Danfoss VLT® HVAC Drive FC 102 110-1400 kW Operating instructions

Type
Operating instructions

This manual is also suitable for

Contents
1 How to Read these Operating Instructions
5
Copyright, limitation of liability and revision rights 5
2 Safety
7
High Voltage Warning 7
Safety Instructions 7
General Warning 7
Before Commencing Repair Work 8
Special Conditions 8
Avoid unintended start 8
Safe Stop of the frequency converter 9
IT Mains 10
3 Mechanical Installation
11
How to Get Started 11
Pre-installation 11
Planning the Installation Site 11
Receiving the Frequency Converter 12
Transportation and Unpacking 12
Lifting 13
Mechanical Dimensions 15
Rated Power 22
Mechanical Installation 23
Terminal Locations - Frame size D 25
Terminal Locations - Frame size E 27
Terminal Locations - Frame size F 31
Cooling and Airflow 34
Field Installation of Options 41
Installation of Duct Cooling Kit in Rittal Enclosures 41
Installation of Top-only Duct Cooling Kit 42
Installation of Top and Bottom Covers for Rittal Enclosures 42
Installation of Top and Bottom Covers 43
Outside Installation/ NEMA 3R Kit for Rittal Enclosures 43
Outside Installation /NEMA 3R Kit of Industrial Enclosures 44
Installation of IP00 to IP20 Kits 45
Installation of IP00s D3, D4, & E2 Cable Clamp Bracket 45
Installation on Pedestal 45
Installation of Mains Shield for Frequency Converters 46
F Frame USB Extension Kit 46
Installation of Input Plate Options 47
VLT HVAC Drive High Power Operating In-
structions
Contents
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
1
Installation of D or E Loadshare Option 47
Frame size F Panel Options 48
4 Electrical Installation
51
Electrical Installation 51
Power Connections 51
Mains Connection 65
Fuses 66
Control Cable Routing 70
Electrical Installation, Control Terminals 71
Connection Examples 73
Start/Stop 73
Pulse Start/Stop 73
Electrical Installation - additional 75
Electrical Installation, Control Cables 75
Switches S201, S202, and S801 77
Final Set-up and Test 78
Additional Connections 80
Mechanical Brake Control 80
Motor Thermal Protection 80
5 How to Operate the Frequency Converter
81
How to Operate Graphical LCP (GLCP) 81
Tips and Tricks 88
6 How to Programme
91
Quick Menu mode 93
Function Set-ups 100
Parameter lists 130
Main Menu Structure 130
0-** Operation and Display 131
1-** Load / Motor 132
2-** Brakes 133
3-** Reference / Ramps 133
4-** Limits / Warnings 134
5-** Digital In / Out 135
6-** Analog In / Out 136
8-** Communication and Options 137
9-** Profibus 138
10-** CAN Fieldbus 139
11-** LonWorks 139
13-** Smart Logic Controller 140
Contents
VLT HVAC Drive High Power Operating In-
structions
2
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
14-** Special Functions 141
15-** FC Information 142
16-** Data Readouts 144
18-** Info & Readouts 146
20-** FC Closed Loop 147
21-** Ext. Closed Loop 148
22-** Application Functions 150
23-** Time Based Funtions 151
24-** Application Functions 2 152
25-** Cascade Pack Controller 153
26-** Analog I / O Option MCB 109 154
7 General Specifications
155
8 Warnings and Alarms
169
Alarms and Warnings 169
Fault Messages 173
Index
179
VLT HVAC Drive High Power Operating In-
structions
Contents
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
1 How to Read these Operating Instructions
VLT HVAC Drive High Power Operating In-
structions
4
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
1
1 How to Read these Operating Instructions
1.1.1 Copyright, limitation of liability and revision rights
This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the information contained herein
will be used solely for operating equipment from Danfoss or equipment from other vendors provided that such equipment is intended for communication
with Danfoss equipment over a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical,
hardware or software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss 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 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 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 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.
1.1.2 Symbols
Symbols used in this manual:
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
✮ Indicates default setting
1.1.3 Available Literature for VLT HVAC Drive
- Operating Instructions MG.11.Ax.yy provide the necessary information for getting the frequency converter up and running.
- Operating Instructions VLT HVAC Drive High Power, MG.11.Fx.yy
- Design Guide MG.11.Bx.yy entails all technical information about the frequency converter and customer design and applications.
