Danfoss VLT AQUA Drive FC 202 Design Manual

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Programming manual (770 pages)

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ENGINEERING TOMORROW

Design Guide

VLT

AQUA Drive FC 202

110–800 kW, Enclosure Sizes D and E

www.DanfossDrives.com

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

Page 1 ENGINEERING TOMORROW Design Guide ® AQUA Drive FC 202 110–800 kW, Enclosure Sizes D and E www.DanfossDrives.com...
Page 3: Table Of Contents
5.8 Flow Confirmation Overview 5.9 Advanced Minimum Speed Monitoring Overview 5.10 Dynamic Braking Overview 5.11 Load Share Overview 5.12 Regen Overview 5.13 Back-channel Cooling Overview 6 Options and Accessories Overview 6.1 Fieldbus Devices MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 4 8.10 E2h Exterior and Terminal Dimensions 8.11 E3h Exterior and Terminal Dimensions 8.12 E4h Exterior and Terminal Dimensions 9 Mechanical Installation Considerations 9.1 Storage 9.2 Lifting the Unit 9.3 Operating Environment 9.4 Mounting Configurations 9.5 Cooling Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 5 12.10 Wiring Configuration for a Submersible Pump 12.11 Wiring Configuration for a Cascade Controller 12.12 Wiring Configuration for a Fixed Variable Speed Pump 12.13 Wiring Configuration for Lead Pump Alternation 13 How to Order a Drive MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 6 AQUA Drive FC 202 13.1 Drive Configurator 13.2 Ordering Numbers for Options and Accessories 13.3 Ordering Numbers for Filters and Brake Resistors 13.4 Spare Parts 14 Appendix 14.1 Abbreviations and Symbols 14.2 Definitions Index Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 7: Introduction
• ® The VLT FC Series - Safe Torque Off Operating name, parameter option. Guide describes how to use Danfoss drives in • All dimensions in drawings are in mm (in). functional safety applications. This manual is • supplied with the drive when the Safe Torque Off An asterisk (*) indicates a default setting of a option is present.
Page 8: Safety
Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury. • Ensure the correct grounding of the equipment by a certified electrical installer. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 9 • Check which relay options are installed, if any. ® The only allowed relay option is VLT Extended Relay Card MCB 113. 1, 2 Relay plugs Figure 2.1 Location of Relay Plugs MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 10: Approvals And Certifications
This section provides a brief description of the various The aim of the directive is to ensure personal safety and approvals and certifications that are found on Danfoss avoid property damage when operating electrical drives. Not all approvals are found on all drives.
Page 11 An ECCN number is used to classify all drives that are the packaging label. All products used within the EAC area, subject to export control regulations. The ECCN number is must be bought at Danfoss inside the EAC area. provided in the documents accompanying the drive. 3.1.1.6 UKrSEPRO...
Page 12: Enclosure Protection Ratings
The drives meet the requirements of both. NEMA and UL Chassis IP00 Protected chassis IP20 Type 1 IP21 Type 12 IP54 Table 3.2 NEMA and IP Number Cross-reference Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 13 Protected from water at 60° angle. – Protected from splashing water. – Protected from water jets. – Protected from strong water jets. – Protected from temporary immersion. – Protected from permanent immersion. Table 3.3 IP Number Breakdown MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 14: Product Overview
• Lower power consumption for control room cooling equipment. • Reduced ownership costs. • Consistent user interface across the entire range of Danfoss drives. • Application-oriented start-up wizards. • Multi-language user interface. 4.2 Enclosure Size by Power Rating...
Page 15: Overview Of Enclosures, 380-500
2) S = standard, O = optional, and a dash indicates that the option is unavailable. 3) Heat sink access is not available with stainless steel back-channel option. 4) With optional load share and regen terminals. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 16 2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20. 3) S = standard, O = optional, and a dash indicates that the option is unavailable. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 17: Overview Of Enclosures, 525-690
2) S = standard, O = optional, and a dash indicates that the option is unavailable. 3) Heat sink access is not available with stainless steel back-channel option. 4) With optional load share and regen terminals. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 18 2) If the enclosure is configured with load share or regen terminals, then the protection rating is IP00, otherwise the protection rating is IP20. 3) S = standard, O = optional, and a dash indicates that the option is unavailable. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 19: Kit Availability
13.2.6 Ordering Numbers for D1h–D8h Kits and chapter 13.2.7 Ordering Numbers for E1h–E4h Kits. 2) The graphical LCP comes standard with enclosures D1h–D8h and E1h–E4h. If more than 1 graphical LCP is required, the kit is available for purchase. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 20: Product Features
This situation occurs in following cases: Overvoltage control (OVC) By automatically extending the ramp-down time, OVC reduces the risk of the drive tripping due to an overvoltage on the DC-link. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 21 High motor load. drive is allowed, however fault messages can appear. • High DC-link voltage. Danfoss does not recommend using this feature for 525– • Low motor speed. 690 V drives connected to an IT mains network. As a response to a critical level, the drive adjusts the 5.1.6 Overload Protection...
Page 22: Custom Application Features
They require minimum programming or set- up. See the programming guide for instructions on activating these functions. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 23 Ex-d motor. The function ensures that the drive Even at low speeds, the drive meets I2t Class 20 electronic limits motor current to prevent overheating. motor overload standards. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 24 Figure 5.2 Motor Nameplate showing Drive Requirements PTC protection device can be used. • Sine-wave filter is required when When matching drive and motor, Danfoss specifies the Long cables (voltage peaks) or increased following extra requirements to ensure adequate motor mains voltage produce voltages...
