Danfoss VLT AQUA Drive FC 202 Installation Manual
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Danfoss VLT AQUA Drive FC 202 Installation Manual

Danfoss VLT AQUA Drive FC 202 Installation Manual

Low harmonic drive
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ENGINEERING TOMORROW
Installation Manual
®
VLT
AQUA Drive FC 202 Low Harmonic Drive
www.DanfossDrives.com

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

  • Page 1 ENGINEERING TOMORROW Installation Manual ® AQUA Drive FC 202 Low Harmonic Drive www.DanfossDrives.com...

  • Page 5: Table Of Contents

    3.3.3 Cable Entry and Anchoring 3.3.4 Terminal Locations - Frame Size D13 3.3.5 Terminal Locations - Frame Size E9 3.3.6 Terminal Locations for Enclsoure Size F18 3.3.7 Torque 4 Electrical Installation 4.1 Safety Instructions MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 6 4.9.3 Parallel Connection of Motors 4.9.4 Motor Thermal Protection 4.9.5 Voltage/Current Input Selection (Switches) 4.10 Final Set-up and Test 4.11 F-frame Options 5 Commissioning 5.1 Safety Instructions 5.2 Applying Power 5.3 Local Control Panel Operation Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 7 8 Specifications 8.1 Power-Dependent Specifications 8.1.1 Mains Supply 3x380–480 V AC 8.1.2 Derating for Temperature 8.2 Mechanical Dimensions 8.3 General Technical Data - Adjustable Frequency Drive 8.4 Fuses 8.4.1 Non- UL compliance MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 8 8.5 General Torque Tightening Values 9 Appendix A - Parameters 9.1 Description of Parameters 9.2 Frequency Converter Parameter Lists 9.3 Active Filter Parameter Lists 10 Appendix B 10.1 Abbreviations and Conventions Index Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 9: Introduction

    Danfoss website: vlt- drives.danfoss.com/Support/Technical- Documentation/ for downloads or additional information. • ® The VLT Active Filter AAF00x Instruction Manual provides additional information about the filter portion of the low harmonic drive. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 10: Working Principle

    The low harmonic drive meets the highest harmonic standards with a THDi less than 5% at full load for <3% pre-distortion on a 3% unbalanced 3-phase grid. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 11: Exploded View Drawings

    Soft-charge fuses Input terminal mounting plate assembly Soft-charge card Fan fuse DC inductor Capacitor bank cover plate Soft charge module IGBT gate drive card IGBT module Figure 1.2 Frame Size D13 Drive Enclosure MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 12 LC inductor RFI differential mode filter AC capacitors RFI common mode filter Line power bus bars to drive input HI inductor IGBT fuses Power card Figure 1.3 Frame Size D13 Filter Enclosure Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 13 Upper capacitor bank assembly Input terminal mounting plate Soft-charge fuses AC input bus bar DC inductor Soft-charge card Fan transformer Lower capacitor bank assembly IGBT module Figure 1.4 Frame Size E9 Drive Enclosure MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 14 LC inductor Current transformer (CT) HI inductor Line power bus bars to drive output Power card AC capacitors Control card LCP cradle Lower DC capacitor bank Figure 1.5 Frame Size E9 Filter Enclosure Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 15 AC line power/line fuses (if purchased) Line power AC power input terminals Figure 1.6 Frame Size F18 Options Cabinet *The options cabinet is not optional for the LHD. The ancillary equipment is stored in the cabinet. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 16 AC capacitors discharge board RFI common mode filter LC inductor Line power contactor HI inductor Power card Mixing fan Control card IGBT fuses LCP cradle Figure 1.7 Frame Size F18 Filter Cabinet Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 17 Fan door cover (Optional) back AC fuse mounting bracket SMPS fuse (Optional) middle AC fuse mounting bracket Power card (Optional) front AC fuse mounting bracket Panel connectors Figure 1.8 Frame Size F18 Rectifier Cabinet MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 18 DC fuse SMPS fuse and fan fuse Mounting bracket Motor output bus bar (+) DC bus bar Brake output bus bar (-) DC bus bar Figure 1.9 Frame Size F18 Inverter Cabinet Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 19: Enclosure Sizes And Power Ratings

