Danfoss D1h-D8h VLT Frequency Converters Installation Guide

Danfoss D1h-D8h VLT Frequency Converters

Product Information

The product being referred to in the user manual is a drive manufactured by Danfoss. The drive is used for various applications and requires installation, commissioning, and maintenance by qualified personnel. The user manual provides important safety information and precautions that should be followed to prevent injury, damage to the equipment, or system failure.

Instructions

Safety and Installation Awareness

Before starting installation, read all safety guidelines and precautions in this installation guide. Additional documentation such as the product-specific operating guide, design guide, and programming guide, as well as the functional safety guides can be accessed by scanning the QR code on the front cover. PC tools and MyDrive® ecoSmart™ can be downloaded at www.danfoss.com.

Qualified Personnel

Only qualified personnel are allowed to install, commission, and maintain 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.

Safety Symbols

The following symbols are used in this guide:

• DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTICE: Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

Safety Precautions

WARNING: LACK OF SAFETY AWARENESS

• This guide gives important information on preventing injury and damage to the equipment or the system. Ignoring this information can lead to death, serious injury, or severe damage to the equipment.
• Make sure to fully understand the dangers and safety measures present in the application.
• Before performing any electrical work on the drive, lock out and tag out all power sources to the drive.

WARNING: LIFTING HEAVY LOAD

• The drive is heavy. Lifting heavy objects incorrectly can result in death, injury, or property damage.
• Follow local safety regulations on lifting.
• Check the weight of the drive. The weight is provided on the outside of the shipping box.
• If lifting equipment is used, ensure that it is in proper working condition and can safely lift the weight of the drive.
• Test lift the drive to verify the proper center of gravity lift point. Reposition if not level.

WARNING: 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.
• Only qualified personnel must perform installation, start-up, and maintenance.

WARNING: DISCHARGE TIME

• The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off. Failure to wait the specified time after power has been removed before performing service or repair work can result in death or serious injury.
• Stop the motor.
• Disconnect all power sources, including permanent magnet type motors.
• Wait for capacitors to discharge fully. The discharge time is shown on the nameplate. See Illustration 1.
• Verify full discharge by measuring the voltage level.

WARNING: UNINTENDED START

• When the drive is connected to the AC mains or connected on the DC terminals, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage.
• Stop the drive and motor before configuring parameters.
• Make sure that the drive cannot be started by external switch, a fieldbus command, an input reference signal from the control panel, or after a cleared fault condition.
• Disconnect the drive from the mains whenever safety considerations make it necessary to avoid unintended motor start.
• Check that the drive, motor, and any driven equipment are in operational readiness.

CAUTION: INTERNAL FAILURE HAZARD

• An internal failure in the drive can result in serious injury when the drive is not properly closed.
• Ensure that all safety covers are in place and securely fastened before applying power.

WARNING: 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.
• Use an RCD device.
• When an RCD is used for protection against electrical shock or fire, use only a Type B device on the supply side.

WARNING: INDUCED VOLTAGE

• Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned off and locked out/tagged out. Failure to run output motor cables separately, or to use shielded cables, could result in death or serious injury.
• Run output motor cables separately or use shielded cables.
• Simultaneously lock out/tag out all the drives.

WARNING: ELECTRICAL SHOCK HAZARD

• Due to the stray capacitance of the shielded motor cable, the leakage currents exceed 3.5 mA. Failure to properly ground the drive can result in death or serious injury.
• Ensure that minimum size of the ground conductor complies with the local safety regulations for high touch current equipment.
• Use a reinforced ground conductor according to IEC 60364-5-54 cl. 543.7 or local safety regulations for equipment with leakage current >3.5 mA.

