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Operating Instructions VLT AQUA Drive FC 202

1. 4 Gy ooo 00000000000 o oo bA o pooooooo l pg ORO Es DES 5 L o ol pc t C Tc 9 eee Pp 10 B L1 L2 L3 B PE Y W PE 8 7 Illustration 4 2 EMC compliant Electrical Connection Cable gland Motor 3 phase and PE 1 PLC 6 8 Mains 3 phase and reinforced PE Grounding rail PE Cable insulation stripped Table 4 1 Legend to Illustration 4 2 NOTIC EMC INTERFERENCE Use screened cables for motor and control wiring and separate cables for input power motor wiring and control wiring Failure to isolate power motor and control cables can result in unintended behaviour or reduced performance Minimum 200 mm 7 9 in clearance between power motor and control cables is required Control wiring Equalising min 16 mm 0 025 in MG20MA02 Rev 2013 10 29 13 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 5 Access e Remove cover vvith a screvv driver See 4 6 Motor Connection Illustration 4 3 or by loosening attaching screws See Illustration 4 4 AVVARN IN G INDUCED VOLTAGE Induced voltage from output motor cables that run together can charge equipment capacitors even wi
2. 55 character 54 signal e terminals 2 WIFI O epe ete CONVENTIONS iii iia 64 VLT AQUA Drive FC 202 Operating Instructions Cooling A t e ano Hat A DAR 9 a EI tat a oe rege TR a p s 19 Current l as esc 43 cup 36 D DC CUMENGE ERROR 6 33 Ip Em 35 Default settings ce ERR d 23 Digital NP ani 16 34 36 17 ll Le ER lo EE 53 Discharge TTT 7 Disconnect svvitch 20 Disposal Instruction 6 E Electrical interference 11 EMC Sula 11 NEE 13 Environment sesser 52 Exploded View AR EEGEN 5 External Alarm EE 30 command S s SAYAR b n 6 34 eidel 3 interlocle id 17 Interlock ut th d A aac ai tior 29 F Faultlog NR RNA 21 a GE 18 Feedback artes 18 19 28 39 33 41 Floating delta eere RERO RUE 15 el 11 19 38 42 56 G Ground COMMECEIONS 19 UT cT 11 Gt unded delta 15 Grounding eere 14 15 20 19 H Hand Ori i Re AR 22 32 iris 6 STZ Re T 7 20 32 MG20MAO 2 Rev 2013 10 29 69 Index 1 61800 3 r 15 nitialisation
3. 23 nput a a disconnect DOW b y An povver vviring A E lua aid terminals AA s ai i Installation nstallation Environments Intended Uses sas sa s s 3 Interference isolation 19 Isolated Nr E E 15 Items supplied s SS SA sento 9 J BIST DOR E 17 L Ble LRS T EENEG 8 11 le EE 10 Local Las aye EE 21 32 22 control panel LCP s 21 M Main Menu en a 21 Mains 2222 21 32 MAIN ANC ino 32 Manual initialisation 23 MET Ti DT 16 21 Menu M 21 A tete eee ee en o re e d Me SA 21 SEU ura ss R s 22 Modbus RTU bt ir te ese sd Gebiet 18 Darfi VLT AQUA Drive FC 202 Operating Instructions Motor ele 11 0 14 0 elle 6 26 39 21 CFT ent ON 21 data ER 24 43 36 40 Datas 26 RO 51 Re UE 11 39 21 IT E 26 speeds 24 status 3 thermistor 31 WING M 13 19 MOUNTING 10 19 Multiple frequency converters 11 N Nameplate rococ 9 Navigatio
4. dices 13 19 Serial communication 16 32 33 34 55 22 KT P PD 32 KT e 34 KT E 27 21 SHOCK TTT 9 Short Cil CUIt TTT 37 Sleep Mode einer tita eerie teri li 34 Specifications ictor Ho 18 Speed 2 18 27 29 32 Start TI tiep RR te PT A 23 Status mode RI RR GU RR RES 32 EE 9 Supply voltage 15 16 20 38 el di SA 18 Switching 33 NS 64 System feedback eise pal A ss 3 T Terminal 535 NM ANM Da 18 e SPP 18 Thermal Protection 6 Thermistor Thermistor tete bete itae ee der 15 31 36 titi 15 Tightening of 15 5 55 VLT AQUA Drive FC 202 Operating Instructions Torque ale Te dE et EE 51 T ecc 43 Transient protection s s s 6 Trip U Unintended start 7 20 V Vibration sien Tc 9 Voltage le 35 eege 53 Vie IC 25 W Warnings e e ec 34 Wind milling illa 8 WFC indica 11
5. MG20MAO2 Rev 2013 10 29 57 Specifications VLT AQUA Drive FC 202 Operating Instructions 525 600 V Enclosure Power kW Recommended Recommended Recommended circuit Max trip level A fuse size max fuse breaker Moeller A3 5 5 7 5 gG 10 5 5 gG 32 PKZMO 25 25 A5 1 1 7 5 gG 10 0 75 5 5 gG 32 PKZMO 25 25 B1 11 18 gG 25 11 gG 80 PKZM4 63 63 gG 32 15 gG 40 18 5 B2 22 30 gG 50 22 gG 100 NZMB1 A100 100 151 1 AA a B3 11 18 5 gG 25 11 gG 63 PKZM4 50 50 NUN AA AAA B4 22 37 gG 40 18 5 gG 125 NZMB1 A100 100 gG 50 22 gG 63 30 C1 37 55 gG 63 37 gG 160 37 45 NZMB2 A200 160 gG 100 45 aR 250 55 aR 160 55 a 38200 5 C3 45 55 gG 63 37 gG 150 NZMB2 A200 150 CA 75 90 aR 160 55 aR 250 NZMB2 A250 250 Table 8 15 525 600 V Enclosure Types A B and C 525 690 V Enclosure Power kW Recommended fuse size Recommended Recommended circuit Max trip level max fuse breaker A Danfoss A3 B2 C2 C3 Table 8 16 525 690 V Enclosure Types A B C 58 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 8 2 UL Compliance 1x200 240 V Recommended max fuse Buss Buss Buss Buss Buss Buss SIBA mann mann mann mann mann mann RK1 RK1 J T cc CC CC CC RK1 J FNQ KTK LP 5017906 01 15 FWX 15 KTN R15 JKS 15 R 15 R 15 CC 15 6 KLN R15 ATM R15 A2K 15R HSJ15 FNQ KTK LP 5017906 02 20 FVVX 20 KTN R20 JKS 20 R 20
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7. nce Site AC Brake AMA finish OK AMA ready AMA running Braking AC Brake was selected in 2 70 Brake Function The AC brake over magnetises the motor to achieve a controlled slow down Automatic motor adaptation AMA was carried out successfully AMA is ready to start Press Hand On to start The brake chopper is in operation Generative energy is absorbed by the brake resistor Braking max Coast Ctrl Ramp down The brake chopper is in operation The power limit for the brake resistor defined in 2 12 Brake Power Limit kW has been reached 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 Control Ramp down was selected in 14 10 Mains Failure e The mains voltage is below the value set in 14 11 Mains Voltage at Mains Fault at mains fault e The frequency converter ramps down the motor using a controlled ramp down 32 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an VLT AQUA Drive FC 202 Operating Instructions Current High Current Lovv DC Hold DC Stop Feedback high Feedback lovv Freeze output Freeze output request Freeze ref Jog request The frequency converter output current is above the limit set in 4 57 Warning Current High The frequency converter output current is below the limit set in 4 52 War
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10. AWG Max cable cross section 34 for mains disconnect mm AWG Estimated power loss at rated max load W Efficiency gt R co o 24 2 29 7 37 4 21 9 26 7 34 3 215 26 4 39 6 R R Ln LA a o 35 25 25 2 4 4 16 10 10 6 8 8 0 98 o o o io 00 0 98 Table 8 10 B2 B4 Enclosure Mains Supply 3x525 690 V AC IP20 IP21 IP55 Chassis NEMA 1 NEMA 12 P11K P22K MG20MAO2 Rev 2013 10 29 4 Specifications VLT AQUA Drive FC 202 Operating Instructions Type Designation P30K P37K P45K P55K P75K Typical Shaft output at 690 V kW 37 45 55 75 90 P20 Chassis B4 C3 C3 D3h D3h P21 Type 1 IP55 Type 12 c2 E Output current Continuous 3525550 V TAJ ntermittent 60 s overload 3x525 550 V AI Continuous 951 690 A ntermittent 60 s overload 3x551 690 V A 45 1 57 2 Max input current Continuous at 550 VA 5 70 om Intermittent 60 s overload at 550 V A 53 9 Continuous a 690 V A so so mo mo Intermittent 60 s overload at 690 V A 52 8 688 zo 96 Additional specifications Max cable cross section for mains and motor mm AWG Max cable cross section for load share and brake mm AWG 150 300 MCM 95 3 0 185 150 120 350 MCM 300 MCM 4 0 Max cable cross section for mains 95 70 70 disconnect mm AWG 3 0 2 0 2 0 Estimated power loss at rated max l
11. Cal BT 130BA648 12 b Illustration 3 4 Top and Bottom Mounting Holes See 8 9 Povver Ratings VVeight and Dimensions 130BA715 12 a Illustration 3 5 Top and Bottom Mounting Holes B4 C3 C4 MG20MA02 Rev 2013 10 29 Electrical Installation 4 Electrical Installation 4 1 Safety Instructions See 2 Safety for general safety instructions AVVARNING INDUCED VOLTAGE Induced voltage from output motor cables that run together can charge equipment capacitors even with the equipment turned off and locked out Failure to run output motor cables separately or use screened cables could result in death or serious injury e run output motor cables separately or e use screened cables ACAUTION SHOCK HAZARD The frequency converter can cause a DC current in the PE conductor Failure to follow the recommendation below means the RCD may not provide the intended protection e When a residual current operated protective device RCD is used for protection against electrical shock only an RCD of Type B is permitted on the supply side Over current Protection e Additional protective equipment such as short circuit protection or motor thermal protection between frequency converter and motor is required for applications with multiple motors e Input fusing is required to provide short circuit and over current
12. IN Stored charge wait 15 min Charge residu lle attendez 15 min Type code 1 2 order number Tans nan SSCS Input voltage frequency and current at lovv high voltages Output voltage frequency and current at low high voltages EE EE o femas 10 Discharge ime Wem Illustration 3 1 Product Nameplate Example MG20MA02 Rev 2013 10 29 VLT AQUA Drive FC 202 Operating Instructions NO TIC Do not remove the nameplate from the frequency converter loss of vvarranty 3 1 2 Storage Ensure that requirements for storage are fulfilled Refer to 8 4 Ambient Conditions for further details 3 2 Installation Environments NOTIC In environments with airborne liquids particles or corrosive gases ensure that the IP Type rating of the equipment matches the installation environment Failure to meet requirements for ambient conditions can reduce lifetime of the frequency converter Ensure that requirements for air humidity temperature and altitude are met Vibration and Shock The frequency converter complies with requirements for units mounted on the walls and floors of production premises as well as in panels bolted to walls or floors For detailed ambient conditions specifications refer to 8 4 Ambient Conditions 3 3 Mounting NOTIC Improper mounting can result in overheating and reduced performance Cooling e Ensure that top and bottom clearance for air cooling is provid
13. Missing or open fuses or circuit See open fuses and tripped circuit breaker Follovv the recommendations provided No power to the LCP Check the LCP cable for proper connection Replace the faulty LCP or connection cable E Wire the terminals properly Shortcut on control voltage Check the 24 V control voltage supply for terminal 12 or 50 or at control terminals 12 13 to 20 39 or 10 V supply for Display terminals terminals 50 to 55 7 Incompatible LCP LCP from Use only LCP 101 P N 130B1124 or LCP y unction 2800 or 5000 6000 8000 102 P N 130B1107 FCD or FCM Wrong contrast setting Press Status 4 to adjust the contrast Display LCP is defective Test using a different LCP Replace the faulty LCP or connection cable Internal voltage supply fault or Contact supplier SMPS is defective Overloaded power supply To rule out a problem in the control wiring If the display stays lit then the problem is e SMPS due to improper control disconnect all control wiring by removing in the control wiring Check the wiring for display wiring or a fault within the the terminal blocks short circuits or incorrect connections If frequency converter the display continues to cut out follow the procedure for display dark Service switch open or missing Check if the motor is connected and the Connect the motor and check the service motor connection connection is not interrupted by a service sw
14. 8 SC 28 52 18 92 08 52 x8 SC 64 92 85 52 96 92 49 92 base 29 92 25 42 15 42 09 92 SST Ly ST 9y sc Sv ST ech Deh Cv SC ei 9 ST 02 52 62 52 82 52 12 62 92 82 42 82 veste 22 92 cc Sc 12 82 02 52 CST MG20MA02 Rev 2013 10 29 68 Index Index A Abbreviations Rete e etas 64 AC Tool mere 6 15 ACTAE OE RETIRER 6 15 MEC a 6 Additional Resources 3 PE Q EE 26 Alarm LOG EE 21 E EE 34 AMAL 26 32 36 39 Ambient Condition 52 Analog ju Le 16 35 52 el ue 16 53 signal 2 35 speed reference YID Cis ana 6 Auto On o e de e RS eerie dee 22 27 32 34 Auto reset A 21 Auxiliary 22 19 Back plate ER rica 10 A naenin Ea 37 32 C Gable routing messan A 19 Lee eu CN 6 Circuit A ebd add 19 ICI ibi 56 Clearance reguirements EEN 9 Closed H E 18 Communication option 38 Led IEA sua s a Saa 19 Control e O UTAD 35 Card performance 55 card 10 V 54 Card 24 V DC 54 card RS 485 serial commupicatton 222 52 card USB serial communication
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16. Before completing installation of the unit inspect the entire installation as detailed in Table 4 4 Check and mark the items when completed Inspect for Description Auxiliary equipment e Look for auxiliary equipment switches disconnects or input fuses circuit breakers that may reside on the input power side of the frequency converter or output side to the motor Ensure that they are ready for full speed operation e Check function and installation of any sensors used for feedback to the frequency converter e Remove any power factor correction caps on motor s e Adjust any power factor correction caps on the mains side and ensure that they are dampened Cable routing e Ensure that motor wiring and control wiring are separated or screened or in 3 separate metallic conduits for high frequency interference isolation Control wiring e Check for broken or damaged wires and loose connections e Check that control wiring is isolated from power and motor wiring for noise immunity e Check the voltage source of the signals if necessary e The use of screened cable or twisted pair is recommended Ensure that the shield is terminated correctly Cooling clearance e Measure that top and bottom clearance is adequate to ensure proper air flow for cooling see 3 3 Mounting Fusing and circuit e Check for proper fusing or circuit breakers breakers e Check that all fuses are inserted firmly and are in operational condition and that all circuit breaker
17. CE ee RA 7 m s gt m s Tu s o A5 1 8 1 8 1 8 8 DR IU NN E 2 Z a E G ca Table 8 12 Tightening of Terminals lM V w dia olu w w ala oje w w A w D For different cable dimensions x y where x lt 95 mm and y 2 95 mm MG20MAO2 Rev 2013 10 29 55 Specifications Dont VLT AQUA Drive FC 202 Operating Instructions 8 8 Fuses and Circuit Breakers Use recommended fuses and or circuit breakers on the supply side as protection in case of component break down inside the frequency converter first fault NOTIC Use of fuses on the supply side is mandatory for IEC 60364 CE and NEC 2009 UL compliant installations Recommendations e Fuses of the type gG e Circuit breakers of Moeller types By use of other circuit breaker types ensure that the energy into the frequency converter is equal to or lower than the energy provided by Moeller types If fuses circuit breakers according to recommendations are chosen possible damages on the frequency converter will mainly be limited to damages inside the unit For further information see Application Note Fuses and Circuit Breakers MN90T The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical depending on the frequency converter voltage rating With the proper fusing the frequency converter Short Circuit Current Rating
18. 1 Press Off to stop the motor before uploading or downloading data 2 Go to Main Menu 0 50 LCP Copy and Press OK 3 Select 1 All to LCP to upload data to LCP or select 2 All from LCP to download data from the LCP 4 Press OK A progress bar shows the uploading or downloading process 5 Press Hand On or Auto On to return to normal operation 22 MG20MA02 Rev 2013 10 29 Commissioning 5 3 5 Changing Parameter Settings Vievv changes Quick Menu Q5 Changes Made lists all parameters changed from default settings e The list shows only parameters vvhich have been changed in the current edit setup e Parameters which have been reset to default values are not listed e The message Empty indicates that no parameters have been changed Changing settings Parameter settings can be accessed and changed from the Quick Menu or from the Main Menu The Quick Menu only gives access to a limited number of parameters 1 Press Quick Menu or Main Menu on the LCP 2 Press 4 v to browse through the parameter groups press OK to select a parameter group 3 Press 4 Y to browse through the parameters press OK to select a parameter 4 Press 4 Y to change the value of a parameter setting 5 Press lt gt to shift digit when a decimal parameter is in the editing state 6 Press OK to accept the change 7 Press either Back twice to enter Status or press
