Danfoss VLT FC 103 User manual

MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT®Refrigeration Drive FC 103
75-630 kW
www.danfoss.com/drives

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Approvals and Certifications 4
1.4 Disposal Instruction 4
1.5 Product Overview 5
1.5.1 Interior Views 5
1.6 Internal Controller Functions 7
1.7 Enclosure Types and Power Ratings 8
2 Safety 9
2.1 Qualified Personnel 9
2.2 Safety Precautions 9
3 Installation 11
3.1 Pre-Installation 11
3.1.1 Planning the Installation Site 11
3.1.2 General Considerations 11
3.1.3 Tools Required for Installation 12
3.2 Pre-installation Checklist 12
3.3 Mechanical Installation 12
3.3.1 Cooling 12
3.3.2 Lifting 13
3.3.3 Mechanical Dimensions 14
3.4 Electrical Installation 25
3.4.1 General Requirements 25
3.4.2 Grounding Requirements 28
3.4.2.1 Leakage Current (>3.5 mA) 28
3.4.2.2 Grounding 29
3.4.3 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA 12) 31
3.4.4 Motor Connection 32
3.4.4.1 Terminal Locations: D1h-D4h 33
3.4.4.2 Terminal Locations: D5h-D8h 35
3.4.4.3 Terminal Locations: E1-E2 43
3.4.5 Motor Cable 47
3.4.6 Motor Rotation Check 48
3.4.7 AC Mains Connection 48
3.4.8 Shielding against Electrical Noise 49
3.5 Control Wiring Connection 49
3.5.1 Access 49
Contents Operating Instructions
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3.5.2 Using Screened Control Cables 49
3.5.3 Grounding of Screened Control Cables 50
3.5.4 Control Terminal Types 51
3.5.5 Wiring to Control Terminals 51
3.5.6 Safe Torque Off (STO) 52
3.5.7 Control Terminal Functions 52
3.6 Serial Communication 53
3.7 Optional Equipment 53
3.7.1 Anti-condensation Heater 53
3.7.2 Mains Shield 53
4 Start-up and Functional Testing 54
4.1 Pre-start 54
4.1.1 Safety Inspection 54
4.2 Applying Power 56
4.3 Basic Operational Programming 56
4.3.1 Set-up Wizard 56
4.4 Automatic Motor Adaptation 61
4.5 Check Motor Rotation 61
4.6 Local-control Test 61
4.7 System Start-up 62
5 User Interface 63
5.1 Local Control Panel 63
5.1.1 LCP Layout 63
5.1.2 Setting LCP Display Values 65
5.1.3 Display Menu Keys 65
5.1.4 Navigation Keys 66
5.1.5 Operation Keys 66
5.2 Back-up and Copying Parameter Settings 66
5.2.1 Uploading Data to the LCP 67
5.2.2 Downloading Data from the LCP 67
5.3 Restoring Default Settings 67
5.3.1 Recommended Initialisation 67
5.3.2 Manual Initialisation 67
6 Programming 68
6.1 Introduction 68
6.2 Programming Example 68
6.3 Control Terminal Programming Examples 69
6.4 International/North American Default Parameter Settings 70
Contents Operating Instructions
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6.5 Parameter Menu Structure 71
6.5.1 Main Menu Structure 72
6.6 Remote Programming with
MCT 10 Set-up Software 76
7 Application Examples 77
7.1 Introduction 77
7.2 Application Examples 77
8 Status Messages 81
8.1 Status Display 81
8.2 Status Message Definitions 81
9 Warnings and Alarms 83
9.1 System Monitoring 83
9.2 Warning and Alarm Types 83
9.2.1 Warnings 83
9.2.2 Alarm Trip 83
9.2.3 Alarm Trip-lock 83
9.3 Warning and Alarm Displays 83
9.4 Warning and Alarm Definitions 84
9.5 Fault Messages 85
10 Basic Troubleshooting 92
10.1 Start-up and Operation 92
11 Specifications 95
11.1 Power-dependent Specifications 95
11.2 General Technical Data 98
11.3 Fuse Tables 102
11.3.1 Protection 102
11.3.2 Fuse Selection 102
11.3.3 Short Circuit Current Rating (SCCR) 104
11.3.4 Connection Tightening Torques 104
Index 105
Contents Operating Instructions
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 3

