Danfoss VLT AQUA Drive FC 202 Design Manual

0.25-90 kw

Hide thumbs Also See for VLT AQUA Drive FC 202:

Installation manual

Programming manual (770 pages)

Design manual (228 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

page of 198

/ 198
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual See also: Programming Manual, Design Manual

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT

AQUA Drive FC 202

0.25-90 kW

www.danfoss.com/drives

Table of Contents

Need help?

Do you have a question about the VLT AQUA Drive FC 202 and is the answer not in the manual?

Questions and answers

Summary of Contents for Danfoss VLT AQUA Drive FC 202

Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AQUA Drive FC 202 0.25-90 kW www.danfoss.com/drives...
Page 3: Table Of Contents
2.4.3 Local (Hand On) and Remote (Auto On) Control 2.4.4 Reference Handling 2.4.5 Feedback Handling 2.5 Automated Operational Functions 2.5.1 Short Circuit Protection 2.5.2 Overvoltage Protection 2.5.3 Missing Motor Phase Detection 2.5.4 Mains Phase Imbalance Detection MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 4 2.7 Fault, Warning and Alarm Functions 2.7.1 Operation at Overtemperature 2.7.2 High and Low Reference Warning 2.7.3 High and Low Feedback Warning 2.7.4 Phase Imbalance or Phase Loss 2.7.5 High Frequency Warning 2.7.6 Low Frequency Warning Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 5 3.2.6 Motor Bearing Currents 3.2.7 Harmonics 3.2.8 Earth Leakage Current 3.3 Mains Integration 3.3.1 Mains Configurations and EMC Effects 3.3.2 Low-frequency Mains Interference 3.3.3 Analysing Mains Interference 3.3.4 Options for Reducing Mains Interference MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 6 3.7 Options and Accessories 3.7.1 Communication Options 3.7.2 Input/Output, Feedback and Safety Options 3.7.3 Cascade Control Options 3.7.4 Brake Resistors 3.7.5 Sine-wave Filters 3.7.6 dU/dt Filters 3.7.7 Common-mode Filters 3.7.8 Harmonic Filters Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 7 4.3.7 Lead Pump Alternation Wiring Diagram 5 Special Conditions 5.1 Manual Derating 5.2 Derating for Long Motor Cables or Cables with Larger Cross-Section 5.3 Derating for Ambient Temperature 6 Typecode and Selection MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 8 ® 7.11.4 VLT Extended Relay Card MCB 113 ® 7.11.5 VLT Sensor Input Option MCB 114 ® 7.11.6 VLT Extended Cascade Controller MCO 101 ® 7.11.7 VLT Advanced Cascade Controller MCO 102 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 9 Contents Design Guide 8 Appendix - Selected Drawings 8.1 Mains Connection Drawings (3-phases) 8.2 Motor Connection Drawings 8.3 Relay Terminal Drawings 8.4 Cable Entry Holes Index MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 10: Introduction
Chapter 4 Application Examples: Samples of product applications and guidelines for use. Contact a Danfoss supplier or visit www.danfoss.com for additional information. Chapter 5 Special Conditions: Details on unusual operational environments.
Page 11: Abbreviations, Symbols And Conventions
Kilohertz Variable torque Local control panel Voltage vector control Least significant bit Meter Table 1.1 Abbreviations Milliampere Mille circular mil Motion control tool Inductance in milli Henry Minute Millisecond Most significant bit MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 12: Definitions
Link Cosphi is also known as displacement power factor. • Footnote ® Both lambda and cosphi are stated for Danfoss VLT • Parameter name, parameter group name, frequency converters in chapter 7.2 Mains Supply. parameter option The power factor indicates to which extent the frequency All dimensions are in mm (inch).
Page 13: Document And Software Version
Frequency converters with an integrated safety function machinery directive. If a frequency converter is integrated must comply with the machinery directive. into a machinery system, Danfoss can provide information on safety aspects relating to the frequency converter. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 14: Erp Directive
Carriage of Dangerous Goods by Inland Waterways (ADN). The ErP directive is the European Ecodesign Directive for energy-related products. The directive sets ecodesign Go to www.danfoss.com for additional marine approvals requirements for energy-related products, including information. frequency converters. The aim of the directive is to...
Page 15: Safety
0.37-7.5 kW 11-90 kW 525-600 0.75-7.5 kW 11-90 kW 525-690 1.1-7.5 kW 11-90 kW High voltage may be present even when the warning LED indicator lights are off. Table 1.4 Discharge Time MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 16 An internal failure in the frequency converter can result in serious injury, when the frequency converter is not properly closed. • Ensure that all safety covers are in place and securely fastened before applying power. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 17: Product Overview
Real-time clock • Password protection • Overload protection • Energy saving Smart logic control • Minimum speed monitor Illustration 2.1 Example: Energy Saving • Free programmable texts for information, warnings and alerts MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 18 =Speed 1 Flow =Reduced pressure =Reduced speed Operating point using a throttle valve Table 2.1 Affinity Laws Natural operating point Operating point using speed control Illustration 2.3 Flow Reduction by Valve Control (Throttling) Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 19 2.1.5 Example with Varying Flow over 1 Year 1050rpm 750rpm This example is calculated based on pump characteristics obtained from a pump datasheet, shown in Illustration 2.7. Illustration 2.7 Energy Consumption at Different Speeds MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 20: Description Of Operation
See Table 2.3 for As illustrated in Illustration 2.8, a frequency converter does their functions. not consume more than rated current. Illustration 2.9 Frequency Converter Block Diagram Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 21 L1 91 Resistor L2 92 U 96 L3 93 V 97 R inr Inrush 88(-) W 98 Load sharing - LC Filter - P 14-50 R Filter (5A) Illustration 2.10 Frequency Converter Structure MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 22: Sequence Of Operation
For pre-fuse specifications, maximum motor speed limits (in RPM and Hz), ramp-up refer to chapter 7.1 Electrical Data. See also chapter 7.7 Fuses and Circuit Breakers. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 24: Local (Hand On) And Remote (Auto On) Control
All keys Remote Remote Hand mode Local Table 2.4 Local and Remote Reference Configurations Local reference P 3-13 LCP Hand on, Reference site o and auto on keys Illustration 2.13 Active Reference Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 25: Reference Handling
