Page 1 MAKING MODERN LIVING POSSIBLE Design Guide ® AQUA Drive FC 202 0.25–90 kW www.DanfossDrives.com...
Page 3: Table Of Contents
2.4.1 Control Structure Open-loop 2.4.2 Control Structure Closed-loop 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 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 4 2.6.12 DC Braking 2.6.13 Sleep Mode 2.6.14 Run Permissive 2.6.15 Smart Logic Control (SLC) 2.6.16 STO Function 2.7 Fault, Warning and Alarm Functions 2.7.1 Operation at Overtemperature 2.7.2 High and Low Reference Warning Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 5 3.2 EMC, Harmonics and Ground Leakage Protection 3.2.1 General Aspects of EMC Emissions 3.2.2 EMC Test Results 3.2.3 Emission Requirements 3.2.4 Immunity Requirements 3.2.5 Motor Insulation 3.2.6 Motor Bearing Currents 3.2.7 Harmonics 3.2.8 Ground Leakage Current MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 6 3.5 Additional Inputs and Outputs 3.5.1 Wiring Schematic 3.5.2 Relay Connections 3.5.3 EMC-compliant Electrical Connection 3.6 Mechanical Planning 3.6.1 Clearance 3.6.2 Wall Mounting 3.6.3 Access 3.7 Options and Accessories 3.7.1 Communication Options Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 7 4.2.5 29-5* Flow Confirmation 4.3 Application Set-up Examples 4.3.1 Submersible Pump Application 4.3.2 BASIC Cascade Controller 4.3.3 Pump Staging with Lead Pump Alternation 4.3.4 System Status and Operation 4.3.5 Cascade Controller Wiring Diagram MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 8 7.2 Line Power Supply 7.3 Motor Output and Motor Data 7.4 Ambient Conditions 7.5 Cable Specifications 7.6 Control Input/Output and Control Data 7.7 Fuses and Circuit Breakers 7.8 Power Ratings, Weight and Dimensions Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 9 7.11.7 VLT Advanced Cascade Controller MCO 102 8 Appendix - Selected Drawings 8.1 AC Line Input Connection Drawings (3-phases) 8.2 Motor Connection Drawings 8.3 Relay Terminal Drawings 8.4 Cable Entry Holes Index MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 10: Introduction
Be Chapter 5 Special Conditions: Details on unusual operational sure to see the instructions supplied with the options for environments. specific requirements. Contact a Danfoss supplier or visit www.danfoss.com for additional information. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 11: Abbreviations, Symbols And Conventions
Kilohertz Nominal motor voltage Local control panel Volts Least significant bit Variable torque Meter Voltage vector control Milliampere Mille circular mil Table 1.1 Abbreviations Motion control tool Inductance in millihenry MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 12: Definitions
• Link Cos-phi is also known as displacement power factor. • Footnote ® Both lambda and cos phi are stated for Danfoss VLT • Parameter name, parameter group name, adjustable frequency drives in chapter 7.2 Line Power parameter option Supply.
Page 13: Document And Software Version
Electrical equipment devices used alone or as part of a Table 1.3. system must bear the CE mark. Systems do not require the CE mark, but must comply with the basic protection requirements of the EMC directive. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 14: Machinery Directive
If an adjustable for UL. frequency drive is integrated into a machinery system, Danfoss can provide information on safety aspects relating The adjustable frequency drive complies with UL508C to the adjustable frequency drive. thermal memory retention requirements. For more When adjustable frequency drives are used in machines information, refer to chapter 2.6.2 Motor Thermal Protection.
Page 15 Leakage currents exceed 3.5 mA. Failure to ground the adjustable frequency drive properly can result in death or serious injury. • Ensure the correct grounding of the equipment by a certified electrical installer. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 16 An internal failure in the adjustable frequency drive can result in serious injury when the adjustable frequency drive 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. MG20N622...
Page 17: Product Overview
Real time clock • Password protection • Overload protection • Energy saving Smart logic control • Minimum speed monitor Figure 2.1 Example: Energy Saving • Free programmable texts for information, warnings and alerts MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 18 Assuming an equal efficiency in the speed range. Q=Flow P=Power =Flow 1 =Power 1 =Reduced flow =Reduced power H=Pressure n=Speed regulation =Pressure 1 =Speed 1 =Reduced pressure =Reduced speed Table 2.1 Affinity Laws Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 19 Figure 2.6. The payback period depends on the price of electricity and the price of the adjustable frequency drive. In this example, payback is less than a year, when compared with valves and constant speed. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 20 Such motor starters are not required if an adjustable frequency drive is used. As illustrated in Figure 2.8, an adjustable frequency drive does not consume more than rated current. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 21: Description Of Operation
The adjustable frequency drive supplies the motor with variable voltage/current and frequency, which enables variable speed control of 3-phased, standard asynchronous motors and non-salient PM motors. Figure 2.9 Adjustable Frequency Drive Block Diagram MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 22: Sequence Of Operation
7.7 Fuses and Circuit Breakers. the output waveform. This waveform, as generated by the Danfoss VVC PWM principle at the control card, provides optimal performance and minimal losses in the motor. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 23: Load Sharing
RPM or Hz -100% P 4-10 Motor speed P 3-13 direction Reference LCP Hand on, P 4-12 site Motor speed o and auto on keys low limit [Hz] Figure 2.11 Open-loop Mode Block Diagram MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 24: Control Structure Closed-Loop
• Figure 2.14 illustrates manual configuration mode • for local reference. Start-up frequency - lets the system quickly reach an operating status before the PID controller takes over. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 25: Reference Handling
Serial communication bus references Set the reference site in 3-13 Reference Site, as shown in • A preset relative reference Table 2.4. • A feedback controlled setpoint For more information, refer to the Programming Guide. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 27: Feedback Handling
In addition, the maximum or minimum value lower than setpoint, resulting in a positive difference). can be used. Setpoint 1 is used exclusively in this configu- ration. Figure 2.16 Block Diagram of Feedback Signal Processing MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 28: Automated Operational Functions
(2-10 Brake Function) or using overvoltage control down inside the adjustable frequency drive (first fault). See (2-17 Over-voltage Control). chapter 7.7 Fuses and Circuit Breakers for more information. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 29: Missing Motor Phase Detection
