Danfoss vlt aqua User manual

Contents
1. How to Read these Operating Instructions
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 3
Symbols 3
2. Safety 5
General Warning 6
Before Commencing Repair Work 6
Special conditions 6
Avoid unintended Start 7
Safe Stop of the Frequency Converter (optional) 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 31
Motor wiring overview 32
How to Test Motor and Direction of Rotation. 37
6. Application Examples 45
Closed Loop Wiring 45
Submersible Pump Application 46
7. How to operate the frequency converter 49
Ways of Operation 49
How to operate graphical LCP (GLCP) 49
How to operate numeric LCP (NLCP) 54
Tips and tricks 57
8. How to programme the frequency converter 61
How to programme 61
Q1 My Personal Menu 62
Q2 Quick Setup 62
Q5 Changes Made 65
VLT
®
AQUA Drive
Operating Instructions Contents
MG.20.M4.02 - VLT®is a registered Danfoss trademark 1

Q6 Loggings 65
Common Used Parameters - Explanations 67
Main Menu 67
Parameter Options 99
How to Read the Parameter Tabels 99
Operation/Display 0-** 100
Load/Motor 1-** 102
Brakes 2-** 103
Reference / Ramps 3-** 104
Limits / Warnings 4-** 105
Digital In/Out 5-** 106
Analog In/Out 6-** 107
Comm. and Options 8-** 108
Profibus 9-** 109
CAN Fieldbus 10-** 110
Smart Logic 13-** 111
Special Functions 14-** 112
FC Information 15-** 113
Data Readouts 16-** 115
Data Readouts 2 18-** 117
FC Closed Loop 20-** 118
Ext. Closed Loop 21-** 119
Application Functions 22-** 120
Timed Actions 23-** 122
Cascade Controller 25-** 123
Analog I/O Option MCB 109 26-** 125
Cascade CTL Option 27-** 126
Water Application Functions 29-** 127
Bypass Option 31-** 128
9. Troubleshooting 129
Warning/Alarm list 131
10. Specifications 135
General Specifications 135
Special Conditions 150
Index
155
Contents
VLT
®
AQUA Drive
Operating Instructions
2 MG.20.M4.02 - 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 . By accepting and using this manual the user agrees that the information contained herein will be
used solely for operating equipment from or equipment from other vendors provided that such equipment is intended for communication with equipment
over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.
does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware
or software environment.
Although has tested and reviewed the documentation within this manual, 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 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, 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.
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 customer applications.
-Programming Guide MG.20.OX.YY provides information on how to programme and includes 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+Documenta-
tion.
1.1.2. Approvals
1.1.3. Symbols
Symbols used in these Operating Instructions.
NB!
Indicates something to be noted by the reader.
VLT
®
AQUA Drive
Operating Instructions 1. How to Read these Operating Instructions
MG.20.M4.02 - VLT®is a registered Danfoss trademark 3
1

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.M4.02 - VLT®is a registered Danfoss trademark
1

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 damage to the equipment, serious personal injury or death. Consequently, the instructions 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 disconnect 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 protected 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 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 considerations 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 disconnected from mains.
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.
VLT
®
AQUA Drive
Operating Instructions 2. Safety
MG.20.M4.02 - VLT®is a registered Danfoss trademark 5
2

2.1.2. General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected 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.
525 - 600 V, 1.1 - 7.5 kW, wait at least 4 minutes.
525 - 600 V, 110 - 250 kW, wait at least 20 minutes.
525 - 600 V, 315 - 560 kW, wait at least 30 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. According 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 delayed) 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 expected to be used in most applications.
The frequency converters also support other special applications, whichaffect the electrical ratings of the frequency converter. Special
conditions which affect the electrical 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.
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. Safety
VLT
®
AQUA Drive
Operating Instructions
6 MG.20.M4.02 - VLT®is a registered Danfoss trademark
2

2.1.5. Caution
The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,
disconnect the frequency converter 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. 20 min. 30 min.
200 - 240 V 0.25 - 3.7 kW 5.5 - 45 kW
380 - 480 V 0.37 - 7.5 kW 11 - 90 kW 110 - 250 kW 315 - 450 kW
525-600 V 0.75 kW - 7.5 kW 110 - 250 kW 315 - 560 kW
525-690 V 45 - 400 kW 450 - 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/stopped 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 (optional)
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!
VLT
®
AQUA Drive
Operating Instructions 2. Safety
MG.20.M4.02 - VLT®is a registered Danfoss trademark 7
2

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 between 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.
2.1.9. Software Version and Approvals: VLT AQUA Drive
VLT AQUA Drive
Operating Instructions
Software version: 1.05
This Operating Instructions can be used for all VLT AQUA Drive frequency converters with software version 1.05.
The software version number can be seen from parameter 15-43.
2. Safety
VLT
®
AQUA Drive
Operating Instructions
8 MG.20.M4.02 - VLT®is a registered Danfoss trademark
2

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 leg-
islation.
VLT
®
AQUA Drive
Operating Instructions 2. Safety
MG.20.M4.02 - VLT®is a registered Danfoss trademark 9
2

