Danfoss VLT AQUA Drive FC 202 Operating Manual
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Danfoss VLT AQUA Drive FC 202 Operating Manual

110-800 kw, enclosures d9h-d10h and e5h-e6h
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Operating Guide
VLT® AQUA Drive FC 202
110-800 kW, Enclosures D9h-D10h and E5h-E6h

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Summary of Contents for Danfoss VLT AQUA Drive FC 202

  • Page 1 Operating Guide VLT® AQUA Drive FC 202 110-800 kW, Enclosures D9h-D10h and E5h-E6h...

  • Page 3: Table Of Contents

    Tools Needed Storage Operating Environment 4.5.1 Operating Environment Overview 4.5.2 Gases within the Operating Environment 4.5.3 Dust within the Operating Environment 4.5.4 Potentially Explosive Atmospheres Installation Requirements Cooling Requirements Airflow Rates Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 3...
  • Page 4 Enabling Motor Operation 5.11 Selecting the Voltage/Current Input Signal 5.12 Setting Up RS485 Serial Communication 5.13 Configuring the Passive Harmonic Filter (PHF) 5.14 Configuring the dU/dt Filter 5.15 Configuring the Sine-wave Filter 4 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 5 Wiring Configuration for a Relay Set-up with Smart Logic Control 8.1.12 Wiring Configuration for a Submersible Pump 8.1.13 Wiring Configuration for a Cascade Controller 8.1.14 Wiring Configuration for a Fixed Variable Speed Pump 8.1.15 Wiring Configuration for Lead Pump Alternation Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 5...
  • Page 6 Filter Specifications 10.7.1 Passive Harmonic Filter Specifications 10.7.2 Line Reactor Specifications 10.7.3 dU/dt Filter Specifications 10.7.4 Sine-wave Filter Specifications 10.8 Fuses and Circuit Breakers 10.8.1 Types of Fuses 10.8.2 Panel Fuses 6 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 7 Input Power Option Losses 11.6.1 Contactor Losses 11.6.2 Fusible Disconnect Losses 11.6.3 Non-fusible Disconnect Losses 11.6.4 MCCB Losses 11.6.5 Passive Harmonic Filter Losses 11.6.6 dU/dt Filter Losses 11.6.7 Sine-wave Filter Losses Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 7...

  • Page 8: Introduction

    Table 1: Manual and Software Version Version Remarks Software version MG80H102 First version 3.31 1.4 Approvals and Certifications The following list is a selection of possible type approvals and certifications for Danfoss drives: 8 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 9: Disposal

    Introduction The specific approvals and certification for the enclosed drive are on the nameplate of the drive. For more information, contact the local Danfoss office or partner. Themal memory retention requirement This enclosed drive complies with UL 508C and UL 61800-5-1 thermal memory retention requirements. The enclosed drive is UL listed per UL508A and CSA 14 standards.

  • Page 10: Safety

    This document gives important information on how to prevent injury and damage to the equipment or your system. Ignoring them can lead to death, serious injury, or severe damage to the equipment. Make sure to fully understand the dangers and safety measures incurred in your application. 10 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 11 Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor start. Check that the drive, motor, and any driven equipment is in operational readiness. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 11...
  • Page 12 An internal failure in the drive can result in serious injury when the drive is not properly closed. Ensure that all safety covers are in place and securely fastened before applying power. 12 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 13: Product Overview

    These optional cabinets are shown with dotted lines, while the drive cabinet is shaded. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 13...
  • Page 14 If more than 1 input power option is ordered, the D10h enclosed drive requires an input power options cabinet. Otherwise the single input power option is placed below the control compartment in the drive cabinet. Illustration 2: Possible Configurations for a D10h Enclosed Drive 14 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 15 1 Input filter cabinet (passive harmonic filter or line reactor) 2 Input power options cabinet 3 Drive cabinet 4 Sine-wave filter cabinet 5 Control compartment 6 dU/dt filter cabinet Illustration 3: Possible Configurations for an E5h or E6h Enclosed Drive Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 15...

  • Page 16: Location Of Options Within An Enclosed Drive

    6 Contactor 7 dU/dt filter 8 Common-mode filter 9 Sine-wave filter 10 Drive module (varies in power rating) Illustration 4: Visual Representation of a D9h Enclosure and the Locations of Available Options 16 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 17 6 Contactor 7 dU/dt filter 8 Common-mode filter 9 Sine-wave filter 10 Drive module (varies in power rating) Illustration 5: Visual Representation of a D10h Enclosure and the Locations of Available Options Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 17...

  • Page 18: Drive Identification

    Enclosure size and specific options are used throughout this guide whenever procedures or components differ based on the drive and its options. Use the following steps to identify the enclosed drive: 18 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 19 4 Low harmonic filter option ® • 102 = VLT HVAC Drive 6 Model/power rating ® • 202 = VLT AQUA Drive 8 Option codes ® • 302 = VLT AutomationDrive Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 19...

  • Page 20: Enclosure Size Identification

    Table 4: Low-harmonic Filter Option Codes Character position Option code Description None Active filter Passive filter, THDi=5%, 50 Hz Passive filter, THDi=8%, 50 Hz Passive filter, THDi=5%, 60 Hz Passive filter, THDi=8%, 60 Hz 20 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 21 AC reactor + contactor AC reactor + non-fusible disconnect + contactor Table 7: Output Filter Option Codes Character position Option code Description None dU/dt Sine-wave Common-mode Common-mode + dU/dt Common-mode + sine-wave Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 21...
  • Page 22 120 V AC external + 24 V DC internal Table 11: Back-channel Cooling Option Codes Character position Option code Description Bottom in, top out Back in, back out Back in, top out Bottom in, back out None 22 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 23 Extended I/O terminals + motor heater control + insulation monitor Cabinet heater + motor heater control Cabinet heater + insulation monitor Cabinet heater + motor heater control + insulation monitor Motor heater control + insulation monitor Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 23...

  • Page 24: Power Ratings And Dimensions For D9H-D10H And E5H-E6H Enclosures

    600 (23.6)/800 (31.5) Depth [mm (in)] 600 (23.6) 600 (23.6) 600 (23.6) 600 (23.6) Weight [kg (lb)] 410 (904) 410 (904)/530 530 (1168) 530 (1168)/955 (1168) (2105) Input power options cabinet D10h 24 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 25: Control Compartment And Local Control Panel

    Terminals for internal connections. • Terminals for control cabling. • Product nameplate. • Buttons and indicator lights (on the exterior door). For wiring and terminal descriptions, see 5.7.2 Control Compartment Interior View. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 25...