    Table 1.4 Fundamental and Harmonic Currents wiring and transformers and can impact other devices on the same power line. Current Harmonic current 11-49 Input current <0.1 Table 1.5 Harmonic Currents Compared to the RMS Input Current MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 20: Effect Of Harmonics In A Power Distribution System

    Harmonic currents drawn by non-linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system. Higher impedances result in higher levels of voltage distortion. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 21: Iec Harmonic Standards

    IPCs (internal points of coupling) on industrial or other private supply networks. Any equipment designed for operation on a public supply network is allowed in this class. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 22: Ieee Harmonic Standards

    Limit harmonic currents to specified levels, as shown in Table 1.11. IEEE 519 utilises a ratio between the supply short-circuit current and the maximum current consumption at the PCC, averaged over 15 minutes or 30 minutes. In certain instances Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 23 Table 1.11 Permissible Harmonic Currents at the PCC ® The VLT AQUA Drive FC 202 Low Harmonic Drive complies with the following standards: • IEC61000-2-4 • IEC61000-3-4 • IEEE 519 • G5/4 MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 24: Safety

    AC line input power. Qualified personnel only should perform installation, start-up, and maintenance. Failure to have qualified personnel perform installation, start-up, and maintenance could result in death or serious injury. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 25: Mechanical Installation

    • Line power • Adjustable frequency drive • Motor • Ensure the output current rating is equal to or greater than the motor full load current for peak motor performance. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 26: Mounting

    (2+2, 4x170=680) cfm) IP54/NEMA 12 (1+1, 1230+1445=2675) 6 door fans, 3150 m /h (1854 5 heatsink fans, 4485 m /h (2639 (LHD330) cfm) cfm) (6x525=3150) 2+1+2, ((2x765)+(3x985)=4485) Table 3.1 Heatsink Air Flow Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 27 11.4 18.1 30.8 69.5 152.8 210.8 Pressure Change (Pa) Figure 3.4 E-Frame Derating vs. Pressure Change (Large Fan) P355-P450 Drive Air Flow: 850 cfm (1445 m MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 28: Lifting

    See for the weight of the different frame sizes. Maximum diameter for bar is 1 in [2.5 cm]. The angle from the top of the adjustable frequency drive to the lifting cable should be 60° or greater. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 29: Cable Entry And Anchoring

    227.8 246.0 [8.7] 235.0 [9.0] [9.7] [9.3] 240.0 [9.4] 42.3 [1.7] 350.0 397.3 [13.8] [15.6] 8X 25.0 [1.0] 8X 14.0 [0.6] Cable entry locations Figure 3.9 Cable Entry Diagram, Enclsoure Size D1n MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 30 227.8 [8.7] 246.0 235.0 [9.0] [9.7] [9.3] 330.0 40.4 [13.0] [1.6] 390.0 470.4 [15.4] [18.5] 8X 25.0 [1.0] 8X 14.0 [0.6] Cable entry locations Figure 3.10 Cable Entry Diagram, Enclsoure Size D2n Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 31 Mechanical Installation Installation Manual Bottom view, enclosure size E9 Cable entry locations Figure 3.11 Cable Entry Diagram, E9 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 32 Mechanical Installation AQUA Drive FC 202 Low Harmonic Drive Bottom view, F18 Mains cable entry Motor cable entry Option enclosure Inverter enclosure Filter enclosure Rectifier enclosure Figure 3.12 Cable Entry Diagram, F18 Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 33: Terminal Locations - Frame Size D13

    259.7 [10.2] 796.3 [31.3] Figure 3.13 Frame Size D13 Terminal Locations Allow for bend radius of heavy power cables. NOTICE! All D-frames are available with standard input terminals, fuse, or disconnect switch MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 34: Terminal Locations - Frame Size E9

    [8.9] [14.5] 900.0 [35.4] Figure 3.14 Frame Size E9 Terminal Locations Allow for bend radius of heavy power cables. NOTICE! All E-frames are available with standard input terminals, fuse, or disconnect switch Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 35: Terminal Locations For Enclsoure Size F18

