Danfoss VLT AQUA Drive FC 202 User manual

Contents
1. How to Read these Operating Instructions
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 3
Symbols 4
2. Safety 5
General Warning 6
Before Commencing Repair Work 6
Special conditions 6
Avoid unintended Start 7
Safe Stop of the Frequency Converter 7
IT Mains 8
3. Introduction 11
Type Code String 12
4. Mechanical installation 15
Before starting 15
How to install 16
5. Electrical installation 23
How to connect 23
Mains wiring overview 26
How to connect motor - foreword 30
Motor wiring overview 32
Motor connection for C1 and C2 35
How to Test Motor and Direction of Rotation. 37
6. How to operate the frequency converter 43
Ways of Operation 43
How to operate graphical LCP (GLCP) 43
How to operate numeric LCP (NLCP) 49
Tips and tricks 54
7. How to programme the frequency converter 57
How to programme 57
Initialisation to Default Settings 84
Parameter Options 85
Default settings 85
0-** Operation/Display 86
1-** Load/Motor 88
VLT
®
AQUA Drive
Operating Instructions Contents
MG.20.M2.02 - VLT ®is a registered Danfoss trademark 1

2-** Brakes 89
3-** Reference / Ramps 90
4-** Limits / Warnings 91
5-** Digital In/Out 92
6-** Analog In/Out 94
8-** Comm. and Options 96
9-** Profibus 97
10-**CAN Fieldbus 98
13-** Smart Logic 99
14-** Special Functions 100
15-** FC Information 101
16-** Data Readouts 103
18-** Data Readouts 2 105
20-** FC Closed Loop 106
21-** Ext. Closed Loop 107
22-** Application Functions 109
23-** Timed Actions 111
25-** Cascade Controller 112
26-** Analog I/O Option MCB 109 114
29-** Water Application Functions 115
31-** Bypass Option 116
8. Troubleshooting 117
Warning/Alarm list 119
9. Specifications 123
General Specifications 123
Mains Supply 3 x 200 - 240 VAC 123
Mains Supply 3 x 380 - 480 VAC 127
Special Conditions 136
Purpose of derating 136
Automatic adaptations to ensure performance 139
Index
140
Contents
VLT
®
AQUA Drive
Operating Instructions
2 MG.20.M2.02 - VLT ®is a registered Danfoss trademark

1. How to Read these Operating Instructions
1.1.1. Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss A/S. By accepting and using this
manual the user agrees that the information contained herein will be used solely for operating
equipment from Danfoss A/S or equipment from other vendors provided that such equipment is
intended for communication with Danfoss equipment over a serial communication link. This pub-
lication is protected under the Copyright laws of Denmark and most other countries.
Danfoss A/S does not warrant that a software program produced according to the guidelines pro-
vided in this manual will function properly in every physical, hardware or software environment.
Although Danfoss A/S has tested and reviewed the documentation within this manual,
Danfoss A/S 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 A/S 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 A/S 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 A/S 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.
These Operating Instructions will introduce all aspects of your VLT AQUA Drive.
Available literature for VLT AQUA Drive:
-Operating Instructions MG.20.MX.YY provide the neccessary information for getting the
drive up and running.
-Design Guide MG.20.NX.YY entails technical information about the drive design and cus-
tomer applications.
-Programming Guide MG.20.OX.YY provides information on how to programme and in-
cludes complete parameter descriptions.
X = Revision number
YY = Language code
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/
DrivesSolutions/Documentations/Technical+Documentation.
1.1.2. Approvals
VLT
®
AQUA Drive
Operating Instructions 1. How to Read these Operating Instructions
MG.20.M2.02 - VLT ®is a registered Danfoss trademark 3
1

1.1.3. Symbols
Symbols used in these Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates default setting
1. How to Read these Operating Instructions
VLT
®
AQUA Drive
Operating Instructions
4 MG.20.M2.02 - VLT ®is a registered Danfoss trademark
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2. Safety
2.1.1. Safety note
The voltage of the frequency converter is dangerous whenever connected to mains.
Incorrect installation of the motor, frequency converter or fieldbus may cause dam-
age to the equipment, serious personal injury or death. Consequently, the instruc-
tions in this manual, as well as national and local rules and safety regulations, must
be complied with.
Safety Regulations
1. The frequency converter must be disconnected from mains if repair work is to be carried
out. Check that the mains supply has been disconnected and that the necessary time has
passed before removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of the frequency converter does not dis-
connect the equipment from mains and is thus not to be used as a safety switch.
3. Correct protective earthing of the equipment must be established, the user must be pro-
tected against supply voltage, and the motor must be protected against overload in
accordance with applicable national and local regulations.
