Danfoss VLT AQUA Drive FC 202 User guide

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT

®

AQUA Drive FC 202

0.25–90 kW

www.DanfossDrives.com

Contents

1 Introduction

8

1.1 Purpose of the Design Guide

8

1.2 Organization

8

1.3 Additional Resources

8

1.4 Abbreviations, Symbols and Conventions

9

1.5 Denitions

10

1.6 Document and Software Version

11

1.7 Approvals and Certications

11

1.7.1 CE Mark 11

1.7.1.1 Low Voltage Directive 11

1.7.1.2 EMC Directive 11

1.7.1.3 Machinery Directive 12

1.7.1.4 ErP Directive 12

1.7.2 C-Tick Compliance 12

1.7.3 UL Compliance 12

1.7.4 Marine Compliance 12

1.8 Safety

12

1.8.1 General Safety Principles 12

2 Product Overview

15

2.1 Introduction

15

2.2 Description of Operation

19

2.3 Sequence of Operation

20

2.3.1 Rectier Section 20

2.3.2 Intermediate Section 20

2.3.3 Inverter Section 20

2.3.4 Brake Option 20

2.3.5 Load Sharing 21

2.4 Control Structures

21

2.4.1 Control Structure Open-loop 21

2.4.2 Control Structure Closed-loop 22

2.4.3 Local (Hand On) and Remote (Auto On) Control 22

2.4.4 Reference Handling 23

2.4.5 Feedback Handling 25

2.5 Automated Operational Functions

26

2.5.1 Short Circuit Protection 26

2.5.2 Overvoltage Protection 26

Contents Design Guide

2.5.3 Missing Motor Phase Detection 27

2.5.4 Line Phase Imbalance Detection 27

2.5.5 Switching on the Output 27

2.5.6 Overload Protection 27

2.5.7 Automatic Derating 27

2.5.8 Automatic Energy Optimization 28

2.5.9 Automatic Switching Frequency Modulation 28

2.5.10 Automatic Derating for High Switching Frequency 28

2.5.11 Automatic Derating for Overtemperature 28

2.5.12 Auto Ramping 28

2.5.13 Current Limit Circuit 28

2.5.14 Power Fluctuation Performance 28

2.5.15 Motor Soft Start 29

2.5.16 Resonance Damping 29

2.5.17 Temperature-controlled Fans 29

2.5.18 EMC Compliance 29

2.5.19 Current Measurement on All Three Motor Phases 29

2.5.20 Galvanic Isolation of Control Terminals 29

2.6 Custom Application Functions

29

2.6.1 Automatic Motor Adaptation 29

2.6.2 Motor Thermal Protection 29

2.6.3 Line Drop-out 30

2.6.4 Built-in PID Controllers 30

2.6.5 Automatic Restart 31

2.6.6 Flying Start 31

2.6.7 Full Torque at Reduced Speed 31

2.6.8 Frequency Bypass 31

2.6.9 Motor Preheat 31

2.6.10 Four Programmable Set-ups 31

2.6.11 Dynamic Braking 31

2.6.12 DC Braking 31

2.6.13 Sleep Mode 31

2.6.14 Run Permissive 31

2.6.15 Smart Logic Control (SLC) 32

2.6.16 STO Function 33

2.7 Fault, Warning and Alarm Functions

33

2.7.1 Operation at Overtemperature 33

2.7.2 High and Low Reference Warning 34

Contents

VLT

®

AQUA Drive FC 202

2.7.3 High and Low Feedback Warning 34

2.7.4 Phase Imbalance or Phase Loss 34

2.7.5 High Frequency Warning 34

2.7.6 Low Frequency Warning 34

2.7.7 High Current Warning 34

2.7.8 Low Current Warning 34

2.7.9 No Load/Broken Belt Warning 34

2.7.10 Lost Serial Interface 34

2.8 User Interfaces and Programming

34

2.8.1 Local Control Panel 35

2.8.2 PC Software 35

2.8.2.1 MCT 10 Set-up Software 36

2.8.2.2 VLT

®

Harmonics Calculation Software MCT 31 36

2.8.2.3 Harmonic Calculation Software (HCS) 36

2.9 Maintenance

36

2.9.1 Storage 37

3 System Integration

38

3.1 Ambient Operating Conditions

38

3.1.1 Humidity 38

3.1.2 Temperature 38

3.1.3 Cooling 39

3.1.4 Motor-generated Overvoltage 40

3.1.5 Acoustic Noise 40

3.1.6 Vibration and Shock 40

3.1.7 Aggressive Atmospheres 40

3.1.8 IP Rating Denitions 42

3.1.9 Radio Frequency Interference 42

3.1.10 PELV and Galvanic Isolation Compliance 43

3.1.11 Storage 43

3.2 EMC, Harmonics and Ground Leakage Protection

44

3.2.1 General Aspects of EMC Emissions 44

3.2.2 EMC Test Results 45

3.2.3 Emission Requirements 48

3.2.4 Immunity Requirements 48

3.2.5 Motor Insulation 49

3.2.6 Motor Bearing Currents 49

