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

Danfoss VLT AQUA Drive FC 202 Design Manual

355–800 kw, enclosure size e
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Download this manual See also: Programming Manual, Design Manual
ENGINEERING TOMORROW
Design Guide
VLT® AQUA Drive FC 202
355–800 kW, Enclosure Size E
vlt-drives.danfoss.com

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

  • Page 1 ENGINEERING TOMORROW Design Guide VLT® AQUA Drive FC 202 355–800 kW, Enclosure Size E vlt-drives.danfoss.com...

  • Page 3: Table Of Contents

    5.11 Load Share Overview 5.12 Regen Overview 5.13 Back-channel Cooling Overview 6 Options and Accessories Overview 6.1 Fieldbus Devices 6.2 Functional Extensions 6.3 Motion Control and Relay Cards 6.4 Brake Resistors 6.5 Sine-wave Filters MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 4 10.5 Fuses and Circuit Breakers 10.6 Motor 10.7 Braking 10.8 Residual Current Devices (RCD) and Insulation Resistance Monitor (IRM) 10.9 Leakage Current 10.10 IT Mains 10.11 Efficiency 10.12 Acoustic Noise 10.13 dU/dt Conditions Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 5 13 How to Order a Drive 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 MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 6: Introduction

    Safe Torque Off Operating Guide • An asterisk (*) indicates a default setting of a describes how to use Danfoss drives in functional parameter. safety applications. This manual is supplied with the drive when the safe torque off option is present.

  • Page 7: Safety

    BGV A2, VBG 4. • Only qualified personnel must install, start up, and maintain the drive. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 8 • Check which relay options are installed, if any. ® The only allowed relay option is VLT Extended Relay Card MCB 113. 1, 2 Relay plugs Illustration 2.1 Location of Relay Plugs Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 9: 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 10 1 of more marine certification societies in order guide, the equipment meets the UL standards for electrical ® to receive a regulatory license and insurance. Danfoss VLT and thermal safety. This mark certifies that the product AQUA Drive series drives are certified by up to 12 different performs to all required engineering specifications and marine classification societies.

  • Page 11: 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 MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 12 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 Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 13: Product Overview

    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. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 14: Overview Of Enclosures, 525-690

    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 © 05/2017 All rights reserved. MG22B102...

  • Page 15: Product Features

    The default setting is down time is too short for the energy to be 1000 ms, but it can be adjusted for faster detection. dissipated as a loss throughout the drive system. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 16 As a response to a critical level, the drive adjusts the Danfoss does not recommend using this feature for 525– switching frequency. For high internal temperatures and 690 V drives connected to an IT mains network.

  • Page 17: Custom Application Features

    EMC product standard for drives IEC performance. 61800-3 and the European standard EN 55011. Motor cables must be shielded and properly terminated to comply with the emission levels in EN 55011. For more MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 18 The ETR feature calculates the motor temperature based on actual current and speed. The calculated temperature is visible as a readout parameter in parameter 16-18 Motor Thermal. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 19 Product Features Design Guide When matching drive and motor, Danfoss specifies the • Sine-wave filter is required when following extra requirements to ensure adequate motor Long cables (voltage peaks) or increased thermal protection: mains voltage produce voltages • Do not exceed the maximum allowed ratio exceeding the maximum allowable between drive size and motor size.
  • Page 20 13-52.2 becomes TRUE. The condition leads to an associated action Stop as shown in Illustration 5.3. event P13-02 Illustration 5.4 Order of Execution when 4 Events/Actions are Programmed Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 21: Specific Vlt ® Aqua Drive Features

    Having a good knowledge of the generic and • Sleep mode safety standards for the specific application. The sleep mode feature saves energy by stopping the pump when there is no demand. • Pipe fill mode MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 22: Cascade Control Overview

    The cascade controller option enables control of multiple • pumps configured in parallel by: Deragging. • • Automatically turning individual pumps on/off. Dry-run detection. • • Controlling the speed of the pumps. End of curve detection. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 23 Cascade Controller MCO 102 VSP = Variable-speed pump (directly connected to the drive). FSP = Fixed-speed pump (the motor could be connected via Illustration 5.7 Application Overview contactor, soft starter, or star/delta starter). MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 24: Basic Cascade Controller Overview

