Danfoss VLT AQUA Drive FC 202 Operating Manual

Vlt series 110–400 kw, enclosure sizes d1h–d8h

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Programming manual (294 pages)

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ENGINEERING TOMORROW

Operating Guide

VLT® AQUA Drive FC 202

110–400 kW, Enclosure Sizes D1h–D8h

vlt-drives.danfoss.com

Table of Contents

Troubleshooting

Summary of Contents for Danfoss VLT AQUA Drive FC 202

Page 1 ENGINEERING TOMORROW Operating Guide VLT® AQUA Drive FC 202 110–400 kW, Enclosure Sizes D1h–D8h vlt-drives.danfoss.com...
Page 3: Table Of Contents
5 Electrical Installation 5.1 Safety Instructions 5.2 EMC-compliant Installation 5.3 Wiring Schematic 5.4 Connecting to Ground 5.5 Connecting the Motor 5.6 Connecting the AC Mains 5.7 Connecting Regen/Load Share Terminals 5.8 Terminal Dimensions MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 4 9.6 Troubleshooting 10 Specifications 10.1 Electrical Data 10.2 Mains Supply 10.3 Motor Output and Torque Data 10.4 Ambient Conditions 10.5 Cable Specifications 10.6 Control Input/Output and Control Data 10.7 Fuses and Circuit Breakers Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 5 Contents Operating Guide 10.8 Fastener Tightening Torques 10.9 Enclosure Dimensions 11 Appendix 11.1 Abbreviations and Conventions 11.2 International/North American Default Parameter Settings 11.3 Parameter Menu Structure Index MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 6: Introduction
Table 1.2 Approvals and Certifications the operating guide with the drive. More approvals and certifications are available. Contact the ® local Danfoss office or partner. Drives of voltage 525–690 V is a registered trademark. are UL certified for only 525–600 V. 1.2 Additional Resources The drive complies with UL 61800-5-1 thermal memory retention requirements.
Page 7: Safety
LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury. • Ensure the correct grounding of the equipment by a certified electrical installer. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 8 • Exterior areas marked by the high-temperature symbol (yellow triangle) are hot while the drive is in use and immediately after being powered off. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 9: Product Overview
98 (216) 164 (362) 108 (238) 179 (395) Table 3.1 Power Ratings, Weight, and Dimensions, Enclosure Size D1h–D4h 1) Regen, load share, and brake terminal options are not available for 200–240 V drives. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 10 (inch)] Depth 381 (15) 381 (15) 386 (15) 406 (16) Maximum weight [kg (lb)] 449 (990) 449 (990) 530 (1168) 530 (1168) Table 3.2 Power Ratings, Weight, and Dimensions, Enclosure Size D5h–D8h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 11: Interior View Of D1H Drive
Motor output terminals 96 (U), 97 (V), 98 (W) Ground terminals for IP21/54 (Type 1/12) Cable clamps Lifting ring Ground terminals for IP20 (Chassis) Illustration 3.1 Interior View of D1h Drive (similar to D3h/D5h/D6h) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 12: Interior View Of D2H Drive
Motor output terminals 96 (U), 97 (V), 98 (W) Cable clamps Ground terminals for IP21/54 (Type 1/12) Lifting ring Ground terminals for IP20 (Chassis) Illustration 3.2 Interior View of D2h Drive (Similar to D4h/D7h/D8h) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 13: View Of Control Shelf
Analog I/O connector Digital I/O and 24 V supply Relay 1 (01, 02, 03) on power card Lifting rings Relay 2 (04, 05, 06) on power card Illustration 3.3 View of Control Shelf MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 14: Extended Options Cabinets
If the drive is replaced, it can be replaced independently of the options cabinet. Drive enclosure Extended options cabinet Pedestal Illustration 3.4 Drive with Extended Options Cabinet (D7h) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 15: Local Control Panel (Lcp)
Refer to chapter 3.8.1.2 Q1 My Personal Menu. Callout Parameter number Default setting A1.1 0-20 Reference [Unit] A1.2 0-21 Analog input 53 [V] A1.3 0-22 Motor current [A] 0-23 Frequency [Hz] 0-24 Feedback [Unit] Table 3.4 LCP Display Area MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 16 ◄ ► Moves between items in the menu. mode so it can respond to an external start command by control terminals or Table 3.6 LCP Navigation Keys serial communication. Table 3.8 LCP Operation Keys and Reset Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 17: Lcp Menus