3.2.7 Harmonics 50

3.2.8 Ground Leakage Current 52

Contents Design Guide

3.3 Line Power Integration

54

3.3.1 Line Power Congurations and EMC Eects 54

3.3.2 Low-frequency Line Interference 54

3.3.3 Analyzing Line Interference 55

3.3.4 Options for Reducing Line Interference 55

3.3.5 Radio Frequency Interference 55

3.3.6 Classication of the Operating Site 56

3.3.7 Use with Isolated Input Source 56

3.3.8 Power Factor Correction 56

3.3.9 Input Power Delay 56

3.3.10 Electrical Transients 57

3.3.11 Operation with a Standby Generator 57

3.4 Motor Integration

58

3.4.1 Motor Selection Considerations 58

3.4.2 Sine-wave and dU/dt Filters 58

3.4.3 Proper Motor Grounding 58

3.4.4 Motor Cables 58

3.4.5 Motor Cable Shielding 58

3.4.6 Connection of Multiple Motors 59

3.4.7 Control Wire Isolation 60

3.4.8 Motor Thermal Protection 61

3.4.9 Output Contactor 61

3.4.10 Brake Functions 61

3.4.11 Dynamic Braking 61

3.4.12 Brake Resistor Calculation 61

3.4.13 Brake Resistor Cabling 63

3.4.14 Brake Resistor and Brake IGBT 63

3.4.15 Energy Eciency 63

3.5 Additional Inputs and Outputs

64

3.5.1 Wiring Schematic 64

3.5.2 Relay Connections 65

3.5.3 EMC-compliant Electrical Connection 66

3.6 Mechanical Planning

67

3.6.1 Clearance 67

3.6.2 Wall Mounting 67

3.6.3 Access 68

3.7 Options and Accessories

68

3.7.1 Communication Options 72

Contents

VLT

®

AQUA Drive FC 202

3.7.2 Input/Output, Feedback and Safety Options 72

3.7.3 Cascade Control Options 72

3.7.4 Brake Resistors 74

3.7.5 Sine-wave Filters 74

3.7.6 dU/dt Filters 74

3.7.7 Common-mode Filters 74

3.7.8 Harmonic Filters 75

3.7.9 IP21/NEMA Type 1 Enclosure Kit 75

3.7.10 Remote Mounting Kit for LCP 77

3.7.11 Mounting Bracket for Enclosure Sizes A5, B1, B2, C1 and C2 78

3.8 Serial Interface RS485

80

3.8.1 Overview 80

3.8.2 Network Connection 81

3.8.3 RS485 Bus Termination 81

3.8.4 EMC Precautions 81

3.8.5 FC Protocol Overview 82

3.8.6 Network Conguration 82

3.8.7 FC Protocol Message Framing Structure 82

3.8.8 FC Protocol Examples 86

3.8.9 Modbus RTU Protocol 87

3.8.10 Modbus RTU Message Framing Structure 88

3.8.11 Access to Parameters 91

3.8.12 FC Drive Control Prole 92

3.9 System Design Checklist

98

4 Application Examples

100

4.1 Application Feature Overview

100

4.2 Selected Application Features

100

4.2.1 SmartStart 100

4.2.2 Quick Menu Water and Pumps 101

4.2.3 29-1* Deragging Function 101

4.2.4 Pre/post Lube 102

4.2.5 29-5* Flow Conrmation 103

4.3 Application Set-up Examples

104

4.3.1 Submersible Pump Application 106

4.3.2 BASIC Cascade Controller 108

4.3.3 Pump Staging with Lead Pump Alternation 109

4.3.4 System Status and Operation 109

4.3.5 Cascade Controller Wiring Diagram 110

Contents Design Guide

4.3.6 Fixed Variable-speed Pump Wiring

Diagram 111

4.3.7 Lead Pump Alternation Wiring Diagram 111

5 Special Conditions

115

5.1 Manual Derating

115

5.2 Derating for Long Motor Cables or Cables with Larger Cross-Section

116

5.3 Derating for Ambient Temperature

116

6 Type code and Selection

121

6.1 Ordering

121

6.1.1 Type Code 121

6.1.2 Software Language 123

6.2 Options, Accessories, and Spare Parts

123

6.2.1 Options and Accessories 123

6.2.2 Spare Parts 125

6.2.3 Accessory Bags 125

6.2.4 Brake Resistor Selection 126

6.2.5 Recommended Brake Resistors 127

6.2.6 Alternative Brake Resistors, T2 and T4 139

6.2.7 Harmonic Filters 141

6.2.8 Sine-Wave Filters 144

6.2.9 dU/dt Filters 146

6.2.10 Common Mode Filters 147

7 Specications

148

7.1 Electrical Data

148

7.1.1 Line Power Supply 1x200–240 V AC 148

7.1.2 Line Power Supply 3x200–240 V AC 149

7.1.3 Line Power Supply 1x380–480 V AC 153

7.1.4 Line Power Supply 3x380–480 V AC 154

7.1.5 Line Power Supply 3x525–600 V AC 158

7.1.6 Line Power Supply 3x525–690 V AC 162

