Danfoss VLT FC 100 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions High Power
VLT® HVAC Drive FC 100

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 9
Avoid Unintended Start 9
Safe Stop of the Frequency Converter 10
IT Mains 12
3 Mechanical Installation 13
How to Get Started 13
Pre-installation 13
Planning the Installation Site 13
Receiving the Frequency Converter 14
Transportation and Unpacking 14
Lifting 14
Mechanical Dimensions 16
Rated Power 23
Mechanical Installation 24
Tools Needed 24
General Considerations 24
Terminal Locations - Frame size D 25
Terminal Locations - Frame size E 28
Terminal Locations - Frame size F 33
Cooling and Airflow 36
Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units 39
Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 39
IP21 Drip Shield Installation (Frame size D1 and D2) 41
Field Installation of Options 41
Installation of Duct Cooling Kit in Rittal Enclosures 41
Installation of Top-only Duct Cooling Kit 43
Installation of Top and Bottom Covers for Rittal Enclosures 43
Installation of Top and Bottom Covers 43
Outside Installation/ NEMA 3R Kit for Rittal Enclosures 44
Outside Installation /NEMA 3R Kit of Industrial Enclosures 44
Installation of IP00 to IP20 Kits 45
VLT HVAC Drive High Power Operating In-
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MG.11.F3.02 - VLT® is a registered Danfoss trademark 1

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
Installation of D or E Loadshare Option 47
Frame size F Panel Options 48
Frame Size F Options 48
4 Electrical Installation 51
Electrical Installation 51
Power Connections 51
Earthing 61
RFI Switch 61
Torque 62
Shielded Cables 62
Motor Cable 62
Brake Resistor Temperature Switch 63
Load Sharing 64
Shielding against Electrical Noise 64
Mains Connection 64
External Fan Supply 65
Fuses 66
Control Cable Routing 71
Electrical Installation, Control Terminals 73
Connection Examples 74
Start/Stop 74
Pulse Start/Stop 74
Electrical Installation - additional 76
Electrical Installation, Control Cables 76
Switches S201, S202, and S801 79
Final Set-up and Test 79
Additional Connections 80
Mechanical Brake Control 80
Motor Thermal Protection 81
5 How to Operate the Frequency Converter 83
How to Operate Graphical LCP (GLCP) 83
Tips and Tricks 88
6 How to Programme 91
Quick Menu Mode 94
Contents
VLT HVAC Drive High Power Operating In-
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Function Set-ups 99
Parameter lists 133
Main Menu Structure 133
0-** Operation and Display 134
1-** Load / Motor 136
2-** Brakes 138
3-** Reference / Ramps 139
4-** Limits / Warnings 140
5-** Digital In / Out 141
6-** Analog In / Out 142
8-** Communication and Options 143
9-** Profibus 144
10-** CAN Fieldbus 145
11-** LonWorks 145
13-** Smart Logic Controller 146
14-** Special Functions 147
15-** Drive Information 148
16-** Data Readouts 150
18-** Info & Readouts 152
20-** FC Closed Loop 153
21-** Ext. Closed Loop 154
22-** Application Functions 156
23-** Time Based Funtions 158
24-** Application Functions 2 159
25-** Cascade Pack Controller 160
26-** Analog I / O Option MCB 109 161
7 General Specifications 163
8 Warnings and Alarms 177
Fault Messages 181
Index 187
VLT HVAC Drive High Power Operating In-
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1 How to Read these Operating Instructions
VLT HVAC Drive High Power Operating In-
structions
4MG.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 accept-
ing and using this manual the user agrees that the information con-
tained herein will be used solely for operating equipment from Danfoss
or equipment from other vendors provided that such equipment is in-
tended for communication with Danfoss equipment over a serial com-
munication 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 ex-
pressed 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, inciden-
tal, or consequential damages arising out of the use, or the inability to
use information contained in this manual, even if advised of the possi-
bility of such damages. In particular, Danfoss is not responsible for any
costs, including but not limited to those incurred as a result of lost prof-
its or revenue, loss or damage of equipment, loss of computer pro-
grams, 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
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
-Design Guide MG.11.Bx.yy entails all technical information
about the frequency converter and customer design and appli-
cations.
