Danfoss vlt aqua User manual

Contents
1 How to Read this Instruction Manual
1-1
Copyright, Limitation of Liability and Revision Rights 1-1
Approvals 1-2
Symbols 1-2
2 Safety 2-1
General Warning 2-2
Before Commencing Repair Work 2-2
Special conditions 2-2
Avoid unintended Start. 2-3
Safe Stop of the Adjustable Frequency Drive (optional) 2-4
IT Line Power 2-4
3 Introduction 3-1
Type Code String 3-1
4 Mechanical installation 4-1
Before starting 4-1
5 Electrical installation 5-1
How to connect 5-1
Line power wiring overview 5-6
Motor wiring overview 5-13
DC bus connection 5-18
Brake Connection Option 5-18
Relay Connection 5-20
Electrical Installation and Control Cables 5-25
How to Test Motor and Direction of Rotation. 5-26
6 Application Examples 6-1
Closed-loop Wiring 6-1
Submersible Pump Application 6-2
7 How to operate the adjustable frequency drive 7-1
Ways of Operation 7-1
How to operate the Graphical LCP (GLCP) 7-1
How to operate the numeric LCP (NLCP) 7-6
Tips and tricks 7-9
VLT
®
AQUA Drive
Instruction Manual Contents
MG.20.M5.22 - VLT®is a registered Danfoss trademark

8 How to program the adjustable frequency drive 8-1
How to program 8-1
Q1 My Personal Menu 8-2
Q2 Quick Set-up 8-3
Q5 Changes Made 8-6
Q6 Loggings 8-6
Commonly Used Parameters - Explanations 8-8
Main Menu 8-8
Parameter Options 8-47
Default settings 8-47
0-** Operation/Display 8-48
1-** Load/Motor 8-50
2-** Brakes 8-51
3-** Reference / Ramps 8-52
4-** Limits / Warnings 8-53
5-** Digital In/Out 8-54
6-** Analog In/Out 8-56
8-** Comm. and Options 8-58
9-** Profibus 8-59
10-**CAN Ser. Com. Bus 8-60
13-** Smart Logic 8-61
14-** Special Functions 8-62
15-** FC Information 8-63
16-** Data Readouts 8-65
18-** Data Readouts 2 8-67
20-** FC Closed-loop 8-68
21-** Ext. Closed-loop 8-69
22-** Application Functions 8-71
23-** Timed Actions 8-73
25-** Cascade Controller 8-74
26-** Analog I/O Option MCB 109 8-76
Cascade CTL Option 27-** 8-77
29-** Water Application Functions 8-79
31-** Bypass Option 8-80
9 Troubleshooting 9-1
Fault messages 9-3
Contents
VLT
®
AQUA Drive
Instruction Manual
MG.20.M5.22 - VLT®is a registered Danfoss trademark

10 Specifications 10-1
General Specifications 10-1
Special Conditions 10-17
11 Index 11-1
VLT
®
AQUA Drive
Instruction Manual Contents
MG.20.M5.22 - VLT®is a registered Danfoss trademark

Contents
VLT
®
AQUA Drive
Instruction Manual
MG.20.M5.22 - VLT®is a registered Danfoss trademark

1 How to Read this Instruction Manual
1.1.1 Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss. By accepting and using this manual, the user agrees that the information contained herein
will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication
with Danfoss equipment over a serial communication link. This publication is protected under the copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical,
hardware and software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss 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 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 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 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.
VLT
®
AQUA Drive
Instruction Manual 1 How to Read this Instruction Manual
MG.20.M5.22 - VLT®is a registered Danfoss trademark 1-1
1

This Instruction Manual will introduce all aspects of your VLT AQUA Drive.
Available literature for VLT AQUA Drive:
-The Instruction Manual MG.20.MX.YY provides the necessary information for getting the drive up and running.
-The Design Guide MG.20.NX.YY contains technical information about the drive design and customer applications.
-The Programming Guide MG.20.OX.YY provides information on how to program 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 this Instruction Manual.
NOTE!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates a default setting
1 How to Read this Instruction Manual
VLT
®
AQUA Drive
Instruction Manual
1-2 MG.20.M5.22 - VLT®is a registered Danfoss trademark
1

