Danfoss VLT AQUA Drive FC 202 User manual

ENGINEERING TOMORROW
Operating Guide
VLT® AQUA Drive FC 202
110–400 kW, Enclosure Sizes D1h–D8h
vlt-drives.danfoss.com

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Manual and Software Version 4
1.4 Approvals and Certications 4
1.5 Disposal 4
2 Safety 5
2.1 Safety Symbols 5
2.2 Qualied Personnel 5
2.3 Safety Precautions 5
3 Product Overview 7
3.1 Intended Use 7
3.2 Power Ratings, Weight, and Dimensions 7
3.3 Interior View of D1h Drive 9
3.4 Interior View of D2h Drive 10
3.5 View of Control Shelf 11
3.6 Extended Options Cabinets 12
3.7 Local Control Panel (LCP) 13
3.8 LCP Menus 15
4 Mechanical Installation 16
4.1 Items Supplied 16
4.2 Tools Needed 17
4.3 Storage 17
4.4 Operating Environment 17
4.5 Installation and Cooling Requirements 18
4.6 Lifting the Drive 19
4.7 Mounting the Drive 20
5 Electrical Installation 23
5.1 Safety Instructions 23
5.2 EMC-compliant Installation 23
5.3 Wiring Schematic 26
5.4 Connecting to Ground 27
5.5 Connecting the Motor 29
5.6 Connecting the AC Mains 31
5.7 Connecting Regen/Load Share Terminals 33
5.8 Terminal Dimensions 35
Contents Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 1

5.9 Control Wiring 63
6 Pre-start Check List 68
7 Commissioning 69
7.1 Applying Power 69
7.2 Programming the Drive 69
7.3 Testing Before System Start-up 71
7.4 System Start-up 71
7.5 Parameter Setting 72
8 Wiring Conguration Examples 73
8.1 Wiring Congurations for Automatic Motor Adaptation (AMA) 73
8.2 Wiring Congurations for Analog Speed Reference 73
8.3 Wiring Congurations for Start/Stop 74
8.4 Wiring Congurations for an External Alarm Reset 75
8.5 Wiring Conguration for Speed Reference Using a Manual Potentiometer 76
8.6 Wiring Conguration for Speed Up/Speed Down 76
8.7 Wiring Congurations for RS485 Network Connection 76
8.8 Wiring Conguration for a Motor Thermistor 77
8.9 Wiring Conguration for a Relay Set-up with Smart Logic Control 77
8.10 Wiring Conguration for a Submersible Pump 78
8.11 Wiring Conguration for a Cascade Controller 80
8.12 Wiring Conguration for a Fixed Variable Speed Pump 81
8.13 Wiring Conguration for Lead Pump Alternation 81
9 Maintenance, Diagnostics, and Troubleshooting 82
9.1 Maintenance and Service 82
9.2 Heat Sink Access Panel 82
9.3 Status Messages 83
9.4 Warning and Alarm Types 85
9.5 List of Warnings and Alarms 86
9.6 Troubleshooting 96
10 Specications 98
10.1 Electrical Data 98
10.2 Mains Supply 106
10.3 Motor Output and Torque Data 106
10.4 Ambient Conditions 106
10.5 Cable Specications 107
10.6 Control Input/Output and Control Data 107
10.7 Fuses and Circuit Breakers 110
Contents VLT® AQUA Drive FC 202
2 Danfoss A/S © 09/2018 All rights reserved. MG21A502

10.8 Fastener Tightening Torques 112
10.9 Enclosure Dimensions 113
11 Appendix 148
11.1 Abbreviations and Conventions 148
11.2 International/North American Default Parameter Settings 149
11.3 Parameter Menu Structure 149
Index 155
Contents Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 3

