VACON® 3000 Drive Kit
Transform your toughest applications with a unique modular approach
Medium-voltage definite-purpose drives
Visit: danfossdrives.com
When a standard cabinet drive is just not enough
Heavy-duty industries face complex and competitive engineering environments. The VACON® 3000 Drive Kit offers a strategic combination of unique modular medium-voltage (MV) drive technology, supported by the application knowledge of Danfoss Medium Voltage Partners.
You are a serious player in your industry
As an expert in demanding applications, you understand the critical role of AC drives, where reliability, robustness, space, and weight are crucial, and downtime is a disaster.
Danfoss Medium Voltage Partners complete the team
Danfoss Drives collaborates with selected, qualified partners to advance the medium-voltage drives market. Together, they deliver a unique modular approach, providing flexible and comprehensive solutions for your projects.
Danfoss Drives is the drives expert
Danfoss Drives is committed to innovation and high durability, delivering the best drives in the world. The VACON® 3000 leverages Danfoss' engineering expertise to provide tomorrow's technology today.
Integrate high-performance MV drives to suit your application needs
The VACON® 3000 Drive Kit enables flexible arrangements, straightforward system integration, and easy maintenance, adapting to your industry's demands for adaptability in MV drives. Utilize the flexibility of these modules to optimize the drive for your specific requirements.
Owner or operator?
Discuss your needs with Danfoss Medium Voltage Partners to define a design encompassing the exact characteristics you expect from an MV drive.
Operating benefits:
- Fit-for-purpose MV products in functionality and physical dimensions.
- Low total cost of ownership (TCO) due to reliable and robust operation.
- Reduced downtime through fast and easy serviceability, robust design, uncompromising quality, and premium operating performance.
[Diagram: Illustration showing modular drive components being assembled into a larger system.]
A myriad of ways to maximize ROI
Save energy, reduce wear, save lifetime cost
Utilize medium-voltage (MV) drives in applications where previously not possible. Achieve significant savings by variably adjusting motor voltage and frequency compared to constant speeds. Slash maintenance costs by preventing peaks and extreme loads during motor start-up, which are primary causes of wear.
Versatile design for optimal use of space
The modules allow for structures tailored to individual applications. Beyond conventional solutions, unique space-saving configurations can be developed to meet special requirements in construction shapes, ingress protection classes (e.g., for marine and mining), and facilitate easy IP54 cabinet design with liquid-cooling.
Win flexibility through modularity
The VACON® 3000 features a simple, elegant concept using a few basic modules across the entire power range. Modules combine like building blocks for a complete offering, supporting wide application coverage including low harmonics, regenerative, and braking applications. This modularity saves costs on service and redundancy, with common spares, and a modular, low inventory approach where the same phase module is used across inverter, AFE, and brake chopper units.
Easy to build
Easy to handle
- Compact component size with high power density.
- Manageable component weight.
- All components allow cabinet integration with front access only.
- Easy to handle, lift, move, and repair.
Easy to integrate
- Full harmonization, supporting open solutions.
- Customer-specific interface configuration of cabinets.
- Customer-specific enclosure class.
Easy to operate
- Easy to connect, program, and monitor.
- Features the same user interface and fieldbus option cards as VACON® 100 low-voltage drives.
High performance
- High power density provides maximum power for minimal volume.
- Efficient heat management using liquid-cooled power modules and hybrid-cooled chokes.
- Very good speed and torque control, including sensorless vector control.
- AFE configurations connect to the grid without inrush current.
Robust and reliable in harsh conditions
- Designed for stability: Long lifetime design of power modules with no cooling fans; rugged module enclosure for good protection; reliable insulation; and hybrid cooling of chokes.
Exceptional MV performance in demanding applications
Individually tailored to meet the toughest requirements.
Heavy industry requires high performance from drives sized for the high megawatt power range. Industries such as oil and gas, chemical, petrochemical, mining, ship building, and cement have diverse demands based on local regulations. The VACON® 3000 Drive Kit's flexibility helps meet these industry requirements across a wide range of applications, including:
- Pumps
- Fans
- Compressors
- Mixers
- Mills
- Conveyor systems
- Extruders
- Steel mills
- Test benches
- Marine propulsion
- Marine pumps
- Dredger cutters
These applications push AC drives to their limits, often in adverse environmental conditions like dust, humidity, and aggressive gases. Rugged, water-cooled modules with no internal fans provide high protection and ensure reliable operation. Danfoss and its partners' expertise guarantees safe long-term operations.
When 'standard' is not good enough – go for definite-purpose!
