Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AQUA Drive FC 202 110-1400 kW www.danfoss.com/drives...
Page 3: Table Of Contents
2.12 Galvanic Isolation (PELV) 2.13 Earth Leakage Current 2.14 Control with Brake Function 2.15 Mechanical Brake Control 2.16 Extreme Running Conditions 2.16.1 Motor Thermal Protection 3 Selection 3.1 Options and Accessories MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 4 3.2.7 Frame Size F Options 4 How to Order 4.1 Ordering Form 4.1.1 Drive Configurator 4.1.2 Type Code String 4.2 Ordering Numbers 4.2.1 Ordering Numbers: Options and Accessories 4.2.2 Advanced Harmonic Filters Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 5 5.3.15 12-Pulse Control Cables 5.3.16 Switches S201, S202 and S801 5.4 Connections - Frame Sizes D, E and F 5.4.1 Torque Settings 5.4.2 Power Connections 5.4.3 Power Connections 12-Pulse Frequency Converters MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 6 6.1.8 Cascade Controller Wiring Diagram 6.1.9 Fixed Variable Speed Pump Wiring Diagram 6.1.10 Lead Pump Alternation Wiring Diagram 7 RS-485 Installation and Set-up 7.1 Introduction 7.1.1 Hardware Setup 7.1.2 Parameter Settings for Modbus Communication Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 7 7.8.5 Function Field 7.8.6 Data Field 7.8.7 CRC Check Field 7.8.8 Coil Register Addressing 7.8.9 Function Codes Supported by Modbus RTU 7.9 How to Access Parameters 7.9.1 Parameter Handling 7.9.2 Storage of Data MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 8 8.5.3 Derating for Running at Low Speed 8.5.4 Automatic Adaptations to Ensure Performance 8.5.5 Derating for Ambient Temperature 8.6 Troubleshooting 8.6.1 Alarm Words 8.6.2 Warning Words 8.6.3 Extended Status Words 8.6.4 Warning and Alarm Introduction Index Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 9: How To Read This Design Guide
• Instruction: Analog I/O Option MCB109 • Instruction: Panel through mount kit In no event shall Danfoss be liable for direct, indirect, • special, incidental, or consequential damages arising out of ® Active Filter Operating Instruction.
Page 10 Input: Start-disable command VLT,MAX A stop command belonging to the group 1 control The maximum output current. commands - see this group. Stop command See Control Command. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 11 The digital inputs can be used for controlling various functions of the frequency converter. Residual Current Device. Digital Outputs The drive features two solid-state outputs that can supply a 24 V DC (max. 40 mA) signal. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 12 ) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque. 60° AVM Switching pattern called 60° Asynchronous Vector Modulation (14-00 Switching Pattern). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 13: Introduction
525-690 450-1200 High voltage can be present even when the warning LED • Follow the procedures in these operating indicator lights are off. instructions. Table 2.1 Discharge Time MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 14: Software Version
An internal failure in the frequency converter can result Frequency converters with integrated safety function are in serious injury, when the frequency converter is not now falling under the Machinery Directive. Danfoss CE- properly closed. labels in accordance with the directive and issues a •...
Page 15: Air Humidity
Steam, oil, and salt water can cause corrosion of components and metal parts. In such Danfoss CE labels the frequency converters in accordance environments, use equipment with enclosure rating IP54/ with the low-voltage directive, meaning that if the IP55.
Page 16: Vibration And Shock
When comparing with alternative control systems and Voume % technologies, a frequency converter is the optimum energy Illustration 2.2 Energy Savings control system for controlling fan and pump systems. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 17 Illustration 2.4 Flow Distribution over 1 Year Flow ~n Pressure ~n Power ~n 12,5% 100% Illustration 2.3 Dependence of Flow, Pressure and Power consumption on RPM Flow : Pressure : Power : MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 18 29,0 38.106 1752 35,0 61.320 18,5 32.412 1752 31,5 55.188 11,5 20.148 1752 28,0 49.056 11.388 1752 23,0 40.296 6.132 Σ 100 8760 275.064 26.801 Table 2.5 Energy Savings - Calculation Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 19 50Hz Full load & speed Illustration 2.6 Current Consumption with a Frequency Converter ® AQUA Drive FC 202 Star/delta starter Soft-starter Start directly on mains Table 2.6 Legend to Illustration 2.6 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 20: Control Structures
Table 2.7 describes the functions of the control terminals. Many of these terminals have multiple functions determined by parameter settings. Some options provide more terminals. See chapter 5.1 Mechanical Installation for terminal locations. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 21 Used for reference or feedback signals. A thermistor can be connected here. Common for terminals 53 and 54. RS-485 common. 68, 69 RS-485 interface and serial communication. Table 2.7 Terminal Control Functions (without Optional Equipment) MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 22 0 V (PNP) 24 V (NPN) (COM RS-485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 2.8 D-frame Interconnect Diagram Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 23 Interface 24V (NPN) 32 (D IN) 0V (PNP) (P RS-485) 68 24V (NPN) (COM RS-485) 61 33 (D IN) 0V (PNP) 37 (D IN) Illustration 2.9 E- and F-frame Interconnect Diagram MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 24: Control Structure Open Loop
Local reference forces the configuration mode to open set-ups in parameter group 5–1* Digital Inputs or loop, independent on the setting of 1-00 Configuration parameter group 8–5* Serial Communication. Mode. Local reference is restored at power-down. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 25: Control Structure Closed Loop
While the default values for the closed loop controller often provides satisfactory performance, the control of the system can often be optimised by adjusting some of the parameters of the closed loop controller. It is also possible to autotune the PI constants. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 26: Feedback Handling