1 Introduction
1.1 Purpose of the Manual
This operating guide provides information for safe instal-
lation and commissioning of the VLT®drives.
The operating guide is intended for use by qualied
personnel. To use the unit safely and professionally, read
and follow this operating guide. Pay particular attention to
the safety instructions and general warnings. Always keep
the operating guide with the drive.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
drive functions and programming.
•The programming guide provides greater detail on
working with parameters and many application
examples.
•The design guide provides detailed information
about capabilities and functionality to design
motor control systems.
•Instructions provide information for operation
with optional equipment.
Supplementary publications and manuals are available
from Danfoss. See drives.danfoss.com/knowledge-center/
technical-documentation/ for listings.
1.3 Manual and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the version of the manual and the corresponding software
version.
Manual version Remarks Software version
MG21A5xx Replaces MG21A4xx 3.23
Table 1.1 Manual and Software Version
1.4 Approvals and Certications
Table 1.2 Approvals and Certications
More approvals and certications are available. Contact the
local Danfoss oce or partner. Drives of voltage 525–690 V
are UL certied for only 525–600 V.
The drive complies with UL 61800-5-1 thermal memory
retention requirements. For more information, refer to the
section Motor Thermal Protection in the product-specic
design guide.
NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency
of the drive is limited to 590 Hz. For demands exceeding
590 Hz, contact Danfoss.
1.4.1 Compliance with ADN
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
design guide.
1.5 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction VLT® AQUA Drive FC 202
4 Danfoss A/S © 09/2018 All rights reserved. MG21A502
11

2 Safety
2.1 Safety Symbols
The following symbols are used in this guide:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that 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.
2.2 Qualied Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the drive. Only qualied
personnel are allowed to install or operate this equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the personnel must be familiar with the
instructions and safety measures described in this manual.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Drives contain high voltage when connected to AC mains
input, DC supply, load sharing, or permanent motors.
Failure to use qualied personnel to install, start up, and
maintain the drive can result in death or serious injury.
•Only qualied personnel must install, start up,
and maintain the drive.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply,
or load sharing, the motor can 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 with an external switch, a
eldbus command, an input reference signal from the
LCP or LOP, via remote operation using MCT 10 Set-up
Software, or after a cleared fault condition.
To prevent unintended motor start:
•Press [O/Reset] on the LCP before
programming parameters.
•Disconnect the drive from the mains.
•Completely wire and assemble the drive, motor,
and any driven equipment before connecting
the drive to the AC mains, DC supply, or load
sharing.
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain
charged even when the drive is not powered. High
voltage can be present even when the warning LED
indicator lights are o. Failure to wait the specied time
after power has been removed before performing service
or repair work can result in death or serious injury.
•Stop the motor.
•Disconnect AC mains and remote DC-link power
supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
•Disconnect or lock PM motor.
•Wait for the capacitors to discharge fully. The
minimum waiting time is 20 minutes.
•Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged.
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
•Ensure the correct grounding of the equipment
by a certied electrical installer.
Safety Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 5
22

WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualied personnel
install, start up, and maintain the drive.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this guide.
WARNING
UNINTENDED MOTOR ROTATION
WINDMILLING
Unintended rotation of permanent magnet motors
creates voltage and can charge the unit, resulting in
death, serious injury, or equipment damage.
•Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
WARNING
INTERNAL FAILURE HAZARD
Under certain circumstances, an internal failure can
cause a component to explode. Failure to keep the
enclosure closed and properly secured can cause death
or serious injury.
•Do not operate the drive with the door open or
panels o.
•Ensure that the enclosure is properly closed and
secured during operation.
CAUTION
HOT SURFACES
The drive contains metal components that are still hot
even after the drive has been powered o. Failure to
observe the high temperature symbol (yellow triangle)
on the drive can result in serious burns.
•Be aware that internal components, such as
busbars, can be extremely hot even after the
drive has been powered o.
•Exterior areas marked by the high-temperature
symbol (yellow triangle) are hot while the drive
is in use and immediately after being powered
o.
NOTICE
MAINS SHIELD SAFETY OPTION
A mains shield option is available for enclosures with a
protection rating of IP21/IP54 (Type 1/Type 12). The
mains shield is a cover installed inside the enclosure to
protect against the unintended touch of the power
terminals, according to BGV A2, VBG 4.
Safety VLT® AQUA Drive FC 202
6 Danfoss A/S © 09/2018 All rights reserved. MG21A502
22