All parameters can be changed in the main menu. Option cards added to the unit enable extra parameters associated 3.8.1.5 Q5 Changes Made with the option device. Select Q5 Changes Made for information about: MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 18: Mechanical Installation
Part number and serial number Power rating Input voltage, frequency, and current Output voltage, frequency, and current Discharge time Illustration 4.1 Example Nameplate for Drive Only (D1h–D4h) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 19: Tools Needed
Fans provide airflow to cool the drive. When fans are Danfoss regarding PELV. exposed to dusty environments, the dust can damage the Table 4.1 Installation at High Altitudes fan bearings and cause premature fan failure. Also, dust MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 20: Installation And Cooling Requirements
PTB-certified for potentially explosive back-channel cooling air can be ventilated out of atmospheres. the room so that the heat from the back channel is not dissipated into the control room. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 21: Lifting The Drive
All, 200–240 V 840 m • (500 CFM) To guard against injury, wear personal protective equipment such as gloves, safety Table 4.2 Airflow glasses, and safety shoes. 65° Illustration 4.3 Lifting the Drive MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 22: Mounting The Drive
Fasten 4 M5 screws through the front flange of the pedestal and into the gland plate mounting holes. Cable entry hole Metal gland plate Illustration 4.4 Cable Openings in Sheet Metal Gland Plate Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 23 Mounting flange at drive top Front flange of pedestal Mounting holes Front cover plate of pedestal M10 nuts (fasten to threaded posts) M5 screw (fasten through front flange) Illustration 4.6 Pedestal Installation in D7h/D8h Drives MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 24 The number varies with enclosure size. See Illustration 4.6. Mounting holes Bottom of pedestal Illustration 4.7 Pedestal-to-floor Mounting Holes Top mounting holes Lower fastener slots Illustration 4.8 Drive-to-wall Mounting Holes Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 25: Electrical Installation
If shielded cables or metal conduits are not used, the unit and the installation do not meet regulatory limits See chapter 10.5 Cable Specifications for recommended wire on radio frequency (RF) emission levels. sizes and types. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 26 For installations above 2000 m (6500 ft) altitude, contact Danfoss regarding PELV compliance. NOTICE PELV COMPLIANCE Prevent electric shock by using protective extra low voltage (PELV) electrical supply and complying with local and national PELV regulations. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 27 Mains supply Brake resistor Bare (unpainted) surface Metal box Star washers Connection to motor Brake cable (shielded) Motor Motor cable (shielded) EMC cable gland Illustration 5.1 Example of Proper EMC Installation MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 28: Wiring Schematic
1) TB6 contactor is found only in D6h and D8h drives with a contactor option. ® 2) Terminal 37 (optional) is used for Safe Torque Off. Refer to the VLT FC Series - Safe Torque Off Operating Guide for installation instructions. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 29: Connecting To Ground
There is a risk of burst transient when the ground potential between the drive and the control system is different. Install equalizing cables between the system components. Recommended cable cross-section: 16 mm (5 AWG). MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 31: Connecting The Motor
Connect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W). See Illustration 5.4. Tighten the terminals in accordance with the information provided in chapter 10.8.1 Fastener Torque Ratings. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 33: Connecting The Ac Mains