19. ALARM 70 Illegal FC configuration The control card and power card are incompatible Contact the supplier with the type code of the unit from the nameplate and the part numbers of the cards to check compatibility ALARM 71 PTC 1 safe stop Safe Stop has been activated from the MCB 112 PTC Thermistor Card motor too warm Normal operation can be resumed when the MCB 112 applies 24 V DC to T37 again when the motor temperature reaches an acceptable level and when the Digital Input from the MCB 112 is deactivated When that happens a reset signal must be is be sent via Bus Digital I O or by pressing Reset NOTIC If automatic restart is enabled the motor may start when the fault is cleared ALARM 72 Dangerous failure Safe Stop with Trip Lock Unexpected signal levels on safe stop and digital input from the MCB 112 PTC thermistor card WARNING 73 Safe Stop auto restart Safe stopped With automatic restart enabled the motor may start when the fault is cleared WARNING 76 Power unit setup The required number of power units does not match the detected number of active power units Troubleshooting When replacing an F frame module this occurs if the power specific data in the module power card does not match the rest of the frequency converter Confirm the spare part and its power card are the correct part number WARNING 77 Reduced power mode This warning indicates that the frequency converter is operating in re
20. KLSR fuses from Littel fuse may substitute KLNR fuses for 240 V frequency converters A6KR fuses from Ferraz Shawmut may substitute A2KR for 240 V frequency converters MG20MAO2 Rev 2013 10 29 59 Specifications VLT AQUA Drive FC 202 Operating Instructions 3x200 240 V Recommended max fuse Power kW Bussmann Bussmann Bussmann Bussmann Bussmann un ma xo o 1 4 15 KTN R 80 JKS 80 JJN 80 a ewro s a x mung ex uno o a xm Xm mz Table 8 19 3x200 240 V Enclosure Types A B and C Recommended max fuse Power SIBA Littel fuse Ferraz Ferraz Bussmann Littel fuse Ferraz Ferraz kW Type RK1 Type RK1 Shawmut Shawmut Type FHR2 JFHR2 Shawmut Shawmut Type CC Type RK1 JFHR2 0 25 0 37 5017906 005 KLN R 05 ATM R 05 A2K 05 R FX5 Hs 0 55 1 1 5017906 010 KLN R 10 ATM R 10 A2K 10 R FWX 10 HSJ 10 1 5 5017906 016 KLN R 15 ATM R 15 A2K 15 R FWX 15 S HSJ 15 2 2 5017906 020 KLN R 20 ATM R 20 A2K 20 R FWX 20 HSJ 25 45 2028220 250 KLN R 250 A2K 250 R FWX 250 L25S 250 A25X 250 HSJ 250 Table 8 20 3x200 240 V Enclosure Types A B and C 1 KTS fuses from Bussmann may substitute KTN for 240 V frequency converters 2 FWH fuses from Bussmann may substitute FWX for 240 V frequency converters 3 A6KR fuses from Ferraz Shawmut may substitute A2KR for 240 V frequency converters 4 A50X fuses from Fer
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22. Continuous 200 240 VA s 7s we 32s 367 22 a 594 Ts termine 3200240 V A Continuous KVA 208 V AC S A PER ES DS E RE EE Max input current Continuous 1200 240 IN intermittent 1x200 240 Y A Additional specifications Estimated power loss at rated max load W nu Lu E Max cable size mains motor brake mm AWG 2 Table 8 1 Mains Supply 1x200 240 V AC Normal Overload 110 for 1 Minute P1K1 P22K 8 1 2 Mains Supply 3x200 240 V AC Type Designation PK25 PK37 PK55 PK75 P1K1 P1K5 P2K2 P3KO P3K7 Typical Shaft Output HP at 208 V oss IP21 Type 1 ee a IP55 Type 12 ran E Output current Continuous 3200 240 V TAJ va 24 Tas Tas 66 75 es vs ur intermittent 3x200 240 V A Continuous KVA 208 V AC kVA oss oss 126 166 238 270 saz aso 600 Max input current Continuous 3x200 240 V A is T 32 a so 68 95 m lim intermittent 34200 240 V A Additional Specifications Estimated power loss at rated max load W Max cable size mains motor brake mm AWG 2 0 2 4 4 10 Efficiency 094 094 oss 095 096 05 05 096 096 Table 8 2 Mains Supply 3x200 240 V AC Normal overload 11096 for 1 minute PK25 P3K7 Mo O MGOMO Reva Specifications Dont VLT AQUA Drive FC 202 Operating Instructions Type Designation Typical Shaft Output kW Typical Shaft Output HP at 208 V P5K5 P7K5 P11K P15K P18K
23. DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 AOUT 42 COM 39 A A53 130BB683 10 Parameters 6 10 Terminal 53 10 07 V Low Voltage 6 11 Terminal 53 110 V High Voltage 6 14 Terminal 53 0 Hz Lovv Ref Feedb Value 6 15 Terminal 53 1500 Hz High Ref Feedb Value Notes comments Default Value D IN 37 is an option Table 6 6 Speed Reference Using a Manual Potentiometer 6 1 3 Run Stop 24 V 12 24 V 13 DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 A OUT 42 COM 39 30BB680 10 Parameters 5 10 Terminal 18 8 Start Digital Input 5 12 Terminal 27 7 External Digital Input Interlock Default Value Notes comments D IN 37 is an option Table 6 7 Run Stop Command with External Interlock MG20MAQ02 Rev 2013 10 29 29 Application Set up Examples VLT AQUA Drive FC 202 Operating Instructions Parameters 6 1 4 External Alarm Reset S Funcion Setting 1244 12 001 5 10 Terminal 18 8 Start Parameters sal DIN 1890 s 12 Terminal 27 7 External 5 11 Terminal 19 1 Reset DIN 19 Digital Input Interlock E Digital Input COM 20 Default Value mu Default Value PIN cl Notes comments Notes comments i If 5 12 Terminal 27 Digital Input D IN 37 is an option is set to 0 No operation a DIN 33
24. Motor Data and 1 4 are active The necessary data can be found on the motor nameplate and in the motor data sheet Program the following parameters in the listed order 1 24 Motor Current 2 1 26 Motor Cont Rated Torque 3 1 25 Motor Nominal Speed 4 1 39 Motor Poles 5 1 30 Stator Resistance Rs Enter line to common stator vvinding resistance Rs If only line line data are available divide the line line value vvith 2 to achieve the line to common starpoint value 6 1 37 d axis Inductance Ld Enter line to common direct axis inductance of the PM motor If only line line data are available divide the line line value with 2 to achieve the line common starpoint value 7 1 40 Back EMF at 1000 RPM Enter line to line back EMF of PM Motor at 1000 RPM mechanical speed RMS value Back EMF is the voltage generated by a PM motor when no drive is connected and the shaft is turned externally Back EMF is normally specified for nominal motor speed or for 1000 RPM measured between 2 lines If the value is not available for a motor speed of 1000 RPM calculate the correct value as follows If back EMF is e g 320 V at 1800 RPM it can be calculated at 1000 RPM as follows Back EMF Voltage RPM 1000 320 1800 1000 178 This is the value that must be programmed for 1 40 Back EMF at 1000 RPM Dont VLT AQUA Drive FC 202 Operating Instructions Test Motor Operation 1 Start the motor at low speed 100 to 2
25. R 82 Brake 15mA 130 200 mA A resistor 50 10 V OUT A 10V DC e 1 R 81 A53 0 10V DC TT 53 A IN o 10V DC WI z ON 0 4 20 mA relay1 e 0 4 20 mA A54 OFF 0 10 V DC 03 0 10V DC F 854 AIN WI 9 10V DC 3 240V AC 2A 10V DC 1 0 4 20 mA m 7 55 COM A IN oy po X relay2 12 24 V OUT 067 d E L 240V AG 2A T T 13 24 V OUT 3 05 SS 400V AC 2A 24 T T 18 DIN 0 V PNP 2 24 V NPN 19 DIN OV PNP J COMA OUT 39 77 Analog Output L A OUT Qi 04 20 mA 1 20 COMDIN vE 27 DIN OUT 2007 S801 F 24 OV PNP Gu ON Terminated wll Z OFF Open ov SV 29 DIN OUT La gt ETT 0V PNP J i S801 ov 10M AA LEA RS 485 A l N RS 485 69 R 485 24V NPN Interface SS i Y 32 DIN DV PNP P RS 485 68 24 V NPN 33 DIN OV PNP COM RS 485 61 1757 Chassis T 37 DIN nu UE Illustration 4 1 Basic Wiring Schematic A Analog D Digital Terminal 37 optional is used for Safe Torque Off For Safe Torque Off installation instructions refer to the Safe Torque Off Operating Instructions for Danfoss VLT Frequency Converters Do not connect cable screen 12 MG20MA02 Rev 2013 10 29 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 130BD529 10
26. be increased 1 66 Min Current at Low Speed should be increased gt 100 for a prolonged time can overheat the motor Table 5 7 Recommendations in Different Applications If the motor starts oscillating at a certain speed increase 1 14 Damping Gain Increase the value in small steps Depending on the motor a good value for this parameter can be 10 or 100 higher than the default value Starting torque can be adjusted in 1 66 Min Current at Low Speed 100 provides nominal torque as starting torque MG20MAO2 Rev 2013 10 29 25 Commissioning 5 4 5 Automatic Energy Optimisation AEO NOTIC AEO is not relevant for PM motors Automatic Energy Optimisation AEO is recommended for e Automatic compensation for oversized motors e Automatic compensation for slow system load change e Automatic compensation for seasonal changes e Automatic compensation for low motor loading e Reduced energy consumption e Reduced motor heating e Reduced motor noise To activate AEO set parameter 1 03 Torque Characteristics to 2 Auto Energy Optim CT or 3 Auto Energy Optim VT 5 4 6 Automatic Motor Adaptation AMA NOTIC AMA is not relevant for PM motors Automatic motor adaptation AMA is a procedure that optimises compatibility between the frequency converter and the motor e The frequency converter builds a mathematical model of the motor for regulating output motor current The procedure also tests the input p
27. g e1oulay sinoH Bujuuny ssed g pom snieis ssed g uoneAnoy epo 1591 Aejag au dil ssed g Aejaq au 31815 ssed g apow ssed g uondo ssed g wyo 10151599 21819 D Aujiquedwo gt s31n e94 eDads emu Ann suo yw Dia Jamod uo Dead dH 42Mod peeds MA samog p ds ZH p ds ubiH Ly SE 9v SE SvV SE OSCH Ev SE Cat si S LE SE 9E SE SE SE ve se xE SE 12 66 92 98 42 56 La X S 11 66 91 66 91 56 VL SE l SE 90 SE 40 52 vO SE 0 SE 20 56 10 56 00 52 40 46 61 16 LL LE OL LE 60 16 20 12 LO LE 00 12 18 06 8 06 6 26 62 ct 6c LE 67 06 62 62 62 Wdy p ds dH 4amog p ds o1 MA J2MOd paads MOT ZH p ds moq Wd p ds moq Aejaq Jamod esq J032e4 4 5es q dH je Mog M JaMog Heq Bulun 1amog besaq Aejag HO ZH p ds Wdy p ds Dead au ung do3s mexs 1e Dead sep Besag uon unj 5ul55es q JWI lqesiq MO 4 ON qulodjes ajey Id did SWI IIIJ edid ZH p ds wm edid Wdu peeds ili adig ajqeua II edid Wd did suonouny uonge gt i ddy 1391eM uiq 1ndino Aejay epe se uiq indino Aejay apedse gt padueapy sn3e3S waysks apedse gt smeis uondo ape gt se wede 2101 JO 96 92U9 9Joy ope se s nopeay Aejay suo p3uuo indy esi5iq 1 99X eus in
28. q N 619 EEE EEE ese eee SEE OLE 062 0 2 02 806 02 806 e 0L 80 O T 169 125 008 oto s sseu sissey 0c ue 210 duz 19 LLO 119 LL C9 428 08 08 08 2 ww sajoy maids MEN es 069 619 619 CL 619 aa to oe oe uiu 01060 ve Toz Tox Ton o o Pe Peru e mi EELER uondo OLE 80 LEC 491 cre cre uondo OLE 80 LEZ 402 cre cre 2 UO YUM ajejd peq jo YIPIM we w wc s mc O sre pe jo EN uu pu sr ws sw w v w or tor ose cee ose 22 s s Sunnou s m n souris s lqe snapjatd 464 61 KA vLE 103 ajejd BuijdnoD ap yum 3ubl H ww 3ubl H Xv ZL L SCT Xb 21 1 dAL L ed sisseyd ed sisseyd VININ 99 SS 1Z LZ 02 LZ 02 d 99 6S 1Z LL A 069 SCSX 21 1 Xv 21 L sIsseyo sisseu ad L ad L G 75 0c 0c 99 SS LZ 99 45 12 SS LE 1222 S 8L LL S 8L LL SCSC0 SZ SL0 A 009 SZSXE SS LE 1222 S8L LL S 8L LL SELEO 0 v 0 EA 07 6 0 A 08t 08 X 81 5 sz 7 Ov UL A 08b 08 XL 0 s 8l S 8L SL LL S S LE STO SCO0 LE 0 SC O A 0Tc 00 X SL 5 SS LESL UL Cell S 5 A OvC 00CXL MA ad AL a nsopug 8 9 Power Ratings Weight and D 63 MG20MAO2 Rev 2013 10 29 Appendix VLT AQUA Drive FC 202 Operating Instructions 9 Appendix 9 1 Symbols Abbreviations and Conventions Tum Torque Limit VLT MAX The Maximum Outpu
29. ung unululW ZZ ZZ SULIS Uaawia 9 22 uon2eiojg l 42 MOUS SL ZZ u0on2eioJd aA HOUS yL ZZ el q 199 UMoIg 29 22 jeg uexyojg 19 22 uonbounj 4198 USO 09 22 uon eijeq 199 u yolq x9 ZZ Aejaqg ann JO Du IS ZZ UO DUNJ eAJn JO pu3 0s cc BAIN JO pu3 s cc sul 15009 WINWIXEIN 9 22 15009 1ulodies 22 g4 9 M dn ayem vr cc ZH p ds dn ayem 22 Wdy p ds dn ayem 27 22 eui dee s unullulW 17 22 eui ung WNWIUIW 22 PON d ls b ZZ dH p ds 4 1 66 22 MA p ds UD 82 22 ZH p ds 2 22 Wdu p ds 96 22 dH paade SE ZZ MJ J2MOd peeds MOT pe zz ZH peeds moq 69 22 Wdu p ds moq 22 22 1024 40 2 4 19 22 J2MOd MO J ON 02 22 Bulun J2MOd MOH ON EE ZH p dS MOT MOJ4 ON 62 22 Wdu paads MOT MOJ4 ON 82 22 Kejaq dung Mg 2 22 uon unj dwng Ad 92 22 Age MO 4 ON FE uon unj MOl ON 22 22 uon q p ds MoT 22 22 uon q JIMOJ MO 12 22 dn jes oiny JeMod MOT 02 22 uon q MO J 0N Aejaq opeiu jeux 00 22 sno up l siyy 20 22 suon unu4 id Vur 120 HO XI 79 17 SU 3X3 29 12 eun 3x3 29 12 uep jeuonjodoJg 3X3 19 12 04100 3X3 09 12 014 15 3X3 49 12 1961 and no 3 62 12 un eqpee4 XI 85 12 Wun adualajay
30. 14 Wiring Schematic 12 MG20MA02 Rev 2013 10 29 71 www danfoss com drives Danfoss Power Electronics A S Ulsnaes 1 6300 Graasten Denmark www danfoss com Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 130R0336 MG20MA02 DTE n Tl E M G2 8 M A 8 2
31. 54 0 07 V Gene 6 21 Terminal 54 10 V Epos 6 24 Terminal 54 0 Lovv Ref Feedb Value 6 25 Terminal 54 150 High Ref Feedb Value Default Value Notes comments D IN 37 is an option Table 6 3 Analog Voltage Feedback Transducer 4 wire 28 MG20MA02 Rev 2013 10 29 Application Set up Examples 6 1 2 Speed VLT AQUA Drive FC 202 Operating Instructions i P 6 10 24V 12 Q a 424V 13 o DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 A OUT s 10 10V COM 39 E A53 Parameters 6 10 Terminal 53 0 07 V 1 77 6 11 Terminal 53 10 v 77 6 14 Terminal 53 Low Ref Feedb Value 6 15 Terminal 53 50 Hz High Ref Feedb Value Default Value Notes comments D IN 37 is an option 2 N 24 V 12 a ES 424V 13 S e D IN 18 i DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 546 COM 55 A OUT 1 m 4 20mA COM 39 U I A A53 Parameters Funcion seming 6 12 Terminal 53 4 mA 6 13 Terminal 53 20 mA Bra 6 14 Terminal 53 10 Hz Lovv Ref Feedb Value 6 15 Terminal 53 150 Hz High Ref Feedb Value Default Value Notes comments D IN 37 is an option Table 6 5 Analog Speed Reference Current 24V 12 24V 13 DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32
32. 8 2 Mains Supply Mains supply L1 L2 L3 Supply voltage 200 240 V 10 Mains voltage low mains drop out During low mains voltage or a mains drop out the frequency converter continues until the intermediate circuit voltage drops below the minimum stop level which corresponds typically to 15 below the lowest rated supply voltage of the frequency converter Power up and full torque cannot be expected at mains voltage lower than 10 below the lowest rated supply voltage of the frequency converter Supply frequency 50 60 Hz 4 6 The frequency converter power supply is tested in accordance with IEC61000 4 28 50 Hz 4 6 Max imbalance temporary between mains phases 3 0 of rated supply voltage 1 The unit is suitable for use on a circuit capable of delivering not more than 100 000 RMS symmetrical Amperes 240 480 600 690 V maximum 8 3 Motor Output and Motor Data Motor output U V W Output voltage 0 10006 of supply voltage Dependent on power size Torque characteristics Starting torque Constant torque maximum 11096 for 1 min Starting torque maximum 135 up to 0 5 5 Overload torque Constant torque maximum 11096 for 1 min Percentage relates to the nominal torque of the frequency converter MG20MAQ02 Rev 2013 10 29 51 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 4 Ambient Conditions Environment Enclosure type A IP20 Chassis I
33. EU The following limitations apply Units with an input current below 16 A and an input power above 1 kW are only intended for professional use in trades professions or industries and not for sale to the general public Designated application areas are public pools public water supplies agriculture commercial buildings and industries All other single phase units are only intended for use in private low voltage systems interfacing with public supply only at a medium or high voltage level Operators of private systems must ensure that the EMC environment complies with IEC 610000 3 6 and or the contractual agreements NOTIC 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 frequency converter in applications which are non compliant with specified operating conditions and environments Ensure compliance with the conditions specified in 8 Specifications MG20MA02 Rev 2013 10 29 3 7 ntroduction VLT AQUA Drive FC 202 Operating Instructions 1 4 2 Features The VLT AQUA Drive FC 202 is designed for water and wastewater applications The range of standard and optional features includes Cascade control Dry run detection End of curve detection Motor alternation Deragging 2 step ramps e Check valve protection Safe Torque Off Low flow detection Pipe fill mode Sleep mode Real t
34. Phases 5 4 2 Commissioning via Main Menu Recommended parameter settings are intended for start 1 Basic Programming Program e g motor data Select and program Go to water and pump 3 Water and Pump Features dedicated parameters up and checkout purposes Application settings may vary Enter data with power ON but before operating the frequency converter 1 Press Main Menu on the LCP 2 Press the navigation keys to scroll to parameter group 0 Operation Display and press OK K 1107 RPM 3 84A 1 1 Main menu 0 x Operation Display 1 x Load Motor 2 xx Brakes 3 xx Reference Ramps Illustration 5 2 Main Menu 3 Press navigation keys to scroll to parameter group 0 0 Basic Settings and press OK 0 0 0 00A 1 10 05 Basic Settings 0 15 Set up Operations o 0 2 LCP Display 0 3 LCP Custom Readout Illustration 5 3 Operation Display 4 Press navigation keys to scroll to 0 03 Regional Settings and press OK 130BP066 10 130BP087 10 VLT AQUA Drive FC 202 Operating Instructions SEN o 0 0 0 00A Ms g l 8 a 0 03 Regional Settings m 0 International v Illustration 5 4 Basic Settings 5 Press navigation keys to select 0 International or 1 North America as appropriate and press OK This changes the default settings for
