Danfoss VLT FC 100 User manual

MAKING MODERN LIVING POSSIBLE
Service Manual
VLT®FC Series, D-Frame
VLT®HVAC Drive FC 100 • VLT®AQUA Drive FC 200
VLT® Automation Drive FC 300 • VLT® Refrigeration Drive FC 103
www.danfoss.com/drives

Contents
1 Introduction 7
1.1 Purpose 7
1.2 Product Overview 7
1.3 For Your Safety 7
1.4 Electrostatic Discharge (ESD) 8
1.5 Frame Size Definitions 8
1.6 Tools Required 9
1.7 General Torque Tightening Values 10
1.8 Exploded Views 11
1.9 Power-dependent Specifications 13
2 Operator Interface and Adjustable Frequency Drive Control 21
2.1 Introduction 21
2.2 User Interface 21
2.2.1 How to Operate the VLT®Control Panel LCP 102 21
2.2.2 Numeric Local Control Panel (NLCP) 24
2.2.3 Changing Settings with the LCP 25
2.3 Status Messages 26
2.4 Status Message Definitions 26
2.5 Service Functions 28
2.6 Adjustable Frequency Drive Inputs and Outputs 28
2.6.1 Input signals 29
2.6.2 Output signals 29
2.6.3 Control Power Supply 30
2.7 Control Terminals 30
2.8 Control Terminal Functions 31
2.9 Grounding Shielded Cables 32
3 Internal Adjustable Frequency Drive Operation 33
3.1 General 33
3.2 Description of Operation 33
3.2.1 Logic Section 34
3.2.2 Logic to Power Interface 35
3.2.3 Power Section 35
3.3 Sequence of Operation 36
3.3.1 Rectifier section 36
3.3.2 Intermediate Section 38
3.3.3 Inverter Section 40
Contents Service Manual
MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

3.3.4 Brake Option 42
3.3.5 Cooling Fans 44
3.3.6 Fan Speed Control 44
3.3.7 Load Sharing & Regeneration 45
3.3.8 Specific Power Card Connections 45
4 Troubleshooting 46
4.1 Troubleshooting Tips 46
4.2 Exterior Fault Troubleshooting 46
4.3 Fault Symptom Troubleshooting 46
4.4 Visual Inspection 47
4.5 Fault Symptoms 48
4.5.1 No Display 48
4.5.2 Intermittent Display 48
4.5.3 Motor Will not Run 48
4.5.4 Incorrect Motor Operation 49
4.6 Warning/Alarm Messages 49
4.7 After Repair Tests 58
5 Adjustable Frequency Drive and Motor Applications 59
5.1 Torque Limit, Current Limit, and Unstable Motor Operation 59
5.1.1 Overvoltage Trips 60
5.1.2 Line Phase Loss Trips 60
5.1.3 Control Logic Problems 61
5.1.4 Programming Problems 61
5.1.5 Motor/Load Problems 62
5.2 Internal Adjustable Frequency Drive Problems 62
5.2.1 Overtemperature Faults 62
5.2.2 Current Sensor Faults 62
5.2.3 EMI Signal and Power Wiring 63
5.2.4 Effects of EMI 63
5.2.5 Sources of EMI 64
5.2.6 EMI Propagation 64
5.2.7 Preventive Measures 67
5.2.8 Proper EMC Installation 68
6 Test Procedures 69
6.1 Introduction 69
6.1.1 Tools Required 69
Contents Service Manual
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6.1.2 Signal Test Board 70
6.2 Access to DC Bus 70
6.3 Static Test Procedures 70
6.3.1 Pre-check Precautions 70
6.3.2 Rectifier Circuits Test 73
6.3.3 Inverter Section Tests 73
6.3.4 Brake IGBT Test 74
6.3.5 Intermediate Section Tests 74
6.3.6 IGBT Temperature Sensor Test 75
6.3.7 Gate Resistor Test 75
6.3.8 Electrical Fuse Test 75
6.3.9 Disconnect Test 76
6.3.10 Circuit Breaker Test 76
6.3.11 Contactor Test 76
6.4 Dynamic Test Procedures 77
6.4.1 No Display Test 79
6.4.2 Input Voltage Test 79
6.4.3 Basic Control Card Voltage Test 79
6.4.4 DC Bus Voltage Test 80
6.4.5 Switch Mode Power Supply (SMPS) Test 80
6.4.6 Input Imbalance of Supply Voltage Test 80
6.4.7 Input Waveform Test 81
6.4.8 Input SCR Test 81
6.4.9 Output Imbalance of Motor Voltage and Current 82
6.4.10 IGBT Switching Test 83
6.4.11 IGBT Gate Drive Signals Test 83