(grounded delta), ensure that parameter 14-50 RFI Filter is set to [0] Off to avoid damage to the DC link and to reduce ground capacity currents. NOTICE OUTPUT CONTACTOR Danfoss does not recommend using an output contactor on 525–690 V drives that are connected to an IT mains network. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 34 Electrical Installation VLT® AQUA Drive FC 202 Illustration 5.5 AC Mains Terminals (D1h shown). For a detailed view of terminals, see chapter 5.8 Terminal Dimensions. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 35: Connecting Regen/Load Share Terminals
Connect the DC(+) cable to the DC(+) terminal, and secure with 1 M10 fastener. Connect the DC(-) cable to the DC(-) terminal, and secure with 1 M10 fastener. Tighten the terminals in accordance with chapter 10.8.1 Fastener Torque Ratings. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 36 Side opening for regen/load share terminals Hole for M10 fastener Top view Close-up view Side view Regen/load share terminals View without cover Front view Illustration 5.6 Regen/Load Share Terminals in Enclosure Size D Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 37: Terminal Dimensions
Electrical Installation Operating Guide 5.8 Terminal Dimensions 5.8.1 D1h Terminal Dimensions 200 (7.9) 94 (3.7) 88 (3.5) Mains terminals Motor terminals Ground terminals – – Illustration 5.7 D1h Terminal Dimensions (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 38 Electrical Installation VLT® AQUA Drive FC 202 (0.5) (0.5) (1.3) (1.3) Mains terminals Motor terminals Illustration 5.8 D1h Terminal Dimensions (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 39 Operating Guide 5.8.2 D2h Terminal Dimensions 331 (13.0) 211 (8.3) 168 (6.6) 168 (6.6) 143 (5.6) 143 (5.6) Mains terminals Motor terminals Ground terminals – – Illustration 5.9 D2h Terminal Dimensions (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 40 Electrical Installation VLT® AQUA Drive FC 202 15 (0.6) 15 (0.6) 19 (0.8) 18 (0.7) 35 (1.4) 38 (1.5) Mains terminals Motor terminals Illustration 5.10 D2h Terminal Dimensions (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 41 Electrical Installation Operating Guide 5.8.3 D3h Terminal Dimensions 292 (11.5) 188 (7.4) 83 (3.3) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 5.11 D3h Terminal Dimensions (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 42 13 (0.5) 13 (0.5) 32 (1.3) 32 (1.3) 1 and 6 Bottom brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Illustration 5.12 D3h Terminal Dimensions (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 43 Electrical Installation Operating Guide 5.8.4 D4h Terminal Dimensions 376 (14.8) 319 (12.6) 200 (7.9) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 5.13 D4h Terminal Dimensions (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 44 19 (0.8) 18 (0.7) 38 (1.5) 35 (1.4) 1 and 6 Brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Illustration 5.14 D4h Terminal Dimensions (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 45 5.8.5 D5h Terminal Dimensions 227 (9.0) 221 (8.7) 196 (7.7) 148 (5.8) 118 (4.6) 90 (3.6) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 5.15 D5h Terminal Dimensions with Disconnect Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 46 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.16 D5h Terminal Dimensions with Disconnect Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 47 Electrical Installation Operating Guide 727 (28.6) 623 (24.5) 517 (20.4) 511 (20.1) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 5.17 D5h Terminal Dimensions with Brake Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 48 Electrical Installation VLT® AQUA Drive FC 202 Brake terminals Motor terminals Mains terminals – – Illustration 5.18 D5h Terminal Dimensions with Brake Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 49 195 (7.7) 153 (6.0) 123 (4.8) 96 (3.8) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Illustration 5.19 D6h Terminal Dimensions with Contactor Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 50 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.20 D6h Terminal Dimensions with Contactor Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 51 Electrical Installation Operating Guide 225 (8.9) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Illustration 5.21 D6h Terminal Dimensions with Contactor and Disconnect Options (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 52 Electrical Installation VLT® AQUA Drive FC 202 Brake terminals Motor terminals Mains terminals – – Illustration 5.22 D6h Terminal Dimensions