A remote reference is comprised of the following (see Illustration 2.15). • Preset references • External references (analog inputs, pulse frequency inputs, digital potentiometer inputs, and serial communication bus references) • A preset relative reference • A feedback controlled setpoint MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 26 Digipot ref. DigiPot Decrease ±200% Analog inputs Closed loop Setpoint ±200% Frequency inputs From Feedback Handling Ext. closed loop outputs Clear DigiPot Open loop reference Illustration 2.15 Block Diagram Showing Remote Reference Handling Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 27: Feedback Handling
P 20-04 Average (1+2+3) P 20-03 Minimum (1|2|3) Maximum (1|2|3) Feedback conv. Feedback 3 Feedback 3 Source P 20-07 P 20-06 Feedback Function P 20-20 Illustration 2.16 Block Diagram of Feedback Signal Processing MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 28: Automated Operational Functions
7.7 Fuses and Circuit Breakers for more information. NOTICE To ensure compliance with IEC 60364 for CE or NEC 2009 for UL, it is mandatory to use fuses and/or circuit breakers. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 29: Missing Motor Phase Detection
V/Hz curve because the frequency The current limit is controlled in 4-18 Current Limit. converter automatically adjusts motor voltage. Speed limit Define lower and upper limits for the operating speed range using the following parameters: MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 30: Automatic Switching Frequency Modulation
Auto ramping protects that can affect an electrical circuit due to electromagnetic against this by extending the motor ramping rate induction or radiation from an external source. The Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 31: Current Measurement On All Three Motor Phases
AMA is performed without the motor rotating and without calculates the motor temperature based on actual current uncoupling the load from the motor. and speed. The calculated temperature is visible as a read- out parameter in 16-18 Motor Thermal. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 32: Mains Drop-Out
Independent set-ups are used, for example, to change feed pumps, valve control or for aeration with different references, or for day/night or summer/winter operation, or levels. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 33: Dynamic Braking
When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Illustration 2.20 shows an example with 4 event/actions: MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 34: Sto Function
STO functionality. For full For an example of SLC, refer to chapter 4.3 Application Set- ® information about STO, refer to the VLT Safe Torque Off up Examples.3 Operating Instructions. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 35: Fault, Warning And Alarm Functions
In open-loop operation, the reference signal directly been reached. determines the speed of the converter. The display shows a flashing reference high or low warning when the programmed maximum or minimum is reached. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 36: Low Current Warning
Product Overview Design Guide 2.7.8 Low Current Warning Remote user interface For remote programming, Danfoss offers a software program for developing, storing, and transferring This function is similar to low frequency warning (see programming information. MCT 10 Set-up Software allows chapter 2.7.6 Low Frequency Warning), except a low current...
Page 37: Pc Software
Do not to use a PC power cable with a ground plug when All parameters are now transferred to the frequency the PC is connected to the frequency converter through a USB cable. It reduces the ground potential difference, but converter. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 38: Vlt ® Harmonics Calculation Software Mct
Both the harmonic distortion of Danfoss frequency converters as well as non-Danfoss frequency converters with additional harmonic reduction devices, such as Danfoss AHF filters and 12-18-pulse rectifiers, can be calculated. MCT 31 can also be downloaded from www.danfoss.com/ BusinessAreas/DrivesSolutions/Softwaredownload/.
Page 39: System Integration
Control structure and programming design temperature. • Serial communication • Even devices with IP54, IP55, or IP66 protection • Equipment size, shape, weight ratings must adhere to the specified ambient temperature ranges. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 40: Cooling
Subtracting 37 °C from 45 °C gives 8 °C (=8 K). is the heat Q to be transferred. Multiply the result Dividing 5693 m x K/h by 8 K gives: 711.6 m Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 41: Motor-Generated Overvoltage
0.7 g forces, over the range of 18 to 1000 Hz Installation of frequency converters in environments with randomly, in 3 directions, for 2 hours. All Danfoss high dust exposure is often unavoidable. Dust affects wall- frequency converters comply with requirements that...
Page 42 The modulation of the output voltage may generate unallowable high peak voltage for e classification. In practice, using a sine-wave filter at the frequency Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 43: Ip Rating Definitions
Table 3.3 IEC 60529 Definitions for IP Ratings conformance is not tested. NOTICE 3.1.8.1 Cabinet Options and Ratings To ensure interference-free operation of the frequency Danfoss frequency converters are available with 3 different converter/motor system, always use a category C1 RFI protection ratings: filter. •...
Page 44: Pelv And Galvanic Isolation Compliance
Connect the motor cable screen to the frequency converter enclosure For installations at high altitude, contact Danfoss regarding PELV compliance. Danfoss A/S © 09/2014 All rights reserved.
Page 45 Moreover, ensure good electrical contact from the Ground wire AC mains supply Screened motor cable Screen Frequency converter Motor Illustration 3.2 Generation of Leakage Currents MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 46: Emc Test Results
3) Hx versions can be used according to EN/IEC 61800-3 category C4. 4) T7, 37–90 kW complies with class A group 1 with 25 m motor cable. Some restrictions for the installation apply (contact Danfoss for details). 5) 100 m for phase-neutral, 150 m for phase-phase (but not from TT or TT). Single-phase frequency converters are not intended for 2-phase supply from a TT or TN network.
Page 47: Emission Requirements
