Danfoss VLT AQUA Drive FC 202 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®AQUA Drive FC 202
0.25-90 kW
www.danfoss.com/drives

Contents
1 Introduction 4
1.1 Purpose of the Operating Instructions 4
1.2 Additional Resources 4
1.3 Document and Software Version 4
1.4 Product Overview 4
1.5 Approvals and Certifications 7
1.6 Disposal 7
2 Safety 8
2.1 Safety Symbols 8
2.2 Qualified Personnel 8
2.3 Safety Precautions 8
3 Mechanical Installation 10
3.1 Unpacking 10
3.2 Installation Environments 10
3.3 Mounting 10
4 Electrical Installation 12
4.1 Safety Instructions 12
4.2 EMC-compliant Installation 12
4.3 Grounding 12
4.4 Wiring Schematic 13
4.5 Access 15
4.6 Motor Connection 15
4.7 AC Mains Connection 16
4.8 Control Wiring 16
4.8.1 Control Terminal Types 16
4.8.2 Wiring to Control Terminals 18
4.8.3 Enabling Motor Operation (Terminal 27) 18
4.8.4 Voltage/Current Input Selection (Switches) 18
4.8.5 Safe Torque Off (STO) 19
4.8.6 RS-485 Serial Communication 19
4.9 Installation Check List 20
5 Commissioning 21
5.1 Safety Instructions 21
5.2 Applying Power 21
5.3 Local Control Panel Operation 21
5.3.1 Local Control Panel 21
Contents Operating Instructions
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5.3.2 LCP Layout 21
5.3.3 Parameter Settings 23
5.3.4 Uploading/Downloading Data to/from the LCP 23
5.3.5 Changing Parameter Settings 23
5.3.6 Restoring Default Settings 23
5.4 Basic Programming 24
5.4.1 Commissioning with SmartStart 24
5.4.2 Commissioning via [Main Menu] 24
5.4.3 Asynchronous Motor Set-up 25
5.4.4 PM Motor Setup in VVC+25
5.4.5 Automatic Energy Optimisation (AEO) 26
5.4.6 Automatic Motor Adaptation (AMA) 26
5.5 Checking Motor Rotation 27
5.6 Local-control Test 27
5.7 System Start-up 27
6 Application Set-up Examples 28
7 Maintenance, Diagnostics and Troubleshooting 32
7.1 Maintenance and Service 32
7.2 Status Messages 32
7.3 Warning and Alarm Types 34
7.4 List of Warnings and Alarms 35
7.5 Troubleshooting 41
8 Specifications 44
8.1 Electrical Data 44
8.1.1 Mains Supply 1x200-240 V AC 44
8.1.2 Mains Supply 3x200-240 V AC 45
8.1.3 Mains Supply 1x380-480 V AC 48
8.1.4 Mains Supply 3x380-480 V AC 49
8.1.5 Mains Supply 3x525-600 V AC 53
8.1.6 Mains Supply 3x525-690 V AC 57
8.2 Mains Supply 60
8.3 Motor Output and Motor Data 60
8.4 Ambient Conditions 61
8.5 Cable Specifications 61
8.6 Control Input/Output and Control Data 61
8.7 Connection Tightening Torques 64
8.8 Fuses and Circuit Breakers 65
8.9 Power Ratings, Weight, and Dimensions 72
Contents Operating Instructions
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9 Appendix 73
9.1 Symbols, Abbreviations, and Conventions 73
9.2 Parameter Menu Structure 73
Index 78
Contents Operating Instructions
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1 Introduction
1.1 Purpose of the Operating Instructions
These Operating Instructions provide information for safe
installation and commissioning of the frequency converter.
The Operating Instructions are intended for use by
qualified personnel.
Read and follow the Operating Instructions to use the
frequency converter safely and professionally, and pay
particular attention to the safety instructions and general
warnings. Keep these Operating Instructions available with
the frequency converter at all times.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•The VLT
®
Programming Guide provides greater
detail on working with parameters and many
application examples.
