Danfoss FC 200 Operating guide

VLT AQUA High Power Instruction Manual Contents

Contents

1 How to Read this Instruction Manual

Copyright, Limitation of Liability and Revision Rights 1-1

Approvals 1-1

Symbols 1-2

2 Safety

General Warning 2-2

Before Commencing Repair Work 2-2

Special conditions 2-2

Avoid unintended Start. 2-3

Safe Stop Installation 2-4

Safe Stop of the Adjustable Frequency Drive 2-5

IT Line Power 2-7

3 How to Install

How to Get Started 3-1

Pre-installation 3-2

Planning the Installation Site 3-2

1-1

2-1

3-1

Receiving the Adjustable Frequency Drive 3-2

Transportation and Unpacking 3-3

Lifting 3-4

Mechanical Dimensions 3-6

Rated Power 3-13

Mechanical Installation 3-14

Terminal locations - frame size D 3-15

Terminal Locations - frame size E 3-17

Terminal Locations - frame size F 3-21

Cooling and Airflow 3-25

Field Installation of Options 3-31

Installation of Duct Cooling Kit in Rittal Enclosures 3-31

Outside installation/ NEMA 3R kit for Rittal enclosures 3-34

Installation on pedestal 3-36

Input plate option 3-38

Installation of Line Power Shield for Adjustable Frequency Drives 3-39

Frame size F Panel Options 3-40

Frame size F Panel Options 3-40

Electrical Installation 3-43

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Contents VLT AQUA High Power Instruction Manual

Power Connections 3-43

Power and Control Wiring for Unshielded Cables 3-54

AC line input connections 3-60

Fuses 3-61

Motor Insulation 3-64

Motor Bearing Currents 3-65

Control cable routing 3-66

Electrical Installation, Control Terminals 3-68

Connection Examples 3-69

Start/Stop 3-69

Pulse Start/Stop 3-69

Electrical Installation - continued 3-71

Electrical Installation, Control Cables 3-71

Switches S201, S202, and S801 3-74

Final Set-up and Test 3-75

Additional Connections 3-77

Mechanical Brake Control 3-77

Motor Thermal Protection 3-78

4 How to operate the adjustable frequency drive

Ways of Operation 4-1

How to operate the Graphical LCP (GLCP) 4-1

How to operate the numeric LCP (NLCP) 4-7

Tips and tricks 4-11

5 How to program the adjustable frequency drive

How to program 5-1

Q1 My Personal Menu 5-3

Q2 Quick Set-up

Q5 Changes Made 5-6

Q6 Loggings 5-6

Commonly Used Parameters - Explanations 5-8

Main Menu 5-8

4-1

5-1

5-3

Parameter Options 5-50

Default settings 5-50

0-** Operation/Display 5-52

1-** Load/Motor 5-53

2-** Brakes 5-53

3-** Reference / Ramps 5-54

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VLT AQUA High Power Instruction Manual Contents

4-** Limits / Warnings 5-55

5-** Digital In/Out 5-56

6-** Analog In/Out 5-57

8-** Comm. and Options 5-58

9-** Profibus 5-59

10-**CAN Ser. Com. Bus 5-59

13-** Smart Logic 5-60

14-** Special Functions 5-60

15-** FC Information 5-61

16-** Data Readouts 5-62

18-** Data Readouts 2 5-63

20-** FC Closed-loop 5-63

21-** Ext. Closed-loop 5-64

22-** Application Functions 5-65

23-** Timed Actions 5-66

25-** Cascade Controller 5-67

26-** Analog I/O Option MCB 109 5-68

Cascade CTL Option 27-** 5-69

29-** Water Application Functions 5-70

31-** Bypass Option 5-70

6 General Specifications

7 Troubleshooting

Fault messages 7-4

8 Index

6-1

7-1

8-1

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Contents VLT AQUA High Power Instruction Manual

MG.20.P3.22 - VLT® is a registered Danfoss trademark

VLT AQUA High Power Instruction Manual 1 How to Read this Instruction Manual

1 How to Read this Instruction Manual

1

1.1.1 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss. By accepting and using this manual, the user agrees that the information contained herein

will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication

with Danfoss equipment over a serial communication link. This publication is protected under the copyright laws of Denmark and most other countries.

Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical,

hardware and software environment.

Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or representation, neither expressed nor

implied, with respect to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information

contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss is not responsible for any costs, including but not

limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute

these, or any claims by third parties.

Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former

or present users of such revisions or changes.

This Instruction Manual will introduce all aspects of your VLT AQUA Drive.

Available literature for VLT AQUA Drive:

- The Instruction Manual MG.20.MX.YY provides the necessary information for getting the drive up and running.

- The Design Guide MG.20.NX.YY contains technical information about the drive design and customer applications.

- The Programming Guide MG.20.OX.YY provides information on how to program and includes complete parameter descriptions.

X = Revision number

YY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documenta-

tion.

1.1.2 Approvals

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1 How to Read this Instruction Manual VLT AQUA High Power Instruction Manual

1.1.3 Symbols

1

Symbols used in this Instruction Manual.

NOTE!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

* Indicates a default setting

1-2

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VLT AQUA High Power Instruction Manual 2 Safety

2Safety

2.1.1 Safety note

The voltage of the adjustable frequency drive is dangerous whenever connected to line power. Incorrect installation of the motor,

adjustable frequency drive or serial communication bus may cause damage to the equipment, serious personal injury or death. Con-

sequently, the instructions in this manual, as well as national and local rules and safety regulations, must be followed.

Safety Regulations

1. The adjustable frequency drive must be disconnected from line power if repair work is to be carried out. Make sure that the line power supply

has been disconnected and that the necessary time has passed before removing motor and line plugs.

2. The [STOP/RESET] key on the control panel of the adjustable frequency drive does not disconnect the equipment from line power and is thus

not to be used as a safety switch.

3. Correct protective grounding of the equipment must be established, the user must be protected against supply voltage, and the motor must be

protected against overload in accordance with applicable national and local regulations.

4. The ground leakage currents are higher than 3.5 mA.

5. Protection against motor overload is set by par. 1-90

(default value) or data value [ETR warning]. Note: The function is initialized at 1.16 x rated motor current and rated motor frequency. For the

North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and line power supply while the adjustable frequency drive is connected to line power. Make sure that

the line power supply has been disconnected and that the necessary time has passed before removing motor and line plugs.

7. Please note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3 when load sharing (linking of the DC intermediate

circuit) and external 24 V DC have been installed. Make sure that all voltage inputs have been disconnected and that the necessary time has

passed before commencing repair work.

Installation at High Altitudes

Motor Thermal Protection

. If this function is desired, set par. 1-90 to data value [ETR trip]

2

At altitudes higher than 6,600 feet [2 km], please contact Danfoss regarding PELV.

Warning against Unintended Start

1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop while the adjustable frequency drive is

connected to line power. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not

sufficient. 2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated; following

which data can be modified. 3. A motor that has been stopped may start if faults occur in the electronics of the adjustable frequency drive, or if a temporary

overload or a fault in the supply line or the motor connection ceases.

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.

Also, make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well

as the motor connection for kinetic backup.

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2 Safety VLT AQUA High Power Instruction Manual

2.1.2 General Warning

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from line power.

Als o m ak e s ur e t ha t other voltage inputs ha ve be en disconnected, (lin ka ge of DC intermediate cir cu it ), as we ll as the motor con nection

for kinetic backup.

Before touching any potentially live parts of the VLT AQUA Drive FC 200, wait at least the minimum time as follows:

380-480 V, 150-600 hp [110-450 kW], wait at least 15 minutes.

525-690 V, 175-850 hp [132-630 kW], wait at least 20 minutes.

A shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage Current

The ground leakage current from the VLT AQUA Drive FC 200 exceeds 3.5 mA. According to IEC 61800-5-1, a reinforced protective

ground connection must be ensured by means of: a min. 0.015 in² [10 mm²] Cu or 0.025 in² [16 mm²] Al PE wire or an additional PE

wire, with the same cable cross-section as the line power wiring, must be terminated separately.

Residual Current Device

This product can cause DC current in the protective conductor. If a residual current device (RCD) is used for extra protection, only an

RCD of Type B (time delayed) may be used on the supply side of this product. See also RCD Application Note MN.90.GX.02.

Protective grounding of the VLT AQUA Drive FC 200 and the use of RCDs must always follow national and local regulations.

2.1.3 Before Commencing Repair Work

1. Disconnect the adjustable frequency drive from line power.

2. Disconnect DC bus terminals 88 and 89.

3. Wait at least the time mentioned above in the section General Warning.

4. Remove motor cable

2.1.4 Special conditions

Electrical ratings:

The rating indicated on the nameplate of the adjustable frequency drive is based on a typical 3-phase line power supply within the specified voltage,

current and temperature ranges, which are expected to be used in most applications.

The adjustable frequency drives also support other special applications, which affect the electrical ratings of the adjustable frequency

drive. Special conditions that affect the electrical ratings might be:

• Single phase applications.

• High temperature applications which require derating of the electrical ratings

• Marine applications with more severe environmental conditions.

®

Consult the relevant clauses in these instructions and in the VLT

Installation requirements:

The overall electrical safety of the adjustable frequency drive requires special installation considerations regarding:

• Fuses and circuit breakers for overcurrent and short-circuit protection

• Selection of power cables (line power, motor, brake, load sharing and relay)

• Grid configuration (IT,TN, grounded leg, etc.)

• Safety of low-voltage ports (PELV conditions).

Consult the relevant clauses in these instructions and in the VLT

AQUA Drive Design Guide for information about the electrical ratings.

®

AQUA Drive Design Guide for information about the installation requirements.

2-2

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VLT AQUA High Power Instruction Manual 2 Safety

2.1.5 Caution

The adjustable frequency drive's DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock

hazard, disconnect the adjustable frequency drive from line power before carrying out maintenance. Before doing service on the

adjustable frequency drive, wait at least the amount of time indicated below:

Voltage Power size Min. Waiting Time

380–480 V 150–350 HP [110–250 kW] 20 minutes

450–1350 HP [315–1000 kW] 40 minutes

525–690 V 60–550 HP [45–400 kW] 20 minutes

450–1200 kW 30 minutes

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.6 Avoid unintended Start.

While the adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus

commands, references or via the Local Control Panel.

• Disconnect the adjustable frequency drive from line power whenever personal safety considerations make it necessary to avoid an unintended

start.

• To avoid an unintended start, always activate the [OFF] key before changing parameters.

• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the line power supply or lost motor connection may cause a

stopped motor to start.

2

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2 Safety VLT AQUA High Power Instruction Manual

2.1.7 Safe Stop Installation

To carry out an installation of a Category 0 Stop (EN60204) in

conformity with Safety Category 3 (EN954-1), follow these in-

structions:

1. The bridge (jumper) between Terminal 37 and 24 V DC must be

removed. Cutting or breaking the jumper is not sufficient. Re-

move it entirely to avoid short-circuiting. See jumper on illus-

tration.

2. Connect terminal 37 to 24 V DC by a short circuit-protected ca-

ble. The 24 V DC voltage supply must be interruptible by an

EN954-1 category 3 circuit interrupt device. If the interrupt de-

vice and the adjustable frequency drive are placed in the same

installation panel, you can use an unshielded cable instead of a

shielded one.

The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1). The circuit interruption is caused by an opening

door contact. The illustration also shows how to connect a non-safety-related hardware coast.

Figure 2.1: Bridge jumper between terminal 37 and 24 VDC

Figure 2.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN

954-1).

2-4

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VLT AQUA High Power Instruction Manual 2 Safety

2.1.8 Safe Stop of the Adjustable Frequency Drive

For versions fitted with a Safe Stop terminal 37 input, the adjustable frequency drive can perform the safety function

draft CD IEC 61800-5-2) or

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and

use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality

and safety category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety

Category 3 in EN 954-1, the related information and instructions of the VLT AQUA Drive Design Guide MG.20.NX.YY must be followed! The information

and instructions of the Instruction Manual are not sufficient for a correct and safe use of the Safe Stop functionality!

Stop Category 0

(as defined in EN 60204-1).

Safe Torque Off

(As defined by

2

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2 Safety VLT AQUA High Power Instruction Manual

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VLT AQUA High Power Instruction Manual 2 Safety

2.1.9 IT Line Power

IT Line Power

Do not connect 400 V adjustable frequency drives with RFI filters to line supplies with a voltage between phase and ground of more

than 440 V.

For IT line power and delta ground (grounded leg), AC line voltage may exceed 440 V between phase and ground.

2

par. 14-50

to A2 level.

