Danfoss VLT AQUA Drive FC 202 Operating Manual Download Page 6

Page: 6 / 174

4.10.2

Creating Cable Openings for an E3h/E4h

4.10.3

Installing Load share/Regen Terminals to an E3h/E4h

5 Electrical Installation

5.1

Safety Instructions

5.2

EMC-compliant Installation

5.3

Wiring Schematic

5.4

Connecting the Motor

5.5

Connecting the AC Mains

5.6

Connecting to Ground

5.7

E1h Terminal Dimensions

5.8

E2h Terminal Dimensions

5.9

E3h Terminal Dimensions

5.10 E4h Terminal Dimensions

5.11 Control Wiring

5.11.1

Control Cable Access

5.11.2

Routing Control Cables

5.11.3

Control Terminal Types

5.11.4

Relay Terminals

5.11.5

Connecting the Control Cable to the Control Terminals

5.11.6

Disconnecting the Control Cable from the Control Terminals

5.11.7

Enabling Motor Operation

5.11.8

Configuring RS485 Serial Communication

5.11.9

Safe Torque Off (STO) Wiring

5.11.10 Space Heater Wiring

5.11.11 Auxiliary Contact Wiring for Disconnects

5.11.12 Wiring the Brake Resistor Temperature Switch

5.11.13 Selecting the Voltage/Current Input Signal

6 Starting the Drive

6.1

Pre-start Check List

6.2

Applying Power to the Drive

6.3

Programming the Drive

6.3.1

Parameter Overview

6.3.2

Parameter Navigation

6.3.3

Entering System Information

6.3.4

Configuring Automatic Energy Optimization

6.3.5

Configuring Automatic Motor Adaptation

6.4

Testing Before System Start Up

6.4.1

Testing Motor Rotation

6.4.2

Testing Encoder Rotation

6.5

Starting Up the Drive for the First Time

Contents

Operating Guide | VLT® AQUA Drive FC 202

AQ275652274277en-000101 /

Summary of Contents for VLT AQUA Drive FC 202

Page 1: ...Operating Guide VLT AQUA Drive FC 202 355 800 kW Enclosure Sizes E1h E4h...

Page 2: ......

Page 3: ......

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Page 5: ...u 19 4 Mechanical Installation 22 4 1 Items Supplied 22 4 2 Tools Needed 22 4 3 Storing the Drive 23 4 4 Operating Environment 23 4 4 1 Overview 23 4 4 2 Gases 23 4 4 3 Dust 24 4 4 4 Potentially Explo...

Page 6: ...he Control Terminals 61 5 11 7 Enabling Motor Operation 61 5 11 8 Configuring RS485 Serial Communication 62 5 11 9 Safe Torque Off STO Wiring 63 5 11 10 Space Heater Wiring 63 5 11 11 Auxiliary Contac...

Page 7: ...ng Configuration for a Relay Setup with Smart Logic Control 91 7 1 12 Wiring Configuration for a Submersible Pump 91 7 1 13 Wiring Configuration for a Cascade Controller 94 7 1 14 Wiring Configuration...

Page 8: ...puts 140 9 6 10 Control Card 10 V DC Output 141 9 6 11 Control Characteristics 141 9 6 12 Control Card Performance 141 9 6 13 Control Card USB Serial Communication 141 9 7 Fuses 141 9 8 Enclosure Dime...

Page 9: ...he Drive chapter by combining Commissioning and Pre start Check List chapters 3 40 MG22A2xx Previous version 2 70 1 3 Trademarks VLT is a registered trademark for Danfoss A S 1 4 Approvals and Certifi...

Page 10: ...r to the ADN compliant Installation section in the product specific design guide 1 5 Disposal Do not dispose of equipment containing electrical components together with domestic waste Collect it separ...

Page 11: ...ed electrical engineers and are suitably experienced to operate devices systems plant and machinery in accordance with pertinent laws and regulations Are familiar with the basic regulations concerning...

Page 12: ...inutes for the capacitors to discharge fully before performing any service or repair work Measure the voltage level to verify full discharge WARNING UNINTENDED START When the drive is connected to the...

Page 13: ...en the drive is not properly closed Ensure that all safety covers are in place and securely fastened before applying power NOTICE MAINS SHIELD SAFETY OPTION A mains shield option is available for encl...

Page 14: ...iant with specified operating conditions and environments 3 2 Power Ratings Weights and Dimensions for E1h E4h Enclosures Table 2 Power Ratings Weights and Dimensions for E1h E4h Enclosures Standard C...

Page 15: ...REGEN 82 2 6 4 5 11 12 9 1 7 10 8 3 1 Control shelf see illustration 4 3 RFI filter optional 5 Mains terminals 7 Fan power card 2 Local control panel LCP cradle 4 Mains fuses required for UL Complianc...

Page 16: ...ater optional 10 Brake regeneration terminals optional 12 Ground terminals Illustration 2 Interior View of Enclosure E1h Enclosure E2h is Similar Product Overview Operating Guide VLT AQUA Drive FC 202...

Page 17: ...E 82 FASTENER TORQUE M10 19Nm 14FT LB M12 35Nm 26FT LB DC 88 e30bf211 11 1 6 2 5 9 12 13 11 7 8 3 10 4 1 Load share regeneration terminals optional 3 Local control panel LCP cradle 5 Mains fuses optio...