6.4.12 Current Sensors Test 86
6.4.13 Fan Tests 87
6.4.14 Input Terminal Signal Tests 88
6.5 After Repair Tests 89
7 Disassembly and Assembly Instructions 91
7.1 Introduction 91
7.2 Electrostatic Discharge (ESD) 91
7.3 D1h/D3h Disassembly and Assembly Instructions 91
7.3.1 General Information 91
7.3.2 Control Card and Control Card Mounting Plate 91
7.3.3 Power Card Mounting Plate 92
7.3.4 Power Card 93
Contents Service Manual
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7.3.5 AC Input Bus Bars 93
7.3.5.1 Electrical Fuses Only 93
7.3.5.2 RFI Only 93
7.3.5.3 Fuses and RFI 94
7.3.5.4 No Options 94
7.3.6 Line Power Input Terminal Block 94
7.3.7 Motor Terminal Block 95
7.3.8 Power Terminal Mounting Plate 95
7.3.9 Current Sensors 95
7.3.10 Mixing Fan 95
7.3.11 Balance/High Frequency Card 95
7.3.11.1 400 V AC Power Size 95
7.3.11.2 690 V AC Power Size 96
7.3.12 DC Bus Rails 96
7.3.13 Inrush Card 97
7.3.14 IGBT Gate Drive Card 97
7.3.15 SCR Input Bus Bars 97
7.3.16 SCRs 98
7.3.17 Brake IGBT Module 98
7.3.18 IGBTs 99
7.3.18.1 400 V AC Power Size 99
7.3.18.2 690 V AC Power Size 99
7.3.19 DC Capacitors 100
7.3.19.1 400 V AC Power Size 100
7.3.19.2 690 V AC Power Size 101
7.3.20 Heatsink Fan 102
7.3.21 Door Fan: IP21 (NEMA 1) or IP54 (NEMA 12) Enclosures Only 102
7.3.22 Top Fan: (IP20 Enclosures Only) 102
7.4 D2h/D4h Disassembly and Assembly Instructions 103
7.4.1 General Information 103
7.4.2 Control Card and Control Card Mounting Plate 103
7.4.3 Power Card Mounting Plate 103
7.4.4 Power Card 104
7.4.5 AC Input Bus Bars 104
7.4.5.1 Electrical Fuses Only 104
7.4.5.2 RFI Only 105
7.4.5.3 Fuses and RFI 105
7.4.5.4 No Options 105
Contents Service Manual
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7.4.6 Line Power Input Terminal Block 105
7.4.7 EMC Shield 105
7.4.8 Brake Terminal (optional) 105
7.4.9 Motor Terminal Block 105
7.4.10 Power Terminal Mounting Plate 106
7.4.11 Current Sensors 106
7.4.12 Mixing Fan 107
7.4.13 Balance/High Frequency Card 107
7.4.13.1 400 V AC Power Size 107
7.4.13.2 690 V AC Power Size 107
7.4.14 IGBT Gate Drive Card 108
7.4.15 Inrush Card 108
7.4.16 SCR Input Bus Bars 109
7.4.17 SCRs 109
7.4.18 DC Bus Rails 109
7.4.18.1 Without Optional Brake 109
7.4.18.2 With Optional Brake 110
7.4.19 IGBTs 110
7.4.19.1 400 V AC Power Size 110
7.4.19.2 690 V AC Power Size 111
7.4.20 DC Capacitors 112
7.4.20.1 400 V AC Power Size 112
7.4.20.2 690 V AC Power Size 113
7.4.21 Heatsink Fan 114
7.4.22 Door Fan: IP21 (NEMA 1) or IP54 (NEMA 12) Enclosures Only 114
7.4.23 Top Fan (IP20 Enclosures only) 114
7.4.24 Brake IGBT Module 114
7.5 D6h Disassembly and Assembly Instructions 115
7.5.1 Overview 115
7.5.2 Removing the Heatsink Fan with Options Cabinet Present 115
7.5.3 Removing the Frequency Converter from the Options Cabinet 115
7.5.4 Contactor 116
7.5.5 Disconnect 116
7.6 D8h Disassembly and Assembly Instructions 116
7.6.1 Overview 116
7.6.2 Replacing the Heatsink Fan with Options Cabinet Present 117
7.6.3 Removing the Adjustable Frequency Drive from the Options Cabinet 117
7.6.4 Contactor 118
Contents Service Manual
MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

7.6.5 Disconnect 118
8 Special Test Equipment 120
8.1 Test Equipment 120
8.1.1 Split Bus Power Supply 120
8.1.2 Signal Test Board (p/n 176F8437) 120
8.1.3 Signal Test Board Extension 121
8.1.4 Signal Test Board Pin Outs 121
9 Spare Parts 125
9.1 Spare Parts 125
9.1.1 General Notes 125
