Danfoss VLT AQUA Drive FC 202, VLT Refrigeration Drive FC 103, FC 102, VLT FC 103 Operating Manual

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ENGINEERING TOMORROW

Operating Guide

VLT® AQUA Drive FC 202

355–800 kW, Enclosure Size E

vlt-drives.danfoss.com

Contents Operating Guide

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Manual and Software Version

1.4 Approvals and Certications

1.5 Disposal

2 Safety

2.1 Safety Symbols

2.2 Qualied Personnel

2.3 Safety Precautions

3 Product Overview

3.1 Intended Use

3.2 Power Ratings, Weights, and Dimensions

3.3 Interior View of Enclosures E1h and E2h

3.4 Interior View of Enclosures E3h and E4h

3.5 Control Shelf

3.6 Local Control Panel (LCP)

4 Mechanical Installation

4.1 Items Supplied

4.2 Tools Needed

4.3 Storage

4.4 Operating Environment

4.5 Installation and Cooling Requirements

4.6 Lifting the Unit

4.7 E1h/E2h Mechanical Installation

4.8 E3h/E4h Mechanical Installation

5 Electrical Installation

5.1 Safety Instructions

5.2 EMC-compliant Installation

5.3 Wiring Schematic

5.4 Connecting the Motor

5.5 Connecting the AC Mains

5.6 Connecting to Ground

5.7 Terminal Dimensions

5.8 Control Wiring

5.9 Pre-start Check List

Contents VLT® AQUA Drive FC 202

6 Commissioning

6.1 Safety Instructions

6.2 Applying Power

6.3 LCP Menu

6.4 Programming the Drive

6.5 Testing Before System Start-up

6.6 System Start-up

6.7 Parameter Settings

7 Wiring Conguration Examples

7.1 Wiring for Open-loop Speed Control

7.2 Wiring for Start/Stop

7.3 Wiring for External Alarm Reset

7.4 Wiring for a Motor Thermistor

7.5 Wiring for Regeneration

8 Maintenance, Diagnostics, and Troubleshooting

8.1 Maintenance and Service

8.2 Heat Sink Access Panel

8.3 Status Messages

8.4 Warning and Alarm Types

8.5 List of Warnings and Alarms

8.6 Troubleshooting

9 Specications

9.1 Electrical Data

9.2 Mains Supply

9.3 Motor Output and Motor Data

9.4 Ambient Conditions

9.5 Cable Specications

9.6 Control Input/Output and Control Data

9.7 Fuses

9.8 Enclosure Dimensions

9.9 Enclosure Airow

9.10 Fastener Torque Ratings

100

10 Appendix

10.1 Abbreviations and Conventions

10.2 International/North American Default Parameter Settings

10.3 Parameter Menu Structure

Index

101

102

108

Introduction Operating Guide

1 Introduction

1.1 Purpose of the Manual

This operating guide provides information for safe instal-

lation and commissioning of the VLT® drives in an enclosure size E (E1h, E2h, E3h, and E4h).

The operating guide is intended for use by qualied personnel. To use the unit safely and professionally, read and follow this operating guide. Pay particular attention to the safety instructions and general warnings. Always keep the operating guide with the drive.

VLT® is a registered trademark.

1.2 Additional Resources

Other resources are available to understand advanced E1h– E4h drive functions and programming.

The VLT® AQUA Drive FC 202 Programming Guide

•

provides greater detail on working with parameters and aqua application examples.

The VLT® AQUA Drive FC 202, 110–1400 kW Design

•

Guide provides detailed capabilities and functionality to design motor control systems for aqua applications.

The Safe Torque O Operating Guide.

•

Supplementary publications and manuals are available from Danfoss. See drives.danfoss.com/knowledge-center/ technical-documentation/ for listings.

Manual and Software Version

1.3

This manual is regularly reviewed and updated. All suggestions for improvement are welcome. Table 1.1 shows the version of the manual and the corresponding software version.

Manual version Remarks Software version

MG22A1xx Initial release 2.70

Approvals and Certications

1.4

Table 1.2 Approvals and

More approvals and certications are available. Contact the local Danfoss oce or partner. Drives of voltage T7 (525– 690 V) are UL certied for only 525–600 V.

The drive complies with UL 61800-5-1 thermal memory retention requirements. For more information, refer to the section Motor Thermal Protection in the product-specic design guide.

Certications

NOTICE

IMPOSED LIMITATIONS ON THE OUTPUT FREQUENCY

From software version 1.99, the output frequency of the drive is limited to 590 Hz due to export control regulations.

1.4.1 Compliance with ADN

For compliance with the European Agreement concerning International Carriage of Dangerous Goods by Inland Waterways (ADN), refer to ADN-compliant Installation in the design guide.

Disposal

1.5

Do not dispose of equipment containing

electrical components together with

domestic waste.

Collect it separately in accordance with

local and currently valid legislation.

1 1

Table 1.1 Manual and Software Version

Safety VLT® AQUA Drive FC 202

2 Safety

2.1 Safety Symbols

The following symbols are used in this guide:

WARNING

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

CAUTION

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

NOTICE

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

2.2 Qualied Personnel

WARNING

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor can start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start with an external switch, a eldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up Software, or after a cleared fault condition.

To prevent unintended motor start:

Press [O/Reset] on the LCP before

•

programming parameters.

Disconnect the drive from the mains.

•

Completely wire and assemble the drive, motor,

•

and any driven equipment before connecting the drive to the AC mains, DC supply, or load sharing.

Correct and reliable transport, storage, installation, operation, and maintenance are required for the troublefree and safe operation of the drive. Only qualied personnel are allowed to install or operate this equipment.

Qualied personnel are dened as trained sta, who are authorized to install, commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures described in this manual.

Safety Precautions

2.3

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input, DC supply, load sharing, or permanent motors. Failure to use qualied personnel to install, start up, and maintain the drive can result in death or serious injury.

Only qualied personnel must install, start up,

•

and maintain the drive.

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning LED indicator lights are o. Failure to wait 40 minutes after power has been removed before performing service or repair work can result in death or serious injury.

Stop the motor.

•

Disconnect AC mains and remote DC-link

•

supplies, including battery back-ups, UPS, and DC-link connections to other drives.

Disconnect or lock motor.

•

Wait 40 minutes for the capacitors to discharge

•

fully.

Before performing any service or repair work,

•

use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

WARNING

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment

•

by a certied electrical installer.

Safety Operating Guide

WARNING

EQUIPMENT HAZARD

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

Ensure that only trained and qualied personnel

•

install, start up, and maintain the drive.

Ensure that electrical work conforms to national

•

and local electrical codes.

Follow the procedures in this guide.

•

CAUTION

HOT SURFACES

The drive contains metal components that are still hot even after the drive has been powered o. Failure to observe the high temperature symbol (yellow triangle) on the drive can result in serious burns.

Be aware that internal components, such as

•

busbars, may be extremely hot even after the drive has been powered o.

Exterior areas marked by the high temperature

•

symbol (yellow triangle) are hot while the drive is in use and immediately after being powered

o.

2 2

WARNING

INTERNAL FAILURE HAZARD

Under certain circumstances, an internal failure can cause a component to explode. Failure to keep the enclosure closed and properly secured can cause death or serious injury.

Do not operate the drive with the door open or

•

panels o.

Ensure that the enclosure is properly closed and

•

secured during operation.

NOTICE

MAINS SHIELD SAFETY OPTION

A mains shield option is available for enclosures with a protection rating of IP21/IP 54 (Type 1/Type 12). The mains shield is a Lexan cover installed inside the enclosure to protect against the accidental touch of the power terminals, according to BGV A2, VBG 4.

Product Overview VLT® AQUA Drive FC 202

3 Product Overview

3.1 Intended Use

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

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

•

Monitor system and motor status.

•

Provide motor overload protection.

•

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

NOTICE

In a residential environment, this product can cause radio interference, in which case supplementary mitigation measures can be required.

Foreseeable misuse

Do not use the drive in applications which are non-compliant with specied operating conditions and environments. Ensure compliance with the conditions specied in chapter 9 Specications.

3.2 Power Ratings, Weights, and Dimensions

Table 3.1 provides dimensions for standard congurations. For dimensions on optional congurations, see chapter 9.8 Enclosure Dimensions.

Enclosure size E1h E2h E3h E4h

Rated power at 380–480 V [kW (hp)] 355–450

(500–600)

Rated power at 525–690 V [kW (hp)] 450–630

(450–650)

Enclosure protection rating IP21/Type 1

IP54/Type 12

Unit dimensions

Height [mm (in)] 2043 (80.4) 2043 (80.4) 1578 (62.1) 1578 (62.1)

Width [mm (in)] 602 (23.7) 698 (27.5) 506 (19.9) 604 (23.89)

Depth [mm (in)] 513 (20.2) 513 (20.2) 482 (19.0) 482 (19.0)

Weight [kg (lb)] 295 (650) 318 (700) 272 (600) 295 (650)

Shipping dimensions

Height [mm (in)] 768 (30.2) 768 (30.2) 746 (29.4) 746 (29.4)

Width [mm (in)] 2191 (86.3) 2191 (86.3) 1759 (69.3) 1759 (69.3)

Depth [mm (in)] 870 (34.3) 870 (34.3) 794 (31.3) 794 (31.3)

Weight [kg (lb)] – – – –

500–560

(650–750)

710–800

(750–950)

IP21/Type 1

IP54/Type 12

355–450

(500–600)

450–630

(450–650)

IP20/

Chassis

500–560

(650–750)

710–800

(750–950)

IP 20/

Chassis

Table 3.1 Enclosure Power Ratings and Dimensions

130BF206.11

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

- REGEN 83

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

+ REGEN 82

Product Overview Operating Guide

3.3 Interior View of Enclosures E1h and E2h

3 3

1 Control shelf (see Illustration 3.3) 7 Fan power card

2 Local control panel (LCP) cradle 8 Space heater (optional)

3 RFI lter (optional) 9 Mains disconnect (optional)

4 Mains fuses (required for UL compliance, but otherwise

10 Brake/regeneration terminals (optional)

optional)

5 Mains terminals 11 Motor terminals

6 RFI shield termination 12 Ground terminals

Illustration 3.1 Interior View of Enclosure E1h (Enclosure E2h is Similar)

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

+ DC 89

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

- BRAKE 83

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

+ BRAKE 82

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

- DC 88

130BF211.11

Product Overview VLT® AQUA Drive FC 202

3.4 Interior View of Enclosures E3h and E4h

1 Load share/regeneration terminals (optional) 8 RFI shield termination (optional, but is standard when RFI

2 Control shelf (see Illustration 3.3) 9 Fans (used to cool the front section of enclosure)

lter is ordered)

3 Local control panel (LCP) cradle 10 Fan power card

4 RFI lter (optional) 11 Space heater (optional)

5 Mains fuses (optional) 12 Brake terminals (optional)

6 Mains terminals 13 Motor terminals

7 Ground terminals – –

Illustration 3.2 Interior View of Enclosure E3h (Enclosure E4h is Similar)

130BF148.11

Remove Jumper to activate Safe Stop

12 13 18 19 27 29 32 33 20 37

39 42 50 53 54 55

61 68 69

RELAY 1 RELAY 2

01 02 0304 05 06

Product Overview Operating Guide

3.5 Control Shelf

3 3

1 LCP cradle (LCP not shown) 8 Control shelf

2 Bus terminal switch

3 Serial communication terminals (see Table 5.1) 10 Analog input switches A53/A54

(see chapter 5.8.5 Conguring RS485 Serial Communication)

4 Digital input/output terminals (see Table 5.2) 11 Analog input/output terminals (see Table 5.3)

5 Cable/EMC clamps 12 Brake resistor terminals, 104–106

6 Relay 1 and relay 2 (see Illustration 5.19) 13 Power card (underneath the control shelf)

7 Control card (underneath LCP and control terminals) – –

9 USB port

(see chapter 5.8.10 Selecting Voltage/Current Input Signal)

(on power card underneath control shelf)

Illustration 3.3 View of Control Shelf

130BF154.10

Auto

Reset

Hand

O

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

1(1)

0.00 A

O Remote Stop

0.0 Hz

Alarm

Warn.

0.000

0.000 RPM

0.0000

A1.1

A1.2

A1.3

C4 C5

Product Overview VLT® AQUA Drive FC 202

3.6 Local Control Panel (LCP)

Illustration 3.4 Graphical Local Control Panel (LCP)

A. Display area

Each display readout has a parameter associated with it. See Table 3.2. The information shown on the LCP can be customized for specic applications. Refer to chapter 6.3.1.2 Q1 My Personal Menu.

Callout Parameter number Default setting

A1.1 0-20 Reference [Unit]

A1.2 0-21 Analog input 53 [V]

A1.3 0-22 Motor current [A]

A2 0-23 Frequency [Hz]

A3 0-24 Feedback [Unit]

Table 3.2 LCP Display Area

B. Menu keys

Menu keys are used to access the menu for setting up parameters, toggling through status display modes during normal operation, and viewing fault log data.

Callout Key Function

B1 Status Shows operational information.

B2 Quick Menu Allows access to parameters for initial

set-up instructions. Also provides

detailed application steps. Refer

to chapter 6.3.1.1 Quick Menu Mode.

Callout Key Function

B3 Main Menu Allows access to all parameters. Refer to

chapter 6.3.1.9 Main Menu Mode.

B4 Alarm Log Shows a list of current warnings and the

last 10 alarms.

Table 3.3 LCP Menu Keys

C. Navigation keys

Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. The display brightness can be adjusted by pressing [Status] and [▲]/[▼] keys.

Callout Key Function

C1 Back Reverts to the previous step or list in the

menu structure.

C2 Cancel Cancels the last change or command as

long as the display mode has not changed.

C3 Info Shows a denition of the function being

shown.

C4 OK Accesses parameter groups or enables an

option.

▲ ▼

Table 3.4 LCP Navigation Keys

Moves between items in the menu.

◄ ►

Product Overview Operating Guide

D. Indicator lights

Indicator lights are used to identify the drive status and to provide a visual notication of warning or fault conditions.

Callout Indicator Indicator

D1 On Green Activates when the drive receives

D2 Warn. Yellow Activates when warning

D3 Alarm Red Activates during a fault

Table 3.5 LCP Indicator Lights

Function

light

power from the mains voltage or

a 24 V external supply.

conditions are active. Text

appears in the display area

identifying the problem.

condition. Text appears in the

display area identifying the

problem.

E. Operation keys and reset

The operation keys are found toward the bottom of the local control panel.

Callout Key Function

E1 [Hand on] Starts the drive in local control. An

external stop signal by control input or

serial communication overrides the local

[Hand On].

E2 O Stops the motor but does not remove

power to the drive.

E3 Auto on Puts the system in remote operational

mode so it can respond to an external

start command by control terminals or

serial communication.

E4 Reset Resets the drive manually after a fault has

been cleared.

Table 3.6 LCP Operation Keys and Reset

3 3

Tamb. 55

C/131

F at Full Output Current Derating

IN: 3x525-600V 50/60Hz 743/711 A (UL) OUT: MOTOR 3x0-Vin 0-500Hz 763/730 A

IN: 3x525-690V 50/60Hz 743/711 A (CE)

710 kW / 750 HP, High Overload

OUT: MOTOR 3x0-Vin 0-500Hz 889/850 A

IN: 3x525-690V 50/60Hz 866/828 A (CE)

800 kW / 950 HP, Normal Overload

VLT

T/C: FC-202N710T7E21H2XGC7XKSXXXXA0BXCXXXXD0 P/N: 131N2885 S/N:

AQUA Drive www.danfoss.com

130BF712.10

IN: 3x525-690V 50/60Hz 866/828 A (UL)

ASSEMBLED IN USA

Tamb. 45

C/113

F at Full Output Current

IP21 / TYPE 1

SCCR 100 kA at UL Voltage range 525-600 V

Listed 36U0 E70524 IND. CONT. EQ. UL Voltage range 525-600 V

CAUTION - ATTENTION:

Stored charge, wait 40 min. Charge residuelle, attendez 40

See manual for special condition / prefuses Voir manuel de conditions speciales / fusibles

WARNING - AVERTISSEMENT:

123456H123

1 2

3 4

Danfoss A/S 6340 Nordborg Denmark

Mechanical Installation VLT® AQUA Drive FC 202

4 Mechanical Installation

4.1 Items Supplied

Items supplied can vary according to product congu-

ration.

4.2 Tools Needed

Receiving/unloading

I-beam and hooks rated to lift the weight of the

•

drive. Refer to chapter 3.2 Power Ratings, Weights,

Make sure that the items supplied and the

•

information on the nameplate correspond to the order conrmation.

Visually check the packaging and the drive for

•

damage caused by inappropriate handling during

Installation

shipment. File any claim for damage with the carrier. Retain damaged parts for clarication.

and Dimensions.

Crane or other lifting aid to place the unit into

•

position.

Drill with 10 mm or 12 mm drill bits.

•

Tape measurer.

•

Various sizes of Phillips and at bladed

•

screwdrivers.

Wrench with relevant metric sockets (7–17 mm).

•

Wrench extensions.

•

Torx drives (T25 and T50).

•

Sheet metal punch for conduits or cable glands.

•

I-beam and hooks to lift the weight of the drive.

•

Refer to chapter 3.2 Power Ratings, Weights, and Dimensions.

Crane or other lifting aid to place the drive onto

•

pedestal and into position.

Storage

4.3

Store the drive in a dry location. Keep the equipment sealed in its packaging until installation. Refer to chapter 9.4 Ambient Conditions for recommended ambient temperature.

1 Type code

2 Code number

3 Power rating

Input voltage, frequency, and current (at low/high

voltages)

Output voltage, frequency, and current (at low/high

voltages)

6 Discharge time

Illustration 4.1 Product Nameplate for E2h Enclosure (Example)

NOTICE

Removing the nameplate from the drive can result in the loss or warranty.

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

Mechanical Installation Operating Guide

4.4 Operating Environment

In environments with airborne liquids, particles, or corrosive gases, ensure that the IP/Type rating of the equipment matches the installation environment. For specications regarding ambient conditions, see chapter 9.4 Ambient Conditions.

NOTICE

CONDENSATION

Moisture can condense on the electronic components and cause short circuits. Avoid installation in areas subject to frost. Install an optional space heater when the drive is colder than the ambient air. Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of moisture.

NOTICE

EXTREME AMBIENT CONDITIONS

Hot or cold temperatures compromise unit performance and longevity.

Do not operate in environments where the

•

ambient temperature exceeds 55 °C (131 °F).

The drive can operate at temperatures down to

•

-10 °C (14 °F). However, proper operation at rated load is only guaranteed at 0 °C (32 °F) or higher.

Extra air conditioning of the cabinet or instal-

•

lation site is required if temperature exceeds ambient temperature limits.

4.4.1 Gases

Aggressive gases, such as hydrogen sulphide, chlorine, or ammonia can damage the electrical and mechanical components. The unit uses conformal-coated circuit boards to reduce the eects of aggressive gases. For conformalcoating class specications and ratings, see chapter 9.4 Ambient Conditions.

4.4.2 Dust

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

Periodic maintenance

When dust accumulates on electronic components, it acts as a layer of insulation. This layer reduces the cooling capacity of the components, and the components become warmer. The hotter environment decreases the life of the electronic components.

Keep the heat sink and fans free from dust buildup. For more service and maintenance information, refer to chapter 8 Maintenance, Diagnostics, and Troubleshooting.

Cooling fans

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

4.4.3 Potentially Explosive Atmospheres

WARNING

EXPLOSIVE ATMOSPHERE

Do not install the drive in a potentially explosive atmosphere. Install the unit in a cabinet outside of this area. Failure to follow this guideline increases risk of death or serious injury.

Systems operated in potentially explosive atmospheres must fulll special conditions. EU Directive 94/9/EC (ATEX

95) classies the operation of electronic devices in potentially explosive atmospheres.

species that if a spark occurs, it is

Class d

•

contained in a protected area.

