Danfoss FC 111 Operating guide

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Operating Guide

VLT® Flow Drive FC 111

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VLT® Flow Drive FC 111

Operating Guide

Introduction 6

1.1

Purpose of this Operating Guide 6

Additional Resources 6

1.2

Other Resources 6

1.2.1

1.2.2

MCT 10 Set-up Software Support 6

1.3

Document and Software Version 6

1.4

Disposal 6

Safety 7

Safety Symbols 7

2.1

Qualified Personnel 7

2.2

Safety Precautions 7

2.3

Motor Thermal Protection 8

2.4

Contents

Product Overview 9

Intended Use 9

3.1

3.2

Power Ratings, Weights, and Dimensions 9

3.3

Check Valve Monitoring 12

3.4

Dry Pump Detection 12

3.5

End of Curve Detection 12

3.6

Time-based Functions 12

3.7

Relays and Terminals 13

3.7.1

Relays and Terminals on Enclosure Sizes H1–H5 13

3.7.2

Relays and Terminals on Enclosure Size H11 14

3.7.3

Relays and Terminals on Enclosure Size H12 14

3.7.4

Relays and Terminals on Enclosure Size H13–H14 15

3.8

View of Control Shelf 16

Mechanical Installation 18

4.1

Storage and Operating Environment 18

4.2

Side-by-side Installation 19

4.3

Tools Needed 20

4.4

Installation and Cooling Requirements 20

4.5

Lifting the Drive 22

4.6

Wall Mounting the Drive 22

4.7

Creating Cable Openings 23

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation 25

Safety Instructions 25

5.1

5.2

EMC-compliant Electrical Installation 25

Electrical Wiring 26

5.3

5.4

Fastener Tightening Torques 27

5.5

IT Mains 28

5.6

Mains and Motor Connection 29

5.6.1

Introduction 29

5.6.2

Connecting to the Ground 29

5.6.3

Connecting the Motor 30

5.6.4

Connecting the AC Mains 31

5.7

Fuses and Circuit Breakers 32

5.7.1

Branch Circuit Protection 32

5.7.2

Short-circuit Protection 32

Contents

Overcurrent Protection 32

5.7.3

5.7.4

CE Compliance 32

5.7.5

Recommendation of Fuses 32

5.8

Control Terminals 33

5.9

Acoustic Noise or Vibration 34

Programming 35

6.1

Local Control Panel (LCP) 35

6.2

Set-up Wizard 36

6.2.1

Setup Wizard Introduction 36

6.2.2

Setup Wizard for Open-loop Applications 37

6.2.3

Setup Wizard for Closed-loop Applications 42

6.2.4

Motor Setup 47

6.2.5

Changes Made Function 51

6.2.6

Changing Parameter Settings 51

6.2.7

Accessing All Parameters via the Main Menu 51

Applications 52

7.1

Application Selections 52

7.1.1

Open Loop 52

7.1.2

Process Closed Loop 53

7.1.3

Constant Pressure Water Supply 55

7.1.4

Multiple Pump Control 57

VLT® Flow Drive FC 111

Operating Guide

Cascade Controller 60

Introduction 60

8.1

8.1.1

Cascade Controller 60

Fixed Lead Pump 60

8.1.2

8.1.3

Lead Pump Alternation 60

8.1.4

Bandwidth Management 60

8.2

System Status and Operation 61

8.3

Start/Stop Conditions 61

8.4

Cascade Controller Wizard 62

8.5

Cascade Controller Connection 63

8.5.1

1 Pump, 1 Relay Mode 63

8.5.2

1 Pump, 2 Relay Mode 63

Warnings and Alarms 65

9.1

List of Warnings and Alarms 65

Contents

9.2

LCP Errors Messages 67

Specifications 69

10.1

Mains Supply 69

10.1.1

3x380–480 V AC 69

10.2

EMC Emission Test Results 71

10.3

Special Conditions 72

10.3.1

Dusty or Humid Environment 72

10.3.2

Derating for Ambient Temperature and Switching Frequency 72

10.3.3

Derating for Low Air Pressure and High Altitudes 72

10.4

General Technical Data 72

10.4.1

Protection and Features 72

10.4.2

Mains Supply 72

10.4.3

Motor Output (U, V, W) 73

10.4.4

Cable Length and Cross-section 73

10.4.5

Digital Inputs 73

10.4.6

Analog Inputs 74

10.4.7

Analog Outputs 74

10.4.8

Digital Output 74

10.4.9

RS485 Serial Communication 75

10.4.10

24 V DC Output 75

10.4.11

Relay Output 75

10.4.12

10 V DC Output 75

10.4.13

Ambient Conditions 75

Edition

Remarks

Software version

AQ304735638503, version 0301

Update the manual for 30–90 kW (40–125 hp) drives.

75.02 for 30–90 kW (40–125 hp); 65.02 for other power sizes of the drive.

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with local and currently valid legislation.

VLT® Flow Drive FC 111

Operating Guide

Introduction

1 Introduction

1.1 Purpose of this Operating Guide

This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified personnel.

Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Other Resources

Other resources are available to understand advanced drive functions and programming.

•

The VLT® Flow Drive FC 111 Programming Guide provides information on how to program and includes complete parameter descriptions.

•

The VLT® Flow Drive FC 111 Design Guide provides all technical information about the drive. It also lists options and accessories.

The technical documentation is available in electronic form online at

1.2.2 MCT 10 Set-up Software Support

Download the software from the service and support section on www.danfoss.com. During the installation process of the software, enter access code 81462700 to activate the VLT® Flow Drive FC 111 functionality. A

license key is not required for using the VLT® Flow Drive FC 111 functionality. The latest software does not always contain the latest updates for drives. Contact the local sales office for the latest drive updates (in

the form of *.OSS files).

www.danfoss.com.

1.3 Document and Software Version

The Operating Guide is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.

Table 1: Document and Software Version

1.4 Disposal

VLT® Flow Drive FC 111

Operating Guide

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

Safety

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•

Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

•

Are familiar with the basic regulations concerning health and safety/accident prevention.

•

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.

•

Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

W A R N I N G

HAZARDOUS VOLTAGE

AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform

installation, start-up, and maintenance by skilled personnel can result in death or serious injury.

Only skilled personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during

programming, service, or repair work can result in death, serious injury, or property damage. Start the motor with an external

switch, a fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10

software, or after a cleared fault condition.

Disconnect the drive from the mains.

Press [Off/Reset] on the LCP before programming parameters.

Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x400

0.37–7.5 (0.5–10)

3x400

11–90 (15–125)

3x400

110–315 (150–450)

VLT® Flow Drive FC 111

Operating Guide

Safety

W A R N I N G

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be

present even when the warning indicator lights are off.

Failure to wait the specified time after power has been removed before performing service or repair work could result in death or

serious injury.

Stop the motor.

Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible

on the nameplate on the top of the drive.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 2: Discharge Time

W A R N I N G

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current

equipment.

W A R N I N G

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national and local electrical codes.

Follow the procedures in this manual.

C A U T I O N

INTERNAL FAILURE HAZARD

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.

2.4 Motor Thermal Protection

Procedure

Set parameter 1-90 Motor Thermal Protection to [4] ETR trip 1 to enable the motor thermal protection function.

e30bf984.10

Enclosure Size

H1H2H3H4H5

IP class

IP20

Power [kW (hp)]

3x380–480 V

0.37–1.5 (0.5–2.0)

2.2–4.0 (3.0–5.0)

5.5–7.5 (7.5–10)

11–15 (15–20)

18.5–22 (25–30)

Height [mm (in)]

195 (7.7)

227 (8.9)

255 (10.0)

296 (11.7)

334 (13.1)

(1)

273 (10.7)

303 (11.9)

329 (13.0)

359 (14.1)

402 (15.8)

183 (7.2)

212 (8.3)

240 (9.4)

275 (10.8)

314 (12.4)

Width [mm (in)]

75 (3.0)

90 (3.5)

100 (3.9)

135 (5.3)

150 (5.9)

56 (2.2)

65 (2.6)

74 (2.9)

105 (4.1)

120 (4.7)

Depth [mm (in)]

168 (6.6)

190 (7.5)

206 (8.1)

241 (9.5)

255 (10)

VLT® Flow Drive FC 111

Operating Guide

Product Overview

3 Product Overview

3.1 Intended Use

The drive is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequency and voltage of the output are regulated to control the motor speed or torque. The drive is designed to:

•

Regulate motor speed in response to system feedback or remote commands from external controllers.

•

Monitor system and motor status.

•

Provide motor overload protection.

The drive is designed for industrial and commercial environments in accordance with local laws and standards. Depending on configuration, the drive can be used in standalone applications or form part of a larger system or installation.

N O T I C E

RADIO INTERFERENCE

In a residential environment, this product can cause radio interference.

Take supplementary mitigation measures.

Foreseeable misuse

Do not use the drive in applications which are non-compliant with specified operating conditions and environments. Ensure compliance with the conditions specified in chapter Specifications.

3.2 Power Ratings, Weights, and Dimensions

Illustration 1: Dimensions, Enclosure Sizes H1–H5 & H11–H12

Table 3: Power Ratings, Weights, and Dimensions, Enclosure Sizes H1–H5

Enclosure Size

H1H2H3H4H5

Mounting hole [mm (in)]

9 (0.35)

11 (0.43)

12.6 (0.50)

4.5 (0.18)

5.5 (0.22)

7 (0.28)

5.3 (0.21)

7.4 (0.29)

8.1 (0.32)

8.4 (0.33)

8.5 (0.33)

Maximum weight [kg (lb)]

2.1 (4.6)

3.4 (7.5)

4.5 (9.9)

7.9 (17.4)

9.5 (20.9)

Enclosure Size

H11

H12

IP class

IP20

(1)

Power [kW (hp)]

3x380–480 V

30–45 (40–60)

55–90 (70–125)

Height [mm (in)]

515 (20.3)

550 (21.7)

(2)

545 (21.5)

610.5 (24)

495 (19.5)

521 (20.5)

Width [mm (in)]

233 (9.2)

308 (12.1)

200 (7.9)

270 (10.6)

Depth [mm (in)]

241 (9.5)

323 (12.7)

Mounting hole [mm (in)]

–

–e8.5 (0.33)

8.5 (0.33)

13 (0.5)

17 (0.67)

Maximum weight [kg (lb)]

22.6 (49.8)

40.7 (89.7)

e30bv016.10

VLT® Flow Drive FC 111

Operating Guide

Including decoupling plate.

Table 4: Power Ratings, Weights, and Dimensions H11–H12

Product Overview

Install the protective cover on the mains and motor terminals after connecting the stripped wire. See Illustration 2.

Including decoupling plate.

Illustration 2: Protective Cover

e30bu775.10

b D

(1) (2)

(3)

Front view

Side view

Back view

Enclosure Size

H13

H14

IP class

IP20

Power [kW (hp)]

3x380–480 V

110–160 (150–250)

200–315 (300–450)

Height [mm (in)]

889 (35.0)

1096 (43.1)

(1)

909 (35.8)

1122 (44.2)

844 (33.2)

1051 (41.4)

Width [mm (in)]

250 (9.8)

350 (13.8)

180 (7.1)

280 (11.0)

200 (7.9)

271 (10.7)

VLT® Flow Drive FC 111

Operating Guide

Product Overview

Illustration 3: Dimensions, Enclosure Sizes H13–H14

Table 5: Power Ratings, Weights, and Dimensions H13–H14

Enclosure Size

H13

H14

Depth [mm (in)]

375 (14.8)

Mounting hole [mm (in)]

11 (0.4)

Center of gravity [mm (in)]

128 (5.0)

176 (6.9)

495 (19.5)

611 (24.1)

148 (5.8)

Maximum weight [kg (lb)]

98 (216)

164 (362)

VLT® Flow Drive FC 111

Operating Guide

Including decoupling plate.

The dimensions are only for the physical units.

Product Overview

3.3 Check Valve Monitoring

In the pump application system, a damaged check valve is hard to detect, which therefore causes low efficiency of the whole system. VLT® Flow Drive FC 111 can monitor the status of check valves in the system. After enabling the check valve monitoring function via setting parameter 22-04 Check Valve Monitor to [1] Enabled, the drive trips warning 159, Check Valve Failure if a damaged check valve is detected.

3.4 Dry Pump Detection

In the pump application system, the drive monitors the operation status of the system to detect whether there is water on the pump's suction side. If the pump runs at maximum speed and consumes little power, then it can be assumed that there is no water on the pump's suction side. Via setting parameter 22-26 Dry Pump Function to warning or alarm, the drive trips warning/alarm 93, dry pump if the dry-pump condition is detected.

3.5 End of Curve Detection

In the pump application system, the drive monitors the operation status of the system to detect whether the pressure side of pump is subject to a major leakage. If the pump runs at maximum speed for a defined time period, but the pressure is below the set point, then it can be considered to reflect the end-of-curve situation. Via setting parameter 22-50 End of Curve Function to warning or alarm, the drive trips warning/alarm 94, end of curve if the end-of-curve condition is detected.

3.6 Time-based Functions

In some application scenarios, there are requirements to control the motor running for a specific time, in a specific direction and a specific speed within a specific time interval. For example, checking the motor status in fire mode or exercising pumps, fans, and compressors.

For detailed parameter settings, refer to the parameter group 23-** Time-based Functions in the drive's Programming Guide.

e30bb634.10

-DC

+DC

AINS

Mains

Ground

Motor

Relays

VLT® Flow Drive FC 111

Operating Guide

3.7 Relays and Terminals

3.7.1 Relays and Terminals on Enclosure Sizes H1–H5

Product Overview

Illustration 4: Enclosure Sizes H1–H5 IP20, 380–480 V, 0.37–22 kW (0.5–30 hp)

e30bu937.10

Mains

Ground

Motor

e30bu938.10

Mains

Ground

Motor

VLT® Flow Drive FC 111

Operating Guide

3.7.2 Relays and Terminals on Enclosure Size H11

Product Overview

Illustration 5: Enclosure Size H11 IP20, 380–480 V, 30–45 kW (40–60 hp)

See 3.8 View of Control Shelf for the relay terminals of H11 drives.

3.7.3 Relays and Terminals on Enclosure Size H12

Illustration 6: Enclosure Size H12 IP20, 380–480 V, 55–90 kW (75–125 hp)

See 3.8 View of Control Shelf for the relay terminals of H12 drives.

e30bu777 .10

Mains

Motor

Ground

VLT® Flow Drive FC 111

Operating Guide

3.7.4 Relays and Terminals on Enclosure Size H13–H14

Product Overview

Illustration 7: Enclosure Size H13–H14 IP20, 380–480 V, 110–315 kW (150–450 hp)

See 3.8 View of Control Shelf for the relay terminals of H13–H14 drives.

e30bu939.10

LCP2RS485 termination switch

RS485 fieldbus connector

Relay 1 on power card

Digital I/O and 24 V supply

Analog I/O connector

Relay 2 on power card

VLT® Flow Drive FC 111

Operating Guide

Product Overview

3.8 View of Control Shelf

The control shelf of H11-H14 drives holds the keypad, known as the local control panel or LCP. The control shelf also includes the control terminals, relays, and various connectors.

Illustration 8: View of Control Shelf in H11–H12

e30bu776.10

LCP connector

RS485 termination switch

RS485 fieldbus connector

Analog I/O connector

Digital I/O and 24 V supply

Relay 1 on power card

Relay 2 on power card

VLT® Flow Drive FC 111

Operating Guide

Product Overview

Illustration 9: View of Control Shelf in H13–H14

Voltage [V]

Altitude restrictions

380–480

At altitudes above 3000 m (9842 ft), contact Danfoss regarding PELV.