3 Product Overview
3.1 Intended Use
The drive 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 drive is designed to:
•Regulate motor speed in response to system feedback or to remote commands from external controllers.
•Monitor system and motor status.
•Provide motor overload protection.
The drive is designed for industrial and commercial environments in accordance with local laws and standards. Depending
on conguration, the drive can be used in standalone applications or form part of a larger system or installation.
NOTICE
In a residential environment, this product can cause radio interference, in which case supplementary mitigation
measures can be required.
Foreseeable misuse
Do not use the drive in applications which are non-compliant with specied operating conditions and environments. Ensure
compliance with the conditions specied in chapter 10 Specications.
3.2 Power Ratings, Weight, and Dimensions
For enclosure sizes and power ratings of the drives, refer to Table 3.1. For more dimensions, see chapter 10.9 Enclosure
Dimensions.
Enclosure size D1h D2h D3h D4h D3h D4h
Rated power [kW]
55–75 kW
(200–240 V)
110–160 kW
(380–480 V)
75–160 kW
(525–690 V)
90–160 kW
(200–240 V)
200–315 kW
(380–480 V)
200–400 kW
(525–690 V)
55–75 kW
(200–240 V)
110–160 kW
(380–480 V)
75–160 kW
(525–690 V)
90–160 kW
(200–240 V)200–
315 kW
(380–480 V)
200–400 kW
(525–690 V)
With regeneration or load share
terminals1)
IP
NEMA
21/54
Type 1/12
21/54
Type 1/12
20
Chassis
20
Chassis
20
Chassis
20
Chassis
Shipping
dimensions
[mm (inch)]
Height 587 (23) 587 (23) 587 (23) 587 (23) 587 (23) 587 (23)
Width 997 (39) 1170 (46) 997 (39) 1170 (46) 1230 (48) 1430 (56)
Depth 460 (18) 535 (21) 460 (18) 535 (21) 460 (18) 535 (21)
Drive
dimensions
[mm (inch)]
Height 893 (35) 1099 (43) 909 (36) 1122 (44) 1004 (40) 1268 (50)
Width 325 (13) 420 (17) 250 (10) 350 (14) 250 (10) 350 (14)
Depth 378 (15) 378 (15) 375 (15) 375 (15) 375 (15) 375 (15)
Maximum weight [kg (lb)] 98 (216) 164 (362) 98 (216) 164 (362) 108 (238) 179 (395)
Table 3.1 Power Ratings, Weight, and Dimensions, Enclosure Size D1h–D4h
1) Regen, load share, and brake terminal options are not available for 200–240 V drives.
Product Overview Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 7
33

Enclosure size D5h D6h D7h D8h
Rated power [kW]
110–160 kW
(380–480 V)
75–160 kW
(525–690 V)
110–160 kW
(380–480 V)
75–160 kW
(525–690 V)
200–315 kW
(380–480 V)
200–400 kW
(525–690 V)
200–315 kW
(380–480 V)
200–400 kW
(525–690 V)
IP
NEMA
21/54
Type 1/12
21/54
Type 1/12
21/54
Type 1/12
21/54
Type 1/12
Shipping dimensions
[mm (inch)]
Height 1805 (71) 1805 (71) 2490 (98) 2490 (98)
Width 510 (20) 510 (20) 585 (23) 585 (23)
Depth 635 (25) 635 (25) 640 (25) 640 (25)
Drive dimensions [mm
(inch)]
Height 1324 (52) 1665 (66) 1978 (78) 2284 (90)
Width 325 (13) 325 (13) 420 (17) 420 (17)
Depth 381 (15) 381 (15) 386 (15) 406 (16)
Maximum weight [kg (lb)] 449 (990) 449 (990) 530 (1168) 530 (1168)
Table 3.2 Power Ratings, Weight, and Dimensions, Enclosure Size D5h–D8h
Product Overview VLT® AQUA Drive FC 202
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33

3.3 Interior View of D1h Drive
Illustration 3.1 shows the D1h components relevant to installation and commissioning. The D1h drive interior is similar to
that of the D3h, D5h, and D6h drives. Drives with the contactor option also contain a contactor terminal block (TB6). For the
location of TB6, see chapter 5.8 Terminal Dimensions.
e30bg269.10
1
38
4
6
7
2
5
9
10
1 LCP (local control panel) 6 Mounting holes
2 Control terminals 7 Relays 1 and 2
3 Mains input terminals 91 (L1), 92 (L2), 93 (L3) 8 Motor output terminals 96 (U), 97 (V), 98 (W)
4 Ground terminals for IP21/54 (Type 1/12) 9 Cable clamps
5 Lifting ring 10 Ground terminals for IP20 (Chassis)
Illustration 3.1 Interior View of D1h Drive (similar to D3h/D5h/D6h)
Product Overview Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 9
33

