Danfoss FC 202 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions VLT® AQUA Drive FC 202

110–1400 kW

www.danfoss.com/drives

Contents	VLT AQUA Drive FC 202 Operation Instructions

Contents

1 How to Read these Operating Instructions	4
2 Safety	6
2.1 Safety Note	6
2.1.1 General Warning	6
2.1.2 Before Commencing Repair Work	7
2.1.3 Special Conditions	7
2.1.4 Avoid Unintended Start	7
2.1.5 Safe Torque Off (STO)	7
2.1.6 IT Mains	8
3 How to Install	9
3.1 How to Get Started	9
3.2 Pre-installation	9
3.2.1 Planning the Installation Site	9
3.2.2 Receiving the Frequency Converter	10
3.2.3 Transportation and Unpacking	10
3.2.4 Lifting	10
3.2.5 Mechanical Dimensions	12
3.2.6 Rated Power	18
3.3 Mechanical Installation	20
3.3.1 Tools Needed	20
3.3.2 General Considerations	20
3.3.3 Terminal Locations - Enclosure Type D	21
3.3.4 Terminal Locations - E Enclosures	24
3.3.5 Terminal Locations - Enclosure type F	29
3.3.6 Cooling and Airflow	33
3.3.7 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units	35
3.3.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)	35
3.3.9 IP21 Drip Shield Installation (Enclosure Types D1 and D2)	37
3.4 Field Installation of Options	37
3.4.1 Installation of Duct Cooling Kit in Rittal Enclosures	37
3.4.2 Outside Installation/NEMA 3R Kit for Rittal Enclosures	38
3.4.3 Installation on Pedestal	39
3.4.4 Installation of Input Plate Options	40
3.4.5 Installation of Mains Shield for Frequency Converters	41
3.5 Enclsoure Type F Panel Options	41
3.5.1 Enclsoure Type F Options	41
3.6 Electrical Installation	42
3.6.1 Power Connections	42

MG20P402 - Rev. 2013-12-16

1

Contents	VLT AQUA Drive FC 202 Operation Instructions

3.6.2 Grounding	53
3.6.3 Extra Protection (RCD)	53
3.6.4 RFI Switch	53
3.6.5 Torque	53
3.6.6 Shielded Cables	54
3.6.7 Motor Cable	54
3.6.8 Brake Cable for Frequency Converters with Factory Installed Brake Chopper Op-
tion	55
3.6.9 Brake Resistor Temperature Switch	55
3.6.10 Load Sharing	55
3.6.11 Shielding against Electrical Noise	55
3.6.12 Mains Connection	56
3.6.13 External Fan Supply	56
3.6.14 Fuses	56
3.6.15 Mains Disconnectors	59
3.6.16 F Enclosure Circuit Breakers	59
3.6.17 F Enclosure Mains Contactors	60
3.6.18 Motor Insulation	60
3.6.19 Motor Bearing Currents	60
3.6.20 Control Cable Routing	60
3.6.21 Access to Control Terminals	62
3.6.22 Electrical Installation, Control Terminals	62
3.6.23 Electrical Installation, Control Cables	63
3.6.24 Switches S201, S202, and S801	65
3.7 Connection Examples	66
3.7.1 Start/Stop	66
3.7.2 Pulse Start/Stop	66
3.8 Final Set-up and Test	67
3.9 Additional Connections	68
3.9.1 Mechanical Brake Control	68
3.9.2 Parallel Connection of Motors	68
3.9.3 Motor Thermal Protection	69

4 How to operate the frequency converter	70
4.1 Ways of Operation	70
4.1.1 How to operate graphical LCP (GLCP)	70
4.1.2 How to Operate Numeric LCP (NLCP)	73
4.1.3 Changing Data	75
4.1.4 Changing a Text Value	75
4.1.5 Changing a Group of Numeric Data Values	75
4.1.6 Changing of Data Value, Step-by-Step	76

2	MG20P402 - Rev. 2013-12-16

Contents	VLT AQUA Drive FC 202 Operation Instructions

4.1.7 Read-out and Programming of Indexed Parameters	76
4.1.8 Tips and Tricks	76

5 How to programme the frequency converter	79
5.1 How to programme	79
5.2 Commonly Used Parameters - Explanations	84
5.3 Parameter Menu Structure	112
6 General Specifications	117
7 Troubleshooting	130
Index	142

MG20P402 - Rev. 2013-12-16

3

How to Read these Operating... VLT AQUA Drive FC 202 Operation Instructions

1	1	1 How to Read these Operating Instructions

VLT AQUA Drive

FC 200 Series

Software version: 2.1x

This guide can be used with all FC 202 frequency converters with software

version 2.1x or later. The actual software version number can be read from

15-43 Software Version.

