Danfoss VLT AQUA Drive FC 202 Design Manual
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Danfoss VLT AQUA Drive FC 202 Design Manual

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MAKING MODERN LIVING POSSIBLE
Design Guide
®
VLT
AQUA Drive FC 202 110-1400 kW

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

  • Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AQUA Drive FC 202 110-1400 kW...

  • Page 3: Table Of Contents

    2.12 Earth Leakage Current 2.13 Control with Brake Function 2.14 Mechanical Brake Control 2.15 Extreme Running Conditions 2.15.1 Motor Thermal Protection 2.15.2 Safe Stop Operation (optional) 3 Selection 3.1 General Specifications ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 4 3.7.5 Installation of Mains Shield for Frequency Converters 3.7.6 D-frame Options 3.7.6.1 Load Share Terminals 3.7.6.2 Regeneration Terminals 3.7.6.3 Anti-Condensation Heater 3.7.6.4 Brake Chopper 3.7.6.5 Mains Shield 3.7.6.6 Ruggedized Printed Circuit Boards ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 5 5.3 Electrical Installation 5.3.1 Cables General 5.3.2 Preparing Gland Plates for Cables 5.3.3 Connection to Mains and Earthing 5.3.4 Motor Cable Connection 5.3.5 Motor Cables 5.3.6 Electrical Installation of Motor Cables 5.3.7 Fuses ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 6 5.10 EMC-correct Installation 5.10.1 Electrical Installation - EMC Precautions 5.10.2 Use of EMC-Correct Cables 5.10.3 Earthing of Screened/Armoured Control Cables 5.11 Residual Current Device 6 Application Examples 6.1 Typical Application Examples 6.1.1 Start/Stop ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 7 7.4.12 Conversion 7.4.13 Process Words (PCD) 7.5 Examples 7.5.1 Writing a Parameter Value 7.5.2 Reading a Parameter Value 7.6 Modbus RTU Overview 7.6.1 Assumptions 7.6.2 Prerequisite Knowledge 7.6.3 Modbus RTU Overview ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 8 7.10.4 Read Holding Registers (03 HEX) 7.10.5 Preset Single Register (06 HEX) 7.11 Danfoss FC Control Profile 7.11.1 Control Word According to FC Profile (8-10 Control Profile=FC profile) 7.11.2 Status Word According to FC Profile (STW) (8-10 Control Profile = FC profile) 7.11.3 Bus Speed Reference Value...

  • Page 9: How To Read This Design Guide

    Mode or fitness for a particular purpose. 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 The rated torque (motor). Volts The maximum output current VLT,MAX The instantaneous motor voltage. The rated output current supplied by the VLT,N frequency converter The rated motor voltage (nameplate data). Table 1.2 Abbreviations ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 11 Current input, 0–20 mA, and 4-20 mA periodic duty. Voltage input, 0-10 V DC. Analog Outputs The analog outputs can supply a signal of 0–20 mA, 4–20 mA, or a digital signal. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 12 Vector Modulation (14-00 Switching Pattern). Slip Compensation The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed almost constant. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 13 In addition, a high power factor indicates that the different harmonic currents are low. The built-in DC coils produce a high power factor, which reduces the imposed load on the mains supply. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 14: Introduction

    For installation in altitudes above 3 km (350-500 V), or 2 The voltage of the frequency converter is dangerous km (525-690 V), contact Danfoss regarding PELV. whenever connected to mains. Incorrect installation of the motor, frequency converter, or fieldbus could damage the equipment or cause serious personal injury or death.

  • Page 15: Software Version

    The EMC directive came into effect January 1, 1996. domestic waste. Danfoss CE-labels in accordance with the directive and Collect it separately in accordance with issues a declaration of conformity upon request. To carry local and currently valid legislation.

  • Page 16: Air Humidity

    IP54 or higher (or equivalent environment) to avoid cross faults and short circuits between terminals, connectors, tracks, Danfoss CE labels the frequency converters in accordance and safety-related circuitry caused by foreign objects. with the low-voltage directive, meaning that if the frequency converter is installed correctly, Danfoss guarantees compliance with the low-voltage directive.