Class e prohibits any occurrence of a spark.

•

Motors with class d protection

Does not require approval. Special wiring and containment are required.

Motors with class e protection

When combined with an ATEX approved PTC monitoring

device like the VLT® PTC Thermistor Card MCB 112, installation does not need an individual approval from an approbated organization.

Motors with class d/e protection

The motor itself has an e ignition protection class, while the motor cabling and connection environment is in compliance with the d peak voltage, use a sine-wave lter at the drive output.

When using a drive in a potentially explosive atmosphere, use the following:

Motors with ignition protection class d or e.

•

PTC temperature sensor to monitor the motor

•

temperature.

Short motor cables.

•

Sine-wave output lters when shielded motor

•

cables are not used.

classication. To attenuate the high

4 4

Mechanical Installation VLT® AQUA Drive FC 202

Duct cooling

NOTICE

MOTOR THERMISTOR SENSOR MONITORING

VLT® AutomationDrive units with the VLT® PTC Thermistor Card MCB 112 option are PTB-certied for potentially explosive atmospheres.

4.5 Installation and Cooling Requirements

NOTICE

Improper mounting can result in overheating and reduced performance.

Installation requirements

Locate the unit as near to the motor as possible.

•

See chapter 9.5 Cable Specications for the maximum motor cable length.

Ensure unit stability by mounting the unit to a

•

solid surface.

Enclosures E3h and E4h can be mounted:

•

- Vertically on the back plate of the panel

(typical installation).

- Vertically upside down on the back plate of the panel.

- Horizontally on its back, mounted on the back plate of the panel.

- Horizontally on its side, mounted on oor of the panel.

Ensure that the strength of the mounting location

•

supports the unit weight.

Ensure that there is enough space around the

•

unit for proper cooling. Refer to chapter 9.9 Enclosure Airow.

Ensure enough access to open the door.

•

Ensure cable entry from the bottom.

•

1) For non-typical installation, contact the factory.

Cooling requirements

Ensure that top and bottom clearance for air

•

cooling is provided. Clearance requirement: 225 mm (9 in).

Provide

•

Consider derating for temperatures starting

•

between 45 °C (113 °F) and 50 °C (122 °F) and elevation 1000 m (3300 ft) above sea level. See the design guide for detailed information.

The drive utilizes a back-channel cooling concept that removes heat sink cooling air. The heat sink cooling air carries approximately 90% of the heat out of the back channel of the drive. Redirect the back-channel air from the panel or room by using:

sucient airow ow rate. See Table 4.1.

•

Back-channel cooling kits are available to direct the heat sink cooling air out of the panel when IP20/Chassis drives are installed in Rittal enclosures. Use of these kits reduce the heat in the panel and smaller door fans can be specied.

Back-wall cooling

•

Installing top and base covers to the unit allows the back-channel cooling air to be ventilated out of the room.

NOTICE

For E3h and E4h enclosures (IP20/Chassis), at least 1 door fan is required on the enclosure to remove the heat not contained in the back-channel of the drive. It also removes any additional losses generated by other components inside the drive. To select the appropriate fan size, calculate the total required airow.

Secure the necessary airow over the heat sink.

Frame Door fan/top fan

[m3/hr (cfm)]

E1h 510 (300) 994 (585)

E2h 552 (325) 1053–1206 (620–710)

E3h 595 (350) 994 (585)

E4h 629 (370) 1053–1206 (620–710)

Table 4.1 Airow Rate

Lifting the Unit

4.6

Lifting

Always lift the drive using the dedicated lifting eyes. To avoid bending the lifting holes, use a bar.

Heat sink fan

[m3/hr (cfm)]

WARNING

RISK OF INJURY OR DEATH

Follow local safety regulations for lifting heavy weights. Failure to follow recommendations and local safety regulations can result in death or serious injury.

Ensure that the lifting equipment is in proper

•

working condition.

See chapter 3.2 Power Ratings, Weights, and

•

Dimensions for the weight of the dierent enclosure types.

Maximum diameter for bar: 20 mm (0.8 in).

•

The angle from the top of the drive to the

•

lifting cable: 60° or greater.

130BF685.10

130BF208.10

Mechanical Installation Operating Guide

4 4

Illustration 4.3 Pedestal to Floor Mounting Points

4.7.2 Attaching the E1h/E2h to the Pedestal

Illustration 4.2 Recommended Lifting Method

4.7 E1h/E2h Mechanical Installation

The E1h and E2h enclosure size is intended only for oor installation, and is shipped with a pedestal and a gland plate. The pedestal and gland plate must be installed for proper installation.

The pedestal is 200 mm (7.9 in) and has an opening in the front to allow airow necessary to cool the power components of the drive.

The gland plate is necessary to provide cooling air to the control components of the drive via the door fan, and to maintain the IP21/Type 1 or IP54/Type 12 protection rating.

4.7.1 Securing the Pedestal to the Floor

The pedestal must be secured to the oor using 6 bolts before installing the enclosure.

1. Determine proper placement of the unit, concerning operating conditions and cable access.

2. Access the mounting holes by removing the front panel of the pedestal.

3. Set the pedestal on the oor and secure using 6 bolts through the mounting holes. Refer to the circled areas in Illustration 4.3.

1. Lift the drive and position it on the pedestal. There are 2 bolts in the rear of the pedestal that slide into the 2 slotted holes in the rear of the enclosure. Position the drive by adjusting the bolts up or down. Loosely secure with 2 M10 nuts and locking brackets. See Illustration 4.4.

2. Verify that there is 225 mm (9 in) top clearance for air exhaust.

3. Verify that the air intake at the bottom front of the unit is not obstructed.

4. Around the top of the pedestal, secure the enclosure using 6 M10x30 fasteners. Refer to Illustration 4.5. Loosely tighten each bolt until all bolts are installed.

5. Fasten each bolt securely and torque to 19 Nm (169 in-lb).

6. Torque the 2 M10 nuts at the rear of the enclosure to 19 Nm (169 in-lb).

130BF225.10

130BF207.10

130BF209.10

Mechanical Installation VLT® AQUA Drive FC 202

4.7.3 Creating Cable Openings

The gland plate is a sheet of metal with studs along the outer edge. The gland plate provides cable entry and cable termination points, and must be installed to maintain the IP21/IP54 (Type 1/Type 12) protection rating. The plate is placed between the drive enclosure and the pedestal. Depending on stud orientation, the plate can be installed from inside the enclosure or the pedestal. For gland plate

1 Enclosure 4 Slotted hole in enclosure

2 Pedestal 5 Bolt at rear of pedestal

3 M10 nut 6 Locking bracket

Illustration 4.4 Pedestal to Enclosure Back Mounting Points

dimensions, see chapter 9.8.1 E1h Exterior Dimensions.

Refer to Illustration 4.6 for the following steps.

1. Create cable entry holes in the gland plate using a sheet metal punch.

2. Insert the gland plate using 1 of the following methods:

2a To insert the gland plate through the

pedestal, slide the gland plate through the slot (4) in the front of the pedestal.

2b To insert the gland plate through the

enclosure, angle the gland plate until it can be slid under the slotted brackets.

3. Align the studs on the gland plate to the holes in the pedestal and secure with 10 M5 nuts (2).

4. Torque each nut to 2.3 Nm (20 in-lb).

1 Enclosure 3 M10x30 fasteners

(rear corner bolts not

shown)

2 Pedestal – –

Illustration 4.5 Pedestal to Enclosure Mounting Points

1 Cable entry hole 4 Slot in pedestal base

2 M5 nut 5 Front cover/grill

3 Gland plate – –

Illustration 4.6 Installing the Gland Plate

130BF662.10

Mechanical Installation Operating Guide

4.8 E3h/E4h Mechanical Installation

The E3h and E4h enclosure sizes are intended to be mounted on a wall or on a mounting panel within an enclosure. A plastic gland plate is installed on the enclosure. It is designed to prevent unintentional access to the terminals in an IP20/protected chasis unit.

NOTICE

Regeneration/Load share Option

Due to the exposed terminals at the top of the enclosure, units with the regeneration/load share option have an IP00 protection rating.

4.8.1 Attaching the E3h/E4h to a Mounting Plate or Wall

1. Drill the mounting holes according to the enclosure size. Refer to chapter 9.8 Enclosure Dimensions.

2. Secure the top of the drive enclosure to the mounting plate or wall.

3. Secure the base of the drive enclosure to the mounting plate or wall.

3. Based on the measurement and positions of the cables, create openings in the plastic gland plate by cutting out the necessary squares.

4. Slide the plastic gland plate (7) onto the bottom rails of the terminal cover.

5. Tilt the front of the terminal cover downward until the fastener points (8) rest on the slotted drive brackets (6).

6. Make sure the side panels of the terminal cover are on the outside track guide (5).

7. Push the terminal cover until it is up against the slotted drive bracket.

8. Tilt the front of the terminal cover upward until the fastener hole in the bottom of the drive aligns with the keyhole opening (9) in the terminal. Secure with 2 T25 screws and torque to

2.3 Nm (20 in-lb).

9. Secure the bottom panel with 3 T25 screws and torque to 2.3 Nm (20 in-lb).

4 4

4.8.2 Creating Cable Openings

The gland plate covers the bottom part of the drive enclosure and must be installed to maintain the IP20/ Chassis protection rating. The gland plate consists of plastic squares that can be cut out to provide cable access to the terminals. See Illustration 4.7.

1. Remove the bottom panel and terminal cover. See Illustration 4.8.

1a Detach the bottom panel by removing 4

T25 screws.

1b Remove 5 T20 screws that secure the

bottom of the drive to the top of the terminal cover, and then pull the terminal cover straight out.

2. Determine the size and position of the motor, mains, and ground cables. Note their position and measurements.

1 Plastic square

2 Squares removed for cable access

Illustration 4.7 Plastic Gland Plate

130BF688.10

Mechanical Installation VLT® AQUA Drive FC 202

1 Load share/regeneration terminals (optional) 6 Slotted drive bracket

2 Bottom panel 7 Plastic gland plate (installed)

3 Terminal cover 8 Fastener point

4 Grommet access hole for control wiring 9 Keyhole opening

5 Track guide – –

Illustration 4.8 Assembling the Gland Plate and Terminal Cover

130BF697.10

Mechanical Installation Operating Guide

4.8.3 Installing Load share/Regeneration Terminals

The load share/regeneration terminals, located on the top of the drive, are not installed from the factory to prevent damage during shipping. Refer to Illustration 4.9 for the following steps.

4 4

1 Label fastener, M4

2 Label

3 Load share/regeneration terminal

4 Terminal fastener, M10

5 Terminal plate with 2 openings

Illustration 4.9 Load share/Regeneration Terminals

1. Remove the terminal plate, 2 terminals, label, and fasteners from the accessory bag included with the drive.

2. Remove the cover from the load share/ regeneration opening on the top of the drive. Put aside the 2 M5 fasteners for reuse later.

3. Remove the plastic backing and install the terminal plate over the load share/regeneration opening. Secure with the 2 M5 fasteners and torque to 2.3 Nm (20 in-lb).

4. Install the both terminals to the terminal plate using 1 M10 fastener per terminal. Torque to 19 Nm (169 in-lb).

5. Install the label on the front of the terminals as shown in Illustration 4.9. Secure with 2 M4 screws and torque to 1.2 Nm (10 in-lb).

Electrical Installation VLT® AQUA Drive FC 202

5 Electrical Installation

5.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables from dierent drives that are run together can charge equipment

capacitors even with the equipment turned o and locked out. Failure to run output motor cables separately or use shielded cables could result in death or serious injury.

Run output motor cables separately, or

•

Use shielded cables.

•

Simultaneously lock out all the drives.

•

WARNING

SHOCK HAZARD

The drive can cause a DC current in the ground conductor and thus result in death or serious injury.

When a residual current-operated protective

•

device (RCD) is used for protection against electrical shock, only an RCD of Type B is allowed on the supply side.

Failure to follow the recommendation means that the RCD cannot provide the intended protection.

CAUTION

PROPERTY DAMAGE!

Protection against motor overload is not included in the default setting. To add this function, set

parameter 1-90 Motor Thermal Protection to [ETR trip] or [ETR warning]. For the North American market, the ETR

function provides class 20 motor overload protection in accordance with NEC. Failure to set parameter 1-90 Motor Thermal Protection to [ETR trip] or [ETR warning] means that motor overload protection is not provided and property damage can occur if the motor overheats.

5.2 EMC-compliant Installation

To obtain an EMC-compliant installation, follow the instructions provided in:

chapter 5.3 Wiring Schematic.

•

chapter 5.4 Connecting the Motor.

•

chapter 5.6 Connecting to Ground.

•

chapter 5.8 Control Wiring.

•

NOTICE

TWISTED SHIELD ENDS (PIGTAILS)

Twisted shield ends increase the shield impedance at higher frequencies, which reduces the shield eect and increases the leakage current. Avoid twisted shield ends by using integrated shield clamps.

Overcurrent protection

Extra protective equipment such as short-circuit

•

protection or motor thermal protection between drive and motor is required for applications with multiple motors.

Input fusing is required to provide short circuit

•

and overcurrent protection. If fuses are not factory-supplied, the installer must provide them. See maximum fuse ratings in chapter 9.7 Fuses.

Wire type and ratings

All wiring must comply with local and national

•

regulations regarding cross-section and ambient temperature requirements.

Power connection wire recommendation:

•

Minimum 75 °C (167 °F) rated copper wire.

See chapter 9.5.1 Cable Specications for recommended wire sizes and types.

For use with relays, control cables, a signal

•

interface, eldbus, or brake, connect the shield to the enclosure at both ends. If the ground path has high impedance, is noisy, or is carrying current, break the shield connection on 1 end to avoid ground current loops.

Convey the currents back to the unit using a

•

metal mounting plate. Ensure good electrical contact from the mounting plate through the mounting screws to the drive chassis.

Use shielded cables for motor output cables. An

•

alternative is unshielded motor cables within metal conduit.

NOTICE

SHIELDED CABLES

If shielded cables or metal conduits are not used, the unit and the installation does not meet regulatory limits on radio frequency (RF) emission levels.

Electrical Installation Operating Guide

Ensure that motor and brake cables are as short

•

as possible to reduce the interference level from the entire system.

Avoid placing cables with a sensitive signal level

•

alongside motor and brake cables.

For communication and command/control lines,

•

follow the particular communication protocol standards. For example, USB must use shielded cables, but RS-485/ethernet can use shielded UTP or unshielded UTP cables.

Ensure that all control terminal connections are

•

PELV.

NOTICE

EMC INTERFERENCE

Use shielded cables for motor and control wiring, and separate cables for mains input, motor wiring, and control wiring. Failure to isolate power, motor, and control cables can result in unintended behavior or reduced performance. Minimum 200 mm (7.9 in) clearance between mains input, motor, and control cables is required.

5 5

NOTICE

INSTALLATION AT HIGH ALTITUDE

There is a risk for overvoltage. Isolation between components and critical parts could be insucient, and may not comply with PELV requirements. Reduce the risk for overvoltage by using external protective devices or galvanic isolation. For installations above 2000 m (6500 ft) altitude, contact Danfoss regarding PELV compliance.

NOTICE

PELV COMPLIANCE

Prevent electric shock by using protective extra low voltage (PELV) electrical supply and complying with local and national PELV regulations.

130BF228.10

L1 L2 L3

Electrical Installation VLT® AQUA Drive FC 202

1 PLC 10 Mains cable (unshielded)

Minimum 16 mm2 equalizing cable

3 Control cables 12 Cable insulation stripped

4 Minimum 200 mm between control cables, motor cables, and

mains cables.

5 Mains supply 14 Brake resistor

6 Bare (unpainted) surface 15 Metal box

7 Star washers 16 Connection to motor

8 Brake cable (shielded) 17 Motor

9 Motor cable (shielded) 18 EMC cable gland

11 Output contactor, and so on

13 Common ground busbar. Follow local and national

requirements for cabinet grounding.

Illustration 5.1 Example of Proper EMC Installation

130BF111.11

230 V AC 50/60 Hz

TB5

Regen +

Regen -

Regen (optional)

Brake temperature (NC)

Space heater (optional)

91 (L1) 92 (L2) 93 (L3)

88 (-) 89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24 V OUT)

13 (+24 V OUT)

18 (D IN)

20 (COM D IN)

15 mA

200 mA

(U) 96

(V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

0/4-20 mA

+10 V DC

-10 V DC - +10 V DC

0/4-20 mA

24 V DC

240 V AC, 2A

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

19 (D IN)

24 V (NPN) 0 V (PNP)

24V

(D IN/OUT)

0 V (PNP)

24 V (NPN)

(D IN/OUT)

24V

24 V (NPN) 0 V (PNP)

0 V (PNP)

24 V (NPN)

33 (D IN)

32 (D IN)

1 2

A53 U-I (S201)

A54 U-I (S202)

ON=0-20 mA OFF=0-10 V

400 V AC, 2A

P 5-00

(R+) 82

(R-) 81

37 (D IN)

+ - + -

(P RS485) 68

(N RS485) 69

(COM RS485) 61

S801

RS485

S801/Bus Term. OFF-ON

3-phase power

input

Load share

Switch mode

power supply

Motor

Analog output

interface

Relay1

Relay2

ON=Terminated OFF=Open

Brake resistor

(NPN) = Sink

(PNP) = Source

= ==

240 V AC, 2A

400 V AC, 2A

-10 V DC - +10 V DC

10 V DC

(optional)

Electrical Installation Operating Guide

5.3 Wiring Schematic

5 5

Illustration 5.2 Basic Wiring Schematic

A=Analog, D=Digital

1) Terminal 37 (optional) is used for Safe Torque O. For Safe Torque O installation instructions, refer to the Safe Torque O Operating Guide.

Electrical Installation VLT® AQUA Drive FC 202

5.4 Connecting the Motor

WARNING

INDUCED VOLTAGE

Induced voltage from output motor cables that run together can charge equipment capacitors, even with the equipment turned o and locked out. Failure to run output motor cables separately or use shielded cables could result in death or serious injury.

Comply with local and national electrical codes for cable sizes. For maximum wire sizes, see chapter 9.1 Electrical

•

Data.

Follow motor manufacturer wiring requirements.

•

Motor wiring knockouts or access panels are provided on the pedestal of IP21/IP54 (Type 1/Type 12) units.

•

Do not wire a starting or pole-changing device (for example Dahlander motor or slip ring asynchronous motor)

•

between the drive and the motor.

Procedure

1. Strip a section of the outer cable insulation.

2. Establish mechanical xation and electrical contact between the cable shield and ground by positioning the stripped wire under the cable clamp.

3. Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in chapter 5.6 Connecting to Ground.

4. Connect the 3-phase motor wiring to terminals 96 (U), 97 (V), and 98 (W), see Illustration 5.3.

5. Tighten the terminals in accordance with the information provided in chapter 9.10.1 Fastener Torque Ratings.

130BF150.10

U/T1 96 V/T2 97

W/T3 98

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (26FT-LB)

U/T1 96 V/T2 97

W/T3 98

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (14FT-LB)

+ REGEN 82

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

- REGEN 83

FASTENER TORQUE: M10 19Nm (14FT-LB) M12 35Nm (26FT-LB)

Electrical Installation Operating Guide

5 5

Illustration 5.3 AC motor terminals (E1h shown). For a detailed view of terminals, refer to chapter 5.7 Terminal Dimensions.

Electrical Installation VLT® AQUA Drive FC 202

5.5 Connecting the AC Mains

Size the wiring according to the input current of the drive. For maximum wire sizes, see chapter 9.1 Electrical Data.

•

Comply with local and national electrical codes for cable sizes.

•

Procedure

1. Strip a section of the outer cable insulation.

2. Establish mechanical xation and electrical contact between the cable shield and ground by positioning the stripped wire under the cable clamp.

3. Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions provided in chapter 5.6 Connecting to Ground.

