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N O T I C E

RISK OF DRIVE FAILURE

Combining enclosure sizes that have different inrush control principles may lead to drive failure.

Ensure that the applied inrush control principles are compatible before combining drives in a load sharing application.

Table 12: Inrush Control Principles for Individual Enclosure Sizes

Enclosure size

Principle

A

DC inrush self-limited

B

C

AC inrush thyristor limited

D

AC inrush resistor limited

E

F

The following enclosure size combinations are possible in load sharing applications:

A and B enclosures can be combined with other A or B enclosures.
C, D, E, and F enclosures can be combined with other C, D, E, or F enclosures. However, C enclosures can only be combined with
F enclosures under the following circumstances:

All drives are connected to mains or
only the F enclosure is connected to mains.

It is not possible to combine F and C enclosures if only the C enclosure is connected to mains.
If the A/B enclosure drive is not connected to mains, A and B enclosures can be combined with C, D, E, or F enclosures.

N O T I C E

RISK OF DRIVE FAILURE

Combining A or B enclosures connected to mains with C, D, E, or F enclosures causes overload of the rectifier in the A and B
enclosures during inrush and normal load conditions.

Ensure that A and B enclosures are not connected to mains when combining them with C, D, E, or F enclosures.

To have the correct design of load sharing circuit, consult the application note Load Sharing for more details.

AJ300847815559en-000101 / 130R0337 | 55

Danfoss A/S © 2020.09

Product Features

VLT® AQUA Drive FC 202

Design Guide

Summary of Contents for VLT AQUA Drive FC 202

Page 1: ...Design Guide VLT AQUA Drive FC 202 0 25 90 kW drives danfoss com ...

Page 2: ......

Page 3: ...L Listing 14 EAC 14 UkrSEPRO 15 RCM Mark Compliance 15 Export Control Regulation 15 Enclosure Protection Rating 15 UL Type Standard 15 IP Standard 16 Product Family Overview 17 VLT Drives 17 Product Overview of the VLT AQUA Drive FC 202 17 Advantages of Using AC Drives in Pump and Fan Applications 21 Example of Energy Savings 22 Valve Control versus Speed Control of Centrifugal Pumps 23 Example wi...

Page 4: ... Maintenance Functions 35 Product Features 37 Automated Operational Features 37 Automatic Energy Optimization 37 Short circuit Protection 37 Overvoltage Protection 38 Missing Motor Phase Detection 38 Mains Phase Imbalance Detection 38 Service Switch on the Output 38 Overload Protection 39 Locked Rotor Protection 39 Automatic Derating 39 Overview of Automatic Derating 39 Sine wave Filter Fixed Mode...

Page 5: ...orque at Reduced Speed 48 Frequency Bypass 48 Motor Preheat 48 Programmable Set ups 48 Smart Logic Controller 48 SLC Application Example Setting Up a Ramp up Ramp down Sequence 50 RS Flip Flops 51 Timers 52 Safe Torque Off 53 Dynamic Braking 53 Load Sharing 53 Preconditions and Special Conditions 53 Combinations of Enclosure Sizes 54 Options and Accessories Overview 56 Introduction 56 VLT FC Serie...

Page 6: ...cation Panel LCP 103 69 Specifications 71 Electrical data 71 Mains Supply 1x200 240 V AC 71 Mains Supply 3x200 240 V AC 72 Mains Supply 1x380 480 V AC 76 Mains Supply 3x380 480 V AC 77 Mains Supply 3x525 600 V AC 82 Mains Supply 3x525 690 V AC 86 Mains Supply 89 Motor Output and Motor Data 90 Motor Output U V W 90 Torque Characteristics Normal Overload 90 Torque Characteristics High Overload 90 Am...

Page 7: ...osive Atmospheres 102 Vibration and Shock 103 Maintenance 103 Derating 103 Derating for Running at Low Speed 103 Derating for Low Air Pressure 103 Electrical Installation Considerations 105 Safety Instructions 105 Wiring Schematic 107 Connections 109 Power Connections 109 IT Grid Connection 110 DC Bus Connection 111 Load Sharing Connection 111 Brake Cable Connection 111 Grounding 112 Safety Ground...

Page 8: ...IP21 120 Entry Holes Enclosure Size C1 IP21 120 Entry Holes Enclosure Size C2 IP21 121 Tightening Torques for Cover 121 Control Wiring and Terminals 122 Shielded Control Cables 122 Wiring to Control Terminals 123 Control Terminal Types 123 Terminal Descriptions 124 Fuses and Circuit Breakers 125 Fuse Recommendations 125 CE Compliance 126 UL Compliance 129 Relays 134 Motor 135 Motor Thermal Protect...

Page 9: ...ntrol Principle 159 Local Hand On and Remote Auto On Control 159 Reference Limits 161 Control Principle 163 Control Structure Open Loop 163 Control Structure Closed Loop 163 Basic I O Configurations 165 Application Examples 165 Wiring Configuration for Automatic Motor Adaptation AMA 165 Wiring Configuration for Automatic Motor Adaptation without T27 166 Wiring Configuration Speed 166 Wiring Config...

Page 10: ...istors T2 Horizontal Braking 10 Duty Cycle 185 Order Numbers for Brake Resistors T2 Vertical Braking 40 Duty Cycle 186 Order Numbers for Brake Resistors T2 Flat pack for Horizontal Conveyors 187 Order Numbers for Brake Resistors T4 Flat pack for Horizontal Conveyors 191 Order Numbers for Accessory Bags 197 Ordering of Harmonic Filters 198 Order Numbers for Harmonic Filters 380 415 V 50 Hz 198 Orde...

Page 11: ...e VLT Safe Torque Off Operating Guide describes how to use Danfoss VLT drives in functional safety applications This manual is supplied with the drive when the Safe Torque Off option is present The VLT Brake Resistor MCE 101 Design Guide describes how to select the optimal brake resistor The VLT Advanced Harmonic Filters AHF 005 AHF 010 Design Guide describes harmonics various mitigation methods a...

Page 12: ...considered important but not hazard related for example messages relating to property damage 2 3 Qualified Personnel To allow trouble free and safe operation of the unit only qualified personnel with proven skills are allowed to transport store as semble install program commission maintain and decommission this equipment Persons with proven skills Are qualified electrical engineers or persons who ...

Page 13: ...011 65 EU Radio Equipment Directive 3 2014 53 EU REACH Directive 1907 2006 EC 1 Machinery Directive conformance is only required for drives with an integrated safety function 2 For China RoHS contact Danfoss application support to get the certificate 3 Radio Equipment Directive is only required for interfaces supporting wireless communication 3 2 1 1 Low Voltage Directive The aim of the Low Voltag...

Page 14: ...shing minimum energy efficiency standards 3 2 1 5 ATEX Directive Illustration 1 ATEX Logo 3 2 1 6 RoHS Directive The Restriction of Hazardous Substances RoHS Directive is an EU directive that restricts the use of hazardous materials in the man ufacturing of electronic and electrical products Read more on www danfoss com 3 2 1 7 Radio Equipment Directive Devices that emit or receive radio waves as ...

Page 15: ...tact Danfoss Drives Global or the local sales office 3 4 Enclosure Protection Rating The VLT drive series are available in various enclosure protection ratings to accommodate the needs of the application Enclosure protection ratings are provided based on 2 international standards UL type validates that the enclosures meet NEMA National Electrical Manufacturers Association standards The constructio...

Page 16: ...Type 1 IP21 Type 12 IP54 Table 4 IP Number Breakdown 1st digit 2nd digit Level of protection 0 No protection 1 Protected to 50 mm 2 0 in No hands would be able to get into the enclosure 2 Protected to 12 5 mm 0 5 in No fingers would be able to get into the enclosure 3 Protected to 2 5 mm 0 1 in No tools would be able to get into the enclosure 4 Protected to 1 0 mm 0 04 in No wires would be able to...

Page 17: ...onic suppression eliminate the need for higher loss external AC line reactors Optional built in RFI filters are available throughout the power range Regen terminals are available within the standard enclosures for enclosure sizes D E and F In addition to the many valuable features that the Danfoss drives offers as standard there are several other control monitoring and power options available in p...

Page 18: ...rtical pipes Sleep mode The sleep mode feature saves energy by stopping the pump when there is no demand for the pump to run Real time clock This option includes back up battery ensuring synchronization of real time data Password protection Overload protection Smart logic control SLC SLC comprises programming of a sequence consisting of events and actions SLC offers a wide range of PLC functions u...

Page 19: ...2 is available in many power sizes voltage ranges and enclosure protection classes making it easy to find the perfect drive for a given application Table 5 Voltage Ranges and Power Ranges Voltage ranges V Power ranges kW hp 1 x 200 240 1 1 22 1 5 30 1 x 380 480 7 5 37 10 50 3 x 200 240 0 25 160 0 5 250 3 x 380 480 0 37 1000 0 5 1350 3 x 525 600 0 75 90 1 0 125 3 x 525 690 11 1400 15 1875 Enclosure...

Page 20: ...r Sizes Voltage Ranges and Protection Rating Enclosure C1 C2 C3 C4 D3h 1 Power kW 200 240 V 18 5 30 37 45 22 30 37 45 380 480 V 37 55 75 90 45 55 75 90 525 600 V 37 55 75 90 45 55 75 90 525 690 V 37 90 45 55 55 75 e30ba814 11 e30ba815 11 e30ba828 11 e30ba829 11 e30bu371 10 IP 21 55 66 21 55 66 20 21 20 21 20 NEMA Type 1 12 4X Type 1 12 4X Chassis Chassis Chassis 1 Details see separate design guide...

Page 21: ...in Modbus in daisy chain configuration for easy installation Troubleshooting and maintenance Troubleshooting and maintenance of the FC 202 are made easier and more precise with the increased digitalization The sensors in the FC 202 record and store real time information about warnings and alarms By adding the VLT Real time Clock MCB 117 option it is possible to have the stored events time and date...

Page 22: ...o reduced by 20 This is because the flow is directly proportional to the speed The consumption of electricity however is reduced by up to 50 due to the variable torque profile of the pump If the system only supplies a flow that corresponds to 100 a few days in a year while the average is below 80 of the rated flow for the remainder of the year more than 50 of energy is saved See the dependence of ...

Page 23: ...ted accordingly Frequently used methods for flow adaptation are throttling or recycling using valves A recycle valve that is opened too wide can cause the pump to run at the end of the pump curve with a high flow rate at a low pump head These conditions do not only cause a waste of energy due to the high speed of the pump but can also lead to pump cavitation resulting in pump damage Throttling the...

Page 24: ...ame flow can be adjusted by reducing the speed of the pump as shown in Illustration 9 Reducing the speed moved the pump curve down The point of operation is the new intersection point of the pump curve and the system curve 3 The energy savings can be calculated by applying the affinity laws as described in 4 3 1 Example of Energy Savings Flow Head or Pressure Pump curve Operating point Natural Ope...

Page 25: ...pump datasheet The result obtained shows energy sav ings of more than 50 at the given flow distribution over a year The payback period depends on the price per kWh and the price of frequency converter In this example it is less than a year when compared with valves and constant speed Energy savings Pshaft Pshaft output 500 h t 1000 1500 2000 200 100 300 m3 h 400 Q e75ha210 11 Illustration 11 Flow ...

Page 26: ...12 200 20 1752 31 5 55 188 11 5 20 148 150 20 1752 28 0 49 056 6 5 11 388 100 20 1752 23 0 40 296 3 5 6 132 Σ 100 8760 275 064 26 801 4 3 4 Improved Control Using a drive to control the flow or pressure of a system improves control A drive can vary the speed of the fan or pump obtaining variable control of flow and pressure Furthermore a drive can quickly adapt the speed of the fan or pump to new ...

