Danfoss VLT AQUA Drive FC 200 User manual

Rev. 2009-10-09
www.danfoss.com/drives
130R0504 MG20T122 *MG20T122*
VLT®Low Harmonic Drive
Instruction Manual
VLT®AQUA Drive FC 200
MG20T122
VLT®Low Harmonic Drive Instruction Manual
MAKING MODERN LIVING POSSIBLE

Contents
1 How to Read the Instruction Manual
1-1
Copyright, Limitation of Liability and Revision Rights 1-1
Symbols 1-2
2 Safety 2-1
General Warning 2-2
Before Commencing Repair Work 2-2
Special conditions 2-2
Avoid unintended start 2-3
Safe Stop Installation 2-3
Safe Stop of the Adjustable Frequency Drive 2-5
IT Line Power 2-6
3 Introduction to the Low Harmonic Drive 3-1
Working Principle 3-1
IEEE519 Compliance 3-2
Ordering Form Type Code 3-3
4 How to Install 4-1
How to Get Started 4-1
Pre-installation 4-2
Planning the Installation Site 4-2
Receiving the Adjustable Frequency Drive 4-2
Transportation and Unpacking 4-2
Lifting 4-3
Mechanical Dimensions 4-6
Mechanical Installation 4-12
Assembly of F Frame Sections 4-14
Control Wire Connection between Drive and Filter 4-17
Terminal Locations - Frame size D 4-18
Terminal Locations - Frame size E 4-19
Terminal Locations - Frame size F 4-21
Cooling and Airflow 4-23
Field Installation of Options 4-30
Installation of Input Plate Options 4-30
Installation of Line Power Shield for Adjustable Frequency Drives 4-30
Frame size F Panel Options 4-31
Electrical Installation 4-33
VLT AQUA Low Harmonic Drive Instruction
Manual Contents
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Power Connections 4-33
AC line input connections 4-47
Power and Control Wiring for Non-shielded Cables 4-48
Fuses 4-49
Control Cable Routing 4-52
Electrical Installation, Control Terminals 4-54
Connection Examples for Control of Motor with External Signal Provider 4-55
Start/Stop 4-55
Pulse Start/Stop 4-56
Electrical Installation - additional 4-58
Electrical Installation, Control Cables 4-58
Switches S201, S202, and S801 4-60
Final Set-up and Test 4-61
Additional Connections 4-63
Mechanical Brake Control 4-63
Motor Thermal Protection 4-64
5 How to Operate the Low Harmonic Drive 5-1
Ways of Operation 5-1
How to operate the Graphical LCP (GLCP) 5-1
Tips and tricks 5-8
6 How to Program the Low Harmonic Drive 6-1
How to Program the Adjustable Frequency Drive 6-1
How to Program the Active Filter 6-8
Using the Low Harmonic Drive in NPN Mode 6-8
VLT AQUA Drive - Description of Common Parameters 6-9
Main Menu 6-9
Parameter Options 6-48
Default settings 6-48
0-** Operation and Display 6-49
1-** Load / Motor 6-50
2-** Brakes 6-51
3-** Reference / Ramps 6-51
4-** Limits / Warnings 6-52
5-** Digital In / Out 6-53
6-** Analog In / Out 6-54
8-** Communication and Options 6-55
9-** Profibus 6-56
Contents
VLT AQUA Low Harmonic Drive Instruction
Manual
MG.20.T1.22 - VLT®is a registered Danfoss trademark

13-** Smart Logic Controller 6-56
14-** Special Functions 6-57
15-** FC Information 6-58
16-** Data Readouts 6-59
18-** Info & Readouts 6-60
20-** FC Closed-loop 6-60
21-** Ext. Closed-loop 6-61
22-** Application Functions 6-62
23-** Time-based Funtions 6-63
25-** Cascade Controller 6-64
26-** Analog I / O Option MCB 109 6-65
Parameter Options - Filter 6-66
Operation/Display 0-** 6-66
Digital In/Out 5-** 6-67
Comm. and Options 8-** 6-67
Special Functions 14-** 6-68
FC Information 15-** 6-69
Data Readouts 16-** 6-70
AF Settings 300-** 6-70
AF Readouts301-** 6-71
7 RS-485 Installation and Set-up 7-1
Network Configuration 7-5
FC Protocol Message Framing Structure 7-5
Examples 7-11
How to Access Parameters 7-12
8 General Specifications 8-1
9 Troubleshooting 9-1
Alarms and Warnings - Adjustable Frequency Drive (right LCP) 9-1
Alarms and Warnings - Filter (left LCP) 9-10
10 Index 10-1
VLT AQUA Low Harmonic Drive Instruction
Manual Contents
MG.20.T1.22 - VLT®is a registered Danfoss trademark

Contents
VLT AQUA Low Harmonic Drive Instruction
Manual
MG.20.T1.22 - VLT®is a registered Danfoss trademark

1 How to Read the Instruction Manual
1.1.1 Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss. By accepting and using this manual, the user agrees that the information contained herein
will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication
with Danfoss equipment over a serial communication link. This publication is protected under the copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical,
hardware or software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor
implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose.
