Danfoss VLT AQUA Drive FC 202 User manual

Operating Guide
VLT® AQUA Drive FC 202
355-800 kW, Enclosure Sizes E1h-E4h

Contents
1 Introduction 7
1.1 Purpose of this Operating Guide 7
1.2 Manual and Software Version 7
1.3 Trademarks 7
1.4 Approvals and Certifications 7
1.5 Disposal 8
2 Safety 9
2.1 Safety Symbols 9
2.2 Qualified Personnel 9
2.3 Safety Precautions 9
3 Product Overview 12
3.1 Intended Use 12
3.2 Power Ratings, Weights, and Dimensions for E1h–E4h Enclosures 12
3.3 Interior View of Enclosure E1h/E2h 13
3.4 Interior View of Enclosure E3h/E4h 15
3.5 Control Shelf 16
3.6 Local Control Panel (LCP) 17
3.7 LCP Menu 19
4 Mechanical Installation 22
4.1 Items Supplied 22
4.2 Tools Needed 22
4.3 Storing the Drive 23
4.4 Operating Environment 23
4.4.1 Overview 23
4.4.2 Gases 23
4.4.3 Dust 24
4.4.4 Potentially Explosive Atmospheres 24
4.5 Installation Requirements 25
4.6 Cooling Requirements 25
4.7 E1h-E4h Airflow Rates 26
4.8 Lifting the Drive 26
4.9 E1h/E2h Mechanical Installation 27
4.9.1 Securing the Pedestal to the Floor 27
4.9.2 Attaching an E1h/E2h to the Pedestal 28
4.9.3 Creating Cable Openings for an E1h/E2h 30
4.10 E3h/E4h Mechanical Installation 30
4.10.1 Attaching the E3h/E4h to a Mounting Plate or Wall 31
ContentsOperating Guide | VLT® AQUA Drive FC 202
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4.10.2 Creating Cable Openings for an E3h/E4h 31
4.10.3 Installing Load share/Regen Terminals to an E3h/E4h 34
5 Electrical Installation 35
5.1 Safety Instructions 35
5.2 EMC-compliant Installation 36
5.3 Wiring Schematic 40
5.4 Connecting the Motor 41
5.5 Connecting the AC Mains 42
5.6 Connecting to Ground 45
5.7 E1h Terminal Dimensions 47
5.8 E2h Terminal Dimensions 49
5.9 E3h Terminal Dimensions 51
5.10 E4h Terminal Dimensions 54
5.11 Control Wiring 56
5.11.1 Control Cable Access 56
5.11.2 Routing Control Cables 57
5.11.3 Control Terminal Types 58
5.11.4 Relay Terminals 59
5.11.5 Connecting the Control Cable to the Control Terminals 60
5.11.6 Disconnecting the Control Cable from the Control Terminals 61
5.11.7 Enabling Motor Operation 61
5.11.8 Configuring RS485 Serial Communication 62
5.11.9 Safe Torque Off (STO) Wiring 63
5.11.10 Space Heater Wiring 63
5.11.11 Auxiliary Contact Wiring for Disconnects 63
5.11.12 Wiring the Brake Resistor Temperature Switch 64
5.11.13 Selecting the Voltage/Current Input Signal 64
6 Starting the Drive 66
6.1 Pre-start Check List 66
6.2 Applying Power to the Drive 67
6.3 Programming the Drive 68
6.3.1 Parameter Overview 68
6.3.2 Parameter Navigation 68
6.3.3 Entering System Information 68
6.3.4 Configuring Automatic Energy Optimization 69
6.3.5 Configuring Automatic Motor Adaptation 70
6.4 Testing Before System Start Up 70
6.4.1 Testing Motor Rotation 70
6.4.2 Testing Encoder Rotation 71
6.5 Starting Up the Drive for the First Time 71
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6.6 Parameter Settings 72
6.6.1 Parameter Setting Overview 72
6.6.2 Uploading and Downloading Parameter Settings 72
6.6.3 Restoring Factory Default Settings Using the Recommended Initialization 73
6.6.4 Restoring Factory Default Settings Using Manual Initialization 73
7 Wiring Configuration Examples 74
7.1 Application Examples 74
7.1.1 Wiring Configuration for Automatic Motor Adaptation (AMA) 74
7.1.2 Wiring Configuration for Automatic Motor Adaptation without T27 75
7.1.3 Wiring Configuration: Speed 75
7.1.4 Wiring Configuration: Feedback 78
7.1.5 Wiring Configuration: Run/Stop 81
7.1.6 Wiring Configuration: Start/Stop 84
7.1.7 Wiring Configuration: External Alarm Reset 87
7.1.8 Wiring Configuration: RS485 88
7.1.9 Wiring Configuration: Motor Thermistor 88
7.1.10 Wiring for Regen 90
7.1.11 Wiring Configuration for a Relay Setup with Smart Logic Control 91
7.1.12 Wiring Configuration for a Submersible Pump 91
7.1.13 Wiring Configuration for a Cascade Controller 94
7.1.14 Wiring Configuration for a Fixed Variable Speed Pump 96
7.1.15 Wiring Configuration for Lead Pump Alternation 97
8 Maintenance, Diagnostics, and Troubleshooting 98
8.1 Maintenance and Service 98
8.2 Heat Sink Service 98
8.2.1 Heat Sink Access Panel 98
8.2.2 Removing Dust Buildup from the Heat Sink 98
8.3 Status Messages 99
8.3.1 Status Message Overview 99
8.3.2 Status Messages - Operating Mode 100
8.3.3 Status Messages - Reference Site 100
8.3.4 Status Messages - Operation Status 101
8.4 Warnings and Alarms 103
8.5 Troubleshooting 127
9 Specifications 130
9.1 Electrical Data 130
9.1.1 Electrical Data, 380–480 V AC 130
9.1.2 Electrical Data, 525–690 V AC 132
9.2 Mains Supply 135
9.3 Motor Output and Torque Characteristics 135
ContentsOperating Guide | VLT® AQUA Drive FC 202
AQ275652274277en-000101 / | 5Danfoss A/S © 2020.01