RFI 1

can be used to disconnect the internal RFI capacitors from the RFI filter to ground. If this is done, it will reduce the RFI performance

2.1.10 Software Version and Approvals

VLT AQUA Drive

Software version: 1.24

This manual can be used with all VLT AQUA Drive adjustable frequency drives with software version 1.24.

The software version number can be found in parameter 15-43.

2.1.11 Disposal Instructions

Equipment containing electrical components must not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently valid leg­islation.

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VLT AQUA High Power Instruction Manual 3 How to Install

3How to Install

3.1 How to Get Started

3.1.1 About How to Install

This chapter covers mechanical and electrical installations to and from power terminals and control card terminals.

Electrical installation of

options

is described in the relevant Instruction Manual and Design Guide.

3.1.2 How to Get Started

The adjustable frequency drive is designed for quick installation and is EMC-compliant. Just follow the steps described below.

Read the safety instructions before installing the unit.

3

Mechanical Installation

• Mechanical mounting

Electrical Installation

• Connection to Line and Protecting Ground

• Motor connection and cables

• Fuses and circuit breakers

• Control terminals - cables

Quick set-up

•Local Control Panel, LCP

• Automatic Motor Adaptation, AMA

• Programming

Frame size is depending on enclosure type, power range and AC line

voltage

Figure 3.1: Diagram showing basic installation including line

power, motor, start/stop key, and potentiometer for speed

adjustment.

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3 How to Install VLT AQUA High Power Instruction Manual

3.2 Pre-installation

3.2.1 Planning the Installation Site

NOTE!

Before performing the installation, it is important to plan the installation of the adjustable frequency drive. Neglecting this may result

in extra work during and after installation.

Select the best possible operation site by considering the following (see details on the following pages and in the respective Design

Guides):

• Ambient operating temperature

• Installation method

• How to cool the unit

• Position of the adjustable frequency drive.

•Cable routing

• Ensure the power source supplies the correct voltage and necessary current.

• Ensure that the motor current rating is within the maximum current from the adjustable frequency drive.

• If the adjustable frequency drive is without built-in fuses, ensure that the external fuses are rated correctly.

3.2.2 Receiving the Adjustable Frequency Drive

When receiving the adjustable frequency drive, make sure that the packaging is intact, and look for any damage that might have occurred to the unit

during transport. If damage has occurred, immediately contact the shipping company to make a damage claim.

3-2

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VLT AQUA High Power Instruction Manual 3 How to Install

3.2.3 Transportation and Unpacking

Before unpacking the adjustable frequency drive, it is recommended to unload it as close as possible to the final installation site.

Remove the box and handle the adjustable frequency drive on the pallet, as long as possible.

NOTE!

The card box cover contains a drilling master for the mounting holes in the D frames. For the E size, please refer to section

Dimensions

later in this chapter.

Mechanical

3

Figure 3.2: Mounting Template

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3 How to Install VLT AQUA High Power Instruction Manual

3.2.4 Lifting

Always lift the adjustable frequency drive using the dedicated lifting holes. For all D and E2 (IP00) frames, use a bar to avoid bending the lifting holes of

the adjustable frequency drive.

Figure 3.3: Recommended lifting method, frame sizes D and E .

NOTE!

The lifting bar must be able to handle the weight of the adjustable frequency drive. See

different frame sizes. Maximum diameter for bar is 1 in [25 cm]. The angle from the top of the drive to the lifting cable should be 60

degrees or greater.

Mechanical Dimensions

for the weight of the

Figure 3.4: Recommended lifting method, frame size F1.

3-4

Figure 3.5: Recommended lifting method, frame size F2.

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VLT AQUA High Power Instruction Manual 3 How to Install

3

Figure 3.6: Recommended lifting method, frame size F3.

Figure 3.7: Recommended lifting method, frame size F4.

NOTE!

Note the plinth is provided in the same packaging as the adjustable frequency drive but is not attached to Unit SizesF1-F461-64 frames

during shipment. The plinth is required to allow airflow to the drive to provide proper cooling. The Unit SizesF6 frames should be

positioned on top of the plinth in the final installation location. The angle from the top of the drive to the lifting cable should be 60

degrees or greater.

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3 How to Install VLT AQUA High Power Instruction Manual

3.2.5 Mechanical Dimensions

3-6

Please note airflow directions

*

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VLT AQUA High Power Instruction Manual 3 How to Install

3

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Please note airflow directions

*

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3 How to Install VLT AQUA High Power Instruction Manual

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Please note airflow directions

*

VLT AQUA High Power Instruction Manual 3 How to Install

3

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Please note airflow directions

*

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3 How to Install VLT AQUA High Power Instruction Manual

F1 IP 21/54 - NEMA 1/12 F3 IP 21/54 - NEMA 1/12

3-10

1) Minimum clearance from ceiling

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VLT AQUA High Power Instruction Manual 3 How to Install

3

F2 IP 21/54 - NEMA 1/12 F4 IP 21/54 - NEMA 1/12

1) Minimum clearance from ceiling

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3 How to Install VLT AQUA High Power Instruction Manual

3

Frame Size D1 D2 D3 D4

150–175 HP [110–132 kW] at

60–250 HP [45–160 kW] at 690

IP
NEMA
Ship­ping di­men­sions

Drive
dimen­sions

Frame Size E1 E2 F1 F2 F3 F4

IP
NEMA
Shipping di­mensions

Drive dimen­sions

Height

Width

Depth

Height

Width

Depth 15 in [380 mm] 15 in [380 mm] 15 in [380 mm] 15 in [380 mm] 14.8 in [375 mm] 14.8 in [375 mm]

Max weight 229 lb [104 kg] 229 lb [104 kg]

Mechanical dimensions, frame size E and F

Height

Width 86.5 in [2197 mm] 67.1 in [1705 mm] 61.8 in [1569 mm] 77.2 in [1962 mm] 85 in [2159 mm]

Depth 28 in [736 mm] 28 in [736 mm] 36.5 in [927 mm] 36.5 in [927 mm] 36.5 in [927 mm] 36.5 in [927 mm]

Height 78.7 in [2000 mm] 60.9 in [1547 mm] 2204 2204 2204 2204

Width 23.6 in [600 mm] 23 in [585 mm] 1400 1800 2000 2400
Depth 19.5 in [494 mm] 19.6 in [498 mm] 606 606 606 606
Max
weight

21
Type 1

25.6 in [650
mm]

68.1 in [1730
mm]

22.4 in [570
mm]

47.6 in [1209
mm]

16.5 in [420
mm]

450–600 HP

[315–450 kW]

at 400 V
(380–480 V)
600–850 HP

[450–630 kW]

at 690 V
(525–690 V)

21, 54
Type 1/ Type 1200Chassis

33.1 in [840 mm] 32.7 in [831 mm] 91.5 in [2324 mm] 91.5 in [2324 mm] 91.5 in [2324 mm] 91.5 in [2324 mm]

690 lbs [313 kg] 610 [277 kg] 1004 1246 1299 1541

Mechanical dimensions, Frame size D

400 V

(380–480 V)

V

(525–690 V)

54
Type 12

25.6 in [650 mm]

68.1 in [1730 mm]

22.4 in [570 mm]

47.6 in [1209 mm]

16.5 in [420 mm]

450–600 HP

[315–450 kW] at

400 V

(380–480 V)

1000–850 HP

[450–630 kW] at

690 V

(525–690 V)

250–350 HP [160–250 kW] at

300–550 HP [200–400 kW] at

21
Type 1

25.6 in [650

68.1 in [1730

22.4 in [570

62.6 in [1589

16.5 in [420

332.9 lbs [151

675–950 HP

[500–710 kW]

at 400 V

(380–480 V)

950–1200 HP

[710–900 kW]

at 690 V

(525–690 V)

21, 54
Type 1/ Type 12

(380–480 V)

(525–690 V)

mm]

mm]

mm]

mm]

mm]

kg]

150–175 HP

400 V

690 V

54
Type 12

25.6 in [650 mm] 25.6 in [650 mm] 25.6 in [650 mm]

68.1 in [1730 mm] 48 in [1220 mm]

22.4 in [570 mm] 22.4 in [570 mm] 22.4 in [570 mm]

62.6 in [1589 mm]

16.5 in [420 mm] 16.1 in [408 mm] 16.1 in [408 mm]

332.9 lbs [151 kg] 200 lbs [91 kg] 304 lbs [138 kg]

1075–1350 HP

[800–1000 kW]

at 400 V

(380–480 V)

1350–1600 HP

[1000–1200

kW] at 690 V

(525–690 V)

21, 54
Type 1/ Type 12

[110–132 kW]

at 400 V

(380–480 V)

60–250 HP

[45–160 kW]

at 690 V

(525–690 V)

00
Chassis

41.2 in [1046
mm]

675–950 HP

[500–710 kW] at

400 V

(380–480 V)

950–1200 HP

[710–900 kW] at

690 V

(525–690 V)

21, 54
Type 1/ Type 12

250–350 HP

[160–250 kW]

at 400 V
(380–480 V)
300–550 HP

[200–400 kW]

at 690 V
(525–690 V)

00
Chassis

58.7 in [1490
mm]

52.2 in [1327
mm]

1075–1350 HP

[800–1000 kW]

at 400 V

(380–480 V)

1350–1600 HP

[1000–1200 kW]

at 690 V

(525–690 V)

21, 54
Type 1/ Type 12

100.1 in [2559
mm]

3-12

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VLT AQUA High Power Instruction Manual 3 How to Install

3.2.6 Rated Power

Frame size D1 D2 D3 D4

3

Enclosure

protection

Normal overload

rated power - 110%

overload torque

Frame size E1 E2 F1/F3 F2/F4

Enclosure

protection

Normal overload

rated power -

110% overload

IP 21/54 21/54 00 00

NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis

110 - 132 kW at 400 V

(380 - 480 V)

60–250 HP [45–160 kW] at

690 V

(525–690 V)

IP 21/54 00 21/54 21/54

NEMA Type 1/ Type 12 Chassis Type 1/ Type 12 Type 1/ Type 12

450–600 HP [315–450 kW]

at 400 V

(380–480 V)

600–850 HP [450–630 kW]

torque

at 690 V

(525–690 V)

200–350 HP [150–250 kW] at

400 V

(380–480 V)

300–550 HP [200–400 kW] at

690 V

(525–690 V)

450–600 HP [315–450

kW] at 400 V

(380–480 V)

600–850 HP [450–630

kW] at 690 V

(525–690 V)

150–175 HP [110–132 kW] at

400 V

(380–480 V)

60–250 HP [45–160 kW] at

690 V

(525–690 V)

675–950 HP [500–710 kW] at 400

V

(380–480 V)

950–1200 HP [710–900 kW] at 690

V

(525–690 V)

175–350 HP [150–250 kW] at

300–550 HP [200–400 kW] at

1075–1350 HP [800–1000 kW] at

1350–1600 HP [1000–1200 kW]

400 V

(380–480 V)

690 V

(525–690 V)

400 V

(380–480 V)

at 690 V

(525–690 V)

NOTE!

The F frames have four different sizes, F1, F2, F3 and F4 The F1 and F2 consist of an inverter cabinet on the right and rectifier cabinet

on the left. The F3 and F4 have an additional options cabinet left of the rectifier cabinet. The F3 is an F1 with an additional options

cabinet. The F4 is an F2 with an additional options cabinet.

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3 How to Install VLT AQUA High Power Instruction Manual

3.3 Mechanical Installation

Preparation of the mechanical installation of the adjustable frequency drive must be done carefully to ensure proper results and to avoid additional work

during installation. Start by taking a close look at the mechanical drawings at the end of this instruction manual to become familiar with the space demands.

3.3.1 Tools Needed

3

To perform the mechanical installation, the following tools are needed:

• Drill with 0.39 or 0.47 in [10 or 12 mm] drill.

• Tape measure

• Wrench with relevant metric sockets (0.28-0.67 in (7-17 mm))

• Extensions to wrench

• Sheet metal punch for conduits or cable connectors in IP 21/Nema 1 and IP 54 units

• Lifting bar to lift the unit (rod or tube max. Ø1 in [25 mm], able to lift minimum 880 lbs [400 kg].

• Crane or other lifting aid to place the adjustable frequency drive in position

• A Torx T50 tool is needed to install the E1 in IP21 and IP54 enclosure types.

3.3.2 General Considerations

Space

Ensure proper space above and below the adjustable frequency drive to allow airflow and cable access. In addition, space in front of the unit must be

considered to allow the panel door to be opened.

Figure 3.8: Space in front of IP21/IP54 enclosure type,

frame size D1 and D2.

Wire access

Ensure that proper cable access is present including necessary bending allowance. As the IP00 enclosure is open to the bottom cables must be fixed to

the back panel of the enclosure where the adjustable frequency drive is mounted, e.g., by using cable clamps.