(feedback is higher than setpoint, resulting in a negative difference). If [13] Multi-Setpoint Min is selected, Zone 2 setpoint and feedback is sent to the PID controller, since it has the larger difference (feedback is lower than setpoint, resulting in a positive difference). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 27: Feedback Conversion
For an example, see Illustration 2.14. Ref. signal Ref. P 20-01 P 20-04 Desired P 20-07 FB conversion Flow Flow signal Illustration 2.14 Feedback Conversion MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 28: Reference Handling
Up to eight preset references can be programmed in the third digital input can be used to reset the digipot frequency converter. The active preset reference can be reference. All reference resources and the bus reference Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 29: Example Of Closed Loop Pid Control
Illustration 2.17 Closed Loop PID Control in a Water Distri- potentiometer or a parameter. The pressure sensor has a bution System range of 0–10 Bar and uses a two-wire transmitter to MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 30: Programming Order
20–93 See chapter 2.9.11 Manual PID Adjustment. 20–94 8) Finished! Save the parameter setting to the LCP for safe keeping 0–50 [1] All to LCP Table 2.9 Programming Closed Loop PID Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 31: Tuning The Closed Loop Controller
(6-16 Terminal 53 Filter Time Constant, 6-26 Terminal 54 Filter Time Constant, 5-54 Pulse Filter Time Constant #29 or 5-59 Pulse Filter Time Constant #33 as required). MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 32: General Aspects Of Emc
Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) comes from the control electronics. For more information on EMC, see chapter 5.9 EMC-correct Installation. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 33: Emission Requirements
EN/IEC 61000-6-3 Emission standard for residential, commercial, Class B (home and office) and light industrial environments. Second environment EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1 (industrial environment) Table 2.12 Generic Emission Standard Limits MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 34: Emc Test Results (Emission)
The individual voltage harmonics calculate the total the cables. voltage distortion (THD) using this formula: THD % = + ... + % of U) Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 36 8 kV AD — — 10V/m — 6 kV CD Table 2.18 EMC Immunity Form 1) Injection on cable shield AD: Air Discharge CD: Contact Discharge CM: Common mode DM: Differential mode Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 37: Galvanic Isolation (Pelv)
WARNING Installation at high altitude: 380-500 V, enclosure D, E, and F: At altitudes above 3 km, contact Danfoss regarding PELV. 525–690 V: At altitudes above 2 km, contact Danfoss regarding PELV. Illustration 2.20 Galvanic Isolation WARNING Touching the electrical parts could be fatal - even after The functional galvanic isolation - indicated by a and b in the equipment has been disconnected from mains.
Page 38: Control With Brake Function
See also Protection Against Electrical Hazards. time also called intermittent duty cycle. The resistor intermittent duty cycle is an indication of the duty cycle at Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 39: Mechanical Brake Control
Time Illustration 2.25 Typical Braking Cycle 2.15.1 Brake Resistor Cabling EMC (twisted cables/shielding) Danfoss offers brake resistors with duty cycles of 10% and Twist the wires to reduce electrical noise between the ® 40% suitable for use with the VLT AQUA Drive FC 202.
Page 40: Motor Thermal Protection
2.16.1 Motor Thermal Protection dissipated as a loss in the frequency converter, the motor, and the installation. Danfoss uses motor thermal protection to keep the motor In-correct slip compensation setting can cause from being overheated. It is an electronic feature that higher DC link voltage.
Page 41 Check that the chosen supply voltage follows the specifi- Set 1-90 Motor Thermal Protection to [2] Thermistor Trip cation of the used thermistor element. Set 1-93 Thermistor Source to [6] Digital Input 33 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 42 ETR is activated in 1-90 Motor Thermal Protection and is controlled in 4-16 Torque Limit Motor Mode. The time before the torque limit warning trips the frequency converter is set in 14-25 Trip Delay at Torque Limit. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 43: Selection
Galvanic isolation in the MCB 101 If using the internal 24 V power supply (terminal 9) to Danfoss offers a wide range of options and accessories for switch digital inputs 7, 8 or 9, establish the connection the frequency converters.
Page 44: Digital Inputs - Terminal X30/1-4
Parameters for set-up: 6–6* and 16–77 Number of analog outputs Output signal level Tolerance Max. impedance 0/4 - 20 mA ± 0.1 mA < 500Ω Table 3.4 Analog Outputs - Terminal X30/5+8 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 45: Relay Option Mcb
Do not combine low voltage parts and PELV systems. At a single fault, the whole system can become dangerous to touch and it could result in death or serious injury. Illustration 3.3 Wiring the Terminals MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 46: Back-Up Option Mcb 107 (Option D)
• Turning frequency converter into de-central I/O block supporting Building Management System with inputs for sensors and outputs for operating dampers and valve actuators Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 47 Accuracy of clock is better than ± 20 ppm at 25 °C. have same options as for analog outputs on control card. The built-in lithium back-up battery lasts on average for minimum 10 years, when the frequency converter is MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 48: Extended Cascade Controller Mco
Warning Dual supply cascade controllers for any application requiring multiple motors configured in parallel. NOTICE Place the label on the LCP frame as shown (UL approved). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 49: Brake Resistors
The resistor is selected in respect to its ohmic value, its power dissipation rate, and its physical size. Danfoss offers a wide variety of different resistors that are specially designed to our frequency converters. See chapter 2.14 Control with Brake Function for the dimensioning of brake resistors.
Page 50: Remote Mounting Kit For Lcp
Danfoss offers two types of passive filters. The Danfoss AHF 005 and AHF 010 are advanced harmonic filters, not to be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially designed to match the Danfoss frequency converters.
