Danfoss vlt aqua User manual

Contents
1. How to Read these Operating Instructions
5
Copyright, Limitation of Liability and Revision Rights 5
Approvals 5
Symbols 6
2. Safety 7
General Warning 8
Before Commencing Repair Work 8
Special conditions 8
Avoid unintended Start 9
Safe Stop Installation 9
Safe Stop of the Frequency Converter 11
IT Mains 13
3. How to Install 15
How to Get Started 15
Pre-installation 15
Planning the Installation Site 15
Receiving the Frequency Converter 16
Transportation and Unpacking 16
Lifting 16
Rated Power 18
Mechanical Dimensions 19
Mechanical Installation 19
Tools Needed 19
General Considerations 20
Installation in Enclosures - IP00 / Chassis units 29
Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 29
Floor Mounting - Pedestal Installation IP21 (NEMA1) and IP54 (NEMA12) 30
Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 32
IP21 Drip shield installation (D1 and D2 enclosure) 33
Field Installation of Options 33
Installation on pedestal 43
Electrical Installation 46
Control Wires 46
Power Connections 47
Mains connection 55
Fuses 56
Electrical Installation, Control Terminals 58
VLT AQUA High Power Operation Instructions Contents
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Connection Examples 60
Start/Stop 60
Pulse Start/Stop 60
Speed Up/Down 61
Potentiometer Reference 61
Electrical Installation - continued 62
Electrical Installation, Control Cables 62
Switches S201, S202, and S801 64
Final Set-up and Test 65
Additional Connections 67
Motor Thermal Protection 67
4. How to programme the frequency converter 69
How to programme 69
Initialisation to Default Settings 96
Parameter Options 97
Default settings 97
0-** Operation/Display 98
1-** Load/Motor 100
2-** Brakes 101
3-** Reference / Ramps 102
4-** Limits / Warnings 103
5-** Digital In/Out 104
6-** Analog In/Out 106
8-** Comm. and Options 108
9-** Profibus 109
10-**CAN Fieldbus 110
13-** Smart Logic 111
14-** Special Functions 112
15-** FC Information 113
16-** Data Readouts 115
18-** Data Readouts 2 117
20-** FC Closed Loop 118
21-** Ext. Closed Loop 119
22-** Application Functions 121
23-** Timed Actions 123
25-** Cascade Controller 124
26-** Analog I/O Option MCB 109 126
29-** Water Application Functions 127
31-** Bypass Option 128
Contents VLT AQUA High Power Operation Instructions
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5. General Specifications 129
6. Troubleshooting 137
Warning/Alarm list 139
7. Annexes 143
Index
149
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1. How to Read these Operating Instructions VLT AQUA High Power Operation Instructions
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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
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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
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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.
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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:
380 - 480 V, 110 - 450 kW, wait at least 15 minutes.
525 - 690 V, 132 - 630 kW, wait at least 20 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.
Consult the relevant clauses in these instructions and in the VLT
®
AQUA Drive Design Guide
for information about the electrical ratings.
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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
15 min. 20 min.
380 - 480 V 110 - 450 kW
525 - 690 V 132 - 630 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 Installation
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformity with
Safety Category 3 (EN954-1), follow
these instructions:
1. The bridge (jumper) between Termi-
nal 37 and 24 V DC must be re-
moved. Cutting or breaking the
jumper is not sufficient. Remove it
entirely to avoid short-circuiting. See
jumper on illustration.
2. Connect terminal 37 to 24 V DC by a
short-circuit protected cable. The 24
V DC voltage supply must be inter-
ruptible by an EN954-1 Category 3
circuit interrupt device. If the inter-
rupt device and the frequency con-
verter are placed in the same instal-
lation panel, you can use an
unscreened cable instead of a
screened one.
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Illustration 2.1: Bridge jumper between terminal
37 and 24 VDC
The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how
to connect a non-safety related hardware coast.
Illustration 2.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN
60204-1) with safety Category 3 (EN 954-1).
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2.1.8. 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
be followed! The information and instructions of the Operating Instructions are not sufficient for
a correct and safe use of the Safe Stop functionality!
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2. Safety VLT AQUA High Power Operation Instructions
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2.1.9. 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.
2.1.10. 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.
2.1.11. 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.
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3. How to Install VLT AQUA High Power Operation Instructions
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3. How to Install
3.1. How to Get Started
3.1.1. About How to Install
This chapter covers mechanical and electrical installations to and from power terminals and control
card terminals.
Electrical installation of
options is described in the relevant Operating Instructions and Design
Guide.
3.1.2. How to Get Started
The frequency converter is designed to achieve a quick and EMC-correct installation by following
the steps described below.
Read the safety instructions before installing the unit.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Mains and Protecting
Earth
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick setup
• Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is depending on enclosure type,
power range and mains voltage
Illustration 3.1: Diagram showing basic installa-
tion including mains, motor, start/stop key, and
potentiometer for speed adjustment.
3.2. Pre-installation
3.2.1. Planning the Installation Site
NB!
Before performing the installation it is important to plan the installation of the fre-
quency converter. Neglecting this may result in extra work during and after instal-
lation.