9.1.2 DC Capacitor Bank 125
10 Block Diagrams 128
Index 130
Contents Service Manual
Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222

1 Introduction
1.1 Purpose
The purpose of this manual is to provide detailed technical
information and instructions to enable a qualified
technician to identify faults and perform repairs on D-
frame adjustable frequency drives.
It provides the reader with a general view of the main
assemblies and a description of the internal processing.
This manual gives technicians the information needed for
troubleshooting and repair.
This manual provides instructions for the adjustable
frequency drive models and voltage ranges described in
chapter 1.5 Frame Size Definitions.
Use this manual with the instruction manual that
accompanied the adjustable frequency drive.
1.2 Product Overview
VLT®HVAC Drive series adjustable frequency drives are
designed for the HVAC markets. They operate in variable
torque mode or constant torque down to 15 Hz and
include special features and options designed for fan and
pump applications.
VLT®AQUA Drive series adjustable frequency drives are
designed for water and wastewater markets. They can
operate in either constant torque or variable torque with
limited overload capabilities. Included are specific features
and options for use on various water pumping and
processing applications.
VLT®AutomationDrive series adjustable frequency drives
are fully programmable for either constant torque or
variable torque industrial applications. They operate a
variety of applications and incorporate a wide range of
control and communication options.
These models are available in IP20 (chassis), IP21 (NEMA 1),
and IP54 (NEMA 12) enclosures.
1.3 For Your Safety
1.3.1 Warnings
WARNING
Adjustable frequency drives contain dangerous voltages
when connected to line power. Only a competent
technician should perform service.
WARNING
For dynamic test procedures, line input power is
required and all devices and power supplies connected
to line power are energized at rated voltage. Use
extreme caution when conducting tests in a powered
adjustable frequency drive. Contact with powered
components could result in electrical shock and personal
injury.
WARNING
In adjustable frequency drives equipped with the
optional contactor or anti-condensation heater, there
may still be power inside the enclosure after the main
power to the unit has been turned off.
1. DO NOT touch electrical parts of the adjustable
frequency drive when connected to line power.
After disconnecting from line power, wait 20
minutes before touching any components.
2. When repair or inspection is made, line power
must be disconnected.
3. The [Stop] key on the control panel does not
disconnect line power.
4. During operation and while programming
parameters, it is possible for the motor to start
without warning. Press [Stop] when changing
data.
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1.4 Electrostatic Discharge (ESD)
WARNING
When performing service, use proper ESD procedures to
prevent damage to sensitive components.
WARNING
Do not touch components on the circuit boards. Hold
circuit boards by the corners and edges only.
Many electronic components within the adjustable
frequency drive are sensitive to static electricity. Voltages
so low that they cannot be felt, seen, or heard can reduce
the life, affect performance, or completely destroy sensitive
electronic components.
