MAKING MODERN LIVING POSSIBLE Operating Instructions VLT® AQUA Drive FC 202 Low Harmonic Drive www danfoss com/drives Contents 1 Introduction 4 1 1 Purpose of the Manual 4 1 2 Additional Resources 4 1[.]
MAKING MODERN LIVING POSSIBLE Operating Instructions VLT® AQUA Drive FC 202 Low Harmonic Drive www.danfoss.com/drives Contents Operating Instructions Contents Introduction 1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Product Overview 1.3.1 Intended Use 1.3.2 Working Principle 1.3.3 Exploded View Drawings 1.4 Enclosure Types and Power Ratings 14 1.5 Approvals and Certifications 14 1.5.1 Approvals 14 1.5.2 Compliance with ADN 14 Safety 15 2.1 Safety Symbols 15 2.2 Qualified Personnel 15 2.3 Safety Precautions 15 Mechanical Installation 3.1 Equipment Pre-Installation Checklist 16 3.2 Unpacking 16 3.2.1 Items Supplied 3.3 Installation Environment 3.3.1 Planning the Installation Site 3.4 Mounting MG21B202 16 16 17 17 17 3.4.1 Cooling and Airflow 17 3.4.2 Lifting 19 3.4.3 Cable Entry and Anchoring 20 3.4.4 Terminal Locations for Frame Size D13 22 3.4.5 Terminal Locations for Frame Size E9 23 3.4.6 Terminal Locations for Frame Size F18 24 3.4.7 Torque 27 Electrical Installation 28 4.1 Safety Instructions 28 4.2 EMC Compliant Installation 28 4.3 Power Connections 28 4.4 Grounding 29 4.5 Input Options 29 4.5.1 Extra Protection (RCD) 29 4.5.2 RFI Switch 29 Danfoss A/S © Rev 2014-01-22 All rights reserved Contents Operating Instructions 4.5.3 Shielded Cables 4.6 Motor Connection 30 4.6.1 Motor Cable 30 4.6.2 Brake Cable 30 4.6.3 Brake Resistor Temperature Switch 31 4.6.4 Motor Insulation 31 4.6.5 Motor Bearing Currents 31 4.6.6 Motor Thermal Protection 32 4.7 AC Mains Connection 32 4.7.1 Mains Connection 32 4.7.2 External Fan Supply 32 4.7.3 Power and Control Wiring for Unscreened Cables 32 4.7.4 Mains Disconnects 34 4.7.5 F-Frame Circuit Breakers 34 4.7.6 F-Frame Mains Contactors 34 4.8 Control Wiring 35 4.8.1 Control Cable Routing 35 4.8.2 Access to Control Terminals 36 4.8.3 Electrical Installation, Control Terminals 36 4.8.4 Electrical Installation, Control Cables 38 4.9 Additional Connections 39 4.9.1 Mechanical Brake Control 39 4.9.2 Parallel Connection of Motors 40 4.9.3 Motor Thermal Protection 40 4.9.4 Safe Torque Off (STO) 41 4.9.5 Switches S201, S202, and S801 41 4.9.6 Serial Communication 41 4.9.7 F-frame Options 41 4.10 Final Set-up and Test Commissioning 43 45 5.1 Safety Instructions 45 5.2 Applying Power 47 5.3 Local Control Panel Operation 47 5.3.1 Local Control Panel 47 5.3.2 LCP Layout 47 5.3.3 Parameter Settings 48 5.3.4 Uploading/Downloading Data to/from the LCP 49 5.4 Basic Programming 30 50 5.4.1 Commissioning with SmartStart 50 5.4.2 Commissioning via [Main Menu] 50 Danfoss A/S © Rev 2014-01-22 All rights reserved MG21B202 Contents Operating Instructions 5.4.3 Asynchronous Motor Set-up 51 5.4.4 Permanent Magnet Motor Set-up 51 5.4.5 Automatic Energy Optimisation (AEO) 52 5.4.6 Automatic Motor Adaptation (AMA) 52 5.5 Checking Motor Rotation 52 5.6 Local-control Test 53 5.7 System Start-up 53 Application Examples 54 6.1 Introduction 54 6.2 Application Examples 54 6.2.1 Speed 54 6.2.2 Start/Stop 55 6.2.3 External Alarm Reset 56 6.2.4 RS-485 57 6.2.5 Motor Thermistor 57 Diagnostics and Troubleshooting 7.1 Status Messages 58 7.2 Warning and Alarm Types 60 7.2.1 Warnings 60 7.2.2 Alarm Trip 60 7.2.3 Alarm Trip-lock 60 7.3 Warnings and Alarm Definitions - Frequency Converter 61 7.4 Warning and Alarm Definitions - Filter (Left LCP) 69 7.5 Troubleshooting 74 Specifications 76 8.1 Power-Dependent Specifications 76 8.1.1 Mains Supply 3x380-480 V AC 76 8.1.2 Derating for Temperature 79 8.2 Mechanical Dimensions 79 8.3 General Technical Data - Frequency Converter 81 8.4 General Technical Data - Filter 86 8.5 Fuses 89 8.5.1 Fuse Specifications Appendix 90 92 9.1 Abbreviations and Conventions Index MG21B202 58 92 93 Danfoss A/S © Rev 2014-01-22 All rights reserved 1 Introduction Operating Instructions Introduction 1.1 Purpose of the Manual 1.3 Product Overview The purpose of this manual is to provide information for the installation and operation of a VLT® Low Harmonic Drive The manual includes relevant safety information for installation and operation Chapter Introduction and chapter Safety introduce the unit function and cover proper mechanical and electrical installation procedures There are chapters on start-up and commissioning, applications and basic troubleshooting Chapter Specifications provides a quick reference for ratings and dimensions, as well as other operating specifications This manual provides a basic knowledge of the unit and explains setup and basic operation VLT® is a registered trademark 1.3.1 Intended Use 1.2 Additional Resources Other resources are available to understand advanced functions and programming • The VLT® AQUA Drive FC 202 Operating Instructions provide details on installation and operation of the frequency converter • The VLT® AQUA Drive FC 202 Programming Guide provides greater detail on working with parameters and many application examples • The VLT® AQUA Drive FC 202 Design Guide provides detailed capabilities and functionality to design motor control systems • Supplemental publications and manuals are available from Danfoss See www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical +Documentation.htm for listings • Optional equipment may change some of the procedures described Reference the instructions supplied with those options for specific requirements Contact the local Danfoss supplier or visit the Danfoss website: www.danfoss.com/ BusinessAreas/DrivesSolutions/Documentations/ Technical+Documentation.htm, for downloads or additional information • The VLT® Active Filter AAF00x Operating Instructions provide additional information about the filter portion of the Low Harmonic Drive A frequency converter (also called a drive) is an electronic motor controller that converts DC into a variable AC waveform output The frequency and voltage of the output are regulated to control the motor speed or torque The frequency converter can vary the speed of the motor in response to system feedback, such as with position sensors on a conveyor belt The frequency converter can also regulate the motor by responding to remote commands from external controllers The frequency converter • • • • monitors the system and motor status issues warnings or alarms for fault conditions starts and stops the motor optimises energy efficiency Operation and monitoring functions are available as status indications to an outside control system or serial communication network A Low Harmonic Drive (LHD) is a single unit that combines the frequency converter with an advanced active filter (AAF) for harmonic mitigation The frequency converter and filter are separate pieces packaged together in an integrated system, but each functions independently In this manual, there are separate specifications for the frequency converter and the filter Since the frequency converter and filter are together in the same enclosure, the unit is transported, installed, and operated as a single entity Danfoss A/S © Rev 2014-01-22 All rights reserved MG21B202 Introduction Operating Instructions 1 1.3.2 Working Principle The VLT Low Harmonic Drive is a high-power frequency converter with an integrated active filter An active filter is a device that actively monitors harmonic distortion levels and injects compensative harmonic current onto the line to cancel the harmonics 130bb406.10 Relay 12 Control & AUX Feedback Soft-Charge NC Relay HI Reactor Lm Mains 380 to 500 VAC Optional RFI Optional Manual Disconnect Optional Fuses Converter Side Filter Lc AC Contactor Lac Lm Lac Lm Lac Power Stage Ir Lc Is Lc It Relay 12 Control & AUX Cef Feedback Ref Cef Ref Capacitor Current Sensors Cef AF Current Sensors Ref Frequency converter Main’s CTs Illustration 1.1 Basic Layout for the Low Harmonic Drive Low Harmonic Drives are designed to draw an ideal sinusoidal current waveform from the supply grid with a power factor of Where traditional non-linear load draws pulse-shaped currents, the Low Harmonic Drive compensates that via the parallel filter path, lowering the stress on the supply grid The Low Harmonic Drive meets the highest harmonic standards with a THiD less than 5% at full load for