VLT® Flow Drive FC 111

Operating Guide

Mechanical Installation

4 Mechanical Installation

4.1 Storage and Operating Environment

Storage

Store the drive in a dry location. Keep the equipment sealed in its packaging until installation. Refer to the Ambient Conditions section for recommended ambient temperature.

Periodic forming (capacitor charging) is not necessary during storage unless storage exceeds 12 months.

Operating Environment

N O T I C E

OPERATING ENVIRONMENT

In environments with airborne liquids, particles, or corrosive gases, failure to meet requirements for ambient conditions can re-

duce the lifetime of the drive.

Ensure that the IP/Type rating of the equipment matches the installation environment.

Ensure that requirements for air humidity, temperature, and altitude are met.

Table 6: Installation at High Altitudes

N O T I C E

CONDENSATION

Moisture can condense on the electronic components and cause short circuits.

Avoid installation in areas subject to frost.

Install an optional space heater when the drive is colder than the ambient air.

Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of

moisture.

N O T I C E

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

Do not operate in environments where the ambient temperature exceeds 55 °C (131 °F).

The drive can operate at temperatures down to -15 °C (5 °F). However, proper operation at rated load is only guaranteed at

0 °C (32 °F) or higher.

Extra air conditioning of the cabinet or installation site is required if temperature exceeds ambient temperature limits.

W A R N I N G

EXPLOSIVE ATMOSPHERE

Do not install the drive in a potentially explosive atmosphere.

Install the unit in a cabinet outside of this area.

Failure to follow this guideline increases risk of death or serious injury.

Size

IP class

Power [kW (hp)]

Clearance above/below [mm (in)]

3x380–480 V

IP20

0.37–1.5 (0.5–2.0)

100 (4)

IP20

2.2–4.0 (3.0–5.4)

100 (4)

IP20

5.5–7.5 (7.5–10)

100 (4)

IP20

11–15 (15–20)

100 (4)

IP20

18.5–22 (25–30)

100 (4)

H11

IP20

30–45 (40–60)

200 (7.9)

H12

IP20

55–90 (70–125)

200 (7.9)

H13

IP20/Chassis

110–160 (150–250)

225 (9)

H14

IP20/Chassis

200–315 (300–450)

225 (9)

VLT® Flow Drive FC 111

Operating Guide

Mechanical Installation

N O T I C E

GASES

Aggressive gases, such as hydrogen sulfide, chlorine, or ammonia can damage the electrical and mechanical components.

The unit uses conformal-coated circuit boards to reduce the effects of aggressive gases.

When installing the drive in dusty environments, pay attention to the following:

Periodic maintenance

When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling capacity of the components, and the components become warmer. The hotter environment decreases the life of the electronic components. Keep the heat sink and fans free from dust build-up.

Cooling fans

Fans provide airflow to cool the drive. When fans are exposed to dusty environments, the dust can damage the fan bearings and cause premature fan failure. Also, dust can accumulate on fan blades causing an imbalance which prevents the fans from properly cooling the unit.

4.2 Side-by-side Installation

The drive can be mounted side by side but requires the clearance above and below for cooling.

Table 7: Clearance Required for Cooling

With IP21 option kit mounted (available for H1–H5 & H11–H12), a distance of 50 mm (2 in) between the units is required.

N O T I C E

•

Tools Needed

Receiving/unloading

Installation

H1–H5

–

3 mm flat-edged screwdriver for terminals.

T20 torx head screwdriver for M5 grounding screw.

H11– H12

I-beam and hooks rated to lift the weight of the drive. Refer to 3.2 Power Ratings, Weights, and Dimensions.

Crane or other lifting aid to place the unit into position.

Allen key 6# (for M8).

T30 torx head screwdriver for terminals.

T25 torx head screwdriver for M6 grounding screw.

H13– H14

Drill with a 12 mm (1/2 in) drill bit.

Tape measurer.

Phillips and flat bladed screwdrivers.

Wrench with 7–17 mm metric sockets.

Wrench extensions.

T25 and T50 torx drives.

Sheet metal punch and/or pliers for cable entry plate.

VLT® Flow Drive FC 111

Operating Guide

4.3 Tools Needed

Table 8: Tools Needed

Mechanical Installation

4.4 Installation and Cooling Requirements

OVERHEATING

Improper mounting can result in overheating and reduced performance.

Install the drive according to the installation and cooling requirements.

Installation requirements

•

Ensure drive stability by mounting the drive vertically to a solid flat surface.

•

Ensure that the strength of the mounting location supports the drive weight. Ensure that the mounting location allows access to open the enclosure door. Refer to 3.2 Power Ratings, Weights, and Dimensions.

•

Ensure that there is enough space around the drive for cooling airflow.

•

Place the drive as near to the motor as possible. Keep the motor cables as short as possible. See 10.4.4 Cable Length and Cross-

section.

•

Ensure the location allows for cable entry at the bottom of the drive.

Cooling and airflow requirements

•

Ensure that top and bottom clearance for air cooling is provided, see 4.2 Side-by-side Installation.

•

Consider derating for temperatures starting between 40 °C (104 °F) and 55 °C (131 °F) and elevation 1000 m (3300 ft) above sea level. See chapter Derating in the Design Guide for detailed information.

•

The drive's maximum heating value could be estimated via the following equation:

Maximumheatingvalue ≈ Power × 1 − Efficiency

For example, the heating value of 110 kW (150 hp) drive could be 2.2 kW. Refer to 10.1.1 3x380–480 V AC for the drive's efficiency at rated load.

•

If multiple drives are installed in 1 cabinet at the same time, the heating value and ventilation volume shall be accumulated.

N O T I C E

Power [kW (hp)]

Ventilation volume reference value of the cabinet

CFM

m3/hr

0.37 (0.5)

240.75 (1.0)

471.5 (2.0)

8142.2 (3.0)

9153 (4.0)

13224 (5.0)

19325.5 (7.5)

22377.5 (10)

406811 (15)

125

15 (20)

100

170

18.5 (25)

135

229

22 (30)

160

272

30 (40)

178

303

37 (50)

220

374

45 (60)

240

408

55 (70)

257

436

75 (100)

350

595

90 (125)

370

629

110 (150)

414

704

132 (175)

499

849

160 (250)

605

1029

200 (300)

757

1286

250 (350)

887

1507

315 (450)

1118

1900

VLT® Flow Drive FC 111

Operating Guide

••If there are other heating devices, increase the ventilation according to the instructions.

If the dust screen needs to be installed, the air volume needs to be appropriately increased according to the wind resistance coefficient of the dust screen. For the wind resistance coefficient of dust screen, contact the dust screen supplier.

Table 9: Ventilation Volume Reference Value of the Cabinet

Mechanical Installation

e30bg512.11

65° min

VLT® Flow Drive FC 111

Operating Guide

Mechanical Installation

4.5 Lifting the Drive

W A R N I N G

HEAVY LOAD

Unbalanced loads can fall or tip over. Failure to take proper lifting precautions increases risk of death, serious injury, or equip-

ment damage.

Move the unit using a hoist, crane, forklift, or other lifting device with the appropriate weight rating. See 3.2 Power Ratings,

Weights, and Dimensions for the weight of the drive.

Failure to locate the center of gravity and correctly position the load can cause unexpected shifting during lifting and trans-

port. For measurements and center of gravity, see 3.2 Power Ratings, Weights, and Dimensions.

The angle from the top of the drive module to the lifting cables affects the maximum load force on the cable. This angle

must be 65° or greater. Refer to the following illustration. Attach and dimension the lifting cables properly.

Never walk under suspended loads.

To guard against injury, wear personal protective equipment such as gloves, safety glasses, and safety shoes.

Always lift the drive using the dedicated eye bolts at the top of the drive. See the following illustration.

Illustration 10: Lifting the Drive

4.6 Wall Mounting the Drive

H13 and H14 are chassis drives intended to be mounted on a wall or on a mounting plate within an enclosure. To wall mount the drive, use the following steps.

Procedure

Fasten 2 M10 bolts in the wall to align with the fastener slots at the bottom of drive.

Slide the lower fastener slots in the drive over the M10 bolts.

e30bg288.10

Top mounting holes

Lower fastener slots

VLT® Flow Drive FC 111

Operating Guide

3. Tip the drive against the wall, and secure the top with 2 M10 bolts in the mounting holes.

Example

Mechanical Installation

Illustration 11: Drive-to-wall Mounting Holes

4.7 Creating Cable Openings

After installing H13-H14 drive, create cable openings in the gland plate to accommodate the mains and motor cables. The gland plate is required to maintain the drive protection rating.

Procedure

e30bf662.10

Plastic tabs

Tabs removed for cable access

VLT® Flow Drive FC 111

Operating Guide

1. Punch out plastic tabs to accommodate the cables.

Illustration 12: Cable Openings in Plastic Gland Plate

Mechanical Installation

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

5 Electrical Installation

5.1 Safety Instructions

See chapter Safety for general safety instructions.

W A R N I N G

INDUCED VOLTAGE

Induced voltage from output motor cables from different drives that are run together can charge equipment capacitors even

with the equipment turned off and locked out. Failure to run output motor cables separately or use shielded cables could result

in death or serious injury.

Run output motor cables separately or use shielded cables.

Simultaneously lock out all the drives.

W A R N I N G

SHOCK HAZARD

The drive can cause a DC current in the ground conductor and thus result in death or serious injury. Failure to follow the recom-

mendation means that the residual current-operated protective device (RCD) cannot provide the intended protection.

When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type

B is allowed on the supply side.

Overcurrent protection

•

Additional protective equipment such as short-circuit protection or motor thermal protection between drive and motor is required for applications with multiple motors.

•

Input fusing is required to provide short circuit and overcurrent protection. If fuses are not factory-supplied, the installer must provide them. See maximum fuse ratings in chapter Fuses and Circuit Breakers.

Wire type and ratings

•

All wiring must comply with local and national regulations regarding cross-section and ambient temperature requirements.

•

Power connection wire recommendation: Minimum 75 °C (167 °F) rated copper wire.

See 10.4.4 Cable Length and Cross-section for recommended wire sizes and types.

5.2 EMC-compliant Electrical Installation

To ensure EMC-correct electrical installation, observe the following:

•

Use only shielded/armored motor cables and shielded/armored control cables.

•

Ground the shield at both ends.

•

Avoid installation with twisted shield ends (pigtails), because it reduces the shielding effect at high frequencies. Use the cable clamps provided.

•

Ensure the same potential between the drive and the ground potential of PLC.

•

Use star washers and galvanically conductive installation plates.

Com.

Warn.

Alarm

Hand On

Reset

Auto

Status Quick

Main Menu

Minimum 16 mm

equalizing cable

Control cables

All cable entries in

one side of the panel

Grounding rail

Cable insulation stripped

Output contactor

Motor cable

Motor, 3 phases and

PLC

Panel

Mains-supply

Minimum 200 mm (7.87 in) between control cable, mains cable, and between mains motor cable

PLC

protective earth

Reinforced protective earth

e30bb761.13

(6 AWG)

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

Illustration 13: EMC-compliant Installation

5.3 Electrical Wiring

L1 L2 L3

3-phase power input

+10 V DC

0-10 V DC-

50 (+10 V OUT)

54 (A IN)

53 (A IN)

55 (COM A IN/OUT)

0/4-20 mA

42 0/4-20 mA A OUT / D OUT

45 0/4-20 mA A OUT / D OUT

18 (D IN)

19 (D IN)

27 (D IN/OUT)

29 (D IN/OUT)

12 (+24 V OUT)

24 V (NPN)

20 (COM D IN)

O V (PNP)

24 V (NPN) O V (PNP)

Bus ter.

RS485 Interface

RS485

(N RS485) 69

(P RS485) 68

(Com RS485 ) 61

(PNP)-Source (NPN)-Sink

ON=Terminated

OFF=Unterminated

1 2

240 V AC 3 A

Not present on all power sizes

Do not connect shield to 61

relay 1

relay 2

UDC+

UDC-

Motor

U V

e30bd467.12

240 V AC 3 A

Power [kW (hp)]

Torque [Nm (in-lb)]

Enclosure size

IP class

3x380–480 V

Mains

Motor

DC connection

Control terminals

Ground

Relay

IP20

0.37–1.5 (0.5–2.0)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

2.2–4.0 (3.0–5.4)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

5.5–7.5 (7.5–10)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

Illustration 14: Basic Wiring Schematic Drawing

There is no access to UDC- and UDC+ on the following units:

5.4 Fastener Tightening Torques

Apply the correct torque when tightening fasteners in the locations that are listed in the following tables. Too low or too high torque when fastening an electrical connection results in a bad electrical connection. To ensure correct torque, use a torque wrench.

Table 10: Tightening Torques for Enclosure Sizes H1–H5 & H11–H12, 3x380–480 V

IP20, 380–480 V, 30–315 kW (40–450 hp)

N O T I C E

Power [kW (hp)]

Torque [Nm (in-lb)]

Enclosure size

IP class

3x380–480 V

Mains

Motor

DC connection

Control terminals

Ground

Relay

IP20

11–15 (15–20)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

IP20

18.5–22 (25–30)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

H11

IP20

30–45 (40–60)

4.5 (40)

–

0.5 (4)

3 (27)

0.5 (4)

H12

IP20

55 (70)

10 (89)

–

0.5 (4)

3 (27)

0.5 (4)

H12

IP20

75 (100)

14 (124)

–

0.5 (4)

3 (27)

0.5 (4)

H12

IP20

90 (125)

24 (212)

(1)

24 (212)

(1)

–

0.5 (4)

3 (27)

0.5 (4)

Location

Bolt size

Torque [Nm (in-lb)]

Mains terminals

M10/M12

19 (168)/37 (335)

Motor terminals

M10/M12

19 (168)/37 (335)

Ground terminals

M8/M10

9.6 (84)/19.1 (169)

Relay terminals

–

0.5 (4)

Door/panel cover

2.3 (20)

Gland plate

2.3 (20)

e30bb612.10

EMC screw

VLT® Flow Drive FC 111

Operating Guide

Cable dimensions >95 mm2.

Table 11: Tightening Torques for Enclosure Sizes H13–H14, 3x380–480 V

Electrical Installation

5.5 IT Mains

C A U T I O N

IT MAINS

Installation on isolated mains source, that is, IT mains.

Ensure that the supply voltage does not exceed 440 V (3x380–480 V units) when connected to mains.

For 380–480 V, IP20, 0.37–22 kW (0.5–30 hp) units, open the RFI switch by removing the screw on the side of the drive when at IT grid.

Illustration 15: IP20, 0.37–22 kW (0.5–30 hp), 380–480 V

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

N O T I C E

If reinserted, use only M3x12 screw.

For 380–480 V, 30–90 kW (40–125 hp) units, set parameter 14-50 RFI Filter to [0] Off when operating in IT mains. For 380–480 V, 110–315 kW (150–450 hp) units, if the drive is supplied from an isolated mains source (IT mains, floating delta, or

grounded delta) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off via parameter 14-50 RFI Filter on the drive and parameter 14-50 RFI Filter on the filter. For more details, see IEC 364-3. In the [Off] position, the filter capacitors between the chassis and the DC link are cut off to avoid damage to the DC link and to reduce the ground capacity currents, according to IEC 61800-3.

