Danfoss VLT AQUA Drive FC 200, Operating Instructions Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT AQUA Drive FC 200...

Page 2: ...in charged even when the frequency converter is not powered To avoid electrical hazards disconnect AC mains any permanent magnet type motors and any remote DC link power supplies including battery bac...

Page 3: ...Safety VLT AQUA Drive Operating Instructions MG 20 M8 02 VLT is a registered Danfoss trademark...

Page 4: ...2 2 Grounding Using Shielded Cable 13 2 4 2 3 Grounding Using Conduit 14 2 4 3 Motor Connection 14 2 4 4 AC Mains Connection 15 2 4 5 Control Wiring 15 2 4 5 1 Access 15 2 4 5 2 Control Terminal Types...

Page 5: ...ual Initialisation 32 5 About Frequency Converter Programming 33 5 1 Introduction 33 5 2 Programming Example 33 5 3 Control Terminal Programming Examples 35 5 4 International North American Default Pa...

Page 6: ...Messages 58 9 Basic Troubleshooting 64 9 1 Start Up and Operation 64 10 Specifications 66 10 2 General Technical Data 75 10 3 Fuse Tables 80 Index 85 Contents VLT AQUA Drive Operating Instructions MG...

Page 7: ...ug 13 Brake 81 82 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Mains input terminals 91 L1 92 L2 93 L3 6 Cable strain relief PE ground 15 USB connector 7 Decoupling plate 16 Serial bu...

Page 8: ...V 98 W 9 Analog switches A53 A54 19 Mains input terminals 91 L1 92 L2 93 L3 10 Relay 1 01 02 03 Table 1 2 1 1 Purpose of the Manual This manual is intended to provide detailed information for the ins...

Page 9: ...alarms for fault conditions starts and stops the motor optimizes energy efficiency and offers many more control monitoring and efficiency functions Operation and monitoring functions are available as...

Page 10: ...4 0 0 37 7 5 11 18 5 22 30 11 18 5 22 37 37 55 75 90 45 55 75 90 525 600 n a 0 75 7 5 n a 0 75 7 5 11 18 5 22 30 11 18 5 22 37 37 55 75 90 45 55 75 90 525 690 n a n a n a n a n a 11 30 n a n a n a 37...

Page 11: ...g are rated for same voltage Mains power Frequency converter Motor Ensure that frequency converter output current rating is equal to or greater than motor full load current for peak motor performance...

Page 12: ...the optional back plate to provide cooling airflow see Illustration 2 2 and Illustration 2 3 Improper mounting can result in over heating and reduced performance Use the slotted mounting holes on the...

Page 13: ...D IN 15mA 200mA U 96 V 97 W 98 PE 99 COM A OUT 39 A OUT 42 0 4 20 mA 03 0 10Vdc 10Vdc 0 10Vdc 0 4 20 mA 240Vac 2A 24Vdc 02 01 05 04 06 240Vac 2A 24V NPN 0V PNP 0V PNP 24V NPN 19 D IN 24V NPN 0V PNP 2...

Page 14: ...and mains 2 Frequency converter 7 Motor 3 phase and PE 3 Output contactor Generally not recommended 8 Mains 3 phase and reinforced PE 4 Earth grounding rail PE 9 Control wiring 5 Cable insulation stri...

Page 15: ...wer and control are run separately Use metallic conduit or separated shielded wire Failure to isolate power motor and control wiring could result in less than optimum equipment performance All frequen...

Page 16: ...ency converter power EN IEC61800 5 1 Power Drive System Product Standard requires special care if the leakage current exceeds 3 5mA Earth grounding must be reinforced in one of the following ways Eart...

Page 17: ...ult in death or serious injury For maximum wire sizes see 10 1 Power dependent Specifications Comply with local and national electrical codes for cable sizes Motor wiring knockouts or access panels ar...

Page 18: ...tructions provided in 2 4 2 Earth Grounding Requirements All frequency converters may be used with an isolated input source as well as with ground reference power lines When supplied from an isolated...

Page 19: ...r programmable digital inputs terminals two additional digital terminals programmable as either input or output a 24V DC terminal supply voltage and a common for optional customer supplied 24V DC volt...