Highly compact solutions for special installation requirements
While standard enclosed MV drives are sufficient for clean electrical rooms, specialized solutions are often needed for installations in confined spaces, such as on ships or in mining operations. The compact, high-performance VACON® 3000 modules are ideal for these scenarios. The active front-end (AFE) and inverter units, based on water-cooled power modules, can be arranged flexibly to optimize cabinet height, width, depth, and shape, allowing for the most compact configuration possible.
Single port of call
Find the optimum AC drive for any low- or medium-voltage application on board a ship at Danfoss Drives.
Main propulsion
Electric propulsion offers design freedom, allowing for more efficient ship designs without traditional equipment layout limits. Unlike fixed power transmission, drive control provides power to the propeller with lighter, less robust mechanical constructions, reducing vessel construction costs and weight. Electric propulsion enables high redundancy through multiple generators and consumes energy only when needed. It also benefits the environment through lower fuel consumption and exhaust emissions.
Refrigeration compressors
Drive-controlled screw compressors typically use 15% less energy than traditional ones. Optimized start/stop cycles reduce wear, and drive-controlled reciprocating and scroll compressors offer higher COP at part loads.
Pumps
AC drives match pump operation to actual process needs, reducing energy consumption. A 20% speed reduction can decrease power consumption by 50%. These drives also protect pumps in various marine applications. With increasingly stringent exhaust emission limits, scrubbers are common. Drive optimization for water pumps used in scrubbers is an ideal application for VLT® and VACON® drives. Other applications include ballast water, bilge water, circulation, cargo, firefighting, feeding, lubrication, and sea water pumps.
Thrusters
VLT® and VACON® drives provide high torque capabilities and precise maneuverability. AC drive-controlled variable speed propellers are 20-30% more energy efficient than fixed-speed ones. Frequency-controlled propellers use 50% less energy than hydraulic ones. Electrically-steered thrusters offer more accurate control and quicker response, with systems designed for redundancy.
Cutter suction dredgers
These dredgers, comprising a cutter head and dredge pump, require high power for cutting and pumping. Electric motors controlled by drives ensure high efficiency and minimal downtime for these operations.
Why choose Danfoss drives for mine and mineral processing environments?
Danfoss AC drives and supporting options are designed to match specific requirements. Compact enclosures, robust design, built-in long motor cable capability, and innovative heat management features help optimize panel, switchboard, and substation design, saving costs and improving competitive position.
Intelligent heat management for significantly lower switchroom costs
As AC drives are increasingly used in mine sites, the heat loads in switchrooms demand larger air-conditioning systems. VACON® liquid-cooled drives significantly reduce heat loads, enabling the use of smaller, lower-cost air-conditioning systems.
Robust mine ventilation
Ensuring reliable mine ventilation is crucial for worker health and safety. AC drives are recognized as the most flexible, energy-efficient, and low-maintenance method for controlling mine ventilation fans, integrating easily into Ventilation on Demand (VOD) systems. VACON® drives offer features for reliable operation even in abnormal conditions.
Long conveyor capability
Smooth control of conveyor acceleration and deceleration reduces mechanical stress, extending the life of drive-train components and conveyor belts. This increases asset availability and lowers maintenance costs. Flexible speed control optimizes the complete system, reduces bottlenecks, and maximizes material flow efficiency.
Maximize belt life
For conveyors with multiple motors, drives ensure load sharing for reliable operation and maximized belt life. Control solutions are selected based on conveyor drive configuration.
Bulk handling
For downhill conveyors requiring regenerative braking, Active Front End (AFE) drives are ideal. VACON® drives are widely used on long conveyors (over 1 km) in applications like run-of-mine (ROM) bin feeder conveyors, stockyards, train loadout conveyors, pipe conveyors, and long overland conveyors.
Applications Overview
[Diagram: An aerial view of a mining operation showing various equipment and processes, with numbered callouts. Page 13 provides a key for these numbers.]
Key Applications:
- Surface Mining & Processing: Long conveyors, stackers, conveyors, dewatering pump skids, ball mills, flotation cells, apron feeders, slurry pumps (transfer, feed, concentrate, tailings), process water pumps, excavators.
- Mine Ventilation: Primary ventilation fans, booster fans.
- Underground Operations: Underground conveyors, crushers, river water pumps, underground mines (ventilation fans, conveyors, pumps, hoists).
Royal IHC Scheldt River dredger
The Scheldt River, a 7,950 m³ dual-fuel (diesel and LNG) dredger built by Royal IHC, features a 'Green Passport' and 'Clean Design' notation, meeting strict international emission requirements. Its main engine is a flex-fuel engine capable of running on natural gas, light fuel oil (LFO), or heavy fuel oil (HFO).