If optimum EMC performance is needed, or parallel motors are connected, or the motor cable length is above 25 m (82 ft), Danfoss recommends setting parameter 14-50 RFI Filter to [On]. It is important to use isolation monitors that are rated for use together with power electronics (IEC 61557-8).

5.6 Mains and Motor Connection

5.6.1 Introduction

The drive is designed to operate all standard 3-phase asynchronous motors.

Use a shielded/armored motor cable to comply with EMC emission specifications and connect this cable to both the decoupling

• plate and the motor.

•

Keep the motor cable as short as possible to reduce the noise level and leakage currents.

For further details on mounting the decoupling plate, see the relevant Decoupling Plate Installation Guide.

•

Also see EMC-Correct Installation in the

•

5.2 EMC-compliant Electrical Installation.

5.6.2 Connecting to the Ground

W A R N I N G

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current

equipment.

For electrical safety:

•

Ground the drive in accordance with applicable standards and directives.

•

Use a dedicated ground wire for input power, motor power, and control wiring.

•

Do not ground 1 drive to another in a daisy chain fashion.

•

Keep the ground wire connections as short as possible.

•

Follow motor manufacturer wiring requirements.

•

Minimum cable cross-section: 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al (or 2 rated ground wires terminated separately).

•

Tighten the terminals in accordance with the information provided in 5.4 Fastener Tightening Torques.

For EMC-compliant installation

•

Establish electrical contact between the cable shield and the drive enclosure by using metal cable glands or by using the clamps provided on the equipment.

•

Reduce burst transient by using high-strand wire.

•

Do not use twisted shield ends (pigtails).

e30bv020.10

Ferrule without plastic sleeve

Ferrule with plastic sleeve

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

N O T I C E

POTENTIAL EQUALIZATION

There is a risk of burst transient when the ground potential between the drive and the control system is different.

Install equalizing cables between the system components. Recommended cable cross-section: 16 mm2 (6 AWG).

5.6.3 Connecting the Motor

W A R N I N G

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned

off and locked out/tagged out. Failure to run output motor cables separately or to use shielded cables could result in death or

serious injury.

Run output motor cables separately or use shielded cables.

Simultaneously lock out/tag out all the drives.

•

Comply with local and national electrical codes for cable sizes. For maximum wire sizes, see 10.4.4 Cable Length and Cross-

section.

•

Follow motor manufacturer wiring requirements.

•

Motor wiring knockouts or access panels are provided at the base of IP21 and higher units.

•

Do not wire a starting or pole-changing device (for example, Dahlander motor or slip ring asynchronous motor) between the drive and the motor.

Procedure

For H12 drives, remove the protective covers using a screwdriver before connecting the stripped wire.

For H1–H5 and H13–H14 drives, strip a section of the outer cable insulation.

For H11-H12 drives:

If ferrule without plastic sleeve is used, strip 16–17 mm (0.63–0.67 in) section of the outer cable insulation.

If ferrule with plastic sleeve is used, strip a section of the outer cable insulation.

Illustration 16: Ferrule with/without Plastic Sleeve

e30bv021.10

Terminal locating slot

Cover positioning pins

Cable block slice

VLT® Flow Drive FC 111

Operating Guide

Position the stripped wire under the cable clamp, establishing mechanical fixation and electrical contact between the cable shield and ground.

Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

5.6.2 Connecting to the Ground.

Connect the 3-phase motor wiring to terminals U, V, and W.

Tighten the terminals in accordance with the information provided in 5.4 Fastener Tightening Torques.

For H12 drives, install the protective cover on the terminals.

Cut the cable block slice according to the wire size.

Put the positioning pin to the terminal locating slot.

Electrical Installation

Illustration 17: Installing Protective Covers, H12

5.6.4 Connecting the AC Mains

•

Size the wiring according to the input current of the drive. For maximum wire sizes, see 10.1.1 3x380–480 V AC.

•

Comply with local and national electrical codes for cable sizes.

Procedure

For H12 drives, remove the protective covers using a screwdriver before connecting the stripped wire.

For H1–H5 and H13–H14 drives, strip a section of the outer cable insulation.

For H11-H12 drives, see the Illustration Ferrule with/without Plastic Sleeve in

If ferrule without plastic sleeve is used, strip 16–17 mm (0.63–0.67 in) section of the outer cable insulation.

If ferrule with plastic sleeve is used, strip a section of the outer cable insulation.

Position the stripped wire under the cable clamp, establishing mechanical fixation and electrical contact between the cable shield and ground.

Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in

5.6.2 Connecting to the Ground.

For H1-H5 & H11-H12 drives, connect the 3-phase AC input power wiring to terminals L1, L2, and L3.

For H13-H14 drives, connect the 3-phase AC input power wiring to terminals R, S, and T.

When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta), ensure that parameter 14-50 RFI Filter is set to [0] Off to avoid damage to the DC link and to reduce ground capacity currents.

Tighten the terminals in accordance with the information provided in 5.4 Fastener Tightening Torques.

10.

For H12 drives, install the protective cover on the terminals, see the Illustration Installing Protective Covers, H12 in 5.6.3 Con-

necting the Motor.

Cut the cable block slice according to the wire size.

Put the positioning pin to the terminal locating slot.

5.6.3 Connecting the Motor.

3x380–480 V IP20 [kW (hp)]

Maximum fuse

0.37 (0.5)

gG-10

0.75 (1.0)

gG-10

1.5 (2.0)

gG-10

2.2 (3.0)

gG-16

3.0 (4.0)

gG-16

4.0 (5.4)

gG-16

5.5 (7.5)

gG-25

7.5 (10)

gG-25

11 (15)

gG-50

15 (20)

gG-50

18.5 (25)

gG-63

22 (30)

gG-63

30 (40)

gG-125

37 (50)

gG-125

45 (60)

gG-125

55 (70)

aR-250

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

5.7 Fuses and Circuit Breakers

5.7.1 Branch Circuit Protection

To prevent fire hazards, protect the branch circuits in an installation, switch gear, machines, and so on, against short circuits and overcurrent. Follow national and local regulations.

5.7.2 Short-circuit Protection

Danfoss recommends using the fuses and circuit breakers listed in this chapter to protect service personnel or other equipment in case of an internal failure in the unit or a short circuit on the DC link. The drive provides full short-circuit protection in case of a short circuit on the motor.

5.7.3 Overcurrent Protection

Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried out according to local and national regulations. Design circuit breakers and fuses for protection in a circuit capable of supplying a maximum of 100000 A

(symmetrical), 480 V maximum.

rms

5.7.4 CE Compliance

To ensure compliance with IEC 61800-5-1, use the circuit breakers or fuses listed in this chapter. Circuit breakers must be designed for protection in a circuit capable of supplying a maximum of 10000 A

(symmetrical), 480 V maximum.

rms

5.7.5 Recommendation of Fuses

N O T I C E

In the event of malfunction, failure to follow the protection recommendation may result in damage to the drive.

Table 12: Recommendation of Fuses

75 (100)

aR-250

90 (125)

aR-250

110 (150)

aR-315

132 (175)

aR-350

160 (250)

aR-400

200 (300)

aR-500

250 (350)

aR-630

315 (450)

aR-800

Model

Fuse Options

Bussman

Littelfuse

Bussman

Siba

Ferraz-Shawmut

Ferraz-Shawmut(Europe)

P110

170M2619

LA50QS300-4

L50S-300

FWH-300A

20 189 20.315

A50QS300-4

6,9URD31D08A0315

P132

170M2620

LA50QS350-4

L50S-350

FWH-350A

20 189 20.350

A50QS350-4

6,9URD31D08A0350

P160

170M2621

LA50QS400-4

L50S-400

FWH-400A

20 189 20.400

A50QS400-4

6,9URD31D08A0400

P200

170M4015

LA50QS500-4

L50S-500

FWH-500A

20 189 20.550

A50QS500-4

6,9URD31D08A0550

P250

170M4016

LA50QS600-4

L50S-600

FWH-600A

20 189 20.630

A50QS600-4

6,9URD31D08A0630

P315

170M4017

LA50QS800-4

L50S-800

FWH-800A

20 189 20.800

A50QS800-4

6,9URD32D08A0800

e30bd331.11

VLT® Flow Drive FC 111

Operating Guide

Table 13: H13–H14 Power/semiconductor Fuse Options, 380–480 V

Electrical Installation

5.8 Control Terminals

Remove the terminal cover (H1-H5 & H11-H12) or the cradle cover (H13-H14) to access the control terminals.

H1-H5 & H11-H12

Use a flat-edged screwdriver to push down the lock lever of the terminal cover under the LCP, then remove the terminal cover as shown in Illustration 18.

Illustration 18: Removing the Terminal Cover

H13-H14

Press the tips of the cradle cover inwards as shown in Illustration 19, and then lift the cradle cover up.

e30bu793.10

e30bv024.10

12 20 55

181927 29 42 54

45 50 53

DIGI IN

616869

COMM. GND

+24 V

GND

10 V OUT

10 V/20 mA IN

0/4-20 mA A OUT/DIG OUT

BUS TER.

OFF

DIGI IN

DIGI IN/OUT

0/4-20 mA A OUT/DIG OUT

10 V/20 mA IN

VLT® Flow Drive FC 111

Operating Guide

Electrical Installation

Illustration 19: Removing the Cradle Cover

All the drive control terminals are shown in Illustration 20. Applying start (terminal 18), connection between terminals 12-27, and an analog reference (terminal 53 or 54, and 55) make the drive run.

The digital input mode of terminal 18, 19, and 27 is set in parameter 5-00 Digital Input Mode (PNP is default value). Digital input 29 mode is set in parameter 5-03 Digital Input 29 Mode (PNP is default value).

Illustration 20: Control Terminals

5.9 Acoustic Noise or Vibration

If the motor or the equipment driven by the motor, for example, a fan, is making noise or vibrations at certain frequencies, configure the following parameters or parameter groups to reduce or eliminate the noise or vibrations:

•

Parameter group 4-6* Speed Bypass.

•

Set parameter 14-03 Overmodulation to [0] Off.

•

Switching pattern and switching frequency parameter group 14-0* Inverter Switching.

•

Parameter 1-64 Resonance Dampening.

e30bu792.11

Com.

4-10 Motor Speed Direction [2] Both directions

Setup 1

13 14 15

Status

Main Menu

Quick Menu

Hand

Off

Reset

Auto

Alarm

Warn.

13 14 15

LCP 32 LCP 31

4-10 Motor Speed Dir ection [2] Both directions

Status

Quick

Main

Com.

Warn.

Alarm

Hand

Off

Reset

Auto

Back

Parameter number and name.

Parameter value.

The setup number shows the active setup and the edit setup. For LCP 32, the setup number only shows in Status menu, the number outside the brackets is active setup, and the number

inside the brackets is edit setup. For example, 1(2) means 1 is the active setup, and 2 is the edit setup. For LCP 31, if the same setup acts as both active and edit setup, only that setup number is shown (factory setting). When the

active and the edit setup differ, both numbers are shown in the display (setup 12). The number flashing indicates the edit setup.

Motor direction is shown to the bottom left of the display – indicated by a small arrow pointing either clockwise or counterclockwise.

The triangle indicates if the LCP is in Status, Quick Menu, or Main Menu.

VLT® Flow Drive FC 111

Operating Guide

6 Programming

6.1 Local Control Panel (LCP)

The LCP is divided into 4 functional sections.

•

A. Display

•

B. Menu key

•

C. Navigation keys and indicator lights

•

D. Operation keys and indicator lights

Programming

Illustration 21: Local Control Panel (LCP)

A. Display

The LCD-display of LCP 32 is illuminated with 3 alphanumeric lines, while the LCD-display of LCP 31 is illuminated with 2 alphanumeric lines. All data is shown on the LCP. The Table 14 describes the information that can be read from the display.

Table 14: Legend to Section A, Illustration 3

B. Menu key

Press [Menu] to select among Status, Quick Menu, or Main Menu.

C. Navigation keys and indicator lights

Com. (yellow indicator): Flashes during bus communication.

On (green indicator): Shows the power-on status.

Warn. (yellow indicator): Indicates a warning.

Alarm (red indicator): Indicates an alarm.

[Back]: For moving to the previous step or layer in the navigation structure.

[▵], [▿], and [▹]: For navigating among parameter groups and parameters, and within parameters. They can also be used for setting local reference.

[OK]: For selecting a parameter and for accepting changes to parameter settings.

[Hand On]: Starts the motor and enables control of the drive via the LCP.

N O T I C E

[2] Coast inverse is the default option for parameter 5-12 Terminal 27 Digital Input. If there is no 24 V supply to terminal 27,

[Hand On] does not start the motor. Connect terminal 12 to terminal 27.

[Off/Reset]: Stops the compressor (Off). If in alarm mode, the alarm is reset.

[Auto On]: The drive is controlled either via control terminals or serial communication.

+24 V (OUT)

DIG IN DIG IN

COM DIG IN

A OUT / D OUT A OUT / D OUT

18 19

27 29

50 53 54

01 02 03

04 05 06

0–10 V

Start

+10 V (OUT) A IN A IN

COM IN/OUT

Reference

e30bb674.11

VLT® Flow Drive FC 111

Operating Guide

Table 15: Legend to Section C, Illustration 3

D. Operation keys and indicator lights

Table 16: Legend to Section D, Illustration 3

Programming

6.2 Set-up Wizard

6.2.1 Setup Wizard Introduction

The built-in wizard menu guides the installer through the setup of the drive in a clear and structured manner for open-loop and closed-loop applications, and for quick motor settings.

Illustration 22: Drive Wiring

The wizard can always be accessed again through the quick menu. Press [OK] to start the wizard. Press [Back] to return to the status view.

Power kW/50 H z

Motor Power

Motor Voltage

Motor Frequency

Motor Current

Motor nominal speed

Select Regional Settings

... the Wizard starts

200-240V/50Hz/Delta

Grid Type

Induction motor

Asynchronous

Motor Type

Motor current

Motor nominal speed

Motor Cont. Rated Torque

Stator resistance

Motor poles

Back EMF at 1000 rpm

Motor type = IPM

Motor type = SPM

d-axis Inductance Sat. (LdSat)

[0]

3.8

3000

RPM

5.4

0.65

Ohms

Start Mode

Rotor Detection

[0]

Position Detection Gain

Off

100

Locked Rotor Detection

[0]

Locked Rotor Detection Time[s]

0.10

q-axis Inductance (Lq)

1.10

400

Max Output Frequency

Motor Cable Length

4.66

1420

RPM

[0]

PM motor

Set Motor Speed low Limit

Set Motor Speed high Limit

Set Ramp 1 ramp-up time

Set Ramp 1 ramp-down Time

Active Flying start ?

Disable

Set T53 low Voltage

Set T53 high Voltage

Set T53 Low Current

Set T53 High Current

Voltage

AMA Failed

Automatic Motor Adaption

Auto Motor Adapt OK Press OK

Select Function of Relay 2 No function

Off

Select Function of Relay 1 [0] No function

Set Max Reference

Set Min Reference

AMA running

-----

Do AMA

(Do not AMA)

AMA OK

[0]

Select T53 Mode

Current

Motor type = Induction

Motor type = PM motor

0000

0050

0010

[0]

04.66

13.30

0050

0220

0000

0050

The next screen is the Wizard screen.