35. SCCR is 100 000 Arms 8 8 1 CE Compliance 200 240 V Enclosure Power kW Recommended Recommended Recommended circuit Max trip level A fuse size max fuse breaker Moeller o A2 0 25 2 2 A3 3 0 3 7 A4 0 25 2 2 A5 0 25 3 7 gG 10 0 25 1 Ex gG 16 2 TLE gG 20 3 gG 10 0 25 1 is gG 16 2 gG 10 0 25 1 E gG 16 2 2 3 2 7 E E eman o B4 ZMB1 A100 100 gG 50 1 3 C1 gG 63 15 gG 160 15 18 5 ZMB2 A200 160 gG 80 18 5 aR 160 22 C2 aR 160 30 aR 200 30 ZMB2 A250 250 C3 gG 80 18 5 gG 150 18 5 ZMB2 A200 150 aR 125 22 aR 160 22 C4 aR 160 30 aR 200 30 ZMB2 A250 250 aR 200 37 Table 8 13 200 240 V Enclosure Types A B and C 56 aR 250 37 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions 380 480 V Enclosure Power kW Recommended Recommended Recommended circuit Max trip level A fuse size max fuse breaker Moeller A2 1 1 4 0 gG 10 0 37 3 gG 25 PKZMO 25 25 gG 16 4 A4 1 1 4 0 gG 10 0 37 3 gG 32 PKZMO 25 25 A5 1 1 7 5 gG 10 0 37 3 gG 32 PKZMO 25 B2 22 30 gG 50 18 5 gG 100 ZMB1 A100 gG 63 22 B3 11 18 gG 40 gG 63 PKZM4 50 B4 22 37 gG 50 18 5 gG 125 ZMB1 A100 gG 63 22 gG 80 30 C1 37 55 9G 80 30 ZMB2 A200 gG 100 37 gG 160 45 C2 75 90 aR 200 55 aR 250 NZMB2 A250 NINE 19 m C3 45 55 gG 150 37 ZMB2 A200 C4 75 90 aR 250 Table 8 14 380 480 V Enclosure Types A B and C
36. TN h s eC GC Illustration 7 3 Status Indicator Lights 130BB467 10 Warn Warning LED Alarm LED On ashing Table 7 4 Status Indicator Lights Explanations 7 4 List of Warnings and Alarms The warning alarm information below defines each warning 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 below 10 V from terminal 50 Remove some of the load from terminal 50 as the 10 V supply is overloaded Max 15 mA or minimum 590 O This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the customer 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 by the user in 6 01 Live Zero Timeout Function The signal on one of the analog inputs is less than 5096 of the minimum value programmed for that input Broken wiring or faulty device sending the signal can cause this condition Troubleshooting e Check connections on all the analog input terminals Control card terminals 53 and 54 for signals terminal 55 common MCB 101 terminals 11 and 12 for signals terminal 10 common MCB Darfi VLT AQUA Drive FC 202 Operating Instructio
37. XJ ZS 1Z yujodyas 3X3 GS 17 92Jnos peqpeej 3X3 pS LT 92JnOS u l l q 1X3 ES LZ 92u28J9jay WNWIXBN 3X3 20 12 92ueJ9jeg uinullulW 3X3 16 12 n n XI 4 12 PA h r led HO c 3X3 Sul c 3X3 aLL cx uleg jeuonjodoJg Z XI 1011002 Z 17 did Z 12 Pa 96 NANO Z x3 Mun xpeqpeej z 3x3 fun C 1X3 qulodyas z 1x3 adINOS yDeqpae4 z 1x3 92Jnog adU9lojoy C KZ VUNWIXEIA z 3x3 92U3J9Jey WINWIUI c 3X3 n n peqpee jed c X3 qa y u Z 12 PAI Mur 129 HO L 3X3 sul uoneyusJSgiq L 3X3 eui je16e3u 3x3 uleg jeuonjodoJg XI 1012002 SH AU IEUHON 3X3 014 L D a 96 ndino L 3x3 Brun peqpasy 3x3 UN XI 3 lod s 3x3 92Jnos y eqp q 1X3 DINOS eouailsjay 3X3 WNUWIXEIN x4 WINWIUIW XI n n y eqp q g XI 0469 L 12 3X3 Bulun oiny did A T eqpeeJ unuuixelw 9537 y eqp z uunulluliy buey indino did BDURWUOLAd Ald ed doo peso 5 15 3x3 doo7 paso 1x3 h rr ued HQ did eui uonenualSyld Ald eui 2169141 Ald uleg jeuonJodoJd Ald dnpuim nuy did J9 043u0 did uipiMpueg aduaJajoy UO ZH p ds ueis did Wdu peeds ueis did 031005 3SI3AU JPUJON Cid s um3 s iseg Ald buiumoiny did
38. a number of basic parameters 6 Press Main Menu on the LCP 7 Press the navigation keys to scroll to 0 01 Language 8 Select language and press OK 9 If a jumper wire is in place between control terminals 12 and 27 leave 5 12 Terminal 27 Digital Input at factory default Otherwise select No Operation in 5 12 Terminal 27 Digital Input For frequency converters with an optional bypass no jumper wire is required between control terminals 12 and 27 10 3 02 Minimum Reference 11 3 03 Maximum Reference 12 3 41 Ramp 1 Ramp Up Time 13 3 42 Ramp 1 Ramp Down Time 14 3 13 Reference Site Linked to Hand Auto Local Remote 5 4 3 Asynchronous Motor Setup Enter the motor data in parameter 7 20 Motor Power kW or 1 21 Motor Power HP to 1 25 Motor Nominal Speed The information can be found on the motor nameplate 1 1 20 Motor Power kW or 1 21 Motor Power HP 1 22 Motor Voltage 1 23 Motor Frequency 1 24 Motor Current R 1 25 Motor Nominal Speed 24 MG20MA02 Rev 2013 10 29 Commissioning 5 4 4 PM Motor Setup in VVCPlus NOTIC Only use permanent magnet PM motor with fans and pumps Initial Programming Steps 1 Activate PM motor operation 1 10 Motor Construction select 1 PM non salient SPM 2 Set 0 02 Motor Speed Unit to 0 RPM Programming motor data After selecting PM motor in 1 70 Motor Construction the PM motor related parameters in parameter groups 1 2 Motor Data 1 3 Adv
39. ajeq 507 wiely au Do wiely enjeA 507 wiely 9po 10413 607 uue v 507 uue y euin pue 3189 Dot 2110351 WI 607 2110351 ANJLA Do 2uoisiH quanq 607 DUOJSIH 607 2103SIH a10j9g sajdues poyy buibbo7 quanq 196611 6ui6601 sonos 5ul55o7 s5um s 607 eea SURIS JO JequinN d yuno sinoH Buluuny jasay J3JUNO YM 1959Y SOA s dui3 s dq Jamod J31UNO YMA sinoH Buluuny sinoy Sunes do eyeq 5unes do uonpulo ul DALIC 9497 yney s5um s yney 2 Aq payddns uondo VLT AQUA Drive FC 202 Operating Instructions Appendix Vie 6 91 CLS LZ S 0 51 9 S 79 S LO SL 09 S x9 SL 69 41 ess LS S OS SL 6b S Gei 17 51 9v S Si S 1 trs cvs 17 61 Ot S b SL LESL 9 S SE S vesl EE S ces LE SL We GH 6291 ccs LZ S 0251 xC Sl vus EL SL cs Ll S OL SL L SL 80 S 0 SL 90 S S0 S vO SL D c0 S LO SL 00 S x0 SL 06 7 6 bL 08 71 suondo UND e1ejeg pEoH AQ AUl PpEOH AQ 4 H AUl 3e UOI DUNY 1e uon unj es q oy SUUN JO JIGUINN jenpy 19114 indino JOHUO A 01340 ue4 uoljesuadwo gt yur 20 19414 148 jueuiuoJAu3 1udso 101014 fouenbaJ4 OJy uonesn u5eyy WNWIUIW LA Buisiundo SUI 493 1410 Ur lin au uonej6a1u 142 uir JUaND uep jeuonJodoJg 419 Ur Juan 139 HU
40. allowed 1317 Option SW in slot CO is not supported not allowed 1318 Option SW in slot C1 is not supported not allowed 1379 Option A did not respond when calculating platform version 1380 Option B did not respond when calculating platform version 1381 Option CO did not respond when calculating platform version 1382 Option C1 did not respond when calculating platform version 1536 An exception in the application oriented control is registered Debug information written in LCP 1792 DSP watchdog is active Debugging of power part data motor oriented control data not transferred correctly 2064 2072 HO81x option in slot x has restarted 2080 2088 HO82x option in slot x has issued a powerup wait 2096 2104 H983x option in slot x has issued a legal powerup wait 2304 Could not read any data from power EEPROM 38 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an No Text 2324 Povver card configuration is determined to be 2325 A power card has stopped communicating while 2326 Power card configuration is determined to be incorrect after the delay for power cards to register 2327 Too many power card locations have been 2330 Power size information between the power cards does not match 2562 No communication from ATACD to DSP state running 2822 USB port overflow 5123 Option in slot A Hardware incompatible with control board hardware 5124 Option i
41. covers Torques Enclosure IP55 IP66 No screws to tighten for A2 A3 B3 B4 C3 C4 Table 4 2 Tightening Torques for Covers Nm 14 MG20MA02 Rev 2013 10 29 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 7 AC Mains Connection 130BD531 10 e Size vviring based upon the input current of the frequency converter For maximum vvire sizes see 8 1 Electrical Data e Comply with local and national electrical codes for cable sizes Procedure 1 Connect 3 phase AC input power wiring to terminals L1 L2 and L3 see Illustration 4 6 2 Depending on the configuration of the equipment input power is connected to the mains input terminals or the input disconnect 3 Ground the cable in accordance with grounding instructions provided in 4 3 Grounding 4 When supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded leg grounded delta ensure that 14 50 RFI Filter is set to OFF to avoid damage to the intermediate circuit and to reduce earth capacity currents in accordance with IEC 61800 3 Illustration 4 5 Motor Connection Illustration 4 6 represents mains input motor and earth grounding for basic frequency converters Actual configu 4 8 Control Wiring rations vary with unit types and optional equipment e solate control vviring from high power components in the frequency converter e When the frequency converter is connected to a
42. in operational readiness when the frequency converter is connected to AC mains 1 Confirm that the input voltage is balanced vvithin 306 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 Panel doors must be closed or cover mounted 4 Apply power to the unit DO NOT start the frequency converter at this time For units with a disconnect switch turn to the ON position to apply power to the frequency converter NO TIC If the status line at the bottom of the LCP reads AUTO REMOTE COASTING or Alarm 60 External Interlock is displayed this indicates that the unit is ready to operate but is missing an input signal on terminal 27 See 4 8 3 Enabling Motor Operation Terminal 27 for details 20 MG20MA02 Rev 2013 10 29 Auto Remote Ramping Commissioning VLT AQUA Drive FC 202 Operating Instructions e ES 5 3 Local Control Panel Operation TX stet fj 8 T799 RPM 7 83 A 364 kVVTT E E 5 3 1 Local Control Panel ge A 0 000 2 WR The local control panel LCP is the combined display and pm keypad on the front of the unit a 1 The LCP has several user functions e Start stop and control speed vvhen in local co
43. installation e Establish electrical contact between cable screen and frequency converter enclosure by using metal cable glands or by using the clamps provided on the equipment see Illustration 4 5 and Illustration 4 6 e Use high strand wire to reduce electrical interference e Do not use pigtalls NO TIC POTENTIAL EQUALISATIONI Risk of electrical interference when the ground potential betvveen the frequency converter and the system is different Install equalising cables betvveen the system components Recommended cable cross section 16 mm MG20MAO2 Rev 2013 10 29 11 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 4 Wiring Schematic X X A Kaka S 91 L1 EN E U 96 l o 57 92 L2 Me r E 2 input 93 L3 4K 4 X W 98 MA I 95 pea AA na tol 44 di PE 99 A 1 Motor E Switch Mode DC bus 1 88 Lal Power Supply N 89 i RE i 10V DC 24V DC ba
44. manual provided with the equipment option 4 8 2 Wiring to Control Terminals Control terminal connectors can be unplugged from the frequency converter for ease of installation as shown in Illustration 4 7 NOTIC Keep control wires as short as possible and separate from high power cables to minimise interference 1 Open the contact by inserting a small screw driver into the slot above the contact and push the screw driver slightly upwards 2 s m ca a Illustration 4 9 Connecting Control Wires 2 Insert the bared control wire into the contact 3 Remove the screw driver to fasten the control wire into the contact 4 Ensure the contact is firmly established and not loose Loose control wiring can be the source of equipment faults or less than optimal operation See 8 5 Cable Specifications for control terminal wiring sizes and 6 Application Set up Examples for typical control wiring connections Darfi VLT AQUA Drive FC 202 Operating Instructions 4 8 3 Enabling Motor Operation Terminal 27 A jumper wire may be required between terminal 12 or 13 and terminal 27 for the frequency converter to operate when using factory default programming values e Digital input terminal 27 is designed to receive an 24 V DC external interlock command In many applications the user wires an external interlock device to terminal 27 e When no interlock device is used wire a jumper between control terminal 12 recomm
45. motor phase connection ie ot ee See 5 5 Checking Motor Rotation Frequency limits set wrong Check output limits in 4 73 Motor Speed Program correct limits High Limit RPM 4 14 Motor Speed High Motor is not hi Limit Hz and 4 19 Max Output Frequency reachin ar sie Reference input signal not Check reference input signal scaling in 6 0 Program correct settings speed scaled correctly Analog I O Mode and parameter group 3 1 References Reference limits in parameter group 3 0 Reference Limit 42 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an Darfi VLT AQUA Drive FC 202 Operating Instructions Symptom Motor speed unstable Motor runs rough Motor will not brake Open power fuses or circuit breaker trip Mains current imbalance greater than 3 Motor current imbalance greater than 3 Frequency converter acceleration problems Frequency converter deceleration problems Acoustic noise or vibration Possible cause Possible incorrect parameter settings Possible over magnetisation Possible incorrect settings in the brake parameters Possible too short ramp down times Phase to phase short Motor overload Loose connections Problem with mains power See Alarm 4 Mains phase loss description Problem with the frequency converter Problem with motor or motor wiring Problem with the frequency converter Motor data are entered incorrectly
46. 00 RPM If the motor does not turn check installation general programming and motor data 2 Check if start function in 1 70 PM Start Mode fits the application requirements Rotor detection This function is the recommended choice for applications where the motor starts from standstill e g pumps or conveyors On some motors an acoustic sound is heard when the impulse is sent out This does not harm the motor 5 Parking This function is the recommended choice Tor applications where the motor is rotating at slow speed eg vvindmilling in fan applications 2 06 Parking Current and 2 07 Parking Time can be adjusted Increase the factory setting of these parameters for applications with high inertia Start the motor at nominal speed If the application does not run well check the VVCPlus PM settings Recommen dations in different applications can be seen in Table 5 7 Application Settings Low inertia applications 1 17 Voltage filter time const to be Load Motor 5 increased by factor 5 to 10 1 14 Damping Gain should be reduced 1 66 Min Current at Low Speed should be reduced lt 100 Keep calculated values 1 14 Damping Gain 1 15 Low Speed Filter Time Const and 1 16 High Low inertia applications 5051Load Motor gt 5 High inertia applications ILoad IMotor gt 50 Speed Filter Time Const should be increased High load at low speed lt 30 rated speed 1 17 Voltage filter time const should
47. 1 3 Frequency Converter Block Diagram Area Title Functions 3 phase AC mains power supply to the frequency converter The rectifier bridge converts the AC input to DC current to supply inverter power Intermediate DC bus circuit handles the DC current Filter the intermediate DC circuit voltage Prove line transient protection Reduce RMS current 4 DC reactors Raise the power factor reflected back to the line Reduce harmonics on the AC input Stores the DC power Provides ride through 5 Capacitor bank protection for short power losses Converts the DC into a controlled PWM AC waveform 6 Inverter for a controlled variable output to the motor VLT AQUA Drive FC 202 Operating Instructions Area Title Functions Input power internal processing output and motor current are monitored to provide efficient operation and control 8 Control circuitry User interface and external commands are monitored and performed Status output and control can be provided Table 1 2 Legend to Illustration 1 3 1 4 5 Enclosure Types and Povver Ratings For enclosure types and povver ratings of the frequency converters refer to 8 9 Povver Ratings VVeight and Dimensions 1 5 Approvals and Certifications O Table 1 3 Approvals and Certifications More approvals and certifications are available Contact local Danfoss partner Frequency converters of enclosure type T7 52
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49. 20 4 0 Efficiency 3 0 96 0 96 0 96 0 96 Table 8 4 Mains Supply 1x380 480 V AC Normal Overload 11096 for 1 Minute P7K5 P37K MG20MAO2 Rev 2013 10 29 45 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 1 4 Mains Supply 3x380 480 V AC Type Designation Typical Shaft Output kW IP20 Chassis 9 IP21 Type 1 IP55 Type 12 IP66 NEMA 4X Output current Continuous 3x380 440 V A Intermittent 3x380 440 V A Continuous 3x441 480 V A Intermittent 3x441 480 V A Continuous kVA 400 V AC kVA Continuous kVA 460 V AC kVA Max input current Continuous 3x380 440 V A Intermittent 3x380 440 V A PK37 PK55 PK75 P1K1 P1K5 P2K2 P3KO P4K0 P5K5 P7K5 Ea os 39 T 5 17 T5 T Pa T l 27 a 08 6a 82 on oss 176 3 30 37 sa 69 90 ws os 13 ow 2 28 a9 so 69 99 To 13 po 24 027 a0 50 es e n5 Continuous 3x441 480 V A Intermittent 3x441 480 V A Max pre fuses A Additional specifications Estimated power loss at rated max load W 2 1 32 1 76 2 42 3 0 Ea 9 9 12 9 1 0 1 4 1 9 2 7 im E 5 7 74 9 9 EM EECH Max cable size mains motor brake mm AWG 2 Efficiency gt 141 10 om ss os os 05 05 05 097 097 09 Table 8 5 Mains Supply 3x380 480 V AC Normal overload 110 for 1 minute PK37 P7K5 MG20MA02 Rev 2013 10 29 46 Specificatio
