Danfoss VLT AQUA Drive FC 202 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® AQUA Drive FC 202 0.25-90 kW
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Safety
Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start up,
and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Frequency converters are connected to hazardous mains
voltages. Extreme care should be taken to protect against
shock. Only trained personnel familiar with electronic
equipment should install, start, or maintain this equipment.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency converter,
motor, and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
frequency converter is connected to AC mains could result
in death, serious injury, equipment, or property damage.
Unintended Start
When the frequency converter is connected to the AC
mains, the motor may be started by means of an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate cautions to
guard against an unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is not
powered. To avoid electrical hazards, disconnect AC mains,
any permanent magnet type motors, and any remote DC-
link power supplies, including battery backups, UPS and
DC-link connections to other frequency converters. Wait for
the capacitors to fully discharge before performing any
service or repair work. The amount of wait time is listed in
the Discharge Time table. Failure to wait the specified time
after power has been removed before doing service or
repair could result in death or serious injury.
Voltage [V] Minimum Waiting Time (Minutes)
4 7 15
200-240 0.25-3.7 kW 5.5-45 kW
380-480 0.37-7.5 kW 11-90 kW
525-600 0.75-7.5 kW 11-90 kW
525-690 1.1-7.5 kW 11-90 kW
High voltage may be present even when the warning LED
display lights are off.
Discharge Time
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which can result
in minor or moderate injury. It can also be used to alert
against unsafe practices.
CAUTION
Indicates asituation that could result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information to regard with attention
to avoid mistakes or operate equipment at less than
optimal performance.
Approvals
NOTE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 1.99 the output frequency of the
frequency converter is limited to 590 Hz. Software versions
1x.xx also limit the maximum output frequency to 590 Hz,
but these versions cannot be flashed, i.e. neither
downgraded nor upgraded.
Safety VLT®AQUA Drive
Operating Instructions
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Safety VLT®AQUA Drive
Operating Instructions
MG20M902 - VLT®is a registered Danfoss trademark
Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [email protected]

Contents
1 Introduction 4
1.1 Purpose of the Manual 6
1.2 Additional Resources 6
1.3 Product Overview 6
1.4 Internal Components Functions 6
1.5 Frame Sizes and Power Ratings 7
1.6 Safe Stop 7
1.6.1 Terminal 37 Safe Stop Function 8
1.6.2 Safe Stop Commissioning Test 10
2 Installation 12
2.1 Installation Site Check List 12
2.2 Frequency Converter and Motor Pre-installation Check List 12
2.3 Mechanical Installation 12
2.3.1 Cooling 12
2.3.2 Lifting 13
2.3.3 Mounting 13
2.3.4 Tightening Torques 13
2.4 Electrical Installation 14
2.4.1 Requirements 16
2.4.2 Earth (Grounding) Requirements 16
2.4.2.1 Leakage Current (>3.5 mA) 17
2.4.2.2 Grounding Using Shielded Cable 17
2.4.3 Motor Connection 17
2.4.4 AC Mains Connection 18
2.4.5 Control Wiring 19
2.4.5.1 Access 19
2.4.5.2 Control Terminal Types 20
2.4.5.3 Wiring to Control Terminals 21
2.4.5.4 Using Screened Control Cables 21
2.4.5.5 Control Terminal Functions 22
2.4.5.6 Jumper Terminals 12 and 27 22
2.4.5.7 Terminal 53 and 54 Switches 22
2.4.5.8 Mechanical Brake Control 22
2.4.6 Serial Communication 23
3 Start Up and Functional Testing 24
3.1 Pre-start 24
3.1.1 Safety Inspection 24
3.2 Applying Power to the Frequency Converter 26
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3.3 Basic Operational Programming 26
3.3.1 Required Initial Frequency Converter Programming 26
3.4 PM Motor Setup in VVCplus 27
3.5 Automatic Motor Adaptation 28
3.6 Check Motor Rotation 28
3.7 Local-control Test 29
3.8 System Start Up 29
3.9 Acoustic Noise or Vibration 29
4 User Interface 30