This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein is used solely for operating equipment from Danfoss or equipment from other vendors if 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 functions properly in every physical, hardware or 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.

1.1.1 Available Literature

•VLT® AQUA Drive FC 202 Operating Instructions provide the neccessary information for getting the frequency converter up and running.

•VLT® AQUA Drive FC 202, 110-1400 kW Operating Instructions provide the neccessary information for getting the high power frequency converter up and running.

•VLT® AQUA Drive FC 202 Design Guide entails all technical information about the frequency converter and customer design and applications.

•VLT® AQUA Drive FC 202 Programming Guide provides information on how to programme and includes complete parameter descriptions.

•VLT® AQUA Drive FC 202 Profibus

•VLT® AQUA Drive FC 202 DeviceNet

•Output Filters Design Guide

•VLT® AQUA Drive FC 202 Cascade Controller

•Application Note MN20A: Submersible Pump Application

•Application Note MN20: Master/Follower Operation Application

•Application Note MN20F: Drive Closed Loop and Sleep Mode

•Installation Instruction for Mounting Brackets Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or IP66

•Instruction for Analog I/O Option MCB109

•Instruction for Panel through mount kit

•VLT® Active Filter Operating Instruction

Danfoss technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/ Documentations/Technical+Documentation.htm.

4	MG20P402 - Rev. 2013-12-16

How to Read these Operating...	VLT AQUA Drive FC 202 Operation Instructions
		1	1
The frequency converter complies with UL508C thermal

memory retention requirements. For more information, refer to the section Motor Thermal Protection in the Design Guide.

NOTICE

Imposed limitations on the output frequency (due to export control regulations):

From software version 6.72 the output frequency of the frequency converter is limited to 590 Hz. Software versions 6x.xx also limit the maximum output frequency to 590 Hz, but these versions cannot be flashed, i.e. neither downgraded nor upgraded.

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that may result in damage to equipment or property.

MG20P402 - Rev. 2013-12-16

5

Safety	VLT AQUA Drive FC 202 Operation Instructions

2 Safety

2 2

2.1 Safety Note

WARNING

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter or fieldbus may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.

Safety Regulations

1.The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

2.The [STOP/RESET] key on the control panel of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch.

3.Correct protective earthing 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 earth leakage currents are higher than 3.5 mA.

5.Protection against motor overload is set by par. 1-90 Motor Thermal Protection. If this function is desired, set par. 1-90 to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is initialised 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 mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.

7.Note that the frequency converter has voltage inputs other than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been disconnected and that the necessary time has passed before commencing repair work.

NOTICE

Installation at high altitude:

380 - 480 V: At altitudes above 3,000 m, contact Danfoss regarding PELV.

525 - 690 V: At altitudes above 2,000 m, contact Danfoss regarding PELV.

Warning against Unintended Start

1.The motor can be stopped with digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. To avoid personal injury, these stop functions are not sufficient to ensure that no unintended start occurs.

2.While parameters are being changed, the motor may start. Consequently, always press [RESET]; following which data can be modified.

3.A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

WARNING

Warning:

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

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 back-up.

2.1.1 General Warning

WARNING

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been

disconnected, (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up.

Before touching any potentially live parts of the frequency converter, wait at least as follows: Be aware that there may be high voltage on the DC link even when the Control Card LEDs are turned off. A red LED is mounted on a circuit board inside the frequency converter to indicate the DC bus voltage. The red LED stays lit until the DC link is 50 V DC or lower.

6	MG20P402 - Rev. 2013-12-16

Safety	VLT AQUA Drive FC 202 Operation Instructions

WARNING

Leakage Current

The earth leakage current from the frequency converter exceeds 3.5 mA. According to IEC 61800-5-1 a reinforced Protective Earth connection must be ensured by means of: a min. 10mm² Cu or 16mm² Al PE-wire or an addtional PE wire - with the same cable cross section as the Mains wiring - must be terminated separately. Residual Current Device

This product can cause a D.C. current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only an RCD of Type B (time delayed) shall be used on the supply side of this product. See also RCD Application Note MN.90.GX.02. Protective earthing of the frequency converter and the use of RCD's must always follow national and local regulations.

2.1.2 Before Commencing Repair Work

1.Disconnect the frequency converter from mains.

