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

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-

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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

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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-

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1 How to Read these Operating Instructions

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is a registered Danfoss trademark

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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

™

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

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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-

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2 Safety

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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

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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-

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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.

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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-

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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

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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-

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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

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*

Please note airflow directions

3.2.5 Mechanical Dimensions

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3

*

Please note airflow directions

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MG.11.F3.02 - VLT

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*

Please note airflow directions

VLT HVAC Drive High Power Operating In-

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3

*

Please note airflow directions

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F1 IP 21/54 - NEMA 1/12 F3 IP 21/54 - NEMA 1/12

1) Minimum clearance from ceiling

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F2 IP 21/54 - NEMA 1/12 F4 IP 21/54 - NEMA 1/12

1) Minimum clearance from ceiling

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