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Revised September 1, 2005

Danfoss VLT 5000 Overview

Optimized Bookstyle Enclosure
Protected chassis (IP 20) enclosure Saves panel space Side-by-side flush mounting requires less panel space 1-10 HP

Factory Installed Options in Drives Enclosure

VLT 5000 Series drives are available in a variety of enclosure styles and protective ratings.

Load sharing 24 VDC backup supply connections Dynamic brake module RFI filter to meet CE directives

Exclusive Patented VVCPLUS Performance

Sensorless vector control Fast response 3ms 1ms Speed or torque control Full torque down to zero speed (open loop) Full torque at zero speed (closed loop) Smooth torque ripple Wide speed range Four quadrant operation

There's a Drive to Meet Your Needs

For cost effectiveness and system optimization, VLT 5000 drives are available in different hardware configurations: ST: Standard SB: Standard with dynamic brake EX: Extended EB: Extended with dynamic brake NEW! Available on VLT 5122-5552; 380-500 VAC units and VLT 5042-5352; 525-690 VAC units: DE: Extended with brake and fuse/disconnect DX: Extended with fuse/disconnect PS: 24V input for logic supply PF: 24V input for logic supply and mains fuses PD: 24V input for logic supply and mains fuses/disconnect PB: 24V input for logic supply and mains fuses/disconnect and dynamic brake Units with dynamic brake require an external brake resistor to complete the installation. The extended configuration offers connection terminals for load sharing capabilities between VLT 5000 units, plus input terminals for a remote 24 VDC supply to maintain the control card and logic during removal of the AC input power. RFI filters are standard on all 1-10 HP (460 VAC) and 1-5 HP (230 VAC) configurations and are available as a built-in option for higher HP models.

Extended AC Line Voltage

200 to 240 VAC 10% 380 to 500 VAC 10% NEW! 525 to 690 VAC 10% for 40 to 350 HP range

Contents
D2 Overview and Features D 14 Performance Data D 28 General Technical Data D 32 Dimensions D 44 Options D 68 Ordering Information VLT 5000 APU Program D 69 Overview D 70 NEMA 1/12 Bypass Package D 73 NEMA 1 Integrated APUs D 75 Ordering Information D2 www.namc.danfoss.com 1.800.432.6367

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Compact Enclosures for all VLT 5000 Units

Chassis NEMA 1 (IP 20) NEMA 12 (IP 54) Available for units 1-550 HP Side-by-side flush mounting

Applications
Constant Torque Conveyors Palletizers Centrifuges Sequencing Positioning Synchronizing Pumps Tooling Machines Hoists Grinders

Extended Horsepower Range

NEW! Up to 550 HP high overload/650 HP normal overload 1-600 HP normal overload Constant Torque (CT) or Variable Torque (VT) operation High torque overload mode: 160% torque overload Constant Torque (CT) Normal torque overload mode: 110% overload (CT/VT) allows units to be used at one greater horsepower level for 100% continuous output with 110% torque overload capability

Variable Torque Pumps Fans

VLT 5000

New Display/Keypad
Removable Local Control Panel (LCP) allows downloading of program from drive to drive Displays multiple setup parameters Quick menu setup for easy commissioning Easy remote mounting of LCP

Enhanced Software
Automatic motor adaptation Built-in PID control Multiple data menu sets for quick system changeover Open or closed loop motor thermal protection Closed loop speed control available standard

Protection Features
Self-testing Overvoltage Overcurrent Undervoltage Overload Overheating External fault Electronic thermal Ground fault

Options
Remote keypad kit Din rail adaptor kit Brake resistors EMC filters Floor mounting kits (125-500 HP)

International Approvals
UL cUL CE

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Features Keypad and Display Functions

Fast, Simple, Automatic Start-Up
The VLT 5000 Series has a two-level, menu-prompted software structure. The first level, referred to as the Quick Set-Up Menu (see facing page), contains the thirteen most commonly used parameters; the second level offers comprehensive programming capabilities. If the drive and the motor are of the same rated size, programming is not normally necessary simply connect the AC line, the motor and the control wires, and start the VLT 5000 Series unit.