with Contactor and Disconnect Options (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 53 Electrical Installation Operating Guide 467 (18.4) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 5.23 D6h Terminal Dimensions with Circuit Breaker Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 54 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.24 D6h Terminal Dimensions with Circuit Breaker Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 55 5.8.7 D7h Terminal Dimensions 545 (21.4) 515 (20.3) 412 (16.2) 395 (15.6) 372 (14.7) Mains terminals Motor terminals Brake terminals Ground terminals Illustration 5.25 D7h Terminal Dimensions with Disconnect Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 56 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.26 D7h Terminal Dimensions with Disconnect Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 57 Electrical Installation Operating Guide 1260 (49.6) 1202 (47.3) 1082 (42.6) 1034 (40.7) 1009 (39.7) Mains terminals Brake terminals Ground terminals Motor terminals Illustration 5.27 D7h Terminal Dimensions with Brake Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 58 Electrical Installation VLT® AQUA Drive FC 202 Brake terminals Motor terminals Mains terminals – – Illustration 5.28 D7h Terminal Dimensions with Brake Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 59 521 (20.5) 418 (16.5) 401 (15.8) 378 (14.9) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Illustration 5.29 D8h Terminal Dimensions with Contactor Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 60 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.30 D8h Terminal Dimensions with Contactor Option (Side Views) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 61 Electrical Installation Operating Guide 567 (22.3) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Illustration 5.31 D8h Terminal Dimensions with Contactor and Disconnect Options (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 62 Electrical Installation VLT® AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Illustration 5.32 D8h Terminal Dimensions with Contactor and Disconnect Options (Side View) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 63 Electrical Installation Operating Guide (23.8) Mains terminals Ground terminals Brake terminals Motor terminals Illustration 5.33 D8h Terminal Dimensions with Circuit Breaker Option (Front View) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 64 15 (0.6) 32 (1.3) 16 (0.6) (0.8) 14 (0.5) 35 (1.4) 18 (0.7) Mains terminals Motor terminals Brake terminals – – Illustration 5.34 D8h Terminal Dimensions with Circuit Breaker Option (Side View) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 65: Control Wiring
Digital Input Parameter 5-11 [10] Terminal 19 Reversing Digital Input Parameter 5-14 [0] No Illustration 5.35 Control Terminal Locations Terminal 32 operation Digital Input Parameter 5-15 [0] No Terminal 33 operation Digital Input MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 66 Switches A53 and A54 select mA or V. Parameter Feedback Illustration 5.37 Connecting Solid Control Wires group 6-2* Analog Input 2 – – Common for analog input. Table 5.3 Analog Input/Output Terminal Descriptions Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 67 12 13 18 19 27 29 32 33 RS485 is a 2-wire bus interface compatible with multi-drop network topology, and it contains the following features: • Either Danfoss FC or Modbus RTU communication protocol, which are internal to the drive, can be used. •...
Page 68 • /[V]: 690 • /[kV]: 4 • Pollution degree: 3 • /[A]: 16 • Cable size: 1...2x0.75...2.5 mm • Maximum fuse: 16 A/gG • NEMA: A600, R300, wire size: 18–14 AWG, 1(2) Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 69 Remove any optional equipment covering the switches. Set switches A53 and A54 to select the signal type (U = voltage, I = current). Illustration 5.40 Location of Terminal 53 and 54 Switches MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 70: Pre-Start Check List
For D3h and D4h enclosures, ensure that the unit is mounted on an unpainted, metal surface. • Vibration Check that the unit is mounted solidly, or that shock mounts are used, if necessary. • Check for an unusual amount of vibration. Table 6.1 Pre-start Check List Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 71: Commissioning