Page 18: ...5 Control Shelf e30bf148 11 Remove Jumper to activate Safe Stop 12 13 18 19 27 29 32 33 20 37 39 42 50 53 54 55 61 68 69 1 3 4 12 9 8 RELAY 1 RELAY 2 01 02 03 04 05 06 2 6 10 7 5 11 13 1 LCP cradle L...

Page 19: ...l Info OK Status 1 1 0 00 kW Off Remote Stop 0 0 Hz On Alarm Warn 0 00 A 0 RPM 0 0 A1 1 A1 2 A1 3 A2 A3 B1 B2 B4 B3 C1 C2 C3 C4 C5 D1 D2 D3 E1 E2 E3 E4 Illustration 5 Graphical Local Control Panel LCP...

Page 20: ...Also provides detailed application steps Refer to Quick Menu mode in the LCP Menu section B3 Main Menu Allows access to all parameters Refer to Main Menu mode in the LCP Menu section B4 Alarm Log Show...

Page 21: ...Reset Resets the drive manually after a fault has been cleared E4 Auto On Puts the system in remote operational mode so it can respond to an external start command by control terminals or serial commu...

Page 22: ...made from default setting Q6 Loggings Use Q6 Loggings for fault finding To get information about the display line readout select Loggings The information is shown as graphs Only parameters selected i...

Page 23: ...on Display 1 Load and Motor 2 Brakes 3 Reference Ramps 0 0 0 00 A Main Menu 1 1 Illustration 7 Main Menu View Product Overview Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 21...

Page 24: ...amb 45 C 113 F at Full Output Current IP21 TYPE 1 SCCR 100 kA at UL Voltage range 525 600 V Listed 36U0 E70524 IND CONT EQ UL Voltage range 525 600 V CAUTION ATTENTION Stored charge wait 40 min Charge...

Page 25: ...nal space heater when the unit is colder than the ambient air Operating in standby mode reduces the risk of condensation as long as the power dissipation keeps the circuitry free of moisture NOTICE EX...

Page 26: ...rature Install short motor cables Use sine wave output filters when shielded motor cables are not used As required by the EU Directive 2014 34 EU any electrical or electronic device intended for use i...

Page 27: ...it weight Ensure that there is enough space around the unit for proper cooling Refer to 9 9 Enclosure Airflow Ensure enough access to open the door Ensure cable entry from the bottom 4 6 Cooling Requi...

Page 28: ...an m3 hr cfm Heat sink fan m3 hr cfm E1h 510 300 994 585 E2h 552 325 1053 1206 620 710 E3h 595 350 994 585 E4h 629 370 1053 1206 620 710 4 8 Lifting the Drive WARNING LIFTING HEAVY LOAD The weight of...

Page 29: ...s of the drive The cable entry plate is necessary to provide cooling air to the control components of the drive via the door fan and to maintain the IP21 Type 1 or IP54 Type 12 protection rating 4 9 1...

Page 30: ...up or down Loosely secure with 2 M10 nuts and locking brackets See illustration 11 2 Verify that there is 225 mm 9 in top clearance for air exhaust 3 Verify that the air intake at the bottom front of...

Page 31: ...g bracket Illustration 11 Pedestal to Enclosure Back Mounting Points e30bf207 10 1 2 3 1 Enclosure 3 M10x30 fasteners rear corner bolts not shown 2 Pedestal Illustration 12 Pedestal to Enclosure Mount...

Page 32: ...e using a sheet metal punch 2 Insert the cable entry plate using 1 of the following methods To insert the cable entry plate through the pedestal slide the cable entry plate through the slot 4 in the f...

Page 33: ...e illustration 14 Procedure 1 Remove the bottom panel and terminal cover See illustration 15 A Detach the bottom panel by removing 4 T25 screws B Remove 5 T20 screws that secure the bottom of the driv...

Page 34: ...10 2 1 Plastic square 2 Squares removed for cable access Illustration 14 Plastic Cable Entry Plate Mechanical Installation Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 32 Da...

Page 35: ...terminals optional 3 Terminal cover 5 Track guide 2 Bottom panel 4 Grommet access hole for control wiring 6 Slotted drive bracket Mechanical Installation Operating Guide VLT AQUA Drive FC 202 AQ27565...

Page 36: ...the 2 M5 fasteners for reuse later 3 Remove the plastic backing and install the terminal plate over the load share regen opening Secure with the 2 M5 fasteners and torque to 2 3 Nm 20 in lb 4 Install...

Page 37: ...gether can charge equipment capacitors even with the equipment turned off and locked out Failure to run output motor cables separately or use shielded cables could result in death or serious injury Ru...

Page 38: ...el alongside motor and brake cables For communication and command control lines follow the particular communication protocol standards For example USB must use shielded cables but RS485 ethernet can u...

Page 39: ...ve devices or galvanic isolation For installations above 2000 m 6500 ft altitude contact Danfoss regarding PELV compliance NOTICE PELV COMPLIANCE Prevent electric shock by using protective extra low v...

Page 40: ...C 3 Control cables 5 Mains supply 7 Star washers 9 Motor cable shielded 2 Minimum 16 mm2 6 AWG equalizing cable 4 Minimum 200 mm 7 9 in between control cables motor cables and mains cables 6 Bare unpa...