4. The earth 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 initialised 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 mains supply while the frequency converter
is connected to mains. Check that the mains supply has been disconnected and that the
necessary time has passed before removing motor and mains plugs.
7. Please note that the frequency converter has voltage inputs other than L1, L2 and L3,
when load sharing (linking of DC intermediate circuit) and external 24 V DC have been
installed. Check that all voltage inputs have been disconnected and that the necessary
time has passed before commencing repair work.
Installation at High Altitudes
By altitudes above 2 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 frequency converter is connected to mains. If personal safety consider-
ations 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 [STOP/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 frequency converter, or if
a temporary overload or a fault in the supply mains or the motor connection ceases.
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
VLT
®
AQUA Drive
Operating Instructions 2. Safety
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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 back up.
2.1.2. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
Also make sure that other voltage inputs have been disconnected, (linkage of DC
intermediate circuit), as well as the motor connection for kinetic back-up.
Before touching any potentially live parts of the VLT AQUA Drive FC 200, wait at
least as follows:
200 - 240 V, 0.25 - 3.7 kW: wait at least 4 minutes.
200 - 240 V, 5.5 - 45 kW: wait at least 15 minutes.
380 - 480 V, 0.37 - 7.5 kW: wait at least 4 minutes.
380 - 480 V, 11 - 90 kW, wait at least 15 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The earth leakage current from the VLT AQUA Drive FC 200 exceeds 3.5 mA. Ac-
cording to IEC 61800-5-1 a reinforced Protective Earth connection must be ensured
by means of: a min. 10mm² Cu or 16mm² Al PE-wire or an addtional PE wire - with
the same cable cross section as the Mains wiring - must be terminated separately.
Residual Current Device
This product can cause a D.C. current in the protective conductor. Where a residual
current device (RCD) is used for extra protection, only an RCD of Type B (time de-
layed) shall be used on the supply side of this product. See also RCD Application
Note MN.90.GX.02.
Protective earthing of the VLT AQUA Drive FC 200 and the use of RCD's must always
follow national and local regulations.
2.1.3. Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned in section 2.1.2
4. Remove motor cable
2.1.4. Special conditions
Electrical ratings:
The rating indicated on the nameplate of the frequency converter is based on a typical 3-phase
mains power supply, within the specified voltage, current and temperature range, which is ex-
pected to be used in most applications.
The frequency converters also support other special applications, which affect the
electrical ratings of the frequency converter. Special conditions which affect the elec-
trical ratings might be:
• Single phase applications
• High temperature applications which require derating of the electrical ratings
• Marine applications with more severe environmental conditions.
2. Safety
VLT
®
AQUA Drive
Operating Instructions
6 MG.20.M2.02 - VLT ®is a registered Danfoss trademark
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Consult the relevant clauses in these instructions and in the VLT
®
AQUA Drive Design Guide
for information about the electrical ratings.
Installation requirements:
The overall electrical safety of the frequency converter requires special installation
considerations regarding:
• Fuses and circuit breakers for over-current and short-circuit protection
• Selection of power cables (mains, motor, brake, loadsharing 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 VLT
®
AQUA Drive Design Guide
for information about the installation requirements.
2.1.5. Caution
The frequency converter's DC link capacitors remain charged after power has been
disconnected. To avoid an electrical shock hazard, disconnect the frequency con-
verter from the mains before carrying out maintenance. Wait at least as follows
before doing service on the frequency converter:
Voltage Min. Waiting Time
4 min. 15 min.
200 - 240 V 0.25 - 3.7 kW 5.5 - 45 kW
380 - 480 V 0.37 - 7.5 kW 11 - 90 kW
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
2.1.6. Avoid unintended Start
While the frequency converter is connected to mains, the motor can be started/stop-
ped using digital commands, bus commands, references or via the Local Control
Panel.
• Disconnect the frequency converter from mains whenever personal safety considerations
make it necessary to avoid 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
mains supply, or lost motor connection may cause a stopped motor to start.
2.1.7. Safe Stop of the Frequency Converter
For versions fitted with a Safe Stop terminal 37 input, the frequency converter 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 VLT AQUA Drive Design Guide MG.20.NX.YY must
VLT
®
AQUA Drive
Operating Instructions 2. Safety
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be followed! The information and instructions of the Operating Instructions are not sufficient for
a correct and safe use of the Safe Stop functionality!
2.1.8. IT Mains
IT Mains
Do not connect 400 V frequency converters with RFI-filters to mains supplies with a
voltage between phase and earth of more than 440 V.
For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V be-
tween phase and earth.
Par. 14-50 RFI 1 can be used to disconnect the internal RFI capacitiors from the RFI filter to
ground. If this is done it will reduce the RFI performance to A2 level.