•The VLT
®
Design Guide provides detailed
information about capabilities and functionality to
design motor control systems.
•Instructions for operation with optional
equipment.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical+Documentation.htm
for listings.
1.3 Document and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Please send
suggestions via email to
[email protected], including a
reference to the document version.
Table 1.1 shows the document version and the
corresponding software version.
Edition Remarks Software version
MG20MBxx Replaces MG20MAxx 2.2x
Table 1.1 Document and Software Version
1.4 Product Overview
1.4.1 Intended Use
The frequency converter is an electronic motor controller
intended for:
•Regulation of motor speed in response to system
feedback or to remote commands from external
controllers. A power drive system consists of the
frequency converter, the motor, and equipment
driven by the motor.
•System and motor status surveillance.
Depending on configuration, the frequency converter can
be used in standalone applications or form part of a larger
appliance or installation.
The frequency converter is allowed for use in residential,
industrial, and commercial environments in accordance
with local laws, standards, and emission limits as described
in the Design Guide.
Single phase frequency converters (S2 and S4) installed
in the EU
The following limitations apply:
•Units with an input current below 16 A and an
input power above 1 kW are only intended for
professional use in trades, professions, or
industries and not for sale to the general public.
•Designated application areas are public pools,
public water supplies, agriculture, commercial
buildings, and industries. All other single phase
units are only intended for use in private low-
voltage systems interfacing with public supply
only at a medium or high voltage level.
•Operators of private systems must ensure that
the EMC environment complies with IEC
610000-3-6 and/or the contractual agreements.
NOTICE
In a residential environment, this product can cause
radio interference, in which case supplementary
mitigation measures may be required.
Foreseeable misuse
Do not use the frequency converter in applications, which
are non-compliant with specified operating conditions and
environments. Ensure compliance with the conditions
specified in chapter 8 Specifications.
Introduction Operating Instructions
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1

1.4.2 Features
The VLT®AQUA Drive FC 202 is designed for water and wastewater applications. The range of standard and optional
features includes:
•Cascade control • Dry run detection • End of curve detection • SmartStart
•Motor alternation • Deragging • 2-step ramps • Flow Confirmation
•Check valve protection • Safe Torque Off • Low flow detection • Pre/Post Lubrication
•Pipe fill mode • Sleep mode • Real-time clock • User configurable info texts, warnings and alarms
•Password protection • Overload protection • Smart logic control • Dual Power rating (High/Normal Overload)
1.4.3 Exploded Views
1
2
3
4
5
6
7
8
9
10
11
12 13
16
17
18
19
14
15
FANMOUNTING
QDF-30
DC- DC+
Removejumper to activate Safe Stop
Max.24 Volt !
12 13 18 19 27 29 32 33 20
61 68 39 42 50 53 54
06 05 04 03 02 01
130BB493.10
1 Local Control Panel (LCP) 11 Relay 2 (04, 05, 06)
2 Cover 12 Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable screen connector
6 Cable screen connector 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Illustration 1.1 Exploded View Enclosure Types B and C, IP55 and IP66
Introduction Operating Instructions
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1
23
4
5
6
7
8
9
10
11
12
13
14
8
15
16
17
18
130BB492.10
1 Local Control Panel (LCP) 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable screen connector 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Screened cable grounding clamp and strain relief 18 Cover
Illustration 1.2 Exploded View Enclosure Type A, IP20
Introduction Operating Instructions
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1

Illustration 1.3 is a block diagram of the internal
components of the frequency converter. See Table 1.2 for
their functions.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
1 Mains input •3-phase AC mains power supply
to the frequency converter.
2 Rectifier
•The rectifier bridge converts the
AC input to DC current to supply
inverter power.
3 DC bus •Intermediate DC bus circuit
handles the DC current.
4 DC reactors
•Filter the intermediate DC circuit
voltage.