Page 27: ...the domestic commer cial and industrial sectors throughout Europe The Ecodesign requirements are only mandatory within the European Union These requirements are like the legislative require ments for energy related products which apply in North America and Australia Terms like Complete Drive Module CDM and Power Drive Systems PDS are used to define the elements in the design The objec tive is to m...

Page 28: ...ent to the efficiency of the whole drive system The new efficiency classes International Efficiency for Systems IES allow a simple determination of the total losses for a whole drive system PDS Danfoss offers the MyDrive ecoSmart tool which is available online or as a Smartphone app to assist with the efficiency calcula tion Use MyDrive ecoSmart to Look up part load data as defined in IEC 61800 9 ...

Page 29: ...yDrive ecoSmart determines the energy efficiency of the drive being used and system efficiency class according to IEC 61800 9 MyDrive ecoSmart uses information about the selected motor load points and an AC drive to calculate the efficiency class and part load efficiency for a Danfoss drive either for a standalone drive CDM or for a drive with a motor PDS VLT Motion Control Tool MCT 10 The MCT 10 ...

Page 30: ...lities and protection without increasing the enclosure size More space saving features Built in DC link reactors for harmonic suppression eliminate the need for higher loss external AC line reactors Optional built in RFI filters are available throughout the power range Optional input fuses and load share terminals are available within the standard enclosures In addition to the many valuable featur...

Page 31: ...een phases and ground generate high frequency bearing currents and shaft voltages While bearing currents and shaft voltages can also occur in direct on line motors these phenomena are accentuated when the motor is fed from a drive Most bearing damage in motors fed by drives is caused by vibrations misalignment excessive axial or radial loading improper lubri cation and impurities in the grease Som...

Page 32: ...ly these current pulses can erode the bearing races and rolling elements Op tional dU dt filters protect the motor insulation system and reduce bearing currents Optional common mode filters mainly reduce bearing currents Insulated N end non drive end bearings protect the motor bearings Practical tips Usually the shielding surface of the motor cable is connected to the frame of the terminal box and...

Page 33: ...ctionality PE U V W e30bd839 10 Illustration 18 Installing Common mode Cores Depending on the power rating of the drive installation and the quantity of motor cables connected in parallel several same size common mode cores might be used In dedicated product manuals preselection tables advise on the required minimal quantity of single common mode cores to install The number of cores depend on the ...

Page 34: ...tion 20 Mounting of CM Cores Inside the Motor Terminal Box To ensure minimal bearing currents in the motor Danfoss recommends ordering the drive with output motor filters as a power op tion 5 2 Functional Safety 5 2 1 Protection of Personnel and Equipment Danfoss AC drives offer functional safety solutions for smart machine design The VLT AQUA Drive has Safe Torque Off STO built in as an option Al...

Page 35: ...d Monitoring The function uses the drive as a smart sensor for monitoring the condition of the motor and application The VLT AQUA Drive fea tures licensed functions that enforce predictive maintenance actions such as Motor stator winding monitoring Vibration monitoring Load envelope monitoring Set various thresholds and determine the baseline with different methods according to relevant standards ...

Page 36: ...alignment Mechanical resonance The function is not able to identify bearing wear out in early stages Drive correlates vibration with motor speed N O T I C E EVALUATING VIBRATION The ISO 10816 standard provides guidance for evaluating vibration severity for machines operating within 10 200 Hz of frequen cy range The standard shall be complied with before commissioning of vibration monitoring functi...

Page 37: ...ic Energy Optimization The AEO requires correct advanced motor data meaning that a complete automatic motor adaptation AMA has to be run 6 1 2 Short circuit Protection Motor phase to phase The drive is protected against short circuits on the motor side by current measurements in each of the 3 motor phases A short circuit between 2 output phases causes an overcurrent in the inverter The inverter is...

Page 38: ...e breaking torque without exceeding the overvoltage limit N O T I C E An AC brake is not as efficient as dynamic braking with a resistor and should not be used on frequently repeated braking applica tions as it may overheat the motor Overvoltage control OVC OVC reduces the risk of the drive tripping due to an overvoltage on the DC link This is managed by automatically extending the ramp down time ...

Page 39: ...temperature sensors and reacts immediately to critical values via hard coded limits 6 1 8 Locked Rotor Protection There can be situations when the rotor is locked due to excessive load or other factors The locked rotor cannot produce enough cooling which in turn can overheat the motor winding The drive is able to detect the locked rotor situation with PM VVC control parameter 30 22 Locked Rotor De...

Page 40: ...ating Contributions The switching frequency is first derated due to motor current followed by DC link voltage motor frequency and then temperature If multiple deratings occur on the same iteration the resulting switching frequency would be the same as though only the most significant derating occurred by itself the deratings are not cumulative Each of these functions is presented in the following ...

Page 41: ... Im e30bb973 10 Udc No automatic derating e30bb974 10 UDC UDC TRIP UDC START DERATING Requested f sw fsw f s 10 15 Hz 80 86 of fmotor nom fmotor Hz PWM SFAVM 60 PWM optional e30bc143 10 fsw kHz e30bb975 10 SFAVM only 3 9 4 9 9 10 15 fsw fm1 fsw fm2 fsw fm3 fsw fm4 T e30bc142 10 TAMB TPWM SWITCH 60 PWM SFAVM e30bb976 10 TAMB High warning Low warning fsw t1 t2 AJ300847815559en 000101 130R0337 41 Dan...

Page 42: ...derating are individual for each frame size and are coded in the EEPROM fsw kHz f1 f2 U1 U2Udc V e30bb978 10 Illustration 27 Derating of switching frequency according to voltage on the DC link f1 f2 U1 and U2 are coded in EEPROM In EEPROM the limits depend on the modulation mode In 60 AVM f1 and f2 are higher than for SFAVM U1 and U2 are independ ent of the modulation mode 6 1 9 6 Low Motor Speed ...

Page 43: ...or Different Stator Frequencies fm The points that limit the derating are individual for each frame size and are coded in the EEPROM N O T I C E The VLT AQUA DriveFC 202 never derates the current automatically Automatic derating refers to adaptation of the switching fre quency and pattern For VT applications the load current is considered before derating the switching frequency at low motor speed ...

Page 44: ... 6 1 12 Power Fluctuation Performance The drive withstands mains fluctuations such as Transients Momentary dropouts Short voltage drops Surges The drive automatically compensates for input voltages 10 from the nominal to provide full rated motor voltage and torque With auto restart selected the drive automatically powers up after a voltage trip With flying start the drive synchronizes to motor rot...

Page 45: ...in the motor windings and connected on a standard AI or DI PT100 or PT1000 in the motor windings and motor bearings connected on VLT Sensor Input Card MCB 114 and VLT Pro grammable I O MCB 115 PTC thermistor input on VLT PTC Thermistor Card MCB 112 ATEX approved Mechanical thermal switch Klixon type on a DI Built in electronic relay ETR ETR calculates motor temperature by measuring current frequen...

Page 46: ...is device monitors the tem perature in the motor windings If there is a critical temperature level or a malfunction the device switches off the motor The VLT PTC Thermistor MCB 112 option provides ATEX approved monitoring of motor temperature It is a prerequisite that the drive is equipped with 3 6 PTC thermistors in series according to DIN 44081 or 44082 Alternatively an external ATEX approved PT...

Page 47: ...ion is relevant for high inertia applica tions such as centrifuges and fans Kinetic back up This selection ensures that the drive runs as long as there is energy in the system For short mains dropout the operation is restored after mains return without bringing the application to a stop or losing control at any time Several variants of kinetic back up can be selected Configure the behavior of the ...

Page 48: ...ts See parameter 2 00 DC Hold Current in the programming guide for more detail The motor preheat function can eliminate the need for a space heater 6 2 11 Programmable Set ups The drive has 4 set ups that can be independently programmed Using multi setup it is possible to switch between independently programmed functions activated by digital inputs or a serial command Independent set ups are used ...

Page 49: ... evaluated When the SLC starts it evaluates event 0 and only event 0 each scan interval Only when event 0 is evaluated true the SLC executes action 0 and starts evaluating event 1 It is possible to program 1 20 events and actions per sequence When the last event action has been executed the sequence starts over again from event 0 action 0 See Illustration 34 for an example with 3 events actions e3...

Page 50: ...n 36 Logic Rules 6 2 12 3 SLC Application Example Setting Up a Ramp up Ramp down Sequence This example shows how to set up a ramp up ramp down sequence with the SLC The sequence has the following states start ramp up run at reference speed for 2 s ramp down Hold shaft until stop 2 sec Max ref P 3 03 2 sec Preset ref 0 P 3 10 0 State 1 State 3 State 2 Preset ref 1 P 3 10 1 Term 18 P 5 10 start e30b...

Page 51: ...on 1 to 10 Select preset 0 Set Action 2 in parameter 13 52 SL Controller Action 2 to 29 Start Timer 0 Set Action 3 in parameter 13 52 SL Controller Action 3 to 11 Select preset 1 Set Action 4 in parameter 13 52 SL Controller Action 4 to 1 No Action Set the SLC in parameter 13 00 SL Controller Mode to 1 On A start stop command is applied on terminal 18 If the stop signal is applied the drive ramps ...

Page 52: ...le 0 Output from parameter 13 41 Log ic Rule Operator 1 0 Parameter 13 16 RS FF Operand R 0 27 Logic rule 1 Output from parameter 13 41 Log ic Rule Operator 1 1 Parameter 13 51 SL Controller Event 0 94 RS Flipflop 0 Output from parameter 13 15 RSFF Operand S and parameter 13 16 RSFF Operand R Parameter 13 52 SL Controller Action 0 22 Run Parameter 13 51 SL Controller Event 1 27 Logic rule 1 Parame...

Page 53: ...ting the drive from overheating if the brake resistor is overloaded The brake IGBT gate sig nal originates on the control card and is delivered to the brake IGBT via the power card and gatedrive card Also the power and control cards monitor the brake IGBT for a short circuit The power card also monitors the brake resistor for overloads External brake resistor placement has the advantages of select...

Page 54: ... combined with a drive with brake When the drive with a brake is braked the other drive receives an overcurrent warning Performance is not affected N O T I C E The start up time of the drive may be slightly longer than normal N O T I C E According to the EMC Directive a system is defined as a combination of several types of equipment finished products and or components combined designed and or put...

Page 55: ...be combined with F enclosures under the following circumstances All drives are connected to mains or only the F enclosure is connected to mains It is not possible to combine F and C enclosures if only the C enclosure is connected to mains If the A B enclosure drive is not connected to mains A and B enclosures can be combined with C D E or F enclosures N O T I C E RISK OF DRIVE FAILURE Combining A ...

Page 56: ...e typically communication options for example for adding fieldbus functionality The B slot options typically host functional extension options The C slot options host special function options for example for advanced cascade control The D slot option is used for an external power supply and for the real time clock The options are slot specific So an A option does only fit in an A option slot Some ...

Page 57: ... 124 A x x VLT BACNet IP MCA 125 A x x VLT DeviceNet Converter MCA 194 A x 7 4 VLT Functional Extensions This topic gives an overview of currently available option cards for functional extension More detailed descriptions of the functional extension option cards can be found in the Installation Guides Programming Guides and Operating Guides for the individual options These manuals can be downloade...

Page 58: ...x VLT Position Controller MCO 351 C x Integrated Motion Controller IMC S067 software option x 7 6 License Features This topic gives an overview of currently available license features Table 16 License Features Option name FC 102 FC 103 FC 202 FC 301 FC 302 Condition based Monitoring LX1X software option x x x x VLT Digital Cascade Controller LXX1 software option x 7 7 VLT Power Options 7 7 1 VLT H...

Page 59: ...ers Option name FC 102 FC 103 FC 202 FC 301 FC 302 VLT Sine wave Filter MCC 102 x x x x x Danfoss supplies dU dt filters dU dt filters are differential mode low pass filters that reduce motor terminal phase to phase peak voltages and reduce the rise time to a level that lowers the stress on the insulation at the motor windings This is especially an issue with short motor cables Compared to the sin...