  • Page 26: Control Compartment Door

    4 Run indicator light 5 Insulation fault indicator light 6 USB slot 7 0–1 Start switch 8 Reset button 9 Nameplate Illustration 8: Exterior Door of Control Compartment (Shown with All Options) 26 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 27: Local Control Panel (Lcp)

    Parameter 0-24 Display Line 3 Large Feedback [Unit] B. Menu keys Menu keys are used to access the menu for setting up parameters, toggling through status display modes during normal operation, and viewing fault log data. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 27...
  • Page 28 Starts the drive in local control. An external stop signal by control input or serial communication overrides the local [Hand On]. Stops the motor but does not remove power to the drive. Reset Resets the drive manually after a fault has been cleared. 28 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 29: Lcp Menu

    Mechanical brake. • Conveyor. • Pump/fan. The [Info] key can be used to see help information for various selections, settings, and messages. Q5 Changes Made Select Q5 Changes Made for information about: Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 29...
  • Page 30 List the parameter groups available to the drive and drive options. • Change parameter values. 0.0% 0.00 A 1(1) Main Menu O-** Operation / Display 1-** Load and Motor 2-** Brakes 3-** Reference / Ramps Illustration 11: Main Menu View 30 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 31: Mechanical Installation

    All necessary fasteners needed for reassembly are provided in the delivery. To reassemble a split shipment, refer to 4.10 Combining Multiple Cabinets from a Split Shipment 5.6.1 Connecting Wiring Harnesses. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 31...

  • Page 32: Tools Needed

    The drive can operate at temperatures down to -10 °C (14 °F). However, proper operation at rated load is only guaranteed at 0 °C (32 °F) or higher. Provide extra air conditioning for the cabinet or installation site when the temperature exceeds ambient temperature limits. 32 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 33: Gases Within The Operating Environment

    Motors with class e protection ® When combined with an ATEX-approved PTC monitoring device like the VLT PTC Thermistor Card MCB 112, installation does not need an individual approval from an approbated organization. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 33...

  • Page 34: Installation Requirements

    The heat sink cooling air carries approximately 90% of the heat out of the back channel of the drive. A back-channel cooling option allows the cooling air to be brought into and vented out of the room where the drive is installed. 34 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 35: Airflow Rates

    – – Input options – – 510 (310) Drive 1053–1206 (620–710) 629 (370) 430 (255) dU/dt 665 (392) – – Sine-wave 2x900 (530) – – Top entry/top exit – – – Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 35...

  • Page 36: Lifting The Drive

    Test lift the drive approximately 610 mm (24 in) to verify the proper center of gravity lift point. Reposition the lifting point if the unit is not level. Never walk under suspended loads. >60 >60 Illustration 13: Recommended Lifting Method 36 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 37: Combining Multiple Cabinets From A Split Shipment

    D Secure the lifting eyelets to the top of the cabinets. See illustration Join the grounding bars using the connector piece (see the shaded piece in illustration 16). Example: 1 Front brackets 2 Back brackets Illustration 14: Bracket Mounting Points for Cabinets Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 37...
  • Page 38 Operating Guide | VLT® AQUA Drive FC 202 Mechanical Installation Illustration 15: Connecting the Lifting Eyelet Between Cabinets Illustration 16: Connecting the Grounding Bar Between Cabinets 38 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 39: Installing The Enclosed Drive

    4. Terminate the shields properly. - Use the metallic glands to terminate the output cable shields. - Use the flex sheets to firmly terminate the shields. For certain configurations, Danfoss supplies the flex sheets. Example: Illustration 17: Installing Motor and Mains Cables Through an IP54 (IEC version) Cable Entry Plate Danfoss A/S ©...

  • Page 40: Installing The Drive With Back-Channel Cooling Option

    To use the mounting bracket, first attach it to the floor by sliding the edge of the cabinet pedestal under the mounting bracket. Then secure the 2 mounting holes to the front base of the pedestal. 40 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 41 B The 2 mounting points at the front base of the pedestal C The 2 mounting points at the upper back of the cabinet D The 2 mounting points in the mounting bracket Illustration 19: Cabinet Mounting Points Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 41...

  • Page 42: Electrical Installation

    Enable the ETR function by setting parameter 1-90 Motor Thermal Protection to [ETR trip] or [ETR warning]. 5.2 EMC-compliant Installation To obtain an EMC-compliant installation, be sure to follow all electrical installation instructions. 42 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 43 There is a risk for overvoltage. Isolation between components and critical parts could be insufficient, and may not comply with PELV requirements. Use external protective devices or galvanic isolation. For installations above 2000 m (6500 ft) altitude, contact Danfoss regarding protective extra low voltage (PELV) compliance.
  • Page 44 4 Minimum 200 mm (7.9 in) between control cables, motor cables, and mains cables 5 Mains supply 6 Bare (unpainted) surface 7 Star washers 8 Brake cable (shielded) 9 Motor cable (shielded) 10 Mains cable (unshielded) 44 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 45 13 Common ground busbar. Follow local and national 14 Brake resistor requirements for cabinet grounding. 16 Connection to motor 15 Metal box 18 EMC cable gland 17 Motor Illustration 20: Example of Proper EMC Installation Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 45...

  • Page 46: Wiring Schematic For D9H And D10H Enclosed Drives

    1 Terminal 37 (optional) is used for Safe Torque Off. Refer to the VLT ® FC Series - Safe Torque Off Operating Guide for installation instructions. Illustration 21: Basic Wiring Schematic for Enclosures D9h and D10h 46 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 47: Wiring Schematic For E5H And E6H Enclosed Drives

    0 V (PNP) XD2.1 24 V (NPN) XD2.17 (COM RS485) 61 33 (D IN) 0 V (PNP) (PNP) = Source (NPN) = Sink XD2.19 37 (D IN) - option Drive cabinet Control compartment Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 47...

  • Page 48: Wiring Diagram Cross-Reference

    12 13 18 27 29 33 20 37 05 06 1 User-accessible terminals (control compartment) 2 Serial communication terminals (drive module) 3 Analog input/output terminals (drive module) 4 Digital input/output terminals (drive module) 48 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 49: Split Shipment Wiring Harnesses

    (R/S/T) to the corresponding terminals in the input power options cabinet. Then connect the unattached line reactor cable ends (L1R/L2S/L3T) to the R/S/T terminals in the drive cabinet. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 49...