  • Page 17: Vibration And Shock

    = Reduced speed More than 50% energy savings can be obtained in typical Table 2.4 Laws of Proportionality applications when a frequency converter is used to reduce fan capacity to 60%. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 18 Illustration 2.4 Flow Distribution over 1 Year speed of the fan or pump to new flow or pressure conditions in the system. Simple control of process (flow, level, or pressure) utilising the built-in PID control. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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 Illustration 2.9 for terminal locations. NOTE The example provided does not show optional equipment. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 22 (N RS-485) 69 0V (PNP) 24V (NPN) (COM RS-485) 61 33 (D IN) 0V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 2.8 D-frame Interconnect Diagram ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 23 (N RS-485) 69 0V (PNP) 24V (NPN) (COM RS-485) 61 33 (D IN) 0V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) Illustration 2.9 E- and F-frame Interconnect Diagram ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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). ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 29: Example Of Closed Loop Pid Control

    0 and 10 Bar using a 0–10 V Illustration 2.17 potentiometer or a parameter. The pressure sensor has a range of 0–10 Bar and uses a two-wire transmitter to ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 30: Programming Order

    Adjust the closed loop controller, if needed. 20–93 See 2.8.11 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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). ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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. See 5.10 EMC-correct Installation for more information on EMC. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • 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 2.11 Limits ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 34: Emc Test Results (Emission)

    The harmonics do not affect the power consumption directly but increase the heat losses in the installation (transformer, cables). In plants with a high percentage of THD % = U + ... + ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 35: Harmonics Emission Requirements

    2.9.6 Harmonics Test Results (Emission) environment. All Danfoss frequency converters comply with the requirements for the industrial environment as well as the lower requirements for home and office Power sizes P110 - P450 in T4 also complies with IEC/EN environment with a large safety margin.

  • Page 36: Galvanic Isolation (Pelv)

    Galvanic (ensured) isolation is obtained by fulfilling contact Danfoss regarding PELV. requirements for higher isolation and by providing the 525–690 V: At altitudes above 2 km, contact Danfoss relevant creapage/clearance distances. These requirements regarding PELV. are described in the EN 61800-5-1 standard.

  • Page 37: Earth Leakage Current

    Use RCDs of type B only, capable of detecting AC and DC currents Use RCDs with an inrush delay to prevent faults due to transient earth currents Dimension RCDs according to the system configu- ration and environmental considerations ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 38: Control With Brake Function

    Time Leakage current [mA] Illustration 2.25 Typical Braking Cycle 100 Hz 2 kHz Danfoss offers brake resistors with duty cycles of 10% and 100 kHz ® 40% suitable for use with the VLT AQUA Drive FC 202. If a 10% duty cycle resistor is applied, it can absorb braking power up to 10% of the cycle time with the remaining 90% being used to dissipate heat from the resistor.

  • Page 39: Mechanical Brake Control

    (Alarm 16 Trip Lock. Danfoss uses motor thermal protection to keep the motor To protect the drive against a short circuit at the load from being overheated. It is an electronic feature that sharing and brake outputs, see the design guidelines.
  • Page 40 PTC / Thermistor Set 1-90 Motor Thermal Protection to [2] Thermistor Trip >3.0 k Ω Set 1-93 Thermistor Source to [6] Digital Input 33 Illustration 2.30 Analog Input 10 V Power Supply ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 41: Safe Stop Operation (Optional)

    The safe stop function of FC 202 can be used for asynchronous and synchronous motors. WARNING Safe Stop activation (that is, removal of 24 V DC voltage supply to terminal 37) does not provide electrical safety. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 42: Selection

    Weight, enclosure IP21 kg (lbs.) 272 [598] Weight, enclosure IP54 kg (lbs.) [594] 0.98 Efficiency Output frequency [Hz] 0–590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 3.1 Mains Supply 3x380-480 V AC ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 43 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 44: Mains Supply 3X525-690 V Ac

    Weight, enclosures IP20, IP21, 62 (135) IP54 kg (lbs.) 0.98 Efficiency Output frequency [Hz] 0–590 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 3.3 Mains Supply 3x525-690 V AC ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 45 Weight, enclosure IP20, IP21, IP54 kg (lbs.) 125 (275) 0.98 Efficiency Output frequency [Hz] 0–590 0–525 Heatsink overtemp. trip [°C] Power card ambient trip [°C] Table 3.4 Mains Supply 3x525-690 V AC ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 46 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 47: 12-Pulse Specifications

    Weight enclosure IP 54 kg (lb) Efficiency 0.98 Output Frequency 0-590 Hz Heatsink overtemp. trip 110 °C 95 °C Power card ambient trip 85 °C Table 3.7 Mains Supply 380-480 V AC ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 48 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 49 110% for 1 minute Starting torque maximum 135% up to 0.5 s Overload torque (Constant torque) maximum 110% for 1 minute *Percentage relates to nominal torque of VLT AQUA Drive. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 50 Accuracy on analog output Max. error: 0.8% of full scale Resolution on analog output 8 bit The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 51 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 52 See 3.5 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 53: Efficiency