1.5 Frame Size Definitions
Model FC 102, FC 103, and FC 202
kW @400 V AC HP @460 V AC Frame Size
N110 110 150 D1h/D3h/
D5h/D6h
N132 132 200 D1h/D3h
D5h/D6h
N160 160 250 D1h/D3h
D5h/D6h
N200 200 300 D2h/D4h/
D7h/D8h
N250 250 350 D2h/D4h/
D7h/D8h
N315 315 450 D2h/D4h/
D7h/D8h
Table 1.1 FC 102, FC 103, and FC 202 380–480 V AC
Model FC 302 High/Normal Overload
kW @400
V AC
HP @460
V AC
kW @500
V AC
Frame
Size
N90K 90/110 125/150 110/132 D1h/D3h/
D5h/D6h
N110 110/132 150/200 132/160 D1h/D3h/
D5h/D6h
N132 132/160 200/250 160/200 D1h/D3h/
D5h/D6h
N160 160/200 250/300 200/250 D2h/D4h/
D7h/D8h
N200 200/250 300/350 250/315 D2h/D4h/
D7h/D8h
N250 250/315 350/450 315/355 D2h/D4h/
D7h/D8h
Table 1.2 FC 302 380–500 V AC
Model FC 102, FC 103, and FC 202
kW @550
V AC
HP @575
V AC
kW @690
V AC
Frame
Size
N75K 55 75 75 D1h/D3h/
D5h/D6h
N90K 75 100 90 D1h/D3h/
D5h/D6h
N110 90 125 110 D1h/D3h/
D5h/D6h
N132 110 150 132 D1h/D3h/
D5h/D6h
N160 132 200 160 D1h/D3h/
D5h/D6h
N200 160 250 200 D2h/D4h/
D7h/D8h
N250 200 300 250 D2h/D4h/
D7h/D8h
N315 250 350 315 D2h/D4h/
D7h/D8h
N400 315 400 400 D2h/D4h/
D7h/D8h
Table 1.3 FC 102, FC 103, and FC 202 525–690 V AC
Model
FC 302
High/Normal Overload
kW @550
V AC
HP @575
V AC
kW @690
V AC
Frame Size
N55k 45/55 60/75 55/75 D1h/ D3h/
D5h/D6h
N75k 55/75 75/100 75/90 D1h/D3h/
D5h/D6h
N90k 75/90 100/125 90/110 D1h/D3h/
D5h/D6h
N110 90/110 125/150 110/132 D1h/D3h/
D5h/D6h
N132 110/132 150/200 132/160 D1h/D3h/
D5h/D6h
N160 132/160 200/250 160/200 D2h/D4h/
D7h/D8h
N200 160/200 250/300 200/250 D2h/D4h/
D7h/D8h
N250 200/250 300/350 250/315 D2h/D4h/
D7h/D8h
N315 250/315 350/400 315/400 D2h/D4h/
D7h/D8h
Table 1.4 FC 302 525–690 V AC
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1.6 Tools Required
Additional Tools Recommended for Testing
•Digital volt/ohmmeter (PWM-compatible)
•Analog voltmeter
•Oscilloscope
•Clamp-on style ammeter
•Split-bus power supply p/n 130B3146
•Signal test board p/n 176F8437
•Signal test board extension p/n 130B3147
•Metric socket set (0.28 - 0.75 in [7–19 mm])
•Socket extensions (3.94–5.91 in [100–150 mm])
•Torx driver set (T10–T50)
•Torque wrench (4.4–168.2 in-lbs [0.5–19 Nm])
•Needle nose pliers
•Magnetic sockets
•Ratchet
•Screwdrivers
•ESD protective mat and wrist strap
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1.7 General Torque Tightening Values
For fastening hardware described in this manual, the torque values in the tables below are used. These values are not
intended for SCR, diode, or IGBT fasteners. See the instructions included with those replacement parts for correct values.
Shaft Size Drives Size
Torx/Hex
Class A
Nm [in-lbs]
Class Bin
Nm [in-lbs]
M4 T20/7 mm [0.28 in] 1.2 (10) 0.8 (7)
M5 T25/8 mm [0.31 in] 2.3 (20) 1.2 (10)
M6 T30/10 mm [0.39 in] 3.9 (35) 2.3 (20)
M8 T40/13 mm [0.51 in] 9.6 (85) 3.9 (35)
M10 T50/17 mm [0.67 in] 19 (169) 9.6 (85)
M12 18 mm [0.71 in]/19 mm
[0.75 in]
19 (169)
Table 1.5 Torque Values Standard Thread
Shaft Size Drives Size
Torx/Hex
Class A
Nm [in-lbs]
Class B
Nm [in-lbs]
M4.8 T25 5.7 (50) 3.1 (27)
M5 T25 1.7 (15)
Table 1.6 Torque Values for Thread Cutting into Metal
Shaft Size Drives Size
Torx/Hex
Class A
Nm [in-lbs]
Class Bin
Nm [in-lbs]
M4 T20 2.8 (24) 2.8 (24)
M5 T25 5.1 (45) 4.0 (35)
Table 1.7 Torque Values for Thread Forming into Plastic
Class A: Clamping metal Class B: Clamping PCA or plastic
Optional Equipment Location
Main Enclosure Option Cabinet
RFI filter X
Electrical fuses only X
Contactor* X
Disconnect* X
Circuit breaker* X
Contactor + disconnect* X
Table 1.8 Options Locations
*Contactor, disconnect, or circuit breaker options always include fuses. When these options are selected, the electrical fuses are in the options
cabinet.