NOTE!

All cable lugs/shoes must mount within the width of the terminal bus bar.

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Figure 3.9: Space in front of IP21/IP54 enclosure type,

frame size E1.

VLT AQUA High Power Instruction Manual 3 How to Install

3.3.3 Terminal locations - frame size D

Take the following terminal positions into consideration when you design for cable access.

3

Figure 3.10: Position of power connections, frame size D3 and D4

Figure 3.11: Position of power connections with disconnect switch, frame size D1 and D2

Be aware that the power cables are heavy and hard to bend. Give thought to the optimum position of the adjustable frequency drive for ensuring easy

installation of the cables.

NOTE!

All D frames are available with standard input terminals or disconnect switch. All terminal dimensions can be found in the table on the

next page.

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3 How to Install VLT AQUA High Power Instruction Manual

IP 21 (NEMA 1) / IP 54 (NEMA 12) IP 00 / Chassis

Frame size D1 Frame size D2 Frame size D3 Frame size D4

A 277 (10.9) 379 (14.9) 119 (4.7) 122 (4.8)

B 227 (8.9) 326 (12.8) 68 (2.7) 68 (2.7)

C 173 (6.8) 273 (10.8) 15 (0.6) 16 (0.6)

D 179 (7.0) 279 (11.0) 20.7 (0.8) 22 (0.8)

E 370 (14.6) 370 (14.6) 363 (14.3) 363 (14.3)

F 300 (11.8) 300 (11.8) 293 (11.5) 293 (11.5)

G 222 (8.7) 226 (8.9) 215 (8.4) 218 (8.6)

H 139 (5.4) 142 (5.6) 131 (5.2) 135 (5.3)

I 55 (2.2) 59 (2.3) 48 (1.9) 51 (2.0)

J 354 (13.9) 361 (14.2) 347 (13.6) 354 (13.9)

K 284 (11.2) 277 (10.9) 277 (10.9) 270 (10.6)

L 334 (13.1) 334 (13.1) 326 (12.8) 326 (12.8)

M 250 (9.8) 250 (9.8) 243 (9.6) 243 (9.6)

N 167 (6.6) 167 (6.6) 159 (6.3) 159 (6.3)

O 261 (10.3) 260 (10.3) 261 (10.3) 261 (10.3)

P 170 (6.7) 169 (6.7) 170 (6.7) 170 (6.7)

Q 120 (4.7) 120 (4.7) 120 (4.7) 120 (4.7)

R 256 (10.1) 350 (13.8) 98 (3.8) 93 (3.7)

S 308 (12.1) 332 (13.0) 301 (11.8) 324 (12.8)

T 252 (9.9) 262 (10.3) 245 (9.6) 255 (10.0)

U 196 (7.7) 192 (7.6) 189 (7.4) 185 (7.3)

V 260 (10.2) 273 (10.7) 260 (10.2) 273 (10.7)

Table 3.1: Cable positions as shown in the drawings above. Dimensions in mm (inches).

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VLT AQUA High Power Instruction Manual 3 How to Install

3.3.4 Terminal Locations - frame size E

Terminal locations - E1

Give thought to the following terminal positions when designing the cable access.

3

Figure 3.12: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) enclosure power connection positions

Figure 3.13: IP21 (NEMA type 1) and IP54 (NEMA type 12) enclosure power connection positions (detail B)

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.14: IP21 (NEMA type 1) and IP54 (NEMA type 12) enclosure power connection position of disconnect switch

Frame size UNIT TYPE DIMENSION FOR DISCONNECT TERMINAL

IP54/IP21 UL AND NEMA1/NEMA12

350/450 hp [250/315 kW] (400 V) AND

500/600–675/850 hp [355/450–500/630 KW]

E1

450/500–550/600 hp [315/355-400/450 kW]

(690 V)

(400 V)

381 (15.0) 253 (9.9) 253 (9.9) 431 (17.0) 562 (22.1) N/A

371 (14.6) 371 (14.6) 341 (13.4) 431 (17.0) 431 (17.0) 455 (17.9)

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VLT AQUA High Power Instruction Manual 3 How to Install

Terminal locations - E2

Give thought to the following terminal positions when designing the cable access.

3

Figure 3.15: IP00 enclosure power connection positions

Figure 3.16: IP00 enclosure power connection positions

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.17: IP00 enclosure power connections positions of disconnect switch

Note that the power cables are heavy and difficult to bend. Give thought to the optimum position of the adjustable frequency drive for ensuring easy

installation of the cables.

Each terminal allows for the use of up to 4 cables with cable lugs or the use of standard box lug. Ground is connected to relevant termination point in

the drive.

Figure 3.18: Terminal in details

NOTE!

Power connections can be made to positions A or B

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VLT AQUA High Power Instruction Manual 3 How to Install

Frame size UNIT TYPE DIMENSION FOR DISCONNECT TERMINAL

IPOO/CHASSIS A B C D E F

350/450 hp [250/315 kW] (400 V) AND

500/600–675/850 hp [355/450–500/630 KW]

E2

450/500–550/600 hp [315/355-400/450 kW]

(690 V)

(400 V)

381 (15.0) 245 (9.6) 334 (13.1) 423 (16.7) 256 (10.1) N/A

383 (15.1) 244 (9.6) 334 (13.1) 424 (16.7) 109 (4.3) 149 (5.8)

3.3.5 Terminal Locations - frame size F

NOTE!

The F framesUnit Sizes 5 have four different sizes, F1, F2, F3 and F461, 62, 63 and 64. The F1 and F261 and 62 consist of an inverter

cabinet on the right and rectifier cabinet on the left. The F3 and F463 and 64 have an additional options cabinet left of the rectifier

cabinet. The F363 is an F161 with an additional options cabinet. The F464 is an F262 with an additional options cabinet.

Terminal locations - frame size F1 and F3

3

Figure 3.19: Terminal locations - Inverter Cabinet - F1 and F3 (front, left and right side view)

1) Earth ground bar

2) Motor terminals

3) Brake terminals

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3 How to Install VLT AQUA High Power Instruction Manual

Terminal locations - frame size F2 and F4

Figure 3.20: Terminal locations - Inverter Cabinet - F2 and F4 (front, left and right side view)

1) Earth ground bar

Terminal locations - Rectifier (F1, F2, F3 and F4)

Figure 3.21: Terminal locations - Rectifier (Left side, front and right side view)

1) Load Share Terminal (-)

2) Earth ground bar

3) Load Share Terminal (+)

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VLT AQUA High Power Instruction Manual 3 How to Install

Terminal locations - Options Cabinet (F3 and F4)

3

Figure 3.22: Terminal locations - Options Cabinet (Left side, front and right side view)

1) Earth ground bar

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3 How to Install VLT AQUA High Power Instruction Manual

Terminal locations - Options Cabinet with circuit breaker/ molded case switch (F3 and F4)

Figure 3.23: Terminal locations - Options Cabinet with circuit breaker/ molded case switch (Left side, front and right side view)

1) Earth ground bar

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VLT AQUA High Power Instruction Manual 3 How to Install

3.3.6 Cooling and Airflow

Cooling

Cooling can be obtained in different ways, by using the cooling ducts in the bottom and the top of the unit, by taking air in and out the back of the unit

or by combining the cooling possibilities.

Duct cooling

A dedicated option has been developed to optimize installation of IP00/chassis frame adjustable frequency drives in Rittal TS8 enclosures utilizing the

fan of the adjustable frequency drive for forced air cooling of the backchannel. The air out the top of the enclosure could but ducted outside a facility so

the heat losses from the backchannel are not dissipated within the control room reducing air-conditioning requirements of the facility.

Please see

Back cooling

The backchannel air can also be ventilated in and out the back of a Rittal TS8 enclosure. This offers a solution where the backchannel could take air from

outside the facility and return the heat losses outside the facility thus reducing air-conditioning requirements.

Installation of Duct Cooling Kit in Rittal enclosures

NOTE!

A door fan or fans are required on the Rittal cabinet to remove the losses not contained in the backchannel of the drive. The minimum

door fan airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door fan airflow

required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm). If the ambient is below maximum or if additional components

and heat loss are added within the enclosure, a calculation must be made to ensure the proper airflow is provided to cool the inside

of the Rittal enclosure.

, for further information.

3

Airflow

The necessary airflow over the heatsink must be ensured. The flow rate is shown below.

Enclosure protection

IP21 / NEMA 1

IP54 / NEMA 12

IP21 / NEMA 1 F1, F2, F3 and F4

IP54 / NEMA 12 F1, F2, F3 and F4

IP00 / Chassis D3 and D4

* Airflow per fan. Frame size F contain multiple fans.

Table 3.2: Heatsink Air Flow

NOTE!

The fan runs for the following reasons:

1. AMAAuto-tune

2. DC Hold

3. Pre-Mag

4. DC Brake

5. 60% of nominal current is exceeded

6. Specific heatsink temperature exceeded (power-size dependent).

Once the fan is started, it will run for a minimum of 10 minutes.

D1 and D2

E1

E2

Frame size Door fan/Top fan airflow Airflow over heatsink

6,003 ft3/h [170 m3/h] (100 cfm) 27,015 ft 3 [765 m3/h] (450 cfm)

3

12,006 ft

24,720 ft3/h [700 m3/h] (412 cfm)* 34,784 ft3/h [985 m3/h] (580 cfm)

3

18,540 ft

9,005 ft3/h [255 m3/h] (150 cfm) 27,015 ft3 [765 m3/h] (450 cfm)

3

/h [255 m3/h] (150 cfm) 50,994 ft3/h [1,444 m3/h] (850 cfm)

9,005 ft

/h [340 m3/h] (200 cfm) 50,994 ft3/h [1,444 m3/h] (850 cfm)

/h [525 m3/h] (309 cfm)* 34,784 ft3/h [985 m3/h] (580 cfm)

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3 How to Install VLT AQUA High Power Instruction Manual

3.3.7 Installation on the wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units

This only applies to frame sizes D1 and D2 . Thought must be given to where the unit should be installed.

Take the relevant points into consideration before you select the final installation site:

• Clearance space for cooling

• Clearance for opening the door

• Cable entry clearance from the bottom

Mark the mounting holes carefully using the mounting template on the wall, and drill the holes as indicated. Ensure proper distance to the floor and the

ceiling for cooling. A minimum of 8.9 in [225 mm] below the adjustable frequency drive is needed. Mount the bolts at the bottom and lift the adjustable

frequency drive up on the bolts. Tilt the adjustable frequency drive against the wall and mount the upper bolts. Tighten all four bolts to secure the

adjustable frequency drive against the wall.

Figure 3.24: Lifting method for mounting drive on wall

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VLT AQUA High Power Instruction Manual 3 How to Install

3.3.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)

Cables are connected through the gland plate from the bottom. Remove the plate, and plan where to place the entry for the glands or conduits. Prepare

holes in the marked area on the drawing.

NOTE!

The gland plate must be fitted to the adjustable frequency drive to ensure the specified protection degree, as well as ensuring proper

cooling of the unit. If the gland plate is not mounted, the adjustable frequency drive may trip on Alarm 69, Pwr. Card Temp

3

Figure 3.25: Example of proper installation of the gland plate.

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3 How to Install VLT AQUA High Power Instruction Manual

Frame size D1 + D2

Frame size E1

Cable entries viewed from the bottom of the adjustable frequency drive - 1) Line power side 2) Motor side

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VLT AQUA High Power Instruction Manual 3 How to Install

Frame size F1

3

Frame size F2

Frame size F3

Frame size F4

F1-F4: Cable entries viewed from the bottom of the adjustable frequency drive - 1) Place conduits in marked areas

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.26: Mounting of bottom plate,Frame size E1.

The bottom plate of the E1 frame can be mounted from either inside or outside of the enclosure, allowing flexibility in the installation process, i.e., if

mounted from the bottom, the glands and cables can be mounted before the adjustable frequency drive is placed on the pedestal.

3.3.9 IP21 Drip shield installation (frame size D1 and D2 )

To comply with the IP21 rating, a separate drip shield is to be

installed as explained below:

• Remove the two front screws.

• Insert the drip shield and replace the screws.

• Torque the screws to 5.6 Nm (50 in-lbs).

Figure 3.27: Install the drip shield.

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VLT AQUA High Power Instruction Manual 3 How to Install

3.4 Field Installation of Options

3.4.1 Installation of Duct Cooling Kit in Rittal Enclosures

This section deals with the installation of IP00 / chassis enclosed adjustable frequency drives with duct work cooling kits in Rittal enclosures. In addition

to the enclosure an 8 in [200 mm] base/plinth is required.