Power-up Screen

e30bu808.12

q-axis Inductance Sat. (LqSat)

Current at Min Inductance for d-axis

100

Current at Min Inductance for q-axis

100

d-axis Inductance (Lq)

... the Wizard starts

0-** FC-xxx Wizard

2-** Motor Setup

Status

Quick Menu

Main

Com.

Warn.

Alarm

Hand

Off

Reset

Auto

Back

1-** Closed Loop Set

0.0 Hz

Auto On

Status

Quick Menu

Main

Com.

Warn.

Alarm

Hand

Off

Reset

Auto

Back

0.000 kW

1 (1)

VLT® Flow Drive FC 111

Operating Guide

6.2.2 Setup Wizard for Open-loop Applications

Programming

Illustration 23: Setup Wizard for Open-loop Applications

•

Parameter

Option

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

[10] 380–440 V/50 Hz/IT-grid [11] 380–440 V/50 Hz/Delta [12] 380–440 V/50 Hz [20] 440–480 V/50 Hz/IT-grid [21] 440–480 V/50 Hz/Delta [22] 440–480 V/50 Hz [110] 380–440 V/60 Hz/IT-grid [111] 380–440 V/60 Hz/Delta [112] 380–440 V/60 Hz [120] 440–480 V/60 Hz/IT-grid [121] 440–480 V/60 Hz/Delta [122] 440–480 V/60 Hz

Size related

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

N O T I C E

Compared to 380–440 V groups, when selecting 440–

480 V groups, the rated current decreases accordingly.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

Parameter 1-48 Current at Min Inductance for d-axis.

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

VLT® Flow Drive FC 111

Operating Guide

Table 17: Setup Wizard for Open-loop Applications

Programming

•

Parameter

Option

Default

Usage

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

Parameter 4-14 Motor Speed High Limit [Hz].

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–1000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–9999 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–1000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-29 Automatic Motor Adaption (AMA)

See parameter 1-29 Automatic Motor Adaption (AMA).

Off

Performing an AMA optimizes motor performance.

Parameter 1-30 Stator Resistance (Rs)

0.000–99.990 Ω

Size related

Set the stator resistance value.

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Option

Default

Usage

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

This parameter corresponds to the inductance saturation of Ld. Ideally, this parameter has the same value as parameter 1-37 d-axis Inductance (Ld). However, if the motor supplier provides an induction curve, enter the induction value, which is 200% of the nominal current.

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

This parameter corresponds to the inductance saturation of Lq. Ideally, this parameter has the same value as parameter 1-38 q-axis Inductance (Lq). However, if the motor supplier provides an induction curve, enter the induction value, which is 200% of the nominal current.

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a motor spinning due to mains drop-out. Select [0] Disabled if this function is not required. When this parameter is set to [1] Ena-

bled, parameter 1-71 Start Delay and parameter 1-72 Start Function are not functional. Parameter 1-73 Flying Start is ac-

tive in VVC+ mode only.

Parameter 3-02 Minimum Reference

-4999.000–4999.000

The minimum reference is the lowest value obtainable by summing all references.

Parameter 3-03 Maximum Reference

-4999.000–4999.000

The maximum reference is the lowest obtainable by summing all references.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Option

Default

Usage

Parameter 3-41 Ramp 1 Ramp Up Time

0.01–3600.00 s

Size related

If induction motor is selected, the ramp-up time is from 0 to rated parameter 1-23 Motor Frequency. If PM motor is selected, the ramp-up time is from 0 to parameter 1-25 Motor

Nominal Speed.

Parameter 3-42 Ramp 1 Ramp Down Time

0.01–3600.00 s

Size related

For induction motors, the ramp-down time is from rated pa- rameter 1-23 Motor Frequency to 0. For PM motors, the rampdown time is from parameter 1-25 Motor Nominal Speed to 0.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100 Hz

Enter the maximum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100 Hz

Enter the maximum output frequency value. If parameter 4-19 Max Output Frequency is set lower than parameter 4-14 Motor Speed High Limit [Hz], parameter 4-14 Motor Speed High Limit [Hz] is set equal to parameter 4-19 Max Output Frequency automatically.

Parameter 5-40 Function Relay

See parameter 5-40 Function Relay.

[9] Alarm

Select the function to control output relay 1.

Parameter 5-40 Function Relay

See parameter 5-40 Function Relay.

[5] Drive running

Select the function to control output relay 2.

Parameter 6-10 Terminal 53 Low Voltage

0.00–10.00 V

0.07 V

Enter the voltage that corresponds to the low reference value.

Parameter 6-11 Terminal 53 High Voltage

0.00–10.00 V

10 V

Enter the voltage that corresponds to the high reference value.

Parameter 6-12 Terminal 53 Low Current

0.00–20.00 mA

4 mA

Enter the current that corresponds to the low reference value.

Parameter 6-13 Terminal 53 High Current

0.00–20.00 mA

20 mA

Enter the current that corresponds to the high reference value.

Parameter 6-19 Terminal 53 mode

[0] Current [1] Voltage

[1] Voltage

Select if terminal 53 is used for current or voltage input.

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1 s

0.10 s

–

VLT® Flow Drive FC 111

Operating Guide

Programming

6-29 Terminal 54 Mode

[1]

Voltage

6-25 T54 high Feedback

0050

20-94 PI integral time

0020.00

Current

Voltage

This dialog is forced to be set to [1] Analog input 54

20-00 Feedback 1 source

[1]

Analog input 54

3-10 Preset reference [0]

0.00

3-03 Max Reference

50.00

3-02 Min Reference

0.00

Induction motor

1-73 Flying Start

[0]

1-22 Motor Voltage

400

1-24 Motor Current

04.66

1-25 Motor nominal speed

1420

RPM

3-41 Ramp 1 ramp-up time

0010

3-42 Ramp1 ramp-down time

0010

0-06 Grid Type

4-12 Motor speed low limit

0016

4-14 Motor speed high limit

0050

e30bc402.16

1-20 Motor Power

1.10

1-23 Motor Frequency

6-22 T54 Low Current

6-24 T54 low Feedback

0016

6-23 T54 high Current

13.30

6-25 T54 high Feedback

0050

0.01

20-81 PI Normal/Inverse Control

[0]

Normal

20-83 PI Normal/Inverse Control

0050

20-93 PI Proportional Gain

00.50

1-29 Automatic Motor Adaption

[0]

Off

6-20 T54 low Voltage

0050

6-24 T54 low Feedback

0016

6-21 T54 high Voltage

0220

6-26

T54 Filter time const.

1-00 Configuration Mode

[3]

Closed Loop

0-03 Regional Settings

[0]

Power kW/50 Hz

3-16 Reference Source 2

[0]

No Operation

1-10 Motor Type

[0]

Asynchronous

[0]

200-240V/50Hz/Delta

1-30 Stator Resistance

0.65

Ohms

1-25 Motor Nominal Speed

3000

RPM

1-24 Motor Current

3.8

1-26 Motor Cont. Rated Torque

5.4

1-38 q-axis inductance(Lq)

4-19 Max Ouput Frequency

0065

1-40 Back EMF at 1000 RPM

PM motor

1-39 Motor Poles

04.66

Motor type = Induction

Motor type = PM motor

Motor type = IPM

Motor type = SPM

1-44 d-axis Inductance Sat. (LdSat)

(1-70) Start Mode

Rotor Detection

[0]

1-46 Position Detection Gain

Off

100

30-22 Locked Rotor Detection

[0]

30-23 Locked Rotor Detection Time[s]

0.10

1-42 Motor Cable Length

(1-45) q-axis Inductance Sat. (LqSat)

(1-48) Current at Min Inductanc e for d-axis

100

1-49 Current at Min Inductanc e for q-axis

100

1-37 d-axis inductance(Lq)

... the Wizard starts

VLT® Flow Drive FC 111

Operating Guide

6.2.3 Setup Wizard for Closed-loop Applications

Programming

Illustration 24: Setup Wizard for Closed-loop Applications

•

Parameter

Range

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

Size selected

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

Parameter 1-00 Configuration Mode

[0] Open loop [3] Closed loop

[0] Open loop

Select [3] Closed loop.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

Parameter 1-48 Current at Min Inductance for d-axis.

VLT® Flow Drive FC 111

Operating Guide

Table 18: Setup Wizard for Closed-loop Applications

Programming

•

Parameter

Range

Default

Usage

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

Parameter 4-14 Motor Speed High Limit [Hz].

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–1000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–60000 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–10000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-29 Automatic Motor Adaption (AMA)

–

Off

Performing an AMA optimizes motor performance.

Parameter 1-30 Stator Resistance (Rs)

0.000–9999.000 Ω

Size related

Set the stator resistance value.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a spinning motor in, for example, fan applications. When PM is selected, this parameter is enabled.

Parameter 3-02 Minimum Reference

-4999.000–4999.000

The minimum reference is the lowest value obtainable by summing all references.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Range

Default

Usage

Parameter 3-03 Maximum Reference

-4999.000–4999.000

The maximum reference is the highest value obtainable by summing all references.

Parameter 3-10 Preset Reference

-100–100%

Enter the setpoint.

Parameter 3-41 Ramp 1 Ramp Up Time

0.05–3600.0 s

Size related

Ramp-up time from 0 to rated parameter 1-23 Motor Frequen-

cy for induction motors. Ramp-up time from 0 to parameter 1-25 Motor Nominal Speed for PM motors.

Parameter 3-42 Ramp 1 Ramp Down Time

0.05–3600.0 s

Size related

Ramp-down time from rated parameter 1-23 Motor Frequency to 0 for induction motors. Ramp-down time from parameter

1-25 Motor Nominal Speed to 0 for PM motors.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0.0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100 Hz

Enter the minimum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100 Hz

Parameter 6-20 Terminal 54 Low Voltage

0.00–10.00 V

0.07 V

Enter the voltage that corresponds to the low reference value.

Parameter 6-21 Terminal 54 High Voltage

0.00–10.00 V

10.00 V

Enter the voltage that corresponds to the high reference value.

Parameter 6-22 Terminal 54 Low Current

0.00–20.00 mA

4.00 mA

Enter the current that corresponds to the low reference value.

Parameter 6-23 Terminal 54 High Current

0.00–20.00 mA

20.00 mA

Enter the current that corresponds to the high reference value.

Parameter 6-24 Terminal 54 Low Ref./Feedb. Value

-4999–4999

Enter the feedback value that corresponds to the voltage or current set in parameter 6-20 Terminal 54 Low Voltage/param-

eter 6-22 Terminal 54 Low Current.

Parameter 6-25 Terminal 54 High Ref./ Feedb. Value

-4999–4999

Enter the feedback value that corresponds to the voltage or current set in parameter 6-21 Terminal 54 High Voltage/pa-

rameter 6-23 Terminal 54 High Current.

Parameter 6-26 Terminal 54 Filter Time Constant

0.00–10.00 s

0.01

Enter the filter time constant.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Range

Default

Usage

Parameter 6-29 Terminal 54 mode

[0] Current [1] Voltage

[1] Voltage

Select if terminal 54 is used for current or voltage input.

Parameter 20-81 PI Normal/Inverse Control

[0] Normal [1] Inverse

[0] Normal

Select [0] Normal to set the process control to increase the output speed when the process error is positive. Select [1] In-

verse to reduce the output speed.

Parameter 20-83 PI Start Speed [Hz]

0–200 Hz

0 Hz

Enter the motor speed to be attained as a start signal for commencement of PI control.

Parameter 20-93 PI Proportional Gain

0.00–10.00

0.01

Enter the process controller proportional gain. Quick control is obtained at high amplification. However, if amplification is too high, the process may become unstable.

Parameter 20-94 PI Integral Time

0.1–999.0 s

999.0 s

Enter the process controller integral time. Obtain quick control through a short integral time, though if the integral time is too short, the process becomes unstable. An excessively long integral time disables the integral action.

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1.00 s

0.10 s

–

Parameter

Range

Default

Usage

Parameter 0-03 Regional Settings

[0] International [1] US

[0] International

–

Parameter 0-06 GridType

Size selected

Select the operating mode for restart after reconnection of the drive to mains voltage after power down.

Parameter 1-10 Motor Construction

*[0] Asynchron [1] PM, non-salient SPM [3] PM, salient IPM

[0] Asynchron

Setting the parameter value might change these parameters:

VLT® Flow Drive FC 111

Operating Guide

Programming

6.2.4 Motor Setup

The motor setup wizard guides users through the needed motor parameters.

Table 19: Motor Setup Wizard Settings

•

Parameter

Range

Default

Usage

Parameter 1-01 Motor Control Principle.

Parameter 1-03 Torque Characteristics.

Parameter 1-08 Motor Control Bandwidth.

Parameter 1-14 Damping Gain.

Parameter 1-15 Low Speed Filter Time Const.

Parameter 1-16 High Speed Filter Time Const.

Parameter 1-17 Voltage Filter Time Const.

Parameter 1-20 Motor Power.

Parameter 1-22 Motor Voltage.

Parameter 1-23 Motor Frequency.

Parameter 1-24 Motor Current.

Parameter 1-25 Motor Nominal Speed.

Parameter 1-26 Motor Cont. Rated Torque.

Parameter 1-30 Stator Resistance (Rs).

Parameter 1-33 Stator Leakage Reactance (X1).

Parameter 1-35 Main Reactance (Xh).

Parameter 1-37 d-axis Inductance (Ld).

Parameter 1-38 q-axis Inductance (Lq).

Parameter 1-39 Motor Poles.

Parameter 1-40 Back EMF at 1000 RPM.

Parameter 1-44 d-axis Inductance Sat. (LdSat).

Parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-46 Position Detection Gain.

Parameter 1-48 Current at Min Inductance for d-axis.

Parameter 1-49 Current at Min Inductance for q-axis.

Parameter 1-66 Min. Current at Low Speed.

Parameter 1-70 PM Start Mode.

Parameter 1-72 Start Function.

Parameter 1-73 Flying Start.

Parameter 1-80 Function at Stop.

Parameter 1-82 Min Speed for Function at Stop [Hz].

Parameter 1-90 Motor Thermal Protection.

Parameter 2-00 DC Hold/Motor Preheat Current.

Parameter 2-01 DC Brake Current.

Parameter 2-02 DC Braking Time.

Parameter 2-04 DC Brake Cut In Speed.

Parameter 2-10 Brake Function.

Parameter 4-14 Motor Speed High Limit [Hz].

Parameter 4-19 Max Output Frequency.

Parameter 4-58 Missing Motor Phase Function.

Parameter 14-65 Speed Derate Dead Time Compensation.

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-20 Motor Power

0.18–110 kW/0.25–150 hp

Size related

Enter the motor power from the nameplate data.

Parameter 1-22 Motor Voltage

50–1000 V

Size related

Enter the motor voltage from the nameplate data.

Parameter 1-23 Motor Frequency

20–400 Hz

Size related

Enter the motor frequency from the nameplate data.

Parameter 1-24 Motor Current

0.01–10000.00 A

Size related

Enter the motor current from the nameplate data.

Parameter 1-25 Motor Nominal Speed

50–9999 RPM

Size related

Enter the motor nominal speed from the nameplate data.

Parameter 1-26 Motor Cont. Rated Torque

0.1–1000.0 Nm

Size related

This parameter is available when parameter 1-10 Motor Con- struction is set to options that enable permanent motor mode.

N O T I C E

Changing this parameter affects the settings of other pa-

rameters.

Parameter 1-30 Stator Resistance (Rs)

0–99.990 Ω

Size related

Set the stator resistance value.