4. Connect the 3-phase AC input power wiring to terminals R, S, and T (see Illustration 5.4).

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

6. Tighten the terminals in accordance with the information provided in chapter 9.10.1 Fastener Torque Ratings.

130BF151.10

T/L3 93

S/L2 92

R/L1 91

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (26FT-LB)

T/L3 93

S/L2 92

R/L1 91

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (26FT-LB)

Electrical Installation Operating Guide

5 5

Illustration 5.4 AC mains terminals (E1h shown). For a detailed view of terminals, refer to chapter 5.7 Terminal Dimensions.

Electrical Installation VLT® AQUA Drive FC 202

5.6 Connecting to Ground

WARNING

LEAKAGE CURRENT HAZARD

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

Ensure the correct grounding of the equipment by a certied electrical installer.

•

For electrical safety

Ground the drive in accordance with applicable standards and directives.

•

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

•

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

•

Keep the ground wire connections as short as possible.

•

Follow motor manufacturer wiring requirements.

•

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

•

Tighten the terminals in accordance with the information provided in chapter 9.10.1 Fastener Torque Ratings.

•

For EMC-compliant installation

Establish electrical contact between the cable shield and the drive enclosure by using metal cable glands or by

•

using the clamps provided on the equipment.

Reduce burst transient by using high-strand wire.

•

Do not use pigtails.

•

NOTICE

POTENTIAL EQUALIZATION

There is a risk of burst transient when the ground potential between the drive and the control system is dierent. Install equalizing cables between the system components. Recommended cable cross-section: 16 mm2 (5 AWG).

130BF152.10

U/T1 96 V/T2 97

W/T3 98

T/L3 93S/L2 92R/L1 91

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (26FT-LB)

U/T1 96 V/T2 97

W/T3 98

T/L3 93S/L2 92R/L1 91

FASTENER TORQUE M10 19Nm (14FT-LB), M12 35Nm (26FT-LB)

Electrical Installation Operating Guide

5 5

Illustration 5.5 Ground terminals (E1h shown). For a detailed view of terminals, refer to chapter 5.7 Terminal Dimensions.

130BF683.10

6X 613 (24.1)

383 (15.1)

472 (18.6)

423 (16.7)

165 (6.5)

0 (0.0)

101 (4.0)

82 (3.2)

721 (28.4)

0 (0.0)

200 (7.9)

515 (20.3)

485 (19.1)

248 (9.8)

241 (9.5)

171 (6.7)

414 (16.3)

361 (14.2)

331 (13.0)

501 (19.7)

497 (19.6)

431 (17.0)

512 (20.2)

Electrical Installation VLT® AQUA Drive FC 202

5.7 Terminal Dimensions

5.7.1 E1h Terminal Dimensions

1 Mains terminals 3 Motor terminals

2 Brake or regeneration terminals 4 Ground terminals, M10 nut

Illustration 5.6 E1h Terminal Dimensions (Front View)

130BF650.10

649 (25.5)649 (25.5)

0 (0.0)

164 (6.4)

290 (11.4)

377 (14.8)

0 (0.0)

164 (6.4)

290 (11.4)

18 (0.7)

0 (0.0)

84 (3.3)

42 (1.7)

0 (0.0)

36 (1.4)

44 (1.8)

14 (0.5)

Electrical Installation Operating Guide

5 5

Illustration 5.7 E1h Terminal Dimensions (Side Views)

130BF689.10

721 (28.4)

6X 613 (24.1)

515 (20.3)

485 (19.1)

0 (0.0)

200 (7.9)

185 (7.3)

0 (0.0)

101 (4.0)

89 (3.5)

289 (11.4)

281 (11.1)

195 (7.7)

483 (19.0)

409 (16.1)

387 (15.2)

597 (23.5)

579 (22.8)

503 (19.8)

479 (18.9)

568 (22.4)

519 (20.4)

608 (23.9)

Electrical Installation VLT® AQUA Drive FC 202

5.7.2 Mains, Motor, and Ground for E2h

1 Mains terminals 3 Motor terminals

2 Brake or regeneration terminals 4 Ground terminals, M10 nut

Illustration 5.8 E2h Terminal Dimensions (Front View)

649 (25.5)649 (25.5)

0 (0.0)

164 (6.4)

290 (11.4)

377 (14.8)

0 (0.0)

164 (6.4)

290 (11.4)

130BF690.10

18 (0.7)

0 (0.0)

84 (3.3)

42 (1.7)

0 (0.0)

36 (1.4)

44 (1.8)

14 (0.5)

Electrical Installation Operating Guide

5 5

Illustration 5.9 E2h Terminal Dimensions (Side Views)

130BF660.10

336 (13.2)

425 (16.7)

376 (14.8)

465 (18.3)

256 (10.1)

33 (1.3)

6X 148 (5.8)

90 (3.5)

50 (2.0)

0 (0.0)

64 (2.5)

35 (1.4)

91 (3.6)

118 (4.6)

194 (7.6)

174 (6.9)

201 (7.9)

284 (11.2)

340 (13.4)

314 (12.3)

367 (14.4)

444 (17.5)

423 (16.7)

450 (17.7)

Electrical Installation VLT® AQUA Drive FC 202

5.7.3 Mains, Motor, and Ground for E3h

1 Mains terminals 3 Motor terminals

2 Brake or regeneration terminals 4 Ground terminals, M8 and M10 nuts

Illustration 5.10 E3h Terminal Dimensions (Front View)

130BF661.10

0 (0.0)

160 (6.3)

0 (0.0)

373 (14.7)

287 (11.3)

160 (6.3)

0 (0.0)

184

(7.2)

184 (7.2)

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

18 (0.7)

0 (0.0)

84 (3.3)

42 (1.7)

Electrical Installation Operating Guide

5 5

Illustration 5.11 E3h Mains, Motor, and Ground Terminal Dimensions (Side Views)

130BF663.10

0 (0.0)

234 (9.2)

314 (12.4)

0 (0.0)

176 (6.9)

8X 14 (0.5)

20 (0.8)

0 (0.0)

35(1.4)

0 (0.0)

15 (0.6)

35 (1.4)

50 (2.0)

75 (3.0)

90 (3.5)

125 (4.9)

140 (5.5)

2X 125 (4.9)

0 (0.0)

Electrical Installation VLT® AQUA Drive FC 202

Illustration 5.12 E3h Load Share/Regeneration Terminal Dimensions

130BF668.10

6X 148 (5.8)

90 (3.5)

50 (2.0)

0 (0.0)

64 (2.5)

41 (1.6)

105 (4.1)

137 (5.4)

194 (7.6)

200 (7.9)

233 (9.2)

402 (15.8)

339 (13.4)

410 (16.1)

499 (19.6)

435 (17.1)

531 (20.9)

256 (10.1)

33 (1.3)

540 (21.2)

432 (17.0)

521 (20.5)

472 (18.6)

561 (22.1)

Electrical Installation Operating Guide

5.7.4 Mains, Motor, and Ground for E4h

5 5

1 Mains terminals 3 Motor terminals

2 Brake or regeneration terminals 4 Ground terminals, M8 and M10 nuts

Illustration 5.13 E4h Terminal Dimensions (Front View)

130BF681.10

5X 14 (0.5)

44 (1.8)

0 (0.0)

36 (1.4)

0 (0.0)

373 (14.7)

287 (11.3)

160 (6.3)

0 (0.0)

160 (6.3)

0 (0.0)

287 (11.3)

184

(7.2)

184

(7.2)

18 (0.7)

0 (0.0)

84 (3.3)

42 (1.7)

Electrical Installation VLT® AQUA Drive FC 202

Illustration 5.14 E4h Mains, Motor, and Ground Terminal Dimensions (Side Views)

130BF682.10

20 (0.8)

0 (0.0)

35(1.4)

0 (0.0)

15 (0.6)

35 (1.4)

50 (2.0)

75 (3.0)

90 (3.5)

125 (4.9)

140 (5.5)

8X 14 (0.5)

2X 125 (4.9)

0 (0.0)

234 (9.2)

314 (12.4)

0 (0.0)

219 (8.6)

Electrical Installation Operating Guide

5 5

Illustration 5.15 E4h Load Share/Regeneration Terminal Dimensions

130BF715.10

130BF144.10

12 13 18 19 27 29 32 33 20 37

39696861 42 50 53 54 55

130BF145.10

Electrical Installation VLT® AQUA Drive FC 202

5.8 Control Wiring

All terminals to the control cables are inside the drive below the LCP. To access, either open the door (E1h and E2h) or remove the front panel (E3h and E4h).

5.8.2 Control Terminal Types

Illustration 5.17 shows the removable drive connectors. Terminal functions and default settings are summarized in Table 5.1 – Table 5.3.

5.8.1 Control Cable Routing

Tie down and route all control wires as shown in Illustration 5.16. Remember to connect the shields in a proper way to ensure optimum electrical immunity.

Fieldbus connection

Connections are made to the relevant options on the control card. For more detail, see the relevant eldbus instruction. The cable must be tied down and routed along with other control wires inside the unit. See Illustration 5.16.

Isolate control wiring from high-power cables in

•

the drive.

When the drive is connected to a thermistor,

•

ensure that the thermistor control wiring is shielded and reinforced/double insulated. A 24 V DC supply voltage is recommended.

Illustration 5.17 Control Terminal Locations

1 Serial communication terminals

Illustration 5.16 Control Card Wiring Path

2 Digital input/output terminals

3 Analog input/output terminals

Illustration 5.18 Terminal Numbers Located on the Connectors

Serial communication terminals

Terminal Parameter Default

setting

61 – – Integrated RC-lter for

Description

cable shield. ONLY for

connecting the shield

in the event of EMC

problems.

RELAY 1 RELAY 2

01 02 03 04 05 06

130BF156.10

Electrical Installation Operating Guide

Serial communication terminals

Terminal Parameter Default

setting

68 (+) Parameter

group 8-3* FC

Port Settings

69 (-) Parameter

group 8-3* FC

Port Settings

01, 02, 03 Parameter 5-40

Function Relay

[0]

04, 05, 06 Parameter 5-40

Function Relay

[1]

Table 5.1 Serial Communication Terminal Descriptions

Digital input/output terminals

Terminal Parameter Default

12, 13 – +24 V DC 24 V DC supply

18 Parameter 5-10

Terminal 18

Digital Input

19 Parameter 5-11

Terminal 19

Digital Input

32 Parameter 5-14

Terminal 32

Digital Input

33 Parameter 5-15

Terminal 33

Digital Input

27 Parameter 5-12

Terminal 27

Digital Input

29 Parameter 5-13

Terminal 29

Digital Input

20 – – Common for digital

– RS485 interface. A

–

Relays

[0] No

operation

[0] No

operation

setting

[8] Start Digital inputs.

[10]

Reversing

[0] No

operation

[0] No

operation

[2] Coast

inverse

[14] JOG

Description

switch (BUS TER.) is

provided on the

control card for bus

termination

resistance. See

Illustration 5.22.

Form C relay output.

For AC or DC voltage

and resistive or

inductive loads.

Description

voltage for digital

inputs and external

transducers.

Maximum output

current 200 mA for all

24 V loads.

For digital input or

output. Default

setting is input.

inputs and 0 V

potential for 24 V

supply.

Digital input/output terminals

Terminal Parameter Default

setting

37 – STO When not using the

Table 5.2 Digital Input/Output Terminal Descriptions

Analog input/output terminals

Terminal Parameter Default

setting

39 – – Common for analog

42 Parameter 6-50

Terminal 42

Output

50 – +10 V DC 10 V DC analog

53 Parameter

group 6-1*

Analog Input 1

54 Parameter

group 6-2*

Analog Input 2

55 – – Common for analog

Table 5.3 Analog Input/Output Terminal Descriptions

[0] No

operation

Reference Analog input. For

Feedback

Description

optional STO feature,

a jumper wire is

required between

terminal 12 (or 13)

and terminal 37. This

set-up allows the

drive to operate with

factory default

programming values.

Description

output.

Programmable analog

output. 0–20 mA or

4–20 mA at a

maximum of 500 Ω.

supply voltage for

potentiometer or

thermistor. 15 mA

maximum.

voltage or current.

Switches A53 and

A54 select mA or V.

input.

Relay terminals:

Illustration 5.19 Relay 1 and Relay 2 Terminals

Relay 1 and relay 2. The location of the outputs

•

depends on the drive conguration. See chapter 3.5 Control Shelf.

Terminals on built-in optional equipment. See the

•

manual provided with the equipment option.

5 5

130BD546.11

10 mm

[0.4 inches]

12 13 18 19 27 29 32 33

Electrical Installation VLT® AQUA Drive FC 202

5.8.3 Wiring to Control Terminals

Control terminal connectors can be unplugged from the drive for ease of installation, as shown in Illustration 5.20.

Illustration 5.20 Connecting Control Wires

NOTICE

Minimize interference by keeping control wires as short as possible and separate from high-power cables.

1. Open the contact by inserting a small screwdriver

2. Insert the bare control wire into the contact.

3. Remove the screwdriver to fasten the control wire

4. Ensure that the contact is rmly established and

See chapter 9.1 Electrical Data for control terminal wiring sizes and chapter 7 Wiring Conguration Examples for typical control wiring connections.

5.8.4 Enabling Motor Operation (Terminal 27)

A jumper wire is required between terminal 12 (or 13) and terminal 27 for the drive to operate when using factory default programming values.

•

into the slot above the contact and push the screwdriver slightly upwards.

into the contact.

not loose. Loose control wiring can be the source of equipment faults or reduced performance.

Digital input terminal 27 is designed to receive 24 V DC external interlock command.

When no interlock device is used, wire a jumper between control terminal 12 (recommended) or 13 to terminal 27. This wire provides an internal 24 V signal on terminal 27.

When the status line at the bottom of the LCP reads AUTO REMOTE COAST, the unit is ready to operate, but is missing an input signal on terminal 27.

When factory-installed optional equipment is

•

wired to terminal 27, do not remove that wiring.

NOTICE

The drive cannot operate without a signal on terminal 27, unless terminal 27 is reprogrammed using parameter 5-12 Terminal 27 Digital Input.

5.8.5 Conguring RS485 Serial Communication

RS485 is a 2-wire bus interface compatible with multi-drop network topology, and it contains the following features:

Either Danfoss FC or Modbus RTU communication

•

protocol, which are internal to the drive, can be used.

Functions can be programmed remotely using

•

the protocol software and RS485 connection or in

parameter group 8-** Communications and Options.

Selecting a

•

changes various default parameter settings to match the specications of the protocol, making more protocol-specic parameters available.

Option cards for the drive are available to provide

•

more communication protocols. See the option card documentation for installation and operation instructions.

A switch (BUS TER) is provided on the control

•

card for bus termination resistance. See Illustration 5.22.

For basic serial communication set-up, perform the following steps:

1. Connect RS485 serial communication wiring to terminals (+)68 and (-)69.

1a Use shielded serial communication cable

1b See chapter 5.6 Connecting to Ground for

2. Select the following parameter settings:

2a Protocol type in parameter 8-30 Protocol.

2b Drive address in parameter 8-31 Address.

2c Baud rate in parameter 8-32 Baud Rate.

specic communication protocol

(recommended).

proper grounding.

130BB489.10

RS485

Electrical Installation Operating Guide

5.8.8 Wiring the Auxiliary Contacts to the Disconnect

The disconnect is an option that is installed at the factory. The auxiliary contacts, which are signal accessories used with the disconnect, are not installed at the factory to allow more exibility during installation. The contacts snap into place without the need for tools.

Illustration 5.21 Serial Communication Wiring Diagram

5.8.6 Wiring Safe Torque O (STO)

The Safe Torque O (STO) function is a component in a safety control system. STO prevents the unit from generating the voltage required to rotate the motor.

To run STO, more wiring for the drive is required. Refer to

Safe Torque

O Operating Guide for further information.

5.8.7 Wiring the Space Heater

The space heater is an option used to prevent condensation from forming inside the enclosure when the unit is turned o. It is designed to be eld wired and controlled by an HVAC management system.

Specications

Nominal voltage: 100–240

•

Wire size: 12–24 AWG

•

Contacts must be installed in disconnect depending upon their functions. Refer to the datasheet included in the accessory bag that comes with the drive.

Specications

Ui/[V]: 690

•

/[kV]: 4

imp

•

Pollution degree: 3

•

Ith/[A]: 16

•

Cable size: 1...2x0.75...2.5 mm

•

Maximum fuse: 16 A/gG

•

NEMA: A600, R300, wire size: 18–14 AWG, 1(2)

•

specic locations on the

5.8.9 Wiring the Brake Resistor Temperature Switch

The brake resistor terminal block is located on the power card and allows for the connection of an external brake resistor temperature switch. The switch can be congured as normally closed or normally open. If the input changes, a signal trips the drive and shows alarm 27, Brake chopper fault on the LCP display. At the same time, the drive stops braking and the motor coasts.

1. Locate the brake resistor terminal block (terminals 104–106) on the power card. See Illustration 3.3.

2. Remove the M3 screws that hold the jumper to the power card.

3. Remove the jumper and wire the brake resistor temperature switch in 1 of the following congu-

rations:

3a Normally closed. Connect to terminals

104 and 106.

3b Normally open. Connect to terminals

104 and 105.

4. Secure the switch wires with the M3 screws. Torque to 0.5-0.6 Nm (5 in lb).

5 5

130BF146.10

BUS TER.

OFF-ON

A53 A54

U- I U- I

N O

Electrical Installation VLT® AQUA Drive FC 202

5.8.10 Selecting Voltage/Current Input Signal

The analog input terminals 53 and 54 allow setting of input signal to voltage (0–10 V) or current (0/4–20 mA).

Default parameter setting:

Terminal 53: Speed reference signal in open loop

•

(see parameter 16-61 Terminal 53 Switch Setting).

Terminal 54: Feedback signal in closed loop (see

•

parameter 16-63 Terminal 54 Switch Setting).

NOTICE

Disconnect power to the drive before changing switch positions.

1. Remove the LCP (local control panel). See chapter 6.3 LCP Menu.

2. Remove any optional equipment covering the switches.

3. Set switches A53 and A54 to select the signal type (U = voltage, I = current).

Illustration 5.22 Location of Terminal 53 and 54 Switches

Electrical Installation Operating Guide

5.9 Pre-start Check List

Before completing installation of the unit, inspect the entire installation as detailed in Table 5.4. Check and mark the items when completed.

Inspect for Description

Auxiliary equipment•Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that reside on the input

power side of the drive or output side to the motor. Ensure that they are ready for full-speed operation.

Check function and installation of any sensors used for feedback to the drive.

•

Remove any power factor correction caps on motor.

•

Adjust any power factor correction caps on the mains side and ensure that they are dampened.

•

Cable routing

Control wiring

Cooling clearance

Ambient conditions

Fusing and circuit

breakers

Grounding

Input and output

power wiring

Panel interior

Switches

Vibration

Ensure that motor wiring, brake wiring (if equipped), and control wiring are separated or shielded, or in 3

•

separate metallic conduits for high-frequency interference isolation.

Check for broken or damaged wires and loose connections.

•

Check that control wiring is isolated from high-power wiring for noise immunity.

•

Check the voltage source of the signals, if necessary.

•

The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated correctly.

•

Measure top clearance for adequate airow for cooling, see chapter 4.5.1 Installation and Cooling

•

Requirements.

Check that requirements for ambient conditions are met. See chapter 9.4 Ambient Conditions.

•

Check for proper fusing or circuit breakers.

•

Check that all fuses are inserted rmly and are in operational condition and that all circuit breakers (if

•

used) are in the open position.

Check for good ground connections that are tight and free of oxidation.

•

Grounding to conduit, or mounting the back panel to a metal surface, is not a suitable grounding.

•

Check for loose connections.

•

Check that motor and mains are in separate conduit or separated shielded cables.

•

Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion.

•

Verify that all installation tools have been removed from unit interior.

