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Danfoss VLT Training Manual
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Danfoss VLT Training Manual

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Summary of Contents for Danfoss VLT

  • Page 3 Danfoss Drives, VLT - Installation Startup Check List General Installation This presentation deals with the start-up of a Danfoss Drive, also known as a VLT. It is designed to help handle the start-up of the drive for general installation in normal applications.

  • Page 4: General Installation

    Control Wiring, Programming and Startup of the VLT are covered in greater detail in following module designed for a specific drive and application. Rev.02...
  • Page 5 24Vdc, brake and load- sharing. North America Motion Controls Confidential / Property of Danfoss Drives A/S Objectives These objectives are listed as a goal for this training module. A review at the end of this module tests the student concerning these objectives.
  • Page 6 Confidential / Property of Danfoss Drives A/S Warning Touching the electrical parts of the VLT may be fatal — even after it has been disconnected from the AC line. Even after power has been removed, the DC Link Capacitors may take up to 50 minutes to fully discharge. The larger the drive the...

  • Page 7: Reference Material

    These three pieces of reference material may be available to you when you are starting up a drive. a) The VLT Instruction Manual provides general information on topics like mounting clearances, fuses, terminal tightening torques, and drive parameters. An instruction Manual is shipped with each drive.

  • Page 8: Pre-Installation Checks

    3) Pre-Installation Checks Visual Inspection Proper Handling Remove IM and kits from box Check that VLT matches what was ordered Check Incoming Power, Drive and Motor that they are the same voltage range. Insure that all hand tools, auxiliary equipment and kits are available.
  • Page 9 Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks a. Once you have opened the box, check the VLT for any visual damage. If there is major damage, please contact the organization that sold you the drive. b. Some of the VLTs are very large, which require special equipment to remove it from its container and mount it safely.
  • Page 10 Accessory Kit if present. North America Motion Controls Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks c. It is important that all extra material, such as the Instruction Manual and accessory kit be removed from the drive’s container. These are used later. If you can not find the Instruction Manual, contact the person who originally opened the container.

  • Page 11: Catalog Number

    Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks d. Compare the VLT model number with what was ordered. The drive has two identifying numbers, the catalog number and the sales number. A Catalog Number, which is explained on the next slide, is the long number. In the example above the catalog number is VLT 5011-P-T2-CN1-ST-R0-DL-F00-A00.
  • Page 12 VLT Installation 3) Pre-Installation Checks d. Compare drive Compare VLT number with what was ordered. Look for the RED label, typically on the Top or Left Side Catalog Order Number System Example: - XXXX–P-T5-B20–ST-R0–DL-F00-A00-C0 Series: VLT, FC, FCM, FCD Model Number ---------------------| Application --------------------------------| P –...
  • Page 13 VLT Installation 3) Pre-Installation Checks d. Compare VLT drive & APU Panel Drive with Panel – Label inside the panel Material Number Serial Number Schematic Number Output Ratings Input Ratings North America Motion Controls Confidential / Property of Danfoss Drives A/S A drive with an APU Panel has a nameplate with complete rating information inside the panel enclosure.
  • Page 14 VLT Installation 3) Pre-Installation Checks d. Compare VLT drive & APU Panel Drive with Panel – Label inside the panel On the right or left side of the drive Material Number Serial Number On the panel or the right side of...
  • Page 15 VLT Installation 3) Pre-Installation Checks e. Match power, drive and motor Be sure the Incoming Power, VLT and Motor have the same voltage range North America Motion Controls Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks e. Before installing the drive, check to be sure that the power line, the drive, and the motor are all rated for the same voltage range.
  • Page 16 North America Motion Controls Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks f. Insure that all hand tools, auxiliary equipment and kits are available. Options and kits: Part numbers for a dynamic brake resistor, additional RFI Filters, an LCP remote mounting kit, serial communication card, application card, additional relay card, LC filters and terminal lug kits are covered in the catalog.
  • Page 17 Always insure that VLT can handle maximum current of the motor. It is important to check the technical data of the instruction manual for the drive you are installing to certify that the VLT is able to handle the maximum FLA of the motor.
  • Page 18 – Motor Current (FLA) – Motor Speed (RPM) North America Motion Controls Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks h. Record motor data information Write down the motor nameplate information. This is important later during programming. A conversion between HP and kW must be calculated 1Hp = 0.75kW.
  • Page 19 Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks The VLT takes all size information in kilowatts (kW), so horsepower (Hp) must be converted to kW. The formula is 1 Hp = ¾ of a kW. The chart above shows the equivalent.
  • Page 20 • 2-speed motors (Star-Delta) must be wired for full speed • Part-winding start motors, must be wired for run. • Check motor wiring to see if it is the same voltage as VLT. North America Motion Controls Confidential / Property of Danfoss Drives A/S 3) Pre-Installation Checks i.

  • Page 21: Installation Checks

    Confidential / Property of Danfoss Drives A/S 4) Installation Checks Section 4 covers the 4 installation checks, which are input fuses, environmental concerns, general wiring practices and finally the actual mounting of the VLT, which is known in the Instruction Manual as the mechanical installation. Rev.02...
  • Page 22 The types of fuses needed for each VLT are shown in the technical data section of the instruction manual. Most VLT units do not include fuses and it is the responsibility of the installer to ensure the proper fusing in order to comply with local electrical codes and satisfy UL requirements.
  • Page 23 VLT Installation 4) Installation Checks b. Environmental Concerns • Use the index in the VLT Instruction Manual to find “Derating for ambient temperature” a concern above 40°C (104°F) • Enclosure should be suitable for environment • Airborne contaminants and corrosive gases might require conformal coating.
  • Page 24 24-hour period or the temp goes above max, then the VLT must be derated. To avoid derating the VLT, the only methods are to get a larger drive and run it at a lower output say 80%, or incorporate mechanical cooling into the environment where the VLT is located.
  • Page 25 Notice at 2km (6600 feet) the output of the VLT is approximately 93%. Derating can also occur when the switching frequency is increased, larger than rated cable sizes are used and when running the motors continually at slow speeds.
  • Page 26 4) Installation Checks b. Environmental Concerns The VLT can be supplied with a chassis, NEMA 1 (IP 20, 21) or NEMA 12 (IP 54) enclosure. These enclosures provides some degree of protection from falling dust and water. Therefore, drives with a NEMA 1 (IP 20) and 12 (IP 54) enclosures should be mounted indoors in a relatively clean and dry location.
  • Page 27 VLT Installation 4) Installation Checks b. Environmental Concerns VLT and APU NEMA 1 Configurations Stand-alone VLT VLT with APU Panels North America Motion Controls Confidential / Property of Danfoss Drives A/S The above pictures illustrate the standard types of NEMA 1 enclosure configurations available to the public.
  • Page 28 To provide for indoor environments where the drive may be subjected to dripping Water or large amounts of dirt, the VLT can be supplied with a NEMA 12 enclosure. If the drive is to be mounted outdoors, NEMA 3R and NEMA 12 enclosures can be supplied.

  • Page 29: Environmental Concerns

    Environmental Concerns Environmental Concerns • Keep the drive clean • Consider traffic patterns • Use dust covers to cover VLT during construction • Remove the dust covers before applying power North America Motion Controls Confidential / Property of Danfoss Drives A/S 4) Installation Checks b.
  • Page 30 • Larger drives have a removable conduit entry or gland plate North America Motion Controls Confidential / Property of Danfoss Drives A/S 4) Installation Checks c. General Wiring Preparations Most smaller drives have knock-outs for conduit entry. Larger drives provide a removable conduit entry plate.
  • Page 31 In order to provide proper cooling, most drives are mounted vertically, unless otherwise stated in the VLT Instruction Manual. In is important to check the wall strength and mounting hardware to insure it can handle the weight of the drive.
  • Page 32 4) Installation Checks d. Mounting The VLT cools itself by drawing cooling air through the bottom of its enclosure and exhausting it out the top. It is therefore important to provide enough space above and below the drive to ensure proper flow of cooling air. To determine the necessary clearances, see the “mechanical installation”...
  • Page 33 Control North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive This next section covers some of the wiring of the drive. The first area to be covered is general wiring practices. The next part covers the power or line wiring from incoming power to the drive.
  • Page 34 • Check Torque required for connectors North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive a. General Practices At least three separate conduits must be connected to the drive. One is for the incoming power wiring, one is for the motor output wiring between the drive and the controlled motor, and the third is for the control wiring.
  • Page 35 The proper style and rating for these fuses is specified in the Instruction Manual. Terminals 91 (L1), 92 (L2) and 93 (L3) on a VLT are always used for incoming power. Rev.02...
  • Page 36 VLT Installation 5) Wiring c. Motor Output Motor Wiring • Use Terminals 96 (U), 97(V), 98(W) • Check maximum motor length, Example: VLT 5000/6000/8000 is 300m (1000’) unshielded • Disconnect OK North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive c.

  • Page 37: External +24Vdc Power Supply

    • To keep LCP Display and Serial Communications active North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive d. External +24Vdc Some VLTs have the ability to connect an external 24Vdc to terminals 35 (+24Vdc) and 36 (Com).
  • Page 38 North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive e. Dynamic Brake and Loadsharing On Standard with Brake (SB) units there is an extra terminal labeled R – (81) and R + (82).

  • Page 39: Control Wiring

    • Terminals 12-27 • Control wires must be separate from Power. North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive f. Control Wiring This next part covers some general information about control wiring. It is always best to have control wiring in a separate conduit away from power wiring.
  • Page 40 • Use Relay 1 (terminals 01,02, 03) for pilot duty 48 to 240Vac North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive f. Control Wiring The maximum voltage for the control circuit must not exceed 24Vdc. Do NOT connect any voltage higher than 24Vdc for it will cause damage.
  • Page 41 When this jumper is made, the bottom line reads, “STANDBY”. North America Motion Controls Confidential / Property of Danfoss Drives A/S 5) Wiring the Drive f. Control Wiring In its default state, the way it comes from the factory, a jumper or a connection is required for operation.
  • Page 42 VLT Installation Review 1) One of the main warnings for the VLT is to wait a maximum of 30 minutes before a person can work on the VLT. Which of the following is the best reason for this wait? A. The IGBTs need time to cool off.
  • Page 43 A. The Instructions Manual B. The Terminal Connection Diagram C. The Electric Schematic Diagram D. Both A and B E. All 3 are always present, A, B and C. North America Motion Controls Confidential / Property of Danfoss Drives A/S Rev.02...
  • Page 44 A. Display – yes; Coating - yes B. Display – no; Coating – yes C. Display – yes;Coating – no D. Display – no; Coating – no North America Motion Controls Confidential / Property of Danfoss Drives A/S Rev.02...
  • Page 45 VLT Installation Review 6) When installing a VLT, to comply with UL/cUL, which of the following must always be connected to the incoming power? A. Isolation Transformer B. Fuses C. Circuit Breakers D. 3% Input Line Reactor E. To comply with UL / cUL, all of the above...
  • Page 46 VLT Installation Review 7) When looking at environmental concerns as mentioned in the VLT Instructional Manual, what is the difference between maximum temperature and average temperature? A. Maximum temperature is 3°C (5°F) above average temperature. B. Maximum temperature is 3°C (5°F) below average temperature.
  • Page 47 VLT Installation Review 8) When wiring the control signals to a VLT, which of the following, is a correct statement for proper operation? A. The control wiring can be wired in the same conduit as incoming power. B. The control wiring can be wired in the same conduit as the motor output.
  • Page 48 VLT Installation Review 9) Incoming Power is always wired to which of the following terminal numbers on a VLT? A. Terminals 18, 19 and 20 B. Terminals 35, 36 and 20 C. Terminals 91, 92 and 93 D. Terminals 94, 95 and 96 E.
  • Page 49 10) Which of the following statements is NOT part of the Pre-Installation Check? A. Make a Visual inspection of the drive and its packaging. B. Insure VLT can handle maximum current of the motor. C. Record Motor Nameplate Data D. Determine if motor is IEC or NEMA rated.
  • Page 50 24Vdc, brake and load-sharing. Answers to the questions are on the Note Pages North America Motion Controls Confidential / Property of Danfoss Drives A/S Answers: 1) E 2) A 3) D...
  • Page 51 If you have any comments or questions, please contact: Technical Support Danfoss Drives 4401 N. Bell School Rd Loves Park, Illinois 61111 USA phone: (800) 432-6367 or (815) 639-8600 North America Motion Controls Confidential / Property of Danfoss Drives A/S Rev.02...