3.4 Interior View of D2h Drive
Illustration 3.2 shows the D2h components relevant to installation and commissioning. The D2h drive interior is similar to
that of the D4h, D7h, and D8h drives. Drives with the contactor option also contain a contactor terminal block (TB6). For the
location of TB6, see chapter 5.8 Terminal Dimensions.
2
410
5
12
e30bg271.10
6
7
3
11
8
9
1
1 Fieldbus top entry kit (optional) 7 Mounting hole
2 LCP (local control panel) 8 Relays 1 and 2
3 Control terminals 9 Terminal block for anti-condensation heater (optional)
4 Mains input terminals 91 (L1), 92 (L2), 93 (L3) 10 Motor output terminals 96 (U), 97 (V), 98 (W)
5 Cable clamps 11 Ground terminals for IP21/54 (Type 1/12)
6 Lifting ring 12 Ground terminals for IP20 (Chassis)
Illustration 3.2 Interior View of D2h Drive (Similar to D4h/D7h/D8h)
Product Overview VLT® AQUA Drive FC 202
10 Danfoss A/S © 09/2018 All rights reserved. MG21A502
33

3.5 View of Control Shelf
The control shelf holds the keypad, known as the local control panel or LCP. The control shelf also includes the control
terminals, relays, and various connectors.
2
4
10
3
9
11
12
6
7
e30bg270.10
5
1
8
1 Local control panel (LCP) 7 Mounting holes
2 RS485 termination switch 8 LCP connector
3 USB connector 9 Analog switches (A53, A54)
4 RS485 eldbus connector 10 Analog I/O connector
5 Digital I/O and 24 V supply 11 Relay 1 (01, 02, 03) on power card
6 Lifting rings 12 Relay 2 (04, 05, 06) on power card
Illustration 3.3 View of Control Shelf
Product Overview Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 11
33

3.6 Extended Options Cabinets
If a drive is ordered with any of the following options, it is
supplied with an extended options cabinet to contain the
optional components.
•Brake chopper.
•Mains disconnect.
•Contactor.
•Mains disconnect with contactor.
•Circuit breaker.
•Regeneration terminals.
•Load sharing terminals.
•Oversized wiring cabinet.
•Multiwire kit.
Illustration 3.4 shows an example of a drive with an options
cabinet. Table 3.3 lists the variants of the drive that include
these options.
Drive model Possible options
D5h Brake, disconnect
D6h Contactor, contactor with disconnect, circuit
breaker
D7h Brake, disconnect, multiwire kit
D8h Contactor, contactor with disconnect, circuit
breaker, multiwire kit
Table 3.3 Overview of Extended Options
The D7h and D8h drives include a 200 mm (7.9 in)
pedestal for oor mounting.
There is a safety latch on the front cover of the options
cabinet. If the drive includes a mains disconnect or circuit
breaker, the safety latch locks the cabinet door while the
drive is energized. Before opening the door, open the
disconnect or circuit breaker to de-energize the drive, and
remove the cover of the options cabinet.
For drives purchased with a disconnect, contactor or circuit
breaker, the nameplate label includes a type code for a
replacement drive that does not include the options. If the
drive is replaced, it can be replaced independently of the
options cabinet.
e30bg830.10
1
2
3
1 Drive enclosure
2 Extended options cabinet
3 Pedestal
Illustration 3.4 Drive with Extended Options Cabinet (D7h)
Product Overview VLT® AQUA Drive FC 202
12 Danfoss A/S © 09/2018 All rights reserved. MG21A502
33