4.1 Local Control Panel 30
4.1.1 LCP Layout 30
4.1.2 Setting LCP Display Values 31
4.1.3 Display Menu Keys 31
4.1.4 Navigation Keys 32
4.1.5 Operation Keys 32
4.2 Back Up and Copying Parameter Settings 32
4.2.1 Uploading Data to the LCP 33
4.2.2 Downloading Data from the LCP 33
4.3 Restoring Default Settings 33
4.3.1 Recommended Initialisation 33
4.3.2 Manual Initialisation 33
5 About Frequency Converter Programming 34
5.1 Introduction 34
5.2 Programming Example 34
5.3 Control Terminal Programming Examples 35
5.4 International/North American Default Parameter Settings 36
5.5 Parameter Menu Structure 37
5.5.1 Quick Menu Structure 38
5.5.2 Main Menu Structure 40
5.6 Remote Programming with MCT 10 Set-up Software 44
6 Application Set Up Examples 45
6.1 Introduction 45
6.2 Application Examples 45
7 Status Messages 49
7.1 Status Display 49
7.2 Status Message Definitions 49
8 Warnings and Alarms 52
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8.1 System Monitoring 52
8.2 Warning and Alarm Types 52
8.3 Warning and Alarm Displays 52
8.4 Warning and Alarm Definitions 53
9 Basic Troubleshooting 54
9.1 Start Up and Operation 54
10 Specifications 57
10.1 Power-dependent Specifications 57
10.2 General Technical Data 68
10.3 Fuse Specifications 73
10.3.1 CE Compliance 73
10.3.2 Fuse Tables 73
10.3.3 UL Compliance 76
10.4 Connection Tightening Torques 81
Index 82
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1 Introduction
1
23
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
Illustration 1.1 Exploded View A Size
1 LCP 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief/PE ground 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate
Table 1.1 Legend to Illustration 1.1
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1
2
3
4
5
6
7
8
9
10
11
12 13
16
17
18
19
14
15
FAN MOUNTING
QDF-30
DC- DC+
Removejumper to activate Safe Stop
Max.24 Volt !
12 13 18 19 27 29 32 33 20
61 68 39 42 50 53 54
06 05 04 03 02 01
130BB493.10
Illustration 1.2 Exploded View B and C Sizes
1 LCP 11 Relay 2 (04, 05, 06)
2 Cover 12 Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable strain relief / PE ground
6 Cable strain relief/PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Table 1.2 Legend to Illustration 1.2
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1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and of the frequency converter. 2 Instal-
lation provides requirements for mechanical and electrical
installation, including input, motor, control and serial
communications wiring, and control terminal functions.
3 Start Up and Functional Testing provides detailed
procedures for start up, basic operational programming,
and functional testing. The remaining chapters provide
supplementary details. These include user interface,
detailed programming, application examples, start-up
troubleshooting, and specifications.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•The VLT
®
Design Guide is intended to provide
detailed capabilities and functionality to design
motor control systems.
•Supplemental publications and manuals are
available from Danfoss.
See Danfoss website /BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical
+Documentation.htm for listings.
•Optional equipment is available that may change
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website /
BusinessAreas/DrivesSolutions/Documentations/VLT
+Technical+Documen-tation.htm, for downloads
or additional information.
1.3 Product Overview
A frequency converter is an electronic motor controller
that converts AC mains input into a variable AC waveform
output. The frequency and voltage of the output are
regulated to control the motor speed or torque. The
frequency converter can vary the speed of the motor in
response to system feedback, such as changing
temperature or pressure for controlling fan, compressor, or
pump motors. The frequency converter can also regulate
the motor by responding to remote commands from
external controllers.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, and offers many more control, monitoring, and
efficiency functions. Operation and monitoring functions
are available as status indications to an outside control
system or serial communication network.