Page 20: ...een when experiencing EMC problems Terminal Description Digital Inputs Outputs Terminal Parameter Default Setting Description 68 8 3 RS 485 Interface A control card switch is provided for termination...

Page 21: ...ended to initiate frequency converter functioning in a typical operational mode 2 4 5 6 Jumper Terminals 12 and 27 A jumper wire may be required between terminal 12 or 13 and terminal 27 for the frequ...

Page 22: ...eric and safety guidelines given in this description and the extended description in the Design Guide Have a good knowledge of the generic and safety standards applicable to the specific application U...

Page 23: ...ctor failure In spite of the activation of the Safe torque off function the frequency converter system can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees p denote...

Page 24: ...r Coast 9 5V DC 4 Frequency converter 10 Safe channel 5 Mains 11 Short circuit protected cable if not inside installation cabinet 6 Control board Table 2 5 Safe Stop Commissioning Test After installat...

Page 25: ...onal crane lift regulations L1 L2 L3 U V W 02 01 A1 A2 130BA902 10 Drive Output relay Command Circuit 220Vac Mechanical Brake Shaft Motor Frewheeling diode Brake 380Vac Output Contactor Input Power Ci...

Page 26: ...verter disconnect switches for input power isolation 2 Verify that there is no voltage on input terminals L1 91 L2 92 and L3 93 phase to phase and phase to ground 3 Verify that there is no voltage on...

Page 27: ...adequate to ensure proper air flow for cooling EMC considerations Check for proper installation regarding electromagnetic compatibility Environmental considerations See equipment label for the maximu...

Page 28: ...Illustration 2 22 for details 3 3 Basic Operational Programming Frequency converters require basic operational programming prior to running for best performance Basic operational programming requires...

Page 29: ...eave 3 11 Jog Speed Hz 10Hz at the factory default this is not used in initial programming 15 A jumper wire should be in place between control terminals 12 and 27 If this is the case leave 5 12 Termin...

Page 30: ...and right arrow keys move the display cursor in the numeric display 1 Press Hand ON 2 Accelerate the frequency converter by pressing to full speed Moving the cursor left of the decimal point provides...

Page 31: ...n personal injury or equipment damage 1 Press Auto On 2 Ensure that external control functions are properly wired to the frequency converter and all programming completed 3 Apply an external run comma...

Page 32: ...rogramming Guide MG 20 OX YY for details on use of the NLCP 4 1 1 LCP Layout The LCP is divided into four functional groups see Illustration 4 1 Auto on Reset Hand on Off Status Quick Menu Main Menu A...

Page 33: ...m Log Illustration 4 4 Key Function Status Press to show operational information In Auto mode press and hold to toggle between status read out displays Press repeatedly to scroll through each status d...

Page 34: ...nd at the bottom of the control panel 130BP046 10 Hand on Off Auto on Reset Illustration 4 6 Key Function Hand On Press to start the frequency converter in local control Use the navigation keys to con...

Page 35: ...he frequency converter Initialisation can be through 14 22 Operation Mode or manually Initialisation using 14 22 Operation Mode does not change frequency converter data such as operating hours serial...

Page 36: ...p using the quick menu This procedure programs the frequency converter to receive a 0 10V DC analog control signal on input terminal 53 The frequency converter will respond by providing 20 50Hz output...

Page 37: ...at the minimum voltage received on Terminal 53 0V equals 20Hz output 130BT773 11 Q3 21 14 7 0 00 A 1 1 Analog Reference 6 14 Terminal 53 Low Ref Feedb Value 000020 000 Illustration 5 8 9 6 15 Terminal...

Page 38: ...igital Input 8 Start 14 7 0 00A 1 1 Digital Inputs Illustration 5 13 5 4 International North American Default Parameter Settings Setting 0 03 Regional Settings to International or North America change...

Page 39: ...ion 5 14 3 Select Q5 2 Since Factory Setting to view all programming changes or Q5 1 Last 10 Changes for the most recent Q5 130BP090 10 Q5 1 Last 10 Changes Q5 2 Since Factory Setti Q5 3 Input Assignm...