In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information
contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not
limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute
these, or any claims by third parties.
Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former
or present users of such revisions or changes.
1.1.2 Available Literature for VLT
®
AQUA DriveFC 200
-VLT®AQUA Drive Instruction Manual MG.20.Mx.yy provides the neccessary information for getting the drive up and running.
-VLT® AQUA Drive High Power Instruction Manual MG.20.Px.yy provides the neccessary information for getting the HP drive up and running.
-VLT®AQUA Drive Design Guide MG.20.Nx.yy contains all the technical information about the drive and customer design and applications.
-VLT® AQUA Drive Programming Guide MN.20.Ox.yy provides information on how to program and includes complete parameter descriptions.
-VLT® AQUA Drive FC 200 Profibus MG.33.Cx.yy
-VLT® AQUA Drive FC 200 DeviceNet MG.33.Dx.yy
-Output Filters Design Guide MG.90.Nx.yy
-VLT®AQUA Drive FC 200 Cascade Controller MI.38.Cx.yy
-Application Note MN20A102: Submersible Pump Application
-Application Note MN20B102: Master/Follower Operation Application
-Application Note MN20F102: Drive Closed-loop and Sleep Mode
-Instruction MI.38.Bx.yy: Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66
-Instruction MI.90.Lx.yy: Analog I/O Option MCB109
-Instruction MI.33.Hx.yy: Panel through mount kit
x = Revision number
yy = Language code
Danfoss technical literature is also available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm .
VLT AQUA Low Harmonic Drive Instruction
Manual 1 How to Read the Instruction Manual
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1.1.3 Software Version and Approvals
VLT AQUA Low Harmonic Drive
Software version: 1.33
This manual can be used with all VLT AQUA Low Harmonic Drive adjustable frequency drives with software version 1.33.
The software version number can be found in parameter 15-43 on the drive LCP.
NOTE!
The VLT AQUA Low Harmonic Drive has two different LCPs, one for the adjustable frequency drive (to the right) and one for the active
filter (to the left). Each LCP controls only the unit it is connected to and there is no communication between the two LCPs
1.1.4 Symbols
Symbols used in this Instruction Manual.
NOTE!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates a default setting
1 How to Read the Instruction Manual
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2Safety
2.1.1 Safety note
The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor,
adjustable frequency drive or serial communication bus may cause damage to the equipment, serious personal injury or death. Con-
sequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
Safety Regulations
1. The adjustable frequency drive must be disconnected from line power if repair work is to be carried out. Make sure that the line power supply
has been disconnected and that the necessary time has passed before removing motor and line power plugs.
2. The [STOP/RESET] key on the control panel of the adjustable frequency drive does not disconnect the equipment from line power and is thus
not to be used as a safety switch.
3. Correct protective grounding of the equipment must be established, the user must be protected against supply voltage, and the motor must be
protected against overload in accordance with applicable national and local regulations.
4. The ground leakage currents are higher than 3.5 mA.
5. Protection against motor overload is set by par. 1-90
Motor Thermal Protection . If this function is desired, set par. 1-90 to data value [ETR trip]
(default value) or data value [ETR warning]. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For the
North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.
6. Do not remove the plugs for the motor and line power supply while the adjustable frequency drive is connected to line power. Make sure that
the line power supply has been disconnected and that the necessary time has passed before removing motor and line power plugs.
7. Please note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3 when load sharing (linking of the DC intermediate
circuit) and external 24 V DC have been installed. Make sure that all voltage inputs have been disconnected and that the necessary time has
passed before commencing repair work.
Installation at High Altitudes
Installation at high altitude:
At altitudes above 9843 ft [3 km], please contact Danfoss Drives regarding PELV.
Warning against Unintended Start
1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the adjustable frequency drive
is connected to line power. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not
sufficient. 2. While parameters are being changed, the motor may start. Consequently, the stop key [RESET] must always be activated; following which
data can be modified. 3. A motor that has been stopped may start if faults occur in the electronics of the adjustable frequency drive, or if a temporary
overload or a fault in the supply line power or the motor connection ceases.
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.
Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as
the motor connection for kinetic backup.
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2.1.2 General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.
Also make sure that other voltage inputs have been disconnected, (linkage of DC intermediate circuit), as well as the motor connection
for kinetic backup.