EN 61000-4-6 (IEC 61000-4-6): RF Common environment standard for residential, mode: Simulation of the effect from radio- (home and commercial and light transmission equipment joined by connection office) industrial environments. cables. See Table 3.7. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 48: Motor Insulation
360° connection in the motor and the frequency converter. Make sure that the impedance from frequency converter to building ground Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 49: Harmonics
+ ... + THD = with 50 Hz or 60 Hz as the fundamental frequency. The harmonics do not affect the power consumption directly, but increase the heat losses in the installation MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 51: Earth Leakage Current
System Integration Design Guide 3.2.7.6 Harmonic Mitigation Non-linear In cases where additional harmonic suppression is required, Danfoss offers a wide range of mitigation System Current Voltage equipment. These are: Impedance • 12-pulse drives • AHF filters Contribution to Disturbance to •...
Page 52 Ground wire (terminal 95) of at least 10 mm cross-section. • 2 separate ground wires both complying with the Illustration 3.9 Influence of the RCD Cut-off Frequency on dimensioning rules. Leakage Current See EN/IEC61800-5-1 and EN50178 for further information. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 53: Mains Integration
Incorrect voltage measurements due to distortion to electrical distribution systems fulfill their intended of the sinusoidal mains voltage. purpose without generating problems. • Cause incorrect power measurements because only RMS-true measuring takes harmonic content into account. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 54: Analysing Mains Interference
NOTICE Environment 1/Class B. They do not have their own high- Danfoss has a very high level of EMC expertise and voltage or medium-voltage distribution transformers for a provides EMC analyses with detailed evaluation or mains separate mains system.
Page 55: Use With Isolated Input Source
States, the input power may be an isolated source. All such as power factor correction equipment. Transients can Danfoss frequency converters may be used with isolated also be caused by short-circuits, tripping of circuit breakers input source as well as with ground reference power lines.
Page 56: Motor Integration
The frequency converter can induce electrical stress on a motor. Consider, therefore, the following effects on the motor when matching motor with frequency converter: • Insulation stress • Bearing stress • Thermal stress Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 57: Motor Cable Shielding
Shielded motor cables also provide immunity to interference from nearby external sources. Even good shielding does not fully eliminate the radiation. System components located in radiation environments must operate without degradation. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 58 Illustration 3.14 Parallel Cables with Load Illustration 3.12 Common Joint Connection for Long Cable Lengths Illustration 3.15 LC Filter for Long Parallel Cables Illustration 3.13 Parallel Cables without Load Illustration 3.16 Long Cables in Series Connection Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 59: Control Wire Isolation
The ETR feature calculates the motor temperature based on actual current • Maximum speed limits the maximum output and speed. speed. • Input is available for an external thermistor. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 60: Output Contactor
(of the cycle time) overvoltage below a perscribed threshold by directing brake energy from the motor to the Danfoss offers brake resistors with duty cycles of 5%, 10%, brake resistor. and 40%. When a 10% duty cycle is applied, the brake resistors absorb brake power for 10% of the cycle time.
Page 61: Brake Resistor Cabling
100% load 75% load 50% load 25% load out when the power transmitted to the brake resistor Illustration 3.19 Typical Efficiency Curves exceeds the limit set in 2-12 Brake Power Limit (kW). MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 63: Additional Inputs And Outputs
Illustration 3.20 Basic Wiring Schematic A=Analog, D=Digital ® *Terminal 37 (optional) is used for STO. For STO installation instructions, refer to the VLT Safe Torque Off Operating Instructions. **Do not connect cable screen. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 64: Relay Connections
(normally closed) Illustration 3.21 Relay Outputs 1 and 2, Maximum Voltages ® 1) To add more relay outputs, install VLT Relay Option ® Module MCB 105 or VLT Relay Option Module MCB 113. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 65: Emc-Compliant Electrical Connection
Control wiring (screened) Cable clamp Potential equalisation min. 16 mm (0.025 in) Cable insulation (stripped) Clearance between control cable, motor cable and mains cable: Minimum 200 mm Cable gland Illustration 3.22 EMC-compliant Electrical Connection MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 66: Mechanical Planning
However the correct mounting order is important. Illustration 3.23 shows how to mount correctly. A1*/A2/A3/A4/ B2/B3/B4/ Enclosure size C2/C4 Illustration 3.23 Correct Side-by-side Mounting with no A5/B1 C1/C3 Clearance a [mm] b [mm] Illustration 3.24 Vertical Clearance Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 67: Wall Mounting
10-100% of the setpoint • Fault memory • TEST/RESET key Back plate Frequency converter with IP66 enclosure Back plate Fibre washer Illustration 3.26 Mounting with Back Plate for Protection Rating IP66 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 68 PLC I/O, contactors, them from being opened while power is still temperature probes, indicator lights, and/or other applied. electronic hardware. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 69 5 • A-cyclic parameterisation using PROFIBUS DP V1, ms in both directions. PROFIdrive or Danfoss FC profile state machines, • Built-in web-server for remote diagnosis and PROFIBUS DP V1, Master Class 1 and 2 Ordering reading out basic frequency converter number 130B1100 uncoated –...
Page 70 PTC thermistor card MCB 112 • Provides accurate flow, pressure, and level control With the MCB 112 PTC thermistor card, all Danfoss for optimising the efficiency of systems that use frequency converters with STO can be used to supervise multiple pumps or blowers.
Page 71: Communication Options
• MCO 102 (advanced cascade controller) Each pump, variable speed or fixed speed, is controlled by a relay in the master frequency converter. For further information, see chapter 7 Specifications. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 72: Brake Resistors