1 Introduction
1.1 Purpose of the Manual
This manual provides detailed information for the instal-
lation and start-up of the frequency converter.
Chapter 3 Installation provides requirements for mechanical
and electrical installation, including:
•Input
•Motor
•Control wiring
•Serial communication wiring
•Control terminal functions
Chapter 4 Start-up and Functional Testing provides detailed
procedures for:
•Start-up
•Basic operational programming
•Functional testing
The remaining chapters provide supplementary details.
These details include:
•User interface
•Detailed programming
•Application examples
•Start-up
•Troubleshooting
•Specifications.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced
frequency converter functions and programming.
•The VLT
®
Refrigeration Drive FC 103 Programming
Guide provides greater detail on working with
parameters and many application examples.
•The VLT
®
Refrigeration Drive FC 103 Design Guide
provides detailed capabilities and functionality to
design motor control systems.
•Supplemental publications and manuals are
available from Danfoss.
See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/Documentations/VLT+Technical
+Documentation.htm for listings.
•Optional equipment is available that may change
some of the procedures described. Refer to the
instructions supplied with those options for
specific requirements. Contact the local Danfoss
supplier or visit the Danfoss website:
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/VLT+Technical+Documen-
tation.htm, for downloads or additional
information.
1.3 Approvals and Certifications
More approvals and certifications are available. Contact the
local Danfoss partner.
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the Design
Guide.
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
Design Guide.
1.4 Disposal Instruction
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction Operating Instructions
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1

1.5 Product Overview
A frequency converter is an electronic motor controller
that converts DC into a variable AC waveform output. The
frequency and voltage of the output are regulated to
control the motor speed or torque. The frequency
converter can vary the speed of the motor in response to
system feedback, such as position sensors on a conveyor
belt. The frequency converter can also regulate the motor
by responding to remote commands from external
controllers.
The frequency converter offers many control, monitoring
and efficiency functions such as:
•Monitoring the system and motor status
•Issuing warnings or alarms for fault conditions
•Starting and stopping the motor
•Optimising energy efficiency
Operation and monitoring functions are available as status
indications to an outside control system or serial communi-
cation network.
1.5.1 Interior Views
130BC252.11
1
15 14
8
9
12
13 (IP 20/Chassis)
13
(IP 21/54
NEMA 1/12)
11
10
16
Illustration 1.1 Interior Components - Enclosure Type D
130BC301.11
1
2
3
4
5
6
7
8
9
10
11
1LCP (Local Control Panel) 9 Relay 2 (04, 05, 06)
2 RS-485 fieldbus
connector
10 Lifting ring
3 Digital I/O and 24 V
supply
11 Mounting slot
4 Analog I/O connector 12 Cable clamp (PE)
5 USB connector 13 Ground
6 Fieldbus terminal switch 14 Motor output terminals 96
(U), 97 (V), 98 (W)
7 Analog switches (A53),
(A54)
15 Mains input terminals 91
(L1), 92 (L2), 93 (L3)
8 Relay 1 (01, 02, 03) 16 TB5 (IP21/54 only). Terminal
block for anti-condensation
heater
Illustration 1.2 Close-up View: LCP and Control Functions
Introduction Operating Instructions
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130BB019.10
1
2
3
4
5
6
7
8
9
10
Illustration 1.3 Compact IP21 (NEMA 1) and IP54 (NEMA 12)
Enclosure Type E1
130BB020.10
1
2
3
4
5
6
7
8
10
Illustration 1.4 Compact IP00 (Chassis) with Disconnect, Fuse
and RFI Filter, Enclosure Type E2
1) AUX relay 5) Load sharing
01 02 03 -DC +DC
04 05 06 88 89
2) Temp switch 6) SMPS fuse
106 104 105 7) Fan fuse
3) Mains 8) AUX fan
R S T 100 101 102 103
91 92 93 L1 L2 L1 L2
L1 L2 L3 9) Mains ground
4) Brake 10) Motor
-R +R U V W
81 82 96 97 98
T1 T2 T3
Table 1.1 Legend to Illustration 1.3 and Illustration 1.4
Introduction Operating Instructions
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1.6 Internal Controller Functions
Illustration 1.5 is a block diagram of the frequency
converter's internal components.
Illustration 1.5 Frequency Converter Block Diagram
Area Title Functions
1 Mains input •3-phase AC mains supply to the
frequency converter
2 Rectifier
•The rectifier bridge converts the
AC input to DC current to
supply inverter power.
3 DC-bus •Intermediate DC-bus circuit
handles the DC current.
4 DC reactors
•Filter the intermediate DC circuit
voltage.
•Prove line transient protection.
•Reduce RMS current.
•Raise the power factor reflected
back to the line.
•Reduce harmonics on the AC
input.
5 Capacitor bank
•Stores the DC power.
•Provides ride-through protection
for short power losses.
6 Inverter
•Converts the DC into a
controlled PWM AC waveform
for a controlled variable output
to the motor.
7 Output to motor •Regulated 3-phase output
power to the motor
8 Control circuitry
•Input power, internal
processing, output, and motor
current are monitored to
provide efficient operation and
control.
•User interface and external
commands are monitored and
performed.
•Status output and control can
be provided.
Table 1.2 Legend to Illustration 1.5
Introduction Operating Instructions
MG16J202 Danfoss A/S © Rev. 05/2014 All rights reserved. 7
11