- Programming Guide MG.11.Cx.yy provides information on how to programme and includes complete parameter descriptions.
VLT HVAC Drive High Power Operating In-
structions
1 How to Read these Operating Instructions
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
5
1
- Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.yy
- Application Note, Temperature Derating Guide, MN.11.Ax.yy
-
PC-based Configuration Tool MCT 10, MG.10.Ax.yy enables the user to configure the frequency converter from a Windows
â„¢
based PC environ-
ment.
-
Danfoss VLT
®
Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions
then choose PC Software Download
-
VLT
®
VLT HVAC Drive Drive Applications, MG.11.Tx.yy
- Operating Instructions VLT HVAC Drive Profibus, MG.33.Cx.yy.
- Operating Instructions VLT HVAC Drive Device Net, MG.33.Dx.yy
- Operating Instructions VLT HVAC Drive BACnet, MG.11.Dx.yy
- Operating Instructions VLT HVAC Drive LonWorks, MG.11.Ex.yy
- Operating Instructions VLT HVAC Drive Metasys, MG.11.Gx.yy
- Operating Instructions VLT HVAC Drive FLN, MG.11.Zx.yy
- Output Filter Design Guide, MG.90.Nx.yy
- Brake Resistor Design Guide, MG.90.Ox.yy
x = Revision number
yy = Language code
Danfoss technical literature is available in print from your local Danfoss Sales Office or online at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm
1.1.4 Abbreviations and Standards
Abbreviations: Terms: SI-units: I-P units:
a Acceleration
m/s
2
ft/s
2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°CCelsius
I Current A Amp
I
LIM
Current limit
Joule Energy J = N∙m ft-lb, Btu
°F
Fahrenheit
FC Frequency Converter
f Frequency Hz Hz
kHz Kilohertz kHz kHz
LCP Local Control Panel
mA Milliampere
ms Millisecond
min Minute
MCT Motion Control Tool
M-TYPE Motor Type Dependent
Nm Newton Metres in-lbs
I
M,N
Nominal motor current
f
M,N
Nominal motor frequency
P
M,N
Nominal motor power
U
M,N
Nominal motor voltage
par. Parameter
PELV Protective Extra Low Voltage
Watt Power W Btu/hr, hp
Pascal Pressure Pa = N/m² psi, psf, ft of water
I
INV
Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
T Temperature C F
t Time s s,hr
T
LIM
Torque limit
U Voltage V V
Table 1.1: Abbreviation and standards table .
1 How to Read these Operating Instructions
VLT HVAC Drive High Power Operating In-
structions
6
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
1
2Safety
2.1.1 High Voltage Warning
The voltage of the frequency converter and the MCO 101 option card is dangerous whenever it is connected to mains. Incorrect
installation of the motor or frequency converter may causedeath, serious injury or damage to the equipment. Consequently, it is
essential to comply with the instructions in this manual as well as local and national rules and safety regulations.
2.1.2 Safety Instructions
Prior to using functions directly or indirectly influencing personal safety (e.g. Safe Stop, Fire Mode or other functions either forcing
the motor to stop or attempting to keep it functioning) a thorough risk analysis and system test must be carried through. The
system tests must include testing failure modes regarding the control signalling (analog and digital signals and serial communication.
NB!
Before using Fire Mode, contact Danfoss
• Make sure the frequency converter is properly connected to earth.
• Do not remove mains connections, motor connections or other power connections while the frequency converter is connected to power.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
• The earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from mains.
2.1.3 General Warning
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected 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 frequency converter, wait at least as follows: Be aware that there may be high voltage
on the DC link even when the Control Card LEDs are turned off. A red LED is mounted on a circuit board inside the drive to indicate
the DC bus voltage. The red LED will stay lit until the DC link is 50 Vdc or lower.
Leakage Current
The earth leakage current from the frequency converter exceeds 3.5 mA. According 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 delayed) shall be used on the supply side of this product. See also RCD Application Note MN.90.GX.02.
Protective earthing of the frequency converter and the use of RCD's must always follow national and local regulations.
VLT HVAC Drive High Power Operating In-
structions
2 Safety
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
7
2
2.1.4 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 General Warning above
4. Remove motor cable
2.1.5 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 expected 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 electrical ratings might be:
• Single phase applications
• High temperature applications which require de-rating of the electrical ratings
• Marine applications with more severe environmental conditions.
