VLT® Textile
Contents
1. VLT AutomationDrive comes in a basic version FC301 and an advanced version FC 302 with additional functionalities A choice of different heat exchange concepts and enclosures accommodates any require ments whether the drive is mounted in a cabinet or in the open exposed to the envi ronment VLT 2800 Series An extremely compact series of multi purpose drives designed for side by side mounting and developed specifically for low power applica tions VLT Micro Drive A cost effective very compact drive with basic functionality and excellent performance Made for easy commissioning and operation Although a basic drive it is made to the same high quality standards of other VLT drives and with high emphasis on user friendliness For mounting on any motor or near the motor No additional installation box due to integrated T distributor and loop through cage clamp terminals Integrated Profibus or DeviceNet fieldbus interface Built in optional service switch Optional electromechanical brake control 0 25 3 7 kW 200 240 V 0 37 800 kW 380 500 V 37 1 2 MW 525 690 V Bookstyle IP 20 IP 21 NEMA 1 IP 4X top and IP 55 NEMA 12 Compact drive IP 55 and IP 66 NEMA 4 Built in PID controller DC coils and RFI filter Integrated Smart Logic Controller USB and RS485 as standard Integrated optional communication options Profibus DP V1 DeviceNet CanOpen and more Integrated optional ad2. VLT Textile Reliable drives solutions for textile applications THE REAL DRIVE Service you can rely on 24 7 around the world Extended and customised service solutions available With the DrivePro service programme production uptime can be optimised and costs reduced A customised service programme is self financing Proven reliability in the textile business Danfoss Drives is a proven preferred supplier within textile industries Unsurpassed reliability characterizes both our drives and the global sales and service organisation Danfoss Drives leaves customers confident that production downtime will not be due to the VLT drives Dedicated organisation A dedicated staff is ready to support customers within the textile industry anywhere in the world Local sales and service companies in more than 100 countries provide backup all over the world Meets tough conditions in textile Danfoss offer solutions tailored to the specific needs of the textile industry combining all the necessary compo nents in integrated package solution Heat exchange concepts to meet tough environments Excellent run through and controlled ramp down functions Dedicated textile functionality wobble winder Basic and advanced motion control functionality Outstanding EMC performance Application knowledge With extensive knowledge of your business we offer process expertise in all stages of application develop
3. direct field mount e Center winder option e Scalable master slave operation e Standard function for surface winding e Multi motor operation e Coating of PCBs 3C2 as standard 3C3 optionally VLT AutomationDrive e Built in DC harmonic filter Prevents aggressive substances from entering the drives Long lifetime in harsh environments Energy savings Improves operational reliability Reduces unscheduled stops Reduced harmonics Less need for AC choke Space saved Saves cabinet space Saves cabinet space Precise tension optimal product quality Cost effective speed dependencies No external control functionality is required for basic winding functions Cost savings Long lifetime in harsh environments Complies with harmonic standards No external AC choke needed Less wiring and less cabinet space Stenter features e Motion Control Option e Tension control e Multi motor operation e Coating of PCBs 3C2 as standard 3C3 optionally VLT AutomationDrive e 50 C ambient temperature Benefits Precise synchronization of motors Maintains precise tension for optimal product quality Cost savings Improved immunity to aggressive ambience Improves operational reliability Reduces unscheduled stops 13 Product overview VLT AutomationDrive An extremely flexible and cost effective drive suitable for all industry applications from simple speed control to dynamic servo applica tions
4. dissipated heat to surroundings A smart dedicated back channel cooling duct kit allows IP 00 chassis style drive enclosures to be mounted in Rittal cabinets so cool air removes 85 of excess heat without contact to the electronics Process optimising Spun yarn and fabric Standard built in features and dedicated textile futures make VLT solutions the optimum choice for operating yarn and fabric applica tions Challenging environments e Can operate in temperatures up to 50 C Intelligent heat management Reduction of switching frequency to lower internal losses Alarm Controlled shut down e Alternative heat exchange con cepts to meet various requirements e Availability of IP 55 66 to prevent entry of dust particles e Coating of printed circuit boards to prevent corrosion due to humidity and presence of lint Speed profiles e Smart Logic Control SLC basic PLC function as standard for basic motion control tasks e g for ringspinner profile e Motion Control Options for extended functionality Switching frequency adjusts to temperature Switching frequency Output current Temperature A VLT drive will overcome short periods of over temperature It will run through it by changing switching frequency and diminishing output current to live through and avoid tripping e Fewer interruptions e Drive protection Energy savings e High efficiency e High energy saving