For units with a disconnect switch, turn the Press [Back] twice to show the status view. switch to the ON position to apply power to the • Press [Main Menu] once to go back to the main drive. menu. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 72 Select [1] Enable complete AMA and press [OK]. Auto Press [Hand On] and then [OK]. Parameter 1-29 Automatic Motor Adaptation The test runs automatically and indicates when it (AMA) is complete. Table 7.2 Quick Set-up Settings Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 73: Testing Before System Start-Up
Press [►] for positive speed reference (parameter 1-06 Clockwise Direction at [0] Normal). In parameter 16-57 Feedback [RPM], check that the feedback is positive. For more information on the encoder option, refer to the option manual. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 74: Parameter Setting
Press and hold [Status], [Main Menu], and [OK] simultaneously while applying power to the unit (approximately 5 s or until an audible click sounds and the fan starts). Start-up takes slightly longer than normal. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 75: Wiring Configuration Examples
Table 8.1 Wiring Configuration for AMA with T27 Connected Value U - I Parameter 6-15 1500 RPM Terminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 8.3 Wiring Configuration for Analog Speed Reference (Voltage) MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 76: Wiring Configurations For Start/Stop
27 is not needed. A OUT Latched Start (18) Stop Inverse (27) Table 8.5 Wiring Configuration for Start/Stop Command with Safe Torque Off Illustration 8.2 Latched Start/Stop Inverse Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 77: Wiring Configurations For An External Alarm Reset
Preset ref. 1 Preset ref. 2 Preset ref. 3 100% *=Default value Notes/comments: Table 8.8 Wiring Configuration for an External Alarm Reset Table 8.7 Wiring Configuration for Start/Stop with Reversing and 4 Preset Speeds MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 78: Wiring Configuration For Speed Reference Using A Manual Potentiometer
Digital Input D IN Parameter 5-14 [22] Speed Terminal 32 Down Digital Input *=Default value Table 8.11 Wiring Configuration for RS485 Network Connection Notes/comments: Table 8.10 Wiring Configuration for Speed Up/Speed Down Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 79: Wiring Configuration For A Motor Thermistor
5 s, the drive continues and the warning disappears. Reset relay 1 by pressing [Reset] on the LCP. Table 8.13 Wiring Configuration for a Relay Set-up with Smart Logic Control MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 80: Wiring Configuration For A Submersible Pump
Pipe-fill mode can be enabled to prevent water which is normally 30 Hz. hammering. The Danfoss drive can fill the vertical pipes • The motor reactance is nonlinear in submersible using the PID controller to ramp up the pressure slowly pump motors and, therefore, automatic motor with a user-specified rate (units/second).
Page 81 Table 8.15 Example of Settings for Submersible Pump Application Parameter Setting Parameter 29-00 Pipe Fill Enable Disabled Parameter 29-04 Pipe Fill Rate (Feedback units) Parameter 29-05 Filled Setpoint (Feedback units) Table 8.16 Example of Settings for Pipe-Fill Mode MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 82: Wiring Configuration For A Cascade Controller
4–20 mA transmitter, and system safety interlock. Power Card Control Card MOTOR MAINS System System Start/ Safety Stop Interlock From Motor Control Circuitry Pressure Transmitter 4-20 mA, 24 V dc Illustration 8.6 Cascade Controller Wiring Diagram Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 83: Wiring Configuration For A Fixed Variable Speed Pump
At alternation, both relays de-energize and now relay 2 is energized as the 1 relay. For a detailed description of commissioning for mixed ® pump and master/slave applications, refer to VLT Cascade Controller Options MCO 101/102 Operating Instructions. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 84: Maintenance, Diagnostics, And Troubleshooting
Replace the panel and secure it to the back of sink and allows the heat sink to be cleaned of any dust the enclosure with the screws previously buildup. removed. Tighten the fasteners according to chapter 10.8 Fastener Tightening Torques. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 85: Status Messages