2.Disconnect DC bus terminals 88 and 89.

3.Wait at least the time mentioned in chapter 2.1.1 General Warning.

2.1.3 Special Conditions

Electrical ratings

The rating indicated on the nameplate of the frequency converter is based on a typical 3-phase mains power supply, within the specified voltage, current and temperature range, which is expected to be used in most applications.

The frequency converters also support other special applications, which affect the electrical ratings of the frequency converter. Special conditions which 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 Design Guide for information about the electrical ratings.

Installation requirements

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

•Fuses and circuit breakers for over-current and short-circuit protection

•Selection of power cables (mains, motor, brake, loadsharing and relay)

•	Grid configuration (IT,TN, grounded leg, etc.)
•	Safety of low-voltage ports (PELV conditions)	2
	2

Consult the relevant clauses in these instructions and in the Design Guide for information about the installation requirements.

WARNING

The frequency converter's DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Before doing service on the frequency converter, wait at least the amount of time indicated below:

Voltage	Power size		Min. Waiting Time
380 - 480 V	110 - 250 kW		20 minutes
	315	- 1000 kW	40 minutes
525 - 690 V	45	- 400 kW	20 minutes
	4501400 kW		30 minutes

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

Table 2.1 Discharge Time

2.1.4 Avoid Unintended Start

WARNING

While the frequency converter is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the Local Control Panel.

•Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start.

•To avoid 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 mains supply, or lost motor connection may cause a stopped motor to start.

2.1.5 Safe Torque Off (STO)

To run Safe Torque Off, additional wiring for the frequency converter is required, refer to Safe Torque Off Operating Instructions for Danfoss VLT® Frequency Converters for further information.

MG20P402 - Rev. 2013-12-16

7

Safety	VLT AQUA Drive FC 202 Operation Instructions

2.1.6 IT Mains

2 2 WARNING

IT mains

Do not connect frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V for 400 V converters and 760 V for 690 V converters.

For 400 V IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth. For 690 V IT mains and delta earth (grounded leg), mains voltage may exceed 760 V between phase and earth. Failure to follow recommendations could result in death or serious injury.

14-50 RFI Filter can be used to disconnect the internal RFI capacitors from the RFI filter to ground.

2.1.7 Disposal Instruction

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.

8	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

3 How to Install

3.1 How to Get Started

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

Operating Instructions and Design Guide.

The frequency converter is designed to achieve a quick and EMC-correct installation by following the steps described below.

WARNING

Read the safety instructions before installing the unit. Failure to follow recommendations could result in death or serious injury.

Mechanical Installation

•Mechanical mounting

Electrical Installation

•Connection to Mains and Protecting Earth

•Motor connection and cables

•Fuses and circuit breakers

•Control terminals - cables

Quick Setup

•Local Control Panel, LCP

•Automatic Motor Adaptation, AMA

•Programming

Frame size is depending on enclosure type, power range and mains voltage

L1		<![if ! IE]> <![endif]>130BA015.13
L2
L3
PE

F1

91	92	93	95	88	89		12
				DC-	DC+		27
L1	L2	L3	PE				1
							37
							18
							50
							53
U	V	W	PE				55
					R-	R+
96	97	98	99		81	82

M

3

Illustration 3.1 Diagram showing basic installation including mains, motor, start/stop key, and potentiometer for speed adjustment.

3.2 Pre-installation

3.2.1 Planning the Installation Site

CAUTION

Before performing the installation it is important to plan the installation of the frequency converter. 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 the respective Design Guides)

•Ambient operating temperature

•Installation method

•How to cool the unit

•Position of the frequency converter

•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 frequency converter

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

3 3

MG20P402 - Rev. 2013-12-16

9

How to Install	VLT AQUA Drive FC 202 Operation Instructions

3.2.2 Receiving the Frequency Converter

When receiving the frequency converter, make sure that the packaging is intact, and be aware of any damage that might have occurred to the unit during transport. In case

3 3 damage has occurred, contact immediately the shipping company to claim the damage.

3.2.3 Transportation and Unpacking

Before unpacking the frequency converter it is recommended that it is located as close as possible to the final installation site.

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

3.2.4 Lifting

Always lift the frequency converter in the dedicated lifting eyes. For all D and E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the frequency converter.