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1.8 Exploded Views
130BX0501.10
12
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Figure 1.1 Exploded View D3h Frame Size (D1h Frame is similar)
1Local control panel mounting bracket 9 Heatsink fan
2 Control card and mounting plate 10 Gate drive support bracket
3 Power card and mounting plate 11 Capacitor bank
4 Inrush card 12 Balance/High frequency card
5 Top fan (IP20 only) 13 Motor output terminals
6 DC inductor 14 Line power input terminals
7 SCR/Diode modules 15 Gate drive card
8 IGBT modules 16 (optional) RFI filter
Table 1.9 Legend to Figure 1.1
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130BX0502.10
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
5
Figure 1.2 Exploded View D4h Frame Size (D2h Frame is similar)
1Local control panel mounting bracket 10 Heatsink fan
2 Control card and mounting plate 11 Gate drive support bracket
3 Power card and mounting plate 12 Capacitor bank
4 Inrush card 13 Balance/High frequency card
5 Inrush card mounting bracket 14 Motor output terminals
6 Top fan (IP20 only) 15 Line power input terminals
7 DC inductor 16 Gate drive card
8 SCR/Diode modules 17 (optional) RFI filter
9 IGBT modules
Table 1.10 Legend to Figure 1.2
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1.9 Power-dependent Specifications
FC 302 N90K N110 N132 N160 N200 N250
High/Normal Load* HO NO HO NO HO NO HO NO HO NO HO NO
Typical Shaft output at 400 V [kW] 90 110 110 132 132 160 160 200 200 250 250 315
Typical Shaft output at 460 V [hp] 125 150 150 200 200 250 250 300 300 350 350 450
Typical Shaft Output at 500 V [kW] 110 132 132 160 160 200 200 250 250 315 315 355
Enclosure IP21 D1h D1h D1h D2h D2h D2h
Enclosure IP54 D1h D1h D1h D2h D2h D2h
Enclosure IP20 D3h D3h D3h D4h D4h D4h
Output current
Continuous (at 400 V) [A] 177 212 212 260 260 315 315 395 395 480 480 588
Intermittent (60 s overload) (at 400 V) [A] 266 233 318 286 390 347 473 435 593 528 720 647
Continuous (at 460/500 V) [A] 160 190 190 240 240 302 302 361 361 443 443 535
Intermittent (60 s overload) (at 460/500 V)
[kVA]
240 209 285 264 360 332 453 397 542 487 665 588
Continuous kVA (at 400 V) [kVA] 123 147 147 180 180 218 218 274 274 333 333 407
Continuous kVA (at 460 V) [kVA] 127 151 151 191 191 241 241 288 288 353 353 426
Continuous kVA (at 500 V) [kVA] 139 165 165 208 208 262 262 313 313 384 384 463
Max. input current
Continuous (at 400 V) [A] 171 204 204 251 251 304 304 381 381 463 463 567
Continuous (at 460/500 V) [A] 154 183 183 231 231 291 291 348 348 427 427 516
Max. cable size: line power, motor, brake
and load share [mm2(AWG2))]5)
2x95
(2x3/0)
2x185
(2x350 mcm)
Max. external electrical fuses [A]1315 350 400 550 630 800
Estimated power loss at 400 V [W] 42031 2559 2289 2954 2923 3770 3093 4116 4039 5137 5005 6674