The drive uses reference values from the LCP. Feedback low The sum of all active feedbacks is below the feedback limit set in parameter 4-56 Warning Table 9.2 Reference Site Feedback Low. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 87: Warning And Alarm Types
Warning indicator light Alarm indicator light • Digital reset input command. Warning • Serial communication reset input command. Alarm On (flashing) • Trip lock On (flashing) Auto reset. Illustration 9.4 Status Indicator Lights MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 88: List Of Warnings And Alarms
Troubleshooting WARNING/ALARM 10, Motor overload temperature • Check the supply voltage and supply currents to According to the electronic thermal protection (ETR), the the drive. motor is too hot. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 90 Remove the power to the drive and replace the The value of this warning/alarm indicates the cause:. brake resistor (refer to parameter 2-15 Brake 0 = The torque reference was not reached before timeout Check). (parameter 2-27 Torque Ramp Time). Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 91 Motor phase W between the drive and the motor is • Dirty heat sink. missing. For drives in enclosure sizes D and E, this alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 92 Check for loose or missing wiring. make sure that there is no remaining voltage on It may be necessary to contact the Danfoss supplier or the drive. service department. Note the code number for further troubleshooting directions.
Page 93 Option in slot C1: Hardware incompatible with the The supply on the power card is out of range. control board hardware. 5376–6231 Internal fault. Contact the Danfoss supplier or There are 4 supplies generated by the switch mode power Danfoss service department. supply on the power card: •...
Page 94 4-19 Max Output Frequency, the drive issues a ALARM 50, AMA calibration failed warning. The warning ceases when the output drops Contact the Danfoss supplier or Danfoss service below the maximum limit. If the drive is unable to limit department.
Page 95 ALARM 70, Illegal FC configuration ALARM 78, Tracking error The control card and power card are incompatible. To check compatibility, contact the Danfoss supplier with the The difference between setpoint value and actual value type code from the unit nameplate and the part numbers exceeds the value in parameter 4-35 Tracking Error.
Page 96 1: frequency too high. • The Klixon switch opened due to an overtem- WARNING/ALARM 148, System temp perature condition in the brake resistor. One or more of the system temperature measurements is too high. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 97 3 = Third drive module from left (in 4-module Troubleshooting module systems). • Reset to remove the warning and to resume 4 = Fourth drive module from left (in 4-module normal operation. module systems). MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 98: Troubleshooting
Check if a reversing command is programmed Deactivate reversing signal. direction for the terminal in parameter group 5-1* Digital inputs. Wrong motor phase – See chapter 7.3.1 Warning - Motor Start. connection. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 99 9.5 List of Warnings and Alarms. parameter 3-42 Ramp 1 Ramp Down Time. problems Check that motor data are entered correctly. Enable overvoltage control in parameter 2-17 Over-voltage Control. Table 9.5 Troubleshooting MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 100: Specifications
If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 101 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 102 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 103 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 104 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 105 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 106 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 107 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyefficiency. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 108: Mains Supply
Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft) 1) For more information on derating, see the design guide. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 109: Cable Specifications