Other applications might also affect the electrical ratings.
Consult the relevant sections in this manual and in the
VLT HVAC Drive Design Guide, MG.11.BX.YY
for information about the electrical ratings.
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 (grounded delta transformer leg, IT,TN, etc.)
• Safety of low-voltage ports (PELV conditions).
Consult the relevant clauses in these instructions and in the
VLT HVAC Drive Design Guide
for information about the installation requirements.
2.1.6 Installation at High Altitudes (PELV)
Installation at high altitude:
380 - 480 V: At altitudes above 3 km, please contact Danfoss regarding PELV.
525 - 690 V: At altitudes above 2 km, please contact Danfoss regarding PELV.
2.1.7 Avoid unintended start
While the frequency converter is connected to mains, the motor can be started/stopped 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 unin-
tended 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 Safety
VLT HVAC Drive High Power Operating In-
structions
8
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
2
2.1.8 Safe Stop of the frequency converter
For versions fitted with a Safe Stop terminal 37 input, the frequency converter can perform the safety function
Safe Torque Off
(As defined by draft CD
IEC 61800-5-2) or
Stop Category 0
(as defined in EN 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and
use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality
and safety category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety
Category 3 in EN 954-1, the related information and instructions of the
VLT HVAC Drive Design Guide
must be followed! The information and instructions
of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!
130BA491
This certificate also covers FC 102 and FC 202!
VLT HVAC Drive High Power Operating In-
structions
2 Safety
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
9
2
2.1.9 IT Mains
IT mains
Do not connect frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V
for 400 V converters and 760 V for 690 V converters.
For 400 V IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth.
For 690 V IT mains and delta earth (grounded leg), mains voltage may exceed 760 V between phase and earth.
Par. 14-50
RFI Filter
can be used to disconnect the internal RFI capacitors from the RFI filter to ground.
2.1.10 Software Version and Approvals: VLT HVAC Drive
VLT HVAC Drive
Software version: 3.2.x
This manual can be used with all VLT HVAC Drive frequency converters with software version 3.2.x.
The software version number can be seen from par. 15-43
Software Version
.
2.1.11 Disposal Instruction
Equipment containing electrical components must not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently valid leg-
islation.
2 Safety
VLT HVAC Drive High Power Operating In-
structions
10
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
2
3 Mechanical Installation
3.1 How to Get Started
3.1.1 About How to Install
This chapter covers mechanical and electrical installations to and from power terminals and control card terminals.
Electrical installation of
options
is described in the relevant Operating Instructions and Design Guide.
3.1.2 How to Get Started
The frequency converter is designed to achieve a quick and EMC-correct installation by following the steps described below.
Read the safety instructions before installing the unit.
Failure to follow recommendations could result in death or serious injury.
Mechanical Installation
• Mechanical mounting
Electrical Installation
• Connection to Mains and Protecting Earth
• Motor connection and cables
• Fuses and circuit breakers
• Control terminals - cables
Quick Setup
•Local Control Panel, LCP
• Automatic Motor Adaptation, AMA
• Programming
Frame size is depending on enclosure type, power range and mains volt-
age
Illustration 3.1: Diagram showing basic installation including
mains, motor, start/stop key, and potentiometer for speed
adjustment.
3.2 Pre-installation
3.2.1 Planning the Installation Site
NB!
Before performing the installation it is important to plan the installation of the frequency converter. Neglecting this may result in extra
work during and after installation.
VLT HVAC Drive High Power Operating In-
structions
3 Mechanical Installation
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
11
3
Select the best possible operation site by considering the following (see details on the following pages, and the respective Design
Guides):
• Ambient operating temperature
• Installation method
• How to cool the unit
• Position of the frequency converter
•Cable routing
• Ensure the power source supplies the correct voltage and necessary current
• Ensure that the motor current rating is within the maximum current from the frequency converter
• If the frequency converter is without built-in fuses, ensure that the external fuses are rated correctly.
3.2.2 Receiving the Frequency Converter
When receiving the frequency converter please make sure that the packaging is intact, and be aware of any damage that might have occurred to the
unit during transport. In case damage has occurred, contact immediately the shipping company to claim the damage.
3.2.3 Transportation and Unpacking
Before unpacking the frequency converter it is recommended that it is located as close as possible to the final installation site.