The resistor is selected based on its ohmic value, its power dissipation rate and its physical size. Danfoss offers a wide variety of different resistors that are specially designed to Danfoss frequency converters. See chapter 3.4.12 Brake Built-in Resistor Calculation for dimensioning of brake resistors.
Page 73: Du/Dt Filters
Filters), the dU/dt filters have a cut off frequency above the 3.7.8 Harmonic Filters switching frequency. The Danfoss AHF 005 and AHF 010 are advanced harmonic 3.7.7 Common-mode Filters filters, not to be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially High-frequency common-mode cores (HF-CM cores) reduce designed to match the Danfoss frequency converters.
Page 74: Ip21/Nema Type 1 Enclosure Kit
C at the bottom of the frequency converter and use the clamps from the accessory bag to fasten the cables correctly. Holes for cable glands: • Size A2: 2x M25 and 3xM32 • Size A3: 3xM25 and 3xM32 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 75 Illustration 3.34 Enclosure Sizes B4, C3, and C4 Top cover Brim Base part Illustration 3.33 Enclosure Size B3 Base cover Screw(s) Fan cover Top clip Table 3.21 Legend to Illustration 3.33 and Illustration 3.34 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 76: Remote Mounting Kit For Lcp
Table 3.22 Technical Data 64,5± 0.5 mm (2.54± 0.04 in) Panel cut out Illustration 3.37 Dimensions of LCP Kit Illustration 3.35 LCP Kit with Graphical LCP, Fasteners, 3 m Cable and Gasket Ordering Number 130B1113 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 77: Mounting Bracket For Enclosure Sizes A5, B1, B2, C1 And C2
Illustration 3.39 Upper Bracket See dimensions in Table 3.23. Enclosure Size A [mm] B [mm] Ordering number 55/66 130B1080 21/55/66 130B1081 21/55/66 130B1082 21/55/66 130B1083 21/55/66 130B1084 Table 3.23 Details of Mounting Brackets MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 78: Serial Interface Rs485
(S801) of the frequency converters or a biased termination resistor network. Always use screened twisted pair (STP) cable for bus cabling, and follow good common installation practice. Illustration 3.40 RS485 Bus Interface Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 79: Network Connection
When crossing is unavoidable, the RS485 cable must cross motor and brake resistor cables at an angle of 90°. RS 232 RS 485 Illustration 3.41 Parallel Connections MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 80: Fc Protocol Overview
A stop bit completes a character, thus consisting of 11 bits 3.8.5 FC Protocol Overview in all. The FC protocol, also referred to as FC bus or standard bus, is the Danfoss standard fieldbus. It defines an access Start Even Stop...
Page 81 The slave returns the address byte unchanged to the master in the response telegram. 3.8.7.5 Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the telegram is received, the calculated checksum is 0. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 82 PCD1 PCD2 high Illustration 3.47 Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Illustration 3.48 Text Block Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 84: Fc Protocol Examples
0 s⇒conversion index 0 PKE=1155 hex - Read parameter value in 3-41 Ramp 1 0.00 s⇒conversion index -2 Ramp Up Time. 0 ms⇒conversion index -3 IND=0000 hex 0.00 ms⇒conversion index -5 PWEHIGH=0000 hex PWELOW=0000 hex Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 85: Modbus Rtu Protocol
3.8.9.1 Assumptions 3.8.9.3 Frequency Converter with Modbus Danfoss assumes that the installed controller supports the interfaces in this document, and strictly observes all The frequency converter communicates in Modbus RTU requirements and limitations stipulated in the controller format over the built-in RS485 interface.
Page 86: Modbus Rtu Message Framing Structure
This tells the master messages. No response is permitted for broadcast what kind of error occurred, or the reason for the messages. A typical message frame is shown in Table 3.35. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 87 Holding register 40001 is addressed as register 0000 in the data address field of the message. The function code field already specifies a holding-register operation. Therefore, the 4XXXX reference is implicit. Holding register 40108 is addressed as register 006BHEX (107 decimal). MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 88 Output data: Frequency converter status word register (STW). 50210 Output data: Frequency converter main actual value register (MAV). Table 3.39 Holding Registers 1) Used to specify the index number to be used when accessing an indexed parameter. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 89: Access To Parameters
1 register (2 characters) up to 10 registers (20 Reading 3-14 Preset Relative Reference (32bit): The holding registers 3410 & 3411 holds the parameter’s value. A value characters). of 11300 (decimal), means that the parameter is set to 1113.00. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 90: Fc Drive Control Profile
Reference [3] Bit 07=0: No reset. Bit 07=1: Resets a trip. Reset is activated on the signal’s Table 3.44 Reference Values leading edge, for example, when changing from logic 0 to logic 1. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 91 Bit 03=1: The frequency converter trips. To re-establish operation, enter [Reset]. Bit 04, No error/error (no trip) Bit 04=0: The frequency converter is not in fault mode. Bit 04=1: The frequency converter shows an error but does not trip. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 92 Bit 15=1: One of the timers exceeds 100%. All bits in the STW are set to 0 if the connection between the interbus option and the frequency converter is lost, or an internal communication problem has occurred. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 93 It is possible to turn off the control word, if it should not NOTICE be used for updating or reading parameters. The selection in 8-50 Coasting Select determines how bit 03 is linked with the corresponding function of the digital inputs. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 94 When bit 01 of the control word is 1, then bit 04=1. Bit 05, On 3/Off 3 When bit 02 of the control word is 0, then bit 05=0. When bit 02 of the control word is 1, then bit 05=1. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 95 4-16 Torque Limit Motor Mode and 4-17 Torque Limit Generator Mode. When bit 14=1, the limit selected in 4-16 Torque Limit Motor Mode or 4-17 Torque Limit Generator Mode is exceeded. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 96: System Design Checklist