50. 5 690 V are not certified for UL The frequency converter complies with UL508C thermal memory retention requirements For more information refer to the section Motor Thermal Protection in the Design Guide 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 1 6 Disposal Do not dispose of equipment containing electrical components together with domestic waste Collect it separately in accordance with local and currently valid legislation Table 1 4 Disposal Instruction 6 MG20MA02 Rev 2013 10 29 Safety 2 Safety 2 1 Safety Symbols The follovving symbols are used in this document AWARNING Indicates a potentially hazardous situation which could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which could result in minor or moderate injury It may also be used to alert against unsafe practices NOTIC Indicates important information including situations that may result in damage to equipment or property 2 2 Qualified Personnel Correct and reliable transport storage installation operation and maintenance are required for the trouble free and safe operation of the frequency converter Only qualified personnel is allowed to install or operate this equipment Qualified personnel is defined as trained staff who are authorised
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52. G 66 Heat sink temperature low The frequency converter 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 frequency converter whenever the motor is stopped by setting 2 00 DC Hold Preheat Current at 5 and 1 80 Function at Stop Troubleshooting The heatsink temperature measured as 0 C could indicate that the temperature sensor is defective causing the fan speed to increase to the maximum If the sensor wire between the IGBT and the gate drive card is disconnected this warning would result Also check the IGBT thermal sensor ALARM 67 Option module configuration has changed One or more options have either been added or removed since the last power down Check that the configuration change is intentional and reset the unit ALARM 68 Safe Stop activated Safe stop 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 VLT AQUA Drive FC 202 Operating Instructions Troubleshooting e Check the operation of the door Tans e Check that the filters for the door Tans are not blocked e Check that the gland plate is properly installed on IP21 IP54 NEMA 1 12 frequency converters
53. H cvx WHEL nIPA qpas3 jeu MOT 6 WL abeyon ubiH zyx euro 9beyoA MOT 6 euluma cVX 3ndul bojeuy 7 NT LEY WAL juejsuo SUI 1 WAL YBIH 1 ZPX Wa nIPA QP3994 J98 MOT L ChX WEL ebeyoA YIH L zyx 241 9beyoA MOT ZpX eutuJa LcvXx indu bojeuy S cvx euu 9pow 6 jeuruua SPOW L cvx 2 4 po 0 I Poleuy uondo 0 1 bojeuy uoneujej y enuen y oH lul duing DIAOS SJe1uno Aejay 1959y au NO Aejay awl NO dung sn3e3s Aejay dung pea1 smes dung smes epe se smes Aejaq suleyy uo uny Aejaq dung 3x N ung uoneul liy 1e apoy Buibexs 0S gt peo Ji aiguia1g SWI uoNewayy 9njeA Ju 8143 U aw UONCUIDY quaAq uoneuje1lv uoneul liy dung pea s5um s uoneul iy ZH p ds Buibexsag Wdy p ds Burbexsag ZH p ds Burbexs Wdy peeds Buibeis Buibexsag pjoysa1y 1 Buibeis Aejaq dn due Aejaq umog due s5um3 s buibeis au UONDUNI ebeiseg uon unj abejsag euin uon un4 abeis uonounj 5e3s MO 4 ON IN ebeisag SUL MJO Aejaq buibeisaq Mas Aejaq Buibers MIS yipimpueg paads paxty YIpIMpUeg yipimpueg upes sbunzas yipimpueg 42 92 9 12 92 02 92 C 9 11 92 91 92 51 92 91 92 11 92 01 92 1 97 20 92 10 92 00 92 0 97 L6 SZ 06 52 x6 SC 98 S7 S8 SC v8 sz
54. M quan APO adIAJas 6 ney ye e q d r ywn anbioy ye Aejag d k bunies epooed uonejedo aw 161599 WewWo Ny apow 1959Y suon un4 3esey e2uejequu surrey 18 uon unj y ney suley 18 beyon sue auniey suleyy 3J0 UO suteiy wopuey WMd uoneinpouusAQ Aduanbas4 Buiu iiMs uJayjed BUIYIIMS buius suopuny enads llonuo2 TS JU9AY 19 043u0 TS sajeis ueejoog ajny 21607 Z 10181900 ajny 21601 Z ueajoog e ny 21607 L JoyeJadg any 21607 ueajoog lng 21601 sa ny 21601 d llonu02 TS saaw 9njeA 403545dU402 101861900 Joyesedwo gt puesado Jojesed o gt sJojeJeduwo gt DIS 10599 quanq dote jue 3 Wels s llonuo 1S 8 1 29 1 19 71 09 7 x9 Vl 6S bL ssp S vL 26 71 L ck 09 71 SVL 1 7 1 0T iz ab VL cE vL Le p O pL 6cv 821 9271 Sc 2 1 da il LCP 021 xC VL civ 1 1 OL vL L bL 0 1 20 71 10 71 00 71 40 71 24 61 15 61 SEL Yi l ebel CFE L 17 61 Ov EL b EL 02 21 xC tl TL EL LIEL OL EL 20 21 20 61 10 21 00 21 sbunzas 215 21607 Meus S193uno PIPIN 49 UNOD pH lul buuoulW Hod 193 14 UMOIS 1se peoJjg uon olq UMOIS 3seopeolg u16ue 10413 lqe 4 101 X IAW nsoufeiq lqe SaDdIAJaS 19419413 padueApy 30g Jeuueu 194905 JUaJedsues dLINS
55. MAKING MODERN LIVING POSS BLE Operating nstructions VLT AQUA Drive FC 202 0 25 90 kw www danfoss com driveS AS Contents VLT AQUA Drive FC 202 Operating Instructions Contents 1 ntroduction 3 MG20MA02 Rev 2013 10 29 Contents VLT AQUA Drive FC 202 Operating Instructions 5 4 1 Commissioning with SmartStart 23 2 MG20MA02 Rev 2013 10 29 Introduction 1 Introduction 1 1 Purpose of the Manual These operating instructions provide information for safe installation and commissioning of the frequency converter The operating instructions are intended for use by qualified personnel Read and follow the operating instructions to use the frequency converter safely and professionally and pay particular attention to the safety instructions and general warnings Keep these operating instructions available with the frequency converter at all times 1 2 Additional Resources Other resources are available to understand advanced frequency converter functions and programming The VLT Programming Guide provides greater detail on working with parameters and many application examples The VLT Design Guide provides detailed information about capabilities and functionality to design motor control systems e Instructions for operation with optional equipment Supplementary publications and manuals are available from Danfoss See www danfoss com BusinessAreas DrivesSo lutions Documentatio
56. Main Menu once to enter Main Menu 5 3 6 Restoring Default Settings NO TIC Risk of loosing programming motor data localisation and monitoring records by restoration of default settings To provide a backup upload data to the LCP before initialisation Restoring the default parameter settings is done by initiali sation of the frequency converter Initialisation is carried out through 14 22 Operation Mode recommended or manually e Initialisation using 14 22 Operation Mode does not reset frequency converter settings such as operating hours serial communication selections personal menu settings fault log alarm log and other monitoring functions e Manual initialisation erases all motor programming localisation and monitoring data and restores factory default settings Darfi VLT AQUA Drive FC 202 Operating Instructions Recommended initialisation procedure via 14 22 Operation Mode 1 Press Main Menu twice to access parameters 2 Scroll to 14 22 Operation Mode and press OK 3 Scroll to Initialisation and press OK 4 Remove power to the unit and wait for the display to turn off 5 Apply power to the unit Default parameter settings are restored during start up This may take slightly longer than normal 6 Alarm 80 is displayed 7 Press Reset to return to operation mode Manual initialisation procedure 1 Remove power to the unit and wait for the display to turn off 2 Press
57. Motor data are entered incorrectly Resonances Table 7 6 Troubleshooting Test Check the settings of all motor parameters including all motor compensation settings For closed loop operation check PID settings Check for incorrect motor settings in all motor parameters Check brake parameters Check ramp time settings Solution 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 group 2 0 DC Brake and 3 0 Reference Limits Motor or panel has a short phase to phase Eliminate any short circuits detected Check motor and panel phase for shorts Motor is overloaded for the application Perform startup test and verify motor current is within specifications If motor current is exceeding nameplate full load current motor may run only with reduced load Review the specifications for the application Perform pre startup check for loose Tighten loose connections connections Rotate input power leads into the C C to A Rotate input power leads into the C C to A Rotate output motor leads 1 position U to V V to W W to U Rotate output motor leads 1 position U to V V to W W to U If warnings or alarms occur see 7 4 List of Warnings and Alarms Check that motor data are ent
58. O SL d21 uo y Dasaul 9 1 421 uo y uo ony 07 1 421 uo Aay YO 6 d21 uo y uo pueH Le L ped y 421 9 I Goal Kejdsiq BEY Z 3x l eldsiq ve l at Aejdsiq 461 n PA XBW NOpeay ulo sn LE anjeA ui 3nopp q WOISN 0 L yun yNopesy uoisn L ynopesy wojsnd 421 6c NUA jeuosJed W 821 96187 aur Aejdsiq OCL 36187 Z aur Kejdsiq ST pews CL eur Kejdsig FCL ews CL eur ejdsig EZ L pews UL eur Zeldsiq cc 4510 427 121 JauueyD sdn 3es 3nopeey 02 1 sdn 3 s pexur INOpeay xC l o p yur dn ies 511 111 dn 195 9L L dn jas AH V SL L suones do dn jas vul HUT Spo 15201 L L dn s2Mog 1e 93835 Dungiado OL L sbumas jeuolbay DM yun p ds 1070W 90 L abenbue7 0 L s5um3 s iseg p ds q uoneJado 65 MG20MAQ02 Rev 2013 10 29 03 02 10 S ul uondo UO S A MS uondo g 1015 g 1015 ul uondo UOISJ9A MS uondo Y 1015 Y 105 ur uondo ON Jeues uondo ON Bunapio uodo 015 MS uondo pajunoy uondo uondo weu 4 AISD JequinwN Jelss DIE s Mod Jequinw elas 19312Au00 Aduanbal4 DIS 19Mod d MS pe 1onuo q MS ON PI 421 ON SuL p O DIE Jamod ON BUNSPIO 1919AUO Buys epooed jeni y Bulls po d4I pasapio UOISJ9A 9JeM3jOS abeyjon uon ass J9MOd ed 54 uone ynuep HUN MID sse oJg 607 uue v puewag quan 607 wiely 607 uue v quiodyas 607 wiely au pue
59. P21 Type 1 IP55 Type 12 IP66 Type 4X Derating for high ambient temperature see section on special conditions in the Design Guide Minimum ambient temperature during full scale operation 0 C Derating for high altitude see section on special conditions in the Design Guide EMC standards Emission EN 61800 3 See section on special conditions in the Design Guide 8 5 Cable Specifications Cable lengths and cross sections for control cables Max motor cable length screened armoured 150 m For power cables see electrical data tables in 8 1 Electrical Data See electrical data tables in 8 1 Electrical Data for more information 8 6 Control Input Output and Control Data Control card RS 485 serial communication Terminal number 68 P TX RX 69 N TX RX The RS 485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage PELV Analog inputs Number OF analog inputs 2 Terminal Ri a a a a a a a aa Modes Voltage or current 52 MG20MA02 Rev 2013 10 29 Darfi Specifications VLT AQUA Drive FC 202 Operating Instructions Mode select Switch S201 and switch S202 SE Input resistance Ri approx 10 kQ Max voltage 20 V ed Current level a 4 10 20 MA scaleable Input resistance R approx 200 2 Accuracy of analog 5 Ma error 0 5 of full scale
60. P22K P30K P37K P45K Pies zl IP20 Chassis 2 IP21 Type 1 IP55 Type 12 IP66 NEMA 4X Output current Continuous 3x200 240 V A Intermittent 3x200 240 V A Continuous kVA 208 V AC kVA Max input current Continuous 3x200 240 V A Intermittent 3x200 240 V A Max pre fuses A Additional Specifications Estimated power loss at rated max load W 2 Max cable size mains motor brake mm AWG 2 Efficiency gt E 7 5 10 15 20 25 30 40 50 60 e fe Je so vs m 2 ww am weg 1501 1 0 4 0 MCM os 05 os ow es 057 097 097 ow 10 7 35 2 Table 8 3 Mains Supply 3x200 240 V AC Normal overload 11096 for 1 minute P5K5 P45K 8 1 3 Mains Supply 1x380 480 V AC Type Designation Typical Shaft Output kW Typical Shaft Output HP at 240 V P7K5 P11K P18K P37K Output current Continuous 3x380 440 V fAI ntermittent 3x380 440 V A Continuous 3x441 480 V A ntermittent 3x441 480 V A Continuous kVA 400 V AC kVA Continuous kVA 460 V AC kVA Max input current Continuous 1x380 440 V A Intermittent 1x380 440 V A Continuous 1x441 480 V A Intermittent 1x441 480 V A Max pre fuses A Additional specifications P55 Type 12 B1 B2 C1 C2 P66 NEMA 4X B1 B2 C1 C2 Estimated power loss at rated max load W 300 440 740 Max cable size mains motor brake mm AWG 2 10 7 35 2 50 1 0 1
61. R 20 CC 20 0 KLN R20 ATM R20 A2K 20R HSJ20 2 S Er A2K 35R HSJ35 FWX 50 KTN R50 JKS 50 FWX 60 KTN R60 JKS 60 Ka FVVX 80 KTN R80 JKS 80 pa FWX 15 KTN 150 0 R150 JKS 150 JJN 150 FWX 20 KTN 200 0 R200 JKS 200 JJN 200 Table 8 17 1x200 240 V Enclosure Types A B and C 5014006 05 5014006 06 AE LET 5014006 08 KLN R80 FNQ KTK LP 5012406 03 FWX 30 KTN R30 JKS 30 R 30 R 30 CC 30 2 KLN R30 ATM R30 A2K 30R HSJ30 15 20 30 35 50 60 80 pass A2K 150 A2K 200 JJ JJ JJ JJ JJ JJ JJ 0 2028220 15 2028220 20 Siba allowed up to 32 A Siba allowed up to 63 A 1x380 500 V Recommended max fuse Powe E Buss Buss Littel fuse Ferraz Ferraz Ferraz r mann mann RK1 Shawmu Shawmu Shawmu kw CC CC t J 75 60 FWH 60 KTS R60 5 60 38 60 5014006 063 KLS R60 A6K 60R HSJ60 11 FWH 80 KTS R80 Jks 80 Js 80 2028220 100 KLS R80 A6K 80R HsJ80 FWH 15 KTS A6K 150 22 150 0 R150 JKS 150 JJS 150 2028220 160 KLS R150 R HSJ150 FWH 20 KTS A6K 200 zm Rees Table 8 18 1x380 500 V Enclosure Types B and C KTS fuses from Bussmann may substitute KTN for 240 V frequency converters FWH fuses from Bussmann may substitute FWX for 240 V frequency converters JJS fuses from Bussmann may substitute JJN for 240 V frequency converters
62. T 2 DIN 37 jumper wire to terminal 27 is not needed 410V 50 D IN 37 is an option AIN 53 AIN 54 COM 10V 50 A OUT AIN COM 2 32 COM 55 A OUT 42 CH COM 39 02 R 04 S J 05 Lo Table 6 10 External Alarm Reset Parameters Funcion seno 24 V 12 5 10 Terminal 18 8 Start 24 V 13 Digital Input DIN 18 5 11 Terminal 19 52 Run D IN 19 Digital Input Permissive COM 20 5 12 Terminal 27 7 External DIN 27 Digital Input nterlock pin SN 5 40 Function 167 Start DIN 32 Relay command DIN 33 t DIN a3 act Default Value 10V 50 Notes comments AIN 53 D IN 37 is an option AIN 54 COM 55 AOUT 42 COM 39 r 01 02 03 04 S 05 06 Table 6 9 Run Permissive 30 MG20MA02 Rev 2013 10 29 Application Set up Examples 6 1 5 RS 485 VLT AQUA Drive FC 202 Operating Instructions 6 1 6 Motor Thermistor 5 iu 24V 12 ea 24V 13 bal DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 A OUT 42 COM 39 01 r 02 03 04 S d 05 06 RS 485 61 68 69 Table 6 11 RS 485 Network Connection Parameters ACAUTION THERMISTOR INSULATION Risk of equipment damage exists 8 32 Baud Rate Use only thermistors with reinforced or double Default Value insulation to meet PELV insulation requir
63. The talos inputs are r galarie isolated hom the at voltage PELV and other pie voltage sentina b PELV isolation 24V Control 18 Mains 130BA117 10 High 37 voltage Motor Functional n M isolation DC Bus RS485 Illustration 8 1 PELV Isolation of Analog Inputs Analog output Number of programmable analog outputs 1 Terminal number 200500 Current range at analog output 0 4 20 mA The analog output is galvanically isolated from the supply voltage PELV and other high voltage terminals Digital inputs Programmable digital inputs 4 6 Input resistance Ri corr Aprox 4 ko All digital inputs are dalvanicaliy ikolafed om Pa D vakade PELV ES other High voltage terrinas 1 Terminals 27 and 29 can also be programmed as output Digital output Programmable digital pulse outputs 2 Max nad at frequency output ik Max capacitive load at frequency output 10 nF MG20MA02 Rev 2013 10 29 53 Specifications VLT AQUA Drive FC 202 Operating Instructions Minimum output frequency at frequency output 0 Hz 1 Terminal 27 and 29 can also be programmed as input The digital output is galvanically isolated from the supply voltage PELV and other high voltage terminals Pulse inputs Programmable pulse inputs Control card 24 V DC output Terminal number 12 13 The 24 V DC supply is galvanically isolated from the su
64. a terminal functions Speed Up and Speed Down A jog command was given but the motor remains stopped until a run permissive signal is received via a digital input Jogging Motor check OVC control PowerUnit Off Protection md QStop Ramping Ref high Ref low MG20MAO2 Rev 2013 10 29 The motor is running as programmed in 3 19 Jog Speed RPM e Jog was selected as function for a digital input parameter group 5 1 Digital Inputs The corresponding terminal e g Terminal 29 is active e The Jog function is activated via the serial communication e The Jog function was selected as a reaction for a monitoring function e g No signal The monitoring function is active In 1 80 Function at Stop Motor Check was selected A stop command is active To ensure that a motor is connected to the frequency converter a permanent test current is applied to the motor Overvoltage control was activated in 2 17 Over voltage Control 2 Enabled The connected motor is supplying the frequency converter with generative energy The overvoltage control adjusts the V Hz ratio to run the motor in controlled mode and to prevent the frequency converter from tripping Only frequency converters with an external 24 V power supply installed Mains supply to the frequency converter was removed and the control card is supplied by the external 24 V Protection mode is active The unit has detected a critical status o