5. lower peak currents Excellent torque and speed characteristics Maintenance free compared to DC systems 50 C ambient temperature Kinetic back up Common DC link Coating of PCBs 3C2 as standard 3C3 optionally VLT AutomationDrive Built in DC filter Draw texturiser features Stable operation Cost savings Prevent over temp alarm and downtime Run through capability at brown out Controlled ramp down at power loss Synchronised ramp down at power loss Improved immunity to aggressive ambience Reduced harmonics No need for external AC choke Space savings Benefits Minimum air over electronics Coating of PCBs 3C2 as standard 3C3 optionally VLT AutomationDrive Side by side mounting 50 Cambient temperature Wobble function as standard Synchronised start and stop Common DC link Cone cheese winder features Long service life Extends lifetime of drive Saves cabinet space Improves operational reliability Reduces unscheduled stops Optimal yarn pattern Cost savings improved flexibility Improved yarn quality and less yarn breakage Synchronised ramp down at power loss External power back up source possible Benefits Side by side mounting Wobble function as standard 8 preset references A single drive can power multiple motors Soft ramp up ramp down Multi language key pad Built in user manual Wobble functions for winders Integrated wobble functiona
6. products Local backup globally VLT motor controllers are operating in applications all over the world and Danfoss Drives experts located in more than 100 countries are ready to support our customers with applica tion advice and service wherever they may be Danfoss Drives experts don t stop until the customer s drive challenges are solved PESSA SU RYKSAG 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 Produced by KKM AO 2007 08
7. No extra cabinet space required for retrofit Realization of speed vs time profile External controller and its wiring omissible Saves space and external wiring Less wiring and less cabinet space Card features Innovative cold plate design Closed loop speed control e Motion control option Common DC link e Built in DC harmonic filter Small foot print Side by side mounting e Easy pluggable firm grip connectors Circular knitting features Benefits Drive is isolated from the environment Reduced heat load in the cabinet Drive fan can be turned off Optimal product quality Synchronized operation of motors Load sharing energy savings No need for an external AC chokes and saves space cost of AC choke wiring space Saves cabinet space Easy wiring Reduces maintenance cost Benefits Cold plate Minimum air over electronics e Basic drive with excellent performance FC51 In built basic PLC Smart Logic Controller e Soft ramp up ramp down High resistance to mechanical vibrations Drive is isolated from the environment Long service intervals Cost savings System PLC can be omitted Prevents yarn breaks less stress on mechanical components Long life less downtime Process optimising Man made fibre Up time is doubly important in the textile industry Unplanned stops mean lost produc tion time and leads often to broken yarns variations in product quality and expensive time us
8. T AutomationDrive is built on a modular platform allowing for highly customised drives mass produced tested and delivered from the factory Upgrades and further options dedicated for specific industries are a matter of plug and play Fieldbus options Options for serial bus communica tion Profibus Ethernet Devicenet CanOpen etc are delivered ready to plug and play Display options Danfoss Drives renowned removable Local Control Panel has an improved user interface Choose between 27 built in languages including Chinese or have it customised with your own Two of the languages can be changed by the user On board manual is also available from the display Hot plugable LCP The local control panel LCP can be plugged in or out during operation Settings are easily transferred via the control panel from one drive to another or from a PC with MCT 10 set up software FUE Phe I O options General purpose I O relay and ther mistor expand the flexibility of the drives Control terminals Specially developed removable spring loaded cage clamps add to 24V supply Harmonic suppression reliability and facilitate easy commis 24 V supply keeps the VLT drives The renowned DC coil ensures sioning and service logically alive in situations when the very low harmonic disturbance AC power supply is removed of the power supply according to Safety IEC 1000 3 2 Compact design The new VLT series can be ordered EMC per
9. adds function ality and flexibility to the drive and allows you to integrate sophisti cated control in the drive simpli fying your installation or saving a PLC in a machine Challenging environments Can operate in temperatures up to 50 C Intelligent heat management Reduction of switching frequency to lower internal losses Alarm Controlled shut down Alternative heat exchange con cepts to meet various requirements Availability of IP 55 66 to prevent entry of dust particles Optional coating of printed circuit boards to prevent corrosion due to humidity and aggressive substances Precise control of motor speed and torque VVC Plus and FLUX Vector Algorithms for asynchronous motors and permanent magnet motors Winder Systems Danfoss offers solutions for center winders and surface winders A broad range of frequency convert ers ensures a drive for every require ment be it simple or high dynamic e Low torque ripple ensures smooth winding e Feedback to PID controller from a dancer roller maintains web tension e Web protection due to built in torque controller Benefits Piece dyeing features e High protection class e Coating of PCBs 3C2 as standard 3C3 optional VLT AutomationDrive e High efficiency e 50 C ambient temperature e Built in DC harmonic filter Continuous dyeing features e Small footprint e Side by side mounting e IP 21 IP 55 design for