Type Length Fuses Type Size Rating Options Connectors Contacts Filters Output Cables Type Length Fuses Type Size Rating Options Filters Control Wiring Type Length Terminal connections Communication Protocol Connection Wiring Options Connectors Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 97 System Integration Design Guide ☑ Category Details Notes Contacts Filters Motor Type Rating Voltage Options Special tools and equipment Moving and storage Mounting Electrical connection Table 3.50 System Design Checklist MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 98: Application Examples
• • Master-follower: Control up to 8 frequency Low-flow detection converters and pumps to ensure smooth This feature detects no-flow or low-flow operation of the overall pump system. conditions of the system. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 99: Quick Menu Water And Pumps
Depending on the application and the purpose of using it, this feature can be used as a preventive or reactive measure and can be triggered/started in the following ways: MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 100: Pre/Post Lube
Used only when [3] is already ramping up. See the related parameters in Pre & running & post Table 4.1. is selected in 29-40 Pre/Post Lube Function. Table 4.1 Pre/Post Lube Parameters Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 101: Flow Confirmation
Digital signal from an external device becomes active before 29-50 Validation Time expires. When 29-51 Verification Time passes, the frequency converter checks the signal from the external device again and then runs normally. Illustration 4.3 Flow Confirmation MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 102: Application Set-Up Examples
Set the ramping times in 3-41 Ramp 1 Ramp Up Time and 3-42 Ramp 1 Ramp Down Time to the desired times tacc × nnorm par . 1 − 25 tramp = ref RPM Set terminal 27 to [0] No Operation (5-12 Terminal 27 Digital Input) Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 103 Action 2 Start Timer (29) State 1 Event 4 False (0) Action 4 No Action (1) Event 3 Time Out (30) State 2 Action 3 Select Preset ref. (11) Illustration 4.6 SLC Application Example MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 104: Submersible Pump Application
Pipe-fill mode can be enabled to prevent water which is normally 30 Hz. hammering. The Danfoss frequency converter is capable of The motor reactance is nonlinear in submersible filling vertical pipes using the PID controller to ramp up...
Page 105: Basic Cascade Controller
The alternation of the Filled setpoint Time lead pump can take place at a command signal or at Illustration 4.8 Pipe Fill-Mode, Performance Curve staging (adding another pump). MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 106: Pump Staging With Lead Pump Alternation
2 relays are cut out. are running, fixed speed pumps are being staged/de-staged and lead pump alternation is occurring. • De-stage at no-flow ensures that all fixed-speed pumps are stopped individually until the no-flow status disappears. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 107: 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 4.11 Cascade Controller Wiring Diagram MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 108: Fixed Variable Speed Pump Wiring Diagram
When all relays are de-energised, the first built-in relay that is energised 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 © 09/2014 All rights reserved. MG20N602...
Page 109 D IN 37 is an option. A IN A OUT -10 - +10V A OUT 0 - 10V U - I U - I Table 4.10 Analog Speed Reference (Voltage) Table 4.8 Analog Voltage Feedback Transducer (3-wire) MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 110 D IN 37 is an option. A IN A IN A IN A OUT A OUT U - I Table 4.12 Speed Reference (Using a Manual Potentiometer) Table 4.14 Run/Stop Command without External Interlock Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 111 Table 4.16 Motor Thermistor Table 4.15 Run Permissive 4.3.12 Motor Thermistor WARNING THERMISTOR INSULATION Risk of personal injury or equipment damage. • Use only thermistors with reinforced or double insulation to meet PELV insulation requirements. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 112: Special Conditions
Illustration 5.2 Derating of Output Current versus Altitude at speed, there is no need for additional cooling or derating for Enclosure Sizes D3h. AMB, MAX of the motor. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 113: Derating For Long Motor Cables Or Cables With Larger Cross-Section
(kHz) Enclosure Sizes B1 and B2, using 60° AVM in Normal Overload Mode (110% Overtorque) Illustration 5.4 Derating of I for Different T AMB, MAX Enclosures Type A, using SFAVM MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 114 Converters, Enclosure Size B; SFAVM, NO 130BB832.10 110% 100% 45 C 50 C (kHz) Illustration 5.10 Derating of I for different T AMB, MAX Enclosure Sizes B3 and B4, using SFAVM in Normal Overload Mode (110% Overtorque) Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 115 Enclosure Sizes C3 and C4, using SFAVM in Normal Overload Mode (110% Over Torque) (kHz) Illustration 5.15 Derating of I for Different T AMB, MAX Enclosure Sizes C1 and C2, using 60° AVM in Normal Overload Mode (110% Over Torque) MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 116 I out (A) all options 28.9 45°C 27.2 20.4 50°C 13.6 55°C f sw (kHz) Illustration 5.21 Output Current Derating with Switching Frequency and Ambient Temperature for Enclosure Size C2, 60° AVM. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 117: Typecode And Selection
EN 55011 Class A1/B and EN/IEC The Drive Configurator can also establish a project list with 61800-3 Category 1/2 several products and send it to a Danfoss sales represen- H2: No additional EMC filter. Fulfill tative. EN 55011 Class A2 and EN/IEC...
Page 118 DX: No option D0: Extended 24 V DC back-up Table 6.2 Ordering Type Code, Options NOTICE ® For power sizes over 90 kW, see the VLT AQUA Drive FC 202 110-1400 kW Design Guide. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 119: Software Language
Back plate in stainless steel IP66/NEMA Type 4X, enclosure size B1 ® 130B3465 Back plate in stainless steel IP66/NEMA Type 4X, enclosure size B2 ® 130B3468 Back plate in stainless steel IP66/NEMA Type 4X, enclosure size C1 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 120 130B1264 Extended relay card MCB 113 Option for slot D ® 130B1108 130B1208 24 V DC supply MCB 107 Leakage current monitor kits ® 130B5645 Leakage current monitor kit, enclosure sizes A2/A3 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 121: Spare Parts
Options can be ordered as factory built-in options, see ordering information, chapter 6.1 Ordering. Table 6.4 Ordering Numbers for Options and Accessories 6.2.2 Spare Parts Consult the VLT shop or the configurator for spare parts available for your specification, VLTShop.danfoss.com. 6.2.3 Accessory Bags Type Description Ordering no.