7.2 Line Power Supply

165

7.3 Motor Output and Motor Data

165

7.4 Ambient Conditions

166

7.5 Cable Specications

166

7.6 Control Input/Output and Control Data

167

7.7 Fuses and Circuit Breakers

170

7.8 Power Ratings, Weight and Dimensions

179

Contents

VLT

®

AQUA Drive FC 202

7.9 dU/dt Testing

182

7.10 Acoustic Noise Ratings

185

7.11 Selected Options

185

7.11.1 VLT

®

General Purpose I/O Module MCB 101 185

7.11.2 VLT

®

Relay Card MCB 105 185

7.11.3 VLT

®

PTC Thermistor Card MCB 112 187

7.11.4 VLT

®

Extended Relay Card MCB 113 189

7.11.5 VLT

®

Sensor Input Option MCB 114 190

7.11.6 VLT

®

Extended Cascade Controller MCO 101 191

7.11.7 VLT

®

Advanced Cascade Controller MCO 102 192

8 Appendix - Selected Drawings

195

8.1 AC Line Input Connection Drawings (3-phases)

195

8.2 Motor Connection Drawings

198

8.3 Relay Terminal Drawings

200

8.4 Cable Entry Holes

201

Index

205

Contents Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide for Danfoss VLT

®

AQUA Drive adjustable

frequency drives is intended for:

•

Project and systems engineers

•

Design consultants

•

Application and product specialists

The design guide provides technical information to

understand the capabilities of the adjustable frequency

drive for integration into motor control and monitoring

systems.

The purpose of the design guide is to provide design

considerations and planning data for integration of the

adjustable frequency drive into a system. The design guide

caters for selection of adjustable frequency drives and

options for a diversity of applications and installations.

Reviewing the detailed product information in the design

stage enables the development of a well-conceived system

with optimal functionality and eciency.

VLT

®

is a registered trademark.

1.2

Organization

Chapter 1 Introduction: The general purpose of the design

guide and compliance with international directives.

Chapter 2 Product Overview: The internal structure and

functionality of the adjustable frequency drive and

operational features.

Chapter 3 System Integration: Environmental conditions;

EMC, harmonics, and ground leakage; line power input;

motors and motor connections; other connections;

mechanical planning; and descriptions of options and

accessories available.

Chapter 4 Application Examples: Samples of product

applications and guidelines for use.

Chapter 5 Special Conditions: Details on unusual operational

environments.

Chapter 6 Type code and Selection

: Procedures for ordering

equipment and options to meet the intended use of the

system.

Chapter 7 Specications: A compilation of technical data in

table and graphics format.

Chapter 8 Appendix - Selected Drawings: A compilation of

graphics illustrating line power and motor connections,

relay terminals, and cable entries.

1.3 Additional Resources

Resources available to understand advanced adjustable

frequency drive operation, programming, and directives

compliance:

•

The VLT

®

AQUA Drive FC 202 Instruction Manual

(referenced as Instruction Manual in this manual)

provide detailed information for the installation

and start-up of the adjustable frequency drive.

•

The VLT

®

AQUA Drive FC 202 Design Guide

provides information required for design and

planning for integration of the adjustable

frequency drive into a system.

•

The VLT

®

AQUA Drive FC 202 Programming Guide

(referenced as Programming Guide in this manual)

provides greater detail about how to work with

parameters and many application examples.

•

The VLT

®

Safe Torque O Instruction Manual

describes how to use Danfoss adjustable

frequency drives in functional safety applications.

This manual is supplied with the adjustable

frequency drive when the STO option is present.

