Danfoss VLT 5000 FLUX Frequency Converter Manuals

Manuals and User Guides for Danfoss VLT 5000 FLUX Frequency Converter. We have 6 Danfoss VLT 5000 FLUX Frequency Converter manuals available for free PDF download: Operating Instructions Manual, Service Manual

Danfoss VLT 5000 FLUX Operating Instructions Manual (159 pages)

Brand: Danfoss | Category: DC Drives | Size: 6 MB

Table of Contents
1
Safety

3
Introduction

5
- Output
  5
- Switch NO/NC
  5
- Miscellaneous
  6
- Motor
  6
- References
  6
- Control Principle
  8
- Flux Vector Control Principle
  8
- Programmable Signal Outputs
  8
- Technology
  8
- Mechanical Dimensions
  14
Technical Data

14
- Enclosure Type
  17
- Installation of VLT 5001-5302
  17
- Side by Side/Flange by Flange
  17
- Installation of VLT 5350-5500 380-500 V Compact
  18
- Ip 00 Vlt 5350 - 5500 380 - 500 V
  18
- Electrical Installation - Mains Supply
  19
- High Voltage Test
  19
- Motor Connection
  19
- Safety Earthing
  19
- Terminal Designation
  19
- Electrical Installation - Brake Resistor Temperature Switch
  20
- Electrical Installation - Loadsharing
  20
- Electrical Installation - 24 Volt External DC Supply
  22
- Electrical Installation - Relay Outputs
  22
- Extra Protection (RCD)
  22
  - Compact IP 20/Nema 1
    24
  - Compact IP 54
    24
  - Electrical Installation, Power Cables
    24
  - Installation of Control Cables
    32
- Terminal Designation
  32
  - Connection of Encoder
    33
  - Feedback System
    33
  - Leds on Encoder Board
    33
  - Bus Connection RS 232
    35
  - Bus Termination
    35
  - DIP Switches 1-4
    35
  - Hardware Connection of the RS 232
    35
  - 2-Wire Start/Stop
    36
- Connection Examples
  36
  - Pulse Start/Stop
    36
  - Setup Change
    36
  - Potentiometer Reference
    37
  - Two-Wire Transmitter
    37
- Electrical Installation - EMC Precautions
  38
- Use of Emc-Correct Cables
  40
- Correct Earthing
  41
- Electrical Installation - Earthing of Control Cables
  41
  - Wrong Earthing
    41
  - Mains Supply Connected to Earth
    42
  - Mains Supply Isolated from Earth
    42
  - Position of RFI Switches
    42
- RFI Switch
  42
Control Panel (LCP)

45
- Leds
  45
- Display
  45
- Control Keys
  45
- Quick Setup Via Quick Menu
  48
- Menu Mode (Parameter Setting)
  48
- Initialisation to Factory Setting
  50
- Manual Initialisation
  50
- Local and Remote Control
  51
Reference Handling

51
- Handling of Single References
  52
- Handling of Multi-References
  54
- List of Handling of Multi-References
  54
- Programming of Stop at Torque Limit
  55
- Dynamic Brake Function(Brake Resistor)
  56
- Selection of Brake Resistor
  56
- Automatic Motor Adaptation, AMA
  57
  - How to Perform an AMA
    57
  - Limitations and Preconditions
    57
- Flying Start
  58
- Normal/High Overload Torque Control
  59
- Flying Start Is Active
  59
- Operation and Display
  60
  - Changes During Operation
    60
  - 4-Setup:
    60
  - Conversion Index
    60
Programming

60
- Active Setup
  61
- Language
  61
- Local Reference
  61
- Local/Remote Control
  61
- Copying of Setups
  62
- LCP Copy
  62
- Programming Setup
  62
- Display Line 2
  63
- Display Scaling Speed
  63
- Display Line 1.1
  64
- Display Line 1.2
  64
- Display Line 1.3
  64
- Local Operation Mode
  64
- Local Reset of Trip
  65
- Local Reversing
  65
- Local Stop
  65
- Lock for Data Change
  65
- Operating State at Power Up, Local Control
  66
- Quick Menu Setup
  66
- Userdefined Quick Menu
  66
- Load and Motor
  67
  - Configuration
    69
  - Motor Power
    69
  - Torque Characteristics
    69
  - Motor Current
    70
  - Motor Frequency
    70
  - Motor Voltage
    70
  - Rated Motor Speed
    70
  - Slip Compensation
    71
  - Slip Compensation Time Constant
    71
  - High Starting Torque
    72
  - Start Delay (START DELAY)
    72
  - Start Function (START FUNCTION)
    72
  - DC Braking Current
    73
  - DC Braking Time
    73
  - DC Holding Current
    73
  - Min. Speed for Activating Function at Stop
    73
  - DC Brake Cut-In Speed
    74
  - External Motor Fan
    74
  - Motor Thermal Protection
    74
  - Initial Current
    75
  - Rotor Resistance
    75
  - Start Speed
    75
  - Stator Resistance
    75
  - Iron Loss Resistance
    76
  - Pole Number
    76
  - Rotor Leakage Reactance
    76
  - Stator Leakage Reactance
    76
- Functional Stop Delay, Par 163 - Flux
  77
- References and Limits
  79
  - Minimum Reference
    80
  - Output Speed Range/Direction
    80
  - Reference/Feedback Area
    80
  - Maximum Reference
    81
  - Ramp Type
    81
  - Ramp-Down Time 1
    81
  - Ramp-Up Time 1
    81
  - Jog Ramp Time
    82
  - Quick Stop Ramp-Down Time
    82
  - Ramp-Down Time 2
    82
  - Ramp-Up Time 2
    82
  - Reference Function
    83
  - Catch Up/Slow down Value
    84
  - Torque Limit for Motor Mode
    84
  - Torque Limit for Generating Operation
    85
  - Warning: High Current
    85
  - Warning: Low Current
    85
  - Low Speed Current
    86
  - Phase Loss Monitor
    86
  - Warning: High Speed
    86
  - Warning: Low Speed
    86
  - Acceleration Jerk
    87
  - Deceleration Jerk 1
    87
  - Model Shift Speed
    87
  - Introduction
    88
  - Digital Input Functions
    89
  - Analog Inputs
    92
  - Terminal 53, Analog Input Voltage
    93
  - Terminal 53, Min. Scaling
    93
  - Terminal 54, Analog Input Voltage
    93
  - Terminal 54, Min. Scaling
    93
  - Function after Time out
    94
  - Terminal 60, Max. Scaling
    94
  - Terminal 60, Min. Scaling
    94
  - Time out
    94
  - Analog Outputs
    95
  - Terminal 42 Output
    95
  - Terminal 45, Output
    95
  - Digital and Relay Outputs
    96
  - Relay 01, off Delay
    98
  - Relay 01, on Delay
    98
  - Relay 01, Output
    98
  - Relay 04, Output
    98
  - Encoder Direction
    99
  - Encoder Monitoring
    99
  - Terminal 46, Digital Output
    99
  - Terminal 46, Output, Pulse Scaling
    99
  - Terminal 26, Digital Output
    100
  - Terminal 26, Output, Pulse Scaling
    100
  - Terminal 42, Output Maximum Scaling
    100
  - Terminal 42, Output Minimum Scaling
    100
  - KTY Sensor Type
    101
  - Max Tracking Error
    101
- Special Functions
  102
  - Brake Function/Overvoltage Control
    103
  - Brake Power Limit, Kw
    103
  - Brake Resistor, Ohm
    103
  - Power Monitoring
    103
  - Brake Check
    104
  - Reset Function (RESET MODE)
    104
  - Automatic Restart Time
    105
- Mains Failure, Par 407 - Flux
  105
  - Trip Delay Torque
    105
  - Flying Start
    106
  - Speed Filt. Time
    106
  - Speed PID Integral Time
    106
  - Speed PID Proportional Gain
    106
  - AEO Cos Phi
    107
  - Inductance LC-Filter
    107
  - LC-Filter Connected
    107
  - Mains Voltage at Mains Fault
    107
  - Adaptive Gain Max. Speed
    108
  - Adaptive Gain Min. Speed
    108
  - Adaptive Gain Scale
    108
- Serial Communication
  109
  - Address
    110
  - Coasting
    110
  - DC-Brake
    110
  - Quick-Stop
    110
  - Bus Jog 1
    111
  - Bus Jog 2
    111
  - Reversing
    111
  - Telegram Profile
    111
  - Bus Time Interval Function
    112
  - Digital Input, Parameter 528
    113
  - Frequency, Parameter 518
    113
  - Motor Current, Parameter 520
    113
  - Torque, Parameter 521
    113
  - Alarm Word, Parameter 538
    114
  - Brake Power/Sec., Parameter 536
    114
  - Heat Sink Temperature, Parameter 537
    114
  - VLT Control Word, Parameter 539
    114
- Technical Functions
  115
  - Hours Run, Parameter 601
    116
  - Kwh Counter, Parameter 602:
    116
  - Fault Log: Error Code
    117
  - Fault Log: Time
    117
  - Fault Log: Value
    117
  - Reset of Kwh Counter
    117
  - Operation Mode
    118
  - Flash Test
    119
- Trouble-Shooting
  120
Miscellaneous