Page 122: Brake Resistor Selection
Typecode and Selection Design Guide 6.2.4 Brake Resistor Selection Horizontal and Vertical Loads The Danfoss brake resistor range consists of 2 groups: When the speed reference of a frequency converter is • Brake resistors for horizontal loads (conveyors, reduced, the motor acts as a generator and the frequency trolleys, gantry cranes, etc.), see Illustration 6.2;...
Page 123: Recommended Brake Resistors
Mains Voltage class Rated motor size for frequency converter type Minimum permissible brake resistor by frequency converter Recommended brake resistor resistance of Danfoss brake resistors Thermo relay Brake current setting of external thermo relay Part number Danfoss brake resistor order numbers Recommended minimum value based upon PVC insulated copper cable.
Page 124 14.0 3.200 175u3307 175u3414 175u3413 14.7 10.2 5.500 175u3176 175u3177 18.5 6.000 175u3233 8.000 175u3234 9.000 175u3235 14.000 175u3224 17.000 175u3227 Table 6.8 T2, Vertical Braking 40% Duty Cycle, Recommended Brake Resistors Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 127 29.2 10.000 175u3200 17.1 23.6 14.000 175u3204 13.5 19.4 17.000 175u3207 11.7 15.8 13.5 21.000 175u3208 11.5 26.000 175u3211 30.000 175u3241 Table 6.12 T6, Vertical Braking 40% Duty Cycle, Recommended Brake Resistors MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 128 2 x 2.6 2 x 2.2 2 x 2.0 1000 3 x 2.6 1200 3 x 2.4 1400 3 x 2.0 Table 6.13 T7, Horizontal Braking 10% Duty Cycle, Recommended Brake Resistors Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 130: Alternative Brake Resistors, T2 And T4
6.2.6 Alternative Brake Resistors, T2 and T4 Mains Voltage class Rated motor size for frequency converter type Minimum permissible brake resistor - by frequency converter Recommended brake resistor resistance of Danfoss brake resistors Duty cycle x100/Pm br,cont. Part number Danfoss brake resistor order numbers Brake resistor average rated power.
Page 131: Harmonic Filters
130B2864 130B3085 130B2459 45.0 130B3127 130B2865 130B3086 130B2488 55.0 130B3128 130B2866 130B3087 130B2489 75.0 130B3129 130B2867 130B3088 130B2498 90.0 130B3130 130B2868 130B3089 130B2499 Table 6.19 Harmonic Filters for 380-415 V, 60 Hz MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 132 130B5287 75.0 130B5025 130B5170 130B5326 130B5288 90.0 130B5026 130B5172 130B5327 130B5289 Table 6.22 Harmonic Filters for 500-690 V, 50 Hz 1) Frequency converter power and current ratings according to actual operating conditions Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 133: Sine-Wave Filters
130B2281 130B2307 59.4 46.5 130B2282 130B2308 18.5 74.8 130B2283 130B2309 130B3179 130B3181* 130B3182 130B3183* Table 6.23 Sine-wave Filters for Frequency Converters with 380-500 V 1) Ordering numbers marked with * are IP23. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 134 14-01 Switching Frequency Set according the individual filter. Listed at filter product label and in output filter manual. Sine-wave filters do not allow lower switching frequency than specified by the individual filter. 14-55 Output Filter [2] Sine-wave filter fixed Table 6.25 Parameter Settings for Sine-wave Filter Operation Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 135: Du/Dt Filters
Higher operating switching frequency than specified by the individual filter is not recommended. 14-55 Output Filter [0] No filter 14-56 Capacitance Output Filter Not used 14-57 Inductance Output Filter Not used Table 6.27 Parameter Settings for dU/dt Filter Operation MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 136: Common Mode Filters
Core dimension Weight [kg] A and B 130B3257 22.3 0.25 130B7679 82.8 57.5 45.5 20.6 C2, C3, C4 130B3258 130B3259 2.45 Table 6.28 Common Mode Filters, Ordering Numbers Illustration 6.4 HF-CM Core Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 137: Specifications
Estimated power loss at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 Table 7.1 Mains Supply 1x200–240 V AC, Normal Overload 110% for 1 Minute, P1K1–P22K MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 138: Mains Supply 3X200-240 V Ac
6, 4, 4 (10, 12, 12) ] [(AWG)] Estimated power loss at rated maximum load [W] Efficiency 0.96 0.96 0.96 0.96 0.96 Table 7.3 Mains Supply 3x200–240 V AC, P1K1–P3K7 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 139 16, 10, 10 (6, 8, 8) 35 (2) ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.96 0.96 0.96 0.96 Table 7.4 Mains Supply 3x200–240 V AC, P5K5–P15K MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 140: Mains Supply 1X380-480 V Ac
71.5 Continuous kVA at 400 V [kVA] 11.0 16.6 50.6 Continuous kVA at 460 V [kVA] 11.6 16.7 27.1 51.8 Maximum input current Continuous (1x380–440 V) [A] Intermittent (1x380–440 V) [A] 85.5 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 141: Mains Supply 3X380-480 V Ac
6, 4, 4 (10, 12, 12) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.93 0.95 0.96 0.96 0.97 Table 7.7 Mains Supply 3x380–480 V AC, PK37–P1K5 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 142 6, 4, 4 (10, 12, 12) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.97 0.97 0.97 0.97 0.97 Table 7.8 Mains Supply 3x380–480 V AC, P2K2–P7K5 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 143 16, 10, 10 (6, 8, 8) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.98 0.98 0.98 0.98 0.98 Efficiency Table 7.9 Mains Supply 3x380–480 V AC, P11K–P30K MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 144 (3/0, 2/0, 2/0) MCM, 4/0) ] ([AWG]) Estimated power loss 1083 1022 1384 1232 1474 at rated maximum load [W] 0.98 0.98 0.98 0.98 0.99 Efficiency Table 7.10 Mains Supply 3x380–480 V AC, P37K–P90K Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 145: Mains Supply 3X525-600 V Ac
] ([AWG]) Maximum cable cross-section 6,4,4 (10,12,12) mains disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.97 0.97 0.97 0.97 Efficiency Table 7.11 Mains Supply 3x525–600 V AC, PK75–P2K2 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 146 ] ([AWG]) Maximum cable cross-section 6,4,4 (10,12,12) mains disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.97 0.97 0.97 0.97 Table 7.12 Mains Supply 3x525–600 V AC, P3K0–P7K5 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 147 (6, 8, 8) (1, 2, 2) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load Efficiency 0.98 0.98 0.98 0.98 0.98 0.98 Table 7.13 Mains supply 3x525-600 V AC, P11K-P37K MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 148 [mm ] ([AWG]) 4/0) Estimated power loss 1100 1100 1500 1500 1800 at rated maximum load [W] 0.98 0.98 0.98 0.98 Efficiency Table 7.14 Mains supply 3x525–600 V AC, P45K–P90K Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 149: Mains Supply 3X525-690 V Ac