    Ground bar Figure 3.15 Input Option Cabinet, Enclosure Size F18 - Fuses Only The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 36 1) Disconnect location and related dimensions vary with kilowatt rating. Figure 3.16 Input Option Cabinet with Circuit Breaker, Enclosure Size F18 The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 37 Left side view Right side view Figure 3.17 Inverter Cabinet, Enclosure Size F18 The gland plate is 42 mm below the 0 level. Shown are the left side view, front, and right. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 38: Torque

    8.5–20.5 Nm Brake (75–181 in-lbs) Line power 19–40 Nm Motor (168–354 in-lbs) 19–40 Nm Load sharing (168–354 in-lbs) 8.5–20.5 Nm Brake (75–181 in-lbs) 8.5–20.5 Nm Regen (75–181 in-lbs) Table 3.2 Torque for terminals Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 39: Electrical Installation

    All wiring must comply with local and national Figure 4.1 Power Cable Connections regulations regarding cross-section and ambient temperature requirements. • Power connection wire recommendation: minimum 167 °F [75 °C] rated copper wire. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 40: Grounding

    DC component, which can charge the filter capacitors and cause a transient ground current. The earth leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 41: Input Options

    1-28 Motor Rotation Check and following the Refer to the application note VLT on IT line power. It is steps shown in the display. important to use isolation monitors that work together with power electronics (IEC 61557-8). MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 42: Brake Cable

    DC bar is limited to 82 ft [25 m]. Although failure due to bearing currents is infrequent, use the following strategies to reduce the likelihood: Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 43: Ac Mains Connection

    Ensure that the power supply can supply the necessary current to the adjustable frequency drive. If the unit is without built-in fuses, ensure that the appropriate fuses have the correct current rating. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 44: Line Power Disconnects

    Merlin Gerin NRJF36200U31AABSCYP Table 4.8 Recommended Circuit Breakers 4.7.6 F-Frame Line Power Contactors Frame size Power & Voltage Type P450–P500 380–500 V Eaton XTCE650N22A P560–P630 380–500 V Eaton XTCEC14P22B Table 4.9 Recommended Contactors Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 45: Control Wiring

    The cable must be placed in the provided path inside the adjustable frequency drive and tied down together with other control wires (see Figure 4.5 and Figure 4.6). Figure 4.5 Control Card Wiring Path for Frame Size D13 Figure 4.6 Control Card Wiring Path for Frame Size E9 MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 46: Access To Control Terminals

    Figure 4.7 Control Card Wiring Path for Frame Size F18 Figure 4.9 Inserting the Cable in the Terminal Block Remove the screwdriver. The cable is now mounted in the terminal. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 47 To remove the cable from the terminal: Insert a screwdriver (max. 0.016x0.1 in [0.4x2.5 mm]) in the square hole. Pull out the cable. Figure 4.11 Control Terminal Locations Figure 4.10 Removing the Screwdriver after Cable Insertion MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 48: Electrical Installation, Control Cables

    These connections are on terminals 20, 55, and 39 for both the filter and adjustable frequency drive sections. If ground loops occur, break the shield or insert a 100 nF capacitor between shield and chassis, if needed. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 49: Safe Torque Off (Sto)

    To comply with EMC emission specifications, shielded/ armored cables are recommended. If using non-shielded/ armored cable, see chapter 4.7.3 Power and Control Wiring for Non-shielded Cables. If using non-shielded control cables, use ferrite cores to improve EMC performance. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 50: Additional Connections

    Cable Shielded twisted pair (STP) 120 Ω Impedance Max. 4000 ft [1200 m] (including drop lines) Cable length Max. 1,650 ft [500 m] station-to-station Table 4.10 Cable Recommendations Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 51: Motor Thermal Protection

    Problems are possible at start and at low RPM values if motor sizes vary widely. The relatively high ohmic resistance in the stator of small motors calls for a higher voltage at start and at low RPM values. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 52: Final Set-Up And Test

    Parameter 1-25 Motor Nominal Speed Press [OK]. The display shows Press Table 4.11 Quick Set-up Parameters [Hand On] to start. Press [Hand On]. A progress bar indicates whether the AMA is in progress. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 53: F-Frame Options

    (50% of main alarm set-point) and a main alarm set-point. Associated with each set-point is an SPDT Table 4.14 Ramp Times alarm relay for external use. Requires an external window- type current transformer (supplied and installed by the customer). MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 54 • Integrated into the frequency converter Safe rate, and its physical size. Danfoss offers a wide variety of Torque Off circuit. different resistors that are specifically designed for Danfoss •...