For reinforced grounding

Use a ground conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al, or an extra ground conductor of the same cross-sectional area as the original ground conductor as specified by IEC 60364-5-54, with a minimum cross-sectional area of 2.5 mm2 (14 AWG) mechanically protected or 4 mm2 (12 AWG) not mechanically protected. Use a ground conductor inside an enclosure or otherwise protected throughout its length against mechanical damage. Use a ground conductor that is part of a multi-conductor power cable with a minimum PE conductor cross-section of 2.5 mm2 (14 AWG) that is permanently connected or plugged in by an industrial connector. The multi- conductor power cable must be installed with an appropriate strain relief.

CAUTION: THERMISTOR INSULATION

• Risk of personal injury or equipment damage.
• To meet PELV insulation requirements, use only thermistors with reinforced or double insulation.

NOTICE: 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.
• Use additional protective devices such as short-circuit protection or motor thermal protection between the drive and the motor for applications with multiple motors.
• Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer must provide them.

NOTICE: 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 overheats.
• Enable the ETR function. See the application guide for more information.

Required Tools

• Lifting aid
• Tape measure
• Drill with assorted bits
• Screwdrivers (Torx, Phillips, slotted)
• Wrench with 7–17 mm sockets
• Socket extensions
• Sheet metal punch and/or pliers
• Wire crimper

Verifying the Shipment and the Contents

• Make sure that the items supplied and the information on the nameplate match the order. The nameplate is on the exterior of the drive.

NOTICE

The type code is used in the fuse table. Write down the type code (T/C) and serial number (S/N) for future reference.

1. Type code
2. Part number and serial number
3. Power rating
4. Input/output voltage, frequency, and current
5. Enclosure protection rating
6. Enclosure size

EMC-compliant Installation

• For more information, refer to the product-specific operating guide.
• Use shielded cables for motor (unshielded cables in metal conduit are acceptable), brake, DC, and control wiring.
• Ensure that motor, brake, and DC cables are as short as possible to reduce the interference level from the entire system. Provide a minimum space of 200 mm (7.9 in) between mains input, motor cables, and control cables.
• Convey the currents back to the drive using a metal mounting plate. Ensure good electrical contact from the mounting plate through the mounting screws to the metal frame of the enclosure.
• If the shield connection points have a voltage potential difference, connect a low impedance equalizing wire parallel to the shielded cable.
• When using relays, control cables, a signal interface, fieldbus, or brake, connect the shield to the enclosure at both ends. If the ground path has high impedance, is noisy, or is carrying current, break the shield connection on 1 end to avoid ground current loops.

Installing the Drive

The installation location is important. Full output current is available when the following installation conditions are met. For temperatures and altitudes outside this range, consult the Derating sections in the product-specific design guide.

• Maximum surrounding air temperature: 45 ºC (113 ºF) average over 24 hours and 50 ºC (122 ºF) for 1 hour.
• Minimum surrounding air temperature: 0 ºC (32 ºF).
• Altitude < 1000 m (3280 ft) above sea level.

Procedure

1. Identify the enclosure size. See Illustration 1.
2. Identify any options that need extra wiring and setup by using the type code. See step 1 in the Illustrations section.
   • Scanning the QR code on the cover opens the documentation search page. Use the option number to search for related documentation. For example, use MCA 120 to search for VLT® PROFINET MCA 120 documentation.
3. Make sure that the operating environment and electrical installation meet the following standards.
   • Indoor unconditioned/pollution degree 2.
   • Overvoltage category 3.
4. Review the wiring diagram. See step 2 in the Illustrations section.
   • All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements.
   • Loose connections can cause equipment faults or reduced performance. Tighten the terminals according to the proper torque value shown in step 9 in the Illustrations section.
5. Review the fuse specifications. See step 3 in the Illustrations section.
   • The drive can be suitable for use on a circuit capable of delivering up to 100 kA short circuit current rating (SCCR) at 480/600 V. For circuit breaker and switch SCCR ratings, see the product-specific design guide.
6. Review the power cable specifications. See step 4 in the Illustrations section.
   • Use copper wire with a minimum 70 ºC (158 ºF) rating. For aluminum wire, see the product-specific design guide.
7. Install the drive following the numbered steps in the Illustrations section. Certain illustrations/steps pertain to specific enclosure sizes and are marked as such.
   • Attach accessory bag components to the drive (step 5).
   • Mount the drive on or against a solid, non-combustible mounting surface such as concrete or metal (step 6). Ensure proper cooling by providing minimum clearance above and below the drive.
   • D3h–D4h are wall mounted, D1h–D2h and D5h–D6h are wall or floor mounted, and D7h–D8h are floor mounted.
   • Create cable openings in the cable entry plate (step 7).
   • Install the control wiring (step 8).
   • Install the motor, mains, and ground wiring (step 9).
   • Route the control cables (step 10)
8. Securely fasten the cover to the drive.
9. Perform initial drive and motor setup. Consult the product-specific programming guide.