The torque limit feature protects the motor against overload, independent of the speed. Torque limit is controlled in 4-16 Torque Limit Motor Mode or 4-17 Torque Limit Generator Mode and the time before the torque limit MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 30: Automatic Energy Optimization
With auto restart selected, the adjustable frequency drive automatically powers up after a voltage trip. With flying start, the adjustable frequency drive synchronizes to motor rotation before start. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 31: Motor Soft Start
PTC sensor in the motor windings and connected on a standard AI or DI. PT100 or PT1000 in the motor windings ® and motor bearings, connected on VLT Sensor Input Card MCB 114. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 32: Line Drop-Out
This feature allows regulating a system with different feedback requirements. The adjustable frequency drive makes control decisions by comparing the two signals to optimize system performance. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 33: Automatic Restart
This can eliminate the need for a space heater. 2.6.14 Run Permissive The drive can wait for a remote system ready signal before starting. When this feature is active, the drive remains stopped until receiving permission to start. Run permissive MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 34: Smart Logic Control (Slc)
[0]) each scan interval. Only when event [0] is evaluated Logic Rule Boolean 3 TRUE, the SLC executes action [0] and starts evaluating Figure 2.22 Logic Rules event [1]. It is possible to program from 1 to 20 events and actions. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 35: Sto Function
(see chapter 5.3 Derating • IEC 62061: 2005 SIL CL2 for Ambient Temperature). • ISO 13849-1: 2006 Category 3 PL d • ISO 14118: 2000 (EN 1037) – prevention of unexpected startup MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 36: High And Low Reference Warning
The unit will not issue a low frequency warning when it is stopped nor upon start up until after the operating frequency has been reached. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 37: Local Control Panel
The Main Menu accesses all parameters and allows for advanced applications programming. Remote user interface For remote programming, Danfoss offers a software program for developing, storing, and transferring programming information. MCT 10 Set-up Software allows the user to connect a PC to the adjustable frequency drive and perform live programming rather than using the LCP keypad.
Page 38: Mct 10 Set-Up Software
2.9 Maintenance Open MCT 10 Set-up Software. Select the USB port or the RS485 interface. Danfoss adjustable frequency drive models up to 90 kW are maintenance-free. High power adjustable frequency Select copy. drives (rated at 110 kW or higher) have built-in filter mats Select the project section.
Page 39: Storage
Like all electronic equipment, adjustable frequency drives must be stored in a dry location. Periodic forming (capacitor charging) is not necessary during storage. It is recommended to keep the equipment sealed in its packaging until installation. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 40: System Integration
A complete design concept includes detailed specification equipment and maximizes overall system reliability. Follow of needs and use. the recommendations listed for maximum performance and equipment longevity. • Adjustable frequency drive types • Motors Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 41: Cooling
In case of overtemperature inside the adjustable frequency drive, it derates the switching frequency and pattern. See chapter 5.1 Derating for more info. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 42: Motor-Generated Overvoltage
The adjustable frequency drive attempts to do this by automat- ically lengthening the ramp-down time if the overvoltage occurs during deceleration. If this is unsuccessful, or if the Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 43 Above a certain size, these fans are fitted with filter mats. These filters can become quickly clogged when used in dusty environments. Preventive measures are necessary under these conditions. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 44: Ip Rating Definitions
AQUA Drive FC 202 NOTICE! 3.1.8.1 Cabinet Options and Ratings Adjustable frequency drives with the MCB 112 option Danfoss adjustable frequency drives are available with have PTB-certified motor thermistor sensor monitoring three different protection ratings: capability for potentially explosive atmospheres.
Page 45: Pelv And Galvanic Isolation Compliance
Galvanic (ensured) isolation is obtained by fulfilling using external protective devices or galvanic isolation. requirements for higher isolation and by providing the For installations at high altitude, contact Danfoss regarding relevant creepage/clearance distances. These requirements are described in the EN 61800-5-1 standard.
Page 46: Emc, Harmonics And Ground Leakage Protection
5 MHz. Since the leakage higher than 50 MHz (airborne) is especially generated by current (I ) is carried back to the unit through the shield the control electronics. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 47: Emc Test Results
(Ölflex Classic 100 CY) at nominal switching frequency. Table 3.4 states the maximum motor cable lengths for compliance. NOTICE! Conditions may change significantly for other set-ups. NOTICE! Consult Table 3.17 for parallel motor cables. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 48 0.37–90 kW (0.5–125 hp) 380–480 V 10 (33) 50 (164) 50 (164) 1.1–30 kW (1.5–40 hp) 100 (330) 100 (330) 525–690 V FC 202 37–90 kW (50–125 hp) 150 (500) 150 (500) 525–690 V Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 49 H3 – Integrated EMC filter. Fulfill EN 55011 class A1/B and EN/IEC 61800-3 Category 1/2. H4 – Integrated EMC filter. Fulfill EN 55011 class A1 and EN/IEC 61800-3 Category 2. H5 – Marine versions. Ruggedized version, fulfills same emissions levels as H2 versions. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 50: Emission Requirements
(home and commercial and light office) industrial environments. Second EN/IEC 61000-6-4 Emission Class A Group 1 environment standard for industrial (industrial environments. environment) Table 3.6 Correlation between Generic Emission Standards and EN 55011 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 51: Motor Insulation
Table 3.8 Motor Insulation connection between the motor and the adjustable frequency drive, for instance, by a shielded cable which has a 360° connection in the motor and the adjustable frequency drive. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 52: Harmonics
An adjustable frequency drive takes up a non-sinusoidal drive is equipped with passive filters. DC coils reduce the current from the line power, which increases the input total harmonic distortion (THD) to 40%. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 54: Ground Leakage Current
Harmonic voltage distortion causes disturbance to other loads and increase losses in other loads. 3.2.7.6 Harmonic Mitigation Non-linear In cases where additional harmonic suppression is required, Danfoss offers a wide range of mitigation equipment. These are: System Current Voltage Impedance •...