    (adding another Time pump). Illustration 5.11 Lead Pump Alternation After a time delay, the relay for the fixed-speed pump cuts in (staged) and this pump becomes the new lead pump. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 25: Deragging Overview

    • A digital output can be configured to reflect the active deragging status. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 26: Pre/Post Lube Overview

    See the related parameters in Table 5.1. parameter 29-40 Pre/ Post Lube Function. Table 5.1 Pre/Post Lube Parameters Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 27: Flow Confirmation Overview

    Digital signal from an external device becomes active before parameter 29-50 Validation Time expires. When parameter 29-51 Verification Time passes, the drive checks the signal from the external device again and then runs normally. Illustration 5.14 Flow Confirmation MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 28: Dynamic Braking Overview

    For a diagram of a load share application in which best resistor across the DC bus to remove excess DC voltage practices are applied, see Illustration 5.16. present on the bus capacitors. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 29: Regen Overview

    Returning excess energy back to the power grid is the most efficient use of regenerated energy in applications using continuous braking. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 30: Back-Channel Cooling Overview

    225 mm (8.9 in) Illustration 5.17 Standard Airflow Configuration for E1h/E2h (Left) and E3h/E4h (Right) 225 mm (8.9 in) Illustration 5.18 Optional Airflow Configuration Through the Back Wall for E1h/E2h (Left) and E3h/E4h (Right) Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 31: Options And Accessories Overview

    Built-in, high-performance switch enabling line- file. topology, which eliminates the need for external • Acyclic parameterization using PROFIBUS DP-V1, switches. PROFdrive, or Danfoss FC profile state machines. • DLR Ring (from October 2015). • Advanced switch and diagnosis functions. 6.1.2 VLT ®...

  • Page 32: Motion Control And Relay Cards

    VLT AQUA Drive series. • For ordering numbers, refer to chapter 13.2 Ordering Protects the motor from overheating. Numbers for Options and Accessories. • ATEX-approved for use with Ex-d motors. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 33: Brake Resistors

    The resistor is selected based on its ohmic value, its power and ground. dissipation rate, and its physical size. Danfoss offers a wide variety of different resistors that are specially designed to Installed around the 3 motor phases (U, V, W), the Danfoss drives.

  • Page 34: Specifications

    Fan power card overtemperature trip [°C (°F)] 85 (185) 85 (185) 85 (185) Active in-rush card overtemperature trip 85 (185) 85 (185) 85 (185) [°C (°F)] Table 7.1 Technical Specifications, Mains Supply 3x380–480 V AC Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 35 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 www.danfoss.com/vltenergyefficiency. 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 36: Electrical Data, 525-690

    85 (185) Fan power card overtemperature trip [°C (°F)] 85 (185) 85 (185) Active in-rush card overtemperature trip [°C (°F)] 85 (185) 85 (185) Table 7.3 Technical Specifications, Mains Supply 3x525–690 V AC Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 37 85 (185) Fan power card overtemperature trip [°C (°F)] 85 (185) 85 (185) 85 (185) 85 (185) Active in-rush card overtemperature trip [°C (°F)] Table 7.4 Technical Specifications, Mains Supply 3x525–690 V AC MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 38 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 www.danfoss.com/vltenergyefficiency. 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 39: Mains Supply

    Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft) 1) For more information on derating, see chapter 9.6 Derating. EMC standards, Emission EN 61800-3 MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 40: Cable Specifications

    10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 41 Resolution of frequency outputs 12 bit 1) Terminals 27 and 29 can also be programmed as inputs. The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 42 1:100 of synchronous speed 30–4000 RPM: Maximum error of ±8 RPM Speed accuracy (open loop) All control characteristics are based on a 4-pole asynchronous motor. Control card performance Scan interval 5 ms Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 43 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from ground. Use only isolated laptop/PC as connection to the USB connector on the drive or an isolated USB cable/converter. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 44: Exterior And Terminal Dimensions

    8.1 E1h Exterior and Terminal Dimensions 8.1.1 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) Illustration 8.1 Front View of E1h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 45 Exterior and Terminal Dimen... Design Guide 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 Illustration 8.2 Side View of E1h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 46 168 (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) Illustration 8.3 Back View of E1h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 47 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 Illustration 8.4 Door Clearance and Gland Plate Dimensions for E1h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 48 8.1.2 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 Illustration 8.5 E1h Terminal Dimensions (Front View) Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 49 Exterior and Terminal Dimen... Design Guide 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.6 E1h Terminal Dimensions (Side Views) MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 50: E2H Exterior And Terminal Dimensions