For single phase frequency converters (S2 and S4) installed
in the EU the following applies:
Single phase frequency converters (S2 and S4) with an
input current less than 16 A and an input of more than 1
kW are intended for use as professional equipment in
trades, professions, or industries. Designated application
areas are:
•Public pools, public water supplies, agriculture,
commercial buildings and industries.
They are not intended for general public use or use in
residential areas. All other single phase frequency
converters are only intended for use in private low-voltage
systems interfacing with public supply only at a medium or
high voltage level. Operators of private systems must
ensure that the EMC environment complies with IEC
610000-3-6 and/or the contractual agreements.
1.4 Internal Components Functions
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.3 for their
functions.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
1 Mains input •Three-phase AC mains power
supply to the frequency
converter
2 Rectifier •The rectifier bridge converts
the AC input to DC current to
supply inverter power
3 DC bus •Intermediate DC-bus circuit
handles the DC current
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Area Title Functions
4 DC reactors •Filter the intermediate DC
circuit voltage
•Prove line transient protection
•Reduce RMS current
•Raise the power factor
reflected back to the line
•Reduce harmonics on the AC
input
5 Capacitor bank •Stores the DC power
•Provides ride-through
protection for short power
losses
6 Inverter •Converts the DC into a
controlled PWM AC waveform
for a controlled variable
output to the motor
Area Title Functions
7 Output to motor •Regulated three-phase output
power to the motor
8 Control circuitry •Input power, internal
processing, output, and motor
current are monitored to
provide efficient operation
and control
•User interface and external
commands are monitored and
performed
•Status output and control can
be provided
Table 1.3 Legend to Illustration 1.3
1.5 Frame Sizes and Power Ratings
References to frames sizes used in this manual are defined in Table 1.4.
Frame Size [kW]
Volts [V] A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4
200-240 0.25-2.2 3.0-3.7 0.25-2.2 0.25-3.7 5.5-11 15 5.5-11 15-18.5 18.5-30 37-45 22-30 37-45
380-480 0.37-4.0 5.5-7.5 0.37-4.0 0.37-7.5 11-18.5 22-30 11-18.5 22-37 37-55 75-90 45-55 75-90
525-600 n/a 0.75-7.5 n/a 0.75-7.5 11-18.5 22-30 11-18.5 22-37 37-55 75-90 45-55 75-90
525-690 n/a 1.1-7.5 n/a n/a n/a 11-30 n/a n/a n/a 37-90 45-55 n/a
Single phase
200-240 n/a 1.1 n/a 1.1 1.5-5.5 7.5 n/a n/a 15 22 n/a n/a
380-480 n/a n/a n/a n/a 7.5 11 n/a n/a 18.5 37 n/a n/a
Table 1.4 Frames Sizes and Power Ratings
1.6 Safe Stop
The frequency converter can perform the safety function
Safe Torque Off (STO, as defined by EN IEC 61800-5-21) and
Stop Category 0 (as defined in EN 60204-12).
Danfoss has named this functionality Safe Stop. Before
integration and use of Safe Stop in an installation, perform
a thorough risk analysis to determine whether the Safe
Stop functionality and safety levels are appropriate and
sufficient. Safe Stop is designed and approved suitable for
the requirements of:
-Safety Category 3 according to EN ISO 13849-1
-Performance Level "d" according to EN ISO
13849-1:2008
-SIL 2 Capability according to IEC 61508 and EN
61800-5-2
-SILCL 2 according to EN 62061
1) Refer to EN IEC 61800-5-2 for details of Safe torque off
(STO) function.
2) Refer to EN IEC 60204-1 for details of stop category 0
and 1.
Activation and Termination of Safe Stop
The Safe Stop (STO) function is activated by removing the
voltage at Terminal 37 of the Safe Inverter. By connecting
the Safe Inverter to external safety devices providing a safe
delay, an installation for a safe Stop Category 1 can be
obtained. The Safe Stop function can be used for
asynchronous, synchronous, and permanent magnet
motors.
WARNING
After installation of Safe Stop (STO), a commissioning test
as specified in 1.6.2 Safe Stop Commissioning Test must be
performed. A passed commissioning test is mandatory
after first installation and after each change to the safety
installation.
