Danfoss VLT HVAC Drive FC 102 User manual

Operating Guide
VLT® HVAC Drive FC 102
110-800 kW, D9h-D10h and E5h-E6h Enclosed Drives
drives.danfoss.com

1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.6.1
3.6.2
3.6.3
3.6.4
4
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.4
Contents
Introduction 8
Purpose of this Operating Guide 8
Additional Resources 8
Manual Version 8
Approvals and Certifications 8
Finding the Declaration of Conformity Certificate 9
Declaration of Conformity Certificate 10
Safety 14
Safety Symbols 14
Qualified Personnel 14
Safety Precautions 15
Product Overview 17
Intended Use 17
What is an Enclosed Drive? 17
Location of Options within an Enclosed Drive 20
Drive Identification 22
Identifying the Drive and Its Options 22
Enclosure Size Identification 23
Type Code Identification 24
Power Ratings, Weight, and Dimensions 31
Control Compartment and Local Control Panel 33
Control Compartment Overview 33
Control Compartment Door 34
Local Control Panel (LCP) 35
LCP Menu 37
Mechanical Installation 39
Items Supplied 39
Split Shipment 39
Tools Needed 40
Storing the Drive 40
Operating Environment 40
Overview 40
Gases 40
Dust 40
Potentially Explosive Atmospheres 41
AQ262141314214en-000301/130R0880 | 3Danfoss A/S © 2021.11
Contents
VLT® HVAC Drive FC 102
Operating Guide

4.6
4.7
4.8
4.9
4.10
4.11
4.11.1
4.11.2
4.11.3
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6
5.9
5.9.1
Installation Requirements 41
Cooling Requirements 42
Airflow Rates 42
Lifting the Drive 44
Combining Multiple Cabinets from a Split Shipment 44
Installing the Enclosed Drive 46
Creating an Entry for Cables 46
Installing the Drive with Back-channel Cooling Option 46
Securing the Cabinet(s) to the Floor 47
Electrical Installation 49
Safety Instructions 49
EMC-compliant Installation 49
Wiring Overview for D9h and D10h Enclosed Drives 53
Wiring Overview for E5h and E6h Enclosed Drives 54
Control Terminal Wiring Diagram Cross-reference 55
Split Shipment Wiring Harnesses 56
Connecting Wiring Harnesses 56
Cable Routing 57
D10h Wiring Harness 65
E5h Wiring Harness 69
E6h Wiring Harness 75
Control Compartment Wiring 81
Safety Precautions 81
Control Compartment Interior View 82
Control Terminals 83
Relay Terminals 84
Option Card Terminals 84
Control Compartment Options 88
Connecting Motor, Mains, and Ground Cables 95
Power Cabling and Grounding Considerations 95
Connecting to the Mains 96
Connecting the Drive Module to the Motor 98
Connecting the Sine-wave Filter to the Motor 100
Connecting the dU/dt Filter to the Motor 101
Connecting to Ground 103
Installing Upstream Fuses 104
Upstream Fuse Considerations 104
AQ262141314214en-000301/130R08804 | Danfoss A/S © 2021.11
Contents
VLT® HVAC Drive FC 102
Operating Guide

5.9.2
5.9.3
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
6
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.3
7.3.1
7.3.2
7.4
7.5
7.5.1
7.5.2
7.5.3
7.5.4
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
Recommended Fuse Ratings for IEC Installation 104
Recommended Fuse Ratings for UL Installation 105
Enabling Motor Operation 106
Selecting the Voltage/Current Input Signal 106
Setting Up RS485 Serial Communication 107
Configuring the Passive Harmonic Filter (PHF) 108
Configuring the dU/dt Filter 108
Configuring the Sine-wave Filter 108
MCCB Configuration 108
Safe Torque Off (STO) Wiring 109
Pre-start Check 110
Commissioning 112
Applying Power to the Drive 112
Programming the Drive 112
Parameter Overview 112
Parameter Navigation 113
Programming Example for an Open-loop Application 113
Entering System Information 114
Configuring Automatic Energy Optimization 115
Configuring Automatic Motor Adaptation 115
Testing Before System Start-up 115
Testing Motor Rotation 115
Testing Encoder Rotation 115
Starting Up the Drive for the First Time 116
Parameter Settings 116
Parameter Setting Overview 116
Uploading and Downloading Parameter Settings 116
Restoring Factory Default Settings Using the Recommended Initialization 117
Restoring Factory Default Settings Using Manual Initialization 117
Wiring Configuration Examples 118
Application Examples 118
Wiring Configuration for Automatic Motor Adaptation (AMA) 118
Wiring Configuration for Automatic Motor Adaptation (AMA) without T27 118
Wiring Configuration: Speed 119
Wiring Configuration: Feedback 121
Wiring Configuration: Run/Stop 122
AQ262141314214en-000301/130R0880 | 5Danfoss A/S © 2021.11
Contents
VLT® HVAC Drive FC 102
Operating Guide

8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.12
8.1.13
8.1.14
9
9.1
9.2
9.3
9.4
9.5
10
10.1
10.1.1
10.1.2
10.2
10.3
10.3.1
10.3.2
10.4
10.5
10.6
10.6.1
10.6.2
10.6.3
10.6.4
10.6.5
10.6.6
10.6.7
10.6.8
10.6.9
10.6.10
10.6.11
Wiring Configuration: Start/Stop 124
Wiring Configuration: External Alarm Reset 126
Wiring Configuration: RS485 126
Wiring Configuration: Motor Thermistor 127
Wiring for Regeneration 127
Wiring Configuration for a Relay Set-up with Smart Logic Control 128
Wiring Configuration for a Cascade Controller 128
Wiring Configuration for a Fixed Variable Speed Pump 129
Wiring Configuration for Lead Pump Alternation 130
Maintenance, Diagnostics, and Troubleshooting 131
Maintenance and Service 131
Disposal 131
Status Messages 131
Warnings and Alarms 135
Troubleshooting 151
Specifications 154
Electrical Data 154
Electrical Data, 380–480 V AC 154
Electrical Data, 525–690 V AC 157
Mains Supply 160
Motor Output and Motor Data 160
Motor Output (U, V, W) 160
Torque Characteristics 160
Ambient Conditions 161
Motor and Control Cables 161
Control Input/Output and Control Data 161
Control Card, USB Serial Communication 161
STO Terminal XD2.19 (Terminal XD2.19 is Fixed PNP Logic) 162
Control Card, 24 V DC Output 162
Control Card, 10 V DC Output 162
Digital Outputs 162
Digital Inputs 163
Pulse/Encoder Inputs 163
Control Characteristics 163
Relay Outputs 164
Analog Output 164
Analog Inputs 164
AQ262141314214en-000301/130R08806 | Danfoss A/S © 2021.11
Contents
VLT® HVAC Drive FC 102
Operating Guide

10.6.12
10.6.13
10.7
10.7.1
10.7.2
10.7.3
10.7.4
10.8
10.8.1
10.8.2
10.8.3
10.8.4
10.8.5
10.9
10.9.1
10.9.2
10.9.3
10.9.4
10.9.5
10.10
10.11
11
11.1
11.2
11.3
11.4
11.5
11.6
11.6.1
11.6.2
11.6.3
11.6.4
11.6.5
11.6.6
11.6.7
11.6.8
Control Card, RS485 Serial Communication 165
Control Card Performance 165
Filter Specifications 165
Passive Harmonic Filter Specifications 165
Line Reactor Specifications 166
dU/dt Filter Specifications 167
Sine-wave Filter Specifications 167
Fuses, Circuit Breakers, and Switches 168
Panel Fuses 169
Contactor Switches 170
Fusible Disconnect Switches 171
Non-fusible Disconnect Switches 172
Molded-case Circuit Breakers 173
Enclosure Dimensions 174
Pedestal Dimensions 174
D9h Enclosed Drive Exterior Dimensions 174
D10h Enclosed Drive Exterior Dimensions 175
E5h Enclosed Drive Exterior Dimensions 176
E6h Enclosed Drive Exterior Dimensions 177
Enclosure Airflow 178
Fastener Torque Ratings 178
Appendix 179
Conventions 179
Abbreviations 179
International/North American Default Parameter Settings 181
Required Parameter Settings for Drive Options 182
Block Diagrams 183
Input Power Option Losses 186
Contactor Losses 186
Fusible Disconnect Losses 187
Non-fusible Disconnect Losses 188
Molded-case Circuit Breaker (MCCB) Losses 189
Passive Harmonic Filter Losses 190
Line Reactor Losses 191
dU/dt Filter Losses 192
Sine-wave Filter Losses 193
AQ262141314214en-000301/130R0880 | 7Danfoss A/S © 2021.11
Contents
VLT® HVAC Drive FC 102
Operating Guide