  • Page 50: D10H Wiring Harness

    3 Additional terminal connections 4 Thermal protection wiring harness to output filter cabinet Illustration 24: Split Shipment Electrical Connections (Input Filter Cabinet + Input Power Options Cabinet + D10h Drive Cabinet) 50 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 51 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 25: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 51...
  • Page 52 Operating Guide | VLT® AQUA Drive FC 202 Electrical Installation 1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 26: Split Shipment Electrical Connections (Top Exit Cabinet) 52 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 53 3 DC-link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 27: Split Shipment Electrical Connections (D10h Sine-wave Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 53...

  • Page 54: E5H Wiring Harness

    6 DC-link harness to fan supply in the input power options (R/S/T) in the drives cabinet cabinet 7 Cabinet heater supply harness to input power options 8 Additional terminal connections cabinet Illustration 28: Split Shipment Electrical Connections (Input Filter Cabinet) 54 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 55 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 29: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 55...
  • Page 56 Operating Guide | VLT® AQUA Drive FC 202 Electrical Installation 1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 30: Split Shipment Electrical Connections (Top Exit Cabinet) 56 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 57 3 DC-link harness to fan supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 31: Split Shipment Electrical Connections (E5h/E6h Sine-wave Cabinets) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 57...
  • Page 58 3 Cabinet heater supply harness to output filter cabinet 5 Thermal protection wiring harness to output filter cabinet Illustration 32: Split Shipment Electrical Connections (Input Filter Cabinet + Input Power Options Cabinet + E5h Drive Cabinet) 58 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 59 8 Cabinet heater supply harness to output filter cabinet 9 Available terminal connections 10 Thermal protection wiring harness to output filter cabinet Illustration 33: Split Shipment Electrical Connections (Input Power Options Cabinet + E5h Drive Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 59...

  • Page 60: E6H Wiring Harness

    6 DC-link harness to fan supply in the input power options (R/S/T) in the drives cabinet cabinet 7 Cabinet heater supply harness to input power options 8 Additional terminal connections cabinet Illustration 34: Split Shipment Electrical Connections (Input Filter Cabinet) 60 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 61 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 35: Split Shipment Electrical Connections (dU/dt Cabinet + Top Exit Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 61...
  • Page 62 Operating Guide | VLT® AQUA Drive FC 202 Electrical Installation 1 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 36: Split Shipment Electrical Connections (Top Exit Cabinet) 62 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 63 3 DC-link harness to fan power supply in drive cabinet 4 Cabinet heater supply harness to drive cabinet 5 Motor cables (U/V/W) to motor terminals (U/V/W) in drive cabinet Illustration 37: Split Shipment Electrical Connections (E5h/E6h Sine-wave Cabinets) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 63...
  • Page 64 8 Mains cables (L1R/L2S/L3T) to output terminals (L1R/L2S/L3T) filter cabinet in the input filter cabinet Illustration 38: Split Shipment Electrical Connections (Input Power Options Cabinet + E6h Drive Cabinet + Top Exit Cabinet) 64 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 65 9 Cabinet heater supply harness to output filter cabinet 10 Available terminal connections 11 Thermal protection wiring harness to output filter cabinet Illustration 39: Split Shipment Electrical Connections (Input Power Options Cabinet + E6h Drive Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 65...

  • Page 66: Control Compartment Wiring

    Only qualified personnel must install, start up, and maintain the drive. Disconnect the external voltage supply. 66 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 67: Control Compartment Interior View

    12 Thermal trip indicator relay, input filter cabinet (-KFJ.3) 13 PHF capacitor connect/disconnect contactor relay (-QAF) 14 +24 DC supply protection MCB (-FC7) 15 AC circuit protection MCB (-FC6) 16 AC distribution circuit terminal block (-XD1) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 67...

  • Page 68: Control Terminals

    For digital input or output. Default setting is input. Input Parameter 5-13 Terminal 29 Digital [14] JOG Input – – Common for digital inputs and 0 V potential for 24 V supply. 68 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 69: Relay Terminals

    If the option card is ordered along with the drive using the type code, the factory installs the option card and its wiring. If the option is ordered separately, the customer is responsible for installing the option card and the wiring extensions to the control compartment. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 69...
  • Page 70 Option card terminal Corresponding terminal within the control compartment X46.1 XDF.1 X46.2 XDF.2 X46.3 XDF.3 X46.4 XDF.4 X46.5 XDF.5 X46.6 XDF.6 X46.7 XDF.7 X46.8 XDF.8 X46.9 XDF.9 X46.10 XDF.10 X46.11 XDF.11 70 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 71 X47.6 XDF.26 X47.7 XDF.27 X47.8 XDF.28 X47.9 XDF.29 X47.10 XDF.30 X47.11 XDF.31 X47.12 XDF.32 Table 32: Option D Terminal Connections Option card terminal Corresponding terminal within the control compartment XD2.28 XD2.29 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 71...

  • Page 72: Overview Of Options Wiring

    This configuration allows the control voltage to be disconnected with the main switch. 72 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 73 The 24 V DC external supply option enables other auxiliary options to be connected to a 24 V DC supply within the control compartment. -FC7 -XD1 L1-L2 -TB7 24 V 60 W Illustration 44: 24 V DC External Supply Terminals Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 73...
  • Page 74 450 VA (IEC variant) and 230 VA (UL variant). When using a transformer supply, the maximum output power is 200 VA for both variants. -FCC -XD10 -XD1 -XD1 Illustration 45: AC Customer Socket Terminals 74 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 75 The extended I/O terminal option includes 25 control terminals (-XDW) in the control compartment for use by the customer. If the enclosed drive is configured with any option C1 card, the -XDW terminal block is used for the option C1 card wiring. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 75...
  • Page 76 The function is disabled when MCB –FCE is open. -FCE -QAM -EB1.1 -XD1 -XD4 -XD4 -EB1.2 -EB1.3 -EB1.4 Illustration 46: Cabinet Heater Terminals 76 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 77 -XDN output terminals. When the drive is in run state, the control relay disconnects the external supply to the motor heater. The function is disabled when MCB –FCN is open. -FCE -QAM -EB1.1 -XD1 -XD4 -XD4 -EB1.2 -EB1.3 -EB1.4 Illustration 47: Motor Heater Control (Heater Element not Included) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 77...
  • Page 78 The indicator light and reset button option includes indicator lights on the control compartment door for run and fault states of the AC drive. The door also has a button for the reset function of the drive. 78 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 79: Connecting Motor, Mains, And Ground Cables