•

The VLT

®

Brake Resistor Design Guide explains

optimal brake resistor selection.

Supplemental publications and manuals are available for

download from danfoss.com/Product/Literature/Technical

+Documentation.htm.

NOTICE!

Optional equipment is available that may change some

of the information described in these publications. Be

sure to see the instructions supplied with the options for

specic requirements.

Contact a Danfoss supplier or visit www.danfoss.com for

additional information.

Introduction

VLT

®

AQUA Drive FC 202

1

1.4 Abbreviations, Symbols and Conventions

60° AVM 60° asynchronous vector modulation

A Ampere/AMP

AC Alternating current

AD Air discharge

AEO Automatic energy optimization

AI Analog input

AMA Automatic motor adaptation

AWG American wire gauge

°C

Degrees celsius

CD Constant discharge

CM Common mode

CT Constant torque

DC Direct current

DI Digital input

DM Dierential mode

D-TYPE Drive dependent

EMC Electromagnetic compatibility

EMF Electromotive force

ETR Electronic thermal relay

f

JOG

Motor frequency when jog function is

activated.

f

M

Motor frequency

f

MAX

The maximum output frequency the

adjustable frequency drive applies on its

output.

f

MIN

The minimum motor frequency from

adjustable frequency drive.

f

M,N

Nominal motor frequency

FC Adjustable frequency drive

g Gram

Hiperface

®

Hiperface

®

is a registered trademark by

Stegmann

hp Horse power

HTL HTL encoder (10–30 V) pulses - High-voltage

transistor logic

Hz Hertz

I

INV

Rated inverter output current

I

LIM

Current limit

I

M,N

Nominal motor current

I

VLT,MAX

The maximum output current

I

VLT,N

The rated output current supplied by the

adjustable frequency drive

kHz Kilohertz

LCP Local control panel

lsb Least signicant bit

m Meter

mA Milliampere

MCM Mille circular mil

MCT Motion control tool

mH Inductance in millihenry

min Minute

ms Millisecond

msb Most signicant bit

η

VLT

Eciency of the adjustable frequency drive

dened as the ratio between power output

and power input.

nF Capacitance in nano Farad

NLCP Numerical local control panel

Nm Newton meter

n

s

Synchronous motor speed

Online/Oine

Parameters

Changes to online parameters are activated

immediately after the data value is changed.

P

br,cont.

Rated power of the brake resistor (average

power during continuous braking).

PCB Printed circuit board

PCD Process data

PELV Protective extra low voltage

P

m

Adjustable frequency drive nominal output

power as high overload (HO).

P

M,N

Nominal motor power

PM motor Permanent magnet motor

Process PID The PID regulator maintains the desired speed,

pressure, temperature, and so on.

R

br,nom

The nominal resistor value that ensures a

brake power on the motor shaft of 150/160%

for 1 minute

RCD Residual current device

Regen Regenerative terminals

R

min

Minimum permissible brake resistor value by

adjustable frequency drive

RMS Root mean square

RPM Revolutions per minute

R

rec

Recommended brake resistor resistance of

Danfoss brake resistors

s Second

SFAVM Stator ux-oriented asynchronous vector

modulation

STW Status word

SMPS Switch mode power supply

THD Total harmonic distortion

T

LIM

Torque limit

TTL TTL encoder (5 V) pulses - transistor transistor

logic

U

M,N

Nominal motor voltage

V Volts

VT Variable torque

VVC

+

Voltage vector control

Table 1.1 Abbreviations

Introduction

Design Guide

1

Conventions

Numbered lists indicate procedures.

Bullet lists indicate other information and descriptions of

gures.

Italicized text indicates:

•

Cross reference

•

Link

•

Footnote

•

Parameter name, parameter group name,

parameter option

All dimensions are in inch (mm).

* indicates a default setting of a parameter.

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation that could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE!

Indicates important information, including situations that

can result in damage to equipment or property.

1.5 Denitions

Brake resistor

The brake resistor is a module capable of absorbing the

braking energy generated in regenerative braking. This

regenerative braking energy increases the intermediate

circuit voltage and a brake chopper ensures that the power

is transmitted to the brake resistor.

Coast

The motor shaft is in free mode. No torque on the motor.

CT characteristics

Constant torque characteristics used for all applications

such as conveyor belts, displacement pumps and cranes.

Initializing

If initialization is carried out (14-22 Operation Mode), the

adjustable frequency drive returns to the default setting.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty

cycles. Each cycle consists of an on-load and an o-load

period. The operation can be either periodic duty or non-

periodic duty.