Page 25 This drive differs from variable torque drives and constant torque drives. Variable torque drives provide reduced motor torque at low speed. Constant torque drives provide excess voltage, heat, and motor noise at less than full speed. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 26 [0] and starts evaluating the next event. It is possible to program 1–20 events and actions. When the last event/action has been executed, the sequence starts over again from event [0]/action [0]. Figure 5.4 shows an example with 4 event/actions: Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 27: Specific Vlt ® Aqua Drive Fc 202 Features
• Preventive maintenance • Dry-run detection The preventive maintenance feature enables The feature prevents damage of the pump by programming of scheduled service intervals into avoiding dry-running and pump overheat. the drive. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 28: Cascade Control Overview
VLT AQUA Drive FC 202. The following options for cascade control are available: • Built-in BASIC cascade controller (standard cascade controller). • MCO 101 (extended cascade controller). Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 29 ® 6 VSP Extended Cascade parameter group 27-** Cascade CTL Controller MCO 101 Option ® 8 VSP Advanced Cascade parameter group 27-** Cascade CTL Controller MCO 102 Option Figure 5.9 Application Overview MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 30: Basic Cascade Controller Overview
(maximum of 2 pumps). In this operation, the run- time between pumps is equalized, reducing the required pump maintenance and increasing reliability and lifetime Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 32: Pre/Post Lube Overview
Pre-lube also supports applications that require certain exhaust fans to be running. The pre-lube feature signals an external device Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 33: Flow Confirmation Overview
92, No flow. Table 5.2 Flow Confirmation Parameters NOTICE! The parameters are only visible on the LCP when a digital input is configured as flow confirmation. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 34: Advanced Minimum Speed Monitoring Overview
AC brake The brake energy is distributed in the motor by changing the loss conditions in the motor (parameter 2-10 Brake Function = [2]). The AC brake function cannot be used in applications Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 35: Load Share Overview
Load sharing in this manner can reduce the need for external dynamic brake resistors, while also saving energy. The number of units MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 36: Regen Overview
225 mm (8.9 in) 225 mm (8.9 in) 225 mm (8.9 in) 225 mm (8.9 in) 225 mm (8.9 in) Figure 5.17 Standard Airflow Configuration for Enclosures D1h/D2h (Left), D3h/D4h (Center), and D5h–D8h (Right). Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 37 Figure 5.18 Optional Airflow Configuration Using Back-channel Cooling Kits for Enclosures D1h–D8h. (Left) In-bottom/out-back cooling kit for enclosures D1h/D2h. (Center) In-bottom/out-top cooling kit for enclosures D3h/D4h. (Right) In-back/out-back cooling kit for enclosures D5–D8h. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 38 225 mm (8.9 in) Figure 5.19 Standard Airflow Configuration for E1h/E2h (Left) and E3h/E4h (Right) 225 mm (8.9 in) Figure 5.20 Optional Airflow Configuration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 39: Options And Accessories Overview
• Built-in, high-performance switch enabling line- • Acyclic parameterization using PROFIBUS DP-V1, topology, which eliminates the need for external PROFIdrive, or Danfoss FC profile state machines. switches. • DLR Ring (from October 2015). 6.1.2 VLT ® DeviceNet MCA 104 •...
Page 40: Functional Extensions
Advanced Cascade Controller MCO 102 • upgrades the built-in cascade controller to operate up to 8 3 analog outputs, each configurable as 0–10 V pumps and more advanced pump control in master/slave outputs. mode. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 41: Motion Control And Relay Cards
The resistor is selected based on its ohmic value, its power Installed around the 3 motor phases (U, V, W), the dissipation rate, and its physical size. Danfoss offers a wide common mode filters reduce high-frequency common- variety of different resistors that are specially designed to mode currents.
Page 42: Harmonic Filters
Advanced Harmonic Filters AHF 005 & AHF 010 should not be compared with traditional harmonic trap filters. The Danfoss harmonic filters have been specially designed to match the Danfoss drives. By connecting the AHF 005 or AHF 010 in front of a Danfoss drive, the total harmonic current distortion generated back to the mains is reduced to 5% and 10%.
Page 43: Specifications
If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 44 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 45 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 46 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 47: Electrical Data, 525-690
If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 48 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 49 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 50 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 51 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 52 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 53 If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to drives.danfoss.com/knowledge-center/energy- efficiency-directive/#/. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.
Page 54: Mains Supply
-10 °C (14 °F) Minimum ambient temperature at reduced performance -25 to +65/70 °C (13 to 149/158 °F) Temperature during storage/transport Maximum altitude above sea level without derating 1000 m (3281 ft) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 55: Cable Specifications
-10 V to +10 V (scaleable) Input resistance, R Approximately 10 kΩ ±20 V Maximum voltage Current mode Switch A53/A54=(I) Current level 0/4 to 20 mA (scaleable) Approximately 200 Ω Input resistance, R MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 56 Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 57 Control characteristics ±0.003 Hz Resolution of output frequency at 0–1000 Hz ≤2 m/s System response time (terminals 18, 19, 27, 29, 32, 33) Speed control range (open loop) 1:100 of synchronous speed MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 58: Enclosure Weights