    Motor wiring knockouts or access panels are provided on the pedestal of IP21/IP54 (NEMA 1/NEMA 12) units. • Do not wire a starting or pole-changing device (for example Dahlander motor or slip ring induction motor) between the drive and the motor. Ground connection Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 79...
  • Page 80 6 Cable 3 7 Cable 1 lug 8 Bolt holder on the connector 9 Terminal connector 10 Cable 2 lug Illustration 48: Different Ways of Connecting Multiple Cables to 1 Terminal 80 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 81: Connecting To The Mains

    14-50 RFI Filter is set to [0] Off to avoid damage to the DC link and to reduce ground capacity currents. 7. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 81...
  • Page 82 1 Cabinet screen (lower) 2 Terminal cover 3 Brake and load share terminals 4 Mains terminals 5 Ground terminals 6 Grounding bar Illustration 49: Connection Points for Mains to Drive Module 82 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 83 2 Input power terminals (contactor option is shown) 3 DC terminals 4 Grounding bar Illustration 50: Connection Points for Mains to Input Power Option (Enclosed Drive Configured without Power Options Cabinet) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 83...
  • Page 84 3 Cabinet screen (lower) 4 Input power terminals (disconnect option is shown) 5 Grounding bar Illustration 51: Connection Points for Mains to Input Power Option (Enclosed Drive Configured with Power Options Cabinet) 84 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 85: Connecting The Drive Module To The Motor

    5. Connect the 3-phase AC motor cables to terminals U (T1), V (T2), and W (T3). 6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 85...
  • Page 86 1 Cabinet screen (lower) 2 DC terminals 3 Terminal cover 4 Motor terminals 5 Ground terminals on drive module 6 Grounding bar Illustration 52: Connection Points for Drive Module to Motor 86 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 87: Connecting The Sine-Wave Filter To The Motor

    2, 4, 6, or 8). 1 cable is not allowed. The cables are required to be equal length. 6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 87...
  • Page 88 Operating Guide | VLT® AQUA Drive FC 202 Electrical Installation Example: 1 DC bus terminals 2 Motor terminals 3 Grounding bar Illustration 53: Connection Points for the Sine-wave Filter to Motor 88 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 89: Connecting The Du/Dt Filter To The Motor

    5. Connect the 3-phase AC motor wiring to the dU/dt terminals U (T1), V (T2), and W (T3). 6. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 89...
  • Page 90 2 Cabinet screen (lower) 3 Factory-installed power cables from the drive module 4 Factory-installed cables 5 Motor terminals 6 Grounding bar Illustration 54: Connection Points for the dU/dt Filter to Motor 90 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 91: Connecting To Ground

    4. Tighten the terminals in accordance with the specifications shown in 10.11 Fastener Torque Ratings. Example: 1 Symbol indicating grounding terminals 2 Grounding points on drive module 3 Grounding bar (provided in every cabinet) Illustration 55: Connection Grounding Points Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 91...

  • Page 92: Installing Upstream Fuses

    • Danfoss recommends the fuse type gG (IEC 60269-1) for the mains fuses. Use only fuses with a sufficient voltage rating according to the mains voltage. Do not use larger fuses than what is recommended. These fuses are selected for short-circuit protection only.

  • Page 93: Recommended Fuse Ratings For Ul Installation

    35000 1000 Class J N450 Mersen A4BY1000 1000 15000 35000 1000 Class J N500 Mersen A4BY1000 1100 18500 42000 1100 Class J N560 Mersen A4BY1200 1200 19000 42000 1200 Class J Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 93...

  • Page 94: Enabling Motor Operation

    5.11 Selecting the Voltage/Current Input Signal Context: The analog input terminals XD2.7 and XD2.8 in the control compartment allow setting of input signal to voltage (0–10 V) or current (0/4–20 mA). 94 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 95: Setting Up Rs485 Serial Communication

    RS485 is a 2-wire bus interface compatible with multi-drop network topology. This interface contains the following features: • Either Danfoss FC or Modbus RTU communication protocol can be used. • Functions can be programmed remotely using the protocol software and RS485 connection or in parameter group 8-** Communications and Options.

  • Page 96: Configuring The Passive Harmonic Filter (Phf)

    Verify that the value in parameter 5-31 Terminal 29 is set to [188] AHF Capacitor Connect. Procedure 1. Set parameter 5-02 Terminal 29 Mode to [1] Output. 2. Set parameter 5-31 Terminal 29 to [188] AHF Capacitor Connect. 5.14 Configuring the dU/dt Filter Context: 96 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 97: Configuring The Sine-Wave Filter

    Short circuit instant trip setting (I) is targeted at 300% of the 100% normal overload FLA (I ) of the drive. • Neutral setting (N) is 100%. • Frequency of operation is set at 50 Hz from the factory. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 97...

  • Page 98: Safe Torque Off (Sto) Wiring

    The Safe Torque Off (STO) function is a component in a safety control system. STO prevents the unit from generating the voltage ® required to rotate the motor. To run the STO function, more wiring for the drive is required. Refer to the VLT FC Series - Safe Torque Off Operating Guide. 98 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 99: Pre-Start Check List

    Look for any obstructions in the airflow path. • Measure top and bottom clearance of the drive to verify that there is at least 225 mm (9 in) of clearance for adequate airflow. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 99...
  • Page 100 For enclosures with a IP20/Chassis protection rating, ensure that the unit is mounted to an unpainted, metal surface. Vibration • Ensure that the unit is mounted solidly, or that shock mounts are used, if necessary. • Check for an unusual amount of vibration. 100 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 101: Commissioning

    Parameter settings are assigned a default value at the factory, but can be configured for their unique application. Each parameter has a name and number that remain the same regardless of the programming mode. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 101...

  • Page 102: Parameter Navigation

    53. The drive responds by providing 20–50 Hz output to the motor proportional to the input signal (0–10 V DC=20–50 Hz). The wiring connections used to enable the external device set-up are shown in illustration 102 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 103: Entering System Information

    Application settings vary. Although these steps assume that an induction motor is used, a permanent magnet motor can also be used. For more information on specific motor types, see the product-specific programming guide. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 103...