Before touching any potentially live parts of the adjustable frequency drive, wait at least as follows:
380–480 V, 215–335 hp [160–250 kW], wait at least 20 minutes.
380–480 V, 450–950 hp [315–710 kW], wait at least 40 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit. Be aware that there may be high voltage on the DC
links even when the control card LEDs are turned off. A red LED is mounted on a circuit board inside both the drive and the active filter
to indicate the DC bus voltages. The red LED will stay lit until the DC link is 50 VDC or lower.
Leakage Current
The ground leakage current from the adjustable frequency drive exceeds 3.5 mA. According to IEC 61800-5-1, a reinforced protective
ground connection must be ensured by means of: a min. 0.015 in² [10 mm²] Cu or 0.025 in² [16 mm²] Al PE wire or an additional PE
wire - with the same cable cross-section as the line power wiring - must be terminated separately.
Residual Current Device
This product can cause DC current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only
an RCD of Type B (time delayed) shall be used on the supply side of this product. See also RCD Application Note MN.90.GX.02.
Protective grounding of the adjustable frequency drive and the use of RCDs must always follow national and local regulations.
2.1.3 Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from line power.
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned above in the section General Warning.
4. Remove motor cable
2.1.4 Special conditions
Electrical ratings:
The rating indicated on the nameplate of the adjustable frequency drive is based on a typical 3-phase line power supply within the specified voltage,
current and temperature ranges, which are expected to be used in most applications.
The adjustable frequency drives also support other special applications, which affect the electrical ratings of the adjustable frequency
drive. Special conditions that affect the electrical ratings might be:
• Single phase applications.
• High temperature applications which require derating of the electrical ratings
• Marine applications with more severe environmental conditions.
Consult the relevant clauses in these instructions and in the Design Guide for information about the electrical ratings.
2 Safety
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Installation requirements:
The overall electrical safety of the adjustable frequency drive requires special installation considerations regarding:
• Fuses and circuit breakers for overcurrent and short-circuit protection
• Selection of power cables (line power, motor, brake, load sharing and relay)
• Grid configuration (IT,TN, grounded leg, etc.)
• Safety of low-voltage ports (PELV conditions).
Consult the relevant clauses in these instructions and in the Design Guide for information about the installation requirements.
2.1.5 Avoid unintended start
While the adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus com-
mands, references or via the Local Control Panel.
• Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to
avoid an unintended start.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the line power supply, or lost motor
connection may cause a stopped motor to start.
2.1.6 Safe Stop Installation
To carry out an installation of a Category 0 Stop (EN60204) in
conformity with Safety Category 3 (EN954-1), follow these in-
structions:
1. The bridge (jumper) between Terminal 37 and 24 V DC must be
removed. Cutting or breaking the jumper is not sufficient. Re-
move it entirely to avoid short-circuiting. See jumper in figure.
2. Connect terminal 37 to 24 V DC by a short circuit-protected ca-
ble. The 24 V DC voltage supply must be interruptible by an
EN954-1 category 3 circuit interrupt device. If the interrupt de-
vice and the adjustable frequency drive are placed in the same
installation panel, you can use a non-shielded cable instead of
a shielded one.
Figure 2.1: Bridge jumper between terminal 37 and 24 VDC
The figure below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1). The circuit interruption is caused by an opening door
contact. The figure also shows how to connect a non-safety-related hardware coast.
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Figure 2.2: Figure of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1).
2 Safety
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2.1.7 Safe Stop of the Adjustable Frequency Drive
For versions fitted with a Safe Stop terminal 37 input, the adjustable frequency drive can perform the safety function Safe Torque Off (As defined by
draft CD IEC 61800-5-2) or
Stop Category 0 (as defined in EN 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and
use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality
and safety category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety
Category 3 in EN 954-1, the related information and instructions of the
Design Guide must be followed. The information and instructions of the Instruction
Manual are not sufficient for a correct and safe use of the safe stop functionality.
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2.1.8 IT Line Power
IT line power
Do not connect adjustable frequency drives with RFI filters to line power supplies with a voltage between phase and ground of more
than 440 V for 400 Vs and 760 V for 690 V drives.
For 400 V IT line power and delta ground (grounded leg), AC line voltage may exceed 440 V between phase and ground.
Par. 14-50 RFI filter can be used to disconnect the internal RFI capacitors from the RFI filter to ground. Par. 14-50 RFI filter on both the drive and the
filter must be turned off.
2.1.9 Disposal Instructions
Equipment containing electrical components may not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently valid leg-
islation.
2 Safety
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3 Introduction to the Low Harmonic Drive
3.1.1 Working Principle
The VLT Low Harmonic Drive is a VLT High Power adjustable frequency drive with an integrated active filter. An active filter is a device that actively
monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel out the harmonics.