2Safety
2.1.1 Safety note
The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor,
adjustable frequency drive or serial communication bus may cause damage to the equipment, serious personal injury or death. Con-
sequently, the instructions in this manual, as well as national and local rules and safety regulations, must be followed.
Safety Regulations
1. The adjustable frequency drive must be disconnected from line power if repair work is to be carried out. Make sure that the line power supply
has been disconnected and that the necessary time has passed before removing motor and line plugs.
2. The [STOP/RESET] key on the control panel of the adjustable frequency drive does not disconnect the equipment from line power and is thus
not to be used as a safety switch.
3. Correct protective grounding 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 ground 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 initialized 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 line power supply while the adjustable frequency drive is connected to line power. Make sure that
the line power supply has been disconnected and that the necessary time has passed before removing motor and line plugs.
7. Please note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3 when load sharing (linking of the DC intermediate
circuit) and external 24 V DC have been installed. Make sure that all voltage inputs have been disconnected and that the necessary time has
passed before commencing repair work.
Installation at High Altitudes
At altitudes higher than 6,600 feet [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 adjustable frequency drive is
connected to line power. 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 adjustable frequency drive, or if a temporary
overload or a fault in the supply line or the motor connection ceases.
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.
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 backup.
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®
AQUA Drive
Instruction Manual 2 Safety
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2.1.2 General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.
Also make sure that other voltage inputs have been disconnected, (linkage of DC intermediate circuit), as well as the motor connection
for kinetic backup.
Before touching any potentially live parts of the VLT AQUA Drive FC 200, wait at least the minimum time as follows:
200–240 V, [0.25–3.7 kW]: wait at least 4 minutes.
200–240 V, 7.5–60 hp [5.5–45 kW]: wait at least 15 minutes.
380–480 V, 5–10 hp [0.37–7.5 kW]: wait at least 4 minutes.
380–480 V, 15–125 hp [11–90 kW]: wait at least 15 minutes.
525–600 V, 1.5–10 hp [1.1–7.5 kW]: wait at least 4 minutes.
525–600 V, 150–350 hp [110–250 kW]: wait at least 20 minutes.
525–600 V, 175–750 hp [315–560 kW], wait at least 30 minutes.
A shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The ground leakage current from the VLT AQUA Drive FC 200 exceeds 3.5 mA. According to IEC 61800-5-1, a reinforced protective
ground connection must be ensured by means of: a min. 0.016 in² [10 mm²] Cu or 0.025 in² [16 mm²] Al PE-wire, or an additional
PE wire - with the same cable cross-section as the line power wiring - must be terminated separately.
Residual Current Device
This product can cause DC 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 grounding of the VLT AQUA Drive FC 200 and the use of RCDs must always follow national and local regulations.
2.1.3 Before Commencing Repair Work
1. Disconnect the adjustable frequency drive from line power.
2. Disconnect DC bus terminals 88 and 89.
3. Wait at least the time mentioned above in the section General Warning.
4. Remove motor cable
2.1.4 Special conditions
Electrical ratings:
The rating indicated on the nameplate of the adjustable frequency drive is based on a typical 3-phase line power supply within the specified voltage,
current and temperature ranges, which are expected to be used in most applications.
The adjustable frequency drives also support other special applications, which affect the electrical ratings of the adjustable frequency
drive. Special conditions that 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.
2 Safety
VLT
®
AQUA Drive
Instruction Manual
2-2 MG.20.M5.22 - VLT®is a registered Danfoss trademark
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Installation requirements:
The overall electrical safety of the adjustable frequency drive requires special installation considerations regarding:
• Fuses and circuit breakers for overcurrent and short-circuit protection
• Selection of power cables (line power, motor, brake, load sharing 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 adjustable frequency drive DC link capacitors remain charged after power has been disconnected. To avoid the risk of electrical