<![if ! IE]>

<![endif]>176FA245.10

Illustration 3.2 Recommended Lifting Method, Enclosure Types

D and E

WARNING

The lifting bar must be able to handle the weight of the frequency converter. See Mechanical Dimensions for the weight of the different enclosure type. Maximum diameter for bar is 2.5 cm (1 inch). The angle from the top of the frequency converter to the lifting cable should be 60° or greater.

<![if ! IE]>

<![endif]>130BA832.11

Illustration 3.3 Recommended Lifting Method, Enclsoure Type

F1 (460 V, 600 to 900 HP, 575/690 V, 900 to 1150 HP)

<![if ! IE]>

<![endif]>130BA834.11

Illustration 3.4 Recommended Lifting Method, Enclosure Type F2 (460 V, 1000 to 1200 HP, 575/690 V, 1250 to 1350 HP)

10	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

<![if ! IE]>

<![endif]>130BA833.11

Illustration 3.5 Recommended Lifting Method, Enclosure Type F3 (460 V, 600 to 900 HP, 575/690 V, 900 to 1150 HP)

<![if ! IE]>

<![endif]>130BA835.11

Illustration 3.6 Recommended Lifting Method, Enclosure Type F4 (460 V, 1000 to 1200 HP, 575/690 V, 1250 to 1350 HP)

<![if ! IE]>

<![endif]>130BB753.10

<![if ! IE]>

<![endif]>130BB688.10

3 3

Illustration 3.8 Recommended lifting method, Enclosure Type F9/F10

<![if ! IE]>

<![endif]>130BB689.10

Illustration 3.9 Recommended lifting method, Enclosure Type

F11/F12/F13/F14

Illustration 3.7 Recommended lifting method, Enclosure Type

F8

MG20P402 - Rev. 2013-12-16

11

How to Install VLT AQUA Drive FC 202 Operation Instructions

NOTICE

The plinth is provided in the same packaging as the frequency converter but is not attached to enclosure types F1-F4 during shipment. The plinth is required to allow airflow to the frequency converter to provide proper cooling. The F enclosures should be positioned on top of the plinth in the final installation location. The angle from the top of the frequency converter to the lifting cable should be 60° or greater.

3 3 In addition to the drawings above a spreader bar is an acceptable way to lift the F enclosures.

3.2.5 Mechanical Dimensions

	IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
	D1
	A		B
74			304	25
				(1.0)	225
(2.9)			(12.0)
					(8.9)
		120
		(4.7)
				160.0
				(6.3)
					1362
		849			(53.6)
	1166	(33.4)		1154
		1209
981	(45.9)	(47.6)		(45.4)
(38.6)
	310	160.0
	(12.2)	(6.3)
163	380		177.0		225
(6.4)	(15.0)		(7.0)
					(8.9)
420	417	C	354.0
(16.5)	(16.4)		(13.9)
Illustration 3.10

	D2
72
(2.8)
	120
	(4.7)
	977
	(38.5)
1547	1589
(60.9)	(62.6)
	160.0
	(6.3)
423
(16.6)
157	380
(6.2)	(15.0)
420	417
(16.5)	(16.4)

	304	25
	(12.0)
		(1.0)
		160.0
		(6.3)
		1535
		(60.4)
	184.5
	(7.3)
	369.0
	(14.5)

225.0	<![if ! IE]> <![endif]>130BA443.11
(8.9)
225.0
(8.9)

* Note airflow directions

		D3		IP00 / CHASSIS
						66	298
		A	B			( 2.6)	( 11.7)
	66	298	304	25
				(1.0)	225
	( 2.6)	(11.7)	(12.0)
					(8.9)
		120
		( 4.7)
				160.0
				( 6.30)
		696					1280
		( 27.4)		1001		1099
							(50.4)
	997	1046		( 39.4)		(43.3)
818		( 41.2)
	( 39.3)
( 32.2)
		160
	147	( 6.3)					161
	( 5.8)
							( 6.3)
	157	375	177		225	151	375
	( 6.2)	(14.8)	(7.0)	C	(8.9)	(5.9)	( 14.8)
	408	417	354				417
						408
	(16.1)	(16.4)	(13.9)			( 16.1)	( 16.4)

D4

120 ( 4.7)

1327

(52.2)

977 ( 38.5)

160 ( 6.3)

304	25
( 12.0)	( 1.0)
	160.0
	( 6.30 )
	1282
	( 50.5)
185
( 7.3 )
369
( 14.5)

225.0	<![if ! IE]> <![endif]>138BA442.10
( 8.9)
225.0
(8.9)

				IP00/IP21/IP54 - ALL SIZES
										51
A			B			49		Ø 11	C	11						( 2.0)
				( 1.9 )			( .4)			( 0.4)