3

Figure 3.28: Installation of IP00 in Rittal TS8 enclosure.

The minimum enclosure dimension is:

• D3 and D4 frame: Depth 19.7 in [500 mm] and width 23.6 in [600 mm].

• E2 frame: Depth 23.6 in [600 mm] and width 31.5 in [800 mm].

The maximum depth and width are as required for the installation. When using multiple adjustable frequency drives in one enclosure it is recommended

that each drive is mounted on its own back panel and supported along the mid-section of the panel. These duct work kits do not support the “in frame”

mounting of the panel (see Rittal TS8 catalog for details). The duct work cooling kits listed in the table below are suitable for use only with IP 00 / Chassis

adjustable frequency drives in Rittal TS8 IP 20 and UL and NEMA 1 and IP 54 and UL and NEMA 12 enclosures.

For the E2 frames, it is important to mount the plate at the absolute rear of the Rittal enclosure due to the weight of the adjustable

frequency drive.

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3 How to Install VLT AQUA High Power Instruction Manual

NOTE!

A door fan or fans are required on the Rittal cabinet to remove the losses not contained in the backchannel of the drive. The minimum

door fan airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door fan airflow

required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm). If the ambient is below maximum or if additional components

and heat loss are added within the enclosure, a calculation must be made to ensure the proper airflow is provided to cool the inside

of the Rittal enclosure.

Ordering Information

Rittal TS-8 Enclosure

71 in [1800 mm] 176F1824 176F1823 Not possible

79 in [2000 mm] 176F1826 176F1825 176F1850

86.6 in [2200 mm] 176F0299

Kit Contents

• Ductwork components

• Mounting hardware

•Gasket material

• Delivered with D3 and D4 frame kits:

• 175R5639 - Mounting templates and top/bottom cut out for Rittal enclosure.

• Delivered with E2 frame kits:

• 175R1036 - Mounting templates and top/bottom cut out for Rittal enclosure.

All fasteners are either:

• 0.39 in [10 mm], M5 Nuts torque to 2.3 Nm (20 in-lbs)

• T25 Torx screws torque to 2.3 Nm (20 in-lbs)

Frame D3 Kit Part No. Frame D4Kit Part No. Frame E2 Part No.

NOTE!

Please see the

Duct Kit Instruction Manual, 175R5640,

for further information

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VLT AQUA High Power Instruction Manual 3 How to Install

External ducts

If additional duct work is added externally to the Rittal cabinet, the pressure drop in the ducting must be calculated. Use the charts below to derate the

adjustable frequency drive according to the pressure drop.

3

Figure 3.29: D Frame Derating vs. Pressure Change

Drive air flow: 450 cfm (765 m3/h)

Figure 3.30: E Frame Derating vs. Pressure Change (Small Fan), P250T5 and P355T7-P400T7

Drive air flow: 650 cfm (1105 m3/h)

Figure 3.31: E Frame Derating vs. Pressure Change (Large Fan), P315T5-P400T5 and P500T7-P560T7

Drive air flow: 850 cfm (1445 m3/h)

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3 How to Install VLT AQUA High Power Instruction Manual

3.4.2 Outside installation/ NEMA 3R kit for Rittal enclosures

This section is for the installation of NEMA 3R kits available for the adjustable frequency drive frames D3, D4 and E2. These kits are designed and tested

to be used with IP00/ Chassis versions of these frames in Rittal TS8 NEMA 3R or NEMA 4 enclosures. The NEMA-3R enclosure is an outdoor enclosure

that provides a degree of protection against rain and ice. The NEMA-4 enclosure is an outdoor enclosure that provides a greater degree of protection

against weather and hosed water.

The minimum enclosure depth is 19.7 in [500 mm] (23.6 in [600 mm] for E2 frame) and the kit is designed for a 23.6 in [600 mm] (31.5 in [800 mm]

for E2 frame) wide enclosure. Other enclosure widths are possible, however additional Rittal hardware is required. The maximum depth and width are

as required for the installation.

NOTE!

The current rating of drives in D3 and D4 frames are de-rated by 3%, when adding the NEMA 3R kit. Drives in E2 frames require no

derating

NOTE!

A door fan or fans are required on the Rittal cabinet to remove the losses not contained in the backchannel of the drive. The minimum

door fan airflow required at the drive maximum ambient for the D3 and D4 is 391 m^3/h (230 cfm). The minimum door fan airflow

required at the drive maximum ambient for the E2 is 782 m^3/h (460 cfm). If the ambient is below maximum or if additional components

and heat loss are added within the enclosure, a calculation must be made to ensure the proper airflow is provided to cool the inside

of the Rittal enclosure.

Ordering information

Frame size D3: 176F4600

Frame size D4: 176F4601

Frame size E2: 176F1852

Kit contents:

• Ductwork components

• Mounting hardware

• 0.63 in [16 mm], M5 torx screws for top vent cover

• 0.39 in [10 mm], M5 for attaching drive mounting plate to enclosure

• M10 nuts to attach drive to mounting plate

•Gasket material

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VLT AQUA High Power Instruction Manual 3 How to Install

Torque requirements:

1. M5 screws/ nuts torque to 20 in-lbs (2.3 N-M)

2. M6 screws/ nuts torque to 35 in-lbs (3.9 N-M)

3. M10 nuts torque to 170 in-lbs (20 N-M)

4. T25 Torx screws torque to 20 in-lbs (2.3 N-M)

NOTE!

Please see the instructions

175R5922

for further information

3

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3 How to Install VLT AQUA High Power Instruction Manual

3.4.3 Installation on pedestal

This section describes the installation of a pedestal unit available for the

adjustable frequency drives frames D1 and D2. This is an 8 in [200 mm]

high pedestal that allows these frames to be floor mounted. The front of

the pedestal has openings for input air to the power components.

The adjustable frequency drive connector plate must be installed to pro-

vide adequate cooling air to the control components of the adjustable

frequency drive via the door fan and to maintain the IP21/NEMA 1 or

IP54/NEMA 12 degrees of enclosure protections.

Figure 3.32: Drive on pedestal

There is one pedestal that fits both frames D1 and D2. Its ordering number is 176F1827. The pedestal is standard for E1 frame.

Required Tools:

• Socket wrench with 0.28–0.67 in (7–17 mm) sockets

• T30 Torx Driver

Torques:

• M6 - 4.0 Nm (35 in-lbs)

• M8 - 9.8 Nm (85 in-lbs)

• M10 - 19.6 Nm (170 in-lbs)

Kit Contents:

• Pedestal parts

• Instruction Manual

Figure 3.33: Mount the drive onto pedestal.

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VLT AQUA High Power Instruction Manual 3 How to Install

Install the pedestal on the floor. Fixing holes are to be drilled according

to this figure:

3

Figure 3.34: Drill master for fixing holes in floor.

Mount the drive on the pedestal and using the enclosed bolts, attach it

to the pedestal, as shown in the illustration.

NOTE!

Please see the

Pedestal Kit Instruction Manual, 175R5642

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Figure 3.35: Mounting the drive to the pedestal

, for further information.

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3 How to Install VLT AQUA High Power Instruction Manual

3.4.4 Input plate option

This section is for the field installation of input option kits available for adjustable frequency drives in all D and E frames.

Do not attempt to remove RFI filters from input plates. Damage may occur to the RFI filters if they are removed from the input plate.

NOTE!

Where RFI filters are available, there are two different types of RFI filters depending on the input plate combination and the RFI filters

interchangeable. Field installable kits in certain cases are the same for all voltages.

380–480 V

380–500 V

D1 All D1 power sizes 176F8442 176F8450 176F8444 176F8448 176F8446

D2 All D2 power sizes 176F8443 176F8441 176F8445 176F8449 176F8447

E1 FC102/ 202: 315 kW

FC 302: 250 kW

FC102/ 202: 500–600 HP

[355–450 kW]

FC 302: 450–550 HP

[315–400 kW]

525–690 V Fuses Disconnect Fuses RFI RFI Fuses RFI Disconnect

D1 FC102/ 202: 60–125 HP

[45–90 kW]

FC302: 50–100 HP [37–

75 kW]

FC102/202: 150–250 HP

[110–160 kW]

FC302: 125–175 HP [90–

132 kW]

D2 All D2 power sizes 175L8827 175L8826 175L8825 NA NA

E1 FC102/202: 600–675 HP

[450–500 kW]

FC302: 500–550 HP

[355–400 kW]

FC102/202: 750–850 HP

[560–630 kW]

FC302: 675–750 HP

[500–560 kW]

Fuses Disconnect Fuses RFI RFI Fuses RFI Disconnect

Fuses

176F0253 176F0255 176F0257 176F0258 176F0260

176F0254 176F0256 176F0257 176F0259 176F0262

Fuses

175L8829 175L8828 175L8777 NA NA

175L8442 175L8445 175L8777 NA NA

176F0253 176F0255 NA NA NA

176F0254 176F0258 NA NA NA

Kit contents

- Input plate assembled

- Instruction sheet 175R5795

- Modification Label

- Disconnect handle template (units w/ line power disconnect)

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VLT AQUA High Power Instruction Manual 3 How to Install

Cautions

- The adjustable frequency drive contains dangerous voltages when connected to line voltage. No disassembly should be at-

tempted with power applied

- Electrical parts on the adjustable frequency drive may contain dangerous voltages even after line power has been discon-

nected. Wait the minimum time listed on the drive label after disconnecting line power before touching any internal

components to ensure that capacitors have fully discharged

- The input plates contain metal parts with sharp edges. Use hand protection when removing and reinstalling.

- E frames input plates are heavy (44–77 lbs [20–35 kg] depending on configuration). It is recommended that the disconnect

switch be removed from the input plate for easier installation and then be reinstalled on the input plate after the input plate

has been installed on the drive.

NOTE!

For further information, please see the Instruction Sheet,

175R5795

3.4.5 Installation of Line Power Shield for Adjustable Frequency Drives

3

This section is for the installation of a line power shield for the adjustable frequency drive series with D1, D2 and E1 frames. It is not possible to install

in the IP00/ Chassis versions as these have included as standard a metal cover. These shields satisfy VBG-4 requirements.

Ordering numbers:

Frames D1 and D2 : 176F0799

Frame E1: 176F1851

Torque requirements

M6 - 35 in-lbs (4.0 N-M)

M8 - 85 in-lbs (9.8 N-M)

M10 - 170 in-lbs (19.6 N-M)

NOTE!

For further information, please see the Instruction Sheet,

175R5923

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3 How to Install VLT AQUA High Power Instruction Manual

3.5 Frame size F Panel Options

3.5.1 Frame size F Panel Options

Space Heaters and Thermostat

Mounted on the cabinet interior of frame size F adjustable frequency drives, space heaters controlled via automatic thermostat help control humidity

inside the enclosure, extending the lifetime of drive components in damp environments.

Cabinet Light with Power Outlet

A light mounted on the cabinet interior of frame size F adjustable frequency drives increase visibility during servicing and maintenance. The housing light

includes a power outlet for temporarily powering tools or other devices, available in two voltages:

• 230 V, 50 Hz, 2.5 A, CE/ENEC

• 120 V, 60 Hz, 5 A, UL/cUL

Transformer Tap Set-up

If the cabinet light and outlet and/or the space heaters and thermostat are installed, transformer T1 requires it taps to be set to the proper input voltage.

A 380–480/500 V380–480 V drive will initially be set to the 525 V tap and a 525–690 V drive will be set to the 690 V tap to insure no overvoltage of

secondary equipment occurs if the tap is not changed prior to power being applied. See the table below to set the proper tap at terminal T1 located in

the rectifier cabinet. For location in the drive, see illustration of rectifier in the

Input Voltage Range Tap to Select

380–440 V 400 V

441–490 V 460 V

491–550 V 525 V

551–625 V 575 V

626–660 V 660 V

661–690 V 690 V

Power Connections

section.

NAMUR Terminals

NAMUR is an international association of automation technology users in the process industries, primarily chemical and pharmaceutical industries in

Germany. Selection of this option provides terminals organized and labeled to the specifications of the NAMUR standard for drive input and output

terminals. This requires the MCB 112 PTC thermistor card and MCB 113 extended relay card.

RCD (Residual Current Device)

Uses the core balance method to monitor ground fault currents in grounded and high-resistance grounded systems (TN and TT systems in IEC termi-

nology). There is a pre-warning (50% of main alarm setpoint) and a main alarm setpoint. Associated with each setpoint is an SPDT alarm relay for external

use. Requires an external “window-type” current transformer (supplied and installed by customer).