Page 41: ...cabinet grounding 15 Metal box 17 Motor 12 Cable insulation stripped 14 Brake resistor 16 Connection to motor 18 EMC cable gland Illustration 17 Example of Proper EMC Installation Electrical Installat...

Page 42: ...NPN 33 D IN 32 D IN 1 2 ON A53 U I S201 ON 2 1 A54 U I S202 ON 0 4 20 mA OFF 0 to 10 V 95 400 V AC 2A P 5 00 R 82 R 81 37 D IN 1 P RS485 68 N RS485 69 COM RS485 61 0V 5V S801 RS485 RS485 2 1 ON S801...

Page 43: ...pedestal of IP21 IP54 Type 1 Type 12 units Do not wire a starting or pole changing device for example Dahlander motor or slip ring induction motor between the drive and the motor Procedure 1 Strip a...

Page 44: ...83 FASTENER TORQUE M10 19Nm 14FT LB M12 35Nm 26FT LB Illustration 19 AC Motor Terminals E1h shown 5 5 Connecting the AC Mains Context Size the wiring according to the input current of the drive For m...

Page 45: ...h the grounding instructions provided in 5 6 Connecting to Ground 4 Connect the 3 phase AC input power wiring to terminals R S and T See illustration 20 5 Tighten the terminals in accordance with the...

Page 46: ...9Nm 14FT LB M12 35Nm 26FT LB T L3 93 S L2 92 R L1 91 FASTENER TORQUE M10 19Nm 14FT LB M12 35Nm 26FT LB Illustration 20 AC Mains Terminals E1h shown Electrical Installation Operating Guide VLT AQUA Dri...

Page 47: ...ction 10 mm2 6 AWG or 2 rated ground wires terminated separately Tighten the terminals in accordance with the information provided in 9 10 Fastener Torque Ratings For EMC compliant installation Establ...

Page 48: ...19Nm 14FT LB M12 35Nm 26FT LB U T1 96 V T2 97 W T3 98 T L3 93 S L2 92 R L1 91 FASTENER TORQUE M10 19Nm 14FT LB M12 35Nm 26FT LB FASTENER TORQUE M10 19Nm 14FT LB M12 35Nm 26FT LB Illustration 21 Ground...

Page 49: ...8 241 9 5 171 6 7 414 16 3 361 14 2 331 13 0 501 19 7 497 19 6 431 17 0 512 20 2 4 1 Mains terminals 3 Motor terminals 2 Brake or regen terminals 4 Ground terminals M10 nut Terminal dimensions Illustr...

Page 50: ...11 4 377 14 8 0 0 0 164 6 4 290 11 4 18 0 7 0 0 0 84 3 3 42 1 7 5X 0 0 0 36 1 4 44 1 8 14 0 5 Illustration 23 E1h Terminal Dimensions Side Views Electrical Installation Operating Guide VLT AQUA Drive...

Page 51: ...3 19 0 409 16 1 387 15 2 597 23 5 579 22 8 503 19 8 479 18 9 568 22 4 519 20 4 608 23 9 2 3 4 1 Mains terminals 3 Motor terminals 2 Brake or regen terminals 4 Ground terminals M10 nut Illustration 24...

Page 52: ...0 0 164 6 4 290 11 4 e30bf690 10 A 18 0 7 0 0 0 84 3 3 42 1 7 5X 0 0 0 36 1 4 44 1 8 14 0 5 A Illustration 25 E2h Terminal Dimensions Side Views Electrical Installation Operating Guide VLT AQUA Drive...

Page 53: ...4 7 6 174 6 9 201 7 9 284 11 2 340 13 4 314 12 3 367 14 4 444 17 5 423 16 7 450 17 7 2 3 4 1 1 Mains terminals 3 Motor terminals 2 Brake or regen terminals 4 Ground terminals M8 and M10 nuts Illustrat...

Page 54: ...0 0 184 7 2 184 7 2 A 5X 14 0 5 44 1 8 0 0 0 36 1 4 18 0 7 0 0 0 84 3 3 42 1 7 A Illustration 27 E3h Mains Motor and Ground Terminal Dimensions Side Views Electrical Installation Operating Guide VLT...

Page 55: ...0 0 35 1 4 0 0 0 15 0 6 35 1 4 50 2 0 75 3 0 90 3 5 125 4 9 140 5 5 2X 125 4 9 0 0 0 Illustration 28 E3h Load Share Regen Terminal Dimensions Side Views Electrical Installation Operating Guide VLT AQ...

Page 56: ...499 19 6 435 17 1 531 20 9 256 10 1 33 1 3 2 3 4 540 21 2 432 17 0 521 20 5 472 18 6 561 22 1 1 Mains terminals 3 Motor terminals 2 Brake or regen terminals 4 Ground terminals M8 and M10 nuts Illustra...

Page 57: ...0 0 0 0 0 0 160 6 3 0 0 0 287 11 3 184 7 2 184 7 2 A 18 0 7 0 0 0 84 3 3 42 1 7 Illustration 30 E4h Mains Motor and Ground Terminal Dimensions Side Views Electrical Installation Operating Guide VLT A...

Page 58: ...lustration 31 E4h Load Share Regen Terminal Dimensions Side Views 5 11 Control Wiring 5 11 1 Control Cable Access All terminals to the control cables are inside the drive below the LCP To access eithe...

