Danfoss VLT AQUA Drive FC 202 Guide

MAKING MODERN LIVING POSSIBLE
Design Guide
VLT®AQUA Drive FC 202
110-1400 kW
www.danfoss.com/drives

Contents
1 How to Read this Design Guide 7
2 Introduction 11
2.1 Safety 11
2.2 Software Version 12
2.3 CE Labelling 12
2.4 Air Humidity 13
2.5 Aggressive Environments 13
2.6 Vibration and Shock 14
2.7 Safe Torque Off (STO) 14
2.8 Frequency Converter Benefits 14
2.9 Control Structures 18
2.9.1 Control Principle 18
2.9.2 Control Structure Open Loop 22
2.9.3 Local (Hand On) and Remote (Auto On) Control 22
2.9.4 Control Structure Closed Loop 23
2.9.5 Feedback Handling 24
2.9.6 Feedback Conversion 25
2.9.7 Reference Handling 26
2.9.8 Example of Closed Loop PID Control 27
2.9.9 Programming Order 28
2.9.10 Tuning the Closed Loop Controller 29
2.9.11 Manual PID Adjustment 29
2.10 General Aspects of EMC 30
2.10.1 General Aspects of EMC Emissions 30
2.10.2 Emission Requirements 31
2.10.3 EMC Test Results (Emission) 32
2.10.4 General Aspects of Harmonics Emission 32
2.10.5 Harmonics Emission Requirements 33
2.10.6 Harmonics Test Results (Emission) 33
2.11 Immunity Requirements 33
2.12 Galvanic Isolation (PELV) 35
2.13 Earth Leakage Current 35
2.14 Control with Brake Function 36
2.15 Mechanical Brake Control 37
2.16 Extreme Running Conditions 37
2.16.1 Motor Thermal Protection 38
3 Selection 41
3.1 Options and Accessories 41
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3.1.1 General Purpose Input Output Module MCB 101 41
3.1.2 Digital Inputs - Terminal X30/1-4 42
3.1.3 Analog Voltage Inputs - Terminal X30/10-12 42
3.1.4 Digital Outputs - Terminal X30/5-7 42
3.1.5 Analog Outputs - Terminal X30/5+8 42
3.1.6 Relay Option MCB 105 43
3.1.7 24 V Back-Up Option MCB 107 (Option D) 44
3.1.8 Analog I/O option MCB 109 44
3.1.9 Extended Cascade Controller MCO 101 and Advanced Cascade Controller, MCO
102 46
3.1.10 Extended Cascade Controller MCO 101 46
3.1.11 Brake Resistors 47
3.1.12 Remote Mounting Kit for LCP 48
3.1.13 Input Filters 48
3.1.14 Output Filters 49
3.2 High Power Options 49
3.2.1 Installation of Back Channel Cooling Kit in Rittal Enclosures 50
3.2.2 Outside Installation/NEMA 3R Kit for Rittal Enclosures 51
3.2.3 Installation on Pedestal 52
3.2.4 Installation of Input Plate Options 53
3.2.5 Installation of Mains Shield for Frequency Converters 54
3.2.6 D-frame Options 54
3.2.6.1 Load Share Terminals 54
3.2.6.2 Regeneration Terminals 54
3.2.6.3 Anti-Condensation Heater 54
3.2.6.4 Brake Chopper 54
3.2.6.5 Mains Shield 54
3.2.6.6 Ruggedized Printed Circuit Boards 54
3.2.6.7 Heat Sink Access Panel 54
3.2.6.8 Mains Disconnect 54
3.2.6.9 Contactor 55
3.2.6.10 Circuit Breaker 55
3.2.7 Frame Size F Options 55
4 How to Order 57
4.1 Ordering Form 57
4.1.1 Drive Configurator 57
4.1.2 Type Code String 57
4.2 Ordering Numbers 62
4.2.1 Ordering Numbers: Options and Accessories 62
4.2.2 Advanced Harmonic Filters 63
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4.2.3 Sine-Wave Filter Modules, 380-690 V AC 69
4.2.4 Ordering Numbers: dU/dt Filters 71
4.2.5 Ordering Numbers: Brake Resistors 72
5 How to Install 73
5.1 Mechanical Installation 73
5.1.1 Mechanical Mounting 76
5.1.2 Pedestal Installation of D-frames 76
5.1.3 Pedestal Installation of F-frames 77
5.1.4 Safety Requirements of Mechanical Installation 77
5.2 Pre-installation 78
5.2.1 Planning the Installation Site 78
5.2.2 Receiving the Frequency Converter 78
5.2.3 Transportation and Unpacking 79
5.2.4 Lifting 79
5.2.5 Tools Needed 81
5.2.6 General Considerations 81
5.2.7 Cooling and Airflow 83
5.2.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 85
5.2.9 Gland/Conduit Entry, 12-Pulse - IP21 (NEMA 1) and IP54 (NEMA12) 87
5.3 Electrical Installation 90
5.3.1 Cables General 90
5.3.2 Preparing Gland Plates for Cables 90
5.3.3 Connection to Mains and Earthing 90
5.3.4 Motor Cable Connection 91
5.3.5 Motor Cables 91
5.3.6 Electrical Installation of Motor Cables 92
5.3.7 Fuses 93