Power factor

The true power factor (lambda) takes all the harmonics

into consideration and is always smaller than the power

factor (cosphi) that only considers the 1st harmonics of

current and voltage.

cosϕ = 

P kW

P kVA

 = 

UλxIλxcosϕ

UλxIλ

Cos-phi is also known as displacement power factor.

Both lambda and cos phi are stated for Danfoss VLT

®

adjustable frequency drives in chapter 7.2 Line Power

Supply.

The power factor indicates to which extent the adjustable

frequency drive imposes a load on the line power supply.

The lower the power factor, the higher the I

RMS

for the

same kW performance.

In addition, a high power factor indicates that the

harmonic currents are low.

All Danfoss adjustable frequency drives have built-in DC

coils in the DC link to have a high power factor and reduce

the THD on the main supply.

Set-up

Save parameter settings in four set-ups. Change between

the four parameter set-ups and edit one set-up while

another set-up is active.

Slip compensation

The adjustable frequency drive compensates for the motor

slip by giving the frequency a supplement that follows the

measured motor load, keeping the motor speed almost

constant.

Smart logic Control (SLC)

The SLC is a sequence of user-dened actions executed

when the associated user-dened events are evaluated as

true by the SLC. (Parameter group 13-** Smart Logic).

FC Standard bus

Includes RS485 bus with FC protocol or MC protocol. See

8-30 Protocol.

Thermistor

A temperature-dependent resistor placed where the

temperature is to be monitored (adjustable frequency drive

or motor).

Trip

A state entered in fault situations, such as when the

adjustable frequency drive is subject to an overtem-

perature or when it protects the motor, process or

mechanism. Restart is prevented until the cause of the

fault has disappeared and the trip state is cancelled. Cancel

the trip state by:

•

activating reset or

•

programming the adjustable frequency drive to

reset automatically

Introduction

VLT

®

AQUA Drive FC 202

1

Do not use trip for personal safety.

Trip locked

A state entered in fault situations when the adjustable

frequency drive is protecting itself and requires physical

intervention, for example, if the adjustable frequency drive

is subject to a short circuit on the output. A locked trip

can only be canceled by cutting o line power, removing

the cause of the fault, and reconnecting the adjustable

frequency drive. Restart is prevented until the trip state is

canceled by activating reset or, in some cases, by being

programmed to reset automatically. Do not use trip for

personal safety.

VT Characteristics

Variable torque characteristics for pumps and fans.

1.6 Document and Software Version

This manual is regularly reviewed and updated. All

suggestions for improvement are welcome.

Table 1.2 shows the document version and the

corresponding software version.

Edition Remarks Software version

MG20N6xx Replaces MG20N5xx 2.20 and later

Table 1.2 Document and Software Version

1.7

Approvals and Certications

Adjustable frequency drives are designed in compliance

with the directives described in this section.

For more information on approvals and certicates, go to

the download area at http://www.danfoss.com/Busines-

sAreas/DrivesSolutions/Documentations/.

1.7.1

CE Mark

Figure 1.1 CE

The CE mark (Communauté Européenne) indicates that the

product manufacturer conforms to all applicable EU

directives. The EU directives applicable to the design and

manufacture of adjustable frequency drives are listed in

Table 1.3.

NOTICE!

The CE mark does not regulate the quality of the

product. Technical specications cannot be deduced from

the CE mark.

NOTICE!

Adjustable frequency drives with an integrated safety

function must comply with the machinery directive.

EU directive Version

Low voltage directive 2006/95/EC

EMC directive 2004/108/EC

Machinery directive

1)

2006/42/EC

ErP directive 2009/125/EC

ATEX directive 94/9/EC

RoHS directive 2002/95/EC

Table 1.3 EU Directives Applicable to Adjustable Frequency

Drives

1) Machinery directive conformance is only required for adjustable

frequency drives with an integrated safety function.

Declarations of conformity are available on request.

1.7.1.1

Low Voltage Directive

The low voltage directive applies to all electrical

equipment in the 50–1000 V AC and the 75–1600 V DC

voltage ranges.

The aim of the directive is to ensure personal safety and

avoid property damage when operating electrical

equipment that is installed and maintained correctly and in

its intended application.

1.7.1.2

EMC Directive

The purpose of the EMC (electromagnetic compatibility)

directive is to reduce electromagnetic interference and

enhance the immunity of electrical equipment and instal-

lations. The basic protection requirement of the EMC

Directive 2004/108/EC states that devices that generate

electromagnetic interference (EMI), or whose operation

could be aected by EMI, must be designed to limit the

generation of electromagnetic interference and shall have

a suitable degree of immunity to EMI when properly

installed, maintained, and used as intended.