Page 59: ...ure that the thermistor control cable is shielded and reinforced double insulated A 24 V DC supply is recommended 5 Connect the control cables to the relevant options on the control card For more deta...

Page 60: ...Connectors Table 10 Serial Communication Terminals Terminal Parameter Default Setting Description 61 Integrated RC filter for cable shield ONLY for connecting the shield if EMC problems exist 68 Para...

Page 61: ...set up allows the drive to operate with factory default program ming values Table 12 Analog Input Output Terminal Descriptions Terminal Parameter Default setting Description 39 Common for analog outpu...

Page 62: ...inimum and maximum control cable cross section refer to 9 5 Cable Specifications NOTICE ELECTRICAL INTERFERENCE Minimize interference by keeping control wires as short as possible and separate from hi...

Page 63: ...push the screwdriver inward 2 Pull gently on the wire to free it from the control terminal contact 5 11 7 Enabling Motor Operation Context If the status line at the bottom of the LCP reads AUTO REMOT...

Page 64: ...group 8 Communications and Options Selecting a specific communication protocol changes various default parameter settings to match the specifications of the protocol making more protocol specific par...

Page 65: ...eld wired and controlled by an HVAC management system Specifications Nominal voltage 100 240 Wire size 12 24 AWG 4 0 25 mm2 5 11 11 Auxiliary Contact Wiring for Disconnects The disconnect is an option...

Page 66: ...wire the brake resistor temperature switch in 1 of the following configurations Normally closed Connect to terminals 104 and 106 Normally open Connect to terminals 104 and 105 4 Secure the switch wire...

Page 67: ...ER OFF ON A53 A54 U I U I 1 2 N O 1 2 N O 1 2 N O 1 2 N O Illustration 39 Location of Switches A53 and A54 Electrical Installation Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R070...

Page 68: ...the signals if necessary Use shielded cable or twisted pair and ensure that the shield is terminated correctly Input output cables Check for loose connections Check that motor and mains are in separat...

Page 69: ...interlock is shown it indicates that the unit is ready to operate but is missing an input signal on for example terminal 27 See 5 11 7 Enabling Motor Operation for details Procedure 1 Before applying...

Page 70: ...s Parameter subgroup Parameter 0 01 Language Parameter Parameter 0 02 Motor Speed Unit Parameter Parameter 0 03 Regional Settings Parameter 6 3 2 Parameter Navigation Use the following LCP keys to nav...

Page 71: ...rameter 1 20 Motor Power kW 4 00 kW C Parameter 1 22 Motor Voltage 400 V D Parameter 1 23 Motor Frequency 50 Hz E Parameter 1 24 Motor Current 9 00 A F Parameter 1 25 Motor Nominal Speed 1420 RPM G Pa...

Page 72: ...ress OK 4 Select parameter 1 29 Automatic Motor Adaptation AMA and press OK 5 Select 1 Enable complete AMA and press OK 6 Press Hand On and then OK The test runs automatically and indicates when it is...

Page 73: ...is positive the test was successful If feedback is negative the encoder connection is wrong Use either parameter 5 71 Term 32 33 Encoder Direction or parameter 17 60 Feedback Direction to inverse the...

Page 74: ...s can be uploaded into the LCP memory and stored as a back up Multiple units can be programmed quickly by connecting the LCP to the unit and downloading the stored parameter settings Settings that are...

Page 75: ...up Start up takes slightly longer than normal 6 After alarm 80 Drive initialized appears press Reset 6 6 4 Restoring Factory Default Settings Using Manual Initialization Context NOTICE LOSS OF DATA Re...

Page 76: ...1 1 Wiring Configuration for Automatic Motor Adaptation AMA Table 16 Wiring Configuration for AMA with T27 Connected Parameters 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A O...

Page 77: ...omments Parameter group 1 2 Motor Data must be set ac cording to motor 7 1 3 Wiring Configuration Speed Table 18 Analog Speed Reference Voltage Parameters 10V A IN A IN COM A OUT COM 50 53 54 55 42 39...

Page 78: ...es comments D IN 37 is an option Table 20 Speed Reference Using a Manual Potentiometer Parameters 10 V A IN A IN COM A OUT COM 50 53 54 55 42 39 A53 U I 5k e30bb683 11 Drive Function Setting Parameter...

Page 79: ...Digital Input 19 Freeze Reference Parameter 5 13 Terminal 29 Digital Input 21 Speed Up Parameter 5 14 Terminal 32 Digital Input 22 Speed Down Default value Notes comments D IN 37 is an option e30bb840...

Page 80: ...54 55 42 39 A 54 U I e30bb675 11 Drive Function Setting Parameter 6 22 Terminal 54 Low Current 4 mA Parameter 6 23 Terminal 54 High Current 20 mA Parameter 6 24 Terminal 54 Low Ref Feedb value 0 Param...

Page 81: ...V e30bb676 11 Drive Function Setting Parameter 6 20 Terminal 54 Low Voltage 0 07 V Parameter 6 21 Terminal 54 High Voltage 10 V Parameter 6 24 Terminal 54 Low Ref Feedb value 0 Parameter 6 25 Terminal...

Page 82: ...V e30bb677 11 Drive Function Setting Parameter 6 20 Terminal 54 Low Voltage 0 07 V Parameter 6 21 Terminal 54 High Voltage 10 V Parameter 6 24 Terminal 54 Low Ref Feedb value 0 Parameter 6 25 Terminal...