   •   * Functional safety options require extra wiring and parameter configuration. See the specific functional safety operating guide, such as the Safe Torque Off Operating Guide, for more information on installing the safety option.

Descriptions

A (29–30)

AX| –
A0| VLT® PROFIBUS DP V1 MCA 101
A4| VLT® DeviceNet MCA 104
A6| VLT® CANopen MCA 105
A8| VLT® EtherCAT/IP MCA 124
AG| VLT® LonWorks MCA 108
AJ| VLT® BACnet MCA 109
AK| VLT® BACnet/IP MCA 125
AL| VLT® PROFINET MCA 120
AN| VLT® EtherNet/IP MCA 121
AQ| VLT® POWERLINK MCA 122
AT| VLT® PROFIBUS Converter MCA 113
AU| VLT® PROFIBUS Converter MCA 114
AY| VLT® Powerlink MCA 123

B (31–32)

BX| –
B0| VLT® Analog I/O Option MCB 109
B2| VLT® PTC Thermistor Card MCB 112
B4| VLT® Sensor Input MCB 114
B6| VLT® Safety Option MCB 150
B7| VLT® Safety Option MCB 151
B8| VLT® Safety Option MCB 152
BK| VLT® General Purpose I/O MCB 101
BP| VLT® Relay Card MCB 105
BR| VLT® Encoder Input MCB 102
BU| VLT® Resolver Input MCB 103
BY| VLT® Extended Cascade Controller MCO 101
BZ| VLT® Safe PLC I/O MCB 108

C1 (35)

X| –
R| VLT® Extended Relay Card MCB 113
7| VLT® Sensorless Safety MCB 159

C0 (33–34) + C (36–37)

CX_XX| –
C4_XX| VLT® Motion Control Option MCO 305
C4_10| VLT® Synchronizing Controller MCO 350
C4_11| VLT® Position Controller MCO 351

Wiring Diagram

Wiring

A| B| C|
---|---|---|---
|

IEC

Bussmann P/N

|

UL

Bussmann P/N

102/103/202| T2| N55K| 170M2620| 170M2620
102/103/202| T2| N75K| 170M2621| 170M2621
102/103/202| T2| N90K| 170M4015| 170M4015
102/103/202| T2| N110| 170M4015| 170M4015
102/103/202| T2| N150| 170M4016| 170M4016
102/103/202| T2| N160| 170M4018| 170M4018
102/103/202| T4| N110| 170M2619| 170M2619
102/103/202| T4| N132| 170M2620| 170M2620
102/103/202| T4| N160| 170M2621| 170M2621
102/103/202| T4| N200| 170M4015| 170M4015
102/103/202| T4| N250| 170M4016| 170M4016
102/103/202| T4| N315| 170M4018| 170M4018
102/103/202| T7| N75K| 170M2616| 170M2616
102/103/202| T7| N90K| 170M2619| 170M2619
102/103/202| T7| N110| 170M2619| 170M2619
102/103/202| T7| N132| 170M2619| 170M2619
102/103/202| T7| N160| 170M2619| 170M2619
102/103/202| T7| N200| 170M4015| 170M4015
102/103/202| T7| N250| 170M4015| 170M4015
102/103/202| T7| N315| 170M4015| 170M4015
102/103/202| T7| N400| 170M4015| 170M4015