  • Page 104: Configuring Automatic Energy Optimization

    3. Select 1–0* General Settings and press [OK]. 4. Select parameter 1-03 Torque Characteristics and press [OK]. 5. Select either [2] Auto Energy Optim CT or [3] Auto Energy Optim VT and press [OK]. 104 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 105: Configuring Automatic Motor Adaptation

    The motor runs briefly at either 5 Hz or the minimum frequency set in parameter 4-12 Motor Speed Low Limit [Hz]. 4. If the motor rotation is wrong, set parameter 1-06 Clockwise Direction to [1] Inverse. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 105...

  • Page 106: Testing Encoder Rotation

    5. Remove the external run command. 7.5 Parameter Settings 7.5.1 Parameter Setting Overview Parameters are operational settings accessed through the LCP that are used to configure and operate the drive and motor for specific applications. 106 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 107: Uploading And Downloading Parameter Settings

    Restoring default settings results in a loss of programming, motor data, localization, and monitoring records. To create a back-up, upload data to the LCP before initialization. See 7.5.2 Uploading and Downloading Parameter Settings. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 107...

  • Page 108: Restoring Factory Default Settings Using Manual Initialization

    Manually initializing does not reset the following parameter settings: • Parameter 15-00 Operating Hours • Parameter 15-03 Power Up's • Parameter 15-04 Over Temp's • Parameter 15-05 Over Volt's Start-up takes slightly longer than normal. 108 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 109: Wiring Configuration Examples

    XD2.16 Set parameter group 1-2* Motor Data according to motor nameplate. D IN XD2.17 D IN XD2.19 Terminal 27 in the parameter title corresponds to terminal XD2.14 in the control compartment. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 109...

  • Page 110: Wiring Configuration For Automatic Motor Adaptation (Ama) Without T27

    *=Default value A OUT XD2.5 0–10 V XD2.4 Notes/comments: U - I D IN 37 is an option. Terminal 53 in the parameter title corresponds to terminal XD2.7 in the control compartment. 110 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 111 XD2.9 A OUT XD2.5 *=Default value XD2.4 Notes/comments: U - I D IN 37 is an option. Terminal 53 in the parameter title corresponds to terminal XD2.7 in the control compartment. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 111...
  • Page 112 Terminal 32 in the parameter title corresponds to terminal XD2.16 in the control compartment. Speed Reference Start (XD2.12) Freeze ref (XD2.14) Speed up (XD2.15) Speed down (XD2.16) Illustration 60: Speed Up/Down 112 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 113: Wiring Configuration: Feedback

    Terminal 54 in the parameter title corresponds to terminal XD2.8 in the control compartment. +10 V XD2.6 A IN XD2.7 A IN XD2.8 4-20 mA XD2.9 A OUT XD2.5 XD2.4 U - I A 54 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 113...
  • Page 114 Terminal 54 in the parameter title corresponds to terminal XD2.8 in the control compartment. +10 V XD2.6 A IN XD2.7 A IN XD2.8 XD2.9 XD2.5 A OUT 0-10 V XD2.4 U - I 114 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 115: Wiring Configuration: Run/Stop

    Terminal 18 in the parameter title corresponds to terminal XD2.12 in the control compartment. D IN XD2.17 D IN XD2.19 Terminal 27 in the parameter title corresponds to terminal XD2.14 in the control compartment. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 115...
  • Page 116 A IN XD2.7 A IN XD2.8 Terminal 27 in the parameter title corresponds to terminal XD2.14 in the control compartment. XD2.9 A OUT XD2.5 XD2.4 XD2.21 XD2.22 XD2.23 XD2.24 XD2.25 XD2.26 116 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 117: Wiring Configuration: Start/Stop

    Terminal 27 in the parameter title corresponds to terminal XD2.14 in the control compartment. Terminal 37 in the parameter title corresponds to terminal XD2.19 in the control compartment. Speed Start/Stop (XD2.12) Illustration 61: Wiring Configuration for Start/Stop Command with Safe Torque Off Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 117...
  • Page 118 Terminal 18 in the parameter title corresponds to terminal XD2.12 in the control compartment. Terminal 27 in the parameter title corresponds to terminal XD2.14 in the control compartment. Speed Latched Start (XD2.12) Stop Inverse (XD2.14) Illustration 62: Latched Start/Stop Inverse 118 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 119: Wiring Configuration: External Alarm Reset

    D IN 37 is an option. XD2.18 D IN XD2.14 Terminal 19 in the parameter title corresponds to terminal XD2.13 in the control compartment. D IN XD2.15 D IN XD2.16 D IN XD2.17 D IN XD2.19 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 119...

  • Page 120: Wiring Configuration: Rs485

    If only a warning is required, set parameter 1-90 Motor Thermal Protection to [1] Thermistor warn- XD2.4 ing. D IN 37 is an option. U - I Input 53 in the parameter corresponds to terminal XD2.7 in the control compartment. 120 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 121: Wiring For Regeneration

    XD2.13 XD2.18 XD2.14 D IN D IN XD2.15 XD2.16 D IN D IN XD2.17 D IN XD2.19 +10 V XD2.6 A IN XD2.7 A IN XD2.8 XD2.9 A OUT XD2.5 XD2.4 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 121...

  • Page 122: Wiring Configuration For A Relay Set-Up With Smart Logic Control

    8.1.12 Wiring Configuration for a Submersible Pump ® The system consists of a submersible pump controlled by a Danfoss VLT AQUA Drive and a pressure transmitter. The transmitter gives a 4–20 mA feedback signal to the drive, which keeps a constant pressure by controlling the speed of the pump. To design a drive for a submersible pump application, there are a few important issues to consider.
  • Page 123 • It is important that the system is operated with a minimum of wear and tear on the pump and motor. A Danfoss sine-wave filter can lower the motor insulation stress and increase lifetime (check actual motor insulation and the drive dU/dt specification). Most manufacturers of submersible pumps require the use of output filters.
  • Page 124 To set up the feedback settings in the PID controller, use the Closed-loop wizard under Quick Menu, Function Set-up. Table 71: Example of Settings for Pipe-Fill Mode Parameter Setting Parameter 29-00 Pipe Fill Enable Disabled Parameter 29-04 Pipe Fill Rate (Feedback units) Parameter 29-05 Filled Setpoint (Feedback units) 124 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 125: Wiring Configuration For A Cascade Controller

    8.1.13 Wiring Configuration for a Cascade Controller illustration 65 for an example of a built-in basic cascade controller with 1 variable-speed pump (lead) and 2 fixed-speed pumps, a 4–20 mA transmitter, and system safety interlock. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 125...
  • Page 126 XD2. XD2. XD2. XD2. XD2. XD2. XD2. System System start/ safety stop interlock From motor control circuitry Pressure transmitter 4-20 mA, 24 V DC Ground Illustration 65: Cascade Controller Wiring Diagram 126 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 127: Wiring Configuration For A Fixed Variable Speed Pump

    Operating Guide | VLT® AQUA Drive FC 202 Wiring Configuration Examples 8.1.14 Wiring Configuration for a Fixed Variable Speed Pump L1/L2/L3 L1/L2/L3 L1/L2/L3 Drive Illustration 66: Fixed Variable Speed Pump Wiring Diagram Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 127...