Page 83: ...OM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 e30bb680 11 Drive Function Setting Parameter 5 10 Terminal 18 Digital Input 8 Start Parameter 5 12 Terminal 27 Digital Input 7 External interlock Def...

Page 84: ...1 Drive Function Setting Parameter 5 10 Terminal 18 Digital Input 8 Start Parameter 5 12 Terminal 27 Digital Input 7 External interlock Default value Notes comments If parameter 5 12 Terminal 27 Digit...

Page 85: ...ion Setting Parameter 5 10 Terminal 18 Digital Input 8 Start Parameter 5 11 Terminal 19 Digital Input 52 Run permissive Parameter 5 12 Terminal 27 Digital Input 7 External interlock Parameter 5 40 Fun...

Page 86: ...r 5 12 Terminal 27 Digital Input 0 No operation Parameter 5 19 Terminal 37 Safe Stop 1 Safe Stop Alarm Default value Notes comments If parameter 5 12 Terminal 27 Digital Input is set 0 No operation a...

Page 87: ...hed Start Parameter 5 12 Terminal 27 Digital Input 6 Stop Inverse Default value Notes comments If parameter 5 12 Terminal 27 Digital Input is set 0 No operation a jumper wire to terminal 27 is not nee...

Page 88: ...rminal 19 Digital Input 10 Reversing Parameter 5 12 Terminal 27 Digital Input 0 No operation Parameter 5 14 Terminal 32 Digital Input 16 Preset ref bit 0 Parameter 5 15 Terminal 33 Digital Input 17 Pr...

Page 89: ...10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 e30bb928 12 Drive Function Setting Parameter 5 11 Terminal 19 Digital Input 1 Reset Default value Notes comments D IN 37 i...

Page 90: ...eter 8 31 Address 1 Parameter 8 32 Baud Rate 9600 Default value Notes comments Select protocol address and baud rate in the above mentioned parameters D IN 37 is an option 7 1 9 Wiring Configuration M...

Page 91: ...ve Function Setting Parameter 1 90 Motor Thermal Protection 2 Thermistor trip Parameter 1 93 Thermistor Source 1 Analog input 53 Default value If only a warning is required set parameter 1 90 Motor Th...

Page 92: ...39 e30bd667 11 Drive Function Setting Parameter 1 90 Motor Thermal Protection 100 Default value To disable regen decrease parameter 1 90 Motor Thermal Protection to 0 If the application uses motor bra...

Page 93: ...ator 0 Parameter 13 52 SL Controller Action 32 Set digital out A low Parameter 5 40 Function Relay 80 SL digital output A Default value Notes comments If the limit in the feedback monitor is exceeded...

Page 94: ...ion could be to use a shielded cable above the well and to attach the shield to the steel well pipe A sine wave filter also reduces the EMI from unshielded motor cables To prevent damage to the thrust...

Page 95: ...unit in parameter 20 12 Reference Feed back Unit Parameter 3 84 Initial Ramp Time 2 s Parameter 3 88 Final Ramp Time 2 s Parameter 3 41 Ramp 1 Ramp Up Time 8 s depending on size Parameter 3 42 Ramp 1...

Page 96: ...for Pipe Fill Mode 7 1 13 Wiring Configuration for a Cascade Controller Refer to illustration 45 for an example with the built in basic cascade controller with 1 variable speed pump lead and 2 fixed...

Page 97: ...20 mA L1 L2 L3 Ground N e30ba378 10 P 24 V DC 12 13 18 19 27 29 32 33 20 39 42 50 53 54 55 COM D IN D IN 1 D IN1 D IN1 D OUT D IN1 D OUT D IN 1 D IN 1 A IN2 A OUT1 COM A OUT 10 V OUT A IN1 COM A IN 96...

Page 98: ...eed Pump L1 L2 L3 L1 L2 L3 L1 L2 L3 Relay 1 Relay 2 e30ba376 10 Drive Illustration 46 Fixed Variable Speed Pump Wiring Diagram Wiring Configuration Examples Operating Guide VLT AQUA Drive FC 202 AQ275...

Page 99: ...n the contactor corresponding to the pump controlled by the relay For example relay 1 cuts in contactor K1 which becomes the lead pump K1 blocks for K2 via the mechanical interlock preventing mains fr...

Page 100: ...that the drive motor and any driven equipment are in operational readiness 8 2 Heat Sink Service 8 2 1 Heat Sink Access Panel The drive can be ordered with an optional access panel in the back of the...

Page 101: ...Messages 8 3 1 Status Message Overview When the drive is in status mode status messages automatically appear in the bottom line of the LCP display See illustration 49 Maintenance Diagnostics and Troub...

Page 102: ...d Auto The drive requires external commands to execute functions The start stop commands are sent via the control ter minals and or the serial communication Hand The navigation keys on the LCP can be...

Page 103: ...in parameter 2 00 DC Hold Current DC stop The motor is held with a DC current parameter 2 01 DC Brake Current for a specified time parameter 2 02 DC Brak ing Time DC brake is activated in parameter 2...

Page 104: ...parameter 3 81 Quick Stop Ramp Time 4 Quick stop inverse was selected as a function for a digital input parameter group 5 1 Digital Inputs The cor responding terminal is not active The quick stop fun...