3.7 Local Control Panel (LCP)
The local control panel (LCP) is the combined display and keypad on the front of the drive. The term LCP refers to the
graphical LCP. A numeric local control panel (NLCP) is available as an option. The NLCP operates in a manner similar to the
LCP, but there are dierences. For details on how to use the NLCP, see the product-specic programming guide.
The LCP is used to:
•Control the drive and motor.
•Access drive parameters and program the drive.
•Display operational data, drive status, and warnings.
130BF154.11
Auto
On Reset
Hand
On Off
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(1)
0.00 A
Off Remote Stop
0.0 Hz
On
Alarm
Warn.
0.000
0.000 RPM
0.0000
A1.1
A1.2
A1.3
A2
A3
B1
B2
B4
B3
C1
C2
C3
C4
C5
D1
D2
D3
E1
E2
E3
E4
Illustration 3.5 Graphical Local Control Panel (LCP)
A. Display area
Each display readout has a parameter associated with it. See Table 3.4. The information shown on the LCP can be
customized for specic applications. Refer to chapter 3.8.1.2 Q1 My Personal Menu.
Callout Parameter number Default setting
A1.1 0-20 Reference [Unit]
A1.2 0-21 Analog input 53 [V]
A1.3 0-22 Motor current [A]
A2 0-23 Frequency [Hz]
A3 0-24 Feedback [Unit]
Table 3.4 LCP Display Area
Product Overview Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 13
33

B. Menu keys
Menu keys are used to access the menu for setting up
parameters, toggling through status display modes during
normal operation, and viewing fault log data.
Callout Key Function
B1 Status Shows operational information.
B2 Quick Menu Allows access to parameters for initial
set-up instructions. Also provides
detailed application steps. Refer
to chapter 3.8.1.1 Quick Menus.
B3 Main Menu Allows access to all parameters. Refer to
chapter 3.8.1.8 Main Menu Mode.
B4 Alarm Log Shows a list of current warnings and the
last 10 alarms.
Table 3.5 LCP Menu Keys
C. Navigation keys
Navigation keys are used for programming functions and
moving the display cursor. The navigation keys also
provide speed control in local (hand) operation. To adjust
the display brightness, press [Status] and [▲]/[▼] keys.
Callout Key Function
C1 Back Reverts to the previous step or list in the
menu structure.
C2 Cancel Cancels the last change or command as
long as the display mode has not changed.
C3 Info Shows a denition of the function being
shown.
C4 OK Accesses parameter groups or enables an
option.
C5 ▲▼◄►Moves between items in the menu.
Table 3.6 LCP Navigation Keys
D. Indicator lights
Indicator lights are used to identify the drive status and to
provide a visual notication of warning or fault conditions.
Callout Indicator Indicator
light
Function
D1 On Green Activates when the drive receives
power from the mains voltage or
a 24 V external supply.
D2 Warn. Yellow Activates when warning
conditions are active. Text
appears in the display area
identifying the problem.
D3 Alarm Red Activates during a fault
condition. Text appears in the
display area identifying the
problem.
Table 3.7 LCP Indicator Lights
E. Operation keys and reset
The operation keys are found toward the bottom of the
local control panel.
Callout Key Function
E1 Hand on Starts the drive in local control. An
external stop signal by control input or
serial communication overrides the local
[Hand On].
E2 O Stops the motor but does not remove
power to the drive.
E3 Reset Resets the drive manually after a fault has
been cleared.
E4 Auto on Puts the system in remote operational
mode so it can respond to an external
start command by control terminals or
serial communication.
Table 3.8 LCP Operation Keys and Reset
Product Overview VLT® AQUA Drive FC 202
14 Danfoss A/S © 09/2018 All rights reserved. MG21A502
33