65. and hold Status Main Menu and OK at the same time while applying power to the unit approximately 5 s or until audible click and fan starts Factory default parameter settings are restored during start up This may take slightly longer than normal Manual initialisation does not reset the following frequency converter information e 15 00 Operating hours e 15 03 Power Up s e 15 04 Over Temp s e 15 05 Over Volt s 5 4 Basic Programming 5 4 1 Commissioning vvith Smartstart The SmartStart wizard enables fast configuration of basic motor and application parameters e At first povver up or after initialisation of the frequency converter SmartStart starts by itself e Follow on screen Instructions to complete commissioning of the frequency converter Always reactivate SmartStart by selecting Quick Menu Q4 SmartStart e For commissioning without use of the SmartStart wizard refer to 5 4 2 Commissioning via Main Menu or the Programming Guide NOTIC Motor data are required for the SmartStart setup The required data are normally available on the motor nameplate MG20MAO2 Rev 2013 10 29 23 Commissioning The SmartStart configures the frequency converter in 3 phases each consisting of several steps see Table 5 6 Phase Comment appropriate application e Single pump motor 2 Application Section e Motor alternation e Basic cascade control 5 e Master follower Table 5 6 SmartStart Setup in 3
66. ate circuit voltage DC link drops below the under voltage limit the frequency converter checks if a 24 V DC back up supply is connected If no 24 V DC back up supply is connected the frequency converter trips after a fixed time delay The time delay varies with unit size Troubleshooting e Check that the supply voltage matches the frequency converter voltage e Perform input voltage test e Perform soft charge circuit test WARNING ALARM 9 Inverter overload The frequency converter is about to cut out because of an overload too high current for too long The counter for electronic thermal inverter protection gives a warning at 98 and trips at 100 while giving an alarm The MG20MA02 Rev 2013 10 29 35 Maintenance Diagnostics an frequency converter cannot be reset until the counter is belovv 9006 The fault is that the frequency converter is overloaded by more than 10006 for too long Troubleshooting e Compare the output current shown on the LCP vvith the frequency converter rated current e Compare the output current shovvn on the LCP vvith measured motor current e Display the Thermal Drive Load on the LCP and monitor the value When running above the frequency converter continuous current rating the counter should increase When running below the frequency converter continuous current rating the counter should decrease VVARNING ALARM 10 Motor overload temperature According to the electronic therma
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68. bus communication fault The fieldbus on the communication option card is not working WARNING ALARM 36 Mains failure This warning alarm is only active if the supply voltage to the frequency converter is lost and 14 10 Mains Failure is NOT set to 0 No Function Check the fuses to the frequency converter and mains power supply to the unit ALARM 38 Internal fault When an internal fault occurs a code number defined in the Table 7 6 is displayed Troubleshooting e Cycle power e Check that the option is properly installed e Check for loose or missing vviring Contact the Danfoss supplier or service department if required Note the code number for further trouble shooting directions VLT AQUA Drive FC 202 Operating Instructions No Text 0 Serial port cannot be initialised Contact theDanfoss supplier or Danfoss Service Department 256 258 Povver EEPROM data is defective or too old 512 Control board EEPROM data is defective or too old 513 Communication time out reading EEPROM data 514 Communication time out reading EEPROM data 515 Application oriented control cannot recognize the EEPROM data 516 Cannot write to the EEPROM because a write command is on progress 518 Failure in the EEPROM 1024 1279 A centelegram that has to be sent couldn t be 1284 Cannot read digital signal processor software 1315 Option SW in slot A is not supported not allowed 1316 Option SW in slot B is not supported not
69. d check if the motor shaft can be turned e Check that the motor size matches the frequency converter e Check parameters 1 20 to 1 25 for correct motor data ALARM 14 Earth ground fault There is current from the output phases to ground either in the cable between the frequency converter and the motor or in the motor itself Troubleshooting e Remove power to the frequency converter and repair the earth fault e Check for earth faults in the motor by measuring the resistance to ground of the motor leads and the motor vvith a megohmmeter 36 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an e Perform current sensor test ALARM 15 Hardware mismatch A fitted option is not operational with the present control board hardware or software Record the value of the following parameters and contact the Danfoss supplier e 15 40 FC Type e 15 41 Power Section e 15 42 Voltage e 15 43 Software Version e 15 45 Actual Typecode String e 15 49 SVV ID Control Card e 15 50 SVV ID Power Card e 15 60 Option Mounted e 15 61 Option SW Version for each option slot ALARM 16 Short circuit There is short circuiting in the motor or motor vviring Remove povver to the frequency converter and repair the short circuit VVARNING ALARM 17 Control vvord timeout There is no communication to the frequency converter The vvarning is only active vvhen 8 04 Control VVord Timeout Function is NOT set to OFF If 8 04 Control Wo
70. d lovv Standby starts the motor vvith a start signal from a digital input or serial communication Start delay In 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 Start forward and start reverse were selected as functions for 2 different digital inputs parameter group 5 1 Digital Inputs The motor starts in forward or reverse depending on which corresponding terminal is activated Stop The frequency converter has received a stop command from the LCP digital input or serial communication Trip An alarm occurred and the motor is stopped Once the cause of the alarm is cleared the frequency converter can be reset manually by pressing Reset or remotely by control terminals or serial communication Trip lock An alarm occurred and the motor is stopped Once the cause of the alarm is cleared power must be cycled to the frequency converter The frequency converter can then be reset manually by pressing Reset or remotely by control terminals or serial communication Table 7 3 Operation Status NOTIC In auto remote mode the frequency converter requires external commands to execute functions 7 3 Warning and Alarm Types Warnings A warning is issued when an alarm condition is impending or when an abnormal operating condition is present and may result in the frequency converter issuing an alarm A warning clea
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72. duced power mode i e less than the allowed number of inverter sections This warning is generated on power cycle when the frequency converter is set to run with fewer inverters and remains on ALARM 79 Illegal power section configuration The scaling card is the incorrect part number or not installed Also MK102 connector on the power card could not be installed ALARM 80 Drive initialised to default value Parameter settings are initialised to default settings after a manual reset Reset the unit to clear the alarm 40 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an VLT AQUA Drive FC 202 Operating Instructions ALARM 81 CSIV corrupt CSIV Customer Specific Initialisation Values file has syntax errors ALARM 82 CSIV parameter error CSIV Customer Specific Initialisation Values failed to init a parameter ALARM 85 Dang fail PB Profibus Profisafe Error ALARM 92 No flow A no flow condition has been detected in the system 22 23 No Flow Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 93 Dry pump A no flow condition in the system with the frequency converter operating at high speed may indicate a dry pump 22 26 Dry Pump Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 94 End of curve Feedback is lower than the set point This may indicate leakage
73. e ALARM 55 AMA parameter out of range The parameter values of the motor are outside of the acceptable range AMA will not run ALARM 56 AMA interrupted by user The user has interrupted the AMA MG20MAO2 Rev 2013 10 29 39 Maintenance Diagnostics an ALARM 57 AMA internal fault Try to restart AMA again a number of times until the AMA is carried out Note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased In most cases hovvever this is not critical AMA internal fault Contact the Danfoss supplier VVARNING 59 Current limit The current is higher than the value in 4 18 Current Limit Ensure that motor data in parameters 1 20 to 1 25 are set correctly Possibly increase the current limit Be sure that the system can operate safely at a higher limit WARNING 60 External interlock External interlock has been activated To resume normal operation apply 24 V DC to the terminal programmed for external interlock and reset the frequency converter via serial communication digital I O or by pressing Reset WARNING 62 Output frequency at maximum limit The output frequency is higher than the value set in 4 19 Max Output Frequency ALARM 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 control card has reached its trip temperature of 75 C WARNIN
74. ed See Illustration 3 2 for clearance requirements Mechanical installation 7 130BD528 10 c 130BD504 10 at a Bei at co B 7 Illustration 3 2 Top and Bottom Cooling Clearance A2 A5 100 B1 B4 200 Enclosure C1 C3 200 C2 C4 225 a mm Table 3 1 Minimum Airflow Clearance Requirements Lifting e To determine a safe lifting method check the weight of the unit see 8 9 Power Ratings Weight and Dimensions e Ensure that the lifting device is suitable for the task e If necessary plan for a hoist crane or forklift with the appropriate rating to move the unit e For lifting use hoist rings on the unit when provided Mounting 1 Ensure that the strength of the mounting location supports the unit vveight The frequency converter allovvs side by side installation 2 Locate the unit as near to the motor as possible Keep the motor cables as short as possible 3 Mount the unit vertically to a solid flat surface or to the optional back plate to provide cooling airflow 4 Use the slotted mounting holes on the unit for wall mounting when provided VLT AQUA Drive FC 202 Operating Instructions Mounting with back plate and railings ei Ly Illustration 3 3 Proper Mounting with Back Plate NOTIC Back plate is required when mounted on railings
75. ements Notes comments q Select protocol address and baud rate in the above Parameters mentioned parameters m e Function Setting D IN 37 is an option on 1 90 Motor 2 424V 13 2 Thermal Thermistor DIN 18 7 Protection trip DIN 19 1 93 Thermistor 1 Analog COM 20 Source input 53 DIN 29 Dib 3 Notes comments DIN s If only a warning is desired DIN 1 90 Motor Thermal Protection sog P should be set to 1 Thermistor AIN 53 warning AIN 54 D IN 37 is an option COM 55 A OUT 42 COM 39 E A53 Table 6 12 Motor Thermistor MG20MAQ02 Rev 2013 10 29 31 7 Maintenance Diagnostics an VLT AQUA Drive FC 202 Operating Instructions 7 Maintenance Diagnostics and Troubleshooting This chapter includes maintenance and service guidelines status messages warnings and alarms and basic trouble shooting 7 1 Maintenance and Service Under normal operating conditions and load profiles the frequency converter is maintenance free throughout its designed lifetime To prevent breakdown danger and damage examine the frequency converter 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 AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Failure to perfo
76. ended or 13 to terminal 27 This provides an internal 24 V signal on terminal 27 e When the status line at the bottom of the LCP reads AUTO REMOTE COAST this indicates that the unit is ready to operate but is missing an input signal on terminal 27 e VVhen factory installed optional equipment is vvired to terminal 27 do not remove that vviring NO TIC The frequency converter cannot operate without a signal on terminal 27 unless terminal 27 is re programmed MG20MAQ02 Rev 2013 10 29 17 Dont Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 8 4 Voltage Current Input Selection 4 8 6 RS 485 Serial Communication Switches Connect RS 485 serial communication wiring to terminals 4068 and 69 The analog input terminals 53 and 54 allow setting of input signal to voltage 0 10 V or current 0 4 20 mA Use screened serial communication cable Default parameter settings recommended Terminal 53 speed reference signal in open loop See 4 3 Grounding for proper grounding see 16 61 Terminal 53 Switch Setting Terminal 54 feedback signal in closed loop see 16 63 Terminal 54 Switch Setting y NOTIC Disconnect power to the frequency converter before s changing switch positions 1 Remove the local control panel see s A Illustration 4 10 130BB489 10 2 Remove any optional equipment covering the switches Illustration 4 11 Serial Communica
77. ered correctly If warnings or alarms occur see 7 4 List of Warnings and Alarms Check that motor data are entered correctly Bypass critical frequencies by using parameters in parameter group 4 6 Speed Bypass Turn off over modulation in 14 03 Overmo Change switching pattern and frequency in Increase Resonance Dampening in MG20MA02 Rev 2013 10 29 frequency converter 1 position A to B B to power problem Check mains power frequency converter 1 position A to B B to terminal it is a problem with the unit If imbalanced leg follows the wire it is a supply If imbalance leg stays on same input Contact the supplier If imbalanced leg follows the wire the problem is in the motor or motor wiring Check motor and motor wiring If imbalance leg stays on same output terminal it is a problem with the unit Contact the supplier Increase the ramp up time in 3 41 Ramp 1 Ramp Up Time Increase current limit in 4 18 Current Limit Increase torque limit in 4 16 Torque Limit Motor Mode Increase the ramp down time in 3 42 Ramp 1 Ramp Down Time Enable overvoltage control in 2 17 Over voltage Control Check if noise and or vibration have been reduced to an acceptable limit 43 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 Specifications 8 1 Hectrical Data 8 1 1 Mains Supply 1x200 240 V AC Type Designation P1K1 P1K5 P2K2 P3KO P3K7 P5K5 P7K5 P15K P22K Output current
78. esistor see 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 intermediate circuit voltage and the brake resistance value set in 2 16 AC brake Max Current The warning is active when the dissipated braking is higher than 90 of the brake resistance power If 2 Trip is selected in 2 13 Brake Power Monitoring the frequency converter trips when the dissipated braking power reaches 100 AWARNING There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short circuited 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 frequency converter is still operational but since the brake transistor has short circuited substantial power is transmitted to the brake resistor even if it is inactive Remove power to the frequency converter and remove the brake resistor This alarm warning could also occur should the brake resistor overheat Terminals 104 and 106 are available as brake resistors Klixon inuputs see Brake Resistor Temperature Switch in the Design Guide WARNING ALARM 28 Brake check failed The brake resistor is not connected or not working Check 2 75 Brake Check ALARM 29 Heat Sink temp The max
79. f acceleration or deceleration problems see 7 5 Troubleshooting See 7 4 List of Warnings and Alarms for resetting the frequency converter after a trip 5 7 System Start up 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 AWARNING 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 e Ensure equipment is safe to operate under any condition e Ensure that the motor system and any attached equipment are ready for start 1 Press Auto On 2 Apply an external run command 3s Adjust the speed reference throughout the speed range 4 Remove the external run command 5 Check sound and vibration level of the motor to ensure that the system is vvorking as intended MG20MAO2 Rev 2013 10 29 27 Application Set up Examples 6 Application Set up Examples The examples in this section are intended as a quick reference for common applications e Parameter settings are the regional default values unless othervvise indicated selected in 0 03 Regional Settings e Parameters associated with the terminals and their settings are shown next to the drawings e Where switch settings for analog terminals A53 or A54 are required these are also shown NOTIC When the optional Safe Torq
