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

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).

+ 84 hidden pages

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