25
( 1.0)	25	10
		(0.4)
	( 1.0 )
		20.0
		(0.8)
		22
22		(0.9)
(0.9)

Illustration 3.11

12	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

* Note airflow directions

E1	IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
			185	185
	F		( 7.3 ) ( 7.3 )
			58	484
			( 2.3 )	(19.1)
			23	185
72		72		( 7.3 )
		( 2.8 )	(0.9)
( 2.8 )
				27
				( 1.1 )
			160	2X13
			( 6.3 )
				(0.5)
		1043
		( 41.1 )
	2000
	(78.74)
1551	164
( 61.1 )
	( 6.5 )
		160
		( 6.3 )
	727
	( 28.6 )
		145
		( 5.7 )
600	392	198		CABLE BASE
(23.62)	( 15.4 )
	494	( 7.8 )
	( 19.4 )
	538
	( 21.2 )

225	<![if ! IE]> <![endif]>130BA444.10
( 8.86 )

SIDE CABLE ENTRY

KNOCK-OFF PLATE BOTTOM CABLE ENTRY

F	56
	( 2.2 )
	25
	(1.0)
Ø 25
( 1.0 )

Illustration 3.12

* Note airflow directions

3 3

MG20P402 - Rev. 2013-12-16

13

How to Install

VLT AQUA Drive FC 202 Operation Instructions

			E2		IP00 / CHASSIS
						139	304
						(5.5)	(12.0)
						184	184
						(7.3)	(7.3)
				D		14	184
3	3					(1.5)
		64		498	25	120	2X13
		(2.5)		(19.5)
					(1.0)	(4.7)	(0.5)
					1043
				1547	(41.1)
		1320			1502
				(60.9)	(59.1)
		(52.0)
					160
					(6.3)
			269
			(10.6)
			156
			(6.2)	539
		585		(21.2)		E
		(23.0)
		D	23
			(0.9)
		25		25		E
		(1.0)
				(1.0)
							27
							(1.0)
						13
						(0.5)

Illustration 3.13

* Note airflow directions

<![if ! IE]>

<![endif]>130BA445.10

225

(8.9)

225

(8.9)

14	MG20P402 - Rev. 2013-12-16

	F1				IP 21/54 - NEMA 1/12	F3			IP 21/54 - NEMA 1/12		<![if ! IE]> <![endif]>How
			1		<![if ! IE]> <![endif]>130BB027.10						<![if ! IE]> <![endif]>Install to
	1400.0	ø29.0		225.0
	(55.12)			(8.85)
		(1.14)
								1		<![if ! IE]> <![endif]>130BB029.10
						1997			225.0
							ø29		(8.85)
						(78.6)
							( 1.1)
	2281.4
	(89.82)
						2280					<![if ! IE]> <![endif]>VLT
	2206.4					(89.7)
						2205
<![if ! IE]> <![endif]>.Rev - MG20P402	(86.87)					(86.8)					<![if ! IE]> <![endif]>FC Drive AQUA
						1497
						(58.9)
	1499.2
	(59.02)
<![if ! IE]> <![endif]>16-12-2013										607	<![if ! IE]> <![endif]>Operation 202
										(23.9)
					607.0						<![if ! IE]> <![endif]>Instructions
					(23.9)

1) Minimum clearance from ceiling

Table 3.1

<![if ! IE]>

<![endif]>15

<![if ! IE]>

<![endif]>3

<![if ! IE]>

<![endif]>3

How to Install	VLT AQUA Drive FC 202 Operation Instructions

<![if ! IE]> <![endif]>NEMA 1/12

10.130BB030

<![if ! IE]> <![endif]>604

<![if ! IE]> <![endif]>(23.8)

<![if ! IE]> <![endif]>-

3

3

<![if ! IE]> <![endif]>IP 21/54

<![if ! IE]> <![endif]>225.0 (8.85)

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>Ø29 (1.1)

<![if ! IE]> <![endif]>2401 (94.5)

<![if ! IE]> <![endif]>F4

<![if ! IE]> <![endif]>2280

<![if ! IE]> <![endif]>(89.7)

<![if ! IE]> <![endif]>2205

<![if ! IE]> <![endif]>(86.8)

<![if ! IE]> <![endif]>1497

<![if ! IE]> <![endif]>(58.9)

<![if ! IE]> <![endif]>IP 21/54 - NEMA 1/12

10.130BB028

<![if ! IE]> <![endif]>(23.8)