•Prove line transient protection.
•Reduce RMS current.
•Raise the power factor reflected
back to the line.
•Reduce harmonics on the AC
input.
5 Capacitor bank
•Stores the DC power.
•Provides ride-through protection
for short power losses.
6 Inverter
•Converts the DC into a controlled
PWM AC waveform for a
controlled variable output to the
motor.
7 Output to motor •Regulated 3-phase output power
to the motor.
8 Control circuitry
•Input power, internal processing,
output, and motor current are
monitored to provide efficient
operation and control.
•User interface and external
commands are monitored and
performed.
•Status output and control can be
provided.
Table 1.2 Legend to Illustration 1.3
1.4.4 Enclosure Types and Power Ratings
For enclosure types and power ratings of the frequency
converters, refer to chapter 8.9 Power Ratings, Weight, and
Dimensions.
1.5 Approvals and Certifications
More approvals and certifications are available. Contact
your local Danfoss partner. Frequency converters of
enclosure type T7 (525-690 V) are not certified for UL.
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product specific design guide.
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.
1.6 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 Operating Instructions
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11

2 Safety
2.1 Safety Symbols
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.
2.2 Qualified Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the frequency converter. Only
qualified personnel are allowed to install or operate this
equipment.
Qualified personnel are defined as trained staff, who are
authorised to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Additionally, the personnel must be familiar
with the instructions and safety measures described in
these operating instructions.
2.3 Safety Precautions
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
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 after a cleared fault
condition.
To prevent unintended motor start:
•Disconnect the frequency converter from the
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
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, could result in death or serious
injury.
1. Stop the motor.
2. Disconnect the AC mains, permanent magnet
type motors, and remote DC-link power
supplies, including battery back-ups, UPS, and
DC-link connections to other frequency
converters.
3. 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.
Safety Operating Instructions
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Voltage [V] Minimum waiting time (minutes)
4 7 15
200-240 0.25-3.7 kW 5.5-45 kW
380-480 0.37-7.5 kW 11-90 kW
525-600 0.75-7.5 kW 11-90 kW
525-690 1.1-7.5 kW 11-90 kW
High voltage may be present even when the warning LED
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
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.
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.
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.
Safety Operating Instructions
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3 Mechanical Installation
3.1 Unpacking
3.1.1 Items Supplied
Items supplied may vary according to product configu-
ration.
•Make sure the items supplied and the
information on the nameplate correspond to the
order confirmation.
•Check the packaging and the frequency converter
visually for damage caused by inappropriate
handling during shipment. File any claim for
damage with the carrier. Retain damaged parts
for clarification.
130BD666.10
CHASSIS/ IP20 Tamb.45 C/113 F
V LT
MADE IN
DENMARK
R
P/N: 131F6653 S/N: 038010G502
45kW(400V) / 60HP(460V)
IN: 3x380-480V 50/60Hz 82/73A
OUT: 3x0-Vin 0-590Hz 90/80A
o
CAUTION:
See manual for special condition/mains fuse
voir manual de conditions speclales/fusibles
WARNING:
Stored charge, wait 15 min.
Charge residuelle, attendez 15 min.
* 1 3 1
F
6 6 5 3 0 3 8 0 1 0 G 5 0 2 *
`
AQUA Drive
www.danfoss.com
T/C: FC-202P45KT4E20H1XGXXXXSXXXXAXBXCXXXXDX
Listed 76X1 E134261 Ind. Contr. Eq.
o
`
1
2
4
5
6
78
9
10
3
1 Type code
2 Order number
3 Serial number
4 Power rating
5Input voltage, frequency and current (at low/high
voltages)
6Output voltage, frequency and current (at low/high
voltages)
7 Enclosure type and IP rating
8 Maximum ambient temperature
9 Certifications
10 Discharge time (Warning)
Illustration 3.1 Product Nameplate (Example)
NOTICE
Do not remove the nameplate from the frequency
converter.