Parameter 1-37 d-axis Inductance (Ld)

0.000–1000.000 mH

Size related

Enter the value of the d-axis inductance. Obtain the value from the permanent magnet motor datasheet.

Parameter 1-38 q-axis Inductance (Lq)

0.000–1000.000 mH

Size related

Enter the value of the q-axis inductance.

Parameter 1-39 Motor Poles

2–100

Enter the number of motor poles.

Parameter 1-40 Back EMF at 1000 RPM

10–9000 V

Size related

Line-line RMS back EMF voltage at 1000 RPM.

Parameter 1-42 Motor Cable Length

0–100 m

50 m

Enter the motor cable length.

Parameter 1-44 d-axis Inductance Sat. (LdSat)

0.000–1000.000 mH

Size related

Parameter 1-45 q-axis Inductance Sat. (LqSat)

0.000–1000.000 mH

Size related

VLT® Flow Drive FC 111

Operating Guide

Programming

Parameter

Range

Default

Usage

Parameter 1-46 Position Detection Gain

20–200%

100%

Adjusts the height of the test pulse during position detection at start.

Parameter 1-48 Current at Min Inductance for d-axis

20–200%

100%

Enter the inductance saturation point.

Parameter 1-49 Current at Min Inductance for q-axis

20–200%

100%

This parameter specifies the saturation curve of the d- and qinductance values. From 20–100% of this parameter, the inductances are linearly approximated due to parameter 1-37

d-axis Inductance (Ld), parameter 1-38 q-axis Inductance (Lq), parameter 1-44 d-axis Inductance Sat. (LdSat), and parameter 1-45 q-axis Inductance Sat. (LqSat).

Parameter 1-70 PM Start Mode

[0] Rotor Detection [1] Parking [3] Rotor Last Position

[1] Parking

Select the PM motor start mode.

Parameter 1-73 Flying Start

[0] Disabled [1] Enabled

[0] Disabled

Select [1] Enabled to enable the drive to catch a spinning motor.

Parameter 3-41 Ramp 1 Ramp Up Time

0.05–3600.0 s

Size related

Ramp-up time from 0 to rated parameter 1-23 Motor Frequen-

cy.

Parameter 3-42 Ramp 1 Ramp Down Time

0.05–3600.0 s

Size related

Ramp-down time from rated parameter 1-23 Motor Frequency to 0.

Parameter 4-12 Motor Speed Low Limit [Hz]

0.0–400.0 Hz

0.0 Hz

Enter the minimum limit for low speed.

Parameter 4-14 Motor Speed High Limit [Hz]

0.0–400.0 Hz

100.0 Hz

Enter the maximum limit for high speed.

Parameter 4-19 Max Output Frequency

0.0–400.0 Hz

100.0 Hz

Parameter 30-22 Locked Rotor Detection

[0] Off [1] On

[0] Off

–

Parameter 30-23 Locked Rotor Detection Time [s]

0.05–1.00 s

0.10 s

–

VLT® Flow Drive FC 111

Operating Guide

Programming

VLT® Flow Drive FC 111

Operating Guide

6.2.5 Changes Made Function

The changes made function lists all parameters changed from default settings.

•

The list shows only parameters that have been changed in the current edit setup.

•

Parameters that have been reset to default values are not listed.

•

The message Empty indicates that no parameters have been changed.

6.2.6 Changing Parameter Settings

Procedure

To enter the Quick Menu, press the [Menu] key until the indicator in the display is placed above Quick Menu.

Press [▵] [▿] to select the wizard, closed-loop setup, motor setup, or changes made.

Press [OK].

Press [▵] [▿] to browse through the parameters in the Quick Menu.

Press [OK] to select a parameter.

Press [▵] [▿] to change the value of a parameter setting.

Press [OK] to accept the change.

Press either [Back] twice to enter Status, or press [Menu] once to enter the Main Menu.

6.2.7 Accessing All Parameters via the Main Menu

Procedure

Press the [Menu] key until the indicator in the display is placed above Main Menu.

Press [▵] [▿] to browse through the parameter groups.

Press [OK] to select a parameter group.

Press [▵] [▿] to browse through the parameters in the specific group.

Press [OK] to select the parameter.

Press [▵] [▿] to set/change the parameter value.

Press [OK] to accept the change.

Programming

Parameter

Option/value

Parameter 1-10 Motor Construction

[0] Asynchron

Parameter 1-20 Motor Power

Configuration dependent

Parameter 1-22 Motor Voltage

Configuration dependent

Parameter 1-23 Motor Frequency

Configuration dependent

Parameter 1-24 Motor Current

Configuration dependent

Parameter 1-25 Motor Nominal Speed

Configuration dependent

Parameter 1-29 Automatic Motor Adaption (AMA)

[0] Off

Parameter 1-39 Motor Poles

–

Parameter 1-40 Back EMF at 1000 RPM

–

Parameter 1-73 Flying start

[0] Disabled

Parameter 3-02 Minimum Reference

Parameter 3-03 Maximum Reference

Parameter 3-10 [0] Preset Reference

–

Parameter 3-15 Reference 1 Source

[1] Analog Input 53

Parameter 3-16 Reference 2 Source

[0] No function

Parameter 3-17 Reference 3 Source

[11] Local bus reference

Parameter 3-41 Ramp 1 Ramp Up Time

10.00 s

Parameter 3-42 Ramp 1 Ramp Down Time

10.00 s

Parameter 4-12 Motor Speed Low Limit [Hz]

0 Hz

Parameter 4-14 Motor Speed High Limit [Hz]

100 Hz

Parameter 5-10 Terminal 18 Digital Input

[8] Start

Parameter 5-11 Terminal 19 Digital Input

[0] No operation

Parameter 5-40 [1] Function Relay

[9] Alarm

Parameter 5-40 [2] Function Relay

[5] Drive running

VLT® Flow Drive FC 111

Operating Guide

Applications

7 Applications

7.1 Application Selections

Use the 4 selections for quick application setup of the most common applications via changing the setting of parameter 0-16 Appli- cation Selection.

Open loop control.

•

Process closed loop control.

•

Constant pressure water supply.

•

Multiple pump control.

•

7.1.1 Open Loop

Table 20: Parameter settings

Parameter

Option/value

Parameter 6-10 Terminal 53 Low Voltage

0.07 V

Parameter 6-11 Terminal 53 High Voltage

10 V

Parameter 6-12 Terminal 53 Low Current

4 mA

Parameter 6-13 Terminal 53 High Current

20 mA

Parameter 6-14 Terminal 53 Low Ref./Feedb. Value

Parameter 6-15 Terminal 53 High Ref./Feedb. Value

50.0

Parameter 6-19 Terminal 53 mode

[1] Voltage mode

Parameter 8-01 Control Site

–

Parameter 8-02 Control Source

–

Parameter 8-03 Control Timeout Time

–

Parameter 8-04 Control Timeout Function

–

Parameter

Option/value

Parameter 1-00 Configuration Mode

[3] Process Closed Loop

Parameter 1-10 Motor Construction

[0] Asynchron

Parameter 1-20 Motor Power

Configuration dependent

Parameter 1-22 Motor Voltage

Configuration dependent

Parameter 1-23 Motor Frequency

Configuration dependent

Parameter 1-24 Motor Current

Configuration dependent

Parameter 1-25 Motor Nominal Speed

Configuration dependent

Parameter 1-29 Automatic Motor Adaption (AMA)

[0] Off

Parameter 1-39 Motor Poles

–

Parameter 1-40 Back EMF at 1000 RPM

–

Parameter 1-73 Flying start

[0] Disabled

Parameter 3-02 Minimum Reference

Parameter 3-03 Maximum Reference

Parameter 3-15 Reference 1 Source

[1] Analog Input 53

Parameter 3-16 Reference 2 Source

[0] No function

Parameter 3-17 Reference 3 Source

[11] Local bus reference

Parameter 3-41 Ramp 1 Ramp Up Time

10.00 s

Parameter 3-42 Ramp 1 Ramp Down Time

10.00 s

VLT® Flow Drive FC 111

Operating Guide

Applications

7.1.2 Process Closed Loop

Table 21: Parameter settings

Parameter

Option/value

Parameter 4-12 Motor Speed Low Limit [Hz]

0 Hz

Parameter 4-14 Motor Speed High Limit [Hz]

50 Hz

Parameter 5-10 Terminal 18 Digital Input

[8] Start

Parameter 5-11 Terminal 19 Digital Input

[0] No operation

Parameter 5-40 [1] Function Relay

[9] Alarm

Parameter 5-40 [2] Function Relay

[5] Drive running

Parameter 6-10 Terminal 53 Low Voltage

0.07 V

Parameter 6-11 Terminal 53 High Voltage

10 V

Parameter 6-12 Terminal 53 Low Current

4 mA

Parameter 6-13 Terminal 53 High Current

20 mA

Parameter 6-14 Terminal 53 Low Ref./Feedb. Value

Parameter 6-15 Terminal 53 High Ref./Feedb. Value

50.0

Parameter 6-19 Terminal 53 mode

[1] Voltage mode

Parameter 6-20 Terminal 54 Low Voltage

0.07 V

Parameter 6-21 Terminal 54 High Voltage

10 V

Parameter 6-22 Terminal 54 Low Current

4 mA

Parameter 6-23 Terminal 54 High Current

20 mA

Parameter 6-24 Terminal 54 Low Ref./Feedb. Value

Parameter 6-25 Terminal 54 High Ref./Feedb. Value

Parameter 6-26 Terminal 54 Filter Time Constant

0.01 s

Parameter 6-29 Terminal 54 mode

[1] Voltage mode

Parameter 8-01 Control Site

–

Parameter 8-02 Control Source

–

Parameter 8-03 Control Timeout Time

–

Parameter 8-04 Control Timeout Function

–

Parameter 20-00 Feedback 1 Source

[2] Analog Input 54

Parameter 20-01 Feedback 1 Conversion

–

Parameter 20-12 Reference/Feedback Unit

–

Parameter 20-21 Setpoint 1

–

Parameter 20-81 PI Normal/ Inverse Control

[0] Normal

VLT® Flow Drive FC 111

Operating Guide

Applications

Parameter

Option/value

Parameter 20-83 PI Start Speed [Hz]

0 Hz

Parameter 20-93 PI Proportional Gain

0.50

Parameter 20-94 PI Integral Time

20 s

Parameter

Option/value

Parameter 1-00 Configuration Mode

[3] Process Closed Loop

Parameter 1-01 Motor Control Principle

[0] U/f

Parameter 1-10 Motor Construction

–

Parameter 1-20 Motor Power

Configuration dependent

Parameter 1-22 Motor Voltage

Configuration dependent

Parameter 1-23 Motor Frequency

Configuration dependent

Parameter 1-24 Motor Current

Configuration dependent

Parameter 1-26 Motor Cont. Rated Torque

Configuration dependent

Parameter 1-39 Motor Poles

–

Parameter 1-40 Back EMF at 1000 RPM

–

Parameter 3-03 Maximum Reference

Parameter 3-15 Reference 1 Source

[0] No function

Parameter 3-16 Reference 2 Source

[0] No function

Parameter 3-17 Reference 3 Source

[11] Local bus reference

Parameter 3-41 Ramp 1 Ramp Up Time

10.00 s

Parameter 3-42 Ramp 1 Ramp Down Time

10.00 s

Parameter 4-12 Motor Speed Low Limit [Hz]

25 Hz

Parameter 4-14 Motor Speed High Limit [Hz]

100 Hz

Parameter 4-19 Max Output Frequency

100.0 Hz

Parameter 4-40 Warning Freq. Low

0 Hz

Parameter 4-41 Warning Freq. High

100 Hz

Parameter 4-57 Warning Feedback High

4999 ProcessCtrlUnit

Parameter 5-12 Terminal 27 Digital Input

[2] Coast inverse

Parameter 5-40 [1] Function Relay

–

Parameter 5-40 [2] Function Relay

–

Parameter 6-10 Terminal 53 Low Voltage

0.07 V

VLT® Flow Drive FC 111

Operating Guide

7.1.3 Constant Pressure Water Supply

Table 22: Parameter settings

Applications

Parameter

Option/value

Parameter 6-11 Terminal 53 High Voltage

10 V

Parameter 6-12 Terminal 53 Low Current

4 mA

Parameter 6-13 Terminal 53 High Current

20 mA

Parameter 6-14 Terminal 53 Low Ref./Feedb. Value

Parameter 6-15 Terminal 53 High Ref./Feedb. Value

–

Parameter 6-19 Terminal 53 mode

[0] Current mode

Parameter 6-20 Terminal 54 Low Voltage

0.07 V

Parameter 6-21 Terminal 54 High Voltage

10 V

Parameter 6-22 Terminal 54 Low Current

4 mA

Parameter 6-23 Terminal 54 High Current

20 mA

Parameter 6-24 Terminal 54 Low Ref./Feedb. Value

Parameter 6-25 Terminal 54 High Ref./Feedb. Value

–

Parameter 6-29 Terminal 54 mode

[0] Current mode

Parameter 6-70 Terminal 45 Mode

[0] 0-20 mA

Parameter 6-71 Terminal 45 Analog Output

[100] Output frequency

Parameter 6-73 Terminal 45 Output Min Scale

Parameter 6-74 Terminal 45 Output Max Scale

50%

Parameter 6-90 Terminal 42 Mode

[1] 4-20 mA

Parameter 6-91 Terminal 42 Analog Output

[102] Feedback

Parameter 6-93 Terminal 42 Output Min Scale

50%

Parameter 6-94 Terminal 42 Output Max Scale

75%

Parameter 8-31 Address

Parameter 8-32 Baud Rate

[2] 9600 Baud

Parameter 8-33 Parity / Stop Bits

[2] No Parity, 1 Stop Bit

Parameter 8-43 [0] PCD Read Configuration

[7] [1603] Status Word

Parameter 8-43 [1] PCD Read Configuration

[8] [1605] Main Actual Value [%]

Parameter 8-43 [2] PCD Read Configuration

[13] [1613] Frequency

Parameter 8-43 [3] PCD Read Configuration

[13] [1613] Frequency

Parameter 8-43 [4] PCD Read Configuration

[15] [1615] Frequency [%]

Parameter 8-80 Bus Message Count

–

Parameter 14-20 Reset Mode

[3] Automatic reset x 3

Parameter 15-43 Software Version

VLT® Flow Drive FC 111

Operating Guide

Applications

Parameter

Option/value

Parameter 20-00 Feedback 1 Source

[1] Analog Input 53

Parameter 20-21 Setpoint 1

Parameter 20-81 PI Normal/ Inverse Control

[0] Normal

Parameter 20-93 PI Proportional Gain

Parameter 20-94 PI Integral Time

1 s

Parameter 22-40 Minimum Run Time

60 s

Parameter 22-41 Minimum Sleep Time

5 s

Parameter 22-43 Wake-Up Speed [Hz]

49 Hz

Parameter 22-44 Wake-Up Ref./FB Diff

Parameter 22-45 Setpoint Boost

Parameter 22-46 Maximum Boost Time

30 s

Parameter 22-47 Sleep Speed [Hz]