80. hase balance of electrical power It compares the motor characteristics with the data entered in parameters 1 20 to 1 25 e The motor shaft does not turn and no harm is done to the motor vvhile running the AMA e Some motors may be unable to run the complete version of the test In that case select 2 Enable reduced AMA e If an output filter is connected to the motor select Enable reduced AMA e f vvarnings or alarms occur see 7 4 List of Warnings and Alarms e Run this procedure on a cold motor for best results To run AMA 1 Press Main Menu to access parameters 2 Scroll to parameter group 1 Load and Motor and press OK 3 Scroll to parameter group 1 2 Motor Data and press OK Dont VLT AQUA Drive FC 202 Operating Instructions 4 Scroll to 7 29 Automatic Motor Adaptation AMA and press OK 5 Select 1 Enable complete AMA and press OK 6 Follow on screen instructions 7 The test runs automatically and indicate when it is complete 5 5 Checking Motor Rotation AWARNING 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 e Ensure equipment is safe to operate under any condition e Ensure that the motor system and any attached equipment are ready for start NO TIC Risk of damage to pumps compressors caused by motor running in vvrong direction Before running
81. he problem 17 Alarm A fault condition causes the red alarm light to flash and an alarm text is displayed Table 5 4 Legend to Illustration 5 1 Indicator Lights LEDs D Operation keys and reset Operation keys are located at the bottom of the LCP Key Function Starts the frequency converter in local control e An external stop signal by control input or serial communication overrides the local hand on Off Stops the motor but does not remove power to the frequency converter Puts the system in remote operational mode e Responds to an external start command by control terminals or serial communi cation Resets the frequency converter manually after a fault has been cleared Table 5 5 Legend to Illustration 5 1 Operation Keys and Reset NO TIC The display contrast can be adjusted by pressing Status and 4 v keys 5 3 3 Parameter Settings Establishing the correct programming for applications often requires setting functions in several related parameters Details for parameters are provided in 9 2 Parameter Menu Structure Programming data are stored internally in the frequency converter e For back up upload data into the LCP memory e To download data to another frequency converter connect the LCP to that unit and dovvnload the stored settings e Restoring factory default settings does not change data stored in the LCP memory 5 3 4 Uploading Dovvnloading Data to from the LCP
82. hrough status display modes during normal operation and viewing fault log data Function Key 6 Status Shows operational information 7 Quick Menu Allows access to programming parameters for initial set up instructions and many detailed application instructions MG20MAO2 Rev 2013 10 29 21 Commissioning VLT AQUA Drive FC 202 Operating Instructions Function Key Allovvs access to all programming 77777 Alarm Log Displays a list of current vvarnings the last Nil ae Table 5 2 Legend to Illustration 5 1 Display Menu Keys C Navigation keys and indicator lights LEDs Navigation keys are used for programming functions and moving the display cursor The navigation keys also provide speed control in local operation There are also 3 frequency converter status indicator lights in this area Key Function Back Reverts to the previous step or list in the 5755555 Cancel Cancels the last change or command as long PT Seem 12 lnfo Press for a definition of the function being IT ie 13 Navigation Use the 4 navigation keys to move between 14 Use to access parameter groups or to enable DAMI ol ndicator Light Function 15 Green The ON light activates when the frequency converter receives povver from mains voltage a DC bus terminal or an external 24 V supply 16 Warn Yellow When warning conditions are met the yellow WARN light comes on and text appears in the display area identifying t
83. ime clock e Password protection Overload protection Smart logic control 1 4 3 Exploded Views 130BB493 10 Local control panel LCP 11 a 2 04 05 06 len aliena d 5 cable sen neg i Te Brake terminal 1 Serial bus terminal svvitch 18 Motor output terminals 96 U 97 V 98 W Analog switches A53 A54 19 Mains input terminals 91 L1 92 L2 93 L3 0 Relay 1 01 02 Illustration 1 1 Exploded View Enclosure Types B and C IP55 and IP66 4 MG20MA02 Rev 2013 10 29 Introduction VLT AQUA Drive FC 202 Operating Instructions 130BB492 10 Local control panel LCP 10 Motor output terminals 96 U 97 V 98 W 1 2 R5485 seral bus connector 6865 n ey RR 00 4 Brake 81 82 and load sharing 88 89 terminals 5 Mains input terminals 91 L1 92 L2 93 L3 6 2 8 9 Decoupling pe i6 sesibist mnissn Screened cable grounding damp and sran eiet s O O OSOS Illustration 1 2 Exploded View Enclosure Type A IP20 MG20MA02 Rev 2013 10 29 5 Introduction 1 4 4 Block Diagram of the Frequency Converter Illustration 1 3 is a block diagram of the internal components of the frequency converter See Table 1 4 for their functions ee TU9LOVZSZL Illustration
84. imum temperature of the heatsink has been exceeded The temperature fault does not reset until the temperature drops below a defined heatsink temperature The trip and reset points are different based on the frequency converter power size Troubleshooting Check for the following conditions e Ambient temperature too high e Motor cable too long e Incorrect airflow clearance above and below the frequency converter MG20MAO2 Rev 2013 10 29 37 Maintenance Diagnostics an e Blocked airflovv around the frequency converter e Damaged heatsink fan e Dirty heatsink This alarm is based on the temperature measured by the heatsink sensor mounted inside the IGBT modules Troubleshooting e Check Tan resistance e Check soft charge fuses e IGBT thermal sensor ALARM 30 Motor phase U missing Motor phase U between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase U ALARM 31 Motor phase V missing Motor phase V between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase V ALARM 32 Motor phase W missing Motor phase W between the frequency converter and the motor is missing Remove power from the frequency converter and check motor phase W ALARM 33 Inrush fault Too many power ups have occurred within a short time period Let the unit cool to operating temperature WARNING ALARM 34 Field
85. in the system 22 50 End of Curve Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 95 Broken belt Torque is below the torque level set for no load indicating a broken belt 22 60 Broken Belt Function is set for alarm Troubleshoot the system and reset the frequency converter after the fault has been cleared ALARM 100 Derag limit fault The Deragging feature failed during execution Check pump impeller for blockage WARNING ALARM 104 Mixing fan fault The fan monitor checks that the fan is spinning at frequency converter power up or whenever the mixing fan is turned on If the fan is not operating then the fault is annunciated The mixing fan fault can be configured as a warning or an alarm trip by 74 53 Fan Monitor Troubleshooting Cycle power to the frequency converter to determine if the warning alarm returns WARNING 250 New spare part A component in the frequency converter has been replaced Reset the frequency converter for normal operation WARNING 251 New typecode The power card or other components have been replaced and the typecode changed Reset to remove the warning and resume normal operation MG20MAO2 Rev 2013 10 29 41 Maintenance Diagnostics an VLT AQUA Drive FC 202 Operating Instructions 7 5 Troubleshooting Symptom Possible cause Test Solution Missing input povver See Table 4 4 Check the input povver source
86. itch switch or other device No mains power with 24 V DC lf the display is functioning but no output Apply mains power to run the unit option card check that mains power is applied to the frequency converter LCP Stop Check if Off has been pressed Press Auto On or Hand On depending on operation mode to run the motor Motor not Missing start signal Standby Check 5 10 Terminal 18 Digital Input for Apply a valid start signal to start the running correct setting for terminal 18 use default motor setting Motor coast signal active Check 5 12 Coast inv for correct setting for Apply 24 V on terminal 27 or program this Coasting terminal 27 use default setting terminal to No operation Wrong reference signal source Check reference signal Local remote or Program correct settings Check bus reference Preset reference active 3 13 Reference Site Set preset reference Terminal connection correct Scaling of active in parameter group 3 1 References terminals correct Reference signal Check for correct wiring Check scaling of available terminals Check reference signal Motor rotation limit Check that 4 70 Motor Speed Direction is Program correct settings programmed correctly Motor running Active reversing signal Check if a reversing command is Deactivate reversing signal in vvron x programmed for the terminal in parameter direction ora group 5 1 Digital inputs Wrong
87. l protection ETR the motor is too hot Select whether the frequency converter gives a vvarning or an alarm vvhen the counter reaches 10006 in 7 90 Motor Thermal Protection The fault occurs when the motor is overloaded by more than 100 for too long Troubleshooting e Check for motor overheating e Check if the motor is mechanically overloaded e Check that the motor current set in 7 24 Motor Current is correct e Ensure that Motor data in parameters 1 20 through 1 25 are set correctly e If an external fan is in use check in 7 97 Motor External Fan that it is selected D Running AMA in 1 29 Automatic Motor Adaptation AMA tunes the frequency converter to the motor more accurately and reduces thermal loading WARNING ALARM 11 Motor thermistor over temp The thermistor might be disconnected Select whether the frequency converter gives a warning or an alarm in 1 90 Motor Thermal Protection Troubleshooting e Check for motor overheating e Check if the motor is mechanically overloaded e Check that the thermistor is connected correctly between either terminal 53 or 54 analog voltage input and terminal 50 10 V supply and that the terminal switch for 53 or 54 is set for voltage Check 1 93 Thermistor Source selects terminal 53 or 54 e When using digital inputs 18 or 19 check that the thermistor is connected correctly between Dont VLT AQUA Drive FC 202 Operating Instructions either terminal 18 or 19 digital in
88. lands are firmly tightened 3 Ensure that input povver to the unit is OFF and locked out Do not rely on the frequency converter disconnect svvitches for input povver 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 VV phase to phase and phase to ground 6 Confirm continuity of the motor by measuring ohm values on U V 96 97 V VV 97 98 and VV U 98 96 7 Check for proper grounding of the frequency converter as well as the motor 8 Inspect the frequency converter for loose connections on terminals 9 Confirm that the supply voltage matches voltage of frequency converter and motor VLT AQUA Drive FC 202 Operating Instructions 5 2 Applying Power AWARNING UNINTENDED START When the frequency converter is connected to AC mains the motor may start at any time causing risk of death serious injury equipment or property damage Examples start by means of an external switch via a serial bus command via an input reference signal from the LCP or LOP or after a cleared fault condition e Disconnect the frequency converter from mains whenever personal safey considerations make it necessary to avoid unintended motor start e Press Off on the LCP before programming parameters e The frequency converter motor and any driven equipment must be
89. m se m mew Max pre fuses A 10 10 20 Additional specifications Estimated power loss at rated max load W 2 Max cable size mains motor 10 2 41 24 10 brake mm AWG 2 Table 8 7 Mains Supply 3x525 600 V AC Normal overload 110 for 1 minute PK75 P11K Type Designation P15K P18K P22K P30K P37K P45K P55K P75K P90K Output current Continuous 1525 550 V TAJ intermittent DEEL 3 4 9 2 o e s Continuous 3525 600 V TA intermittent 3x525 600 Y 2 3 as v e o 10 commos wa Ep zs mr e wa es es ww 195 Continuous WA 575 VACINA 219 69 339 405 sis ew amp 056 105 Max input current Continuous 3x525 600 W 209 254 327 39 4 s s 055 intermittent 3x525 600 V IA Do msl Additional specifications Estimated povver loss at rated 1020 1130 max load W 2 Max cable size mains motor 1351 2 1501 1 19591 3 0 brake mm AWG 2 Table 8 8 Mains supply 3 525 600 V AC Normal overload 110 for 1 minute P15K P90K 48 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 1 6 Mains Supply 3x525 690 V AC Type Designation Typical Shaft output kVV IP20 Chassis Output current Continuous 3x525 550 V A P1K1 P1K5 P2K2 P3KO P4KO P5K5 P7K5 o is T T T Ts Ts ES LA A3 A3 Intermittent 3x525 550 V A Continuo
90. n 24 32 21 22 Open loop teste 18 Operation 2222 Optional equipment Output SN TT 33 36 Performance U V VV 51 power wiring 219 terminal eoi Ft ore p ce ees a 20 Over current protection A A e eet e es P PM de 25 Potential equalisation 11 Povver Sel ase lT 11 El de 6 19 7 5 17 22 35 21 PULSO UNES cirio a 54 Qualified 7 Quick PIVOT GEN 21 UE 21 H Ramp down mee 43 70 MG20MA02 Rev 2013 10 29 Index Ramp p time cin id 43 Referencia 28 32 33 21 Relay Outputs ess ere deep e teg 54 Relays see meo bai Pana NER 16 Remote commands reference sides OE Reset dec E REL FOR e EN 15 RMS current uere iet on tied ee bred e oe 6 RS 485 network connection 31 Serial Communication 18 Run COMIN E 27 KIT UE 33 PermISS VE iris 30 Run Stop 7 25 29 5 Safe Torque stenge EA 18 Screened cable
91. n Bussman SIBA Littel fuse Ferraz Ferraz kw Type RK1 n n n Type RK1 Type RK1 Shawmut Shawmut Type J Type CC Type CC EN Type RK1 J 1 45 KTS R 100 JKS 100 JJS 100 5014006 100 KLS R 100 A6K 100 R HSJ 100 90 Jaune 6175 202820200 HSJ 175 Table 8 23 3x525 600 V Enclosure Types A B and C 1 170M fuses shown from Bussmann use the 80 visual indicator TN 80 Type T 110 or TN 110 Type T indicator fuses of the same size and amperage may be substituted 3x525 690 V Recommended max fuse Power Max Bussmann Bussmann Bussmann SIBA LittelFuse Ferraz Ferraz kw prefuse E52273 E4273 E4273 E180276 E81895 Shawmut Shawmut A RK1 JDDZ J JDDZ T JDDZ RK1 JDDZ RK1 JDDZ E163267 E2137 E2137 RK1 DDZ J HSJ n x so es seo soroososs Hsrso x so sso ss sso sonoosos ksmo7 asesor Hsreo as 9o es nso 5014006700 Kisnooo Laser Hsrso s 100 krsn ioo 310 5100 _5014006100_ Ra astron Hsrioo 73 50 Table 8 24 3x525 690 V Enclosure Types B and C 62 MG20MA02 Rev 2013 10 29 VLT AQUA Drive FC 202 Operating Instructions Specifications suoisuawig pue 4619M sbuney amod ST g QLL payjeisul suondo UHP YUM AJRA JIM 3INSOJDUI Jo uideg xx sejou Bununow ujoj1oq pue do 10 EE UO BISHI pue FE UONDAISNI 99S y cec FE RR O D xew LC LO LO Ln m N m bal N m o N 99
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93. n slot B Hardware incompatible with Control board hardware 5125 Option in slot CO Hardware incompatible with control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware Table 7 5 Code Numbers for Internal Faults ALARM 39 Heat Sink sensor No feedback from the heatsink 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 gate drive card or the ribbon cable between the power card and gate drive card WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital I O Mode and 5 01 Terminal 27 Mode WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O Mode and 5 02 Terminal 29 Mode VLT AQUA Drive FC 202 Operating Instructions VVARNING 42 Overload of digital output on X30 6 or overload of digital output on X30 7 For X30 6 check the load connected to X30 6 or remove the short circuit connection Check 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7 or remove the short circuit connection Check 5 33 Term X30 7 Digi Out MCB 101 ALARM 46 Power card supply The supply on the power card is out of range There are 3 power supplies generated by the switch mode power
94. ning Speed Low DC hold is selected in 1 80 Function at Stop and a stop command is active The motor is held by a DC current set in 2 00 DC Hold Preheat Current The motor is held with a DC current 2 01 DC Brake Current for a specified time 2 02 DC Braking Time e DC Brake is activated in 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 7 Digital Inputs The corresponding terminal is not active The DC Brake is activated via serial communication The sum of all active feedbacks is above the feedback limit set in 4 57 Warning Feedback High The sum of all active feedbacks is below the feedback limit set in 4 56 Warning Feedback Low The remote reference is active which holds the present speed e Freeze output was selected as a function for a digital input parameter group 5 7 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 was given but the motor remains stopped until a run permissive signal is received Freeze Reference was selected as a function for a digital input parameter group 5 7 Digital Inputs The corresponding terminal is active The frequency converter saves the actual reference Changing the reference is now only possible vi
