Danfoss VLT AQUA Drive FC 202 User Manual Download

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MAKING MODERN LIVING POSSIBLE

Instruction Manual

VLT

AQUA Drive FC 202

0.25–90 kW

www.DanfossDrives.com

Summary of Contents for VLT AQUA Drive FC 202

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual VLT AQUA Drive FC 202 0 25 90 kW www DanfossDrives com...

Page 2: ......

Page 3: ...ons 14 4 2 EMC compliant Installation 14 4 3 Grounding 14 4 4 Wiring Schematic 16 4 5 Access 18 4 6 Motor Connection 18 4 7 AC Line Input Connection 19 4 8 Control Wiring 19 4 8 1 Control Terminal Typ...

Page 4: ...ooting 49 8 Specifications 52 8 1 Electrical Data 52 8 1 1 Line Power Supply 1x200 240 V AC 52 8 1 2 Line Power Supply 3x200 240 V AC 53 8 1 3 Line Power Supply 1x380 480 V AC 54 8 1 4 Line Power Supp...

Page 6: ...nt version and the corresponding software version Edition Remarks Software version MG20MAxx Replaces MG20M9xx 2 xx Table 1 1 Document and Software Version 1 4 Product Overview 1 4 1 Intended Use The a...

Page 7: ...rive 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...

Page 8: ...slot 4 Digital I O and 24 V power supply 14 Grounding clamp PE 5 Analog I O connector 15 Cable shield connector 6 Cable shield connector 16 Brake terminal 81 82 7 USB connector 17 Load sharing termin...

Page 9: ...82 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Line power input terminals 91 L1 92 L2 93 L3 6 Cable shield connector 15 USB connector 7 Decoupling plate 16 Serial bus terminal switc...

Page 10: ...ns 8 Control circuitry Input power internal processing output and motor current are monitored to provide efficient operation and control User interface and external commands are monitored and performe...

Page 11: ...fety measures described in this document 2 3 Safety Precautions WARNING HIGH VOLTAGE Adjustable frequency drives contain high voltage when connected to AC line power Failure to perform instal lation s...

Page 12: ...e warning LED indicator lights are off Table 2 1 Discharge Time WARNING LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to ground the adjustable frequency drive properly could result in...

Page 13: ...requency and current at low high voltages 6 Output voltage frequency and current at low high voltages 7 Enclosure type and IP rating 8 Maximum ambient temperature 9 Certifications 10 Discharge time Wa...

Page 14: ...ist crane or forklift with the appropriate rating to move the unit For lifting use hoist rings on the unit when provided Mounting 1 Ensure that the strength of the mounting location supports the unit...

Page 15: ...op and Bottom Mounting Holes See chapter 8 9 Power Ratings Weight and Dimensions a e f 130BA715 12 Figure 3 5 Top and Bottom Mounting Holes B4 C3 C4 Mechanical Installation Instruction Manual MG20MA22...

Page 16: ...by the installer See maximum fuse ratings in chapter 8 8 Fuses and Circuit Breakers Wire Type and Ratings All wiring must comply with local and national regulations regarding cross section and ambien...

Page 17: ...6 Use high strand wire to reduce electrical interference Do not use pigtails NOTICE POTENTIAL EQUALIZATION Risk of electrical interference when the ground potential between the adjustable frequency dr...

Page 18: ...97 W 98 PE 99 0 V 5 V S801 RS 485 03 24 V DC 02 01 05 04 06 27 24 V 0 V 0 V 24 V 29 1 2 ON S201 ON 2 1 ON 0 4 20 mA OFF 0 10 V DC 10 V DC 95 P 5 00 2 1 ON S801 R 82 R 81 130BD552 10 3 phase power inp...

Page 19: ...ation stripped 10 Equalizing min 0 025 in2 16 mm2 Table 4 1 Legend to Figure 4 2 NOTICE EMC INTERFERENCE Run cables for input power motor wiring and control wiring in three separate metallic conduits...

Page 20: ...and national electrical codes for cable sizes For maximum wire sizes see chapter 8 1 Electrical Data Follow the motor manufacturer wiring requirements Motor wiring knockouts or access panels are prov...