37 Hz

Parameter 22-48 Sleep Delay Time

10 s

Parameter 22-49 Wake-Up Delay Time

0 s

Parameter

Option/value

Parameter 1-00 Configuration Mode

[3] Process Closed Loop

Parameter 1-01 Motor Control Principle

[0] U/f

Parameter 1-20 Motor Power

Configuration dependent

Parameter 1-22 Motor Voltage

Configuration dependent

Parameter 1-23 Motor Frequency

Configuration dependent

Parameter 1-24 Motor Current

Configuration dependent

Parameter 1-26 Motor Cont. Rated Torque

Configuration dependent

Parameter 1-39 Motor Poles

–

Parameter 3-03 Maximum Reference

50.0

Parameter 3-15 Reference 1 Source

[1] Analog Input 53

Parameter 3-16 Reference 2 Source

[0] No function

Parameter 3-41 Ramp 1 Ramp Up Time

10.00 s

Parameter 3-42 Ramp 1 Ramp Down Time

10.00 s

Parameter 4-12 Motor Speed Low Limit [Hz]

25 Hz

Parameter 4-14 Motor Speed High Limit [Hz]

50 Hz

VLT® Flow Drive FC 111

Operating Guide

Applications

7.1.4 Multiple Pump Control

Table 23: Parameter settings

Parameter

Option/value

Parameter 5-11 Terminal 19 Digital Input

[130] Pump 1 Interlock

Parameter 5-13 Terminal 29 Digital Input

[131] Pump 2 Interlock

Parameter 5-40 [1] Function Relay

–

Parameter 5-40 [2] Function Relay

–

Parameter 5-41 On Delay, Relay

0.01 s

Parameter 5-42 Off Delay, Relay

0.01 s

Parameter 6-10 Terminal 53 Low Voltage

0.07 V

Parameter 6-11 Terminal 53 High Voltage

10 V

Parameter 6-12 Terminal 53 Low Current

–

Parameter 6-13 Terminal 53 High Current

–

Parameter 6-14 Terminal 53 Low Ref./Feedb. Value

Parameter 6-15 Terminal 53 High Ref./Feedb. Value

–

Parameter 6-19 Terminal 53 mode

[1] Voltage mode

Parameter 6-20 Terminal 54 Low Voltage

0.07 V

Parameter 6-21 Terminal 54 High Voltage

10 V

Parameter 6-22 Terminal 54 Low Current

–

Parameter 6-23 Terminal 54 High Current

–

Parameter 6-24 Terminal 54 Low Ref./Feedb. Value

Parameter 6-25 Terminal 54 High Ref./Feedb. Value

–

Parameter 6-29 Terminal 54 mode

[1] Voltage mode

Parameter 20-00 Feedback 1 Source

[2] Analog Input 54

Parameter 20-21 Setpoint 1

Parameter 20-81 PI Normal/ Inverse Control

[0] Normal

Parameter 20-93 PI Proportional Gain

Parameter 20-94 PI Integral Time

1 s

Parameter 22-40 Minimum Run Time

60 s

Parameter 22-41 Minimum Sleep Time

5 s

Parameter 22-43 Wake-Up Speed [Hz]

49 Hz

Parameter 22-44 Wake-Up Ref./FB Diff

Parameter 22-45 Setpoint Boost

Parameter 22-46 Maximum Boost Time

30 s

Parameter 22-47 Sleep Speed [Hz]

37 Hz

VLT® Flow Drive FC 111

Operating Guide

Applications

Parameter

Option/value

Parameter 22-48 Sleep Delay Time

10 s

Parameter 22-49 Wake-Up Delay Time

0 s

Parameter 25-00 Cascade Controller

[1] Enabled

Parameter 25-04 Pump Cycling

[1] Enabled

Parameter 25-05 Fixed Lead Pump

[0] No

Parameter 25-06 Number of Pumps

Parameter 25-20 Staging Bandwidth

–

Parameter 25-21 Override Bandwidth

–

Parameter 25-22 Fixed Speed Bandwidth

–

Parameter 25-23 SBW Staging Delay

25 s

Parameter 25-24 SBW Destaging Delay

15 s

Parameter 25-25 OBW Time

10 s

Parameter 25-27 Stage Function

[1] Enabled

Parameter 25-28 Stage Function Time

15 s

Parameter 25-29 Destage Function

[1] Enabled

Parameter 25-30 Destage Function Time

15 s

Parameter 25-42 Staging Threshold

96%

Parameter 25-43 Destaging Threshold

50%

Parameter 25-50 Lead Pump Alternation

[3] At staging or command

Parameter 25-51 Alternation Event

[1] Alternation Time Interval

Parameter 25-52 Alternation Time Interval

8 h

Parameter 25-56 Staging Mode at Alternation

[1] Quick

Parameter 25-57 Relays per Pump

Parameter 25-58 Run Next Pump Delay

1.1 s

Parameter 25-59 Run on Mains Delay

2.1 s

VLT® Flow Drive FC 111

Operating Guide

Applications

e30ba362.10

Variable speed pumps (1)

Constant speed pumps (2)

Pressure sensor

Drive with cascade controller

Motor starter

VLT® Flow Drive FC 111

Operating Guide

8 Cascade Controller

8.1 Introduction

8.1.1 Cascade Controller

Illustration 25: Cascade Controller

Cascade Controller

The cascade controller is used for pump applications where a certain pressure (head) or level needs to be maintained over a wide dynamic range. Running a large pump at variable speed over a wide range is not an ideal solution because of low pump efficiency, and because there is a practical limit of about 25% rated full load speed for running a pump.

In the cascade controller, the drive controls a variable speed motor as the variable speed pump (lead) and can stage up to 2 additional constant speed pumps on and off. By varying the speed of the initial pump, variable speed control of the entire system is provided, which maintains constant pressure while eliminating pressure surges, resulting in reduced system stress and quieter operation in pumping systems.

8.1.2 Fixed Lead Pump

The motors must be of equal size. The cascade controller allows the drive to control up to 5 equal size pumps using the 2 built-in relays of the drive and terminals 27, 29 (digital input/digital output). When the variable pump (lead) is connected directly to the drive, the other 4 pumps are controlled by the 2 built-in relays and terminals 27, 29 (digital input/digital output). Lead pump alternation cannot be selected when lead pump is fixed.

8.1.3 Lead Pump Alternation

The motors must be of equal size. This function makes it possible to cycle the drive between the pumps in the system (when param- eter 25-57 Relays per Pump=1, the maximum number of pumps is 4. When parameter 25-57 Relays per Pump=2, the maximum number of pumps is 3). In this operation, the run time between pumps is equalized reducing the required pump maintenance and increasing reliability and lifetime of the system. The alternation of the lead pump can take place at a command signal or at staging (adding lag pump).

The command can be a manual alternation or an alternation event signal. If the alternation event is selected, the lead pump alternation takes place every time the event occurs. Selections include whenever an alternation timer expires, when the lead pump goes into sleep mode. Staging is determined by the actual system load.

When parameter 25-55 Alternate if Load <= 50% is set to [1] Enabled, alternation does not happen if the load exceeds 50%. If load <50%, alternation happens. When parameter 25-55 Alternate if Load <= 50% is set to [0] Disabled, alternation happens regardless of the load. The total pump capacity is determined as lead pump plus lag speed pumps capacities.

8.1.4 Bandwidth Management

In cascade control systems, to avoid frequent switching of fixed-speed pumps, the desired system pressure is kept within a bandwidth rather than at a constant level. The staging bandwidth provides the required bandwidth for operation. When a large and quick change in system pressure occurs, the override bandwidth overrides the staging bandwidth to prevent immediate response

e75za673.10

Override bandwidth

SBW3Setpoint

Digital input commands

Variable speed pump (lead)

Fixed-speed pumps (lag)

Start (system start/stop)

Ramps up (if stopped and there is a demand)

Staging (if stopped and there is a demand) Lead pump start

Ramps up if system start is active

Not affected

Coast (emergency stop)

Coast to stop

Cut out (corresponding relays, terminal 27/29 and 42/45)

External interlock

Coast to stop

Cut out (built-in relays are deenergized)

VLT® Flow Drive FC 111

Operating Guide

Cascade Controller

to a short duration pressure change. An override bandwidth timer can be programmed to prevent staging until the system pressure has stabilized and normal control established.

When the cascade controller is enabled and running normally, and the drive issues a trip alarm, the system head is maintained by staging and destaging fixed-speed pumps. To prevent frequent staging and destaging, and to minimize pressure fluctuations, use a wider fixed-speed bandwidth instead of the staging bandwidth.

Illustration 26: Bandwidth

8.2 System Status and Operation

Only when lead pump is working, the drive can go into sleep mode. When the cascade controller is enabled, the operation status for each pump and the cascade controller is shown in parameter 25-81 Pump Status and parameter 25-80 Cascade Status on the LCP.

The cascade controller information shown includes:

Pumps status: A readout of the status for the relays assigned to each pump. The display shows pumps that are disabled, off,

• running on the drive, or running on the mains/motor starter.

Cascade status: A readout of the status for the cascade controller. The display shows that if cascade controller is disabled, all

• pumps are running off, fixed-speed pumps are being staged/de-staged, and lead pump alternation is occurring.

8.3 Start/Stop Conditions

See parameter group 5-1* Digital Inputs.

Table 24: Commands Assigned to Digital Inputs

LCP keys

Variable speed pump (lead)

Fixed-speed pumps (lag)

[Hand On]

Ramps up (if stopped by a normal stop command) or stays in operation if already running.

Destaging (if running) [Off]

Ramps down

Destaging

[Auto On]

Starts and stops according to commands via terminals or serial bus. The cascade controller only works when the drive is in auto-on mode.

Staging/destaging

P1-00=Closed Loop

P25-00=Enabled

P25-05 Fixed lead Pump

[1]

Yes

P25-57 Relays per Pump

P25-04 Pump Cycling

[0]

Disable

if P25-05=Yes

P25-50 Lead Pump Alternation

[0]

Oﬀ

P25-51 Alternation Event

[0]

External

P25-52 Alternation Time Interval

P25-55 Alternate if Load 50%

[1]

Enabled

P25-56 Staging Mode at Alternation

[0]

Slow

P25-58 Run Next Pump Delay

0.1

P25-59 Run on Mains Delay

0.1

P25-20 Staging Bandwidth

10%

P25-21 Override Bandwidth

100%

P25-22 Fixed Speed Bandwidth

10%

P25-23 SBW Staging Delay

P25-24 SBW Destaging Delay

25-25 OBW Time

25-27 Stage Function

[1]

Enabled

25-28 Stage Function Time

25-30 Destage Function Time

25-29 Destage Function

[1]

Enabled

25-42 Staging Threshold

90%

25-43 Destaging Threshold

50%

P25-06 Number of Pump

e30bd161.11

Enable

VLT® Flow Drive FC 111

Operating Guide

Table 25: LCP Key Functions

8.4 Cascade Controller Wizard

Cascade Controller

Illustration 27: Cascade Controller Wizard (Recommended Logistic)

FC 111

+24 V

D IN

D IN/OUT

COM

D IN/OUT

COM RS-485

P RS-485

N RS-485

+10

A IN

COM

A OUT/D OUT

616869

A OUT/D OUT

123

Start

3# Pump

4# Pump

Pressure +

Pressure -

1# Pump

2# Pump

VLT® Flow Drive FC 111

Operating Guide

8.5 Cascade Controller Connection

8.5.1 1 Pump, 1 Relay Mode

1 pump, 1 relay mode: When parameter 25-57 Relays per Pump=1

Cascade Controller

Illustration 28: 1 Pump, 1 Relay Mode

Every pump operation is controlled by 1 output.

•

When parameter 25-04 Pump Cycling=[0] Disable: maximum 5 pumps.

•

When parameter 25-04 Pump Cycling=[1] Enable: maximum 4 pumps.

•

2 relays and 2 digital outputs are available.

8.5.2 1 Pump, 2 Relay Mode

1 pump, 2 relay mode: When parameter 25-57 Relays per Pump=2

FC 111

+24 V

D IN

D IN/OUT

COM

D IN/OUT

COM RS-485

P RS-485

N RS-485

+10

A IN

COM

A OUT/D OUT

695053

5542A OUT/D OUT

345

Start

2# Pump_Main

2# Pump_Drive

Pressure +

Pressure -

1# Pump_Main

1# Pump_Drive

3# Pump_Drive

3# Pump_Main

VLT® Flow Drive FC 111

Operating Guide

Cascade Controller

Illustration 29: 1 Pump, 2 Relay Mode

Every pump operation is controlled by 2 outputs.

•

Dedicated PLC not necessary as control.

•

When parameter 25-04 Pump Cycling=[0] Disable: no pump.

•

When parameter 25-04 Pump Cycling=[1] Enable: maximum 3 pumps.

2 relays, 2 digital outputs, and 2 analog outputs are available.

•

Fault

num-

ber

Alarm/

warning

bit num-

ber

Fault text

Warn-

ing

Alarm

Trip

locked

Cause of problem

216Live zero error

XX–

Signal on terminal 53 or 54 is less than 50% of the value set in parameter 6-10 Terminal 53 Low Voltage, parameter

6-12 Terminal 53 Low Current, parameter 6-20 Terminal 54 Low Voltage, or parameter 6-22 Terminal 54 Low Current.

See also parameter group 6-0* Analog I/O Mode.

3–No motor

X––

No motor is connected to the output of the drive.

414Mains ph. loss

XXX

Missing phase on the supply side or too high voltage imbalance. Check the supply voltage. See parameter 14-12 Function at Mains Imbalance.

711DC over volt

XX–

DC-link voltage exceeds the limit.

810DC under volt

XX–

DC-link voltage drops below voltage warning low-limit.

99Inverter over-

load

XX–

More than 100% load for a long time.

108Motor ETR

over

XX–

Motor is too hot due to more than 100% load for a long time. See parameter 1-90 Motor Thermal Protection.

117Motor th over

XX–

Thermistor or thermistor connection is disconnected. See parameter 1-90 Motor Thermal Protection.

135Over current

XXX

Inverter peak current limit is exceeded.

142Earth fault

–XX

Discharge from output phases to ground.

1612Short circuit

–XX

Short circuit in motor or on motor terminals.

174Ctrl. word TO

XX–

No communication to drive. See parameter group 8-0* General Settings.

2450Fan fault

XX–

The heat sink cooling fan is not working (only on 400 V, 30–315 kW (40–450 hp) units).

3019U phase loss

–XX

Motor phase U is missing. Check the phase. See parameter 4-58 Missing Motor Phase Function.

3120V phase loss

–XX

Motor phase V is missing. Check the phase. See parameter 4-58 Missing Motor Phase Function.

3221W phase loss

–XX

Motor phase W is missing. Check the phase. See parame- ter 4-58 Missing Motor Phase Function.

3817Internal fault

–XX

Contact the local Danfoss supplier.

4428Earth fault

–XX

Discharge from output phases to ground, using the value of parameter 15-31 Alarm Log Value if possible.

4633Control volt-

age fault

–XX

Control voltage is low. Contact the local Danfoss supplier.

VLT® Flow Drive FC 111

Operating Guide

9 Warnings and Alarms

9.1 List of Warnings and Alarms

Table 26: Warnings and Alarms

Warnings and Alarms

Fault num-

ber

Alarm/ warning bit num-

ber

Fault text

Warn-

ing

Alarm

Trip

locked

Cause of problem

472324 V supply

low

XXX

24 V DC supply may be overloaded.

5115AMA U

nom

–X–

The setting of motor voltage, motor current, and motor power is wrong. Check the settings.

52–AMA low I

nom

–X–

The motor current is too low. Check the settings.

53–AMA big mo-

tor

–X–

The motor is too big to perform AMA.

54–AMA small

motor

–X–

The motor is too small to perform AMA.

55–AMA par.

range

–X–

The parameter values found from the motor are outside the acceptable range.