Versatile Data Display

The VLT 5000 Series drives four line, alphanumeric, backlit LCD display is easy to read from any angle. The display has three lines of 20 characters and one line of eight doublesized characters. Up to four measurements can be shown continuously on the top two lines of the display. Choose from twentyfive different items to display, including input reference, motor current, hours run, output frequency, horsepower, kW or kWh, or select from custom units, such as GPM.

Local Control Panel

All VLT 5000 Series drives use the same control panel, menu-driven operating system and cabling connections. Once familiar with one drive, an operator can start up, program and operate any other VLT 5000 drive throughout the HP range. Interchangeable keypad contains non-volatile memory for uploading/downloading parameters for single and multiple drive installations. LCPs may be removed for secure, tamper-proof operation. (The drives status lights operate independent of keypad). The operational status on the drive include green "ON," yellow "WARNING," and red "ALARM" LEDs. The LCP on all units can be mounted up to 10 feet (3 meters)from the drive using the optional NEMA 12 mounting kit (ideal for machine panel mounting).

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Features Quick Set-up Menu

Quick Start Up
With the direct-access Quick Menu, most installations are commissioned by simply scrolling through the 13 parameter settings to confirm that they match your requirements. Once checked, the values set are automatically stored in non-volatile memory. Thats it! After setting up one drive, the removable LCP can be used to transfer the same settings to all other VLT 5000 Series drives. Quick Set-up Menu items include: Language select Motor power Motor voltage Motor frequency Motor current Rated motor speed Automatic motor adaptation Minimum reference Maximum reference Ramp up time VLT 5000 Ramp down time Local/remote control Local reference D

The + and - keys are used to scroll and select the data values. For example, in the Language set-up menu (above), the + and - keys scroll through the choices of nine languages. Once the desired language is selected, pressing the Menu key stores the data value. The optional LCP-2 Keypad/Display provides all the features and performance benefits of the VLT 5000 Series LCP, and is also interchangeable with the VLT 2800 Series drives.

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Features VVCPLUS: The Heart of VLT 5000 Technology

The VLT 5000 with VVCPLUS
VLT 5000 Series features an inverter control system called VVCPLUS, which is a further development of the Voltage Vector Control (VVC) from the Danfoss VLT Series 3000. VVCPLUS controls an induction motor by energizing it with a variable frequency and a voltage that matches it. If the motor load is changed, the magnetization of the motor changes too, and so does its speed. Consequently, the motor current is measured continuously and the actual voltage requirement and slip of the motor are calculated from a motor model. Motor frequency and voltage are adjusted to insure that the motor operating point remains optimal under varying conditions. The development of the VVC principle is the result of a wish to maintain robust, sensorless regulation that is tolerant to different motor characteristics without motor derating.
PLUS

Advantages of VVCPLUS
Up to 160% torque for up to 1 minute Up to 180% starting breakaway torque (0.5 sec.) Up to 100% acceleration torque of rated torque Accurate slip compensation Full torque (up to 100%) down to 0 rpm in open loop control Full holding torque (up to 100%) at 0 rpm in closed loop control Fast compensation for speed variations with load changes High speed stability High resolution of output frequency Fast system response of 3 ms (1 ms) No motor derating Maximum stability during load changes

Quick, Complete Control

In order to make programming simple and easy to grasp, we have included special features such as a Quick Menu and easy data transfer. The Quick Menu guides users through the programming of the few parameters that are typically needed to get started. For more complex operations, users can create, modify and store up to four different control programs tailored to precise application requirements using the user-defined setups in the Menu Mode. The LCP (Local Control Panel) is detachable. It features a four-line alphanumeric display, enabling four measuring values to be displayed at the same time. Using the detachable LCP, programmed settings can be copied from one VLT 5000 Series unit to the next, eliminating time spent programming when changing drives or integrating a new drive into the installation. The entire programming process is easier than ever before. The VLT 5000 Series makes most adjustments automatically.