Page 105: ...the drive is subject to an overtemperature or when the drive is protecting the motor process or mechanism The drive prevents a restart until the cause of the fault has disappeared To cancel the trip...

Page 106: ...k On On flashing e30bp086 13 Status 0 0Hz 0 000kW 0 00A 0 0Hz 0 Earth Fault A14 Auto Remote Trip 1 1 Illustration 51 Alarm Example 8 4 2 WARNING 1 10 Volts Low Cause The control card voltage is less t...

Page 107: ...erminals 1 3 and 5 for signals terminals 2 4 and 6 common Check that the drive programming and switch settings match the analog signal type Perform an input terminal signal test 8 4 4 WARNING ALARM 3...

Page 108: ...ot be reset until the counter is below 90 Troubleshooting Compare the output current shown on the LCP with the drive rated current Compare the output current shown on the LCP with the measured motor c...

Page 109: ...only and terminal 50 Select the terminal to use in parameter 1 93 Thermistor Resource 8 4 12 WARNING ALARM 12 Torque Limit Cause The torque has exceeded the value in parameter 4 16 Torque Limit Motor...

Page 110: ...tage Parameter 15 43 Software Version Parameter 15 45 Actual Typecode String Parameter 15 49 SW ID Control Card Parameter 15 50 SW ID Power Card Parameter 15 60 Option Mounted Parameter 15 61 Option S...

Page 111: ...lay Troubleshooting Set the affected parameter to a valid value 8 4 19 WARNING ALARM 22 Hoist Mechanical Brake Cause The value of this warning alarm shows the type of warning alarm 0 The torque refere...

Page 112: ...ational but without the brake function Troubleshooting Remove the power to the drive and replace the brake resistor refer to parameter 2 15 Brake Check 8 4 23 WARNING ALARM 26 Brake Resistor Power Lim...

Page 113: ...rrect airflow clearance above and below the drive Blocked airflow around the drive Damaged heat sink fan Dirty heat sink 8 4 27 ALARM 30 Motor Phase U Missing Cause Motor phase U between the drive and...

Page 114: ...the drive and the motor is missing Troubleshooting WARNING HIGH VOLTAGE AC drives contain high voltage when connected to AC mains input DC supply or load sharing Failure to perform installation start...

Page 115: ...ALARM 38 Internal Fault Cause When an internal fault occurs a code number defined in table 43 is shown Troubleshooting Cycle power Check that the option is properly installed Check for loose or missin...

Page 116: ...the control card 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with the control b...

Page 117: ...4 V DC external supply or specify that no external supply is used via parameter 14 80 Option Supplied by External 24VDC 0 No A change in parameter 14 80 Option Supplied by External 24VDC requires a po...

Page 118: ...C supply is used verify proper supply power Check for a defective heat sink fan 8 4 43 WARNING 47 24 V Supply Low Cause The supply on the power card is out of range There are 3 supplies generated by t...

Page 119: ...tor voltage motor current and motor power are wrong Troubleshooting Check settings in parameters 1 20 to 1 25 8 4 48 ALARM 52 AMA Low Inom Cause The motor current is too low Troubleshooting Check the...

Page 120: ...rent limit if necessary Ensure that the system can operate safely at a higher limit 8 4 56 WARNING 60 External Interlock Cause A digital input signal indicates a fault condition external to the drive...

Page 121: ...LARM 63 Mechanical Brake Low Cause The actual motor current has not exceeded the release brake current within the start delay time window 8 4 60 WARNING 64 Voltage Limit Cause The load and speed combi...

Page 122: ...esume normal operation apply 24 V DC to terminal 37 then send a reset signal via bus digital or by pressing Reset 8 4 65 ALARM 69 Power Card Temperature Cause The temperature sensor on the power card...

Page 123: ...ly device using STO specified through selection 4 PTC 1 alarm or 5 PTC 12 warning in parameter 5 19 Terminal 37 Safe Stop STO is activated but X44 10 is not activated 8 4 69 WARNING 73 Safe Stop Auto...

Page 124: ...ooting Disable the function or select an alarm warning in parameter 4 34 Tracking Error Function Investigate the mechanics around the load and motor Check feedback connections from motor encoder to dr...

Page 125: ...RM 88 Option Detection Cause A change in the option layout is detected Parameter 14 89 Option Detection is set to 0 Frozen configuration and the option layout has been changed Troubleshooting To apply...

Page 126: ...ARNING ALARM 104 Mixing Fan Fault Cause The fan is not operating The fan monitor checks that the fan is spinning at power up or whenever the mixing fan is turned on The mixing fan fault can be configu...

Page 127: ...The temperature fault cannot reset until the temperature drops below the defined heat sink temperature The trip and reset points are different based on the power size This alarm is equivalent to Alar...

Page 128: ...power card PUD Troubleshooting Press Reset to stop the alarm 8 4 98 ALARM 425 FPC Update Failure Cause This alarm is generated after the control card failed to update the fan power card PUD Troublesh...

Page 129: ...r terminals 50 55 Wire the terminals properly Incompatible LCP LCP from VLT 2800 or 5000 6000 8000 FCD or FCM Use only LCP 101 P N 130B1124 or LCP 102 P N 130B1107 Wrong contrast setting To adjust the...

Page 130: ...tor phase connection or set parameter 1 06 Clockwise Direction to 1 Inverse Motor is not reaching maxi mum speed Frequency limits set wrong Check output limits in parameter 4 13 Motor Speed High Limit...