1) With optional load share and regen terminals. Enclosure 380–480/500 V 525–690 V 295 (650) 295 (650) 318 (700) 318 (700) 272 (600) 272 (600) 295 (650) 295 (650) Table 7.13 Enclosure E1h–E4h Weights, kg (lb) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 59: Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8 Exterior and Terminal Dimensions 8.1 D1h Exterior and Terminal Dimensions 8.1.1 D1h Exterior Dimensions Figure 8.1 Front View of D1h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 62 AQUA Drive FC 202 298 (11.7) 404 (15.9) Figure 8.4 Door Clearance for D1h 27 (1.0) 137 (5.4) 138 (5.4) 205 (8.1) Mains side Motor side Figure 8.5 Gland Plate Dimensions for D1h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 63 Exterior and Terminal Dimen... Design Guide 8.1.2 D1h Terminal Dimensions 200 (7.9) 94 (3.7) 88 (3.5) Mains terminals Motor terminals Ground terminals – – Figure 8.6 D1h Terminal Dimensions (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 64 ® Exterior and Terminal Dimen... AQUA Drive FC 202 (0.5) (0.5) (1.3) (1.3) Mains terminals Motor terminals Figure 8.7 D1h Terminal Dimensions(Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 65: D2H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.2 D2h Exterior and Terminal Dimensions 8.2.1 D2h Exterior Dimensions 96 (3.8) 211 (8.3) 871 (34.3) 602 (23.7) Figure 8.8 Front View of D2h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 66 ® Exterior and Terminal Dimen... AQUA Drive FC 202 378 (14.9) 142 (5.6) 18 (0.7) 20 (0.8) 148 (5.8) 1050 (41.3) 718 (28.3) Figure 8.9 Side View of D2h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 67 130 (5.1) 11 (0.4) (4.2) 213 (8.4) 1099 (43.3) 320 (12.6) 1051 (41.4) 857 (33.7) 75 (2.9) 11 (0.4) 20 (0.8) 24 (0.9) 9 (0.3) 271 (10.7) Figure 8.10 Back View of D2h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 69 Exterior and Terminal Dimen... Design Guide 369 (14.5) 27 (1.0) 185 (7.3) 145 (5.7) 196 (7.7) Mains side Motor side Figure 8.12 Gland Plate Dimensions for D2h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 70 AQUA Drive FC 202 8.2.2 D2h Terminal Dimensions 331 (13.0) 211 (8.3) 168 (6.6) 168 (6.6) 143 (5.6) 143 (5.6) Mains terminals Motor terminals Ground terminals – – Figure 8.13 D2h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 71 Exterior and Terminal Dimen... Design Guide 15 (0.6) 15 (0.6) 19 (0.8) 18 (0.7) 35 (1.4) 38 (1.5) Mains terminals Motor terminals Figure 8.14 D2h Terminal Dimensions (Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 72: D3H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... AQUA Drive FC 202 8.3 D3h Exterior and Terminal Dimensions 8.3.1 D3h Exterior Dimensions 61 (2.4) 128 (5.0) 660 (26.0) 495 (19.5) Figure 8.15 Front View of D3h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 74 25 (1.0) 909 (35.8) 11 (0.4) 78 (3.1) 200 (7.9) 889 (35.0) 844 (33.2) 656 (25.8) 25 (1.0) 11 (0.4) 20 (0.8) 200 (7.9) (0.9) 9 (0.3) Figure 8.17 Back View of D3h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 75 Exterior and Terminal Dimen... Design Guide 8.3.2 D3h Terminal Dimensions 292 (11.5) 188 (7.4) 83 (3.3) Mains terminals Motor terminals Brake terminals Ground terminals Figure 8.18 D3h Terminal Dimensions (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 76 13 (0.5) 13 (0.5) 32 (1.3) 32 (1.3) 1 and 6 Bottom brake/regen terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Figure 8.19 D3h Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 77: D4H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.4 D4h Exterior and Terminal Dimensions 8.4.1 D4h Enclosure Dimensions 59 (2.3) 176 (6.9) 868 (34.2) 611 (24.1) Figure 8.20 Front View of D4h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 78 ® Exterior and Terminal Dimen... AQUA Drive FC 202 39 (1.5) 375 (14.8) 18 (0.7) 142 (5.6) 20 (0.8) 148 (5.8) 1050 (41.3) Figure 8.21 Side Dimensions for D4h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 79 25 (1.0) (4.2) 1122 (44.2) 213 (8.4) 320 (12.6) 1096 (43.1) 1051 (41.4) 857 (33.7) (1.6) 11 (0.4) 24 (0.9) 20 (0.8) 9 (0.3) 271 (10.7) Figure 8.22 Back Dimensions for D4h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 80 Exterior and Terminal Dimen... AQUA Drive FC 202 8.4.2 D4h Terminal Dimensions 376 (14.8) 319 (12.6) 200 (7.9) Mains terminals Motor terminals Brake terminals Ground terminals Figure 8.23 D4h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 81 15 (0.6) 19 (0.8) 18 (0.7) 38 (1.5) 35 (1.4) 1 and 6 Brake/regeneration terminals 3 and 5 Mains terminals 2 and 7 Motor terminals Ground terminals Figure 8.24 D4h Terminal Dimensions(Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 82: D5H Exterior And Terminal Dimensions
® Exterior and Terminal Dimen... AQUA Drive FC 202 8.5 D5h Exterior and Terminal Dimensions 8.5.1 D5h Exterior Dimensions 149 (5.9) 1107 (43.6) 733 (28.9) Figure 8.25 Front View of D5h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 84 (3.1) 11 (0.4) (7.9) 1324 (52.1) 1276 (50.2) 1111 (43.7) (4.8) 130 (5.1) (2.5) 11 (0.4) (3.1 220 (8.7) (7.9) 24 (0.9) (0.3) (0.8) 200 (7.9) Figure 8.27 Back View of D5h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 86 AQUA Drive FC 202 298 (11.7) 404 (15.9) Figure 8.29 Door Clearance for D5h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Figure 8.30 Gland Plate Dimensions for D5h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 87 8.5.2 D5h Terminal Dimensions 227 (9.0) 221 (8.7) 196 (7.7) 148 (5.8) 118 (4.6) 90 (3.6) Mains terminals Brake terminals Ground terminals Motor terminals Figure 8.31 D5h Terminal Dimensions with Disconnect Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 88 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Figure 8.32 D5h Terminal Dimensions with Disconnect Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 89 Exterior and Terminal Dimen... Design Guide 727 (28.6) 623 (24.5) 517 (20.4) 511 (20.1) Mains terminals Motor terminals Brake terminals Ground terminals Figure 8.33 D5h Terminal Dimensions with Brake Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 90 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Figure 8.34 D5h Terminal Dimensionswith Brake Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 91: D6H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.6 D6h Exterior and Terminal Dimensions 8.6.1 D6h Exterior Dimensions 159 (6.3) 1447 (57.0) 909 (35.8) Figure 8.35 Front View of D6h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 93 (7.9) 1663 (65.5) 1615 (63.6) 1452 (57.2) (4.8) 130 (5.1) (3.1) (7.9) 11 (0.4) 64 (3.0) 559 (22.0) 24 (0.9) 9 (0.1) 20 (0.8) 200 (7.9) Figure 8.37 Back View of D6h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 95 Design Guide 298 (11.7) 404 (15.9) Figure 8.39 Door Clearance for D6h 242 (9.5) 121 (4.8) 43 (1.7) 224 (8.8) 111 (4.4) Mains side Motor side Figure 8.40 Gland Plate Dimensions for D6h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 96 195 (7.7) 153 (6.0) 123 (4.8) 96 (3.8) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Figure 8.41 D6h Terminal Dimensions with Contactor Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 97 