• Integrated into the drive’s safe-stop circuit

• IEC 60755 Type B device monitors AC, pulsed DC, and pure DC ground fault currents

• LED bar graph indicator of the ground fault current level from 10–100% of the setpoint

• Fault memory

• TEST / RESET button

Insulation Resistance Monitor (IRM)

Monitors the insulation resistance in ungrounded systems (IT systems in IEC terminology) between the system phase conductors and ground. There is

an ohmic pre-warning and a main alarm setpoint for the insulation level. Associated with each setpoint is an SPDT alarm relay for external use. Note:

only one insulation resistance monitor can be connected to each ungrounded (IT) system.

• Integrated into the drive’s safe-stop circuit

• LCD display of the ohmic value of the insulation resistance

•Fault Memory

• INFO, TEST, and RESET buttons

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VLT AQUA High Power Instruction Manual 3 How to Install

IEC Emergency Stop with Pilz Safety Relay

Includes a redundant 4-wire emergency-stop pushbutton mounted on the front of the enclosure and a Pilz relay that monitors it in conjunction with the

drive’s safe-stop circuit and the line power contactor located in the options cabinet.

3

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3 How to Install VLT AQUA High Power Instruction Manual

Manual Motor Starters

Provide 3-phase power for electric blowers often required for larger motors. Power for the starters is provided from the load side of any supplied contactor,

circuit breaker, or disconnect switch. Power is fused before each motor starter, and is off when the incoming power to the drive is off. Up to two starters

are allowed (one if a 30-amp, fuse-protected circuit is ordered). Integrated into the drive’s safe-stop circuit.

Unit features include:

• Operation switch (on/off)

• Short-circuit and overload protection with test function

• Manual reset function

30 Amp, Fuse-Protected Terminals

• 3-phase power matching incoming AC line voltage for powering auxiliary customer equipment

• Not available if two manual motor starters are selected

• Terminals are off when the incoming power to the drive is off

• Power for the fused protected terminals will be provided from the load side of any supplied contactor, circuit breaker, or disconnect switch.

24 VDC Power Supply

• 5 amp, 120 W, 24 VDC

• Protected against output overcurrent, overload, short circuits, and overtemperature

• For powering customer-supplied accessory devices such as sensors, PLC I/O, contactors, temperature probes, LEDs, and/or other electronic

hardware

• Diagnostics include a dry DC ok-contact, a green DC ok-LED, and a red overload LED

External Temperature Monitoring

Designed for monitoring temperatures of external system components, such as the motor windings and/or bearings. Includes eight universal input modules

plus two dedicated thermistor input modules. All ten modules are integrated into the drive’s safe-stop circuit and can be monitored via a serial commu-

nication bus network (requires the purchase of a separate module/bus coupler).

Universal inputs (8)

Signal types:

• RTD inputs (including Pt100), 3-wire or 4-wire

• Thermocouple

• Analog current or analog voltage

Additional features:

• One universal output, configurable for analog voltage or analog current

• Two output relays (N.O.)

• Dual-line LC display and LED diagnostics

• Sensor lead wire break, short-circuit, and incorrect polarity detection

• Interface set-up software

Dedicated thermistor inputs (2)

Features:

• Each module is capable of monitoring up to six thermistors in a series

• Fault diagnostics for wire breakage or short-circuits of sensor leads

• ATEX/UL/CSA certification

• A third thermistor input can be provided by the PTC thermistor option card MCB 112, if necessary.

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VLT AQUA High Power Instruction Manual 3 How to Install

3.6 Electrical Installation

3.6.1 Power Connections

Cabling and Fusing

NOTE!

Cables General

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (167°F [75°C])

conductors are recommended.

The power cable connections are situated as shown below. Dimensioning of cable cross-section must be done in accordance with the current ratings and

local legislation. See the

For protection of the adjustable frequency drive, the recommended fuses must be used or the unit must be with built-in fuses. Recommended fuses can

be seen in the tables of the fuse section. Always ensure that proper fusing is made according to local regulation.

The AC line input connections are fitted to the line power switch if this is included.

Specifications section

for details.

3

See section

NOTE!

To comply with EMC emission specifications, shielded/armored cables are recommended. If an unshielded/unarmored cable is used,

see section

General Specifications

Power and Control Wiring for Unshielded Cables.

for correct dimensioning of motor cable cross-section and length.

For more information, see

EMC Test Results

in the Design Guide.

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3 How to Install VLT AQUA High Power Instruction Manual

Shielding of cables:

Avoid installation with twisted shield ends (pigtails). They spoil the shielding effect at higher frequencies. If it is necessary to break the shield to install

a motor isolator or motor contactor, the shield must be continued at the lowest possible HF impedance.

Connect the motor cable shield to both the de-coupling plate of the adjustable frequency drive and to the metal housing of the motor.

Make the shield connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices within the

adjustable frequency drive.

Cable-length and cross-section:

The adjustable frequency drive has been EMC tested with a given length of cable. Keep the motor cable as short as possible to reduce the noise level

and leakage currents.

Switching frequency:

When adjustable frequency drives are used together with sine-wave filters to reduce the acoustic noise from a motor, the switching frequency must be

set according to the instructions in par. 14-01

Switching Frequency

.

Term. no.

U1 V1 W1

U1 V1 W1

1)Protected Ground Connection

96 97 98 99

U V W

W2 U2 V2 6 wires out of motor

1)

Motor voltage 0–100% of AC line voltage.

PE

1)

PE

1)

PE

3 wires out of motor

Delta-connected

Star-connected U2, V2, W2

U2, V2 and W2 to be interconnected separately.

NOTE!

In motors without phase insulation paper or other in-

sulation reinforcement suitable for operation with volt-

age supply (such as a adjustable frequency drive), fit

a sine-wave filter on the output of the adjustable fre-

quency drive.

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VLT AQUA High Power Instruction Manual 3 How to Install

3

Figure 3.36: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12), frame size D1

Figure 3.37: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) with disconnect, fuse and RFI filter, frame size D2

1) AUX Relay 5) Brake

01 02 03 -R +R

04 05 06 81 82

2) Temp Switch 6) SMPS Fuse (see fuse tables for part number)

106 104 105 7) AUX Fan

3) Line 100 101 102 103

R S T L1 L2 L1 L2

91 92 93 8) Fan Fuse (see fuse tables for part number)

L1 L2 L3 9) Line power ground

4) Load sharing 10) Motor

-DC +DC U V W

88 89 96 97 98

T1 T2 T3

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.38: Compact IP 00 (Chassis), frame size D3

Figure 3.39: Compact IP 00 (Chassis) with disconnect, fuse and RFI filter, frame size D4

1) AUX Relay 5) Brake

01 02 03 -R +R

04 05 06 81 82

2) Temp Switch 6) SMPS Fuse (see fuse tables for part number)

106 104 105 7) AUX Fan

3) Line 100 101 102 103

R S T L1 L2 L1 L2

91 92 93 8) Fan Fuse (see fuse tables for part number)

L1 L2 L3 9) Line power ground

4) Load sharing 10) Motor

-DC +DC U V W

88 89 96 97 98

T1 T2 T3

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VLT AQUA High Power Instruction Manual 3 How to Install

3

Figure 3.40: Position of ground terminals IP00, frame sizes

D

Figure 3.41: Position of ground terminals IP21 (NEMA type

1) and IP54 (NEMA type 12)

NOTE!

D2 and D4 shown as examples. D1 and D3 are equivalent.

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.42: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) frame size E1

Figure 3.43: Compact IP 00 (Chassis) with disconnect, fuse and RFI filter, frame size E2

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VLT AQUA High Power Instruction Manual 3 How to Install

1) AUX Relay 5) Load sharing

01 02 03 -DC +DC

04 05 06 88 89

2) Temp Switch 6) SMPS Fuse (see fuse tables for part number)

106 104 105 7) Fan Fuse (see fuse tables for part number)

3) Line 8) AUX Fan

R S T 100 101 102 103

91 92 93 L1 L2 L1 L2

L1 L2 L3 9) Line power ground

4) Brake 10) Motor

-R +R U V W

81 82 96 97 98

T1 T2 T3

3

Figure 3.44: Position of ground terminals IP00, frame sizes E

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.45: Rectifier Cabinet, frame size F1, F2, F3 and F4

1) 24 V DC, 5 A 5) Loadsharing

T1 Output Taps -DC +DC

Temp Switch 88 89

106 104 105 6) Control Transformer Fuses (2 or 4 pieces). See fuse tables for part numbers

2) Manual Motor Starters 7) SMPS Fuse. See fuse tables for part numbers

3) 30 A Fuse Protected Power Terminals 8) Manual Motor Controller fuses (3 or 6 pieces). See fuse tables for part numbers

4) Line 9) Line Fuses, F1 and F2 frame (3 pieces). See fuse tables for part numbers

R S T 10) 30 Amp Fuse Protected Power fuses

L1 L2 L3

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3

Figure 3.46: Inverter Cabinet, frame size F1 and F3

1) External Temperature Monitoring 6) Motor

2) AUX Relay U V W

01 02 03 96 97 98

04 05 06 T1 T2 T3

3) NAMUR 7) NAMUR Fuse. See fuse tables for part numbers

4) AUX Fan 8) Fan Fuses. See fuse tables for part numbers

100 101 102 103 9) SMPS Fuses. See fuse tables for part numbers

L1 L2 L1 L2

5) Brake

-R +R

81 82

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3 How to Install VLT AQUA High Power Instruction Manual

Figure 3.47: Inverter Cabinet, frame size F2 and F4

1) External Temperature Monitoring 6) Motor

2) AUX Relay U V W

01 02 03 96 97 98

04 05 06 T1 T2 T3

3) NAMUR 7) NAMUR Fuse. See fuse tables for part numbers

4) AUX Fan 8) Fan Fuses. See fuse tables for part numbers

100 101 102 103 9) SMPS Fuses. See fuse tables for part numbers

L1 L2 L1 L2

5) Brake

-R +R

81 82

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VLT AQUA High Power Instruction Manual 3 How to Install

3

Figure 3.48: Options Cabinet, frame size F3 and F4

1) Pilz Relay Terminal 4) Safety Relay Coil Fuse with PILS Relay

2) RCD or IRM Terminal See fuse tables for part numbers

3) Line power 5) Line Fuses, F3 and F4 (3 pieces)

R S T See fuse tables for part numbers

91 92 93 6) Contactor Relay Coil (230 V AC). N/C and N/O Aux Contacts

L1 L2 L3 7) Circuit Breaker Shunt Trip Control Terminals (230 V AC or 230 V DC)

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.2 Power and Control Wiring for Unshielded Cables

Induced Voltage!

Run motor cables from multiple drives separately. Induced voltage from output motor cables run together can charge equipment

capacitors even with the equipment turned off and locked out. Failure to run output cables separately could result in death or serious

injury.

3

Run drive input power, motor wiring, and control wiring in three separate metallic conduits or raceways for high frequency noise

isolation. Failure to isolate power, motor, and control wiring could result in less than optimum controller and associated equipment

performance.

Because the power wiring carries high frequency electrical pulses, it is important that input power and motor power are run in separate conduit. If the

incoming power wiring is run in the same conduit as the motor wiring, these pulses can couple electrical noise back onto the building power grid. Control

wiring should always be isolated from the high voltage power wiring.

When shielded/armored cable is not used, at least three separate conduits must be connected to the panel option (see figure below).

• Power wiring into the enclosure

• Power wiring from the enclosure to the motor

• Control wiring

Figure 3.49: Power and control wiring connection

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VLT AQUA High Power Instruction Manual 3 How to Install

3.6.3 Grounding

The following basic issues need to be considered when installing an adjustable frequency drive, so as to obtain electromagnetic com-

patibility (EMC).

• Safety grounding: Please note that the adjustable frequency drive has a high leakage current and must be grounded appropriately for safety

reasons. Always follow local safety regulations.

• High-frequency grounding: Keep the ground wire connections as short as possible.

Connect the different ground systems at the lowest possible conductor impedance. The lowest possible conductor impedance is obtained by keeping the

conductor as short as possible and by using the greatest possible surface area.

The metal cabinets of the different devices are mounted on the cabinet rear plate using the lowest possible HF impedance. This prevents having different

HF voltages for the individual devices and prevents the risk of radio interference currents running in connection cables that may be used between the

devices, as radio interference is reduced.

In order to obtain a low HF impedance, use the fastening bolts of the devices as HF connections to the rear plate. It is necessary to remove insulating

paint and the like from the fastening points.

3.6.4 Extra Protection (RCD)

ELCB relays, multiple protective grounding or grounding can be used as extra protection, provided that local safety regulations are complied with.

In the case of a ground fault, a DC component may develop in the fault current.

3

If ELCB relays are used, local regulations must be observed. Relays must be suitable for protection of 3-phase equipment with a bridge rectifier and for

a brief discharge on power-up.