3.8 LCP Menus
3.8.1.1 Quick Menus
The Quick Menus mode provides a list of menus used to
congure and operate the drive. Select Quick Menus by
pressing the [Quick Menu] key. The resulting readout
appears on the LCP display.
130BF242.10
01 My Personal Menu
02 Quick Setup
05 Changes Made
06 Loggings
0.0% 0.00
Quick Menus
1(1)
07 Water and Pumps
03 Function Setups
04 Smart Start
Illustration 3.6 Quick Menu View
3.8.1.2 Q1 My Personal Menu
Use My Personal Menu to determine what is shown in the
display area. Refer to chapter 3.7 Local Control Panel (LCP).
This menu can also show up to 50 pre-programmed
parameters. These 50 parameters are manually entered
using parameter 0-25 My Personal Menu.
3.8.1.3 Q2 Quick Setup
The parameters found in Q2 Quick Setup contain basic
system and motor data that are always necessary for
conguring the drive. See chapter 7.2.3 Entering System
Information for the set-up procedures.
3.8.1.4 Q4 Smart Setup
Q4 Smart Setup guides the user through typical parameter
settings used to congure 1 of the following 3
applications:
•Mechanical brake.
•Conveyor.
•Pump/fan.
The [Info] key can be used to display help information for
various selections, settings, and messages.
3.8.1.5 Q5 Changes Made
Select Q5 Changes Made for information about:
•The 10 most recent changes.
•Changes made from default setting.
3.8.1.6 Q6 Loggings
Use Q6 Loggings for fault nding. To get information about
the display line readout, select Loggings. The information is
shown as graphs. Only parameters selected in
parameter 0-20 Display Line 1.1 Small through
parameter 0-24 Display Line 3 Large can be viewed. It is
possible to store up to 120 samples in the memory for
later reference.
Q6 Loggings
Parameter 0-20 Display Line 1.1 Small Reference [Unit]
Parameter 0-21 Display Line 1.2 Small Analog Input 53 [V]
Parameter 0-22 Display Line 1.3 Small Motor current [A]
Parameter 0-23 Display Line 2 Large Frequency [Hz]
Parameter 0-24 Display Line 3 Large Feedback [Unit]
Table 3.9 Logging Parameter Examples
3.8.1.7 Q7 Motor Setup
The parameters found in Q7 Motor Setup contain basic and
advanced motor data that are always necessary for
conguring the drive. This option also includes parameters
for encoder set-up.
3.8.1.8 Main Menu Mode
The Main Menu mode lists all the parameter groups
available to the drive. Select the Main Menu mode by
pressing the [Main Menu] key. The resulting readout
appears on the LCP display.
e30bg272.10
O-** Operation / Display
1-** Load and Motor
2-** Brakes
3-** Reference / Ramps
0 RPM 0.00 A
Main Menu
1(1)
Illustration 3.7 Main Menu View
All parameters can be changed in the main menu. Option
cards added to the unit enable extra parameters associated
with the option device.
Product Overview Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 15
33

4 Mechanical Installation
4.1 Items Supplied
Items supplied can vary according to product congu-
ration.
•Make sure the items supplied and the information
on the nameplate correspond to the order conr-
mation. Illustration 4.1 and Illustration 4.2 show
sample nameplates for a D-sized drive either with
or without an options cabinet.
•Check the packaging and the drive visually for
damage caused by inappropriate handling during
shipment. File any claim for damage with the
carrier. Retain damaged parts for clarication.
OUT: 3x0-Vin 0-590Hz 177/160 A
IN: 3x380-480V 50/60Hz 171/154 A
90 kW / 125 HP, High Overload
VLT
T/C: FC-202N110T4E20H2TGC7XXSXXXXAQBXCXXXXD0
P/N: 136G7653 S/N:
123456H123
RAQUA Drive
www.danfoss.com
e30bg627.10
ASSEMBLED IN USA
Max Tamb. 55° C/131° F w/ Output Current Derating
CHASSIS / IP20 Tamb. 40° C/104° F
SCCR 100 kA at UL Voltage range 380-480 V
Listed 36U0 E70524 IND. CONT. EQ.
UL Voltage range 380-480 V
CAUTION - ATTENTION:
Stored charge, wait 20 min.
Charge residuelle, attendez 20 min.
See manual for special condition / mains fuse
Voir manuel de conditions speciales / fusibles
WARNING - AVERTISSEMENT:
`
`
1
2
3
4
5
6
Danfoss A/S
6430 Nordborg
Denmark
089
OUT: 3x0-Vin 0-590Hz 212/190 A
IN: 3x380-480V 50/60Hz 204/183 A
110kW / 150 HP, Normal Overload
1 Type code
2 Part number and serial number
3 Power rating
4 Input voltage, frequency, and current
5 Output voltage, frequency, and current
6 Discharge time
Illustration 4.1 Example Nameplate for Drive Only (D1h–D4h)
OUT: 3x0-Vin 0-590Hz 315/302 A
IN: 3x380-480V 50/60Hz 304/291 A
160 kW / 250 HP, High Overload
VLT
T/C: FC-202N200T4E5MH2XJC3XXSXXXXAXBXCXXXXDX
P/N: 136G7973 S/N:
123456H123
RAQUA Drive
www.danfoss.com
e30bg628.10
ASSEMBLED IN USA
Max Tamb. 55
° C/131° F w/ Output Current Derating
Type 12 / IP54 Tamb. 40° C/104° F
SCCR 100 kA at UL Voltage range 380-480 V
Listed 36U0 E70524 IND. CONT. EQ.
UL Voltage range 380-480 V
CAUTION - ATTENTION:
Stored charge, wait 20 min.
Charge residuelle, attendez 20 min.
See manual for special condition / mains fuse
Voir manuel de conditions speciales / fusibles
WARNING - AVERTISSEMENT:
`
`
1
2
3
4
5
6
Danfoss A/S
6430 Nordborg
Denmark
Use the following Typecode to order Drive-only replacement:
T/C: FC-202N200T4E5MH2XJC7XXSXXXXAXBXCXXXXDX
OUT: 3x0-Vin 0-590Hz 395/361 A
IN: 3x380-480V 50/60Hz 381/348 A
200 kW / 300 HP, Normal Overload
1 Type code
2 Part number and serial number
3 Power rating
4 Input voltage, frequency, and current
5 Output voltage, frequency, and current
6 Discharge time
Illustration 4.2 Example Nameplate for Drive with Options
Cabinet (D5h-D8h)
NOTICE
LOSS OF WARRANTY
Do not remove the nameplate from the drive. Removing
the nameplate can result in loss of warranty.
Mechanical Installation VLT® AQUA Drive FC 202
16 Danfoss A/S © 09/2018 All rights reserved. MG21A502
44