2. Safety
VLT
®
AQUA Drive
Operating Instructions
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2.1.9. Software Version and Approvals: VLT AQUA Drive
VLT AQUA Drive
Operating Instructions
Software version: 1.00
This Operating Instructions can be used for all VLT AQUA Drive frequency converters with
software version 1.00.
The software version number can be seen from parameter 15-43.
2.1.10. Disposal Instruction
Equipment containing electrical components must not be disposed of
together with domestic waste.
It must be separately collected with electrical and electronic waste
according to local and currently valid legislation.
VLT
®
AQUA Drive
Operating Instructions 2. Safety
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3. Introduction
VLT
®
AQUA Drive
Operating Instructions
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3. Introduction
3.1. Introduction
3.1.1. Frequency Converter Identification
Below is an example of an identification label. This label is situated on the frequency converter
and shows the type and options fitted to the unit. See table 2.1 for details of how to read theType
code string (T/C).
Illustration 3.1: This example shows an identification label for VLT AQUA Drive.
Please have T/C (type code) number and serial number ready before contacting Danfoss.
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AQUA Drive
Operating Instructions 3. Introduction
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3.1.2. Type Code String
Description Pos Possible choice
Product group & VLT Series 1-6 FC 202
Power rating 8-10 0.25 - 90 kW
Number of phases 11 Three phases (T)
Mains voltage 11-12 T 2: 200-240 V AC
T 4: 380-480 V AC
Enclosure 13-15 E20: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E66: IP66
P21: IP21/NEMA Type 1 w/backplate
P55: IP55/NEMA Type 12 w/backplate
RFI filter 16-17 H1: RFI filter class A1/B
H2: Class A2
H3:RFI filter A1/B (reduced cable length)
Brake 18 X: No brake chopper included
B: Brake chopper included
T: Safe Stop
U: Safe + brake
Display 19 G: Graphical Local Control Panel (GLCP)
N: Numeric Local Control Panel (NLCP)
X: No Local Control Panel
Coating PCB 20 X. No coated PCB
C: Coated PCB
Mains option 21 X: No Mains disconnect switch
1: With Mains disconnect switch (IP55 only)
Adaptation 22 Reserved
Adaptation 23 Reserved
Software release 24-27 Actual software
Software language 28
A options 29-30 AX: No options
A0: MCA 101 Profibus DP V1
A4: MCA 104 DeviceNet
AG: MCA 108 LON works
B options 31-32 BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BY: MCO 101 Extended Cascade Control
C0 options MCO 33-34 CX: No options
C1 options 35 X: No options
C option software 36-37 XX: Standard software
D options 38-39 DX: No option
D0: DC back-up
Table 3.1: Type code description.
The various options are described further in the VLT AQUA Drive Design Guide.
3. Introduction
VLT
®
AQUA Drive
Operating Instructions
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3.1.3. Abbreviations and Standards
Terms: Abbreviations: SI-units: I-P units:
Acceleration m/s² ft/s²
American wire gauge AWG
Automatic Motor Tuning AMT
Current A Amp
Current limit I
LIM
Energy J = N·m ft-lb, Btu
Fahrenheit ˚F
Frequency Converter FC
Frequency Hz Hz
Kilohertz kHz
Local Control Panel LCP
Milliampere mA
Millisecond ms
Minute min
Motion Control Tool MCT
Motor Type Dependent M-TYPE
Newton Metres Nm
Nominal motor current I
M,N
Nominal motor frequency f
M,N
Nominal motor power P
M,N
Nominal motor voltage U
M,N
Parameter par.
Protective Extra Low Voltage PELV
Power W Btu/hr, hp
Pressure Pa = N/m² psi, psf, ft of
water
Rated Inverter Output Current I
INV
Revolutions Per Minute RPM
Size Related SR
Temperature ˚C˚F
Time s s,hr
Torque limit T
LIM
Voltage V V
Table 3.2: Abbreviation and Standards table .
