VLT 5000 Installation Startup Check List • • • • Reference material Pre-Installation Installation Checks Wiring – – – – – Incoming Power Motor Brake Control Serial Communications This presentation deals with the start-up of VLT 5000 drives. It is designed to help you handle the start-up of the drive in normal applications. Because of the flexibility of these drives, there may be some specialized applications that are not specifically covered by these instructions.
! DANGER Touching the electrical parts may be fatal — even after the equipment has been disconnected from the AC line. To be sure that the capacitors have fully discharged, wait 15 minutes after power has been removed before touching any internal component Because the drive uses large electrolytic capacitors in its power circuitry, it can maintain a dangerous voltage level for up to 15 minutes after power has been removed.
Reference Material • Instruction Manuals • Connection Diagram • Schematic Diagram These three pieces of reference material might be available to you when you are starting up a drive. The VLT 5000 Instruction Manual provides general information on topics like mounting clearances, drive fuses, terminal tightening torques, and drive parameters. From the Customer, a Connection Diagram might be available which provides a sketch indicating the layout and use the equipment in the system.
Hp to kW Chart Model 5001 5002 5003 5004 5005 5006 5008 5011 5016 5022 5027 Hp 0.25 0.33 0.50 0.75 1.0 1.5 2.0 3.0 4.0 5.0 7.5 10.0 15.0 20.0 25.0 kW 0.18 0.25 0.37 0.55 0.75 1.1 1.5 2.2 3.0 4.0 5.5 7.5 11.0 15.0 18.5 Model 5032 5042 5052 5062 5075 5100 5125 5150 5200 5250 5300 5350 5450 5500 Hp 30.0 40.0 50.0 60.0 75.0 100.0 125.0 150.0 200.0 250.0 300.0 350.0 450.0 500.0 kW 22.0 30.0 37.0 45.0 55.0 75.0 90.0 110.0 132.0 160.0 200.0 250.0 315.0 355.0 • 1 Hp = 0.
The Nameplates All Drives – On the Top or Left Side of the Drive Catalog Number Sales Number Serial Number Output Ratings of Drive 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. When ordered, the Catalog Number is converted into a Sales Number which is much less cumbersome.
Pre-Installation Check Catalog Order Number System (Found on page D 62 of the catalog) Example: VLT- 5008–P-T5-B20–EB-R0–DL-F00-A00-C0 VLT: Series 5XXX: Model Number -------------| P: Process Application -----------------| AC Line Voltage -----------------------------| T2: 3 phase 200 – 240 Vac T5: 3 phase 380 – 500 Vac T6: 3 phase 550 – 600 Vac Enclosure (dimensions -page 39)-------------| B20: Bookstyle Chassis (IP20) C00: Compact Chassis (IP 00) C20: Compact Protected Chassis (IP 20) CN1: Compact NEMA 1
Pre-Installation Check • Be sure the Line Power, AFD and Motor have the same voltage range • Insure that all hand tools and kits are available. Before installing the drive, check to be sure that the power line, the drive, and the motor are all rated for the same voltage. It may be necessary to check the wiring inside the motor's conduit box to confirm its voltage rating.
Pre-Installation Check • Record motor data information – – – – – Motor Power Motor Voltage Motor Frequency Motor Current (FLA) Motor Speed (RPM) Write down the motor nameplate information. This will be important later during programming. A conversion between HP and kW must be calculated 1Hp = 0.75kW. In the example 20Hp = 15kW.
Pre-Installation Check • Always ensure that Drive can handle maximum current of the motor. • Example page 20 – VLT 5100 – CT, HO It is always important to check the technical data of the instruction manual for the drive you are installing to certify that the drive is able to handle the maximum current of the motor. In the example above a 100Hp (75kW) motor uses 125amps maximum current.
Pre-Installation Check • Check Motor Wiring – No power correction capacitors between drive and motor – 2-speed motors must be wired for full speed – Part-winding start motors, must be wired for run. Insure that there are no power correction capacitors between the drive and the motor. These types of capacitors must always be located on the incoming power to the drive, never the output of the drive.
Installation Checks • Fuses must be installed – Sized using Pages 34-35 in Instruction Manual To comply with UL / cUL, fuses must be wired on the incoming power side of the drive. The types of fuses are shown in the technical data section of the instruction manual. In the example above fuses and a disconnect switch are diagramed. To comply with UL never wire the drive to circuit breakers because they do not trip as fast as fuses.