Page 52: Installation Of Back Channel Cooling Kit In Rittal Enclosures
The minimum enclosure dimension is: • D3h frame: Depth 500 mm and width 400 mm • D4h frame: Depth 500 mm and width 600 mm. • E2 frame: Depth 600 mm and width 800 mm. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 53: Outside Installation/Nema 3R Kit For Rittal Enclosures
3R kit. Frequency converters in E2 frames require no derating. Frame Size Part Number Instruction Number 176F3633 177R0460 176F3634 177R0461 176F1852 176R5922 Table 3.15 NEMA-3R Kit Ordering Information Illustration 3.15 Cutaway Side View of Cabinet MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 54: Installation On Pedestal
IP21 (NEMA 1) or IP54 (NEMA 12) enclosure ratings. Illustration 3.16 Frequency Converter Mounted on a Pedestal Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 55: Installation Of Input Plate Options
Not Applicable Not Applicable FC302: 355-400 FC102/FC202: 560–630 176F0254 176F0258 Not Applicable Not Applicable Not Applicable FC302: 500–560 Table 3.18 Input Options NOTICE For further information, see the Instruction Sheet, 175R5795 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 56: Installation Of Mains Shield For Frequency Converters
Table 3.19 provides more detail converter, must be installed to maintain the IP20 rating of about which disconnects are used. the enclosure. Illustration 3.18 shows both the covered and uncovered terminals. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 57: Contactor
Table 3.21 Circuit Breaker Information systems (TN and TT systems in IEC terminology). There is a pre-warning (50% of main alarm set-point) and a main alarm set-point. Each set-point is associated with an SPDT MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 58 2 • starters may be selected. The starter is integrated into the Interface setup software safe torque off circuit. Unit features include: Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 59: How To Order
The Drive Configurator automatically generates an eight-digit sales number for the local sales office. Furthermore,it´s possible to establish a project list with several products and send it to a Danfoss sales representative. The Drive Configurator can be found on the global internet site: www.danfoss.com/drives.
Page 60 C00: IP00/Chassis (for installation in external enclosure) w/ stainless steel back channel E21: IP 21/NEMA Type 1 E54: IP 54/NEMA Type 12 E2M: IP 21/NEMA Type 1 with mains shield E5M: IP 54/NEMA Type 12 with mains shield Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 61 Table 4.2 Ordering Type Code for E-Frame Frequency Converters Description Possible choice Product group 1–3 Drive series 4–6 Power rating 8–10 500–1200 kW Mains voltage T 4: 380–480 V AC T 7: 525–690 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 62 G: Mains disconnect, contactor, loadsharing terminals & fuses H: Mains circuit breaker, contactor, loadsharing terminals & fuses J: Mains circuit breaker & fuses K: Mains circuit breaker, loadsharing terminals & fuses Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 63 XX: Standard software D options 38–39 DX: No option D0: DC backup The various options are described further in this Design Guide. Table 4.3 Ordering Type Code for F-Frame Frequency Converters MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 64: Ordering Numbers
130B1218 Option for Slot C MCO 102 Advanced Cascade Control 130B1154 130B1254 Option for Slot D MCB 107 24 V DC back-up 130B1108 130B1208 Table 4.4 Ordering Numbers: Options and Accessories Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 65: Advanced Harmonic Filters
Table 4.5 Ordering Numbers: Options and Accessories Options can be ordered as factory built-in options, see ordering information. For information on fieldbus and application option compatibility with older software versions, contact your Danfoss supplier. 4.2.2 Advanced Harmonic Filters Harmonic filters are used to reduce mains harmonics: •...
Page 66 1510 1175 <77 130B2872 130B2855 130B3135 130B3094 N250 1850 1542 <77 130B2873 130B2856 2x130B3133 2x130B3092 N315 2576 1810 <80 2x130B2871 2x130B2819 Table 4.8 Advanced Harmonic Filters, 380-415 V, 60 Hz, D-frame Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 67 130B3165 130B2259 130B1786 N250 1852 1542 <77 130B1769 130B1751 130B1900+ 130B1783+ N315 2482 1769 <80 130B2200 130B1784 130B1765+ 130B1497+ 130B1766 130B1498 Table 4.10 Advanced Harmonic Filters 440-480 V, 60 Hz, D-frame MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 68 N250 1852 1288 <75 130B5260 130B5226 2x130B5273 130B5244 N315 2812 1542 <75 2x130B5258 130B5227 2x130B5273 130B5245 N400 2812 1852 <75 2x130B5258 130B5228 Table 4.12 Advanced Harmonic Filters, 600 V, 60 Hz Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 69 2x130B5197 130B5295 2x130B5042 130B5334 N355 381 2812 1852 130B5042 130B5330 +130B5066 +130B5331 N400 413 N400 395 2916 2127 130B5197 130B5292 +130B5198 +130B5293 Table 4.14 Advanced Harmonic Filters, 500-690 V, 50 Hz MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 70 P800 962 1000 P900 920 6516 4118 2x130B5199 2x130B5294 +2x130B5197 +130B5295 6x130B5042 3x130B5333 1098 P1M0 1079 P1M0 1032 8436 4626 6x130B5197 3x130B5295 Table 4.15 Advanced Harmonic Filters, 500-690 V, 50 Hz Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 71: Sine-Wave Filter Modules, 380-690 V Ac
F2/F4, F12/F13 3X130B3188 3X130B3189 1460 F2/F4, F12/F13 1200 1380 1000 1380 F2/F4, F12/F13 3X130B3191 3X130B3192 1000 1720 1350 1530 1100 1530 F2/F4, F12/F13 Table 4.16 Sine Wave Filter Modules, 380-500 V MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 72 Table 4.17 Sine Wave Filter Modules 525-690 V NOTICE When using sine-wave filters, ensure that the switching frequency complies with filter specifications in 14-01 Switching Frequency. See also Advanced Harmonic Filters Design Guide. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 73: Ordering Numbers: Du/Dt Filters