10. ditional I O digital I O s encoders incremental absolute sin cos resolver Integrated Motion Control Option 0 37 2 2 kW 200 240 V and 0 55 18 5 kW 380 480 V Bookstyle IP 20 Side by side mounting in any direction Built in PID controller RFl filter and DC coils Integrated RS 485 interface as standard Integrated Profibus optional Wobble function as standard 0 18 3 7 kW 200 240 V 0 37 7 5 kW 400 V 50 C ambient temperature Bookstyle IP 20 Side by side mounting No forced air flow over the electronics Integrated Smart Logic Controller SLC as standard VLT Decentral Frequency Converter 0 37 3 3 kW FCD 0 37 7 5 kW FCM IP 66 a corrosion resistant coating May be mounted on the wall close to the motor or directly onto the motor e Twin part design makes commissioning and service easy VLT AutomationDrive IP 20 enclosures optimized for panel installation The installation volume and or the foot print are reduced by up to 60 compared with previous series The service sections nevertheless fulfil the highest requirements even for applications with high overload long motor cables and ambient tempera tures up to 50 C Optimised design Optimised efficiency and intelligent cooling technology make the com pact and service friendly design pos sible Even equipment such as EMC filters harmonics suppression and brake modules are integrated in the enclosure For managi
11. ed for re establishing the production VLT drives are built to prevent unforeseen stops They handle temporary overheating varying power quality and even stop in optimal ways Operational reliability e Kinetic backup for controlled ramp down in case of power loss e Common DC connectors for connection to back up power source for synchronised ramp down Intelligent heat management e High tolerance to low quality power supply Dedicated functions e Wobble function as standard Tolerates low quality power supply Drives from Danfoss incorporate a number of features to improve tolerance towards low quality power supply and ensure continued opera tion and or controlled termination of operation e Large tolerance for nominal voltage e g 380 480 V e Kinetic or battery back up via common DC bus e Self protection for power failure by utilising kinetic backup feature Stretching systems High stretching accuracy Optimised load sharing with common DC bus Flexible production For asynchronous or synchronous motors Danfoss offers built in controller for asynchronous or synchronous motors m DC voltage m Drive frequency Motor frequency Generated Power drop power Power supply resumed Motor runs in generatoric mode e Controlled synchronised ramp down to stop when necessary e Extended tolerance to voltage sags to prevent tripping e Built in DC chokes ensures a power factor near unity and
12. formance No need for external modules with safe stop functionality suitable Built in RFI filter available in versions for category 3 installations according covering emission categories C1 C2 PELV to EN 954 1 This feature prevents the and C3 according to the EMC prod All VLT drives comply to the PELV drive from starting unintentionally uct standard EN61800 3 previously Protective Extra Low Voltage require The functionality is standard in the classes B A1 and A2 ments and are surge proof in accord FC302 version ance with VDE 0160 Inputs and outputs are electrically isolated EROST amp SULLIVAN Danfoss Drives received the Frost amp iF The local control panel LCP was given Sullivan Award for Product Innovation the international iF design award 2004 2006 for the unique VLT Automation design awara N the category interface in communi Drive series wer cation 2004 Product Innovation Award oe No forced airflow over electronics Complete separation between the heatsink area and the electronics prevents contamination of the elec tronics Programmable options Freely programmable option MCO 305 for user specific control algo rithms and programs allows integra tion of PLC programs Conformal coating The electronic components fulfil IEC 60721 3 3 class 3C2 as standard For harsh and aggressive environments coating class 3C3 is an option Enclosure The drive meets relevant require ments for al
13. ies ready to respond whenever and wherever you need around the clock 7 days a week Find your local expert team on www danfoss com drives 3 VLT solutions optimise processes anywhere in a textile plant Ring spinning ry ry T A a FA Ke u I Si i Circular knitting Reliable and flexible VLT drives are available for any application within the textile industry The VLT family ranges from 0 18 kW to 1 2 MW and from basic motor control to servo performance The VLT family is designed to be extremely reliable and easy to connect operate and service ensuring maximum up time and lowest lifetime cost Full power range Danfoss expands the VLT power range up to 1 2 MW All performance levels have the same intuitive operating concept e Components in for example a 750 kW drive can be commissioned as easily as in a 0 75 kW drive Compact dimensions e The smallest frequency convert ers of their class they require less control cabinet space No side clearance required between individual units allowing more drives in a cabinet Optional extras can be integrated at the factory or retrofitted at a later date Carding Extruding Optimum customisation e P 00 IP 20 IP 21 NEMA Type 1 and IP 55 NEMA Type 12 and IP 66 enclosures are available Optional modules enable individual configuration of the drive e Options capable of integration include mains disconnec