Page 55 RCD with high f cut- Leakage current THVD=0% Frequency 50 Hz 150 Hz THVD=5% Mains 3rd harmonics Cable Figure 3.8 Main Contributions to Leakage Current Figure 3.7 Line Distortion Influences Leakage Current MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 56: Line Power Integration
2 kHz, which is not addressed by the ground conductor results in poor EMC character- standard, and label them as interference-free. Limits for istics. this region are currently being studied. Adjustable frequency drives do not shift line interference. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 57: Analyzing Line Interference
The overall harmonic content is called NOTICE! the total harmonic distortion (THD). Danfoss has a very high level of EMC expertise and 3.3.2.5 Effects of Line Interference provides EMC analyses with detailed evaluation or line power calculations to customers in addition to training Harmonics and voltage fluctuations are two forms of low- courses, seminars, and workshops.
Page 58: Classification Of The Operating Site
3.3.6.1 Environment 1/Class B: Residential ground. Although not in common use in the United States, the input power may be an isolated source. All Danfoss Operating sites connected to the public low-voltage power adjustable frequency drives may be used with isolated grid, including light industrial areas, are classified as input source as well as with ground reference power lines.
Page 59: Electrical Transients
This causes the total harmonic • distortion to increase. With proper design, generators can Controlled B6 rectifier⇒maximum 10% of rated operate in a system containing devices that induce generator load. harmonics. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 61: Connection Of Multiple Motors
Figure 3.16. NOTICE! When motors are connected in parallel, set 1-01 Motor Control Principle to [0] U/f. Figure 3.14 Parallel Cables with Load Figure 3.11 Common Joint Connection for Short Cable Lengths MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 62: Control Wire Isolation
Divider strips are essential with smaller separations or interference may be coupled in or transferred. • Control cable shields must be connected at both ends in the same way as motor cable shields. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 63: Motor Thermal Protection
In that way, the motor is protected expression of intermittent duty cycle. from overheating even at low speed. The ETR feature calculates the motor temperature based on actual current and speed. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 64 x M x η x η motor br ( motor Danfoss offers brake resistors with duty cycles of 5%, 10%, η is typically at 0.90 motor and 40%. When a 10% duty cycle is applied, the brake η is typically at 0.98. resistors absorb braking energy for 10% of the cycle time.
Page 65: Brake Resistor Cabling
To calculate the system efficiency, multiply the efficiency of efficiency does not change when other U/f characteristics the adjustable frequency drive by the efficiency of the are selected. However, the U/f characteristics do influence motor. the efficiency of the motor. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 66: Additional Inputs And Outputs
Figure 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 Instruction Manual. **Do not connect cable shield. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 67: Relay Connections
Relay Option Module MCB 113. For more information about relays, refer to chapter 7 Specifications and chapter 8.3 Relay Terminal Drawings. For more information about relay options, refer to chapter 3.7 Options and Accessories. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 68: Emc-Compliant Electrical Connection
Potential equalization min. 16 mm (0.025 in /AWG 6) Cable insulation (stripped) Clearance between control cable, motor cable and line cable: Minimum 200 mm (7.9 in) Cable connector Figure 3.22 EMC-compliant Electrical Connection Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 69: Mechanical Planning
Horizontal clearance, IP21 enclosure kit When the IP21 enclosure kit is used on enclosure sizes A1, A2 or A3, ensure a clearance between the adjustable frequency drives of minimum 50 mm (2 in). MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 70: Access
DC ground fault currents • LED bar graph indicator of the ground fault Figure 3.26 Mounting with Backplate for Protection Rating current level from 10–100% of the setpoint IP66 • Fault memory • TEST/RESET key Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 71 5 Amp, 120 W, 24 V DC. drive, increasing safety during servicing. The • Protected against output overcurrent, overload, disconnect is interlocked with the enclosure short circuits, and overtemperature. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 72 A-cyclic parameterization using PROFIBUS DP V1, based networks, such as Groupe Schneider PLC system via PROFIdrive or Danfoss FC profile state machines, the Modbus TCP Protocol. The option is able to handle a PROFIBUS DP V1, Master Class 1 and 2 Ordering single connection with an actual packet interval down to 5 number 130B1100 uncoated –...
Page 73 Extends the capabilities of the standard cascade controller PTC thermistor card MCB 112 built into adjustable frequency drives. With the MCB 112 PTC thermistor card, all Danfoss • Provides eight additional relays for staging of adjustable frequency drives with STO can be used to additional motors.
Page 74: Communication Options
(staged) and turned off (de- For further information, refer to chapter 7 Specifications. staged) as needed in order to satisfy the required system output for flow or pressure. The speed of pumps Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 75 25-** Cascade Controller 8 VSP MCO 102 parameter group 27-** Cascade CTL Option 1 VSP + 8 FSP MCO 102 parameter group 25-** Cascade Controller Figure 3.29 Application Overview Figure 3.27 Application Overview MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 76: Brake Resistors
Danfoss offers a wide variety of different resistors that are performance compared to regular ferrite cores. The HF-CM specially designed to Danfoss adjustable frequency drives.
Page 77: Harmonic Filters
(U, V, W) through each core, as shown in Figure 3.30. Figure 3.30 HF-CM Core with Motor Phases 3.7.8 Harmonic Filters The Danfoss AHF 005 and AHF 010 are advanced harmonic filters, not to be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially designed to match the Danfoss adjustable frequency drives.
Page 79: Remote Mounting Kit For Lcp
Ordering Number 130B1113 Figure 3.34 Enclosure Sizes B4, C3, and C4 Top cover Brim Base part Base cover Screw(s) Fan cover Top clip Table 3.21 Legend to Figure 3.33 and Figure 3.34 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 80: Mounting Bracket For Enclosure Sizes A5, B1, B2, C1 And C2
Figure 3.38 LCP Kit with Graphical LCP, Fasteners, 3 m (10 ft) Ordering Number 130B1114 Cable and Gasket, for US only 3.7.11 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1 and C2 Figure 3.37 Dimensions of LCP Kit Figure 3.39 Lower Bracket Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 81 495 (19.49) 130B1080 21/55/66 535 (21.06) 550 (21.65) 130B1081 21/55/66 705 (27.76) 720 (28.35) 130B1082 21/55/66 730 (28.74) 745 (29.33) 130B1083 21/55/66 820 (32.28) 835 (32.87) 130B1084 Table 3.23 Details of Mounting Brackets MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 82: Serial Interface Rs485
Table 3.24 Cable Specifications drives or a biased termination resistor network. Always use shielded twisted pair (STP) cable for bus cabling and follow good common installation practice. Figure 3.41 RS485 Bus Interface Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 83: Network Connection
Set the communication protocol to 8-30 Protocol. 3.8.4 EMC Precautions The following EMC precautions are recommended to achieve interference-free operation of the RS485 network. Observe relevant national and local regulations, for example, regarding protective ground connection. Keep MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 84: Fc Protocol Overview
3.8.5 FC Protocol Overview The FC protocol, also referred to as FC bus or standard bus, is the Danfoss standard serial communication bus. It defines an access technique according to the master-slave Figure 3.45 Content of a Character principle for communications via a serial bus.