The VACON® 3000 contributes to the dredger's green design in several applications:
- Boosting an 8,000 kW dredge pump, utilizing PTI technology for load sharing with the main engine.
- Controlling a 1,700 kW submersible dredge pump, retrofitted with a sine filter.
- Operating on lower supply frequency and voltage via AFE technology, saving energy by allowing the generator engine to run at optimized speed.
- An MV switchboard with a sine filter manages selection between inboard and submersible dredge pumps.
Relevant product characteristics: The VACON® 3000 met IHC D&A specifications for marine environments, including minimum weight, small footprint, and low volume. Its power module design is well-suited for the task, with measures to prevent dust and pollution contamination during ship construction.
You're covered with DrivePro® Life Cycle service products
Maximize your systems' potential with DrivePro® services for Danfoss VLT® and VACON® drives. These services go beyond basic troubleshooting and maintenance, proactively improving productivity, performance, and uptime.
[Diagram: A circular flow illustrating DrivePro® services including Retrofit, Spare Parts, Exchange, Protection, Start-up, Extended Warranty, Service Contract, and Preventive Maintenance.]
DrivePro® Services encompass pre-sales support, training, leading to higher performance, more uptime, and a healthier budget.
Danfoss Drives' comprehensive portfolio covers the entire life cycle of your drives, delivered by experts customized to your needs. DrivePro® services add value, provide know-how, and keep you at the forefront of innovation.
Learn more at: http://drives.danfoss.us/services/drivepro-programs/#/
DrivePro® app
The DrivePro® app provides fast access to services, enhancing productivity and system uptime. It allows users to find service partners, place requests, register drives, and access product information and manuals.
A winning combination of modular components...
The VACON® 3000 Drive Kit offers a unique modular concept, enabling the creation of purpose-built MV drives. Its adaptable components ensure reliability in harsh conditions and optimal use of space, allowing for designs that better suit application needs.
...and a partner with proven track record
Benefit from market-leading guidance from Danfoss Medium Voltage Partners. These partners integrate drive modules and filter technology into compact, fully assembled units, providing on-site support for installation and start-up. Through the MVP Program®, partners create tailored system and cabinet offerings, providing expert support throughout the system lifecycle and adaptable integration capabilities.
VACON® 3000 Drive Kit units
[Diagram: An image showing the internal components and modular structure of VACON® 3000 Drive Kit units.]
Functional Units:
- 1 Inverter unit (INU): Robust, compact, water-cooled, state-of-the-art technology for latest system design. Easy to handle and maintain.
- 2 Front-end unit: Available in 12-pulse standard rectifier or active front-end (AFE) configurations for regenerative applications.
- 3 Pre-charge unit: Compact design, limits load current, facilitates safe start-up, and provides thermal protection.
- 4 Control unit: Based on the VACON® 100 controller, featuring integrated Ethernet and graphical display for comprehensive control of frequency, speed, and torque (U/f control, Open loop, Closed loop).
- 5 Filters: Key system components including L, C, and common mode filters, optimized for efficiency.
Reference designs for reduced engineering
The VACON® 3000 Drive Kit offers a unique business model with commercial advantages for system integrators, OEMs, and equipment owners. Close collaboration with Danfoss Medium Voltage Partners ensures strong system performance, energy efficiency, and compact, power-dense solutions.
Authorized Medium Voltage Partners have access to reference designs for definite-purpose drives, facilitating the creation of reference or original designs.
[Diagram: A single-line diagram illustrating an AFE configuration of the VACON® 3000 Drive Kit, showing components like Mains contactor, Filters, Control unit, Inverter unit, Pre-charging unit, Motor, and power supplies.]
Partner focus
A partner you can trust
The Danfoss Drives Medium Voltage Partner Program (MVP Program®) connects Danfoss with experienced partner companies that integrate drive modules and filter technology into compact, fully assembled units, providing on-site support. Danfoss provides partners with tools, training, and support to create custom MV drives.
Partner programs for individual solutions
Partners, including OEMs and system integrators, leverage their knowledge of the medium-voltage sector to compile systems tailored to customer requirements using VACON® 3000 modules.
Center of Excellence for Danfoss Drives high-power and medium-voltage drives
Danfoss Centers of Excellence offer engineering solutions and optimized processes, providing access to experienced staff for system development and optimization. These centers feature MV and LV drive specialists and test stations for application testing and simulation.
VACON® 3000 Drive Kit – functional units and kits
The VACON® 3000 Drive Kit includes all main parts for the drive, available in two configurations: regenerative with Active Front-End (AFE) or non-regenerative with Diode Front-End (DFE).
