® Contents AQUA Drive FC 202 Operating Instructions Contents 1 Introduction 1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Document and Software Version 1.4 Product Overview 1.5 Approvals and Certifications 1.6 Disposal 2 Safety 2.1 Safety Symbols 2.2 Qualified Personnel 2.3 Safety Precautions 3 Mechanical Installation 3.1 Unpacking...
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® Contents AQUA Drive FC 202 Operating Instructions 5.4.1 Commissioning with SmartStart 5.4.2 Commissioning via [Main Menu] 5.4.3 Asynchronous Motor Setup plus 5.4.4 PM Motor Setup in VVC 5.4.5 Automatic Energy Optimisation (AEO) 5.4.6 Automatic Motor Adaptation (AMA) 5.5 Checking Motor Rotation 5.6 Local-control Test 5.7 System Start-up 6 Application Set-up Examples...
Supplementary publications and manuals are available general public. Designated application areas are public from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo- pools, public water supplies, agriculture, commercial lutions/Documentations/VLT+Technical+Documentation.htm buildings, and industries. All other single phase units are for listings.
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Introduction ® AQUA Drive FC 202 Operating Instructions 1.4.2 Features ® The VLT AQUA Drive FC 202 is designed for water and wastewater applications. The range of standard and optional features includes: • Cascade control • Dry run detection • End of curve detection •...
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Introduction ® AQUA Drive FC 202 Operating Instructions Local control panel (LCP) Motor output terminals 96 (U), 97 (V), 98 (W) RS-485 serial bus connector (+68, -69) Relay 2 (01, 02, 03) Analog I/O connector Relay 1 (04, 05, 06) LCP input plug Brake (-81, +82) and load sharing (-88, +89) terminals Analog switches (A53), (A54)
Prove line transient protection More approvals and certifications are available. Contact • Reduce RMS current DC reactors local Danfoss partner. Frequency converters of enclosure • Raise the power factor type T7 (525-690 V) are not certified for UL. reflected back to the line The frequency converter complies with UL508C thermal •...
Safety ® AQUA Drive FC 202 Operating Instructions 2 Safety WARNING 2.1 Safety Symbols UNINTENDED START When the frequency converter is connected to AC mains, The following symbols are used in this document: the motor may start at any time, causing risk of death, serious injury, equipment, or property damage.
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Safety ® AQUA Drive FC 202 Operating Instructions WARNING LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury. • Ensure correct grounding of the equipment by a certified electrical installer. WARNING EQUIPMENT HAZARD Contact with rotating shafts and electrical equipment...
Failure for clarification. to meet requirements for ambient conditions can reduce lifetime of the frequency converter. Ensure that AQUA Drive www.danfoss.com requirements for air humidity, temperature and altitude are met. T/C: FC-202P45KT4E20H1XGXXXXSXXXXAXBXCXXXXDX P/N: 131F6653 S/N: 038010G502...
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Mechanical Installation ® AQUA Drive FC 202 Operating Instructions Mounting with back plate and railings Illustration 3.3 Proper Mounting with Back Plate NOTICE Back plate is required when mounted on railings. Illustration 3.2 Top and Bottom Cooling Clearance Enclosure A2-A5 B1-B4 C1, C3 C2, C4...
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4 Electrical Installation 4.1 Safety Instructions 4.2 EMC-compliant Installation To obtain an EMC-compliant installation, follow the See 2 Safety for general safety instructions. instructions provided in 4.3 Grounding, 4.4 Wiring Schematic, 4.6 Motor Connection, and 4.8 Control Wiring. WARNING 4.3 Grounding INDUCED VOLTAGE...
A=Analog, D=Digital *Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off ® Operating Instructions for Danfoss VLT Frequency Converters. **Do not connect cable screen. MG20MA02 - Rev. 2013-10-29...
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Electrical Installation ® AQUA Drive FC 202 Operating Instructions Illustration 4.2 EMC-compliant Electrical Connection Cable gland Frequency converter Motor, 3-phase and PE Output contactor Mains, 3-phase and reinforced PE Grounding rail (PE) Control wiring Cable insulation (stripped) Equalising min. 16 mm (0.025 in) Table 4.1 Legend to Illustration 4.2 NOTICE...
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4.5 Access 4.6 Motor Connection • Remove cover with a screw driver (See Illustration 4.3) or by loosening attaching screws WARNING (See Illustration 4.4). INDUCED VOLTAGE Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out.