Oscilloscope trace of a motor phase current provided by a conventional pulse width modulation system with harmonic elimination (left); a Danfoss VVCPLUS system (right).

First and foremost, the current measurement and the motor model have been improved. The current is split into magnetizing and torque-generating parts and provides for more accurate and quicker estimation of the actual motor loads. It is now possible to compensate for rapid load changes. Full torque as well as extremely accurate speed control can now be attained at low speeds or even at standstill. In a special motor mode, permanent magnet synchronous motors and/or parallel motors can be used. Compared with a standard voltage/frequency control, VVCPLUS offers improved dynamics and stability, both when the speed reference and the load torque are changed. In addition, we have implemented a fully digitalized protection concept, which insures reliable operation even under the worst possible operating conditions. Naturally, the VLT 5000 Series also offers full protection against faulty coupling, short-circuiting, ground fault and overload. Danfoss drives with the VVCPLUS control system tolerate shock loads throughout their speed range and react swiftly to changes in reference. MOTION CONTROLS D6

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Features Installation and Start-up

Display Mode Quick Menu Mode
1 2 3 4 5 6 7 8 9 10 11 12 13 Language Motor Output Motor Voltage Motor Frequency Motor Current Rated Motor Speed Automatic Motor Adaptation Minimum Frequency Maximum Frequency Ramp-Up Time 1 Ramp-Down Time 1 Local/Remote Control Local Reference

Menu Mode
Setup 1 2 Group Description 0 1 2 3 4 5 6 Operation and Display Load and Motor References and Limits Inputs and Outputs Special Functions Serial Communication Technical Functions Parameters 000-099 100-199 200-299 300-399 400-499 500-599 600-699 3 4

Excellent Torque Control

Good torque control properties, smooth transitions to and from current limit operation and robust pull-out torque protection are insured. After automatic motor adjustment, VVCPLUS will help to insure extremely accurate motor control. The VLT 5000 Series design accommodates a number of integral components that would normally have to be purchased and installed separately. These integral components, such as DC coils and serial communication port (standard), RFI filter and dynamic brake (optional), are space-savers that simplify installation, save cost and ensure optimum performance.

Choice of Overload Torque Modes can Dramatically Reduce Drive Cost

The VLT 5016 and above are software selectable to perform in two operating modes depending on the requirements of the application. In High Overload torque mode, the VLT 5000 Series provides up to 160% overload torque for 1 minute using an appropriately sized motor. For many applications, however, this high overload torque is unnecessary. With the VLT 5000 Series Normal Overload torque mode feature, the drive can now provide up to 110% for 1 minute in constant torque at one HP size larger. Whats the advantage? Used in conjunction with an oversized motor, a VLT 5000 Series drive operating in Normal Overload mode can provide a substantial increase in constant torque horsepower without derating. Normal Overload mode gives the VLT 5000 Series drive the ability to operate one power size higher. For example, a drive rated for 15 HP constant torque (with a 160% overload rating) can now provide 20 HP constant torque (with a 110% overload rating). Obviously, if the application can allow the reduced overload rating, this VLT 5000 Series design feature can be a major cost savings when specifying a drive. VLT 5000

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Features Built-in Protection

Input Line Protection from Extreme Running Conditions
Line Disturbances and Transients To protect itself from AC line voltage disturbances, the drive monitors all three phases and interrupts drive operation for phase loss or if there is phase imbalance. Transients on the AC line are suppressed by MOVs as well as zener diodes for extreme transients. Danfoss drives meet VDE 0160 (European standard) for transient protection. Voltage Sags and Surges The VLT 5000 Series is designed for a wide range of operating conditions. The 230 volt drives will operate on 180264 VAC. The 460 volt drive will operate from 342 550 VAC. The 575 volt drive will operate from 495660 VAC. The 690 volt drive will operate on 472-759 VAC . Full rated motor voltage and torque can be delivered down to 10% under nominal AC line voltage. During an AC line drop-out, the VLT 5000 continues until the intermediate circuit voltage drops below the minimum stop level, which is typically 15% below the VLT 5000 Series lowest rated supply voltage. Short Circuit The VLT 5000 Series is protected against short circuits by means of current measurement in each of the three motor phases. A short circuit between two output phases will safely shut down the inverter when the short circuit current exceeds the permitted value. Ground Fault The VLT 5000 Series provides complete protection from potentially damaging ground fault conditions: On the supply side On the motor side In the control leads

VLT 5000 Series has Built-in Protection to Maximize System Reliability Against:
System overloads Motor failures Heat Voltage disturbances Power surges Loss of phase Phase-to-phase and phase-to-ground short circuit Ground fault Switching on input/output Electrical disturbances

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Features Built-in Protection

Minimal Harmonic Distortion
The DC link inductor reduces the harmonic distortion currents that an adjustable frequency drive injects back into the AC line. A properly sized inductor, such as that in a VLT 5000 Series, can reduce line harmonic currents to 40% or less of the fundamental current. This eliminates the need and cost of additional AC line reactors and their resultant line voltage reduction.

Exclusive Soft Turn On IGBT Technology

With the patented Danfoss soft turn on, the IGBT transistors produce one of the lowest dV/dt in the industry. Motor cable lengths up to 1,000 feet standard Motor output reactors provided as standard on all drives 125 HP and larger Unlimited switching on the output

VVC

PLUS

Output Switching Pattern

Unique digital VVCPLUS voltage vector control provides: Nearly perfect output sine wave Fully rated motor voltage at rated frequency High efficiency for both drive and motor Full motor performance without derating

Thermal Protection for the Drive and Motor

The ETR (Electronic Thermal Relay) is an open loop method built into the VLT 5000 Series software to guard against motor overheating requiring no additional sensors or wiring. This function is UL recognized (Class 20) as an effective guard against motor thermal overload. The VLT 5000 Series has drive thermal protection and also accepts thermistor signal input from the motor to create closed loop thermal protection for the entire system.

Output Protection
VLT 5000 Series drives incorporate both DC-link filters and motor output protection as standard design features. This provides short circuit protection and allows unlimited switching on the output without damage to the drive, eliminating the need for additional output reactors or switch interlocks. The DC-link filter improves overall efficiency by increasing the power factor and lowering the ripple current in the bus voltage for an almost threefold increase in capacitor and drive life. As a result, motor operation is smooth and quiet and longer motor life can be expected.

VLT 5000

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Features Enclosure Protection

Enclosure Finishes

NEW!
350 to 550 HP 380-500 VAC

NEW!
40 to 350 HP 525-690 VAC

The new high power VLT 5000 Series drives are available in Chassis, NEMA 1 and NEMA 12 enclosures.

VLT 5000 Series Enclosures

The VLT 5000 Series is available with Chassis (IP 20), NEMA 1 or NEMA 12 enclosures. Chassis Enclosures Our Chassis enclosures allow easy mounting in panels, quick access to terminals and greater heat tolerance. NEMA 1 Enclosures All NEMA 1 drives are designed for minimal width, allowing drives to fit into crowded equipment rooms. Multiple drives can be mounted with no side clearance. Conduit entry is provided on the bottom of all drives. NEMA 12 Enclosures VLT 5000 Series units provide one of the most compact and cost effective NEMA 12 solutions on the market. Now the increased environmental protection offered by a NEMA 12 enclosure can fit both the equipment room and the budget. High power VLT Series units (125 HP) provide an optimum, dedicated NEMA 12 (IP 54) enclosure the smallest package on the market.