  • Page 128: Wiring Configuration For Lead Pump Alternation

    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. 128 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 129: Maintenance, Diagnostics, And Troubleshooting

    Replace worn or damaged parts with Danfoss authorized parts. For service and support, contact the local Danfoss supplier. W A R N I N G...

  • Page 130: Status Messages - Operating Mode

    [1] Ctrl. ramp-down was selected in parameter 14-10 Mains Failure. down • The mains voltage is below the value set in parameter 14-11 Mains Voltage at Mains Fault. • The drive ramps down the motor in a controlled manner. 130 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 131 Wave Filter Fixed. Otherwise, the switching frequency is reduced to 1.0 kHz. • If possible, protection mode ends after approximately 10 s. • Protection mode can be restricted in parameter 14-26 Trip Delay at Inverter Fault. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 131...
  • Page 132 An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, cycle power to the drive. Reset the drive manually by 1 of the following: • Pressing [Reset]. • Remotely by control terminals. • Via serial communication. 132 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 133: Warnings And Alarms

    When a fault is triggered, the LCP indicates the type of fault (alarm, warning, or trip lock) and shows the alarm or warning number in the display. Warn. Alarm Illustration 69: Status Indicator Lights Table 75: Type of fault Warning indicator light Alarm indicator light Warning Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 133...
  • Page 134 Check connections on all analog mains terminals. Control card terminals 53 and 54 for signals, terminal 55 common. • Check that the drive programming and switch settings match the analog signal type. 134 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 135 Activate the functions in parameter 2-10 Brake Function. • Increase parameter 14-26 Trip Delay at Inverter Fault. • If the alarm/warning occurs during a power sag, use kinetic back-up (parameter 14-10 Mains Failure). Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 135...
  • Page 136 If an external fan is in use, check that it is selected in parameter 1-91 Motor External Fan. • Running AMA in parameter 1-29 Automatic Motor Adaptation (AMA) tunes the drive to the motor more accurately and reduces thermal loading. 136 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 137 Ground fault is issued if the deviation of the 2 currents is too large. The current going out of the drive must be the same as the current going into the drive. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 137...
  • Page 138 9.3.16 ALARM 15, Hardware Mismatch Cause A fitted option is not operational with the present control card hardware or software. Troubleshooting Record the value of the following parameters and contact Danfoss. • Parameter 15-40 FC Type. • Parameter 15-41 Power Section.
  • Page 139 For drives with DC fans, a feedback sensor is mounted in the fan. If the fan is commanded to run and there is no feedback from the sensor, this alarm appears. For drives with AC fans, the voltage to the fan is monitored. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 139...
  • Page 140 The brake transistor is monitored during operation, and if a short circuit occurs, the brake function is disabled, and a warning is issued. The drive is still operational, but since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is inactive. 140 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 141 Only qualified personnel must perform installation, start-up, and maintenance. • Disconnect power before proceeding. • Remove the power from the drive and check motor phase U. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 141...
  • Page 142 Remove the power from the drive and check motor phase W. 9.3.32 ALARM 33, Inrush Fault Cause Too many power-ups have occurred within a short time period. Troubleshooting • Let the unit cool to operating temperature. 142 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 143 Check that the option is properly installed. • Check for loose or missing wiring. It may be necessary to contact the Danfoss supplier or service department. Note the code number for further troubleshooting directions. Table 76: Internal Fault Codes Number Text The serial port cannot be initialized.
  • Page 144 Operating Guide | VLT® AQUA Drive FC 202 Troubleshooting Number Text 1024-1284 Internal fault. Contact the Danfoss supplier or Danfoss service department. 1299 The option software in slot A is too old. 1300 The option software in slot B is too old.
  • Page 145 9.3.43 ALARM 45, Earth Fault 2 Cause Ground fault. Troubleshooting • Check for proper grounding and loose connections. • Check for proper wire size. • Check the motor cables for short circuits or leakage currents. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 145...
  • Page 146 The 1.8 V DC supply used on the control card is outside of the allowed limits. The supply is measured on the control card. Troubleshooting • Check for a defective control card. • If an option card is present, check for overvoltage. 146 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 147 9.3.48 ALARM 50, AMA Calibration Failed Troubleshooting • Contact the Danfoss supplier or service department. 9.3.49 ALARM 51, AMA Check Unom and Inom Cause The settings for motor voltage, motor current, and motor power are wrong.
  • Page 148 Open the control compartment and check for any lights in relays KFJ.1, KFJ.2, and KFJ.3. If no lights are present, check for other external interlocks. • Clear the external fault condition. • To resume normal operation, apply 24 V DC to the terminal programmed for external interlock. • Reset the drive. 148 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 149 The cutout temperature of the control card has exceeded the upper limit. Troubleshooting • Check that the ambient operating temperature is within the limits. • Check the fan operation. • Check the control card. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 149...
  • Page 150 Check that the ambient operating temperature is within the limits. • Check for clogged filters. • Check fan operation. • Check the power card. 9.3.68 ALARM 70, Illegal FC Configuration Cause The control card and power card are incompatible. 150 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 151 Operating Guide | VLT® AQUA Drive FC 202 Troubleshooting Troubleshooting • To check compatibility, contact the Danfoss supplier with the type code from the unit nameplate and the part numbers on the cards. 9.3.69 ALARM 71, PTC 1 Safe Stop Cause ®...
  • Page 152 The scaling card has an incorrect part number or is not installed. The MK102 connector on the power card could not be installed. 9.3.78 ALARM 80, Drive Initialized to Default Value Cause Parameter settings are initialized to default settings after a manual reset. To clear the alarm, reset the unit. 152 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 153 A change in the option layout is detected. Parameter 14-89 Option Detection is set to [0] Frozen configuration and the option layout has been changed. Troubleshooting • To apply the change, enable option layout changes in parameter 14-89 Option Detection. • Alternatively, restore the correct option configuration. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 153...
  • Page 154 9.3.91 WARNING 163, ATEX ETR Cur.Lim.Warning Cause The drive has run above the characteristic curve for more than 50 s. The warning is activated at 83% and deactivated at 85% of the allowed thermal overload. 154 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 155 The power card or other components have been replaced, and the typecode has changed. 9.3.97 ALARM 421, Temperature Fault Cause A fault caused by the on-board temperature sensor is detected on the fan power card. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 155...
  • Page 156 The number of found fan power cards do not match the number of configured fan power cards. See parameter group 15-6* Option Ident for the number of configured fan power cards. Troubleshooting • Check fan power card wiring. • Replace fan power card. 156 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 157: Troubleshooting