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4.7 AC Mains Connection • Size wiring based upon the input current of the frequency converter. For maximum wire sizes see 8.1 Electrical Data. • Comply with local and national electrical codes for cable sizes.
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4.8.1 Control Terminal Types Terminal description Illustration 4.7 and Illustration 4.8 show the removable Default frequency converter connectors. Terminal functions and Terminal Parameter setting Description default settings are summarised in Table 4.3. Digital Inputs/Outputs 12, 13 +24 V DC...
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4.8.3 Enabling Motor Operation (Terminal 01, 02, 03 5-40 [0] [9] Alarm Form C relay output. For AC or DC voltage 04, 05, 06 5-40 [1] [5] Running and resistive or inductive loads.
4.8.5 Safe Torque Off (STO) documentation for installation and operation instructions To run Safe Torque Off, additional wiring for the frequency converter is required, refer to Safe Torque Off Operating ® Instructions for Danfoss VLT Frequency Converters for further information. MG20MA02 - Rev. 2013-10-29...
Electrical Installation ® AQUA Drive FC 202 Operating Instructions 4.9 Installation Check List Before completing installation of the unit, inspect the entire installation as detailed in Table 4.4. Check and mark the items when completed. ☑ Inspect for Description • Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the input power side of the frequency converter or output side to the motor.
Commissioning ® AQUA Drive FC 202 Operating Instructions 5 Commissioning 5.1 Safety Instructions 5.2 Applying Power WARNING See 2 Safety for general safety instructions. UNINTENDED START WARNING When the frequency converter is connected to AC mains, HIGH VOLTAGE the motor may start at any time, causing risk of death, serious injury, equipment, or property damage.
Software. The software is available for download (basic version) or for ordering (advanced version, order number 130B1000). For more information and downloads, see A. Display area www.danfoss.com/BusinessAreas/DrivesSolutions/Software The display area is activated when the frequency converter +MCT10/MCT10+Downloads.htm. receives power from mains voltage, a DC bus terminal, or an external 24 V DC supply.
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Commissioning ® AQUA Drive FC 202 Operating Instructions Function Function Main Menu Allows access to all programming Hand On Starts the frequency converter in local parameters. control. • An external stop signal by control input Alarm Log Displays a list of current warnings, the last or serial communication overrides the 10 alarms, and the maintenance log.
Commissioning ® AQUA Drive FC 202 Operating Instructions 5.3.5 Changing Parameter Settings Recommended initialisation procedure, via 14-22 Operation Mode View changes Press [Main Menu] twice to access parameters. Quick Menu Q5 - Changes Made lists all parameters Scroll to 14-22 Operation Mode and press [OK]. changed from default settings.
Commissioning ® AQUA Drive FC 202 Operating Instructions The SmartStart configures the frequency converter in 3 0.0% 0.00A 1(1) phases, each consisting of several steps, see Table 5.6. Basic Settings 0-03 Regional Settings Phase Comment Basic Programming Program e.g. motor data Select and program [0] International appropriate application:...
Commissioning ® AQUA Drive FC 202 Operating Instructions 5.4.4 PM Motor Setup in VVC plus Test Motor Operation Start the motor at low speed (100 to 200 RPM). If NOTICE the motor does not turn, check installation, general programming and motor data. Only use permanent magnet (PM) motor with fans and pumps.
Commissioning ® AQUA Drive FC 202 Operating Instructions 5.4.5 Automatic Energy Optimisation (AEO) Scroll to 1-29 Automatic Motor Adaptation (AMA) and press [OK]. NOTICE Select [1] Enable complete AMA and press [OK]. AEO is not relevant for PM motors. Follow on-screen instructions. The test runs automatically and indicate when it Automatic Energy Optimisation (AEO) is recommended for is complete.
Commissioning ® AQUA Drive FC 202 Operating Instructions If warnings or alarms occur, see 7.4 List of Warnings and Alarms. 5.6 Local-control Test WARNING MOTOR START Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equipment damage.
Application Set-up Examples ® AQUA Drive FC 202 Operating Instructions 6 Application Set-up Examples The examples in this section are intended as a quick Parameters reference for common applications. Function Setting 6-20 Terminal 54 0.07 V* +24 V • Parameter settings are the regional default values Low Voltage +24 V unless otherwise indicated (selected in...