•

For E3h and E4h enclosures, ensure that the unit is mounted on an unpainted, metal surface.

•

Ensure that all switch and disconnect settings are in the proper positions.

•

Check that the unit is mounted solidly, or that shock mounts are used, if necessary.

•

Check for an unusual amount of vibration.

•

☑

5 5

Table 5.4 Pre-start Check List

CAUTION

POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE If the drive is not properly secured with covers, personal injury can occur.

Before applying power, ensure all safety covers (door and panels) are in place and securely fastened. Refer to

•

chapter 9.10.1 Fastener Torque Ratings.

Commissioning VLT® AQUA Drive FC 202

6 Commissioning

6.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input power. Failure to use qualied personnel to install, start up, and maintain the drive can result in death or serious injury.

Only qualied personnel must install, start up,

•

and maintain the drive.

Before applying power:

1. Close cover properly.

2. Check that all cable glands are rmly tightened.

3. Ensure that input power to the unit is OFF and locked out. Do not rely on the drive disconnect switches for input power isolation.

4. Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase, and phase-to-ground.

5. Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-tophase, and phase-to-ground.

6. Conrm continuity of the motor by measuring ohm values on U–V (96–97), V–W (97–98), and W– U (98–96).

7. Check for proper grounding of the drive and the motor.

8. Inspect the drive for loose connections on the terminals.

9. Conrm that the supply voltage matches the voltage of the drive and the motor.

Applying Power

6.2

WARNING

UNINTENDED START

To prevent unintended motor start:

Press [O/Reset] on the LCP before

•

programming parameters.

Disconnect the drive from the mains.

•

Completely wire and assemble the drive, motor,

•

and any driven equipment before connecting the drive to the AC mains, DC supply, or load sharing.

1. Conrm that the input voltage between phases is balanced within 3%. If not, correct input voltage imbalance before proceeding. Repeat this procedure after the voltage correction.

2. Ensure that optional equipment wiring, if present, matches the installation application.

3. Ensure that all operator devices are in the OFF position.

4. Close all panel doors and securely fasten all covers.

5. Apply power to the unit. DO NOT start the drive now. For units with a disconnect switch, turn to the ON position to apply power to the drive.

NOTICE

If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or alarm 60, External Interlock is shown, this status indicates that the unit is ready to operate but is missing an input signal on terminal 27. See chapter 5.8.4 Enabling Motor Operation (Terminal 27) for details.

130BF242.10

01 My Personal Menu

02 Quick Setup

05 Changes Made

06 Loggings

0.0% 0.00

Quick Menus

1(1)

07 Water and Pumps

03 Function Setups

04 Smart Start

130BP066.12

Keypad Set-Up

Parameter Data Set

Parameter Data Check

Drive Information

18.4% 5.22A

Main Menu

1(1)

07 Motor Setup

Commissioning Operating Guide

6.3 LCP Menu

For more detailed instructions regarding the menus or parameters, refer to the programming guide.

6.3.1.1 Quick Menu Mode

The LCP provides access to parameters via the Quick Menus. To list the quick menu options, press [Quick Menus].

Illustration 6.1 Quick Menu View

6.3.1.6 Q5 Changes Made

Select Q5 Changes Made for information about:

The 10 most recent changes.

•

Changes made from default setting.

•

6.3.1.7 Q6 Loggings

Use Q6 Loggings for fault nding. To get information about the display line readout, select Loggings. The information is shown as graphs. Only parameters selected in

parameter 0-20 Display Line 1.1 Small through parameter 0-24 Display Line 3 Large can be viewed. It is

possible to store up to 120 samples in the memory for later reference.

Q6 Loggings

Parameter 0-20 Display Line 1.1 Small Reference [Unit]

Parameter 0-21 Display Line 1.2 Small Analog Input 53 [V]

Parameter 0-22 Display Line 1.3 Small Motor current [A]

Parameter 0-23 Display Line 2 Large Frequency [Hz]

Parameter 0-24 Display Line 3 Large Feedback [Unit]

Table 6.1 Logging Parameter Examples

6.3.1.2 Q1 My Personal Menu

The Personal Menu is used to determine what is shown in the display area. Refer to chapter 3.6 Local Control Panel (LCP). This menu can also show up to 50 pre-programmed parameters. These 50 parameters are manually entered using parameter 0-25 My Personal Menu.

6.3.1.3 Q2 Quick Setup

The parameters found in the Q2 Quick Setup contain basic system and motor data that are always necessary for

conguring the drive. See chapter 6.4.2 Entering System Information for the set-up procedures.

6.3.1.4 Q3 Function Setups

The parameters found in the Q3 Function Setups contain data for fan, compressor, and pump functions. This menu also includes parameters for LCP display, digital preset speeds, scaling of analog references, closed-loop single zone, and multizone applications.

6.3.1.8 Q7 Water and Pumps

The parameters found in the Q7 Water and Pumps contain basic data that is necessary for conguring water pump applications.

6.3.1.9 Main Menu Mode

The LCP provides access to the Main Menu mode. Select the Main Menu mode by pressing the [Main Menu] key. The resulting readout appears on the LCP display.

Illustration 6.2 Main Menu View

6.3.1.5 Q4 Smart Start

The Q4 Smart Start function prompts the user for questions based on the previous answer which, in turn, automatically congures the motor and selected pump/fan/conveyor application.

Lines 2 through 5 on the display show a list of parameter groups that can be selected via the [▲] and [▼] keys.

All parameters can be changed in the main menu. Option cards added to the unit enable extra parameters associated with the option device.

130BT112.12

Q1 My Personal Menu

Q2 Quick Setup

Q3 Function Setups

Q5 Changes Made

69.3% 5.20A 1(1)

Quick Menus

130BF725.10

Q3-1 General Settings

Q3-2 Open Loop Settings

Q3-3 Closed Loop Settings

Q3-4 Application Settings

28.4% 2.05A 1(1)

Function Setups

Commissioning VLT® AQUA Drive FC 202

6.4 Programming the Drive

For detailed information on the key functions on the local control panel (LCP), see chapter 3.6 Local Control Panel

(LCP). For information on parameter settings, see the programming guide.

Parameter overview

Parameter settings control the operation of the drive, and are accessed via the LCP. These settings are assigned a default value at the factory, but can be unique application. Each parameter has a name and number that remain the same regardless of the programming mode.

In the Main Menu mode, the parameters are divided into groups. The rst digit of the parameter number (from the left) indicates the parameter group number. The parameter group is then broken down into sub groups, if necessary. For example:

0-** Operation/Display Parameter group

0-0* Basic Settings Parameter sub group

Parameter 0-01 Language Parameter

Parameter 0-02 Motor Speed Unit Parameter

Parameter 0-03 Regional Settings Parameter

Table 6.2 Example of Parameter Group Hierarchy

congured for their

6.4.1 Programming Example for an Openloop Application

This procedure, which is used to congure a typical openloop application, programs the drive to receive a 0–10 V DC analog control signal on input terminal 53. The drive responds by providing 20–50 Hz output to the motor proportional to the input signal (0–10 V DC=20–50 Hz).

Press [Quick Menu] and complete the following steps:

1. Select Q3 Function Setups and press [OK].

2. Select Parameter Data Set and press [OK].

Illustration 6.3 Q3 Function Setups

Moving around parameters

Navigate through the parameters using the following LCP keys:

Press [▲] [▼] to scroll up or down.

•

Press [◄] [►] to shift a space to the left or right of

•

a decimal point while editing a decimal parameter value.

Press [OK] to accept the change.

•

Press [Cancel] to disregard the change and exit

•

edit mode.

Press [Back] twice to show the status view.

•

Press [Main Menu] once to go back to the main

•

menu.

3. Select Q3-2 Open Loop Settings and press [OK].

Illustration 6.4 Q3-2 Open Loop Settings

130BF726.10

Q3-2

Q3-20 Digital Reference

Q3-21 Analog Reference

14.7% 0.00A 1(1)

Open Loop Settings

130BF727.10

Q3-21

3-02 Minimum Reference

0.000 Hz

14.7% 0.00A 1(1)

Analog Reference

130BF728.10

Q3-21

3-03 Maximum Reference

50.000 Hz

14.7% 0.00A 1(1)

Analog Reference

130BF729.10

Q3-21

6-10 Terminal 53 Low

Voltage

0.00 V

14.7% 0.00A 1(1)

Analog Reference

130BF730.10

Q3-21

6-11 Terminal 53 High

Voltage

10.00 V

14.7% 0.00A 1(1)

Analog Reference

130BF731.10

Q3-21

14.7 % 0.00 A 1(1)

Analog Reference

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

000020.000

Commissioning Operating Guide

4. Select Q3-21 Analog Reference and press [OK].

Illustration 6.5 Q3-21 Analog Reference

5. Select parameter 3-02 Minimum Reference. Set the minimum internal drive reference to 0 Hz and press [OK].

7. Select parameter 6-10 Terminal 53 Low Voltage. Set the minimum external voltage reference on terminal 53 at 0 V and press [OK].

Illustration 6.8 Parameter 6-10 Terminal 53 Low Voltage

8. Select parameter 6-11 Terminal 53 High Voltage. Set maximum external voltage reference on terminal 53 at 10 V and press [OK].

Illustration 6.6 Parameter 3-02 Minimum Reference

6. Select parameter 3-03 Maximum Reference. Set the maximum internal drive reference to 60 Hz and press [OK].

Illustration 6.7 Parameter 3-03 Maximum Reference

Illustration 6.9 Parameter 6-11 Terminal 53 High Voltage

9. Select parameter 6-14 Terminal 53 Low Ref./Feedb. Value. Set minimum speed reference on terminal

53 at 20 Hz and press [OK].

Illustration 6.10 Parameter 6-14 Terminal 53 Low Ref./Feedb.

Value

130BF732.10

Q3-21

14.7 % 0.00 A 1(1)

Analog Reference

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

50.000

6-1*

A53

U - I

130BB482.10

0-10V

Commissioning VLT® AQUA Drive FC 202

10. Select parameter 6-15 Terminal 53 High Ref./Feedb. Value. Set maximum speed reference on terminal

53 at 50 Hz and press [OK].

Illustration 6.11 Parameter 6-15 Terminal 53 High Ref./Feedb.

Value

With an external device providing a 0–10 V control signal connected to drive terminal 53, the system is now ready for operation.

NOTICE

In Illustration 6.11, the scroll bar on the right of the display is at the bottom. This position indicates the procedure is complete.

Illustration 6.12 shows the wiring connections used to enable the external device set up.

6.4.2 Entering System Information

NOTICE

SOFTWARE DOWNLOAD

For commissioning via PC, install MCT 10 Set-up Software. The software is available for download (basic version) or for ordering (advanced version, code number 130B1000). For more information and downloads, see www.drives.danfoss.com/services/pc-tools.

The following steps are used to enter basic system information into the drive. Recommended parameter settings are intended for start-up and checkout purposes. Application settings vary.

NOTICE

Although these steps assume that an asynchronous motor is used, a permanent magnet motor can be used. For more information on specic motor types, see the product-specic programming guide.

1. Press [Main Menu] on the LCP.

2. Select 0-** Operation/Display and press [OK].

3. Select 0-0* Basic Settings and press [OK].

4. Select parameter 0-03 Regional Settings and press [OK].

5. Select [0] International or [1] North America as appropriate and press [OK]. (This action changes the default settings for some basic parameters).

6. Press [Quick Menus] on the LCP and then select 02 Quick Setup.

7. Change the following parameters settings listed in Table 6.3 if necessary. The motor data is found on the motor nameplate.

Illustration 6.12 Wiring Example for External Device Providing

0–10 V Control Signal

Parameter Default setting

Parameter 0-01 Language English

Parameter 1-20 Motor Power [kW ] 4.00 kW

Parameter 1-22 Motor Voltage 400 V

Parameter 1-23 Motor Frequency 50 Hz

Parameter 1-24 Motor Current 9.00 A

Parameter 1-25 Motor Nominal Speed 1420 RPM

Parameter 5-12 Terminal 27 Digital Input Coast inverse

Parameter 3-02 Minimum Reference 0.000 RPM

Parameter 3-03 Maximum Reference 1500.000 RPM

Parameter 3-41 Ramp 1 Ramp Up Time 3.00 s

Parameter 3-42 Ramp 1 Ramp Down Time 3.00 s

Parameter 3-13 Reference Site Linked to Hand/

Auto

Parameter 1-29 Automatic Motor Adaptation

(AMA)

Table 6.3 Quick Setup Settings

O

Commissioning Operating Guide

NOTICE

MISSING INPUT SIGNAL

When the LCP shows AUTO REMOTE COASTING or alarm 60, External Interlock, the unit is ready to operate but is missing an input signal. See chapter 5.8.4 Enabling Motor Operation (Terminal 27) for details.

6.4.3 Conguring Automatic Energy Optimization

Automatic energy optimization (AEO) is a procedure that minimizes voltage to the motor, reducing energy consumption, heat, and noise.

1. Press [Main Menu].

2. Select 1-** Load and Motor and press [OK].

3. Select 1-0* General Settings and press [OK].

4. Select parameter 1-03 Torque Characteristics and press [OK].

5. Select either [2] Auto Energy Optim CT or [3] Auto Energy Optim VT and press [OK].

6.4.4 Conguring Automatic Motor Adaptation

Automatic motor adaptation is a procedure that optimizes compatibility between the drive and the motor.

The drive builds a mathematical model of the motor for regulating output motor current. The procedure also tests the input phase balance of electrical power. It compares the motor characteristics with the data entered in parameters 1-20 to 1-25.

NOTICE

If warnings or alarms occur, see chapter 8.5 List of Warnings and Alarms. Some motors are unable to run the

complete version of the test. In that case, or if an output

lter is connected to the motor, select [2] Enable reduced AMA.

Run this procedure on a cold motor for best results.

1. Press [Main Menu].

2. Select 1-** Load and Motor and press [OK].

3. Select 1-2* Motor Data and press [OK].

4. Select parameter 1-29 Automatic Motor Adaptation (AMA) and press [OK].

5. Select [1] Enable complete AMA and press [OK].

6. Press [Hand On] and then [OK]. The test runs automatically and indicates when it is complete.

Testing Before System Start-up

6.5

WARNING

MOTOR START

Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equipment damage. Before start,

Ensure that equipment is safe to operate under

•

any condition.

Ensure that the motor, system, and any

•

attached equipment are ready for start.

6.5.1 Motor Rotation

NOTICE

If the motor runs in the wrong direction, it can damage equipment. Before running the unit, check the motor rotation by briey running the motor. The motor runs briey at either 5 Hz or the minimum frequency set in parameter 4-12 Motor Speed Low Limit [Hz].

1. Press [Hand On].

2. Move the left cursor to the left of the decimal point by using the left arrow key, and enter an RPM that slowly rotates the motor.

3. Press [OK].

4. If the motor rotation is wrong, set parameter 1-06 Clockwise Direction to [1] Inverse.

6.5.2 Encoder Rotation

If encoder feedback is used, perform the following steps:

1. Select [0] Open Loop in parameter 1-00 Congu- ration Mode.

2. Select [1] 24 V encoder in parameter 7-00 Speed PID Feedback Source.

3. Press [Hand On].

Press [►] for positive speed reference (parameter 1-06 Clockwise Direction at [0] Normal).

5. In parameter 16-57 Feedback [RPM], check that the feedback is positive.

For more information on the encoder option, refer to the option manual.

Commissioning VLT® AQUA Drive FC 202

NOTICE

NEGATIVE FEEDBACK

If the feedback is negative, the encoder connection is wrong. Use either parameter 5-71 Term 32/33 Encoder Direction or parameter 17-60 Feedback Direction to inverse the direction, or reverse the encoder cables. Parameter 17-60 Feedback Direction is only available with

the VLT® Encoder Input MCB 102 option.

6.6 System Start-up

WARNING

MOTOR START

Failure to ensure that the motor, system, and any attached equipment are ready for start can result in personal injury or equipment damage. Before start,

Ensure that equipment is safe to operate under

•

any condition.

Ensure that the motor, system, and any

•

attached equipment are ready for start.

The procedure in this section requires user-wiring and application programming to be completed. The following procedure is recommended after application set-up is completed.

1. Press [Auto On].

2. Apply an external run command. Examples of external run commands are a switch, button, or programmable logic controller (PLC).

3. Adjust the speed reference throughout the speed range.

4. Ensure that the system is working as intended by checking sound and vibration level of the motor.

5. Remove the external run command.

If warnings or alarms occur, see chapter 8.5 List of Warnings and Alarms.

Parameter Settings

6.7

NOTICE

REGIONAL SETTINGS

Some parameters have dierent default settings for international or North America. For a list of the dierent default values, see chapter 10.2 International/North American Default Parameter Settings.

Parameter settings are stored internally in the drive, allowing the following advantages:

Parameter settings can be uploaded into the LCP

•

memory and stored as a back-up.

Multiple units can be programmed quickly by

•

connecting the LCP to the unit and downloading the stored parameter settings.

Settings that are stored in the LCP are not

•

changed when restoring factory default settings.

Changes made to default settings as well as any

•

programming entered into parameters are stored and available for viewing in the quick menu. See chapter 6.3 LCP Menu.

6.7.1 Uploading and Downloading Parameter Settings

The drive operates using parameters stored on the control card, which is located within the drive. The upload and download functions move the parameters between the control card and the LCP.

1. Press

2. Go to parameter 0-50 LCP Copy and press [OK].

3. Select 1 of the following:

4. Press [OK]. A progress bar shows the uploading or

5. Press [Hand On] or [Auto On].

[O].

3a To upload data from the control card to

the LCP, select [1] All to LCP.

3b To download data from the LCP to the

control card, select [2] All from LCP.

downloading process.

6.7.2 Restoring Factory Default Settings

NOTICE

LOSS OF DATA

Loss of programming, motor data, localization, and monitoring records occurs when restoring default settings. To create a back-up, upload data to the LCP before initialization. Refer to chapter 6.7.1 Uploading and Downloading Parameter Settings.

Restore the default parameter settings by initializing the unit. Initialization is carried out through parameter 14-22 Operation Mode or manually.

Establishing the correct programming for applications requires setting several parameter functions. Details for parameters are provided in the programming guide.

Commissioning Operating Guide

Parameter 14-22 Operation Mode does not reset settings such as the following:

Running hours

•

Serial communication options

•

Personal menu settings

•

Fault log, alarm log, and other monitoring

•

functions

Recommended initialization

1. Press [Main Menu] twice to access parameters.

2. Go to parameter 14-22 Operation Mode and press [OK].

3. Scroll to Initialization and press [OK].

4. Remove power to the unit and wait for the display to turn o.

5. Apply power to the unit. Default parameter settings are restored during start-up. Start-up takes slightly longer than normal.

6. After alarm 80, Drive initialized to default value appears, press [Reset].

Manual initialization

Manual initialization resets all factory settings except for the following:

Parameter 15-00 Operating hours

•

Parameter 15-03 Power Up's

•

Parameter 15-04 Over Temp's

•

Parameter 15-05 Over Volt's

•

To perform manual initialization:

1. Remove power to the unit and wait for the display to turn o.

2. Press and hold [Status], [Main Menu], and [OK] simultaneously while applying power to the unit (approximately 5 s or until an audible click sounds and the fan starts). Start-up takes slightly longer than normal.

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

-10 - +10V

130BB926.10

130BB927.10

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

4 - 20mA

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

A53

U - I

≈ 5kΩ

130BB683.10

Wiring Conguration Exampl... VLT® AQUA Drive FC 202

7 Wiring Conguration Examples

The examples in this section are intended as a quick reference for common applications.

Parameter settings are the regional default values

•

unless otherwise indicated (selected in parameter 0-03 Regional Settings).

Parameters associated with the terminals and

•

their settings are shown next to the drawings.