95. ns 109 terminals 1 3 5 for signals terminals 2 4 6 common e Check that the frequency converter programming and svvitch settings match the analog signal type e Perform Input Terminal Signal Test VVARNING ALARM 3 No motor No motor has been connected to the output of the frequency converter VVARNING 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 rectifier on the frequency converter Options are programmed at 74 72 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the frequency converter WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Troubleshooting e Connect a brake resistor e Extend the ramp time e Change the ramp type e Activate the functions in 2 70 Brake Function e Increase 14 26 Trip Delay at Inverter Fault WARNING ALARM 8 DC under voltage If the intermedi
96. ns VLT AQUA Drive FC 202 Operating Instructions Type Designation P11K P15K P18K P22K P30K P37K P45K P55K P75K P90K Typical Shaft Output HP at 460 V 15 20 25 30 40 50 60 75 100 125 IP20 Chassis 2 B3 B3 B3 B4 B4 B4 C3 C3 C4 Output current so ELM C2 C2 C2 2 Intermittent 3x441 480 V 7 S er poa s sepu 176 Max input current Continuous 3x380 440 V 133 161 TST E E E E s Additional specifications Estimated power loss at rated max 1083 1384 1474 load W 2 Max cable size mains motor 120 120 10 7 35 2 1501 1 0 brake mm AWG 2 4 0 4 0 Table 8 6 Mains Supply 3x380 480 V AC Normal overload 110 for 1 minute P11K P90K ES MG20MAO2 Rev 2013 10 29 47 Specifications VLT AQUA Drive FC 202 Operating Instructions 8 1 5 Mains Supply 3x525 600 V AC Type Designation PK75 P1K1 1 5 P2K2 P3KO PAKO P5K5 P7K5 P11K P20 Chassis A2 A2 A2 A2 A2 A2 A3 A3 P21 Type 1 P55 Type 12 A5 A5 A5 A5 A5 A5 A5 A5 B1 Output current Continuous 3525 550 V A ntermittent 525550 vita 29 32 as sz 70 105 127 nm Continuous 5256000 a 17 24 27 39 49 61 90 ml sl ntermittent nee v 26 30 4 ss 67 99 121 Continuous WA 525 VACINA 17 25 28 39 se si 90 mo tes Continuous WA 875 y AQ VAL 17 24 27 39 a er 90 no vs Max input current T Tuz aa p e s s ps pw T mil EEE m om e
97. ns VLT Technical Documentation htm for listings Disclosure duplication and sale of this document as well as communication of its content are prohibited unless explicitly permitted Infringement of this prohibition incurs liability for damages All rights reserved with regard to patents utility patents and registered designs VLT is a registered trademark 1 3 Document and Software Version This manual is regularly reviewed and updated All suggestions for improvement are welcome Table 1 1 shows the document version and the corresponding software version Edition Remarks Software version MG20MAxx Replaces MG20M9xx Table 1 1 Document and Software Version VLT AQUA Drive FC 202 Operating Instructions 1 4 Product Overview 1 4 1 Intended Use The frequency converter is an electronic motor controller intended for e regulation of motor speed in response to system feedback or to remote commands from external controllers A power drive system consists of the frequency converter the motor and equipment driven by the motor e system and motor status surveillance Depending on configuration the frequency converter can be used in standalone applications or form part of a larger appliance or installation The frequency converter is allovved for use in residential industrial and commercial environments in accordance vvith local lavvs and standards Single phase frequency converters S2 and S4 installed in the
98. ntrol e Display operational data status vvarnings and 5 cautions e Programming frequency converter functions e Manually reset the frequency converter after a fault when auto reset is inactive An optional numeric LCP NLCP is also available The NLCP operates in a manner similar to the LCP See the Programming Guide for details on use of the NLCP NOTIC For commissioning via PC install MCT 10 Set up Software The software is available for download basic version or for ordering advanced version order number 130B1000 For more information and downloads see www danfoss com BusinessAreas DrivesSolutions Software A Display area MCT10 MCT10 Downloads htm The display area is activated when the frequency converter receives power from mains voltage a DC bus terminal or an external 24 V DC supply Illustration 5 1 Local Control Panel LCP 5 3 2 LCP Layout The information displayed on the LCP can be customised for user application Select options in the Quick Menu The LCP is divided into 4 functional groups see Q3 13 Display Settings Illustration 5 1 Display Parameter number Default setting 5 B Display menu keys 2 3 02 Feelen 3 5 Reference Table 5 1 Legend to Illustration 5 1 Display Area C Navigation keys and indicator lights LEDs D Operation keys and reset B Display menu keys Menu keys are used for menu access for parameter set up toggling t
99. oad W 2 Efficiency Table 8 11 B4 C2 C3 Enclosure Mains Supply 3x525 690 V AC IP20 IP21 IP55 Chassis NEMA1 NEMA 12 P30K P75K 7 For type of fuse see 8 8 Fuses and Circuit Breakers 2 American Wire Gauge 3 Measured using 5 m screened motor cables at rated load and rated frequency The typical power loss is at normal load conditions and expected to be within 15 tolerance relates to variety in voltage and cable conditions Values are based on a typical motor efficiency Lower efficiency motors will also add to the power loss in the frequency converter and vice versa If the switching frequency is raised from nominal the power losses may rise significantly LCP and typical control card power consumptions are included Further options and customer load may add up to 30 W to the losses Though typically only 4 W extra for a fully loaded control card or options for slot A or slot B each Although measurements are made with state of the art equipment some measurement inaccuracy must be allowed for 45 5 Motor and mains cable 300 MCM 150 mm 6 A2 A3 may be converted to IP21 using a conversion kit See also Mechanical mounting and IP21 Type 1 Enclosure kit in the Design Guide 7 B3 4 and C3 4 may be converted to IP21 using a conversion kit See also Mechanical mounting and IP21 Type 1 Enclosure kit in the Design Guide 50 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions
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101. pply voltage PELV but has the same potential as the analog and digital inputs and outputs Relay outputs Programmable relay outputs 2 1 IEC 60947 parts 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation PELV 2 Overvoltage Category Il 3 UL applications 300 VAC 2 A Control card 10 V DC output Terminal number 50 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 0 590 Hz 0 003 Hz 54 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions Speed accuracy open loop 30 4000 rpm Maximum error of 8 RPM All control characteristics are based on a 4 pole asynchronous motor Control card performance AA RA a 1 Control card USB serial communication USB standard l 1 1 Full speed ACAUTION 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 protection earth Use only isolated laptop PC as connection to the USB connector on the frequency converter or an isolated USB cable converter 8 7 Connection Tightening Torques Torque Nm DC Enclosure Brake Ground connection
102. protection If not factory supplied fuses must be provided by the installer See maximum fuse ratings in 8 8 Fuses and Circuit Breakers Wire Type and Ratings e All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements e Povver connection wire recommendation minimum 75 C rated copper wire See 8 1 Electrical Data and 8 5 Cable Specifications for recommended wire sizes and types VLT AQUA Drive FC 202 Operating Instructions 4 2 EMC compliant Installation To obtain an EMC compliant installation follow the instructions provided in 4 3 Grounding 4 4 Wiring Schematic 4 6 Motor Connection and 4 8 Control Wiring 4 3 Grounding AVVARNING LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to ground the frequency converter properly could result in death or serious injury e Ensure correct grounding of the equipment by a certified electrical installer For electrical safety e Ground the frequency converter in accordance vvith applicable standards and directives e Use a dedicated ground wire for input power motor povver and control vviring e Do not ground one frequency converter to another in a daisy chain fashion e Keep the ground wire connections as short as possible e Follow motor manufacturer wiring requirements e Minimum cable cross section 10 mm or 2 rated ground wires terminated separately For EMC compliant
103. provides 4 programmable digital inputs terminals 2 additional digital terminals programmable as either input or output a 24 V DC terminal supply voltage and a common for 50 optional customer supplied 24 V DC voltage 4 20 mA at a maximum of 500 Q 10 V DC 10 V DC analog supply voltage for potenti Connector 2 terminals 68 and 69 are for an ometer or thermistor RS 485 serial communication connection 15 mA maximum ole gt KM l a a 53 Reference Analog input For Connector 3 provides 2 analog inputs 1 analog m Feedback voltage or current output 10 V DC supply voltage and commons Switches A53 and A54 for the inputs and output ad Ra Connector 4 is a USB port available for use with 55 Common for analog the MCT 10 Set up Software input Serial Communication 61 Integrated RC Filter for cable screen ONLY for connecting the screen in the event of EMC problems 68 EE RS 485 Interface A 69 8 3 control card switch is provided for termination resistance Relays 16 MG20MA02 Rev 2013 10 29 Electrical Installation 01 02 03 04 05 06 Form C relay output For AC or DC voltage and resistive or 5 40 11 5 Running inductive loads Table 4 3 Terminal Description Additional terminals e 2 form C relay outputs Location of the outputs depends on frequency converter configuration e Terminals located on built in optional equipment See the
104. put PNP only and terminal 50 e If a KTY sensor is used check for correct connection betvveen terminals 54 and 55 e If using a thermal switch or thermistor check that the programming if 1 93 Thermistor Resource matches sensor wiring e f using a KTY sensor check the programming of 1 95 KTY Sensor Type 1 96 KTY Thermistor Resource and 1 97 KTY Threshold level match sensor vviring VVARNING ALARM 12 Torque limit The torque has exceeded the value in 4 76 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torque Limit can change this from a vvarning only condition to a vvarning follovved by an alarm Troubleshooting e If the motor torque limit is exceeded during ramp up extend the ramp up time e If the generator torque limit is exceeded during ramp down extend the ramp down time e If torque limit occurs while running possibly increase the torque limit Be sure the system can operate safely at a higher torque e Check the application for excessive current draw on the motor WARNING ALARM 13 Over current The inverter peak current limit approximately 20096 of the rated current is exceeded The warning lasts about 1 5 s then the frequency converter trips and issues an alarm This fault may be caused by shock loading or fast acceleration with high inertia loads If extended mechanical brake control is selected trip can be reset externally Troubleshooting e Remove power an
105. raz Shawmut may substitute A25X for 240 V frequency converters 60 MG20MA02 Rev 2013 10 29 Specifications VLT AQUA Drive FC 202 Operating Instructions 3x380 480 V Recommended max fuse Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann sm so 1l o se e 9 1 sse ee e 1 gt Est e 211 esp ui we Me A RE rasos s is EE KTS R 125 JKS 125 JJS 125 EE ksaxo Lem sm 4 HH sm YO Table 8 21 3x380 480 V Enclosure Types A B and C Recommended max fuse Povver SIBA Littel fuse Ferraz Ferraz Bussmann Ferraz Ferraz Littel fuse kw Type RK1 Type RK1 Shawmut Shawmut JFHR2 Shawmut Shawmut JFHR2 Type CC Type RK1 JFHR2 J 4 5017906 020 LS R 20 ATM R 20 A6K 20 R FWH 20 HSJ 20 E ES EE EEE ES E EEE 22 5014006 063 LS R 60 Aekenn FWH 60 HSJ 60 30 2028220 100 LS R 80 A6KBOR FWH 80 HSJ 80 37 2028220 125 KLS R 100 A6K 100 R FWH 100 HSJ 100 15 5014006 050 KLS R 50 A6K 50 R FWH 50 HSJ 50 45 2028220 125 KLS R 125 55 2028220 160 KLS R 150 75 2028220 200 KLS R 200 A50 P 225 Table 8 22 3x380 480 V Enclosure Types A B and C 1 Ferraz Shavvmut A50QS fuses may substitute A50P fuses MG20MAO2 Rev 2013 10 29 61 Specifications VLT AQUA Drive FC 202 Operating Instructions 3x525 600 V Recommended max fuse Power Bussmann Bussman Bussmann Bussmann Bussma
106. rd Timeout Function is set to Stop and Trip a warning appears and the frequency converter ramps down until it trips then displays an alarm Troubleshooting e Check connections on the serial communication cable e Increase 8 03 Control Word Timeout Time e Check the operation of the communication equipment e Verify a proper installation based on EMC requirements WARNING ALARM 22 Hoist mechanical brake Report value shows what kind it is 0 The torque ref was not reached before timeout 1 There was no brake feedback before timeout WARNING 23 Internal fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting e Check Tan resistance e Check soft charge fuses VVARNING 24 External fan fault The fan vvarning function is an extra protective function that checks if the fan is running mounted The fan warming can be disabled in 74 53 Fan Monitor 101 Disabled VLT AQUA Drive FC 202 Operating Instructions Troubleshooting e Check fan resistance e Check soft charge fuses VVARNING 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 frequency converter is still operational but without the brake function Remove power to the frequency converter and replace the brake r
107. rm installation start up and maintenance by qualified personnel could result in death or serious injury e Installation start up and maintenance must be performed by qualified personnel only 7 2 Status Messages When the frequency converter is in status mode status messages are generated automatically and appear in the bottom line of the display see Illustration 7 1 im E 799RPM 7 83A 36 4kW Q 0 000 9 53 296 Auto Remote Ramping Hand n Local Stop Off Running Jogging Stand by 1 1 2 3 1 Operation mode see Table 7 2 Reference site see Table 7 3 Operation status see Table 7 4 Illustration 7 1 Status Display Table 7 2 to Table 7 4 describe the displayed status messages Off The frequency converter does not react to any control signal until Auto On or Hand On is pressed Auto On The frequency converter is controlled from the control terminals and or the serial communi cation Hand On The frequency converter is controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the control terminals override local control Table 7 1 Operation Mode Remote Local Table 7 2 Refere The speed reference is given from external signals serial communication or internal preset references The frequency converter uses Hand On control or reference values from the LCP
108. rocedures in this manual ACAUTION WINDMILLING Unintended rotation of permanent magnet motors causes risk of personal injury and equipment damage e Ensure that permanent magnet motors are blocked to prevent unintended rotation ACAUTION POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the frequency converter is not properly closed e Before applying power ensure all safety covers are in place and securely fastened 8 MG20MA02 Rev 2013 10 29 Mechanical installation 3 Mechanical Installation 3 1 Unpacking 3 1 1 Items Supplied Items supplied may vary according to product configu ration e Make sure the items supplied and the information on the nameplate correspond to the order confirmation e Check the packaging and the frequency converter visually for damage caused by inappropriate handling during shipment File any claim for damage vvith the carrier Retain damaged parts for clarification VLT AQUA Drive www danfoss com 5 5 T C FC 202P45KTAE20H1XGXXXXSXXXXAXBXCXXXXDX 3 gt P N 131F6653 S N 0380106502 45kW 400V 60HP 460V c 130BD666 10 9 5 IN 3x380 480V 50 60Hz 82 73A C 6 OUT 3x0 Vin 0 590Hz 90 80A CHASSIS IP20 Tamb 45 C 113 F MADE IN EET xu UO Listed 76X1 E134261 Ind Contr Eq CAUTION d See manual for special condition mains fuse 75 voir manual de conditions speclales fusibles VVARNING