    25% load at 50% speed. Illustration 3.2 shows Table 3.9 Acoustic Noise Levels 0.97 - rated efficiency for a 160 kW frequency converter is 0.98. The actual efficiency is then: 0.97x 0.98=0.95. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 54: Peak Voltage On Motor

    The cooling capability of air is decreased at lower air pressure. Below 1000 m altitude no derating is necessary but above 1000 m the ambient temperature (T ) or max. output current (I ) derate in accordance with ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 55: Derating For Running At Low Speed

    In constant torque applications, it is possible for a motor to draw full current while operating at slow speeds. In such cases, the cooling fins do not adequately cool the motor, causing it to overheat. When the motor is operating ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 56: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 57 E & F-Frame P450 to P1M0 525-690 V 45 C 50 C 40 C 45 C 55 C 50 C 55 C Table 3.17 Derating Tables for Frequency Converters Rated 525–690 V (T7) ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 58: Options And Accessories

    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 59: 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 3.21 Analog Outputs - Terminal X30/5+8 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 60: Relay Option Mcb

    Do not combine low voltage parts and PELV systems. At a Relay 7 Relay 8 Relay 9 single fault, the whole system can become dangerous to touch and it could result in death or serious injury. Illustration 3.8 Wiring the Terminals ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 61: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 62 The speed of pumps connected to ® AQUA Drive FC 202 is also controlled to provide a Analog outputs are scalable by parameters for each continuous range of system output. output. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 63: General Description

    Two relays are standard in controlled by the cascade controller. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 64: Extended Cascade Controller Mco

    Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate, and its physical ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 65: Remote Mounting Kit For Lcp

    ® Selection AQUA Drive FC 202 Design Guide size. Danfoss offers a wide variety of different resistors that are specially designed to our frequency converters. See 2.13 Control with Brake Function for the dimensioning of brake resistors. Code numbers can be found in 4 How to Order.

  • Page 66: High Power Options

    /h (230 cfm). The minimum airflow required at an ambient temperature of 45°C for the E2 frequency converter is 782 m /h (460 cfm). Illustration 3.19 Installation of IP00/IP20/Chassis in Rittal TS8 Enclosure. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 67 E-frame kit. External ducts If more duct work is added externally to the Rittal cabinet the pressure drop in the ducting must be calculated. See 5.2.7 Cooling and Airflow for further information. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 68: Outside Installation/Nema 3R Kit For Rittal Enclosures

    The current rating of frequency converters in D3h and D4h frames are de-rated by 3%, when adding the NEMA 3R kit. Frequency converters in E2 frames require no derating. Illustration 3.21 Frequency Converter Mounted on a Pedestal ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 69 D5h/D6h 176F3452 177R0500 D7h/D8h Included with unit Included with unit Included with unit Included with unit Table 3.31 Pedestal Ordering Information Illustration 3.22 Mounting of the Frequency Converter to the Pedestal ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 70: Installation Of Input Plate Options

    IP20 rating of the enclosure. Illustration 3.23 extend out the top of the frequency converter. A terminal shows both the covered and uncovered terminals. cover, supplied with the frequency converter, must be ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 71: Anti-Condensation Heater

    3.7.7 Frame Size F Options Space Heaters and Thermostat Mounted on the cabinet interior of frame size F frequency converters, space heaters controlled via automatic thermostat help control humidity inside the enclosure, ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 72 • Terminals are off when the incoming power to • IEC 60755 Type B device monitors AC, pulsed DC, the frequency converter is off and pure DC ground fault currents ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 73 One universal output, configurable for analog voltage or analog current • Two output relays (N.O.) • Dual-line LC display and LED diagnostics • Sensor lead wire break, short-circuit, and incorrect polarity detection • Interface setup software ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 74: 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 75: Type Code String

    Software release 24–27 Actual software Software language The various options are described further in this Design Guide. 1): Available for all D frames. Table 4.1 Ordering Type Code for D-frame Frequency Converters ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 76 The various options are described further in this Design Guide. 1): Available for all E frames 380-480/500 VAC only 2) Consult factory for applications requiring maritime certification Table 4.2 Ordering Type Code for E-Frame Frequency Converters ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 77 N: IEC Emergency stop push button with brake IGBT and brake terminals P: IEC Emergency stop push button with regeneration terminals Display G: Graphical Local Control Panel LCP Coating PCB C: Coated PCB ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 78 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 79: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 80: Ordering Numbers: 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 Ordering Numbers: Advanced Harmonic Filters Harmonic filters are used to reduce mains harmonics.
  • Page 81 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 82 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 83 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 84 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 85: Ordering Numbers: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 86 Table 4.17 Sine Wave Filter Modules 525-690 V NOTE When using Sine-wave filters, the switching frequency should comply with filter specifications in 14-01 Switching Frequency. NOTE See also Output Filter Design Guide ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 87: 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 NOTE See also Output Filter Design Guide ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 88: Ordering Numbers: Brake Resistors