  • Page 55: Commissioning

    The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly. • Cooling clearance Make sure that the top and bottom clearance is adequate to ensure proper airflow for cooling. • EMC considerations Check for proper installation regarding electromagnetic compatibility. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 56: Applying Power

    Manually reset the frequency converter or active filter after a fault when auto-reset is inactive. Apply power to the unit. Do not start the adjustable frequency drive at this time. For units Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 57: Lcp Layout

    DC bus terminal, or an external 24 V DC supply. The information displayed on the LCP can be customised for user application. Select options in the Quick Menu Q3-13 Display Settings. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 58: Parameter Settings

    Programming data are stored internally in the adjustable The list only shows parameters, which have been frequency drive. changed in the current edit set-up. • Parameters, which have been reset to default values, are not listed. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 59: Restoring Default Settings

    (approximately 5 s or until audible click and fan starts). Factory default parameter settings are restored during start-up. This may take slightly longer than normal. Manual initialisation does not reset the following frequency converter information: MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 60: Commissioning Via [Main Menu]

    Parameter 1-30 Stator Resistance (Rs). Press the navigation keys to select [0] Interna- Parameter 1-31 Rotor Resistance (Rr). tional or [1] North America as appropriate and Parameter 1-33 Stator Leakage Reactance (X1). Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 61: Permanent Magnet Motor Set-Up

    Parameter 1-30 Stator Resistance (Rs) Enter line to common stator winding resistance ). If only line-line data are available, divide the line-line value by 2 to achieve the line to common (starpoint) value. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 62: Automatic Energy Optimization (Aeo)

    Start the motor at nominal speed. If the application does not run well, check the VVC PM settings. Recommen- dations for different applications can be seen in Table 5.7. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 63: Automatic Motor Adaptation (Ama)

    4-12 Motor Speed Low Limit [Hz]. If warnings or alarms occur, see chapter 7.3 Warnings and Alarm Definitions - Adjustable Frequency Drive or chapter 7.4 Warning and Alarm Definitions - Filter (Left LCP). MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 64: Application Examples

    The following examples refer only to the frequency -10 - +10V Notes/comments: converter control card (right LCP), not the filter. D IN 37 is an option. U - I Table 6.1 Analog Speed Reference (Voltage) Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 65 A IN Feedb. Value * = Default Value A OUT Notes/comments: Figure 6.1 Speed Up/Down D IN 37 is an option. U - I Table 6.3 Speed Reference (using a Manual Potentiometer) MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 66 Table 6.6 Pulse Start/Stop Table 6.5 Start/Stop Command with Safe Stop Option Speed Speed Latched Start (18) Start (18) Stop Inverse (27) Figure 6.2 Start/Stop Command with Safe Stop Figure 6.3 Latched Start/Stop Inverse Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 67 Preset ref. 2 Preset ref. 3 100% Table 6.8 External Alarm Reset * = Default Value Notes/comments: D IN 37 is an option. Table 6.7 Start/Stop with Reversing and Four Preset Speeds MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 68 Protection should be set to [1] A IN Thermistor warning. A IN D IN 37 is an option. RS-485 A OUT U - I Table 6.9 RS485 Network Connection Table 6.10 Motor Thermistor Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 69: Diagnostics And Troubleshooting