Estimated power loss at 460 V [W] 1828 2261 2051 2724 2089 3628 2872 3569 3575 4566 4458 5714
Weight, enclosure IP21, IP54 kg (lbs) 62 (135) 125 (275)
Weight, enclosure IP20 kg (lbs) 62 (135) 125 (275)
Efficiency4) 0.98
Output frequency 0–800 Hz 0–600 Hz
*High overload = 150% current for 60 s, Normal overload = 110% current for 60 s
Table 1.11 Line Power Supply 3x380–500 V AC
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FC 102, FC 202, and FC 103 N110 N132 N160 N200 N250 N315
High/Normal Load* NO NO NO NO NO NO
Typical Shaft output at 400 V [kW] 110 132 160 200 250 315
Typical Shaft output at 460 V [hp] 150 200 250 300 350 450
Typical Shaft Output at 480 V [kW] 132 160 200 250 315 355
Enclosure IP21 D1h D1h D1h D2h D2h D2h
Enclosure IP54 D1h D1h D1h D2h D2h D2h
D3h D3h D3h D4h D4h D4h
Output current
Continuous (at 400 V) [A] 212 260 315 395 480 588
Intermittent (60 s overload) (at 400 V) [A] 233 286 347 435 528 647
Continuous (at 460/500 V) [A] 190 240 302 361 443 535
Intermittent (60 s overload) (at 460/500 V)
[kVA]
209 264 332 397 487 588
Continuous kVA (at 400 V) [kVA] 147 180 218 274 333 407
Continuous kVA (at 460 V) [kVA] 151 191 241 288 353 426
Max. input current
Continuous (at 400 V) [A] 204 251 304 381 381 463 463 567
Continuous (at 460/500 V) [A] 183 231 291 348 348 427 427 516
Max. cable size: line power, motor, brake
and load share [mm2] (AWG2))5)
2x95
(2x3/0)
2x185
(2x350)
Max. external electrical fuses [A]1) 315 350 400 550 630 800
Estimated power loss at 400 V [W] 4) 2555 2949 3764 4109 5129 6663
Estimated power loss at 460 V [W] 2257 2719 3622 3561 4558 5703
Weight, enclosure IP21, IP54 kg (lbs) 62 (135) 125 (275)
Weight, enclosure IP20 kg (lbs) 62 (135) 125 (275)
Efficiency4) 0.98
Output frequency 0–800 Hz 0–600 Hz
*Normal overload = 110% current for 60 s
Table 1.12 Line Power Supply 3x380–480 V AC
1) For type of fuse, see the Instruction Manual.
2) American Wire Gauge
3) Measured using 16.5 ft [5 m] shielded motor cables at rated load and rated frequency.
4) The typical power loss is at nominal load conditions and within ± 15% (depending on various voltage and cable
conditions).
5) Field wiring terminals on FC 102 N132, N160, and N315 models are not intended to receive conductors one size
larger.
Values are based on a typical motor efficiency (eff2/eff3 border line). Motors with lower efficiency add to the
power loss in the adjustable frequency drive and those with higher efficiency decrease it.
The losses are based on the default switching frequency. The losses increase significantly at higher switching
frequencies. LCP and typical control card power consumption values are included. Further options and customer
load may add up to 30 W to the losses. (Though typically, only 4 W extra for a fully loaded control card, or options
for slot A or slot B, each).