Safe Stop Technical Data
The following values are associated to the different types
of safety levels:
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Reaction time for T37
-Maximum reaction time: 20 ms
Reaction time = delay between de-energizing the STO
input and switching off the frequency converter output
bridge.
Data for EN ISO 13849-1
-Performance Level "d"
-MTTFd(Mean Time To Dangerous Failure): 14000
years
-DC (Diagnostic Coverage): 90%
-Category 3
-Lifetime 20 years
Data for EN IEC 62061, EN IEC 61508, EN IEC 61800-5-2
-SIL 2 Capability, SILCL 2
-PFH (Probability of Dangerous failure per
Hour)=1E-10/h
-SFF (Safe Failure Fraction) >99%
-HFT (Hardware Fault Tolerance)=0 (1001
architecture)
-Lifetime 20 years
Data for EN IEC 61508 low demand
-PFDavg for one year proof test: 1E-10
-PFDavg for three year proof test: 1E-10
-PFDavg for five year proof test: 1E-10
No maintenance of the STO functionality is needed.
Security measures have to be taken by the user e.g. instal-
lation in a closed cabinet that is only accessible for skilled
personnel.
SISTEMA Data
Functional safety data is available via a data library for use
with the SISTEMA calculation tool from the IFA (Institute
for Occupational Safety and Health of the German Social
Accident Insurance), and data for manual calculation. The
library is permanently completed and extended.
1.6.1 Terminal 37 Safe Stop Function
The frequency converter is available with safe stop
functionality via control terminal 37. Safe stop disables the
control voltage of the power semiconductors of the
frequency converter output stage. This in turn prevents
generating the voltage required to rotate the motor. When
the Safe Stop (T37) is activated, the frequency converter
issues an alarm, trips the unit, and coasts the motor to a
stop. Manual restart is required. The safe stop function can
be used as an emergency stop for the frequency converter.
In normal operating mode when safe stop is not required,
use the regular stop function instead. When automatic
restart is used, ensure the requirements of ISO 12100-2
paragraph 5.3.2.5 are fulfilled.
Liability Conditions
It is the responsibility of the user to ensure that qualified
personnel installs and operates the safe stop function:
•Read and understand the safety regulations
concerning health and safety/accident prevention
•Understand the generic and safety guidelines
given in this description and the extended
description in the relevant Design Guide
•Have a good knowledge of the generic and safety
standards applicable to the specific application
User is defined as: integrator, operator, service technician,
maintenance technician.
Standards
Use of safe stop on terminal 37 requires that the user
satisfies all provisions for safety including relevant laws,
regulations and guidelines. The optional safe stop function
complies with the following standards.
•IEC 60204-1: 2005 category 0 – uncontrolled stop
•IEC 61508: 1998 SIL2
•IEC 61800-5-2: 2007 – safe torque off (STO)
function
•IEC 62061: 2005 SIL CL2
•ISO 13849-1: 2006 Category 3 PL d
•ISO 14118: 2000 (EN 1037) – prevention of
unexpected startup
The information and instructions of the instruction manual
are not sufficient for a proper and safe use of the safe stop
functionality. The related information and instructions of
the relevant Design Guide must be followed.
Protective Measures
•Qualified and skilled personnel are required for
installation and commissioning of safety
engineering systems
•The unit must be installed in an IP54 cabinet or
in an equivalent environment. In special
applications a higher IP degree is required
•The cable between terminal 37 and the external
safety device must be short circuit protected
according to ISO 13849-2 table D.4
•When external forces influence the motor axis (for
example, suspended loads), additional measures
are required (for example, a safety holding brake)
to eliminate potential hazards
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Safe Stop Installation and Set-Up
WARNING
SAFE STOP FUNCTION!
The safe stop function does NOT isolate mains voltage to
the frequency converter or auxiliary circuits. Perform work
on electrical parts of the frequency converter or the motor
only after isolating the mains voltage supply and waiting
the length of time specified in Table 1.1. Failure to isolate
the mains voltage supply from the unit and waiting the
time specified could result in death or serious injury.