Parameters

Function Setting

Parameter 6-12 Terminal

53 Low Current

Parameter 6-13 Terminal

53 High Current

Parameter 6-14 Terminal

53 Low Ref./Feedb.

4 mA*

20 mA*

0 Hz

Value

Required switch settings for analog terminals A53

•

or A54 are also shown.

NOTICE

When not using the optional STO feature, a jumper wire is required between terminal 12 (or 13) and terminal 37

for the drive to operate with factory default programming values.

Parameter 6-15 Terminal

50 Hz

53 High Ref./Feedb.

Value

* = Default value

Notes/comments:

Assumptions are 4 mA input =

0 Hz speed and 20 mA input =

50 Hz speed.

7.1 Wiring for Open-loop Speed Control

Parameters

Function Setting

Parameter 6-10 Termi

nal 53 Low Voltage

Parameter 6-11 Termi

nal 53 High Voltage

Parameter 6-14 Termi

nal 53 Low Ref./

Feedb. Value

Parameter 6-15 Termi

nal 53 High Ref./

Feedb. Value

* = Default value

Notes/comments:

Assumptions are 0 V DC input

= 0 Hz speed and 10 V DC

input = 50 Hz speed.

Table 7.1 Analog Speed Reference (Voltage)

0.07 V*

10 V*

0 Hz

50 Hz

Table 7.2 Analog Speed Reference (Current)

Parameters

Function Setting

Parameter 6-12 Terminal

53 Low Current

Parameter 6-13 Terminal

53 High Current

Parameter 6-14 Terminal

53 Low Ref./Feedb.

Value

Parameter 6-15 Terminal

53 High Ref./Feedb.

Value

* = Default value

Notes/comments:

Assumptions are 0 V DC input

= 0 RPM speed and 10 V DC

input = 1500 RPM speed.

Table 7.3 Speed Reference (Using a Manual Potentiometer)

4 mA*

20 mA*

0 Hz

50 Hz

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB804.11

130BB840.12

Speed

Reference

Start (18)

Freeze ref (27)

Speed up (29)

Speed down (32)

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB802.10

130BB805.12

Speed

Start/Stop (18)

Wiring Conguration Exampl... Operating Guide

Parameters

Function Setting

Parameter 5-10 Termin

al 18 Digital Input

Parameter 5-12 Termin

al 27 Digital Input

Parameter 5-13 Termin

al 29 Digital Input

Parameter 5-14 Termin

al 32 Digital Input

* = Default value

Notes/comments:

[8] Start*

[19]

Freeze

Referenc

[21]

Speed

[22]

Speed

Down

7.2 Wiring for Start/Stop

Parameters

Function Setting

Parameter 5-10

Terminal 18

Digital Input

Parameter 5-12

Terminal 27

Digital Input

Parameter 5-19

Terminal 37

Digital Input

* = Default value

Notes/comments:

If parameter 5-12 Terminal 27

Digital Input is set to [0] No

operation, a jumper wire to

terminal 27 is not needed.

Table 7.5 Start/Stop Command with Safe Torque O Option

[8] Start*

[0] No

operation

[1] Safe Stop

Alarm

7 7

Table 7.4 Speed Up/Speed Down

Illustration 7.2 Start/Stop Command with Safe Torque O

Illustration 7.1 Speed Up/Speed Down

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB803.10

Speed

130BB806.10

Latched Start (18)

Stop Inverse (27)

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

130BB934.11

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BB928.11

Wiring Conguration Exampl... VLT® AQUA Drive FC 202

Parameters

Function Setting

Parameter 5-1

[9] Latched

0 Terminal 18

Digital Input

Parameter 5-1

2 Terminal 27

Digital Input

* = Default value

Notes/comments:

Start

[6] Stop

Inverse

Parameters

Function Setting

Parameter 5-10

Terminal 18

Digital Input

Parameter 5-11

Terminal 19

Reversing*

Digital Input

Parameter 5-12

Terminal 27

[8] Start

[10]

[0] No

operation

Digital Input

Parameter 5-14

Terminal 32

[16] Preset

ref bit 0

Digital Input

Parameter 5-15

Terminal 33

[17] Preset

ref bit 1

Digital Input

Parameter 3-10

Preset

Reference

Preset ref. 0

Preset ref. 1

Preset ref. 2

Preset ref. 3

25%

50%

75%

100%

* = Default value

Table 7.6 Pulse Start/Stop

Notes/comments:

Table 7.7 Start/Stop with Reversing and 4 Preset Speeds

Wiring for External Alarm Reset

7.3

Parameters

Function Setting

Parameter 5-11 T

[1] Reset

erminal 19

Digital Input

* = Default value

Notes/comments:

Illustration 7.3 Latched Start/Stop Inverse

Table 7.8 External Alarm Reset

130BB686.12

VLT

+24 V

D IN

COM

D IN

+10 V

A IN

COM

A OUT

COM

A53

U - I

D IN

+24 V

D IN

COM

D IN

+10

A IN

COM

A OUT

COM

130BD667.11

Wiring Conguration Exampl... Operating Guide

7.4 Wiring for a Motor Thermistor

WARNING

THERMISTOR INSULATION

Risk of personal injury or equipment damage.

To meet PELV insulation requirements, use only

•

thermistors with reinforced or double insulation.

Parameters

Function Setting

Parameter 1-90

Motor Thermal

Protection

Parameter 1-93

Thermistor

Source

* = Default value

Notes/comments:

If only a warning is desired, set

parameter 1-90 Motor Thermal

Protection to [1] Thermistor

warning.

[2] Thermistor

trip

[1] Analog

input 53

Wiring for Regeneration

7.5

Parameters

Function Setting

Parameter 1-90

100%*

Motor Thermal

Protection

* = Default value

Notes/comments:

To disable regeneration,

decrease parameter 1-90 Motor

Thermal Protection to 0%. If the

application uses motor brake

power and regeneration is not

enabled, the unit trips.

7 7

Table 7.9 Motor Thermistor

Table 7.10 Regeneration

130BF210.10

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

8 Maintenance, Diagnostics, and Troubleshooting

8.1 Maintenance and Service

This chapter includes:

Maintenance and service guidelines.

•

Status messages.

•

Warnings and alarms.

•

Basic troubleshooting.

•

Under normal operating conditions and load proles, the drive is maintenance-free throughout its designed lifetime. To prevent breakdown, danger, and damage, examine the drive at regular intervals depending on the operating conditions. Replace worn or damaged parts with original spare parts or standard parts. For service and support, refer to www.danfoss.com/contact/sales_and_services/.

8.2.1 Removing the Heat Sink Access Panel

WARNING

UNINTENDED START

To prevent unintended motor start:

Press [O/Reset] on the LCP before

•

programming parameters.

Disconnect the drive from the mains.

•

Completely wire and assemble the drive, motor,

•

and any driven equipment before connecting the drive to AC mains, DC supply, or load sharing.

8.2 Heat Sink Access Panel

The drive can be ordered with an optional access panel in the back of the unit. This access panel provides access to the heat sink and allows the heat sink to be cleaned of any dust buildup.

Illustration 8.1 Heat Sink Access Panel Removed from the Rear

of the Drive

1. Remove power from the drive and wait 40 minutes for the capacitors to discharge completely. Refer to chapter 2 Safety.

2. Position the drive so that the back of the drive is fully accessible.

3. Remove the 8 M5 fasteners securing the access panel to the back of the enclosure using a 3 mm hex bit.

4. Inspect the leading edge of the heat sink for damage or debris.

5. Remove material or debris with a vacuum.

6. Reinstall the panel and secure it to the back of the enclosure with the 8 fasteners. Tighten the fasteners according to chapter 9.10.1 Fastener Torque Ratings.

Status

799RPM 7.83A 36.4kW

0.000

53.2%

1(1)

Auto Hand O

Remote Local

Ramping Stop Running Jogging . . . Stand-by

130BB037.11

Maintenance, Diagnostics, a... Operating Guide

NOTICE

DAMAGE TO HEAT SINK

Using fasteners that are longer than those originally supplied with the heat sink panel will damage the heat sink cooling ns.

8.3 Status Messages

When the drive is in status mode, status messages automatically appear in the bottom line of the LCP display. Refer to Illustration 8.2. Status messages are dened in Table 8.1 – Table 8.3.

1 Where the stop/start command originates. Refer to Table 8.1.

2 Where the speed control originates. Refer to Table 8.2.

3 Provides the drive status. Refer to Table 8.3.

Illustration 8.2 Status Display

NOTICE

In auto/remote mode, the drive requires external commands to execute functions.

Table 8.1 to Table 8.3 dene the meaning of the shown status messages.

O The drive does not react to any control signal

until [Auto On] or [Hand On] is pressed.

Auto The start/stop commands are sent via the

control terminals and/or the serial communi-

cation.

Hand The navigation keys on the LCP can be used

to control the drive. Stop commands, reset,

Table 8.1 Operating Mode

reversing, DC brake, and other signals applied

to the control terminals override local control.

Remote The speed reference is given from

external signals.

•

serial communication.

•

internal preset references.

•

Local The drive uses reference values from the LCP.

Table 8.2 Reference Site

AC brake AC brake was selected in parameter 2-10 Brake

Function. The AC brake overmagnetizes the

motor to achieve a controlled slow down.

AMA nish OK Automatic motor adaptation (AMA) was

carried out successfully.

AMA ready AMA is ready to start. To start, press [Hand

On].

AMA running AMA process is in progress.

Braking The brake chopper is in operation. The brake

resistor absorbs the generative energy.

Braking max. The brake chopper is in operation. The power

limit for the brake resistor dened in

parameter 2-12 Brake Power Limit (kW) has

been reached.

Coast

Ctrl. ramp-down [1] Ctrl. ramp-down was selected in

Current high The drive output current is above the limit set

Current low The drive output current is below the limit set

DC hold DC hold is selected in parameter 1-80 Function

[2] Coast inverse was selected as a function

•

for a digital input (parameter group 5-1*

Digital Inputs). The corresponding terminal

is not connected.

Coast activated by serial communication.

•

parameter 14-10 Mains Failure.

The mains voltage is below the value set

•

in parameter 14-11 Mains Voltage at Mains

Fault at mains fault.

The drive ramps down the motor using a

•

controlled ramp down.

in parameter 4-51 Warning Current High.

in parameter 4-52 Warning Speed Low.

at Stop and a stop command is active. The

motor is held by a DC current set in

parameter 2-00 DC Hold/Preheat Current.

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

DC stop The motor is held with a DC current

(parameter 2-01 DC Brake Current) for a

specied time (parameter 2-02 DC Braking

Time).

DC brake is activated in parameter 2-03 DC

•

Brake Cut In Speed [RPM] and a stop

command is active.

DC brake (inverse) is selected as a function

•

for a digital input (parameter group 5-1*

Digital Inputs). The corresponding terminal

is not active.

The DC brake is activated via serial

•

communication.

Feedback high The sum of all active feedbacks is above the

feedback limit set in parameter 4-57 Warning

Feedback High.

Feedback low The sum of all active feedbacks is below the

feedback limit set in parameter 4-56 Warning

Feedback Low.

Freeze output The remote reference is active, which holds

Freeze output

request

Freeze ref. [19] Freeze Reference was selected as a

Jog request A jog command has been given, but the

Jogging The motor is running as programmed in

the present speed.

[20] Freeze Output was selected as a

•

function for a digital input (parameter

group 5-1* Digital Inputs). The

corresponding terminal is active. Speed

control is only possible via the terminal

functions speed up and speed down.

Hold ramp is activated via serial communi-

•

cation.

A freeze output command has been given, but

the motor remains stopped until a run

permissive signal is received.

function for a digital input (parameter group

5-1* Digital Inputs). The corresponding terminal

is active. The drive saves the actual reference.

Changing the reference is now only possible

via terminal functions speed up and speed

down.

motor is stopped until a run permissive signal

is received via a digital input.

parameter 3-19 Jog Speed [RPM].

[14] Jog was selected as function for a

•

digital input (parameter group 5-1* Digital

Inputs). The corresponding terminal (for

example, terminal 29) is active.

The jog function is activated via the serial

•

communication.

The jog function was selected as a reaction

•

for a monitoring function (for example, No

signal). The monitoring function is active.

Motor check In parameter 1-80 Function at Stop, [2] Motor

Check was selected. A stop command is active.

To ensure that a motor is connected to the

drive, a permanent test current is applied to

the motor.

OVC control Overvoltage control was activated in

parameter 2-17 Over-voltage Control, [2]

Enabled. The connected motor is supplying

the drive with generative energy. The

overvoltage control adjusts the V/Hz ratio to

run the motor in controlled mode and to

prevent the drive from tripping.

Power unit o (For drives with a 24 V external supply

installed only.) Mains supply to the drive is

removed, but the control card is supplied by

the external 24 V.

Protection md Protection mode is active. The unit has

detected a critical status (an overcurrent or

overvoltage).

To avoid tripping, the switching frequency

•

is reduced to 1500 kHz if

parameter 14-55 Output Filter is set to [2]

Sine-Wave Filter Fixed. Otherwise, the

switching frequency is reduced to 1000 Hz.

If possible, protection mode ends after

•

approximately 10 s.

Protection mode can be restricted in

•

parameter 14-26 Trip Delay at Inverter Fault.

QStop The motor is decelerating using

parameter 3-81 Quick Stop Ramp Time.

[4] Quick stop inverse was selected as a

•

function for a digital input (parameter

group 5-1* Digital Inputs). The

corresponding terminal is not active.

The quick stop function was activated via

•

serial communication.

Ramping The motor is accelerating/decelerating using

the active ramp up/down. The reference, a

limit value, or a standstill is not yet reached.

Ref. high The sum of all active references is above the

reference limit set in parameter 4-55 Warning

Reference High.

Ref. low The sum of all active references is below the

reference limit set in parameter 4-54 Warning

Reference Low.

Run on ref. The drive is running in the reference range.

The feedback value matches the setpoint

value.

Run request A start command has been given, but the

motor is stopped until a run permissive signal

is received via digital input.

Running The drive is driving the motor.

130BP086.12

Status

0.0Hz 0.000kW 0.00A

0.0Hz 0

Earth Fault [A14]

Auto Remote Trip

1(1)

Maintenance, Diagnostics, a... Operating Guide

Sleep mode The energy saving function is enabled. This

function being enabled means that now the

motor has stopped, but that it restarts

automatically when required.

Speed high The motor speed is above the value set in

parameter 4-53 Warning Speed High.

Speed low The motor speed is below the value set in

parameter 4-52 Warning Speed Low.

Standby In auto-on mode, the drive starts the motor

with a start signal from a digital input or serial

communication.

Start delay In parameter 1-71 Start Delay, a delay starting

time was set. A start command is activated

and the motor starts after the start delay time

expires.

Start fwd/rev [12] Enable Star t Forward and [13] Enable Start

Reverse were selected as functions for 2

dierent digital inputs (parameter group 5-1*

Digital Inputs). The motor starts in forward or

reverse depending on which corresponding

terminal is activated.

Stop The drive has received a stop command from

1 of the following:

LCP

•

Digital input

•

Serial communication

•

Trip An alarm occurred and the motor is stopped.

Once the cause of the alarm is cleared, reset

the drive using 1 of the following:

Pressing [Reset].

•

Remotely by control terminals.

•

Via serial communication.

•

Pressing [Reset] or remotely by control

terminals or via serial communication.

Trip lock An alarm occurred and the motor is stopped.

Once the cause of the alarm is cleared, cycle

power to the drive. Reset the drive manually

by 1 of the following:

Pressing [Reset].

•

Remotely by control terminals.

•

Via serial communication.

•

8.4 Warning and Alarm Types

Warning/

alarm type

Warning A warning indicates an abnormal operating

Alarm An alarm indicates a fault that requires

Trip

When tripping, the drive suspends operation to prevent damage to the drive and other equipment. When a trip occurs, the motor coasts to a stop. The drive logic continues to operate and monitor the drive status. After the fault condition is remedied, the drive is ready for a reset.

Trip lock

When trip locking, the drive suspends operation to prevent damage to the drive and other equipment. When a trip lock occurs, the motor coasts to a stop. The drive logic continues to operate and monitor the drive status. The drive starts a trip lock only when serious faults occur that can damage the drive or other equipment. After the faults are xed, cycle the input power before resetting the drive.

Warning and alarm displays

•

Description

condition that leads to an alarm. A warning stops

when the abnormal condition is removed.

immediate attention. The fault always triggers a

trip or trip lock. Reset the drive after an alarm.

Reset the drive in any of 4 ways:

Press [Reset]/[O/Reset].

•

Digital reset input command.

•

Serial communication reset input command.

•

Auto reset.

•

A warning is shown in the LCP along with the warning number.

An alarm ashes along with the alarm number.

8 8

Table 8.3 Operation Status

NOTICE

In auto/remote mode, the drive requires external commands to execute functions.

Illustration 8.3 Alarm Example

In addition to the text and alarm code in the LCP, there are 3 status indicator lights.

Back

Cancel

Info

Alarm

Warn.

130BB467.11

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

Perform an input terminal signal test.

•

WARNING/ALARM 3, No motor

No motor has been connected to the output of the drive.

WARNING/ALARM 4, Mains phase loss

A phase is missing on the supply side, or the mains voltage imbalance is too high. This message also appears for a fault in the input rectier. Options are programmed in parameter 14-12 Function at Mains Imbalance.

Troubleshooting

Check the supply voltage and supply currents to

•

Warning indicator light Alarm indicator light

Warning On O

Alarm O On (ashing)

Trip lock On On (ashing)

Illustration 8.4 Status Indicator Lights

8.5 List of Warnings and Alarms

The following warning and alarm information denes each warning or alarm condition, provides the probable cause for the condition, and details a remedy or troubleshooting procedure.

WARNING 1, 10 Volts low

The control card voltage is less than 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Maximum 15 mA or minimum 590 Ω.

A short circuit in a connected potentiometer or incorrect wiring of the potentiometer can cause this condition.

Troubleshooting

Remove the wiring from terminal 50. If the

•

warning clears, the problem is with the wiring. If the warning does not clear, replace the control card.

WARNING/ALARM 2, Live zero error

This warning or alarm only appears if programmed in parameter 6-01 Live Zero Timeout Function. The signal on 1 of the analog inputs is less than 50% of the minimum value programmed for that input. Broken wiring or a faulty device sending the signal can cause this condition.

Troubleshooting

Check connections on all analog mains terminals.

•

- Control card terminals 53 and 54 for

signals, terminal 55 common.

VLT® General Purpose I/O MCB 101 terminals 11 and 12 for signals, terminal 10 common.

VLT® Analog I/O Option MCB 109 terminals 1, 3, and 5 for signals, terminals 2, 4, and 6 common.

Check that the drive programming and switch

•

settings match the analog signal type.

WARNING 5, DC link voltage high

The DC-link voltage (DC) is higher than the high-voltage warning limit. The limit depends on the drive voltage rating. The unit is still active.

WARNING 6, DC link voltage low

The DC-link voltage (DC) is lower than the low voltage warning limit. The limit depends on the drive voltage rating. The unit is still active.

WARNING/ALARM 7, DC overvoltage

If the DC-link voltage exceeds the limit, the drive trips after a time.

Troubleshooting

WARNING/ALARM 8, DC under voltage

If the DC-link voltage drops below the undervoltage limit, the drive checks for 24 V DC back-up supply. If no 24 V DC back-up supply is connected, the drive trips after a xed time delay. The time delay varies with unit size.

Troubleshooting

WARNING/ALARM 9, Inverter overload

The drive has run with more than 100% overload for too long and is about to cut out. The counter for electronic thermal inverter protection issues a warning at 98% and trips at 100% with an alarm. The drive cannot be reset until the counter is below 90%.

the drive.

Extend the ramp time.

•

Change the ramp type.

•

Increase parameter 14-26 Trip Delay at Inverter

•

Fault.

Check that the supply voltage matches the active

•

front-end drive voltage.

Perform input voltage test.

•

Check that the supply voltage matches the drive

•

voltage.

Perform an input voltage test.