shock, disconnect the adjustable frequency drive from the line power before performing maintenance procedures. Wait at least as long
as follows before servicing the adjustable frequency drive:
Voltage Min. Waiting Time
4 min. 15 min. 20 min. 30 min.
200–240 V 0.34–5 hp [0.25–3.7 kW] 7.5–60 hp [5.5–45 kW]
380–480 V 0.5–10 hp [0.37–7.5 kW] 11–90 kW 150–160 hp [110–250 kW] 450–600 hp [315–450 kW]
525–600 V 1–10 hp [0.75 kW–7.5 kW] 150–160 hp [110–250 kW] 450–750 hp [315–560 kW]
525–690 V 60–550 hp [45–400 kW] 600–850 hp [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 adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus
commands, references or via the Local Control Panel.
• Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to avoid an unintended
start.
• To avoid an 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 line power supply or lost motor connection may cause a
stopped motor to start.
VLT
®
AQUA Drive
Instruction Manual 2 Safety
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2.1.7 Safe Stop of the Adjustable Frequency Drive (optional)
For versions fitted with a safe stop terminal 37 input, the adjustable frequency drive 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 deemed suitable for the requirements of Safety Category 3 in EN 954-1. This function is called safe stop. Prior to integrating and using
safe stop in an installation, a thorough risk analysis must be carried out on the installation 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 contained in the Instruction Manual are not sufficient for a correct and safe use of the safe stop functionality!
2.1.8 IT Line Power
IT Line Power
Do not connect 400 V adjustable frequency drives with RFI filters to line supplies with a voltage between phase and ground of more
than 440 V.
For IT line power and delta ground (grounded leg), AC line voltage may exceed 440 V between phase and ground.
par. 14-50 RFI 1 can be used to disconnect the internal RFI capacitors from the RFI filter to ground. If this is done, it will reduce the RFI performance
to A2 level.
2 Safety
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®
AQUA Drive
Instruction Manual
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2.1.9 Software Version and Approvals
VLT AQUA Drive
Software version: 1.24
This manual can be used with all VLT AQUA Drive adjustable frequency drives with software version 1.24.
The software version number can be found in parameter 15-43.
2.1.10 Disposal Instructions
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
Instruction Manual 2 Safety
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2 Safety
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®
AQUA Drive
Instruction Manual
2-6 MG.20.M5.22 - VLT®is a registered Danfoss trademark
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3Introduction
3.1 Introduction
3.1.1 Type Code String
VLT
®
AQUA Drive
Instruction Manual 3 Introduction
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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)
AC line voltage 11-12
S2: 220–240 V AC single phase
S4: 380–480 V AC single phase
T 2: 200–240 V AC
T 4: 380–480 V AC
T 6: 525–600 V AC
T 7: 525–690 V AC
Enclosure 13-15
E20: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E2M: IP21/NEMA Type 1 w/ line power shield
E5M: IP 55/NEMA Type 12 w/ line power shield
E66: IP66
F21: IP21 kit without backplate
G21: IP21 kit with backplate
P20: IP20/chassis with backplate
P21: IP21/NEMA Type 1 w/ backplate
P55: IP55/NEMA Type 12 w/ backplate
RFI filter 16-17
HX: No RFI filter
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
Line power option 21
D: Loadsharing
X: No line power disconnect switch
1: With line power disconnect switch
8: Line Power Disconnect + Loadsharing
Adaptation 22 Reserved
Adaptation 23 Reserved
Software release 24-27 Current 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 backup
The various options are described further in the VLT AQUA Drive Design Guide .
Table 3.1: Type code description.
3 Introduction
VLT
®
AQUA Drive
Instruction Manual
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3.1.2 Adjustable Frequency Drive Identification
Below is an example of an identification label. This label is situated on the adjustable frequency drive and shows the type and the options with which the
unit is equipped. See table 2.1 for details of how to read theType code string (T/C).
Figure 3.1: This example shows an identification label for the VLT AQUA Drive.
Please have T/C (type code) number and serial number ready before contacting Danfoss.
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∙mft-lb, Btu
°FFahrenheit
FC Adjustable Frequency Drive
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 meters 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
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®