1000 1317 1350 1260 1200 1260 F2/F4, F12/F13 1100 1479 1550 1415 1400 1415 F2/F4, F12/F13 3x130B2853 3x130B2854 Table 4.18 dU/dt Filter Ordering Numbers NOTICE See also Output Filter Design Guide MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 74: Ordering Numbers: Brake Resistors
=Nominal resistance required to achieve 150% braking torque. br, nom 1) Larger frequency converters include multiple inverter modules with a brake chopper in each inverter. Connect equal resistors to each brake chopper. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 77 The F9 is an F8 with an additional options cabinet. The F11 is an F10 with an additional options cabinet. The F13 is an F12 with an additional options cabinet. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 78: Mechanical Mounting
Fasten 2 M5 screws through the back pedestal flange into the pedestal drive mounting bracket. Fasten 4 M5 screws through the front pedestal flange into the front gland plate mounting holes. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 79: Pedestal Installation Of F-Frames
See chapter 8.5.5 Derating for Ambient bolts per cabinet. Refer to Illustration 5.4 Temperature. Failure to consider derating for ambient temperature can reduce the service life of the frequency converter. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 80: Pre-Installation
Ensure that the motor current rating is within the maximum current from the frequency converter • If the frequency converter is without built-in fuses, ensure that the external fuses are rated correctly. Illustration 5.5 Nameplate Label Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 81: Transportation And Unpacking
Maximum diameter for the bar is 2.5 cm (1 inch). The angle from the top of the drive to the lifting cable should be 60° or greater. Illustration 5.6 Recommended Lifting Method, D-frame Size MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 82 Illustration 5.9 Recommended Lifting Method, Frame Sizes F3, F4, F11, F12 and F13 Illustration 5.10 Recommended Lifting Method, Frame Size F8 Illustration 5.8 Recommended Lifting Method, Frame Sizes F1, F2, F9 and F10 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 83: Tools Needed
In addition, space in front of the unit must be considered to enable opening of the door of the panel. Illustration 5.13 Front Clearance of IP21/IP54 Enclosure Type, Frame Size E1. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 84 Frame Size F13 Frame Size F4 (30.6) Illustration 5.18 Front Clearance of IP21/IP54 Enclosure Type, Frame Size F8 (22.8) (30.6) Illustration 5.19 Front Clearance of IP21/IP54 Enclosure Type, Frame Size F9 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 85: Cooling And Airflow
700 (412) 12-Pulse P315 to P1M0 P450 to P1M4 985 (580) F12/F13 IP54/NEMA 12 525 (309) Table 5.5 Heatsink and Front Channel Airflow * Airflow per fan. F-frames contain multiple fans. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 86 69.5 152.8 210.8 Pressure Change (Pa) Specific control card ambient temperature Illustration 5.26 E-frame Derating vs. Pressure Change (Large exceeded Fan), P315T5-P400T5 and P500T7-P560T7. Frequency Converter Airflow: 850 cfm (1,445 m Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 87: Gland/Conduit Entry - Ip21 (Nema 1) And Ip54 (Nema12)
[1.0] [10.8] [5.4] [8.8] [5.4] [4.4] [8.1] 1 Mains side 2 Motor side Illustration 5.30 D5h & D6h, Bottom View 1 Mains side 2 Motor side Illustration 5.28 D1h, Bottom View MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 88 [1.398] 36.2 594.8 [1.425] [23.417] 1727.8 [68.024] 62.5 202.8 130.0 1 Cable conduit entry 98.6 Illustration 5.34 F2, Bottom View 1 Mains side 2 Motor side Illustration 5.32 E1, Bottom View Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 89: Gland/Conduit Entry, 12-Pulse - Ip21 (Nema 1) And Ip54 (Nema12)
35.5 (1.398) 597.0 (23.504) 36.2 1130.0 (44.488) Place conduits in shaded areas (1.425) 1191.8 (46.921) 2324.8 (91.528) Illustration 5.37 Frame Size F8 1 Cable conduit entry Illustration 5.36 F4, Bottom View MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 90 Illustration 5.38 Frame Size F9 593.0 70.0 [23.346] [2.756] 199.5 [7.854] 535.0 [21.063] 258.5 [10.177] 36.5 37.2 [1.437] [1.466] 733.0 [28.858] 800.0 [31.496] 1533.0 [60.354] Place conduits in shaded areas Illustration 5.39 Frame Size F10 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 91 [39.146] 593.0 70.0 [23.346] [2.756] 199.5 [7.854] 535.0 [21.063] 258.5 [10.177] 36.5 37.2 [1.437] 733.0 [1.466] [28.858] 800.0 [32] 1933.0 [76] Place conduits in shaded areas Illustration 5.41 Frame Size F12 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 92: Electrical Installation
EN 50178. converter. The mains connection is fitted to the main switch if included. NOTICE Check that mains voltage corresponds to the mains voltage of the frequency converter name plate. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 93: Motor Cable Connection
Avoid mounting with twisted screen ends (pigtails), which spoils high frequency screening effects. • If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 94: Electrical Installation Of Motor Cables
Aluminum conductors are not recommended. Terminals can accept aluminum conductors but the conductor surface has to be clean, free of oxidation and sealed with neutral acid free Vaseline grease before the conductor is connected. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 95: Fuses
Short circuit protection The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned in Table 5.7 and Table 5.8 to protect service personnel or other equipment in case of an internal failure.