•

Perform a soft-charge circuit test.

•

Maintenance, Diagnostics, a... Operating Guide

Troubleshooting

Compare the output current shown on the LCP

•

with the drive rated current.

Compare the output current shown on the LCP

•

with the measured motor current.

Show the thermal drive load on the LCP and

•

monitor the value. When running above the drive continuous current rating, the counter increases. When running below the drive continuous current rating, the counter decreases.

WARNING/ALARM 10, Motor overload temperature

According to the electronic thermal protection (ETR), the motor is too hot.

Select 1 of these options:

The drive issues a warning or an alarm when the

•

counter is >90% if parameter 1-90 Motor Thermal Protection is set to warning options.

The drive trips when the counter reaches 100% if

•

parameter 1-90 Motor Thermal Protection is set to trip options.

The fault occurs when the motor runs with more than 100% overload for too long.

Troubleshooting

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

Check that the motor current set in

•

parameter 1-24 Motor Current is correct.

Ensure that the motor data in parameters 1-20 to

•

1-25 is set correctly.

If an external fan is in use, check that it is

•

selected in parameter 1-91 Motor External Fan.

Running AMA in parameter 1-29 Automatic Motor

•

Adaptation (AMA) tunes the drive to the motor more accurately and reduces thermal loading.

WARNING/ALARM 11, Motor thermistor overtemp

Check whether the thermistor is disconnected. Select whether the drive issues a warning or an alarm in parameter 1-90 Motor Thermal Protection.

Troubleshooting

Check for motor overheating.

•

Check if the motor is mechanically overloaded.

•

When using terminal 53 or 54, check that the

•

thermistor is connected correctly between either terminal 53 or 54 (analog voltage input) and terminal 50 (+10 V supply). Also check that the terminal switch for 53 or 54 is set for voltage. Check that parameter 1-93 Thermistor Source selects terminal 53 or 54.

When using terminal 18, 19, 31, 32, or 33 (digital

•

inputs), check that the thermistor is connected correctly between the digital input terminal used

(digital input PNP only) and terminal 50. Select the terminal to use in parameter 1-93 Thermistor Source.

WARNING/ALARM 12, Torque limit

The torque has exceeded the value in

parameter 4-16 Torque Limit Motor Mode or the value in parameter 4-17 Torque Limit Generator Mode. Parameter 14-25 Trip Delay at Torque Limit can change this

warning from a warning-only condition to a warning followed by an alarm.

Troubleshooting

If the motor torque limit is exceeded during

•

ramp-up, extend the ramp-up time.

If the generator torque limit is exceeded during

•

ramp-down, extend the ramp-down time.

If torque limit occurs while running, increase the

•

torque limit. Make sure that the system can operate safely at a higher torque.

Check the application for excessive current draw

•

on the motor.

WARNING/ALARM 13, Over current

The inverter peak current limit (approximately 200% of the rated current) is exceeded. The warning lasts approximately

1.5 s, then the drive trips and issues an alarm. Shock loading or quick acceleration with high-inertia loads can cause this fault. If the acceleration during ramp-up is quick, the fault can also appear after kinetic back-up. If extended mechanical brake control is selected, a trip can be reset externally.

Troubleshooting

Remove the power and check if the motor shaft

•

can be turned.

Check that the motor size matches the drive.

•

Check that the motor data is correct in

•

parameters 1-20 to 1-25.

ALARM 14, Earth (ground) fault

There is current from the output phase to ground, either in the cable between the drive and the motor, or in the motor itself. The current transducers detect the ground fault by measuring current going out from the drive and current going into the drive from the motor. Ground fault is issued if the deviation of the 2 currents is too large. The current going out of the drive must be the same as the current going into the drive.

Troubleshooting

Remove power to the drive and repair the ground

•

fault.

Check for ground faults in the motor by

•

measuring the resistance to ground of the motor cables and the motor with a megohmmeter.

Reset any potential individual oset in the 3

•

current transducers in the drive. Perform the

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

manual initialization or perform a complete AMA. This method is most relevant after changing the power card.

ALARM 15, Hardware mismatch

A tted option is not operational with the present control card hardware or software.

Record the value of the following parameters and contact Danfoss.

Parameter 15-40 FC Type.

•

Parameter 15-41 Power Section.

•

Parameter 15-42 Voltage.

•

Parameter 15-43 Software Version.

•

Parameter 15-45 Actual Typecode String.

•

Parameter 15-49 SW ID Control Card.

•

Parameter 15-50 SW ID Power Card.

•

Parameter 15-60 Option Mounted.

•

Parameter 15-61 Option SW Version (for each

•

ALARM 16, Short circuit

There is short-circuiting in the motor or motor wiring.

Troubleshooting

option slot).

Remove the power to the drive and repair the

•

short circuit.

WARNING

HIGH VOLTAGE

Drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to use qualied personnel to install, start up, and maintain the drive can result in death or serious injury.

Disconnect power before proceeding.

•

WARNING/ALARM 17, Control word timeout

There is no communication to the drive. The warning is only active when parameter 8-04 Control Timeout Function is NOT set to [0] O. If parameter 8-04 Control Timeout Function is set to [5] Stop and trip, a warning appears, and the drive ramps down to a stop and shows an alarm.

Troubleshooting

Check the connections on the serial communi-

•

cation cable.

Increase parameter 8-03 Control Timeout Time.

•

Check the operation of the communication

•

equipment.

Verify that proper EMC installation was

•

performed.

WARNING/ALARM 20, Temp. input error

The temperature sensor is not connected.

WARNING/ALARM 21, Parameter error

The parameter is out of range. The parameter number is reported in the display.

Troubleshooting

Set the aected parameter to a valid value.

•

WARNING 22, Hoist mechanical brake

0 = The torque reference was not reached before timeout. 1 = There was no brake feedback before the timeout.

WARNING 23, Internal fan fault

The fan warning function is a protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

There is a feedback sensor mounted in the fan. If the fan is commanded to run and there is no feedback from the sensor, this alarm appears. This alarm also shows if there is a communication error between the fan power card and the control card.

Check the alarm log (see chapter 3.6 Local Control Panel (LCP)) for the report value associated with this warning.

If the report value is 2, there is a hardware problem with 1 of the fans. If the report value is 12, there is a communication problem between the fan power card and the control card.

Fan troubleshooting

Cycle power to the drive and check that the fan

•

operates briey at start-up.

Check for proper fan operation. Use parameter

•

group 43-** Unit Readouts to show the speed of each fan.

Fan power card troubleshooting

Check the wiring between the fan power card

•

and the control card.

Fan power card may need to be replaced.

•

Control card may need to be replaced.

•

WARNING 24, External fan fault

The fan warning function is a protective function that checks if the fan is running/mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

Check the alarm log (see chapter 3.6 Local Control Panel (LCP)) for the report value associated with this warning.

If the report value is 1, there is a hardware problem with 1 of the fans. If the report value is 11, there is a communication problem between the power card and the control card.

Maintenance, Diagnostics, a... Operating Guide

Fan troubleshooting

Cycle power to the drive and check that the fan

•

operates briey at start-up.

Check for proper fan operation. Use parameter

•

group 43-** Unit Readouts to show the speed of each fan.

Power card troubleshooting

Check the wiring between the power card and

•

the control card.

Power card may need to be replaced.

•

Control card may need to be replaced.

•

WARNING 25, Brake resistor short circuit

The brake resistor is monitored during operation. If a short circuit occurs, the brake function is disabled and the warning appears. The drive is still operational, but without the brake function.

Troubleshooting

Remove the power to the drive and replace the

•

brake resistor (refer to parameter 2-15 Brake Check).

WARNING/ALARM 26, Brake resistor power limit

The power transmitted to the brake resistor is calculated as a mean value over the last 120 s of run time. The calculation is based on the DC-link voltage and the brake resistor value set in parameter 2-16 AC brake Max. Current. The warning is active when the dissipated braking power is higher than 90% of the brake resistor power. If option [2] Trip is selected in parameter 2-13 Brake Power Monitoring, the drive trips when the dissipated braking power reaches 100%.

WARNING/ALARM 27, Brake chopper fault

The brake transistor is monitored during operation, and if a short circuit occurs, the brake function is disabled, and a warning is issued. The drive is still operational, but since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is inactive.

Troubleshooting

Remove power to the drive and remove the brake

•

resistor.

WARNING/ALARM 28, Brake check failed

The brake resistor is not connected or not working.

Troubleshooting

Check parameter 2-15 Brake Check.

•

ALARM 29, Heat Sink temp

The maximum temperature of the heat sink has been exceeded. This alarm is based on the temperature measured by the heat sink sensor mounted inside the IGBT modules. The temperature fault does not reset until the temperature drops below a dened heat sink temperature. The trip and reset points are dierent based on the drive power size.

Troubleshooting

Check for the following conditions:

•

- Ambient temperature too high

- Motor cable too long

- Incorrect airow clearance above and

below the drive

- Blocked airow around the drive

- Damaged heat sink fan

- Dirty heat sink

Check fan resistance.

•

Check soft charge fuses.

•

Check IGBT thermal.

•

ALARM 30, Motor phase U missing

Motor phase U between the drive and the motor is missing.

WARNING

HIGH VOLTAGE

Disconnect power before proceeding.

•

Troubleshooting

Remove the power from the drive and check

•

motor phase U.

ALARM 31, Motor phase V missing

Motor phase V between the drive and the motor is missing.

WARNING

HIGH VOLTAGE

Disconnect power before proceeding.

•

Troubleshooting

Remove the power from the drive and check

•

motor phase V.

ALARM 32, Motor phase W missing

Motor phase W between the drive and the motor is missing.

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

WARNING

HIGH VOLTAGE

Disconnect power before proceeding.

•

Troubleshooting

Remove the power from the drive and check

•

motor phase W.

ALARM 33, Inrush fault

Too many power-ups have occurred within a short time period.

Troubleshooting

Let the unit cool to operating temperature.

•

Check potential DC-link fault to ground.

•

WARNING/ALARM 34, Fieldbus communication fault

eldbus on the communication option card is not

The working.

WARNING/ALARM 35, Option fault

An option alarm is received. The alarm is option-specic. The most likely cause is a power-up or a communication fault.

WARNING/ALARM 36, Mains failure

This warning/alarm is only active if the supply voltage to the drive system is lost and parameter 14-10 Mains Failure is not set to option [0] No Function.

Check the fuses to the drive system and the

•

mains supply to the unit.

Check that mains voltage conforms to product

•

specications.

Check that the following conditions are not

•

present:

Alarm 307, Excessive THD(V), alarm 321, Voltage imbalance, warning 417, Mains undervoltage, or warning 418, Mains overvoltage is reported if any

of the listed conditions are true:

- The 3-phase voltage magnitude drops below 25% of the nominal mains voltage.

- Any single-phase voltage exceeds 10% of the nominal mains voltage.

- Percent of phase or magnitude imbalance exceeds 8%.

- Voltage THD exceeds 10%.

ALARM 37, Phase imbalance

There is a current imbalance between the power units.

ALARM 38, Internal fault

When an internal fault occurs, a code number dened in Table 8.4 is shown.

Troubleshooting

Cycle power.

•

Check that the option is properly installed.

•

Check for loose or missing wiring.

•

It may be necessary to contact the Danfoss supplier or service department. Note the code number for further troubleshooting directions.

Number Text

0 The serial port cannot be initialized. Contact the

Danfoss supplier or Danfoss Service Department.

256–259,

266, 268

512–519 Internal fault. Contact the Danfoss supplier or

783 Parameter value outside of minimum/maximum

1024–1284 Internal fault. Contact the Danfoss supplier or the

1299 Option SW in slot A is too old.

1300 Option SW in slot B is too old.

1301 Option SW in slot C0 is too old.

1302 Option SW in slot C1 is too old.

1315 Option SW in slot A is not supported (not

1316 Option SW in slot B is not supported (not allowed).

1317 Option SW in slot C0 is not supported (not

1318 Option SW in slot C1 is not supported (not

1360–2819 Internal fault. Contact the Danfoss supplier or

2561 Replace control card.

2820 LCP stack overow.

2821 Serial port overow.

2822 USB port overow.

3072–5122 Parameter value is outside its limits.

5123 Option in slot A: Hardware incompatible with

5124 Option in slot B: Hardware incompatible with

5125 Option in slot C0: Hardware incompatible with

5126 Option in slot C1: Hardware incompatible with

5127 Illegal option combination (2 options of the same

The power EEPROM data is defective or too old.

Replace power card.

Danfoss Service Department.

limits.

Danfoss Service Department.

allowed).

Danfoss Service Department.

control board hardware.

kind mounted, or encoder in E0 and resolver in E1

or similar).

Maintenance, Diagnostics, a... Operating Guide

Number Text

5168 Safe stop/safe torque o was detected on a

control card that does not have safe stop/safe

torque o.

5376–65535 Internal fault. Contact the Danfoss supplier or

Danfoss Service Department.

Table 8.4 Internal Fault Codes

ALARM 39, Heat sink sensor

No feedback from the heat sink temperature sensor.

The signal from the IGBT thermal sensor is not available on the power card. The problem could be on the power card, on the gatedrive card, or the ribbon cable between the power card and gatedrive card.

WARNING 40, Overload of digital output terminal 27

Check the load connected to terminal 27 or remove the short circuit connection. Check parameter 5-00 Digital I/O Mode and parameter 5-01 Terminal 27 Mode.

WARNING 41, Overload of digital output terminal 29

Check the load connected to terminal 29 or remove the short-circuit connection. Also check parameter 5-00 Digital I/O Mode and parameter 5-02 Terminal 29 Mode.

WARNING 42, Overload of digital output on X30/6 or overload of digital output on X30/7

For terminal X30/6, check the load connected to terminal X30/6 or remove the short-circuit connection. Also check

parameter 5-32 Term X30/6 Digi Out (MCB 101) (VLT General Purpose I/O MCB 101).

For terminal X30/7, check the load connected to terminal X30/7 or remove the short-circuit connection. Check

parameter 5-33 Term X30/7 Digi Out (MCB 101) (VLT General Purpose I/O MCB 101).

ALARM 43, Ext. supply

VLT® Extended Relay Option MCB 113 is mounted without external 24 V DC. Either connect a 24 V DC external supply or specify that no external supply is used via parameter 14-80 Option Supplied by External 24VDC, [0] No. A change in parameter 14-80 Option Supplied by External 24VDC requires a power cycle.

ALARM 45, Earth fault 2

Ground fault.

Troubleshooting

Check for proper grounding and loose

•

connections.

Check for proper wire size.

•

Check the motor cables for short circuits or

•

leakage currents.

ALARM 46, Power card supply

The supply on the power card is out of range.

There are 3 supplies generated by the switch mode supply (SMPS) on the power card:

24 V.

•

5 V.

•

±18 V.

•

When powered with VLT® 24 V DC Supply MCB 107, only the 24 V and 5 V supplies are monitored. When powered with 3-phase mains voltage, all 3 supplies are monitored.

Troubleshooting

Check for a defective power card.

•

Check for a defective control card.

•

Check for a defective option card.

•

If a 24 V DC supply is used, verify proper supply

•

power.

WARNING 47, 24 V supply low

The supply on the power card is out of range.

There are 3 supplies generated by the switch mode supply (SMPS) on the power card:

24 V.

•

5 V.

•

±18 V.

•

Troubleshooting

Check for a defective power card.

•

WARNING 48, 1.8 V supply low

The 1.8 V DC supply used on the control card is outside of the allowable limits. The supply is measured on the control card.

Troubleshooting

Check for a defective control card.

•

If an option card is present, check for

•

overvoltage.

WARNING 49, Speed limit

The warning is shown when the speed is outside of the

specied range in parameter 4-11 Motor Speed Low Limit [RPM] and parameter 4-13 Motor Speed High Limit [RPM].

When the speed is below the specied limit in parameter 1-86 Trip Speed Low [RPM] (except when starting or stopping), the drive trips.

ALARM 50, AMA calibration failed

Contact the Danfoss supplier or Danfoss service department.

ALARM 51, AMA check U

The settings for motor voltage, motor current, and motor power are wrong.

Troubleshooting

Check the settings in parameters 1-20 to 1-25.

•

ALARM 52, AMA low I

The motor current is too low.

Troubleshooting

Check the settings in parameter 1-24 Motor

•

Current.

nom

and I

nom

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

ALARM 53, AMA motor too big

The motor is too large for the AMA to operate.

ALARM 54, AMA motor too small

The motor is too small for the AMA to operate.

ALARM 55, AMA parameter out of range

The AMA cannot run because the parameter values of the motor are outside of the acceptable range.

ALARM 56, AMA interrupted by user

The AMA is manually interrupted.

ALARM 57, AMA internal fault

Try to restart the AMA. Repeated restarts can overheat the motor.

ALARM 58, AMA Internal fault

Contact the Danfoss supplier.

WARNING 59, Current limit

The current is higher than the value in

parameter 4-18 Current Limit. Ensure that the motor data in parameters 1-20 to 1-25 is set correctly. Increase the current

limit if necessary. Ensure that the system can operate safely

at a higher limit.

WARNING 60, External interlock

A digital input signal indicates a fault condition external to the drive. An external interlock has commanded the drive to trip. Clear the external fault condition. To resume normal operation, apply 24 V DC to the terminal programmed for external interlock, and reset the drive.

WARNING 61, Tracking Error

An error has been detected between the calculated motor speed and the speed measurement from the feedback device. The function for Warning/Alarm/Disable is set in parameter 4-30 Motor Feedback Loss Function. Error setting is found in parameter 4-31 Motor Feedback Speed Error. Allowed error time is found in parameter 4-32 Motor Feedback Loss Timeout. During the commissioning process, this function can be useful.

WARNING 62, Output frequency at maximum limit

The output frequency has reached the value set in parameter 4-19 Max Output Frequency. Check the application for possible causes. Possibly increase the output frequency limit. Be sure that the system can operate safely at a higher output frequency. The warning clears when the output drops below the maximum limit.

ALARM 63, Mechanical brake low

The actual motor current has not exceeded the release brake current within the start delay time window.

WARNING 64, Voltage Limit

The load and speed combination demands a motor voltage higher than the actual DC-link voltage.

WARNING/ALARM 65, Control card over temperature

The cutout temperature of the control card is 85 °C (185 °F).

Troubleshooting

Check that the ambient operating temperature is

•

within the limits.

Check for clogged lters.

•

Check the fan operation.

•

Check the control card.

•

WARNING 66, Heat sink temperature low

The drive is too cold to operate. This warning is based on the temperature sensor in the IGBT module. Increase the ambient temperature of the unit. Also, a trickle amount of current can be supplied to the drive whenever the motor is stopped by setting parameter 2-00 DC Hold/Preheat Current to 5% and parameter 1-80 Function at Stop.

ALARM 67, Option module conguration has changed

One or more options have either been added or removed since the last power-down. Check that the conguration change is intentional and reset the unit.

ALARM 68, Safe Stop activated

Safe torque o (STO) has been activated. To resume normal operation, apply 24 V DC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing [Reset]).

ALARM 69, Power card temperature

The temperature sensor on the power card is either too hot or too cold.

Troubleshooting

Check that the ambient operating temperature is

•

within limits.

Check for clogged lters.

•

Check fan operation.

•

Check the power card.

•

ALARM 70, Illegal FC conguration

The control card and power card are incompatible. To check compatibility, contact the Danfoss supplier with the type code from the unit nameplate and the part numbers of the cards.

WARNING/ALARM 71, PTC 1 Safe Stop

Safe torque o (STO) has been activated from the VLT® PTC Thermistor Card MCB 112 because the motor is too warm. Once the motor cools and the digital input from the MCB 112 is deactivated, normal operation can resume when the MCB 112 applies 24 V DC to terminal 37 again. When the motor is ready for normal operation, a reset signal is sent (via serial communication, digital I/O, or by pressing [Reset] on the LCP). If automatic restart is enabled, the motor can start when the fault is cleared.