    Investigate as indicated in the alarm or warning. The following warning/alarm information defines each warning/alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 70 The unit is still adjustable frequency drive continuous current active. rating, the counter increases. When running below the adjustable frequency drive continuous current rating, the counter decreases. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 71 1-96 KTY Thermistor Resource and Perform current sensor test. parameter 1-97 KTY Threshold level match sensor ALARM 15, Hardware mismatch wiring. A fitted option is not operational with the present control board hardware or software. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 72 The fan warning The brake resistor is not connected or not working. can be disabled in parameter 14-53 Fan Monitor ([0] Check parameter 2-15 Brake Check. Disabled). Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 73 Damaged heatsink fan. Check for loose or missing wiring Dirty heatsink. It may be necessary to contact Danfoss service or the For the D, E, and F enclosures, this alarm is based on the supplier. Note the code number for further troubleshooting temperature measured by the heatsink sensor mounted directions.
  • Page 74 24 V and 5 V supplies are monitored. 5123 Option in slot A: Hardware incompatible with When powered with three phase AC line voltage, all three control board hardware supplies are monitored. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 75 WARNING 62, Output frequency at maximum limit The output frequency is higher than the value set in ALARM 50, AMA calibration failed parameter 4-19 Max Output Frequency. Contact the Danfoss supplier or Danfoss Service. ALARM 63, Mechanical brake low ALARM 51, AMA check U and I...
  • Page 76 The control card and power card are incompatible. To WARNING/ALARM 104, Mixing fan fault check compatibility, contact the Danfoss supplier with the The fan is not operating. The fan monitor checks that the type code of the unit from the nameplate and the part fan is spinning at power-up or whenever the mixing fan is numbers of the cards.
  • Page 77 4 = far right inverter module in F14 frame size. 2 = right inverter module in F10 or F11 frame 5 = rectifier module. sizes. 6 = right rectifier module in F14 frame size. MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 78: Warning And Alarm Definitions - Filter (Left Lcp)

    Mains phase loss DC link voltage high DC link voltage low DC overvoltage DC undervoltage Overcurrent Ground fault Hardware mismatch Short-circuit Control word timeout 8-04 Internal fan fault External fan fault 14-53 Heatsink temp Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 79 A trip lock is an action that occurs in conjunction with an alarm, which may cause damage to the adjustable frequency drive or connected parts. A trip lock situation can only be reset by power cycling. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 80 See also parameter 16-90 Alarm Word, parameter 16-92 Warning Word and parameter 16-94 Ext. Status Word. “Reserved” means that the bit is not guaranteed to be any particular value. Reserved bits should not be used for any purpose. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 81 Time. Change parameter 8-04 Control Timeout Function indicate that the temperature sensor is defective, causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is discon- MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 82 Verify that parameter 300-10 Active Filter Nominal of alarm (from left): Voltage and parameter 300-22 CT Nominal Voltage are set 1-4 inverter correctly. If so, contact Danfoss or supplier. 5-8 rectifier ALARM 312, CT Range ALARM 248, Illegal power section configuration Current transformer measurement limitation was detected.

  • Page 83: Troubleshooting

    Check the wiring for shorts or Intermittent display frequency drive terminal blocks. incorrect connections. If the display continues to cut out, follow the procedure for display dark. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 84 Possible overmagnetization Check for incorrect motor settings Check motor settings in parameter in all motor parameters groups 1-2* Motor Data, 1-3* Addl. Motor runs rough Motor Data, and 1-5* Load Indep. Setting. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 85 Change switching pattern and acceptable limit certain frequencies) frequency in parameter group 14-0* Inverter Switching Increase Resonance Dampening in parameter 1-64 Resonance Damping Table 7.5 Troubleshooting MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 86: Specifications

    105 °C 105 °C 105 °C Power card ambient trip 85 °C * High overload = 150% current for 60 s, normal overload = 110% current for 60 s. Table 8.1 D-frame Ratings Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 87 Heat sink overtemperature trip 105 °C Power card ambient trip 85 °C * High overload = 160% current for 60 s, normal overload = 110% current for 60 s. Table 8.2 E-frame Ratings MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 88 Heat sink overtemperature trip 105 °C Power card ambient trip 85 °C * High overload = 160% current for 60 s, normal overload = 110% current for 60 s. Table 8.3 F-frame Ratings Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 89: Derating For Temperature