3. Introduction
VLT
®
AQUA Drive
Operating Instructions
10 MG.20.M4.02 - VLT®is a registered Danfoss trademark
3

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.
VLT
®
AQUA Drive
Operating Instructions 3. Introduction
MG.20.M4.02 - VLT®is a registered Danfoss trademark 11
3

3.1.2. Type Code String
Description Pos Possible choice
Product group & VLT Series 1-6 FC 202
Power rating 8-10 0.25 - 630 kW
Number of phases 11 Three phases (T)
Mains voltage 11-12
T 2: 200-240 VAC
T 4: 380-480 VAC
T 6: 525-600 VAC
T 7:
Enclosure 13-15
E20: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E2M: IP21/NEMA Type 1 w/mains shield
E5M: IP 55/NEMA Type 12 w/mains shield
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: RFI filter class A2
H3: RFI filter class A1/B (reduced cable length)
H4: RFI filter class A2/A1
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
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
B options 31-32
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO:MCB 109 Analog I/O option
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
12 MG.20.M4.02 - VLT®is a registered Danfoss trademark
3

3.1.3. Abbreviations and Standards
Abbreviations: Terms: SI-units: I-P units:
Acceleration m/s2ft/s2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°CCelsius
Current AAmp
ILIM Current limit
Energy J = N·m ft-lb, Btu
°F Fahrenheit
FC Frequency Converter
Frequency Hz Hz
kHz Kilohertz
LCP Local Control Panel
mA Milliampere
ms Millisecond
min Minute
MCT Motion Control Tool
M-TYPE Motor Type Dependent
Nm Newton Metres in-lbs
IM,N Nominal motor current
fM,N Nominal motor frequency
PM,N Nominal motor power
UM,N Nominal motor voltage
par. Parameter
PELV Protective Extra Low Voltage
Power WBtu/hr, hp
Pressure Pa = N/m² psi, psf, ft of water
IINV Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
Temperature ˚C˚F
Time ss,hr
TLIM Torque limit
Voltage V V
Table 3.2: Abbreviation and Standards table .
VLT
®
AQUA Drive
Operating Instructions 3. Introduction
MG.20.M4.02 - VLT®is a registered Danfoss trademark 13
3

4. Mechanical installation
VLT
®
AQUA Drive
Operating Instructions
14 MG.20.M4.02 - VLT®is a registered Danfoss trademark
4

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/ 21)
A3
(IP 20/21)
A5
(IP 55/ 66)
B1/B3
(IP20/ 21/ 55/
66)
B2/B4
(IP20/ 21/
55/66)
C1/C3
(IP20/21/ 55/66)
C2/C4
(IP20/21/ 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 - 30
kW
37 - 45
kW
380-480 V 0.37-4.0
kW 5.5-7.5 kW 0.37-7.5 kW
11-18.5
kW
22-37
kW
37 - 55
kW
75 - 90
kW
525-600 V 0.75-4.0
kW 5.5-7.5 kW 0.75-7.5 kW
11-18.5
kW
22-37
kW 45-55 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.
VLT
®
AQUA Drive
Operating Instructions 4. Mechanical installation
MG.20.M4.02 - VLT®is a registered Danfoss trademark 15
4

4.2. How to install
4.2.1. Checklist
Please use the following table to follow mounting instructions
Enclosure: A2
(IP 20/
21)
A3
(IP 20/
21)
A5
(IP 55/
66)
B1 /B3
(IP
20/ 21/
55/66)
B2 /B4
(IP20/ 21/
55/66)
C1/C3
(IP20/21/ 55/66)
C2/C4
(IP20/21/
55/66)
Unit size:
200-240 V 0.25-3.0
kW
3.7
kW
0.25-3.7
kW 5.5-11 kW 15 kW
18.5-30
kW
37-45
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
525-600 V 0.75-4.0 kW 5.5-7.5 kW 0.75-7.5 kW 11-18.5
kW
22-37
kW 45-55 kW 75-90 kW
Table 4.2: Mounting table.
The frequency converter can be mounted side by side for all IP rating units and requires 100 mm free space above and below for cooling. With regard
to ambient temperature ratings, please see Special Conditions.
4. Mechanical installation
VLT
®
AQUA Drive
Operating Instructions
16 MG.20.M4.02 - VLT®is a registered Danfoss trademark
4

Illustration 4.1: Side by side mounting of all frame sizes.
Illustration 4.2: This is the correct way to mount the unit.
VLT
®
AQUA Drive
Operating Instructions 4. Mechanical installation
MG.20.M4.02 - VLT®is a registered Danfoss trademark 17
4

Illustration 4.3: Other than A2 and A3 enclosures do not mount units
as shown without back plate. 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
position 14-15). A2 and A3 units have back-plate as standard.
4. Mechanical installation
VLT
®
AQUA Drive
Operating Instructions
18 MG.20.M4.02 - VLT®is a registered Danfoss trademark
4

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.
VLT
®
AQUA Drive
Operating Instructions 4. Mechanical installation
MG.20.M4.02 - VLT®is a registered Danfoss trademark 19
4

Mechanical dimensions
Voltage
200-240 V Frame size A2 0.25-3.0 kW Frame size A3 3.7 kW
Voltage
380-480 V 0.37-4.0 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.M4.02 - VLT®is a registered Danfoss trademark
4