    =Nominal resistance required to achieve 150% braking torque. br, nom Larger frequency converters include multiple inverter modules with a brake chopper in each inverter. Connect equal resistors to each brake chopper. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 89: How To Install

    ® How to Install AQUA Drive FC 202 Design Guide 5 How to Install 5.1 Mechanical Installation ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 90 ® How to Install AQUA Drive FC 202 Design Guide ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 91 The F9, F11 and F13 have an additional options cabinet left of the rectifier cabinet. 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 92: Mechanical Mounting

    Illustration 5.1. Table 5.5 Legend to Illustration 5.2 Illustration 5.1 Wall Mounting Spacer ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 93: Pedestal Installation On F-Frame Drives

    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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 94: Receiving The Frequency Converter

    See Table 5.2 for the weight of the different frame sizes. 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 95: Tools Needed

    (1 inch), able to lift minimum 400 kg (880 lbs)). • Crane or other lifting aid to place the frequency converter in position. • Use a Torx T50 tool to install the E1 in IP21 and IP54 enclosure types. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 96: General Considerations

    [15.6] 2x579 (22.8) (22.8) (24.6) [20.6] Illustration 5.17 Front Clearance of IP21/IP54 Enclosure Type, Frame Size F4 Illustration 5.12 Front Clearance of IP21/IP54 Enclosure Type, Frame Size D2h, D7h, and D8h. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 97 Frame Size F11 (22.8) (30.6) (24.6) Illustration 5.22 Front Clearance of IP21/IP54 Enclosure Type, Frame Size F12 (22.8) (30.6) (30.6) (24.6) Illustration 5.23 Front Clearance of IP21/IP54 Enclosure Type, Frame Size F13 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 98: Cooling And Airflow

    DC mixing fan mounted under the input plate. This fan the fans is provided to reduce overall acoustical noise and operates anytime the frequency converter is powered on. extend the life of the fans. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 99 Change Frequency Converter Air Flow: 580 cfm (985 m 27.3 45.9 89.3 115.7 Pressure Increase (Pa) Illustration 5.24 D-Frame Derating vs. Pressure Change Frequency Converter Air Flow: 450 cfm (765 m ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 100: Gland/Conduit Entry - Ip21 (Nema 1) And Ip54 (Nema12)

    Illustration 5.28 Example of Proper Installation of Gland Plate [9.5] [4.8] [1.7] [1.0] [10.8] [5.4] [5.4] [8.8] [4.4] [8.1] Illustration 5.31 D5h & D6h, Bottom View Illustration 5.29 D1h, Bottom View ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 101: Gland/Conduit Entry, 12-Pulse - Ip21 (Nema 1) And Ip54 (Nema12)

    Cable entries viewed from the bottom of the frequency 460.0 (18.110) converter 216.5 199.5 (8.524) (7.854) 535.0 (21.063) 281.8 258.5 (11.096) (10.177) 533.0 35.5 36.2 (20.984) (1.398) (1.425) 595.8 (23.457) 1328.8 (52.315) Illustration 5.34 F1, Bottom View ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 102: Electrical Installation

    Provide support for the gland plate around the Illustration 5.41 Frame Size F11 hole being punched or drilled. Remove debris from the hole. Mount the cable entry on the frequency converter. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 103: Connection To Mains And Earthing

    92 (L2) input 93 (L3) If motors are not inverter-duty rated, fit a Sine-wave filter 95 PE on the output of the frequency converter. Illustration 5.44 Terminals for Mains and Earthing ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 104: Motor Cables

    The wires are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 105: 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 5.10 and Table 5.11 to protect service personnel or other equipment in case of an internal failure in the unit.
  • Page 106 P450-P500T7 aR-700 aR-700 P560-P630T7 aR-900 (500-560) aR-900 (500-560) aR-1600 aR-1600 P710-P1M0T7 aR-2000 aR-2000 P1M2T7 aR-2500 aR-2500 P1M4T7 Table 5.11 525-690 V, Fuse Recommendations, Frame Sizes D, E and F ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 107: Access To Control Terminals

    Remove the screw driver. The cable is now mounted to the terminal. To remove the cable from the terminal: Insert a screw driver in the square hole. Pull out the cable. Max. 0.4 x 2.5 mm ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 108: 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 5.51 Terminal 37 available with Safe Stop Function only! ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 109: Control Cable Length

    (N RS-485) 69 0V (PNP) 24V (NPN) (COM RS-485) 61 33 (D IN) 0V (PNP) (PNP) = Source (NPN) = Sink 37 (D IN) - option Illustration 5.52 Interconnect Diagram for D frames ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 110 (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups. For example, switching on the digital input disturbs the analog input signal. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 111 ® How to Install AQUA Drive FC 202 Design Guide Illustration 5.54 Screened Control Cable ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 112: 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 5.55 Control Cable Diagram ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 113 Terminal 37 is the input to be used for Safe Stop. For instructions on Safe Stop installation, refer to 5.7 Safe Stop Installation. 1) F8/F9 = (1) set of terminals. 2) F10/F11 = (2) sets of terminals. 3) F12/F13 = (3) sets of terminals. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 114: Switches S201, S202 And S801

    NOTE Change switch position at power off only. Illustration 5.57 Input Polarity of Control Terminals NPN (Sink) Digital input wiring Illustration 5.59 Switch Locations Illustration 5.58 Input Polarity of Control Terminals ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 115: 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-F9 Regen 19.1 (169) 17.7-20.5 (156-182.) Earth 9.5 (85) 8.8-10.3 (78.2-90.8) Brake Table 5.12 Terminal Tightening Torques ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 116: Power Connections

    If it is necessary to break the screen to install a motor isolator or motor contactor, the screen must be continued at the lowest possible HF impedance. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 117 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 5.14 Legend to Illustration 5.62 and Illustration 5.63. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 118 BRAKE/REGEN TERMINALS MAINS TERMINAL BRAKE TERMINAL 9 [ ] GROUND 148 GROUND 2X 118 MOTOR TERMINAL 3X M10X20 STUD WITH NUT 0 [ ] Illustration 5.66 Terminal Locations, D5h with Disconnect Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 119 BRAKE/REGEN TERMINALS MAINS TERMINAL TB6 Terminal block for contactor 18.0 BRAKE TERMINAL 3X M10X20 STUD WITH NUT GROUND 153 GROUND 3X123 MOTOR TERMINAL Illustration 5.68 Terminal Locations, D6h with Contactor Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 120 ® How to Install AQUA Drive FC 202 Design Guide SECTION A-A MAINS TERMINALS TB6 Terminal block for contactor MAINS TERMINAL Illustration 5.69 Terminal Locations, D6h with Contactor and Disconnect Options ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 121 ® How to Install AQUA Drive FC 202 Design Guide SECTION A-A MAINS TERMINALS MAINS TERMINAL 18.4 Illustration 5.70 Terminal Locations, D6h with Circuit Breaker Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 122 MOTOR TERMINAL MAINS TERMINAL 21.4 20.3 GROUND 412 16.2 15.6 BRAKE GROUND 3X 372 14.7 TERMINAL 4X M10X20 STUD WITH NUT 0 [ ] Illustration 5.71 Terminal Locations, D7h with Disconnect Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 123 49.6 1202 47.3 1082 42.6 GROUND 2X 1034 MOTOR TERMINAL 40.7 GROUND 2X 1009 4X M10X20 STUD 39.7 WITH NUT 0 [ ] Illustration 5.72 Terminal Locations, D7h with Brake Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 124 35.3 MOTOR TERMINAL BRAKE TERMINAL 4X M10X20 STUD 20.5 WITH NUT GROUND 418 16.5 15.8 GROUND 3X 378 14.9 0 [ ] Illustration 5.73 Terminal Locations, D8h with Contactor Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 125 How to Install AQUA Drive FC 202 Design Guide SECTION C-C MAINS TERMINALS TB6 Terminal block for contactor MAINS TERMINAL 22.3 Illustration 5.74 Terminal Locations, D8h with Contactor and Disconnect Options ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 126 ® How to Install AQUA Drive FC 202 Design Guide SECTION D-D MAINS TERMINALS MAINS TERMINAL 23.8 Illustration 5.75 Terminal Locations, D8h with Circuit Breaker Option ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 127 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] Illustration 5.76 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 128 How to Install AQUA Drive FC 202 Design Guide 19 Nm [14 FTa 453[17.8] 0[0.0] Illustration 5.77 IP21 (NEMA type 1) and IP54 (NEMA type 12) Enclosure Power Connection Positions (detail B) ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 129 253 (9.9) 431 (17.0) 562 (22.1) 355/450-500/630 KW (690 V) 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) Table 5.15 Legend to Illustration 5.78 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 130 T/L3 93 186[7.3] U/T1 96 V/T2 97 W/T3 98 17[0.7] 0[0.0] Illustration 5.79 IP00 Enclosure Power Connection Positions R 81 019Nm (14 F) 147(5.8) 0(0.0) Illustration 5.80 IP00 Enclosure Power Connection Positions ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 131 Each terminal allows use of up to 4 cables with cable lugs or use of standard box lug. Earth is connected to a relevant termination point in the frequency converter. 104[4.1] 35[1.4] 10[0.4] 0[0.0] Illustration 5.82 Terminal in Detail ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 132 Illustration 5.83 Terminal Locations - Inverter Cabinet - F1 and F3 (Front, Left and Right Side View). The Gland Plate is 42 mm below .0 level. 1) Earth ground bar 2) Motor terminals 3) Brake terminals ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 133 0.0 [0.00] Illustration 5.85 Terminal Locations - Inverter Cabinet - F2 and F4 (Front, Left and Right Side View). The Gland Plate is 42 mm below .0 level. 1) Earth ground bar ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 134 Illustration 5.87 Terminal Locations - Rectifier (Left, Front and Right Side View). The Gland Plate is 42 mm below .0 level. 1) Loadshare Terminal (-) 2) Earth ground bar 3) Loadshare Terminal (+) ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 135 Illustration 5.89 Terminal Locations - Options Cabinet with Circuit Breaker/Molded Case Switch (Left, Front and Right Side View). The Gland Plate is 42 mm below .0 level. 1) Earth ground bar ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 136: Power Connections 12-Pulse Drives