3.1.2 Storage
Ensure that the requirements for storage are fulfilled. Refer
to chapter 8.4 Ambient Conditions for further details.
3.2 Installation Environments
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 frequency converter. Ensure that
requirements for air humidity, temperature, and altitude
are met.
Vibration and Shock
The frequency converter complies with requirements for
units mounted on the walls and floors of production
premises, as well as in panels bolted to walls or floors.
For detailed ambient conditions specifications, refer to
chapter 8.4 Ambient Conditions.
3.3 Mounting
NOTICE
Improper mounting can result in overheating and
reduced performance.
Cooling
•Ensure that top and bottom clearance for air
cooling is provided. See Illustration 3.2 for
clearance requirements.
Mechanical Installation Operating Instructions
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33

a
a
130BD528.10
Enclosure A2-A5 B1-B4 C1, C3 C2, C4
a [mm] 100 200 200 225
Illustration 3.2 Top and Bottom Cooling Clearance
Lifting
•To determine a safe lifting method, check the
weight of the unit, see chapter 8.9 Power Ratings,
Weight, and Dimensions.
•Ensure that the lifting device is suitable for the
task.
•If necessary, plan for a hoist, crane, or forklift with
the appropriate rating to move the unit.
•For lifting, use the hoist rings on the unit, when
provided.
Mounting
1. Ensure that the strength of the mounting location
supports the unit weight. The frequency
converter allows side-by-side installation.
2. Locate the unit as near to the motor as possible.
Keep the motor cables as short as possible.
3. Mount the unit vertically to a solid flat surface or
to the optional back plate to provide cooling
airflow.
4. Use the slotted mounting holes on the unit for
wall mounting, when provided.
Mounting with back plate and railings
130BD504.10
Illustration 3.3 Proper Mounting with Back Plate
NOTICE
A back plate is required when mounted on railings.
C
a
b
130BA648.12
f
e
B
A
a
d
e
b
c
Illustration 3.4 Top and Bottom Mounting Holes (See
chapter 8.9 Power Ratings, Weight, and Dimensions)
a
e
f
130BA715.12
Illustration 3.5 Top and Bottom Mounting Holes (B4, C3, C4)
Mechanical Installation Operating Instructions
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33

4 Electrical Installation
4.1 Safety Instructions
See chapter 2 Safety for general safety instructions.
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors, even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•Run output motor cables separately, or
•Use screened cables
CAUTION
SHOCK HAZARD
The frequency converter can cause a DC current in the
PE conductor. Failure to follow the recommendation
below means the RCD may not provide the intended
protection.
•When a residual current-operated protective
device (RCD) is used for protection against
electrical shock, only an RCD of Type B is
permitted on the supply side.
Overcurrent protection
•Additional protective equipment, such as short
circuit protection or motor thermal protection
between frequency converter and motor, is
required for applications with multiple motors.
•Input fusing is required to provide short circuit
and overcurrent protection. If not factory-
supplied, fuses must be provided by the installer.
See maximum fuse ratings in chapter 8.8 Fuses
and Circuit Breakers.
Wire type and ratings
•All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•Power connection wire recommendation:
Minimum 75 °C rated copper wire.
See chapter 8.1 Electrical Data and chapter 8.5 Cable Specifi-
cations for recommended wire sizes and types.
4.2 EMC-compliant Installation
To obtain an EMC-compliant installation, follow the
instructions provided in chapter 4.3 Grounding,
chapter 4.4 Wiring Schematic, chapter 4.6 Motor Connection,
and chapter 4.8 Control Wiring.
4.3 Grounding
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
frequency converter properly could result in death or
serious injury.
•Ensure the correct grounding of the equipment
by a certified electrical installer.
For electrical safety
•Ground the frequency converter in accordance
with applicable standards and directives.
•Use a dedicated ground wire for input power,
motor power, and control wiring.