14. l possible installation conditions Enclosure class IP 00 Chassis IP 20 Chassis IP 21 NEMA 1 IP 54 55 NEMA 12 or IP 66 NEMA 4x Drives can be mounted side by side no spacing is required Advanced operation control Center Winder with closed loop tension control Follows line speed Diameter calculator adjusts winder reference Tension PID adjusts reference Wobble function For winding applications ensures optimal yarn pattern Smart Logic Control The new VLT drives have Smart Logic Control built in Basic logic functions can be performed by the drive itself hence the Smart Logic Control can often replace a PLC in the system Intelligent heat management The VLT family of drives offers various heat exchange concepts to accommodate different demands on location space requirements contamination considerations etc Convection cooling The traditional way of cooling by means of air circulated around the drive Panel Through Mount With the drive safely enclosed in a tight cabinet its cooling fins are out in cold air The main fan can be removed if an external air flow is available Cold plate The heat is transported out of the cabinet to a cold surface leaving only a fraction of the heat where the drive is located Duct cooling Danfoss has introduced a princi ple that allows simple and easy installation of high power drives in cabinets or control rooms removing the major part of
15. lity ensures optimal yarn packaging and provides more flexibility compared to a fixed or mechanical traverse function The wobble function is standard in the VLT 2800 series Multiple motor operation possible for bobbin drive system Higher winding speed and better bobbin filling due to built in wobble function for traverse system No mirror effect on yarn package Programming in relative and absolute parameters Saves cabinet space Optimal yarn pattern Cost savings improved flexibility Easy change over between yarn types Cost savings Prevents yarn breaks less stress on mechanical components Easy programming Saves time Frequency Time 11 Process optimising Printing dyeing and finishing Precision combined with flexibility and robust reliability makes VLT drives the optimal choice for treatment of yarn and fabric Built in intelligence freely pro grammable options leads to precise control and optimised process time Dedicated functions for winding and re winding e Smart Logic Control SLC PLC function as standard for basic motion control tasks Embedded surface winding func tionality Solutions for positioning and synchronising VLT Motion Control MCO 305 Dedicated function for surface and center winding VLT Motion Control MCO 352 VLT Motion Control Option VLT Motion Control Option MCO 305 is an integrated freely pro grammable controller for VLT AutomationDrive It
16. ment and implementation VLT experts will work with you to design and select optimal solutions Comprehensive product range With our modular product range we are able to combine relatively few components into a multitude of varia tions and solutions while passing the benefits to you Stable operation High quality VLT frequency convert ers and softstarters designed for virtually every purpose in the textile industry put an end to costly down time The VLT brand is widely known and respected within the textile industry 9 out of 10 enterprises globally knows Danfoss as a competent and reliable partner and drives provider Customer driven innovation Customer requirements for an intui tive user interface have been adopted and made the VLT user interface the most user friendly interface on the market winner of the iF design award The VLT drives also received the Frost amp Sullivans innovation award 2006 Innovative supply chain The modular technology concept allows for mass production of highly customised drives The production setup is able to assemble and test a customised drive one out of thou sands of hardware configurations in 24 hours Sales and Service Contacts worldwide Helping to optimise your pro ductivity improve your mainte nance e 24 7 availability e Local hotlines local language and local stock The Danfoss service organisation is present in more than 100 coun tr
17. ng Drive ParameterS in systems the new Motion Control Tool MCT10 is the perfect tool for handling all drive related data The MCT10 offers you e Project orientation one file that contains all parameters settings plus user defined documents e Explorer like view gives the user a fast learning curve e VLT Motion Control Tool offers pro gramming of synchronisation and positioning in same environment one PC tool for all tasks e On line and off line commissioning e Support of different interfaces RS485 RS232 USB and Profibus plus more to come e Importation of drive settings from Windows and DOS version of Dialog VLT Motion Control Tool MCT 10 Save installation time The IP 20 series is designed for easy accessibility and time saving installa tion Mechanical fastening points are easy to access from the front even with automatic tools All terminals are sufficiently dimensioned and clearly marked One need only loosen a few screws to get to the terminals Acces sories for bonding of screened cables are included The compact enclosures are easier to install This is important especially within existing installations with poor accessibility Modular and fully compatible The IP 20 enclosed series completes the enclosure program of the modu lar VLT AutomationDrive series with IP 21 IP 55 and IP 66 enclosures They all support completely the modular platform of the VLT AutomationDrive series An exte