9.3.1 Motor Output (U, V, W) 135
9.3.2 Torque Characteristics 135
9.4 Ambient Conditions 136
9.5 Cable Specifications 137
9.6 Control Input/Output and Control Data 137
9.6.1 Digital Inputs 137
9.6.2 STO Terminal 37 137
9.6.3 Analog Inputs 138
9.6.4 Pulse/encoder Inputs 138
9.6.5 Analog Output 139
9.6.6 Control Card, RS485 Serial Communication 139
9.6.7 Digital Outputs 139
9.6.8 Control Card, 24 V DC Output 140
9.6.9 Relay Outputs 140
9.6.10 Control Card, +10 V DC Output 141
9.6.11 Control Characteristics 141
9.6.12 Control Card Performance 141
9.6.13 Control Card, USB Serial Communication 141
9.7 Fuses 141
9.8 Enclosure Dimensions 143
9.8.1 E1h Exterior Dimensions 143
9.8.2 E2h Exterior Dimensions 147
9.8.3 E3h Exterior Dimensions 151
9.8.4 E4h Exterior Dimensions 155
9.9 Enclosure Airflow 159
9.10 Fastener Torque Ratings 159
10 Appendix 161
10.1 Conventions 161
10.2 Abbreviations 161
10.3 International/North American Default Parameter Settings 163
ContentsOperating Guide | VLT® AQUA Drive FC 202
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1 Introduction
1.1 Purpose of this Operating Guide
This operating guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions
and general warnings. Always keep this operating guide available with the drive.
1.2 Manual and Software Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
Table 1: Manual and Software Version
Manual version Remarks Software ver‐
sion
AQ275652274277xx-xx01-01 Updated power losses in Electrical Data table. Created Starting the Drive chapter
by combining Commissioning and Pre-start Check List chapters.
3.40
MG22A2xx Previous version. 2.70
1.3 Trademarks
VLT® is a registered trademark for Danfoss A/S.
1.4 Approvals and Certifications
e30bu682.10
Illustration 1: Approvals and Certifications
More approvals and certifications are available. Contact the local Danfoss office or partner. Drives of voltage T7 (525–690 V) are UL
certified for only 525–600 V.
Thermal memory retention requirement
The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to the Motor Thermal
Protection section in the product-specific design guide.
NOTICE
OUTPUT FREQUENCY LIMIT
From software version 1.99, the output frequency of the drive is limited to 590 Hz due to export control regulations.
Introduction
Operating Guide | VLT® AQUA Drive FC 202
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Danfoss A/S © 2020.01

ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to the ADN-compliant Installation section in the product-specific design guide.
1.5 Disposal
Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with
applicable local regulations.
Introduction
Operating Guide | VLT® AQUA Drive FC 202
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8 | Danfoss A/S © 2020.01