5.3.8 Fuse Specifications 93
5.3.9 Access to Control Terminals 94
5.3.10 Control Terminals 94
5.3.11 Control Cable Terminals 94
5.3.12 Basic Wiring Example 95
5.3.13 Control Cable Length 96
5.3.14 Electrical Installation, Control Cables 96
5.3.15 12-Pulse Control Cables 99
5.3.16 Switches S201, S202 and S801 101
5.4 Connections - Frame Sizes D, E and F 102
5.4.1 Torque Settings 102
5.4.2 Power Connections 103
5.4.3 Power Connections 12-Pulse Frequency Converters 127
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5.4.4 Shielding against Electrical Noise 129
5.4.5 External Fan Power Supply 129
5.5 Input Options 130
5.5.1 Mains Disconnects 130
5.5.2 Circuit Breakers 131
5.5.3 Mains Contactors 131
5.5.4 Relay Output D Frame 132
5.5.5 Relay Output E & F-Frame 132
5.6 Final Set-Up and Test 133
5.7 Installation of Miscellaneous Connections 133
5.7.1 RS-485 Bus Connection 133
5.7.2 How to Connect a PC to the Unit 134
5.7.3 PC Software Tools 134
5.7.3.1 MCT 10 134
5.7.3.2 MCT 31 135
5.8 Safety 135
5.8.1 High Voltage Test 135
5.8.2 Safety Earth Connection 135
5.9 EMC-correct Installation 135
5.9.1 Electrical Installation - EMC Precautions 135
5.9.2 Use of EMC-Correct Cables 137
5.9.3 Earthing of Screened/Armoured Control Cables 137
5.10 Residual Current Device 139
6 Application Examples 140
6.1 Typical Application Examples 140
6.1.1 Start/Stop 140
6.1.2 Pulse Start/Stop 140
6.1.3 Potentiometer Reference 141
6.1.4 Automatic Motor Adaptation (AMA) 141
6.1.5 BASIC Cascade Controller 143
6.1.6 Pump Staging with Lead Pump Alternation 144
6.1.7 System Status and Operation 144
6.1.8 Cascade Controller Wiring Diagram 145
6.1.9 Fixed Variable Speed Pump Wiring Diagram 146
6.1.10 Lead Pump Alternation Wiring Diagram 146
7 RS-485 Installation and Set-up 148
7.1 Introduction 148
7.1.1 Hardware Setup 148
7.1.2 Parameter Settings for Modbus Communication 148
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7.1.3 EMC Precautions 148
7.2 FC Protocol Overview 149
7.3 Network Connection 150
7.4 FC Protocol Message Framing Structure 150
7.4.1 Content of a Character (Byte) 150
7.4.2 Telegram Structure 150
7.4.3 Telegram Length (LGE) 150
7.4.4 Frequency Converter Address (ADR) 151
7.4.5 Data Control Byte (BCC) 151
7.4.6 The Data Field 151
7.4.7 The PKE Field 152
7.4.8 Parameter Number (PNU) 152
7.4.9 Index (IND) 152
7.4.10 Parameter Value (PWE) 152
7.4.11 Data Types Supported 153
7.4.12 Conversion 153
7.4.13 Process Words (PCD) 153
7.5 Examples 154
7.5.1 Writing a Parameter Value 154
7.5.2 Reading a Parameter Value 154
7.6 Modbus RTU Overview 154
7.6.1 Assumptions 154
7.6.2 Prerequisite Knowledge 154
7.6.3 Modbus RTU Overview 154
7.6.4 Frequency Converter with Modbus RTU 155
7.7 Network Configuration 155
7.7.1 Frequency Converter with Modbus RTU 155
7.8 Modbus RTU Message Framing Structure 155
7.8.1 Frequency Converter with Modbus RTU 155
7.8.2 Modbus RTU Message Structure 155
7.8.3 Start/Stop Field 156
7.8.4 Address Field 156
7.8.5 Function Field 156
7.8.6 Data Field 156
7.8.7 CRC Check Field 156
7.8.8 Coil Register Addressing 157
7.8.9 Function Codes Supported by Modbus RTU 159
7.9 How to Access Parameters 160
7.9.1 Parameter Handling 160
7.9.2 Storage of Data 160
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7.9.3 IND 160
7.9.4 Text Blocks 160
7.9.5 Conversion Factor 160
7.9.6 Parameter Values 160
7.10 Examples 160
7.10.1 Read Coil Status (01 HEX) 160
7.10.2 Force/Write Single Coil (05 HEX) 161
7.10.3 Force/Write Multiple Coils (0F HEX) 161
7.10.4 Read Holding Registers (03 HEX) 161
7.10.5 Preset Single Register (06 HEX) 162
7.11 Danfoss FC Control Profile 162
7.11.1 Control Word According to FC Profile 162
7.11.2 Status Word According to FC Profile 164
7.11.3 Bus Speed Reference Value 165
8 General Specifications and Troubleshooting 166
8.1 General Specifications 166
8.1.1 Mains Supply 3x380-480 V AC 166
8.1.2 Mains Supply 3x525-690 V AC 169
8.1.3 12-Pulse Specifications 175
