Danfoss Turbocor, Installation Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Installation Guide Danfoss Turbocor www danfoss com drives ...

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Page 3: ... 3 4 2 Grounding Requirements 10 3 4 2 1 Leakage Current 3 5 mA 10 3 4 2 2 Grounding IP21 Enclosures 11 3 4 3 Motor Connection 11 3 4 3 1 Terminal Locations 12 3 4 4 Motor Cable 13 3 4 5 Motor Rotation Check 13 3 4 6 AC Mains Connection 13 3 4 7 DC Link Connection 13 3 5 Control Wiring Connection 14 3 5 1 Access 14 3 5 2 Using Screened Control Cables 14 3 5 3 Grounding of Screened Control Cables 1...

Page 4: ...5 2 General Technical Data 20 5 3 Fuse Tables 22 5 3 1 Protection 22 5 3 2 Fuse Selection 22 5 3 3 Short Circuit Current Rating SCCR 23 5 3 4 Connection Tightening Torques 23 Index 24 Contents Danfoss Turbocor 2 Danfoss A S 01 2015 All rights reserved MG35Q202 ...

Page 5: ...ial bus connector 10 Lifting ring 3 Digital I O and 24 V power supply 11 Mounting slot 4 Analog I O connector 12 Cable clamp PE 5 USB connector 13 Earth ground 6 Serial bus terminal switch 14 Motor output terminals 96 U 97 V 98 W 7 Analog switches A53 A54 15 Mains input terminals 91 L1 92 L2 93 L3 8 Relay 1 01 02 03 16 TB5 IP21 only Terminal block for anti condensation heater Table 1 1 Legend to I...

Page 6: ...n network 1 4 Internal Controller Functions Illustration 1 3 is a block diagram of the frequency converter s internal components Illustration 1 3 Frequency Converter Block Diagram Area Title Functions 1 Mains input 3 phase AC mains supply to the frequency converter 2 Rectifier The rectifier bridge converts the AC input to DC current to supply inverter power 3 DC bus Intermediate DC bus circuit han...

Page 7: ...er supplies including battery back ups UPS and DC link connections to other frequency converters Wait for the capacitors to fully discharge before performing any service or repair work The amount of wait time is listed in the Discharge Time table Failure to wait the specified time after power has been removed before doing service or repair could result in death or serious injury Voltage V Power ra...

Page 8: ...ollowing are rated for the same voltage Mains power Frequency converter Motor Ensure that frequency converter output current rating is equal to or greater than motor full load current for peak motor performance Motor size and frequency converter power must match for proper overload protection 3 3 Mechanical Installation 3 3 1 Cooling Top and bottom clearance for air cooling must be provided Genera...

Page 9: ...the bottom 3 4 Electrical Installation 3 4 1 General Requirements This section contains detailed instructions for wiring the frequency converter The following tasks are described Wiring the motor to the frequency converter output terminals Wiring the AC mains to the frequency converter input terminals Connecting control and serial communication wiring After power has been applied checking input an...

Page 10: ... 0 V D IN OUT 0 V PNP 24 V NPN D IN OUT 0 V 24 V 29 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 1 2 ON A53 U I S201 ON 2 1 A54 U I S202 ON 0 20 mA OFF 0 10 V 95 400 VAC 2A P 5 00 R 82 R 81 P RS 485 68 N RS 485 69 COM RS 485 61 0 V 5 V S801 RS 485 RS 485 2 1 ON S801 Bus Term OFF ON 3 Phase power input Load Share Switch Mode Power Supply Motor Analog Output Interface Relay1 Relay2 ON Terminate...

Page 11: ...nverter provides overload protection for the motor The overload calculates the level of increase to activate timing for the trip controller output stop function The higher the current draw the quicker the trip response The overload provides Class 20 motor protection Because the motor wiring carries high frequency current it is important that wiring for mains motor power and control are run separat...

Page 12: ...3 5 mA A dedicated ground wire is required for input power motor power and control wiring Use the clamps provided with the equipment for proper ground connections Do not ground one frequency converter to another in a daisy chain fashion Keep the ground wire connections as short as possible Using high strand wire to reduce electrical noise is recommended Follow motor manufacturer wiring requirement...

Page 13: ...t in death or serious injury For maximum cable sizes see chapter 5 1 Power dependent Specifications Comply with local and national electrical codes for cable sizes Gland plates are provided at the base of IP21 units Do not install power factor correction capacitors between the frequency converter and the motor Do not wire a starting or pole changing device between the frequency converter and the m...

Page 14: ...Illustration 3 5 Terminal Locations D1h B B A A 254 7 10 0 0 0 GROUND143 4 6 0 0 0 GROUND168 4 7 331 2 13 211 1 8 GROUND 168 4 7 GROUND 143 4 6 42 4 2 0 0 0 68 1 3 125 8 5 183 5 7 245 8 10 299 8 12 353 8 14 377 6 15 284 2 11 0 0 0 R S T U V W 4X M10x20 STUD WITH NUT SECTION B B MOTOR TERMINALS AND BRAKE TERMINALS MOTOR TERMINAL SECTION A A MAINS TERMINALS MAINS TERMINAL 130BC332 10 Illustration 3 ...