Page 85 The slave returns the address byte unchanged to the master in the response message. 3.8.7.5 Data Control Byte (BCC) The checksum is calculated as an XOR-function. Before the first byte in the message is received, the calculated checksum is 0. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 86 PCD1 PCD2 high Figure 3.48 Parameter Block Text block The text block is used to read or write texts via the data block. PCD1 PCD2 Figure 3.49 Text Block Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 87 Table 3.29 Response Slave⇒Master does not contain a numerical value, but several data options, e.g., 0-01 Language where [0] is English, and [4] is Danish, select the data value by entering the value in the MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 88: Fc Protocol Examples
Parameter values are transferred as whole numbers only. Conversion factors are therefore used to transfer decimals. 4-12 Motor Speed Low Limit [Hz] has a conversion factor of 0.1. To preset the minimum frequency to 10 Hz, transfer Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 89: Modbus Rtu Protocol
If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave Danfoss assumes that the installed controller supports the constructs an error message and sends it in response or a interfaces in this document, and strictly observes all timeout occurs.
Page 90: Modbus Rtu Message Framing Structure
A typical message frame is shown in Table 3.35. Table 3.33 Modbus RTU Parameters Start Address Function Data check T1-T2-T3- 8 bits 8 bits N x 8 bits 16 bits T1-T2-T3- Table 3.35 Typical Modbus RTU Message Structure Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 91 This tells the master what kind of error occurred, or the reason for the exception. Also refer to chapter 3.8.10.10 Function Codes Supported by Modbus RTU and chapter 3.8.10.11 Modbus Exception Codes. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 92 Table 3.37 Adjustable Frequency Drive Control Word (FC 50210 Output data: Adjustable frequency drive main Profile) 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. MG20N622...
Page 93: Access To Parameters
3410 and 3411 hold the parameter’s value. A value of 11300 (decimal), means that the parameter is set to 1113.00. For information on the parameters, size and converting index, consult the Programming Guide. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 94: Fc Drive Control Profile
03 hex Read Holding Registers and written using 3-10 Preset function 10 hex Preset Multiple Registers. Readable sizes Reference [3] range from one register (two characters) up to ten registers Table 3.44 Reference Values (20 characters). Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 95 Bit 07, Reset Bit 07=0: No reset. Bit 07=1: Resets a trip. Reset is activated on the signal’s leading edge, for example, when changing from logic 0 to logic 1. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 96 Bit 13=0: There are no voltage warnings. Bit 03=0: The adjustable frequency drive is not in fault Bit 13=1: The DC voltage in the adjustable frequency mode. drive’s intermediate circuit is too low or too high. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 97 State 1: Switching on inhibited. Bit 03, Coasting/No coasting Coasting stop bit 03=0 leads to a stop. When bit 03=1, the adjustable frequency drive can start if the other start conditions are satisfied. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 98 Speed. Jog 2 is only possible if bit 04=0 and bit 00-03=1. Logic or or Logic and is selected. Bit 10, Data invalid/valid Is used to tell the adjustable frequency drive whether the control word is to be used or ignored. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 99 When bit 01 of the control word is 0, then bit 04=0. selected in 4-16 Torque Limit Motor Mode and 4-17 Torque When bit 01 of the control word is 1, then bit 04=1. Limit Generator Mode. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 100: System Design Checklist
Air quality/dust Derating requirements Enclosure size Input Cables Type Length Fuses Type Size Rating Options Connectors Contacts Filters Output Cables Type Length Fuses Type Size Rating Options Filters Control Wiring Type Length Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 101 Details Notes Terminal connections Communication Protocol Connection Wiring Options Connectors Contacts Filters Motor Type Rating Voltage Options Special tools and equipment Moving and storage Mounting Electrical connection Table 3.50 System Design Checklist MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 102: Application Examples
• Single pump/motor in open-loop or closed-loop • • Motor alternation: When two motors share one STO enables safe stop (coast) when a critical adjustable frequency drive. situation arises. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 103: Quick Menu Water And Pumps
Status in the LCP: Auto Remote Derag. • A bit in the extended status word (Bit 23, 80 0000 hex). • A digital output can be configured to reflect the active deragging status. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 104: Pre/Post Lube
Figure 4.2 shows a different usage of the feature. In this Function. case, the delay expires while the adjustable frequency drive is already ramping up. See the related parameters in Table 4.1 Pre/Post Lube Parameters Table 4.1. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 105: Flow Confirmation
Digital signal from an external device becomes active before 29-50 Validation Time expires. When 29-51 Verification Time passes, the adjustable frequency drive checks the signal from the external device again and then runs normally. Figure 4.3 Flow Confirmation MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 106: Application Set-Up Examples
When the optional STO feature is used, a jumper wire may be required between terminal 12 (or 13) and terminal 37 for the adjustable frequency drive to operate when using factory default programming values. SLC Application Example One sequence 1: Start. Ramp-up. Run at reference speed 2 s. Ramp-down. Hold shaft until stop. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 107 Set the in 13-00 SL Controller Mode to ON. Start/stop command is applied on terminal 18. If the stop signal is applied, the adjustable frequency drive ramps down and goes into free mode. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 108: Submersible Pump Application
The motor is a so-called CAN motor with a motor. A Danfoss sine-wave filter can lower the stainless steel can between the rotor and stator. motor insulation stress and increase lifetime...
Page 109 Pipe-fill mode can be enabled to prevent water 3-88 Final Ramp Time (2 s) hammering. The Danfoss adjustable frequency drive is 3-41 Ramp 1 Ramp-up Time (8 s depending on size) capable of filling vertical pipes using the PID controller to...