Page 60: ...pplications 7 8 Kits and Accessories 7 8 1 Panel Through Mounting Kits for VLT FC Series Enclosure Sizes A B and C IP21 The panel through mounting kit are designed for IP21 enclosures and can be used for cooling the heat sink via an external air stream or where there is a wish to use a separate air duct The electronics are sealed from the external air by use of the mounting flange and sealing gask...

Page 61: ...used an IP20 unit is upgraded to comply with enclosure IP21 4X top Nema Type 1 The IP4X top can be applied to all standard IP20 enclosure variants A B C D E e30bt323 10 Illustration 43 IP21 Nema Type 1 Kit on A2 Enclosure A Top cover B Brim C Base part D Base cover E Screw s AJ300847815559en 000101 130R0337 61 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 62: ...is used fit the brim to cover the top inlet Place the base part C at the bottom of the drive and use the clamps from the accessory bag to correctly fasten the cables Holes for cable glands Enclosure size A2 2x M25 and 3xM32 Enclosure size A3 3xM25 and 3xM32 AJ300847815559en 000101 130R0337 62 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 63: ...tion 45 IP21 Nema Type 1 Kit on B3 Enclosure A Top cover B Brim C Base part D Base cover E Screw s F Fan cover AJ300847815559en 000101 130R0337 63 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 64: ...clip When option module A and or option module B is are used fit the brim B to the top cover A N O T I C E Side by side installation is not possible when using the IP21 IP4X Nema Type 1 Enclosure Kit AJ300847815559en 000101 130R0337 64 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 65: ...reases 7 8 3 Mounting Brackets for VLT FC Series Enclosure Sizes A5 B1 B2 C1 and C2 The kits contain an upper and a lower bracket for the respective enclosure size Table 24 Mounting Brackets Dimensions Enclosure size Protection Rating A mm in B mm in A5 IP55 66 480 18 9 495 19 5 B1 IP21 55 66 535 21 1 550 21 7 B2 IP21 55 66 705 27 8 720 28 4 C1 IP21 55 66 730 28 7 745 29 3 C2 IP21 55 66 820 32 3 8...

Page 66: ...2 and LCP 103 with Cover for Outdoor Mounting The kit allows the LCP to be mounted apart from the drive for example in a wall or panel The LCP mounting kit provides the follow ing features Simple mounting only one 24 mm bore required for mounting IP54 protection rating of the LCP mounting Protecting LCP from direct sunlight Possibility to lock the LCP cover to prevent unauthorized access LCP cover...

Page 67: ...s 90 male connector and straight female connector Cable to the LCP Blind cover with M12 female connector Base plate with D sub connector and M12 male connector Two gaskets and 1 nut for the D sub connector Intermediate cover with the front cover Disassembly tool e30bf910 10 Illustration 48 Remote Connection of the LCP AJ300847815559en 000101 130R0337 67 Danfoss A S 2020 09 Options and Accessories ...

Page 68: ... to the front of a cabinet The kit contains the following parts Optional Graphical LCP 102 numerical LCP 101 or Wireless Control Panel LCP 103 3 m 10 ft cable to the LCP Gasket Fasteners For order number see 13 2 7 Order Numbers for Local Control Panel Options 130BA138 11 AJ300847815559en 000101 130R0337 68 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 69: ... easier to perform commissioning operation monitoring and mainte nance tasks Utilizing the active point to point wireless connection maintenance personnel can receive real time error messages via the app to ensure a quick response to potential issues and reduce downtime The VLT Wireless Communication Panel LCP 103 supports client mode enabling multiple drives to connect with a common Wi Fi point T...

Page 70: ...e30bg047 10 Illustration 52 VLT Wireless Communication Panel LCP 103 AJ300847815559en 000101 130R0337 70 Danfoss A S 2020 09 Options and Accessories Overview VLT AQUA Drive FC 202 Design Guide ...

Page 71: ...t 208 V kVA 2 4 2 7 3 8 4 5 6 0 8 7 11 1 21 4 31 7 Maximum input current Continuous 1x200 240 V A 12 5 15 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 section mains motor brake mm2 AWG 0 2 4 4 10 10 7 35 2 50 1 0 95 4 0 Maximum cable cross section fo...

Page 72: ...lass see 8 4 1 Environment 8 1 2 Mains Supply 3x200 240 V AC Table 26 Mains Supply 3x200 240 V AC PK25 PK75 Type designation PK25 PK37 PK55 PK75 High normal overload 1 HO NO HO NO HO NO HO NO Typical shaft output kW 0 25 0 37 0 55 0 75 Typical shaft output at 208 V hp 0 34 0 50 0 75 1 0 Protection rating IP20 Chassis 2 A2 A2 A2 A2 Protection rating IP21 Type 1 A2 A2 A2 A2 Protection rating IP55 Ty...

Page 73: ...d efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment Table 27 Mains Supply 3x200 240 V AC P1K1 P3K7 Type designation P1K1 P1K5 P2K2 P3K0 P3K7 High normal overload 1 HO NO HO NO HO NO HO NO HO NO Typical shaft output kW 1 1 1 5 2 2 3 0 3 7 Typical shaft output at 208 V hp 1 5 2 0 3 0 4 0 5 0 Prote...

Page 74: ...ive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment Table 28 Mains Supply 3x200 240 V AC P5K5 P15K Type designation P5K5 P7K5 P11K P15K High normal overload 1 HO NO HO NO HO NO HO NO Typical shaft output kW 3 7 5 5 5 5 7 5 7 5 11 11 15 Typical shaft output at 208 V hp 5 0 7 5 7 5 10 10 15 15 20 IP20 Chassis 2 B3 B3 B3 B4 Protection rating IP21 Type 1 Protection rating IP55 T...

Page 75: ...y For more detailed efficiency values and part load losses ac cording IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment Table 29 Mains Supply 3x200 240 V AC P18K P45K Type designation P18K P22K P30K P37K P45K High normal overload 1 HO NO HO NO HO NO HO NO HO NO Typical shaft output kW 15 18 5 18 5 22 22 30 30 37 37 45 Typical shaft output at 2...

Page 76: ...efficiency class see 8 4 1 Environment 5 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart on www danfoss com For efficiency class see 8 4 1 Environment 6 Measured using 5 m 16 ft shielded motor cables at rated load and rated frequency For more detailed efficiency values and part load losses ac cord...

Page 77: ...alues and part load losses ac cording IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 8 1 4 Mains Supply 3x380 480 V AC Table 31 Mains Supply 3x380 480 V AC PK37 P1K5 Type designation PK37 PK55 PK75 P1K1 P1K5 High normal overload 1 HO NO HO NO HO NO HO NO HO NO Typical shaft output kW 0 37 0 55 0 75 1 1 1 5 Typical shaft output at 460 V hp 0...

Page 78: ... ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 5 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart on www danfoss com For efficiency class see 8 4 1 Environment 6 Measured using 5 m 16 ft shielded motor cables at rated load and rated frequency For more detailed efficiency va...

Page 79: ...ded For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 5 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart on www danfoss com For efficiency class see 8 4 1 Environment 6 Measured...

Page 80: ...o sure kit in the design guide 3 The 3 values for the maximum cable cross section are for single core flexible wire and flexible wire with sleeve respectively 4 Applies for dimensioning of drive cooling If the switching frequency is higher than the default setting the power losses may increase LCP and typical control card power consumptions are included For more detailed efficiency values and part...

Page 81: ... 3x441 480 V A 70 5 64 9 88 5 80 3 110 105 143 130 177 160 Maximum pre fuses A 100 125 160 250 250 Additional specifications Protection rating IP20 maximum ca ble cross section for mains and mo tor mm2 AWG 35 2 50 1 50 1 150 300 MCM 150 300 MCM Protection rating IP20 maximum ca ble cross section for brake and load sharing mm2 AWG 35 2 50 1 50 1 95 4 0 95 4 0 Protection ratings IP21 IP55 IP66 maxim...

Page 82: ...ble 35 Mains Supply 3x525 600 V AC PK75 P2K2 Type designation PK75 P1K1 P1K5 P2K2 High normal overload 1 HO NO HO NO HO NO HO NO Typical shaft output kW 0 75 1 1 1 5 2 2 Typical shaft output hp 1 1 5 2 3 Protection rating IP20 Chassis Protection rating IP21 Type 1 A3 A3 A3 A3 Protection rating IP55 Type 12 A5 A5 A5 A5 Output current Continuous 3x525 550 V A 1 8 2 6 2 9 4 1 Intermittent 3x525 550 V...

Page 83: ...2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment Table 36 Mains Supply 3x525 600 V AC P3K0 P7K5 Type designation P3K0 P4K0 P5K5 P7K5 High normal overload 1 HO NO HO NO HO NO HO NO Typical shaft output kW 3 0 4 0 5 5 7 5 Typical shaft output hp 4 0 5 0 7 5 10 Protection rating IP20 Chassis Protection rating IP21 Type 1 A2 A2 A3 A3 IP55 Type 12 A5 A5 A5 A5 Ou...

Page 84: ...signation P11K P15K P18K P22K P30K P37K High normal overload 1 HO NO HO NO HO NO HO NO HO NO HO NO Typical shaft output kW 7 5 11 11 15 15 18 5 18 5 22 22 30 30 37 Typical shaft output hp 10 15 15 20 20 25 25 30 30 40 40 50 Protection rating IP20 Chassis B3 B3 B3 B4 B4 B4 Protection rating IP21 Type 1 Protection rating IP55 Type 12 Protection rating IP66 NEMA 4X B1 B1 B1 B2 B2 C1 Output current Co...

Page 85: ...d part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart on www danfoss com For efficiency class see 8 4 1 Environment 5 Measured using 5 m 16 ft shielded motor cables at rated load and rated frequency For more detailed efficiency values and part load losses ac cording IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment Table 38 ...

Page 86: ...es may increase LCP and typical control card power consumptions are included For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 4 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart...

Page 87: ...d For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 4 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecos mart on www danfoss com For efficiency class see 8 4 1 Environment 5 Measured u...

Page 88: ...the default setting the power losses may increase LCP and typical control card power consumptions are included For more detailed efficiency values and part load losses according IEC EN 61800 9 2 refer to mydrive ecosmart on www danfoss com For efficiency class see 8 4 1 Environment 4 Efficiency measured at nominal current For more detailed efficiency values and part load losses according IEC EN 61...

Page 89: ...ad 110 torque for a duration of 60 s 3 The 3 values for the maximum cable cross section are for single core flexible wire and flexible wire with sleeve respectively 4 Applies for dimensioning of drive cooling If the switching frequency is higher than the default setting the power losses may increase LCP and typical control card power consumptions are included For more detailed efficiency values an...

Page 90: ...rque constant torque Maximum 110 for 60 s once in 10 minutes 1 Overload torque constant torque Maximum 110 for 60 s once in 10 minutes 1 1 Percentage relates to the nominal torque of the drive dependent on power size 8 3 3 Torque Characteristics High Overload Starting torque constant torque Maximum 150 160 for 60 s once in 10 minutes 1 Overload torque constant torque Maximum 150 160 for 60 s once ...

Page 91: ...m 492 ft Maximum motor cable length unshielded unarmored 300 m 984 ft Maximum cross section to motor mains load sharing and brake 1 Maximum cross section to control terminals rigid wire 1 5 mm2 16 AWG Maximum cross section to control terminals flexible wire 1 mm2 18 AWG Maximum cross section to control terminals cable with enclosed core 0 5 mm2 20 AWG Minimum cross section to control terminals 0 2...

Page 92: ... freewheel diode or alternatively a 30 V or 50 V MOV for quicker response time across the coil Typical contactors can be bought with this diode 8 6 3 Analog Inputs Number of analog inputs 2 Terminal number 53 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201 switch S202 OFF U Voltage level 0 10 V scaleable Input resistance Ri Approximately 10 kΩ Maximum v...

Page 93: ...ull scale Resolution of frequency outputs 12 bit 1 Terminals 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 8 6 6 Analog Output Number of programmable outputs 1 Terminal number 42 Current range at analog output 0 4 20 mA Maximum resistor load to common analog output 500 Ω Accuracy on analog output ...

Page 94: ...d 24 V DC 0 1 A Relay 02 terminal number 4 6 break 4 5 make Maximum terminal load AC 1 1 on 4 5 NO resistive load 2 3 400 V AC 2 A Maximum terminal load AC 15 on 4 5 NO inductive load cosφ 0 4 240 V AC 0 2 A Maximum terminal load DC 1 1 on 4 5 NO resistive load 80 V DC 2 A Maximum terminal load DC 13 1 on 4 5 NO inductive load 24 V DC 0 1 A Maximum terminal load AC 1 1 on 4 6 NC resistive load 240...

Page 95: ...4 24 124 221 1 14 124 14 124 3 27 0 6 5 C3 10 89 10 89 10 89 10 89 3 27 0 6 5 C4 14 24 124 221 1 14 24 124 221 1 14 124 14 124 3 27 0 6 5 1 For different cable dimensions x y where x 95 mm2 3 AWG and y 95 mm2 3 AWG 8 8 Power Ratings Weight and Dimensions Table 43 Power Ratings Weight and Dimensions Enclosure Size A Enclosure size A2 A3 A4 A5 3x525 690 V T7 1 1 7 5 1 10 3x525 600 V T6 0 75 7 5 1 0 ...

Page 96: ...0 32 d ø11 ø0 43 ø11 ø0 43 ø11 ø0 43 ø11 ø0 43 ø12 ø0 47 ø12 ø0 47 e ø5 5 ø0 22 ø5 5 ø0 22 ø5 5 ø0 22 ø5 5 ø0 22 ø6 5 ø0 26 ø6 5 ø0 26 f 9 0 35 9 0 35 9 0 35 9 0 35 6 0 24 9 0 35 Maximum weight kg lb 4 9 10 8 5 3 11 7 6 6 14 6 7 15 4 9 7 21 4 14 31 1 See Illustration 54 and Illustration 55 2 Depth of enclosure varies with different options installed Table 44 Power Ratings Weight and Dimensions Enc...

Page 97: ...9 0 75 ø19 0 75 ø12 ø0 47 e ø9 0 35 ø9 0 35 6 8 0 27 8 5 0 33 f 9 0 35 9 0 35 7 9 0 31 15 0 59 Maximum weight kg lb 23 51 27 60 12 26 5 23 5 52 1 See Illustration 54 and Illustration 55 2 Depth of enclosure varies with different options installed Table 45 Power Ratings Weight and Dimensions Enclosure Size C Enclosure size C1 C2 C3 C4 3x525 690 V T7 37 90 50 125 45 55 60 75 3x525 600 V T6 37 55 50 ...

Page 98: ... 7 334 13 1 270 10 6 330 13 Depth mm in 2 Depth without option A B C 310 12 2 335 13 2 333 13 1 333 13 1 With option A B C 310 12 2 335 13 2 333 13 1 333 13 1 Screw holes mm in c 12 0 47 12 0 47 d ø19 0 75 ø19 0 75 e ø9 0 35 ø9 0 35 8 5 0 33 8 5 0 33 f 9 8 0 39 9 8 0 39 17 0 67 17 0 67 Maximum weight kg lb 45 99 65 143 35 77 50 110 1 See Illustration 54 and Illustration 55 2 Depth of enclosure var...

Page 99: ...a e f e30ba715 12 Illustration 55 Top and Bottom Mounting Holes Enclosure Sizes B4 C3 and C4 AJ300847815559en 000101 130R0337 99 Danfoss A S 2020 09 Specifications VLT AQUA Drive FC 202 Design Guide ...

Page 100: ...isk of condensa tion as long as the power dissipation keeps the circuitry free of moisture N O T I C E EXTREME AMBIENT CONDITIONS Hot or cold temperatures compromise unit performance and longevity Do not operate in environments where the ambient temperature exceeds 55 C 131 F The drive can operate at temperatures down to 10 C 14 F However proper operation at rated load is only guaranteed at 0 C 32...

Page 101: ...ers High power drives are equipped with cooling fans that expel hot air from the interior of the unit Above a certain size these fans are fitted with filter mats These filters can quickly become clogged when used in dusty environments Preventive measures are neces sary under these conditions Periodic maintenance Under the conditions described above it is recommended to clean the drive during perio...

Page 102: ...and triggering a false alarm For temperatures below 20 C Set the fan control to low temperature environment setting in parameter 14 52 to switch off the heat sink fan and therefore the external fan This adjusts the fan control to the cold environment to prevent the negative effect from further cooling and triggering a false alarm Disable parameter 14 53 This prevents warnings to be issued falsely ...

Page 103: ... CT mode A problem may occur at low RPM values in constant torque applications In a constant torque application a motor may overheat at low speeds due to less cooling air from the motor integral fan Therefore if the motor is to be run continuously at an RPM value lower than half of the rated value the motor must be supplied with extra air cooling or a motor designed for this type of operation may ...

Page 104: ...000 m 6561 ft contact Danfoss regarding PELV Alternatively lower the ambient temperature at high altitudes and thereby ensure 100 output current at high altitudes As an ex ample of how to read the graph the situation at 2000 m 6561 ft is elaborated for an enclosure size B with TAMB MAX 50 C 122 F Either the output current has to be reduces to 91 at TAMB MAX or the maximum temperature has to be red...

Page 105: ...imum 10 mm2 8 AWG Cu or 16 mm2 6 AWG OR There must be an automatic disconnection of the mains if the protective earthing conductor breaks OR There must be a terminal for a 2nd protective earthing conductor in the same cross sectional are as the 1st protective earthing conductor Cross sectional area of the phase conductors S mms AWG The minimum cross sectional area of the protective earthing con du...

Page 106: ...nsient Do not use pigtails Overcurrent protection Extra protection equipment such as short circuit protection or motor thermal protection between drive and motor are required for applications with multiple motors Input fusing is required to provide short circuit and overcurrent protection If fuses are not factory supplied the installer must provide them See maximum fuse ratings in and Wire type an...

Page 107: ...0 V PNP 24 V NPN 19 D IN 24 V NPN 0 V PNP 27 24 V 0 V D IN OUT 0 V PNP 24 V NPN D IN OUT 0 V 24 V 29 24 V NPN 0 V PNP 0 V PNP 24 V NPN 33 D IN 32 D IN 1 2 ON A53 ON 2 1 A54 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 Chassis PE 2 240 V AC 2 A 400 V AC 2 A 1 Ground 1 Ground 2 Ground Illustration 59 Basic Wiring Schematic A Analog D Digital 1 Terminal 37 optional is used for S...

Page 108: ...8 7 10 9 4 11 13 4 4 6 15 90 DC BR B M AIN S L1 L2 L3 91 92 93 RELA Y 1 RELA Y 2 99 LC UV W MOTOR Illustration 60 EMC compliant Electrical Connection AJ300847815559en 000101 130R0337 108 Danfoss A S 2020 09 Electrical Installation Considerations VLT AQUA Drive FC 202 Design Guide ...

Page 109: ... 75 C 167 F copper conductors Non UL applications can use 75 C 167 F and 90 C 194 F copper conductors N O T I C E The plug connector for power is pluggable on drives up to 7 5 kW 10 hp The power cable connections are located as shown in Illustration 61 See for correct dimensioning or motor cable cross section and length For protection of the drive use the recommended fuses unless the unit has buil...

Page 110: ...thout phase insulation paper or other insulation reinforcement suitable for operation with voltage supply use a sine wave filter on the output of the drive U1 V1 W1 e75za114 11 96 97 98 96 97 98 U2 V2 W2 U1 V1 W1 U2 V2 W2 1 2 Illustration 62 Motor Cable Connection 1 Motor 2 Drive 10 3 2 IT Grid Connection Mains supply isolated from ground If the drive is supplied from an isolated mains source IT m...

Page 111: ... or put together by the same person system manufacturer intended to be placed on the market for distribution as a single functional unit for an end user and intended to be installed and operated together to perform a specific task The EMC directive applies to products systems and installations but in case the installation is built up of CE marked products systems the installation can also be consi...

Page 112: ...een reduced To obtain a low HF impedance use the fastening bolts of the devices as HF connection to the rear plate It is necessary to remove insulating paint or similar from the fastening points 10 3 7 Safety Ground Connection W A R N I N G LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to ground the drive properly can result in death or serious injury Ensure the correct grounding o...

Page 113: ...yer of braided copper wire with a magnetic shielded armored intermediate layer 6 Cable that runs in copper tube or steel tube 7 Lead cable with 1 1 mm 0 04 in wall thickness 10 4 2 Preparing Cable Entry Holes Procedure Remove cable entry from the drive Avoid that foreign parts fall into the drive when removing the knockouts Support the cable entry where the knockout is to be removed Remove the kno...

Page 114: ...3 4 28 4 M25 4 Control cable 1 2 22 5 M20 5 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm 10 4 3 2 Entry Holes Enclosure Size A3 IP21 4 5 6 1 3 2 e30bb657 10 Table 48 Dimensions of Entry Holes for Enclosure Size A3 IP21 Hole number and recommended use Dimensions 1 Nearest metric UL in mm 1 Mains 3 4 28 4 M25 2 Motor 3 4 28 4 M25 AJ300847815559en 000101 130R0337 114 Danfoss A S 2020 09 Electrical I...

Page 115: ...ric UL in mm 1 Mains 3 4 28 4 M25 2 Motor 3 4 28 4 M25 3 Brake loadsharing 3 4 28 4 M25 4 Control cable 1 2 22 5 M20 5 Removed 1 Tolerance 0 2 mm 10 4 3 4 Entry Holes Enclosure Size A4 IP55 Threaded Gland Holes 4 2 3 5 1 e30bb665 10 Table 50 Dimensions of Entry Holes for Enclosure Size A4 IP55 Threaded Gland Holes Hole number and recommended use Metric thread size 1 Mains M25 2 Motor M25 3 Brake l...

Page 116: ...ol cable 2 3 4 28 4 M25 1 Tolerance 0 2 mm 2 Knockout hole 10 4 3 6 Entry Holes Enclosure Size A5 IP55 Threaded Gland Holes 4 5 3 6 2 1 e30bb666 10 Table 52 Dimensions of Entry Holes for Enclosure Size A5 IP55 Threaded Gland Holes Hole number and recommended use Metric thread size 1 Mains M25 2 Motor M25 3 Brake loadsharing 28 4 mm 1 4 Control cable M25 5 Control cable M25 6 Control cable M25 1 Kn...

Page 117: ...ce 0 2 mm 10 4 3 8 Entry Holes Enclosure Size B1 IP55 5 4 3 6 2 1 e30bb667 10 Table 54 Dimensions of Entry Holes for Enclosure Size B1 IP55 Hole number and recommended use Dimensions 1 Nearest metric UL in mm 1 Mains 1 34 7 M32 2 Motor 1 34 7 M32 3 Brake loadsharing 1 34 7 M32 4 Control cable 3 4 28 4 M25 5 Control cable 1 2 22 5 M20 6 Control cable 2 1 2 22 5 M20 1 Tolerance 0 2 mm 2 Knockout hol...

Page 118: ...rol cable 22 5 mm 1 1 Knockout hole 10 4 3 10 Entry Holes Enclosure Size B2 IP21 1 4 5 3 2 e30bb660 11 Table 56 Dimensions of Entry Holes for Enclosure Size B2 IP21 Hole number and recommended use Dimensions 1 Nearest metric UL in mm 1 Mains 1 1 4 44 2 M40 2 Motor 1 1 4 44 2 M40 3 Brake loadsharing 1 34 7 M32 4 Control cable 3 4 28 4 M25 5 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm AJ3008478155...

Page 119: ...5 Control cable 2 1 2 22 5 M20 1 Tolerance 0 2 mm 2 Knockout hole 10 4 3 12 Entry Holes Enclosure Size B2 IP55 Threaded Gland Holes 4 3 2 5 1 e30bb670 10 Table 58 Dimensions of Entry Holes for Enclosure Size B2 IP55 Threaded Gland Holes Hole number and recommended use Metric thread size 1 Mains M40 2 Motor M40 3 Brake loadsharing M32 4 Control cable M25 5 Control cable M20 AJ300847815559en 000101 ...

Page 120: ... 6 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm 10 4 3 14 Entry Holes Enclosure Size C1 IP21 5 3 2 4 1 e30bb661 11 Table 60 Dimensions of Entry Holes for Enclosure Size C1 IP21 Hole number and recommended use Dimensions 1 Nearest metric UL in mm 1 Mains 2 63 3 M63 2 Motor 2 63 3 M63 3 Brake loadsharing 1 1 2 50 2 M50 4 Control cable 3 4 28 4 M25 5 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm AJ3...

Page 121: ... Control cable 1 2 22 5 M20 6 Control cable 1 2 22 5 M20 1 Tolerance 0 2 mm 10 4 4 Tightening Torques for Cover Table 62 Tightening Torque Values Nm Enclosure size IP20 IP21 IP55 IP66 A1 1 2 2 2 A2 1 1 2 2 A3 1 1 2 2 A4 A5 2 2 2 2 B1 2 1 2 2 2 2 B2 1 2 2 2 2 2 B3 1 2 2 2 B4 1 2 2 2 C1 2 1 2 2 2 2 C2 2 1 2 2 2 2 C3 2 2 2 2 C4 2 2 2 2 1 No screws to tighten 2 Does not exist AJ300847815559en 000101 1...

Page 122: ... loops may occur To eliminate ground loops connect 1 end of the shield to the ground with a 100 nF capacitor keeping leads short 100nF FC PE PE PLC 10 mm e30bb609 12 Illustration 65 Connection with a 100 nF Capacitor 10 5 1 2 Avoid EMC Noise on Serial Communication This terminal is connected to ground via an internal RC link Use twisted pair cables to reduce interference between conductors The rec...

Page 123: ...9 32 33 Illustration 68 Connecting Control Wires 10 5 3 Control Terminal Types Find the location of the removable drive connectors in Illustration 69 and Illustration 70 Terminal functions and default settings are summarized in 10 5 4 Terminal Descriptions e30bf144 10 Illustration 69 Control Terminal Locations AJ300847815559en 000101 130R0337 123 Danfoss A S 2020 09 Electrical Installation Conside...

Page 124: ...ommons for the inputs and output 10 5 4 Terminal Descriptions Table 63 Digital Inputs Outputs Terminal Parameter Default setting Description 12 13 24 V DC 24 V DC supply voltage for digital inputs and ex ternal transducers Maximum output current 200 mA for all 24 V loads 18 Parameter 5 10 Terminal 18 Digital In puts 8 Start Digital inputs 19 Parameter 5 11 Terminal 19 Digital In puts 0 No operatio...

Page 125: ... FC Port Settings Table 66 Relays Terminal Parameter Default setting Description 01 02 03 Parameter 5 40 Function Relay 0 9 Alarm Form C relay output For AC or DC voltage and resistive or in ductive loads 04 05 06 Parameter 5 40 Function Relay 1 5 Running Table 67 Additional Terminals Terminal Location 1 form C relay outputs The location of the outputs depend on the drive configuration Terminals o...

Page 126: ...er Moeller Maximum trip level A A2 0 25 1 5 0 34 2 0 gG 10 gG 25 PKZM0 25 25 2 2 3 0 gG 16 A3 3 0 4 0 gG 16 gG 32 PKZM0 25 25 3 7 5 0 gG 20 A4 0 25 1 5 0 34 2 0 gG 10 gG 32 PKZM0 25 25 2 2 3 0 gG 16 A5 0 25 1 5 0 34 2 0 gG 10 gG 32 PKZM0 25 25 2 2 3 0 3 0 4 0 gG 16 3 7 5 0 gG 20 B1 5 5 7 5 gG 25 gG 80 PKZM4 63 63 7 5 11 10 15 gG 32 B2 15 20 gG 50 gG 100 NZMB1 A100 100 B3 5 5 7 5 7 5 10 gG 25 gG 63...

Page 127: ...ZMB1 A100 100 30 40 gG 63 37 50 gG 80 C1 37 50 gG 80 gG 160 NZMB2 A200 160 45 60 gG 100 55 75 gG 160 C2 75 100 aR 200 aR 250 NZMB2 A250 250 90 125 aR 250 C3 45 60 gG 100 gG 150 NZMB2 A200 150 55 75 gG 160 gG 160 C4 75 100 aR 200 aR 250 NZMB2 A250 250 90 125 aR 250 Table 70 525 600 V Enclosure Sizes A B and C Enclosure Power kW hp Recommended fuse size Recommended maximum fuse Recommended circuit b...

Page 128: ...3 45 60 gG 63 gG 150 NZMB2 A200 150 55 75 gG 100 C4 75 100 aR 160 aR 250 NZMB2 A250 250 90 125 aR 200 Table 71 525 690 V Enclosure Sizes A B and C Enclosure Power kW hp Recommended fuse size Recommended maxi mum fuse Recommended circuit breaker Moeller Maximum trip lev el A A3 1 1 1 5 gG 6 gG 25 PKZM0 16 16 1 5 2 0 gG 6 gG 25 2 2 3 0 gG 6 gG 25 3 0 4 0 gG 10 gG 25 4 0 5 0 gG 10 gG 25 5 5 7 5 gG 16...

Page 129: ... 3 7 5 0 50 FWX 50 KTN R50 JKS 50 JJN 50 5 5 7 5 60 FWX 60 KTN R60 JKS 60 JJN 60 7 5 10 80 FWX 80 KTN R80 JKS 80 JJN 80 15 20 150 FWX 150 KTN R150 JKS 150 JJN 150 22 30 200 FWX 200 KTN R200 JKS 200 JJN 200 Table 73 Recommended Maximum Fuse 1x200 240 V Enclosure Sizes A B and C Power kW hp Maximum Prefuse size A SIBA Type RK1 Littelfuse Type RK1 Ferraz Shaw mut Type CC Ferraz Shawmut Type RK1 1 Fer...

Page 130: ...se size A SIBA RK1 Littelfuse RK1 1 Ferraz Shaw mut CC Ferraz Shawmut RK1 2 Ferraz Shaw mut J 7 5 10 60 5014006063 KLS R60 A6K 60R HSJ60 11 15 80 2028220100 KLS R80 A6K 80R HSJ80 22 30 150 2028220160 KLS R150 A6K 150R HSJ150 37 50 200 2028220200 KLS 200 A6K 200R HSJ200 1 KLSR fuses from Littelfuse may substitute KLNR fuses for 240 V drives 2 A6KR fuses from Ferraz Shawmut may substitute A2KR for 2...

Page 131: ...5 A2K 25 R FWX 25 HSJ 25 3 7 4 0 5012406 032 KLN R 30 ATM R 30 A2K 30 R FWX 30 HSJ 30 5 5 7 5 7 5 10 5014006 050 KLN R 50 A2K 50 R FWX 50 HSJ 50 11 15 5014006 063 KLN R 60 A2K 60 R FWX 60 HSJ 60 15 20 5014006 080 KLN R 80 A2K 80 R FWX 80 HSJ 80 18 5 22 25 30 2028220 125 KLN R 125 A2K 125 R FWX 125 HSJ 125 30 40 2028220 150 KLN R 150 A2K 150 R FWX 150 L25S 150 A25X 150 HSJ 150 37 50 2028220 200 KLN...

Page 132: ...Ferraz Shaw mut Type RK1 Bussmann Type JFHR2 Littel fuse JFHR2 Ferraz Shawmut JFHR2 1 Ferraz Shawmut J 5017906 006 KLS R 6 ATM R 6 A6K 6 R FWH 6 HSJ 6 1 1 2 2 0 75 3 0 5017906 010 KLN R 10 ATM R 10 A6K 10 R FWH 10 HSJ 10 3 0 4 0 5017906 016 KLN R 15 ATM R 15 A6K 15 R FWH 15 HSJ 15 4 0 5 0 5017906 020 KLN R 20 ATM R 20 A6K 20 R FWH 20 HSJ 20 5 5 7 5 5017906 025 KLN R 25 ATM R 25 A6K 25 R FWH 25 HSJ...

Page 133: ...R 30 KTK R 30 LP CC 30 11 15 15 20 KTS R 35 JKS 35 JJS 35 18 24 KTS R 45 JKS 45 JJS 45 22 30 KTS R 50 JKS 50 JJS 50 30 40 KTS R 60 JKS 60 JJS 60 37 50 KTS R 80 JKS 80 JJS 80 45 60 KTS R 100 JKS 100 JJS 100 55 75 KTS R 125 JKS 125 JJS 125 75 100 KTS R 150 JKS 150 JJS 150 90 125 KTS R 175 JKS 175 JJS 175 Table 81 Recommended Maximum Fuse 525 600 V Enclosure Sizes A B and C Power kW hp SIBA Type RK1 ...

Page 134: ... JKS 100 JJS 100 5014006 100 KLS R 100 A6K 100 R HST 100 75 100 125 KTS R 125 JKS 125 JJS 125 2028220 125 KLS 150 A6K 125 R HST 125 90 125 150 KTS R 150 JKS 150 JJS 150 2028220 150 KLS 175 A6K 150 R HST 150 Table 83 Recommended Maximum Fuse 525 690 V Enclosure Sizes B and C Power kW hp Maxi mu m prefuse A Bussmann E52273 RK1 JDDZ Bussmann E4273 J JDDZ Buss mann E4273 T JDDZ SIBA E180276 RK1 JDDZ L...

Page 135: ...on 71 Relay Outputs 1 and 2 To set the relay output see parameter group 5 4 Relays Table 84 Description of Relays Terminal numbers Function 01 02 Make normally open 01 03 Break normally closed 04 05 Make normally open 04 06 Break normally closed 10 8 Motor All types of 3 phase asynchronous standard motors can be used with a drive The factory setting is for clockwise rotation with the drive output ...

Page 136: ...Guide for details on how to set up the drive for safe operation of Ex e or Ex n motors 10 8 2 Parallel Connection of Motors The drive can control several parallel connected motors When using parallel motor connection observe the following Recommended to run applications with parallel motors in U F mode parameter 1 01 Motor Control Principle 0 Set the U F graph in parameter 1 55 U f Characteristic ...

Page 137: ...s are kept short less than 10 m 32 ft each Table 85 Maximum Cable Lengths Enclosure sizes Power size kW hp Voltage V 1 cable m ft 2 cables m ft 3 cables m ft 4 cables m ft A1 A2 A4 A5 0 37 0 75 0 5 1 0 400 150 492 45 147 6 8 0 26 6 0 19 7 500 150 492 7 0 23 4 0 13 3 0 9 8 A2 A4 A5 1 1 1 5 1 5 2 0 400 150 492 45 147 6 20 65 6 8 0 26 500 150 492 45 147 6 5 0 16 4 4 0 13 A2 A4 A5 2 2 4 0 3 0 5 0 400 ...

Page 138: ...de Standard mitigation strategies Use an insulated bearing Apply rigorous installation procedures Ensure that the motor and load motor are aligned Strictly follow the EMC Installation guideline Reinforce the PE so the high frequency impedance is lower in the PE than the input power leads Provide a good high frequency connection between the motor and the drive for instance by shielded cable which h...

Page 139: ...time T ta tc tb to ta tc tb to ta e30ba167 10 Load Time Speed Illustration 74 Dynamic Braking Cycle Time Brake resistors have a duty cycle of 5 10 and 40 If a 10 duty cycle is applied the brake resistors are able to absorb brake power for 10 of the cycle time The remaining 90 of the cycle time is spent on dissipating excess heat Table 87 Braking at High Overload Torque Level Cycle time s Braking d...

Page 140: ...202 3x380 480 V 778 810 820 FC 202 3x525 600 V 943 965 975 FC 202 3x525 690 V 1099 1109 1130 N O T I C E For use of 3rd party brake resistors make sure to comply with the table above The VLT Brake Resistor MCE 101 series is optimized for Danfoss VLT series drives Danfoss recommends a brake resistance Rrec that can guarantee that the drive can brake at the highest brake power Mbr of 150 The formula...

Page 141: ...not ground leakage protected Overvoltage control OVC can be selected as an alternative brake function in parameters for overvoltage control This function is active for all units and ensures that if the DC link voltage increases the output frequency also increases to limit the voltage from the DC link which avoids a trip N O T I C E OVC cannot be activated when running a PM motor while parameters f...

Page 142: ...he line distortion e30bb956 12 THDv 0 THDv 5 Leakage current Illustration 76 Influence of Line Distortion on Leakage Current If the leakage current exceeds 3 5 mA compliance with EN IEC 61800 5 1 power drive system product standard requires special care Reinforce grounding with the following protective earth connection requirements AJ300847815559en 000101 130R0337 142 Danfoss A S 2020 09 Electrica...

Page 143: ...tions The leakage current includes several frequencies originating from both the mains frequency and the switching frequency Whether the switching frequency is detected depends on the type of RCD used e30bb958 12 Leakage current Frequency 3rd harmonics Mains Cable RCD with low fcut off RCD with high fcut off 50 Hz 150 Hz fsw Illustration 77 Mains Contributions to Leakage Current The amount of leak...

Page 144: ...efficiency is then 0 97x0 98 0 95 The MyDrive ecoSmart tool helps to calculate the efficiency refer to www ecosmart danfoss com Efficiency of the motor ηMOTOR The efficiency of a motor connected to the drive depends on the magnetizing level In general the efficiency is as good as with mains operation The efficiency of the motor depends on the type of motor In the range of 75 100 of the rated torqu...

Page 145: ...sulation reinforcement designed for operation of the drive install a VLT dU dt filter MCC 102 or a VLT Sine wave Filter MCC 101 on the output of the drive When a transistor in the inverter bridge switches the voltage across the motor increases by a dU dt ratio depending on Motor inductance Motor cable type cross section length shielded unshielded The natural induction causes an overshoot voltage p...

Page 146: ... Table 91 for the maximum motor cable lengths for compliance N O T I C E Conditions may change significantly for other setups N O T I C E Consult Illustration 73 for parallel motor cables Table 91 EMC Test Results Emission Maximum Motor Cable Length RFI filter type Conducted emission Radiated emission Cable length m ft Standards and require ments EN 55011 CISPR 11 Class B Class A Group 1 Class A G...

Page 147: ...for 2 phase supply from a TT or TN network 2 T7 37 90 kW complies with class A group 1 with 25 m 82 ft motor cable Some restrictions for the installation apply contact Danfoss for details 3 Enclosure size B2 4 Enclosure size C2 5 Hx versions can be used according to EN IEC 61800 3 category C4 Hx H1 H2 H3 H4 or H5 is defined in the type code positions 16 17 for EMC filters H1 Integrated EMC filter ...

Page 148: ...ents Class A Group 1 N O T I C E According to the EMC Directive a system is defined as a combination of several types of equipment finished products and or components combined designed and or put together by the same person system manufacturer intended to be placed on the market for distribution as a single functional unit for an end user and intended to be installed and operated together to perfo...

Page 149: ...RF Common mode Simulation of the effect from radio transmission equipment joined by con nection cables The immunity requirements should follow product standard IEC 61800 3 See Table 94 Table 94 EMC Immunity Voltage range 200 240 V 380 480 V Basic standard Burst IEC 61000 4 4 Surge IEC 61000 4 5 ESD IEC 61000 4 2 Radiated electro magnetic field IEC 61000 4 3 RF common mode voltage IEC 61000 4 6 Acc...

Page 150: ...ts To achieve a high level of immunity use drives with high quality RFI filters N O T I C E In a residential environment this product can cause radio interference in which case supplementary mitigation measures may be required PELV and galvanic isolation compliance All control and relay terminals comply with PELV excluding grounded Delta leg above 400 V To obtain galvanic ensured isolation fulfill...

Page 151: ...within metal conduit Ensure that motor and brake cables are as short as possible to reduce the interference level from the entire system Avoid placing cables with a sensitive signal level alongside motor and brake cables For communication and command control lines follow the particular communication protocol standards For example USB must use shielded cables but RS485 ethernet can use shielded UTP...

Page 152: ...ge PELV compliance N O T I C E PROTECTIVE EXTRA LOW VOLTAGE PELV COMPLIANCE Prevent electric shock by using PELV electrical supply and complying with local and national PELV regulations e30bf228 11 L1 L2 L3 PE L1 L2 L3 PE PE u v w 2 1 3 5 IEC 60309 16 17 18 14 12 8 7 10 9 4 11 13 4 4 6 15 90 DC BR B M AIN S L1 L2 L3 91 92 93 RELA Y 1 RELA Y 2 99 LC UV W MOTOR Illustration 81 Example of Proper EMC ...

Page 153: ...les of the basic current frequency These components are referred to as harmonics It is important to con trol the total harmonic distortion on the mains supply Although the harmonic currents do not directly affect electrical energy con sumption they generate heat in the wiring and transformers that can affect other devices on the same power line 10 17 1 Harmonics Analysis Since harmonics increase h...

Page 154: ...Z Z Z Z Recti er 1 Recti er 2 Recti er 3 Other Loads xfr 2 1 3 e30bb540 10 Illustration 82 Small Distribution System Harmonic currents drawn by non linear loads cause distortion of the voltage because of the voltage drop on the impedances of the distribution system Higher impedances result in higher levels of voltage distortion Current distortion relates to apparatus performance and it relates to ...

Page 155: ...quirements for compatibility levels for PCC point of common coupling of low voltage AC systems on a public supply network Limits are specified only for harmonic voltage and total harmonic distortion of the voltage EN 61000 2 2 does not define limits for harmonic currents In situations where the total harmonic distortion THDv 8 PCC limits are identical to those limits specified in the EN 61000 2 4 ...

Page 156: ...s below 90 kW and in Table 102 for power sizes above 90 kW Table 101 Typical Harmonic Emission Values for VLT Drives FC 102 FC 103 FC 202 FC 302 below 90 kW Individual harmonic current Ih Iref I5 I7 I11 I13 Typical value 38 20 10 8 Limit for RSCE 120 1 40 25 15 10 Harmonic current distortion factor THC Iref PWHC Iref Typical value 2 42 41 Limit for RSCE 120 1 48 46 1 According to IEC 61000 3 12 20...

Page 157: ...ctor which is wired in series between a power source and a load Line reactors also called input AC reactors are used in motor drive applications The main function of the line reactor is to limit the current Line reactors also reduce the main harmonics limit the inrush currents and protect drives and motors Line reactors help achieving an overall improvement of the true power factor and the quality...

Page 158: ... line reactor series VLT Line Reactor MCC 103 For more information go to www danfoss com AJ300847815559en 000101 130R0337 158 Danfoss A S 2020 09 Electrical Installation Considerations VLT AQUA Drive FC 202 Design Guide ...

Page 159: ...0bf777 11 4 Illustration 84 Internal Processing 1 Rectifier SCR diodes 2 DC link DC bus 3 Inverter IGBTs 4 Control area 11 2 1 Control Principle The control structure is a software process that controls the motor based on user defined references for example RPM and whether feedback is used or not closed loop open loop The operator defines the control by selecting the configuration mode The control...

Page 160: ...t commonly through an analog control input All reference sources and the bus references are added to produce the total external reference The active reference can be selected from the following External reference Preset reference Setpoint Sum of the external reference preset reference and setpoint The active reference can be scaled The scaled reference is calculated as follows Reference X X Y 100 ...

Page 161: ...ot ref Increase Decrease Clear DigiPot Closed loop Ref 2 source Ref 3 source Analog inputs Frequency inputs Analog inputs Frequency inputs Ext closed loop outputs Ext closed loop outputs P 3 10 P 3 15 P 3 16 P 3 17 Y X P 1 00 P 3 14 100 e30ba357 13 P 3 04 200 200 200 0 200 P 1 00 200 0 1 0 1 0 1 S S S Illustration 86 Remote Handling of Reference 11 3 Reference Limits The reference range minimum re...

Page 162: ...ences When Reference Range is Set to 1 The minimum reference cannot be set to less than 0 unless the configuration mode is set to Process In that case the following relations between the resulting reference after clamping and the sum of all references are as shown in Illustration 89 e30bh326 10 Reference range Minimum to maximum Resulting reference Maximum reference Minimum reference Sum of all re...

Page 163: ...amp 1 P 3 5 Ramp 2 Illustration 91 Open loop Structure In open loop configurations the resulting reference from the reference handling system or the local reference is received and fed through the ramp limitation and speed limitation before being sent to the motor control The output from the motor control is then limited by the maximum frequency limit 11 4 2 Control Structure Closed Loop The inter...

Page 164: ...llustration 92 Control Structure Closed loop While the default values for the closed loop controller of the drive often provide satisfactory performance the control of the system can often be optimized by adjusting parameters It is also possible to autotune the PI constants AJ300847815559en 000101 130R0337 164 Danfoss A S 2020 09 Basic Operating Principles VLT AQUA Drive FC 202 Design Guide ...

Page 165: ... 12 1 1 Wiring Configuration for Automatic Motor Adaptation AMA Table 103 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 OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 e30bb929 11 Drive Function Setting Parameter 1 29 Automatic Motor Adaptation AMA 1 Enable complete AMA Parameter 5 12 Terminal 27 Digital Inp...

Page 166: ...tes comments Parameter group 1 2 Motor Data must be set ac cording to motor 12 1 3 Wiring Configuration Speed Table 105 Analog Speed Reference Voltage Parameters 10V A IN A IN COM A OUT COM 50 53 54 55 42 39 A53 U I 0 10 V e30bb926 11 Drive Function Setting Parameter 6 10 Terminal 53 Low Voltage 0 07 V Parameter 6 11 Terminal 53 High Voltage 10 V Parameter 6 14 Terminal 53 Low Ref Feedb value 0 Hz...

Page 167: ... 10 Terminal 53 Low Voltage 0 07 V Parameter 6 11 Terminal 53 High Voltage 10 V Parameter 6 14 Terminal 53 Low Ref Feedb value 0 Hz Parameter 6 15 Terminal 53 High Ref Feedb Value 50 Hz Default value Notes comments D IN 37 is an option Table 108 Speed Up Down Parameter 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 12 13 18 19 20 27 29 32 33 37 e30bb804 12 Drive Function Setting Parameter 5 10 T...

Page 168: ... IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 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 Parameter 6 25 Terminal 54 High Ref Feedb Value 50 Default value Notes comments D IN 37 is an option AJ300847815559en 000101 130R0337 168 Danfoss ...

Page 169: ... value Notes comments D IN 37 is an option Table 111 Analog Voltage Feedback Transducer 4 wire 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 OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A54 U I 0 10 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 ...

Page 170: ... OUT COM 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 Default value Notes comments D IN 37 is an option AJ300847815559en 000101 130R0337 170 Danfoss A S 2020 09 Basic I O Configurations VLT AQUA Drive FC 202 Design Guide ...

Page 171: ...681 11 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 Digital Inputs is set to 0 No operation a jumper wire to terminal 27 is not needed D IN 37 is an option AJ300847815559en 000101 130R0337 171 Danfoss A S 2020 09 Basic I O Configurations VLT AQUA Drive...

Page 172: ... IN 37 is an option 12 1 6 Wiring Configuration Start Stop Table 115 Start Stop Command with Safe Torque Off Option Parameter 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 12 13 18 19 20 27 29 32 33 37 e30bb802 12 Drive Function Setting Parameter 5 10 Terminal 18 Digital Input Start Parameter 5 12 Terminal 27 Digital Input 0 No operation Parameter 5 19 Terminal 37 Safe Stop 1 Safe Stop Alarm De...

Page 173: ...g Parameter 5 10 Terminal 18 Digital Input 9 Latched 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 needed D IN 37 is an option Speed e130bb806 11 Latched Start 18 Stop Inverse 27 Illustration 95 Latched Start Stop Inverse AJ300847815559en 000101 130R033...

Page 174: ...erminal 33 Digital Input 17 Preset ref bit 1 Parameter 3 10 Preset Reference Preset ref 0 Preset ref 1 Preset ref 2 Preset ref 3 25 50 75 100 Default value Notes comments D IN 37 is an option 12 1 7 Wiring Configuration External Alarm Reset Table 118 External Alarm Reset Parameter 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 50 53 54 5...

Page 175: ...54 55 42 39 01 02 03 04 05 06 61 68 69 RS485 e30bb685 11 Drive Function Setting Parameter 8 30 Protocol FC Parameter 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 AJ300847815559en 000101 130R0337 175 Danfoss A S 2020 09 Basic I O Configurations VLT AQUA Drive FC 202 Design Guide...

Page 176: ...5 42 39 A53 U I D IN 37 Drive 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 Thermal Protection to 1 Thermistor warn ing D IN 37 is an option AJ300847815559en 000101 130R0337 176 Danfoss A S 2020 09 Basic I O Configurations VLT AQUA Drive FC 202 Design...

Page 177: ...arning Parameter 13 02 Stop Event 44 Reset key Parameter 13 10 Comparator Operand 21 Warning no Parameter 13 11 Comparator Operator 1 equal Parameter 13 12 Comparator Value 90 Parameter 13 51 SL Controller Event 22 Comparator 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...

Page 178: ...D0 The meaning of the characters in the string is described in Table 122 and Table 123 In the example above a PROFIBUS V1 and a 24 V back up option is built in Table 122 Ordering Type Code Enclosure Sizes A B and C Description Position Possible options Product group 1 2 FC Drive series 4 6 202 Power rating 8 10 0 25 90 kW 0 34 110 hp Phases 11 S Single phase T Three phases Mains voltage 12 S2 200 ...

Page 179: ... Ruggedized X No coated PCB Mains option 21 X No mains option 1 Mains disconnect 3 Mains disconnect and fuse 1 5 Mains disconnect fuse and load sharing 1 2 7 Fuse 1 8 Mains disconnect and load sharing 2 A Fuse and load sharing 1 2 D Load sharing 3 Adaptation 22 X Standard cable entries O European metric thread in cable entries A4 A5 B1 and B2 S Imperial cable entries A5 B1 B2 C1 and C2 only Adapta...

Page 180: ... software 36 37 XX Standard controller D options 38 39 DX No option D0 VLT Extended 24 V DC Back up MCB 107 D1 VLT Real time Clock MCB 117 N O T I C E For power sizes over 90 kW see the VLT AQUA Drive 110 1400 kW Design Guide 13 1 2 Language Packages Drives are automatically delivered with a language package relevant to the region from which it is ordered 4 regional language packages cover the fol...

Page 181: ...ns Descriptions Ordering number Uncoated Coated VLT General Purpose I O MCB 101 130B1125 130B1212 VLT Relay Option MCB 105 130B1110 130B1210 VLT Analog I O Option with RTC MCB 109 130B1143 130B1243 VLT PTC Thermistor Card MCB 112 130B1137 VLT Sensor Input Option MCB 114 130B1172 130B1272 VLT Programmable I O MCB 115 130B1266 VLT Extended Cascade Controller MCO 101 130B1118 130B1218 13 2 3 Order Nu...

Page 182: ...3 130B5764 VLT Leakage Current Monitor Kit enclosure size B4 130B5765 VLT Leakage Current Monitor Kit enclosure size C3 130B6226 VLT Leakage Current Monitor Kit enclosure size C4 130B5647 13 2 6 Order Numbers for Miscellaneous Hardware Table 130 Ordering Numbers for Hardware Options Description Ordering number Uncoated VLT Panel through kit enclosure size A5 130B1028 VLT Panel through kit enclosur...

Page 183: ...eel IP66 Type 4X enclosure size B1 130B3434 VLT Back plate in stainless steel IP66 Type 4X enclosure size B2 130B3465 VLT Back plate in stainless steel IP66 Type 4X enclosure size C1 130B3468 VLT Back plate in stainless steel IP66 Type 4X enclosure size C2 130B3491 VLT PROFIBUS Adapter Sub D9 Connector 130B1112 PROFIBUS shield plate kit for IP20 enclosure sizes A2 and A3 130B0524 Terminal block fo...

Page 184: ...number VLT Motion Control Tool MCT 10 1 license 130B1000 VLT Motion Control Tool MCT 10 5 licenses 130B1001 VLT Motion Control Tool MCT 10 10 licenses 130B1002 VLT Motion Control Tool MCT 10 25 licenses 130B1003 VLT Motion Control Tool MCT 10 50 licenses 130B1004 VLT Motion Control Tool MCT 10 100 licenses 130B1005 VLT Motion Control Tool MCT 10 100 licenses 130B1006 13 2 9 Ordering of VLT Brake R...

Page 185: ...ble 133 Ordering Numbers for Brake Resistors T2 Horizontal Braking 10 Duty Cycle FC 202 Horizontal braking 10 duty cycle Drive data Brake resistor data Installation Danfoss part numbers Mains type Pm kW Rmin Ω Rbr nom Ω Rrec Ω Pbr cont kW Wire IP54 Screw ter minal IP65 Screw ter minal IP20 Bolt con nec tion IP20 Cable cross section mm2 AWG Ther mo re lay A T2 0 25 0 34 380 691 3 630 0 100 175U3002...

Page 186: ...rder Numbers for Brake Resistors T2 Vertical Braking 40 Duty Cycle Table 134 Order Numbers for Brake Resistors T2 Vertical Braking 40 Duty Cycle FC 202 Vertical braking 40 duty cycle Drive data Brake resistor data Installation Danfoss part numbers Mains type Pm kW Rmin Ω Rbr nom Ω Rrec Ω Pbr cont kW Wire IP54 Screw ter minal IP65 Screw ter minal IP20 Bolt con nection IP20 Cable cross section mm2 A...

Page 187: ...Conveyors Table 135 Flat pack IP65 Brake Resistors for Horizontal Conveyors FC 202 T2 200 240 V Flat pack IP65 for horizontal conveyors FC 202 T2 Pm kW Rmin Ω Rbr nom Ω Rrec per item Ω W Duty cycle Ordering number PK25 0 25 0 34 380 691 3 430 100 40 175U1002 PK37 0 37 0 50 380 466 7 430 100 27 175U1002 PK55 0 55 0 75 275 313 7 330 100 18 175U1003 PK55 0 55 0 75 275 313 7 310 200 36 175U0984 PK75 0...

Page 188: ...82 437 3 410 0 100 175U3004 1 5 16 0 5 T4 2 2 3 0 260 293 3 270 0 200 175U3007 1 5 16 0 8 T4 3 0 4 0 189 212 7 200 0 200 175U3008 1 5 16 0 9 T4 4 0 5 0 135 157 3 145 0 300 175U3300 1 5 16 1 3 T4 5 5 7 5 99 113 3 110 0 450 175U3335 175U3450 175U3449 1 5 16 1 9 T4 7 5 10 72 82 4 80 0 570 175U3336 175U3452 175U3451 1 5 16 2 5 T4 11 15 50 55 3 56 0 680 175U3337 175U3027 175U3028 1 5 16 3 3 T4 15 20 36...

Page 189: ...7 2 x 35 2 x 2 157 T4 400 550 1 2 1 4 1 2 36 000 175U3098 2 x 50 2 x 1 1 0 173 T4 450 600 1 1 1 3 1 1 42 000 175U3099 2 x 50 2 x 1 1 0 196 T4 500 650 0 9 1 1 2 x 1 9 T4 560 750 0 9 1 0 2 x 1 7 T4 630 850 0 8 0 9 2 x 1 5 T4 710 950 0 7 0 8 2 x 1 3 T4 800 1075 0 6 0 7 3 x 1 8 T4 1000 1350 0 5 0 6 3 x 1 6 13 2 9 5 Order Numbers for Brake Resistors T4 Vertical Braking 40 Duty Cycle Table 137 Order Num...

Page 190: ...0 175U3313 175U3422 175U3421 1 5 16 2 7 T4 5 5 7 5 99 113 3 110 1 700 175U3314 175U3424 175U3423 1 5 16 3 7 T4 7 5 10 72 82 4 80 2 200 175U3315 175U3138 175U3139 1 5 16 5 0 T4 11 15 50 55 3 56 3 200 175U3316 175U3428 175U3427 1 5 16 7 1 T4 15 20 36 40 3 38 5 000 175U3236 1 5 16 11 5 T4 18 5 25 27 32 5 28 6 000 175U3237 2 5 14 14 7 T4 22 30 20 3 27 2 22 8 000 175U3238 4 12 19 T4 30 40 18 19 8 19 10...

Page 191: ...Resistors T4 Flat pack for Horizontal Conveyors Table 138 Flat pack IP65 Brake Resistors for Horizontal Conveyors FC 202 T4 380 480 V Flat pack IP65 for horizontal conveyors FC 202 T4 Pm kW Rmin Ω Rbr nom Ω Rrec per item Ω W Duty cycle Ordering number PK75 0 75 1 0 620 910 2 830 100 13 175U1000 P1K1 1 1 1 5 546 607 3 620 100 9 175U1001 P1K1 1 1 1 5 546 607 3 620 100 18 175U0982 P1K5 1 5 2 0 382 43...

Page 192: ...9 1 850 0 100 175U3001 1 5 16 0 4 T6 1 5 2 0 550 642 7 570 0 100 175U3003 1 5 16 0 4 T6 2 2 3 0 380 431 1 415 0 200 175U3005 1 5 16 0 7 T6 3 0 4 0 260 312 5 270 0 200 175U3007 1 5 16 0 8 T6 4 0 5 0 189 231 6 200 0 300 175U3342 1 5 16 1 1 T6 5 5 7 5 135 166 6 145 0 450 175U3343 175U3012 175U3013 1 5 16 1 7 T6 7 5 10 99 121 1 100 0 570 175U3344 175U3136 175U3137 1 5 16 2 3 T6 11 15 69 81 6 72 0 680 ...

Page 193: ... mo relay A T6 0 75 1 0 620 1329 7 1200 0 360 175U3102 175U3103 1 5 16 0 6 T6 1 1 1 5 620 889 1 850 0 280 175U3317 175U3104 175U3105 1 5 16 0 6 T6 1 5 2 0 550 642 7 570 0 450 175U3318 175U3430 175U3429 1 5 16 0 9 T6 2 2 3 0 380 431 1 415 0 570 175U3319 175U3432 175U3431 1 5 16 1 1 T6 3 0 4 0 260 312 5 270 0 960 175U3320 175U3434 175U3433 1 5 16 1 8 T6 4 0 5 0 189 231 6 200 1 130 175U3321 175U3436 ...

