Danfoss Vlt aqua User manual

Contents

1. How to Read these Operating Instructions

Approvals 5

Symbols 6

2. Safety

General Warning 8

Before Commencing Repair Work 8

Special conditions 8

Avoid unintended Start 9

Safe Stop Installation 9

Safe Stop of the Frequency Converter 11

IT Mains 13

3. How to Install

How to Get Started 15

Pre-installation 15

Planning the Installation Site 15

Receiving the Frequency Converter 16

Transportation and Unpacking 16

Lifting 16

Rated Power 18

Mechanical Dimensions 19

Mechanical Installation 19

Tools Needed 19

General Considerations 20

Installation in Enclosures - IP00 / Chassis units 29

Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 29

Floor Mounting - Pedestal Installation IP21 (NEMA1) and IP54 (NEMA12) 30

Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 32

IP21 Drip shield installation (D1 and D2 enclosure) 33

Field Installation of Options 33

Installation on pedestal 43

Electrical Installation 46

Control Wires 46

Power Connections 47

Mains connection 55

Fuses 56

Electrical Installation, Control Terminals 58

VLT AQUA High Power Operation Instructions Contents

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

Connection Examples 60

Start/Stop 60

Pulse Start/Stop 60

Speed Up/Down 61

Potentiometer Reference 61

Electrical Installation - continued 62

Electrical Installation, Control Cables 62

Switches S201, S202, and S801 64

Final Set-up and Test 65

Additional Connections 67

Motor Thermal Protection 67

4. How to programme the frequency converter

How to programme 69

Initialisation to Default Settings 96

Parameter Options 97

Default settings 97

0-** Operation/Display 98

1-** Load/Motor 100

2-** Brakes 101

3-** Reference / Ramps 102

4-** Limits / Warnings 103

5-** Digital In/Out 104

6-** Analog In/Out 106

8-** Comm. and Options 108

9-** Profibus 109

10-**CAN Fieldbus 110

13-** Smart Logic 111

14-** Special Functions 112

15-** FC Information 113

16-** Data Readouts 115

18-** Data Readouts 2 117

20-** FC Closed Loop 118

21-** Ext. Closed Loop 119

22-** Application Functions 121

23-** Timed Actions 123

25-** Cascade Controller 124

26-** Analog I/O Option MCB 109 126

29-** Water Application Functions 127

31-** Bypass Option 128

Contents VLT AQUA High Power Operation Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

5. General Specifications

129

6. Troubleshooting

137

Warning/Alarm list 139

7. Annexes

143

Index

149

VLT AQUA High Power Operation Instructions Contents

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

1. How to Read these Operating Instructions VLT AQUA High Power Operation Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

1. How to Read these Operating Instructions

1.1.1. Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss A/S. By accepting and using this

manual the user agrees that the information contained herein will be used solely for operating

equipment from Danfoss A/S or equipment from other vendors provided that such equipment is

intended for communication with Danfoss equipment over a serial communication link. This pub-

lication is protected under the Copyright laws of Denmark and most other countries.

Danfoss A/S does not warrant that a software program produced according to the guidelines pro-

vided in this manual will function properly in every physical, hardware or software environment.

Although Danfoss A/S has tested and reviewed the documentation within this manual,

Danfoss A/S makes no warranty or representation, neither expressed nor implied, with respect to

this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall Danfoss A/S be liable for direct, indirect, special, incidental, or consequential

damages arising out of the use, or the inability to use information contained in this manual, even

if advised of the possibility of such damages. In particular, Danfoss A/S is not responsible for any

costs, including but not limited to those incurred as a result of lost profits or revenue, loss or

damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or

any claims by third parties.

Danfoss A/S reserves the right to revise this publication at any time and to make changes to its

contents without prior notice or any obligation to notify former or present users of such revisions

or changes.

These Operating Instructions will introduce all aspects of your VLT AQUA Drive.

Available literature for VLT AQUA Drive:

-Operating Instructions MG.20.MX.YY provide the neccessary information for getting the

drive up and running.

-Design Guide MG.20.NX.YY entails technical information about the drive design and cus-

tomer applications.

-Programming Guide MG.20.OX.YY provides information on how to programme and in-

cludes complete parameter descriptions.

X = Revision number

YY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/

DrivesSolutions/Documentations/Technical+Documentation.

1.1.2. Approvals

VLT AQUA High Power Operation Instructions 1. How to Read these Operating Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

1.1.3. Symbols

Symbols used in these Operating Instructions.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

1. How to Read these Operating Instructions VLT AQUA High Power Operation Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

2. Safety

2.1.1. Safety note

The voltage of the frequency converter is dangerous whenever connected to mains.

Incorrect installation of the motor, frequency converter or fieldbus may cause dam-

age to the equipment, serious personal injury or death. Consequently, the instruc-

tions in this manual, as well as national and local rules and safety regulations, must

be complied with.

Safety Regulations

1. The frequency converter must be disconnected from mains if repair work is to be carried

out. Check that the mains supply has been disconnected and that the necessary time has

passed before removing motor and mains plugs.

2. The [STOP/RESET] key on the control panel of the frequency converter does not dis-

connect the equipment from mains and is thus not to be used as a safety switch.

3. Correct protective earthing of the equipment must be established, the user must be pro-

tected against supply voltage, and the motor must be protected against overload in

accordance with applicable national and local regulations.

4. The earth leakage currents are higher than 3.5 mA.

5. Protection against motor overload is set by par. 1-90

Motor Thermal Protection

. If this

function is desired, set par. 1-90 to data value [ETR trip] (default value) or data value

[ETR warning]. Note: The function is initialised at 1.16 x rated motor current and rated

motor frequency. For the North American market: The ETR functions provide class 20

motor overload protection in accordance with NEC.

6. Do not remove the plugs for the motor and mains supply while the frequency converter

is connected to mains. Check that the mains supply has been disconnected and that the

necessary time has passed before removing motor and mains plugs.

7. Please note that the frequency converter has voltage inputs other than L1, L2 and L3,

when load sharing (linking of DC intermediate circuit) and external 24 V DC have been

installed. Check that all voltage inputs have been disconnected and that the necessary

time has passed before commencing repair work.

Installation at High Altitudes

By altitudes above 2 km, please contact Danfoss Drives regarding PELV.

Warning against Unintended Start

1. The motor can be brought to a stop by means of digital commands, bus commands, references

or a local stop, while the frequency converter is connected to mains. If personal safety consider-

ations make it necessary to ensure that no unintended start occurs, these stop functions are not

sufficient. 2. While parameters are being changed, the motor may start. Consequently, the stop

key [STOP/RESET] must always be activated; following which data can be modified. 3. A motor

that has been stopped may start if faults occur in the electronics of the frequency converter, or if

a temporary overload or a fault in the supply mains or the motor connection ceases.

Warning:

Touching the electrical parts may be fatal - even after the equipment has been dis-

connected from mains.

VLT AQUA High Power Operation Instructions 2. Safety

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load

sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back up.

2.1.2. General Warning

Warning:

Touching the electrical parts may be fatal - even after the equipment has been dis-

connected from mains.

Also make sure that other voltage inputs have been disconnected, (linkage of DC

intermediate circuit), as well as the motor connection for kinetic back-up.

Before touching any potentially live parts of the VLT AQUA Drive FC 200, wait at

least as follows:

380 - 480 V, 110 - 450 kW, wait at least 15 minutes.

525 - 690 V, 132 - 630 kW, wait at least 20 minutes.

Shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage Current

The earth leakage current from the VLT AQUA Drive FC 200 exceeds 3.5 mA. Ac-

cording to IEC 61800-5-1 a reinforced Protective Earth connection must be ensured

by means of: a min. 10mm² Cu or 16mm² Al PE-wire or an addtional PE wire - with

the same cable cross section as the Mains wiring - must be terminated separately.

Residual Current Device

This product can cause a D.C. current in the protective conductor. Where a residual

current device (RCD) is used for extra protection, only an RCD of Type B (time de-

layed) shall be used on the supply side of this product. See also RCD Application

Note MN.90.GX.02.

Protective earthing of the VLT AQUA Drive FC 200 and the use of RCD's must always

follow national and local regulations.

2.1.3. Before Commencing Repair Work

1. Disconnect the frequency converter from mains

2. Disconnect DC bus terminals 88 and 89

3. Wait at least the time mentioned in section 2.1.2

4. Remove motor cable

2.1.4. Special conditions

Electrical ratings:

The rating indicated on the nameplate of the frequency converter is based on a typical 3-phase

mains power supply, within the specified voltage, current and temperature range, which is ex-

pected to be used in most applications.

The frequency converters also support other special applications, which affect the

electrical ratings of the frequency converter. Special conditions which affect the elec-

trical ratings might be:

• Single phase applications

• High temperature applications which require derating of the electrical ratings

• Marine applications with more severe environmental conditions.

Consult the relevant clauses in these instructions and in the VLT

AQUA Drive Design Guide

for information about the electrical ratings.

2. Safety VLT AQUA High Power Operation Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

Installation requirements:

The overall electrical safety of the frequency converter requires special installation

considerations regarding:

• Fuses and circuit breakers for over-current and short-circuit protection

• Selection of power cables (mains, motor, brake, loadsharing and relay)

• Grid configuration (IT,TN, grounded leg, etc.)

• Safety of low-voltage ports (PELV conditions).

Consult the relevant clauses in these instructions and in the VLT

AQUA Drive Design Guide

for information about the installation requirements.

2.1.5. Caution

The frequency converter's DC link capacitors remain charged after power has been

disconnected. To avoid an electrical shock hazard, disconnect the frequency con-

verter from the mains before carrying out maintenance. Wait at least as follows

before doing service on the frequency converter:

Voltage Min. Waiting Time

15 min. 20 min.

380 - 480 V 110 - 450 kW

525 - 690 V 132 - 630 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.6. Avoid unintended Start

While the frequency converter is connected to mains, the motor can be started/stop-

ped using digital commands, bus commands, references or via the Local Control

Panel.

• Disconnect the frequency converter from mains whenever personal safety considerations

make it necessary to avoid unintended start.

• To avoid unintended start, always activate the [OFF] key before changing parameters.

• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the

mains supply, or lost motor connection may cause a stopped motor to start.

2.1.7. Safe Stop Installation

To carry out an installation of a Catego-

ry 0 Stop (EN60204) in conformity with

Safety Category 3 (EN954-1), follow

these instructions:

1. The bridge (jumper) between Termi-

nal 37 and 24 V DC must be re-

moved. Cutting or breaking the

jumper is not sufficient. Remove it

entirely to avoid short-circuiting. See

jumper on illustration.

2. Connect terminal 37 to 24 V DC by a

short-circuit protected cable. The 24

V DC voltage supply must be inter-

ruptible by an EN954-1 Category 3

circuit interrupt device. If the inter-

rupt device and the frequency con-

verter are placed in the same instal-

lation panel, you can use an

unscreened cable instead of a

screened one.

VLT AQUA High Power Operation Instructions 2. Safety

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

Illustration 2.1: Bridge jumper between terminal

37 and 24 VDC

The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN

954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how

to connect a non-safety related hardware coast.

Illustration 2.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN

60204-1) with safety Category 3 (EN 954-1).

2. Safety VLT AQUA High Power Operation Instructions

MG.20.P1.02 - VLT ®is a registered Danfoss trademark

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