Electrical equipment devices used alone or as part of a

system must bear the CE mark. Systems do not require the

CE mark, but must comply with the basic protection

requirements of the EMC directive.

Introduction

Design Guide

1

1.7.1.3 Machinery Directive

The aim of the machinery directive is to ensure personal

safety and avoid property damage for mechanical

equipment used in its intended application. The machinery

directive applies to a machine consisting of an aggregate

of interconnected components or devices of which at least

one is capable of mechanical movement.

Adjustable frequency drives with an integrated safety

function must comply with the machinery directive.

Adjustable frequency drives without the safety function do

not fall under the machinery directive. If an adjustable

frequency drive is integrated into a machinery system,

Danfoss can provide information on safety aspects relating

to the adjustable frequency drive.

When adjustable frequency drives are used in machines

with at least one moving part, the machine manufacturer

must provide a declaration stating compliance with all

relevant statutes and safety measures.

1.7.1.4

ErP Directive

The ErP directive is the European Ecodesign Directive for

energy-related products. The directive sets eco design

requirements for energy-related products, including

adjustable frequency drives. The aim of the directive is to

increase energy eciency and the level of protection of

the environment, while increasing the security of the

energy supply. Environmental impact of energy-related

products includes energy consumption throughout the

entire product life cycle.

1.7.2

C-Tick Compliance

Figure 1.2 C-Tick

The C-Tick label indicates compliance with the applicable

technical standards for Electromagnetic Compatibility

(EMC). C-Tick compliance is required for placing electrical

and electronic devices on the market in Australia and New

Zealand.

The C-Tick regulatory is about conducted and radiated

emission. For adjustable frequency drives, apply the

emission limits specied in EN/IEC 61800-3.

A declaration of conformity can be provided on request.

1.7.3

UL Compliance

UL-listed

Figure 1.3 UL

NOTICE!

525–690 V adjustable frequency drives are not certied

for UL.

The adjustable frequency drive complies with UL508C

thermal memory retention requirements. For more

information, refer to chapter 2.6.2 Motor Thermal Protection.

1.7.4

Marine Compliance

1.8 Safety

1.8.1 General Safety Principles

If handled improperly, adjustable frequency drives contain

high-voltage components and have the potential for fatal

injury. Only qualied personnel should install and operate

the equipment. Do not attempt repair work without rst

removing power from the adjustable frequency drive and

waiting the designated amount of time for stored electrical

energy to dissipate.

Strict adherence to safety precautions and notices is

mandatory for safe operation of the adjustable frequency

drive.

1.8.2

Qualied Personnel

Correct and reliable transport, storage, installation,

operation, and maintenance are required for the trouble-

free and safe operation of the adjustable frequency drive.

Only qualied personnel are allowed to install or operate

this equipment.

Qualied personnel are dened as trained sta, who are

authorized to install, commission, and maintain equipment,

systems, and circuits in accordance with pertinent laws and

regulations. Additionally, the qualied personnel must be

familiar with the instructions and safety measures

described in this instruction manual.

Introduction

VLT

®

AQUA Drive FC 202

1

WARNING

HIGH VOLTAGE

Adjustable frequency drives contain high voltage when

connected to AC line power input, DC power supply, or

load sharing. Failure to perform installation, start-up, and

maintenance by qualied personnel can result in death

or serious injury.

•

Installation, start-up, and maintenance must be

performed by qualied personnel only.

WARNING

UNINTENDED START

When the adjustable frequency drive is connected to AC

line power, DC power supply, or load sharing, the motor

may start at any time. Unintended start during

programming, service, or repair work can result in death,

serious injury, or property damage. The motor can start

via an external switch, a serial bus command, an input

reference signal from the LCP, or after a cleared fault

condition.

To prevent unintended motor start:

•

Disconnect the adjustable frequency drive from

line power.

•

Press [O/Reset] on the LCP before

programming parameters.

•

The adjustable frequency drive, motor, and any

driven equipment must be fully wired and

assembled when the adjustable frequency drive

is connected to AC line power, DC power

supply, or load sharing.

WARNING

DISCHARGE TIME

The adjustable frequency drive contains DC link

capacitors that can remain charged even when the

adjustable frequency drive is not powered. Failure to

wait the specied time after power has been removed

before performing service or repair work can result in

death or serious injury.

•

Stop the motor.

•

Disconnect AC line power and remote DC link

power supplies, including battery backups, UPS,

and DC link connections to other adjustable

frequency drives.

•

Disconnect or lock any PM motor.

•

Wait for the capacitors to discharge fully before

performing any service or repair work. The

duration of waiting time is specied in Table 1.4.