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®
AQUA Drive
Operating Instructions 3. Introduction
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4. Mechanical installation
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®
AQUA Drive
Operating Instructions
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4. Mechanical installation
4.1. Before starting
4.1.1. Checklist
When unpacking the frequency converter, ensure that the unit is undamaged and complete. Use
the following table to identify the packaging:
Enclosure
type: A2
(IP 20/IP
21)
A3
(IP 20/IP
21)
A5
(IP 55/IP
66)
B1
(IP 21/IP
55/IP 66)
B2
(IP 21/IP
55/IP66)
C1
(IP21/IP
55/66)
C2
(IP21/IP
55/66)
Unit size:
200-240 V 0.25-3.0
kW
3.7
kW
0.25-3.7
kW
5.5-7.5
kW
11-15
kW
18.5 - 22
kW
30 - 45
kW
380-480 V 0.37-4.0
kW
5.5-7.5
kW
0.37-7.5
kW
11-18.5
kW
22-30
kW
37 - 55
kW
75 - 90
kW
Table 4.1: Unpacking table
Please note that a selection of screwdrivers (phillips or cross-thread screwdriver and torx), a side-
cutter, drill and knife is also recommended to have handy for unpacking and mounting the
frequency converter. The packaging for these enclosures contains, as shown: Accessories bag(s),
documentation and the unit. Depending on options fitted there may be one or two bags and one
or more booklets.
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®
AQUA Drive
Operating Instructions 4. Mechanical installation
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4.2. How to install
4.2.1. Checklist
Please use the following table to follow mounting instructions
Enclo-
sure: A2
(IP 20/
IP 21)
A3
(IP 20/
IP 21)
A5
(IP 55/
IP 66)
B1
(IP 21/
IP 55/
IP66)
B2
(IP 21/
IP 55/
IP66)
C1
(IP21/
IP 55/66)
C2
(IP21/
IP 55/66)
Unit size:
200-240 V 0.25-3.0
kW
3.7
kW
0.25-3.7
kW
5.5-7.5
kW
11-15
kW
18.5 - 22
kW
30 - 45
kW
380-480 V 0.37-4.0
kW
5.5-7.5
kW
0.37-7.5
kW
11-18.5
kW
22-30
kW
37 - 55
kW
75 - 90
kW
Table 4.2: Mounting table.
The Danfoss VLT series can be mounted side by side for all IP rating units and require 100 mm
free space above and below for cooling. With regard to ambient temperature ratings, please see
Special Conditions.
4. Mechanical installation
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®
AQUA Drive
Operating Instructions
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Illustration 4.1: Side by side mounting of all frame sizes.
Illustration 4.2: This is the correct way to mount
the unit.
Illustration 4.3: Other than A2 and A3 enclosures
do not mount units as shown without back plate.
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®
AQUA Drive
Operating Instructions 4. Mechanical installation
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4

Cooling will be insufficient and service life can be
drastically shortened.
Illustration 4.4: If the unit must be mounted a
small distance from the wall please order the back
plate with the unit (see Ordering type code posi-
tion 14-15). A2 and A3 units have back-plate as
standard.
4. Mechanical installation
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®
AQUA Drive
Operating Instructions
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4.2.2. Mounting A2 and A3.
Illustration 4.5: Drilling of holes
Step 1: Drill according to the dimensions in the
following table.
Illustration 4.6: Correct mounting of screws.
Step 2A: This way it is easy to hang the unit
on the screws.
Illustration 4.7: Wrong mounting of screws.
Step 2B: Do not tighten screws completely.
Illustration 4.8: Mounting of unit.
Step 3: Lift the unit onto the screws.
Illustration 4.9: Tightening of screws
Step 4: Tighten screws completely.
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®
AQUA Drive
Operating Instructions 4. Mechanical installation
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Mechanical dimensions
Voltage
200-240 V
380-480 V
Frame size A2
0.25-3.0 kW
0.37-4.0 kW
Frame size A3
3.7 kW
5.5-7.5 kW
Encapsulation IP20 IP21/Type 1 IP20 IP21/Type 1
Height
Height of back plate A268 mm 375 mm 268 mm 375 mm
Distance between mounting holes a257 mm 350 mm 257 mm 350 mm
Width
Width of back plate B90 mm 90 mm 130 mm 130 mm
Distance between mounting holes b70 mm 70 mm 110 mm 110 mm
Depth
Depth without option A/B C205 mm 205 mm 205 mm 205 mm
With option A/B C220 mm 220 mm 220 mm 220 mm
Without option A/B D 207 mm 207 mm
With option A/B D 222 mm 222 mm
Screw holes
c 8.0 mm 8.0 mm 8.0 mm 8.0 mm
d ø11 mm ø11 mm ø11 mm ø11 mm
e ø5.5 mm ø5.5 mm ø5.5 mm ø5.5 mm
f 9 mm 9 mm 9 mm 9 mm
Maximum weight 4.9 kg 5.3 kg 6.6 kg 7.0 kg
Table 4.3: A2 and A3 mechanical dimensions
NB!
Option A/B are serial communication and I/O options, which when fitted increase
the depth on some enclosure sizes.
4. Mechanical installation
VLT
®
AQUA Drive
Operating Instructions
20 MG.20.M2.02 - VLT ®is a registered Danfoss trademark
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