Page 21: ...configuration of the equipment input power is connected to the line power input terminals or the input disconnect 3 Ground the cable in accordance with grounding instructions provided in chapter 4 3...

Page 22: ...utputs 12 13 24 V DC 24 V DC supply voltage for digital inputs and external transducers Maximum output current 200 mA for all 24 V loads 18 5 10 8 Start Digital inputs 19 5 11 0 No operation 32 5 14 0...

Page 23: ...r typical control wiring connections 4 8 3 Enabling Motor Operation Terminal 27 A jumper wire may be required between terminal 12 or 13 and terminal 27 for the adjustable frequency drive to operate wh...

Page 24: ...ure 4 11 Serial Communication Wiring Diagram For basic serial communication set up select the following 1 Protocol type in 8 30 Protocol 2 Adjustable frequency drive address in 8 31 Address 3 Baud rat...

Page 25: ...clearance is adequate to ensure proper air flow for cooling see chapter 3 3 Mounting Ambient conditions Check that requirements for ambient conditions are met Fusing and circuit breakers Check for pro...

Page 26: ...otor 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 t...

Page 27: ...10 MCT10 Downloads htm 5 3 2 LCP Layout The LCP is divided into four functional groups see Figure 5 1 A Display area B Display menu keys C Navigation keys and indicator lights LEDs D Operation keys an...

Page 28: ...s parameter groups or to enable a choice Table 5 3 Legend to Figure 5 1 Navigation Keys Indicator Light Function 15 On Green The ON light activates when the adjustable frequency drive receives power f...

Page 29: ...Press to browse through the parameter groups press OK to select a parameter group 3 Press to browse through the parameters press OK to select a parameter 4 Press to change the value of a parameter se...

Page 30: ...efer to chapter 5 4 2 Commissioning via Main Menu or the Programming Guide NOTICE Motor data are required for the SmartStart set up The required data are normally available on the motor nameplate The...

Page 31: ...14 3 13 Reference Site Linked to Hand Auto Local Remote 5 4 3 Asynchronous Motor Set up Enter the motor data in parameter 1 20 Motor Power kW or 1 21 Motor Power HP to 1 25 Motor Nominal Speed The inf...

Page 32: ...tia Start the motor at nominal speed If the application does not run well check the VVCplus PM settings Recommen dations for different applications can be seen in Table 5 7 Application Settings Low in...

Page 33: ...d press OK 5 Select 1 Enable complete AMA and press OK 6 Follow the on screen instructions 7 The test runs automatically and indicate when it is complete 5 5 Checking Motor Rotation WARNING MOTOR STAR...

Page 34: ...arms for resetting the adjustable frequency drive after a trip 5 7 System Start up The procedure in this section requires user wiring and application programming to be completed The following procedur...

Page 35: ...l 54 Low Ref Feedb Value 0 6 25 Terminal 54 High Ref Feedb Value 50 Default Value Notes comments D IN 37 is an option Table 6 1 Analog Current Feedback Transducer Parameters FC 24 V 24 V D IN D IN D I...

Page 36: ...Notes comments D IN 37 is an option Table 6 5 Analog Speed Reference Current Parameters FC 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 OUT COM 12 13 18 19 20 27 29 32 33 37...

Page 37: ...M R1 R2 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 01 02 03 04 05 06 130BB684 10 Function Setting 5 10 Terminal 18 Digital Input 8 Start 5 11 Terminal 19 Digital Input 52 Run Permissive 5 12 Term...

Page 38: ...ATION Risk of equipment damage exists Use only thermistors with reinforced or double insulation to meet PELV insulation requirements Parameters 130BB686 12 VLT 24 V 24 V D IN D IN D IN COM D IN D IN D...

Page 39: ...nce must be performed by qualified personnel only 7 2 Status Messages When the adjustable frequency drive is in status mode status messages are generated automatically and appear in the bottom line of...

Page 40: ...ng Time 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 1 Digital Inputs The corre...

Page 41: ...rive 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 d...

Page 42: ...ss Reset on the LCP Digital reset input command Serial communication reset input command Auto reset Trip lock Input power is cycled The motor coasts to a stop The adjustable frequency drive continues...