Figure 3.1: Basic layout for the Low Harmonic Drive
VLT AQUA Low Harmonic Drive Instruction
Manual 3 Introduction to the Low Harmonic Drive
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3.1.2 IEEE519 Compliance
Low harmonic drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of 1. Where traditional non-
linear load draws pulse-shaped currents, the low harmonic drive compensates for this via the parallel filter path which lowers the stress on the supply
grid. The low harmonic drive meets the toughest harmonic standards and has a THiD of less then 5% at full load for <3% pre-distortion on a balanced
three-phased grid. The unit is designed to meet IEEE519 recommendations for Isc/Il >20 for both uneven and even individual harmonic levels. The filter
portion of a low harmonic drive has a progressive switching frequency which leads to a wide frequency spreads producing lower individual harmonic levels
above the 50th.
Figure 3.2: Typical harmonic frequency spectrum and THD value at the line power terminals of the drive
n = harmonic order
.....IEEE519 (Isc/IL>20) limits for individual harmonics
3 Introduction to the Low Harmonic Drive
VLT AQUA Low Harmonic Drive Instruction
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3.1.3 Ordering Form Type Code
It is possible to design a VLT Low Harmonic Drive according to the application requirements by using the ordering number system.
Product groups 1-3
Adjustable frequency
drive series
4-6
Power rating 8-10
Phases 11
AC Line Voltage 12
Enclosure 13-15
Enclosure type
Enclosure class
Control supply volt-
age
Hardware configu-
ration
RFI filter 16-17
Brake 18
Display (LCP) 19
Coating PCB 20
Line power option 21
Adaptation A 22
Adaptation B 23
Software release 24-27
Software language 28
A options 29-30
B options 31-32
C0 options, MCO 33-34
C1 options 35
C option software 36-37
D options 38-39
To order a VLT Low Harmonic Drive, type the letter “L” in position 16 of
the type code string. Not all choices/options are available for each ad-
justable frequency drive variant. To verify if the appropriate version is
available, please consult the Drive Configurator on the Internet. For more
information on the options available, please see the
Design Guide .
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Manual 3 Introduction to the Low Harmonic Drive
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3 Introduction to the Low Harmonic Drive
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4HowtoInstall
4.1 How to Get Started
4.1.1 About How to Install
This chapter covers mechanical and electrical installations to and from power terminals and control card terminals.
Electrical installation of
options is described in the relevant Instruction Manual and Design Guide.
4.1.2 How to Get Started
The adjustable frequency drive is designed for quick installation and is EMC-compliant. Just follow the steps described below.
Read the safety instructions before installing the unit.
Failure to follow recommendations could result in death or serious injury.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Line and Protecting Ground
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick Setup
• Local Control Panel (LCP) of adjustable frequency drive
• Local Control Panel of filter
• Automatic Motor Adaptation, AMA
• Programming
Frame size is depending on enclosure type, power range and AC line
voltage Figure 4.1: Diagram showing basic installation including line
power, motor, start/stop key, and potentiometer for speed
adjustment.
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4.2 Pre-installation
4.2.1 Planning the Installation Site
NOTE!
Before performing the installation, it is important to plan the installation of the adjustable frequency drive. Neglecting this may result
in extra work during and after installation.
Select the best possible operation site by considering the following (see details on the following pages and in the respective Design
Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the adjustable frequency drive.
•Cablerouting
• Ensure the power source supplies the correct voltage and necessary current.
• Ensure that the motor current rating is within the maximum current from the adjustable frequency drive.
• If the adjustable frequency drive is without built-in fuses, ensure that the external fuses are rated correctly.
4.2.2 Receiving the Adjustable Frequency Drive
When receiving the adjustable frequency drive, make sure that the packaging is intact, and look for any damage that might have occurred to the unit
during transport. If damage has occurred, immediately contact the shipping company to make a damage claim.
4.2.3 Transportation and Unpacking
Before unpacking the adjustable frequency drive, it is recommended to unload it as close as possible to the final installation site.
Remove the box and handle the adjustable frequency drive on the pallet, as long as possible.
4 How to Install
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4.2.4 Lifting
Always lift the adjustable frequency drive using the dedicated lifting holes. For all D and E frames, use a bar to avoid bending the lifting holes of the
adjustable frequency drive.
Figure 4.2: Recommended lifting method, frame sizes D and E.
The lifting bar must be able to handle the weight of the adjustable frequency drive. See Mechanical Dimensions for the weight of the
different frame sizes. Maximum diameter for bar is 1 in [2.5 cm]. The angle from the top of the drive to the lifting cable should be
60°or greater.
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