-Programming Guide MG.11.Cx.yy provides information on how
to programme and includes complete parameter descriptions.
-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 environment.
-Danfoss VLT® Energy Box software at
www.danfoss.com/Busi-
nessAreas/DrivesSolutions then choose PC Software Download
-Operating Instructions VLT HVAC Drive BACnet,
MG.11.Dx.yy
-Operating Instructions VLT HVAC Drive Metasys,
MG.11.Gx.yy
-Operating Instructions VLT HVAC Drive 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
VLT HVAC Drive High Power Operating In-
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1

1.1.4 Abbreviations and Standards
Abbreviations Terms SI-units I-P units
a Acceleration m/s2ft/s2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°CCelsius
I Current A Amp
ILIM Current limit
IT mains Mains supply with star point in transformer floating to ground
Joule Energy J = N∙m ft-lb, Btu
°FFahrenheit
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
IM,N Nominal motor current
fM,N Nominal motor frequency
PM,N Nominal motor power
UM,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
IINV Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
T Temperature C F
t Time s s,hr
TLIM Torque limit
U Voltage V V
Table 1.1: Abbreviation and standards table
1 How to Read these Operating Instructions
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2 Safety
2.1.1 High Voltage Warning
The voltage of the frequency converter and the MCO
101 option card is dangerous whenever it is connec-
ted to mains. Incorrect installation of the motor or
frequency converter may causedeath, serious injury
or damage to the equipment. Consequently, it is es-
sential to comply with the instructions in this manual
as well as local and national rules and safety regula-
tions.
2.1.2 Safety Instructions
Prior to using functions directly or indirectly influenc-
ing personal safety (e.g. Safe Stop, Fire Mode or
other functions either forcing the motor to stop or at-
tempting 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 af-
ter 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 fre-
quency 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 con-
verter exceeds 3.5 mA. According to IEC 61800-5-1 a
reinforced Protective Earth connection must be en-
sured by means of: a min. 10mm² Cu or 16mm² Al
PE-wire or an addtional PE wire - with the same ca-
ble cross section as the Mains wiring - must be termi-
nated separately.
Residual Current Device
This product can cause a D.C. current in the protec-
tive 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 lo-
cal regulations.
VLT HVAC Drive High Power Operating In-
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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 Safety
VLT HVAC Drive High Power Operating In-
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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 condi-
tions.
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 com-
mands, bus commands, references or via the Local
Control Panel.
• Disconnect the frequency converter from
mains whenever personal safety considera-
tions 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 elec-
tronic fault, temporary overload, a fault in
the mains supply, or lost motor connection
may cause a stopped motor to start.
VLT HVAC Drive High Power Operating In-
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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 anal-
ysis 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 ac-
cordance 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 Oper-
ating Instructions are not sufficient for a correct and safe use of the
Safe Stop functionality!
2 Safety
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130BA491
Illustration 2.1: This certificate also covers FC 102FC 102 and FC 202.
VLT HVAC Drive High Power Operating In-
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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.
Failure to follow recommendations could result in
death or serious injury.
Par. 14-50 RFI Filter can be used to disconnect the internal RFI capaci-
tors 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 con-
verters with software version 3.2.x.
The software version number can be seen from par. 15-43 Soft-
ware 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 legislation.
2 Safety
VLT HVAC Drive High Power Operating In-
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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 Operating
Instructions and Design Guide.
The frequency converter is designed to achieve a quick and EMC-cor-
rect 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
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
Illustration 3.1: Diagram showing basic installation includ-
ing 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. Ne-
glecting this may result in extra work during and af-
ter installation.
Select the best possible operation site by considering the fol-
lowing (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 nec-
essary 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.
VLT HVAC Drive High Power Operating In-
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3

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 oc-
curred to the unit during transport. In case damage has occurred, con-
tact 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.
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.
176FA245.10
Illustration 3.2: 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.
130BA832.11
Illustration 3.3: Recommended Lifting Method, Frame Size
F1
(460V, 600 to 900 HP, 575/690V, 900 to 1150 HP).
3 Mechanical Installation
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130BA834.11
Illustration 3.4: Recommended Lifting Method, Frame Size
F2
(460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP).