Page 110: Basic Cascade Controller
To prevent frequent staging and destaging and minimize pressure fluctuations, a wider fixed-speed bandwidth is Figure 4.9 BASIC Cascade Controller used instead of the staging bandwidth. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 111: Pump Staging With Lead Pump Alternation
) for a programmed amount of time, with a fixed- speed pump running, the lead pump contributes little to the system. When programmed value of the timer expires, the lead pump is removed, avoiding water heating problems. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 112: Cascade Controller Wiring Diagram
Figure 4.11 shows an example with the built-in BASIC cascade controller with one variable-speed pump (lead) and two fixed- speed pumps, a 4–20 mA transmitter and system safety interlock. Figure 4.11 Cascade Controller Wiring Diagram Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 113: Fixed Variable-Speed Pump Wiring Diagram
Every pump must be connected to two contactors (K1/K2 and K3/K4) with a mechanical interlock. Thermal relays or other motor protection devices must be applied according to local regulation and/or individual demands. Table 4.6 External Alarm Reset MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 114 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) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 115 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 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 116: Vlt ® Sensor Input Option Mcb
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. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 117: Special Conditions
An alternative is to reduce the load level of the motor by selecting a larger motor. However, the design of the adjustable frequency drive puts a limit on the motor size. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 118: Derating For Long Motor Cables Or Cables With Larger Cross-Section
A1-A3 55°C, A4-A5 50°C f sw (kHz) Figure 5.5 Derating of I for Different T for Enclosures AMB, MAX Type A, using 60° AVM and Maximum 10 m (33 ft) Motor Cable Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 119 45 C 50 C 55 C (kHz) Figure 5.8 Derating of I for Different T for Enclosure AMB, MAX Sizes B3 and B4, using 60° AVM in Normal Overload Mode (110% Overtorque) MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 120 Ambient Temperature for Enclosure Sizes B2 and B4, Figure 5.12 Output Current Derating with Switching Frequency SFAVM. and Ambient Temperature for 600 V Adjustable Frequency Drives, Enclosure Size B; SFAVM, NO Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 121 Sizes C3 and C4, using SFAVM in Normal Overload Mode (110% Over Torque) Figure 5.16 Derating of I for Different T for Enclosure AMB, MAX Sizes C3 and C4, using 60° AVM in Normal Overload Mode (110% Over Torque) MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 122 T LOAD at T max +5 °C LOAD at T max +5 °C LOAD f sw (kHz) Figure 5.23 Output Current Derating with Switching Frequency and Ambient Temperature for Enclosure Size C3 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 123: Type Code And Selection
P21: IP21/NEMA Type 1 (with The drive configurator can also establish a project list with backplate) several products and send it to a Danfoss sales represen- P55: IP55/NEMA Type 12 (with tative. backplate) Z20: IP 20...
Page 124 B2: MCB 112 PTC thermistor card B4: MCB 114 VLT sensor input C0 options CX: No option C1 options X: No option R: MCB 113 Ext. relay card 5: MCO 102 Advanced cascade control Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 125: Software Language
Backplate IP20/NEMA Type 1, enclosure size C3 ® 130B4171 Backplate IP20/NEMA Type 1, enclosure size C4 ® 130B3242 Backplate IP66/NEMA Type 4X, enclosure size A5 ® 130B3434 Backplate in stainless steel IP66/NEMA Type 4X, enclosure size B1 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 126 Mounting kit for C option, 40 mm (1.6 in), enclosure size B3 ® 130B1414 Mounting kit for C option, 60 mm (2.4 in), enclosure size B3 Options for slot C ® 130B1154 130B1254 Advanced cascade controller MCO102 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 127: 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 128: Brake Resistor Selection
DC link. The function of the Horizontal and Vertical Loads brake resistor is to provide a load on the DC link during The Danfoss brake resistor range consists of two groups: braking, thereby ensuring that the braking energy is •...
Page 129: Recommended Brake Resistors
Line power Voltage class Rated motor size for adjustable frequency drive type Minimum permissible brake resistor by adjustable frequency drive Recommended brake resistor resistance of Danfoss brake resistors Thermo relay Brake current setting of external thermo relay Part number Danfoss brake resistor order numbers Cable cross-section Recommended minimum value based upon PVC insulated copper cable.
Page 130 6 (10) (2.949) 2.800 37 (50) 175u3333 175u3448 175u3447 10 (8) (3.753) 3.200 45 (60) 175u3334 175u3086 175u3087 16 (6) (4.289) Table 6.7 T2, Horizontal Braking 10% Duty Cycle, Recommended Brake Resistors Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 131 9.000 30 (40) 175u3235 16 (6) (12.064) 14.000 37 (50) 175u3224 25 (4) (18.767) 17.000 45 (60) 175u3227 35 (2) (22.788) Table 6.8 T2, Vertical Braking 40% Duty Cycle, Recommended Brake Resistors MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 132 175u3065 175u3066 4 (12) (5.630) 5.500 75 (100) 175u3070 175u3071 6 (10) (7.373) 7.000 90 (125) 175u3231 10 (8) (9.383) 9.000 175u3079 16 (6) (150) (12.064) 11.000 175u3083 25 (4) (175) (14.745) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 133 2 x 1.7 (750) 2 x 1.5 (850) 2 x 1.3 (950) 3 x 1.8 (1075) 1000 3 x 1.6 (1350) Table 6.9 T4, Horizontal Braking 10% Duty Cycle, Recommended Brake Resistors MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 134 55 (75) 10.7 175u3213 16 (6) (28.150) 26.000 75 (100) 175u3216 25 (4) (34.853) 36.000 90 (125) 175u3219 35 (2) (48.257) 42.000 175u3221 50 (1/0) (150) (56.300) 52.000 175u3223 70 (3/0) (175) (69.705) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 135 2 x 1.7 (750) 2 x 1.5 (850) 2 x 1.3 (950) 3 x 1.8 (1075) 1000 3 x 1.6 (1350) Table 6.10 T4, Vertical