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Figure 8.42 D6h Terminal Dimensions with Contactor Option (Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 98 AQUA Drive FC 202 225 (8.9) Mains terminals Brake terminals Ground terminals Motor terminals TB6 terminal block for contactor – – Figure 8.43 D6h Terminal Dimensions with Contactor and Disconnect Options (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 99 Exterior and Terminal Dimen... Design Guide Brake terminals Motor terminals Mains terminals – – Figure 8.44 D6h Terminal Dimensions with Contactor and Disconnect Options (Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 100 ® Exterior and Terminal Dimen... AQUA Drive FC 202 467 (18.4) Mains terminals Brake terminals Ground terminals Motor terminals Figure 8.45 D6h Terminal Dimensions with Circuit Breaker Option (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 101 Exterior and Terminal Dimen... Design Guide Mains terminals Motor terminals Brake terminals – – Figure 8.46 D6h Terminal Dimensions with Circuit Breaker Option (Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 102: D7H Exterior And Terminal Dimensions
® Exterior and Terminal Dimen... AQUA Drive FC 202 8.7 D7h Exterior and Terminal Dimensions 8.7.1 D7h Exterior Dimensions 209 (8.2) 1754 (69.1) 1282 (50.5) Figure 8.47 Front View of D7h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 104 11 (0.4) 130 (5.1) (1.0) (4.2) (8.4) (12.6) 1953 (76.9) (77.9) 1760 (69.3) 130 (5.1) 385 (15.2) (2.8) (4.2) (8.4) 25 (1.0) (12.6) (9.3) (26.3) 14 (0.6) Figure 8.49 Back View of D7h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 106 ® Exterior and Terminal Dimen... AQUA Drive FC 202 1731 (68.1) 1537 (60.5) (18.4) 11 (0.4) (10.7) 23 (0.9) Figure 8.51 Wall Mount Dimensions for D7h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 108 ® Exterior and Terminal Dimen... AQUA Drive FC 202 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Figure 8.53 Gland Plate Dimensions for D7h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 109 8.7.2 D7h Terminal Dimensions 545 (21.4) 515 (20.3) 412 (16.2) 395 (15.6) 372 (14.7) Mains terminals Motor terminals Brake terminals Ground terminals Figure 8.54 D7h Terminal Dimensions with Disconnect Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 110 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Figure 8.55 D7h Terminal Dimensions with Disconnect Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 111 Exterior and Terminal Dimen... Design Guide 1260 (49.6) 1202 (47.3) 1082 (42.6) 1034 (40.7) 1009 (39.7) Mains terminals Brake terminals Ground terminals Motor terminals Figure 8.56 D7h Terminal Dimensions with Brake Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 112 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Brake terminals Motor terminals Mains terminals – – Figure 8.57 D7h Terminal Dimensions with Brake Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 113: D8H Exterior And Terminal Dimensions
Exterior and Terminal Dimen... Design Guide 8.8 D8h Exterior and Terminal Dimensions 8.8.1 D8h Exterior Dimensions 215 (8.5) 1699 (66.9) (30.2) 1400 (55.1) (4.4) Figure 8.58 Front View of D8h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 114 ® Exterior and Terminal Dimen... AQUA Drive FC 202 406 (16.0) 156 (6.2) 23 (0.9) 25 (1.0) 162 (6.4) 2236 (88.0) Figure 8.59 Side View of D8h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 115 11 (0.4) (8.4) 25 (1.0) (12.6) 2259 (88.9) 130 (5.1) 2284 (89.9) 2065 (81.3) (4.2) (8.4) 385 (15.2) 72 (2.8) (12.6) (38.3) (9.3) (1.0) 14 (0.6) Figure 8.60 Back View of D8h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 118 ® Exterior and Terminal Dimen... AQUA Drive FC 202 337 (13.3) 169 (6.6) 43 (1.7) 222 (8.7) 115 (4.5) Mains side Motor side Figure 8.63 Gland Plate Dimensions for D8h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 119 521 (20.5) 418 (16.5) 401 (15.8) 378 (14.9) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Figure 8.64 D8h Terminal Dimensions with Contactor Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 120 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Figure 8.65 D8h Terminal Dimensions with Contactor Option (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 121 Exterior and Terminal Dimen... Design Guide 567 (22.3) Mains terminals TB6 terminal block for contactor Brake terminals Motor terminals Ground terminals – – Figure 8.66 D8h Terminal Dimensions with Contactor and Disconnect Options (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 122 ® Exterior and Terminal Dimen... AQUA Drive FC 202 Mains terminals Motor terminals Brake terminals – – Figure 8.67 D8h Terminal Dimensions with Contactor and Disconnect Options (Side View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 123 Exterior and Terminal Dimen... Design Guide (23.8) Mains terminals Ground terminals Brake terminals Motor terminals Figure 8.68 D8h Terminal Dimensions with Circuit Breaker Option (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 124 15 (0.6) 32 (1.3) 16 (0.6) (0.8) 14 (0.5) 35 (1.4) 18 (0.7) Mains terminals Motor terminals Brake terminals – – Figure 8.69 D8h Terminal Dimensions with Circuit Breaker Option (Side View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 125: E1H Exterior And Terminal Dimensions
8.9 E1h Exterior and Terminal Dimensions 8.9.1 E1h Exterior Dimensions 22 (0.8) 13 (0.5) 2043 (80.4) 2002 (78.8) 1553 (61.1) 1393 (54.9) (35.9) 393 (15.5) 602 (23.7) Figure 8.70 Front View of E1h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 126 Exterior and Terminal Dimen... AQUA Drive FC 202 2X 101 (4.0) 2X 9 (0.7) 20 (0.8) 125 (4.9) 280 (11.0) 35 (1.4) 190 (7.5) (20.2) (22.3) Knockout panel Figure 8.71 Side View of E1h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 127 168 (6.6) 154 (6.1) 1800 (70.9) 168 (6.6) 1209 (47.6) 601 (23.7) 4X 73 (2.8) 4X 457 (18.0) 69 (2.7) 464 (18.3) Heat sink access panel (optional) Figure 8.72 Back View of E1h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 128 11 (0.4) (16.7) (7.3) 22 (0.8) 17 (0.7) (5.4) 412 (16.2) 560 (22.0) 293 (11.5) 173 (6.8) 560 (22.0) 22 (0.8) Gland plate Figure 8.73 Door Clearance and Gland Plate Dimensions for E1h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 129 8.9.2 E1h Terminal Dimensions 721 (28.4) 613 (24.1) 515 (20.3) 485 (19.1) 200 (7.9) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M10 nut Figure 8.74 E1h Terminal Dimensions (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 130 ® Exterior and Terminal Dimen... AQUA Drive FC 202 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Figure 8.75 E1h Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 131: E2H Exterior And Terminal Dimensions