0/4 to 20 mA (scaleable) Approximately 200 Ω Input resistance, R Maximum current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 110 Resolution of frequency outputs 12 bit 1) Terminals 27 and 29 can also be programmed as inputs. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 111 1:100 of synchronous speed 30–4000 RPM: Maximum error of ±8 RPM Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor. Control card performance Scan interval 5 M/S MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 112: Fuses And Circuit Breakers
Table 10.10 D1h–D8h Power/Semiconductor Fuse Options, 380–480 V Model Bussmann part number N55K 170M2616 N75K 170M2619 N90K 170M2619 N110 170M2619 N132 170M2619 N160 170M4015 N200 170M4015 N250 170M4015 N315 170M4015 Table 10.11 D1h–D8h Power/Semiconductor Fuse Options, 525–690 V Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 113 1) With gL/gG fuses: 425 A maximum fuse size for D6h, and 630 A maximum fuse size for D8h. 2) With external upstream Class J fuses: 450 A maximum fuse size for D6h, and 600 A maximum fuse size for D8h. MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 114: Fastener Tightening Torques
Regeneration terminals (Enclosures D1h/D2h) 9.6 (84) Relay terminals 0.5 (4) Door/panel cover 2.3 (20) Gland plate 2.3 (20) Heat sink access panel 3.9 (35) Serial communication cover 2.3 (20) Table 10.18 Fastener Torque Ratings Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 115: Enclosure Dimensions
Specifications Operating Guide 10.9 Enclosure Dimensions 10.9.1 D1h Exterior Dimensions Illustration 10.2 Front View of D1h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 118 VLT® AQUA Drive FC 202 298 (11.7) 404 (15.9) Illustration 10.5 Door Clearance for D1h 27 (1.0) 137 (5.4) 138 (5.4) 205 (8.1) Mains side Motor side Illustration 10.6 Gland Plate Dimensions for D1h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 120 Specifications VLT® AQUA Drive FC 202 378 (14.9) 142 (5.6) 18 (0.7) 20 (0.8) 148 (5.8) 1050 (41.3) 718 (28.3) Illustration 10.8 Side View of D2h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 121 130 (5.1) 11 (0.4) (4.2) 213 (8.4) 1099 (43.3) 320 (12.6) 1051 (41.4) 857 (33.7) 75 (2.9) 11 (0.4) 20 (0.8) 24 (0.9) 9 (0.3) 271 (10.7) Illustration 10.9 Back View of D2h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 122 VLT® AQUA Drive FC 202 395 (15.6) 523 (20.6) Illustration 10.10 Door Clearance for D2h 369 (14.5) 27 (1.0) 185 (7.3) 145 (5.7) 196 (7.7) Mains side Motor side Illustration 10.11 Gland Plate Dimensions for D2h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 124 Specifications VLT® AQUA Drive FC 202 375 (14.8) 82 (3.2) 39 (1.5) 18 (0.7) 20 (0.8) 148 (5.8) 844 (33.2) Illustration 10.13 Side View of D3h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 125 25 (1.0) 909 (35.8) 11 (0.4) 78 (3.1) 200 (7.9) 889 (35.0) 844 (33.2) 656 (25.8) 25 (1.0) 11 (0.4) 20 (0.8) 200 (7.9) (0.9) 9 (0.3) Illustration 10.14 Back View of D3h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 126 Specifications VLT® AQUA Drive FC 202 10.9.4 D4h Enclosure Dimensions 59 (2.3) 176 (6.9) 868 (34.2) 611 (24.1) Illustration 10.15 Front View of D4h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 128 25 (1.0) (4.2) 1122 (44.2) 213 (8.4) 320 (12.6) 1096 (43.1) 1051 (41.4) 857 (33.7) (1.6) 11 (0.4) 24 (0.9) 20 (0.8) 9 (0.3) 271 (10.7) Illustration 10.17 Back View of D4h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 131 (3.1) 11 (0.4) (7.9) 1324 (52.1) 1276 (50.2) 1111 (43.7) (4.8) 130 (5.1) (2.5) 11 (0.4) (3.1 220 (8.7) (7.9) 24 (0.9) (0.3) (0.8) 200 (7.9) Illustration 10.20 Back View of D5h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 133 Operating Guide 298 (11.7) 404 (15.9) Illustration 10.22 Door Clearance for D5h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Illustration 10.23 Gland Plate Dimensions for D5h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 134 Specifications VLT® AQUA Drive FC 202 10.9.6 D6h Exterior Dimensions 159 (6.3) 1447 (57.0) 909 (35.8) Illustration 10.24 Front View of D6h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 136 (7.9) 1663 (65.5) 1615 (63.6) 1452 (57.2) (4.8) 130 (5.1) (3.1) (7.9) 11 (0.4) 64 (3.0) 559 (22.0) 24 (0.9) 9 (0.1) 20 (0.8) 200 (7.9) Illustration 10.26 Back View of D6h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 138 VLT® AQUA Drive FC 202 298 (11.7) 404 (15.9) Illustration 10.28 Door Clearance for D6h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Illustration 