Page 43: ...h voltage warning limit The limit is dependent on the adjustable frequency drive voltage rating The unit is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than...

Page 44: ...source and 1 97 KTY Threshold level match sensor wiring WARNING ALARM 12 Torque limit The torque has exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode...

Page 45: ...istance Check soft charge fuses WARNING 25 Brake resistor short circuit The brake resistor is monitored during operation If a short circuit occurs the brake function is disabled and the warning appear...

Page 46: ...rial communication bus 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 adjustable frequency drive is lost...

Page 47: ...2 No communication from ATACD to DSP state running 2816 Stack overflow control board module 2817 Scheduler slow tasks 2818 Fast tasks 2819 Parameter thread 2820 LCP stack overflow 2821 Serial port ove...

Page 48: ...out Note that repeated runs may heat the motor to a level where the resistance Rs and Rr are increased In most cases however this is not critical AMA internal fault Contact the Danfoss supplier WARNI...

Page 49: ...the allowed number of inverter sections This warning is generated on power cycle when the adjustable frequency drive is set to run with fewer inverters and remains on ALARM 79 Illegal power section co...

Page 50: ...t A component in the adjustable frequency drive has been replaced Reset the adjustable frequency drive for normal operation WARNING 251 New type code The power card or other components have been repla...

Page 51: ...motor connection Check if the motor is connected and the connection is not interrupted by a service switch or other device Connect the motor and check the service switch No line power with 24 V DC op...

Page 52: ...pplication Loose connections Perform pre start up check for loose connections Tighten loose connections Line power current imbalance greater than 3 Problem with line power See Alarm 4 Mains phase loss...

Page 53: ...and or vibration have been reduced to an acceptable limit Turn off over modulation in 14 03 Overmo dulation Change switching pattern and frequency in parameter group 14 0 Inverter Switching Increase...

Page 54: ...5 20 5 24 32 46 59 111 172 Intermittent 1x200 240 V A 13 8 16 5 22 6 26 4 35 2 50 6 64 9 122 1 189 2 Maximum pre fuses A 20 30 40 40 60 80 100 150 200 Additional specifications Maximum cable cross sec...

Page 55: ...1 98 2 64 3 85 5 06 7 26 8 3 11 7 13 8 18 4 Continuous kVA 208 V AC kVA 0 65 0 86 1 26 1 66 2 38 2 70 3 82 4 50 6 00 Max input current Continuous 3x200 240 V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 I...

Page 56: ...96 0 97 0 97 0 97 0 97 Table 8 3 Line Power Supply 3x200 240 V AC Normal overload 110 for 1 minute P5K5 P45K 8 1 3 Line Power Supply 1x380 480 V AC Type Designation P7K5 P11K P18K P37K Typical Shaft...

Page 57: ...Continuous kVA 400 V AC kVA 0 9 1 3 1 7 2 1 2 8 3 9 5 0 6 9 9 0 11 0 Continuous kVA 460 V AC kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max input current Continuous 3x380 440 V A 1 2 1 6 2 2 2 7 3 7...

Page 58: ...30 5 42 3 50 6 62 4 73 4 102 123 Continuous kVA 460 V AC kVA 16 7 21 5 27 1 31 9 41 4 51 8 63 7 83 7 104 128 Max input current Continuous 3x380 440 V A 22 29 34 40 55 66 82 96 133 161 Intermittent 3x...

Page 59: ...2 6 3 0 4 3 5 4 6 7 9 9 12 1 20 Continuous kVA 525 V AC kVA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 18 1 Continuous kVA 575 V AC kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 17 9 Max input current Continuous 3x525 6...

Page 60: ...600 V AC Normal overload 110 for 1 minute P15K P90K 8 1 6 Line Power Supply 3 x 525 690 V AC Type Designation P1K1 P1K5 P2K2 P3K0 P4K0 P5K5 P7K5 Typical Shaft output kW 1 1 1 5 2 2 3 0 4 0 5 5 7 5 IP2...

Page 61: ...32 3 40 6 Max input current Continuous at 550 V A 19 5 24 0 29 0 36 0 Intermittent 60 s overload at 550 V A 21 5 26 4 31 9 39 6 Continuous at 690 V A 19 5 24 0 29 0 36 0 Intermittent 60 s overload at...