Design Guide 8.10 E2h Exterior and Terminal Dimensions 8.10.1 E2h Exterior Dimensions 13 (0.5) (3.8) 2043 (80.4) 2002 (78.8) 1553 (61.1) 1393 (54.9) (35.9) (15.5) (27.5) Figure 8.76 Front View of E2h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 132 Exterior and Terminal Dimen... AQUA Drive FC 202 2X 101 (4.0) 2X 9 (0.7) 20 (0.8) 125 (4.9) 280 (11.0) 35 (1.4) (20.2) 190 (7.5) (22.3) Knockout panel Figure 8.77 Side View of E2h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 133 168 (6.6) 154 (6.1) 1800 (70.9) 168 (6.6) 1209 (47.6) 601 (23.7) 4X 121 (4.8) 4X 457 (18.0) 560 (22.0) 69 (2.7) Heat sink access panel (optional) Figure 8.78 Back View of E2h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 134 11 (0.4) (16.7) (7.3) 22 (0.8) 17 (0.7) (5.4) 508 (20.0) 656 (25.8) 293 (11.5) 173 (6.8) 22 (0.8) 656 (25.8) Gland plate Figure 8.79 Door Clearance and Gland Plate Dimensions for E2h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 135 8.10.2 E2h Terminal Dimensions 721 (28.4) 613 (24.1) 515 (20.3) 485 (19.1) 200 (7.9) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M10 nut Figure 8.80 E2h Terminal Dimensions (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 136 ® Exterior and Terminal Dimen... AQUA Drive FC 202 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Figure 8.81 E2h Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 137: E3H Exterior And Terminal Dimensions
8.11 E3h Exterior and Terminal Dimensions 8.11.1 E3h Exterior Dimensions 13 (0.5) 1537 (60.5) 1578 (62.1) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) (1.2) 10 (0.4) (19.9) Figure 8.82 Front View of E3h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 138 ® Exterior and Terminal Dimen... AQUA Drive FC 202 20 (0.8) 2X 101 (4.0) 2X 19 (0.7) 2X 18 (0.7) 2X 21 (0.8) 482 (19.0) Figure 8.83 Side View of E3h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 139 1335 (52.5) 744 (29.3) 168 (6.6) 136 (5.4) 39 (1.5) 215 (8.5) 430 (16.9) 4X 457 (18.0) 22 (0.9) 464 (18.3) Heat sink access panel (optional) Figure 8.84 Back View of E3h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 140 (11.6) 19 (0.7) 2X 219 (8.6) 2X 220 (8.6) (6.3) RFI shield termination (standard with RFI option) Cable/EMC clamp Gland plate Figure 8.85 RFI Shield Termination and Gland Plate Dimensions for E3h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 141 6X 148 (5.8) 90 (3.5) 50 (2.0) 33 (1.3) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M8 and M10 nuts Figure 8.86 E3h Terminal Dimensions (Front View) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 142 Exterior and Terminal Dimen... AQUA Drive FC 202 (7.2) (7.2) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Figure 8.87 E3h Mains, Motor, and Ground Terminal Dimensions (Side Views) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 143 Exterior and Terminal Dimen... Design Guide 2X 125 (4.9) 0 (0.0) 20 (0.8) 0 (0.0) 14 (0.5) 35(1.4) Figure 8.88 E3h Load Share/Regen Terminal Dimensions MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 144: E4H Exterior And Terminal Dimensions
8.12 E4h Exterior and Terminal Dimensions 8.12.1 E4h Exterior Dimensions 13 (0.5) 1578 1537 (62.1) (60.5) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) 10 (0.4) (1.2) (23.8) Figure 8.89 Front View of E4h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 145 Exterior and Terminal Dimen... Design Guide 20 (0.8) 2X 101 (4.0) 2X 19 (0.7) 2X 18 (0.7) 2X 21 (0.8) 482 (19.0) Figure 8.90 Side View of E4h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 146 744 (29.3) 168 (6.6) 136 (5.4) 39 (1.5) 263 (10.4) 4X 74 (2.9) 4X 457 (18.0) 526 (20.7) 22 (0.9) 560 (22.0) Heat sink access panel (optional) Figure 8.91 Back View of E4h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 147 (11.6) 19 (0.7) 2X 268 (10.6) 2X 220 (8.6) (6.3) RFI shield termination (standard with RFI option) Cable/EMC clamp Gland plate Figure 8.92 RFI Shield Termination and Gland Plate Dimensions for E4h MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 148 6X 148 (5.8) 90 (3.5) 50 (2.0) 33 (1.3) 0 (0.0) Mains terminals Motor terminals Brake or regen terminals Ground terminals, M8 and M10 nuts Figure 8.93 E4h Terminal Dimensions (Front View) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 149 Exterior and Terminal Dimen... Design Guide (7.2) (7.2) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Figure 8.94 E4h Mains, Motor, and Ground Terminal Dimensions (Side Views) MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 150 ® Exterior and Terminal Dimen... AQUA Drive FC 202 2X 125 (4.9) 0 (0.0) 20 (0.8) 0 (0.0) 14 (0.5) 35(1.4) Figure 8.95 E4h Load Share/Regen Terminal Dimensions Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 151: Mechanical Installation Considerations
Install an optional space heater when the drive is colder than the ambient air. Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of moisture. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 153: Mounting Configurations
Use of these kits reduce the heat in Table 9.1 Mounting Configurations the panel and smaller door fans can be specified. 1) Can be wall mounted, but Danfoss recommends that the drive is • Back-wall cooling panel mounted inside an enclosure due to its protection rating.
Page 154: Derating
Manual derating provided, a motor designed for low RPM/constant torque applications can be used instead. When the following conditions are present, Danfoss recommends selecting a drive 1 power size higher (for Variable (quadratic) torque applications example P710 instead of P630): Extra cooling or derating of the motor is not required in •...
Page 155 Figure 9.2 shows that at 41.7 °C (107 °F), 100% of the rated output current is available. At 45 °C (113 °F) (T , MAX-3 K), 91% of the rated output current is available. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 156 AQUA Drive FC 202 9.6.3 Derating for Ambient Temperature and Switching Frequency NOTICE! FACTORY DERATING Danfoss drives are already derated for operational temperature (55 °C (131 °F) T and 50 °C (122 °F) T AMB,MAX AMB,AVG Use the graphs in Table 9.4 to Table 9.5 to determine if the output current must be derated based on switching frequency and ambient temperature.
Page 157 40 ˚C (104 ˚F) 50 ˚C (122 ˚F) 45 ˚C (113 ˚F) 55 ˚C (131 ˚F) 50 ˚C (122 ˚F) 55 ˚C (131 ˚F) Table 9.5 Derating Tables for Drives Rated 525–690 V MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 158: Electrical Installation Considerations
Thermal Protection to [ETR trip] or [ETR warning] means that motor overload protection is not provided and, if NOTICE! the motor overheats, property damage can occur. The drive is supplied with Class 20 motor overload protection. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 159: Wiring Schematic