(10, 12, 12) ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.96 0.96 0.96 0.96 0.96 0.96 0.96 Table 7.15 A3 Enclosure, Mains Supply 3x525–690 V AC IP20/Protected Chassis, P1K1–P7K5 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 150 [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 0.98 Table 7.16 B2/B4 Enclosure, Mains Supply 3x525–690 V AC IP20/IP21/IP55, Chassis/NEMA 1/NEMA 12, P11K–P22K Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 151: Mains Supply
9) 2 wires are required. 10) Variant not available in IP21. 7.2 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 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 152: Motor Output And Motor Data
150/160% for 1 minute, once in 10 minutes Overload torque (constant torque) maximum 150/160% for 1 minute, once in 10 minutes 2) Percentage relates to the nominal torque of the frequency converter, dependent on power size. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 153: Ambient Conditions
It is mandatory to ground the mains connection properly using T95 (PE) of the frequency converter. The ground connection cable cross section must be at least 10 mm or 2 rated mains wires terminated separately according to EN 50178. See also chapter 3.2.8 Earth Leakage Current. Use unscreened cable. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 154: Control Input/Output And Control Data
10 bit (+ sign) Accuracy of analog inputs maximum error 0.5% of full scale Bandwidth 200 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 155 Terminal number pulse 29, 33 Maximum frequency at terminal 29, 33 110 kHz (push-pull driven) Maximum frequency at terminal 29, 33 5 kHz (open collector) Minimum frequency at terminal 29, 33 4 Hz MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 156 1:100 of synchronous speed 30–4000 RPM: maximum error of ±8 RPM Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor. Control card performance Scan interval 5 ms Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 157: Fuses And Circuit Breakers
The fuses below are suitable for use on a circuit capable of delivering 100000 A (symmetrical), depending on the frequency converter voltage rating. With the proper fusing, the frequency converter short-circuit current rating (SCCR) is 100000 A MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 158 (37) 22–30 gG-80 (18.5) gG-150 (18.5) NZMB2-A200 aR-125 (22) aR-160 (22) 37–45 aR-160 (30) aR-200 (30) NZMB2-A250 aR-200 (37) aR-250 (37) Table 7.19 200–240 V, Enclosure Sizes A, B, and C Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 159 (55) aR-250 NZMB2-A250 aR-250 (75) 45–55 gG-100 (37) gG-150 (37) NZMB2-A200 gG-160 (45) gG-160 (45) 75–90 aR-200 (55) aR-250 NZMB2-A250 aR-250 (75) Table 7.20 380–480 V, Enclosure Sizes A, B, and C MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 160 CTI25M 10-16 gG-25 gG-63 gG-25 gG-63 gG-32 gG-32 gG-40 gG-63 gG-80 gG-63 gG-100 gG-80 gG-125 gG-100 gG-160 gG-100 gG-125 gG-125 gG-160 Table 7.22 525–690 V, Enclosure Sizes A, B, and C Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 161 JJS-fuses from Bussmann may substitute JJN for 240 V frequency converters. • KLSR fuses from Littel fuse may substitute KLNR fuses for 240 V frequency converters. • A6KR fuses from Ferraz-Shawmut may substitute A2KR for 240 V frequency converters. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 162 2) A6KR fuses from Ferraz-Shawmut may substitute A2KR for 240 V frequency converters. 3) FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters. 4) A50X fuses from Ferraz-Shawmut may substitute A25X for 240 V frequency converters. Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 163 2028220-200 KLS-R-200 A6K-200-R FWH-200 HSJ-200 A50-P-225 L50-S-225 2028220-250 KLS-R-250 A6K-250-R FWH-250 HSJ-250 A50-P-250 L50-S-250 Table 7.28 3x380–480 V, Enclosure Sizes A, B, and C 1) Ferraz-Shawmut A50QS fuses may substitute A50P fuses. MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 164 A6K-90-R HST-90 KTS-R-100 JKS-100 JJS-100 5014006-100 KLS-R-100 A6K-100-R HST-100 KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 KTS-R-150 JKS-150 JJS-150 2028220-150 KLS-175 A6K-150-R HST-150 Table 7.30 3x525–690 V, Enclosure Sizes B and C Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 166: Du/Dt Testing
[m] [μsec] [kV] [kV/μsec] 0.444 0.538 0.977 0.226 0.616 2.142 0.262 0.626 1.908 Table 7.38 Frequency Converter, P30K, T2 0.650 0.614 0.757 0.745 0.612 0.655 Table 7.32 Frequency Converter, P5K5, T2 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 167 1.056 3.326 0.408 0.718 1.402 0.465 1.048 1.803 0.364 1.050 2.376 0.815 1.032 1.013 0.400 0.980 2.000 0.890 1.016 0.913 Table 7.44 Frequency Converter, P11K, T4 Table 7.50 Frequency Converter, P45K, T4 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 168: Acoustic Noise Ratings
Table 7.56 Frequency Converter, P55K, T6 525–690V (T7) Mains Cable voltage Rise time dU/dt PEAK [μsec] [kV/μsec] length [m] [kV] 0.580 1.728 2.369 0.930 1.824 1.569 0.925 1.818 1.570 Table 7.57 Frequency Converter, P7K5, T7 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 169: Selected Options
S801 • Cable strips for fastening cables to relay module WARNING ! The label MUST be placed on the LCP frame as shown (UL approved). Relay card Illustration 7.3 Enclosure Sizes A2-A3-B3 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 170 Select the relay functions in 5-40 Function Relay [6-8], 5-41 On Delay, Relay [6-8] and 5-42 Off Delay, Relay [6-8]. NOTICE Array [6] is relay 7, array [7] is relay 8, and array [8] is relay 9 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 171: Vlt ® Ptc Thermistor Card Mcb
(or a digital input of a mounted option) must be set to [80] PTC Card 1 to use the information from X44/10. Configure 5-19 Terminal 37 Digital Input to the desired STO functionality (default is safe stop alarm). MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 172 EN 61508 for Tu=75 °C ongoing 2 for maintenance cycle of 2 years 1 for maintenance cycle of 3 years PFD (for yearly functional test) 4.10x10 λ + λ 8494 FIT λ 934 FIT Ordering number 130B1137 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 173: Vlt ® Extended Relay Card Mcb
PNP/NPN Input impedance 4 kW Low trigger level 6.4 V High trigger level 17 V Maximum throughput delay 10 ms Analog outputs Numbers Range 0/4 -20 mA Resolution 11 bit Linearity <0.2% MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 174: Vlt