Page 131: ...alance greater than 3 Problem with motor or motor wiring Rotate output motor cables 1 posi tion U to V V to W W to U If the imbalanced leg follows the wire the problem is in the motor or motor wiring...

Page 132: ...A 430 470 470 540 540 582 Continuous kVA at 480 V kVA 449 491 491 564 564 607 Maximum input current Continuous at 400 V A 578 634 634 718 670 771 Continuous at 460 480 V A 520 569 569 653 653 704 Maxi...

Page 133: ...ft shielded motor cables at rated load and rated frequency Efficiency measured at nominal current For energy efficiency class see 9 4 Ambient Conditions For part load losses see www danfoss com vlten...

Page 134: ...requency is higher than the default setting the power losses can increase LCP and typical control card power consumptions are included For power loss data according to EN 50598 2 refer to www danfoss...

Page 135: ...0 0 590 Heat sink overtemperature trip C F 110 230 110 230 110 230 Control card overtemperature trip C F 80 176 80 176 80 176 Power card overtemperature trip C F 85 185 85 185 85 185 Fan power card ov...

Page 136: ...690 V A 549 607 607 704 704 819 Maximum number and size of cables per phase E1h E2h Mains and motor without brake mm2 AWG 5x240 5x500 mcm 6x240 5x500 mcm 6x240 5x500 mcm Mains and motor with brake mm...

Page 137: ...kA short circuit current rating SCCR at 480 600 V Supply terminals L1 L2 L3 Supply voltage 1 380 480 500 V 10 525 690 V 10 Supply frequency 50 60 Hz 5 Maximum imbalance temporary between mains phases...

Page 138: ...3 Class 3C3 Test method according to IEC 60068 2 43 H2S 10 days Ambient temperature at 60 AVM switching mode with derating Maximum 55 C 131 F 1 at full continuous FC output current HO Maximum 50 C 12...

Page 139: ...0 PNP 5 V DC Voltage level logic 1 PNP 10 V DC Voltage level logic 0 NPN 19 V DC Voltage level logic 1 NPN 14 V DC Maximum voltage on input 28 V DC Pulse frequency range 0 110 kHz Input resistance Ri...

Page 140: ...o 20 mA scaleable Input resistance Ri Approximately 200 Maximum current 30 mA Resolution for analog inputs 10 bit sign Accuracy of analog inputs Maximum error 0 5 of full scale Bandwidth 100 Hz The an...

Page 141: ...RX Terminal number 61 Common for terminals 68 and 69 The RS485 serial communication circuit is galvanically isolated from the supply voltage PELV 9 6 7 Digital Outputs Programmable digital pulse outp...

Page 142: ...load 24 V DC 0 1 A Minimum terminal load on 1 3 NC 1 2 NO 24 V DC 10 mA 24 V AC 2 mA Environment according to EN 60664 1 Overvoltage category III pollution degree 2 Relay 02 terminal number 4 6 break...

Page 143: ...standard host device USB cable 2 The USB connection is galvanically isolated from the supply voltage PELV and other high voltage terminals 3 The USB connection is not galvanically isolated from ground...

Page 144: ...a factory installed disconnect switch require Class L branch circuit fusing to meet the 100 kA SCCR for the drive If a circuit breaker is used the SCCR rating is 42 kA The input voltage and power rati...

Page 145: ...ensions e30bf648 10 22 0 8 393 15 5 602 23 7 2043 80 4 2002 78 8 1553 61 1 1393 54 9 912 35 9 13 0 5 3X Illustration 53 Front View of E1h Specifications Operating Guide VLT AQUA Drive FC 202 AQ2756522...

Page 146: ...2X 9 0 7 2X 35 1 4 2X 125 4 9 2X 280 11 0 2X 190 7 5 1 513 20 2 567 22 3 1 Knockout panel Illustration 54 Side View of E1h Specifications Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101...

Page 147: ...47 6 168 6 6 1800 70 9 601 23 7 69 2 7 464 18 3 4X 457 18 0 4X 73 2 8 1 96 3 8 1 Heat sink access panel optional Illustration 55 Back View of E1h Specifications Operating Guide VLT AQUA Drive FC 202...

Page 148: ...750 29 5 558 22 0 75 22 0 8 137 5 4 560 22 0 412 16 2 184 7 3 424 16 7 1 Cable entry plate Illustration 56 Door Clearance and Cable Entry Plate Dimensions for E1h Specifications Operating Guide VLT AQ...

Page 149: ...80 4 2002 78 8 1553 61 1 1393 54 9 912 35 9 394 15 5 698 27 5 97 3 8 13 0 5 3X e30bf654 10 Illustration 57 Front View of E2h Specifications Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 00010...

Page 150: ...13 20 2 567 22 3 2X 280 11 0 2X 190 7 5 2X 35 1 4 2X 125 4 9 e30bf653 10 1 Knockout panel Illustration 58 Side View of E2h Specifications Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101...

Page 151: ...6 601 23 7 69 2 7 4X 121 4 8 560 22 0 4X 457 18 0 1209 47 6 508 20 0 254 10 0 1 1 Heat sink access panel optional Illustration 59 Back View of E2h Specifications Operating Guide VLT AQUA Drive FC 202...