120
- Status Messages
  121
  - Catch-Up (REM. CATCH UP)
    121
  - Output Speed High (REM. SPEED HIGH)
    121
  - Output Speed High (LOCAL SPEED HIGH)
    121
  - Ramp Operation (REM. RAMPING)
    122
  - Ramp Operation (LOCAL RAMPING)
    122
  - Ramp Operation (MIXED RAMPING)
    122
  - Running, Remote Control (REM. RUN OK)
    122
  - Overvoltage Control
    123
  - Automatic Motor Adaptation
    123
- List of Warnings and Alarms
  124
- Warnings
  125
  - Alarm Messages
    125
  - Undervoltage (DC LINK UNDERVOLT)
    126
  - Brake Resistor Fault
    127
  - Brake Resistor Power 100%
    127
  - Brake Transistor Fault
    127
  - Heat Sink Temperature too High
    127
  - Motor Phase U Missing
    128
  - Motor Phase V Missing
    128
  - Out of Speed Range
    128
  - Mains Failure (MAINS FAILURE)
    128
  - Encoder Loss (ENCODER FAULT)
    129
  - Tracking Fault
    129
Appendix

131
- Parameter Survey
  131
- General Technical Data
  138
- Electrical Data
  143
  - Bookstyle and Compact, Mains Supply
    143
  - Compact, Mains Supply 3 X 200 - 240 V
    144
- Fuses
  153
- Non UL Compliance
  154
Index

155

Danfoss VLT 5000 FLUX Service Manual (158 pages)

Brand: Danfoss | Category: DC Drives | Size: 11 MB

Table of Contents
3
Introduction
9
Purpose
9
Vlt Product Overview
9
For Your Safety
9
Electrostatic Discharge (Esd)
9
Tools Required
11
Section 1 Operator Interface and Drive Control
21
Introduction
21
- Normal Display
  21
- Status Display
  22
- Factory Default Display Settings
  22
Warnings and Alarms
26
- Alarms
  26
- Warnings
  26
Service Functions
26
Fault Message Table
27
Drive Inputs and Outputs
28
- Input Signals
  28
- Output Signals
  28
- Control Terminals
  29
- Control Terminal Functions
  29
- Grounding Shielded Cables
  31
Section 2 Internal Drive Operation
33
General
33
Description of Operation
33
- Logic Section
  33
- Logic to Power Interface
  34
- Power Section
  35
Sequence of Operation
36
- Rectifier Section
  36
- Intermediate Section
  38
- Inverter Section
  40
- Brake Option
  42
- Cooling Fans
  43
- Load Sharing
  43
- Specific Card Connections
  43
Section 3 Troubleshooting
45
Troubleshooting Tips
45
3 Fault Symptoms

47
- Display
  47
  - No Display
    47
  - Intermittent Display
    47
  - Display (Line 2) Flashing
    47
  - WRONG or WRONG LCP Displayed
    47
- Motor
  48
  - Motor will Not Run
    48
  - Incorrect Motor Operation
    49
- Warning and Alarm Messages
  50
- After Repair Tests
  57
- Section 4 Drive and Motor Applications
  59
  - Torque Limit, Current Limit, and Unstable Motor Operation
    59
  - Overvoltage Trips
    60
  - Mains Phase Loss Trips
    60
  - Control Logic Problems
    61
  - Programming Problems
    61
  - Motor/Load Problems
    61
- Internal Drive Problems
  62
- Signal Conductor Currents
  64
  - Preventative Measures
    65
  - Proper EMC Installation
    66
- Section 5 Test Procedures
  67
- Introduction
  67
- Tools Required for Testing
  67
  - Signal Test Board
    67
  - Test Cable
    67
5 Test Procedures

68
- Static Test Procedures
  68
  - Soft Charge and Rectifier Circuits Test: D-Frame Size
    69
- Soft Charge Card Fuses
  69
  - Soft Charge Rectifier Test: D-Frame Size
    71
- Soft Charge Card Connectors
  71
  - Soft Charge and Rectifier Circuits Test: E-Frame Sizes
    72
- Soft Charge Card Fuse Location
  72
- Dynamic Test Procedures
  79
  - No Display Test
    80
  - Input Voltage Test
    80
  - Basic Control Card Voltage Test
    80
  - Switch Mode Power Supply (SMPS) Test
    81
  - Zero DC Bus Voltage Test
    81
  - DC under Voltage Test
    82
  - Input Phase Imbalance Test
    82
  - Input Waveform Test
    83
  - Input SCR Test
    85
  - Output Phase Imbalance Test
    86
  - IGBT Gate Drive Signals Test
    87
  - IGBT Switiching Test
    90
  - Brake IGBT Test
    90
  - Current Sensors Test
    91
  - Fan Tests
    92
  - Input Terminal Signal Tests
    93
  - Control Card Test
    94
- Initial Start up or after Repair Drive Tests
  95
- Section 6 D-Frame Sizes Disassembly and Assembly Instructions
  97
- Electrostatic Discharge (Esd)
  97
6 Instructions