•It is not recommended to stop the frequency
converter by using the Safe Torque Off function.
If a running frequency converter is stopped by
using the function, the unit trips and stops by
coasting. If unacceptable or dangerous, use
another stopping mode to stop the frequency
converter and machinery, before using this
function. Depending on the application, a
mechanical brake can be required.
•For synchronous and permanent magnet motor
frequency converters, in a multiple IGBT power
semiconductor failure: In spite of the activation of
the Safe Torque Off function, the system can
produce an alignment torque which maximally
rotates the motor shaft by 180/p degrees. p
denotes the pole pair number.
•This function is suitable for performing
mechanical work on the system or affected area
of a machine only. It does not provide electrical
safety. Do not use this function as a control for
starting and/or stopping the frequency converter.
Follow these steps to perform a safe installation of the
frequency converter:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking
the jumper is not sufficient to avoid short-
circuiting. (See jumper on Illustration 1.4.)
2. Connect an external Safety monitoring relay via a
NO safety function to terminal 37 (safe stop) and
either terminal 12 or 13 (24 V DC). Follow the
instruction for the safety device. The Safety
monitoring relay must comply with Category
3 /PL “d” (ISO 13849-1) or SIL 2 (EN 62061).
12/13
37
130BA874.10
Illustration 1.4 Jumper between Terminal 12/13 (24 V) and 37
130BC971.10
12
2
4
1
5
3
37
Illustration 1.5 Installation to Achieve a Stopping Category 0 (EN
60204-1) with Cat. 3 /PL “d” (ISO 13849-1) or SIL 2 (EN 62061).
1 Frequency converter
2 [Reset] key
3 Safety relay (cat. 3, PL d or SIL2
4 Emergency stop button
5 Short-circuit protected cable (if not inside installation IP54
cabinet)
Table 1.5 Legend to Illustration 1.5
Safe Stop Commissioning Test
After installation and before first operation, perform a
commissioning test of the installation using safe stop.
Moreover, perform the test after each modification of the
installation.
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WARNING
Safe Stop activation (that is removal of 24 V DC voltage
supply to terminal 37) does not provide electrical safety.
The Safe Stop function itself is therefore not sufficient to
implement the Emergency-Off function as defined by EN
60204-1. Emergency-Off requires measures of electrical
isolation, for example, by switching off mains via an
additional contactor.
1. Activate the Safe Stop function by removing the
24 V DC voltage supply to the terminal 37.
2. After activation of Safe Stop (that is, after the
response time), the frequency converter coasts
(stops creating a rotational field in the motor).
The response time is typically less than 10 ms.
The frequency converter is guaranteed not to restart
creation of a rotational field by an internal fault (in
accordance with Cat. 3 PL d acc. EN ISO 13849-1 and SIL 2
acc. EN 62061). After activation of Safe Stop, the display
shows the text ”Safe Stop activated”. The associated help
text says, "Safe Stop has been activated”. This means that
the Safe Stop has been activated, or that normal operation
has not been resumed yet after Safe Stop activation.
NOTE
The requirements of Cat. 3 /PL “d” (ISO 13849-1) are only
fulfilled while 24 V DC supply to terminal 37 is kept
removed or low by a safety device which itself fulfills Cat.
3 PL “d” (ISO 13849-1). If external forces act on the motor,
it must not operate without additional measures for fall
protection. External forces can arise for example, in the
event of vertical axis (suspended loads) where an
unwanted movement, for example caused by gravity, could
cause a hazard. Fall protection measures can be additional
mechanical brakes.
By default the Safe Stop function is set to an Unintended
Restart Prevention behaviour. Therefore, to resume
operation after activation of Safe Stop,
1. reapply 24 V DC voltage to terminal 37 (text Safe
Stop activated is still displayed)
2. create a reset signal (via bus, Digital I/O, or
[Reset] key.
The Safe Stop function can be set to an Automatic Restart
behaviour. Set the value of 5-19 Terminal 37 Digital Input
from default value [1] to value [3].
Automatic Restart means that Safe Stop is terminated, and
normal operation is resumed, as soon as the 24 V DC are
applied to Terminal 37. No Reset signal is required.
WARNING
Automatic Restart Behaviour is permitted in one of the two
situations:
1. The Unintended Restart Prevention is
implemented by other parts of the Safe Stop
installation.
2. A presence in the dangerous zone can be
physically excluded when Safe Stop is not
activated. In particular, paragraph 5.3.2.5 of ISO
12100-2 2003 must be observed
1.6.2 Safe Stop Commissioning Test
After installation and before first operation, perform a
commissioning test of an installation or application, using
Safe Stop.
Perform the test again after each modification of the
installation or application involving the Safe Stop.
NOTE
A passed commissioning test is mandatory after first instal-
lation and after each change to the safety installation.
The commissioning test (select one of cases 1 or 2 as
applicable):
Case 1: Restart prevention for Safe Stop is required (that is
Safe Stop only where 5-19 Terminal 37 Digital Input is set
to default value [1], or combined Safe Stop and MCB 112
where 5-19 Terminal 37 Digital Input is set to [6] PTC 1 &
Relay A or [9] PTC 1 & Relay W/A):
1.1 Remove the 24 V DC voltage supply to
terminal 37 using the interrupt device while the
frequency converter drives the motor (that is
mains supply is not interrupted). The test step is
passed when
•the motor reacts with a coast, and
•the mechanical brake is activated (if
connected)
•the alarm “Safe Stop [A68]” is displayed
in the LCP, if mounted
1.2 Send Reset signal (via Bus, Digital I/O, or
[Reset] key). The test step is passed if the motor
remains in the Safe Stop state, and the
mechanical brake (if connected) remains
activated.
1.3 Reapply 24 V DC to terminal 37. The test step
is passed if the motor remains in the coasted
state, and the mechanical brake (if connected)
remains activated.
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1.4 Send Reset signal (via Bus, Digital I/O, or
[Reset] key). The test step is passed when the
motor becomes operational again.
The commissioning test is passed if all four test steps 1.1,
1.2, 1.3 and 1.4 are passed.
Case 2: Automatic Restart of Safe Stop is wanted and
allowed (that is, Safe Stop only where 5-19 Terminal 37
Digital Input is set to [3], or combined Safe Stop and MCB
112 where 5-19 Terminal 37 Digital Input is set to [7] PTC 1
& Relay W or [8] PTC 1 & Relay A/W):
2.1 Remove the 24 V DC voltage supply to
terminal 37 by the interrupt device while the
frequency converter drives the motor (that is
mains supply is not interrupted). The test step is
passed when
•the motor reacts with a coast, and
•the mechanical brake is activated (if
connected)
•the alarm “Safe Stop [A68]” is displayed
in the LCP, if mounted
2.2 Reapply 24 V DC to terminal 37.
The test step is passed if the motor becomes operational
again. The commissioning test is passed if both test steps
2.1 and 2.2 are passed.
NOTE
See warning on the restart behaviour in 1.6.1 Terminal 37
Safe Stop Function
WARNING
The Safe Stop function can be used for asynchronous,
synchronous and permanent magnet motors. Two faults
can occur in the power semiconductor of the frequency
converter. When using synchronous or permanent magnet
motors a residual rotation can result from the faults. The
rotation can be calculated to Angle = 360/(Number of
Poles). The application using synchronous or permanent
magnet motors must take this residual rotation into
consideration and ensure that it does not pose a safety
risk. This situation is not relevant for asynchronous motors.
Introduction VLT®AQUA Drive
Operating Instructions
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11
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2 Installation
2.1 Installation Site Check List
•The frequency converter relies on the ambient air
for cooling. Observe the limitations on ambient
air temperature for optimal operation
•Ensure that the installation location has sufficient
support strength to mount the frequency
converter
•Keep the manual, drawings, and diagrams
accessible for detailed installation and operation
instructions. It is important that the manual is
available for equipment operators.