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FC 302 N55K N75K N90K N110 N132 N160
High/Normal Load* HO NO HO NO HO NO HO NO HO NO HO NO
Typical Shaft output at 550 V [kW] 45 55 55 75 75 90 90 110 110 132 132 160
Typical Shaft output at 575 V [hp] 60 75 75 100 100 125 125 150 150 200 200 250
Typical Shaft output at 690 V [kW] 55 75 75 90 90 110 110 132 132 160 160 200
Enclosure IP21 D1h D1h D1h D1h D1h D2h
Enclosure IP54 D1h D1h D1h D1h D1h D2h
Enclosure IP20 D3h D3h D3h D3h D3h D4h
Output current
Continuous (at 550 V) [A] 76 90 90 113 113 137 137 162 162 201 201 253
Intermittent (60 s overload) (at 550 V)
[A] 122 99 135 124 170 151 206 178 243 221 302 278
Continuous (at 575/690 V) [A] 73 86 86 108 108 131 131 155 155 192 192 242
Intermittent (60 s overload)
(at 575/690 V) [kVA]
117 95 129 119 162 144 197 171 233 211 288 266
Continuous kVA (at 550 V) [kVA] 72 86 86 108 108 131 131 154 154 191 191 241
Continuous kVA (at 575 V) [kVA] 73 86 86 108 108 130 130 154 154 191 191 241
Continuous kVA (at 690 V) [kVA] 87 103 103 129 129 157 157 185 185 229 229 289
Max. input current
Continuous (at 550 V) [A] 77 89 89 110 110 130 130 158 158 198 198 245
Continuous (at 575 V) [A] 74 85 85 106 106 124 124 151 151 189 189 234
Continuous (at 690 V) 77 87 87 109 109 128 128 155 155 197 197 240
Max. cable size: line power, motor,
brake and load share [mm2] (AWG) 2x95 (2x3/0) 2x185 (2x350)
Max. external electrical fuses [A] 160 315 315 315 315 550
Estimated power loss at 575 V [W] 1098 1162 1162 1428 1430 1740 1742 2101 2080 2649 2361 3074
Estimated power loss at 690 V [W] 1057 1204 1205 1477 1480 1798 1800 2167 2159 2740 2446 3175
Weight, enclosure IP21, IP54 kg (lbs) 62 (135) 125 (275)
Weight, enclosure IP20 kg (lbs) 125 (275)
Efficiency 0.98
Output frequency 0–590 Hz
Heatsink overtemperature trip 230°F [110°C]
Control card ambient trip 167°F [75°C]
*High overload=150% current for 60 s, Normal overload=110% current for 60 s.
Table 1.13 Line Power Supply 3 x 525–690 V AC
Introduction Service Manual
MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved. 15
11

FC 302 N200 N250 N315
High/Normal Load* HO NO HO NO HO NO
Typical Shaft output at 550 V [kW] 160 200 200 250 250 315
Typical Shaft output at 575 V [hp] 250 300 300 350 350 400
Typical Shaft output at 690 V [kW] 200 250 250 315 315 400
Enclosure IP21 D2h D2h D2h
Enclosure IP54 D2h D2h D2h
Enclosure IP20 D4h D4h D4h
Output current
Continuous (at 550 V) [A] 253 303 303 360 360 418
Intermittent (60 s overload) (at 550 V) [A] 380 333 455 396 540 460
Continuous (at 575/690 V) [A] 242 290 290 344 344 400
Intermittent (60 s overload) (at 575/690 V) [kVA] 363 319 435 378 516 440
Continuous kVA (at 550 V) [kVA] 241 289 289 343 343 398
Continuous kVA (at 575 V) [kVA] 241 289 289 343 343 398
Continuous kVA (at 690 V) [kVA] 289 347 347 411 411 478
Max. input current
Continuous (at 550 V) [A] 245 299 299 355 355 408
Continuous (at 575 V) [A] 234 286 286 339 339 390
Continuous (at 690 V) 240 296 296 352 352 400
Max. cable size: line power, motor, brake and load share
[mm2] (AWG) 2x185 (2x350)
Max. external electrical fuses [A] 550
Estimated power loss at 575 V [W] 3012 3723 3642 4465 4146 5028
Estimated power loss at 690 V [W] 3123 3851 3771 4614 4258 5155
Weight, enclosure IP21, IP54 kg (lbs) 125 (275)
Weight, enclosure IP20 kg (lbs) 125 (275)
Efficiency 0.98
Output frequency 0–590 Hz
Heatsink overtemperature trip 230°F [110°C]
Control card ambient trip 167°F [75°C]
*High overload=150% current for 60 s, Normal overload=110% current for 60 s.
Table 1.14 Line Power Supply 3 x 525–690 V AC
The typical power loss is at nominal load conditions and expected to be within ±15% (tolerance relates to variety
in voltage and cable conditions).
The losses are based on the default switching frequency. The losses increase significantly at higher switching
frequencies.
The options cabinet adds weight to the adjustable frequency drive. The maximum weights of the D5h–D8h frames
is shown in the instruction manual.