    Check the wiring for a fault within the AC drive. wiring by removing the terminal shorts or incorrect connections. If the blocks. display continues to cut out, follow the procedure for Display dark\No function. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 157...
  • Page 158 Possible incorrect settings in Check brake parameters. Check Check parameter groups 2-0* DC Brake brake the brake parameters. Ramp- ramp time settings. and 3-0* Reference Limits. down times may be too short. 158 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 159 Warnings and Alarms section. rameter 3-42 Ramp 1 Ramp Down Time. lems Check that motor data are entered Enable overvoltage control in parame- correctly. ter 2-17 Over-voltage Control. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 159...

  • Page 160: Specifications

    Drive module power loss at 400 V [W] 1828 2261 2051 2724 2089 3628 Drive module power loss at 460 V [W] (1) (2) (3) 0.98 0.98 0.98 Drive efficiency 0–590 0–590 0–590 Output frequency [Hz] 160 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 161 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 162 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 163 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 164 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.

  • Page 165: Electrical Data, 525-690 V Ac

    1798 1800 2167 2159 2740 2446 3175 Drive module power loss at 690 V [W] (1) (2) (3) 0.98 0.98 0.98 0.98 Drive efficiency 0–590 0–590 0–590 0–590 Output frequency [Hz] Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 165...
  • Page 166 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 167 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 168 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.
  • Page 169 (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies to dimensioning of drive cooling. 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/#/.

  • Page 170: Mains Supply

    Maximum 110% up to 0.5 s once in 10 minutes Torque rise time in flux (for 5 kHz f 1 ms 10 ms Torque rise time in VVC (independent of f 170 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 171: Ambient Conditions

    For power cables, see 10.1.1 Electrical Data, 380–480 V AC 10.1.2 Electrical Data, 525–690 V 10.6 Control Input/Output and Control Data 10.6.1 Control Card, USB Serial Communication USB standard 1.1 (full speed) Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 171...

  • Page 172: Sto Terminal Xd2.19 (Terminal Xd2.19 Is Fixed Pnp Logic)

    Maximum load 15 mA The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. 10.6.5 Digital Outputs Programmable digital/pulse outputs XD2.14, XD2.15 Terminal number 172 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 173: Digital Inputs

    5 kHz Maximum frequency at terminals XD2.15, XD2.16, XD2.17 4 kHz Voltage level See Control Input/Output and Control Data. Maximum voltage on input 28 V DC Input resistance, R Approximately 4 kΩ Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 173...

  • Page 174: Control Characteristics

    IEC 60947 parts 4 and 5. The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV). Overvoltage category II. UL applications 300 V AC 2 A. 174 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 175: Analog Output

    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 © 2018.10 AQ262141056213en-000101 / 130R0882 | 175...

  • Page 176: Filter Specifications

    The line reactor configuration varies depending on the enclosure and voltage required. Table 86: Line Reactor Configuration for D9h–D10h and E5h–E6h Enclosures, 380–480 V Enclosure Model Line reactor [A] N110 N132 N160 D10h N200 N250 2x312 N315 2x312 176 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 177: Du/Dt Filter Specifications

    Storage temperature [°C (°F)] -25 (-13) to +60 (150) Transport temperature [°C (°F)] -25 (-13) to +70 (158) Maximum ambient temperature with derating [°C (°F)] 55 (131) Maximum altitude without derating [°C (°F)] – Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 177...

  • Page 178: Sine-Wave Filter Specifications

    10.7.4 Sine-wave Filter Specifications Voltage rating 3x380–480 V and 525–690 V AC Nominal current @ 50 Hz 212 A and 315 A for 380–480 V, 137 A and 222 A for 525–690 V 178 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 179: Fuses And Circuit Breakers

    1 normally closed). They are located on the sides of the contactor. By default, the NO auxiliary contact is wired at the factory and used by the system. Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 179...

  • Page 180: Panel Fuses

    Mersen P/N NH3GG69V500 NH3GG69V500 NH4GG69V630 NH4GG69V800 NH4GG69V800 UL (Class J/L/T) 600 A/600 V 600 A/600 V 650 A/600 V 750 A/600 V 800 A/600 V Mersen P/N A4J600 A4J600 A4BY650 A4BY750 A4BY800 180 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 181: Fusible Disconnect Switches

    OS600J30 Table 98: Fusible Disconnect Switches for N400–N630 Models, 525–690 V N400 N450 N500 N560 N630 630 A/690 V 630 A/690 V 1250 A/690 V 1250 A/690 V 1250 A/690 V Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 181...

  • Page 182: Non-Fusible Disconnect Switches

    OT400E30 OT400E30 OT630E30 OT630E30 OT630E30 400 A/690 V 400 A/690 V 400 A/690 V 600 A/690 V 600 A/690 V 600 A/690 V ABB P/N OT400U30 OT400U30 OT400U30 OT600U30 OT600U30 OT600U30 182 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 183: Contactor Fuses

    XTCE400M22A XTCE400M22A XTCE400M22A XTCE400M22A XTCE500M22A 185 A/1000 V 185 A/1000 V 185 A/1000 V 400 A/1000 V 400 A/1000 V 580 A/1000 V Eaton P/N XTCE400M22A XTCE400M22A XTCE400M22A XTCE400M22A XTCE580N22A XTCE580N22A Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 183...

  • Page 184: Molded-Case Circuit Breakers

    800 A/600 V 800 A/600 V ABB P/N T5L400T T5L400T T5L400T T6L800T T6L800T T6L800T 400 A/690 V 400 A/690 V 400 A/690 V 600 A/690 V 600 A/690 V 800 A/690 V 184 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 185: Enclosure Dimensions

    T7L1250LSPR23 1 DS-LS 1200 A/600 V 1200 A/600 V ABB P/N T7L1200PR231/ P T7L1200PR231/ P 10.9 Enclosure Dimensions 10.9.1 Pedestal Dimensions The pedestal on which the enclosure sits is available in 3 sizes: Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 185...