10.29 Gland Plate Dimensions for D6h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 141 11 (0.4) 130 (5.1) (1.0) (4.2) (8.4) (12.6) 1953 (76.9) (77.9) 1760 (69.3) 130 (5.1) 385 (15.2) (2.8) (4.2) (8.4) 25 (1.0) (12.6) (9.3) (26.3) 14 (0.6) Illustration 10.32 Back View of D7h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 144 VLT® AQUA Drive FC 202 395 (15.6) 523 (20.6) Illustration 10.35 Door Clearance for D7h 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Illustration 10.36 Gland Plate Dimensions for D7h Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 145 Specifications Operating Guide 10.9.8 D8h Exterior Dimensions 215 (8.5) 1699 (66.9) (30.2) 1400 (55.1) (4.4) Illustration 10.37 Front View of D8h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 147 11 (0.4) (8.4) 25 (1.0) (12.6) 2259 (88.9) 130 (5.1) 2284 (89.9) 2065 (81.3) (4.2) (8.4) 385 (15.2) 72 (2.8) (12.6) (38.3) (9.3) (1.0) 14 (0.6) Illustration 10.39 Back View of D8h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 149 Operating Guide 395 (15.6) 523 (20.6) Illustration 10.41 Door Clearance for D8h 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Illustration 10.42 Gland Plate Dimensions for D8h MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 150: Appendix
Footnote Miniature circuit breakers Motion control option Parameter name Motor control processor Parameter group name Motion control tool Parameter option MDCIC Multi-drive control interface card • All dimensions are in mm (inch). Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 151: International/North American Default Parameter Settings
3) This parameter is only visible when parameter 0-02 Motor Speed Unit is set to [0] RPM. 4) This parameter is only visible when parameter 0-02 Motor Speed Unit is set to [1] Hz. 11.3 Parameter Menu Structure MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 157: Index
Cable length and cross-section..........107 Installation warning................ 23 Maximum number and size per phase......98, 100 Opening..........113, 117, 127, 132, 137, 143 Routing..................63, 68 Shielded....................23 Specifications............98, 100, 102, 107 CAN motor....................78 MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 158 D4h..................... 124 Wiring of....................66 D5h..................... 127 Wiring schematic................26 D6h..................... 132 High voltage..................89, 90 D7h..................... 137 D8h..................... 143 High voltage warning................5 External alarm reset wiring configuration........75 Humidity....................17 Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 159 Leakage....................27 Maintenance..................17, 82 Losses................98, 100, 102 Manual Ratings................98, 100, 102 Version number................... 4 Specifications.................. 100 MCT 10...................... 70 Power card MCT 10 Set-up Software..............70 Warning....................92 Programming..................14 MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 160 Clamps....................23 Points for 200–240 V drives............98 Mains....................... 6 Points for 380–480 V drives............100 Twisted ends..................23 Points for 525–690 V drives............102 Shipping dimensions................ 7, 8 Short circuit.................... 88 Danfoss A/S © 09/2018 All rights reserved. MG21A502...
Page 161 Weight....................7, 8 Windmilling....................6 Wire size....................29 Wiring control terminals..............64 Wiring diagram Cascade controller................80 Fixed variable speed pump............81 Lead pump alternation..............81 Wiring schematic Drive...................... 26 Typical application examples............73 MG21A502 Danfoss A/S © 09/2018 All rights reserved.
Page 162 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

Danfoss VLT AQUA Drive FC 202 Operating Manual

1 Introduction

2 Safety

3 Product Overview

4 Mechanical Installation

5 Electrical Installation

6 Pre-Start Check List

7 Commissioning

8 Wiring Configuration Examples

9 Maintenance, Diagnostics, and Troubleshooting

10 Specifications

11 Appendix

Index

Quick Links

Troubleshooting

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

Table of Contents