109. rs by itself when the abnormal condition is removed Darfi VLT AQUA Drive FC 202 Operating Instructions Alarms Trip An alarm is issued when the frequency converter is tripped which means that the frequency converter suspends operation to prevent frequency converter or system damage The motor coasts to a stop The frequency converter logic continues to operate and monitor the frequency converter status After the fault condition is remedied the frequency converter can be reset It is then ready to start operation again Resetting the frequency converter after trip trip lock A trip can be reset in any of 4 ways e Press Reset on the LCP e Digital reset input command e Serial communication reset input command D Auto reset Trip lock Input power is cycled The motor coasts to a stop The frequency converter continues to monitor the frequency converter status Remove input power to the frequency converter correct the cause of the fault and reset the frequency converter Warning and Alarm Displays e A warning is displayed in the LCP along with the warning number e An alarm flashes along with the alarm number 2 0 0Hz 0 000kVV 0 00A 2 0 0Hz amp 0 E A Earth Fault A14 Auto Remote Trip Illustration 7 2 Alarm Display Example 34 MG20MA02 Rev 2013 10 29 Maintenance Diagnostics an n addition to the text and alarm code in the LCP there are 3 status indicator lights
110. s are in the open position Grounding e Check for sufficient ground connections that are tight and free of oxidation e Grounding to conduit or mounting the back panel to a metal surface is not a suitable grounding Input and output e Check for loose connections 2 e Check that motor and mains are in separate conduit or separated screened cables Panel interior e Inspect that the unit interior is free of dirt metal chips moisture and corrosion e Check that the unit is mounted on an unpainted metal surface Vibration e Check that the unit is mounted solidly or that shock mounts are used as necessary e Check for an unusual amount of vibration Table 4 4 Installation Check List ACAUTION POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the frequency converter is not properly closed e Before applying power ensure all safety covers are in place and securely fastened MG20MAO2 Rev 2013 10 29 19 Commissioning 5 Commissioning 5 1 Safety Instructions See 2 Safety for general safety instructions AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury e Installation start up and maintenance must be performed by qualified personnel only Before applying power 1 Close cover properly 2 Check that all cable g
111. supply SMPS on the power card 24 V 5 V 18 V When powered with 24 V DC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with 3 phase mains voltage all 3 supplies are monitored WARNING 47 24 V supply low The 24 V DC is measured on the control card The external 24 V DC backup power supply may be overloaded otherwise contact the Danfoss supplier WARNING 48 1 8 V supply low The 1 8 V DC supply used on the control card is outside of allowable limits The power supply is measured on the control card Check for a defective control card If an option card is present check for an overvoltage condition WARNING 49 Speed limit When the speed is not within the specified range in 4 11 Motor Speed Low Limit RPM and 4 13 Motor Speed High Limit RPM the frequency converter shows a warning When the speed is below the specified limit in 1 86 Trip Speed Low RPM except when starting or stopping the frequency converter trips ALARM 50 AMA calibration failed Contact the Danfoss supplier or Danfoss Service Department ALARM 51 AMA check Unom and Inom The settings for motor voltage motor current and motor power are wrong Check the settings in parameters 1 20 to 1 25 ALARM 52 AMA low Inom The motor current is too low Check the settings ALARM 53 AMA motor too big The motor is too big for the AMA to operate ALARM 54 AMA motor too small The motor is too small for the AMA to operat
112. t Current VLT N The Rated Output Current Supplied by the Frequency Converter AC Alternating Current AWG E FC IP Ingress Protection 21 The Maximum Output Current o The Rated Output Current Supplied by the Frequency Converter Table 9 1 Symbols and Abbreviations Conventions Numbered lists indicate procedures Bullet lists indicate other information and description of illustrations Italicised text indicates e cross reference e link e parameter name 9 2 Parameter Menu Structure 64 MG20MA02 Rev 2013 10 29 VLT AQUA Drive FC 202 Operating Instructions Appendix aje gt s UNA indino Zy ura indino Zp 6 41 v indino bojeuy 0J89Z ZL OEX WAL JUPISUOD SUI CL OEX WEL YBIH 21 06 wuel MOT 21 06 WAL abeyon YBIH 21 06 eus MOT ZL O X ula ZL OEX indu 6ojeuy 019Z BAIT LL OEX WEL 1uejsuo awl LL OEX WAL LL OEX WL enjeA qpae3 jed MOT LL OEX WEL abeyon YBIH LL O X eus abeyon MOT LL O X 2414 LL OEX indu 5oleuy 0197 BAI TS 6 4 1uejsuo sul 192 14 YS 201 YBIH ys euro y nlPA QP994 J0H MOT yS uan YBIH ps eure JU311N MOT ER 01 9beyoA YBIH ps euro 9beyoA MOT Fe EU UH L Fe indu b
113. ter is not powered Failure to wait the specified time after power has been removed before performing service or repair work could result in death or serious injury 1 Stop motor 2 Disconnect AC mains permanent magnet type motors and remote DC link povver supplies including battery back ups UPS and DC link connections to other frequency converters 3 Wait for the capacitors to discharge fully before performing any service or repair vvork The duration of vvaiting time is specified in Table 2 1 Voltage V Minimum waiting time minutes eee ee EC aaa aaa __ o ozsrs now High voltage may be present even when the warning LED 200 240 380 480 525 600 525 690 indicator lights are off Table 2 1 Discharge Time MG20MA02 Rev 2013 10 29 7 Safety VLT AQUA Drive FC 202 Operating Instructions AWARNING LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to ground the frequency converter properly could result in death or serious injury e Ensure correct grounding of the equipment by a certified electrical installer AWARNING EQUIPMENT HAZARD Contact with rotating shafts and electrical equipment can result in death or serious injury e Ensure only trained and qualified personnel perform installation start up and maintenance e Ensure that electrical work conforms to national and local electrical codes e Follow the p
114. th the equipment turned off and locked out Failure to run output motor cables separately or use screened cables could result in death or serious injury 130BT248 10 e run output motor cables separately or e use screened cables e Comply with local and national electrical codes for cable sizes For maximum wire sizes see 8 1 Electrical Data e Follow motor manufacturer wiring requirements e Motor vviring knockouts or access panels are provided at the base of IP21 NEMA1 12 and higher units Illustration 4 3 Access to Wiring for IP20 and IP21 Enclosures e Do not wire a starting or pole changing device e g Dahlander motor or slip ring induction motor betvveen the frequency converter and the motor y 130BT334 10 Procedure 1 Strip a section of the outer cable insulation 2 Position the stripped wire under the cable clamp to establish mechanical fixation and electrical contact between cable screen and ground 3 Connect ground wire to the nearest grounding terminal in accordance with grounding instructions provided in 4 3 Grounding see lllustration 4 5 4 Connect the 3 phase motor wiring to terminals Illustration 4 4 Access to Wiring for IP55 and IP66 Enclosures 96 U 97 V and 98 W see Illustration 4 5 5 Tighten terminals in accordance with the information provided in 8 7 Connection Tightening See Table 4 2 before tightening the
115. the frequency converter check the motor rotation The motor runs briefly at 5 Hz or the minimum frequency set in 4 72 Motor Speed Low Limit Hz 1 Press Main Menu 2 Scroll to 7 28 Motor Rotation Check and press OK 3 Scroll to 7 Enable The following text appears Note Motor may run in wrong direction 4 Press OK 5 Follow the on screen instructions NO TIC To change the direction of rotation remove power to the frequency converter and vvait for povver to discharge Reverse the connection of any 2 of the 3 motor vvires on the motor or frequency converter side of the connection 26 MG20MA02 Rev 2013 10 29 Dont Commissioning VLT AQUA Drive FC 202 Operating Instructions If warnings or alarms occur see 7 4 List of Warnings and Alarms 5 6 Local control Test 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 e Ensure equipment is safe to operate under any condition e Ensure that the motor system and any 5 attached equipment are ready for start 1 Press Hand On to provide a local start command to the frequency converter 2 Accelerate the frequency converter by pressing 4 to full speed Moving the cursor left of the decimal point provides quicker input changes 3 Note any acceleration problems 4 Press Off Note any deceleration problems In the event o
116. thermistor ensure that the thermistor control wiring is screened and reinforced double insulated A 24 V DC supply voltage is recommended 130BB920 10 Illustration 4 6 Example of Motor Mains and Ground Wiring MG20MAQ02 Rev 2013 10 29 15 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 8 1 Control Terminal Types Terminal description Illustration 4 7 and Illustration 4 8 show the removable frequency converter connectors Terminal functions and Terminal Parameter default settings are summarised in Table 4 3 Digital Inputs Outputs 12 13 24 V DC 24 V DC supply voltage for digital inputs and external transducers A Maximum output current 200 mA for all 24 V loads 18 Start 8 19 5 11 0 No 32 5 14 0 No Digital inputs 0 No operati 2 Default setting Description 130BB921 11 eration Illustration 4 7 Control Terminal Locations 27 5 12 Coast For digital input or inverse output Default setting 29 5 13 is input 12 13 18 19 27 29 32 33 20 37 E 20 Common for digital 0000000000 8 inputs and 0 V 2000000000 potential for 24 V 2 3 supply e oe E E 25 2 37 Safe Torque Safe input optional sli ila NE d ce Analog Inputs Outputs Illustration 4 8 Terminal Numbers 39 Common for analog 124577 42 Speed 0 Programmable analog High Limit output 0 20 mA or e Connector 1
117. tion Wiring Diagram 3 Set switches A53 and A54 to select the signal type U selects voltage 1 selects current For basic serial communication set up select the following 130BD530 10 1 Protocol type in 8 30 Protocol 2 Frequency converter address in 8 31 Address 3 Baud rate in 8 32 Baud Rate e 2 communication protocols are internal to the frequency converter Danfoss FC E o Modbus RTU e Functions can be programmed remotely using the protocol softvvare and RS 485 connection or in parameter group 8 Communications and BUSTER Options OFF ON 52454 267 8 e Selecting a specific communication protocol changes various default parameter settings to match that protocol s specifications along vvith making additional protocol specific parameters available Illustration 4 10 Location of Terminals 53 and 54 Switches e Option cards which install into the frequency converter are available to provide additional communication protocols See the option card 4 8 5 Safe Torque Off STO documentation for installation and operation instructions 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 18 MG20MA02 Rev 2013 10 29 Electrical Installation VLT AQUA Drive FC 202 Operating Instructions 4 9 Installation Check List
118. to install commission and maintain equipment systems and circuits in accordance with pertinent laws and regulations Additionally the personnel must be familiar with the instructions and safety measures described in this document 2 3 Safety Precautions AWARNING HIGH VOLTAGE Frequency converters contain high voltage when connected to AC mains input power Failure to perform installation start up and maintenance by qualified personnel could result in death or serious injury e Installation start up and maintenance must be performed by qualified personnel only VLT AQUA Drive FC 202 Operating Instructions AWARNING UNINTENDED START When the frequency converter is connected to AC mains the motor may start at any time causing risk of death serious injury equipment or property damage The motor can start by means of an external switch a serial bus command an input reference signal from the LCP or LOP or after a cleared fault condition e Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended motor start e Press Off on the LCP before programming parameters e The frequency converter motor and any driven equipment must be in operational readiness when the frequency converter is connected to AC mains AWARNING DISCHARGE TIME The frequency converter contains DC link capacitors which can remain charged even when the frequency conver
119. ue Off feature is used a jumper wire may be required between terminal 12 or 13 and terminal 37 for the frequency converter to operate when using factory default programming values 6 1 Application Examples 6 1 1 Feedback Parameters lt Function E m S 16 22 Terminal 54 424V 136 Low Current DIN 18 16 23 Terminal 54 20 mA DIN 19 High Current 55 COM 20 6 24 Terminal 54 0 DIN 27 Lovv Ref Feedb DIN 29 Value DIN 32 6 25 Terminal 54 50 DIN 33 High Ref Feedb DIN 37 Value FION 4 Notes comments AIN 53 D IN 37 is an option AIN 54 COM 55 4 20mA A OUT 42 COM 39 U I E A54 Table 6 1 Analog Current Feedback Transducer VLT AQUA Drive FC 202 Operating Instructions 24V 12 24 V 13 DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 A OUT 42 COM 39 E A54 30BB676 10 0 10V Parameters 6 20 Terminal 54 10 07 V Eros 6 21 Terminal 54 110 V Eu 6 24 Terminal 54 10 Lovv Ref Feedb Value 6 25 Terminal 54 50 High Ref Feedb Value Default Value Notes comments D IN 37 is an option 24 V 12 24 V 130 DIN 18 DIN 19 COM 20 DIN 27 DIN 29 DIN 32 DIN 33 DIN 37 10V 50 AIN 53 AIN 54 COM 55 A OUT 42 COM 39 U I A A54 130BB677 10 0 10V Parameters 6 20 Terminal
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121. uondo UOISIaA MS uondo 03 02 10 S 89 9 29 91 99 9 S9 9 9 91 9 9 79 9 19 91 09 9 9 91 69 91 89 9 95 9 59 91 9 9 S 9 25 91 0 9 9 91 67 91 9 6 9 8 91 LE 9 9 9 S 91 9 ECO 28 91 0 9 OSCH 22 91 02 9 81 9 11 91 91 9 SL 9 bL 9L 1 9 21 9 11 91 01 9 L 9L 60 91 S0 9 0 9 20 91 10 9 00 9 0 91 66 S 86 SL 6 S 76 S x6 SL LL S 9L S SL SL 67 MG20MA02 Rev 2013 10 29 VLT AQUA Drive FC 202 Operating Instructions Appendix 7 2 8 WAL 1 15407 auul 19114 Z 8gpx lgl Z 8bX WHEL MOT 2 UND 1usun YBIH z gyx Wa JU3JIND MOT Z 8px al Z 8vX du 5oleuy ywn duet 01 8 H T MW duet MOT OL 8pX WAL Joyuow d l l 01 8EX Wa juejsuo SUI 01 8 WHEL 0L 8tX du duet d l l YIH gyx H T ywq dua MOT 8pX H T JoWUOW dwa 8YX Wal 1uejsuo awl WA L 84X indu dusel r duet We ywn duet MO y 8yX Wa JOYUO y da p gyx Wwe JUBISUOD v gX WIE V 8VX 3ndul duet uon un4 uue v Josuas ainjesaduual ad 1 1ndu 01 8pX uma yun almjesadua 01 8YX Wal ad indu Z 8pX uma n n gpx WAL ed indu p gpx wa iuf p gpx US apow anduj dus uondo yndu Josuas uoneAn2y ssed
122. us 3x551 690 V A Intermittent 3x551 690 V A Continuous KVA 525 V AC Continuous KVA 690 V AC Max input current Continuous 3x525 550 V A Intermittent 3x525 550 V A Continuous 3x551 690 V A Intermittent 3x551 690 V A Additional specifications Max cable cross section load sharing mm AWG Max Cable cross section for disconnect mm AWG Estimated power loss at rated max load W Efficiency gt CG Em 2 2 v 2 9N gt WIBRLOTO oola A gt N Un LA Un S Un for mains motor brake and 4 4 4 12 12 12 min 0 2 24 6 4 4 10 12 12 v s os os os ii E N ib Table 8 9 A3 Enclosure Mains Supply 3x525 690 V AC IP20 Protected Chassis P1K1 P7K5 Type Designation Typical Shaft output at 550 V kW Typical Shaft output at 690 V kW IP20 Chassis IP21 Type 1 IP55 Type 12 Output current Continuous 3x525 550 V A Intermittent 60 s overload 3x525 550 V A Continuous 3x551 690 V A Intermittent 60 s overload 3x551 690 V A P11K P15K P18K T P22K N w N continuous KVA at 550 V KVA continuous KVA at 690 V AC KVA Max input current Continuous at 550 V A Intermittent 60 s overload at 550 V A Continuous at 690 V A Intermittent 60 s overload at 690 V A Additional specifications Max cable cross section 5 for mains motor load share and brake mm
123. vercurrent or overvoltage e To avoid tripping switching frequency is reduced to 4 kHz If possible protection mode ends after approximately 10 s Protection mode can be restricted in 14 26 Trip Delay at Inverter Fault The motor is decelerating using 3 81 Quick Stop Ramp Time e Quick stop inverse was selected as a function for a digital input parameter group 5 1 Digital Inputs The corresponding terminal is not active e The quick stop function was activated via serial communication The motor is accelerating decelerating using the active Ramp Up Down The reference a limit value or a standstill is not yet reached The sum of all active references is above the reference limit set in 4 55 Warning Reference High The sum of all active references is below the reference limit set in 4 54 Warning Reference Low 33 Maintenance Diagnostics an Run on ref The frequency converter is running in the reference range The feedback value matches the setpoint value Run request A start command was given but the motor remains stopped until a run permissive signal is received via digital input Running The motor is driven by the frequency converter Sleep Mode The energy saving function is enabled The motor has stopped but restarts automatically When required Motor speed is above the value set in Motor speed is belovv the value set in n Auto On mode the frequency converter Speed high Spee

Operating Instructions VLT AQUA Drive FC 202

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