See also the section

Special Conditions

in the Design Guide.

3.6.5 RFI Switch

Line power supply isolated from ground

If the adjustable frequency drive is supplied from an isolated line power source ( IT line power, floating delta and grounded delta) or TT/TN-S line power

with grounded leg, the RFI switch is recommended to be turned off (OFF)

EMC performance is needed, parallel motors are connected or the motor cable length is above 82 ft [25 m], it is recommended to set par. 14-50

to [ON].

1)

Not available for 525–600/690 V adjustable frequency drives.

In OFF, the internal RFI capacities (filter capacitors) between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate

circuit and to reduce the ground capacity currents (according to IEC 61800-3).

Please also refer to the application note

power electronics (IEC 61557-8).

VLT on IT line power, MN.90.CX.02.

1)

via par. 14-50

It is important to use isolation monitors that are capable of being used with

RFI 1

. For further reference, see IEC 364-3. In case optimum

RFI 1

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.6 Torque

When tightening all electrical connections, it is very important to tighten

with the correct torque. Too low or too high torque results in a bad elec-

trical connection. Use a torque wrench to ensure correct torque.

Figure 3.50: Always use a torque wrench to tighten the

bolts.

Frame size Terminal Torque Bolt size

D1, D2, D3 and D4 Line power

Motor

Load sharing

Brake

E1 and E2 Line power

Motor

Load sharing

Brake 9.5 (84 in-lbs) M8

F1, F2, F3 and F4 Line power

Motor

Load sharing

Brake

Regen

19 Nm (168 in-lbs) M10

9.5 (84 in-lbs) M8

19 NM (168 in-lbs) M10

19 Nm (168 in-lbs) M10

19 Nm (168 in-lbs)

9.5 Nm (84 in-lbs)

19 Nm (168 in-lbs)

M10

M8

M10

Table 3.3: Torque for terminals

3.6.7 Shielded Cables

It is important that shielded and armored cables are connected properly to ensure high EMC immunity and low emissions.

Connection can be made using either cable connectors or clamps:

• EMC cable connectors: Generally available cable connectors can be used to ensure an optimum EMC connection.

• EMC cable clamp: Clamps allowing for easy connection are supplied with the adjustable frequency drive.

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VLT AQUA High Power Instruction Manual 3 How to Install

3.6.8 Motor cable

The motor must be connected to terminals U/T1/96, V/T2/97, W/T3/98. Ground to terminal 99. All types of three-phase asynchronous standard motors

can be used with an adjustable frequency drive unit. The factory setting is for clockwise rotation with the adjustable frequency drive output connected

as follows:

Terminal No.

96, 97, 98, 99 Line power U/T1, V/T2, W/T3

• Terminal U/T1/96 connected to U-phase

• Terminal V/T2/97 connected to V-phase

• Terminal W/T3/98 connected to W-phase

The direction of rotation can be changed by switching two phases in the motor cable or by changing the setting of par. 4-10

Motor rotation check can be performed using par. 1-28

Function

Ground

Motor Rotation Check

and following the steps shown in the display.

Motor Speed Direction

3

.

F frame Requirements

F1/F3 requirements: Mo tor ph ase ca b le qua nti tie s mu st be 2 , 4, 6, o r 8 ( mul tip le s of 2, 1 ca bl e is not all owe d) to ob tain e qua l amou nt of wi re s attached

to both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the first common

point of a phase. The recommended common point is the motor terminals.

F2/F4 requirements: Motor phase cable quantities must be 3, 6, 9, or 12 (multiples of 3, 2 cables are not allowed) to obtain equal amount of wires

attached to each inverter module terminal. The wires are required to be equal length within 10% between the inverter module terminals and the first

common point of a phase. The recommended common point is the motor terminals.

Output junction box requirements: The length, minimum 8 ft [2.5 m], and quantity of cables m ust be e qual from eac h inverter module to the common

terminal in the junction box.

NOTE!

If a retrofit application requires unequal amount of wires per phase, please consult the factory for requirements.

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.9 Brake Cable Drives with factory-installed brake chopper option

(Only standard with letter B in position 18 of typecode).

The connection cable to the brake resistor must be shielded and the max. length from the adjustable frequency drive to the DC bar is limited to 82 feet

[25 m].

3

Terminal No.

81, 82 Brake resistor terminals

The connection cable to the brake resistor must be shielded. Connect the shield by means of cable clamps to the conductive backplate at the adjustable

frequency drive and to the metal cabinet of the brake resistor.

Size the brake cable cross-section to match the brake torque. See also

safe installation.

Please note that voltages up to 1099 V DC, depending on the supply voltage, may occur on the terminals.

F Frame Requirements

The brake resistor(s) must be connected to the brake terminals in each inverter module.

Function

Brake Instructions, MI.90.Fx.yy

and

MI.50.Sx.yy

for further information regarding

3.6.10 Brake Resistor Temperature Switch

Torque: 0.5–0.6 Nm (5 in-lbs)

Screw size: M3

This input can be used to monitor the temperature of an externally connected brake resistor. If the input between 104 and 106 is established, the

adjustable frequency drive will trip on warning / alarm 27, “Brake IGBT”. If the connection is closed between 104 and 105, the adjustable frequency drive

will trip on warning/alarm 27, “Brake IGBT”.

Normally closed: 104-106 (factory-installed jumper)

Normally open: 104-105

Terminal No.

106, 104, 105 Brake resistor temperature switch.

If the temperature of the brake resistor gets too high

and the thermal switch drops out, the adjustable fre-

quency drive will stop braking. The motor will start

coasting.

A KLIXON switch must be installed that is 'normally

closed'. If this function is not used, 106 and 104 must

be short-circuited together.

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Function

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VLT AQUA High Power Instruction Manual 3 How to Install

3.6.11 Load Sharing

Terminal No. Function

88, 89 Load sharing

The connection cable must be shielded and the max. length from the adjustable frequency drive to the DC bar is limited to 82 ft [25 m].

Load sharing enables the linking of the DC intermediate circuits of several adjustable frequency drives.

3

Please note that voltages up to 1099 V DC may occur on the terminals.

Load sharing calls for extra equipment and safety considerations. For further information, see load sharing instructions MI.50.NX.YY.

Please note that a line power disconnect may not isolate the adjustable frequency drive due to DC link connection

3.6.12 Shielding against Electrical Noise

Before mounting the line power cable, mount the EMC metal cover to ensure best EMC performance.

NOTE: The EMC metal cover is only included in units with an RFI filter.

Figure 3.51: Mount the EMC shield.

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.13 AC line input connections

The line power supply must be connected to terminals 91, 92 and 93. Ground is connected to the terminal to the right of terminal 93.

3

Terminal No.

91, 92, 93

94

Check the nameplate to ensure that the AC line voltage of the adjustable frequency drive matches the power supply of your plant.

Ensure that the power supply can supply the necessary current to the adjustable frequency drive.

If the unit is without built-in fuses, ensure that the appropriate fuses have the correct current rating.

Function

Line power R/L1, S/L2, T/L3

Ground

3.6.14 External Fan Supply

If the adjustable frequency drive is supplied by DC or if the fan must run independently of the power supply, an external power supply can be applied.

The connection is made on the power card.

Terminal No.

100, 101

102, 103

Function

Auxiliary supply S, T

Internal supply S, T

The connector located on the power card provides the AC line voltage connection for the cooling fans. The fans are factory-equipped to be supplied from

a common AC line (jumpers between 100-102 and 101-103). If an external supply is needed, the jumpers are removed and the supply is connected to

terminals 100 and 101. A 5 Amp fuse should be used for protection. In UL applications, this should be a LittleFuse KLK-5 or equivalent.

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3.6.15 Fuses

Branch circuit protection:

In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines, etc., must be short-

circuited and overcurrent protected according to national/international regulations.

Short-circuit protection:

The adjustable frequency drive must be protected against short-circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned

below to protect service personnel and equipment in case of an internal failure in the drive. The adjustable frequency drive provides full short-circuit

protection in case of a short-circuit on the motor output.

Overcurrent protection

Provide overload protection to avoid fire hazard due to overheating of the cables in the installation. The adjustable frequency drive is equipped with

internal overcurrent protection that can be used for upstream overload protection (UL applications excluded). See par. 4-18

fuses or circuit breakers can be used to provide the overcurrent protection in the installation. Overcurrent protection must always be carried out according

to national regulations.

Non-UL compliance

If UL/cUL is not to be complied with, we recommend using the following fuses, which will ensure compliance with EN50178:

In case of malfunction, not following the recommendation may result in unnecessary damage to the adjustable frequency drive.

P110 - P250 380–480 V type gG
P315 - P450 380–480 V type gR

Current Limit

. Moreover,

3

380–480 V, frame sizes D, E and F

The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240 V, or 480 V, or 500 V, or 600 V depending on

the drive voltage rating. With the proper fusing, the drive Short Circuit Current Rating (SCCR) is 100,000 Arms.

Size/

Type

P110 FWH-

P132 FWH-

P160 FWH-

P200 FWH-

P250 FWH-

Table 3.4: Frame size D, Line fuses, 380–480 V

Size/Type

P315 170M4017 700 A, 700 V 6.9URD31D08A0700 20 610 32.700
P355 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900
P400 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900
P450 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900

Table 3.5: Frame size E, Line fuses, 380–480 V

Size/Type

P500 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P560 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P630 170M7082 2000 A, 700 V 20 695 32.2000 170M7082
P710 170M7082 2000 A, 700 V 20 695 32.2000 170M7082
P800 170M7083 2500 A, 700 V 20 695 32.2500 170M7083
P1M0 170M7083 2500 A, 700 V 20 695 32.2500 170M7083

Bussmann

E1958

JFHR2**

300

350

400

500

600

Bussmann

E4273

T/JDDZ**

JJS­300
JJS­350
JJS­400
JJS­500
JJS­600

Bussmann PN* Rating Ferraz Siba

Bussmann PN* Rating Siba Internal Bussmann Option

SIBA

E180276

JFHR2

2061032.315 L50S-300 A50-P300 NOS-

2061032.35 L50S-350 A50-P350 NOS-

2061032.40 L50S-400 A50-P400 NOS-

2061032.50 L50S-500 A50-P500 NOS-

2062032.63 L50S-600 A50-P600 NOS-

LittelFuse

E71611

JFHR2**

Ferraz-

Shawmut

E60314

JFHR2**

Bussmann

E4274

H/JDDZ**

300

350

400

500

600

Bussmann

E125085

JFHR2*

170M3017 170M3018

170M3018 170M3018

170M4012 170M4016

170M4014 170M4016

170M4016 170M4016

Internal

Option

Bussmann

Table 3.6: Frame size F, Line fuses, 380–480 V

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3 How to Install VLT AQUA High Power Instruction Manual

Size/Type Bussmann PN* Rating Siba
P500 170M8611 1100 A, 1000 V 20 781 32.1000
P560 170M8611 1100 A, 1000 V 20 781 32.1000
P630 170M6467 1400 A, 700 V 20 681 32.1400
P710 170M6467 1400 A, 700 V 20 681 32.1400
P800 170M8611 1100 A, 1000 V 20 781 32.1000
P1M0 170M6467 1400 A, 700 V 20 681 32.1400

Table 3.7: Frame size F, Inverter module DC Link Fuses, 380–480 V

3

*170M fuses from Bussmann shown use the -/80 visual indicator; -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage

may be substituted for external use

**Any minimum 500 V UL listed fuse with associated current rating may be used to meet UL requirements.

525–690 V, frame sizes D, E and F

Bussmann

Size/Type

P45K 170M3013 125 2061032.125 6.6URD30D08A0125 170M3015
P55K 170M3014 160 2061032.16 6.6URD30D08A0160 170M3015
P75K 170M3015 200 2061032.2 6.6URD30D08A0200 170M3015
P90K 170M3015 200 2061032.2 6.6URD30D08A0200 170M3015
P110 170M3016 250 2061032.25 6.6URD30D08A0250 170M3018
P132 170M3017 315 2061032.315 6.6URD30D08A0315 170M3018
P160 170M3018 350 2061032.35 6.6URD30D08A0350 170M3018
P200 170M4011 350 2061032.35 6.6URD30D08A0350 170M5011
P250 170M4012 400 2061032.4 6.6URD30D08A0400 170M5011
P315 170M4014 500 2061032.5 6.6URD30D08A0500 170M5011
P400 170M5011 550 2062032.55 6.6URD32D08A550 170M5011

Table 3.8: Frame size D, 525–690 V

Size/Type

P450 170M4017 700 A, 700 V 6.9URD31D08A0700 20 610 32.700
P500 170M4017 700 A, 700 V 6.9URD31D08A0700 20 610 32.700
P560 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900
P630 170M6013 900 A, 700 V 6.9URD33D08A0900 20 630 32.900

Table 3.9: Frame size E, 525–690 V

Size/Type

P710 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P800 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P900 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P1M0 170M7081 1600 A, 700 V 20 695 32.1600 170M7082
P1M2 170M7082 2000 A, 700 V 20 695 32.2000 170M7082
P1M4 170M7083 2500 A, 700 V 20 695 32.2500 170M7083

E125085

JFHR2

Bussmann PN* Rating Ferraz Siba

Bussmann PN* Rating Siba Internal Bussmann Option

Amps

SIBA

E180276

JFHR2

Ferraz-Shawmut

E76491

JFHR2

Internal

Option

Bussmann

Table 3.10: Frame size F, Line fuses, 525–690 V

Size/Type

P710 170M8611 1100 A, 1000 V 20 781 32. 1000
P800 170M8611 1100 A, 1000 V 20 781 32. 1000
P900 170M8611 1100 A, 1000 V 20 781 32. 1000
P1M0 170M8611 1100 A, 1000 V 20 781 32. 1000
P1M2 170M8611 1100 A, 1000 V 20 781 32. 1000
P1M4 170M8611 1100 A, 1000 V 20 781 32.1000

Table 3.11: Frame size F, Inverter module DC Link Fuses, 525–690 V

*170M fuses from Bussmann shown use the -/80 visual indicator; -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage

may be substituted for external use.

Suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes, 500/600/690 Volts maximum when protected by the

above fuses.

3-62

Bussmann PN* Rating Siba

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VLT AQUA High Power Instruction Manual 3 How to Install

Supplementary fuses

Frame size Bussmann PN* Rating

D, E and F KTK-4 4 A, 600 V

Table 3.12: SMPS Fuse

Size/Type

P110-P315, 380–480 V KTK-4 4 A, 600 V

P45K-P500, 525–690 V KTK-4 4 A, 600 V

P355-P1M0, 380–480 V KLK-15 15A, 600 V

P560-P1M4, 525–690 V KLK-15 15A, 600 V

Table 3.13: Fan Fuses

Size/Type

P500-P1M0, 380–480 V 2.5–4.0 A LPJ-6 SP or SPI 6 A, 600 V Any listed Class J Dual Ele-

P710-P1M4, 525–690 V LPJ-10 SP or SPI 10 A, 600 V Any listed Class J Dual Ele-

P500-P1M0, 380–480 V 4.0–6.3 A LPJ-10 SP or SPI 10 A, 600 V Any listed Class J Dual Ele-

P710-P1M4, 525–690 V LPJ-15 SP or SPI 15 A, 600 V Any listed Class J Dual Ele-

P500-P1M0, 380–480 V 6.3–10 A LPJ-15 SP or SPI 15 A, 600 V Any listed Class J Dual Ele-

P710-P1M4, 525–690 V LPJ-20 SP or SPI 20 A, 600 V Any listed Class J Dual Ele-

P500-P1M0, 380–480 V 10–16 A LPJ-25 SP or SPI 25 A, 600 V Any listed Class J Dual Ele-

P710-P1M4, 525–690 V LPJ-20 SP or SPI 20 A, 600 V Any listed Class J Dual Ele-

Table 3.14: Manual Motor Controller Fuses

Frame size

F LPJ-30 SP or SPI 30 A, 600 V Any listed Class J Dual Element, Time

Bussmann PN* LittelFuse Rating

Bussmann PN* Rating Alternative Fuses

ment, Time Delay, 6 A

ment, Time Delay, 10 A

ment, Time Delay, 10 A

ment, Time Delay, 15 A

ment, Time Delay, 15 A

ment, Time Delay, 20 A

ment, Time Delay, 25 A

ment, Time Delay, 20 A

Bussmann PN* Rating Alternative Fuses

Delay, 30 A

3

Table 3.15: 30 A Fuse Protected Terminal Fuse

Frame size

F LPJ-6 SP or SPI 6 A, 600 V Any listed Class J Dual Element, Time

Table 3.16: Control Transformer Fuse

Frame size

F GMC-800MA 800 mA, 250 V

Table 3.17: NAMUR Fuse

Frame size

F LP-CC-6 6 A, 600 V Any listed Class CC, 6 A

Table 3.18: Safety Relay Coil Fuse with PILS Relay

Bussmann PN* Rating Alternative Fuses

Delay, 6 A

Bussmann PN* Rating

Bussmann PN* Rating Alternative Fuses

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.16 Line power disconnectors - frame size D, E and F

Frame size Power & Voltage Type

D1/D3 P110-P132 380–480 V & P110-P160 525–690 V ABB OETL-NF200A

D2/D4 P160-P250 380–480 V & P200-P400 525–690 V ABB OETL-NF400A

E1/E2 P315 380–480 V & P450-P630 525–690 V ABB OETL-NF600A

E1/E2 P355-P450 380–480 V ABB OETL-NF800A

F3 P500 380–480 V & P710-P800 525–690 V Merlin Gerin NPJF36000S12AAYP

F3 P560-P710 380–480 V & P900 525–690 V Merlin Gerin NRK36000S20AAYP

F4 P800-P1M0 380–480 V & P1M0-P1M2 525–690 V Merlin Gerin NRK36000S20AAYP

3.6.17 F frame circuit breakers

Frame size Power & Voltage Type

F3 P500 380–480 V & P710-P800 525–690 V Merlin Gerin NPJF36120U31AABSCYP

F3 P630-P710 380–480 V & P900 525–690 V Merlin Gerin NRJF36200U31AABSCYP

F4 P800 380–480 V & P1M0-P1M2 525–690 V Merlin Gerin NRJF36200U31AABSCYP

F4 P1M0 380–480 V Merlin Gerin NRJF36250U31AABSCYP

3.6.18 F frame line power contactors

Frame size Power & Voltage Type

F3 P500-P560 380–480 V & P710-P900 525–690 V Eaton XTCE650N22A

F3 P630 380–480 V Eaton XTCE820N22A

F3 P710 380–480 V Eaton XTCEC14P22B

F4 P1M0 525–690 V Eaton XTCE820N22A

F4 P800-P1M0 380–480 V & P1M2 525–690 V Eaton XTCEC14P22B

3.6.19 Motor Insulation

For motor cable lengths ≤ than the maximum cable length listed in the

General Specifications tables, the following motor insulation ratings are

recommended because the peak voltage can be up to twice the DC link

voltage, 2.8 times the AC line voltage due to transmission line effects in

the motor cable. If a motor has lower insulation rating, it is recommended

to use a du/dt or sine-wave filter.

Nominal AC Line Voltage Motor Insulation

UN ≤ 420 V Standard ULL = 1300 V

420 V < U

500 V < UN ≤ 600 V Reinforced ULL = 1800 V

600 V < U

≤ 500 V Reinforced ULL = 1600 V

N

≤ 690 V Reinforced ULL = 2000 V

N

3-64

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VLT AQUA High Power Instruction Manual 3 How to Install

3.6.20 Motor Bearing Currents

All motors installed with 150 hp [110 kW] or higher power drives should have NDE (Non-Drive End) insulated bearings installed to eliminate circulating

bearing currents. To minimize DE (Drive End) bearing and shaft currents proper grounding of the drive, motor, driven machine, and motor to the driven

machine is required.

Standard Mitigation Strategies:

1. Use an insulated bearing

2. Apply rigorous installation procedures

- Strictly follow the EMC Installation guideline

- Provide a good high frequency connection between the motor and the adjustable frequency drive for instance by shielded cable which

has a 360° connection in the motor and the adjustable frequency drive.

- Provide a low impedance path from adjustable frequency drive to building ground and from the motor to building ground. This can be

difficult for pumps

- Make a direct ground connection between the motor and load machine

- Reinforce the PE so the high frequency impedance is lower in the PE

- Ensure the motor and load motor are aligned

3. Lower the IGBT switching frequency

4. Modify the inverter waveform, 60° AVM vs. SFAVM

5. Install a shaft grounding system or use an isolating coupling between motor and load

6. Apply conductive lubrication

7. If the application allows, avoid running at low motor speeds by using the minimum speed settings of the drive.

8. Try to ensure the line voltage is balanced to ground. This can be difficult for IT, TT, TN-CS or Grounded leg systems

9. Use a dU/dt or sinus filter

3

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.21 Control cable routing

Tie down all control wires to the designated control cable routing as

shown in the picture. Remember to connect the shields in a proper way

to ensure optimum electrical immunity.

Serial communication bus connection

Connections are made to the relevant options on the control card. For

details, see the relevant serial communication bus instruction. The cable

must be placed to the left inside the adjustable frequency drive and tied

down together with other control wires (see picture).

Figure 3.52: Wire path for control wiring.

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VLT AQUA High Power Instruction Manual 3 How to Install

In the Chassis (IP00) and NEMA 1 units, it is also possible to connect the

serial communication bus from the top of the unit as shown on the picture

to the right. On the NEMA 1 unit, a cover plate must be removed.

Kit number for serial communication bus top connection: 176F1742

3

Figure 3.53: Top connection for serial communication bus.

Installation of 24 Volt external DC Supply

Torque: 0.5–0.6 Nm (5 in-lbs)

Screw size: M3

No.

35 (-), 36 (+) 24 V external DC supply

24 VDC external supply can be used as low voltage supply to the control card and any option cards installed. This enables full operation of the LCP

(including parameter setting) without a connection to line power. Please note that a warning of low voltage will be given when 24 V DC has been connected;

however, there will be no tripping.

Use 24 V DC supply of type PELV to ensure correct galvanic isolation (type PELV) on the control terminals of the adjustable frequency

drive.

Function

3.6.22 Access to Control Terminals

All terminals to the control cables are located beneath the LCP. They are accessed by opening the door of the IP21/ 54 version or removing the covers

of the IP00 version.

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3 How to Install VLT AQUA High Power Instruction Manual

3.6.23 Electrical Installation, Control Terminals

To connect the cable to the terminal:

1. Strip insulation by about 0.34–0.39 in [9–10 mm]

2.

Insert a screwdriver

3. Insert the cable in the adjacent circular hole.

4. Remove the screwdriver. The cable is now mounted in the terminal.

To remove the cable from the terminal:

1.

Insert a screwdriver

2. Pull out the cable.

1)

Max. 0.015 x 0.1 in. [0.4 x 2.5 mm]

1)

in the square hole.

1)

in the square hole.

1.

2.

3.

3-68

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VLT AQUA High Power Instruction Manual 3 How to Install

3.7 Connection Examples

3.7.1 Start/Stop

Terminal 18 = par. 5-10

Terminal 27 = par. 5-12

fault

coast inverse

Terminal 37 = Safe stop

Terminal 18 Digital Input

Terminal 27 Digital Input

)

3.7.2 Pulse Start/Stop

Terminal 18 = par. 5-10

Terminal 27= par. 5-12

Terminal 37 = Safe stop

Terminal 18 Digital Input

Terminal 27 Digital Input

[8]

Start

[0]

No operation

[9]

Latched start

[6]

Stop inverse

(De-

3

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3

3 How to Install VLT AQUA High Power Instruction Manual

3.7.3 Speed Up/Down

Terminals 29/32 = Speed up/down:

Terminal 18 = par. 5-10

fault)

Terminal 27 = par. 5-12

ence [19]

Terminal 29 = par. 5-13

Terminal 32 = par. 5-14

Note: Terminal 29 only in FC x02 (x=series type).

3.7.4 Potentiometer Reference

Voltage reference via a potentiometer:

Reference Source 1 = [1]

Terminal 53, Low Voltage = 0 Volt

Terminal 53, High Voltage = 10 Volt

Terminal 53, Low Ref./Feedback = 0 RPM

Terminal 53, High Ref./Feedback = 1,500 RPM

Switch S201 = OFF (U)

Terminal 18 Digital Input

Terminal 27 Digital Input

Terminal 29 Digital Input

Terminal 32 Digital Input

Analog input 53

(default)

Start [9] (de-

Freeze refer-

Speed up [21]

Slow [22]

3-70

MG.20.P3.22 - VLT® is a registered Danfoss trademark



VLT AQUA High Power Instruction Manual 3 How to Install

3.8 Electrical Installation - continued

3.8.1 Electrical Installation, Control Cables

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Figure 3.54: Diagram showing all electrical terminals without options.

Terminal 37 is the input to be used for safe stop. For instructions on safe stop installation, refer to the section

Safe Stop Installation

in the

adjustable frequency drive Design Guide. See also sections Safe Stop and Safe Stop Installation.

In rare cases, very long control cables and analog signals may, depending on installation, result in 50/60 Hz ground loops due to noise from line power

supply cables.