Page 96: Access To Control Terminals
Insert the cable in the adjacent circular hole. Remove the screw driver. The cable is now mounted to the terminal. Illustration 5.49 Control Cable Terminals Control cable torque value is 0.5-0.6 Nm (5 in-lbs.) Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 97: Basic Wiring Example
Connect terminals 18 and 27 to +24 V (terminal 12/13) Default settings: 18 = Start 27 = stop inverse Start Stop inverse Safe Stop Speed Start (18) Start (27) Illustration 5.50 Terminal 37 available with Safe Stop Function only! MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 98: Control Cable Length
0 V (PNP) 24 V (NPN) (COM RS-485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 5.51 Interconnect Diagram for D-frames Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 99 (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input disturbs the analogue input signal. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 100 How to Install Design Guide Use a clamp from the accessory bag to connect the screen to the frequency converter de-coupling plate for control cables. Illustration 5.53 Screened Control Cable Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 101: 12-Pulse Control Cables
11 12 13 14 11 12 13 14 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 Illustration 5.54 Control Cable Diagram MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 102 Terminal 37 is the input to be used for safe torque off. For instructions on safe torque off installation, refer to VLT Frequency Converters Safe Torque Off Operating Instructions.. 1) F8/F9 = (1) set of terminals. 2) F10/F11 = (2) sets of terminals. 3) F12/F13 = (3) sets of terminals. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 103: Switches S201, S202 And S801
NOTICE Illustration 5.56 Input Polarity of Control Terminals Change switch position at power off only. NPN (Sink) Digital input wiring Illustration 5.57 Input Polarity of Control Terminals Illustration 5.58 Switch Locations MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 104: Connections - Frame Sizes D, E And F
17.7-20.5 (156-182 in-lbs.) Motor Load Sharing Regen: 9.5 (85) 8.8-10.3 (78.2-90.8) 19.1 (169) 17.7-20.5 (156-182) F8-F13 Regen 19.1 (169) 17.7-20.5 (156-182.) Earth 9.5 (85) 8.8-10.3 (78.2-90.8) Brake Table 5.9 Terminal Tightening Torques Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 105: Power Connections
Make the screen connections with the largest possible surface area (cable clamp) by using the installation devices within the frequency converter. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 106 14 Motor output terminals 96 (U), 97 (V), 98 (W) Analog switches (A53), (A54) 15 Mains input terminals 91 (L1), 92 (L2), 93 (L3) Relay 1 (01, 02, 03) Table 5.11 Legend to Illustration 5.61 and Illustration 5.62 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 107 Terminal Locations - D1h/D2h Take the following position of the terminals into consideration when designing the cable access. Illustration 5.63 Position of Ground Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12), D1h/D2h MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 108 Take the following position of the terminals into consideration when designing the cable access. Illustration 5.64 Position of Ground Terminals IP20 (Chassis), D3h/D4h Ground Terminals Table 5.12 Legend to Illustration 5.63 and Illustration 5.64 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 109 Take the following position of the terminals into consideration when designing the cable access. 9 [ ] 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.65 Terminal Locations, D5h with Disconnect Option MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 110 How to Install Design Guide 28.6 24.5 20.4 20.1 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.66 Terminal Locations, D5h with Brake Option Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 111: Analog I/O Option Mcb
Take the following position of the terminals into consideration when designing the cable access. 18.0 Mains Terminals Motor Terminals TB6 Terminal block for contactor Ground Terminals Brake Terminals Illustration 5.67 Terminal Locations, D6h with Contactor Option MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 112 How to Install Design Guide Brake Terminals Ground Terminals TB6 Terminal block for contactor Mains Terminals Motor Terminals Illustration 5.68 Terminal Locations, D6h with Contactor and Disconnect Options Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 113 How to Install Design Guide 18.4 Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.69 Terminal Locations, D6h with Circuit Breaker Option MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 114 Take the following position of the terminals into consideration when designing the cable access. 21.4 20.3 16.2 15.6 14.7 0 [ ] Mains Terminals Ground Terminals Motor Terminals Brake Terminals Illustration 5.70 Terminal Locations, D7h with Disconnect Option Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 115 Design Guide 1260 49.6 1202 47.3 1082 42.6 1034 40.7 1009 39.7 0 [ ] Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.71 Terminal Locations, D7h with Brake Option MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 116 Take the following position of the terminals into consideration when designing the cable access. 35.3 20.5 16.5 15.8 14.9 0 [ ] TB6 Terminal block for contactor Brake Terminals Motor Terminals Mains Terminals Ground Terminals Illustration 5.72 Terminal Locations, D8h with Contactor Option Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 117 How to Install Design Guide 22.3 TB6 Terminal block for contactor Motor Terminals Mains Terminals Ground Terminals Brake Terminals Illustration 5.73 Terminal Locations, D8h with Contactor and Disconnect Options MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 118 How to Install Design Guide 23.8 Mains Terminals Motor Terminals Brake Terminals Ground Terminals Illustration 5.74 Terminal Locations, D8h with Circuit Breaker Option Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 119 Take the following position of the terminals into consideration when designing the cable access. 492[19.4] 323[12.7] 0[0.0] 195[7.7] Front View of Unit Illustration 5.75 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 120 How to Install Design Guide 19 Nm [14 FTa 453[17.8] 0[0.0] Illustration 5.76 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions (Detail B) Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 121 315/355-400/450 kW (400 V) 371 (14.6) 371 (14.6) 341 (13.4) 431 (17.0) 431 (17.0) 455 (17.9) Illustration 5.77 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Position of Disconnect Switch MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 122 T/L3 93 186[7.3] U/T1 96 V/T2 97 W/T3 98 17[0.7] 0[0.0] Illustration 5.78 IP00 Enclosure Power Connection Positions R 81 019Nm (14 F) 147(5.8) 0(0.0) Illustration 5.79 IP00 Enclosure Power Connection Positions Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 123 Each terminal allows use of up to 4 cables with cable lugs or use of standard box lugs. Ground is connected to a relevant termination point in the frequency converter. 104[4.1] 35[1.4] 10[0.4] 0[0.0] Illustration 5.81 Terminal in Detail MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 124 Front Side Ground bar Left Side Motor Terminals Right Side Brake Terminals Illustration 5.82 Terminal Locations - Inverter Cabinet - F1 and F3. Gland Plate is 42 mm below .0 Level. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 125 180.3 [7.10] 0.0 [0.00] Front Side Right Side Left Side Ground bar Illustration 5.84 Terminal Locations - Inverter Cabinet - F2 and F4. Gland Plate is 42 mm below .0 Level. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 126 432.5 [17.03] 81.4 [3.20] Left Side Loadshare Terminal (-) Front Side Ground bar Right Side Loadshare Terminal (+) Illustration 5.86 Terminal Locations - Rectifier. Gland Plate is 42 mm below .0 Level. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 127 Take the following position of the terminals into consideration when designing the cable access. 1031.4[40.61] 939.0[36.97] 134.6[5.30] 0.0[0.00] 0.0[1.75] 244.4[1.75] 244.4[9.62] Left Side Right Side Front Side Ground bar Illustration 5.87 Terminal Locations - Options Cabinet. Gland Plate is 42 mm below .0 Level. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 128 Power size 450 kW (480 V), 630-710 kW (690 V) 34.9 86.9 122.2 174.2 500-800 kW (480 V), 800-1000 kW (690 V) 46.3 98.3 119.0 171.0 Table 5.14 Dimension for Terminal Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 129: Power Connections 12-Pulse Frequency Converters
91-1 (L1-1) 6 Phase 92-1 (L2-1) power 93-1 (L3-1) input 91-2 (L1-2) 92-2 (L2-2) 93-2 (L3-2) 95 PE Illustration 5.89 Mains Connection NOTICE For more information, see chapter 5.9 EMC-correct Installation. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 130 4) If one of the 6-pulse modular rectifiers becomes inoperable, it is possible to operate the frequency converter at reduced load with a single 6-pulse rectifier. Contact Danfoss for reconnection details. 5) No paralleling of mains cabling is shown here. A 12-pulse frequency converter used as a 6-pulse should have mains cables of equal numbers and lengths.