4.2 Tools Needed
Receiving/unloading
•I-beam and hooks rated to lift the weight of the
drive. Refer to chapter 3.2 Power Ratings, Weight,
and Dimensions.
•Crane or other lifting aid to place the unit into
position.
Installation
•Drill with 10 mm (0.39 in) or 12 mm (0.47 in) drill
bits.
•Tape measurer.
•Various sizes of Phillips and at bladed
screwdrivers.
•Wrench with relevant metric sockets (7–17 mm/
0.28–0.67 in).
•Wrench extensions.
•Torx drives (T25 and T50).
•Sheet metal punch for conduits or cable glands.
•I-beam and hooks to lift the weight of the drive.
Refer to chapter 3.2 Power Ratings, Weight, and
Dimensions.
•Crane or other lifting aid to place the drive onto
pedestal and into position.
4.3 Storage
Store the drive in a dry location. Keep the equipment
sealed in its packaging until installation. Refer to
chapter 10.4 Ambient Conditions for recommended ambient
temperature.
Periodic forming (capacitor charging) is not necessary
during storage unless storage exceeds 12 months.
4.4 Operating Environment
NOTICE
In environments with airborne liquids, particles, or
corrosive gases, ensure that the IP/type rating of the
equipment matches the installation environment. Failure
to meet requirements for ambient conditions can reduce
the lifetime of the drive. Ensure that requirements for
humidity, temperature, and altitude are met.
Voltage [V] Altitude restrictions
200–240 At altitudes above 3000 m (9842 ft), contact
Danfoss regarding PELV.
380–480 At altitudes above 3000 m (9842 ft), contact
Danfoss regarding PELV.
525–690 At altitudes above 2000 m (6562 ft), contact
Danfoss regarding PELV.
Table 4.1 Installation at High Altitudes
For detailed ambient conditions specications, refer to
chapter 10.4 Ambient Conditions.
NOTICE
CONDENSATION
Moisture can condense on the electronic components
and cause short circuits. Avoid installation in areas
subject to frost. Install an optional space heater when
the drive is colder than the ambient air. Operating in
standby mode reduces the risk of condensation as long
as the power dissipation keeps the circuitry free of
moisture.
NOTICE
EXTREME AMBIENT CONDITIONS
Hot or cold temperatures compromise unit performance
and longevity.
•Do not operate in environments where the
ambient temperature exceeds 55 °C (131 °F).
•The drive can operate at temperatures down to
-10 °C (14 °F). However, proper operation at
rated load is only guaranteed at 0 °C (32 °F) or
higher.
•If temperature exceeds ambient temperature
limits, extra air conditioning of the cabinet or
installation site is required.
4.4.1 Gases
Aggressive gases, such as hydrogen sulde, chlorine, or
ammonia can damage the electrical and mechanical
components. The unit uses conformal-coated circuit boards
to reduce the eects of aggressive gases. For conformal-
coating class specications and ratings, see
chapter 10.4 Ambient Conditions.
4.4.2 Dust
When installing the drive in dusty environments, pay
attention to the following:
Periodic maintenance
When dust accumulates on electronic components, it acts
as a layer of insulation. This layer reduces the cooling
capacity of the components, and the components become
warmer. The hotter environment decreases the life of the
electronic components.
Keep the heat sink and fans free from dust buildup. For
more service and maintenance information, refer to
chapter 9 Maintenance, Diagnostics, and Troubleshooting.
Cooling fans
Fans provide airow to cool the drive. When fans are
exposed to dusty environments, the dust can damage the
fan bearings and cause premature fan failure. Also, dust
Mechanical Installation Operating Guide
MG21A502 Danfoss A/S © 09/2018 All rights reserved. 17
44