Page 62: ...V AC IP20 IP21 IP55 Chassis NEMA1 NEMA 12 P30K P75K For fuse ratings see chapter 8 8 Fuses and Circuit Breakers 1 High overload 150 or 160 torque for a duration of 60 s Normal overload 110 torque for...

Page 63: ...d supply voltage True Power Factor 0 9 nominal at rated load Displacement Power Factor cos near unity 0 98 Switching on input supply L1 L2 L3 power ups 7 5 kW maximum 2 times min Switching on input su...

Page 64: ...70 C Maximum altitude above sea level without derating 3300 ft 1000 m Maximum altitude above sea level with derating 10 000 ft 3000 m Derating for high altitude see section on special conditions in t...

Page 65: ...resistance Ri approx 200 Max current 30 mA Resolution for analog inputs 10 bit sign Accuracy of analog inputs Max error 0 5 of full scale Bandwidth 200 Hz The analog inputs are galvanically isolated...

Page 66: ...Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Max error 0 1 of full scale Resolution of frequency outputs 12 bit 1 Terminal 27 and 29 can also be programmed as input...

Page 67: ...4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation PELV 2 Overvoltage Category II 3 UL applications 300 V AC 2 A Control card 10 V DC output Ter...

Page 68: ...es and Circuit Breakers Use recommended fuses and or circuit breakers on the supply side as protection in case of component breakdown inside the adjustable frequency drive first fault NOTICE Use of fu...

Page 69: ...10 7 5 gG 80 PKZM4 63 63 B2 15 gG 50 gG 100 NZMB1 A100 100 B3 7 5 15 5 5 11 gG 25 gG 63 PKZM4 50 50 B4 11 24 15 18 gG 32 10 7 5 gG 50 15 11 gG 63 20 15 gG 125 NZMB1 A100 100 C1 25 40 18 5 30 gG 63 20...

Page 70: ...2 30 40 22 30 gG 50 25 18 5 gG 63 30 22 gG 100 NZMB1 A100 3 94 100 B3 15 25 11 18 gG 40 gG 63 PKZM4 50 50 B4 30 50 22 37 gG 50 25 18 5 gG 63 30 22 gG 80 40 30 gG 125 NZMB1 A100 100 C1 50 75 37 55 gG 8...

Page 71: ...30 22 gG 63 40 30 gG 100 NZMB1 A100 100 B3 15 25 11 18 5 gG 25 15 11 gG 32 20 15 gG 63 PKZM4 50 50 B4 30 50 22 37 gG 40 25 18 5 gG 50 30 22 gG 63 40 30 gG 125 NZMB1 A100 100 C1 50 75 37 55 gG 63 50 37...

Page 72: ...I25M 10 16 16 5 4 gG 10 gG 25 CTI25M 10 16 16 7 5 5 5 gG 16 gG 25 CTI25M 10 16 16 10 7 5 gG 16 gG 25 CTI25M 10 16 16 B2 15 11 gG 25 gG 63 15 gG 25 gG 63 24 18 gG 32 30 22 gG 32 C2 40 30 gG 40 50 37 gG...

Page 73: ...TN R150 JKS 150 JJN 150 2028220 150 KLN R150 A2K 150R HSJ150 30 22 200 FWX 200 KTN R200 JKS 200 JJN 200 2028220 200 KLN R200 A2K 200R HSJ200 Table 8 17 1x200 240 V Enclosure Types A B and C Siba allow...

Page 74: ...CC Ferraz Shawmut Type RK13 Bussmann Type JFHR22 Littelfuse JFHR2 Ferraz Shawmut JFHR24 Ferraz Shawmut J 0 34 5 0 25 0 37 5017906 005 KLN R 05 ATM R 05 A2K 05 R FWX 5 HSJ 6 0 75 1 5 0 55 1 1 5017906...

Page 75: ...Shawmut Type CC Ferraz Shawmut Type RK1 Bussmann JFHR2 Ferraz Shawmut J Ferraz Shawmut JFHR21 Littelfuse JFHR2 5017906 006 KLS R 6 ATM R 6 A6K 6 R FWH 6 HSJ 6 1 5 3 1 1 2 2 5017906 010 KLS R 10 ATM R...