Voltage

[V]

Minimum waiting time

(minutes)

4 7 15

200–240 0.25–3.7 kW

(0.34–5 hp)

- 5.5–45 kW (7.5–

60 hp)

380–480 0.37–7.5 kW

(0.5–10 hp)

- 11–90 kW (15–

125 hp)

525–600 0.75–7.5 kW (1–

10 hp)

- 11–90 kW (15–

125 hp)

525–690 - 1.1–7.5 kW

(1.5–10 hp)

11–90 kW (15–

125 hp)

High voltage may be present even when the warning LED

indicator lights are o.

Table 1.4 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the

adjustable frequency drive properly can result in death

or serious injury.

•

Ensure the correct grounding of the equipment

by a certied electrical installer.

Introduction Design Guide

1

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment

can result in death or serious injury.

•

Ensure that only trained and qualied personnel

perform installation, start-up, and maintenance.

•

Ensure that electrical work conforms to national

and local electrical codes.

•

Follow the procedures in these document.

WARNING

UNINTENDED MOTOR ROTATION

WINDMILLING

Unintended rotation of permanent magnet motors

creates voltage and can charge the unit, resulting in

death, serious injury, or equipment damage.

•

Ensure that permanent magnet motors are

blocked to prevent unintended rotation.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the adjustable frequency drive can

result in serious injury when the adjustable frequency

drive is not properly closed.

•

Ensure that all safety covers are in place and

securely fastened before applying power.

Introduction

VLT

®

AQUA Drive FC 202

1

2 Product Overview

2.1 Introduction

This chapter provides an overview of the adjustable

frequency drive’s primary assemblies and circuitry. It

describes the internal electrical and signal processing

functions. A description of the internal control structure is

also included.

Also described are automated and optional adjustable

frequency drive functions available for designing robust

operating systems with sophisticated control and status

reporting performance.

2.1.1

Product Dedication to Water and

Wastewater Applications

The VLT

®

AQUA Drive FC 202 is designed for water and

wastewater applications. The integrated SmartStart wizard

and the quick menu Water and Pumps guide the user

through the commissioning process. The range of standard

and optional features includes:

•

Cascade control

•

Dry-run detection

•

End of curve detection

•

Motor alternation

•

Deragging

•

Initial and

nal ramp

•

Check valve ramp

•

STO

•

Low-ow detection

•

Pre-lube

•

Flow conrmation

•

Pipe ll mode

•

Sleep mode

•

Real time clock

•

Password protection

•

Overload protection

•

Smart logic control

•

Minimum speed monitor

•

Free programmable texts for information,

warnings and alerts

2.1.2

Energy Savings

Compared to alternative control systems and technologies,

an adjustable frequency drive is the optimum energy

control system for controlling fan and pump systems.

By using an adjustable frequency drive to control the ow,

a pump speed reduction of 20% leads to energy savings of

about 50% in typical applications.

Figure 2.1 shows an example of the achievable energy

reduction.

130BD889.10

60

50

40

30

20

10

H

s

0 100 200 300 400

(mwg)

1350rpm

1650rpm

0

10

20

30

(kW)

40

50

60

200100 300

(m

3

/h)

(

m

3

/h)

400

1350rpm

1650rpm

P

shaft

1

1 Energy saving

Figure 2.1 Example: Energy Saving

Product Overview Design Guide

2 2

2.1.3 Example of Energy Savings

As shown in Figure 2.2, the ow is controlled by changing

the pump speed, measured in RPM. By reducing the rated

speed by only 20%, the ow is also reduced by 20%. This

is because the ow is directly proportional to the speed.

The consumption of electricity, however, is reduced by up

to almost 50%.

If the system only has to supply a ow that corresponds to

100% a few days in a year, while the average is below 80%

of the rated ow for the remainder of the year, the energy

savings are even greater than 50%.

Figure 2.2 describes the dependence of

ow, pressure, and

power consumption on pump speed in RPM for centrifugal

pumps.

n

100%

50%

25%

12,5%

50% 100%

80%

175HA208.10

Power ~n

3

Pressure ~n

2

Flow ~n

Figure 2.2 Anity Laws for Centrifugal Pumps

Flow:

Q

1

Q

2

 = 

n

1

n

2

Pressure:

H

1

H

2

 = 

n

1

n

2

Power: 

P

1

P

2

 = 

n

1

n

2

3

Assuming an equal eciency in the speed range.

Q=Flow

P=Power

Q

1

=Flow 1 P

1

=Power 1

Q

2

=Reduced ow P

2

=Reduced power

H=Pressure n=Speed regulation

H

1

=Pressure 1 n

1

=Speed 1

H

2

=Reduced pressure n

2

=Reduced speed

Table 2.1 Anity Laws

2.1.4

Valve Control versus Speed Control of

Centrifugal Pumps

Valve control

As the demand for process requirements in water systems

varies, the ow has to be adjusted accordingly. Frequently

used methods for ow 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

ow 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 with resultant

pump damage.

Throttling the ow with a valve adds a pressure drop

across the valve (HP-HS). This can be compared with

accelerating and pulling the brake at the same time in an

attempt to reduce car speed. Figure 2.3 shows that

throttling makes the system curve turn from point (2) on

the pump curve to a point with signicantly reduced

eciency (1).

Product Overview

VLT

®

AQUA Drive FC 202

22

100% speed

Flow

Pump curve

Head or pressure Head or pressure

Natural

operating point

Operating

point

Throttled

Unthrottled

Throttled system

Unthrottled system

60

65

70

75

78

80

78

75

3

1

2

3

Hs

Hp

130BD890.10

1 Operating point using a throttle valve

2 Natural operating point

3 Operating point using speed control

Figure 2.3 Flow Reduction by Valve Control (Throttling)

Speed control

The same

ow can be adjusted by reducing the speed of

the pump, as shown in Figure 2.4. Reducing the speed

moves 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

anity laws as described in

chapter 2.1.3 Example of Energy Savings.

Flow

Head or Pressure

Pump curve

Operating

point

Natural

Operating point

system

Unthrottled

Speed

reduction

1

2

3

Hp

Hs

130BD894.10

1

Operating point using a throttle valve

2 Natural operating point

3 Operating point using speed control

Figure 2.4 Flow Reduction by Speed Control

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0 10 20 30 40 50 60 70 80 90 100

Recirculation

Throttle

control

Cycle

control

VSD

control

Ideal pump

control

Q(%)

P(%)

130BD892.10

Figure 2.5 Comparative Flow Control Curves

2.1.5

Example with Varying Flow over 1

Year

This example is calculated based on pump characteristics

obtained from a pump datasheet, shown in Figure 2.7.

The result obtained shows energy savings in excess of 50%

at the given ow distribution over a year,

see Figure 2.6. The payback period depends on the price of

electricity and the price of the adjustable frequency drive.

In this example, payback is less than a year, when

compared with valves and constant speed.

Product Overview

Design Guide

2 2

500

[h]

t

1000

1500

2000

200100 300

[m

3

/h]

400

Q

175HA210.11

t [h]

Duration of ow. See also Table 2.2.

Q [m

3

/h]

Flow rate

Figure 2.6 Flow Distribution over 1 Year (Duration versus Flow

Rate)

Figure 2.7 Energy Consumption at Dierent Speeds

Flow

rate

Distribution Valve regulation Adjustable

frequency drive

control

% Duration Power Consump-

tion

Power Consump-

tion

[m

3

/h]

[h] [kW

(hp)]

[kWh] [kW

(hp)]

[kWh]

350 5 438 42.5

(57)

1)

18.615 42.5

(57)

1)

18.615

300 15 1314 38.5

(52)

50.589 29.0

(39)

38.106

250 20 1752 35.0

(47)

61.320 25

(18.5)

32.412

200 20 1752 42

(31.5)

55.188 11.5

(15.5)

20.148

150 20 1752 28.0

(37.5)

49.056 6.5

(8.7)

11.388

100 20 1752 23.0

(31)

2)

40.296 3.5

(4.7)

3)

6.132

Σ

10

0

8760 – 275.064 – 26.801

Table 2.2 Result

1) Power reading at point A1

2) Power reading at point B1

3) Power reading at point C1

2.1.6

Improved Control

Using an adjustable frequency drive to control the ow or

pressure of a system improves control.

An adjustable frequency drive can vary the speed of the

fan or pump, obtaining variable control of ow and

pressure.

Furthermore, an adjustable frequency drive can quickly

adapt the speed of the fan or pump to new ow or

pressure conditions in the system.

Obtain simple control of process (ow, level, or pressure)

utilizing the built-in PI control.

2.1.7

Star/Delta Starter or Soft Starter

When large motors are started, it is necessary in many

countries to use equipment that limits the start-up current.

In more traditional systems, a star/delta starter or soft

starter is widely used. Such motor starters are not required

if an adjustable frequency drive is used.

As illustrated in Figure 2.8, an adjustable frequency drive

does not consume more than rated current.

Product Overview

VLT

®

AQUA Drive FC 202

22

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