Page 40: ...Motor Adaptation AMA Relay 1 5 40 Function Relay 6 20 Terminal 54 Low Voltage Q3 1 General Settings Relay 2 5 40 Function Relay 6 21 Terminal 54 High Voltage Q3 10 Clock Settings Q3 2 Open Loop Settin...

Page 41: ...Motor Control Principle 1 50 Motor Magnetisation at Zero Speed 1 8 Stop Adjustments 0 14 Readout Prog Set ups Channel 0 50 LCP Copy 1 03 Torque Characteristics 1 51 Min Speed Normal Magnetising RPM 1...

Page 42: ...3 87 Check Valve Ramp End Speed HZ 5 02 Terminal 29 Mode 5 55 Term 33 Low Frequency 6 1 Analog Input 53 3 0 Reference Limits 3 9 Digital Pot Meter 5 1 Digital Inputs 5 56 Term 33 High Frequency 6 10 T...

Page 43: ...og Input X30 12 8 04 Control Timeout Function 8 54 Reversing Select 9 18 Node Address 9 92 Changed Parameters 3 6 40 Terminal X30 12 Low Voltage 8 05 End of Timeout Function 8 55 Set up Select 9 22 Te...

Page 44: ...31 Current Lim Ctrl Integration Time 15 04 Over Temp s 15 41 Power Section 10 33 Store Always 13 42 Logic Rule Boolean 2 14 32 Current Lim Ctrl Filter Time 15 05 Over Volt s 15 42 Voltage 10 34 Devic...

Page 45: ...Card Temp 16 77 Analog Out X30 8 mA 18 34 Analog Out X42 9 V 20 70 Closed Loop Type 15 98 Drive Identification 16 40 Logging Buffer Full 16 8 Fieldbus FC Port 18 35 Analog Out X42 11 V 20 71 PID Perf...

Page 46: ...ce 22 33 Low Speed Hz 22 81 Square linear Curve Approximation 23 6 Trending 21 15 Ext 1 Setpoint 21 53 Ext 3 Reference Source 22 34 Low Speed Power kW 22 82 Work Point Calculation 23 60 Trend Variable...

Page 47: ...5 Mode 26 40 Terminal X42 7 Output 29 04 Pipe Fill Rate 25 20 Staging Bandwidth 25 52 Alternation Time Interval 26 1 Analog Input X42 1 26 41 Terminal X42 7 Min Scale 29 05 Filled Setpoint 25 21 Over...

Page 48: ...d simply downloaded into frequency converter Or the entire frequency converter profile can be loaded onto the PC for back up storage or analysis The USB connector or RS 485 terminal are available for...

Page 49: ...comments Table 6 1 Analog Current Feedback Transducer 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 50 53 54 55 42 39 A54 U...

Page 50: ...6 5 Analog Speed Reference Current NOTE Please note switch setting for selecting voltage or 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 1...

Page 51: ...6 14 Terminal 53 Low Ref Feedb Value 0 6 15 Terminal 53 High Ref Feedb Value 50 Default Value Notes comments Table 6 9 Speed Reference using a manual potentiometer Parameters FC 24 V 24 V D IN D IN D...

Page 52: ...mistors must use reinforced or double insulation to meet PELV insulation requirements 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 3...

Page 53: ...minals and or the serial communi cation Hand On The frequency converter can be controlled by the navigation keys on the LCP Stop commands reset reversing DC brake and other signals applied to the cont...

Page 54: ...down Operation Status Jog request A jog command has been given but the motor will be stopped until a run permissive signal is received via a digital input Jogging The motor is running as programmed i...

Page 55: ...1 71 Start Delay a delay starting time was set A start command is activated and the motor will start after the start delay time expires Start fwd rev Start forward and start reverse were selected as f...

Page 56: ...requency converter logic will continue to operate and monitor the frequency converter status After the fault condition is remedied the frequency converter can be reset It will then be ready to start o...

Page 57: ...ge X X 9 Inverter overloaded X X 10 Motor overload temperature X X 1 90 11 Motor thermistor over temperature X X 1 90 12 Torque limit X X 13 Over current X X X 14 Earth fault X X X 15 Hardware mismatc...

Page 58: ...utput frequency at maximum limit X 64 Voltage limit X 65 Control board over temperature X X X 66 Heatsink temperature low X 67 Option configuration has changed X 68 Safe stop activated X1 69 Power car...

Page 59: ...an alarm has appeared The trip will coast the motor and can be reset by pressing the reset button or make a reset by a digital input parameter group 5 1 1 The origin event that caused an alarm cannot...

Page 60: ...t External Interlock DC voltage low Compressor Interlock Braking max Stand by 13 2000 8192 Inrush fault Illegal Option Combi DC voltage high Mechanical Brake Sliding Braking Freeze Output Request 14 4...

Page 61: ...witch settings match the analog signal type Perform Input Terminal Signal Test WARNING ALARM 3 No motor No motor has been connected to the output of the frequency converter WARNING ALARM 4 Mains phase...

Page 62: ...witch for 53 or 54 is set for voltage Check 1 93 Thermistor Source selects terminal 53 or 54 When using digital inputs 18 or 19 check that the thermistor is connected correctly between either terminal...

Page 63: ...cy converter and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake resistor power limit The power transmitted to the brake resistor is calculated as a mean value over the last 120...

Page 64: ...4V DC with the MCB 107 option only the 24V and 5V supplies are monitored When powered with three phase mains voltage all three supplied are monitored Troubleshooting Check for a defective power card C...

Page 65: ...d and power card are incompatible Contact your supplier with the typecode of the unit from the nameplate and the part numbers of the cards to check compatibility ALARM 72 Dangerous failure WARNING ALA...

Page 66: ...t of range Report value indicates source of alarm from left 1 4 Inverter 5 8 Rectifier ALARM 247 Pwr card temp Power card over temperature Report value indicates source of alarm from left 1 4 Inverter...

Page 67: ...he control wiring Check the wiring for shorts or incorrect connections If the display continues to cut out follow the procedure for display dark Motor not running Service switch open or missing motor...

Page 68: ...ttings Check parameter group2 0 DC brake and 3 0 Reference limits Open power fuses or circuit breaker trip Phase to phase short Motor or panel has a short phase to phase Check motor and panel phase to...

Page 69: ...10 Specifications Specifications VLT AQUA Drive Operating Instructions 66 MG 20 M8 02 VLT is a registered Danfoss trademark 10 10...

Page 70: ...0 12 27 18 30 Max cable size mains motor brake mm 2 AWG 2 0 2 4 4 10 10 7 35 2 50 1 0 95 4 0 Max input current 130BA057 10 Continuous 1 x 200 240V A 12 5 15 20 5 24 32 46 59 111 172 Intermittent 1 x 2...

Page 71: ...2 38 2 70 3 82 4 50 6 00 Max cable size mains motor brake mm 2 AWG 2 0 2 4 mm 2 4 10 AWG Max input current 130BA057 10 Continuous 3 x 200 240V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 Intermittent 3 x...

Page 72: ...kVA 8 7 11 1 16 6 21 4 26 9 31 7 41 4 51 5 61 2 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 95 4 0 120 250 MCM Max input current 130BA057 10 Continuous 3 x 200 240V A 22 0 28 0 42 0 5...

Page 73: ...inuous kVA 460V AC kVA 11 6 16 7 27 1 51 8 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 120 4 0 Max input current 130BA057 10 Continuous 1 x 380 440V A 33 48 78 151 Intermittent 1 x 38...

Page 74: ...kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Max cable size mains motor brake mm 2 AWG 2 4 10 Max input current 130BA057 10 Continuous 3 x 380 440V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermi...

Page 75: ...2 4 73 4 102 123 Continuous kVA 460V AC kVA 16 7 21 5 27 1 31 9 41 4 51 8 63 7 83 7 104 128 Max cable size mains motor brake mm 2 AWG 2 10 7 35 2 50 1 0 120 4 0 120 4 0 Max input current 130BA057 10 C...

Page 76: ...3 x 525 600V A 2 7 3 0 4 5 5 7 6 4 9 5 11 5 19 23 28 36 43 54 65 87 105 137 Max pre fuses 1 A 10 10 10 20 20 20 32 32 40 40 50 60 80 100 150 160 225 250 Environment Estimated power loss at rated max l...