8.2 Efficiency 184
8.3 Acoustic Noise 184
8.4 Peak Voltage on Motor 184
8.5 Special Conditions 185
8.5.1 Purpose of Derating 185
8.5.2 Derating for Low Air Pressure 185
8.5.3 Derating for Running at Low Speed 186
8.5.4 Automatic Adaptations to Ensure Performance 187
8.5.5 Derating for Ambient Temperature 187
8.6 Troubleshooting 188
8.6.1 Alarm Words 193
8.6.2 Warning Words 194
8.6.3 Extended Status Words 195
8.6.4 Warning and Alarm Introduction 196
Index 202
Contents Design Guide
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1 How to Read this Design Guide
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 to use the information contained herein solely for
operating equipment from Danfoss or equipment from
other vendors if such equipment is intended for communi-
cation 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 functions properly in every physical, hardware, or
software environment.
Although Danfoss has tested and reviewed the documen-
tation 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 costs 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 losses, or any claims by third
parties.
Danfoss reserves the right to revise this publication at any
time and to change its contents without prior notice or
any obligation to notify former or present users of such
revisions or changes.
1.1.2 Available Literature
•VLT®AQUA Drive FC 202, 0.25-90 kW, Operating
Instructions provide the necessary information for
getting the frequency converter up and running.
•VLT®AQUA Drive FC 202, 110-400 kW, D frame
Operating Instructions provide installation,
startup, and basic information for the newest D-
frame models.
•VLT®AQUA Drive FC 202 High Power Operating
Instructions provide the necessary information for
getting the HP frequency converter up and
running.
•VLT®AQUA Drive FC 202, 110-1400 kW, Design
Guide provides all technical information about
the frame D, E, and F frequency converter and
customer design and applications.
•VLT®AQUA Drive FC 202 Programming Guide
provides information on how to programme and
includes complete parameter descriptions.
•VLT®AQUA Drive FC 202 Profibus.
•VLT®AQUA Drive FC 202 DeviceNet.
•Output Filters Design Guide.
•VLT®AQUA Drive FC 202 Cascade Controller.
•Application Note: Submersible Pump Application
•Application Note: Master/Follower Operation
Application
•Application Note: Drive Closed Loop and Sleep
Mode
•Instruction: Analog I/O Option MCB109
•Instruction: Panel through mount kit
•VLT®Active Filter Operating Instruction.
•VLT
®
Frequency Converters Safe Torque Off
Operating Instructions
Danfoss technical literature is also available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/Technical+Documentation.htm.
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE
Indicates important information, including situations that
can result in damage to equipment or property.
How to Read this Design Gui... Design Guide
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11

1.1.3 Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celsius °C
Direct current DC
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
Frequency converter FC
Gram g
Hertz Hz
Horsepower hp
Kilohertz kHz
Local Control Panel LCP
Meter m
Millihenry Inductance mH
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Nanofarad nF
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Permanent Magnet motor PM motor
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Regenerative terminals Regen
Second sec.
Synchronous Motor Speed ns
Torque limit TLIM
Volts V
The maximum output current IVLT,MAX
The rated output current supplied by the
frequency converter
IVLT,N
Table 1.1 Abbreviations
1.1.4 Definitions
Frequency converter:
Input:
IVLT,MAX
The maximum output current.
IVLT,N
The rated output current supplied by the frequency
converter.
UVLT, MAX
The maximum output voltage.
Control command
Stop the connected motor with LCP and the digital inputs.