can accumulate on fan blades causing an imbalance which
prevents the fans from properly cooling the unit.
4.4.3 Potentially Explosive Atmospheres
WARNING
EXPLOSIVE ATMOSPHERE
Do not install the drive in a potentially explosive
atmosphere. Install the unit in a cabinet outside of this
area. Failure to follow this guideline increases risk of
death or serious injury.
Systems operated in potentially explosive atmospheres
must fulll special conditions. EU Directive 94/9/EC
(ATEX 95) classies the operation of electronic devices in
potentially explosive atmospheres.
•Class d species that if a spark occurs, it is
contained in a protected area.
•Class e prohibits any occurrence of a spark.
Motors with class d protection
Do not require approval. Special wiring and containment
are required.
Motors with class e protection
When combined with an ATEX–approved PTC monitoring
device like the VLT®PTC Thermistor Card MCB 112, the
installation does not need an individual approval from an
approbated organization.
Motors with class d/e protection
The motor itself has an e ignition protection class, while
the motor cabling and connection environment is in
compliance with the d classication. To attenuate the high
peak voltage, use a sine-wave lter at the drive output.
When using a drive in a potentially explosive
atmosphere, use the following:
•Motors with ignition protection class d or e.
•PTC temperature sensor to monitor the motor
temperature.
•Short motor cables.
•Sine-wave output lters when shielded motor
cables are not used.
NOTICE
MOTOR THERMISTOR SENSOR MONITORING
Drives with the VLT®PTC Thermistor Card MCB 112
option are PTB-certied for potentially explosive
atmospheres.
4.5 Installation and Cooling Requirements
NOTICE
MOUNTING PRECAUTIONS
Improper mounting can result in overheating and
reduced performance. Observe all installation and
cooling requirements.
Installation requirements
•Ensure unit stability by mounting vertically to a
solid at surface.
•Ensure that the strength of the mounting location
supports the unit weight. Refer to
chapter 3.2 Power Ratings, Weight, and Dimensions.
•Ensure that the mounting location allows access
to open the enclosure door. See
chapter 10.8 Fastener Tightening Torques.
•Ensure that there is adequate space around the
unit for cooling airow.
•Place the unit as near to the motor as possible.
Keep the motor cables as short as possible. See
chapter 10.5 Cable Specications.
•Ensure that the location allows for cable entry at
the bottom of the unit.
Cooling and airow requirements
•Ensure that top and bottom clearance for air
cooling is provided. Clearance requirement:
225 mm (9 in).
•Consider derating for temperatures starting
between 45 °C (113 °F) and 50 °C (122 °F) and
elevation 1000 m (3300 ft) above sea level. See
the product-specic design guide for detailed
information.
The drive uses back-channel cooling to circulate the heat
sink cooling air. The cooling duct carries approximately
90% of the heat out of the back channel of the drive.
Redirect the back-channel air from the panel or room by
using:
•Duct cooling. Back-channel cooling kits are
available to direct the air away from the panel
when an IP20/chassis drive is installed in a Rittal
enclosure. Use of a kit reduces the heat in the
panel and smaller door fans can be specied on
the enclosure.
•Cooling out the back (top and base covers). The
back-channel cooling air can be ventilated out of
the room so that the heat from the back channel
is not dissipated into the control room.
Mechanical Installation VLT® AQUA Drive FC 202
18 Danfoss A/S © 09/2018 All rights reserved. MG21A502
44