•Locate equipment as near to the motor as
possible. Keep motor cables as short as possible.
Check the motor characteristics for actual
tolerances. Do not exceed
•300 m (1000 ft) for unshielded motor
leads
•150 m (500 ft) for shielded cable.
•Ensure that the ingress protection rating of the
frequency converter is suitable for the installation
environment. IP55 (NEMA 12) or IP66 (NEMA 4)
enclosures may be necessary.
CAUTION
Ingress protection
IP54, IP55 and IP66 ratings can only be guaranteed if the
unit is properly closed.
•Ensure that all cable glands and unused holes for
glands are properly sealed.
•Ensure that the unit cover is properly closed
CAUTION
Device damage through contamination
Do not leave the frequency converter uncovered.
2.2 Frequency Converter and Motor Pre-
installation Check List
•Compare the model number of unit on the
nameplate to what was ordered to verify the
proper equipment
•Ensure each of the following are rated for same
voltage:
Mains (power)
Frequency converter
Motor
•Ensure that the frequency converter output
current rating is equal to or greater than motor
full load current for peak motor performance
Motor size and frequency converter
power must match for proper overload
protection
If frequency converter rating is less than
motor, full motor output cannot be
achieved
2.3 Mechanical Installation
2.3.1 Cooling
•To provide cooling airflow, mount the unit to a
solid flat surface or to the optional back plate
(see 2.3.3 Mounting)
•Top and bottom clearance for air cooling must be
provided. Generally, 100-225 mm (4-10 in) is
required. See Illustration 2.1 for clearance
requirements
•Improper mounting can result in over heating
and reduced performance
•Derating for temperatures starting between 40 °C
(104 °F) and 50 °C (122 °F) and elevation 1000 m
(3300 ft) above sea level must be considered. See
the equipment Design Guide for detailed
information.
Installation VLT®AQUA Drive
Operating Instructions
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a
b
130BA419.10
Illustration 2.1 Top and Bottom Cooling Clearance
Enclosure A2-A5 B1-B4 C1, C3 C2, C4
a/b [mm] 100 200 200 225
Table 2.1 Minimum Airflow Clearance Requirements
2.3.2 Lifting
•Check the weight of the unit to determine a safe
lifting method
•Ensure that the lifting device is suitable for the
task
•If necessary, plan for a hoist, crane, or forklift with
the appropriate rating to move the unit
•For lifting, use hoist rings on the unit, when
provided
2.3.3 Mounting
•Mount the unit vertically
•The frequency converter allows side by side
installation
•Ensure that the strength of the mounting location
will support the unit weight
•Mount the unit to a solid flat surface or to the
optional back plate to provide cooling airflow
(see Illustration 2.2 and Illustration 2.3)
•Improper mounting can result in over heating
and reduced performance
•Use the slotted mounting holes on the unit for
wall mounting, when provided
130BA219.10
A
Illustration 2.2 Proper Mounting with Back Plate
Item Ais a back plate properly installed for required
airflow to cool the unit.
130BA228.10
A
Illustration 2.3 Proper Mounting with Railings
NOTE
Back plate is needed when mounted on railings.
2.3.4 Tightening Torques
See 10.4 Connection Tightening Torques for proper
tightening specifications.
Installation VLT®AQUA Drive
Operating Instructions
MG20M902 - VLT®is a registered Danfoss trademark 13
22

2.4 Electrical Installation
This section contains detailed instructions for wiring the
frequency converter. The following tasks are described.
•Wiring the motor to the frequency converter
output terminals
•Wiring the AC mains to the frequency converter
input terminals
•Connecting control and serial communication
wiring
•After power has been applied, checking input
and motor power; programming control terminals
for their intended functions
Illustration 2.4 shows a basic electrical connection.