Remove the box and handle the frequency converter on the pallet, as long as possible.
NB!
The card box cover contains a drilling master for the mounting holes in the D frames. For the E size, please refer to section
Mechanical
Dimensions
later in this chapter.
Illustration 3.2: Mounting Template
3 Mechanical Installation
VLT HVAC Drive High Power Operating In-
structions
12
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
3.2.4 Lifting
Always lift the frequency converter in the dedicated lifting eyes. For all D and E2 (IP00) enclosures, use a bar to avoid bending the lifting holes of the
frequency converter.
Illustration 3.3: Recommended lifting method, frame sizes D and E .
The lifting bar must be able to handle the weight of the frequency converter. See
Mechanical Dimensions
for the weight of the different
frame sizes. Maximum diameter for bar is 2.5 cm (1 inch). The angle from the top of the drive to the lifting cable should be 60° C or
greater.
Illustration 3.4: Recommended lifting method, frame size
F1.
Illustration 3.5: Recommended lifting method, frame size
F2.
VLT HVAC Drive High Power Operating In-
structions
3 Mechanical Installation
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
13
3
Illustration 3.6: Recommended lifting method, frame size
F3.
Illustration 3.7: Recommended lifting method, frame size
F4.
NB!
Note the plinth is provided in the same packaging as the frequency converter but is not attached to frame sizes F1-F4 during shipment.
The plinth is required to allow airflow to the drive to provide proper cooling. The F frames should be positioned on top of the plinth in
the final installation location. The angle from the top of the drive to the lifting cable should be 60° C or greater.
In addition to the drawings above a spreader bar is an acceptable way to lift the F Frame.
3 Mechanical Installation
VLT HVAC Drive High Power Operating In-
structions
14
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
*
Please note airflow directions
3.2.5 Mechanical Dimensions
VLT HVAC Drive High Power Operating In-
structions
3 Mechanical Installation
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
15
3
*
Please note airflow directions
3 Mechanical Installation
VLT HVAC Drive High Power Operating In-
structions
16
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
*
Please note airflow directions
VLT HVAC Drive High Power Operating In-
structions
3 Mechanical Installation
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
17
3
*
Please note airflow directions
3 Mechanical Installation
VLT HVAC Drive High Power Operating In-
structions
18
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
F1 IP 21/54 - NEMA 1/12 F3 IP 21/54 - NEMA 1/12
1) Minimum clearance from ceiling
VLT HVAC Drive High Power Operating In-
structions
3 Mechanical Installation
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
19
3
F2 IP 21/54 - NEMA 1/12 F4 IP 21/54 - NEMA 1/12
1) Minimum clearance from ceiling
3 Mechanical Installation
VLT HVAC Drive High Power Operating In-
structions
20
MG.11.F3.02 - VLT
®
is a registered Danfoss trademark
3
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126
  • Page 127 127
  • Page 128 128
  • Page 129 129
  • Page 130 130
  • Page 131 131
  • Page 132 132
  • Page 133 133
  • Page 134 134
  • Page 135 135
  • Page 136 136
  • Page 137 137
  • Page 138 138
  • Page 139 139
  • Page 140 140
  • Page 141 141
  • Page 142 142
  • Page 143 143
  • Page 144 144
  • Page 145 145
  • Page 146 146
  • Page 147 147
  • Page 148 148
  • Page 149 149
  • Page 150 150
  • Page 151 151
  • Page 152 152
  • Page 153 153
  • Page 154 154
  • Page 155 155
  • Page 156 156
  • Page 157 157
  • Page 158 158
  • Page 159 159
  • Page 160 160
  • Page 161 161
  • Page 162 162
  • Page 163 163
  • Page 164 164
  • Page 165 165
  • Page 166 166
  • Page 167 167
  • Page 168 168
  • Page 169 169
  • Page 170 170
  • Page 171 171
  • Page 172 172
  • Page 173 173
  • Page 174 174
  • Page 175 175
  • Page 176 176
  • Page 177 177
  • Page 178 178
  • Page 179 179
  • Page 180 180
  • Page 181 181
  • Page 182 182
  • Page 183 183

Danfoss VLT® HVAC Drive FC 102 110-1400 kW Operating instructions

Type
Operating instructions
This manual is also suitable for

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI