Danfoss VLT HVAC Drive FC 102 Operating instructions

Contents

1 How to Read these Operating Instructions

5

Copyright, Limitation of Liability and Revision Rights 5

2 Safety

9

Safety instructions 9

General Warning 9

Before commencing repair work 10

Special conditions 10

Avoid unintended start 11

Safe Stop of the frequency converter 11

IT mains 13

3 Mechanical Installation

15

How to Get Started 15

Pre-installation 15

Planning the Installation Site 15

Receiving the Frequency Converter 16

Transportation and Unpacking 16

Lifting 17

Mechanical Dimensions 19

Rated Power 26

Mechanical Installation 27

Terminal locations - frame size D 28

Terminal Locations - frame size E 30

Terminal Locations - frame size F 34

Cooling and Airflow 36

Field Installation of Options 41

Installation of Duct Cooling Kit in Rittal Enclosures 41

Outside installation/ NEMA 3R kit for Rittal enclosures 44

Installation on pedestal 45

Input plate option 47

Installation of Mains Shield for frequency converters 48

Frame size F Panel Options 48

4 Electrical Installation

51

Electrical Installation 51

Power Connections 51

Mains connection 66

Fuses 67

Motor Insulation 70

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is a registered Danfoss trademark

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Motor Bearing Currents 70

Control cable routing 71

Electrical Installation, Control Terminals 72

Connection Examples 74

Start/Stop 74

Pulse Start/Stop 74

Electrical Installation - additional 76

Electrical Installation, Control Cables 76

Switches S201, S202, and S801 78

Final Set-up and Test 79

Additional Connections 81

Mechanical Brake Control 81

Motor Thermal Protection 81

5 How to operate the frequency converter

83

How to operate graphical LCP (GLCP) 83

How to operate numeric LCP (NLCP) 88

Tips and tricks 92

6 How to Programme

95

Quick Menu Mode 97

Function Setups

103

Parameter lists 136

Main Menu Structure 136

0-** Operation and Display 137

1-** Load / Motor 139

2-** Brakes 140

3-** Reference / Ramps 141

4-** Limits / Warnings 142

5-** Digital In / Out 143

6-** Analog In / Out 145

8-** Communication and Options 147

9-** Profibus 148

10-** CAN Fieldbus 149

11-** LonWorks 150

13-** Smart Logic Controller 151

14-** Special Functions 152

15-** FC Information 153

16-** Data Readouts 155

18-** Info & Readouts 157

20-** FC Closed Loop 158

21-** Ext. Closed Loop 159

Contents

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22-** Application Functions 161

23-** Time Based Funtions 163

24-** Application Functions 2 164

25-** Cascade Controller 165

26-** Analog I / O Option MCB 109 167

7 General Specifications

169

8 Warnings and Alarms

181

Fault messages 184

Index

190

VLT HVAC Drive High Power Operating In-

structions

Contents

MG.11.F2.02 - VLT

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is a registered Danfoss trademark

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1 How to Read these Operating Instructions

VLT HVAC Drive High Power Operating In-

structions

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MG.11.F2.02 - VLT

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is a registered Danfoss trademark

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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.

VLT HVAC Drive High Power Operating In-

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1

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

- Operating Instructions MG.11.Ax.yy provide the neccessary information for getting the frequency converter up and running.

- 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.

- Mounting Instruction, Analog I/O Option MCB109, MI.38.Bx.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

®

HVAC Drive Applications, MG.11.Tx.yy

- Operating Instructions BACnet, MG.11.Dx.yy

- Operating Instructions Profibus, MG.33.Cx.yy.

- Operating Instructions Device Net, MG.33.Dx.yy

- Operating Instructions LonWorks, MG.11.Ex.yy

- Operating Instructions High Power, MG.11.Fx.yy

- Operating Instructions Metasys, MG.11.Gx.yy

- Operating Instructions FLN, MG.11.Zx.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 How to Read these Operating Instructions

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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 .

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2 Safety

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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 cause damage to the equipment, serious injury or death. 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:

380 - 480 V, 110 - 250 kW, wait at least 20 minutes.

380 - 480 V, 315- 1000 kW, wait at least 40 minutes.

525 - 690 V, 45 - 400 kW, wait at least 20 minutes.

525 - 690 V, 450 - 1200 kW, wait at least 30 minutes.

Shorter time is allowed only if indicated on the nameplate for the specific unit.

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.

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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

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 (IT,TN, grounded leg, etc.)

• Safety of low-voltage ports (PELV conditions).

Consult the relevant clauses in these instructions and in the

Design Guide

for information about the installation requirements.

2.1.6 Caution

The frequency converter's DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,

disconnect the frequency converter from the mains before carrying out maintenance. Before doing service on the frequency converter,

wait at least the amount of time indicated below:

Voltage Power size Min. Waiting Time

380 - 480 V 110 - 250 kW 20 minutes

315 - 1000 kW 40 minutes

525 - 690 V 45 - 400 kW 20 minutes

450- 1200 kW 30 minutes

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2 Safety

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2.1.7 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.

2.1.8 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 unintended 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.

2.1.9 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

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!

VLT HVAC Drive High Power Operating In-

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MG.11.F2.02 - VLT

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is a registered Danfoss trademark

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2

130BA491

This certificate also covers FC 102 and FC 202!

2 Safety

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2.1.10 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 capacitiors from the RFI filter to ground.

2.1.11 Software version and approvals:

Software version: 2.8.x

This manual can be used with all frequency converters with software version 2.8.x.

The software version number can be seen from par. 15-43

Software Version

.

2.1.12 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

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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.

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.

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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) frames, use a bar to avoid bending the lifting holes of the frequency

converter.

Illustration 3.3: Recommended lifting method, frame sizes D and E .

NB!

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 25 cm (1 inch). The angle from the top of the drive to the lifting cable should be 60 degrees

or greater.

Illustration 3.4: Recommended lifting method, frame size

F1.

Illustration 3.5: Recommended lifting method, frame size

F2.