Enclosure VLT 5000 Style Model Chassis (IP00) 5032-5052 5122-5552 5042-5352 Protected Chassis (IP20) 5001-5027 5001-5102 5001-5032 NEMA 1 (IP21) 5001-5027 5032-5102 5001-5552 5001-5032 5042-5352 NEMA 12 (IP54) 5001-5027 5032-5052 5001-5552 5042-5352

VAC Class 230 460 690 230 460 575 230 230 460 575 690 230 230 460 690

Material Steel Steel Steel Aluminum Aluminum Aluminum Aluminum Steel Aluminum Aluminum Aluminum Aluminum Steel Aluminum Aluminum

Vibration and Shock

The VLT 5000 Series is tested to the following standards: IEC 68-2-6; Vibration (sinusoidal) IEC 68-2-34; Random vibration broad-band general requirements IEC 68-2-35; Random vibration broad-band high reproducibility IEC 68-2-36; Random vibration broad-band medium reproducibility VLT 5000 Series drives comply with requirements that correspond to conditions when the unit is mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

Conformal Coating
Some applications require the drive to be operated in environments with airborne contaminants, such as wastewater treatment plants and paper pulp plants where corrosive gasses are present. These corrosive gases attack components in the drive; in particular, printed circuit assemblies and their components. High humidity and high ambient temperatures exacerbate the situation. Conformal coating is used to mitigate these corrosive effects. Danfoss has chosen a protective polyurethane coating that has good resistance to chemicals and fungus and meets UL requirements for use in electronic controls. Performance of the coating has been verified by independent laboratory testing of VLT 5000 Series using

Mounting
All VLT 5000 drives provide for a vertical wall-mounting arrangement. Most VLT 5000 Series drives allow for sideby-side mounting with zero side clearances.

Humidity
The VLT 5000 Series has been designed to meet the IEC 68-2-3 standard, EN 50178 pkt. 9.4.2.2/DIN 40040, class E, at 40C. See Specifications section for further information. MOTION CONTROLS

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Features Speed Control

both coated and uncoated printed circuit assemblies in IP 20 and IP 54 versions. Note: VLT 5352-5552; 460 V and VLT 5042-5352; 690 V units supplied with conformal coating standard.

Cooling
Danfoss VLT Series units are all designed for optimum thermal efficiency. On the high power units (>125 HP/460 VAC), the power component cooling air and internal electronics air are isolated, preventing the potential introduction of contaminants.

Speed Control of a Grinding Mill

A chemical processing plant has a unit that grinds solid materials into finer grain sizes. The grinding mill (2) runs at fixed speed. Internal parts of the grinding mill are occasionally damaged when they encounter pieces of hard material such as stones or tramp metal. The tank (1) often becomes overfilled, causing the grinding mill motor to overload and trip. Frequent starting and stopping causes high maintenance costs of the mill and drive train. When the silo (3) becomes too full, material drops onto the conveyor (5) and spills over onto the floor due to excessive pressure at the silo discharge.

Solution The grinding mill (2) runs at variable speed and is controlled by a VLT Adjustable Frequency Drive. The max. torque is set to a value that causes the VLT to go into current limit when the grinding mill is blocked. A stall monitor automatically cuts off the line contactor if the grinding mill slows down to an adjustable preset low speed limit and the grinding mill can be manually cleared. If the grinding mill is partially blocked or overloaded by too much material in the tank (1), the VLT can remain in current limit and the grinding mill will continue to run at reduced speed. If the flow of material into the tank is temporarily stopped, the grinding mill can usually clear itself. The speed of the grinding mill is dependent upon the level in the silo (3). The level controller (4) sends a signal to the VLT to regulate the level by controlling the speed of the grinding mill motor. The setpoint of the level controller keeps the level in the silo constant, therefore the pressure at the silo discharge is kept constant, thus controlling the amount of material discharged onto the conveyor.