Figure 10.1 Basic Wiring Schematic A=Analog, D=Digital ® 1) Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the VLT FC Series - Safe Torque Off Operating Guide. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 161 When connecting the PC to the drive through a USB cable, 88, 89 Load sharing Danfoss recommends using a USB isolator with galvanic Table 10.3 Load Sharing Terminals isolation to protect the PC USB host controller from ground potential differences. It is also recommended not...
Page 162: Control Wiring And Terminals
See the relevant fieldbus instruction. The Ground cable must be tied down and routed along with other Ground 100 nF control wires inside the unit. See Figure 10.5. Drive Drive Ground Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 163 8-3* FC switch (BUS TER.) is Port Settings provided on the control card for bus Parameter 69 (-) – termination group 8-3* FC resistance. Port Settings Table 10.5 Serial Communication Terminal Descriptions MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 164 Parameter Default Description setting – – Common for analog output. Parameter 6-50 [0] No Programmable analog Terminal 42 operation output. 0–20 mA or Output 4–20 mA at a maximum of 500 Ω. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 165: Fuses And Circuit Breakers
If the drive is supplied with a mains disconnect, the SCCR of the drive is 100000 amps at all voltages (380–690 V). If the drive is supplied with a circuit breaker, the SCCR depends on the voltage. See Table 10.13. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 166 Circuit breaker 100000 Class L fuse, 1200 A 525–690 450–630 (450–650) 40000 Circuit breaker 100000 Class L fuse, 800 A 525–690 710–800 (750–950) 42000 Circuit breaker 100000 Class L fuse, 1200 A Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 167: Motor
When motors are connected in parallel, parameter 1-02 Flux Motor Feedback Source cannot be used, and parameter 1-01 Motor Control Principle must be set to [0] U/f. Figure 10.9 Changing Motor Rotation MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 168 The total motor cable length specified in chapter 7.6 Cable Specifications is valid as long as the parallel cables are kept less than 10 m (32 ft) each. Figure 10.10 Different Parallel Connections of Motors Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 169: Braking
This procedure can be difficult for IT, cations, use the motor insulation ratings shown in TT, TN-CS, or grounded leg systems. Table 10.18. If a motor has lower insulation rating, Danfoss • Use a dU/dt or sine-wave filter.
Page 170 Cycle time (s) [25 °C (77 °F)] Current (%) Braking time (s) Overload braking Cycle time (s) [25 °C (77 °F)] Current (%) Braking time (s) Table 10.22 E1h–E4h Braking Capability, 525–690 V Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 171 Check that the brake resistor can handle a voltage of A relay/digital output can be used to protect the brake 410 V, 820 V, 850 V, 975 V, or 1130 V. Danfoss brake resistor against overloading or overheating by generating a resistors are rated for use on all Danfoss drives.
Page 172: Residual Current Devices (Rcd) And Insulation Resistance Monitor (Irm)
Reinforce grounding with the following protective ground connection requirements: • Ground wire (terminal 95) of at least 10 mm (8 AWG) cross-section. • 2 separate ground wires both complying with the dimensioning rules. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 173: It Mains
If optimum EMC performance is needed, or parallel motors are connected, or the motor cable length is above 25 m (82 ft), Danfoss recommends setting parameter 14-50 RFI 1 to [ON]. Refer also to the Application Note, VLT on IT Mains.
Page 174: Efficiency
A new fan control algorithm for E1h-E4h enlosure sizes helps improve audible noise performance by allowing the operator to select different fan operation modes based on specific conditions. For more information, see parameter 30-50 Heat Sink Fan Mode. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 175: Du/Dt Conditions
1557 1370 200–315 (300–450) 30 (98) 1.10 1116 150 (492) 2.53 1028 300 (984) 1.29 Table 10.26 IEC dU/dt Test Results for D1h–D8h with Unshielded Cables and No Output Filter, 380–480 V MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 176 30 (98) – – – 150 (492) 1.00 2022 1617 300 (984) 1.15 2097 1459 Table 10.30 IEC dU/dt Test Results for D1h–D8h with Shielded Cables and No Output Filter, 525–690 V Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 177 Table 10.34 IEC dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 380–480 V Figure 10.17–Figure 10.20 show the typical rate of rise voltage and peak voltages at the motor terminals for both shielded and unshielded cables in various configurations. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 178 Shielded cable with dU/dt filter Unshielded cable with no filter Figure 10.17 dU/dt at Motor Terminals for Enclosures E1h/E3h, Figure 10.18 Peak Voltages at Motor Terminals for Enclosures 380–480 V E1h/E3h, 380–480 V Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 179 DC-link voltage increases by 20%. This effect is similar to increasing the mains voltage by 20%. Consider this voltage increase when performing motor insulation analysis for braking applications. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 180 Unshielded cable with no filter Unshielded cable with no filter Figure 10.22 Peak Voltages at Motor Terminals for Enclosures Figure 10.24 Peak Voltages at Motor Terminals for Enclosures E2h/E4h, 525–690 V E2h/E4h, 525–690 V Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 181: Electromagnetic Compatibility (Emc) Overview
Common-mode leakage current AC mains supply Shielded motor cable Drive Safety ground (4 conductor in motor cables) Shielded motor cable Unintended common-mode current Motor – – Figure 10.25 Electric Model Showing Possible Leakage Currents MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 182 Supply voltage equal to or above 1000 V. An EMC plan must be made. • Rated current equal to or above 400 A. • Intended for use in complex systems. Table 10.38 Emission Requirements Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 183 The immunity requirements for drives depend on the installation environment. The requirements for the industrial environment are higher than the requirements for the home and office environment. All Danfoss drives comply with the requirements for both the industrial and the home/office environment.
Page 184 The goal is to obtain systems that operate stably without radio frequency interference between components. To achieve a high level of immunity, use drives with high- quality RFI filters. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 185: Emc-Compliant Installation