If this occurs, it may be necessary to break the shield or insert a 100 nF capacitor between shield and chassis.

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3

3 How to Install VLT AQUA High Power Instruction Manual

The digital and analog inputs and outputs must be connected separately to the adjustable frequency drive common inputs (terminal 20, 55, 39) to avoid

ground currents from both groups to affect other groups. For example, switching on the digital input may disturb the analog input signal.

Input polarity of control terminals

NOTE!

To comply with EMC emission specifications, shielded/armored cables are recommended. If an unshielded/unarmored cable is used,

see section

Power and Control Wiring for Unshielded Cables.

For more information, see

EMC Test Results

in the Design Guide.

3-72

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VLT AQUA High Power Instruction Manual 3 How to Install

Connect the wires as described in the Instruction Manual for the adjustable frequency drive. Remember to connect the shields properly to ensure optimum

electrical immunity.

3

MG.20.P3.22 - VLT® is a registered Danfoss trademark

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3 How to Install VLT AQUA High Power Instruction Manual

3.8.2 Switches S201, S202, and S801

Switches S201 (A53) and S202 (A54) are used to select a current (0-20 mA) or a voltage (-10 to 10 V) configuration for the analog input terminals 53

and 54, respectively.

Switch S801 (BUS TER.) can be used to enable termination on the RS-485 port (terminals 68 and 69).

3

See drawing

Default setting:

Diagram showing all electrical terminals

S201 (A53) = OFF (voltage input)

S202 (A54) = OFF (voltage input)

S801 (Bus termination) = OFF

When changing the function of S201, S202 or S801, be careful not to force the switch over. It is recommended to remove the LCP

fixture (cradle) when operating the switches. The switches must not be operated while the adjustable frequency drive is powered.

in section

Electrical Installation.

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VLT AQUA High Power Instruction Manual 3 How to Install

3.9 Final Set-up and Test

To test the set-up and ensure that the adjustable frequency drive is running, follow these steps.

Step 1. Locate the motor nameplate

NOTE!

The motor is either star- (Y) or delta-connected (). This information is located on the motor nameplate data.

3

Step 2. Enter the motor nameplate data in this parameter list.

To access this list, first press the [QUICK MENU] key, then select “Q2

Quick Set-up”.

MG.20.P3.22 - VLT® is a registered Danfoss trademark

1. par. 1-20
par. 1-21

2. par. 1-22

3. par. 1-23

4. par. 1-24

5. par. 1-25

Motor Power [kW]
Motor Power [HP]
Motor Voltage
Motor Frequency
Motor Current
Motor Nominal Speed

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3 How to Install VLT AQUA High Power Instruction Manual

Step 3. Activate the Automatic Motor Adaptation (AMA)

Performing an AMA will ensure optimum performance. The AMA measures the values from the motor model equivalent diagram.

1. Connect terminal 37 to terminal 12 (if terminal 37 is available).

2. Connect terminal 27 to terminal 12 or set par. 5-12

3. Activate the AMA par. 1-29

4. Choose between complete or reduced AMA. If a sine-wave filter is mounted, run only the reduced AMA, or remove the sine-wave filter during

the AMA procedure.

5. Press the [OK] key. The display shows “Press [Hand on] to start”.

6. Press the [Hand on] key. A progress bar indicates if the AMA is in progress.

Stop the AMA during operation

1. Press the [OFF] key - the adjustable frequency drive enters into alarm mode and the display shows that the AMA was terminated by the user.

Successful AMA

1. The display shows “Press [OK] to finish AMA”.

2. Press the [OK] key to exit the AMA state.

Unsuccessful AMA

1. The adjustable frequency drive enters into alarm mode. A description of the alarm can be found in the

2. "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the AMA, before the adjustable frequency drive entered

alarm mode. This number, along with the description of the alarm, will assist you in troubleshooting. If you contact Danfoss for service, make

sure to mention the number and alarm description.

Automatic Motor Adaptation (AMA)

Terminal 27 Digital Input

.

to 'No function' (par. 5-12

Terminal 27 Digital Input

Warnings and Alarms

chapter.

[0])

NOTE!

Unsuccessful AMA is often caused by incorrectly registered motor nameplate data or a too big difference between the motor power

size and the adjustable frequency drive power size.

Step 4. Set speed limit and ramp time

par. 3-02
par. 3-03

Table 3.19: Set up the desired limits for speed and ramp time.

par. 4-11

Minimum Reference
Maximum Reference

Motor Speed Low Limit [RPM]

or par. 4-12

Speed Low Limit [Hz]

par. 4-13

Motor Speed High Limit [RPM]

or par. 4-14

Speed High Limit [Hz]

par. 3-41
par. 3-42

Ramp 1 Ramp-up Time
Ramp 1 Ramp-down Time

Motor

Motor

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VLT AQUA High Power Instruction Manual 3 How to Install

3.10 Additional Connections

3.10.1 Mechanical Brake Control

In hoisting/lowering applications, it is necessary to be able to control an electro-mechanical brake:

• Control the brake using any relay output or digital output (terminal 27 or 29).

• Keep the output closed (voltage-free) as long as the adjustable frequency drive is unable to ‘support’ the motor, such as when the load is too

heavy, for example.

•Select

• The brake is released when the motor current exceeds the preset value in par. 2-20

• The brake is engaged when the output frequency is less than the frequency set in par. 2-21

If the adjustable frequency drive is in alarm mode or in an overvoltage situation, the mechanical brake immediately cuts in.

Mechanical brake control

Brake Speed [Hz]

[32] in par. 5-4* for applications with an electro-mechanical brake.

Release Brake Current

, and only if the adjustable frequency drive carries out a stop command.

.

Activate Brake Speed [RPM]

3.10.2 Parallel Connection of Motors

The adjustable frequency drive can control several parallel-connected

motors. The total current consumption of the motors must not exceed

the rated output current I

for the adjustable frequency drive.

M,N

or par. 2-22

Activate

3

NOTE!

Installation with cables connected in a common joint,

as in the illustration below, is only recommended for

short cable lengths.

NOTE!

When motors are connected in parallel, par. 1-29

tomatic Motor Adaptation (AMA)

NOTE!

The electronic thermal relay (ETR) of the adjustable

frequency drive cannot be used as motor protection for

the individual motor in systems with parallel-connec-

ted motors. Provide further motor protection with, for

example, thermistors in each motor or individual ther-

mal relays (circuit breakers are not suitable for pro-

tection).

Problems may arise at start and at low RPM values if motor sizes are widely different because small motors' relatively high ohmic resistance in the stator

calls for a higher voltage at start and at low RPM values.

cannot be used.

Au-

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3 How to Install VLT AQUA High Power Instruction Manual

3.10.3 Motor Thermal Protection

3

The electronic thermal relay in the adjustable frequency drive has received UL approval for single motor protection, when par. 1-90

Protection

For thermal motor protection, it is also possible to use the MCB 112 PTC thermistor card option. This card provides an ATEX certificate to protect motors

in explosion hazard areas, Zone 1/21 and Zone 2/22. Please refer to the

is set for

ETR Trip

and par. 1-24

Motor Current

is set to the rated motor current (see motor nameplate).

Design Guide

for further information.

Motor Thermal

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4 How to operate the adjustable frequency

VLT AQUA High Power Instruction Manual

4 How to operate the adjustable frequency drive

4.1 Ways of Operation

4.1.1 Ways of Operation

The adjustable frequency drive can be operated in 3 ways:

1. Graphical Local Control Panel (GLCP), see 6.1.2

2. Numeric Local Control Panel (NLCP), see 6.1.3

3. RS-485 serial communication or USB, both for PC connection, see 6.1.4

If the adjustable frequency drive is equipped with the serial communication option, please refer to the relevant documentation.

4.1.2 How to operate the Graphical LCP (GLCP)

The following instructions are valid for the GLCP (LCP 102).

The GLCP is divided into four functional groups:

1. Graphical display with status lines.

2. Menu keys and LEDs - for selecting mode, changing parameters and switching between display functions.

3. Navigation keys and indicator lights (LEDs).

4. Operation keys and LEDs.

drive

4

Graphical display:

The LCD display is backlit with a total of 6 alpha-numeric lines. All data is displayed on the LCP, which can show up to five operating variables while in

[Status] mode.

Display lines:

a. Status line: Status messages displaying icons and graphics.

b. Line 1-2: Operator data lines displaying data and variables de-

fined or chosen by the user. By pressing the [Status] key, up to

one extra line can be added.

c. Status line: Status messages displaying text.

The display is divided into three sections:

Top section (a)

shows the status when in status mode, or up to two variables when not

in status mode and in the case of an alarm/warning.

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4 How to operate the adjustable frequency
drive

VLT AQUA High Power Instruction Manual

The number of the active set-up (selected as the active set-up in par. 0-10) is shown. When programming in a set-up other than the active set-up, the

number of the set-up being programmed appears to the right in brackets.

Middle section (b)

shows up to 5 variables with related unit, regardless of status. In case of an alarm/warning, the warning is shown instead of the variables.

It is possible to toggle between three status readout displays by pressing the [Status] key.

Operating variables with different formatting are shown in each status screen - see below.

Several values or measurements can be linked to each of the displayed operating variables. The values/measurements to be displayed can be defined

via par. 0-20, 0-21, 0-22, 0-23, and 0-24, which can be accessed via [QUICK MENU], "Q3 Function Set-ups", "Q3-1 General Settings", "Q3-11 Display

Settings".

Each value/measurement readout parameter selected in par. 0-20 to par. 0-24 has its own scale and number of digits after a possible decimal point.

Larger numeric values are displayed with few digits after the decimal point.

Ex.: Current readout

5.25 A; 15.2 A 105 A.

Status display I

This readout state is standard after start-up or initialization.

Use [INFO] to obtain information about the value/measurement linked to

the displayed operating variables (1.1, 1.2, 1.3, 2 and 3).

See the operating variables shown in the display in this illustration. 1.1,

1.2 and 1.3 are shown in small size, while 2 and 3 are shown in medium

size.

1.1

1.2

2

3

1.3

0
1

.
1
4
0
P
B
0
3
1

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VLT AQUA High Power Instruction Manual

Status display II

See the operating variables (1.1, 1.2, 1.3 and 2) shown in the display in

this illustration.

In the example, Speed, Motor current, Motor power and Frequency are

selected as variables in the first and second lines.

1.1, 1.2 and 1.3 are shown in small size, while 2 is shown in large size.

Status display III:

This state displays the event and action of the smart logic control. For

further information, see the section

Smart Logic Control

.

4 How to operate the adjustable frequency

drive

1.3

1. 1

1. 2

2

0
1

.
3
6
0
P

B
0
3
1

4

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T

4

4 How to operate the adjustable frequency
drive

Bottom section

always shows the state of the adjustable frequency drive in status mode.

Display Contrast Adjustment

Press [status] and [▲] for darker display.

Press [status] and [▼] for brighter display.

LEDs:

If certain threshold values are exceeded, the alarm and/or warning LED lights up. A status and alarm text appears on the control panel.

The On LED is activated when the adjustable frequency drive receives power from AC line voltage, a DC bus terminal or an external 24 V supply. At the

same time, the back light is on.

• Green LED/On: Control section is working.

• Yellow LED/Warn.: Indicates a warning.

• Flashing Red LED/Alarm: Indicates an alarm.

VLT AQUA High Power Instruction Manual

op section

Middle section

Bottom section

GLCP keys

Menu keys

The menu keys are divided into functions. The keys below the display and

LEDs are used for parameter set-up, including display indication selection

during normal operation.

[Status]

Indicates the status of the adjustable frequency drive and/or the motor. Three different readouts can be chosen by pressing the [Status] key:

5-line readouts, 4-line readouts or smart logic control.

Use

[Status] for selecting the mode of display or for changing back to display mode from either the quick menu mode, main menu mode or alarm mode.

The [Status] key can also be used to toggle between single and double readout modes.

[Quick Menu]

Allows quick set-up of the adjustable frequency drive. The most common functions can be programmed here.

The [Quick Menu] consists of:

- Q1: My Personal Menu

-Q2: Quick Set-up

- Q3: Function Set-ups

- Q5: Changes Made

- Q6: Loggings

The function set-up provides quick and easy access to all parameters required for the majority of water and wastewater applications including variable

torque, constant torque, pumps, dosing pumps, well pumps, booster pumps, mixer pumps, aeration blowers and other pump and fan applications. Among

other features, it also includes parameters for selecting which variables to display on the LCP, digital preset speeds, scaling of analog references, closed-

loop single zone and multi-zone applications and specific functions related to water and wastewater applications.

130BP045.10

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MG.20.P3.22 - VLT® is a registered Danfoss trademark