<![if ! IE]> <![endif]>606

<![if ! IE]> <![endif]>225.0

<![if ! IE]> <![endif]>(8.85)

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>Ø29

<![if ! IE]> <![endif]>(1.1)

<![if ! IE]> <![endif]>ceiling

<![if ! IE]> <![endif]>F2

<![if ! IE]> <![endif]>1804

<![if ! IE]> <![endif]>(71.0)

<![if ! IE]> <![endif]>1) Minimum clearance from

<![if ! IE]> <![endif]>(86.9)

<![if ! IE]> <![endif]>1499

<![if ! IE]> <![endif]>(59.0)

<![if ! IE]> <![endif]>Table 3.2

<![if ! IE]> <![endif]>2281

<![if ! IE]> <![endif]>(89.8)

<![if ! IE]> <![endif]>2206

16

MG20P402 - Rev. 2013-12-16

How to Install					VLT AQUA Drive FC 202 Operation Instructions
Enclosure type Size				D1			D2		D3	D4
										160 - 250 kW
			110-132 kW at 400 V			160-250 kW at 400 V			110-132 kW at 400 V	at 400 V
			(380-480 V)				(380-480 V)		(380-480 V)	(380-480 V)
			45-160 kW at 690 V			200-400 kW at 690 V			45-160 kW at 690 V	200-400 kW
			(525-690 V)				(525-690 V)		(525-690 V)	at 690 V			3		3
										(525-690 V)
IP			21		54	21		54	00	00
NEMA			Type 1		Type 12	Type 1		Type 12	Chassis	Chassis
Shipping		Height
dimensions			650		650	650		650	650	650
[mm]
		Width	1730		1730	1730		1730	1220	1490
		Depth	570		570	570		570	570	570
Frequency
converter		Height	1209		1209	1589		1589	104	1327
dimensions
[mm]
		Width	420		420	420		420	408	408
		Depth	380		380	380		380	375	375
		Max
		weight	104		104	151		151	91	138
		[kg]
Table 3.3	Mechanical dimensions, Enclosure type D

MG20P402 - Rev. 2013-12-16

17

				How to Install				VLT AQUA Drive FC 202 Operation Instructions
				Enclosure Type Size			E1	E2		F1	F2		F3	F4
							315-450 kW at	315-450 kW at		500-710 kW at	800-1000 kW at		500-710 kW at	800-1000 kW at
							400 V	400 V		400 V	400 V		400 V	400 V
							(380-480 V)	(380-480 V)		(380-480 V)	(380-480 V)		(380-480 V)	(380-480 V)
							450-630 kW at	450-630 kW at		710-900 kW at	1000-1200 kW at		710-900 kW at	1000-1400 kW at
3		3					690 V	690 V		690 V	690 V		690 V	690 V
							(525-690 V)	(525-690 V)		(525-690 V)	(525-690 V)		(525-690 V)	(525-690 V)
				IP			21, 54	00		21, 54	21, 54		21, 54	21, 54
				NEMA			Type 1/ Type 12	Chassis		Type 1/Type 12	Type 1/Type 12		Type 1/Type 12	Type 1/Type 12
				Shipping		Height
				dimensions			840	831		2324	2324		2324	2324
				[mm]
						Width	2197	1705		1569	1962		2159	2559
						Depth	736	736		1130	1130		1130	1130
				Frequency
				converter		Height	2000	1547		2204	2204		2204	2204
				dimensions
				[mm]
						Width	600	585		1400	1800		2000	2400
						Depth	494	498		606	606		606	606
						Max
						weight	313	277		1004	1246		1299	1541
						[kg]
				Table 3.4	Mechanical dimensions, Enclosure Types E and F

3.2.6 Rated Power

	Enclosure type		D1	D2	D3	D4
						<![if ! IE]> <![endif]>130BA819.10
			<![if ! IE]> <![endif]>130BA816.10	<![if ! IE]> <![endif]>130BA817.10		<![if ! IE]> <![endif]>130BA820.10
	Enclosure	IP	21/54	21/54	00	00
	protection	NEMA	Type 1/Type 12	Type 1/Type 12	Chassis	Chassis
	Normal overload		110 - 132 kW at 400 V	150 - 250 kW at 400 V	110 - 132 kW at 400 V	150 - 250 kW at 400 V
			(380 - 480 V)	(380 - 480 V)	(380 - 480 V)	(380 - 480 V)
	rated power - 110%
			45 - 160 kW at 690 V	200 - 400 kW at 690 V	45 - 160 kW at 690 V	200 - 400 kW at 690 V
	overload torque
			(525-690 V)	(525-690 V)	(525-690 V)	(525-690 V)