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Application Set-up Examples ® AQUA Drive FC 202 Operating Instructions 6.1.2 Speed Parameters Function Setting 6-10 Terminal 53 0.07 V* +24 V Low Voltage +24 V Parameters 6-11 Terminal 53 10 V* D IN Function Setting High Voltage D IN 6-10 Terminal 53 0.07 V* 6-14 Terminal 53...
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Application Set-up Examples ® AQUA Drive FC 202 Operating Instructions 6.1.4 External Alarm Reset Parameters Function Setting 5-10 Terminal 18 [8] Start* Parameters +24 V Digital Input Function Setting +24 V 5-12 Terminal 27 [7] External D IN 5-11 Terminal 19 [1] Reset +24 V D IN...
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Application Set-up Examples ® AQUA Drive FC 202 Operating Instructions 6.1.5 RS-485 6.1.6 Motor Thermistor CAUTION Parameters Function Setting THERMISTOR INSULATION 8-30 Protocol +24 V Risk of equipment damage exists. 8-31 Address +24 V • Use only thermistors with reinforced or double 8-32 Baud Rate 9600* D IN...
DC brake, and other signals standard parts. For service and support, refer to applied to the control terminals override local www.danfoss.com/contact/sales_and_services/. control. WARNING Table 7.1 Operation Mode HIGH VOLTAGE...
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Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions Current High The frequency converter output current is Jogging The motor is running as programmed in above the limit set in 4-51 Warning Current 3-19 Jog Speed [RPM]. • High. Jog was selected as function for a digital input (parameter group 5-1* Digital Inputs).
Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions Alarms Run on ref. The frequency converter is running in the Trip reference range. The feedback value matches An alarm is issued when the frequency converter is the setpoint value. tripped, which means that the frequency converter Run request A start command was given, but the motor...
Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions In addition to the text and alarm code in the LCP, there 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 are 3 status indicator lights. common). • Check that the frequency converter programming and switch settings match the analog signal type •...
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Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions frequency converter cannot be reset until the counter is either terminal 18 or 19 (digital input PNP only) below 90%. and terminal 50 The fault is that the frequency converter is overloaded by •...
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WARNING 25, Brake resistor short circuit Record the value of the following parameters and contact The brake resistor is monitored during operation. If a short the Danfoss supplier: circuit occurs, the brake function is disabled and the warning appears. The frequency converter is still •...
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DSP watchdog is active. Debugging of power part • Check for loose or missing wiring data, motor oriented control data not transferred Contact the Danfoss supplier or service department if correctly. required. Note the code number for further trouble- 2049 Power data restarted.
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Option in slot C0: Hardware incompatible with control board hardware. ALARM 50, AMA calibration failed 5126 Option in slot C1: Hardware incompatible with Contact the Danfoss supplier or Danfoss Service control board hardware. Department. 5376-6231 Out of memory. ALARM 51, AMA check U...
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• Check that the gland plate is properly installed AMA internal fault on IP21/IP54 (NEMA 1/12) frequency converters Contact the Danfoss supplier. ALARM 70, Illegal FC configuration WARNING 59, Current limit The control card and power card are incompatible. Contact The current is higher than the value in 4-18 Current Limit.
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Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions ALARM 81, CSIV corrupt CSIV (Customer Specific Initialisation Values) file has syntax errors. ALARM 82, CSIV parameter error CSIV (Customer Specific Initialisation Values) failed to init a parameter. ALARM 85, Dang fail PB Profibus/Profisafe Error.
Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions 7.5 Troubleshooting Symptom Possible cause Test Solution Missing input power See Table 4.4. Check the input power source. Missing or open fuses or circuit See open fuses and tripped circuit breaker Follow the recommendations provided.
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Maintenance, Diagnostics an... ® AQUA Drive FC 202 Operating Instructions Symptom Possible cause Test Solution Possible incorrect parameter Check the settings of all motor parameters, Check settings in parameter group 1-6* Motor speed settings including all motor compensation settings. Load Depen. Setting. For closed-loop unstable For closed-loop operation, check PID operation, check settings in parameter...
Specifications ® AQUA Drive FC 202 Operating Instructions 8.2 Mains Supply Mains supply (L1, L2, L3) 200-240 V ±10% Supply voltage 380-480 V ±10% Supply voltage 525-600 V ±10% Supply voltage 525-690 V ±10% Supply voltage Mains voltage low/mains drop-out: During low mains voltage or a mains drop-out, the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the lowest rated supply voltage of the frequency converter.