-58–399 °F Temperature range Galvanic Isolation The sensors to be connected are expected to be galvanically isolated from the mains voltage level IEC 61800-5-1 and UL508C Cabling Maximum signal cable length 500 m Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 175 5 V 10 mA Max switching rate at rated load/min load 6 min /20 s Relay 10 Relay 11 Relay 12 Table 7.61 MCO 101 Electrical Data Illustration 7.14 Usage of Connections MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 176 Specifications Design Guide Illustration 7.15 Mounting of Cables WARNING Do not combine low voltage parts and PELV systems (see Illustration 7.16. Live part PELV Illustration 7.16 Incorrect and Correct Relay Wiring Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 177 Tools required Some items are needed for the installation of a C option mounting kit (depending on the enclosure): Illustration 7.17 Enclosure A2, A3 (and B3) 40 mm (only one C option) MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 178 Fit the extended cradle and terminal cover. Remount the LCP. Connect power to the frequency converter. Wiring the Terminals Illustration 7.19 Advanced Cascade Controller MCO 102 Terminal Connections, 8 Relays Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 179 PE on the left side of the frequency converter. Illustration 8.1 Support Bracket Mains connection for enclosures A4/A5 Illustration 8.4 Mains Connection Enclosures B1 and B2 Illustration 8.2 Mains and Grounding without Disconnector MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 180 Appendix - Selected Drawing... Design Guide Illustration 8.5 Mains Connection Enclosure B3 Illustration 8.6 Mains Connection Enclosure B4 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 181 Appendix - Selected Drawing... Design Guide Illustration 8.8 Mains Connection Enclosures C3 (IP20). Illustration 8.7 Mains Connection Enclosures C1 and C2 (IP21/ NEMA Type 1 and IP55/66/NEMA Type 12). MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 182 W2 U2 V2 6 wires out of motor U1 V1 W1 Star-connected U2, V2, W2 U2, V2 and W2 to be intercon- nected separately. Table 8.1 Terminal Descriptions 1) Protected Ground Connection Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 183 Design Guide Illustration 8.12 Motor Connection for Enclosures A4/A5 Illustration 8.14 Motor Connection for Enclosure B3 Illustration 8.13 Motor Connection for Enclosures B1 and B2 Illustration 8.15 Motor Connection for Enclosure B4 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 184 Illustration 8.18 Terminals for Relay Connection (Enclosure Sizes A1, A2 and A3). Illustration 8.17 Motor Connection for Enclosures C3 and C4 Illustration 8.19 Terminals for Relay Connection (Enclosure Sizes C1 and C2). Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 185 28.4 (Enclosure Sizes A5, B1 and B2). 2 Motor 28.4 3 Brake/load 28.4 sharing 4 Control cable 22.5 5 Control cable 22.5 1) Tolerance ±0.2 mm Illustration 8.21 Enclosure Size A2, IP21 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 186 Illustration 8.25 Enclosure Size A5, IP55 1 Mains 28.4 2 Motor 28.4 3 Brake/load 28.4 sharing 4 Control cable 22.5 5 Removed 1) Tolerance ±0.2 mm Illustration 8.23 Enclosure Size A4, IP55 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 187 5 Control cable 5 Control cable 22.5 6 Control cable 22.5 mm 1) Tolerance ±0.2 mm 1) Knock-out hole Illustration 8.27 Enclosure Size B1, IP21 Illustration 8.29 Enclosure Size B1, IP55 Threaded Gland Holes MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 188 5 Control cable 22.5 3) Mains for S2 variants with Mains Disconnect. 6 Control cable 22.5 1) Tolerance ±0.2 mm Illustration 8.31 Enclosure Size B2, IP55 Illustration 8.33 Enclosure Size B3, IP21 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 189 UL [in] [mm] Mains 63.3 Motor 63.3 Brake/load sharing 1 1/2 50.2 Control cable 28.4 Control cable 22.5 Control cable 22.5 1) Tolerance ±0.2 mm Illustration 8.35 Enclosure Size C2, IP21 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 190 Galvanic isolation......29, 35, 42, 68, 170, 171, 172 Automatic motor adaptation..........9, 29, 103 Marine compliance................12 see also AMA UL listed....................12 Autoramping..................39 Condensation..................37 Contactor................. 66, 69, 70, 106 Back plate....................65 Back-up power system............... 53 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 191 Rated output current................ 9 Ripple current................33, 71 Data control byte................. 78, 79 field....................... 85 type....................82, 87 brake................58, 83, 85, 88 current..................30, 31, 58 DC-link voltage................... 120 Definition................10, 45, 48, 51 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 192 IP21/NEMA Type 1 enclosure kit............. 72 LC..................54, 55, 56, 164 Radio frequency interference............41 see also RFI Sine-wave............. 20, 54, 70, 71, 102 Jog......................89 Fixed speed pump................69 Flow confirmation................15 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 193 Modulation..........9, 28, 40, 111, 112, 113, 114 Options Moment of inertia................. 26 Advanced cascade controller.......... 175, 176 Extended cascade controller............. 173 MCB 114.................... 172 MCO 101................... 173 MCO 102................... 175 Sensor input..................172 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 194 PID controller........21, 22, 25, 30, 102, 103, 172 Pilz......................66 Pipe fill mode............15, 96, 97, 102, 103 PKE field....................81 Point of common coupling............... 48 Potentiometer..................108 Power factor............10, 19, 52, 53, 54, 150 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 195 Starting torque................150 Smart logic control......10, 15, 31, 35, 96, 98, 100, 101 characteristic................... 150 limit..................9, 27, 57, 90 SmartStart..................15, 96 Variable torque..................9 Soft starter..................18, 70 VT characteristics................11 MG20N602 Danfoss A/S © 09/2014 All rights reserved.
Page 196 Wiring................40, 41, 47, 57, 94 Wiring Electrical wiring................102 Relay wiring................169, 174 Wiring..............61, 63, 105, 173, 176 schematic.................... 61 Wiring diagram Fixed variable speed pump............106 Lead pump alternation..............106 Wizard....................15, 96 Danfoss A/S © 09/2014 All rights reserved. MG20N602...
Page 198 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 Introduction

2 Product Overview

3 System Integration

4 Application Examples

5 Special Conditions

6 Typecode and Selection

7 Specifications

Quick Links

Need help?

Questions and answers

Related Manuals for Danfoss VLT AQUA Drive FC 202

Summary of Contents for Danfoss VLT AQUA Drive FC 202

Table of Contents