Danfoss VLT HVAC Drive FC 102 User manual

MAKING MODERN LIVING POSSIBLE
Instruction Manual
VLT®HVAC Drive FC 102
315–1400 kW
www.DanfossDrives.com

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 5
1.3 Document and Software Version 5
1.4 Approvals and Certications 5
2 Safety 6
2.1 Safety Symbols 6
2.2 Qualied Personnel 6
2.3 Safety Precautions 6
2.3.1 Safe Torque O (STO) 7
3 Mechanical Installation 8
3.1 How to Get Started 8
3.2 Pre-installation 8
3.2.1 Planning the Installation Site 8
3.2.2 Receiving the Adjustable Frequency Drive 9
3.2.3 Transportation and Unpacking 9
3.2.4 Lifting 9
3.2.5 Mechanical Dimensions 12
3.2.6 Rated Power 16
3.3 Mechanical Installation 17
3.3.1 Tools Needed 17
3.3.2 General Considerations 17
3.3.3 Terminal Locations - E Enclosures 18
3.3.4 Terminal Locations - Enclosure type F 24
3.3.5 Cooling and Airow 28
3.3.6 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 30
3.4 Field Installation of Options 31
3.4.1 Installation of Duct Cooling Kit in Rittal Enclosures 31
3.4.2 Installation of Top-only Duct Cooling Kit 32
3.4.3 Installation of Top and Bottom Covers for Rittal Enclosures 33
3.4.4 Installation of Top and Bottom Covers 33
3.4.5 Outside Installation/NEMA 3R Kit for Rittal Enclosures 34
3.4.6 Outside Installation/NEMA 3R Kit for Industrial Enclosures 34
3.4.7 Installation of IP00 to IP20 Kits 35
3.4.8 Installation of IP00 E2 Cable Clamp Bracket 35
3.4.9 Installation of Line Power Shield for Adjustable Frequency Drives 35
Contents Instruction Manual
MG11F522 Danfoss A/S © 08/2014 All rights reserved.

3.4.10 Enclosure Size F USB Extension Kit 35
3.4.11 Installation of Input Plate Options 36
3.4.12 Installation of E Load Share Option 37
3.5 Enclosure Type F Panel Options 37
3.5.1 Enclosure Type F Options 37
4 Electrical Installation 39
4.1 Electrical Installation 39
4.1.1 Power Connections 39
4.1.2 Grounding 47
4.1.3 Extra Protection (RCD) 47
4.1.4 RFI Switch 47
4.1.5 Torque 47
4.1.6 Shielded Cables 48
4.1.7 Motor Cable 48
4.1.8 Brake Cable for Adjustable Frequency Drives with Factory-installed Brake
Chopper Option 49
4.1.9 Brake Resistor Temperature Switch 49
4.1.10 Load Sharing 49
4.1.11 Shielding against Electrical Noise 50
4.1.12 AC line input connections 50
4.1.13 External Fan Supply 50
4.1.14 Fuses 50
4.1.15 Motor Insulation 54
4.1.16 Motor Bearing Currents 54
4.1.17 Control Cable Routing 55
4.1.18 Access to Control Terminals 56
4.1.19 Electrical Installation, Control Terminals 56
4.1.20 Electrical Installation, Control Cables 58
4.1.21 Switches S201, S202 and S801 61
4.2 Connection Examples 61
4.2.1 Start/Stop 61
4.2.2 Pulse Start/Stop 62
4.3 Final Set-up and Test 63
4.4 Additional Connections 64
4.4.1 Mechanical Brake Control 64
4.4.2 Parallel Connection of Motors 64
4.4.3 Motor Thermal Protection 65
Contents VLT®HVAC Drive FC 102
Danfoss A/S © 08/2014 All rights reserved. MG11F522