ALARM 72, Dangerous failure

Safe torque o (STO) with trip lock. Unexpected signal

levels on safe torque o and digital input from the VLT PTC Thermistor Card MCB 112.

WARNING 73, Safe Stop auto restart

Safe torque o (STO). With automatic restart enabled, the motor can start when the fault is cleared.

Maintenance, Diagnostics, a... Operating Guide

ALARM 74, PTC Thermistor

Alarm related to VLT® PTC Thermistor Card MCB 112. The PTC is not working.

ALARM 75, Illegal prole sel.

Do not write the parameter value while the motor is running. Stop the motor before writing the MCO prole to parameter 8-10 Control Prole.

WARNING 76, Power unit setup

The required number of power units does not match the detected number of active power units. When replacing an enclosure size F module, this warning occurs if the power- specic data in the module power card does not match the rest of the drive. If the power card connection is lost, the unit also triggers this warning.

Troubleshooting

Conrm that the spare part and its power card

•

are the correct part number.

Ensure that the 44-pin cables between the MDCIC

•

and power cards are mounted properly.

WARNING 77, Reduced power mode

This warning indicates that the drive is operating in reduced power mode (that is, less than the allowed number of inverter sections). This warning is generated on power cycle when the drive is set to run with fewer inverters and remains on.

ALARM 78, Tracking error

dierence between setpoint value and actual value

The exceeds the value in parameter 4-35 Tracking Error.

Troubleshooting

Disable the function or select an alarm/warning

•

in parameter 4-34 Tracking Error Function.

Investigate the mechanics around the load and

•

motor. Check feedback connections from motor encoder to drive.

Select motor feedback function in

•

parameter 4-30 Motor Feedback Loss Function.

Adjust the tracking error band in

•

parameter 4-35 Tracking Error and parameter 4-37 Tracking Error Ramping.

ALARM 79, Illegal power section conguration

The scaling card is the incorrect part number or not installed. Also, the MK102 connector on the power card could not be installed.

ALARM 80, Drive initialised to default value

Parameter settings are initialized to default settings after a manual reset. To clear the alarm, reset the unit.

ALARM 81, CSIV corrupt

CSIV le has syntax errors.

ALARM 82, CSIV parameter error

CSIV failed to initialize a parameter.

ALARM 83, Illegal option combination

The mounted options are incompatible.

ALARM 84, No safety option

The safety option was removed without applying a general reset. Reconnect the safety option.

ALARM 85, Dang fail PB

PROFIBUS/PROFIsafe error.

ALARM 88, Option detection

A change in the option layout is detected.

Parameter 14-89 Option Detection is set to [0] Frozen conguration and the option layout has been changed.

To apply the change, enable option layout

•

changes in parameter 14-89 Option Detection.

Alternatively, restore the correct option congu-

•

ration.

WARNING 89, Mechanical brake sliding

The hoist brake monitor detects a motor speed exceeding 10 RPM.

ALARM 90, Feedback monitor

Check the connection to encoder/resolver option and, if

necessary, replace VLT® Encoder Input MCB 102 or VLT Resolver Input MCB 103.

ALARM 91, Analog input 54 wrong settings

Set switch S202 in position OFF (voltage input) when a KTY sensor is connected to analog input terminal 54.

ALARM 99, Locked rotor

Rotor is blocked.

WARNING/ALARM 104, Mixing fan fault

The fan is not operating. The fan monitor checks that the fan is spinning at power-up or whenever the mixing fan is turned on. The mixing-fan fault can be warning or an alarm trip in parameter 14-53 Fan Monitor.

Troubleshooting

Cycle power to the drive to determine if the

•

warning/alarm returns.

WARNING/ALARM 122, Mot. rotat. unexp.

The drive performs a function that requires the motor to be at standstill, for example DC hold for PM motors.

WARNING 163, ATEX ETR cur.lim.warning

The drive has run above the characteristic curve for more than 50 s. The warning is activated at 83% and deactivated at 65% of the allowed thermal overload.

ALARM 164, ATEX ETR cur.lim.alarm

Operating above the characteristic curve for more than 60 s within a period of 600 s activates the alarm, and the drive trips.

WARNING 165, ATEX ETR freq.lim.warning

The drive is running for more than 50 s below the allowed minimum frequency (parameter 1-98 ATEX ETR interpol. points freq.).

ALARM 166, ATEX ETR freq.lim.alarm

The drive has operated for more than 60 s (in a period of 600 s) below the allowed minimum frequency (parameter 1-98 ATEX ETR interpol. points freq.).

congured as a

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

ALARM 244, Heat Sink temperature

The maximum temperature of the heat sink has been exceeded. The temperature fault cannot reset until the temperature drops below a dened heat sink temperature. The trip and reset points are dierent based on the power size. This alarm is equivalent to alarm 29, Heat Sink Temp.

Troubleshooting

Check for the following conditions:

Ambient temperature too high.

•

Motor cables too long.

•

Incorrect airow clearance above or below the AC

•

drive.

Blocked airow around the unit.

•

Damaged heat sink fan.

•

Dirty heat sink.

•

WARNING 251, New typecode

The power card or other components are replaced, and the type code has changed.

ALARM 421, Temperature fault

A fault caused by the on-board temperature sensor is detected on the fan power card.

Troubleshooting

Check wiring.

•

Check sensor.

•

Replace fan power card.

•

ALARM 423, FPC updating

The alarm is generated when the fan power card reports it has an invalid PUD. The control card attempts to update the PUD. A subsequent alarm can result depending on the update. See A424 and A425.

ALARM 424, FPC update successful

This alarm is generated when the control card has successfully updated the fan power card PUD. The drive must be reset to stop the alarm.

ALARM 425, FPC update failure

This alarm is generated after the control card failed to update the fan power card PUD.

Troubleshooting

Check the fan power card wiring.

•

Replace fan power card.

•

Contact supplier.

•

ALARM 426, FPC cong

The number of found fan power cards does not match the number of congured fan power cards. See parameter group 15-6* Option Ident for the number of congured fan power cards.

Troubleshooting

Check fan power card wiring.

•

Replace fan power card.

•

ALARM 427, FPC supply

Supply voltage fault (5 V, 24 V, or 48 V) on fan power card is detected.

Troubleshooting

Check fan power card wiring.

•

Replace fan power card.

•

Maintenance, Diagnostics, a... Operating Guide

8.6 Troubleshooting

Symptom Possible cause Test Solution

Display

dark/No

function

Intermittent

display

Motor not

running

Motor

running in

wrong

direction

Missing input power. See Table 5.4. Check the input power source.

Missing or open fuses. See Open power fuses in this table for possible

causes.

No power to the LCP. Check the LCP cable for proper connection or

damage.

Shortcut on control voltage

(terminal 12 or 50) or at control

terminals.

Incompatible LCP (LCP from

VLT® 2800 or 5000/6000/8000/

FCD or FCM).

Wrong contrast setting. –

Display (LCP) is defective. Test using a dierent LCP. Replace the faulty LCP or connection

Internal voltage supply fault or

SMPS is defective.

Overloaded supply (SMPS) due

to improper control wiring or a

fault within the AC drive.

Service switch open or missing

motor connection.

No mains power with 24 V DC

option card.

LCP Stop. Check if [O] has been pressed. Press [Auto On] or [Hand On] (depending

Missing start signal (Standby). Check parameter 5-10 Terminal 18 Digital Input

Motor coast signal active

(Coasting).

Wrong reference signal source. Check reference signal:

Motor rotation limit. Check that parameter 4-10 Motor Speed

Active reversing signal. Check if a reversing command is programmed

Wrong motor phase

connection.

Check the 24 V control voltage supply for

terminal 12/13 to 20–39, or 10 V supply for

terminals 50–55.

– Use only LCP 101 (P/N 130B1124) or LCP

– Contact supplier.

To rule out a problem in the control wiring,

disconnect all control wiring by removing the

terminal blocks.

Check if the motor is connected and the

connection is not interrupted by a service

switch or other device.

If the display is functioning, but there is no

output, check that mains power is applied to

the AC drive.

for correct setting for terminal 18. Use default

setting.

Check parameter 5-12 Terminal 27 Digital Input

for correct setting for terminal 27 (use default

setting).

Local

•

Remote or bus reference?

•

Preset reference active?

•

Terminal connection correct?

•

Scaling of terminals correct?

•

Reference signal available?

•

Direction is programmed correctly.

for the terminal in parameter group 5-1*

Digital inputs.

– See chapter 6.5.1 Warning - Motor Start.

Follow the recommendations provided.

Replace the faulty LCP or connection

cable.

Wire the terminals properly.

102 (P/N. 130B1107).

Press [Status] + [▲]/[▼] to adjust the

contrast.

cable.

If the display stays lit, the problem is in

the control wiring. Check the wiring for

shorts or incorrect connections. If the

display continues to cut out, follow the

procedure for Display dark\No function.

Connect the motor and check the service

switch.

Apply mains power.

on operating mode).

Apply a valid start signal.

Apply 24 V on terminal 27 or program

this terminal to [0] No operation.

Program correct settings. Check

parameter 3-13 Reference Site. Set preset

reference active in parameter group 3-1*

References. Check for correct wiring. Check

scaling of terminals. Check reference

signal.

Program correct settings.

Deactivate reversing signal.

8 8

Maintenance, Diagnostics, a... VLT® AQUA Drive FC 202

Symptom Possible cause Test Solution

Motor is not

reaching

maximum

speed

Motor speed

unstable

Motor runs

rough

Motor does

not brake

Open power

fuses

Mains current

imbalance

greater than

Motor current

imbalance

greater than

AC drive

acceleration

problems

AC drive

deceleration

problems

Frequency limits set wrong. Check output limits in parameter 4-13 Motor

Speed High Limit [RPM], parameter 4-14 Motor

Speed High Limit [Hz], and parameter 4-19 Max

Output Frequency

Reference input signal not

scaled correctly.

Possible incorrect parameter

settings.

Possible overmagnetization. Check for incorrect motor settings in all

Possible incorrect settings in

the brake parameters. Ramp-

down times may be too short.

Phase-to-phase short. Motor or panel has a short phase-to-phase.

Motor overload. Motor is overloaded for the application. Perform start-up test and verify that

Loose connections. Perform pre-start-up check for loose

Problem with mains power (see

alarm 4, Mains phase loss

description).

Problem with the AC drive. Rotate input power leads into the AC drive 1

Problem with motor or motor

wiring.

Problem with AC drive. Rotate output motor cables 1 position: U to V,

Motor data are entered

incorrectly.

Motor data are entered

incorrectly.

Check reference input signal scaling in

parameter group 6-0* Analog I/O mode and

parameter group 3-1* References.

Check the settings of all motor parameters,

including all motor compensation settings.

For closed-loop operation, check PID settings.

motor parameters.

Check brake parameters. Check ramp time

settings.

Check motor and panel phases for shorts.

connections.

Rotate input power leads into the 1 position:

A to B, B to C, C to A.

position: A to B, B to C, C to A.

Rotate output motor cables 1 position: U to V,

V to W, W to U.

If warnings or alarms occur, see

chapter 8.5 List of Warnings and Alarms.

Check that motor data are entered correctly.

If warnings or alarms occur, see

chapter 8.5 List of Warnings and Alarms.

Check that motor data are entered correctly.

Program correct limits.

Program correct settings.

Check settings in parameter group 1-6*

Load Depen. Setting. For closed-loop

operation, check settings in parameter

group 20-0* Feedback.

Check motor settings in parameter groups

1-2* Motor data, 1-3* Adv Motor Data, and

1-5* Load Indep. Setting.

Check parameter groups 2-0* DC Brake and

3-0* Reference Limits.

Eliminate any shorts detected.

motor current is within specications. If

motor current is exceeding the nameplate

full load current, the motor can run only

with reduced load. Review the speci-

cations for the application.

Tighten loose connections.

If imbalanced leg follows the wire, it is a

power problem. Check the mains supply.

If the imbalanced leg stays on same input

terminal, it is a problem with the AC

drive. Contact supplier.

If the imbalanced leg follows the wire, the

problem is in the motor or motor wiring.

Check motor and motor wiring.

If the imbalanced leg stays on same

output terminal, it is a problem with the

unit. Contact supplier.

Increase the ramp-up time in

parameter 3-41 Ramp 1 Ramp Up Time.

Increase current limit in

parameter 4-18 Current Limit. Increase

torque limit in parameter 4-16 Torque Limit

Motor Mode.

Increase the ramp-down time in

parameter 3-42 Ramp 1 Ramp Down Time.

Enable overvoltage control in

parameter 2-17 Over-voltage Control.

Table 8.5 Troubleshooting

Specications Operating Guide

9 Specications

9.1 Electrical Data

9.1.1 Mains Supply 3x380–480 V AC

FC 202 N355 N400 N450

High/normal load HO NO HO NO HO NO

(High overload=150% current during 60 s,

normal overload=110% current during 60 s)

Typical shaft output at 400 V [kW] 315 355 355 400 400 450

Typical shaft output at 460 V [hp] 450 500 500 600 550 600

Enclosure size E1h/E3h E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 400 V) [A] 600 658 658 745 695 800

Intermittent (60 s overload)

(at 400 V) [A]

Continuous (at 460/500 V) [A] 540 590 590 678 678 730

Intermittent (60 s overload)

(at 460/500 V) [A]

Continuous kVA (at 400 V) [kVA] 416 456 456 516 482 554

Continuous kVA (at 460 V) [kVA] 430 470 470 540 540 582

Maximum input current

Continuous (at 400 V) [A] 590 647 647 733 684 787

Continuous (at 460/500 V) [A] 531 580 580 667 667 718

Maximum number and size of cables

per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Brake or regeneration [mm2 (AWG)

Maximum number and size of cables

per phase (E3h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Load share or regeneration [mm2 (AWG)

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]3)

Estimated power loss at 460 V [W]

Eciency

Output frequency 0–590 Hz 0–590 Hz 0–590 Hz

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

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

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

Fan power card overtemperature trip [°C (°F)]

Active in-rush card overtemperature trip

[°C (°F)]

3)4)

900 724 987 820 1043 880

810 649 885 746 1017 803

5x240 (5x500 mcm) 5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800 800

6794 7532 7498 8677 7976 9473

6118 6724 6672 7819 7814 8527

0.98 0.98 0.98

110 (230) 110 (230) 110 (230)

80 (176) 80 (176) 80 (176)

85 (185) 85 (185) 85 (185)

9 9

Table 9.1 Technical Specications, Mains Supply 3x380–480 V AC

Specications VLT® AQUA Drive FC 202

FC 202 N500 N560

High/normal load HO NO HO NO

(High overload=150% current during 60 s, normal overload=110%

current during 60 s)

Typical shaft output at 400 V [kW] 450 500 500 560

Typical shaft output at 460 V [hp] 600 650 650 750

Enclosure size E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 400 V) [A] 800 880 880 990

Intermittent (60 s overload)

(at 400 V) [A]

Continuous (at 460/500 V) [A] 730 780 780 890

Intermittent (60 s overload)

(at 460/500 V) [A]

Continuous kVA (at 400 V) [kVA] 554 610 610 686

Continuous kVA (at 460 V) [kVA] 582 621 621 709

Maximum input current

Continuous (at 400 V) [A] 779 857 857 964

Continuous (at 460/500 V) [A] 711 759 759 867

Maximum number and size of cables

per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Brake or regeneration [mm2 (AWG)

Maximum number and size of cables

per phase (E4h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Load share or regeneration [mm2 (AWG)

Maximum external mains fuses [A]

Estimated power loss at 400 V [W]

Estimated power loss at 460 V [W] 3)

Eciency

3)4)

Output frequency [Hz] 0–590 0–590

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

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

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

Fan power card overtemperature trip [°C (°F)]

Active in-rush card overtemperature trip [°C (°F)]

1200 968 1320 1089

1095 858 1170 979

6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

1200 1200

9031 10162 10146 11822

8212 8876 8860 10424

0.98 0.98

110 (230) 100 (212)

80 (176) 80 (176)

85 (185) 85 (185)

Table 9.2 Technical Specications, Mains Supply 3x380–480 V AC

1) American Wire Gauge.

2) For fuse ratings, see chapter 9.7 Fuses.

3) Typical power loss is at normal conditions and expected to be within

15% (tolerance relates to variety in voltage and cable conditions.) These

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyeciency. Options and

customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.

4) Measured using 5 m (16.4 ft) shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy

eciency class, see chapter 9.4 Ambient Conditions. For part load losses, see www.danfoss.com/vltenergyeciency.

Specications Operating Guide

9.1.2 Mains Supply 3x525–690 V AC

FC 202 N450 N500

High/normal load HO NO HO NO

(High overload=150% current during 60 s, normal

overload=110% current during 60 s)

Typical shaft output at 550 V [kW] 315 355 315 400

Typical shaft output at 575 V [hp] 400 450 400 500

Typical shaft output at 690 V [kW] 355 450 400 500

Enclosure size E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 550 V) [A] 395 470 429 523

Intermittent (60 s overload) (at 550 V) [A] 593 517 644 575

Continuous (at 575/690 V) [A] 380 450 410 500

Intermittent (60 s overload) (at 575/690 V) [A] 570 495 615 550

Continuous kVA (at 550 V) [kVA] 376 448 409 498

Continuous kVA (at 575 V) [kVA] 378 448 408 498

Continuous kVA (at 690 V) [kVA] 454 538 490 598

Maximum input current

Continuous (at 550 V) [A] 381 453 413 504

Continuous (at 575 V) [A] 366 434 395 482

Continuous (at 690 V) [A] 366 434 395 482

Maximum number and size of cables

per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Brake or regeneration [mm2 (AWG)

Maximum number and size of cables

per phase (E3h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Load share or regeneration [mm2 (AWG)

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]3)

Estimated power loss at 690 V [W]3)

Eciency

Output frequency [Hz] 0–590 0–590

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

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

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

Fan power card overtemperature trip [°C (°F)]

Active in-rush card overtemperature trip [°C (°F)]

5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800

4424 5323 4795 6010

4589 5529 4970 6239

0.98 0.98

110 (230) 110 (230)

80 (176) 80 (176)

85 (185) 85 (185)

9 9

Table 9.3 Technical Specications, Mains Supply 3x525–690 V AC

Specications VLT® AQUA Drive FC 202

FC 202 N560 N630

High/normal load HO NO HO NO

(High overload=150% current during 60 s, normal

overload=110% current during 60 s)

Typical shaft output at 550 V [kW] 400 450 450 500

Typical shaft output at 575 V [hp] 500 600 600 650

Typical shaft output at 690 V [kW] 500 560 560 630

Enclosure size E1h/E3h E1h/E3h

Output current (3-phase)

Continuous (at 550 V) [A] 523 596 596 630

Intermittent (60 s overload) (at 550 V) [A] 785 656 894 693

Continuous (at 575/690 V) [A] 500 570 570 630

Intermittent (60 s overload) (at 575/690 V) [A] 750 627 855 693

Continuous kVA (at 550 V) [kVA] 498 568 568 600

Continuous kVA (at 575 V) [kVA] 498 568 568 627

Continuous kVA (at 690 V) [kVA] 598 681 681 753

Maximum input current

Continuous (at 550 V) [A] 504 574 574 607

Continuous (at 575 V) [A] 482 549 549 607

Continuous (at 690 V) [A] 482 549 549 607

Maximum number and size of cables

per phase (E1h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Brake or regeneration [mm2 (AWG)

Maximum number and size of cables

per phase (E3h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Load share or regeneration [mm2 (AWG)

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]

Estimated power loss at 690 V [W]

Eciency

3)4)

Output frequency [Hz] 0–590 0–590

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

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

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

Fan power card overtemperature trip [°C (°F)]

Active in-rush card overtemperature trip [°C (°F)]

5x240 (5x500 mcm) 5x240 (5x500 mcm)

4x240 (4x500 mcm) 4x240 (4x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

800 800

6493 7395 7383 8209

6707 7653 7633 8495

0.98 0.98

110 (230) 110 (230)

80 (176) 80 (176)

85 (185) 85 (185)

Table 9.4 Technical Specications, Mains Supply 3x525–690 V AC

Specications Operating Guide

FC 202 N710 N800

High/normal load HO NO HO NO

(High overload=150% current during 60 s, normal

overload=110% current during 60 s)

Typical shaft output at 550 V [kW] 500 560 560 670

Typical shaft output at 575 V [hp] 650 750 750 950

Typical shaft output at 690 V [kW] 630 710 710 800

Enclosure size E2h/E4h E2h/E4h

Output current (3-phase)

Continuous (at 550 V) [A] 659 763 763 889

Intermittent (60 s overload) (at 550 V) [A] 989 839 1145 978

Continuous (at 575/690 V) [A] 630 730 730 850

Intermittent (60 s overload) (at 575/690 V) [A] 945 803 1095 935

Continuous kVA (at 550 V) [kVA] 628 727 727 847

Continuous kVA (at 575 V) [kVA] 627 727 727 847

Continuous kVA (at 690 V) [kVA] 753 872 872 1016

Maximum input current

Continuous (at 550 V) [A] 642 743 743 866

Continuous (at 575 V) [A] 613 711 711 828

Continuous (at 690 V) [A] 613 711 711 828

Maximum number and size of cables

per phase (E2h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Brake or regeneration [mm2 (AWG)

Maximum number and size of cables

per phase (E4h)

- Mains and motor without brake [mm2 (AWG)]

- Mains and motor with brake [mm2 (AWG)

- Load share or regeneration [mm2 (AWG)

Maximum external mains fuses [A]

Estimated power loss at 600 V [W]3)

Estimated power loss at 690 V [W]3)

Eciency

Output frequency [Hz] 0–590 0–590

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

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

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

Fan power card overtemperature trip [°C (°F)]

Active in-rush card overtemperature trip [°C (°F)]

6x240 (6x500 mcm) 6x240 (6x500 mcm)

5x240 (5x500 mcm) 5x240 (5x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

6x240 (6x500 mcm) 6x240 (6x500 mcm)

2x185 (2x350 mcm) 2x185 (2x350 mcm)

4x185 (4x350 mcm) 4x185 (4x350 mcm)

1200 1200

8075 9500 9165 10872

8388 9863 9537 11304

0.98 0.98

110 (230) 110 (230)

80 (176) 80 (176)

85 (185) 85 (185)

9 9

Table 9.5 Technical Specications, Mains Supply 3x525–690 V AC

1) American Wire Gauge.