    VLT® AQUA Drive FC 202 8.2 E2h Exterior and Terminal Dimensions 8.2.1 E2h Exterior Dimensions 13 (0.5) (3.8) 2043 2002 (80.4) (78.8) 1553 (61.1) 1393 (54.9) (35.9) (15.5) (27.5) Illustration 8.7 Front View of E2h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 51 Exterior and Terminal Dimen... Design Guide 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 Illustration 8.8 Side View of E2h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 52 168 (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) 69 (2.7) 560 (22.0) Heat sink access panel (optional) Illustration 8.9 Back View of E2h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 53 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 Illustration 8.10 Door Clearance and Gland Plate Dimensions for E2h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 54 8.2.2 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 Illustration 8.11 E2h Terminal Dimensions (Front View) Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 55 Exterior and Terminal Dimen... Design Guide 649 (25.5) 649 (25.5) 0 (0.0) 0 (0.0) 14 (0.5) 44 (1.8) 0 (0.0) 36 (1.4) Illustration 8.12 E2h Terminal Dimensions (Side Views) MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 56: E3H Exterior And Terminal Dimensions

    8.3 E3h Exterior and Terminal Dimensions 8.3.1 E3h Exterior Dimensions 13 (0.5) 1578 1537 (62.1) (60.5) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) (1.2) 10 (0.4) (19.9) Illustration 8.13 Front View of E3h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 57 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) Illustration 8.14 Side View of E3h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 58 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) Illustration 8.15 Back View of E3h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 59 (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 Illustration 8.16 RFI Shield Termination and Gland Plate Dimensions for E3h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 60 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 Illustration 8.17 E3h Terminal Dimensions (Front View) Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 61 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) Illustration 8.18 E3h Mains, Motor, and Ground Terminal Dimensions (Side Views) MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 62 Exterior and Terminal Dimen... VLT® AQUA Drive FC 202 2X 125 (4.9) 0 (0.0) 20 (0.8) 0 (0.0) 14 (0.5) 35(1.4) Illustration 8.19 E3h Load Share/Regen Terminal Dimensions Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 63: E4H Exterior And Terminal Dimensions

    8.4 E4h Exterior and Terminal Dimensions 8.4.1 E4h Exterior Dimensions 13 (0.5) 1578 1537 (62.1) (60.5) 1348 (53.1) 13 (0.5) 15 (0.6) 10 (0.4) (1.2) 10 (0.4) (23.8) Illustration 8.20 Front View of E4h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 64 Exterior and Terminal Dimen... VLT® 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) Illustration 8.21 Side View of E4h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 65 744 (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) Illustration 8.22 Back View of E4h MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 66 (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 Illustration 8.23 RFI Shield Termination and Gland Plate Dimensions for E4h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 67 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 Illustration 8.24 E4h Terminal Dimensions (Front View) MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 68 Exterior and Terminal Dimen... VLT® 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) Illustration 8.25 E4h Mains, Motor, and Ground Terminal Dimensions (Side Views) Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 69 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) Illustration 8.26 E4h Load Share/Regen Terminal Dimensions MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 70: Mechanical Installation Considerations

    Periodic maintenance When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling Illustration 9.1 Recommended Lifting Method capacity of the components, and the components become Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 71: Mounting Configurations

    Ensure cable entry from the bottom. • PTC temperature sensor to monitor the motor 1) For non-typical installation, contact the factory. temperature. • Short motor cables. • Sine-wave output filters when shielded motor cables are not used. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 72: Cooling

    Cables with a large cross-section. elevation 1000 m (3300 ft) above sea level. See chapter 9.6 Derating for detailed information on If these conditions are present, Danfoss recommends derating. stepping up 1 power size. The drive utilizes a back-channel cooling concept that 9.6.1 Derating for Low-Speed Operation...
  • Page 73 K), 91% of the rated output current is available. 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 9.3 to Table 9.4 to determine if the output current must be derated based on switching frequency...
  • Page 74 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 9.4 Derating Tables for Drives Rated 525–690 V Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 75: Electrical Installation Considerations