Table 3.5

18	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

Enclosure type		E1	E2		F1/F3		F2/F4
		<![if ! IE]> <![endif]>130BA818.10	<![if ! IE]> <![endif]>130BA821.10	F3 F1	<![if ! IE]> <![endif]>130BA959.10	F4 F2	<![if ! IE]> <![endif]>130BB092.11
							3	3
Enclosure	IP	21/54	00		21/54		21/54
protection	NEMA	Type 1/Type 12	Chassis	Type 1/Type 12		Type 1/Type 12

Normal overload	315 - 450 kW at 400 V	315 - 450 kW at 400 V	500 - 710 kW at 400 V	800 - 1000 kW at 400 V
rated power -	(380 - 480 V)	(380 - 480 V)	(380 - 480 V)	(380 - 480 V)
110% overload	450 - 630 kW at 690 V	450 - 630 kW at 690 V	710 - 900 kW at 690 V	1000 - 1400 kW at 690 V
torque	(525-690 V)	(525-690 V)	(525-690 V)	(525-690 V)

Table 3.6

NOTICE

The F enclosures are available in 4 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.

MG20P402 - Rev. 2013-12-16

19

How to Install	VLT AQUA Drive FC 202 Operation Instructions

3.3 Mechanical Installation

Preparation of the mechanical installation of the frequency converter must be done carefully to ensure a proper result and to avoid additional work during installation. Start taking a close look at the mechanical drawings at the end

3 3 of this instruction to become familiar with the space demands.

3.3.1 Tools Needed

To perform the mechanical installation the following tools are needed:

•Drill with 10 or 12 mm drill

•Tape measure

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

•Extensions to wrench

•Sheet metal punch for conduits or cable glands in IP21/Nema 1 and IP54 units

•Lifting bar to lift the unit (rod or tube max. Ø 5 mm (1 inch), able to lift minimum 400 kg (880 lbs).

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

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

<![if ! IE]>

<![endif]>176FA235.11

399

(15.7)

526

(20.7)

<105,0°

Illustration 3.14 Space in Front of IP21/IP54 Rated Enclosure Types D1 and D2

<![if ! IE]>

<![endif]>176FA276.12

579

(22.8)

748

(29.5) ≤105,0°

Illustration 3.15 Space in Front of IP21/IP54 Rated Enclosure Type E1

3.3.2 General Considerations

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 frequency converter is mounted, i.e. by using cable clamps.

CAUTION

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

Space

Ensure proper space above and below the frequency converter to allow airflow and cable access. In addition space in front of the unit must be considered to enable opening of the door of the panel.

578	776	<![if ! IE]> <![endif]>130BB003.13
(22.8)	(30.6)

Illustration 3.16 Space in Front of IP21/IP54 Rated Enclosure Type F1

2X578	776	<![if ! IE]> <![endif]>130BB004.13
[22.8]
	[30.6]

Illustration 3.17 Space in Front of IP21/IP54 Rated Enclosure Type F3

624	579	<![if ! IE]> <![endif]>130BB005.13
578
[22.8]	[22.8]
[24.6]

Illustration 3.18 Space in Front of IP21/IP54 Rated Enclosure Type F2

20	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

2x579

(22.8)

624 (24.6)

578 (22.8)

<![if ! IE]>

<![endif]>130BB006.10

Illustration 3.19 Space in Front of IP21/IP54 Rated Enclosure
	3		3
Type F4

3.3.3 Terminal Locations - Enclosure Type D

Consider the following terminal positions when designing for cables access.

	R/12 91				S/L2 92	T/L3 93
A
	-DC 88		+DC 89
B
-R	81	+R		82	U/T1 96	V/T2 97	W/T3 98	D
C								0,
								(0,)
E	J	L		F K M G		N H	I	0,
								(0,)

Illustration 3.20 Position of Power Connections, Enclosure Types D3 and D4

			<![if ! IE]> <![endif]>176FA238.10
O	P	Q	0,
			(0,)

MG20P402 - Rev. 2013-12-16

21

How to Install	VLT AQUA Drive FC 202 Operation Instructions

			R/L1	91	S/L2	92 T/L3	93			<![if ! IE]> <![endif]>176FA239.10
		R	-DC	+DC
3	3	-R	81	+R	82	U/T1 96	V/T2 97	W/T398
		0,
		(0,)
			S		T		U	0,	V	0,
								(0,)		(0,)

Illustration 3.21 Position of Power Connections with Disconnect Switch, Enclosure Types D1 and D2

Be aware that the power cables are heavy and hard to bend. Consider the optimum position of the frequency converter for ensuring easy installation of the cables.