Braking 40% Duty Cycle, Recommended Brake Resistors MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 136 15.8 13.5 175u3057 175u3058 4 (12) (5.630) 5.500 75 (100) 11.5 175u3063 175u3064 (7.373) 7.000 90 (125) 175u3245 10 (8) (9.383) Table 6.11 T6, Horizontal Braking 10% Duty Cycle, Recommended Brake Resistors Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 137 55 (75) 11.7 15.8 13.5 175u3208 16 (6) (28.150) 26.000 75 (100) 11.5 175u3211 25 (4) (34.853) 30.000 90 (125) 175u3241 (40) Table 6.12 T6, Vertical Braking 40% Duty Cycle, Recommended Brake Resistors MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 138 (9.383) 9.000 10.6 175u3067 16 (6) (150) (12.064) 11.000 175u3072 16 (6) (175) (14.745) 13.000 175u3075 16 (6) (225) (17.426) 16.000 175u3078 25 (4) (275) (21.448) 20.000 175u3082 35 (2) (350) (26.809) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 139 2 x 2.0 (1200) 1000 1.1 (1.5) 3 x 2.6 (1350) 1200 3 x 2.4 (1600) 1400 3 x 2.0 (1875) Table 6.13 T7, Horizontal Braking 10% Duty Cycle, Recommended Brake Resistors MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 140 (150) (56.300) 52.000 175u3215 50 (1/0) (175) (69.705) 60.000 175u3218 70 (3/0) (225) (80.429) 78.000 2 x 35 (2 x 175u3220 (275) (104.558) 90.000 2 x 35 (2 x 175u3222 (350) (120.643) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 141: Alternative Brake Resistors, T2 And T4
6.2.6 Alternative Brake Resistors, T2 and T4 Line power Voltage class Rated motor size for adjustable frequency drive type Minimum permissible brake resistor - by adjustable frequency drive 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 142 300/200 2 x 0985 P5K5 5.5 (7.5) 99.0 113.3 130/200 2 x 0990 P7K5 7.5 (10) 72.0 82.4 80/240 2 x 0090 Table 6.17 Line power: 380–480 V (T4), Alternative Brake Resistors Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 143: Harmonic Filters
55.0 (75) 55 (75) 130B3128 130B2866 130B3087 130B2489 75.0 (100) 75 (100) 130B3129 130B2867 130B3088 130B2498 90.0 (125) 90 (125) 130B3130 130B2868 130B3089 130B2499 Table 6.19 Harmonic Filters for 380–415 V, 60 Hz MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 144 55.0 (75) 60 (80) 130B5268 130B5253 130B5236 130B5219 75.0 (100) 75 (100) 130B5269 130B5254 130B5237 130B5220 90 (125) 90 (125) 130B5270 130B5255 130B5238 130B5221 Table 6.21 Harmonic Filters for 600 V, 60 Hz Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 145 130B5025 130B5326 90.0 90 (125) 130B5172 130B5289 (125) 130B5026 130B5327 Table 6.22 Harmonic Filters for 500–690 V, 50 Hz 1) Adjustable frequency drive power and current ratings according to actual operating conditions MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 146: Sine-Wave Filters
75 (100) 37 (50) 75 (100) 90 (125) 130B3182 130B3183* 45 (60) 90 (125) Table 6.23 Sine-wave Filters for Adjustable Frequency Drives with 380–500 V 1) Ordering numbers marked with * are IP23. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 147 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 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 148: Du/Dt Filters
(50) (125) (125) (60) Table 6.26 dU/dt Filters for 200–690 V 1) Dedicated A3 enclosure sizes supporting foot print mounting and book style mounting. Fixed shielded cable connection to adjustable frequency drive. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 149: Common Mode Filters
61 (2.4) 28 (1.1) 37 (1.46) 1.6 (3.53) 130B3259 189 (7.44) 143 (5.63) 126 (4.96) 80 (3.15) 37 (1.46) 2.45 (5.4) Table 6.28 Common Mode Filters, Ordering Numbers Figure 6.4 HF-CM Core MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 150: 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 Line Power Supply 1x200–240 V AC, Normal Overload 110% for 1 Minute, P1K1–P22K Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 151: Line Power Supply 3X200-240 V Ac
6, 4, 4 (10, 12, 12) ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.94 0.94 0.95 0.95 Table 7.2 Line Power Supply 3x200–240 V AC, PK25–PK75 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 152 6, 4, 4 (10, 12, 12) ] [(AWG)] Estimated power loss at rated maximum load [W] 0.96 0.96 0.96 0.96 0.96 Efficiency Table 7.3 Line Power Supply 3x200–240 V AC, P1K1–P3K7 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 153 16, 10, 10 (6, 8, 8) 35 (2) ] ([AWG]) Estimated power loss at rated maximum load [W] 0.96 0.96 0.96 0.96 Efficiency Table 7.4 Line Power Supply 3x200–240 V AC, P5K5–P15K MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 154 ] ([AWG]) MCM, 4/0) Estimated power loss at rated maximum 1140 1143 1353 1400 1636 load [W] Efficiency 0.96 0.97 0.97 0.97 0.97 Table 7.5 Line Power Supply 3x200–240 V AC, P18K–P45K Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 155: Line Power Supply 1X380-480 V Ac
120 (4/0) ]] ([AWG]) 1480 Estimated power loss at rated maximum load [W] 0.96 0.96 0.96 0.96 Efficiency Table 7.6 Line Power Supply 1x380–480 V AC, Normal Overload 110% for 1 Minute, P7K5–P37K MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 156: Line Power Supply 3X380-480 V Ac
6, 4, 4 (10, 12, 12) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.93 0.95 0.96 0.96 0.97 Efficiency Table 7.7 Line Power Supply 3x380–480 V AC, PK37–P1K5 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 157 6, 4, 4 (10, 12, 12) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.97 0.97 0.97 0.97 0.97 Efficiency Table 7.8 Line Power Supply 3x380–480 V AC, P2K2–P7K5 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 158 16, 10, 10 (6, 8, 8) disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 0.98 Table 7.9 Line Power Supply 3x380–480 V AC, P11K–P30K Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 159 MCM, 4/0) ] ([AWG]) Estimated power loss 1083 1022 1384 1232 1474 at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 0.99 Table 7.10 Line Power Supply 3x380–480 V AC, P37K–P90K MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 160: Line Power Supply 3X525-600 V Ac