    NEC. Failure to set parameter 1-90 Motor RCD cannot provide the intended protection. Thermal Protection to [ETR trip] or [ETR warning] means that motor overload protection is not provided and, if the motor overheats, property damage can occur. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 76: E1H-E4H Wiring Diagram

    37 (D IN) Illustration 10.1 E1h–E4h Wiring Diagram A=Analog, D=Digital 1) Terminal 37 (optional) is used for Safe Torque Off. For Safe Torque Off installation instructions, refer to the Safe Torque Off Operating Guide. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 77: Connections

    Terminal Function Make the shield connections with the largest possible 88, 89 DC Bus surface area (cable clamp) by using the installation devices within the drive. Table 10.2 DC Bus Terminals MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 78: Control Wiring And Terminals

    Illustration 10.4. Remember to connect the shields in a proper way to ensure optimum electrical immunity. The load sharing feature requires extra equipment and safety considerations. Consult Danfoss for ordering and • Isolate control wiring from high-power cables. installation recommendations.
  • Page 79 [10] Illustration 10.6 Terminal Numbers Located on the Connectors Terminal 19 Reversing Digital Input Parameter 5-14 [0] No Terminal 32 operation Digital Input Parameter 5-15 [0] No Terminal 33 operation Digital Input MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 80 Analog Input 1 Switches A53 and A54 select mA or V. Parameter Feedback group 6-2* Analog Input 2 – – Common for analog input. Table 10.7 Analog Input/Output Terminal Descriptions Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 81: Fuses And Circuit Breakers

    All types of 3-phase asynchronous standard motors can be used with a drive unit. The motor must be connected to the following terminals: • U/T1/96 • V/T2/97 • W/T3/98 • Ground to terminal 99 MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 82 Principle must be set to [0] U/f. parameter 4-10 Motor Speed Direction. Motor rotation check can be performed using parameter 1-28 Motor Rotation Check and following the configuration shown in Illustration 10.8. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 83 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. Illustration 10.9 Different Parallel Connections of Motors MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 84: Braking

    Use a dU/dt or sine-wave filter. cations, use the motor insulation ratings shown in 10.7 Braking Table 10.10. If a motor has lower insulation rating, Danfoss recommends using a dU/dt or sine-wave filter. 10.7.1 Brake Resistor Selection Nominal mains voltage...
  • Page 85 Table 10.12 Braking Capability, 525–690 V 107780 200V :  R   =     Ω motor Danfoss offers brake resistors with duty cycle of 5%, 10%, 464923 500V :  R =     Ω and 40%. If a 10% duty cycle is applied, the brake resistors...

  • Page 86: Residual Current Devices (Rcd) And Insulation Resistance Monitor (Irm)

    If the brake IGBT is overloaded or overheated, the relay/digital signal from the brake to the drive turns off the brake IGBT. This relay/digital signal does not protect against a short circuit in the brake IGBT. Danfoss recommends a means to disconnect the brake if a short circuit occurs in the brake IGBT.

  • Page 87: Leakage Current

    Illustration 10.11 Motor Cable Length and pPower Size dimensioning rules. Influence the Leakage Current. Power Size a > Power Size b. See EN/IEC61800-5-1 and EN 50178 for further information. The leakage current also depends on the line distortion. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 88: It Mains

    25 m switching frequency. Whether the switching frequency is (82 ft), Danfoss recommends setting parameter 14-50 RFI detected depends on the type of RCD used. Filter to [ON]. Refer also to the Application Note, VLT on IT Mains.

  • Page 89: Acoustic Noise

    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. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 90 5 (16) 0.27 1042 3132 30 (98) – – – 150 (492) 0.52 1233 1897 Table 10.19 IEC dU/dt Test Results for E1h–E4h with Shielded Cables and No Output Filter, 380–480 V Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 91: Electromagnetic Compatibility (Emc) Overview