Page 131: Shielding Against Electrical Noise
A fuse for protection. In UL applications, use a LittelFuse KLK-5 or equivalent. Terminal no. Function 100, 101 Auxiliary supply S, T 102, 103 Internal supply S, T Table 5.16 External Power Supply MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 132: Input Options
ABB OT400U12-121 P560 ABB OT400U12-121 P630 ABB OETL-NF600A P710 ABB OETL-NF600A P800 ABB OT800U21 P900 ABB OT800U21 P1M0 Merlin Gerin NPJF36000S12AAYP P1M2 Merlin Gerin NPJF36000S12AAYP Table 5.18 Mains Disconnects, 12-Pulse Frequency Converters Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 133: Circuit Breakers
N110-N160 380-480 V GE CK95BE311N N55-N132 525-690 V GE CK95CE311N N75-N160 525-690 V GE CK95BE311N N160-N250 380-500 V N200-N315 380-480 V GE CK11CE311N N160-N315 525-690 V N200-N400 525-690 V Table 5.21 D-frame Contactors MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 134: Relay Output D Frame
240Vac, 2A 240Vac, 2A 400Vac, 2A relay2 relay2 240Vac, 2A 240Vac, 2A 400Vac, 2A 400Vac, 2A Illustration 5.93 E- and F-Frame Additional Relay Outputs Illustration 5.92 D-Frame Additional Relay Outputs Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 135: Final Set-Up And Test
Press [OK] to exit the AMA state. Unsuccessful AMA RS 485 The frequency converter enters into alarm mode. A description of the alarm can be found in Illustration 5.94 Parallel Connections MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 136: How To Connect A Pc To The Unit
All frequency converters are equipped with a serial communication port. A PC tool for communication Ext. User Interface • between PC and frequency converter is available. Preventive Maintenance Schedule • Clock settings • Timed Action Programming Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 137: Safety
2 separate earth ground wires both complying frequency converters as well as non-Danfoss frequency with the dimensioning rules converters with additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can 5.9 EMC-correct Installation be calculated. Ordering number: 5.9.1 Electrical Installation - EMC...
Page 138 Motor cable between con- trol cables, motor cable and Mains-supply mains cable Motor, 3 phases and Reinforced protective earth Protective earth Illustration 5.96 EMC-Correct Electrical Installation of a Frequency Converter in Cabinet Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 139: Use Of Emc-Correct Cables
Minimum cable cross- section: 16 mm For 50/60 Hz earth loops If long control cables are used, 50/60 Hz earth loops are possible. Solve this problem by MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 140 RC link. Use twisted-pair cables for reducing the differential mode interference between the conductors. PLC etc. PLC etc. Min. 16mm Equalizing cable PLC etc. 100nF Illustration 5.99 Earthing Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 141: Residual Current Device
If RCD relays are used, local regulations must be observed. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief discharge on power-up see chapter 2.13 Earth Leakage Current for further information. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 142: Application Examples
Stop inverse Safe Stop Speed Speed Start/Stop [18] Illustration 6.1 Terminal 37: Available only with Safe Stop Function! Start (18) Start (27) Illustration 6.2 Terminal 37: Available only with Safe Stop Function! Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 143: Potentiometer Reference
[1]/action [1]. The Repeated AMA runs could lead to a heating of illustration shows an example with three events/actions: the motor, which results in an increase of the MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 144 Set Action 3 in 13-52 SL Controller Action [3] to Select preset 1 [11] Set Action 4 in 13-52 SL Controller Action [4] to No Action [1] Set the in 13-00 SL Controller Mode to ON. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 145: Basic Cascade Controller
2 built-in relays control the other two pumps. When lead pump alternations are enabled, pumps are connected to the built-in relays and the frequency converter can operate 2 pumps. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 146: Pump Staging With Lead Pump Alternation
(de-staged). status disappears. The lead pump continues to ramp up and then ramps down to a stop and the 2 relays are cut out. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 147: Cascade Controller Wiring Diagram
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 6.9 Cascade Controller Wiring Diagram MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 148: Fixed Variable Speed Pump Wiring Diagram
When all relays are de-energized, the first built-in relay that is energized cuts in the contactor corresponding to the pump controlled by the relay. For example, RELAY 1 cuts in contactor K1, which becomes the lead pump. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 149 Ramps down Cut out Auto On Starts and stops according to commands via Staging/Destaging terminals or serial bus Table 6.2 Function of LCP Keys MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 150: Installation And Set-Up
Normally a distance of 200 mm (8 in) is sufficient. However, in situations where cables run in parallel over long distances, keeping the greatest possible distance Illustration 7.1 Terminator Switch Factory Setting between cables is recommended. When crossing is Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 151: Fc Protocol Overview
7.2 FC Protocol Overview The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard fieldbus. It defines an access technique according to the master-slave principle for communications via a serial bus. One master and a maximum of 126 slaves can be connected to the bus.
