Danfoss VLT AQUA Drive FC 202 User manual

Contents
1. How to Read these Operating Instructions
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 4
Symbols 4
2. Safety 5
General Warning 6
Before Commencing Repair Work 6
Special conditions 6
Avoid unintended Start 7
Safe Stop of the Frequency Converter (optional) 7
IT Mains 8
3. Introduction 11
Type Code String 11
4. Mechanical installation 13
Before starting 13
5. Electrical installation 19
How to connect 19
Mains wiring overview 23
Motor wiring overview 30
DC bus connection 34
Brake Connection Option 35
Relay Connection 36
Electrical Installation and Control Cables 40
How to Test Motor and Direction of Rotation. 42
6. Application Examples 47
Closed Loop Wiring 47
Submersible Pump Application 48
7. How to operate the frequency converter 51
Ways of Operation 51
How to operate graphical LCP (GLCP) 51
How to operate numeric LCP (NLCP) 56
Tips and tricks 59
8. How to programme the frequency converter 63
How to programme 63
Q1 My Personal Menu 64
VLT
®
AQUA Drive
Operating Instructions Contents
MG.20.M5.02 - VLT®is a registered Danfoss trademark 1

Q2 Quick Setup 64
Q5 Changes Made 67
Q6 Loggings 67
Commonly Used Parameters - Explanations 69
Main Menu 69
Parameter Options 108
Default settings 108
Operation/Display 0-** 109
Load/Motor 1-** 111
Brakes 2-** 112
Reference / Ramps 3-** 113
Limits / Warnings 4-** 114
Digital In/Out 5-** 115
Analog In/Out 6-** 116
Comm. and Options 8-** 117
Profibus 9-** 118
CAN Fieldbus 10-** 119
Smart Logic 13-** 120
Special Functions 14-** 121
FC Information 15-** 122
Data Readouts 16-** 124
Data Readouts 2 18-** 126
FC Closed Loop 20-** 127
Ext. Closed Loop 21-** 128
Application Functions 22-** 130
Timed Actions 23-** 132
Cascade Controller 25-** 133
Analog I/O Option MCB 109 26-** 135
Cascade CTL Option 27-** 136
Water Application Functions 29-** 138
Bypass Option 31-** 139
9. Troubleshooting 141
Fault messages 143
10. Specifications 147
General Specifications 147
Special Conditions 163
Index
169
Contents
VLT
®
AQUA Drive
Operating Instructions
2 MG.20.M5.02 - VLT®is a registered Danfoss trademark

1. How to Read these Operating Instructions
1.1.1. Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss. 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 or 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
Operating Instructions 1. How to Read these Operating Instructions
MG.20.M5.02 - VLT®is a registered Danfoss trademark 3
1

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.
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.M5.02 - VLT®is a registered Danfoss trademark
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2. Safety
2.1.1. Safety note
The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency
converter or fieldbus may cause 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.M5.02 - VLT®is a registered Danfoss trademark 5
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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 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.M5.02 - VLT®is a registered Danfoss trademark
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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.M5.02 - VLT®is a registered Danfoss trademark 7
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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 Filter 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
Software version: 1.24
This manual can be used with all VLT AQUA Drive frequency converters with software version 1.24.
The software version number can be found in parameter 15-43.
2. Safety
VLT
®
AQUA Drive
Operating Instructions
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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.M5.02 - VLT®is a registered Danfoss trademark 9
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3. Introduction
VLT
®
AQUA Drive
Operating Instructions
10 MG.20.M5.02 - VLT®is a registered Danfoss trademark
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