•Do not ground one frequency converter to
another in a daisy chain fashion.
•Keep the ground wire connections as short as
possible.
•Follow motor manufacturer wiring requirements.
•Minimum cable cross-section: 10 mm2(or 2 rated
ground wires terminated separately).
For EMC-compliant installation
•Establish electrical contact between the cable
screen and the frequency converter enclosure by
using metal cable glands or by using the clamps
provided on the equipment (see
chapter 4.6 Motor Connection).
•Use high-strand wire to reduce electrical
interference.
•Do not use pigtails.
NOTICE
POTENTIAL EQUALISATION
Risk of electrical interference, when the ground potential
between the frequency converter and the system is
different. Install equalising cables between the system
components. Recommended cable cross-section: 16 mm2.
Electrical Installation Operating Instructions
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44

4.4 Wiring Schematic
130BD552.12
3-phase
power
input
DC bus Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated
OFF=Open
Brake
resistor
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24 V OUT)
13 (+24 V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10 V DC
15 mA 200 mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0 V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10 V DC
0/-10 V DC -
+10 V DC
+10 V DC
0/4-20 mA
0/-10 V DC-
240 V AC, 2 A
24 V DC
02
01
05
04
06
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
19 (D IN)
24 V (NPN)
0 V (PNP)
27
24 V
0 V
(D IN/OUT)
0 V (PNP)
24 V (NPN)
(D IN/OUT)
0 V
24 V
29
24 V (NPN)
0 V (PNP)
0 V (PNP)
24 V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
A53
ON
21
A54
ON=0/4-20 mA
OFF=0/-10 V DC -
+10 V DC
95
P 5-00
21
ON
S801
(R+) 82
(R-) 81
: Chassis
: PE
**
240 V AC, 2 A
400 V AC, 2 A
*: Ground 1
: Ground 2
: Ground
Illustration 4.1 Basic Wiring Schematic
A=Analog, D=Digital
*Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off
Operating Instructions for Danfoss VLT
®
Frequency Converters.
**Do not connect cable screen.
Electrical Installation Operating Instructions
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130BD529.11
1
2
3
4
5
6
7
8
PE
U
V
W
9
L1
L2
L3
PE
10
11
1 PLC 6 Cable gland
2 Frequency converter 7 Motor, 3-phase and PE
3 Output contactor 8 Mains, 3-phase and reinforced PE
4 Grounding rail (PE) 9 Control wiring
5 Cable insulation (stripped) 10 Equalising min. 16 mm2(0.025 in)
Illustration 4.2 EMC-compliant Electrical Connection
NOTICE
EMC INTERFERENCE
Use screened cables for motor and control wiring and separate cables for input power, motor wiring, and control
wiring. Failure to isolate power, motor, and control cables can result in unintended behaviour or reduced performance.
Minimum clearance requirement between power, motor and control cables is 200 mm (7.9 in).
Electrical Installation Operating Instructions
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4.5 Access
•Remove the cover with a screw driver (See
Illustration 4.3) or by loosening the attaching
screws (See Illustration 4.4).
130BT248.10
Illustration 4.3 Access to Wiring for IP20 and IP21 Enclosures
130BT334.10
Illustration 4.4 Access to Wiring for IP55 and IP66 Enclosures
Tighten the cover screws using the tightening torques
specified in Table 4.1.
Enclosure IP55 IP66
A4/A5 2 2
B1/B2 2.2 2.2
C1/C2 2.2 2.2
No screws to tighten for A2/A3/B3/B4/C3/C4.
Table 4.1 Tightening Torques for Covers [Nm]
4.6 Motor Connection
WARNING
INDUCED VOLTAGE
Induced voltage from output motor cables that run
together can charge equipment capacitors, even with the
equipment turned off and locked out. Failure to run
output motor cables separately or use screened cables
could result in death or serious injury.