1.7 Enclosure Types and Power Ratings
Normal
Over-
load
[kW]
55 75 90 110 132 160 200 250 315 355 400 450 500 560 630
400 V D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/D3h/
D5h/D6h
D2h/D4h/
D7h/D8h
D2h/
D4h/
D7h/
D8h
D2h/D4h/
D7h/D8h
E1/E2 E1/E2 E1/E2
525 V D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D2h/D4h/
D7h/D8h
D2h/D4h/
D7h/D8h
D2h/
D4h/
D7h/
D8h
D2h/D4h/
D7h/D8h
E1/E2 E1/E2 E1/E2 E1/
E2
690 V D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D1h/D3h/
D5h/D6h
D2h/D4h/
D7h/D8h
D2h/
D4h/
D7h/
D8h
D2h/D4h/
D7h/D8h
E1/E2 E1/
E2
E1/E2 E1/E2
Table 1.3 kW Rated Frequency Converters
Normal
Overload
[hp]
75 100 125 150 200 250 300 350 400 450 500 550/
600
600 650
460 V D1h/D3h/
D5h/D6h
D1h/
D3h/
D5h/
D6h
D1h/
D3h/
D5h/
D6h
D2h/
D4h/
D7h/
D8h
D2h/
D4h/
D7h/
D8h
D2h/
D4h/
D7h/
D8h
E1/E2 E1/
E2
E1/E2
575 V D1h/D3h/
D5h/D6h
D1h/
D3h/
D5h/
D6h
D1h/D3h/
D5h/D6h
D1h/D3h/
D5h/D6h
D1h/
D3h/
D5h/
D6h
D2h/
D4h/
D7h/
D8h
D2h/
D4h/
D7h/
D8h
D2h/
D4h/
D7h/
D8h
D2h/
D4h/
D7h/
D8h
E1/E2 E1/E2 E1/E2 E1/E2
Table 1.4 Hp Rated Frequency Converters
Introduction Operating Instructions
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