Danfoss VLT 2800 Manuel utilisateur

Contents

Introduction to VLT 2800

Software version 4

High voltage warning 5

These rules concern your safety 5

Warning against unintended start 5

Technology 6

CE labelling 8

Motor coils 12

Ordering numbers for VLT 2800 200-240 V 16

Ordering numbers for VLT 2800 380-480V 18

PC Software tools 21

Accessories for the VLT 2800 22

Control unit 29

Manual initialisation 29

Hand Auto 30

Automatic motor tuning 31

The LCP 2 Control unit, option 32

Parameter selection 35

Installation

Mechanical dimensions 37

Mechanical installation 41

General information about electrical installation 42

EMC-correct electrical installation 43

Earthing of screened/armoured control cables 45

Diagram 46

Electrical installation 47

Safety clamp 49

Pre-fuses 49

Mains connection 49

Motor connection 49

RFI switch 50

Direction of motor rotation 50

Parallel connection of motors 50

Motor cables 51

Motor thermal protection 51

Brake connection 51

Earth connection 51

Load sharing 52

Tightening Torque, Power Terminals 52

Control of mechanical brake 52

Access to control terminals 52

Electrical installation, control cables 53

Tightening torques, control cables 54

Electrical installation, controlterminals 54

Relay connection 54

VLT Software Dialog 54

MG.27.E2.02 - VLT is a registered Danfoss trademark 1

Connection examples 55

Use of internal PID-controller - closed loop process control 57

Programming

Operation & Display 59

Setup configuration 59

Load and Motor 67

DC Braking 72

References & Limits 77

Handling of references 77

Reference function 81

Inputs and outputs 85

Special functions 95

PID functions 98

Handling of feedback 99

Enhanced Sleep Mode 106

Serial communication for VLT 2800 111

Control Word according to FC protocol 115

Status Word according to FC Profile 117

Control word according to Fieldbus Profile 118

Status word according to Profidrive protocol 119

Serial communication 122

Technical functions 130

All about VLT 2800

134

Special conditions 134

Galvanic Isolation (PELV) 134

Earth leakage current and RCD relays 134

Extreme operating conditions 134

dU/dt on motor 135

Switching on the input 135

Acoustic noise 135

Temperature-dependent switch frequency 136

Derating for air pressure 136

Derating for running at low speed 136

Derating for long motor cables 136

Derating for high switching frequency - VLT 2800 136

Vibration and shock 137

Air humidity 137

UL Standard 137

Efficiency 137

Mains supply interference/harmonics 138

Power factor 138

Generic EMC standards/product standards 139

EMC emission 139

EMC Immunity 140

Harmonic Current Emission 141

Aggressive environments 141

Display readout 143

2 MG.27.E2.02 - VLT is a registered Danfoss trademark

Warnings/alarm messages 143

Warning words, extended status words and Alarmwords 147

General technical data 148

Technical data, mains supply 1 x 220 - 240 V/3 x 200-240V 153

Technical data, mains supply 3 x 380 - 480 V 154

Available literature 155

Supplied with the unit 155

Index

163

MG.27.E2.02 - VLT is a registered Danfoss trademark 3

VLT 2800

Design Guide

Software version: 2.9x

This Design Guide can be used for all VLT 2800 Series frequency converters with software version 2.9x.

The software version number can be seen from parameter 640.

NB!

This symbol indicates something that

should be noted by the reader.

Indicates a general warning.

This symbol indicates a warning of high

voltage.

4 MG.27.E2.02 - VLT is a registered Danfoss trademark

High voltage warning

The voltage of the frequency converter is

dangerouswhenevertheconverteriscon-

nected to mains. Incorrect fitting of the

motor or frequency converter may cause

damage to the equipment, serious injury

or death. Consequently, it is essential to

complywith the instructionsinthis manual

as well as local and national rules and

safety regulations.

These rules concern your safety

1. The frequency converter must be disconnec-

ted from the mains if repair work is to be

carried out. Check that the mains supply has

been disconnected and that the prescribed

time has passed before removing motor and

mains plugs.

2. The [STOP/RESET] key on the control panel

of the frequency converter does not discon-

nect the equipment from mains and is thus

not to be used as a safety switch.

3. The unit must be properly connected to the

earth, the user must be protected against the

supply voltage and the motor must be pro-

tected against overloading pursuant to pre-

vailing national and local regulations.