    Figure 8.4 Derating Enclosure Sizes E and F, P315 to P710 50 C 55 C 380–480 V (T5) Normal Overload 110%, SFAVM Figure 8.2 Derating Enclosure Size D, N160 to N250 380–480 V (T5) Normal Overload 110%, SFAVM MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 90: Mechanical Dimensions

    [75.4] [66.9] [70.1] [61.7] [69.1] 807,3 [31.8] 677,3 [26.7] 411,0 [16.2] 251,0 377,8 301,9 [9.9] 929.2 [11.9] [14.9] [36.6] 369,0 221,0 [14.5] [8.7] 664,4 [26.2] 864,4 [34.0] Figure 8.5 Enclosure Size D1n Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 91 [75.4] [70.1] 1562,4 [5.1] [61.5] [6.3] 470,92 [18.5] 251,89 [9.9] 184,5 117,4 377,8 1024,2 [7.3] [4.6] [14.9] [40.3] [14.5] 534,5 [21] 641,17 [25.2] 747,83 [29.4] 854,5 [33.6] Figure 8.6 Enclosure Size D2n MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 92 [78.8] 160.0 [6.3] 160.0 [6.3] 725.0 [28.5] 248.0 [9.8] 184.5 1200.0 493.5 369.0 [7.3] [19.4] [47.2] [14.5] 553.5 [21.8] 600.0 [23.6] 784.5 [30.9] 969.0 [38.2] 1153.5 [45.4] Figure 8.7 Enclosure Size E9 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 93 Specifications Installation Manual 2278.4 2078.4 2792.0 605.8 [110] [24] Figure 8.8 Enclosure Size F18, Front and Side View MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 94: General Technical Data - Adjustable Frequency Drive

    Input resistance, R approx. 4 kΩ All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 1) Terminals 27 and 29 can also be programmed as output. Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 95 Max. resistor load to common at analog output Accuracy on analog output Max. error: 0.8% of full scale Resolution on analog output 8 bit The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 96 1) IEC 60947 parts 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV). 2) Overvoltage Category II 3) UL applications 300 V AC 2 A Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 97 The adjustable frequency drive is protected against short-circuits on motor terminals U, V, W. • If a line phase is missing, the adjustable frequency drive trips or issues a warning (depending on the load). MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 98 Best performance <4% THiD Depending on filter vs. distortion ratio. Individual harmonic mitigation ability: Current maximum RMS [% of rated RMS current] 10th 11th 13th 14th 16th 17th 19th 20th 22nd 23rd 25th Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 99 Terminal number Max. load 200 mA The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs. MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 100 The active filter monitors the line power current as well as internal currents to ensure that current levels do not reach critical levels. If current exceeds a critical level, the filter trips. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 101: Fuses

    100% of the rated output current is available. Non- UL compliance Altitude Derating Derating of output current versus altitude at T If UL/cUL is not to be complied with, Danfoss recommends AMB, MAX frame sizes D, E and F. using the following fuses, which ensures compliance with EN50178: P160–P250...

  • Page 102: Danfoss A/S © 10/2015 All Rights Reserved

    *170M fuses from Bussmann shown use the -/80 visual indicator; -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for external use **Any minimum 500 V UL listed fuse with associated current rating may be used to meet UL requirements. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 103: Supplementary Fuses - High Power

    Any listed class CC, 6 A Table 8.16 Safety Relay Coil Fuse with PILS Relay Frame size Littelfuse PN Rating D, E, F KLK-15 15 A, 600 V Table 8.17 Electrical Fuses (Power Card) MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 104: General Torque Tightening Values

    IGBTs. See the instructions included with those replacement parts for correct values. Shaft Size Driver Size Torx/Hex [mm] Torque [Nm] Torque [in-lbs] T-20/7 T-25/8 T-30/10 T-40/13 T-50/17 19.2 18/19 Table 8.20 Torque Values Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 105: Appendix A - Parameters

    The main menu includes all available parameters in the frequency converter. All parameters are grouped by name indicating the function of the parameter group. All parameters are listed by name and number in this manual. 9.2 Frequency Converter Parameter Lists MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 106 ® Appendix A - Parameters AQUA Drive FC 202 Low Harmonic Drive Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 107 Appendix A - Parameters Installation Manual MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 108 ® Appendix A - Parameters AQUA Drive FC 202 Low Harmonic Drive Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 109 Appendix A - Parameters Installation Manual MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 110: Active Filter Parameter Lists