Functions are divided into two groups.
Functions in group 1 have higher priority than functions in
group 2.
Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-
stop, DC braking, Stop and the "Off" key.
Group 2 Start, Pulse start, Reversing, Start reversing, Jog, and
Freeze output
Table 1.2 Control Command
Motor:
fJOG
The motor frequency when the jog function is activated
(via digital terminals).
fM
The motor frequency.
fMAX
The maximum motor frequency.
fMIN
The minimum motor frequency.
fM,N
The rated motor frequency (nameplate data).
IM
The motor current.
IM,N
The rated motor current (nameplate data).
nM,N
The rated motor speed (nameplate data).
PM,N
The rated motor power (nameplate data).
TM,N
The rated torque (motor).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
ηVLT
The efficiency of the frequency converter is defined as the
ratio between the power output and the power input.
Start-disable command
A stop command belonging to the group 1 control
commands - see this group.
Stop command
See Control Command.
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References:
Analog Reference
A signal transmitted to the analog inputs 53 or 54, can be
voltage or current.
Bus Reference
A signal transmitted to the serial communication port (FC
port).
Preset Reference
A defined preset reference from -100% to +100% of the
reference range. Selection of eight preset references via
the digital terminals.
Pulse Reference
A pulse frequency signal transmitted to the digital inputs
(terminal 29 or 33).
RefMAX
Determines the relationship between the reference input
at 100% full scale value (typically 10 V, 20 mA) and the
resulting reference. The maximum reference value set in
3-03 Maximum Reference.
RefMIN
Determines the relationship between the reference input
at 0% value (typically 0 V, 0 mA, 4 mA) and the resulting
reference. The minimum reference value set in
3-02 Minimum Reference.
Miscellaneous:
Analog Inputs
The analog inputs are used for controlling various
functions of the frequency converter.
There are two types of analog inputs:
Current input, 0–20 mA, and 4-20 mA
Voltage input, 0-10 V DC.
Analog Outputs
The analog outputs can supply a signal of 0–20 mA, 4–20
mA, or a digital signal.
Automatic Motor Adaptation, AMA
AMA algorithm determines the electrical parameters for
the connected motor at standstill.
Brake Resistor
The brake resistor is a module capable of absorbing the
brake power generated in regenerative braking. This
regenerative braking power increases the intermediate
circuit voltage and a brake chopper ensures that the
power is transmitted to the brake resistor.
CT Characteristics
Constant torque characteristics used for positive
displacement pumps and blowers.
Digital Inputs
The digital inputs can be used for controlling various
functions of the frequency converter.
Digital Outputs
The drive features two solid-state outputs that can supply
a 24 V DC (max. 40 mA) signal.
DSP
Digital Signal Processor.
Relay Outputs
The frequency converter features two programmable relay
outputs.
ETR
Electronic Thermal Relay is a thermal load calculation
based on present load and time. Its purpose is to estimate
the motor temperature.
GLCP
Graphical Local Control Panel (LCP 102)
Initialising
If initialising is carried out (14-22 Operation Mode), the
programmable parameters of the frequency converter
return to their default settings.
Intermittent Duty Cycle
An intermittent duty rating refers to a sequence of duty
cycles. Each cycle consists of an on-load and an off-load
period. The operation can be either periodic duty or none-
periodic duty.
LCP
The Local Control Panel (LCP) makes up a complete
interface for control and programming of the frequency
converter. The control panel is detachable and can be
installed up to 3 metres from the frequency converter, for
example, in a front panel with the installation kit option.
The Local Control Panel is available in two versions:
•Numerical LCP 101 (NLCP)
•Graphical LCP 102 (GLCP)
lsb
Least significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for
cable cross-section. 1 MCM ≡0.5067 mm2.
msb
Most significant bit.
NLCP
Numerical Local Control Panel LCP 101
On-line/Off-line Parameters
Changes to on-line parameters are activated immediately
after the data value is changed. Enter [OK] to activate
changes to off-line parameters.
PID Controller
The PID controller maintains the desired speed, pressure,
temperature by adjusting the output frequency to match
the varying load.
RCD
Residual Current Device.
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Set-up
Save parameter settings in 4 set-ups. Change between the
4 parameter set-ups and edit one set-up, while another
set-up is active.
SFAVM
Switching pattern called Stator Flux oriented Asynchronous
Vector Modulation (14-00 Switching Pattern).
Slip Compensation
The frequency converter compensates for the motor slip
by giving the frequency a supplement that follows the
measured motor load keeping the motor speed almost
constant.
Smart Logic Control (SLC)
The SLC is a sequence of user-defined actions executed
when the associated user-defined events are evaluated as
true by the SLC.