2) For fuse ratings, see chapter 9.7 Fuses.

3) Typical power loss is at normal conditions and expected to be within

15% (tolerance relates to variety in voltage and cable conditions.) These

values are based on a typical motor eciency (IE/IE3 border line). Lower eciency motors add to the power loss in the drive. Applies for

dimensioning of drive cooling. If the switching frequency is higher than the default setting, the power losses can increase. LCP and typical control

card power consumptions are included. For power loss data according to EN 50598-2, refer to www.danfoss.com/vltenergyeciency. Options and

customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W.

4) Measured using 5 m shielded motor cables at rated load and rated frequency. Eciency measured at nominal current. For energy eciency

class, see chapter 9.4 Ambient Conditions. For part load losses, see www.danfoss.com/vltenergyeciency.

Specications VLT® AQUA Drive FC 202

9.2 Mains Supply

Mains supply (L1, L2, L3) Supply voltage 380–500 V ±10%, 525–690 V ±10%

Mains voltage low/mains voltage drop-out: During low mains voltage or a mains drop-out, the drive continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the drive's lowest rated supply voltage.

Supply frequency 50/60 Hz ±5%

Maximum imbalance temporary between mains phases 3.0% of rated supply voltage True power factor (λ) ≥0.9 nominal at rated load Displacement power factor (cos Φ) near unity (>0.98) Switching on input supply L1, L2, L3 (power ups) Maximum 1 time/2 minutes Environment according to EN60664-1 Overvoltage category III/pollution degree 2

The drive is suitable for use on a circuit capable of delivering up to 100kA short-circuit current rating (SCCR) at 480/600 V.

1) Calculations based on UL/IEC61800-3.

9.3 Motor Output and Motor Data

Motor output (U, V, W) Output voltage 0–100% of supply voltage

Output frequency 0–590 Hz Switching on output Unlimited

Ramp times 0.01–3600 s

1) Dependent on voltage and power.

Torque characteristics

Starting torque (constant torque) Maximum 150% for 60 s

Overload torque (constant torque) maximum 150% for 60 s

1) Percentage relates to the drive's nominal current.

2) Once every 10 minutes.

1)2)

9.4 Ambient Conditions

Environment E1h/E2h enclosure IP21/Type 1, IP54/Type 12 E3h/E4h enclosure IP20/Chassis Vibration test (standard/ruggedized) 0.7 g/1.0 g Relative humidity 5%-95% (IEC 721-3-3; Class 3K3 (non-condensing) during operation) Aggressive environment (IEC 60068-2-43) H2S test class Kd Aggressive gases (IEC 60721-3-3) class 3C3 Test method according to IEC 60068-2-43 H2S (10 days) Ambient temperature (at SFAVM switching mode)

- with derating maximum 55 °C (maximum 131 °F)

- with full output power of typical EFF2 motors (up to 90% output current) maximum 50 °C (maximum 122 °F)

- at full continuous FC output current maximum 45 °C (maximum 113 °F) Minimum ambient temperature during full-scale operation 0 °C (32 °F) Minimum ambient temperature at reduced performance 10 °C (50 °F) Temperature during storage/transport -25 to +65/70 °C (13 to 149/158 °F) Maximum altitude above sea level without derating 1000 m (3281 ft) Maximum altitude above sea level with derating 3000 m (9842 ft)

1) For more information on derating, refer to the product-specic design guide.

EMC standards, Emission EN 61800-3

Specications Operating Guide

EMC standards, Immunity EN 61800-3

Energy eciency class

2) Determined according to EN 50598-2 at:

Rated load.

•

90% rated frequency.

•

Switching frequency factory setting.

•

Switching pattern factory setting.

•

IE2

9.5 Cable Specications

Cable lengths and cross-sections for control cables Maximum motor cable length, shielded/armored 150 m (492 ft) Maximum motor cable length, unshielded/unarmored 300 m (984 ft) Maximum cross-section to motor, mains, load sharing, and brake See chapter 9.1 Electrical Data

Maximum cross-section to control terminals, rigid wire 1.5 mm2/16 AWG (2x0.75 mm2)

Maximum cross-section to control terminals, exible cable 1 mm2/18 AWG

Maximum cross-section to control terminals, cable with enclosed core 0.5 mm2/20 AWG

Minimum cross-section to control terminals 0.25 mm2/23 AWG

1) For power cables, see electrical tables in chapter 9.1 Electrical Data.

9.6 Control Input/Output and Control Data

Digital inputs Programmable digital inputs 4 (6)

Terminal number 18, 19, 271), 291), 32, 33 Logic PNP or NPN Voltage level 0–24 V DC Voltage level, logic 0 PNP <5 V DC Voltage level, logic 1 PNP >10 V DC Voltage level, logic 0 NPN >19 V DC Voltage level, logic 1 NPN <14 V DC Maximum voltage on input 28 V DC Input resistance, R

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

1) Terminals 27 and 29 can also be programmed as outputs.

Approximately 4 kΩ

9 9

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Switches A53 and A54 Voltage mode Switch A53/A54=(U) Voltage level -10 V to +10 V (scaleable) Input resistance, R Maximum voltage ±20 V Current mode Switch A53/A54=(I) Current level 0/4 to 20 mA (scaleable) Input resistance, R Maximum current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Maximum error 0.5% of full scale Bandwidth 100 Hz

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

Approximately 10 kΩ

Approximately 200 Ω

Mains

Functional isolation

PELV isolation

Motor

DC-bus

High voltage

Control

+24 V

RS485

130BA117.10

Specications VLT® AQUA Drive FC 202

Illustration 9.1 PELV Isolation

Pulse inputs Programmable pulse inputs 2 Terminal number pulse 29, 33 Maximum frequency at terminal 29, 33 110 kHz (push-pull driven) Maximum frequency at terminal 29, 33 5 kHz (open collector) Minimum frequency at terminal 29, 33 4 Hz Voltage level See Digital Inputs in chapter 9.6 Control Input/Output and Control Data Maximum voltage on input 28 V DC Input resistance, R

Approximately 4 kΩ

Pulse input accuracy (0.1–1 kHz) Maximum error: 0.1% of full scale

Analog output Number of programmable analog outputs 1 Terminal number 42 Current range at analog output 0/4-20 mA Maximum resistor load to common at analog output 500 Ω Accuracy on analog output Maximum error: 0.8% of full scale Resolution on analog output 8 bit

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

Control card, RS485 serial communication Terminal number 68 (P, TX+, RX+), 69 (N, TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

Digital output Programmable digital/pulse outputs 2

Terminal number 27, 29

Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1% of full scale Resolution of frequency outputs 12 bit

1) Terminals 27 and 29 can also be programmed as inputs.

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

Specications Operating Guide

Control card, 24 V DC output Terminal number 12, 13 Maximum load 200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

Relay outputs Programmable relay outputs 2

Maximum cross-section to relay terminals 2.5 mm2 (12 AWG)

Minimum cross-section to relay terminals 0.2 mm2 (30 AWG) Length of stripped wire 8 mm (0.3 in) Relay 01 terminal number 1–3 (break), 1–2 (make)

Maximum terminal load (AC-1)1) on 1–2 (NO) (Resistive load)

Maximum terminal load (AC-15)1) on 1–2 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 1–2 (NO) (Resistive load) 80 V DC, 2 A

Maximum terminal load (DC-13)1) on 1–2 (NO) (Inductive load) 24 V DC, 0.1 A

Maximum terminal load (AC-1)1) on 1–3 (NC) (Resistive load) 240 V AC, 2 A

Maximum terminal load (AC-15)1) on 1–3 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 1–3 (NC) (Resistive load) 50 V DC, 2 A

Maximum terminal load (DC-13)1) on 1–3 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 1–3 (NC), 1–2 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2 Relay 02 terminal number 4–6 (break), 4–5 (make)

Maximum terminal load (AC-1)1) on 4–5 (NO) (Resistive load)

Maximum terminal load (AC-15)1) on 4–5 (NO) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 4–5 (NO) (Resistive load) 80 V DC, 2 A

Maximum terminal load (DC-13)1) on 4–5 (NO) (Inductive load) 24 V DC, 0.1 A

Maximum terminal load (AC-1)1) on 4–6 (NC) (Resistive load) 240 V AC, 2 A

Maximum terminal load (AC-15)1) on 4–6 (NC) (Inductive load @ cosφ 0.4) 240 V AC, 0.2 A

Maximum terminal load (DC-1)1) on 4–6 (NC) (Resistive load) 50 V DC, 2 A

Maximum terminal load (DC-13)1) on 4–6 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 4–6 (NC), 4–5 (NO) 24 V DC 10 mA, 24 V AC 2 mA Environment according to EN 60664-1 Overvoltage category III/pollution degree 2

1) IEC 60947 part 4 and 5. The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

2) Overvoltage Category II.

3) UL applications 300 V AC 2 A.

2)3)

400 V AC, 2 A

9 9

Control card, +10 V DC output Terminal number 50 Output voltage 10.5 V ±0.5 V Maximum load 25 mA

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

Control characteristics Resolution of output frequency at 0–1000 Hz ±0.003 Hz System response time (terminals 18, 19, 27, 29, 32, 33) ≤2 ms Speed control range (open loop) 1:100 of synchronous speed Speed accuracy (open loop) 30–4000 RPM: Maximum error of ±8 RPM

All control characteristics are based on a 4-pole asynchronous motor.

Specications VLT® AQUA Drive FC 202

Control card performance Scan interval 5 ms

Control card, USB serial communication USB standard 1.1 (full speed) USB plug USB type B device plug

NOTICE

Connection to PC is carried out via a standard host/device USB cable. The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB connection is not galvanically isolated from ground. Use only isolated laptop/PC as connection to the USB connector on the drive or an isolated USB cable/converter.

9.7 Fuses

Fuses ensure that possible damage to the drive is limited to damages inside the unit. To ensure compliance with EN 50178, use identical Bussmann fuses as replacements. Refer to Table 9.6.

NOTICE

Use of fuses on the supply side is mandatory for IEC 60364 (CE) and NEC 2009 (UL) compliant installations.

Input voltage (V) Bussmann part number

380–500 170M7309

525–690 170M7342

Table 9.6 Fuse Options

The fuses listed in Table 9.6 are suitable for use on a circuit capable of delivering 100000 A the drive voltage rating. With the proper fusing, the drive short-circuit current rating (SCCR) is 100000 A drives are supplied with internal drive fusing to meet the 100 kA SCCR. E3h and E4h drives must be tted with Type aR fuses to meet the 100 kA SCCR.

NOTICE

DISCONNECT SWITCH

All units ordered and supplied with a factory-installed disconnect switch require Class L branch circuit fusing to meet the 100 kA SCCR for the drive. If a circuit breaker is used, the SCCR rating is 42 kA. The specic Class L fuse is determined by the input voltage and power rating of the drive. The input voltage and power rating is found on the product nameplate. See chapter 4.1 Items Supplied.

Input voltage (V) Power rating (kW) Short circuit rating (A) Required protection

380–480 355–450 42000 Circuit breaker

100000 Class L fuse, 800 A

380–480 500–560 42000 Circuit breaker

100000 Class L fuse, 1200 A

525–690 450–630 42000 Circuit breaker

10000 Class L fuse, 800 A

525–690 710–800 42000 Circuit breaker

100000 Class L fuse, 1200 A

(symmetrical), depending on

rms

. E1h and E2h

rms

130BF648.10

22 (0.8)

393 (15.5)

602 (23.7)

2043

(80.4)

2002

(78.8)

1553

(61.1)

1393 (54.9)

912

(35.9)

13 (0.5)

Specications Operating Guide

9.8 Enclosure Dimensions

9.8.1 E1h Exterior Dimensions

9 9

Illustration 9.2 Front View of E1h

130BF649.10

20 (0.8)

2X 101 (4.0)

2X 9 (0.7)

35 (1.4)

125 (4.9)

280 (11.0)

190 (7.5)

513

(20.2)

567

(22.3)

Specications VLT® AQUA Drive FC 202

1 Knockout panel

Illustration 9.3 Side View of E1h

130BF684.10

168 (6.6)

18 (0.7)

412 (16.2)

154 (6.1)

206

(8.1)

1209 (47.6)

168 (6.6)

1800 (70.9)

601 (23.7)

69 (2.7)

464 (18.3)

4X 457 (18.0)

4X 73 (2.8)

96 (3.8)

Specications Operating Guide

9 9

1 Heat sink access panel (optional)

Illustration 9.4 Back View of E1h

130BF651.10

293 (11.5)

173 (6.8)

560 (22.0)

22 (0.8)

17 (0.7)

14 (0.6)

11 (0.4)

750 (29.5)

558

(22.0)

22 (0.8)

137 (5.4)

560 (22.0)

412 (16.2)

184

(7.3)

424

(16.7)

Specications VLT® AQUA Drive FC 202

1 Gland plate

Illustration 9.5 Door Clearance and Gland Plate Dimensions for E1h

2043

(80.4)

2002

(78.8)

1553

(61.1)

1393 (54.9)

912

(35.9)

394

(15.5)

698

(27.5)

(3.8)

13 (0.5)

130BF654.10

Specications Operating Guide

9.8.2 E2h Exterior Dimensions

9 9

Illustration 9.6 Front View of E2h

2X 101 (4.0)

2X 9 (0.7)

20 (0.8)

513

(20.2)

567

(22.3)

280 (11.0)

190 (7.5)

35 (1.4)

125 (4.9)

130BF653.10

Specications VLT® AQUA Drive FC 202

1 Knockout panel

Illustration 9.7 Side View of E2h

130BF655.10

168 (6.6)

18 (0.7)

96 (3.8)

154 (6.1)

1800 (70.9)

168 (6.6)

601 (23.7)

69 (2.7)

4X 121 (4.8)

560 (22.0)

4X 457 (18.0)

1209 (47.6)

508 (20.0)

254

(10.0)

Specications Operating Guide

9 9

1 Heat sink access panel (optional)

Illustration 9.8 Back View of E2h

14 (0.6)

11 (0.4)

130BF652.10

871 (34.3)

424

(16.7) 184 (7.3)

17 (0.7)

137

(5.4)

653

(25.7)

22 (0.8)

508 (20.0)

656 (25.8)

293 (11.5)

173 (6.8)

656 (25.8)

22 (0.8)

Specications VLT® AQUA Drive FC 202

1 Gland plate

Illustration 9.9 Door Clearance and Gland Plate Dimensions for E2h

130BF656.10

1578

(62.1)

1537

(60.5)

1348

(53.1)

13 (0.5)

506

(19.9)

(1.2)

13 (0.5)

10 (0.4)

15 (0.6)

Specications Operating Guide

9.8.3 E3h Exterior Dimensions

9 9

Illustration 9.10 Front View of E3h

130BF658.10

20 (0.8)

2X 101 (4.0)

2X 19 (0.7)

2X 18 (0.7)

2X 21 (0.8)

482 (19.0)

Specications VLT® AQUA Drive FC 202

Illustration 9.11 Side View of E3h

130BF657.10

168 (6.6)

18 (0.7)

168 (6.6)

1335 (52.5)

136 (5.4)

154 (6.1)

744 (29.3)

39 (1.5)

22 (0.9)

215 (8.5)

48 (1.9)

206 (8.1)

412

(16.2)

430 (16.9)

4X 457 (18.0)

464 (18.3)

Specications Operating Guide

9 9

1 Heat sink access panel (optional)

Illustration 9.12 Back View of E3h

130BF659.10

262

(10.3)

294

(11.6)

163

(6.4)

19 (0.7) 2X 219 (8.6)

2X 220

(8.6)

160

(6.3)

Specications VLT® AQUA Drive FC 202

1 RFI shield termination (standard with RFI option)

2 Cable/EMC clamp

3 Gland plate

Illustration 9.13 RFI Shield Termination and Gland Plate Dimensions for E3h

130BF664.10

13 (0.5)

10 (0.4)

15 (0.6)

1578

(62.1)

1537

(60.5)

1348

(53.1)

(1.2)

604

(23.8)

13 (0.5)

Specications Operating Guide

9.8.4 E4h Exterior Dimensions

9 9

Illustration 9.14 Front View of E4h

130BF666.10

20 (0.8)

2X 101 (4.0)

2X 19 (0.7)

2X 18 (0.7)

2X 21 (0.8)

482 (19.0)

Specications VLT® AQUA Drive FC 202

Illustration 9.15 Side View of E4h

130BF665.10

18 (0.7)

48 (1.9)

508

(20.1)

254

(10.0)

168 (6.6)

1335 (52.5)

168 (6.6)

136 (5.4)

39 (1.5)

22 (0.9)

263 (10.4)

4X 457 (18.0)

744 (29.3)

4X 74 (2.9)

560 (22.0)

526 (20.7)

154 (6.1)

Specications Operating Guide

9 9

1 Heat sink access panel (optional)

Illustration 9.16 Back View of E4h

294

(11.6)

163 (6.4)

130BF667.10

262

(10.3)

19 (0.7) 2X 268 (10.6)

2X 220

(8.6)

160

(6.3)

Specications VLT® AQUA Drive FC 202

1 RFI shield termination (standard with RFI option)

2 Cable/EMC clamp

3 Gland plate

Illustration 9.17 RFI Shield Termination and Gland Plate Dimensions for E4h

Danfoss VLT AQUA Drive FC 202, VLT Refrigeration Drive FC 103, FC 102, VLT FC 103 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual