MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® AQUA Drive FC 202
110–1400 kW
www.danfoss.com/drives
Contents VLT AQUA Drive FC 202 Operation Instructions
Contents
1 How to Read these Operating Instructions
2 Safety
2.1 Safety Note
2.1.1 General Warning 6
2.1.2 Before Commencing Repair Work 7
2.1.3 Special Conditions 7
2.1.4 Avoid Unintended Start 7
2.1.5 Safe Torque Off (STO) 7
2.1.6 IT Mains 8
3 How to Install
3.1 How to Get Started
3.2 Pre-installation
3.2.1 Planning the Installation Site 9
3.2.2 Receiving the Frequency Converter 10
3.2.3 Transportation and Unpacking 10
3.2.4 Lifting 10
4
6
6
9
9
9
3.2.5 Mechanical Dimensions 12
3.2.6 Rated Power 18
3.3 Mechanical Installation
3.3.1 Tools Needed 20
3.3.2 General Considerations 20
3.3.3 Terminal Locations - Enclosure Type D 21
3.3.4 Terminal Locations - E Enclosures 24
3.3.5 Terminal Locations - Enclosure type F 29
3.3.6 Cooling and Airflow 33
3.3.7 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 35
3.3.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 35
3.3.9 IP21 Drip Shield Installation (Enclosure Types D1 and D2) 37
3.4 Field Installation of Options
3.4.1 Installation of Duct Cooling Kit in Rittal Enclosures 37
3.4.2 Outside Installation/NEMA 3R Kit for Rittal Enclosures 38
3.4.3 Installation on Pedestal 39
3.4.4 Installation of Input Plate Options 40
20
37
3.4.5 Installation of Mains Shield for Frequency Converters 41
3.5 Enclsoure Type F Panel Options
3.5.1 Enclsoure Type F Options 41
3.6 Electrical Installation
3.6.1 Power Connections 42
MG20P402 - Rev. 2013-12-16 1
41
42
Contents VLT AQUA Drive FC 202 Operation Instructions
3.6.2 Grounding 53
3.6.3 Extra Protection (RCD) 53
3.6.4 RFI Switch 53
3.6.5 Torque 53
3.6.6 Shielded Cables 54
3.6.7 Motor Cable 54
3.6.8 Brake Cable for Frequency Converters with Factory Installed Brake Chopper Option 55
3.6.9 Brake Resistor Temperature Switch 55
3.6.10 Load Sharing 55
3.6.11 Shielding against Electrical Noise 55
3.6.12 Mains Connection 56
3.6.13 External Fan Supply 56
3.6.14 Fuses 56
3.6.15 Mains Disconnectors 59
3.6.16 F Enclosure Circuit Breakers 59
3.6.17 F Enclosure Mains Contactors 60
3.6.18 Motor Insulation 60
3.6.19 Motor Bearing Currents 60
3.6.20 Control Cable Routing 60
3.6.21 Access to Control Terminals 62
3.6.22 Electrical Installation, Control Terminals 62
3.6.23 Electrical Installation, Control Cables 63
3.6.24 Switches S201, S202, and S801 65
3.7 Connection Examples
3.7.1 Start/Stop 66
3.7.2 Pulse Start/Stop 66
3.8 Final Set-up and Test
3.9 Additional Connections
3.9.1 Mechanical Brake Control 68
3.9.2 Parallel Connection of Motors 68
3.9.3 Motor Thermal Protection 69
66
67
68
4 How to operate the frequency converter
4.1 Ways of Operation
4.1.1 How to operate graphical LCP (GLCP) 70
4.1.2 How to Operate Numeric LCP (NLCP) 73
4.1.3 Changing Data 75
4.1.4 Changing a Text Value 75
4.1.5 Changing a Group of Numeric Data Values 75
4.1.6 Changing of Data Value, Step-by-Step 76
2 MG20P402 - Rev. 2013-12-16
70
70
Contents VLT AQUA Drive FC 202 Operation Instructions
4.1.7 Read-out and Programming of Indexed Parameters 76
4.1.8 Tips and Tricks 76
5 How to programme the frequency converter
5.1 How to programme
5.2 Commonly Used Parameters - Explanations
5.3 Parameter Menu Structure
6 General Specifications
7 Troubleshooting
Index
79
79
84
112
117
130
142
MG20P402 - Rev. 2013-12-16 3
How to Read these Operating... VLT AQUA Drive FC 202 Operation Instructions
1
1 How to Read these Operating Instructions
notice or any obligation to notify former or present users
VLT AQUA Drive
FC 200 Series
Software version: 2.1x
This guide can be used with all FC
202 frequency converters with
software
version 2.1x or later.
The actual software version
number can be read from
15-43 Software Version.
This publication contains information proprietary to
Danfoss. By accepting and using this manual the user
agrees that the information contained herein is used solely
for operating equipment from Danfoss or equipment from
other vendors if such equipment is intended for communication with Danfoss equipment over a serial
communication link. This publication is protected under
the Copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program
produced according to the guidelines provided in this
manual functions properly in every physical, hardware or
software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or
representation, neither expressed nor implied, with respect
to this documentation, including its quality, performance,
or fitness for a particular purpose.
In no event shall Danfoss be liable for direct, indirect,
special, incidental, or consequential damages arising out of
the use, or the inability to use information contained in
this manual, even if advised of the possibility of such
damages. In particular, Danfoss is not responsible for any
costs, including but not limited to those incurred as a
result of lost profits or revenue, loss or damage of
equipment, loss of computer programs, loss of data, the
costs to substitute these, or any claims by third parties.
of such revisions or changes.
1.1.1 Available Literature
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Danfoss technical literature is also available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/Technical+Documentation.htm.
VLT® AQUA Drive FC 202 Operating Instructions
provide the neccessary information for getting
the frequency converter up and running.
VLT® AQUA Drive FC 202, 110-1400 kW Operating
Instructions provide the neccessary information
for getting the high power frequency converter
up and running.
®
VLT
AQUA Drive FC 202 Design Guide entails all
technical information about the frequency
converter and customer design and applications.
®
VLT
AQUA Drive FC 202 Programming Guide
provides information on how to programme and
includes complete parameter descriptions.
VLT® AQUA Drive FC 202 Profibus
®
VLT
AQUA Drive FC 202 DeviceNet
Output Filters Design Guide
VLT® AQUA Drive FC 202 Cascade Controller
Application Note MN20A: Submersible Pump
Application
Application Note MN20: Master/Follower Operation
Application
Application Note MN20F: Drive Closed Loop and
Sleep Mode
Installation Instruction for Mounting Brackets
Enclosure type A5, B1, B2, C1 and C2 IP21, IP55 or
IP66
Instruction for Analog I/O Option MCB109
Instruction for Panel through mount kit
®
Active Filter Operating Instruction
VLT
Danfoss reserves the right to revise this publication at any
time and to make changes to its contents without prior
4 MG20P402 - Rev. 2013-12-16
How to Read these Operating... VLT AQUA Drive FC 202 Operation Instructions
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the Design
Guide.
NOTICE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 6.72 the output frequency of the
frequency converter is limited to 590 Hz. Software
versions 6x.xx also limit the maximum output frequency
to 590 Hz, but these versions cannot be flashed, i.e.
neither downgraded nor upgraded.
The following symbols are used in this document:
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
1
1
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
NOTICE
Indicates important information, including situations that
may result in damage to equipment or property.
MG20P402 - Rev. 2013-12-16 5
Safety VLT AQUA Drive FC 202 Operation Instructions
2 Safety
22
2.1 Safety Note
WARNING
The voltage of the frequency converter is dangerous
whenever connected to mains. Incorrect installation of
the motor, frequency converter or fieldbus may cause
damage to the equipment, serious personal injury or
death. Consequently, the instructions in this manual, as
well as national and local rules and safety regulations,
must be complied with.
Safety Regulations
1. The frequency converter must be disconnected
from mains if repair work is to be carried out.
Check that the mains supply has been disconnected and that the necessary time has passed
before removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of the
frequency converter does not disconnect the
equipment from mains and is thus not to be used
as a safety switch.
3. Correct protective earthing of the equipment
must be established, the user must be protected
against supply voltage, and the motor must be
protected against overload in accordance with
applicable national and local regulations.
4. The earth leakage currents are higher than 3.5
mA.
5. Protection against motor overload is set by par.
1-90 Motor Thermal Protection. If this function is
desired, set par. 1-90 to data value [ETR trip]
(default value) or data value [ETR warning]. Note:
The function is initialised at 1.16 x rated motor
current and rated motor frequency. For the North
American market: The ETR functions provide class
20 motor overload protection in accordance with
NEC.
6. Do not remove the plugs for the motor and
mains supply while the frequency converter is
connected to mains. Check that the mains supply
has been disconnected and that the necessary
time has passed before removing motor and
mains plugs.
7. Note that the frequency converter has voltage
inputs other than L1, L2 and L3, when load
sharing (linking of DC intermediate circuit) and
external 24 V DC have been installed. Check that
all voltage inputs have been disconnected and
that the necessary time has passed before
commencing repair work.
NOTICE
Installation at high altitude:
380 - 480 V: At altitudes above 3,000 m, contact Danfoss
regarding PELV.
525 - 690 V: At altitudes above 2,000 m, contact Danfoss
regarding PELV.
Warning against Unintended Start
1. The motor can be stopped with digital
commands, bus commands, references or a local
stop, while the frequency converter is connected
to mains. To avoid personal injury, these stop
functions are not sufficient to ensure that no
unintended start occurs.
2. While parameters are being changed, the motor
may start. Consequently, always press [RESET];
following which data can be modified.
3. A motor that has been stopped may start if faults
occur in the electronics of the frequency
converter, or if a temporary overload or a fault in
the supply mains or the motor connection ceases.
WARNING
Warning:
Touching the electrical parts may be fatal - even after
the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been
disconnected, such as external 24 V DC, load sharing
(linkage of DC intermediate circuit), as well as the motor
connection for kinetic back-up.
General Warning
2.1.1
WARNING
Warning:
Touching the electrical parts may be fatal - even after
the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been
disconnected, (linkage of DC intermediate circuit), as well
as the motor connection for kinetic back-up.
Before touching any potentially live parts of the
frequency converter, wait at least as follows: Be aware
that there may be high voltage on the DC link even
when the Control Card LEDs are turned off. A red LED is
mounted on a circuit board inside the frequency
converter to indicate the DC bus voltage. The red LED
stays lit until the DC link is 50 V DC or lower.
6 MG20P402 - Rev. 2013-12-16
Safety
VLT AQUA Drive FC 202 Operation Instructions
WARNING
Leakage Current
The earth leakage current from the frequency converter
exceeds 3.5 mA. According to IEC 61800-5-1 a reinforced
Protective Earth connection must be ensured by means
of: a min. 10mm² Cu or 16mm² Al PE-wire or an
addtional PE wire - with the same cable cross section as
the Mains wiring - must be terminated separately.
Residual Current Device
This product can cause a D.C. current in the protective
conductor. Where a residual current device (RCD) is used
for extra protection, only an RCD of Type B (time
delayed) shall be used on the supply side of this
product. See also RCD Application Note MN.90.GX.02.
Protective earthing of the frequency converter and the
use of RCD's must always follow national and local
regulations.
Grid configuration (IT,TN, grounded leg, etc.)
•
Safety of low-voltage ports (PELV conditions)
•
Consult the relevant clauses in these instructions and in
the Design Guide for information about the installation
requirements.
WARNING
The frequency converter's DC link capacitors remain
charged after power has been disconnected. To avoid an
electrical shock hazard, disconnect the frequency
converter from the mains before carrying out
maintenance. Before doing service on the frequency
converter, wait at least the amount of time indicated
below:
Voltage Power size
Min. Waiting Time
2 2
Before Commencing Repair Work
2.1.2
1. Disconnect the frequency converter from mains.
2. Disconnect DC bus terminals 88 and 89.
3.
Wait at least the time mentioned in
chapter 2.1.1 General Warning.
Special Conditions
2.1.3
Electrical ratings
The rating indicated on the nameplate of the frequency
converter is based on a typical 3-phase mains power
supply, within the specified voltage, current and
temperature range, which is expected to be used in most
applications.
The frequency converters also support other special
applications, which affect the electrical ratings of the
frequency converter. Special conditions which affect the
electrical ratings might be:
Single phase applications
•
High temperature applications which require
•
derating of the electrical ratings
Marine applications with more severe environ-
•
mental conditions.
Consult the relevant clauses in these instructions and in
the Design Guide for information about the electrical
ratings.
Installation requirements
The overall electrical safety of the frequency converter
requires special installation considerations regarding:
Fuses and circuit breakers for over-current and
•
short-circuit protection
Selection of power cables (mains, motor, brake,
•
loadsharing and relay)
380 - 480 V 110 - 250 kW 20 minutes
315 - 1000 kW 40 minutes
525 - 690 V 45 - 400 kW 20 minutes
450- 1400 kW 30 minutes
Be aware that there may be high voltage on the DC link even
when the LEDs are turned off.
Table 2.1 Discharge Time
Avoid Unintended Start
2.1.4
WARNING
While the frequency converter is connected to mains, the
motor can be started/stopped using digital commands,
bus commands, references or via the Local Control Panel.
Disconnect the frequency converter from mains
•
whenever personal safety considerations make
it necessary to avoid unintended start.
To avoid unintended start, always activate the
•
[Off] key before changing parameters.
Unless terminal 37 is turned off, an electronic
•
fault, temporary overload, a fault in the mains
supply, or lost motor connection may cause a
stopped motor to start.
Safe Torque Off (STO)
2.1.5
To run Safe Torque Off, additional wiring for the frequency
converter is required, refer to Safe Torque Off Operating
Instructions for Danfoss VLT® Frequency Converters for
further information.
MG20P402 - Rev. 2013-12-16 7
Safety VLT AQUA Drive FC 202 Operation Instructions
2.1.6 IT Mains
22
WARNING
IT mains
Do not connect frequency converters with RFI-filters to
mains supplies with a voltage between phase and earth
of more than 440 V for 400 V converters and 760 V for
690 V converters.
For 400 V IT mains and delta earth (grounded leg), mains
voltage may exceed 440 V between phase and earth.
For 690 V IT mains and delta earth (grounded leg), mains
voltage may exceed 760 V between phase and earth.
Failure to follow recommendations could result in death
or serious injury.
14-50 RFI Filter can be used to disconnect the internal RFI
capacitors from the RFI filter to ground.
Disposal Instruction
2.1.7
Equipment containing electrical components
must not be disposed of together with
domestic waste.
It must be separately collected with electrical
and electronic waste according to local and
currently valid legislation.