•Run output motor cables separately, or
•Use screened cables
•Comply with local and national electrical codes
for cable sizes. For maximum wire sizes see
chapter 8.1 Electrical Data.
•Follow motor manufacturer wiring requirements.
•Motor wiring knockouts or access panels are
provided at the base of IP21 (NEMA1/12) and
higher units.
•Do not wire a starting or pole-changing device
(e.g. Dahlander motor or slip ring induction
motor) between the frequency converter and the
motor.
Procedure
1. Strip a section of the outer cable insulation.
2. Position the stripped wire under the cable clamp
to establish mechanical fixation and electrical
contact between the cable screen and ground.
3. Connect the ground wire to the nearest
grounding terminal in accordance with the
grounding instructions provided in
chapter 4.3 Grounding, see Illustration 4.5.
4. Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W), see Illustration 4.5.
5. Tighten the terminals in accordance with the
information provided in chapter 8.7 Connection
Tightening Torques.
Electrical Installation Operating Instructions
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44

130BD531.10
U
VW
96
97
98
Illustration 4.5 Motor Connection
Illustration 4.6 represents mains input, motor, and earth
grounding for basic frequency converters. Actual configu-
rations vary with unit types and optional equipment.
95
130BB920.10
+DC
BR- B
MAINS
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
- LC -
U V W
MOTOR
99
Illustration 4.6 Example of Motor, Mains and Ground Wiring
4.7 AC Mains Connection
•Size the wiring based upon the input current of
the frequency converter. For maximum wire sizes,
see chapter 8.1 Electrical Data.
•Comply with local and national electrical codes
for cable sizes.
Procedure
1. Connect the 3-phase AC input power wiring to
terminals L1, L2, and L3 (see Illustration 4.6).
2. Depending on the configuration of the
equipment, connect the input power to the
mains input terminals or the input disconnect.
3. Ground the cable in accordance with the
grounding instructions provided in
chapter 4.3 Grounding.
4. When supplied from an isolated mains source (IT
mains or floating delta) or TT/TN-S mains with a
grounded leg (grounded delta), ensure that
14-50 RFI Filter is set to [0] Off to avoid damage to
the intermediate circuit and to reduce earth
capacity currents in accordance with IEC 61800-3.
4.8 Control Wiring
•Isolate the control wiring from the high power
components in the frequency converter.
•When the frequency converter is connected to a
thermistor, ensure that the thermistor control
wiring is screened and reinforced/double
insulated. A 24 V DC supply voltage is
recommended.
4.8.1 Control Terminal Types
Illustration 4.7 and Illustration 4.8 show the removable
frequency converter connectors. Terminal functions and
default settings are summarised in Table 4.2.
2
3
4
1
130BB921.11
Illustration 4.7 Control Terminal Locations
Electrical Installation Operating Instructions
16 Danfoss A/S © Rev. 05/2014 All rights reserved. MG20MB02
44

12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
130BB931.10
1
2 3
Illustration 4.8 Terminal Numbers
•Connector 1 provides:
-4 programmable digital inputs terminals.
-2 additional digital terminals
programmable as either input or output.
-24 V DC terminal supply voltage.
-Optional customer supplied 24 V DC
voltage.
•Connector 2 terminals (+)68 and (-)69 are for an
RS-485 serial communication connection.
•Connector 3 provides:
-2 analog inputs.
-1 analog output.
-10 V DC supply voltage.
-Commons for the inputs and output.
•Connector 4 is a USB port available for use with
the MCT 10 Set-up Software.
Terminal description
Terminal Parameter
Default
setting Description
Digital Inputs/Outputs
12, 13 - +24 V DC 24 V DC supply voltage
for digital inputs and
external transducers.
Maximum output
current 200 mA for all
24 V loads.
18 5-10 [8] Start
Digital inputs.
19 5-11 [0] No
operation
32 5-14 [0] No
operation
33 5-15 [0] No
operation
27 5-12 [2] Coast
inverse
For digital input or
output. Default setting
is input.