*
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24V OUT)
13 (+24V OUT)
18 (D IN)
20 (COM D IN)
15mA 200mA
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42 0/4-20 mA
03
0-10Vdc
+10Vdc
0-10Vdc
0/4-20 mA
240Vac, 2A
24Vdc
02
01
05
04
06 240Vac, 2A
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
19 (D IN)
24V (NPN)
0V (PNP)
27
24V
0V
(D IN/OUT)
0V (PNP)
24V (NPN)
(D IN/OUT)
0V
24V
29
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON=0-20mA
OFF=0-10V
95
400Vac, 2A
P 5-00
(R+) 82
(R-) 81
37 (D IN)
+ - + -
130BA544.12
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
RS-485
RS-485
21
ON
S801
3 Phase
power
input
DC bus Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
Brake
resistor
(NPN) = Sink
(PNP) = Source
Illustration 2.4 Basic Wiring Schematic Drawing.
* Terminal 37 is an option
Installation VLT®AQUA Drive
Operating Instructions
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1
2
3
4
5
6
7
8
PE
U
V
W
9
L1
L2
L3
PE
130BB607.10
10
Illustration 2.5 Typical Electrical Connection
1 PLC 6 Min. 200 mm (7.9 in) between control cables, motor and mains
2 Frequency converter 7 Motor, 3-phase and PE
3 Output contactor (Generally not recommended) 8 Mains, 3-phase and reinforced PE
4 Earth (grounding) rail (PE) 9 Control wiring
5 Cable insulation (stripped) 10 Equalising min. 16 mm2(0.025 in)
Table 2.2 Legend to Illustration 2.5
Installation VLT®AQUA Drive
Operating Instructions
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2.4.1 Requirements
WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be hazardous.
All electrical work must conform to national and local
electrical codes. It is strongly recommended that instal-
lation, start up, and maintenance be performed only by
trained and qualified personnel. Failure to follow these
guidelines could result in death or serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in three
separate metallic conduits or use separated shielded cable
for high frequency noise isolation. Failure to isolate power,
motor and control wiring could result in less than
optimum frequency converter and associated equipment
performance.
For your safety, comply with the following requirements.
•Electronic controls equipment is connected to
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
•Run motor cables from multiple frequency
converters separately. Induced voltage from
output motor cables run together can charge
equipment capacitors even with the equipment
turned off and locked out.
Overload and Equipment Protection
•An electronically activated function within the
frequency converter provides overload protection
for the motor. The overload calculates the level of
increase to activate timing for the trip (controller
output stop) function. The higher the current
draw, the quicker the trip response. The overload
provides Class 20 motor protection. See
8 Warnings and Alarms for details on the trip
function.
•Because the motor wiring carries high frequency
current, it is important that wiring for mains,
motor power, and control are run separately. Use
metallic conduit or separated shielded wire.
Failure to isolate power, motor, and control
wiring could result in less than optimum
equipment performance.
•All frequency converters must be provided with
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Illustration 2.6. If not factory supplied, fuses must
be provided by the installer as part of installation.
See maximum fuse ratings in 10.3 Fuse Specifi-
cations.
L1
L1
L2
L2
L3
L3
GND
91 92 93
Fuses
130BB460.10
Illustration 2.6 Fuses
Wire Type and Ratings
•All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•Danfoss recommends that all power connections
be made with a minimum 75°C rated copper
wire.
•See 10.1 Power-dependent Specifications for
recommended wire sizes.
2.4.2 Earth (Grounding) Requirements
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground the
frequency converter properly in accordance with national
and local electrical codes as well as instructions contained
within this document. Ground currents are higher than 3.5
mA. Failure to ground the frequency converter properly
could result in death or serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding (earthing) of the
equipment in accordance with national and local electrical
codes and standards.
•Follow all local and national electrical codes to
ground electrical equipment properly
•Proper protective grounding for equipment with
ground currents higher than 3.5 mA must be
established, see 2.4.2.1 Leakage Current (>3.5 mA)
•A dedicated ground wire is required for input
power, motor power and control wiring
Installation VLT®AQUA Drive
Operating Instructions
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22
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