18. nsive range of options and accessories is available optimising the drive for the respective applica tion Running in applications are faster due to the graphical overview of dynamics Data are logged and will be available as performance documentation Pag thee She ed Sem ey ES O Protects environment VLT products are manufactured with respect for environment safety and wellbeing All activities are planned and per formed taking into account the individ ual employee the work environment and the external environment Produc tion takes place with a minimum of noise smoke or other pollution and environmentally safe disposal of the products is assured UN Global Compact Danfoss has signed the UN Global Compact on social and environmental responsibility and our companies act responsibly towards local societies EU Directives All factories are certified according to ISO 14001 standard All products fulfil the EU Directives for General Product Safety and the Machinery directive Danfoss Drives is in all product series implementing the EU Directive con cerning Hazardous Substances in Elec trical and Electrical Equipment RoHS and is designing all new product series according to the EU Directive on Waste Electrical and Electronic Equipment WEEE Products impact One year s production of VLT drives will save energy equivalent to the energy production of a power plant Better process cont
19. rol at the same time improves product quality and reduces waste and wear on equipment What VLT is all about Danfoss Drives is the world leader among dedicated drives providers and still gaining market share Dedicated to drives Dedication has been a key word since 1968 when Danfoss introduced the world s first mass produced variable speed drive for AC motors and named it VLT Two thousand employees develop manufacture sell and service drives and softstarters in more than one hundred countries focused only on drives and softstarters Intelligent and innovative Developers at Danfoss Drives have fully adopted modular principles in development as well as design production and configuration Tomorrow s features are developed in parallel using dedicated technology platforms This allows the develop ment of all elements to take place in parallel at the same time reducing time to market and ensuring that customers always enjoy the benefits of the latest features Danfoss Drives Ulsnaes 1 DK 6300 Graasten Denmark Tel 45 74 88 22 22 Fax 45 74 65 25 80 www danfoss com drives E mail textile danfoss com DKDD PB 26 A1 02 VLT is a trademark of Danfoss A S Rely on the experts We take responsibility for every element in our products The fact that we develop and produce our own features hardware software power modules printed circuit boards and accessories is your guarantee for reliable
20. s possibility compared to machines without drives Humidification The use of variable speed drives saves substantial amounts of energy typically 20 or more and improves reaction to changes in humidity and temperature ae La career ier rd cd E aaa E r ris r F i f i1 n p _ di ii Coated PCB VLT drives are all available with coated circuit boards for maximum reliability in humid aggressive and dusty environments Coating to withstand 3C2 moderate environments according to IEC721 3 3 as well as 3C3 harsh environments are available Conformal coating is available to the entire range of VLT AutomationDrive VLT 2800 and VLT Micro Drive Benefits Ringspinner features e Panel through mount 50 C ambient temperature e 3C2 coating as standard 3C3 as option Graphical display and motion control option e In built basic PLC Smart Logic Controller Disconnect switch High efficiency Automatic Energy Optimizer function IP 55 design for direct field mount e Integrated Motion Control Option Built in RFI filter e Built in DC harmonic filter No air over electronics Only minor heat generation in the cabinet No over temperature trip less down time Improved immunity to humid and aggressive ambience Direct programming of RS speed profile PLC can be omitted No switch required on the cabinet Less heat loss on drive Less thermal load on humidification plant
21. t fuses and EMC filters in any combination To customise your drive optional extras can be mounted at the fac tory and or retrofitted as and when required Motion Control Options thermistor fieldbus additional I O etc Cone winding Maximum availability and reliability All drives are tested under full load before delivery e Factory tested and certified options increase the reliability of the drive e High ambient temperatures permitted Up to 50 C e Fewer sub assemblies reduce the number of spare parts needed Energy conservation The high degree of efficiency typi cally over 98 reduces power loss power consumption and waste heat Less cooling investment and less operational cost on cooling leads to cost Savings Piece dyeing Time saving installation and commissioning Standard operation software and options for the entire VLT AutomationDrive series Operation in national language Front access for all installation and servicing work Backwards compatible Finishing Fabric dyeing Handles tough environment e Choice of heat exchange concepts cold plate fan cooled panel through mount with removable fan for cooling by external air source e Coated PCBs Intelligent heat management system e Various degree of enclosures up to IP 66 See graphics below IP A NEMA 54 55 21 00 20 Chassis 0 10 100 1000 kW The modular VLT technology platform VL
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