29 5-13 [14] JOG
Terminal description
Terminal Parameter
Default
setting Description
20 - Common for digital
inputs and 0 V
potential for 24 V
supply.
37 - Safe Torque
Off (STO)
Safe input (optional).
Used for STO.
Analog Inputs/Outputs
39 - Common for analog
output
42 6-50 Speed 0 -
High Limit
Programmable analog
output. 0-20 mA or
4-20 mA at a maximum
of 500 Ω
50 - +10 V DC 10 V DC analog supply
voltage for potenti-
ometer or thermistor.
15 mA maximum
53 6-1 Reference Analog input. For
voltage or current.
Switches A53 and A54
select mA or V.
54 6-2 Feedback
55 - Common for analog
input
Serial Communication
61 - Integrated RC-Filter for
cable screen. ONLY for
connecting the screen
in the event of EMC
problems.
68 (+) 8-3 RS-485 Interface. A
control card switch is
provided for
termination resistance.
69 (-) 8-3
Relays
01, 02, 03 5-40 [0] [9] Alarm Form C relay output.
For AC or DC voltage
and resistive or
inductive loads.
04, 05, 06 5-40 [1] [5] Running
Table 4.2 Terminal Description
Additional terminals:
•2 form C relay outputs. Location of the outputs
depends on frequency converter configuration.
•Terminals located on built-in optional equipment.
See the manual provided with the equipment
option.
Electrical Installation Operating Instructions
MG20MB02 Danfoss A/S © Rev. 05/2014 All rights reserved. 17
44

4.8.2 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
frequency converter for ease of installation, as shown in
Illustration 4.7.
NOTICE
Keep control wires as short as possible and separate
from high power cables to minimise interference.
1. Open the contact by inserting a small screwdriver
into the slot above the contact and push the
screwdriver slightly upwards.
130BD546.10
2
1
10 mm
29
27 32
19
18
13
12 33
Illustration 4.9 Connecting Control Wires
2. Insert the bared control wire into the contact.
3. Remove the screwdriver to fasten the control wire
into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
See chapter 8.5 Cable Specifications for control terminal
wiring sizes and chapter 6 Application Set-up Examples for
typical control wiring connections.
4.8.3 Enabling Motor Operation (Terminal
27)
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to operate
when using factory default programming values.
•Digital input terminal 27 is designed to receive 24
V DC external interlock command.
•When no interlock device is used, wire a jumper
between control terminal 12 (recommended) or
13 to terminal 27. This provides an internal 24 V
signal on terminal 27.
•When the status line at the bottom of the LCP
reads AUTO REMOTE COAST, this indicates that the
unit is ready to operate but is missing an input
signal on terminal 27.
•When factory installed optional equipment is
wired to terminal 27, do not remove that wiring.
NOTICE
The frequency converter cannot operate without a signal
on terminal 27, unless terminal 27 is re-programmed.
4.8.4 Voltage/Current Input Selection
(Switches)
The analog input terminals 53 and 54 allow setting of
input signal to voltage (0-10 V) or current (0/4-20 mA).
Default parameter settings:
•Terminal 53: speed reference signal in open loop
(see 16-61 Terminal 53 Switch Setting).
•Terminal 54: feedback signal in closed loop (see
16-63 Terminal 54 Switch Setting).
NOTICE
Disconnect power to the frequency converter before
changing switch positions.
1. Remove the LCP (or Local Control Panel) (see
Illustration 4.10).
2. Remove any optional equipment covering the
switches.
3. Set switches A53 and A54 to select the signal
type. U selects voltage, I selects current.
130BD530.10
12
N O
VLT
BUSTER.
OFF-ON
A53 A54
U- I U- I
Illustration 4.10 Location of Terminal 53 and 54 Switches
Electrical Installation Operating Instructions
18 Danfoss A/S © Rev. 05/2014 All rights reserved. MG20MB02
44