Maximum cable cross-section for line 6,4,4 (10,12,12) power disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] Efficiency 0.97 0.97 0.97 0.97 Table 7.11 Line Power Supply 3x525–600 V AC, PK75–P2K2 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 161 Maximum cable cross-section 6,4,4 (10,12,12) line power disconnect [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.97 0.97 0.97 0.97 Efficiency Table 7.12 Line Power Supply 3x525–600 V AC, P3K0–P7K5 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 162 [mm (6, 8, 8) (1, 2, 2) ([AWG]) Estimated power loss at rated maximum load [W] 0.98 0.98 0.98 0.98 0.98 0.98 Efficiency Table 7.13 Line Power supply 3x525-600 V AC, P11K-P37K Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 163 [mm ] ([AWG]) 4/0) Estimated power loss 1100 1100 1500 1500 1800 at rated maximum load [W] Efficiency 0.98 0.98 0.98 0.98 Table 7.14 Line Power supply 3x525–600 V AC, P45K–P90K MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 164: Line Power 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, Line Power Supply 3x525–690 V AC IP20/Protected Chassis, P1K1–P7K5 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 165 [mm ] ([AWG]) Estimated power loss at rated maximum load [W] 0.98 0.98 0.98 0.98 0.98 Efficiency Table 7.16 B2/B4 Enclosure, Line Power Supply 3x525–690 V AC IP20/IP21/IP55, Chassis/NEMA 1/NEMA 12, P11K–P22K MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 166 7) Enclosure sizes B3+B4 and C3+C4 can be converted to IP21 using a conversion kit. See also chapter 3.6 Mechanical Planning. 8) Enclosure sizes for N75K, N90K are D3h for IP20/Chassis, and D5h for IP54/Type 12. 9) 2 wires are required. 10) Variant not available in IP21. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 167: Line Power Supply
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 adjustable frequency drive, dependent on power size. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 168: Ambient Conditions
10 mm or 2 rated line power wires terminated separately according to EN 50178. See also chapter 3.2.8 Ground Leakage Current. Use non-shielded cable. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 169: 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. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 170 Resolution of frequency outputs 12 bit 1) Terminal 27 and 29 can also be programmed as input. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 171 System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open-loop) 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. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 172: Fuses And Circuit Breakers
The fuses below are suitable for use on a circuit capable of delivering 100000 A (symmetrical), depending on the adjustable frequency drive voltage rating. With the proper fusing, the adjustable frequency drive short-circuit current rating (SCCR) is 100000 A Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 173 22–30 (30–40) gG-80 (18.5) gG-150 (18.5) NZMB2-A200 aR-125 (22) aR-160 (22) 37–45 (50–60) 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 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 174 NZMB2-A250 aR-250 (75) 45–55 (60–75) gG-100 (37) gG-150 (37) NZMB2-A200 gG-160 (45) gG-160 (45) 75–90 (100–125) aR-200 (55) aR-250 NZMB2-A250 aR-250 (75) Table 7.20 380–480 V, Enclosure Sizes A, B, and C Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 175 75–90 (100–125) aR-200 (75) aR-250 NZMB2-A250 45–55 (60–75) gG-63 (37) gG-150 NZMB2-A200 gG-100 (45) 75–90 (100–125) aR-160 (55) aR-250 NZMB2-A250 aR-200 (75) Table 7.21 52–-600 V, Enclosure Sizes A, B, and C MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 176 45 (60) gG-63 gG-100 55 (75) gG-80 gG-125 75 (100) gG-100 gG-160 37 (50) gG-100 gG-125 45 (60) gG-125 gG-160 Table 7.22 525–690 V, Enclosure Sizes A, B, and C Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 177 FWH fuses from Bussmann may substitute FWX for 240 V adjustable frequency drives. • JJS fuses from Bussmann may substitute JJN for 240 V adjustable frequency drives • KLSR fuses from Littelfuse may substitute KLNR fuses for 240 V adjustable frequency drives. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 178 2) A6KR fuses from Ferraz-Shawmut may substitute A2KR for 240 V adjustable frequency drives. 3) FWH fuses from Bussmann may substitute FWX for 240 V adjustable frequency drives. 4) A50X fuses from Ferraz-Shawmut may substitute A25X for 240 V adjustable frequency drives. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 179 A6K-200-R FWH-200 HSJ-200 A50-P-225 L50-S-225 90 (125) 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. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 180 JJS-100 5014006-100 KLS-R-100 A6K-100-R HST-100 75 (100) KTS-R-125 JKS-125 JJS-125 2028220-125 KLS-150 A6K-125-R HST-125 90 (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. MG20N622...
Page 184: Du/Dt Testing
= 0.244 0.608 1.993 Rise time Data is measured according to IEC 60034-17. 0.568 0.580 0.832 Cable lengths are in meters. 0.720 0.574 0.661 Table 7.36 Adjustable Frequency Drive, P18K, T2 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 185 [m] [μsec] [kV] [kV/μsec] 0.440 1.000 1.818 0.172 0.890 4.156 0.520 0.990 1.510 0.310 2.564 0.370 1.190 1.770 Table 7.48 Adjustable Frequency Drive, P30K, T4 Table 7.42 Adjustable Frequency Drive, P4K0, T4 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 186 Table 7.59 Adjustable frequency drive, P55K, T7 PEAK length [m] [μsec] [kV] [kV/μsec] 0.304 1.560 4.105 0.300 1.550 4.133 0.536 1.640 2.448 0.576 1.640 2.278 Table 7.54 Adjustable frequency drive, P11K, T6 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 187: Acoustic Noise Ratings
Relay module MCB 105 • Enlarged LCP fixture and enlarged terminal cover • Label for covering access to switches S201, S202 and S801 • Cable strips for fastening cables to relay module MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 188 Figure 7.5 Warning Label Placed on Option How to add the Relay card MCB 105 option: Disconnect power to the adjustable frequency Figure 7.7 Correct Wire Inserting drive. Disconnect power to the live part connections on relay terminals. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 189: Vlt ® Ptc Thermistor Card Mcb
[80] PTC Card 1 to use the information from X44/10. Configure 5-19 Terminal 37 Safe Stop to the desired STO functionality (default is safe stop alarm). MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 190 EN 61508 for Tu=75 °C (167 °F) 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. MG20N622...