Thermistor
A temperature-dependent resistor placed where the
temperature is monitored (frequency converter or motor).
Trip
A state entered in fault situations, for example, the
frequency converter is subject to an over-temperature or
when the frequency converter is protecting the motor
process or mechanism. Restart is prevented until the cause
of the fault has disappeared and the trip state is cancelled
by activating reset or, in some cases, by being
programmed to reset automatically. Do not use trip for
personal safety.
Trip Locked
A state entered in fault situations when the frequency
converter is protecting itself and requiring physical
intervention, for example, the frequency converter is
subject to a short circuit on the output. A locked trip can
only be cancelled by cutting off mains, removing the cause
of the fault, and reconnecting the frequency converter.
Restart is prevented until the trip state is cancelled by
activating reset or, in some cases, by being programmed
to reset automatically. Do not use trip lock for personal
safety.
VT Characteristics
Variable torque characteristics used for pumps and fans.
VVC+
If compared with standard voltage/frequency ratio control,
Voltage Vector Control (VVC+) improves the dynamics and
the stability, both when the speed reference is changed
and in relation to the load torque.
60°AVM
Switching pattern called 60° Asynchronous Vector
Modulation (14-00 Switching Pattern).
1.1.5 Power Factor
The power factor is the relation between I1and IRMS.
Power factor =3 ×
U × I
1 × COS ϕ
3 × U × IRMS
The power factor for 3-phase control:
=
I
1 ×
cos ϕ1
IRMS
=
I
1
IRMS
since cos ϕ1 = 1
The power factor indicates to which extent the frequency
converter imposes a load on the mains supply.
The lower the power factor, the higher the IRMS for the
same kW performance.
IRMS = I
1
2 +
I
5
2 +
I
7
2 +. . +
In
2
In addition, a high power factor indicates that the different
harmonic currents are low.
The built-in DC coils produce a high power factor, which
reduces the imposed load on the mains supply.
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2 Introduction
2.1 Safety
WARNING
HIGH VOLTAGE
Frequency converters contain high voltage when
connected to AC mains input, DC power supply, or load
sharing. Failure to perform installation, start-up, and
maintenance by qualified personnel can result in death
or serious injury.
•Installation, start-up, and maintenance must be
performed by qualified personnel only.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors,
which can remain charged even when the frequency
converter is not powered. Failure to wait the specified
time after power has been removed before performing
service or repair work, can result in death or serious
injury.
•Stop motor.
•Disconnect AC mains and remote DC-link power
supplies, including battery back-ups, UPS, and
DC-link connections to other frequency
converters.
•Disconnect or lock PM motor.
•Wait for the capacitors to discharge fully, before
performing any service or repair work. The
duration of waiting time is specified in
Table 2.1.
Voltage
[V]
Power range
[kW]
Minimum waiting
time
(minutes)
380-480 110-315 20
380-480 45–400 20
525-690 315-1000 40
525-690 450-1200 30
High voltage can be present even when the warning LED
indicator lights are off.
Table 2.1 Discharge Time
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly can result in death or
serious injury.
•Ensure the correct grounding of the equipment
by a certified electrical installer.
WARNING
UNINTENDED START
When the frequency converter is connected to AC mains,
DC power supply, or load sharing, the motor may start at
any time. Unintended start during programming, service
or repair work can result in death, serious injury, or
property damage. The motor can start by means of an
external switch, a serial bus command, an input
reference signal from the LCP or LOP, via remote
operation using MCT 10 software, or after a cleared fault
condition.
To prevent unintended motor start:
•Disconnect the frequency converter from mains.
•Press [Off/Reset] on the LCP, before
programming parameters.
•The frequency converter, motor, and any driven
equipment must be fully wired and assembled
when the frequency converter is connected to
AC mains, DC power supply, or load sharing.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualified
personnel perform installation, start up, and
maintenance.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in these operating
instructions.
Introduction Design Guide
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22

CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the frequency converter can result
in serious injury, when the frequency converter is not
properly closed.
•Ensure that all safety covers are in place and
securely fastened before applying power.
WARNING
UNINTENDED MOTOR ROTATION
WINDMILLING
Unintended rotation of permanent magnet motors can
result in serious injury or equipment damage.
•Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
2.1.1 Disposal Instruction
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Table 2.2 Disposal Instruction
2.2 Software Version
2.2.1 Software Version and Approvals
VLT®AQUA Drive FC 202
This manual can be used with all VLT AQUA Drive frequency
converters with software version 1.95.
The software version number can be found in parameter 15–43.