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Select the best possible operation site by considering the following (see details on
the following pages, and the respective Design Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the frequency converter
•Cablerouting
• Ensure the power source supplies the correct voltage and necessary current
• Ensure that the motor current rating is within the maximum current from the frequency
converter
• If the frequency converter is without built-in fuses, ensure that the external fuses are
rated correctly.
3.2.2. Receiving the Frequency Converter
When receiving the frequency converter please make sure that the packaging is intact, and be
aware of any damage that might have occurred to the unit during transport. In case damage has
occurred, contact immediately the shipping company to claim the damage.
3.2.3. Transportation and Unpacking
Before unpacking the frequency converter it is recommended that it is located as close as possible
to the final installation site.
Remove the cardboard box and handle the frequency converter on the pallet, as long as possible.
Remark: The card box cover contains a drilling master for the mounting holes.
Illustration 3.2: Mounting Template
3.2.4. Lifting
Always lift the frequency converter in the dedicated lifting eyes. Use a bar to avoid bending the
lifting holes of the frequency converter.
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Illustration 3.3: Recommended lifting method
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Enclosure type
D1 D2 D3 D4 E1 E2
Enclosure protection
IP 21/54 21/54 00 00 21/54 00 NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis Type 1/ Type 12 Chassis
Rated power
110 - 132 kW at 400 V
(380 - 480 V)
110 - 160 kW at 600 V
(525-690 V)
150 - 250 kW at 400 V
(380 - 480 V)
200 - 400 kW at 600 V
(525-690 V)
110 - 132 kW at 400 V
(380 - 480 V)
132 - 160 kW at 600 V
(525-690 V)
150 - 250 kW at 400 V
(380 - 480 V)
200 - 400 kW at 600 V
(525-690 V)
315 - 450 kW at 400 V
(380 - 480 V)
450 - 630 kW at 600 V
(525-690 V)
315 - 450 kW at 400 V
(380 - 480 V)
450 - 630 kW at 600 V
(525-690 V)
3.3.1. Rated Power
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3.3.2. Mechanical Dimensions
Mechanical dimensions , D Enclosures
Frame size D1 D2 D3 D4
110 - 132 kW
(380 - 480 V)
132 - 160 kW
(525 - 690 V)
150 - 250 kW
(380 - 480 V)
200 - 400 kW
(525 - 690 V)
110 - 132 kW
(380 - 480 V)
132 - 160 kW
(525 - 690 V)
150 - 250 kW
(380 - 480 V)
200 - 400 kW
(525-690 V)
IP
NEMA 21
Type 1
54
Type 12
21
Type 1
54
Type 12
00
Chassis
00
Chassis
Card board box
size
Shipping dimen-
sions
Height
650 mm 650 mm 650 mm 650 mm 650 mm 650 mm
Width 1730
mm 1730 mm 1730 mm 1730 mm 1220 mm 1490 mm
Depth 570 mm 570 mm 570 mm 570 mm 570 mm 570 mm
Drive dimensions Height 1159
mm 1159 mm 1540 mm 1540 mm 997 mm 1277 mm
Width 420 mm 420 mm 420 mm 420 mm 408 mm 408 mm
Depth 373 mm 373 mm 373 mm 373 mm 373 mm 373 mm
Max
weight 104 kg 104 kg 151 kg 151 kg 91 kg 138 kg
Mechanical dimensions, E Enclosures
Frame size E1 E2
315 - 450 kW
(380 - 480 V)
450 - 630 kW
(525-690 V)
315 - 450 kW
(380 - 480 V)
450 - 630 kW
(525-690 V)
IP
NEMA 21 Type 12
54
Type 12
00
Chassis
Card board box size
Shipping dimensions Height 840 mm 840 mm 831 mm
Width 2197 mm 2197 mm 1705 mm
Depth 736 mm 736 mm 736 mm
Drive dimensions Height 2000 mm 2000 mm 1499 mm
Width 600 mm 600 mm 585 mm
Depth 494 mm 494 mm 494 mm
Max
weight 313 kg 313 kg 277 kg
3.4. Mechanical Installation
Preparation of the mechanical installation of the frequency converter must be done carefully to
ensure a proper result and to avoid additional work during installation. Start taking a close look
at the mechanical drawings at the end of this instruction to become familiar with the space de-
mands.
3.4.1. Tools Needed
To perform the mechanical installation the following tools are needed:
• Drill with 10 or 12 mm drill
• Tape measure
• Wrench with relevant metric sockets (7-17 mm)
• Extensions to wrench
• Sheet metal punch for conduits or cable glands in IP 21 and IP 54 units
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• Lifting bar to lift the unit (rod or tube Ø 20 mm (0.75 inch)) able to lift minimum 400 kg
(880 lbs).
• Crane or other lifting aid to place the frequency converter in position
• A Torx T50 tool is needed to install the E1 enclosure in IP21 and IP54 enclosure types.
3.4.2. General Considerations
Space
Ensure proper space above and below the frequency converter to allow airflow and cable access.
In addition space in front of the unit must be considered to enable opening of the door of the
panel.
Illustration 3.4: Space in front of IP21/IP54 enclo-
sure type D1 and D2.
Illustration 3.5: Space in front of IP21/IP54 enclo-
sure type E1.
Illustration 3.6: Airflow direction and necessary space for cooling
Left: Enclosure IP21/54, D1 and D2.
Right: Enclosure IP00, D3, D4 and E2.
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