Page 191: Vlt ® Extended Relay Card Mcb
Mode 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% MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 192: Vlt
Galvanic Isolation The sensors to be connected are expected to be galvanically isolated from the AC line voltage level. IEC 61800-5-1 and UL508C Cabling Maximum signal cable length 500 m (1640 ft) Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 193 5 V 10 mA Connect power to the adjustable frequency drive. Max switching rate at rated load/min load 6 min /20 s Table 7.61 MCO 101 Electrical Data Figure 7.14 Usage of Connections MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 194: Vlt ® Advanced Cascade Controller Mco
(40 mm (1.57 in) for one C Option) Accessory bag MCO 102 Accessory Bag 130B0152 Table 7.63 Ordering Numbers for Mounting Kits and Accessory Live part PELV Figure 7.16 Incorrect and Correct Relay Wiring Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 195 Connect the control cables and relieve the cables by the enclosed cable strips. Fit the extended cradle and terminal cover. Remount the LCP. Connect power to the adjustable frequency drive. Figure 7.18 Enclosures B (except B3) and C MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 196 Figure 7.19 Advanced Cascade Controller MCO 102 Terminal Connections, 8 Relays Figure 7.20 Advanced Cascade Controller MCO 102 Terminal Connections to the Seven Digital Inputs and Access to the Internal 24 V DC Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 197: Appendix - Selected Drawings
S2 variants in enclosure size B2, the extra terminal block must be used for AC line input connection. When disconnector is used (enclosures A4/A5), mount the PE on the left side of the adjustable frequency drive. MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 198 Appendix - Selected Drawing... ® AQUA Drive FC 202 Figure 8.4 AC Line Input Connection Enclosures B1 and B2 Figure 8.6 AC Line Input Connection Enclosure B4 Figure 8.5 AC Line Input Connection Enclosure B3 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 199 Figure 8.8 AC Line Input Connection Enclosures C3 (IP20). Figure 8.7 AC Line Input Connection Enclosures C1 and C2 (IP21/NEMA Type 1 and IP55/66/NEMA Type 12). Figure 8.9 AC Line Input Connection Enclosures C4 (IP20). MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 200: Motor Connection Drawings
Normally, small motors are star-connected (230/400 V, Y). Large motors are normally delta-connected (400/690 V, Δ). Refer to the motor nameplate for correct connection mode and voltage. Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 201 Figure 8.13 Motor Connection for Enclosures B1 and B2 Figure 8.15 Motor Connection for Enclosure B4 Figure 8.14 Motor Connection for Enclosure B3 Figure 8.16 Motor Connection Enclosures C1 and C2 (IP21/ NEMA Type 1 and IP55/66/NEMA Type 12) MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 202: Relay Terminal Drawings
(Enclosure Sizes C1 and C2). 8.3 Relay Terminal Drawings Figure 8.18 Terminals for Relay Connection (Enclosure Sizes A1, A2 and A3). Figure 8.20 Terminals for Relay Connection (Enclosure Sizes A5, B1 and B2). Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 203: Cable Entry Holes
UL [in] [mm] recommended metric 1 Line power 28.4 2 Motor 28.4 3 Brake/load 28.4 sharing 4 Control cable 22.5 5 Removed 1) Tolerance ±0.2 mm Figure 8.23 Enclosure Size A4, IP55 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 204 1) Tolerance ±0.2 mm sharing 2) Knockout hole 4 Control cable 34.7 5 Control cable 22.5 Figure 8.25 Enclosure Size A5, IP55 1) Tolerance ±0.2 mm Figure 8.27 Enclosure Size B1, IP21 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 205 1) Tolerance ±0.2 mm Figure 8.29 Enclosure Size B1, IP55 Threaded Connector Holes 2) Knockout hole 3) Line power for S2 variants with Line Power Disconnect. Figure 8.31 Enclosure Size B2, IP55 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 206 5 Control cable 22.5 6 Control cable 22.5 6 Control cable 22.5 1) Tolerance ±0.2 mm 1) Tolerance ±0.2 mm Figure 8.33 Enclosure Size B3, IP21 Figure 8.35 Enclosure Size C2, IP21 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 207: Index
Coating..................40, 68, 121 Auto on....................22, 23 Coil register..................... 89 Automatic energy optimization.......... 9, 28, 29 Comparator................32, 33, 100 see also AEO Automatic motor adaptation..........9, 29, 107 see also AMA Autoramping..................40 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 208 Motor efficiency................63 Overcurrent..................31 Efficiency......... 16, 28, 29, 63, 72, 108, 164, 166 Rated current................48, 106 Rated output current................ 9 Electronic thermal relay..............61 Ripple current................34, 74 see also ETR Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 209 Harmonic filter............75, 141, 142, 143 Inverter section..................20 LC..................58, 59, 60, 182 Radio frequency interference............42 IP rating definition................42 see also RFI IP21/NEMA Type 1 enclosure kit............. 75 Sine-wave..............20, 58, 74, 106 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 210 Network configuration..............88 MCB 114.................... 190 Overview..................... 87 MCO 101................... 191 Protocol....................87 MCO 102................... 192 RS485 interface................. 88 Sensor input..................190 Modulation..........9, 28, 41, 116, 117, 118, 120 Moment of inertia................26 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 211 PELV....9, 29, 43, 114, 115, 167, 168, 169, 170, 186, 192 Phase imbalance................27, 34 PID controller............22, 25, 31, 107, 190 Pilz......................69 Pipe fill mode............. 15, 100, 101, 107 PKE field....................85 Point of common coupling............... 51 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 212 Thermistor..............10, 43, 61, 70, 187 protection................... 26 ratio....................... 52 Thrust bearing................106, 107 Side-by-side installation..............67 Slave adjustable frequency drive............ 73 Sleep mode......... 15, 29, 31, 100, 101, 108, 109 Slip compensation................ 10, 26 Danfoss A/S © 09/2014 All rights reserved. MG20N622...
Page 213 Ventilation.................... 141 Vertical clearance.................. 67 Vertical load..................126 Vibration....................40 Voltage level..................168 VVC+..................... 9, 20 Wall mounting..................67 Weight................38, 98, 147, 179 Windmilling.................... 14 Wiring................41, 42, 50, 60, 98 MG20N622 Danfoss A/S © 09/2014 All rights reserved.
Page 214 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. 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 Type Code and Selection

7 Specifications

8 Appendix - Selected Drawings

Index

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