4. The earth leakage currents are higher than

3.5 mA.

5. Protection against motor overload is not in-

cluded in the factory setting. If this function is

required, set parameter 128 Motor thermal

protection todatavalue ETR trip ordatavalue

ETR warning.FortheNorthAmerican market:

The ETR functions provide overload protec-

tionofthemotor,class20,inaccordancewith

NEC.

6. Do not remove the plugs for the motor - and

mains supply while the frequency converter

is connected to mains. Check that the mains

supply has been disconnected and that the

prescribed time has passed before removing

motor and mains plugs.

7. Note that the frequency converter has more

voltage inputs than L1, L2 and L3 when the

DC bus terminals are used. Check that all

voltage inputs are disconnected and that the

prescribed time has passed before repair

work is commenced.

Warning against unintended start

1. The motor can be broughtto a stopby means

of digital commands, bus commands, refer-

ences or a local stop, while the frequency

converter is connected to mains. If personal

safety considerations make it necessary to

ensurethatnounintendedstartoccurs,these

stop functions are not sufficient.

2. While parameters are being changed, the

motor may start. Consequently, the stop key

[STOP/RESET] must always be activated,

following which data can be modified.

3. A motor that has been stopped may start if

faults occur in the electronics of the frequen-

cy converter, or if a temporary overload or a

fault in the supply mains or the motor con-

nection ceases.

Use on isolated mains

See section RFI Switch regarding use on isolated

mains.

It is important to follow the recommendations regard-

ing installation on IT-mains, since sufficient protection

of the complete installation must be observed. Not tak-

ing care using relevant monitoring devices for IT-

mains may result in damage.

MG.27.E2.02 - VLT is a registered Danfoss trademark 5

Introduction to VLT 2800

Technology

Control principle

A frequency converter rectifies AC voltage from the

mains supply into DC voltage, following which it

changes this voltage to an AC voltage with variable

amplitude and frequency.

The motor thus receives a variable voltage and fre-

quency,whichenablesinfinitelyvariable speedcontrol

of three-phase, standard AC motors.

1. Mains voltage

1 x 220 - 240 V AC, 50 / 60 Hz

3 x 200 - 240 V AC, 50 / 60 Hz

3 x 380 - 480 V AC, 50 / 60 Hz

2. Rectifier

Three-phase rectifier bridge which rectifies AC voltage

into DC voltage.

3. Intermediate circuit

DC voltage 2 x mains voltage [V].

4. Intermediate circuit coils

Evensouttheintermediatecircuitcurrentandlimitsthe

load on mains and components (mains transformer,

cables, fuses and contactors).

5. Intermediate circuit condenser

Evens out the intermediate circuit voltage.

6. Inverter

Converts DC voltage into a variable AC voltage with a

variable frequency.

7. Motor voltage

Variable AC voltage depending on supply voltage.

Variable frequency: 0.2 - 132 / 1 - 1000 Hz.

8. Control card

Here is the computer that controls the inverter which

generates the pulse pattern by which the DC voltage

is converted into variable AC voltage with a variable

frequency.

VLT 2800 control principle

A frequency converter is an electronic unit which is

able to infinitely variably control the rpm of an AC mo-

tor. The frequency converter governs the motor speed

by converting the regular voltage and frequency from

mains, e.g. 400 V / 50 Hz, into variable magnitudes.

Today the frequency converter controlled AC motor is

a natural part of all types of automated plants.

The frequency converter has an inverter control sys-

tem called VVC (Voltage Vector Control). VVC con-

trols an induction motor by energizing with a variable

frequencyand avoltagesuitableforit. Ifthe motorload

changes, so do its energizing and speed. That is why

the motor current is measured on an ongoing basis,

and a motor model is used to calculate the actual volt-

age requirement and slip of the motor.

Programmable inputs and outputs in four Setups

In the frequency converter is possible to program the

different control inputsand signal outputsand to select

four different user-defined Setups for most parame-

ters. It is easy for the user to program the required

functions on the control panel or via serial communi-

cation.

Mains protector

The frequency converter is protected against the tran-

sients that occur on the mains sometimes, e.g. if cou-

pling with a phase compensation system, or if fuses

blow when lightning strikes.

Rated motor voltage and full torque can be maintained

down to approx. 10% undervoltage in the mains sup-

ply.