    5 MHz. Most of the leakage current (I1) is carried back to the unit through the PE (I3), leaving only a small electromagnetic field (I4) from the shielded motor cable. The shield reduces the radiated interference but increases the low-frequency interference on the mains. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 92 This type of power drive system is not intended to be used on a low-voltage public network that supplies domestic premises. Radio frequency interference is expected if used on such a network, and supplementary mitigation measures may be required. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 93 EN/IEC 61000-6-3 Emission standard for residential, commercial, Class B (home and office) and light industrial environments. Second environment EN/IEC 61000-6-4 Emission standard for industrial environments. Class A Group 1 (industrial environment) Table 10.24 Generic Emission Standard Limits MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 94 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 95 These requirements are described in the EN 61800–5–1 standard. Electrical isolation is provided as shown (see Illustration 10.17). The components described comply with both PELV and the galvanic isolation requirements. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 96: Emc-Compliant Installation

    Failure to isolate power, motor, and control cables can result in unintended behavior or reduced performance. Minimum 200 mm (7.9 in) clearance between mains input, motor, and control cables are required. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 97 Mains supply Brake resistor Bare (unpainted) surface Metal box Star washers Connection to motor Brake cable (shielded) Motor Motor cable (shielded) EMC cable gland Illustration 10.18 Example of Proper EMC Installation MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 98: Harmonics Overview

    PCC, the configuration of the distribution system and by the mains impedance for the frequency in question. The relevant impedances must be known. total voltage distortion (THDi) is calculated based on the individual voltage harmonics using this formula: Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 99 Typically, a class cannot be defined ahead of time without considering the intended equipment and processes to be used in ® the environment. VLT high-power drives observe the limits of Class 3 under typical supply system conditions (R >10 or <10%). Line MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 100 • 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 101: 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 102 If Y, parameter 3-14 Preset Relative Reference, is set to 0%, through the serial communications bus. the scaling does not affect the reference. External references can also be supplied to the drive, most commonly through an analog control input. All reference Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 103 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 Illustration 11.3 Remote Handling of Reference MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 104 P 20-04 Average (1+2+3) P 20-03 Minimum (1|2|3) Maximum (1|2|3) Feedback conv. Feedback 3 Feedback 3 Source P 20-07 P 20-06 Feedback Function P 20-20 Illustration 11.4 Block Diagram of Feedback Signal Processing Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 105 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. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 106 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. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 107 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. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 108 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. Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 109 Select [3] Process in parameter 1-00 Configuration Mode to use the process PID control for closed-loop control of that is, speed or pressure in the controlled application. The process PID parameters are found in parameter groups 7-2* Process Ctrl. Feedb and 7-3* Process PID Ctrl. MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 110 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. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 111: Application Examples

    D IN Notes/comments: Set D IN parameter group 1-2* Motor Data according to motor +10 V nameplate. A IN A IN A OUT Table 12.2 Wiring Configuration for AMA without T27 Connected MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 112: Wiring Configurations For Analog Speed Reference

    A OUT 4 - 20mA Ref./Feedb. Value Parameter 6-15 T 1500 RPM U - I erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 12.4 Wiring Configuration for Analog Speed Reference (Current) Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 113 Notes/comments: Table 12.6 Wiring Configuration for Pulse Start/Stop Speed Table 12.7 Wiring Configuration for Start/Stop with Reversing and 4 Preset Speeds Latched Start (18) Stop Inverse (27) Illustration 12.2 Latched Start/Stop Inverse MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 114: Wiring Configuration For An External Alarm Reset

    53 Low Ref./Feedb. Value Parameter 6-15 T 1500 RPM U - I erminal 53 High Ref./Feedb. Value *=Default value Notes/comments: Table 12.9 Wiring Configuration for Speed Reference (Using a Manual Potentiometer) Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 115: Wiring Configuration For Rs485 Network Connection

    D IN Notes/comments: D IN Select protocol, address, and D IN baud rate in the parameters. +10 V A IN A IN A OUT RS-485 Table 12.11 Wiring Configuration for RS485 Network Connection MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 116: Wiring Configuration For A Motor Thermistor

    5 s, the drive continues and the warning disappears. Reset relay 1 by pressing [Reset] on the LCP. Table 12.13 Wiring Configuration for a Relay Set-up with Smart Logic Control Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 117: Wiring Configuration For A Submersible Pump