Page 152: Network Connection
LGE=12+1+1=14 bytes • The length of telegrams containing texts is 10 bytes 1) The 10 represents the fixed characters, while the “n’” is variable (depending on the length of the text). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 153: Frequency Converter Address (Adr)
PCD1 PCD2 high Illustration 7.8 Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Illustration 7.9 Text Block MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 154: The Pke Field
If a parameter contains not a numerical value but several data options, for example, 0-01 Language [0] English, and [4] Danish, select the data value by entering the value in the PWE Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 155: Data Types Supported
16 bits, which always occur in the defined sequence. Table 7.6 Data Types Supported PCD 1 PCD 2 Reference-value Control Telegram (master⇒follower Control word) Present output Control Telegram (follower⇒master) Status word frequency Table 7.8 PCD Sequence MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 156: Examples
=0000 Hex high =03E8 Hex - Data value 1,000, corresponding to 100 7.6.1 Assumptions Hz, see chapter 7.4.12 Conversion. Danfoss assumes that the installed controller supports the interfaces in this manual, and strictly observes all E19E 0000 H 0000 H 03E8 requirements and limitations stipulated in the controller and frequency converter.
Page 157: Frequency Converter With Modbus Rtu
Characters for transmission must be in hexadecimal 00 to FF format in each field. The frequency converter continuously monitors the network bus, also during ‘silent’ intervals. When the first field (the address MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 158: Start/Stop Field
When the follower responds to the master, it uses the function code field to indicate either a normal (error- free) response, or that an error has occurred (called an exception response). For a normal response, the follower Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 159: Coil Register Addressing
0 = Parameter changes are written to the RAM of the frequency converter Master to follower 1 =Parameter changes are written to the RAM and EEPROM of the frequency converter. 66-65536 Reserved Table 7.12 Coils and Holding Registers MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 160 Output data: frequency converter status word register (STW). 50210 Output data: frequency converter main actual value register (MAV). Table 7.15 Holding Registers * Used to specify the index number used when accessing an indexed parameter. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 161: Function Codes Supported By Modbus Rtu
Invalid data length or value Invalid function code There is no bus access to the parameter called Data change is not possible because factory set-up is selected Table 7.18 Error Codes MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 162: How To Access Parameters
4x registers (40001–4FFFF). The parameters are read using function 03 HEX "Read Holding Registers" and written using function 10 HEX "Preset Multiple Registers." Readable sizes range from 1 register (2 characters) up to 10 registers (20 characters). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 163: Force/Write Single Coil (05 Hex)
Response The register data in the response message are packed as 2 bytes per register, with the binary contents right justified within each byte. For each register, the first byte contains MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 164: Preset Single Register (06 Hex)
[3] 3-10 Preset Field Name Example (HEX) Reference Slave Address Function Table 7.29 Control Bits Register Address HI Register Address LO Preset Data HI Preset Data LO Error Check (CRC) Table 7.28 Response Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 165 Bit 07, Reset Bit 07=’0’: No reset. Bit 07=’1’: Resets a trip. Reset is activated on the leading edge of the signal, that is, when changing from logic ’0’ to logic ’1’. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 167: Bus Speed Reference Value
Reverse Forward (1) -max- +max Par.3-03 Par.3-03 Max reference Max reference 100% (0hex) (4000hex) Par.3-00 set to Forward (0) min-max Par.3-02 Par.3-03 Min reference Max reference Illustration 7.19 Reference and MAV MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 168: General Specifications And Troubleshooting
Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s Table 8.1 Technical Specifications, D1h-D4h, Mains Supply 3x380-480 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 169 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s Table 8.2 Technical Specifications, E1/E2, Mains Supply 3x380-480 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 170 A or slot B, each). 4) Measured using 5 m screened motor cables at rated load and rated frequency. 5) Wiring terminals on N132, N160, and N315 frequency converters cannot receive cables one size larger. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 171: Mains Supply 3X525-690 V Ac
Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.4 Technical Specifications, D1h/D3h, Mains Supply 3x525-690 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 172 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.5 Technical Specifications, D2h/D4h, Mains Supply 3x525-690 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 173 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.6 Technical Specifications, E1/E2, Mains Supply 3x525-690 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 174 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.7 Technical Specifications, E1/E2, Mains Supply 3x525-690 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 175 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.8 Technical Specifications, F1/F3, Mains Supply 3x525-690 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 176 Further options and customer load can add up to 30 W to the losses (though typically only 4 W extra for a fully loaded control card or options for slot A or slot B, each). 4) Measured using 5 m screened motor cables at rated load and rated frequency. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 177: 12-Pulse Specifications
Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s Table 8.11 Technical Specifications F8/F9 12-Pulse, Mains Supply 6x380-480 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 178 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s Table 8.12 Technical Specifications F10-F13 12-Pulse, Mains Supply 6x380-480 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 179 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.13 Technical Specifications F8/F9 12-Pulse, Mains Supply 6x525-690 V AC MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 180 Heatsink overtemp. trip [°C] Power card ambient trip [°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 8.14 Technical Specifications F10/F11 12-Pulse, Mains Supply 6x525-690 V AC Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 181 Further options and customer load can add up to 30 W to the losses (though typically only 4 W extra for a fully loaded control card or options for slot A or slot B, each) 4) Measured using 5 m screened motor cables at rated load and rated frequency MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 182 Starting torque (constant torque) maximum 110% for 1 minute Starting torque maximum 135% up to 0.5 s Overload torque (constant torque) maximum 110% for 1 minute 1) Percentage relates to nominal torque. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 183 Accuracy on analogue output Max. error: 0.8% of full scale Resolution on analogue output 8 bit The analogue output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 184 4-5 (NO) (Inductive load @ cosφ 0.4) Max. terminal load (AC-15) 240 V AC, 0.2 A Max. terminal load (DC-1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 185 See chapter 8.5 Special Conditions for more information. Control card performance Scan interval 5 ms Control card, USB serial communication USB standard 1.1 (Full speed) USB plug USB type B “device” plug MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 186: Efficiency