Functional Units: Control unit (CNU), Inverter unit (INU), Active Front End unit (AFE) or Diode Front End unit (DFE), Pre-charge unit (PRC), Brake chopper unit (BCU)*, Filters* (*optional).
Modules: L20 and L30 phase modules (liquid-cooled single-phase power conversion units) and D20 and D30 power modules (liquid-cooled diode front-end power conversion units) are key components, offering robust performance and reliability.
Form factor
The VACON® 3000 Drive Kit allows flexible module arrangement to suit various applications and overcome space restrictions. Examples of assemblies include single-stack, six-pack, and seven-pack configurations.
Technical data
| Parameter | Specification |
|---|---|
| Topology | 3-level neutral point clamped (NPC) with grounded heatsink |
| Inverter capacity | L20-HLx3, L30-HLx3 |
| Input voltage | 3300 V, 3 phases ± 10% or 4160 V, 3 phases ± 10% |
| Input frequency | 50 Hz ± 5% or 60 Hz ± 5% |
| Rectifier | AFE or 12-pulse DFE |
| Input current THD | <5% (AFE), typically <15% (DFE) |
| Power factor | >0.95 |
| Output voltage levels | 3 (5 phase-to-phase) |
| Output frequency | 0-120 Hz |
| Accel./Decel. time | 0.1-3600 s |
| Grounding | Resistance grounded neutral point or high/low resistance grounding system. Consult Danfoss for IT network operation. |
| Switching frequency | AFE: 1050/1260 Hz; INU: 900 Hz synchronous PWM |
| Motor control method | U/f control, Open loop, Indirect closed loop, Closed loop |
| Communication | AI/O, DI/O, fieldbuses (PROFIBUS DPV1, DeviceNet), industrial Ethernet (PROFINET IO, EtherNet/IP™), VACON® PC tool |
| Main protective functions | Torque/power limit, current limit, overcurrent, overvoltage, undervoltage, loss of auxiliary power/communication, ground fault detection |
| Efficiency | >97.5% (AFE), >98.5% (DFE, excluding input transformer) |
| Temperature (Operational) | 0 °C to +45 °C (+30 °F to +113 °F) |
| Temperature (Storage) | -40 °C to +70 °C (-40 °F to +158 °F) |
| Cooling liquid temperature | Min. 2 °C (3.6 °F) above dew point |
| Relative humidity | < 95% RH, non-condensation, non-corrosive |
| Cooling | Liquid cooled or Hybrid cooling |
| Standards | IEC, UL (certification pending) |
Power rating
12-pulse DFE drives
| AC drive type | Continuous rating (variable torque) | Low overload rating 110% (constant torque) | High overload rating 150% (constant torque) | Output frame size | |||
|---|---|---|---|---|---|---|---|
| Current Ith [A] | Power [kVA] | Current IL [A] | Power [kVA] | Current IH [A] | Power [kVA] | ||
| Nominal voltage 3300 V | |||||||
| VACON3000-12-0425-03 | 425 | 2430 | 386 | 2209 | 283 | 1620 | L20-HLx3 (425-03) |
| VACON3000-12-0640-03 | 640 | 3660 | 582 | 3327 | 427 | 2440 | L30-HLx3 (640-03) |
| VACON3000-12-0820-03 | 820 | 4690 | 745 | 4264 | 547 | 3127 | L20-HLx6 (425-03) |
| VACON3000-12-1230-03 | 1230 | 7030 | 1118 | 6391 | 650 | 4680 | L30-HLx6 (640-03) |
| Nominal voltage 4160 V | |||||||
| VACON3000-12-0340-04 | 340 | 2450 | 309 | 2227 | 227 | 1633 | L20-HLx3 (340-04) |
| VACON3000-12-0510-04 | 510 | 3670 | 464 | 3336 | 340 | 2447 | L30-HLx3 (510-04) |
| VACON3000-12-0650-04 | 650 | 4680 | 591 | 4255 | 433 | 3120 | L20-HLx6 (340-04) |
| VACON3000-12-0980-04 | 980 | 7060 | 891 | 6418 | 650 | 4680 | L30-HLx6 (510-04) |
[Diagram: Schematic of a 12-pulse DFE drive configuration.]