  • Page 186: D9H Enclosed Drive Dimension

    400 (15.8) 400 (15.8) 600 (23.6) 1 Passive harmonic filter/line reactor cabinet 2 D9h drive cabinet 3 Sine-wave cabinet 4 Standard pedestal Illustration 72: Dimensions for D9h Enclosure with Standard Pedestal 186 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 187: D10H Enclosed Drive Dimensions

    2 Options cabinet (provided when more than 1 input option is ordered) 3 D10h drive cabinet 4 Sine-wave cabinet 5 Standard pedestal Illustration 73: Dimensions for D10h Enclosure with Standard Pedestal Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 187...

  • Page 188: E5H Enclosed Drive Dimensions

    1 Passive harmonic filter/line reactor cabinet 2 Options cabinet 3 E5h drive cabinet 4 Sine-wave cabinet 5 dU/dt cabinet 6 Standard pedestal Illustration 74: Dimensions for E5h Enclosure with Standard Pedestal 188 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 189: E6H Enclosed Drive Dimensions

    1 Passive harmonic filter/line reactor cabinet 2 Options cabinet 3 E6h drive cabinet 4 Sine-wave cabinet 5 dU/dt cabinet 6 Standard pedestal Illustration 75: Dimensions for E6h Enclosure with Standard Pedestal Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 189...

  • Page 190: Enclosure Airflow

    Load sharing terminals M10/M12 19 (168)/37 (335) Relay terminals 0.5 (4) Door/panel cover 2.3 (20) Cable entry plate 2.3 (20) Heat sink access panel 2.3 (20) Serial communication cover 2.3 (20) 190 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 191: Appendix

    Central processing unit CSIV Customer-specific initialization values Current transformer Direct current Digital voltmeter EEPROM Electrically erasable programmable read-only memory Electromagnetic compatibility Electromagnetic interference Electrostatic discharge Electronic thermal relay Nominal motor frequency High frequency Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 191...
  • Page 192 Motion control tool MDCIC Multi-drive control interface card Millivolts NEMA National Electrical Manufacturers Association Negative temperature coefficient Nominal motor power Printed circuit board Protective earth PELV Protective extra low voltage Passive harmonic filter 192 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 193: International/North American Default Parameter Settings

    Parameter 0-71 Date Format DD-MM-YYYY MM/DD/YYYY Parameter 0-72 Time Format 24 h 12 h Parameter 1-23 Motor Frequency 50 Hz 60 Hz Parameter 1-25 Motor Nominal Speed 1400 RPM 1680 RPM Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 193...

  • Page 194: Required Parameter Settings For Drive Options

    Table 121: Parameter Settings for the Indicator Light + Reset Button Option (Typecode Character 28–29 = D1/DA/DB/DC/DD/DE) Parameter Change value to Parameter 5-40 Function Relay [1] [5] Running Parameter 5-40 Function Relay [2] [5] Running Parameter 5-11 Terminal 19 Digital Input [1] Reset 194 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 195: Block Diagrams

    R1 Resistor -RF5 Passive harmonic filter (PHF) L0 -RF4 PHF inductors -CA5 PHF capacitors -QA2 PHF contactor -RFL Line reactor -QAF PHF relay -QB7 Molded-case circuit breaker (MCCB) -QA3 Mains contactor Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 195...
  • Page 196 -CA4 Sine-wave filter capacitor -RF1 dU/dt filter inductor -CA3 dU/dt filter capacitor -RF3 Common-mode filter -MA1 Motor (customer side) -TA1 Drive module LCP Local control panel Illustration 77: Electrical Power Flow for D9h/D10h Enclosure 196 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 197 -QA2 PHF contactor -RFL Line reactor -QAF PHF relay -QB7 Molded-case circuit breaker (MCCB) -QA3 Mains contactor -QB2 Mains fused disconnect -QB8 Mains disconnect -MA7 dU/dt and sine-wave filter fans -MA8 PHF fans Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 197...

  • Page 198: Input Power Option Losses

    N400 N450 N500 Table 123: Power Losses for Contactor Option, 525–690 V (Losses Shown in Watts) Model 525–550 V 551–690 V – N90K N110 N132 N160 N200 N250 N315 N355 N400 198 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 199: Fusible Disconnect Losses

    N500 Table 125: Power Losses for Fusible Disconnect Option, 525–690 V (Losses Shown in Watts) Model 525–550 V 551–690 V – N90K N110 N132 N160 N200 N250 N315 N355 N400 N500 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 199...

  • Page 200: Non-Fusible Disconnect Losses

    Table 127: Power Losses for Non-fusible Disconnect Option, 525–690 V (Losses Shown in Watts) Model 525–550 V 551–690 V – N90K N110 N132 N160 N200 N250 N315 N355 N400 N500 N560 200 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 201: Mccb Losses

    Table 129: Power Losses for MCCB Option, 525–690 V (Losses Shown in Watts) Model 525–550 V 551–690 V – N90K N110 N132 N160 N200 N250 N315 N355 N400 N500 N560 N630 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 201...

  • Page 202: Passive Harmonic Filter Losses

    8246 N355 7768 6872 6872 5498 N400 10995 6872 7768 6872 N500 9919 9919 8605 7768 N560 10995 9919 9919 8605 N630 13744 10995 10995 9919 N710 13744 13744 13744 10995 202 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...

  • Page 203: Du/Dt Filter Losses

    Table 133: Power Losses for dU/dt Filter Option, 525–690 V (Losses Shown in Watts) Model 525–550 V 551–690 V – N90K N110 N132 N160 N200 N250 N315 N355 N400 N500 N560 N630 N710 1430 1054 1308 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 203...

  • Page 204: Sine-Wave Filter Losses

    2401 N355 3237 2286 2967 2116 N400 4004 2697 3663 2463 N500 3603 2772 3296 2536 N560 4027 3603 4027 3296 N630 5909 4406 5406 4027 N710 8018 5906 7330 5406 204 | Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882...
  • Page 205 Operating Guide | VLT® AQUA Drive FC 202 Danfoss A/S © 2018.10 AQ262141056213en-000101 / 130R0882 | 205...
  • Page 206 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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