97
- Control Card Cassette
  97
- Interface Card
  98
- Power Card
  98
- Control Card/Power Card Mounting Plate
  98
- Interface Card, Power Card, and Mounting Plate
  98
  - Gate Drive Card
    99
  - Soft Charge Card
    99
- Soft Charge Card Assy
  99
  - Capacitor Bank(S)
    100
  - Upper Capacitor Bank D2 Units
    100
  - Lower Capacitor Bank D2 Units
    100
  - Single Capacitor Bank D1 Units
    101
  - Soft Charge (SC) Resistors D2 Units
    102
- Soft Charge Resistor
  102
  - Soft Charge (SC) Resistors D1 Units
    103
- D2 Soft Charge Resistor
  103
- D1 Soft Charge Resistor
  104
  - Input Terminal Mounting Plate Assy
    106
  - Scr/Diode Module D2 Units
    107
- D2 Scr/Diode Module
  110
- D1 Scr/Diode Module
  110
  - Scr/Diode Module D1 Units
    111
  - Current Sensor
    114
  - Fan Assembly
    115
- Fanassembly
  115
  - AC Input Terminals
    117
  - IGBT Modules D2 Units
    118
- D2 IGBT Modules
  118
  - IGBT Modules D1 Units
    121
- Section 7 E-Frame Sizes Disassembly and Assembly Instructions
  123
- Electrostatic Discharge (Esd)
  123
7 Instructions

123
- Control Card Cassette
  123
- Interface Card
  124
- Power Card
  124
- Control Card/Power Card Mounting Plate
  124
- Gate Drive Card
  125
- Soft Charge Card
  125
- Capacitor Banks
  126
- Upper Capacitor Bank
  126
- Lower Capacitor Bank
  126
- Upper and Lower Capacitor Bank Assemblies
  126
  - Input Terminal Mounting Plate Assy Option
    127
  - Soft Charge Resistor
    128
  - SCR and Diode Modules
    129
  - Current Sensor
    132
- Current Sensors
  132
  - Fan Assembly
    133
- Fanassembly
  133
  - AC Input, Motor, Load Sharing or Regen Terminals
    134
- Terminal Blocks
  134
  - IGBT Modules
    135
- Section 8 Special Test Equipment
  139
- Test Equipment
  139
  - Test Cable and SCR Shorting Plug (P/N 176F8439)
    139
- Test Cable and SCR Shorting Plug
  139
  - Signal Test Board (P/N 176F8437)
    140
  - Signal Test Board Pin Outs: Description and Voltage Levels
    140
- Signal Test Board
  140

Danfoss VLT 5000 FLUX Operating Instructions Manual (88 pages)

Synchronizing Controller

Brand: Danfoss | Category: Controller | Size: 1 MB

Danfoss VLT 5000 FLUX Operating Instructions Manual (63 pages)

Brand: Danfoss | Category: Media Converter | Size: 1 MB

Table of Contents
2
MG.90.G1.02 - VLT Is a Registered Danfoss Trademark
2
Introduction

4
- About this Manual
  4
- Assumptions
  5
- Background Knowledge
  5
- Profibus DP
  6
- Baudrate
  6
- Profibus DP V1
  6
The PROFIBUS Option Card

7
PPO Description

18
- Communication Connections
  18
- PPO Description (Overview)
  18
PCA Interface

19
- PCA Processing
  19
- Parameter Description
  20
Spontaneous Messages

22
SYNC and FREEZE

23
- Sync/Unsync
  23
- Freeze/Unfreeze
  23
Control Word/Status Word

24
Bus Reference Value

30
Examples

31
GSD File

35
- DP V1 Identifications
  35
Parameters

36
Warning and Alarm Messages

44
- Warnings and Alarm Messages
  44
- Spontaneous Messages
  44
- Additional Display Readings
  44
- Warn. 34
  44
- Warnings
  44
- Warning Word, Extended Status Word and Alarm Word
  45
- Station Address
  47
- Extended Diagnosis
  48
Parameter List