Table 2.3 Software Version
2.3 CE Labelling
2.3.1 CE Conformity and Labelling
What is CE Conformity and Labelling?
The purpose of CE labelling is to avoid technical trade
obstacles within EFTA and the EU. The EU has introduced
the CE label as a simple way of showing whether a
product complies with the relevant EU directives. The CE
label says nothing about the specifications or quality of
the product. There are three EU directives that regulate
frequency converters:
The machinery directive (2006/42/EC)
Frequency converters with integrated safety function are
now falling under the Machinery Directive. Danfoss CE-
labels in accordance with the directive and issues a
declaration of conformity upon request. Frequency
converters without safety function do not fall under the
machinery directive. However, if a frequency converter is
supplied for use in a machine, we provide information on
safety aspects relating to the frequency converter.
The low-voltage directive (2006/95/EC)
Frequency converters must be CE labelled in accordance
with the low-voltage directive of January 1, 1997. The
directive applies to all electrical equipment and appliances
used in the 50–1000 V AC and the 75–1500 V DC voltage
ranges. Danfoss CE-labels in accordance with the directive
and issues a declaration of conformity upon request.
The EMC directive (2004/108/EC)
EMC is short for electromagnetic compatibility. The
presence of electromagnetic compatibility means that the
mutual interference between different components/
appliances does not affect the way the appliances work.
The EMC directive came into effect January 1, 1996.
Danfoss CE-labels in accordance with the directive and
issues a declaration of conformity upon request. To carry
out EMC-correct installation, see the instructions in this
Design Guide. Additionally, find specifications of which
standards the Danfoss products comply with. The filters
presented in the specifications are part of the product
range. Furthermore, Danfoss offers other types of
assistance to ensure optimum EMC result.
2.3.2 What Is Covered
The EU "Guidelines on the Application of Council Directive
2004/108/EC" outline three typical situations of using a
frequency converter. See the following list for EMC
coverage and CE labelling.
1. The frequency converter is sold directly to the
end consumer, for example, to a DIY market. The
end consumer is a layman who installs the
frequency converter for use with a household
appliance. For such applications, the frequency
converter must be CE labelled in accordance with
the EMC directive.
2. The frequency converter is sold for installation in
a plant designed by trade professionals. The
frequency converter and the finished plant do
not have to be CE labelled under the EMC
directive. However, the unit must comply with
the basic EMC requirements of the directive.
Compliance is ensured by using components,
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appliances, and systems that are CE labelled
under the EMC directive.
3. The frequency converter is sold as part of a
complete system, such as an air-conditioning
system. The entire system must be CE labelled in
accordance with the EMC directive. The
manufacturer can ensure CE labelling under the
EMC directive either by using CE labelled
components or by testing the EMC of the system.
If the manufacturer chooses to use only CE
labelled components, there is no need to test the
entire system.
2.3.3 Danfoss Frequency Converter and CE
Labelling
CE labelling is a positive feature when used for its original
purpose, which is to facilitate trade within the EU and
EFTA.
CE labelling can cover many different specifications, so
check the CE label to ensure that it covers the relevant
applications.
Danfoss CE labels the frequency converters in accordance
with the low-voltage directive, meaning that if the
frequency converter is installed correctly, Danfoss
guarantees compliance with the low-voltage directive.
Danfoss issues a declaration of conformity that confirms
our CE labelling in accordance with the low-voltage
directive.
The CE label also applies if following the instructions for
EMC-correct installation and filtering.
Detailed instructions for EMC-correct installation are found
in . Furthermore, Danfoss specifies which standards our
products comply with.
2.3.4 Compliance with EMC Directive
2004/108/EC
The primary users of the frequency converter are trade
professionals, who use it as a complex component forming
part of a larger appliance, system, or installation. The
responsibility for the final EMC properties of the appliance,
system, or installation rests with the installer. As an aid to
the installer, Danfoss has prepared EMC installation
guidelines for the power drive system. If the EMC-correct
instructions for installation are followed, the standards and
test levels stated for power drive systems are complied
with. See chapter 2.11 Immunity Requirements.
2.4 Air Humidity
The frequency converter has been designed to meet the
IEC/EN 60068-2-3 standard, EN 50178 pkt. 9.4.2.2 at 50 °C.
2.5 Aggressive Environments
A frequency converter contains many mechanical and
electronic components. All are to some extent vulnerable
to environmental effects.
CAUTION
The frequency converter must not be installed in
environments with airborne liquids, particles, or gases
capable of affecting and damaging the electronic
components. Failure to take the necessary protective
measures increases the risk of stoppages, thus reducing
the life of the frequency converter.