•
•
•
•
1 Introduction
1.1 Purpose of this Operating Guide
This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel.
Read and follow the instructions to use the drive safely and professionally.
Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.
VLT®is a registered trademark for Danfoss A/S.
1.2 Additional Resources
Other resources are available to understand advanced drive functions and programming.
The Programming Guide provides detailed information on the LCP, menu system, parameters, and troubleshooting with alarms
and warnings.
The Design Guide provides detailed information about capabilities and functionality to design motor control systems.
The Safe Torque Off Operating Guide provides detailed specifications, requirements, and installation instructions for the Safe
Torque Off function.
Supplementary publications and manuals are available from Danfoss, see www.danfoss.com.
1.3 Manual Version
This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
Table 1: Manual and Software Version
Version
Remarks
Software version
AQ262141314214 - 0201
Updated enclosure illustrations and the input power option loss tables.
5.41
MG80G1xx
First version
5.32
1.4 Approvals and Certifications
The following list is a selection of possible type approvals and certifications for Danfoss drives:
089
The specific approvals and certification for the enclosed drive or drive module are on the nameplate of the drive. For more informa-
tion, contact the local Danfoss office or partner.
AQ262141314214en-000301 / 130R08808 | Danfoss A/S © 2021.11
Introduction
VLT® HVAC Drive FC 102
Operating Guide

1.
2.
3.
4.
a.
b.
5.
Thermal memory retention requirement
The enclosed drive is UL listed per UL508A and CSA 14 standards. The drive module in the enclosed drive system complies with UL
508C or UL 61800-5-1 thermal memory retention requirements. For more information on UL 508C thermal memory retention re-
quirements, refer to the Motor Thermal Protection section in the product-specific Design Guide.
NOTICE
OUTPUT FREQUENCY LIMIT
Due to export control regulations, the output frequency of the enclosed drive (with no output filters) is limited to 590 Hz. For
demands exceeding 590 Hz, contact Danfoss. For enclosed drives with output filters, the maximum output frequency is limited to
60 Hz without derating and to 100/120 Hz with derating.
ADN-compliance
For more information on compliance with the European Agreement concerning International Carriage of Dangerous Goods by In-
land Waterways (ADN), refer to section ADN-compliant Installation in the product-specific Design Guide.
1.5 Finding the Declaration of Conformity Certificate
Open a web browser and enter https://www.danfoss.com/en/service-and-support/documentation/.
Click Certificates & declarations.
Use the Search field to search for PLV*.
The system provides a list of the search results.
Filter the search results be entering the following criteria.
Business unit = Drives
Documents/Document types = Certificate
Scroll down until you find the PLV XXX titled certificate for the specific product segment, such as PLV 102 EU Declaration.
Double click the link to the open the certificate. For an example, see 1.6 Declaration of Conformity Certificate.
AQ262141314214en-000301 / 130R0880 | 9Danfoss A/S © 2021.11
Introduction
VLT® HVAC Drive FC 102
Operating Guide

1.6 Declaration of Conformity Certificate
AQ262141314214en-000301 / 130R088010 | Danfoss A/S © 2021.11
Introduction
VLT® HVAC Drive FC 102
Operating Guide