Page 77: ...60 160 Environment Estimated power loss at rated max load W 4 201 285 335 375 430 592 720 880 1200 1440 Weight IP21 kg 27 27 27 27 27 65 65 65 65 65 IP55 kg 27 27 27 27 27 65 65 65 65 65 Efficiency 4...

Page 78: ...typically to 15 below the FC s lowest rated supply voltage Power up and full torque cannot be expected at mains voltage lower than 10 below the FC s lowest rated supply voltage Supply frequency 50 60H...

Page 79: ...ent Mode select Switch S201 and switch S202 Voltage mode Switch S201 switch S202 OFF U Voltage level 0 to 10V scaleable Input resistance Ri approx 10 k Max voltage 20V Current mode Switch S201 switch...

Page 80: ...e inputs 2 Terminal number pulse 29 33 Max frequency at terminal 29 33 110kHz Push pull driven Max frequency at terminal 29 33 5kHz open collector Min frequency at terminal 29 33 4Hz Voltage level see...

Page 81: ...assis Enclosure type C1 C2 IP21 Type 1 IP55 Type 12 IP66 Enclosure type C3 C4 IP20 Chassis Enclosure type D1 D2 E1 IP21 Type 1 IP54 Type12 Enclosure type D3 D4 E2 IP00 Chassis Enclosure kit available...

Page 82: ...tage PELV and other high voltage terminals The USB connection is not galvanically isolated from protection earth Use only isolated laptop PC as connection to the USB connector on VLT AQUA Drive or an...

Page 83: ...motor output Over current protection Provide overload protection to avoid fire hazard due to overheating of the cables in the installation Over current protection must always be carried out according...

Page 84: ...0 gG 15K 63A1 380 480 gG 18K 63A1 380 480 gG 22K 63A1 380 480 gG 30K 80A1 380 480 gG 37K 100A1 380 480 gG 45K 125A1 380 480 gG 55K 160A1 380 480 gG 75K 250A1 380 480 aR 90K 250A1 380 480 aR Table 10 9...

Page 85: ...erraz Shawmut 380 500 V 525 600 kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 11K KTS R40 JKS 40 JJS 40 5014006 040 KLS R40 A6K 40R 15K KTS R40 JKS 40 JJS 40 5014006 040 KLS R40 A6K 40R...

Page 86: ...R6 JKS 6 JJS 6 5017906 006 KLS R6 ATM R6 A6K 6R 1K5 2K2 KTS R10 JKS 10 JJS 10 5017906 010 KLS R10 ATM R10 A6K 10R 3K0 KTS R15 JKS 15 JJS 15 5017906 016 KLS R16 ATM R16 A6K 16R 4K0 KTS R20 JKS 20 JJS 2...

Page 87: ...3 7 3 7 3 7 3 7 3 3 0 6 0 6 B3 5 5 11 11 18 5 11 18 5 1 8 1 8 1 8 1 8 3 0 6 B4 15 18 5 22 37 22 37 4 5 4 5 4 5 4 5 3 0 6 C1 18 5 30 37 55 37 55 10 10 10 10 3 0 6 C2 37 45 75 90 75 90 14 241 14 241 14...

Page 88: ...34 50 System 6 Terminals 10 26 31 50 52 35 17 Wire 17 Wiring 12 17 24 15 Cooling Cooling 8 Clearance 24 Copying Parameter Settings 31 Current Limit 27 59 61 Rating 8 59 D Danfoss FC 22 DC Current 6 51...

Page 89: ...es 8 12 14 27 Current 6 26 59 61 30 Data 26 27 32 59 61 26 Frequency 26 30 Leads 59 Output 75 Power 10 12 61 30 Protection 12 75 Rotation 27 30 Speeds 25 Status 6 Wiring 12 13 Wiring And 24 Mounting 9...

Page 90: ...47 Start Up 5 32 33 24 64 Status Mode 50 Stop Command 51 Supply Voltage 15 16 23 58 61 Surroundings 78 Switching Frequency 51 59 Symbols 1 System Feedback 6 Monitoring 53 Start Up 27 T Technical Data...

Page 91: ...www danfoss com drives MG20M802 130R0336 MG20M802 Rev 2012 03 19...