Degree of protection as per IEC 60529
The safe stop function can only be installed and operated
in a control cabinet with degree of protection IP54 or
higher (or equivalent environment) to avoid cross faults
and short circuits between terminals, connectors, tracks,
and safety-related circuitry caused by foreign objects.
Liquids can be carried through the air and condense in the
frequency converter and can cause corrosion of
components and metal parts. Steam, oil, and salt water can
cause corrosion of components and metal parts. In such
environments, use equipment with enclosure rating IP54/
IP55. As an extra protection, coated printed circuit boards
can be ordered as an option.
Airborne Particles such as dust can cause mechanical,
electrical, or thermal failure in the frequency converter. A
typical indicator of excessive levels of airborne particles is
dust particles around the frequency converter fan. In dusty
environments, use equipment with enclosure rating IP54/
IP55 or a cabinet for IP00/IP20/NEMA 1 equipment.
In environments with high temperatures and humidity,
corrosive gases such as sulphur, nitrogen, and chlorine
compounds cause chemical processes on the frequency
converter components.
Such chemical reactions damage the electronic
components quickly. In such environments, mount the
equipment in a cabinet with fresh air ventilation, keeping
aggressive gases away from the frequency converter.
An extra protection in such areas is a coating of the
printed circuit boards, which can be ordered as an option.
NOTICE
Mounting frequency converters in aggressive
environments increases the risk of stoppages and consid-
erably reduces the life of the converter.
Before installing the frequency converter, check the
ambient air for liquids, particles, and gases by observing
existing installations in this environment. Typical indicators
of harmful airborne liquids are water or oil on metal parts,
or corrosion of metal parts.
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Excessive dust particle levels are often found on instal-
lation cabinets and existing electrical installations. One
indicator of aggressive airborne gases is blackening of
copper rails and cable ends on existing installations.
D and E enclosures have a stainless steel back channel
option to provide more protection in aggressive
environments. Proper ventilation is still required for the
internal components of the frequency converter. Contact
Danfoss for more information.
2.6 Vibration and Shock
The frequency converter has been tested according to the
procedure based on the following standards:
The frequency converter complies with requirements that
exist for units mounted on the walls and floors of
production premises, as well as in panels bolted to walls or
floors.
•IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970
•IEC/EN 60068-2-64: Vibration, broad-band random
2.7 Safe Torque Off (STO)
STO is an option. To run STO, additional wiring for the
frequency converter is required. Refer to VLT
®
Frequency
Converters Safe Torque Off Operating Instructions for further
information.
2.8 Frequency Converter Benefits
2.8.1 Why use a Frequency Converter for
Controlling Fans and Pumps?
A frequency converter takes advantage of the fact that
centrifugal fans and pumps follow the laws of propor-
tionality for such fans and pumps. For further information,
see the text and Illustration 2.1.
2.8.2 The Clear Advantage - Energy Savings
The clear advantage of using a frequency converter for
controlling the speed of fans or pumps lies in the
electricity savings.
When comparing with alternative control systems and
technologies, a frequency converter is the optimum energy
control system for controlling fan and pump systems.
SYSTEM CURVE
FAN CURVE
PRESSURE%
130BA780.10
A
B
C
0
20
40
60
80
100
120
20 40 60 80 100 120 140 160 180
VOLUME%
Illustration 2.1 Fan Curves (A, B and C) for Reduced Fan
Volumes
More than 50% energy savings can be obtained in typical
applications when a frequency converter is used to reduce
fan capacity to 60%.
120
100
80
60
40
20
020 40 60 80 100 120 140 160 180
120
100
80
60
40
20
0 20 40 60 80 100 120 140 160 180
Voume %
Voume %
INPUT POWER % PRESSURE %
SYSTEM CURVE
FAN CURVE
A
B
C
130BA781.10
ENERGY
CONSUMED
Illustration 2.2 Energy Savings
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2.8.3 Example of Energy Savings
As can be seen in Illustration 2.3, the flow is controlled by
changing the RPM. Reducing the speed only 20% from the
rated speed reduces the flow by 20%. This reduction
occurs because the flow is directly proportional to the
RPM. The consumption of electricity, however, is 50%
lower.
If the system in question must supply a flow that
corresponds to 100% only a few days in a year, while the
average is below 80% of the rated flow for the remainder
of the year, the amount of energy saved is even more than
50%.