Page 152: ...4 653 25 7 22 0 8 508 20 0 656 25 8 1 293 11 5 173 6 8 656 25 8 22 0 8 1 Cable entry plate Illustration 60 Door Clearance and Cable Entry Plate Dimensions for E2h Specifications Operating Guide VLT AQ...

Page 153: ...5 1348 53 1 13 0 5 3X 506 19 9 30 1 2 13 0 5 10 0 4 10 0 4 15 0 6 A A 447 17 6 346 13 6 1 1 Disconnect option only Illustration 61 Front View of E3h Specifications Operating Guide VLT AQUA Drive FC 2...

Page 154: ...8 10 20 0 8 2X 2X 101 4 0 2X 19 0 7 2X 18 0 7 2X 21 0 8 482 19 0 Illustration 62 Side View of E3h Specifications Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 152 Danfoss A S...

Page 155: ...44 29 3 39 1 5 22 0 9 215 8 5 48 1 9 206 8 1 412 16 2 430 16 9 4X 457 18 0 464 18 3 1 1 Heat sink access panel optional Illustration 63 Back View of E3h Specifications Operating Guide VLT AQUA Drive F...

Page 156: ...2 1 RFI shield termination standard with RFI option 3 Cable entry plate 2 Cable EMC clamp Illustration 64 RFI Shield Termination and Cable Entry Plate Dimensions for E3h Specifications Operating Guide...

Page 157: ...0 4 15 0 6 A A 1578 62 1 1537 60 5 1348 53 1 30 1 2 604 23 8 13 0 5 3X 447 17 6 337 13 3 1 1 Disconnect option only Illustration 65 Front View of E4h Specifications Operating Guide VLT AQUA Drive FC 2...

Page 158: ...6 10 20 0 8 2X 2X 101 4 0 2X 19 0 7 2X 18 0 7 2X 21 0 8 482 19 0 Illustration 66 Side View of E4h Specifications Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 156 Danfoss A S...

Page 159: ...6 136 5 4 39 1 5 22 0 9 263 10 4 4X 457 18 0 744 29 3 4X 74 2 9 560 22 0 526 20 7 154 6 1 1 1 Heat sink access panel optional Illustration 67 Back View of E4h Specifications Operating Guide VLT AQUA D...

Page 160: ...2 1 RFI shield termination standard with RFI option 3 Cable entry plate 2 Cable EMC clamp Illustration 68 RFI Shield Termination and Cable Entry Plate Dimensions for E4h Specifications Operating Guide...

Page 161: ...E1h E2h Left and E3h E4h Right 9 10 Fastener Torque Ratings Apply the correct torque when tightening fasteners in the locations that are listed in table 51 Too low or too high torque when fastening an...

Page 162: ...84 Load sharing terminals M10 M12 19 168 37 335 Regen terminals Enclosures E1h E2h M8 9 6 84 Regen terminals Enclosures E3h E4h M10 M12 19 168 37 335 Relay terminals 0 5 4 Door panel cover M5 2 3 20 C...

Page 163: ...ating current AEO Automatic energy optimization ACP Application control processor AMA Automatic motor adaptation AWG American wire gauge CPU Central processing unit CSIV Customer specific initializati...

Page 164: ...Lq Motor q axis inductance LC Inductor capacitor LCP Local control panel LED Light emitting diode LOP Local operation pad mA Milliamp MCB Miniature circuit breakers MCCB Molded case circuit breaker M...

Page 165: ...er STO Safe Torque Off TLIM Torque limit UM N Nominal motor voltage V Volt VVC Voltage vector control Xh Motor main reactance 10 3 International North American Default Parameter Settings Setting param...

Page 166: ...terlock Parameter 5 40 Function Relay Alarm No alarm Parameter 6 15 Terminal 53 High Ref Feedb Value 50 Hz 60 Hz Parameter 6 50 Terminal 42 Output Speed 0 HighLim Speed 4 20 mA Parameter 14 20 Reset M...

Page 167: ...cation 14 16 Terminal torque rating 160 Brake resistor Terminal location 17 Warning 110 Wiring schematic 40 Wiring the temperature switch 64 Burst transient 45 Bus termination switch 16 C Cable entry...

Page 168: ...147 E3h 151 E4h 155 External alarm reset 87 External interlock 81 118 F Factory default settings 73 Fan power card Location 13 16 Overtemperature trip point 131 133 Warning 125 127 Fans Dust 24 Exter...

Page 169: ...Terminal torque rating 160 Wiring schematic 40 M Main menu 18 Mains Cable specifications 130 133 Connecting 42 Specifications 135 Terminal dimensions 47 49 51 54 Terminal location 13 15 Terminal torqu...

Page 170: ...201 S202 switches 138 Safe Torque Off Terminal 37 specifications 137 Warning 120 121 121 121 Wiring schematic 40 Safety instructions 35 Serial communication Configuring RS485 62 Descriptions and defau...

Page 171: ...10 67 98 USB Port location 17 Specifications 141 V Version number 7 Voltage Safety warning 9 67 108 111 112 112 Selecting input signal 64 Voltage level 137 W Warnings Definition 103 Indicator light 19...

Page 172: ...Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 170 Danfoss A S 2020 01...

Page 173: ...Operating Guide VLT AQUA Drive FC 202 AQ275652274277en 000101 130R0708 171 Danfoss A S 2020 01...

Page 174: ...der 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 D...

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