Ensure good electrical contact from the mounting plate through the mounting screws to the drive chassis. • Use shielded cables for motor output cables. An alternative is unshielded motor cables within metal conduit. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 186 Mains supply Brake resistor Bare (unpainted) surface Metal box Star washers Connection to motor Brake cable (shielded) Motor Motor cable (shielded) EMC cable gland Figure 10.27 Example of Proper EMC Installation Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 187: Harmonics Overview
It is not possible to determine the by the mains impedance for the frequency in question. The voltage distortion in the PCC knowing only the harmonic performance of the load. To predict the distortion in the MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 188 Class 3 relates to compatibility levels greater than the public supply network. This class applies only to IPCs in industrial environments. Use this class where the following equipment is found: Large drives. Welding machines. Large motors starting frequently. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 189 • Total cost of ownership (initial cost, efficiency, and maintenance). 10.16.6 Harmonic Calculation Use the free Danfoss MCT 31 calculation software to determine the degree of voltage pollution on the grid and needed ® precaution. The VLT Harmonic Calculation MCT 31 is available at www.danfoss.com.
Page 190: Basic Operating Principles Of A Drive
11 Basic Operating Principles of a Drive 11.2 Drive Controls This chapter provides an overview of the primary assemblies and circuitry of a Danfoss drive. It describes the The following processes are used to control and regulate internal electrical and signal processing functions. A...
Page 191 External references can also be supplied to the drive, most commonly through an analog control input. All reference sources and the bus reference are added to produce the total external reference. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 192 No function 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 Figure 11.3 Remote Handling of Reference Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 193 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 Figure 11.4 Block Diagram of Feedback Signal Processing MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 194 The function is used in mechanically robust applications, but its accuracy is limited. Open-loop torque function works only in 1 speed direction. The torque is calculated based on current measurement within the drive. See chapter 12 Application Examples. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 195 If the feedback signal exceeds the setpoint reference, the drive ramps down to reduce the pressure. Similarly, if the pipe pressure is lower than the setpoint reference, the drive ramps up to increase the pump pressure. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 196 See Active/Inactive Parameters in Different Drive Control Modes in the programming guide for an overview of which control configuration is available for your application, depending on selection of AC motor or PM non-salient motor. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 197 Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of, for example, speed or pressure in the controlled application. The process PID parameters are in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 198 Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of the controlled application. The process PID parameters are found in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 199 When the drive is at the current limit during motor operation or regenerative operation, it tries to get below the preset torque limits as quickly as possible without losing control of the motor. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 200: Application Examples
Table 12.1 Wiring Configuration for AMA with T27 Connected Parameter 6-15 T 1500 RPM U - I erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 12.3 Wiring Configuration for Analog Speed Reference (Voltage) Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 201: Wiring Configurations For Start/Stop
27 is not needed. A OUT Table 12.5 Wiring Configuration for Start/Stop Command with Latched Start (18) Safe Torque Off Stop Inverse (27) Figure 12.2 Latched Start/Stop Inverse MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 202: Wiring Configuration For An External Alarm Reset
Preset ref. 1 Preset ref. 2 Preset ref. 3 100% *=Default value Notes/comments: Table 12.8 Wiring Configuration for an External Alarm Reset Table 12.7 Wiring Configuration for Start/Stop with Reversing and 4 Preset Speeds Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 203: Wiring Configuration For Speed Reference Using A Manual Potentiometer
Table 12.10 Wiring Configuration for Speed Up/Speed Down Table 12.9 Wiring Configuration for Speed Reference (Using a Manual Potentiometer) Speed Reference Start (18) Freeze ref (27) Speed up (29) Speed down (32) Figure 12.3 Speed Up/Speed Down MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 204: Wiring Configuration For Rs485 Network Connection
Protection to [1] Thermistor +10 V warning. A IN A IN A OUT U - I RS-485 Table 12.12 Wiring Configuration for a Motor Thermistor Table 12.11 Wiring Configuration for RS485 Network Connection Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 205: Wiring Configuration For A Relay Set-Up With Smart Logic Control
It is important that the system is operated with a Event minimum of wear and tear on the pump and Parameter 13-52 [32] Set digital motor. A Danfoss sine-wave filter can lower the SL Controller out A low motor insulation stress and increase lifetime Action...
Page 206 Pipe-fill mode can be enabled to prevent water Parameter 3-41 Ramp 1 Ramp Up (8 s depending on size) hammering. The Danfoss drive can fill the vertical pipes Time using the PID controller to ramp up the pressure slowly Parameter 3-42 Ramp 1 Ramp (8 s depending on size) with a user-specified rate (units/second).
Page 207: Wiring Configuration For A Cascade Controller
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 Figure 12.6 Cascade Controller Wiring Diagram MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 208: Wiring Configuration For A Fixed Variable Speed Pump
12.13 Wiring Configuration for Lead Pump ® pump and master/slave applications, refer to VLT Cascade Alternation Controller Options MCO 101/102 Operating Instructions. L1/L2/L3 L1/L2/L3 L1/L2/L3 Figure 12.8 Lead Pump Alternation Wiring Diagram. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 209: How To Order A Drive