Active Front End drives
| AC drive type | Continuous rating (variable torque) | Low overload rating 110% (constant torque) | High overload rating 150% (constant torque) | Output frame size | |||
|---|---|---|---|---|---|---|---|
| Current Ith [A] | Power [kVA] | Current IL [A] | Power [kVA] | Current IH [A] | Power [kVA] | ||
| Nominal voltage 3300 V | |||||||
| VACON3000-4Q-0425-03 | 425 | 2430 | 386 | 2209 | 283 | 1620 | L20-HLx3 (425-03) |
| VACON3000-4Q-0640-03 | 640 | 3660 | 582 | 3327 | 427 | 2440 | L30-HLx3 (640-03) |
| VACON3000-4Q-0820-03 | 820 | 4690 | 745 | 4264 | 547 | 3127 | L20-HLx6 (425-03) |
| VACON3000-4Q-1230-03 | 1230 | 7030 | 1118 | 6391 | 650 | 4680 | L30-HLx6 (640-03) |
| Nominal voltage 4160 V | |||||||
| VACON3000-4Q-0340-04 | 340 | 2450 | 309 | 2227 | 227 | 1633 | L20-HLx3 (340-04) |
| VACON3000-4Q-0510-04 | 510 | 3670 | 464 | 3336 | 340 | 2447 | L30-HLx3 (510-04) |
| VACON3000-4Q-0650-04 | 650 | 4680 | 591 | 4255 | 433 | 3120 | L20-HLx6 (340-04) |
| VACON3000-4Q-0980-04 | 980 | 7060 | 891 | 6418 | 650 | 4680 | L30-HLx6 (510-04) |
[Diagram: Schematic of an AFE drive configuration.]
Options
The VACON® 3000 Drive Kit offers a range of options for I/O, communications, power dependency, auxiliary units, and warranty extensions. These options allow for customization to meet specific application needs.
Default Options: Graphical keypad, Industrial Ethernet protocols (PROFINET IO, EtherNet/IP™), Real time clock battery, Printed manuals, English (USA) language, and various warranty extensions.
Liquid to liquid heat exchangers
Danfoss offers liquid-to-liquid heat exchangers (HX) to improve the availability and usability of AC drive systems. These pre-designed, tested, and functional packages ensure safety and reliability.
Intelligent system interfaces for heavy industries: Features include self-supporting module rack construction, cooling circuits with threaded joints or flanges, heavy industry stainless steel, and industrial water heat exchangers with three-way valves and pumps.
Liquid to liquid heat exchangers specifications:
| Feature | HXL/M-M/V/R-120-N-P | HXL/M-M/R-300-N-P |
|---|---|---|
| Cooling power | 0...120 kW | 0...300 kW |
| Mains supply | 380...420 VAC | 380...500 VAC |
| Flow | 120...360 l/min | 360...900 l/min |
| Distribution pressure | HXL: 1 bar/l = 40 m, DN50; HXM: 0.7 bar/l = 30 m, DN50 | HXL: 1 bar/l = 40 m, DN80; HXM: 0.7 bar/l = 25 m, DN80 |
| Double pump | HXM | HXM |
| Cabinets | VEDA, Rittal | Rittal |
| Dimensions W x H x D [mm] (without cabinet) | 705 (982) x 1885 x 603 | 1100 x 1900 x 750 |
Phase module dimensions and weight
[Diagrams: Dimensional drawings and weight specifications for L-series (PCU-L20HL, PCU-L30HL) and D-series (PCU-D20HL, PCU-D30HL) phase modules.]
Typecode key
The VACON® 3000 Drive Kit type code specifies product range, front end (12-pulse or AFE), drive rating (e.g., 425 A), motor voltage/output voltage (e.g., 3300 V), and options (e.g., input common mode filter).
Optimize your configuration using our expertise
Leverage Danfoss Drives' Application Development Centres (ADCs) for expert consulting and testing services. ADCs offer production and testing of MV AC drives, with capabilities for configurations up to 4.5 MW (expandable to 9 MW). Centers are located in Research Triangle Park, NC, and the Netherlands (Marine and Offshore focus).
A better tomorrow is driven by drives
Danfoss Drives is a global leader in variable speed control of electric motors, offering competitive advantages through quality, application-optimized products, and comprehensive lifecycle services. Danfoss drives are used across major motor brands and technologies in various power sizes.
VACON® drives combine innovation and durability for sustainable industries. They provide long lifetime, top performance, and full-throttle process throughput for demanding process industries and marine applications.
Danfoss serves diverse industries including Marine and Offshore, Oil and Gas, Metals, Mining and Minerals, Pulp and Paper, Energy, Elevators and Escalators, Chemical, and other heavy-duty industries. VLT® drives are also highlighted for their role in urbanization, supporting cold chains, fresh food supply, building comfort, clean water, and environmental protection.
Contact:
- Tel: +1 (888) DANFOSS
- Website: www.danfossdrives.com
- Email: salesinformation@danfoss.com