Installation Checks • Environmental Concerns – Clean and Dry – 24-Hour temperature limit – page 214 – Altitude Limits – page 214 The VLT 5000 can be supplied with a NEMA 1(IP 20) or NEMA 12(IP 54) enclosure. These enclosures provides some degree of protection from falling dust. Therefore, drives with a NEMA 1(IP 20) and 12(IP 54) enclosures should be mounted indoors in a relatively clean and dry location.
Installation Checks • Mounting – Vertical – Flush Mounted Only In order to provide proper cooling, the drive must always be mounted vertically. It is also important to establish a "chimney" around the drive's heat sink to ensure that all cooling air passes along the entire length of the heat sink. If a drive with no option panel is not mounted directly to a vertical flat surface, it is important to see if this leaves any heat sink fins exposed in the back.
Installation Checks • Mounting – Side by Side is acceptable – Needs space above and below drive The VLT 5000 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 “installation” section of the Instruction Manual, pages 43-44.
Mounting the Drive • Keep the drive clean – Use dust covers to keep construction dust from getting into it – Remove the dust covers before applying power If construction work continues after the drive is mounted, it is important to keep the drive as free as possible from concrete dust and similar dirt. If the drive does not have power applied to it, it should be kept covered. If the drive must be powered up and run, this cover must be removed.
Wiring the Drive • • • • • • General Wiring Power Input Brake Motor Output Control Serial Comms This next section covers the wiring of the drive. The first area to be covered is general wiring practices. The other sections cover power or line wiring from the drive to incoming power, brake wiring. The motor wiring covers the connections between the drive and the motor. Control wiring for Digital Inputs/Outputs and Analog Input/Outputs are also covered.
Wiring the Drive • Conduit entry – All wiring enters the bottom of drive – Knock-outs are provided on many drives – Larger drives have a removable conduit entry or gland plate General Practices Most smaller drives have knock-outs for conduit entry. Larger drives provide a removable conduit entry plate. It is important to remove this plate before drilling or punching it.
Wiring the Drive • • At least three separate METALLIC conduits must be connected to the drive – Power into the drive [L1, L2, L3 and a ground back to the distribution panel] – Power from the drive to the motor [U, V, W, and PE (power earth ground)] – Control wiring A dedicated ground wire is needed At least three separate conduits must be connected to the drive.
Wiring the Drive • Input fuses – All drives must have input fuses installed in the power supply to the drive – Refer to the Instruction Manual for fuse sizing In order to fulfill the requirements of Underwriters Laboratory (UL) as was stated on page 11, all drives must be provided with fast-acting input power line fuses. The proper style and rating for these fuses is specified in the Instruction Manual on page 24.
Wiring • General Information – Maximum voltage to control card is 24Vdc – Do NOT connect 120/240/460/575 to Control terminals – Use Relay 01, 02, 03 for 120 or 240Vac The maximum voltage for the control circuit must not exceed 24Vdc. A separate relay terminal 01, 02, 03 is used for higher voltages, 120/240 Vac.
Wiring • Motor Wiring – Use Terminals 96, 97, 98 – Check torque – page 53 – Distance limits – Disconnect OK A disconnect switch between the drive and motor may be required to meet electrical codes. During operation if the disconnect switch is opened, no harm is done to the drive or motor. If the disconnect is then closed and the drive is running, the motor may attempt to draw locked rotor current from the drive. This may cause the drive to shut down on an over-current fault trip.
Wiring • Brake Wiring on SB & EB units – Use Terminals 88 & 89 for resistor – Load sharing for EB units – External 24Vdc. On Standard with Brake (SB) units there is an extra terminal labeled R – (81) and R + (82). The dynamic brake resistor is wired to these 2 terminals. Brake resistors come separately and are sized using a centrifuge as a model. If over a 2-minute window the dynamic brake is used infrequently, less than 12 seconds, then a 10% brake resistor is adequate.
Wiring • Control Wiring – – – – Digital Inputs Analog Inputs Analog Output Digital/Relay Outputs This next section covers control wiring. It covers Digital Input Wiring first, followed by Analog Inputs. Analog Outputs are covered followed by Digital Outputs then Relay Outputs. It is always best to have control wiring in a separate conduit away from power wiring.
Wiring • Digital Inputs – 12 to 27 Enable – Jumper terminal 12 (+24Vdc) to terminal 27 (enable command) – Without jumper, bottom line of the display reads, “UNIT READY” and it does not operate the motor. When this jumper is made, the bottom line reads, “STANDBY”. In its default state, the way it comes from the factory, a jumper or a connection is required for operation. It must be connected between terminals 12 (24Vdc) and 27 (Digital Input), which defaults to a “coasting stop inverse” command.
Wiring • Digital Inputs – Push button – – – – Normally Open - Momentary Functions: Latched Start (terminal 18 only) Reset Jog Push-Button (PB) Switch – Normally Open (NO) Some options: Latched Start can be configured using terminal 18 only. Reset can be accomplished from a remote location when the drive trips. Jog can also be accomplished with a push-button NO switch. The Jog frequency is set by parameter 213 and the ramp to the jog frequency is set by parameter 211.
Wiring • Digital Inputs – Push Button – Normally Closed - Momentary – Stop Inverse means loss of 24Vdc to that terminal, stops the motor. – If multiple “stop” commands are required, additional terminals (16, 17, 27, 29, 32 and 33) can be wired in parallel each programmed for “Stop Inverse”. Push-Button Switch – Normally Closed (NC) Some options: Normally closed switch is programmed for “Stop Inverse”. Inverse means that the command, “Stop” is given when 24Vdc is gone.
Wiring • Digital Inputs – Push Button – Normally Closed (NC) - Momentary (Push Button) – Multiple stop commands can be wired in series to accommodate more stop commands. Any switch opens, stops the motor. If more stop commands are needed the diagram above shows multiple NC PB stop switches using one Digital Input. If any of the 5 switches are opened the drive stops. With each input programmed as a Stop Inverse command, the drive stays off until it sees a “Latched Start” command.
Wiring • Digital Inputs – Pushbuttons - 3 Wire Start/Stop – Term. 18 (P 302) set to “Latched Start” – Term. 16 (P 300) set to “Stop Inverse” for terminal 17, 27, 29, 32 or 33. The diagram above shows the wiring for a 3-wire Start/Stop. Power comes from terminal 12, a source of +24Vdc. Terminal 18 is programmed for Latched Start and terminal 16 is programmed for Stop Inverse.
Wiring • Digital Inputs – Pushbuttons - Changing the Reference – Pulsed Increase/Decrease Reference Speed – Term. 32 (P 306) set to “Speed UP”; Term. 33 (P 307) set to “Speed DOWN” – Term. 17 defaults to “Freeze Ref.” or on newer units set P 330 to “Freeze Reference” saving terminal 17 for another function. – Sensitivity of buttons is determined by values placed in P 209 for increase speed & P 210 for decrease speed. Here is the a diagram for using 2 Digital Inputs as a push button reference.
Wiring • Digital Inputs – Continuous – – – – Single-pole, double throw (SPDT) 2-wire Start/Stop using term 18. Reverse using term 19 (P 303) – P 200 set to Both Directions Other functions: Quick Stop, Direction Change, Ramp 2 Continuous Switch This diagram shows a 2-wire Start/Stop using terminal 18 which is programmed for Start. When the switch is ON, the drive starts. When the switch is OFF the drive stops. The switch wired to terminal 19 determines direction when the drive is ON.
Wiring • Digital Inputs – Multiple Starts from One command – Common connected, terminal 20, on each unit – Maximum of 200mV In the example above, one switch is used to start multiple drives. The +24Vdc from the first drive is being sent to the other drives. Notice that a wire most be connected between all the Digital Input commons, terminal 20. There is a maximum of 200mV coming from the power supply of the first drive, which limits the number of drives that may be started.
Wiring • Digital Inputs – One switch ON/OFF and Direction – SPDT Center OFF – Terminal 18 (P 302) set for “Start” – Terminal 19 (P 303) set for “Start & Reverse” Single Pole Double Throw with Center OFF. This switch is used to start the drive in either direction, and turn it OFF in the center position. Notice that +24Vdc from terminal 12 goes to the center of the switch. When the switch is completed to terminal 18 is goes Forward.
Wiring • Digital Inputs – Preset Speeds – – – – 4 Preset Speeds set in Parameters 215, 216, 217 and 218 4-Position Switch using diodes for signal isolation Parameter 214 is set to “External/Preset” For additional presets up to maximum of 16, change between setups and presets. 4-Position Rotary switch for Preset Speeds In the diagram above terminal 16, programmed for “Preset Reference” turns the preset speeds ON or OFF. This assumes that parameter 214 has been set to “External/Preset”.
Wiring • Digital Inputs – Changing Setups – 4-Position Switch and relay used for signal isolation – P 004 must be set to Multi Setup 4-position with a relay for Changing Setups In the diagram above a 4-position switch is used to shift between 4 different program setups. Notice the binary chart for setups # 1 through # 4. In order for the setup change to work, parameter 004 must be set for “Multi Setup”. A DPDT (double-pole double-throw) relay is used when position 4 is selected.