AQUA Drive
Instruction Manual 3 Introduction
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3 Introduction
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®
AQUA Drive
Instruction Manual
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4 Mechanical installation
4.1 Before starting
4.1.1 Checklist
When unpacking the adjustable frequency drive, make sure 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 (kW):
200–240 V 0.25–3.0 3.7 0.25–3.7 5.5–11/
5.5–11
15/
15–18.5
18.5–30/
22–30
37-45/
37-45
380–480 V 0.37–4.0 5.5–7.5 0.37–7.5 11–18.5/
11–18.5
22-30/
22-37
37-55/
45-55
75 - 90/
75-90
525–600 V 0.75–7.5 0.75–7.5 11–18.5/
11–18.5
22-37/
22-37
45-55/
45-55
75 - 90/
75-90
Table 4.1: Unpacking table
Please note that a selection of screwdrivers (Philips or cross-thread screwdriver and torx), a side-cutter, drill and knife is also recommended to have
handy for unpacking and mounting the adjustable frequency drive. The packaging for these enclosures contains, as shown: accessory bag(s), documen-
tation and the unit. Depending on options fitted, there may be one or two bags and one or more booklets.
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®
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Instruction Manual 4 Mechanical installation
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A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4
IP20/21 IP20/21 IP55/66 IP21/55/66 IP21/55/66 IP20 IP20 IP21/55/66 IP21/55/66 IP20 IP20
Accessory bags containing necessary brackets, screws and connectors are included with the drives upon delivery. Top and bottom mounting holes. (C3+C4 only)
All measurements in mm.
* A5 in IP55/66 only!
4.2.1 Mechanical Front Views
4 Mechanical installation
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®
AQUA Drive
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Mechanical dimensions
Frame size (kW): A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4 200–240 V 380–480 V 525–600 V
0.25–3.0 0.37–4.0
–
3.7
5.5–7.5
0.75–7.5
0.25–3.7 0.37–7.5 0.75–7.5
5.5–11
11–18.5 11–18.5
15
22-30 22-30
5.5–11
11–18.5 11–18.5
15–18.5
22–37 22–37
18.5–30
37–55 37–55
37-45 75-90 75-90
22-30 45-55 45-55
37-45 75-90 75-90
IP NEMA
20
Chassis
21
Type 1
20
Chassis
21
Type 1
55/66
Type 12
21/ 55/66
Type 1/12
21/55/66
Type 1/12
20
Chassis
20
Chassis
21/55/66
Type 1/12
21/55/66
Type 1/12
20
Chassis
20
Chassis
Height (mm) Enclosure A** 246 372 246 372 420 480 650 350 460 680 770 490 600 ..with de-coupling plate A2 374 -374 - - - - 419 595 - - 630 800 Backplate A1 268 375 268 375 420 480 650 399 520 680 770 550 660 Distance between mount. holes a257 350 257 350 402 454 624 380 495 648 739 521 631 Width (mm) Enclosure B90 90 130 130 242 242 242 165 231 308 370 308 370 With one C option B130 130 170 170 242 242 242 205 231 308 370 308 370 Backplate B90 90 130 130 242 242 242 165 231 308 370 308 370 Distance between mount. holes b70 70 110 110 215 210 210 140 200 272 334 270 330 Depth (mm) Without option A/B C205 205 205 205 200 260 260 248 242 310 335 333 333 With option A/B C* 220 220 220 220 200 260 260 262 242 310 335 333 333 Screw holes (mm)
c8.0 8.0 8.0 8.0 8.2 12 12 8 - 12 12 - -
Diameter ø d11 11 11 11 12 19 19 12 -19 19 - - Diameter ø e5.5 5.5 5.5 5.5 6.5 9 9 6.8 8.5 9.0 9.0 8.5 8.5
f 9 9 9 9 9 9 9 7.9 15 9.8 9.8 17 17
Max weight (kg) 4.9 5.3 6.6 7.0 14 23 27 12 23.5 45 65 35 50 * Depth of enclosure will vary with different options installed. ** The free space requirements are above and below the bare enclosure height measurement A. See section 3.2.3 for further information.
4.2.2 Mechanical Dimensions
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®
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4.2.3 Mechanical mounting
All IP20 enclosure sizes as well as IP21/ IP55 enclosure sizes except A2 and A3 allow side-by-side installation.
If the IP 21 Enclosure kit (130B1122 or 130B1123) is used on enclosure A2 or A3, there must be a clearance between the drives of min. 50 mm.
For optimal cooling conditions allow a free air passage above and below the frequency converter. See table below.
Air passage for different enclosures
Enclo-
sure: A2 A3 A5 B1 B2 B3 B4 C1 C2 C3 C4
a (mm): 100 100 100 200 200 200 200 200 225 200 225
b (mm): 100 100 100 200 200 200 200 200 225 200 225
1. Drill holes in accordance with the measurements given.
2. You must provide screws suitable for the surface on which you want to mount the frequency converter. Retighten all four screws.
Table 4.2: Mounting frame sizes A5, B1, B2, B3, B4, C1, C2, C3 and C4 on a non-solid back wall, the drive must be provided with a back plate A due
to insufficient cooling air over the heat sink.
4 Mechanical installation
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®
AQUA Drive
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