    The motor cable must be screened/armoured. If an unscreened/unarmoured cable is used, some EMC requirements are not complied with. Use a screened/ armoured motor cable to comply with EMC emission specifications. For more information, see 5.10 EMC-correct Installation. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 137 Screening of cables Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies. If it is necessary to break the screen to install a motor isolator or ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 138 In motors without phase insulation paper or other insulation reinforcement suitable for operation with voltage supply (such as a frequency converter), fit a Sine- wave filter on the output of the frequency converter. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 139 246.0 [ 9.69 ] 0.0 [ 0.00 ] 0.0 [ 0.00 ] Illustration 5.92 F8 (Front, Left and Right Side Views) 1) Earth ground bar The gland plate is 42 mm below Ø level ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 140 628.8 [ 24.75 ] 443.8 [ 17.47 ] 386.7 [ 15.22 ] 151.3 [ 5.96 ] 0.0 [ 0.00 ] 244.4 [ 9.62 ] Illustration 5.93 F9 Input Options Cabinet with Disconnect and Fuses ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 141 494.5 [ 19.47 ] 400.7 [ 15.77 ] 151.3 [ 5.96 ] 0.0 [ 0.00 ] 0.0 [ 0.00 ] 244.4 [ 9.62 ] Illustration 5.94 F9 Input Options Cabinet with Fuse only ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 142 AQUA Drive FC 202 Design Guide 308.3 [ 12.1] 253.1 [ 10.0 ] 180.3 [ 7.1 ] [ .0 ] 44.40 [ 1.75] 244.40 [ 9.62 ] Illustration 5.95 F10/F11 Inverter Cabinet 1) Earth ground bar ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 143 [ 2.23 ] 56.6 [ 0.00 ] 44.4 [ 1.75 ] 244.4 [ 9.62 ] Illustration 5.96 F10/F12 Rectifier Cabinet 1) Earth ground bar The gland plate is 42 mm below Ø level ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 144 ® How to Install AQUA Drive FC 202 Design Guide 547.8 21.57 440.4 17.34 151.3 5.96 Illustration 5.97 F11/F13 Input Option Cabinet with Disconnect and Fuses 1) Earth ground bar ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 145 180.3 [ 7.10 ] 0.0 [ 0.00 ] Illustration 5.98 F12/F13 Inverter Cabinet, Front, Left and Right Side Views) 1) Earth ground bar The gland plate is 42 mm below Ø level ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 146: Shielding Against Electrical Noise

    100 and 101. Use a 5 Amp fuse for protection. In UL applications, use a LittelFuse KLK-5 or equivalent. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 147: 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 5.21 Mains Disconnects, 12-Pulse Frequency Converters ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 148: Mains Contactors

    Eaton XTCEC14P22B P900 525-690 V Eaton XTCE820N22A P710-P800 380-500 V & P1M2 525-690 V Eaton XTCEC14P22B Table 5.25 F-Frame Contactors NOTE Customer supplied 230 V supply is required for mains contactors. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 149: Relay Output D Frame

    1-22 Motor Voltage • Terminal 04: common 1-23 Motor Frequency • Terminal 05: normal open 400 V AC 1-24 Motor Current • Terminal 06: normal closed 240 V AC 1-25 Motor Nominal Speed ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 150: Safe Stop Installation

    This number along with the description of the alarm helps with troubleshooting. If contacting Danfoss Service, make sure to mention number and alarm description. NOTE AMA often fails because of incorrectly registered motor name plate data or too great a difference between the Illustration 5.102 Bridge Jumper between Terminal 37 and 24 V...