130BA833.11
Illustration 3.5: Recommended Lifting Method, Frame Size
F3
(460V, 600 to 900 HP, 575/690V, 900 to 1150 HP).
VLT HVAC Drive High Power Operating In-
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130BA835.11
Illustration 3.6: Recommended Lifting Method, Frame Size
F4
(460V, 1000 to 1200 HP, 575/690V, 1250 to 1350 HP).
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.
3.2.5 Mechanical Dimensions
IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
AB
C
120
(4.7)
177.0
(7.0)
354.0
(13.9)
1166
(45.9)
310
(12.2)
163
(6.4)
420
(16.5)
981
(38.6)
74
(2.9)
417
(16.4)
380
(15.0)
D1
D2
130BA443.11
417
(16.4)
380
(15.0)
225
(8.9)
225
(8.9)
225.0
(8.9)
225.0
(8.9)
369.0
(14.5)
849
(33.4)
1209
(47.6)
160.0
(6.3)
160.0
(6.3)
160.0
(6.3)
160.0
(6.3)
304
(12.0)
304
(12.0)
25
(1.0)
25
(1.0)
1154
(45.4)
1362
(53.6)
420
(16.5)
157
(6.2)
72
(2.8)
1547
(60.9) 1589
(62.6)
423
(16.6)
120
(4.7)
1535
(60.4)
184.5
(7.3)
977
(38.5)
* Please note airflow directions
3 Mechanical Installation
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AB
C
IP00 / CHASSIS
IP00/IP21/IP54 - ALL SIZES
1099
43.3( )
1280
50.4( )
1327
52.2
()
375
14.8( )
417
16.4( )
298
11.7( )304
12.0( )
120
4.7( )
977
38.5( )
160
6.3( )
185
7.3( )
369
14.5( )
1282
50.5( )
25
1.0( )
161
6.3( )
225
(8.9)
225
(8.9)
997
39.3( )
818
32.2( )
408
16.1( )
66
2.6( )
408
16.1( )
66
2.6( )
298
11.7
( )
375
14.8( )
1046
41.2( )
120
4.7( )
696
27.4( )
160
6.3( )
1001
25
1.0( )
39.4( )
304
12.0( )
151
5.9( )
157
6.2( )
147
5.8( )
417
16.4( )
177
7.0( )
354
13.9( )
25
1.0( )
22
0.9
( )
49
1.9( )
25
1.0( )
Ø 11
.4( )
20.0
0.8
( )
10
0.4
( )
51
2.0( )
11
0.4( )
160.0
6.30( )
160.0
6.30( )
225.0
8.9( )
225.0
8.9( )
D3 D4
BA C
22
0.9
( )
138BA442.10
* Please note airflow directions
VLT HVAC Drive High Power Operating In-
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E1
225
8.86( )
1551
61.1( )
2000
(78.74)
727
28.6( )
72
2.8( )
164
600
(23.62) 198
7.8( )
145
5.7( )
494
19.4( )
392
15.4( )
538
21.2( )
160
6.3( )
1043
41.1( )
160
6.3( )
72
2.8( )
27
1.1( )
23
0.9( )
185
7.3( )
185
7.3( )
58
2.3( )
484
19.1
()
2X 13
0.5
( )
25
1.0
()
56
2.2( )
6.5( )
185
7.3( )
1.0( )
F
F
130BA444.10
SIDE CABLE ENTRY
KNOCK-OFF PLATE
CABLE BASE BOTTOM CABLE ENTRY
IP21 AND IP54 / UL AND NEMA TYPE 1 AND 12
Ø 25
* Please note airflow directions
3 Mechanical Installation
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130BA445.10
225
64
1320
585
269
156
23
25
498
539
1547 1502
160
1043
14
184 184
184
139 304
2X13
(2.5)
(23.0)
(52.0)
(6.2)
(19.5)
(10.6)
(21.2)
(60.9)
(5.5) (12.0)
(7.3) (7.3)
(0.5)
(1.5)
120
(4.7)
25
(1.0)
(59.1)
(41.1)
(6.3)
(8.9)
225
(8.9)
(1.0) 25
(1.0)
(0.9)
27
(1.0)
13
(0.5)
E2
D
E
D
E
IP00 / CHASSIS
* Please note airflow directions
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