49
Appendix

59
- Glossar
  59
- Abbreviations Used
  60
- Operating Instructions
  63

Danfoss VLT 5000 FLUX Operating Instructions Manual (51 pages)

Positioning Controller

Brand: Danfoss | Category: Controller | Size: 1 MB

Table of Contents
2
Table of Contents

4
Safety Regulations

4
Introduction

5
- Hardware
  6
  - VLT Control Card Terminals
    6
  - Technical Data
    6
  - Option Card Terminals
    6
  - Supply Voltages
    7
  - Encoder Monitor
    8
  - Option Card Layout
    9
- Technical Data
  11
Description of the Electrical and Field Bus Interface

13
- Electrical Interface VLT
  13
- Field Bus Interface
  18
  - Data Layout
    18
Description of the Available Parameters

21
- Special LCP Functions
  21
- Description of Parameters
  22
An Application Example

36
- Wiring Diagram
  37
- Basic Set-Up
  37
- Parameter Settings
  39
Troubleshooting

42
- Frequently Asked Questions
  42
Appendix

45

Danfoss VLT 5000 FLUX Operating Instructions Manual (38 pages)

DeviceNet

Brand: Danfoss | Category: Controller | Size: 0 MB

Table of Contents
2
Introduction to Danfoss VLT Series and Devicenet

3
- Product Overview
  3
- Product and Environment
  3
- Overall Function
  3
- Network
  3
- User Profile
  3
- Data Communication Interface
  3
- Initialization of VLT Frequency Converter Interface
  3
- Network Variable Handling
  4
- Error Handling
  4
- Overall Function
  4
Technical Data

6
- Identity Object
  6
- Message Router
  6
- General Information
  6
- Network Power Supply
  6
- Cable Lengths
  7
- Cable Specifications
  7
- Cable Cross Section
  8
- Connection of the Cable Screen
  9
- VLT 2800 Earth Connection
  9
- Devicenet Connection
  9
- User Interface
  10
- Understanding Module Configuration Switches
  11
- EMC Precautions
  12
- Setting the Devicenet Node Address
  13
- Switch Settings for Devicenet Node Addressing
  13
- Setting the Baud Rate
  13
- VLT Response Time
  14
- General Purpose Discrete I/O
  14
- I/O Assembly Instances
  14
Fieldbus Profile

15
Programming

22
- Quick Setup
  22
- Special Attention
  22
- Warning and Alarm Messages
  27
- Factory Settings
  28

Danfoss Categories

Controller DC Drives Thermostat Control Unit Air Compressor

More Danfoss Manuals

Danfoss VLT 5000 FLUX Frequency Converter Manuals

Danfoss VLT 5000 FLUX Operating Instructions Manual (159 pages)

Table of Contents

Safety

Introduction

Technical Data

Control Panel (LCP)

Reference Handling

Programming

Miscellaneous

Appendix

Index

Danfoss VLT 5000 FLUX Service Manual (158 pages)

Table of Contents

3 Fault Symptoms

5 Test Procedures

6 Instructions

7 Instructions

Danfoss VLT 5000 FLUX Operating Instructions Manual (88 pages)

Table of Contents

Operating Instructions

Safety Regulations

Introduction

Function Description

List of Illustrations

Tips and Tricks for Synchronization Tasks

Hardware

Technical Data

Examples of Encoder Interface Connections

Description of Terminals

Description of Field Bus Interface

Description of Parameters

Initializing the Parameters

Speed Synchronization

Function Diagrams for Speed Synchronization

Application Example - Admixture

Position Synchronization (Angle Synchronization)

Function Diagrams for Position Synchronization

Application Example - Embossing Patterns on Mould

Marker Synchronizing

Function Diagrams for Marker Synchronization

Application Example - Packaging

Appendix

Messages and Error Reference

Parameter Overview

Glossary of Key Terms

List of Illustrations

Danfoss VLT 5000 FLUX Operating Instructions Manual (63 pages)

Table of Contents

Introduction

The PROFIBUS Option Card

PPO Description

PCA Interface

Spontaneous Messages

SYNC and FREEZE

Control Word/Status Word

Bus Reference Value

Examples

GSD File

Parameters

Warning and Alarm Messages

Parameter List

Appendix

Danfoss VLT 5000 FLUX Operating Instructions Manual (51 pages)

Table of Contents

Table of Contents

Safety Regulations

Introduction

Description of the Electrical and Field Bus Interface

Description of the Available Parameters

An Application Example

Troubleshooting

Appendix

Danfoss VLT 5000 FLUX Operating Instructions Manual (38 pages)

Table of Contents

Introduction to Danfoss VLT Series and Devicenet

Technical Data

Fieldbus Profile

Programming

Related Products