  • Page 151: Safe Stop Commissioning Test

    RS 232 activated. RS 485 Send a Reset signal (via Bus, Digital I/O, or [Reset] key). If the motor becomes operational again, this step is not necessary. Illustration 5.104 Parallel Connections ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 152: How To Connect A Pc To The Unit

    All frequency converters are equipped with a serial settings incl. diagrams communication port. A PC tool for communication Ext. User Interface between PC and frequency converter is available. • Preventive Maintenance Schedule • Clock settings ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 153: Safety

    Good engineering practice to ensure EMC-correct converters with additional harmonic reduction devices, electrical installation: such as Danfoss AHF filters and 12-18-pulse rectifiers, can • Use only braided screened/armoured motor be calculated. cables and braided screened control cables. The Ordering number: screen provides a minimum coverage of 80%.
  • Page 154 Motor cable between con- trol cables, motor cable and Mains-supply mains cable Motor, 3 phases and Reinforced protective earth Protective earth Illustration 5.106 EMC-correct Electrical Installation of a Frequency Converter in Cabinet ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 155: Use Of Emc-Correct Cables

    5.10.2 Use of EMC-Correct Cables 0,01 100 MHz Danfoss recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables. Illustration 5.108 Transfer Impedance Z The ability of a cable to reduce the incoming and...
  • Page 156 RC link. Use twisted-pair cables for reducing the differential PLC etc. mode interference between the conductors. Min. 16mm Equalizing cable PLC etc. 100nF Illustration 5.109 Earthing ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 157: 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 2.12 Earth Leakage Current for further information. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 158: Application Examples

    Start/Stop 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! ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 159: Potentiometer Reference

    Repeated AMA runs could lead to a heating of It is possible to program from 0 to 20 events and actions. the motor, which results in an increase of the When the last event/action has been executed, the ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 160: Smart Logic Control Programming

    Set the timer 0 for constant running speed in 13-20 SL Controller Timer [0]. Ex.: 2 s Set Event 1 in 13-51 SL Controller Event [1] to True [1] Set Event 2 in 13-51 SL Controller Event [2] to On Reference [4] ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 161 Set the Smart Logic Control in 13-00 SL Controller Mode to ON. Start/stop command is applied on terminal 18. If the stop signal is applied, the frequency converter ramps down and goes into free mode. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 162: Basic Cascade Controller

    The alternation of the lead pump can take place at a command signal or at staging (adding another pump). ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 163: Pump Staging With Lead Pump Alternation

    • Cascade Status, is a read out of the status for the Cascade Controller. The display shows that the Cascade Controller is disabled, all pumps are off, ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 164: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 165: 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. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 166 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 167: Installation And Set-Up

    When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor NOTE cables at an angle of 90°. The factory setting for the dip switch is OFF. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 168: Fc Protocol Overview

    7.3 Network Connection The FC protocol, also referred to as FC bus or Standard bus, is the Danfoss standard fieldbus. It defines an access One or more frequency converters can be connected to a technique according to the master-slave principle for control (or master) using the RS-485 standardised interface.

  • Page 169: Fc Protocol Message Framing Structure

    A byte denoting the frequency converter address first byte in the telegram is received, the Calculated (ADR) Checksum is 0. A number of data bytes (variable, depending on the type of telegram) follows. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 170: The Data Field

    The PKE field contains two sub fields: Parameter command and response AK, and Parameter number PNU: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Illustration 7.10 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 171: Parameter Number (Pnu)

    To write a text via the PWE block, set the Data change is not possible because factory setup parameter command (AK) to ’F’ Hex. The index characters is selected high-byte must be “5.” Table 7.5 Fault Report ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 172: Data Types Supported

    0.00 ms⇒conversion index -5 IND=0000 Hex =0000 Hex high =03E8 Hex - Data value 1,000, corresponding to 100 Hz, see 7.4.12 Conversion. E19E 0000 H 0000 H 03E8 high Illustration 7.12 Telegram ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 173: Reading A Parameter Value

    Danfoss assumes that the installed controller supports the in response, or a time-out occurs. interfaces in this document, and strictly observes all requirements and limitations stipulated in the controller and frequency converter.