    Pipe-fill mode can be enabled to prevent water which is normally 30 Hz. hammering. The Danfoss drive can fill the vertical pipes • The motor reactance is nonlinear in submersible using the PID controller to ramp up the pressure slowly pump motors and, therefore, automatic motor with a user-specified rate (units/second).
  • Page 118 Table 12.15 Example of Settings for Submersible Pump Application Parameter Setting Parameter 29-00 Pipe Fill Enable Disabled Parameter 29-04 Pipe Fill Rate (Feedback units) Parameter 29-05 Filled Setpoint (Feedback units) Table 12.16 Example of Settings for Pipe-Fill Mode Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 119: 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 Illustration 12.6 Cascade Controller Wiring Diagram MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 120: Wiring Configuration For A Fixed Variable Speed Pump

    At alternation, both relays de-energize and now relay 2 is energized as the 1 relay. For a detailed description of commissioning for mixed ® pump and master/slave applications, refer to VLT Cascade Controller Options MCO 101/102 Operating Instructions. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 121: How To Order A Drive

    C1 options To order drives with a different language package, contact the local Danfoss sales office. C option software 36–37 D options 38–39 Table 13.2 Type Code Example for Ordering a Drive MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 122 Hardware, adaptation B X: No option Q: Heat sink access Software release 24–28 SXXX: Latest release - standard software Software language X: Standard language pack Table 13.3 Ordering Type Code for Enclosures E1h–E4h Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 123 C option software/E1 options 36–37 XX: No software option D options 38–39 DX: No option ® D0: VLT 24 V DC Supply MCB 107 Table 13.4 Type Code Ordering Options for Enclosures E1h–E4h MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 124: Ordering Numbers For Options And Accessories

    Panel mounting kit including numerical LCP, fasteners and gasket. 130B1114 LCP kit, IP21 Panel mounting kit for all LCPs including fasteners, 3 m (9 feet) cable 130B1117 and gasket. Options for slot A (Fieldbus Devices) Uncoated Coated Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 125: 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. MG22B102 Danfoss A/S © 05/2017 All rights reserved.

  • Page 126: Appendix

    Rated output current supplied by the drive VLT,N Total harmonic distortion Kilohertz Torque limit Local control panel TTL encoder (5 V) pulses - transistor logic Least significant bit Nominal motor voltage Meter Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 127: Definitions

    This All Danfoss drives have built-in DC coils in the DC link to regenerative brake power increases the DC-link voltage have a high-power factor and reduce the THD on the main and a brake chopper ensures that the power is transmitted supply.
  • Page 128 Appendix VLT® AQUA Drive FC 202 VT characteristics Variable torque characteristics for pumps and fans. Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 129: Index

    Limits....................83 Specifications..................40 Use as an alternative brake function......... 84 Control terminals.................. 77 Break-away torque................125 Conventions....................4 Cooling Dust warning..................68 Overview of back-channel cooling..........28 Requirements..................70 CSA/cUL approval................... 8 MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 130 Formula for drive efficiency............124 Drive efficiency................124 Using AMA..................15 Output current................124 Electrical specifications 380–480 V..........32 Rated power of the brake resistor........... 124 Electrical specifications 525–690 V..........34 Fourier series analysis................. 96 Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 131 Thermal protection..............16, 80 Inverter..................... 99 Thermistor wiring configuration..........114 IP rating...................... 9 Wiring diagram................. 74 IT mains....................86 Mounting configurations..............69 Kinetic back-up..................17 NEMA protection rating................ 9 Kits......................31 Knockout panel..................43 MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 132 Restart....................... 17 PROFIBUS..................29, 123 PROFINET....................29 Filter...................... 93 Location of E3h shield termination........... 57 Programming guide................4 Location of E4h shield termination........... 64 Using switch with IT mains............86 Rise time....................87 Danfoss A/S © 05/2017 All rights reserved. MG22B102...
  • Page 133 Storage..................... 68 Submersible pump Settings..................... 116 Warnings..................... 5, 73 Used with advanced minimum speed monitoring....25 Wiring diagram................115 Wires......................73 see also Cables Switches A53 and A54................38, 78 Disconnect..................79 MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 134 Index VLT® AQUA Drive FC 202 Wiring diagram Cascade controller................. 117 E1h–E4h....................74 Fixed variable speed pump............118 Lead pump alternation..............118 Danfoss A/S © 05/2017 All rights reserved. MG22B102...

  • Page 135: Mg22B102 Danfoss A/S © 05/2017 All Rights Reserved

    Index Design Guide MG22B102 Danfoss A/S © 05/2017 All rights reserved.
  • Page 136 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

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