5 How to Operate the Adjustable Frequency Drive 66
5.1 Operating with LCP 66
5.1.1 Three Ways of Operating 66
5.1.2 How to Operate the Graphical LCP (GLCP) 66
5.2 Operating via Serial Communication 70
5.2.1 RS-485 Bus Connection 70
5.3 Operating via PC 70
5.3.1 How to Connect a PC to the Adjustable Frequency Drive 70
5.3.2 PC Software Tools 70
5.3.3 Tips and Tricks 71
5.3.4 Quick Transfer of Parameter Settings when Using GLCP 72
5.3.5 Initialization to Default Settings 72
6 How to Program 74
6.1 Basic Programming 74
6.1.1 Parameter Set-up 74
6.1.2 Quick Menu Mode 78
6.1.3 Function Set-ups 82
6.1.4 5-1* Digital Inputs 94
6.1.5 Main Menu Mode 107
6.1.6 Parameter Selection 107
6.1.7 Changing Data 107
6.1.8 Changing a Text Value 108
6.1.9 Changing a Group of Numeric Data Values 108
6.1.10 Changing of Data Value, Step by Step 108
6.1.11 Readout and Programming of Indexed Parameters 108
6.2 Parameter Menu Structure 108
7 General Specications 113
7.1 Motor Output and Motor Data 113
7.2 Ambient Conditions 113
7.3 Cable Specications 114
7.4 Control Input/Ouput and Control Data 114
7.5 Electrical Data 118
8 Warnings and Alarms 123
Index 135
Contents Instruction Manual
MG11F522 Danfoss A/S © 08/2014 All rights reserved.

1 Introduction
1.1 Purpose of the Manual
This instruction manual provides information for safe instal-
lation and commissioning of the adjustable frequency
drive.
This instruction manual is intended for use by qualied
personnel.
Read and follow the instruction manual to use the
adjustable frequency drive safely and professionally, and
pay particular attention to the safety instructions and
general warnings. Keep this instruction manual available
with the adjustable frequency drive at all times.
VLT®is a registered trademark.
1.1.1 Intended Use
The adjustable frequency drive is an electronic motor
controller intended for:
•Regulation of motor speed in response to system
feedback or to remote commands from external
controllers. A power drive system consists of the
adjustable frequency drive, the motor and
equipment driven by the motor.
•System and motor status surveillance.
The adjustable frequency drive can also be used for motor
protection.
Depending on conguration, the adjustable frequency
drive can be used in stand-alone applications or form part
of a larger appliance or installation.
The adjustable frequency drive is allowed for use in
residential, industrial and commercial environments in
accordance with local laws and standards.
NOTICE!
In a residential environment, this product can cause
radio interference, in which case supplementary
mitigation measures can be required.
Foreseeable misuse
Do not use the adjustable frequency drive in applications
which are non-compliant with specied operating
conditions and environments. Ensure compliance with the
conditions specied in chapter 7 General Specications.
1.1.2 Abbreviations and Standards
Abbrevi-
ations Terms SI units I-P units
aAcceleration m/s2ft/s2
AWG American wire gauge
Auto Tune Automatic motor tuning
°CCelsius
I Current A Amp
ILIM Current limit
IT line
power
Line power supply with star
point in transformer oating
to ground
Joule Energy J=N∙m ft-lb, Btu
°FFahrenheit
FC Adjustable frequency drive
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 meters in-lbs
IM,N Nominal motor current
fM,N Nominal motor frequency
PM,N Nominal motor power
UM,N Nominal motor voltage
PELV Protective extra low voltage
Watt Power WBtu/hr,
hp
Pascal Pressure Pa =
N/m²
psi, psf,
ft of
water
IINV Rated inverter output current
RPM Revolutions per minute
s Second
SR Size related
T Temperature C F
t Time s s, hr
TLIM Torque limit
U Voltage V V
Table 1.1 Abbreviations and Standards
Introduction VLT®HVAC Drive FC 102
4 Danfoss A/S © 08/2014 All rights reserved. MG11F522
1
1

1.2 Additional Resources
•VLT
®
HVAC Drive FC 102 Design Guide holds all
technical information about the adjustable
frequency drive and customer design and
applications.
•VLT
®
HVAC Drive FC 102 Programming Guide
provides information on how to program and
includes complete parameter descriptions.
•Application Note, Temperature Derating Guide.
•MCT 10 Set-up Software Instruction Manual enables
the user to congure the adjustable frequency
drive from a Windows™-based PC environment.
•Danfoss VLT®Energy Box software at
www.danfoss.com/BusinessAreas/DrivesSolutions,
then select PC Software Download.
•VLT
®
HVAC Drive BACnet, Instruction Manual.
•VLT
®
HVAC Drive Metasys, Instruction Manual.
•VLT
®
HVAC Drive FLN, Instruction Manual.
Danfoss technical literature is available in print from local
Danfoss Sales Oces, or as electronic copies at:
www.danfoss.com/BusinessAreas/DrivesSolutions/Documen-
tations/Technical+Documentation.htm
1.3 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
MG11F5xx Replaces MG11F4xx 4.1x
Table 1.2 Document and Software Version
1.4 Approvals and Certications
The adjustable frequency drive complies with UL508C
thermal memory retention requirements. For more
information, refer to the section Motor Thermal Protection
in the product specic design guide.
NOTICE!
Imposed limitations on the output frequency
(due to export control regulations):
From software version 3.92, the output frequency of the
adjustable frequency drive is limited to 590 Hz.
Introduction Instruction Manual
MG11F522 Danfoss A/S © 08/2014 All rights reserved. 5
11

2 Safety
2.1 Safety Symbols
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.
2.2 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.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE!
Adjustable frequency drives contain high voltage when
connected to AC line input power. Installation, start-up,
and maintenance must be performed by qualied
personnel only. Failure to perform installation, start-up,
and maintenance by qualied personnel could result in
death or serious injury.
WARNING
UNINTENDED START!
When the adjustable frequency drive is connected to AC
line power, the motor may start at any time. The
adjustable frequency drive, motor, and any driven
equipment must be in operational readiness. Failure to
be in operational readiness when the adjustable
frequency drive is connected to AC line power could
result in death, serious injury, equipment, or property
damage.
WARNING
DISCHARGE TIME!
Adjustable frequency drives contain DC link capacitors
that can remain charged even when the adjustable
frequency drive is not powered. To avoid electrical
hazards, disconnect AC line power, any permanent
magnet type motors, and any remote DC link power
supplies, including battery backups, UPS and DC link
connections to other adjustable frequency drives. Wait
for the capacitors to discharge completely before
performing any service or repair work. The waiting time
duration is listed in Table 2.1. Failure to wait for the
specied period of time after power has been removed
to do service or repair could result in death or serious
injury.
Voltage [V] Power Size [kW (hp)] Min. waiting time
(min)
380–480 315–1000 (425–1350) 40
525–690 450–1400 (600–1875) 30
Be aware that there may be high voltage on the DC link even
when the LEDs are turned o.
Table 2.1 Discharge Time
WARNING
LEAKAGE CURRENT HAZARD!
Leakage currents are higher than 3.5 mA. It is the
responsibility of the user or certied electrical installer to
ensure correct grounding of the equipment. Failure to
ground the adjustable frequency drive properly could
result in death or serious injury.
Safety VLT®HVAC Drive FC 102
6 Danfoss A/S © 08/2014 All rights reserved. MG11F522
2
2

WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be
hazardous. All electrical work must conform to national
and local electrical codes. Installation, start-up, and
maintenance are performed only by trained and qualied
personnel. Failure to follow these guidelines could result
in death or serious injury.
WARNING
WINDMILLING!
Unintended rotation of permanent magnet motors
causes a risk of personal injury and equipment damage.
Ensure permanent magnet motors are blocked to
prevent unintended rotation.
CAUTION
POTENTIAL HAZARD IN THE EVENT OF
INTERNAL FAILURE!
Risk of personal injury when the adjustable frequency
drive is not properly closed. Before applying power,
ensure all safety covers are in place and securely
fastened.
2.3.1 Safe Torque O (STO)
STO is an option. To run STO, additional wiring for the
adjustable frequency drive is required. Refer to VLT
®
Adjustable Frequency Drives Safe Torque O Instruction
Manual for further information.
Safety Instruction Manual
MG11F522 Danfoss A/S © 08/2014 All rights reserved. 7
22

3 Mechanical Installation
3.1 How to Get Started
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
instruction manual and design guide.
The adjustable frequency drive is designed to achieve a
quick and EMC-compatible installation.
WARNING
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 line and protective ground.
•Motor connection and cables.
•Fuses and circuit breakers.
•Control terminals - cables.
Quick Set-up
•Local Control Panel, LCP.
•Automatic Motor Adaptation, AMA.
•Programming.
Enclosure size depends on enclosure type, power range
and AC line voltage.
M
3
96 97 9998
37
91 92 93 12
L1
W PEVU
F1
L2
L3
PE
130BA015.13
1
18
81 82
R+R-
95
55
50
53
27
88 89
DC- DC+
L1 L2 PEL3
Figure 3.1 Diagram showing basic installation including line
power, motor, start/stop key, and potentiometer for speed
adjustment.
3.2 Pre-installation
3.2.1 Planning the Installation Site
CAUTION
It is important to plan the installation of the adjustable
frequency drive. Neglecting to plan may result in extra
work during and after installation.
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 adjustable frequency drive.
•Cable routing.
Mechanical Installation VLT®HVAC Drive FC 102
8 Danfoss A/S © 08/2014 All rights reserved. MG11F522
33