Page 76: ...30 KLS R 030 A6K 30 R HSJ 30 15 20 11 15 KTS R 35 JKS 35 JJS 35 5014006 040 KLS R 035 A6K 35 R HSJ 35 24 18 KTS R 45 JKS 45 JJS 45 5014006 050 KLS R 045 A6K 45 R HSJ 45 30 22 KTS R 50 JKS 50 JJS 50 50...

Page 77: ...HST 45 40 30 60 KTS R 60 JKS 60 JJS 60 5014006 063 KLS R 060 A6K 60 R HST 60 50 37 80 KTS R 80 JKS 80 JJS 80 5014006 080 KLS R 075 A6K 80 R HST 80 60 45 90 KTS R 90 JKS 90 JJS 90 5014006 100 KLS R 090...

Page 78: ...m Height of backplate A 10 6 268 14 8 375 10 6 268 14 8 375 15 35 390 16 54 420 18 9 480 25 6 650 15 71 399 20 5 520 26 8 680 30 32 770 21 65 550 25 98 660 Height with decoupling plate for serial comm...

Page 79: ...0 43 11 0 47 12 0 47 12 0 75 19 0 75 19 0 47 12 0 75 19 0 75 19 e 0 22 5 5 0 22 5 5 0 22 5 5 0 22 5 5 0 26 6 5 0 26 6 5 0 35 9 0 35 9 0 27 6 8 0 34 8 5 0 35 9 0 0 35 9 0 0 34 8 5 0 34 8 5 f 0 35 9 0...

Page 80: ...Magnet Motor PELV Protective Extra Low Voltage PCB Printed Circuit Board PWM Pulse Width Modulated ILIM Current Limit IINV Rated Inverter Output Current RPM Revolutions Per Minute Regen Regenerative T...

Page 81: ...ference 3 Source 3 19 Jog Speed RPM 3 4 Ramp 1 3 41 Ramp 1 Ramp up Time 3 42 Ramp 1 Ramp down Time 3 5 Ramp 2 3 51 Ramp 2 Ramp up Time 3 52 Ramp 2 Ramp down Time 3 8 Other Ramps 3 80 Jog Ramp Time 3 8...

Page 82: ...Data Config Write 12 22 Process Data Config Read 12 27 Primary Master 12 28 Store Data Values 12 29 Store Always 12 3 EtherNet IP 12 30 Warning Parameter 12 31 Net Reference 12 32 Net Control 12 33 CI...

Page 83: ...Reference 21 13 Ext 1 Reference Source 21 14 Ext 1 Feedback Source 21 15 Ext 1 Setpoint 21 17 Ext 1 Reference Unit 21 18 Ext 1 Feedback Unit 21 19 Ext 1 Output 21 2 Ext CL 1 PID 21 20 Ext 1 Normal In...

Page 84: ...ge Delay 27 3 Staging Speed 27 30 Auto Tune Staging Speeds 27 31 Stage On Speed RPM 27 32 Stage On Speed Hz 27 33 Stage Off Speed RPM 27 34 Stage Off Speed Hz 27 4 Staging Settings 27 40 Auto Tune Sta...

Page 85: ...put 64 Control card RS 485 serial communication 63 Control card USB serial communication 65 Control characteristics 65 Control signal 37 Control terminals 26 29 37 39 Control wiring 14 17 21 23 Conven...

Page 86: ...ure 26 Modbus RTU 22 Motor cables 14 0 14 0 18 Motor current 8 25 31 46 Motor Current 25 Motor data 29 42 46 50 Motor Data 31 Motor output 61 Motor power 14 25 46 Motor rotation 31 Motor speeds 28 Mot...

Page 87: ...Shock 11 Short circuit 43 Sleep Mode 39 Specifications 22 Speed reference 21 32 34 38 Start up 27 Status mode 37 Storage 11 Supply voltage 19 20 24 44 Switch 21 Switching frequency 39 Symbols 78 Syste...

Page 88: ...gs brochures or other printed material Danfoss reserves the right to alter its products at any time without notice provided that alterations to products already on order shall not require material cha...

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