56–AMA user in-

terrupt

–X–

The AMA has been interrupted by the user.

57–AMA timeout

–X–

Try to restart the AMA several times, until the AMA is carried out.

N O T I C E

Repeated runs may heat the motor to a level where the

resistance Rs and Rr are increased. In most cases, how-

ever, this is not critical.

58–AMA internal

XX–

Contact the local Danfoss supplier.

5925Current limit

X––

The current is higher than the value in parameter 4-18 Cur- rent Limit.

6044External Inter-

lock

–X–

External interlock has been activated. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock and reset the drive (via serial communication, digital I/O, or by pressing [Reset] key on the LCP).

6626Heat sink tem-

perature Low

X––

This warning is based on the temperature sensor in the IGBT module (on 400 V, 30–90 kW (40–125 hp) units).

691Pwr. card

temp

XXX

The temperature sensor on the power card exceeds the upper or lower limits.

7036Illegal FC con-

figuration

–XX

The control card and power card are not matched.

79–Illegal power section configuration

XX–

Internal fault. Contact the local Danfoss supplier.

8029Drive initialised

–X–

All parameter settings are initialized to default settings.

92–No-Flow

XX–

A no-flow condition has been detected in the system. Pa- rameter 22-23 No-Flow Function is set for alarm.

VLT® Flow Drive FC 111

Operating Guide

Warnings and Alarms

Fault num-

ber

Alarm/ warning bit num-

ber

Fault text

Warn-

ing

Alarm

Trip

locked

Cause of problem

9338Dry pump

XX–

A dry-pump condition has been detected in the system. Parameter 22-26 Dry Pump Function is set for alarm.

9439End of curve

XX–

An end-of-curve condition has been detected in the system. Parameter 22-50 End of Curve Function is set for alarm.

9540Broken belt

XX–

Torque is below the torque level set for no load, indicating a broken belt. See parameter group 22-6* Broken Belt Detection.

99–Locked rotor

–XX

The rotor is blocked.

101

–

Flow/pressure Info Missing

–––

Sensorless-pump table is missing or wrong. Download sensorless-pump table again.

126

–

Motor Rotating

–X–

High back EMF voltage. Stop the rotor of the PM motor.

127

–

Back EMF too high

X––

This warning applies to PM motors only. When the back EMF exceeds 90% x U

invmax

(overvoltage threshold) and does not drop to normal level within 5 s, this warning is reported. The warning remains until the back EMF returns to a normal level.

159

Check valve failure

X––

When the drive is not in operation, a broken check valve leads to the motor runs in reverse.

200

–

Fire mode

X––

Fire mode has been activated.

202

–

Fire mode limits exceeded

X––

Fire mode has suppressed 1 or more warranty voiding alarms.

250

–

New spare part

–XX

The power or switch mode power supply has been exchanged (on 400 V, 30–90 kW (40–125 hp) units). Contact the local Danfoss supplier.

251

–

New type code

–XX

The drive has a new type code (on 400 V, 30– 90 kW (40– 125 hp) units). Contact the local Danfoss supplier.

e30bu794.10

0-**: Operation / Dis 1-**: Load and Motor Button disabled

VLT® Flow Drive FC 111

Operating Guide

Warnings and Alarms

9.2 LCP Errors Messages

LCP errors are not warnings or alarms. They do not affect the operation of the drive. An LCP error example on the LCP is shown in the following illustration.

Illustration 30: LCP Error Example

LCP error

code

Error message

Description

Err 84

LCP comm. lost

Communication between the LCP and the drive is lost.

Err 85

Key disabled

The LCP key is disabled. One of the LCP keys has been disabled in parameter group 0-4* LCP Keypad.

Err 86

LCP copy failed

Data copy failure. This error occurs when data is copied from drive to LCP, or from LCP to drive (parameter 0-50 LCP Copy).

Err 88

Data not compatible

LCP data incompatible. This error occurs when data is being copied from LCP to drive (parameter 0-50 LCP Copy). The typical reason is that data is moved between drive and LCP that have major software differences.

Err 89

Read only

Parameter read only. An operation is issued via LCP to write a value to a parameter that is read-only.

Err 90

Database busy

The parameter database of the drive is busy.

Err 91

Parameter invalid

The parameter value that is input via the LCP is invalid.

Err 92

Exceeds limits

The parameter value that is input via the LCP exceeds limits.

Err 93

Motor is running

The LCP copy operation cannot be performed when the drive is running.

Err 95

Not while running

The parameter cannot be changed while the drive is running.

Err 96

Password rejected

The password that is input via the LCP is incorrect.

VLT® Flow Drive FC 111

Operating Guide

Table 27: LCP Error List

Warnings and Alarms

Drive

PK37

PK75

P1K5

P2K2

P3K0

P4K0

P5K5

P7K5

P11K

P15K

Typical shaft output [kW]

0.37

0.75

1.5

2.2

3.0

4.0

5.5

7.5

11.0

15.0

Typical shaft output [hp]

0.5

1.0

2.0

3.0

4.0

5.0

7.5

10.0

15.0

20.0

Protection rating IP20

H1H1H1H2H2H2H3H3H4

Maximum cable size in terminals (mains, motor) [mm2 (AWG)]

4 (10)

16 (6)

Output current at 40°C (104°F) ambient temperature

(1)

Continuous [A]

1.2

2.2

3.7

5.3

7.2

9.0

12.0

15.5

23.0

31.0

Intermittent (110% overload 60 s) [A]

(2)

1.3

2.4

4.1

5.8

7.9

9.9

13.2

17.1

25.3

34.0

Maximum input current

Continuous [A]

1.2

2.1

3.5

4.7

6.3

8.3

11.2

15.1

22.1

29.9

Intermittent [A]

1.3

2.3

3.9

5.2

6.9

9.1

12.3

16.6

24.3

32.9

Maximum external mains fuses [A]

See 5.7.5 Recommendation of Fuses.

Estimated power loss [W]

(3)

1521575883

118

131

198

274

379

Weight enclosure protection rating IP20 [kg (lb)]

2.0

(4.4)

2.0

(4.4)

2.1

(4.6)

3.3

(7.3)

3.3

(7.3)

3.4

(7.5)

4.3

(9.5)

4.5

(9.9)

7.9

(17.4)

7.9

(17.4)

Efficiency [%]

(4)

97.3

97.6

97.2

97.9

97.8

97.6

98.0

97.8

97.9

97.8

Drive

P18K

P22K

P30K

P37K

P45K

P55K

P75K

P90K

Typical shaft output [kW]

18.5

22.0

30.0

37.0

45.0

55.0

75.0

90.0

Typical shaft output [hp]

25.0

30.0

40.0

50.0

60.0

70.0

100.0

125.0

Protection rating IP20

H5H5H11

H11

H12

Maximum cable size in terminals (mains, motor) [mm

(AWG)]

16 (6)

50 (1)

95 (0)

120 (250

MCM)

VLT® Flow Drive FC 111

Operating Guide

10 Specifications

10.1 Mains Supply

10.1.1 3x380–480 V AC

Table 28: 3x380–480 V AC, 0.37–15 kW (0.5–20 hp), Enclosure Sizes H1–H4

Specifications

Refer to the chapter Derating in the Design Guide for the derating curves at 50°C (122°F) ambient temperature.

The drive also supports 150% overload for 60 s when selecting 1 level higher power size.

Applies for dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and

typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to Danfoss

Efficiency measured at nominal current. For energy efficiency class, see 10.4.13 Ambient Conditions. For part load losses, see Danfoss MyDrive®

ecoSmart website.

Table 29: 3x380–480 V AC, 18.5–90 kW (25–125 hp), Enclosure Sizes H5, H11–H12

MyDrive® ecoSmart website.

Drive

P18K

P22K

P30K

P37K

P45K

P55K

P75K

P90K

Output current at 40°C/45°C (104°F/113°F) ambient temperature

(1)

Continuous [A]

37.0

42.5

61.0

73.0

90.0

106.0

147.0

177.0

Intermittent (110% overload 60 s) [A]

(2)

40.7

46.8

67.1

80.3

99.0

116.6

161.7

194.7

Maximum input current

Continuous [A]

35.2

41.5

57.0

70.3

84.2

102.9

140.3

165.6

Intermittent [A]

38.7

45.7

62.7

77.3

92.6

113.2

154.3

182.2

Maximum external mains fuses [A]

See 5.7.5 Recommendation of Fuses.

Estimated power loss [W]

(3)

403

468

630

848

1175

1250

1507

1781

Weight enclosure protection rating IP20 [kg (lb)]

9.5 (20.9)

22.4

(49.4)

22.5

(49.6)

22.6

(49.8)

37.3

(82.2)

38.7

(85.3)

40.7

(89.7)

Efficiency [%]

(4)

98.1

97.9

98.19897.79898.2

98.3

Drive

P110

P132

P160

P200

P250

P315

Typical shaft output [kW]

110

132

160

200

250

315

Typical shaft output [hp]

150

175

250

300

350

450

Protection rating IP20

H13

H14

Maximum cable size in terminals (mains, motor) [mm2 (AWG)]

2x95 (2x3/0)

2x185 (2x350 mcm)

Output current at 40°C/45°C (104°F/113°F) ambient temperature

(1)

Continuous [A]

212

260

315

395

480

588

Intermittent (110% overload 60 s) [A]

(2)

233

286

347

435

528

647

Maximum input current

Continuous [A]

204

251

304

381

463

567

Intermittent [A]

224

276

334

419

509

623

Maximum external mains fuses [A]

See 5.7.5 Recommendation of Fuses. Estimated power loss [W]

(3)(4)

2559

2954

3770

4116

5137

6674

VLT® Flow Drive FC 111

Operating Guide

Specifications

P18K, P22K, and P90K operates at 40°C (104°F). P30K, P37K, P45K, P55K, and P75K operates at 45°C (113°F). Refer to the chapter Derating in the

Design Guide for the derating curves at 50°C (122°F) ambient temperature.

The drive also supports 150% overload for 60 s when selecting 1 level higher power size.

Applies for dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses may increase. LCP and

typical control card power consumptions are included. For power loss data according to EN 50598-2, refer to Danfoss

Efficiency measured at nominal current. For energy efficiency class, see

ecoSmart website.

Table 30: 3x380–480 V AC, 110–315 kW (150–450 hp), Enclosure Sizes H13–H14

10.4.13 Ambient Conditions. For part load losses, see Danfoss MyDrive®

MyDrive® ecoSmart website.

Drive

P110

P132

P160

P200

P250

P315

Efficiency

(4)

0.98

Output frequency [Hz]

0–500

Heat sink overtemperature trip [°C (°F)]

110 (230)

Weight, enclosure protection rating IP20 kg (lbs)

98 (216)

164 (362)

Control card overtemperature trip [°C (°F)]

75 (167)

80 (176)

RFI filter type

Conduct emission. Maximum shielded cable length [m (ft)]

Radiated emission Industrial environment

EN 55011

Class A Group 2

Industrial environment

Class A Group 1

Industrial environment

Class B

Housing, trades and light industries

Class A Group 1

Industrial environment

Class B

Housing, trades and light industries

EN/IEC 61800-3

Category C3

Second environment industrial

Category C2

First environment home and office

Category C1

First environment home and office

Category C2

First environment home and office

Category C1

First environment home and office

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

Without external filter

With external filter

H2 RFI filter (EN55011 A2, EN/IEC61800-3 C3)

0.37–22 kW (0.5–30 hp) 3x380– 480 V IP20

25 (82)

–––––––––

H2 RFI filter (EN 55011 A2, EN/IEC 61800-3 C3)

30–90 kW (40–125 hp) 3x380– 480 V IP20

25 (82)

–––––No–No–

VLT® Flow Drive FC 111

Operating Guide

Refer to the chapter Derating in the Design Guide for the derating curves at 50°C (122°F) ambient temperature.

The drive also supports 150% overload for 60 s when selecting 1 level higher power size.

Typical power loss is at normal conditions and expected to be within ±15% (tolerance relates to variety in voltage and cable conditions). These values are based on a typical motor efficiency (IE/IE3 border line). Lower efficiency motors add to the power loss in the drive. Applies for 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 Danfoss MyDrive® ecoSmart website. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.

Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Efficiency measured at nominal current. For energy efficiency class, see

10.4.13 Ambient Conditions. For part load losses, see Danfoss MyDrive® ecoSmart website.

Specifications

10.2 EMC Emission Test Results

The following test results have been obtained using a system with a drive, a shielded control cable, a control box with potentiometer, and a shielded motor cable.

Table 31: EMC Emission Test Results, H1–H5 & H11–H12

RFI filter type

Conduct emission. Maximum shielded cable length [m (ft)]

Radiated emission

EN 55011

Class B Housing, trades and light industries

Class A Group 1 Industrial environment

Class A Group 2 Industrial environment

Class B Housing, trades and light industries

Class A Group 1 Industrial environment

Class A Group 2 Industrial environment

EN/IEC 61800-3

Category C1

First environment home and office

Category C2

First environment home and office

Category C3

Second environment industrial

Category C1

First environment home and office

Category C2

First environment home and office

Category C3

First environment home and office

H2 RFI filter (EN 55011 A2, EN/IEC 61800-3 C3)

110–315 kW (150– 450 hp) 3x380–480 V IP20

NoNo150 m (492 ft)

NoNoYes

Supply voltage

380–480 V ±10%

Supply frequency

50/60 Hz

Maximum imbalance temporary between mains phases

3.0% of rated supply voltage

VLT® Flow Drive FC 111

Operating Guide

Table 32: EMC Emission Test Results, H13–H14

10.3 Special Conditions

Specifications

10.3.1 Dusty or Humid Environment

N O T I C E

Do not use IP20/IP21 VLT® Flow Drive FC 111 units in dusty or humid environments. See chapter General Technical Data for details.

10.3.2 Derating for Ambient Temperature and Switching Frequency

Ensure that the ambient temperature measured over 24 hours is at least 5 °C (9 °F) lower than the maximum ambient temperature that is specified for the drive. If the drive is operated at a high ambient temperature, decrease the constant output current. For derating specifications, see the VLT® Flow Drive FC 111 Design Guide.

10.3.3 Derating for Low Air Pressure and High Altitudes

The cooling capability of air is decreased at low air pressure. For altitudes above 2000 m (6562 ft), contact Danfoss regarding PELV. Below 1000 m (3281 ft) altitude, derating is not necessary. For altitudes above 1000 m (3281 ft), decrease the ambient temperature or the maximum output current. Decrease the output by 1% per 100 m (328 ft) altitude above 1000 m (3281 ft) or reduce the maximum ambient cooling air temperature by 1 °C (1.8 °F) per 200 m (656 ft).

10.4 General Technical Data

10.4.1 Protection and Features

•

Electronic motor thermal protection against overload.

•

Temperature monitoring of the heat sink ensures that the drive trips if there is overtemperature.

•

The drive is protected against short circuits between motor terminals U, V, W.

•

When a motor phase is missing, the drive trips and issues an alarm.

•

When a mains phase is missing, the drive trips or issues a warning (depending on the load).

•

Monitoring of the DC-link voltage ensures that the drive trips when the DC-link voltage is too low or too high.

•

The drive is protected against ground faults on motor terminals U, V, W.