English, German, Slovenian, Bulgarian, Serbian, Romanian, D options 38–39 Hungarian, Czech, and Russian. Language package 4 Table 13.2 Type Code Example for Ordering a Drive English, German, Spanish, English US, Greek, Brazilian Portuguese, Turkish, and Polish. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 210 Adaptation X: No adaptation Q: Heat sink access panel Software release 24-27 Actual software Software language X: Standard language pack Table 13.3 Ordering Type Code for Enclosures D1h–D8h Available for all D-frames. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 211 D: Load share terminals (only enclosures E3h/E4h) Hardware, adaptation A X: No option Hardware, adaptation B X: No option Q: Heat sink access Software release 24–28 SXXX: Latest release - standard software S067: Integrated motion control software MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 212: Ordering Numbers For Options And Accessories
EtherNet/IP MCA 121 ® 130B1196 130B1296 Modbus TCP MCA 122 Table 13.6 Ordering Numbers for A Options For information on fieldbus and application option compatibility with older software versions, contact the Danfoss supplier. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 213 Shield designed to protect drive openings from direct sun, snow, and 176F6302 shield, D1h falling debris. Drives using this shield must be ordered from the factory as NEMA 3R ready, which is found in the type code as E5S enclosure option. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 214 Terminal blocks Screw terminal blocks for replacing spring loaded terminals. 130B1116 (1 pc 10 pin 1 pc 6 pin and 1 pc 3-pin connectors) Back-channel cooling kits Standard Stainless steel Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 215 Terminal blocks Screw terminal blocks for replacing spring loaded terminals. 130B1116 (1 pc 10 pin 1 pc 6 pin and 1 pc 3-pin connectors) Back-channel cooling kits Standard Stainless steel MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 216 LCP kit, IP21 Panel mounting kit for all LCPs including fasteners, 3 m (9 ft) cable 130B1117 and gasket. External options EtherNet/IP Ethernet master. 175N2584 Table 13.12 Kits Available for Enclosures E1h–E4h Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 217: Ordering Numbers For Filters And Brake Resistors
Advanced Harmonic Filters AHF 005/AHF 010 Design Guide. • Output Filters Design Guide. 13.4 Spare Parts ® Consult the VLT Shop or the Drive Configurator (www.danfoss.com/drives) for the spare parts that are available for your application. MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 218: Appendix
Rated inverter output current modulation Current limit Status word Nominal motor current SMPS Switch mode power supply Maximum output current VLT,MAX Total harmonic distortion Rated output current supplied by the drive VLT,N Torque limit Kilohertz Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 219: Definitions
This regenerative brake power increases the DC-link voltage All Danfoss drives have built-in DC coils in the DC link to and a brake chopper ensures that the power is transmitted have a high-power factor and reduce the THD on the main to the brake resistor.
Page 220 Restart is prevented until the trip state is canceled by activating reset. VT characteristics Variable torque characteristics for pumps and fans. Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 221: Index
Control with brake function............169 RS485 specifications............... 54 Dynamic braking................32 Specifications..................56 Limits....................169 Use as an alternative brake function........170 Control terminals................161 Break-away torque................217 Conventions....................5 Cable clamp..................160 MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 222 EAC mark....................9 Efficiency Calculation..................172 Formula for drive efficiency............216 Specifications................41, 45 Using AMA..................21 Electrical specifications 380–480 V..........42 Electrical specifications 525–690 V..........45 Electromagnetic interference............20 Electronic thermal overload............. 21 Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 223 Electrical.................... 156 Sine-wave filter................ 39, 158 Qualified personnel................6 Flow confirmation................31 Requirements.................. 151 Flux Insulation....................167 Control structure in flux sensorless......... 196 Inverter....................188 Control structure in flux with motor feedback....197 MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 224 Contactor................171, 184 Specifications..................54 Switch....................19 Overcurrent protection..............156 Overload Electronic thermal overload............21 Issue with harmonics..............185 Limits....................19 Overtemperature................217 Overvoltage Alternative brake function............170 Braking....................39 Protection................... 18 Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 225 Terminal location................162 Wiring configuration..............199 Wiring schematic................157 Qualified personnel................6 Safety Quick menu.................... 26 Instructions................. 6, 156 Scaled reference................. 189 Sensor input option................38 Radiated emission................180 Serial communication..............161 MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 226 Sine-wave filter................ 39, 158 Enclosure protection rating............10 Use with RCDs................. 171 Listing mark..................9 USB specifications................56 User input..................... 188 Temperature..................150 Voltage imbalance................19 VVC+....................195, 197 Warnings................... 6, 156 Danfoss A/S © 01/2018 All rights reserved. MG22B222...
Page 227 Index Design Guide Wires....................... 156 see also Cables Wiring diagram Cascade controller................. 205 Fixed variable speed pump............206 Lead pump alternation..............206 Wiring schematic Drive....................157 Typical application examples............ 198 MG22B222 Danfoss A/S © 01/2018 All rights reserved.
Page 228 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 Safety

3 Approvals and Certifications

4 Product Overview

5 Product Features

6 Options and Accessories Overview

7 Specifications

8 Exterior and Terminal Dimensions

9 Mechanical Installation Considerations

10 Electrical Installation Considerations

11 Basic Operating Principles of a Drive

12 Application Examples

13 How to Order a Drive

14 Appendix

Index

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