Page 194: ...w ter minal IP65 Screw ter minal IP20 Bolt con nection IP20 Cable cross section mm2 AWG Ther mo relay A T7 1 1 1 5 620 830 630 0 100 175U3002 1 5 16 0 4 T7 1 5 2 0 513 600 570 0 100 175U3003 1 5 16 0 4 T7 2 2 3 0 340 403 415 0 200 175U3005 1 5 16 0 7 T7 3 0 4 0 243 292 270 0 300 175U3361 1 5 16 1 0 T7 4 0 5 0 180 216 200 0 360 175U3009 175U3010 1 5 16 1 3 T7 5 5 7 5 130 156 145 0 450 175U3012 175U...

Page 195: ...6 1 13 000 175U3075 16 6 46 T7 200 300 4 2 5 8 5 0 16 000 175U3078 25 4 57 T7 250 350 3 4 4 6 4 0 20 000 175U3082 35 2 71 T7 315 450 2 3 3 7 3 2 26 000 175U3085 50 1 1 0 90 T7 400 550 2 3 2 9 2 5 32 000 175U3089 70 2 0 113 T7 450 600 2 0 2 6 2 3 36 000 175U3090 2 x 35 2 x 2 125 T7 500 650 1 9 2 3 2 0 42 000 175U3092 2 x 35 2 x 2 145 T7 560 750 1 5 2 1 1 6 52 000 175U3094 2 x 50 2 x 1 1 0 180 T7 63...

Page 196: ...6 2 0 T7 4 0 5 0 180 216 200 1 700 175U3122 175U3123 1 5 16 2 8 T7 5 5 7 5 130 156 145 2 200 175U3106 175U3107 1 5 16 3 7 T7 7 5 10 94 113 105 3 200 175U3132 175U3133 1 5 16 5 2 T7 11 15 94 5 110 9 105 4 200 175U3134 175U3135 1 5 16 6 0 T7 15 20 69 7 80 7 72 4 200 175U3142 175U3143 1 5 16 7 2 T7 18 5 25 46 8 65 1 52 6 000 175U3242 2 5 14 10 8 T7 22 30 36 54 5 42 8 000 175U3243 2 5 14 13 9 T7 30 40...

Page 197: ...ng Numbers for Accessory Bags Accessory bag type Description Ordering number Accessory bag A2 A3 Accessory bag enclosure sizes A2 A3 130B1022 Accessory bag A5 Accessory bag enclosure type A5 130B1023 Accessory bag A1 A5 Accessory bag enclosure sizes A1 A5 brake and load sharing connector 130B0633 Accessory bag B1 Accessory bag enclosure size B1 130B2060 Accessory bag B2 Accessory bag enclosure siz...

Page 198: ...fers 2 different harmonic filters VLT Advanced Harmonic Filter AHF 005 with 5 current distortion VLT Advanced Harmonic Filter AHF 010 with 10 current distortion The filters are cooled by natural convection or with built in fans Secure sufficient airflow through the filter during installation to prevent overheating the filter An airflow of minimum 2 m s is required through the filter 13 2 11 1 Orde...

Page 199: ...204 204 130B1251 130B1214 X6 V3 IP20 ef X6 V3 IP20 if 132 251 251 130B1258 130B1215 X7 V3 IP20 if X7 V3 IP20 if 160 304 304 130B1259 130B1216 X7 V3 IP20 if X7 V3 IP20 if 325 130B3152 3 130B3136 3 X8 V3 IP20 if X7 V3 IP20 if 200 381 381 130B1260 130B1217 X8 V3 IP20 ef X7 V3 IP20 if 250 463 480 130B1261 130B1228 X8 V3 IP20 ef X8 V3 IP20 ef 315 590 608 2 x 130B1259 2 x 130B1216 See individual filters...

Page 200: ...ype AHF 005 IP20 AHF 010 IP20 AHF 005 IP20 AHF 010 IP20 0 37 1 2 10 130B2857 130B2262 X1 V3 IP20 if X1 V3 IP20 if 0 55 1 6 0 75 2 2 1 1 2 7 1 5 3 7 2 2 5 0 3 0 6 5 4 0 9 0 5 5 11 7 14 130B2858 130B2265 X1 V3 IP20 ef X1 V3 IP20 ef 7 5 14 4 11 22 22 130B2859 130B2268 X2 V3 IP20 ef X2 V3 IP20 if 15 29 29 130B2860 130B2294 X2 V3 IP20 ef X2 V3 IP20 if 18 5 34 34 130B2861 130B2297 X3 V3 IP20 if X3 V3 IP...

Page 201: ...r and not necessarily the type code power rating Changing operating condi tions between HO and NO changes the actual operating conditions and the filter selection must reflect actual operating conditions 2 The fan control system allows extended input voltage range as 200 415 V The AHFs for 380 415 V 60 Hz mains operation can be operated with 200 240 V mains supply 3 Filters are used as paralleling...

Page 202: ...1764 130B1496 X6 V3 IP20 ef X6 V3 IP20 if 132 200 231 231 231 130B1765 130B1497 X7 V3 IP20 if X7 V3 IP20 if 160 250 291 291 291 130B1766 130B1498 X8 V3 IP20 if X7 V3 IP20 if 200 300 348 355 355 130B1768 130B1499 X8 V3 IP20 ef X7 V3 IP20 ef 380 380 130B3167 3 130B3165 3 X8 V3 IP20 ef X7 V3 IP20 ef 250 350 427 436 436 130B1769 130B1751 X8 V3 IP20 ef X8 V3 IP20 ef 315 450 531 522 522 130B1765 130B176...

Page 203: ...0B5246 130B5212 X3 V3 IP20 if X3 V3 IP20 if 15 20 15 20 19 5 20 20 130B5247 130B5213 X3 V3 IP20 if X3 V3 IP20 if 18 5 25 20 24 24 24 24 130B5248 130B5214 X3 V3 IP20 ef X3 V3 IP20 ef 22 30 25 31 29 29 29 130B5249 130B5215 X4 V3 IP20 ef X4 V3 IP20 ef 30 40 30 37 36 36 36 130B5250 130B5216 X4 V3 IP20 ef X4 V3 IP20 ef 37 50 40 47 49 50 50 130B5251 130B5217 X5 V3 IP20 ef X5 V3 IP20 ef 45 60 50 56 59 58...

Page 204: ...the filter selection must reflect actual operating conditions 2 Typical HP shaft output at 575 V 13 2 11 5 Order Numbers for Harmonic Filters 500 690 V 50 Hz Table 148 Ordering Numbers for Harmonic Filters 500 690 V 50 Hz Drive values AHF values Power rating kW 1 Input current A Current rating at 690 V Ordering numbers Enclosure type T6 525 550 V T7 525 550 V T7 690 V AHF 005 A AHF 010 A AHF 005 I...

Page 205: ...4 130B5295 710 743 711 788 732 4 x 130B5197 2 x 130B5295 800 866 828 888 888 3 x 130B5199 3 x 130B5294 900 962 920 986 958 2 x 130B5199 2 x 130B5197 2 x 130B5294 130B5295 1 The power ratings in selection table are the actual operating power and not necessarily the type code power rating Changing operating condi tions between HO and NO changes the actual operating conditions and the filter selectio...

Page 206: ...55 106 75 105 37 143 75 147 90 130 180 170 135 3 0 130B3182 130B3183 45 170 90 177 1 Ordering numbers marked with are IP23 Table 150 Ordering Numbers for Sine wave Filters for 525 690 V Drives Drive Power and Current Ratings Filter current rating Switching frequency Ordering numbers 525 600 V 690 V 525 550 V 50 Hz 60 Hz 100 Hz IP00 IP20 23 1 kW A kW A kW A A A A kHz 0 75 1 7 1 1 1 6 4 5 4 0 3 0 4 ...

Page 207: ...40 380 440 441 500 380 60 Hz 200 400 440 50 Hz 460 480 60 Hz 500 525 50 Hz IP00 IP20 IP54 kW A kW A kW A A A 3 0 12 5 5 5 13 5 5 11 17 15 N A 130B7367 1 N A 3 7 16 7 5 16 7 5 14 5 5 5 24 2 11 24 11 21 44 40 130B2835 130B2836 130B2837 7 5 30 8 15 32 15 27 18 5 37 5 18 5 34 22 44 22 40 11 46 2 30 61 30 52 90 80 130B2838 130B2839 130B2840 15 59 4 37 73 37 65 18 5 74 8 45 90 55 80 22 88 55 106 75 105 ...

Page 208: ...113 90 108 160 131 108 130B2844 130B2845 130B2846 90 137 1 Dedicated A3 enclosures supporting footprint mounting and book style mounting Fixed shielded cable connection to the drive 13 2 14 Order Numbers for VLT Common mode Filters MCC 105 Table 153 Order Numbers and Dimensions for Common mode Filters Enclosure size Order number Core dimensions mm in Weight kg lbs W w H h d A and B 130B3257 60 2 3...

Page 209: ...ns 13 2 15 Spare Parts Visit the VLT Shop or the configurator for ordering spare parts available for a specific application on VLTshop danfoss com AJ300847815559en 000101 130R0337 209 Danfoss A S 2020 09 How to Order a Drive VLT AQUA Drive FC 202 Design Guide ...

Page 210: ...ional safety 34 Conformal coating 100 Control Terminals 44 Control card 93 93 94 94 Control card performance 94 Control characteristics 94 Control structure closed loop 163 Cross section control cable 91 Current Minimizing bearing and shaft currents 138 Leakage current 141 Transient ground 143 Fundamental current 153 Harmonic current 153 Distortion 154 D DC Brake 53 Derating for low air pressure 1...

Page 211: ... cables 31 O Open loop speed control configurations 166 Options Fieldbus 57 Functional extensions 57 License features 58 Order numbers for option D 182 Ordering 24 V back up suppy 182 Overload Electronic thermal overvoltage 45 Issues with harmonics 153 Overvoltage Limits 39 Alternative brake function 141 P Panel mounting kit for LCP 68 Panel through mounting kit 60 Payback period 25 PDS 27 See Pow...

Page 212: ... IEC 60364 NEC 2017 EN 60079 7 46 Star delta starter 27 Start stop command 172 STO 92 Storage 100 Supply voltage 89 124 124 Switching frequency 59 143 Symbols 12 T Thermal protection 136 Thermal Protection for Ex e or Ex n Motors 46 Thermistor Wiring configuration 176 176 Tightening torque 95 Torque Torque characteristics 90 90 Transformer 154 TÜV 14 U UL Enclosure protection rating 15 USB serial ...

Page 213: ...ndition Based Monitoring monitors the machine condition and perform ance when the drive is in service and detects mechanical motor or applica tion failures in advance Corrective actions can be performed before the process or application is impacted CDM A CDM is a drive system without the motor and without the measuring sen sors which are mechanically connected to the motor shaft The drive sys tem ...

Page 214: ...ntroller IMC is a functionality that enables an AC drive to perform high precision positioning and synchronization operations without the need for additional modules or hardware Intermittent duty cycle An intermittent duty rating refers to a sequence of duty cycles Each cycle consists of an on load and an off load period The operation can be either periodic duty or non periodic duty L LCP The loca...

Page 215: ... the mains supply The lower the power factor the higher the IRMS for the same kW perform ance IRMS I1 2 I5 2 I7 2 In 2 In addition a high power factor indicates that the different harmonic cur rents are low The DC coils in the drive produce a high power factor which minimizes the imposed load on the mains supply Preset reference A defined preset reference to be set from 100 to 100 of the reference...

Page 216: ...vertemperature or when the drive is protecting the motor process or mechanism The drive prevents a restart until the cause of the fault has dis appeared To cancel the trip state restart the drive Do not use the trip state for personal safety Trip lock The drive enters this state in fault situations to protect itself The drive re quires physical intervention for example when there is a short circui...

Page 217: ...AJ300847815559en 000101 130R0337 217 Danfoss A S 2020 09 Glossary VLT AQUA Drive FC 202 Design Guide ...

Page 218: ...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 res...

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