8 MG20P402 - Rev. 2013-12-16
M
3
96 97 9998
37
91 92 93
12
L1
W PEVU
F1
L2
L3
PE
130BA015.13
1
18
81 82
R+R-
95
55
50
53
27
88
89
DC- DC+
L1 L2 PEL3
How to Install
3 How to Install
3.1 How to Get Started
VLT AQUA Drive FC 202 Operation Instructions
This chapter covers mechanical and electrical installations
to and from power terminals and control card terminals.
Electrical installation of options is described in the relevant
Operating Instructions and Design Guide.
The frequency converter is designed to achieve a quick
and EMC-correct installation by following the steps
described below.
WARNING
Read the safety instructions before installing the unit.
Failure to follow recommendations could result in death
or serious injury.
Mechanical Installation
Mechanical mounting
•
Electrical Installation
Connection to Mains and Protecting Earth
•
Motor connection and cables
•
Fuses and circuit breakers
•
Control terminals - cables
•
Quick Setup
Local Control Panel, LCP
•
Automatic Motor Adaptation, AMA
•
Programming
•
Frame size is depending on enclosure type, power range
and mains voltage
3 3
Illustration 3.1 Diagram showing basic installation including
mains, motor, start/stop key, and potentiometer for speed
adjustment.
3.2 Pre-installation
3.2.1 Planning the Installation Site
CAUTION
Before performing the installation it is important to plan
the installation of the frequency converter. Neglecting
this may result in extra work during and after installation.
Select the best possible operation site by considering
the following (see details on the following pages, and
the respective Design Guides)
Ambient operating temperature
MG20P402 - Rev. 2013-12-16 9
•
Installation method
•
How to cool the unit
•
Position of the frequency converter
•
Cable routing
•
Ensure the power source supplies the correct
•
voltage and necessary current
Ensure that the motor current rating is within the
•
maximum current from the frequency converter
If the frequency converter is without built-in
•
fuses, ensure that the external fuses are rated
correctly.
176FA245.10
130BA832.11
130BA834.11
How to Install VLT AQUA Drive FC 202 Operation Instructions
3.2.2 Receiving the Frequency Converter
When receiving the frequency converter, make sure that
the packaging is intact, and be aware of any damage that
might have occurred to the unit during transport. In case
damage has occurred, contact immediately the shipping
33
company to claim the damage.
3.2.3 Transportation and Unpacking
Before unpacking the frequency converter it is
recommended that it is located as close as possible to the
final installation site.
Remove the box and handle the frequency converter on
the pallet, as long as possible.
Lifting
3.2.4
Illustration 3.3 Recommended Lifting Method, Enclsoure Type
Always lift the frequency converter in the dedicated lifting
eyes. For all D and E2 (IP00) enclosures, use a bar to avoid
bending the lifting holes of the frequency converter.
F1 (460 V, 600 to 900 HP, 575/690 V, 900 to 1150 HP)
Illustration 3.2 Recommended Lifting Method, Enclosure Types
D and E
WARNING
The lifting bar must be able to handle the weight of the
frequency converter. See Mechanical Dimensions for the
weight of the different enclosure type. Maximum
diameter for bar is 2.5 cm (1 inch). The angle from the
top of the frequency converter to the lifting cable should
be 60° or greater.
Illustration 3.4 Recommended Lifting Method, Enclosure Type
F2 (460 V, 1000 to 1200 HP, 575/690 V, 1250 to 1350 HP)
10 MG20P402 - Rev. 2013-12-16
130BA833.11
130BA835.11
130BB753.10
130BB688.10
130BB689.10
How to Install VLT AQUA Drive FC 202 Operation Instructions
Illustration 3.5 Recommended Lifting Method, Enclosure Type
F3 (460 V, 600 to 900 HP, 575/690 V, 900 to 1150 HP)
3 3
Illustration 3.6 Recommended Lifting Method, Enclosure Type
F4 (460 V, 1000 to 1200 HP, 575/690 V, 1250 to 1350 HP)
Illustration 3.7 Recommended lifting method, Enclosure Type
F8
Illustration 3.8 Recommended lifting method, Enclosure Type
F9/F10
Illustration 3.9 Recommended lifting method, Enclosure Type
F11/F12/F13/F14
MG20P402 - Rev. 2013-12-16 11
IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
A
B
C
120
(4.7)
177.0
(7.0)
354.0
(13.9)
1166
(45.9)
310
(12.2)
163
(6.4)
420
(16.5)
981
(38.6)
74
(2.9)
417
(16.4)
380
(15.0)
D1
D2
130BA443.11
417
(16.4)
380
(15.0)
225
(8.9)
225
(8.9)
225.0
(8.9)
225.0
(8.9)
369.0
(14.5)
849
(33.4)
1209
(47.6)
160.0
(6.3)
160.0
(6.3)
160.0
(6.3)
160.0
(6.3)
304
(12.0)
304
(12.0)
25
(1.0)
25
(1.0)
1154
(45.4)
1362
(53.6)
420
(16.5)
157
(6.2)
72
(2.8)
1547
(60.9)
1589
(62.6)
423
(16.6)
120
(4.7)
1535
(60.4)
184.5
(7.3)
977
(38.5)
A
B
C
IP00 / CHASSIS
IP00/IP21/IP54 - ALL SIZES
1099
43.3( )
1280
50.4( )
1327
52.2()
375
14.8( )
417
16.4( )
298
11.7(
)
304
12.0(
)
120
4.7(
)
977
38.5( )
160
6.3( )
185
7.3( )
369
14.5( )
1282
50.5( )
25
1.0( )
161
6.3( )
225
(8.9)
225
(8.9)
997
39.3( )
818
32.2( )
408
16.1( )
66
2.6( )
408
16.1(
)
66
2.6( )
298
11.7
( )
375
14.8( )
1046
41.2( )
120
4.7( )
696
27.4( )
160
6.3( )
1001
25
1.0( )
39.4(
)
304
12.0( )
151
5.9( )
157
6.2( )
147
5.8( )
417
16.4( )
177
7.0( )
354
13.9( )
25
1.0( )
22
0.9
( )
49
1.9( )
25
1.0( )
Ø 11
.4( )
20.0
0.8
( )
10
0.4
( )
51
2.0( )
11
0.4( )
160.0
6.30(
)
160.0
6.30( )
225.0
8.9( )
225.0
8.9( )
D3 D4
BA
C
22
0.9
( )
138BA442.10
How to Install VLT AQUA Drive FC 202 Operation Instructions
NOTICE
The plinth is provided in the same packaging as the frequency converter but is not attached to enclosure types F1-F4
during shipment. The plinth is required to allow airflow to the frequency converter to provide proper cooling. The F
enclosures should be positioned on top of the plinth in the final installation location. The angle from the top of the
frequency converter to the lifting cable should be 60° or greater.
33
In addition to the drawings above a spreader bar is an acceptable way to lift the F enclosures.
3.2.5 Mechanical Dimensions
Illustration 3.10
*
Note airflow directions
Illustration 3.11
12 MG20P402 - Rev. 2013-12-16
E1
225
8.86( )
1551
61.1( )
2000
(78.74)
727
28.6( )
72
2.8( )
164
600
(23.62)
198
7.8( )
145
5.7( )
494
19.4( )
392
15.4( )
538
21.2( )
160
6.3( )
1043
41.1( )
160
6.3( )
72
2.8( )
27
1.1( )
23
0.9( )
185
7.3( )
185
7.3( )
58
2.3( )
484
19.1()
2X13
0.5
( )
25
1.0
(
)
56
2.2( )
6.5( )
185
7.3( )
1.0( )
F
F
130BA444.10
SIDE CABLE ENTRY
KNOCK-OFF PLATE
CABLE BASE
BOTTOM CABLE ENTRY
IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
Ø 25
How to Install VLT AQUA Drive FC 202 Operation Instructions
*
Note airflow directions
3 3
Illustration 3.12
*
Note airflow directions
MG20P402 - Rev. 2013-12-16 13
130BA445.10
225
64
1320
585
269
156
23
25
498
539
1547
1502
160
1043
14
184
184
184
139
304
2X13
(2.5)
(23.0)
(52.0)
(6.2)
(19.5)
(10.6)
(21.2)
(60.9)
(5.5)
(12.0)
(7.3) (7.3)
(0.5)
(1.5)
120
(4.7)
25
(1.0)
(59.1)
(41.1)
(6.3)
(8.9)
225
(8.9)
(1.0)
25
(1.0)
(0.9)
27
(1.0)
13
(0.5)
E2
D
E
D
E
IP00 / CHASSIS
How to Install VLT AQUA Drive FC 202 Operation Instructions
33
Illustration 3.13
*
Note airflow directions
14 MG20P402 - Rev. 2013-12-16
1
130BB027.10
2281.4
(89.82)
2206.4
(86.87)
1499.2
(59.02)
1400.0
(55.12)
ø29.0
(1.14)
225.0
(8.85)
607.0
(23.9)
225.0
(8.85)
1
130BB029.10
2280
(89.7)
2205
(86.8)
1497
(58.9)
1997
(78.6)
ø29
( 1.1)
607
(23.9)
How to Install VLT AQUA Drive FC 202 Operation Instructions
3 3
F1 IP 21/54 - NEMA 1/12 F3 IP 21/54 - NEMA 1/12
Table 3.1
MG20P402 - Rev. 2013-12-16 15
1) Minimum clearance from ceiling
225.0
(8.85)
2281
(89.8)
1499
(59.0)
Ø29
(1.1)
1804
(71.0)
2206
(86.9)
606
(23.8)
130BB028.10
1
1
130BB030.10
2280
(89.7)
2205
(86.8)
1497
(58.9)
2401
(94.5)
Ø29
(1.1)
225.0
(8.85)
604
(23.8)
How to Install VLT AQUA Drive FC 202 Operation Instructions
33
1) Minimum clearance from ceiling
F2 IP 21/54 - NEMA 1/12 F4 IP 21/54 - NEMA 1/12
Table 3.2
16 MG20P402 - Rev. 2013-12-16
How to Install VLT AQUA Drive FC 202 Operation Instructions
Enclosure type Size D1 D2 D3 D4
160 - 250 kW
IP
NEMA
Shipping
dimensions
[mm]
Frequency
converter
dimensions
[mm]
110-132 kW at 400 V
(380-480 V)
45-160 kW at 690 V
(525-690 V)
21
Type 1
Height
650 650 650 650 650 650
Width 1730 1730 1730 1730 1220 1490
Depth 570 570 570 570 570 570
Height 1209 1209 1589 1589 104 1327
Width 420 420 420 420 408 408
Depth 380 380 380 380 375 375
Max
weight
[kg]
104 104 151 151 91 138
54
Type 12
160-250 kW at 400 V
(380-480 V)
200-400 kW at 690 V
(525-690 V)
21
Type 1
54
Type 12
110-132 kW at 400 V
(380-480 V)
45-160 kW at 690 V
(525-690 V)
00
Chassis
at 400 V
(380-480 V)
200-400 kW
at 690 V
(525-690 V)
Chassis
3 3
00
Table 3.3 Mechanical dimensions, Enclosure type D
MG20P402 - Rev. 2013-12-16 17
130BA816.10
130BA817.10
130BA819.10
130BA820.10
How to Install VLT AQUA Drive FC 202 Operation Instructions
Enclosure Type Size E1 E2 F1 F2 F3 F4
315-450 kW at
400 V
(380-480 V)
450-630 kW at
690 V
33
IP
NEMA
Shipping
dimensions
[mm]
Frequency
converter
dimensions
[mm]
Height
Width 2197 1705 1569 1962 2159 2559
Depth 736 736 1130 1130 1130 1130
Height 2000 1547 2204 2204 2204 2204
Width 600 585 1400 1800 2000 2400
Depth 494 498 606 606 606 606
Max
weight
[kg]
(525-690 V)
21, 54
Type 1/ Type 12
840 831 2324 2324 2324 2324
313 277 1004 1246 1299 1541
315-450 kW at
400 V
(380-480 V)
450-630 kW at
690 V
(525-690 V)
00
Chassis
500-710 kW at
400 V
(380-480 V)
710-900 kW at
690 V
(525-690 V)
21, 54
Type 1/Type 12
800-1000 kW at
400 V
(380-480 V)
1000-1200 kW at
690 V
(525-690 V)
21, 54
Type 1/Type 12
500-710 kW at
400 V
(380-480 V)
710-900 kW at
690 V
(525-690 V)
21, 54
Type 1/Type 12
800-1000 kW at
400 V
(380-480 V)
1000-1400 kW at
690 V
(525-690 V)
21, 54
Type 1/Type 12
Table 3.4 Mechanical dimensions, Enclosure Types E and F
Rated Power
3.2.6
Enclosure type D1 D2 D3 D4
Enclosure
protection
Normal overload
rated power - 110%
overload torque
IP 21/54 21/54 00 00
NEMA Type 1/Type 12 Type 1/Type 12 Chassis Chassis
110 - 132 kW at 400 V
(380 - 480 V)
45 - 160 kW at 690 V
(525-690 V)
150 - 250 kW at 400 V
(380 - 480 V)
200 - 400 kW at 690 V
(525-690 V)
110 - 132 kW at 400 V
(380 - 480 V)
45 - 160 kW at 690 V
(525-690 V)
150 - 250 kW at 400 V
200 - 400 kW at 690 V
(380 - 480 V)
(525-690 V)
Table 3.5
18 MG20P402 - Rev. 2013-12-16
130BA818.10
130BA821.10
F3
F1
130BA959.10
F4
F2
130BB092.11
How to Install VLT AQUA Drive FC 202 Operation Instructions
Enclosure type E1 E2 F1/F3 F2/F4
Enclosure
protection
Normal overload
rated power -
110% overload
torque
Table 3.6
IP 21/54 00 21/54 21/54
NEMA Type 1/Type 12 Chassis Type 1/Type 12 Type 1/Type 12
315 - 450 kW at 400 V
(380 - 480 V)
450 - 630 kW at 690 V
(525-690 V)
315 - 450 kW at 400 V
(380 - 480 V)
450 - 630 kW at 690 V
(525-690 V)
500 - 710 kW at 400 V
(380 - 480 V)
710 - 900 kW at 690 V
(525-690 V)
800 - 1000 kW at 400 V
(380 - 480 V)
1000 - 1400 kW at 690 V
(525-690 V)
NOTICE
The F enclosures are available in 4 different sizes, F1, F2, F3 and F4 The F1 and F2 consist of an inverter cabinet on the
right and rectifier cabinet on the left. The F3 and F4 have an additional options cabinet left of the rectifier cabinet. The
F3 is an F1 with an additional options cabinet. The F4 is an F2 with an additional options cabinet.
3 3
MG20P402 - Rev. 2013-12-16 19
176FA235.11
<105,0°
526
(20.7)
399
(15.7)
748
(29.5)
579
(22.8)
176FA276.12
≤105,0°
130BB003.13
578
(22.8)
776
(30.6)
2X578
[22.8]
776
[30.6]
130BB004.13
130BB005.13
624
[24.6]
579
[22.8]
578
[22.8]
How to Install VLT AQUA Drive FC 202 Operation Instructions
3.3 Mechanical Installation
Preparation of the mechanical installation of the frequency
converter must be done carefully to ensure a proper result
and to avoid additional work during installation. Start
taking a close look at the mechanical drawings at the end
33
of this instruction to become familiar with the space
demands.
3.3.1 Tools Needed
To perform the mechanical installation the following
tools are needed:
Drill with 10 or 12 mm drill
•
Tape measure
•
Wrench with relevant metric sockets (7-17mm)
•
Extensions to wrench
•
Sheet metal punch for conduits or cable glands
•
in IP21/Nema 1 and IP54 units
Lifting bar to lift the unit (rod or tube max. Ø 5
•
mm (1 inch), able to lift minimum 400 kg (880
lbs).
Crane or other lifting aid to place the frequency
•
converter in position
A Torx T50 tool is needed to install the E1 in IP21
•
and IP54 enclosure types.
General Considerations
3.3.2
Wire access
Ensure that proper cable access is present including
necessary bending allowance. As the IP00 enclosure is
open to the bottom cables must be fixed to the back
panel of the enclosure where the frequency converter is
mounted, i.e. by using cable clamps.
Illustration 3.14 Space in Front of IP21/IP54 Rated Enclosure
Types D1 and D2
Illustration 3.15 Space in Front of IP21/IP54 Rated Enclosure
Type E1
Illustration 3.16 Space in Front of IP21/IP54 Rated Enclosure
Type F1
CAUTION
All cable lugs/shoes must mount within the width of the
terminal bus bar.
Space
Ensure proper space above and below the frequency
converter to allow airflow and cable access. In addition
space in front of the unit must be considered to enable
opening of the door of the panel.
20 MG20P402 - Rev. 2013-12-16
Illustration 3.17 Space in Front of IP21/IP54 Rated Enclosure
Type F3
Illustration 3.18 Space in Front of IP21/IP54 Rated Enclosure
Type F2
624
(24.6)
2x579
578
(22.8)
130BB006.10
0,
(0,)
0,
(0,)
O
P
Q0,
(0,)
NMLJ KE F G H I
A
B
C
D
176FA238.10
R/12 91
W/T3 98V/T2 97U/T1 96
+R 82-R 81
+DC 89-DC 88
T/L3 93S/L2 92
How to Install VLT AQUA Drive FC 202 Operation Instructions
Illustration 3.19 Space in Front of IP21/IP54 Rated Enclosure
Type F4
3.3.3 Terminal Locations - Enclosure Type D
Consider the following terminal positions when designing for cables access.
3 3
Illustration 3.20 Position of Power Connections, Enclosure Types D3 and D4
MG20P402 - Rev. 2013-12-16 21
R/L1 S/L2
U/T1 96 V/T2 97 W/T398
T/L391
81 82
9392
-DC +DC
-R +R
0,
(0,)
UTS
R
0,
(0,)
176FA239.10
0,
(0,)
V
How to Install VLT AQUA Drive FC 202 Operation Instructions
33
Illustration 3.21 Position of Power Connections with Disconnect Switch, Enclosure Types D1 and D2
Be aware that the power cables are heavy and hard to bend. Consider the optimum position of the frequency converter for
ensuring easy installation of the cables.
22 MG20P402 - Rev. 2013-12-16
How to Install VLT AQUA Drive FC 202 Operation Instructions
NOTICE
All D enclosures are available with standard input terminals or disconnect switch. All terminal dimensions can be found
in Table 3.7.
IP21 (NEMA 1)/IP54 (NEMA 12) IP00/Chassis
D1 D2 D3 D4
A 277 (10.9) 379 (14.9) 119 (4.7) 122 (4.8)
B 227 (8.9) 326 (12.8) 68 (2.7) 68 (2.7)
C 173 (6.8) 273 (10.8) 15 (0.6) 16 (0.6)
D 179 (7.0) 279 (11.0) 20.7 (0.8) 22 (0.8)
E 370 (14.6) 370 (14.6) 363 (14.3) 363 (14.3)
F 300 (11.8) 300 (11.8) 293 (11.5) 293 (11.5)
G 222 (8.7) 226 (8.9) 215 (8.4) 218 (8.6)
H 139 (5.4) 142 (5.6) 131 (5.2) 135 (5.3)
I 55 (2.2) 59 (2.3) 48 (1.9) 51 (2.0)
J 354 (13.9) 361 (14.2) 347 (13.6) 354 (13.9)
K 284 (11.2) 277 (10.9) 277 (10.9) 270 (10.6)
L 334 (13.1) 334 (13.1) 326 (12.8) 326 (12.8)
M 250 (9.8) 250 (9.8) 243 (9.6) 243 (9.6)
N 167 (6.6) 167 (6.6) 159 (6.3) 159 (6.3)
O 261 (10.3) 260 (10.3) 261 (10.3) 261 (10.3)
P 170 (6.7) 169 (6.7) 170 (6.7) 170 (6.7)
Q 120 (4.7) 120 (4.7) 120 (4.7) 120 (4.7)
R 256 (10.1) 350 (13.8) 98 (3.8) 93 (3.7)
S 308 (12.1) 332 (13.0) 301 (11.8) 324 (12.8)
T 252 (9.9) 262 (10.3) 245 (9.6) 255 (10.0)
U 196 (7.7) 192 (7.6) 189 (7.4) 185 (7.3)
V 260 (10.2) 273 (10.7) 260 (10.2) 273 (10.7)
3 3
Table 3.7 Cable Positions Dimensions in mm (inch)
MG20P402 - Rev. 2013-12-16 23
176FA278.10
0[0.0]
0[0.0]
600[23.6]
525[20.7]
412[16.2]
300[11.8]
188[7.4]
75[3.0]
B
492[19.4]
323[12.7]
195[7.7]
0[0.0]
155[6.1]
193[7.6]
280[11.0]
371[14.6]
409[16.1]
How to Install VLT AQUA Drive FC 202 Operation Instructions
3.3.4 Terminal Locations - E Enclosures
Terminal Locations - E1
Take the following position of the terminals into consideration when designing the cable access.