Specifications ® AQUA Drive FC 202 Operating Instructions 8.4 Ambient Conditions Environment Enclosure type A IP20/Chassis, IP21/Type 1, IP55/Type 12, IP66/Type 4X Enclosure type B1/B2 IP21/Type 1, IP55/Type 12, IP66/Type 4X Enclosure type B3/B4 IP20/Chassis Enclosure type C1/C2 IP21/Type 1, IP55/Type 12, IP66/Type 4X Enclosure type C3/C4 IP20/Chassis Enclosure kit available ≤...
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Specifications ® AQUA Drive FC 202 Operating Instructions Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level 0 to +10 V (scaleable) Input resistance, R approx. 10 kΩ ±20 V Max. voltage Current mode Switch S201/switch S202 = ON (I) Current level...
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Specifications ® AQUA Drive FC 202 Operating Instructions Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Max. error: 0.1% of full scale Resolution of frequency outputs 12 bit 1) Terminal 27 and 29 can also be programmed as input.
Specifications ® AQUA Drive FC 202 Operating Instructions 30-4000 rpm: Maximum error of ±8 RPM Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor Control card performance Scan interval 5 ms Control card, USB serial communication USB standard 1.1 (Full speed) USB plug...
Specifications ® AQUA Drive FC 202 Operating Instructions 8.8 Fuses and Circuit Breakers Use recommended fuses and/or circuit breakers on the supply side as protection in case of component break-down inside the frequency converter (first fault). NOTICE Use of fuses on the supply side is mandatory for IEC 60364 (CE) and NEC 2009 (UL) compliant installations. Recommendations •...
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Table 8.15 525-600 V, Enclosure Types A, B and C 525-690 V Enclosure Power [kW] Recommended fuse size Recommended Recommended circuit Max. trip level max. fuse breaker Danfoss gG-6 gG-25 CTI25M 10-16 gG-6 gG-25 CTI25M 10-16 gG-6 gG-25 CTI25M 10-16...
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Specifications ® AQUA Drive FC 202 Operating Instructions 8.8.2 UL Compliance 1x200-240 V Recommended max. fuse Powe Max. Buss- Buss- Buss- Buss- Buss- Buss- Buss- SIBA Littel Ferraz- Ferraz- Ferraz- r [kW] prefus mann mann mann mann mann mann mann fuse Shawmu Shawmu...
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Specifications ® AQUA Drive FC 202 Operating Instructions 3x200-240 V Recommended max. fuse Power [kW] Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Type J Type T Type CC Type CC Type RK1 0.25-0.37 KTN-R-05 JKS-05 JJN-05 FNQ-R-5 KTK-R-5 LP-CC-5 0.55-1.1 KTN-R-10 JKS-10 JJN-10 FNQ-R-10...
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Specifications ® AQUA Drive FC 202 Operating Instructions 3x380-480 V Recommended max. fuse Power Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW] Type RK1 Type J Type T Type CC Type CC Type CC KTS-R-6 JKS-6 JJS-6 FNQ-R-6 KTK-R-6 LP-CC-6 1.1-2.2 KTS-R-10 JKS-10 JJS-10...
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Specifications ® AQUA Drive FC 202 Operating Instructions 3x525-600 V Recommended max. fuse Power Bussmann Bussman Bussmann Bussmann Bussman Bussman SIBA Littel fuse Ferraz- Ferraz- [kW] Type RK1 Type T Type CC Type RK1 Type RK1 Shawmut Shawmut Type J Type CC Type CC Type RK1...
Appendix ® AQUA Drive FC 202 Operating Instructions 9 Appendix 9.1 Symbols, Abbreviations and Conventions Alternating Current Automatic Energy Optimization American Wire Gauge Automatic Motor Adaptation °C Degrees Celsius Direct Current Electro Magnetic Compatibility Electronic Thermal Relay Frequency Converter Local Control Panel Motion Control Tool Ingress Protection Nominal Motor Current...
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Appendix ® AQUA Drive FC 202 Operating Instructions MG20MA02 - Rev. 2013-10-29...
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Appendix ® AQUA Drive FC 202 Operating Instructions MG20MA02 - Rev. 2013-10-29...
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Appendix ® AQUA Drive FC 202 Operating Instructions MG20MA02 - Rev. 2013-10-29...
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Appendix ® AQUA Drive FC 202 Operating Instructions MG20MA02 - Rev. 2013-10-29...
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