10.4.2 Mains Supply

True power factor (λ)

≥0.9 nominal at rated load

Displacement power factor (cosφ) near unity

(>0.98)

Switching on the input supply L1, L2, L3 (power-ups) enclosure sizes H1–H5

Maximum 1 time/30 s

Switching on the input supply L1, L2, L3 (power-ups) enclosure sizes H11–H12

Maximum 1 time/minute

Switching on the input supply R, S, T (power-ups) enclosure sizes H13–H14

Maximum 1 time/2 minutes

Environment according to EN 60664-1

Overvoltage category III/pollution degree 2

Output voltage

0–100% of supply voltage

Output frequency in U/f mode (for AM motor)

0–500 Hz

Output frequency in VVC+ mode (for AM motor)

0–200 Hz

Output frequency in VVC+ mode (for PM motor)

0–400 Hz

Switching on output

Unlimited

Ramp time

0.01–3600 s

Maximum motor cable length, shielded/armored (EMC-correct installation)

See 10.2 EMC Emission Test Results.

Maximum motor cable length, unshielded/unarmored, H1–H5

50 m (164 ft)

Maximum motor cable length, shielded, H11–H12

50 m (164 ft)

Maximum motor cable length, unshielded/unarmored, H11–H12

100 m (328 ft)

Maximum motor cable length, shielded, H13–H14

150 m (492 ft)

Maximum motor cable length, unshielded, H13–H14

300 m (984 ft)

Maximum cross-section to motor, mains

See 10.1.1 3x380–480 V AC for more information

Cross-section DC terminals for filter feedback on enclosure sizes H1–H3

4 mm2/12 AWG

Cross-section DC terminals for filter feedback on enclosure sizes H4–H5

16 mm2/6 AWG

Maximum cross-section to control terminals, rigid wire, H1–H5 & H11–H12

2.5 mm2/14 AWG

Maximum cross-section to control terminals, rigid wire, H13–H14

1.5 mm2/16 AWG (2x0.75 mm2)

Maximum cross-section to control terminals, flexible cable, H1– H5 & H11–H12

2.5 mm2/14 AWG

Maximum cross-section to control terminals, flexible cable, H13– H14

1 mm2/18 AWG

Maximum cross-section to control terminals, cable with enclosed core, H13–H14

0.05 mm2/20 AWG

Minimum cross-section to control terminals, H1–H5 & H11–H12

0.05 mm2/30 AWG

Minimum cross-section to control terminals, H13–H14

0.25 mm2/23 AWG

Programmable digital inputs

Terminal number

18, 19, 27, 29

Logic

PNP or NPN

Voltage level

0–24 V DC

VLT® Flow Drive FC 111

Operating Guide

The unit is suitable for use on a circuit capable of delivering not more than 100000 A

10.4.3 Motor Output (U, V, W)

Specifications

symmetrical Amperes, 240/480 V maximum.

rms

10.4.4 Cable Length and Cross-section

10.4.5 Digital Inputs

Voltage level, logic 0 PNP

<5 V DC

Voltage level, logic 1 PNP

>10 V DC

Voltage level, logic 0 NPN

>19 V DC

Voltage level, logic 1 NPN

<14 V DC

Maximum voltage on input

28 V DC

Input resistance, R

Approximately 4 kΩ

Digital input 29 as thermistor input

Fault: >2.9 kΩ and no fault: <800 Ω

Digital input 29 as pulse input

Maximum frequency 32 kHz push-pull-driven & 5 kHz (O.C.)

Number of analog inputs

Terminal number

53, 54

Terminal 53 mode

Parameter 16-61 Terminal 53 Setting: 1 = voltage, 0 = current

Terminal 54 mode

Parameter 16-63 Terminal 54 Setting: 1 = voltage, 0 = current

Voltage level

0–10 V

Input resistance, R

Approximately 10 kΩ

Maximum voltage

20 V

Current level

0/4–20 mA (scalable)

Input resistance, R

<500 Ω

Maximum current

29 mA

Resolution on analog input

10 bit

Number of programmable analog outputs

Terminal number

42, 45

(1)

Current range at analog output

0/4–20 mA

The load resistor to common at analog out

≤ 500 Ω

Maximum voltage at analog output

17 V

Accuracy on analog output

Maximum error: 0.4% of full scale

Resolution on analog output

10 bit

Number of digital outputs

Terminals 27 and 29

Terminal number

27, 29

(1)

Voltage level at digital output

0–24 V

Maximum output current (sink and source)

40 mA

Terminals 42 and 45

Terminal number

42, 45

(2)

Voltage level at digital output

17 V

Maximum output current at digital output

20 mA

VLT® Flow Drive FC 111

Operating Guide

The digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

10.4.6 Analog Inputs

Specifications

10.4.7 Analog Outputs

Terminals 42 and 45 can also be programmed as digital outputs.

10.4.8 Digital Output

The load resistor at digital output

≥ 1 kΩ

Terminal number

68 (P, TX+, RX+), 69 (N, TX-, RX-)

Terminal number

61 common for terminals 68 and 69

Terminal number

Maximum load

80 mA

Programmable relay output

Relay 01 and 02

01–03 (NC), 01–02 (NO), 04–06 (NC), 04–05 (NO)

Maximum terminal load (AC-1)

(1)

on 01–02/04–05 (NO) (Resistive

load)

250 V AC, 3 A

Maximum terminal load (AC-15)

(1)

on 01–02/04–05 (NO) (Induc-

tive load @ cosφ 0.4)

250 V AC, 0.2 A

Maximum terminal load (DC-1)

(1)

on 01–02/04–05 (NO) (Resistive

load)

30 V DC, 2 A

Maximum terminal load (DC-13)

(1)

on 01–02/04–05 (NO) (Induc-

tive load)

24 V DC, 0.1 A

Maximum terminal load (AC-1)

(1)

on 01–03/04–06 (NC) (Resistive

load)

250 V AC, 3 A

Maximum terminal load (AC-15)

(1)

on 01–03/04–06 (NC) (Inductive

load @ cosφ 0.4)

250 V AC, 0.2 A

Maximum terminal load (DC-1)

(1)

on 01–03/04–06 (NC) (Resistive

load)

30 V DC, 2 A

Minimum terminal load on 01–03 (NC), 01–02 (NO)

24 V DC 10 mA, 24 V AC 20 mA

Environment according to EN 60664-1

Overvoltage category III/pollution degree 2

Terminal number

Output voltage

10.5 V ±0.5 V

Maximum load

25 mA

Enclosure protection rating (H1–H5 & H11–H14)

IP20/Chassis

Vibration test (H1–H5 & H11–H14)

1.0 g

Maximum relative humidity (H1–H5 & H11–H14)

5–95% (non-condensing) during operation

VLT® Flow Drive FC 111

Operating Guide

Terminals 27 and 29 can also be programmed as input.

Terminals 42 and 45 can also be programmed as analog output.

Specifications

The digital outputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

10.4.9 RS485 Serial Communication

The RS485 serial communication outputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

10.4.10 24 V DC Output

The 24 V DC output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

10.4.11 Relay Output

IEC 60947 parts 4 and 5. Endurance of the relay varies with different load type, switching current, ambient temperature, driving configuration, working profile, and so forth. It is recommended to mount a snubber circuit when connecting inductive loads to the relays.

10.4.12 10 V DC Output

The 10 V DC output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

10.4.13 Ambient Conditions

Aggressive environment (IEC 60721-3-3), coated enclosure sizes (H1–H5 & H11–H14)

Class 3C3

Aggressive gases (IEC 60721-3-3), enclosure sizes (H13–H14)

Class 3C3

Aggressive environment (IEC 60068-2-43) H2S test enclosure sizes H13–H14

Class Kd

Test method according to IEC 60068-2-43

H2S (10 days)

Ambient temperature-full output current (H1–H5 & H11–H14)

(1)

See maximum output current at 45 °C (113 °F) in 10.1.1 3x380–

480 V AC

(2)

Ambient temperature with derating (H1–H5 & H11–H14)

Maximum 55° C (131° F)

(1)

Minimum ambient temperature during full-scale operation (H1– H5 & H11–H14)

-15 °C (5 °F)

(3)

Minimum ambient temperature at reduced performance (H1–H5 & H11–H14)

-20 °C (-4 °F)

(4)

Temperature during storage/transport (H1–H5 & H11–H12)

-30 to +65/70 °C (-22 to +149/158°F)

Temperature during storage/transport (H13–H14)

-25 to +65/70 °C (-13 to +149/158 °F)

Maximum altitude above sea level without derating

1000 m (3281 ft)

Maximum altitude above sea level with derating

3000 m (9843 ft)

(1)

Derating for high altitude

See 10.3.3 Derating for Low Air Pressure and High Altitudes.

Safety standards (H1–H5 & H11–H12)

EN/IEC 61800-5-1

EMC standards, Emission (H1–H5 & H11–H14)

EN/IEC 61800-3, IEC 61000-6-2/3/12, EN55011

EMC standards, Immunity (H1–H5 & H11–H14)

EN/IEC 61800-3, IEC 61000-6-2, IEC 61000-4-2/3/4/5/6, IEC

61000-4-11/13/27/28/34

Energy efficiency class

IE2

(5)

VLT® Flow Drive FC 111

Operating Guide

Specifications

For more information on derating, see chapter Derating in the Design Guide.

Apply for enclosure sizes H1, H2, H4, H11, H12, H13, and H14. For enclosure sizes H3, H5, and 90 kW (125 hp) drives, the maximum ambient tem-

perature is 40 °C (104 °F).

Apply for enclosure sizes H13–H14. For enclosure sizes H1–H5 and H11–H12 drives, the minimum ambient temperature during full-scale operation

is -10 °C (14 °F).

Apply for enclosure sizes H13–H14. For enclosure sizes H1–H5 and H11–H12 drives, the minimum ambient temperature at reduced performance is

-15 °C (5 °F).

Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

VLT® Flow Drive FC 111

Operating Guide

Index

AC mains..........................................................................................................31

Additional resource........................................................................................6

Ambient conditions.....................................................................................75

Ambient temperature.................................................................................72

Analog input.................................................................................................. 74

Branch circuit protection...........................................................................32

Burst transient............................................................................................... 29

Capacitor storage.........................................................................................18

Cascade controller....................................................................................... 60

CE compliance...............................................................................................32

Check valve monitoring.............................................................................12

Circuit breaker............................................................................................... 32

Constant pressure water supply.............................................................55

Control input/output........................................................................... 75, 75

Control shelf...................................................................................................16

Cooling.............................................................................................................20

DC voltage output, 10 V.............................................................................75

DC voltage output, 24 V.............................................................................75

Derating....................................................................................................72, 72

Digital input....................................................................................................73

Digital output................................................................................................ 74

Display..............................................................................................................35

Document version..........................................................................................6

Drive

Definition..................................................................................................9

Dry pump detection....................................................................................12

Index

LCP.....................................................................................................................35

Leakage current.................................................................................8, 29, 29

Lifting.........................................................................................................20, 22

Local control panel...................................................................................... 35

Low air pressure............................................................................................72

Mains supply.................................................................................................. 72

MCT 10 setup software.......................................................................... 6, 35

Menu key.........................................................................................................35

Motor

Connection............................................................................................30

Output.....................................................................................................73

Mounting.........................................................................................................20

Multiple pump control............................................................................... 57

Navigation key...............................................................................................35

Open loop....................................................................................................... 52

Operating environment.............................................................................18

Operation key................................................................................................ 36

Overcurrent protection..............................................................................32

Overload protection....................................................................................72

Periodic forming...........................................................................................18

Potential equalization.................................................................................29

Process closed loop..................................................................................... 53

Programming.................................................................................................35

Electrical installation................................................................................... 27

EMC-compliant installation...................................................................... 25

End of curve detection............................................................................... 12

Energy efficiency class................................................................................76

Fuse................................................................................................................... 32

Ground............................................................................................................. 29

High altitudes................................................................................................ 72

Indicator light......................................................................................... 35, 36

Installation

Qualified personnel.............................................................................. 7

Interference

Radio...........................................................................................................9

Isolated main..................................................................................................31

Qualified personnel...................................................................................6, 7

Relay output...................................................................................................75

RS485................................................................................................................ 75

Short-circuit protection..............................................................................32

Side-by-side installation............................................................................ 19

Software version............................................................................................. 6

Storage.............................................................................................................18

Switching frequency................................................................................... 72

Symbols..............................................................................................................7

Tightening torques......................................................................................27

Time-based functions................................................................................. 12

Tools..................................................................................................................20

Tools required................................................................................................20

Voltage

Safety warning........................................................................................7

VLT® Flow Drive FC 111

Operating Guide

Wire size...........................................................................................................30

Index

Wiring schematic..........................................................................................26

VLT® Flow Drive FC 111

Operating Guide

Index

Danfoss A/S

Ulsnaes 1 DK-6300 Graasten vlt-drives.danfoss.com

Danfoss can accept no responsibility for possible errors in catalogs, 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. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

*130R0265*

AQ304735638503en-000301 / 130R0265

*M0018901*

Danfoss FC 111 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Introduction

1.1 Purpose of this Operating Guide

1.2 Additional Resources

1.2.1 Other Resources

1.2.2 MCT 10 Set-up Software Support

1.3 Document and Software Version

1.4 Disposal

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Safety Precautions

2.4 Motor Thermal Protection

3 Product Overview

3.1 Intended Use

3.2 Power Ratings, Weights, and Dimensions

3.3 Check Valve Monitoring

3.4 Dry Pump Detection

3.5 End of Curve Detection

3.6 Time-based Functions

3.7 Relays and Terminals

3.7.1 Relays and Terminals on Enclosure Sizes H1–H5

3.7.2 Relays and Terminals on Enclosure Size H11

3.7.3 Relays and Terminals on Enclosure Size H12

3.7.4 Relays and Terminals on Enclosure Size H13–H14

3.8 View of Control Shelf

4 Mechanical Installation

4.1 Storage and Operating Environment

4.2 Side-by-side Installation

4.3 Tools Needed

4.4 Installation and Cooling Requirements

4.5 Lifting the Drive

4.6 Wall Mounting the Drive

4.7 Creating Cable Openings

5 Electrical Installation

5.1 Safety Instructions

5.2 EMC-compliant Electrical Installation

5.3 Electrical Wiring

5.4 Fastener Tightening Torques

5.5 IT Mains

5.6 Mains and Motor Connection

5.6.1 Introduction

5.6.2 Connecting to the Ground

5.6.3 Connecting the Motor

5.6.4 Connecting the AC Mains

5.7 Fuses and Circuit Breakers

5.7.1 Branch Circuit Protection

5.7.2 Short-circuit Protection

5.7.3 Overcurrent Protection

5.7.4 CE Compliance

5.7.5 Recommendation of Fuses

5.8 Control Terminals

5.9 Acoustic Noise or Vibration

6 Programming

6.1 Local Control Panel (LCP)

6.2 Set-up Wizard

6.2.1 Setup Wizard Introduction

6.2.2 Setup Wizard for Open-loop Applications

6.2.3 Setup Wizard for Closed-loop Applications

6.2.4 Motor Setup

6.2.5 Changes Made Function

6.2.6 Changing Parameter Settings

6.2.7 Accessing All Parameters via the Main Menu

7 Applications

7.1 Application Selections

7.1.1 Open Loop

7.1.2 Process Closed Loop

7.1.3 Constant Pressure Water Supply

7.1.4 Multiple Pump Control

8 Cascade Controller

8.1 Introduction

8.1.1 Cascade Controller

8.1.2 Fixed Lead Pump

8.1.3 Lead Pump Alternation

8.1.4 Bandwidth Management

8.2 System Status and Operation