Wiring • Digital Inputs – Encoder – – – – – A Channel showing speed comes into term 33 (P 307) B Channel showing direction comes into term 32 (P 306) +24Vdc power from terminal 13, common terminal 39 P 329 sets PPR for Encoder P 345 sets loss timeout, P 346 sets loss function Encoder For a Speed Closed Loop application, the encoder is wired directly into the control section.
Wiring • Analog Inputs – 0 to 10Vdc – – – – Potentiometer Term 53 (P 308) set to “Reference” by default Term 54 (P 311) set to “No operation” by default Term 50 is +10Vdc; Term 55 is common Analog Input – potentiometer. A potentiometer or pot (typically 1K ohm) can be used to give a remote reference to the drive. One side of the pot is wired to terminal 50 a source of +10Vdc. The other side of the pot is wired to terminal 55, which is the Analog Input common.
Wiring • Analog Inputs – Potentiometer – P 203 is Min – Max or –Max to +Max – P 215 sets offset, may be negative In the diagram to the left, parameters are indicated to show the relationship between the signal coming from the pot and the reference. The signal from the pot is indicated on the left of the graph. Notice that parameters 309 and 310 set the voltage range. Parameter 308 sets the function for this signal, in this case the reference. On the bottom, the reference is indicated.
Wiring • Analog Inputs – One Potentiometer feeds multiple drives One Pot controlling multiple drives In the example above, one potentiometer is used to send a 0-10Vdc reference to the top drive. To send this same reference signal to the next drive, terminals 53 are wired together and terminals 55 (AI common) are wired together.
Wiring • Analog Inputs – 2-wire Transmitter – Term 12 or 13 supplies power +24Vdc – Jumper 39 to 55 to connect commons Analog Input – 2-wire Transmitter The picture above shows a 2-wire 4-20mA current transmitter. This type of transmitter requires power from the drive. The positive side of the transmitter is wired to terminal 12 or 13(+24Vdc). Terminal 39 (common for power) must be wired to terminal 55 (common for the Analog Inputs).
Wiring • Analog Inputs – – – – 3-wire Transmitter Term 12 or 13 supplies power +24Vdc Transmitter’s Signal wired to terminal 60 (P 314 = Feedback). Jumper 39 to 55 to connect commons Analog Input – 3-wire Transmitter The picture above shows a 3-wire 4-20mA current transmitter. This type of transmitter also requires power from the drive. Terminal 12 on the drive sends power to the transmitter labeled +24Vdc. A common terminal on the transmitter is wired back to terminal 39 (common for power) on the drive.
Wiring • Analog Outputs – – – – Meter Indication Terminal 42 and 45 set to AO or DO If using 0-Fmax 0-20mA, meter trim is P 202. New software – meter trim – use P 357 – 360. Analog Outputs The current meter shown above has its positive terminal wired to terminal 42 of the drive and the negative terminal wired to terminal 39. Terminal 45 can also be used for meter indication.
Wiring • Analog Outputs – Master/Slave (Leader/Follower) – AO of Master to AI of Slave – Use 0-Fmax 4-20mA, use P 202 on master to match slope. – Use P 215 on slave to match intercept. Analog Output – Master/Slave If 2 drives are to work together, at the same frequency, a master/slave (leader/follower) setup is of benefit. In the diagram above, the Analog Output from the master is wired to the analog input of the slave. Terminal 42 of the master is wired to terminal 60 of the slave.
Wiring • Analog Output - Pulse – Master/Slave (Leader/Follower) – DO of Master to DI of Slave set for Pulsed Reference – Use 0-Fmax 0-32,000 pulses, set max pulses to 32,000 use P 202 on master to match slope. – Use P 215 on slave to match intercept. Analog Output – Pulse The diagram above shows another way to connect 2 drives together in a Master/Slave (Leader/Follower) arrangement. This arrangement acts like an encoder and is slightly more accurate, perhaps 0.
Wiring • Digital/Relay Outputs – Digital Output powered +24Vdc – Relay Outputs are dry (no power) contacts Digital Outputs Terminals 42 and 45 besides being used as Analog Outputs can also be used as Digital Outputs. Digital Outputs are always +24Vdc powered 2-state outputs. In the diagram to the left a 24Vdc light is wired directly to terminals 42 (DO signal) and 39 (common).
Wiring • Serial Communications – Need repeater (amplifier) after 31 drives attached together – Dip switch settings 2 & 3 to OFF except for 2 bus ends Serial Communications This diagram shows how the serial communications is wired. Notice that it is an RS485 connection, which means that all the positive terminals (68) are wired together and all the negatives (69) are wired together. These connections must be in a “Daisy Chain” fashion which only has 2 ends. Star configurations should NOT be used.