Introduction Service Manual
16 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222
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1

FC 102, FC 202 and FC103 N75K N90K N110 N132 N160 N200
Normal Load* NO NO NO NO NO NO
Typical Shaft output at 550 V [kW] 55 75 90 110 132 160
Typical Shaft output at 575 V [hp] 75 100 125 150 200 250
Typical Shaft output at 690 V [kW] 75 90 110 132 160 200
Enclosure IP21 D1h D1h D1h D1h D1h D2h
Enclosure IP54 D1h D1h D1h D1h D1h D2h
Enclosure IP20 D3h D3h D3h D3h D3h D4h
Output current
Continuous (at 550 V) [A] 90 113 137 162 201 253
Intermittent (60 s overload)
(at 550 V) [A] 99 124 151 178 221 278
Continuous (at 575/690 V) [A] 86 108 131 155 192 242
Intermittent (60 s overload)
(at 575/690 V) [kVA] 95 119 144 171 211 266
Continuous kVA (at 550 V) [kVA] 86 108 131 154 191 241
Continuous kVA (at 575 V) [kVA] 86 108 130 154 191 241
Continuous kVA (at 690 V) [kVA] 103 129 157 185 229 289
Max. input current
Continuous (at 550 V) [A] 89 110 130 158 198 245
Continuous (at 575 V) [A] 85 106 124 151 189 234
Continuous (at 690 V) [A] 87 109 128 155 197 240
Max. cable size: line power, motor,
brake and load share [mm2] (AWG) 2x95 (2x3/0) 2x185
(2x350 mcm)
Max. external electrical fuses [A] 160 315 315 315 350 350
Estimated power loss at 575 V [W] 1161 1426 1739 2099 2646 3071
Estimated power loss at 690 V [W] 1203 1476 1796 2165 2738 3172
Weight, enclosure IP21, IP54 kg
(lbs) 62 (135) 125 (275)
Weight, enclosure IP20 kg (lbs) 62 (135) 125 (275)
Efficiency 0.98
Output frequency 0–590 Hz
Heatsink overtemp. trip 230°F [110°C]
Power card ambient trip 167°F [75°C]
*Normal overload=110% current for 60 s
Table 1.15 Line Power Supply 3 x 525–690 V AC
Introduction Service Manual
MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved. 17
11

FC 102, FC 202 and FC 103 N250 N315 N400
Normal Load* NO NO NO
Typical Shaft output at 550 V [kW] 200 250 315
Typical Shaft output at 575 V [hp] 300 350 400
Typical Shaft output at 690 V [kW] 250 315 400
Enclosure IP21 D2h D2h D2h
Enclosure IP54 D2h D2h D2h
Enclosure IP20 D4h D4h D4h
Output current
Continuous (at 550 V) [A] 303 360 418
Intermittent (60 s overload) (at 550 V) [A] 333 396 460
Continuous (at 575/690 V) [A] 290 344 400
Intermittent (60 s overload) (at 575/690 V) [kVA] 319 378 440
Continuous kVA (at 550 V) [kVA] 289 343 398
Continuous kVA (at 575 V) [kVA] 289 343 398
Continuous kVA (at 690 V) [kVA] 347 411 478
Max. input current
Continuous (at 550 V) [A] 299 355 408
Continuous (at 575 V) [A] 286 339 390
Continuous (at 690 V) [A] 296 352 400
Max. cable size: line power, motor, brake, and load
share, [mm2] (AWG) 2x185 (2x350 mcm)
Max. external electrical fuses [A] 400 500 550
Estimated power loss at 575 V [W] 3719 4460 5023
Estimated power loss at 690 V [W] 3848 4610 5150
Weight, enclosure IP21, IP54 kg (lbs) 125 (275)
Weight, enclosure IP20 kg (lbs) 125 (275)
Efficiency 0.98
Output frequency 0–590 Hz
Heatsink overtemp. trip 230°F [110°C]
Power card ambient trip 167°F [75°C]
*Normal overload=110% current for 60 s
Table 1.16 Line Power Supply 3 x 525–690 V AC
The typical power loss is at nominal load conditions and expected to be within ±15% (tolerance relates to variety
in voltage and cable conditions).
The losses are based on the default switching frequency. The losses increase significantly at higher switching
frequencies.
The options cabinet adds weight to the adjustable frequency drive. The maximum weights of the D5h–D8h frames
is shown in the instruction manual.
Introduction Service Manual
18 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222
1
1