In general, the motor voltage before it stabilises itself at a level efficiency is as good as with mains operation. The efficiency of the motor depends on the type of motor. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 187: Special Conditions
Table 8.18 P400 - P1M0, T4/380-500 V 1) With Danfoss dU/dt filter. N110-N160, T7 (525-690 V) Mains Rise time dU/dt Cable voltage Vpeak length [m] [μsec] [kV] [kV/μsec] 0.36 2135 2.197 Table 8.19 N110-N160, T7 (525-690 V) MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 188: Derating For Running At Low Speed
An alternative is to reduce the load level of the motor by choosing a larger motor. However, the design of the frequency converter puts a limit to the motor size. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 189: Automatic Adaptations To Ensure Performance
Normal overload NO, 110% 60 AVM Normal overload NO, 110% SFAVM model D-Frame N110 to N315 525-690 V 40 C 45 C 45 C 50 C 50 C 55 C 55 C MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 190: Troubleshooting
Reset alarms to restart operation once their cause has been rectified. If an alarm cannot be reset, the reason may be that its cause has not been rectified, or the alarm is trip-locked (see also Table 8.25). Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 191 Brake check 2-15 Drive over temperature Motor phase U missing 4-58 Motor phase V missing 4-58 Motor phase W missing 4-58 Inrush fault Fieldbus communication fault Out of frequency range Mains failure MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 192 0-7* 104 Mixing fan fault 14-53 201 Fire M was active 202 Fire M limits exceeded 203 Missing motor 204 Locked rotor 243 Brake IGBT 244 Heatsink temp 245 Heatsink sensor Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 193 A trip lock is an action when an alarm occurs, which may cause damage to frequency converter or connected parts. A trip lock situation can only be reset by a power cycling. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 194 The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnosis. See also 16-90 Alarm Word, 16-92 Warning Word and 16-94 Ext. Status Word. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 195: Alarm Words
20000000 Drive initialised 20000000 Reserved 40000000 Safe torque off [A68] 40000000 PTC 1 Safe Torque Off [A71] 80000000 80000000 Dangerous Failure [A72] Table 8.28 Alarm Word Table 8.29 Alarm Word 2 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 196: Warning Words
10000000 Reserved 20000000 20000000 Reserved 40000000 Safe torque off [W68] 40000000 PTC 1 Safe Torque Off [W71] 80000000 Not used 80000000 Reserved Table 8.30 Warning Words Table 8.31 Warning Words 2 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 197: Extended Status Words
08000000 Reserved 08000000 Reserved 10000000 Reserved 10000000 Reserved 20000000 Reserved 20000000 Reserved 40000000 Reserved 40000000 Reserved 80000000 Reserved 80000000 Reserved Table 8.32 Extended Status Word Table 8.33 Extended Status Word 2 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 198: Warning And Alarm Introduction
The limit is dependent on the gives a warning or an alarm when the counter reaches frequency converter voltage rating. The unit is still active. 100% in 1-90 Motor Thermal Protection. The fault occurs Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 199 Check the application for excessive current draw If 8-04 Control Timeout Function is set to Stop and Trip, a on the motor. warning appears and the frequency converter ramps down until it stops then displays an alarm. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 200 90% of the brake resistance power. If [2] Trip is selected in 2-13 Brake Power Monitoring, the frequency converter trips when the dissipated braking power reaches 100%. Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 201 • Check for loose or missing wiring WARNING 42, Overload of digital output on X30/6 or If necessary, contact the Danfoss supplier or service overload of digital output on X30/7 department. Note the code number for further trouble- For X30/6, check the load connected to X30/6 or remove shooting directions.
Page 202 The cutout temperature of the control card is 80 °C. Thermistor Card enables X44/10 but safe torque off is not enabled. Furthermore, if the MCB 112 is the only device using safe torque off (specified through selection [4] or [5] Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 203 The mixing-fan fault can be configured as a warning or an alarm trip by 14-53 Fan Monitor. Troubleshooting Cycle power to the frequency converter to determine if the warning/alarm returns. MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 204: Index
Control card, 10 V DC output............183 Brake resistor..................37 Control card, 24 V DC output............182 Brake resistor cabling................37 Control Card, RS-485 serial communication......181 Brake resistors..................47 Control card, USB serial communication........183 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 205 Efficiency..................143, 184 Electrical installation..............92, 96 Harmonic filter..................63 Electrical installation, EMC guidelines........135 Harmonics emission requirements..........33 Electrical noise..................129 Harmonics emission, general Aspects.......... 32 EMC directive (2004/108/EC), the........... 12 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 206 Modbus Protocol................155 LED indications................... 192 Modbus RTU................154, 155 Lifting, frequency converter............. 79 Modbus RTU, frequency converter with........155 Lifting, use lifting bar................79 Modbus status word................. 158 Line Distortion..................35 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 207 Read holding registers (03 HEX)........... 161 Real-time clock (RTC)................45 Parameter values................160 Receiving frequency converter............78 Pay back period..................15 Reference handling................27 PC software tools................134 Regeneration................54, 123 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 208 Variable control, flow and pressure..........16 Software versions................. 63 Variable speed pumps................ 46 Space......................81 Varying flow over one year............... 15 Space heaters and thermostat............55 Vibration and shock................14 Specifications Air Flow............... 83 Danfoss A/S © Rev. 06/2014 All rights reserved. MG20Z202...
Page 209 Wire access....................81 Wiring..................... 145 Wiring diagram Fixed variable speed pump............146 Lead pump alternation..............146 Wiring diagram D-frame..............20 Wiring diagram E-frame..............21 Wiring diagram F-frame..............21 Wiring example, basic................. 95 MG20Z202 Danfoss A/S © Rev. 06/2014 All rights reserved.
Page 210 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 Design Manual

1 How to Read this Design Guide

2 Introduction

3 Selection

4 How to Order

5 How to Install

6 Application Examples

7 Installation and Set-Up

8 General Specifications and Troubleshooting

Index

Quick Links

Troubleshooting

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

Table of Contents