Status Display 6.8.2 Status Messages - Operating Mode. 6.8.4 Status Messages - Operation Status.
  • Page 44 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Operation Description status AMA ready AMA is ready to start. To start, press [Hand On]. AMA run- AMA process is in progress. ning Braking The brake chopper is in operation. The brake resistor absorbs the generative energy.
  • Page 45 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Operation Description status • [14] Jog was selected as function for a digital input (parameter group 5–1* Digital Inputs). The corresponding terminal (for example, terminal 29) is active. • The jog function is activated via the serial communication.

  • Page 46: Warnings And Alarms

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Operation Description status • LCP. • Digital input. • Serial communication. Trip/Trip An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, reset the drive using 1 of the...
  • Page 47 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Table 18: Fault Types Type of fault Warning indicator light Alarm indicator light Warning Alarm On (flashing) Trip lock On (flashing) Status 1(1) 0.0Hz 0.000kW 0.00A 0.0Hz Earth Fault [A14]...
  • Page 48 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Warn. Alarm Illustration 27: Status Indicator Lights Table 19: Fault Types Type of fault Warning indicator light Alarm indicator light Warning Alarm On (flashing) Trip lock On (flashing) Status 1(1) 0.0Hz...
  • Page 49 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Control card terminals 53 and 54 for signals, terminal 55 common. VLT® General Purpose I/O MCB 101 terminals 11 and 12 for signals, terminal 10 common. VLT® Analog I/O Option MCB 109 terminals 1, 3, and 5 for signals, terminals 2, 4, and 6 common.
  • Page 50 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Troubleshooting • Compare the output current shown on the LCP with the drive rated current. • Compare the output current shown on the LCP with the measured motor current. •...
  • Page 51 6.9.17 ALARM 15, Hardware Mismatch Cause A fitted option is not operational with the present control card hardware or software. Troubleshooting Record the value of the following parameters and contact Danfoss. • Parameter 15-40 FC Type. • Parameter 15-41 Power Section.
  • Page 52 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Troubleshooting W A R N I N G 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.
  • Page 53 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.24 WARNING 24, External Fan Fault Cause The fan warning function is a protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).
  • Page 54 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.30 ALARM 30, Motor Phase U Missing Cause Motor phase U between the drive and the motor is missing. Troubleshooting W A R N I N G 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.
  • Page 55 Check that the option is properly installed. • Check for loose or missing wiring. It may be necessary to contact the Danfoss supplier or service department. Note the code number for further troubleshooting guid- ance. Table 20: Internal Fault Codes...
  • Page 56 5126 Option in slot C1: Hardware incompatible with the control board hardware. 5376– 6231 Internal fault. Contact the Danfoss supplier or Danfoss service department. 6.9.39 ALARM 39, Heat Sink Sensor Cause There is no feedback from the heat sink temperature sensor.
  • Page 57 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Troubleshooting Choose 1 of the following: • Connect a 24 V DC external supply. • Specify that no external supply is used via parameter 14-80 Option Supplied by External 24VDC, [0] No. A change in parameter 14-80 Option Supplied by External 24VDC requires a power cycle.
  • Page 58 6.9.49 ALARM 50, AMA Calibration Failed Cause A calibration error has occurred. Troubleshooting • Contact the Danfoss supplier or Danfoss service department. 6.9.50 ALARM 51, AMA Check Unom and Inom Cause The settings for motor voltage, motor current, and motor power are wrong. Troubleshooting •...
  • Page 59 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.57 ALARM 58, AMA Internal Fault Cause Internal fault. Troubleshooting Contact the Danfoss supplier. 6.9.58 WARNING 59, Current Limit Cause The current is higher than the value in parameter 4-18 Current Limit.
  • Page 60 The control card and power card are incompatible. Troubleshooting • To check compatibility, contact the Danfoss supplier with the type code from the unit nameplate and the part numbers on the cards. 6.9.69 ALARM 71, PTC 1 Safe Stop Cause Because the motor is too warm, the VLT PTC Thermistor Card MCB 112 activated the Safe Torque Off (STO).
  • Page 61 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.71 WARNING 73, Safe Stop Auto Restart Cause STO activated. Troubleshooting • With automatic restart enabled, the motor can start when the fault is cleared. 6.9.72 ALARM 74, PTC Thermistor Cause The PTC is not working.
  • Page 62 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.81 ALARM 83, Illegal Option Combination Cause The mounted options are incompatible. 6.9.82 ALARM 84, No Safety Option Cause The safety option was removed without applying a general reset. Troubleshooting •...
  • Page 63 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.91 WARNING 163, ATEX ETR Cur.Lim.Warning Cause The drive has run above the characteristic curve for more than 50 s. The warning is activated at 83% and deactivated at 65% of the allowed thermal overload.

  • Page 64: Troubleshooting

    VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive 6.9.100 ALARM 425, FPC Update Failure Cause This alarm is generated after the control card failed to update the fan power card PUD. Troubleshooting • Check the fan power card wiring.
  • Page 65 VLT Ea4 Parallel Drive Modules Operating Guide Operating the Drive Symptom Possible cause Test Solution Display (LCP) is defective. Test using a different LCP. Replace the faulty LCP or connection cable. Internal voltage supply fault – Contact supplier. or SMPS is defective.

  • Page 66: Maintenance And Service

    To prevent breakdown, danger, and damage, examine the drive for loose terminal connections, excessive dust buildup, and worn parts at regular intervals. Replace worn or damaged parts with Danfoss authorized parts. For service and support, contact the local Danfoss supplier.

  • Page 67: Specifications

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications 7 Specifications 7.1 Electrical Data, 380–500 V AC Table 22: Electrical Data, Mains Supply 3x380–500 V AC (4-Drive System) VLT® AutomationDrive FC 302 N1M1 Drive modules 0–590 Output Frequency [Hz] High/normal overload High overload=150% torque for a duration of 60 s.

  • Page 68: Mains Supply To Drive Modules

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications 7.2 Mains Supply to Drive Modules The unit is suitable for use on a circuit capable of delivering not more than 100 kA short circuit current rating (SCCR) at 480 V. Supply terminals...

  • Page 69: Cable Specifications

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications Temperature during storage/transport -25 to +65/70 °C (-13 to +149/158 °F) Maximum altitude above sea level without derating 1000 m (3280 ft) Maximum altitude above sea level with derating 3000 m (9842 ft)

  • Page 70: Analog Inputs

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications Typical input current at 20 V 60 mA rms Input capacitance 400 nF All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. For further information about terminal 37 and Safe Torque Off, see the VLT FC Series- Safe Torque Off Operating Guide.

  • Page 71: Analog Output

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications Encoder input accuracy (1–11 kHz) Maximum error: 0.05% of full scale FC 302 only. Encoder inputs: 32=A and 33=B. 7.7.5 Analog Output Number of programmable outputs Terminal number Current range at analog output...

  • Page 72: Control Card, +10 V Dc Output

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications Maximum terminal load (AC-1) on 1–2 (NO) (Resistive load) 400 V AC, 2 A (2)(3) Maximum terminal load (AC-15) 1–2 (NO) (Inductive load @ 240 V AC, 0.2 A cosφ 0.4) Maximum terminal load (DC-1) on 1–2 (NO) (Resistive load)

  • Page 73: Control Card Performance

    VLT Ea4 Parallel Drive Modules Operating Guide Specifications All control characteristics are based on a 4-pole asynchronous motor. 7.7.12 Control Card Performance Scan interval 5 ms 7.7.13 Control Card, USB Serial Communication USB standard 1.1 (full speed) USB plug USB type B plug (2)(3) Connection to PC is carried out via a standard host/device USB cable.
  • Page 76 Danfoss can accept no responsibility for possible errors in catalogs, 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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