Q = Flow P = Power
Q1= Rated flow P1= Rated power
Q2= Reduced flow P2= Reduced power
H = Pressure n = Speed regulation
H1= Rated pressure n1= Rated speed
H2= Reduced pressure n2= Reduced speed
Table 2.4 Laws of Proportionality
n
100%
50%
25%
12,5%
50% 100%
80%
80%
175HA208.10
Power ~n
3
Pressure ~n
2
Flow ~n
Illustration 2.3 Dependence of Flow, Pressure and Power
consumption on RPM
Flow :
Q
1
Q
2 =
n
1
n
2
Pressure :
H
1
H
2 =
n
1
n
2
2
Power :
P
1
P
2 =
n
1
n
2
3
2.8.4 Example with Varying Flow Over One
Year
Illustration 2.4 is calculated based on pump characteristics
obtained from a pump datasheet.
The result obtained shows energy savings in excess of 50%
at the given flow distribution over a year. The pay back
period depends on the price per kWh and the price of the
frequency converter. In this example, it is less than a year
when compared with valves and constant speed.
Energy savings
Pshaft=Pshaft output
500
[h] t
1000
1500
2000
200100 300 [m
3
/h]
400 Q
175HA210.11
Illustration 2.4 Flow Distribution over 1 Year
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175HA209.11
60
50
40
30
20
10
Hs
0 100 200 300 400
(mwg)
B
C
A
750rpm
1050rpm
1350rpm
1650rpm
0
10
20
30
(kW)
40
50
60
200100 300 (m
3
/h)
(m
3
/h)
400
750rpm
1050rpm
1350rpm
1650rpm
Pshaft
C
1
B
1
A
1
Illustration 2.5 Energy Savings in a Pump Application
m3/
h
Distri-
bution
Valve regulation Frequency converter
control
% Hours Power Consump-
tion
Power Consump-
tion
A1- B1kWh A1- C1kWh
350 5 438 42,5 18.615 42,5 18.615
300 15 1314 38,5 50.589 29,0 38.106
250 20 1752 35,0 61.320 18,5 32.412
200 20 1752 31,5 55.188 11,5 20.148
150 20 1752 28,0 49.056 6,5 11.388
100 20 1752 23,0 40.296 3,5 6.132
Σ100 8760 275.064 26.801
Table 2.5 Energy Savings - Calculation
2.8.5 Better Control
If a frequency converter is used for controlling the flow or
pressure of a system, improved control is obtained.
A frequency converter can vary the speed of the fan or
pump, obtaining .
Furthermore, a frequency converter can quickly adapt the
speed of the fan or pump to new flow or pressure
conditions in the system.
Simple control of process (flow, level, or pressure) utilising
the built-in PID control.
2.8.6 Cos φCompensation
Generally speaking, the frequency converter has a cos φof
1 and provides power factor correction for the cos φof the
motor, which means that there is no need to make
allowance for the cos φof the motor when sizing the
power factor correction unit.
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2.8.7 Star/delta Starter or Soft-starter not
required
When larger motors are started, it is necessary in many
countries to use equipment that limits the start-up current.
In more traditional systems, a star/delta starter or soft-
starter is widely used. Such motor starters are not required
if a frequency converter is used.
As shown in Illustration 2.6, a frequency converter does not
consume more than rated current.
Full load
% Full load current
& speed
500
100
00 12,5 25 37,5 50Hz
200
300
400
600
700
800
4
3
2
1
175HA227.10
Illustration 2.6 Current Consumption with a Frequency
Converter
1VLT®AQUA Drive FC 202
2 Star/delta starter
3 Soft-starter
4 Start directly on mains
Table 2.6 Legend to Illustration 2.6
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2.9 Control Structures
2.9.1 Control Principle
A frequency converter rectifies AC voltage from mains into DC voltage, after which this DC voltage is converted into AC
power with a variable amplitude and frequency.
The motor is supplied with variable voltage/current and frequency, which enables infinitely variable speed control of three-
phased, standard AC motors and permanent magnet synchronous motors.
130BC514.12
3-phase
power
input
DC bus
Motor
Brake
resistor
88 (-)
89 (+)
95 PE
93 (T/L3)
92 (S/L2)
91 (R/L1)
(R-) 81
(R+) 82
(PE) 99
(U/T1) 96
(V/T2) 97
(W/T3) 98
Illustration 2.7 Control Principle
The control terminals provide for wiring feedback, reference, and other input signals to the following:
•frequency converter
•output of frequency converter status and fault conditions
•relays to operate auxiliary equipment
•serial communication interface
Control terminals are programmable for various functions by selecting parameter options described in the main or quick
menus. Most control wiring is customer supplied unless factory ordered. A 24 V DC power supply is also provided for use
with the frequency converter control inputs and outputs.
Table 2.7 describes the functions of the control terminals. Many of these terminals have multiple functions determined by
parameter settings. Some options provide more terminals. See chapter 5.1 Mechanical Installation for terminal locations.
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