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VLT® AQUA Drive FC 202 0.25-90 kW - files.danfoss.com

MAKING MODERN LIVING POSSIBLE. Design guide VLT AQUA Drive FC 202. kW. Contents Design guide Contents 1 Introduction 8. Purpose of the Design guide 8. Organisation 8. Additional Resources 8. Abbreviations, Symbols and Conventions 9. Definitions 10. Document and Software Version 11. Approvals and Certifications 11. CE Mark 11. Low Voltage Directive 11. EMC Directive 11. Machinery Directive 11. ErP Directive 12. C-tick Compliance 12. UL Compliance 12. Marine Compliance 12. Safety 13. General Safety Principles 13. 2 Product Overview 15. Introduction 15. Description of Operation 18. Sequence of Operation 20. Rectifier Section 20. Intermediate Section 20. Inverter Section 20.

Contents 1 Introduction 8 1.1 Purpose of the Design Guide 8 1.2 Organisation 8 1.3 Additional Resources 8 1.4 Abbreviations, Symbols and Conventions 9 1.5 Definitions

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Transcription of VLT® AQUA Drive FC 202 0.25-90 kW - files.danfoss.com

1 MAKING MODERN LIVING POSSIBLE. Design guide VLT AQUA Drive FC 202. kW. Contents Design guide Contents 1 Introduction 8. Purpose of the Design guide 8. Organisation 8. Additional Resources 8. Abbreviations, Symbols and Conventions 9. Definitions 10. Document and Software Version 11. Approvals and Certifications 11. CE Mark 11. Low Voltage Directive 11. EMC Directive 11. Machinery Directive 11. ErP Directive 12. C-tick Compliance 12. UL Compliance 12. Marine Compliance 12. Safety 13. General Safety Principles 13. 2 Product Overview 15. Introduction 15. Description of Operation 18. Sequence of Operation 20. Rectifier Section 20. Intermediate Section 20. Inverter Section 20.

2 Brake Option 20. Load Sharing 20. Control Structures 20. Control Structure Open Loop 20. Control Structure Closed Loop 21. Local (Hand On) and Remote (Auto On) Control 22. Reference Handling 23. Feedback Handling 25. Automated Operational Functions 26. Short Circuit Protection 26. Overvoltage Protection 26. Missing Motor Phase Detection 27. Mains Phase Imbalance Detection 27. MG20N602 Danfoss A/S 09/2014 All rights reserved. 1. Contents Design guide Switching on the Output 27. Overload Protection 27. Automatic Derating 27. Automatic Energy Optimisation 27. Automatic Switching Frequency Modulation 28. Automatic Derating for High Switching Frequency 28. Automatic Derating for Overtemperature 28.

3 Auto Ramping 28. Current Limit Circuit 28. Power Fluctuation Performance 28. Motor Soft Start 28. Resonance Damping 28. Temperature-controlled Fans 28. EMC Compliance 28. Current Measurement on All Three Motor Phases 29. Galvanic Isolation of Control Terminals 29. Custom Application Functions 29. Automatic Motor Adaptation 29. Motor Thermal Protection 29. Mains Drop-out 30. Built-in PID Controllers 30. Automatic Restart 30. Flying Start 30. Full Torque at Reduced Speed 30. Frequency Bypass 30. Motor Preheat 30. Four Programmable Set-ups 30. Dynamic Braking 31. DC Braking 31. Sleep Mode 31. Run Permissive 31. Smart Logic Control (SLC) 31. STO Function 32. Fault, Warning and Alarm Functions 33.

4 Operation at Overtemperature 33. High and Low Reference Warning 33. High and Low Feedback Warning 33. Phase Imbalance or Phase Loss 33. High Frequency Warning 33. Low Frequency Warning 33. 2 Danfoss A/S 09/2014 All rights reserved. MG20N602. Contents Design guide High Current Warning 33. Low Current Warning 34. No Load/Broken Belt Warning 34. Lost Serial Interface 34. User Interfaces and Programming 34. Local Control Panel 34. PC Software 35. MCT 10 Set-up Software 35. VLT Harmonics Calculation Software MCT 31 36. Harmonic Calculation Software (HCS) 36. Maintenance 36. Storage 36. 3 System Integration 37. Ambient Operating Conditions 37. Humidity 37. Temperature 37.

5 Cooling 38. Motor-generated Overvoltage 39. Acoustic Noise 39. Vibration and Shock 39. Aggressive Atmospheres 39. IP Rating Definitions 41. Radio Frequency Interference 41. PELV and Galvanic Isolation Compliance 42. Storage 42. EMC, Harmonics and Earth Leakage Protection 42. General Aspects of EMC Emissions 42. EMC Test Results 44. Emission Requirements 45. Immunity Requirements 45. Motor Insulation 46. Motor Bearing Currents 46. Harmonics 47. Earth Leakage Current 49. Mains Integration 51. Mains Configurations and EMC Effects 51. Low-frequency Mains Interference 51. Analysing Mains Interference 52. Options for Reducing Mains Interference 52. MG20N602 Danfoss A/S 09/2014 All rights reserved.

6 3. Contents Design guide Radio Frequency Interference 52. Classification of the Operating Site 52. Use with Isolated Input Source 53. Power Factor Correction 53. Input Power Delay 53. Mains Transients 53. Operation with a Standby Generator 53. Motor Integration 54. Motor Selection Considerations 54. Sine-wave and dU/dt Filters 54. Proper Motor Grounding 54. Motor Cables 54. Motor Cable Shielding 55. Connection of Multiple Motors 55. Control Wire Isolation 57. Motor Thermal Protection 57. Output Contactor 58. Brake Functions 58. Dynamic Braking 58. Brake Resistor Calculation 58. Brake Resistor Cabling 59. Brake Resistor and Brake IGBT 59. Energy Efficiency 59. Additional Inputs and Outputs 61.

7 Wiring Schematic 61. Relay Connections 62. EMC-compliant Electrical Connection 63. Mechanical Planning 64. Clearance 64. Wall Mounting 65. Access 65. Options and Accessories 65. Communication Options 69. Input/Output, Feedback and Safety Options 69. Cascade Control Options 69. Brake Resistors 70. Sine-wave Filters 70. dU/dt Filters 71. Common-mode Filters 71. Harmonic Filters 71. 4 Danfoss A/S 09/2014 All rights reserved. MG20N602. Contents Design guide IP21/NEMA Type 1 Enclosure Kit 72. Remote Mounting Kit for LCP 74. Mounting Bracket for Enclosure Sizes A5, B1, B2, C1 and C2 75. Serial Interface RS485 76. Overview 76. Network Connection 77. RS485 Bus Termination 77.

8 EMC Precautions 77. FC Protocol Overview 78. Network Configuration 78. FC Protocol Message Framing Structure 78. FC Protocol Examples 82. Modbus RTU Protocol 83. Modbus RTU Message Framing Structure 84. Access to Parameters 87. FC Drive Control Profile 88. System Design Checklist 94. 4 Application Examples 96. Application Feature Overview 96. Selected Application Features 96. SmartStart 96. Quick Menu Water and Pumps 97. 29-1* Deragging Function 97. Pre/post Lube 98. 29-5* Flow Confirmation 99. Application Set-up Examples 100. Submersible Pump Application 102. BASIC Cascade Controller 103. Pump Staging with Lead Pump Alternation 104. System Status and Operation 104.

9 Cascade Controller Wiring Diagram 105. Fixed Variable Speed Pump Wiring Diagram 106. Lead Pump Alternation Wiring Diagram 106. 5 Special Conditions 110. Manual Derating 110. Derating for Long Motor Cables or Cables with Larger Cross-Section 111. Derating for Ambient Temperature 111. 6 Typecode and Selection 115. MG20N602 Danfoss A/S 09/2014 All rights reserved. 5. Contents Design guide Ordering 115. Type Code 115. Software Language 117. Options, Accessories, and Spare Parts 117. Options and Accessories 117. Spare Parts 119. Accessory Bags 119. Brake Resistor Selection 120. Recommended Brake Resistors 121. Alternative Brake Resistors, T2 and T4 128. Harmonic Filters 129.

10 Sine-Wave Filters 131. dU/dt Filters 133. Common Mode Filters 134. 7 Specifications 135. Electrical Data 135. Mains Supply 1x200 240 V AC 135. Mains Supply 3x200 240 V AC 136. Mains Supply 1x380 480 V AC 138. Mains Supply 3x380 480 V AC 139. Mains Supply 3x525 600 V AC 143. Mains Supply 3x525 690 V AC 147. Mains Supply 149. Motor Output and Motor Data 150. Ambient Conditions 151. Cable Specifications 151. Control Input/Output and Control Data 152. Fuses and Circuit Breakers 155. Power Ratings, Weight and Dimensions 163. dU/dt Testing 164. Acoustic Noise Ratings 166. Selected Options 167. VLT General Purpose I/O Module MCB 101 167. VLT Relay Card MCB 105 167. VLT PTC Thermistor Card MCB 112 169.


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