    Integer 32 Int32 Unsigned 8 Uint8 Unsigned 16 Uint16 Unsigned 32 Uint32 Visible String VisStr Normalized value 2 bytes Bit sequence of 16 Boolean variables Time difference w/o date TimD Table 9.2 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 111 Access to Main Menu w/o Password [0] Full access 1 set-up TRUE Uint8 0-65 Quick Menu Password 200 N/A 1 set-up TRUE Int16 0-66 Access to Quick Menu w/o Password [0] Full access 1 set-up TRUE Uint8 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 112 5-4* Relays 5-40 Function Relay [0] No operation All set-ups TRUE Uint8 5-41 On Delay, Relay 0.30 s All set-ups TRUE Uint16 5-42 Off Delay, Relay 0.30 s All set-ups TRUE Uint16 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 113 All set-ups TRUE Int32 14-5* Environment 14-50 RFI filter [1] On 1 set-up FALSE Uint8 14-53 Fan Monitor [1] Warning All set-ups TRUE Uint8 14-54 Bus Partner 1 N/A 2 set-ups TRUE Uint16 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 114 Slot B Option SW Version 0 N/A All set-ups FALSE VisStr[20] 15-74 Option in Slot C0 0 N/A All set-ups FALSE VisStr[30] 15-75 Slot C0 Option SW Version 0 N/A All set-ups FALSE VisStr[20] Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 115 All set-ups FALSE Uint32 16-92 Warning Word 0 N/A All set-ups FALSE Uint32 16-93 Warning Word 2 0 N/A All set-ups FALSE Uint32 16-94 Ext. Status Word 0 N/A All set-ups FALSE Uint32 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 116 Uint8 300-51 Sleep Mode Trig Source [0] Line power All set-ups TRUE Uint8 300-52 Sleep Mode Wake-up Trigger ExpressionLimit All set-ups TRUE Uint32 300-53 Sleep Mode Sleep Trigger All set-ups TRUE Uint32 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 117 301-2* Line Power Status 301-20 Line Power Current [A] All set-ups TRUE Int32 301-21 Line Power Frequency 0 Hz All set-ups TRUE Uint8 301-22 Fund. Line Power Current [A] All set-ups TRUE Int32 MG21B322 Danfoss A/S © 10/2015 All rights reserved.

  • Page 118: Abbreviations And Conventions

    Table 10.1 Abbreviations Conventions Numbered lists indicate procedures. Bullet lists indicate other information and description of illustrations. Italicised text indicates: • Cross-reference. • Link. • Footnote. • Parameter name, parameter group name, parameter option. Danfoss A/S © 10/2015 All rights reserved. MG21B322...

  • Page 119: Index

    DC link....................66, 77 Brake cable....................38 Default settings................55, 106 Brake Chopper..................38 Definition....................5 Braking..................... 68 Delta......................48 Branch circuit protection..............97 Derating for altitude................97 Bus termination switch............... 48 Digital In/Out..................108 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 120 Manual motor starter................50 Grounding................36, 37, 51, 52 MCT 10...................... 53 Mechanical brake control..............46 Mechanical dimension............... 86 Hand on....................54 Menu key....................53 Harmonic mitigation performance..........94 Menu structure..................53 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 121 Phase loss....................66 SmartStart....................55 Planning, installation site..............21 Special Functions................109 Point of common coupling............... 16 Speed reference..............47, 59, 60 Power connection................35 Speed reference, analog..............60 Power connections................35 MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 122 Torque for terminals................34 Total harmonic distortion..............15 Transformers................... 15 Trip Trip......................64 Undervoltage..................17 Voltage imbalance................66 Voltage level..................90, 95 VVC+......................58 Wire size....................35 Wiring......................15 Working principle................... 6 Danfoss A/S © 10/2015 All rights reserved. MG21B322...
  • Page 123 Index Installation Manual MG21B322 Danfoss A/S © 10/2015 All rights reserved.
  • Page 124 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.

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