33
Illustration 3.22 IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Enclosure Power Connection Positions
24 MG20P402 - Rev. 2013-12-16
176FA272.10
0[0.0]
55[2.2]
91[3.6]
139[5.5]
175[6.9]
0[0.0]
453[17.8]
B
A A A A
-R 81
9
19 Nm [14 FTa
How to Install VLT AQUA Drive FC 202 Operation Instructions
3 3
Illustration 3.23 IP21 (NEMA type 1) and IP54 (NEMA type 12)
Enclosure Power Connection Positions (Detail B)
MG20P402 - Rev. 2013-12-16 25
E
F
B
C
D
0 0.0[ ]
51 2.0[ ]
226 8.9[ ]
266 10.5[ ]
441 17.4[ ]
0 0.0[ ]
28 1.1[ ]
167 6.6[ ]
195 7.7[ ]
A
0 0.0[ ]
176FA279.11
How to Install
VLT AQUA Drive FC 202 Operation Instructions
33
Illustration 3.24 IP21 (NEMA type 1) and IP54 (NEMA type 12) Enclosure Power Connection Position of Disconnect Switch
Enclosure
types
E1
IP54/IP21 UL AND NEMA1/NEMA12
250/315 kW (400 V) AND 355/450-500/630
Unit type Dimensions [mm]/(inch)
KW (690 V)
396 (15.6) 267 (10.5) 332 (13.1) 397 (15.6) 528 (20.8) N/A
315/355-400/450 kW (400 V) 408 (16.1) 246 (9.7) 326 (12.8) 406 (16.0) 419 (16.5) 459 (18.1)
Table 3.8 Dimensions for Disconnect Terminal
26 MG20P402 - Rev. 2013-12-16
176FA280.10
585[23.0]
518[20.4]
405[15.9]
68[2.7]
0[0.0]
186[7.3]
0[0.0]
0[0.0]
181[7.1]
293[11.5]
409[16.1]
371[14.6]
280[11.0]
192[7.6]
154[6.1]
17[0.7]
A
R/L1 91
9
S/L2 92
U/T1 96 V/T2 97
T/L3 93
W/T3 98
FASTENER TORQUE M8 9.6 Nm (7 FT-LB) FASTENER TORQUE M8 9.6 Nm (7 FT-LB)
176FA282.10
0(0.0)
47(1.9)
83(3.3)
131(5.2)
167(6.6)
0(0.0)
147(5.8)
A A A A
019Nm (14 F)
9
A
R 81
How to Install VLT AQUA Drive FC 202 Operation Instructions
Terminal locations - enclosure type E2
Take the following position of the terminals into consideration when designing the cable access.
3 3
Illustration 3.25 IP00 Enclosure Power Connection Positions
Illustration 3.26 IP00 Enclosure Power Connection Positions
MG20P402 - Rev. 2013-12-16 27
E
0
0.0[ ]
F
B
0 0.0[ ]
C
D
A
0 0.0[ ]
176FA281.11
104[4.1]
35[1.4]
10[0.4]
0[0.0]
0[0.0]
40[1.6]
78[3.1]
0[0.0]
26[1.0]
26[1.0]
176FA271.10
How to Install VLT AQUA Drive FC 202 Operation Instructions
33
Illustration 3.27 IP00 Enclosure Power Connections Positions of Disconnect Switch
NOTICE
The power cables are heavy and difficult to bend. Consider the optimum position of the frequency converter for
ensuring easy installation of the cables.
Each terminal allows use of up to 4 cables with cable lugs or use of standard box lug. Earth is connected to relevant
termination point in the frequency converter.
If lugs are wider than 39 mm, install supplied barriers on the mains input side of the disconnect.
Illustration 3.28 Terminal in Details
28 MG20P402 - Rev. 2013-12-16
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