As all 400 V units in the VLT 2800 Series have inter-

mediate circuit coils, there is only a low amount of

harmonicmains supplyinterference. Thisgivesagood

power factor (lower peak current), which reduces the

load on the mains installation.

Frequency converter protections

The current measurement in the intermediate circuit

constitutes perfect protection of the frequency in case

there is a short-circuit or an earth fault on the motor

connection.

Constant monitoring of the intermediate circuit current

enables switching on the motor output, e.g. by means

of a contactor.

Efficientmonitoringof themainssupplymeans thatthe

unit will stop in the case of a phase drop-out. In this

6 MG.27.E2.02 - VLT is a registered Danfoss trademark

way, the inverter and the condensers in the intermedi-

ate circuit are not overloaded, which would dramati-

callyreducethe service lifeof the frequency converter.

Thefrequencyconverteroffers temperature protection

asstandard.Ifthereis athermal overload,this function

cuts out the inverter.

Reliable galvanic isolation

In the frequency converter all digital inputs/outputs,

analogue inputs/outputs and the terminals for serial

communication are supplied from orin connection with

circuits that comply with PELV requirements. PELV is

also complied within relation to relay terminals, sothat

they can be connected to the mains potential.

For further information see the section entitled Gal-

vanic Isolation (PELV).

Advanced motor protection

The frequency converter has integral electronic motor

protection.

The frequency converter calculates the motor temper-

ature on the basis of current, frequency and time.

As opposed to traditional, bimetallic protection, elec-

tronic protection takes account of reduced cooling at

low frequencies because of reduced fan speed (mo-

tors with internal fan). This function cannot protect the

individual motors when motors are connected in par-

allel. Thermal motor protection can be compared to a

protective motor switch, CTI.

To give the motor maximum protection against over-

heating when it is covered or blocked, or if the fan

should fail, you can install a thermistor and connect it

to the frequency converter's thermistor input (Digital

input), see parameter 128 Thermal motor protection.

See also the section entitled Galvanic Isolation (PELV)

for further information.

NB!

This function cannot protect the individual

motors in the case of motors linked in par-

allel.

MG.27.E2.02 - VLT is a registered Danfoss trademark 7

Introduction to VLT 2800

CE labelling

What is CE labelling?

The purpose of CE labelling is to avoid technical ob-

stacles to trade within EFTA and the EU. The EU has

introduced the CE label as a simple way of showing

whether a product complies with the relevant EU di-

rectives. The CE label says nothing about the specifi-

cationsor qualityofthe product.Frequencyconverters

are regulated by three EU directives:

•The machinery directive (98/37/EEC)

All machines with critical moving parts are covered by

the machinery directive, which came into force on 1

January 1995. Since a frequency converter is largely

electrical,itdoesnotfallunderthe machinerydirective.

However, if a frequency converter is supplied for use

inamachine,weprovideinformationonsafetyaspects

relating to the frequency converter. We do this by

means of a manufacturer's declaration.

•The low-voltage directive (73/23/EEC)

Frequency converters must be CE labelled in accord-

ance with the low-voltage directive, which came into

force on 1 January 1997. The directive applies to all

electrical equipment and appliances used in the 50 -

1000 Volt AC and the 75 - 1500 Volt DC voltage

ranges. Danfoss CE labels in accordance with the di-

rective and issues a declaration of conformity upon

request.

•The EMC directive (89/336/EEC)

EMC is short for electromagnetic compatibility. The

presence of electromagnetic compatibility means that

the mutual interference between different compo-

nents/appliances is sosmall that the functioning of the

appliances is not affected.

The EMC directive came into force on 1 January 1996.

Danfoss CE labels in accordance with the directive

and issues a declaration of conformity upon request.

In order that EMC-correct installation can be carried

out, this manual gives detailed instructions for instal-

lation. In addition, we specify the standards which our

different products comply with. We offer the filters that

can be seen from the specifications and provide other

typesofassistanceto ensuretheoptimumEMC result.

In the great majority of cases, the frequency converter

is used by professionals of the trade as a complex

component forming part of a larger appliance, system

or installation. It must be noted that the responsibility

for the final EMC properties of the appliance, system

or installation rests with the installer.

8 MG.27.E2.02 - VLT is a registered Danfoss trademark

Order form

This section makes it easier for you to specify and

order a VLT 2800.