22	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

NOTICE

All D enclosures are available with standard input terminals or disconnect switch. All terminal dimensions can be found in Table 3.7.

	IP21 (NEMA 1)/IP54 (NEMA 12)					IP00/Chassis				3		3
	D1		D2		D3		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 3.7 Cable Positions Dimensions in mm (inch)

MG20P402 - Rev. 2013-12-16

23

How to Install	VLT AQUA Drive FC 202 Operation Instructions

3.3.4 Terminal Locations - E Enclosures

Terminal Locations - E1

Take the following position of the terminals into consideration when designing the cable access.

3

3

<![if ! IE]> <![endif]>176FA278.10

492[19.4]

323[12.7]

B

0[0.0]

195[7.7]

<![if ! IE]> <![endif]>600[23.6]

<![if ! IE]> <![endif]>525[20.7]

<![if ! IE]> <![endif]>412[16.2]

<![if ! IE]> <![endif]>300[11.8]

<![if ! IE]> <![endif]>188[7.4]

<![if ! IE]> <![endif]>75[3.0]

<![if ! IE]> <![endif]>0[0.0]

<![if ! IE]> <![endif]>409[16.1]

<![if ! IE]> <![endif]>371[14.6]

<![if ! IE]> <![endif]>280[11.0]

<![if ! IE]> <![endif]>193[7.6]

<![if ! IE]> <![endif]>155[6.1]

<![if ! IE]> <![endif]>0[0.0]

Illustration 3.22 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions

24	MG20P402 - Rev. 2013-12-16

How to Install	VLT AQUA Drive FC 202 Operation Instructions

	B					<![if ! IE]> <![endif]>176FA272.10
	-R	81			9	3	3
	A	A	A	A
					19 Nm [14 FTa
	453[17.8]

0[0.0]

<![if ! IE]> <![endif]>0[0.0]

<![if ! IE]> <![endif]>55[2.2]

<![if ! IE]> <![endif]>91[3.6]

<![if ! IE]> <![endif]>139[5.5]

<![if ! IE]> <![endif]>175[6.9]

Illustration 3.23 IP21 (NEMA type 1) and IP54 (NEMA type 12)

Enclosure Power Connection Positions (Detail B)

MG20P402 - Rev. 2013-12-16

25

How to Install	VLT AQUA Drive FC 202 Operation Instructions

											<![if ! IE]> <![endif]>176FA279.11
3	3
	F
	E
				0	[ 0.0	]
					28	[ 1.1	]
					167	[ 6.6	]
					195	[ 7.7	]
	<![if ! IE]> <![endif]>D	<![if ! IE]> <![endif]>C	<![if ! IE]> <![endif]>B	<![if ! IE]> <![endif]>[ 0.0 ]			<![if ! IE]> <![endif]>17.4 ] A	<![if ! IE]> <![endif]>10.5 ]	<![if ! IE]> <![endif]>[ 8.9 ]	<![if ! IE]> <![endif]>[ 2.0 ]	<![if ! IE]> <![endif]>[ 0.0 ]
				<![if ! IE]> <![endif]>0			<![if ! IE]> <![endif]>[	<![if ! IE]> <![endif]>[	<![if ! IE]> <![endif]>226	<![if ! IE]> <![endif]>51	<![if ! IE]> <![endif]>0
							<![if ! IE]> <![endif]>441	<![if ! IE]> <![endif]>266

Illustration 3.24 IP21 (NEMA type 1) and IP54 (NEMA type 12) Enclosure Power Connection Position of Disconnect Switch

Enclosure		Unit type				Dimensions [mm]/(inch)
types
		IP54/IP21 UL AND NEMA1/NEMA12
E1		250/315 kW (400 V) AND 355/450-500/630	396	(15.6)	267 (10.5)	332	(13.1)	397	(15.6)	528	(20.8)	N/A
		KW (690 V)
		315/355-400/450 kW (400 V)	408	(16.1)	246 (9.7)	326	(12.8)	406	(16.0)	419	(16.5)	459 (18.1)
Table 3.8	Dimensions for Disconnect Terminal

26	MG20P402 - Rev. 2013-12-16