VLT 5000

Advantages
4

The adjustable current limit and the built-in trip function prevent mechanical overload. A starting torque up to 160% of nominal motor torque enables restart of the grinding mill. The electronic reversing feature incorporated in the VLT helps to eliminate blocking and jamming. Less material spills over the conveyor onto the floor. Greater control reduces maintenance costs and downtime. The unit can be rapidly reset for different types of materials. The slip compensation feature in the VLT gives near constant speed that varies less than 1% with changing load.

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Features Inputs and Outputs

Shown below is how a VLT 5000 Series typically interfaces with other components in a system. The terminal numbers and functions are identical on all VLT 5000 Series drives. The analog, digital and relay terminals are all programmable. The functions shown here are typical, but show only a small portion of the total capability. Optional relay output cards provide up to four additional relay outputs.

Control Card Benefits

The standard I/O supplied on the VLT 5000 drive is equal to or greater than that supplied by most competitor drives featuring extended I/O options.

Standard I/O Includes:

8 digital inputs 2 pulse/encoder inputs 3 analog inputs 2 digital/pulse and analog outputs 2 relay outputs

91 (L1) 3-Phase Power Input 92 (L2) 93 (L3) 99 (PE) External DC Bus Connection 88 (-) 89 (+) External 24 V DC Supply +10 V DC 0 - 10 V DC Ref. Input* 0 - 10 V DC Ref. Input* 35 (-) 36 (+) 50 (+10 V OUT) 53 (A IN) 54 (A IN) 55 (COM A IN) 0/4 - 20 mA Ref. Input* 60 (A IN) 12 (+24 V OUT) 13 (+24 V OUT) Reset* Preset Speed Run/Stop* Reverse* 16 (D IN) 17 (D IN) 18 (D IN) 19 (D IN) 20 (COM D IN) Q Stop Jog Setup Select* Setup Select* 27 (D IN) 29 (D IN) 32 (D IN) 33 (D IN)

(R+) 82 (R-) 81 (U) 96 (V) 97 (W) 98

Brake Resistor

Motor (PE) 95

(AUX RELAY) 01 (AUX RELAY) 02 (AUX RELAY) 03 (RELAY) 04 (RELAY) 05 (COM A OUT) 39 (A OUT) 42 Output Speed Indication* 0/4 - 20 mA (A OUT) 45 (P RS-485) 68 (N RS-485) 69 (COM RS-485) 61 + RS-485 Output Current Indication* 0/4 - 20 mA Run Indication* 50 VAC, 1 A Max Fault Indication* 240 VAC, 2 A Max

These terminals can be programmed for other functions

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Features Inputs and Outputs

Isolation
All analog and digital inputs and outputs and the RS485 serial communication port are galvanically isolated. Because these points do not share a common, the drive will not induce ground loop problems. In the VLT 5000 Series, all control terminals as well as terminals 1-5 (AUX relays) are supplied by or connected to circuits that comply with PELV (high impedance) requirements in relation to the AC line potential.

Analog Inputs
Two analog inputs for voltage signals and one input for current signals are provided for reference and feedback signals. A thermistor can also be connected to either voltage input. The two analog voltage inputs can be scaled in the range of 0-10 VDC; the current input in the range of 0-20 mA.

Digital Inputs
The VLT 5000 System offers eight fully programmable digital inputs for over thirty functions.

Pulse/Encoder Inputs
Two inputs are available for pulse scaling or for feedback from up to two encoders. VLT 5000 D

Relay Outputs
Relay outputs may be selected to indicate thirty different functions such as ready, run, trip, current above a customer preset value, current above current limit, frequency within customer preset limits, frequency above a customer preset value, electronic motor overtemperature protection warning, or that remote operation mode has been selected.

Digital/Pulse and Analog Outputs

The two digital/pulse and analog outputs can be programmed for digital, pulse scaling or analog functions. When used as a digital output, the VLT 5000 presents status with a 0 or 24 VDC signal. Pulse scaling is also available for following power, torque, frequency or current. The drive supports two types of analog signals: 020 mA and 4-20 mA. The terminals can also be configured for voltage output (0-10 V) with the addition of a pulldown resistor.

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