Choice of frequency converter

Thefrequency convertermustbechosenonthebasis

of the present motor current at maximum loading of

the unit. The frequency converter's rated output cur-

rent I

INV.

must be equal to or greater than the required

motor current.

Mains voltage

VLT 2800 is available for two mains voltage ranges:

200-240 V and 380-480 V.

Select whether the frequency converter is connected

to a mains voltage of:

-1 x 220 - 240 V single-phase AC voltage

-3 x 200 - 240 V three-phase AC voltage

-3 x 380 - 480 V three-phase AC voltage

1 x 220 - 240 Volt mains voltage

Typical shaft output

INV.

Max. constant output current I

INV.

Max. constant output power at

230 V S

INV.

Type [kW] [HP] [A] [kVA]

2803 0.37 0.5 2.2 0.9

2805 0.55 0.75 3.2 1.3

2807 0.75 1.0 4.2 1.7

2811 1.1 1.5 6.0 2.4

2815 1.5 2.0 6.8 2.7

2822 2.2 3.0 9.6 3.8

2840 3.7 5.0 16 6.4

3 x 200 - 240 Volt mains voltage

Typical shaft output

INV.

Max. constant output current I

INV.

Max. constant output power at

230 V S

INV.

Type [kW] [HP] [A] [kVA]

2803 0.37 0.5 2.2 0.9

2805 0.55 0.75 3.2 1.3

2807 0.75 1.0 4.2 1.7

2811 1.1 1.5 6.0 2.4

2815 1.5 2.0 6.8 2.7

2822 2.2 3.0 9.6 3.8

2840 3.7 5.0 16.0 6.4

MG.27.E2.02 - VLT is a registered Danfoss trademark 9

Introduction to VLT 2800

3 x 380 - 480 Volt mains voltage

Typical shaft output

INV.

Max. constant output current I

INV.

Max. constant output power at

400 V S

INV.

Type [kW] [HP] [A] [kVA]

2805 0.55 0.75 1.7 1.1

2807 0.75 1.0 2.1 1.7

2811 1.1 1.5 3.0 2.0

2815 1.5 2.0 3.7 2.6

2822 2.2 3.0 5.2 3.6

2830 3.0 4.0 7.0 4.8

2840 4.0 5.0 9.1 6.3

2855 5.5 7.5 12.0 8.3

2875 7.5 10.0 16.0 11.1

2880 11 15 24 16.6

2881 15 20 32 22.2

2882 18.5 25 37.5 26.0

Enclosure

All VLT 2800 units are supplied with IP 20 enclosure

as standard.

This enclosure level is ideal for panel mounting in

areas where a high degree of protection is required; at

the same time IP 20 enclosures allow side-by-side in-

stallation without any need for extra cooling equip-

ment.

IP 20 units can be upgraded with IP 21 / top cover and/

or NEMA 1 by fitting a terminal cover. See ordering

number for terminal cover under Accessories for VLT

2800 .

In addition, VLT 2880-82 and 2840 PD2 units are sup-

plied with Nema 1 enclosure as standard.

Brake

VLT 2800 is available with or without an integral brake

module. See also the section entitled Brake resistors

for ordering a Brake resistor.

RFI filter

VLT 2800 is available with or without an integral 1A

RFI-filter. The integral 1A RFI filter complies with EMC

standards EN 55011-1A.

With an integral RFI filter there is compliance with EN

55011-1B with a max. 15-metre screened/armoured

motor cable on VLT 2803-2815 1 x 220-240 Volt.

VLT 2880-82 with integral 1B filter comply with EMC

standard EN 50011 - 1B

Harmonic filter

The harmonic currents do not affect power consump-

tion directly, but they increase the heat losses in the

installation (transformer, cables). That is why, in asys-

tem with a relatively high percentage of rectifier load,

it is important to keep the harmonic currents at a low

level so as to avoid a transformer overload and high

cable temperature. For the purpose of ensuring low

harmonic currents, VLT 2822-2840 3 x 200-240 V and

VLT 2805-2882 380-480 V are fitted with coils in their

intermediate circuit as standard. This reduces the in-

put current I

RMS

by typically 40 %.

Please note that 1 x 220-240 V units up to 1.5 kW are

not supplied with coils in their intermediate circuit.

10 MG.27.E2.02 - VLT is a registered Danfoss trademark

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