  • Page 174: Frequency Converter With Modbus Rtu

    A typical message frame is shown in Table 7.12. Start Address Function Data check T1-T2-T3- 8 bits 8 bits N x 8 16 bits T1-T2-T3- bits Table 7.11 Typical Modbus RTU Message Structure ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 175: Start/Stop Field

    1. In addition, the slave places a unique code into the data field of the response message. This code tells the master what error occurred, or the reason for the exception. See 7.8.9 Function Codes Supported by Modbus RTU. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 176: Coil Register Addressing

    Set up MSB Not in current limit Current limit No reversing Reversing No thermal warning Thermal warning Table 7.13 Frequency Converter Control Word (FC Profile) Table 7.14 Frequency Converter Status Word (FC Profile) ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 177: Function Codes Supported By Modbus Rtu

    Restart communication Return diagnostic register Clear counters and diagnostic register Return bus message count Return bus communication error count Return bus exception error count Return slave message count Table 7.17 Function Codes ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 178 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 179: How To Access Parameters

    03HEX "Read Holding Registers" and written using Coil 33 is addressed as Coil 32, for example. function 10HEX "Preset Multiple Registers." Readable sizes range from 1 register (2 characters) up to 10 registers (20 characters). ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 180: Force/Write Single Coil (05 Hex)

    Starting Address LO D5 (Register address 3029) No. of Points HI No. of Points LO 02 - (Par. 3–03 is 32 bits long, that is, 2 registers) Error Check (CRC) Table 7.25 Query ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 181: Preset Single Register (06 Hex)

    Example: Hex 0016E360 = 1.500.000 = 1,500 RPM. Error Check (CRC) Table 7.28 Response Field Name Example (HEX) Slave Address Function 7.11 Danfoss FC Control Profile Byte Count 7.11.1 Control Word According to FC Data HI Profile (8-10 Control Profile=FC (Register 3030) profile)
  • Page 182 Bit 03 Coasting stop • Bit 02 DC braking • Digital input (5-10 Terminal 18 Digital Input to 5-15 Terminal 33 Digital Input) programmed to DC braking, Coasting stop, or Reset and coasting stop. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 183: Status Word According To Fc Profile (Stw) (8-10 Control Profile = Fc Profile)

    Bit 05 is not used in the status word. Bit 06, No error/triplock Bit 06=’0’: The frequency converter is not in fault mode. Bit 06=“1”: The frequency converter is tripped and locked. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 184 Bit 14, Torque OK/limit exceeded Bit 14=’0’: The motor current is lower than the torque limit selected in 4-18 Current Limit. Bit 14=’1’: The torque limit in 4-18 Current Limit is exceeded. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 185: 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 ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 186: Troubleshooting

    Live zero error 6-01 Live Zero Timeout Function No motor 1-80 Function at Stop Mains phase loss 14-12 Function at Mains Imbalance DC link voltage high DC link voltage low DC over voltage ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 187 Speed limit AMA calibration failed AMA check U and I AMA low I AMA motor too big AMA motor too small AMA parameter out of range AMA interrupted by user AMA timeout ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 188 A trip lock is an action when an alarm occurs, that can damage the frequency converter or connected parts. A Trip Lock situation can only be reset by a power cycling. ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 189 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. ® MG20Z102 - VLT is a registered Danfoss trademark...

  • Page 190: Index

    DU/dt Filters..................64, 85 Building Management System............59 Duct Cooling..................96 Cable Earth Clamp....................153 Connection..................101 Clamps....................151 Leakage Current..............151, 35 Length And Cross-section............102 Lengths And Cross Sections............48 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 191 Entry, 12-Pulse - IP21 (NEMA 1) And IP54 (NEMA12)..99 Master Drive................... 61 101......................77 Harmonic Filters..................78 104......................77 Harmonics 108......................77 Emission Requirements..............33 Test Results (Emission)..............33 High Voltage Test................151 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 192 Performance (U, V, W)..............47 Outputs....................49 Outputs For Actuators................ 59 Residual Current Device..............155 Outside Installation/NEMA 3R Kit For Rittal........ 66 Rise Time....................52 Over-current Protection..............103 RS-485 RS-485....................165 Bus Connection................149 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 193 Surroundings..................50 Switches S201, S202 And S801............112 Switching Frequency............. 102, 114, 136 Symbols...................... 7 System Status And Operation............161 Telegram Length (LGE)..............167 Terminal 37......................39 Blocks....................77 Locations..................125 ® MG20Z102 - VLT is a registered Danfoss trademark...
  • Page 194 130R0279 MG20Z102 Rev. 2012-12-21 *MG20Z102*...

Table of Contents