Page 15: ...internal RFI filter capacitors between the chassis and the intermediate circuit are isolated Isolating the capacitors prevents damage to the intermediate circuit and reduces ground capacity currents in accordance with IEC 61800 3 Size wiring is based upon the input current of the frequency converter Comply with local and national electrical codes for cable sizes 1 Ground the cable in accordance wi...

Page 16: ...c noise however a screen with a lower transfer impedance ZT value is more effective than a screen with a higher transfer impedance ZT Transfer impedance ZT is rarely stated by cable manufac turers but it is often possible to estimate transfer impedance ZT by assessing the physical design of the cable Transfer impedance ZT can be assessed on the basis of the following factors The conductibility of ...

Page 17: ...natively the connection to terminal 61 can be omitted PE FC PE FC 130BB924 12 PE PE 69 69 68 68 1 2 10 mm 1 Min 16 mm2 2 Equalizing cable Illustration 3 12 Screening without Using Terminal 61 3 5 4 Control Terminal Types 1 4 2 3 130BA012 12 61 68 69 39 42 50 53 54 55 12 13 18 19 27 29 32 33 20 37 Illustration 3 13 Control Terminal Locations Connector 1 provides four programmable digital input term...

Page 18: ...the frequency converter Always use screened twisted pair STP cable for bus cabling and always follow good common installation practice Low impedance earth ground connection of the screen at every node is important including at high frequencies Thus connect a large surface of the screen to earth ground for example with a cable clamp or a conductive cable gland It may be necessary to apply potential...

Page 19: ...re proper air flow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental consider ations See equipment label for the maximum ambient operating temperature limits Humidity levels must be 5 95 non condensing Fusing and circuit breakers Check for proper fusing or circuit breakers Check that all fuses are inserted firmly and in operational c...

Page 20: ...ure to be in operational readiness when the frequency converter is connected to the energised DC bus could result in death serious injury equipment or property damage 1 Confirm input voltage is balanced within 3 If not correct input voltage imbalance before proceeding Repeat procedure after voltage correction 2 Ensure optional equipment wiring if present matches installation application 3 Ensure t...

Page 21: ... 65 Table 5 1 Mains Supply 3x380 500 V AC DTC 302 N165 N232 Typical shaft output at 575 V kW 165 232 Typical shaft output at 575 V hp 221 311 Enclosure IP21 D1h D2h Output current Continuous at 575 V A 205 286 Continuous kVA at 575 V kVA 179 252 Max input current Continuous at 575 V A 188 264 Max cable size mains motor mm AWG 2x95 2x3 0 2x185 2x350 Max external mains fuses A 315 550 Estimated powe...

Page 22: ...ent on voltage and power Cable lengths and cross sections Max motor cable length screened armoured 150 m Max motor cable length unscreened unarmoured 300 m Max cross section to motor mains Maximum cross section to control terminals rigid wire 1 5 mm2 16 AWG 2x0 75 mm2 Maximum cross section to control terminals flexible cable 1 mm2 18 AWG Maximum cross section to control terminals cable with enclos...

Page 23: ...g 1 000 m Maximum altitude above sea level with derating 3 000 m 1 For more information on derating see the Design Guide section on Special Conditions EMC standards Emission EN 61800 3 EN 61000 6 3 4 EN 55011 IEC 61800 3 EMC standards Immunity EN 61800 3 EN 61000 6 1 2 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 See the Design Guide section on Special Conditions Control card p...

Page 24: ...regulations 5 3 2 Fuse Selection Danfoss recommends using the following fuses which ensures compliance with EN 50178 In case of malfunction not following the recommendation may result in unnecessary damage to the frequency converter The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical N165 N232 N262 380 500 V type aR N165 N232 575 V type aR Table 5 3 Rec...

Page 25: ...oo high torque results in a bad electrical connection Use a torque wrench to ensure correct torque Always use a torque wrench to tighten the bolts Frame size Terminal Torque Nm in lbs Bolt size D1h Mains Motor Load sharing Regen 19 40 168 354 M10 Earth Ground Brake 8 5 20 5 75 181 M8 D2h Mains Motor Regen Load sharing Earth ground 19 40 168 354 M10 Brake 8 5 20 5 75 181 M8 Table 5 6 Torque for Ter...

Page 26: ...ctrical installation 7 Electrical noise 10 EMC 15 17 21 Equalizing cable 15 External command 4 External controller 4 F Feedback 17 Floating delta 13 Frequency converter block diagram 4 Full load current 6 Functional testing 4 Fuse 17 Fusing 9 17 G Ground connection 10 17 Ground loop 15 Ground wire 10 17 Grounded delta 13 Grounding 10 17 Grounding hazard 10 Grounding IP21 54 enclosure 11 Grounding ...

Page 27: ...ut 15 Remote command 4 Reset 21 RFI filter 13 RMS current 4 RS485 16 S Safe torque off 16 Screened control cable 15 Screened control cable using 14 Serial communication 4 15 16 Shielded cable 7 17 Shielded wire 9 Specification 4 Start up 4 STO 16 Supply voltage 14 15 Surroundings 21 System feedback 4 T Temperature limit 17 Terminal location D1h 12 Terminal location D2h 12 Thermal protection 5 Ther...

Page 28: ...ducts 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 Danfoss A S Ulsnaes 1 DK 6300 Graasten www danfoss com drives MG35Q202 130R0572 MG35Q202 01 2015 ...