A| B| C|
---|---|---|---
|

IEC

Bussmann P/N

|

UL

Bussmann P/N

302| T2| N45K| 170M2620| 170M2620
302| T2| N55K| 170M2621| 170M2621
302| T2| N75K| 170M4015| 170M4015
302| T2| N90K| 170M4015| 170M4015
302| T2| N110| 170M4016| 170M4016
302| T2| N150| 170M4018| 170M4018
302| T5| N90K| 170M2619| 170M2619
302| T5| N110| 170M2620| 170M2620
302| T5| N132| 170M2621| 170M2621
302| T5| N160| 170M4015| 170M4015
302| T5| N200| 170M4016| 170M4016
302| T5| N250| 170M4018| 170M4018
302| T7| N55K| 170M2616| 170M2616
302| T7| N75K| 170M2619| 170M2619
302| T7| N90K| 170M2619| 170M2619
302| T7| N110| 170M2619| 170M2619
302| T7| N132| 170M2619| 170M2619
302| T7| N160| 170M4015| 170M4015
302| T7| N200| 170M4015| 170M4015
302| T7| N250| 170M4015| 170M4015
302| T7| N315| 170M4015| 170M4015

|

---|---
L1/L2/L3| U/V/W| -DC/+DC| R+/R-
D1h| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)
D2h| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)
D3h| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)
D4h| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)
D5h| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)
D6h| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)| 2 x 95 (2 x 3/0)
D7h| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)
D8h| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)| 2 x 185 (2 x 350 mcm)

Illustration 5

D1h–D8h

Dimensions And Installation

D1h–D6h

| A| A1| A2| B| B1| B2| C| C1| D| ****
---|---|---|---|---|---|---|---|---|---|---
D1h| 844 (33.2)| 25 (1.0)| 20 (0.8)| 180 (7.1)| 33 (1.3)| –| 200 (7.9)| 63 (2.5)| 225 (8.9)| 4 x M10
D2h| 1051 (41.4)| 25 (1.0)| 20 (0.8)| 280 (7.1)| 33 (1.3)| –| 271 (10.7)| 75 (2.9)| 225 (8.9)| 4 x M10
D3h| 844 (33.2)| 25 (1.0)| 20 (0.8)| 180 (7.1)| 33 (1.3)| –| 200 (7.9)| 25 (1.0)| 225 (8.9)| 4 x M10
D4h| 1051 (41.4)| 25 (1.0)| 20 (0.8)| 280 (11.0)| 33 (1.3)| –| 271 (10.7)| 40 (1.6)| 225 (8.9)| 4 x M10
D5h| 1276 (50.2)| 25 (1.0)| 20 (0.8)| 180 (7.1)| 33 (1.3)| 33 (1.3)| 200 (7.9)| 64 (2.5)| 225 (8.9)| 4 x M10
D6h| 1615 (63.6)| 25 (1.0)| 20 (0.8)| 280 (11.0)| 33 (1.3)| 33 (1.3)| 271 (10.7)| 40 (1.6)| 225 (8.9)| 4 x M10

• [mm (in)]

D1h–D2h

T25

• [2.3 Nm (20 in-lb)]
• [19 Nm (168 in-lb)]

D5h–D8h

T25

• [2.3 Nm (20 in-lb)]
• [19 Nm (168 in-lb)]

D3h–D4h

D1h–D8h

D1h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D2h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D3h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D4h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D5h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D6h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D7h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D8h

| M8 [9.6 Nm (84 in-lb)]

M10 [19 Nm (168 in-lb)]

D3h–D4h

Danfoss A/S

• Nordborgvej 81 DK-6430 Nordborg
• www.danfoss.com

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. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

References

• Search | Danfoss
• Global AC drive manufacturer - Danfoss Drives | Danfoss
• Engineering Tomorrow | Danfoss
• MyDrive® ecoSmart
• MyDrive® ecoSmart

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